Powergen Digit 3001 Instruction Manual

INSTRUCTIONS MANUAL DIGIT 3001

RELEASE. N.2_M 13_10_08
POWERGEN S.R.L. VIA XXV APRILE , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

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 , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

www.batterychargerpowergen.it P.Iva 01572290516 - 2 -

q INDEX

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

6.1 Problem - 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 , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

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 , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

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 , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

www.batterychargerpowergen.it P.Iva 01572290516 - 5 -

1. INSTALLATION

q The installation environment shall be capable of ensuring the User’s safety and the

conditions for a correct operation.

q Powergen Processor battery charger is exclusively designed to recharge traction

batteries and each unit is assigned to a specific battery.

q Powergen 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.

q Do not lay any materials which may obstruct the natural cooling air flow.
q The 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

q It 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)

q Make sure also the EARTH cable has been correctly connected.
q The unit comes pre-set for a 400÷415 VAC three-phase mains supply.
q The single phase unit comes is pre-set for a 230 - 240 VAC.
q Should 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 , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

www.batterychargerpowergen.it P.Iva 01572290516 - 6 -

3. MAINS VOLTAGE SETTING

q During 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.

q As a result, check this value and adjust it, if needed, via the ADJUSTING PLUGS

placed in the terminal board on the transformer.

q Such 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 , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

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4. MAINTENANCE

q No 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.

q Any maintenance intervention shall only be carried out after disconnecting the rectifier

from mains and from the battery.

q For 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 , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

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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 has not 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 , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

www.batterychargerpowergen.it P.Iva 01572290516 - 9 -

6. WARRANTY
q The duration of the battery charger warranty is 12 (twelve) months from its start-

up.

q The warranty covers all proven defects in components, assembly and

construction.

q Any incorrect installation or use of the charger NULLIFIES the warranty.
q The warranty is void due to improper use, incorrect installation or tampering
q The 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, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

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)

INSTRUCTIONS MANUAL DIGIT 3001

RELEASE. N.2_M 13_10_08
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

www.batterychargerpowergen.it P.Iva 01572290516 - 11 -

7. REQUEST OF SPARE PARTS AND/OR SERVICE REQUEST
q We recommend to always advise the serial number of the battery charger.

8. DIGIT 3001

DIGIT 3001 allows to select the operation modes and the execution time of charging
cycles via dip-switch DSW1 included in the card:

- Operation mode: programming (Program) or charge (Charge);

- Operation time: normal (Normal) or concentrated (Test). In Test mode, time is

reduced by a factor 60, for example 1 hour = 1 minute.

Switching between operation modes and between execution times can be done by directly
selecting the correct position of the dip-switch, as shown on the card silk screen print,
without disconnecting the supply during the charging cycle and in the programming
phases.

DIGIT 3001 is provided with a control panel with six LED's displaying the operating status
of the battery charger, with a four digit display showing the charging parameters and with a
keyboard to programme and read parameters and functions settings.
This card is also provided with a standard serial interface RS232 for communication with
Personal Computer and external devices.

The LED's included in the control panel show the following conditions:

1. red LED power failure

2. yellow LED battery connected

3. yellow LED timed charging cycle

4. green LED charge completed

5. red LED safety cycle

6. yellow LED equalized charge

__ __ __ __ __ __

/

__ __

INSTRUCTIONS MANUAL DIGIT 3001

RELEASE. N.2_M 13_10_08
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

www.batterychargerpowergen.it P.Iva 01572290516 - 12 -

GLOSSARY

Symbol Description

Prog

PROGRAMMING

Bdis

BATTERY DISCONNECTED

Stop

CYCLE STOPPED

End

CYCLE CONCLUDED

Umin

BATTERY MINIMUM VOLTAGE

Umax

BATTERY MAXIMUM VOLTAGE

Equ

EQUALIZED CHARGE CYCLE

Sto

CYCLES REALIZED (THE LAST 10)

Def

DEFAULT PARAMETERS

8.1. Operation mode: PROGRAMMING

DIGIT 3001 is fully programmable in all its functions and widely configurable in every
charging parameter. This feature gives the card extreme flexibility, thus facilitating its use
in numerous applications.

Following parameters can be set via this card:

- amount of stages

- rated battery voltage

- battery threshold voltage

- charging time in timed charging cycle

- maximum safety cycle time

- battery minimum voltage

- battery maximum voltage

- battery minimum current

- charging mode

- capacity delivered to the battery.

After selecting programming mode and after connecting at least one of the supply
sources, “ProG” will be shown on the display and the User will be enabled to set

the charging parameters. By pressing “A/V” button in the middle the User will be able to
browse the programming menu, to scroll the lines and to confirm the settings. Setting
values are increased and decreased via the “EQU” button on the right-hand side and the
“ON/OFF” button on the left-hand side, respectively. The auto repeat function is
implemented in the right and left hand buttons. This allows to automatically increase or
decrease the setting values by keeping relevant button pressed.

INSTRUCTIONS MANUAL DIGIT 3001

RELEASE. N.2_M 13_10_08
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

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The programming menu consists of 10 lines:

1. amount of stages: single (Wa charge) "St1", or dual (Wo-Wa charge) "St2";

2. rated battery voltage: “24”, “36”, “40”, “48”, “72”, “80”, “96”;

3. battery threshold voltage: is related to the rated battery voltage. The value may be set from a
minimum equal to the minimum battery voltage up to a maximum equal to the maximum battery
voltage.

4. charging time in timed charging cycle: the value may be set from a minimum of 0 to a maximum of
600 minutes;

5. maximum safety cycle time: the value may be set from a minimum of 0 to a maximum of 960
minutes;

6. minimum battery voltage: the value may be set from a minimum of 0 to a maximum equalling the
set threshold voltage;

7. maximum battery voltage: the value may be set from a minimum equalling the threshold voltage to
a maximum of 3V multiplied by the amount of cells;

8. minimum battery current*: the value may be set from a minimum of 4.4A to a maximum of 40.4A;

9. charging mode**: “00” or “01”;

10. capacity to be integrated (ampere-hours to be integrated into the battery)***: the value may be set
from a minimum of 0Ah to a maximum of 9999Ah.

*Minimum battery current: is the threshold of minimum charging current below which,
during the timed cycle, the charging cycle will be interrupted, provided the voltage/cell
is > 2.5V.

**Charging mode: with charging mode "00", the timed charging cycle shall be entirely
performed as programmed in point 4. With charging mode "01", if the battery voltage
reaches the threshold voltage in more than 2 hours, the timed charging cycle shall be
entirely performed as programmed. Otherwise the timed charging cycle shall be
performed for half of the set time.

*** Capacity to be integrated: is given by the total ampere-hours to be delivered to the
battery during the charging phase.

During the programming phase, some presetting values are proposed and displayed for
each programming line in order to facilitate configuration operations, after selecting the
rated value of battery voltage. Such values can be modified by the User within the
available range however, as specified above.

The control card also allows to retrieve the setting of default values by following a specific
procedure.

8.2. Operation mode: CHARGE

The normal charging cycle occurs via the following phases: an initial non-clocked cycle
which will take the battery to the threshold voltage. After reaching such voltage the cycle
will stay in initial charge for another three minutes, then the timed cycle will start and allow
the battery to complete the charge.
In the case of a dual stage, WoWa charge, the timed cycle is performed with a charging
current lower than the one of the initial charge.

In parallel to the described operation logic, which provides a voltage control followed by a
time control for the charge, DIGIT 3001 can also automatically activate a charge
completion control, if correctly set, which verifies the ampere-hours integrated into the
battery (see line no. 10 of the programming menu) and the minimum value of current
being delivered (see line no. 8 of the programming menu). Once these controls have been
activated, the charge will be completed when the conditions of at least one of said controls
are fulfilled.

