Clarke Start-N-Charge BC150 User manual

HEAVY DUTY BATTERY
BOOSTERS / CHARGERS
MODEL Nos. BC150, BC170, BC180B & BC200B
OPERATING INSTRUCTIONS 1202
HEAVY DUTY BATTERY
BOOSTERS / CHARGERS

For Spare Parts and Service, please contact your nearest dealer,
or CLARKE International, on one of the following numbers.
PARTS & SERVICE TEL: [phone]
PARTS & SERVICE FAX: [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [email protected]
NOTES
11
11
11818
1818
18

Thank you for purchasing this CLARKE Battery Charger. These units are suitable for
charging and boosting 12 Volt lead acid batteries. Models BC180B and BC200B
are also capable of charging 24Volt batteries.
Before attempting to operate the unit, please read this instruction manual
thoroughly,andfollow alldirections carefully.By doing so you will ensure thesafety
of yourself,and othersaround you,and atthe sametime, youshould lookforward
to the unit giving long and trouble free service.
GUARANTEE
This product is guaranteed against faults in manufacture for 12 months from date
of purchase. Please keep your receipt as proof of purchase.
This guarantee is invalid if the product has been found to have been abused in
any way, or not used for the purpose for which it was intended, or to have been
tampered with in any way. The reason for return must be clearly stated.
This guarantee does not affect your statutory rights.
CONTENTS PAGE
Parts and Service Contacts............................................................1
Safety Precautions ..........................................................................3
Assembly Instructions ......................................................................4
Electrical Connections 12 Volt Charging ..................................5
24 Volt Charging ..................................5
Parts Identification...........................................................................6
Procedure For Normal Charging ...................................................7
Procedure For Engine Starting .......................................................9
Specifications ..................................................................................10
Replacement Fuses.........................................................................10
Parts & Service Contacts ................................................................10
Parts Lists & Diagrams......................................................................11
Wiring Diagrams...............................................................................15
22
22
2
1717
1717
17

IMPORTANT: SAFETY PRECAUTIONS
PLEASE READ BEFORE USING THIS UNIT
1.
WARNING :Some electronic equipment can be damaged by boost
charging or use of start facility. Check your vehicle handbook before using
your Start ’N’ Charge. If in doubt consult the vehicle manufacturer.
Nevertheless, you should not operate this equipment unless you are fully
conversant with vehicle electrical systems, and battery charging techniques.
2. WARNING :Because highly inflammable hydrogen gas is released in the
process of battery charging, please remember to switch OFF the charger
first, and so avoid sparking which will occur when CONNECTING OR
DISCONNECTING LIVE LEADS.
3. Black negative (-ve) lead must always be clipped to the negative, and Red
positive (+ve) lead must always be clipped to the positive.
When charging with battery installed in vehicle, or boosting, FIRST connect the
appropriate lead to the UNEARTHED battery terminal (on most modern cars this
is the positive (+ve) terminal), then connect the other lead to the chassis (or a
suitable engine bolt) away from the battery and fuel line. It is advisable to
disconnect the unearthed terminal from the battery, when charging in situ.
When disconnecting, remove the chassis lead FIRST, then the battery lead.
4. To prevent battery overheating and consequent damage, use the BOOST
facility sparingly and do not exceed our recommendations.
5. 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.
6. When charging is completed, ensure that the vehicle battery leads are
secured to the proper terminals which should be clean and lightly smeared
withpetroleum jellyto preventcorrosion. Finally,re-check the electrolytelevel.
7. Do not expose this unit to rain.
8. Never touch together the negative and positive leads on this unit whilst the
unit is switched on.
9. Never attempt any electrical or mechanical repair. If you have a problem
with your machine contact your local stockist for service information.
10. WARNING : Certain types of sealed or maintenance-free batteries need
extra care when charging. Please consult battery manufacturers instructions
before using this unit.
11. WARNING : Since toxic fumes may be released during battery charging,
ONLY USE THIS UNIT IN A WELL VENTILATED AREA.
12. 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.
33
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3
BC180B
BC200B
WIRING DIAGRAMS
1616
1616
16

BC150
BC170
WIRING DIAGRAMS
1515
1515
15
ASSEMBLY INSTRUCTIONS.
BCI80B and BC200B
1) Insert the plastic handle into the top of the unit and secure with the screws provided.
2) Insert the tubular metal handle into the plastic handle and secure with two screws
provided.
3) Using the four small bolts supplied secure the metal supporting foot to the base of the
charger and at same time locate the axle in the slot provided.
4) Push one wheel onto each end of the axle and retain in position by tapping one of
the retaining washers supplied, about 5 mm. on to the axle shaft at each end using a
piece of tube or old socket etc., noting that the tines of the washer face outwards.
44
44
4

.ELECTRICAL CONNECTIONS
WARNING! THIS APPLIANCE MUST BE EARTHED.
A. 12 volt CHARGING - All Models
Connect the mains lead to a 230 volt (50Hz) domestic electrical supply via a standard 13
amp BS 1363 plug fitted with a 13 amp fuse, or a suitably fused isolator switch.
IMPORTANT: The wires in the mains lead are coloured in accordance with the following code:
Green & Yellow - Earth
Blue - Neutral
Brown - Live
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 & YELLOW coloured cord to plug terminal marked with a letter ‘E’ or
Earth symbol “ ”, or coloured GREEN or GREEN & YELLOW.
• Connect BROWN coloured cord to plug terminal marked ‘L’ or coloured RED.
• Connect BLUE coloured cord to plug terminal marked ‘N’ or coloured BLACK.
We strongly recommend that this unit is connected to the mains supply via a Residual
Current Device (RCD).
IMPORTANT!
If this appliance is fitted with a plug which is moulded onto the electric cable (i.e.
non-rewireable) please note:
1. The plug must be thrown away if it is cut from the electric cable. There is a
danger of electric shock if it is subsequently inserted into a socket outlet.
2. Never use the plug without the fuse cover fitted.
3. Should you wish to replace a detachable fuse carrier, ensure that the correct
replacement is used (as indicated by marking or colour code).
4. Replacement fuse covers can be obtained from your local dealer or most
electrical stockists.
Fuse Rating
The fuse in the plug must be replaced with one of the same rating (13 amps) and this
replacement must be ASTA approved to BS1362.
Extension Cable
If an extension cable is fitted, ensure the minimum cross section of the conductor is 1.5mm2
for up to 15 metres in length, and 2.5mm2for up to 25 metres.
B. 24 Volt Charging (BC180B and BC200B)
If these units are used for 24 volt boosting or charging, they MUST be connected to a 230V
50Hz, single phase supply, through a suitably fused isolator, with a fuse rating of 15 Amps.
DO NOT connect via a 13 Amp Plug.
55
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5
PARTS LIST AND DIAGRAM
BC200B
Upper Panel EM33705007
Handle EM21600004
Back Panel EM33715037
Rectifier EM22400006
Thermostat EM04600113
Lower Panel EM33700023
Switch EM22205007
Switch Knob EM21690015
Ammeter EM22600015
Input Cable EM22610006
Orange Pilot-lamp EM22610012
Cable Clamp EM21605010
Input Cable EM20220014
Black Cable EM43200014
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Red Cable EM43200026
Clamp EM22110005
Din. Plug EM22100001
Foot EM33740015
Din. Socket EM22100002
Wheels-axle EM55200012
Wheel EM21625006
Transformer EM44105006
Fuse Holder Box EM21690113
Fuse I00A EM22220030
Small Fuse Box Cover EM21690109
Handle EM33725029
Handle-extension Knob EM21600006
15
16
17
18
19
20
21
22
23
24
25
26
27
No. Description Part No.
No. Description Part No.
1414
1414
14

PARTS LIST AND DIAGRAM
BC180B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
No. Description Part No.
No. Description Part No.
1313
1313
13
Upper Panel EM33705007
Handle EM21600004
Back Panel EM33715037
Rectifier EM22400020
Thermostat EM04600113
Lower Panel EM33700021
Switch EM22205008
Switch Knob EM21690015
Ammeter EM22600014
Green Pilot-lamp EM22610006
Orange Pilot-lamp EM22610012
Cable Clamp EM21605010
Input Cable EM20220014
Black Cable EM43200012
Red Cable EM43200010
Clamp EM22110005
Din. Plug EM22100001
Foot EM33740015
Din. Socket EM22100002
Wheels-axle EM55200012
Wheel EM21625014
Transformer Starter EM44105022
Fuse Holder Box EM21690113
Fuse 120A EM22220029
Small Fuse Box Cover EM21690109
Handle EM33725029
Rubber Grip EM21600006
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6
BC150 & 170
FIG. 1
1 - Ammeter
2 - Charge/Boost Start Switch
3 - MIN/MAX Charge Rate Sw.
4 - ON/OFF Switch
5 - Mains Lead
6 - RED, Positive Lead
7 - Black Negative Lead
BC180B & BC200B
FIG. 2
1 - Amperage Control Knob
2 - Ammeter
3 - Mains indicator Lamp
4- Thermal Overloadindicator
5 - Mains Lead
6 - 24V Positive Terminal
7 - 12 V Positive Terminal
8 - RED, Positive Lead
9 - Black, Negative Lead
PARTS IDENTIFICATION

