Minelab F Operation Manual

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
P0564-B
DISCHARGE
Ready
Power
Discharging
F-SERIES
CHARGER
MINELAB
DISCHARGE
Ready
Power
Discharging

   
      
        
 
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F Series Battery Charger Operations Manual
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WARNING
THIS DOCUMENT CONTAINS
MINELAB ELECTRONICS PTY LIMITED
RIGHTS TECHNICAL DATA OR
RESTRICTED RIGHTS DATA OR BOTH.
Minelab Electronics Pty Ltd
This work is copyright. Apart from any use as permitted under the Copyright Act 1968, no part may be reproduced by any process
without written permission from
Minelab Electronics Pty Ltd,
118 Hayward Avenue, Torrensville, SA 5031,
Australia.
DISCLAIMER
Certain descriptions and illustrations contained in this manual may
differ from the exact model purchased. In addition, Minelab reserves
the right to respond to ongoing technical progress by introducing
changes in design, appearance, equipment and technical features at
any time.
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F Series Battery Charger Operations Manual
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F Series Battery Charger Operations Manual
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The F Series Battery Charger
Operations Manual
CONTENTS
Page No
1. Introduction............................................................................... 6
2. List of Parts............................................................................... 7
3. Using a DC Source to Charge Batteries.................................... 8
4. Using Mains AC to Charge Batteries......................................... 9
5. Using an AC Generator to Charge Batteries ........................... 10
6. Using an AC Source and a DC Source to Charge Batteries.... 10
7. Set-Up Procedure to Charge Batteries.................................... 11
8. Battery Charging Procedure ................................................... 12
9. Battery Discharging Procedure ............................................... 14
10. Specifications ......................................................................... 16
11. Trouble Shooting Guide.......................................................... 17
12. Internal Fuse Replacement..................................................... 19
13. Warranty Information .............................................................. 21
14. Product Information ................................................................ 21
15. Rechargeable Battery Management Guidelines...................... 22
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F Series Battery Charger Operations Manual
1. Introduction
The F Series Battery Charger is a robust, intelligent, fast charging device designed to charge Minelab 4.5 Ah 'D' cell rechargeable batteries. The Charger can charge two sets of four batteries in approximately three hours. A user initiated discharge-before-charge facility is provided to allow cycling of the batteries if required.
The Charger has been designed for global portability, and as such can operate from a wide range of power sources. Automatic detection of input power allows the Charger to run from 12V or 24V DC automotive supplies, or from 85V to 250V AC Mains and Generator supplies without the need for user intervention.
P0564-A
Figure 1. F Series Battery Charger Unit
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F Series Battery Charger Operations Manual
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2. List of Parts
The Minelab F Series Battery Charger comprises the following parts:
Minelab
Description Qty Part No
1. F Series Battery Charger Unit 1 0302-0039
2. Bag F Series Battery Charger 1 3001-0035
3. F Series Battery Charger Operations Manual 1 4901-0039
4. DC Power Cable 4 pin/Alligator 1 3011-0048
5. Mains Power Cable US Mains Cable, or 1 3011-0056 AUS Mains Cable, or 1 3011-0038 EURO Mains Cable 1 3011-0045
Optional: Battery NiCad ‘D’ Cell 4.5Ah 0303-0010
MINELAB
DISCHARGE
Ready
Power
Charging
Discharging
DISCHARGE
Ready
Power
Charging
Discharging
F-SERIES
CHARGER
P0567-C
1
2
3
4
5
Figure 2. F Series Battery Charger Kit
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F Series Battery Charger Operations Manual
3. Using a DC Source to Charge Batteries
12V or 24V systems such as vehicle power outlets and lead acid batteries are acceptable sources of power for the Charger. Power sources other than nominal 12V or 24V cannot be used.
The DC supply to be used must be capable of supplying sufficient current to operate the number of Chargers connected to it. As each Charger can draw up to 4 Amps (when charging two sets of batteries), a 12V vehicle battery system requires the DC supply wiring to be capable of supplying 4 amps for each Charger.
To avoid completely discharging a vehicle’s battery, an inbuilt feature of the Charger will suspend charging if the power source voltage drops below a preset level. As each Charger can draw substantial amounts of power from a vehicle’s battery, Minelab recommends charging no more than 2 sets of 4 batteries while the vehicle’s engine is switched off. Charging more than this could result in difficulties when starting the engine.
