Duralast DL-200D Battery Charger User Manual

Duralast DL-200D Battery Charger

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

• This manual contains important safety and operating instructions.
• This charger is not intended for use by children.
• Do not expose the charger to rain or snow.
• 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.
• To reduce the risk of damage to the electric plug and cord, pull by the plug rather than the cord when disconnecting the charger.
• An extension cord should not be used unless necessary. The use of improper extension cords could result in a risk of fire and electric shock. If an extension cord must be used, make sure.
  • The pins on the plug of the extension cord are the same number, size, and shape as those of the plug on the charger
  • The extension cord is properly wired and in good electrical condition
  • The wire size is large enough for the ACampere rating of the charger as specified in section 8.
• Do not operate the charger with a damaged cord or plug – replace the cord or plug immediately.
• 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 serviceman.
• Do not disassemble the charger; take it to a qualified serviceman when service or repair is required. Incorrect reassembly may result in a risk of electric shock or fire.
• To reduce the risk of electric shock, unplug the charger from the outlet before attempting any maintenance or cleaning. Turning off controls will not reduce this risk.
• 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 REASON, IT IS OF UTMOST IMPORTANCE THAT YOU FOLLOW THE INSTRUCTIONS EACH TIME YOU USE THE CHARGER.
  • 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.

PERSONAL SAFETY PRECAUTIONS

• Consider having someone close enough by to come to your aid when you work near a lead-acid battery.
• Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
• Wear complete eye protection and clothing protection. Avoid touching your eyes while working near the battery.
• If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters the eye, immediately flood the eye with running cold water for at least 10 minutes and get medical attention immediately.
• NEVER smoke or allow a spark or flame in the vicinity of the battery or engine.
• Be extra cautious to reduce the risk of dropping a metal tool onto the battery. It might spark or short-circuit the battery or another electrical part which may cause an explosion.
• Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid battery. Alead-acid batteries can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn.
• Use a charger for charging only 12V LEAD-ACID (STD, AGM, or GEL) rechargeable batteries. It is not intended to supply power to a low-voltage electrical system other than in a starter-motor application. Do not use a 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.
• NEVER charge a frozen battery.

PREPARING TO CHARGE

• If necessary to remove the battery from the vehicle to charge, 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.
• Be sure the area around the battery is well-ventilated while the battery is being charged.
• Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes.
• Add distilled water in each cell until battery acid reaches the level specified by the battery manufacturer. Do not overfill. For a battery without removable cell caps, such as valve valve-regulated lead acid batteries, carefully follow the manufacturer’s recharging instructions.
• Study all battery manufacturer’s specific precautions while charging and recommended rates of charge.
• Determine the voltage of the battery by referring to the car owner’s manual and make sure that the output voltage selector switch is set at the correct voltage. If the charger has an adjustable charge rate, charge the battery initially at the lowest rate.

CHARGER LOCATION

• Locate the charger as far away from the battery as DC 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 electrolyte-specific gravity or filling the battery.
• Do not operate the charger in a closed area or restrict ventilation in any way.
• Do not set a battery on top of the charger.

DC CONNECTION PRECAUTIONS

• Connect and disconnect DC output clips only after setting any charger switches to the “off” position and removing the AC cord from the electric outlet. Never allow the clips of the charger to touch each other. Clips may be energized and they may spark.
• Attach clips to battery and chassis, as indicated in sections 6 and 7

FOLLOW THESE STEPS WHEN THE BATTERY IS INSTALLED IN VEHICLE

• WARNING:

A SPARK NEAR THE BATTERY MAY CAUSE A BATTERYEXPLOSION. TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY:

• Position AC and DC cords to reduce the risk of damage by hood, door, or moving engine part.
• Stay clear of fan blades, belts, pulleys, and other parts that can cause injury to persons.
• Check the polarity of battery posts. POSITIVE(POS, P, +) battery post usually has a larger diameter than NEGATIVE (NEG, N,–) post.
• Determine which post of the battery is grounded (connected) to the chassis. If the negative post is grounded to the chassis (as in most vehicles), see (6.5). If a positive post is grounded to the chassis, see (6.6).
• For negative-grounded vehicles, connect the POSITIVE (RED) clip from the battery charger to the POSITIVE (POS, P, +) ungrounded post of the battery. Connect NEGATIVE (BLACK)
• clip to the vehicle chassis or engine block away from the battery. Do not connect the clip to the carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gauge metal part of the frame or engine block.
• For positive-grounded vehicles, connect the NEGATIVE (BLACK) clip from the battery charger to the NEGATIVE (NEG, N, –)ungrounded post of the battery. ConnectPOSITIVE (RED) clip to the vehicle chassis or engine block away from the battery. Do not connect the clip to the carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gauge metal part of the frame or engine block.
• When disconnecting the charger, turn the switches off, disconnect the AC cord, remove the clip from the vehicle chassis, and then remove the clip from the battery terminal.
• See Operating Instructions for length of charge information.

