Prévia do material em texto

TD-650 
Rev K 
September 19, 2019 
DCR 60255 
 
 
 
 
 
 
OPERATING INSTRUCTIONS 
 
FOR 
 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
 
Model Part Number NSN 
RF80-K 121630-001 6130-01-361-0642 
RF80-K (CE) 121630-006 6130-01-512-3228 
 
 
 
 
 
 
 
MARATHONNORCO AEROSPACE, INC. 
P.O. BOX 8233 
8301 Imperial Drive 
Waco, TX. 76714-8233 
 
www.mnaerospace.com 
Phone: (254) 776-0650 
Fax: (254) 776-6558 
 
http://www.mnaerospace.com/
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 W-1 
SEPTEMBER 19/19 
 
 
LIMITED WARRANTY 
 
MODEL RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
MANUFACTURED BY MARATHONNORCO AEROSPACE, INC. 
 
 
 MarathonNorco Aerospace, Inc. warrants the RF80-K Aircraft Battery Charger / 
Analyzer to the extent of the parts necessary to correct any defect in workmanship or 
materials which may develop under proper and normal use for a period of one (1) year 
from date of receipt of the equipment by the customer, but not to exceed eighteen (18) 
months from the date of shipment from MarathonNorco. This warranty also includes any 
labor necessary to effect such repair, if the Charger / Analyzer is returned to 
MarathonNorco Aerospace, Inc. in Waco, Texas, USA, properly packaged and insured. 
 
 The above shall constitute fulfillment of all MarathonNorco’s liabilities in respect 
to said equipment, and MarathonNorco shall not be liable for any consequential damages 
nor for any damage in shipment. The Charger / Analyzer or faulty part must be returned 
to MarathonNorco. The cost of any transportation and insurance is not included with this 
warranty. 
 
 
 
 
 
 
 
 
 
 
MARATHONNORCO AEROSPACE, INC. 
P.O. Box 8233 
8301 Imperial Drive 
Waco, TX. 76714-8233 
 
www.mnaerospace.com 
Phone: (254) 776-0650 
Fax: (254) 776-6558 
 
http://www.mnaerospace.com/
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 W-2 
SEPTEMBER 19/19 
 
 
 
 
 
ABOUT TD-661 
(Military RF80-K Operator’s Manual) 
 
 When the RF80-K (121630-001) was first introduced in 1992, it included the 
Operator’s Manual TD-650. In 1993, Christie issued the TD-661 RF80-K Operator’s 
Manual for units sold to the US Military. The RF80-K (CE) P/N 121630-006 was 
released in 2002 to satisfy European CE requirements. This unit became our standard 
commercial unit and the Operator’s Manual TD-650 was supplied with it. 
 
 The TD-661 Operator’s Manual differs very little in content from the TD-650 
Operator’s Manual. Revision H and following of TD-650 (as of August 22, 2011) 
incorporates all material unique to the TD-661 Operator’s Manual so that all RF80-K 
units can share the same TD-650 Operator’s Manual. All RF80-K units (121630-001 
and 121630-006) will now ship with the TD-650 Operator’s Manual. 
 
 Please note that the TD-650 Operator’s Manual has been restructured in order to 
consolidate and group similar information in a format that is easier to read and use. In 
addition, the Appendix A Battery Application Guide has been removed. Please refer to 
the applicable battery Operating or Component Maintenance Manual for the battery’s 
specific charge rates and times. 
 
 
 
Please contact the factory with any questions: 
 
MARATHONNORCO AEROSPACE, INC. 
P.O. BOX 8233 
8301 IMPERIAL DRIVE 
WACO, TX. 76714-8233 
 
PHONE: (254) 776-0650 
FAX: (254) 776-6558 
 
www.mnaerospace.com 
 
 
 
 
 
 
http://www.mnaerospace.com/
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 TC-1 
SEPTEMBER 19/19 
 
Table of Contents 
 INTRODUCTION .................................................................................................... 1 
 INSPECTION AND INSTALLATION ................................................................... 6 
2.1 Unpacking and Inspection ................................................................................................ 6 
2.2 Placement Considerations ................................................................................................ 7 
2.3 Input Power Requirements ............................................................................................... 8 
2.4 Preparation for Shipment or Storage .............................................................................. 10 
 DESCRIPTION OF FEATURES AND MODES................................................... 11 
3.1 Front Panel Features ....................................................................................................... 11 
3.2 Feature Descriptions ....................................................................................................... 12 
3.3 ReFLEX Charging Description ...................................................................................... 16 
 OPERATIONAL INSTRUCTIONS ....................................................................... 17 
4.1 General ........................................................................................................................... 17 
4.2 Battery Manufacturer’s Instructions............................................................................... 17 
4.3 Operation Instructions .................................................................................................... 18 
4.4 Operational Flowchart .................................................................................................... 20 
4.5 DigiFLEX® Display ...................................................................................................... 21 
 MAINTENANCE ................................................................................................... 22 
5.1 General ........................................................................................................................... 22 
5.2 Periodic Inspection and Preventative Maintenance ....................................................... 22 
5.2.1 Work Area ............................................................................................................... 22 
5.2.2 Mechanical Condition ............................................................................................. 22 
5.2.3 Electrical Condition ................................................................................................ 22 
5.2.4 Wiring ..................................................................................................................... 23 
5.2.5 Cables and Connectors ............................................................................................ 23 
5.2.6 Printed Circuit Boards............................................................................................. 23 
5.3 Cleaning ......................................................................................................................... 23 
5.3.1 Cabinet .................................................................................................................... 24 
5.3.2 Circuit Card Assemblies ......................................................................................... 24 
5.3.3 Surfaces ................................................................................................................... 24 
5.4 Lubrication ..................................................................................................................... 24 
5.5 Fuse Complement ........................................................................................................... 24 
 CALIBRATION AND SPARES ............................................................................ 25 
6.1 Calibration Verification Check ...................................................................................... 25 
6.1.1 Equipment Requirements ........................................................................................ 25 
6.1.2 Accuracy .................................................................................................................25 
6.1.3 Battery Voltage Metering ....................................................................................... 25 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 TC-2 
SEPTEMBER 19/19 
 
6.1.4 Cell Voltage Metering............................................................................................. 25 
6.1.5 Battery Current Metering ........................................................................................ 25 
6.1.6 Discharge Voltage Termination .............................................................................. 26 
6.1.7 Timer Accuracy ...................................................................................................... 27 
6.2 Recommended Spares Provisioning List........................................................................ 28 
6.3 Illustrated Parts Lists ...................................................................................................... 29 
 OPTIONAL ACCESSORIES ................................................................................. 37 
7.1 DATAFX™ ..................................................................................................................... 37 
7.2 Data Logging and / or Controlling Equipment............................................................... 37 
APPENDIX A ............................................................................................................................... 38 
 
 
 
LIST OF ILLUSTRATIONS 
 
Figure 1-1: RF80-K Aircraft Battery Charger/Analyzer ................................................................ 2 
Figure 2-1: RF80-K Placement Illustration .................................................................................... 7 
Figure 2-2: RF80-K Input Voltage Settings.................................................................................... 9 
Figure 3-1: RF80-K Front Panel ................................................................................................... 11 
Figure 4-1: RF80-K Operation Details ......................................................................................... 18 
Figure 4-2: Operational Flowchart................................................................................................ 20 
Figure 4-3: DigiFLEX® Indicator ................................................................................................ 21 
Figure 6-1: RF80-K Battery Charger/Analyzer and Cables ......................................................... 29 
Figure 6-2: RF80-K Terminal Block Assembly ........................................................................... 30 
Figure 6-3: RF80-K Capacitor Assembly ..................................................................................... 32 
Figure 6-4: RF80-K Front Panel Assembly (Sheet 1 of 3) ........................................................... 33 
Figure 6-5: RF80-K Front Panel Assembly (Sheet 2 of 3) ........................................................... 34 
Figure 6-6: RF80-K Front Panel Assembly (Sheet 3 of 3) ........................................................... 35 
Figure 7-1: DATAFX™ Front Panel ............................................................................................ 37 
 
Figure A-1: RF80-K Schematic .................................................................................................... 38 
 
