Table of Contents
Summary of Contents for Intelligent Charging CT75A
- Page 1 CT75A : Battery Capacity Tester Operators Manual CT75A BATTERY CAPACITY TESTER OPERATORS MANUAL Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 1 of 55 Printed On : 16/02/22...
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Page 2: Table Of Contents
6.4 Capacity Test To Failed Cells....................30 6.5 Automatic Cell Balancing....................31 6.6 Full Battery Discharge......................32 6.7 Performing A Capacity Test....................33 Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 2 of 55 Printed On : 16/02/22... - Page 3 11.4.4 Ribbon Cartridge Replacement................50 11.4.5 Consumables Available....................51 12 Specifications........................52 13 Product Disposal Instructions....................53 14 Product Warranty.........................54 15 Owners Notes........................55 Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 3 of 55 Printed On : 16/02/22...
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Page 4: Manual Revision History
Updated to reflex major software update. 22-06-2020 Added cell monitor connection details. 15-02-2022 Added information on the manual cell scan and balance functions. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 4 of 55 Printed On : 16/02/22... -
Page 5: Equipment Description
Capacity Test 12V at 100A Or 24V at 80A The unit contains a high flow rate fan to extract the heat energy generated internally when running in capacity test mode. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 5 of 55... -
Page 6: Capacity Testing Modes
This report can be used to complement the service schedule by providing full traceability. The print can also include the printed serial number of the battery, Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt... - Page 7 The external printer when fitted allows the operator to print hard copies of the charge and test results upon completion of the test. This report can be used to complement the service schedule by providing full traceability. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 7 of 55...
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Page 8: Component Parts
BREAKER BREAKER POWER BATTERY CELL MONITOR I ntelligent Charging BATTERY MUST BE ISOLATED FROM Limited EQUIPMENT BEFORE CONNECTION intelligent-charging.com Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 8 of 55 Printed On : 16/02/22... -
Page 9: Controls And Indicators
This 6 pin connector is the power connector for the cell monitoring unit. (E) – KEYPAD All battery charge and capacity test functions are activated via this 16 key keypad. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 9 of 55... -
Page 10: Rear Panel Controls And Indicators
Operation of the circuit breaker is an indication of a fault and the unit will need to be checked before using. Rear Panel Controls And Indicators Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 10 of 55... - Page 11 This is the entry point for the power lead into the unit. Always check that the lead is not damaged before use. (L) - Mains Fuse. The mains fuse fitted to the CT75A is 3.15A Anti-Surge 1¼” Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt...
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Page 12: Cell Monitor Interface
Operators Manual 3 Cell Monitor Interface General The CT75A battery analyser has built in support for the cell-monitoring interface (TH20). This allows the monitoring of NiCd batteries of up to 20 cells. For upgrade details please contact Intelligent Charging Limited or your local reseller. -
Page 13: Cell Monitor Connection
UNDER NO CIRCUMSTANCES CONNECT A BATTERY TO THE CELL MONITOR WITHOUT IT FIRST HAVING POWER APPLIED FROM THE CHARGER AS DAMAGE MAY OCCUR TO THE INTERNAL SENSING CIRCUITRY. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 13 of 55... -
Page 14: Flying Lead Connection Diagram
CT75A : Battery Capacity Tester Operators Manual 3.2.3 Flying Lead Connection Diagram 24.0V Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 14 of 55 Printed On : 16/02/22... -
Page 15: Crown Connection Diagram
CT75A : Battery Capacity Tester Operators Manual 3.2.4 Crown Connection Diagram 24.0V Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 15 of 55 Printed On : 16/02/22... -
Page 16: Discharging With The Cell Monitor
The cell monitor printout is a similar format to the figure below: Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt... -
