BS CHARGER BS 60 Smart Battery Charger User Manual

BS CHARGER BS 60 Smart Battery Charger

BOX CONTENT

• 1x CHARGER
  

• QUICK CONNECTION

• 1x Clamps set – 61 cm
  

• 1x Eyelets terminals set (m6) – 61 cm
  

IMPORTANT SAFETY ADVICE AND WARNINGS

• The charger is designed to charge and maintain 12V batteries AGM & WET, CALCIUM and GEL.
• Always refer to the battery manufacturer’s specifications and recommendations if you’re unsure of your battery charging requirements. E.g. such as removing or not removing cell caps whilst charging, battery type, maximum charge rate etc…
• Explosive gases may escape from the battery during charging so please ensure the battery is being charged in a well-ventilated area.
• This charger is designed for indoor use only and should never be exposed to water, rain, snow, liquids etc.
• Do not attempt to use the charger if it has been dropped or damaged.
• Do not attempt to use the charger if the cables or plugs are damaged.
• If battery acid contacts your skin or clothing, wash immediately with soap and water. If acid enters your eye, immediately flush the eye with running cold water for at least 10 minutes and seek medical attention. Someone should always be within range of your voice.
• Never attempt to charge a damaged battery, frozen battery or non-rechargeable battery.
• Never put the charger on the battery or battery on the charger.
• When working with lead-acid batteries, remove personal metal items such as rings, bracelets, necklaces, watches and make sure you don’t short circuit the battery terminals with any type of metal tool as this will cause an explosion. You can wrap your spanner with insulation tape to minimize the risk of a short circuit.
• NEVER smoke, use an open flame or create sparks near a battery or charger during charging operation as this may cause an explosion and explosive gases.
• Do not disassemble the charger. Take it to a qualified and authorized person for repair.
• If using a generator, you must ensure you use a surge protector to protect the charger from voltage spikes.
• The charger must not be used or played with by infirm persons or children. Also keep it away from any pets.

MAIN FEATURES

• 100% automatic smart battery charger & maintainer with reconditioning function.

• The battery charger is easy to use and requires no technical experience.

• Fully microprocessor controlled with safety timers at every stage.

• Battery condition analysis.

• Selectable battery type.

• Selectable charge rate / mode.

• Patented battery rejuvenation (reconditioning).

• Battery voltage retention analysis.

• Pulse charge for long term maintenance.

• Ultra low power consumption (ECO Mode).

• Multi Stage:
  1. Qualification – Battery condition check
  2. Battery rejuvenation (reconditioning mode)
  3. Soft start charging
  4. Bulk charging
  5. Absorption charging
  6. Equalization charging
  7. Battery analysis
  8. Float mode
  9. Long term maintenance pulse charge

• Automatic diagnosis and charge: on power-up, the charger will automatically diagnose the battery condition and determine if the rejuvenation (reconditioning mode) or charge cycle is required.

• Patented battery rejuvenation technology: the charger has a unique and patented rejuvenation feature which uses high voltage equalizing and peak pulse reconditioning to repair sulphated batteries. This feature is fully automatic and depends on the internal impedance of the battery.

• Can be left on 24/7 to ensure your battery is always maintained and fully charged: The battery charger can be left unattended and left permanently connected all year round. The intelligent charger will monitor the battery voltage and will maintain it at peak performance with a special pulse charge during long term maintenance.

• Short circuit and reverse polarity protection.

• Heavy-duty and corrosion-resistant output connectors.

• Crocodile clips: It comes with a quick connect fly lead and heavy duty, fully insulated crocodile clips.

• Rapid charge mode: uses maximum charging current to ensure the fastest charge time. You may here have the fan turned on during this mode.

• Silent charge mode: charges at a slightly reduced charge rate so the cooling fan is not required.

• Maintenance mode: ideal and recommended for long term maintenance charging or charging of smaller batteries.

TEMPERATURE & SAFETY PROTECTION

• INTERNAL OVERHEAT PROTECTION: the charger has a built-in overheat and an overload protection. This protects the charger from being damaged if overheated or overloaded and will automatically decrease the charging current. Once the unit’s internal temperature decreases to a safe level, the charger will resume normal charging.
• SAFETY TIMER PROTECTION: the charger has safety timers for every stage. If the battery voltage doesn’t reach a certain voltage within a certain amount of time, the unit will stop charging as it’s highly likely that you’re attempting to charge a severely discharged or heavily sulphated battery. If any of the stages time out, the charger will immediately stop charging in order to protect the battery. This will be indicated with the ERROR LED flashing slowly.
• REVERSE POLARITY: the charger has a reverse polarity protection. If the charger output leads are connected with a reverse polarity, the ERROR LED will light on and the charger will be disabled. Simply unplug the charger from AC power and then connect the output leads to the correct polarity.
• SHORT CIRCUIT PROTECTION: the charger will automatically turn off if the output leads are short circuited and the ERROR LED will light on. This prevents the charger from being damaged if the positive and negative crocodile clips or the optional ring terminals accidently touch each other while the charger is turned on.
• ECO MODE: this battery charger has a built in ultra-low power consumption circuit. If AC power is connected and the battery is disconnected, after 10 seconds the charger will automatically go into an ECO mode. During this mode the power drawn is less than 0.36W which totals 0.01kWh per day power consumption. If AC power is connected and the battery is connected, once the battery is fully charged and during the long term maintenance stage, the total power consumption is around 0.03kWh per day. Both the selected charge rate and battery type LED’s will flash GREEN to indicate ECO mode.

