SIP Chargestar T27 User manual

20
FOR HELP OR ADVICE ON THIS PRODUCT PLEASE CONTACT YOUR DISTRIBUTOR,
OR SIP DIRECTLY ON:
TEL: [phone]
EMAIL: [e-mail] or [e-mail]
www.sip-group.com
Ref: 091116
Please dispose of packaging for the product in a responsible
manner. It is suitable for recycling. Help to protect the
environment, take the packaging to the local amenity tip and
place into the appropriate recycling bin.
Never dispose of electrical equipment or batteries in with your
domestic waste. If your supplier offers a disposal facility please
use it or alternatively use a recognised re-cycling agent. This
will allow the recycling of raw materials and help protect the
environment.
Please read and fully understand the instructions in this manual
before operation. Keep this manual safe for future reference.
03982
Chargestar T27
12/24v Battery Charger

2
19
Declaration of Conformity
We
SIP (Industrial Products) Ltd
Gelders Hall Road
Shepshed
Loughborough
Leicestershire
LE12 9NH
England
As the manufacturer's authorised representative within the EC
declare that the
Chargestar T27 Battery Charger - SIP Part. No. 03982
Conforms to the requirements of the following directive(s), as indicated.
2006/95/EC Low Voltage Directive
2004/108/EC EMC Directive
2011/65/EU RoHS
Signed: …………………………………...
Mr P. Ippaso - Managing Director - SIP (Industrial Products) Ltd
Date: 29/07/2015.
DECLARATION OF CONFORMITY
And the relevant standard(s), including:
EN 60335-2-29:2004+A2:2010
EN 60335-1:2012+A11:2014
EN 62233:2008
EN 55014-1:2006+A1:2009+A2:2011
EN 55014-2:1997+A1:2001+A2:2008
EN 61000-3-2:2006+A1:2009+A2:2009
EN 61000-3-3:2013

18
NOTES
3
CONTENTS
Page No. Description
4. Safety Symbols Used Throughout This Manual
4. Safety Instructions
7. Electrical Connection
9. Guarantee
9. Technical Specifications
10. Getting to Know Your Battery Charger
11. Operating Instructions
13. Troubleshooting
14. Wiring Diagram
15. Exploded Drawing
16. Parts List
19. Declaration of Conformity

4
SAFETY SYMBOLS USED THROUGHOUT THIS MANUAL
Danger / Caution: Indicates risk of personal injury and/or the possibility of
damage.
SAFETY INSTRUCTIONS
IMPORTANT: Please read the following instructions carefully, failure to do
so could lead to serious personal injury and / or damage to the Battery
Charger.
Note: Supplementary information.
Warning: Risk of electrical injury or damage!
This battery charger is designed for the charging of lead acid batteries. They should
not be used as a DC power source, or used to recharge non-rechargeable batteries.
To do so may cause fire, electric shock, etc.
It is designed to be powered from a 230v ~ 50Hz supply, which is reliably connected
to the buildings ground (earth) point.
If connecting the charger to a battery whilst still connected to the vehicle, check with
the vehicle’s manufacturer that it is safe to do so. Always connect the battery terminal
not connected to the chassis first. The other connection is to be made to the chassis
as far away as practical from the battery and fuel line (a spark can be generated
when connecting the second clamp which can ignite battery or fuel gases). The bat-
tery charger is then to be connected to the mains supply. Once charging is com-
plete, disconnect the battery charger from mains supply first, and then remove the
chassis connection followed by the battery connection.
During charging, batteries give off some hydrogen and oxygen creating a highly ex-
plosive mix. Ensure adequate ventilation exists and avoid sparks, smoking, etc.
During battery maintenance ensure adequate clean water is available in the event of
an acid spill. The liquid inside batteries is highly corrosive therefore ensure that it is not
17
NOTES