FOLLOW THESE STEPS WHEN THE BATTERY IS OUTSIDE THE VEHICLE

WARNING:

A SPARK NEAR THE BATTERY MAY CAUSE A BATTERYEXPLOSION. TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY:

• Check the polarity of battery posts. POSITIVE(POS, P, +) battery post usually has a larger diameter than NEGATIVE (NEG, N, –) post.
• Attach at least a 24-inch-long 6-gauge(AWG) insulated battery cable to the NEGATIVE (NEG, N, –) battery post.
• Connect the POSITIVE (RED) charger clip to the POSITIVE (POS, P, +) post of the battery.
• Position yourself and free the end of the cable as far away from the battery as possible – then connect the NEGATIVE (BLACK) charger clip to the free end of the cable.
• Do not face the battery when making a connection.
• When disconnecting the charger, always do so in the reverse sequence of the connecting procedure and break the first connection while as far away from the battery as practical.
• A marine (boat) battery must be removed and charged on shore. To charge it on board requires equipment specially designed for marine use.

GROUNDING AND AC POWER CORD CONNECTIONS

• This battery charger is for use on a nominal 120-volt circuit and has a grounded plug. The charger must be grounded, to reduce the risk of electric shock. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances. The plug pins must fit the receptacle (outlet). Do not use an ungrounded system.
• DANGER: Never alter the AC cord or plug provided – if it does not fit the outlet, have a properly grounded outlet installed by a qualified electrician. An improper connection can result in a risk of an electric shock or electrocution.NOTE: Pursuant to Canadian Regulations, the use of an adapter plug is not allowed in Canada. Use of an adapter plug in the United States is not recommended and should not be used.
• USING AN EXTENSION CORD

The use of an extension cord is not recommended. If you must use an extension cord, follow these guidelines:

• • The pins on the plug of the extension cord must be the same number, size, and shape as those of the plug on the charger.
  • Ensure that the extension cord is properly wired and in good electrical condition.
  • Wire size must be large enough for the AC ampere rating of the charger, as specified:

ASSEMBLY INSTRUCTIONS

• Remove all cord wraps and uncoil the cables before using the battery charger.
• Extend the handle from the retracted position by pulling it upward until it locks into place. (Press the small silver buttons inward, if necessary.)

CONTROL PANEL RATE SELECTION BUTTON

Use this button to select one of the following:

• 6A<>2A CHARGE/MAINTAIN –For charging small and large batteries. Not recommended for industrial applications.
• 40A BOOST – For quickly adding energy to a severely discharged or large capacity battery prior to Engine Start
• 200A ENGINE START – Provides 200 amps for cranking an engine with a weak or run-down battery. Always use it in combination with a battery.
   
• START/STOP BUTTON Press to immediately begin charging your properly connected battery. If the button is not pressed, charging should begin automatically in 30 seconds
• LED INDICATORSON (yellow/orange) LED lit: The charger is charging the battery.
• CHARGED/MAINTAINING (green)LED lit: The battery is fully charged and the charger is in maintenance mode.
• CLAMPS REVERSED/BAD BATTERY(red) LED flashing: The connections are reversed.

OPERATING INSTRUCTIONS

WARNING: A SPARK NEAR THEBATTERY MAY CAUSE AN EXPLOSION.CHARGING A BATTERY IN THE VEHICLE

1. Turn off all the vehicle’s accessories.
2. Keep the hood open.
3. Clean the battery terminals.
4. Place the charger on a dry, non-flammable surface.
5. Lay the AC/DC cables away from any fan blades, belts, pulleys, and other moving parts.
6. Connect the battery, following the precautions listed in sections 6 and 7
7. Connect the charger to a live, grounded 120V AC outlet.
8. Select the charge rate.
9. Press the START button to begin charging immediately. If the START button is not pressed within thirty seconds after the unit was first powered up, and the charger detects a battery that is properly connected, the charging process will automatically begin and finish. The unit will automatically use the Boost rate for the first 10 minutes and then change to the Charge rate if selected.
10. When charging is complete, indicated by the Charged/Maintaining LED lit, or if you are done, press the STOP button, disconnect the charger from the AC power, disconnect the clamp attached to the vehicle’s chassis, and finally remove the clamp from the battery terminal.

