Novak IONIC-D Operating Manual

IONIC-D

#55-4465-1

The Ionic-D takes advanced charger technology and puts it into an affordable, easy-to-use charger with a simple user-interface, highly visible LED display, and auto-battery conditioning.

The Ionic-D is equipped with Ni-Cd Linear Mode for all Ni-Cd cells, and the NOVAK Ni-MH Mode for the ultimate charge of all sizes of Ni-MH cells.

Case Size ........................................................................5.10” x 4.20” x 2.80” (130x107x71 mm)

Weight ................................................................................................ 22.56 ounces (640 grams)

AC Input Voltage ................................................. 100-240 volts AC

DC Input Voltage ....................................... 12 volts DC (Internal) 12.5-14.5 volts DC (External)

TIONS

Operation Modes ............. 3 (Auto Discharge Before Charge, Charge Only and Discharge Only)

Charging Modes ..............................................................................

Charging Capability (AC/DC model w/built-in supply) ............................................... 4-7 cells (1.2 VDC/cell)

Charging Capability (with 12.5-14.5V External/Aux. supply) ..................................... 4-8 cells (1.2 VDC/cell)

Charge Rates ............................................................................................. 0.5, 1.0, & 4.0 amps

Discharge Rates ..................................................................................................... 1 & 10 amps

SPECIFICA

Circuit Protection ..................

Input & Output RVP/Short-Circuits, Shorted Batteries, Thermal Overload

(built-in supply UL & CE approved)

Ni-Cd Linear • Novak Ni-MH

OPERATION

IMPORTANT PRECAUTIONS

The following precautions will help to prevent possible damage to the Ionic-D, the battery pack or the input power source.

• Always charge in a well ventilated area.

• Never leave battery pack & the Ionic-D unattended during charging.

• For proper cooling, remove battery pack from vehicle to charge.

• Disconnect battery pack from the Ionic-D when done charging.

MANUAL

• Never tamper with the internal electronics. Risk of electrical shock.

• Charge only nickel-cadmium or nickel-metal hydride rechargeable battery packs. Never charge lithium polymer, lithium-ion, lead-acid, or gel cell batteries as damage will occur.

• Never allow water, moisture, or other foreign materials to enter the Ionic-D.

• Do not use automobile battery chargers to power the Ionic-D––False peaks can occur, and

excessive voltage spikes can damage the Ionic-D.

• Do not obstruct the air intake on the top or side of the Ionic-D––Overheating/thermal shut down will occur.

• Do not charge batteries with fewer than 4 or more than 8 cells––connected in series.

• Do not charge battery packs connected in parallel––Batteries will be damaged.

•

Do not charge battery packs with fewer cells than indicated by the Ionic-D’s “# OF CELLS” LED (a 6 cell battery pack is not to be charged on the 7 or 8 cell settings).

•

Excessive charge current can damage batteries––Follow battery maker recommendations.

• Never exceed 15 volts DC input power source to power the Ionic-D.

• Never connect AC voltage to the DC input power connector of the Ionic-D.

• Gases from lead-acid battery may ignite if sparks occur when connecting/disconnecting the

Ionic-D’s alligator clips––Using a lead-acid battery as a power source may generate hydrogen gas & should only be used in a well ventilated area. Avoid open flames & sparks which may ignite battery gases. NEVER START THE ENGINE WHEN CHARGER IS CONNECTED TO A CAR’S BATTERY!

PLEASE FOLLOW ALL INSTRUCTIONS CAREFULLY

INTRODUCTION

Thank you for purchasing the Novak Ionic-D AC/DC Charger & Discharger. Your new Ionic-D comes programmed with automatic battery care features which run with a simple press of the “START” button. Depending on the condition of your battery pack, the Ionic-D will either Auto Discharge Before Charge, Charge, or Condition your battery pack.

Read the section below to gain an understanding of the basic operations of the Ionic-D. During Charging: The appropriate “MODE”, “AMPS” and “CHGR/ON” LEDs will be lit.

The appropriate “# OF CELLS” LED will flash at an increasing rate to represent the approximate charge state of the battery pack. A slow flash indicates very little charge while a faster blink indicates a nearly full charge. When charging is complete, an alarm will sound and all LEDs will strobe from left to right.

