Intelligent Charging TS25 MKII User manual

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240
Battery charger/analyser : Operat rs Manual
Doc: DWG1044-09-R16 TS25 MKII Operators manual.odt Page 1 of 46 Copyright Material of Intelligent Charging Limited © 2015
Printed On : 12/06/17
DANGER
Disconnect the
mainssupplybefore
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
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

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240
Battery charger/analyser : Operat rs Manual
TAB E OF CONTENTS
1 MANUA REVISION HISTORY 4
2 TS25 MKII DESCRIPTION 5
3 CONTRO S AND INDICATORS 7
3.1 DISP AY 8
3.2 POWER SWITCH 9
3.3 AUDIB E A ARM 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 DISP AY MNEMONICS 24
4.8 ERROR CODES 25
5 CA IBRATION 27
5.1 EQUIPMENT REQUIRED 27
5.2 PERFORMANCE CHECKING 27
5.3 RE-CA IBRATION 28
5.4 CA IBRATION PROB EMS 29
5.5 CA IBRATION EQUIPMENT CONNECTIONS 30
6 ROUTINE MAINTENANCE 31
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TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240
Battery charger/analyser : Operat rs Manual
6.1 INTERNA BATTERY REP ACEMENT 31
7 BATTERY IBRARY 32
7.1 RETRIEVING A IBRARY ITEM 32
7.2 ENTERING OR MODIFYING A IBRARY ENTRY 32
8 DEFAU T BATTERY IBRARY 33
9 SPECIFICATIONS 43
10 PRODUCT DISPOSA INSTRUCTIONS 44
11 PRODUCT WARRANTY 45
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Printed On : 12/06/17

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240
Battery charger/analyser : Operat rs Manual
1 Manual Revision History
ev Date Description
0 08-03-2007 FI ST W ITTEN
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 CH G & TEST on keypad legend.
11 26-01-2009 Added Enersys 9750D0730 to built in library
12 30-09-2014 Corrected annotation on keypad diagram CH G and TEST reversed.
13 21-11-2014 eworded the data entry paragraphs in section 4.4 to make clearer.
14 20-01-2015 Graphic images of TS25 amended as they show CH G & 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.
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Printed On : 12/06/17

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240
Battery charger/analyser : Operat rs 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.
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TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240
Battery charger/analyser : Operat rs 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.
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TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240
Battery charger/analyser : Operat rs Manual
3 CONTRO S AND INDICATORS
Doc: DWG1044-09-R16 TS25 MKII Operators manual.odt Page 7 of 46 Copyright Material of Intelligent Charging Limited © 2015
Printed On : 12/06/17
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
CHANNELA CHARGE SAFETY CIRCUIT BREAKER
DANGER
Disconnectthe
mainssupply before
removing thiscover
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
ASET PROC
V SETCHRG BATT
TEST ONE T SET
START
STOP MUTE
EXTD ENTR
DISP DATA
ASET PROC V SETCHRG BATT
TEST T SET
START
STOP

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240
Battery charger/analyser : Operat rs Manual
3.1 DISP AY
•NUME IC 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). Capacity test time is displayed in
Minutes to a resolution of 1 Minute.
oBattery capacity is displayed in percent to a
resolution of 1%.
•NUME IC DISPLAY INDICATO S
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 capacity 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.
oALA M 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.
Doc: DWG1044-09-R16 TS25 MKII Operators manual.odt Page 8 of 46 Copyright Material of Intelligent Charging Limited © 2015
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 : Operat rs 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 WHI E THE UNIT IS
PERFORMING A CAPACITY TEST OR CHARGE.
3.3 AUDIB E A ARM
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
A WAYS 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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TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240
Battery charger/analyser : Operat rs 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 UNNING
Doc: DWG1044-09-R16 TS25 MKII Operators manual.odt Page 10 of 46 Copyright Material of Intelligent Charging Limited © 2015
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 : Operat rs 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 SHOU D NEVER BE CONNECTED OR DISCONNECTED FROM THE
UNIT WHEN A CHARGE OR TEST IS IN PROGRESS AS ARCING CAN OCCUR
CAUSING AN EXP OSION FROM GASSES VENTING FROM BATTERIES BEING
PROCESSED
THE BATTERY SHOU D A WAYS BE ISO ATED 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: -
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Printed On : 12/06/17

