BORMANN PRO BBC4020 12-24V Car Battery Charger Instruction Manual

BORMANN PRO BBC4020 12-24V Car Battery Charger Instruction Manual

Important Safety Instructions

WARNING ! READ AND UNDERSTAND ALL INSTRUCTIONS.
Failure to follow all instructions listed below, may result in electric shock, fire and /or serious personal injury.

Safety precautions for working in the vicinity of a battery

1. Batteries generate explosive gases during normal operation. Use in well-ventilated area.
2. Consider having someone close enough or within the range of your voice to come to your aid when you work near a battery.
3. Do NOT smoke, strike a match, or cause a spark in vicinity of battery or engine. Avoid explosive gas, flames and sparks.
4. Remove all personal jewelry, such as rings, bracelets, necklaces, and watches while working with a vehicle battery. These items may produce a short-circuit that could cause severe burns.
5. 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.
6. Wear complete eye protection, hand and clothing protection. Avoid touching eyes while working near a battery.
7. Study all battery manufacturer’s specific precautions such as removing or not removing cell caps while charging and recommended rates of charge.
8. Clean battery terminals before connected with the charger. Be  careful to keep corrosion from coming in contact with eyes.
9. When it is necessary to remove a battery from vehicle to charge, always remove grounded terminal from battery first. Make sure all accessories in the vehicle are off in order to prevent an arc.
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. If battery electrolyte contacts skin or clothing, wash immediately with soap and water. If an electrolyte enters eye, immediately flood eye with running clean cold water for at least 15 minutes and get medical attention immediately.

Safety precautions for using the charger

1. Do NOT place the charger in the engine compartment or near moving parts or near the battery; place as far away from them as DC cable permits. NEVER place a charger directly above a battery being charged; gases or fluids from battery will corrode and damage charger.
2. Do NOT cover the charger while charging.
3. Do NOT expose to rain or wet conditions.
4. Connect and disconnect DC output only after setting AC cord from electric outlet.
5. Use of an attachment not recommended or sold by the manufacturer may result in a risk of fire, electric shock or injury to persons.
6. Do not overcharge batteries by selecting the wrong charge mode.
7. To reduce the risk of damage to electric plug and cord, pull by the plug rather than the cord when disconnecting charger.
8. To reduce risk of electric shock, unplug charger from outlet before attempting any maintenance or cleaning.
9. Operate with caution if the charger has received direct hit of force or been dropped. Have it checked and repaired if damaged.
10. Any repair must be carried out by the manufacturer or an authorized repair agent in order to avoid danger

BBC4020 charger

1. The BBC4020 charger is designed for charging 12V/24V lead-acid and 12V lithium-ion batteries (LIFEPO4).
2. Built-in intelligent microprocessor makes charging faster, easier and safer.
3. This charger has safety features, including spark proof, protection for reverse polarity, short circuit, overheat and overcharge.
4. When starting, the battery voltage type is 12V by default. The user can select battery voltage type by pressing “12V/24V” button in standby.
5. When starting, the charger works for STD battery type by default. The user can select battery type including STD, COLD/AGM, CAL, LIFEPO4 (only for 12V battery) by pressing and holding “FUNCTION/TYPE” button for 3 seconds in standby.
6. When the charger is powered on, it enters the standby mode by default. The user can select functions including CHARGE, SUPPLY, REPAIR by pressing “FUNCTION/TYPE” button. The charger’s technical specifications can be seen below:

3V Cold/AGM Mode: Υes, Dedicated Repair Mode only for 12V/24V, Supply Mode: Yes, 13,6 V / 5A, ALT-Check function & CCA test function, detailed error lights to remind the abnormal processes
Battery Type| All 12 V & 24 V lead acid battery types (WET/MF/CA/EFB/GEL/AGM), & 12 V lithium batteries
Housing Protection| IP54
Ambient Temperature| 0 oC – 40 oC
Other characteristics| LCD screen, independent selection mode for 12V/24V battery and memory function
Certificate| RoHS

LCD ICONS:

Connecting to the battery

1. Identify 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.
4. 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.
5. 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.
6. When disconnecting, disconnect in the reverse sequence, removing the negative first (or positive first for positive ground systems).
7. A marine (boat) battery must be removed and charged on shore. To charge it on board requires equipment specially designed for marine use.

