Clarke IBC40 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC1020 - ISS 2
INTELLIGENT BATTERY
CHARGER/MAINTAINER
MODEL NO: IBC40
PART NO: 6267014

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INTRODUCTION
Thank you for purchasing this CLARKE Battery Charger / Maintainer.
Before use, read this manual thoroughly and follow all instructions given.
1. The IBC40 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) batteries.
2. A built-in intelligent microprocessor makes charging faster, easier and safer.
3. This charger has safety features, including protection for reverse polarity,
short circuit, overheat and overcharge.
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.

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SAFETY INSTRUCTIONS
SAFETY PRECAUTIONS FOR WORKING IN THE VICINITY OF A BATTERY
1. If battery electrolyte contacts skin or clothing, wash immediately with soap
and water. If electrolyte enters your eye, immediately flood the eye with
running clean cold water for at least 15 minutes and get medical attention
immediately.
2. Clean the battery terminals before they are connected to the charger. Be
careful to keep corrosion from coming into contact with your eyes.
3. Batteries generate explosive gases during normal operation. Use in a well-
ventilated area.
4. Consider having someone close enough or within the range of your voice
to come to your aid when you work near a battery.
5. DO NOT smoke, strike a match, or cause a spark in vicinity of a battery or
engine. Avoid explosive gas, flames and sparks.
6. Remove all rings, bracelets, necklaces, and watches while working with a
vehicle battery. These items may produce a short-circuit that could cause
severe burns.
7. 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.
8. Study all battery manufacturer's specific precautions such as removing or
not removing cell caps while charging and recommended rates of
charge.
9. When it is necessary to remove a battery from a vehicle to charge it,
always remove the grounded terminal from the battery first. Make sure all
accessories in the vehicle are off.
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.
WARNING: WEAR EYE PROTECTION, HAND AND CLOTHING PROTECTION.
AVOID TOUCHING EYES WHILE WORKING WITH A BATTERY. SEE YOUR
LOCAL CLARKE DEALER FOR ALL YOUR PPE REQUIREMENTS.

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SAFETY PRECAUTIONS FOR USING THE CHARGER
1. NEVER place the charger in the engine compartment or near moving parts
or near the battery; place as far away from them as the clamp leads allow.
2. DO NOT cover the charger while charging.
3. DO NOT expose to rain or wet conditions.
4. Use of an attachment not recommended or sold by the manufacturer may
result in a risk of fire, electric shock or injury to persons.
5. DO NOT overcharge batteries by selecting the wrong charge mode.
6. To reduce the risk of damage to the electric plug and lead, pull by the plug
rather than the lead when disconnecting the charger.
7. Operate with caution if the charger has received a impact/blow or been
dropped. Have it checked and repaired if damaged.
8. Any repair must be carried out by the manufacturer or an authorized
CLARKE repair agent in order to avoid danger.
CHARGER LOCATION
1. Place the charger as far away from the battery as possible.
2. DO NOT position the charger above 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 enclosed space with reduced airflow.
SAFETY SYMBOLS
WARNING: ALWAYS SWITCH OFF THE CHARGER WHEN CONNECTING OR
DISCONNECTING LEADS.
Wear eye protection Wear protective
clothing
Wear protective gloves

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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.
•TheBlue wire must be connected to the terminal marked Nor coloured Black.
•TheBrown wire must be connected to the terminal marked Lor 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)

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THE CHARGING PROCESS
STEP 1: DIAGNOSIS
Check if the battery has connected with the charger and also check the
battery voltage.
STEP 2: DESULPHATION
If battery voltage is too low, the program automatically generates a pulsing
current to remove sulphate.
STEP 3: ANALYSE
Check if the battery voltage reaches to the minimum threshold after
desulphation, and charging begins if the battery voltage is OK.
STEP 4: SOFT START
Charge with stepped constant current.
STEP 5: BULK
Charge with constant maximum current until the battery voltage has reached
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. (pulse form protection).

