Schumacher SF 4020, SF 6030, SF 4022, SF 2001, SF-8050 User Manual

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Schumacher SF 4020, SF 6030, SF 4022, SF 2001, SF-8050 User Manual

Models

OWNER'S MANUAL

SF 2001, SF 4020,

Important Instructions

SF 4022, SF 6030, SF 8050

Save These Instructions

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.

A.

GENERAL BATTERY SAFETY

 

 

1.Before you use your battery charger, be sure to read all instructions and cautions printed on:

Battery Charger

Battery

Vehicle or unit using battery

2.Use battery charger on LEAD ACID type rechargeable batteries only, such as used in autos, trucks, tractors, airplanes, vans, RV's, trolling motors, etc. Charger is not intended to supply power to low-voltage electrical system other than in an automotive application.

WARNING: Do not use battery charger for charging dry-cell batteries that are commonly used with home appliances. These batteries may burst and cause injury to persons and damage to property.

3.Use only attachments recommended or sold by manufacturer. Use of non-recommended attachments may result in fire, electric shock, or injury.

4.When disconnecting the battery charger, pull by the plug not by the cord. Pulling on the cord may cause damage to cord or plug.

5.Locate battery power cord so it cannot be stepped on, tripped over, or subjected to damage or stress.

6.Do not operate charger with damaged cord or plug. Have cord replaced immediately.

7.Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged in any way. Take it to a qualified professional for inspection and repair.

8.Do not disassemble charger. Take it to a qualified professional when service or repair is required. Incorrect reassembly may result in electric shock or fire.

9.To reduce risk of electric shock, unplug charger from outlet before attempting any maintenance or cleaning.

10.Do not use an extension cord unless absolutely necessary. Use of an improper extension cord could result in fire or

electric shock. If an extension cord must be used, make sure that:

Pins on plug of extension cord are the same number, size, and shape as those of the plug on the charger.

Extension cord is properly wired and in good electrical condition.

Wire size is large enough for AC ampere rating of charger, as specified below:

_____________________________________________

Length of cord (feet):

25

50

100

150

AWG size of cord:

16

12

10

8

(American Wire Gauge)

_____________________________________________

11.Always charge battery in a well ventilated area.

NEVER operate in a closed-in or restricted area without adequate ventilation because of risk of explosive gases. WARNING: Risk of explosive gas.

12.Locate charger as far away from battery as DC charger cables permit.

13.Do not expose charger to rain or snow.

14.NEVER charge a frozen battery. If battery fluid (electrolyte) is frozen, bring into a warm area to thaw before charging.

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

16.NEVER set a battery on top of charger.

17.NEVER place charger directly above battery being charged. Gases from battery will corrode and damage charger.

18.NEVER touch the battery clips together when the charger is energized.

WARNING: Battery chargers get hot during operation and must have proper ventilation. Air needs to flow around entire charger.

Do not set on flammable items like carpeting, upholstery, paper, cardboard, etc. Will damage leather and melt plastic and rubber.

IMPORTANT SAFETY INSTRUCTIONS •

SAVE THESE INSTRUCTIONS •

ELECTRIC CORPORATION

801 BUSINESS CENTER DRIVE • MOUNT PROSPECT, ILLINOIS 60056-2179

In Canada, for warranty claims and replacement, please return item to place of purchase during warranty period with receipt of purchase.

553-300

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B. PERSONAL PRECAUTIONS AND SAFETY

1.WARNING: Wear complete eye protection and clothing protection, when working with lead-acid batteries.

2.Make sure someone is within range of your voice or close enough to come to your aid when you work with or near a lead-acid battery.

3.Have plenty of fresh water and soap nearby for use if battery acid contacts skin, clothing, or eyes. If battery acid contacts skin or clothing, wash immediately with soap and water.

4.Avoid touching your eyes while working with a battery. Acid particles (corrosion) may get into your eyes! If acid enters your eye, immediately flood eye with running cold water for at least 10 minutes. Get medical attention immediately.

5.Remove all 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 the like) to metal, causing a severe burn.

6.Take care not to drop a metal tool or other metal onto the battery. Metal may cause sparking or short circuit the battery or another electrical devise. Sparking may cause an explosion.

7.Always operate battery charger in an open well ventilated area.

8.NEVER smoke or allow a spark or flame in the vicinity of the battery or engine. Batteries generate explosive gases!

