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1. e Gharging Output Control Characteristics e Charging Flow Battery condition detect gt Soft Start Charge gt Bulk Charge gt Absorption Charge gt Sulfate Check gt Float Charge e Soft Start Charging Activity conditions Battery Voltage is over 6 Vdc and less than 21Vdc e Soft Start Charging output current conirol 1 0 25 Adc e Soft Start Charging Time Limited Stops charge if battery cannot be charged over 21 0 V after 6 hrs Error LED flash indicated 6 0 25 Hours e Bulk Charging Activity conditions Battery Voltage is over 21Vdc e Bulk Charging Current control 4 0 22 0 Adc e Max rated output voltage and current 29 4 V at 4Adc e Bulk Charging Time Limited Stops charge if battery cannot be fully charged 29 4 V after 20 hrs error LED flash indicated 20 1 Hours At 25 C Rev C 080211 Page 30 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 DETAILED SPECIFICATIONS VDC Model No 24041 AA S3 con t Absorption mode transitions to Float mode conditions in AGM setting Mode 1 Charging current 2 5 Hours Time out after 5 Hours unit switches to Float Charge Mode Absorption mode Thermal Runaway Protection Stops Charging when the second current sample is larger than the first current sample Positive dl dt GREEN Charge Float LED will blink Float Charge output Voltage control 27 2 0 25 Vdc Float Charge current control 4A Rate 2 Adc 0 25 Float charge transitions to PWM Float Charg2. most sulfated battery will receive the majority of the desulfation pulse energy Rev C 080211 Page 24 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 ALWAYS test each individual battery to be certain it is healthy and free of sulfate before attempting to charge or maintain them either as a single battery or in sets NEVER connect multiple batteries together for charging purposes using less than 18 Gauge insulated wire VDC Electronics Inc does not make nor can it supply or recommend any type of wire harness to connect individual batteries for the purpose of charging them in groups due to the many battery terminal sizes and configurations that exist See diagram adjacent for the most common multiple battery configuration 24041 AA S3 24 Volt BatteryMINDer Battery Configuration TO CHARGER TO CHARGER To Charger 1 To Charger 12 VOLT Series Connected 24V 24 VOLT Parallel Connected 24V Rev C 080211 Page 25 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 Troubleshooting Model 24041 AA S3 We use the word Indicator to mean the various LEDs Light Emitting Diodes showing the various faults modes and conditions of the battery and or charger The words unit charger or recharger means your model 24041 AA S3 BatteryMINDer PROBLEM Power ON indicator does not light SOLUTION Check electrical outlet If controlle
3. AA S3 defective Be very suspicious of any 24 V battery that does not have at least 22 Volts OCV before it is recharged It may well be seriously damaged and unsafe for any type of use or recharge The unit s Battery Condition Indication LED will help you determine if battery is less than 22 Volts WELLOW or greater than 22 Volts GREEN 5 After battery has been fully charged the GREEN Charge Float LED Indicator will begin blinking It will continue to blink indefinitely unless unit is disconnected from battery or Stop Restart button is pressed Should battery be unable to be fully charged the LED will not blink and the RED Error LED will blink Battery may not be able to be fully charged may be too large or too deeply discharged to be fully charged in the normal time allowed by charger If you are certain battery is not defective having read and understood completely all of the above concerns and conditions proceed to restart the charger by pressing and holding the Stop Restart button for approx 5 seconds until all LEDs Flash This allows charger to begin charging battery again If battery is not defective it should be able to be fully charged after being restarted After sufficient time has lapsed the GREEN charge LED Indicator will blink confirming when if battery is now fully charged Note If attempting to charge more than one battery at a time it is very likely the charger will need to be restarted as described in order t
