Motomaster Classic Series Battery Charger

Introduction

The Motomaster® Classic Series Battery Charger features advanced technology for faster, easier, and safer battery charging, helping to maximize battery performance and lifespan. This charger is designed for all types of 12-volt lead-acid batteries, including Wet (flooded), Maintenance-free (MF), Calcium (Ca), Enhanced Flooded (EFB), Absorbed Glass Mat (AGM), and Gel. It is suitable for charging batteries rated from 10 to 160 Amp-hours and maintaining batteries from 10 to 400 Amp-hours. This manual provides instructions for safe and effective use.

Important Safety Instructions

SAVE THESE INSTRUCTIONS.

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

• 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 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 absolutely necessary. Use of an improper extension cord could result in a risk of fire and electric shock. If an extension cord must be used, ensure:
  • 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 AC ampere rating of the charger, as specified in the chart below.
• 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 service professional.
• Do not disassemble the charger. Incorrect assembly may result in fire or electric shock.

⚠️ RISK OF EXPLOSIVE GASES.

Working in the vicinity of a lead-acid battery is dangerous. Batteries generate explosive gases during normal battery operation. It is of utmost importance to 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 the manufacturer of any equipment used near the battery. Review cautionary markings on these products and on the engine.

Personal Safety Instructions:

• Consider having someone nearby when working near a lead-acid battery.
• Have fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
• Wear complete eye protection and clothing protection. Avoid touching eyes while working near the battery.
• If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eyes, immediately flood eyes with running cold water for at least 10 minutes and seek medical attention.
• Never smoke or allow a spark or flame in the vicinity of the battery or engine.
• Take extra precautions to avoid dropping a metal tool onto the battery, as it may spark or create a short circuit that can cause an explosion.
• Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid battery, as the high short-circuit current can cause severe burns.
• Use the 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 charger for dry-cell batteries.
• Never charge a frozen battery.

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.

AC Electrical Connections

Plugging Charger In

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

Using an Extension Cord

An extension cord should not be used unless absolutely necessary. If an extension cord must be used, ensure it meets the following criteria:

*AWG = American Wire Gauge

Preparing to Charge

• If it is necessary to remove the battery from the vehicle to charge, always remove the grounded terminal from the battery first. Ensure all accessories in the vehicle are off to prevent an arc.
• Ensure the area around the battery is well-ventilated while the battery is being charged.
• Clean battery terminals. Be careful to keep corrosion from coming into contact with eyes.
• Add distilled water in each cell until the battery acid reaches the level specified by the battery manufacturer. Do not overfill. For batteries without removable cell caps (e.g., valve-regulated lead-acid batteries), follow the manufacturer's recharging instructions carefully.
• Study all battery manufacturer's specific precautions while charging and follow recommended rates of charge.
• Determine the voltage of the battery by referring to the car owner's manual and ensure 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-in 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 removing the AC cord from the electrical outlet.
• Never allow clips to touch each other.
• Attach clips to the battery and chassis as indicated in the "Connecting Your Battery" section.

Connecting Your Battery

When Battery is Installed in Vehicle

⚠️ WARNING: A SPARK NEAR THE BATTERY MAY CAUSE A BATTERY EXPLOSION. TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY:

• Position AC and DC cords to reduce risk of damage by hood, door, or moving engine parts.
• Stay clear of fan blades, belts, pulleys, and other parts that can cause injury to persons.
• Check polarity of battery posts. The POSITIVE (POS, P, +) battery post usually has a larger diameter than the 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), follow the steps for a "negative-grounded vehicle".
  • If the positive post is grounded to the chassis, follow the steps for a "positive-grounded vehicle".
• For negative-grounded vehicle: Connect the POSITIVE (RED) clip from the battery charger to the POSITIVE (POS, P, +) ungrounded post of the battery. Connect the 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 vehicle: Connect the NEGATIVE (BLACK) clip from the battery charger to the NEGATIVE (NEG, N, -) ungrounded post of the battery. Connect the POSITIVE (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 switches to off, disconnect the AC cord, remove the clip from the vehicle chassis, and then remove the clip from the battery terminal.

When Battery is Outside Vehicle

⚠️ WARNING: A SPARK NEAR THE BATTERY MAY CAUSE A BATTERY EXPLOSION. TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY:

• Check polarity of battery posts. The POSITIVE (POS, P, +) battery post usually has a larger diameter than the NEGATIVE (NEG, N, -) post.
• Attach at least a 24" (61 cm) 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 the free 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 the final 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. Charging it on board requires equipment specially designed for marine use.

⚠️ WARNING: A SPARK NEAR A BATTERY MAY CAUSE A BATTERY EXPLOSION! Battery chargers may get hot during operation. Do not set the charger on flammable materials like carpeting, upholstery, paper, cardboard, etc. The charger may damage leather and plastic.

Controls and Indicators

Illustration of the Motomaster Classic Series Battery Charger, showing its front panel with digital display, mode button, and status indicators, as well as the overall casing design with a handle and ventilation grilles.

Diagram showing the Motomaster Classic Series Battery Charger with labels pointing to: A - Digital Display, B - Charge Status Indicators (CHARGING LED, CHARGED/MAINTAINING LED, Error LED), and C - Mode Button/Charging Modes panel.

A. Digital Display

During charging, the digital display alternates between Volts (V), Amps (A), and Battery State of Charge (%). It can also display Fault Codes if a charging error is detected.

