Powergen Smart 3000 Instruction Manual

INSTRUCTIONS MANUAL SMART 3000

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 -

Smart 3000

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 SMART 3000

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. TECHNICAL NOTE................................................................................................... 11

CONFORMITY DECLARATION............................................................................................... 12

ORDER FOR SPARE PARTS BATTERY CHARGER .............................................................. 13

WARRANTY CERTIFICATE...................................................................................... 15

INSTRUCTIONS MANUAL SMART 3000

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 -

Smart 3000

Battery Charger

Versions: Single/Three_Phase

All battery chargers Smart 3000 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 SMART 3000

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 SMART 3000

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.

q Make sure also the EARTH cable has been correctly connected.
q The unit comes connected for a 400V three-phase line.

INSTRUCTIONS MANUAL SMART 3000

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 mains

voltage of the supply line which, 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 230V

WARNING

Connect the auxiliary
Transformer at 400V

WARNING

INSTRUCTIONS MANUAL SMART 3000

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 - 7 -

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 Smart 3000 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 SMART 3000

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 ( Green) Battery connected – Initial charge. Charge starts and voltage per cell is

lower than 2.4V.

Led 3 (Yellow) Final charge. Shows voltage per cell is higher than 2.4V. The charging
process continues for 3 – 4 hours and at 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 now.

Led 5 (Red) Maximum time. Lights if the battery charger has not completed its charging
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 preset time of 48 hours (weekend 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 SMART 3000

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

startup.

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 SMART 3000

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 SMART 3000

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.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 41773 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.

__ __ __ __ __ __

/

__ __

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 41773 standard,
see table “Addition of a second charging stage”

INSTRUCTIONS MANUAL SMART 3000

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 -

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 Smart 3000

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 SMART 3000

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 - 13 -

ORDER FOR SPARE PARTS BATTERY CHARGER

Powergenprocessor

Customer’s stamp and signature

Fill in and send to:

Powergen Italia 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 SMART 3000

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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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 SMART 3000

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 - 15 -

WARRANTY CERTIFICATE

Powergenprocessor ________________

Customer’s stamp and signature

Fill in and send to:

Powergen Italia 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 SMART 3000

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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Thank you very much for chosing our product. Con

gratulations 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 certificate and it cannot be extended

due to the inactivity of the equipment caused by repair.

3. The warranty only covers fa

ults 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 warranty is not applied in case of damages caused by

negligence, use or installation not complying with the delivered

instructio

ns, 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 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 inductive/electrostatic

discharges or flashovers caused by lightnings or other

phenomena outside the equipment.

5. Parts sub

ject 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.