VDC Electronics BatteryMINDer 12248 User manual

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BatteryMINDer®Model 12248
Charger / Maintainer /
Desulphator-Conditioner
VDC Electronics, Inc.
147 D Woodbury Rd.
Huntington, NY 11743
www.vdcelectronics.com
[email protected]
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Rev. G-061606 P/N VDC12248-MNL-F

TABLE OF CONTENTS
SAFETY INSTRUCTIONS..........................................................................................................3
PREPARING TO CHARGE.........................................................................................................5
CHARGER LOCATION...............................................................................................................5
DC CONNECTION PRECAUTIONS ..........................................................................................6
QUALIFYING YOUR BATTERY: ................................................................................................8
TESTING A FILLER CAP OR MANIFOLD-TYPE LEAD ACID BATTERY...................................8
TESTING WITH A HOT/COLD CALIBRATED HYDROMETER TESTER..................................10
TESTING A SEALED, AGM OR GELLED-TYPE LEAD ACID BATTERY .................................10
UNIT WITH CALL-OUTS ...........................................................................................................12
SIMPLIFIED OPERATING INSTRUCTIONS .............................................................................13
LED INDICATOR FUNCTIONS .................................................................................................14
DETAILED OPERATION INSTRUCTIONS ...............................................................................16
MAINTAINING MULTIPLE BATTERIES.....................................................................................22
BATTERY CONFIGURATIONS .................................................................................................23
TROUBLESHOOTING - MODEL 12248 ...................................................................................24
DETAILED SPECIFICATIONS - VDC MODEL NO. 12248........................................................26
CHARGING PROFILE................................................................................................................31
FOR REPAIR OR REPLACEMENT............................................................................................32
NOTES........................................................................................................................................33
GUARANTEE AND WARRANTY................................................................................................34
BatteryMINDer®Model 12248
Rev. G-061606 Page 2 P/N VDC12248-MNL-B

