Bren-Tronics BTC-70819 Operation manual

850036-1 REV C
OPERATION AND SERVICE MANUAL
SPC LITE
Universal Portable Charger
Dual-Position
BTC-70819
NSN 6130-01-555-7817
USA Tel: [phone] · Fax: [phone]
email address: [email protected]
www.bren-tronics.com

850036-1 REV C
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.
Table of Contents
CHAPTER 1 – INTRODUCTION Para Pg
Scope......................................................... 1-1 1-1
Technical Specifications…………………... 1-2 1-2
Declaration of Conformity ..........................1-3 1-3
Accessories…………………………………. 1-4 1-4
Charge Cycle Description…………………. 1-5 1-7
Updating Charger Software……………… 1-6 1-8
CHAPTER 2 – OPERATING PROCEDURES
Panel Controls and Indicators……………. 2-1 2-1
Preliminary Setup Procedures…………… 2-2 2-4
Charging Batteries………………………… 2-3 2-5
Battery Revitalization and De-Storage….. 2-4 2-6
Blackout…………………………………….. 2-5 2-7
Battery Charger Labels……………. 2-6 2-8
Solid Red Fault LED Troubleshooting…… 2-7 2-9
Flashing Red Fault LED Troubleshooting.. 2-8 2-9
Para Pg
Operation in Extreme Environmental
Conditions............................................ 2-9 2-10
Preparation for Movement..................... 2-10 2-11
Battery State-of-Charge Displays.......... 2-11 2-11
Battery Capacity Retention.................... 2-12 2-12
Battery Storage..................................... 2-13 2-12
CHAPTER 3 – MAINTENANCE INSTRUCTIONS
Introduction............................................. 3-1 3-1
Cleaning................................................. 3-2 3-1
Inspection............................................... 3-3 3-1
Basic Functional Test............................. 3-4 3-2
Simplified Operator
Troubleshooting Procedures................ 3-5 3-3
Warranty / Repair Information................ 3-6 3-5
Upgrade / Update Information................ 3-7 3-5

INTRODUCTION
850036-1 REV C 1-1
CHAPTER 1
INTRODUCTION
1-1. SCOPE
The Soldier Portable Charger Lite (P/N BTC-70819) is a state-of-the-art, high
performance lightweight portable battery charger designed for field deployment or shop
usage. It provides fast reactivation of various rechargeable batteries. It is capable of
simultaneously charging two batteries completely unattended.
The Soldier Portable Charger Lite (SPC Lite) is simple to use by design. Without any
user intervention, the SPC Lite typically charges two batteries. The charge time for a
fully discharged BB-2590/U or BB-390B/U is less than 3.5 hours. The Charge times are
substantially less for partially discharged batteries. The charger automatically identifies
the specific battery type and provides the appropriate charge profile. Based on the
current operating environment, the SPC Lite automatically customizes the charge profile
to provide the quickest charge in a safe manner. The charge status for the two batteries
is conveyed to the user via three easy-to-understand panel mounted LED indicators
(amber – CHARGE, green – READY and red – FAULT).
The SPC Lite 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 90-264
VAC and 47-440 Hz operation without any adjustment or user intervention. Additionally,
the DC input power permits a range of 22-33 VDC, standard on most military vehicles.
The Charger is available with an additional 12 VDC input. This allows the Charger to be
powered from an 11-18 VDC such as a standard 12 VDC automotive system. When
operated with either DC power source, an Under-voltage Lockout Circuit prevents the
Charger from excessively discharging the vehicle battery so there is always enough
power to restart the vehicle.
The SPC Lite is adaptive by design. It is microprocessor controlled and is presently
programmed to automatically charge over 80 different battery types (and growing) as
listed in Table 1. With the appropriate battery adapter, however, it can be readily
reprogrammed via the RS232 software upgrade port in the field 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, solid polypropylene case. The
assembled unit is watertight when the cover is securely latched and the pressure
equalization valve is closed.

