BORMANN PRO BBC7020 & BBC7550 Battery Charger and Engine Starter

Important Safety Information

CAUTION: Read and follow all safety rules and operating instructions before every use of this product. SAVE THESE INSTRUCTIONS.

WARNING SYMBOLS AND DEFINITION

• DANGER: Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
• WARNING: Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION: Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
• NOTICE: Addresses practices not related to personal injury.
• The safety alert symbol (!) is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Safety Instructions

Safety precautions for working in the vicinity of a battery

• Batteries generate explosive gases during normal operation. Use in a well-ventilated area.
• Consider having someone close enough or within earshot to assist you when working near a battery.
• Do NOT smoke, strike a match, or cause a spark near a battery or engine. Avoid explosive gas, flames, and sparks.
• Remove all personal jewelry, such as rings, bracelets, necklaces, and watches, while working with a vehicle battery. These items may produce a short circuit that could cause severe burns.
• Be extra cautious to reduce the risk of dropping a metal tool onto the battery. It might spark or short-circuit a battery or other electrical hardware, which may cause an explosion or fire.
• Wear complete eye protection, hand, and clothing protection. Avoid touching eyes while working near a battery.
• Study all battery manufacturer's specific precautions, such as removing or not removing cell caps while charging and recommended rates of charge.
• Clean battery terminals before connecting the charger. Be careful to keep corrosion from coming into contact with eyes.
• When removing a battery from a vehicle to charge, always remove the grounded terminal from the battery first. Ensure all accessories in the vehicle are off to prevent an arc.
• This product is NOT intended to supply power to an extra-low-voltage electrical system or to charge dry-cell batteries. Charging dry-cell batteries may burst and cause injury to persons and property.
• NEVER charge a frozen, damaged, leaking, or non-rechargeable battery.
• If battery electrolyte contacts skin or clothing, wash immediately with soap and water. If electrolyte enters the eye, immediately flood the eye with running clean cold water for at least 15 minutes and seek medical attention immediately.

Safety precautions for using the charger

• Do NOT place the charger in the engine compartment or near moving parts or near the battery; place it as far away from them as the DC cable permits. NEVER place a charger directly above a battery being charged; gases or fluids from the battery will corrode and damage the charger.
• Do NOT cover the charger while charging.
• Do NOT expose to rain or wet conditions.
• Connect and disconnect the DC output only after connecting/disconnecting the AC cord from the electric outlet.
• Use of an attachment not recommended or sold by the manufacturer may result in a risk of fire, electric shock, or injury to persons.
• Do not overcharge batteries by selecting the wrong charge mode.
• To reduce the risk of damage to the electric plug and cord, pull by the plug rather than the cord when disconnecting the charger.
• To reduce the risk of electric shock, unplug the charger from the outlet before attempting any maintenance or cleaning.
• Operate with caution if the charger has received a direct hit or been dropped. Have it checked and repaired if damaged.
• Any repair must be carried out by the manufacturer or an authorized repair agent to avoid danger.

Grounding and AC power cord connections

This battery charger is for use on a nominal 230 volt circuit. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances. The plug pins must fit the receptacle (outlet). Do not use with an ungrounded system. Use of an adapter plug is not recommended.

Using an extension cord

The use of an extension cord is not recommended. If you must use an extension cord, follow these guidelines:

1. Pin sockets on the extension cord plug must be the same number, size, and shape as those of the plug on the charger.
2. Ensure that the extension cord is properly wired and in good electrical condition.
3. Wire size must be large enough for the AC ampere rating of the charger, as specified below:

Description of Mains Parts and Features

The charger features a digital display, various LED indicators, buttons for selection, and connections for battery clamps and AC power.

• ENGINE START BUTTON (1)
• ENGINE START indicator (2)
• DIGITAL DISPLAY (3)
• CHARGED LED indicator (4)
• CHARGING LED indicator (5)
• WARNING LED indicator (6)
• STD LED indicator (7)
• GEL LED indicator (8)
• AGM LED indicator (9)
• 12V-LITHIUM indicator (10)
• TYPE BUTTON (11)
• NORMAL(5A/15A) LED indicator (12)
• BOOST(25A) LED indicator (13)
• 24V quick connector (28)
• REPAIR LED indicator (14)
• 12V quick connector (29)
• FUNCTION BUTTON (15)
• Alternator % LED indicator (16)
• Battery % LED indicator (17)
• TEST BUTTON (18)
• Voltage LED indicator (19)
• Plastic Handle (20)
• Plastic panel (21)
• FUSE (22)
• Metal shell (23)
• AC PLUG (24)
• Wheel (25)
• Negative Battery clamp (26)
• Positive Battery clamp (27)

This product is designed for charging all types of 12V lead-acid and 24V lead-acid batteries, including WET (Flooded), MF (Maintenance-Free), EFB (Enhanced Flooded Battery), GEL, AGM (Absorbed Glass Mat), and 12V Lithium Ion Batteries (4-cell LiFePO4). It features a built-in intelligent microprocessor for faster, easier, and safer charging. Safety features include spark-proof, reverse polarity, short circuit, overheat, overcharge, and over-current protection. The charging start-up threshold is 1V. The charger has clamp storage on the back and two wheels.

Technical Data

* The manufacturer reserves the right to make minor changes to product design and technical specifications without prior notice unless these changes significantly affect the performance and safety of the products. The parts described / illustrated in the pages of the manual that you hold in your hands may also concern other models of the manufacturer's product line with similar features and may not be included in the product you just acquired.

* Please note that our equipment has not been designed for use in commercial, trade or industrial applications. Our warranty will be voided if the machine is used in commercial, trade or industrial businesses or for equivalent purposes.

