Motomaster Classic Series Battery Charger

Introduction

This Motomaster® 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 Information

General Safety Precautions

• Read all instructions, warnings, and cautions printed on the battery charger, battery and vehicle or equipment using battery.
• Use the charger for charging lead-acid batteries only (such as those used in cars, trucks, motorcycles, boats, etc.).
• Battery chargers are not intended to supply power to a low-voltage electrical system or to charge dry-cell batteries commonly used in household appliances such as radios, toys, cameras, etc. Charging dry-cell batteries may cause them to burst and cause injury to persons and damage to property.
• Use of an attachment not recommended by the battery charger manufacturer may result in the risk of fire or electric shock.
• 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.

Electrical Safety

• To reduce risk of electrical shock, unplug the charger from the outlet before attempting any maintenance or cleaning.
• DO NOT expose charger to rain or snow.
• NEVER charge a frozen battery. If battery acid becomes frozen, bring battery to a warm area and allow it to thaw before you begin charging.
• NEVER touch battery clamps together when the charger is on. This may cause a spark.
• NEVER operate a charger if it has received a hard blow, been dropped or otherwise damaged. Take it to a qualified professional for inspection.
• NEVER pull out the plug by the cord when unplugging the charger, as this may cause damage to the cord or plug.

Personal Safety Instructions

• Make sure that someone is within range of your voice to come to your aid if needed while you work with or are near a lead-acid battery.
• Wear complete eye and clothing protection when working with lead-acid batteries.
• Avoid touching your eyes while working with a battery. Have plenty of fresh water and soap nearby for use in case battery acid contacts your eyes, skin or clothing. If this happens, wash immediately with soap and water, then get medical attention.

WARNING! Handling the cord on this product or objects associated with the use of this product may expose you to lead. Wash hands after handling.

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 the utmost importance that each time before using your charger, you read and follow the instructions provided exactly. To reduce risk of battery explosion, follow these instructions and those published by the battery manufacturer.

Electrical Connections & Usage

Plugging In

Your charger requires a 3-pin, grounded 120 V AC electrical wall outlet receptacle installed according to local codes and ordinances.

Using an Extension Cord

The use of an extension cord is NOT recommended. If an extension cord must be used, follow these guidelines:

• Make sure that the pins on the charger's power cord fit firmly into the extension cord and that the extension cord fits firmly into the receptacle.
• Check that the extension cord is properly wired and in good electrical condition.
• Make sure that the wire size is large enough for its length and for the AC ampere rating of the charger, as specified in the chart below.

Minimum Recommended Extension Cord

*AWG = American Wire Gauge

WARNING! DO NOT operate the charger if it has a damaged power cord or plug. Have the cord replaced.

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 the utmost importance that each time before using your charger, you read and follow the instructions provided exactly. To reduce risk of battery explosion, follow these instructions and those published by the battery manufacturer.

Preparing to Charge

Charger Location

• DO NOT expose charger to rain or snow.
• Locate the charger as far away from the battery being charged as the cables will permit.
• Be sure to position the power cord to prevent it from being stepped on, tripped over or damaged.
• NEVER place charger directly above battery being charged. Gases from the battery will corrode and damage the charger.
• NEVER set a battery on top of a charger.
• NEVER allow battery acid to drop on charger.
• ALWAYS charge a battery in a well-ventilated area.

Battery Preparation

• When removing battery from vehicle to charge it, always remove grounded terminal from battery first.
• Make sure all accessories in the vehicle are OFF in order to prevent sparks.
• Be sure that the area around the battery is well ventilated while being charged.
• Clean the battery terminals. Be careful to keep corrosion or battery acid from getting in or around your eyes.

Battery Fluid Level

• For batteries with removable vent caps, if required, add distilled water to each cell until the battery fluid reaches the level specified by the battery manufacturer.
• DO NOT overfill.
• For batteries without removable vent caps, carefully follow the manufacturer's charging instructions.