If the Charger has suspended charging due to low input voltage, normal operation will resume once the voltage has returned to normal (eg. by starting the vehicle engine). Similarly, if the power source voltage is too high, the Charger will suspend charging until the voltage returns to normal.
Insert the four-pin plug of the DC Crocodile Clip lead into the four-pin socket on the rear panel of the Charger (refer Figure 3). Tighten the plug-retaining nut to prevent the cable becoming loose – finger tight only.
Next, attach the Red clip to the positive (+) terminal of the battery, and the Black clip to the negative (-) terminal. Ensure each clip is making good contact by cleaning the battery terminals first. A poor connection could be caused by dirt or corrosion.
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F Series Battery Charger Operations Manual
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4. Using Mains AC to Charge Batteries
Using automatic supply voltage detection, the Charger can operate from most AC Mains supplies around the world. AC power will also be accepted from most portable generator sets.
Warning: When using Mains AC, ensure the Charger is connected to an earth socket outlet. If a non-grounded AC supply is to be used, ensure the Ground terminal on the rear panel of the Charger is connected to a Ground stake. A qualified person should do this.
To charge using Mains AC connect one end of the supplied AC Power Lead to the AC socket located on the rear panel of the Charger (refer Figure 3), and the other end to the AC power outlet.
P0566-C
DC INPUT VOLTAGE
+12V DC to +15V DC +24V DC to +30V DC
CAUTION
Risk of electric shock.
Dry location use only.
AC INPUT VOLTAGE
85 - 250 VAC
50 - 60Hz
GROUND TERMINAL
CLASS 2 BATTERY
CHARGER
FUSES 2A (In Holder)
Max Power 60VA
MINELAB
SN 00000
MN 0302-0039
Figure 3. F Series Battery Charger Rear Panel
DC Input
Socket
AC Input
Socket
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F Series Battery Charger Operations Manual
5. Using an AC Generator to Charge Batteries
A generator capable of supplying a nominal 110V or 240V is suitable as a source of power for the Charger. It is important that only self-regulating generators are used. A generator that has to have its speed manually adjusted as different loads are connected and disconnected is unsuitable for use with the Charger. Such generators can easily produce over 350V if no other loads are connected and the speed is set too high. This could cause permanent damage to any Charger connected.
Note that the case of the Charger is connected to the Ground pin of the AC supply socket on the rear panel. As such, a Ground connected AC supply should be used. When using a generator, either ensure the separate Ground terminal on the rear panel of the Charger, or the generator itself is properly connected to a Ground stake.
Connect one end of the supplied AC Power Lead to the AC socket located on the rear panel of the Charger (refer Figure 3), and the other end to the AC power outlet of the generator.
6. Using an AC Source and a DC Source to Charge Batteries
If a Charger is connected to both a Mains or generator supply (AC source) and a vehicle supply (DC source) simultaneously, the Charger will only draw charging current from the AC supply.
If the Mains or generator is switched off, the Charger will begin to draw charging current from the DC source in order to complete the battery charging cycle. This feature allows battery charging to continue should the AC supply only be available for short periods of time.
Refer to Section 3 for connection details to a DC source, and Sections 4 and 5 for connection details to Mains AC or generator.
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F Series Battery Charger Operations Manual
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7. Set-Up Procedure to Charge Batteries
To charge one or two sets of batteries:
a. Place the Charger upright on its plastic feet.
b. As NiCad batteries can only be fast charged between 0°C and +45°C,
direct exposure to sunlight, snow or ice could prevent the Charger entering fast charge mode. Ensure the Charger is protected from rain, snow or any other liquid.
c. NiCad batteries gradually get warmer whilst being charged. As such, if
warm batteries are inserted into the Charger the charger may, after only a short time, believe the batteries have received a full charge. To avoid premature charge termination, allow the batteries to cool to the same temperature as the Charger before inserting into the battery tubes.
d. Connect the Charger to a suitable power source (refer Sections 3 to 6).
e. The red "Power" LED indicates that the power source being used is
acceptable. If one or both red “Power” LED’s do not illuminate, refer to the Trouble Shooting Guide at Section 11.
f. The Charger is now ready for use.