* To ensure the safety and reliability of the product and the warranty validity, all repair, inspection, repair or replacement work, including maintenance and special adjustments, must only be carried out by technicians of the authorized service department of the manufacturer.

* Always use the product with the supplied equipment. Operation of the product with non-provided equipment may cause malfunctions or even serious injury or death. The manufacturer and the importer shall not be liable for injuries and damages resulting from the use of non-conforming equipment.

Operating Instructions

Display messages

Start up: After the display screen and all LEDs illuminate for 0.5 second, the battery voltage is shown (meanwhile the battery VOLTAGE LED is lit).

Display Information

Battery Type Button

Function Selection Button

Engine Start (press ENGINE START BUTTON to enter)

Provides additional amps for cranking an engine with a weak or run-down battery.

WARNING: Always use in combination with a battery. Must NOT touch or disconnect clamps when ENGINE START mode works, otherwise there may be serious injuries to people or property.

Error Situations

Connecting to the Battery

Follow these steps to connect the charger to the battery:

1. Identify polarity of battery posts. The positive battery terminal is typically marked with letters or symbols (POS, P, +). The negative battery terminal is typically marked with letters or symbols (NEG, N, -).
2. Do not make any connections to the carburetor, fuel lines, or thin metal parts.
3. Identify if you have a negative or positive grounded vehicle. This can be done by identifying which battery post (NEG or POS) is connected to the chassis.
4. For a negative grounded vehicle (most common): connect the RED POSITIVE clamp first to the positive battery terminal, then connect the BLACK NEGATIVE clamp to the negative battery terminal or vehicle chassis.
5. For a positive grounded vehicle (very uncommon): connect the BLACK NEGATIVE clamp first to the negative battery terminal, then connect the RED POSITIVE clamp to the positive battery terminal or vehicle chassis.
6. When disconnecting, disconnect in the reverse sequence, removing the negative first (or positive first for positive ground systems).
7. A marine (boat) battery must be removed and charged on shore. To charge it on board requires equipment specially designed for marine use.

Operating Steps

Note: When the digital tube is only displayed as OFF, the charger can choose the corresponding mode in FUNCTION SELECTION.

Engine Start Function

Your battery charger can be used to jump-start your car if the battery is low. Follow all safety instructions and precautions for charging your battery. Wear complete eye protection and protective clothing.

WARNING: Using the ENGINE START feature WITHOUT a battery installed in the vehicle will damage the vehicle's electrical system.

1. With the charger unplugged from the AC outlet, connect the charger to the battery following the instructions in the CONNECTING TO THE BATTERY section.
2. Plug the charger AC power cord into the AC outlet. With the charger plugged in and connected to the battery and chassis, press the ENGINE START button until the ENGINE START LED is lit.
3. Crank the engine until it starts or 3 seconds pass. If the engine does not start, wait 3 minutes before cranking again. This allows the charger and battery to cool down.
4. If the engine fails to start, use the BOOST rate to charge for 5 minutes before attempting to crank the engine again.
5. After the engine starts, unplug the AC power cord before disconnecting the battery clamps from the vehicle.

NOTE: If the engine does turn over but never starts, there is not a problem with the starting system; there is a problem somewhere else with the vehicle. STOP cranking the engine until the other problem has been diagnosed and corrected.

Starting Sequence States:

1. Wait for cranking: While waiting, the digital display shows START-READY. The charger waits until the engine is actually being cranked before delivering amps for engine start.
2. Cranking: When cranking is detected, the charger will automatically deliver up to its maximum output as required by the starting system for up to 5 seconds.
3. Cool Down: After cranking, the charger enters a mandatory 240-second cool-down state (pressing any button does NOT work). The digital display indicates the remaining cool-down time. After 4 minutes, the digital display will change from displaying the countdown to displaying START-READY.

Voltage Tester and Charger

When first turned on, the unit operates only as a tester, not as a charger. If the "TEST" function is used, stop the "FUNCTION" and the corresponding working mode is turned off. Then select the "TEST" button to detect and view the connected battery voltage and charge level.

NOTE: The battery tester is only designed to test batteries. Testing a device with a rapidly changing voltage could yield unexpected or inaccurate results.

Alternator Check

1. With the charger unplugged from the AC outlet, connect the charger to the battery, following the instructions in previous sections.
2. Plug the charger AC power cord into the AC outlet.
3. Start the vehicle and turn on the vehicle's headlights. Read the state on the digital display. If you get a reading "0-100%", the alternator is working properly. If the reading is "LO" or "HI", have the charging system checked by a qualified technician.

NOTE: When first turned on, the unit operates only as a tester, not as a charger (the charger must stop charging).

Charging Steps

During the charging process, the charger performs the following operations:

Charging Stage Diagram: The diagram illustrates the typical voltage and current curves during the charging process, showing stages 1 through 8.

Protecting the Environment

When your appliance needs replacement or is no longer useful, consider environmental protection. Retailers will accept used tools and ensure they are disposed of in an environmentally safe way. Separate collection of used products and packaging allows materials to be recycled and reused, helping to prevent pollution and reduce demand for raw materials.

Local regulations may provide for separate collection of electrical products from households at municipal waste sites or by the retailer when you purchase a new product.

Lead-acid batteries can be recharged many times. At the end of their useful life, discard batteries with due care for the environment: Do not dispose of the battery in fire, as this may result in an explosion. Lead-acid (Pb) batteries are recyclable and must not be disposed of with household waste. The battery must be removed and disposed of in accordance with local regulations. Do not short-circuit the battery terminals. Be aware that the battery is heavy.

If possible, operate the appliance to run the battery down completely. Place the battery in suitable packaging to ensure that the terminals cannot be short-circuited. Take the battery to your service agent or a local recycling station. Collected batteries will be recycled or disposed of properly.