TSI 854036 Environmental DustTrak Rechargeable Battery System Instruction Manual

TSI 854036 Environmental DustTrak Rechargeable Battery System Instruction Manual

Safety Information

NOTICE

Prior to using the Battery Pack for the first time, a full recharge is recommended. Recharging Battery Pack(s) immediately after use (within one hour maximum) is critical to obtaining optimal recharge time, battery health, and battery life.

Reusing and Recycling

As part of TSI® Incorporated’s effort to have a minimal negative impact on the communities in which its products are manufactured and used:

DO NOT dispose of used batteries in the trash. Follow local environmental requirements for battery recycling.

If instrument becomes obsolete, return to TSI for disassembly and recycling.

This guide will help you quickly install the Batteries into the DustTrak Environmental Monitor.

Unpack the Battery Kit (854036)

1. Unpack the Battery Kit (854036) and verify that all the items listed in the following table are present.
2. Contact TSI immediately if items are missing or broken.

Install the Battery Tray

Connect the Harness to the Batteries

NOTICE

The batteries can be used individually or in pairs. The DO NOT need to both be connected at the same time.

Route the Harness and Connect to DIN Rail

• The battery kit can be used as the sole source of power for the DustTrak™ monitor, or as a back-up to units normally powered by mains AC that are at risk of a power loss. The battery harness can be connected into the DIN rail in one of two locations depending on how the battery kit is used.

• If using the battery kit as the sole source of power, connect the wiring harness to the large pair of connectors on the left.
  NOTICE
  If an AC/DC adapter is configured with the instrument and you do not plan to use AC mains power, unplug the adapters connector from the DIN rail and plug the battery harness into the same spot.

• If using the battery kit as a back-up source of power, connect the wiring harness to the large pair of connectors on the right.
  

Safe Handling and Usage Guide

• Read the “Battery Charger User’s Manual” before using the battery charger.
• DO NOT modify the battery packs (P/N 801808) or battery charger (P/N 801809) in any way from the original state received from TSI®. The warranty period on the replacement battery packs (P/N 801808) or the replacement battery charger (P/N

801809. are valid for one year from date of shipment from TSI Incorporated.

• NEVER use a substitute charger to charge battery packs. Only use TSI P/N 801809 chargers to charge battery packs (P/N 801808).
• ALWAYS disconnect (unplug) power from charger before removing battery packs from the charger.
• ALWAYS completely charge battery packs before use.
• ALWAYS inspect battery packs and cables prior to charging or use.
• PLACE BATTERY PACKS ON CHARGE IMMEDIATELY AFTER USE. Waiting to charge batteries after use will result in poor battery health, longer charge times and decreased battery life.
• Keep battery packs on charge when NOT in use.
• It is important to check the health of battery packs at least once every three (3) months. To check the current health status of a battery pack, perform the “Battery Pack Health Check Procedure” provided in the Maintenance section below for details.
• REMOVE from service and appropriately recycle any battery pack that provides less than 17 hours of run-time (no heated inlet).
• REMOVE from service and appropriately recycle any battery pack that has triggered an error while charging as this is an indication of a battery that will not take a charge any longer.
• Keep battery packs AWAY from the presence of flammable materials at all times, as the battery pack can be a source of ignition.
• DO NOT expose a battery pack to temperatures less than 5°F/-15°C or greater than 122°F/50°C at any time.
• Charge and store battery packs in a cool, clean, dry, and well-ventilated environment.
• DO NOT leave a battery pack inverted for long periods of time.
• Battery packs should only be handled using the battery straps mounted on the top of the battery case from TSI® factory.
• DO NOT handle or carry the battery pack using the power cable connector.
• REMOVE (disconnect) any wire connections from power cable connector before attempting to remove batteries from Environmental Enclosure or prior to charging.
• ONLY connect battery packs together using the Battery Wiring Harness provided with the Battery Kit.
• DO NOT attempt to charge battery packs using the Battery Wiring Harness or Dual Battery Wiring Harness (P/N 801817); it will not work and could cause serious damage to either the battery packs or the battery charger. The Dual Battery Wiring Harnesses are is designed to be used to supply power to various models of DustTrak™ monitors and TSI® accessories only.
• If strain is applied to battery pack power cables, evaluate the cable for damage before using.
• If any damage is observed to any battery pack power cable at any time, DO NOT attempt to use or charge the battery pack. REMOVE and dispose of the damaged cable.

Operation

Changing and Re-charging the Batteries

It is recommended to change the battery pack at least every 24 hours of use or every 48 hours if using two batteries. If using the Heated Inlet accessory with the Environmental Enclosure, change the battery at least every 15 hours of use or 30 hours if using two batteries.

A voltage cutoff switch will cut the power to the DustTrak™ II/DRX aerosol monitor when the battery voltage reaches 10.5 V. This ensures that the battery does not become too deeply discharged to recover, and also prevents the DustTrak™ monitor from operating below its rated voltage input. Preventing this condition will prolong the life of the battery.

If storage is required, battery packs should be fully charged prior to storage to prolong the life of the battery and be left off of charge for no longer than three months maximum. However, it is NOT recommended to store battery packs off of charge. Battery packs stored off charge may result in shorter than average life.

Battery packs will age over time per usage and care. The battery packs will last 180 to 200 cycles on average. One cycle being defined as one battery pack discharge and one recharge process. With optimal use and care, the life of a battery pack may possibly increase beyond 200 cycles. For optimal battery health, keep battery packs on charge in a cool, dry, and well-ventilated area while NOT in use, and recharge battery packs immediately after use.

If battery packs are stored off of charge for durations longer than 30 days then longer charge times and shorter run-times may result due to degraded battery health. Battery pack health will diminish at a much more rapid pace if NOT recharged immediately (within one hour maximum) after use.

It is important to remove a battery pack from service if signs of diminished run-time or longer charge time are observed. These are signs of battery pack aging and poor general battery health. To identify unhealthy battery packs, it is important to review and adhere to the Battery Pack Health Check Procedure in the Maintenance section below.

A battery pack in good health will take near 8 to 9 hours to fully charge.

A battery pack that provides 30% less product run-time than expected is ready to be removed from service. If a given battery pack provides a run-time of 17 hours or less for the DustTrak™ Environmental Monitor or a runtime of 10 hours or less for when combined with the Heated Inlet, the battery pack should be removed from service and properly recycled in accordance with local environmental regulations.

NOTICE

Prior to using the Battery Pack for the first time, a full recharge is recommended. Recharging Battery Pack(s) immediately after use (within one hour maximum) is critical to obtaining optimal recharge time, battery health, and battery life.

Charging Battery Pack

1. Disconnect the battery pack from the DustTrak™ Environmental Monitor and remove it from the Environmental Enclosure. Take it to a protected area where it can be charged undisturbed for 6 to 8 hours. Before charging any battery pack, please completely read the “Battery Charger Owner’s Manual” that was provided along with your charger. DO NOT attempt to charge Battery Packs using the Dual Battery Wiring Harness (P/N 801817). The Dual Battery Wiring Harness is designed to be used to power the instrument only.
   The information below is NOT intended as a substitute to the charger manual. The charger manual will cover all important warnings and operating instructions for using the charger. The steps below will guide you through the battery pack charging process steps.

2. Connect the charger to the battery using the quick disconnect cable that matches the connector on the battery pack. Additional quick disconnect cables included have alligator clips and ring terminals, these are not needed for charging the TSI battery packs and
   are simply additional accessories for the charger.

3. Plug in the battery charger to AC power supply or wall receptacle.

4. Select the proper mode using the MODE button on the charger. Normal mode should be used to charge the battery pack.

5. If the battery has been fully discharged, the >8 (hour) LED will illuminate, indicating a charge time of roughly hours is needed to completely charge the battery. It is important to allow the charger to go through a complete charging cycle in order to charge each battery pack to an optimum level.
   NOTICE
   DO NOT stop charging a battery before it is completely charged.

6. When the “GO” LED has been illuminated, the battery has reached a full charge. Battery packs should be completely charged before using. The charger can remain connected in this state indefinitely—it will continue to float charge the battery at a very low level with no risk of overcharging the battery. When this occurs the “CARE” LED will illuminate.
   IMPORTANT
   Leaving battery packs connected to the charger while not in use is highly recommended, and doing so will maintain the battery at a fully charged state and support optimum battery pack health while it is not in use.

7. The battery can now be disconnected from the charger and used. ALWAYS DISCONNECT THE CHARGER FROM THE AC POWER SUPPLY (REMOVE AC PLUG FROM WALL SOCKET) BEFORE REMOVING THE BATTERY PACK FROM THE CHARGER AFTER CHARGING HAS COMPLETED. This will prevent the possibility of arcing during the battery disconnect process.

Error Lamp Feature

The charger is equipped with an “ERROR” feature. This feature can identify batteries that have poor battery health and will not charge. The red LED next to the “!” on the left side of the charger, will illuminate if the charger is unable to charge the battery pack. The feature is designed to prevent over- charging an aging battery or batteries having poor health due to abuse.

In the event that a battery has been identified to have an error, attempt to recondition the battery using the “RECOND” mode on the charger. If the error persists, remove the battery pack from service immediately and recycle the battery pack appropriately.

Using the Dual Battery Wiring Harness

The Dual Battery Wiring Harness (P/N 801817) is a product option used to connect two battery packs together to provide roughly twice the run-time provided with a single battery pack. To use the Dual Battery Wiring Harness, simply connect two battery packs to the Dual Battery Wiring Harness at the male connectors and then connect the female connector to the Internal DC Power Cable connector. Once the cable is connected, power will be delivered to the DustTrak™ Aerosol Monitor and any accessories.

The Dual Battery Wiring Harness is NOT intended for use to charge battery packs. The cable is designed specifically to prevent the use of the cable to charge battery packs through the cable interface. Be careful to NOT put unnecessary strain on the cable or connectors.

Only connect the Dual Battery Wiring Harness after installing battery packs into the environmental enclosure case. Moreover, be sure to disconnect the Dual Battery Wiring Harness prior to removing battery packs from the environmental enclosure case. Only use the cable internal to the environmental enclosure case.

The Dual Battery Wiring Harness is water-resistant, but NOT waterproof, the cable may fail if subjected to abundant water exposure including submersion in water.

Maintenance

When to Change the Battery

Single battery packs are designed to provide power to the monitor for a minimum of 24 hours, even under cold ambient conditions. Adding the optional heated inlet accessory will result in 15 hours minimum battery life.

If using the Dual Battery Wiring Harness, two battery packs will provide power to the monitor for roughly 48 hours or 30 hours with the heated inlet accessory. To ensure uninterrupted operation, the packs should be replaced daily or within the time period listed above.

If a battery pack has been forgotten and is left connected to a running DustTrak™ monitor, the extended-life battery will automatically quit delivering power after its voltage drops below 10.5 V. This cutoff provides protection to the battery pack, which will extend the lifetime of the pack.

NOTICE

The logged data WILL NOT be lost even if both battery packs lose power.

Battery Pack Life

Battery packs will age over time per usage and care. The battery packs will last 180 to 200 cycles on average. One cycle being defined as one battery pack discharge and one recharge process. With optimal use and care the life of a battery pack may possibly be increased beyond 200 cycles. To obtain optimal battery health, keep battery packs on charge in a cool, dry, and well- ventilated area while NOT in use, and recharge battery packs immediately after use. This assumes that the batteries are being used to run a DustTrak™ Environmental Monitor every day and that they are properly cared for and rotated daily. Replacement battery packs may be ordered from TSI®.

If battery packs are stored off of charge for durations longer than 30 days then longer charge times and shorter run-times may result due to degraded battery health. Battery pack health will diminish at a much more rapid pace if NOT recharged immediately (within one hour maximum) after use.

It is important to remove a battery pack from service if signs of diminished run-time or longer charge time are observed. These are signs of battery pack aging and poor general battery health. A battery pack in good health will take near 8 to 9 hours to fully charge. A battery pack that provides 30% less product run-time than expected is ready to be removed from service. If a given battery pack provides a run-time of 17 hours or less for the DustTrak™ monitor, or a run-time of 10 hours or less with the heated inlet accessory, the battery pack should be removed from service and properly recycled in accordance with local environmental regulations.

Battery Pack Health Status Check

TSI® highly recommends consistently monitoring the health of all battery packs in possession. This status check is intended to help with that process and should be performed in addition to the use and handling instructions listed within this manual. This status check is not intended as a replacement for any other use and handling instructions as all instructions are important to follow to maintain battery health and to get the maximum life from battery packs. It is important to follow the following process to help to identify a battery pack that is no longer in good health and needs to be recycled.

Battery Pack Health Check Procedure

1. Check the battery pack visually for any signs of bulging or abnormal appearance.

2. Connect the battery to the TSI® Battery Charger Part #801809.

3. Plug in power to the charger.

4. Keep the battery pack on charge until the charger’s “GO” LED light is lit green indicating that the battery isnow completely charged.

5. Disconnect power from the charger.

6. Disconnect the battery pack from the charger.

7. Let the battery pack rest (off the charger) for at least one hour.

8. Using a DC Volt Meter, connect the “red” (positive) test lead of the meter to the battery pack output connector at the conductor located closest to the triangle-shaped side of the connector. Please see the illustration.

9. Connect the “black” (negative) test lead of the DC Volt Meter to the battery pack output connector at the bottom conductor as illustrated in the picture above.

10. Record the voltage measured by the DC Volt Meter.

11. If the measured voltage is ≤12.9 volts, this battery pack is no longer in good condition and should NOT be charged. Remove this battery from service and recycle the battery according to local, state, or federal regulations.

12. However, if the measured voltage is ≥13 volts, this battery is in good operating condition and is able to be charged unattended, using the TSI® Battery Charger Part #801809.

TSI Incorporated – Visit our website www.tsi.com for more information.

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China Tel: +86 10 8219 7688
Singapore Tel: +65 6595 6388

TSI and TSI logo are registered trademarks of TSI Incorporated in the United States and may be protected under other country’s trademark registrations. DustTrak is a trademark of TSI Incorporated.

P/N 6008712 Rev. D
©2022 TSI Incorporated
Printed in U.S.A.

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