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OVERVIEW

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CONNECTING TO THE BATTERY
1. Identify the 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.
•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.
•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.
4. When disconnecting, disconnect in the reverse sequence, removing the
negative first (or positive first for positive ground systems).
CHARGING MODESS
CAUTION: A MARINE (BOAT) BATTERY MUST BE REMOVED AND
CHARGED ON SHORE. TO CHARGE IT ON BOARD REQUIRES EQUIPMENT
SPECIALLY DESIGNED FOR MARINE USE.
SELECT MODE FOR BATTERY SIZE (AH)
12V 5A 10 - 150Ah
12V 10A 40 - 300Ah
12V 20A 60 - 500Ah
12V 40A 120 - 500Ah
24V 5A 10 - 150Ah
24V 10A 40 - 300Ah
24V 20A 60 - 220Ah
12V 40A BOOST Any Capacity
12V ALTERNATOR CHECK Any Capacity

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OPERATION
1. Connect the battery as described on page 8.
2. Plug in the mains plug and switch it on.
3. The charger will automatically detect the battery voltage (12V or 24V).
4. After 10 seconds the charger will begin charging the battery using the
following mode 12V/5A or 24V/5A.
• The user can manually select charging voltage / current modes by
pressing the "VOLTAGE" or “CURRENT” button within the first 10 seconds
after switching on (a countdown is shown on the LCD).
NOTE: If you choose 24V Mode(s) for 12V battery, the 12V battery will be
damaged
• Once the battery type has been selected successfully and charging is
started, you must disconnect the AC plug and plug in again if you want
to change the battery type mode of the charger.
• During charging, the display will show voltage (12V or 24V) and
charging current alternately.
• When the "VOLTAGE" button is pressed, the display shows battery
voltage (e.g. 12.1 V) .
5. During charging, pressing the "CHARGE" button will cause the charger to
turn off.
• The charger will be restarted by pressing "CHARGE" button again.
6. Battery level is indicated by the "battery level icon". When the battery is
fully charged, the charger will automatically switch from full charge to
maintenance status without overcharging or damaging the battery.
BATTERY LEVEL INDICATOR
LEVEL ICON EXPLANATION LEVEL ICON EXPLANATION
The 25% bar will slowly flash
when the battery level is less
than 25%. When 25% is
reached, the bar will be
solid.
The 50% bar will slowly flash
when the battery level is less
than 50%. When 50% is
reached, the bar will be solid.
The 75% bar will slowly flash
when the battery level is less
than 75%. When 75% is
reached, the bar will be
solid.
The 100% bar will slowly flash
when the battery level is less
than 100%. When 100% is
reached, the bar will be solid.
Meanwhile the maintenance
charging is activated.

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ADVANCED CHARGING MODES
The following modes are advanced charging modes that require your full
attention before selecting.
USING 12V BOOST
1. Connect the charger to the battery as shown on page 7 and switch on at
the mains power supply.
2. Allow the charger to start charging after an initial 10 second wait.
3. Press the BOOST/QUICK CHARGE button to start the boost charge mode
• For optimum results, allow boost to complete its 5-minute charge cycle.
• After 5 minutes the display will show
“000”, and you are ready to start your
vehicle.
• After each boost, the charger has a
mandatory 5-minute rest for safety
reasons (even if you press the BOOST/
QUICK CHARGE button again, the
charger will not work).
• After cooling, the LCD shows “End”
4. Press any button to enter the normal
charging mode, or the charger will
automatically enter the normal
charging mode after 10 minutes.
5. If unsuccessful when starting your
vehicle, let the battery rest for 15
minutes and try boost again. Most
vehicles will start with one boost.
6. Using 12V ALTERNATOR CHECK
WARNING: DO NOT USE BOOST MORE THAN TWO TIMES IN A 24-HOUR
PERIOD. IF TWO BOOSTS CANNOT SUCCESSFULLY START YOUR VEHICLE,
HAVE YOUR BATTERY REPLACED OR EVALUATED BY A LOCAL BATTERY
STORE.

