DeWalt DXAEC80, DXAEC80CA Instruction Manual

DXAEC80/DXAEC80CA

30A Bench Battery Charger with 80A Engine Start 30A banc chargeur de batterie avec 80A démarrage moteur 30A cargador de batería banco con 80A arranque del motor

INSTRUCTION MANUAL GUIDE D’UTILISATION MANUAL DE INSTRUCCIONES

If you have questions or comments, contact us.

Pour toute question ou tout commentaire, nous contacter.

Si tiene dudas o comentarios, contáctenos.

1-888-394-3392

RD082616

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Deﬁnitions: Safety Guidelines

The definitions below describe the level of severity for each signal word. Please read the manual and pay attention to these symbols.

DANGER: Indicates an imminently hazardous situation which,

if not avoided, will result in death or serious injury.

WARNING: Indicates a potentially hazardous situation which,

if not avoided, could result in death or serious injury.

CAUTION: Indicates a potentially hazardous situation which,

if not avoided, may result in minor or moderate injury. NOTICE: Indicates a practice not related to personal injury

which, if not avoided, may result in property damage.

IF YOU HAVE ANY QUESTIONS OR COMMENTS ABOUT THIS DeWA LT TOOL, CALL US TOLL FREE AT: 1-888-394-3392.

WARNING: Read all instructions before operating product. Failure to follow all instructions listed below may result in electric

shock, fire and/or serious injury.

30A Bench Battery Charger w/80A Engine Start

The DXAEC80/DXAEC80CA 30A Bench Battery Charger with 80A Engine Start is a DeWA LT 30A battery charger that features 80A engine start, alternator check, and battery reconditioning functions; a USB port and an AC power outlet.

WARNING: This apparatus or its power cord contains lead, a

chemical known to the State of California to cause cancer and birth defect or other reproductive harm. Wash hands after handling.

Important Safety

Instructions

1. Keep these instructions.

2. Heed all warnings.

3. Follow all instructions.

4. Avoid dangerous environments. Don’t use battery chargers in damp or wet locations. Do not use the charger in the rain or snow.

5. Clean only with a dry cloth.

6. Keep children away from the charging area. Keep the charger away from children. This is not a toy!

7. Store indoors. When not in use, battery chargers should be stored indoors in dry, and high or locked-up places – out of the reach of children.

8. Unplug the battery charger when not in use.

9. Stay alert. Use common sense. Do not operate this equipment when you are tired or impaired.

10. Only use attachments/accessories specified by the manufacturer.

11. Use only on a flat, level surface. If a cart is used, use caution when moving the cart/apparatus combination to avoid injury from tip-over.

12. Check for damaged parts. Any part that is damaged should be properly repaired or replaced by manufacturer unless otherwise indicated elsewhere in this instruction manual before further use. Servicing is required when the apparatus has been damaged in any way, such as power-supply cord or plug is damaged, liquid has been spilled or objects have fallen into the apparatus, the apparatus has been exposed to rain or moisture, does not operate normally, or has been dropped. Contact the manufacturer at 1-888-394-3392 for more information.

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13. Apparatus shall not be exposed to dripping or splashing and no objects filled with liquids, shall be placed on the apparatus.

This Class B digital apparatus complies with Canadian ICES-003. CAN ICES-3(B).

NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to ratio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

•Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and the

receiver.

• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected

• Consult the dealer or an experienced radio/TV technician for help.

NOTICE: Per FCC Part 15, changes or modifications to this equipment not expressly approved by DeWALT could void your authority to operate this equipment.

READ ALL INSTRUCTIONS

Speciﬁc Safety Instructions for Power Cords

•Don’t abuse the cord. Protect the power cord from being walked

on or pinched particularly at plugs, convenience receptacles, and the point where they exit from the apparatus. Never carry the apparatus by cord or yank it to disconnect from receptacle. Keep the cord from heat, oil, and sharp edges. Pull by plug rather than cord when unplugging the unit.

•Ground fault circuit interrupter (GFCI) protection should be

provided on the circuits or outlets to be used. Receptacles are available having built in GFCI protection and may be used for this measure of safety.

DANGER – Never alter AC Power Cord or plug provided. If it will

not fit the outlet, have aproper outlet installed by a qualified electrician. Improper connection can result in a risk of an electric shock.

Extension Cords

An extension cord should not be used unless absolutely necessary. Use of an improper extension cord could result in a risk

of fire and electric shock, and will void warranty. If an extension cord must be used, make sure your extension cord

is in good condition. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. The following table shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

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Recommended Minimum AWG Size for Extension Cords

for Battery Chargers AC Input Rating American Wire Gage (AWG) Size of Cord Amperes Length of Cord, feet (m)

Equal to or But less

25 (7.6) 50 (15.2) 100 (30.5) 150 (45.6)

greater than than

0 2 18 18 18 16 2 3 18 18 16 14 3 4 18 18 16 14 4 5 18 18 14 12 5 6 18 16 14 12 6 8 18 16 12 10 8 10 18 14 12 10 10 12 16 14 10 8 12 14 16 12 10 8 14 16 16 12 10 8 16 18 14 12 8 8 18 20 14 12 8 6

POWER CORD SAFETY

The battery charger is for use on a nominal 120 volt circuit, and has a grounding plug that looks like the plug illustrated in Figure A. A temporary adapter, which looks like the plug illustrated in Figures B and C may be used to connect this plug to a two-pole receptacle as shown in Figure B if a properly grounded outlet is not available. The temporary adapter should be used only until a properly grounded outlet can be installed by a qualified electrician.

DANGER: Before using an adapter as shown in the following

illustration, be certain that center screw of outlet plate is grounded. The green-colored rigid ear or lug extending from adapter must be connected to a properly grounded outlet– make certain it is grounded. If necessary, replace the original outlet cover plate screw with a longer screw that will secure the adapter ear or lug to outlet cover plate and make ground connection to a grounded outlet.

