Powergen Digit 3001 User manual

INSTRUCTIONS MANUAL DIGIT 3001
RELEASE.N.2_M 13_10_08
POWERGEN S.R.L.VIA XXV APRILE ,5LOC.CORSALONE CHIUSI DELLA VERNA (AREZZO)
)[phone] -Telefax [phone] E mail [email protected]
www.batterychargerpowergen.it P.Iva 01572290516 -1 -
Digit 3001
Single/Three 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 DIGIT 3001
RELEASE.N.2_M 13_10_08
POWERGEN S.R.L.VIA XXV APRILE ,5LOC.CORSALONE CHIUSI DELLA VERNA (AREZZO)
)[phone] -Telefax [phone] E mail [email protected]
www.batterychargerpowergen.it P.Iva 01572290516 -2 -
qINDEX
1. INSTALLATION .......................................................................................................... 5
2. CONNECTION TO THE SINGLE/THREE-PHASE LINE............................................. 5
3. MAINS VOLTAGE SETTING ...................................................................................... 6
4. MAINTENANCE .......................................................................................................... 7
5. OPERATION ............................................................................................................... 8
6. WARRANTY................................................................................................................ 9
6.1Problem -Solutions and checks................................................................ 10
7. REQUEST OF SPARE PARTS AND/OR SERVICE REQUEST............................... 11
8. DIGIT 3001................................................................................................................ 11
8.1. Operation mode: PROGRAMMING ....................................................... 12
8.2. Operation mode: CHARGE.................................................................... 13
8.2.1. Functions and Displayed Messages................................................ 14
8.2.2. LED bar............................................................................................... 15
8.3. Equalization............................................................................................ 16
8.3.1. Displayed Messages............................................................................ 16
8.3.2. LED bar................................................................................................. 16
8.4. Charging Cycle Log............................................................................... 16
8.5. Alarms and Safeties............................................................................... 17
8.6. Setting of Default Parameters............................................................... 18
9. TECHNICAL NOTE................................................................................................... 19
CONFORMITY DECLARATION............................................................................................... 20
ORDER FOR SPARE PARTS BATTERY CHARGER.............................................................. 23
WARRANTY CERTIFICATE.................................................................................................... 25

INSTRUCTIONS MANUAL DIGIT 3001
RELEASE.N.2_M 13_10_08
POWERGEN S.R.L.VIA XXV APRILE ,5LOC.CORSALONE CHIUSI DELLA VERNA (AREZZO)
)[phone] -Telefax [phone] E mail [email protected]
www.batterychargerpowergen.it P.Iva 01572290516 -3 -
Digit 3001
Battery Charger
Versions: Single_Phase/Three_Phase
All battery chargers Digit 3001 are 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.
The information contained in the present manual is Powergen s.r.l.’s property. Powergen
s.r.l. reserves the right to provide it to its own customers for their exclusive use.
No other use is allowed without Powergen s.r.l.’s written authorization.
Powergen is not liable for inexact data, misprint and clerical errors.
The data of the present manual may be altered without notice, also in the end user’s
interest.

INSTRUCTIONS MANUAL DIGIT 3001
RELEASE.N.2_M 13_10_08
POWERGEN S.R.L.VIA XXV APRILE ,5LOC.CORSALONE CHIUSI DELLA VERNA (AREZZO)
)[phone] -Telefax [phone] E mail [email protected]
www.batterychargerpowergen.it P.Iva 01572290516 -4 -
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 DIGIT 3001
RELEASE.N.2_M 13_10_08
POWERGEN S.R.L.VIA XXV APRILE ,5LOC.CORSALONE CHIUSI DELLA VERNA (AREZZO)
)[phone] -Telefax [phone] E mail [email protected]
www.batterychargerpowergen.it P.Iva 01572290516 -5 -
1. INSTALLATION
qThe installation environment shall be capable of ensuring the User’s safety and the
conditions for a correct operation.
qPowergen Processor battery charger is exclusively designed to recharge traction
batteries and each unit is assigned to a specific battery.
qPowergen Processor 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.
POWERGEN s.r.l.
2. CONNECTION TO THE SINGLE/THREE-PHASE LINE
qIt is absolutely necessary to plug into a current outlet being proportional to the power
of the installed battery charger (s.the KW value on the rating plate put on the side or
on the rear)
qMake sure also the EARTH cable has been correctly connected.
qThe unit comes pre-set for a 400÷415 VAC three-phase mains supply.
qThe single phase unit comes is pre-set for a 230 -240 VAC.
qShould the charger be supplied with a three phase mains supply of 230÷240 VAC,
it is necessary to perform voltage adjustments on the terminal board, tap on the
auxiliary transformers (s.page no) are required and to install to suitable mains
fuse.

INSTRUCTIONS MANUAL DIGIT 3001
RELEASE.N.2_M 13_10_08
POWERGEN S.R.L.VIA XXV APRILE ,5LOC.CORSALONE CHIUSI DELLA VERNA (AREZZO)
)[phone] -Telefax [phone] E mail [email protected]
www.batterychargerpowergen.it P.Iva 01572290516 -6 -
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.
WARNING
Connect the auxiliary
Transformer at 230-240V
WARNING
Connect the auxiliary
Transformer at 400÷415V
WA
RNING

INSTRUCTIONS MANUAL DIGIT 3001
RELEASE.N.2_M 13_10_08
POWERGEN S.R.L.VIA XXV APRILE ,5LOC.CORSALONE CHIUSI DELLA VERNA (AREZZO)
)[phone] -Telefax [phone] E mail [email protected]
www.batterychargerpowergen.it P.Iva 01572290516 -7 -
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
POWERGEN s.r.l.

INSTRUCTIONS MANUAL DIGIT 3001
RELEASE.N.2_M 13_10_08
POWERGEN S.R.L.VIA XXV APRILE ,5LOC.CORSALONE CHIUSI DELLA VERNA (AREZZO)
)[phone] -Telefax [phone] E mail [email protected]
www.batterychargerpowergen.it P.Iva 01572290516 -8 -
5. OPERATION
Led 1 (Red ) Power failure.
Led 2 ( Yellow ) Battery connected -Initial charge.Charge starts and voltage per cell is
lower than 2,4 V.
Led 3 ( Yellow ) Final charge. Shows voltage per cell is higher than 2,4 V.The charging
process continues for 3-4 hours, and the end of this time the charge is completed and the
remote control switch will be placed in quiescent position.
Led 4 ( Green ) Charged battery. Shows that 3-4 hours have gone since Led 3 (Yellow) lit
and the battery is charged.
LED 5 (Red ) Maximun time. Lights if the battery charter hasnot completed its cycle
within 12 hours.The electronic card is provided with a safety timer interrupting the cycle in
order not to damage the battery.The remote control switch is placed in quiescent position.
Led 6 ( Yellow ) . Equalization. This led will light after pressing the red circuit
breaker.Such charge will take place at the end of the normal cycle by executing 5 minutes
of charge and 55 minutes of break on an hourly basis.The disconnection will occur
automatically after the present time of 48 hours (week end charge).
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.
POWERGEN s.r.l.

INSTRUCTIONS MANUAL DIGIT 3001
RELEASE.N.2_M 13_10_08
POWERGEN S.R.L.VIA XXV APRILE ,5LOC.CORSALONE CHIUSI DELLA VERNA (AREZZO)
)[phone] -Telefax [phone] E mail [email protected]
www.batterychargerpowergen.it P.Iva 01572290516 -9 -
6. WARRANTY
qThe duration of the battery charger warranty is 12 (twelve) months from its start-
up.
qThe warranty covers all proven defects in components, assembly and
construction.
qAny incorrect installation or use of the charger NULLIFIES the warranty.
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.
The warranty is NULLIFIES if the 3 thermocouple transformer switch will be
by-pass

INSTRUCTIONS MANUAL DIGIT 3001
RELEASE.N.2_M 13_10_08
POWERGEN S.R.L.VIA XXV APRILE,5LOC.CORSALONE CHIUSI DELLA VERNA (AREZZO)
)[phone] -Telefax [phone] E mail [email protected]
www.batterychargerpowergen.it
P.Iva 01572290516
-
10
-
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
-Check the efficiency of fuses in the three-pole base
-Make sure the auxiliary transformer is correctly fed and that 24Vac voltage is present on the output
-Check the efficiency of the remote control switch coil
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)