Douglas Battery datatrac User manual

Douglas
DataTrac™
Wireless Battery Data
Recorder and Transmitter
Installation and Operation Manual
June 2013
3-3005-44-01
Information Solutions
Information Solutions

If after carefully following the instructions in this manual, you have
difculty installing or operating the product described, contact
technical support at www.DouglasBattery.com
Note
This document is based on information available at the time of its publication.
While efforts have been made to be accurate, the information contained herein
does not purport to cover all details or variations in hardware or software, nor to
provide for every possible contingency in connection with installation, operation, or
maintenance. Features may be described herein which are not present in all systems.
Aker Wade Power Technologies, LLC T 434.975.6001
4035 Hunterstand Court F 434.975.0984
Charlottesville, VA 22911
© Copyright 2013 Aker Wade Power Technologies, LLC. All rights reserved. All trademarks and logos are
the property of Aker Wade®except DataTrac™and Douglas Data Manager™, which are trademarks of
EnerSys®. Subject to change without notice. E.&O.E.
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Section 1: Introduction
Features and Capabilities
Data Available for Analysis
DataTrac Software Tools
Section 2: Specications
Section 3: Safety Precautions
Section 4: Setup and Initialization
 ConguringaPCtoCommunicatewiththeDataTrac
Testing Communications with the DataTrac
Initializing the DataTrac
Section 5: DataTrac Installation
For Battery Installation to Track Single-Battery Usage Data
Truck Installation for Tracking Throughput Measurements in Battery Change-Out Operations
Removing the DataTrac Unit for All Installations
Section 6: Optional Accessories
Section 7: Reading DataTrac Battery Data
Index
Contents
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4
5
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6
7
9
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10
12
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18
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21
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Connect the DataTrac and enhance your ability to manage battery usage,
maintenance and overall life. Start tracking daily usage, charge return,
temperature, water level and equalization events. With the DataTrac, you’ll collect
data needed to:
• Conrmoperatorcompliancechargingandequalizing
• Identifybatterymaintenanceneeds
• Easilyoptimizeeetsizeandtruckoperation
Features and Capabilities
DataTrac is an intelligent battery data-collection device for use with industrial
battery applications. It contains instrumentation to continuously measure
temperature, current and voltage. DataTrac is available with a split-core current
transducer, for applications which require portability and with a solid core
transducer, which is designed to be installed permanently on a single battery for
long term energy metering applications. DataTrac has an internal sensor which it
usestomonitortemperature.Itcanalsobeconguredwithanexternalthermistor
which can be inserted between two battery cells, for more precise temperature
measurements.Itcanoptionallybeconguredtomonitorbatteryelectrolytelevel
and to drive a 24V solid-state relay.
DataTrac can have one or two serial ports. One serial port is used for host
communicationandistypicallyconguredwithaBluetooth®radio for wireless
communicationsbutcanalsobeconguredasanRS232portforcommunicating
with a truck based host computer. The other serial port may be used in some
applications to communicate with the charger via an isolated RS232 serial port.
Itcontinuouslymonitorsthestateofthebatteryafterbeingconguredand
startedbytheuser.Dataisretainedinonboardashmemoryandeventsare
recorded detailing the operating condition of the battery. At all times the battery is
considered to be in one of three states:
• Charging
• Discharging
• Idle
When DataTrac determines that the state of the battery has changed, an event
record is generated and stored that records the cumulative data of the state that
has just ended, and a new summary recording the data of the new state is started.
In addition, key high and low values measured during the operating state are
recorded with this event record.
® Bluetooth is a registered trademark of Bluetooth SIG, Inc.
Section 1: Introduction

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Data Available For Analysis
• StartTimeandDate,TotalTimeandTotalAmperehoursforeachchargeprole
state (Charge, Discharge or Idle)
• Battery Temperature, voltage and electrolyte sensor level (for units with this
optioninstalled)atbeginningandendofeachchargeprolestate
• Summaries for total plug-ins, average charge duration, average AHRs returned,
calculated daily and averaged over entire measurement period
• BatteryorTruckIdentication(Serial/ModelNumber)canbeconguredonthe
DataTracforeasyreportidentication
DataTrac data is divided into three types:
Conguration Data contains the data necessary to manage the operation of
DataTrac,includingbatteryandtruckserialnumbers,batterycongurationandput
in service date.
Event Data is a record of the operation of the battery to which DataTrac is
attached. Events are recorded for each operating state of the battery (charge,
discharge and idle). Event data is used to compile an accurate record of battery
use.
Summary Data contains aggregate usage data which is compiled by software
analysis tools.
DataTrac Software Tools
TheDouglasDataManagerapplicationsoftwareisusedtoconguretheDataTrac
and analyze the data that it collects. Douglas Data Manager communicates with
DataTrac via Bluetooth and compiles and displays the data in different formats for
the end users: analysis such as ampere hours returned, temperature over time and
SOC over time. Douglas Data Manager uses a standard SQL database to maintain
DataTrac data, so that it can be easily accessed by any third party application.
For more information on using Douglas Data Manager with DataTrac devices, see
the Douglas Data Manager User’s Manual.

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Section 2: Specications
Name Description
Nominal Battery Voltage 24 V – 80 V
Operating Voltage 10 V – 110 V
Operating Temperature -4º F – 158º F (-20º C – 70º C)
Bi-directional Current Measurement Allows for throughput data collection using a Hall effect sensor which can measure +/- 600A
Voltage Measurement Continuous monitoring of overall battery voltage. Can be installed on truck or battery
Temperature Internal sensor or optional external thermistor
Electrolyte Level Detection With optional electrolyte sensor
Interface Bluetooth® communication
Real Time Clock Time keeping and stamping of data
Data Collection Upload data to PC or ExpressLink™via Bluetooth®
Data Storage 4000 event log records
Wireless Range Up to 100 meters
Power Consumption 1 Watt (integrated 950mWhr backup)
Protection •Over voltage
•Reverse Polarity Protection
Packaging •Water and acid resistant
•UL 94V-0
Physical Dimensions 5.0”L ×2.0”W ×1.2”H
Compliance Classified by UL®to UL 583
Table 1. Specications for DataTrac
® Bluetooth is a registered trademark of Bluetooth SIG, Inc.

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SAVE THESE INSTRUCTIONS
This manual contains important safety and operating instructions.
CAUTION! Installation of DataTrac must be performed by qualied
personnel only.
CAUTION! Working in the vicinity of lead-acid batteries is dangerous.
Batteries can generate explosive gases during normal battery operation. For this
reason, it is of utmost importance that you read these instructions and follow them
exactly.
• Wear complete eye protection and clothing protection. Avoid touching eyes
while working near the battery.
• If battery acid contacts the skin or clothing, wash immediately with soap and
water.Ifacidenterseye,immediatelyoodeyewithrunningcoldwaterfora
minimum of 10 minutes and get medical attention immediately.
• Make sure that the area in which you are working is well ventilated.
• NEVERsmokeorallowasparkorameinvicinityofbattery.
• Be extra cautious to reduce risk of dropping a metal tool onto battery. It is
capable of producing a spark or short-circuiting the battery or other electrical
part and causing an explosion
• Turn off all the electrical loads on the vehicle and set the brake before installing
or removing the DataTrac unit.
Section 3: Safety Precautions
This danger symbol indicates that personnel must
practice safety procedures in order to prevent
equipment damage, bodily injury, or death.

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CONSERVER CES INSTRUCTIONS
Ce manuel comporte des consignes importantes de sécurité et
d’utilisation.
ATTENTION! L’installation de L’DataTrac doit être effectuée
uniquement par du personnel qualié.
ATTENTION! Travailler à proximité de batteries plomb-acide est
dangereux.
• Les batteries peuvent générer des gaz explosifs durant leur fonctionnement
normal. Pour cette raison, il est de la plus grande importance de lire ces
instructions et de les suivre à la lettre.
• Porter des lunettes de protection et une combinaison de protection. Éviter de se
toucher les yeux pendant le travail à proximité de la batterie.
• Si l’acide de la batterie entre en contact avec la peau ou les vêtements, laver
immédiatement avec du savon et de l’eau. Si l’acide entre dans l’œil, rincer
immédiatement abondamment à l’eau froide en la laissant couler pendant un
minimum de 10 minutes et consulter immédiatement un médecin.
• S’assurer que l’espace de travail est ventilé correctement.
• NeJAMAISfumerouallumerd’étincelleoudeammeàproximitédela
batterie.
• Être extrêmement prudent pour ne pas laisser tomber un outil en métal sur la
batterie. Ceci pourrait produire une étincelle ou un court-circuit au niveau de
la batterie ou d’un autre composant électrique et provoquer une explosion.
• Éteindre toutes les charges électriques sur le véhicule et serrer le frein à main
avant d’installer ou de retirer l’unité DataTrac.
Ce symbole de danger indique que le personnel
doit suivre les procédures de sécurité de façon à
prévenir une détérioration de l’équipement, un
dommage corporel ou la mort.

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Conguring a PC to Communicate with the DataTrac
To communicate with the DataTrac from a PC, the PC must have a Bluetooth
radio installed (supplied with the Douglas Data Manager product) and be running
the Douglas Data Manager software. Refer to the Douglas Data Manager User’s
Manual for installing the software and the Bluetooth radio.
Testing Communications with the DataTrac
To verify that PC can communicate with DataTrac, prior to installing the DataTrac
on a truck or battery:
1. Gather Tools: DataTrac unit, DC power supply with output of at least 12 volts and
no more than 100 volts (such as bench power supply or 12V DC transformer), PC
with Douglas Data Manager software and Bluetooth radio.
2. Attach the red wire power lead of the DataTrac unit to the positive connection
of the DC power supply and the black wire power lead to the negative
connection. Apply power to the DC supply.
3. The red and green LEDs will blink rapidly as the DataTrac unit powers up. After a
delay of several seconds, you will see the green light of the unit begin to blink,
indicating that it is collecting data and ready to communicate with a host PC.
Note:
Only the green LED should be blinking on the DataTrac unit. If the DataTrac unit
isconguredwithanElectrolytelevelsensorandthesensoriseithernotinstalled
or detects a low Electrolyte level, the red LED will blink steadily. Any other blink
patterns are indicative of an error. If the unit displays any of the following LED
patterns, please call customer service:
• RedandgreenLEDashingsimultaneously–Realtimeclockerror(Batterymay
need to be replaced)
• RedandgreenLEDashingalternating–Unithasnotbeencalibratedorhaslost
calibration
• RedLEDashing3shortbursts,followedbylongburst-hardwareerror.
Section 4: Setup and Initialization

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Initializing DataTrac
Follow the instructions in the Douglas Data Manager User’s Manual for Creating an
DouglasDataManagerdatabaseandConguringtheDataTracunit.
Oncetheunithasbeencongured,the“getcurrentvalues”functioncanbeused
to make sure that the unit is reading voltage, current and temperature properly.
If the DataTrac unit is being deployed in a new location, you may also want to
cleartheeventdataontheunit.DataTraccanstore4087charge/discharge
events, so it is generally not necessary to clear events.