INSTRUCTION MANUAL Charger / Maintainer
Contents
1. 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 the first current sample Positive dl dt owitch to Float mode in Bulk charge or Absorption mode when Battery type Button is Pressed For 3 oeconds or longer GREEN Charge Float LED will blink Float Charge output Voltage control 26 8 24 C 75 F 0 25 Vdc Float Charge current control 1A Rate 5 Adc 0 25 2A Rate 1 Adc 0 25 4A Rate 2 Adc 0 25 Float charge transitions to PWM Float Charge Mode after 1 Hour Float Pulse Charge voltage control 26 8 24 C 0 25 Float Pulse Charge current control 1A Rate 5 Adc 0 25 2A Rate 1 Adc 0 25 4A Rate 2 Adc 0 25 Rev H 070708 Page 31 P N VDC24041 MNL BatteryMINDer Model 24041 DETAILED SPECIFICATIONS VDC Model No 24041 con t Battery sulphation 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 Desulphation output pulse current control lp p 3 Full time Desulphation output PWM frequency 100 x10Hz Full time Desulphtation du2. INSTRUCTION MANUAL BatteryMINDer Model 24041 Charger Maintainer Minim cnni VDC Electronics Inc 147 D Woodbury Rd Huntington NY 11743 www batteryminders com techsupport vdcelectronics com NOT for use with Aviation Type 24 V Batteries Rev H 070708 P N VDC24041 MNL BatteryMINDer Model 24041 TABLE OF CONTENTS Safely faba gt 0 oe ne eee ne ce ee ee eee eee ees eee eee ae 3 Preparing To 5 Charger rinnen EEE EEE EA EE 5 DC Connection 6 Qualifying Your Battery 8 Testing A Filler Cap Or Manifold type Lead Acid 8 Testing With A Hot Cold Calibrated Hydrometer Tester eu 10 Testing A Sealed Agm Or Gelled type Lead Acid Battery 10 Unit With 12 Simplified Operating Instructions ecce eee eee eere nenne nnn anu a aaa raa un 13 LED Indicator Functions met 14 15
3. Detailed Operation Instructions Lee e 16 Temperature Sensor ABS 248 At the Battery Sensor OPTIONAL 17 21 24 Maintaining Multiple _ 25 Battery 26 FFOUDIESMIOOUIING Model 02 OR 27 Detailed Specifications VDC Model No 24041 nennen nnn nnns 29 33 95 RTT 34 For Repair 35 Guarantee And 36 Rev H 070708 Page 2 P N VDC24041 MNL BatteryMINDer Underwriters Laboratories UL REQUIRED SAFETY INSTRUCTIONS WARNING TO REDUCE THE RISK OF FIRE ELECTRIC SHOCK OR INJURY TO PERSON OBSERVE THE FOLLOWING 1 Do not expose charger to rain or snow It is designed to operate ONLY INDOORS 2 USE of any attachment not specifically recom mended by the battery charger manufacturer for use with this exact model of charger may result in risk of fire amp electric shock or injury to person 3 An extensio
4. O to 95 RH Rev H 070708 Page 33 P N VDC24041 MNL BatteryMINDer Model 24041 U On Full Time Desulphator gt Full Time Desulphator ___ gt O gt l Battery Voltage 29 2 Volt 27 0 Volt Gel Mode 28 2 Volt 24 26 6 Volt AGM Mode 29 2 Volt 24 C i l Flooded Mode 28 8 Volt 24 I with Temperature compensation l 21 0 Volt l Bulk Charge pr 1A 2A 4A 20 Hours Soft Start timer limited Sulphate 0 25A 0 5A 1A Absorption Charge Check es Chargel 6 Hours 5 hours timer Limited 10 min one hour time out I limited du c Charging Current l Float Pulse Charge PWM 0 5A 1A 2A Max current Limited ut l Time Unlimited 5 5 UJ i l l i Time Rev H 070708 Page 34 P N VDC24041 MNL BatteryMINDer FOR REPAIR OR REPLACEMENT In the event that you believe your product may be defective you MUST speak to a VDC Electronics tech nician at 1 800 379 5579 x206 ET before proceeding further If after speaking with our tech support personnel it is necessary to return the unit you MUST request an RMA number All returns must be authorized by VDC Electronics Items must be returned within 10 days after receiving your Return Merchandise Authorization number and must be packed in the original packaging with manual and all connectors in
5. N VDC24041 MNL BatteryMINDer Gel Charge and Float Voltages at Various Temperature Ranges Temp F 120 110 120 100 109 90 99 Optimum 26 00 Maximum 26 60 27 00 Optimum 25 60 25 80 26 00 26 20 26 40 26 80 27 10 27 40 27 80 28 40 Maximum 26 00 Model 24041 Temp C 49 44 48 38 43 32 37 27 31 21 26 16 20 10 15 5 9 4 East Penn Technical Manual of Valve Reguated Lead Acid VRLA Gelled Electrolyte gel E P M Form 0139 Hev 3 04 Note This chart shows the Charge and Float voltage ranges v temperature for sealed 24 Volt Gel type batteries Values will differ for sealed AGM Flooded filler cap or maintenance free types Manifold cover s Rev H 070708 Page 24 P N VDC24041 MNL BatteryMINDer MAINTAINING MULTIPLE BATTERIES BatteryMINDer 24041 maintenance charger Desulphators 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 sulphate and meeting the minimum full charge rested see pg 9 voltage of 2 13 volts cell after being fully desulphated Press the Maintenance Float charge button immediately to ensure BatteryMINDer is in the proper mode for maintenance charging desulphating immediately after making proper connection to the batteries ALL batteries Must be properly tested to ensure they are in good condition no dead dying cells