 
LIST OF TABLES 
 
Table 1-1: Ratings and Salient Characteristics ............................................................................... 3 
Table 2-1: RF80-K Parts List (121630-001) ................................................................................... 6 
Table 2-2: RF80-K Parts List (121630-006) ................................................................................... 6 
Table 2-3: Input Power Requirements ............................................................................................ 8 
Table 4-1: Quick Operating Setup (Before turn on) ..................................................................... 19 
Table 4-2: DigiFLEX® Indicator Chart ....................................................................................... 21 
Table 6-1: RF80-K Battery Charger/Analyzer and Cables Parts List........................................... 29 
Table 6-2: RF80-K Terminal Block Assembly Parts List ............................................................ 31 
Table 6-3: RF80-K Capacitor Assembly Parts List ...................................................................... 32 
Table 6-4: RF80-K Front Panel Assembly Parts List ................................................................... 36 
file://mnaisv/vol1/EVERYONE/Eng/DCR_Files/60000-69999/DCR60255/TD-650/TD-650-K%20Draft%20(20181019_0915).docx#_Toc527704157
file://mnaisv/vol1/EVERYONE/Eng/DCR_Files/60000-69999/DCR60255/TD-650/TD-650-K%20Draft%20(20181019_0915).docx#_Toc527704158
file://mnaisv/vol1/EVERYONE/Eng/DCR_Files/60000-69999/DCR60255/TD-650/TD-650-K%20Draft%20(20181019_0915).docx#_Toc527704164
file://mnaisv/vol1/EVERYONE/Eng/DCR_Files/60000-69999/DCR60255/TD-650/TD-650-K%20Draft%20(20181019_0915).docx#_Toc527704165
file://mnaisv/vol1/EVERYONE/Eng/DCR_Files/60000-69999/DCR60255/TD-650/TD-650-K%20Draft%20(20181019_0915).docx#_Toc527704166
file://mnaisv/vol1/EVERYONE/Eng/DCR_Files/60000-69999/DCR60255/TD-650/TD-650-K%20Draft%20(20181019_0915).docx#_Toc527704167
file://mnaisv/vol1/EVERYONE/Eng/DCR_Files/60000-69999/DCR60255/TD-650/TD-650-K%20Draft%20(20181019_0915).docx#_Toc527704168
file://mnaisv/vol1/EVERYONE/Eng/DCR_Files/60000-69999/DCR60255/TD-650/TD-650-K%20Draft%20(20181019_0915).docx#_Toc527704169
file://mnaisv/vol1/EVERYONE/Eng/DCR_Files/60000-69999/DCR60255/TD-650/TD-650-K%20Draft%20(20181019_0915).docx#_Toc527704170
file://mnaisv/vol1/EVERYONE/Eng/DCR_Files/60000-69999/DCR60255/TD-650/TD-650-K%20Draft%20(20181019_0915).docx#_Toc527704171
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 1 
SEPTEMBER 19/19 
 
 
 
INTRODUCTION 
 
Congratulations! You have acquired the CHRISTIE® RF80-K Charger-Analyzer, the 
most versatile aircraft battery charger-analyzer in the world. The RF80-K is used by 
commercial, military and corporate aircraft operators worldwide for properly maintaining 
lead acid, nickel cadmium and other aircraft batteries. With its many features, you will 
easily be able to perform all of the charge and discharge functions specified by all aircraft 
battery manufacturers. 
 
The RF80-K offers a choice of charging techniques such as constant current, 
constant potential and the exclusive ReFLEX® charge method, which enables faster 
charging and reconditioning of batteries. The ReFLEX® charging method utilizes a 
special circuit called DigiFLEX® to incorporate a negative discharge component within 
the charge function to measure the batteries state of charge. Among the benefits of this 
are accelerated charge times, more efficient charging, lower battery charge temperatures 
and improvement in cell balance all of which contribute to increased battery life. The 
DigiFLEX® circuit incorporates a luminescent trend bar display offering a visual 
confirmation during the charging process of the charge status of the battery. 
 
The user-friendly switches will permit you to automatically charge, discharge, 
pause and recharge your batteries. The displays keep you informed of time to charge, 
elapsed discharge time, battery voltage and charge or discharge currents. You can even 
check individual cell voltages. 
 
You may wish to investigate the optional accessories for the RF80-K such as the 
DataFX® for cell monitoring and data recording on screen and through a compatible 
serial printer. Also available is a fully computerized aircraft battery test and analysis 
system linking multiple charger-analyzers as well as automating battery servicing and 
simplifying data gathering and data storage.Please take the time to review this manual to ensure the proper installation and 
operation of the RF80-K. 
 
 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 2 
SEPTEMBER 19/19 
 
 
 
 
 
 
 
 
 
1 NOTE: CE label not present on 121630-001. 
Figure 1-1: RF80-K Aircraft Battery Charger/Analyzer1 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 3 
SEPTEMBER 19/19 
 
Table 1-1: Ratings and Salient Characteristics 
RATINGS 
PART NUMBER: 
 121630-001 (Military) 
 121630-006 (Commercial) 
NSN: 
6130-01-361-0642 
6130-01-512-3228 
 
INPUT POWER: 
 
 VOLTS - 208/230 (187-250) VAC Single Phase 
 FREQUENCY - 50/60 (47-53/57-63) Hertz 
 INPUT CURRENT - 23 Amperes Maximum 
 
OUTPUT POWER: 
 
 CHARGE VOLTAGE: 
 VOLTS: 0 to 42.4 VDC 
 
 CHARGE CURRENT: 
 REFLEX: 2 to 80 Amperes DC adjustable 
 CONSTANT CURRENT: 1 to 65 Amperes DC adjustable 
 CONSTANT POTENTIAL: 1 to 65 Amperes DC adjustable 
 
 DISCHARGE CURRENT: 
 0.2 to 60 amperes DC adjustable* 
 
*NOTE: Only RF80-K units with a silver “60A MAX DISCHARGE” sticker on the front panel have a range of 0.2 
to 60 amperes DC. All other units are rated at 0.2 to 50 amperes DC. 
 
 
BATTERY CELL RANGE: 
 
 NICKEL-CADMIUM - 
 Batteries: 11, 19, 20, and 22 cells 
 Vented type - REFLEX charge 
 Cells : 1 to 24 cells 
 Vented type - CONSTANT CURRENT charge 
 
 LEAD-ACID - 
 Batteries: 3, 6, 12, and 14 cells 
 Vented or Sealed - CONSTANT POTENTIAL, 
 CONSTANT CURRENT or 2 STEP CONSTANT 
 CURRENT charge. 
 
CHARGE METHODS AVAILABLE: 
 
 REFLEX: Nickel-Cadmium 
 CONSTANT CURRENT: Nickel-Cadmium, Lead Acid 
 2 STEP CONSTANT CURRENT: Nickel-Cadmium , Lead-Acid 
 CONSTANT POTENTIAL: Lead-Acid 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 4 
SEPTEMBER 19/19 
 
Table 1-1: Ratings and Salient Characteristics 
DISCHARGE MODES: (Nickel-Cadmium Only) 
 
 LONG CYCLE : Voltage Termination 
 SHORT CYCLE : Time Termination 
 DEEP CYCLE : To 0 Volts (Nickel-Cadmium Batteries Only) 
 
DISCHARGED BATTERY MINIMUM VOLTAGE: 
 
 NICKEL-CADMIUM: Preset to 1.0 Volts per cell 
 LEAD-ACID: Preset to 1.80 Volts per cell 
SALIENT CHARACTERISTICS 
 
DIMENSIONS: 
 
 OVERALL- Width : 18.55 in. (47.12 cm) 
 Depth : 21.50 in. (54.61 cm) 
 Height: 11.00 in. (27.94 cm) 
 CABINET- Width : 17.00 in. (43.18 cm) 
 Depth : 20.81 in. (52.86 cm) 
 Height: 10.25 in. (26.04 cm) 
 WEIGHT 145 Lbs. (65.90 kg.) 
 
ENVIRONMENTAL CHARACTERISTICS: 
 
 TEMPERATURE: Non-Operating - 40o to 71oC (-40 o to 159.8oF) 
 Operating 0o to 50oC (32o to 122oF) 
 ALTITUDE: Non-Operating 0 to 50,000 ft. 
 Operating 0 to 8,000 ft. 
 HUMIDITY: Operating Up to 95% 
CABLES: 
 
 AC - One 6 ft. input power cable without plug. 
 DC - One 8 ft. battery charging cable with 2 interchangeable battery adapters. 
 
TIMERS AND DISPLAYS: 
 
 CHARGE TIMER: 59 hours, 59 minutes may be selected in 
 one minute increments. 
 
 CHARGE DISPLAY: Displays charge time remaining. 
 
 DISCHARGE TIMER: 59 hours, 59 minutes may be selected in 
 one minute increments. 
 
 DISCHARGE DISPLAY: Displays elapsed discharge time. 
 
 
 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 5 
SEPTEMBER 19/19 
 
Table 1-1: Ratings and Salient Characteristics 
 
INDICATORS: 
 
 GREEN - Battery acceptable, GO 
 RED - Battery reject, NO-GO 
 YELLOW - Negative Slope 
 
DISPLAYS: 
 TIME: 59 hours, 59 minutes 
 AMPERES: Zero to 99.99 Amperes (80 amps maximum) 
 BATTERY VOLTS: Zero to 99.99 Volts DC 
 CELL VOLTS: Zero to 10.00 Volts DC 
 
BATTERY TYPES (NICKEL-CADMIUM): 
 
 "A" TYPE - Low impedance (rate) cells. 
 "B" TYPE - Medium impedance (rate) cells. 
 