Charging modes

Important Note:
The BBC4020 charger has 12 modes: Standby, 12V STD, 12V COLD/AGM, 12V LITHIUM (LIFEPO4), 12V CAL, 24V STD, 24V COLD/AGM, 24V CAL , 13,6V SUPPLY, REPAIR, 12V ALTERNATOR CHECK, BATTERY HEALTH CHECK. Do not operate the charger until you confirm the appropriate charge mode for your battery.
CAUTION: If you choose 24V Mode(s) for 12V battery, the 12V battery will be damaged!

Remaining Battery Capacity (State of Charge)
12 V STD| 14-230| Charging 12V STD batteries
12 V COLD/AGM| 14-230| Charging 12 V batteries below 10o C (50o F) or 12V AGM battery
12 V CAL| 14-230| Charging 12 V CAL batteries
24 V STD| 14-115| Charging 24 V STD batteries
24 V COLD/AGM| 14-115| Charging 24 V batteries below 10 o C (50 o F) or 24 V AGM battery (Green LED)
24 V CAL| 14-115| Charging 24 V CAL batteries
12 V LITHIUM| 14-230| Charging 12 V lithium-ion (LiFePO4) batteries only
REPAIR| 14-230| An advanced battery recovery mode for repairing old, idle, stratified or sulfated batteries
13,6 V SUPPLY| –| Converting to a DC power supply for powering 12 V DC device or as a memory retainer when replacing a battery.
12V ALTERNATOR CHECK| –| Check vehicle’s alternator output
BATTERY HEALTH CHECK| –| Check battery health (LEAD-ACID only), including SOC, SOH, CCA and internal resistance

The following modes are advanced charging modes that require your full attention before selecting.

Using Instructions

Using 12V LITHIUM

This mode is designed for 12V lithium-ion (LiFePO4) batteries only. Some lithium-ion batteries may be unstable and unsuitable for charging. Consult the lithium battery manufacturer before charging and ask for recommended charging voltage and current.

Using REPAIR (12V only)

This mode is for LEAD-ACID batteries only. It is an advanced battery recovery mode for repairing old, idle, stratified or sulfated batteries. NOT all batteries can be recovered. For optimal results, take the battery through a full charge cycle, bringing the battery to full charge, before using this mode. One REPAIR cycle can take up to eight (8) hours to complete the recovery process and will enter to standby when completed. This mode uses a high charging voltage and may cause some water loss in WET cell batteries. Plus, some batteries and electronics may be sensitive to high charging voltages. To minimize risks, disconnect the battery from the vehicle before using this mode.

Using 13,6 V SUPPLY

This mode converts the charger to a constant voltage, constant current DC power supply. It can be used to power 12 V DC devices. Prior to use, read your 12 V DC device manual to determine if it is suitable for use with this mode. As a power supply, it can also be used to retain a vehicle’s on-board computer settings during battery repair or replacement. 13,6 V Supply Mode provides 13,6 V at 5A (Max). Both spark proof and reverse polarity protection are disabled in this mode. Do NOT allow the positive and negative battery clamp to touch or connect to each other as the charger could generate sparks.

Using 12 ALTERNATOR CHECK (press ALT-CHECK in standby)

Alternator % (12 V only) – Before the charger is connected with the battery which is well settled in the vehicle and ALTN CHECK button is pressed, start the vehicle and turn on the vehicle’s headlights. The digital display shows an estimated output percentage of the vehicle’s charging system connected to the charger’s battery clamps, compared to a properly functioning system. The alternator percent range is from 0% to 100%, and LCD will show “OUTPUT GOOD”. Readings below 0% (13.2 volts) will be regarded as LOW (LCD show “OUTPUT LOW”) and readings above 100% (14.6 volts) will be regarded as HIGH (LCD show “OUTPUT LOW”). If you get a LOW or HIGH reading, have the electrical system checked by a qualified technician.

