Powergen EAGLE HF Instruction Manual

EAGLE HF - INSTRUCTIONS MANUAL

RELEASE. N.0_M 02_04_0 8
POWERGEN S.R.L. VIA XXV APRILE , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) +39- (0)575-531015 - Telefax [phone] E mail [e-mail]

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EAGLE HF

Three Phase Switching Battery Charger

Instructions manual (UK)
Warranty (UK)

Read the following instructions carefully before connecting the charger to the mains
and to the battery.

EAGLE HF - INSTRUCTIONS MANUAL

RELEASE. N.0_M 02_04_0 8
POWERGEN S.R.L. VIA XXV APRILE , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) +39- (0)575-531015 - Telefax [phone] E mail [e-mail]

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q INDEX

1. INSTALLATION........................................................................................................................5

2. CONNECTION TO THE MAIN VOLTAGE...........................................................................5

3. MAINTENANCE........................................................................................................................6

4. OPERATION..............................................................................................................................7

5. WARRANTY ........................................................................................................................... 10

5.1 Problem - Solutions and checks ...........................................................................11

6. REQUEST OF SPARE PARTS AND/OR SERVICE REQUEST...................................12

7. TECHNICAL NOTE...............................................................................................................13

CONFORMITY DECLARATION........................................................................................... 14

ORDER FOR SPARE PARTS BATTERY CHARGER ........................................................... 17

WARRANTY CERTIFICATE................................................................................................ 18

EAGLE HF - INSTRUCTIONS MANUAL

RELEASE. N.0_M 02_04_0 8
POWERGEN S.R.L. VIA XXV APRILE , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) +39- (0)575-531015 - Telefax [phone] E mail [e-mail]

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EAGLE HF

Three Phase Switching Battery Charger

All EAGLE battery chargers are conform to the following European standard

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.

EAGLE HF - INSTRUCTIONS MANUAL

RELEASE. N.0_M 02_04_0 8
POWERGEN S.R.L. VIA XXV APRILE , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) +39- (0)575-531015 - Telefax [phone] E mail [e-mail]

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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 charger to the

main voltage and to the battery.

EAGLE HF - INSTRUCTIONS MANUAL

RELEASE. N.0_M 02_04_0 8
POWERGEN S.R.L. VIA XXV APRILE , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) +39- (0)575-531015 - Telefax [phone] E mail [e-mail]

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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 tractio n 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 TIGHTN ESS.

POWERGEN s.r.l.

2. CONNECTION TO THE MAIN VOLTAGE

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 suitable for a 400 - 415 VAC three-phase mains supply.

EAGLE HF - INSTRUCTIONS MANUAL

RELEASE. N.0_M 02_04_0 8
POWERGEN S.R.L. VIA XXV APRILE , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) +39- (0)575-531015 - Telefax [phone] E mail [e-mail]

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3. 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 charger 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 :

- 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.

EAGLE HF - INSTRUCTIONS MANUAL

RELEASE. N.0_M 02_04_0 8
POWERGEN S.R.L. VIA XXV APRILE , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) +39- (0)575-531015 - Telefax [phone] E mail [e-mail]

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4. OPERATION

EAGLE HF is a high frequency three phases battery charger developed in switching mode topology. It is
controlled and supervised by a microprocessor electronic card engineered with a superficial component
assembly SMD (Surface Mount Device).

The controller is an electronic card developed and customized for the specific control of battery chargers . It
is a flexible and modular unit able to satisfy all requirements connected to the recharging of batteries in
general and to specifically resolve all that is necessary for the final utilisation.

In particular, the unit is composed by a mother card (main board) and of various daughter cards among
these, a CPU card, a display card, a transceiver radio card, and a remote Battery Monitor device.

The controller is completely programmable and easy to use thanks to the userfriendly graphic interface
shown on the display. Organised by menu, the display allows to setup configuration data and parameters
and reports measures during the charge.

During the charging cycle the graphic display permits the visualisation of the following real time measures:

- battery voltage and battery cell voltage,

- battery current,

- output power of the battery charger,

- duration of the complete charging cycle and the duration of the charging phase in process,

- integrated capacity during the charging cycle,

It shows the status of the battery charger, the charging phase and many additional information present in the
menu.

The user can access the following menu:

- Battery,

- Counters,

- Charging mode,

- Setting,

- Alarms,

- Historical data,

- Connectivity

- Info.

In the Battery folder the user can find the settings listed below:

- nominal battery voltage,

- range of battery voltage (min and max),

- battery current (min and max),

- Ah capacity to integrate in the charging cycle (it is possible to change the value to adjust correctly for
the battery ).

In the Counters menu it is possible to modify the delay of the automatic start, by default it is set to 10” after
the connection of the main voltage and the battery. It is possible to set the delay to 2, 4, 6 or 8 hours.

In the Ch arging mode folder it is shown the reference of the charging curve.
In the Settings menu the user can modify the following;

- the display language,

- control card date and time,

EAGLE HF - INSTRUCTIONS MANUAL

RELEASE. N.0_M 02_04_0 8
POWERGEN S.R.L. VIA XXV APRILE , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) +39- (0)575-531015 - Telefax [phone] E mail [e-mail]

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- password to access the menu (by default the password is 1234).

In the Alarms folde r it is shown the list of the the alarms present during the charging cycle.
Inside the Historical log menu the user can find the relevant data of all the charging cycles.
The Connectivity menu points out if the wireless connectivity is enabled.
In the Info folder Info the user can find general information about the charger:

- charger voltage and current,

- microcontroller firmware release,

- charger serial number.

In parallel to the logic of the battery charging process which follows the specific charging curve, the charger
verify automatically, during the process, the achievement of the Ah capacity integrated. Once the controls
have been activated, the charge concludes on the satisfaction of the conditions of at least one of the
controls.

In the events that the charger doesn’t operate in stand-alone configuration, but is provided with the
radio transceiver card and the Battery Monitor remote unit, we achieve instead an efficient charge
system in able to keep account of the actual charge and discharge processes of the battery.

The remote unit calculates the actual discharged capacity and communicates to the central unit of the
battery charger the exact value of capacity to reintegrate in the course of charging cycle.

The charger control unit is able to detect the malfunctioning alarms of the charging cycle and submit them to
the user through an appropriate menu for management and resolution of the same.

At the end of each charging cycle, relevant data are saved inside the historical logs and remain allocated in
the microcontroller memory for further use or analysis.

The control card is provided with a basic circuitry able to carry out the standard control operations for the
battery charger and of optional circuitry’s for the added operation implementation and to satisfy specific
requirements.

The control card is provided with:

- real-time clock and calendar,

- internal microcontroller and external watchdog hardware,

- USB communication interface,

- CPU card,

- Display card,

- Radio Transceiver card (optionally to communicate with BatMon devices).

The real-time clock has the functions of a system clock that supplies a temporary reference useful for
associating a temporary position to the events and facilitate the memorisation, the recall and the analysis.

The external hardware wa tchdog is attained with an electronic circuitry external to the micro-controller and
dedicated capable to verify the correct functioning of the microprocessor. You add it to the existing watchdog
hardware circuit to increase global reliability of the controller unit.

The USB communication interface allows to connect the battery charger to a personal computer by using
a standard USB communication cable. The communicating interfaces equipped of an applicable original
software that allows the programming and the setting of all the parameters of the machine, the calibration of
the measuring instruments volt/ampere-metrical put at the interface disposal two analogue signals of
communication wireless and not, the past data download and the functionality of analysis and reportage.

EAGLE HF - INSTRUCTIONS MANUAL

RELEASE. N.0_M 02_04_0 8
POWERGEN S.R.L. VIA XXV APRILE , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) +39- (0)575-531015 - Telefax [phone] E mail [e-mail]

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Lastly, the controller unit can be interfaced at external device or a sensor through internal analogue and
digital signals and a clean exit contact.

The CPU card accommodates a micro-controller at 8-bit based on RISC architecture equipped with 128k
memory flash and an extra external memory flash of the capacity equal to 4Mbit. The microprocessor on
board is responsible of all the functions and the controls the same controller unit.

The display card is provided of a liquid -crystal graphic display 64 x 128.
The radio transceiver card has a transceiver form FSK multi-channel completely programmable, PLL with

double frequency conversion and selectable channels through software, working in the 434 MHz band. In
transmission, the form presents a typical potency up to 10 mW (+10 dbm), while the sensibility in receiving
reaches – 108 dbm. The exit power of the transmitter is adjustable in a digital manner, and is kept constant
by a control at closed loop. The double conversion at medium frequency together with the use of a SAW filter
in entry renders the device highly selected, immune to the adjacent channel interference and perfectly
compatible with the regulations.

ATTENTION, PLEASE:

BEFORE DISCONNECTING THE CONNECTOR BETWEEN THE BATTERY AND THE
CHARGER, PLEASE, MAKE SURE THE CHARGE 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.

EAGLE HF - INSTRUCTIONS MANUAL

RELEASE. N.0_M 02_04_0 8
POWERGEN S.R.L. VIA XXV APRILE , 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) +39- (0)575-531015 - Telefax [phone] E mail [e-mail]

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5. 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

EAGLE HF - INSTRUCTIONS MANUAL

RELEASE. N.0_M 02_04_0 8
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 -

5.1 PROBLEM – SOLUTIONS AND CHECKS

PROBLEM SOLUTIONS AND CHECKS

The battery charger is not starting

- Check the alarms list

- 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

The battery charger is not charging
sufficiently

- Make sure the three phases for line input are present

The battery charger is delivering an
excessive charge

- Make sure the control panel is preset for the type of battery used (correct choise of battery cells amount)

The system is efficient, though the
battery cannot keep the autonomy for
the required time

- Check the batteries’ status (sulphated battery – faulty cells)

EAGLE HF - INSTRUCTIONS MANUAL

RELEASE. N.0_M 02_04_0 8
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) +39- (0)575-531015 - Telefax [phone] E mail [e-mail]

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

__ __ __ __ __ __

/

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EAGLE HF - INSTRUCTIONS MANUAL

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7 TECHNICAL NOTE:

• 400V or 230V three-phase supply (with possibility to request voltages different from the
standard ones), adjustable to ± 5% or ± 10%

• Microprocessor-controlled programming and measuring via digital gearcase. Such
microprocessor control is designed to optimize the charging cycles for any type of battery.

• Three mains input fuses

• Auxiliary transformer suitable to supply the external fans.

• DC fuse on rectifier output

• DC output polarized cables

• Modular installation on galvanized steel base

• Sheet steel case with modular panels so as to assure maximum accessibility in case of service.

• Epoxy powder coating, oven-baked

• Standard colour: RAL 5015 Bleu

• Lab-tested electronic circuit conforming to the directive on electomagnetic compatibility and CE
marking.

• Automatic Start

• Automatic disconnection of battery charger due to battery disconnection

• Smart charging system according to the discharge level of the battery

• Short check of functions and times

• Option: custom -made colour

• Custom -made logo and silk-screen printing

• Final acceptange test conforming to safety regulation

• Complete with mains and battery cables; assembly of plugs and battery connectors on request

• IUIa charging curve

EAGLE HF - INSTRUCTIONS MANUAL

RELEASE. N.0_M 02_04_0 8
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) +39- (0)575-531015 - Telefax [phone] E mail [e-mail]

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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 EAGLE______

Serial N° __________ manufacturing year 200__

Complies with the following standards:

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

EAGLE HF - INSTRUCTIONS MANUAL

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NOTE

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EAGLE HF - INSTRUCTIONS MANUAL

RELEASE. N.0_M 02_04_0 8
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) +39- (0)575-531015 - Telefax [phone] E mail [e-mail]

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NOTE

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EAGLE HF - INSTRUCTIONS MANUAL

RELEASE. N.0_M 02_04_0 8
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) +39- (0)575-531015 - Telefax [phone] E mail [e-mail]

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ORDER FOR SPARE PARTS BATTER Y 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]

__ __ __ __ __ __

/

__ __

EAGLE HF - INSTRUCTIONS MANUAL

RELEASE. N.0_M 02_04_0 8
POWERGEN S.R.L. VIA XXV APRILE, 5 LOC. CORSALONE CHIUSI DELLA VERNA (AREZZO)
) +39- (0)575-531015 - Telefax [phone] E mail [e-mail]

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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° ____________________________

EAGLE HF - INSTRUCTIONS MANUAL

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Thank y

ou 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 pur

chaser 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 certificate 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 exclus

ively 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 warranty is not applied in case of damages caused by

negligence, use or installation no

t complying with the delivered

instructions, damages caused by interventions performed by

unauthorized persons, damages due to accidental causes or to the

purchaser’s negligence. Moreover it is not applied in case of faults

resulting from connections of th

e 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 inductive/electrostatic discharges or flashovers caused by
lightnings or other pheno mena 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 part

s and the labour costs according to ANIE rates or

equivalent ones.