BatteryMINDer E12248-AA-S2 Instruction Manual
Rev. A-021210 Page 1 P/N VDC E12248-S2-MNL
BatteryMINDer
®
E12248-AA-S2
INSTRUCTION MANUAL
Rev. A-021210 P/N VDC E12248AA-S2-MNL
VDC Electronics, Inc.
147 D Woodbury Rd.
Huntington, NY 11743 U.S.A.
www.batteryminders.com
techsupport@vdcelectronics.com
*For use with Aviation Type 12-V Batteries ONLY. Requires proper
installation of Battery Temperature Sensor (ABS-248 - supplied). Not
for use with Gill LT Series or Odyssey Aircraft Batteries.
READ AND SAVE THESE
INSTRUCTIONS
BatteryMINDer
®
Model
E
12248-AA-S2*
Aviation Charger /
Maintainer /
Desulfator-Conditioner
See Page 13 for Simplied Operating Instructions
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E12248-AA-S2
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 Flooded (wet-cell) 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-248 (At-the-Battery Sensor).......17, 21 - 24
Maintaining Multiple Batteries.............................................25
Battery Configurations .....................................................26
Troubleshooting - Model E12248-AA-S2..................................27
Detailed Specifications - VDC Model No. E12248-AA-S2.........29 - 33
Charging Profile..............................................................34
For Repair Or Replacement..................................................35
Warranty........................................................................36
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E12248-AA-S2
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.
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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
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 en
gine.
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, neck
laces, 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 bat
teries 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
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E12248-AA-S2
NEVER CHARGE A FROZEN BATTERY OR ONE AT A
TEMPERATURE ABOVE 123° F.
PREPARING TO CHARGE
a. Turn off all accessories in the aircraft, so as not to cause an
arc. If battery manufacturer requires battery to be removed from
aircraft before charging, always remove ground wire rst.
b. Be sure area around battery is well ventilated while battery is
being charged. Force gas vapors away by using a piece of nonmetallic 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 spe-
cic 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.
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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.
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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 permanently install charger not specifically designedapproved for permanent installation, especially in a wet
high moisture environment.
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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.
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
self-discharge to 12.4 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.
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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 or momentarily apply
a small load to remove the “surface” charge which creates false
voltage readings.
* “RESTED” = a battery that has been as fully charged as
possible, using a 3 stage charger (model E12248-AA-S2)
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. 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.
TABLE 1
Temp. Compensated Hydrometer
or 4 ball type
Full Capacity
Percentage
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
0%
Specific Gravity – Capacity
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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 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
reconditioned-desulfated. Dispose of the battery.
If each cell floats three (3) or more balls (or 1250 on gauge-type),
your battery can be desulfated-reconditioned.
4. Always rinse the tester with fresh water after every use.
Failure to do so will cause false readings.
Testing a Sealed, AGM or Flooded (wet-cell)
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 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.
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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 12.6 volts (Typically 75% of charge) the
battery may be too heavily sulfated to be fully recoverable. If
voltage is 12.6-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.
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
12.9 - 13.1 Volts 100%
12.6 - 12.9 Volts 75%
12.4 - 12.6 Volts 50%
12.2 - 12.4 Volts 25%
12.0 - 12.2 Volts 0%
<11 Volts
= shorted
OCV=Open Circuit No Load Voltage
TABLE 2
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