SBS MicroSMART Series Release Note

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SBS MicroSMART
Battery charger Technical handbook English

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1. Foreword
The intention with this document is to describe all features and functions in the SBS
MicroSMART battery charger.
This document is intended for use as training and reference material by personnel with
general knowledge about SBS battery chargers.
In this document charger menu items are written in Italic and charger panel buttons are
written in bold.
Due to continuous development of SBS MicroSMART functionality the availability of features
mentioned in this handbook can vary between charger software versions.

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2. Table of contents
1. Foreword........................................................................................................................3
2. Table of contents ............................................................................................................5
3. Charger panel .................................................................................................................7
3.1. Status indicators.......................................................................................................7
3.2. STOP button .............................................................................................................8
3.3. F1 and F2 button ......................................................................................................8
3.4. Keyboard..................................................................................................................8
3.5. Mains indicator ........................................................................................................8
3.6. Display .....................................................................................................................9
3.7. Shortcuts..................................................................................................................9
4. General functionality ....................................................................................................11
4.1. Battery detection ...................................................................................................11
4.2. BMU communication..............................................................................................11
4.3. Automatic cable Ri calculation................................................................................12
5. Menu system ................................................................................................................13
5.1. Structure ................................................................................................................13
5.2. Access levels...........................................................................................................13
5.3. Main screen...........................................................................................................13
5.3.1. Battery status..................................................................................................14
5.3.2. Charging status................................................................................................14
5.4. Statistics.................................................................................................................16
5.4.1. Charging cycles................................................................................................16
5.4.2. Charger ...........................................................................................................17
5.5. Service ...................................................................................................................17
5.5.1. Charger info ....................................................................................................17
5.5.2. Charging param...............................................................................................17
5.5.3. Time restrictions .............................................................................................19
5.5.4. Extra charge ....................................................................................................20
5.5.5. Equalize...........................................................................................................20
5.5.6. BBC, Best Battery Choice .................................................................................21
5.5.7. I/O control.......................................................................................................22
5.5.8. Parallel control ................................................................................................25
5.5.9. F1 and F2 button .............................................................................................26
5.5.10. Date and time ..............................................................................................27
5.5.11. Display.........................................................................................................27
5.5.12. Radio ...........................................................................................................27

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5.5.13. CAN .............................................................................................................31
5.5.14. Calibration ...................................................................................................33
5.5.15. Factory settings ...........................................................................................33
5.5.16. Advanced.....................................................................................................35
5.6. Log out/Log in ........................................................................................................36
5.7. Language................................................................................................................36
6. Charging curves ............................................................................................................37
7. Alarms ..........................................................................................................................40
8. Appendix 1, I/O board connections...............................................................................42
9. Appendix 2, Tutorials ....................................................................................................44
9.1. Enter the service menu ..........................................................................................44
9.2. Edit parameters......................................................................................................44
9.3. Set date and time ...................................................................................................46
9.4. Start a new radio network ......................................................................................47
9.5. Connect to an existing network ..............................................................................49
9.6. Activate a BBC system ............................................................................................51
9.7. Calibrate the charger..............................................................................................52
9.8. Start with a new control board ...............................................................................54
9.9. Restore a forgotten PIN-code .................................................................................57
9.10. Store and restore default settings .......................................................................57
9.11. Activate instant log .............................................................................................58
9.12. Activate time restricted charge ...........................................................................59
9.13. Activate an extra charge .....................................................................................60
9.14. Activate an equalize charge ................................................................................61
9.15. Activate Remote in Start/Stop ............................................................................63
9.16. Activate parallel control......................................................................................65
9.17. Activate BMU controlled charge .........................................................................67
10. Appendix 3, Menu structure .........................................................................................70
11. Appendix 4, Statistic logs ..............................................................................................72
11.1. History log ..........................................................................................................72
11.2. Event log.............................................................................................................74
11.3. Instant log...........................................................................................................75
11.4. Status log ............................................................................................................75
11.5. Momentary log ...................................................................................................78
12. Appendix 5, Power units ...............................................................................................79
12.1. Matrix.................................................................................................................79
12.2. Chronological list ................................................................................................79

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6
2
3
5
3. Charger panel
1
3.1. Status indicators
The combinations of the status indicators during charging can be defined in the charging
curve. Therefore these indicators can show combinations of light that differ from below
depending on the actual charging curve. Please refer to the charging curve definition for exact
information about the status indicators during charging.
Red constant light An alarm is active.
Red fast flashing light Software malfunction.
Yellow constant light A battery is connected to the charger and a charge is
in progress.
Yellow flashing light
A battery is connected to the charger but charging is
restricted. The restriction can be due to settings in
the Time restrictions, Remote in function or a BMU
initialization is ongoing.
Green constant light A battery is connected to the charger and the
charging process is completed.
Green flashing light The charging process has been manually stopped.
Press ESC to resume charging.
Green constant light and yellow
flashing light.
Equalize charging in progress.
4