During Discharging: Both “MODE” LEDs will be on while the “CHGR/ON” and the appropriate “# OF CELLS” LEDs will flash. The “CHGR/ON” LED will flash at a constant rate while the “# OF CELLS” LED will flash at a decreasing rate. A fast flash indicates a fully charged battery pack and a slow flash indicates a nearly discharged battery pack. If the Ionic-D is in the Auto Discharge Before Charge Mode, when discharging is complete, the Ionic-D will sound an alarm tone and rest for a brief period before entering the charge mode. If the Ionic-D is in Discharge Only Mode, when discharging is complete, the IonicD will sound an alarm tone and all LEDs will strobe from left to right.

Battery Conditioning: Battery conditioning occurs automatically if the Ionic-D detects very low voltage in your battery pack. The Ionic-D will charge your battery pack at 0.5 amps for a short period of time to bring the voltage back up safely. After the low amp charge, normal charging will take place with a peak detect “lock out” period to avoid false-peaking.

Please continue reading this manual to understand all the features of your new Ionic-D.

CHANGE SETTINGS

If you need to change one or more of the Ionic-D’s default settings, follow these steps:

1.ENTER SETUP MODE - While the Ionic-D is at rest, press the “SELECT” button to enter

setup mode.

2.SELECT CHARGE MODE -

charge mode. When the correct mode is selected, press the “ENTER” button.

Press the “SELECT” button to choose either the Ni-Cd or Ni-

WARNING: Setting the battery type incorrectly may cause damage to your battery pack!

3.SELECT CHARGE CURRENT - Press the “SELECT” button to choose 0.5, 1.0 or 4.0 amps

charge current. Press the “ENTER” button when the correct LED is flashing. NOTE: See your battery manufacturer’s recommended charging rates. Never use a HIGHER

rate than recommended, LOWER rates are fine and usually help prolong the life of the battery pack. When the Ionic-D’s charge rate is set at either 0.5 or 1.0 amp, the discharge rate will be 1 amp. When the Ionic-D’s charge rate is set at 4 amps, the discharge rate will be 10 amps.

4.SELECT # OF CELLS IN BATTERY PACK - Press the “SELECT” button to choose 4, 5, 6, 7

or 8 cells (8 cells is only available when using an Auxiliary 12.5-14.5 volt DC power supply). Press the and exit. The Ionic-D

“ENTER” button when the proper LED is flashing to save your settings

will retain your settings until you change them again.

WARNING: Setting the number of cells incorrectly may damage your battery pack!

For Novak suggested settings to charge different battery types, see the “RECOMMENDED SETTINGS” section later in this manual.

FORCE MODES

QUICK START

The Ionic-D comes programmed with the following default settings:

Operation Mode: Auto Discharge Before Charge Charge Mode: Ni-MH Charge Current: 4.0 amps Number of Cells: 6

If you need to change any of these settings, please refer to the “CHANGE SETTINGS” section of this manual. The default operation mode of the Ionic-D is Auto Discharge Before Charge. In this mode, the Ionic-D will automatically discharge (if it is determined that the battery pack has sufficient voltage) and then charge your battery pack. If you do not wish to use the Auto Discharge Before Charge Mode, please see the “FORCE MODE” section of this manual.

STEP 1 - Attach the provided AC input cord to the Ionic-D. Plug the other end into an appropriate AC outlet. For DC operation, see the “DC OPERATION” section. The LEDs will blink and strobe for a few moments while the Ionic-D performs a self-test.

output leads

(to battery pack

being charged)

STEP 2 - Connect the Ionic-D’s output leads to your battery pack. Be sure to maintain proper polarity between the output leads and the battery. The red clip connects to the positive terminal, while the black clip (blue wire) connects to the negative terminal.

battery pack with

solder tabs

NEG(–)

BLUE output lead

STEP 3 - Press the Ionic-D’s “START” button. The charger will beep, then flash the “CHGR/ ON” LED 3 TIMES. At this point, the Ionic-D is checking the status of your battery. After the battery pack’s condition is determined, the charger will begin to discharge or charge your battery pack accordingly. Wait for the LEDs to strobe from left to right, and your battery pack will be charged. To interrupt any operation, press the Ionic-D’s “STOP” button.

