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1. 26 Troubleshooting Model 24041 AA S5 27 Detailed Specifications VDC Model No 24041 AA S5 29 33 Charging PHOT aaa NAA 34 For Repair Or Replacement 35 Wal AY PAA AA AA 36 Rev A 053111 Page 2 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 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 oper ate ONLY INDOORS 2 USE of any attachment not specifically recommended 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 per son 3 An extension cord should not be used unless absolutely necessary Use of an improper extension 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 b Extension cord is properly wired and in good condition 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 s2. Rev A 053111 Page 10 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 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 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 amf 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 A 053111 Page 11 P N VDC 24041AA S5 MNL 24041 AA S5 BatteryMINDer 62 Iz I 60 pulu Buli pug p409 Ul A Josuas pz 07 81 S e sbd snlels uonipuo5 Asayyeg ne uoigoauuos Tamod 40 SJ0 p9IDu 037 uo
3. Electronics technician at 1 800 379 5579 x206 ET before proceeding further NOTES MODEL BatteryMINDer 24041 AA S5 SERIAL NUMBER PLACE OF PURCHASE DATE OF PURCHASE Rev A 053111 Page 35 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 1 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 expressly 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 B
4. 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 equip ment or not used for extended time without a charger maintain er 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 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 Rev A 053111 Page 27 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 Repeat recharge by pressing and holding Stop Restart for 5 sec until ALL LEDs light Press 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 S
5. 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 Rev A 053111 Page 16 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 Correct polarity and a good connection will be your reward Attach the BCA to the proper 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 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 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 full
6. charged over 10 5V 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 at 4A mode 4 0 22 0 Adc e Max rated output voltage and current 26 0V at 4Adc 27 2V at 3 25Adc e Bulk Charging Time Limited Stops charge if battery cannot be fully charged 28 2V after 20 hrs error LED flash indicated 20 1 Hours At 24 C Rev A 053111 Page 30 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 DETAILED SPECIFICATIONS VDC Model No 24041 AA S5 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 svvitches 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 0 0 25 Vdc Float Charge current control 4A Rate 2 Adc 0 25 Float charge transitions to PWM Float Charge Mode after 1 Hour Float Pulse Charge voltage control 27 0 Q 24 V 0 25 Vdc Float Pulse Charge current control 4A Rate 2 Adc 0 25 Rev A 053111 Page 31 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 DETAILED SPECIFICATIONS VDC Model No 24041 AA S5 con t Battery sulfation check period After absorption charge is finished 10 minutes Unloaded output voltage when
7. 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 2 165 Plastic enclosure material UL 94VO 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 O to 95 RH Rev A 053111 Page 33 P N VDC 24041AA S5 MNL 24041 AA S5 BatteryMINDer abiey 1901 lt Asayeg IenpiAIpul Ag pauiwla ag sy Dove HON O Z Dob 10A 8 PO N UOHEIAY I I 1 1 I 1 I I i 1 01 papu s i I YIBYY abJey uondiosqv ajeydjns I I I i I 1 1 1 uonesu duuo2 aunyeiadway yum 1 1 Joyeydjnsag awit n4 lt juawing 1 p yw s tin s noH 021 vr abJey9 ying abejj01 Aayeg pay 1no uun s noH 9 WL HEIS HOS Jojeydjnsag awl N4 yuan Legs HON 9 YON T 8T OA abe P N VDC 24041AA S5 MNL Page 34 Rev A 053111 BatteryMINDer 24041 AA S5 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
8. 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 A 053111 Page 21 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 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 Installed 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 temperatur
9. 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 insertino 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 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 mini mum of 12 hours before testing with a digital voltmeter only
10. maintenance Stop See Instruction Manual Restart Hold for 5 sec for full reset 4A AVIATION TABLE 5 TABLE 6 Rev A 053111 Page 15 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 Detailed Operation Instructions Model 24041 AA S5 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 char ger 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 installed will normally prove the safest and most 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 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
11. 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 sul fation before maintaining them in multiples Only healthy fully desulfated 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 accurate DIGITAL type ONLY voltmeter The Minimum 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 desulfate it until you reach a rested see pg 9 voltage of 2 13 volts cell 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 most sulfated battery will receive the majority of the desulfation pulse energy Rev A 053111 Page 25 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 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 se
