Propel BB-590 Battery Charger
© Brooke Clarke 2005
<no Plainfield NJ>
I bought this charger on eBay (j5w23
in a box marked "New BB-590" and the charger was wrapped in
plastic, line cord has tie wrap, no marks of use and does in fact
appear to be new.
The hand soldering is probably why these are on the market and/or
the BB-390 has replaced the BB-590. Mine
had an open circuit between one of the charging wires and the
jack and also had the 110 VAC switch wires routed through a hole
chassis with sharp metal edges. I resoldered the four
cable ends to the banana jacks and removed the two brown wires
metal and resoldered them to the power switch.
Make these changes prior to using the charger!
Different units with Same Model Number
There are at least two different units, both marked Model
The one with the 1702 smart charger ICs does NOT have the south
plainfield NJ under the Propel at the top center front
the front panel label includes "SOUTH PLAINFIELD, N.J." then the
charger is NOT the smart one.
I have not tested the
Plainfield model and so don't know if it's also a "Burp" charger
This is a Charger & Discharger for
the BB-590 Ni-Cad battery or any 20 cell Nickel chemistry battery
my 5590BA Battery Adapter
independently charge or
discharge two batteries at the same time. The charging is
using a patented pulse method rather than a DC
two wires go to the battery wired positive (white) to pin 4 and
negative (black) to pin 2. In the battery
pin 1 is jumpered to pin 5. The charging
plug is a 5 key slot type and so could be plugged into a primary
battery like a BA-5590. It would have been better to wire
plug using pin 3 as the negative (black) , jumper pins 2 and 4 and
pin 5 as the positive (white), this way the charger could not
The "test" banana jacks on the front panel are wired in parallel
the battery positive and negative terminals.
The heart of this charger is a couple of the Galaxy
Power ICX1702 ICs.
BatteryPlugs are Amphenol 10-101980-128 back shell and
hermetic plug. There are very expensive in any quanity.
COMMERCE BUSINESS DAILY ISSUE OF
NOVEMBER 25,1996 PSA#1728
Defense General Supply Center 8000 Jeff Davis Hwy Richmond, VA
61 -- CHARGER, BATTERY SOL SP0400-97-Q-Q164 DUE 120496 POC
for copies of RFP/IFB solicitations (available at least 15 days
announcement, for copies of RFQ Solicitations, contact the
buyer: Myra Sevrt/ZY187/804-27 9-4286. PR-NO: FPG96302001922
charger, Battery. propel Inc. P/N bb-590.
36 -EA Del to Mechanicsburg
PA 17055-0789 Del by 24 Dec 96. 59 -EA Del to Tracy CA
delivery 120 days ARO.
Incremental quantities: min: 95 max: 209.
responsible sources may submit offer which DGSC shall
Are they still in business?
NJ 07080 0000
When a battery is installed the Galaxy
IC does a soft start and then uses the patented pulse charging
method. When the fast charge (FULL LED) mode is terminated
switches over to a topping charge (Trickle LED) and when that's
the maintence charge.
When the trickle LED turned on after charging 20 Ni-MH cells in
the box was not even
took about 2 hours.
The next morning after "Trickle" charging all night the battery
voltages are: 14.14 & 14.05 Volts for a total of 28.19 Volts
Next a PRC-104
discharge test. WOW!
The run time came in at 6.2 hours,
better than the Maha C777+ using the same batteries. The
terminated with the voltage goes below 20 Volts (which usually is
the 1.5 amp load) so when the Open Circuit Voltage is checked
after the test it's around 24 Volts.
Connecting 20 new 1.0 AH Ni-Cad cells starting off at 26 volts,
switches to trickle charge in about 4 hours with the battery
pulsing around 29 to 30 Volts. The Ni-Cads are slightly warm
(about 95 F). Putting some different new Ni-Cads on the Maha
C777+ has a much different result.
First try - charger stops after about 10 minutes saying the
are charged and only a small amount of charge has been added.
Second try - similar to the first try.
Third try - about 1 AH is added (the full capacity rating is 1.0
So the "Soft Start" in the Propel patent really seems to work in
Using 22 cells in the 5590BA
Since this charger terminates
based on the shape of the voltage vs. time curve it should
5590BA when 22 cells are used. After charging the terminal
voltage is about 30.3 volts with a 100 ma load. This
May 2005) see what capacity is in the cells by using the 1/2
discharge cycle. The run time is 7.8 hours, and since
cells charged the same way using the Propel charger gave 8
appears that the Propel is NOT properly charging a 22 cell
Note that chargers that use charge termination methods that are
based on a fixed voltage should charge 22 cells. This
could be a
simple charger that operates with a constant current or a smart
The data sheet for the 1702 indicates that it can do both smart
and smart discharge. This includes automatic battery connect
sense for either charge or discharge. Switching to DISCH.
then plugging in a battery with a terminal
voltage of 24.7 V causes the Trickle LED to flash. The
voltage is being pulse loaded (the voltage is jumping between 23
). In a few minutes the Trickle LED turned off and the
voltage is a steady 24.37.
Next these same batteries that were charged using a lab supply
charged using the Propel charger to see if it again gets more from
theexact same cells. Gave about the same result 4.7 hours
Propel and 4.8 hours for lab supply at 300 ma.
Galaxy IC used in Propel Charger
of controlling the application and
termination of charge to a rechargeable battery - The Galaxy
may be a Motorola 68--05 programmed with the algorithm. Feb 4,
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