Ni-MH BATTERY CARE SHEET

Basic Ni-MH Battery Care
Ni-MH packs should be charged at a maximum rate of 4.5-5.0 amps until warm (not hot), and used as soon as they are done charging for optimum performance. If the pack sits for more than 10 minutes you will not get full performance. You can re-peak a pack that has sat longer than 10 minutes to improve performance (re-peak only once). Some may tell you that it is good to get the packs a little hotter for racing applications. This technique may offer slightly better initial performance, but the long term effects are detrimental to the cells and is not recommended. Delta Peak chargers (chargers that look for a voltage threshold to determine when the charge cycle is complete) are not good for regular use with Ni-MH cells, as this method causes excessive battery heating and results in internal damage to the structure of the cell. Pulse chargers should never be used. We recommend using the Novak Millennium Pro (#4490) or the Novak Ionic (#4475) chargers in the Novak Ni-MH2 charge mode. New Ni-MH cells often false-peak the first couple of times they are charged. This is the nature of the Ni-MH cell. If the battery pack is not warm to the touch, a false-peak has occurred, and the charge cycle should be re-started.
Using Battery Equalizing Trays Before Charging
There are a numerous battery equalizing trays available from manufacturers who all have different views on the usage & maintenance of Ni-MH batteries. Through extensive testing, we have found that Ni-MH batteries should not be discharged below 0.9 volts per cell, and that battery trays can be very helpful in maintaining pack performance and consistency. We highly recommend using an equalizing discharge tray that has a userselectable cut-off voltage like the Novak Smart Tray (#4500). The Smart Tray also features individual status LEDs to let you know when each cell has completely discharged. Using the Novak Smart Tray before each charge will give you the best possible performance from your batteries.
Packs That Continue To False-Peak
Some customers may experience false-peaks with sport packs, receiver packs, or packs that have been previously abused or are very old. This can be due to lower quality cells or the construction of the packs. The Ni-MH cells in these packs are often never discharged properly so the cells can be very problematic. The first thing that should be done for these packs is to discharge them and let them cool completely. Next, charge them at a lower amp rate than normal. When a false-peak occurs, try restarting the charger. If it the pack continues to false-peak you may need to set the charger up differently. The Ni-Cd Linear charge mode found in the Novak Millennium Pro and the Novak Ionic chargers uses voltage threshold to determine the batterys peak. For a problematic Ni-MH pack, this may be the only way to get it to take a full charge. Set the charger at your desired current with the voltage threshold set to 4 mV/cell. If false-peaking continues, increase the voltage threshold by 2 mV/cell. Do not exceed 10 mV/cell. If you reach this setting and repeated false-peaking continues, you can activate the Trickle charge in the Millennium Pro by turning this feature on in the Edit Charge mode. If a false-peak occurs now, the trickle mode will continue to charge the pack at a very slow rate. Let the trickle charge continue for about 10 minutes, then restart the normal charge cycle. When the pack finishes the normal charge, the trickle will start again, so make sure that you remove the battery from the charger at the end of the main charge cycle (after it peaks) if it has successfully charged and did not false-peak. Remember to turn off the trickle charge function for future use.

Batteries Used Weekly

Batteries that are used every week should be fairly easy to maintain. You can either run the batteries down until the vehicle runs slowly, or discharge the pack to 0.9 volts per cell (for a 6 cell pack that would be 5.4 volts) using a quality discharger that has a cut-off voltage setting like the Novak Smart Tray (#4500--available 3/2004). The Smart Tray is a digital microprocessorcontrolled equalizing discharger that discharges each individual cell of the battery pack with no risk of damaging the batteries, as each cells discharge is shut off after reaching the preset cut-off voltage. When the battery pack has cooled back down to room temperature, it can safely be charged again for reuse. For the best performance, we recommend no more than two (2) cycles per day.
Batteries Stored More Than 2 Weeks
If you do not use your batteries weekly, you will get better performance if some care is taken before storing your packs. After using the packs for the final time, put about 2-5 minutes of charge back into the batteries and then store them. When you use the packs again, discharge them to 0.9 volts per cell and let them cool completely before charging. The discharge before charging will give the best performance and should help prevent false-peaking.

www.teamnovak.com

AD-NIMH-1 2/2004

OPERATION MANUAL

AC input of built-in power supply connect AC power cord to 100-240VAC outlet BLUE output lead RED output lead RED output lead BLUE output lead

IONIC-D

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. 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-DFalse 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-DOverheating/thermal shut down will occur. Do not charge batteries with fewer than 4 or more than 8 cellsconnected in series. Do not charge battery packs connected in parallelBatteries will be damaged. Do not charge battery packs with fewer cells than indicated by the Ionic-Ds # 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 batteriesFollow 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-Ds alligator clipsUsing 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 CARS BATTERY! PLEASE FOLLOW ALL INSTRUCTIONS CAREFULLY

#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-MH2 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 (built-in supply UL & CE approved) DC Input Voltage.. 12 volts DC (Internal) 12.5-14.5 volts DC (External) Operation Modes. 3 (Auto Discharge Before Charge, Charge Only and Discharge Only) Charging Modes... Ni-Cd Linear Novak Ni-MH2 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 Circuit Protection. Input & Output RVP/Short-Circuits, Shorted Batteries, Thermal Overload

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.