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ALTERNATOR % (12V ONLY) -
1. Connect the charger to the battery an shown on page 7 and switch on at
the mains power supply
NOTE: The battery must be installed in the vehicle.
2. Press and hold the ALTN CHECK button for 3 seconds.
•The icon will appear.
3. Start the vehicle and turn on the vehicle's headlights.
• The digital display shows an estimated output percentage of the
vehicle's charging system.
• If you get a LOW or HIGH reading, have the electrical system checked
by a qualified technician. After 10 seconds, the charger will return to the
normal charging process.
CARE & MAINTENANCE
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.
• Clean the case and leads if necessary with a moist cloth and clean any
corrosion from the clamps with a solution of water and baking soda.
READING OUTPUT IS: ICON
0% to 100% GOOD
Below 0% (13.2 volts) LOW
Flashes Slowly
Above 100% (14.6 volts) HIGH
Flashes Quickly
WARNING: ALWAYS BE SURE THE CHARGER IS UNPLUGGED BEFORE
PERFORMING ANY MAINTENANCE OR CLEANING. ANY REPAIRS MUST BE
DONE BY A QUALIFIED CLARKE SERVICE TECHNICIAN.

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TROUBLESHOOTING
DISPLAY CAUSE SOLUTION
E01 (with
buzzer)
The charger is overheating The charging will automatically pause
with the alarm sound. Do NOT cut off
the power supply and the charger will
work again when cooled down.
E02 1) Open-circuit 1) Connect the red and black clamps
to the battery posts
2) Dirty Battery Posts 2) Clean the battery posts
3) Dead Battery 3) Replace the battery with a new
one immediately
4) Output Short Circuit 4) Disconnect red and black output
terminals
E03 Charging in 12V Mode(s)
for 24V battery
An alarm sound will remind you.
Please restart the charger and
choose the correct charge mode.
CAUTION: If you choose 24V Mode(s)
for 12V battery, the 12V battery will be
damaged!
E04 Battery cannot store
electric charge during
charging process
Replace the battery with a new one
immediately
E05 Battery is heavily corroded
and cannot be recovered
through desulphation
process
Replace the battery with a new one
immediately

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SPECIFICATIONS
E06 Reverse Polarity Swap the position of the charging
leads.
Battery
does not
charge
Lack of AC input power. Make sure that the charger is plugged
into the AC outlet and the POWER LED
is lit.
Very slow
charging
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 charge will increase as the
battery warms up.
Never attempt to charge a frozen
battery.
Model Number IBC40
Input Voltage 230V AC, ~ 50 - 60Hz,
Battery charging voltages: 12V & 24V DC
Output current 12VDC, 5A/10A/20A/40A
24VDC, 5A/10A/20A
12VDC, 40A, 300s (Boost)
Efficiency 85% approx
IP Rating IP20
Battery Capacity 10-500 Ah (12V), 10-300 Ah (24V)
Charging steps 8 steps (smart charger)
Operating Temperature Range -10 to 50°C
Dimensions (D x W x H) 187 x 285 x 320 mm
Weight 3.6 kg
Charging lead length (red& black) 1.85 m
Mains power cable length 1.2 m
DISPLAY CAUSE SOLUTION

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COMPONENT PARTS
No Part Name QTY Part Number
1 Back Shell 1 GTIBC4001
2 Front Shell 1 GTIBC4002
3 Middle Shell 1 GTIBC4003
4 Front Handle 1 GTIBC4004
5 Back Handle 1 GTIBC4005
6 Rubber Feet 2 GTIBC4006
7 Display Panel 1 GTIBC4007
8 LCD Surround 1 GTIBC4008
9 Transparent Screen 1 GTIBC4009
10 LCD Support 1 GTIBC4010
11 PCB A 1 GTIBC4011
12 PCB B 1 GTIBC4012
13 5020 Fan 2 GTIBC4013

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DECLARATION OF CONFORMITY