BLACKMAX. BALANCE CHARGER/DISCHARGER FOR LiFe/LiPo/LiIon/NiCd/NiMH/PB BATTERIES. BLACKMAX Users Guide

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1 Booma-RC BLACKMAX BALANCE CHARGER/DISCHARGER FOR LiFe/LiPo/LiIon/NiCd/NiMH/PB BATTERIES Dual Charge MAXPACK READY Charge 2 Booma MAXPACK Batteries Simultaneously BLACKMAX Users Guide BLACKMAX is a rapid charger/discharger with built-in balancer, computerised with microprocessor and specialised operating software. Please read this operating manual before attempting to use your new Booma-RC BLACKMAX charger

2 Features Optimized operating software BLACKMAX is a new generation in Battery Charge/Discharging management systems offering intelligent microprocessor control of all functions. Current fed into and drawn out of your battery system is optimised for each battery chemistry. This intelligent technology can prevent over-charging which (in some battery chemistries) has led to battery destruction and in some cases battery explosion. The sophisticated circuity inside BLACKMAX is monitored at every stage of the Charge/ Discharge process to afford maximum safety. BLACKMAX offers many user functions so your battery charge/discharge requirements can be tailored to your specific needs. BLACKMAX also comes to you with a multitude of connector options and offers intelligent balancing Charge/Discharge algorithms for 2 to 6 lithium cells. When used with Booma-RC optional MAXPACK batteries, BLACKMAX can charge two packs simultaneously. High-power and high-performance circuit BLACKMAX offers high powered circuitry with a maximum output power of 50W. This gives you the ability to charge up to 15 cells of NiCd/NiMH and 6 Cells (in series) of Lithium batteries with a charge current of between 0.1 and 5.0A. The BLACKMAX internal cooling system ensures that the high power generated during the Charge/ Discharge process can be easily maintained. Individual voltage balancer for Lithium batteries BLACKMAX also offers an individual-lithium cell-voltage balancer. The accuracy of this balancer is achieved by high tolerance balancing resistors. BLACKMAX does not require an external balancer when balance charging Lithium batteries (Lilo/LiPO/LiFe). Nice :) Discharge balance of individual cells BLACKMAX also offers individual cell balanced discharge for Lithium battery chemistry. Intelligent circuitry and software will detect if the voltage of any one cell varies abnormally. This will cause the Discharge process to stop. Latest Lithium battery chemistry BLACKMAX has been designed to work with the latest Lithium battery chemistry LiFe (A123), Lilo and LiPo. Each of these battery chemistries has unique voltage and Charge/ Discharge characteristics requiring individual charge/discharge software algorithms. BLACKMAX closely monitors the Lithium Charge/Discharge process to ensure maximum safety of charging. Booma-RC advises that you use BLACKMAX at your discretion and that you accept full responsibility for Charging/Discharging Lithium chemistry batteries. Lithium battery Fast Charge and Storage mode BLACKMAX provides you with a special fast charge algorithm. The Fast charge algorithm reduces the charging time to maximise your enjoyment of RC flying/racing. BLACKMAX also offers Storage mode for maximizing the life of Lithium batteries.

3 Maximized Safety Features Delta-peak sensitivity for NiMH and NiCd chemistry: The automatic charge termination program works on the principle of the Delta-peak voltage detection. When charging NiCd or NiMH using the AUTO current algorithm, you can set the upper limit of charge current to avoid overcharge of your battery pack. This algorithm is highly desirable when charging low impedance small capacity NiMH battery packs. Capacity limit: When charging all battery chemistries you have the option of setting a maximum capacity. Once this capacity is reached BLACKMAX will automatically terminate the charge process. Temperature limit: BLACKMAX comes to you with a temperature sensor probe. When using this probe in conjunction with the temp sens function the temperature of the battery is monitored and Charging is terminated if the battery pack should reach the user set temperature limit. Processing time limit: BLACKMAX further ensures the safe charging process by monitoring a user defined maximum charge time. Once the charge time is reached the charge process is automatically terminated. Input power monitor: BLACKMAX monitors the input voltage to it s system. If the input voltage drops to an unusable level (car battery going flat) BLACKMAX will automatically terminate the charging process. Built in cooling fan: BLACKMAX comes with a built in cooling fan which runs automatically when the internal temperature of the unit requires cooling. 5 User Programmable Settings BLACKMAX offers storage for 5 user programs to store your favorite user settings. Cyclic charging/discharging BLACKMAX can breath new life into those battery packs that you thought were at end of life. You can perform between 1 and 5 cycles of charge>discharge or discharge>charge for NiCd and Nimh packs. PC based analysis using USB communication For the technical minded BLACKMAX offers PC based program analysis of the charge discharge process via the USB port. Included software will allow you to graph voltage, current, capacity and temperature curves. Individual voltage of each cell can also be monitored when using balance charge functions.