C. GROUND AND AC POWER CORD CONNECTIONS

Charger should be grounded to reduce the risk of electric shock. Charger is equipped with an electric cord having an equipment grounding conductor and a grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances. This battery charger is designed for use on a nominal 120 volt circuit and has a grounded plug that looks like the plug illustrated in FIGURE 1

(A). This plug should be used in a grounded outlet. The plug pins must fit the receptacle (outlet).

ADAPTER: A temporary adapter, as shown in FIGURE 1 (B) and (C), may be used to connect the charger plug to a two pole receptacle (outlet), as shown in FIGURE 1 (B).

NOTE: The temporary adapter should be used only until a properly grounded outlet can be installed by a qualified electrician.

GROUNDING

SCREW

FIGURE 1 GROUNDING METHODS

DANGER: Never alter the AC cord or plug provided. If it will not fit outlet, have a proper outlet installed by a qualified electrician. Improper connection can result in a risk of an electrical shock. DANGER: Before using an adapter, as illustrated, be certain that the center screw of the outlet plate is grounded. The greencolored rigid ear or lug extending from the adapter must be connected to a properly grounded outlet. Make certain it is grounded. If necessary, replace original outlet cover plate screw with a longer screw that will secure adapter ear or lug to outlet cover plate and make ground connection to grounded outlet.

 

"Use of adapter plug not allowed in Canada"

 

 

D.

PREPARING TO CHARGE

 

 

1.Make sure you have a 12 volt or a 6 volt lead-acid battery and select battery charger switch accordingly.

2.Clean battery terminals. Take care to keep corrosion from coming in contact with your eyes.

3.If required, add distilled water in each cell until battery acid reaches levels specified by battery manufacturer. This helps purge excessive gas from cells. Do not overfill. For a battery without cell caps, carefully follow manufacturer's recharging instructions.

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

5.Be sure area around battery is well ventilated while battery is being charged. Gas can be forcefully blown away by using a piece of cardboard or other non-metallic material as a fan.

6.If necessary to remove battery from vehicle to charge, always remove grounded terminal from battery first. Make sure all accessories in the vehicle are off, so as not to cause an arc.

7.A marine (boat) battery must be removed and charged on shore. To charge it on board requires equipment specially designed for marine use.

E.

CHARGER LOCATION PRECAUTIONS

Never place charger directly above the battery being charged, gases from battery could damage the charger.

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

Never operate charger in a closed in area, or restrict ventilation in any way.

Do not set battery on top of the charger.

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F.OPERATING INSTRUCTIONS: CHARGING BATTERY IN VEHICLE

When charging battery in the vehicle, take care to determine the battery type and which post is grounded. To reduce risk of a spark near battery, follow these steps when battery is installed in vehicle. WARNING: A spark near battery may cause battery explosion.

1.Position AC power cord and DC charging cords to reduce risk of damage by hood, door, or moving engine parts.

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

3.Check polarity of battery posts. Battery case will be marked by each post: POSITIVE (POS, P, +) and NEGATIVE (NEG, N, -). NOTE: The positive battery post usually has a larger diameter than the negative post.

4.Determine which post of battery is ground (connected) to chassis.

NOTE: The negative post is normally grounded.

NEGATIVE GROUNDED POST

5A. For negative-grounded vehicle, connect POSITIVE (RED) clip from battery charger to POSITIVE (POS, P, +) ungrounded post of battery. Connect NEGATIVE (BLACK) clip to vehicle chassis or engine block away from battery. Connect to a heavy gauge metal part of the frame or engine block.

POSITIVE GROUNDED POST

5B. For positive-grounded vehicle, connect NEGATIVE (BLACK) clip from battery charger to NEGATIVE (NEG, N, -) ungrounded post of battery. Connect POSITIVE (RED) clip to vehicle chassis or engine block away from battery. Connect to a heavy gauge unpainted metal part of the frame or engine block.

WARNING: Do not connect clip to carburetor, fuel lines, or sheetmetal body parts. NOTE: Attach clips to battery post and twist or rock back and forth several times to make a good connection. This tends to keep clips from slipping off terminals and helps to reduce risk of sparking.

6.Select amperage.

7.Follow steps 1-4 in Battery Charger Section K.

8.When the battery is fully charged, unplug the charger from the AC power source.

9.Remove charger clips from (1) chassis and (2) battery pole in that order.

10.Clean and store battery charger.

