Clarke BC 430N, 6261067 User guide

STARTER/CHARGER

MODEL NO: BC430N

PART NO: 6261067

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC11/18

INTRODUCTION

Thank you for purchasing this CLARKE Starter/ Charger. This unit is suitable for
charging and boosting 12 or 24 Volt lead acid batteries.

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 Charger 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.

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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.

PLEASE READ BEFORE USING THIS UNIT

1. 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.

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

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

4. Never attempt any electrical or mechanical repair, other than
replacement of fuses. If you have a problem with your machine 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.

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

6. This appliance 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.

7. 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.

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

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

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.

ELECTRICAL CONNECTIONS

Connect the three core mains cable to a suitable industrial supply isolator, or
heavy duty plug meeting the requirements of BS EN 60309. This charger must
be connected to a supply having a rated capacity of greater than 13 Amps.

Connect the three core mains lead to a suitable industrial supply isolator or
heavy duty plug. This charger must be connected to a supply having a rated
capacity of greater than 13 Amps. A normal 13 Amp (BS1363) plug must NOT
be used.

NOTE: The maximum input current for this unit is 48 amps.

WARNING: THIS APPLIANCE MUST BE EARTHED.

IMPORTANT: The wires in this mains lead are coloured in accordance with
the following code:

GREEN AND YELLOW - EARTH E

BLUE - NEUTRAL (N)

BROWN - LIVE (L)

As the colours of the flexible cable of this appliance may not correspond with
the coloured markings identifying terminals in your plug, proceed as follows:

• Connect GREEN AND YELLOW coloured cable to plug terminal marked

letter “E” or Earth Symbol or coloured or Green and Yellow.

• Connect BROWN cable to the plug terminal marked letter ‘L’ or

coloured Red.

• Connect BLUE cable to the plug terminal marked letter “N’ or coloured

Black.

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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 - 12V
and 24V as shown below.

A single Start/ Charge switch allows for switching between functions and for
charging at different rates with different charge rates as displayed on the
ammeter.

The main fuse is mounted behind a cover on the front panel.

The Timer control knob allows charging time durations from zero to 2 hours.

The 430N has a Thermal Overload indicator fitted, see below. Please read
Thermal Overload notes on page 9.

The illustration below identifies the various control components.

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PROCEDURE FOR NORMAL CHARGING

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 that the mains supply is OFF and that the Current Control Knob (B) is
in the ‘O’ OFF position.

3. Connect the appropriate clamp to the unearthed battery terminal. 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.

• NOTE: Ensure the lead is plugged into the 12V or 24V socket, depending

upon the voltage of the battery to be charged.

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

5. Switch ON the mains supply.

6. Turn the Current Control Knob (B) to the position necessary to obtain the
required charge rate, as indicated on the ammeter.

7. Keep the battery on charge until the Ammeter reads zero (or 0-2 amps) or
has stopped moving down, then turn the Current Control Knob (B) to the
OFF position.

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

.

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 YOUR START N CHARGE IS FITTED
WITH A POLARITY PROTECTION FEATURE. IT WILL HOWEVER BE NECESSARY
TO REPLACE THE INTERNAL FUSE. REMOVE THE BLACK PLASTIC COVER ON
THE FRONT PANEL (MARKED FUSE) AND REPLACE THE BURNT FUSE.

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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 seen 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: NEVER ATTEMPT TO RE-CHARGE NON-RECHARGEABLE BATTERIES

CHARGING WITH TIMER

1. Follow the same instructions as for Normal Charging up to and including
para. 5.

2. Turn the timer control knob (C) clockwise to the desired charging time
setting.

3. Switch ON the mains supply.

4. Turn the Current Control Knob (B) clockwise to position 5 or 6, to obtain the
desired charging rate as indicated on the ammeter.

NOTES ON CHARGING PROCEDURE

*A complete charge is best done slowly in order to protect your battery We
recommend the charging rate be no more than 10% of the battery capacity
rating (AH). eg. a typical battery has a rating of 40 Ampere Hours, therefore
the charging rate should be 4 amps, and a complete charge will take 10
hours.

**If a low current reading (2 amps or less) is seen on the gauge, 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.

Check the Specific Gravity of the battery with a hydrometer.

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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 ON/OFF switch and current control switch are in the OFF
position.

2. Connect the cables as for normal charging.

3. Switch ON the mains supply - the green lamp will illuminate.

4. Turn the Current Control Knob to the ‘START’ position.

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

This equipment is provided with an automatic boost start function. The current
required to start an engine will be detected by the systems’ electronics and
supplied to the starter motor. As the load reduces, the system will compensate
accordingly.

Once the engine has started, the system will automatically shut down the
boost start function.

6. At this point, switch the Current Control Knob to the OFF (O) position, and
disconnect the leads from the battery in the same manner as that for
normal charging.

NOTE: If the Start and Charge unit is overloaded at any time, a thermal cut

out will automatically come into operation, rendering it inoperative.
These models are equipped with a thermal overload indicator (yellow
indicator light) which will illuminate. Allow approximately 5-10 minutes,
or wait for the indicator light to go out before using the unit again.

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THERMAL OVERLOAD

This Booster/Charger is provided with a Thermal Overload cut-out.

Should the Duty Cycle be exceeded or should the unit overheat for any
reason, the thermal overload will intervene, shutting down the charger.

If this occurs, wait for 15 - 20 minutes, depending upon ambient temperature,
before attempting to re-use.

The amber indicator lamp on the panel will illuminate when the overload has
intervened. It will extinguish once it has reset and the unit is ready for use once
again.

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MAINTANENCE

This charger requires minimal maintenance. As with any appliance or tool, a
few common sense rules will prolong the life of the battery charger.

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.

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

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

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

REPLACEMENT FUSES

ODEL PART NO AMPS QTY REQUIRED

M

BC430N EM22220011 60 1

STORAGE

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

2. Store in a clean, dry area.

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DECLARATION OF CONFORMITY

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PARTS LIST - BC430N

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PARTS LIST BC430N

No Description Part No No Description Part No

1 Knob D38 04600270 16 Black Cable

25sqmm W/Clamp
120

2 Switch 22205133 17 Red Cable

25sqmm 2,5M

3 Timer 16A / 250V 22215001 18 Dinse Plug 25sqmm

Cx20

4 Timer Knob 21690034 19 Clamps 120A Red-

black

5 Green Pilot-lamp 22610008 20 Axle (L=488mm) 55200001

6 Ammeter 22600050 21 Wheel D.175. Hole

D.20

7 Contactor 220V

10A

8 LED 33710624 23 Fuse Box Cover 21690110

9 Front Frame 21690322 24 Fuse 300A 22220011

10 Thermostat 1001

c/w Support

11 Rectifier PMS 20/2/

2 CB

12 Supply Cable 3x2,5

M.2,5

13 Transformer 44105075 28 Front Panel 33700722

14 Thermostat Vebe

1301

15 Lower Panel 33700028 30 Ampererometric

22225006 22 Handle 33725080

04600113 25 C.P.S. Control PCB 22700040

22400011 26 Female Dinse Plug

25sqmm

20220020 27 Cable Clamp D.10

+ Screw

04600261 29 Cover Panel 33705346

Shunt

43200025

43200024

22100001

04600067

21625009

22100002

04600234

22600047

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WIRING CIRCUIT DIAGRAMS

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SPECIFICATIONS

Model Number BC430N

Part No 6261067

Dimensions (DxWxH) 330 x 490 x 730 mm

Weight 38 kg

Supply Voltage @50Hz 230 V AC

Max charge 60A (continuous)

Max Boost 400A

Boost/Charge 12V/24V

NOTES

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