The BB-2590 is NOT supported. See the newest SPC PP-8498 for that, or other military battery chargers.
90 - 125 VAC
100 - 250 VAC
.An adapter is used to connect the batteries to be charged to the PP-8444A/U. There are different adapters for different rechargeable batteries. The adapter has a Cinch Jones 18 pin plug that mates with the charger and has receptacles on top to hold two batteries.
Fig 1 Top Fig 2 Bottom
A Cinch Jones P-318-CCT 18 contact plug is needed to mate with the socket on the PP-8444A/U charger.
In Fig 1 Top - the upper battery is "A" and the lower battery is "B".
In Fig 2 Bottom - the upper right connector pin is #1, the bottom right pin is #3, the upper left pin is #16 and the bottom left pin is #18.
Note that the PP-8444()/U can charge two batteries that Bren-tronics calls Battery A and Battery B. The BB-390/U battery is really two separate batteries with side a and side b. Keep this use of A and B in mind when reading the table below where I have used lower case letters for the sides and upper case for the batteries.
I/O Pin # Pin Function** I/O Pin #* Battery term 1 B1 control
on = a side batt
#4 2k1 1.1v
#13 2k1 1.1v
#15 1k1 .75v
#16 2k1 1.1v
2 B thermistor nc 3 B charge Com + nc A4 & A5 4 B2 control
on = b side batt
#13 2k1 1.1v
#15 1k1 .77v
#16 2k2 1.1v
A6 & B6
5 B Charge to
nc 6 Relay +24 VDC #9 4k6 1.9v
#12 9k3 2.5v
A6 & B6
7 nc nc 8 nc nc 9 R2 (full voltage) #12 4k6 1.9v A6 & B6 10 nc nc 11 nc nc 12 thermistor
nc 4k6 -1.9v to
13 A2 control
on = a side batt
#15 1k0 .74v
#16 2k2 1.1v
14 A charge current
nc 15 R1 pack voltage #16 1k1 .50v 16 A1 control
on = b side batt
nc 17 A thermistor nc 18 A charge Com + nc B4 & B5
* Ohm meter test of BTA-70290
* *Based on documents by Trevor Barron. My pin numbers are based on those that are part of a Cinch Jones plug. My #1 is his #18, my 3 is his 6, my 16 is his 13 and my 18 is his 1. With my pin numbers you can see that the functions are grouped in a logical way. Neither the commercial manual for the BTC-UN108 nor TM 11-6130-489-13&P has any more info. The only diagram in either manual is a block diagram where the interconnecting wires are not labeled by function, only numbered.
The socket for the 24 VDC power cord is a standard IEC line cord socket. Note that the AC line cord is permanently attached so this is the only socket for supplying 24 VDC only.
Source Bren-tronics p/n mil p/n NSN NATO Slave Plug
BTA-70413 J-6362/U 5940-01-427-9395 Clips BTA-70431-1 NATO Plug BTA-70431-2
TM 11-6130-489-13&P, Battery Charger PP-8444/U, 1 September 1997
Operation and Service Manual, Universal Portable Battery Charger BTC-UN108 (Commercial version of the PP-8884/U)
Both are available from Bren-Tronics who makes the charger and has very good customer support.
On page 2-8 of the Technical Manual there is a graph showing that after 3 months 80% of the capacity of a NiCad or NMH battery has been lost due to self discharge, but for a Li-Ion battery it takes a year for the same 80% loss of capacity.
The following troubleshooting was done 22 Nov. 2002 without any documentation on the charger just by observation and some Ohm meter and diode tests (Fluke 87 DMM) plus desoldering a few components to separate component problems.Note: I got the manual after completing the troubleshooting but, according to the TM trouble shooting guide I should replace the power supply brick. The manual seems to be wrong.
When the AC power switch is turned on the LEDs flash, but the fan and Red POWER ON light do not come on.
Removing the 4 screws on the bottom of the case allows removal of the charger from it's case.
It smells like something has overheated.
Removing 8 black screws around the edge of the panel allows the panel to be folded forward 180 degrees.
The main components of the PP-8444A/U are:
When the AC is turned on the 24 VDC goes to zero. If the red wires going to both Charger PCBs are removed then the fan turns and the POWER ON light comes on indicating a problem with both charging boards.
- Front panel
- Nemic-Lambda Brick power supply (120 VAC in 24 VDC out)
- Control PCB
- 2 each Charger PCBs
- Chassis with Relay
The Charger PCBs have three connections to the rest of the PP-8444A/U:
- a 16 wire ribbon cable to the Control PCB
- an 8 wire harness to the front panel
- a 2 wire (Red & Black) connection to the Control PCB. The Red wire going to the Control PCB comes from the relay mounted on the chassis. I think that the 24 VDC from the Lambda supply goes through the DC POWER switch and when an external DC source is used the DC POWER switch selects either the internal source or the external source. The relay i8solates the charger outputs from any batteries that may be connected when the input power to the charger is turned off..
The DC resistance across the Red & Black binding posts that are the 24 VDC input to both Charger PCBs reads <2.0 Ohms with nothing connected to the PCB. So 24 V / 2 Ohms = 12 Amps this is a problem.
The rear Charger board has white scum on the left half, maybe one or both of the 1,000 uF 50 V electrolytic caps have died. C11 is directly across the input Red-Black terminals.
The T-220 diodes and transistors all seem to be fine.
Removing C11 on the rear Charger board did not fix the problem, the PCB still shows the 2 Ohms and C11 tested OK.
There are a number of Tantalum caps and C5 measures 0.02 Ohms and C5 on the other board also shows as a short. The SG-1144 also had defective Tantalum caps. When C5 is removed it measures 0.2 Ohms = dead cap. It is a Yellow tear drop marked 106, +16K. Both C5 caps were installed to match the polarity markings on the board so either the board is marked wrong or more likley C5 has too low a voltage rating or like in the SG-1144 the cap is of poor quality.
But after removing C5 the input still looks like 2 Ohms, so something else is wrong.
C9 and C10 measure about 2 Ohms, so maybe this is the short I'm looking for. . . . Both of these caps are OK, the board shows the 2 Ohm short. Checked U2 and U6 both CD4066 quad switches and they look OK.
Very close to C10 is U3 an MC34163 Inverting switching regulator made by Motorola with a 9717 date code. The short that measures 1.47 Ohms is 1.32 Ohms across this IC. The IC shows signs of severe overheating on both boards.
The other board shows 1.78 Ohms at pins 5 & 7 and 1.94 Ohms at the Red-Black connector. It looks like both of the switching regulators have failed.
After removing U3 the Red Black input tests as an open. SOLVED. Now to get the parts to repair.
- 17 Jan 2003 - Replaced both C5 Tantalum caps and both U3 MC34163 (available from On Semiconductor). Now when powering on the PP-8444/U without any battery adapter:
- All 6 LEDs in that status panel come on briefly and also the Red Power On light is lit,
after a few seconds only the two Fault Red LEDs and the Power On light are lit (this is normal)
- After plugging in an empty battery adapter the Fault LEDs go out and the Yellow Charging LEDs blink (this is normal)
So the unit seems to be fixed.
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page created 13 June 2002.