Clarke BC520P Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC01/18 REV 5
STARTER/CHARGER
MODEL NO: BC520P
PART NO: 6261082

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INTRODUCTION
Thank you for purchasing this CLARKE Starter/ Charger.
Please read this manual thoroughly, before attempting to operate, 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 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.
If disposing of this product or any damaged components, do not dispose of
with general waste. This product contains valuable raw materials. Metal
products should be taken to your local civic amenity site for recycling of metal
products.

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SPECIFICATIONS
Model Number BC520P
Dimensions (D x W x H) 320 x 490 x 730
Weight 24 kg
Open circuit protection 200A Lamellar Fuse
IP Rating IP20
Operating Temperature Range 0 to 40°C
Input Voltage @50Hz 230 V AC
Duty Cycle (Starting) 10 sec On / 30 sec Off
Max Rated Input current
Starting @ 12V/24V 33A
Charging @ 12V/24V 33A
Max Output Current
Starting @12V/24V 50A
Charging @12V/24V 50A

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SAFETY PRECAUTIONS
PLEASE READ BEFORE USING THIS UNIT
1. Battery acid is very corrosive. If spilled, clean the area immediately and
wash with water. If battery acid comes into contact with the eyes, get
medical help immediately.
2. Do not expose this charger/starter to rain.
3. Never touch the negative and positive leads on this unit together while the
unit is switched on.
4. Never attempt any electrical or mechanical repair, other than
replacement of fuses. If you have a problem with your machine contact
your local stockist for service information.
5. Before charging, make sure that the battery terminals are clean, and that
the cells are filled to the correct level by adding distilled water where
necessary.
6. This appliance is not intended for use by persons with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge,
unless they have been given supervision or instruction concerning use of
the charger/starter by a person responsible for their safety. Keep children
well away from the charger/starter.
7. After charging, secure the vehicle battery leads to the correct terminals
which should be clean, and lightly smeared with petroleum jelly to prevent
corrosion. Finally, re-check the battery electrolyte level.
8. Do not use this charger/starter unless you are aware of vehicle electrical
systems, and battery charging techniques.
WARNING: HIGHLY INFLAMMABLE HYDROGEN GAS IS RELEASED IN THE
PROCESS OF BATTERY CHARGING. ALWAYS REMEMBER TO SWITCH OFF
THE CHARGER/STARTER FIRST TO AVOID SPARKING.
WARNING: CERTAIN TYPES OF SEALED OR MAINTENANCE-FREE BATTERIES
NEED EXTRA CARE WHEN CHARGING. PLEASE CONSULT THE BATTERY
MANUFACTURERS INSTRUCTIONS BEFORE USING THIS CHARGER/STARTER
WARNING: TOXIC FUMES MAY BE RELEASED DURING BATTERY
CHARGING. ONLY USE THIS CHARGER/STARTER IN A WELL VENTILATED
AREA.

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9. Always consult the vehicle manufacturers instructions for disconnecting /
charging the vehicle battery.
ELECTRICAL CONNECTIONS
Connect the three core mains cable to a suitable industrial supply isolator, or
heavy duty plug meeting the requirements of BS EN 60309. This charger must
be connected to a supply having a rated capacity of greater than 16 Amps.
Connect the three core mains lead to a suitable industrial supply isolator, or
heavy duty plug. This charger must be connected to a supply having a rated
capacity of greater than 13 Amps. A normal 13 Amp (BS1363) plug must NOT
be used.
NOTE: The maximum input current for this unit is 33 amps.
WARNING: THIS APPLIANCE MUST BE EARTHED.
IMPORTANT: The wires in this mains lead are coloured in accordance with
the following code:
GREEN AND YELLOW - EARTH E )
BLUE - NEUTRAL (N)
BROWN - LIVE (L)
As the colours of the flexible cord of this appliance may not correspond with
the coloured markings identifying terminals in your plug, proceed as follows:
• Connect GREEN AND YELLOW coloured cord to plug terminal marked
letter “E” or Earth Symbol or coloured or Green and Yellow.
• Connect BROWN cord to plug terminal marked letter ‘L’ or coloured
Red.
• Connect BLUE cord to plug terminal marked letter “N’ or coloured Black.
CAUTION: SOME ELECTRONIC EQUIPMENT CAN BE DAMAGED BY BOOST
CHARGING OR USE OF START FACILITY. CHECK YOUR VEHICLE
HANDBOOK BEFORE USING YOUR STARTER/CHARGER. IF IN DOUBT
CONSULT THE VEHICLE MANUFACTURER.
WARNING: READ THE ELECTRICAL SAFETY INSTRUCTIONS THOROUGHLY.
WARNING: A 13 AMP (BS1363) PLUG IS NOT SUITABLE.
WARNING: THIS APPLIANCE MUST BE EARTHED.

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OVERVIEW
The illustration above identifies the various components and controls.
The charger is provided with a pair of leads complete with clamps for
connection to a battery. It is provided with appropriate outlet connections -
12V and 24V, as shown above. A Boost Start/ Charge Switch allows for
switching between functions.
A MAX/MIN switch allows for charging at two different rates and the unit is
provided with a two position Power Setting switch, which allows for even
greater control of charge rates as displayed on the Ammeter.
The main fuse is mounted on the front panel,as shown.
A Thermal Overload indicator fitted, see below. Please read thermal overload
notes on page 9.
A ON/OFF Switch G RED positive lead with clamp
B Boost Start/Charger Switch H BLACK negative Lead with clamp
C MAX/MIN Switch J 12V Output
D Ammeter K 24V Output
E Fuse Cover L Power Setting Switch
F Mains Lead with Plug M Thermal Overload Indicator

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ASSEMBLY
The handle and wheels need to be assembled before use.
Locate the handle at the back of the upper panel and secure with the four
self tapping screws provided.
Pass the axle into its housings at the bottom of the unit, then slide a wheel on
to each end. Retain in position by tapping on the retaining star washers
supplied, ensuring the tines of the washers point outwards.
PROCEDURE FOR NORMAL CHARGING
NOTE: Before charging or boosting, ensure that, where applicable, the cells
are filled with electrolyte to the correct level, by adding distilled water.
1. When charging a car battery in situ, we recommend that the non earthed
lead on the battery is disconnected prior to charging (On most vehicles,
this would be the RED, Positive lead - but check the vehicle handbook if
you are unsure).
This precaution is necessary as it is possible that damage could occur to any
electronically controlled system fitted to the vehicle, such as engine
management system, anti-theft alarm, alternator etc.
2. Check that the ON/OFF switch on the unit is in the OFF position.
3. Connect the RED, positive lead to either the 12V or 24V output on the
charger, as appropriate.
4. Connect the appropriate clamp to the unearthed battery terminal. On
most modern cars this is the RED, positive clamp connected to the RED,
positive terminal of the battery, but check your handbook if unsure. Then
connect the other clamp to the chassis (or a suitable engine bolt) away
from the battery and fuel line.
5. Remove the battery filler caps, where applicable, during charging, in order
to prevent the build up of dangerous gases within the battery.
6. Switch the CHARGE/BOOST START switch to the CHARGE position.
NOTE: Set the Power switch to position ‘1’.
7. Set the MIN (minimum charge) MAX (maximum charge) switch to the MIN
position. This is suitable for charging most normal car batteries (having an
ampere hour rating of approximately 40 A.H.).
8. Switch the ON/OFF switch to ON, and charging will commence.
Adjustments may be made to the charging rate by switching to MAX, and

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on larger models by also switching the Power Setting switch to the 1 or 2
position as appropriate. i.e. 4 charging rates are possible - MIN-1, MIN-2,
MAX-1 and MAX-2.
9. Keep the battery on charge until the Ammeter gauge reads zero (or 0-2
amps) or has stopped moving down. Then switch off at the machine.
NOTES ON CHARGING PROCEDURE
• A complete charge is best done slowly in order to protect your battery,
so we recommend the MIN setting as described above.
• A complete charge may take up to 10 hours.
• If a low amperage reading (2 amps or less) is seen on the gauge at
either the MIN or MAX setting. This may indicate that the battery is either
(a) already fully charged or (b) at the end of its useful life and in need of
replacement.
• Do not charge the battery for longer than is necessary.
WARNING: NEVER ATTEMPT TO RE-CHARGE NON-RECHARGEABLE BATTERIES
WARNING: IF THE FIXED POSITIVE LEAD AND THE FIXED NEGATIVE LEAD
ARE CONNECTED TO THE WRONG TERMINALS, THEN A FLASH WILL OCCUR
WHEN THE 2ND. CLAMP IS ATTACHED. DAMAGE TO THE CHARGING UNIT
AND THE BATTERY WILL BE AVOIDED AS YOUR START N CHARGE IS FITTED
WITH A POLARITY PROTECTION FEATURE. IT WILL HOWEVER BE NECESSARY
TO REPLACE THE INTERNAL FUSE. REMOVE THE BLACK PLASTIC COVER ON
THE FRONT PANEL (MARKED FUSE) AND REPLACE THE BURNT FUSE.

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PROCEDURE FOR ENGINE STARTING
NOTE: We recommend that before attempting to boost start, you charge the
battery for 10-15 minutes. This will improve the chance of a first time
start, particularly with bigger engines. When the battery is completely
flat, you must charge the battery for 10-15 minutes before attempting
to start, otherwise you may cause damage to the vehicle electronic
systems.
1. Check that the ON/OFF switch is in the OFF position.
2. Connect the cables as for normal charging - see para c and d, page 6.
3. Check that the CHARGE/BOOST START switch is in the CHARGE position.
4. Switch the ON/OFF switch to the ON position.
5. Turn the key in the vehicle’s ignition to ‘START’, and get an assistant to
switch the CHARGE/BOOST START switch to BOOST START position.
IMPORTANT: If the engine fails to start almost immediately, you MUST return
the CHARGE/BOOST START switch to CHARGE position after a maximum
period according to the BOOST START DUTY CYCLE - i.e. 10 secs ON followed
by 30 secs before retrying.
IMPORTANT: Failure to do this could damage some vehicle electronic
equipment, the battery, and possibly the Start ‘N’ Charge unit which may
invalidate your guarantee.
THERMAL OVERLOAD
This Booster/Charger is provided with a Thermal Overload cut-out.
Should the Duty Cycle be exceeded or should the unit overheat for any
reason, the thermal overload will intervene, shutting down the charger.
If this occurs, wait for 15 - 20 minutes, depending upon ambient temperature,
before attempting to re-use.
An amber indicator lamp is found on the top panel, which will illuminate when
the overload has intervened. It will extinguish once it has reset and the unit is
ready for use once again.

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MAINTANENCE
This charger requires minimal maintenance. As with any appliance or tool, a
few common sense rules will prolong the life of the battery charger.
1. Clean the case and leads with a moist cloth.
2. Clean corrosion from the clamps with a solution of water and baking soda.
3. Examine the leads at regular intervals for damage and have them
replaced if necessary
STORAGE
1. Wind up the connecting leads and power cable when not in use and store
in the compartment when not being used.
2. Store in a clean, dry area.
WARNING: ALWAYS BE SURE THE CHARGER IS UNPLUGGED FROM THE
MAINS AND ANY BATTERY BEFORE PERFORMING ANY MAINTENANCE OR
CLEANING.
WARNING: ALL OTHER SERVICING/REPAIRS SHOULD BE DONE BY
QUALIFIED SERVICE PERSONNEL ONLY.

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DECLARATION OF CONFORMITY

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PARTS LIST
No Description No Description
1 Cover Panel 14 Front panel
2 Handle 15 Axle L=415
3 Front Frame 16 Lower Panel
4 Ammeter 50A/Start 17 Wheel
5 Female Dinse Plug 18 Transformer Starter
6 Clamps 120A 19 n/a
7 Black Charge Cable 20 Front Control Panel
8 Fuse 200A 21 Rectifier
9 Small Fuse Cover 22 Thermostat
10 PVC Input cable 23 High/Low Power Switch
11 Cable Clamp 24 On/OFF Switch
12 Dinse Plug 25 Orange Pilot Lamp
13 Red Charge Cable

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PARTS DIAGRAM

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CIRCUIT DIAGRAM

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NOTES
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