AutoMeter BusPro-620s User manual

Professional
BusPro-620s
Instruction Manual
The BusPro-620s is an automated 12-Volt Battery Charging System that
will charge and maintain up to six batteries at a time. The BusPro-620s
delivers a voltage recommended by battery manufacturers for the
longest life and greatest performance of your batteries.

CONGRATULATIONS!
You have made a purchase of Auto Meter’s BusPro-620s designed to
charge 12 Volt batteries. The system is fully automated with LED’s indicat-
ing unattended viewing status.
BusPro-620s
Charges ------------------------------------------------------12 Volt Batteries
Input-----------------------------------------------------220 VAC @ 2.5 Amps
Charging output mode----------------------------------------- 5 Amps Max.
Maintenance output mode----------0 to 2.5 Amp variation as needed
Leads ---------------------------------------------------------------- 6 ft. 18 GA.
Size ---------------------------------------------------------26” W 8” H 3.25” D
Weight ----------------------------------------------------------------------31 lbs.
Optional AC-8 Jumper Leads ------------------------------------- Set of six
CONTENTS
Safety Instructions----------------------------------------------------------- 3
Personal Safety -------------------------------------------------------------- 4
Setting Up the BusPro-620s ---------------------------------------------- 5
Inspecting The Battery------------------------------------------------------ 6
Hooking up the Clamps ---------------------------------------------------- 7
Reading the Indicator Lights --------------------------------------------6-7
Disconnecting the BusPro-620s ----------------------------------------- 8
Hookup Potential (3 units together and optional leads) ------------ 9
What to Expect from your BusPro-620s ------------------------------10
2

SAFETY INSTRUCTIONS
WARNING:
Lead Acid Batteries are Dangerous! During use and charging they may
generate EXPLOSIVE Hydrogen Gas. This means YOU MUST carefully
read all of the safety and operating instructions before using the BusPro-
620s. Be sure you understand all of the safety instructions in this manual
and on the BusPro-620s before attempting to connect, charge, or work
with a lead acid battery.
GENERAL SAFETY RULES FOR SAFE OPERATION
Batteries are dangerous. Auto Meter provides the following Warnings for
your safety:
1. Use the BusPro-620s only on 12 Volt LEAD ACID AND GELLED
ELECTROLYTE (GEL-CELL) Batteries. DO NOT attempt to use on other
types of batteries (Dry Cell, Nickel Cadmium, Nickel Metal Hydride, etc.)
commonly found in small home appliances. This may cause the batteries to
burst, resulting in damage or injury to person and/or property.
2. DO NOT use the BusPro-620s on batteries that are in use or that are
installed. Remove batteries from the vehicle and take to a properly installed
BusPro-620s location.
3. DO NOT use attachments with the BusPro-620s that are not approved or
sold by Auto Meter. Non-approved attachments may result in injury, electric
shock, or re and voids the warranty.
4. When disconnecting the power cord from the wall, grasp the plug and pull.
Never pull the cord, it may damage the plug and/or the cord.
5. Place the power cords in a location where they will not be stepped on,
tripped over, or subjected to stress or abuse of any kind.
6. Never operate the BusPro-620s if any portion of its housing, cords or
attachments appear to be damaged in any way. If damage has occurred,
have it inspected and serviced by Auto Meter.
7. If the BusPro-620s has been dropped, received a sharp blow, or abused in
any way, have it inspected and repaired by Auto Meter if necessary.
8. Do not use an extension cord to operate the BusPro-620s. An inadequate
extension cord could result in re or explosion due to a large number of
batteries being charged and will not provide the AC amperage rating needed
by the BusPro-620s.
9. Each BusPro-620s Station has its own AC fuse. Other than this fuse
replacement, Auto Meter should be contacted for trouble shooting and
instructions on how to repair or replace parts and charging stations. Any
unauthorized repair, tampering or incorrect assembly may result in re or
electric shock and voids the warranty. Check with Auto Meter for instructions.
10. To prevent injury during cleaning or maintenance, disconnect all batteries
and move them away from the unit. Unplug the BusPro-620s from the
wall outlet (grasping the plug). Use a slightly dampened cloth to clean the
housing and lead sets. Do not use solvents or soaps.
3