16
PARTS LIST
Ref. No. Description SIP Part No. Ref. No. Description SIP Part No.
1. Cables (c/w clamps) PW02-00175 19. Transformer board PW02-00193
2. Fuse 35A PW02-00176 20. Pad M8 PW02-00194
3. Voltage terminal PW02-00177 21. Spring washer M8 PW02-00195
4. Cable gland PW02-00178 22. Nut M8 PW02-00196
5. Screw ST 3x10 PW02-00179 23. Screw (M5 x 15) PW02-00197
6. Screw M8 PW02-00180 24. Spring washer M5 PW02-00198
7. Bolt (M4 x 16) PW02-00181 25. Ammeter PW02-00199
8. Screw (M3 x 10) PW02-00182 26. Fuse holder PW02-00200
9. Spring washer M4 PW02-00183 27. Fuse 10A PW02-00201
10. Pad PW02-00184 28. Selector switch PW02-00202
11. Ventilator PW02-00185 29. On / Off switch PW02-00203
12. Nut M4 PW02-00186 30. Mains lead PW02-00204
13. Rectifier bridge PW02-00187 31. Screw M5 PW02-00205
14. Screw ST 5x20 PW02-00188 32. Handle PW02-00206
15. Chassis PW02-00189 33. Nut M5 PW02-00207
16. Transformer pad PW02-00190 34. Pad PW02-00208
17. Transformer PW02-00191 35. Cover PW02-00209
18. Upper pad PW02-00192
5
SAFETY INSTRUCTIONS….cont
When using your battery charger, basic safety precautions should always be followed
to reduce the risk of fire, electric shock, personal injury and / or damage to the battery
charger. Read all these instructions before operating the charger and save this user
manual for future reference.
SIP recommends that this charger should not be modified or used for any application
other than that for which it was designed. If you are unsure of its relative applications
do not hesitate to contact us and we will be more than happy to advise you.
KNOW YOUR BATTERY CHARGER: Read and understand the owner's manual and la-
bels affixed to the charger. Learn its applications and limitations, as well as the poten-
tial hazards specific to it.
DO NOT USE THE BATTERY CHARGER IN DANGEROUS ENVIRONMENTS: Do not use your
Battery charger in damp or wet locations, or expose it to rain. Always provide ade-
quate space around the battery charger.
KEEP CHILDREN AND UNTRAINED PERSONNEL AWAY FROM THE WORK AREA: All visitors
should be kept at a safe distance from the work area.
STAY ALERT: Always watch what you are doing and use common sense.
DISCONNECT THE BATTERY CHARGER FROM THE MAINS SUPPLY: When not in use.
DO NOT ABUSE THE MAINS LEAD: Never pull the mains lead to remove the plug from
the mains socket, or to move the battery charger. Keep the mains lead away from
heat, oil and sharp edges. If the mains lead is damaged, it must be replaced by the
manufacturer or its service agent or a similarly qualified person in order to avoid un-
wanted hazards.
HAVE YOUR BATTERY CHARGER REPAIRED BY A QUALIFIED PERSON: The battery charger
is in accordance with the relevant safety requirements. Repairs should only be carried
out by qualified persons using original spare parts, otherwise this may result in consid-
erable danger to the user and void the warranty.
DANGER! Check that the battery charger is in sound condition and good working
order. Take immediate action to repair or replace damaged parts.
WARNING! Only operate on a level and stable surface.
WARNING! Do not allow untrained persons to operate the machine and do not op-
erate the machine without all covers etc. correctly fitted.
WARNING! RISK OF ELECTRIC SHOCK. Do not expose the battery charger to water
spray, rain, dripping water or moisture of any kind.
allowed to make contact with the skin, and especially the eyes. In the event of con-
tact, flush the area with clean water and immediately consult a doctor.
Lead acid batteries store a large amount of energy. Short-circuiting the battery or
charger terminals will cause the battery to try and release this energy immediately,
which can result in fire or personal injury. Prevent any metal object (or other conduc-
tive material) from touching the + and –terminals of the charger or battery at the
same time.

6
SAFETY INSTRUCTIONS….cont
CAUTION: The warnings and cautions mentioned in this user manual can not cover all
possible conditions and situations that may occur. It must be understood by the oper-
ator that common sense and caution are factors which cannot be built into this prod-
uct, but must be applied.
Use recommended parts only - Unapproved parts may be dangerous and will inval-
idate the warranty.
Do not move or handle the machine when it is running.
Do not leave the machine unattended when in use. Switch the machine off and
unplug from the mains supply before leaving the work area.
Do not allow children or animals near the battery charger, particularly when in use.
Ensure that the battery charger is correctly turned off when not in use and store in a
safe, dry area, out of reach of children.
Do not unplug the battery charger to switch it off - always use the on/off switch.
Always locate the battery charger on a stable and level surface.
Always keep children and animals away from charger.
Never stand on the charger.
Do not dismantle or tamper with the battery charger, as this may be dangerous and
will invalidate the warranty.
Boost charge should be used for a maximum of 1 hour, after which if required the
battery charger should be switched to normal charge, or turned off so it can cool
down for a few hours.
Boost charge is not designed to jump start a vehicle.
Understand the operating environment; Before each use the operator should assess,
understand and where possible reduce the specific risks and dangers associated
with the operating environment. Bystanders should also be made aware of any risks
associated with the operating environment.
Keep all combustible materials away from this battery charger.
If a problem with the battery charger is experienced, or if the mains lead or plug be-
come damaged, contact your distributor for repair.
If the battery charger is to be used on business premises - ensure that all local and na-
tional regulations are followed concerning the use of portable electrical appliances at
work.
WARNING: Risk of Electric Shock!
Use only the electrical power (voltage and frequency) specified on the model plate
of the battery charger. If in doubt contact the manufacturer.
Use only a three-prong, grounded outlet and where required.
Always unplug the battery charger when not in use.
15
EXPLODED DRAWING

