CTEK UC 800 Owner's Manual

UC 800
Battery Charger
For lead-acid batteries 2–32Ah
User Manual and Guide to professional
charging of starter and deep cycle batteries.
Model 1019
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INTRODUCTION
UC 800 is a switch mode charger with pulse maintenance and is a part of a series of
professional battery chargers from CTEK Power Inc. These chargers represent the latest
technology within battery charging. An UC 800 gives the battery maximum life. Read this
User’s Manual and follow the instructions carefully before you start to use the charger.
IMPORTANT SAFETY INSTRUCTIONS
California Proposition 65
WARNING: This product contains chemical known to the state of California to cause
cancer or reproductive toxicity.
1. SAVE THESE INSTRUCTIONS – This manual contains
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important safety and operating instructions for battery charger models 1019.
When charging, batteries can emit explosive gases, therefore it is essential to preYHQWÀDPHVDQGVSDUNV7KHFKDUJHULVGHVLJQHGIRUFKDUJLQJOHDGDFLGEDWWHULHV
from 2 to 32Ah. Do not use for any other purpose. Do not expose to rain or snow.
Always provide good ventilation when charging.
Use of an attachment not recommended or sold by the battery charger manufacWXUHUPD\UHVXOWLQDULVNRI¿UHHOHFWULFVKRFNRULQMXU\WRSHUVRQV
To reduce risk of damage to electric plug and cord, pull by the plug rather than cord
when disconnecting charger.
An extension cord should not be used unless absolutely necessary. Use of imSURSHUH[WHQVLRQFRUGFRXOGUHVXOWLQDULVNRI¿UHDQGHOHFWULFVKRFN,IDQH[WHQsion cord must be used, make sure that: a) Pins on plug of extension cord are the
same number, size and shape as those of plug on charger; b) Extension cord is
properly wired and in good electrical condition; and c) Wire size is large enough for
DFDPSHUHUDWLQJRIFKDUJHUDVVSHFL¿HGLQ³WHFKQLFDOGDWD´
Do not operate charger with damaged cord or plug – return the charger to the
place where purchased.
Never operate the charger if it has received a sharp blow, been dropped or otherZLVHGDPDJHGLQDQ\ZD\WDNHLWWRDTXDOL¿HGVHUYLFHPDQ
'RQRWGLVDVVHPEOHFKDUJHUWDNHLWWRDTXDOL¿HGVHUYLFHPDQZKHQVHUYLFHRUUHSDLULVUHTXLUHG,QFRUUHFWUHDVVHPEO\PD\UHVXOWLQDULVNRIHOHFWULFDOVKRFNRU¿UH
To reduce risk of electric shock, unplug charger from AC outlet before attempting
any maintenance or cleaning.
11. WARNING - RISK OF EXPLOSIVE GASES
a) 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.
b) To reduce risk of battery explosion, follow these instructions and those published
by the battery manufacturer and the manufacturer of any equipment you intend
to use in vicinity of battery. Review cautionary marking on these products and
on engine.
12. PERSONAL PRECAUTIONS
a) Consider have some one close enough by to come to your aid when you work near
a lead-acid battery.
b) Have plenty of fresh water and soap nearby in case battery acid contacts skin,
clothing or eyes.
c) Wear complete eye protection and clothing protection. Avoid touching eyes while
working near battery.
d) If battery acid contacts skin or clothing, wash immediately with soap and water.
,IDFLGHQWHUVH\HLPPHGLDWHO\ÀRRGH\HZLWKUXQQLQJFROGZDWHUIRUDWOHDVW
minutes and get medical attention immediately.
e) 1(9(5VPRNHRUDOORZDVSDUNRUÀDPHLQYLFLQLW\RIEDWWHU\RUHQJLQH
f) Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark
or short-circuit battery or other electrical part that may cause explosion.
g) Remove personal metal items such as rings, bracelets, necklaces, and watches
when working with lead-acid battery. A lead-acid battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn.
h) Use 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 battery charger for charging dry-cell batteries that are commonly used
ZLWKKRPHDSSOLDQFHV7KHVHEDWWHULHVPD\EXUVWDQGFDXVHLQMXU\WRSHUVRQVDQG
damage to property.
i) Never charge a frozen battery.
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13. PREPARING TO CHARGE
a) If necessary to remove battery from vehicle to charge, always remove grounded
WHUPLQDOIURPEDWWHU\¿UVW0DNHVXUHDOODFFHVVRULHVLQWKHYHKLFOHDUHRIIVRDV
not to cause an arc.
b) Be sure area around battery is well ventilated while battery is being charged.
c) Clean battery terminals. Be careful to keep corrosion from coming in contact
with eyes.
d) $GGGLVWLOOHGZDWHULQHDFKFHOOXQWLOEDWWHU\DFLGUHDFKHVOHYHOVSHFL¿HGE\EDWWHU\PDQXIDFWXUHU'RQRWRYHU¿OO)RUDEDWWHU\ZLWKRXWUHPRYDEOHFHOOFDSVVXFK
as valve regulated lead acid batteries, carefully follow manufacturer’s recharging
instruction.
e) 6WXG\DOOEDWWHU\PDQXIDFWXUHU¶VVSHFL¿FSUHFDXWLRQVZKLOHFKDUJLQJDQGUHFRPmended rates of charge.
f) Determine voltage of battery by referring to car owner’s manual and make sure that
WKHRXWSXWYROWDJHVHOHFWRUVZLWFKLVVHWDWFRUUHFWYROWDJH,IFKDUJHUKDVDGMXVWDEOH
charge rate, charge battery initially at lowest rate.
14. CHARGER LOCATION
a) Locate charger as far away from battery as DC cables permit.
b) Never place charger directly above battery being charged; gases from battery will
corrode and damage charger.
c) 1HYHUDOORZEDWWHU\DFLGWRGULSRQFKDUJHUZKHQUHDGLQJHOHFWURO\WHVSHFL¿FJUDYLW\
RU¿OOLQJEDWWHU\
d) Do not operate charger in a closed-in area or restrict ventilation in any way.
e) Do not set a battery on top of charger.
15. DC CONNECTION PRECAUTIONS
a) Connect and disconnect dc output clips only after setting any charger switches to
³RII´SRVLWLRQDQGUHPRYLQJDFFRUGIURPHOHFWULFRXWOHW1HYHUDOORZFOLSVWRWRXFK
each other.
b) Attach clips to battery and chassis as indicated in 16(e), 16(f), 17(b) through 17(d).
16. FOLLOW THESE STEPS WHEN BATTERY
IS INSTALLED IN VEHICLE. A SPARK
NEAR BATTERY MAY CAUSE BATTERY
EXPLOSION. TO REDUCE RISK OF A SPARK
NEAR BATTERY:
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a) Position AC and DC cords to reduce risk of damage by hood, door or moving
engine part.
b) 6WD\FOHDURIIDQEODGHVEHOWVSXOOH\VDQGRWKHUSDUWVWKDWFDQFDXVHLQMXU\WR
persons.
c) Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has
larger diameter than NEGATIVE (NEG, N, -) post.
d) Determine which post of battery is grounded (connected) to the chassis. If negative post is grounded to the chassis (as in most vehicles) see (e). If positive post is
grounded to the chassis, see (f).
e) For Negative-grounded vehicle, connect POSITIVE (RED) clip from battery
charger to POSITIVE (POS, P, +) ungrounded post of battery. Connect NEGATIVE
(BLACK) clip to vehicle chassis or engine block away from battery. Do not connect
clip to carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gage
metal part of the frame or engine block.
Charger connection.
1. Connect positive charger clip (red) to positive battery terminal.
2. Connect negative charger clip (black) to a good metal engine ground away from
the battery. Do no connect clip to fuel lines or sheet-metal body parts.
3. Connect the AC cord to the socket. The red alarm indication light will indicate
a battery which is connected to reverse polarity.
f) For Positive grounded vehicle, connect NEGATIVE (BLACK) clip from battery
charger to NEGATIVE (NEG, N, –) ungrounded post of battery. Connect POSITIVE
(RED) clip to vehicle chassis or engine block away from battery. Do not connect
clip to carburetor, fuel lines, or sheet-metal body parts. Connect to a heavy gage
metal part of the frame or engine block.
Charger connection.
1. Connect negative charger clip (black) to negative battery terminal.
2. Connect positive charger clip (red) to a good metal engine ground away from the
battery. Do no connect clip to fuel lines or sheet-metal body parts.
3. Connect the AC cord to the socket. The red alarm indication light will indicate
a battery which is connected to reverse polarity.
g) When disconnecting charger, turn switches to off, disconnect AC cord, remove clip
from vehicle chassis, and then remove clip from battery terminal.
h) See operating instructions for length of charge information.