PROCEDURE FOR NORMAL CHARGING
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7
BCI50 & BC170 (Ref: Fig. 1).
1) Before charging or boosting, ensure that the cells are filled with electrolyte to the
correct level by adding distilled water where necessary.
2) Where appropriate we recommend that the non-earthed lead on the battery is
disconnected prior to charging. It is possible that damage may occur to any
electronically controlled system fitted to the vehicle such as engine management,
anti-theft alarm, alternator etc.
3) Check that the ON/OFF switch (4) on the unit is in the OFF position.
4) Connect the appropriate lead to the unearthed battery terminal (on most modern
cars this is positive (+ve) terminal), then connect the other lead to the chassis (or a
suitable engine bolt) away from the battery and fuel line.
5) Remove the battery filler caps during charging in order to prevent the build up of
dangerous gases within the battery.
6) Switch the CHARGE/BOOST START switch (2) to the CHARGE position.
7) Set the MIN/MAX (minimum charge/maximum charge) switch (3) to the MIN position.
Thisissuitable for charging most normal car batteries (having aratingofapproximately
40 A.H.).
8) Switch the ON/OFF switch (4) to ON, and charging will commence.
9) Keep the battery on charge until the Ammeter gauge (1) reads zero (or 0-2 amps) or
has stopped moving down. Then switch OFF at the machine.
10) When disconnecting the charger, disconnect 1. supply, 2. chassis conductor
and 3. battery conductor, IN THAT ORDER.
Important:
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 back panel (marked ‘fuse’) and replace the
burnt fuse with an exact replacement. See page 10 for replacement fuses.
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: Do not attempt to re-charge non-rechargeable batteries.
PARTS LIST AND DIAGRAM
BC170
No. Description Qty Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
1212
1212
12
Hamdle
Upper Pamel
Fromt Pamel
Om/Off Switch
Weldimg Curremt Switch
Ammeter
Imput Cable W/Plug+13a Fuse
Cable Clamp
Red Cable
Earth Clamp
Black Cable
Lower Pamel
Tramsformer
Tramsformer Thermostat
Rectifier
Complete Thermostat + Support
Fuse Holder Box
Fuse 120a
Small Fuse Cover
1
1
1
1
2
1
1
3
1
2
1
1
1
1
1
1
1
1
1
EM21600001
EM33705108
EM33710281
EM22200002
EM22200006
EM22600014
EM20220068
EM21605009
EM43200011
EM22110005
EM43200012
EM33700089
EM44105058
EM22210603
EM22400088
EM04600113
EM21690113
EM22220029
EM21690109

7. BCI8OB and BC200B (Ref: Fig. 2).
1) Before charging or boosting ensure that the cells are filled with electrolyte to the
correct level by adding distilled water where necessary.
2) Where appropriate we recommend that the non-earthed lead on the battery is
disconnected prior to charging. It is possible that damage may occur to any
electronically controlled system fitted to the vehicle such as engine management
anti-theft alarm, alternator etc.
3) Check the mains supply is OFF and the amperage control knob (1) is in the OFF position.
4) Connect the red positive lead (8) to either the (+ve) 24V terminal (6), or the (+ve)
12V terminal (7) as appropriate, by inserting the jack plug and twisting clockwise to
a locked position.
5) Connect the appropriate lead to the unearthed battery terminal (on most modern
cars this is the positive (+ve) terminal), then connect the other lead to the chassis (or
a suitable engine bolt) away from the battery and fuel line.
6) Remove the battery filler caps during charging to prevent the build-up of dangerous
gases within the battery.
7) Switch on the mains supply.
8) Turn the amperage control knob (1) clockwise to the position necessary to obtain
the desired charging rate as indicated on the ammeter (2) (see notes below).
9) Keep the battery on charge until the ammeter (2) reads zero (or 0-2 amps), or has
stopped moving down. Then switch the amperage control knob (1) back to the OFF
position.
NOTE: The BC180B is fitted with a 3 position amperage control knob...the BC200B with a 6
position knob, giving a wider range of control.
10) When disconnecting the charger, disconnect 1. supply, 2. chassis conductor
and 3. battery conductor, IN THAT ORDER.
Important:
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 back panel (marked ‘fuse’) and replace the
burnt fuse with an exact replacement. See page 10 for replacement fuses.
Notes on charging procedure.
* A complete charge is best done slowly in order to protect your battery. We recommend that
the charging rate (amps) should not exceed 10% of the battery capacity rating (Amps
hours) i.e., an average normal car battery has an Amp hour rating of approximately 40 A.H.
so the charging rate should not exceed 4 amps (a complete charge should therefore take
approximately 10 hours). Select the position on the amperage control knob (1) which
indicates as near as possible this charging rate on the Ammeter gauge (2).
** If a low amperage reading (2 amps or less) is seen on the Ammeter gauge (2) at any of the
settings on the amperage control knob (1), it 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.
WARNING: Do not attempt to recharge non-rechargeable batteries.
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PARTS LIST AND DIAGRAM
BC150
No. Description Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1111
1111
11
Handle
Upper Panel
Front Panel
On/Off Switch
Welding Current Switch
Ammeter
Input Cable W/Plug -13a Fuse
Cable Clamp
Red Cable
Earth Clamp 120a
Black Cable
Lower Panel
Transformer
Thermostat
Rectifier
Fuse Holder Box
Fuse 75a
Small Fuse Cover
1
1
1
1
2
1
1
3
1
2
1
1
1
1
1
1
1
1
EM21600001
EM33705108
EM33710281
EM22200002
EM22200006
EM22600014
EM20220068
EM21605009
EM43200011
EM22110005
EM43200012
EM33700089
EM44105067
EM22210014
EM22400042
EM21690113
EM22220031
EM21690109

