TABLE OF CONTENTS Introduction......................................................................................................03 Special Features .............................................................................................05 Warning and Safety Notes...............................................................................07 Program Flow Chart ........................................................................................10 Connecting the Charger ........................
INTRODUCTION Thank you for purchasing the Prodigy 620 DUO charger from ProTek R/C. You are now the owner of a professional-level battery management system. The Prodigy 620 DUO is very simple to use, but unlocking the full power of such a capable charger requires some knowledge on the part of the user; these instructions are to help familiarize the user with the features of the charger, as well as how to use them to their fullest capabilities.
INTRODUCTION Left View Smart Fan Power Input (12-18V DC) Output 1 Balancing Port 1 Temperature Sensor 1 Right View Display 1 Large 2x16 LCD for Easy Reading Temperature Balancing Port 2 Sensor 2 Output 2 Smart Fan Output 1 Batt Type/ INC/DEC Stop Button Button Display 2 Large 2x16 LCD for Easy Reading Navigation Buttons Output 2 Enter/Start Batt Type/ INC/DEC Enter/Start Button Stop Button Button Button · 04
SPECIAL FEATURES SET CONTENTS 1 2 3 5 4 1. Prodigy 620 DUO Charger 2. JST-XH Balancing Adaptor (2 Sets) 3. Alligator Clip Charging Cable (1) 4. 18AWG Wire Charging Cable (2) 5. Plug-in Battery Clamps SPECIAL FEATURES Operating software optimized for ease of use and maximum safety The user can adjust each of Prodigy 620 DUO’s settings and parameters.
SPECIAL FEATURES Compatible with all types of lithium batteries The Prodigy 620 DUO is capable of charging various types of lithium batteries, such as LiPo, LiFe, and Li-Ion. Fast charge and storage charge modes for lithium batteries Fast charge alters the rate of change in charge current to reduce the duration of the charging process, while the storage charge mode brings the voltage of the pack to a suitable level for long-term storage.
WARNING AND SAFETY NOTES These warnings and safety notes are particularly important. Please follow the instructions for maximum safety; failure to adhere to these instructions may damage the charger and/or battery and may cause a fire. Never leave the charger unattended when connected to its power supply. If any malfunction occurs, TERMINATE THE PROCESS AT ONCE and refer to the instruction manual. Keep the charger well away from dust, moisture, rain, heat, direct sunshine and vibration.
WARNING AND SAFETY NOTES Never attempt to charge a battery that is: - made of different types of cells. - made of cells from multiple manufacturers. - non-rechargeable. - not among the types listed as compatible with Prodigy 620 DUO (NiCD, NiMH, LiPo, LiFe, Li-Ion, or lead-acid). - faulty or damaged. - fitted with a charge circuit or protection circuit. - installed in a device, or electrically linked to other components. - incompatible with the available charge current.
WARNING AND SAFETY NOTES Special attention should be paid to the connection of Lithium batteries. Do not attempt to disassemble the battery pack. Lithium battery packs can be wired in parallel and in series. In parallel connection, the battery’s capacity is calculated by multiplying single battery capacity by the number of cells. Attempting to charge cells with different voltage levels that are wired in parallel may cause fire or explosion. ProTek R/C recommends charging lithium batteries in series only.
PROGRAM FLOW CHART · 10
CONNECTING THE CHARGER Connecting the Charger The Prodigy 620 DUO comes with male 4mm Bullet connectors attached to the power INPUT cables. These cables are appropriate for attaching directly to most high-quality AC-DC power supply units, such as the ProTek R/C "Super Pro 1000" (30V/40A/1000W). Also included are large Terminal Clips with matching 4mm female bullet connectors for attaching directly to 12V car batteries. It is critically important that you use either a fully charged 13.
CONNECTING THE BATTERY Connecting the Battery Before connecting the Prodigy 620 DUO to a battery, it’s essential to verify that the charger’s parameters match the battery to be charged or discharged; incorrect settings may damage the battery and can cause a fire. To avoid short-circuiting the battery pack, always connect the large leads to the charger before connecting to the battery. When disconnecting, unplug the battery first and then the charger.
INITIAL PROGRAMMING SETUP (USERS SETUP) Initial Programming Setup When powering up your new Prodigy 620 DUO for the first time, its charge parameters will be set to their default values. You may change the values of each parameter and then store these new settings to recall later. To change the value of a specific parameter, press the “Start/Enter” button to make it blink; when blinking, press the INC or DEC buttons to change the parameter to the desired value.
INITIAL PARAMETER SETUP (USERS SETUP) DEC DEC INC DEC INC DEC DEC INC DEC DEC INC DEC DEC INC When using the optional temperature probe to monitor the battery, the temperature cut-off can be turned on or off. When turned on, the maximum temperature of the battery can be set. If the battery reaches this temperature the charge process will be terminated automatically. DEC INC A battery pack may become hot when cycled through multiple charge and discharge cycles.
LITHIUM BATTERY (LI-ION/LIPO/LIFE) PROGRAM Lithium Battery Charge Overview These programs are only compatible with Lithium batteries with nominal voltages of 3.3V, 3.6V, or 3.7V per cell. These batteries require a charge technique called the CC-CV (constant current-constant voltage) method. The charge current varies according the battery capacity and performance. V/A /A h A Lithium battery is charged at a constant current (A) until it reaches the final charge voltage of 4.2V per cell (B).
CHARGING LITHIUM BATTERIES Charging lithium batteries in the charge mode Lithium batteries with no balance lead should be charged using the standard charge mode (indicated on the right of the first line of the screen). Note: ProTek R/C recommends charging lithium batteries with a balance lead in the Balance Mode only. - + DEC INC Batt Type Stop - + DEC INC The left side of the first line shows the type of battery to be charged.
