Thunderstruck TSM2500 Series User manual

TSM2500 Series High Efficiency Intelligent Charger
ThunderStruck User Manual Ver. 1.08

Table Of Contents
I. Product Overview
II. Safety
III. Preventing Short Circuits and Fire
1.Correct use of Breakers, Sockets and Cables
2. Correct Input Connections
3. Charging Environment Requirements
IV. Regular Maintenance
V. Technical Specifications
VI. Parts List
VII. LED Charge Light Information
VIII. Input and Output Interface
IX. Appearance and Installation Dimensions
X. Connections and Wiring
XI. Faults & Solutions

I. Product Overview
The TSM2500 series high efficiency intelligent charger is designed to charge traction
batteries of electric vehicles. This series of products adopt the most advanced technologies such
as LLC resonant, active power factor correction, microcomputer measurement and control,
digital adjusting, and extremely water resistant technology. Its features include: wide input
voltage range, high input power factor that significantly reduces the input current as well as heat
generated from the input cable, and low harmonic current that reduces interference to other
electric equipment. Full range soft switching is used to achieve high conversion efficiency and
very little electromagnetic interference. The charger is designed according to IP66 protection
grade and is highly water resistant. It is also small in size, lightweight, quiet, beautiful, simple to
install and of course easy operation and maintenance.
The charger uses microcomputer measurements and control technology, the embedded
CPU can accurately detect battery voltage and charge current.
The charger has temperature compensation functions, as well as automatic shut down
after being fully charged. Reverse battery connection protection as well as output short circuit
protection, AC input under voltage protection, and overheating protection. These functions help
to ensure safe and reliable use.
These are canbus controlled chargers, which require a charge controller to initiate a
charge, such as the ThunderStruck EVCC. Canbus information is available if needed for custom
applications. The non-canbus 48v charger model is designed for lead acid batteries, and provide
a pre-programmed charge profile without canbus control.

II. Safety
1. Please do not disassemble the charger; this may cause electric shock or other injuries.
2. If the charger needs to be connected to an AC power supply with extension cables, please
make sure that the extension cable can withstand the maximum input current (GB 2.5mm2
copper core cable is recommended to be used), and limit the extension cable length within 10m.
3. Don’t place the charger where it can get wet, this may cause damage to the charger as
well as electric shock to the operator.
4. The charger’s DC output plug should be connected reliably to the socket, if they are
damaged or loose, please replace them immediately, otherwise it will cause overheating in the
plug position, and can even cause fire.
5. If the charger produces any abnormal sound or smell while on, please unplug the
power immediately and contact the service department. Do not attempt to open the charger case.
6. Make sure that all air vents are unobstructed to prevent charger overheating. Do not place
the charger near a heat source; the charger should be left with enough space to ensure proper
ventilation.
7. Please disconnect the charger's AC input power if you need to move it.
8. Make sure that AC power supply voltage matches chargers’ input voltage. For inquiries,
please contact your supplier or local power Supply Corporation.
9. Battery voltage and the nominal voltage of the charger must be matched or it
could damage both the charger and the batteries.
10. To avoid damage to the charger’s cables, do not pull, twist or shake the cables or the
connection terminals. If the cable is worn, please replace it immediately.

III. Preventing Short Circuits and Fire
1. Correct use of Breakers, Sockets and Cables
1. Use stranded copper cables with flame-retardant jackets. The cable core diameter must be
at least 2.5mm in diameter for the AC power input.
2. Prevent plugs and sockets from coming in contact with water.
Note: According to statistics, 80% of electric car fires occur during charging. The main reasons
for this include insufficient cable size, poor quality plugs and sockets, poor contact of plugs and
sockets, poor flame-retardant sheath or shells of breakers, plugs and sockets, and uncontrolled
charge cycles.
2. Correct Input Connections
Make sure that the charge plug and connectors are clean, undamaged and free of dirt before
charging.
3. Charging Environment Requirements
Avoid the use of flammable materials. Charger should be mounted in a well-ventilated space.
Avoid mounting/placing the charging plugs, charging cables or the charger itself on synthetic
seats and other flammable objects.
4. Lithium Cell Safety
A lithium battery pack should have a battery management system to ensure safe charging. A
battery pack with no BMS can be very dangerous. We are not responsible for damage to batteries
due to using a charger with no BMS.
Most prismatic lithium batteries should be contained in a manner that prevents them from
swelling during charging and discharging. Consult your battery manufacturer’s recommendations
for the best way to package your cells.
IV. Regular Maintenance
1. Check all connectors and J1772 Socket regularly for corrosion, discoloration or other
conduction inhibitors. Poor contact may result in overheating and burning inside connectors,
which could cause a fire.
2. Make sure to use a charger that has a dedicated breaker and wire running to it.
3. Make sure that the charger’s shell and cooling fan are free of debris and dirt.

V. Technical Specifications
Rated input voltage: 220VAC 50/60Hz
Input voltage range: 85~265VAC (Note: When the Input voltage is lower than 185VAC, the
output power will be limited to 1.5KW)
Power Factor: ≥ 0.99 @ 220VAC input, full power output;
Total Harmonic Current: ≤ 5% @ 220VAC input, full power output;
Nominal output voltage: 144V
Maxim output voltage: 180V
Rated output current: 15A
Voltage regulation accuracy: ≤ 0.5%
Current regulation accuracy: ≤ 2%
Conversion efficiency: ≥ 95% @ 220VAC input, full power output
Protection class: IP66
Audible Noise: ≤ 40dB
Seismic rating: Designed according to IEC60335-2-29-2004-Part.21
Working temperature: -25~55°C (Note: models whose output power greater than 2KW
Storage temperature: - 40~80°C
Recognition certificates: CE SGS will ensure 2KW output at 60°C. )

VI. Parts List
A -AC Input Cables
B -DC Output Cables
C -Signal Cables
D -Charging Indicator E Mounting plate F Shell
G -Cooling Fan and Fan Cover
VII. LED Charge Light Information
When...
Then...
Red Light Flashing
The pack is approximately < 80% Charged
Yellow Light Flashing
The pack is approximately > 80% Charged
Green Light Flashing
The pack is approximately 100% Charged
Flashing Yellow, Red and Green in Various
Orders
Charging has recently stopped or has a
Fault with Charger or Batteries.
Repeated flashing sequence like Red, Green,
Yellow, Yellow, Yellow
Suggests a connection issue is detected (canbus or
high voltage output). Check all connections.

VIII. Input and output interface
Input Cables
Terminal Model
DJ7031-4.8-11
Direction of view: form the cables to terminal.
Terminal Model for
matching
DJ7031-4.8-21
Needle No.
Wire Color
Wire core diameter
Description
1#
brown
2.5 mm2
L——Live wire
2#
blue
2.5 mm2
N——Neutral wire
3#
Yellow
and green
2.5 mm2
PE——Protective grounding wire
Output Cables
Terminal Model
SB50
Needle No.
Wire Color
Wire core diameter
Description
+
red
6 mm2
Output positive pole
-
black
6 mm2
Output negative pole
Signal Cables
Needle No.
Wire Color
Wire core diameter
Description
Needle No.
1#
brown
2#
Blue
DJ7031Y-2.3-21
external LED
indicator interface
DJ7031Y-2.3-11
3#
yellow
4#
purple
DJ7021-1.5-21
Battery Temperature
sensor interface
DJ7021-1.5-11
5#
white
6#
pink
DJ7043-2-21
Serial
communication
interface
DJ7043-2-11
7#
Yellow and
green
8#
Blue and
white
9#
Green and
white

10#
orange
DJ7021-2-11
Driveaway
Protection
(normally closed)
DJ7021-2-21
11#
grey
Wire core diameter
0.5 mm2 for all Signal wires
Signal Cables Terminal Diagram (prior to 2020)
Direction of view: form the cables to terminal.
DJ7031Y-2.3-11
DJ7021-1.5-11
DJ7043-2-11
DJ7021-2-21

IX. Appearance and Installation Dimensions
Do not bend the wires coming out of the charger until they have at least 50mm of space from
where they enter the shell of the charger.
Ensure that there is a 50mm gap above the charger to allow for proper ventilation.

X. Connections and Wiring
Input Cables
Canbus Connection –prior to 2020
Note: The Yellow and Pink wires are not used
Refer to the EVCC Manual for more details on EVCC wiring.
Canbus Connection –2020 and later
Note: If wire colors do not match, then compare connector orientation.

Remote Charge Indicator Connector
Note: Remote light provided with charger
AC Input Connection Options
`

Output Cables
HV DC Output Connector
12v DC Output Connector –2020 and Later
Note: During charge only, provides up to 2 amps at 12v DC
Driveaway Protection Switch Output
Note: EVCC can also provide driveaway protection. The above connects to a
normally closed (NC) internal switch. The switch is closed when the charger is
NOT plugged into AC power. This can be used to activate a 12v low current (200
ma) external relay which enables drive components only when the charger is
unplugged.

XI. Faults and Solutions
Please refer to the table to help resolve common charger issues. Please email ThunderStruck
Motors if troubleshooting is unsuccessful. Please include all test results and measurement details.
Fault
Analysis
Solutions
No Fan or Light
Poor connection on charger
AC input. AC supply circuit
breaker is open or supply is
off. Charger fault
Check connectors and breaker for heat
damage or open circuit. Minimum
supply wiring 12 ga or larger. Check
J1772 Proximity connections. Contact
us if fault.
Charging timeout
Battery circuit open or high
resistance
Check DC connections at charger and
entire battery circuit
High temperature
indication with
cool charger
Charger error
Please contact us
Charger reports
incorrect voltage
Poor output connection,
charger fault
Check output connections, pack
connections. Contact us if fault.
Reaches max
voltage after
short charge
Poor contact between charger
and battery, battery fully
charged, low battery capacity
Check if the battery is damaged, battery
connections are tight, the battery is fully
charged
Low battery
capacity after full
charge
Wrong charge voltage, battery
is aging, power circuit cable
fault
Check voltage settings, replace the
battery, repair cable fault
Low current
during charge
Cables are too long or too thin
Between the charger and
battery, wrong current setting
Use proper cable size for length used,
check charge current settings
Charger fan off or
intermittent but
light flashes
Poor input connection, dirty
fan, fan faulty
Repair connections, clean fan, contact
us if fan faulty
Arching when
connecting to
battery
Minor arcing is normal.
Significant arcing means
wrong polarity or bad charger
Check and connect the battery correctly,
contact us
Over-Temperature
Fault
Charging environment
temperature is too high;
cooling fan is fault; air vents
are obstructed
Keep charger case away from surfaces
for cooling. Ventilate charger space.
Verify fan is operating.
Battery
Overheating
Battery overcharging, wrong
charger voltage, damaged or
aging battery
Check charge settings, Test and replace
battery