CH0007 Nine-Position Smart Charger Operation Manual 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 CH0007 Operation Manual Newark, New York | 315-332-7100 | Fax: 315-331-7800 ©2010 Ultralife Corporation • www.ultralifecorp.
Copyright Copyright © 2009, 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 Corporation believes that information in this publication is accurate as of its publication date.
CONTENTS 1 1.1 1.2 2 ABOUT THIS MANUAL ................................................................................................5 SYMBOLS USED .................................................................................................................5 GENERAL SAFETY INSTRUCTIONS .......................................................................................6 PRODUCT DESCRIPTION ...........................................................................................7 2.
LIST OF FIGURES FIGURE 1: CH0007 FRONT VIEW ..................................................................................................................... 8 FIGURE 2: CH0007 REAR VIEW ....................................................................................................................... 9 FIGURE 3: CONTROL PANEL OF CH0007 ........................................................................................................ 10 FIGURE 4: VFD LABEL .....................................
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 CH0007 Nine-Position Battery Charger. 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 Use only with appropriate DC input voltage and CA0011 power cable. Attempt to charge only approved batteries in this charger. Carefully check to make sure all power connections are properly insulated. Clean the contact area of the battery prior to insertion into charger to assure adequate contact. Latch the lid in position after batteries have been loaded and charging is taking place to assure that contact is maintained throughout the charge cycle.
2 PRODUCT DESCRIPTION The Ultralife Nine-Position Smart Charger is designed to charge Land Warrior type batteries that have charge and communication pins on the case top. The batteries in this series are UBBL03, S00072 and S00118. The charger is designed to support charging future battery types still under development at Ultralife. The charger is designed to charge and verify functionality of nine batteries simultaneously at currents up to 5A and 16.8 volts.
2.1 Physical Description 2.1.1 Exterior – Front View Figure 1: CH0007 Front View (A) (B) (C) (D) (E) (F) (G) (H) Charger Body – The charger body is made from aluminum Charger Lid – The charger lid is made from aluminum Charger Lid View Ports – Several areas of the charger lid have polycarbonate label- covered windows for viewing the status of the charger without opening the lid. Lid Latches – Metal push button-style latches secure the lid tightly to the base.
2.1.2 Exterior – Rear View Figure 2: CH0007 Rear View (A) (B) (C) (D) (E) (F) (G) (H) (I) (J) Charger Body – The charger body is made from aluminum. Charger Lid – The charger lid is made from aluminum. Charger Lid View Ports – Several areas of the charger lid have polycarbonate label- covered windows for viewing the status of the charger without having to open the lid. Lid Latches – Metal push button-style latches secure the lid tightly to the base.
2.1.
2.2 Functional Description 2.2.1 Smart Battery The batteries intended for use with this charger are “smart” batteries. This refers to the capability of a battery to retain, calculate, and communicate information with another device. A smart battery stores information regarding charge voltage, charge current, remaining capacity, cycles completed, internal temperature, and other characteristics. 2.2.2 Basic Charge The charger is capable of charging nine batteries simultaneously at currents up to 5A and 16.
Repeated charging and use of batteries without calibration may result in inaccurate fuel gauge information. 2.2.5 VFD Display The VFD on the charger control panel allows graphics and alphanumeric characters to be displayed. Through this display the user is supplied several important parameters and information as to the status of the battery and the charger.
2.2.6 LED Display The LED displays at each battery position give a quick status of the battery contained in that particular position. The status codes are on the “LED Display Information” label on the inside of the top lid. This label is shown in Fig. 6 below for reference. Figure 5: LED Status Label 2.2.7 Input Power Protection If the input voltage to the charger is less than 22V the low power LED on the control panel illuminates. If the input voltage drops below 21V, the charger stops operating.
3 OPERATION 3.1 Unpack and Setup The charger is fully assembled when shipped from the factory. The only component required for use is the power cable. Ultralife Batteries, Inc. recommends using only approved power cables (Ultralife part number: CA0011) with this charger. The power cable should be connected to a DC power source providing the required voltage for operation. The power cable is supplied with free terminals on one side for universal connection to multiple sources.
The VFD displays status of the battery and the charger in two separate fields. In the VFD label these correspond to ‘Battery Status’ and ‘Charger Status’ respectively. When no battery is detected the charger status will read ‘RDY’ and the battery status will read ‘EMP’. The battery status display will change from ‘EMP’ to ‘CHG’ when the battery has been successfully detected and is being charged. The charger status will read ‘ACT’ when the battery is being charged, discharged or conditioned.
3.3.2 Charger Status Codes Charger status codes give real-time information on charger status. These status codes are displayed on the VFD at the position marked in Figure 5. The following table gives in- depth information on each status code and their meaning related to charger operation. Code ACT Charger status reads ACT when charger is active.
3.3.3 Battery Status Codes Battery status codes give real time information on batteries as they are charged, discharged or conditioned in the charger. These status codes are displayed on the VFD at the position marked in Figure 5. The following table gives in-depth information on each status code and their meaning as related to charger operation.
3.4 Mounting The charger is heavy. Use appropriate tools and team lift strategy while mounting and transporting Mounting is through ¼-20 PEM nut. Mounting bracket holes are 17.38” center to center (width-wise) and 2.52” center to center (height-wise). Figure 8: Mounting Bracket Dimensions CH0007 Operation Manual Newark, New York | 315-332-7100 | Fax: 315-331-7800 ©2010 Ultralife Corporation • www.ultralifecorp.
4 MAINTENANCE Maintenance for the CH0007 is described in the following sections. 4.1 Cleaning The charger exterior and control panel can be cleaned with mild detergent. Use non-abrasive cleaning supplies for this purpose. Care should be taken when cleaning the battery cavities to prevent damage to charge pins. Avoid fluid seepage into battery cavities during cleaning. Allow charger to fully dry before use. Periodically tighten the lid hinge tension screw. This will ensure that the lid hinges remain taut.
5 PACKAGING AND SHIPPING INSTRUCTIONS The charger can be mounted to a vehicle or a rack for normal use. If it needs to be transported other than in a vehicle, please observe the following guidelines. Whenever possible pack the charger in the original packing material as shown in Fig. 13. The charger should be packed such that it does not move about within the container. Failure to do so might result in damage to charger exterior.
Figure 10: CH0007 Recommended Packaging 1. 2. 3. 4. 5. 6. Prepare Carton Insert Bottom Foam Pad Fix foam end caps to the charger Insert charger into the carton. The bottom foam pad should rest between the two end caps. Insert front foam pad Insert top foam pad. Close and seal carton. CH0007 Operation Manual Newark, New York | 315-332-7100 | Fax: 315-331-7800 ©2010 Ultralife Corporation • www.ultralifecorp.
6 SPECIFICATIONS 6.1 Physical Characteristics Dimension Measurement Width 8.4 inches (21.3 cm) (Including mounting brackets) Length 27.3 inches (69.3 cm) Height 14 inches (35.6 cm) Weight without Cables and Batteries 36 Lb. (16.3 kg) Color Olive Drab Green Case CARC coating - MIL-DTL-64159 Display VFD graphical and LED status displays Controls On/Off Toggle Switch, Conditioning Override toggle switch, VFD brightness tog switch Typical Charge Time (UBBL03) < 2.
6.3 Miscellaneous Labeling 6.3.1 Instruction Label Figure 11: CH0007 Instruction Label 6.3.2 ID Label Figure 12: ID Label CH0007 Operation Manual Newark, New York | 315-332-7100 | Fax: 315-331-7800 ©2010 Ultralife Corporation • www.ultralifecorp.
7 ACCESSORIES 7.1 Power Cable Recommended power cable for the charger is CA0011 and is supplied with the charger. One end of the power cable is terminated with a connector that mates to the charger and the other end is left free. The user is required to wire the free end to the DC power source based on the following chart.
8 CHARGER RECORD Charger Serial Number: _____________________ Charger Purchase Date: _____________________ CH0007 Operation Manual Newark, New York | 315-332-7100 | Fax: 315-331-7800 ©2010 Ultralife Corporation • www.ultralifecorp.
