Intelligent Charging MB/TS25 PC211 Operator's Manual

MB/TS25 PC211 UPGRADE Battery Charger

Operators Manual

Printed On : 02/09/15

MUTE

EXTD

ENTR

DISP DATA

A SET PROC

V SETTEST BATT

CHRG T SET

START

STOP

EXTD

ENTR

DISP DATA

A SET PROC

V SETTEST BATT

CHRG ONE T SET

START

STOP

VOLTS TIME

AMPS

TEST

END ONE

VOLTSTIME

AMPS

TEST

END

ALARM

MEM

Bxx

OFFIO

MEM

Bxx

OFFIO

MEM

Bxx

OFFIO

MEM

Bxx

OFFIO

I N T E L L I G E N T C H A R G I N G

CHARGE TRIP

ANALYSER TRIP

MAINS POWER

BATTERY 'B'BATTERY 'A'

MB/TS25 PC211 UPGRADE

BATTERY CHARGER/ANALYSER OPERATORS MANUAL

MB/TS25 PC211 UPGRADE Battery Charger

Operators Manual

TABLE OF CONTENTS

1 MANUAL REVISION HISTORY 3

2 TS25 PC211 UPGRADE DESCRIPTION 4

2.1 GENERAL NOTES 4

2.2 DIFFERENCES 4

3 CONTROLS AND INDICATORS 5

3.1 DISPLAY 6

3.2 POWER SWITCH 7

3.3 AUDIBLE ALARM 7

3.4 CHARGE & CAPACITY TEST CIRCUIT BREAKERS 7

3.5 BATTERY CONNECTORS 7

3.6 KEYBOARD 8

4 USING THE TS25 UPGRADE 9

4.1 CONNECTING BATTERIES 9

4.2 CAPACITY TESTING BATTERIES 12

4.3 CHARGING BATTERIES 15

4.4 ENTERING BATTERY DATA 18

4.5 USING THE ONE MODE OF OPERATION 20

4.6 RESETTING THE TS25 UPGRADE 20

4.7 DISPLAY MNEMONICS 22

4.8 ERROR CODES 23

5 CALIBRATION 25

Printed On : 02/09/15

MB/TS25 PC211 UPGRADE Battery Charger

Operators Manual

5.1 EQUIPMENT REQUIRED 25

5.2 PERFORMANCE CHECKING 25

5.3 RE-CALIBRATION 26

5.4 CALIBRATION PROBLEMS 28

5.5 CALIBRATION EQUIPMENT CONNECTIONS 29

6 ROUTINE MAINTENANCE 30

6.1 INTERNAL BATTERY REPLACEMENT 30

7 BATTERY LIBRARY 31

7.1 RETRIEVING A LIBRARY ITEM 31

7.2 ENTERING OR MODIFYING A LIBRARY ENTRY 31

8 DEFAULT BATTERY LIBRARY 32

9 SPECIFICATIONS 42

10 PRODUCT DISPOSAL INSTRUCTIONS 43

1 Manual Revision History

Rev Date Description

0 12-02-2008 First Written

1 10-03-2009 Removed Warranty Section. Added New Battery Details To Library.

2 24-11-2014 Changed drawings so that an actual TS25 model is shown.

Printed On : 02/09/15

MB/TS25 PC211 UPGRADE Battery Charger

Operators Manual

2 TS25 PC211 UPGRADE DESCRIPTION

2.1 GENERAL NOTES

You have chosen to have your TS25 Model battery charger analyser upgraded to a TS25 (UPGRADE) Model.

The upgrade involves the removal of the antiquated processor board (PC200) and the separate display board (PC204) to the new PC211 combined display and processor board.

This upgrade extends the life cycle of your equipment by employing a fully supported processor unit with higher accuracy speed and functionality.

Some TS25 units will be also be able to benefit from the upgrades ability to increase the charging current from 10A to 12A (24A in one mode).

Operation of the unit is predominantly the same but there are differences because of the extended functionality. It is important that this manual is read carefully before undertaking control of the unit to establish the minor differences and how to employ them.

