Clarke DIGICAR 900 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
LS0715
BATTERY BOOSTER/CHARGER
MODEL NO: DIGICAR 900
PART NO: 6261205

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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 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 maximum input current for this unit is 25amps
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 WHEELS
1. Use the two bolts supplied to fit
the front foot to the base as
shown.
2. Fit one of the circlips to the axle as
shown.
3. Slide the axle through the wheel
(from the outside)
4. Pass the free end of the axle
through the two holes on the
base.
5. Place the second wheel on the
end of the axle.
6. Secure with the second circlip.
FITTING THE HANDLE
1. Slide the handle into position as
shown.
2. Secure using the four screws
provided.

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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
Overtemperature 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 Socket
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: 18V For 24V batteries. If the
voltages are lower then this or if you want to charge a fully discarged
battery or, See “FORCED CHARGING” on page 12.
1. Connect the battery charger to the mains.
2. Switch ON the battery charger 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).
• To stop the charge before the 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 12.
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 below7.5V 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 minus 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 FOLLOWING 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 car without damaging the electronics on board your vehicle.
THE CORRECT PROCEDURE TO BOOST YOUR CAR 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. Switch ON the battery
charger: the green led will light.
5. 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 CAR.
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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6. Push the boost start/stop button
(9) and then try to start the car.
• 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 Overtemperature
protection activates, the yellow
LED (3) will light up and the
battery charger will not work
until it has cooled sufficiently.
7. Once the car starts, the battery
charger will automatically stop
supplying current. Press the boost
start/stop button (9).
8. Disconnect the cables from the
battery and replace the battery caps
9. 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 1800W
Output Voltages (Battery Voltages) 12V, 24V
Max charging current 50 A
Charging current according to EN norms 40 A
Max boosting current 550 A
Boosting current with 1V/cell 380 A
Max battery size to be charged in 15 hours 750 Ah
Product Dimensions 320 x 487 x 745 mm
Weight 33.5 kg

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WIRING DIAGRAM

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PARTS DIAGRAM

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PARTS LIST
No DESCRIPTION PART NUMBER
01 FRONT FRAME EM21690657
02 FRONT PANEL LABEL EM77650259
03 INSERT EM21690658
04 LABEL EM77650260
05 CONTROL PANEL EM33710589 9005
06 FEMALE DINSE PLUG EM22100002
07 SWITCH EM22205009
08 RECTIFIER EM22400130
09 PROBE EM26075013
10 300A FUSE EM22220011
11 LEFT SIDE PANEL EM33705669 3020
12 BLACK CHARGING CABLE EM43200072
13 FUSE BOX COVER EM21690110
14 KIT CLAMPS RED-BLACK EM04600407
15 PLASTIC FOOT EM337402809005
16 FRONT PANEL EM33700733 3020
17 CABLE CLAMP EM04600234
18 MAINS POWER CABLE EM20220022
19 LOWER PANEL EM33700339 3020
20 RIGHT PANEL EM33705668 3020
21 TRANSFORMER EM44105088
22. THERMOSTAT VEBE 100Ø SUPPORT EM04600261
23 CONTACTOR EM22225006
24 COMPLETE THERMOSTAT 100Ø + SUPPORT EM04600113
25 PCB SUPPORT EM33640455
26 POWER PC BOARD EM22700037
27 CONTROL P.C.BOARD EM22700036
29 KNOB FOR RED SWITCH + INDICATOR EM04600268
30 KNOB EM21690549
31 HANDLE EM33725114 9005
32 BACK PANEL EM33715190 9005
33 WHEEL EM21625051
34 AXLE EM55200016
35 DINSE PLUG EM22100021
36 RED CHARGING CABLE EM43200073

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