Manufacturer Recommendations

• Study all of the battery manufacturer's specific precautions and recommendations for charging and for recommended rates of charge.

Battery Voltage Check

• Make sure that you have a 12 V lead-acid battery. Determine voltage of battery by referring to the vehicles owner's manual. If the charger has an adjustable charge rate, charge battery at the lowest rate first.

Assembly

• Remove all cord wraps and uncoil the cables prior to 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.)

WARNING! Battery chargers may get hot during operation. DO NOT set charger on flammable materials like carpeting, upholstery, paper, cardboard, etc. Charger may damage leather and plastic.

Connecting Your Battery

Battery in Vehicle (Negative Grounded)

1. Before connecting and disconnecting the DC output clamps, remove the AC plug from the electrical outlet.
2. Check polarity of battery posts. A positive (POS, P, +) battery post usually has a larger diameter than a negative (NEG, N, -) battery post.
3. Connect the positive (red) clip from the battery charger to the positive (POS, P, +) ungrounded post of battery.
4. Connect the negative (black) clip to vehicle chassis (must be a heavy gauge metal part of the frame) or engine block away from battery. DO NOT connect clip to carburetor, fuel lines, or sheet-metal body parts.
5. Connect charger AC supply cord to electric outlet. (Reverse process to remove charger.)

Battery in Vehicle (Positive Grounded)

1. Before connecting and disconnecting the DC output clamps, remove the AC plug from the electrical outlet.
2. Connect the negative (black) clip from the battery charger to the negative (NEG, N, -) ungrounded post of battery.
3. Connect the positive (red) clip to vehicle chassis (must be a heavy gauge metal part of the frame) or engine block away from battery. DO NOT connect clip to carburetor, fuel lines, or sheet-metal body parts.
4. Connect charger AC supply cord to electric outlet. (Reverse process to remove charger.)

NOTE: NEVER allow the DC output clamps to touch each other. This may cause a spark. Remove the AC plug from the electrical outlet before connecting and disconnecting the DC output clamps. To reduce the risk of a spark near battery:

• Position AC and DC cords to reduce the risk of damage by hood, door, or moving engine part.
• Stay clear of fan blades, pulleys, and other parts that can cause injury.
• Check polarity of battery posts. A positive (POS, P, +) battery post usually has a larger diameter than a negative (NEG, N, -) battery post.

WARNING! A spark near a battery may cause a battery explosion!

NOTE: A marine battery installed in a boat must be removed and charged on shore. To charge it onboard requires equipment specially designed for marine use.

Battery Removed from Vehicle

1. Before connecting and disconnecting the DC output clamps, remove the AC plug from the electrical outlet.
2. Connect the positive (red) charger clip to the positive (POS, P, +) post of battery.
3. Attach at least a 60 cm (24") long 6-gauge (AWG) insulated battery cable to a negative (NEG, N, -) battery post.
4. Position yourself and the free end of cable as far away from battery as possible, then connect the negative (black) charger clip to the free end of cable. DO NOT face battery when making final connection.
5. Connect charger AC supply cord to electric outlet. (Reverse process to remove charger.)
6. When disconnecting chargers, ALWAYS do so in reverse sequence of connecting procedure and break first connection while standing as far away from battery as practical.

NOTE: NEVER allow the DC output clamps to touch each other. This may cause a spark. Check polarity of battery posts. A positive (POS, P, +) battery post usually has a larger diameter than a negative (NEG, N, -) battery post.

WARNING! A spark near a battery may cause a battery explosion!

NOTE: A marine battery installed in a boat must be removed and charged on shore. To charge it onboard requires equipment specially designed for marine use.

Know Your Charger

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.

Rate Selection Button

Use this button to select one of the following:

• 6 A Charge – For charging small and large batteries. Not recommended for industrial applications.
• 40 A<>15 A Boost Charge – For quickly adding energy to a severely discharged or large capacity battery prior to Engine Start, or for fast charging of larger batteries.
• 200 A Engine Start – Provides additional amps for cranking an engine with a weak or run-down battery. Always use in combination with a battery.

