U5041A AR Series 2
AR SERIES 2
All-Chemistry Charging Systems
Instruction Manual
*
*Advanced Charging System
◗ Back in the early 1980s PAG’s
Research & Development team
ensures greater flexibility, reliability
conducted a full study into the
and full control over the battery
behaviour patterns of Nickel-Cadmium charging process.
batteries used in the television
industry.
◗ This study turned out to be far more
complex than anyone had originally
imagined, but it enabled PAG to
develop the most advanced and
sophisticated microcomputercontrolled charging system available
in the world today.
detects faulty batteries immediately.
detects fully charged batteries within
20 seconds.
maintains the balance of individual
cells thereby removing the most
common cause of battery failure.
◗ This charging system is faster,
more accurate, and significantly
increases, rather than decreases, the
duty cycle life of any battery charged automatically provides an adaptive
maintenance charge after full
with it.
◗ The system has been further
enhanced to enable the charging
of Nickel-Metal Hydride and
Lithium-Ion batteries.
◗ PAG are proud to have labelled
this system PAG ACS - Advanced
Charging System and have
incorporated it into the AR Series 2
range of chargers.
charge. This is designed to keep
batteries in peak condition and
ready for instant use.
accommodates batteries of varied
voltages, capacities and cell
chemistries.
longer battery life = fewer discarded
batteries = cleaner environment.
AR Series 2
All-Chemistry Charging Systems
Instruction Manual
CONTENTS
SECTION
PAGE
1
SAFETY RULES
2
2
SPECIFICATION
3
3
INSTALLATION
6
4
OPERATING INSTRUCTIONS
6
5
SERVICING & REPAIRS
12
6
WARRANTY
13
1
SECTION 1
SAFETY RULES
1.1
This manual contains important safety and operating instructions.
Please read these fully and note all warnings before using the charger.
Please follow all instructions and retain this manual for future reference.
1.2
AR Series 2 chargers are not intended for any use other than the charging of
batteries as detailed in Section 2 - 'Specification'.
1.3
IMPORTANT: Use only on AC supplies 100-250V, 50/60Hz.
Supply connection to the unit should be made using only the standard lead
supplied with this equipment.
1.4
Protect the power cord from being walked on or pinched, particularly at
plugs. Unplug this apparatus during lightning storms or when unused for long
periods of time.
1.5
Ensure that the ventilation slots are not obstructed when in use, e.g. do not
site the charger on a deep pile carpet, or cover when in use.
1.6
WARNING: Indoor use only. To reduce the risk of fire or electric shock, do not
expose this apparatus to rain or moisture.
1.7
Although the charger is reverse polarity and short circuit protected, extreme
care should always be taken not to short circuit the battery itself.
Rechargeable batteries can deliver power at a very high rate, and short
circuiting even a partially charged battery could result in a fire or personal
injury. PAG supplies a range of connector leads for most charging
requirements, and does not accept responsibility for any other form of
charging connection.
1.8
Do not disassemble the power supply. There are no user-serviceable parts
inside. Incorrect re-assembly may result in a safety hazard.
1.9
Double Insulation: When servicing use only identical replacement parts.
1.10 Refer all servicing to qualified service personnel. Servicing is required when
the apparatus has been damaged in any way, such as supply cord or plug is
damaged, liquid has been spilled, the apparatus has been exposed to rain or
moisture, does not operate normally, or has been dropped. In this event you
should seek advice from your nearest PAG Dealer, or direct from PAG Ltd.,
London, by telephoning +44 (0)20 8543 3131, or emailing [email protected]
2
SECTION 2
SPECIFICATION
2.1
AR Series 2 Model Range:
Model No. 9792 AR124PLD:
◗ Four sequential charging channels.
◗ Four PAGlok and four PP90 (2.1mm) connectors.
◗ Built-in discharger.
Model No. 9793 AR124NPD:
◗ Four sequential charging channels.