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PROCEDURE FOR ENGINE STARTING
BC150 & BC170 (Re: Fig.1)
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 big 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.
a) Check that the ON/OFF switch (4) is in the OFF position.
b) Connect the cables as for normal charging.
c) Check that the CHARGE/BOOST START switch (2) is in the BOOST position.
d) Switch the ON/OFF, switch to the ON position.
e) Turn the key in the vehicles ignition to ‘start’, and get an assistant to switch the
CHARGE/ BOOST START switch (2) to CHARGE position IMMEDIATELYthe engine starts,
or after a maximum of 5 seconds (BC150) or 10 seconds (BC170), if the engine fails
to start. Failure to do this may cause damage to some electronic equipment.
IMPORTANT: You must return the CHARGE/BOOST START switch to CHARGE position
after a maximum of 5 seconds - 150 or 10 seconds - 170, on boost start. Wait 20
seconds - 150 or 60 seconds - 170, before repeating. Failure to do this may damage
the battery and the Start ‘N’ Charge unit and may invalidate your guarantee.
BCI8O and BC200B (Re: Fig.2)
Note: We recommend that before attempting to boost start, you charge the battery for 10 to 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.
a) Check that the mains supply is OFF and that the amperage controller knob (1) is in
the OFF position.
b) Connect the cables as for normal charging.
c) Switch ON the mains supply.
d) Turnthekeyinthevehiclesignition to ‘start’, and get an assistant to hold the amperage
control knob (1) in the BOOST START position.
Release the amperage control knob so that it reverts to the OFF position immediately
the engine starts, or after a maximum of 10 seconds if the engine fails to start. Failure
to do this may cause damage to some electronic equipment. If in doubt consult
vehicle handbook or manufacturer.
IMPORTANT: You must return the amperage control switch to the OFF position after a
maximumof10secondsonbooststart,thenwaitatleast 30 seconds before repeating.
Failure to do this may damage the battery AND the Start ‘N’ Charge unit and may
invalidate your guarantee.
NOTE: If the Start and Charge unit is overloaded at any time, a thermal cut out will
automaticallycomeintooperation,rendering it inoperative. TheBC180B&200Bareequipped
with a thermal overload indicator (4) which will illuminate. Allow approximately 5-10 minutes,
or wait for the indicator light to go out before using the unit again.
MODEL 150 170 180B 200B
MAX CHARGE (AMPS) 15 20 20 30
MAX BOOST (AMPS) 140 160 180 200
BOOST/CHARGE (VOLTS) 12 12 12/24 12/24
BOOST START DUTY CYCLE Max 5 secs ON Max 10 secs ONMax 10 secs ON Max 10 secs ON
20 secs OFF 60 secs OFF 30 secs OFF 30 secs OFF
THERMAL OVERLOAD YES YES YES YES
PROTECTION
DIMENSIONS 260X260X250 260X260X210 260X300X770 260X300X770
(LxWxH) mm.
WEIGHT kg. 10 12.5 16 21
PART NO. 6210185 6210190 6210180 6220000
This battery charger is designed to charge either 12V or 24V lead-acid automotive batteries.
Do not attempt to recharge any other type of battery. Do not use the battery charger as a
power source.
SPECIFICATIONS
REPLACEMENT FUSES
MODEL PART No.. AMPS QTY REQUIRED
BC150 EM22220031 75 1
BC170 EM22220029 120 1
BC180B EM22220029 120 1
BC200B EM22220030 100 2
PARTS & SERVICE CONTACTS
For Spare Parts and Service, please contact your nearest dealer,
or CLARKE International, n one of the following numbers.
PARTS & SERVICE TEL: [phone]
PARTS & SERVICE FAX: [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [email protected]
1010
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