2.2 DIFFERENCES

 When accessing data entry functions the STOP key can be pressed to ABORT the data

entry mode.

 The library has been modified to list the standard set of batteries used by the UK MOD.

Check the data with manufacturers data sheets before using any data library entries.

 Accessing constant voltage and constant current charging modes are no longer done via

the library number. Use the PROC key to set the charge mode. This is also preserved with the library data.

 Automatic calibration checks to ensure that wrongly entered values are not used, which

could potentially damage the battery or unit.

 All process terminations are highlighted with an “E” number to indicate to the operator

why a capacity test or charge has stopped.

 Start and run-time checks are employed to ensure that wrongly entered data does not

make the unit perform outside of its capabilities, the run—time checks also test for battery disconnection while being processed, wrongly connected battery and checks for possible internal faults. Extra runtime checks are done to ensure that both cables are connected when used in ONE mode.

 The unit now employs 12 bit Analogue to Digital conversion devices which have

dramatically improved its stability and accuracy.

 Ability to view the firmware revision and internal resets can be accessed by the keypad.

 The ONE mode of operation where both channels can be connected in parallel to double

charge or discharge rates has been simplified.

Printed On : 02/09/15

MB/TS25 PC211 UPGRADE Battery Charger

Operators Manual

3 CONTROLS AND INDICATORS

Printed On : 02/09/15

AUDIBLE ALARM

MUTE

EXTD

ENTR

DISP DATA

A SET PROC

V SETTEST BATT

CHRG T SET

START

STOP

EXTD

ENTR

DISP DATA

A SET PROC

V SETTEST BATT

CHRG ONE T SET

START

STOP

VOLTS TIME

AMPS

TEST

END ONE

VOLTSTIME

AMPS

TEST

END

ALARM

MEM

Bxx

OFF

MEM

Bxx

OFF

MEM

Bxx

OFF

MEM

Bxx

OFF

I N T E L L I G E N T C H A R G I N G

CHARGE

TRIP

ANALYSER

TRIP

MAINS

POWER

BATTERY 'B'BATTERY 'A'

A CHANNEL DISPLAY

B CHANNEL DISPLAY

POWER SWITCH

AC POWER FUSE & INLET

B CHANNEL DATA

ENTRY KEYPAD

A CHANNEL DATA

ENTRY KEYPAD

CHANNEL A POSITIVE

BATTERY LEAD CONNECTOR

CHANNEL A NEGATIVE

BATTERY LEAD CONNECTOR

CHANNEL B NEGATIVE

BATTERY LEAD CONNECTOR

CHANNEL B POSITIVE

BATTERY LEAD CONNECTOR

CHANNEL A SAFETY CIRCUIT BREAKERS

CHANNEL B SAFETY CIRCUIT BREAKERS

MB/TS25 PC211 UPGRADE Battery Charger

Operators Manual

3.1DISPLAY

 NUMERIC DISPLAY

o Voltage is displayed in volts to a resolution of 0.1V

o Current is displayed in Amperes to a resolution of

0.1A

o Capacity test time is displayed in minutes to a

resolution of 1 minute.

o Charge time is displayed in hours to a resolution of

0.1H (One tenth)

o Battery efficiency is displayed in percent to a

resolution of 1%.

 NUMERIC DISPLAY INDICATORS

o VOLTS illuminated means voltage is being displayed

or entered.

o AMPS illuminated means current is being displayed

or entered.

o TIME illuminated means time is being displayed or

entered.

o % Illuminated means that battery efficiency is

being displayed.

o TEST illuminated means that the unit is set to

capacity test mode otherwise it is set to charge mode.

o END illuminated means that the unit is stopped.

o ALARM illuminated means that the unit has just

stopped and the alarm has sounded.

o ONE illuminated means that ONE mode has been

selected and the paralleling leads must be used.

Printed On : 02/09/15

ALARM

CHANNEL A NUMERIC DISPLAY CHANNLE B NUMERIC DISPLAY

CHANNEL A NUMERIC DISPLAY MODE INDICATOR CHANNEL B NUMERIC DISPLAY MODE INDICATOR

ILLUMINATED IF CAPTEST SELECTED ILLUMINATED IF CHANNEL B CAPTEST MODE IS SELECTED

ILLUMINATED IF THE CHARGER ALARM HAS SOUNDED

ILLUMINATED IF CHANNEL A IS STOPPED ILLUMINATED IF CHANNEL B IS STOPPED

ILLUMINATED IF THE "ONE" MODE OF OPERATION IS SELECTED

MB/TS25 PC211 UPGRADE Battery Charger

Operators Manual

3.2 POWER SWITCH

Operation of this switch will either apply or remove the ac inlet power from the TS25 UPGRADE

WARNING

AVOID REMOVING THE POWER FROM THE UNIT WHILE THE UNIT IS

PERFORMING A CAPACITY TEST OR CHARGE.

3.3 AUDIBLE ALARM

When a charge or capacity test has completed or stopped in error the audible alarm will sound until the MUTE or STOP key is pressed.

3.4 CHARGE & CAPACITY TEST CIRCUIT BREAKERS

The circuit breakers are fitted to prevent high currents from being driven into the battery or into the unit should a fault condition occur. Always ensure that the circuit breaker is in the ON position before starting a charge or capacity test.

WARNING

NEVER SWITCH THE CIRCUIT BREAK TO ON WHEN THE UNIT IS PERFORMING

A CHARGE OR CAPACITY TEST AS SEVERE DAMAGE MAY OCCUR TO THE

BATTERY OR THE TS25 UPGRADE

ALWAYS PRESS STOP FIRST

If the circuit breaker operates during a charge immediately press STOP on BOTH charger channels and remove power from the unit and disconnect the battery.

Operation of the circuit breaker is an indication of a fault and the unit will need to be checked before use.

3.5 BATTERY CONNECTORS

The battery terminal are where the supplied leads are connected to the TS25 UPGRADE. It is recommended that replacement leads are always purchased from Intelligent Charging.

Printed On : 02/09/15

MB/TS25 PC211 UPGRADE Battery Charger

Operators Manual

3.6 KEYBOARD

Each keypad on the unit controls only information for that channel, except when the unit is put into ONE mode both keypads control the ONE mode of operation. The only difference is that if a data entry function is invoked in the channel B keypad the data entry will always have to be performed on the right hand keypad. There are 16 keys on each keypad and each key performs a particular function depending if the channel is running or stopped.

3.6.1 STOPPED KEY MAPPING

Increases Display Brighness

Reduces Display Brightness

Selects CHARGE MODE

Selects CAPACITY TEST MODE

2 X To Save Battery Data Into The LIBRARY

Selects A Battery From The LIBRARY

2 X Reset Parameters In The Unit

Cycles Through Displayed Data

Briefly Displays Battery Data

Enters The Battery AMPS

Enters The Battery VOLTS

Enters The Battery TIME

Starts CHARGE/CAPACITY TEST

Clears The Display And Alarm

On CHANNEL A (ONE) Selects ONE Mode

On CHANNEL B (MUTE) Stops The Audible Alarm

Enters The Battery MODE

EXTD

ENTR

DISP DATA

A SET PROC

V SETCHRG BATT

TEST ONE T SET

START

STOP

3.6.2 RUNNING KEY MAPPING

Increases Display Brighness

Reduces Display Brightness

2 X To Initiate CALIBRATION

Briefly Displays Battery Number

Cycles Through Displayed Data

Briefly Displays Battery Data

Breifly Displays The Battery AMPS

Breifly Displays The Battery VOLTS

Briefly Displays The Battery TIME

Manually STOPS The CHARGE/CAPACITY TEST

Breifly Displays The Battery MODE

EXTD

ENTR

DISP DATA

A SET PROC

V SETCHRG BATT

TEST ONE T SET

START

STOP

Note keys that have no comments against them do nothing while RUNNING

Printed On : 02/09/15

MB/TS25 PC211 UPGRADE Battery Charger

Operators Manual

4 USING THE TS25 UPGRADE

4.1 CONNECTING BATTERIES

For all methods of use of the battery charger the battery to be tested or charged must only be connected when the charger is either:

SWITCHED OFF

SWITCHED ON AND END LAMP ILLUMINATED

Connecting a battery while the charge is operational would damage the equipment, and possible draw an electrical arc that, may cause an explosion from the venting gases being emitted from the battery.

