BORMANN BBC7020 550W Battery Charger Instruction Manual

BORMANN BBC7020 550W Battery Charger

CAUTION: Read and follow all safety rules and operating instructions before every use of this product. SAVE THESE INSTRUCTIONS.

WARNING SYMBOLS AND DEFINITION

DANGER: Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING: Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION: Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE CAUTION: Addresses practices not related to personal injury.
This is the safety alert symbol .It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

SAFETY INSTRUCTIONS

WARNING! Read and understand all Important Safety and Operating instructions before using this charger. In addition, read and follow all battery and vehicle manufacturer’s instructions and cautionary markings.

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 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. This product 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 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.

Grounding and AC power cord connections
This battery charger is for use on a nominal 230 volt circuit. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances. The plug pins must fit the receptacle (outlet).
Do not use with an ungrounded system. Use of an adapter plug is not recommended; an adaptor plug should not be used.

Using an extension cord
The use of an extension cord is not recommended. If you must use an extension cord, follow these guidelines:

1. Pins sockets on the extension cord plug must be the same number, size, and shape as those of plug on charger.
2. Ensure that the extension cord is properly wired and in good electrical condition.
3. Wire size must be large enough for the AC ampere rating of the charger, as specified below:

DESCRIPTION OF MAINS PARTS AND FEATURES

1. ENGINE START BUTTON

2. ENGINE START indicator

3. DIGITAL DISPLAY

4. CHARGED LED indicator

5. CHARGING LED indicator

6. WARNING LED indicator

7. STD LED indicator

8. GEL LED indicator

9. AGM LED indicator

10. 12V-LITHIUM indicator

11. TYPE BUTTON

12. NORMAL(5A/15A) LED indicator

13. BOOST(25A) LED indicator 28.24V quick connector

14. REPAIR LED indicator 29.12V quick connector

15. FUNCTION BUTTON

16. Alternator % LED indicator

17. Battery % LED indicator

18. TEST BUTTON

19. Voltage LED indicator

20. Plastic Handle

21. Plastic panel

22. FUSE

23. Metal shell

24. AC PLUG

25. Wheel

26. Negative Battery clamp

27. Positive Battery clamp

28. 24V quick connector

29. 12V quick connector

30. This product 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, AGM (Absorbed Glass Mat) and 12V Lithium Ion Batteries (4-cell LiFePO4) batteries.

31. Built-in intelligent microprocessor makes charging faster, easier and safer.

32. This charger has safety features, including spark proof, protection for reverse polarity, short circuit, overheat, overcharge and over- current.

33. Charging start-up threshold is 1V.

34. The charger has clamp storage panel on the back as well as two wheels.

TECHNICAL DATA

GEL/AGM)
Lowest Chargeable Voltage:| 3V| 3V
Additional specifications:|

• Alternator check function
• Independent STD/GEL/AGM battery type selection
• Automatically detects 12V/24V battery
• Digital display
• Detailed error messages on screen
• Charging functions: 10 steps, Fully-automatic Charging Cycle
• Housing protection: IP20

|

• Alternator check function

• Independent STD/GEL/AGM battery type selection

• Automatically detects 12V/24V battery

• Digital display

• Detailed error messages on screen

• Charging functions: 10 steps, Fully-automatic Charging Cycle

• Housing protection: IP20

• 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.

• Always use the product with the supplied equipment. Operation of the product with non-provided equipment may cause malfunctions or even serious injury or death. The manufacturer and the importer shall not be liable for injuries and damages resulting from the use of non-conforming equipment.

OPERATING INSTRUCTIONS

Display messages
Start up – After display screen and all LEDs illuminate for 0.5 second, battery voltage shows (meanwhile battery VOLTAGE LED is lit).

DISPLAY BUTTON

Digital display| LED indicator| Description
Battery-voltage| Voltage LED lit| When the charger is NOT working in ENGINE START, the display will show the battery VOLTAGE.
Battery – %| Battery % LED lit| When the charger is NOT working in ENGINE START, the digital display shows percentage of the battery connected to the charger’s battery clamps.
Alternator – %| Alternator % LED lit| 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%. Readings below 0% (13.4 volts/26.8 volts) will read LO and readings above 100% (14.4 volts/28.8 volts) will read HI. If you get a HI or LO reading, have the electrical system checked by a qualified technician.
BATTERY TYPE BUTTON

Digital display| LED indicator| Description
12V| STD LED lit| (STANDARD)-Charged Voltage is 14.4V.When charging, pressing this button does NOT work.
GEL LED lit| (GEL)-Charged Voltage is 14.5V.When charging, pressing this button does NOT work.
AGM LED lit| (AGM)-Charged Voltage is 14.8V.When charging, pressing this button does NOT work.
LITHIUM LED lit| Charging 12V lithium-ion batteries only, including (4-cell LiFePO4).
24V| STD LED lit| (STANDARD)-Charged Voltage is 28.8V.When charging, pressing this button does NOT work.
GEL LED lit| (GEL)-Charged Voltage is 29V.When charging, pressing this button does NOT work.
AGM LED lit| (AGM)-Charged Voltage is 29.6V.When charging, pressing this button does NOT work.
FUNCTION SELECTION BUTTON

Mode| Explanation
NORMAL-10A| Charging 12V Lead-acid & 12V Lithium Ion

Batteries (4-cell LiFePO4)and 24v Lead-acid batteries.

NORMAL-20A| Charging 12V Lead-acid & 12V Lithium Ion

Batteries (4-cell LiFePO4)and 24v Lead-acid batteries.

BOOST-30A| Charging 12V Lead-acid & 12V Lithium Ion

Batteries (4-cell LiFePO4)and 24v Lead-acid batteries.

REPAIR| Charging 12V Lead-acid and 24v Lead-acid batteries.

ENGINE START (press ENGINE START BUTTON to enter)
Provides additional amps for cranking an engine with a weak or run-down battery.

WARNING: Always use in combination with a battery. Must NOT touch or disconnect clamps when ENGINE START mode works, otherwise there may be serious injuries to people or property.

ERROR SITUATIONS

Digital display| Warning LED indicator| Meaning| SOLUTION
E01| WARNING

LED lit

| The connections are reversed.| Change red and black clamps or ring terminals to the correct battery posts
E02| WARNING

LED lit

| Output current reduces to 0 when tem- perature in charger is too high.| DO NOT remove the AC plug immediately. After cooling down, the battery charger will work again.
E03| WARNING

LED lit

| The battery cannot store electric charge (dead battery).| Replace the battery with a new one or try the REPAIR MODE.
Digital display| Warning LED indicator| Meaning| SOLUTION
E04| WARNING
LED lit| No battery connected / battery voltage is lower than 1 volt (dead battery) / red and black clamps are connected together.|

1. Connect the red and black clamps or ring terminals to battery posts
2. Clean the battery posts
3. Replace the battery with a new one immediately
4. Disconnect red and black output terminals

BATT – MISMATCH| WARNING

LED lit

| Charging in 12V Mode for 24V battery| Replace the battery or connect the positive out- put line to the correct connector .

Connecting to the battery

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

OPERATING STEPS

Step no.| Determine whether or not to connect| Step select key
Step1| Ensure battery connection| Digital display: Connected battery voltage
Step2
Confirm battery type| Ensure battery type| Corresponding battery type LED:

Step3
Confirm FUNCTION| Ensure charging mode| Corresponding Function LED: NORMAL-10A-Digital display: “CHARGING” NORMAL-30A-Digital display: “CHARGING” BOOST-50A-Digital display: “CHARGING” 12V-REPAIR-Digital display: “REPAIR-ON”
Confirm ENGINE START| Ensure start charging| Corresponding Function LED:
ENGINE START-Digital display: “START- READY”
Note: When the digital tube is only displayed as OFF, the charger can choose the corresponding mode, in FUNCTION SELECTION.

Engine start function
Your battery charger can be used to jump start your car if the battery is low. Follow all safety instructions and precautions for charging your battery. Wear com-plete eye protection and protective clothing. The procedures are as follows.
WARNING: Using the ENGINE START feature WITHOUT a battery installed in the vehicle will damage the vehicle’s electrical system.

1. With the charger unplugged from the AC outlet, connect the charger to the battery following the instructions given in the CONNECTING TO THE BATTERY section.

2. Plug the charger AC power cord into the AC outlet. With the charger plugged in and connected to the battery and chassis, press the ENGINE START button until the ENGINE START LED is lit.
   NOTE: During extremely cold weather, or if the battery is under 2 volts, charge the battery for 5 minutes before cranking the engine.

3. Crank the engine until it starts or 3 seconds pass. If the engine does not start, wait 3 minutes before cranking again. This allows the charger and battery to cool down.

4. If the engine fails to start, use the BOOST rate to charge for 5 minutes before attempting to crank the engine again.

5. After the engine starts, unplug the AC power cord before disconnecting the battery clamps from the vehicle.

NOTE: If the engine does turn over but never starts, there is not a problem with the starting system; there is a problem somewhere else with the vehicle. STOP cranking the engine until the other problem has been diagnosed and corrected.

During the starting sequence listed above, the charger is set to one of three states:

1. Wait for cranking – While waiting for cranking, the digital display shows START-READY . The charger waits until the engine is actually being cranked before delivering the amps for engine start.
2. Cranking – When cranking is detected, the charger will automatically deliver up to its maximum output as required by the starting system for up to 5 seconds.
3. Cool Down – After cranking, the charger enters a mandatory 240 seconds cool down state (Pressing any button does NOT work). The digital display indicates the remaining cool down time in seconds. It starts at 240 and counts down to 0. After 4 minutes, the digital display will change from displaying the countdown to displaying START-READY.

Voltage tester and charger
When first turned on, the unit operates only as a tester, not as a charger.
If the “TEST” function is used, stop the “FUNCTION” and the corresponding working mode is turned off. Then select the “TEST” button to detect and view the connected battery voltage and Charge level.
NOTE: The battery tester is only designed to test batteries. Testing a device with a rapidly changing voltage could yield unexpected or inaccurate results.

Alternator check

1. With the charger unplugged from the AC outlet, connect the charger to the battery, following the instructions given in previous sections.
2. Plug the charger AC power cord into the AC outlet.
3. Start the vehicle and turn on the vehicle’s headlights. Read the state on the digital display. If you get a reading “0-100%”, the alternator is working properly. If the reading is “LO” or ”HI” , have the charging system checked by a qualified technician.

NOTE: When first turned on, the unit operates only as a tester, not as a charger (The charger must stop charging).

Charging steps
During the charging process, the charger performs the following operations.

AINING LED is out

| Analyzing whether the battery voltage type and the current mode match.
DESULPHATION| CHARGING BATT-12/24| CHARGING LED lit| Removing sulphate and reactivating battery
BULK| CHARGING BATT-12/24| CHARGING LED lit| Providing high current to quick charge
ANALYSIS-2| ANALYSING-2 BATT-12/24| CHARGING LED lit| Analyzing if the battery can absorb current.
ABSORPTION| CHARGING BATT-12/24| CHARGING LED lit| Reducing the current according to the increase in voltage
FLOATING| CHARGING BATT-12/24| CHARGING LED lit| Maintaining the battery voltage to continuously absorb current.
ANALYSIS-3| ANALYSING-3 BATT-12/24| CHARGING LED lit| Analysing if the battery can store electric charge.
MAINTAINING| MAINTAINING BATT-12/24| CHARGED/MAINTAINING LED lit| The battery is charged and the charger is maintaining the battery.

Protecting the environment
Should you find one day that your appliance needs replacement, or if it is of no further use to you, think of the protection of the environment. The retailers will accept used tools and ensure that they are disposed of in an environmentally safe way.
Separate collection of used products and packaging allows materials to be recycled and used again. Re-use of recycled materials helps prevent environmental pollution and reduces the demand for raw materials.
Local regulations may provide for separate collection of electrical products from the household, at municipal waste sites or by the retailer when you purchase a new product.

Lead acid batteries can be recharged many times. At the end of their useful life, discard batteries with due care for our environment: Do not dispose of the battery in fire, as this may result in an explosion.
Lead acid (Pb) batteries are recyclable. They must not be disposed of with household waste.
The battery must be removed and disposed of in accordance with local regulations. Do not short-circuit the battery terminals.
Be aware that the battery is heavy.
If possible, operate the appliance to run the battery down completely. Place the battery in a suitable packaging to ensure that the terminals cannot be short-circuited.
Take the battery to your service agent or a local recycling station. Collected batteries will be recycled or disposed of properly.

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