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Green flashing light and yellow
flashing light.
Watering in progress. Watering can be active without
this indication.
Green, yellow and red flashing light An indication request has been sent from the PC-
software SBS MicroSMART Service tool.
Green, yellow, red, F1, F2, blue
constant light
Charger is in boot loader mode. Wait until charger
automatically restarts.
3.2. STOP button
The STOP button stops the ongoing charging or prevents next charging to start. To resume
charging the ESC button must be pressed.
If external CAN control is activated the STOP button overrides the external control and stops
the power module until the ESC button is pressed.
3.3. F1 and F2 button
The functionality of F1 and F2 buttons can be configured in the menu system. If a configured
function is active the button will show yellow light.
3.4. Keyboard
The keyboard consists of six buttons for navigating the menu system:
OK: Enter the menu system or selected menu, confirm and edited values.
ESC: Exit present menu, cancel edit, resume charging.
Arrow up: Go up one step, increase/toggle values during editing.
Arrow down: Go down one step, decrease/toggle values during editing.
Arrow left: Previous menu page, change selected digit during edit.
Arrow right: Next menu page, change selected digit during edit.
3.5. Mains indicator
A constant blue light indicates that mains supply is connected.

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3.6. Display
In the display charger status, parameters, and information can be viewed and edited. The
display lights up when a button is pressed, a battery is connected to the charger or a battery
is disconnected from the charger. In the display menu, the Backlight time can be edited
together with display Contrast.
3.7. Shortcuts
F1 + F2 pressed at mains supply power on.
The entire flash memory is cleared
including all configured parameters,
calibration values and statistical data. The
charger must be configured prior to use
after this shortcut has been used.
Warning!
The synchronization between the PC-
software SBS MicroSMART
Service tool
and the charger will be lost. All data
stored in the SBS MicroSMART Service
tool that is related to the present charger
should be cleared.
OK + ESC pressed at mains supply power on.
The charger is configured with Default
settings. The Default settings can be set or
reset in the
Factory settings
menu.
Arrow down pressed for two seconds.
If the charger is connected to a radio
network Join enable is activated.
If the charger is not connected to a radio
network but the radio Function
is set to
Enabled, the charger tries to connect to a
network. If Network Settings
are set to
Auto the charger will try to join any
network where Join enable is activated. If
Network Settings are set to User def. the
charger will only try to join the specified
network.

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4. General functionality
4.1. Battery detection
When a battery is connected to the charger the charging process is started automatically. After
the battery has been connected there is a short delay of approximately 2 seconds before the
charging process starts. If the battery is disconnected and reconnected again the delay is
approximately 10 seconds after the battery is disconnected until the charging process starts
again.
The measured battery voltage at which the charger considers a battery to be connected or
disconnected is defined by the charging curve and the Cells parameters. Normally the battery
is considered to have been connected if the measured battery voltage is greater than 1,05 V
*Cells or lower than 2,65 V * Cells. The battery is considered to have been disconnected if the
measured battery voltage is lower than 1,0 V * Cells or higher than 2,9 V *Cells.
4.2. BMU communication
If charging parameters Source is set to BMU or Dual the charger will try to contact the BMU
when it senses a battery voltage greater than 5 V. The charger shows the display text BMU init
and sends current pulses with information about PAN-ID, channel and charger node address
on the battery cables. The BMU reads the information and, if not connected to the received
network, the BMU tries to join any node with Join enable set within thenetwork.
If the charger fails to contact the BMU with current pulses and is set to Source BMU it tries
with a second method, alternating current levels. 3 current levels, 4seconds each, are set by
the charger which thereafter sends a broadcast message with information about the levels
set. The BMU that has detected the correct levels answer the charger and the handshaking is
ready. Please note that for this second method to work, the charger and BMU needs to be
connected to the same network. If the second method fails as well, a BMU init alarm is shown
in the charger display and charging is not started.
If the charger fails to contact the BMU with current pulses and is set to Source Dual, it will
start Charging init. In Charging init the charger checks the battery voltage towards the set Cells
parameter. When the voltage changes less than 10 mV/cell/minute and is within 1.9 to 2.3
VPC, charging will start according to charger set Charging param. If the voltage changes less
than 10 mV/cell/minute and is below 1.9 VPC or above 2.3 VPC an alarm for low or high battery
voltage is raised. The Dual function cannot feel the difference between 72 and 80 V batteries.
If the Dual function is used in a fleet with batteries of same voltage, the batteries with highest
rated capacity should be equipped with BMU and the lower capacity entered in Charging
param.
When the BMU connected to the charger it sends it’s charging parameters and the charger
starts charging. After this handshaking, the BMU and charger communicates once every
minute, sharing battery temperature, current, voltage, water and equalize information. When
the battery is disconnected and end of charge message is sent from charger to BMU with
information about performed charging phases etc. that can be read in the BMU historical log.