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17. FOLLOW THESE STEPS WHEN BATTERY
IS OUTSIDE VEHICLE. A SPARK NEAR
BATTERY MAY CAUSE BATTERY
EXPLOSION. TO REDUCE RISK OF
A SPARK NEAR BATTERY:
a) Check polarity of battery terminals. POSITIVE (POS, P, +) battery post usually has
a larger diameter than NEGATIVE (NEG, N, -) post.
b) Attach at least a 24-inch-long 6-gauge (AWG) insulated battery cable to
NEGATIVE (NEG, N, -) battery post.
c) Connect POSITIVE (RED) charger clip to POSITIVE (POS, P, +) battery of post.
d) Position yourself and free end of cable as far away from battery as possible – then
connect NEGATIVE (BLACK) charger clip to free end of cable.
e) 'RQRWIDFHWKHEDWWHU\ZKHQPDNLQJWKH¿QDOFRQQHFWLRQ
f) When disconnecting charger, always do so in reverse sequence of connecting
SURFHGXUHDQGEUHDN¿UVWFRQQHFWLRQZKLOHDVIDUDZD\IURPEDWWHU\DVSUDFWLFDO
g) When disconnecting charger, disconnect in reverse sequence from connecting
procedure. See operating instructions for charge information.
h) A marine (boat) battery must be removed and charged on shore. To charge it on
board requires equipment specially designed for marine use.
The battery charger must be connected to the battery according to
the instructions above.
IMPORTANT SAFETY INFORMATION!
The UC 800 cannot be used to restore a fully worn out battery. If the UC 800 does not
switch to maintenance charge after three days (green light illuminated), there is a fault.
Possible causes:
• The battery is probably worn out and should be replaced.
• Some large antimony batteries may behave differently and can allow the UC 800 to
charge the battery for too long, which can lead to overcharging. See caution!
• ,ISRZHUFRQVXPHUVOLNH¿WWHGDODUPVDQGQDYLJDWLRQFRPSXWHUVDUHFRQQHFWHGWRWKH
battery, the charging process takes longer and this can also overcharge the battery.
• $VXOSKDWHGEDWWHU\ZLOORQO\DFFHSWFXUUHQWZLWKGLI¿FXOW\DQGFRQVHTXHQWO\WKHFKDUJing process takes a particularly long time. A worn out battery cannot be fully charged.
Therefore you should always check whether the charger has been switched to maintenance charge before you leave it turned on or unobserved for any length of time.
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Caution: If the UC 800 does not switch to maintenance mode after three days, it has to
be manually disconnected.
Note: A battery that hasn’t changed to maintenance charge after three days is most likely
worn out and needs to be replaced. All other batteries can be maintained for a very long
time.
BATTERY TYPES
The following recommendations should only be considered as guidelines. In the event of
uncertainty always refer to the battery manufacturer’s recommendations.
UC 800 is suitable for charging all types of 6V lead-acid batteries: open batteries, MF,
Wet, AGM and most GEL-batteries. Battery sizes from 2 to 32Ah. The charger can maintain batteries up to 100Ah.
CHARGING
The battery charger must be connected to the battery according to
the instructions above.
Starting the charging process:
1. Once you have established that the battery cable has been correctly connected you
can start the charging process. To do so, insert the charger plug into the AC socket.
2. Now either the charge indicator
or the maintenance charge indicator
lights up.
When the maintenance charge indicator lights up, the battery is fully charged. If the
battery voltage drops, the charger sends a pulse to the battery. The length of the pulse
depends on how much charge the battery has lost. The UC 800 may be connected for
months at a time. However it is recommended to monitor batteries on charge.
3. The red alarm indication light will indicate a battery, which is connected to reverse
polarity.
4. If nothing happens: If no indicator is illuminated, the connection to the battery or the
chassis could be faulty, or the battery could be defective. If the charging process
has not started, this could be due to the fact that the power socket is not supplying a
current.
5. The charging process can be interrupted at any time. In addition pull the plug of the
charger out of the power socket. Always remove the plug of the charger from the
power socket before disconnecting the battery cable. If you interrupt the charging proFHVVRIDEDWWHU\¿WWHGLQDYHKLFOHWKHEDWWHU\FDEOHPXVWDOZD\VEH¿UVWGLVFRQQHFWHG
from the chassis and then from the other battery cable.
6. If the indicators for charge
and maintenance charge DUHÀDVKLQJDOWHUQDWHO\
this may have the following causes:
• Interruption of the charging process because of a lost connection or because the
battery is not conducting.
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• 7KHEDWWHU\LVVXOSKDWHG,IWKHLQGLFDWRUVÀDVKHVIRUPRUHWKDQPLQXWHVWKHEDWtery may be defective and should be replaced.
• ,IWKHÀDVKLQJVLJQDOLVÀDVKLQJDWLQWHUYDOVRIPRUHWKDQVHFRQGVWKHQWKHUHLVD
high self discharge of the battery, indicating a bad battery.
CHARGING CYCLE
UC 800 has a four step fully automatic charging cycle. At the start of charging the battery charger delivers maximum current to the battery and the battery voltage increases
constantly to a set level of 7.2V. At this point the voltage will be regulated and kept constant while the charging current is successively lowered. Once the charging current has
dropped below 0.4A the charger switches to maintenance charging.
