6267010 CLARKE | Alldatasheet
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OPERATION & MAINTENANCE INSTRUCTIONS ORIGINAL INSTRUCTIONS DL1122 - ISS 3 INTELLIGENT BATTERY CHARGER/MAINTAINER MODEL NO: IBC15 PART NO: 6267010
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com INTRODUCTION Thank you for purchasing this CLARKE Battery Charger. Please read this manual thoroughly, before attempting to operate this product 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 effect your statutory rights. ENVIRONMENTAL RECYCLING POLICY Through 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 recognised disposal facility.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com SAFETY PRECAUTIONS PLEASE READ BEFORE USING THIS UNIT 1. Battery acid is highly corrosive. If spillage occurs, wipe off immediately and wash copiously with water. Particularly avoid contact with the eyes, but if this occurs, you must seek medical advice. 2. Before charging ensure the battery terminals are clean and that the cells are filled with electrolyte to the correct level by adding distilled water where necessary. 3. This product is not intended for us e by persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge. 4. Children must not play with the charger. 5. Do not expose this charger to rain. 6. Never touch the negative an d positive leads together. 7. Never attempt any repairs yourself. If you have a problem with your charger contact your local Clarke dealer or contact Service@Clarkeinternational.com 8. When charging is completed, ensure that the vehicle battery leads are secured to the proper terminals which should be clean, and lightly smeared with petroleum jelly to prevent corrosion. Finally, re-check the electrolyte level. WARNING: ALWAYS SWITCH OFF THE CHARGER WHEN CONNECTING OR DISCONNECTING LEADS TO AVOID SPARKING AS HIGHLY INFLAMMABLE HYDROGEN GAS IS RELEASED IN THE PROCESS OF BATTERY CHARGING WARNING: CERTAIN TYPES OF SEALED OR MAINTENANCE-FREE BATTERIES NEED EXTRA CARE WHEN CHARGING. PLEASE CONSULT THE BATTERY MANUFACTURERS INSTRUCTIONS BEFORE USING THIS UNIT. WARNING: SINCE TOXIC FUMES MAY BE RELEASED DURING BATTERY CHARGING, ONLY USE THIS UNIT IN A WELL VENTILATED AREA.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com ELECTRICAL CONNECTIONS 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 a mains socket could cause an electrical hazard. If the colours 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.
- T h e Blue wire must be connected to the terminal marked N or coloured Black. T h e Brown wire must be connected to the terminal marked L or coloured Red. We strongly recommend that this machine is connected to the mains 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. WARNING! READ THESE ELECTRICAL SAFETY INSTRUCTIONS THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS SUPPLY. WARNING! THE WIRES IN THE POWER CABLE OF THIS PRODUCT ARE COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE: Blue = Neutral Brown = Live Plug must be BS1363/A approved. Always fit a 5 Amp fuse. Ensure that the outer sheath of the cable is firmly held by the clamp Neutral (Blue) Live (Brown)
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com OVERVIEW The IBC15 is designed for charging all types of 12V lead-acid batteries including WET (flooded), GEL, MF (Maintenance Free), EFB (Enhanced flooded battery), and AGM (Absorbed Glass Mat) batteries. The in-built microprocessor provides fast and safe charging using its safety features to protect against sparking, reversed polarity, short circuit, overcurrent, overcharge and over heating. The auto-memory feature means that after powering on, the visual display will show the last selected mode (except BOOST mode).
1 Power LED 8 Digital Display
2 Error LED Wrong Connection 9 Power On/Off Button
3 Boost LED 10 Boost Selector
4 Charge LED 11 NEGATIVE (BLACK) lead
5 Battery Full LED 12 Cigarette Lighter Socket
6 Charging Voltage Selector 13 POSITIVE (RED) lead
7 Charging Current Selector
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com Once connected, the charger will begin charging after approx 5 seconds. The yellow CHARGE LED will be on during charging and this will be replaced by the FULL LED when charging is completed. If the charger remains connected, it will automatically switch from charging to maintenance status to maintain the batteries during periods of storage. Pressing the VOLTAGE button will display the current voltage level of the battery. PREPARATION 1. If may be necessary to remove the battery from a vehicle to charge it. Always remove the grounded term inal from the battery first. Ensure all accessories in the vehicle are switched off to prevent sparking. 2. Clean the battery terminals. Be carefu l to keep any corrosive matter from coming in contact with eyes. 3. If the battery can be topped up, ad d distilled water to each cell until the battery acid reaches the level specified by the battery manufacturer. This helps remove unwanted gas from the cell. Do not overfill. For a battery without cell caps, follow the manufacturer's instructions. 4. Study all the battery manufacturer's specified precautions: for example, removing or not removing cell caps while being charged, and recommended rates of charge. 5. Refer to the vehicle manual to find the voltage of the battery and make sure that the output is set to the correct voltage. 6. If the charger has adjustable charge ra te, charge the battery initially at the lowest rate. CHARGER LOCATION 1. Place the charger as far away from the battery as possible. 2. Do not position the charger abov e the battery during the charging procedure. Gases from the battery will corrode and damage the charger. 3. Do not let battery acid drip on the charger when reading a hydrometer for specific gravity or when you fill the battery. 4. Do not use the charger in an en closed space with reduced airflow.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com CONNECTING TO A BATTERY WHEN THE BATTERY IS INSTALLED IN THE VEHICLE 1. Route the leads carefully to reduce the risk of damage by the bonnet, door, or engine parts. 2. Keep away from the fan blades, belt s, pulleys, and other parts that can cause injury. 3. Check the polarity of the battery posts. 4. Refer to the vehicle manual to find out if the vehicle has a 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) lead to the vehicle chassis, engine block or suitable earthing point away from the battery. Do not connect the lead to the carburettor, (if fitted) fuel lines, or sheet metal body parts. For positive earth vehicles, (ver y rare today) connect the NEGATIVE (BLACK) lead from the battery charger to the NEGATIVE terminal on the battery. Connect the POSITIVE (RED) lead to the vehicle chassis or engine block away from the battery. Do not connect the lead to the carburettor (if used) fuel lines, or sheet metal body parts. NOTE: If the battery clamps are reversed, the ERROR LED will be on. 5. When charging is completed, switch off the charger and disconnect the plug from the power supply. Remove the lead from the vehicle chassis, and then remove the leads from the battery. WHEN THE BATTERY HAS BEEN 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. Reach over and connect the NEGATIVE (BLACK) lead at arms length to the NEGATIVE post on the battery. WARNING: A SPARK NEAR THE BATTERY MA Y CAUSE BATTERY EXPLOSION. TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY: Turn off the charger before you connect/disconnect the DC output clips. Do not let the clamps touch each other. Attach the clamps to the battery terminals and make sure that you get a good connection.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 4. When charging is completed, switch off the charger and disconnect the plug from the power supply. When you disconnect the charger from the battery always do it in the opposite order to the sequence of connection. NOTE: A marine (boat) battery must be removed and charged on shore. To charge it on board requires equipment specially designed for marine use. THE CHARGING PROCESS This charger has have a sophisticated computer system that performs a 7 - stage automatic charging cycle as follows: STEP 1: DIAGNOSIS Checks that the battery has connected with the charger and also checks the battery voltage. STEP 2: DESULPHATION If battery voltage is too low, this step automatically generates a pulsing current to remove sulphate. STEP 3: ANALYSE Checks if the battery voltage reaches the threshold after desulphation and charging begins if the battery voltage is OK. STEP 4: SOFT START Charges with constant current. STEP 5: BULK Charges with constant maximum current until battery voltage has reached the threshold. STEP6: ABSORPTION A gradually declining current charge for maximum battery voltage. STEP 7: ANALYSE Testing if the battery can hold a charge STEP 8: MAINTENANCE Continuously monitors the battery and charging current and will intelligently adapt to the variable battery voltage. After the full charging cycle, use this battery to start the vehicle’s engine. If the engine does not start (excluding a defect with the vehicle its-self), it indicates this battery has declined storage capacity and needs to be replaced.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com CHARGING SETTINGS The IBC15 has the following selectable charging settings: BOOST and SUPPLY modes can be selected according to the following: USING THE 12V BOOST FUNCTION To operate BOOST, the charger must be connected to a 12V lead-acid battery with the battery clamps connected. For optimal results, allow boost to MODE DISPLAY POWER LIGHT BOOST LIGHT EXPLANATION power. If you want charging to pause, press the ON/OFF button & the unit will enter standby mode. 12V/2A 02A On Press the CURRENT button repeatedly until 2A is shown. (This mode is recommended for 2-60 AH batteries.) 