Novak Dually ESC (4460) - Manual (Page 2)

NOVAK ELECTRONICS, INC.
18910 Teller Avenue
Irvine, CA 92612
DIGI-PEAK OPERATION
DETAILED INFORMATION
TO START CHARGING
1. Connect charger as shown in STEP 1 and STEP 2 on
front of instructions.
2. Adjust charging current as described in STEP 4 on
front of instructions.
3. Press and hold the START button until LED is lit.
Once the DIGI-PEAK charger starts charging, there is a
100 second lock-out time, during which the charger will
ignore voltage peaks and will not shut off. Be careful how
many times you repeak the battery pack, as the battery pack
voltage will continue to drop during the lock-out and may
damage the battery pack. After the lock-out time, the
DIGI-PEAK's peak detection circuitry is active. When the
battery voltage peaks and begins to drop, the charger
will shut off and the LED will go out (or flash, if trickle rate
is set above zero in the LINEAR mode). At this time, the
batteries will be warm to the touch, and are fully charged
and ready to run.
TO STOP CHARGING Disconnect the battery pack from
the output alligator clips. Remember that the 100 second
lock-out time is reset to zero whenever the charger is started.
PACK VOLTAGE
If you are using the DIGI-PEAK PLUS version charger,
turn on the LCD display and select VOLTS on the meter
slide switch to monitor the battery pack voltage. During
the charge cycle, the LCD meter will display the voltage
of the battery pack. If the charger is not connected to a
power source and is connected to a battery pack, the
LCD will display the battery pack voltage. If you are in the
LINEAR mode with the charger connected to an input
power source and no battery pack connected, the LCD
will display the approximate input voltage.
If you have the DIGI-PEAK version without the built-in
LCD display, you can connect an external voltmeter to
the charger to monitor the battery pack voltage during
the charge cycle.
MONITOR BATTERY PACK VOLTAGE USING A VOLTMETER
1. Set the voltmeter to the 20 volt DC range.
2. Insert the RED (Positive) voltmeter probe into the red
(+) output jack located on the back of the charger,
and insert the BLACK (Negative) probe into the black
(-) output jack also located on the back of the charger.
Refer to illustration below
3. The battery pack voltage is equal to that displayed on
the voltmeter.
Red (Positive) Voltmeter
Probe to Red (+) Output Jack
Black (Negative) Voltmeter
Probe to Black (-) Output Jack
COOLING FAN
If you have purchased DIGI-PEAK or DIGI-PEAK PLUS
chargers without the factory installed cooling fan, follow
these steps to install the Novak Cooling Fan Kit #5635.
INSTALLING THE COOLING FAN
The Novak Cooling Fan is factory wired with a connector
to plug directly into the DIGI-PEAK and DIGI-PEAK PLUS
chargers, and includes two self-tapping screws to mount
into existing holes in the back plate of the charger.
1. Locate the air flow & rotation direction arrows that are
molded into the plastic housing of the cooling fan.
2. Mount fan with the air flow direction arrow pointing
towards the back plate of charger. Refer to illustration below
3. Make sure the plug on the cooling fan wiring will
reach the receptacle sockets on the lower left of the
charger back plate. If needed, rotate the cooling fan.
4. Insert screw into upper left and lower right holes on
cooling fan and through the openings of the heat sink
into the pre-drilled holes in back plate. Screw into
back plate with a screwdriver until screw heads just
touch the fan housing. Overtightening the fan screws
will warp and damage the back plate.
5. Insert plug from the cooling fan into the receptacle
sockets on lower left of the back plate. The red wire
should be closest to the heat sink for proper polarity.
Fan will not run if plugged in backwards.
BATTERY TIPS
GETTING THE MOST OUT OF YOUR BATTERIES
Getting the most run time and the longest life from your
batteries requires more than just charging at the correct
current. Proper care is a must for your battery packs.
REPEAK FOR MAXIMUM CAPACITY
When the battery pack voltage peaks at the end of the
charge and begins to drop, one or more cells are fully
charged and start to 'self discharge'. The excess energy
that is put into the cell after it has peaked results in the
dissipation of heat. You may notice when the battery
pack peaks, some of the cells get warmer than others.
This is because charge times differ slightly from cell to cell.
A good way to reduce the problem of some cells having
a more complete charge then others, is to repeak the
battery pack after about 30 minutes. This allows the cells
that have over-charged to discharge down to the level of
the remaining cells in the pack. Repeaking after the cells
have equalized with each other brings all the cells in the
pack up together for maximum capacity. It is best to time
this process so that you are able to run immediately after
repeaking, this will minimize the 'self-discharging' of the
batteries.
DISCHARGE FOR EXTENDED RUN TIME AND LONG LIFE
When you are done for the day, you should discharge
your battery packs to prepare them for the next time you
will use them. Storing and recharging a partially charged
battery pack will result in decreased performance from
your batteries, and will reduce the number of effective
charge cycles you will get from your batteries.
The simplest method to discharge your batteries is to put
a 30 ohm/10 watt resistor across the battery terminals as
shown below. As the pack discharges, some of the cells
will become reversed (the cell voltage becomes negative)
and will charge backwards. Charging a cell backwards at
high rates will damage the cell. However, the current
drawn through a 30 ohm resistor is low enough for the
cell to tolerate without damage. Connect the resistor to
the battery until the resistor cools to room temperature.
This may take several hours. Remove the resistor from the
battery pack at this time. Damage to the battery pack can
also occur if the resistor remains attached to the pack for
a time period longer than 24 hours.
Discharging Battery Pack
• Always discharge your battery packs after using them to
get the maximum performance and longest battery life.
30 Ω / 10W
Resistor
TROUBLE-SHOOTING GUIDE
This section describes typical charger problems, causes,
and solutions. If you are unable to solve the problem, call
our Customer Service Department for assistance.
Charger Stops Before Battery Pack Is Fully Charged
• Input power supply is unstable. Connect the charger
input to a 12 volt DC automobile battery to check.
• The battery pack has one or more bad cells in it. Try
charging different battery packs. Monitor battery pack
voltage while charging. If voltage starts to drop before
the charger shuts off, charger is operating normally.
• Charging current is too high. If charge current is too
high for the battery pack, it will heat up prematurely
and cause the voltage to drop, shutting off the charger.
Reduce the charge current.
• Try charging using the LINEAR mode. Some battery
packs will not accept PULSE charging at higher charge
rates and will peak before the battery is fully charged.
• The charging current was lowered while charging after
the lockout time expired. Press the START button to
restart the charge cycle.
• Poor connection to the input power source or battery
pack. Check, clean, and tighten all connections.
• Charger has over-heated and has thermally shut down.
(See Below)
Charger Stops And Will Not Restart
Thermal Shut-Down has occurred–Try Novak Cooling Fan Kit #5635
• Cooling fan (if equipped) is not running. Fan should
run whenever the heat sink temperature rises above
115
° F. Make sure fan is not plugged in backwards.
• Charger input voltage too high or charge current set
too high. Reduce input voltage to 1.5 volts DC above
the peak-voltage of the battery pack being charged or
reduce charge current. This more commonly happens
when charging 4 cell packs at too high of a current.
Charger Will Not Start
• Charger has thermally shut down and is cooling off.
Charger can be restarted after a few minutes when the
proper operating temperature has been reached.
• Bad connection in charging circuit. Check input/output
connections. Try charging a different battery pack.
Charger Stays On But Battery Pack Does Not Charge
• Input voltage too low. Input voltage to the charger
should be at 1.5 volts DC above the peak-voltage of the
battery pack being charged.
• Charge current set too low. Increase current.
Charge Current Will Not Adjust Properly
• Input voltage too low. The input voltage to the charger
should be 1.5 volts DC above the peak-voltage of the
battery pack being charged.
