CASC System TS25 MKII User manual

INTELLIGENT CHARGING
TS25 MKII Battery Charger Analyser Operator Manual
Doc: DWG1044-09-R14 TS25 MKII Operators manual.odt Page 1 of 46 Copyright Material of CasC Systems Ltd © 2015
Printed On : 02/02/15
TS25 MKII
BATTERY CHARGER/ANALYSER
OPERATORS MANUAL
DANGER
Disconn ect the
mains supply before
removing t his 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
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

INTELLIGENT CHARGING
TS25 MKII Battery Charger Analyser Operator 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 PO ER S ITCH 9
3.3 AUDIBLE ALARM 9
3.4 CHARGE & CAPACITY TEST CIRCUIT BREAKERS 9
3.5 BATTERY CONNECTORS 9
3.6 KEYBOARD 10
3 6 1 STOPPED KEY MAPPING 10
3 6 2 RUNNING KEY MAPPING 10
4 USING THE TS25 MKII 11
4.1 CONNECTING BATTERIES 11
4.2 CAPACITY TESTING BATTERIES 14
4 2 1 MANUAL CAPACITY TEST 14
4 2 2 LIBRARY CAPACITY TEST 15
4 2 3 REVIEWING CAPACITY TEST PARAMETERS 15
4 2 4 STARTING A CAPACITY TEST 15
4 2 5 STOPPING A CAPACITY TEST 16
4 2 6 CAPACITY TEST AUTO TERMINATE 16
4.3 CHARGING BATTERIES 17
4 3 1 MANUAL CHARGING 17
4 3 2 LIBRARY CHARGING 18
4 3 3 REVIEWING CHARGE PARAMETERS 18
4 3 4 STARTING A CHARGE 18
4 3 5 STOPPING A CHARGE 19
4 3 6 CHARGE PROCESS AUTO TERMINATE 19
4.4 ENTERING BATTERY DATA 20
4 4 1 SETTING CAPACITY TEST MODE 20
4 4 2 SETTING THE CHARGE MODE 20
4 4 3 ENTERING CURRENT DATA 20
4 4 4 ENTERING VOLTAGE DATA 21
4 4 5 ENTERING CAPACITY TEST TIME 21
4 4 6 ENTERING CHARGE TIME 21
4.5 USING THE ONE MODE OF OPERATION 22
4.6 RESETTING THE TS25 MKII 22
4 6 1 GENERAL PARAMETER DATA 22
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INTELLIGENT CHARGING
TS25 MKII Battery Charger Analyser Operator Manual
4 6 2 DEFAULT LIBRARY DATA 22
4 6 3 CALIBRATION PARAMETERS 23
4 6 4 SELECTING RESET MODE 23
4.7 DISPLAY MNEMONICS 24
4.8 ERROR CODES 25
5 CALIBRATION 27
5.1 EQUIPMENT REQUIRED 27
5.2 PERFORMANCE CHECKING 27
5 2 1 Charge Calibration Check: 27
5 2 2 Capacity Test Calibration Check 28
5.3 RE-CALIBRATION 28
5 3 1 Charge Re-Calibration: 28
5 3 2 Capacity Test Re-Calibration 29
5.4 CALIBRATION PROBLEMS 29
5.5 CALIBRATION EQUIPMENT CONNECTIONS 30
6 ROUTINE MAINTENANCE 31
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 ARRANTY 45
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INTELLIGENT CHARGING
TS25 MKII Battery Charger Analyser Operator 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
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INTELLIGENT CHARGING
TS25 MKII Battery Charger Analyser Operator 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 efficiency 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,
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INTELLIGENT CHARGING
TS25 MKII Battery Charger Analyser Operator Manual
where the charge will then continue charging until the additional time specified has
passed
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
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INTELLIGENT CHARGING
TS25 MKII Battery Charger Analyser Operator Manual
3 CONTROLS AND INDICATORS
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A CHANNEL DISPLAY B CHANNEL DISPLAY
AUDIBLE ALARM
POWER SWITCH
AC POWER FUSE& INLET
B CHANNEL DATA ENTRY KEYPAD
ACHANNEL 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
Disconnectthe
mainssupplybefore
removingthiscover
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
POWER SWITCH POWER SWITCH
POWER SWITCH
KEEP AIRFLOW CLEAR
KEEP AIRFLOW CLEAR KEEP AIRFLOW CLEAR
KEEP AIRFLOW CLEAR
10cm
10cm 10cm
10cm
KEEP AIRFLOW CLEAR
KEEP AIRFLOW CLEAR KEEP AIRFLOW CLEAR
KEEP AIRFLOW CLEAR
10cm
10cm 10cm
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

INTELLIGENT CHARGING
TS25 MKII Battery Charger Analyser Operator Manual
3.1 DISPLAY
•NUMERIC DISPLAY
oVoltage is displayed in volts to a resolution
of 0 1V
oCurrent is displayed in Amperes to a
resolution of 0 1A
oCapacity test time is displayed in minutes
to a resolution of 1 minute
oCharge time is displayed in hours to a
resolution of 0 1H (One tenth)
oBattery efficiency is displayed in percent to
a resolution of 1%
•NUMERIC DISPLAY INDICATORS
oVOLTS illuminated means voltage is being
displayed or entered
oAMPS illuminated means current is being
displayed or entered
oTIME illuminated means time is being
displayed or entered
o% Illuminated means that battery
efficiency is being displayed
oTEST illuminated means that the unit is set
to capacity test mode otherwise it is set to
charge mode
oEND illuminated means that the unit is
stopped
oALARM illuminated means that the unit has
just stopped and the alarm has sounded
oONE illuminated means that ONE mode has
been selected and the paralleling leads
must be used
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Printed On : 02/02/15
%
%
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

INTELLIGENT CHARGING
TS25 MKII Battery Charger Analyser Operator Manual
3.2 PO ER S ITCH
Operation of this switch will either apply or remove the ac inlet power from
the TS25 MKII
ARNING
AVOID REMOVING THE PO ER FROM THE UNIT HILE 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
ARNING
NEVER S ITCH THE CIRCUIT BREAK TO ON HEN THE UNIT IS
PERFORMING A CHARGE OR CAPACITY TEST AS SEVERE DAMAGE MAY
OCCUR TO THE BATTERY OR THE TS25 MKII
AL AYS 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
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INTELLIGENT CHARGING
TS25 MKII Battery Charger Analyser Operator 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
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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