Clarke DIGICAR 600 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
LS0815
BATTERY BOOSTER/CHARGER
MODEL NO: DIGICAR 600
PART NO: 6261200

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INTRODUCTION
Thank you for purchasing this CLARKE Battery booster / charger which is
suitable for charging and boosting 12 + 24 Volt batteries.
Please read this manual thoroughly, before attempting to operate, and
carefully follow all instructions given.
It is vitally important that ALL precautions are taken, as specified, which will not
only provide protection for yourself and that of others around you, but will also
ensure that the Battery Charger will give you long and satisfactory service.
GUARANTEE
This CLARKE product is guaranteed against faulty manufacture for a period of
12 months from the date of purchase. Please keep your receipt as proof of
purchase.
This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.
Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.
This guarantee does not effect your statutory rights.
ENVIRONMENTAL RECYCLING POLICY
Through purchase of this product, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the WEEE.
In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing
Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal
facility.

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SAFETY PRECAUTIONS
1. To prevent the battery from overheating and consequent damage, use
the BOOST START facility sparingly and do not exceed our
recommendations.
2. Battery acid is highly corrosive. If spillage occurs, wipe off immediately and
wash copiously with water. Particularly avoid contact with the eyes.
3. Do not expose this unit to rain.
4. Never touch the negative and positive leads together.
5. Never attempt any electrical or mechanical repair. If you have a problem
with your machine contact your local stockist for service information.
6. Before charging ensure the battery terminals are clean, and that the cells
are filled with electrolyte to the correct level by adding distilled water
where necessary.
7. Where appropriate we recommend that the positive (+) lead to the
battery is disconnected on the vehicle prior to charging. This will prevent
damaging the vehicle electronics.
8. When charging is completed, ensure that the vehicle battery leads are
secured to the correct terminals which should be clean and lightly
smeared with petroleum jelly to prevent corrosion. Finally, re check the
electrolyte level.
WARNING: BECAUSE HIGHLY FLAMMABLE HYDROGEN GAS IS RELEASED
IN THE PROCESS OF BATTERY CHARGING, ALWAYS REMEMBER TO SWITCH
OFF FIRST TO AVOID SPARKING, WHICH CAN OCCUR WHEN
CONNECTING OR DISCONNECTING LIVE LEADS.
WARNING: CERTAIN TYPES OF SEALED OR MAINTENANCE-FREE BATTERIES
NEED EXTRA CARE WHEN CHARGING. PLEASE CONSULT BATTERY
MANUFACTURERS INSTRUCTIONS BEFORE USING THIS UNIT.
WARNING: TOXIC FUMES CAN BE RELEASED DURING BATTERY
CHARGING, ONLY USE THIS UNIT IN A WELL VENTILATED AREA.

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ELECTRICAL CONNECTIONS
Connect the three core mains lead to a suitable industrial supply isolator, or
heavy duty plug. These chargers must be connected to a supply having a
rated capacity of greater than 13 Amps.
The recommended supply current for this unit is 25A,
the supply should therfore be fitted with a 25A rated
circuit breaker
IMPORTANT: The wires in the mains lead are coloured in accordance with
the following code:
As the colours of the flexible cord of this appliance may not correspond with
the coloured markings identifying terminals in your plug proceed as follows:
• Connect GREEN & YELLOW coloured cord to plug terminal marked with
a letter ‘E’ or Earth symbol ‘ ’ or coloured GREEN or GREEN & YELLOW.
• Connect BROWN cord to terminal marked with a letter L or coloured
RED
• Connect BLUE cord to terminal marked with a letter N or coloured
BLACK
If in doubt, consult a qualified electrician.
WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS THOROUGHLY.
WARNING: A 13 AMP (BS1363) PLUG IS NOT SUITABLE.
WARNING: THIS APPLIANCE MUST BE EARTHED
Green & Yellow Earth
Blue Neutral
Brown Live

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ASSEMBLY
FITTING THE HANDLE
1. Place the handle into position as
shown.
2. Secure using the two screws
provided.
3. Fix the screw caps in the screw
holes.
NOTES ON CHARGING PROCEDURE
LOCATION
• Use the battery charger only and exclusively indoors;
• The premises must be well-ventilated;
• The premises must be dry and dust-free;
• The air vents should be free of obstructions;
• The battery charger should be placed on a stable surface.
WARNING: NEVER ATTEMPT TO RE-CHARGE NON-RECHARGEABLE
BATTERIES.

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CHARGING MORE THAN ONE BATTERY AT THE SAME TIME
If it is necessary to charge more than one battery at the same time, they can
be connected in series or in parallel.
• Connection in series is preferred because this makes it possible to
monitor the current circulating in each battery, this will be shown on the
display.
• Please foillow the diagram below.
WARNING: DO NOT CHARGE BATTERIES WITH DIFFERENT CAPACITIES OR
DIFFERENT TYPES OF BATTERIES AT THE SAME TIME.