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F Series Battery Charger Operations Manual
DISCHARGE DISCHARGE
CAUTION
: Use only Minelab
specified rechargeable batteries.
Other types of batteries may burst
causing injury to persons and damage.
Ready
Power
Charging
Discharging
Ready
Power
Charging
Discharging

 

P0565-A
Figure 4. F Series Battery Charger Front Panel
8. Battery Charging Procedure
Warning: Do not attempt to recharge alkaline or carbon batteries. Use only 4.5Ah NiCad batteries with the Charger.
Ensure that the Set-up procedure (Section 7) has been completed.
a. Remove either the two left or two right hand side battery retaining caps
from the Charger by rotating them one quarter turn anti-clockwise. Note that a set of four batteries will not charge if two are placed in one right side tube, and two in one left side tube. Never mix batteries with different levels of charge. Mixing discharged batteries with partially charged batteries could result in damage to the batteries.
b. Insert four “D” cell rechargeable batteries into the battery tubes (two
batteries per tube) ensuring the ‘+’ end of each battery faces to the front of the Charger.
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F Series Battery Charger Operations Manual
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c. Replace the battery caps by lining up the metal ridges with the slotted
holes. Lightly push the caps into the tubes and lock them into position by rotating them one quarter turn clockwise.
d. If required, place a second set of four batteries to be charged in the two
unused tubes in the same manner.
e. Note that batteries placed in the right side tubes are charged
independently of those in the left side tube. This allows two sets of batteries to start and finish charging independently of each other.
f. Once the batteries have been inserted, the orange "Charging" LED for
that side will flash for several seconds. This indicates that the Charger is checking the state of the batteries before beginning its fast charge cycle.
g. When the "Charging" LED remains illuminated the Charger has begun
its fast charging cycle.
h. Once the batteries have been fully charged the green "Ready" LED will
illuminate and the "Charging" LED will switch off. This indicates that the batteries are ready for use. (Until the batteries are removed, and while power remains connected to the Charger, the batteries will receive a trickle charge, which will keep them fully charged.)
Note: If at any time the input power voltage drops below or rises above the preset limits, all LEDs will switch off and charging will stop. When the supply voltage returns to normal, charging will recommence. Even fully charged batteries will begin receiving a fast charge again, but in approximately 10 minutes charging will stop and the “Ready” LED will illuminate again.
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F Series Battery Charger Operations Manual
DISCHARGE DISCHARGE
Ready
Power
Charging
Discharging
Ready
Power
Charging
Discharging
P0568-A
Figure 5. Front Panel Display
9. Battery Discharging Procedure
Minelab supplied batteries do not require discharge before recharging. However, if cycling of a set of batteries is required, the Charger can be used to automatically conduct a discharge-before-charge cycle once initiated by the user. Discharging a set of Minelab batteries in a Charger will take around nine hours.
Ensure that the Set-up procedure (Section 7) has been completed.
Note: If the discharge button has been pressed and discharge is not required, remove and replace one battery end cap to reset the Charger.
To discharge a set of four batteries:
a. Remove either the two left or two right hand side battery retaining caps
from the Charger by rotating them one quarter turn anti-clockwise. Insert the four “D” cell rechargeable batteries to be discharged into the battery tubes (two batteries per tube) ensuring the ‘+’ end of each battery faces to the front of the Charger. Replace the battery caps by lining up the metal ridges with the slotted holes. Lightly push the caps into the tubes and lock them into position by rotating them one quarter turn clockwise.
b. Press the "Discharge" button. The "Charging" LED should re-
commence flashing and will continue to flash until the batteries are fully discharged (approximately nine hours for fully charged 4.5Ah batteries).
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F Series Battery Charger Operations Manual
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c. Once the batteries have been fully discharged, the Charger will
automatically enter the charging mode, as indicated by the constantly illuminated "Charging" LED.
d. Charging will proceed as normal, until fully charged. Once the
batteries have been fully charged (approximately three hours) the green "Ready" LED will illuminate and the "Charging" LED will switch off. This indicates that the batteries are ready for use. (Until the batteries are removed, and while power remains connected to the Charger, the batteries will receive a trickle charge, which will keep them fully charged.)
e. The “Discharge” button can be pushed again if another discharge-
before-charge cycle is required. This process can be repeated as many times as required, but is normally required only once.
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F Series Battery Charger Operations Manual
10. Specifications
Electrical
AC Input: 85V - 250V, 50 - 60 Hz 60W maximum AC Fuses: 2 x 2A fuses in AC supply socket (5x20mm Fast Blow) 2 x 5A internal fuses (5x20mm Fast Blow) DC Input: 12V to 15V and 24V to 30V 4A maximum Output voltage: 4VDC to 8VDC Output Current: Fast charge: 2A approx. (per battery set) Trickle charge: 130mA approx. Reverse Polarity Protection: Yes - built-in
Environmental
Temperature: Operation: 0°C to +45°C Storage: -20°C to +75°C
Humidity: Operation: 10% to 90% Storage: 0% to 100% Vibration: Will withstand vibration consistent with normal road
transport conditions without damage.
Physical
Size: 13.5cms (W), 14.4cms (H), 21cms (D) Weight: 2.2kg (Charger only, without batteries or bag)
Certification
The Minelab Charger has been tested and found to comply with UL1310, the Underwriters Laboratories electrical safety standard for Class 2 power supplies.
The ‘CE’ symbol indicates compliance of this device with the relevant directives of the European community including the EMC (Electromagnetic Compatibility) and LVD (Low Voltage Directive) standards.
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F Series Battery Charger Operations Manual
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11. Trouble Shooting Guide
Problem Solutions
AC Mains or Generator power is connected but "Power" LED will not illuminate.
Generator voltage too low.
Blown fuse (Generator voltage
too high).
Check generator output.
Check generator output and fuses in
AC input socket. Replace if blown.
(Refer Figure 6.) DC charging power is connected but "Power" LED will not illuminate.
Voltage not within limits.
Bad connection.
Blown fuse.
Refer to Specifications for limits.
Check connection of DC power lead
plug and crocodile clips.
Check fuses in AC input socket. Replace if blown. (Refer Figure 6.)
"Charging" LED keeps flashing.
Discharge button has been pressed.
Batteries or Charger too hot.
Batteries or Charger too cold.
Batteries over-discharged.
Batteries faulty.
If discharge is not required, remove
and replace one battery end cap to reset Charger.
Batteries will not charge if above 45°C. Place Charger in cool place
and wait for batteries to cool down.
The batteries will not charge if below 0°C. Place batteries and Charger in warmer place.
Leave in Charger for 1 hour. If “Charging” LED still flashing, replace batteries.
Replace batteries.
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F Series Battery Charger Operations Manual
"Charging" LED flashes, stops, then flashes again.
Input DC source is not adequate to supply the Charger, or is faulty.
- Ensure DC Power Lead is connected correctly.
Will not charge batteries.
No power source connected.
Charger or batteries too hot.
Incorrect battery installation.
Power” LED illuminated but no
other LEDs illuminated on one side.
Connect AC or DC power.
Place Charger or batteries in cool
place and wait to cool down.
Check that all batteries have the + end facing towards the front of the Charger.
Blown internal fuse. Replace fuse (see Section 12),
P0846-C
AC Input Socket -
Main Power
Fuse Location
(2 Fuses
240V, 2A
5mm x 20mm
each)
DC INPUT VOLTAGE
+12V DC to +15V DC +24V DC to +30V DC
CAUTION
Risk of electric shock. Dry location use only.
AC INPUT VOLTAGE
85 - 250 VAC
50 - 60Hz
GROUND TERMINAL
CLASS 2 BATTERY
CHARGER
FUSES 2A (In Holder)
Max Power 60VA
MINELAB
SN 00000
MN 0302-0039
Figure 6 Charger Main Power Fuse Location on Rear Panel
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F Series Battery Charger Operations Manual
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12. Internal Fuse Replacement
NOTE
A qualified person should do this
If both ‘Power’ LEDs are illuminated but one side of the charger won’t charge or discharge, the internal fuse on one side may be blown. To replace the fuse:
a. remove the 12 screws and 2 washers from the rear panel and slide the
rear panel out from the charger (see Figure 7)
1. Remove the 12 screws and 2 washers from the rear panel.
2. Slide the rear panel (with attached PCB) from the charger.
P0847-A
Figure 7 Rear Panel Removal
b. locate and remove the fuse (5A fast blow 5mm x 20mm) and replace it
(Fuse location shown in Figure 8).
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F Series Battery Charger Operations Manual
Figure 8 Internal Fuse Location
c. refit the Rear Panel into the Charger and refit the 12 screws and 2
washers.
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F Series Battery Charger Operations Manual
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13. Warranty Information
Minelab provides a 15 month parts and labour warranty for the Charger. For service or repairs the Charger must be returned, with cables, to the nearest Minelab Office or a Minelab authorised repair centre. This Warranty does not cover damage to the Charger or injury to persons due to accident, deliberate misuse, alteration, modification, or unauthorised use of this product.
14. Product Information
This product is manufactured by Minelab Electronics Pty Ltd, 118 Hayward Ave, Torrensville, SA, 5031, Australia. Minelab is an ISO9001 endorsed company, and hence all areas of product quality are carefully controlled and monitored. In order to ensure the product works reliably throughout its operational life, the user must adhere to the following cautions to prevent damage to the product, or injury to themselves or others.
WARNINGS:
Risk of electric shock if opened.
- This appliance is not intended for use by young children or infirm persons unless they have been adequately supervised by a responsible person to ensure that they can use the appliance safely.
- Do not expose to liquid, vapour or rain.
- Use only Minelab supplied AC and DC power cables.
- Use only Minelab specified rechargeable batteries. Other types of batteries may burst causing injury to persons and damage.
- Always use a Ground connected AC supply. If running from a generator, connect the Ground terminal on the rear panel of the Charger to a properly installed Ground stake.
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F Series Battery Charger Operations Manual
15. Rechargeable Battery Management Guidelines
Battery Management Ideally, NiCd and NiMh batteries should be frequently used to get maximum life from them. If properly charged and used (regularly fully discharged to 'Battery Low'), a life of 2 to 5 years can be realistically expected. All references to NiCd batteries in the following text also apply to NiMh batteries. Batteries must be kept in the same sets of 4 during charge and use, this is the single most important factor for efficient rechargeable battery management. (This can be easily accomplished by numbering the batteries by set.) If batteries with unequal levels of charge are mixed, the following problems can be expected:
During use, after the battery with the least charge is fully discharged, power is drawn from the remaining batteries until the detector low battery alarm is triggered. During this period, power passing through the discharged battery may force it into reverse polarity, and some damage to the battery will occur.
During charging, depending on the charger and charge state of the individual batteries, not all batteries may be fully charged, or some batteries will be overcharged. If all the batteries are not fully charged, discharge time will be shortened. When NiCd batteries are overcharged they overheat and suffer some damage.
Every time a NiCd battery is overcharged or discharged to the point of reverse polarity, some damage to them will occur. Therefore if NiCd batteries are continuously mismanaged, their working life will be significantly shortened. Storage and use in very hot (over 40 deg C), or very cold (less than 5 deg C) temperatures will also shorten battery working life.
Minelab supplied NiCd batteries should be fully discharged at least once a month. This can be achieved by either using them in the detector until Battery Low alarm is triggered, or using the discharge function on the F Series Charger. One discharge/ charge cycle using the F Series Charger will take approximately 12 hours per set of four batteries.
Additional notes: Self discharge: NiCd batteries slowly lose their charge during storage. The rate of self discharge depends on environmental conditions (not too hot or cold), condition of the battery (new or well managed batteries will self discharge slower) and charge state of the batteries (fully charged batteries will
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F Series Battery Charger Operations Manual
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discharge quicker). NiCds should be recharged before use if stored for more than 4 or 5 days, if a full charge is required. Storage: NiCd batteries should ideally be stored in temperatures between 5 and 30 degrees C, with relative humidity between 5 and 60%. When stored under these conditions, shelf life can be measured in years. Shelf life is not affected by the charge state of the batteries when put into storage.
Sample Battery Management Procedures
Note: F Series Charger Operations Manual should be read by all personnel conducting battery management.
On Receipt of New Batteries:
Divide batteries into sets of 4.
Number each battery in the set with the same unique number.
(Numbering can start at 001 for example.)
Make up battery carry boxes (with compartments and lids) to hold enough sets of 4 batteries for a platoon or group of deminers (one set for each deminer and one spare set per group). (Another option would be to use piece of 10cm x 20cm thick wood and drill sets of 4 holes for each set of batteries.) For a platoon of 12 deminers, it may be easier to make 2 boxes each holding 7 sets of batteries. See picture of examples below.
New batteries should be put through 2 charge discharge cycles before use.
Battery Management Routine: Start of day: Team leaders or logistics staff hand each deminer one set of batteries at the start of the day. Team leaders or logistics staff check that all batteries in the set have the same number. End of day: Deminers return the set of batteries to team leaders or logistic staff. Team leaders or logistics staff to check that all batteries in the set have the same number and insert into storage box.
Charging and Discharging: Set-up:
Place F Series Chargers on bench next to each other. Place boxes with uncharged batteries to the left of the F Series Chargers and boxes for charged batteries to the right.
Connect generator power to the F Series Chargers (ideally through a power conditioner), additionally a 12V or 24V car/truck battery can
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F Series Battery Charger Operations Manual
also be connected to the F Series Chargers (so that if generator stops for any reason, batteries will still be charging until generator power becomes available again).
Each F Series Charger should have both red “POWER” lights illuminated.
Charging: Place batteries to be charged on left hand side, fully charged batteries on right hand side.
Operator takes one set of 4 uncharged batteries from a compartment in the box on the left, checks that all batteries in the set have the same number, and inserts them in one side of an F Series Charger. Orange “CHARGING” light on that side of the F Series Charger should illuminate.
Repeat the above step until all batteries are being charged or all F Series Charger are full.
When the green “READY” light illuminates for a set of batteries, remove the 4 charged batteries and place them into a compartment in the box on the right.
Discharge/charge cycle: Each set of batteries should be given one discharge/charge cycle at least once a month as follows:
Operator takes one set of 4 batteries from a compartment in the box on the left, checks that all batteries in the set have the same number, and inserts them in one side of a F Series Charger. Orange “CHARGING” light on that side of the F Series Charger should illuminate.
Press the “DISCHARGE” button on that side of the F Series Charger. The “CHARGE” light should start flashing.
When the green “READY” light illuminates, remove the 4 charged batteries and place them into the box on the right.
Note: One full discharge/charge cycle takes up to 12 hours.
Data recording: All battery sets should be listed to ensure that each set is given at least one discharge/cycle per month.
Action when one set of batteries is defective:
Determine which battery is faulty (multi-meter can be used – one battery will probably have a different voltage to other 3, this will be the defective battery).
Replace faulty battery with battery from spares.
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F Series Battery Charger Operations Manual
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Number new battery with same number of other three.
Put this set of batteries through 2 discharge/charge cycles before use.
Each compartment holds
4 batteries
Sets of 4 holes, each hole
the size of one battery
Figure 9 Example of Battery Carry Boxes (straps may be added)
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F Series Battery Charger Operations Manual
Working for a Cleaner, Greener Future.
For users within the European Union: Do not dispose of this equipment in general household waste.
The crossed out wheeled bin symbol on this equipment is an indicator that this unit should not be disposed of in general household waste, but recycled in compliance with local government regulations or environmental requirements.
Please dispose of this equipment via a recycling service or centre, or by returning the unit to the respective Minelab outlet as appropriate for your unit. This will enable the equipment to be disposed of in an environmentally safe manner.
Disposal of unwanted electrical and electronic equipment by means other than described above may contribute to adverse long-term environmental effects which, in turn, may be harmful to human health.
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Contact Details: Minelab Electronics Pty Ltd PO Box 537 Torrensville Plaza South Australia 5031
AUSTRALIA email: countermine@minelab.com.au tel: +61 88238 0888
Minelab USA 871 Grier Drive, Suite B-1 Las Vegas, Nevada 89119 UNITED STATES OF AMERICA email: countermine@minelab.com.au tel: +1 702 891 8809
Minelab International Limited Laragh, Bandon Co. Cork IRELAND email: countermine@minelab.com.au tel: +353 23 52101
www.minelab.com
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