Clarke Start-N-Charge BC260N Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC1018 - ISS 4
HEAVY DUTY BATTERY STARTERS/CHARGERS
MODEL NO: IBC260N & BC335
PART NO: 6225053 & 6235055

2
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
INTRODUCTION
Thank you for purchasing this CLARKE Battery Charger.
Please read this manual thoroughly, before attempting to operate this
product, 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 Battery 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.

3
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
SAFETY PRECAUTIONS
PLEASE READ BEFORE USING THIS UNIT
1. 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.
2. 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.
3. This product is not intended for use by persons with reduced physical,
sensory or mental capabilities or lack of experience and knowledge.
4. Children must not play with the charger.
5. Do not expose this charger to rain.
6. Never touch the negative and positive leads together.
7. Never attempt any repairs yourself. If you have a problem with your
charger contact your local Clarke dealer or contact
[email protected]
8. When charging is completed, ensure that the vehicle battery leads are
secured to the proper terminals which should be clean, and lightly
smeared with petroleum jelly to prevent corrosion. Finally, re-check the
electrolyte level.
WARNING: ALWAYS SWITCH OFF THE CHARGER WHEN CONNECTING OR
DISCONNECTING LEADS TO AVOID SPARKING AS HIGHLY INFLAMMABLE
HYDROGEN GAS IS RELEASED IN THE PROCESS OF BATTERY CHARGING
WARNING: CERTAIN TYPES OF SEALED OR MAINTENANCE-FREE BATTERIES
NEED EXTRA CARE WHEN CHARGING. PLEASE CONSULT THE BATTERY
MANUFACTURERS INSTRUCTIONS BEFORE USING THIS UNIT.
WARNING: SINCE TOXIC FUMES MAY BE RELEASED DURING BATTERY
CHARGING, ONLY USE THIS UNIT IN A WELL VENTILATED AREA.

4
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
ELECTRICAL CONNECTIONS
Connect the three core mains lead to a suitable industrial supply isolator, or
heavy duty plug. These chargers must be connected to a supply having a rated
capacity of greater than 13 Amps.
WARNING: A 13 Amp (BS1363) plug is not suitable.
The maximum input amperages for these units are:
BC260N - 40amps, BC335 - 36amps
WARNING: THIS APPLIANCE MUST BE EARTHED
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 wire which is coloured Blue must be connected to the terminal
which is marked Nor coloured Black.
• The wire which is coloured Brown must be connected to the terminal
which is marked Lor coloured Red.
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.
WARNING! THE WIRES IN THE POWER CABLE OF THIS PRODUCT
ARE COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE:
Blue = Neutral Brown = Live

5
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
OVERVIEW
A Timer Control Knob E Mains Indicator Lamp
B Current Control Knob F Thermal Overload Indicator
C 12V Positive Terminal G Ammeter
D 24V Positive Terminal H Fuse

6
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
PROCEDURE FOR NORMAL CHARGING
NOTE: All references in brackets refer to 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 mains supply is OFF and the Current Control Knob (B) is in
the ‘O’ 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.
NOTE: Ensure the RED (+ve) lead is plugged into the 12V or 24V receptacle,
depending upon the voltage of the battery to be charged.
5. Remove the battery filler caps, where appropriate, during charging in
order to prevent the build up of dangerous gases within the battery.
6. Switch ON the mains supply.
7. Turn the Current Control Knob (B) to the position necessary to obtain the
required charge rate, as indicated on the ammeter - 3 charging rates are
provided.
CAUTION: Avoid high charge rates with sealed batteries
8. Keep the battery on charge until the Ammeter (G) reads zero (or 0-2 amps)
or has stopped moving down, then turn the Current Control Knob (B) to the
OFF position.
9. 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 front panel (marked ‘fuse’) and replace the burnt fuse
with an exact replacement. See ‘Specifications’ for replacement fuses.

7
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
CHARGING WITH TIMER
1. Follow the same instructions as for Normal Charging up to and including
para. 6.
2. Turn the timer control knob (A) clockwise to the desired charging time
setting.
3. Switch ON the mains supply.
4. Turn the Current Control Knob (B) clockwise to position 5 or 6, to obtain the
desired charging rate as indicated on the ammeter.
NOTES ON CHARGING PROCEDURE
*A complete charge is best done slowly in order to protect your battery We
recommend the charging rate be no more than 10% of the battery capacity
rating AH). eg. a typical battery has a rating of 40 Ampere Hours, therefore the
charging rate should be 4 amps, and a complete charge will take 10 hours.
** If a low current reading (2 amps or less) is seen on the gauge, 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. Check the SG of the battery with a hydrometer.
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 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.
1. Check that mains supply switch is OFF and the Current Control Switch is in
the OFF position.
2. Connect the cables as for normal charging.
3. Switch ON the mains supply.
4. Turn the Current Control Knob (B) in the BOOST START position.
5. Turn the vehicle’s ignition switch to ‘start’, then press the button on the
Remote Control to provide a boost.
IMPORTANT: If the engine fails to start after a MAXIMUM of 10 seconds,
release the button on the remote control and the ignition switch. You must