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OVERVIEW
1 ON/OFF Switch
2 Green LED Lights up when the battery
charger is connected to the
mains supply
3 Yellow LED Lights up when the “Over-
temperature” protection
activates
4 Battery Type Selector Pb/Gel, Ca/Ca or AGM
5 Charge Process Selector Automatic or Floating
6 Charge Current / Charge Time selector
7 Charge Current / Time Adjustment knob
8 Charge Start / Stop button
9 Boost Start / Stop button
10 Voltage / Charge percentage display: Shows either the battery voltage
or the charge percentage.
11 Current / Timer display: Shows the charge current and
the remaining charge time
12 12V / 24V Positive Cable Sockets
13 Protection Fuse
14 Negative Cable
15 Positive Cable

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BATTERY CHARGING
NOTE: The charging process only activates if the battery connected has a
minimum voltage of 7.5V for 12V batteries or 18V for 24V batteries. If
the voltages are lower then this, or if you want to charge a fully
discharged battery or, See “FORCED CHARGING” on page 11.
1. Connect the battery charger to the mains.
2. Switch the battery charger on using the on/off switch.
• The green LED (2) will light up
SELECT THE BATTERY TYPE
3. Press the battery type selector (4)
to select the battery type.
• This battery charger can be
used with normal lead batteries
(sealed or unsealed), GEL,
AGM batteries or calcium
batteries.
NOTE: If you are not sure of the
battery type, select calcium battery.
SELECT THE CHARGING PROCESS
4. Select the charging process (5):
Automatic or Floating.
AUTOMATIC
• This mode will perform a full
charge (at the set current) until
the set time has elapsed.
• The charger will then stop and
the display will show “END”.
• If you then turn the adjustment knob the display will then show the set
charge current.
• If the charging time has not been set, the charger will run for 9,9 hours
(the maximum default value).
•Tostopthechargebeforethe set time, just push the Charge Start / Stop
button.

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FLOATING:
• This mode will perform a full charge (at the set current) until the set time
has elapsed.
• The charging current will decrease to a lower fixed current. A buzzer will
signal the transition from full charge to floating charge.
SELECT THE CHARGE CURRENT
5. Press the charge current/time
selector (6) until the charge
current LED lights up:
6. Turn the adjustment knob (7) to
set the desired charge current.
• The current value will be shown
in the bottom display (11).
• You should set up a value that is 10% of the battery capacity. For
example, if you have a 140Ah battery you should set up 14A.
• This battery charger allows you to set up any value of current from 1
Amp to the maximum rated amperage of the battery charger.
SELECT THE CHARGE TIME
7. Press the charge current/time
selector (6) until the charge time
LED lights up.
8. Turn the adjustment knob (7) to
set the desired charge time.
• The current value will be shown
in the bottom display (11).
9. Connect the red cable to the
required 12V/24V positive socket.
• Insert the plug on the cable
into the socket (12) on the front
of the battery charger and
then turn the plug clockwise in
order to lock it in place.
• Make sure the socket selected
is correct for the battery being
charged.
10. Connect the clamp on the red cable to the positive terminal of the
battery.

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11. Connect the clamp on the black cable to the negative terminal of the
battery.
• If all connections are correct, the top display will show the battery
voltage and the charge status of the battery (expressed in %. 99%
means that the battery is full).
• If you have not made the right connections the top display will show the
wording “Alb”: double check the battery voltage and connect the red
cable to the right positive socket.
• If the battery charger is not connected to a battery, the display will show
“StB” (stand by).
• If after connecting the battery, the display shows “StB” and charging is
not activated (by pressing the charge start/stop button), it means that
the battery is fully discharged, short-circuited or interrupted.
• To charge a fully discharged battery, See “FORCED CHARGING” on
page 11.
START CHARGING
12. Check if all the parameters that
you set are correct and push the
charge start/stop button (8) to
begin charging.
• During the charge you cannot
change any of the settings.
• To change a setting, you must
push the charge start/stop
button (8) to STOP the charge.
• After you have changed the settings, you can start the charging
process again by pushing charge start/stop button again.
DURING THE CHARGE
• The top display (10) will show
the actual voltage value of the
battery.
• The bottom display (11) will
show the charging current and
the remaining charge time
alternately.

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FORCED CHARGING
Use forced charging if the battery voltage is below 7.5V for 12V batteries or
18V for 24V batteries.
1. Connect the battery charger to the mains.
2. Switch ON the battery charger.
3. Connect the black cable to the negative terminal of the battery.
4. Connect the red cable to the
required 12V/24V positive socket.
• Insert the plug on the cable
into the socket (12) on the front
of the battery charger and
then turn the plug clockwise in
order to lock it in place.
• Make sure the socket selected
is correct for the battery being charged.
5. Connect the clamp on the red cable to the positive terminal of the
battery.
6. Select the type of battery, the type of charge and the charge current as
described in the previous section.
7. Ensure that the cables are securely fixed to the battery terminals and hold
the charge start/stop button (8) till the top display shows “24” and the
bottom display shows “12”.
8. Select the charge voltage.
• Press the battery type selector
button (4) for 24V or
• Press the charge current
selector button (6) for 12V.
9. Charging will start 1 second after
the charge voltage selection.
NOTE: Charging can be stopped at any time by pressing the charge start/
stop button (8) again.
NOTE: To reactivate the security functions, turn the charger off and on again.
WARNING: WHEN YOU FOLLOW THE PROCEDURE BELOW, CERTAIN SAFETY
CHECKS ARE DISABLED (CHECK FOR SHORT-CIRCUITED BATTERY AND
CORRECT CONNECTION). PAY EXTRA ATTENTION TO THE POLARITY OF
THE CONNECTIONS AND THE BATTERY VOLTAGE.

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OPERATION AS BOOST STARTER
This battery charger is equipped with a boosting system that will let you start
your vehicle without damaging the electronics on board your vehicle.
THE CORRECT PROCEDURE TO BOOST YOUR VEHICLE IS:
1. Connect the black cable to the minus terminal of the battery.
2. Connect the red cable to the
required 12V/24V positive socket.
• Insert the plug on the cable
into the socket (12) on the front
of the battery charger and
then turn the plug clockwise in
order to lock it in place.
• Make sure the socket selected
is correct for the battery being
charged.
3. Connect the clamp on the red cable to the positive terminal of the
battery.
4. Connect the battery charger to the mains. Check that the socket is
equipped with protection fuses or circuit breakers.
5. Switch ON the battery charger.
• The green led will light.
6. Before starting the boosting procedure is advisable to perform a fast
charge with the maximum current for 10-15 minutes.
WARNING: BOOST STARTS MUST BE PERFORMED WHEN THE BATTERY IS
STILL MOUNTED ON THE VEHICLE. IT IS SUGGESTED TO PERFORM A
NORMAL CHARGE AT THE MAXIMUM CURRENT FOR 10/15 MINUTES
BEFORE YOU TRY TO BOOST YOUR VEHICLE.
WARNING: THE BOOST PROCESS ACTIVATES ONLY IF THE BATTERY
CHARGER IS CONNECTED TO A BATTERY THAT COMPLIES WITH THE
FOLLOWING MINIMUM VOLTAGE VALUES: MORE THAN 7.5V FOR 12V
BATTERIES: MORE THAN 18V FOR 24V BATTERIES.

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7. Push the boost start/stop button
(9) and then try to start the
vehicle.
• The battery charger will start to
supply energy to the battery.
• If the boost is not successful,
wait a few minutes and try
again.
• To prevent damage to your
battery, the boost function will not be carried out if the battery is
damaged (short circuit or broken elements).
• If the “Over-temperature”
protection activates, the yellow
LED (3) will light up and the
battery charger will not work
until it has cooled sufficiently.
8. Once the vehicle starts, the
battery charger will automatically
stop supplying current. Press the
boost start/stop button (9).
9. Disconnect the cables from the
battery and replace the battery caps.
• Switch OFF the battery charger, disconnect it from the mains supply and
store it in a dry place

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SPECIFICATIONS
Input Voltage 230V @ 50-60Hz
Input Power 800W
Output Voltages (Battery Voltages) 12V, 24V
Max charging current 30A
Charging current according to EN norms 30A
Max boosting current 500A
Boost Start with 1V/cell 350A (12V) , 310A (24V)
Max battery size to be charged in 15 hours 375Ah
Product Dimensions 345 x 250 x 280 mm
Weight 20 kg

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WIRING DIAGRAM

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PARTS DIAGRAM

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PARTS LIST
No DESCRIPTION PART NUMBER
01 FRONTAL-CONTROL PC BOARD EM22700019
02 THERMOSTAT EM22210014
03 PLASTIC HANDLE EM21600030
04 UPPER PANEL EM33705380 3020
05 THERMOSTAT VEBE EM04600276
06 CABLE CLAMP FOR CABLE EM04600233
07 INPUT CABLE EM20220016
08 FRONT FRAME EM21690326
09 FRONT PANEL EM33710437 9005
10 POLYCARBONATE PLATE EM77650281
11 RED KNOB EM04600332
12 DOUBLE POLE SWITCH EM22200043
13 CABLE CLAMP EM04600233
14 LOWER PANEL EM33700187 3020
15 POWER PCB EM22700020
16 RECTIFIER EM22400096
17 TRANSFORMER EM44105083
18 FUSE HOLDER BOX EM21690113
19 FUSE EM22220030
20 SMALL FUSE COVER EM21690109
21 FEMALE DINSE PLUG EM22100002
22. BLACK CABLE EM43200016
23 CLAMPS 120A FOR BATTERY CHARGING.RED-BLACK EM04600067
24 RED CABLE EM43200026
25 DINSE PLUG EM22100001

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