Black and Decker Smart Battery Charger User Manual

Black and Decker Smart Battery Charger

IMPORTANT SAFETY INSTRUCTIONS

1. RISK OF EXPLOSIVE GAS MIXTURES — WORKING IN THE 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.
2. To reduce the risk of battery explosion, follow these instructions and those published by the battery manufacturer and the manufacturer of any equipment you intend to use in the vicinity of the battery. Review cautionary markings on these products and on the engine.
3. 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.

Battery Safety

1. Use of an attachment not recommended or sold by the battery charger manufacturer may result in a risk of fire, electric shock, or injury to persons.
2. To reduce the risk of damage to the electric plug and cord, pull by plug rather than the cord when disconnecting the charger.
3. 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 the warranty. If an extension cord must be used, make sure:
   a. The pins on the plug of the extension cord are the same number, size, and shape as those of the plug on the charger.
   b. That extension cord is properly wired and in good electrical condition.
   c. That wire size is AWG#10 (10 gauge) for 100 feet and AWG#8 for distances over 100 feet.
4. Do not operate the charger with a damaged cord or plug — take it to a qualified technician for replacement of the plug or cord immediately.
5. Do not operate the charger if it has received a sharp blow, been dropped, or otherwise damaged in any way; take it to a qualified service technician.
6. Do not disassemble the charger; take it to a qualified service technician when service or repair is required. Incorrect re-assembly may result in a risk of electric shock or fire, and will void the warranty.
7. To reduce the risk of electric shock, unplug the charger from the outlet before attempting any maintenance or cleaning. Turning off controls without unplugging will not reduce this risk.
8. Do not expose the charger to rain, snow, or use it when wet.

Personal Safety

1. Another person should be within range of your voice or close enough to come to your aid when you work near a lead-acid battery.
2. Fresh water and soap should be nearby in case battery acid contacts skin, clothing, or eyes.
3. Wear complete eye and clothing protection. Avoid touching eyes while working with a battery. Acid particles, or corrosion may get into the eyes. Immediately flood eye with cold water (Eye Wash Station) for at least 15 minutes and seek medical attention immediately.
4. If battery acid contacts skin or clothing, wash immediately with soap and water. If redness, pain, or irritation occurs, seek immediate medical attention.
5. NEVER smoke or allow a spark or flame in the vicinity of the battery or engine.
6. Be extra cautious to reduce the risk of dropping a metal tool onto the battery. This might cause sparks or short-circuit the battery or other electrical parts, which can cause an explosion.
7. 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 cause a severe burn.
8. Use a charger for charging a LEAD-ACID battery only. It is not intended to supply power to a low-voltage electrical system other than in a starter-motor application. Do not use the 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 property.
9. NEVER ATTEMPT TO CHARGE A FROZEN BATTERY.

Power Cord Safety

• The charger should be grounded to reduce the risk of electric shock. The charger is equipped with an AC cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into a properly installed and grounded 110/120-volt AC outlet in accordance with all local codes and ordinances (see Figure 1A).
• If a properly grounded outlet is not available, a temporary adapter (like the adapter shown in Figure 1B) may be used to connect this plug to a two-pole receptacle. The temporary adapter should be used ONLY until a properly grounded outlet can be installed by a qualified electrician.

 Preparing to Charge

1. Determine the voltage of the battery to be charged by referring to the owner’s manual.
2. If it is necessary to remove the battery from the vehicle to charge or to clean terminals, always remove the grounded terminal from the battery first. Make sure all accessories in the vehicle are off, so as not to cause an arc.
3. Clean battery terminals. Do not allow corrosion to come in contact with the eyes.
4. Add distilled water in each cell until the 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 the manufacturer’s charging instructions.
5. Study all battery manufacturers’ specific precautions, such as removing or not removing cell caps while charging, and recommended rates of charge.
6. The area around the battery should be well ventilated while the battery is being charged. Gas can be forcefully blown away by using a piece of cardboard or other nonmetallic material as a fan.
7. Make sure the initial charging rate does not exceed the battery manufacturer’s requirement.

Charger Location

1. Locate the charger as far away from the battery as cables permit.
2. NEVER place the charger directly above the battery being charged; gases from the battery will corrode and damage the charger.
3. NEVER allow battery acid to drip on the charger when reading the gravity or filling the battery.
4. NEVER operate a charger in a closed-in area or restrict ventilation in any way.
5. Marine batteries must be removed and charged on shore.
6. Do not set a battery on top of the charger.

DC Connection Precautions

1. Connect and disconnect DC output clamps only after removing the AC cord from the electric outlet.
2. Never allow clamps to touch each other.
3. Attach clamps to the battery chassis as indicated in “Battery Installed in Vehicle” steps 5 and 6, and in “Battery Outside of Vehicle” steps 2, 4, and 5.

FEATURES

• This unit has four charge rate settings, accessed by the 4/10/20/40 AMP button:
• a) 4 amps: smaller batteries, as in lawn mowers, snowmobiles, motorcycles, etc.
• b) 10 amps: mid-sized batteries, as in small cars
• c) 20 amps: automobiles and light trucks
• d) 40 amps: large truck batteries, banks of RV batteries
• 110 amp engine start
• Automatic Temperature Compensation
• Battery type selection
• Digital diagnostics
• Alternator voltage and battery voltage check
• Digital display shows charge rate, operating mode, fault codes, and FUL when charged
• 1-minute engine start
• 3-stage high-frequency switch-mode automatic rapid charging
• Spark-resistant reverse polarity and short circuit protection for the user
• Built-in battery reconditioning (disulfate)
• Lightweight, high-efficiency design
• Internal short circuit protection
• Cables and clamps are self-stored
• Reverse polarity indication
• Microprocessor control (Digital Smart Control), high-frequency power
• Compensates for low AC from extension cord use
• Equalization function
• Battery reconditioning function

Controls and Indicators

• CONTROL PANEL
• DIGITAL READOUT CIRCULATING PATTERN

Battery Type (Step 1)

Allows the user to select Wet, Gel, or AGM type of battery for efficient and safe charging. Most automotive batteries are Wet batteries. Refer to the battery manufacturer’s specifications for battery type. 4/10/20/40 AMP (Charge Rate Selector) (Step 2)— allows the user to select the charge rate based on battery size. This selection and the actual battery charge rate are monitored by the microprocessor. The charger will stop charging if the rate is too fast or too slow for the battery size or condition. 110 AMP Engine Start— places the charger in an engine start sequence. This button will not be activated unless the charger is in the 40 amp charge mode; set the 4/10/20/40 AMP button to 40 amps first to activate this button.

Battery Recond.

It is an automatic mode that, once started, continues for 24 hours and then stops. A series of electrical pulses breaks the crystalline form of lead sulfate to return these chemicals into useful battery electrolytes. More than 24 hours may be needed to restore. Periodic reconditioning is recommended to maintain a battery’s optimum performance. However, if 5 cycles do not improve battery performance, discontinue and recycle the battery.

Battery Voltage (Alternator Voltage Check)

It is a quick check that measures the battery voltage. This check is repeated at various electrical load levels, and the tests allow the user to determine if the alternator can keep up with the loads.

OPERATING INSTRUCTIONS

Ensure that all installation and operating instructions and safety precautions are understood and carefully followed by anyone installing or using the charger. Follow the steps outlined in “Important Safety Instructions” at the front of this manual.

Charging the Battery

1. Press the Battery Type selector until the desired battery type LED lights. Note: The default selection is “GEL” type battery.
2. Press 4/10/20/40 AMP button to begin charging at the 4 amp rate; the unit sounds a beep, and the charging current LED lights. The charger starts charging at 4 4-amp rate automatically if 4/10/20/40 AMP button is not pressed within 3 minutes after applying AC power. If the Display on the charger varies between “F03” and the amp rate, the battery is sulfated, and the charger is trying to give it some charge. If, after approximately 2 hours, the display just shows “F03”, then the battery will not charge. The charger occasionally sounds a beep and displays “0.0” during self-test or charging stage changes.
3. Pressing the 4/10/20/40 AMP button again advances the charging rate to 10 amps, pressing once more advances the charging rate to 20 amps, and again to 40 amps. (Pressing the button again will turn OFF the charger output, and the Display will show “000”.) This selection and actual battery charge rate are monitored by the microprocessor, and the unit will stop charging if the selected rate is too fast or too slow for the battery size or condition. As the battery nears full charge capacity, the unit’s output will automatically drop to a lower charge rate. Pressing the 4/10/20/40 AMP button repeatedly advances to standby mode; the unit sounds a beep, displays “000”, and stops charging.
4. The battery charger displays the charge current. To view the battery voltage, press the  BATTERY VOLTAGE button. The charger will sound a beep and display the battery voltage for 3 seconds, then returns to displaying the charge current.
5. The display shows “FUL” when the battery is fully charged.
6. Follow the steps outlined in “Important Safety Instructions” at the front of this manual to disconnect.

Automatic Float Charging

Automatic Float Charging is ideal for maintaining a fully charged battery.

1. Keep the AC power and battery connected after the battery is fully charged.
2. The charger monitors the battery and tops it off as needed.
3. The Float Charge indicator lights; the display shows charge current when topping off the battery and returns to “FUL” when completed.
4. To view battery voltage, press the Battery Voltage button.

Equalizing

Equalizing is the process by which the fluid in each of a battery’s cells is equalized. This process occurs after charging is complete.

1. Do not use this mode on sealed or valve-regulated batteries. This mode is only meant for wet (unsealed/vented) batteries.
2. Make sure there are no flammable sources near the recharging site.
3. Wear safety glasses, gloves, and protective clothing.
4. Remove the battery from the vehicle. MAKE SURE THAT THE BATTERY HAS GOOD VENTILATION.  The process causes the release of hydrogen and oxygen. An accumulation of these gases presents a real danger of explosion.
5. Open the battery cap, if removable.
6. Fill the battery with distilled water according to the manufacturer’s instructions. Since batteries may rapidly bubble while being charged, remember to refill (only with distilled water) after the equalization process is complete and the voltage is back to normal.
7. Follow the steps in the “Charging the Battery” section on page 5 of this manual.
8. Push the Battery Type Selector Switch until “WET” is displayed. (This mode will only work if a WET battery is selected.)
9. Choose the correct charge rate and start charging. You can check the battery voltage by pushing the Battery Voltage button. This will trigger the Battery Voltage indicator button.
10. Push the Equalize button at any time, and the battery will automatically begin to equalize in 4 4-amp limited current. Note that in order to push the recessed button, you will need a small pin or ballpoint pen.
11. Every hour, the temperature should be checked by touching the battery. If the battery is hot to the touch, stop the charging and allow the battery to cool.
12. The voltage rises, but does not go over 15.3V to 16.2V (2.55-2.7V per cell), depending on ambient temperature; it will automatically adjust.
13. The “WET” LED flashes while the charger is in equalize mode.
14. The digital readout will show “FUL” when the equalization process is complete.

Engine Start

The Engine Start function can supply 110 amps for engine starting.

1. Set the 4/10/20/40 AMP button to 40 amp mode and immediately press the 110A button switch to activate the Engine Start mode.
2. The digital display will count down from “999” to “000.”
3. When the “000” count is reached and begins flashing on the Display, the vehicle is ready to start.
4. Crank the engine using the manufacturer’s guidelines, typically in 3 to 5-second bursts. The high-current engine starting function requires a resting/cooling period between tries. The charger will switch back to regular charge mode after 5 seconds and will not allow operation in this mode for 4 minutes. Wait 4 to 5 minutes before a second attempt at starting the engine, if needed.
5. During the rest period, the battery is charging at 40 amps. After the engine starts, follow the steps outlined in “Important Safety Instructions” at the front of this manual to disconnect.

Recondition Mode

Whenever a lead-acid battery begins to discharge, lead sulfate, an insulator, begins to build up on the battery’s internal plates. This reduces the ability of the battery to hold a full charge. When that battery has an immediate charge, most of the lead sulfate is dissolved, and the plates are free of this insulation. If a battery remains in a discharged condition over a longer period of time, the lead sulfate changes to a hard crystalline form, making a full charge difficult to achieve. Reconditioning may “save” a sulfated battery. Remove or disconnect the vehicle’s battery when reconditioning.

1. Make sure the charger is in initialization state with a circulating pattern on the display or in charge OFF mode with “000” on the display. If not, press 4/10/20/40 AMP button repeatedly until “000” shows on the display.
2. Press the Battery Recondition button to start the process.
3. DES appears on the display for 3 seconds, then it changes to three horizontal moving bars.
4. The process takes 24 hours and stops automatically. The display shows “000” when complete.

CARE AND MAINTENANCE

With proper care and minimal maintenance, the 4/10/20/40 Amp 12-Volt Smart Battery Charger will provide years of dependable service. For maximum performance, the manufacturer recommends:

• After each use, clean the battery charger clamps — be sure to remove any battery fluid that will cause corrosion of the clamps.
• Clean the outside case of the charger with a soft cloth and, if necessary, mild soap solution.
• Do not allow liquid to enter the charger. Do not operate when the charger is wet.
• Keep the charger cords loosely coiled during storage to prevent damage to the cords.

TROUBLESHOOTING

Display Indications/Common Problems/Possible Solutions

No Functions

• Check and make sure the charger is plugged into a live 110/120-volt AC outlet.
• Follow the steps outlined in the Operating Instructions section.

F01 — Internal Shorted Cell Battery

If the battery being charged has an internally shorted cell, the F01 will show. We recommend taking your battery to a certified automotive service center for evaluation.

F02 — Bad Battery Connection or Battery Voltage Too Low to Accept Charge

When F02 appears, the most common cause is a poor connection to the battery.

• Follow the steps outlined in “Important Safety Instructions” at the front of this manual to disconnect the AC cord and clamps, clean the battery terminal, and reconnect.
• If the situation persists, we recommend taking your battery to a certified automotive service center for evaluation.

F03 — Sulfate or Unchargeable Battery

Appears when the battery is highly sulfated and cannot accept normal charge current.

• Follow the steps in “Recondition Mode” to recondition the battery.
• Follow the steps in “Equalizing” to equalize the battery.
• If the situation persists after reconditioning and equalizing, we recommend taking your battery to a certified automotive service center for evaluation.

F04 — Overtime Condition

Appears when charging time exceeds 18 hours. You may be using a charge current rate too low for a large battery. Select a higher charge rate to charge the battery.

F05 — Overheated Condition

The ventilation grill that prevents the air from flowing in and out of the charger may be blocked.

• Follow the steps outlined in “Important Safety Instructions” at the front of this manual to disconnect the AC cord and clamps, allow the unit to cool for 30 minutes, and reconnect.
• Make sure there is ample ventilation before resuming operation.

F06 — Reverse Polarity

The connections to the battery’s POSITIVE and NEGATIVE terminals are incorrect. Follow the steps outlined in “Important Safety Instructions” at the front of this manual to disconnect the AC cord and clamps and reconnect to the battery with correct polarity.

F07 — Alternator Voltage

The alternator output voltage is out of the typical operation range.

Charging a Very Cold Battery

If the battery to be charged is very cold (in temperatures below freezing, — 0°C/32°F), it cannot accept a high rate of charge. The initial charge rate will be low. The charge rate will increase as the battery warms. Never attempt to charge a frozen battery.

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