Speciﬁc Safety Instructions for Battery Chargers

WARNING – Burst hazard: Do not use the unit for charging dry-cell

batteries that are commonly used with home appliances. These batteries may burst and cause injury to persons and damage property. Use the unit for charging/boosting a 12 volt battery only. It is not intended to supply power to a low-voltage electrical system other than in a starter-motor application.

•Use of accessories and attachments: The use of any accessory

or attachment not recommended by manufacturer for use with this battery charger could be hazardous.

•Do not operate the battery charger near flammable liquids or in

gaseous or explosive atmospheres. Motors may spark, and the sparks might ignite fumes.

WARNING: To reduce the risk of electric shock, never immerse the

battery charger in water or any other liquid, or use when wet.

WARNING – Risk of explosive gases:

•Working in the vicinity of a lead acid battery is dangerous. Batteries generate explosive gases during normal battery operation. For this

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reason, it is of the utmost importance that each time before using the battery charger you read this manual and follow instructions exactly.

•To reduce the risk of battery explosion, follow these instructions and those published by the battery manufacturer and manufacturer of any equipment you intend to use in the vicinity of the battery. Review cautionary markings on these products and on the engine.

•This equipment employs parts (switches, relays, etc.) that produce arcs or sparks. Therefore, if used in a garage or enclosed area, the unit MUST be placed not less than 18 inches above the floor.

•THIS UNIT IS NOT FOR USE BY CHILDREN AND SHOULD ONLY BE OPERATED BY ADULTS.

WARNING – To reduce the risk of fire:

•Do not operate near flammable materials, dust, fumes or gases.

•Do not expose to extreme heat or flames.

CAUTION – To reduce the risk of injury or property damage:

•NEVER ATTEMPT CHARGE A FROZEN BATTERY.

•Do not charge the battery while the engine is operating.

•Stay clear of fan blades, belts, pulleys, and other parts that can

cause injury to persons.

•Vehicles that have on-board computerized systems may be damaged if vehicle battery is jump-started. Before jump-starting, read the vehicle’s owner’s manual to confirm that external-starting assistance is suitable.

•When working with lead acid batteries, always make sure someone is close enough to provide immediate assistance in case of accident or emergency.

•Always have protective eyewear when using this product: contact with battery acid may cause blindness and/or severe burns. Be aware of first aid procedures in case of accidental contact with battery acid.

•Have plenty of fresh water and soap nearby in case battery acid contacts skin.

•If battery acid contacts skin or clothing, wash immediately with soap and water for at least 10 minutes and get medical attention immediately.

•Never smoke or allow a spark or flame in vicinity of vehicle battery, engine or battery charger.

•Remove personal metal items such as rings, bracelets, necklaces and watches when working with a lead acid battery. A lead acid battery can produce a short circuit current high enough to weld a ring, or similar metal object, to skin causing a severe burn.

•Be extra cautious to avoid dropping a metal tool onto the battery. It might spark or short-circuit the battery or another electrical part, and that may cause an explosion.

•Never allow battery acid to come in contact with this apparatus.

•Do not operate this apparatus in a closed area or restrict ventilation

in any way.

•Always turn the battery charger off by unplugging it when not in use.

•DO NOT OPEN THE BATTERY CHARGER — there are no user-

serviceable parts inside. Opening the battery charger will void manufacturer’s warranty.

•Operate battery charger only as described in this Instruction Manual.

•Check battery charger and components periodically for wear and

tear. Return to manufacturer for replacement of worn or defective parts immediately.

WARNING: To reduce the risk of injury, follow these instructions

and those published by the battery manufacturer and manufacturer of any equipment you intend to use with this unit. Review cautionary markings on this product and on engine.

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Speciﬁc Safety Instructions for the USB Port

•Do not insert foreign objects into the USB Port.

•Do not attach USB hubs or more than one personal electronic device

to the USB Port.

•Do not use this unit to operate appliances that require more than 3.1 amps in total to operate from the USB Ports.

Speciﬁc Safety Instructions for the AC Pass Through

•Do not insert foreign objects into the AC Pass Through.

•Do not attach AC outlet taps or multi-outlet extension cords, or

attach more than one electrical appliance to the AC Pass Through.

•Observe all Safety Instructions in the “Specific Safety Instructions for Power Cords” section of this Instruction Manual.

First aid

•Skin: if battery acid comes in contact with skin, rinse immediately with water, then wash thoroughly with soap and water. If redness, pain, or irritation occurs, seek immediate medical attention.

•Eyes: If battery acid comes in contact with eyes, flush eyes immediately, for a minimum of 15 minutes and seek immediate medical attention.

•LCD liquid crystal display: If liquid crystal comes in contact with your skin: Wash area off completely with plenty of water. Remove contaminated clothing. If liquid crystal gets into your eye: Flush the affected eye with clean water and then seek medical attention. If liquid crystal is swallowed: Flush your mouth thoroughly with water. Drink large quantities of water and induce vomiting. Then seek medical attention.

SAVE THESE

INSTRUCTIONS

FOR FUTURE USE

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Front Panel Components (Fig. 1)

A. LCD Screen B. AC Pass-Through C. Bank 2 Cable Connectors

(black = negative; red =

positive) D. Battery Charge Button E. Battery Voltage Button F. Engine Start Button

G. Battery Recondition Button H. Single/Multi-Bank Selection

Button I. Alternator Check Button J. USB Power Button K. USB Port L. USB Power/Fault Indicator

A B

C D F H JE G I

Back Panel Components (Fig. 2)

M. Padded Storage Tray N. High-Speed Cooling Fan O. Storage Tray P. Built-in Negative Clamp

(black) (Bank 1)

Q. Built-in Positive Clamp (red)

(Bank 1)

R. AC Power Cord (bottom of

apparatus) S. Fuse T. Fuse Holder U. Clamp Cable Set with

O-ring Connectors (for Bank

2 channel connection, sold

separately)

M N O

R U

S T

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LCD Screen (Fig. 3)

A. Battery Reconditioning

Icons

B. Battery Recondition

Indicator

C. High Temperature

Compensation Icon

D. Low Temperature

Compensation Icon

E. Digital Display (varies by

function)

F. Seconds/Voltage/Ampere/

Percentage Indicator

G. DC Power Supply Mode

Indicator H. Bank 1 Indicator I. Bank 2 Indicator

C D E F HG

MNOPR

J. USB Icon K. Fault Icon L. Alternator Good/Fault

Indicators M. Alternator Icon N. Pump Engine Icon O. Overheat Alarm Icon

P. Alarm Icon Q. Clamp Icons R. Reverse Polarity Icons S. Battery Icon

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Preparing to Charge

1. Be sure the area around battery is well ventilated while the battery is being charged.

2. Remove the battery completely from a boat/airplane or any confined area before charging.

3. If it is necessary to remove battery from a vehicle to charge or to clean terminals, always remove the grounded terminal from the battery first. Make sure all accessories in the vehicle are turned off, so as not to cause an electrical arc.

4. Clean the battery terminals, taking care to avoid getting corrosive material in your eyes.

5. Add distilled water in each cell until battery acid reaches the level specified by the battery manufacturer. This helps purge excessive gas from cells. Do not overfill. For a battery without cell caps (maintenance free), carefully follow manufacturer’s charging instructions.

6. Study all battery manufacturer’s specific precautions, such as removing or not removing cell caps while charging, and recommended rates of charge.

7. Determine the voltage of the battery to be charged by referring to the vehicle manual. This unit is for charging a 12 volt battery only.

NOTE: The Bank 1 battery clamps and the Bank 2 cable connections can be used simultaneously.

CHARGER LOCATION

•Locate the charger as far away from the battery as cables permit.

•Never place the charger directly above the battery being charged;

gases from the battery will corrode and damage the charger.

•Never allow battery acid to drip on the charger when reading gravity

or filling the battery.

•Never operate the charger in a closed-in area or restrict ventilation

in any way.

•A marine (boat) battery must be removed and charged on shore. To charge it on board requires equipment specifically designed for marine use. This unit is NOT designed for such use.

•Do not set a battery on top of the charger.

CONNECTING THE CHARGER

WARNING – To prevent risk of injury and explosion: Never connect more than one set of cables to a single battery. Always make sure that each set of bank connectors is only connected to one battery at a time.

CONNECTION PRECAUTIONS

•Connect and disconnect output clamps only after removing AC Power

Cord from electric outlet.

•Never allow the clamps to touch each other.

•Attach the clamps to the battery and chassis as indicated in the

appropriate section (“Charging a battery installed in a vehicle” or “Charging a battery that has been removed from a vehicle”).

FOLLOW THESE STEPS WHEN THE BATTERY IS INSTALLED IN A VEHICLE

WARNING – A spark near the battery may cause an explosion. To reduce risk of a spark near the battery:

Through Bank 1 Using the Built-in Battery Clamps:

1. Do not charge the battery while the engine is operating.

2. Position AC and clamp cords to reduce risk of damage by hood,

door, or moving engine part.

3. Stay clear of fan blades, belts, pulleys, and other parts that can

cause injury to persons.

4. Check polarity of the battery posts. The positive post (marked

POS, P, +) usually has a larger diameter than the negative battery post (marked NEG, N, –).

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5. Determine which post of battery is grounded (connected) to the chassis. If negative post is grounded to chassis (as in most vehicles), see 6. If positive post is grounded to the chassis, see 7.

6. For a negative-grounded vehicle, connect the positive (red) clamp from the battery charger to the positive (POS, P, +) ungrounded post of battery. Connect the negative (black) clamp to vehicle chassis or engine block away from battery. Do not connect clip to carburetor, fuel lines, or sheet-metal body parts. Connect to heavy gauge metal part of the frame or engine block.

7. For a positive-grounded vehicle, connect the negative (black) clamp from the battery charger to the negative (NEG, N, –) ungrounded post of battery. Connect positive (red) clamp to vehicle chassis or engine block away from battery. Do not connect clip to carburetor, fuel lines or sheet-metal body parts. Connect to a heavy gauge metal part of the frame or engine block.

8. See operating instructions for length of charge information.

9. When disconnecting charger, unplug the AC Power Cord, remove the clamp from vehicle chassis, and then remove the clamp from the battery terminal.

Through Bank 2 Using the Clamp Cable Set with O-ring Connectors (sold separately):

The terminal posts (connections) for Bank 2 are located on the front of the battery charger. Refer to the Fig. 1.

WARNING – To prevent risk of injury and explosion, only connect

manufacturer-supplied clamp cable sets.

1. Do not charge the battery while the engine is operating.

2. Position AC and clamp cords away from hood, door, or moving engine part.

3. Stay clear of fan blades, belts, pulleys, and other parts that can cause injury to persons.

4. Turn the red plastic cap on the battery charger’s Bank 2 positive (+) terminal post (counterclockwise) and remove. Attach the O-ring

at the end of the red clamp cable onto the battery charger’s Bank 2 positive (+) terminal post. Replace the cap and turn clockwise to secure. Do not over-tighten.

5. Turn the black plastic cap on the battery charger’s Bank 2 negative (–) terminal post (counterclockwise) and remove. Attach the O-ring at the end of the black clamp cable onto the battery charger’s Bank 2 negative (–) terminal post. Replace the cap and turn clockwise to secure. Do not over-tighten.

6. Check the polarity of battery posts. The positive (POS, P, +) battery post usually has larger diameter than the negative (NEG, N, –) post.

7. Determine which post of battery is grounded (connected) to the chassis. If negative post is grounded to the chassis (as in most vehicles), see 8. If positive post is grounded to the chassis, see 9.

8. For a negative-grounded vehicle, connect the positive (red) clamp from the clamp cable set to the positive (POS, P, +) ungrounded post of the battery. Connect the negative (black) clamp from the same clamp cable set(s) to vehicle chassis or engine block away from battery. Do not connect the clamp to the carburetor, fuel lines, or sheet-metal body parts. Connect to heavy gauge metal part of the frame or engine block.

9. For positive-grounded vehicle, connect negative (black) clamp from the clamp cable set to negative (NEG, N, –) ungrounded post of battery. Connect the positive (red) clamp to the vehicle chassis or engine block away from battery. Do not connect clip to the carburetor, fuel lines or sheet metal body parts. Connect to a heavy gauge metal part of the frame or engine block.

10. See operating instructions for length of charge information.

11. When disconnecting charger, unplug the AC Power Cord, remove the clamp from the vehicle chassis, and then remove the clamp from the battery terminal.

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FOLLOW THESE STEPS WHEN THE BATTERY HAS BEEN REMOVED FROM A VEHICLE

WARNING – A spark near the battery may cause an explosion. To

reduce risk of a spark near the battery:

Through Bank 1 Using the Built-in Battery Clamps:

1. Check polarity of the battery posts. The positive post (marked POS, P, +) usually has a larger diameter than the negative battery post (marked NEG, N, –).

2. Attach a 24-inch (minimum length) AWG #6 insulated battery cable to the negative battery post (marked NEG, N, –).

3. Connect the positive (red) clamp to the positive battery post (red or marked POS, P, +).

4. Stand as far back from the battery as possible, and do not face the battery when making final connection.

5. Carefully connect the negative (black) clamp to the free end of the battery cable connected to the negative terminal.

6. When disconnecting the charger, always do so in reverse sequence of connecting procedure and break first connection while as far away from battery as practical.

Through Bank 2 Using the Clamp Cable Set with O-ring Connectors (sold separately):

The terminal posts (connections) for Bank 2 are located on the front of the battery charger. Refer to the Fig. 1.

WARNING – To prevent risk of injury and explosion, only connect

manufacturer-supplied clamp cable sets.

1. Turn the red plastic cap on the battery charger’s Bank 2 positive (+) terminal post (counterclockwise) and remove. Attach the O-ring at the end of the red clamp cable onto the battery charger’s Bank 2 positive (+) terminal post. Replace the cap and turn clockwise to secure. Do not over-tighten.

2. Turn the black plastic cap on the battery charger’s Bank 2 negative (–) terminal post (counterclockwise) and remove. Attach the O-ring at the end of the black clamp cable onto the battery charger’s Bank 2 negative (–) terminal post. Replace the cap and turn clockwise to secure. Do not over-tighten.

3. Check the polarity of battery posts. The positive (POS, P, +) battery post usually has larger diameter than the negative (NEG, N, –) post.

4. Attach a 24-inch (minimum length) AWG #6 insulated battery cable to the negative battery post (marked NEG, N, –).

5. Connect the positive (red) clamp to the positive battery post (red or marked POS, P, +).

6. Stand as far back from the battery as possible, and do not face battery when making final connection.

7. Carefully connect the negative (black) clamp to the free end of the battery cable connected to the negative terminal.

8. When disconnecting charger, always do so in reverse sequence of connecting procedure and break the first connection while as far away from battery as practical.

Single-Bank and Multi-Bank Mode Selection

This battery charger can perform operations utilizing either or both charging Banks, allowing dual tasks to be performed simultaneously. Refer to the following tables to select the appropriate Mode for your application.

NOTE: The Engine Start function is only available on Bank 1 in SingleBank Mode.

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Single-Bank Mode (Default)

NOTE: The Bank 1 Indicator flashes and the Bank 2 Indicator is blank when you are using the unit in the Single-Bank Mode.

Connection Maximum

Charge Rate

Engine Start

Functions

Built-in battery clamps only

30A continuous

80A for 5 seconds

(All functions) Battery Voltage Check, Battery Charging, Battery Reconditioning, Alternator Check and Engine Start

Multi-Bank Mode (Up to 2 Simultaneous Connections — Banks 1 and 2)

Connection Maximum

Charge Rate

Engine Start

Functions

•Built-in battery clamps (Bank 1)

•Clamp Cable Set with O-ring Connectors (sold separately) (Bank 2)

15A continuous per Bank (the overall charging capability is 30A continuous when both battery banks are active)

Not applicable

Battery Voltage Check, Battery Charging, Battery Reconditioning and Alternator Check

Charging the Battery

IMPORTANT: If a problem is encountered during the battery charging process, refer to the “Indications and Faults – All Modes” section that follows the battery charging directions.

Single-Bank Battery Charging

1. Plug the battery charger’s AC Power Cord into a functioning AC outlet. A beep will sound and the LCD Screen will show the following:

The Bank 1 Indicator flashes to indicate that the unit is in Single-

Bank Mode (the default mode) and that Bank 1 is selected. (The Bank 2 panel remains blank in Single-Bank Mode.) The empty Battery Icon will light solid to indicate the built-in battery clamps are not yet connected to a battery.

2. Connect the battery charger to the battery using the built-in battery clamps, following the appropriate directions in the “Preparing to Charge” section of this Instruction Manual.

If the clamps are properly connected with regard to polarity, a beep

will sound and the LCD Screen will show the following, indicating the unit is in Standby Mode:

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The Bank 1 Indicator flashes. The Digital Display shows the voltage

of the connected battery. The bars on the Battery Icon represent the charge level of the connected battery. The Clamp Icons and the Battery Icon light solid.

NOTE: In Standby Mode, the Digital Display shows the voltage

(V) of the connected battery by default. Press the Battery Voltage Button once to show the charge status of the battery as a percentage (%) of full. Pressing the Voltage Button cycles through different standby status views of the connected battery.

IMPORTANT: If the battery clamps are connected incorrectly

with regard to polarity, the LCD Screen shows the following:

The Bank 1 Indicator flashes. The (empty) Battery Icon and the

Clamp Icons light solid. The Alarm Icon, Reverse Polarity Icons, and the “+” and “–” signs on both the Clamp Icons and the Battery Icon flash. The unit emits a continuous warning sound until the clamps are disconnected. Remove the clamps and then reconnect the clamps properly.

3. When the clamps are connected correctly, press the Battery Charge Button. The LCD Screen will show the following:

The Bank 1 Indicator flashes. The Digital Display shows the output

current that is charging the battery. The Clamp Icons light solid

and the bars on the Battery Icon will change from empty to solid (bottom to top) to indicate the unit is in Charging Mode.

NOTES:

A. In Single-Bank Mode, the maximum output current is

approximately 30A.

B. If the battery is already charged to nearly full capacity, the

unit’s output current may be automatically reduced by a few amperes, despite the maximum output current rating of 30A.

C. The charging process will start automatically approximately

one minute after the unit is properly connected to a battery if no other actions are taken.

D. The charging process can be terminated by pressing the

Battery Charge Button again to stop the function. The unit will revert to the Standby Mode. It will automatically restart the charging process after approximately one minute if no other actions are taken.

E. In Charging Mode, the Digital Display shows the output

current (A) that is charging the battery by default. Press the Battery Voltage Button once to show the voltage (V) of the connected battery. Press the Battery Voltage Button again to show the charge status of the battery as a percentage (%) of full. Pressing the Voltage Button cycles through different charging status views of the connected battery.

4. When the battery is completely charged, the unit automatically goes into Float Charge Mode. In this mode, the unit monitors the battery voltage and charges as necessary to assure the battery maintains a full charge. The unit remains in Float Charge Mode as

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long as the charger is connected to the battery and plugged into a functioning AC outlet. The LCD Screen shows the following:

The Bank 1 Indicator flashes. The Digital Display shows “FLO”

indicating that the unit is in Float Charge Mode. The Clamp Icons and the Battery Icon (with three bars) will light solid.

NOTE: In Float Charge Mode, the Digital Display shows “FLO” by

default. Press the Battery Voltage Button once to show the voltage (V) of the connected battery. Press the Battery Voltage Button again to show the charge status of the battery as a percentage (%) of full. Pressing the Voltage Button cycles through different charging status views of the connected battery.

5. When disconnecting the battery charger, unplug the AC Power Cord, remove the clamp from the vehicle chassis, and then remove the clamp from the battery terminal.

Multi-Bank Battery Charging

1. Plug the battery charger’s AC Power Cord into a functioning AC outlet. A beep will sound and the LCD Screen will show the following:

The Bank 1 Indicator flashes to indicate that the unit is in Single-

Bank Mode (the default mode) and that Bank 1 is selected. (The

Bank 2 panel remains blank in Single-Bank Mode.) The empty Battery Icon will light solid to indicate the built-in battery clamps are not yet connected to a battery.

2. Press the Single/Multi-Bank Selection Button once to select the Multi-Bank Mode. A beep will sound and the LCD Screen will show the following:

The Bank 2 Indicator lights solid and the Bank 1 Indicator flashes,

indicating Bank 1 (the default) is selected. The (empty) Battery Icon will light solid to indicate the built-in battery clamps (Bank 1) are not yet connected to a battery.

3. Press the Single/Multi-Bank Selection Button again for one second. A beep will sound and the LCD Screen will show the following:

The Bank 1 Indicator lights solid and the Bank 2 Indicator flashes,

indicating Bank 2 is selected. The (empty) Battery Icon will light solid to indicate the Clamp Cable Set (Bank 2) is not yet connected to a battery.

4. Connect the battery charger to the battery using the built-in battery clamps (Bank 1 only) or the Clamp Cable Set (Bank 2), following the appropriate set of directions in the “Preparing to Charge” section at the front of this manual.

Repeat this process for each Bank you will be using.

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5. Once either or both charging Banks are properly connected to a battery with regard to polarity, a beep will sound for each Bank connection and the LCD Screen will show the following to indicate the unit is in Standby Mode (the bars on the Battery Icon represent the charge level of the selected battery; and the Clamp Icons and the Battery Icon light solid):

NOTES:

A. The Bank Indicator of the selected charging Bank flashes.

Toggle between Bank 1 and Bank 2 by pressing and holding the Single/Multi-Bank Selection Button for one second. A beep will sound each time the button is pressed.

B. The Digital Display shows the voltage (V) of the battery

connected to the selected charging Bank by default. Press the Battery Voltage Button once to show the charge status of the battery as a percentage (%) of full. Pressing the Voltage Button cycles through different standby status views of the selected battery.

IMPORTANT: If the clamps of EITHER charging Bank are

incorrectly connected with regard to polarity, the LCD Screen will go directly to the Bank Indicator that is in fault. For example,

if the Bank 1 connections were incorrectly connected with regard to polarity, the LCD Screen would show the following:

The Bank 2 Indicator lights solid and the Bank 1 Indicator flashes,

indicating Bank 1 is currently selected. The (empty) Battery Icon and the Clamp Icons light solid. The Alarm Icon, Reverse Polarity Icons, and the “+” and “–” signs on both the Clamp Icons and the Battery Icon flash. The unit emits a continuous warning sound until the clamps are disconnected (or the Clamp Cable Set is disconnected when using Bank 2). Remove the clamps (or the Clamp Cable Set when using Bank 2) and then reconnect the clamps properly.