BALANCE CHARGING LITHIUM BATTERIES Charging lithium batteries in the balance mode The balance charging mode (indicated on the right of the first line of the screen) balances the voltage of the cells in a lithium battery during the charge process. In order to balance charge a lithium battery you must connect its balance lead to the charger in addition to connecting the power leads to the battery.
FAST CHARGING LITHIUM BATTERIES Charging lithium batteries in the fast charge mode When charging in CC-CV mode, the charge current is reduced throughout the process until it reaches 1/10 of the battery’s capacity. In order to charge the battery more quickly, the fast charge mode slows down more gradually until reaching 1/5 of the battery’s capacity. Fast charging may not charge the battery to the same capacity as the normal charging mode, but the charging time will be reduced.
CHARGING LITHIUM BATTERIES FOR STORAGE Charging Lithium batteries in the storage mode The Prodigy 620 DUO features a storage mode that is ideal for preparing lithium batteries for long-term storage. Storage mode will charge or discharge the battery to a specific voltage per cell (LiPo: 3.85V LiFe: 3.3V Li-Ion: 3.75V) that is roughly 50% that of a fully charged pack. - + DEC INC - + DEC INC Batt Type Stop The left side of the first line shows the type of battery to be stored.
CHARGING NICD/NIMH BATTERIES Voltage Balancing and Monitoring During the Discharge Process The Prodigy 620 DUO monitors the voltage of each cell of a Lithium battery during the storage and discharge processes. If the voltage of any cell in the pack is abnormal, which may indicate a bad connection or a damaged cell, Prodigy 620 DUO with show an error message and terminate the process. You may press the INC button to view the voltages of each cell to determine which is damaged.
DISCHARGING NICD/NIMH BATTERIES Discharging NiCd/NiMH Batteries - + DEC INC Batt Type Stop - + DEC To begin discharging, you must set the discharge current (0.1-5.0A) on the left and final voltage (0.1-25.0V) on the right. Press and hold the Start/Enter button for more than three seconds to start the discharge process. INC Start Enter '> 3 seconds’ Battery Elapsed Type Time Battery Voltage Discharged Capacity Discharge Current This screen indicates the real-time status of the discharge process.
CHARGING LEAD-ACID BATTERIES Charging Lead Acid Batteries This mode is only suitable for charging lead-acid (Pb) batteries with a nominal voltage between 2-24V. Because lead-acid batteries can only deliver current lower than their capacity, the charge program reflects this; lead-acid batteries cannot be charged at a current higher than 1/10 of the battery’s capacity. Lead-acid batteries cannot be fast charged, and you should always follow the instructions of the battery’s manufacturer.
SAVING CHARGE PROFILES Saving Charge Profiles For your convenience, the Prodigy 620 DUO can store the parameters for up to ten charge profiles (per channel) that can be recalled without having to go through the setup process. Start Enter Data Number Voltage Batt Type Stop DEC INC Capacity Type of Battery This screen indicates the current settings of the active profile.
LOADING CHARGE PROFILES Loading Charge Profiles Once you’ve saved a charge profile in the Prodigy 620 DUO, you can load those settings to use later. Start Enter To recall a charge profile, press the Start/Enter button to load the data. Press the INC or DEC buttons to choose the profile you wish to recall; the data for the active profile will be shown on the screen. Press and hold the Start/Enter button for more than three seconds to load the active profile.
WARNING AND ERROR MESSAGES The Prodigy 620 DUO constantly monitors its performance to ensure safe operation. Should an error be detected, an alarm will sound and an error message will be displayed. Battery was connected incorrectly. Check that the polarity of the charge leads is correct. The battery is no longer connected to the charger. Check to make sure the charge leads are plugged in securely, and examine the charge leads for damage. The charge leads have been short-circuited.
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CONFORMITY DECLARATION The Prodigy 620 DUO satisfies all relevant and mandatory EC directives and FCC Part 15 Subpart B: 2008.
MAXIMUM CIRCUIT POWER CHART Maximum circuit power chart (Output 1 & 2) The actual amount of charge current feeding to the battery is automatically be limited to 400 Watts each, so not to exceed the charger's maximum rated charging power. The maximum discharge power is approximately 25 Watts. The discharge current delivered to the charger is limited by charger's internal thermal sensor for maximum discharge current.
MAXIMUM CIRCUIT POWER CHART Battery Type Pb 6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0 7.4 9.8 12.3 14.8 17.2 19.7 22.1 24.6 20.0 20.0 20.0 20.0 20.0 20.0 18.0 16.0 3.4 2.5 2.0 1.7 1.5 1.3 1.1 1.0 Specification Input voltage: Maximum power output: Charge current: Discharge current: Current drain for balancing lithium batteries LiPo/LiFe/Li-Ion cell count: NiCd/NiMH cell count: Lead Acid (Pb) battery voltage: Net weight Dimensions 12-18V DC Charge: 400W per channel Discharge: 25W per channel 0.1-20.0A 0.
COMMONLY USED TERMS Commonly used terms Final charge voltage: the voltage at which the battery's charge limit (capacity limit) is reached. The charge process switches from a high current to a low maintenance rate (trickle charge) at this point. From this point on further high current charging would cause overheating and eventual terminal damage to the pack. Final discharge voltage: the voltage at which the battery's discharge limit is reached.
Manufactured by ProTek R/C www.ProTekRC.com All specifications and figures are subject to change without notice.