BatteryMINDer 28252-AA-Series User manual
READ AND SAVE THESE
INSTRUCTIONS
INSTRUCTION MANUAL
BatteryMINDer®Model 28252-AA-Series
(With Desulfation)
28-Volt @ 25 Amp
Avionic Power Supply / Charger -
Desulfator
See Page 12 for Simplified Operating Instructions
Outside of US & Canada,
see page 35 for contact
information
VDC Electronics, Inc.
147D Woodbury Road
Huntington, NY 11743 U.S.A.
www.BatteryMINDers.com
FOR 24-V LEAD-ACID AIRCRAFT BATTERY ONLY.
Contact VDC Electronics for any other resets needed
Rev. I-100511 P/N VDC28252-AA-Series-MNL
1 8
765
432
Gill 7000 Series, Odyssey & Hawker
1 8
765
432
Standard Aviation
1 8
765
432
Concorde Aviation
Dip Switch Settings
Rev. I-100511 Page 2 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
TABLE OF CONTENTS
Cautions and Features 4
Required Safety Instructions 6
Never Charge a Frozen Battery 7
Unit Location 7
DC Connection Precautions 7
A Spark Near the Battery May Cause Battery Explosion 8
Testing a Filler Cap Lead Acid Battery 9
Qualifying Your Battery 9 - 10
Specific Gravity – Capacity 10
Testing a Sealed, AGM, Lead Acid Battery 11
Use a Digital Voltmeter Only 11
Open Circuit No Load Voltage Table 11
Operating Instructions (Simplified) 12
Control and Indicators 13
Battery Connectors (Included & Optional) 14
Temp Sensor & A2GPU 15
Dip Switch Instructions 15
Operating Instructions (Detailed) 16 - 18
Display (LCD) Error Code Table 17
Temperature Sensor ABS-2825 Instructions 19
LED Indicator Functions 20
Effects of Temperature on Battery Life 21
AGM and Flooded Charge & Float Voltages at Various
Temperature Ranges 22
Troubleshooting 23
Detailed Specifications 24
AC Power Input Characteristics 25
Factory Preset Table 26 - 27
Rev. I-100511 Page 3 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
TABLE OF CONTENTS (con’t.)
Power Supply Mode Selected Table 28
Safety and Protection Table 28
Electrical Cable and Physical Parameters 29
Desulfator Wave 30
Top View and Dimensions 31
LED Aviation Display Table 32
Your Notes 33
Repair or Replacement (US & Canada) 34
Repair or Replacement (Outside US & Canada) 35
Warranty 36
Rev. I-100511 Page 4 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
CAUTIONS: READ AND FULLY UNDERSTAND BEFORE
OPERATING. Contact VDC Electronics if uncertain about
any settings or operation.
BatteryMINDer® Charger / Power Supply / Desulfator /
V-balancer
Switching mode with Microprocessor-controlled
Input: 100-240Vac / Output: 24Vdc 25Amp
User’s Manual and Important Safety Information
Model: 28252-AA-Series
FEATURES
Congratulations on purchasing VDC Electronic’s new generation
switching mode Battery Charger - Power Supply - HF Pulse-Type
Desulfator.
This BatteryMINDer®comprises both patented technology
and patent pending technology and incorporates the following
features:
High frequency switching mode = reduced weight, size and higher
(>85%)
Microprocessor controlled - ensures precise voltage, current and time
related functions
Auto universal AC input with Power Factor Correction (PFC) control
- no manual switching = error free match to input power source world-
wide
High efficiency with low input current allow use of AC extension cable
(up to 250’-16AWG)
Aviation specific charging modes - ensures full compliance with major
aviation battery manufacturer’s specifications
V-balancing mode provides individual battery voltage balancing (2 x
12-V battery connected in series) and battery internal cells balancing
(US Patent Pending). Requires VDC Authorized reset and
additional Temp-Voltage Sensor.
Manual button select power supply output for “no battery drain”
when powering avionics-electronics.