14
WIRING DIAGRAM
7
WARNING! It is the responsibility of the owner and the operator to read, understand
and comply with the following:
You must check all electrical products, before use, to ensure that they are safe.
You must inspect power cables, plugs, sockets and any other connectors for wear or
damage.
You must ensure that the risk of electric shock is minimised by the installation of appro-
priate safety devices; A residual current circuit Breaker (RCCB) should be incorporated
in the main distribution board. We also recommend that a residual current device
(RCD) is used. It is particularly important to use an RCD with portable products that are
plugged into a supply which is not protected by an RCCB. If in any doubt consult a
qualified electrician.
Connecting to the power supply:
This SIP battery charger is fitted with a standard UK 230v ~ 13 amp type plug. Before
using the battery charger, inspect the mains lead and plug to ensure that neither are
damaged. If any damage is visible have the battery charger inspected / repaired by
a suitably qualified person. If it is necessary to replace the plug a heavy duty impact
resistant plug would be preferable.
ELECTRICAL CONNECTION
The wires for the plug are coloured in the following way:
Yellow / green Earth
Blue Neutral
Brown Live
As the colours of the wires may not correspond with the markings in your plug, pro-
ceed as follows: The wire which is coloured blue, must be connected to the terminal
marked with N or coloured black. The wire which is coloured brown, must be connect-
ed to the terminal, which is marked L or coloured red. The wire which is coloured yel-
low / green should be connected to the terminal which is coloured the same or
marked
Always secure the wires in the plug terminal carefully and tightly.
Secure the cable in the cord grip carefully.
Cord Grip

8
ELECTRICAL CONNECTION….cont
Warning: Never connect any phase wires to the earth terminal of the plug or
board. Only fit an approved plug with the correct rated fuse. If in doubt consult
a qualified electrician.
Note: Always make sure the mains supply is of the correct voltage and the
correct fuse protection is used. In the event of replacing the fuse always
replace the fuse with the same value as the original.
Note: If an extension lead is required in order to reach the mains supply;
ensure that this too is rated for the correct voltage and fuse rating.
Note: The cross section of the extension lead should be checked so that it
is of sufficient size so as to reduce the chances of voltage drops.
13
TROUBLESHOOTING
The following form lists the common operating issues with problems and solutions.
Please read the form carefully and follow it.
If any of the following symptoms occurs during your operation, stop using the battery charger immediate-
ly, or serious personal injury could result. Only a qualified person or an authorised service centre should
perform repairs on the battery charger. Disconnect from the mains supply before attempting repairs or
adjustments and when replacing parts etc.
Note: Repairs should be carried out by a qualified person.
Fault Possible Cause Solution
No charging current.
Bad contact or power socket.
Initial voltage is too low.
+ or - polarity battery terminals are oxi-
dised or dirty.
Battery is damaged.
Fuse blown.
Repair or replace socket.
Replace damaged battery.
Clean terminals.
Replace battery.
Replace fuse.
Low charging current. Battery not accepting charge. Replace battery.
Excessive transformer noise. Battery is fully charged.
Unstable position.
Measure specific gravity.
Place in stable position.

12
Ensure the mains supply to the battery charger is off.
Check battery liquid and top up if required.
Connect the + (red) lead to the correct voltage terminal on the charger de-
pending on the voltage of the vehicle to be started.
Connect the lead to the battery first (normally +). The other connection is to be
made to the chassis as far away as practical from the battery and fuel line (a
spark can be generated when connecting the second clamp which can ignite
battery or fuel gases).
Once the clamp is attached to the battery, slightly rotate it so as to remove any
dirt or oxidization, this will ensure a good contact.
Select charge (setting 1 slow or 2 medium) or boost charge (maximum) on the
switch, (boost charge is for a maximum of 1 hour, after 1 hour you must manually
turn off boost charge or you will damage the charger/battery/car).
Note: The battery clamp connected to the chassis should be removed
first. The other clamp connection can then be removed from the battery
terminal.
Note: The battery terminal not connected to the chassis has to be connected
first. The other connection is to be made to the chassis, remote from the bat-
tery and fuel line.
Important: Check with the manufacturer of the vehicle that the battery
can be charged whilst still connected to avoid any unwanted damage to
the vehicle.
Danger: The engine must not be running whilst the battery charger is
charging the battery.
CHARGING A BATTERY ON A VEHICLE
OPERATING INSTRUCTIONS….cont
Note: Never exceed the boost charge setting; maximum 1 hour charge, after which
if required the battery charger should be switched to normal charge or turned off so
it can cool down for a few hours. Failure to adhere to this will void your warranty.
The battery charger should then be connected to the mains supply and switched
on.
Once the battery on the vehicle has charged, remove the clamps from the bat-
tery / vehicle - chassis connection first followed by the battery connection.
9
TECHNICAL SPECIFICATION
Battery Capacity 40 - 240AH
Input Voltage 230v ~ 50 Hz
Charge 12v (Setting 1) 8.5 amp
Charge 12v (Setting 2) 11 amp
Boost Charge 12v 22.5 amp
Charge 24v (Setting 1) 9 amp
Charge 24v (Setting 2) 14 amp
Boost Charge 24v 24 amp
Protection IP20
This SIP Battery Charger is covered by a 12 month parts and labour warranty covering
failure due to manufacturers defects. This does not cover failure due to misuse or op-
erating the battery charger outside the scope of this manual - any claims deemed to
be outside the scope of the warranty may be subject to charges Including, but not
limited to parts, labour and carriage costs.
This guarantee does not cover consumables such as fuses, clamps etc.
In the unlikely event of warranty claims, contact your distributor as soon as possible.
GUARANTEE
Note: Proof of purchase will be required before any warranty can be hon-
oured.

10
GETTING TO KNOW YOUR BATTERY CHARGER
Ref. No. Description Ref. No. Description
1. Ammeter 7. On / Off Switch
2. Output (fuse 30amp) 8. 12v Output
3. Carry Handle 9. Positive Clamp
4. Input (fuse 10amp) 10. Negative Clamp
5. Setting Switch 11. 24v Output
6. Charge / Boost Charge Switch
1
2
3 4 5 6
7
8
9
11
10
11
OPERATING INSTRUCTIONS
CHARGING A BATTERY
Remove the battery from the vehicle.
Remove the battery caps to allow any excess gas to escape and to prevent the
case bursting.
Check the battery liquid and top up if required.
Connect the + (red) lead to the correct voltage terminal on the charger de-
pending on the voltage of the battery to be charged.
Put the red clamp of the charger to the + terminal on the battery and the black
clamp to the - terminal on the battery and confirm that connection is correct.
After both clamps are attached to the battery, slightly rotate it so as to remove
any dirt or oxidization, this will ensure a good contact.
Select charge (setting 1 slow or 2 medium) or boost charge (maximum) on the
switch, (boost charge is for a maximum of 1 hour, after 1 hour you must manually
turn off boost charge or you will damage the charger/battery).
The battery charger should then be connected to the mains supply and switched
on.
CAUTION: Do not leave the battery connected to the charger once the charge
has finished, this may cause excessive heating of the cells and the electrolyte to
“boil”. If this happens during charging select a lower setting or stop the charge.
Danger / Caution: Do not touch the positive clamp (red) with the negative clamp
(black) to check the battery charger output –this may cause the internal fuse to
blow or the mains fuse to blow.
Important: The boost charge is not designed to jump start a car, doing so
will damage the charger/battery and void any warranty you may have.
Note: Never exceed the boost charge setting; maximum 1 hour charge, after which
if required the battery charger should be switched to normal charge or turned off so
it can cool down for a few hours. Failure to adhere to this will void your warranty.
Charge Setting 1: Slow charge rate.
Setting 2: Medium charge rate.
Boost Charge
Maximum charge rate, boost charge should only be used for a
maximum of 1 hour, after which if required the battery charger
should be switched to normal charge or turned off so it can cool
down for a few hours (when boost charge is selected it will override
the charge settings).