BATTERY SERVICE METHODS: 
 
NICKEL-CADMIUM: 
 
 ANALYZE (REFLEX): CHARGE-DISCHARGE-RECHARGE 
 ANALYZE W/WAIT (REFLEX): CHARGE-DISCHARGE-WAIT-RECHARGE 
 CHARGE ONLY (REFLEX) 
 DISCHARGE ONLY 
 DISCHARGE (RECHARGE) (REFLEX): DISCHARGE-WAIT-RECHARGE 
 2 STEP CONSTANT CURRENT 
 CONSTANT CURRENT 
 
LEAD-ACID: 
 
 ANALYZE (CP): CHARGE-DISCHARGE-RECHARGE 
 ANALYZE W/WAIT (CP): CHARGE-DISCHARGE-WAIT-RECHARGE 
 CHARGE ONLY (CP) 
 DISCHARGE ONLY 
 DISCHARGE (RECHARGE) (CP): DISCHARGE-WAIT-RECHARGE 
 2 STEP CONSTANT CURRENT 
 CONSTANT CURRENT 
 
SPECIAL FEATURES: 
 
DigiFLEX ANALYSIS: 
 During REFLEX charging, as the battery nears a fully charged condition, the DigiFLEX 
display indicates relative state-of-charge. Individual cell voltages may be measured with 
the external cell probes. 
NEGATIVE SLOPE SENSING: 
 Charge automatically terminates when battery is not accepting charge or decreasing 
voltage. 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 6 
SEPTEMBER 19/19 
 
 
 
INSPECTION AND INSTALLATION 
 
2.1 Unpacking and Inspection 
 
Inspect the RF80-K upon receipt for general condition and examine for possible shipping 
damage. It is packaged in a sturdy container designed to protect the unit from damage 
during all normal conditions. After opening the shipping container, carefully examine the 
exterior of the unit for damage, paying special attention to indications such as dents in the 
cabinet, and looseness or damage of panel controls. In the event of damage, notify the 
transportation company at once for inspection and proper handling of claims. Check that 
all items listed on the packing slip are present. Save the original factory shipping 
container for future use—it has been designed to collapse by simply removing all wood 
screws. 
Table 2-1: RF80-K Parts List (121630-001) 
RF80-K Parts List (121630-001) 
PART NO. DESCRIPTION 
121630-001 RF80-K 
TD-650 Operator's Manual, RF80-K 
526020-064 Test Lead Set 
121666-001 Output Cable Adapter (Quick Disconnect) 
121666-002 Output Cable Adapter (Ring Lugs) 
123001 Declaration Of Conformity 
596000-093 Crate; RF80-K Shipping 
596000-181 Crate Insert Set (2 Pcs.) 
594801-001 Certificate of Calibration 
596000-186 MIL-D-3464 Desiccant 
596000-187 MIL-I-8835A Humidity Indicator 
 
Table 2-2: RF80-K Parts List (121630-006) 
RF80-K Parts List (121630-006) 
PART NO. DESCRIPTION 
121630-006 RF80-K (CE) 
TD-650 Operator's Manual, RF80-K 
526020-064 Test Lead Set 
121666-001 Output Cable Adapter (Quick Disconnect) 
121666-002 Output Cable Adapter (Ring Lugs) 
123001 Declaration Of Conformity 
596000-093 Crate; RF80-K Shipping 
596000-181 Crate Insert Set (2 Pcs.) 
594801-001 Certificate of Calibration 
 
 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 7 
SEPTEMBER 19/19 
 
2.2 Placement Considerations 
 
Proper placement is essential for efficient operation as well as for ease of use. Cooling is 
an important consideration. Forced-air cooling is achieved by a fan that draws cooling 
air through openings on the sides of the cabinet. The top must always be closed during 
operation as the cabinet is designed with specific airflow patterns to ensure proper 
cooling of all critical components. The heated air is exhausted by the cooling fan out the 
rear of the cabinet. 
 
To ensure proper cooling, make sure that the conditions illustrated and outlined in Figure 
2-1 are carefully observed during installation. 
 
Figure 2-1: RF80-K Placement Illustration 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER/ ANALYZER 
 
TD-650 8 
SEPTEMBER 19/19 
 
 
2.3 Input Power Requirements 
 
The RF80-K requires an input power source given below: 
 
Table 2-3: Input Power Requirements 
Input Power Requirements 
Line Voltage 208 or 230 (±10%) VAC, 
Single Phase 
See terminal block adjustments in Figure 
2-2. The unit is normally configured at the 
factory for 230 VAC operation. If the 
source voltage is always between 215 and 
250 VAC, no internal wiring connection 
changes are required. If source voltage is 
always between 190 and 215 VAC, 
conversion is required. 
Line Frequency 50 or 60 Hz Conversion for 50 or 60 Hz operation is 
not required. 
Circuit Breaker 
or Fuse 
30 A Input current required by the RF80-K is 23 
A max; a 30 A circuit breaker provides 
sufficient protection. 
 
Measure source input voltage at the outlet or circuit breaker. The unit is normally 
configured at the factory for 230 VAC operation. If the source voltage is always 
between 215 and 250 VAC, no internal wiring connection changes are required. If source 
voltage is always between 190 and 215 VAC, conversion is required. Refer to Figure 2-2 
for conversion instructions. 
 
The input power cord is provided without a connector. The RF80-K is used worldwide 
and common domestic connectors compatible with facility outlets are more easily 
obtained locally by the user. In selecting these connectors, make sure that they are rated 
for at least 230 VAC, 30 Amperes. In addition, the user has the option to wire directly 
into a circuit breaker. 
 
CAUTION—NEVER OPERATE THE CHARGER/ANALYZER WITH THE CABINET 
COVER OPEN OR REMOVED IN AN ATTEMPT TO IMPROVE COOLING. THE UNIT IS 
DESIGNED FOR PROPER COOLING ONLY WITH THE CABINET COVER INSTALLED. 
REMOVAL OF THE COVER DURING USE WILL RESULT IN OVERHEATING AND 
POSSIBLE DAMAGE TO THE UNIT. DO NOT EXPOSE TO RAIN. 
 
WARNING—EXPLOSIVE GASES: NEVER OPERATE THE CHARGER/ANALYZER 
UNLESS THE AREA IS WELL VENTILATED. KEEP BATTERY GASSES OUT OF 
CHARGER. CHECK LOCAL CODES AND REGULATIONS FOR THIS REQUIREMENT. 
PREVENT FLAMES AND SPARKS - PROVIDE ADEQUATE VENTILATION DURING 
CHARGING. 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 9 
SEPTEMBER 19/19 
 
 
Figure 2-2: RF80-K Input Voltage Settings 
 
WARNING—ALWAYS DISCONNECT THE POWER CONNECTOR AND SHUT OFF 
THE CIRCUIT BREAKER AHEAD OF THE UNIT (FOR WIRED-IN TYPE 
CONNECTION) BEFORE OPENING THE CABINET TOP. EXPOSED VOLTAGES 
DANGEROUS TO HUMAN LIFE ARE PRESENT IN THE CHARGER/ANALYZER 
CIRCUITRY WHENEVER POWER IS APPLIED TO POWER CORD REGARDLESS 
OF CHARGER ANALYZER AC POWER SWITCH POSITION. DISCONNECT THE 
SUPPLY BEFORE MAKING OR BREAKING THE CONNECTIONS TO THE 
BATTERY. 
CAUTION—IF THE INPUT POWER CORD IS DAMAGED, IT SHOULD BE 
REPLACED BY MARATHONNORCO AEROSPACE, INC. OR ITS SERVICE AGENT 
OR A SIMILARLY QUALIFIED PERSON IN ORDER TO AVOID A HAZARD. 
SELECTING A CONNECTOR PLUG FOR THE INPUT POWER CORD: THE 
GROUND PIN ON THE ATTACHMENT PLUG MUST BE THE FIRST CONNECTION 
MADE AND THE LAST BROKEN WHEN THE PLUG IS INSERTED INTO OR 
REMOVED FROM AN OUTLET. 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 10 
SEPTEMBER 19/19 
 
2.4 Preparation for Shipment or Storage 
 
Use standard procedures for preparing the Charger/Analyzer for shipment or storage to 
ensure adequate protection. Always use the original factory shipping container. If this is 
not available, please contact MarathonNorco. No special procedures are required. 
 
 
CAUTION—THE RF80-K MUST BE USED EVERY 6 MONTHS FOR ONE HOUR 
TO MAINTAIN THE ELECTROLYTE IN CAPACITOR C1. WITHOUT REGULAR 
MAINTENCE, IT COULD FAIL. IT IS LOCATED INSIDE THE UNIT IN THE 
RIGHT REAR CORNER, NEAR THE BATTERY INLET. DO NOT USE THE RF80-K 
IF C1 HAS FAILED. A REPLACEMENT CAPACITOR IS AVAILABLE FROM 
MARATHONNORCO AEROSPACE, INC. TO PLACE AN ORDER FOR THE 
REPLACEMENT PART, CONTACT THE SALES DEPARTMENT AT: 254-776-0650 
OR FAX: 254-776-6558 AND ORDER PART NUMBER 530175-302. 
 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 11 
SEPTEMBER 19/19 
 
 
 
DESCRIPTION OF FEATURES AND MODES 
 
3.1 Front Panel Features 
 
 
Figure 3-1: RF80-K Front Panel 
 Name Name 
1 AC Power Switch 10 Set Discharge Time 
2 Set Charge Time 11 Discharge Cycle 
3 Time to Charge 12 Metering Display 
4 Charge Current Adjust 13 DigiFLEX® 
5 Cycle Indicators 14 Meter Switch 
6 Elapsed Discharge Time 15 Cell Volts 
7 Mode Switch 16 Charge Method Switch 
8 Cycle Reset 17 Battery Type Switch 
9 Discharge Current Adjust 
 
 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 12 
SEPTEMBER 19/19 
 
3.2 Feature Descriptions 
 
1. AC Power Switch— Primary or mains AC power ON/Off Switch 
2. Set Charge Time—Establishes charge time (HH:MM). Set time by pushing the buttons at top 
or bottom of each thumb-wheel switch. Times up to 59 hours, 59 minutes may be selected. 
Time will be entered into program when CYCLE RESET button is pushed to start the function. 
3. Time to Charge—Displays charge time remaining. The Charge timer counts down. 
4. Charge Current Adjust—Allows charging current to be set to desired value. Make sure the 
Meter Switch (14) is set to Amps to see the current adjustment. 
5. Cycle Indicators—Indicator lights mean the process has terminated with the following results: 
Color Cycle Indicator Description 
Green Cycle Complete Cycle completed normally (GO indication in Analyze Mode) 
Red Battery Reject Battery voltage low-did not meet capacity requirement (NO-GO indication in 
Analyze Mode) 
Yellow Negative Slope The battery voltage was rising and experienced a sharp drop. This condition 
could indicate overheating or a breakdown of the cell gas barrier. This is a 
safety function and can indicate to the technician that gas barrier breakdown 
should be investigated. The cycle terminated and the battery is possibly hot. 
 
6. Elapsed Discharge Time—Displays elapsed discharge time. The discharge timer counts up. 
7. Mode Switch—Sets RF80-K process to one of the following: 
Mode Switch Description 
Cell Test The Cell Test mode is for a cell fatigue (cellophane barrier) test if required by battery 
manufacturers. The negative slope sensing is disabled so the operator can detect drops 
in battery voltages without the RF80-K shutting off (Negative Slope Failure). This 
mode must be used with the Constant Current setting. 
Charge The RF80-K is capable of three different types of charges depending on the setting of the 
Charge Method Switch (16): REFLEX, CONSTANT CURRENT, and CONSTANT 
POTENTIAL. See Charge Method Switch (16) for a description of each charge method. 
Discharge 
Wait/Recharge 
The Charger/Analyzer will provide a constant current discharge to the proper low 
voltage cut-off point, followed by a wait period, equal to the pre-selected CHARGE 
time, followed by a recharge cycle. To perform this function, recharge time must be 
pre-set on the charge timer. 
2 Step CC In the 2 Step CONSTANT CURRENT charge mode, the Charger/Analyzer provides an 
initial high charge rate for a pre-set time. The Charger/Analyzer then automatically 
reduces the charge current for an equal charge time. The 2 Step Constant Current mode 
is designed such that if the initial charge current is set to C/2 (main charge), the second 
charge step will be automatically reduced to the C/5 rate (topping charge). In this 
mode, the battery is automatically charged and top charged. 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 13 
SEPTEMBER 19/19 
 
Mode Switch Description 
Analyze The ANALYZE function allows automatic battery analysis using a pre-programmed 
Charge-Discharge-Recharge cycle, with evaluation of battery capacityby GO/NO-GO 
(green or red) indicator lights and by actual ampere-hour capacity as determined by 
elapsed time. The pre-programmed ANALYZE cycle takes approximately 3 hours 
with most low impedance nickel-cadmium batteries. Charging is by ReFLEX (nickel-
cadmium) or constant potential (lead-acid). Discharging is by regulated constant 
current. The GO/NO-GO point may be set to any percentage of rated battery capacity 
by an authorized Christie service center. 
Analyze 
W/Wait 
The RF80-K will introduce a wait state after the discharge cycle, equal to the pre-
selected charge time to allow the battery to cool prior to recharging. 
 
8. Cycle Reset—Resets the Automatic cycle to the beginning of the selected mode. To start a 
process after all settings are complete, press the CYCLE RESET button. 
9. Discharge Current Adjust—Allows discharge current to be set to desired value. Make sure the 
Meter Switch (14) is set to Amps to see the current adjustment. 
10. Set Discharge Time—Establishes discharge time (HH:MM). Set time by pushing the buttons at 
top or bottom of each thumb-wheel switch. Times up to 59 hours, 59 minutes may be selected. 
Time will be entered into program when CYCLE RESET button is pushed to start the function. 
11. Discharge Cycle—Set to either Short, Deep, or Long. If the user is unsure of this setting, always 
set to Short. 
Discharge 
Cycle 
Description 
Short TIME TERMINATION-Short cycle analysis of the battery is accomplished by discharging 
at a constant rate until the pre-programmed discharge time is reached. In an Analyze Mode, 
if the battery drops below the minimum acceptable endpoint voltage before the end of the 
pre-programmed time, the red BATTERY REJECT light will illuminate. 
Deep 0V TERMINATION-Nickel-cadmium batteries ONLY! Cells or groups of cells are 
constant current discharged to 0 volts for reconditioning or storage. 
Long NOMINAL DISCHARGE VOLTAGE TERMINATION-Long cycle analysis of the 
battery ampere-hour capacity is accomplished by discharging at a constant rate until the 
average battery voltage reaches 1.0 volts per cell for nickel-cadmium, and 1.8 volts per cell 
for lead-acid. At this voltage, the battery is fully discharged. The position of the battery 
CHARGE METHOD SWITCH determines this discharge voltage value. In an Analyze 
Mode, if the battery voltage drops below the minimum level prior to the pre-programmed 
discharge time established by the operator, the red BATTERY REJECT light will illuminate. 
12. Metering Display—Displays battery voltage, cell voltage, or charge/discharge current depending 
on the METERING SWITCH (14). 
NOTE—“C" is equivalent to the ampere-hour rating of the battery at the one-hour rate. For 
example, the "C" rating of a battery rated at 40 ampere-hours at the one-hour rate is 40. Thus, C/2 
would be equivalent to 20 amps (40/2); C/5 would be equivalent to 8 amps (40/5). 
 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 14 
SEPTEMBER 19/19 
 
13. DigiFLEX®—The RF80-K incorporates a special circuit called DigiFLEX which measures the battery 
condition during the charge cycle. This circuit presents information on the DigiFLEX display, 
located on the front panel. A series of luminescent bars shows the relative battery state of 
charge and condition of health. Green bars will appear when the battery has attained about 
90% capacity. At full charge, the green bars may extend completely to the right side of the 
display. As nickel-cadmium battery characteristics differ by brand, type, service history, 
temperature, etc., one battery may be fully charged when 8 green bars are illuminated, yet 
another battery may produce 10 bars when fully charged. Use of the DigiFLEX process as 
described above should not be substituted for capacity tests as required by the battery 
manufacturer, airframe manufacturer or applicable government agency. 
14. Meter Switch—Selects metering display inputs to: 
Meter Switch Description 
AMPS Charge or discharge current. 
BATTERY VOLTS Overall battery volts measured at the battery connection. 
CELL VOLTS Cell volts measured from external probes attached to the banana jack-style plugs. 
 