4 Exterior of the unit Lithium balance charge program connection WARNING Damage may result to your batteries or your BLACKMAX charger if batteries are connected incorrectly. When charging using the balance program please connect the balance connector of the battery pack to the 2,3,4,5 or 6 cell balance connector and then connect the main power cables to the positive and negative connectors on the side of the unit. BALANCE CONNECTORS POWER CONNECTORS

5 Warnings and safety notes Never leave BLACKMAX unsupervised during the Charge/Discharge process. If any abnormal charging characteristic is observed, immediately terminate the process and refer to the operation manual. To maximise the life of your BLACKMAX charger keep it away from dust, damp, rain, heat direct sunshine and vibration. Be careful not to drop your BLACKMAX charger. The BLACKMAX circuitry will operate when powered from a 10-18V DC only. AC power is possible with the optional Booma-RC BLACKMAX AC power adaptor. This unit and the battery to charge or discharge should be set up on a heat-resistant, non-inflammable and non-conductive surface. Never place them on a car seat, carpet or similar. Keep all the inflammable volatile materials well away from operating area. It is your responsibility to understand the chemistry of the battery to be charged or discharged. If incorrect battery chemistry is selected the battery can be damaged or destroyed and fire may result. Please read and thoroughly understand the following battery information. NiCd/NiMH Voltage level:1.2v/cell Allowable fast charge current:1c-2c depends on the performance of cell Discharge voltage cut off level 0.85V/cell(NiCd), 1.0V/cell(NiMH) Lilo LiPo Voltage level:3.6v/cell. Max.charge voltage:4.1v/cell. Allowable fast charge current: 1C or less. Min.discharge voltage cut off level:2.5v/cell or higher. Voltage level:3.7v/cell. Max.charge voltage:4.2v/cell. Allowable fast charge current: 1C or less. Discharge voltage cut off level:3.0v/cell or higher. Life (A123) Voltage level:3.3v/cell Max.charge voltage:3.6v/cell Allowable fast charge current: 4C or less(e.g. A123M1) Discharge voltage cut off level:2.0v/cell or higher Pb Voltage level:2.0v/cell (Lead-acid) max.charge voltage:2.46v/cell Allowable fast charge current:0.4c or less Discharge voltage cut off level:1.50v/cell or higher To avoid short-circuits when connecting batteries to BLACKMAX, always connect the charge cable to the unit first and only then to the battery.

6 -Never attempt to disassemble a battery pack. -It is imperative that you pay attention to the capacity and the voltage of the Lithium battery pack. Lithium battery packs may be composed of parallel and series connection cells. Cells in series multiply the voltage of each cell by the number of cells. Cells in parallel multiply the capacity of the cell. Most Lithium packs will have information stamped on the outside of the package. It is your responsibility to understand the configuration of your battery packs. Discharge Discharging a battery pack is used to determine the residual capacity of the battery, or to lower the voltage of battery to a defined long storage level. When you discharge a battery pack you should pay close attention to the voltage levels to avoid the battery becoming deep-discharged. Lithium batteries should never be deep-discharged to lower than the minimum manufacturers recommended voltage. Generally, you do not need to discharge Lithium battery packs. -Some NiCd and NiMH batteries are said to have a memory effect. If they are partly used and recharged before the whole charge is drawn out, they remember this and next time will only use that part of their capacity. BLACKMAX offers a Charge/Discharge cycling algorithm to assist in maximizing the life of your NiCd and NiMH battery packs. -A new NiCd battery pack requires several charge/discharge operations to reach it s full capacity. The cyclic process of charging and discharging will optimize the capacity of battery pack. - Lithium battery chemistry is better suited to partial rather than a full discharge. Frequent full discharges should be avoided if possible. Instead, charge the battery more often or use a larger battery. Warnings and safety notes are important. To avoid injury, loss of property or damage to the charger please follow the instructions.

7 Program Flow Chart

8 Initial Parameter set up (Users set up) BLACKMAX will start with basic user settings when it is connected to a 12V battery for the first time. The screen displays the BLACKMAX BRC6 welcome screen and then will switch to the last used setting. You can freely change the parameter as required. To select different battery programs repeatedly select the Batt Type. This will cycle through the different battery basic chemistries. To alter the parameter of any battery chemistry press the Enter/Start key. This will cause the selected parameter to start flashing. Pressing the Enter/Start repeatedly will cycle through each parameter in the selected chemistry type. When a parameter is blinking the INC or DEC key is used to change the value up or down. Pressing the enter key will store the selected value. Here is an example: Press the battery type button until the screen shows USER SET PROGRAM. Press the Enter key to display the chemistry type. Press the Enter again key and the battery cell voltage should blink. Press the INC or DEC keys to change the Lithium battery voltage (and type). There are three kinds of Lithium battery: LiFe(3.3V), Lilo(3.6V) or LiPo(3.7V). Selecting the correct lithium chemistry is very important when charging lithium batteries. If the incorrect battery type is selected the battery may be overcharged and can explode during charge process. BLACKMAX will perform voltage detection to recognise the cell count of Lithium batteries automatically at the beginning of charge or discharge process. This algorithm cannot accurately recognise cells count if the battery pack is deeply discharged. BLACKMAX allows you to set the time of intelligent detection up to 10 minutes. In most cases (if a lithium battery pack is in usable condition) 10 minutes is sufficient to recognise the cell count correctly. You can override the automatic cell count selection by manually setting the cell count of your lithium battery pack prior to commencing the charge process.

9 For NIMH and NiCd battery chemistry you can set the trigger voltage for automatic charge termination. The effective value ranges from 5 to 20mV per cell. If the trigger voltage is set higher, there is a danger of overcharging the battery; if it is set lower, there is a possibility of premature termination. Please refer the technical specification of the battery.(nicd default:12mv, NiMH default:7mv). BLACKMAX BRC6 comes to you with the ability to monitor battery cell temperature or to connect to a PC for more refined monitoring of the charge/ discharge cycle. For temperature monitoring please connect the supplied temperature probe to the 3-pin port at left side of the unit. To monitor battery charge/discharge via your PC please connect the USB port to your PC via the supplied USB cable. You can choose to monitor temperature or PC functionally in the USER PROGRAM setting. To run the PC software you will need to install the software and USB driver prior to connecting the BLACKMAX BRC6 to your PC. Temperature monitoring, you can set the maximum temperature at which the charger should allow battery to reach during charge. Once a battery reaches this temperature during charge, the process will be automatically terminated to protect the battery. Cyclic Charge/Discharge, with cyclic battery charge/discharge the battery can often become warm. Within user settings you can adjust the time delay to occur after each charge and discharge process to allow the battery adequate time to cool down before being subjected to the next process. The value ranges from 1 to 60 minutes. Automatic Charge Timer When you start a charge process, the integral safety timer automatically starts running at the same time. This is programmed to prevent overcharging the battery. The value for the safety timer should be set to allow a full charge of the battery.