Underwriters Laboratories (UL)
REQUIRED SAFETY INSTRUCTIONS
WARNING
TO REDUCE THE RISK OF FIRE,
ELECTRIC SHOCK, OR INJURY TO
PERSON, OBSERVE THE FOLLOWING:
1. Do not expose charger to rain or snow. It is
designed to operate ONLY INDOORS.
2. USE of any attachment not specifically recom-
mended by the battery charger manufacturer for
use with this exact model of charger may result
in risk of fire & electric shock or injury to person.
3. An extension cord should not be used, unless
absolutely necessary. Use of an improper exten-
sion cord could result in fire or electric shock. If
extension cord must be used be sure:
a. Pins on plug of extension cord are the same
number, size, & shape of plug on charger
b. Extension cord is properly wired and in
good condition.
c. Wire size is enough for AC ampere of charger
as specified below: Length of cord, feet (meters)
25 (7.6), 60 (15.2), 100 (30.5), 150 (45.6) AWG
Size #18.
4. Do not use charger if it received a sharp blow,
been dropped, or damaged.
5. Charger contains no serviceable parts. If it
fails for any reason, return to the address shown
within for a free replacement under warranty.
6. To reduce risk of electric shock, unplug charg-
er from outlet before attempting any cleaning.
7. WARNING - RISK OF EXPLOSIVE
GASES.WHENEVER YOU WORK NEAR A
LEAD ACID BATTERY IT IS DANGEROUS.
BATTERIES GENERATE EXPLOSIVE GASES
DURING NORMAL BATTERY OPERATION.
FOR THIS REASON, IT IS OF UTMOST
IMPORTANCE THAT EACH TIME BEFORE
USING YOUR CHARGER, YOU MUST READ
THIS MANUAL AND FOLLOW THE INSTRUC-
TIONS EXACTLY.
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To reduce risk of battery explosion, follow these
instructions and those published by the battery
manufacturer and the manufacturer of any
equipment you plan to use in the vicinity of the
battery. Review cautionary markings on the
products and the engine.
8. PERSONAL PRECAUTIONS when working
with or near a lead acid battery.
a. Someone should be able to hear your
voice or close enough to aid you when working
near a lead acid battery.
b. Have fresh water and soap nearby
case battery acid contact skin, clothing, or eyes.
Wear complete eye protection and clothing pro-
tection. Avoid touching eyes while working near
battery.
c. If battery acid does contact skin or
clothing, wash immediately with soap and water.
If acid entered the eye, immediately flood the
eye with running water for at least 10 minutes
and get help immediately.
d. NEVER smoke or allow a spark of
flame near battery or engine.
e. Be extra cautious to reduce risk of
dropping a metal tool or auto part onto battery. It
might spark or short circuit battery or other elec-
trical part that may cause an explosion.
f. Remove personal metal items such as
rings, bracelets, necklaces, and watches when
working with a lead acid battery. A lead acid bat-
tery can produce a short circuit current high
enough to weld a ring or the like to metal, caus-
ing a severe burn.
g. Charger is designed to be used for
recharging lead acid batteries ONLY. Never use
it to power a low voltage electrical system, or for
attempting to recharge dry cell batteries that are
commonly used in house holds. These batteries
may explode and cause injury to persons and
damage property
BatteryMINDer®Model 12248
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NEVER CHARGE A FROZEN BATTERY OR
ONE AT A TEMPERATURE ABOVE 123° F.
PREPARING TO CHARGE
a. If necessary to remove battery from
equipment to charge. Always remove ground ter-
minal first. Turn off all accessories in the vehicle,
so as not to cause an arc.
b. Be sure area around battery is well
ventilated while battery is being charged. Force
gas vapors away by using a piece of non-metal-
lic material as a fan.
c. Clean battery terminals. Be careful to
keep corrosion from contacting eyes.
d. Add distilled water to each cell until
battery acid reaches level specified by the man-
ufacturer. This helps Purge excessive gas from
cells. Do not overfill. For a battery without caps,
follow manufacturer's recharging instructions.
e. Study all battery manufacturer's specif-
ic instructions such as removing cell caps while
charging and recommended charge rates.
f. Determine condition of battery, by refer-
ring to instructions herein, before ever attempt-
ing to charge or desulphate any / all batteries.
CHARGER LOCATION
a. Make sure charger is as far away from
battery as output cables permit.
b. Never place charger directly above bat-
tery being charged; gases from battery will cor-
rode and damage charger.
c. Never allow battery acid to drip on
charger when reading specific gravity or filling.
d. Do not operate charger in a closed-in
area or restrict ventilation in any way.
e. Do not set battery on top of charger.
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DC CONNECTION PRECAUTIONS
a. Connect and disconnect DC output clips from
battery only after removing charger power cord
from outlet.
b. Attach clips to battery posts and twist or rock
back and forth several times to make good con-
tact. This tends to keep clips from slipping off
terminals and reduces risk of sparking.
FOLLOW THESE INSTRUCTIONS WHEN BAT-
TERY IS INSTALLED IN EQUIPMENT (VEHI-
CLE, PWC, BOAT, TRACTOR, ETC.) A SPARK
NEAR BATTERY MAY CAUSE BATTERY TO
EXPLODE. TO REDUCE RISK OF A SPARK
NEAR BATTERY:
c. Position DC output cord to reduce risk of dam-
age by hood, door, covers, or moving engine
parts.
d. Stay clear of fan blades, belts, pulleys, and
other parts that can cause injuries.
e. Check polarity of battery posts. POSITIVE
(POS, P,+) usually has a larger diameter than
NEGATIVE -.
f. Determine which post of battery is grounded
(connected) to the chassis of equipment. If neg-
ative post is grounded see Item N. If positive
post is grounded see item P.
N. For negative grounded equipment, connect
POSITIVE (RED) clip from charger to POSITIVE
(POS, P, +) ungrounded post of battery. Connect
NEGATIVE (BLACK) clip to vehicle chassis or
engine block away from battery. Do not connect
clip to carburetor, fuel lines, or metal body parts.
g. For positive ground equipment, connect NEG-
ATIVE (BLACK) clip from charger to NEGATIVE
(NEG, N,) UNGROUNDED POST OF BATTERY.
Connect POSITIVE (RED) CLIP to chassis or
engine block away from battery.
BatteryMINDer®Model 12248
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RED
RED