6. When all connections are made correctly, select the desired Bank and press the Battery Charge Button to begin charging the battery connected to that charging Bank. The LCD Screen will show the following:

The selected charging Bank Indicator flashes. (For example, the

Bank 2 Indicator lights solid and the Bank 1 Indicator flashes when displaying the charge status of the battery connected to Bank 1.) The Digital Display shows the output current that is charging the selected battery. The Clamp Icons light solid and the bars on the Battery Icon will change from empty to solid (bottom to top) to indicate the selected charging Bank is in Charging Mode.

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NOTES:

A. In Multi-Bank Mode, the maximum output current is

approximately 15A for each Bank.

B. If the selected battery is already charged to nearly full capacity,

the unit’s output current may be automatically reduced by a few amperes, despite the maximum output current rating of 15A.

C. The charging process will start automatically approximately

one minute after the clamps of either Bank are properly connected to a battery if no other actions are taken.

D. The charging process can be terminated by pressing the

E. In Charging Mode, the Digital Display shows the output

current (A) that is charging the selected battery by default. Press the Battery Voltage Button once to show the voltage (V) of the connected battery. Press the Battery Voltage Button again to show the charge status of the battery as a percentage (%) of full. Pressing the Voltage Button cycles through different charging status views of the selected battery.

F. Press and hold the Single/Multi-Bank Selection Button for

one second to cycle through to view a different Bank in Multi-Bank Mode.

G. Press the Single/Multi-Bank Selection Button again to switch

the unit to Single-Bank Mode.

7. When the battery is completely charged, the corresponding Bank automatically goes into Float Charge Mode. In this mode, the unit monitors the battery voltage and charges as necessary to assure

the selected battery maintains a full charge. The unit remains in Float Charge Mode as long as the charger is connected to the battery and plugged into a functioning AC outlet. For example, if the Bank 1 channel is in Float Charge Mode, the backlit LCD screen will display the following:

The selected charging Bank Indicator flashes. The Digital Display

shows “FLO” indicating that the unit is in Float Charge Mode. The Clamp Icons and the Battery Icon (with three bars) will light solid.

NOTES:

A. In Float Charge Mode, the Digital Display shows “FLO” by

default. Press the Battery Voltage Button once to show the voltage (V) of the selected battery. Press the Battery Voltage Button again to show the charge status of the selected battery as a percentage (%) of full. Pressing the Voltage Button cycles through different charging status views of the selected battery.

B. Press and hold the Single/Multi-Bank Selection Button for

one second to cycle through to view a different Bank in MultiBank Mode.

C. Press the Single/Multi-Bank Selection Button again to switch

the unit to Single-Bank Mode.

8. When disconnecting the battery charger, unplug the AC Power Cord, and then disconnect the battery charger from the battery (or batteries) following the last step of the appropriate set of directions in the “Preparing to Charge” section of this Instruction Manual.

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Indications and Faults – All Charging Modes

LCD Screen Shows: Indication | Solution:

Temperature Compensation Activated: The “ ” Icon will appear if the surrounding ambient temperature is higher than approximately 40°C. The “ ” Icon will appear if the surrounding ambient temperature is lower than 0°C. This is not a fault code, but indicates that the unit’s temperature compensation feature is operating.

No user action is required.

Overheat Protection Activated: If the charger is overheated, the charging process for the corresponding charging Bank automatically terminates and the LCD Screen goes directly to the corresponding charging Bank Indicator. The corresponding Bank Indicator, Fault Icon and the Overheat Alarm Icon flash. The (full) Battery Icon and Clamp Icons light solid.

Disconnect all battery charger connections and allow the charger to cool for several minutes. Make sure there is adequate ventilation around the unit before attempting to charge again.

Battery Problem Detected: The charger automatically checks the battery condition 3 minutes after the charging process starts. If the charger detects a problem with a battery, the charging process for the corresponding charging Bank automatically terminates and the LCD Screen goes directly to the corresponding charging Bank Indicator. The corresponding charging Bank Indicator, Fault Icon and the (empty) Battery Icon flash. The Clamp Icons light solid.

Disconnect the corresponding Bank connections. Have the battery checked by a qualified technician.

Possible Battery Problem Detected: If the battery is not fully charged after 18 hours of continuous charging, the battery may have internal damage and will not accept a charge. After 18 hours, the charging process for the corresponding charging Bank automatically terminates and the LCD Screen goes directly to the corresponding charging Bank Indicator. The Digital Display shows “F04”. The corresponding Bank Indicator, Fault Icon and the (empty) Battery Icon flash.

Disconnect the corresponding Bank connections. Have the battery checked by a qualified technician.

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Reconditioning the Battery

Periodic reconditioning is recommended to maintain a battery’s optimum performance. Battery recondition sends a series of electrical pulses to break up the crystalline form of lead sulfate and turn these chemicals into useful battery electrolytes.

1. Refer to the “Charging the Battery” section of this Instruction Manual. Set up the battery charger and connect to the battery following steps 1 and 2 in the “Single-Bank Charging” section or steps 1 through 5 in the “Multi-Bank Charging” section (selecting the desired charging Bank). The unit will be in Standby Mode.

2. Press the Battery Recondition Button once. A beep will sound and the Digital Display will show the following:

The selected charging Bank Indicator flashes. The Battery

Recondition Indicator and the Battery Icon light solid. The Battery Recondition Icons flash, and the bars on the Battery Icon change from solid to empty (top to bottom) repeatedly.

The process stops automatically after 24 hours. To end the process

sooner, press the Battery Recondition Button once again to turn it off. A beep will sound and the corresponding charging Bank will return to Standy Mode.

More than 24 hours may be needed to restore performance on

some batteries. If so, repeat the process.

3. When disconnecting the battery charger, unplug the AC Power Cord, and then disconnect the battery charger from the battery (or batteries) following the last step of the appropriate set of directions in the “Preparing to Charge” section of this Instruction Manual.

Notes Concerning the Battery Recondition Function:

A. IMPORTANT: If 5 cycles of reconditioning does not improve

battery performance, discontinue and recycle the battery.

