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products we sell. The instructions are exact copies of what the manufacturer includes with the
product being sold.
That means the quality and accuracy of the instructions is solely dependent on what the
manufacturer produces. We do our best to make the text legible and the pictures viewable.
However, the end result depends largely on the quality of instructions the manufacturer
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To the best of our knowledge the instructions and application information contained in the
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or
MODEL : TM220 / TM221
AC : 100 – 240VAC
DC : 2.8A 12V
0.90A @ 100Vac / 0.40A @ 240Vac
50-60Hz
INSTRUCTIONS FOR USE
IMPORTANT: Read completely
before charging
+-
1 x 12V
STD / AGM-MF / GEL / CYCLIC CELL
7.5 - 120Ah (48 hour charge)
Automatic charger for 12V lead/acid batteries
100 - 240VAC
TEST MAINTAIN
30min
ON
ACTIVATE
DESULFATE
1
2
3.1
3.2
55
6
4.1
CHARGE
VERIFY
4.2
12,40V
12,40V
IMPORTANT SAFETY
INSTRUCTIONS FOR CANADA & USA
THIS PORTION OF THE MANUAL CONTAINS IMPORTANT SAFETY INSTRUCTIONS FOR
THE OPTIMATE 5 BATTERY CHARGER. IT IS OF THE UTMOST IMPORTANCE THAT
EACH TIME, BEFORE USING THE CHARGER, YOU READ AND EXACTLY FOLLOW THESE
INSTRUCTIONS. SAVE THESE INSTRUCTIONS.
AUTOMATIC CHARGER FOR 12V LEAD-ACID BATTERIES
DO NOT USE FOR NiCd, NiMH, Li-Ion OR NON-RECHARGEABLE BATTERIES.
1. CAUTION : CLASS II APPLIANCE. DO NOT CONNECT TO GROUND.
2. For indoor use only. Do not expose charger to rain or snow.
3. Use of an attachment not recommended or sold by the battery charger manufacturer may result in a risk of fi re, electric shock,or injury to
persons.
4. To reduce risk of damage to electric plug and cord,pull by plug rather than cord when disconnecting charger.
5. An extension cord should not be used unless absolutely necessary. Use of improper extension cord could result
in a risk of fi re and electric shock.If extension cord must be used make sure that :
a) pins on plug of extension cord are the same number, size and shape as those of plug on charger.
b) the extension cord is property wired and in good electrical condition,and
c) the conductor wire size is large enough for the AC ampere rating of the charger as specifi ed in the table below.
SAFETY
AC INPUT RATING IN AMPERES
Equal to or greater than But less than
2A 3A 25 (17.6)
6. Do not operate charger with damaged cord or plug - replace the cord or plug 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 qualifi ed serviceman.
8. Do not disassemble charger; take it to a qualifi ed serviceman when service or repair is required.
Incorrect reassembly may result in a risk of electric shock or fi re.
9. To reduce risk of electric shock, unplug the charger from outlet before attempting any maintenance or cleaning.
Turning off controls will not reduce this risk.Clean only with slightly moist,not wet, cloth.Do not use solvents.
10. WARNING - RISK OF EXPLOSIVE GASES.
a) WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. B ATTERIES GENERATE EXPLOSIVE GASES
DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT YOU FOLLOW THE
INSTRUCTIONS EACH TIME YOU USE THE CHARGER.
b) To reduce risk of battery explosion,follow these instructions and those published by the battery manufacturer
and manufacturer of any equipment you intend to use in vicinity of the battery. Review cautionary marking on
these products and on engine.
LENGTH OF CORD,
FEET (m)
50 (15.2)
100 (30.5)
AWG SIZE
OF CORD
18
18
14
11. PERSONAL PRECAUTIONS.
a) Someone should be within range of your voice OR close enough to come to your aid when you work near a lead-acid battery.
b) Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes.
c) Wear complete eye protection and clothing protection. Avoid touching eyes while working near battery.
d) If battery acid contacts or enters eye, fl ood eye with cold running water for at least 10 minutes and get medical
attention immediately. If battery acid contacts skin or clothing, wash immediately with soap & water. If acid enters
an eye , immediately fl ood eye with running cold water for at least 10 minutes & get medical attention immediately.
e) NEVER smoke or allow a spark or fl ame in vicinity of battery or engine.
f) Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short-circuit battery or other electrical
part that may cause explosion.
g) 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 the like to metal,
causing a severe burn.
i) NEVER charge a frozen battery.
3
12. PREPARING TO CHARGE
a) If necessary to remove battery from vehicle to charge,always remove grounded terminal from battery fi rst.
Make sure all accessories in the vehicle are off, so as not to cause an arc.
b) 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.
c) Clean battery terminals.Be careful to keep corrosion from coming in contact with eyes.
d) Add distilled water in each cell until battery acid reaches level specifi ed by battery manufacturer. This helps purge
excessive gas from cells. Do not overfi ll. For a battery without cell caps, such as valve regulated lead acid (VRLA) or absorbed
glass mat (AGM) batteries, carefully follow manufacturer’s recharging instructions.
e) Study all battery manufacturer’s specifi c precautions such as removing or not removing cell caps while charging
and recommended rates of charge.
SAFETY US & CAN
f) Determine voltage of battery by referring to vehicle or other user’s manual and BEFORE MAKING THE BATTERY
CONNECTIONS , MAKE SURE TH AT THE VOLTAGE OF THE BATTERY YOU ARE GOING TO CHARGE MATCHES THE
OUTPUT VOLTAGE OF THE CHARGER.
13. CHARGER LOCATION.
a) Locate charger as far away from battery as DC cables permit.
b) Never place charger directly above batterv being charged; gases from battery will corrode and damage the charger. c) Never
allow battery acid to drip on charger when reading gravity or fi lling battery. Do not operate charger in a closed-in area or
restrict ventilation in any way.
d) Do not set a battery on top of charger. IMPORTANT : Place charger on a hard fl at surface or mount onto a vertical surface. Do
not place on plastic, leather or textile surface.
14. DC CONNECTION PRECAUTIONS
a) Connect and disconnect DC output clips only after setting any charger switches to off position and removing AC
cord from electric outlet. Never allow clips to touch each other, however should this happen no damage will result to
the charger circuit & the automatic charging programme will just reset to «start».
b) Attach clips to battery and chassis as indicated in 15(e), 15(f), and 16(b) through 16(d).
NOTE : This battery charger has an automatic safety feature that will prevent it from operating if the battery has been inversely
connected. Set charger switches to off position and/or remove AC cord from electrical outlet, disconnect the battery clips, then
reconnect correctly according to the instructions below.
15. FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE. A SPARK NEAR A BATTERY MAY CAUSE BATTERY
EXPLOSION. TO REDUCE RISK OF A SPARK NEAR BATTERY :
a) Position AC and DC cords so as to reduce risk of damage by hood, door or moving engine part.
b) Stay clear of fan -blades, belts,pulleys,and other parts that can cause injury to persons.
c) Check polarity of battery posts.POSITIVE (POS, P, +) battery post usually has larger diameter than NEGATIVE (NEG,
N,–) post.
d) Determine which post of battery is grounded (connected) to the chassis. If negative post is grounded to chassis
(as in most vehicles),see (e). If positive post is grounded to the chassis,see (f).
e) 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.
Do not connect clip to carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gage metal part of the
frame or engine block.
f) 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. Do
not connect clip to carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gage metal part of the
frame or engine block.
g) When disconnecting charger, turn switches to off, disconnect AC cord,remove clip from vehicle chassis,and then
remove clip from battery terminal.
h) See operating instructions for length of charge information.
16. FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE. A SPARK NEAR THE BATTERY MAY CAUSE BATTERY
EXPLOSION. TO REDUCE RISK OF A SPARK NEAR BATTERY :
a) Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has a larger diameter than NEGATIVE
(NEG,N, -) post.
b) This battery charger has an automatic safety feature that will prevent it from operating if the battery has been inversely
connected. The charger does allow charge current unless a voltage of at least 2V is sensed.
c) Connect POSITIVE (RED) charger clip to POSITIVE (POS, P, +) post of battery.
d) Connect NEGATIVE (BLACK) charger clip to NEGATIVE (NEG, N, -) battery post of the battery.
e) Do not face battery when making fi nal connection.
f) When disconnecting charger, always do so in reverse sequence of connecting procedure & break fi rst connection
while as far away from battery as practical.
g) A marine (boat) battery must be removed & charged on shore. To charge it on board requires equipment specially
designed for marine use.
4
AUTOMATIC DIAGNOSTIC CHARGER FOR 12V LEAD-ACID BATTERIES
FROM 7,5Ah TO 120Ah, AS FOUND IN:
DO NOT USE FOR NiCd, NiMH, Li-Ion OR NON-RECHARGEABLE BATTERIES.
Charge rate: 2,5 Ah / hour, will recharge a 120Ah battery in 48 hours.
Input: 100-240V
IMPORTANT: READ THE FOLLOWING INSTRUCTIONS BEFORE USING THE CHARGER
This appliance is not intended for use by persons (including children) with reduced physical, sensory
or mental capabilities, or lack of experience and knowledge, unless they have been given supervision
or instruction concerning use of the appliance by a person responsible for their safety. Children
should be supervised to ensure that they do not play with the appliance.
SAFETY WARNING AND NOTES:
Disconnect AC power supply before making or breaking DC/battery connections. Battery acid is highly corrosive. Wear
protective clothing and eyewear and avoid contact. In case of accidental contact, wash immediately with soap and water.
Check that the battery posts are not loose; if so, have the battery professionally assessed. If the battery posts are corroded,
clean with a copper wire brush; if greasy or dirty clean with a rag damped in detergent. Use the charger only if the input and
output leads and connectors are in good, undamaged condition. If the input cable is damaged, it is essential to have it replaced
without delay by the manufacturer, his authorised service agent or a qualifi ed workshop, to avoid danger. Protect your charger
from acid and acid fumes and from damp and humid conditions both during use and in storage. Damage resulting from
corrosion, oxidation or internal electrical short-circuiting is not covered by warranty. Distance the charger from the battery
during charging to avoid contamination by or exposure to acid or acidic vapours. If using it in the horizontal orientation, place
the charger on a hard, fl at surface, but NOT on plastic, textile or leather. Use the fi xing holes provided in the enclosure base to
attach the charger to any convenient, sound vertical surface.
EXPOSURE TO LIQUIDS:
casing from above, or to light rainfall. Prolonged exposure to falling rain is inadvisable and longer service life will be obtained
by minimizing such exposure.Failure of the charger due to oxidation resulting from the eventual penetration of liquid into the
electronic components, connectors or plugs,is not covered by warranty.
BATTERY CONNECTIONS:
clips for charging the battery off-vehicle, the other connection set comes with metal eyelet lugs for permanent connection to
the battery posts, and re-sealable weatherproof cap on the connector that connects to the charger output cable. This
connection set allows easy and sure connection of the charger to maintain the battery on-vehicle. The resealable weatherproof
cap is designed to protect the connector from dirt and damp whenever the charger is not attached. Consult a professional
service agent for assistance in attaching the metal eyelets to the battery posts. Secure the connector with weatherproof cap so
that it cannot foul any moving part of the vehicle or the cable can be pinched or damaged by sharp edges. The in-line fuse in
the eyelets connection set protects the battery against such accidental shorting across positive and negative conductors.
Replace any burnt fuse only with a similar new fuse of 15A rating.
CONNECTING THE CHARGER TO THE BATTERY
1. Disconnect AC power supply before making or breaking DC / battery connections.
2. If charging a battery in the vehicle with the battery clips, before making connections, fi rst check that the battery clips can
be safely and securely positioned clear from surrounding wiring, metal tubing or the chassis. Make connections in the
following order: First connect to the battery terminal not connected to the chassis (normally positive), then connect the
other battery clip (normally negative) to the chassis well away from the battery and fuel line. Always disconnect in reverse
sequence.
3. When charging a battery out of the vehicle with the battery clips, place it in a well ventilated area. Connect the charger to
the battery: RED clamp to POSITIVE (POS, P or +) terminal and BLACK clamp to NEGATIVE (NEG, N or –) terminal. Make
sure the connections are fi rm and secure. Good contact is important.
4. If the battery is deeply discharged (and possibly sulphated), remove from the vehicle and inspect the battery
before connecting the charger for a recovery attempt. Visually check the battery for mechanical defects such as a
bulging or cracked casing, or signs of electrolyte leakage. If the battery has fi ller caps and the plates within the cells can
be seen from the outside, examine the battery carefully to try to determine if any cells seem different to the others (for
example, with white matter between the plates, plates touching). If mechanical defects are apparent do not attempt to
charge the battery, have the battery professionally assessed.
5. If the battery is new, before connecting the charger read the battery manufacturer’s safety and operational instructions
carefully. If applicable, carefully and exactly follow acid fi lling instructions.
maximum 0,90A. The maximum output current is 2,8A.
SAFETY
Batteries emit EXPLOSIVE GASES - prevent fl ame or sparks near batteries.
This charger is designed to withstand exposure to liquids accidentally spilled or splashed onto the
2 interchangeable connection sets are available, supplied with the charger is a set of battery
5
USING THE OPTIMATE 5: PROCEEDING TO CHARGE
For safety reasons, the OptiMate output will only activate if a battery retaining at least 2V is connected, whereupon the
circuit instantly diagnoses the battery condition and engages the appropriate charge mode and lights the corresponding charge
tus LED.
sta
The charger’s special recovery mode cannot engage if it senses that the battery is still connected to a vehicle wiring
circuit which effectively offers a lower electrical resistance than the battery on its own. However, if the deep-discharged
battery is not removed for recovery, neither battery nor vehicle electronics will be damaged.
VERY FLAT NEGLECTED BATTERIES:
important for relatively small batteries such as those used on motorcycles, lawn tractors, jet-ski’s, snowmobiles and
similar: A battery left deep-discharged for an extended period may develop permanent damage in one or more cells. Such
batteries may heat up excessively during high current charging.
Monitor the battery temperature during the fi rst hour, then hourly there-after. Check for unusual signs, such as bubbling or
leaking electrolyte, heightened activity in one cell compared to others, or hissing sounds. If at any time the battery is
uncomfortably hot to touch or you notice any unusual signs, DISCONNECT THE CHARGER IMMEDIATELY.
ECO POWER SAVING MODE WHEN THE CHARGER IS CONNECTED TO AC SUPPLY:
consumption OptiMate 5 employs two converter circuits, a power converter to charge the battery and an auxiliary converter to
power the control circuitry and LED display. The power converter is switched off when the charger is not connected to a battery
resulting in a very low power draw of less than 1,7W, equivalent to power consumption of 0,042 kWh per day. When a battery
is connected to the charger power consumption depends on the current demand of the battery and its connected vehicle /
electronic circuitry. After the battery has been charged and the charger is in long term maintenance charge mode (to keep the
battery at 100% charge) the total power consumption is estimated to be 0,060 kWh or less per day.
The LED indicators referred to below, and the clauses dealing with them, are sequenced as they may come on through
the course of the program.
Pay particularly close attention to the following which is especially
To reduce long term power
1
55
2
3.1
3.2
1.
LED #1 - Power on. Confi rms AC power supply to the charger. Light intensity is low during POWER SAVING MODE.
2.
LED #2 indicates inverse polarity - wrong output connections. Swap around to activate output.
3.
Circuit activation and recovery of deep-discharged, neglected batteries
3.1 ACTIVATION - If the battery voltage is above 2V, LED #3 lights briefl y to confi rm circuit activation.
For batteries with a good state of health LED #3 goes out immediately and charge LED #4 comes on.
3.2 RECOVERY - For neglected batteries in poor state of health, LED #3 remains on and indicates steadily. The charge
ge is limited at a maximum 22V while the circuit attempts to deliver a current of 400mA into the battery.
volta
If step 3 has not concluded after 2 hours, step 4 engages automatically.
4.
Charge and charge verifi cation
4.1 CHARGE: The BULK CHARGE stage (steady LED #4) delivers a constant current of about 2,8Amps maximum into the
ttery, up to a voltage of 14,2 -14,5V.
ba
4.2 VERIFICA
TION: LED #4 fl ashes while the circuit verifi es battery charge level.
If the battery requires further charging the programme reverts to CHARGE for brief periods, delivering a variable current
pulse to the ba
demand belo
condition allows).
When LED #4 has fl ashed continuously for 30 minutes, step 5 engages and a voltage retention test starts.
ttery. These reversions may occur as many times as is necessary to reduce the battery’s current
w 400mA at 13,6V (which is consistent with a battery that has accepted as much charge as its basic
4.1
4.2
6
6
5. 6.
Voltage retention tests alternating half-hourly with battery maintenance
Flashing LED #5 - Voltage retention test
or a good battery LED #5 fl ashes throughout the 30 minute test. NO CHARGE CURRENT.
F
If the battery voltage falls below 12,4V during the test LED #6 (red) will come on and indicate steadily.
The red LED means that after being charged the battery’s voltage is not being sustained or that despite recovery
attempts the battery was irrecoverable. This may be due to a defect in the battery itself, such as a short-circuited cell
or total sulphation, or, in the case of a battery still connected to the vehicle’s wiring system, the red LED #6 may be
signalling a loss of current through deteriorated wiring or a degraded switch or contact, or in-circuit current-consuming
accessories. A sudden load such as the headlights being switched on while the charger is connected can also cause
the battery voltage to dip signifi cantly. Always remove the battery from the vehicle, reconnect the OptiMate™ and
allow it to proceed through its programme once more.
Steady on LED #5 or 6 - Automatic batter
Maintenance - fl
Whichever LED (#5 fl
draw current as required to support small loads and counter self-discharge.
Maintenance and voltage retention test periods continue alternating half-hourly until the battery is disconnected.
The test result is updated during each subsequent test.
oat charge at a safe voltage limit of 13,6V and up to 2,8A is available to counter self-discharge.
ashing or #6 steady) was indicating at the end of the TEST now indicates steadily. The battery can
Accuracy of voltage retention test:
condition, which can be more precisely established by using a TestMate™mini which tests 12V batteries on the vehicle during
cranking, as well as the charging system operation.
Maintaining a battery for extended periods:
months at a time. At least once every two weeks, check that the connections between the charger and battery are secure, and,
in the case of batteries with fi ller caps on each cell, disconnect the battery from the charger, check the level of the electrolyte
and if necessary, top up the cells (with distilled water, NOT acid), then reconnect. When handling batteries or in their vicinity,
always take care to observe the SAFETY WARNINGS above.
Charging time:
otherwise undamaged battery is roughly equal to 1/3 the battery’s Ah rating, so a 60Ah battery should take no more than about
20 hours to progress to the self-discharge check (§ 5). Deep-discharged batteries may take signifi cantly longer.
NOTE: The total charging time of the steps 4.1 and 4.2 is not limited.
The time required for the OptiMate™5 to complete a charge on a fl at but not severely discharged and
y maintenance
This test is a strongly indicative but not necessarily a conclusive test of battery
The OptiMate will maintain a battery whos basic condition is good, for
More information on
TecMate products can be found at www.tecmate.com.
7
MOUNTING NOTICE
4,5mm (1/6")
L +20mm (+4/5")
4x
2m (6ft) max.
2m (6ft) + SAE-73 (2,5m / 8ft) = 4,5m (14ft) max.
for North America:
EXTEND by a further 15ft with SAE-73 STD or WP
SAE-73
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