BatteryMINDer 24041-AA-S1 User Manual
BatteryMINDer
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Charger / Maintainer /
Full Time De-Sulfator - Conditioner
Model 24041-AA-S1 24-Volt @ 4 Amp
4 A
Until
4A Lit
Until
Aviation Lit
PRESSPRESSPRESS
MAINTENANCE
MODE ONLY
(HOLD 3 SEC.)
Start / Reset
/ Stop
U.S. Patents: 5783929 & 6078166
VDC Electronics, Inc.
800-379-5579 (ET)
www.vdcelectronics.com
AVIATION
AVIATION-CALIBRATED
AIRCRAFT BATTERY ONLY
FOR LEAD-ACID
GA BATTERY ONLY
Green = Power ON
ERROR:
Red = Polarity Reversed
/ Battery = less than 6-Volts*
Red (Blinking) = Battery not fully charged charger in float-maintenance mode
*
Battery Condition Indication
Power On & Battery Connected
Before Start Charge:
Green = OK - Accepted
Yellow = Weak / Sulfated / Deep Discharge
*
After Charge:
Green = Good
Yellow = Sulfated / Weak*
Charge - Float
Green (solid) = Charging
Green (blinking) = Float (maintenance)
*See Instruction Manual
Hold for 5 sec. for full reset
®
INSTRUCTION MANUAL
Model 24041-AA-S1
Rev. F-103007 P/N VDC24041AA-S1-MNL
Rev. F-103007 P/N VDC24041AA-S1-MNL
BatteryMINDer®
Model 24041-AA-S1*
Charger / Maintainer /
Desulfator-Conditioner
VDC Electronics, Inc.
147 D Woodbury Rd.
Huntington, NY 11743
www.vdcelectronics.com
techsupport@vdcelectronics.com
*For use with Aviation Type 24-V Batteries ONLY.
Requires proper installation of Battery Temperature
Sensor (ABS-124 - supplied) and proper battery type
selection.
READ AND SAVE THESE INSTRUCTIONS
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BatteryMINDer
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Model 24041-AA-S1
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, 15
Detailed Operation Instructions ................................................................................................ 16
Temperature Sensor ABS-124 (At-the-Battery Sensor).............................................. 17, 21 - 24
Maintaining Multiple Batteries................................................................................................... 25
Battery Configurations .............................................................................................................. 26
Troubleshooting - Model 24041-AA-S1...................................................................................... 27
Detailed Specifications - VDC Model No. 24041-AA-S1......................................................... 29 - 33
Charging Profile.......................................................................................................................... 34
For Repair Or Replacement....................................................................................................... 35
Guarantee And Warranty............................................................................................................ 36
Rev. F-103007 P/N VDC24041AA-S1-MNL
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BatteryMINDer
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Model 24041-AA-S1
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 recommended 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 extension 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 charger
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 INSTRUCTIONS EXACTLY.
Rev. F-103007 P/N VDC24041AA-S1-MNL
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BatteryMINDer
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Model 24041-AA-S1
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 protection. 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 ood the eye with
running water for at least 10 minutes and get help
immediately.
d. NEVER smoke or allow a spark of ame 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 electrical 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 battery
can produce a short circuit current high enough to
weld a ring or the like to metal, causing 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
Rev. F-103007 P/N VDC24041AA-S1-MNL
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BatteryMINDer
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Model 24041-AA-S1
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 terminal rst.
Turn off all accessories in the aircraft, 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-metallic 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 specied by the manufacturer.
This helps purge excessive gas from cells. Do not
overll. For a battery without caps, follow manufacturer’s recharging instructions.
e. Study all battery manufacturer’s specic
instructions such as removing cell caps while
charging and recommended charge rates.
f. Determine condition of battery, by referring
to instructions herein, before ever attempting to
charge or desulfate 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 battery
being charged; gases from battery will corrode
and damage charger.
c. Never allow battery acid to drip on charger
when reading specic gravity or lling.
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.
Rev. F-103007 P/N VDC24041AA-S1-MNL
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BatteryMINDer
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Model 24041-AA-S1
DC CONNECTION PRECAUTIONS
Note: Steps to be done in a well-ventilated area
away from aircraft.
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 contact. This tends to keep clips from slipping off terminals and reduces risk of sparking.
c. Position DC output cord to reduce risk of
damage 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 nega-
tive 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, con
-
nect NEGATIVE (BLACK) clip from charger to
NEGATIVE (NEG, N,) UNGROUNDED POST OF
BATTERY. Connect POSITIVE (RED) CLIP to
chassis or engine block away from battery.
Rev. F-103007 P/N VDC24041AA-S1-MNL
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BatteryMINDer
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Model 24041-AA-S1
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, disconnect 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 AIRCRAFT 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. POSITIVE
(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 connect
NEGATIVE (BLACK) charger clip to free end of
cable.
d. Do not face battery when making final con-
nections.
e. When disconnecting charger, always do so
in reverse sequence of connecting procedure
and break first connection while as far away from
battery as practical. Do not attempt to per-
manently install any charger not specifically
designed for permanent installation, especially in a wet / marine environment
Rev. F-103007 P/N VDC24041AA-S1-MNL
Page 7
BatteryMINDer
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Model 24041-AA-S1
QUALIFYING YOUR BATTERY:
Preliminary Requirements
NOTE: The BatteryMINDer has no electrical
output unless it is connected to a healthy
battery. Testing the BatteryMINDer with a volt
or an Amp meter without the unit being connected across a good battery will result in a false
reading. 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:
techsupport@vdcelectronics.com or call our tollfree 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 chargemaintain or desulfate them. Remember, even if
you just purchased a “new” battery it may have
been subjected to conditions that have caused
“sulfation” such as high temperature (>=80°).
NOTE: If your battery is new and you are
certain it was not subject to conditions that
could have caused sulfation*, even before
you purchased it, then you can disregard our
recommendations for qualifying / testing your
battery, before using the BatteryMINDer.
* Such as high temperature storage (=/> 80°F)
and/or allowed to self-discharge to 24.8 Volts or
lower.
Testing a Filler Cap Lead Acid Battery
1. Carefully remove all filler caps 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 sulfation has taken place.
Significant recharge/reconditioning time is needed
to restore these plates to a condition where the
battery can be expected to function normally.
Rev. F-103007 P/N VDC24041AA-S1-MNL
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BatteryMINDer
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Model 24041-AA-S1
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 instructions.
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 12 hours
before testing with a temperature compensated
hydrometer and/or digital type voltmeter only.
* “RESTED” = a battery that has been as fully
charged as possible, using a 3 stage charger
(model 24041-AA-S1) and left disconnected
from charger or any type load for a minimum
of 12 hours.
5. If the BatteryMINDer battery condition LED
lights (YELLOW) within 72 hours (single battery)
or no balls float in one or more cells, your battery may be too far gone to be fully desulfated.
Reconnect battery to your BatteryMINDer and
press the Maintenance mode button. Allow battery
to remain in maintenance mode for a minimum of
72 hours, before re-test. Use a hot/cold calibrated
hydrometer tester for the most accurate results
(see Table 1) if you see an increase in the Specific
Gravity (SG) or voltage indicating that there is an
improvement in the battery’s condition, continue
desulfating for an additional 72 hours and retest
the battery. Continue this process until the SG or
voltage readings no longer increase.
Specific Gravity – Capacity
Temp. Compensated Hydrometer
- meter or 4 ball type
1.270 (4 Balls oating) 100%
1.250 (3 Balls oating) 75%
1.190 (2 Balls oating) 50%
1.150 (1 Balls oating) 25%
1.120 (0 Balls oating)
May denote shorted cell or battery
that has been severely discharged
and may not be recoverable
TABLE 1
Full Capacity
Percentage
0%
Rev. F-103007 P/N VDC24041AA-S1-MNL
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BatteryMINDer
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Model 24041-AA-S1
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 desulfated or does not qualify for desulfation.
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 reconditioneddesulfated. Dispose of the battery.
If each cell floats three (3) or more balls (or 1250
on gauge-type), your battery can be desulfatedreconditioned.
4. Always rinse the tester with fresh water
after every use. Failure to do so will cause false
readings.
Testing a Sealed, AGM or Gelled-type Lead
Acid Battery
These batteries have no filler caps or manifoldtype 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 possible, before you determine its
condition. Allow battery to “rest” (see pg. 9) overnight for a minimum of 12 hours before testing
with a digital voltmeter only.
Rev. F-103007 P/N VDC24041AA-S1-MNL
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BatteryMINDer
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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 24.8 volts
(Typically 50% of charge) the battery may be too
heavily sulfated to be fully recoverable. If voltage
is 24.8-V or higher full recovery can be expected,
given sufficient time (average 1-2 weeks for batteries that are heavily sulfated).
3. Connect the BatteryMINDer to the battery.
Select type of 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 capacity level or
no further increase is seen.
Model 24041-AA-S1
OCV=Open Circuit No Load Voltage
OCV - “Rested”
Voltage
Full Capacity
Percentage
25.8 - 26.2 Volts 100%
25.2 - 25.8 Volts 75%
24.8 - 25.2 Volts 50%
24.4 - 24.8 Volts 25%
24.0 - 24.4 Volts 0%
<22 Volts
= shorted
TABLE 2
Note: Do not expect to completely eliminate
sulfate in a few days. Long established sulfate will require several weeks or longer to
be fully dissolved. Be patient and you will be
rewarded with a “sulfate-free” battery.
Rev. F-103007 P/N VDC24041AA-S1-MNL
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