B. Press and hold the Single/Multi-Bank Selection Button for

one second to toggle to view a different charging Bank in the Multi-Bank mode.

C. Press the Single/Multi-Bank Selection Button to switch the

unit to either the Single-Bank or Multi-Bank mode.

Checking the Alternator

PART 1

No Load (turn OFF all vehicle’s accessories): The vehicle battery must be fully charged before testing the alternator. Run the engine long enough to achieve normal idle speed and verify there is a no-load voltage.

2. Press the Alternator Check Button to start the check. (In the examples in “Part 1,” charging Bank 1 is selected in Single Bank Mode.) The Digital Display shows the following to indicate the unit is analyzing the alternator:

The selected charging Bank Indicator (Bank 1 in this example)

flashes. The Alternator Icon will flash and the Battery icon with two bars will light solid.

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3. If the unit detects that the selected alternator is good, the LCD Screen shows the following:

The Alternator Icon, “ALT GOOD” and the FULL Battery Icon will

light solid.

4. If the unit detects that the selected alternator is out of typical voltage range, the LCD Screen shows the following:

The Fault Icon will flash. The Alternator Icon, “ALT” and the (empty)

Battery Status Icon will light solid.

5. Press the Alternator Check Button again to stop the check.

PART 2

Under Load (accessories ON): Next, load the alternator by turning on as many accessories as possible (except for the A/C and Defrost).

2. Press the Alternator Check Button to start the check. (In the examples in “Part 2,” charging Bank 2 is selected in Multi-Bank

Mode.) The Digital Display shows the following to indicate the unit is analyzing the alternator:

The selected charging Bank Indicator (Bank 2 in this example)

flashes. The unselected charging Bank Indicator lights solid. The Alternator Icon will flash and the Battery icon with two bars will light solid.

3. If the unit detects that the selected alternator is good, the LCD Screen shows the following:

The Alternator Icon, “ALT GOOD” and the FULL Battery Icon will

light solid.

4. If the unit detects that the selected alternator is out of typical voltage range, the LCD Screen shows the following:

The Fault Icon will flash. The Alternator Icon, “ALT” and the (empty)

Battery Status Icon will light solid.

5. Press the Alternator Check Button again to stop the check.

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6. When disconnecting the battery charger, unplug the AC Power Cord, and then disconnect the battery charger from the battery (or batteries) following the last step of the appropriate set of directions in the “Preparing to Charge” section of this Instruction Manual.

Notes Concerning the Alternator Check Function:

A. IMPORTANT: This check may not be accurate for every make,

manufacturer and model of vehicle. Check only 12 volt systems.

B. The unit may detect that the alternator is out of typical

voltage range because someone has added a number of accessory loads on the charging system, thereby increasing current demand from the alternator. MAKE SURE THAT THE ALTERNATOR IS RATED TO SUPPORT THE APPLICATION.

C. Press and hold the Single/Multi-Bank Selection Button for one

second to toggle to view a different charging Bank in the MultiBank mode.

D. Press the Single/Multi-Bank Selection Button to switch the unit

to either the Single-Bank or Multi-Bank mode.

Starting the Engine

IMPORTANT: The Engine Start function can ONLY be performed in Single-Bank Mode (using the Bank 1 battery clamps).

2. Press the Engine Start Button once. A beep will sound and the LCD Screen shows the following:

The Bank 1 Indicator and the Pump Engine Icon flash. The Digital

Display shows the countdown from “60” to “0” to indicate the Bank 1 is in Engine Start Mode. The bars on the Battery Icon will change from empty to solid (bottom to top) repeatedly. The Clamp Icons and the Battery Icon will light solid.

NOTES:

A. The Engine Start function may not be started if the battery

charger detects that the battery is at full capacity (fully charged).

B. The Engine Start countdown process can be terminated by

pressing the Engine Start Button again to stop the function.

3. When “0” is reached, a beep will sound and the LCD Screen will show the following:

The Bank 1 Indicator flashes. The Pump Engine Icon will light solid and the Digital Display shows “0 SEC” to indicate the vehicle is ready to start. The Clamps Icon and the Battery Icon light solid. The bars on the Battery Icon will change from empty to solid (bottom to top) repeatedly.

4. Crank the engine using manufacturer’s guidelines, typically in 3 to 5 second bursts. The Digital Display shows “5 SEC” (a 5-second countdown to use as a timer when cranking the engine).

5. After cranking, the unit will automatically adjust the charging current to 7.5A for 5 minutes, and then revert to Charging Mode. To stop charging, press the Battery Charge Button.

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IMPORTANT: The Engine Start function requires a resting/cooling

period between attempts. Wait 4 to 5 minutes before a second attempt at starting the engine, if needed.

6. When disconnecting the battery charger, unplug the AC Power Cord, and then disconnect the battery charger from the battery following the last step of the appropriate set of directions in the “Preparing to Charge” section of this Instruction Manual.

USB Port

The USB Power Button and the USB Port are located on the front of unit. The USB Power/Fault Indicator is a translucent ring around the USB Port. Refer to Fig. 1 to locate.

Important Notes Concerning the USB Port

1. This unit’s USB Port does not support data communication. It only provides power to an external USB-powered device. The USB Port provides up to 3.1A (5V).

2. When the USB Port is in use, the unit will monitor for the following USB fault conditions: thermal fault, overload and short circuit. If a fault condition exists the USB Power/Fault Indicator will flash blue. In any of these cases, the LCD screen will continuously display the following:

The USB Icon and the Fault Icon will flash. The USB Port will

automatically shut down. Should this occur:

a. Disconnect the USB-powered device and press the USB Power

Button again to turn off the USB Port immediately.

b. Allow the unit to cool down for several minutes before attempting

to use the USB Port again.

c. If a fault occurs again, make sure that the draw of the USB

device plugged into the USB Port does not exceed 3.1A.

d. If an individual USB device is within specifications and the fault

occurs, have the USB device checked for malfunction and do not continue to use it with this USB Port.