10 Maximum Charge Capacity, this setting sets the maximum charge capacity that will be supplied to the battery during charge. If the delta-peak voltage is not detected nor the safety timer expired for any reason, this feature will automatically stop the process at the selected capacity value. User feedback, BLACKMAX offers user feedback in the form of a programmable beep at every key press and/or to warn of the completion of a charge cycle. These audible beep sounds can be programmed to be ON or OFF in the user settings. Input Voltage Level, monitors the voltage of input battery. If the voltage drops below the value you set the operation is terminated to protect the input battery. Lithium battery Lilo/LiPo/LiFe (A123) program These programs are only suitable for charging and discharging Lithium batteries with a nominal voltage of 3.3V, 3.6V and 3.7V per cell. These batteries have a different charge technique termed constant voltage (CV) and constant current (CC) method. The charge current varies according to the battery capacity and performance. The final voltage of charge process is precisely matched with the lithium battery chemistry being: 4.2V for LiPo, 4.1V for Lilo, and 3.6 V for LiFe (A123). It is important that you choose the correct lithium chemistry type (voltage) and battery capacity before you commence charging your batteries. Charging Lithium Batteries The left side of the first line shows the type of battery you select at the users setting. The value on the left side of second line sets a charge current and the value on the right side of second line sets the voltage of the battery pack. After setting the current and voltage press Start/Enter key for more than 3 seconds to start the process. (Charge current:0.1~5.0a,voltage:1~6 series)

11 Once the charge process starts you will be shown the number of cells you set up and the processor will auto detect the number of cells and ask you to confirm it s findings. R: shows the number of cells found by the charger and S: is the number of cells selected by you at the previous screen. If both numbers are identical you can start charging by pressing Start/Enter button. If not, press Batt Type/ Stop button to go back to previous screen. Then carefully check the number of cells of the battery pack before attempting to charge again. To stop charging press Batt Type/Stop key once. Charging Lithium batteries in balance mode This mode is used for balancing the voltage of individual Lithium battery cells and for charging Booma-RC MAXPACK batteries. If charging a single battery pack, connect the balance charge jack to the appropriate balance port on the right side of the BLACKMAX charger. You then connect the main power output lead to the output plug to the output of charger. When you charge in this mode charger will monitor the voltage of each cell of the battery pack and adjust charging current that is feeding to each cell. This is balance charging and this mode will give you maximum life of your MAXPACK battery. YOU CAN BALANCE CHARGE 2 x MAXPACK battery packs with the Booma-RC 2 x MAXPACK adaptor. Please see instruction supplied with the MAXPACK adaptor for details. The value on the left side of second line sets the charge current and the value on the right side of second line sets the voltage of the battery pack. After setting the current and voltage press the Start/ Enter key for more than 3 seconds to start the process. (Charge current:0.1~5.0a, Voltage:1~6 series) Once the charge process starts you will be shown the number of cells you set up and the processor will auto detect the number of cells and ask you to confirm it s findings. R: shows the number of cells found by the charger and S: is the number of cells selected by you at the previous screen. If both numbers are identical you can start charging by pressing Start/Enter button. If not, press the Batt Type/Stop button to go back to previous screen. Then carefully check the number of cells of the battery pack to charge again.

12 After charging starts the screen shows details of the charge process. To stop charging press Batt type/ Stop key once. FAST charging Lithium batteries Fast charging is designed so you can maximise your enjoyment of the battery usage in a reduced time frame. The algorithm will reduce the time to charge your lithium battery with a slightly reduced capacity. The charge process follows the standard CV/CC algorithm but stops the charge process at 1/5 of the initial charge value instead of 1/10 of normal charge current. Just as with normal and balance charging you can set the desired values prior to commencing the Fast Charge process. Starting the charge process is the same as balance and normal charging. The screen shows the present situation during charge process. To stop charging press Batt type/ Stop key once. STORAGE control of Lithium batteries This is for charging or discharging Lithium battery for long term storage. The program will automatically determine whether to charge or discharge the battery to the storage voltage depending on the voltage of the battery. Each lithium battery chemistry has a preferred storage voltage being: 3.75V for Lilo, 3.85V for LiPo and 3.3V for LiFe (A123) per cell. Prior to commencing the storage program please set the voltage and capacity of the battery pack. Depending on the charge level of the battery pack, BLACKMAX will charge or discharge the battery to reach the desired storage level.

13 After charge/discharge starts the screen shows details of the charge process. To stop charging press Batt type / Stop key once. Discharging Lithium batteries When discharging lithium batteries it is recommended that the value of discharge current (Shown on the left side of the LCD screen) not exceed 1C. The final voltage (Shown on the right side of the LCD screen) should be selected for the appropriate battery chemistry being discharged. Failure to select the correct final voltage may damage the battery. To start the discharge process, press the Start/ Enter key for more than 3 seconds. To stop discharging press Batt type/stop key once. Voltage balancing and monitoring during the discharge process During a balance charge/discharge the processor monitors the voltage of individual cells for storage-mode and discharge of Lithium battery packs. If the cells are well matched and in good condition BLACKMAX will balance the voltage of each cell. This process wil micro charge/discharge a cell to achieve a balance condition. Monitoring each cells voltage can be achieved by pressing the inc button during the charge/discharge process. If the voltage of any one (or more) cells varies abnormally during the procedure, BLACKMAX will terminate the process and an error message will be displayed. If this happens, the battery pack may contain a bad cell or a bad connection exists. In the example to the left, BLACKMAX has discovered the voltage of one of the cells in the Lithium battery pack is too low. In this case, the 4th cell is bad. Check cables and if the cables are good then the cell of the battery is bad.

14 NiMH/NiCd battery program The NiMH/NiCD programs are for charging or discharging NiMH (Nickel-Metal- Hydride) or NiCd (Nickel-Cadmium) batteries. To alter the value at the display, press Start/Enter key to make it blink then change the value using INC or DEC key.the value will be stored by pressing Start/Enter key once. To start the process, press Start/ Enter button for more than 3 seconds. Charging NiCd/NiMH batteries BLACKMAX offers 2 Modes for charging NiMH/NiCD batteries. 1) Auto program mode will charge the battery pack using a smart algorithm that applies charge/ discharge techniques to arrive at the final delta peak voltage of the battery pack. Auto mode has a user set current limit function to limit charge current fed into low impedance packs during the early stages of the charge process. 2) Manual program mode will charge the pack at the user set current and sense the Delta Peak value of the battery pack to stop the charge process. Each mode can be switched by pressing the INC and DEC buttons simultaneously when the current value is blinking. Discharging NiCd/NiMH battery When discharging NiMH/NiCD packs you set the discharge current and final voltage of the pack at discharged state. Discharge current is seen on the left and final voltage on the right of the LCD screen. The discharge current ranges from 0.1 to 1.0A and the final voltage ranges from 0.1 to 25.0V. To start the process, press the Start /Enter key for more than 3 seconds. The screen displays the current state of discharge. You can alter the discharge current by pressing StartEnter key during the process. Once you change the current value, store it by pressing Start /Enter button again. To stop charge/discharging press Batt type/ Stop key.

15 Charge/Discharge & Discharge/Charge cycle NiMH/NiCd battery The Charge/Discharge cycle algorithm will allow you cycle packs up to 5 times to break-in a new NiMH/NiCD pack or revitalise older packs. Set the sequence (discharge/charge or charge/ discharge) on the left and the number of cycles on the right. Set the number of cycles on the right. A temperature cool down pause time can be set in the user program section to pause between the cycle process. To stop the process, press Batt type/stop key once. At the end of the process, by pressing the INC or DEC button, you can see charged or discharged capacity of the battery for each cycle. Pb( lead-sulphuric acid) battery program The Pb (lead-sulphuric acid) program will allow you to charge lead acid batteries from 2 to 20V. The optimal charge current will be 1/10 of the capacity. Pb batteries must not be charged rapidly. Charging a Pb battery Charge current is shown on the left and the nominal voltage of the battery on the right of the LCD screen. Charge current ranges from 0.1 to 5.0A and the voltage should be matched with the battery being charged. Start the charge process by pressing Start/Enter key for more than 3 seconds.

16 During the charge process the LCD screen displays the charge state of the battery. To stop the charging process, press Batt type/stop key. Discharging Pb battery Discharge current is set on the left and final voltage on the right of the LCD screen. The discharge current ranges from 0.1 to 1.0A. During the discharge process the screen displays the state of the battery. You can alter the discharge current by pressing Start/Enter key during the process. Once you change the value, store it by pressing Start Enter button again. Save Data Program BLACKMAX comes with 5 user programmable memories for you to store your battery charge discharge setups. Saving a program to a memory position is a simple task of selecting battery type and parameters as explained earlier in this user guide and then using the Batt Type button scroll to the Save Data page. Press and hold the Select button for more than 3 seconds to store the data in the selected memory. The following example shows how to set up and save a program for a NiMH battery pack of 12cells and 3000mAh of capacity.

17 Select the charge current for manual charge mode, or the current limit for automatic charge mode. Set up discharge current and final voltage. Set up the cycle type (charge/discharge or discharge/ charge) and number of cycles. Press and hold the Select button for more than 3 seconds to store the data in the selected memory. Load Data Program Your previously saved programs can be recalled from memory. To load a previously saved program: 1) Press the Batt Type button to scroll to the Load Data page. 2) Press the select button and the memory number will flash. Use the + and - buttons to select the desired program to load. 3) Press Start /Enter key for more than 3 seconds. The selected program will load into memory.

18 Information screens BLACKMAX gives you the opportunity to view information on the LCD screen during charging or discharging process. Sequentially pressing the DEC - button will show the user settings. In balance charge mode you can monitor the voltage of individual cells by pressing INC + button. End Voltage. The final battery voltage when the charge process terminates. Capacity cut-off. When set on ON the charge process will terminate if the preset capacity is reached irrespective of whether the battery is fully charged. Safety time function. When set to ON the charge process will terminate if the safety timer value is reached irrespective of whether the battery is fully charged. USB/Temp. Assigns the data port as USB (connect to a PC) or temperature measurement (requires the use of the temperature probe). If the temperature function is selected then temperature will be displayed when using the thermal probe. The present voltage of input DC power. If the voltage falls below the user preset input voltage then a warning is shown and the charge process will terminate. When balance charging/discharging with Booma-RC MAXPACKS pressing the + button will show the individual voltage of each cell in the battery pack. When using the Booma Dual Charge adaptor 2 x Booma-RC MAXPACKS can be simultaneously charged and the voltage of each individual cell of both packs can be viewed. This type of balanced charging ensures the best life and capacity for your Booma-RC MAXPACKS.

19 Warning and error messages BLACKMAX incorporates a microprocessor and intelligent algorithms to give you the maximum possible safety and protection for your batteries. When an error occurs you will be shown one of the following errors. BLACKMAX output is connected to a battery with incorrect polarity. A connection between the battery and BLACKMAX has become open circuit. A short circuit has happened on the output of BLACKMAX. BLACKMAX input voltage has droped below the required input level. The voltage of the battery pack was selected incorrectly. Please check the cell count of the battery pack. An internal software/hardware malfunction has occurred. Please contact Booma-RC for assistance. Lithium pack voltage is set lower than the pack voltage indicates. Please check the cell count of the battery pack. Lithium pack voltage is set higher than the pack voltage indicates. Please check the cell count of the battery pack. The voltage of one of the cells in a Lithium battery pack is too low. This may indicate a faulty cell. The voltage of one of the cells in a Lithium battery pack is too high. Please check the voltage of the cell one by one.

20 BLACKMAX has found a bad connection in the balance connector. Please check the connector and cables carefully. BLACKMAX internal temperature is too high. Please disconnect all batteries and power and allow BLACKMAX to cool down. BLACKMAX cannot control the level of output current. Please contact Booma-RC for assistance. Specifications Operating voltage range: Circuit power: Charge current range: Discharge current range: Lipo balancing current: NiCd/ NiMH battery cell count: Lithium battery cell count: Pb battery voltage: Weight: Dimension: 10.0~18.0Volt Max.50W for charging. 5W for discharging. 0.1~5.0A 0.1~1.0A 300mAh/cell 1~15cells 1~6Series 2 to 20V 400g mm Warranty and service Booma-RC warrants BLACKMAX for a period of one year (12 months) against manufacturer defect from the date of purchase. The guarantee applies only to such material or operational defects, which are present at the time of purchasing the product. During that period, we will replace without service charge any product deemed defective due to those causes. You will be required to present proof of purchase (invoice or receipt). This warranty does not cover the damage due to wear, overloading, incompetent handling or using of incorrect accessories. Booma-RC 85 Wattle Road, Flinders NSW