MULTI-POSITION UNIVERSAL PP-8481B/U

Transcription

1 OPERATION AND SERVICE MANUAL VEHICLE MOUNTED CHARGER A Drop-in replacement for all versions of PP-8481 (Charger on the Move) MULTI-POSITION UNIVERSAL PP-8481B/U Manufactured for the U.S. Army Communications-Electronics Command (CECOM) Ft. Monmouth, N.J. USA Tel: (631) Fax: (631) address: info@bren-tronics.com NOTE: We recommend you give the PP-8481B/U a test run in the commo shop or office to learn the basic functionality before vehicle installation REV E

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. CHAPTER 1 INTRODUCTION PARA PG Scope Technical Specifications Accessories Charge Cycle Description Sequential Charging Description Multi-Charging Description Adapter Loading Table of Contents PARA PG Operation Under Extreme Environmental Conditions Removing The Charger From The Vehicle Battery State-of-Charge Displays Battery Capacity Retention Battery Storage CHAPTER 2 OPERATING PROCEDURES Controls and Indicators Installation Preliminary Setup Procedures Operating Procedures Charging Batteries Operating Procedures Blackout Charging LED Quick Reference Charger Instruction Label Solid Red LED troubleshooting Flashing Red LED troubleshooting CHAPTER 3 MAINTENANCE INSTRUCTIONS Introduction Cleaning Inspection Basic Functional Test Adapter Replacement Inverting Control Panel Text Simplified Operator Troubleshooting Procedures Warranty / Repair Information Upgrade / Update Information REV E

3 INTRODUCTION CHAPTER 1 INTRODUCTION 1-1. SCOPE The Vehicle Mounted Charger (VMC), PP-8481B/U (P/N BTC-70836), is a state-of-theart, 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 sixteen batteries, two at a time, completely unattended, and multi-charge up to eight batteries at one time. This charger is the next generation of the Charger on the Move (COTM) and is a direct replacement to the PP-8481/U and the PP-8481A/U. The VMC is designed to fit into the same space, use the same mounting holes, and use the same power cables as the COTM. The Vehicle Mounted Charger (VMC) is simple to use by design. Without any user intervention, the VMC typically charges fully depleted BB-2590/Us or BB-390B/Us 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 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 easyto-understand panel mounted LED indicators (amber CHARGE, green READY and red FAULT). The VMC is universal by design. It can readily use either AC or DC input power whichever is most convenient for the user. The universal AC input fully allows VAC at Hz operation without any adjustment or user intervention. Additionally, the DC input power permits a range of VDC, standard on most military vehicles. The VMC is shipped with two BTA Universal Adapters, one 10-foot AC line cord cable (with US style 3 prong plug), one 10-foot DC line cord cable, Mounting Hardware, a Mounting Template, and this Manual. The VMC is adaptive by design. It is microprocessor controlled and is presently programmed, with the appropriate battery adapter, to automatically charge over 25 different types of battery as listed in the Table It can be readily reprogrammed via its RS232 software upgrade port in the field. 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 gasketed 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 mounted reversed for use in vehicles such as the Stryker REV E 1-1

4 1-2. TECHNICAL SPECIFICATIONS INTRODUCTION Dimensions.. 27 in. (686 mm) W x 14 in. (356 mm) D x 8.0 in. (204 mm) H Weight.. 34 lbs (15.7 kg) Power Requirements AC operation. Automatic selection: 90 to 260 VAC, single-phase, 47 to 420 Hz, 375 VA max, with included 10 ft. (305 cm) detachable three-wire power cord. (Power draw Amps) DC operation VDC, 15A; with included 10 ft (305 cm) detachable DC cable assembly. (Power draw Amps) Charging Output Voltage... Automatically selected for each battery type Duty Cycle Continuous Protective Features. Resettable circuit breakers for AC (7A) and DC (20A) power sources 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.) Loose Cargo Bounce. Meets requirements of MIL-STD-810E, Method 514.4, Category 3 Case Material.. Powder-Coated Welded Aluminum Case Color... Olive Drab #34088 per Fed-Std-595B Shipment.. No restrictions REV E 1-2