INTRODUCTION
850036-1 REV C 1-2
1-2. TECHNICAL SPECIFICATIONS
Dimensions……………………….. 13.73 inches (348.8 mm) W x 10.28 inches (261 mm) D
x 7.65 inches (194.4 mm) H
Weight (less adapters and cables)…...13 lbs. (5.9 kg)
Power Requirements
AC Operation……………...Automatic Selection: 90 to 260 VAC, single-phase,
47 to 440 Hz
28V DC Operation………...22 to 33 VDC, 13A
12V DC Operation………...11 to 18 VDC, 20A (BTC-70819-3 Only)
Charging Output Voltage………... Automatically selected for each battery type
Duty Cycle………………………… Continuous
Protective Features……………….Resettable circuit breakers:
AC ( 3A)
28 VDC (13A)
12 VDC (20A)
Operating Temp. Range………… -4°F (-20°C) to +122°F (+50°C)
Storage Temp. Range…………… -40°F (-40°C) to +158°F (+70°C)
Case Material ……………………. Solid Polypropylene
Case Color………………………... Olive Drab #34088 per Fed-Std-595B
Shipment………………………….. No restrictions

INTRODUCTION
850036-1 REV C 1-3
1-3. DECLARATION OF CONFORMITY

INTRODUCTION
850036-1 REV C 1-4
1-4. ACCESSORIES
Table 1 shows the various batteries and appropriate adapter plates the SPC Lite supports at the
time this document was written.
Table 2 shows various power cables and accessories.
Table 1 – Supported Batteries and Adapters
ADAPTER ADAPTER NSN BATTERY TYPE BATTERY NSN
BTA-70360 6130-01-555-7818 BB-4600 NiCd 6140-13-113-0171
BTA-70394 5940-01-427-9247 BB-503A/U NiCd 6140-01-419-8193
BTA-70395 (1) 5940-01-427-9183 BB-326/U
BB-516A/U
NiMH
NiCd
6140-01-533-7674
6140-01-419-8191
BTA-70396 5940-01-427-9278 BB-2847A/U
BB-2847/U
Li Ion
Li Ion
6140-01-493-8092
6140-01-419-8194
BTA-70443 5940-01-467-8813 BB-2600/U
BB-2600A/U
Li Ion
Li Ion
6140-01-467-5853
6140-01-490-4311
BTA-70492A 5940-01-513-5662 BT-70477
BT-70492
BT-70492A
NiMH
Li Ion
Li Ion
6140-14-513-5369
6140-01-523-9840
6140-01-523-9840
BTA-70557 5940-01-467-5852 BB-557/U NiCd 6140-01-071-5070
BTA-70574 5940-01-483-6772 ICOM SI NiCd ---
BTA-70581 --- CSEL Li Ion 6140-01-534-3856
BTA-70581A 5940-01-544-3476 CSEL Li Ion 6140-01-534-3856
BTA-70582 ---
A
LI 124
ALI 142/BA-682A
BA-682B
BA-684A
NiCd
Li Ion
Li Ion
Li Ion
---
6140-14-328-2258
6140-14-561-1542
6140-14-529-5971
BTA-70589 6130-01-564-8116 ALI 116
ALI 124
ALI 142/BA-682A
ALI 143/BA-687A
ALI 243
BA-684A
BA-685A
BA-682B
ALI 147
ALI 247
NiCd
NiCd
Li Ion
Li Ion
Li Ion
Li Ion
Li Ion
Li Ion
Li Ion
Li Ion
---
---
6140-14-328-2258
6140-14-530-0061
6140-14-553-4062
6140-14-529-5971
6140-14-529-5973
6140-14-561-1542
---
---
BTA-70589A --- ALI 142/BA-682A
ALI 143/BA-687A
ALI 243
BA-684A
BA-685A
BA-682B
ALI 147
ALI 247
Li Ion
Li Ion
Li Ion
Li Ion
Li Ion
Li Ion
Li Ion
Li Ion
6140-14-328-2258
6140-14-530-0061
6140-14-553-4062
6140-14-529-5971
6140-14-529-5973
6140-14-561-1542
---
---
BTA-70598 --- BT-70598 Li Ion ---
BTA-70715 5940-01-573-9693 BT-70593
BT-70715
Li Ion
Li Ion
---
---
BTA-70721 6130-01-573-4962 BT-70721 Li Ion ---
BTA-70732 --- BT-70732 Li Ion ---
BTA-70737 --- BT-70737 Li Ion ---

INTRODUCTION
850036-1 REV C 1-5
BTA-70740 --- BT-70740 Li Ion ---
BTA-70763 6130-01-555-7821 BN-2250 NiCd 6140-13-116-5482
BTA-70774 5940-01-573-9679 Motorola –
NNTN7032A
NTN9816A
NTN9815A
Li Ion
NiCd
NiCd
---
---
---
---
BTA-70807 5940-01-493-6750 BB-2800/U Li Ion 6140-01-490-5372
BTA-70808 5940-01-493-6388 BB-2588/U
BB-388/U
Li Ion
NiMH
6140-01-493-7623
6140-01-490-4313
BTA-70810 5940-01-493-6751 THALES – MBITR Li Ion ---
BTA-70811 5940-01-493-7622 AA CELLS NiMH ---
BTA-70812 5940-01-492-7238 BB-2557/U
BB-557/U
Li Ion
NiCd
6140-01-490-5387
6140-01-071-5070
BTA-70817 --- D CELLS NiMH ---
BTA-70834 5940-01-501-3312 BB-2590/U
BT-70791A
BT-70791E
BB-390B/U
BB-590/U
BT-70876
SAFT – SAI-2590
Li Ion
Li Ion
Li Ion
NiMH
NiCd
Li Ion
Li Ion
6140-01-490-4316
---
---
6140-01-490-4317
6140-01-063-3918
---
---
BTA-70899 --- BB-2590/U
BB-390B/U
BT-70791A
BT-70791E
BT-70899A
BT-70876
Saft – SAI-2590
Ultralife – UBI-2590
Li Ion
NiMH
Li Ion
Li Ion
Li Ion
Li Ion
Li Ion
Li Ion
6140-01-490-4316
6140-01-490-4317
---
---
---
---
---
---
BTA-70858 --- DRT 4453/4411 Li Ion ---
BTA-70406-3 --- BA-386 NiCd ---
BTA-70851 (1) --- Racal 931 NiCd ---
BTA-70852 --- PTR-349 NiCd ---
BTA-70853 --- Loral – RT1606 NiCd ---
BTA-70872 --- BB-NM10 NiCd ---
BTA-70868 --- LI-145
LI-80
Li Ion
Li Ion
---
---
BTA-70706-1 --- BB-2598 Li Ion ---
BTA-70406 --- BB-586 NiCd 6140-01-084-1460
BTA-70661 --- BT-70661 Li Ion ---
NOTES:
1) The BB-516A,BB-326, and RACAL 931 can only charge with AC power on the BTC-70819.
There is no limitation on the BTC-70819-3
2) The Adapter BTA-70480/3 is not compatible with this charger.
3) This list was complete at the date of publication. Additional adapters may be available, but
may require updated software.

INTRODUCTION
850036-1 REV C 1-6
Table 2 – Power Cables and Accessories
DESCRIPTION BTI P/N GENERAL P/N NSN
AC Power Cord US 591609 ------ ------
AC Power Cord EU 590233-3 ------ ------
AC Power Cord UK 590233-4 ------ ------
DC Power Cable w/rings BTA-70844-24 ------ ------
DC Power Cable w/allig. clips BTA-70844-24-AL ------ ------
Gabriel DC Power Cable BTA-70819-24 ------ ------
DC Hummer Cable BTA-70835 J-6362A/U 5940-01-501-6714
DC Splitter Cable BTA-70816 CX-13560/G 5995-01-505-7883
BB-390/2590 Self Discharger BTF-70791 SDD2 6130-01-490-4310
Figure 1-4.1: BTA-70844-24
Figure 1-4.2: BTA-70835
Figure 1-4.3: BTA-70816(for use with
BTA-70835)
Figure 1-4.4: BTF-70791
Figure 1-4.5 BTA-70589A Figure 1-4.6 BTA-70589

INTRODUCTION
850036-1 REV C 1-7
1-5. CHARGE CYCLE DESCRIPTION
Each of type the battery that are capable of being charged by the Charger is connected
to the charger via their respective battery adapter (plate or cable). Each adapter can
charge two batteries simultaneously. The appropriate battery adapter is installed on the
control panel 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)
d. Time (t)
e. Voltage change (ΔV)
f. 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
LED (amber) blinks slowly 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 LED (amber) blinks rapidly during this process.
c. Fast Charge – A timed fast charge cycle brings the battery to approximately 90%
of full charge capacity. The CHARGE LED (amber) is lit solid during this process.
d. Ready – The fast charge cycle is complete. The Battery may be removed and
used at this time. The READY LED (green) is lit steadily at this time.
e. Trickle / Top-off – When fast charge is complete, the charger will top off of the
battery to 100%. 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 READY LED (green) blinks during this process.
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.

INTRODUCTION
850036-1 REV C 1-8
1-6. UPDATING CHARGER SOFTWARE
The software in the charger is field upgradeable. By loading new software into the
charger, it is possible to alter its operation and add or change the charging profiles for
the batteries. Loading new software into the charger is accomplished via the use of a
standard RS232 interface of a personal computer (PC) running Windows 95™ or higher.
Utilizing special software running on the PC in conjunction with the boot program
resident within the charger, a two-way communication link is established and the revised
operational parameters and battery charge profiles can be loaded into the charger.
Specific instructions for upgrading the Charger software are provided with the software
upgrades.

OPERATION
850036-1 REV C 2-1
SECTION 2
OPERATING PROCEDURES
2-1. PANEL CONTROLS AND INDICATORS
Battery charger panel components are described below and shown in Figure 2-1.1 and
2-1.2
FIGURE 2-1.1
FIGURE 2-1.2

OPERATION
850036-1 REV C 2-2
Item Function
1. On/Off Switch...................................... Turns battery charger on or off.
2. AC Circuit Breaker.............................. Turns power to the charger off in an overload
condition. Remove the overload condition and
push to reset.
3. Power On Indicator LED (Green)…….The Power On Indicator LED lights when the
charger has sufficient power from either AC or
DC.
4. Low Vehicle Power LED (Red)............The Low Vehicle power indicator lights when
external DC power is too low to charge
batteries. The charger will stop charging
batteries until sufficient power is available from
the DC course.
5. Temp Fault LED (Amber).................... The Temperature Fault indicator lights when
charger temperature is too high (50°C) or too
low (-20°C). The charger will stop charging
batteries.
6. Blackout Switch……………………….. Enables / Disables Blackout Mode. Pressing it
once turns off all panel LEDs. Pressing it again
turns on all panel LEDs. Holding down the
button during turn-on keeps the LED’s off during
the Lamp Test.
7. DC Circuit Breakers............................ Turns power to the charger off in an overload
condition. Remove the overload condition and
push to reset.
8. Charge LED (Amber).......................... The Amber LED lights steady while the
associated 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.
9. Ready LED (Green)............................ The Green LED indicates the associated battery
is fully charged and ready to be removed for
use. Steady light means the battery has
completed fast charge. A blinking indication
means the battery is being topped off.

OPERATION
850036-1 REV C 2-3
10. Fault LED (Red)................................ If the Red LED lights steadily, 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.
11. AC Input Connector...........................Input connection for AC cable assembly.
12. DC Input Connector.......................... Input connection for DC cable assembly.
13. Adapter Port………………………….. Provides interface connection for battery
adapters.
14. Recondition Switch………………….. Activates NiCd revitalization or Li-Ion de-
storage.
15. Recondition LED (Amber)…………...Lights amber during revitalization / de-storage
process.
16. RS-232 Port Cover………………...... Remove this cover to upgrade the charger’s software.
Otherwise leave the cover in place.
17. Pressure Equalization Valve………...This valve must be loosen before the cover is opened
and latches unfastened.

OPERATION
850036-1 REV C 2-4
2-2. PRELIMINARY SETUP PROCEDURES
Step 1. Place the unit on the work surface. Loosen the Pressure Equalization Valve
(Fig 2.1-2 #17) by unscrewing the knob two full turns in a counterclockwise
direction. Unfasten latches and open cover.
Step 2. Set the On/Off Switch (Fig 2.1-1 #1) to OFF position.
Step 3. The cover may be removed by removing both hinge pins with pliers.
Step 4. For AC operation: Connect the AC power cord from AC Input Connector (Fig
2.1-1 #11) to an AC power source and set the On/Off Switch (Fig 2.1-1 #1) to
ON position. Observe that the Power On Indicator LED (Fig 2.1-1 #3) lights,
the fan operates, and all the indicator LEDs blink in order (amber, then green,
then red) briefly when power is first applied.
Step 5. For DC operation: Connect the DC cable from the DC Input Connector (Fig
2.1-1 #12) to a DC power source such as the NATO slave receptacle found in
most military vehicles. Set the On/Off Switch (Fig 2.1-1 #1) to the ON position.
Observe that the Power On Indicator LED (Fig 2.1-1 #3) lights, the fan
operates, and all the status indicator LEDs (Fig 2.1-1 #8, #9, and #10) blink in
order (amber, green, then red) briefly when power is first applied.
Note: If both Multiple Power Sources are connected:
•For the BTC-70819-3 if AC and DC are connected the charger will use
AC power. If 12 and 28 VDC power are connected the charger will use
28VDC.
•For the BTC-70819 if AC and DC are connected the charger will use DC
power.
Step 6. Observe that only the Power On Indicator LED (Fig 2.1-1 #3) is lit.
Step 7. Install the appropriate battery adapter into the Adapter Port (Fig 2.1-1 #13) for
battery type to be charged. Install the adapter by first placing the back of the
adapter into the rear retainer. Note the alignment of the pins. The connector can
only be plug in one way, do not force it. Be sure that battery adapter is fully
seated on the panel. For Cable adapters, line up the pins to the Adapter Port
(Fig 2.1-1 #13). 18 Pin Connectors will plug in toward the right side on the
charger, do not force the connector.
Step 8. Observe, after a short delay, that the two amber Charge LEDs (Fig 2.1-1 #8)
will blink for several seconds. 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 status indicator LEDs (Fig 2.1-1 #8, #9, and #10) for a
channel light at the same time, the adapter could not be recognized or the
adapter is damaged, insure it is seated correctly. If running on DC, verify that
the battery is supported by DC charging (ex: the BB516 is not). Verify that the
charger software revision supports the adapter and battery.

OPERATION
850036-1 REV C 2-5
2-3. CHARGING BATTERIES
Step 1. With the appropriate battery adapter installed, insert the first battery to be
charged into the channel “A“ battery location. Insure the battery is fully seated
in the adapter. Observe that the amber Charge LED (Fig 2.1-1 #8) for the
corresponding location is lit or blinking rapidly. The Charge LED (Fig 2.1-1 #8)
for the “B” battery location will continue to blink if the channel “B” battery location
is left empty. If the red Fault LED (Fig 2.1-1 #10) is lit, the battery or adapter
may be defective, check by removing the battery and the adapter. Then reinstall
the adapter and battery. If the Fault LED (Fig 2.1-1 #10) still lights, go to the
Troubleshooting section (section 2.7, 2.8, and 3-5) of this Guide.
Step 2. Install the next battery into the Channel B battery location.
Step 3. After fast charging is complete, the amber Charge LED (Fig 2.1-1 #8) will turn
off and the green Ready LED (Fig 2.1-1 #9) will be lit. The charger will then top-
off the batteries that have successfully completed fast charge. The battery is
slow-charged to full capacity, as indicated by the blinking green Ready LED (Fig
2.1-1 #9). For Lithium-ion 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 green Ready LED (Fig 2.1-1 #9) is lit (blinking or
solid) the battery may be removed and returned to service and another battery
may be installed for charging.
NOTE
The BB-390A/U and the 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 on the charger for long
periods of time without damaging the batteries or the charger. This is true
whether if the charger is on or off.

