BATTERY BOOSTER/CHARGER MODEL NO: DIGICAR 600

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1 BATTERY BOOSTER/CHARGER MODEL NO: DIGICAR 600 PART NO: OPERATION & MAINTENANCE INSTRUCTIONS LS0815

2 INTRODUCTION Thank you for purchasing this CLARKE Battery booster / charger which is suitable for charging and boosting Volt batteries. Please read this manual thoroughly, before attempting to operate, and carefully follow all instructions given. It is vitally important that ALL precautions are taken, as specified, which will not only provide protection for yourself and that of others around you, but will also ensure that the Battery Charger will give you long and satisfactory service. GUARANTEE This CLARKE product is guaranteed against faulty manufacture for a period of 12 months from the date of purchase. Please keep your receipt as proof of purchase. This guarantee is invalid if the product is found to have been abused or tampered with in any way, or not used for the purpose for which it was intended. Faulty goods should be returned to their place of purchase, no product can be returned to us without prior permission. This guarantee does not effect your statutory rights. ENVIRONMENTAL RECYCLING POLICY Through purchase of this product, the customer is taking on the obligation to deal with the WEEE in accordance with the WEEE regulations in relation to the treatment, recycling & recovery and environmentally sound disposal of the WEEE. In effect, this means that this product must not be disposed of with general household waste. It must be disposed of according to the laws governing Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal facility. 2

3 SAFETY PRECAUTIONS WARNING: BECAUSE HIGHLY FLAMMABLE HYDROGEN GAS IS RELEASED IN THE PROCESS OF BATTERY CHARGING, ALWAYS REMEMBER TO SWITCH OFF FIRST TO AVOID SPARKING, WHICH CAN OCCUR WHEN CONNECTING OR DISCONNECTING LIVE LEADS. WARNING: CERTAIN TYPES OF SEALED OR MAINTENANCE-FREE BATTERIES NEED EXTRA CARE WHEN CHARGING. PLEASE CONSULT BATTERY MANUFACTURERS INSTRUCTIONS BEFORE USING THIS UNIT. WARNING: TOXIC FUMES CAN BE RELEASED DURING BATTERY CHARGING, ONLY USE THIS UNIT IN A WELL VENTILATED AREA. 1. To prevent the battery from overheating and consequent damage, use the BOOST START facility sparingly and do not exceed our recommendations. 2. Battery acid is highly corrosive. If spillage occurs, wipe off immediately and wash copiously with water. Particularly avoid contact with the eyes. 3. Do not expose this unit to rain. 4. Never touch the negative and positive leads together. 5. Never attempt any electrical or mechanical repair. If you have a problem with your machine contact your local stockist for service information. 6. Before charging ensure the battery terminals are clean, and that the cells are filled with electrolyte to the correct level by adding distilled water where necessary. 7. Where appropriate we recommend that the positive (+) lead to the battery is disconnected on the vehicle prior to charging. This will prevent damaging the vehicle electronics. 8. When charging is completed, ensure that the vehicle battery leads are secured to the correct terminals which should be clean and lightly smeared with petroleum jelly to prevent corrosion. Finally, re check the electrolyte level. 3

4 ELECTRICAL CONNECTIONS WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS THOROUGHLY. Connect the three core mains lead to a suitable industrial supply isolator, or heavy duty plug. These chargers must be connected to a supply having a rated capacity of greater than 13 Amps. WARNING: A 13 AMP (BS1363) PLUG IS NOT SUITABLE. The recommended supply current for this unit is 25A, the supply should therfore be fitted with a 25A rated circuit breaker WARNING: THIS APPLIANCE MUST BE EARTHED IMPORTANT: The wires in the mains lead are coloured in accordance with the following code: Green & Yellow Blue Brown Earth Neutral Live As the colours of the flexible cord of this appliance may not correspond with the coloured markings identifying terminals in your plug proceed as follows: Connect GREEN & YELLOW coloured cord to plug terminal marked with a letter E or Earth symbol or coloured GREEN or GREEN & YELLOW. Connect BROWN cord to terminal marked with a letter L or coloured RED Connect BLUE cord to terminal marked with a letter N or coloured BLACK If in doubt, consult a qualified electrician. 4

5 ASSEMBLY FITTING THE HANDLE 1. Place the handle into position as shown. 2. Secure using the two screws provided. 3. Fix the screw caps in the screw holes. NOTES ON CHARGING PROCEDURE WARNING: NEVER ATTEMPT TO RE-CHARGE NON-RECHARGEABLE BATTERIES. LOCATION Use the battery charger only and exclusively indoors; The premises must be well-ventilated; The premises must be dry and dust-free; The air vents should be free of obstructions; The battery charger should be placed on a stable surface. 5

6 CHARGING MORE THAN ONE BATTERY AT THE SAME TIME WARNING: DO NOT CHARGE BATTERIES WITH DIFFERENT CAPACITIES OR DIFFERENT TYPES OF BATTERIES AT THE SAME TIME. If it is necessary to charge more than one battery at the same time, they can be connected in series or in parallel. Connection in series is preferred because this makes it possible to monitor the current circulating in each battery, this will be shown on the display. Please foillow the diagram below. 6

7 OVERVIEW 1 ON/OFF Switch 2 Green LED Lights up when the battery charger is connected to the mains supply 3 Yellow LED Lights up when the Overtemperature protection activates 4 Battery Type Selector Pb/Gel, Ca/Ca or AGM 5 Charge Process Selector Automatic or Floating 6 Charge Current / Charge Time selector 7 Charge Current / Time Adjustment knob 8 Charge Start / Stop button 9 Boost Start / Stop button 10 Voltage / Charge percentage display: Shows either the battery voltage or the charge percentage. 11 Current / Timer display: Shows the charge current and the remaining charge time 12 12V / 24V Positive Cable Sockets 13 Protection Fuse 14 Negative Cable 15 Positive Cable 7

8 BATTERY CHARGING NOTE: The charging process only activates if the battery connected has a minimum voltage of 7.5V for 12V batteries or 18V for 24V batteries. If the voltages are lower then this, or if you want to charge a fully discharged battery or, See FORCED CHARGING on page Connect the battery charger to the mains. 2. Switch the battery charger on using the on/off switch. The green LED (2) will light up SELECT THE BATTERY TYPE 3. Press the battery type selector (4) to select the battery type. This battery charger can be used with normal lead batteries (sealed or unsealed), GEL, AGM batteries or calcium batteries. NOTE: If you are not sure of the battery type, select calcium battery. SELECT THE CHARGING PROCESS 4. Select the charging process (5): Automatic or Floating. AUTOMATIC This mode will perform a full charge (at the set current) until the set time has elapsed. The charger will then stop and the display will show END. If you then turn the adjustment knob the display will then show the set charge current. If the charging time has not been set, the charger will run for 9,9 hours (the maximum default value). To stop the charge before the set time, just push the Charge Start / Stop button. 8

9 FLOATING: This mode will perform a full charge (at the set current) until the set time has elapsed. The charging current will decrease to a lower fixed current. A buzzer will signal the transition from full charge to floating charge. SELECT THE CHARGE CURRENT 5. Press the charge current/time selector (6) until the charge current LED lights up: 6. Turn the adjustment knob (7) to set the desired charge current. The current value will be shown in the bottom display (11). You should set up a value that is 10% of the battery capacity. For example, if you have a 140Ah battery you should set up 14A. This battery charger allows you to set up any value of current from 1 Amp to the maximum rated amperage of the battery charger. SELECT THE CHARGE TIME 7. Press the charge current/time selector (6) until the charge time LED lights up. 8. Turn the adjustment knob (7) to set the desired charge time. The current value will be shown in the bottom display (11). 9. Connect the red cable to the required 12V/24V positive socket. Insert the plug on the cable into the socket (12) on the front of the battery charger and then turn the plug clockwise in order to lock it in place. Make sure the socket selected is correct for the battery being charged. 10. Connect the clamp on the red cable to the positive terminal of the battery. 9

10 11. Connect the clamp on the black cable to the negative terminal of the battery. If all connections are correct, the top display will show the battery voltage and the charge status of the battery (expressed in %. 99% means that the battery is full). If you have not made the right connections the top display will show the wording Alb : double check the battery voltage and connect the red cable to the right positive socket. If the battery charger is not connected to a battery, the display will show StB (stand by). If after connecting the battery, the display shows StB and charging is not activated (by pressing the charge start/stop button), it means that the battery is fully discharged, short-circuited or interrupted. To charge a fully discharged battery, See FORCED CHARGING on page 11. START CHARGING 12. Check if all the parameters that you set are correct and push the charge start/stop button (8) to begin charging. During the charge you cannot change any of the settings. To change a setting, you must push the charge start/stop button (8) to STOP the charge. After you have changed the settings, you can start the charging process again by pushing charge start/stop button again. DURING THE CHARGE The top display (10) will show the actual voltage value of the battery. The bottom display (11) will show the charging current and the remaining charge time alternately. 10

11 FORCED CHARGING Use forced charging if the battery voltage is below 7.5V for 12V batteries or 18V for 24V batteries. WARNING: WHEN YOU FOLLOW THE PROCEDURE BELOW, CERTAIN SAFETY CHECKS ARE DISABLED (CHECK FOR SHORT-CIRCUITED BATTERY AND CORRECT CONNECTION). PAY EXTRA ATTENTION TO THE POLARITY OF THE CONNECTIONS AND THE BATTERY VOLTAGE. 1. Connect the battery charger to the mains. 2. Switch ON the battery charger. 3. Connect the black cable to the negative terminal of the battery. 4. Connect the red cable to the required 12V/24V positive socket. Insert the plug on the cable into the socket (12) on the front of the battery charger and then turn the plug clockwise in order to lock it in place. Make sure the socket selected is correct for the battery being charged. 5. Connect the clamp on the red cable to the positive terminal of the battery. 6. Select the type of battery, the type of charge and the charge current as described in the previous section. 7. Ensure that the cables are securely fixed to the battery terminals and hold the charge start/stop button (8) till the top display shows 24 and the bottom display shows Select the charge voltage. Press the battery type selector button (4) for 24V or Press the charge current selector button (6) for 12V. 9. Charging will start 1 second after the charge voltage selection. NOTE: Charging can be stopped at any time by pressing the charge start/ stop button (8) again. NOTE: To reactivate the security functions, turn the charger off and on again. 11

12 OPERATION AS BOOST STARTER This battery charger is equipped with a boosting system that will let you start your vehicle without damaging the electronics on board your vehicle. WARNING: BOOST STARTS MUST BE PERFORMED WHEN THE BATTERY IS STILL MOUNTED ON THE VEHICLE. IT IS SUGGESTED TO PERFORM A NORMAL CHARGE AT THE MAXIMUM CURRENT FOR 10/15 MINUTES BEFORE YOU TRY TO BOOST YOUR VEHICLE. WARNING: THE BOOST PROCESS ACTIVATES ONLY IF THE BATTERY CHARGER IS CONNECTED TO A BATTERY THAT COMPLIES WITH THE FOLLOWING MINIMUM VOLTAGE VALUES: MORE THAN 7.5V FOR 12V BATTERIES: MORE THAN 18V FOR 24V BATTERIES. THE CORRECT PROCEDURE TO BOOST YOUR VEHICLE IS: 1. Connect the black cable to the minus terminal of the battery. 2. Connect the red cable to the required 12V/24V positive socket. Insert the plug on the cable into the socket (12) on the front of the battery charger and then turn the plug clockwise in order to lock it in place. Make sure the socket selected is correct for the battery being charged. 3. Connect the clamp on the red cable to the positive terminal of the battery. 4. Connect the battery charger to the mains. Check that the socket is equipped with protection fuses or circuit breakers. 5. Switch ON the battery charger. The green led will light. 6. Before starting the boosting procedure is advisable to perform a fast charge with the maximum current for minutes. 12

13 7. Push the boost start/stop button (9) and then try to start the vehicle. The battery charger will start to supply energy to the battery. If the boost is not successful, wait a few minutes and try again. To prevent damage to your battery, the boost function will not be carried out if the battery is damaged (short circuit or broken elements). If the Over-temperature protection activates, the yellow LED (3) will light up and the battery charger will not work until it has cooled sufficiently. 8. Once the vehicle starts, the battery charger will automatically stop supplying current. Press the boost start/stop button (9). 9. Disconnect the cables from the battery and replace the battery caps. Switch OFF the battery charger, disconnect it from the mains supply and store it in a dry place 13

14 SPECIFICATIONS Input Voltage Input Power Output Voltages (Battery Voltages) Max charging current Charging current according to EN norms Max boosting current Boost Start with 1V/cell Max battery size to be charged in 15 hours Product Dimensions Weight 50-60Hz 800W 12V, 24V 30A 30A 500A 350A (12V), 310A (24V) 375Ah 345 x 250 x 280 mm 20 kg 14

15 WIRING DIAGRAM 15

16 PARTS DIAGRAM 16

17 PARTS LIST No DESCRIPTION PART NUMBER 01 FRONTAL-CONTROL PC BOARD EM THERMOSTAT EM PLASTIC HANDLE EM UPPER PANEL EM THERMOSTAT VEBE EM CABLE CLAMP FOR CABLE EM INPUT CABLE EM FRONT FRAME EM FRONT PANEL EM POLYCARBONATE PLATE EM RED KNOB EM DOUBLE POLE SWITCH EM CABLE CLAMP EM LOWER PANEL EM POWER PCB EM RECTIFIER EM TRANSFORMER EM FUSE HOLDER BOX EM FUSE EM SMALL FUSE COVER EM FEMALE DINSE PLUG EM BLACK CABLE EM CLAMPS 120A FOR BATTERY CHARGING.RED-BLACK EM RED CABLE EM DINSE PLUG EM

18 18

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