BATTERY TYPES & CAPACITY

Suits 12V conventional lead acid batteries (VRLA) AGM, Calcium, Gel & Wet. The Ah (Ampere Hours) capacities shown below are to be used as a general guide only. Some batteries may be able to handle a higher charge current. Refer to the battery manufacturer’s specifications and recommendations for your charging requirements.

ELECTRICAL PARTS & ACCESSORIES

60cm with fused ring terminals

TECHNICAL SPECIFICATIONS

AGM & WET – 14.4V
Calcium – 14.7V
Equalizing Voltage| Gel – 14.3V
AGM & WET – 14.6V
Calcium – 15.5V
Float voltage| 13.6V
Start voltage| 3V
Operating temperature| -15 to 50° C
Storage temperature| -25 to 85°C
Operating humidity| 90% RH Max.
Size (LxWxH)| 182x88x48 mm
Weight| 0.75kg
Approvals| CE

CHARGING INSTRUCTIONS

STEP 1 – Pre charge check & electrolyte level check

• Check the Battery Electrolyte levels (Not required on sealed & maintenance free batteries). If necessary, remove the vent caps and add distilled water so the levels are halfway between the upper and lower fill lines.
• Check the battery voltage, type and Ah capacity to ensure the charger is compatible and to determine which Battery Type and Charge Rate settings you will use.
• Ensure the battery is in a well-ventilated area and the charger should be as far away from the battery as the cables permit.

STEP 2 – Connecting the battery charger to your battery

• If the Battery is out of the vehicle:

• Connect the Red (+) Crocodile clip or optional ring terminal to the (+) battery terminal.

• Connect the Black (-) Crocodile clip or optional ring terminal to the (-) battery terminal.
  

• If the battery is still in the vehicle, determine if the vehicle is positively or negatively earthed. If negatively earthed (Most Common) FIRST Connect the Red (+) Crocodile clip or optional ring terminal lead to the (+) battery terminal and then connect the Black (-) Crocodile clip or optional ring terminal lead to the vehicle’s chassis. DO NOT connect the Black (-) lead to the carburetor or fuel
  

• If Positively Earthed – FIRST Connect the Black (-) Crocodile clip or optional ring terminal lead to the (-) battery terminal and then connect the Red (+) Crocodile clip or optional ring terminal lead to the vehicle’s chassis. DO NOT connect the Red (+) lead to the carburetor or fuel lines.
  

STEP 3 – Connect the battery charger to Mains Power (230Vac)

• The charger will automatically start when AC power is connected and switched on.
• IMPORTANT: please make sure the correct Battery Type and your desired Charge Rate is selected to suit your battery by pressing the Select Buttons within the first 5 minutes of charging. For example do not charge a Gel Battery on the Calcium Battery Type setting as this may damage your battery and / or reduce your battery life.
  Note: if the Error Indicator LED illuminates Red, please check your connections as it’s likely that the positive and negative leads are reversed.

STEP 4 – Disconnecting the Battery charger from Battery

• If the Battery is out of the vehicle:

1. Switch OFF and Remove the AC Power Socket from the outlet.
2. Remove the Black lead and then the Red lead.

• If the battery is still in the vehicle:

1. Switch OFF and Remove the AC Power Socket from the outlet.
2. Remove the lead from the vehicle chassis.
3. Remove the lead from the battery.

Note: check electrolyte levels if possible after charging as they may need topping up with distilled water. (This does not apply to sealed maintenance free batteries)

1. Qualification – Battery condition check When the charger is first switched on it checks the battery condition to determine whether the battery needs reconditioning. During this qualification process it checks the internal impedance and initial voltage of the battery and it will determine how much charge current, if any that the battery will accept. It’s also senses whether the battery is still connected in the vehicle.

2. Enhanced battery rejuvenation – Blue bulk LED flashing fast If the initial qualification detected that the battery was in poor condition, the patented rejuvenation process will begin automatically. During the rejuvenation process a high voltage equalizing and peak pulse reconditioning charge is used to repair the sulphated battery. This unique patented feature will break down and dissolve the lead-sulphate crystal build up on the battery plates which will extend the life of your battery. It can also balance out high concentrations of acid.

