Zig X-3 User manual

THEZIGX-3
CHARGERANDPOWER
SUPPLY UNIT
INSTRUCTIONSFORFITTING
AND USE

INSTRUCTIONSFORUSEANDFITTING
Pieasereadthefollowinginstructionscarefullybeforeinstallingoroperatingthe
X-3chargerandpowersupplyunit.
INTRODUCTION
TheX-3isafullyautomaticbatterycharger,connectedtoa sixcellleadacidbattery
witha nominalvoltageof13.8volts,theunitwillchargeandrechargethebatteryby
raisingtheterminalvoltagetoequalthatoftheoutputofthebatterycharger.Asthe
batteryvoltageincreasestheinputcurrentfromthebatterychargerautomatically
reducesuntilitceasestoflow,thisprovidesfastandefficientbatterychargingand
eliminatesthepossibilityofovercharging,unlessthebatteryis atfault.
LOCATION
Choosea suitablelocationfortheX-3bearinginmindthefollowing:-
a. Minimumsizeofcompartmentmustbe450x300x250mmthiswillallowcool
airtocirculatearoundtheunit,necessaryforcorrectoperation.
b.Ventilationpreferablytotheoutsideofthevanintheformofatleast2x 25mm
diameterventedholesmustbeprovided.
N.B.Alltransformeroperatedappliancesgenerateheatandthereforerunhotwhen
operatingatfullcapacity.
c.Accesstothebatterycompartmentandmainsinletdistributionsystemwill
berequired.
d. Theunitmaybefittedhorizontallyorverticallyandmustbesecurelyfixedto
preventmovementwhilstthevehicleis inmotion.
N.B.Iftheunitis mountedverticallytheconnectionterminalsmustbesituateda*
thebottom.
WARNING
Thechargerisfittedwitha safetydevicewhichprovidesa timedelay:-
approximately2 secondstoreducethesurgeofinrushcurrentwhenswitchec: -
Forthisdevicetofunctioncorrectlytheremustbeanintervalof45secc" =
betweenswitchingoffandon.
Thegreenindicatorlightwillilluminatewhenthechargerisworking.
NOTE
Checkappliancebeforeinstallation,ifthesupplycordisdamageditmust
replacedbya repairshopapprovedbythemanufacturerasspecialist:::= =-=
required.
2

INSTALLATIONX-3
1. TheX-3mustbemountedtoa securesurfaceusing4 x No.8x 11/4
woodscrewsorsimilarthroughthe5mmdiameterholesinthefeetofthe
charger,togivea minimumclearanceofatleast25mmallround.
INSTALLINGTHEBATTERY
Ifa spacehasnotbeenallocatedforthebatteryduringmanufacturethefollowing
mustbeobservedbeforeinstallation.
1. Theinteriorofthebatterycompartmentmustbeprotectedagainstcorrosive
effectsofacid-ladengasesthatmaybereleasedfroma batterywhenitis on
charge.
2. Thecompartmentmustbeventilatedatlowandhighleveltotheoutsideof
thevan.Ifitisaccessiblefromtheoutsideitmustbesealedfromtheinside
structure.
3.Thebatterymustbesecureduprightwhereitcannottipover-itmustbefree
frommovementwhenthevehicleisinmotion.
TheX-3is designedtocharge12Vleadacidtypebatteries,thecapacityofthe
batterymustnotbelessthan60amperehour.(Thebiggerthebatterythebetter).
Shouldthebatterycontainafaultycelltheterminalvoltagewillnotrisesufficiently
toswitchthechargeroffandthebatterywilleventuallyboildry,themostcommon
causeforcellfailureis dischargingthebatterybelowtherecommendedlevel,
approximately10V.
WIRING
Usingcableofatleast2.5mmsq.(50/0.25),eachwirewhenfittedshouldhave
identificationnumbers,letters,orcolourcodes.
ConnectionsaremadetotheX-3using1/4"fastoninsulatedcrimptypeconnectors.
Pleaserefertosuggestedwiringdiagramonpage6.
AUXILIARYBATTERYCONNECTIONS
Terminal 1 ontheX-3topositiveterminalontheauxiliarybattery(via25ampin-line
fusesupplied).
Terminal4 ontheX-3tonegativeterminalontheauxiliarybattery.
12SCONNECTIONS
Terminal2 ontheX-3topin2 onthe12Splug
Terminal3 ontheX-3topin3 onthe12S plug.
CONTROLPANELCONNECTIONS
Terminal1 ontheX-3toauxiliarybatteryconnectiononthecontrol/distribution
panel.
Terminal4 ontheX-3tonegativeonthecontrolpanel.
Terminal5 ontheX-3topowerremotecharger"ON"indicator(ifutilized).
3

MAINS ELECTRIC 240VWIRING
The X-3doesnotcontrolthemainsfacilitieswithinyourvan - it usesmains240volts
during its operation:-
WARNING
Mains electricity can be dangerousparticularly in mobileinstallationssuch as
caravansandyachts. If you do not havethenecessaryknowledgeyoushould not
attemptthefollowinginstallationyoushouldentrust it to a qualifiedelectrician.The
installationmust bein accordancewith the relevant IEE wiringregulations.
A residualCurrentCircuitBreaker(RCCB) or EarthLeakageCircuitBreaker
(ELCB) must be fitted.This isan inexpensive way of protectingagainstelectric
shocks. The devicefittedmust beof currentoperatedtype of the following
specification:
25 amp 30 milliampoperating in approximately 30 milliseconds.
When allthe necessary 12 voltconnectionshavebeenmadethemainswiring can
becompleted.Themainsinput plug andsocketmust be polarised(connectioncan
only be madeonewayround).Should you findyourself ina situationwhere the
polarity is reversed,possibly on the continent the operation of theZig unitwill
continue as normalhoweverstepsmust be taken to rectifythesituation as soon as
possible as otherelectricaldevicesmay be a source of shock. We recommend you
carry a polaritytesterwhentravellingabroad.
The plugsandsocketsarewidelyavailablefromcaravandealersandchandlersand
must beto BS4343.Differenttypes may be requiredabroad ifin doubtyoursite
operatorwill be able to help.
The socketchosenmay be flush or surfacemounted,andshould be situated as near
to the RCCB as possible and should be connectedusing2.5mm sq cable not
exceeding 2 metres in length.Theinput cable for theX-3 maynow be connected
preferably via a coveredjunction boxas follows:
BROWN to LIVE (marked L or red in colour)
BLUE to NEUTRAL(marked N or black in colour)
GREEN/YELLOW to EARTH (marked E or green in colour)
Input198-240voltsA.C.50/60HZ
WARNING: Thisappliancemust be earthed.
We stronglyrecommendtheX-3 is builtintothevanpermanently,theuse of plug
andsocketconnections is not advised.
If a 13 amp plug is usedthismust be connected as follows:
The wire w
letter N or
GREEN & YELLOW
BLUE
BROWN
to earth -
to neutral
to live
The colours of the wires in the mainslead maynot correspondwith the coloured
markingsidentifying the terminals in the plug, if so proceed as follows:
The wirethat is colouredgreenandyellowmust be connected to theterminal in the
plug markedwith the letter E or theearthsymbol. ±
The wire A~:
the letter _ : i
Secure a — =
no strands ofl
Do not cc";
Once the c:
qualified e e:
The mains p
supply via a I
size ofat leas
In order tce-
1.
2.
3.
4.
5.
Disc;-
Hoc::
Switc-
If the "
Repia:
The unit ism
supply(see s:
when travel -
WIRINGTHE
Pin 4 - (gre=-
Pin 3 •
Pin 2
Pin 6
(white -
(bite= :
(rec e:
N.B. Under
The above =:•
availablefrc~
REVERSED •
The X-3sup: •
this happer :
round and a I:
N.B.Ifa bar-
accessories -.
Your Zig cha-:
tested andcz~
BS 6765
BS. EN.60335-
NCC/SMMT =
RFI : FCC2C-E
VDE0S"-
AndtheirE_-:
4

Thewirewhichis colouredbluemustbeconnectedtotheterminalmarkedwiththe
letterN orcolouredblack.
Thewirewhichis colouredbrownmustbeconnectedtotheterminalmarkedwith
theletterL orcolouredred.
Secureallmainsconnectionswithcableclipsandchecktheinstallationensuring
nostrandsofwireareastraywhichmayshorttoearth.
Donotconnectthemainssupplyatthisstage.
Oncethecompleteelectricalinstallationhasbeensatisfactorilycheckedbya
qualifiedelectricantheX-3canbetested.
Themainspowertoyourcaravanshouldbeobtainedfroma normaldomestic
supplyviaa fixedconnectionpoint.Thehook-upcableshouldhavea conductor
sizeofatleast2.5mmsq.andwhenconnectedshouldbeuncoiled.
Inordertoensuretheunitis functioningcorrectlynotethefollowingprocedure:-
1. Disconnectauxiliarybatterybyremovingthein-linefuse.
2. Hookthecaravantothemainssupply.
3.SwitchtheX-3powersupplyon.
4. Ifthe12voltaccessoriesworkinthevantheunitisfunctioningcorrectly.
5.Replacein-linefuse.
Theunitisunaffectedbylowinputvoltagesorreversedpolarityintheincoming
supply(seespecification)ensuringthatitworkstoitsfullpotentialparticularly
whentravellingabroad.
WIRINGTHETOWCAR
Pin4 - (green,vehiclepositivesupply)
Pin3 - (white,negative)
Pin2 - (blue,splitcharging)
Pin6 - (red,refrigeratorsupply).
N.B.Undernocircumstancesmustanyoftheabovecircuitsbeinterconnected.
Theaboveisprovidedforyourinformationonly,pleasenotethesplitchargefacility
availablefromthecaris automaticandistotallyindependentfromtheX-3.
REVERSEDBATTERYCONNECTION
TheX-3supplyunitisfullyprotectedagainstreversedbatteryconnection.Should
thishappenitwillbenecessarytoreconnectthebatteryleadsthecorrectway
roundandalsoreplacethe25ampereinlinefuse.
N.B.Ifa batteryis notusedorisheavilydischargedtheloaddrawnbythe
accessoriesmustnotexceedtheratedoutputoftheX-3.
YourZigchargeris designedtogiveyearsoftroublefreeserviceitis rigorously
testedandcomplieswiththefollowingstandards:-
BS6765
BS. EN.60335-2-29:1991.
NCC/SMMTRegulations
RFI: FCC20780levelB
VDE0871levelA
AndtheirEuropeanNormswhereapplicable.
5

PRODUCTSPECIFICATION- X-3POWERSUPPLY
InputSpecification:
1. Ratedinputvoltage
2. Ratedinputcurrent 198-240VAC
0.8A(RMS)maxat230VAC
3. Ratedinputfrequency: 47Hz-63Hz.
OutputSpecification
1.
Ratedoutputvoltage: Nominal13.8V
2.
Ratedoutputcurrent(continuous) OA- 6.5A
3. RippleandNoise: 100mvp-p
4.
Outputvoltage,stability: +/-0.5%
5. Maximumpower: 139watts
6. Maximumcurrent: 10A
jiim* I
RCCD
TRIP
i
5amp
<
10amp
toign.
car
battery
ISA '1
25A
RM14
o
CONNECTION
X-3
123 4
IT'T'T'T1
CONTROLPANEL
+aux
+car —negative
This= — m wm
una..:-: • ; r:r
Fusesi~z -jmgai
What:: ::- ij«J
1. •I'j-M
2.C:-JC-*»
3.If *«-.:: m
CARAVAN
BATTERY
SUGGESTEDWIRING
DIAGRAMX-3 (b)Al
(c)A i
ThisG^ar
6

GUARANTEE
Thankyouforpurchasinga ZIGproduct.
PeterEverardLtd.,anditssubsidiaryZigElectronicsLtd.,Guaranteethisproductagainst
failureduetofaultyworkmanshipand/ormaterialfora periodof12monthsfromthedateof
originalpurchase.
ThisGuaranteewillbeextendedwhentheproductisfittedtoacaravanormotor-caravanbyan
originalequipmentmanufacturer,thetermwillthenbe12monthsfromthedatethatthe
caravanfirstbecamethesubjectofa retailsale.
Itshallbeatthecompany'sdiscretiontodeterminethemethodofrectifyingthefault.
ThisGuaranteeisnottransferableandanyclaimsmadeundertheGuaranteeMUSTbemade
tothesupplierfromwhomtheproductwaspurchased;(ortothedealerwhosuppliedthe
caravanoriginally).Itisimportantthatproofofthedateofpurchaseissuppliedbythe
customer.
Intheeventofa claimunderthisGuaranteepleasedooneofthefollowingthings:
1. Returntheproductorthecaravantotheoriginalsuppliertogetherwithproofofthedate
ofpurchase.
2. Contactthedealerforinformationaboutrepairsin situ.
N.B.TherearenouserserviceablepartswithintheX-3.
IMPORTANT
Thisguaranteewillbeinvalidatedifanyattempthasbeenmadetoopen,modifyorrepairby
unauthorisedpersonnel.
Fusesandfuseholdersarenotcoveredforfailureordamagebywhatevercause.
Whattodoifa problemoccursoutsidetheGuaranteeperiod:
1. Askyourlocalcaravandealerifhecanservicetheunitforyou.
2. Contacta qualifiedelectrician(oriftheproblemisconfinedtothe12voltcircuits),a
qualifiedauto-electrician.
3.If1 and2 aboveareunsuccessful,youmayreturntheproducttothemanufacturers:
PeterEverardLtd.,atCashesGreen,Stroud,Glos.GL54RAsubjecttothe
following:
(a)TheproductispackagedinaccordancewithPostOfficerequirements,e.a
minimumof2"(50mm)ofpackingmaterialaroundtheparcel.PeterEverardLtd.,
willnotberesponsibleforanydamageintransit.
(b)A letterdescribingfulldetailsofthefault,includinghowandwhen: cc:_"e:
(c)A chequefor£23.50 (incl. vat)madepayabletoPeterEvera--_:ci~-s = ::
defraychargesforcheckingandreturnpostage.Ifanyrepa-s-ec_rez e>zaz
thisfigureyouwillbeadvisedinwritingbeforerepsi'scon-n-e-ce. : .z-
decidenottoproceedtheaboveamountwiilce r5".-roen' :z yc-ess".~ezzs: :z
returnpostage.
ThisGuaranteedoesnotinanywayaffectyourstatutoryrights
7

WARNING: Thisdocumentiscopyright,itmaynotbereproduced
inanyform,copied,orinanywayretrievedforanypurpose
whatsoeverexceptwiththewrittenconsentofthepublishers.The
manufacturersreservetherighttoalterthispublicationatanytime.
COPYRIGHT,PeterEverardLtd.1993