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If the charger and BMU can’t communicate during charging the parameters last received by
the charger is used.
4.3. Automatic cable Ri calculation
If the BMU with software 11612008 revision 5 or greater is used together with a SBS
MicroSMART battery charger with software type 11613004 an automatic cable Ri calculation
can be activated.
The resistance in the charger cables causes the voltage between battery and charger to differ
depending on actual charging current. If the automatic cable Ri calculation is activated the
charger will once every minute during charging when current is greater than half the rated
current compare BMU measured battery voltage with charger measured voltage. The
difference between these voltages is then used to calculate the cable Ri. The calculated cable
Ri can be seen in the SBS MicroSMART battery charger display under Charging status 
Charging param  Cable Ri.
Automatic cable Ri calculation is activated by setting the DC cable Ri to 0 in BMU configuration.

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5. Menu system
5.1. Structure
The menu system is intended to be an easy to use user interface for viewing status and
information and edit parameters.
The keyboard is used to navigate through the menu system, see section 3.4.
See also appendix 3 for overview of the structure.
5.2. Access levels
All information and parameters in the menu system can be viewed without pin code but to
edit three access levels are used. Access level one does not require any pin code and is used
for editing Display Backlight and similar basic parameters. The second and third access level
requires a pin code and the menu system informs the user when a pin code is needed and
which access level that is required.
The pin codes for access level two and three can be changed by using the PC-software SBS
MicroSMART Service tool.
When the Display Backlight is switched off, any access level entered will be lost.
1. Radio function activated. When data is send through radio additional “waves” are
shown on top of the symbol.
2. Date and time.
3. Charging phase.
4. Actual battery charging current. If a Base load is configured this charging current will
be measured charging current – Base load.
5. Actual battery charging cell voltage. If a Cable Ri is defined this voltage will be
(measured charging voltage – Cable Ri*measured battery chargingcurrent)/Cells.
6. Charged ampere hours (Ah) since start of charge cycle.
7. Actual battery charging voltage. This voltage is equal to Actual battery charging cell
voltage*Cells.
5.3. Main screen
2
1
3
4
5
6
7

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When configured as CAN controlled BMS ctrl or Slave the main screen text will be different.
Please refer to section CAN.
5.3.1. Battery status
The battery status menu is visible when a BMU is connected to the charger and shows
information about the connected BMU. The information is updated once every minute during
charging.
B-ID
Battery numeric identifier, configured in BMU.
Tag
Battery alphanumeric identifier, configured in BMU.
SOC
Current battery state of charge calculated by the BMU.
Battery temp
Battery temperature measured by the BMU.
5.3.2. Charging status
The charging status menu is shown when a battery is connected to the charger. Charging
status shows information about the ongoing battery charge.
Start date Date when the battery was connected to the charger.
Start time Time when the battery was connected to the charger.
Start VPC Actual battery voltage per cell when the battery was connected to
the charger. Measured before start of charge.
End VPC
Actual battery voltage per cell when the charging main stage was
completed. Measured prior to main charge end. This value will
show N/A until the main stage is completed.
If the battery is disconnected prior to completion of the main stage
End VPC will be the battery voltage per cell 5 seconds before the
battery was disconnected.
Charged Ah Charged Ah since battery connected to the charger.
Charged Ah (%)
Charged Ah in main stage in percent of configured battery
Capacity. For a cycle log to be stored this value must be greater
than 2.

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5.3.2.1. Alarms
In the alarms view any alarm that occurs during the ongoing charge is shown. If no alarms
present, this menu cannot be entered.
5.3.2.2. Charging param
In the Charging param menu the charging parameters being used in the ongoing charge can
be seen, these parameters are stored when a battery is connected. If parameters in the Service
Charging param menu are altered during an ongoing charge those parameters will be used
after the battery is disconnected and reconnected again.
Source
The source of the charging parameters. The possible values are:
•User def.
•BMU.
•Dual.
•Multi.
A detailed description of Source is found in Service Charging param
section.
B-ID Battery monitoring unit id, if present.
Curve Name of the charging curve being used.
Capacity Battery capacity being used (in ampere hours).
Cells Number of cells being used.
Cable Ri Battery cable resistance being used.
Base load Base load being present in the charging circuit during charging.
5.3.2.3. Momentary data
Momentary data shows actual measured values in the charger.
Phase Current charging phase.
P (W)
Power delivered from the charger. This indicates the total power
and is only equal to U(VPC)*I(A) if Cable Ri and Base load is set to
zero.

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U (VPC)
Actual charging cell voltage. If a Cable Ri is defined this voltage will
be (measured charging voltage – Cable Ri*measured charging
current)/Cells.
I (A)
Actual charging current. If a Base load is configured this charging
current will be measured charging current – base load.
Charger temp (ºC)
Charger heat sink temperature. When this temperature reaches
approximately 70ºC the charger starts to reduce the current to
prevent overheating.
PCB temp (ºC) Charger board temperature.
Limiter
The regulator parameter that is limiting the battery current
regulation. Possible values are:
•Iset, Charging algorithm set value for current.
•Uset, Charging algorithm set value for voltage.
•Ths, Power unit heat sink temperature.
•Pset, Charging algorithm set value for power.
•IdcLimit. Configured DC current limit.
•IacLimit, Configured AC current limit.
•PacLimit, Configured AC power/current limit.
•PmaxEngine, Power limit defined in power unit.
5.4. Statistics
In the statistics menu cycle logs and charger operation information can be read. The statistical
information can be cleared in the Factory settings menu.
5.4.1. Charging cycles
5.4.1.1. Cycles summary
In this menu, a summary of all performed charging cycles are shown. The cycles are divided
into different percentage of charged ampere hours in main stage in percent of configured
battery capacity.
The charged ampere hours in main stage indicates the battery state of charge when the
battery was connected to the charger.
5.4.1.2. Cycle log
The cycle log shows data stored during the previous charging cycles. Description of the data
can be read under Charging status. The latest cycle is automatically selected when entering
this menu. To select another cycle, press OK and select Cycle no by arrow up or arrow down
on the keyboard.
A large amount of additional data is also stored with each Cycle log, and can be accessed by
using the PC-software SBS MicroSMART Service tool.

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5.4.2. Charger
Run time (h) Total time in operation since reset of statistic information. The time
is calculated when the power unit is active.
Charged Ah Totally charged ampere hours since last reset of statistic
information.
Charged kWh Totally charged kilo watt hours since last reset of statistic
information.
AC OVP Number of mains over voltage protection (OVP) activations. The
OVP is counting if a main over voltages is detected during charging.
5.5. Service
The service menu is used to edit or view parameters stored in the charger.
5.5.1. Charger info
HW S/N Production serial number of the control board. This number can
also be read on the control board sticker.
Main FW type Part number of the main microprocessor firmware.
Main FW ver Version of the main microprocessor firmware.
Radio FW type Part number of the radio microprocessor firmware.
Radio FW ver Version of the radio microprocessor firmware.
5.5.2. Charging param
In the Charging param menu parameters used for charging can be edited.
If Source is set to BMU and a BMU is connected to the charger, the parameters uploaded from
BMU are shown. If these parameters are edited while the BMU is connected new parameters
will be written to the BMU when Esc is pressed.
Source
The source of the charging parameters. The possible values are:
•User def, user defined parameters in the service menu.
•BMU, parameters will be uploaded from the separate product
Battery Monitoring Unit. When battery connected, the charger
will try to communicate with the BMU. This is done in two steps
BMU Init 1 and BMU Init 2. BMU Init 1 takes up to 15 seconds.
If BMU Init 1 fails BMU Init 2 will start. BMU Init2 can take up to
50 seconds. If BMU Init 2 fails a BMU Init fail alarm will be shown
and charging stopped.

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If the communication between charger and BMU fails during
charging the latest received BMU information (SOC, Battery
temperature, alarm etc.) are used for
charging. A new radio
communication attempt is made once every minute. See the
BMU communication chapter for more information.
•Dual, attempt will be made to upload parameters from BMU
(BMU Init 1 only), if no BMU present normal charging will start
accordin
g to parameters set from menu. See the BMU
communication chapter for more information.
•Multi, attempt will be made to upload parameters from BMU
(BMU Init 1 only), if no BMU present charger will determine the
nominal battery voltage and set charging parameters
thereafter. The charging parameters to be used are set from
charger Charging param sub menues Battery 6 cells, Battery 12
cells, Battery 18 cells, Battery 24 cells or Battery 40 cells. When
battery voltage is determined two conditions must be fulfilled.
First of all, the voltage must be stable, delta voltage must be
below 10mV/cell/minute.
Secondly the measured battery voltage must be within 1.9VPC
and 2.3VPC of any of the nominal voltages supported. The
charger will not start until the two conditions are fulfilled. This
can take some minutes depending on the state of the battery. If
measured battery voltage is not within limits of any of the
nominal voltages supported the charger will not start charging
and display battery error (Code 8).
Curve Name of the charging curve.
Capacity
Battery capacity in ampere hours. Minimum allowed capacity is 1
Ah and maximum allowed capacity is 9999 Ah.
Cells
2V battery cell count. Minimum allowed cell count is 1 and
maximum is 999.
Cable Ri
Battery cable resistance, 0–99 mΩ.
Set according to below if original 3 m DC harness is used.
SBS MicroSMART 24/60
10
mΩ
SBS MicroSMART 24/80
7
mΩ
SBS MicroSMART 24/100
5
mΩ
SBS MicroSMART 24/100
5
mΩ
SBS MicroSMART 24/150
4
mΩ
SBS MicroSMART 24/120
4
mΩ
SBS MicroSMART 24/300
2
mΩ
SBS MicroSMART 36/40
10
mΩ
SBS MicroSMART 36/60
10
mΩ
SBS MicroSMART 36/80
7
mΩ
SBS MicroSMART 36/100
5
mΩ
SBS MicroSMART 36/130
4
mΩ

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SBS MicroSMART 36/150
4
mΩ
SBS MicroSMART 36/300
2
mΩ
SBS MicroSMART 48/60
10
mΩ
SBS MicroSMART 48/60
10
mΩ
SBS MicroSMART 48/80
7
mΩ
SBS MicroSMART 48/100
5
mΩ
SBS MicroSMART 48/130
4
mΩ
SBS MicroSMART 48/200
2
mΩ
SBS MicroSMART 48/260
2
mΩ
SBS MicroSMART 72/40
10
mΩ
SBS MicroSMART 72/60
10
mΩ
SBS MicroSMART 72/80
7
mΩ
SBS MicroSMART 72/100
5
mΩ
SBS MicroSMART 72/120
4
mΩ
SBS MicroSMART 72/160
2
mΩ
SBS MicroSMART 80/40
10
mΩ
SBS MicroSMART 80/60
10
mΩ
SBS MicroSMART 80/80
7
mΩ
SBS MicroSMART 80/100
5
mΩ
SBS MicroSMART 80/120
4
mΩ
SBS MicroSMART 80/160
2
mΩ
Base load
Base load being present in the charging circuit during charging. 0-
65535 mA.
Battery temp
Fixed battery temperature to be used when no BMU is connected
to the charger.
Please note that this parameter is not stored in the historical log.
Curve param
This sub-menu is only visible if Curve param setting have been
activated and the selected Curve supports editable parameters. If
these conditions are fulfilled pre-defined parameters in the
selected Curve can be modified according to customer needs.
5.5.3. Time restrictions
The time restrictions function can be used to restrict charging at certain times. When this
function is set to Enabled charging is restricted according to the time settings.

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5.5.3.1. Time settings
Time settings are set by first selecting the weekday on which charging should be restricted.
For each weekday three restrictions can be set. Ctrl should be set to X to activate the
restriction and then the start time, From, and end time, To.
When a time restriction is active charging can be resumed/started by pressing the ESC button.
5.5.4. Extra charge
To enable an additional charge for example before Monday morning after a weekend of rest
the Extra charge function can be used. This function restarts the charging cycle automatically
on the configured weekday and time. The Extra charge function has the same effect as if the
battery was manually disconnected and reconnected again.
Status Indicates if the ongoing charging cycle is trigged by the Extra charge
function. On=trigged by the Extra charge function.
Week day The day of the week when the Extra charge will be activated.
Time Time on the Week day when the Extra charge function will restart
the charging cycle.
5.5.5. Equalize
The Equalize function enables equalize charging upon different decision criteria. The function
can be set to Cyclic or Weekday.
When Cyclic is selected an equalize charge will be performed with Interval number of cycles
of 2 % or more of the battery capacity charged in main phase between. Cycles to next indicate
how many cycles are left until next equalize charge. I.e. if Interval is set to 1 an equalize charge
will be performed every other cycle.