6. VDC Model No 24041 con t Charging Output Control Characteristics Charging Flow Battery condition detect gt Soft Start Charge gt Bulk Charge gt Absorption Charge gt Sulphate Check gt Float Charge soft Start Charging Activity conditions Battery Voltage is over 6 and less than 21Vdc the charger will start at 1A mode amp Gel mode automatically soft Start Charging output current control 1A 2 4A mode 1 2 4 0 25 Adc Soft Start Charging Time Limited Stop charge If battery cannot be charged over 10 5V after 6 hrs error LED flash indicated 6 0 25 Hours Bulk Charging Activity conditions Battery Voltage is over 21Vdc the charger will start at 1A mode amp Gel mode automatically Bulk Charging Current control at 1A mode Selected by pressing Charge Rate Button 2 0 35 0 Adc Bulk Charging Current control at 2A mode Selected by pressing Charge Rate Button 4 0 40 O Adc Bulk Charging Current control at 4A mode Selected by pressing Charge Rate Button 8 0 45 0 Adc Max rated output voltage and current 26 0V at 4Adc 27 2V 3 25 Bulk Charging Time Limited Stop charge If battery cannot be charged reach 28 2 28 8 29 2 V after 20 hrs error LED flashes 20 1 Hours Rev H 070708 Page 30 P N VDC24041 MNL BatteryMINDer Model 24041 DETAILED SPECIFICATIONS VDC Model No 24041 con t Absorption mode transitions to Float mode conditions in AGM setting
7. for consequential damages This limited warranty is not transferable PAVUNA YNYS BatteryMINDer 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 with Proof of Purchase directly to VDC Electronics Inc NOT TO THE DEALER FROM WHICH IT WAS PURCHASED a Zh BANISINISESASISINIS SE Rev H 070708 Page 36 P N VDC24041 MNL
8. to chassis or engine block away from battery Rev H 070708 Page 6 P N VDC24041 MNL BatteryMINDer DO NOT CONNECT CLIP TO CARBURETOR FUEL LINES OR SHEET METAL BODY PARTS Connect to heavy gauge metal part of frame or engine h When disconnecting charger disconnect char ger from AC outlet then remove clips from vehicle chassis and battery posts Operating instructions for charge information FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE OF VEHICLE OR EQUIPMENT A SPARK NEAR THE BATTERY MAY CAUSE BATTERY EXPLOSION TO REDUCE RISK OF A SPARK NEAR BATTERY a Check polarity of battery posts POSITIVE POS P usually has a large diameter than NEGATIVE NEG N battery post b Connect RED charger clip to POS post of battery Rev H 070708 Page 7 Model 24041 c 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 d Do not face battery when making final connec tions e When disconnecting charger always do so in reverse sequence of connecting procedure and break first connection while as far away from bat tery as practical DO NOT ATTEMPT TO PERMANENTLY INSTALL ANY CHARGER NOT SPECIFICALLY DESIGNED FOR PERMANENT INSTALLATION ESPECIALLY IN A WET MARINE ENVIRONMENT P N VDC24041 MNL BatteryMINDer QUALIFYING YOUR BATTERY Preliminary Requirements NOTE The BatteryMINDer has no electrical out ou
9. understand all of the following before beginning your installation Do NOT modify by extending or shortening the extension cord Your first choice should be to connect it to the positive or Negative post clamp or screw of the battery This is the best location to sense the Rev H 070708 Page 21 Model 24041 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 P N VDC24041 MNL BatteryMINDer Model 24041 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 When properly installed on the battery your char ger 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 aver age annual temperature of 25 C 77 F As the temperature increases above 25 C 77 F the life of the battery decreases he chart below shows the effects of temperature Battery Temperature Temperature Battery Life 25 C F 50 C 122 F 5 C F 25 SF 50 1220F 50 C 12278 50 C 12276 250 TF
10. 24041 Volts MALLOW or greater than 22 Volts GREEN 7 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 his allows charger to begin charging battery again P N VDC24041 MNL BatteryMINDer If battery is not defective it should be able to be fully charged after being restarted After sufficient time has lapsed the 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 char ger will need to be restarted as described in order to completely charge multiple batter ies 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 close ly A better solution is to charge e
11. 50 122 For example If a battery s design life is 10 years at 25 C 77 F but the average battery temperature is 35 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 H 070708 Page 22 P N VDC24041 MNL BatteryMINDer Model 24041 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 Charge and Float Voltages at Various Temperature Ranges Temp F Optimum Maximum Optimum Maximum Temp C 120 27 2 27 8 25 6 26 49 110 120 27 6 28 2 25 8 26 4 43 49 100 110 27 8 28 4 26 26 6 38 43 90 100 28 28 6 26 2 26 8 32 38 80 90 28 2 28 8 26 4 27 27 32 70 80 28 6 29 2 26 8 27 4 21 27 60 70 28 9 29 5 27 1 27 7 16 21 50 60 29 2 29 8 27 4 28 10 16 40 50 29 6 30 2 27 8 28 4 4 10 40 30 2 30 8 28 4 29 East Penn Technical Manual of Valve Regulated Lead Acid VRLA Absorbed Glass Mat AGM Bat teries E P M Form No Rev 3 04 Note The above chart shows the Charge and Float voltage ranges v temperature for sealed 24 Volt AGM type batteries Values will differ for sealed Gel or Flooded filler cap or maintenance free types Rev H 070708 Page 23 P
12. C24041 MNL BatteryMINDer DC CONNECTION PRECAUTIONS a Connect and disconnect DC output clips from battery only after removing charger power cord from outlet b Attach clips to battery posts and twist or rock back and forth several times to make good con tact his tends to keep clips from slipping off ter minals and reduces risk of sparking FOLLOW THESE INSTRUCTIONS WHEN BATTERY IS INSTALLED IN EQUIPMENT VEHICLE PWC BOAT TRACTOR ETC A SPARK NEAR BATTERY MAY CAUSE BATTERY TO EXPLODE TO REDUCE RISK OF A SPARK NEAR BATTERY c Position DC output cord to reduce risk of dam age by hood door covers or moving engine parts d Stay clear of fan blades belts pulleys and other parts that can cause injuries e Check polarity of battery posts POSITIVE Model 24041 POS P usually has a larger diameter than NEGATIVE f Determine which post of battery is grounded connected to the chassis of equipment If nega tive post is grounded see Item N If positive post Is grounded see item P N For negative grounded equipment connect POSITIVE RED clip from charger to POSITIVE POS P 4 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 metal body parts g For positive ground equipment con nect NEGATIVE BLACK clip from charger to NEGATIVE NEG N UNGROUNDED POST OF BATTERY Connect POSITIVE RED CLIP
13. E A FROZEN BATTERY OR ONE AT A TEMPERATURE ABOVE 123 F PREPARING TO CHARGE a If necessary to remove battery from equipment to charge Always remove ground terminal first Turn off all accessories in the vehicle so as not to cause an arc b Be sure area around battery is well ventilated while battery is being charged Force gas vapors away by using a piece of non metallic material as a fan c Clean battery terminals Be careful to keep cor rosion from contacting eyes d Add distilled water to each cell until battery acid reaches level specified by the manufacturer This helps Purge excessive gas from cells Do not overfill For a battery without caps follow manu facturer s recharging instructions e Study all battery manufacturer s specific instruc tions such as removing cell caps while charging Rev H 070708 Page 5 Model 24041 and recommended charge rates f Determine condition of battery by referring to instructions herein before ever attempting to charge or desulphate any all batteries CHARGER LOCATION a Make sure charger is as far away from battery as output 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 specific gravity or filling d Do not operate charger in a closed in area or restrict ventilation in any way e Do not set battery on top of charger P N VD
14. SONAL PRECAUTIONS when working with or near a lead acid battery a Someone should be able to hear your voice or close enough to aid you when working near a lead acid battery b Have fresh water and soap nearby case battery acid contact skin clothing or eyes Wear com plete eye protection and clothing protection Avoid touching eyes while working near battery If battery acid does contact skin or clothing wash immediately with soap and water If acid entered the eye immediately flood the eye with running water for at least 10 minutes and get help immediately Rev H 070708 Page 4 Model 24041 d NEVER smoke or allow a spark of flame near battery or engine e Be extra cautious to reduce risk of dropping a metal tool or auto part onto battery It might spark or short circuit battery or other electrical part that may cause an explosion f Remove personal metal items such as rings bracelets necklaces and watches when work ing 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 g Charger is designed to be used for recharging lead acid batteries ONLY Never use it to power a low voltage electrical system or for attempting to recharge dry cell batteries that are commonly used in house holds These batteries may explode and cause injury to persons and damage property P N VDC24041 MNL BatteryMINDer NEVER CHARG
15. ach battery separately using model 24041 BatteryMINDer and then connect them together if desired for long term maintenance float charging We suggest your reading the detailed specifica Rev H 070708 Page 20 Model 24041 tions on pages 29 34 including the addi tional LED indicator functions pgs 14 15 not already covered above After carefully reading these instructions and Troubleshooting pgs 27 28 sections should you still have questions please e mail our techni cal support department at techsupportQvdcelectronics 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 P N VDC24041 MNL BatteryMINDer INSTRUCTIONS TEMPERATURE SENSOR Type ABS 248 At the Battery Sensor OPTIONAL If battery is being charged or maintained in temperatures as low as 32 F to a high of 125 F this sensor must be used Congratulations on purchasing the most advanced charger maintainer desulphator conditioner on the market today Read you manual carefully to un derstand all of its features If you purchased the optional At the Battery Temperature Sensor please read and fully
16. as most modern cars trucks boats RVs etc as far away from battery as possible for maximum safety Never connect to any type of fuel line Note Older vehicles or other devices may be Positive ground installations requiring differ ent connection recommendations If unfamiliar or unsure which battery type of grounding system you have check with our Tech Support personnel before proceeding further Note Temperature compensation Sensor Assembly Part ABS 248 OPTIONAL See pages 21 24 for full detailed instructions 3 Determine the type of battery you wish to charge When certain press the Select Battery Rev H 070708 Page 17 Model 24041 Type button The most common is the Flooded Kind distinguished by removable filler caps 6 or two 2 manifold covers Maintenance Free which should not be removed unless specifically allowed by the battery manufacturer The second most popular is the Absorbed Glass Mat AGM sealed valve regulated type Lastly is the sealed valve regulated Gel battery Note If unsure of your battery type check with the battery seller manufacturer or our Tech Support before proceeding further The normal default setting of your charger is GEL as this is the low est voltage output and thus the one least likely to cause your battery to be overcharged should you incorrectly select the wrong battery type However be aware that using the wrong set ting for a particular type battery can dramat
17. battery s May return to solid GREEN intermittently or if power interruption occurs to Gel 2 A modes 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 21 24 IMPORTANT If in doubt about what type consult with seller or manufacturer of battery s before going further Choosing the wrong setting will cause over or under charge leading to shortened battery life or generating potentially hazardous hydrogen gas See full instructions if not lit GREEN Rev H 070708 Page 13 P N VDC24041 MNL BatteryMINDer Model 24041 LED INDICATOR FUNCTIONS Tables 3 top and 4 A amp B bottom Battery Condition Indication Battery connected BEFORE full charge Vb lt 22V Vb 22V GREEN STOPS CHARGING PRESS AGAIN TO RESTART Battery Sulphation check AFTER FULL CHARGE amp RESTED See p 9 Vb 25 6V Vb 25 6V LED Status Power Error and Charge LEDs POWER ERROR CHARGE FLOAT GREEN RED power disconnected battery connected correctly 0 _ GREEN GREEN GREEN GREEN RED ON RED ON RED FLASH RED FLASH RED FLASH Rev H 070708 Page 14 P N VDC24041 MNL A C power connected Reversed Battery Polarity RED ON Model 24041 i ep ap TT VDC Electronics Inc 800 379 5579 ET www batteryminders com U S Patented amp Patent Pending Green Power ON Re
18. cluded Your Return Merchandise Authorization number must be shown on the return shipping label as follows VDC Electronics Inc Returns Department Attn RMA Enter Your RMA Here 147 D Woodbury Rd Huntington NY 11743 Rev H 070708 Page 35 Model 24041 Note If your questions relate to safety con cerns please contact customersupport vdcelectronics com or if a potentially hazardous emergency may exist cease using the product immediately and call 800 379 5579 ext 202 ET Monday Friday or contact our tech support at ext 206 Standard operating questions clearly answered in this manual will not be answered by phone YOUR NOTES P N VDC24041 MNL BatteryMINDer Model 24041 Guarantee and Warranty NOTE ALL returns must be authorized by VDC Electronics after soeaking to a VDC Electronics technician at 1 800 379 5579 x206 ET Please see Page 35 for details a ae ae ee SS S VN IS NI UN UIS EN U SS SENSN UIS ENS EN Y 5 YEAR LIMITED WARRANTY 2 SS ONE 1 YEAR 100 VDC Electronics Inc warrants this UNCONDITIONAL product for FIVE years from date MONEY BACK GUARANTEE of purchase at retail against defective material or workmanship It will be repaired or replaced at no charge providing it is returned to VDC Electronics Inc freight prepaid together with proof of purchase We make no warranty other than this limited warranty and expressly exclude any implied warranty including any warranty
19. d Polarity Reversed BatteryMINDer LED INDICATOR FUNCTIONS LED indicators refer to charger label at right 1A 2A 4A Charger Maintainer 1A OFF OFF Full Time De Sulfator Conditioner 24 1 2 4 Amp 2A OFF OFF Model 24041 ERROR 4A OFF OFF e e FLOODED e GEL TABLE 5 ID LUE MAINTENANCE B e Green blinking Float maintenance Select Select Stop aN See Instruction Manual Charge Rate Battery Type Restart TABLE 6 Rev H 070708 Page 15 Battery less than 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 Hold for 5 sec for full reset P N VDC24041 MNL BatteryMINDer Detailed Operation Instructions Model 24041 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 10 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 depend ing on your preference However never use both assemblies at the same t
20. dicate a battery that is not fully desulphated or does not qualify for desulpha tion 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 desul Rev H 070708 Page 10 Model 24041 phated Dispose of the battery If each cell floats three 3 or more balls or 1250 on gauge type your battery can be desulphated reconditioned 4 Always rinse the tester with fresh water after every use Failure to do so will cause false read ings Testing a Sealed AGM or Gelled type Lead Acid Battery These batteries have no filer 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 BatteryMINDer to ensure it is as completely charged as possible before you determine its condition Allow battery to rest see pg 9 overnight for a minimum of 12 hours before testing with a digital voltmeter only P N VDC24041 MNL BatteryMINDer 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 24 8 volts Typically 5096 of charge the battery may be too heavily sulphated to be fully recoverable If vo
21. e 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 various and most common multiple battery configurations Rev H 070708 Page 26 Model 24041 24041 Battery Configuration Model 24041 24 VOLT BatteryMINDer TO CHARGER 12 VOLT SERIES CONNECTED 24 v P N VDC24041 MNL BatteryMINDer Troubleshooting Model 24041 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 BatteryMINDer Problem Power ON indicator does not light Solution Check electrical outlet If controlled 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 f still remains RED check battery voltage If 3 Volts or less battery may be damaged and should Rev H 070708 Page 27 Model 24041 not be recharged If battery was just recently removed from a load headlights door lights
22. e Float mode GREEN blink ing indicator for 72 hours or longer Then stop charger by pressing Stop Restart button and observe Indicator If still YELLOW repeat up to full cycles or until indicator lights GREEN Problem Battery Condition Indicator lights YELLOW May be several causes Before battery is completely charged Solution Battery can be weak due to sulphation self dis charge or was very deeply discharged Attempt a full recharge and recheck after comple Rev H 070708 Page 28 Model 24041 tion If still VALLOW follow procedure for After battery has been completely charged Problem Charger Indicators show battery is fully charged but fails to provide good cranking lighting or equipment run time as it did when newer Solution You may have chosen too high a charge rate 2A or 4A for the size capacity and or condition of your battery repeat full recharge cycle at a lower charge rate and leave in maintenance float mode for 72 hrs before retesting Note Slow charging in most cases is preferable to higher faster rates of charge Problem Error and Charge LEDs blink simultaneously Solution Charger has timed out before battery has com pletely charged Reset unit Repeat reset full recharge by pressing Stop Restart button and holding it down until ALL LEDs flash Reset charge rate and battery type if needed Press stop Restart button to begin full recharge P N VDC24041 MNL Batt
23. eryMINDer Model 24041 DETAILED SPECIFICATIONS VDC Model No 24041 GEL 28 2V FLOODED 28 8V AGM 29 2V 1 2 4A MCU controlled 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 Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radi ate 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 encour aged to try to correct the interference by one of more of the following measures e Reorient or relocate the receiving antenna e ncrease 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 Electrical Parameters Input Voltage 90 140 Vac Input Frequency 50 60 Hz Unloaded input current 80 mAac Input Current consumption at 120Vac input output 13V 8A loading UL1236 Approx 1Aac Rev H 070708 Page 29 P N VDC24041 MNL BatteryMINDer Model 24041 DETAILED SPECIFICATIONS
24. etc or vehicle 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 tt If after battery has rested see pg 9 it may not be able to be recovered recharged It should be safely discarded recycled 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 bat tery 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 hold ing Stop Restart for 5 sec untill ALL LEDs light Reset charge rate and battery type if needed Press otop Restart button to begin full recharge P N VDC24041 MNL BatteryMINDer 3 If recharging multiple batteries 2 or more complete recharge cycles may be needed Repeat full recharge by pressing Stop Restart but ton 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 sulpha tion and must stay connected to charger and remain in Maintenanc
25. harge 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 21 0 V minimum the unit will begin charging in the Soft Start mode to deter mine if the battery can be safely charged If it can not the Power ON Error LED will flash RED and charging will be stopped Battery should be care fully checked under a load by a qualified person before further attempting to charge it P N VDC24041 MNL BatteryMINDer Note If the battery does not have a mini mum no load OCV Open Circuit Voltage the ERROR LED will light battery of 6 volts RED charger will reject No further effort should be made to charge this bat tery 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 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 Rev H 070708 Page 19 Model
26. ically shorten its life and or cause potentially explosive gas to be emitted from the battery P N VDC24041 MNL BatteryMINDer 4 After selecting battery type determine the cor rect charge rate for your particular battery Small batteries 10 AH should be charged at the 1 Amp setting rate Larger types 10 30 AH such as used in motorcycles PWC etc are best charged at the 2 Amp rate setting For batteries whose capacity rating is greater than or a fast recharge is needed set charger to the 4 Amp rate If unsure or recharge time is not important always choose a low setting 1 or 2 Amp Note The safest procedure is to choose the lowest possible setting when in doubt or recharge time is not important REGARDLESS OF CHARGE RATE 1 2 OR 4A YOUR BATTERYMINDER WILL NEVER OVERCHARGE WHEN LEFT CONNECTED FOR LONG PERIODS TO THE BATTERY 5 After selecting both battery type and charge rate plug the unit s Power cord into a standard grounded 120 Vac electrical outlet The Power ON Rev H 070708 Page 18 Model 24041 LED Indicator will light GREEN If it does not light GREEN check the outlet to be sure it Is function ing In addition be sure if outlet is controlled 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 6 Within 15 seconds the C
27. ime for any reason what soever Never use either of these assemblies on any other charger or for any other purpose such as improvised jumper cables etc Using the RIA on batteries remaining in their nor mal use location in same place they are regularly installed will normally prove the safest and most Rev H 070708 Page 16 Model 24041 convenient If 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 15 Amp auto motive 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 15 Amps as seriously harmful results may occur 2 Identify the positive and negative posts or connections on your battery usually clearly des ignated 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 P N VDC24041 MNL BatteryMINDer Correct polarity and a good connection will be your reward Attach the BCA to the proper bat tery posts clamps or screw terminals depending on type of battery ALWAYS connect the nega tive Black clip to a metal grounding point Negative ground installations such
28. ltage is 24 8 V or higher full recovery can be expected given sufficient time average 1 2 weeks for batteries that are heavily sulohated 3 Connect the BatteryMINDer to the battery 4 Charge battery to its maximum level Press Maintenance Float select Battery type button if it does not go into this mode automatically 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 Rev H 070708 Page 11 Model 24041 OCV Open Circuit No Load Voltage OCV Rested Full Capacity Voltage Percentage 25 8 26 2 Volts 100 25 2 25 8 Volts as shorted TABLE 2 Note OPTIMA brand Yellow Top starter deep cycle batteries have a fully charged resting voltage of 26 2 OCV Increase above values accordingly P N VDC24041 MNL BatteryMINDer Model 24041 1 8 6 1 Battery clip cordset w qwik connect plug pgs 13 16 8 Battery type selection button pgs 13 17 18 2 Ring terminal cordset w qwik connect plug pgs 13 16 9 Stop Restart selection button pgs 13 17 18 3 Mounting tabs 10 LED indicators for power connection fault battery 4 Input power cordset pg 13 18 condition charge status pgs 13 15 18 20 24 5 Output cord w qwik connect plug pg 13 16 11 12 Volt Power cordset Optional 6 Temperature sensor input connector pg 13 17 21 12 Tem
29. m 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 sulphation 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 P N VDC24041 MNL BatteryMINDer 3 Refill each cell with distilled water only to the liquid level indicator found in each cell Before proceeding further you must be thoroughly familiar with the safety and operating instruc tions 4 Recharge the battery with the BatteryMINDer to ensure that it is slowly and completely charged before you determine its condition Allow battery to rest overnight for a minimum of 12 hours before testing with a temperature compensated hydrometer and or digital type voltmeter only RESTED a battery that has been as fully charged as possible using a 3 stage charger model 24041 and left disconnected from charger or any type load for a minimum of 12 hours 5 If the BatteryMINDer battery condition LED lights MALLOW within 72 hours single battery or no balls float in one or more cells your bat tery may be too far gone to be fully desulphated Heconnect battery to your BatteryMINDer and press the Maintenance mode button Allow battery Rev H 070708 Page 9 Model 24041 to remain in maintenance mode for a minimum of 72 hours before re test Use a hot cold cali brated h
30. n cord should not be used unless absolutely necessary Use of an improper exten sion cord could result in fire or electric shock If extension cord must be used be sure a Pins on plug of extension cord are the same number size amp shape of plug on charger Extension cord is properly wired and in good condition Rev H 070708 Page 3 Model 24041 c Wire size is enough for AC ampere of charger as specified below Length of cord feet meters 25 7 6 60 15 2 100 30 5 150 45 6 AWG Size 18 4 Do not use charger if it received a sharp blow been dropped or damaged 5 Charger contains no serviceable parts If it fails for any reason return to the address shown within for a free replacement under warranty 6 To reduce risk of electric shock unplug charger from outlet before attempting any cleaning 7 WARNING RISK OF EXPLOSIVE GASES WHENEVER YOU WORK NEAR A LEAD ACID BATTERY IT IS DANGEROUS BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION FOR THIS REASON IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE USING YOUR CHARGER YOU MUST READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY P N VDC24041 MNL BatteryMINDer To reduce risk of battery explosion follow these instructions and those published by the battery manufacturer and the manufacturer of any equip ment you plan to use in the vicinity of the battery Review cautionary markings on the products and the engine 8 PER
31. or excessive sulphation before maintaining them in multiples Only healthy fully desulphated batteries should ever be MAINTAINED in sets of 2 or more Test each cell of All filler cap batteries using an accurate temperature compensated hydrometer Test sealed no filler caps batteries using an accu rate DIGITAL type ONLY voltmeter The Minimum Rev H 070708 Page 25 Model 24041 voltage Must not be less than 2 13 volts cell after fully charging battery and letting it Rest for 12 hours minimum before testing If battery voltage is less than 2 13 cell you must first desulphate it until you reach a Rested voltage of 2 13 volts cell Attempting to desulphate more than one 1 bat tery at a time will yield very poor results as the strongest healthiest and not the weakest most sulphated battery will receive the majority of the desulphation pulse energy Exception is when two batteries are identical and have been used in paral lel or series with each other during their entire life Never mix batteries of different type construction chemistry or condition old with new ALWAYS test each individual battery to be certain it is see pg 9 P N VDC24041 MNL BatteryMINDer healthy and free of sulphate before attempting to charge or maintain them either as a single bat tery or in sets NEVER connect multiple batteries together for charging purposes using less than 18 Gauge insulated wir
32. perature sensor with cord and ring terminal pgs 17 7 Charge rate selection button pg 13 17 18 21 24 Optional Rev H 070708 Page 12 P N VDC24041 MNL BatteryMINDer Model 24041 Simplified Operating Instructions Read and thoroughly understand ALL SAFETY Instructions on pages 8 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 termi nal 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 if supplied to battery and then to if required 3 Select desired charge rate 1 A for small batteries 2 A for medium or 4 A for deeply discharged large or multiple batteries Charger will automatically start in Gel and 1 Amp modes when first plugged into 120 Vac power and has to be unplugged from wall or shut off by pushing Stop Restart button Reset to correct modes if required 4 Select Correct battery type Flooded wet filer caps or manifold Sealed AGM dry or Sealed 5 Plug AC power cord into 120 Vac electrical outlet Observe REVERSED Polarity LED indicator If lit RED reverse battery connector attachments on battery 6 Observe Power On Error Indicator LED Must be lit GREEN 7 Observe GREEN LED indicator labeled Charge Float Solid when charging Blinking when maintaining
33. t 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 or call our toll free technical support line 800 379 5579 x206 Eastern Time Be certain to leave your phone number with the area code time zone and the best time to call To gain the best result from your new charger and to maximize the life and performance of your bat teries we strongly recommend you qualify test your batteries before attempting to either charge maintain or desulohate them Remember even if you just purchased a new battery it may have been subjected to conditions that have caused Rev H 070708 Page 8 Model 24041 sulohation 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 sulphation 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 or Manifold type Lead Acid Battery 1 Carefully remove all 6 caps or both mani fold type covers fro
34. ty 0 3 Pulse Width Modulated Temperature Compensation with ABS 248 Battery Temperature Sensor LED Indicator functions Tables 5 amp 6 Nn a EM Rev H 070708 Page 32 P N VDC24041 MNL BatteryMINDer Model 24041 DETAILED SPECIFICATIONS VDC Model No 24041 con t Transformer Transformer Type Ferrite core transformer Rising Temperature of Transformer 80 C Max Insulation Primary to Secondary insulation Test 1240 Vac 60Hz with 1 minutes 10mA ac no break down found Primary to core insulation test 1240 Vac 60Hz with 1 minutes 10m4A ac no break down found Secondary to core insulation test 500 Vac 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 24 2 1015 105 C VW 1 16AWG with Ring terminal amp blade type Fuse External Length 24 Ring terminal D dimensions Negative 8mm Positive 10mm Physical Parameters Weight 2 2 lbs Plastic enclosure material UL 94V0 1 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
35. ydrometer tester for the most accurate results see next page if you see an increase in the Specific Gravity SG or voltage indicating that there is an improvement in the battery s condition continue desulphating 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 Hydrom Full Capacity eter meter or 4 ball type Percentage 1 270 4 Balls floating 10096 1 250 3 Balls floating 1 190 2 Balls floating 1 150 1 Balls floating 1 120 Balls floating May denote shorted cell or battery that has been severely discharged and may not be recoverable TABLE 1 P N VDC24041 MNL BatteryMINDer Testing with a Hot Cold 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 bat tery fluid and let it sit for 1 2 hour or longer This will soak the balls in order to give you more accu rate 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 in
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