Clarke WBC400 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
GC0116
BATTERY CHARGER-STARTER
MODEL NO: WBC240 & WBC400
PART NO: 6261505 & 6261515

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INTRODUCTION
Thank you for purchasing this CLARKE Battery Charger/Starter.
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 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.
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 WBC240 WBC400
Dimensions (D x W x H) 274 x 370 x 590 390 x 442 x 631
Weight 14.8 kg 24.65 kg
IP Rating IP20
Suitable Battery Type Lead Acid, GEL, WET, AGM with 12/24 voltages
Minimum Battery Size 5 AH
Maximum Battery Size 700 AH 1000 AH
Operating Temperature Range 0 to 40°C
Estimated Engine Capacity up to 2.5 L up to 3.5 L
Input Voltage @50Hz 230 V AC
Duty Cycle (Starting) 3 sec On / 120 sec Off
Max Input current
Starting @ 12V/24V 12V/25A and 24V/39A 12V/40A and 24V/75A
Charging @ 12V/24V 12V/4.6A and 24V/7A 12V/6A and 24V/10A
Open Circuit Voltage (Output)
Start @ 12V/24V 14.77/29.45V 15.98/31.91V
Charging 1@ 12V/24V 11.91/23.75V 9.98/19.80V
Charging 2 @ 12V/24V 10.48/20.92V 10.44 / 20.69V
Charging 3 @ 12V/24V 11.13/22.21V 10.91/21.69V
Timer Charge 4@12V/24V N/A 11.22/22.34V
Timer Charge 5@12V/24V N/A 11.79/23.55V
Timer Charge 6@12V/24V N/A 12.46/24.87V
Max Output Current
Starting @12V/24V 290/240A 420/350A
Charging @12V/24V 45/45 A 60/60A

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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.
The maximum input current for the WBC240 (24V output) is 39
amps with a duty cycle of 3 secs on/120 secs off.
The maximum input current for the WBC400 (24V output) is 75
amps with a duty cycle of 3 secs on/120 secs off.
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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WBC240 OVERVIEW
The WBC240 is provided with a pair of leads complete with clamps for
connection to a battery via the appropriate outlet connections - 12V and 24V,
as shown.
Three selector switches provide for different functions as shown above. The
main fuse is mounted on the front panel, as shown and the model
incorporates a thermal overload cut-out.
1 Fuse Holder 6 Power On/Off Switch
2 Charging condition meter (Amps) 7 Positive Terminal +24V
3 High/Low Charging Selector 8 Positive Terminal +12V
4 Min/Boost Charge Charging Selector 9 Negative (BLACK) lead
5 Battery Charge/Jump Start Mode
Selector switch
10 Positive (RED) lead

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WBC400 OVERVIEW
The WBC400 is provided with a pair of leads complete with clamps for
connection to a battery via the appropriate outlet connections (12V and
24V), as shown.
Two selector switches provide for different functions as shown above. The
main fuse is mounted on the front panel, as shown and the model
incorporates a thermal overload cut-out.
1 Fuse Holder 7 Fast Charge Timer
2 Charging condition meter (ammeter) 8 Positive Terminal +12V
3 Charging ‘ON’ Indicator 9 Positive Terminal +24V
4 Start Mode 10 Negative (BLACK) lead
5 Charging Mode Indicator 11 Positive (RED) lead
6 Charging Level Selector

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ASSEMBLY
ASSEMBLY
1. Pass the axle through the holes in
the body of the machine and fit
circlips to the axle at the position
shown.
1. Slide the wheels onto each end of
the axle and secure with further
circlips outside each wheell.
2. Press-fit the caps to the wheels.
3. Install the foot to the base of the
machine using the three screws as
shown.
4. Fit the positive battery lead to the
terminal of your choice (12/24V)
to match the voltage of the
battery.

