Power Designers PowerTrac SP Series Specification sheet

PowerTrac SP
PTSP 24-84V
Operation and Installation Manual
Ver. 1.1
Battery Management Solutions by

TABLE OF CONTENTS
1. SAFETY......................................................................................................... 1
2. DEFINITIONS AND ABBREVIATIONS......................................................... 3
3. PRODUCT DESCRIPTION............................................................................ 4
4. TECHNICAL SPECIFICATIONS ................................................................... 6
5. PROCEDURE FOR INSTALLATION AND OPERATION ............................. 7
5.1 PACKAGE CONTENT.......................................................................................... 7
5.2 POWERTRAC SP INSTALLATION PROCESS........................................................ 10
5.2.1 Sealed Battery ....................................................................................... 10
5.2.1.1 Shunt Mounting......................................................................................... 10
5.2.1.2 PowerTrac-SP Module Mounting .............................................................. 11
5.2.2 Flooded Battery...................................................................................... 11
5.2.2.1 Shunt Mounting......................................................................................... 11
5.2.2.2 PowerTrac-SP Module Mounting .............................................................. 16
6. SOFTWARE INSTALLATION AND OPERATION ...................................... 18
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6.2 INSTALLING THE PALM APPLICATION TO THE HANDHELD..................................... 18
6.1 MINIMUM SYSTEM REQUIREMENTS .................................................................. 18
6.2.1 Palm Installation Check.......................................................................... 20
6.3 INSTALLING THE WINDOWS APPLICATION TO YOUR PC ...................................... 20
6.4 POWERTRAC SP SETUP ................................................................................. 21
6.4.1 A. Setting Battery Parameters................................................................ 21
6.4.2 Setting PowerTrac Configuration Parameters........................................ 24
6.5 DATA ACQUISITION ......................................................................................... 27
6.5.1 Downloading Data to the Palm Device................................................... 27
6.5.2 Viewing Palm Summary Data ................................................................ 29
6.5.3 Viewing Palm Detailed Data................................................................... 30
6.5.4 Downloading Data to the PC.................................................................. 30
6.6 BUILDING CHARTS & GENERATING REPORTS ...................................... 34
6.6.1 Building Charts....................................................................................... 34
6.6.2 Generating Reports................................................................................ 36
6.6.3 Browsing Events .................................................................................... 40
6.7 PALM MENU DESCRIPTIONS ............................................................................ 43
6.8 PALM SCREEN DESCRIPTIONS ......................................................................... 44
7. TROUBLESHOOTING ................................................................................ 51
8. WARRANTIES............................................................................................. 56
9. CONTACTING POWERDESIGNERS ......................................................... 57
POWERTRACSP SOFTWARE LICENSE AGREEMENT ................................... 58
PoweTrac SP ii

LIST OF FIGURES
Figure 1: PowerTrac SP block diagram ..................................................................... 4
Figure 2: PowerTrac SP package .............................................................................. 7
Figure 3: Close up top view of the PowerTrac SP unit............................................... 8
Figure 4: PowerTrac SP leads ................................................................................... 8
Figure 5: Bolt-On shunt.............................................................................................. 9
Figure 6: Clamp-On shunt.......................................................................................... 9
Figure 7: Locating the intercell connector to be replaced......................................... 12
Figure 8: Locating the intercell connector to be replaced......................................... 12
Figure 9: Locating the punch holes .......................................................................... 13
Figure 10: Marked punch holes ............................................................................... 13
Figure 11: Drilling off the intercell connectors .......................................................... 14
Figure 12: Placing the fiber washers........................................................................ 14
Figure 13: Dropping the shunt in place .................................................................... 15
Figure 14: Filling the holes with lead if needed ........................................................ 15
Figure 15: PowerTrac SP installed........................................................................... 17
Figure 16: Installation Files Window ........................................................................ 19
Figure 17: PowerTrac Software Icon........................................................................ 19
Figure 18: Installation Verification: Quick Look ........................................................ 20
Figure 19: PowerTrac Windows Startup Screen ...................................................... 21
Figure 20: PowerTrac Menu Bar – Selecting Batt Settings Submenu...................... 22
Figure 21: PowerTrac Palm Batt Settings Screen.................................................... 22
Figure 22: Saving Battery Settings........................................................................... 24
Figure 23: PowerTrac Palm Menu Bar – Selecting Admin Settings Submenu......... 24
Figure 24: PowerTrac Palm Admin Settings Screen ................................................ 25
Figure 25: Admin Settings Screen - Saving Battery Settings ................................... 25
Figure 26: Downloading Events File ........................................................................ 27
Figure 27: Downloading Events File - Password and Progress Screens ................. 28
Figure 28: Downloaded Events Files ....................................................................... 28
Figure 29: Viewing Battery Data - Battery Status and Summary Screens ............... 29
Figure 30: Record Menu – Detailed Data Screens................................................... 30
Figure 31: Pam PC Connection Menu – PC Transfer .............................................. 31
Figure 32: Palm PC Transfer Screen ....................................................................... 31
Figure 33: PowerTrac Windows Menu Bar – Palm Connection ............................... 32
Figure 34: PowerTrac Windows Connection Screen................................................ 32
Figure 35: PowerTrac Windows File Download Screen ........................................... 33
Figure 36: PowerTrac Database Files...................................................................... 33
Figure 37: PowerTrac Chart Selection Screen......................................................... 35
Figure 38: A Sample Chart ...................................................................................... 36
Figure 39: Generating Reports Screen .................................................................... 37
Figure 40: A Sample Report .................................................................................... 37
Figure 41: Browsing Events Window ....................................................................... 41
Figure 42: A Sample Events Table .......................................................................... 41
Figure 43: Connection Menu.................................................................................... 43
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Figure 44: Record Menu .......................................................................................... 43
Figure 45: Records List Screen ............................................................................... 44
Figure 46: Settings Screen ...................................................................................... 45
Figure 47: Administration Screen............................................................................. 46
Figure 48: Password Screen.................................................................................... 47
Figure 49: “Battery Info” Screen............................................................................... 48
Figure 50: “Battery Summary” Screen ..................................................................... 48
Figure 51: “Curr Event Info” Screen ......................................................................... 49
Figure 52: “PowerTrac Settings” Screen.................................................................. 50
Figure 53: Communication Timeout Error ................................................................ 52
Figure 54: Line Error ................................................................................................ 53
Figure 55: CRC Error ............................................................................................... 54
Figure 56: Not Acknowledged (NAK) packet received Error .................................... 55
©PoweTrac SP iv

LIST OF TABLES
Table 1: PowerTrac Tool Bar Icons.......................................................................... 21
Table 2: Batt Settings Screen Parameters............................................................... 23
Table 3: Admin Settings Screen Parameters ........................................................... 26
Table 4: Chart Selection Options ............................................................................. 35
Table 5: PowerTrac Report - Event Summary Data................................................. 38
Table 6: PowerTrac Report - Battery Settings Data ................................................. 39
Table 7: PowerTrac Report – PowerTrac SP Lifetime Accumulated Summary ....... 40
©PoweTrac SP v

1. Safety
BEFORE ATTEMPTING TO BEGIN RECHARGING USING THE CHARGER,
PLEASE READ THIS MANUAL CAREFULLY.
While every care has been taken to ensure the completeness and accuracy of this
manual, PowerDesigners, LLC assumes no responsibility or liability for losses or
damages resulting from the use of the information contained in this document. Due
to technical improvements, some information contained in this manual may change
without notice.
SAVE THESE INSTRUCTIONS -- This manual contains important instructions for
PowerTrac SP series product line that shall be followed during installation and
maintenance of the charger.
Before attempting to install and begin charging with PowerCharge, please read this
manual.
WARNING: RISK OF ELECTRIC SHOCK AND/OR ELECTRIC ENERGY -
HIGH CURRENT LEVELS - DO NOT TOUCH UN-INSULATED
BATTERY, CONNECTORS OR TERMINALS. BE SURE TO
DISCHARGE STATIC ELECTRICITY FROM TOOLS AND
TECHNICIAN BY TOUCHING A GROUNDED SURFACE IN THE
VICINITY OF THE BATTERIES BUT AWAY FROM THE CELLS
AND FLAME ARRESTORS.
ALL TOOLS SHOULD BE ADEQUATELY INSULATED TO AVOID
THE POSSIBILITY OF SHORTING CONNECTIONS. DO NOT
LAY TOOLS ON THE TOP OF THE BATTERY.
IMPORTANT: FOLLOW MANUFACTURER'S PUBLISHED INSTRUCTIONS
WHEN INSTALLING, CHARGING AND SERVICING BATTERIES.
Recommended Practices, Technical Sources -- These instructions assume a
certain level of competence by the installer / user. The following practices and
codes contain relevant information, and should be consulted for safe
handling, installation, testing, and maintaining standby batteries. Applicable
state and local codes must be followed.
NESC, National Electric Safety Code, ANSI C2-1993 (or latest revision)
Copies may be obtained by writing:
The Institute of Electrical and Electronics Engineers, Inc.
345 East 47th Street, New York, NY 10017, USA
NEC National Electrical Code NFPA-70 (or latest version) available from:
National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
©PoweTrac SP 1

Federal Codes:
29CFR1926.441 "Safety Requirements for Special Equipment"
29CFR1910.151(c) "Medical Services and First Aid"
29CFR1910.305(j) "Wiring Methods, Components and Equipment"
STD 1-8.2(e) "OSHA Standing Directive"
©PoweTrac SP 2

2. Definitions and Abbreviations
The following abbreviations and abbreviations are used extensively throughout this
document.
Ahr Amp-Hours. This is a measure of energy in the battery
system. It is a simple accumulation that assumes 1 amp for
1 hour is equal to 1 Ahr.
Battery Pack Individual cells configured in a series connection.
Cell An individual battery cell in a battery pack.
Charge Current into the battery pack greater than 1.5 amps for 3
consecutive sample periods.
Discharge Current out of the battery pack greater than 1.5 amps for 3
consecutive sample periods.
Cycle A complete discharge/charge process of the battery pack. A
cycle starts with a discharge and ends with a charge and
may include open states in between.
Event A change in the battery pack state from charge, discharge,
and open circuit states to a different state.
Open Circuit The state where the current into or out of the battery pack
less than the “Open Circuit Current Limit” for three
consecutive sample periods.
Sample Period Time between samples for PowerTrac SP.
CRC Cyclic Redundancy Check code. It is used for error detection
during to communication process.
PDA Personal Digital Assistant.
©PoweTrac SP 3

3. Product Description
PowerTrac SP is a battery-monitoring system designed specifically to meet the
needs of motive and stationary batteries. PowerTrac SP monitors and logs various
data of interest including battery voltage, battery temperature, and battery current. A
conventional current shunt is used to provide continuous battery current sensing.
The PowerTrac SP is equipped with an Infra Red (IR) port for wireless interface
through PDA devices, such as a Palm Pilot. Figure 1 shows a block diagram of the
PowerTrac SP monitoring system.
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VB+VB-
Temp
Sensor
+
Battery
IR
Interface
Current
Shunt
-
PowerTrac SP
Figure 1: PowerTrac SP block diagram
The PowerTrac SP has the capability to monitor battery systems with nominal
voltages ranging from 12V to 84V. The PowerTrac SP logs and stores battery
voltage, current, and temperature and reports the stored to a host when requested.
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In addition, the PowerTrac SP stores out-of-bounds conditions such as over-voltage,
over-current, and over-temperature during charge and discharge events.
A host device can communicate with the PowerTrac SP via the infrared (IR)
interface. An optional isolated RS-232 interface can be also provided. This
communication with the host is exclusive: it allows for only one host and one
PowerTrac SP. The communication is a Master-Slave protocol with the host being
the master and the PowerTrac SP being the slave.
The PowerTrac SP has an extended set of data logging capabilities. Anytime an
event occurs, various conditions are stored in a non-volatile storage memory. Other
data such as the time of the event, the maximum and minimum voltages,
temperatures, and currents are also stored. This enables the PowerTrac SP to be
powered down and the battery history to be saved. In addition, the PowerTrac SP
has a real time clock capability. This allows the PowerTrac SP to accurately monitor
time and date information and use this information in the data logging. The real time
clock is battery backed with a coin-type lithium cell. This allows the PowerTrac SP
to be removed from a battery string and the time information to be accurately tracked
without power.
PowerTrac SP logs and saves various battery data including:
 Charge and Discharge Events
 Time of Charge & Discharge Events and Duration
 Ampere hours for Charge & Discharge (Per Event and Cumulative)
 Maximum Voltage Charging During Charge Events
 Maximum Current During Charge & Discharge Events and Duration
 Maximum Temperature During Charge & Discharge Events and Duration
 Over Temperature Detection w/ Memory
 Multi-Battery Voltage (12-84V)
 IR Download Capability
 Windows 95 and Higher/ Excel Compatible User Graphical Interface
 Report Generation
A user graphical user interface will also be provided for easy data access and
interface. The software allows users to access all relevant data and generate
relevant reports that are of interest to the user. The software also allows users to
perform real time data logging and diagnostics for testing purposes.
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4. Technical Specifications
Nominal Battery Voltage Rating 12V – 84V
Operational Voltage Range 10V – 120V
Voltage Resolution ±50mV
Operating Temperature Range -25oC – 60oC
Temperature Resolution ±1.0oC
Operating Current Draw < 50mA at 12V
Current Resolution ±1%
Interface  IR port
 RS232 (optional)
Data Storage  128k
(~6 months or 180 days at 15 events / day)
Battery Backup Coin-type lithium cell
Protection  Over Voltage
 Reverse Polarity Protection
Current Shunt Standard 50mV shunt
(500A shunt included)
MTBF 75,000 hrs (>8 years)
Dimensions 5.5”x2.0”x 0.815”
Packaging  Sealed
 Splash Proof
 UL 94V-0
©PoweTrac SP 6

5. Procedure for Installation and Operation
5.1 Package Content
The PowerTrac SP package should contain the following items (Figure 2):
 1 PowerTrac SP unit
 1 Shunt: Clamp-On or a Bolt-On (per your order)
 1 Shunt cover
 1 CD: includes Windows & Palm S/W as well as the user’s manual
 1 Quick Installation and Reference Guide manual
 1 Clamp-On installation kit (for Clamp-On shunts)
 2 Corrosion prevention felt washers (flooded batteries
 Tie wraps
 2 ¼-20x2” Self tapping bolts
If any of the items listed above are missing, please contact PowerDesigners for
replacement.
Figure 2: PowerTrac SP package
©PoweTrac SP 7

A close up of the PowerTrac SP module is shown in Figure 3. The IR receiver is
accessed through the clear plastic cover shown in Figure 3.
IR Window
Figure 3: Close up top view of the PowerTrac SP unit
The PowerTracSP unit has two battery voltage/power supply terminals/leads
(separate leads), two current shunt leads (twisted and sleeved), and one
temperature lead as shown in Figure 4.
Temperature
sense lead
Shunt leads
Negative battery lead
Positive battery lead
Figure 4: PowerTrac SP leads
The package includes a current shunt for battery current measurement. There are
two shunt styles that can be used. For sealed batteries, a Bolt-On shunt is included
©PoweTrac SP 8

as shown in Figure 5. For a flooded battery, a Clamp-On shunt is included as shown
in Figure 6.
Figure 5: Bolt-On shunt
Figure 6: Clamp-On shunt
©PoweTrac SP 9

5.2 PowerTrac SP Installation Process
Read the entire manual before installing or operating the unit.
Make sure that you understand the functionality and operation of unit before
connecting it to the battery. There are no user serviceable parts inside enclosure,
and any attempt to service those parts may void any applicable warranties.
Please follow the following “Installation Safety Precautions” before starting
the installation process:
 Select an area that is well lighted with access to electrical power and away from
flammable materials.
 Lead-acid batteries present certain shock, explosion and acid hazards. For your
personal safety and that of others, read and observe the warnings placed on the
batteries.
 Do not wear jewelry or any metallic objects while servicing a battery. Batteries
are a source of high electrical energy; contact between metallic objects and
battery terminals or inter-cell connectors could result in electrical shock, serious
burns, sparks or explosion. Never place metallic objects on top of a battery.
 Before working on a battery, be sure to discharge static electricity that can build
up on tools or the technician by touching a grounded surface in the vicinity of the
battery but far enough from the cells.
 Avoid creating sparks or exposing cells to open flames that could ignite the
gases produced by a charging battery.
 Expel hydrogen gas from all cells by removing the vent caps and directing a
stream of low pressure air into the cell openings. Do not permit electrolyte spray
to contact eyes, skin or clothing.
 Follow battery manufacturers recommended safe practices at all times.
 Disconnect the battery supply from the load it is attached to (vehicle or charger).
Connect or disconnect battery connector from the charger only when the charge
cycle is complete.
5.2.1 Sealed Battery Ground
Stud
5.2.1.1 Shunt Mounting
1. Remove the inter-cell connector nearest to negative post.
2. Clean the posts and the area around the base of the posts.
3. Place corrosion preventive felt washers around posts.
4. Place shunt over posts
5. Replace bolts and tighten securely.
6. Insert (2) #10-32 screws into shunt.
PoweTrac SP 10 ©

5.2.1.2 PowerTrac-SP Module Mounting
1. Locate a convenient area between cells where module will fit
securely without protruding above the intercell connectors, with a
clear line to the IR port (the IR window should be accessible, i.e.
facing up).
2. Secure the module to intercell connector with nylon wire ties
provided, Velcro, or magnetic tape.
3. Attach black/red wire pair to shunt using screws provided.
4. Note: The black wire must be attached to the shunt on the side
closer to the negative battery post (with the shunt placed before
the negative post). Failure to do so will result in negative current
readings on the charge cycle rather than discharge cycle. Upon
power up, if this is the case, follow disconnect procedure and
reverse the shunt wires.
5. Attach the wire with the heavy Black lug marked TEMP to the
innermost cell connector.
CAUTION: DO NOT CUT THIS WIRE. This wire has a
thermocouple integrated into the lug and is used to measure battery
temperature. Cutting this wire will result in no temperature readings.
6. Attach the single BLACK wire to the negative battery post.
7. Attach the single RED wire to the positive battery post.
8. Use nylon wire ties to route wires securely on top of battery.
5.2.2 Flooded Battery
5.2.2.1 Shunt Mounting
1. Using the correct drill, remove the inter-cell connector nearest to the
negative battery post leaving center of posts.
2. Clean post and area around the base of the posts.
3. Place corrosion preventive felt washers around posts.
4. Remove all screws from shunt before installation.
5. Position shunt, centered over posts.
6. Fill holes in the shunt with lead, filling completely to the top of the post.
7. Clean off excess lead from shunt and battery.
8. Insert (2) ¼-20x2” screws and washers into shunt clamp.
9. Tighten shunt clamps securely onto new posts. Do not over-torque.
10.Insert (2) #10-32 screws into shunt
The following procedure outlines the details of installing the shunt to a flooded
battery:
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1. Locate the 3” intercell connector closest to the Negative post of the battery.
Figure 7: Locating the intercell connector to be replaced
2. Position the shunt with nylon spacers (normally used to position replacement
intercell connectors) so it is centered on the battery posts.
Figure 8: Locating the intercell connector to be replaced
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3. Using the ¼” transfer punch and hammer transfer a center point into each
post.
Figure 9: Locating the punch holes
Figure 10: Marked punch holes
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4. Drill off the intercell connector.
Figure 11: Drilling off the intercell connectors
5. Place a fiber washer over the posts.
Figure 12: Placing the fiber washers
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6. Drop the shunt over the posts and tighten clamp bolts
Figure 13: Dropping the shunt in place
7. The hole in the shunt may be larger than the post. If necessary, fill the hole
with lead so it flows and fills the entire hole.
Figure 14: Filling the holes with lead if needed
PoweTrac SP 15 ©