Holaday Industries 491198-48 Series User manual

Series 491198-48
NiMH Battery Fast Charger
User's Manual
Copyright ©1999-2000 by Holaday Industries, Inc.
Manual #600087 5/00 $12.50

Revision Record
Manual #600087
Series 491198-48 NiMH Battery Fast Charger
Revision Description Date
--- Release 4/99
AChanged Area Code 2/00
BAdded charging information 5/00

General safety considerations
This symbol alerts the user that important
literature concerning the operation and
maintenance of this unit has been included.
Therefore, it should be read carefully in order
to avoid any problems.
Warning This is aSafety Class Iproduct (provided with
aprotective earthing ground incorporated in
the power cord). The mains plus shall only be
inserted in asocket outlet provided with a
protective earth contact. Any interruption of
the protective conductor, inside or outside the
instrument, is likely to make the instrument
dangerous.Intentional interruption is
prohibited. DO NOT defeat the earth-
grounding protection by using an extension
cable, power cable, or autotransformer without
a protective ground conductor.
This instrument is to be used with athree-wire
power cord set which meets or exceeds the
requirements of EN60799. The power cord
set used must be rated for aminimum of
250V/10A. When connected to an
appropriate power line outlet, this cable
grounds the instrument cabinet.
Warning No operator serviceable parts inside. Refer
servicing to qualified personnel. To prevent
electrical shock, do not remove cover.
Warning If this instrument is used in a manner not
specified by Holaday Industries, the protection
provided by the instrument may be impaired.

Warning This battery charger incorporates parts, such
as aswitch and relays, that are likely to
produce sparks or arcs. Therefore, when
charging abattery in a garage or in a similar
location, locate the battery charger in aroom
or enclosure provided for this purpose, if
applicable.
Warning For indoor use only, do not expose to rain.

LIMITED WARRANTY
HOLADAY INDUSTRIES, INC. WARRANTS EACH SERIES 491198-48
NiMH BATTERY FAST CHARGER TO BE FREE FROM DEFECTS IN
MATERIAL AND WORKMANSHIP FOR A PERIOD OF ONE YEAR FROM
DATE OF SHIPMENT TO THE PURCHASER. THIS WARRANTY EXTENDS
TO THE ORIGINAL PURCHASER ONLY AND DOES NOT APPLY TO
BATTERIES OR ANY PRODUCT OR PARTS SUBJECT TO MISUSE,
NEGLECT, ACCIDENT, UNAUTHORIZED SERVICE OR ABNORMAL
CONDITIONS OF OPERATION.
IN THE EVENT OF DEVICE FAILURE COVERED BY THIS WARRANTY,
HOLADAY INDUSTRIES, INC. WILL, WITHOUT CHARGE, REPAIR THE
PRODUCT IF RETURNEDTO THEIR FACTORY WITHIN ONE YEAR OF
THE ORIGINAL PURCHASE, PROVIDED THAT HOLADAY INDUSTRIES'
EXAMINATION DISCLOSES TO ITS SATISFACTION THAT THE
PRODUCT WAS DEFECTIVE. HOLADAY INDUSTRIES, INC. MAY, AT ITS
OPTION, REPLACE THE PRODUCT IN LIEU OF REPAIR. IF THE DEFECT
WAS CAUSED BY MISUSE, NEGLECT, ACCIDENT, UNAUTHORIZED
SERVICE OR ABNORMAL CONDITIONS OF OPERATIONS, REPAIRS
WILL BE BILLED AT ANOMINAL COST. IN SUCH CASE, AN ESTIMATE
WILL BE PROVIDED BEFORE WORK IS STARTED IF REQUESTED BY THE
PURCHASER.
FOR WARRANTY SERVICE, CONTACT HOLADAY INDUSTRIES, INC.
GIVING FULL DETAILS OF THE FAILURE OF THE INSTRUMENT.YOU
WILL THEN BE GIVEN SERVICE INFORMATION OR SHIPPING
INSTRUCTIONS. RETURN THE INSTRUMENT TO THE FACTORY
TRANSPORTATION PREPAID. REPAIRS WILL BE MADE AT THE
FACTORY AND THE INSTRUMENT RETURNED TO YOU
TRANSPORTATION PAID. HOLADAY INDUSTRIES, INC. ASSUMES NO
RESPONSIBILITY FOR LOSS OF, OR DAMAGE TO, PRODUCTS IN
TRANSIT.
WARNING
SPECIAL CAUTION IS ADVISED WHEN WORKING WITH NiMH
BATTERIES. ANiMH BATTERY CAN EXHIBIT EXTREMELY LARGE
DISCHARGE CURRENT IF SHORTED. THIS CAN LEAD TO BURNS AND
INJURY. HOLADAY INDUSTRIES, INC. ASSUMES NO LIABILITY FOR
DAMAGES OR PERSONAL INJURY WHICH MAY RESULT FROM
ACCIDENTS ARISING OUT OF THE USE OF NiMH BATTERIES OR THE
BATTERY CHARGER.
NOTE
NiMH BATTERIES CONTAIN ENVIRONMENTALLY HAZARDOUS
MATERIALS AND MUST BE DISPOSED OF PROPERLY. HOLADAY
INDUSTRIES WILL ACCEPT AND DISPOSE ANY NiMH BATTERY USED
IN A HOLADAY PRODUCT, AT NO CHARGE.

