Overlander VSRmini User manual

VSRmini
OPERATING MANUAL
AC BALANCE CHARGER/DISCHARGER
for LiPo/LiFe/LiHV/LiIon/NiMH/NiCd/Pb Batteries
Please read and understand this entire operating
manual before using.

PLEASE FOLLOW THE FOLLOWING DIRECTIONS TO ENSURE
SAFE AND SUCCESSFUL USE OF THE OVERLANDER VSRmini
AC BALANCE CHARGER.
WARNING : Read and familiarise yourself with the instruction manual before operating the
charger, seek advice from other charger users or Overlander if you are unsure of any
procedures.
This charger automatically balances Lithium batteries in charge/discharge and storage mode.
When charging Lithium batteries, always ensure that the balance connector is connected FIRST
in the sequence. This charger will not start a charge/discharge or storage charge if the balance
lead is not connected. This charger will NOT charge batteries without a balance lead.
WARNING : This charger is not a domestic appliance, it should be only used and positioned in
the correct environment.
Due to the power volatility of Lithium batteries it should be positioned on a fireproof base at least
1.5 metres from any flammable materials
WARNING : • Never charge in a domestic setting
• Never leave the charger unattended
• Never exceed maximum battery charge rate
• Never charge a standard LiPo battery on LiHV setting
• Never charge non-approved or non EU compliant batteries
• Never charge in the wrong mode
• Never charge near flammable material
• Never charge near any items of value. Overlander or its retailers take no
responsibility for 3rd party items that may be damaged by incorrect use.
OVERLANDER VSRmini
CHARGER USER WARNINGS

Contents
1. Features .........................................................................................................1
2. Exterior of the unit ........................................................................................2
3. Warnings and safety notes ..........................................................................3
4. Program flow chart .......................................................................................5
5. Parameter set up (User settings) ..................................................................6
6. Lithium battery (LiPo/LiFe/LiHV/LiIon) programs .......................................8
6.1 Charging ....................................................................................................8
6.2 Balance mode ............................................................................................9
6.3 'FAST' charging .......................................................................................10
6.4 'STORAGE' mode ....................................................................................10
6.5 Discharging .............................................................................................11
6.6 Voltage balancing and monitoring during discharge .................................11
7. NiMH/NiCd battery programs ......................................................................12
7.1 Charging ..................................................................................................12
7.2 Discharging ..............................................................................................12
7.3 ‘CYCLE’ mode ..........................................................................................13
8. Pb (lead acid) battery program ..................................................................13
8.1 Charging Pb battery ................................................................................13
8.2 Discharging Pb battery ............................................................................14
9. Battery internal resistance testing system ...............................................14
10. Save Data Program ...................................................................................15
11. Load Data Program ...................................................................................16
12. Program information .................................................................................16
13. Warning and error messages ...................................................................17
14. Specifications ............................................................................................19
15. Warranty and service ................................................................................19
PLEASE FOLLOW THE FOLLOWING DIRECTIONS TO ENSURE
SAFE AND SUCCESSFUL USE OF THE OVERLANDER VSRmini
AC BALANCE CHARGER.
WARNING : Read and familiarise yourself with the instruction manual before operating the
charger, seek advice from other charger users or Overlander if you are unsure of any
procedures.
This charger automatically balances Lithium batteries in charge/discharge and storage mode.
When charging Lithium batteries, always ensure that the balance connector is connected FIRST
in the sequence. This charger will not start a charge/discharge or storage charge if the balance
lead is not connected. This charger will NOT charge batteries without a balance lead.
WARNING : This charger is not a domestic appliance, it should be only used and positioned in
the correct environment.
Due to the power volatility of Lithium batteries it should be positioned on a fireproof base at least
1.5 metres from any flammable materials
WARNING : • Never charge in a domestic setting
• Never leave the charger unattended
• Never exceed maximum battery charge rate
• Never charge a standard LiPo battery on LiHV setting
• Never charge non-approved or non EU compliant batteries
• Never charge in the wrong mode
• Never charge near flammable material
• Never charge near any items of value. Overlander or its retailers take no
responsibility for 3rd party items that may be damaged by incorrect use.

1. Features
Optimised operating software
The VSRmini has an ‘AUTO’ function that sets the current automatically when charging or
discharging, preventing the battery from over-charging, which could lead to a fire or
explosion. These specifications can also be set by the user. The built in balance charge
port makes it convenient for use with Lithium batteries. This charger also comes with XT60
to Deans conversion lead for Deans type batteries.
High-power and high-performance circuit
The max output is 80W. The max charge is 7A. The max discharge current is 1A. It can
charge/discharge NiMH/NiCd battery with up to 15 cells, and Lithium batteries with 6 cells.
The CPU operating program works under such power as the charger is fitted with a highly
efficient cooling system.
Individual voltage balancer for Lithium batteries inside
The charger has a special internal function for Lithium battery voltage balancing. You do
not require an additional balancer to balance the voltage when charging Lithium batteries
(LiPo/LiFe/LiIon).
Balance individual cells
The charger also monitors and balances the individual cells of a Lithium battery pack
during the charging/discharging process. If the voltage of any cell varies abnormally, the
process will be stopped automatically and an error message will appear on the screen.
Accept various types of Lithium battery
This charger can be used with a wide range of batteries with different chemistries (LiPo,
LiHV, LiFe, LiIon, NiMH, NiCd and Pb). Choose the corresponding program, setting the
parameters on the base of the battery type and specifications, before you start to
charge/discharge.
Lithium battery 'Fast' and 'Storage' mode
The “Fast” charge reduces the charging time of Lithium batteries. The “Storage” mode
controls the nominal voltage of the battery to make it suitable for long-term storage.
NiMH/NiCd cyclic charging/discharging
With this charger you can perform 1-4 cycles of charge>discharge or discharge>charge
continually for battery refreshing and balancing.
Data store/load
This charger can store a maximum of 5 different batteries data. These settings can then be
called out at any time and the process can be executed without having to reselect all of the
correct settings.
-1 -

2. Exterior of the unit
Maximum safety
- Delta-peak Sensitivity: when the battery voltage of NiMH/NiCd batteries reaches the
highest point and begins to drop, the charging process with automatically stop.
- Capacity Limit: the charging process will terminate automatically when the maximum
capacity value that is set is reached.
- Temperature Limit: the temperature of the battery will rise during the charging process
due to internal chemical reactions. In order to prevent overheating the charging process
will forcibly end if the temperature limit that is set is reached. This function is only available
by connecting an optional temperature probe, which is not included in the package. Avail-
able from Overlander (SKU: 2598).
- Charge Time Limit: charging will stop when charge time limit set is reached to avoid any
possible over-charging/over-discharging.
- Input Current Check: to prevent the battery from being damaged by the input current,
the charger monitors the voltage and ends the process automatically when the voltage
drops below the lowest limit.
- Automatic cooling fan: the automatic electric cooling fan controls the internal tempera-
ture of the charger to prevent over-heating.
-2 -
AC Input (100-240V)
LCD Display
Stop/Main Menu
Balance Lead Port
Charging Lead Port Temp. Sensor Port
Start/Enter
Cooling Fan
Increase INC(+)
Decrease DEC(-)

3. Warnings and Safety notes
IMPORTANT! Please follow these instructions for maximum safety, otherwise
the charger and/or battery could be badly damaged and may lead to fire,
explosion, injury or property loss.
- Never leave the charger unattended when it is connected to its power supply.
-If any malfunction is observed, terminate the process immediately and refer to the manual.
- Keep the charger away from dust, damp, humidity, rain, heat, direct sunshine and vibration.
- The circuit of the unit is designed to be powered by 100-240V AC only.
Voltage level: 1.2V/cell
Recommended fast charge current: 1C~2C depends on
the performance of cell discharge voltage cut off level
0.85V/cell (NiCd), 1.0V/cell (NiMH)
Voltage level:3.6V/cell
Max. charge voltage: 4.1V/cell
Recommended fast charge current: 1C or less
Min. discharge voltage cut off level: 2.5V/cell or higher
Voltage level: 3.7V/cell
Max. charge voltage: 4.2V/cell
Recommended fast charge current: 1C or less
Min. discharge voltage cut off level: 3.0V/cell or higher
Voltage level: 3.8V/cell
Max. charge voltage: 4.3V / 4.35V / 4.4V/cell
Recommended fast charge current: 1C or less
Min. discharge voltage cut off level: 3.0V/cell
Ensure maximum charge voltage is set. This would
usually be 4.35V but please check instructions with the
LiHV battery. Never charge standard LiPo battery on
LiHV setting.
Voltage level:3.3V/cell
Max. charge voltage:3.6V/cell
Recommended fast charge current: 4C or less
Discharge voltage cut off level:2.0V/cell or higher
Voltage level:2.0V/cell (Lead-acid)
Max. charge voltage:2.46V/cell
Recommended fast charge current:0.4C or less
Min. discharge voltage cut off level:1.50V/cell or higher
NiCd / NiMH
LiIon
LiPo
LiHV
LiFe
Pb
-3 -

-Do not place the charger on flammable or conductive surfaces when
charging/discharging. Never use the charger on car seats, carpets or similar surfaces. Do
not operate near items of value or anything with the potential to catch fire or explode.
- Ensure the unit remains well ventilated by making sure that all ventilation holes are
unblocked and uncovered.
-Set the parameters correctly, otherwise the battery could be severely damaged. Lithium
batteries especially can cause a fire or explosion when over-charged. Always check that
the selected chemistry is correct. Never charge standard LiPo batteries on LiHV setting.
- To avoid short-circuits between the wires, always connect the charge cable to the unit first
and then to the battery. Reverse the sequence when disconnecting.
-Always check the capacity and voltage of a Lithium battery pack before starting
any process. It may be a mixture of parallel and series connections. In parallel, individual
cell capacity multiplied by the cell count is the pack capacity, but the voltage remains the
same. It is important to enter the correct parameters in order to prevent the risk of
fire/explosions.
- When setting the discharge parameter, it must be according to the residual capacity of
the pack to lower the voltage of the battery. To avoid over-discharging, please set the
nominal discharge correctly. The voltage of Lithium batteries must not be discharged lower
than the minimum voltage because this can lead to a rapid loss of capacity or a total
failure. Generally there is no need to discharge a Lithium battery.
- Some batteries have a ‘memory’, in that if the capacity is only partially used the battery
will ‘remember’ to just use the same amount in the future:
- NiMH and NiCd batteries do have a memory function, but usually run complete cycles.
This means they are fully charged and then completely used.
-Lithium batteries prefer a partial rather than full discharge. Frequent full discharge
should be avoided if possible. Instead you should charge the battery more often or
keep the nominal voltage.
-This charger is not a domestic appliance. It should be used and positioned in the correct
environment and should not be used in a domestic setting. Due to the power and volatility
of Lithium batteries the charger and battery should be placed on a fireproof base at least
1.5 metres from any flammable materials. Overlander or its retailers accept no liability for
losses to 3rd party items caused by failure to follow these instructions.
-By purchasing this product the user assumes all risks associated with its use. If you do
not agree with this clause then please return the item immediately before use.
-Failure to comply with these instructions will result in all warranties being deemed void.
-4 -

4. Program ow chart
PROGRAM SELECT
LIXX BATT
PROGRAM SELECT
NiMH BATT
PROGRAM SELECT
NiCd BATT
PROGRAM SELECT
Pb BATT
PROGRAM SELECT
SAVE DATA
PROGRAM SELECT
LOAD DATA
USER SET
PROGRAM
NiMH CHARGE
‘Aut’ / ‘Man’
NiCD CHARGE
‘Aut’ / ‘Man’
LIXX CHARGE
Pb CHARGE Pb DISCHARGE
LOAD DATA
SAVE DATA
LIXX BALANCE
LIXX V.TYPE LiIo / LiPo / LiFe /
LiHV CHK Time NiMH Sensitivity
D.Peak NiCD Sensitivity D.Peak
Temp Cut-Off
USB Enable
Waste Time
CHG > DCHG
Safety Timer
Input Power Low
Cut-Off
Capacity Cut-Off
Key Beep
Buzzer
NiMH DISCHARGE
NiCD DISCHARGE
NiMH CYCLE
NiCD CYCLE
LIXX DISCHARGE
LIXX FAST CHG LIXX STORAGE
Batt type
stop
Start
Enter INC>
<DEC
INC>
<DEC
INC>
<DEC
INC>
<DEC
INC>
<DEC
INC>
<DEC
INC>
<DEC
INC>
<DEC
INC> <DEC
INC> <DEC
INC>
<DEC
INC>
<DEC
INC>
<DEC
INC>
<DEC
INC>
<DEC
INC>
<DEC
INC>
<DEC
Start
Enter
Start
Enter
Start
Enter
Start
Enter
Start
Enter
Start
Enter
Batt type
stop
Batt type
stop
Batt type
stop
Batt type
stop
Batt type
stop
Batt type
stop
-5 -
INC> <DEC
TEST LiXX INTERNAL
RESISTANCE
Measuring IR
WAIT PLEASE...
1:026 050 044 mΩ
4:039 042 044 mΩ
Battery Pack IR
231Ω
INC>
<DEC
INC>
<DEC
Start
Enter

5. Parameter set-up (User settings)
The charger will automatically be operated with the default user settings when it is
connected to a 12V battery for the first time. The screen displays the following
information in sequence and the user can change the value of the parameters on
each screen. If you want to alter the parameter value in the program, press Start/
Enter to make it blink then change the value with INC or DEC. The value will then be
stored by pressing Start/Enter.
The screen displays the nominal voltage of the
Lithium battery. There are four kinds of Lithium
battery; LiFe (3.3V), LiIon (3.6V), LiPo (3.7V) or
LiHV (3.8V). It is very important that you check
the battery carefully to ensure it is set up
correctly. If the incorrect values are selected the
battery could ignite or explode during the
charging process.
The charger will recognise the cell count of the
battery automatically at the beginning of the
charge or discharge process to reduce the
chances of incorrect settings being selected by
the user. However, a deeply discharged battery
can be perceived incorrectly, so it is important to
check that all of the information is correct. To
prevent any errors, you can set the time term to
verify the cell count detected by the processor.
Normally 10 minutes is enough to perceive the
cell count correctly. For a battery of a larger
capacity, you may need to extend the time term.
However, be careful not to set the time term for
too long for a battery of a smaller capacity, as the
charge or discharge process can be finished
within the time term with the wrong cell count,
which could then result in over-charging the
battery.
If the processor recognises the cell count
incorrectly at the beginning of the charge or
discharge process, you may extend the time.
Otherwise, it is recommended that you use the
default value.
Display
LiPo/LiIo/LiFe
CHK time 10min
< Dec Inc >
< Dec Inc >
Display
LiFe
V.Type 3.3v
< Dec Inc >
- +
-6 -

This shows the trigger voltage for automatic
charge termination of NiMH and NiCd battery.
The effective value ranges from 5 to 20mV per
cell. If the trigger voltage is set higher, there is a
danger of overcharging the battery; if it is set
lower, there is a possibility of premature
termination. Please refer to the technical
specifications of the battery. (NiCd default:
12mV, NiMH default: 7mV)
This program sets the maximum charge capacity
that will be supplied to the battery during charge.
If the delta-peak voltage is not detected, or if the
safety timer is not working for any reason, this
feature will automatically stop the process when
the battery reaches the selected capacity value.
The 3-pin port at the left side is a temperature
port. You can use a temperature probe to contact
the surface of a battery. You can set the maximum
temperature at which the charger will allow the
battery to reach during charging. Once a battery
reaches this temperature during charge, the
process will be terminated to protect the battery.
This shows a battery that is on a cyclic process of
charge and discharge. These can often become
warm after the charge or discharge period. This
program can insert a time delay to occur after
each charge and discharge process to allow the
battery adequate time to cool down before being
subjected to the next process. The value ranges
from 1 to 60 minutes.
When you start a charge process, the integral
safety timer automatically starts running at the
same time. This is programmed to prevent
overcharge if the battery proves to be faulty and
the termination circuit cannot detect if the battery
is full. The value for the safety timer should be
generous enough to allow a full charge of the
battery.
< Dec Inc >
< Dec Inc >
< Dec Inc >
< Dec Inc >
< Dec Inc >
< Dec Inc >
Display
NiMH sensitivity
D.Peak Default
< Dec Inc >
- +
Display
Capacity Cutoff
ON 5000mAh
< Dec Inc >
- +
Display
NiCD sensitivity
D.Peak Default
< Dec Inc >
- +
Display
Safety Temp
Temp Cut-off 80C
< Dec Inc >
- +
Display
Waste Time
CHG/DCHG 5min
< Dec Inc >
- +
Display
Safety Timer
ON 120min
< Dec Inc >
- +
-7 -