Clarke IBC40 Intelligent Battery Charger or Maintainer Instruction Manual

IBC40 Intelligent Battery Charger or Maintainer
**Instruction Manual

**

INTELLIGENT BATTERY CHARGER/MAINTAINER
MODEL NO: IBC40
PART NO: 6267014

OPERATION & MAINTENANCE INSTRUCTIONS
ORIGINAL INSTRUCTIONS
DL0722 – ISS 3

INTRODUCTION

Thank you for purchasing this CLARKE Battery Charger / Maintainer. Before use, read this manual thoroughly and follow all instructions given.

1. The IBC40 is designed for charging all types of 12V lead-acid and 24V lead-acid batteries, including WET (Flooded), MF (Maintenance-Free), EFB (Enhanced Flooded Battery), GEL, and AGM (Absorbed Glass Mat) batteries.
2. A built-in intelligent microprocessor makes charging faster, easier and safer.
3. This charger has safety features, including protection for reverse polarity, short circuits, overheating and overcharging.

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.

SAFETY INSTRUCTIONS

WARNING: WEAR EYE PROTECTION, AND HAND AND CLOTHING PROTECTION. AVOID TOUCHING YOUR EYES WHILE WORKING WITH A BATTERY. SEE YOUR LOCAL CLARKE DEALER FOR ALL YOUR PPE REQUIREMENTS.
SAFETY PRECAUTIONS FOR WORKING IN THE VICINITY OF A BATTERY

1. If battery electrolyte contacts skin or clothing, wash immediately with soap and water. If electrolyte enters your eye, immediately flood the eye with running clean cold water for at least 15 minutes and get medical attention immediately.
2. Clean the battery terminals before they are connected to the charger. Be careful to keep corrosion from coming into contact with your eyes.
3. Batteries generate explosive gases during normal operation. Use in a well-ventilated area.
4. Consider having someone close enough or within the range of your voice to come to your aid when you work near a battery.
5. DO NOT smoke, strike a match, or cause a spark in the vicinity of a battery or engine. Avoid explosive gas, flames and sparks.
6. Remove all rings, bracelets, necklaces, and watches while working with a vehicle battery. These items may produce a short circuit that could cause severe burns.
7. Be extra cautious to reduce risk of dropping a metal tool onto the battery. It might spark or short-circuit a battery or other electrical hardware which may cause an explosion or fire.
8. Study all battery manufacturer’s specific precautions such as removing or not removing cell caps while charging and recommended rates of charge.
9. When it is necessary to remove a battery from a vehicle to charge it, always remove the grounded terminal from the battery first. Make sure all accessories in the vehicle are off.
10. It is NOT intended to supply power to an extra-low-voltage electrical system or to charge dry-cell batteries. Charging dry-cell batteries may burst and cause injury to persons and property.
11. NEVER charge a frozen, damaged, leaking or non-rechargeable battery.
12. DO NOT let battery acid drip on the charger when reading a hydrometer for specific gravity or when you fill the battery.

SAFETY PRECAUTIONS FOR USING THE CHARGER
WARNING: ALWAYS SWITCH OFF THE CHARGER WHEN CONNECTING OR DISCONNECTING LEADS.

1. NEVER place the charger in the engine compartment or near moving parts or near the battery; place as far away from them as the clamp leads allow.
2. DO NOT cover the charger while charging.
3. DO NOT expose to rain or wet conditions.
4. Use of an attachment not recommended or sold by the manufacturer may result in a risk of fire, electric shock or injury to persons.
5. DO NOT overcharge batteries by selecting the wrong charge mode.
6. To reduce the risk of damage to the electric plug and lead, pull by the plug rather than the lead when disconnecting the charger.
7. Operate with caution if the charger has received an impact/blow or been dropped. Have it checked and repaired if damaged?
8. Any repair must be carried out by the manufacturer or an authorized  CLARKE repair agent in order to avoid danger.

CHARGER LOCATION

1. Place the charger as far away from the battery as possible.
2. DO NOT position the charger above the battery during the charging procedure. Gases from the battery will corrode and damage the charger.
3. DO NOT use the charger in an enclosed space with reduced airflow.

SAFETY SYMBOLS

Wear eye protection
**** Wear protective clothing
Wear protective gloves

ELECTRICAL CONNECTIONS
WARNING! READ THESE ELECTRICAL SAFETY INSTRUCTIONS THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS SUPPLY.
Before switching the product on, make sure that the voltage of your electricity supply is the same as that indicated on the rating plate. This product is designed to operate on 230VAC 50Hz. Connecting it to any other power source may cause damage. This product may be fitted with a non- rewireable plug. If it is necessary to change the fuse in the plug, the fuse cover must be refitted. If the fuse cover becomes lost or damaged, the plug must not be used until a suitable replacement is obtained. If the plug has to be changed because it is not suitable for your socket, or due to damage, it should be cut off and a replacement fitted, following the wiring instructions shown below. The old plug must be disposed of safely, as insertion into the main socket could cause an electrical hazard.
If the colors of the wires in the power cable of this product do not correspond with the markings on the terminals of your plug, proceed as follows.

