West Mountain Radio CBA Charger User manual
www.westmountainradio.com
1020 Spring City Drive
Waukesha, WI 53186
262-522-6503
©2012 West Mountain Radio, All rights reserved. All trademarks are
the property of their respective owners.
CBA Charger
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West Mountain Radio Operating Manual
Introduction
Thank you for choosing the West Mountain Radio CBA Charger. It
can be used with a West Mountain Radio CBA IV and a user provided
battery charger to automate life cycle tests, automatically alternating
between periods of charging the battery and discharging the battery.
By automatically switching between charge and discharge cycles of the
battery a hands-free lifetime test of the battery can be performed.
When the unit is idle, the two pairs of Power-poles are open. When the
unit is in a charging state, the two Power-poles are connected together,
connecting the user provided battery charger to the battery.
The CBA Charger and software can determine when the battery is done
being charged by inspecting an output signal of the user provided battery
charger, which the user will have to connect to the IN-A or IN-B inputs of
the CBA Charger. If the user provided battery charger doesn’t provide
an external signal to signify a charge is complete, an LED on the user
provided battery charger could be used instead by connecting leads from
the LED to the IN-A or IN-B of the CBA charger. If the user provided
battery requires a button to be pressed or other external signal to start
a charge cycle, the OUT-A and OUT-B connections of the CBA Charger
can be used. When the unit goes into charge cycle, the CBA Charger
closes the OUT-A and OUT-B connectors. When the unit is idle, OUT-A
and OUT-B are open.
CBA Charger Interface
Charge / Discharge Test
The WMR Charger Interface board has the following inputs and outputs:
• IN-A and IN-B: These should connect to a signal on the charging
unitthatindicateschargingiscomplete.AnLEDwillsufce.These
inputs can handle up to 12V.
• OUT-A and OUT-B: These outputs are shorted (relays closed) when
the software is starting a charge cycle. The purpose of this is to
connect to a push-button on a charging unit, where the push button
might control the start/stop of the charger.
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West Mountain Radio Operating Manual
• Powerpoles: When a Charge/Discharge test is not running, or
during the Discharge cycle of a Charge/Discharge test, these poles
will be open. During a Charge cycle, these power poles will close
(short) and the WMR Charger Interface and the CBA Software
can read the current drawn by the battery from the charger unit.
• Green LED: This is lit when the CBA software has connected
to the WMR Charging Interface board. NOTE: There is a green
power LED also.
• Yellow LED: This is lit when the CBA software is currently
performing a Charge/Discharge test. It will go dark when test is
complete.
• Red LED: This is lit when the CBA software is currently in a
charging phase of a Charge/Discharge test (the power poles are
closed and the charging unit is connected to the battery).
When starting a charging cycle, the CBA software will close both the
OUT-A and OUT-B relays and leave them closed for the duration of the
cycle. If this is not compatible with charging unit in use or if needing
moreexibleoptions,contactWMRandsupportmaybeaddedtothe
charging unit.
While performing a charging cycle, the CBA software will look for a
high on either IN-A or IN-B to signify a charge complete. If this is not
compatiblewiththechargingunitunitinuseorifneedingmoreexible
options, contact WMR and added support may be added to the charging
unit.
Typical Setup
The CBA and battery are both connected in parallel to the indicated
Powerpole connector. When the test is in Discharge the relay on the
Charger Interface board is open and creates an open circuit. Similarly,
during charge mode, the CBA acts as an open circuit while the Charger
Interface board relay is closed and the battery is charged. A setup
diagram is shown on the next page.