G.OPERATING INSTRUCTIONS: CHARGING BATTERY OUT OF VEHICLE

When charging battery out of vehicle, take care to determine the battery type. To reduce risk of a spark near battery, follow these steps when battery is outside vehicle. WARNING: A spark near the battery may cause battery explosion. WARNING: When removing battery from vehicle or boat, disconnect grounded pole first. When disconnecting, make sure all accessories are off, so as not to cause an arc. (NOTE: A marine (boat) battery must be removed and charged on shore. (To charge on board requires special equipment designed for marine use.) WARNING: When reinstalling battery, attach the ground post first.

24" Cable

Battery

 

Cable

Do not use to parallel charge batteries

1.Check polarity of battery posts. Battery case will be marked by each post: POSITIVE (POS, P, +) and NEGATIVE (NEG, N, -). NOTE: The positive battery post usually has a larger diameter than the negative post.

2.Attach a 24-inch long (or longer) 6-gauge (AWG) insulated battery cable to NEGATIVE (NEG, N, -) battery post.

(The 24" lead is not supplied. You may purchase at most automotive stores.)

The 24" lead provides a safer connection condition. Spark-

ing or arcing could occur when connecting the charger clip to the lead.

3.Connect POSITIVE (RED) charger clip to POSITIVE (POS, P, +) post of battery. Rock clip back and forth to make good connection.

4.Position yourself and free end of 24 inch cable as far away from battery as possible. Then connect NEGATIVE (BLACK) charger clip to free end of cable.

WARNING: Do not face battery when making final connection. Rock clip back and forth to make a good connection.

5.Select amperage:

6.Follow steps 1-4 in Battery Charger Section.

7.When battery is fully charged, unplug charger from AC outlet.

8.When battery is fully charged and the charger is unplugged:

(1)Remove clip from end of the Negative end of cable, then

(2)Remove clip from Positive battery post, in that order.

9.Clean and store battery charger.

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

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H.

OUTPUT SELECTOR CONTROLS

 

 

CHARGE RATE

CHARGE TIME/MINUTES

SF 2001

200 amp start

 

2 amp

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

#1

 

 

 

#2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Ammeter

40 amp

 

40 amp

 

 

 

 

 

 

 

 

200 amp

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VOLT/RATE SELECTOR

CHARGE TIME/MINUTES

 

 

 

 

 

 

 

 

SF 4020

 

 

12 VOLT

 

 

 

 

 

 

 

 

 

 

 

 

10 AMP

 

 

 

 

 

 

 

 

12 VOLT

 

 

 

 

 

 

 

12 VOLT

40 AMP

 

 

 

 

 

 

 

(Range: .5-1AMP)

 

 

 

 

 

 

MAINTAINER

 

 

 

 

 

 

 

 

 

 

 

 

Ammeter

 

6 VOLT

12 VOLT

 

 

 

 

 

 

 

40 AMP/

200 AMP

 

 

 

 

 

 

 

100 AMP

START

 

 

 

 

 

 

 

START

 

 

 

 

 

 

 

 

 

OFF

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VOLT/RATE SELECTOR

CHARGE TIME/MINUTES

 

SF 4022

 

 

 

 

 

 

 

12 VOLT/10 AMP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6 VOLT/40 AMP START

 

 

 

 

 

 

 

 

12 VOLT

 

 

 

BATTERY

 

 

 

 

12 VOLT

40 AMP

 

Voltmeter

 

TEST

 

 

 

 

 

 

2 AMP

 

 

 

 

 

 

 

6 VOLT

 

 

 

 

 

6 VOLT

6 VOLT

 

 

 

 

 

 

 

 

Ammeter

 

 

 

 

50 AMP

40AMP/

 

 

 

 

 

 

100 AMP

 

 

 

 

 

 

 

 

START

 

 

 

12 VOLT

 

 

 

 

 

OFF

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VOLT/RATE SELECTOR

CHARGE TIME/MINUTES

 

 

 

 

 

 

 

6 VOLT

 

 

SF 6030

 

 

60 AMP/200 AMP

 

 

 

 

START

 

 

 

 

 

 

 

6 VOLT

 

 

 

 

 

 

 

 

30 AMP

12 VOLT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

30 AMP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OFF

 

 

 

Ammeter

 

 

12 VOLT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

60 AMP

 

 

 

 

 

 

 

 

12 VOLT

 

 

 

 

 

 

 

 

300 AMP

 

 

 

 

 

 

 

 

START

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TIMER: The main function of the timer is to prevent over charging while allowing a battery time to obtain a satisfactory charge. To properly set the timer you must know the size of the battery in ampere hours or reserve capacity in minutes and the state of charge. Often the state of charge is not known, this is one reason why the timer was limited to 2.25 hours. With the aid of a battery load tester the state of charge can be obtained within a few seconds. For example, the average size automotive battery at a 50% state of charge will require 1 to 1.5 hours of charging at the 40 amp rate to reach the full charge state. For the same battery with the timer set to it’s maximum, 2.25 hours, over charging will occur, but not likely cause harm to a battery that was other wise in good condition. When the charge state is not known, start out with a timer setting of 1 hour or less.