Care must also be executed in ensuring that the bared ends of the battery leads do not come in contact with the metalwork of the charger as this may also cause electrical arcing and or explosion risk.

WARNING

THE BATTERY SHOULD NEVER BE CONNECTED OR DISCONNECTED FROM THE

UNIT WHEN A CHARGE OR TEST IS IN PROGRESS AS ARCING CAN OCCUR

CAUSING AN EXPLOSION FROM GASSES VENTING FROM BATTERIES BEING

PROCESSED

THE BATTERY SHOULD ALWAYS BE ISOLATED FROM ANY EQUIPMENT

BEFORE BEING CONNECTED

Stray ground loops between the attached equipment and the TS25 UPGRADE could cause catastrophic damage to the unit and the attached equipment.

The battery or batteries must be connected to the TS25 UPGRADE as shown in the following diagram: -

Printed On : 02/09/15

MB/TS25 PC211 UPGRADE Battery Charger

Operators Manual

SINGLE OR TWIN CHANNEL BATTERY CONNECTION

Printed On : 02/09/15

AVIATION BATTERY

BATTERY #1

BATTERY #2

MUTE

EXTD

ENTR

DISP DATA

A SET PROC

V SETTEST BATT

CHRG T SET

START

STOP

EXTD

ENTR

DISP DATA

A SET PROC

V SETTEST BATT

CHRG ONE T SET

START

STOP

VOLTS TIME

AMPS

TEST

END ONE

VOLTSTIME

AMPS

TEST

END

ALARM

MEM

Bxx

OFF

MEM

Bxx

OFF

MEM

Bxx

OFF

MEM

Bxx

OFF

I N T E L L I G E N T C H A R G I N G

CHARGE

TRIP

ANALYSER

TRIP

MAINS

POWER

BATTERY 'B'BATTERY 'A'

MB/TS25 PC211 UPGRADE Battery Charger

Operators Manual

BATTERY CONNECTION WHEN USING “ONE” MODE OF OPERATION

Printed On : 02/09/15

AVIATION BATTERY

MUTE

EXTD

ENTR

DISP DATA

A SET PROC

V SETTEST BATT

CHRG T SET

START

STOP

EXTD

ENTR

DISP DATA

A SET PROC

V SETTEST BATT

CHRG ONE T SET

START

STOP

VOLTS TIME

AMPS

TEST

END ONE

VOLTSTIME

AMPS

TEST

END

ALARM

MEM

Bxx

OFFIO

MEM

Bxx

OFFIO

MEM

Bxx

OFFIO

MEM

Bxx

OFFIO

I N T E L L I G E N T C H A R G I N G

CHARGE TRIP

ANALYSER TRIP

MAINS POWER

BATTERY 'B'BATTERY 'A'

MB/TS25 PC211 UPGRADE Battery Charger

Operators Manual

4.2 CAPACITY TESTING BATTERIES

The main purpose of a capacity test is to establish that a battery under test can maintain current output as specified by its ampere hour rating above a certain terminal voltage.

As a rule of thumb a battery will maintain an output voltage 5/6ths above its terminal voltage for one hour if discharged at its ampere hour rating. A battery that can maintain this is considered 100% or more of its rated capacity.

For example a 24V 20 A/H battery would be capacity tested at 20A for one hour and have the voltage end point set to 20V. If after a one hour discharge at 20A the battery terminal voltage was greater than 20V the battery would be considered at least 100% efficient.

Intelligent Charging do not make any recommendations on what point a battery is considered not efficient enough to be used, although a rule of thumb is that a battery less than 80% should be discarded where it it's use is considered critical.

The TS25 UPGRADE has two capacity test modes: -

 Perform a capacity test only to the time period specified.

This mode will auto terminate the process if either the battery voltage reaches the voltage end point, or if the total capacity test time is achieved. At the end of the test the TS25 UPGRADE will report a percentage of 100% or less depending on why the capacity test was terminated.