LED Indicators

• Charging (yellow) LED lit: The charger is charging the battery.
• Charged/Maintaining (green) LED lit: The battery is fully charged and the charger is in maintain mode.
• Red LED solid: The connections are reversed.
• Red LED blinking: The charger has detected a problem with the battery. See the Troubleshooting section for more information.

NOTE: Charger will NOT begin charging if the solid Red LED is on, indicating the battery clamps are reversed. See the Operation section for a complete description of the charger modes.

Operation

Charging Your 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. Upon power-up, the default selection for charge rate will be Boost Charge. If this is not preferred, choose the 6 A rate.
3. Press the Start/Stop button to begin charging immediately. If the Start button is not pressed within 30 seconds after power-up, and a battery is properly connected, the charging process will begin automatically.
4. When charging is complete,
   • a. Or if done charging, press the Stop button, disconnect the charger from AC power, and disconnect the battery clamps following the instructions for disconnection in the Connecting Your Battery section.
   • b. To keep the battery in maintain mode, do not press the Stop button, and leave all connections. For more information, see the Maintain Mode section.

Battery Charging Times

Ah – Amp Hour

CCA – Cold Cranking Amps

RC – Reserve Capacity

NR - Not Recommended

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

Aborted Charge

If charging cannot be completed normally, charging will abort. When charging aborts, the charger's output is shut off and the Red LED will blink. To reset after an aborted charge, unplug the charger from the AC outlet, wait a few moments and then plug it back in.

Modes of Operation

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. Normal charging will resume after the battery is desulfated. Desulfation could take up to 10 hours. If desulfation fails, charging will abort and the red LED will blink.

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 maintain mode. In this mode, the charger keeps the battery fully charged by delivering a charge current when necessary. If the charger has to provide an excessive maintain current for a continuous 12 hour period, it will go into abort mode (see Aborted Charge section). This is usually caused by a drain on the battery or the battery could be bad.

Maintaining a Battery

This product charges and maintains 12 V batteries. 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.

Power-Up Auto Start

The 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 Charge. The charging process will automatically start, and the Charging (yellow) LED will light.

Using the Engine Start Feature

Your battery charger can be used to jump start your car if the battery is low. Follow all safety instructions and precautions for charging your battery. Wear complete eye protection and protective clothing.

1. With the charger unplugged from the AC outlet, connect the charger to the battery following the instructions given in Battery in Vehicle section.
2. Connect the charger to a live grounded 120 V AC outlet.
3. With the charger plugged in and connected to the battery and chassis, press the Rate Selection button until the Engine Start LED is lit, and then press the Start button.
4. Crank the engine until it starts or 5 seconds pass. If the engine does not start, repeat. Do not crank during the cool 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 V, 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.

Engine Starting Notes

During the starting sequence listed above, the charger is set to one of four states:

• Wait for ready – The charger charges the battery for 2 minutes before the Wait for Cranking state. While waiting for ready, the engine can be cranked. For severely discharged batteries, it is not recommended to crank during this time.
• Wait for cranking – The charger waits until the engine is actually 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 5 seconds.
• Cool Down – After repeated cranking during a 3-minute ready period, the charger enters a mandatory 3-minute (180-second) cool down state. After 2 hours of Engine Starting, the unit will automatically exit from the Engine Start mode, just as if the Stop button had been pressed; the Charging LED will not be lit. During this time, the Engine Start LED will blink to indicate the Engine Start operation is temporarily paused.

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

WARNING! Using the Engine Start feature WITHOUT a battery installed in the vehicle could cause damage to the vehicle's electrical system.

Maintenance

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 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 clamps clipped together, on or around metal, or clipped to the cables.

Troubleshooting

NOTE: For more information about troubleshooting or replacement parts, call toll-free: 1-866-942-6686.

Technical Specifications

Made in Mexico
Motomaster Canada
Toronto, Canada M4S 2B8