HOLD This position defeats the timer function, allowing for continuous operation. Use when you want to charge more than 2.25 hours. This is normally the case when the 2 amp charge rate is selected. Be sure to monitor the charging and stop the charge when the battery is charged.

Switch #1 use this switch to select the 200 amp engine start and the 40 amp charge rate. Switch #2 must be in the down position (40amp /200 amp select) when using switch #1.

Switch #2 Use this switch to select the 2 amp charge rate. Also use to select use of switch #1.

VOLT/RATE SELECTOR

CHARGE TIME/MINUTES

 

 

 

 

6 VOLT

 

SF 8050

BATTERY

60 AMP/200 AMP

 

 

TEST

START

 

 

 

 

 

 

6 VOLT

 

 

 

 

 

 

30 AMP

 

 

 

 

 

 

12 VOLT

 

 

 

 

 

 

30 AMP

 

 

Voltmeter

 

 

 

 

 

 

 

 

 

 

LOAD ON

 

 

 

 

OFF

 

 

 

 

6 VOLT

 

 

 

 

 

 

 

 

 

 

12 VOLT

 

 

Ammeter

 

 

 

60 AMP

 

 

 

 

 

12 VOLT

 

 

 

 

 

 

300 AMP

 

 

 

12 VOLT

START

 

 

 

 

 

 

 

 

 

Rotary switch - Use the rotary switch (volt / rate selector, on all models except the SF 2001) to select the charge rate or engine start setting you require. Read the switch dial for those available on this charger.

Load Tester Switch (on SF 8050 only)

Use this switch to apply load to the battery.

Follow these easy steps:

1.Select the correct setting of the meter ( 6v or 12v ) to agree with the battery to be tested.

2.Connect the charger leads to the battery following the instructions in section F.

3.Press the Load Switch to load on for 10 seconds and read the voltmeter.

Good (green) - indicates the battery capacity is OK. Battery may or may not be fully charged. Check the specific gravity of battery to determine the state of charge. If the specific gravity is less than full charge, check for electrical drain or possible charging system trouble. Recharge battery to full level.

Yellow or Red, but needle remains steady - indicates that the battery capacity is not satisfactory. Battery may be either defective or not fully charged. Check specific gravity to see which condition exists. It charging does not bring the battery specific gravity to full charge, the battery should be replaced.

Yellow or Red, but needle remains falling - indicates the battery may be defective or run down. Release the load switch and note voltmeter reaction. Voltage recovery into green or above within seconds indicates a defective battery. Slow recovery indicates run down condition. For best results, check specific gravity.

The Ammeter indicates the amount of current measured in amperes that is being drawn by the battery. For example, In the 40 amp charge rate a typical discharged battery will initially draw approximately 40 amps. As the battery continues to charge, current will taper to 15 to 20 amps at full charge. The Start area of the meter indicates a high rate of current being drawn from the charger. When cranking an engine, the starter motor draws upwards to 200300 amps. The meter needle will be at the extreme right side of the start area. Sometimes a battery for the first few minutes of it’s charge will draw more than 40/50 amps, in this case the needle may be within but not to the extreme right side of the start area. The 2 amp charge rate (on some models) may indicate some activity on the meter. The meter doesn’t have the resolution to display this low rate.

The Voltmeter indicates the voltage at the battery terminals. Note that Model SF 4022 is not a Load tester, but a voltmeter. Use as follows:

1.Charger need not be plugged into AC outlet. Timer should be in the Off position, 6v/12v switch in position to match battery being tested, and then connect following instructions in Section F.

2.Observe the meter indication. Keep in mind that this reading is only a battery voltage reading, a false surface charge may mislead you. We suggest that you turn on your headlamps for a couple of minutes before you read the meter. Read a couple of minutes after you have shut the headlamps off, then follow the convenient color code of the meter.

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I.

ENGINE START

 

 

1.Set charge rate switch and timer to OFF positions.

2.With the charger unplugged from the AC outlet, connect the charger to the battery following instructions given in section F.

3.Plug the charger AC power cord into the AC outlet, then move timer from OFF to HOLD position.

4.Set the charge rate switch to the engine start position that matches the vehicle battery and then crank the engine. Follow the duty cycle printed on the front panel of your charger for proper ON / OFF times. During extremely cold weather or when the battery is severely exhausted, charge the battery for about 5 minutes before cranking the engine.

5.If the engine fails to start, charge the battery for 5 more minutes before attempting to crank the engine again.

6.After the engine starts, move the charge rate switch to OFF and unplug the AC power cord from the outlet before disconnecting DC clips.

Do not try to engine start a vehicle without a battery in it. You may damage the vehicle’s system. If the engine spins, but doesn’t start after several starting attempts, there is a problem with the engine of the vehicle other than its starting system. STOP cranking the engine until the other problem has been found and corrected.

J.

CHARGE PERIOD

 

 

Determine the charge level of your battery with a hydrometer or electronic percent of charge tester. Determine the ampere hour rating of your battery. It may be on the battery information label. If the battery is rated in Reserve Capacity, convert to ampere hour rating using the following formula:

Ampere Hour rating = (Reserve Capacity) + 16

Example: AH rating = (168 Reserve Capacity) + 16 or AH = 100

(2)

(2)

(Reserve capacity is in minutes)

 

Use the following formula to determine the time of charge required: (AH x % of charge needed) divided by amp setting of the charger, times 1.25 = hours of charge: Example: State of charge of the battery is 50%

Percent of charge needed is 100% - 50% = 50% (.50 decimal) Ampere rating of the battery is 100AH

Charger setting is 10 amps

100 x .50 =

x 1.25 =

6.25 hours of charge needed

10+ 1.00 hour more if charging a deep cycle battery

7.25hours total for a deep cycle battery.

A hydrometer reading of the specific gravity of the electrolyte (fluid) of the battery in good condition should be between 1.25 and 1.28. When a battery reaches 80-85% of full charge, bubbles will appear on the surface of the fluid. As the battery nears full charge, bubbling will become more vigorous.

K.

BATTERY CHARGING

 

 

CHARGER MUST BE ASSEMBLED BEFORE USING.

1.Before charging any battery, make sure the electrolyte (battery liquid) in each cell is at correct level.

2.Set all switches and timers to the OFF position.

3.If the battery is being charged inside the vehicle, use connection procedures outlined in Section F. Should the battery be removed from the vehicle, follow the instruction in Section D, step 6 and Section G. Plug the power cord into the AC outlet.

4.Set the charge rate switch to the desired charge position. See Charge Rate Charts.

5. Set the timer from OFF position to desired timed charge, 30135 minutes.

NOTE: These battery chargers are not automatic and can overcharge a battery if permitted to operate for extended periods of time. Monitor the charging often.

BATTERY SIZE/RATING

 

CHARGE RATE*/CHARGING TIME - HOURS**

 

 

 

 

 

 

 

 

 

 

 

 

 

2 AMP

10 AMP

30 AMP

40 AMP

50 AMP

60 AMP

SMALL

Motorcycle, Garden

 

6 - 12 AH

1.5 to 3

NR

NR

NR

NR

NR

BATTERIES

Tractor, etc.

 

12 - 32 AH

3 to

8

 

 

 

 

 

 

 

200 - 315 CCA

 

40 - 60 RC

11 to 15

2.5 to 3

.75 to 1

.5 to .75

NR

NR

CAR/TRUCKS

315 - 550 CCA

 

60 - 85 RC

15 to

18

3 to 4

1 to 1.5

.75 to 1

.5 to .75

.5 to .63

 

550 - 875 CCA

 

85 - 125 RC

18 to

25

4 to 5

1.5 to 1.7

1 to 1.5

.75 to 1

.63 to .75

 

 

 

55 MC

15

 

4

NR

NR

NR

NR

MARINE/

 

 

80 MC

19

 

5

2

1.75

NR

NR

DEEP CYCLE

 

 

 

 

 

105 MC

23

 

6

2.5

2

NR

NR

 

 

 

 

*Charge Rates for this model are listed on the front panel.

**Based on battery at 50% charge.

AH

Ampere Hours

NR

Not Recommended

CCA

Cold Cranking Amps

RC

Reserve Capacity

MC

Marine Capacity

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