TecMate OptiMATE 4 Automatic Battery Charger

Introduction and Overview

The TecMate OptiMATE 4 is an automatic diagnostic charger designed for 12V lead-acid batteries, including STD, AGM-MF, and GEL types. It is suitable for batteries ranging from 3Ah to 50Ah for charging within 48 hours, and up to 70Ah for long-term maintenance. This charger is not intended for use with NiCd, NiMH, Li-Ion, or non-rechargeable dry cell batteries.

Safety Instructions

General Safety: Always read the instructions completely before charging. Ensure children do not play with the device. The charger is not intended for use by individuals with reduced physical, sensory, or mental capabilities, or lack of experience, unless supervised.

Battery Hazards: Batteries can emit explosive gases; keep flames and sparks away from batteries. Battery acid is corrosive; wear protective clothing and eyewear. If acid contacts skin, wash immediately with soap and water.

Charger Care: Protect the charger from acids, fumes, and moisture. Avoid placing it on plastic, textile, or leather surfaces if used horizontally; use the provided mounting holes for secure vertical placement. Damage due to corrosion or moisture is not covered by the warranty.

Power Cable: If the power cable is damaged, it must be replaced by the manufacturer or an authorized representative to prevent hazards.

Connecting the Charger to the Battery

The OptiMATE 4 comes with two connection sets:

• Alligator Clips: For temporary connection to batteries outside a vehicle.
• Eyelet Connectors: For permanent connection, featuring a sealed, waterproof connector cap that attaches to the charger. This allows for easy and safe connection while the battery remains in the vehicle. The cap protects the connector from dirt and moisture.

Consult a professional for attaching eyelets. Secure the connector cap to avoid interference with moving vehicle parts or cable damage. The connection set includes a fuse to protect against accidental short circuits; replace blown fuses only with a 15A fuse of the same type.

Connection Procedure:

1. Ensure the charger is unplugged from the AC outlet before making or breaking DC connections.
2. When connecting to a battery in a vehicle, ensure terminals are safely positioned away from surrounding wiring and chassis components. Connect the terminal not connected to the chassis (usually positive) first, then connect the other terminal (usually negative) to the chassis away from the battery and fuel lines. Disconnect in the reverse order.
3. For batteries outside the vehicle, place them in a well-ventilated area. Connect the RED clamp to the POSITIVE (+) terminal and the BLACK clamp to the NEGATIVE (-) terminal. Ensure secure connections for good contact.
4. For deeply discharged or sulfated batteries, remove and inspect the battery for mechanical defects before attempting recovery. Do not charge if defects are found; consult a professional.
5. Review the battery manufacturer's instructions before connecting a new battery.

Using the OptiMATE 4: Programs and Indicators

The OptiMATE 4 features two charging programs: STANDARD and CAN-bus. Only one program can be active at a time.

Program Selection Indicator (when not connected to AC/battery):

• STANDARD: LED #1 (POWER ON) is lit.
• CAN-bus: LED #1 (POWER ON) is lit, and LEDs #3 (DESULFATE) and #4 (CHARGE) flash intermittently.

Switching Programs: Disconnect AC power, connect the negative clamp to the positive clamp, reconnect AC power. Observe LED flashes (#3, #4, #5, #6, #7 flash 12 times) to confirm the change. Disconnect clamps. The selected program is now active.

LED Indicators:

• LED #1 (POWER ON): Confirms AC power supply.
• LED #2 (REVERSE POLARITY): Lights up if the battery is connected incorrectly. The charger is protected, and output remains off until corrected.
• LEDs #8, #9, #10 (CHARGE CURRENT BAR): Indicate charging current: #8 (0.2A), #8+#9 (0.5A), #8+#9+#10 (0.8A).

Program 1 - STANDARD

Deeply Discharged/Neglected Batteries: Remove and inspect the battery. Be cautious with small batteries; deeply discharged ones can overheat. Monitor battery temperature during charging and disconnect immediately if it feels unpleasantly hot or shows unusual signs (bubbling, leakage).

Prequalification Test (LEDs #5, 6, 7): Indicates battery condition before charging. Charging starts after 10 seconds. If LED #7 flashes continuously, the battery cannot be recovered.

Recovery/Desulfation (LED #3): Activated if prequalification LEDs #7 (red) or #6 (yellow) are lit.

• Standard Recovery (LED #3 solid): Up to 16V, 0.2A.
• TURBO Recovery (LED #3 flashing): Up to 22V, 0.2A, for heavily neglected batteries.
• PULSE Recovery (last 15 mins, LED #3 solid): Up to 0.8A pulses, preparing the battery for normal charging.

Charging (LED #4):

• BULK Charge (LED #4 solid): 0.8A at max 14.2-14.4V.
• END Charge (LED #4 flashing): Pulse absorption (0.2-0.8A pulses) for rapid full charge, followed by a check step (13.6V) to monitor charge level.

Note: Total charging time is limited to 48 hours.

Voltage Retention Test (LED #5 flashing): Power is interrupted for 30 minutes to check if the battery holds charge. A healthy battery shows LED #5 (green) flashing continuously. Refer to "EARLY SIGNS OF BATTERY PROBLEMS" for other indications.

Maintenance Charging (LEDs #5, 6, 7 solid): Charging circuit supplies current for 30 minutes at 13.6V, alternating with test periods, until disconnected.

Program 2 - CAN-bus

Important: High-voltage STANDARD and RECOVERY modes are disabled. Use for vehicles with CAN-bus systems. Recommended connection via vehicle's 12V outlet (TMT-72 or TM-95 connector).

LED Indications Before Battery Connection:

• LEDs #3+4 Flashing: Detecting/activating CAN-bus 12V outlet.
• LEDs #3+4+5+6+7 Flashing: Output short circuit detected. LED #2 (Reverse Polarity) lit indicates incorrect connection.

Prequalification Test (LEDs #5, 6, 7): Indicate CAN-bus outlet activation and battery condition. Charging starts after 10 seconds. If the outlet does not activate, check program selection, connection, battery power, or vehicle CAN-bus program.

Recovery/Desulfation (LED #3): Only low-voltage PULSE recovery (15 mins, up to 0.8A pulses) is available.

Charging (LED #4):

• BULK Charge (LED #4 solid): 0.8A at max 14.2-14.4V.
• END Charge (LED #4 flashing): Pulse absorption followed by a check step.

Notes: Program resets automatically after 2 minutes of disconnection or CAN-bus outlet deactivation. Total charging time limited to 48 hours.

Voltage Retention Test (LED #5 flashing): Power is interrupted for 30 minutes to check charge holding. The CAN-bus system may switch off the outlet. After the test, the program re-initializes the outlet and switches to MAINTENANCE CHARGING.

Maintenance Charging (LEDs #5, 6, 7 solid): Charging circuit supplies current for 30 minutes at 13.6V, alternating with test periods.

Notes on Test Results

1. If test result is not green LED #5, disconnect from the system, reconnect OptiMATE. Improved result suggests an electrical system issue. Persistent poor results require professional battery testing.
2. Test results remain displayed during maintenance cycles. A temporary voltage drop due to a transient leak might improve LED indications.
3. Serious Problem (LED #7 red, or #6 yellow + #7 red): Indicates battery voltage does not hold or the battery is unrecoverable, possibly due to internal defects or external current drain. Sudden loads can also cause voltage drops.
4. GOOD TEST RESULT, but insufficient power: Permanent battery damage may cause excessive self-discharge. Wait at least 12 hours after disconnecting the OptiMATE before reconnecting and retesting.

Automatic Battery Maintenance

The maintenance cycle consists of 30-minute charge periods alternating with 30-minute rest periods. This "50% cycle" helps optimize battery lifespan for seasonal use by preventing electrolyte loss and minimizing water loss. The circuit maintains a safe 13.6V ("trickle charge") to compensate for low current draw and minor electrical loads.

Repeating Test and Maintenance Cycles

The test and maintenance cycles repeat every 24 hours as long as the charger remains connected.

Maintaining a Battery for Long Periods

The OptiMATE can safely maintain a non-defective battery for months. Check connections bi-weekly. For batteries with filler caps, disconnect, check electrolyte levels, and refill with distilled water if necessary. Always follow safety precautions.

Charging Time

A minimum of 45 minutes is required for a charge/test cycle. Charging time for a flat but undamaged battery is approximately its Ah rating (e.g., 20 hours for a 20Ah battery). Deeply discharged batteries may take longer. If a large-capacity car battery is deeply discharged, full charge may exceed the 48-hour safety limit; follow the reset procedure if necessary.

Resetting the Charge or Test Cycle

Disconnect the charger from AC power. Wait for the POWER ON LED (#1) to turn off. Reconnecting to AC power will cause LEDs #3, #4, #5, #6, #7 to flash twice, confirming microprocessor integrity.

Limited Warranty

TecMate (International) SA provides a three-year limited warranty from the date of purchase, covering defects in materials and workmanship. Return defective units to the manufacturer or distributor with proof of purchase for repair or replacement at TecMate's discretion. The warranty excludes damage from accidents, misuse, or unauthorized repairs. Statutory rights are not affected. For warranty service, visit www.tecmate.com/warranty or contact warranty@tecmate.com.

Copyright © 2010 TecMate International.

OptiMATE 4 and other TecMate product names are registered trademarks of TecMate International NV. More information is available at www.tecmate.com.