11. NEVER attempt to charge a frozen battery. Allow the battery to return to room
temperature before connection.
12. ALWAYS use the BusPro-620s in an open and well-ventilated area. The area
should be dry and free of trash, debris and combustibles.
13. WARNING! Explosive Hydrogen gas may be present around batteries.
14. Do not use the BusPro-620s in direct sunlight or adverse weather conditions
such as rain or snow.
15. Mount the BusPro-620s on a secure wall location at least two feet above the
batteries being charged. This prevents acid drips and spills from landing on the
BusPro-620s during battery lling or specic gravity testing. This also prevents
battery fumes from reaching the BusPro-620s.
16. Do not place small objects or tools on the top edge of the mounted BusPro-
620s unit.
17. NEVER use the BusPro-620s in or on any boat or watercraft. You must remove
the battery from the boat or watercraft and charge the battery at the properly
installed location of the BusPro-620s unit.
18. DO NOT install the BusPro-620s where it will be exposed to moisture,
inclement weather nor around combustibles, ammable liquids or
vapors and trash.
SAFETY INSTRUCTIONS Cont.
PERSONAL SAFETY PRECAUTIONS
1. Wear protective goggles or a full-face shield.
2. Wear protective clothing. Leave no exposed skin.
3. Have plenty of fresh water and hand soap available for use if acid
should contact your eyes, skin or clothing.
4. Have someone close by in the event you need emergency assistance
when working with a battery.
5. Remove all metal objects (pens, tools, jewelry, etc.) from your body.
These items can create a direct short between the battery terminals
and can cause serious burns.
6. DO NOT carry tools or metal objects within the vicinity of a battery.
These items can fall on the battery terminals creating a high current
short. This could result in a re, burns, explosion, etc.
7. DO NOT touch your face, eyes or other body parts with out rst
washing your hands. Battery acid can burn and irritate eye and skin
tissue.
8. DO NOT allow any source of ignition in the area of a battery. Keep
all ame and spark producing devices out of the area and NEVER
SMOKE near a battery.
9. Use the one hand rule! Keep one hand in your pocket whenever you
make an electrical connection. This reduces the risk of electrical shock
to the user.
4

1SETTING UP THE BusPro-620s
The BusPro-620s Charger has two mounting keyholes. YOU MUST
mount the BusPro-620s to a wall that provides a secure surface. This will
keep it out of the way and prevent damage due to accidents. If needed,
you may leave the two screws slightly extended from the wall to allow
easy removal through the keyhole slots.
DISCONNECTING THE BusPro-620s
Caution: In determining placement of the BusPro-620s Charger check
the following:
n Make sure the batteries can be placed at least two feet away. For
example, If the batteries are placed on the oor make sure the
BusPro-620s Charger is mounted securely at least two feet above,
but no more than the working length of the leads.
n Make sure the room has plenty of ventilation.
n Make sure no sparks or ames can occur near the charging area.
n Mount the BusPro-620s Charger away from vehicle repair or service
area.
n Never start or run an engine near the batteries being charged. It
takes very little to ignite explosive gases given off by a lead-acid
battery. Remember: You may be charging several batteries at a
time. This compounds the need for a strict safety program.
See page 9 for hooking up three BusPro-600 units together.
The BusPro-620 comes without a plug. The user is responsible for
proper installation of the appropriate plug for the 220 VAC receptacle to
be used. Have a qualied electrician install it for you. The BusPro-620 is
designed to work with various 220 VAC receptacles. Whether you have
a single 220 VAC hot wire or two 110 VAC hot wires the BusPro-620s will
work with both. You cannot damage the BusPro-620s by hooking it up
to a 110 VAC supply, but it will not perform. The following is given for the
benet of the installer:
WARNING! Do not alter the cord on the BusPro-620s Charger.
Any alterations will void the warranty.
BLACKBROWN BLACK or BROWN
WHITEBLUE WHITE or BLUE
GREEN w/
YELLOW STRIPE
GREEN
CORD IN
OPTIONAL ADD ON CORD
FOR 2nd & 3rd UNITS
GROMMET
220 VAC
(HOT)
NEUTRAL
GROUND
110 VAC
PHASE 1
110 VAC
PHASE 2
CASE GROUND
(OR)
(See page 12 for optional add on cord instructions)
5

What To Expect From The BusPro-620s
The Professional BusPro-620s Charger is equipped with sophisticated
circuitry that will:
n Check Each Battery’s Condition The BusPro-620s will indicate bad batteries
that are sulfated or have bad cells. This allows the battery to be replaced
without unnecessary charging.
n Fully Charge Six 12 volt Batteries (5 Amps. each). With the optional Jumper
Lead Kit the BusPro-620s can charge up to twelve batteries at 2.5 Amps each.
n Maintain Each Battery The BusPro-620s provides a separate charging station
for each battery. With the optional kit, each station can maintain two batteries.
n Provide Worry Free Attention The BusPro-620s has safe circuitry that
automatically adjusts the volt/current relationship in order to maintain the
battery at full charge. If the voltage drops below 12.5 volts, the BusPro-620s
will automatically charge the battery with up to 5 Amps. When the battery
reaches the threshold again the unit goes into maintenance mode.
n Maximize Battery Life The BusPro-620s Charger is designed to maximize
the life of a serviceable lead acid battery. A serviceable battery is a battery
that is not defective or damaged. The BusPro-620s is fully compatible with
gelled electrolyte (gel-cell) batteries (sometimes used in place of liquid
electrolyte batteries in many heavy duty applications). DO NOT USE WITH
DRY CELL, NICKEL CADMIUM, and NICKEL METAL HYDRIDE OR SIMILAR
BATTERIES.
n Increase Multiple Battery Charging Capability The BusPro-620s provides
the opportunity to charge more batteries with less time spent charging
defective batteries that need to be replaced.
n Provide Valuable Protection The BusPro-620s maintains batteries while they
are uninstalled. Maintaining a battery increases its life and protects its capacity.
n Maintain Batteries Not In Use. Some examples are automobiles under
long term repair, farm machinery and eet vehicles in repair or storage. The
Bus Pro-620s is ideal for rental equipment not in use or for charging and
maintaining batteries for replacement. The BusPro-620s can be used to re-
charge, check and maintain all starting and deep cycle batteries. Each Bus
Pro-620s can charge, check and maintain up to six batteries. With the optional
Jumper Lead Kit twelve batteries can be charged or maintained.
n Provide Easy Care The BusPro-620s is designed for easy care and
maintenance. Occasional cleaning of the leads and housing will help keep
the unit looking new, and give you many years of satisfaction. CLEANING
PROCEDURE: Unplug the BusPro-620s and use a slightly dampened cloth to
clean the housing and lead sets. DO NOT use solvents or soaps.
n Provide Long Lasting Performance The BusPro-620s Charger Tester has
been designed and manufactured to provide superior performance. Quality is
built in and assured with circuit burn-in, computerized testing and inspection.
n Fuse Protected Each charging station is protected by a replaceable AC fuse.
10

5DISCONNECTING THE BusPro-620s
The BusPro-620s charger is safely maintaining the battery at a full
charge when the green light is on. Simply remove the clamps and set
them on the working surface clear from the other batteries and clamps.
You can now load-test the battery.
Note: When the clamps are accidentally disconnected while charging is
in effect the BusPro-620s will shut the individual station off. Both indicator
lights will go out. Simply reconnect the battery.
Note:The BusPro-620s is designed to send a 5 amp charge only when
the circuitry determines the clamps have been attached correctly and the
battery is in need of charging. Under normal operation the clamps will not
cause any sparks if the black (-) and red (+) come in contact or if any clip
comes in contact with another.
Caution: BATTERIES ARE DANGEROUS! Be sure to practice these
proper safety rules when connecting and disconnecting batteries from
the BusPro-620s:
n Wear safety Glasses.
n Make sure no sparks occur such as an engine starting etc.
n Make sure no tools or metal objects are in the vicinity of the
batteries
n Connect clips to a clean, properly inspected battery
n Do not disconnect a battery while charging. Wait for the green
light (OK) or ashing red (Defective).
n Handle clips carefully and set them from safely aside other
batteries and clamps.
8

2INSPECTING THE BATTERY
Remove and Inspect the battery before connecting it to a BusPro-620s
Charger. A clean battery and battery terminals insure proper operation of
the BusPro-620s Charger and the vehicle charging system.
n Check for dirty or loose terminals.
n Check for any cracks or distortion in the battery case.
n Make sure the battery is the correct group size and capacity for the
vehicle.
n Make sure the battery is clean between battery posts to avoid self dis-
charge.
n Check the electrolyte level.
Inspecting the electrical system If the battery and terminals have a white
or bluish crust on them, the charging system may be having problems.
Use one of Auto Meter’s BVA Analyzers to test the charging and starting
system. These problems should be corrected before the battery is installed.
4READING THE INDICATOR LIGHTS
The Professional Bus Pro-620s has two lights for each
charging station.
No Light = Check the following:
n Connections reversed. Make sure
the red spring clip is connected to the positive (+) battery post and the
black spring clip is connected to the negative (-) battery post.
n Bad connection at one or both battery posts.
n No AC power.
n The battery voltage is below 1 volt.
Red light = Charging -The Professional Bus Pro-620s is delivering up to
a 5 Amp charge.
Red Light Flashing = Defective Battery: The BusPro-620s is designed to
detect either a sulfated battery or a bad cell. Make sure the battery posts
and clamps are clean. If the red light continues to ash the battery should
be replaced.
6
RED LIGHT
GREEN LIGHT

BusPro-620s HOOKUP POTENTIAL
Charge up to 36 12-Volt batteries
n Each station delivers 5 Amps to one battery
n With optional AC-8 lead sets each station
delivers 2.5 Amps to each battery
n In order to charge 36 batteries follow the steps
below:
Using optional AC-8 lead
sets hookup two 12 Volt
batteries in parallel
to each station of
the BusPro-620s as
shown.
Note: If red light
ashes detach
one battery
to determine
which battery is
defective. Recommended
for maintenance only or comparable
batteries in size and state of charge.
Step 2 Using the
Optional Lead Sets
Step 1 Hooking Up 3 Bus-Pro-620s Chargers
Hook 3 units together by plugging the next unit into the AC cord
(If cord must be added See PG. 5). Make sure the power source
supplied to the rst BusPro-620s is adequate. A typical outlet will
only supply 3 BusPro-620s units.
9

INSPECTING THE BATTERY 3HOOKING UP THE CLAMPS
Each charging station has a lead set with a red positive (+) and a black
negative (-) clamp. If the BusPro-620s has been installed correctly, at
least two feet above the work station, the clamps should lie on a clean
dry surface.
NOTE: Side mounted and threaded steel post batteries will require Lead
Post Adapters. Using steel bolts and connecting clamps to threaded steel
posts is not safe, and will inhibit accurate results.
n Connect the RED clamp
to the positive (+) termi-
nal post. Turn or wiggle
the clip on the battery
post to insure a good
connection.
n Connect the BLACK
clamp to the negative (-)
battery post.
Red & Green light = Finishing Full Charge. “Ready for Load Test”:
The battery is at least 70% charged and ready to load test and return to
service. Continued charging will take the battery to full charge.
Note:
Some batteries will pass and accept a charge, but will not be
able to pass a load test. All batteries should be load-tested after
charging.
Green light = Charged and Maintaining: The BusPro-620s is safely
adjusting the voltage/current relationship to maintain the battery at a
full charge. The battery can be load tested. If the battery voltage drops
below 12.5 volts, the BusPro-620s shifts automatically into (Red Light)
Charging Mode. 7
RED LIGHT
GREEN LIGHT

Test Equipment
Remove Cover
Drill 13mm hole through circle on decal at the opposite end from the cord.
Insert supplied grommet (zip tied to black and white wires) into hole. Route
new cord through grommet. Connect hot wire (220 VAC hot or 110 VAC
Phase 1) from new cord to black wire inside unit, connect (neutral or 110
VAC Phase 2) wire from new cord to white wire inside unit. Connect wires
with appropriate size wire nuts and tape, connect ground to transformer
mounting stud.
NOTE: Wiring in a cord for a 2nd unit must be performed by a
qualied electrician.
OPTIONAL ADD ON CORD FOR 2nd and 3rd UNITS
ADD ON CORD INSTRUCTIONS
12
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