SPECIFICATIONS

CHANGE SETTINGS
If you need to change one or more of the Ionic-Ds 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 - Press the SELECT button to choose either the Ni-Cd or NiMH2 charge mode. When the correct mode is selected, press the ENTER button. 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 manufacturers 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-Ds charge rate is set at either 0.5 or 1.0 amp, the discharge rate will be 1 amp. When the Ionic-Ds 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 ENTER button when the proper LED is flashing to save your settings and exit. The Ionic-D 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-MH2 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. 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 indicate 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.

output leads (to battery pack being charged)
STEP 2 - Connect the Ionic-Ds 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() POS(+) NEG() POS(+) battery pack with Tamiya connector POS(+) BLUE output lead RED output lead NEG() battery pack with Deans connectors

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
sub-C & larger (sub-C, D, & F) 2/3 A & smaller (above 600mAh cells) 2/3 A & smaller (below 600mAh cells) sub-C & larger (sub-C, D, & F) 2/3 A & smaller (above 600mAh cells) 2/3 A & smaller (below 600mAh cells)
Ni-Cd Ni-Cd Ni-Cd Ni-MH2 Ni-MH2 Ni-MH2

4.0 1.0 0.5 4.0 1.0 0.5

# OF CELLS

4-8 4-8 4-8 4-8 4-8 4-8

STEP 3 - Press the Ionic-Ds 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 packs 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-Ds STOP button.
Ionic-D Keypad and LEDs SELECT button START/ENTER/ STOP button
Nickel-Cadmium Nickel-Cadmium Nickel-Cadmium Nickel-Metal Hydride Nickel-Metal Hydride Nickel-Metal Hydride
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-Ds 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.

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-Ds 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.

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
DO NOT BLOCK VENTILATION GRILLS/SLOTS
If all of the LEDs except for CHGR/ON are illuminated on the chargers 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 illuminated

Ni-Cd Ni-MH2

0.5 1.0 4.0 4

#OF CELLS

CHGR ON

Charger overheated
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 flashing

DC OPERATION & CONNECTION
INPUT POWER SOURCE VOLTAGE should be 1.5V above the battery packs peak voltage*.
Example 1: (6 cell Ni-Cd pack peak-voltage10.5 volts) + (1.5 volts) = 12 volts DC Example 2: (8 cell transmitter pack peak-voltage13.0 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 SUPPLYIf adequate voltage is not available, the charger will not allow the selection of 8 cells during setup. ***If the power supplys voltage is not high enough to peak the battery pack, charge 8 cell packs as two 4 cell packs.

CELL# LED illuminated

CELL# LED ILLUMINATED

FAULT CODE

Battery pack not connected Output leads shorted Power supply not connected Battery failure Insufficient voltage to charge 8 cell pack
DC INPUT POWER CONNECTOR is on the left side of the Ionic-Ds case. The supplied Input Power Harness has a matching connector on it that plugs directly into the Ionic-Ds connector. The input power connector in the charger has 3 pins (see case bottom for pin polarity). 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. The top pin is for an External/Aux. power supply that outputs 12.5-14.5 volts DC. The pin closest to the front of the charger is the common negative ().

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.
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 chargesCharged 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. DC input connector
Ext/Aux.12-15VDC pos.(+) Built-in 12VDC pos.(+) common negative ()
ACCEPTABLE INPUT POWER SOURCES: DC power supply (built-in or Aux) or lead-acid battery**
*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.
CUSTOMER SERVICE & REPAIRS
NOVAK ELECTRONICS, INC. 17032 Armstrong Ave. Irvine, CA 92614 (949) 833-8873 FAX (949) 833-1631 www.teamnovak.com
Monday-Thursday: 8:00am-5:00pm (PST) Friday: 8:00am-4:00pm (closed every other Friday) 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:
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-Ds Aux. positive (+) pin to the power supplys positive (+) DC output terminal. Connect the wire that goes to the Ionic-Ds negative () pin to the power supplys negative () DC output terminal.

to negative () pin black wire to neg.() red wire to pos.(+) 15A ATC Fuse (x2) to External/Aux. positive (+) pin
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. 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-Ds Aux. positive (+) pin to the RED alligator clip. Solder the wire that goes to the Ionic-Ds negative () pin to the BLACK alligator clip.
12 volt DC lead-acid battery
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.

red clip to pos.(+)

black clip to neg.()

PRODUCT WARRANTY

15A ATC Fuse (x2) to negative () pin
to External/Aux. positive (+) pin
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 products 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.

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.