Intelligent Charging TS25 MKII, TS25-BAS1-KIT, TS25-BAS1-CAN-240 Operator's Manual

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240

Battery charger/analyser : Operators Manual

Printed On : 12/06/17

DANGER

Disconnect the mains supply before removing this cover

MEM

Bxx

ON

OFFIO

MEM

Bxx

ON

OFFIO

MEM

Bxx

ON

OFFIO

MEM

Bxx

ON

OFFIO

VOLTS TIME

AMPS

TEST

END ONE

VOLTSTIME

AMPS

TEST

END

%

ALARM

POWER SWITCH

POWER SWITCHPOWER SWITCH

POWER SWITCH

KEEP AIRFLOW C LEAR

KEEP AIRFLOW C LEARKEEP AIRFLOW C LEAR

KEEP AIRFLOW C LEAR

10cm

10cm10cm

10cm

KEEP AIRFLOW CLEAR

KEEP AIRFLOW CLEARKEEP AIRFLOW CLEAR

KEEP AIRFLOW CLEAR

10cm

10cm10cm

10cm

EXTD

ENTR

DISP DATA

A SET PROC

V SETCHRG BATT

TEST ONE T SET

START

STOP MUTE

EXTD

ENTR

DISP DATA

A SET PROC

V SETCHRG BATT

TEST T SET

START

STOP

TS25 MKII

TS25-BAS1-KIT

TS25-BAS1-CAN-240

Battery Charger/Analyser

Operators Manual

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240

Battery charger/analyser : Operators Manual

TABLE OF CONTENTS

1 MANUAL REVISION HISTORY 4

2 TS25 MKII DESCRIPTION 5

3 CONTROLS AND INDICATORS 7

3.1 DISPLAY 8

3.2 POWER SWITCH 9

3.3 AUDIBLE ALARM 9

3.4 CHARGE & CAPACITY TEST CIRCUIT BREAKERS 9

3.5 BATTERY CONNECTORS 9

3.6 KEYBOARD 10

4 USING THE TS25 MKII 11

4.1 CONNECTING BATTERIES 11

4.2 CAPACITY TESTING BATTERIES 14

4.3 CHARGING BATTERIES 17

4.4 ENTERING BATTERY DATA 20

4.5 USING THE ONE MODE OF OPERATION 22

4.6 RESETTING THE TS25 MKII 22

4.7 DISPLAY MNEMONICS 24

4.8 ERROR CODES 25

5 CALIBRATION 27

5.1 EQUIPMENT REQUIRED 27

5.2 PERFORMANCE CHECKING 27

5.3 RE-CALIBRATION 28

5.4 CALIBRATION PROBLEMS 29

5.5 CALIBRATION EQUIPMENT CONNECTIONS 30

6 ROUTINE MAINTENANCE 31

Printed On : 12/06/17

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240

Battery charger/analyser : Operators Manual

6.1 INTERNAL BATTERY REPLACEMENT 31

7 BATTERY LIBRARY 32

7.1 RETRIEVING A LIBRARY ITEM 32

7.2 ENTERING OR MODIFYING A LIBRARY ENTRY 32

8 DEFAULT BATTERY LIBRARY 33

9 SPECIFICATIONS 43

10 PRODUCT DISPOSAL INSTRUCTIONS 44

11 PRODUCT WARRANTY 45

Printed On : 12/06/17

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240

Battery charger/analyser : Operators Manual

1 Manual Revision History

Rev Date Description

0 08-03-2007 FIRST WRITTEN

1 01-11-2007 Detail Changes

2 26-02-2008 Added calibration procedures and maintenance.

3 05-03-2008 Added battery connection diagrams

4 11-03-2008 Added Controls & Indicators Section

5 11-05-2008 Added Enersys batteries 9750D0740 & 0744 to library. More error fault codes

added.

6 13-06-2008 Added new error code where if current fails to be driven then warning 14 occurs.

7 19-06-2008 Added text about warning 15 for detection of battery voltage greater than target

while constant voltage charging.

8 25-06-2008 Changed library entry 61 to correct part No.

