Clarke IBC80 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS DL0921
12V & 24V 80A INTELLIGENT BATTERY
CHARGER
MODEL NO: IBC80
PART NO: 6267019

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INTRODUCTION
Thank you for purchasing this CLARKE Battery Charger.
Before use, read this manual thoroughly and follow all instructions given.
1. The IBC80 is designed for charging all types of 12V & 24V lead-acid
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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OVERVIEW
1 Negative (Black) Lead 5 Cable Rack
2 Positive (Red) Lead 6 Screw Clamp for Positive Lead
for Charging 24V Batteries
3 Display & Control Panel 7 Screw Clamp for Positive Lead
for Charging 12V Batteries
4 Handle 8 2 x 50A Fuses

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SPECIFICATIONS
Model Number IBC80
Input Voltage 230V AC, 50Hz,
Battery Charging Voltages 12V DC & 24V DC
Battery Types WET (Flooded), MF (Maintenance-Free),
EFB (Enhanced Flooded Battery), GEL
(Gelified Electrolyte), AGM (Absorbed
Glass Mat)
Output Currents 5A/10A/20A 80A Start Mode
Boost Duty Cycle 5 Seconds On, 180 Seconds Off
IP Rating IP20
Min./Max. Charging Battery Size 4Ah - 350Ah
Charging Steps 10 Steps (Intel. Charger - Maintainer)
Operating Temperature Range 0°C to 40°C
Dimensions (D x W x H) 270mm x 250mm x 160mm
Weight 9 kg
Charging Lead Length (red& black) 1.90 m
Mains Power Cable Length 1.76 m
Max.
Input
Power
Max.
Input
Current
Output
(Charging/
Starting)
Charging
Voltage
Charge-12V-20A 390W 2.2A 20A 12V
12V-Start(6V) 1034W 5A 60A 6V
12V-Start(3V) 1350W 6.5A 85A 3V
Charge-24V-20A 695W 4.3A 20A 24V
24V-Start(6V) 2620W 12.5A 75A 10V
24V-Start(3V) 2744W 13.4A 80A 8V

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SAFETY INSTRUCTIONS
SAFETY PRECAUTIONS FOR WORKING IN THE VICINITY OF A BATTERY
1. This charger SHOULD NOT be used to charge Lithium-Ion batteries.
2. Wear complete eye, hand and clothing protection. Avoid touching eyes
while working near a battery.
3. Clean the battery terminals before they are connected to the charger. Be
careful to keep corrosion from coming into contact with your eyes.
4. 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.
5. Batteries generate explosive gases during normal operation. Use in a well-
ventilated area.
6. Consider having someone close enough or within the range of your voice
to come to your aid when you work near a battery.
7. DO NOT smoke, strike a match or cause a spark in vicinity of a battery or
engine. Avoid explosive gas, flames and sparks.
8. 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.
9. 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.
10. Study all battery manufacturer's specific precautions such as removing or
not removing cell caps while charging and recommended rates of
charge.
11. 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 in order to prevent an arc.
12. 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.
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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13. NEVER charge a frozen, damaged, leaking or non-rechargeable battery.
SAFETY PRECAUTIONS FOR USING THE CHARGER
1. DO NOT cover the charger while charging.
2. DO NOT expose to rain or wet conditions.
3. Use of an attachment not recommended or sold by the manufacturer may
result in a risk of fire, electric shock or injury to persons.
4. DO NOT overcharge batteries by selecting the wrong charge mode.
5. To reduce the risk of damage to the electric plug and lead, pull by the plug
rather than the lead when disconnecting the charger.
6. Operate with caution if the charger has received a impact/blow or been
dropped. Have it checked and repaired if damaged.
7. Any repair must be carried out by the manufacturer or an authorized
CLARKE repair agent in order to avoid danger.
CHARGER LOCATION
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 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.
WARNING: ALWAYS SWITCH OFF THE CHARGER WHEN CONNECTING OR
DISCONNECTING LEADS.