Using 12 BATTERY HEALTH CHECK

This mode is the advanced mode that takes a close look at the health of LEAD- ACID battery. Following parameters are what the charger checks to determine battery health.

CCA (Cold Cranking Amperage): The starting current that the battery can provide to the engine at low temperature. More than 30% of the labeled value is normal, and less than 30% of the labeled value requires replacement of batteries.

SOC (State of Charge): The ratio of the remaining capacity of the battery after a period of time or long-term shelf to the capacity of its fully charged state, commonly expressed as a percentage. When SOC = 0, the battery discharges completely, and when SOC = 100%, the battery is fully charged.

SOH (State of Health): The ratio of performance parameters after a period of service to nominal parameters of batteries. SOH of new battery is 100% and reject battery is 0%.

Internal Resistance: The larger the internal resistance, the worse the capacity of the battery to absorb electricity.

How to operate: Press CCA button will enter CCA RATE SET, you can  press “+” and “-”button to set CCA rate and default value is 500. When CCA rate has been set, press CCA button again, and LCD will display the actual CCA, SOH, SOC, and internal resistance. If SOC is less than 15% which means the battery power is very low, the CCA detection value may be incorrect, LCD will display “RETRY AFTER CHARGE”, please try to charge the battery and try the BATTERY HEALTH CHECK mode again.

Charging Steps

STEP 1: DIAGNOSIS (Check if battery has connected with the charger and also check battery voltage)
STEP 2: DESULPHATION (If battery voltage is too low, programs automatically generate pulsing current to remove sulphate, up to 10 minutes)
STEP 3: ANALYSE (Check if the battery voltage reaches to the threshold after desulphation, and charging begins if the battery voltage is OK)
STEP 4: SOFT START (Charge with echelon constant current)
STEP 5: BULK (Charge with constant maximum current until battery voltage is reached to the threshold)
STEP 6: ABSORPTION (Provide gradually declining current charge for maximum battery voltage)
STEP 7: ANALYSE (Test if the battery can hold charge)
STEP 8: MAINTENANCE (Continuously monitor the battery, and charging current will intelligently adapt to the variable battery voltage)

Troubleshooting

automatically pause. Do NOT cut off the power supply, and the charger will work again when cooled down.
ERROR + NO CONNECTION| ****

1. Open-circuit

2. Dirty Battery Posts

3. Dead Battery

4. Output Short Circuit

| ****

1. Connect the red and black clamps to the battery posts

2. Clean the battery posts

3. Replace the battery with a new one immediately

4. Disconnect red and black output terminals

ERROR + BATTERY VOLTAGE MISMATCH| Charging in 12 V Mode(s) for 24 V battery| Restart the charger and choose the correct charge mode.
ERROR + BAD BATTERY| Battery cannot store energy or cannot be recovered through Repair Mode| 1) Replace the battery with a new one

2. If REPAIR Mode has not be tried, try it for recovery

ERROR + REVERSE POLARITY| Reverse Polarity| Exchange the red and black clamps to the correct battery posts
ERROR + OVERLOAD| Overload in SUPPLY Mode (will automatically shut down for 30 seconds as protection)| Disconnect the external device

• The manufacturer reserves the right to make minor changes to product design and technical specifications without prior notice unless these changes significantly affect the performance and safety of the products. The parts described / illustrated in the pages of the manual that you hold in your hands may also concern other models of the manufacturer’s product line with similar features and may not be included in the product you just acquired.
• Please note that our equipment has not been designed for use in commercial, trade or industrial applications. Our warranty will be voided if the machine is used in commercial, trade or industrial businesses or for equivalent purposes.
• To ensure the safety and reliability of the product and the warranty validity, all repair, inspection, repair or replacement work, including maintenance and special adjustments, must only be carried out by technicians of the authorized service department of the manufacturer.

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