Gill TCT-1000 User manual

NUMBER O01-1000 REVISION
D 7-8-16 Page 1of 10
TITLE TCT-1000 OPERATING INSTRUCTIONS
Teledyne Battery Products
1. INTRODUCTION
The TCT -1000 Battery Capacity Analyzer has been designed to perform automatic
capacity testing of 12 and 24 Volt lead-acid batteries. This unit is capable of accurately
measuring the capacity of a fully charged battery with a rating between 10 and 59 amp-
hours. It is self-contained and easy to operate.
The load tester will display, in percentage, the conformance to the battery’s one hour
rating.
2. SCOPE
This document provides instructions on how to calibrate and operate the TCT-1000
Battery Load Tester. The calibration instruction has been broken down into the following
categories:
•Calibrate Cutoff at 20.0 Volts
•Calibrate Cutoff at 10.0 Volts
•Calibrate Frequency
•Calibrate 24 Volt 10 Amp Setting
•Calibrate 24 Volt 50 Amp Setting
•Calibrate 12 Volt 10 Amp Setting
•Calibrate 12 Volt 50 Amp Setting
3. OPERATION PROCEDURE
3.1. Set Up
3.1.1. Before starting the capacity test, the battery should be fully charged per
manufacturer’s instructions.
3.1.2. The load tester must be located in an atmosphere that is free of combustible
material and gasses.
3.1.3. The POWER switch – see picture below, must be in the “OFF” position.
3.2. Operation
3.2.1. Connect the RED cable to the POSITIVE terminal and the BLACK cable to the
NEGATIVE terminal.
CAUTION
Wear SAFETY GLASSES whenever handling batteries

NUMBER O01-1000 REVISION
D 7-8-16 Page 2of 10
TITLE TCT-1000 OPERATING INSTRUCTIONS
Teledyne Battery Products
3.2.2. Turn the POWER switch “ON”
3.2.3. Set the one hour capacity (see Tables 1and 2) using the switches
located under the RATING display window.
3.2.4. Press the button located on the right of the tester above the GILL logo.
3.2.5. After the battery has been discharged to the appropriate end voltage (10V for a
12V battery and 20V for a 24V battery), the unit will terminate the testing and
the CAPACITY window will display the actual capacity in percentage of the one
hour rating of the battery.
3.2.6. Turn the POWER switch “OFF” and disconnect the cables from the battery
terminals.
3.2.7. The battery must meet the minimum requirements specified by the
manufacturer.
3.2.8. Recharge the battery before placing it in service.

NUMBER O01-1000 REVISION
D 7-8-16 Page 3of 10
TITLE TCT-1000 OPERATING INSTRUCTIONS
Teledyne Battery Products
Table 1
VRLA Battery Capacity Ratings
Battery Type
Battery Voltage
(V)
One Hour Rate
(A)
30 Minute Rate
(A)
G-242S 24 10 17
7025-20 12 20 32
7035-28 12 28 45
7243-14 24 14 22
7243-16 24 16 25
7243-16T 24 14 22
7641-20 24 20 35
7639-25 24 25 40
7639-27 24 27 45
7639-30LT 24 30 50
7639-34 24 34 55
7638-36 24 36 63
7638-38HT 24 38 63
7638-44/T 24 44 70
7638-48P 24 48 75
7638-53 24 53 80
7407-28 24 28 45

NUMBER O01-1000 REVISION
D 7-8-16 Page 4of 10
TITLE TCT-1000 OPERATING INSTRUCTIONS
Teledyne Battery Products
Table 2
Flooded Battery Capacity Ratings
*
Note: 30 minute rate must be used for these battery types.
Battery Type Battery Voltage
(V) One Hour Rate (A) 30 Minute Rate (A)
G-25 12 18 30
G-35 and 35M 12 23 40
G-240* 24 8 13
G-241* 24 8 13
G-242 24 10 17
G-243 24 10 17
G-244 24 18 30
G-245 24 18 30
G-246 24 19 32
G-247 24 19 32
G-639E/C 24 24 40
G-641E 24 18 30
G-6381E/C 24 43 70
G-640C 24 14 25
GE-50E/C 24 31 55
GE-51E/C 24 22 35
GE-54E/C 24 10 16
G-88 12 65 108