Manual button select for high power Desulfation pulse output to
prolong battery life- (USA Patented and Patent pending).
LCD meter- display shows charging status and function settings.
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Rev. I-100511 Page 5 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
Displays charging current, voltage, charging time, charging AH,
output power, battery temperature.
Displays function settings: Power supply, Charge, Maintenance,
Desulfation.
Dip switch resets for different transition current and charging voltage
levels.
Detachable AC input cord receptacle for IEC world wide safety
approved cord sets.
14’ DC output cable with Heavy duty Anderson connector.
AC On / Off power switch Plug ‘n Run simplified operation.
Dip switch setting for equalization mode.
Output short circuit and reverse polarity protection.
Internal over-heat protection.
Severe battery plate sulfation diagnostics.
Battery Charging temperature compensation (At the Battery).
Battery thermal run-away protection (DI/Dt).
Charging time management for each charging stage.
RS232 interface connector provided for data communication with
PC (Future Option Date TBD).
Remote LCD display provided-(Future Option date TBD).
Designed to UL/cUL, CE, FCC, EMC safety certification standards.
800-379-5579 (ET) for instructions on this subject
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Rev. I-100511 Page 6 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
REQUIRED SAFETY INSTRUCTIONS
WARNING
TO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK, OR INJURY
TOPERSON, OBSERVE THE FOLLOWING:
This unit is designed for protected use and should never be exposed
to rain.
Do not attempt to use the unit if it has been dropped or damaged.
Never attempt to charge a damaged battery, frozen battery or non-
rechargeable battery.
Do not use the unit in a closed area or poorly-ventilated area.
Never smoke, use an open flame, or create sparks near a battery
or unit during charging operation as this may cause an explosion /
explosive gas.
Do not operate the unit if the cord or plug is damaged.
Do not disassemble. VDC Electronics MUST be contacted for repair,
replacement or analysis. Keep away from infants, children and pets.
Switch off or remove AC power before connecting or disconnecting
to battery.
Refer to the battery Manufacturer’s specific recommended values
to determine if standard unit settings are correct. Contact VDC
Electronics Tech Support before making any changes
Check Battery Manufacturer’s specific precautions - such as removing
or not removing battery from aircraft before charging.
Always remove battery from aircraft before equalizing or desulfating.
Someone should be within range of your voice or close enough to
come to your aid if working near a lead-acid battery.
Wear protective goggles and turn your face away when connecting or
disconnecting a battery.
If battery acid contacts your skin or clothing, wash immediately with
soap and water. If acid enters your eye, immediately flush the eye
with running cold water for at least 10 minutes and seek medical
attention immediately.
To reduce risk of damaging the Battery, avoid dropping any metal
tools onto the battery.
Never rest the Battery being charged on top of your Battery
Charger.
The Battery Charger / power supply should be kept as far away from
the Battery as the output cables permit.
When using the Temperature Sensor at any location other then on a
battery the ring terminal must be insulated.
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Rev. I-100511 Page 7 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
Always follow battery manufacturer’s strict
instructions for proper care, charging and testing of
battery. Always use their FAA Approved “Instructions
for Continued Airworthiness” (ICA). Questions
relating to the subject should be referred directly
to the battery manufacturer to be certain of current
requirements that may have been added to or changed
since publication of their instructions.
NEVER CHARGE A FROZEN BATTERY OR ONE AT A
TEMPERATURE ABOVE 123° F.
PREPARING TO CHARGE
Always remove ground wire first.
Be sure area around battery is well ventilated while battery is
being charged. Force gas vapors away by using a fan.
Clean battery terminals. Be careful to keep corrosion from
contacting eyes.
Study all battery manufacturer’s specific instructions such as
recommended charge rates.
Determine condition of battery, by referring to instructions
herein, before ever attempting to charge or desulfate any /
all batteries.
Make sure unit is as far away from battery as output cables
permit.
Never place unit directly above battery being charged; gases
from battery will corrode and damage unit.