4. Charge Float 110 120 28 40 26 20 43 49 100 110 28 60 26 40 38 43 Rev C 080211 Page 22 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 Notes Rev C 080211 Page 23 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 MAINTAINING MULTIPLE BATTERIES BatteryMINDer 24041 AA S3 maintenance charger Desulfators can be used to maintain up to three 24 volt batteries at a time providing each battery is fully operational no dead dying cells free of sulfate and meeting the minimum full charge rested see pg 9 voltage of 2 13 volts cell after being fully desulfated ALL batteries MUST be properly tested to ensure they are in good condition no dead dying cells or excessive sulfation before maintaining them in multiples Only healthy fully desulfated batteries should ever be MAINTAINED in sets of 2 or more Test using an accurate DIGITAL type ONLY voltmeter The Minimum voltage Must not be less than 25 56 volts after fully charging battery and letting it rest for 12 hours minimum before testing If battery voltage is less than 25 56 you must first desulfate it until you reach a rested see pg 9 voltage of 25 56 volts Remember you must desulfate each battery by itself one at a time before maintaining them for extended periods Attempting to desulfate more than one 1 battery at a time will yield very poor results as the strongest healthiest and not the weakest
5. a metal tool onto battery It might spark or short circuit battery or other electrical part that may cause explosion Rev C 080211 Page 4 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 g Remove personal metal items such as rings bracelets necklaces 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 h Use charger for charging a LEAD ACID battery only It is not intended to supply power to a low voltage electrical system other than in a starter motor application Do not use battery charger for charging dry cell batteries that are commonly used with home appliances These batteries may burst and cause injury to persons and damage to property i NEVER charge a frozen battery or a battery at a temperature above 123 F 12 PREPARING TO CHARGE a If necessary to remove battery from vehicle to charge always remove grounded terminal from battery first Make sure all accessories in the vehicle are off so as not to cause an arc b Be sure area around battery is well ventilated while battery is being charged c Clean battery terminals Be careful to keep corrosion from coming in contact with eyes d Add distilled water in each cell until battery acid reaches level specified by battery manufacturer Do not overfill For a battery without removable cell caps such as valve regulated lead acid b
6. 11 Page 8 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 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 24041 AA S3 and left disconnected from charger or any type load for a minimum of 12 hours 5 Ifthe BatteryMINDer battery condition LED lights MALLOW 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 main tenance 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 Specific Gravity Capacity Temp Compensated Hydrometer Full Capacity meter or 4 ball type Percentage 1 285 100 1 140 0 May denote shorted cell or battery that has been severely discharged and may not be recoverable TABLE 1 Rev C 080211 Page 9 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 Testing with a Hot Co
7. 41 E AA S3 MNL 24041 E24041 AA S3 BatteryMINDer ez Z 21 6d guna Bull pue p109 YM Josuas alnjejadua 6 yz 02 81 GL 1 s6d snyers abueyo U0I IpU09 J8 9q nej U01I 99UU09 r Jamod JO SJ0 E91pUI 31 9 PE9IN HOW LON AINO S3143118 VO Q19V 0V31 sdV3 H311I4 LIM 40 GQ31V3S H04 91 uoynq U01 99 93S uersoy do s Bd 0 98uU09 indu Josuas arnjeladua 91 ey Bd Bnjd joauuo9 yIMb m p109 1ndin0 g e1 Bd asps09 Jamod indu sqe Bununo A Oo SOd 6n d 199uu03 yimb m 19SD102 peura Bury 9L E L s d Bn d 199uu02 y mb M 9SD109 dijo AJ9 9 9 7 9 G y z L P N VDC 24041 E AA S3 MNL Page 12 Rev C 080211 BatteryMINDer 24041 amp E24041 AA S3 Simplified Operating Instructions Read and thoroughly understand ALL SAFETY Instructions on pages 3 7 and Qualifying Your Battery pages 8 11 BEFORE proceeding further 1 Attach a battery connector assembly supplied to output cordset of charger either the clips or ring terminal assembly NEVER BOTH at same time 2 Attach output to battery terminals RED band Positive BLACK band Negative 2 a Attach temperature sensor ABS 248 to battery and then to charger 3 Plug AC power cord into electrical outlet Observe REVERSED Polarity LED indicator If lit RED reverse battery connector attachments on battery 4 Observe GREEN LED indicat
8. 8 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 DETAILED SPECIFICATIONS VDC Model No 24041 AA S3 MCU controlled H F Battery Charger Note This equipment has been tested and found to comply with the limits for a Class B digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equip ment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one of more of the following measures e Reorient or relocate the receiving antenna e Increase the separation between the equipment and receiver e Connect the equipment into an outlet on a circuit different from that to which the receiver is connected po 2404 AAS3 E24041 AA S3 kedeke AREK du 80mA AC 80mA Ac Current Input Current Consumption at Full 1A AC 1A AC Output UL1236 Rev C 080211 Page 29 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 DETAILED SPECIFICATIONS VDC Model No 24041 AA S3 con t
9. 800 379 5579 x206 ET for advice when service or repair is required Incorrect reassembly may result in a risk of electric shock or fire 9 To reduce risk of electric shock unplug charger from outlet before attempting any maintenance or cleaning Turning off controls will not reduce this risk 10 WARNING RISK OF EXPLOSIVE GASES a WORKING IN VICINITY OF A LEAD ACID BATTERY IS DANGEROUS BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION FORTHIS REASON IT IS OF UTMOST IMPORTANCE THAT YOU FOLLOW THE INSTRUCTIONS EACH TIME YOU USE THE CHARGER b To reduce risk of battery explosion follow these instructions and those published by manufacturer of any equipment you intend to use in vicinity of battery Review cautionary marking on these products and on engine 11 PERSONAL PRECAUTIONS a Consider having someone close enough by to come to your aid when you work near a lead acid battery b Have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes c Wear complete eye protection and clothing protection Avoid touching eyes while working near battery d If battery acid contacts skin or clothing wash immediately with soap and water If acid enters eye immediately flood eye with running cold water for at least 10 minutes and get medical attention immediately e NEVER smoke or allow a spark or flame in vicinity of battery or engine f Be extra cautious to reduce risk of dropping
10. A V 67 IDLIOA P N VDC 24041 E AA S3 MNL Page 34 Rev C 080211 BatteryMINDer 24041 amp E24041 AA S3 FOR REPAIR OR REPLACEMENT All returns must be authorized by VDC Electronics In the event that you believe your product may be defective you MUST speak to a VDC Electronics technician at 1 800 379 5579 x206 ET before proceeding further NOTES MODEL BatteryMINDer 24041 AA S3 or E24041 AA S3 SERIAL NUMBER PLACE OF PURCHASE DATE OF PURCHASE Rev C 080211 Page 35 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 ALL returns must be authorized by VDC Electronics after speaking to a VDC Electronics technician at 800 379 5579 x206 ET Please see our Repair or Replacement section of this manual for additional information BatteryMINDer One Year 100 Unconditional Money Back Guarantee This BatteryMINDer product is guaranteed to perform as claimed or WE will refund your full purchase price including all taxes shipping or handling cost applicable to the purchase Unit must be returned freight prepaid together with Proof of Purchase directly to VDC Electronics Inc NOT TO THE DEALER FROM WHICH IT WAS PURCHASED BatteryMINDer Five Year Limited Warranty VDC Electronics Inc warrants this product for FIVE years from date of purchase at retail against defective material or workmanship and will be repaired or replaced at no charge We make no warranty other than this limited warranty and ex
11. Der Unit Label 15 Detailed Operation InstructionsS 16 Temperature Sensor ABS 248 At the Battery Sensor 17 21 24 Maintaining Multiple Batteris 24 Battery Configurations 25 Troubleshooting Model 24041 M S3 26 Detailed Specifications VDC Model No 24041 AA SS3 29 33 Charging Profile J 34 For Repair Or Replacement 35 Wall uu 36 VDC Electronics Inc 147 D Woodbury Rd Huntington NY 11743 U S A www BatteryMINDers com techsupport vdcelectronics com Rev C 080211 Page 2 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 Underwriters Laboratories UL REQUIRED IMPORTANT SAFETY INSTRUCTIONS for the BATTERYMINDER 2000 SERIES WARNING TO REDUCE THE RISK OF FIRE ELECTRIC SHOCK OR INJURY TO PERSON OBSERVE THE FOLLOWING 1 SAVE THESE INSTRUCTIONS This manual contains important safety and operating instructions for BatteryMINDer 24041 AA S3 Series 2 Do not expose charger to rain or snow 3 Use of an attachment not recommended or sold by VDC Electronics may result in a risk of fire electric shock or injury to persons 4 To reduce risk of damage
12. INSTRUCTION MANUAL BatteryMINDer Models 24041 AA S3 E24041 AA S3 24 Volt For Hawker Odyssey or Gill LT 7000 Series ONLY Charger Maintainer Desulfator Conditioner FOR SEALED or WET FILLER CAPs LEAD ACID GA BATTERIES ONLY NOT FOR NiCad Requires proper installation of Battery Temperature Sensor ABS 248 supplied Please note both models are referred to as model 24041 AA S3 for the purposes of this manual except for the table on Page 29 Rev C 080211 VDC ELECTRONICS P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 TABLE OF CONTENTS SEL LEA SII ONS c su sk sk On 3 Preparing To GNA L s c c sas s u cu un y nya ns na sa kan Qu s Sr L An a aw WA Wa WA WR WA 5 Charger Location Q 5 DC Connection Precautions 6 Qualifying Your Battery 8 Testing A Filler Cap 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 CGall outs 12 Simplified Operating Instructions 13 LED Indicator Functions 14 BatteryMiN
13. Y EXPLOSION TO REDUCE RISK OF A SPARK NEAR BATTERY a Check polarity of battery posts POSITIVE POS P battery post usually has a larger diameter than NEGATIVE NEG N post b Attach at least a 24 inch long 6 gauge AWG insulated battery cable to NEGATIVE NEG N battery post c Connect POSITIVE RED charger clip to POSITIVE POS P post of battery d 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 e Do not face battery when making final connection f When disconnecting charger always do so in reverse sequence of connecting procedure and break first connection while as far away from battery as practical g A marine boat battery must be removed and charged on shore To charge it on board requires equipment specially designed for marine use Rev C 080211 Page 7 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 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 fro
14. atteries carefully follow manufacturer s recharging instructions e Study all battery manufacturer s specific precautions while charging and recommended rates of charge f Determine voltage of battery by referring to car owner s manual and make sure it matches output rating of battery charger 13 CHARGER LOCATION a Locate charger as far away from battery as DC 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 electrolyte specific gravity or filling battery d Do not operate charger in a closed in area or restrict ventilation in any way e Do not set a battery on top of charger Rev C 080211 Page 5 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 14 DC CONNECTION PRECAUTIONS a Connect and disconnect dc output clips only after setting any charger switches to off position and removing AC cord from electric outlet Never allow clips to touch each other b Attach clips to battery and chassis as indicated in 15 e 15 f and 16 b through 16 d 15 FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE A SPARK NEAR BATTERY MAY CAUSE BATTERY EXPLOSION TO REDUCE RISK OF A SPARK NEAR BATTERY a Position ac and dc cords to reduce risk of damage by hood door or moving engine part b Stay clear of fan blades belts pulleys and other parts that can Cause injury t
15. d by a wall switch be sure switch is on and try to prevent accidental shutting it off while charger is working PROBLEM ERROR indicator lights RED several possibilities can be the Cause SOLUTION 1 Output leads connections to battery may be reversed Switch reverse connections at battery 2 If still remains RED check battery voltage If 3 Volts or less battery may be damaged and should not be recharged If battery was just recently removed from a load lights electronic equipment or not used for extended time without a charger maintainer allow battery to recover by letting it rest without a load If battery is healthy and just deeply discharged it should recover its voltage rise above 6 volts sufficiently to allow charger to begin an attempt to fully recharge it If after battery has rested see pg 9 it may not be able to be recovered recharged It should be safely discarded recycled Rev C 080211 Page 26 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 PROBLEM ERROR Indicator lights RED and is blinking SOLUTION 1 Battery s may be weak heavily sulfated or too large to fully charge before unit times out Allow battery to remain in Maintenance Float mode for 72 hours or more and then attempt to recharge again 2 Battery may be so large it may require a second full recharge Repeat recharge by pressing and holding Stop Restart for 5 sec until ALL LEDs light Pres
16. e Mode after 1 Hour Float Pulse Charge voltage control 27 2 25 V 0 25 Vdc Float Pulse Charge current control 4A Rate 2 Adc 0 25 Rev C 080211 Page 31 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 DETAILED SPECIFICATIONS VDC Model No 24041 AA S3 con t Battery sulfation check period After absorption charge is finished 10 minutes Unloaded output voltage when battery is disconnected 0 5 Vdc max Output short circuit current when battery disconnected 5mA dc max Battery flow back current to the charger when connected to 24V battery AC Power disconnected 30 max mA dc All LED indicators will shut off if AC power is disconnected for 5 Minutes Full time Desulfation output pulse current control Ip p 3 Adc Full time Desulfation output PWM frequency 100 10Hz Full time Desulfation duty 0 3 Pulse Width Modulated Temperature Compensation with ABS 248 Battery Temperature Sensor detailed on pages 21 23 Rev C 080211 Page 32 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 DETAILED SPECIFICATIONS VDC Model No 24041 AA S3 con t Transformer Transformer Type Ferrite core transformer Rising Temperature of Transformer 80 C Max Insulation Primary to Secondary insulation Test 1240 Vac 50Hz 60Hz with 1 minutes 10mA ac no break down found Primary to core insulation test 1240 Vac 50Hz 60Hz with 1 minutes 10mA ac no break down found Secondary to co
17. ed or Maintenance type Aviation batteries regardless of construction AGM Free Electrolyte filler caps Congratulations on purchasing the most advanced charger maintainer desulfator conditioner on the market today Read you manual carefully to understand all of its features Your charger came with the At the Battery Sensor ABS 248 Please read and fully understand all of the following before beginning your installation Your temperature sensing system is made up of two components The thermal sensor w ring terminal and male plug w dust cover both shown below with extension cord attached This cord then attaches directly to the mating female receptacle located on the charger Do NOT modify by extending or shortening the extension cord Attaching the temperature sensor with extension cord Your first choice should be to connect it to the Negative post clamp screw of the battery This is the best location to sense the temperature of the battery The second choice is to place it as close to the battery as possible Attachment of the sensor to the side or top of battery is also a possible option under the right circumstances Be careful to ensure it will not come loose in service Rev C 080211 Page 20 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 Finally if placing the sensor on the battery in not practical place it where the ambient temperature the battery is exposed to Surrounded by can be sensed I
18. ed by a switch no one will accidentally shut off the power to the outlet Check for correct polarity no ERROR RED LED Indicator If ERROR Indicator is lit reverse the charger s output connections to the battery 4 Charger will automatically start within 30 seconds or less The Charge Float LED Indicator will light GREEN The charger will now begin charging by first checking the battery to determine its voltage and ability to accept a charge Should the battery not have a normal fully discharged voltage 10 5 V minimum the unit will begin charging in the Soft Start mode to determine if the battery can be safely charged If it cannot the Battery Connected Error LED will flash RED and charging will be stopped Battery should be carefully checked under a load by a qualified person before further attempting to charge it Note If the battery does not have a minimum no load OCV Open Circuit Voltage of 6 volts the ERROR LED will light RED and charger will reject battery No further effort should be made to charge this battery with this charger or any charger Discard this battery unless it has just been subjected to a long period of continuous discharge under a load such as can occur with leaving lights on or cranking an engine excessively Allow such a battery to Rest for several hours overnight if possible before determining if it is Rev C 080211 Page 17 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041
19. ed will normally prove the safest and most convenient lf you have several applications you may wish to purchase additional Ring Terminal Assemblies RTA available from your dealer or VDC Electronics Inc directly Note this assembly contains a 10 Amp automotive type fuse and is replaceable should for any reason it were to blow Never replace this fuse with any type whose rating is higher than 10 Amps as seriously harmful results may occur 2 Identify the positive and negative posts or connections on your battery usually clearly designated with the polarity markings of positive and negative If you have previously installed the RTA referred to in 1 above you need only to press the connector plug of the charger s output cord into the mating plug of the RTA Push firmly and do not leave any space between them Correct polarity and a good connection will be your reward Attach the BCA to the proper Rev C 080211 Page 16 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 battery posts clamps or screw terminals depending on type of battery Note Temperature Compensation Sensor Assembly Part ABS 248 See pages 21 23 for full detailed instructions 3 Plug the unit s Power cord into a standard grounded 120 Vac electrical outlet The Battery Connected LED Indicator will light GREEN If it does not light GREEN check the outlet to be sure it is functioning In addition be sure if outlet is controll
20. ics Inc 800 379 5579 x201 ET www BatteryMINDers com U S Patented amp Patent Pending Green Power ON ERROR Red Polarity Reversed or Battery lt 6 Volts Red Blinking Battery not fully charged charger in float maintenance mode Battery Condition Indication Power On amp Battery Connected Before Start Charge Green OK Accepted Yellow Weak Sulfated Deep Discharge After Charge Green Good Yellow Sulfated Weak Charge Float Green solid Charging Green blinking Float maintenance See Instruction Manual Hold for 5 sec for full reset P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 Detailed Operation Instructions Model 24041 AA S3 After carefully reading and understanding the Safety Instructions contained in this manual pages 3 to 7 and having evaluated your battery as described in Qualifying Your Battery pages 8 to 11 you are properly prepared to begin using your charger 1 Attach output cord of charger to either the Battery Clip s Assembly BCA supplied or the Ring Terminal Assembly RTA Supplied depending on your preference However never use both assemblies at the same time for any reason whatsoever Never use either of these assemblies on any other charger or for any other purpose such as improvised jumper cables etc Using the RTA on batteries remaining in their normal use location in same place they are regularly install
21. ld 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 Batte
22. m 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 gt 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 gt 80 F and or allowed to self discharge to 24 8 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 3 Refill each cell with distilled water only to the liquid level indicator found in each cell Before proceeding further you must be thor oughly 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 Rev C 0802
23. nstalled properly your charger is set to provide your battery with what it needs to out live and out perform any similar battery used in the same application conditions by a factor of two 2 Temperature has a direct effect on the life of a battery The design life of the battery is based on an average annual temperature of 25 C 77 F As the temperature increases above 25 C 77 F the life of the battery decreases The chart below shows the effects of temperature Effects of Temperature on Battery Life Maximum Annual Aver Maximum Battery Percent Reduction in age Temperature Battery Life Battery Temperature 50 C 122 F 25 C 777 C 77 F 50 C 122 F For example If a battery s design life is 10 years at 25 C 77 F but the average battery temperature is 35 C 95 F the life of the battery will be only 5 years a 50 decrease GNB Industrial Power A Division of Exide Technologies Section 92 30 Part No Z99 Mar Sep I amp O REV 10 01 Rev C 080211 Page 21 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 The chart below shows the need to regulate the output voltage of the charger to ensure against over or under charging your battery over a wide range of temperatures Using your At the Battery Sensor will accomplish this better than any other known method AGM and Flooded wet cell Charge and Float Voltages at Various Temperature Ranges Temp F Optimal Optimal Temp C
24. o completely charge multiple batteries We do not recommend charging more than one battery at a time without confirming the individual condition of each battery and monitoring the charging and batteries closely A better solution is to charge each battery separately Rev C 080211 Page 18 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 using your BatteryMINDer model 24041 AA S3 and then connect them together if desired for long term maintenance float charging We suggest your reading the Detailed Specifications on pages 29 33 including the additional LED indicator functions pg 14 not already covered above After carefully reading these instructions and Troubleshooting pgs 26 28 sections should you still have questions please e mail our technical support department at techsupportOvdcelectronics com Allow up to 3 business days for a detailed response to your questions Always identify the model number of the product and revision letter of this manual contained on this page below Without this information we may not be able to assist you correctly If your questions have already been answered in this manual you can expect a response referring you back to this manual and the specific page s Rev C 080211 Page 19 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 INSTRUCTIONS TEMPERATURE SENSOR Type ABS 248 At the Battery Sensor MANDATORY WHEN CHARGER IS USED WITH Seal
25. o persons c Check polarity of battery posts POSITIVE POS P battery post usually has larger diameter than NEGATIVE NEG N post d Determine which post of battery is grounded connected to the chassis If negative post is grounded to chassis as in most vehicles see e If positive post is grounded to the chassis see f e For negative grounded vehicle connect POSITIVE RED clip from battery charger to POSITIVE POS P ungrounded post of battery Connect NEGATIVE BLACK clip to vehicle chassis or engine block away from battery Do not connect clip to carburetor fuel lines or sheet metal body parts Connect to a heavy gage metal part of the frame or engine block f For positive grounded vehicle connect NEGATIVE BLACK clip from battery charger to NEGATIVE NEG N ungrounded post of battery Connect POSITIVE RED clip to vehicle chassis or engine block away from battery Do not connect clip to carburetor fuel lines or sheet metal body parts Connect to a heavy gage metal part of the frame or engine block g When disconnecting charger turn switches to off disconnect AC cord remove clip from vehicle chassis and then remove clip from battery terminal h See operating instructions for length of charge information Rev C 080211 Page 6 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 16 FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE A SPARK NEAR THE BATTERY MAY CAUSE BATTER
26. or labeled Charge Float Solid when charging Blinking when maintaining battery s Charger will automatically start within 30 seconds or less 5 Observe Battery Connected Error Indicator LED Must be lit GREEN IF IN DOUBT REGARDING ANY OF THE ABOVE REFER TO FULL INSTRUCTIONS See detailed instructions for need and method of properly connecting sensor to battery pgs 20 22 See full instructions if not lit GREEN Rev C 080211 Page 13 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 LED INDICATOR FUNCTIONS Tables 3 top and 4 A amp B bottom x LL A IB LLL _IL EW paterctonditonindicatin Battery connected BEFORE full charge Vb lt 22V Vb gt 22V GREEN If Stop Restart Button in Pressed during charging mode STOPS CHARGING PRESS AGAIN TO RESTART Battery Sulfation check AFTER FULL CHARGE RESTED See p 9 Vb lt 25 0V Vb gt 25 0V LED Status Battery Connected Error and Charge LEDs CONNECTED ERROR CHARGE FLOAT GREEN RED A C power disconnected battery connected correctly OF A C power connected battery connected GREEN GREEN GREEN GREEN RED ON RED ON RED ON RED FLASH RED FLASH RED FLASH Rev C 080211 Page 14 P N VDC 24041 E AA S3 MNL BatteryMINDer Rev C 080211 24041 amp E24041 AA S3 BatteryMINDer 24041 AA S3 Unit Label Page 15 FOR SEALED or WET FILLER CAPs LEAD ACID GA BATTERIES ONLY NOT FOR NiCad VDC Electron
27. pressly exclude any implied warranty including any warranty for consequential damages This limited warranty is not transferable Unit must be returned freight prepaid together with Proof of Purchase directly to VDC Electronics Inc NOT TO THE DEALER FROM WHICH IT WAS PURCHASED IMPORTANT NOTICE BatteryMINDer Five Year Warranty Registration Reminder Online Registration http www batteryminders com register Please register your unit online within 10 days of purchase Due to the ever changing technology associated with this BatteryMINDer unit we may be unable to keep you apprised of significant upgrades changes etc without your registration The information you provide upon registration will be used to keep a record of your purchase and will assist in providing support should you ever need to contact our Technical Service department techsupport vdcelectronics com 800 379 5579 x206 ET Rev C 080211 Page 36 P N VDC 24041 E AA S3 MNL
28. re insulation test 500 Vac 50Hz 60Hz with 1 minutes 10mA ac no break down found Electrical Cable Input Lead and plug specifications CUL SJT 18AWG X2 with UL 2 pin plug External Length 6 ft Output lead 1015 105 C VW 1 16AWG with Trailer connector External Length 6 ft Extension cord 1 1015 105 C VW 1 16AWG with Trailer connector amp battery clamp External Length 6 ft 2 1015 105 C VW 1 16AWG with Ring terminal amp blade type Fuse External Length 6 ft Thermal Sensor Extension Cord 11 8 Ring terminal I D dimensions Negative 8mm Positive 10mm Physical Parameters Weight 2 2 lbs Plastic enclosure material UL 94V0 1 Noryl or 2 PC ABS 3 PC Enclosure Dimension Approx 5 713 W x 5 516 L x 2 86 H inches Environmental Characteristics Operating temperature 10 to 40 C Storage temperature 10 to 80 C Operating Humidity range 0 to 95 RH Rev C 080211 Page 33 P N VDC 24041 E AA S3 MNL J9 9g enpinipu Ag paultui319q sy 24041 E24041 AA S3 96 249 olJ o a EE EEE s L c Sp J96 O A C Z lt soJeydinsag au n4 gt BatteryMINDer Juang Buibseyy I l I l p uun sinou G 961e49 uondiosqv l l I l l l p lluul saw SINOH Oz vb 961849 Jing uonesuadwos sunjeladua ym J86 A V 6d obe1J0A 19neg T JOyeudinseg aw 11my p lluull n0 g9ull SJNOH 9 VL HES HOS UO
29. ryMINDer to ensure it is as completely charged as possible before you determine its condi tion Allow battery to rest see pg 9 overnight for a minimum of 12 hours before testing with a digital voltmeter only 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 25 2 volts Typically 75 of charge the battery may be too heavily sulfated to be fully recoverable If voltage is 25 2 V or Rev C 080211 Page 10 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 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 OCV Open Circuit No Load Voltage OCV Rested Voltage Percentage See shorted TABLE 2 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 Rev C 080211 Page 11 P N VDC 240
30. s Stop Restart button to begin full recharge 3 If recharging multiple batteries 2 or more complete recharge cycles may be needed Repeat full recharge by pressing Stop Restart button again If still RED blinking you may need to charge each battery separately PROBLEM Battery Condition Indicator lights YELLOW After battery has been completely charged SOLUTION Battery still has an unacceptable level of sulfation and must stay connected to charger and remain in Maintenance Float mode GREEN blinking indicator for 72 hours or longer Then stop charger by pressing Stop Restart button and observe Indicator If still VEALLOW repeat up to 3 full cycles or until indicator lights GREEN PROBLEM Battery Condition Indicator lights WEULOW May be several causes Before battery is completely charged SOLUTION Battery can be weak due to sulfation self discharge or was very Rev C 080211 Page 27 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 deeply discharged Attempt a full recharge and recheck after completion If still YELLOW follow procedure for After battery has been completely charged PROBLEM Error and Charge LEDs blink simultaneously SOLUTION Charger has timed out before battery has completely charged Reset unit Repeat reset full recharge by pressing Stop Restart button and holding it down until ALL LEDs flash Press Stop Restart button to begin full recharge Rev C 080211 Page 2
31. to electric plug and cord pull by plug rather than cord when disconnecting charger 5 An extension cord should not be used unless absolutely neces sary Use of improper extension cord could result in a risk of fire and electric shock If an extension cord must be used make sure a That pins on plug of extension cord are the same number size and shape as those of plug on charger b That extension cord is properly wired and in good electrical condition and c That wire size is large enough for ac ampere rating of charger as specified in Table below Recommended minimum AWG size for extension cords for battery chargers AC Input Rating AWG Size of Cord amperes Equal To Length of Cord feet m or But Less Greater Than 25 50 100 150 Than 7 6 15 2 30 5 45 6 alf the input rating of a charger is given in watts rather than in amperes the corresponding ampere rating is to be determined by dividing the wattage rating by the voltage rating for example 1250 watts 125 volts 10 amperes Rev C 080211 Page 3 P N VDC 24041 E AA S3 MNL BatteryMINDer 24041 amp E24041 AA S3 6 Do not operate charger with damaged cord or plug replace the cord or plug immediately 7 Do not operate charger if it has received a sharp blow been dropped or otherwise damaged in any way call VDC Electronics Tech Support Dept 800 379 5579 x206 ET for advice 8 Do not disassemble charger call VDC Electronics Tech Support Dept
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