Charger Appears To Be Trickling
• The charge indicator LED will flash whenever the
charge current is below approximately 0.30 amp. The
charger is operating normally.
Charger Starts When First Connected To Battery Pack
• The 100 second lockout period of the charger is active.
Repress the START button to ensure proper startup.
(-)(+)
SERVICE PROCEDURES
Before sending in your DIGI-PEAK or DIGI-PEAK PLUS
charger for service, review the Trouble-Shooting guide
and the instructions. The charger may appear to have
failed when other problems exist.
PLEASE NOTE: DIGI-PEAK & DIGI-PEAK PLUS chargers
that operate normally when received will be charged
a minimum service fee and return shipping costs.
WHAT TO SEND: Fill out all of the information requested
on the enclosed CHARGER SERVICE CARD and return it
with your charger.
WARRANTY WORK: For warranty work, customer MUST
CLAIM WARRANTY on the CHARGER SERVICE CARD and
include a valid cash register receipt with purchase date
on it, or an invoice from previous service work for the
charger. If any warranty provisions have been voided
there will be a service charge.
SERVICE COSTS: Customer is responsible for all service
costs (Parts, labor, and shipping/handling charges).
Chargers returned UPS/COD CASH ONLY. See CHARGER
SERVICE CARD for other payment and shipping options.
ADDITIONAL NOTES:
• Hobby dealers/distributors are not authorized to re-
place chargers thought to be defective.
• If a hobby dealer sends your charger in for service, be
sure to submit a completed CHARGER SERVICE CARD
to the dealer and make sure it is sent with the charger.
• To provide the most efficient service possible to our
customers, it is not out policy to contact customers by
phone or mail.
• Novak Electronics does not make any electronic compo-
nents (transistors, resistors, fans, etc.) available for sale.
SEND CHARGERS TO:
NOVAK ELECTRONICS, INC.
18910 Teller Avenue
Irvine, CA 92612
PRODUCT WARRANTY
Novak Electronics, Inc. guarantees the DIGI-PEAK and
DIGI-PEAK PLUS chargers to be free from defects in ma-
terials or workmanship for a period of 90 days from the
original date of purchase (verified by dated, itemized
sales receipt). This warranty does not cover components
worn by use, damage due to charging more than 8 or
less than 4 cells, damage to battery packs resulting from
improper connection or charging of a receiver battery
pack, any splices to the input or output wires, compo-
nents damaged from excessive force when pressing the
START button or over-rotating the current adjust dials,
disassembling the case, tampering with the internal elec-
tronics, allowing water, moisture, or any other foreign
material to enter charger or get onto the PC board, or
allowing and exposed wire to short-circuit.
In no case shall our liability exceed the product's original
cost. We reserve the right to modify the provisions stated
in this warranty without notice.
Because Novak Electronics, Inc. has no control over the
connection and use of the charger, no liability may be
assumed nor will liability be accepted for damaged result-
ing from the use of this product. Every charger is thor-
oughly tested before leaving our facility and is, therefore,
considered operational. By the act of connecting or oper-
ating this charger, the user accepts all resulting liability.
CUSTOMER SERVICE
CUSTOMER SERVICE HOURS (PST)
Monday-Thursday: 8 a.m. - 5 p.m.
Friday: 8 a.m. - 4 p.m. (Closed every other Friday)
(949) 833-8873 • FAX (949) 833-1631
©1999 Novak Electronics, Inc. • All Rights Reserved
No part of these operating instructions may be reproduced without the written
permission of Novak Electronics, Inc.
All Novak chargers are designed and manufactured in the U.S.A.
DIGI-PEAK and DIGI-PEAK PLUS Digital Peak Detection Charger, and Digital
Peak Detection Circuitry are trademarks of Novak Electronics, Inc.
Printed in the U.S.A. (8/99) #IM-4400-4
Air Flow Direction Arrow
Cooling fan runs
only if heatsink
exceeds 115
° F
Fan Receptacle Sockets