If the battery is loaded and the battery’s terminal voltage drops to 6.45V the charger
automatically switches back to the beginning of the four step cycle. The charger requires a
reverse voltage from the battery of at least 3V to start the charging cycle, this means that
if the battery is so deeply discharged that the terminal voltage is lower than 3V the charger
cannot charge the battery in question. A normal discharged battery has a terminal voltage
of 5,25V.
Charging phases:
Desulphation - Desulphation with pulsing for sulphated batteries.
Bulk - Main charge when 80% of charging takes place. The charger delivers a constant
current until the terminal voltage has risen to the set level.
Absorption - Complete charge up to virtually 100%. The terminal voltage is maintained
at the set level. During this phase the current drops successively so the terminal voltage
does not become too high. If the absorption phase has been in progress for more than 18
hours the charger switches to maintenance charging. This function prevents damage if the
battery is faulty.
Pulse - Maintenance charging. Charging level varies between 95% and 100%. The battery receives a pulse when the voltage drops. Keeps the battery in perfect condition when
it is not used. The charger can be connected for months at a time.
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BULK CHARGING TIME
Battery capacity (Ah)
2
8
20
32
Time to ~80% charge (h)
1.5
6
20
36
SPECIFICATION
Model
Voltage AC
1019
100–120VAC, 50–60Hz. Output power is reduced at
lower input voltage.
Current
0.2A rms (at full charging current)
Back current drain*
<1mA
Charging voltage
7.2V, Nominal: 6V
Ripple**
Max 50mV rms, max 0.05A rms.
Charging current
0.8A max.
Battery cable fuse
5A
Ambient temperature
-4°F to +122°F. Automatic reduction of power at increased
ambient temperature.
Cooling
Natural convection. Do not cover the charger.
Charge cycle
UC 800 is a four-step fully automatic charger.
Type of batteries
All types of 6V lead-acid batteries (Wet, Maintenance Free,
AGM and most GEL).
Battery capacity
2 to 32Ah, up to 100Ah for maintenance.
Dimensions
5½ x 2 x 1½ inches (L x W x H)
Weight
0.7 lbs
*) Back Current Drain is what the charger uses to drain the battery if the power cord is
disconnected. The reverse current of the UC 800 is very low and corresponds to 1Ah per
month.
**) The ripple wave describes how many disturbances are exhibited by current and voltage. A rippled voltage can cause damage to other equipment connected to the battery.
The UC 800 supplies voltage and current with very low voltage rippling. This increases the
life of the battery and ensures that equipment connected to it will not be damaged.
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Recommended Minimum AWG Size for AC Extension cords
Length of cord feet (m)
AWG Size of cord
25 (7.6)
50 (15.2)
100 (30.5)
150 (45.6)
18
18
18
16
BATTERY CABLES
UC 800 is equipped with a set of battery cables with battery terminal clips and one set of
battery cables with eyelet terminals. Do not shorten the battery cables.
Connecting the provided cables with eyelet terminals
Make sure that the cable is not pinched or in contact with warm surfaces or sharp edges.
When the cable is mounted on the battery, it should not be connected to the charger.
Connect the eyelet terminals to the battery's poles - the red cable to the positive pole and
the black cable to the negative pole. After this, the quick connector can be connected.
OVERHEATING PROTECTION
The UC 800 is equipped with overheating protection. In high ambient temperatures the
output power is reduced. Do not cover the charger.
MAINTENANCE
The UC 800 is maintenance-free. The charger must not be opened; doing so will invalidate
the warranty. If the power cable is damaged it must be replaced by CTEK or its authorized
representative. The charger casing can be cleaned using a damp cloth and mild cleaning
agent. Remove the plug from the power socket before cleaning.
LIMITED WARRANTY
CTEK Power Inc, 2374 Edison Blvd, Twinsburg, OH 44087-2376, USA issues this limited
warranty to the original purchaser of this product. This limited warranty is not transferable.
CTEK Power Inc warrants this unit for 5 years from the date of purchase against defect
workmanship or material. It is the obligation of the purchaser to forward the unit together
with proof of purchase to the manufacturer or its representative with transportation cost
prepaid. This warranty is void if the unit is abused, handled carelessly or repaired by anyone other than CTEK Power Inc or its authorized representative. CTEK Power Inc makes
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no warranty other than this limited warranty and expressly excludes any implied warranty
including any warranty for consequential damages. This is the only expressed limited
warranty and CTEK Power Inc neither assumes nor authorizes anyone to assume or make
any other obligation towards the product other than this limited warranty.
CTEK Power Inc.
2374 Edison Blvd
Twinsburg, OH 44087-2376
USA
Fax: + 1 330 963 0982
www.ctek.com
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