TABLE OF CONTENTS
1.0 DESCRIPTION ..................... 1
2.0 UNPACKING AND ACCEPTANCE ........ 3
Introduction ....................... 3
3.0 SPECIFICATIONS ................... 5
4.0 OPERATING INSTRUCTIONS ........... 7
Input Power Requirements ............. 7
Fuse Replacement ................... 7
Charging a Battery .................. 9
Charging Indicators .................. 9
Discharging a Battery ............... 11
5.0 MAINTENANCE ................... 13

Fast Charger Manual Page -- 1
1.0 DESCRIPTION
The 491198-48 NiMH Battery Fast Charger is a dual
power source battery charger. It charges 4.8 volt 25 mA
NiMH batteries and is powered by 85 -264 Vac line
power or 12.5 Vdc. The 491198-48 uses a -(dV)/(dT)
(negative delta V) technique to determine when the
battery is fully charged, typically one hour. With this
technique, the charge state of the battery has no effect
other than shortening the charge time.
Housed in arugged enclosure, power enters the battery
charger through a power entry module, which contains
the fuses, or an optional cigarette lighter plug adapter.
LEDs and the label on the front face of the unit provide
operating status. The battery charger connects to the
device being charged through ashort cord terminated
with a power jack.
An integrated circuit within the charger monitors the
battery voltage and controls the charging functions
according to the charge state of the battery.

2 -- Page Fast Charger Manual
Figure 1
4.8V Battery Charger

Fast Charger Manual Page -- 3
2.0 UNPACKING AND ACCEPTANCE
Introduction
This section contains information on unpacking and
acceptance of the 491198-48 NiMH Battery Fast
Charger.
Step 1. Upon delivery of your order, inspect the
shipping container(s) for evidence of damage.
Record any damage on the delivery receipt
before signing. In case of concealed damage
or loss, retain the packing materials for
inspection by the carrier.
Step 2. Remove the product from its shipping
container. Save boxes and any protective
packing materials for future use.
Step 3. Check all materials against the packing list to
verify that the equipment received matches
that which was ordered. If you find any
discrepancies, note them and call Holaday
Customer Service for further instructions.
Be sure that you are satisfied with the contents of your
order and the condition of your equipment before using it.

4 -- Page Fast Charger Manual

Fast Charger Manual Page -- 5
3.0 SPECIFICATIONS
Power:
Main: IEC filtered AC power input module
110 - 240 Vac
500 mA MAX.
50 - 100 Hz
Alternate: Automobile cigarette lighter to 2mm
power plug adapter cord.
12.5 Vdc
100 mA
Fuses:
250 Volt, 1.0 Amp, Type T (5 mm x 20 mm)
Output:
Output Open Circuit Voltage: 12 Vdc
Fast Charge Pending Current: 2.0 mA
Fast Charge Current: 25 mA
Pulsed Trickle Charge Current: 2.0 mA
Output Voltage (During Fast Charge): 4 - 8 Vdc
NiMH Battery:
4.8 Volt 4Cell NiMH Battery, 25 mAH (Rapid charge
cells, 1.2 volts/cell); Holaday Part #491193
Environmental:
Operating temperature 10 to 40° C
Humidity: 5% to 95% relative humidity, non-
condensing
Power Cable:
This charger is shipped with a three-wire power cable.
When this cable is connected to an appropriate AC
power source, it connects the chassis to earth ground.
The type of power cable shipped with each battery
charger depends on the country of destination.

6 -- Page Fast Charger Manual
Power Cable Set Information:
Holaday # Unicable # and information
2217500 Unicable #5850-02M-BB
Type SVT, Foil shielded, PVC Jacketed, 60/C
Molded PVC Grounding Plug NEMA 5-15P UC-004
Molded PVC Receptacle IEC320/C13 UC-005
18 Ga. 3 Cond. 10A-125V
2217506C Unicable #5892-02M-BB
Type SVT, Foil shielded, PVC Jacketed, 60/C
Molded PVC Grounding Plug NEMA 5-15P UC-004
Molded PVC Right-Angle Receptacle IEC320/C13 UC-006
18 Ga. 3 Cond. 10A-125V
Countries: Canada, Japan, Puerto Rico, Taiwan, Venezuela, Hong Kong,
United States
221100 Unicable #8150-25M-BB
Type H05VV-F, PVC Jacketed, 70/C
Molded PVC Right-Angle Grounding Plug CEE 7/7 UC-814
Molded PVC Receptacle IEC320/C13 UC-051
1.0mm23 Cond. 10A-250V
Countries: Argentina, Austria, Brazil, Finland, France, Germany, Israel,
Italy, Holland, Korea, Netherlands, Norway, Sweden, Turkey
222600 Unicable #8550-25M-BB
Type H05VV-F, PVC Jacketed, 70/C, Harmonized
Molded PVC Grounding Plug BS 1363, Fused UC-851
Molded PVC Receptacle IEC320/C13 UC-852
1.0mm23 Cond. 10A-250V
Countries: England, Ireland, Malaysia, Scotland, Singapore, South Africa,
Wales
221600 Unicable #8250-25M-BB
Type SAA, Ordinary Duty, PVC Jacketed, 75/C
Molded Grounding Plug AS3112 UC-822
Molded PVC Receptacle IEC320/C13 UC-051
1.0mm23 Cond. 10A-250V
Countries: Australia, China
221500 Unicable #8450-25M-BB
Type H05VV-F, PVC Jacketed, 70/C
Molded PVC Grounding Plug SEV 1011 UC-841
Molded PVC Receptacle IEC320/C13 UC-051
1.0mm23 Cond. 10A-250V
Countries: Switzerland

Fast Charger Manual Page -- 7
4.0 OPERATING INSTRUCTIONS
The 491198-48 battery charger is intended to charge the
4.8 volt NiMH batteries within the HI-6005, either in the
lab or in the field.
Input Power Requirements
The 491198-48 charger can be powered by standard line
voltage (110 -240 Vac, 50 - 60 Hz) or by an optional
automobile cigarette lighter plug (12.5 Vdc) (see
Specifications). The AC power entry module contains a
fuse.
Fuse Replacement
If afuse has blown, it must be replaced with the same
type and value or an unsafe condition may result. Refer
to Figure 2 for fuse replacement.
The fuse is contained in the fuse drawer in the power
input module. To access the fuse, use a screwdriver to
pry the drawer open and remove it from the module. The
drawer holds two fuses, the fuse towards the outside of
the drawer is a spare.
After the fuse has been replaced, slide the fuse drawer
back into the module. Make sure that it snaps securely
into it’s locked position.
CAUTION!
NEVER attempt to change the fuse with the battery
charger plugged in.

8 -- Page Fast Charger Manual
Figure 2
Fuse Replacement

Fast Charger Manual Page -- 9
Charging a Battery
After connecting the battery charger to a proper power
source, the battery charger simply plugs into the charger
jack on the HI-6005. The HI-6005 must be turned off or
the battery will not charge.
CAUTION!
NEVER attempt to recharge a non-rechargeable battery.
Charging Indicators
The fast chargers for the HI-6005 are intelligent chargers.
Six LEDs located on the front of the charger provide
operating information to the user.
The POWER ON LED (green) will remain lit as long as the
charger is plugged into the AC power source.
If the charger does not detect a battery, the NO
BATTERY LED (amber) will light.
When the charger does detect the HI-6005's battery, the
PENDING LED (amber) lights. Before fast charging can
begin, the battery voltage must fall within predetermined
acceptable limits. A Pulse-Trickle charge is provided to
bring a depleted battery to a valid charge prior to fast
charge.
Once the voltage pre-qualification condition has been
met, fast charge begins and the CHARGING LED (amber)
will light. Fastcharging continues until termination by a
peak voltage detect or amaximum charge time. For peak
voltage detect, the fast charge is terminated when the
battery voltage is lower than the previously measured
values by 24mV. If a peak voltage is not detected, then
the fast charge is terminated when the maximum time
limit of 180 minutes is reached.

10 -- Page Fast Charger Manual
If the probe is turned on during the fast charge period of
the charge cycle, the current surge that the battery
provides to the electronics in the probe will cause a
momentary voltage drop on the battery, causing the
charger to terminate the fast charge based on apeak
voltage detect condition. When a fast charging peak
voltage is detected, the charger COMPLETE LED (green)
will light.
The charger switches to Top-Off charge mode which
provides acharge current one eighth of the fast charge
rate. This charge continues from the time when a peak
voltage detect terminates the fast charge, until the
maximum time of 180 minutes is reached. If the probe is
disconnected from the charger at this point in the charge
cycle, the battery will still operate properly.
Following the maximum time of 180 minutes, a Pulse
trickle charge mode is used to compensate for the self
discharge of the battery while idle in the charger.
The batteries are quite small, and the fast charge current
is very low. The fast charge current is low enough that
there is not always enough heating of the battery cells to
cause the voltage to drop. With no voltage drop there is
no peak voltage detection, and the fast charge will
terminate after the maximum time of 180 minutes is
reached.
The chargers will not damage the battery even when left
connected for long periods of time.