Pite 3986 User manual

PITE3986 Battery Charger/Discharger Complex
User Manual
P-120710-V1.2
4/F, Bldg A, Chiwan Industrial Park, Shaodi Rd.,
Chiwan, Shekou Area, Shenzhen, China
TEL: [phone]
FAX: [phone]
www.pitetech.com

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Catalog
1. INTRODUCTION .....................................................................................................................................3
1.1 ACCESSORIES ...................................................................................................................................... 3
1.2 SAFETY INFORMATION........................................................................................................................... 4
1.3 OPERATING PRECAUTIONS.................................................................................................................... 5
2. OVERVIEW ............................................................................................................................................. 7
2.1 ABOUT PITE 3986 ............................................................................................................................... 7
2.2 DISPLAY AND KEYPAD ........................................................................................................................... 7
2.3 FEATURES............................................................................................................................................ 8
2.4 SPECIFICATION..................................................................................................................................... 8
2.5 PITE 3986 MODELS ............................................................................................................................. 9
2.6 MEASUREMENT FLOWCHART................................................................................................................. 9
3. MEASUREMENT PREPARATION.......................................................................................................... 9
3.1 CONNECTION ....................................................................................................................................... 9
3.1.1 Check Conditions ................................................................................................................. 9
3.1.2 Connection of Cables ......................................................................................................... 10
3.1.3 Connect with DAC .............................................................................................................. 13
3.2 POWER ON........................................................................................................................................ 13
4 MEASUREMENT....................................................................................................................................14
4.1 BATTERY ACTIVATION.......................................................................................................................... 14
4.2 BATTERY DISCHARGE ......................................................................................................................... 16
4.3 BATTERY CHARGE .............................................................................................................................. 16
5 SYSTEM MANAGEMENT......................................................................................................................17
5.1 DATA MANAGEMENT............................................................................................................................ 17
5.2 TIME SETTING .................................................................................................................................... 18
6 Data Management in PC Software.......................................................................................................19
6.1 SOFTWARE INSTALLATION ................................................................................................................... 19
6.2 VIEW DATA ......................................................................................................................................... 20
6.3 DATA IMPORT AND EXPORT.................................................................................................................. 21
7 SERVICE AND MAINTENANCE............................................................................................................22
7.1 CLEANING .......................................................................................................................................... 22
7.2 STORAGE........................................................................................................................................... 22
7.3 FAQ .................................................................................................................................................. 22
8 CONTACT PITE .....................................................................................................................................23

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1. INTRODUCTION
This Users Manual gives full information on how to use PITE 3986 Battery Charger/Discharger Complex
safely and effectively. It applies to all PITE 3986 models. Please read the manual carefully so as to obtain
maximum performance of the PITE 3986 and its accessories.
Warning: Read this manual completely before connecting and powering on the unit to avoid possible
damage caused by improper use of this instrument.
1.1 Accessories
After receiving the PITE 3986 unit, please ensure that no damage occurred during transportation. Upon
any damage or failure of operation based on this instrument, please contact your supplier immediately. And
make sure you have each items below:
PITE 3986 main unit (1) *
AC Power Cord (1)
Load Cables (black and red in one)
Voltage test lead with two clamps (1)
Data Acquisition Case (DAC) *
Data Acquisition Leads *
Antenna *
Data Communication Terminal (1) *
USB-RS232 converter (1) *
USB drive (1)
Users Manual (1)
Grounding line (1)
NOTE:
1) Amount of Accessories marked with “*” may vary based on different PITE 3986 models. Please
confirm with your supplier before each order.
2) For wireless monitor of cell voltage, you will need optional DAC (Data Acquisition Case), antenna, data
communication terminal and USB-RS. Amount of DAC and DAC serial cables may vary in different
models. In some basic complex units, there is no DAC and relevant cables. For detailed connection of
DAC and software monitor, please refer to separate user manual.
PITE 3986 main body
3 phase power code*
load cable (black and red)

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Voltage test lead with two
clamps
DAC (Optional)
Antenna
(for main body)
DAC serial cable, 3-lead
(Optional with DAC)
DAC serial cable, 7-lead
(Optional with DAC)
USB drive
Grounding line
User Manual
Data Communication
Terminal,
USB-RS232 converter
*NOTE: Based on different PITE 3986 models, main body may have different designing. Below is
referenced picture of Model DCC-4801 main body which is mainly used in lower capacity. In this model, it
will use some different designing of testing lines and single phase AC input as blow:

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DCC-4801 main body power core load cable
1.2 Safety Information
When you read this user manual, please carefully observe all warnings, precautions and instructions for
effective operation of PITE 3986.
WARNING: Servicing described in this manual is to be done only by qualified personnel. To avoid electrical
shock, do not service the instrument unless you are qualified enough under PITE’s instruction.
DANGER
Safety testing has been done on this instrument thoroughly
before shipment. However, mishandling during use could result
in injury or other bad consequences, as well as damage to the
instrument. Make sure that you understand the instructions and
precautions in the manual before use. We disclaim any
responsibility for accidents or injuries not resulted directly from
instrument defects.
Safety Symbols
Description of symbols used in this manual.
WARNING Indicates correct operation to prevent a significant hazard that
could result in serious injury or other bad consequences to
users or the product.
NOTE Indicates advisory items related to performance or correct
operation of the instrument.
1.3 Operating Precautions
WARNING:
The electrical voltage and current used in battery testing is potentially lethal.
Ensure that the AC supply is isolated and any battery under test is disconnected before attempting any
cleaning or maintenance of PITE 3986.
Do not connect or disconnect any of the cables unless the circuit breaker (power control) is turned off.
Connection and disconnection procedures are extremely important. Be sure to follow the instructions
faithfully.
Do not touch conducting parts of the load cables or the voltage cables when they are connected to
PITE 3986.
Explosion risk when using PITE 3986 (all models)
When a lead acid battery is charged or discharged i.e. when there is a current flow through the battery

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it is always a risk that the battery can explode.
For new open (vented) batteries the risk is medium to low but in old VRLA (sealed) batteries the risk is
medium to high.
If there is a bad connection inside the battery and there is a current flow - the connection will burn off
and there will be an arc, which will ignite the oxyhydrogen gas in the battery.
To minimize the risk for personnel injuries: Always place PITE 3986 as far away from the battery as
possible - use long load cables and do not stand close to a battery during charge or discharge.
Too high discharge current applied on a battery can cause the battery to explode or get over-heated.
And may also over-wear the batteries. Be sure to not set too high current.
If the external current measurement is interrupted or giving false values during the test, the current will
rise to a higher level than the set value before the test is shut down. If the battery is too small for this
current or in a bad condition - it may explode.
If you see any spark from batteries, testing cables or PITE 3986 main body, please switch off the unit
and disconnect all cables for further inspection.
IMPORTANT:
To use PITE 3986 efficiently and avoid electrical shock, fire or any damage to the PITE 3986 or its
accessories, please do read these precautions carefully before using PITE 3986:
Except as explained in this manual, do not attempt to service this equipment yourself.
To avoid frequency interference, please do not run two PITE 3986 simultaneously in the same location
within 100 meters if it is not parallel connection. If you really have to, please contact PITE for
presetting.
Before use, check to see if the nominal voltage ranges on the PITE 3986 matches the batteries that
you are going to test. Do not apply PITE 3986 of lower voltage in higher voltage. For example, if PITE
3986 nominal voltage is 48V, do not connect the unit with batteries of 220V. Otherwise, some parts
inside PITE 3986 main body may get damaged.
Please make sure the output AC power supply is high-current withstanding. It is strongly suggested
that the AC power output is connected after protecting relay.
Do not operate the PITE 3986 around explosive gas or vapor.
Use only insulated load cables and test leads supplied with PITE 3986.
Before use, please inspect the PITE 3986, load cables, test leads and accessories for mechanical
damage and replace them when they are damaged. Pay special attention to the insulation surrounding
the connectors.
If you have more than one PITE 3986, please use them separately, do not mix them up. Their
accessories may not compromise with each other.
Remove all clamps, test leads and accessories that are not in use.
Make sure that the mains voltage and frequency fit the local AC power supply. Do not apply the unit to
voltages that are above the rated mains of the instrument.
Ensure that the equipment is provided with adequate ventilation. Do not block equipment ventilation
openings.
Proper installation is essential to the correct functioning of your analyzing software CD. If you have any
questions about installation, please contact your supplier for assistance.
After testing batteries for some hours, please keep the main body powered on for at least 10 minutes.
This will help cool down the resistors and other electronics inside the main body and prevent it from
over wearing.

