Votronic 1218 User manual

InstallationandOperatingManual
LCD BatteryComputer with Shunt 100 ANo. 1218
LCD BatteryComputer with Shunt 200 ANo. 1219
LCD BatteryComputer with Shunt 400 ANo. 1220
Pleasereadtheoperatingmanualthoroughlypriortouse, connectionandstart-upof
thesolarcontroller.
Preciseand completebatterycontrolforlead-acidbatteriesand lead-gelbatteriesinvehicles, boatsor
controlofstationarybatteries.
TheVOTRONIC LCD BatteryComputer calculatestheexactchargingstateofthebattery anddisplaysthe
chargingstatelikea FUEL GAUGEFORTHEBATTERY. Incontrasttosimpleampere-hourmeters, the
capacitybeingavailablewill bedeterminedasresidual chargeinampere-hours (Ah) bymeansof programmed
characteristicdiagramsandwill bedisplayedaschargingstate.
Moreover,thedisplayfunctionsforthe Batteryvoltage(V) andthecharginganddischarging current (A) allow
aninstantaneouscheckof theconsumersaswell asof thebatterychargingequipment.
Themeasuringshuntbeingprovidedwiththeunit isextraordinaryrobustandshowsextremeoverloadcapacity
(alsoreferto"Technical Data").
Appearance anddimensionsof theunit areadaptedtotheVOTRONIC modularsystem. TheVOTRONIC
modularsystemincludesthetankdisplayunits(freshandsewagewateraswell asfeces), theLCDseries(solar
display, voltmeter, ammeter, thermometerandclock), aswell astheswitchandfusepanels.
SafetyRegulationsand AppropriateApplication:
TheLCDBatteryComputerhasbeen designed according tothevalid safetyregulations.
Appropriateapplicationisrestrictedto:
1. Controloflead-gelorlead-acidbatteriesoftheindicatednominalvoltageandofconnectedconsumersin
fixedinstalledsystems.
2. Withobservationofthecapacitylimitsofthemeasuring shunt(see „TechnicalData“).
3. Together withthesuppliedmeasuring shunt.
4. Technicallyfaultless condition.
5. Installationina well-ventilatedroom, protectedfromrain, humidity, dust, aggressivebattery gas,aswell as
inanenvironmentbeing free fromcondensationwater.
6. Witha rearinsulating cover ofthedisplayunit.
• Never usetheunitatlocationswhere theriskofgasordustexplosionexists!
• Open-airoperation oftheunit isnotallowed.
• Cablesarealwaystobelaid in such awaythatdamageisexcluded. Observetofasten themtightly.
• Neverlay12 V(24 V)cablesand 230 Vmainssupplycablesintothesamecableconduit (emptyconduit).
• Livecablesorleadsbeing connected totheunit arealwaystobechecked forinsulation faults, pointsofbreak or
loosened connections. Ifafault hasbeen detected, disconnecttheunit immediatelyfromtheconnectionsand
remedythefaults.
• Theunit istobedisconnected fromanyconnection priortoexecution ofelectricallywelding orwork on the
electricsystem.
• Ifthenon-commercialend-userisnotabletorecognize thecharacteristicvaluesbeing valid foraunit orthe
regulationstobeobserved, aspecialistisalwaystobeconsulted.
• Theuser/buyerisobliged toobserveanyconstruction and safetyregulations.
• Keep children awayfromthebatteriesand themeasuring shunt.
• Observethesafetyregulationsofthebatterymanufacturer.
• Ventilatethebatteryroom.
• Alwaysusethesamecarfusesforreplacement!
• Theunitisnotequippedwithparts, whichcanbereplacedbytheuser.
• Non-observance mayresult in injuryormaterialdamage.
• Never usesolventsoraggressivehouseholdcleanersforcleaning ofthedisplay!
