IntelliQuip TOUGHPOWER TP-600 Operator's manual

USER INSTRUCTION MANUAL
Models: TP-600
TP-1000
TP-1000DUAL
ToughPower User Manual August 2017

Congratulations on purchasing the most powerful compact portable battery box on the market!
You can take great pride in knowing that the ToughPower is the only portable battery box that has:
1. 600W or 1000W Pure Sine Wave Inverter for high power appliances
2. Automatic Low Voltage Shutdown and   Recovery   to protect the battery
3. The internal microprocessor monitors and displays on the LCD all charging inputs - Mains, Car, Solar,
External, and Dual Battery (TP1000  DUAL   model   only)
4. Dual Battery Bypass Controller (TP-1000  DUAL model only) - direct connection to the car Alternator for
BULK charging and then DC-DC Charger to finish off the battery charge - automatically controlled
5. With Dual Battery Bypass Controller setup - direct BULK power from the car Alternator to the 1000W
Pure Sine Wave Inverter. Effectively providing power indefinitely to high power appliances. TP-1000  DUAL
model   only
6.  Integrated Mains Charger, DC-DC Charger and MPPT Controller (for 12V Nominal   Solar Panels)
7. The fastest, most powerful Mains Charger 10A integrated inside   the Lid
8. The fastest, most powerful DC-DC Charger 10A integrated   inside   the Lid
Good Choice…you won’t be disappointed
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1.  Table of Contents
1.  Table of Contents 3
2.  Product Safety & Warnings 5
3.  What’s Included... 6
4.  General Specifications 6
5.  Quick Start - Initial Setup 7
6.  Battery Selection, Fitting and Configuration 8
6.1  Battery Type Selection 8
6.2  Battery Capacity & Condition Setup 10
6.3  Battery Bank Setup 11
6.4  Charging a Spare/Boat Battery 11
7.  Charging the Battery 13
7.1  Mains Power Charging – (MAINS) 13
7.2  Car Power Charging – (CAR) 12V Systems only 14
7.3  Solar Power Charging – (SOLAR) 12V Nominal Solar Panels only 14
7.4  Dual Battery Smart Bypass Controller:  TP-1000DUAL model only 15
7.5  Multiple Charging Sources Connected 16
7.6  External Power Charging – (EXT) 17
7.7  Charging Stages 18
7.8  Charging Voltage Limits 18
7.9  Charging Complete 19
7.10  Charging Protections 19
8.  Using the ToughPower 20
8.1  Time Prediction - LCD Screen 20
8.2  LCD Touch Screen Calibration 21
8.3  LCD Automatic Shutoff 21
8.4  LCD HOME Screen 22
8.4.1 Battery Status 22
8.4.2 System Output LOAD 22
8.4.3 System Input CHARGE 22
8.5  LCD INFO Screen 23
8.5.1 General Information 23
8.5.2 Usage Information 24
8.6  LCD LOGS Screen 25
8.6.1 Battery Voltage logs 25
8.6.2 Amps In logs 25
8.6.3 Amps Out logs 26
8.7  USB Charger 26
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8.8  LED Lighting 26
8.9  240VAC 50Hz Mains Power Output 28
8.9.1 Timer AC 29
8.9.2 Pure Sine Wave Inverter Safety Protections 29
8.9.3 AC Overload 29
8.9.4 Car Alternator BULK Power supply to Inverter 30
8.10  12VDC Power 30
8.10.1 Low Current Outlets 30
8.10.2 High Current Outlets 30
8.11  System Protections 31
8.11.1  Low Voltage Protection 31
8.11.2  Recovery Protection 32
8.11.3  Over Temperature Protection 33
8.11.4  Over Temperature LCD Protection 33
8.11.5 Over Load Protection 34
8.11.6 USB Low Voltage Protection 34
8.11.7 FAULT LED Indication 34
9.  TroubleShooting 35
10. Warranty & Contact 35
Company contact details: 35
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2.  Product Safety & Warnings
The ToughPower is intended for indoor use only. Ensure the unit is mounted correctly in the upright
position, undercover and located with adequate ventilation around the box.
Avoid all contact with water, rain, snow or spray! Do not power ON the unit if it is wet as it could
potentially result in electrocution and/or permanent irreparable damage to the internal electronics.