NUMBER O01-1000 REVISION
D 7-8-16 Page 5of 10
TITLE TCT-1000 OPERATING INSTRUCTIONS
Teledyne Battery Products
4. CALIBRATION
4.1. TEST EQUIPMENT
4.1.1. TCT-1000 Battery Capacity Analyzer Test
Fixture: Kelly Aerospace P/N 20758 Test
Fixture (Pictured at right)
4.1.2 Battery: 24 Volt, fully charged per
Manufacturer’s recommendation
4.1.3 Battery: 12 Volt, fully charged per manufacturers recommendation
4.1.4 DC Power Supply: Capable of at lease 24 volts and 20 amps with course and
fine voltage adjustments
4.1.5 Battery Chargers: 4.1.5 (a) or 4.1.5 (b)
a. (1) 12 Volt Charger & (1) 24 Volt Charger
b. (1) At least one DC Power Supply capable of 28 volts or any other means for
charging batteries to manufacturer’s recommendation.
4.1.6 Calibrated FLUKE 87 or Equivalent Multi-meter with DC volts & milli-volts
ranges (DVM)
4.1.7 Stop watch
4.1.8 Small common screwdriver for adjusting P1 through P4 calibration pots
4.1.9 Miscellaneous hand tools for connecting Test Fixture to batteries and power
supply.
4.1.10 Photocopy of Page 8 showing Records table with blank values in Measured
Value, Pass & Fail columns
5 CALIBRATION PROCEDURE
5.1 Connections
a. Connect 20758 test fixture to 24 volt 20 amp power supply by connecting the red
lead to positive terminal of power supply and the black lead to the negative
terminal of power supply.
b. Plug the connector for the 20758 test fixture into the TCT-1000 connector.
c. Connect the DVM leads to the power supply leads.
d. Record the DVM calibration expiration date in the blank below the Records table.
5.2 20.0 Volt Cutoff
a. It may be necessary to repeat procedure 5.2. & 5.3 until all values fall within
range. When this is necessary there will be interim values that do no need to be
recorded in the Records section. The “final” readings to be recorded are the
readings in which no adjustment is required to complete Procedure 5.3.
b. Set the DVM to DC-Volts and a range capable of measuring up to 22 volts.
c. Turn Power Switch off.
d. Adjust power supply until DVM reads 21.0 volts.

NUMBER O01-1000 REVISION
D 7-8-16 Page 6of 10
TITLE TCT-1000 OPERATING INSTRUCTIONS
Teledyne Battery Products
e. Adjust the current limiting for the power supply to 20 amps or more.
b. Turn Power Switch on.
c. 24 VOLT LED illuminates.
d. READY LED illuminates.
e. RATING display should be flashing at 10.
f. Press START button (hold briefly for test to start, then release START button).
g. READY LED extinguishes.
h. TESTING LED illuminates.
i. RATING LED should stop flashing and continue to read 10.
j. Wait until CAPACITY display reads 001 or higher.
k. Slowly decrease power supply voltage while monitoring the DVM.
l. TESTING LED should extinguish and the COMPLETE LED illuminate between
19.80 volts & 20.20 volts (as indicated by the DVM).
m. If that voltage falls below 19.80 volts turn P4 Clock-wise (CW), if that voltage is
above 20.20 volts turn P4 Counter-clockwise (CCW).
n. If P4 required adjustment repeat procedure 5.2 until no adjustment is required.
o. Enter the final voltage reading in the “Measured Value” column in the “20.0 Volt
Cutoff” row in the Records table.
5.3 10.0 Volt Cutoff
a. Turn Power Switch off.
b. Adjust power supply until DVM reads 11.0 volts.
c. Turn Power Switch on.
d. 12 VOLT LED illuminates.
e. READY LED illuminates.
f. RATING display should be flashing at 10.
g. Press START Button (hold briefly for test to start, then release START button).
h. READY LED extinguishes.
i. TESTING LED illuminates.
j. RATING LED should stop flashing and continue to read 10.
k. Wait until CAPACITY display reads 001 or higher.
l. Slowly decrease power supply voltage while monitoring the DVM.
m. TESTING LED should extinguish and the COMPLETE LED illuminate between
9.90 volts & 10.10.10 volts (as indicated by the DVM).
n. If that voltage falls below the 9.90 volts turn P4 CW, if that voltage is above 10.10
volts turn P4 CCW.
o. If P4 required adjustment repeat procedures 5.2. & 5.3 until no adjustment is
required.
p. Enter the final voltage reading in the “Measured Value” column in the “10.0 Volt
Cutoff” row in the Records table.
5.4 Frequency