9 02-07-2008 Added comment on suitability of capacity test parameters for Enersys 9750-0744

Battery

10 12-08-2008 Corrected position of CHRG & TEST on keypad legend.

11 26-01-2009 Added Enersys 9750D0730 to built in library

12 30-09-2014 Corrected annotation on keypad diagram CHRG and TEST reversed.

13 21-11-2014 Reworded the data entry paragraphs in section 4.4 to make clearer.

14 20-01-2015 Graphic images of TS25 amended as they show CHRG & TEST reversed.

15 21-07-2015 Formatting changes.

16 23-09-2015 Corrected use of “efficiency” where should read “capacity”. Corrected resolution for

capacity test time.

Printed On : 12/06/17

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240

Battery charger/analyser : Operators Manual

2 TS25 MKII DESCRIPTION

The TS25 MKII Dual Channel Battery Charger / Analyser is an electronically controlled combined universal battery charging unit with built in battery analysing capabilities. It is housed in a heavy-duty metal enclosure designed to free stand on a workbench. As it is supplied it is configured for use from a standard 240V 50/60Hz supply.

Equipment control is via an interactive numeric display and led state indicators. Data entry is via two 16-key keypads. Each channel displayed data and data entry is independent of the status of the other channel. So new processes can be set up even when the other channel is in the middle of a charge or capacity test.

Battery data is stored internally in the unit in battery-backed memory. A list of commonly used batteries is included along with the accepted charging and testing data. The operator can extend or modify this list by entering the details of the battery to be included on the display and keyboard. The battery library data can be restored to the defaults by a special key sequence permitted via the keyboard.

Batteries are connected to the front of the unit by means of two individual heavy duty connectors. Connection to the battery has to be made via the appropriate connectors for that battery. Contact Intelligent-Charging for special lead sets made to order.

The TS25 MKII has extended operating capabilities compared to its predecessor the TS25. Maximum charge current has been increased to 12A per channel, and capacity testing still remains at 25A per channel.

The TS25 MKII still has paralleling mode where using a common paired cable both channels can be run in parallel to provide a charge capability of 24A and a capacity test capability of 50A.

There are two capacity test programs built into the unit and these can be selected via the configuration menu and capacity testing can be performed such that it will stop testing when a battery reached 100% or less, or alternately can carry on capacity testing until the battery reached the set termination threshold and thus reporting the actual battery capacity greater than 100%.

There are three charging modes built into the unit, for Lead Acid (Pb) constant voltage charging can be performed for a fixed period of time and for Nickel Cadmium (NiCd) constant current charging can be performed with termination on time and over voltage parameters, and also for Nickel Cadmium batteries a new charge mode which allows a constant current charge to be performed up until a voltage set point, where the charge will then continue charging until the additional time specified has passed.

Printed On : 12/06/17

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240

Battery charger/analyser : Operators Manual

The TS25 MKII contains the ability that will allow it to be calibrated by the end user. The equipment needed is a good 24V battery, an ammeter capable of reading up to 25A (or a shunt and milli-voltmeter combination) and a voltmeter capable of reading up to 30V. The re-calibration process only takes a few minutes and this is done without the need to access the interior of the TS25 MKII.

The TS25 MKII no longer supports deep discharge recovery mode. It is thought that if a battery requires this level of charge to "recover" it then the battery is not fit for use anyway and should be disposed of for re-cycling.

The TS25 MKII contains two hi flow rate fans to extract the heat energy generated internally when running in capacity test mode.