Do not operate unit in a closed-in area or restrict ventilation
in any way.
Do not set battery on top of unit.
DC CONNECTION PRECAUTIONS
Note: Steps to be done in a well-ventilated area.
a. Connect and disconnect DC output clips from battery only
after removing unit power cord from outlet.
b. Attach clips to battery posts and twist or rock back and forth
several times to make good contact. This tends to keep clips
from slipping off terminals and reduces risk of sparking.
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Rev. I-100511 Page 8 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
UNIT LOCATION
A SPARK NEAR THE BATTERY MAY CAUSE BATTERY
EXPLOSION. TO REDUCE RISK OF A SPARK NEAR
BATTERY:
a. Connect (RED) charger clip to (POS+) post of battery.
b. Position yourself and free end of cable as far away from
battery as possible, then connect NEGATIVE (BLACK) charger
clip to free end of cable.
c. Do not face battery when making final connections.
d. When disconnecting unit, always do so in reverse sequence
of connecting procedure and break first connection while as far
away from battery as practical. Do not attempt to permanently
install unit not specifically designed-approved for permanent
installation, especially in a wet high moisture environment.
Rev. I-100511 Page 9 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
QUALIFYING YOUR BATTERY:
Preliminary Requirements
NOTE: The BatteryMINDer has no electrical output unless it is
connected to a healthy battery. Testing the BatteryMINDer with
a volt or an Amp meter without the unit being connected across a
good battery will result in a false reading. If you experience any
problems, or are not sure of how to properly use or connect your
BatteryMINDer, please e-mail our Tech Support Dept. at:
support line 800-379-5579 x206 (Eastern Time) (USA & Canada
ONLY). Be certain to leave your phone number with the area
code, time zone and the best time to call.
To gain the best result from your unit and to maximize the life and
performance of your batteries we strongly recommend you qualify
(test) your batteries before attempting to either charge-maintain
or desulfate them. Remember, even if you just purchased a
“new” battery it may have been subjected to conditions that
have caused “sulfation” such as an extended period at high
temperature (>=80°F).
NOTE: If your battery is new and you are certain it was
not subject to conditions that could have caused sulfation*,
even before you purchased it, then you can disregard our
recommendations for qualifying / testing your battery, before
using the BatteryMINDer.
* Such as high temperature storage (=/> 80°F) and/or allowed to
self-discharge to 24.8 Volts or lower.
Testing a Filler Cap Lead Acid Battery
1. Carefully remove all filler caps from your battery.
2. Check the water-liquid electrolyte level. If the level is low or
has ever been below top of plates, severe lead plate sulfation
has taken place. Significant recharge/reconditioning time is
needed to restore these plates to a condition where the battery
can be expected to function normally.
3. Refill each cell with distilled water only to the liquid level
indicator found in each cell. Before proceeding further you must
Rev. I-100511 Page 10 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
TABLE 1
Temp. Compensated Hydrometer
- meter or 4 ball type
Full Capacity
Percentage
1.285 100%
1.245 75%
1.210 50%
1.175 25%
1.140
May denote shorted cell or battery
that has been severely discharged
and may not be recoverable
0%
Specific Gravity – Capacity
be thoroughly familiar with the safety and operating instructions.
4. Recharge the battery with the BatteryMINDer to ensure that
it is slowly and completely charged before you determine its
condition. Allow battery to “rest”* overnight or momentarily apply
a small load to remove the “surface” charge which creates false
voltage readings.
* “RESTED” = a battery that has been as fully charged as possible and left
disconnected from charger or any type load overnight. Apply a small load to
remove surface charge effect.
Rev. I-100511 Page 11 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
TESTING A SEALED, AGM
LEAD ACID BATTERY
These batteries have no filler caps or manifold-type covers. Because you
cannot gain access to the interior of your battery you cannot test it with a
hydrometer.
USE A DIGITAL VOLTMETER ONLY:
1. Recharge the battery with the BatteryMINDer to ensure it is as
completely charged as possible, before you determine its condition. Allow
battery to “rest” (see pg. 9) overnight before testing with a digital voltmeter
only.
Failure to test a “rested” (see pg. 9) battery will cause false readings. Be
certain to read and understand all safety related instructions (pages 3 to
7) before proceeding further.
2. Measure battery’s voltage, without any load attached. If the voltage
is less than 25.2 volts (Typically 75% of charge) the battery may be too
heavily sulfated to be fully recoverable. If voltage is 25.2-V or higher
recovery can be expected, given sufficient time.
3. Press desulfation button to start process of dissolving sulfate crystals.
Ensure battery is removed from aircraft prior to desulfation. Continue
in this mode for 72 hours. Stop process by pressing desulfation button.
Test battery voltage and compare to table 2 below. If voltage is not in the
full capacity range restart the desulfation process and continue for an
additional 72 hours before retesting. Continue repeating this procedure
until no further increase in battery voltage is observed.
Note: Do not expect to completely dissolve sulfate in a day. Long
established sulfate will require a longer period to be fully dissolved. Be
patient and you will be rewarded with a “sulfate-free” battery. If not
seriously damaged by sulfate, battery has a very good chance of meeting
80% Cap (Airworthy) Test.
OCV - “Rested”
Voltage
Full Capacity
Percentage
25.8 - 26.2 Volts 100%
25.2 - 25.8 Volts 75%
24.8 - 25.2 Volts 50%
24.4 - 24.8 Volts 25%
24.0 - 24.4 Volts 0%
<22 Volts
= shorted
OCV=Open Circuit
No Load Voltage
TABLE 2
Rev. I-100511 Page 12 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
Simplified Operating Instructions
The BatteryMINDer has no electrical output unless it is connected to a
battery with a minimum of 6-Volts or when in Power Supply Mode.
• Attach Temperature/Voltage Sensor to TempSensor Receptacle A
and Ring Terminal to positive Battery Terminal.
• Attach Battery Connector Attachments (BCA) to DC-CORD Output of
unit.
• Plug AC Power Cord into 95 - 240 Vac electrical outlet. Turn AC
POWER Switch On. Unit will automatically start in Charge Mode
(expect up to a 10 second delay).
• Observe ERROR LED indicator. If lit RED, and LCD displays error
code (E01), shut power off and reverse battery connector attachments
on battery.
• Always power-off unit before disconnecting from battery(s).
NOTES:
If ambient temperatures are ≥80°F or ≤60°F, you MUST ALWAYS use
Temperature/Voltage Sensor (on positive terminal of battery) to prevent
improper charging.
Unit automatically starts in charging mode.
Hold Power Supply button 5 seconds to operate as a power supply.
Press Desulfation button to operate desulfation mode. Ensure battery is
removed from aircraft prior to desulfation.
To Change the Mode on the Batteryminder 28252-AA-Series:
After the unit is powered on, if you do not press a Mode Button within 30
seconds, you will need to press the Mode Button TWICE.
If the unit has not had a Mode changed within 30 seconds, you will need
to press the Mode Button TWICE
In each instance, you only need to press the Mode Button ONCE if done
within 30 seconds after the previous operation.
See additional information on this function on Page 19.
IF IN DOUBT REGARDING ANY OF THE ABOVE, REFER TO FULL
INSTRUCTIONS
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Rev. I-100511 Page 13 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
PWR SUPPLY CHARGE DESULFATION
NORMAL AVIATION V-BALANCING
VA
°C%
KW
AH
FLOAT -
MAINTENANCE
(GREEN)
ABSORPTION
CHARGING
(BLUE)
BULK
CHARGING
(YELLOW)
POWER
(GREEN)
ERROR
(RED)
DESULFATION
(BLUE)
CURRENT OUTPUT
VOLT OUTPUT
TIME ELAPSED
DESULFATION
(Press to Start)
DESULFATION
(Press to Start)
AVIATION
Rev. I-100511 Page 14 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
A2ELCON
ELCON Type
Connector
(optional)
ABS-2825
Temperature/Voltage
Sensor
(At-the-Battery
Sensor)
(included)
BC 2410
Battery Clips
(included)
A2RT
11/32” Ring Terminals
(optional)
Included & Optional
Battery Connectors
A2GPU-1
Anderson SB-50 to
Cessna style GPU Plug (optional)
*Must be used on aircraft where a relay needs to be activated in order to connect the
battery and GPU.
Rev. I-100511 Page 15 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
When using the Temperature Sensor at any location (other then
on a battery) the ring terminal must be insulated, heat shrink
tubing is recommended. If using the A2GPU-1 or A2GPU-
2 and are unable to place the Temperature Sensor on a battery
terminal, it may be inserted into the unused cavity of the A2GPU
plug and secured with cable clamp.
A2GPU-1 Plug Instructions
Connect A2GPU
Turn on 28252
Hold down “Power Supply/Charge” for 5 seconds and release
Quickly press “Power Supply/Charge” twice to start charging cycle
Dip Switch Instructions
Disconnect unit from Battery and AC power.
Remove Dip Switch access panel using provided Triangle Bit.
Set switches for desired battery brand setting as shown.
Replace access panel.
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1 8
765
432
Gill 7000 Series, Odyssey & Hawker
1 8
765
432
Standard Aviation
1 8
765
432
Concorde Aviation
Dip Switch Settings
Important!
If you require changes to dip switch factory settings, be aware
such changes may negatively affect other battery types if not
reset according to our directions. This may cause harmful levels
of overcharge leading to “out-gassing” of the electrolyte.
If battery is in an enclosed-confined area, harmful and corrosive
hydrogen gas will be generated. In addition, dip switches are not
built to be changed frequently and should be very carefully “switched
only when needed”. Any damage occurring is NOT covered by our
warranty or guarantee.
Questions? Call our Tech Support, at (800) 379-5579 ext 206 (ET).
Triangle Bit
Rev. I-100511 Page 16 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
OPERATING INSTRUCTIONS
1. Pre-Charge Check
(a) Check the Battery Electrolyte level (Non-sealed Batteries).
If necessary, remove the vent caps and add distilled water so
levels are halfway between the upper and lower fill lines.
(b) Location – Ensure the Battery is in a well ventilated area.
Keep the Unit as far away from Battery as the cables permit.
Never place the unit directly above the battery being charged as
gasses from the Battery will corrode and damage the unit. Also,
keep the unit away from high corrosion / wet and moist areas.
2. Connecting BatteryMINDer to your Battery
(Temp/Volt Sensor A) is used to detect the battery voltage and
temperature and to avoid undercharging and overcharging.
Rev. I-100511 Page 17 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
3. Aviation charge mode connection
(1). Connect to 24V Aviation battery.
(2). You MUST connect Temperature/Voltage Sensor ABS-2825
(no substitute) to the Positive (+) battery terminal.
(3). Connect the output DC cable RED clips to the battery Positive
polarity (+), the BLACK clips to the battery Negative polarity (-).
4. Connect the unit to AC input power
Turn on the AC power switch.
Note: If the Error Indicator LED is ON and LCD displays E01,
please check your connections as it’s likely that the Positive and
Negative Leads are reversed. Refer to the following Error code
table and Troubleshooting Page for further information.
Display (LCD) Error code table:
Output lead(s) shorted or battery reverse
connected
E01
Soft-Start timed out E02
Bulk charging timed out E03
Battery severely sulfated or damaged E04
Fan faulty E05
Unit shuts down by internal over-
temperature protection
E06
Battery Temp. >131°F/55°C; Resumes
charge at <113°F/45°C
E07
NOTE:
• Unit automatically starts in charging mode.
• Hold Power Supply button 5 seconds to operate
as a power supply.
• Error codes are for Charging Mode only unless
otherwise .
Rev. I-100511 Page 18 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
5. The Charging Process
The Charging LED’s will indicate the Charging Stages. LCD will display
the values and functional setting.
The charging stages are as follows:
Soft Start: Charges the battery using half the maximum current
until the battery voltage is over 22V (indicated by YELLOW Bulk
LED FLASHING). Soft Start occurs if the initial voltage is less than
22V (due to severe-deep discharge)
Bulk Charge: Charges using a constant maximum current until
the battery rises to the Absorption level = 85% full (indicated by the
YELLOW Bulk LED ON)
Absorption: This stage charges the battery using a constant
voltage providing that the Battery Voltage is over 85% (indicated by
the BLUE Absorption LED ON) .
Equalization: Mode is only activated by calling VDC Electronics
Technical Support at (800) 379-5579 x206. Do not use unless
battery is removed from aircraft. Regular use of this mode may
damage battery. Mode ensures full charge to ageing-marginal
batteries and improves performance on capacity tests.
Float / Full: Battery is in Float stage and fully charged, it will be
maintained at a safe voltage and ready for use. (The GREEN Float
LED ON - indicates the battery is fully charged).
Desulfation: Mode is activated by pressing “Desulfation” button.
Do not use unless battery is removed from aircraft. See Page
11.
6. Disconnecting BatteryMINDer from Battery.
(a) If the Battery is not in end-use installation:
Switch OFF AC power switch, remove the AC Power Socket from
the outlet.
Remove the BLACK lead and then the RED lead, remove the Sensor
A.
Check electrolyte levels if possible (may need topping up with distilled
water after charging)
(b) If Battery is in end-use installation:
Switch OFF AC power switch, remove the AC Power Socket
from the outlet.
Remove leads from battery. Remove Sensor A.
Check electrolyte levels if possible (may need topping up with
distilled water after charging).
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Rev. I-100511 Page 19 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
To Change the Mode on the BatteryMINDer 28252-AA-Series:
• After the unit is powered on, if you do not press a Mode Button
within 30 seconds, you will need to press the Mode Button
TWICE
• If the unit has not had a Mode changed within 30 seconds, you will
need to press the Mode Button TWICE
In each instance, you only need to press the Mode Button ONCE if
done within 30 seconds after the previous operation
This is a safety feature to help prevent inadvertent operations, similar to
an ATM asking you to confirm a transaction. If a Mode Button has not
been pressed within 30 seconds, the button will be locked in the previous
setting. Once you press the button again, the unit will be unlocked. This
“double-press” feature goes into effect after approximately 30 seconds of
not pressing any buttons.
INSTRUCTIONS:
TEMPERATURE SENSOR Type:
ABS-2825 (At-the-Battery Sensor)
MANDATORY WHEN UNIT IS USED WITH Sealed or Maintenance-
type Aviation batteries, regardless of construction (AGM, Free-
Electrolyte = filler caps)
Do NOT modify by extending or shortening the Sensor cord.
Attaching the temperature sensor to battery:
Connect it to the Positive (+) terminal post (clamp or screw) of the
battery.
ABS-2825
Unit is ON
Press Mode
Button TWICE
Press Mode
Button ONCE
Has Mode been
changed within 30
seconds?
NO
YES
Rev. I-100511 Page 20 P/N VDC28252-AA-Series-MNL
BatteryMINDer® Model 28252-AA-Series
LED INDICATOR FUNCTIONS
AC power display LED
AC Power LED On AC power ON
Error LED
RED Error LED ON or Flashing See Troubleshooting section
Desulfation LED
BLUE Desulfation LED Flashing Unit is in Desulfation mode
Charging Status indicated LED
Bulk LED YELLOW Flashing Indicates the battery is at low level and in soft start stage
Bulk LED YELLOW On Indicates the unit is at a maximum charging rate
Absorption LED BLUE On Indicates Battery is over 85% charged
Absorption LED BLUE Flashing Indicates automatic equalization stage is running
Float LED GREEN On Indicates battery is fully charged
Table of contents