SELECT button

POS(+)

RED output lead

Ionic-D Keypad and LEDs

NEG(–)

POS(+)

NEG(–)

battery pack with Deans connectors

battery pack with Tamiya connector

AC input

of built-in

power supply

connect AC

power cord to

100-240VAC

outlet

BLUE output lead

START/ENTER/

STOP button

RED output lead

If you do not want the Ionic-D to automatically discharge your battery pack before charging, it is possible to force the Ionic-D into either the Discharge Only or Charge Only mode.

DISCHARGE ONLY MODE

To force the Ionic-D into the Discharge Only Mode, follow these steps:

1.Properly connect your battery pack to the Ionic-D.

2.Ensure the Ionic-D has all proper settings in place, refer to “CHANGE SETTINGS” section.

3.Press the “START” button.

4.When the “# OF CELLS” LED begins to flash, press and hold the “SELECT” button for 2

seconds. When the button is released, you will hear an alarm tone.

5.Both “MODE” LEDs will light up solid, the “AMPS” LED will be off and the “CHGR/ON”

LED will begin to flash at a constant rate to indicate the Ionic-D is discharging.

6.The appropriate “# OF CELLS” LED will flash during discharging. The flashing will change

from fast to slow as the battery pack discharges.

7.When the Ionic-D has finished discharging, an alarm will sound and ALL LEDs will strobe

from left to right. NOTE: When the charge rate is set at either 0.5 or 1.0 amp, the discharge rate will be 1

amp. When the charge rate is set at 4.0 amps, the discharge rate will be 10 amps.

CHARGE ONLY MODE

To force the Ionic-D into the Charge Only Mode, follow these steps:

1.Properly connect your battery pack to the Ionic-D.

2.Ensure the Ionic-D has all proper settings in place, refer to “CHANGE SETTINGS” section.

3.Press the “START” button.

4.When the “# OF CELLS” and “CHGR/ON” LED begin to flash, press and hold the “START”

button for 2 seconds. When the button is released, you will hear an alarm tone.

5.The appropriate “MODE”, “AMPS” and the “CHGR/ON” LEDs will light up solid to indi-

cate the Ionic-D is charging.

6.The appropriate “# OF CELLS” LED will flash during charging. The flashing will change

from slow to fast as the battery pack charges.

7.When the Ionic-D has finished charging, an alarm will sound and ALL LEDs will strobe

from left to right.

RECOMMENDED SETTINGS

For the best charge performance and battery life, use the following settings for your Ionic-D charger depending on the given battery type and size. Note that in order to charge 8 cells you must use an auxiliary power supply that is at least 12.5-14.5 volts DC. If the external power supply does not have enough voltage, the charger will not let you select 8 cells.

BATTERY TYPE CELL SIZE MODE AMPS

Nickel-Cadmium sub-C & larger Nickel-Cadmium 2/3 A & smaller

Nickel-Cadmium 2/3 A & smaller Nickel-Metal Hydride sub-C & larger Nickel-Metal Hydride 2/3 A & smaller Nickel-Metal Hydride 2/3 A & smaller

In the Ni-Cd mode the Ionic-D uses a constant current linear charge and looks for a delta-peak (voltage threshold) of 5mV/cell to determine when the battery is completely charged.

The Ionic-D’s Ni-MH2 mode is an exclusive charge algorithm (developed by Novak Electronics) that uses an innovative method to determine the end of charge so precisely, that overheated battery packs are a thing of the past.

(sub-C, D, & F)

(above 600mAh cells) (below 600mAh cells)

(sub-C, D, & F)

(above 600mAh cells) (below 600mAh cells)

Ni-Cd 4.0 4-8 Ni-Cd 1.0 4-8 Ni-Cd 0.5 4-8

Ni-MH

# OF CELLS

4.0 4-8

1.0 4-8

0.5 4-8

COOLING FAN

The Ionic-D has a built-in cooling fan that runs whenever it is charging or discharging. The cooling fan may also run when the Ionic-D is not operating, because the Ionic-D’s circuitry monitors the ambient temperature and runs the fan when it requires cooling. It is very important that you do not block the ventilation grills on the top or side of the charger. Doing so may cause the charger to overheat and thermally shut down.

DO NOT BLOCK

VENTILATION GRILLS/SLOTS

DC OPERATION & CONNECTION

INPUT POWER SOURCE VOLTAGE

Example 1: (6 cell Ni-Cd pack peak-voltage≈10.5 volts) + (1.5 volts) = 12 volts DC Example 2: (8 cell transmitter pack peak-voltage≈13.0 volts) + (1.5 volts) = 14.5 volts DC***

Remember that older battery packs peak at higher voltages.

NOTE: 8 CELL CHARGING REQUIRES 12.5-14.5 volt DC POWER SUPPLY––If adequate voltage is not available, the charger will not allow the selection of 8 cells during setup.

***If the power supply’s voltage is not high enough to peak the battery pack, charge 8 cell packs as two 4 cell packs.

DC INPUT POWER CONNECTOR is on the left side Power Harness has a matching connector on it that plugs directly into the Ionic-D’s connec-

The input power connector in the charger has

tor.

When looking at the bottom of the charger, the two pins toward the back of the charger are the positive (+) connections. The center pin is for the built-in power supply

for an External/Aux. power supply that outputs 12.5-14.5 volts front of the charger is the common negative (–).

should be 1.5V above the battery pack’s peak voltage*.

of the Ionic-D’s case. The supplied Input

3 pins (see case bottom for pin polarity).

. The top pin is

DC. The pin closest to the

TROUBLE-SHOOTING GUIDE

The Ionic-D charger has built-in fault detection circuitry that can detect problems with the charger, the battery or the connections. Any problems detected are then displayed in the form of fault codes by illuminating certain combinations of LEDs on the keypad.

The LED fault codes are described here:

ALL KEYPAD LEDs ARE ILLUMINATED

•If all of the LEDs except for “CHGR/ON” are illuminated on the charger’s keypad, the

charger has entered a cool-down mode because an overheat condition has occurred. The LEDs will remain illuminated until the charger has cooled down. When the Ionic-D has cooled down sufficiently, it will resume the last operation.

All LEDs Charger

illuminated overheated

MODE AMPS #OF CELLS

Ni-Cd Ni-MH2

0.5 1.0 4.0 4 5 6 7 8 ON

MODE LEDs FLASHING & CELL# LED IS ILLUMINATED

•

If both of the MODE LEDs are flashing and any CELL# LED is illuminated, the charger has detected a problem with either the connections or the battery. The CELL# LED that is illuminated indicates one of the fault codes listed below. If this occurs, check the connections and the battery to resolve the problem, then press the ENTER button to clear the fault. If you are unable to solve the problem, refer to the Customer Service & Repairs section.

MODE LEDs CELL# LED

flashing illuminated

MODE AMPS #OF CELLS

Ni-Cd Ni-MH2

0.5 1.0 4.0 4 5 6 7 8 ON

CELL# LED ILLUMINATED FAULT CODE

4 Battery pack not connected 5 Output leads shorted 6 Power supply not connected 7 Battery failure 8 Insufficient voltage to charge 8 cell pack

NO LEDs WHEN CONNECTED VIA EXTERNAL/AUX DC POWER SUPPLY

•If no LEDs will illuminate, and the Ionic-D is connected to an External/Aux 12.5-14.5 volts DC power supply, check the 15 amp ATC fuses in the input power harness. Replace any blown fuses with the supplied spares. If this does not solve your problem, refer to the Customer Service & Repairs section.

CHGR

Ext/Aux.12-15VDC pos.(+)

Built-in 12VDC pos.(+)

common negative (–)

DC input

connector

ACCEPTABLE INPUT POWER SOURCES: DC power supply (

*Output current of power source should meet/exceed desired charge rate. **Connect input power harness to lead-acid battery before connecting harness to the Ionic-D.

built-in or Aux)

or lead-acid battery**

If using the Ionic-D with an External/Aux. power supply, cut and strip the wires of the included input power harness to the desired length and secure them to the output terminal screws of the 12.5-14.5 volt DC power supply.

• Connect the wire that goes to the Ionic-D’s Aux. positive (+) pin to the power supply’s positive (+) DC output terminal.