5 1-3. ACCESSORIES INTRODUCTION Table shows the various batteries and appropriate adapter plates the VMC supports as of the writing of this document. Table Supported Batteries and Adapters Adapter Name NSN Army (Bren-Tronics)P/N Batteries Charged/Position VMC-390/ J-6581/U (BTA-70820) BB-390/2590 Positions 1-4 (Figure 1-3.3) VMC-CSEL J-6583/U (BTA-70827) CSEL* Positions 4-7 (Figure 1-3.4) BB-2800 Position 1 BB-390/2590 Position 2 BB-2847 Position 3 VMC-MBITR (Figure 1-3.5) VMC-Universal (Figure 1-3.6) VMC-557/2557/2600 (Figure 1-3.7) VMC-FALCON (Figure 1-3.8) VMC-IISR (Figure 1-3.9) 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 BB388/2588 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 NOTES: 1) * Battery is capable of parallel charging on the adapter specified; pictures shown on following page. 2) This list was complete at the date of publication. Additional adapters may be available, but may require updated software REV E 1-3

6 INTRODUCTION Table Accessories Accessories Name NSN Part Number AC Cable, US Plug (Figure 1-3.1) CX (BTA ) AC Cable, Euro plug BTA AC Cable, UK plug BTA VDC Cable, 8 ft. (Figure 1-3.2) CX (BTA ) 24VDC Cable, 30 ft. BTA BB-390 Self Discharger PP-8497/U REV E 1-4

7 INTRODUCTION Figure 1-3.1: VMC AC Adapter Cable Figure 1-3.2: DC Adapter Cable Figure 1-3.3: VMC-390/2590 Figure 1-3.4: VMC-CSEL Figure 1-3.5: VMC-MBITR Figure 1-3.6: VMC Universal Adapter Figure 1-3.7: VMC-557/2557/2600 Figure 1-3.8: VMC-FALCON Figure 1-3.9: VMC-IISR Figure : VMC-AA Figure : USLW, VMC Figure : VMC, EAGLE REV E 1-5

8 1-4. CHARGE CYCLE DESCRIPTION INTRODUCTION Each of the battery types that are capable of being charged by the VMC 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) c. Time (t) d. Voltage change (ΔV) e. Temperature rate of change (ΔT/Δt) 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-390, BB-2590, BB-557, BB-2557). 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 REV E 1-6

9 INTRODUCTION 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 REV E 1-7

10 1-5. SEQUENTIAL CHARGING CYCLE DESCRIPTION INTRODUCTION The VMC can sequentially charge the supported batteries with the appropriate adapter. With the shipped Universal Adapters, the VMC can automatically charge up to twelve batteries in less than 16 Hours. This depends on the battery type and state-of-charge and temperature. Other adapters can support up to a maximum 8 batteries each. Two independent charging ports, designated A and B, can charge one battery at a time. Upon charge completion of the first battery, each port sequentially charges the additional batteries that are waiting in queue. Sequencing to the other positions is performed completely automatic and requires no intervention by the user. The batteries charged by the A Port are located in the adapter closest to the Control Panel. The batteries charged by the B Port are located in the adapter at the other side. This is readily seen in Figure Figure VMC with Universal Adapters Installed The Adapter in Port A does not have to be the same type as the on in Port B. 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 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-390, BB-2590, BB-557, and BB-2557) 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 REV E 1-8

11 1-6. MULTI-CHARGING CYCLE DESCRIPTION INTRODUCTION Along with sequential charging, the VMC charges can also charge up to 8 batteries at once. This feature was implemented as a software upgrade that can be downloaded on all existing VMCs. Chargers with Revision A Software or greater already have this new Multi-charge feature. The charger will automatically identify batteries than can be multi-charged; no special action is required by the user. The new feature charges the batteries in parallel. Eight standard CSEL batteries can be charged in less than 4 hours. Significant time savings will be noticed for smaller groups of batteries. Multi-Charging does not require any special setup. Two different adapters can be used at the same time. The charger will automatically detect which batteries can be charged as a group. The Multi-Charging process works as follows. The VMC has two high power charging channels. The unique characteristics of Lithium Ion batteries allow the charger to charge the 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 compare to three hours for just one. The charging sequence is similar to normal battery charging with the exception that if a multichargeable 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 get the most time savings from 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 charging time. Group them on channel A or on channel B since the channels operate independently. 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 yet still use the same adapters. Remember that parallel 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 a parallel charge.) REV E 1-9