NUMBER O01-1000 REVISION
D 7-8-16 Page 7of 10
TITLE TCT-1000 OPERATING INSTRUCTIONS
Teledyne Battery Products
a. It may be necessary to repeat procedure 5.4 until all values fall within range.
When this is necessary there will be interim values that do no need to be
recorded in the Records section. The “final” readings to be recorded are the
readings in which no adjustment is required when calibration finishes Procedure
5.4.
b. Turn Power Switch off.
c. Adjust power supply to 24 Volts.
d. Turn Power Switch on.
e. 24 VOLT LED illuminates.
f. READY LED illuminates.
g. RATING display should be flashing at 10.
h. Press START button (hold briefly for test to start, then release START button).
i. READY LED extinguishes.
j. TESTING LED illuminates.
k. RATING LED should stop flashing and continue to read 10.
l. Wait until CAPACITY display reads 001 or higher.
m. With a stopwatch, measure the time interval for the CAPACITY display to increase
by 10 units. For example, measure the amount of time from the instant the display
changes to 003 until the instant it changes to 013.
n. The period of the interval should be 357 to 363 seconds.
o. If that time falls below the 357 seconds turn P1 CCW, if that time is above 363
seconds turn P1 CW.
p. If P1 has been adjusted repeat procedure 5.4 until no adjustment is required.
q. Enter the final time in the “Measured Value” column in the “Frequency” row in the
Records table.
r. Turn Power Switch off.
5.5 Connections
a. Plug the DVM leads into the 20758 test fixture terminal jacks. The positive lead in
the red jack and the negative lead in the black jack.
b. Plug the connector for the 20758 test fixture into the TCT-1000 connector.
5.6 24 Volt 10 Amp Setting
a. It may be necessary to repeat procedure 5.6, 5.7, 5.8 & 5.9 until all values fall
within range. When this is necessary there will be interim values that do no need
to be recorded in the Records section. The “final” readings to be recorded are
the readings in which no adjustment is required when calibration finishes
Procedure 5.9.
b. Connect 20758 test fixture to a fully charged 24-volt battery by connecting the red
lead to the positive terminal and the black lead to the negative terminal.
c. Set the DVM to DC-Volts and a range capable of measuring up to 20 mV.
d. Turn Power Switch on.

NUMBER O01-1000 REVISION
D 7-8-16 Page 8of 10
TITLE TCT-1000 OPERATING INSTRUCTIONS
Teledyne Battery Products
e. 24 VOLT LED illuminates.
f. READY LED illuminates.
g. RATING display should be flashing at 10.
h. Press START button (hold briefly for test to start, then release START button).
i. READY LED extinguishes.
j. TESTING LED illuminates.
k. RATING LED should stop flashing and continue to read 10.
l. DVM should read 9.8 mV – 10.2 mV.
m. If it reads within range, record the final value read in the “Measured Value”
column in the “24 Volt 10 Amp Setting” row in the Records table.
n. If the reading is below 9.8 mV turn P3 CW until it reads 10.0 mV, if that voltage is
above 10.2 mV turn P3 CCW until it reads 10.0 mV.
o. Turn Power Switch off.
5.7 24 Volt 50 Amp Setting
a. Set the DVM to DC-Volts and a range capable of measuring up to 100 mV.
b. Turn Power Switch on.
c. 24 VOLT LED illuminates.
d. READY LED illuminates.
e. RATING display should be flashing at 10.
f. Using left ▲ to set 10’s digit, set RATING display to 50.
g. Press START button (hold briefly for test to start, then release START button).
h. READY LED extinguishes.
i. TESTING LED illuminates.
j. RATING LED should stop flashing and continue to read 50.
k. DVM should read 49.6 mV – 50.4 mV.
l. If it reads within range, record final value read in the “Measured Value” column in
the “24 Volt 150 Amp Setting” row in the Records table.
m. If the reading is below 9.8 mV turn P2 CW until it is within range, if that voltage is
above 50.4 mV turn P2 CCW until it is within range.
n. Turn Power Switch off.
o. If P2 has been adjusted go back and repeat procedures 5.6 & 5.7 until no
adjustment is required.
5.8 12 Volt 10 Amp Setting
a. Connect 20758 test fixture to a fully charged 12 volt battery by connecting the red
lead to the positive terminal and the black lead to the negative terminal.
b. Set the DVM to DC-Volts and a range capable of measuring up to 20 mV.
c. Turn Power Switch on.
d. 12 VOLT LED illuminates.
e. READY LED illuminates.
f. RATING display should be flashing at 10.
g. Press START button (hold briefly for test to start, then release START button).

