BatteryMINDer 24041-AA-S3 Instruction Manual

Rev. A-021009 P/N VDC24041AA-S3-MNL

BatteryMINDer

®

Model 24041-AA-S3

Page 1

INSTRUCTION MANUAL

BatteryMINDer®

Model 24041-AA-S3*

Gill LT Series 24-Volt

Aviation Charger / Maintainer /

Desulphator-Conditioner

VDC Electronics, Inc.
147 D Woodbury Rd.
Huntington, NY 11743
www.batteryminders.com
[e-mail]

READ AND SAVE THESE INSTRUCTIONS

9LL=JQ'#(=J

¸

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

*For use with Gill LT Aircraft Batteries ONLY.
Requires proper installation of Battery Temperature
Sensor (ABS-248 - supplied).

9LL=JQ'#(=J

¸

Charger / Maintainer /
Full Time Desulfator - Conditioner
Model 24041-AA-S3 24-Volt @ 4 Amp

4 A

Charge - Float
Green (solid) = Charging
Green (blinking) = Float (maintenance)

*See Instruction Manual

PRESS

Stop

VDC Electronics, Inc.
800-379-5579 (ET)

www.batteryminders.com

U.S. Patented & Patent Pending

Gill LT
Series
ONLY

AVIATION-CALIBRATED

GILL LT SERIES 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*

Restart

Hold for 5 sec. for full reset

Rev. A-021009 P/N VDC24041AA-S3-MNL

Rev. A-021009 P/N VDC24041AA-S3-MNL

BatteryMINDer

®

Model 24041-AA-S3

Page 2

TABLE OF CONTENTS

Safety Instructions...................................................................................................................... 3

Preparing To Charge................................................................................................................... 5

Charger Location......................................................................................................................... 5

DC Connection Precautions....................................................................................................... 6

Qualifying Your Battery .............................................................................................................. 8

Testing With A Hot/Cold Calibrated Hydrometer Tester.......................................................... 10

Unit With Call-outs ..................................................................................................................... 12

Simplified Operating Instructions ............................................................................................. 13

LED Indicator Functions ............................................................................................................ 14, 15

Detailed Operation Instructions ................................................................................................ 16

Temperature Sensor ABS-248 (At-the-Battery Sensor).............................................. 17, 21 - 24

Maintaining Multiple Batteries................................................................................................... 25

Battery Configurations .............................................................................................................. 26

Troubleshooting - Model 24041-AA-S3...................................................................................... 27

Detailed Specifications - VDC Model No. 24041-AA-S3......................................................... 29 - 33

Charging Profile.......................................................................................................................... 34

For Repair Or Replacement....................................................................................................... 35

Guarantee And Warranty............................................................................................................ 36

Rev. A-021009 P/N VDC24041AA-S3-MNL

BatteryMINDer

®

Model 24041-AA-S3

Page 3

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. A-021009 P/N VDC24041AA-S3-MNL

BatteryMINDer

®

Model 24041-AA-S3

Page 4

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 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
Gill LT Series 24V 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. A-021009 P/N VDC24041AA-S3-MNL

BatteryMINDer

®

Model 24041-AA-S3

Page 5

NEVER CHARGE A FROZEN BATTERY OR

ONE AT A TEMPERATURE ABOVE 123° F.

PREPARING TO CHARGE

a. 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. Study all battery manufacturer’s specic

instructions such as recommended charge rates.
e. 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 specic 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. A-021009 P/N VDC24041AA-S3-MNL

BatteryMINDer

®

Model 24041-AA-S3

Page 6

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.

Rev. A-021009 P/N VDC24041AA-S3-MNL

BatteryMINDer

®

Model 24041-AA-S3

Page 7

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 con­nections.
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 permanent-

ly install charger not specifically designed­approved for permanent installation, espe­cially in a wet high moisture environment.

Rev. A-021009 P/N VDC24041AA-S3-MNL

BatteryMINDer

®

Model 24041-AA-S3

Page 8

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:
[e-mail] or call our toll­free technical support line 800-379-5579 x201
(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 storage

(>=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.

Rev. A-021009 P/N VDC24041AA-S3-MNL

BatteryMINDer

®

Model 24041-AA-S3

Page 9

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.

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 25.2 volts
(Typically 75% of charge) the battery may be too
heavily sulfated to be fully recoverable. If voltage
is 25.2-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.

4. Charge battery to its maximum level. 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.

Rev. A-021009 P/N VDC24041AA-S3-MNL

BatteryMINDer

®

Model 24041-AA-S3

Page 10

Before proceeding further you must be thor­oughly familiar with the safety and operating
instructions.

1. Recharge the battery with the BatteryMINDer
to ensure that it is completely charged before you

determine its condition. Allow battery to “rest”*

overnight for a minimum of 12 hours before test­ing with a digital type voltmeter only.

* “RESTED” = a battery that has been as fully
charged as possible, using a 3 stage charger
(model 24041-AA-S3) and left disconnected
from charger or any type load for a minimum
of 12 hours.

2. If the BatteryMINDer battery condition LED
lights (YELLOW) after 72 hours (single battery

- battery voltage ±/≤ 25.2), your battery may be
too far gone to be fully desulfated. Reconnect
battery to your BatteryMINDer. Allow battery to
remain in maintenance mode for a minimum of 72
hours, before re-test. If you see an increase in the
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 voltage readings no
longer increase.

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.

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

OCV=Open Circuit No Load Voltage

TABLE 1

Rev. A-021009 P/N VDC24041AA-S3-MNL

BatteryMINDer

®

Model 24041-AA-S3

Page 11

Your Notes: