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Thank you for purchasing the PolyCharge4 lithium-polymer
charger! Capable of charging 4 separate lithium-polymer packs
simultaneously, the PolyCharge4 charger is specially designed
for today’s electric flight modeler. Adjustable capacities from 300
to 3000mAh, tri-color LED indicators and ease of use make this
a must-have item! Audio sound cues indicate charge completion
and errors, while each individual port’s status can be read at a
glance by the LED. Do NOT attempt to use this charger with
NiCd, NiMH or Lithium-Ion batteries as they are not
compatible! Please read this entire manual to learn about
specific functions and features as well as safety
information. Damage resulting from misuse or modification
of this charger will void your warranty.
Input V oltage: 12.0 - 15.0V DC
Number of Outputs: Four
Specifications for EACH Output:
Battery Types: Lithium-Polymer Only
Number Cells: 1 to 4 Cells (3.7-14.8V)
Charge Control: Pushbutton Start
Fast Charge Termination: Constant Current/
Constant V oltage
Max. Cell Capacity: 300mAh to 3000mAh
Charge Current: 300mA to 3.0A
Safety Timer: 3 Hours Maximum Charge Time
Output Connectors: Banana Jacks
Status Indicators: Tri-Colored LED and
Audible Buzzer
Input Connectors: Alligator Clips
Fuse: 20A Replaceable Spade Fuse
(Auto Type)
Case Size: 8.19"x1.50"x4.96" (208x38x126mm)
Weight: 21.8 oz. (617g)
• Four independent outputs—like having four chargers in one!
• Charge up to four 4-cell LiPo packs simultaneously
• Input voltage boost circuitry to handle 3 and 4-cell packs
with ease.
• Set the battery capacity on each output with an adjustment
dial, 300mAh to 3000mAh
• Charge current sets automatically, based on battery mAh
selection, 300mA to 3.0 amps
• Automatically detects the number of cells on each output—
no switch to set
• Pushbutton start for each output
• Uses the constant-current/constant-voltage charge
technique for each output
• Each output has a built-in 3 hour safety timer
• Tri-color LED and audible indicators for each output
indicates charge status, as well as for improper input
voltage, output reverse polarity, open-circuit, and more
• Built-in fan keeps charger cool for efficient operation and
extended lifetime
• Rugged metal case for durability.
• Reverse polarity and current overload protection on input
(20A spade fuse included)
• 12V DC only input
• Charge ONLY lithium-polymer rechargeable batteries. Do
not attempt to charge other types of rechargeable
batteries—including different types of lithium batteries—as
permanent damage to the battery, charger and surrounding
environment could result!
• NEVER leave the charger unattended while in use!!
• IMMEDIATELY disconnect the battery from the charger
if it begins to swell, emits smoke, or is warm to the
touch! Place warm or hot batteries in a fire-safe location,
such as a container made of metal (such as an empty
ammunition box) or ceramic. Always monitor the area with
a smoke or fire alarm, and have an “ABC type” fire
extinguisher available at all times.
• DO NO Tset the battery capacity dial to a value g reater than
the battery’s 1C value as permanent damage could result.
• DO NOT allow LiPo cells to overheat at any time! Cells
which reach greater than 140 degrees Fahrenheit (60°C)
can and USUALLY WILL become damaged physically and
could possibly catch FIRE!! Always inspect a battery which
has previously overheated for potential damage, and do not
re-use if you suspect it has been damaged in any way.
• ALWAYS provide adequate ventilation around Li-Po batteries
during charge, discharge, while in use, and during storage. If
a battery becomes overheated, remove it from the charger
IMMEDIA TELY and place it in a fire-proof location until it cools.
• Use a charge lead that is directly compatible with the
“charge” connector on the Li-Po battery. It is strongly
recommended to use pre-assembled charge leads which can
be found at most hobby retailers .Great Planes’2-Pin/Banana
Plug Charge Adapter (GPMM3105) is directly compatible
with ElectriFly Li-Po battery charge leads, having banana
plugs on the opposite end for connection to the charger.
• Do not use automotive type chargers to power charger.
• Do not allow water, moisture or foreign objects to enter
the charger.
• Do not block the air intake holes or fan, which could cause
the charger to overheat.
• Do not attempt to charge packs containing more than 4
cells wired in series.
• Always disconnect the charger from the input power source
when not in use.
• Keep out of reach of children.
IMPORTANT PRECAUTIONS
SPECIAL FEATURES
SPECIFICATIONS
INTRODUCTION
INSTRUCTIONS
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WARNING!! Never attempt to care for lithium-polymer
(Li-Po) cells in the same way as other battery types!! It is
very important to have a good understanding of the operating
characteristics of Li-Po batteries—especially their exact rated
voltage and maximum acceptable charge current. Always
read the specifications printed on the label of your Li-Po
battery prior to use. Great Planes will not be held responsible
for any and all incidental damages and bodily harm that may
result from improper use of lithium-polymer batteries with this
charger. Failure to follow the care and handling instructions
can quickly result in severe, permanent damage to the
batteries and its surroundings and even start a FIRE!
Do not mistaken lithium-polymer cells for other lithium-based cell
types (such as lithium-metal, lithium-phosphate, etc.), as other
lithium hybrids have different care and handling characteristics
as well. All “lithium” based batteries types are NOT the same.
It is strongly recommended to use packs which have been
assembled with a built-in charge protection circuit.Such circuits
help to regulate the maximum voltage per cell in the pack to
ensure that that they do not accidentally become overcharged.
The PolyCharge4 charger is designed to detect the proper
voltages for Li-Po batteries, but it is always a good idea to have
a second level of protection on the batteries as well.
IMMEDIATELY remove a Li-Po batter y from a model if it is
involved in a cr ash in any w a y. Carefully inspect the battery for
even the smallest of dents, cracks, splits, punctures or
damage to the wiring and connectors. CAUTION! Cells may
be hot! DO NOT allow the battery’s internal electrolyte to get
in the eyes or on skin - wash affected areas immediately if
they come in contact with the electrolyte. A Li-Po battery
might not appear to be damaged after a crash, but it could
smolder over a short amount of time and suddenly catch fire
unexpectedly. If in doubt, place the battery in a fire-proof
location indefinitely.
The PolyCharge4 charger only accepts 12 to 15V DC input
power .The charger will not function properly if the input voltage
exceeds this range. Input power could come from a dedicated
AC/DC power supply or automotive type battery. Due to the
larger potential currents when charging high capacity packs, a
12V hobby field battery may not be suitable for all-day usage.
An AC/DC power supply or 12V automotive battery may be
needed in these applications. The power supply chosen must
be able to supply 14A at 12V DC in order to achieve the
maximum potential from the charger. Applying less than 12V
may result in errors indicated by audio alerts as well as flashing
orange LEDs. It is best to use a clean DC source which has a
filtered output to reduce noise, and high quality connections.
INPUT POWER LEAD: The input power lead is located on
top-rear of the charger.
FOUR OUTPUTS: The PolyCharge4 is equipped with four
separate outputs, each being totally independent of the others.
This means that each output should be handled as one single
charger.Each output is rated to deliver a maximum of 30 watts of
power .It is possible that for batteries with high cell counts (3 or 4
cells) and high capacity ratings (over 2.0 amps), the maximum
current actually delivered to the battery might be limited due to
the maximum power rating of the output.This is normal.
There is never a need to be concerned with the setup of one
output in respect to another output. For simplicity, each output is
color coded.The controls and jacks for output 1 are colored in red,
output 2 is is black, output 3 is in yellow, and output 4 is in blue.
Each output consists of (a) one set of banana jacks, (b) a dial
by which to set the rated capacity of the battery to be
charged, (c) a pushbutton, and (d) a tri-colored LED.