NUMBER O01-1000 REVISION
D 7-8-16 Page 9of 10
TITLE TCT-1000 OPERATING INSTRUCTIONS
Teledyne Battery Products
h. READY LED turns off.
i. TESTING LED extinguishes.
j. RATING display should stop flashing & continue to read 10.
k. DVM should read 9.8 mV – 10.2 mV.
l. If it reads within range, record final value read in the “Measured Value” column in
the “12 Volt 10 Amp Setting” row in the Records table.
m. If the reading is below 9.8 mV turn P3 CW until it is within range, if that voltage is
above 10.2 mV turn P3 CCW until it is within range.
n. Turn Power Switch off.
o. If P3 has been adjusted go back and repeat procedures 5.6, 5.7 & 5.8 until no
adjustment is required.
5.9 12 Volt 50 Amp Setting
a. Set the DVM to DC-Volts and a range capable of measuring up to 100 mV.
b. Turn Power Switch on.
c. 12 VOLT LED illuminates.
d. READY LED illuminates.
e. RATING display should be flashing at 10.
f. Using left ▲ to set 10’s digit, set RATING display to 50.
g. Press START button (hold briefly for test to start, then release START button).
h. READY LED turns off.
i. TESTING LED extinguishes.
j. RATING display should stop flashing & continue to read 50.
k. DVM should read 49.6 mV – 50.4 mV.
l. If it reads within range, record final value read in the “Measured Value” column in
the “12 Volt 50 Amp Setting” row in the Records table.
m. If the reading is below 49.6 mV turn P2 CW until it is within range, if that voltage
is above 50.4 mV turn P2 CCW until it is within range.
n. Turn Power Switch off.
o. If P2 has been adjusted repeat procedures 5.6, 5.7, 5.8 & 5.9 until no adjustment is
required.
p. Disconnect unit from test fixture.
q. Test is complete.
5.10 Records
5.10.1 If all values input into the records section are within range, check the
corresponding space in the “Pass” column.
5.10.2 If any value cannot be brought within range, using this calibration procedure
check the corresponding space in the “Fail” column.
5.10.3 If all value, are checked as “Pass”, check the space in the “Pass” column in the
TCT-1000 Battery Capacity Analyzer.
5.10.4 Sign and date the bottom of the Records section.
5.10.5 Retain that sheet for your records.

NUMBER O01-1000 REVISION
D 7-8-16 Page 10 of 10
TITLE TCT-1000 OPERATING INSTRUCTIONS
Teledyne Battery Products
5.10.6 If any values are checked as “Fail”, check the space in the “Fail” column in the
TCT-1000 Battery Capacity Analyzer.
5.10.7 Send the unit back to Teledyne Battery Products for repair or replacement.
6 RECORDS – P/N: TCT-1000; S/N: _________________
TCT-1000 Battery Capacity Analyzer
Record Name
Measured Value
Specification
Pass
Fail
20.0 Volt Cutoff 20.20 – 19.80 Volts
10.0 Volt Cutoff 10.10 – 9.90 Volts
Frequency
(Period for 10 Unit
Increase)
357 sec. – 363 sec.
24 Volt 10 Amp Setting 9.8 – 10.2 mV
24 Volt 50 Amp Setting 49.6 – 50.4 mV
12 Volt 10 Amp Setting 9.8 – 10.2 mV
12 Volt 50 Amp Setting 49.6 – 50.4 mV
Multi-meter Calibration Expiration Date: ________
TCT-1000 Calibration performed as specified by _____________; Date ________
NOTE: THE UNIT MUST BE CALIBRATED ANNUALLY.