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SAFETY SYMBOLS
Wear Eye Protection Wear Protective
Clothing
Wear Protective Gloves WEEE Directive
Indoor Use Only Warning: Risk of
Electrical Shock
Warning: Battery
Charging

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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.
• The Blue wire must be connected to the terminal marked N or
coloured Black.
• The Brown wire must be connected to the terminal marked L or
coloured Red.
• The Yellow and Green wire must be connected to the terminal
marked E or or coloured Green.
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.
WARNING! READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE
MAINS SUPPLY.
Plug must be BS1363/A approved.
Always fit a 13 Amp fuse.
Ensure that the outer sheath of the cable is firmly held by the clamp
Neutral
(Blue)
Live
(Brown)
Earth
(Green and Yellow)

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THE CHARGING PROCESS
STEP 1: ANALYSING 1: Checks if the battery has connected with the charger.
STEP 2: DESULPHATION: If battery voltage is too low, the program automatically
generates a pulsing current to remove sulphate.
STEP 3: SOFT START: Charges with gradually increasing charging current.
STEP 4: CONTROLLED CURRENT CHARGE: Adjusts the charging current intelligently.
STEP 5: ANALYSING 2: Tests if the battery can absorb charge.
STEP 6: CONSTANT OUTPUT CHARGE: Charges with constant voltage and
compensates for any fake full charge caused by high current charging.
STEP 7: RECOVERY CYCLE CHARGE: Absorbs more charge and compensates for
the side effect of reduced charging current.
STEP 8: ABSORPTION: Charges with constant trickle current for maximum battery
voltage.
STEP 9: ANALYSING 3: Tests if the battery can hold charge.
STEP 10: MAINTENANCE: Continuously monitors the battery, and charges with
trickle current once the voltage is lower than threshold.

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CONNECTING TO THE BATTERY
1. Identify the voltage of the battery to be charged, 12V or 24V. Connect the
Positive (Red) lead to the appropriate screw clamp on the rear of the
charger.
2. 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,-).
3. DO NOT make any connections to the carburetor, fuel lines, or thin metal
parts.
4. 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.
5. When disconnecting, disconnect in the reverse sequence, removing the
negative first (or positive first for positive ground systems).
CAUTION: A MARINE (BOAT) BATTERY MUST BE REMOVED AND
CHARGED ON SHORE. TO CHARGE IT ON BOARD REQUIRES EQUIPMENT
SPECIALLY DESIGNED FOR MARINE USE.

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OPERATION
DISPLAY BUTTON
Press the DISPLAY button until the following LED is lit:
1. VOLTAGE/V - When the charger is NOT charging a battery, the display will
show the battery voltage.
2. BATTERY% - When in charging, the digital display shows an estimated
charge percentage of the battery connected to the chargers battery
clamps.
3. ALTERNATOR% - The digital display shows an estimated output percentage
of the vehicles charging system connected to the chargers battery
clamps, compared to a properly functioning system.
FUNCTION BUTTON
1. CHARGE - Press & hold the RATE SELECTION button for 3 seconds to choose
battery type (STD/GEL/AGM) first, and press & hold the same button for 3
seconds until the digital display shows OFF. Then press the RATE SELECTION
button once to choose the charging current. After that, press the
FUNCTION button until the CHARGING LED is lit to enter this mode (digital
display shows CHARGE-ON).When in charging, the battery type cannot be
changed. To stop charging, press the FUNCTION button again and
CHARGE LED will be off (digital display shows CHARGE-OFF).
2. STATRT - Your battery charger can be used to jump start your car if the
battery is low. Follow all safety instructions and precautions for charging

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your battery. Wear complete eye protection and protective clothing. The
procedures are as follows:
• Connect the charger to the battery following the instructions given on
page 10.
• With the charger plugged in and connected to the battery and chassis,
press the FUNCTION button until the START LED is lit.
• Turn on the vehicles ignition until the vehicle starts or 3 seconds has
passed. If the engine does not start, wait 4 minutes before trying again.
This allows the charger and battery to cool down.
• If the engine fails to start, use the CHARGE maximum rate (10A) to
charge for some minutes before attempting to start the engine again.
• After the engine starts, unplug the AC power cord before disconnecting
the battery clamps from the vehicle.
NOTE: If the engine turns over but never starts, there is not a problem with the
starting system; there is a problem somewhere else with the vehicle.
STOP all ignition attempts until the other problem has been diagnosed
and corrected.
During the starting sequence listed above, the charger is set to one of
three states:
While waiting for ignition, the digital display shows:
•START-READY - The charger waits until the engine is actually being
started before delivering the amps for the engine start.
•CRANKING - When ignition is detected, the charger will automatically
deliver up to its maximum output as required by the starting system for
up to 10 seconds.
•COOL DOWN - After ignition, the charger enters a mandatory 180
seconds cool down state (Pressing any button DOES NOT work). The
digital display indicates the remaining cool down time in seconds. It
starts at 180 and counts down to 0. After 3 minutes, the digital display will
change from displaying the countdown to displaying START-READY.
3. REPAIR - Press & hold the FUNCTION button for 3 seconds until the REPAIR
LED is lit to enter this mode (digital display shows REPAIR-ON). It is an
advanced battery recovery mode for repairing old, idle, stratified or
sulfated batteries. NOT all batteries can be recovered. For optimal results,
take the battery through a full charge cycle, bringing the battery to full
WARNING: USING THE ENGINE START FEATURE WITHOUT A BATTERY
INSTALLED IN THE VEHICLE WILL DAMAGE THE VEHICLE’S ELECTRICAL
SYSTEM.

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charge before using this mode. This mode uses a high charging voltage
and may cause some water loss in WET cell batteries. Plus, some batteries
and electronics may be sensitive to high charging voltages. To minimise
risks, disconnect the battery from the vehicle before using this mode. To
stop repairing, press the FUNCTION button again and REPAIR LED will go off
(digital display shows REPAIR-OFF).
ALTERNATOR CHECK
Before the charger is connected with the battery which should be well
seated in the vehicle, press the DISPLAY button until the ALTERNATOR%
LED is lit, start the vehicle and turn the vehicles headlights on. The
alternator percentage range is from 0% to 100%. Readings below 0% will
read LO and readings above 100% will read HI.If you get a HI or LO
reading, have the electrical system checked by a qualified technician.
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.
Battery
Size - Ah
Approx. Time to Charge
12V 24V
5A 10A 20A 5A 10A 20A
10 2.5h 1.5h 33mins 2.5h 1.5h 55mins
20 4h 2.5h 1.5h 4h 2.5h 1.5h
40 5h 5h 2.5h 5h 5h 2.5h
80 17h 9h 5h 17h 9h 5h
100 33h 17h 9h 33h 17h 9h
350 71h 36h 18.5h 71h 36h 18.5h

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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.
ERROR MESSAGES
1. E01 Display + ERROR LED lit: Reverse connection
2. E02 Display + ERROR LED lit: Temperature in charger is too high
3. E03 Display + ERROR LED lit: The battery cannot store electric charge (dead
battery)
4. E04 Display + ERROR LED lit: No battery connected/battery voltage is lower
than 1 volt (dead battery)
5. REPAIR-ON displayed + REPAIR LED flashing: Charger automatically enters
repairing mode
6. REPAIR-ON displayed + REPAIR LED solid lit: Manually choose repairing
mode
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
Problem Cause Solution
Battery
does not
charge
Lack of AC input
power.
Make sure that the charger is plugged
into AC outlet and check 50A fuses on
rear of the charger.
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 (below freezing), it will not accept a
high rate of charge, so the initial
charging rate will be slow.
The rate of charging will increase as the
battery warms.
NEVER attempt to charge a frozen
battery.
Display not
showing
Lack of AC input
power.
Make sure that the charger is plugged
into AC outlet and check 50A fuses on
rear of the charger.
Check AC plug fuse and replace if
necessary

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COMPONENT PARTS DIAGRAM

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COMPONENT PARTS LIST
PART NO DESCRIPTION PART NO DESCRIPTION
1 Front Cover 11 Main PCB - Radiator
2 Rectifier Bridge 12 Rear Cover
3 Transformer 13 Cable Rack
4 Control - PCB 14 Fuse
5 Handle 15 12VDC Positive Red Cable
Joint
6 Exterior Metal Case 16 24VDC Positive Red Cable
Joint
7 Fan 17 Clamps
8 Fan Holder 18 12/24VDC Negative Black
Cable
9 Base Plate 19 AC Power Cable
10 Relay

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DECLARATION OF CONFORMITY - UKCA

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DECLARATION OF CONFORMITY - EU