Clarke BC 205N, 6261032 User guide

STARTER/CHARGER

MODEL NO: BC205N

PART NO: 6261032

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC01/19

INTRODUCTION

Thank you for purchasing this CLARKE Starter/ Charger. This unit is suitable for
charging both 12 Volt and 24 Volt lead acid batteries and for providing a
boost charge in the case of a flat battery.

Please read this manual thoroughly before attempting to operate and
carefully follow all instructions given.

It is vitally important that ALL precautions are taken as specified, which will not
only provide protection for yourself and that of others around you, but will also
ensure that the product will give you long and satisfactory service.

GUARANTEE

This CLARKE product is guaranteed against faulty manufacture for a period of
12 months from the date of purchase. Please keep your receipt as proof of
purchase.

This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.

Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.

This guarantee does not effect your statutory rights.

ENVIRONMENTAL RECYCLING POLICY

Through purchase of this product, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the WEEE.

In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing
Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal
facility.

If disposing of this product or any damaged components, do not dispose of
with general waste. This product contains valuable raw materials. Metal
products should be taken to your local civic amenity site for recycling of metal
products.

2

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

SAFETY PRECAUTIONS

WARNING: HIGHLY INFLAMMABLE HYDROGEN GAS IS RELEASED IN THE
PROCESS OF BATTERY CHARGING. ALWAYS REMEMBER TO SWITCH OFF
THE CHARGER/STARTER FIRST TO AVOID SPARKING.

Battery acid is very corrosive. If spilled, clean the area immediately and wash
with water. If battery acid comes into contact with the eyes, get medical help
immediately.

1. Do not expose this charger/starter to rain.

2. Never touch the negative and positive leads on this unit together while the
charger is switched on.

3. Never attempt any electrical or mechanical repair other than
replacement of fuses. If you have a problem with your charger contact
your local stockist for service information.

WARNING: CERTAIN TYPES OF SEALED OR MAINTENANCE-FREE BATTERIES
NEED EXTRA CARE WHEN CHARGING. PLEASE CONSULT THE BATTERY
MANUFACTURERS INSTRUCTIONS BEFORE USING THIS CHARGER/STARTER

WARNING: TOXIC FUMES MAY BE RELEASED DURING BATTERY
CHARGING. ONLY USE THIS CHARGER/STARTER IN A WELL VENTILATED
AREA.

4. Before charging, ensure the battery terminals are clean, and that the cells
are filled to the correct level by adding distilled water where necessary.

5. This charger is not intended for use by persons with reduced physical,
sensory or mental capabilities or lack of experience and knowledge, unless
they have been given supervision or instruction concerning use of the
charger/starter by a person responsible for their safety. Keep children well
away from the charger/starter.

6. After charging, secure the vehicle battery leads to the correct terminals
which should be clean and lightly smeared with petroleum jelly to prevent
corrosion. Finally, re-check the battery electrolyte level.

7. Do not use this charger/starter unless you are aware of vehicle electrical
systems, and battery charging techniques.

8. Always consult the vehicle manufacturers instructions for disconnecting /
charging the vehicle battery.

3

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

ELECTRICAL CONNECTIONS

Plug must be BS1363/A approved.

Always fit

Ensure that the outer sheath of

Neutral

(Blue)

Live

(Brown)

Earth

(Green and

a 13 Amp

the cable is firmly held by the clamp

fuse.

Yel low)

WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE HEATER TO THE MAINS
SUPPLY.

Connect the mains lead to a standard, 230 Volt (50Hz) electrical supply
through an approved 13 amp BS 1363 plug or a suitably fused isolator switch.

If the plug has to be changed because it is not suitable for your socket, or
because of damage, it must be removed and a replacement fitted, following
the wiring instructions shown below. The old plug must be discarded safely as
insertion into a power socket could cause an electrical hazard.

WARNING: THE WIRES IN THE POWER CABLE OF THIS PRODUCT ARE
COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE:
BLUE = NEUTRAL BROWN = LIVE YELLOW AND GREEN = EARTH

If the colours of the wires in the power cable do not agree with the markings
on the plug.