FUSE: The over-current protection fuse is located on the left side
of the charger.This charger requires an “ATO” fuse, sometimes
referred to an “auto”or “spade” type fuse.The rating of the fuse is
20A (amps) at 32V (volts).Do NOT replace with a fuse of a higher
current rating than 20A, as it could result in damage to the charger
if an over-current condition occurs! Using a fuse with a rating of
less than 20A might cause the fuse to blow too easily.
F AN:The internal fan is located on the upper-left side of the face
of the charger. The fan helps to keep all internal components
cool during operation.This will help extend the service life of the
charger, as well as allo w the charger to function more accurately
and efficiently.The fan will turn on anytime a load is present on
the charger’s output.Do not block the cooling fan and other
vent holes as it could cause an overheating condition to
occur,possibly causing permanent damage to the charger!
1. CONNECTING INPUT POWER: Connect the input power
lead to 12V DC input power. Connect the red, positive (+)
lead to the power source’s positive (+) terminal, and the
black, negative (–) lead to the power source’s negative (–)
terminal. Note that there is no ON/OFF power control
switch.Once connected, the charger is always “on”.Always
disconnect the charger from input power when not in use.
2. CHOOSE AN OUTPUT: Determine which one of the four
outputs which will be used to charge a battery. It is not
necessary to use the outputs in any specific order.One battery
only can be charged on any output, two batteries can be
charged simultaneously on any two outputs, four batteries
simultaneously, etc.
CHARGING A BATTERY PACK
CONTROLS AND BATTERY CONNECTIONS
WARNING! Ne ver accidentally short together the positive
(+) and negative (–) input connections when connected to
12V DC power .Failure to do so could result in permanent
damage to the power source and the charger.
INPUT POWER
IMPORTANT PRECAUTIONS FOR
HANDLING LITHIUM-POLYMER BATTERIES
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3.CONNECTING CHARGE AD APTER:it will be necessary to use
a separate adapter lead to connect the battery to the output.
A. It’s highly recommended to use a pre-assembled charge
lead to avoid possible erroneous operation which could
result from using poor quality hand-made leads. Great
Planes’ “2 Pin / Banana Plug Charge Adapter”
(GPMM3105, available separately) comes pre-assembled
with banana plugs on one end, with a 2-pin connector on
the opposite end. This adapter is directly compatible with
many different commonly available Li-Po battery packs,
including all ElectriFly LiPo batteries.
B. If charging an ElectriFly brand Li-Po battery, be sure
that only the battery’s lead marked “charge” is
connected to the charger.Do NOT attempt to charge the
battery through the lead marked “discharge”.
C. ALWAYS connect the charge lead to the charger
FIRST. Securely connect the charge lead’s red, positive
(+) connector to the output’s red jack, and the charge
lead’s black, negative (–) lead to the output’s black jack.
D. Make sure not to connect a lead to the jacks of two
different outputs. For example, do not connect the
adapter lead’s black plug to the black jack of output 1
and the red plug to the red jack of output 2, as the
charger will not recognize that the battery is connected.
4. SET THE BATTERY CAPACITY RATING ON THE
ADJUSTMENT DIAL:
A. Look at the label on the Li-Po battery to find it’s
rated capacity (listed as “mAh”).If the “mAh”rating is not
found on the battery itself, do not guess! Refer to your
battery’s instruction sheet or your supplier for details
before proceeding.
B. Adjust the dial for the respective output to match the
capacity rating of the battery. For example, if a battery
rated at “1500mAh”is connected to output “3” (in yellow),
rotate the dial for output “3”so that the triangular indicator
points to the “1500”mark.Similarly, if a battery’s capacity
rating is “700mAh”, set the dial to the “700”mark, etc. For
values which do not have an actual numerical mark
around the dial, it is o.k. to make a close estimate of the
necessary location to rotate the dial. It is o.k. to set the
dial to a value which is LOWER than the mAh rating of the
battery.It is highly recommended NOT to set the dial
to a value which is GREATER than the mAh rating of
the battery! Failure to follow this warning could result
in the battery becoming dangerously overcharged!