INSTRUCTIONS MANUAL DIGIT 3001

RELEASE. N.2_M 13_10_08
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

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8.2.1. Functions and Displayed Messages

After selecting the charge mode and after connecting the mains supply and the battery
(the sequence is irrelevant), the charging cycle will be activated. This will start

automatically after about 5 seconds. “nor” will be shown on the display.
During the charge, by pressing the middle "A/V" button, the User will be able to browse the

display menu and to scroll and read the following parameters in real time:

- charging mode: “A. XXX” expressed in amps;

- battery voltage: “U.XXX” expressed in volts;

- voltage per cell: “E.XXX” expressed in volts;

- Total charging time: “t.XXX” expressed in minutes;

- charging time in timed charging cycle: “F.XXX” expressed in minutes;

- delivered capacity (ampere-hours integrated into the battery): “AH.” ,

“XXXX” expressed in ampere-hours. The value is shown in two
subsequent displays. Display “XXXX” is shown automatically after about

1 second from display “AH.” .

At the end of the charging cycle, “End” will be shown on the display. By
pressing the middle "A/V" button, the User will be able to browse the display menu and to
scroll and read the latest values of the charging parameters:

- charging current: “A. XXX”;

- battery voltage: “U.XXX”;

- voltage per cell: “E.XXX”;

- Total charging time: “t.XXX”;

- charging time in timed charging cycle: “F.XXX”;

- delivered capacity (ampere-hours integrated into the battery): “AH.” “XXXX”. The

value is shown in two subsequent displays. Display “XXXX” is shown automatically
after about 1 second from display “AH.”

When entering the display menu, after ten seconds of buttons inactivity, the display will
show “End” message again. By pressing the middle button again, real time

readouts are scrolled. As the charging cycle has finished, the only active readouts are
those of battery voltage and voltage per cell. The others are all set to zero.

INSTRUCTIONS MANUAL DIGIT 3001

RELEASE. N.2_M 13_10_08
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

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Once the charging cycle has started, it can be manually interrupted by pressing the left­hand “ON/OFF” button. “StoP” will be shown on the display. By pressing the

left-hand "ON/OFF" button again, the charging cycle will be enabled. This will be started
again automatically after 5 seconds. The cycle will resume from where it stopped.

The display menu is also available during the cycle interruption. By pressing the middle
"A/V" button, the User will be able to browse the display menu and to scroll and read the
following charging parameters:

- charging current in real time: “A. XXX”;

- battery voltage in real time: “U.XXX”;

- voltage per cell in real time: “E.XXX”;

- Total time of performed charge: “t.XXX”;

- charging time of performed timed cycle: “F.XXX”;

- delivered capacity (ampere-hours integrated into the battery): “AH.” “XXXX”. The

value is shown in two subsequent displays. Display “XXXX” is shown automatically
after about 1 second from display “AH.”

Should mains voltage fail during the operation of the charging cycle, this will be interrupted
and “StoP” will be shown on the display. Once mains voltage is restored, the

cycle will start again automatically after 5 seconds from where it stopped.
In case of battery disconnection during the charging cycle, this will be interrupted and

“UMIn” will be shown on the display first and then “bdIS” . As soon as
the battery is reconnected, the cycle will resume its operation from the start (initial charge),

setting to zero the active time meters, if any. “StoP” and then “nor”
will be shown on the display.

If the battery cable is disconnected when the cycle has finished or has not yet started,
“UMIn” will be shown on the display.

8.2.2. LED bar

During the charging cycle, the card will not only control the display of charging parameters,
but also the switching on/off of the LED's on the front panel (see General Description)
based on the following sequence:
in case of mains and battery present, before the cycle starts automatically, the second
LED "battery connected" will be steadily lit. Once the charging cycle has started (initial
charge) the same LED will start blinking. Once the battery threshold voltage is reached,
the third LED "timed cycle" will be steadily lit and after three minutes the timed charging
cycle will start and the LED will start blinking. After the time set in the timed cycle has
elapsed, the charging cycle will be completed and the fourth LED "charge completed" will
be steadily lit (the second one will remain steadily lit and the third one will be off).

INSTRUCTIONS MANUAL DIGIT 3001

RELEASE. N.2_M 13_10_08
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

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8.3. Equalization

The equalization function retrieves a charging cycle that provides the execution of 48
cycles lasting one hour, during which the battery charger will remain in standby for the first
55 minutes and will charge the battery for the remaining 5 minutes.
Such function may only be carried out after a full battery charge, and may be retrieved at
any time during the charging cycle before the cycle ends, by pressing the right-hand
"EQU" button. Once this function has been retrieved, it can be disabled by pressing the
"EQU" button again.

8.3.1. Displayed Messages

In case the equalization function has been retrieved, once the charging cycle has been
completed, “End” and then “EqU” will be shown on the display.

During the whole equalized charging cycle, the display menu proposes the following
parameters in real time, and the menu can be browsed by pressing the middle "A/V"
button:

- charging current: “A. XXX”;

- battery voltage: “U.XXX”;

- amount of completed charging cycles: “C.XXX”.

At the end of the equalized charging cycle, “End” will be shown on the display.

8.3.2. LED bar

During normal charging cycles, before completing the charge, the User may retrieve the
equalization function at any time, by pressing the right-hand "EQU" button. Once this
function has been accessed, the sixth LED "equalized charge" will light, reminding the
User of the reserved function. The reservation may be deleted by pressing the same
button again. The LED will be off.
During the equalization cycle, the previous LED will remain steadily lit in the 55 minutes of
standby and will blink in the 5 minutes of charge. The LED will be off when the cycle is
completed.
The second LED "battery connected" and the fourth LED "charge completed" will remain
steadily lit during the equalized charging phase and also after its end.

8.4. Charging Cycle Log

DIGIT 3001 includes a filing function of charge end data regarding the latest 10 completed
cycles. In particular, a cyclic memory buffer with 10 positions and FIFO filling modality
(First In First Out) has been implemented, based on which the first data entered are the
first to leave. After 10 completed cycles, the data of the oldest cycle (first in) are eliminated
in order to make space for those of the new cycle.
The charging data included in the charging cycle log may be retrieved and displayed at the

end of the charging cycle when “End” is shown on the display.

INSTRUCTIONS MANUAL DIGIT 3001

RELEASE. N.2_M 13_10_08
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

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Charge end parameters may be accessed starting from the ones of the most recent cycle
(indicated with -0 ) to the ones of the oldest cycle (indicated with -9 ),

and vice versa. Cycle –0 is retrieved by pressing the right-hand "EQU" button. Cycle –9 is
retrieved by pressing the left-hand "ON/OFF" button. Memory cells are browsed by
pressing the following buttons; via the "EQU" button the memory buffer is browsed from
cell –0 to cell –9 and the other way around via the "ON/OFF" button.

After selecting the concerned cell, “Sto” will be shown on the display. By
pressing the middle “A/V” button, the User will be able to browse the display menu and to
scroll and read the charging parameters stored for the selected cycle:

§ latest value of charging current delivered to the battery: “A.XXX” expressed in

amps;

§ latest battery voltage value: “U.XXX” expressed in volts;

§ total amount of charging minutes: “t.XXX”;

§ total charging capacity delivered (ampere-hours integrated into the battery): “AH”

and after 1 second “XXXX” expressed in ampere-hours.

After 10 seconds of buttons inactivity, the display will show “Sto” again and then
“End” .

8.5. Alarms and Safeties

DIGIT 3001 implements a whole series of alarms and safety functions, thus assuring a
reliable operation of the control card.

In case of power failures, the charging cycle will not be enabled and, if active, will be
interrupted. The first LED "power failure" will be steadily lit.

In case of programming errors in the rated battery voltage, the charging cycle will not be
enabled and the display will show relevant alarm messages “UMIn” and
“UMAH” .

During the charging cycle, if the battery voltage is lower than the minimum or higher than
the maximum set value, (see line no. 6 and no. 7 of the programming menu), the cycle will

be interrupted and the alarm messages “UMIn” and “UMAH” will be
displayed respectively.

During the charging cycle, the microprocessor controls the charging time and makes sure
the charge is completed in a time shorter than the one set as total charging time (see line
no. 5 of the programming menu). If not, it will interrupt the charging cycle, turn on the fifth

LED "safety cycle" and display the “End” message.
Also in this case the display menu will be available with the latest charging data, as well as

with the present data and the charging cycle log data.

INSTRUCTIONS MANUAL DIGIT 3001

RELEASE. N.2_M 13_10_08
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

www.batterychargerpowergen.it P.Iva 01572290516 - 18 -

8.6. Setting of Default Parameters

DIGIT3001 allows to retrieve the setting of default values based on the following
procedure:

- set dip-switch DSW1 to programming mode. "ProG" will be shown on the
display.

- press the right-hand “EQU” and the left-hand “ON/OFF” buttons simultaneously. "----"

will be shown on the display.

- keep both buttons pressed for about 5 seconds. At the end "dEF" will be
shown on the display and the default values will be accessed at this point;

- "ProG" will be shown again on the display after about 1 second and the
settings of charging parameters may be manually changed, if needed. Also the
charge may be started by setting the dip-switch to the correct charging position
(Charge).
With the present firmware version, the setting of default parameters refers to the
configuration of parameters for a 24V battery with Wa charge; in all the other cases
the User shall reconfigure the charging parameters manually as described in the
programming paragraph.

Monitor and supervision of the correct microprocessor operation via an external

supervising circuit

The supervising circuit is supplied with a watchdog timer to which pulses are periodically
sent by the microprocessor. If no pulses are present, the supervisor will reset the
microprocessor. The periodic transmission of pulses shows the correct operation of the
microprocessor.

Automatic recognition and charging cycle for sulphated batteries
DIGIT3001 is able to automatically recognize whether the battery to be charged is

sulphated or not. In particular, in the first minutes of charge DIGIT3001 keeps battery
voltage and charging current values under control. If the battery voltage exceeds the
threshold voltage and the charging current is lower than the minimum current set in the
programming phase, the control card determi nes that the battery is sulphated and the
charging cycle will not be allowed to switch to timed cycle. The initial cycle will be
maintained instead. Under these conditions the control will wait for battery voltage to drop
below the threshold voltage and then rise again above such value and when the charging
current exceeds the minimum value, it will allow the changeover to the timed charging
cycle.
As in the ordinary charging cycle, the safety alarms for maximum charging time and
minimum and maximum battery voltage are always active, as well as the current control.

INSTRUCTIONS MANUAL DIGIT 3001

RELEASE. N.2_M 13_10_08
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

www.batterychargerpowergen.it P.Iva 01572290516 - 19 -

9. TECHNICAL NOTE:
These charging systems are capable of charging the battery either with the
Wa characteristic according to DIN41774 standard (see table “one charging stage only”)
or, alternatively, when the charging time needs to be reduced, according to the WoWa
characteristic, based on DIN 41774 standard, see table “Addition of a second charging
stage”.
Such systems provide the possibility of carrying out timed equalized charges or voltage
sensing charges, see programming manual.

• Charge at decreasing current with intervention of the final charge at 2.40 V/cell

• Final charge with timed control 9h / 11h

• Fixed charging time (equalization charge excluded)

• Equalization charge (week-end charge) to be recalled. It will start after 55' from
charge end

• Duration of equalized charging phase: each hour 5' (repeated for 48 hours)

• Calculation to determine the size of suitable battery charge: 16A for every 100 Ah
of the battery (e.g. 500 Ah battery: 16Ax5 = 80A)

• Charge at decreasing current with intervention of the final charge at 2.42 V/cell

• Final charge with timed control 7h / 8h

• Fixed charging time (equalization charge excluded)

• Equalization charge (week-end charge) to be recalled. It will start after 55' from
charge end

• Duration of equalized charging phase: each 5' (repeated for 48 hours)

• Calculation to determine the size of suitable battery charge: 16A for every 100 Ah
of the battery (e.g. 500 Ah battery: 16Ax5 = 80A)

INSTRUCTIONS MANUAL DIGIT 3001

RELEASE. N.2_M 13_10_08
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

www.batterychargerpowergen.it P.Iva 01572290516 - 20 -

The Manufacturer Powergen S.r.l. with registered office in Via XXV Aprile, 5

Corsalone Chiusi della Verna (AREZZO)

DECLARES

that the battery charger of Powergenprocessor type Digit 3001______

Serial N° __________ manufacturing year 200__

Complies with the following standards:

q DIN 41772-3-4 : “Charging method and curve of transformers”.
q EN 60335–2-29 : “Safety of electrical appliances and similar”.
q EN 55014 : “E.M.C. standards”.
q 73/23/EEC : “Electric material used within specific voltage limits”, later

modified by directive 93/68/EEC;

q 89/336/EEC : “Electromagnetic compatibility”, later modified by directive.

92/31/EEC.

Powergen S.r.l.

CONFORMITY DECLARATION

INSTRUCTIONS MANUAL DIGIT 3001

RELEASE. N.2_M 13_10_08
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

www.batterychargerpowergen.it P.Iva 01572290516 - 21 -

NOTE

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INSTRUCTIONS MANUAL DIGIT 3001

RELEASE. N.2_M 13_10_08
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

www.batterychargerpowergen.it P.Iva 01572290516 - 22 -

NOTE

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INSTRUCTIONS MANUAL DIGIT 3001

RELEASE. N.2_M 13_10_08
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

www.batterychargerpowergen.it P.Iva 01572290516 - 23 -

ORDER FOR SPARE PARTS BATTERY CHARGER
Powergenprocessor

Customer’s stamp and signature

Fill in and send to:

Powergen S.r.l.
Via XXV Aprile , 5 Loc Corsalone Chiusi della Verna (AR)
tel [phone] - Telefax 0575-511891 www.batterychargerpowergen.it
e-mail adress [e-mail]
[e-mail]

__ __ __ __ __ __

/

__ __

INSTRUCTIONS MANUAL DIGIT 3001

RELEASE. N.2_M 13_10_08
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

www.batterychargerpowergen.it P.Iva 01572290516 - 24 -

Thank you very much for choosing our product.
Congratulations on your decision. This equipment is the
result of the most advanced technology and has been
manufactured according to the most rigorous quality
criteria.

Spare parts

PCB

Diode bridge

AC Fuse

DC Fuse

Contactor

INSTRUCTIONS MANUAL DIGIT 3001

RELEASE. N.2_M 13_10_08
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

www.batterychargerpowergen.it P.Iva 01572290516 - 25 -

WARRANTY CERTIFICATE

Powergenprocessor ________________

Customer’s stamp and signature

Fill in and send to:

Powergen S.r.l.
Via XXV Aprile , 5 Loc Corsalone Chiusi della Verna (AR)
tel [phone] - Telefax 0575-511891

www.batterychargerpowergen.it e mail adress [e-mail]

[e-mail]

Serial N° ____________________________

INSTRUCTIONS MANUAL DIGIT 3001

RELEASE. N.2_M 13_10_08
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) [phone] - Telefax [phone] E mail [e-mail]

www.batterychargerpowergen.it P.Iva 01572290516 - 26 -

Thank you very much for chosing our product. Congratulations on your

decision.

This equipment is the result of the most advanced technology and has

been manufactured according to the most rigorous quality criteria.

Powergenprocessor WARRANTY RULES

1.

The purchaser shall fill in and send the coupon in order to be entitled

to the warranty.

2.

The warranty duration is 12 (twelve) months from the date resulting

from the present certi

ficate and it cannot be extended due to the

inactivity of the equipment caused by repair.

3.

The warranty only covers faults on the product which cause

malfunctions. The guaranteed product shall also have the same

serial number as the one specified on the

present certificate,

otherwise the certificate will be void. Warranty is exclusively meant

as a free-of-

charge repair or replacement of components which have

been acknowledged to be faulty in their manufacture or material,

labour included.

4. The warrant

y is not applied in case of damages caused by

negligence, use or installation not complying with the delivered

instructions, damages caused by interventions performed by

unauthorized persons, damages due to accidental causes or to the

purchaser’s negligenc

e. Moreover it is not applied in case of faults

resulting from connections of the equipment to voltages other than

those specified, or from sudden voltage changes of the mains to

which the equipment is connected, as well as in case of faults

caused by indu

ctive/electrostatic discharges or flashovers caused by

lightnings or other phenomena outside the equipment.

5.

Parts subject to wear resulting from use are excluded from the

warranty.

6. The warranty is void after twelve months from the purchase. In this

case the service interventions will be performed charging for the

replaced parts and the labour costs according to ANIE rates or

equivalent ones.