Clarke IBC7 Operation & Maintenance Instructions Manual

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC0918 - ISS 1

INTELLIGENT BATTERY CHARGER / MAINTAINER

MODEL NO: IBC7

PART NO: 6267008

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INTRODUCTION

Thank you for purchasing this CLARKE Battery Charger.

Please read this manual thoroughly, before attempting to operate this
product, 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 Battery 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.

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SAFETY PRECAUTIONS

PLEASE READ BEFORE USING THIS UNIT

1. Battery acid is highly corrosive. If spillage occurs, wipe off immediately and
wash copiously with water. Particularly avoid contact with the eyes, but if
this occurs, you must seek medical advice.

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

3. This product is not intended for use by persons with reduced physical,
sensory or mental capabilities or lack of experience and knowledge.

4. Children must not play with the charger.

5. Do not expose this charger to rain.

6. Never touch the negative and positive leads together.

7. Never attempt any repairs yourself. If you have a problem with your
charger contact your local Clarke dealer or contact
[e-mail]

8. When charging is completed, ensure that the vehicle battery leads are
secured to the proper terminals which should be clean, and lightly
smeared with petroleum jelly to prevent corrosion. Finally, re-check the
electrolyte level.

WARNING: ALWAYS SWITCH OFF THE CHARGER WHEN CONNECTING OR
DISCONNECTING LEADS TO AVOID SPARKING AS HIGHLY INFLAMMABLE
HYDROGEN GAS IS RELEASED IN THE PROCESS OF BATTERY CHARGING

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

WARNING: SINCE TOXIC FUMES MAY BE RELEASED DURING BATTERY
CHARGING, ONLY USE THIS UNIT IN A WELL VENTILATED AREA.

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ELECTRICAL CONNECTIONS

Before switching the product on, make sure that the voltage of your electricity supply is
the same as that indicated on the rating plate. This product is designed to operate on
230VAC 50Hz. Connecting it to any other power source may cause damage.

This product may be fitted with a non-rewireable plug. If it is necessary to change the
fuse in the plug, the fuse cover must be refitted. If the fuse cover becomes lost or
damaged, the plug must not be used until a suitable replacement is obtained.

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

If the colours of the wires in the power cable of this product do not correspond with the
markings on the terminals of your plug, proceed as follows.

• The wire which is coloured Blue must be connected to the terminal which is
marked N or coloured Black.

• The wire which is coloured Brown must be connected to the terminal which is
marked L or coloured Red.

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

If in any doubt, consult a qualified electrician. DO NOT attempt any repairs yourself.

This symbol indicates that this is a Class II product, and does not require an earth
connection.

WARNING! READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE
MAINS SUPPLY.

WARNING! THE WIRES IN THE POWER CABLE OF THIS PRODUCT
ARE COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE:
Blue = Neutral Brown = Live

Plug must be BS1363/A approved.

Always fit a 13 Amp fuse.

Ensure that the outer sheath of the cable is firmly held by the clamp

Neutral

(Blue)

Live

(Brown)

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OVERVIEW

CHARACTERISTICS

The IBC7 is designed for charging all types of 12V/24V lead-acid batteries
including WET (flooded), GEL, MF (Maintenance Free), EFB (Enhanced flooded
battery), and AGM (Absorbed Glass Mat) batteries. It is suitable for charging
battery capacities from 14 to 200 Amp-Hours (12V) / 14 to 100 Amp-Hours
(24V) and maintaining all battery sizes.

The in-built microprocessor provides fast and safe charging using its safety
features to protect against sparking, reversed polarity, short circuit,
overcurrent, overcharge and over heating.

The CHARGE indicator LED will be on during charging until completion. If the
charger remains connected, it will automatically switch from full charging to
Maintenance status to maintain the batteries during periods of storage.

1 Mains power lead/plug 6 Charging Mode Indicator

2 Error LED 7 Output leads (eyelet connectors)

3 Charge Status LEDs 25-100% 8 Fuse Holder (15 Amp blade fuse)

4 Standby LED 9 Charging lead negative clamp

5 Output (charging) lead 10 Charging lead positive clamp

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WALL MOUNTING

The IBC7 has four external holes for
mounting. Mount the charger in the
desired location with M3 self-tapping
screws. Make sure there are no
obstructions behind the mounting
surface.

It is important to consider the distance
of the charger mounting from the
vehicle battery location. The DC
cable length from the charger, with
either the battery clamp or the eyelet
terminal connectors is approximately 75 inches (1900 mm).

Alternatively the charger can be hung from a hook or peg by extending the
loop shown.

CAUTION: DO NOT HANG THE UNIT FROM THE POWER LEAD.

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PREPARATION

1. If necessary, remove the battery from a vehicle to charge it.

2. Always remove the grounded terminal from the battery first.

3. Ensure all accessories in the vehicle are switched off to prevent sparking.

4. Clean the battery terminals. Be careful to keep any corrosive matter from
coming in contact with eyes.

5. Where possible, add distilled water to each cell until the battery acid
reaches the level specified by the battery manufacturer. This helps remove
unwanted gas from the cell. Do not overfill. For a battery without cell caps,
follow the manufacturer's instructions.

6. Study all the battery manufacturer's specified precautions: for example,
removing or not removing cell caps while being charged, and
recommended rates of charge.

7. Refer to the vehicle manual to find the voltage of the battery and make
sure that the output is set to the correct voltage.

8. If the charger has adjustable charge rate, charge the battery initially at the
lowest rate.

CHARGER LOCATION

1. Place the charger as far away from the battery as possible.

2. Do not position the charger above the battery during the charging
procedure. Gases from the battery will corrode and damage the charger.

3. Do not let battery acid drip on the charger when reading a hydrometer for
specific gravity or when you fill the battery.

4. Do not use the charger in an enclosed space with reduced airflow.

CONNECTING TO A BATTERY

WARNING: A SPARK NEAR THE BATTERY MAY CAUSE BATTERY EXPLOSION.
TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY:

• Turn off the charger before you connect/disconnect the DC
output clips.

• Do not let the clamps touch each other.

• Attach the clamps to the battery terminals and make sure that
you get a good connection.

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WHEN THE BATTERY IS INSTALLED IN THE VEHICLE

1. Route the leads carefully to reduce the risk of damage by the bonnet,
door, or engine parts.

2. Keep away from the fan blades, belts, pulleys, and other parts that can
cause injury.

3. Check the polarity of the battery posts.

4. Refer to the vehicle manual to find out if the vehicle has a Negative or
Positive earth.

• For negative earth vehicles, connect the POSITIVE (RED) lead from the

battery charger to the POSITIVE terminal on the battery. Connect the
NEGATIVE (BLACK) lead to the vehicle chassis, engine block or suitable
earthing point away from the battery. Do not connect the lead to the
carburettor, (if fitted) fuel lines, or sheet metal body parts.

• For positive earth vehicles, (very rare today) connect the NEGATIVE

(BLACK) lead from the battery charger to the NEGATIVE terminal on the
battery. Connect the POSITIVE (RED) lead to the vehicle chassis or
engine block away from the battery. Do not connect the lead to the
carburettor (if used) fuel lines, or sheet metal body parts.

NOTE: If the battery clamps are reversed, the ERROR LED will be on.

5. When charging is completed, switch off the charger and disconnect the
plug from the power supply. Remove the lead from the vehicle chassis,
and then remove the leads from the battery.

WHEN THE BATTERY HAS BEEN REMOVED FROM THE VEHICLE

1. Make sure that you know the polarity of the battery posts.

2. Connect the POSITIVE (RED) lead to the POSITIVE post on the battery.

3. Reach over and connect the NEGATIVE (BLACK) lead at arms length to the
NEGATIVE post on the battery.

4. When charging is completed, switch off the charger and disconnect the
plug from the power supply. When you disconnect the charger from the
battery always do it in the opposite order to the sequence of connection
and break the first connection at arms length from the battery.

NOTE: A marine (boat) battery must be removed and charged on shore. To

charge it on board requires equipment specially designed for marine
use.

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THE CHARGING PROCESS

The IBC7 has a sophisticated computer system that performs a 7 - stage
automatic charging cycle as follows:

STEP 1: DIAGNOSIS

Checks that the battery has connected with the charger and also checks the
battery voltage.

STEP 2: DESULPHATION

If battery voltage is too low, this step automatically generates a pulsing
current to remove sulphate.

STEP 3: ANALYSE

Checks if the battery voltage reaches the threshold after desulphation and
charging begins if the battery voltage is OK.

STEP 4: SOFT START

Charges with constant current.

STEP 5: BULK

Charges with constant maximum current until battery voltage has reached
the threshold.

STEP6: ABSORPTION

A gradually declining current charge for maximum battery voltage.

STEP 7: ANALYSE

Testing if the battery can hold a charge

STEP 8: MAINTENANCE

Continuously monitors the battery and charging current and will intelligently

adapt to the variable battery voltage.

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CHARGING SETTINGS

The IBC7 has the following selectable charging settings:

MODE EXPLANATION

STANDBY

In Standby mode, the charger is not charging or providing any
power to the battery. Energy Save is activated during this mode,
drawing microscopic power from the electrical outlet. When
selected, a green LED will illuminate.
NO POWER

12V
NORM

For charging 12-volt Wet Cell, Gel Cell, Enhanced Flooded,
Maintenance-Free and Calcium batteries. When selected, a
green LED will illuminate.

12V
COLD/
AGM

For charging 12-volt batteries in cold temperatures below 50

o

F

(10

o

C) or AGM batteries. When selected a green LED will

illuminate.

24V
NORM

For charging 24-volt Wet Cell, Gel Cell, Enhanced Flooded,
Maintenance-Free and Calcium batteries. When selected, a blue
LED will illuminate.

24V
COLD/
AGM

For charging 24-volt batteries in cold temperatures below 50

o

F

(10

o

C) or AGM batteries.

When selected a blue LED will illuminate.

12V/24V
REPAIR

An advanced battery recovery mode for repairing idle,
damaged, stratified or sulfated batteries.
When selected a yellow LED and green (12V) or Blue (24V) LED will
illuminate. (16.5V/1.5A)

13.6V
SUPPLY

Converts to a DC power supply for powering any 12V DC device
such as a tire inflator, oil changer or as a memory retainer when
replacing a battery. When selected, a yellow LED will illuminate.
(13.6V/5A)

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USING THE 12V/24V REPAIR MODE

12V/24V Repair is an advanced battery recovery mode for repairing idle,
damaged, stratified or sulfated batteries. Not all batteries can be recovered.

Batteries tend to become damaged if kept at a low charge and/or never
given the opportunity to receive a full charge. The most common battery
problems are battery sulfation and stratification. Both battery sulfation and
stratification will artificially raise the open circuit voltage of the battery,
causing the battery to appear fully charged, while providing low capacity.

Use 12V/4V Repair in attempt to reverse these problems. For optimal results,
take the battery through a full charge cycle, bringing the battery to full
charge before using this mode.

12V/24V Repair can take up to eight hours to complete the recovery process
and will return to Standby when completed.

USING THE 13.6V SUPPLY

The 13.6V Supply converts the charger to a constant current, constant voltage
DC power supply. It can be used to power 12VDC devices, including; tire
inflators, oil changers, coffee pots, seat heaters and more. As a power supply,
it can also be used to retain a vehicle's on-board computer settings during
battery repair or replacement. The 13.6V Supply provides 13.6-volts at 5A with
overload protection at 6A (Max).

CAUTION: USE THIS MODE WITH CARE. THIS MODE IS FOR 12/24 VOLT
LEAD-ACID BATTERIES ONLY. THIS MODE USES A HIGH CHARGING
VOLTAGE AND MAY CAUSE SOME WATER LOSS IN WET (FLOODED) CELL
BATTERIES. BE ADVISED, SOME BATTERIES AND ELECTRONICS MAY BE
SENSITIVE TO HIGH CHARGING VOLTAGES. TO MINIMIZE RISKS TO
ELECTRONICS, DISCONNECT THE BATTERY BEFORE USING THIS MODE.

CAUTION: PRIOR TO USE, READ YOUR 12VDC DEVICE MANUAL TO
DETERMINE IF IT IS SUITABLE FOR USE WITH THIS MODE. BOTH THE SPARK
PROOF AND REVERSE POLARITY SAFETY FEATURES ARE DISABLED IN THIS
MODE. DO NOT ALLOW THE POSITIVE AND NEGATIVE BATTERY CLAMP
OR EYELET TERMINAL CONNECTORS TO TOUCH OR CONNECT TO EACH
OTHER AS THE CHARGER COULD GENERATE SPARKS. CHECK THE
POLARITY OF THE BATTERY TERMINALS BEFORE USING THIS MODE

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OPERATION

TO BEGIN CHARGING THE BATTERY

1. Verify the voltage and chemistry of the battery.

2. Confirm that the battery clamps are correctly connected or eyelet
connectors secure and that the power plug is plugged into a power outlet.

3. All LEDs will flash once after starting and will go into the last memory mode
automatically after 10 seconds.

4. Press the mode button to toggle to the appropriate charge mode (press
and hold for three seconds to enter an advanced charge mode) for the
voltage and chemistry of your battery.

5. The mode LED will illuminate the selected charge mode and the Charge
LEDs will illuminate (depending on the health of the battery) indicating the
charging process has started.

6. When connected, the battery charger can stay in place, providing
continuous charging.

UNDERSTANDING THE CHARGE LEDS

The charger has four Charge LEDs - 25%, 50%, 75% and 100% which indicate
the connected battery state of charge as shown below.

LED E

XPLANATION

25% 50% 75% 100%

The 25% Charge LED (red) will flash when the
battery is less than 25% charged.
When the battery is 25% charged, the charge
LED remains on.

25% 50% 75% 100%

The 50% Charge LED (red) will flash when the
battery is less than 50% charged.
When the battery is 50% charged, the charge
LED remains on.

25% 50% 75% 100%

The 75% Charge LED (red) will flash when the
battery is less than 75% charged.
When the battery is 75% charged, the charge
LED remains on.

25% 50% 75% 100%

The 100% Charge LED (green) will flash when
the battery is less than 100% charged.
When the battery is 100% charged, the charge
LEDs will switch off.

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UNDERSTANDING ADVANCED DIAGNOSTICS

When the ERROR LED warning is flashing it denotes a potential error condition.
Only use the charger after correcting the error. If the cause is not apparent,
consult a qualified person such as your Clarke dealer.

The following error warnings can occur.

1. Battery is not connected.

2. Battery voltage is too low.

3. Reverse polarity.

4. Overload.

CHARGING TIME DURATION

Different battery capacity, residual voltage and charging current will all affect
charging time.

The following table is for guidance in the case of a fully discharged battery.

• when discharging a 12V lead-acid battery to 9V, with 5A discharge
current:

• when discharging a 24V lead acid battery to 18V with 10A discharge
current.

Switch off the charger and disconnect the mains plug from the power socket.

Remove the leads from the battery and store them safely with the charger.

After the full charging cycle, use the battery to start the vehicle’s engine. If the
engine does not start (excluding a defect with the vehicle its-self), it indicates
this battery has declined any storage capacity and needs to be replaced.

B

ATTERY

S

IZE/AH

APPROXIMATE TIME TO

CHARGE IN HOURS (12V)

A

PPROXIMATE TIME TO

CHARGE IN HOURS (24V)

50 5H@14.5V 7H@14.7V 9H@29.3V 11H@30V

60 8H@14.4V 10H@14.7V 11H@29.3V 14H@30V

100 9H@14V 15H@14.5V 19H@29.3V 24H@30V

150 21H@14V 25H@14.8V ------ ------

200 24H@14V 30H@14.7V ------ ------

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CARE & MAINTANENCE

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

1. Wind up the leads when not in use. Examine the leads at regular intervals
for damage and have them replaced if necessary.

2. Clean the case and leads if necessary with a moist cloth and clean any
corrosion from the clamps with a solution of water and baking soda.

3. Both the output cables (eyelet or
crocodile clip) are fitted with a
fuse as protection against short
circuit when connecting to the
battery.

4. Lift the cap and pull out the blown
fuse.

• Replacement 15 amp blade

fuses are available from motor
factors.

WARNING: ALWAYS BE SURE THE CHARGER IS UNPLUGGED BEFORE
PERFORMING ANY MAINTENANCE OR CLEANING. ANY REPAIRS MUST BE
DONE BY A QUALIFIED SERVICE TECHNICIAN.

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TROUBLESHOOTING

Problem Cause Solution

ERROR light flashes Battery not connected or

open circuit

Connect battery correctly.
If unsuccessful have the
battery tested by a
qualified technician.

The battery voltage is to low
to accept a charge.

The battery is wrongly
connected (reverse
polarity)

Overload

Battery does not
charge

Lack of AC input power. Make sure that the charger

is plugged into AC outlet
and the POWER LED is lit.

Faulty connections to
battery terminals.

Unplug the charger and
check the battery
connection; ensure that
there is a good connection
at the battery terminal/post
and/or vehicle chassis.

Wrong charge voltage
selection.

Check that the correct
charge voltage was
selected for the battery
being charged.

Battery voltage too low. Ensure enough charging

time was allowed to charge
battery.

Charging a very cold
battery.

If the battery being
charged is extremely cold, it
will not accept a high rate
of charge, so the initial
charge rate will be slow.
The rate of charger will
increase as the battery
warms up.
Never attempt to charge a
frozen battery.

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COMPONENT PARTS

NO DESCRIPTION

1PCB-A

2PCB-B

3 CT7000 clamp

4 CT7000 steel hanging hook

5 CT7000 top shell

6 CT7000 bottom shell

7 CT7000 Sealing ring

80-ring

9Input cable

10 Outlet cable

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SPECIFICATIONS

Model Number IBC7

Input voltage / Current 220-240V, 50Hz, 1A

Battery charging voltages: 12V and 24V

Power Max 120W

Output current 7A (12V), 3.5A (24V)

Charging steps 8 steps, (smart charger)

Charging Battery Capacity 14-200 Ah (12V), 14-100 Ah (24V)

IP Rating IP54

Operating Temperature Range -10 to 40°C

Dimensions (D x W x H) 300 x 106 x 61 mm

Supply cable length 2900 mm

Charging lead length (Black and Red) 1900 mm

Weight 1.09 kg

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DECLARATION OF CONFORMITY

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NOTES

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