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240
Battery charger/analyser : Operat rs Manual
SING E OR TWIN CHANNE BATTERY CONNECTION
Doc: DWG1044-09-R16 TS25 MKII Operators manual.odt Page 12 of 46 Copyright Material of Intelligent Charging Limited © 2015
Printed On : 12/06/17
AVIATION BATTERY AVIATION BATTERY
BATTERY #1 BATTERY #2
DANGER
Disconnectthe
mainssupply before
removingthis 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
POW ER SWIT CH
POW ER SWIT CH POW ER SWIT CH
POW ER SWIT CH
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

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240
Battery charger/analyser : Operat rs Manual
BATTERY CONNECTION WHEN USING “ONE” MODE OF OPERATION
Doc: DWG1044-09-R16 TS25 MKII Operators manual.odt Page 13 of 46 Copyright Material of Intelligent Charging Limited © 2015
Printed On : 12/06/17
AVIATION BATTERY
DANGER
Disconnect the
mains supplybefore
removingthis 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

TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240
Battery charger/analyser : Operat rs 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
/
6
ths 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 MANUA 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)
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TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240
Battery charger/analyser : Operat rs Manual
To program these values the TS25 MKII needs to powered and not performing
either a capacity test or charge on the channel to be used.
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 ENTE ING BATTE Y DATA for details on how to enter the
required parameters.
4.2.2 IBRARY 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 MKII 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 VO TS,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 VO TS,AMPS,TIME and %. The DATA key can also be
pressed to review the parameters programmed in for the current test under
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TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240
Battery charger/analyser : Operat rs Manual
progress. If the TEST key is pressed this will briefly display the current test
mode.
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 capacity percent value.
Process termination codes:
E 1 The process time is complete.
E 2 Battery voltage has reached the voltage end point.
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TS25 MKII : TS25-BAS1-KIT : TS25-BAS1-CAN-240
Battery charger/analyser : Operat rs Manual
4.3 CHARGING BATTERIES
To keep batteries in good condition it is important that correct charging procedures
are observed.
The TS25 MKII is an important tool in ensuring the its flexibility allows the user to
choose charge processes that are best suited to the battery. The TS25 MKII has two
inbuilt charging processes that suite a wide range of batteries.
The use of constant voltage charging is best suited to lead acid types of batteries and
the TS25 MKII controls constant voltage charging to ensure that no excess of current
can be driven into the batteries causing it damage.
Constant voltage charging is achieved by inserting a maximum specified current into a
battery until its terminal voltage reached the voltage set point. Once this voltage set
point has been reached the unit will reduce the current injected to maintain the
voltage set point. The charging process will continue until the charge time has
elapsed.
Constant current charging is employed mainly for Nickel Cadmium and Nickel Metal
hydride types if batteries, where a constant current can be driven into a battery for a
specified time and parameters can be set to prevent over charging.
Constant current charging is achieved by the unit driving a specified constant current
into the battery for a specified amount of time. During this time it will monitor the
battery voltage and auto terminate the process if this voltage is reached. This voltage
set point can be either the rise point of the battery or can be used as an over-voltage
parameter.
The TS25 MKII has a new charge mode implemented, which is more suitable to
alkaline batteries. In this mode known as Constant Current Plus mode the unit will
drive the constant current into the battery until the voltage set point is reached. Once
this point is reached the unit will continue charging at the same current for the time
specified.
4.3.1 MANUA CHARGING
The unit required four parameters to perform a constant voltage charge. These
are: -
Maximum charge current (Amperes).
Charge time or charge additional time (Hours).
Voltage set point (Volts).
Charge mode.
To program these values the unit needs to powered and not performing either a
capacity test or charge on the channel to be used.
Press ASET to change the charge amperes.
Press VSET to change the charge test voltage set point.
Press TSET to change the charge duration or additional time.
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Battery charger/analyser : Operat rs Manual
Press PROC to change the charge mode.
See section 4.4 ENTE ING BATTE Y DATA for details on how to enter the
required parameters.
4.3.2 IBRARY CHARGING
To perform a charge 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 unit needs to be placed in charge mode by pressing CHRG and ensuring that
the visual indicator TEST is extinguished.
4.3.3 REVIEWING CHARGE PARAMETERS
Once these values have been programmed into the unit they can be reviewed by
selecting the DISP key to cycle the display between VO TS,AMPS and TIME
and then pressing the DATA key. This display will show the values programmed
in and the corresponding indicator will flash. To check the charge mode simply
press the CHRG key and the current charge mode will be displayed CV, CC or CCA.
4.3.4 STARTING A CHARGE
Before a charge 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 charge.
Once satisfied that he data is correct the battery to undergo charging 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 TS25 MKII may occur if a
charge is started in reverse connection.
To begin the charge press START. The display will momentarily display RUN, the
END light will extinguish and it will then display battery voltage. During the
normal charge process the DISP key may be pressed to cycle the display
between VO TS,AMPS and TIME. The DATA key can also be pressed to review
the parameters programmed in for the current test under progress. Pressing the
CHRG key will also briefly display the current charge mode.
4.3.5 STOPPING A CHARGE
At any time during the charge the process can be terminated by simply pressing
the STOP key. When the STOP key is pressed the process will be terminated
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Battery charger/analyser : Operat rs Manual
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.
4.3.6 CHARGE PROCESS AUTO TERMINATE
If constant voltage charging the process will automatically stop when the test
time has been completed.
If constant current charging is programmed then the charge will terminate on the
full charge time completed or if the battery terminal voltage reached the voltage
set point.
If constant current with additional time mode is being performed then the unit
will stop when the additional time has been used or if the voltage set point is not
reached within 24 hours of the charge starting.
In all cases the charge 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.
Process termination codes:
E 1 The process time or additional time is complete.
E 3 Voltage set point reached (Constant Current Mode Only).
E 4 The voltage set point has not been reached within 24Hours.
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Battery charger/analyser : Operat rs Manual
4.4 ENTERING BATTERY DATA
In all cases of entering battery data the channel that data is to be entered on must be
in the stopped state. This is indicated by the END lamps being illuminated.
4.4.1 SETTING CAPACITY TEST MODE
Press PROC the display will flash the current mode on the display. Using the 
and arrow keys the flashing display can be changed from TIM to VOL and visa
versa. Once selection has been made the ENTR key will be pressed to program
this parameter into the unit. If no change is required then simply pressing STOP
will clear the display.
TIM Programs the capacity testing mode to auto terminate when the battery
voltage falls below the voltage end point or when the time up has been
reached.
VOL Programs the capacity testing mode to only auto terminate when the
voltage end point has been reached.
4.4.2 SETTING THE CHARGE MODE
Press PROC the display will flash the current mode on the display. Using the 
and arrow keys the flashing display can be changed from CV,CC and CCA and
visa versa. Once selection has been made the ENTR key will be pressed to
program this parameter into the unit. If no change is required then simply
pressing STOP will clear the display.
CV Programs the charge mode to perform a constant voltage charge where the
charge current is not exceeded until the voltage set point is reached at
which point it reduces current to maintain the voltage set point until the
charge time is completed.
CC Programs the charge mode to perform constant current charging for the
time specified terminating abnormally if the voltage set point is reached.
CCA Programs the charge mode to perform constant current charging until the
voltage set point is reached and then continue charging at the same current
until the additional time has elapsed.
4.4.3 ENTERING CURRENT DATA
Press the ASET key. The current setting will be displayed. The rightmost digit will
be flashing and can be modified by pressing the and arrow keys. Pressing
the EXTD key will cause the middle digit to flash and this can then be modified by
using the and arrow keys. Pressing the EXTD key again will cause the
leftmost digit to flash and this can then be modified using the and arrow
keys. If the EXTD key is pressed again the rightmost digit will then flash. This
cycle is repeated each time the EXTD key is pressed. The values cannot be
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