Page 17: Cell Scan Only Mode
From MAIN page select : - SETTINGS -> SYSTEM -> MORE..-> CELL MONIT -> BALANCE Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 17 of 55... -
Page 18: Initialise The Cell Monitor
Cell scan and print during standard charge modes The charger has an option which allows the use of the cell monitor to monitor and print Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 18 of 55... -
Page 19: Cell Monitor Manual Scan
3.12 Cell Monitor Manual Cell Balance There is a feature in the cell monitor setting which allows a manual cell balance to be Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 19 of 55... -
Page 20: Cell Monitor Specifications
1.0 ±1% 2W Voltage Accuracy 0.004V Note the voltage accuracy is not independent of the overall battery voltage accuracy. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 20 of 55 Printed On : 16/02/22... -
Page 21: Equipment Menu Operation
‘A’, ‘B’, ‘C’ or ‘.’ keys. To get back to the main menu the ‘CLR’ key is pressed repeatedly. The following flowchart illustrate the menu structure. Charging Menu Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 21 of 55... -
Page 22: Capacity Testing Menu
CT75A : Battery Capacity Tester Operators Manual Capacity Testing Menu Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 22 of 55 Printed On : 16/02/22... -
Page 23: Process Operation Menu
CT75A : Battery Capacity Tester Operators Manual Process Operation Menu Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 23 of 55 Printed On : 16/02/22... -
Page 24: Settings Menu
CT75A : Battery Capacity Tester Operators Manual Settings Menu Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 24 of 55 Printed On : 16/02/22... -
Page 25: Connecting A Battery
Once the charger leads are connected to the unit then the battery can be connected. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 25 of 55... - Page 26 BLACK HEATSHRINK AT CRIMP END FOR 100mm +/- 5mm NEGATIVE PLUG Specialist lead sets are available by request to suit many battery types. Please contact Intelligent Charging Limited for prices and availability. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt...
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Page 27: Battery Capacity Test Or Discharge Operation
This is usually 1 Hour. START MAINTAIN TEST CURRENT TARGET VOLTAGE REACHED HAS TIME ELAPSED CLR KEY PRESSED STOP CAPTEST Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 27 of 55 Printed On : 16/02/22... -
Page 28: Capacity Test To Target Voltage
This is usually 1 Hour. START MAINTAIN TEST CURRENT HAS TIME ELAPSED CLR KEY PRESSED STOP CAPTEST Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 28 of 55 Printed On : 16/02/22... -
Page 29: Capacity Test Using Cell Monitor
If a printer STOP CAPTEST is available this value defines the period at which the cell voltages are printed. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 29 of 55 Printed On : 16/02/22... -
Page 30: Capacity Test To Failed Cells
AS FAILED defines the period at which the cell voltages are printed. HAS TIME ELAPSED CLR KEY PRESSED STOP CAPTEST Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 30 of 55 Printed On : 16/02/22... -
Page 31: Automatic Cell Balancing
Test Time : This is the STOP maximum time at which the discharge test performed. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 31 of 55 Printed On : 16/02/22... -
Page 32: Full Battery Discharge
HAS TIME ELAPSED TARGET VOLTAGE REACHED ALARM CLR KEY SOUND ACKNOWLEDGED PRESSED ALARM ALARM MUTE SOUNDING ALARM STOP CAPTEST Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 32 of 55 Printed On : 16/02/22... -
Page 33: Performing A Capacity Test
• If the selected item is marked as NO DATA the name for this item will be • requested. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 33 of 55 Printed On : 16/02/22... -
Page 34: Data Entry Procedure
CAPTEST TO FAILED CELLS AUTOMATIC CELL BALANCE FULL DISCHARGE The following tables explains what the values entered mean. CAPACITY TEST TO TIME Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 34 of 55 Printed On : 16/02/22... - Page 35 Amps The discharge current to maintain. Discharge Time Hour and The maximum time for the capacity test usually 1 Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 35 of 55 Printed On : 16/02/22...
- Page 36 Note during the charge the cell voltages can be manually printed at any time by pressing the '.' key. FULL DISCHARGE Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 36 of 55 Printed On : 16/02/22...
- Page 37 Discharge Time Hours and The discharge will continue for this set amount of Minutes. time. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 37 of 55 Printed On : 16/02/22...
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Page 38: Process Mode
Select RENAME to set a recognisable name. Select VIEW/EDIT to view and edit the process steps. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 38 of 55 Printed On : 16/02/22... -
Page 39: Renaming A Process
Check battery is correctly connected and a voltage is displayed in the main • Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 39 of 55 Printed On : 16/02/22... -
Page 40: Process Termination
At any point during the process the ‘CLR’ key can be pressed to stop the process execution. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 40 of 55 Printed On : 16/02/22... -
Page 41: Calibration
V d.c. V d.c. 1000 1000 200m 200m 200m V a.c. A a.c. 200m V a.c. 200u A a.c. 200u Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 41 of 55 Printed On : 16/02/22... -
Page 42: Check Procedure
Allow the capacity test current to stabilise. • When requested enter the capacity test current and press ‘ENT’ • Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 42 of 55 Printed On : 16/02/22... -
Page 43: Reviewing Calibration Date
Select SETTINGS -> PRINT or DISPLAY -> SYSTEM The unit will then print or display the calibration data. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 43 of 55... -
Page 44: Miscellaneous Unit Functions
‘CLR’ key. • BATTERY REV OR < 0.1V Applies to all modes. Indicates that a battery voltage less that 0.1V has been Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 44 of 55... - Page 45 • BATT VOLTS > TARG VOLTS Applies to CONSTANT VOLTAGE CHARGE mode only. This occurs when the Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 45 of 55...
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Page 46: Print Or Display Previous Operation Results
18/11/2019 mm/dd/yyyy 11/18/2019 yyyy/mm/dd 2019/11/18 yyyy/dd/mm 2019/18/11 dd mmm yyyy 18 Nov 2019 mmm dd yyyy Nov 18 2019 Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 46 of 55 Printed On : 16/02/22... -
Page 47: Modifying Display Intensity
60C, and switched it off when the heatsink temperature falls below 40C. In normal operation on low charge and discharge operations the fan may not run at all this is normal. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 47 of 55... -
Page 48: Service And Maintenance
The cell is a standard Lithium button cell number CR2032. When replacing the battery please observe the correct methods of disposal of the old battery in accordance with your local regulations. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 48 of 55... -
Page 49: Printer Care
To manually advance the paper depress this button as shown in figure 2. paper will continue to advance while the button is pressed. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 49 of 55 Printed On : 16/02/22... -
Page 50: Paper Roll Replacement
(see Figure Carefully press the door and chassis vertically opposite directions until the catch is Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 50 of 55 Printed On : 16/02/22... -
Page 51: Consumables Available
Use of this paper is recommended, as most paper rolls from other sources are too large to fit within the printer housing, and may be of inferior quality causing dust and wear. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 51 of 55... -
Page 52: Specifications
Altitude 0 to 3000 Metres. Discharge Specifications Max Input Volts Max Input Amps Max Input Watts 40.0V 100.0A 1920W Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 52 of 55 Printed On : 16/02/22... -
Page 53: Product Disposal Instructions
Business users should contact their suppliers and check the terms and conditions of the purchase contract and ensure that this product is not mixed with other commercial waste for disposal. Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 53 of 55... -
Page 54: Product Warranty
Intelligent Charging Limited only obligation shall be to repair or replace such products that have proved to be faulty. Intelligent Charging Limited shall not be liable for any injury, loss or damage, direct or consequential, arising out of the use, or the inability to use the product. The customer shall determine the suitability of this product for its intended use, and the customer assumes all risks and liability whatsoever in connection herewith. -
Page 55: Owners Notes
_________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ Copyright Material of Intelligent Charging Limited © 2018 Doc: DWG1051-07-R8 CT75A Operators manual.odt Page 55 of 55 Printed On : 16/02/22...