• The Blue wire must be connected to the terminal marked N or colored Black.
• The Brown wire must be connected to the terminal marked L or colored Red.

We strongly recommend that this machine is connected to the main supply via a Residual Current Device (RCD).
If in any doubt, consult a qualified electrician. DO NOT attempt any repairs yourself.
This symbol indicates that this is a Class II product, and does not require an earth connection.

THE CHARGING PROCESS

STEP 1 : DIAGNOSIS
Check if the battery has connected with the charger and also check the battery voltage.
STEP 2: DESULPHATION
If battery voltage is too low, the program automatically generates a pulsing current to remove sulfate. STEP 3: ANALYSE Check if the battery voltage reaches to the minimum threshold after desulpha tion, and charging begins if the battery voltage is OK.
STEP 4: SOFT START
Charge with a stepped constant current.
STEP 5: BULK
Charge with constant maximum current until the battery voltage has reached the threshold.
STEP 6: ABSORPTION
Provide a gradually declining current charge for maximum battery voltage.
STEP 7 : ANALYSE
Test if the battery can hold a charge
STEP 8 : MAINTENANCE
Continuously monitor the battery, and the charging current will intelligently adapt to the variable battery voltage. (pulse form protection).

OVERVIEW

CONNECTING TO THE BATTERY

CAUTION: A MARINE (BOAT) BATTERY MUST BE REMOVED AND CHARGED ON SHORE. TO CHARGE IT ON BOARD REQUIRES EQUIPMENT SPECIALLY DESIGNED FOR MARINE USE.

1. Identify the polarity of battery posts. The positive battery terminal is typically marked by these letters or symbols (POS,P,+). The negative battery terminal is typically marked by these letters or symbols (NEG,N,-).

2. DO NOT make any connections to the carburetor, fuel lines, or thin metal parts.

3. Identify if you have a negative or positive grounded vehicle. This can be done by identifying which battery post (NEG or POS) is connected to the chassis.
   · FOR A NEGATIVE GROUNDED VEHICLE (MOST COMMON): connect the RED POSITIVE clamp first to the positive battery terminal, then connect the BLACK NEGATIVE clamp to the negative battery terminal or vehicle chassis.
   · FOR A POSITIVE GROUNDED VEHICLE (VERY UNCOMMON): connect the BLACK NEGATIVE clamp first to the negative battery terminal, then connect the RED POSITIVE clamp to the positive battery terminal or vehicle chassis.

4. When disconnecting, disconnect in the reverse sequence, removing the negative first (or positive first for positive ground systems).

CHARGING MODELS

OPERATION

1. Connect the battery as described on page 8.

2. Plug in the mains plug and switch it on.

3. The charger will automatically detect the battery voltage (12V or 24V).

4. After 10 seconds the charger will begin charging the battery using the following mode 12V/5A or 24V/5A.
   · The user can manually select charging voltage / current modes by pressing the “VOLTAGE” or “CURRENT” button within the first 10 seconds after switching on (a countdown is shown on the LCD).
   NOTE: If you choose 24V Mode(s) for 12V battery, the 12V battery will be damaged
   · Once the battery type has been selected successfully and charging is started, you must disconnect the AC plug and plug in again if you want to change the battery type mode of the charger.
   · During charging, the display will show voltage (12V or 24V) and charging current alternately.
   · When the “VOLTAGE” button is pressed, the display shows battery voltage (e.g. 12.1 V) .

5. During charging, pressing the “CHARGE” button will cause the charger to turn off.
   · The charger will be restarted by pressing “CHARGE” button again.

6. The battery level is indicated by the “battery level icon”. When the battery is fully charged, the charger will automatically switch from full charge to maintenance status without overcharging or damaging the battery.

BATTERY LEVEL INDICATOR

25% is reached, the bar will be solid.
| The 50% bar will slowly flash when the battery level is less than 50%. When 50% is reached, the bar will be solid.
| The 75% bar will slowly flash when the battery level is less than 75%. When 75% is reached, the bar will be solid.
| The 100% bar will slowly flash when the battery level is less than 100%. When 100% is reached, the bar will be solid. Meanwhile the maintenance charging is activated.

ADVANCED CHARGING MODES

The following modes are advanced charging modes that require your full attention before selecting.
USING 12V BOOST
WARNING: DO NOT USE BOOST MORE THAN TWO TIMES IN A 24-HOUR PERIOD. IF TWO BOOSTS CANNOT SUCCESSFULLY START YOUR VEHICLE, HAVE YOUR BATTERY REPLACED OR EVALUATED BY A LOCAL BATTERY STORE.