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West Mountain Radio Operating Manual
Specications
Dimensions 1.5 x 6.0 x 4.25 inches
Max Voltage (Powerpoles) 55 V
Max Current during Charging
(through Powerpoles)
10 A at 24 V / 2.5 A at 55 V
Max Voltage (IN-A and IN-B) 50 V
Min Voltage (IN-A and IN-B);
min voltage required to detect
asserted line
3 V
(IN-A and IN-B Detecttion
assertion regardless of
polarity of voltage input)
Max Voltage (OUT-A and
OUT-B)
30 V
Max Current (OUT-A and
OUT-B)
2 A
Powerpole® is a registered trademark of Anderson Power Products
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West Mountain Radio Operating Manual
Safety Precautions
The West Mountain Radio CBA is inherently safe but the batteries it tests
are not. Anything that stores energy is potentially dangerous! Some types
of batteries are safer than others but they are all capable of causing
explosionsorres.
For technical information on your battery, refer to the Battery
Manufacturers web site to get detailed information on the rating of
your battery. Most battery labels have limited information, but the
manufacturer’s web site may have more detailed information. General
Information on batteries is also available on your West Mountain Radio
CD. Select Battery Information and FAQ’s.
Primary Safety Considerations:
• Never discharge a battery at a higher discharge rate than it is
designed for.
• Never use a battery that has poorly insulated or frayed wiring or
exposed metal parts.
• Never connect a battery with reverse polarity.
• Nevertestabatterynearammablematerials.
• Never allow a battery reach a temperature that causes it to get so hot
that it may be too hot to touch.
• Recharge your batteries immediately with an appropriate battery
charger after you have completed your test. Some types do not like to
sit discharged for extended periods of time.
• Never test or charge your batteries while unattended.
• Haveareextinguishernearby.
CBA Operating Requirements:
• Never connect a battery with the polarity reversed!
• Always connect the USB cable BEFORE connecting the battery!
• Never connect a battery to the CBA that is connected to something
else.
• Contact West Mountain Radio for support before connecting to a USB
hub.
• Operate the CBA in a cool dry location.
• Never allow metal parts or wiring of the battery come in contact with
the metal heat sink.
• Never allow the cooling fan to be blocked or jammed.
• Do not ignore the warnings that the software may give you.
• The CBA can get hot. Do not touch the metal heat sink while, or
shortly after, conducting a high power test.
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West Mountain Radio Operating Manual
Lead Acid Battery Safety Warnings:
There may not be a consideration while testing lead acid batteries but there
certainly is while charging lead acid batteries. These batteries, especially
automotive and marine types, give off explosive hydrogen gas when charged.
Anearbyorinternalsparkoramecancausealeadacidbatterytoexplode
sending liquid acid and lead shrapnel in all directions. This is particularly
dangerous and frequently causes blindness or severe scarring injuries.
Never use a standard lead acid battery without proper ventilation. Sealed lead
acid batteries such as gelled or AGM (absorbed glass mat) types are much
safer. Automotive and marine types are not as safe and should be used in
protective ventilated housings.
Never make the last connection to a lead acid battery causing a spark on the
terminal. Always connect the load or charger last, and at a safe distance away
from the battery.
NiCad, NiMh, and Alkaline Safety Warnings:
These batteries can be dangerous also. If they are shorted out, or charged or
discharged at too high a rate, they can overheat and explode. A single D size
NiCad cell can actually melt a 10 penny nail, don’t try this!
Lithium Safety Warnings:
Reprinted with permission of the Academy of Model Aeronautics
Words in bold and ( ) were added by West Mountain Radio
Lithium Battery Fires
Lithium batteries are becoming very popular for powering the control and
power systems in our models. This is true because of their very high energy
density (amp-hrs/wt. ratio) compared to NiCads or other batteries. With high
energy comes increased risk in their use. The, principal, risk is FIRE which
can result from improper charging, crash damage, or shorting the batteries. All
vendors of these batteries warn their customers of this danger and recommend
extremecautionintheiruse.Inspiteofthismanyreshaveoccurredasa
result of the use of Lithium Polymer batteries, resulting in loss of models,
automobiles, and other property. Homes and garages and workshops have
alsoburned.Alithiumbatteryreisveryhot(severalthousanddegrees)and
isanexcellentinitiatorforancillary(resulting)res.Fireoccursduetocontact
between Lithium and oxygen in the air. It does not need any other source of
ignition, or fuel to start, and burns almost explosively.
Thesebatteriesmustbeusedinamannerthatprecludesancillaryre.The
following is recommended:
• Store,andcharge(discharge),inareproofcontainer;neverinyour
model.
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West Mountain Radio Operating Manual
• Charge (discharge), in a protected area devoid of combustibles. Always
stand watch over the charging (discharging), process. Never leave the
charging process unattended.
• In the event of damage from crashes, etc, carefully remove to a safe place
for at least a half hour to observe. Physically damaged cells could erupt
intoame,and,aftersufcienttimetoensuresafety,shouldbediscarded
in accordance with the instructions which came with the batteries. Never
attempt to charge (discharge) a cell with physical damage, regardless of
how slight.
• Alwaysusechargersdesignedforthespecicpurpose,preferably
havingaxedsettingforyourparticularpack.Manyresoccurinusing
selectable/adjustable chargers improperly set. Never attempt to charge
Lithiumcellswithachargerwhichisnotspecicallydesignedforcharging
Lithium cells. Never use chargers designed for Nickel Cadmium batteries.
• Use charging systems that monitor and control the charge state of
each cell in the pack. Unbalanced cells can lead to disaster if it permits
overcharge of a single cell in the pack. If the batteries show any sign of
swelling, discontinue charging, and remove them to a safe place outside
astheycoulderuptintoames.
• Most important: NEVER PLUG IN A BATTERY AND LEAVE IT TO
CHARGE(DISCHARGE),UNATTENDEDOVERNIGHT.Seriousres
have resulted from this practice.
• Do not attempt to make your own battery packs from individual cells.
These batteries CANNOT be handled and charged casually such as has
been the practice for years with other types of batteries. The consequence
of this practice can be very serious resulting in major property damage
and/ or personal harm.
Again Primary Safety Considerations:
• Never discharge a battery at a higher discharge rate than it is designed for.
• Never use a battery that has poorly insulated or frayed wiring or exposed
metal parts.
• Never connect a battery with reverse polarity.
• Nevertestabatterynearammablematerials.
• Never allow a battery reach a temperature that causes it to get so hot that
it may be too hot to touch.
• Recharge your batteries immediately with an appropriate battery charger
after you have completed your test. Some types do not like to sit
discharged for extended periods of time.
• Never test or charge your batteries while unattended.
• Haveareextinguishernearby.
CBA Charger Warranty
CBA Charger is warranted against failure due to defects in
workmanship or materials for one year after the date of purchase
from West Mountain Radio. Warranty does not cover damage caused
by abuse, accident, misuse, improper or abnormal usage, failure
to follow instructions, improper installation, alteration, lightning, or
other incidence of excessive voltage or current. If failure occurs
within this period, return the CBA Charger or accessory to West
Mountain Radio at your shipping expense. The device or accessory
will be repaired or replaced, at our option, without charge, and
returned to you at our shipping expense. Repaired or replaced items
are warranted for the remainder of the original warranty period. You
will be charged for repair or replacement of the CBA Charger or
accessory made after the expiration of the warranty period.
West Mountain Radio shall have no liability or responsibility to
customer or any other person or entity with respect to any liability,
loss, or damage caused directly or indirectly by use or performance
of the products or arising out of any breach of this warranty, including,
but not limited to, any damages resulting from inconvenience,
loss of time, data, property, revenue, or profit, or any indirect, special
incidental, or consequential damages, even if West Mountain Radio has
been advised of such damages.
Except as provided herein, West Mountain Radio makes no
express warranties and any implied warranties, including fitness for
a particular purpose, are limited in duration to the stated duration
provided herein.
www.westmountainradio.com
1020 Spring City Drive, Waukesha, WI 53186
tel 262-522-6503 fax 262-522-6504
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