Clarke WBC 250, 6261525 User guide

INTELLIGENT BATTERY CHARGER-STARTER

MODEL NO: WIBC250

PART NO: 6261525

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS

DL0921

INTRODUCTION

Thank you for purchasing this CLARKE Intelligent Battery Charger-Starter.

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 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.

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 SYMBOLS

Wear Eye Protection Wear Protective

Wear Protective Gloves WEEE Directive

Indoor Use Only Class 1 Appliance

Clothing

War ning: Battery
Charging

Explosive Gases:
Prevent flames & sparks
and provide ventilation
during charging

Warning: Risk of
Electrical Shock

Not suitable for use with
Li-Ion or Li-Poly batteries

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ELECTRICAL CONNECTIONS

WARNING: READ THE ELECTRICAL SAFETY INSTRUCTIONS THOROUGHLY.

WARNING: A 13 AMP (BS1363) PLUG IS NOT SUITABLE.

WARNING: THIS APPLIANCE MUST BE EARTHED.

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 16 Amps.

A normal 13 Amp (BS1363) plug must NOT be used.

NOTE: The maximum input current for this unit is 47 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 cord of this appliance may not correspond with
the coloured markings identifying terminals, proceed as follows:

• Connect GREEN AND YELLOW coloured cord to terminal marked letter
“E” or Earth Symbol or coloured Green and Yellow.

• Connect BROWN cord to terminal marked letter ‘L’ or coloured Red.

• Connect BLUE cord to terminal marked letter “N’ or coloured Black.

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WIBC250 OVERVIEW

1 Handle 5 Positive (Red) Lead

2 Display & Control Panel 6 Positive Lead Terminal +24V

3 Cable Rack 7 Positive Lead Terminal +12V

4 Negative (BLACK) Lead 8 Fuse

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SPECIFICATIONS

Model Number WIBC250

Dimensions (D x W x H) 300mm x 300mm x 850mm

Weight 17.90kg

IP Rating IP20

Suitable Battery Type 12V & 24V WET, MF, EFB, STD, GEL & AGM

Min. Charging Battery Size 4 Ah

Max. Charging Battery Size 550 Ah

Operating Temp. Range 0°C to 40°C

Input Voltage @50Hz 230 V AC

Boost Duty Cycle 5 sec On / 240 sec Off

Max.
Input

Power

Charge-12V-50A 1035W 5.5A 51A 12V

12V-Start(6V) 4280W 22A 200A 6V

12V-Start(3V) 5460W 29A 270A 3V

Charge-24V-50A 1764W 9.8A 50A 24V

24V-Start(10V) 8140W 44.4A 230A 10V

24V-Start(8V) 8455W 47A 250A 8V

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Max.
Input

Current

6

Output

(Charging/

Starting)

Charging

Voltage

SAFETY PRECAUTIONS

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

PLEASE READ BEFORE USING THIS UNIT

1. Batteries can generate explosive gases during normal operation. A LWAYS
use in well ventilated area.

2. DO NOT smoke, strike a match or cause a spark in the vicinity of the battery
or engine. Avoid explosive gas, flames and sparks.

3. Remove all personal jewellery, such as rings, bracelets, necklaces and
watches while working with a vehicle battery. These items may produce a
short circuit and could cause severe burns.

4. Be extra cautious to reduce the risk of dropping a metal tool onto the
battery. It may spark or short circuit the battery or other electrical
hardware which may cause an explosion or fire.

5. Wear complete eye, hand and clothing protection. AVOID touching eyes
while working on or near a battery.

6. Study all battery manufacturers specific precautions, such as removing or
not removing cell caps while charging and recommended rates of
charge.

7. Clean battery terminals before connection with the charger. Be careful to
keep corrosion from coming in to contact with eyes.

8. When it is necessary to remove the battery from the vehicle to charge,
always remove the grounded terminal from the battery first. Make sure all
accessories in the vehicle are switched off in order to prevent an arc.

9. This charger is NOT intended to supply power to an extra low voltage
electrical system or to charge dry cell batteries. Charging dry cell batteries
may cause the battery to burst and cause injury to person or property.

10. NEVER charge a frozen, damaged, leaking or non rechargeable battery.

11. If battery electrolyte contacts skin or clothing, wash immediately with soap
and water. If electrolyte enters your eye, immediately flood eye with
running clean cold water for at least 15 minutes and seek medical
attention immediately.

12. DO NOT place the charger in the engine compartment, near moving parts
or near the battery. Place as far away from them as the cables permit.

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13. NEVER place the charger directly above the battery being charged, gases
or fluids from the battery will corrode and/or damage the charger.

14. DO NOT cover the charger while charging.

15. DO NOT expose to rain or wet conditions.

16. Connect and disconnect the DC output connections only after
disconnecting the charger from the mains power supply.

17. Use of an attachment not recommended or sold by the manufacturer may
result in a risk of fire, electric shock or injury to persons.

18. DO NOT overcharge batteries by selecting the wrong charge mode.

19. Operate with caution if the charger has received a direct hit of force or
been dropped. Have it checked and repaired if damaged.

20. NEVER attempt any repairs yourself. If you have a problem with your
charger contact your local CLARKE dealer or contact
[e-mail]

21. When charging is complete, 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.

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DISPLAY & CONTROL PANEL

DISPLAY BUTTON

Press the DISPLAY button until the following LED is lit:

1. VOLTAGE (V) - When the charger is NOT charging a battery, the digital
display will show the battery voltage.

2. BATTERY (%) - When in charging, the digital display shows an estimated
charge percentage of the battery connected to the charger s battery
clamps.

3. ALTERNATOR (%) - The digital display shows an estimated output
percentage of the vehicle’s charging system connected to the chargers’s
battery clamps, compared to a properly functioning system.

BATTERY TYPE, RATE SELECTION & FUNCTION BUTTONS

1. Press the BATTERY TYPE button to choose the type of battery to be charged:
STD, GEL or AGM

2. Press the RATE SELECTION button to choose the charging current required:
10A, 20A, 35A or 50A.

3. Then press the FUNCTION button until the CHARGING LED is lit (digital
display will show CHARGE-ON).

When in charging mode, pressing the BATTERY TYPE button will not work. To stop
charging, press FUNCTION button again and CHARGING LED will turn off (digital
display will show CHARGE-OFF)

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GENERAL PREPARATION

CHARGER LOCATION

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

2. DO NOT let battery acid drip on anything when reading specific gravity or
when topping up the battery.

3. DO NOT operate the charger in an enclosed space, such as inside the
vehicle. NEVER cover the battery charger when in use.

4. DO NOT stand the battery on top of the charger.

5. ALWAYS stand the battery charger on a firm, level floor.

6. During charging, make sure that the area around the battery has good
ventilation.

OPERATING INSTRUCTIONS

Before charging, make sure the capacity of the battery to be charged is not
lower than 4Ah. On the rear of the charger you will find separate connectors
for 12V and 24V batteries making sure the correct cable is connected to the
appropriate battery.

CONNECTING TO A BATTERY INSTALLED IN THE VEHICLE

1. Arrange the leads carefully to reduce the risk of damage caused by sharp
edges.

2. Identify the voltage of the battery to be charged (12v or 24v) and attach
the POSITIVE (RED) lead to the appropriate terminal on the rear of the
charger.

3. Identify the polarity of the battery posts. The positive battery terminal is
typically marked by the letters/symbols: POS, P or +. The negative battery
terminal is typically marked by the letters/symbols: NEG, N or -.

4. DO NOT make any connections to the carburetor, fuel lines or thin metal
parts.

5. Consult the vehicle manual to confirm if the vehicle has a Negative or
Positive earth.

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

from the battery charger to the POSITIVE terminal on the battery. Then
connect the NEGATIVE (BLACK) lead and clamp to the vehicle frame or
engine block away from the battery.

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• For positive earth vehicles, connect the NEGATIVE (BLACK) lead and

clamp from the battery charger to the NEGATIVE terminal on the
battery. Connect the POSITIVE (RED) lead and clamp to the vehicle
frame or engine block away from the battery.

• DO NOT connect the lead to ancillary engine components.

6. Where appropriate we recommend that the non-earthed lead on the
battery is disconnected prior to charging. It is possible that damage may
occur to the vehicle’s electronic equipment.

7. When charging is completed, switch off the charger. Remove the leads
and clamps in the reverse sequence taken in the relevant step 5.

8. A marine (boat) battery must be removed and charged on shore. To
charge it on board requires equipment specially designed for maritime
use.

CONNECTING TO A BATTERY REMOVED FROM THE VEHICLE

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

2. Identify the voltage of the battery to be charged (12v or 24v) and attach
the POSITIVE (RED) lead to the appropriate terminal on the rear of the
charger.

3. ALWAYS remove the grounded (earth) terminal from the battery first,
making sure that all electrical accessories in the vehicle are switched off to
prevent sparking before removing the battery from the vehicle.

4. Clean the battery terminals. Be careful to prevent battery electrolyte from
coming in contact with your eyes.

5. Except for sealed units, add distilled water to each cell until the battery
acid reaches the level specified by the battery manufacturer.

• This helps drive unwanted gas from the cell. Do not overfill. For a battery

without cell caps, consult the manufacturer's instructions.

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

7. Connect the POSITIVE (RED) lead and clamp to the POSITIVE post on the
battery.

8. Connect the NEGATIVE (BLACK) lead and clamp at arms length to the
NEGATIVE post on the battery.

9. When you disconnect the charger/starter from the battery, A LWAYS do it in
the opposite order to the sequence of connection and remove the first
connection at arms length from the battery.

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CHARGING STEPS

1. ANALYSING 1: Checks if battery is connected with the charger.

2. DESULPHATION: Pulsing charging to remove sulphate.

3. SOFT START: Charges with gradually increasing charging current.

4. CONTROLLED CURRENT CHARGE: Adjusts the charging current intelligently.

5. ANALYSING 2: Tests if the battery can absorb charge.

6. CONSTANT OUTPUT CHARGE: Charges with constant voltage and
compensates fake full charge caused by high current charging.

7. RECOVERY CYCLE CHARGE: Absorbs more charge and compensates side
effect of reduced charging current.

8. ABSORPTION: Charges with constant trickle current for maximum battery
voltage.

9. ANALYSING 3: Tests if the battery can hold charge.

10. MAINTENANCE: Continuously monitors the battery and charges with trickle
current once the voltage is lower than threshold.

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STARTING A CAR - BOOST

The battery charger can be used to start a car if the battery is low. Follow all
safety instructions and precautions for charging your battery. Wear eye

protection and protective clothing. The procedures are as follows:

WARNING: USING THE ENGINE START FEATURE WITHOUT A BATTERY
INSTALLED IN THE VEHICLE WILL DAMAGE THE VEHICLES ELECTRICAL
SYSTEM.

1. Connect the charger to the battery following the instructions given on
page 10.

2. Press the FUNCTION button until the START LED is lit.

3. Turn on the vehicles ignition until it starts or 3 seconds have passed. If the
engine does not start, wait 4 minutes before trying again. This allows the
charger and battery to cool down.

4. If the engine fails to start, use the CHARGE maximum rate (50A) to charge
for some minutes before trying to attempt to start the engine again.

5. After the engine has started, disconnecting the battery charger clamps
from the battery/vehicle.

During the starting sequences listed above, the charger is set to one of three
states:

1. START-READY: The charger waits until the engines ignition is activated
before delivering the amps for the engine start.

2. CRANKING: When the ignition is detected, the charger will automatically
deliver up to its maximum output as required by the starting system for up
to 5 seconds.

3. COOL DOWN: After ignition, the charger enters a mandatory 240 seconds
cool down state (Pressing any button will not work). The digital display
indicates the remaining cool down time in seconds. It starts at 240 and
counts down to 0. After 240 seconds, the digital display will change from
displaying the countdown to displaying START-READY.

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REPAIR FUNCTION

Press the FUNCTION button until the REPAIR LED is lit to enter this mode (digital
display shows REPAIR-ON). It is an advanced battery recovery mode for
repairing old, idle, stratified or sulfated batteries. Not all batteries can be
recovered. For optimal results, take the battery through a full charge cycle,
bringing the battery to full charge, before using this mode. This mode uses a
high charging voltage and may cause some water loss in WET cell batteries.
Some batteries and electronics may be sensitive to high charging voltages. To
minimise the risks, disconnect the battery from the vehicle before using this
mode. To stop repairing, press the FUNCTION button again and the REPAIR LED
will turn off (digital display will show REPAIR-OFF).

ALTERNATOR CHECK

To check the alternator percentage, carry out the following steps:

1. Connect the charger to the battery following the instructions given on
page 10.

2. With the charger connected to the battery and chassis, press the DISPLAY
button until the ALTERNATOR% is lit.

3. Start the vehicle and turn the vehicles headlights on. The percentage will
show on the display screen.

The alternator percentage range is from 0% to 100%. readings below 0% will read
LO and readings above 100% will read HI. If you get a HI or LO reading, have the
electrical system checked by a qualified technician.

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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.

Battery

Size - Ah

10 2h 1h 33mins 2h 1h 33mins

20 4h 2h 1h 4h 2h 1h

40 8h 4h 2h 8.5h 8.5h 2h

80 17h 9h 4h 17h 9h 5h

160 33h 17h 8h 33h 17h 9h

320 65h 33h 17h 65h 33h 17h

550 111h 56h 26.5h 81h 56h 28.5h

Approx. Time to Charge

12V 24V

5A 10A 20A 5A 10A 20A

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FUSES

1. The starter/charger is equipped with a safety fuse which will protect the
unit under the following circumstances:

• Overload - too high a current to the battery.

• Short Circuit - clamps touch or cross connection to battery.

• Prolonged starting attempts.

REPLACING THE FUSE

The fuse fitted is rated at 50A and is
fitted behind the clip-on cover on the
rear of the charger for easy
replacement.

1. Isolate the mains power to the
charger.

2. Allow the unit to cool down and
establish the reason for the failure
and correct.

3. Pull off the fuse cover before
unscrewing the nuts to remove the fuse. Replace only with an identical
fuse and with the same rating, as supplied with your charger.

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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 ISOLATED FROM ITS POWER
SUPPLY 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.

STORAGE

1. Wind up the positive and negative connecting leads onto the cable rack
when not in use.

2. Store in a clean, dry area.

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WIBC250 PARTS DIAGRAM

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WIBC250 PARTS LIST

NO DESCRIPTION NO DESCRIPTION

1 Front Cover 15 Rectifier Bridge

2 Upper Cover 16 Fuse Posts

3 Bottom Cover 17 12V Positive Cable Joint

(Showing Positive Cable
Attached)

4 Base Plate 18 24V Positive Cable Joint

5 Main PCB Radiator 19 Power Cable

6 Control PCB 20 Negative Cable & Clamp

7 Wheels 21 Fuse

8 Wheel Button 22 Fuse Cover

9 Roller 23 Positive Cable & Clamp

10 Fan 24 Handle Rod Support Frame

11 Fan Holding Plate 25 Back Cover

12 Rectifier Bridge Holding Plate 26 Cable Rack

13 Relay 27 Handle Rod

14 Transformer 28 Handle

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ERROR MESSAGES

1. E01 Display + ERROR LED lit: Reverse connection

2. E02 Display + ERROR LED lit: Temperature in charger is too high

3. E03 Display + ERROR LED lit: The battery cannot store electric charge (dead
battery)

4. E04 Display + ERROR LED lit: No battery connected/battery voltage is lower
than 1 volt (dead battery)

5. REPAIR-ON displayed + REPAIR LED flashing: Charger automatically enters
repairing mode

6. REPAIR-ON displayed + REPAIR LED solid lit: Manually choose repairing
mode

TROUBLESHOOTING

Problem Cause Solution

Battery
does not
charge

Lack of AC input
power.

Faulty connections to
battery terminals.

Wrong charge
voltage selection.

Battery voltage too
low.

Charging a very cold
battery.

Make sure that the electrical circuit the
charger is on has power.

Check the battery connections; ensure
that there is a good connection at the
battery terminal/post and/or vehicle
chassis.

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

Ensure enough charging time was
allowed to charge battery.

If the battery being charged is extremely
cold (below freezing), it will not accept a
high rate of charge, so the initial charge
rate will be slow.
The rate of charge will increase as the
battery warms.
NEVER attempt to charge a frozen
battery.

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DECLARATION OF CONFORMITY - UKCA

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DECLARATION OF CONFORMITY - CE

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