• The BLUE wire must be

connected to the
terminal which is
marked N or coloured
black.

• The BROWN wire must

be connected to the
terminal which is
marked L or coloured
red.

• The YELLOW AND

GREEN wire must be

connected to the terminal which is marked E or or coloured green.

We strongly recommend that this machine is connected to the mains supply
through a Residual Current Device (RCD)

If you are not sure, consult a qualified electrician.

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

4

OVERVIEW

The unit is provided with a pair of leads complete with clamps for connection
to a car battery and is provided with appropriate outlet connections as shown
below. The charging rate as displayed on the ammeter.

The illustration below identifies the various components.

ASSEMBLY

1. From the bag of loose parts, locate the four screws with washers and nuts
with which to secure the foot to the base of the unit. Ensure the washers
are at the screw heads. DO NOT fully tighten the nuts. Note that the foot is
located at the front of the charger and the axle housing towards the rear.

2. Slide a wheel on to the axle, then insert the axle into position between the
foot and the body of the charger. Slide the second wheel on to the axle
and secure by pushing on the special locking washer, noting that the
angled tines point outwards.

3. Tighten the four foot securing screws.

4. Slide the handle into its socket on top of the unit and secure with the single
screw provided.

5

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

PROCEDURE FOR NORMAL CHARGING

WARNING: NEVERATTEMPT TO RE-CHARGE NON-RECHARGEABLE
BATTERIES.

CAUTION: SOME ELECTRONIC EQUIPMENT CAN BE DAMAGED BY
CHARGING OR USE OF START FACILITY. CHECK YOUR VEHICLE
HANDBOOK BEFORE USING YOUR STARTER/CHARGER. IF IN DOUBT
CONSULT THE VEHICLE MANUFACTURER.

NOTE: Before charging or boosting, ensure that, where applicable, the cells

are filled with electrolyte to the correct level, by adding distilled water.

1. When charging a car battery in situ, we recommend that the non earthed
lead on the battery is disconnected prior to charging. (On most vehicles,
this would be the RED, positive lead - but check the vehicle handbook if
you are unsure).

• This precaution is necessary as it is possible that damage could occur to

any electronically controlled system fitted to the vehicle, such as engine
management system, anti-theft alarm, alternator etc.

2. Check the mains supply is OFF and the amperage control knob (B) is in the
OFF position.

3. Connect the red positive lead (J) to either the (+ve) 24V terminal (F), or the
(+ve) 12V terminal (G) as appropriate, by inserting the jack plug and
twisting clockwise to a locked position.

4. On most modern cars this is the RED, positive clamp connected to the RED,
positive terminal of the battery, but check your handbook if unsure. Then
connect the other clamp to the chassis (or a suitable engine bolt) away
from the battery and fuel line.

5. Remove the battery filler caps if applicable during charging, in order to
prevent the any build up of dangerous gases within the battery.

6. Switch ON the mains supply.

7. Turn the amperage control knob (B) clockwise to the position necessary to
obtain the desired charging rate as indicated on the ammeter (A) (see
notes below).

8. Keep the battery on charge until the ammeter reads zero (or 0-2 amps) or
has stopped moving down, then switch the amperage control knob (B) to
the off position.

9. When disconnecting the charger, disconnect:-1) Supply, 2) Chassis
Conductor and 3) Battery Conductor, in that order.

6

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

NOTES ON CHARGING PROCEDURE

• A complete charge is best done slowly in order to protect your battery

so we recommend the MIN setting as described above. A complete
charge may take up to 10 hours.

• If a low amperage reading (2 amps or less) is registered on the gauge at

either the MIN or MAX setting, this may indicate that the battery is either
(a) already fully charged or (b) at the end of its useful life and in need of
replacement.

• Do not charge the battery for longer than is necessary.

WARNING: IF THE FIXED POSITIVE LEAD AND THE FIXED NEGATIVE LEAD
ARE CONNECTED TO THE WRONG TERMINALS, THEN A FLASH WILL OCCUR
WHEN THE 2ND CLAMP IS ATTACHED. DAMAGE TO THE CHARGING UNIT
AND THE BATTERY WILL BE AVOIDED AS THIS CHARGER IS FITTED WITH A
POLARITY PROTECTION FEATURE.