12. 1 AA S5 LED INDICATOR FUNCTIONS Tables 3 top and 4 A amp B bottom 5555 Battery Condition indication Battery connected BEFORE full charge Vb 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 amp RESTED See p 9 Vb lt 25 8V Vb gt 25 8V LED Status Battery Connected Error and Charge LEDs CONNECTED ERROR RED RED FLASH RED FLASH RED FLASH A C power connected Reversed Battery Polarity A C power connected charger output Clip shorted Rev A 053111 Page 14 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 LED INDICATOR FUNCTIONS LED indicators refer to charger label at below FOR SEALED or WET FILLER CAPs LEAD ACID GA BATTERIES ONLY NOT FOR NiCad VDC Electronics Inc 800 379 5579 x201 ET Charger Maintainer Full Time Desulfator Conditioner Model 24041 AA S5 24 Volt 4 Amp www BatteryMINDers com AVIATION CALIBRATED FOR CONCORDE ONLY Groon Power oN Red Polarity Reversed or Battery lt 6 Volts Red Blinking Battery not fully charged 5 4A 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
13. AY 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 c Position yourself and free end of cable as far away from bat tery as possible then connect NEGATIVE BLACK charger clip to free end of cable d Do not face battery when making final connections e When disconnecting charger always do so in reverse sequence of connecting procedure and break first connection while as far away from battery as practical Do not attempt to permanently install charger not specifically designed approved for permanent installation especially in a wet high moisture environment Rev A 053111 Page 7 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 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 experi ence 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 from your new charger and to maximize the life and performance of your batteries we strongly recom mend you qualify test your batter
14. INSTRUCTION MANUAL BatteryMINDer Model 24041 AA S5 Charger Maintainer Desulfator z For use with Concorde Aviation Type 24 V Batteries ONLY Requires proper installation of Battery Temperature Sensor ABS 248 supplied VDC Electronics Inc 147 D Woodbury Rd Huntington NY 11743 U S A www batteryminders com techsupport vdcelectronics com Rev A 053111 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 TABLE OF CONTENTS Safety MISIUOTIONS ana 3 Preparing Tu Dharge 5 Charger Laga ANA 5 DC Connection Precautions 6 Qualifying Your Battery 8 Testing A Filler Cap Or Manifold type 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 Gall onts 12 Simplified Operating Instructions 13 LED Indicator Functions 14 15 Detailed Operation Instructions 16 Temperature Sensor ABS 248 At the Battery Sensor 17 21 24 Maintaining Multiple Batteries 25 Battery Configurations
15. atteryMINDer Five Year Warranty Registration Reminder Online Registration hitp 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 Rev A 053111 Page 36 P N VDC 24041AA S5 MNL
16. 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 LED Indicator functions Tables 5 amp 6 AVIATION TABLE 5 TABLE 6 Rev A 053111 Page 32 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 DETAILED SPECIFICATIONS VDC Model No 24041 AA S5 con t Transformer Transformer Type Ferrite core transformer Rising Temperature of Transformer 80 C Max Insulation Primary to Secondary insulation Test 1240 Vac 50 2 60 2 with 1 minutes 10mA ac no break down found Primary to core insulation test 1240 Vac 50 2 60 2 with 1 minutes 10mA ac no break down found Secondary to core 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
17. e Battery Temperature Temperature Battery Life 45 C 113 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 A 053111 Page 22 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 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 Charge and Float Voltages at Various Temperature Ranges Float Ten 22 m n aan Values shown in RED are based on information supplied by Concorde Battery Co effective Sept 14 2010 Values for batteries manufactured by other aviation battery companies are believed to be comparable We strongly recommend checking with the appropriate dealer or battery manufacturer to be certain Rev A 053111 Page 23 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 Notes Rev A 053111 Page 24 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 MAINTAINING MULTIPLE BATTERIES BatteryMINDer 24041 AA S5 maintenance charger Desulfators can be used to maintain up to three 24 volt batteries at a time providing each battery is fully operational
18. egin blinking It will continue to blink indefi nitely 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 condi tions 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 Rev A 053111 Page 19 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 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 to 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 using your BatteryMINDer model 24041 AA S5 and then connect them together if desired f
19. ell 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 manufacturer s recharging instructions e Study all battery manufacturer s specific instructions such as removing cell caps while charging and recommended charge rates f Determine condition of battery by referring to instructions herein before ever attempting to charge or desulfate 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 Rev A 053111 Page 5 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 DC CONNECTION PRECAUTIONS Note Steps to be done in a well ventilated area away from aircraft 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 contact This tends to keep clips from slipping off terminals and reduces risk of sparking Rev A 053111 Page 6 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 A SPARK NEAR THE BATTERY M
20. hown 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 Rev A 053111 Page 3 P N VDC 24041 AA S5 MNL BatteryMINDer 24041 AA S5 To reduce risk of battery explosion follow these instructions and those published by the battery manufacturer and the manufacturer of any equipment you plan to use in the vicinity of the battery Re view cautionary markings on the products and the engine 8 PERSONAL 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 complete eye protection and clothing protection Avoid touching eyes while working near battery c 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 imme diately d NEVER smoke or allow a spark of flame near battery or engine e Be extra cautiou
21. iate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful inter ference 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 fol lowing measures 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 Electrical Parameters Input Voltage 90 140Vac Input Frequency 50 60 Hz Unloaded input current 80 mA ac Input Current consumption at 120 Vac input output 26V 4A loading UL1236 Approx 1A ac Rev A 053111 Page 29 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 DETAILED SPECIFICATIONS VDC Model No 24041 AA S5 con t e Charging 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 control 4A mode 4 0 25 Adc e Soft Start Charging Time Limited Stops charge if battery cannot be
22. ies before attempting to either charge maintain or desulfate them Remember even if you just purchased a new battery it may have been subjected to con ditions 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 Rev A 053111 Page 8 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 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 instructions 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 or momentarily apply a sma
23. ll 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 S5 and left disconnected from charger or any type load for a minimum of 12 hours 5 If the BatteryMINDer battery condition LED lights MEALILOW 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 maintenance 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 meter or 4 ball type Percentage 1 140 0 May denote shorted cell or battery that has been severely discharged and may not be recoverable TABLE 1 Rev A 053111 Page 9 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 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 battery fluid and
24. llnq U01 09 9S upls u dols 7 d 10193uuo3 1101 Josuas 1 9 91 1 6d 6n d 1290002 yIMb p109 ndino G g eL 5d 1 spio3 Jamod Indu y sqe bununow P N VDC 24041AA S5 MNL Page 12 Rev A 053111 BatteryMINDer 24041 AA S5 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 cord set 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 120 Vac electrical outlet Observe REVERSED Polarity LED indicator If lit RED reverse battery connector attachments on battery 4 Observe GREEN LED indicator 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 con necting sensor to battery pgs 21 23 See full instructions if not lit GREEN Rev A 053111 Page 13 P N VDC 24041AA S5 MNL BatteryMINDer 2404
25. olution 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 YELLOW repeat up to 3 full cycles or until indicator lights GREEN Problem Battery Condition Indicator lights MEILILOW May be several causes Before battery is completely charged Solution Battery can be weak due to sulfation self discharge or was very deeply discharged Attempt a full recharge and recheck after completion If still follow procedure for After battery has been com pletely 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 A 053111 Page 28 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 DETAILED SPECIFICATIONS VDC Model No 24041 AA S5 28 2V 4A 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 equipment gener ates uses and can rad
26. or long term maintenance float charging We suggest your reading the detailed specifications on pages 21 26 including the additional 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 technical support department at techsupport vdcelectronics 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 A 053111 Page 20 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 INSTRUCTIONS TEMPERATURE SENSOR Type ABS 248 At the Battery Sensor MANDATORY WHEN CHARGER IS USED WITH Sealed 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
27. s to reduce risk of dropping a metal tool 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 neck laces 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 g Charger is designed to be used for recharging lead acid bat teries 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 Rev A 053111 Page 4 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 NEVER CHARGE A FROZEN BATTERY OR ONE ATA TEMPERATURE ABOVE 123 F PREPARING TO CHARGE a If battery manufacturer requires battery to be removed from aircraft before charging always remove ground terminal first Turn off all accessories in the aircraft so as not to cause an arc NOTE Concorde Battery Corp sealed AGM batteries according to the manufacturer do not need to be removed from aircraft for charging purposes 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 corrosion from contacting eyes d Add distilled water to each c
28. ts 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 S5 24 Volt BatteryMINDer Battery Configuration TO CHARGER TO CHARGER J 2 24 5 Hu 2 2 Da 24V 12 VOLT O Series Gonnected 24V 24 VOLT Parallel Connected 24V Rev A 053111 Page 26 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 Troubleshooting Model 24041 AA S5 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 S5 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 If still remains RED check battery voltage
29. y 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 Rev A 053111 Page 17 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 NOTES Rev A 053111 Page 18 P N VDC 24041AA S5 MNL BatteryMINDer 24041 AA S5 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 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 seri ously 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 MALLOW or greater than 22 Volts GREEN 7 After battery has been fully charged the GREEN Charge Float LED Indicator will b
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