Do not connect clip to carburetor, fuel lines,
or sheet metal body parts. Connect to heavy
gauge metal part of frame or engine.
h. When disconnecting charger, discon-
nect charger from AC outlet, then remove clips
from vehicle chassis, and battery posts.
Operating instructions for charge information.
FOLLOW THESE STEPS WHEN BATTERY IS
OUTSIDE OF VEHICLE OR EQUIPMENT.
A SPARK NEAR THE BATTERY MAY CAUSE
BATTERY EXPLOSION. TO REDUCE RISK OF
A SPARK NEAR BATTERY:
a. Check polarity of battery posts. POSI-
TIVE (POS,P,+) usually has a large diameter
than NEGATIVE (NEG, N, -) battery post.
b. Connect ( RED ) charger clip to
(POS+) post of battery.
c. Position yourself and free end of cable
as far away from battery as possible, then con-
nect NEGATIVE (BLACK) charger clip to free
end of cable.
d. Do not face battery when making final
connections.
e. When disconnecting charger, always
do so in reverse sequence of connecting proce-
dure and break first connection while as far
away from battery as practical. Do not attempt
to permanently install any charger not specif-
ically designed for permanent installation,
especially in a wet / marine environment
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RED

QUALIFYING YOUR BATTERY:
Preliminary Requirements
NOTE: The BatteryMINDer has no electrical
output unless it is connected to a healthy bat-
tery. Testing the BatteryMINDer with a volt or
an Amp meter without the unit being connected
across a good battery will result in a false read-
ing. If you experience any problems, or are not
sure of how to properly use or connect your
BatteryMINDer, please e-mail our technical
support at: [email protected] or
call our toll-free technical support line 800-379-
5579 x206 (Eastern Time). Be certain to leave
your phone number with the area code, time
zone and the best time to call.
To gain the best result from your new charger
and to maximize the life and performance of
your batteries we strongly recommend you
qualify (test) your batteries before attempting to
either charge-maintain or desulphate them.
Remember, even if you just purchased a "new"
battery it may have been subjected to condi-
tions that have caused "sulphation" such as
high temperature (>=80°).
NOTE: If your battery is new and you are cer-
tain it was not subject to conditions that could
have caused sulphation*, even before you pur-
chased it, then you can disregard our recom-
mendations for qualifying / testing your battery,
before using the BatteryMINDer.
* Such as high temperature storage (=/> 80? F)
and/or allowed to self-discharge to 12.4 Volts
or lower.
Testing a Filler Cap or Manifold-type Lead
Acid Battery
1. Carefully remove all 6 caps or both mani-
fold-type covers from your battery.
2. Check the water-liquid electrolyte level. If
the level is low or has ever been below top of
plates, severe lead plate sulphation has taken
place. Significant recharge/reconditioning time
is needed to restore these plates to a
BatteryMINDer®Model 12248
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condition where the battery can be expected to
function normally.
3. Refill each cell with distilled water only to the
liquid level indicator found in each cell. Before
proceeding further you must be thoroughly
familiar with the safety and operating instruc-
tions.
4. Recharge the battery with the BatteryMINDer
to ensure that it is slowly and completely
charged before you determine its condition.
Allow battery to "rest"* overnight for a minimum
of 10 hours before testing with a temperature
compensated hydrometer and/or digital type volt-
meter only.
* "RESTED" = a battery that has been as fully
charged as possible, using a 3 stage charger
(model 12248) and left disconnected from
charger or any type load for a minimum of 12
hours.
5. If the BatteryMINDer battery condition LED
lights (KKKKKKKKKKKKKKKKKK)within 72 hours (single bat-
tery) or no balls float in one or more cells, your
battery may be too far gone to be fully desul-
phated. Reconnect battery to your
BatteryMINDer and press the Maintenance
mode button. Allow battery to remain in mainte-
nance mode for a minimum of 72 hours, before
re-test. Use a hot/cold calibrated hydrometer
tester for the most accurate results** (see next
page) if you see an increase in the Specific
Gravity (SG) or voltage indicating that there is an
improvement in the battery's condition, continue
desulphating for an additional 72 hours and
retest the battery. Continue this process until the
SG or voltage readings no longer increase.
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TABLE 1
YELLOW
OCV=Open Circuit No Load Voltage

BatteryMINDer®Model 12248
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**Testing with a Hot/Cold Calibrated
Hydrometer Tester
Read the tester instructions carefully for most
accurate readings.
1. When using the tester the first time or after a
long period of non-use, fill the tester with the
battery fluid and let it sit for 1/2 hour or longer.
This will soak the balls in order to give you more
accurate readings. Failure to do so will give you
false readings indicating a battery that may not
be in as good a condition as you may have
thought.
2. After inserting the tester in a cell, gently tap
the tester several times against the inside wall of
each cell to dislodge air bubbles that will cause
more balls to float than should. Failure to do so
will yield false readings that indicate a battery
that is not fully desulphated or does not qualify
for desulphation.
3. If no balls float in any cell, the cell is shorted.
This means your battery is beyond the point of
being properly recharged or reconditioned-desul-
phated. Dispose of the battery.
If each cell floats three (3) or more balls (or 1250
on gauge-type), your battery can be desulphat-
ed-reconditioned.
4. Always rinse the tester with fresh water after
every use. Failure to do so will cause false read-
ings.
Testing a Sealed, AGM or Gelled-type Lead
Acid Battery
These batteries have no filler caps or manifold-
type covers. Because you cannot gain access
to the interior of your battery you cannot test it
with a hydrometer.
USE A DIGITAL VOLTMETER ONLY:
1. Recharge the battery with the BatteryMINDer
to ensure it is as completely charged as possi-
ble, before you determine its condition. Allow
battery to "rest" (see pg. 9) overnight for a mini-
mum of 10 hours before testing with a digital
voltmeter only.

Failure to test a "rested" (see pg. 9) battery will
cause false readings. Be certain to read and
understand all safety related instructions (pages
3 to 7) before proceeding further.
2. Measure battery's voltage, without any load
attached. If the voltage is less than 12.4 volts
(Typically 50% of charge) the battery may be too
heavily sulphated to be fully recoverable. If volt-
age is 12.4-V or higher full recovery can be
expected, given sufficient time (average 1-2
weeks for batteries that are heavily sulphated).
3. Connect the BatteryMINDer to the battery.
4. Charge battery to its maximum level. Press
Maintenance-Float (select Battery type) button, if
it does not go into this mode automatically.
Allow battery to remain for a minimum of 72
hours before retesting. If improvement is seen,
continue until battery voltage reaches full capaci-
ty level or no further increase is seen.
Note:OPTIMA brand "Yellow Top"
starter/deep cycle batteries have a fully
charged "resting" voltage of 13.1 (OCV); Blue
Top" deep cycle 12.8 (OCV). Increase above
values accordingly.
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TABLE 2
OCV=Open Circuit No Load Voltage

BatteryMINDer®Model 12248
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9
4
10
8
111-ooptional
2
5
6
122-ooptional
1
7
UNIT WITH CALL-OUTS
1) Battery clip cordset w/ qwik connect plug (pgs.13, 16)
2) Ring terminal cordset w/ qwik connect plug (pgs. 13, 16)
3) Mounting tabs
4) Input power cordset (pg. 13, 18)
5) Output cord w/ qwik connect plug (pg. 13, 16)
6) Temperature sensor input connector (pg. 17)
7) Charge rate selection button (pgs. 13, 17, 18)
8) Battery type selection button (pgs. 13, 17, 18)
9) Start / reset selection button (pgs. 13, 17, 18)
10) LED indicators for power, connection, fault, battery
condition, charge status (pgs.13-15, 18–20, 24)
11) 12 Volt Power cordset (Optional)
12) Temperature sensor with cord and ring terminal (pg. 17)
(Optional)

Simplified Operating Instructions
(Read and understand ALL Safety Instructions on pages (3 -7) and Qualifying Your Battery (pgs.
8 -11) before proceeding)
1. Attach battery connector (either clips or ring terminal assembly) to output cordset of charger. Use
either type, but not both at same time.
2. Attach charger output to battery's terminals. Red sleeve indicator = Positive +,
Black = Negative -.
3. Attach charger power cord to AC electric outlet. (Observe Reversed Polarity LED Indicator.
If lit RED, reverse charger connectors on battery terminals.
4. Observe Battery Voltage Test Indicator; LED Must be lit *.
5. Select Charge rate (2 A for small batteries, 4 A for medium size, 8 A for large and multiple
batteries).
6. Select Battery Type = Flooded, AGM or Gel
7. Press Start/Reset Button to begin charging - LED indicator will light
Note: Pressing Start/Reset button in the charging stage returns the setting to the previous status.
Pressing and holding Start/Reset button (over 3 seconds) until all LEDs light, returns all settings to original.
If only maintenance (float) mode is required, press and hold Battery Type button, until charging- Green
LED indicator blinks.
*See full Instructions if not Green
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GREEN
RED
RED
GREEN
GREEN
GREEN GREEN

BatteryMINDer®Model 12248
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LED INDICATOR FUNCTIONS
LED indicators refer to charger label at right
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TABLE 5
TABLE 6

Detailed Operation Instructions Model 12248
After carefully reading and understanding the
Safety Instructions contained in this manual
(pages 3 to 7) and having evaluated your battery
as described in Qualifying Your Battery (pages 8
to 10) you are properly prepared to begin using
your charger.
1. Attach output cord of charger to either the
Battery Clip(s) Assembly (BCA) (supplied) or the
Ring Terminal Assembly (RTA) (supplied)
depending on your preference. However never
use both assemblies at the same time for any
reason whatsoever. Never use either of these
assemblies on any other charger or for any other
purpose such as improvised “jumper cables",
etc. Using the RTA on batteries remaining in
their normal use location (in same place they are
regularly installed will normally prove the safest
and most convenient. If you have several appli-
cations you may wish to purchase additional
Ring Terminal Assemblies (RTA) available from
your dealer or VDC Electronics, Inc. directly.
Note: this assembly contains a 15 Amp automo-
tive type fuse and is replaceable should for any
reason it were to blow. Never replace this fuse
with any type whose rating is higher than 15
Amps, as seriously harmful results may occur.
2. Identify the positive and negative posts or
connections on your battery, usually clearly des-
ignated with the polarity markings of + (positive)
and – (negative). If you have previously installed
the RTA referred to in 1. above, you need only to
press the connector plug of the charger’s output
cord into the mating plug of the RTA. Push firmly
and do not leave any space between them.
BatteryMINDer®Model 12248
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Correct polarity and a good connection will be
your reward. Attach the BCA to the proper bat-
tery posts, clamps or screw terminals, depending
on type of battery. ALWAYS connect the nega-
tive (Black) clip to a metal grounding point
(Negative ground installations such as most
modern cars, trucks, boats, RVs, etc.) as far
away from battery as possible for maximum
safety. Never connect to any type of fuel line.
Note: Older vehicles or other devices may be
Positive ground installations requiring differ-
ent connection recommendations. If unfamiliar or
unsure which battery type of grounding system
you have, check with our Tech Support person-
nel before proceeding further.
Note: If you have purchased the Optional tem-
perature compensation Sensor Assembly (Part#
OBS-12), attach the ring terminal of the sensor
to the positive post-connection on the battery
and plug the opposite end into the female recep-
tacle on the charger. This sensor detects the
temperature at the battery when properly
installed. Use of this sensor will increase your
battery life significantly, so please try to use. If
you cannot use for your current application(s),
do not discard or misplace.
Attach the ring terminal of the temperature sen-
sor cord assembly to either the Positive or
Negative posts or clamps of the battery,
whichever is most easily accessible.
3. Determine the type of battery you wish to
charge. When certain press the Select Battery
Type button. The most common is the Flooded
kind, distinguished by removable filler caps (6)
or two (2) manifold covers (Maintenance-Free)
which should not be removed unless specifically
allowed by the battery manufacturer. The second
most popular is the Absorbed Glass Mat (AGM)
sealed-valve regulated type. Lastly is the sealed
valve regulated Gel battery.
Note:If unsure of your battery type, check with
our Tech Support before proceeding.
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further. The normal (default) setting of your
charger is GEL, as this is the lowest voltage
output and thus the one least likely to cause
your battery to be overcharged, should you
incorrectly select the wrong battery type.
However be aware that using the wrong set-
ting for a particular type battery can dramati-
cally shorten its life and/or cause potentially
explosive gas to be emitted from the battery.
4. After selecting battery type, determine
thecorrect charge rate for your particular bat-
tery. Small batteries (< 10 AH) should be
charged at the 2 Amp setting rate. Larger
types (10-30 AH) such as used in motorcy-
cles, PWC, etc. are best charged at the 4
Amp rate setting. For batteries whose capaci-
ty rating is greater than 30 to as high as 120
AH set charge at the 8 Amp rate. If unsure or
recharge time is not important, always choose
a low setting (2 or 4 Amp).
Note: The safest procedure is to choose the
lowest possible setting when in doubt or
recharge time is not important, as there may
be conditions such as an internally damaged
battery that cannot be reliably detected.
5. After selecting both battery type and
charge rate, plug the unit’s Power cord into a
standard – grounded 120 Vac electrical outlet.
The Power ON LED Indicator will light Green.
If it does not light Green check the outlet to
be sure it is functioning. In addition, be sure if
outlet is controlled by a switch, no one will
accidentally shut off the power to the outlet.
Check for correct polarity = (no ERROR Red
LED Indicator). If ERROR Indicator is lit,
reverse the charger’s output connections to
the battery.
6. Press the Start / Reset button. The Charge
– Float LED Indicator will light Green. The
charger will now begin charging by first
checking the battery to determine its voltage
and ability to accept a charge. Should the
BatteryMINDer®Model 12248
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RED
GREEN
GREEN
GREEN