• Connect the wire that goes to the Ionic-D’s negative (–) pin to the power supply’s nega-

tive (–) DC output terminal.

black wire to neg.(–)

red wire

to pos.(+)

15A ATC Fuse (x2)

to negative (–) pin

to External/Aux.

positive (+) pin

If powering the Ionic-D with a lead-acid battery or power supply with post-style output terminals, solder the included alligator clips to the included input power harness.

Solder the wire that goes to the Ionic-D’s Aux. positive (+) pin to the RED alligator clip.

•

• Solder the wire that goes to the Ionic-D’s negative (–) pin to the BLACK alligator clip.

12 volt DC

lead-acid

battery

black clip

red clip

to pos.(+)

to neg.(–)

15A ATC Fuse (x2)

to negative (–) pin

to External/Aux.

positive (+) pin

NOTE: The Input Power Harness has two 15 amp ATC fuses installed in-line. These are used to prevent damage to the Ionic-D in case there is a short circuit situation with the Input Power Harness. Do

NOT use fuses rated higher than 15 amps as this could cause damage to

the Ionic-D.

Ni-MH BATTERY PACK FALSE-PEAKS

Ni-MH batteries that have been stored for extended periods (or brand new, sitting on the

shelf) have an increased chance of false-peaking. These cells perform much better when used regularly. Watch stored Ni-MH packs during their initial charges––Charged packs will be warm. Please refer to the included Battery Care Sheet for more information.

If any other problems occur, or if the charger will not power up and you have checked all

connections and power sources, refer to the Customer Service & Repairs section.

CUSTOMER SERVICE & REPAIRS

NOVAK ELECTRONICS, INC. (949) 833-8873

17032 Armstrong Ave. FAX (949) 833-1631

Irvine, CA 92614 www.teamnovak.com

Monday-Thursday: 8:00am-5:00pm (PST) • Friday: 8:00am-4:00pm

Before sending your Ionic-D in for service, thoroughly review the Trouble-Shooting Guide and the instructions. After reviewing the instructions, if you feel your Ionic-D requires service, please obtain the most current product service options and pricing by one of the following methods:

WEBSITE: We have an abundance of information available on our website for all of the

Novak products. Print a copy of the PRODUCT SERVICE FORM from the SERVICE section of the website. Fill out the required information on this form and return it with the Novak product that requires servicing.

PHONE/FAX/E-MAIL:

Contact our customer service department by phone, fax, or e-mail

at cs@teamnovak.com, and we will supply you with the most current service options.

WARRANTY SERVICE: For warranty service work, you MUST CLAIM WARRANTY on the

PRODUCT SERVICE FORM and include a valid cash register receipt or purchase invoice from an authorized dealer dated within the warranty period, or a previous service invoice from Novak. A valid serial number must be present on the Ionic-D. If warranty provisions have been voided there will be service charges.

•

Hobby dealers/distributors are not authorized to replace products thought to be defective.

•

If a hobby dealer returns your product for service, submit a completed PRODUCT SERVICE FORM to the dealer and make sure it is enclosed with the product.

• Novak Electronics, Inc. does not make any electronic components (transistor, resistors, capacitors, etc.) available for sale.

(closed every other Friday)

PRODUCT WARRANTY

Novak Electronics, Inc. guarantees the Ionic-D charger/discharger to be free from defects in materials and workmanship for a period of 120 days from original date of purchase (verified by dated, itemized sales receipt). Warranty does not cover incorrect installation, components worn by use or excessive force, exceeding the recommended input voltage, damage resulting from charging fewer or more than the recommended number of cells, or from improper connection or charging of receiver battery packs or enhanced-voltage batteries, any splices to the output wires or built-in power supplies input/output wires, connecting AC power to the DC input plug, use of fuses rated greater than 15 amps in the Input Power Harness, damage from disassembling the case, tampering with the internal electronics or power supply, or allowing water, moisture, or any foreign materials to enter the charger or get onto the PC board, or any damage caused by flooding or other act of God.

In no case shall our liability exceed the product’s original cost or cover the cost of batteries damaged while charging. We reserve the right to modify the provisions stated in this warranty without notice.

Because Novak Electronics, Inc. has no control over connection and use of this product, no liability may be assumed nor will be accepted for damage resulting from the use of this product. Every Ionic-D charger/discharger is thoroughly tested before leaving our facility, and is therefore considered operational. By the act of connecting/operating this product, the user accepts all resulting liability.