3. Some household USB-powered electronics will not operate with this unit.

USING THE USB PORT

1. Plug the battery charger’s AC Power Cord into a functioning AC outlet. A beep will sound and the LCD Screen will show the following:

The Bank 1 Indicator flashes and the (empty) Battery Icon will light

solid to indicate the built-in Battery Clamps are not yet connected to the battery.

2. Press the USB Power Button to turn on the USB Port. A beep will sound, the USB Power/Fault Indicator around the USB Port will light blue and the LCD Screen will continuously display the following:

The USB Icon will light solid, indicating the USB port is ready to use.

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3. Plug the USB-powered device into the USB power port and operate normally.

4. Press the USB power button again to turn off the USB Port.

AC Pass Through

This unit features a 120V AC Pass Through. When using this feature, follow all instructions and warnings found in the “Specific Safety Instructions for the AC Pass Through” in the front of this Instruction Manual.

NOTE: The 120V AC Pass Through is protected by a fuse located on the back of the unit (see Fig. 2). If the 120V AC Pass Through shuts down when it is in use, this fuse may have blown. Refer to the “Maintenance” and “Troubleshooting” sections for more information.

DC Power Supply

This unit can provide 12VDC / 15A of DC power through the Bank 2 connection.

WARNING: To reduce the risk of injury, follow these instructions

and those published by the manufacturer of any equipment you intend to use with this unit. Review cautionary markings on this product and on the appliance.

1. Refer to the “Charging the Battery” section of this Instruction Manual. Set up the battery charger and connect to the battery following steps 1 through 5 in the “Multi-Bank Charging” section. Make sure the unit is selected to display Bank 2 in the Multi-Bank mode and the LCD Screen will display the following:

The Bank 1 Indicator lights solid and the Bank 2 Indicator flashes,

indicating Bank 2 is selected in Multi-Bank mode. The (empty) Battery Icon will light solid to indicate no connections have been made to the Bank 2 Cable Connectors.

2. Press and hold both of the Single/Multi-Bank Selection Button and the Alternator Check Button simultaneously for 3 seconds. The LCD Screen will display the following:

The Bank 2 Indicator flashes. The DC Power Supply Mode Indicator

lights solid to indicate that the DC power supply on the Bank 2 Cable Connectors is ready to use.

3. Properly connect the DC appliance using the Bank 2 Cable Connectors, following all directions in the instruction manual of the DC appliance. Operate the appliance normally.

4. To turn off the DC Power Supply, press and hold both the Single/ Multi-Bank Selection Button and the Alternator Check Button simultaneously for 3 seconds once more. The LCD will display the following:

The Bank 1 Indicator lights solid and the Bank 2 Indicator flashes,

indicating Bank 2 is selected in Multi-Bank mode. The (empty) Battery Icon will light solid to indicate no connections have been made to the Bank 2 Cable Connectors.

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5. When disconnecting the battery charger, unplug the AC Power Cord, and then disconnect the DC appliance from the Bank 2 Cable Connectors on the battery charger.

Important Notes Concerning the DC Power Supply

The DC Power Supply on the Bank 2 Cable Connectors does not support data communication. It only provides up to 12V/15A of DC power to an external DC appliance.

When the DC Power Supply is in use, the unit will monitor for the following fault conditions on the DC terminals: thermal fault, overload, short circuit and being connected in reverse polarity. If a fault

condition exists in the DC terminals, the DC Power Supply Mode Indicator on the LCD Screen will flash.

If the DC Power Supply Mode Indicator flashes to indicate a fault

condition, the DC Power Supply will automatically shut down. Should this occur:

a. Disconnect the DC-powered appliance immediately. b. Allow the unit to cool down for several minutes before attempting

to use the DC Power Supply again.

If a fault occurs again, make sure that the draw of the DC appliance connected to the DC Power Supply does not exceed 15A

d. If an individual DC appliance is within specifications and the fault

occurs, have the DC appliance checked for malfunction and do not continue to use it with this DC Power Supply.

Care and Maintenance

WARNING: To reduce the risk of electric shock, unplug the battery

charger from the outlet before attempting any maintenance or cleaning. Turning off the controls will not reduce this risk.

CLEANING AND STORAGE

•Store the unit in a clean, dry, cool place when not in use.

•Clean the unit casing and cords (as necessary) with a dry (or slightly

damp) cloth. Ensure that unit is completely disconnected from battery and power source before cleaning.

•To maintain the operating condition and maximize the life of the charger cords, always coil them loosely on the built-in storage spool when not in use. Do not wrap them around the unit or crimp them with a tight band.

REPLACING THE 120V AC PASS THROUGH FUSE

The fuse that protects the AC Pass-Through circuit is located on the back of the unit (see Fig. 2) within the Fuse Holder. The Fuse Holder features a groove to allow locking or unlocking using a small coin or screwdriver.

NOTE: Remove the clamps from the clamp holders before proceeding with the fuse replacement procedure.

1. Use a coin, screwdriver, or other appropriate tool. Align it and

push it forward into the groove of the Fuse Holder, then slightly rotate it counterclockwise about 90 degrees until the Fuse Holder is automatically released.

2. Remove the fuse from the Fuse Holder and check it with a continuity

checker.

3. If the Fuse is blown, locate a replacement 6A fuse.

4. Replace the Fuse into the Fuse Holder.

5. Replace the Fuse Holder by placing it back in position. Then use

a coin, screwdriver, or other appropriate tool aligned in the groove of the Fuse Holder, to push it forward, and then slightly rotate it clockwise about 90 degrees until the Fuse Holder locks back into the unit. Do NOT overtighten.

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DeWalt DXAEC80, DXAEC80CA Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual