BTC Rev G

Transcription

1 Rev G NSN: : Copyright Bren-Tronics, Inc. 2015

2 WARNING HIGH VOLTAGES ARE PRESENT IN THE OPERATION OF THIS EQUIPMENT Avoid contact with AC supply voltage connections during installation, operation or maintenance of the battery charger. CAUTION ACID CONTAMINATES NICKEL-CADMIUM, LITHIUM-ION, LITHIUM-POLYMER and NICKEL-METAL HYDRIDE BATTERIES Every effort must be made to keep Nickel-Cadmium, Lithium-Ion, Lithium Polymer and Nickel-Metal Hydride batteries as far away as possible from Lead- Acid batteries because Lead-Acid batteries contain sulfuric acid. Do Not use the same tools and materials, such as screwdrivers, wrenches, syringes, hydrometers, and gloves for both types of batteries. Any trace of acid or acid fumes will permanently damage Nickel-Cadmium, Lithium-Ion, Lithium Polymer and Nickel-Metal Hydride batteries on contact. WARNING NO SMOKING IS PERMITTED NEAR THE CHARGING STATION Batteries can produce explosive gases during charging or discharge cycles. Never smoke or allow open flames near the charging station. NOTICE TO PERSONS RECEIVING THIS DRAWING AND/OR TECHNICAL INFORMATION: claims proprietary rights in the material disclosed herein. This drawing and/or technical information is issued in confidence for information only and may not be reproduced or used to manufacture anything shown or referred to heron without direct permission from BREN- TRONICS INC. to the user. This drawing and/or technical information is loaned for mutual assurance and is subject to recall by BREN-TRONICS INC. at any time. This drawing and/or technical information is the property of Page 2 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

3 VMC Lite Operation Manual Table of Contents 1 INTRODUCTION SCOPE TECHNICAL SPECIFICATIONS DECLARATION OF CONFORMITY ACCESSORIES CHARGE CYCLE DESCRIPTION SEQUENTIAL CHARGE CYCLE DESCRIPTION MULTI-CHARGING CYCLE DESCRIPTION ADAPTER LOADING OPERATING PROCEDURES PANEL CONTROLS AND INDICATORS INSTALLATION PRELIMINARY SETUP PROCEDURES CHARGING BATTERIES BLACKOUT CHARGING STATUS LED QUICK REFERENCE CHARGER INSTRUCTION LABEL SOLID RED LED TROUBLE SHOOTING FLASHING RED LED TROUBLE SHOOTING OPERATION IN EXTREME ENVIRONMENTAL CONDITIONS REMOVING THE CHARGER FROM THE VEHICLE BATTERY STATE-OF-CHARGE DISPLAYS BATTERY CAPACITY RETENTION BATTERY STORAGE OPERATOR MAINTENANCE INSTRUCTIONS INTRODUCTION CLEANING INSPECTION BASIC FUNCTIONAL TEST ADAPTER REPLACEMENT INVERTING CONTROL PANEL TEXT SIMPLIFIED OPERATOR TROUBLESHOOTING PROCEDURES WARRANTY / REPAIR INFORMATION UPGRADE / UPDATE INFORMATION Page 3 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

4 1 INTRODUCTION 1-1 SCOPE There are various models of VMC Lite. While each model has unique input power requirements, all have the same volume and accept the same battery adapters. The adapters are also identical to those used with the BTC (PP-8481B/U). The VMC Lite is a state-of-the-art, high performance battery charger designed to be mounted to a vehicle. This allows batteries to be charged while the vehicle is moving or stopped. The charger can also be dismounted for shop usage. It provides fast reactivation of various rechargeable batteries. Depending on the adapters used, it is capable of sequentially charging up to eight batteries, one at a time, completely unattended. It can multi-charge up to eight batteries at once if the battery is cable of parallel charging (see asterisk in Table 1-4.1). This charger utilizes the same battery adapters, AC cable, and 24Vdc input cable as the PP-8481B/U. The VMC Lite contains mounting brackets and is designed to be mounted onto the wall or other fixture of a vehicle. The VMC Lite is simple to use by design. Without any user intervention, the VMC Lite typically charges fully depleted BB-2590 s or BB-390B s in less than 3 ½ hours. The charge time is substantially less for partially discharged batteries. Charge times vary based on battery type and the battery s state of charge. The Charger automatically identifies the specific battery type and provides the appropriate charge profile. Based on the current operating environment, the VMC Lite automatically customizes the charge profile to provide the quickest charge in a safe manner. The charge status for each of the batteries is conveyed to the user via easy-to-understand panel mounted LED indicators (amber CHARGE, green READY and red FAULT). The VMC Lite is universal by design. Depending on the specific model, it can be powered with universal AC mains, vehicle +12Vdc or vehicle +24Vdc. When operated with vehicle power, an Under-voltage Lockout Circuit prevents the Charger from excessively discharging the vehicle battery so there is always enough power to restart the vehicle. The VMC Lite is adaptive by design. It is microprocessor controlled and is presently programmed, with the appropriate battery adapter, to automatically charge over 25 different battery types as listed in the Table It can be readily field reprogrammed via its USB software upgrade port. This allows it to charge a countless number of additional battery types and chemistries including: Nickel Metal Hydride, Nickel Cadmium, Lithium Ion, and Lithium Polymer. The battery charger components are housed in a durable aluminum case. The assembled unit is watertight when the cover is securely latched and the pressure equalization screw on the side of the case (near the bottom) is closed. The text on the control panel is reversible so the unit may be reverse-mounted for use in vehicles such as the Stryker. Page 4 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

5 1-2 TECHNICAL SPECIFICATIONS Dimensions 16 in. (406 mm) W x 14 in. (356 mm) D x 8.0 in. (204 mm) H Weight.23 lbs (10.5 kg) Power Requirements.. & -GC AC operation Automatic selection: Vac, single-phase, Hz, 250VA (max) 24Vdc operation 22-33Vdc, 300W (max) -1 (VMBC)... NSN: Vdc operation 22-33Vdc, 300W (max) AC operation Automatic selection: Vac, single-phase, Hz, 250VA (max) 24Vdc operation 22-33Vdc, 250W (max) 12Vdc operation 11-33Vdc, 225W (max) Charging Output Voltage... Automatically selected for each battery type Duty Cycle Continuous Protective Features. Resettable circuit breakers for: Universal AC (3A), 24Vdc (20A), 12Vdc (20A) Operating Temp. Range -4 o F (-20 o C) to 122 o F (50 o C) Storage Temp. Range -40 o F (-40 o C) to 158 o F (70 o C) Case Color... Olive Drab #34094 per Fed-Std-595B Case Material..Powder-Coated Welded Aluminum* Shipment.. No restrictions *All versions of the VMC Lite are Powder-Coated except for the -GC. The -GC is electrically and mechanically identical to the, only with CARC (Chemical Agent Resistant Coating) paint. Page 5 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

6 1-3 DECLARATION OF CONFORMITY Page 6 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

7 Page 7 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

8 1-4 ACCESSORIES Table shows the various batteries and appropriate adapter plates the VMC Lite supports as of the writing of this document. Table Supported Batteries and Adapters Adapter Name NSN Part Number Battery/Position VMC-390/ J-6581/U (BTA-70820) BB-390/2590 Positions 1-4 (Figure 1-4.3) VMC-CSEL J-6583/U (BTA-70827) CSEL* Positions 4-7 (Figure 1-4.4) BB-2800 Position 1 BB-390/2590 Position 2 BB-2847 Position 3 VMC-MBITR (Figure 1-4.5) VMC-Universal (Figure 1-4.6) VMC-557/2557/2600 (Figure 1-4.7) VMC-FALCON (Figure 1-4.8) VMC-IISR (Figure 1-4.9) VMC-AA (Figure ) VMC-USLW (Figure ) VMC-Eagle (Figure ) J-6586/U (BTA-70830) MBITR* Positions 4-7 BB-2800 Position 1 BB-390/2590 Position 2 BB-2847 Position J-6520A/U (BTA-70841) BB-390/2590 Positions 1-2 BB-516A** Position 3 BB-326** Position 3 BB-388/2588 Position 4 BB-2847 Position 5 MBITR Position 6 BB-2800 Position J-6584/U (BTA-70843) BB-2600* Positions 1,2,3 BB-557/2557 Positions 4,5, J-6585/U (BTA-70880) Falcon* Positions 4-7 BB-2800 Position 1 BB-390/2590 Position 2 BB-2847 Position (BTA-70862) Motorola Positions 1-8 NNTN7032A* NTN9816A NTN9815A --- (BTA-70873) Ni-MH size AA Positions 1-6 Ni-Cad size AA --- (BTA ) LI-145* Positions 1-3 LI-80* Positions (BTA-70678) Eagle* Positions 1-8 VMC-SPR/Falcon/ --- (BTA ) SPR Positions /2590 Falcon* Position 5-6 BB-390/2590 Position 7 VMC-Falcon (8) --- (BTA ) Falcon* Positions 1-8 VMC-MBITR (8) --- (BTA ) MBITR Positions 1-8 VMC-Rifleman --- (BTA ) Rifleman Positions Page 8 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

9 NOTES: 1. * Battery is capable of parallel charging on the adapter specified; pictures shown on next page. 2. This list was complete at the date of publication. Additional adapters may be available, but may require updated software. 3. ** The BB-516A and BB-326 can only charge with AC power on the and -GC; and cannot charge on the -1. There is no limitation on the -3. Table Accessories Accessories Name NSN Part Number AC Cable, US Plug (Figure 1-4.1) CX (BTA ) AC Cable, Euro plug BTA AC Cable, UK plug BTA Vdc Cable, 8 ft. (Figure 1-4.2) CX (BTA ) 24Vdc Cable, 30 ft. BTA Vdc Cable BTA BB-390 Self Discharger PP-8497/U Page 9 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

10 Figure 1-4.1: VMC AC Adapter Cable Figure 1-4.2: DC Adapter Cable Figure 1-4.3: VMC-390/2590 Figure 1-4.4: VMC-CSEL Figure 1-4.5: VMC-MBITR Figure 1-4.6: VMC Universal Adapter Figure 1-4.7: VMC-557/2557/2600 Figure 1-4.8: VMC-FALCON Figure 1-4.9: VMC-IISR Figure : VMC-AA Figure : VMC - USLW Figure : VMC - EAGLE Page 10 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

11 1-5 CHARGE CYCLE DESCRIPTION Each of the battery types that are capable of being charged by the VMC Lite is connected to the charger via their respective battery adapter plate. Each adapter can independently charge one battery at a time. The appropriate battery adapter is installed into the adapter port and serves as the electrical interface between the batteries being charged and the charger circuits. The battery charger control circuits constantly monitor the following battery conditions during the charge cycle, as appropriate, to ensure that the battery is properly being charged: a. Temperature (T) b. Voltage (V) c. Current (I) d. Time (t) e. Voltage change ( V) f. Temperature rate of change ( T/ t) The charger operation during a typical charge sequence is automatic and the battery charge status is displayed to the user by the panel LED indicators as follows: a. Detection - The charger tries to detect a battery in an adapter. The CHARGE STATUS LED slowly blinks amber during this process. b. Pre-charge The charger brings the battery voltage up to a safe level before the rapid charge process begins. This step may take several minutes for a very discharged battery. The CHARGE STATUS LED rapidly blinks amber during this process. c. Fast Charge A timed fast charge cycle brings the battery to approximately 90% of full charge capacity. The CHARGE STATUS LED is lit steady amber during this process. d. Trickle / Top-off When fast charge is complete, the charger will top off of the battery to 100%. Each battery is charged for five minutes at a time (10 minutes for dual section batteries i.e. BB-390A/U, BB-390B/U, BB-2590/U, BB-557/U, BB-2557/U). For Lithium Ion and Lithium Polymer batteries the top-off cycle will stop after the battery is 100% charged. For all other types, the Trickle / Top-off cycle is repeated indefinitely to keep the battery at 100% charge. Leaving the battery on the charger will not harm the battery. The battery may be removed and used at this time. The CHARGE STATUS LED slowly blinks green during this process. e. Ready The fast charge cycle is complete. The Battery may be removed and used at this time. The CHARGE STATUS LED is lit steady green at this time. Page 11 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

12 NOTE The Battery may be removed and used at anytime during the charge cycle without damage to the charger or battery. If present, the state-of-charge indicator (SOC) will display the battery condition. NOTE After removing a battery from the charger, wait for the corresponding battery status LED s to turn off before installing a new battery. Page 12 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

13 1-6. SEQUENTIAL CHARGING CYCLE DESCRIPTION The VMC Lite can sequentially charge the supported batteries with the appropriate adapter. Using the Universal Adapter, the VMC Lite can automatically charge up to seven batteries in less than 12 Hours. Charge times will vary based on the battery type, state-of-charge and temperature. Other adapters can support a varying amount of batteries. The charging port can charge one battery at a time, except in the case of multi- charges the additional batteries that are waiting in queue. Sequencing to the other charging. Upon charge completion of the first battery, the charger sequentially positions is performed completely automatic and requires no intervention by the user. Figure VMC Lite with Universal Adapter During the sequencing process, the channel spends only as much time as is necessary to charge each battery to greater than 90% capacity. A partially charged battery will charge quicker than a totally discharged battery. It then sequences, in numerical order (Position 1, Position 2, Position 3 then back to Position 1, etc.) ), to the next battery in queue. As the channel sequences through the Positions and comes to a battery that has already been charged, it will attempt to Trickle or Top-off that battery (if necessary) for approximately 5 minutes (10 minutes for dual section batteries like the BB-390A/U U, BB-390B/U, BB-2590/U, BB-557/U, and BB-2557/U) and then continue onto the next Position. This means batteries added later may charge first, depending on their position on the charger. If certain batteries must be charged first, then this must be taken in to account. When the charger moves to a position it will charge or top off the battery at that position, as necessary. This allows batteries to be added or removed at anytime. The charger automatically keeps track of the current state of each Position. Page 13 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

14 1-7. MULTI-CHARGING CYCLE DESCRIPTION Along with sequential charging, the VMC Lite can also charge up to 8 batteries at once. The charger will automatically identify batteries than can be multi-charged; no special action is required by the user. This feature charges the batteries in parallel. For example, four standard MBITR batteries can be charged within 4 hours. Significant time savings will be noticed for smaller groups of batteries. Multi-Charging does not require any special setup. The Multi-Charging process works as follows. The VMC Lite has one high power charging channel. The unique characteristics of Lithium Ion batteries allow the charger to charge certain batteries in parallel. This allows the channel to use maximum power for a longer time. This can produce a large savings in time, charging four MBITR batteries simultaneously takes four hours compared to three hours for just one. The charging sequence is similar to normal battery charging with the exception that if a multi-chargeable battery is found the charger will pre-qualify it (status indicators flashing amber) and look for more. Incompatible batteries will be skipped, until later. When the charger can find no more batteries it will start the rapid charge phase. The status indicators will now be solid amber. As each battery finishes, the status indicators will turn green one at a time as each battery is completed. A battery with a green indicator can be removed and used as a normally charged battery. After the charger has completed the group, it will continue charging other single or grouped batteries as it finds them. To minimize charge time with Multi-Charging, a few rules apply. While the status indicators are yellow, removing a charging battery will restart the entire group. This is normal. If batteries are added after the LEDs have turned amber, they will not be added to the group. If the LEDs are still flashing amber then batteries can still be added to the group. This is true even if the charger has passed the position, it will go back until it has collected all the batteries to be charged. If there is a large quantity of batteries to be charged, grouping the batteries will save charge time. Batteries that have similar SOC indications should be grouped together. This prevents the almost fully charged batteries from having to wait for a fully discharged one to catch up. Some batteries are available in different capacities, but can still use the same adapters. Remember that multi- charging a group of batteries is always faster than charging them one at a time. (Note: Falcon II and Falcon III batteries, although similar, will not be grouped together for multi-charging.) Page 14 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

15 1-8. ADAPTER LOADING TABLE J-6520A/U (BTA-70841) UNIVERSAL ADAPTER/BATTERY POSITIONS BATTERY POSITION SUPPORTED BATTERIES BB-390A/U, BB-390B/U or BB-2590/U BB-390A/U, BB-390B/U or BB-2590/U BB-516A/U or BB-326/U BB-388/U, BB-388A/U or BB-2588/U BB-2847/U or BB-2847A/U MBITR BB-2800/U FIGURE 1-8.1aa NOTES: 1) Battery Position 4 cannot be used if batteries are placed into Position 3 and/or Position 6. 2) Battery Positions 3 and 6 cannot be used if a battery is placed into Position 4. FIGURE 1-8.1bb Page 15 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

16 TABLE J-6584/U (BTA-70843) - 557/2557/ ADAPTER/BATTERY POSITIONS BATTERY POSITION SUPPORTED BATTERIES BB-2600/U or BB-2600A/U BB-2600/U or BB-2600A/U BB-2600/U or BB-2600A/U BB-557/U or BB-2557/U BB-557/U or BB-2557/U BB-557/U or BB-2557/U FIGURE 1-8.2a NOTES: 1) Battery Position 1 cannot be used if a battery is placed in Position 4 and vise versa. 2) Battery Position 2 cannot be used if a battery is placed in Position 5 and vise versa. 3) Battery Position 3 cannot be used if a battery is placed in Position 6 and vise versa FIGURE 1-8.2b Page 16 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

17 TABLE J-6581/U (BTA-70820) - 390/25900 ADAPTER/ R/BATTERY POSITIONSS BATTERY POSITION SUPPORTED BATTERIES BB-390A/U, BB-390B/U or BB-2590/U BB-390A/U, BB-390B/U or BB-2590/U BB-390A/U, BB-390B/U or BB-2590/U BB-390A/U, BB-390B/U or BB-2590/U FIGURE Page 17 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

18 TABLE J-6583/U (BTA-70827) - CSEL ADAPTER/BATTERY POSITIONS BATTERY POSITION SUPPORTED BATTERIES BB-2800/U BB-390A/U, BB-390B/U or BB-2590/U BB-2847A/U, BB-2547/U CSEL (BT or BT-70581A or BT-70581B) CSEL (BT or BT-70581A or BT-70581B) CSEL (BT or BT-70581A or BT-70581B) CSEL (BT or BT-70581A or BT-70581B) FIGURE NOTES: 1) Battery Position 4 thru 7 are capable of multi-charging. Page 18 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

19 TABLE J-6586/U (BTA-70830) - MBITR ADAPTER/BATTERY POSITIONS BATTERY POSITION SUPPORTED BATTERIES BB-2800/U BB-390A/U, BB-390B/U or BB-2590/U BB-2847A/U, BB-2547/U MBITR (BT-70716) MBITR (BT-70716) MBITR (BT-70716) MBITR (BT-70716) FIGURE NOTES: 1) Battery Position 4 thru 7 are capable of multi-charging. Page 19 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

20 TABLE J-6585/U (BTA-70880) - FALCON ADAPTER/ R/BATTERY POSITIONSS BATTERY POSITION SUPPORTED BATTERIES BB-2800/U BB-390A/U, BB-390B/U or BB-2590/U BB-2847A/U, BB-2547/U FALCON (BT / BT-70715) FALCON (BT / BT-70715) FALCON (BT / BT-70715) FALCON (BT / BT-70715) FIGURE NOTES: 1) Battery Position 4 thru 7 are capable of multi-charging. Page 20 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

21 TABLE (BTA ) - VMC-IISR/BATTERY POSITIONS BATTERY POSITION SUPPORTED BATTERIES NNTN7032A, NTN9816A, NTN9815A NNTN7032A, NTN9816A, NTN9815A NNTN7032A, NTN9816A, NTN9815A NNTN7032A, NTN9816A, NTN9815A NNTN7032A, NTN9816A, NTN9815A NNTN7032A, NTN9816A, NTN9815A NNTN7032A, NTN9816A, NTN9815A NNTN7032A, NTN9816A, NTN9815A FIGURE Page 21 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

22 TABLE (BTA-70873) - VMC-AA/BATTERY POSITIONS BATTERY POSITION SUPPORTED BATTERIES 4 Ni-MH size AAA or 4 Ni-Cad size AA 4 Ni-MH size AAA or 4 Ni-Cad size AA 4 Ni-MH size AAA or 4 Ni-Cad size AA 4 Ni-MH size AAA or 4 Ni-Cad size AA 4 Ni-MH size AAA or 4 Ni-Cad size AA 4 Ni-MH size AAA or 4 Ni-Cad size AA FIGURE NOTES: 1) For each position, (4) AA Batteries Must bee installed ( Note proper orientation of each Battery) 2) When the batteries are properly installed, the corresponding yellow LED will illuminate Page 22 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

23 TABLE (BTA-70678) - VMC-EAGLE/BATTERY POSITIONS BATTERY POSITION SUPPORTED BATTERIES EAGLE RADIO BATTERY ( BT-70678) EAGLE RADIO BATTERY ( BT-70678) EAGLE RADIO BATTERY ( BT-70678) EAGLE RADIO BATTERY ( BT-70678) EAGLE RADIO BATTERY ( BT-70678) EAGLE RADIO BATTERY ( BT-70678) EAGLE RADIO BATTERY ( BT-70678) EAGLE RADIO BATTERY ( BT-70678) FIGURE NOTES: 1) Battery Position 1 thru 8 are capable of multi-charging. Page 23 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

24 TABLE (BTA ) VMC-USLW/BATTERY POSITIONS BATTERY POSITION SUPPORTED BATTERIES LI-145 or LI-80 (BT or BT-70867) LI-145 or LI-80 (BT or BT-70867) LI-145 or LI-80 (BT or BT-70867) LI-80 (BT-70867) LI-80 (BT-70867) LI-80 (BT-70867) FIGURE NOTES: 1) Position 4 cannot be used if a LI-145 is in Position 1 2) Position 5 cannot be used if a LI-145 is in Position 2 3) Position 6 cannot be used if a LI-145 is in Position 3 4) Battery Position 1 thru 6 are capable of multi-charging. Page 24 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

