BS BATTERY BK 20 Smart Bank Battery Charger and Maintainer Instruction Manual

BS BATTERY BK 20 Smart Bank Battery Charger and Maintainer

SMART BANK BATTERY CHARGER & MAINTAINER WITH RECONDITIONING FUNCTION

The Smart Bank Battery Charger & Maintainer is a 3-channel charger that is 100% automatic and can charge 6V/12V batteries at 3x 2A. It is compatible with both lead-acid and lithium (LiFePO4)  batteries. The charger also features a reconditioning function.

Features

• 3 channels
• 100% automatic
• 6V/12V – 3x 2A
• For lead-acid & lithium (LiFePO4) batteries
• Reconditioning function

MAIN FEATURES

• Fully isolate – 3 dependent bank charge output.
• Auto Detect – Auto-detect for Lead acid or LiFePO4 battery hooked.
• Adaptable charging algorithm – Enable the precise charging algorithm targeted for Lead acid or LiFePO4 batteries.
• Smart re-activation – Allows it to wake up “dead” LiFePO4 batteries where the BMS under-voltage protection has been triggered.
• Force re-activation – Allows it to wake up “dead LiFePO4 batteries or low-voltage Lead acid battery by Force mode.
• Two voltage mode – Charge 6V or 12V batteries.
• Battery qualification detection – Automatically detect the battery initial voltage.
• Low voltage Start – Activate the heavy discharged battery from as low as 2.0V at 12mode.
• Battery bad cell detection – Smart detection to the battery bad cells and error indication.
• Weak or sulphated Battery detection – Automatically detect the weak or heavy-sulphated battery and error indication.
• Battery desulphation – Manual recondition to the sulphated Lead acid batteries.
• Charging time management – Multiple charging stages and charging time management.
• Pulse maintenance – Long term pulse mode maintenance to keep the Lead acid battery at optimal performance.
• Flexible output cable – Detachable clamps terminal cord sets with SEA connector.

PROTECTION FEATURES

• Connection spark free.
• Never overcharge your battery.
• Output short circuit or reverse polarity protection.
• Charging timer for each charge phase protection.
• Thermal run-away protection at the battery side.
• Internal over-heat protection.
• Conformal coatings prevent from moisture for the inside circuit board.
• Corrosion-resistant output connectors.

Box Contents

• 1x Charger
• 3x Clamps sets – 140 cm
• 1x AC plug EU – 150 cm
• User manual and guide to professional battery charging for
  Starter and Deep Cycle batteries

Usage Instructions

1. Read the user manual and follow the instructions carefully before using the charger. The charger is designed for workshops and warehouses and is compatible with both lead-acid and lithium (LiFePO4) batteries. Connect the charger to the battery using the quick connection clips provided. Make sure to connect the red lead to the positive terminal and the black lead to the negative terminal.

2. Once the connection instructions have been followed, AC power is presented, power White LED ON. The charger will begin charging automatically, the Charging Blue LED is ON.

3. When full charge is reached, the Maintaining Full Green LED will be ON. The Maintaining Float Mode allows the charger to effectively be left connected to your batteries, over the course of a season for Lead acid batteries, without overcharging your batteries and maintains your battery’s full charge, for a LiFePo4 battery, it will automatically terminate the charge if the battery fully charged and Green LED will be ON.

4. When charging is complete, switch off the charger and remove the AC power socket from the outlet. Remove the black lead first and then the red lead. Check electrolyte levels if possible. (As they may need topping up with distilled water after charging)

5. If needed, use the reconditioning function by pressing the Force mode for 3 seconds. The charger will activate the low voltage dead Lead acid battery and engage de-sulphation; it will wake up the dead LiFePO4 battery where the under-voltage protection has been triggered.

6. The bank charger provides multiple charging phases subjected to  the Lead acid battery sensed or LiFePO4 battery sensed.

7. The different charging phases include:

   • Force mode stage: Activates low voltage dead Lead acid
     battery and engages de-sulphation; wakes up dead LiFePO4 battery
     where under-voltage protection has been triggered.

   • Soft start: Rising voltage and a maximum of 50% of bulk
     phase current is applied to the battery to start the charging
     cycle.

   • Bulk stage: Rising voltage and maximum output current is
     applied to the battery.

   • Analysis-1 Stage: Charger tests battery to detect bad
     cells (only for Lead acid batteries). For abnormal cell detection
     results, refer to the troubleshooting section.

   • Absorption stage: Constant voltage and tapering current
     is applied to the battery to ensure it reaches 85% state of
     charge.

   • Analysis-2 Stage: Charger tests battery again to detect
     bad cells and high levels of sulphation (only for Lead acid
     batteries).

   • Float and Maintenance: Compatible only with Lead Acid
     batteries, this stage is used for long term battery
     maintenance.

THIS MANUAL CONTAINS IMPORTANT SAFETY AND OPERATING INSTRUCTIONS FOR BATTERY CHARGER & MAINTAINER: BK 20

DESIGNED FOR WORKSHOPS AND WAREHOUSES Lithium (LiFePO4) & Lead Acid compatible
IMPORTANT SAFETY INSTRUCTIONS: Please read this manual and follow the instructions carefully before using the charger.

WARNING

• The bank charger is designed to charge 6/12V lead-acid batteries (LA) or 12V LiFePO4 (LFP) battery from 4Ah to 40Ah and maintain batteries up to 80Ah.
• We always recommend that you check the Battery Manufacturers specifications before using this charger.
• Explosive gases may escape from the battery during charging. Provide ventilation to prevent flames and sparks.
• For indoor use. Do not expose charger to rain, snow or liquids.
• Battery acid is corrosive. Rinse immediately with water if acid comes into contact with skin or eyes.
• Never charge a frozen battery.
• Never charge a damaged battery.
• Never place the charger on the battery while charging.
• 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.
• When working with a lead-acid battery, remove personal metal items such as rings, bracelets, necklaces, watches…
• NEVER smoke or allow a spark or flame in vicinity of battery or engine.
• Do not charge non-rechargeable batteries.
• In order to reduce risk of electric shock, unplug charger from AC outlet before doing any maintenance or cleaning. Turn off controls will reduce risk.
• The kit is not supposed to be used by children or by people who are not able to understand the manual, unless they are supervised by a responsible person who ensures the proper use of the kit.

BATTERY TYPES & CAPACITY

• Suits all Lead Acid Type Batteries. (Conventional, AGM & Gel).
• Suits for Lithium (LiFePO4) battery.
• Battery Capacity:

Charge rate| Battery capacity – charging| Battery capacity – maintaining
---|---|---
2Amp| 4-40Ah| 4-80Ah

ELECTRICAL PARTS

Delivered with:

• Input Cord: 150 cm VDE cord with 3PIN plug.
• Output Cord: with quick connector.
• Extend Cord: 140 cm cord with battery clips.

ENVIRONMENTAL CHARACTERISTICS

• Operating Temperature: 0 to 40° C.
• Storage Temperature: -25 to 85°C.
• Operating Humidity Range: 0 to 90% RH.
• Cooling: Natural cooling.

TECHNICAL SPECIFICATIONS

Voltages for 12V mode, x 1/2 for 6V mode.

OPERATING INSTRUCTIONS

STEP 1 – Pre-charge Check & electrolyte level check

• Check the Battery Electrolyte level for Lead acid battery (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 6/12V Switch on the charger and make sure it’s on the correct voltage.

STEP 2 – Connecting the Bank Charger to your Battery

• Connect the Red lead from the charger to the positive (+) battery terminal.
• Connect the Black lead from the charger to the negative (-) battery terminal.

STEP 3 – Connect the battery charger to mains power

• Connect the battery charger to a mains powered socket.
• Turn on the mains power.

Once the connection instructions have been followed, AC power is presented, power White LED ON. The charger will begin charging automatically, the “Charging” Blue LED is ON. When full charge is reached, the “Maintaining” “Full” Green LED will be ON. The Main-taining Float Mode allows the charger to effectively be left connected to your batteries, over the course of a season for Lead acid batteries, without overcharging your batteries and maintains your battery’s full charge, for a LiFePo4 battery, it will automatically terminate the charge if the battery fully charged and Green LED will be ON.

STEP 4 – Disconnecting the Bank charger from Battery

• Switch OFF and Remove the AC Power Socket from the outlet; Remove the Black lead and then the Red lead. Check electrolyte levels if possible. (As they may need topping up with distilled water after charging)

CHARGING PROCESS

• The bank charger provides the multiple charging phases subjected to the Lead acid battery sensed or LiFePO4 battery sensed.

Force mode stage

• Press the Force mode for 3 seconds: the bank charger will activate the low voltage “dead” Lead acid battery and engage de-sulpha-tion; it will wake up the “dead” LiFePO4 battery where the under-voltage protection has been triggered.

Soft start

• In this phase rising voltage and a maximum of 50% of bulk phase current is applied to the battery to start the charging cycle.

Bulk stage

• In this phase rising voltage and maximum output current is applied to the battery.

Analysis-1 Stage

• In this phase the band charger tests the battery in order to detect bad cells (only for Lead acid batteries). For abnormal cell detection results please refer to the troubleshooting section.

Absorption stage

• In this phase a constant voltage and tapering current is applied to the battery to ensure it reaches 85% state of charge.

Analysis- 2 Stage

• In this phase the charger tests the battery again in order to detect bad cells and high levels of sulphation (only for Lead acid batteries)

Float and Maintenance

• Compatible only with Lead Acid batteries this stage is used for long term battery maintenance.

Float returns to Bulk charging

• When battery voltage is dropped below 12.5V.

LiFePo4 Recharge phase

• If the battery voltage falls below 12.8V; the bank charger will automatically return to Bulk phase.
• Voltages are set for 12V mode, x 1/2 for 6V mode.

CHARGE CURVE

• Only if force mode is selected:
  • For lead acid: reconditioning stage.
  • For lithium: wake-up stage.
• No float & maintenance stages for Lithium. Once the battery is fully charged, the charge is stopped.

LED STATUS INIDICATOR TABLE

NORMAL INDICATION

LED STATUS INIDICATOR TABLE
The bank charger is always put on the flat surface.
The bank charger is also ideal to be installed onto the shelf of in-house workshop for battery long term maintenance.

TROUBLESHOOTING

Types of Problems| Indication| Possible Causes| Suggested Solution
---|---|---|---
Charger does not work?| No Indicator lights on.| – No AC power.| – Check AC connections and make sure Power Point is swit- ched ON.

Charger has no DC output?

|

Fault LED is On.

|

– Output is short circuited

– Reverse polarity connec- tion to Battery.

| – Check DC connection between charger and battery and make sure they are not short circuiting.

– Check that the crocodile clips haven’t fallen off the battery.

– Check that the crocodile clips / ring terminals are connec- ted to the correct polarity.

Long charging time, Full light does not come on?| Fault LED is ON.| – Battery capacity too large

– Battery is defective.

| – Check the charger specification matches the battery

capacity.

Long charging time, Full light does not come on?| Fault LED is Flash.| – Battery cells internal shorted, battery heavily sulphated.| – Press Force mode for 3 second to activate and de-sulphate to battery.

– Battery cannot be charged and must be replaced.

MAINTENANCE

The bank charger is maintenance free. If the power cord is damaged, the charger must be left to the reseller for maintenance. The case should be cleaned occasionally. The bank charger should be disconnected from the power while cleaning.

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References

• BS BATTERY – The Power you need

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