Warranty will be voided if there is damage caused by water.
Do not attempt to disassemble the ToughPower as this may result in electric shock. Warranty will be
voided if any attempt is made to modify, repair or attempt unauthorised access to the electronics.
Disconnect all Charging Supply leads before making or breaking the connections to the Battery.
The ToughPower is not a toy! Children must not play with the ToughPower. The ToughPower can only be
used by children aged from 8yrs and above and persons with reduced physical, sensory or mental
capacities or lack of experience and knowledge only if they have been given supervision or instruction
concerning the use of the ToughPower in a safe way and understand the hazards involved.
Do not insert foreign objects into the outlets as this may lead to electrocution and/or damage the
electronics. The 240V AC outlet socket should be respected the same as a standard mains electrical socket.
Warranty will be voided if there is damage caused by such activity.
WARNING – Explosive gases. Prevent flames and sparks. Do not use the ToughPower in close proximity of
flammable fumes, gases, or naked flames. Provide adequate ventilation to allow any heat and battery
gases to be safely dissipated during charging.
Do not attempt to charge non-rechargeable batteries. This product is designed for charging 12V deep cycle
rechargeable batteries 80-120 Ahr capacity.
When the ToughPower is not in use, firstly fully charge the battery, then switch the Master ON/OFF Switch
to OFF. Refer to your Battery manufacturer’s recommended instructions for battery storage. Typically it is
advised to to never store your battery in a discharged state, to keep the battery in a cool and dry location
with   plenty   of   ventilation,   and   to   recharge   every   3-4   months.
Cleaning and user maintenance shall not be made by children without supervision.
Deep cycle batteries are heavy! Be sure to “bend with your knees” when lifting – or ask a friend to help
carry the ToughPower.
For all PLUGGABLE equipment – the socket-outlet shall be installed near the equipment and shall be easily
accessible.
CAUTION
Risk of Explosion if Battery is replaced by an incorrect type.
Dispose of used batteries according to the instructions on the battery.
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3.  What’s Included...
TP-600 & TP-1000
1 x ToughPower
1 x Kettle Cord
1 x 4-Pin CIG Accessory Cable
1 x User Manual
TP-1000DUAL
1 x ToughPower
1 x Kettle Cord
1 x 4-Pin CIG Accessory Cable
1 x 2-Pin Accessory Cable
1 x User Manual
4.  General Specifications
External Dimensions: 394mm x 215mm x 406mm (L x W x H)
Operating Temperature: 0 – 50°C
Material: UV Stable Roto-moulded Box and Lid
Weight:  TP-600 4.5kg  battery   not   included
   TP-1000 5.6kg battery   not   included
   TP-1000DUAL  5.7kg  battery   not   included
Suitable for: 12V Deep Cycle Batteries  AGM/Gel/Calcium/Wet Lead Acid & Lithium LiFePO4 (TP-1000DUAL)
Battery ‘Space Claim’:   344mm x 179mm x 249mm (L x W x H)
   Will fit most deep cycle 80Ah - 120Ah Batteries
Certifications: AU Prov Pat Appln No 2017903530
Electromagnetic Compatibility (EMC) AS/NZS 61000.6.4:2007
Information Technology Equipment - Safety AS/NZS 60950:2015
Safety of Portable Inverters AS/NZS 4763:2011
Household and similar Electrical Appliances - Safety - Particular requirements for Battery
Chargers AS/NZS 60335.2.29:2004 + A1 + A2 with
Household and similar Electrical Appliances - Safety AS/NZS 60335.1:2011 + A1 + A2
Information technology equipment - Safety General requirements
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5.  Quick Start - Initial Setup
Follow these instructions to set-up your ToughPower unit correctly.
1. Ensure the Master Switch is in the OFF position
2. Open the lid
3. Using the Key inserted in the Concealed Key-Switch select the 12V Battery Type that you intend to
fit in the box
a. TP-600 selection: Lead Acid/GEL, Calcium and AGM
b. TP-1000 & TP-1000DUAL selection: Lead Acid/GEL,
Calcium, AGM & Lithium   (LiFePO4)
Note: For Lead   Crystal   batteries select AGM (same charging
profile)
4. Remove the Key and store in a secure location
5. Place your battery inside the box, secure it using the Battery
Strap
6. Connect and secure cables to battery terminals
Warning:   Check the Polarity of your connections!
