BatteryMINDer 48021 User Manual

BatteryMINDer

®

36-Volt 36271 and 48-Volt 48021

Battery Maintainer-Desulfators

INSTRUCTION MANUAL*

All Models Include:

• ATS Temperature Sensor (installed)

• Ring Terminals with 15A Fuse

• EZC-01 EZ Connector + Mounting Screws

• NOT Designed to Replace Original HIGH-OUTPUT Chargers -

*

Use to Maintain and Desulfate Lead Acid Deep-Cycle Battery
Systems After Fully Re-Charging ONLY

• NOT for use with Aviation-type batteries

READ AND SAVE THESE

INSTRUCTIONS

VDC Electronics, Inc. • 155 W. Carver St., Ste. 2 • Huntington, NY 11743

www.BatteryMINDers.com • [e-mail]

Rev. C-070313 P/N VDC36271/48021-MNL

BatteryMINDer

®

Models 36271 & 48021

Table Of Contents

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

Preparing to Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

DC Connection Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Qualifying Your Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Testing a Filler Cap Lead-Acid Battery . . . . . . . . . . . . . . . . . . . . . . . 7

Specific Gravity – Capacity Table. . . . . . . . . . . . . . . . . . . . . . . . . . 9

Testing With a Hot/Cold Calibrated Hydrometer Tester . . . . . . . . . . . . . . . 9

Testing A Sealed, AGM or Flooded (Wet-Cell) Lead Acid Battery . . . . . . . . . . 9

Use a Digital Voltmeter Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

OCV/Full Capacity Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Unit Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Simplified Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . .12

Common Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Battery Condition Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

LED Status Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Detailed Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . .15

Multi-Battery Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Charge and Float Voltages at Various Temperature Ranges . . . . . . . . . . . . .19

Maintaining Multiple Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

For Repair or Replacement / Registration . . . . . . . . . . . . . . . . . . . . 23

Guarantee / Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Glossary of Terms

• Maintain a battery
BatteryMINDer ensures batteries are truly fully charged and will likely
continue improving the condition of the battery to the fullest extent
possible.

• Rested
A battery that has been as fully charged as possible and left disconnected
from charger or any type load overnight.

• Specific Gravity
One of the key parameters of battery operation is the specific gravity of the
electrolyte. Specific gravity is the ratio of the weight of a solution to the
weight of an equal volume of water at a specified temperature. Specific
gravity is used as an indicator of the state of charge of a cell or battery.

• Sulfation

Occurs when the battery sits for long periods of time and the electrolyte
solution begins to break down. Sulfur in the solution leaches from the
electrolyte, sticking to the lead plates as converted lead sulfuric crystals.

Rev. C-070313 Page 2 P/N VDC36271/48021-MNL

BatteryMINDer

®

Models 36271 & 48021

REQUIRED SAFETY INSTRUCTIONS

WARNING

READ AND FULLY UNDERSTAND BEFORE OPERATING

Contact VDC Electronics if uncertain about

any settings or operation.

TO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK, OR

INJURY TO PERSON, OBSERVE THE FOLLOWING:

1. SAVE THESE INSTRUCTIONS

2. This manual contains important safety and operating instructions for
BatteryMINDer Models 36271 and 48021.

3. Do not expose charger to rain or snow.

4. Use of an attachment not recommended or sold by VDC Electronics
may result in a risk of fire, electric shock, or injury to persons.

5. To reduce risk of damage to electric plug and cord, pull by plug rather
than cord when disconnecting charger.

6. An extension cord should not be used unless absolutely necessary.
Use of improper extension cord could result in a risk of fire and electric
shock. If an extension cord must be used, make sure:

• That pins on plug of extension cord are the same number, size, and
shape as those of plug on charger;

• That extension cord is properly wired and in good electrical condition;
and

• That wire size is large enough for ac ampere rating of charger as
specified in Table below.

7. Do not operate charger with damaged cord or plug – replace the cord
or plug immediately.

8. Do not operate charger if it has received a sharp blow, been dropped,

Recommended minimum AWG size for

extension cords for battery chargers

AC input rating,

amperes

Equal to

or

greater

But less

than

than

a

25

(7.6)

AWG size of cord

Length of cord, feet (m)

50

(15.2)

100

(30.5)

150

(45.6)

0 2 18 18 18 16

a

If the input rating of a charger is given in watts rather than in amperes, the

corresponding ampere rating is to be determined by dividing the wattage rating by

the voltage rating - for example: 1250 watts/125 volts = 10 amperes

Rev. C-070313 Page 3 P/N VDC36271/48021-MNL

BatteryMINDer

®

Models 36271 & 48021

or otherwise damaged in any way; call VDC Electronics Tech
Support Dept. 800.379.5579 x6 (ET) for advice.

9. Do not disassemble charger; call VDC Electronics Tech Support
Dept. 800.379.5579 x6 (ET) for advice when service or repair is

required. Incorrect reassembly may result in a risk of electric shock
or fire.

10. To reduce risk of electric shock, unplug charger from outlet before
attempting any maintenance or cleaning. Turning off controls will not
reduce this risk.

11. WARNING – RISK OF EXPLOSIVE GASES

a. WORKING IN VICINITY OF A LEAD-ACID BATTERY IS

DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES
DURING NORMAL BATTERY OPERATION. FOR THIS
REASON, IT IS OF UTMOST IMPORTANCE THAT YOU
FOLLOW THE INSTRUCTIONS EACH TIME YOU USE THE
CHARGER.

b. To reduce risk of battery explosion, follow these instructions and

those published by manufacturer of any equipment you intend to
use in vicinity of battery. Review cautionary marking on these
products and on engine.

12. PERSONAL PRECAUTIONS

a. Consider having someone close enough by to come to your aid

when you work near a lead-acid battery.

b. Have plenty of fresh water and soap nearby in case battery acid

contacts skin, clothing, or eyes.

c. Wear complete eye protection and clothing protection. Avoid

touching eyes while working near battery.

d. If battery acid contacts skin or clothing, wash immediately with

soap and water. If acid enters eye, immediately flood eye with
running cold water for at least 10 minutes and get medical
attention immediately.

e. NEVER smoke or allow a spark or flame in vicinity of battery or

engine.

f. 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 explosion.

g. 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.

Rev. C-070313 Page 4 P/N VDC36271/48021-MNL

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h. Use charger for charging a LEAD-ACID battery only. It is not

intended to supply power to a low voltage electrical system other
than in a starter-motor application. Do not use battery charger
for charging dry-cell batteries that are commonly used with
home appliances. These batteries may burst and cause injury to
persons and damage to property.

i. NEVER charge a frozen battery or a battery at a temperature

above 123° F.

13. PREPARING TO CHARGE

a. If necessary to remove battery from vehicle to charge, always

remove grounded terminal from battery first. Make sure all
accessories in the vehicle are off, so as not to cause an arc.

b. Be sure area around battery is well ventilated while battery is

being charged.

c. Clean battery terminals. Be careful to keep corrosion from

coming in contact with eyes.

d. Add distilled water in each cell until battery acid reaches level

specified by battery manufacturer. Do not overfill. For a battery
without removable cell caps, such as valve regulated lead acid
batteries, carefully follow manufacturer’s recharging instructions.

e. Study all battery manufacturer’s specific precautions while

charging and recommended rates of charge.

f. Determine voltage of battery by referring to car owner’s manual

and make sure it matches output rating of battery charger.

14. CHARGER LOCATION

a. Locate charger as far away from battery as DC 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

electrolyte specific gravity or filling battery.

d. Do not operate charger in a closed-in area or restrict ventilation

in any way.

e. Do not set a battery on top of charger.

15. DC CONNECTION PRECAUTIONS

a. Connect and disconnect DC output clips only after setting any

charger switches to “off” position and removing ac cord from
electric outlet. Never allow clips to touch each other.

b. Attach clips to battery and chassis as indicated

in 15(e), 15(f), and 16(b) through 16(d).

Models 36271 & 48021

Rev. C-070313 Page 5 P/N VDC36271/48021-MNL

BatteryMINDer

®

Models 36271 & 48021

16. FOLLOW THESE STEPS WHEN BATTERY IS
INSTALLED IN VEHICLE. A SPARK NEAR
BATTERY MAY CAUSE BATTERY EXPLOSION.
TO REDUCE RISK OF A SPARK NEAR BATTERY:

a. Position ac and DC cords to reduce risk of damage by hood, door,

or moving engine part.

b. Stay clear of fan blades, belts, pulleys, and other parts that can

cause injury to persons.

c. Check polarity of battery posts. POSITIVE (POS, P, +) battery

post usually has larger diameter than NEGATIVE (NEG, N,–)
post.

d. Determine which post of battery is grounded (connected) to the

chassis. If negative post is grounded to chassis (as in most
vehicles), see (e). If positive post is grounded to the chassis,
see (f).

e. When disconnecting charger, turn switches to off, disconnect AC

cord, remove clip from vehicle chassis, and then remove clip from
battery terminal.

f. See operating instructions for length of charge information.

17. FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE.
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, +) battery

post usually has a larger diameter than NEGATIVE (NEG, N, –)
post.

b. Attach at least a 24-inch-long 6-gauge (AWG) insulated battery

cable to NEGATIVE (NEG, N, –) battery post.

c. Connect POSITIVE (RED) charger clip to POSITIVE (POS, P, +)

post of battery.

d. Position yourself and free end of cable as far away from battery

as possible – then connect NEGATIVE ( ) charger clip to

free end of cable.
e. Do not face battery when making final connection.
f. When disconnecting charger, always do so in reverse sequence

of connecting procedure and break first connection while as far

away from battery as practical.
g. A marine (boat) battery must be removed and charged on shore.

To charge it on board requires equipment specially designed for

marine use.

Rev. C-070313 Page 6 P/N VDC36271/48021-MNL

BatteryMINDer

®

Models 36271 & 48021

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 toll-free technical support line
800-379-5579 x6 (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 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 self­discharge to 37.2 Volts / 49.6 Volts or lower.

Testing a Filler Cap or Manifold-type Lead Acid Battery

1. Carefully remove all 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.

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” (see Glossary of Terms) overnight for a minimum of 12 hours
before testing with a temperature compensated hydrometer and/or digital
type voltmeter only.

Rev. C-070313 Page 7 P/N VDC36271/48021-MNL

BatteryMINDer

®

Specic Gravity – Capacity

Temperature 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

Models 36271 & 48021

Full Capacity

Percentage

0%

Rev. C-070313 Page 8 P/N VDC36271/48021-MNL