Motomaster Simple Series Onboard Battery Charger

Introduction

The Motomaster Simple Series Onboard Battery Charger features advanced microprocessor technology making battery charging faster, easier, and safer than ever before. This manual will explain how to use the charger safely and effectively. Please read and follow these instructions and precautions carefully.

Safety Instructions

General Safety

IMPORTANT SAFETY INSTRUCTIONS. SAVE THESE INSTRUCTIONS.

This manual contains important safety and operating 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, 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 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. Take it to a qualified service professional if service or repair is required. Incorrect assembly may result in fire or electrical shock.
• To reduce 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 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 Instructions

• Make sure that someone is close enough 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 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 other electrical part that may cause an explosion.
• 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 such objects to metal, causing a severe burn.

Usage and Extension Cords

• 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 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.

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. Use of improper extension cord 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 AC ampere rating of the charger, as specified in the chart below.

*AWG = American Wire Gauge

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 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.
• 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 ring terminals only after setting any charger switches to "off" position and removing the AC cord from the electric outlet. Never allow ring terminals to touch each other.
• Attach ring terminals 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 part.
• 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), see the next step. If the positive post is grounded to the chassis, see the step "For positive-grounded vehicle".
• For negative-grounded vehicle: Connect the POSITIVE (RED) ring terminal from the battery charger to the POSITIVE (POS, P, +) ungrounded post of the battery. Connect the NEGATIVE (BLACK) ring terminal to the vehicle chassis or engine block away from the battery. Do not connect the ring terminal 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) ring terminal from the battery charger to the NEGATIVE (NEG, N, -) ungrounded post of the battery. Connect the POSITIVE (RED) ring terminal to the vehicle chassis or engine block away from the battery. Do not connect the ring terminal 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 ring terminal from the vehicle chassis, and then remove the ring terminal from the battery post.
• See the Operation section for charging time information.

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.
• Connect the POSITIVE (RED) charger ring terminal to the POSITIVE (POS, P, +) post of the battery.
• Attach at least a 60 cm (24") long 6-gauge (AWG) insulated battery cable to the NEGATIVE (NEG, N, -) battery post.
• Position yourself and the free end of the cable as far away from the battery as possible – then connect the NEGATIVE (BLACK) charger ring terminal 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 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.

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.

Mounting Instructions

Remove all cord wraps and uncoil the cables prior to using the battery charger.

Mounting the Charger to the Fender Well

The charger can be mounted directly to the fender well of your vehicle, as shown (Fig. 1), using the double-sided adhesive and cable tie (included).

[Fig. 1: Diagram showing the battery charger mounted to the inside of a vehicle's fender well.]

Mounting the Charger Alongside the Battery

The charger can also be mounted alongside your vehicle's battery, using the bracket (sold separately). If possible, mount the charger to the side of the battery away from the engine and fan blades. Mount the bracket to the charger as shown (Fig. 2) using the nuts and bolts provided with the bracket. Loosen the battery retaining hardware enough that you can insert the bracket between the bottom of the battery and the battery mounting tray as shown. Position the charger so that it will not rub against the battery or any other part of the vehicle, and then tighten the battery retaining hardware. NOTE: Do not drill or puncture the battery.

[Fig. 2: Diagram illustrating the mounting bracket being attached to the charger, with placement relative to a battery and its tray.]

Electrical Installation

The output leads of the charger are terminated with 3/8" dia. ring lugs. Route and secure the AC cord and the output wiring away from the gas line, carburetor or other hot, sharp, moving or pinch parts to avoid damage to the insulation (Fig. 3). Secure the AC cord using a cable tie or equivalent.

[Fig. 3: Diagram showing the charger's ring terminals connected to a vehicle battery, with the AC power cord routed away from potential hazards.]

Operation

LED Indicators

• Red LED (solid): The charger is charging the battery.
• Red LED (flashing): The connections are reversed, or the battery is bad.
• Green LED (solid): The battery is fully charged and the charger is in maintenance mode.

Charging Your Battery

NOTE: For a battery with a starting voltage under 1V, use a manual charger to pre-charge the battery for five minutes, to get additional voltage into the battery.

1. Follow the instructions in the "Connecting Your Battery" section to connect your battery, and then connect the charger to a live AC electrical outlet.
2. Charging begins automatically.
3. When charging is complete:
   • If you are finished charging, disconnect the charger from the AC power.
   • If you wish to maintain the battery, leave the charger plugged in.

Battery Charging Times

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

This charger is equipped with an auto-start feature. Current will not be supplied to the ring terminals until a battery is properly connected. The ring terminals will not spark if touched together. Charging will NOT begin if the connections are reversed.

Automatic Voltage Detection

The charger is equipped with Auto Voltage Detection, which automatically detects whether the battery is 6V or 12V and then charges accordingly.

Bad Battery

If charging cannot be completed normally, the charger's output is shut off and the Red LED will flash. Have the battery checked and replaced, if necessary.

Desulfation Mode

If the battery is left discharged for an extended period of time, it could become sulfated and not accept a normal charge. If the charger detects a sulfated battery, the charger will switch to a special mode of operation designed for such batteries. If successful, normal charging will resume after the battery is desulfated. Desulfation could take 8-10 hours. If desulfation fails, the Red LED will flash.

Completion of Charge

Charge completion is indicated by the Green LED. When lit, the charger has switched to the maintenance mode of operation. The charger can be left connected to the battery to keep it topped up while in storage.

Maintenance Mode (Float Mode Monitoring)

When the Green LED is lit, the charger has completed charging and started maintenance mode. In this mode, the charger keeps the battery fully charged by delivering a small current when necessary. If the charger has to provide its maximum maintain current for a continuous 12 hour period, it will go into abort mode. This is usually caused by a drain on the battery or the battery could be bad. Make sure there are no loads on the battery. If there are, remove them. If there are none, have the battery checked or replaced (if necessary).

Maintaining a Battery

This product maintains both 6V and 12V batteries, keeping them at full charge. It is not recommended for industrial applications. The maintain 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 draws. As such, occasionally monitoring your battery and the charging process is required.

Maintenance

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

• Clean the ring terminals each time you are finished charging. Wipe off any battery fluid that may have come in contact with the ring terminals, to prevent corrosion.
• Occasionally cleaning the case of the charger with a soft cloth will help prevent corrosion.
• Coil the input and output cords neatly when storing the charger. This will help prevent accidental damage to the cords 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 ring terminals on or around metal.

Troubleshooting

For more information about troubleshooting or replacement parts, call toll-free: 1-888-942-6686.

Technical Specifications

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