Schumacher 1200A User Manual

OWNER’S MANUAL

Model 1200A For 12-Volt Batteries

Fully Automatic Microprocessor Controlled Battery Charger with Battery Tester

CAUTION:

Read all Safety Rules and Operating Instructions, and follow them with each use of this product.

Schumacher Electric Corporation Mount Prospect, IL 60056 U.S.A.

Send Warranty Product Repairs to:

Customer Service Returns P.O. Box 280,1025 E. Thompson, Hoopeston, IL 60942-0280 Questions? Call Customer Service: 1-800-621-5485

0099000470/1104

TABLE OF CONTENTS

IMPORTANT SAFETY INSTRUCTIONS ......................................................................... 3

PERSONAL SAFETY PRECAUTIONS ........................................................................... 4

BEFORE USING YOUR BATTERY CHARGER ................................................................ 5

PLUGGING IT IN................................................................................................... 5

USING AN EXTENSION CORD ............................................................................ 5

PREPARING YOUR BATTERY TO BE CHARGED .......................................................... 5

OPERATING INSTRUCTIONS ....................................................................................... 6

Charging Battery In The Vehicle ........................................................................... 6

Charging Battery Removed From The Vehicle .................................................... 7

SPEEDCHARGE CONTROLS ....................................................................................... 8

CONTROL PANEL GUIDE ............................................................................................. 9

USING THE BUILT-IN BATTERY TESTER .................................................................... 10

USING YOUR BATTERY CHARGER ............................................................................ 11

KNOW YOUR CHARGER ............................................................................................ 12

CHARGING TIPS ......................................................................................................... 12

MAINTENANCE AND CARE ........................................................................................ 12

BATTERY PERCENT AND CHARGE TIME ................................................................... 13

TROUBLESHOOTING ................................................................................................. 14

LIMITED WARRANTY ................................................................................................. 16

SAVE THIS OWNER’S MANUAL AND READ BEFORE EACH USE.

Model 1200A, Fully Automatic Battery Charger offers features to accommodate the needs for home or light commercial use. This manual will explain how to use the charger safely and effectively. Please read and follow these instructions and precautions carefully.

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 radio 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 on and off, 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 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 technician for help.

IMPORTANT SAFETY INSTRUCTIONS

WARNING – RISK OF EXPLOSIVE GASES

WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE USING YOUR CHARGER, YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY.

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

SAVE THESE INSTRUCTIONS

This manual contains important safety and operating instructions for battery charger Model 1200A.

• WARNING: Handling the cord on this product or cords associated with accessories sold with this product, will expose you to lead, a chemical known to the State of California to cause cancer and birth defects or other reproductive harm.

Wash

hands after handling.

• Read all instructions and cautions printed on the battery charger, battery, and vehicle or equipment using battery.

• Use charger only on lead-acid type rechargeable batteries, such as those used in cars, trucks, tractors, airplanes, vans, RV’s, trolling motors, etc. This charger is not intended to supply power to a low voltage electrical system other than in a starter-motor application.

• Never use charger for charging dry cell batteries that are commonly used with home appliances like radios, stereos, remote controls, etc. These batteries may burst and cause personal injury.

• Do not disassemble charger. Take it to a qualified service professional if service or repair is required. Incorrect assembly may result in fire or electrical shock.

• To reduce risk of electrical shock, unplug the charger from the outlet before attempting any maintenance or cleaning.

• Always charge battery in a wellventilated area.

• WARNING: Battery chargers get hot during operation and must have proper ventilation. Air needs to flow around entire charger. Do not set charger on flammable materials like carpeting, upholstery, paper, cardboard, etc. Charger may damage leather, plastic and rubber.

HELP US HELP YOU ——

Remember:

Place charger as far away from the

battery being charged as the charger cables will permit.

Do not expose charger to rain or snow. Never charge a frozen battery. If battery

fluid (electrolyte) becomes frozen, bring battery into a warm area to allow battery to thaw before you begin charging.

Never allow battery acid to drip on charger when reading specific gravity or filling battery.

Never set a battery on top of charger.

Never place charger directly above battery being charged. The gases from the battery will corrode and damage the charger.

Never touch the battery clamps together when the charger is on. You could cause a spark.

Never operate charger if it has received a hard blow, been dropped, or otherwise damaged. Take it to a qualified professional for inspection and repair.