OPERATION
850036-1 REV C 2-6
2-4. BATTERY REVITALIZATION AND DE-STORAGE
The procedures outlined below describe the means of invoking the Revitalization
and De-storage functions of the charger as well as the sequence of operations the
charger will execute to perform the commanded tasks.
NiCd and Ni-Mh Batteries are revitalized. Li-Ion batteries are de-stored.
The charger will decide what to do based on the batteries’ chemistry.
a. NiCad and Ni-Mh Revitalization
Due to the increased power dissipation from discharging the batteries, this function
will not operate above 45º C. The following procedure is used to invoke the
Revitalization process:
1. Power up the charger.
2. Plug in adapter.
3. Once the adapter is recognized (the two amber Charge LED (Fig 2.1-1 #8)
blink) press the Recondition Switch (Fig 2.1-1 #14) for the A or B channel;
the amber Recondition LED (Fig 2.1-1 #15) will light for the corresponding
channel.
4. Plug the battery into the activated channel.
5. Revitalization will commence upon recognition of the battery.
Autonomously, the charger will perform the following revitalization sequence:
1. Check environment temperature, if the temperature is above 45º C it will
not proceed.
2. Discharge the battery without a capacity measurement.
3. Fully charge the battery.
4. Discharge the battery and calculate the capacity.
5. Fully charge the battery.
6. If the capacity in step 4 is greater than or equal to 80% of the battery
specification, the green Ready LED (Fig 2.1-1 #9) will light, and the
Recondition LED (Fig 2.1-1 #15) will remain lit and the process is complete.
7. If the capacity in step 4 is less than 80%, steps 4 and 5 will repeat a
second time. If after the second cycle the capacity is less than 80% of the
battery specification, the red Fault LED (Fig 2.1-1 #10) will light. The
Recondition LED (Fig 2.1-1 #15) remains lit and the process is complete.
b. Li-Ion De-storage
Due to the increased power dissipation from discharging the batteries, this function
will not operate above 45º C. The following procedure is used to invoke the de-
storage process:
1. Power up the charger.
2. Plug in adapter.
3. Once the adapter is recognized (the two amber Charge LED (Fig 2.1-1 #8)
blink) press the Recondition Switch (Fig 2.1-1 #14) for the A or B channel;

OPERATION
850036-1 REV C 2-7
the amber Recondition LED (Fig 2.1-1 #15) will light for the corresponding
channel.
4. Plug the battery into the activated channel.
5. De-storage will commence upon recognition of the battery. Autonomously,
the Charger will perform the following de-storage sequence:
1. Check environment temperature, if the temperature is above 45º C it will
not proceed.
2. Fully discharge the battery.
3. Fully charge the battery while measuring its capacity.
4. Discharge the battery to 45% of it measured capacity.
5. The green Ready LED (Fig 2.1-1 #9) will light, the Recondition LED (Fig
2.1-1 #15) remains lit and the process is complete.
2-5. BLACKOUT
Pressing the Blackout Switch (Fig 2.1-1 #6) 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 (Fig 2.1-1 #6) down while turning the charger power
switch on will suppress the startup LED Test.

OPERATION
850036-1 REV C 2-8
2-6. BATTERY CHARGER LABELS
Shown below are the instructions contained on the "SHORT FORM - OPERATING
PROCEDURE" label, attached inside the charger cover.
LED INDICATIONS FOR EACH BATTERY
S = STEADY, F = FLASHING
S=Steady LIGHT INDICATIONS FOR EACH BATTERY
F= Flashing
AMBER GREEN RED RECON DEFINITION REMARKS
F F F F CHARGER START UP LIGHTS SCROLL MOMENTARILY
NO ADAPTER PRESENT ADAPTERS MUST BE
INSTALLED
F NO BATTERY PRESENT AWAITING BATTERY TO
CHARGE (SLOW BLINKING)
F CHARGE PREQUALIFICATION
PRE-CHARGE CHECK (RAPID
BLINKING)
S FAST CHARGE IN PROCESS TWO BATTERIES CAN CHARGE
SIMULTANEOUSLY
F TRICKLE CHARGE IN PROCESS BATTERY IS READY TO USE;
REMOVE WHEN READY
S CHARGE IS COMPLETE BATTERY IS READY TO USE;
REMOVE WHEN READY
S FAULTY BATTERY: DO NOT USE CONSULT STANDARD
OPERATING PROCEDURE
F CONTACT PINS ARE DIRTY OR
DAMAGED
CLEAN BATTERY CONTACTS;
CHECK ADAPTER PINS
S S RECONDITION/DESTORE CYCLE
IN PROCESS
RECONDITION (Ni); DESTORE
(Li)
S S RECONDITION/DESTORE FAILED CONSULT STANDARD
OPERATING PROCEDURE
F
EXCESSIVE TEMPERATURE FOR
RECONDITIONING
RELOCATE TO COOLER
ENVIRONMENT
S S S INCOMPATIBLE BATTERY OR
ADAPTER.
UNSUPPORTED OR SOFTWARE
UPDATE REQUIRED
S S S INSUFFICIENT DC VOLTAGE TO
CHARGE THIS BATTERY TYPE USE AN AC POWERSOURCE

OPERATION
850036-1 REV C 2-9
2-7. SOLID RED FAULT LED TROUBLESHOOTING
1. Remove the battery and inspect all the contacts, clean if necessary. Note
the battery location.
2. Reinstall at the same location for another charge cycle.
3. If the Fault LED (Fig 2.1-1 #10) is lit again at the same location remove
battery and do the following:
a. If the battery is NiCad or Ni-Mh and was in storage, try to revitalize
the battery (see section 2.4).
b. Check battery: If the battery is older than 3 yrs, it may be ready for
disposal.
c. Check the warranty instructions on the battery. If the warranty is
expired or no instructions were given on the battery, dispose of the
battery.
d. Note success/failure of the future battery charges at this battery
location. If the Fault LED (Fig 2.1-1 #10) is lit again, the adapter may
need to be changed.
2-8. FLASHING RED FAULT LED TROUBLESHOOTING
1. This condition is telling you that some of the battery contacts are not
connecting to the charger.
a. For BB-390 and other batteries with thermistors, the thermal
contacts may not be making proper contact with the adapter.
b. For Falcon, CSEL, MBITR, and other batteries the communication
pin(s) may not be making proper contact with the adapter.
c. To minimize this issue; before you first start using the charger,
ensure the battery contacts are clean and 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 take longer, and may not fully charge in one cycle.
4. If the flashing "red" condition continues, note the adapter battery location
and battery affected.
a. Remove the battery and clean the thermal contacts.
b. Check adapters again. If problem continues at this location, the
adapter may need to be changed.

OPERATION
850036-1 REV C 2-10
2-9. OPERATION IN EXTREME ENVIRONMENTAL CONDITIONS
Observe these precautions when the charger is operated in areas where severe
climatic conditions may exist:
a. Operation in Arctic Climates. The battery charger is designed to function
in temperature extremes as low as -4°F (-20°C). However, when operating
in arctic climates, the following precautions should be observed:
(1) Handle the equipment carefully. The plastic components may become
more brittle.
(2) Keep the equipment clean and dry.
(3) Prevent ice from forming on the charger and the batteries. Ice
formations may prevent proper electrical connections. Melting ice may
allow water to enter the charger.
When not in use, be sure the cover is fully latched and the Pressure
Equalization Valve (Fig 2.1-2 #17) is fully closed (tighten by turning the
knob in clockwise direction).
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. However, the 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 (Section 3-2) to assure proper operation. When
not in use, be sure the cover is fully latched and the Pressure Equalization
Valve (Fig 2.1-2 #17) is fully closed (tighten by turning the knob in clockwise
direction).
c. Operation in Salt Spray. Keep the equipment clean and dry at all times
and immediately wipe salt spray from all the exposed surfaces on the
charger and cables and connectors. When not in use, be sure the cover is
fully latched and the Pressure Equalization Valve (Fig 2.1-2 #17) is fully
closed (tighten by turning the knob in clockwise direction).
d. Operation in Rain. Keep the equipment dry at all times. Water
penetration in the charger, cables and the connectors will cause equipment
failure. When not in use, be sure the cover is fully latched and the
Pressure Equalization Valve (Fig 2.1-2 #17) is fully closed (tighten by
turning the knob in clockwise direction).