◗ Four NP-type and four PP90 (2.1mm) connectors.
◗ Built-in discharger.
2.2 Range of Batteries Charged:
◗ Nickel-Cadmium batteries having nominal voltages of between 4.8V and
14.4V, and nominal capacities of between 1Ah and 10Ah.
◗ Nickel-Metal Hydride batteries of reputable manufacture having nominal
voltages of between 4.8V and 14.4V, and nominal capacities of
between 1Ah and 10Ah.
◗ PAG Lithium-Ion batteries.
2.3
Battery Connections:
PAGlok: Patented, Professional PAG locking connector compatible with all
PAGlok batteries. Incorporates self-cleaning military-type berylliumcopper leaf contacts.
NP:
Polarised connector suitable for Ni-Cd, Ni-MH and PAG Li-Ion
NP-type batteries. Incorporates superior blade-type berylliumcopper contacts.
PP90:
Polarised connector suitable for PP90 (2.1mm) coaxial DC power
connectors. NOTE: centre pin negative.
2.4 Main Charge Program:
◗ Auto Mode: automatically selects the correct charge current.
◗ Manual selection: 2A, 3A or 4A charge current.
◗ Li-Ion voltage-charge program: only available with PAG intelligent
batteries or suitable PAG intelligent adaptor. PAG intelligent batteries
automatically over-ride the Auto Mode or Manual selection, and control
their own charge regime.
3
2.5 Discharge-then-Charge Program:
This program discharges the battery, automatically determining the fullydischarged condition, and then fully charges it. The discharge capacity
and the subsequent charge loaded into the battery can be displayed on
the screen.
2.6 Recovery Charge:
This special program conditions the battery for a period of one hour. The
charger will then automatically enter the Main Charge program, which will
run until the battery is fully charged. This program also recovers PAG
Li-Ion batteries which have been over-discharged to the point where the
internal safety protection circuit has tripped.
2.7 Ancillary Charging Programs:
The following programs may be automatically entered after charging:
◗ Balancing Charge.
◗ Self-adjusting Maintenance Charge (not applied to PAG Li-Ion
batteries).
2.8 Self Test Program:
The internal microcomputer constantly monitors the battery under charge
or process as well as the operation of the charger’s own functions which
will be shut down to a safe condition should any of the tests fail.
2.9 Mains Input:
100-139V or 140-250V ~ autoselected. Frequency 50-60Hz. Maximum
power consumption 120W.
2.10 Output Protection:
Charger protected against short circuit, open circuit, excess battery
voltage and reverse battery voltage.
2.11 AC Mains Failure Protection:
Should mains failure occur during a charging program, or whilst the
charger is connected, it will shut down to a safe condition.
2.12 User Interface:
The LCD screen has a display area of 94mm x 18mm, which displays 2
lines of text, with 24 characters per line.
The screen incorporates electro-luminescent backlighting with on/off
control via the front panel soft function switch. This switch also provides
for the selection of programs and interrogation of charge and discharge
data.
2.13 Safety:
Designed to comply with electrical safety standard BS EN 60065 & UL6500.
NOTE: U.K. mains leads are fitted with a 1" fuse to BS1362 rated 5A as
standard.
4
2.14 European Union Directives:
Complies with the following EU Directives:
◗ EMC Directive 89/336/EU.
◗ Low Voltage Directive 73/23/EU.
2.15 Operating Temperature Range:
0ºC to 40ºC (+32ºF to +104ºF).
2.16 Overall Dimensions:
9792 AR124PLD:
81.5mm high (90mm with feet extended) x 168mm wide x 240mm deep.
(3.2", 3.5" with feet extended, x 6.6" x 9.5" approx.).
9793 AR124NPD:
78mm high x 142mm wide x 240mm deep. (3.1" x 5.6" x 9.5" approx.).