CHARGING A BATTERY OUTSIDE OF THE VEHICLE

1. Place the battery in a well-ventilated area.
2. Clean the battery terminals.
3. Connect the battery, following the precautions listed in sections 6 and 7.
4. Connect the charger to a live grounded 120V AC outlet
5.  Select the charge rate.
6. Press the START button to begin charging immediately. If the START button is not pressed within thirty seconds after the unit was first powered up, and the charger detects a battery that is properly connected, the charging process will automatically begin and finish. The unit will automatically use the Boost rate for the first 10 minutes and then change to the charge rate if selected.
7. When charging is complete, indicated by Charged/Maintaining LED lighting, or you are done, press the STOP button, disconnect the charger from the AC power, disconnect the negative clamp, and finally the positive clamp.
8. A marine (boat) battery must be removed and charged on shore.

BATTERY CHARGING TIMES Charge time will depend on battery size, as depicted in the chart below.

Times are based on a 50% discharged battery and may change, depending on the age and condition of the battery.

AUTOMATIC CHARGING MODE When the 6<>2A Charge or Boost rate is selected, the charger switches to the maintain mode automatically after the battery is charged.

ABORTED CHARGE If charging cannot be completed normally, charging will abort. When charging aborts, the charger’s output is shut off and the Bad Battery (red) LED will light. Do not continue attempting to charge this battery. Have it checked or replaced.

DESULFATION MODE Desulfation could take 8 to 10 hours. If desulfation fails, charging will abort and the Bad Battery (red) LED will light.

COMPLETION OF CHARGE Charge completion is indicated by the Charged/Maintaining (green) LED. When lit, the charger has switched to the maintain mode of operation.

MAINTAIN MODE(FLOAT MODE MONITORING) When the Charged/Maintaining (green)LED is lit, the charger has started maintainmode. In this mode, the charger keeps the battery fully charged by delivering a small current when necessary. If the charger has to provide an excessive maintenance current for a continuous 12-hour period, it will go into abort mode (see Aborted Chargesection). This is usually caused by a drain on the battery or the battery could be bad.

MAINTAINING A BATTERY This unit charges and maintains 12 Batteries, keeping them at full charge.NOTE: The maintenance mode technology allows you to safely charge and maintain a healthy battery for extended periods of time. However, problems with the battery, electrical problems in the vehicle, improper connections, or other unanticipated conditions could cause excessive current. As such, occasionally monitoring your battery and the charging process is required.

USING THE ENGINE START FEATURE Your battery charger can be used to jumpstart your car if the battery is low. Follow all safety instructions and precautions for charging your battery. Wear complete eye protection and protective clothing.

WARNING: Using the Engine Start feature WITHOUT a battery installed in the vehicle could cause damage to the vehicle’selectrical system.

NOTE: If you have charged the battery and it still will not start your car, do not use theEngine Start feature, or it could damage the vehicle’s electrical system. Have the battery checked.

1. With the charger unplugged from the AC outlet, connect the charger to the battery following the instructions given in Follow These Steps When Battery is Installed in Vehicle.
2. Connect the charger to a live grounded 120V AC outlet.
3. With the charger plugged in and connected to the battery and chassis, press the Rate Selection button untilthe Engine Start LED is lit, and then press the START button.
4. Crank the engine until it starts or 7seconds pass. If the engine does not start, repeat. Do not crank during thecool down period (see below). This allows the charger and battery to cool down. NOTE: During extremely cold weather, or if the battery is under 2 volts, charge the battery for 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, unplug the AC power cord before disconnecting the battery clamps from the vehicle.
7. Clean and store the charger in a dry location.
   NOTE: If the engine does turn over but never starts, there is not a problem with the starting system; there is a problem somewhere else with the vehicle.
   STOP cranking the engine until the other problem has been diagnosed and corrected.
   ENGINE STARTING NOTES During the starting sequence listed above, the charger is set to one of four state

• Wait for ready: The charger charges the battery for 2 minutes before the Wait for Cranking state. While waiting for the ready, the engine can be cranked. Forseverely discharged batteries, it is not recommended to crank during this time.
• Wait for cranking: The charger waits until the engine is being cranked before delivering the amps for engine start.
• Cranking: When cranking is detected, the charger will automatically deliver up to its maximum output as required by the starting system for up to 7 seconds.
• Cool Down: After repeated cranking during a 3-minute ready period, the charger enters a mandatory 3-minute (18-second) cooldown state. After 2 hours of the Engine Starting, the unit will automatically exit from the charging mode, just as if the STOP button had been pressed; the ONLED will not be lit.
• POWER-UP AUTO-START This charger is equipped with an auto-start feature, which is triggered only when the charger is first powered up. If the START button is not pressed within 30 seconds, the unit will search for a battery. If the unit detects a battery that is properly connected the unit will set the rate to Boost, and it will automatically start the charge process. The On (yellow/orange) LED will light.
• FAN OPERATION The fan will operate as needed and it is normal for the fan to sometimes operate continuously. Keep the area near the charger clear of obstructions to allow the fan to operate efficiently.

MAINTENANCE AND CARE

A minimal amount of care can keep your battery charger working properly for years.

• Clean the clamps each time you are finished charging. Wipe off any battery fluid that may have come in contact with the clamps to prevent corrosion.
• Occasionally cleaning the case of the charger with a soft cloth will keep the finish shiny and help prevent corrosion.
• Coil the input and output cords neatly when storing the charger. This will help prevent accidental damage to the cord and charger.
• Store the charger unplugged from the AC power outlet in an upright position.
• Store inside, in a cool, dry place. Do not store the clamps on the handle, clipped together, on or around metal, or clipped to the cables.

BEFORE RETURNING FOR REPAIRS

If these solutions do not eliminate the problem, or for more information about troubleshooting, call: Schumacher Electric Corporation Customer Service1-800-621-5485

Return products under warranty to your local AutoZone store.

SPECIFICATIONS

Input ……………………………120V AC @ 60Hz, 10A max. continuous, 48A max. intermittent

Output ………………………….. 12V@ 2A/40A cont., 6A int.; 60 sec. max on, 120 sec. min off 200A int.; 5 sec. max. on, 180 sec. min. off

LIMITED WARRANTY

THE WARRANTY IS NOT VALID IN MEXICO. SCHUMACHER ELECTRIC CORPORATION, 801 BUSINESS CENTER DRIVE, MOUNT PROSPECT, IL 60056-2179, MAKES THIS LIMITED WARRANTY TO THE ORIGINAL RETAIL PURCHASER OF THIS PRODUCT. THIS LIMITED WARRANTY IS NOT TRANSFERABLE OR ASSIGNABLE.

Schumacher Electric Corporation (the “Manufacturer”) warrants this battery charger for two (2) years from the date of purchase at retail against defective material or workmanship that may occur under normal use and care. If your unit is not free from defective material or workmanship, the Manufacturer’s obligation under this warranty is solely to repair or replace your product with a new or reconditioned unit at the option of the Manufacturer. It is the obligation of the purchaser to forward the unit, along with proof of purchase and mailing charges prepaid to the Manufacturer or its authorized representatives for repair or replacement to occur.

The manufacturer does not provide any warranty for any accessories used with this product that are not manufactured by Schumacher Electric Corporation and approved for use with this product. This Limited Warranty is void if the product is misused, subjected to careless handling, repaired, or modified by anyone other than the Manufacturer or if this unit is resold through an unauthorized retailer.

The manufacturer makes no other warranties, including, but not limited to, express, implied, or statutory warranties, including without limitation, any implied warranty of merchantability or implied warranty of fitness for a particular purpose. Further, the Manufacturer shall not be liable for any incidental, special, or consequential damage claims incurred by purchasers, users, or others associated with this product, including, but not limited to, lost profits, revenues, anticipated sales, business opportunities, goodwill, business interruption, and any other injury or damage. Any and all such warranties, other than the limited warranty included herein, are hereby expressly disclaimed and excluded. Some states do not allow the exclusion or limitation of incidental or consequential damages or length of an implied warranty, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and it is possible you may have other rights which vary from this warranty.

THIS LIMITED WARRANTY IS THE ONLY EXPRESS LIMITED WARRANTY AND THE MANUFACTURER NEITHER ASSUMES NOR AUTHORIZES ANYONE TO ASSUME OR MAKE ANY OTHER OBLIGATION TOWARDS THE PRODUCT OTHER THAN THIS WARRANTY.

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Duralast DL-200D Battery Charger-FAQs