12V/6A 06A On Press the CURRENT button repeatedly until 6A is shown. (This mode is recommended for 14- 230 AH batteries.) 12V/10A 10A On Press the CURRENT button repeatedly until 10A is shown. (This mode is recommended for 25- 300 AH batteries.) 12V/15A 15A On Press the CURRENT button repeatedly until 15A is shown. (This mode is recommended for 30- 400 AH batteries.) BOOST FAS On On When connected to the battery, unit can enter BOOST mode by pressing the BOOST button. It takes 5 minutes (300 seconds) to charge. SUPPLY P12 On When the charger is not connected to a battery it will automatically enter SUPPLY mode. To switch supply to charge, connect the charger to a battery and press the ON/OFF button twice
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com complete its 5-minute charge. After 300 seconds of boost the display will show “000” and it should be possible to start the vehicle (whether FULL light is illuminated or not). If unsuccessful when starting your vehicle, let the battery rest for 15 minutes and try boost again. Most vehicles will start with one boost. Do not use the boost function more than twice within a 24-hour period. If 2 boosts cannot successfully start your vehicle, have your battery replaced or evaluated by a local battery supplier. USING THE 13.6V SUPPLY After powering up, the charger is in the Power Supply mode by default when not connected to a battery. The 13.6V Supply mode provides a current of 7A (constant voltage and constant current). When used as a power supply, the charger can also be used to retain a vehicles on-board computer settings during battery repair or replacement. Both sparking and reverse polarity protection function normally in this mode. If positive and negative clamps are touched together the charger will not create sparks. OPERATION TO CHARGE THE BATTERY 1. Connect the charger to th e battery (see page 7). 2. Connect the charger to the mains supply. If the charger senses an incorrectly connected battery, then the ERROR LED will come on. The fault needs to be identified before you continue connecting the battery correctly. Reasons for the ERROR light are; Battery voltage excessively low R e v e r s e p o l a r i t y O v e r l o a d Temperature in the battery is too hi gh. If the buzzer sounds it indicates that the temperature inside the charger is too high. Once the temperature reduces the charger will automatically start charging again. 3. Use the CURRENT selector button to set the charging current and the value will be shown on the display. 4. Push the on/off button to start the charging process. The Charging LED will come on.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com CHARGING TIME DURATION Different battery capacity, residual voltage and charging current will all affect charging time. The following table is for guidance in the case of a fully discharged battery. When charging is complete the green “FULL” LED will come on Switch off the charger and disconnect the plug from the power socket. Remove the leads from the battery as described on page 8 and store them onboard the charger with the mains lead. CARE & MAINTANENCE This battery charger requires minimal maintenance. As with any appliance or tool, a few common sense rules will prolong its working life. 1. Wind up the leads when not in use. Examine the leads at regular intervals for damage and have them replaced if necessary. 2. Clean the case and leads if necess ary with a moist cloth and clean any corrosion from the clamps with a solution of water and baking soda. BATTERY SIZE APPROXIMATE TIME TO CHARGE IN HOURS /Ah 2A 6A 10A 15A 30 15 5 3 2 40 20 6.7 4 2.7 50 25 8.3 5 3.4 60 30 10 6 4 120 ----- 20 12 8 1 8 0 - - - - - 3 01 81 2 WARNING: ALWA YS BE SURE THE CHARGER IS UNPLUGGED BEFORE PERFORMING ANY MAINTENANCE OR CLEANING. ANY REPAIRS MUST BE DONE BY A QUALIFIED SERVICE TECHNICIAN.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com TROUBLESHOOTING ERROR CODES The following Error Codes may be displayed. 01 - Battery is not connected 02 - Battery voltage is too low 03 - Reverse polarity 04 - Overload Problem Cause Solution ERROR light comes on The battery voltage is to low to accept a charge. Have the battery tested by a qualified technician. Replace the bad battery if necessary.The battery voltage drops below 12V soon after being fully charged. Couldn't reach fully charged status in time limit. Battery does not charge Lack of AC input power. Make sure that the charger is plugged into AC outlet and the POWER LED is lit. 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 too low. Ensure enough charging time was allowed to charge battery. 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 charger will increase as the battery warms up. Never attempt to charge a frozen battery.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com PARTS DIAGRAM
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com PARTS LIST SPECIFICATIONS NO DESCRIPTION NO DESCRIPTION
1 Front Panel 10 Power Cable
2 Front Cover 11 Extension Cable
4 Function Panel 13 Fan Assembly
5 Locking Buckle 14 Partition Assembly
6 Circuit Board Control Module 15 Machine Screw
7 Screws 16 Cigarette Lighter Socket
8 Main Circuit Board 17 Back Cover
9 Clip 18 Screw
Input voltage / Current 230V, 50Hz, 2.5A Battery charging voltages: 12V Power 320W Max Output current 2/6/10/15 A Charging steps 8 steps, (smart charger) Charging Battery Capacity 2 - 400 AH IP Rating IP20 Operating Temperature Range -10 to 40°C Dimensions (D x W x H) 147 x 218 x 212 mm Supply cable length 1.6 m Charging lead length (Black and Red) 1.1 m Weight 1.5 kg
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com DECLARATION OF CONFORMITY