Table of Contents
Troubleshooting
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Summary of Contents for Bren-Tronics BTC-70819
- Page 1 OPERATION AND SERVICE MANUAL SPC LITE Universal Portable Charger Dual-Position BTC-70819 NSN 6130-01-555-7817 USA Tel: (631) 499-5155 · Fax: (631) 499-5504 email address: sales@bren-tronics.com www.bren-tronics.com 850036-1 REV C...
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Page 2: Table Of Contents
WARNING HIGH VOLTAGES ARE PRESENT IN THE OPERATION OF THIS EQUIPMENT Avoid contact with AC supply voltage connections during installation, operation or maintenance of the battery charger. CAUTION ACID CONTAMINATES NICKEL-CADMIUM, LITHIUM-ION, LITHIUM-POLYMER and NICKEL-METAL HYDRIDE BATTERIES Every effort must be made to keep Nickel-Cadmium, Lithium-Ion, Lithium Polymer and Nickel-Metal Hydride batteries as far away as possible from Lead-Acid batteries because Lead-Acid batteries contain sulfuric acid. -
Page 3: Chapter 1 - Introduction
INTRODUCTION 1-1. SCOPE The Soldier Portable Charger Lite (P/N BTC-70819) is a state-of-the-art, high performance lightweight portable battery charger designed for field deployment or shop usage. It provides fast reactivation of various rechargeable batteries. It is capable of simultaneously charging two batteries completely unattended. -
Page 4: Technical Specifications
AC Operation……………... Automatic Selection: 90 to 260 VAC, single-phase, 47 to 440 Hz 28V DC Operation………...22 to 33 VDC, 13A 12V DC Operation………...11 to 18 VDC, 20A (BTC-70819-3 Only) Charging Output Voltage………... Automatically selected for each battery type Duty Cycle………………………… Continuous Protective Features………………. -
Page 5: Declaration Of Conformity
INTRODUCTION 1-3. DECLARATION OF CONFORMITY 850036-1 REV C... -
Page 6: Accessories
INTRODUCTION 1-4. ACCESSORIES Table 1 shows the various batteries and appropriate adapter plates the SPC Lite supports at the time this document was written. Table 2 shows various power cables and accessories. Table 1 – Supported Batteries and Adapters ADAPTER ADAPTER NSN BATTERY TYPE... - Page 7 BT-70661 Li Ion NOTES: 1) The BB-516A,BB-326, and RACAL 931 can only charge with AC power on the BTC-70819. There is no limitation on the BTC-70819-3 2) The Adapter BTA-70480/3 is not compatible with this charger. 3) This list was complete at the date of publication. Additional adapters may be available, but may require updated software.
- Page 8 INTRODUCTION Table 2 – Power Cables and Accessories DESCRIPTION BTI P/N GENERAL P/N AC Power Cord US 591609 ------ ------ AC Power Cord EU 590233-3 ------ ------ AC Power Cord UK 590233-4 ------ ------ DC Power Cable w/rings BTA-70844-24 ------ ------ DC Power Cable w/allig.
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Page 9: Charge Cycle Description
INTRODUCTION 1-5. CHARGE CYCLE DESCRIPTION Each of type the battery that are capable of being charged by the Charger is connected to the charger via their respective battery adapter (plate or cable). Each adapter can charge two batteries simultaneously. The appropriate battery adapter is installed on the control panel and serves as the electrical interface between the batteries being charged and the charger circuits. -
Page 10: Updating Charger Software
INTRODUCTION 1-6. UPDATING CHARGER SOFTWARE The software in the charger is field upgradeable. By loading new software into the charger, it is possible to alter its operation and add or change the charging profiles for the batteries. Loading new software into the charger is accomplished via the use of a standard RS232 interface of a personal computer (PC) running Windows 95™... -
Page 11: Panel Controls And Indicators
OPERATION SECTION 2 OPERATING PROCEDURES 2-1. PANEL CONTROLS AND INDICATORS Battery charger panel components are described below and shown in Figure 2-1.1 and 2-1.2 FIGURE 2-1.1 FIGURE 2-1.2 850036-1 REV C... - Page 12 OPERATION Item Function 1. On/Off Switch........Turns battery charger on or off. 2. AC Circuit Breaker......Turns power to the charger off in an overload condition. Remove the overload condition and push to reset. 3. Power On Indicator LED (Green)……. The Power On Indicator LED lights when the charger has sufficient power from either AC or 4.
- Page 13 OPERATION 10. Fault LED (Red)........ If the Red LED lights steadily, the associated battery, or adapter plate is defective or will not accept charge. A blinking indication means the battery’s temperature sensor or communication connection is not making contact with the adapter.
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Page 14: Preliminary Setup Procedures
AC power. If 12 and 28 VDC power are connected the charger will use 28VDC. • For the BTC-70819 if AC and DC are connected the charger will use DC power. Step 6. Observe that only the Power On Indicator LED (Fig 2.1-1 #3) is lit. -
Page 15: Charging Batteries
OPERATION 2-3. CHARGING BATTERIES Step 1. With the appropriate battery adapter installed, insert the first battery to be charged into the channel “A“ battery location. Insure the battery is fully seated in the adapter. Observe that the amber Charge LED (Fig 2.1-1 #8) for the corresponding location is lit or blinking rapidly. -
Page 16: Battery Revitalization And De-Storage
OPERATION 2-4. BATTERY REVITALIZATION AND DE-STORAGE The procedures outlined below describe the means of invoking the Revitalization and De-storage functions of the charger as well as the sequence of operations the charger will execute to perform the commanded tasks. NiCd and Ni-Mh Batteries are revitalized. Li-Ion batteries are de-stored. The charger will decide what to do based on the batteries’... -
Page 17: Blackout
OPERATION the amber Recondition LED (Fig 2.1-1 #15) will light for the corresponding channel. 4. Plug the battery into the activated channel. 5. De-storage will commence upon recognition of the battery. Autonomously, the Charger will perform the following de-storage sequence: 1. -
Page 18: Battery Charger Labels
OPERATION 2-6. BATTERY CHARGER LABELS Shown below are the instructions contained on the "SHORT FORM - OPERATING PROCEDURE" label, attached inside the charger cover. LED INDICATIONS FOR EACH BATTERY S = STEADY, F = FLASHING S=Steady LIGHT INDICATIONS FOR EACH BATTERY F= Flashing AMBER GREEN... -
Page 19: Solid Red Fault Led Troubleshooting
OPERATION 2-7. SOLID RED FAULT LED TROUBLESHOOTING 1. Remove the battery and inspect all the contacts, clean if necessary. Note the battery location. 2. Reinstall at the same location for another charge cycle. 3. If the Fault LED (Fig 2.1-1 #10) is lit again at the same location remove battery and do the following: a. -
Page 20: Operation In Extreme Environmental Conditions
OPERATION 2-9. OPERATION IN EXTREME ENVIRONMENTAL CONDITIONS Observe these precautions when the charger is operated in areas where severe climatic conditions may exist: a. Operation in Arctic Climates. The battery charger is designed to function in temperature extremes as low as -4°F (-20°C). However, when operating in arctic climates, the following precautions should be observed: (1) Handle the equipment carefully. -
Page 21: Preparation For Movement
OPERATION NOTE Battery charge acceptance varies with ambient temperature conditions. At temperatures lower than 32°F (0°C) or higher than 104°F (40°C) it may be necessary to initiate two complete charging cycles to achieve full charge on the battery. 2-10. PREPARATION FOR MOVEMENT a. -
Page 22: Battery Capacity Retention
OPERATION 2-12. BATTERY CAPACITY RETENTION As shown in the adjoining graph, fully charged batteries that are stored, lose a portion of their charge due to battery chemistry. This is normal and should not be interpreted as battery failure. Storage at higher temperatures increases capacity losses, while storage at lower temperature decreases capacity losses. -
Page 23: Introduction
MAINTENANCE SECTION 3 OPERATOR MAINTENANCE INSTRUCTIONS 3-1. INTRODUCTION Periodic maintenance, inspection and cleaning will help insure the Charger is kept at full readiness. 3-2. CLEANING 1. Brush loose dirt and dust from the charger. Low-pressure air may be used to remove heavy dust from the case, connectors and power switches. Avoid blowing dust into the unit. -
Page 24: Basic Functional Test
15. Press the Blackout Switch (Fig 2.1-1 #6). Verify that all panel LEDs turn off. 16. Press the Blackout Switch (Fig 2.1-1 #6) again. Verify all panel LEDs resume normal operation. 17. For the BTC-70819-3 Only a. Set the On/Off Switch (Fig 2.1-1 #1) to OFF position and disconnect the 28 Volts DC Power. -
Page 25: Simplified Operator Troubleshooting Procedures
3) Operating the chargers edge to edge can cause overheating if there is not adequate air flow. 4) The internal fans have failed. The unit requires repair. Contact Bren-Tronics (see section 3-6) 1) If the unit is running from DC power verify Low Vehicle Power (Fig 2.1-1 #4) is lit. - Page 26 2) The air vents of the charger are blocked. 3) Operating the chargers edge to edge can cause overheating. 4) The internal fan has failed. The unit requires repair. Contact Bren-Tronics (see section 3-6) 1) Battery is defective. Cycle power to clear Fault LED (Fig 2.1-1 #10) stays lit after...
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Page 27: Warranty / Repair Information
3-6. WARRANTY / REPAIR INFORMATION If the Charger or Adapters fail to function they must be returned to Bren-Tronics for repair. The warranty label gives the expiration date on each unit. Contact Bren-Tronics for a Return Material Authorization (RMA) number before returning any hardware to Bren-Tronics.
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