PERSONAL SAFETY PRECAUTIONS

Be sure to position the charger power

cord to prevent it from being stepped on, tripped over, or damaged.

Never pull out the plug by the cord when unplugging the charger. Pulling on the cord may cause damage to the cord or the plug.

Do not operate the charger if it has a damaged power cord or plug. Have the cord replaced.

• Wear complete eye and clothing protection when working with leadacid batteries.

• Make sure that someone is within range of your voice to come to your aid if needed while you work with or are near a lead-acid battery.

• Have plenty of fresh water and soap nearby for use in case battery acid contacts your eyes, skin, or clothing. If this happens, wash immediately with soap and water. Then get medical attention.

• Avoid touching your eyes while working with a battery. Acid particles (corrosion) may get into your eyes. If this occurs, flush eyes immediately with running cold water for at least 10 minutes. Then immediately get medical attention.

• Never charge a frozen battery.

• Remove all personal metal items

from your body such as rings, bracelets, necklaces and watches, while working with a lead-acid battery. A battery can produce a short circuit current high enough to weld a ring (or the like) to metal, causing a severe burn.

• Take care not to drop any metal tool

or metal object onto the battery. This may result in a spark or short circuit across the battery or another electrical device that may cause an explosion.

• Always operate the battery charger in

an open, well-ventilated area.

• Never smoke or allow a spark or

flame in the vicinity of the battery or engine. Batteries generate explosive gases.

• Neutralize any acid spills thoroughly

with baking soda before attempting to clean up.

BEFORE USING YOUR BATTERY CHARGER

It is important to understand the charger’s requirements. This section explains the charger’s electrical requirements and how to prepare a battery for charging.

PLUGGING IT IN

Your charger requires a 120V AC receptacle installed according to all local codes and ordinances.

extension cord, please make sure that you follow these guidelines:

• Make sure that pins on plug of extension cord are the same number, size, and shape as those of plug on charger.

• Check that the extension cord is properly wired and in good electrical condition.

• Make sure that the wire size is large enough for its length and for the AC ampere rating, as specified in the chart below.

USING AN EXTENSION CORD

The use of an extension cord is not recommended. If you must use an

MINIMUM RECOMMENDED EXTENSION CORD

Length of Cord, in Feet 25 50 100 150

AWG* Size of Cord 18 16 12 10

*AWG=American Wire Gauge

PREPARING YOUR BATTERY TO BE CHARGED

It is important that you read and follow these guidelines while you are preparing to charge the battery.

• Make sure that you have a 12 volt lead-acid battery. Determine voltage of battery by referring to vehicle owner’s manual. Charge battery initially at charger’s lowest rate.

• Clean the battery terminals. Be careful to keep corrosion from getting in or around your eyes.

• Wear safety glasses. See additional “Personal Safety Precautions” on page 4.

• For batteries with removable vent caps, if required, add distilled water to each cell until the battery acid reaches the level recommended by the manufacturer. This will help purge excessive gases from the cells. Be careful not to overfill. If you have a sealed battery with non-removable vent caps, no action is necessary.

• Take time to read all of the battery manufacturer’s specific precautions, such as removing or not removing vent caps while charging, and recommended rates of charge.

• Be sure that the area around the battery is well ventilated while it is being charged. Gas can be forcefully blown away by using a piece of cardboard or other nonmetallic material as a fan.

• If it is necessary to remove the battery from the vehicle to charge it, always remove the grounded terminal from the battery first. Turn off all vehicle accessories to avoid sparks from occurring.

• NOTE: A marine (boat) battery installed in a boat must be removed and charged on shore.

OPERATING INSTRUCTIONS

IMPORTANT: Follow all safety instructions and precautions when charging your

battery. Wear complete eye protection and clothing protection. Charge your battery in a well-ventilated area.

CHARGING BATTERY IN THE VEHICLE:

1. Avoid personal injury by keeping clear of fan blades, belts, pulleys and other engine parts.

2. Avoid damaging the charger by keeping the power cord and output cords away from the hood, door or moving engine parts.

3. Note the polarity of the battery posts by checking the identification marks on the battery: POSITIVE (POS, P or +) and NEGATIVE (NEG, N or -). The positive post is usually larger than the negative post.