2.17 Weight:
9792 AR124PLD: 1.23kg (2.70lbs approx.).
9793 AR124NPD: 1.07kg (2.35lbs approx.).
2.18 Typical Battery Charging Times:
Battery Capacity
1Ah
2Ah
4Ah
5Ah
7Ah
10Ah
Charge Time 2A
30mins
60mins
120mins
150mins
See Section 4.5
See Section 4.5
Charge Time 3A
20mins
45mins
90mins
105mins
150mins
See Section 4.5
Charge Time 4A
15mins
30mins
60mins
75mins
105mins
150mins
These times are approximate only, and assume the battery is fully
discharged. Charging times will be less if the battery is already
partially charged.
NOTE: PAG intelligent batteries communicate with the charger, and
automatically optimise the charging output (independently of the manual
selection) to enhance performance and safety. The above charging times
do not apply to these batteries.
5
SECTION 3
INSTALLATION
3.1
All AR Series 2 fast chargers are fitted with a mains input socket conforming
to CEE22 (IEC socket). This is situated on the back panel. Mains connection to
the charger should only be made using the lead supplied with this equipment.
3.2
AR Series 2 chargers have been designed for use on AC mains supplies worldwide, and automatically accept supplies in the range 100-139V or 140-250V ~
autoselected. Mains supply frequency must be in the range 50-60Hz.
3.3
AR Series 2 chargers may be operated from a vehicle 12V battery using the
PAG Vehicle Battery-Power Converter, Model No. 9774.
3.4
PAG TECHNICAL SALES AND INFORMATION:
For further information contact PAG Technical Sales and Information by
telephoning +44 (0)20 8543 3131 or contact your nearest PAG Authorised
Service Centre.
SECTION 4
OPERATING INSTRUCTIONS
4.1 POWERING UP
IMPORTANT: Note section 4.10, Supply Failure. The charger remembers the
status of batteries when the mains supply is disconnected. If the charger
has been previously disconnected from the supply with ‘charged’ batteries
connected, it is important to connect the charger to the supply BEFORE
connecting another set of batteries.
Connect the charger to a suitable supply using the standard lead. The LCD
screen will illuminate and briefly display the PAG logo and charger model
before entering normal operating mode. With no batteries connected, all
channels will indicate ‘absent’.
AR Series 2 chargers may be disconnected from the supply at any time in
complete safety and without damage to the charger or any batteries
connected.
4.2 THE SCREEN
The screen displays two lines of information. The top line indicates battery
status, and the lower line indicates battery voltage, charge loaded, and
discharge capacity. The lower line also confirms charge rate selection.
6
Battery status is indicated by means of text messages. Where the battery
is not undergoing a process, these messages are displayed in a steady
state. Where the battery is undergoing a process, the message blinks.
Due to space considerations, text messages are abbreviated on the fourchannel models. Indications are as follows:
Indication:
(2 Channel)
Indication:
(4 Channel)
Appearance: Status:
ABSENT
ABST
Continuous
No battery connected
WAITING
WAIT
Continuous
Waiting in queue for charge
CHARGING
CHRG
Blinking
Charging in progress
BALANCE
BLNC
Blinking
Balance charge in progress
READY
DONE
Continuous
Program completed
FAULTY
FAIL
Continuous
Battery unsuitable for processing
RECOVERY
RCVY
Blinking
Recovery charge in progress
WAITING/°C
WAIT/°C
Alternate
Waiting - battery too hot or cold
CHARGING/NiMH
CHRG/NiMH
Alternate
Charging of PAG NMH in progress
CHARGING/Liion
CHRG/Liion
Alternate
Charging of PAG Li-Ion in
progress (or other Li-Ion via PAG
Intelligent Charge Adaptor).
DCHG
Blinking
Discharging in progress
DCWT
Continuous
Waiting for discharge
4.3 THE FUNCTION BUTTON
Operating modes and display options are selected by means of the
Function button, the operation of which can be summarised as follows:
Hold in while connecting supply: selects charge rate menu.
Hold in while connecting battery: selects Discharge-then-Charge program.
Hold in during normal operation: turns backlight on/off.
Press once: displays discharge capacity then charge current loaded.
Press twice: Recovery Charge program (channel 1). Further button presses
move the selection to the other channels.
7
4.4 SCREEN ILLUMINATION
The screen will automatically illuminate:
◗ At power-up.
◗ If the Function button is operated.
◗ If a battery is connected or disconnected.
The illumination will remain on for a period of forty seconds following the
last activity, and will then be automatically extinguished.
The illumination can be set to OFF mode. Hold the Function button in.
The screen will illuminate. Continue holding the button in until the
illumination is extinguished (six seconds). The illumination can be returned
to ON mode by holding the button in until the screen illuminates (six
seconds).
NOTE: The charger automatically defaults to illumination ON mode when it
is disconnected from the supply and then reconnected.
4.5 CHANGING THE CHARGE RATE
IMPORTANT: DO NOT CHANGE THE SETTING FROM AUTO MODE UNLESS THERE
ARE GOOD REASONS FOR DOING SO, AND THE IMPLICATIONS OF CHARGING
AT THE ALTERNATIVE RATE ARE FULLY UNDERSTOOD.
Auto Mode: The charger is set to the Auto Mode before leaving the
factory. Auto Mode automatically selects the most appropriate charge
rate for all specified batteries, and it is designed so that even at the
lowest rate it can charge batteries up to 10Ah capacity.
2A charge rate: Nickel-Cadmium or Nickel-Metal Hydride batteries of
reputable manufacture having nominal voltages of between 4.8V and
14.4V, and nominal capacities of between 1Ah and 5Ah. Batteries with a
capacity in excess of 5Ah will not be fully charged.
3A charge rate: Nickel-Cadmium batteries of reputable manufacture,
having nominal voltages of between 4.8V and 14.4V, and nominal
capacities of between 2Ah and 8Ah. Nickel-Metal Hydride batteries of
reputable manufacture, having nominal voltages of between 4.8V and
14.4V, and nominal capacities of between 5Ah and 8Ah. Batteries with a
capacity in excess of 8Ah will not be fully charged.
4A charge rate: Nickel-Cadmium batteries of reputable manufacture,
having nominal voltages of between 4.8V and 14.4V, and nominal
capacities of between 2Ah and 10Ah.
NOTE: PAG intelligent batteries automatically over-ride the Auto Mode or
Manual selection, and control their own charge regime.
8
Hold the Function button in while connecting the charger to the supply.
The screen will display the instruction “HOLD FOR SETUP V x.xxLi”.
Continue to hold the button for a few seconds until the set-up screen
appears. The screen will now display the instruction “CHARGE CURRENT SET
TO AUTO. PRESS BUTTON TO CHANGE”. Press the Function button to choose
between the AUTO mode or 2A, 3A or 4A rate. The displayed rate will be
selected 5 seconds after the last button activity. The screen will now
display the instruction “SETTING SAVED. PLEASE WAIT FOR RESTART”.
The selection will be stored in memory, and will become the default
charge rate for both the Main Charge program and the Discharge-thenCharge program.
4.6 CONNECTING A BATTERY
AR Series 2 chargers are intelligent, requiring only the battery positive
and negative connections (no thermal sensors are necessary). Some
batteries can be connected directly to the charger; other batteries should
be connected to the charger using the appropriate adaptor leads. The first
battery to be connected, irrespective of the channel chosen, will be the
first battery selected.
NOTE: All AR Series 2 chargers offer a choice of connector on each
channel. Batteries may be connected to either but not both connectors at
the same time. Connection of a battery to a front panel PP90 (2.1mm)
socket will disconnect the alternative connector (depending upon model)
for that channel.
4.7 MAIN CHARGE:
Charger set to Auto Mode: connect the battery to the charger. A period of
analysis lasting a minimum of 30 seconds is required before the correct
charge rate is determined, and the display will then indicate the rate by
flashing ‘AU’ and the charge rate (2A, 3A, or 4A) alternately. PAG
intelligent batteries control their own charge rate, and are identified
separately. Charging will then automatically commence. A ‘charging’
indication will blink once every second to show that the charging program
is being executed, and the on-charge battery voltage will be displayed.
Charger set to Manual Selection: the display will indicate the the charge
rate, and charging will automatically commence. PAG intelligent batteries
control their own charge rate, and are identified separately. A ‘charging’
indication will blink once every second to show that the charging program
is being executed, and the on-charge battery voltage will be displayed.
A ‘waiting’ indicator will be displayed on any other channel that has a
battery connected. The balancing process is indicated by ‘balance’. At the
end of the program the screen will display a ‘ready’ indication.
The charge current loaded into the battery can be viewed at any time
during charge by pressing the Function button once. The screen will first
display the discharge capacity and then the charge current loaded, for all
channels. The charge current loaded into the battery can be a useful
9
guide as to the battery’s fitness for use. If a fully discharged battery only
accepts a small amount of charge current against its rated capacity the
battery will require further investigation.
4.8 DISCHARGE-THEN-CHARGE
Hold the Function button in while connecting a battery. This will select the
Discharge-then-Charge program for that channel and indicate the selection
on the screen. A ‘waiting for discharge’ indication will be displayed if the
charger is currently occupied on another channel.
The battery will be automatically discharged to the correct end voltage,
and will then be charged. The screen will indicate ‘discharge’ or ‘charging’
respectively.
The discharge capacity can be viewed at any time by pressing the Function
button once. If the battery was fully charged at the start of the program,
this figure will give a useful indication of battery capacity.
4.9 RECOVERY CHARGE
IMPORTANT: SELECTION OF RECOVERY CHARGE IS A PRIORITY COMMAND,
AND WILL TEMPORARILY SUSPEND OPERATIONS ON ANY OTHER CHANNEL.
Press the Function button twice. The screen will indicate the selection and
any further operation of the button will move the recovery indication to
the next channel. The selection will skip over any channel on which the
Discharge-then-Charge program has been selected. A dwell time of over
five seconds on the selected channel will allow the Recovery Charge
program to be initiated. After a period of one hour the charger will
automatically enter the Main Charge program, which will run until the
battery is fully charged. If a battery is severely faulty, and has not
responded to treatment by the Recovery Charge program, it will be
indicated as faulty when the Main Charge program is entered, and will not
be charged. Rejected batteries should be investigated.
4.10 SUPPLY FAILURE
If the AC mains power fails during operation, the charger will shut down
safely; no damage will occur to either the charger or the batteries.
When the mains power is restored the charger will default to the Main
Charge program. Batteries which had been identified as ‘charged’ or
‘faulty’ before the supply failure, and which had not been removed, are
recorder, and the charger will not attempt to charge these batteries
(note: this does not apply to PAG Li-Ion batteries). The charger will then
fully charge the remaining batteries.
4.11 GENERAL
The charger continuously monitors the status of all channels and provides
this information to the screen.
10
If the charger detects a severely faulty battery while a program is
running, a ‘faulty’ indication will be displayed. This could be caused by
one of several conditions, such as a very old or damaged battery, a short
circuit battery, or an excessively high or low voltage battery. An ‘absent’
indication will be displayed if a battery becomes open circuit while being
charged. Conditions that could cause this include a blown battery fuse, a
battery’s internal thermal cutout operating, intermittent connections, or a
disconnected battery.
The charger will not attempt to process batteries which are indicated as
‘faulty’, or which have completed a program. If a battery is disconnected,
the status will revert to the ‘absent’ state. Another battery can now be
connected to the free channel without affecting any of the other
channels.
To the charger there is no difference between a disconnected battery and
one that is open circuit. If the charger indicates that a battery is
disconnected even though it appears to be plugged in, check the battery
fuse and any leads and adaptors before suspecting the charger of a fault.
Each battery will be charged to its maximum available capacity, and no
advantage is to be gained from attempting to charge it further. Although
re-application is safe, repeated attempts to overcharge a battery may
overheat the battery, resulting in a shortened life.
11
SECTION 5
SERVICING & REPAIRS
5.1
WARNING: To reduce the risk of electric shock, do not attempt any servicing
or repairs unless you are qualified to do so. Refer all servicing or repairs to
qualified servicing personnel. The Power Supply contains advanced electronics
that do not require periodic maintenance. Consequently there are no user
serviceable parts inside.
5.2
Qualified electronics engineers who wish to gain access to internal assemblies
should note that parts of the power circuit retain a high voltage even after
the mains supply has been disconnected. Wait for a period of five minutes
following disconnection before commencing disassembly.
5.3
When the charger is correctly connected to a mains supply and the display is
not functioning, it is an indication that a supply fuse has become open circuit.
Equipment supplied for use in the UK is supplied with a standard UK mains
lead, complete with a moulded, fused plug. If this fuse has become open
circuit it should be replaced by another of the correct rating (see ‘Specification’
section 2.13).
USE ONLY A FUSE OF THE CORRECT RATING. If the replacement of the fuse
fails to correct the above symptoms, do not attempt further fuse replacement.
It is likely that a fault has developed.
Seek advice from your nearest PAG dealer or direct from PAG Ltd., London, by
telephoning +44 (0)20 8543 3131, or emailing [email protected]
5.4
AR Series 2 chargers feature a fail-safe shutdown mode. In the unlikely event
of an internal malfunction, an error message will be displayed on the screen
to show that the charger is in shutdown mode. This could be the result of any
number of undesirable situations from which the system is protecting itself,
such as the obstruction off ventilation slots causing inadequate cooling, or
the microcomputer’s detection of an internal fault. In these cases the charger
should be disconnected from the supply, any obstruction of the air vent
system removed, and the unit allowed to cool before reconnecting to the
supply. Should the charger re-enter the fail-safe shutdown mode, more
detailed investigation is required. Make a note of the error message, and
seek advice from your nearest PAG dealer or direct from PAG Ltd., London,
by telephoning +44 (0)20 8543 3131, or emailing [email protected]
5.5
Unqualified personnel should not attempt further investigation (see paragraph
5.1 above). Any such interference would invalidate the guarantee and
invariably cause more damage than the original fault.
12
SECTION 6
WARRANTY
6.1
Notwithstanding any provision of any agreement the following warranty is
exclusive: PAG Limited warrants each AR Series 2 charger it manufactures to
be free of defects in material and workmanship under use and service for
TWO YEARS from the date of purchase. This warranty extends only to the
original purchaser. This warranty shall not apply to fuses or any product or
parts which have been subject to misuse, neglect, accident or abnormal
conditions of operation.
6.2
In the event of failure of a product covered by this warranty, PAG Limited
will repair and calibrate equipment returned to an authorised service facility
within the period of the warranty, provided the warrantor’s examination
discloses to its satisfaction the product was defective. The warrantor may,
at its option, replace the product in lieu of repair. With regard to any
equipment returned within this period, said repairs or replacements will be
made without charge.
If the failure has been caused by misuse, neglect, accident or abnormal
conditions of operation, repairs will be billed at a nominal cost. In such a
case, an estimate will be submitted before work is started, if requested.
6.3
The foregoing warranty is in lieu of all other warranties, express or implied,
including but not limited to any implied warranty or merchantability, fitness
or adequacy for any particular purpose or use. PAG Limited shall not be liable
for any special, incidental, or consequential damages, whether in contract,
tort, or otherwise.
13
U5041 ISS A / NOV 01
PAG Ltd.
565 Kingston Road
Raynes Park
London SW20 8SA
T +44 (0)20 8543 3131
F +44 (0)20 8540 4116
E [email protected]
www.paguk.com
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