Clarke WBC180 Battery Charger Starter Instruction Manual

WBC180 Battery Charger Starter
Instruction Manual

BATTERY CHARGER-STARTER
MODEL NO: WBC180
PART NO: 6261500
OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS

INTRODUCTION

Thank you for purchasing this CLARKE Battery Charger.
Please read this manual thoroughly, before attempting to operate, and carefully follow all instructions given.
It is vitally important that ALL precautions are taken, as specified, which will not only provide protection for yourself and that of others around you, but will also ensure that the Battery Charger will give you long and satisfactory service.

GUARANTEE

This CLARKE product is guaranteed against faulty manufacture for a period of 12 months from the date of purchase. Please keep your receipt as proof of purchase.
This guarantee is invalid if the product is found to have been abused or tampered with in any way, or not used for the purpose for which it was intended.
Faulty goods should be returned to their place of purchase, no product can be returned to us without prior permission.
This guarantee does not affect your statutory rights.

ENVIRONMENTAL RECYCLING POLICY

Through the purchase of this product, the customer is taking on the obligation to deal with the WEEE in accordance with the WEEE regulations in relation to the treatment, recycling & recovery, and environmentally sound disposal of the WEEE. In effect, this means that this product must not be disposed of with general household waste. It must be disposed of according to the laws governing Waste Electrical and Electronic Equipment (WEEE) at a recognized disposal facility.
If disposing of this product or any damaged components, do not dispose of them with general waste. This product contains valuable raw materials. Metal products should be taken to your local civic amenity site for recycling of metal products.

SPECIFICATIONS

SAFETY PRECAUTIONS

WARNING: HIGHLY INFLAMMABLE HYDROGEN GAS IS RELEASED IN THE PROCESS OF BATTERY CHARGING. ALWAYS REMEMBER TO SWITCH OFF THE CHARGER/STARTER FIRST TO AVOID SPARKING.
PLEASE READ BEFORE USING THIS UNIT

1. Battery acid is very corrosive. If spilled, clean the area immediately and wash with water. If battery acid comes into contact with the eyes, get medical help immediately.

2. Do not expose this charger/starter to rain.

3. Never touch the negative and positive leads together while the unit is switched on.

4. Never attempt any electrical or mechanical repair yourself other than the replacement of fuses. If you have a problem with your battery charger contact your local stockist for service information.
   WARNING: CERTAIN TYPES OF SEALED OR MAINTENANCE-FREE BATTERIES NEED EXTRA CARE WHEN CHARGING. PLEASE CONSULT THE BATTERY MANUFACTURER’S INSTRUCTIONS BEFORE USING THIS CHARGER/STARTER.
   WARNING: TOXIC FUMES MAY BE RELEASED DURING BATTERY CHARGING. ONLY USE THIS CHARGER/STARTER IN A WELL-VENTILATED AREA.

5. Before charging, make sure that the battery terminals are clean, and the cells are filled to the correct level by adding distilled water where necessary.

6. This charger/starter is not intended for use by persons with reduced physical, sensory or mental capabilities, or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the charger/starter by a person responsible for their safety. Keep children well away from the charger/starter.

7. After charging, secure the vehicle battery leads to the correct terminals which should be clean, and lightly smeared with petroleum jelly to prevent corrosion. Finally, re-check the battery electrolyte level.

8. Do not use this charger/starter unless you are aware of vehicle electrical systems and battery charging techniques.

9. Always consult the vehicle manufacturer’s instructions for disconnecting /charging the vehicle battery.

CAUTION: SOME VEHICLE ELECTRONIC EQUIPMENT CAN BE DAMAGED BY BOOST CHARGING OR USE OF THE START FACILITY. CHECK YOUR  VEHICLE HANDBOOK BEFORE USING YOUR STARTER/CHARGER. IF IN DOUBT CONSULT THE VEHICLE MANUFACTURER.

ELECTRICAL CONNECTION

WARNING! READ THESE ELECTRICAL SAFETY INSTRUCTIONS THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS SUPPLY.
WARNING! THIS APPLIANCE MUST BE EARTHED
Connect the mains lead to a standard, 230 Volt (50Hz) electrical supply through an approved 13 amp BS1363 plug, or a suitably fused isolator switch, If the plug has to be changed because it is not suitable for your socket or because of damage, it must be removed and a replacement fitted, following the wiring instructions shown below. The old plug must be discarded safely as insertion into a power socket could cause an electrical hazard.
WARNING: THE WIRES IN THE POWER CABLE OF THIS PRODUCT ARE COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE: BLUE = NEUTRAL BROWN = LIVE YELLOW AND GREEN = EARTH.

If the colours of the wires in the power cable do not agree with the markings on the plug:

• The BLUE wire must be connected to the terminal which is marked “N” or coloured black.
• The BROWN wire must be connected to the terminal which is marked “L” or coloured red.
• The YELLOW AND GREEN wire must be connected to the terminal which is marked “E” or coloured green.
  

We strongly recommend that this machine is connected to the main supply via a Residual Current Device (RCD).
If you are not sure, consult a qualified electrician. DO NOT try to carry out any repairs yourself.
The maximum rated supply current for this unit is 28 amps with a duty cycle of 3 secs on/120 secs off

OVERVIEW

The WBC180 model is provided with a pair of leads complete with clamps for connection to a battery via the appropriate outlet connections – 12V and 24V, as shown.
Three selector switches provide for different functions as shown above. The main fuse is mounted on the front panel, as shown and both models incorporate a thermal overload cut-out.

ASSEMBLY

1. Pass the axle through the holes in the body of the machine and fit circlips to the axle at the position shown.

2. Slide the wheels onto each end of the axle and secure with further circlips outside each wheel.
   

3. Press-fit the caps to the wheels.

4. Install the foot to the base of the machine using the three screws as shown.
   

5. Fit the positive battery lead to the terminal of your choice (12/24V) to match the voltage of the battery.

GENERAL PREPARATION

CHARGER LOCATION

1. Place the charger as far away from the car battery as possible.
2. Do not position the charger above the battery during the charging procedure. Gases from the battery will cause corrosion and damage the charger.
3. Do not let battery acid drip on anything when reading specific gravity or when topping up the battery.
4. Do not operate the charger in an enclosed space, such as inside the vehicle. Never cover the battery charger.
5. Do not stand the battery on top of the charger.
6. Always stand the battery charger on a firm, level floor.
7. During charging, make sure that the area around the battery has good ventilation.

CONNECTING THE BATTERY

1. Before charging, disconnect the battery from the vehicle.

2. Always remove the grounded (earth) terminal from the battery first. Make sure that all electrical accessories in the vehicle are switched off to prevent sparking.

3. Clean the battery terminals. Be careful to prevent battery electrolytes from coming in contact with your eyes.

4. Except for sealed units, add distilled water to each cell until the battery acid reaches the level specified by the battery manufacturer.
   • This helps drive unwanted gas from the cell. Do not overfill. For a battery without cell caps, consult the manufacturer’s instructions.

5. Follow all the battery manufacturer’s specified precautions: for example, removing or not removing cell caps while being charged, and recommended rates of charge.

6. Refer to the vehicle manual to find the voltage of the battery and make  sure that the charging cable is connected to the correct terminal (either 12/24V).

7. This charger has an adjustable charge rate and the battery should be charged initially at the lowest rate.

CONNECTING TO A BATTERY

WARNING: A SPARK NEAR THE BATTERY MAY CAUSE BATTERY EXPLOSION.
TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY:

• Turn off the charger before you connect/disconnect the DC output connectors.
• Do not let the connectors touch each other.
• Attach the connectors to battery terminals and make sure that you get a good connection.

BATTERY CHARGING

CHARGING A BATTERY INSTALLED IN THE VEHICLE

1. Position the leads carefully to reduce the risk of damage from any sharp edges.

2. Check the polarity of the battery posts.

3. Consult the vehicle manual to confirm if the vehicle has Negative or Positive earth.
   • For negative earth vehicles, connect the POSITIVE (RED) lead from the battery charger to the POSITIVE terminal on the battery. Connect the
   NEGATIVE (BLACK) leads to the vehicle frame or engine block away from the battery.
   • For positive earth vehicles, connect the NEGATIVE (BLACK) lead from the battery charger to the NEGATIVE terminal on the battery. Connect the POSITIVE (RED) lead to the vehicle frame or engine block away from the battery.
   • Do not connect the lead to ancillary engine components.

4. Where appropriate, we recommend that the non-earthed lead on the battery is disconnected prior to charging.
   • This will reduce the risk of damage to the vehicle’s electronic equipment.

5. When charging is completed, switch off the charger/starter and unplug it. Remove the lead from the vehicle earth point, and then remove the lead from the battery.

CHARGING A BATTERY REMOVED FROM THE VEHICLE

1. Make sure that you know the polarity of the battery posts.
2. Connect the POSITIVE (RED) lead to the POSITIVE post on the battery.
3. Connect the NEGATIVE (BLACK) lead at arm’s length to the NEGATIVE post on the battery.
4. When you disconnect the charger from the battery, always do it in the opposite order to the sequence of connections and remove the first connection at arm’s length from the battery.

CHARGING MORE THAN ONE BATTERY

1. Simultaneous multiple charging should be carried out in series since this enables monitoring of the current circulating in each battery.
   

2. If two batteries with rated voltages of 12V are connected in series, set up the charger using the positive cable connected to the 24V terminal.

OPERATION OF THE CHARGER

TO CHARGE THE BATTERY

1. Connect the charger to the battery.

2. Connect the charger to the mains supply and switch on.

3. Set the mode switch to the CHARGE function is indicated by the battery symbol.

4. Set the other selector switches to:
   • Low charging rate:- MIN and 1.
   • Medium charging rate:- MIN and 2.
   • High charging rate:- BOOST. (this overrides the 1/2 switch)
   

5. Check the current delivery by reading the ammeter on the front of the battery charger.
   • During charging, the ammeter on the charger will indicate the current delivered to the battery. During the charge, the readout will decrease slowly to the lowest value according to the capacity and condition of the battery. When the reading becomes very low, no further charging is necessary.
   • Charge a sealed battery very slowly at the lowest settings of MIN/1, monitoring the voltage across the battery terminals using a volt meter.
   • When the battery terminal voltage reaches 14.4V for 12V batteries, stop charging.

WHEN CHARGING IS COMPLETE

1. When charging is complete the ammeter reading should be close to “0” and the electrolyte in the battery may begin to gas. Stop charging to protect the battery plates from damage.
2. Switch off the charger and disconnect the plug from the power socket.
   • Remove the leads from the battery as described in the previous sections.
   • Return the battery to the vehicle. Secure and re-connect, ensuring all tools are removed from the battery area.

PROCEDURE FOR ENGINE STARTING

CAUTION: WE RECOMMEND THAT BEFORE ATTEMPTING TO BOOST START, YOU CHARGE THE BATTERY FOR 10-15 MINUTES. THIS WILL IMPROVE THE CHANCE OF A FIRST-TIME START, PARTICULARLY WITH LARGER ENGINES.
CAUTION: WHEN THE BATTERY IS COMPLETELY FLAT, YOU MUST CHARGE THE BATTERY BEFORE ATTEMPTING TO START THE ENGINE, OTHERWISE YOU MAY CAUSE DAMAGE TO THE VEHICLE ELECTRONIC SYSTEM.

1. Check that the main supply switch is OFF.

2. Set the CHARGE/START switch in the START position.

3. Set the MIN/BOOST switch in the MIN position.

4. Connect the cables to the vehicle battery as for charging.

5. Set the ON/OFF switch to ON.

6. Turn the key in the vehicle’s ignition to ‘start’, and crank the engine for a maximum of 3 seconds. If the vehicle does not start, wait 2 minutes before trying again for a maximum of 5 cycles.
   WARNING: IF THE ENGINE WILL NOT START, DO NOT CONTINUE AS THE VEHICLE BATTERY AND ELECTRICAL CIRCUITS MAY BE DAMAGED AND THE FUSE IN THE CHARGER WILL BLOW. DISCONNECT THE CHARGER AND INVESTIGATE FOR VEHICLE FAULTS. THE DUTY CYCLE FOR STARTING (3 SECS ON/2 MINUTES OFF MUST NOT BE EXCEEDED.

7. When the engine starts, switch the charger off immediately. Unplug from the mains power and disconnect the starter/charger from the battery.

THERMAL CUTOUT
NOTE: If the battery charger is overloaded at any time, a thermal cut-out will automatically come into operation, rendering it inoperative. Allow approximately 5-10 minutes before using the unit again.

FUSES

1. The starter/charger is equipped with a safety fuse which will protect the unit under the following circumstances:
   • Overload – too high a current to the battery.
   • Short Circuit – clamps touch or cross connection to the battery.
   • Prolonged starting attempts.

REPLACING THE FUSE
The fuse fitted is rated at 110A and is fitted behind the clip-on cover for easy replacement.

1. Switch the unit off and disconnect from the mains.
2. Allow the unit to cool down and establish the reason for the failure and correct it.
3. Pull off the fuse cover before unscrewing the nuts to remove the fuse. Replace only with an identical fuse and with the same rating, as supplied with your starter/charger.
   • Replacements are available from your Clarke dealer.

MAINTENANCE

This charger requires minimal maintenance. As with any appliance or tool, a few common sense rules will prolong the life of the battery charger.
WARNING: ALWAYS BE SURE THE CHARGER IS UNPLUGGED BEFORE PERFORMING ANY MAINTENANCE OR CLEANING.

1. Clean the case and leads with a moist cloth.
2. Clean corrosion from the clamps with a solution of water and baking soda.
3. Examine the leads at regular intervals for damage and have them replaced if necessary.

WARNING: ALL OTHER SERVICING/REPAIRS SHOULD BE DONE BY QUALIFIED SERVICE PERSONNEL ONLY.
STORAGE

1. Wind up the connecting leads and power cable when not in use and store in the compartment when not being used.
2. Store in a clean, dry area.

PARTS DIAGRAM

PARTS LIST

TROUBLESHOOTING

charger is plugged into a suitable power outlet and the ON/ OFF switch lights up.
Faulty connections to battery terminals.| Unplug the charger and check the battery connection; ensure that there is a good connection at the battery terminal/post and/or vehicle chassis.
Wrong charge voltage selection.| Check that the correct charge voltage was selected for the battery being charged.
Battery voltage is too low.| Ensure enough charging time was allowed to charge the battery.
Charging a very cold battery.| If the battery being charged is extremely cold (below freezing), it will not accept a high rate of charge, so the initial charger rate will be slow. The rate of chargers will increase as the battery warms.
Never attempt to charge a frozen battery.

DECLARATION OF CONFORMITY

A SELECTION FROM THE VAST RANGE OF

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PARTS & SERVICE
: 0208 988 7400
Parts Enquiries Parts@clarkeinternational.com
Servicing & Technical Enquiries Service@clarkeinternational.com
SALES: UK 01992 565333 or Export 00 44 (0)1992 565335
INTERNATIONAL Hernoall Street, Epping, Essex CM164LG
www.clarkeinternational.com

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