K612 BC Battery Controller Instruction Manual

K612 BC Battery Controller
Instruction Manual

Thank you for buying the new professional battery charger BC K612, fully automatic and featuring a multi-cycle charging technology. BC K612 is compatible with all 6V and  12V lead-acid batteries. The device is controlled by a microprocessor which is in charge of monitoring in real-time the current status of your battery and executing autonomously the 8 following charging steps.

CHARGING ALGORITHM – BC K612

Phase 1 – Initialization: the device checks if one or more cells are shorted, to verify that the battery is in a proper condition to be recovered/recharged.
Phase 2 – Recovery: if the battery is deep discharged (starting from 1.5V for 12V batteries, 0.63V for 6V batteries), the device tries to recover it, taking it back to a higher voltage, necessary for the execution of the following step.
Phase 3 – Soft Charge: if the battery is in significantly discharged, the device provides a light pulsing current to the battery, to overcome the critical phase.
Phase 4 – Bulk Charge: during this phase, the device provides full current to the battery, recovering about 85-90% of the battery capacity.
Phase 5 – Desulfation / Absorption: during this phase, the device provides a “controlled overcharge” to recover the remaining 15-20% of the battery capacity, through the desulfation/recovery of the lead-acid cells (for low or medium sulfation).
Phase 6 – Battery Analysis: the device stops providing current to the battery for a short time, in order to verify whether the battery is able to retain the charge received during the previous phases. This test is periodically repeated during maintenance.
Phase 7 – Maintenance: the device keeps your battery in the best charge conditions for very long periods when your vehicle is left unused, without any possible drawback  (battery overcharge/overheating, electrolyte loss…).
Phase 8 – Equalization: every 30 days during long-term maintenance, the device executes an equalization charge in order to balance the battery lead-acid cells, avoiding electrolyte stratification within the cells.

BC K612- FEATURES

• Two Charging Programs: “6V” for 6 Volt batteries and “12V” for 12 Volt batteries. A LED bar always shows the active charging mode.

• A couple of green/red LED diodes to indicate the charging cycle executed and any error.

• Green LED diode (CHARGE): it shows the current charging cycle (Charge, Desulfation, Maintenance…);

• Red LED diode (ERROR): it notifies any occurring problem (polarity inverted, short circuit, battery not connected…).
  For further information on the LED diodes, please refer to the “Working Mode” section.

• Real-time monitoring of the main battery parameters during every charging cycle.

• Battery Overcharge Protection, which triggers in case the microprocessor detects a voltage level higher than a given fixed threshold: no risk of bubble production for all batteries (lead-acid wet, MF, VRLA, Gel, AGM).
  Upon conclusion of every cycle, the device switches automatically to the next one, without any external intervention: BC K612 CAN BE LEFT ALWAYS

CONNECTED TO THE BATTERY WHEN THE VEHICLE IS LEFT UNUSED. The charger belongs to the BC Battery Controller range of products for battery care, distributed by the best dealers. BC products have been designed, manufactured, and tested according to the current norms in order to comply with all requirements for electronic devices’ safety and electromagnetic compatibility. Read carefully this manual and follow all its recommendations before using and installing the device.

DIRECTIONS
This device has to be used according to the working conditions it has been designed for, that is the care of 6V and 12V lead-acid batteries. Any other use is to be considered either dangerous or improper. Do not use the device for NiCd, NiMH, Li-Ion or non-rechargeable batteries. The manufacturer is completely exonerated from whatever responsibility for possible damages due to either wrong or improper use of the device. It is important to remember that the following basic usage principles have to be  considered whenever using the device:

• Do not touch the device with wet hands (or wet feet).
• Do not touch the device barefoot.
• Do not expose the device to the atmospheric agents (rain, water, saltiness…).

Please verify that the input and output cables are in good condition before using the device. If the input cable is damaged, do not use the device: ask the manufacturer or an authorized service agent for repair or replacement. Before executing any cleaning/maintenance operation on the device, please check the device is not connected to the power outlet. In case the device does not work properly, do not attempt to repair it; please ask either your local dealer or the equipment manufacturer (info@batterycontroller.it) for support. Any attempt to open unduly the device shall cause the withdrawal of the warranty.

SAFETY

BC K612 is not intended for use by children or persons with reduced physical, mental or sensory capabilities, or lack of enough experience and knowledge to understand the  instructions on this manual, except in the presence of a responsible person who can ensure the safe use of the device. Keep out of reach of children and ensure that they can not  play with it. The device is designed and manufactured in accordance with the norms and regulations in force in the European Union and provided with the following set of  active guard mechanisms:

1. Protection from battery polarity inversion.
2. Protection from output lines short circuit (even for an indefinite time).
3. Over-temperature protection: the current supplied to the battery gets limited in case of device overheating.