15. Cell Volts—External cell probes can be attached to these banana jack-style plugs to allow “Cell 
Scanning”—manual measurement of individual battery cell voltages—at any time using the 
METERING display (switch set to CELL VOLTS). 
 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 15 
SEPTEMBER 19/19 
 
16. Charge Method Switch—Determines the charge method based on battery chemistry and cell 
count: 
Charge 
Method 
Description 
REFLEX Allows vented nickel cadmium batteries to be main charged in 1 hour or less. REFLEX 
charging consists of alternating charge and discharge pulses. It is important that the 
number of cells (11, 19, 20, 22) be identical to the switch setting because the rate and 
duration of the negative pulses is based upon a full charge voltage of 1.60 times the 
number of cells for which the switch is set. If the switches are set incorrectly, the battery 
will be either overcharged or undercharged. The rate and duration of the negative pulses is 
indicated by the "DigiFLEX" display and controlled by the A/B switch. When using 
REFLEX it is possible to charge at the 2C rate for "A" batteries and at the C rate for "B” 
batteries (See A/B switch section for more information). Green bars will appear when the 
battery has attained about 90% capacity at full charge the green bars may extend 
completely to the right side of the display. REFLEX allows safe and rapid charging with 
minimal heating or electrolyte loss. 
CONSTANT 
CURRENT 
CHARGING 
In the CONSTANT CURRENT mode, the Charger/Analyzer may be used to charge 
vented nickel-cadmium batteries up to 24 cells, as well as individual cells or groups of 
cells. This method is also recommended for some sealed and vented lead-acid batteries. 
The charging rate and time in the CONSTANT CURRENT mode are adjustable. Always 
use the CONSTANT CURRENT mode (instead of REFLEX) when charging individual 
cells or groups of cells other than 11, 19, 20, and 22. 
CONSTANT 
POTENTIAL 
CHARGING 
For vented or sealed lead-acid batteries, CONSTANT POTENTIAL charging is available 
for 3, 6, 12 and 14 cell configurations. The battery charge current limit is set by the 
CHARGE CURRENT adjustment on the front panel. As the average cell voltage rises to 
the preselected value (factory preset to 2.4V/cell), the current will diminish as the battery 
reaches a fully charged condition. This charge method is normally a 6 to 8 hour process 
with the charge current limit set at the C rate. 
 
17. Battery Type Switch—This switch determines the pulse rate in REFLEX charging. 
Battery 
Type 
Description 
A Low impedance cells; can be REFLEX charged at the 2C rate. Time between pulses is 1 second. 
B Medium impedance cells; can be REFLEX charged at the C rate. Time between pulses is 1.5 seconds. 
 
WARNING—NEVER CHARGE A NICKEL-CADMIUM BATTERY IN THE CONSTANT 
POTENTIAL MODE! THIS IS NOT RECOMMENDED BY BATTERY MANUFACTURERS 
AND MAY RESULT IN PERMANENT BATTERY DAMAGE. 
 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 16 
SEPTEMBER 19/19 
 
3.3 ReFLEX Charging Description 
 
 
ReFLEX CHARGING 
REFLEX charging should never be confused with conventional pulse charging and is even 
further removed from constant potential and constant current methods. The negative current 
pulse is what makes REFLEX charging unique. REFLEX charging consists of alternating 
positive current charge pulses with negative current discharge pulses. The duration, or pulse 
width, of each negative current pulse progressively increases during the charging cycle (See 
figure below). 
 
 
REFLEX charging allows safe, high-speed charging upto full capacity without overcharging or 
excessive heating. A 2C, one hour charge is the optimum rate for low impedance nickel-
cadmium batteries. 
 
An extra benefit of REFLEX is the approximate battery state-of-charge indication provided by 
the DigiFLEX display. As the discharge pulses become sufficiently long and the battery nears a 
full state-of-charge, the green bars extend further toward the right. At full charge, the green bars 
may extend completely to the right. This provides an approximate indication of battery state-of-
charge. The REFLEX operator can use this information to reduce the battery charging time even 
more. 
 
 
DigiFLEX Display 
 
The REFLEX charge-pulses are set to the 2C rate for low impedance ("A") batteries and the C 
rate for medium impedance ("B") batteries. After each charge-pulse, a low power, discharge-
pulse is automatically applied until an accurate interrogator shows that depolarization has taken 
place. At that point, another charge-pulse occurs and the cycle is repeated. As the battery nears 
full capacity, the negative pulse becomes longer, eventually reaching a point where the net 
charge (charge minus discharge) becomes small. 
 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 17 
SEPTEMBER 19/19 
 
 
 
OPERATIONAL INSTRUCTIONS 
4.1 General 
 
The RF80-K provides simple, yet sophisticated, automatic charging and analysis of 
nickel-cadmium and lead-acid aircraft batteries. In addition to standard charging and 
analysis, many optional procedures, as recommended by battery manufacturers, may also 
be performed. Within this section are instructions for battery charging, discharging, and 
analysis. 
 
4.2 Battery Manufacturer’s Instructions 
 
Consult individual battery Component Maintenance Manuals (CMMs) for charging 
information and all inspection/rejection criteria. 
CAUTION—THE RF80-K AC POWER SWITCH SHOULD NEVER BE ON UNLESS A 
BATTERY IS CONNECTED TO THE OUTPUT. TURN AC POWER OFF AFTER 
BATTERY CHARGING AND DISCHARGING IS COMPLETE. NEVER DISCONNECT 
THE BATTERY AND LET THE RF80-K RUN IDLE WITH AC POWER ON. 
BATTERIES SHOULD BE CONNECTED AND DISCONNECTED ONLY WHEN THE 
AC POWER SWITCH IS OFF. 
 
NOTE—BECOME FULLY FAMILIAR WITH THE FRONT PANEL CONTROLS AS 
IDENTIFIED AND DESCRIBED IN SECTION 3: 
WARNING—BEFORE OPERATING, READ THE INSTRUCTIONS. BATTERIES OF 
DIFFERENT CHEMISTRIES (SUCH AS NICKEL-CADMIUM AND LEAD-ACID) 
SHOULD NOT BE PROCESSED AT THE SAME TIME OR STORED IN THE SAME 
ROOM. VAPOR RELEASED AS THE BATTERY WARMS MAY DILUTE THE 
ELECTROLYTE OF THE OTHER TYPE AS SOME BATTERIES USE ALKALINE (BASE) 
ELECTROLYTE WHILE OTHERS USE ACID. 
 
DISCONNECT THE SUPPLY BEFORE MAKING OR BREAKING THE CONNECTIONS 
TO THE BATTERY. DO NOT EXPOSE TO RAIN. 
 
WARNING—NEVER USE THE RF80-K TO CHARGE SEALED (CYLINDRICAL, NON-
VENTED, "FLASHLIGHT-TYPE") NICKEL-CADMIUM OR LEAD-ACID CELLS. 
EXPLOSION AND PHYSICAL INJURY MAY OCCUR. 
 
EXPLOSIVE GASSES - PREVENT FLAMES AND SPARKS - PROVIDE ADEQUATE 
VENTILATION DURING CHARGING. 
 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 18 
SEPTEMBER 19/19 
 
4.3 Operation Instructions 
 
The following instructions detail standard RF80-K operation. The steps given in the 
instructions correspond with each numbered callout in Figure 4-1. Reference Table 4-1 
for details on required settings for each operating mode. Further description on each 
switch setting is given in SECTION 3:. 
 
 
Figure 4-1: RF80-K Operation Details 
OPERATION INSTRUCTIONS 
Procedure before power is turned on: (Reference Table 4-1) 
1 CONNECT BATTERY TO THE RF80-K! 
2 Set MODE switch 
3 Set CHARGE METHOD switch 
4 Set CHARGE TIME and/or DISCHARGE TIME 
5 Set BATTERY TYPE switch 
6 Set DISCHARGE CYCLE 
7 Make sure CHARGE CURRENT and DISCHARGE CURRENT pots are turned CCW 
8 Set METER switch to AMPS 
Procedure after setup: 
9 (Verify the battery is connected before turning on power!) Turn on AC power 
10 Press cycle reset (this starts the charge, discharge, etc.) 
11 Adjust charge or discharge current 
 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 19 
SEPTEMBER 19/19 
 
Table 4-1: Quick Operating Setup (Before turn on) 
Operational Instructions Step 2 3 4 5 6 7 8 
 
 
MODE CHARGE METHOD CHARGE 
TIME 
DISCHARGE 
TIME 
BATTERY 
TYPE 
DISCHARGE 
CYCLE 
CHARGE 
CURRENT 
DISCHARGE 
CURRENT 
METERING 
SWITCH SWITCH METHOD # CELLS 
CHARGE: 
REFLEX CHARGE REFLEX SELECT SET 0:00 A or B N/A CCW CCW AMPS 
CONSTANT-CURRENT (CC) CHARGE CC N/A SET 0:00 N/A N/A CCW CCW AMPS 
CONSTANT-POTENTIAL (CP) CHARGE CP SELECT SET 0:00 N/A N/A CCW CCW AMPS 
2 STEP CHARGE: 
CC 2 STEP CC N/A SET 0:00 N/A N/A CCW CCW AMPS 
DISCHARGE 
SHORT DISCHARGE N/A SELECT 0:00 SET N/A SHORT CCW CCW AMPS 
LONG DISCHARGE N/A SELECT 0:00 SET N/A LONG CCW CCW AMPS 
DEEP DISCHARGE N/A SELECT 0:00 N/A N/A DEEP CCW CCW AMPS 
WAIT, REFLEX CHARGE DISCHARGE REFLEX SELECT SET SET A or B SELECT CCW CCW AMPS 
WAIT, CC CHARGE DISCHARGE CC N/A SET SET N/A SELECT CCW CCW AMPS 
WAIT, CP CHARGE DISCHARGE CP SELECT SET SET N/A SELECT CCW CCW AMPS 
ANALYZE 
REFLEX, SHORT ANALYZE REFLEX SELECT SET SET A or B SHORT CCW CCW AMPS 
REFLEX, LONG ANALYZE REFLEX SELECT SET SET A or B LONG CCW CCW AMPS 
CC, SHORT ANALYZE CC N/A SET SET N/A SHORT CCW CCW AMPS 
CC, LONG ANALYZE CC N/A SET SET N/A LONG CCW CCW AMPS 
CP, SHORT ANALYZE CP SELECT SET SET N/A SHORT CCW CCW AMPS 
CP, LONG ANALYZE CP SELECT SET SET N/A LONG CCW CCW AMPS 
ANALYZE WITH WAIT 
REFLEX, SHORT ANA. W/WAIT REFLEX SELECT SET SET A or B SHORT CCW CCW AMPS 
REFLEX, LONG ANA. W/WAIT REFLEX SELECT SET SET A or B LONG CCW CCW AMPS 
CC, SHORT ANA. W/WAIT CC N/A SET SET N/A SHORT CCW CCW AMPS 
CC, LONG ANA. W/WAIT CC N/A SET SET N/A LONG CCW CCW AMPS 
CP, SHORT ANA. W/WAIT CP SELECT SET SET N/A SHORT CCW CCW AMPS 
CP, LONG ANA. W/WAIT CP SELECT SET SET N/A LONG CCW CCW AMPS 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 20 
SEPTEMBER 19/19 
 
4.4 Operational Flowchart 
 
The following flowchart shows the sequence of category (Charge, 2 Step Charge, 
Discharge, Analyze, Analyze with Wait) listed in Table 4-1: 
 
 
Figure 4-2: Operational Flowchart 
MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 21 
SEPTEMBER 19/19 
 
 
4.5 DigiFLEX® Display 
 
As mentioned in SECTION 3:, the DigiFLEX display gives an approximate indication of 
the battery’s status during a process. Table 4-2 (below) gives the status associated with 
Red and Green indicators. 
 
 
 RED Indicators Green Indicators 
Figure 4-3: DigiFLEX® Indicator 
Table 4-2: DigiFLEX® Indicator Chart 
DigiFLEX® Indicator Chart 
Red 
Indicators 
(Charge) 
Green 
Indicators 
(Discharge) 
Battery Status 
Pulse Small Pulse ReFLEX Charging (In Process) 
Pulse Max Pulse ReFLEX Charging (Complete) 
Steady None CC or CP Charging 
None Steady Discharging 
NOTE: Red indicators are scaled to approximately 8 amps per bar. 
 MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 22 
SEPTEMBER 19/19 
 
 
 
 
MAINTENANCE 
5.1 General 
 
This section provides instructions for inspection, preventive and corrective maintenance, 
adjustment, and trouble-shooting of the Charger/Analyzer. The content of this section 
assumes familiarity with the equipment by maintenance personnel. 
 
5.2 Periodic Inspection and Preventative Maintenance 
 
The following are general preventive maintenance procedures which should be performed 
on a 12 month inspection schedule, and detailed preventive maintenance procedures 
which should be performed on anas-required basis, except as otherwise noted. 
 
5.2.1 Work Area 
 
Keep the general work area clean on a daily basis. Do not allow dirt, metal dust, powder, 
and pieces of paper to collect in the area of the Charger/Analyzer as the built-in cabinet 
cooling fan can easily draw such items into the unit. Do not block air inlets or outlets. 
 
5.2.2 Mechanical Condition 
 
 
 
 
 
 
 
 
Remove the top cover and conduct an inspection of the unit for general mechanical 
condition. Tighten all bolts, screws, switches, knobs, etc., which may be loose. Make 
sure plug in components are fully engaged. 
 
 
 
 
 
5.2.3 Electrical Condition 
 
Check all switches and controls for proper operation. All components should be 
inspected for indications of overheating. Inspect for burned resistors, intermittent 
connections, noisy potentiometers, and leaking capacitors. 
WARNING—DISCONNECT THE POWER CORD OR SHUT OFF MAIN POWER 
CIRCUIT AHEAD OF UNIT BEFORE OPENING CABINET. DANGEROUS 
VOLTAGES ARE PRESENT IN EXPOSED CIRCUITS EVEN WITH AC POWER 
SWITCH IN THE OFF POSITION. DISCONNECT THE SUPPLY BEFORE 
MAKING OR BREAKING THE CONNECTIONS TO THE BATTERY. 
 
WARNING—PLUG-IN SEMICONDUCTORS MAY BE STATIC SENSITIVE. DO 
NOT REMOVE FROM MOUNTING SOCKETS 
 
 MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 23 
SEPTEMBER 19/19 
 
 
5.2.4 Wiring 
 
Check the wiring for loose or broken tie-wraps, and frayed or damaged insulation. 
Tighten or replace loose or broken tie-wraps. Repair damaged insulation. Tighten all 
loose mountings, connections, and fastenings. 
 
5.2.5 Cables and Connectors 
 
Examine cables for cracked or deteriorated insulation and for frayed or cut insulation at 
the connecting and supporting points. Inspect for loose cable clamps and for loose or 
corroded connectors. Check cables and connectors for improper placement which might 
subject them to strain, kinks or improper supports. Tighten loose cable clamps, coupling 
rings, and connections. 
 
5.2.6 Printed Circuit Boards 
 
Inspect each printed circuit board for dirt, broken printed circuits, bad connections, 
deteriorated components, and the following general overall conditions: 
 
 
 
 
 
5.2.6.1 Capacitors for signs of dielectric leakage and for bulging of the cases. Check 
terminals for loose connections and corrosion. 
5.2.6.2 Fixed resistors for blistering, discoloration, and other signs of overheating. 
5.2.6.3 Variable resistors for defects and loose mountings. 
 
5.3 Cleaning 
 
Clean the components of the unit as follows: 
 
 
 
 
 
 
 
 
 
 
 
 
NOTE—DISCOLORATION OF CONFORMAL COATING AROUND VARIOUS 
COMPONENTS HAS NO DETRIMENTAL EFFECT UPON OPERATION OF 
CIRCUIT CARDS. 
 
WARNING—DISCONNECT THE POWER CORD OR SHUT OFF MAIN POWER 
CIRCUIT AHEAD OF UNIT BEFORE OPENING CABINET. DANGEROUS 
VOLTAGES ARE PRESENT IN EXPOSED CIRCUITS EVEN WITH AC POWER 
SWITCH IN THE OFF POSITION. 
 
DISCONNECT THE SUPPLY BEFORE MAKING OR BREAKING THE 
CONNECTIONS TO THE BATTERY. 
 MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 24 
SEPTEMBER 19/19 
 
 
5.3.1 Cabinet 
 
Open cabinet top and remove any dust, dirt, or foreign particles from circuit cards, 
components, and cabinet, using clean, dry, filtered compressed air at 15 psig. Remove 
stubborn material with a bristle brush in conjunction with compressed air. Make sure that 
all ventilation openings in the cabinet are clean and free of obstructions. However, never 
add air filters to unit. 
 
 
 
 
 
 
 
 
5.3.2 Circuit Card Assemblies 
 
Clean printed wiring side of circuit card assemblies’ connector contacts, and exposed 
switch contacts using a cloth or soft bristle brush moistened with isopropyl alcohol. Dry 
with compressed air at 15 psig. Recoat circuit card area with HumiSeal, type 1B31. 
 
5.3.3 Surfaces 
 
Remove fingerprints, electrolyte (potassium hydroxide) splatters and dirt from cabinet 
parts, front panel, and meter faces using a soft cloth moistened with a solution of mild 
liquid soap and water. Rinse with cloth moistened with water sufficient to remove all 
traces of soap and dry using soft cloth or compressed air at 15 psig. 
 
5.4 Lubrication 
 
No lubrication of the unit is required. 
 
5.5 Fuse Complement 
 
One, 100 ampere DC output fuse, P/N 546191-041 is used on the RF80-K. 
WARNING—USE OF COMPRESSED AIR FOR CLEANING CAN CREATE AN 
ENVIRONMENT OF PROPELLED FOREIGN PARTICLES, WHICH MAY ENTER 
THE EYES AND CAUSE SERIOUS INJURY. AIR PRESSURE FOR CLEANING 
SHALL NOT EXCEED 15 psig AND EYE PROTECTION IS REQUIRED. A 
VACUUM CLEANER WITH BRUSH MAY BE USED FOR CLEANING. 
 
WARNING—ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE 
CHEMICAL GOGGLES, FORCED VENTILATION OR RESPIRATORS, AND 
GLOVES. KEEP CONTAINER CLOSED AND KEEP SPARKS, FLAMES, AND 
HEAT AWAY. KEEP LIQUID OFF SKIN, EYES, AND CLOTHES. DO NOT 
BREATHE VAPORS. 
 
 MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 25 
SEPTEMBER 19/19 
 
 
 
 CALIBRATION AND SPARES 
 
6.1 Calibration Verification Check 
 
Every 12 months, or less as usage and shop procedures dictate, perform the following 
calibration verification checks. 
 
6.1.1 Equipment Requirements 
 
Digital Multimeter (DMM), Fluke 187 or equivalent, RF80-K calibration cable P/N 
121666-010, 20-cell vented NiCd battery or 12-cell sealed lead-acid battery (if used in a 
shop with lead-acid batteries only). 
 
6.1.2 Accuracy 
 
The RF80-K nominal accuracy is +/- 2% plus one digit of reading and all checks should 
be performed at room temperature with relative humidity between 30-50%. 
 
6.1.3 Battery Voltage Metering 
 
Connect battery and turn RF80-K power on. Set the metering switch to the BATTERY 
VOLTS position. Connect the external DMM to the battery positive and negative 
terminals. Compare the DMM and RF80-K metering display readings. They should not 
vary by more than +/- 2% plus one digit of reading. 
 
6.1.4 Cell Voltage Metering 
 
With the RF80-K still connected to the battery and power on, connect the external test 
leads to the front panel cell volts jacks. Set the metering switch to the CELL VOLTS 
position. Using the external test leads, measure an individual NiCd cell or an external 
alkaline 1.5v battery. Compare the DMM and RF80-K metering display readings. They 
should not vary by more than +/- 2% plus one digit of reading. 
 
6.1.5 Battery Current Metering 
 
With the RF80-K power off, connect the calibration cable (shunt) P/N 121666-010 
between the battery output adapter and RF80-K output cable. Connect the test battery, 
then connect the DMM to the shunt and set to read millivolts. The calibration cable is a 
100 amp, 100 millivolt shunt so 1 millivolts is equal to one amp charge/discharge current. 
 
Turn the RF80-K power on, set to DISCHARGE mode, set the metering to AMPS, and 
number of cells to 20. Set discharge time to 00:03 and discharge cycle to LONG or 
 MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 26 
SEPTEMBER 19/19 
 
SHORT (not deep). Slowly increase the discharge current to -25.00 a (RF80-K) or -
30.00 A (RF80-K Rev. L) as read in millivolts on the external DMM across the 
calibration cable/shunt. The RF80-K metering display should be within +/- 2% plus one 
digit of the DMM reading. 
 
RF80-K Acceptable Metering Display Range +/- 2% 
DMM Current RF80-K Current Meter 
-25.00A (RF80-K) 24.4 to 25.6 A 
-30.00A (RF80-K rev. L) 29.3 to 30.7 A 
 
6.1.6 Discharge Voltage Termination 
 
Using a 20-cell NiCd or 12-cell sealed lead-acid battery (if used in a shop with lead-acid 
batteries only), discharge the battery from the highest to lowest cut-off voltage using the 
DISCHARGE mode and set the discharge time for greater than rated battery capacity.Using a DMM, check the battery voltage while still under load at the time the discharge 
terminates and the green CYCLE COMPLETE indicator lights. The voltage termination 
points are as follows: 
 
RF80-K DISCHARGE VOLTAGE TERMINATION 
# of Cells Cut-Off 
Voltage 
Acceptable 
Range +/- 2% 
14 23.4V 22.9 to 23.9V 
22 (1V/Cell) 22V 21.5 to 22.5V 
22 (0.95V/Cell) 20.9V 20.4 to 21.3V 
12 20.0V 19.5 to 20.4V 
20 (1V/Cell) 20.0V 19.5 to 20.4V 
20 (0.95 V/Cell) 19.0V 18.6 to 19.4V 
19 (1V/Cell) 19.0V 18.6 to 19.4V 
19 (0.95V/Cell) 18.1V 17.7 to 18.5V 
11 (1V/Cell) 11.0V 10.7 to 11.2 
11 (0.95V/Cell) 10.5V 10.2 to 10.7 
6 10.0V 9.7 to 10.2V 
3 5.0V 4.8 to 5.1V 
 
NOTE: Previous revisions of the RF80-K had the NiCd discharge cut-off voltages set to 
0.95 V/Cell (cut-off voltage = # of cells * 0.95V/Cell). Beginning with RF80-K 
Revision L, the discharge cut-off voltages are set to 1.0 V/Cell (cut-off voltage = # of 
cells * 1.0V/Cell). 
 
 MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 27 
SEPTEMBER 19/19 
 
 
6.1.7 Timer Accuracy 
 
With a battery connected, turn the RF80-K power on, set to charge mode, constant 
current and set the charge timer for 00:03 minutes. Press Cycle Reset to start the charge 
and check the timer accuracy beginning after the first RF80-K "minute" is counted. 
Verify that the last two minutes are correct duration, +/- 2 seconds. 
 
6.1.7.1 For control boards (P/N 121622-001) with a revision letter of "A" through "G", 
the internal clock is always running. Therefore, the RF80-K's first "minute" may 
be short, depending upon when during the clock's minute the timer is engaged. 
 
6.1.7.2 For control boards (P/N 121622-001) with a revision letter of "H" or later, the 
timer is reset when CYCLE RESET is pressed. Accuracy may therefore be tested 
beginning with the first minute. 
 
NOTE: If ANY of the above tolerances are exceeded, contact the Christie Division of 
MarathonNorco Aerospace, Inc. or an authorized Christie Repair Facility for service and 
performance of calibration alignment. Authorized Christie Repair Facilities are listed on 
our web site at www.mnaerospace.com. 
 
http://www.mnaerospace.com/
 MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 28 
SEPTEMBER 19/19 
 
 
6.2 Recommended Spares Provisioning List 
 
Experienced operators prefer keeping a few replacement parts on hand. The following 
are suggested, although you may prefer to add other items listed in SECTION 5:. 
 
PART NO. DESCRIPTION 
 
546191-041 100 Amp Fuse 
526020-064 Test Lead Set 
121666-001 Output Cable Adapter Quick-Disconnect 
121666-002 Output Cable Adapter Universal 
547100-002 LED Timer Display 
547500-004 Green DigiFLEX Bar Display 
547500-003 Red DigiFLEX Bar Display 
578012-001 SW, CYCLE RESET 
578211-104 SW, Rotary, MODE, CHARGE METHOD, METERING 
578712-016 SW, Toggle, BATTERY TYPE 
578723-001 SW, Toggle, DISC CYCLE 
578900-043 SW, Thumb-wheel, TIMER 
573203-004 SW, AC POWER 
520570-006 Knob, Pointer Type 
520570-047 Knob, Round Type 
 
 MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 29 
SEPTEMBER 19/19 
 
6.3 Illustrated Parts Lists 
 
This section provides a listing of common user replaceable parts. Circuit boards and 
power devices should only be replaced by an authorized Christie Service Center. 
 
Table 6-1: RF80-K Battery Charger/Analyzer and Cables Parts List 
RF80-K Battery Charger/Analyzer and Cables Parts List 
INDEX 
NUM. DESCRIPTION 
PART 
NUMBER 
QTY 
PER 
1 CABLE ASSEMBLY; INPUT 116980-002 1 
2 CABLE ASSEMBLY; OUTPUT 121665-001 1 
3 CABLE ADAPTER; OUTPUT LUG 121666-002 1 
4 CABLE ADAPTER, OUTPUT CONNECTOR 121666-001 1 
5 TEST LEAD SET 526020-064 1 
Figure 6-1: RF80-K Battery Charger/Analyzer and Cables 
 MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 30 
SEPTEMBER 19/19 
 
 
Figure 6-2: RF80-K Terminal Block Assembly 
 MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 31 
SEPTEMBER 19/19 
 
Table 6-2: RF80-K Terminal Block Assembly Parts List 
RF80-K Terminal Block Assembly Parts List 
INDEX 
NUM. DESCRIPTION PART NUMBER 
QTY 
PER 
1 NUT, M3 HEX 197-0034 2 
2 WASHER, M3 SPLIT 197-0053 2 
3 WASHER, #4 FLAT 496-AN96040000 2 
4 SCREW, M3 PHIL PAN HD 197-0010 2 
5 TERMINAL BLOCK, END SECTION 586999-001 1 
6 LABEL, TERMINAL STRIP 121187-001 1 
7 TERMINAL BLOCK, SECTIONAL 586240-101 7 
8 NUT, M5 HEX 197-0038 1 
9 WASHER, M5 SPLIT 197-0056 1 
10 WASHER, M5 FLAT 197-0046 1 
11 CABLE ASSEMBLY, INPUT 116980-002 1 
12 NUT, M5 BRASS HEX 197-0039 1 
13 WASHER, M5 BRONZE STAR 197-0057 2 
14 SCREW, M5X25, BRASS PAN HD 197-0026 1 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 32 
SEPTEMBER 19/19 
 
 
 
 
NOTE: The capacitor is “C1” and the resistor is “R1” on the RF80-K schematic. 
 
Table 6-3: RF80-K Capacitor Assembly Parts List 
RF80-K Capacitor Assembly Parts List 
INDEX 
NUM. DESCRIPTION 
PART 
NUMBER 
QTY 
PER 
1 CLAMP, CAPACITOR 116937-003 1 
2 CAPACITOR, 60VDC, 75K μF 530175-301 1 
3 TERMINAL LUG, INSUL 10 STUD 583224-003 2 
4 WASHER, #10 BRASS FLAT 196-0091 2 
5 WASHER, #10 SPLIT 496-MS35338430 2 
6 SCREW, #10-32 X 0.50 SLTD PAN HD 496-MS35207263 2 
7 RESISTOR 555013-601 1 
8 TUBING, VINYL CLEAR 0.04" ID 507715-041 0.5 FT 
 
 
Figure 6-3: RF80-K Capacitor Assembly 
 MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 33 
SEPTEMBER 19/19 
 
 
Figure 6-4: RF80-K Front Panel Assembly (Sheet 1 of 3) 
 MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 34 
SEPTEMBER 19/19 
 
 
Figure 6-5: RF80-K Front Panel Assembly (Sheet 2 of 3) 
 MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 35 
SEPTEMBER 19/19 
 
 
Figure 6-6: RF80-K Front Panel Assembly (Sheet 3 of 3) 
 MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 36 
SEPTEMBER 19/19 
 
Table 6-4: RF80-K Front Panel Assembly Parts List 
RF80-K Front Panel Assembly Parts List 
INDEX 
NUM. DESCRIPTION PART NUMBER 
QTY 
PER 
1 CKT BRKR, 2 POLE, LNKD ACT’R 573203-004 1 
2 RESISTOR, VARIABLE, 2W 10K 5% 565014-212 2 
3 SWITCH, PUSH, METRIC ON-ON 578012-002 1 
4 SWITCH, ROTARY, METRIC, 1 POLE 578211-104 3 
5 WASHER, M3 BRASS STAR 197-0052 21 
6 SWITCH, TOGGLE, METRIC DPDT 578723-001 1 
7 SWITCH, TOGGLE, METRIC SPDT 578712-016 1 
8 FRONT PANEL, RF80-K 121626-001 1 
9 TERMINAL PLUG, BANANA, RED 583100-025 1 
10 TERMINAL PLUG, BANANA, BLACK 583100-024 1 
11 KNOB, POINTER, 1/4” SHAFT 520570-006 3 
12 KNOB, SKIRTED, 1/4” SHAFT 520570-047 2 
13 SWITCH, THRMBWHEEL, BCD CODED 578900-043 2 
14 WIRING HARNESS, FRONT PANEL 121655-001 1 
15 SWITCH, PARTS, BEZEL CONE 578100-030 1 
 MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 37 
SEPTEMBER 19/19 
 
 OPTIONAL ACCESSORIES 
7.1 DATAFX™ 
 
The ProEase DataFX is a versatile battery servicing monitoring instrument. The ProEase 
DataFX automates battery servicing documentation by taking battery voltages and 
formatting them into a report that can be sent to a printer or a PC. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
The ProEase DataFX can be used with most charger-analyzers to measure and record 
battery data. The ProEase DataFX scans the battery cells during charge and discharge,measuring the voltage at fixed intervals. The cell voltage, the total battery voltage, and 
the charge/discharge current are displayed on the liquid crystal display (LCD). If errors 
occur during processing, an LED warning light and an alarm will sound to alert the 
battery technician of a problem. The error type is displayed and the cells with the error 
flash on the display. An optional EPSON-compatible serial printer provides a complete 
report of the battery processing data and error conditions. Weak or defective cells can be 
identified immediately and corrective action taken before further damage to the battery 
occurs. 
 
7.2 Data Logging and / or Controlling Equipment 
 
Independent Christie Distributors have developed additional value-added accessories to 
keep track of crucial information recorded during the battery servicing process such as 
serial numbers, water usage, individual cell voltages, etc. and/or to allow control of the 
RF80-K through software for a PC. 
 
 
Contact MarathonNorco Aerospace for further information on these products 
(www.mnaerospace.com). 
Figure 7-1: DATAFX™ Front Panel 
http://www.mnaerospace.com/
 MarathonNorco Aerospace, Inc. 
OPERATING INSTRUCTIONS FOR RF80-K 
AUTOMATIC ReFLEX CHARGER / ANALYZER 
 
TD-650 38 
SEPTEMBER 19/19 
 
 
APPENDIX A 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Figure A-1: RF80-K Schematic 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
To find out about Repair Facilities in your region check our web site at 
www.mnaerospace.com and click on Authorized Repair Facilities. 
Or contact us at: 
 
 
MARATHONNORCO AEROSPACE, INC. 
P.O. BOX 8233 
8301 IMPERIAL DRIVE 
WACO, TX. 76714-8233 
 
PHONE: (254) 776-0650 
FAX: (254) 776-6558 
 
www.mnaerospace.com 
http://www.mnaerospace.com/
http://www.mnaerospace.com/
	SECTION 1: INTRODUCTION
	SECTION 2: INSPECTION AND INSTALLATION
	2.1 Unpacking and Inspection
	2.2 Placement Considerations
	2.3 Input Power Requirements
	2.4 Preparation for Shipment or Storage
	SECTION 3: DESCRIPTION OF FEATURES AND MODES
	3.1 Front Panel Features
	3.2 Feature Descriptions
	3.3 ReFLEX Charging Description
	SECTION 4: OPERATIONAL INSTRUCTIONS
	4.1 General
	4.2 Battery Manufacturer’s Instructions
	4.3 Operation Instructions
	4.4 Operational Flowchart
	4.5 DigiFLEX® Display
	SECTION 5: MAINTENANCE
	5.1 General
	5.2 Periodic Inspection and Preventative Maintenance
	5.2.1 Work Area
	5.2.2 Mechanical Condition
	5.2.3 Electrical Condition
	5.2.4 Wiring
	5.2.5 Cables and Connectors
	5.2.6 Printed Circuit Boards
	5.2.6.1 Capacitors for signs of dielectric leakage and for bulging of the cases. Check terminals for loose connections and corrosion.
	5.2.6.2 Fixed resistors for blistering, discoloration, and other signs of overheating.
	5.2.6.3 Variable resistors for defects and loose mountings.
	5.3 Cleaning
	5.3.1 Cabinet
	5.3.2 Circuit Card Assemblies
	5.3.3 Surfaces
	5.4 Lubrication
	5.5 Fuse Complement
	SECTION 6: CALIBRATION AND SPARES
	6.1 Calibration Verification Check
	6.1.1 Equipment Requirements
	6.1.2 Accuracy
	6.1.3 Battery Voltage Metering
	6.1.4 Cell Voltage Metering
	6.1.5 Battery Current Metering
	6.1.6 Discharge Voltage Termination
	6.1.7 Timer Accuracy
	6.1.7.1 For control boards (P/N 121622-001) with a revision letter of "A" through "G", the internal clock is always running. Therefore, the RF80-K's first "minute" may be short, depending upon when during the clock's minute the timer is engaged.
	6.1.7.2 For control boards (P/N 121622-001) with a revision letter of "H" or later, the timer is reset when CYCLE RESET is pressed. Accuracy may therefore be tested beginning with the first minute.
	6.2 Recommended Spares Provisioning List
	6.3 Illustrated Parts Lists
	SECTION 7: OPTIONAL ACCESSORIES
	7.1 DataFX™
	7.2 Data Logging and / or Controlling Equipment
	APPENDIX A