8
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
then wait for at least 30 seconds before retrying. Failure to follow this
procedure may cause damage to some electronic equipment on the
vehicle and may also damage the battery and the Start ‘N’ Charge unit,
which could invalidate your guarantee.
6. When the engine has started, switch the Current Control knob (B) to the
OFF position, then disconnect the charger. Disconnect (1) supply, (2)
chassis conductor and (3) battery conductor, IN THAT ORDER.

9
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
TROUBLESHOOTING
Problem Cause Solution
Battery does not
charge
Lack of AC input power. Make sure that the charger
is plugged into AC outlet
and the POWER LED is lit.
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, it
will not accept a high rate
of charge, so the initial
charge rate will be slow.
The rate of charger will
increase as the battery
warms up.
Never attempt to charge a
frozen battery.

10
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
COMPONENT PARTS BC260N

11
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
COMPONENT PARTS BC260N
NODESCRIPTION PART NO
01 Switch Knob EM21690015
02 Switch 12A EM22205133
03 Timer 16a 250V EM22215001
04 Timer knob EM21690034
05 Upper control panel EM33710273
06 Ammeter 50A/Start EM22600027
07 Front frame EM21690322
08 Rectifier Pms 20/2/2 EM22400045
09 Thermostat 1004 & support EM04600113
10 PC board for remote control EM22700001
11 Input cable 3x2.5 M2.5 EM20220020
12 Transformer starter 230V EM44105046
13 Lower panel EM33700028
14 Remote control cable without plug EM40210768
15 Black cable 16 sq/mm EM43200016
16 Red cable 16 sq/mm EM04600067
17 Earth clamp (pair) 120A EM22110005
18 Wheels axle EM55200001
19 Wheel 0.175 rubber hole D20 EM21625009
20 Fuse box cover EM21690110
21 Fuse 200A 2EM2220008
22 Orange pilot lamp 220V EM22610014
23 Green pilot lamp 220V EM22610008
24 6-lobe handwheel EM21800042
25 Insulating french washers EM21615012
26 Cable clamp for hose D10 EM21605034
27 Front panel Aut700 EM33700722
28 Cover panel Aut700 EM33705346
29 Handle Aut700 EM33725080

12
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
COMPONENT PARTS BC335

13
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
COMPONENT PARTS BC335
NODESCRIPTION PART NO
01 Switch Knob EM21690015
02 Switch 12A EM22205133
03 Timer 16a 250V EM22215001
04 Timer knob EM21690034
05 Upper control panel EM33710285
06 Ammeter 50A EM22600050
07 Front frame EM21690322
08 Rectifier Pms 20/2/2 EM22400011
09 Thermostat & support EM04600113
10 Auxiliary transformer EM44140049
11 Input cable 3x2.5 M2.5 EM20220020
12 Contactor EM22225025
13 Thermostat support EM04600261
14 Transformer EM44105075
15 Red lower panel EM33700028
16 Remote control cable EM40210768
17 Black cable 16 sq/mm EM43200016
18 Earth cable 16 sq/mm EM43200015
19 Dinse plug 25sq/mm EM22100001
20 Clamps 120A EM04600067
21 Wheels/axle EM55200001
22 Wheel rubber 175mm EM21625009
23 Fuse box cover EM21690110
24 Fuse 300A EM22220011
25 Orange pilot lamp 220V EM22610014
26 Green pilot lamp 220V EM22610008
27 Female dinse plug 25 sq/mm EM22100002
28 Cable clamp EM21605009/8
29 Front panel EM33700722
30 Cover panel EM33705346
31 Handle EM33725080
32 Amperarometric Shunt 100A/60MW EM22600047

14
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
DECLARATION OF CONFORMITY

15
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
SPECIFICATIONS
NOTES
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
Model Number 260N 335
Supply voltage 220-240V, 50Hz 220-240V, 50Hz
Battery charging voltages: 12V and 24V 12V and 24V
Max charge (Amps) 40 50
Max boost (Amps) 250 300
Internal fuse rating 200A 300A
Internal fuse part no EM22220008 EM22220011