1. Connect the charger to the battery as shown on page 7 and switch on at the mains power supply.

2. Allow the charger to start charging after an initial 10-second wait.

3. Press the BOOST/QUICK CHARGE button to start the boost charge mode
   · For optimum results, allow boost to complete its 5-minute charge cycle.
   · After 5 minutes the display will show “000”, and you are ready to start your vehicle.
   · After each boost, the charger has a mandatory 5-minute rest for safety reasons (even if you press the BOOST/ QUICK CHARGE button again, the charger will not work).
   · After cooling, the LCD shows “End”

4. Press any button to enter the normal charging mode, or the charger will automatically enter the normal charging mode after 10 minutes.

5. If unsuccessful when starting your vehicle, let the battery rest for 15 minutes and try boost again. Most vehicles will start with one boost.

6. Using 12V ALTERNATOR CHECK

ALTERNATOR % (12V ONLY)

1. Connect the charger to the battery shown on page 7 and switch on at the mains power supply
   NOTE: The battery must be installed in the vehicle.

2. Press and hold the ALTN CHECK button for 3 seconds.
   · The  icon will appear.

3. Start the vehicle and turn on the vehicle’s headlights.
   · The digital display shows an estimated output percentage of the vehicle’s charging system.

· If you get a LOW or HIGH reading, have the electrical system checked by a qualified technician. After 10 seconds, the charger will return to the normal charging process.

CARE & MAINTENANCE

This battery charger requires minimal maintenance. As with any appliance or tool, a few common sense rules will prolong its working life.
WARNING: ALWAYS BE SURE THE CHARGER IS UNPLUGGED BEFORE PERFORMING ANY MAINTENANCE OR CLEANING. ANY REPAIRS MUST BE DONE BY A QUALIFIED CLARKE SERVICE TECHNICIAN.
1. Wind up the leads when not in use. Examine the leads at regular intervals for damage and have them replaced if necessary. ”

• Clean the case and leads if necessary with a moist cloth and clean any corrosion from the clamps with a solution of water and baking soda.

TROUBLESHOOTING

pause with the alarm sound. Do NOT cut off the power supply and the charger will work again when cooled down.
E02| 1) Open-circuit| 1) Connect the red and black clamps to the battery posts
2) Dirty Battery Posts| 2)Clean the battery posts
3)Dead Battery| 3) Replace the battery with a new one Immediately
4) Output Short Circuit| 4) Disconnect red and black output terminals
E03| Charging in 12V Mode(s) for 24V battery| An alarm sound will remind you. Please restart the charger and
choose the correct charge mode. CAUTION: If you choose 24V Mode(s) for the 12V battery, the 12V battery will be damaged
E04| The battery cannot store electric charge during the charging process| Replace the battery with a new one immediately
E05| The battery Is heavily corroded and cannot be recovered through desulphation process| Replace the battery with a new one Immediately
EGO| Reverse Polarity| Swap the position of the charging leads.
---|---|---
The battery does not charge | Lack of AC input power.| Make sure that the charger is plugged into the AC outlet and the POWER LED
is lit.
Very slow
charging| Charging a very cold
battery.| If the battery being charged is extremely cold, it will not accept a high rate of charge, so the initial charge rate will be slow. The rate of charge will increase as the battery warms up. Never attempt to charge a frozen battery.

SPECIFICATIONS

24VDC, 5A/10A/20A
12VDC, 40A, 300s (Boost)
Efficiency| 85% approx
IP Rating| IP20
Battery Capacity| 10-500 Ah (12V), 10-300 Ah (24V)
Charging steps| 8 steps (smart charger)
Operating Temperature Range| -10 to 50°C
Dimensions (D x W x H)| 187 x 285 x 320 mm
Weight| 3.6 kg
Charging lead length (red& black)| 1.85 m
Mains power cable length| 1.2 m

COMPONENT PARTS

DECLARATION OF CONFORMITY

A SELECTION FROM THE VAST RANGE OF QUALITY PRODUCTS

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AIR COMPRESSORS
From 01Y to industrial, Plus air tools% spray guns, and accessories.
GENERATORS
Prime duty or emergency standby for business, home, and leisure.
POWER WASHERS
Hot and cold electric and engine drove we have what you need
WELDERS
Arc.Tig and Spot. From DIY to auto industrial.
METALWORKING DINS,
winders, and saws for ON and professional use.
WOODWORKING
Saws. sanders, lathes, mortises and dust extraction.
HYDRAULICS
Cranes, body repair kits. transmission racks for all types of workshop use.
WATER PUMPS
Submersible, electric, and engine driver for DIY, agriculture, and industry.
POWER TOOLS
Angle grinders, cordless drill sets. saws and sanders.
STARTERS/CHARGERS
All sires for cal and commercial

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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 Herman Street, Epping. Essex CM16 4LG
www.clarkeinternationaLcom
Parts & Service: 020 8988 7400
E-mail: Parts@clarkeinternational.com
Service@clarkeinternational.com

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