3. Soft start charging – Blue bulk LED flashing slow Gently charges the battery using a reduced charge output until the battery voltages reaches 11V. If the battery voltage doesn’t reach 11V within 6 hours, the safety timer protection will stop the unit from charging and the Red Error LED and Blue Bulk LED will start flashing.

4. Bulk charging – Blue bulk LED ON (Charge voltage depends on battery type selection) Uses the maximum selected charge output until the battery voltage reaches 14.1/14.4/14.7V. If the battery voltage doesn’t reach this within 24 hours, the safety timer protection will stop the unit from charging and the Red Error LED will start flashing and the Blue Bulk LED will be ON.

5. Absorption charging – Green absorption LED ON Uses a constant voltage while reducing the charging output current to ensure the battery receives a full charge without overcharging the battery.

6. Equalization charging – Blue bulk LED and green absorption LED both flashing
   A well proven process that carefully overcharges the battery to restore it’s full capacity. The Equalization stage for CALCIUM Battery type selection is automatic. The Equalization stage for AGM&WET and GEL Battery Types only occurs if the initial start voltage is below 11 Volts.

7. Battery analysis – Green full LED ON The battery analysis stage checks the condition of the battery after the charge cycle is completed. If the battery voltage drops too quickly during the analysis mode, this means the battery is probably faulty. If the battery analysis failed, this is indicated by the Green Full LED flashing.

8. Float mode – Full charge green LED ON This stage allows you to keep the charger connected 24/7 to ensure your battery is well maintained and kept 100% fully charged. Float mode will maintain the battery at a constant 13.6V.

9. Long term maintenance – Full charge green LED ON
   During long term maintenance / float mode, the unit will apply a special pulse charge to ensure the battery is kept in optimal condition.

LED STATUS INDICATOR TABLE

Battery Type LED’s: CALCIUM / AGM / WET / GEL
Green| ON| Indicates which battery type is selected
Charge Rate LED’s: 1A / 4A / 6A
Green| ON| Indicates which charge rate / Charge mode is selected
Charging Status LED’s: BULK / ABSORPTION / FULL CHARGE
Full Charge Green| Flash/ON| Flashing if analysis failed or ON if fully charged – Float / Maintenance mode
Absorption Green| Flash/ON| Flashing during equalization charging or ON during Absorption charging
Bulk Blue| Flash/ON| Fast Flash – Rejuvenation / Slow Flash – Soft Start charging / ON – Bulk charging
Error LED
Red| ON| Short circuit/reverse polarity or Rejuvenation failed if Bulk LED also flashing slow
Red| Flashing| Over temperature protection mode / Soft start charging timed out if Blue Bulk LED also flashing fast / Bulk charging timed out if Blue Bulk LED also ON

CHARGING CURVE

• Initial qualification: test automatically battery condition and determine if chargers engages rejuvenation or charging cycle.
• Rejuvenation: rejuvenates sulphated batteries with a high frequency pulse.
• Soft start: increases battery life by gently starting to charge the battery.
• Bulk charge: reduces charging time by delivering maximum charge to set voltage.
• Absorption: ensures a full charge to the battery without overcharging.
• Equalization: returns a full hydrometer reading to calcium batteries by removing acid stratification.
• Battery test: tests the battery to ensure fully charged.
• Float: float charge maintains the battery at 100% charge. 21 days restart.
• Long term maintenance: if the battery voltage sinks, the special pulses will keep the battery in optimal states.
  

TROUBLE SHOOTING

• No AC power

|

• Check AC connections and make sure the AC Power supply is switched ON
• Try a different AC Power supply which you know is working

Charger has no DC output| Error Red LED is ON|

• Output is short circuited
• Reverse polarity protection
• Loose / bad connection to the battery

|

• Check DC connections between charger and battery and make sure they are not short circuited. (Touching each other)
• Check that the crocodile clips have not fallen off or come loose
• Check that the crocodile clips/ ring terminals are connected with the correct polarity

Note: the charger output current is only present when connected to a battery

No charging current| Error Red LED is Flashing|

• Battery is severely sulphated
• Battery has a damaged cell
• Overheat protection mode

|

• Check the battery condition, age etc.
• Battery may need replacement
• Move battery & charger to a cooler environment

The full/float light won’t come on| Error Red LED is Flashing or Full Charge Green LED is Flashing|

• Battery Ah capacity too large for the battery charger and it has time out
• Battery is defective
• Battery is severely sulphated

|

• Check that the charger specifications match the battery capacity. E.g. make sure that the battery capacity is not too big for the charger
• Battery may need replacement
• The selected charge rate might be too low for the battery. Switch charger off and on and try again or try a higher charge rate setting. Make sure it doesn’t exceed the maximum charge limit for your battery

Customer Support

www.bs-battery.com

References

• BS BATTERY – The Power you need

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