12 1-7. ADAPTER LOADING INTRODUCTION TABLE J-6520A/U (BTA-70841) UNIVERSAL ADAPTER/BATTERY POSITIONS BATTERY POSITION SUPPORTED BATTERIES 1 BB-390A/U, BB-390B/U or BB-2590/U 2 BB-390A/U, BB-390B/U or BB-2590/U 3 BB-516A/U or BB-326/U 4 BB-388/U, BB-388A/U or BB-2588/U 5 BB-2847/U or BB-2847A/U 6 MBITR 7 BB-2800/U BB-388/2588 FIGURE NOTES: 1) Battery Position 4 cannot be occupied if batteries are placed into Position 3 and/or Position 6. 2) Battery Positions 3 and 6 cannot be occupied if battery is placed into Position REV E 1-10

13 INTRODUCTION TABLE J-6584/U (BTA-70843) - 557/2557/2600 ADAPTER/BATTERY POSITIONS BATTERY POSITION SUPPORTED BATTERIES 1 BB-2600/U or BB-2600A/U 2 BB-557/U or BB-2557/U 3 BB-2600/U or BB-2600A/U 4 BB-557/U or BB-2557/U 5 BB-2600/U or BB-2600A/U 6 BB-557/U or BB-2557/U FIGURE NOTES: 1) Battery Position 1 cannot be occupied if a battery is placed in Position 2 and vise versa. 2) Battery Position 3 cannot be occupied if a battery is placed in Position 4 and vise versa. 3) Battery Position 5 cannot be occupied if a battery is placed in Position 6 and vise versa REV E 1-11

14 TABLE J-6581/U (BTA-70820) - 390/2590 ADAPTER/BATTERY POSITIONS BATTERY POSITION SUPPORTED BATTERIES 1 BB-390A/U, BB-390B/U or BB-2590/U 2 BB-390A/U, BB-390B/U or BB-2590/U 3 BB-390A/U, BB-390B/U or BB-2590/U 4 BB-390A/U, BB-390B/U or BB-2590/U INTRODUCTION FIGURE REV E 1-12

15 TABLE J-6583/U (BTA-70827) - CSEL ADAPTER/BATTERY POSITIONS BATTERY POSITION SUPPORTED BATTERIES 1 BB-2800/U 2 BB-390A/U, BB-390B/U or BB-2590/U 3 BB-2847A/U, BB-2547/U 4 CSEL (BT / BT-70581A) 5 CSEL (BT / BT-70581A) 6 CSEL (BT / BT-70581A) 7 CSEL (BT / BT-70581A) INTRODUCTION FIGURE NOTES: 1) Battery Position 4 thru 7 are capable of multi-charging REV E 1-13

16 TABLE J-6586/U (BTA-70830) - MBITR ADAPTER/BATTERY POSITIONS BATTERY POSITION SUPPORTED BATTERIES 1 BB-2800/U 2 BB-390A/U, BB-390B/U or BB-2590/U 3 BB-2847A/U, BB-2547/U 4 MBITR (BT-70716) 5 MBITR (BT-70716) 6 MBITR (BT-70716) 7 MBITR (BT-70716) INTRODUCTION FIGURE NOTES: 1) Battery Position 4 thru 7 are capable of multi-charging REV E 1-14

17 TABLE J-6585/U (BTA-70880) - FALCON ADAPTER/BATTERY POSITIONS BATTERY POSITION SUPPORTED BATTERIES 1 BB-2800/U 2 BB-390A/U, BB-390B/U or BB-2590/U 3 BB-2847A/U, BB-2547/U 4 FALCON (BT / BT-70715) 5 FALCON (BT / BT-70715) 6 FALCON (BT / BT-70715) 7 FALCON (BT / BT-70715) INTRODUCTION FIGURE NOTES: 1) Battery Position 4 thru 7 are capable of multi-charging REV E 1-15

18 INTRODUCTION TABLE (BTA-70862) - VMC-IISR/BATTERY POSITIONS BATTERY POSITION SUPPORTED BATTERIES 1 NNTN7032A, NTN9816A, NTN9815A 2 NNTN7032A, NTN9816A, NTN9815A 3 NNTN7032A, NTN9816A, NTN9815A 4 NNTN7032A, NTN9816A, NTN9815A 5 NNTN7032A, NTN9816A, NTN9815A 6 NNTN7032A, NTN9816A, NTN9815A 7 NNTN7032A, NTN9816A, NTN9815A 8 NNTN7032A, NTN9816A, NTN9815A FIGURE REV E 1-16

19 INTRODUCTION TABLE (BTA-70873) - VMC-AA/BATTERY POSITIONS BATTERY POSITION SUPPORTED BATTERIES 1 4 Ni-Mh size AA or 4 Ni-Cad size AA 2 4 Ni-Mh size AA or 4 Ni-Cad size AA 3 4 Ni-Mh size AA or 4 Ni-Cad size AA 4 4 Ni-Mh size AA or 4 Ni-Cad size AA 5 4 Ni-Mh size AA or 4 Ni-Cad size AA 6 4 Ni-Mh size AA or 4 Ni-Cad size AA FIGURE NOTES: 1) For each position, (4) AA Batteries Must be installed (Note proper Orientation of each Battery) 2) When the batteries are properly installed, the corresponding yellow LED will illuminate REV E 1-17

20 INTRODUCTION TABLE (BTA ) VMC-USLW/BATTERY POSITIONS BATTERY POSITION SUPPORTED BATTERIES 1 LI-145 or LI-80 (BT or BT-70867) 2 LI-145 or LI-80 (BT or BT-70867) 3 LI-145 or LI-80 (BT or BT-70867) 4 LI-80 (BT-70867) 5 LI-80 (BT-70867) 6 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 REV E 1-18

21 INTRODUCTION TABLE (BTA-70678) - VMC-EAGLE/BATTERY POSITIONS BATTERY POSITION SUPPORTED BATTERIES 1 EAGLE RADIO BATTERY (BT-70678) 2 EAGLE RADIO BATTERY (BT-70678) 3 EAGLE RADIO BATTERY (BT-70678) 4 EAGLE RADIO BATTERY (BT-70678) 5 EAGLE RADIO BATTERY (BT-70678) 6 EAGLE RADIO BATTERY (BT-70678) 7 EAGLE RADIO BATTERY (BT-70678) 8 EAGLE RADIO BATTERY (BT-70678) FIGURE NOTES: 1) Battery Position 1 thru 8 are capable of multi-charging REV E 1-19

22 CHAPTER 2 OPERATING PROCEDURES OPERATION 2-1. CONTROLS AND INDICATORS INTERNAL CHARGER COMPONENTS Internal battery charger components are described below and shown in Figure Figure 2-1.1: VMC Internal Charger Component Item Function 1. Control Panel. Contains charger controls and indicators. 2. Battery Adapter Ports Provides interface connection for battery adapters. 3. Adapter Key Pins.. They prevent the adapters from being installed backwards. 4. Screw Wells The adapter retaining screws thread into these. 5. Cover The Cover keeps out dirt and moisture. It also holds the batteries in place while the vehicle is moving. Always keep the cover closed except when loading or unloading the charger. 6. Latches. The three latches keep the cover closed. One full turn counter clockwise to open. Turn the latch one full turn clockwise to lock. Always lock all three latches. 7. Air Grills... Provides airflow to cool the charger and batteries. Do not block the grills REV E 2-1

