Powergen CEMB 3000 User manual

INSTRUCTIONS MANUAL CEMB 3000
RELEASE.N.0_M 13_10_08 -1 -
Cemb 3000
Single phase
Instructions manual (UK)
Warranty (UK)
Read the following instructions carefully before connecting the
rectifier to the supply line and to the battery.

INSTRUCTIONS MANUAL CEMB 3000
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qINDEX
1. INSTALLATION .......................................................................................................... 5
2. CONNECTION TO THE SINGLE/THREE-PHASE LINE............................................. 5
3. MAINS VOLTAGE SETTING ...................................................................................... 5
4. MAINTENANCE .......................................................................................................... 6
5. OPERATION ............................................................................................................... 7
6. WARRANTY................................................................................................................ 8
6.1Problem -Solutions and Checks................................................................. 9
7. REQUEST OF SPARE PARTS AND/OR SERVICE REQUEST............................... 10
8. TECHNICAL NOTE................................................................................................... 10
WARRANTY CERTIFICATE...................................................................................... 11

INSTRUCTIONS MANUAL CEMB 3000
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Cemb 3000
Battery Charger
Versions: Single_Phase
All battery chargers Cemb 3000are conform to the following European standard
DIN 41772-3-4 “Charging method and curve of transformers”.
EN 60335–2-29 “Safety of electrical appliances and similar”.
EN 55014 “E.M.C. standards”.
73/23/EEC “Electric material used within specific voltage limits”,
later modified by directive 93/68/EEC.
89/336/EEC “Electromagnetic compatibility”,
later modified by directive 92/31/EEC.
The following equipment is covered by warranty.
The warranty certificate is attached to the following manual. If not, request it to your dealer.

INSTRUCTIONS MANUAL CEMB 3000
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INSTALLATION -USE -OPERATION
To use the charger, you have to abide by safety prescriptions contained in law and
regulation and in provisions of local authorities.
Obligations of the “USER” : conforming to the operating instructions, the “USER” is any
natural or juridical person using directly Powergen srl battery chargers or anyone using
them for account of the above mentioned person.
Under special circumstances, e.g.leasing renting, the “USER” is the person who takes
following obligations according to the agreements made by owner and “USER”.
The “USER” will be responsible for the installation site of the charger. He shall check,
whether very sensitive appliances are disturbed by the influence of the battery charger.
He shall choose such an installation site,that the operation of the charger(a high current
produces interferences magnetic fields) does not affect the functioning of electromagnetic
devices and magnetic data carriers (f.e.pace makers,monitors,magnetic disks and
diskettes,magnetic tapes,magnetic card, etc…).
The “USER” shall make sure that “USER”s and operators have read and understood the
operating instructions and that they abide by accident prevention and safety rules and the
use and maintenance provisions.
N.B. Read the following instructions carefully before connecting the
rectifier to the supply line and to the battery.

INSTRUCTIONS MANUAL CEMB 3000
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1. INSTALLATION
qThe installation environment shall be capable of ensuring the user’s safety and the
conditions for a correct operation
qProcessor battery charger is exclusively designed to recharge traction batteries and
each unit is assigned to a specific battery.
qProcessor battery charger has IP 20 protection degree, therefore it shall be protected
from rain and water sprays. It shall be installed away from easily inflammable materials
and shall not be used as a supporting top. The presence of dust and/or corrosive
environments may damage the components seriously.
qDo not lay any materials which may obstruct the natural cooling air flow
qThe rectifier shall be laid on the floor in vertical position. For special requirements it
may also be placed on special raised shelves.
ATTENTION :
VIBRATIONS DURING TRANSPORT COULD CAUSE UNPLEASANT
DRAWBACKS, SO BEFORE STARTING UP THE UNIT, PLEASE CHECK NUTS
AND BOLTS FOR TIGHTNESS.
2. CONNECTION TO THE SINGLE_PHASE LINE
qIt is absolutely necessary to plug into a current outlet being proportional to the power of
the installed battery charger
qMake sure also the EARTH cable has been correctly connected.
qThe single phase unit comes is pre-set for a 230 -240 VAC.
3. MAINS VOLTAGE SETTING
qDuring the installation (or after a displacement) we recommend to check the actual
value of the mains voltage, if found high or low compared with the rated values, may
cause problems due to a higher or lower delivery of current during the charge.
qAs a result, check this value and adjust it, if needed, via the ADJUSTING PLUGS
placed in the terminal board on the transformer.
qSuch control is to be carried out by qualified staff and/or by service centres.

INSTRUCTIONS MANUAL CEMB 3000
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4. MAINTENANCE
qNo scheduled maintenance is provided, though control and cleaning inspections may
be performed within the battery charger system depending on its work environment.
However such operations shall only be carried out by qualified staff.
qAny maintenance intervention shall only be carried out after disconnecting the rectifier
from mains and from the battery.
qFor a correct operation we recommend to check the mechanical tightening of electric
connections and the good status of wires and connections and to remove the existing
dust.
Polycarbonate plate with charging data Pic. (1)
-Before charging the unit, read the instruction manual carefully;
ATTENTION :
-Check the input voltage and adapt the regulation on the power transformer
-Explosive gases -Avoid sparks or flames
This battery charger includes parts such as circuit breakers or relays that may
cause electric arcs or sparks. Thus, if used in a garage or a similar environment,
place the battery charger in a suitable room.
-For indoor use only -do not expose the unit to the rain or similar elements

INSTRUCTIONS MANUAL CEMB 3000
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5. OPERATION
LED 1 (yellow)
Battery connected
LED 2 (yellow)
Initial charge. The charge starts and the voltage per cell is lower than 2.4V.
LED 3 (yellow)
Final charge. Shows that the voltage per cell has exceeded 2.4V.
The charging process continues for 3/4 hours and at the end of this time
the charge iscompleted and the remote control switch will be placed in quiescent position.
LED 4 (green)
Charged battery. Means 3/4 hours have gone and the battery is charged.
LED 5 (red)
Maximum time. Lights if the battery has not reached the full charge within 12 hours. The
remote control switch will be placed in quiescent position.
LED 6 (red).
Lights if the voltage per cell exceeds 2.7V at any time of the charge. This situation occurs
if the battery is damaged or overcharged. The charging process will stop and the remote
control switch will be placed in quiescent position.
LED 7 (yellow).
Equalization. When lit, it enables the charge equalization function (weekend charge),
push the EQ.switch.
ATTENTION, PLEASE:
BEFORE DISCONNECTING THE CONNECTOR BETWEEN THE BATTERY AND
THE CHARGER, PLEASE, MAKE SURETHE CHARGE LIFE CYCLE HAS
FINISHED, OTHERWISE BEFORE DISCONNECTING YOU MUST STOP THE
CHARGE MANUALLY, IN ACCORDANCE WITH THE SECURITY STANDARDS.
THIS OPERATION GUARANTEES MORE RELIABILITY OF THE INNER
ELECTRONIC COMPONENTS OF THE EQUIPEMENT.

INSTRUCTIONS MANUAL CEMB 3000
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6. WARRANTY
qThe duration of the battery charger warranty is 12 (twelve) months from its
startup.
qThe warranty is void due to improper use, incorrect installation or tampering
qThe warranty is void if interventions on the equipment are performed by persons
not qualified by Powergen S.r.l.

INSTRUCTIONS MANUAL CEMB 3000
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6.1 PROBLEM –SOLUTIONS AND CHECKS
PROBLEM SOLUTIONS AND CHECKS
The battery charger is not starting
-Check the battery connection
-Make sure the battery voltage is suitable for the battery charger voltage
-Check the efficiency of the d.c. fuse on the output
-Make sure the three phases are present in the line voltage
The battery charger is not charging
sufficiently
-Check the supply voltage. In case it is low, modify the tap on the transformer (-5%)
-Make sure the three phases for line input are present
-Via a clip-on ammeter check the symmetry of alternate currents on the rectifier bridge input
The battery charger is delivering an
excessive charge -Check the supply voltage. In case it is high, modify the tap on the transformer (+5%) -Make sure the control panel is preset for the type of battery used (correct choise of battery cells amount)
The battery charger is connected
correctly, but the control panel is not
switched on (or it is switched on in an
incorrect way)
-Replace the microprocessor-controlled electronic card
The system is efficient, though the
battery cannot keep the autonomy for
the required time -Check the batteries’ status (sulphated battery -faulty cells)

INSTRUCTIONS MANUAL CEMB 3000
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7. REQUEST OF SPARE PARTS AND/OR SERVICE REQUEST
qWe recommend to always advise the serial number of the battery charger.
8.TECHNICAL NOTE:
These charging systems are capable of charging the battery either with the
Wa characteristic according to DIN41774 standard (see table “one charging stage only”)
or, alternatively, when the charging time needs to be reduced, according to the WoWa
characteristic, based on DIN 41774 standard, see table “Addition of a second charging
stage”.
Such systems provide the possibility of carrying out timed equalized charges or voltage
sensing charges, see programming manual.
• Charge at decreasing current with intervention of the final charge at 2.40 V/cell
• Final charge with timed control 9h / 11h
• Fixed charging time (equalization charge excluded)
•Equalization charge (week-end charge) to be recalled. It will start after 55' from
charge end
• Duration of equalized charging phase: each hour 5' (repeated for 48 hours)
• Calculation to determine the size of suitable battery charge: 16A for every 100 Ah
of the battery (e.g. 500 Ah battery: 16Ax5 = 80A)
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