       Reds to Red (Positive to Positive)  Blacks to Black (Negative to Negative)
       Ensure each cable connection to the battery terminal is secure and tight
7. Close the lid and attach the two latches
8. Turn the Master Switch to the ON position
9. The LCD will prompt you to update the battery settings:
a. Touch the arrows to select the correct values for your Battery Condition and Capacity
b. When finished touch SAVE and then HOME
10. Although the unit is now ready to be used, it is highly recommended to allow the ToughPower to
complete a full charge so the internal battery monitor gets synchronised with the battery state of
charge. If you don’t do this you will only ever see the Voltage displayed on the LCD, and no % or
time predictions will be displayed.
The easiest way to achieve this is with the Mains Charger (though you can use Solar or Car charging)
a. Plug the desired input charge source (Mains - Kettle cord)
b. Wait until charging is FULL or Battery percentage shows 100%
Note: This is a Quick Start guide intended for the skilled user only.  For more detailed instructions and
explanations refer to the relevant section in the User Manual.
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6.  Battery Selection, Fitting and Configuration
6.1  Battery Type Selection
The ToughPower has a built-in integrated Multi-Stage DC-DC Battery Charger inside the Lid. This Charger
has specific Charging Profiles for each deep cycle Battery chemistry.  These are:
●Wet Lead Acid/GEL
●AGM (Lead   Crystal   batteries select AGM profile as they have the same charging voltage profile)
●Calcium
●Lithium LiFePO4TP-1000 & TP-1000  DUAL models only.  For other Lithium-Ion batteries refer to
section Charging Voltage Limits to confirm if compatible.
The ToughPower box has been designed to accommodate most 80-120 Ahr sized batteries. We advise that
you check the size of the battery before you buy!  The “space claim” in the ToughPower for the battery is:
344mm x 179mm x 249mm (L x W x H)
To ensure your safety, ongoing integrity of the Battery, and to provide optimised Charging, it is very
important that you correctly set the Battery Type. Failure to do so could result in significant damage to
the battery and electronics, rendering them both inoperable, and/or permanently damage any device
attached to the ToughPower.
Due to the high current Charging capability of the ToughPower, and the safety and product damage risks
mentioned above, the selection of the Battery Type has been provided by a Concealed Key Switch. The
Concealed Key Switch can only be accessed with there is no Battery fitted in the Box.
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Using the Key provided, simply turn the Key to select the Battery Type that you intend to fit in the
ToughPower. After making the selection we recommend that you remove the Key and store it in a secure
location. After which there is no risk that an unsupervised child, or anyone else, can change the Battery
Type selected.
Note: Lithium LiFePO4  TP-1000   &   TP-1000  DUAL   models   only
For  Lead   Crystal   battery select AGM setting
Now you can place your battery inside the box, secure it using the Battery Strap, and then Connect the
Battery Terminals.
Warning: Check the Polarity of your connections!
Reds to Red (Positive to Positive) & Blacks to Black (Negative to Negative)
Connect the thinner black cable (Battery Sensor) to the Negative terminal
TP-1000  DUAL   has two red cables - connect both to the Positive Battery terminal
Ensure each cable connection to the battery terminal is secure and tight
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After closing the Lid, you can turn the ToughPower ON. The LCD screen will display the Battery Type
selected:
6.2  Battery Capacity & Condition Setup
In addition to selecting the battery chemistry type it is necessary to set-up its Capacity and Condition. This
is only required when fitting a new battery, and by doing so, it will ensure that the ToughPower is able to
perform calculations and estimations to keep track of the charge in and out of the unit based on the
battery characteristics.
To update the battery configuration, follow these steps:
1. From the Home screen touch the Battery Icon to see the Battery Setup Configuration.
2. Touch and hold the  EDIT button, the screen will update and display >> next to each parameter.
○To save the configuration touch SAVE button
○To reset the configuration to the default factory settings touch DFLT button and then touch
SAVE
○To modify each parameter, touch the arrows >> next to them and select the desired value
 
3. For Battery Condition, available options are:
○NEW (new battery)
○USED (regular use - up to 2yrs old)
○OLD (2 yrs or older)
4. For Battery Capacity, available options are:
○From 80Ah to 130Ah, & “Battery Bank” option (refer below)
○Enter the Battery Capacity as stated on your Battery
5. When completed, touch SAVE to save the current configuration.
6. Touch HOME button to exit Battery Configuration and return to the Home screen.
Note: Updating the battery setup will reset all LOGS and USAGE records.
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6.3  Battery Bank Setup
A second (or third) battery can be connected to the ToughPower to
create a Battery Bank  . With the addition of a second Battery
connected in parallel you will be able to either extend the time
between charging, or power more devices. The additional Battery
must be the same Type  of Battery chemistry as is fitted in the
ToughPower otherwise you risk damaging the Battery as the Charging
Voltage   is specific to the Battery Type!
You will need to make a small cable with either Ring Terminals or Alligator Clips on both ends to connect to
the terminal posts of both Batteries. Remember: connect Positive to Positive, & Negative to Negative.
Keep the cable as short as possible and we recommend using  AWG6   sized cable.
This method of connecting the two batteries directly to the terminal
posts allows the ToughPower to provide the same Low Voltage
Shutdown   and Charging   Protections   to the second Battery.
Refer to section Battery Capacity & Condition Setup for instructions
on how to set the “Battery Bank  ” option on the ToughPower LCD
Screen.
Note: When the Battery Bank option is setup correctly, the time prediction and battery percentage
functions are disabled. For monitoring, the Battery Voltage will continue to be displayed on the LCD
Screen.
Note: Take special care to attach the Battery Terminals correctly! It must be Parallel Connection - Red to
Red (Positive to Positive), and Black to Black (Negative to Negative). Incorrect terminals connection will
cause permanent damage to the sensitive electronics inside the ToughPower.
Warning: You cannot make a Series Configuration to increase the system Voltage!  The ToughPower is a
12V system only.
6.4  Charging a Boat Battery
A variation of the Battery Bank Setup is possible whereby an external
Battery can be connected and charged by the ToughPower, and then
disconnected after charging. For example: Charging a recreational
boat deep cycle Battery.
Note: This battery must be the same Type  of Battery chemistry as is
fitted in the ToughPower otherwise you risk damaging the Battery as
the Charging Voltage is specific to the Battery Type! The Battery
must have been removed from the boat/vehicle before connecting
to the ToughPower.
Using the same or similar cable as described above in Battery Bank Setup, you will need to make a small
cable with either Ring Terminals or Alligator Clips on both ends to connect to the terminal posts of both
Batteries. Remember: connect Positive to Positive, & Negative to Negative. Keep the cable as short as
possible and we recommend using AWG6   sized cable.
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For the sporadic connecting and charging of an external battery you do not have to change the Battery
Capacity Setting on the LCD. However, if you do this the prediction times displayed will be incorrect whilst
you have the external battery connected (and will revert to correct functionality when the external battery
is removed).
Alternatively, you can connect the external battery via the RHS
Anderson Connector for effective charging, however this is not
recommended as the ToughPower Low Voltage Shutdown  protections
will not comply to the external Battery connected this way.
Note: As soon as you connect the external Battery to the ToughPower
the two Batteries will commence “equalising” their Voltage. You will need to ensure a Charging Source is
attached and charging otherwise you risk flattening the ToughPower Battery.
Note: Take special care to attach the Battery Terminals correctly! It must be Parallel Connection - Red to
Red (Positive to Positive), and Black to Black (Negative to Negative). Incorrect terminals connection will
cause permanent damage to the sensitive electronics inside the ToughPower.
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7.  Charging the Battery
The ToughPower controlled by an integrated microprocessor and includes:
●10 Amp Multi-Stage DC-DC Charger - Input   8-16   VDC
●10 Amp AC-DC Mains Charger - Input   100-240VAC   50/60Hz   2A
●MPPT Solar High Efficient Controller - for 12V Nominal   Solar Panels
●Dual Battery Smart Charging Controller TP-1000  DUAL   model   only
This unique technology provides maximum flexibility and options for charging – Mains Power to charge
when at home, Car Charging for when you are on the move, Solar Power for when you’re free camping.
To start charging your battery from any source first ensure you have selected the correct Battery Type
using the Concealed Key-Switch and the Master ON/OFF Switch is in the ON position.
Note: When multiple CHARGING inputs are attached, and powered simultaneously, the internal electronics
will automatically select the highest charging input.
Note: The battery is protected from OVER-VOLTAGE. Automatic shut-off will occur when the battery is
fully charged.
7.1  Mains Power Charging – (MAINS)
Using the Kettle Cord supplied, connect the Kettle 3-Pin Plug
into the ToughPower and then connect the Australian 3-Pin
Plug into a standard power point socket.
The LCD display will show that the battery is being charged
from MAINS input.
The internal 10 Amp AC-DC Charger will receive and regulate
the Mains input power to charge the Battery fitted in the
ToughPower. The multi-stage charger will charge and
condition the Battery, and will shut-off when charging is
complete.
Note: If this Kettle Cord is damaged, do not use and discard immediately! Contact the manufacturer, or
designated service agent, or similar qualified person for a suitable replacement part.
7.2  Car Power Charging – (CAR) 12V   Systems   only
Attach the provided 4-Pin CIG Plug Accessory Cable to your
vehicle ignition controlled CIG Socket (ie. the car CIG Socket
only has power when the car is running) and to the
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ToughPower. Charging of the Battery will only occur when the Vehicle is running or the Car Key is in the
“Accessories” position.
The LCD display will show that the battery is being charged from CAR input.
The internal 10 Amp DC-DC “Multi-Stage” Charger will receive
and regulate the power to charge the Battery fitted in the
ToughPower. The multi-stage charger is current limited and
cannot draw more than 10 Amps of power. It will charge and
condition the Battery, and will shut-off when charging is
complete.
Note: The current will not exceed 10 Amp through your Vehicle
CIG Socket.
Warning: It is recommended that the vehicle CIG Socket must be ignition controlled so that it is only
powered when the vehicle is in “Accessories” mode or running. Check this with your vehicle manufacturer
or local service provider otherwise you run the risk of discharging your car’s main battery.
7.3  Solar Power Charging – (SOLAR) 12V   Nominal   Solar   Panels   only
The ToughPower can accept Regulated and Unregulated Solar
Power 12V Nominal Solar Panels only. When Unregulated
Solar Panels are connected the internal electronics
automatically detect this and will switch to MPPT Controller
mode.
12V Nominal   Solar Panels:
Max Voc = 25V
The TP-1000DUAL is supplied with a 2-Pin Accessory Cable.
Connect the 2-Pin Plug into the ToughPower then connect the
bare ends to your Solar Panel using your preferred connector.
Note: Check the Polarity of your connections!
The TP-600 & TP-1000 are supplied with a 4-Pin CIG Plug Accessory Cable. This same Accessory Cable is
used for both Car Charging and Solar Charging. To enable you to swap between the two charging options,
it is recommended you attach a female CIG Socket to your Solar Panel, then simply connect the 4-Pin Plug
into the ToughPower and connect the CIG Male Plug end into your Solar Panel female CIG Socket. Note:
Check the Polarity of your connections!
WARNING: Great care must be taken when attaching connectors to ensure the polarity is correct!
The LCD display will show that the battery is being charged from SOLAR input.
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The internal MPPT Controller and multi-stage charger will receive and regulate the power to charge the
Battery fitted in the ToughPower. Up to 10 Amp charging can be achieved through Solar Charging. The
multi-stage charger will charge and condition the Battery, and will shut-off when charging is complete.
7.4  Dual Battery Bypass Controller:  TP-1000  DUAL   model   only
Direct Alternator Bulk Charge & DC-DC Charging
The advanced technology inside the Lid controls when to bypass the internal DC-DC Charger to allow the
Vehicle's Alternator to provide BULK charging power direct to the ToughPower Battery, and then switch
the internal DC-DC Charger inline to finish charging the battery.
This unique capability in the ToughPower allows the best of both existing dual battery charging
technologies! Direct connection to the vehicle Alternator for BULK charging (no excess heat generated as
with high current DC-DC Charging electronics) and then switch the 10A DC-DC Charger inline to complete
the charging.
Dual Battery Setup Instructions
1. Attach the provided 4-Pin CIG Accessory Cable to a
vehicle ignition controlled CIG Socket and to the
ToughPower. Note: the vehicle CIG Socket MUST be
ignition controlled - ie only has power when the car is
running.
2. Attach an AWG6 cable from your vehicle's main battery
to the ToughPower's LHS Anderson Input Socket. We
recommend you include a 100A fuse as close to the
vehicle battery (AWG6 cable and fuse not supplied).
3. Make sure the ToughPower is switched ON and the
internal electronics will do the rest!
With both vehicle input charging cables connected to the
ToughPower, the ToughPower will start charging as soon as the vehicle key is turned into the Accessories
position or the engine starts running. Note: If at any time the CIG Accessory Cable gets disconnected or
the vehicle is turned off charging will be disabled.
Note: The charging current through the CIG Accessory Cable is limited to 10 Amps  . The current will not
exceed 10 Amps through your vehicle CIG Socket.
While charging through the CIG Accessory Cable the ToughPower will evaluate if BULK Charge (from the
vehicle alternator) is required, during this stage the HOME screen displays the BULK icon next to the
charging source to acknowledge the presence of the Dual Battery setup.
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When the charging current through the CIG Accessory Cable exceeds 8.5A the BULK input will be enabled
to test the available vehicle alternator current. After testing for 30 seconds if the BULK charging current
exceeds 10 Amps the ToughPower will remain in ALTERNATOR BULK charge until the charging current
drops below 11 Amps (after the BULK Charging stage). During this stage, the HOME screen will show the
input source as BULK.
When BULK charge has finished, the built-in DC-DC Charger will finish off the charging process providing
the required final charging stages for the selected Battery Type (Note: A TP-1000DUAL fitted with a Lithium
LiFePO4 Battery does not have a float stage).
7.5  Multiple Charging Sources Connected
The ToughPower can be set-up with multiple Input Charging
Sources permanently  connected. The advanced technology
inside the Lid automatically controls when to switch
between Input Sources based on which is providing the
greatest charging power.
This capability includes attaching the Kettle Cord to a Mains
Power supply. Obviously this cannot be done when driving,
however it is a convenient charging option when you have
an overnight stay at a powered site in a caravan park.
7.6  External Power Charging – (EXT)
An External 12V Battery Charger can be connected to the ToughPower to provide high current charging.
Perfect if you already own a Generator and a high current 12V Battery Charger and want to minimise your
Generator run time whilst maximising the input charge into the Battery. This capability is permitted using
the Right Hand Side Anderson Output Connector only. The maximum charging current permitted is 50
Amps as the Anderson Connector is protected with a 50A Self Resetting Circuit Breaker.
Page 16

You will need to fit an Anderson Style Connector to your 12V Battery Charger, then connect it to the RHS
Anderson Output Connector.  Note: Check the Polarity of your connections!
Ensure the ToughPower is switched ON, and all other input Charging Sources must be disconnected from
the ToughPower.
By attaching to the RHS Anderson Connector the internal electronics and microprocessor will monitor the
charging input from the External 12V Battery Charger, and display information on the LCD.
 
Note: All other input charging sources must be disconnected when using an External Charger.
Alternatively, you can open the ToughPower Lid, and attach the External 12V Battery Charger’s Alligator
Clips directly to the Battery terminals. This bypasses  the ToughPower’s electronics and therefore the LCD
will not   display accurate information about the battery state of charge.
Note: For this method of charging, all other input Charging Sources must be disconnected and all Power
Outlets must be disconnected from the ToughPower.
7.7  Charging Stages
The ToughPower it is equipped with a built-in integrated multi-stage DC-DC Battery Charger. This section
provides a brief description of each stage.
For all Lead-Acid battery types the charger will progress through the following stages:
For Lithium LiFePO4 batteries, the charger will progress through the following stages:
●OFF: Charger is disabled.
●CHECKING: In this stage (reduced constant-current/trickle charge), the charger charges the battery
with a reduced constant current. This trickle charge stage occurs for battery voltages between 35%
to 70% (typical) of the voltage limit provided in the Charging   Voltage   Limits   section below.
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●BULK: In this stage (full constant-current) the charger charges the battery with a constant current.
This constant current stage occurs for battery voltages between 70% to 98% (typical) of the voltage
limit provided in the Charging   Voltage   Limits   section below.
●ABSORPTION: In this stage (constant-voltage) the charger charges the battery with a configured
constant voltage. This constant voltage stage occurs for battery voltages above 98% (typical) of the
voltage limit described in Charging   Voltage   Limits   section below.
●FLOAT: In this stage, the charger charges the battery with a reduced constant voltage. Note: This
stage is not applicable for Lithium LiFePO4 batteries.
●FULL: Charger disabled, charging complete.
7.8  Charging Voltage Limits
The Battery Charger applies the appropriate Charging and Float Voltages depending on the Battery Type as
well as combining automatic Temperature Compensation.
Battery
Type
Charging
Voltage (VDC) at
25°c
Float
Voltage (VDC) at
25°c
LEAD/GEL
14.2
13.3
CALCIUM
15.3
13.3
AGM
14.6
13.3
LITHIUM LiFePO4
14.6
N/A
Note: For   Lithium   LiFePO4   batteries there is no FLOAT stage.
7.9  Charging Complete
When charging finishes the HOME screen will show the charging source with a FULL message. At this point
the Battery Charger will automatically shut off and there is no risk of overcharging the battery.
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With the Battery fully charged and synchronized the ToughPower will be able to keep track of the charge in
and out of the unit and estimate the remaining time to Full or Empty.
Under some circumstances the FULL message may disappear because the Battery Charger will resume
charging again if the Battery Charge Level drops. The user can identify that the charge has been completed
because the Battery Charge Level will automatically change from showing Volts to Percentage as well as
showing the time remaining icon.
Note: In the event of LOW VOLTAGE (battery protection), the ToughPower will automatically shut-off and
the Battery Charging State will be reset.
7.10  Charging Protections
The built-in integrated multi-stage charger is equipped with several
protections that will ensure the battery is always protected. The
LCD Screen will indicate this condition with a Warning icon to the
left of the Input Source icon as shown. The FAULT led will also
pulse.  To find out more information simply touch the Warning icon.
Fault: BattTemp
If the battery temperature falls below 0°C or rises above 50°C
charging will be immediately disabled to prevent any damage to the
battery. Charging will automatically resume after the battery
temperature gets above 5°C or below 45°C. During this condition
the FAULT   led   will pulse red twice every 3 seconds.
Fault: BattSense
If the battery sensor harness gets damaged, the multi-stage charger
will be immediately disabled to prevent damage to the battery.
Please contact IntelliQuip support for assistance  . Under this
condition the FAULT led will pulse red once every 3 seconds.
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8.  Using the ToughPower
8.1  Time Prediction - LCD Screen
As described in the section Charging Complete, the Time Prediction feature will be enabled after a FULL
charge of the battery has been completed. This is to ensure that the built-in charger is synchronized with
the battery state and can start keep tracking of the charge in and out of the battery.
For Time Prediction  , the ToughPower uses built-in sensors to measure current (Amps) flowing in and out of
the ToughPower as well as a combination of software algorithms to compensate for the changes in
capacity of Lead-Acid type batteries when being used. The effects are described by Peukert’s Law, the
internal algorithms use the following constants for each type of battery:
Type
Peukert constant
LEAD/GEL
1.30
CALCIUM
1.20
AGM
1.10
LITHIUM LiFePO4
1.00
In addition, the Battery Condition influences the overall capacity as well. The following values are added to
the Peukert constant to improve the accuracy of the calculations:
Condition
Add
NEW
0.00
USED
0.10
OLD
0.20
Note: In terms of Time Prediction it is almost impossible to have 100% accuracy due to several external
variables impacting the result. Hence, time prediction calculations should be taken as a reference only  .
Always check the Battery Voltage and use that as a reference as well.
The time remaining icon will change depending on the overall Load on the system. When the ToughPower
is being discharged the time icon will show Empty and whilst charging it will show Full  , as shown in the
examples below.  Note: Time prediction is updated every 15 seconds.
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