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If you need to test the next battery string right after the first string, please wait for at least 30 minutes to
let the unit cool down also.
2. OVERVIEW
2.1 About PITE 3986
PITE 3986 series are complex units which provide one-stop-solution for battery maintenance. With
charging and discharging for the same battery string, it will greatly simplify your maintenance for batteries.
Extra functions like wireless online monitoring and battery activation will enable you to know your batteries
comprehensively. What’s more, it is simple-to-use, rugged and portable which will be extensively cost
effective and time-saving.
2. 2 Display and Keypad
Operation panel of PITE 3986 main body is as below:
Fig.2.2.1
Parallel com port is for connection with another PITE 3986 for higher discharge current.
USB socket is for connection with USB drive for testing data exportation and software update.
The 6-button keypad enables you for quick navigation through the screen display or menu.
Fig.2.2.2 Keys Operation
Keys Functions
▼▲Move up and down to highlight the selecting options
◄►
1. Change the numbers
2. Move back and forth to highlight the selecting
options

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Confirm the selection or number input
Return to the previous menu
2.3 Features
Suitable for all standby batteries and power batteries: 2V, 6V and 12V
Multi-function in one unit: it uses 3-phase charging, constant current discharging, cell test, optional
online monitor and battery activation
Multi-condition for operation auto-stop: time out, maximum capacity, minimum voltage threshold (for
battery or string)
It adapts PTC ceramic resistor which secures your discharging
Lag-out batteries could be automatically sorted, and activation function is used to enhance their
performance
Instead of merely a load bank, it has optional wireless communication to monitor each battery voltage
in discharging
State-of-the-art technique of soft-off for battery charging
Graphical display, showing test result with curves
Direct USB drive for convenient data transfer to PC
Over voltage protection and under voltage warning function
Thermal protection, auto stop in overheating and auto start in normal temperature
Powerful data view software for complex data analyzing and report printing
Various models applicable to different area of industry like telecom and power utility
2.4 Specification
Parameter Testing range Resolution
& accuracy
Total discharge voltage
96～270V (Norm: 220V)
48～135V (Norm: 110V)
21～58V (Norm: 48V)
Resolution: 10mV
Accuracy: 0.1V
Total charge voltage
output
180～286V (Norm: 220V)
88～143V (Norm: 110V)
38～62V (Norm: 48V)
Resolution:10mV
Accuracy:0.1V
Charge/discharge cell
voltage 0.000V～16.00V Resolution: 1mV
Accuracy: 10mV
Operating Time 0～99h 59m
Other specification:
Mains: 100-240VAC, 50/60Hz or AC 380V, 3 phase 4 wire
Temperature: 0℃～40 (Operating)℃
-30℃～70 (Storage and transportation)℃
Humidity: 5%～90% Relative Humidity
ENT
ESC