4. Identify which battery post is grounded or connected to the chassis. THIS IS NORMALLY THE NEGATIVE POST.

NEGATIVE GROUNDED SYSTEM

5. Connecting to a negative-grounded system: Connect the red (POSITIVE)

output clamp to the POSITIVE post of the battery. Rock and twist the clamp back and forth to be sure a solid electrical connection is made. Then connect the black (NEGATIVE) output clamp to a heavy, unpainted metal

part of the chassis or engine block, away from the battery (see figure above). DO NOT connect clamp to negative battery post, carburetor, and fuel line or sheet metal part.

Connecting to a positive-grounded system: Connect the black (NEGA-

TIVE) output clamp to the NEGATIVE post of the battery. Rock and twist the clamp back and forth to be sure a solid electrical connection is made. Then connect the red (POSITIVE) output clamp to a heavy, unpainted metal part of the chassis or engine block, away from the battery. DO NOT connect clamp to positive battery post, carburetor, and fuel line or sheet metal part.

6. Plug power cord into an AC outlet. The charger will be set to the Tester Mode for REGULAR battery type.

7. Press the appropriate control buttons to select the desired charge rate and battery type. The CHARGING (yellow) LED should light and the charging process should start. If the CHECK (red) LED is on, check for correct cable connections.

8. To disconnect the charger, unplug its power cord before attempting to disconnect the output clamps. Then, standing away from the battery, remove the output clamp from the chassis or engine block. Finally, remove the output clamp from the battery post.

9. Clean and store the charger in a dry location.

CHARGING BATTERY REMOVED FROM THE VEHICLE:

POSITIVE

BATTERY

24", 6 GAUGE CABLE

NEGATIVE

1. Note the polarity of the battery posts by checking the identification marks on the battery: POSITIVE (POS, P or +) and NEGATIVE (NEG, N or -). The positive post is usually larger than the negative post.

2. Attach at least a 24-inch-long, 6gauge (AWG), insulated battery cable to NEGATIVE (NEG, N or -) battery post. Rock and twist the clamp back and forth to be sure a solid electrical connection is made.

3. Connect the red (POSITIVE) output clamp to the POSITIVE battery post. Rock and twist the clamp back and forth to be sure a solid electrical connection is made.

4. Position yourself as far away from the battery as possible, and then connect the black (NEGATIVE) output clamp to the free end of the cable.

5. Plug the power cord into an AC outlet. The charger will be set to the Tester Mode for REGULAR battery type.

BATTERY CHARGER

POWER CORD

TO GROUNDED POWER OUTLET

6. Press the appropriate control buttons to select the desired charge rate and battery type. The CHARGING (yellow) LED should light and the charging process should start. If the CHECK (red) LED is on, check for correct cable connections.

7. To disconnect the charger, unplug its power cord before attempting to disconnect the charger clamps. Then, standing away from the battery, remove the output clamp from the NEGATIVE battery post. Finally, remove the output clamp from the POSITIVE battery post.

8. Clean and store the charger in a dry location.

IMPORTANT: Follow all safety instructions and precautions when charging your battery. Wear complete eye protection and clothing protection. Charge your battery in a well-ventilated area.

SPEEDCHARGE CONTROL

Digital

LED

Status LEDs

1200A CONTROL PANEL

DISPLAY MODE SWITCH

Use this switch to set the function of the digital meter to one of the following:

• BATTERY %: The digital meter

displays an estimate of the percent of charge of the battery connected to the charger battery clamps.

• VOLTAGE: The digital meter displays

the voltage at the charger battery clamps in DC volts.

CHARGE RATE SWITCH

Use this switch button to set the charge rate to one of the following three.

• 2A CHARGE RATE: Intended for

charging small batteries such as those commonly used in garden tractors, snow mobiles and motorcycles. The 2A rate is not intended to be used as a trickle charger for larger batteries.

• 8A or 12A CHARGE RATE: Use for

charging automotive batteries, marine batteries, and deep cycle batteries. Not intended for industrial applications.

BATTERY TYPE SWITCH

Use this switch button to set the type of battery to be charged to one of the following three.

Display

Mode

LEDs

Charge

Rate

LEDs

Switch Buttons

Battery

Type LEDs

• REGULAR: This is the type of battery

usually used in cars, trucks, and motorcycles. These batteries have vent caps and are often marked “low maintenance” or “maintenance-free”.

• DEEP CYCLE: Deep cycle batteries

are usually marked as “deep cycle” or “marine”. Deep cycle batteries are usually larger than the other types.

• AGM, GEL CELL: AGM and gel cell

batteries have sealed cases without vent caps. Such batteries are often smaller than the other types.

With the exception of AGM and gel cell batteries, all other battery types may or may not have vent caps.

Vent caps are located on top of the battery and provide a means to add distilled water when needed

. Batteries should be marked with their type. If charging a battery that is not marked, check the manual of the item that uses the battery. If the battery type is unknown, use the REGULAR setting. Make sure the battery complies with the safety instructions on page 3.

CONTROL PANEL GUIDE

Digital

Display

-C

User selected

User selectedUser selected

User selected

User sel.

User selected

User sel.

1200A CONTROL PANEL GUIDE

MODE OF OPERATION

Initial power-up, battery not detected O O O 0.0

No battery or reversed battery detected O 0% or 0.0V

Battery tester activated O 0~100%

Battery tester with charged battery O O 100%

Battery tester with no battery O O 0%

Voltage meter activated O 0.0~17.0V

2 Amp charge with battery detected O O xx% or xx.xV

8 Amp charge with battery detected O O xx% or xx.xV

12 Amp charge with battery detected O O xx% or xx.xV

Charge complete - Maintain Mode started O 100% or xx.xV

Desulfation mode activated B 15% or 16V

Charge aborted B 18.8 (B)

O indicates an LED that is on continuously.

B indicates an LED that blinks on and off.

USING THE BUILT-IN BATTERY TESTER

OVERVIEW

The charger has a built-in battery tester that displays either an accurate battery voltage or an estimate of the battery’s relative charge based on the battery voltage and a scale set by the Battery Council International.

TESTING SEQUENCE

There are four basic steps required to use the charger as a battery tester.

1. Connect the charger battery clamps to the battery. Be sure to follow all of the precautions listed under “OPERATING INSTRUCTIONS”.

2. Connect the charger power cord to a 120 VAC outlet. Again, be sure to follow all of the precautions listed under “OPERATING INSTRUCTIONS”.

3. If necessary, press the Battery Type button until the correct type is indicated.

4. Read the voltage on the digital meter or press the display mode button to set the tester to “Battery %” and read the battery percent.

TESTER AND CHARGER

When first turned on, the charger operates only as a tester, not as a charger. To continue to use it as only a tester, avoid pressing the CHARGE RATE switch button. Selecting a charge rate activates the battery charger and deactivates the tester.

POWER-UP IDLE TIME LIMIT

If no switch button is pressed within ten minutes after the unit is first powered up, the unit will automatically switch from tester to charger, if a battery is connected. In that case, the unit will be set for the 2A charge rate and REGULAR battery type.

TESTER WITHOUT TIME LIMIT

If either the DISPLAY MODE or BATTERY TYPE button is pressed within the first ten minutes after the unit is powered up, the unit will remain a tester (not a charger) indefinitely, unless a charge rate is selected.

TESTING AFTER CHARGING

After the unit has been changed from tester to charger (by selecting a charge rate), it remains a charger as long as it has power. Disconnect and reconnect the power to change the unit back to a tester.

TESTER STATUS LEDs

When the charger is operating as a battery tester, the status LEDs light under the following conditions.

• The CHARGED (green) LED will light if a fully charged battery is tested.

• The CHARGING (yellow) LED does not light in the battery test mode.

• The CHECK (red) LED will light if a battery is not properly connected.

• When the tester display mode is set to voltage, none of the Status LEDs light (it could be testing a battery) as long as a voltage greater than one volt is detected.

INITIAL PERCENT CALCULATION

When a battery % is calculated for the first time after connecting a battery, the digital meter will show two dashes (“--”) for several seconds while the tester analyzes the battery.

NOTES FOR TESTING BATTERY %

A recently charged battery could have a temporarily high voltage due to what is known as “surface charge”. The voltage of such a battery will gradually drop during the period immediately after the charging system is disengaged. Consequently, the tester could display inconsistent values for such a battery. For a more accurate reading, the surface charge should be removed by temporarily creating a load on the battery, such as by turning on lights or other accessories.

The battery % ranges from 0 to 100. The battery tester is only designed to

test 12V batteries. Testing a device with a rapidly changing voltage could yield unexpected or inaccurate results.

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