5. CONNECT BATTERY: Securely connect the battery to the
charge lead on the charger’s output. Pay special attention to
ensure that the polarities on the battery’s connector match the
polarities on the charge adapter.The battery’s red, positiv e (+)
lead connects to the output’s red jack, and the battery’ s b lack,
negative (–) lead connects to the output’s black jack.
WARNING! Never allow a battery’s positive and negative
leads to accidentally touch each other.This will result in
a short circuit and cause permanent damage to your
battery and or charger and void all warranties.
6. START CHARGE:
A. Press the black START/STOP button for the respective
output to start the charge process.
B. The output’s LED should turn on solid green to indicate
that the battery is properly connected. Here the charger
will also be checking the condition of the battery before it
actually starts to apply a charge.Very little current will flow
at this time.This precheck could last for up to 5 minutes.
C.If the charger has deter mined that the batter y is approved
to accept a charge, the LED will begin to flash green to
indicate that the normal charge process has begun. Here,
the green LED will flash one time for each number of cells
that are wired in series in the pack.For example, two green
flashes means the charger identified two cells wired in
series in the pack (a 7.4V pack), four flashes identifies four
cells (14.8V pack), etc. IMPORTANT: if the number of
flashes DOES NOT match the number of cells in the
battery pack, re-press the START/STOP button or
disconnect the battery to stop the charge process!
Recheck the number of cells in the pack, and try to start
charge again. If the charger continuously mis-identifies the
number of cells in the pack do not attempt to charge the
battery and refer to the Troubleshooting Guide in the rear of
this manual.
D.When the above pre-check is finished and the battery is
ready to accept charge, the PolyCharge4 will
automatically begin the normal charge process. The
amount of current being delivered to the battery at this
time will gradually increase until it reaches the precalculated charge current level (based on the “mAh”
setting on the adjustment dial). It is possible that the
charger might NOT deliver the maximum charge
current if the condition of the battery will not allow it.
This is a built-in safety feature designed to prevent from
damaging the battery pack and causing an unsafe
condition. If the batter y is NOT in suitable condition to
accept a charge, an error indication will show on the
LED (refer to the Error Indications section near the end
of this manual for further details).
E.When the batter y pack has reached full charge at 4.2V
per cell, the LED color will change to red and the audible
tone will sound. Note that the red LED will still flash the
same number of times equal to the number of cells in
the pack. This can assist in determining if the charger
properly identified the number of cells in the pack at the
end of charge. The battery can now be disconnected,
and is ready for use.
F. Repeat this process for each output. All four outputs
are independent.
G. If for some reason the charger does not detect that the
battery has reached full charge after 3 hours, the output
will automatically shut down as a safety precaution.The
orange LED will flash 4 times to indicate this error
condition has occurred.This 3 hour safety feature exists
for all four outputs.
In such case, place the battery in a fireproof location
immediately such as a container made of ceramic or metal
(like an empty ammunition box), and let it rest for at least
30 minutes. Always provide adequate ventilation around
Li-Po batteries while being charged. Always monitor the
charging area with a smoke or fire alarm, and have an
“ABC type” fire extinguisher available at all times.
NEVER leave the battery unattended while being charged!!
WARNING! It is not normal for Li-Po batteries to become
warm during charge. Disconnect batteries from the
charger IMMEDIATELY if they become warm, hot or begin
to swell at any time! Cells which reach 140 degrees
Fahrenheit (60°C) can and USUALLY WILL become
damaged physically and could possibly catch FIRE!!
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If for any reason it is desired to stop the charge process (if the
pack is too warm, incorrect cell detection or charger becoming
excessively hot, etc.), re-press the START/STOP button. The
charger will sound a single beep, and the charge process will
stop (LED will turn off).
For each output, all error alarms are indicated by flashing the
orange LED accompanied by an audio tone. PolyCharge4 can
identify 6 different possible errors during charge.Each error type
is identified by a certain number of flashes of the orange LED
and audible tones.The list of recognizable errors is as follows:
If an error occurs, remove the battery from the respective
output and re-press the START/STOP button to shut off the
alarm. At this point the output will be reset back to idle mode
with the LED flashing green. Refer to the Troubleshooting
Guide for further information.
The PolyCharge4 charger uses solid-state circuitry to protect
against potential damage which could be caused by a shortcircuit or reverse polarity conditions.
CURRENT OVERLOAD: if for some reason a short circuit
condition exists which will try to draw more than 20 amps
through the charger’s input lead, the built-in fuse should blow.
To check the fuse, make sure the charger is disconnected
from the input power source BEFORE attempting to remove
the fuse. Inspect the fuse and replace if necessary with
another fuse of the same rating (20A, 32V).
REVERSE INPUT POLARITY: if power is connected in
reverse to the charger’s input lead the charger will be
protected from damage. Re-check the input connections and
the power source to ensure the proper power and polarities
are observed.
PROBLEM: Charger doesn’t recognize battery.
CAUSES AND CURES:
1. Battery may be connected backwards. Connect batter y
leads properly.
2) Faulty connection or wiring.Correct or replace charge lead.
3) Defective cell in the pack. Replace battery pack or cell.
4) Insufficient input power to charger.
PROBLEM: Charger does not automatically terminate charge
after 3 hours.
CAUSE AND CURE:
Capacity setting too low for respective
port and battery. Reset capacity dial to better match the
battery and start charge again.
PROBLEM: Battery voltage low after charge (below 4.2V per
cell).
CAUSES AND CURES:
1) Battery in poor condition. Replace battery.
2) Automatic safety timer activated before battery reached
full charge. Reset capacity dial to better match the
battery and start again.
3) Power supply voltage too low. Adjust DC input voltage to
12.0V DC minimum.
4) Battery connected in reverse.Connect battery
leads properly.
5) Defective battery needs to be replaced.
PROBLEM: LEDs and controls do not function properly.
CAUSE AND CURE:
Battery possibly connected backwards.
Connect battery leads properly, or contact Hobb y Services
for further details.
PROBLEM: LEDs do not work when unit is connected.
CAUSES AND CURES:
1) Check power supply for improper power.
2) Check input connections for proper contact.
Great Planes warrants this product to be free from defects in materials and
workmanship for a period of one (1) years from the date of purchase. During that
period, Great Planes will, at its option, repair or replace without service charge
any product deemed defective due to those causes. You will be required to
provide proof of purchase (invoice or receipt). This warranty does not cover
damage caused by abuse, misuse, alteration or accident. If there is damage
stemming from these causes within the stated warranty period, Great Planes
will, at its option, repair or replace it for a service charge not greater than 50%
of its then current retail list price. Be sure to include your daytime telephone
number in case we need to contact you about your repair. This warranty gives
you specific rights. You may also have other rights, which vary from state to state.
For service on your Great Planes product, warranty or non-warranty, send it
post-paid and insured to:
HOBBY SERVICES
3002 N. Apollo Drive Suite 1
Champaign, IL 61822
(217) 398-0007
*For warranty and service information if purchased outside the USA or
Canada, see the additional warranty information insert (if applicable) or ask
your retailer for more information.
www.greatplanes.com
www.electriFly.com
Made in Korea ENTIRE CONTENTS © Copyright 2005 GPMZ0315 for GPMM3015
1-YEAR LIMITED WARRANTY
(USA and Canada Only)
TROUBLESHOOTING GUIDE
SOLID-STATE CURRENT OVERLOAD AND
REVERSE POLARITY PROTECTION
Err
or Orange LED Flashes
Input Voltage Exceeds 12-15V Range 1
Battery is Connected in Reverse 2
No Battery Connected 3
3-Hour Safety Timer Expired 4
Battery Voltage Error 5
System Error with Charger 6
ERROR INDICATIONS
ABORTING A CHARGE
LED Legend
Status
No Pack LED Totally Off
Checking Cells Solid Green
Charge Green Flashes ‘x’Times
Charge Done Red LED Flashes ‘x’Times
Errors Orange LED Flashes (See “Error
Indications” Section Below)
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