 Perform a capacity test until the final voltage is reached.

This mode will perform a capacity test until the voltage end point is reached. At the end of test the TS25 UPGRADE will report a percentage, which is the true capacity of the battery, which may be more than 100%. This method is sometimes employed so that records of battery deterioration over time or use can be monitored.

4.2.1 MANUAL CAPACITY TEST

To perform a manual capacity test four parameters have to be programmed. These are: -

 Capacity test current (Amperes).  Capacity test time (Minutes)  Capacity test voltage end point (Volts)  Capacity test mode (Time or Volts)

To program these values the TS25 UPGRADE needs to powered and not performing either a capacity test or charge on the channel to be used.

Printed On : 02/09/15

MB/TS25 PC211 UPGRADE Battery Charger

Operators Manual

Press ASET to change the capacity test amperes.

Press VSET to change the capacity test voltage end point.

Press TSET to change the capacity test duration.

Press PROC to change the capacity test mode.

See section 4.4 ENTERING BATTERY DATA for details on how to enter the required parameters.

4.2.2 LIBRARY CAPACITY TEST

To perform a capacity test from the library the library number has to be selected first. To select the library number the following procedure has to be performed.

Press the BATT key. The display will show the current library item selected and the rightmost digit will be flashing. Enter the library number by using the  and  keys and the EXTD key to move to the next digit. Only library numbers 01 to 99 can be selected.

The TS25 UPGRADE needs to be placed in capacity test mode by pressing TEST and ensuring that the visual indicator TEST is illuminated.

4.2.3 REVIEWING CAPACITY TEST PARAMETERS

Once these values have been programmed into the unit they can be reviewed by selecting the DISP key to cycle the display between VOLTS, AMPS,TIME and

% and then pressing the DATA key. This display will show the values

programmed in and the corresponding indicator will flash. Note when the % indicator is lit there is no data to display. To check the capacity test mode simple press the TEST key and the current capacity test mode will be displayed TIM or

VOL.

4.2.4 STARTING A CAPACITY TEST

Before a capacity test is performed for the first time it is important that the parameters are reviewed using the reviewing feature above as incorrect parameters could damage the battery under test.

Once satisfied that he data is correct the battery to undergo the capacity test must be connected to the unit. Care must be taken when connecting batteries which are not fitted with non reversible connectors, i.e. where the use of crocodile clamps are implemented, as damage to the battery and or unit may occur if a capacity test is started with reverse connection.

To begin the capacity test press START. The display will momentarily display

RUN, the END light will extinguish and it will then display battery voltage. During

the normal capacity test process the DISP key may be pressed to cycle the display between VOLTS, AMPS,TIME and %. The DATA key can also be pressed to review the parameters programmed in for the current test under progress. If the TEST key is pressed this will briefly display the current test mode.

Printed On : 02/09/15

MB/TS25 PC211 UPGRADE Battery Charger

Operators Manual

4.2.5 STOPPING A CAPACITY TEST

At any time during the capacity test the process can be terminated by simply pressing the STOP key. When the STOP key is pressed the process will be terminated immediately and the display will show END and the END led will remain illuminated.

The display will remain in this state until either MUTE of STOP is pressed.

4.2.6 CAPACITY TEST AUTO TERMINATE

If the capacity test has been programmed to auto terminate on time then the process will automatically stop when either the battery voltage falls below the voltage end point or when the capacity test time has elapsed.

If the capacity test has been programmed to auto terminate only when the voltage falls below the voltage end point, then the process will stop when the battery voltage falls below the voltage end point.

In both cases the capacity test process will terminate immediately, the audible alarm will sound and the ALARM and END lights will illuminate and the display will show the reason for terminating the process.

To clear the alarm the MUTE or STOP key must be pressed. Upon these being pressed the display will show the actual efficiency percent value.

Process termination codes:

E 1 The process time is complete.

E 2 Battery voltage has reached the voltage end point.

Printed On : 02/09/15

+ 30 hidden pages

Intelligent Charging MB/TS25 PC211 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual