BT3 - Battery charger VOLTCRAFT - Free user manual and instructions

USER MANUAL BT3 VOLTCRAFT

These Operating Instructions are intended for this product. They contain important advice for use and handling. Please make sure that they are properly observed, even if the product is given to other persons. Basic knowledge of the use of gauges is assumed. Please keep these Operating Instructions for later reference! You can find a list of contents with page numbers on page 19.

Introduction Dear Customer, In purchasing this Voltcraft® product, you have made a very good decision for which we should like to thank you. You have acquired an above-average quality product from a brand family which has distinguished itself in the field of measuring, char- ging and network technology by particular competence and perma- nent innovation. With Voltcraft®, you will be able to cope even with difficult tasks as an ambitious hobbyist just as much as a professio- nal user. Voltcraft® offers you reliable technology at an extraordina- rily favourable cost-performance ratio. We are certain: Your start with Voltcraft will at the same time be the commencement of a long and profitable co-operation. We wish you much enjoyment with your new Voltcraft® product! With this lead battery tester, you have purchased a product con- structed according to latest state of the art. The gauge is equipped with an digital display (gauge) for fast voltage changes and stable clamps for large current loads. The construction of the lead battery tester fulfills VDE 0411= EN 61010. It has been EMV-tested and fulfils the requirements of valid European and national guidelines. The conformity was proven, the appropriate explanations and documents are defined by the manu- facturer. To keep this condition and to guarantee a safe operation, you must as a user observe these operation instructions! 17Intended use of the lead battery tester includes: - Determination of battery status for a 12 V motor vehicle battery to at least 36 Ah with a running measurement (with 100 A). - running voltage measurement (uncharged) on running engine - battery voltage measurement (tester load switch turned off) during ignition - charge measurements on batteries with ignition on or running engine or attached battery charger are not permitted - measurement under adverse conditions is not permitted. Adverse conditions are: - strong precipitation such as rain shower or snow - moisture or high atmospheric humidity (e.g. fog) - dust and combustible gasses, vapors (gasoline, diesel or bat- tery acid) or solvents - thunderstorms or storm conditions like strong electrostatic fields etc. Another use than described above is not permitted and leads to the damage of this product. Beyond that there is a risk of hazards, e.g. short-circuit, fire, electrical shock etc. The entire product may not be changed and/or converted! The safety instructions are to be strictly observed! 18Safety instructions Illustration (open side)

1. Brackets for battery clamps (pole pliers)

2. Cooling holes for power shunt

3. LED lights with colours red for "BAD”

yellow for "WEAK” i.e. threshold or green for "GOOD”

4. 3-digit LED display max. display value 999

5. Button "LOAD” to start automatic measuring process

6. Pole plier black for minus pole (-) of battery

7. Button to set cold start current value (CCA) of battery

• This device is constructed and tested to fulfill DIN 57 411/ Type 1/VDE 0411 Type 1 protection guidelines for electronic gauges, IEC 1010-1 respectively, and has left the factory in technically fla- wless condition. To maintain this condition and guarantee a safe operation, the user must observe the safety instructions and war- nings ("Caution” and "Note"!) contained in these operation instructions. The following symbols should be noted: = read the operating instructions before use

• Gauges and devices do not belong in children’s hands

• Regulations for accident prevention in commercial facilities to the of the association of the commercial professional co-operative societies for electrical systems and devices should be observed.

• In schools, educational facilities, hobby shops and workshops, trained staff are responsible to supervise the use of measurement instruments

• The following safety rules must be observed when working on motor vehicle or measuring battery voltage under load: a) A carbon dioxide fire extinguisher must be easily and perma- nently available. b) Steel wool, grease rags, solvents, gasoline, or fuels may only be stored in designated places and containers. Make sure to observe the rules for fire protection.

c) When working in the engine compartment, wear safety glasses and protective gloves to protect your eyes and hands from battery acid, gasoline, dust, airborne particles and loose machine parts d) Never look into the exhaust pipes of carburetor when the engi- ne is running, since flames can be expected from backfires, misfires, flames it is a flame at a setback, wrong mis-aligned or defective valves from the exhaust pipes. e) When the motor is running, never touch rotating parts such as the ventilator, drive-belts, disc-belts, etc. If you have long hair, wear a hairnet. Do not work with loose clothing and/or neckties if the motor is running. f) No load measurements (toggle switch switched off) with a run- ning engine! ! g) Do not wear any jewelry such as necklaces, rings (also ear- rings), or watches etc. carbon monoxide gas (co. gas) leaving perhaps (at the burning arising) h) Ensure sufficient ventilation (garage or workshop) is uncondi- tional worries for you extremely poisonously).

i) Avoid contact with the exhaust and cooling systems. Risk of

burning! Never open the radiator cap of a running or hot engine. k) Make sure that your vehicle is braked (engaged parking brake), no gear is engaged, and that the vehicle is in "park" with vehicles having automatic transmissions. l) Do not smoke when making measurements or working on the motor vehicle battery! Solvent vapors and hydrogen gas at the charging of lead acid batteries are extremely explosive gasoline! m) Do not leave any tools lying on the battery. Also do not place the gauge on the battery under any circumstances. Short-cir- cuit hazard! Avoid contact with battery acid. The corrosive acid can seriously damage your clothing and "corrode” your skin or eyes. When measuring an external/deconstructed battery, the gauge must be held at a distance of at least 0.5 m (= 50 cm) above the ground.• If it is ascertained that safe operation is no longer possible, then the device should be taken out of operation and secured against accidental operation. Pull out power supply plugs from the plug socket, cigarette lighter line mark! It is ascertained that safe operation is no longer possible, if: the device shows visible damage the device does not work any longer after longer storage under unfavourable conditions, or after heavy transport stresses Never switch the device on right away if it was taken in from a cold area to a warm area. The condensation developing as a result can sometimes destroy the device. Let the switched-off device come to room temperature. Wait for the condensation to evaporate. Use of the lead battery tester Caution! Never operate the lead battery tester in the open air. Caution! Always use only the measurement cables attached tightly for your measurements. Pay attenti- on to the undamaged isolation of the cables and the terminal clamps before every putting into pole pliers. Measurement procedure A Setting the cold start current value of battery Prior to measuring, the cold start current value (CCA = Cold Cran- king Ampere) of the battery has to be set at the measuring device. Normally, this value is stated on the battery. If this value is not sta- ted, it can be requested from the dealer/manufacturer. If the value cannot be found out, the following recommended values can be 22used: car batteries (36 – 100 Ah): 500 – 800 CCA, car batteries (> 100 Ah): 800 – 999 CCA, solar batteries: 300 – 500 CCA Proceed as follows to set the cold start current value:

• Connect the black pole plier (6) to the minus and the red pole plier (8) to the plus pole of the battery to be checked. Jog carefully at the pliers to ensure a safe contact.

• By pressing the button "SET CCA” (7) the cold start current value can be set. This is preset to 500 CCA and each press of the but- ton changes it. B Battery Endurance Testing This test detects whether the battery has enough capacity to start the motor reliably, even under unfavourable climatic conditions. We put a load of approx. 100 A on the battery while measuring. The bat- tery is all right if the battery voltage is relatively constant at> 12 V while measuring (ca. 10 sec). The battery is both defect or over- discharged if the voltage collapses within a very short period of time. Proceed as follows for the measurement:

• Stop the motor, switch off all consumers (except for clock or the car radio’s storage) and remove the ignition key.

• Connect the pole pliers to the battery and set the current value for a cold start. (see point "A. Setting the cold start current value of battery”).

• A connection with the correct polarity displays the "idle voltage” of the battery. If the battery voltage is below ca. 12.0 V, charge the battery before performing an endurance test. If no current value of >12.0V is displayed after recharging, the battery is already damaged. If no display follows, maybe one of the pole pliers is loose, has no contact or the battery voltage is below ca. 7.5 V.

• Shortly press the "LOAD” (5) button once, the relay picks up and the endurance testing is started. "-L-" is displayed when the mea- suring process starts with a battery voltage < 12 V. The battery should be recharged and the test repeated. After approx. 10 seconds a signal is heard to confirm the end of the measuring 23process. Simultaneously, the battery state is displayed via three LED’s (green, yellow or red). If in display (4) "-L-" is shown the battery voltage sank below 7.5 V during the test.

• Please observe the following table, it shows the different battery conditions: LED Display Battery status display: green LED The battery is insufficiently charged. illuminated yellow LED The battery is insufficiently charged. illuminated This battery is either empty or defective. If it is a conventional maintenance-free battery, determi- ne the acid density for battery with an acid pipet- te, (for at least 1.20 to 1.22 kg/l). The value remains under approx. 1.24 kg/l after charging. The battery is used up (after approx. 5 to 8 years) and must be replaced. red LED The battery is possibly defective or seriously undercharged and should be replaced. Caution! During the test, the upper unit cover of the tester gets very hot (with the cooling holes (2)). Let the tester cool down for at least a minute before you perform a further test. Never perform more than 3 test within 5 minutes. C Charging voltage measurement (headlight test) The charging system of the motor vehicle is tested with this measu- rement. A sustained under or overcharging of the motor vehicle bat- tery will inevitably lead to damage. The charge test should be per- formed (described above) before this test. If the battery is OK, you can continue the measurement.

Caution! The engine should be at operating temperature. Proceed as follows: - Attach the pole pliers (+) to the positive terminal (+) of the bat- tery and the black, isolated clamp to the negative terminal (-) of the battery. Gently shake the pole pliers at the terminal to ensu- re contact. - switch off all power loads (lights, fans, discs, boosters, etc.), start the engine and hold at a slowing increasing idle speed of approx. 1500 RPM. - never press the button "LOAD" (5) during this measurement - read the voltage value on the digital display - now turn on the high-beam headlights and set your fans to the highest level. The voltage display should change no more than around approx. 0.1 to 0.3 volts (V). If the display remains relatively stable, the charging system of your motor vehicle is OK. If the voltage changes to more than approx. 0.3 V (above or below), you have your charging electrical equipment (headlights, regulators, brushes, drive-belts, cables, points, cables, plug connector etc.) examined by a mechanic. D Starter test With this test, it can be determined relatively easily whether your vehicle starter does not take enough current from the battery. Cur- rents of more than approx. 200 Amp can be produced. Make abso- lutely sure that the battery is correct before this test. If the battery is weak or defective, then this test is not useful. Proceed as follows:26

• Attach the pole pliers polarity with the insulated terminals of the battery and gently shake the pole pliers for a secure contact (upper oxidation "scratched-off").

• Please observe the following table. It specifies the minimum vol- tage of the battery, during start process with the starter (lower line = cranking) activated or without starter (upper line). However, the values depend strongly on the vehicle type, cylinder capacity etc. The table’s specifications apply for vehicles with a cylinder capa- city lower or equal to 3600 cc. For motors with more than 3600 cc, take the nearest lower voltage value

• the machine (engine) and read the voltage value during the star- ting process. Compare the value with the following table. If the value is sub- stantially lower than the "cranking” voltage, either the starter is defective or there is a bad cable connection (transmission resi- stance) or the battery is too small (under-sized) for the motor vehicle. Load Voltage 10,4 10,6 10,8 11,0 11,2 11,4 11,6 11,8 Min. Cranking Volts 9,7 10,0 10,3 10,6 10,9 11,2 11,4 11,6 Example: The on-load voltage without starter is 11.0 V. During start, the voltage collapses to approx. 10.6 V. The motor’s cylinder capacity is 3600 cc or less. If the cylinder capaci- ty lies above this value, the voltage may not collapse below 10.3 V* (larger starter currents / performance). Additional information about lead batteries!

• The starting power (capacity) of a fully-charged battery drops to under 70% at minus temperatures.

• Most damage to lead batteries comes from overcharging.

• "Warm" batteries are fully-charged at a faster rate than cold bat- teries.

• every battery loses it’s charge. The discharge current is lowest with maintenance-free batteries.27

• a battery that has remained uncharged over a long time period, will sulphurize very easily (sulfur deposits on the plates) and will lose capacity as a result.

• a charged fault-free battery has a no-load voltage of 12.7 V or more. A defective or uncharged battery has a no-load voltage of

Disposal Dispose the unusable, irreparable lead battery tester in accordance with valid laws. Reasons for Error Messages: Er 2 is shown if the relay contact of the charge relay is not open and will release a tone signal. Disconnect the bat- tery tester from the battery to prevent an overload. Knock with a screwdriver on the hexagon nut at the bat- tery tester's rear to release the strucked relay. If the relay does not unscrew, the battery tester must no longer be used for charge measurements. Have the device repai- red in a technical shop. Er 1 is shown if the relay contact of the charge relay is not open and will release a tone signal. The resistance is probably too high or the control is defective. Have the device repaired in a technical shop. Maintenance The lead battery tester is maintenance-free except for occasional cleaning of the clamps and unit cover. It may not be opened underany circumstances. If the lead battery tester is nevertheless opened or modified, the warranty claim expires. Use a clean, lint-free, static- free and dry cleaning cloth for cleaning the device. Caution! Do not use any carbon-containing cleaning agent, gasoline, alcohols or similar for cleaning. This will affect the casing of the gauge. In addition, the fumes are noxious and explosive. Also do not use any sharp tools, screwdrivers, metal brushes or similar for cleaning. Technical data and measurement tolerances Technical data Display: : 3 digit LED display up to 999, 14 mm resolution Test current : approx. 100 A ± 5 % at 13.2 V Voltage measurement : approx. 7.5 to max. approx. 25 VDC range (direct voltage) Running voltage range : approx. 7.5 to max. approx. 16 VDC Charge (test) time : 10s average Red LED less than : 9.1 VDC Yellow LED from : 9.1 to 10.7 VDC Green LED : 10.8 VDC Overcharging switch : at approx. 17 VDC Measuring exactitude : approx. 1 s Operating temperature : 0° C to +55° C Storage temperature : -20° C to +70° C Relative humidity : max. 80%, non-condensing Mass : approx. 1.3 kg Dimensions (L X W X H) : approx. 285 x 107 x 75 mm (without wires)