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Display: 128*64 pixel LCD screen
Safety standard: CE market, EMC standard
2.5 PITE 3986 Models
CODE NOTE Description Dimension & Weight (main unit)
DCC-22001 With DAC For battery 220 VDC
Max discharge current: 30A
Max charge current: 15A
L550*W440* H565mm
32kg
DCC-22001-1 W/O DAC
DCC-11001 With DAC For battery 110 VDC
Max discharge current: 80A
Max charge current: 40A
L550*W440* H565mm
32kg
DCC-11001-1 W/O DAC
DCC-4801 With DAC For battery 48 VDC
Max discharge current: 150A
Max charge current: 50A
L550*W440* H565mm
32kg
DCC-4801-1 W/O DAC
DCC-4802 With DAC For battery 48 VDC
Max discharge current: 200A
Max charge current: 100A
L550*W440* H565mm
32kg
DCC-4802-1 W/O DAC
2.6 Measurement Flowchart
General steps of measurement for PITE 3986 will be as below:
1) Wear necessary protective clothing
2) Connect the 3 phase AC power cord
3) Connect other testing leads
4) Turn the power on
5) Select measuring mode and set parameters
6) Start measurement
7) Disconnect the test leads from the subject of measurement
8) Turn off the power
9) Disconnect the power cord
3. MEASUREMENT PREPARATION
This section describes how to connect all the testing leads and cables in correct way and sequence. It is
very important for the whole process of operation. For the safety of equipments and operators, please read
it carefully.
3.1 Connection
3.1.1 Check Conditions
Before any connection, make sure that:
1). The battery strings are not working and cut off from power supply.
2). There is enough space for testing. Do not test the unit around explosive gas or vapor.
3). The nominal voltage of the PITE 3986 matches that of the battery strings.

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3.1.2 Connection of Cables
IMPORTANT: Power supply and control on-off (circuit breaker) should be turned off before all wire
connections. To ensure the safety, please turn on the control on-off ONLY when all the other connections
are finished.
All switches and cable sockets are at the back of the main unit. Please see blow for the back panel of PITE
3986 for both designings.
Model One
This model uses three phase AC input as below
Fig 3.1.2.1.1
Model Two:
This model uses single phase input as below:
Fig 3.1.2.1.2

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A. Connection of load cables
Connect one end (Anderson connector) of the load cable with the load cable socket of the PITE 3986 and
the other end (with clamp) respectively with negative pole and positive pole of battery string. Black clamp is
connected with negative pole and red clamp with positive.
Fig 3.1.2.2 Anderson Connector Fig 3.1.2.3 Load cables Connect with battery string
WARNING: Make sure they are correctly and tightly connected to avoid electrical fire and short circuit. The
black and red load cables should be firstly connected with PITE 3986 main unit with power off
B. Connect with 3 phase AC power supply
Connect one end of power cord (with 3 colors as Fig 3.1.2.4) with 3 phase input socket with PITE 3986
main body and other ends with L1, L2 and L3 of 380V 3 phase power supply.
The same color code should be connected together as the back of main body.
Fig 3.1.2.4 connector Fig 3.1.2.5 Three phase AC output
NOTE:
If it is single phase AC input, please connect one power core with red connector of PITE 3986 back panel
and the other end with live line of AC power supply. And connect another power core with black connector
at back panel and the other end with Neutral line of AC power supply.

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Fig 3.1.2.6.1 single phase AC core Fig 3.1.2.6.2 Single phase AC output
C. Connection of voltage testing lead
Connect one end (round connector) of the voltage testing lead to the voltage socket of the PITE 3986, and
the other two clamps with two poles of battery string. The red clamp is connected with the positive pole and
the black with the negative of battery string.
D. Connect the antenna to the top of PITE 3986 main body if the equipment is working with DAC for cell
voltage monitoring on PC. Otherwise, no need to connect it.
Below is the picture of back panel after wire connection with AC power supply, voltage testing lead and load
cable.

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Fig 3.1.2.7.1 three phase AC input Fig 3.1.2.7.2 single phase AC input
3.1.3 Connect with DAC
If your tester comes with Data Acquisition Case, please refer to separate user manual for connection of
DAC and software operation for wireless monitor in PC software. If not, let ‘s skip the next section.
3.2 Power On
After all cables are well connected, PITE 3986 is ready for operation. Turn on power switch and control
on/off on PITE 3986, the screen will display as below:
Fig. 3.2.1
After initialization of about 10 seconds, the following screen will show for main testing functions of PITE
3986. We will introduce them one by one.
Fig.3.2.2

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4 MEASUREMENT
4.1 Battery Activation
Procedure of battery activation includes battery discharging and charging in cycles. This is comprehensive
maintenance for battery. Before the measurement, please turn on both input and output control (circuit
breaker) at the back of the main body.
To begin the test, please select “Active” in the main menu. You will come to the screen for parameter
setting of battery activator in Fig 4.1.1.
As per real battery string, please set the string nominal voltage (“strg type”), cell type (optional for 1.2V, 2V,
6V or 12V), cell amount (“Cell No.”), first cell polarity. Press arrow key ↓to page down and continue to set
total cycles in battery activation. Maximal activation cycles are not more than 10.
Fig 4.1.1
First cell polarity means the beginning polarity of the first cells. For different countries, it could either begin
with negative or positive pole. This setting is necessary for PITE 3986 that comes with DAC. For PITE 3986
that does not come with DAC, “cell No.” could be set as 0 and first cell polarity could be set as negative or
positive. In that case, cell voltage will not be recorded.
After setting for activation cycles, we will page down to the screens for parameter setting of each cycle.
Setting of discharge parameter:
The first cycle will begin from setting of discharge parameter for discharge current, discharge capacity,
discharge time, string voltage threshold (“Tot end U”), cell voltage threshold (“Cell end U”).
Discharge capacity, discharge time, string voltage threshold and cell voltage threshold are four conditions
for auto stop of battery discharge. Generally for protection of battery, string voltage threshold and cell
voltage threshold are set as 90% of nominal voltage (e.g. cell of 2V is set as 1.8V).
NOTE: If there is no DAC for cell voltage monitor, it is no need to set cell voltage threshold. Also to simplify
the tests, this user manual only describes parameter setting for units that has no DAC. If your PITE 3986
has optional DAC, please refer to separate user manual for instruction of wire connection and parameter.
Fig 4.1.2

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Setting of charge parameter:
After setting of discharge in the first cycle, please continue to page down and set charge parameter as screen
below for charge voltage, charge current, charge capacity, charge time, charge current threshold (“Stop I”),
charged string voltage threshold (“CHA stop U”), cell voltage threshold (“cell stop U”).
“Charge U” (e.g.121V) is targeted charge voltage, “CHA stop U” (e.g. 132V) is the threshold for charge
voltage that is for charge protection. It will compulsorily shut down charging when voltage goes beyond
targeted value (121V) while charge current is still constant (e.g. 10A). “Charge I” (e.g. 10A) is the constant
current during charging when charge voltage goes from lower to targeted voltage. Then it will be constant
voltage (e.g. around targeted voltage 121V) with limited charge current between 0.4A (example) and 10A
(example).
This way of setting is same as that of 4.3 Battery Charge.
Fig4.1.3
After setting for discharge parameter and charge parameter in the first cycle, please page down to set
Cycle 2 (if it is more than 1 cycle) for discharge and charge in the same way like Cycle 1. Make sure that all
cycles of activation, either charge time or discharge time should not exceed 18 hours. And total cycles time
for battery activation should not exceed 100 hours.
After setting for all cycles, please press the button ENT to continue and select Confirm to begin the
operation for battery activation.
Fig 4.1.4
Whole process of battery activation will be as below:
Cycle 1 Discharge preparationBattery dischargeDischarge over and about 1 min to save
dataCharge preparationBattery chargecharge over and about 1 min to save dataCycle 2
discharge preparation…
It will first discharge then charge in each cycle, and in the same way in the next cycle until all the cycles are
done. Between each operation, there is some break time for data saving. To protect the inner electronic
parts, after the whole procedure is done, please keep the power on and spare for at least 5 minutes to let

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the unit completely cool down. Do not shut down the unit immediately. This is same to battery discharge
and charge when they are operated individually below.
4.2 Battery Discharge
This testing function is only for discharge of battery. Before discharging, please make sure nominal voltage
(e.g. 110V) of the model fit the nominal voltage of battery string. Before the measurement, please turn on
both input and output control (circuit breaker) at the back of the main body.
To start testing in the screen, please select “Discharge” in main menu. You will see the screen for
parameter setting. Most settings will follow the same rules as that in measurement of battery activation.
If your unit has no DAC, please set “Cell No.” as 0. Then “cell end U” and “1# cell polar” will have no
meaning.
Fig 4.2.1 Discharge screen setting
After parameter setting, press the button ENT and select Confirm to start battery string discharge.
There are four conditions for auto-stop of discharge: Discharged capacity, Discharge time, String voltage
threshold and Cell voltage threshold (if with DAC). Once one of the conditions meets its setting value, the
measurement will stop. During discharging, you could press the arrow keys ↑/↓to page up and down to
view the setting parameters.
4.3 Battery Charge
This is individual operation for charge of battery string. All wire connections are same as that of battery
activation and battery discharge. Before the measurement, please turn on the input control (circuit breaker)

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at the back of the main body (DIS circuit breaker could be turn off).
To start setting for battery charge, please select “Charge” in main menu. Set the parameter for string
nominal voltage (“Strt type”), cell type, cell amount (set as 0 if no DAC), charge current, targeted charge
voltage (“charge U”), charge current threshold (“Stop I”), Charged capacity (“Charge C”), Charged time
(“CHA time”), string voltage threshold (“CHA stop U”), cell voltage threshold (“Cell stop U” if with DAC).
First cell polarity has no meaning if there is no DAC.
After the setting, press button ENT and then select Confirm to begin the measurement.
Battery charge will stop when one of these conditions meets setting value: string voltage threshold, cell
voltage threshold (if with DAC), Charged capacity and charged time.
5 SYSTEM MANAGEMENT
System management will include data management, system time setting and parameter management as
screen below:
Fig 5
5.1 Data Management
Select “Data” under the menu “System”, you will come to the screen for data management, you could view
the testing data, transfer to USB drive of analysis in PC, delete them or even format them.

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Fig 5.1
To view the testing data, please select “View Data” under menu “Data”. You will see different data type like
Activation data (“ACT data”), discharge data (“DIS data”), charge data (“CHA data”) and other data (“Assist
data”). Select relevant item and its testing time, and press ENT to view, transfer to USB drive or delete it
(Fig 5.1.1.1)
Fig 5.1.1.1
By selecting “View”, you will see the testing result of your previous measurement like Fig 5.1.1.2. You could
press arrow keys ↑/↓to page up and down to see each page.
To transfer to USB drive, please first connect PITE USB drive well with the main body and select
“WriteToUSB”
To delete the testing data, please make sure you have saved them properly. Once it is deleted, it could not
be recovered.
Fig 5.1.1.2
Data management for other testing function (e.g. battery discharge) is same as operation above.
5.2 Time Setting
Go to “Syst time” under menu “System” and use arrow keys to change the system time as the screen
below and press ENT to save the change.

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Fig 5.2
5.3 Parameter Setting
This section is mainly for parameter calibration. To do this, you will need some specific instrument for
assistance and only qualified personnel are allowed to do this.
All units are well calibrated in PITE’s factory before they are shipped to our customers’. If you really need to
calibrate it upon some accuracy problem, please kindly contact PITE for calibration manual.
Fig 5.3
6 Data Management in PC Software
6.1 Software Installation
The PITE DataView software is stored in PITE’s USB drive together with PITE 3986 firmware and user
manual. To install the PC software, please find the software named “PITE986 DataView oftware Ver3_09)
etup.exe” in the USB drive and save in your PC. And double click it to run as below. you are suggested to
install the software in PC of Windows environment.
Click Next to continue:

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Change installation path if necessary and click Next to continue. It will take seconds to finish software
installation.
6.2 View Data
After installation is done, you will find the short-cut icon on the desktop like this:
PITE3986 DataView Software(Ver3.09).lnk
Double click to run it and you will see the main screen as below:
Fig 6.2.1
In between of the screen, you could see some exemplified testing data. Line one indicate site (station)