• Volts: Displays actual charging voltage, which can reach up to 14.4 V for effective 12-volt battery charging.
• Amps: Displays actual charging amperage. While 2 A, 4 A, or 8 A can be selected, these are maximum currents; the charger adjusts the actual current delivered based on battery feedback.
• Stage of Charge: Shows the approximate battery state of charge. "LO" indicates below 50% charge. Above 50%, it displays in 10% increments from 60% to 90%. "100%" indicates a full charge.
• Note: About 30 minutes after reaching full charge, the charger enters a power-saving mode, and the digital display turns off.
• Fault Codes: The charger monitors charge progress and battery feedback. If an abnormal condition is detected, charging stops, and a fault code (e.g., "F01") may be displayed. Refer to "Troubleshooting/Fault Codes" for details.
• Note: A fault condition is also indicated by the ▲ LED illuminating.

B. Charge Status Indicators

• CHARGING LED: Indicates the battery is charging.
• CHARGED/MAINTAINING LED: Indicates charging is complete and the charger has entered the Maintain stage.
• ▲ LED: Indicates one of three possible error conditions:
  • Amber (solid): No battery detected. Check clamp connections for cleanliness and solidity. If connections are good, the battery may be severely discharged (<1.5 V) and unsafe to charge; it should be tested or replaced.
  • Red (flashing): A fault has been detected, and charging has been aborted. Check the digital display for a Fault Code and refer to "Troubleshooting/Fault Codes".
  • Red (solid): Reverse polarity has been detected. Reverse clamp connections.

C. Charging Modes

There are 4 charging modes. Pressing the MODE button cycles through them. Charging begins automatically about 5 seconds after mode selection.

Note: The charger retains the last selected mode. If AC power is disrupted, it will resume in the last selected mode upon power restoration.

*About the 2 A<>8 A mode: To optimize battery performance and lifespan, charge at an appropriate and safe rate. Charging too high can overheat and shorten battery life. Charging too low can take excessively long and prevent a full charge. The "2 A<>8 A" mode starts with a low, safe current and gradually increases it as the battery accepts higher current, balancing charging time with safety and capacity.

Charging Your Battery

Examples of Battery Sizes in Common Applications:

For reference only. Please check your battery's specifications or consult the battery manufacturer.

1. Connect the charger clamps to the battery (following steps in "Connecting Your Battery").
2. Plug the charger AC plug into an electrical outlet.

   Note: If a fault or error is detected, the ▲ LED will illuminate (see Charge Status Indicators).

3. Press the MODE button to select a charging program.

   Note: If no selection is made within 5 seconds, the charger will default to the last selection in memory and begin charging automatically.

4. Your battery is fully charged when the CHARGED/MAINTAINING LED illuminates and the display reads "100%".

   Note: Your battery is ready to start an engine once it reaches 80%.

5. Stop charging at any time by disconnecting the charger AC plug from the electrical outlet.

Understanding Factors Affecting Charging Time

The time it takes to fully recharge a battery depends on several factors:

1. Battery Depth of Discharge: A battery discharged to 50% will take about twice as long to fully charge as one discharged only 25%.
2. Battery Size: A larger (higher capacity) battery requires more time to charge than a smaller one at the same current. This can be overcome by using a higher current for larger batteries.
3. Battery Age and Condition: As batteries age, their internal resistance increases, affecting their ability to accept current. This is more noticeable in batteries that have not been well-maintained.
4. Battery Type: Some chemistries, like AGM and Gel, have lower internal resistance, allowing them to accept charge better without generating heat. These batteries can charge up to 2 times faster than traditional wet battery types.
5. Charge Rate: Measured in amperes (A). A lower charge rate takes longer. However, always charging at the highest ampere can cause overheating and premature battery failure. A good rule of thumb is to charge at approximately 1/10th of the battery's Amp-hour capacity (e.g., 100 Ah battery x 1/10 = 10 A).
6. Cold Temperature: Cold temperatures slow the chemical reaction inside a battery during charging, increasing the time required. The ideal charging temperature is between 10°C to 25°C (50°F to 77°F).

Understanding the Multi-Stage Charging Process

A multi-stage charging process graph illustrating voltage and current over time, depicting six distinct stages: 1. Desulphation, 2. Soft Start, 3. Bulk, 4. Absorption, 5. Analyze, 6. Maintain.

• Stage 1 DESULPHATION*: Pulses of voltage and current help recover sulphated or deeply discharged batteries.
• Stage 2 SOFT START*: Gently introduces current to condition deeply discharged batteries and prevent overheating.
• Stage 3 BULK: Charging with maximum current to bring the battery to about 80% capacity.
• Stage 4 ABSORPTION: Charging with constant voltage while reducing current to safely bring the battery to 100% capacity. This stage is key to maximizing battery performance and battery life.
• Stage 5 ANALYZE: Tests if the battery is holding charge.
• Stage 6 MAINTAIN: Monitors battery voltage and provides top-up charging as necessary to keep the battery fully charged.

*If necessary

Maintenance and Care

• Wipe clean cords and clamps after each use.
• Store the power and output cables neatly to prevent damage.
• The charger housing may be cleaned using a damp cloth and mild cleaning agent.
• Always unplug the charger when not in use.
• Keep the charger stored in a cool, dry place.

Troubleshooting/Fault Codes

Technical Specifications

Made in China. Imported by Motomaster Canada, Toronto Canada M4S 2B8.