battery not have a normal fully discharged
voltage (10.5-V minimum) the unit will begin
charging in the “Soft-Start” mode to determine
if the battery can be safely charged. If it can-
not, the Power ON – Error LED will flash Red
and charging will be stopped. Battery should
be carefully checked under a load by a quali-
fied person before further attempting to charge
it. Note: If the battery does not have a mini-
mum no load OCV (Open Circuit Voltage) of
3 volts, the ERROR LED will light Red and
charger will reject battery.
No further effort should be made to charge
this battery with this charger or any charg-
er. Discard this battery, unless it has just been
subjected to a long period of continuous dis-
charge under a load such as can occur with
leaving lights on or cranking an engine exces-
sively. Allow such a battery to “Rest” for sever-
al hours (overnight if possible) before deter-
mining if it is defective. Be very suspicious of
any 12-V battery that does not have at least
11-Volts (OCV) before it is recharged. It may
well be seriously damaged and unsafe for any
type of use or recharge. The unit’s Battery
Condition Indication LED will help you deter-
mine if battery is less than 11-Volts (Yellow))
or greater than 11-Volts (Green)
7. After battery has been fully charged, the
Green Charge-Float LED Indicator will begin
blinking. It will continue to blink indefinitely,
unless unit is disconnected from battery or
Start / Reset button is pressed. Should battery
be unable to be fully charged, the LED will not
blink and the Red Error LED will blink. Battery
may not be able to be fully charged, may be
too large or too deeply discharged to be fully
charged in the normal time allowed by charg-
er. If you are certain battery is not defective,
having read and understood completely all of
the above concerns and conditions, proceed
to restart the charger by pressing the Start/
Reset button and allow charger to begin
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GREEN
RED
RED
RED
YELLOW

charging battery again. If battery is not defective
it should be able to be fully charged after being
restarted. After sufficient time has lapsed the
GREEN charge LED Indicator will blink confirm-
ing when / if battery is now fully charged.
Note: If attempting to charge more than one bat-
tery at a time it is very likely the charger will
need to be restarted as described in order to
completely charge multiple batteries. We do not
recommend charging more than one battery at a
time without confirming the individual condition
of each battery and monitoring the charging and
batteries closely. A better solution is to charge
each battery separately using model 12248
BatteryMINDer and then connect them together,
if desired for long term maintenance-float charg-
ing. We suggest your reading the detailed speci-
fications on pages (26 - 31), including the addi-
tional LED indicator functions (pgs. (14-15) not
already covered above.
After carefully reading these instructions and
Troubleshooting (pgs. 24 - 25) sections should
you still have questions, please e mail our tech-
nical support department at:
T[email protected].
Allow up to 3 business days for a detailed
response to your questions. Always identify the
model number of the product and revision letter
of this manual contained on this page below.
Without this information we may not be able to
assist you correctly.
If your questions have already been answered in
this manual you can expect a response referring
you back to this manual and the specific
page(s).
BatteryMINDer®Model 12248
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