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GENERAL PREPARATION
CHARGER LOCATION
1. Place the charger as far away from the car battery as possible.
2. Do not position the charger above the battery during the charging
procedure. Gases from the battery will cause corrosion and damage the
charger.
3. Do not let battery acid drip on anything when reading specific gravity or
when topping up the battery.
4. Do not operate the charger in an enclosed space, such as inside the
vehicle. Never cover the battery charger.
5. Do not stand the battery on top of the charger.
6. Always stand the battery charger on a firm, level floor.
7. During charging, make sure that the area around the battery has good
ventilation.
CONNECTING THE BATTERY
1. Before charging, disconnect the battery from the vehicle.
2. Always remove the grounded (earth) terminal from the battery first. Make
sure that all electrical accessories in the vehicle are switched off to prevent
sparking.
3. Clean the battery terminals. Be careful to prevent battery electrolyte from
coming in contact with your eyes.
4. Except for sealed units, add distilled water to each cell until the battery
acid reaches the level specified by the battery manufacturer.
• This helps drive unwanted gas from the cell. Do not overfill. For a battery
without cell caps, consult the manufacturer's instructions.
5. Follow all the battery manufacturer's specified precautions: for example,
removing or not removing cell caps while being charged, and
recommended rates of charge.
6. Refer to the vehicle manual to find the voltage of the battery and make
sure that the charging cable is connected to the correct terminal (either
12/24V).
7. This charger has an adjustable charge rate and the battery should be
charged initially at the lowest rate.

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CONNECTING TO A BATTERY
WARNING: A SPARK NEAR THE BATTERY MAY CAUSE BATTERY EXPLOSION.
TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY:
• Turn off the charger before you connect/disconnect the DC
output connectors.
• Do not let the connectors touch each other.
• Attach the connectors to battery terminals and make sure that
you get a good connection.

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BATTERY CHARGING
CHARGING A BATTERY INSTALLED IN THE VEHICLE
1. Arrange the leads carefully to reduce the risk of damage caused by sharp
edges.
2. Check the polarity of the battery posts.
3. Consult the vehicle manual to confirm if the vehicle has a Negative or
Positive earth.
• For negative earth vehicles, connect the POSITIVE (RED) lead from the
battery charger to the POSITIVE terminal on the battery. Connect the
NEGATIVE (BLACK) lead to the vehicle frame or engine block away from
the battery.
• For positive earth vehicles, connect the NEGATIVE (BLACK) lead from the
battery charger to the NEGATIVE terminal on the battery. Connect the
POSITIVE (RED) lead to the vehicle frame or engine block away from the
battery.
• Do not connect the lead to ancilliary engine components.
4. 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 the vehicle’s electronic equipment.
5. When charging is completed, switch off the charger/starter and unplug it.
Remove the lead from the earth point and then remove the lead from
battery.
CHARGING A BATTERY REMOVED FROM THE VEHICLE
1. Make sure that you know the polarity of the battery posts.
2. Connect the POSITIVE (RED) lead to the POSITIVE post on the battery.
3. Connect the NEGATIVE (BLACK) lead at arms length to the NEGATIVE post
on the battery.
4. When you disconnect the charger/starter from the battery, always do it in
the opposite order to the sequence of connection and remove the first
connection at arms length from the battery.

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CHARGING MORE THAN ONE BATTERY
1. Simultaneous multiple charging
should be carried out in series
since this enables monitoring of
the current circulating in each
battery.
2. If two batteries with rated
voltages of 12V are connected in
series, set up the charger using
the positive cable connected to
the 24V terminal.
RAPID CHARGING USING THE TIMER
1. The WBC400 has a charge timing device of up to 60 minutes operation.
2. To initiate Rapid Charging, turn
the fast-charge timer to the
required charging time in minutes
and turn the charging level rotary
switch to one of the fast charging
levels of either 4, 5 or 6.
3. When the pre-set time has
elapsed the current is
automatically switched off.
4. Turn the charging level rotary
switch to the off position.

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OPERATION OF THE CHARGER
TO CHARGE THE BATTERY
1. Connect the charger to the battery.
2. Connect the charger to the mains supply and switch on.
WBC240 MODEL
1. Set the mode switch to the
CHARGE function indicated by
the battery symbol.
2. Set the other selector switches to:
• Low charging rate:- MIN and 1.
• Medium charging rate:- MIN
and 2.
3. High charging rate:- BOOST. (this
over-rides the 1/2 switch)
WBC400 MODEL
1. Set the mode rotary switch to the
CHARGE function indicated by
the battery symbol. Set the switch
to low (1-3) or High (4-6) as
required.
2. If required, set the Fast Charge
Timer rotary switch to the required
time duration (15, 30, 45 or 60
minutes).
• The timer is only to be used on
the High charge settings (4, 5 & 6).
BOTH MODELS
1. Check the current delivery by reading the ammeter on the front of the
battery charger.
• During charging, the ammeter on the charger will indicate the current
delivered to the battery. During the charge, the readout will decrease
slowly to the lowest value according to the capacity and condition of
the battery. When the reading becomes very low, no further charging is
necessary.

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• Charge a sealed battery very slowly, monitoring the voltage across the
battery terminals using a voltmeter.
• When the battery terminal voltage reaches 14.4V for 12V batteries, stop
charging.
WHEN CHARGING IS COMPLETE
1. When charging is complete the ammeter reading should be close to “0”
and the electrolyte in the battery may begin to gas. Stop charging to
protect the battery plates from damage.
2. Switch off the charger and disconnect the plug from the power socket.
• Remove the leads from the battery as described in the previous
sections.
• Return the battery to the vehicle. Secure and re-connect, ensuring all
tools are removed from the underbonnet area.

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PROCEDURE FOR ENGINE STARTING
1. Connect the charger to the battery.
2. Connect the charger to the mains supply.
WBC240 MODELS
1. Check that mains supply switch is
OFF.
2. Set the CHARGE/START switch in
the START position.
3. Set the MIN/BOOST switch in the
MIN position.
4. Connect the cables to the vehicle
battery as for charging.
5. Set the ON/OFF switch to ON.
WBC400 MODELS
1. Set the rotary CHARGE/START
switch in the START position.
2. Connect the cables to the vehicle
battery as for charging.
CAUTION: 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 LARGER ENGINES.
CAUTION: WHEN THE BATTERY IS COMPLETELY FLAT, YOU MUST CHARGE
THE BATTERY BEFORE ATTEMPTING TO START THE ENGINE, OTHERWISE
YOU MAY CAUSE DAMAGE TO THE VEHICLE ELECTRONIC SYSTEM.

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BOTH MODELS
1. Turn the key in the vehicles ignition to ‘start’, and crank the engine for a
maximum of 3 seconds. If the vehicle does not start, wait 2 minutes before
trying again for a maximum of 5 cycles.
2. Immediately after the engine starts, switch the charger off, unplug from the
mains power and disconnect the starter/charger from the battery.
THERMAL CUTOUT
NOTE: If the battery charger is overloaded at any time, a thermal cut out will
automatically come into operation, rendering it inoperative. Allow
approximately 5-10 minutes before using the unit again.
FUSES
1. The starter/charger is equipped with 2 x safety fuses which will protect the
unit under the following circumstances:
• Overload - too high a current to the battery.
• Short Circuit - clamps touch or cross connection to battery.
• Prolonged starting attempts.
REPLACING THE FUSE
The fuse fitted is rated at 2 x 60A
(WBC240) and 2 x 100A (WBC400)
and is fitted behind the clip-on cover
for easy replacement.
1. Switch the unit off and disconnect
from the mains.
2. Allow the unit to cool down and
establish the reason for the failure
and correct.
3. Pull off the fuse cover before
unscrewing the nuts to remove the fuse. Replace only with an identical
fuse and with the same rating, as supplied with your starter/charger.
Replacements are available from your Clarke dealer.
WARNING: IF THE ENGINE WILL NOT START, DO NOT CONTINUE AS THE
VEHICLE BATTERY AND ELECTRICAL CIRCUITS MAY BE DAMAGED AND
THE FUSE IN THE CHARGER WILL BLOW. DISCONNECT THE CHARGER AND
INVESTIGATE FOR VEHICLE FAULTS.

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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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TROUBLESHOOTING
Problem Cause Solution
Bad Battery light
comes on
(WBC400 model)
The battery voltage is
between 0.5V and 1.5V.
Have the battery tested by
a qualified technician;
Replace the bad battery if
necessary.
The battery voltage is lower
than 11V, after being
charged for 4 minutes.
The battery voltage drops
below 12V two minutes after
being fully charged.
Unable to reach fully
charged status in 24 hours.
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
(below freezing), it will not
accept a high rate of
charge, so the initial
charger rate will be slow.
The rate of charger will
increase as the battery
warms.
Never attempt to charge a
frozen battery.

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DECLARATION OF CONFORMITY

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WBC240 PARTS DIAGRAM