In order to prevent any accident, please respect the following guidelines:

1. Always wear protective goggles when operating in proximity of the battery.
2. Do not try to recharge a frozen battery.
3. During the charge of a battery, avoid generating flames or sparks in its proximity since it might produce explosive gases. If the battery is out of the vehicle, place it in a well-ventilated area.
4. Do not put the battery charger device on top of the battery during its charge.
5. Batteries contain a corrosive electrolyte. In case the battery electrolyte gets in touch either with your skin or with your eyes, rinse them immediately and abundantly with fresh water and ask for a doctor.
6. Do not try to recharge a 6V battery using 12V charging mode, since it could cause the battery to explode!
7. The charger is specifically designed to provide long-term maintenance in order to prevent the slow self-discharge of the battery. If the device does not complete the Bulk  Charge phase after a time-out period that is about three times the period indicated in this manual (please refer to the “Performance” table), please disconnect the device manually. One of the following problems might have occurred: the battery is definitely worn out; there are electronic devices connected to the battery (alarm, radio, onboard computer…) that drain too much current.

BATTERY CONNECTOR WITH CLAMPS INSTALLATION PROCEDURE
If the battery is out of the vehicle, just connect the black clamp to the (-) negative battery terminal and the red clamp to the (+) positive battery terminal. If charging the battery in a vehicle, connect first to the battery terminal not connected to the chassis (usually the positive one, red clamp to the + battery pole), and then connect the other clamp to the chassis, far from the battery and the fuel line. After using the device, disconnect in reverse sequence.

BATTERY CONNECTOR WITH EYELETS INSTALLATION PROCEDURE
When charging a battery in a vehicle, you can install the battery connector with eyelets, which allows for performing the following procedure just once. The user is kindly requested to execute the installation with maximum care (see “Directions” and “Safety” sections). If necessary, please entrust qualified personnel with the execution of the steps reported  here below:

• Connect the eyelets to the battery: the black wire to the (-) negative battery terminal, the red wire to the (+) positive battery terminal.
• Fix the connector in a stable and easy-to-reach place onboard (for example, under the saddle).

BC K612 CONNECTION PROCEDURE – 6V & 12V MODE

• Connect BC K612 to the power outlet. The red LED (ERROR) is slowly blinking, indicating that the battery is not connected.
• Select the right charging mode (6V or 12V), according to the battery you have to recharge.
• Connect the battery charger to the battery through the insulated clamps (see the previous section), the cable with eyelets, or the cigar socket adapter. The red LED diode  (ERROR) will turn off. The green LED diode (CHARGE) will turn on, blinking, or with fixed light according to the cycle executed (for further information, please refer to the “Working Mode” section).

6V/12V CHARGING PROGRAM SELECTION
To select the charging program (6V or 12V) please follow the instructions on the back of the manual.

WORKING MODEL

In case of normal working conditions, the device indicates the charging cycle executed through the green LED diode (CHARGE) as follows:

• Green LED diode slowly blinking: Charge cycles executed (phases 1, 2, 3, 4).

• Green LED diode swiftly blinking: Desulfation cycle executed (phase 5).

• Green LED diode on (fixed light): Maintenance cycle executed (phase 7).

• Red LED diode (ERROR) off.
  For more details about the charging steps, please refer to the “Charging Algorithm” section on this manual.
  Possible occurring anomalies are indicated by the device as follows:

• Red LED diode on (fixed light): it means the input power is missing.

• Red LED diode slowly blinking: the device is not connected to the battery.

• Red LED diode swiftly blinking: polarity inversion or short circuit.

• Green LED diode (CHARGE) + Red LED diode (ERROR) alternatively blinking: the Battery Analysis (phase 6) failed. The battery is not able to retain the
  charge received, it may be necessary to substitute it.

In case of wrong installation or functioning, please disconnect the device following the procedure reported in the “Disconnection Procedure” section.

BATTERY CHARGER DISCONNECTION PROCEDURE

Please follow the following steps to disconnect the battery charger from the battery:

• Disconnect the battery charger from the power outlet.
• Disconnect the battery charger from the cable with eyelets and put the saver cap on the cable connector. Otherwise, disconnect the clamps from the battery or the cigar socket adapter from the cigar socket.
• Put the battery charger back in its box to minimize its exposure to atmospheric agents.

BATTERY TYPES
BC K612 is specifically designed for the maintenance of all 6V and 12V lead-acid batteries on the market (wet, Gel, MF, AGM, VRLA, etc), thanks to its unique charging algorithm. Please refer to the “Technical Data” for indications about the battery capacity range to which the charger is addressed.

MAINTENANCE

In order to ensure regular functioning, it is suggested to periodically check the correct and stable connection of the eyelets to the battery and to remove dust and oil from the battery poles with a metallic brush. Please read the “Safety” section before. The device has been specifically designed to be maintenance-free. Please remove possible dust which may get accumulated on the cover of the device using a delicate detergent to avoid damaging the stickers. In case any item of the kit does not work correctly, please contact either your local dealer or the manufacturer asking for item repair or substitution. Any attempt to open the device shall imply the warranty becomes no longer valid.

WARRANTY

Forelettronica Srl provides a 36 months warranty to cover the device malfunction or failure due to improper assembly/manufacturing or breakage of any internal component.  Parts, whose deterioration is because of the usage, are not covered by the warranty. Any repairing right under the manufacturer’s warranty decays in any of the following cases:  improper use of the device; unduly opening of the device; repairing performed by unauthorized personnel. This warranty is limited to the original buyer of the device and it can not be transferred to third parties. This warranty excludes implicit forms of warranty, including possible damages due to the usage of the battery charger: Forelettronica Srl is exonerated from any damage to either persons or goods due to the usage of its products. The transportation expenses to return the defective device, together with the Warranty  Coupon reported here and the supplier ticket, are to be paid by the purchaser.

Warning! Never use the device in 12V Mode with a 6V battery! A wrong or improper mode selection could damage the battery and provoke the battery to explode!

STATEMENT OF CONFORMANCE

Forelettronica Srl declares under its responsibility that the battery chargers in BC Battery Controller range fulfil all the relevant norms and regulations in force in the European  Union. The device is CE marked. Rules of reference: IEC-61000-3-2(ed.3);am1;am2, IEC-61000-3-3(ed.2) CEI-CISPR14-1(ed.5);am1;am2, CEICISPR14-2(ed.1);am1;am2,  IEC60335-1(ed.5), IEC-60335-2-29(ed.4);am1;am2.

CHARGING PROGRAM SELECTION

CHARGING PROGRAM SELECTION – 6V/12V
Once you connected the battery charger to the power outlet, a LED will show you the active charging mode (6V or 12V). To change the charging mode, please follow this  procedure:

• With the device disconnected from the battery and from the power outlet, connect the clamps to the device and put the red and the black clamps together (creating a permanent short circuit).
• Connect the device to the power outlet. The active charging mode will change and it will be displayed by the correspondent LED (6V or 12V).
• Disconnect the device from the power outlet and separate the clamps. The selected charging mode will be kept in memory until you repeat this procedure.

CONTENT

BATTERY CHARGER

CONNECTOR WITH CLAMPS

CIGAR SOCKET ADAPTER

TECHNICAL DATA

BC K612 2 AMP: 2.0 A max
Battery Poles Protection| X| X
Short Circuit Protection| X| X
Overcharge Protection| X| X
Overheating Protection| x| x
Charging Algorithm| Automatic
8 cycles| Automatic
8 cycles
Battery Types| 6 V Lead-Acid (Gel, Wet,
MF, AGM, VRLA, Ca/Ca…)| 12 V Lead-Acid (Gel, Wet,
MF, AGM, VRLA, Ca/Ca…)
Battery Capacity| BC K612 1.2 Ah  –  100 Ah
BC K612 2 AMP: 3 Ah – 100 Ah| BC K612 1.2 Ah  –  100 Ah
BC K612 2 AMP: 3 Ah – 100 Ah
Operating Temperature| -20°C  –  +50°C| -20°C  –  +50°C

CHARGING ALGORITHM

PERFORMANCE

Batter (Ah) y Capa city| Recharging Time (h)
BC K612| Recharging Time (h)
BC K6122 AMP
---|---|---
3| <2| <1.5
10| <7| <4
20| < 22| < 13
40| < 48| < 30

* Bulk Charge duration (phase 4)

WARRANTY COUPON – This warranty covers the device malfunction or failure due to improper assembly/manufacturing or breakage of any internal component. Parts,  whose deterioration is because of the usage, are not covered by the warranty. This warranty excludes implicit forms of warranty.
Attention! This coupon has to be returned together with the supplier ticket and the device in its original packaging.

MANUFACTURER
Forelettronica Srl
Via Meucci, 11
20080 Cisliano (MI) – ITALY
info@batterycontroller.it IP44 – WEATHERPROOF
SUITABLE FOR OUTDOOR USE

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| BC BATTERY K612 BC Battery Controller [pdf] Instruction Manual
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