U4997 30V AR Series
30V AR Series
Ni-Cd & Ni-MH Battery Chargers
U4997 ISS A / DEC 98
Instruction Manual
*
*Advanced Charging System
◗ Back in the early 1980s PAG’s
Research & Development team
conducted a full study into the
behaviour patterns of NickelCadmium batteries used in the
television industry.
ensures greater flexibility, reliability
and full control over the battery
charging process.
detects faulty batteries immediately.
◗ 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
microcomputer-controlled
charging system in the world.
◗ A charging system that is faster,
terminates charge more
accurately, and one that
significantly increases, rather
than decreases, the duty cycle
life of any battery charged
using it.
◗ PAG is proud to have labelled
this system PAG ACS Advanced
Charging System and has
incorporated it into the 30V AR
Series of single and fourchannel chargers.
detects fully charged batteries within
20 seconds.
maintains the balance of individual
cells thereby removing the most
common cause of battery failure.
automatically provides an adaptive
maintenance charge after full
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.
30V AR Series
Autoranging Fast-Chargers for
12 to 30V Ni-Cd & Ni-MH batteries
Instruction Manual
CONTENTS
SECTION
PAGE
1
SAFETY
2
2
SPECIFICATION
3
3
INSTALLATION
4
4
PROGRAM DESCRIPTION
5
5
OPERATING INSTRUCTIONS
6
6
FAULT FINDING
9
SECTION 1
SAFETY
1.1
This manual contains important safety and operating instructions.
Please read these fully before using the 30V AR Series fast-charger.
1.2
The charger is rated for indoor use only. Do not expose it to water.
1.3
The charger is not intended for any use other than the charging of
Nickel-Cadmium and Nickel-Metal Hydride batteries as detailed in
Section 2: Specification.
1.4
The charger is extremely rugged and designed for arduous service
conditions. It should not be used, however, if it has received a severe drop
or blow, or been otherwise damaged in any way. The charger should be
returned to your local PAG Dealer, or direct to PAG Ltd. London for service
or repair.
1.5
Do not disassemble the charger. There are no user-serviceable parts inside.
Incorrect reassembly may result in a safety hazard.
1.6
Ensure that the ventilation slots are not obstructed when in use, e.g. do
not site the charger on a deep pile carpet or similar surface.
1.7
Disconnect the charger from the supply before attempting any cleaning.
1.8
Use the charger on a suitable AC supply. See ‘Specification’ Section 2.
1.9
Do not use an extension cord for the supply unless absolutely necessary.
If an extension cord is used, ensure that it is properly wired, has a
conductor cross-sectional area of at least 0.5mm and a length of less than
30 metres. Suitable extension cords should be classified as follows.
Domestic and light commercial application: HO5 W-F. Industrial application:
HO5RR-F OR HO5RN-F.
1.10
WARNING:
Although the charger is short circuit protected, extreme care should be
taken not to short circuit the battery itself. Batteries can deliver power at
very high rates, and a short circuit could result in fire and personal injury.
Do not connect the charger to the battery by means of bare wires or
crocodile clips.
2
SECTION 2
SPECIFICATION
2.1
Description:
30V AR Series: microcomputer-controlled fast-chargers, incorporating
PAG ACS (Advanced Charging System).
Model No. 9763 AR301 (single channel).
Model No. 9765 AR304 (four channel).
2.2
Range of Batteries Charged:
Nickel-Cadmium and Nickel-Metal Hydride batteries of reputable
manufacture, having nominal voltages of between 12V and 30V,
and nominal capacities of between 1.7Ah and 10Ah.
2.3
Battery Connections:
AR301 - 1 x XLR4
AR304 - 4 x XLR4
Note: pin 1 neg pin 4 pos.
2.4
Main Charging Programs:
Fast-charge program under microcomputer-control. Recovery charge program
manually selectable.
2.5
Ancillary Charging Programs:
Balancing charge; self-adjusting maintenance charge (automatically entered
after charging).
2.6
Self Test Program:
The microcomputer constantly monitors the operation of the charger,
which is shut down to a safe condition should any of the tests fail.
2.7
Input Supply:
100-135V or 180-265V AC, auto-selected. Frequency 50Hz to 60Hz.
Maximum power consumption 240W.
2.8
Output Protection:
Charger protected against short circuit, open circuit, excess battery voltage
and reverse battery voltage.
2.9
A.C. 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.
3
2.10
Safety:
Designed to comply with electrical safety standards EN60335-1 and
EN60335-2-29 Class 2 (double insulated) U.K. mains lead fitted with
1" fuse to BS1362 rated 5A.
2.11
Operating Temperature Range:
0°C to 40°C (+32°F to +104°F).
2.12
Overall Dimensions:
78mm high x 142mm wide x 240mm deep. (3.1" x 5.6" x 9.5" approx.).
2.13
Weight:
1.07kg (2.35lbs approx.).
2.14
Typical Battery Charging Times:
Battery Capacity
Charge Time*
2Ah
4Ah
6Ah
7Ah
8Ah
10Ah
0.5 hour
1.0 hour
1.5 hours
1.75 hours
2.0 hours
2.5 hours
*These times are approximate only, and assume the battery is fully
discharged. Charging times will be less if battery is partially charged
at start.
SECTION 3
INSTALLATION
3.1
30V AR Series fast-chargers are fitted with an 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 standard
lead supplied with this equipment.
3.2
30V AR Series chargers have been designed for use on AC mains supplies
worldwide and automatically accept supplies from 100-135V or 180-265V
AC, auto-selected. Mains supply frequency must be in the range 50Hz
to 60Hz.
4
SECTION 4
PROGRAM DESCRIPTION
4.1
Main Charging Program:
Fast-charge program, under microcomputer control.
4.2
Ancillary Charging Programs:
Balancing charge, adaptive maintenance charge (automatically executed
after charging), Recovery Charge.
4.3
Self-Test Program:
The microcomputer constantly monitors the operation of the charger, which
is shut down to a safe condition should any of the tests fail.
4.4
THE FAST-CHARGE PROGRAM
The fast-charge program charges the battery at a rate of 4 Amperes. This
continues until the charger detects that the battery is fully charged. The
software developed to do this is the most powerful and complex part of
the charger design.
To perform properly batteries must be charged by exactly the right amount.
Undercharging gives less than full capacity and consequently short running
times, whereas overcharging can permanently damage the battery.
AR Series chargers cater for a wide range of battery types, voltages and
capacities, as well as the variation of battery characteristics found between
cell manufacturers. To ensure that the fast charge current is stopped at the
correct time, and in order to detect the many varied problems associated
with faulty batteries, the PAG ACS microcomputer uses a combination of
several cut-off algorithms. This gives dependable operation in all cases.
4.5
THE BALANCING CHARGE PROGRAM
When the fast charging phase has been completed, the charger may switch
over automatically to its balancing charge program. Investigations by PAG
Ltd. have shown that imbalance between cells (caused by slight differences
in cell charge acceptance and capacity) can be cumulative without the
ability to address cell imbalance. The duration of the balancing charge is
dependent upon information gained on individual cell condition during the
initial analysis phase of the fast-charge program. A battery in any state of
charge may be applied to the charger. If the PAG ACS determines that a
battery is in a satisfactory state of balance, it will not have the above
balancing charge applied.
5
4.6
THE MAINTENANCE CHARGE PROGRAM
Batteries once charged, tend to self-discharge. The rate varies with the
type, size and temperature of the cell, and no one maintenance rate is ideal
in all cases. AR Series chargers feature a special adaptive maintenance
charge which is automatically executed when all the connected batteries
have been charged.
4.7
THE RECOVERY CHARGE PROGRAM
Batteries which have been over-discharged may be rejected by the charger
and indicated as faulty; batteries in this condition are unsuitable for fastcharging. To overcome this condition, the charger incorporates an ancillary
Recovery Charge program. The selector switch for this program is located on
the front panel and its operation initially allows the user to select the
required output channel.
SECTION 5
OPERATING INSTRUCTIONS
5.1
The AR Series are intelligent chargers, only requiring the battery positive
and negative connections (no thermal sensors necessary). Batteries should
be connected to the charger using the appropriate adaptor leads, when
necessary. The first battery to be connected, irrespective of the channel
chosen, will be the first battery to be charged.
5.2
Fast-charging will automatically commence and the yellow indicator will
blink once every second to show that the charging program is being
executed. The red STANDBY indicator will light on any other channel
that has a battery connected.
5.3
When a battery is almost charged, the charger may give a balancing
charge, indicated by CHARGING and READY indicators flashing alternately.
This indicates that the battery is virtually fully charged and may be
disconnected at this time if it is needed urgently. However, it is
advantageous to leave it connected because this balancing charge
keeps the cells balanced with respect to each other, and maintains the
battery capacity at its maximum to prolong its useful life. If the battery
was already fully charged when connected to the charger, the balancing
charge program is omitted and the green READY indicator lights.
A green READY indicator shows that a battery has received as much
charge as it can safely accept.
6
5.4
The charger will now select the battery connected to the next channel, and
the charging process will be repeated.
5.5
When all connected batteries have been processed, a maintenance charge
is applied. Batteries may be removed, and others connected at any time,
without affecting the operation of the charger.
5.6
The charger will continue to monitor the status of all charging channels.
It will not attempt to fast-charge batteries which are READY or FAULTY.
If a battery is now disconnected, the status will revert to the ABSENT/
FAULTY state. If a new battery is connected to the free channel, the status
will change to STANDBY and the charging sequence will be initiated
automatically. The order in which batteries are connected is therefore
immaterial; the charger will ensure that all batteries are charged in due
course.
5.7
If the charger detects a severely faulty battery while the charging program
is running, the ABSENT/FAULTY indicator will flash. 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. The ABSENT/
FAULTY indicator will be lit if the battery becomes open circuit while being
charged. Conditions that could cause this include: a blown battery fuse,
a battery’s internal thermal cut-out operating, intermittent battery connections, or a disconnected battery.
5.8
Operation of the Recovery switch is shown by the STANDBY and CHARGING
indicators flashing alternately, and any further operation of the switch
within five seconds moves the recovery indication to the next channel.
A dwell time of over five seconds on the selected channel will allow the
Recovery Charge program to be initiated; this will over-ride the charging
process on any other channel. When the Recovery Charge has been completed the charger will automatically enter the fast-charge program, which
will run until the battery is fully charged; the charger will then select the
next channel in sequence for normal fast-charge. If a battery is severely
faulty, and has not responded to treatment by the Recovery Charge
program, it will be rejected and indicated as faulty when the fast-charging
program is entered. While channel selection is in progress, or if an attempt
is made to engage Recovery Charge on a channel where no battery is
connected, the normal activity of the charger is not interrupted.
5.9
The charger cannot tell the difference between a disconnected battery
and one that is open-circuit. If the charger indicates that a battery is
disconnected even though it is plugged in, check the battery fuse,
adaptor and lead before suspecting the charger of a fault.
7
5.10
The charger will not recognise the connection of a battery which has a
voltage substantially outside of its range.
5.11
When a battery is known to be fully charged already, it is not advisable to
attempt to fast-charge it further. The charger will detect this situation and
will stop fast-charging after a short time: up to 1 minute for small capacity
batteries and up to 15 minutes for larger capacity batteries. This does
not mean that the battery is losing its charge, but results from the finite
response time of the cells to overcharging. Although it is safe if this
happens occasionally, repeated attempts to overcharge a battery may
cause internal damage to one or more of the cells, resulting in a shortened
life. The charger will charge a battery to its maximum available capacity
and no advantage is to be gained from trying to charge it further.
5.12
If the AC mains power fails during charging the charger will shut down
safely, and no damage will occur to either the charger or to any connected
batteries. No record is kept of the status, including Recovery Charge, of
each channel. When power is restored the charger will start to analyse
each channel in sequence.
The analysis will take a few minutes for each channel, and the process will
continue until an uncharged battery is reached. Normal charging will then
be resumed.
5.13
8
If the charger should become too hot (perhaps through the ventilation slots
becoming obstructed) the microcomputer will shut the charger down and
this will be shown by the indicators cycling continuously. In this event the
charger should be disconnected from the supply and any obstructions
removed. The charger should be allowed to cool before reconnecting to
the supply.
SECTION 6
FAULT FINDING
6.1
All AR Series chargers contain advanced electronics which do not
require periodic maintenance. Consequently there are no user
serviceable parts inside.
6.2
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.
6.3
When the charger is correctly connected to a mains supply and the
ABSENT/FAULTY indicators are not lit, it is possible that a fuse has
become open circuit.
6.4
Equipment supplied for use in the UK will be supplied with a standard
UK mains lead, terminated with a fused plug. If this fuse has become
open circuit it should be replaced by another of the correct rating (see
Specification Section 2.10) USE ONLY A FUSE OF THE CORRECT RATING.
6.5
If replacement of an open circuit fuse fails to correct the fault described
in paragraph 6.3 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.
6.6
Unqualified personnel should not attempt further investigation. Any
such interference would invalidate the guarantee and could cause
more damage than the original fault. (See paragraph 6.1 above).
9
PAG Ltd.
565 Kingston Road
Raynes Park
London SW20 8SA
E [email protected]
T +44 (0) 20 8543 3131
F +44 (0) 20 8540 4116
www.paguk.com
EU DECLARATION OF CONFORMITY
We
PAG Ltd.
London, England.
hereby declare that the products described below conform to the relevant
requirements of the appropriate EU Directives. This declaration shall cease to be
valid if modifications are made to the products without our approval.
PRODUCT:
PAG 30V AR Series Battery Chargers
MODELS:
9763 & 9765
APPLICABLE EU DIRECTIVES:
EMC DIRECTIVE 89/336/EU
LOW-VOLTAGE DIRECTIVE 73/23/EU
CE MARKING DIRECTIVE 93/68/EU
HARMONISED STANDARDS APPLIED:
PRODUCT SPECIFIC:
GENERIC:
EN 50081 - 1 (EMISSIONS)
EN 50082 - 1 (IMMUNITY)
EN 55022 - B
EN 60555 - 2/3
IEC 801 - 2/3/4
EN 60335 - 1
EN 60335 - 2 - 29
Signed for and on behalf of PAG Ltd.
Alan Lavender
Chief Executive
U4937 ISS C
Date: 26.05.96
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