23 OPERATION INTERNAL CHARGER COMPONENTS Battery charger panel components are described below and shown in Figures & Figure VMC Control Panel (Normal View) Figure VMC Control Panel (Inverted Text /Stryker) Item Function 1. Low Vehicle Power LED... The Low Vehicle power indicator lights when external DC power is too low to charge batteries (22 VDC). The charger will stop charging batteries when external DC power is below 21 VDC. 2. Temp Fault LED. The Temperature Fault indicator lights when charger temperature is too high (122 o F) or too low (-4 o F). The charger will stop charging batteries. 3. Power ON LED The VMC has power connected and is turned on. 4. Charge Status LEDs.. Amber: LED lights steady while the associated REV E 2-2

24 OPERATION 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 battery before charging it. 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 5. Blackout Button.. Enables / disable 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. 6. RS-232 Port Cover. Remove this cover to upgrade the charger s software. Otherwise leave the cover in place. 7. ON/OFF Power Switch.. Turns battery charger AC or DC supply on or off. 8. DC CKT Breaker. Turns power to the charger off in an overload condition. Remove the overload condition and push to reset. 9. AC CKT Breaker. Turns power to the charger off in an overload condition. Remove the overload condition and push to reset REV E 2-3

25 OPERATION EXTERNAL CHARGER COMPONENTS External battery charger components are described below and shown in Figure Figure VMC Side Panel Components Item Function 1. Power Connector Input connection for AC cable assembly or DC cable assembly. Tighten securely to keep out dust and moisture. 2. Vent / Drain Screw. 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. 3. Mounting Brackets.. Use to secure the charger to the vehicle. 4. Heat Sink. Airflow around the charger is important especially around the heat sink. Do not cover the charger with cargo. 5. Led Window. Allows the charger s LED status indicators to be seen without opening the charger cover REV E 2-4

26 2-2. INSTALLATION OPERATION Figure Vehicle Mounting Provisions The charger is designed to mount on a HMMWV vehicle or any other vehicle with a 24- volt DC source. In a typical installation, the battery charger is attached to the wheel well housing via two mounting brackets on the rear 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 vehicle access. Use at least 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. Use it to help insure accurate placing of the mounting holes in the vehicle. 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, and lock washers must be installed to provide adequate installation integrity. NOTE Insure the charger is mounted such that there is adequate airflow around the charger. Poor cooling will degrade the chargers performance. NOTE Insure the Vent / Drain screw is fully closed REV E 2-5

27 2-3. PRELIMINARY SETUP PROCEDURES OPERATION Step 1. VEHICLE MOUNT: Mount the Charger into the vehicle. Insure it is mounted securely (See Para 2-2), and the cover has room to open at least 90 degrees. Insure the charger has free airflow around it. If not the charger may charge batteries more slowly, or overheat and not charge at all. Connect the DC cable to a 20 AMP DC source in the Vehicle. Connect the DC cable securely the charger. SHOP USE: Place the unit on the work surface. Insure the charger has free airflow around it. Connect the AC cable securely the charger. Connect the other end of the AC cable to a standard AC outlet. Step 2 Step 3. Step 4. Step 5. Step 6. Unfasten the three 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. Install appropriate battery adapter(s) into the adapter ports for the battery types to be charged. Install the adapter(s) by locating the base of the adapter over the two polarized 27 pin female connectors on the charger panel at Port A (and/or Port B) 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 into Port A and/or Port B, 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 each 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. Insure it is seated correctly. Verify that the charger software revision supports the adapter REV E 2-6

28 2-4. OPERATING PROCEDURES CHARGING BATTERIES OPERATION Step 1. Step 2. Step 3. Step 4. With the universal adapter or bulk adapter installed, insert the first battery to be charged in the proper Port-A battery location. Insure the battery is fully seated into the adapter. Observe that CHARGE STATUS LED for the corresponding location is lit amber or blinking rapidly amber. The CHARGE STATUS LEDs for the B battery location will continue to slowly blink amber if it is searching for a battery on that Port. If the CHARGE STATUS LED is lit 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 next battery into the proper Port-B battery location. 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 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 REV E 2-7

29 2-5. OPERATING PROCEDURES BLACKOUT OPERATION 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 CHARGING STATUS LED QUICK REFERENCE CHARGING STATUS LED MEANING REMARKS Flash Amber, Green, Red 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 Charger start up 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 two batteries at one time and eight batteries 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 missing REV E 2-8

30 2-7. Charger Instruction Label OPERATION Figure NOTES: 1) This label is for reference only; refer to other sections of this manual and the charger instruction label on the charger cover for charge instruction REV E 2-9

31 2-8. SOLID RED LED TROUBLE SHOOTING OPERATION 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 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 REV E 2-10

32 2-10. OPERATION UNDER EXTREME ENVIRONMENTAL CONDITIONS OPERATION Observe these precautions when the VMC 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 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 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! REV E 2-11

33 2-11. REMOVING THE CHARGER FROM THE VEHICLE OPERATION 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 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 and BB-2557 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 REV E 2-12

34 OPERATION BATTERY CAPACITY RETENTION As shown in the adjoining graph, fully charged batteries that are stored lose a portion of their charge due to battery the 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 REV E 2-13

35 MAINTENANCE 3-1. INTRODUCTION CHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONS Periodic maintenance, inspection and cleaning will help insure the VMC is kept at full readiness 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. Low-pressure air may be blown into the left and right grilles next to the adapters to help remove internal dust. 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 maybe 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. Insure 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 INSPECTION 1. Inspect case for cracks and other damage. 2. Insure the lid gasket is in place. 3. Insure 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. Insure all spring pins are not bent and move freely. 6. Inspect power cords for damage. 7. Insure the power switch moves freely. 8. Insure the pressure equalization valve, located under the power connector is snugly tightened REV E 3-1

36 3-4. BASIC FUNCTIONAL TEST MAINTENANCE 1. Turn off the power switch. 2. Connect the VMC to AC power. 3. Turn On the power switch. 4. The front panel LED s should light in sequence. Amber, then Green, then Red. Insure all LED s light. 5. Insure 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 Channel A. Insure 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 to DC Power. 13. Turn On the power switch. 14. The front panel LED s should light in sequence. Amber, then Green, then Red. 15. End of Test REV E 3-2

37 MAINTENANCE 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. Pull firmly at an angle toward the front of the charger. 6. It may be necessary to wiggle the adapter front to back. 7. The Channel A and Channel B adapters do not have to be the same type. 8. Do not attempt to install adapters from other chargers in the VMC. They will not fit or work. 9. Clean or blow away any loose dust and dirt from the adapter well. Inspect the adapter connectors. Insure there is no dirt or debris in the connectors before continuing. 10. Inspect the new adapters two connectors. Verify none of the pins are bent. Gently straighten any bent pins before continuing. 11. Insure the label marked Hinge Side on the adapter faces the cover hinge. Locate the key-pin hole on the bottom of the new adapter. Insure it lines up with the key-pin on the bottom of the adapter well. 12. Press the adapter firmly and evenly down with both hands. Verify the adapter is fully seated against the bottom of the adapter well. 13. Tighten the center retaining screw until it is fully seated. Do not over tighten. 14. 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. 15. If all 8 LEDs turn red, Insure 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 REV E 3-3

38 MAINTENANCE 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 RS-232 Cover Control Panel Label Plate Figure Control Panel Edge View REV E 3-4

39 MAINTENANCE 1. For installations where the charger must be viewed from the hinge side on the lid. The control panel text may be inverted. The Stryker Vehicle is an example of this type on installation. 2. Remove the two (2) screws from the Software Upgrade Port Cover with a #2 Phillips screwdriver. See figure for the screw locations. 3. Remove the washers and Software Upgrade Port Cover. 4. Remove the four (4) screws from the control panel corners with a #2 Phillips screwdriver. See figure for the screw locations. Take care not to allow the washers to fall into the unit. 5. Gently remove the thin text plate from the charger. Do Not pull up the main control panel. This may cause wires to be disconnected or damaged. See Figure Replace the four (4) screws from the control panel with a #2 Phillips screwdriver. Replace all washers under the screws. 7. Replace the Software Upgrade Port Cover. 8. Replace the two (2) screws from the Software Upgrade Port Cover with a #2 Phillips screwdriver. Replace all washers under the screws. 9. Perform a functional test on the charger before installation. See para Save the label plate for future use REV E 3-5

40 MAINTENANCE 3-7. SIMPLIFIED OPERATOR TROUBLESHOOTING PROCEDURES Item MALFUNCTION POSSIBLE CORRECTIVE ACTION POWER ON LED is not lit during AC operation. POWER ON LED is not lit during DC operation. All Position LED s light RED and stay lit after the charger is turned on. The LED s do not blink in sequence at start up. 1) Inspect Power Cord and AC Switch. 2) Reset AC circuit Breaker. 3) Press the Blackout button. 1) Inspect Power Cord and DC Switch. 2) Reset DC circuit Breaker. 3) Press the Blackout button. 1) The unit has lost its program. a) Re-program the unit. b) The unit requires repair. Call or Bren- Tronics. Info on warranty tag. 1) Verify the Temp Fault and Veh Power indicators are not lit. 2) The unit requires repair. Call or Bren-Tronics. Info is on warranty tag. 5 TEMP FAULT LED is lit. 6 LOW VEH PWR LED is lit. 1) The Charger is too hot or too cold. Move the charger to a more suitable environment. 2) The air vents at the left or right side of the charger are blocked. 3) The internal fan has failed. The unit requires repair. Call or Bren-Tronics. 1) If the unit is running from DC Power verify the voltage is correct. 2) If the unit is running from AC Power the unit requires repair. 7 All 8 LED s are lit RED on one channel. 1) Poor connection between Adapter and Charger. Inspect, clean and reseat Adapter. 2) Defective Adapter, use a different Adapter. 3) Defective Port on Charger, try the other Port. 4) The charger does not support the Adapter. Update the charger software See para ) Check battery: older than 3 yrs? Maybe ready for disposal. Discharge & Recharge, if RED again? 8 FAULT LED is lit on one port. 2) Check warranty instructions on battery. If not covered or no instructions, dispose of. 3) Note success/failure of future battery charges at this Port. More "RED" lights? Change adapter REV E 3-6

41 MAINTENANCE Item MALFUNCTION POSSIBLE CORRECTIVE ACTION FAULT LED is blinking on one or more Ports. Charger never tries to charge a battery. Position LED goes to Amber (CHARGE), but never turns RED (FAULT) or Green (READY), instead it turns off. Batteries charge, but no LEDs are lit. Fault LED stays lit after battery is removed. 1) This condition is telling you the thermal contacts on the BB-390 or communication contacts on other batteries are not making contact with the charger. To minimize this issue before you first start using the charger: Ensure. a) Two Thermal contacts are in place in each battery position on the BB-390, or all contacts on other batteries. b) Adapter contact pins are in place and retain their spring action: Check by pushing down the pins and releasing. The pins should spring up. If not or are missing, you may be able to replace pins/adapter. c) Batteries with contact pins missing or damaged can still be charged; charging times will be extended. The FAULT LED will continue to blink. 2) If flashing "RED" condition continues, note the adapter battery location and battery affected. 3) You can pull batteries and clean thermal contacts on the battery. 4) Check adapters again. Mark for future review. If a problem continues at this location, change the Adapter. 1) Possible poor connection. Inspect and clean battery and Adapter contact. 2) Defective Adapter. Use a different adapter. 3) Defective Charger Position or Channel. Try a different position or Channel. 4) Defective Battery, replace battery. 1) Poor Connection, inspect and clean battery and adapter contact. 2) Defective Adapter. Use a different adapter. 3) Defective Charger Position or Channel. Try a different position or Channel. 4) Defective Battery, replace. 1) Press the Blackout Button to reilluminate the LEDs. 1) Battery is defective. Cycle power to clear fault REV E 3-7