Printed On : 12/06/17

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240

Battery charger/analyser : Operators Manual

3 CONTROLS AND INDICATORS

Printed On : 12/06/17

A CHANNEL DISPLAY B CHANNEL DISPLAY

AUDIBLE ALARM

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 CHARGE SAFETY BREAKER

CHANNEL A CAPACITY TEST SAFETY CIRCUIT BREAKER

CHANNEL B CAPACITY TEST SAFETY CIRCUIT BREAKER

CHANNEL A CHARGE SAFETY CIRCUIT BREAKER

DANGER

Disconnect the

mains supply before

removing this cover

MEM

Bxx

ON

OFF

I

O

MEM

Bxx

ON

OFF

I

O

MEM

Bxx

ON

OFF

I

O

MEM

Bxx

ON

OFF

I

O

VOLTS TIME

AMPS

TEST

END ONE

VOLTSTIME

AMPS

TEST

END

%

ALARM

POWER SWITCH

KEEP AIRFLOW CLEAR

10cm

KEEP AIRFLOW CLEAR

10cm

EXTD

ENTR

DISP DATA

A SET PROC

V SETCHRG BATT

TEST ONE T SET

START

STOP MUTE

EXTD

ENTR

DISP DATA

A SET PROC

V SETCHRG BATT

TEST T SET

START

STOP

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240

Battery charger/analyser : Operators Manual

3.1 DISPLAY

• 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). Capacity test time is displayed in Minutes to a resolution of 1 Minute.

o Battery capacity 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 capacity 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 : 12/06/17

%

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

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240

Battery charger/analyser : Operators Manual

3.2 POWER SWITCH

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

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 MKII

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 MKII. It is recommended that replacement leads are always purchased from Intelligent Charging.

Printed On : 12/06/17

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240

Battery charger/analyser : 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

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 : 12/06/17

Increases Display Brighness

Reduces Display Brightness

Selects CAPACITY TEST MODE

Selects CHARGE 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

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240

Battery charger/analyser : Operators Manual

4 USING THE TS25 MKII

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

or

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 MKII could cause catastrophic damage to the unit and the attached equipment.

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

Printed On : 12/06/17

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240

Battery charger/analyser : Operators Manual

SINGLE OR TWIN CHANNEL BATTERY CONNECTION

Printed On : 12/06/17

AVIATION BATTERY

BATTERY #1

BATTERY #2

DANGER

Disconnect the

mains supply before

removing this cover

MEM

Bxx

ON

OFF

I

O

MEM

Bxx

ON

OFF

I

O

MEM

Bxx

ON

OFF

I

O

MEM

Bxx

ON

OFF

I

O

VOLTS TIME

AMPS

TEST

END ONE

VOLTSTIME

AMPS

TEST

END

%

ALARM

POWER SWIT CH

KEEP AIRFLOW CLEAR

10cm

KEEP AIRFLOW CLEAR

10cm

EXTD

ENTR

DISP DATA

A SET PROC

V SETCHRG BATT

TEST ONE T SET

START

STOP MUTE

EXTD

ENTR

DISP DATA

A SET PROC

V SETCHRG BATT

TEST T SET

START

STOP

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240

Battery charger/analyser : Operators Manual

BATTERY CONNECTION WHEN USING “ONE” MODE OF OPERATION

Printed On : 12/06/17

AVIATION BATTERY

DANGER

Disconnect the mains supply before removing this cover

MEM

Bxx

ON

OFFIO

MEM

Bxx

ON

OFFIO

MEM

Bxx

ON

OFFIO

MEM

Bxx

ON

OFFIO

VOLTS TIME

AMPS

TEST

END ONE

VOLTSTIME

AMPS

TEST

END

%

ALARM

POWER SWITCH

POWER SWITCHPOWER SWITCH

POWER SWITCH

KEEP AIRFLOW CLEAR

KEEP AIRFLOW CLEARKEEP AIRFLOW CLEAR

KEEP AIRFLOW CLEAR

10cm

10cm10cm

10cm

KEEP AIRFLOW CLEAR

KEEP AIRFLOW CLEARKEEP AIRFLOW CLEAR

KEEP AIRFLOW CLEAR

10cm

10cm10cm

10cm

EXTD

ENTR

DISP DATA

A SET PROC

V SETCHRG BATT

TEST ONE T SET

START

STOP MUTE

EXTD

ENTR

DISP DATA

A SET PROC

V SETCHRG BATT

TEST T SET

START

STOP

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240

Battery charger/analyser : 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 voltage5/6ths 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 MKII 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 MKII 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 MKII 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)

Printed On : 12/06/17

Intelligent Charging TS25 MKII, TS25-BAS1-KIT, TS25-BAS1-CAN-240 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual