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
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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
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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
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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
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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"
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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.
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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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