25 2 2-1 OPERATING PROCEDURES PANEL CONTROL LS AND INDICATO ORS INTERNAL CHARGER COMPONENTS Internal battery charger components are described below and shown in Figure Figure 2-1.1: VMC Lite Internal Charger Component Item Control Panel... Battery Adapter Port... Adapter Key Pins... Screw Well... Cover. Latches. Air Grilles.. Function Contains charger controls and indicators. Provides interface connection for battery adapter. They prevent the adapter from being installed backwards. The adapter retaining screws thread into these. The Cover keeps out dirt and moisture. It holds the batteries in place while the vehicle is moving. Always thee cover closed except when loading or unloading the charger. The latches keep the cover closed. One full turn counter clockwise to open. Turn the latch one full turn clockwise to lock. Always lock all latches. Provides airflow to cool the charger and batteries. Do not block the grilles. Page 25 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

26 INTERNAL CHARGER COMPONENTS Battery charger panel components are described below and shown in Figures & Figure VMC Lite Control Panel (Normal View) Item Low Vehicle Power LED... Temp Fault LED.. Figure VMC Lite Control Panel (Inverted Text) Function The Low Vehicle power indicator lights when external DC power is too low to charge batteries (22Vdc or 11Vdc). The charger will stop charging batteries when external power is below 21Vdc or 10Vdc. The Temperature Fault indicator lights when charger temperature is too high (122 o F) or tooo low (-4 o F). The charger will stop charging batteries. Power ON LED Charge Status LEDs... The VMC on. Lite has power connected and is turned Amber: LED lights steady while the associated battery is being fast-charged. A slow blinking indication means the charger is trying to find a battery at the select position. A fast blinking indication means the charger is preconditioning the batteryy before charging it. Page 26 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

27 Green: LED indicates the associated battery is fully charged and ready to be removed for use. A steady light means the battery has completed fast charge. A blinking indication means the battery is being topped off. Red: LED lights steady the associated battery, or adapter plate, is defective or will not accept charge. A blinking indication means the battery s temperature sensor or communication connection is not making contact with the adapter. No Light: No battery installed, no power, or battery awaiting charge Blackout Button... USB Port Cover... ON/OFF Power Switch... 24Vdc CKT Breaker.. 12Vdc CKT Breaker.. AC CKT Breaker.... Enables / disables Blackout Mode. Pressing it once turns off all panel LEDs. Pressing it again allows the LEDs to light again. Holding down the button during turn-on keeps the LED s off during the Lamp Test. Remove this cover to upgrade the charger s software. Otherwise leave the cover in place. Turns battery charger AC or DC supply on or off. Turns power to the charger off in an overload condition. Remove the overload condition and push to reset. Turns power to the charger off in an overload condition. Remove the overload condition and push to reset. Turns power to the charger off in an overload condition. Remove the overload condition and push to reset. Page 27 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

28 EXTERNAL CHARGER COMPONENTS External battery charger components are described below and shown in Figure Figure VMC Lite Side Panel Components Item Power Connector 12Vdc Power Connector.. Dust Cap.. Vent / Drain Screw.. Mounting Brackets.. Heat Sink.. LED Window. Function Input connection for AC cable assembly or 24Vdc cable assembly. Tighten securely to keep out dust and moisture (note- AC option not available on the -1). Input connection for 12Vdc cable assembly. Tighten securely to keep out dust and moisture (note: onlyy on the -3). Use the Dust Cap to cover the unused power connectorr on the -3 (not shown). Loosen the screw to equalize internal air pressure. Unscrew it to drain charger, should it be necessary. The screw is retained and will not fall out. Use to secure the charger to the vehicle. Airflow around the charger is important especially around thee heat sink. Do not cover the charger with cargoo during operation. Allows the charger s LED status indicators to be seen without opening the charger cover. Page 28 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

29 2-2 INSTALLATION Figure Vehicle Mounting Provisions The charger is designed to mount on a HMMWV vehicle or any other vehicle with the appropriate power capability. In a typical installation, the battery charger is attached to the wheel well housing via two mounting brackets on the rearr of the unit, as shown in Figure Eight mounting holes with captive 1/ /4-20 nuts are provided on each bracket to allow for variations of vehiclee access. Use at leastt two holes per bracket. Either or both brackets can be removed and reversed to provide optional mounting access. A full size drill template is included with the charger as shown in Figure Use it to help ensure accurate placing of the mounting holes in the vehicle. Page 29 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

30 Figure Vehicle Mounting Template NOTE Mount the charger unit with a minimum of two bolts on each bracket and tighten the mounting hardware securely. (Eight each 1/4-20 X 1" bolts, 1/4" flat washers, and 1/4" lock washers are included with the unit..) Additional clearance may be required between the charger and mounting surface to allow the cover to swing fully open. Add flat washers as necessary. NOTE For air drops, eight sets of bolts, flat washers, andd lock washers must be installed to provide adequate installationn integrity. NOTE Ensure the charger is mounted so that there is adequate airflow around the charger. Poor cooling will degrade the charger s performance. NOTE Make sure that the Vent / Drain screw is fully closed. Page 30 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

31 2-3 PRELIMINARY SETUP PROCEDURES Step 1. VEHICLE MOUNT: Mount the Charger into the vehicle. Ensure it is mounted securely (See Para 2-2), and the cover has room to open at least 90 degrees. Ensure the charger has free airflow around it. If airflow is restricted, the charger may charge batteries more slowly, or overheat and not charge at all. Connect the appropriate DC cable to a 20 AMP DC source in the Vehicle. Connect the DC cable securely to the charger. Place the Dust Cap over the unused connector if using the -3. SHOP USE: Place the unit on the work surface. Ensure the charger has free airflow around it. Connect the AC cable securely to the charger. Connect the other end of the AC cable to a standard AC outlet (AC power not applicable for -1). Step 2. Step 3. Step 4. Step 5. Step 6. Unfasten the two cover latches and open cover. If necessary, loosen the manual pressure equalization screw on the side of the case (near the input power connector) in a counterclockwise direction about two full turns. Make sure that the screw is re-tightened once equalization is complete. Install appropriate battery adapter into the adapter port for the battery types to be charged. Install the adapter by locating the base of the adapter over the two polarized 27 pin female connectors on the charger panel at Port A and pressing down firmly on the adapter s finger grip handles until the polarized male connectors on the adapter mates with the female polarized 27 pin connector on the charger s panel. Note the alignment of the pins. The multi-pin connectors on the adapter are polarized and can only plug in one way onto the multi-pin connector on the charger s panel. Do not force it. Be sure that the battery adapter and battery connections are fully seated. All battery adapters are interchangeable, only the battery connections are different. Tighten the retaining screw in the center of the adapter (Do Not Over-tighten). Set the power switch to ON position. Observe that the POWER ON LED lights, the fan operates, and all the LED status indicators blink in order (amber, green, then red) briefly when power is first applied. Observe, after a short delay, the amber CHARGE STATUS LED s blink for several seconds at position 1 of the installed adapter. This shows battery charger circuits are initialized to the selected battery adapter and are ready to accept a battery (or batteries) for charging. If all of the Indicators for a channel light red with no batteries installed, the adapter is not be recognized or is damaged. Ensure it is seated correctly. Verify that the charger software revision supports the adapter. Page 31 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

32 2-4 CHARGING BATTERIES Step 1. Step 2. Step 3. With the adapter installed, insert the first battery to be charged in the proper Port-A battery location. Ensure the battery is fully seated into the adapter. Observe that CHARGE STATUS LED for the corresponding location starts rapidly blinking amber. If the CHARGE STATUS LED turns red, the battery or adapter may be defective. Check by removing battery and adapter. Then reinstall adapter and battery. If the CHARGE STATUS LED again lights red, go to the Trouble Shooting section of this Guide. Install the rest of the batteries. The indicators for these batteries will not light until the charger has finished the batteries in the preceding positions. After fast charging is complete, the CHARGE STATUS LED will light green. After the charger cycles through the batteries, it will top-off batteries that have completed fast charge. The battery is slow-charged to full capacity, as indicated by the CHARGE STATUS LED blinking green. The battery is charged for five minutes at a time (10 minutes for dual section batteries) then the charger will move on to the next battery. For Lithium type batteries, the cycle will stop after the battery is 100% charged. For other types the cycle is repeated indefinitely to keep the battery at 100% charge. As long as the CHARGE STATUS LED is lit green (blinking or solid) the battery may be removed and returned to service and another battery may be installed for charging, in its place. NOTE BB-390A/U and BB-390B/U batteries include two independent 12-volt sections. A relay "clicking" may be heard from the battery adapter when battery sections are switched. Other types of adapters may also contain relays and click intermittently during normal operation. NOTE Battery charger power may be left ON while batteries and/or adapters are removed or replaced. Batteries may be left in the charger for long periods of time without damaging the batteries or charger. CAUTION To avoid damage to the adapter or VMC Lite panel connectors, always remove the adapter by first loosening the retaining screw. Then grasping the Tee finger-grips firmly with both hands. Pull the adapter toward you, not straight up. You may need to wiggle the adapter back and forth to remove it. Page 32 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

33 2-5 OPERATING PROCEDURES BLACKOUT Pressing the blackout switch will turn off all the LEDs. Pressing the switch again will turn the LEDs back on. The charger will remember the correct state for all batteries. The blackout mode is disabled each time the charger is turned on. Holding the blackout switch down while turning the charger power switch on will suppress the startup LED Test. 2-6 CHARGING STATUS LED QUICK REFERENCE CHARGING STATUS LED MEANING REMARKS Flash Amber, Green, Red Charger start up Not Lit Slow Flashing Amber Rapid Flashing Amber Steady Amber Slow Flashing Green Steady Green Steady Red All 8 LEDs Red on one Channel Alternate Flashing Red / Amber Alternate Flashing Red/Green Power ON, No battery present or awaiting charge cycle. Possible bad battery if all charging is complete! Power ON, adapter present, no battery present in any adapter Charge pre-qualification Battery is fast charging Charger is topping off Battery Fast charging is complete. Awaiting removal or another top off cycle Faulty battery Unknown adapter Charging at slower rate due to damaged or dirty thermal pins/contacts Charge complete at this location, but damaged or dirty contacts possibly caused longer charge time All LEDs light momentarily when charger is turned ON. Install Battery into adapter or wait for full charge cycle. Bad battery? Hold for later screening, check web site. Install battery(s) on to adapter or turn off charger. Battery pre-charge check. Can fast charge one battery at a time; or up to eight batteries at a time for batteries that are multi-chargeable. Battery is ready to use! Remove when ready. Battery is charged & ready to use! Remove when ready. Attempt to charge battery one additional time. If it fails again, remove & do not use! Consult SOP. If the battery was in storage see para Note position in charger & adapter. If problem repeated, change adapter Software update required. Check web site for info Clean battery contacts. Check adapter spring contact pins. Clean, repair or replace if missing Battery is good to go. Clean battery contacts. Check adapter spring contact pins. Clean, repair or replace if necessary. Page 33 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

34 2-7 CHARGER INSTRUCTION LABEL Figure NOTES: 1) This label is for referencee only; refer to other sections of this manual and the charger instruction label on the chargerr cover for charge instruction. Page 34 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

35 2-8 SOLID RED LED TROUBLE SHOOTING 1. Remove battery and inspect all contacts. Clean if nessasary. Then, reinstall at same location for another charge cycle. Note battery and adapter location for later review. 2. If charge indications go "RED" again at the same location remove battery and do the following: a. If the battery was in storage see para b. Discharge & recharge, if RED again? Check battery: older than 3 yrs? Maybe ready for disposal. c. Check warranty instructions on battery. If not covered or no instructions, dispose of. d. Note success/failure of future battery charges at this location. More "RED" lights? Change adapter. 2-9 FLASHING RED LED TROUBLE SHOOTING 1. This condition is telling you that some of the battery contacts are not connecting to the charger. a. For BB-390 thermal contacts not making contact with the charger. b. For CSEL, Falcon, MBITR, and other batteries the communication pin(s) are not making contact with the charger. 2. To minimize this issue before you first start using the charger: Ensure. a. The contacts are clean on the battery b. The adapter contact pins are in place and retain their spring action: Check by pushing down the pins and releasing. 3. You can still charge Batteries with thermal / communication pins missing or damaged, it will just take longer, and may not fully charge in one cycle. 4. If flashing "RED" condition continues, note the adapter battery location and battery affected. a. You can pull batteries and clean thermal contacts on the battery. b. Check adapters again. Mark for future review, if a continuing problem at this location: change adapter. Page 35 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

36 2-10 OPERATION IN EXTREME ENVIRONMENTAL CONDITIONS Observe these precautions when the VMC Lite is operated in areas where severe climatic conditions may exist. The charger will not charge batteries if it is outside the allowable temperature range. Batteries outside the operating range will charge slowly, or not at all. a. Operation in Arctic Climates. The battery charger is designed to function in temperatures extremes as low as -4 F (-20 C). The following precautions should be observed: (1) Handle equipment carefully. The plastic components may become more brittle. (2) Keep equipment clean and dry. (3) Prevent ice from forming in the VMC Lite and on the batteries. Ice formations may prevent proper electrical connections. Melting ice may cause water to enter the charger. Keep the cover closed and latched except when installing or removing batteries. Dry batteries before placing them in the charger. b. Operation in Desert Climates. The charger is designed to operate in temperature extremes as high as 122 F (50 C) and the dryness associated with a desert environment. Sand and dust accumulation on and in the charger may cause poor electrical connections and reduce the cooling effectiveness of the charger. Follow proper cleaning and maintenance guidelines to assure proper operation. Keep the cover closed and latched, except when installing or removing batteries. Be sure that cover is fully latched and pressure relief valve is fully closed (in a clockwise direction). As the internal charger temperature rises, battery charging time will increase. c. Operation in Salt Spray. Keep equipment clean and dry at all times and immediately wipe salt spray from exposed surfaces, cables and connectors. Wipe off salt and dry batteries before placing them in the charger. Keep the cover closed and latched, except when installing or removing batteries. Be sure that cover is fully latched and pressure relief valve is fully closed (in a clockwise direction). NOTE Battery charge acceptance varies with ambient temperature conditions. At temperatures lower than +32 F (0 C) or higher than +104 F (+40 C) it may be necessary to initiate two complete charging cycles to secure a fully charged battery. It is recommended that the VMC Lite be installed for DC operation to reduce the heating effects caused by the AC power conversion. In arctic conditions however, the extra warmth resulting from AC operation may prove to be a better choice by improving the battery charge acceptance. Bottom line bring along both the AC and DC cables so you ll be ready if your operational environment changes! Page 36 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

37 2-11 REMOVING THE CHARGER FROM THE VEHICLE a. Set the POWER switch to OFF. b. Remove any installed batteries. c. Close the charger lid and secure the cover latches. d. Disconnect the power input cable and replace the connector cover. e. Remove the mounting bolts. f. Remove the charger for the vehicle. g. Close pressure equalization valve on the side of the charger by turning fully clockwise. h. Save the mounting bolts for later installation by reinstalling them in the dismounted charger mounting holes 2-12 BATTERY STATE-OF-CHARGE DISPLAYS Batteries equipped with state-of-charge (SOC) displays indicate battery charge status on a five-segment LCD bar graph readout. The number of LCD segments activated corresponds to the battery state-of-charge as follows: Segments State-of-Charge 0 0% (fully discharged) 1 1 to 20% 2 21 to 40% 3 41 to 60% 4 61 to 80% 5 81 to 100% (fully charged) NOTE The BB-390A/U, BB-390B/U, BB-2590/U, BB-2557/U and some other batteries have two SOC indicators. Each SOC indicator provides state-of-charge indication for each of the two 12V sections. Both SOC s must display 100% for the battery to be fully charged. Page 37 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

38 2-13 BATTERY CAPACITY RETENTION As shown in the adjoining graph, fully charged batteries that are stored lose a portion of their charge due to battery chemistry. This is normal and should not be interpreted as battery failure. Storage at higher temperatures increases capacity losses while storage at lower temperature decreases capacity losses. The graph shows that Nickel based batteries like the BB-390 lose over 30% charge/month (1% /day) on the shelf waiting to be used. The BB-2590 (a Li-Ion based battery) only loses less than 10% a month on the shelf BATTERY STORAGE Nickel based batteries may require 1 or more charge / discharge cycles after long storage. They may not charge fully on the first charge cycle. Repeat the charge if necessary. If the battery does not fully charge after 3 cycles it may no longer be serviceable. Lithium based batteries must be charged yearly if held in storage. Long term storage of fully discharged Lithium based batteries can permanently damage the battery. Lithium Ion batteries do not have a memory effect; hence they do not require charge / discharge cycling after storage. If the battery does not charge (no SOC Bars), place it back on the charge for an additional charge cycle. If the battery does not fully charge it may no longer be serviceable. Page 38 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

39 3 OPERATOR MAINTENANCE INSTRUCTIONS 3-1 INTRODUCTION Periodic maintenance, inspection and cleaning will help insure the VMC Lite is kept at full readiness. 3-2 CLEANING 1. Brush loose dirt and dust from the charger. Low-pressure air may be used to remove heavy dust from the inside of the case, connectors and power switches. Avoid blowing dust into the unit. 2. Wipe internal surfaces with a damp (not wet) rag. Non-solvent cleaners maybe used (ex., Windex, Fantastik, Formula 409 ). Do not spray or drip water or cleaners onto the panel or into the air grills and connectors. 3. External surfaces maybe wiped with a wet rag if the cover is fully latched and the vent screw is closed. Non-solvent cleaners may be used. Do Not use high pressure water on the charger. If the cover is closed it is OK to allow the charger to get wet during vehicle washing. Dry it thoroughly before opening it. 4. The flush mounted 27 pin adapter connectors may be cleaned with electronic grade spray cleaner. Allow the cleaner to dry before installing the adapters. 5. The connections on the Adapters may be cleaned with electronic grade spray cleaner or isopropyl alcohol. Ensure the Adapters are dry before using them. 6. If water or condensation exists in the charger, the vent screw under the power connector may be loosened for drainage. The vent screw should be turned until it hangs free, it will not fall out. 3-3 INSPECTION 1. Inspect case for cracks and other damage. 2. Ensure the lid gasket is in place. 3. Ensure the lid closes and can be properly latched. 4. Inspect the panels and connectors for damage. 5. Inspect all adapters for excessive wear and damage. a. Inspect charger connector for bent or corroded pins. b. Inspect battery connector pins for damage or corrosion. c. Ensure all spring pins are not bent and move freely. 6. Inspect power cords for damage. 7. Ensure the power switch moves freely. 8. Ensure the pressure equalization valve, located under the power connector is snugly tightened. Page 39 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

40 3-4 BASIC FUNCTIONAL TEST 1. Turn off the power switch. 2. Connect the VMC Lite to AC power (if applicable, otherwise use 24Vdc). 3. Turn On the power switch. 4. The front panel LED s should light in sequence. Red, then Amber, then Green. Ensure all LED s light. 5. Ensure the POWER-ON LED is lit. 6. Verify that the CHARGE STATUS LED blinks Amber for several seconds at each position, then moves to the next position. 7. Place a battery in Position 1. Ensure that the POSITION LED blinks amber rapidly then turns on solid amber. 8. Press the blackout button. Verify all panel LEDs turn off. 9. Press the blackout button again. Verify all panel LEDs resume normal operation. 10. Repeat above step for all other positions and channels. 11. Turn off the power switch and disconnect AC Power. 12. Connect the VMC Lite to 24Vdc Power. 13. Turn On the power switch. 14. The front panel LED s should light in sequence. Red, then Amber, then Green. 15. Turn of the power switch and disconnect 24Vdc Power. 16. Connect the VMC Lite to 12Vdc Power (if applicable). 17. Turn on the power switch. 18. The front panel LED s should light in sequence. Red, then Amber, then Green. 19. Turn of the power switch and disconnect 12Vdc Power. 20. End of Test. Page 40 of 46 VMC Lite VEHICLE MOUNTED CHARGER LITE Data presented in this document is subject to change without notice

41 3-5 ADAPTER REPLACEMENT Tee Handle Retaining Screw Tee Handle Figure Adapter Removal 1. Remove all batteries from the adapter. 2. Clean or blow away any loose dust or dirt from the adapter well. 3. Completely loosen the retaining screw in the center of the adapter. 4. Grasp the two Tee grip handles on the adapter using both hands. 5. Pulll firmly at an angle toward the front of the charger. 6. It may be necessary to wiggle the adapter front to back. 7. Do not attempt to install adapters from chargers other than the PP-8481B/ U (VMC, BTC ) into the VMC Lite. They will neither fit nor work. 8. Clean or blow away any loose dust and dirt from the adapter well. Inspect the adapter connectors. Ensure there is no dirt or debris in thee connectors before continuing. 9. Inspect the two connectors. Verify none of the pinss are bent. Gently straighten any bent pins before continuing. 10. Ensure the label marked Hinge Side on the adapter faces the cover hinge. Locate the key-pin hole on the bottom of the new adapter. Ensure it lines up with the key-pin on the bottom of the adapter well. 11. Press the adapter firmly and evenly down with bothh hands. Verify the adapter is fully seated against the bottom of the adapter well. 12. Tighten the center retaining screw until it is fully seated. Do nott over tighten. 13. Turn the charger on, if it is not already on. Verify the Charge Status LEDs blinks for each position on the display panel. For example positions 1 through 7 will blink on the universal adapter. 14. If all 8 LEDs turn red, ensure the adapter is fully seated. If the adapter is a new type of adapter, verify your charger s software revision supports that adapter type. If not update the charger software. Page 41 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice

42 3-6 INVERTING CONTROL PANEL TEXT (4) 6-32 X 3/8 SEMS screw with flat washer (2)) 6-32 X 5/16 SEMS screw with flat washer Figure Control Panel Screws USB Cover Control Panel Label Plate Figure Control Panel Edge View Page 42 of 46 VMCC Lite VEHICLE MOUNTED CHARGER LITE Dataa presented in this document is subject to change without notice