CAUTION: IT WILL HOWEVER BE NECESSARY TO REPLACE THE INTERNAL
FUSE. REMOVE THE BLACK PLASTIC COVER (MARKED FUSE) AND
REPLACE THE BURNT FUSE.

PROCEDURE FOR ENGINE STARTING

NOTE: We recommend that before attempting to boost start, you charge the

battery for 10-15 minutes. This will improve the chance of a first time
start, particularly with bigger engines. When the battery is completely
flat, you must charge the battery for 10 -15 minutes before attempting
to start, otherwise you may cause damage to the vehicle electronic
systems.

1. Check that the mains supply is OFF and that the amperage controller knob
(B) is in the OFF position.

2. Connect the cables as for normal charging.

3. Switch ON the mains supply.

4. Turn the key in the vehicles ignition to ‘start’, and get an assistant to turn
the amperage control knob (B) in the BOOST START position.

5. Turn the amperage control knob to the OFF position immediately the
engine starts, or after a maximum of 10 seconds if the engine fails to start.
Failure to do this may cause damage to some electronic equipment. If in
doubt consult vehicle handbook or manufacturer.

6. Turn the key in the vehicles ignition to ‘start’.

7

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

IMPORTANT: You must switch the amperage control switch back to the off
position after a maximum of 10 seconds on boost start - wait at least 30
seconds before repeating. Failure to do this may damage your battery and
the charger unit, and may invalidate your guarantee.

THERMAL OVERLOAD

If the starter/charger is overloaded at any time, a thermal cut out will
automatically come into operation, rendering it inoperative. This unit is
equipped with a thermal overload indicator lamp which will illuminate. Allow
approximately 5-10 minutes or wait for the indicator light to go out before
using the unit again.

MAINTANENCE

This charger requires minimal maintenance but general care will prolong the
life of the product.

WARNING: ALWAYS BE SURE THE CHARGER IS UNPLUGGED FROM THE
MAINS AND ANY BATTERY BEFORE PERFORMING ANY MAINTENANCE OR
CLEANING.

1. Clean the case and leads with a moist cloth if required.

2. Clean corrosion from the clamps with a solution of water and baking soda.

3. Examine the connecting leads at regular intervals for damage and have
them replaced if necessary.

4. Wind up the leads and power cable when not in use and store in the
compartment when not being used

5. Store in a clean, dry area.

WARNING: ALL OTHER SERVICING/REPAIRS SHOULD BE DONE BY
QUALIFIED SERVICE PERSONNEL ONLY.

8

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

DECLARATION OF CONFORMITY

9

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

PARTS LIST - BC205N

No Description Part No No Description Part No

1 Upper panel EM33705007 16 Earth clamp 120A EM22110067

2 Handle EM21600004 17 Red cable EM43200026

3 Back panel EM33715037 18 Dinse plug EM22100001

4 Rectifier pms EM22400096 19 Orange pilot lamp EM22610012

5 Thermostat EM04600113 20 Green pilot lamp EM22610006

6 Thermostat support EM04600261 21 Wheel 125mm EM21625006

7 Lower panel EM33700024 22 Axle EM55200012

8 Switch knob EM21690015 23 Transformer 12/24V EM44105077

9 Switch EM22205012 24 Fuse holder box EM21690113

10 Ammeter EM22600064 25 Amp’metric Shunt EM22600030

11 Input cable EM20220014 26 Fuse100A EM22220030

12 Cable clamp EM04600233 27 Small fuse cover EM21690109

13 Female dinse plug EM22100002 28 Handle EM33725029

14 Foot EM33740015 29 Cap EM21610018

15 Black cable EM43200086

10

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

WIRING CIRCUIT DIAGRAM BC205N

SPECIFICATIONS

Part No 6261032

Dimensions (D x W x H) 345 x 390 x 822 mm

Weight 21 kg

Supply Voltage @50Hz 230 V AC

Max charge 30A (continuous)

Max Boost 200A

Boost/Charge 12V/24V

Duty Cycle Max 10 secs on /30 secs off

11

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]