CH0003 Battery Charger/Conditioner Operation Manual Equivalent to: NSN: 6130-01-499-7305 Ultralife Corporation 2000 Technology Parkway, Newark, NY 14513 USA Telephone (315) 332-7100 FAX (315) 331-7800 E-MAIL: sales@ulbi.com http://www.ultralifecorporation.com CH0003 Operation Manual Newark, New York | 315-332-7100 | Fax: 315-331-7800 ©2010 Ultralife Corporation • www.ultralifecorp.
Copyright Copyright © 2010, Ultralife Corporation. All Rights Reserved. Disclaimer of Liability Information and descriptions contained in this manual are the property of Ultralife Corporation. Distribution and/or reproduction in part or in whole are expressly forbidden without written consent. Ultralife Corp believes that information in this publication is accurate as of its publication date. Ultralife Corp.
CONTENTS CONTENTS ........................................................................................................ 3 1 ABOUT THIS MANUAL ............................................................................... 4 1.1 1.2 SYMBOLS USED .................................................................................................................4 GENERAL SAFETY INSTRUCTIONS .......................................................................................5 2 PRODUCT DESCRIPTION .....
1 ABOUT THIS MANUAL This manual has been prepared by Ultralife Corp for the purpose of providing a maintenance technician the information necessary to understand and to maintain the CH0003 Battery Charger/Conditioner. 1.1 Symbols Used The symbols shown in this section appear throughout this manual, the first one shown being the NOTE symbol, below, which is self-explanatory. NOTE: Note statements contain important information that may affect how you use this product.
1.2 General Safety Instructions WARNING: Prior to using the CH0003, please read the safety and caution instructions located in this section to prevent the mischarge or catastrophic destruction of a battery. While inherently safe, misuse of the CH0003 may result in damage to the battery and/or the CH0003 battery charger. Specifically: Before using the CH0003 battery charger, read all instructions and cautionary markings on (1) the battery charger, (2) battery, (3) product using the battery.
2 PRODUCT DESCRIPTION The CH0003 Battery Charger/Conditioner is designed to provide a safe and effective recharge of the following batteries: BB-390/U / MAI-390 Nickel Metal Hydride BB-590/U / MAI-590 Nickel Cadmium BB-2590/U Lithium-ion UBI-2590 Lithium-ion UBBL09 Lithium-ion These batteries are rechargeable batteries commonly used with Tactical Communication Equipment. Each battery has the same form factor and in many cases is interchangeable for battery operated equipment.
2.1.3 NiCad OR NiMH Battery Detection With the lack of a contact, as with Lithium Ion batteries, the CH0003 will assume that the battery is a Nickel-based chemistry (NiCad or NiMH). The charger will charge at a constant current of 1A while sampling change in voltage. When a negative change in voltage is detected, the peak has been found and the charge is complete. There is a 6-hour safety timer that will terminate the charge if the battery never peaks.
Figure 1: Name Plate 2.1.9 Equipment Provided Provided with the CH0003 Charger/Conditioner is, an AC power cable and this technical manual. 2.2 Physical Description The CH0003 is 635mm (25") L x 508mm (20") W x 229mm (9") D and weighs approximately 15kg (33 lbs.) Figure 2 shows the physical layout of the charger. The CH0003 consists of six charge modules, an AC to DC Power Module and a Control/Filter Board. Figure 2: CH0003 Charger (Front View) 2.
2.3.1 Charge Supply The Charge Modules are non-repairable potted modules. These modules accept a DC input voltage, monitor battery selection and provide the charging functions for the battery to be charged. The battery detection circuit, discharge switches, battery charge indicator LEDS and charge circuitry are all located on these boards. Each module provides the necessary voltage/current parameters to the battery charge connectors. 2.3.
3 OPERATION This section provides a basic operational description of the CH0003 battery charger and its assemblies/major components. 3.1 Grounding Connections The CH0003 should be grounded to reduce risk of electric shock. The CH0003 is equipped with an electric cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.
CAUTION: Prior to charging any rechargeable battery, verify the type of battery to be charged. The CH0003 consists of six charge modules and a Control/Filter Board. The CH0003 will safely and completely recharge UBI-2590, BB-2590, UBBL09 Li-ION, BB-390/U, BB-590/U, and UBBL02 batteries.
Figure 3 CH0003 Operation Panel 3.6.1 Green LEDs Battery Type Indicators 3.6.2 Green LEDs Charging Indicators 3.6.3 Yellow LEDs Charging Indicators 3.6.4 Yellow LEDs Discharging Indicators Calibrate/Condition Red Push Button Figure 4 LED Indicators CH0003 Operation Manual Newark, New York | 315-332-7100 | Fax: 315-331-7800 ©2010 Ultralife Corporation • www.ultralifecorp.
3.6.1 “Battery Type” Indicator LEDs When a battery is plugged in to the charger, one of the two green LEDs labeled "BATTERY TYPE" will indicate which type of battery (UBI-2590 / UBBL09 / BB-2590 or BB-390 / BB-590) is plugged in. When the correct type of battery is indicated, the battery will be charged correctly. If the incorrect type of battery is indicated, remove the battery from charger.
4 MAINTENANCE Maintenance for the CH0003 is described in the following sections. 4.1 Cleaning Cleaning of the CH0003 is described in the following sections. 4.1.1 Dirt and Dust All external components to the CH0003 can be cleaned with a water dampened non-abrasive cloth and allowed to air dry or wipe dry with a clean dry non-abrasive cloth. 4.1.2 Oils and Grease All external components of the CH0003 can be cleaned with a mild soap/water solution dampened non-abrasive cloth.
5 CUSTOMER ASSISTANCE 5.1 Warranty Information Warranty Statement 4 years for equipment shipped after May 1, 2004. 3 years for equipment shipped prior to May 1, 2004. Ultralife Corporation warrants to its customers that the products it manufactures and sells will be free from defects in materials and workmanship for a period of four (4) years for equipment shipped after May 1, 2004. This warranty shall not apply to any defect, failure or damage caused by improper use or inadequate maintenance and care.
6 SPECIFICATIONS Table 1: Physical Characteristics Dimension Measurement Width 508mm (20 inches) Length 635mm (25 inches) Depth 229mm (9 inches) Weight without Battery 15kg (33 lbs) Table 2: LED Indicators Indicator Meaning Flashing Green Pre-charge Condition Steady Green Fast Charge Green LED Off Fast Charge Complete Table 3: Electrical Characteristics Dimension Measurement DC Input Range 12-36 VDC auto ranging AC Input Range 115-230 VAC 50/60 Hz Charge Rate 1.
