BATTERY BOOSTER/CHARGER...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

BATTERY BOOSTER/CHARGERMODEL NO: DIGICAR 600

PART NO: 6261200

OPERATION & MAINTENANCEINSTRUCTIONS

LS0815

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INTRODUCTION

Thank you for purchasing this CLARKE Battery booster / charger which is suitable for charging and boosting 12 + 24 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.

2arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

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SAFETY PRECAUTIONS

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.

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.


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ELECTRICAL CONNECTIONS

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.

The recommended supply current for this unit is 25A, the supply should therfore be fitted with a 25A rated

circuit breaker

IMPORTANT: The wires in the mains lead are coloured in accordance with the following code:

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.

WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS THOROUGHLY.

WARNING: A 13 AMP (BS1363) PLUG IS NOT SUITABLE.

WARNING: THIS APPLIANCE MUST BE EARTHED

Green & Yellow Earth

Blue Neutral

Brown Live


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ASSEMBLY

FITTING THE HANDLE1. 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

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.

WARNING: NEVER ATTEMPT TO RE-CHARGE NON-RECHARGEABLE BATTERIES.


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CHARGING MORE THAN ONE BATTERY 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.

WARNING: DO NOT CHARGE BATTERIES WITH DIFFERENT CAPACITIES OR DIFFERENT TYPES OF BATTERIES AT THE SAME TIME.


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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 “Over-temperature” 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


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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 11.

1. 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.


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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.


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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.


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FORCED CHARGING

Use forced charging if the battery voltage is below 7.5V for 12V batteries or 18V for 24V batteries.

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.





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 “12”.

8. 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.

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.


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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.

THE CORRECT PROCEDURE TO BOOST YOUR VEHICLE IS:

1. Connect the black cable to the minus 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 10-15 minutes.

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.


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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


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SPECIFICATIONS

Input Voltage 230V @ 50-60Hz

Input Power 800W

Output Voltages (Battery Voltages) 12V, 24V

Max charging current 30A

Charging current according to EN norms 30A

Max boosting current 500A

Boost Start with 1V/cell 350A (12V) , 310A (24V)

Max battery size to be charged in 15 hours 375Ah

Product Dimensions 345 x 250 x 280 mm

Weight 20 kg


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WIRING DIAGRAM


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PARTS DIAGRAM


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PARTS LIST

No DESCRIPTION PART NUMBER

01 FRONTAL-CONTROL PC BOARD EM22700019

02 THERMOSTAT EM22210014

03 PLASTIC HANDLE EM21600030

04 UPPER PANEL EM33705380 3020

05 THERMOSTAT VEBE EM04600276

06 CABLE CLAMP FOR CABLE EM04600233

07 INPUT CABLE EM20220016

08 FRONT FRAME EM21690326

09 FRONT PANEL EM33710437 9005

10 POLYCARBONATE PLATE EM77650281

11 RED KNOB EM04600332

12 DOUBLE POLE SWITCH EM22200043

13 CABLE CLAMP EM04600233

14 LOWER PANEL EM33700187 3020

15 POWER PCB EM22700020

16 RECTIFIER EM22400096

17 TRANSFORMER EM44105083

18 FUSE HOLDER BOX EM21690113

19 FUSE EM22220030

20 SMALL FUSE COVER EM21690109

21 FEMALE DINSE PLUG EM22100002

22. BLACK CABLE EM43200016

23 CLAMPS 120A FOR BATTERY CHARGING.RED-BLACK EM04600067

24 RED CABLE EM43200026

25 DINSE PLUG EM22100001


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Documents

BATTERY BOOSTER/CHARGER...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