• Thewarrantywill bevoid in caseofanyinappropriateutilisation oftheunit, ifit isused beyond thetechnical
specification, in caseofimproperoperation orexternalintervention. Anyimproperoperation orexternal
intervention will makethewarrantyvoid. Theliabilityexclusion isextended toanydamageresulting fromthe
latter. Liabilityexclusion extendsalsotoanyservice being executed bythird, which hasnotbeen ordered byusin
writing. Service istobeeffected exclusivelybyVOTRONICGrebenhain.

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MountingInstructions:
1. Installation:
Thesmall mountingdepthof theelectronicsystemallowsflushmountingintoconventional furnitureboardsto
ensure, that anoptimuminstallationplace canalwaysbechosen. Ifpossible, thedisplayshouldalwaysbe
installedat eye-levelinthelivingareatoensureeaseof operationandwell visibility.
Theclearopeningof thecutoutismin. 70 x66mm toensuresafealignmentof thefrontpanel. Pleaseusethe
delivereddrillingjig,whichhasbeendesignedtoconsidercombinationwithfurtherVOTRONIC displaypanels.
Therearcutoutopeningshouldbecoveredwithelectricallynonconductingmaterial (poplarplywood, 3mm
thickness, orsimilarmaterial)toensureefficientprotectionof theelectronicsystemandfull utilizationof the
storagespace, whichmightbelocatedbehind.
2. InstallationoftheMeasuringShunt:
Anybatterycurrent shouldflowoverthemeasuringshunt. Therefore, it istobeinstalleddirectlynearthe
battery(batteries). Ventilatethebatteryroom(gas). Permanenthighload(100A, 200Aor400A)resultsin
heatingof themeasuringshunt.
3. LayingofCables:
Thecablelengthcanbeextendedbymeansof anextensionof thecontrolcableNo. 2005 (lengthalso5m).
4. ConnectionoftheMeasuringShunt:
Groundstrapsandthelargeconnectingscrewshavetobescrewedinsuchaway,that the„-Battery“connection
isconnectedtothenegativepoleof thebatteryandthe„-Load“connectionisconnectedtothecarbody. The
arrowsontheshuntpointtothedirectionof thebattery(see connectingplan).
ANY batterycurrentshouldflowoverthemeasuringshunttoensurethat thebatterycomputerisabletorecord
anybatteryactivity. Connectionof thebatterysystemscanbedrawnfromthedrawing, page5.
Exceptofthemeasuringshunt, nofurther connection(e. g. ofconsumers)shouldexistat the
negativepole (-) ofthebatteryorat thenegativepole ofthecompletebatterysystem!
Furtherconnectionshavetobemadeeithertothecarbody(ground) or, incaseof vehicle
superstructures, totheminusdistribution. See connectingplan.
5. PlusConnection„+B1“:
Since thebatterycomputershall recordanybatteryactivity, it should permanently beincontactwith„its“
battery(batterysystem). Consequently, theterminal „+B1“istobeconnectedDIRECTLYtothepositivepoleof
thebattery/batteries(continuouspositiveelectricity)bymeansof thedeliveredfuseholder. Cablecross section
0,75mm2–1,5mm2. Furtherdetailsconcerningtheinstallationof thefuseholdercanbedrawnfrompage7. The
plusdistributionat thebatteryisnotchanged, butiseffectedasusual.
See connectingplan.
6. InitialStart-up:
Thecableconnectorsareequippedwithaprotectionagainstwrongpolarizationallowingonlythecorrect
insertingposition. Inserttheconnectoruntil it snapsin(„click“)!
Now, thebatterycomputerisreadyforoperation. Thedisplayshowstwice aflashing„1888“andtheactual
valuesafterthat (referto"Operation").
The12V/24Vcommutationiseffectedautomatically(switchingthreshold16.5V).
7. NonrecurringSettingoftheNominalBatteryCapacity:
Definitionof thenominal capacityAh(ampere-hours)of thecorrespondingbatteryisonlyrequiredonce inthe
batterycomputer.
• Thevalueisimprintedonthebattery, e.g. 120 Ah.
• Should2valuesbeindicated, e. g. 100 Ah(20h)120 Ah(100h), setthehighestvalue, so120 Ah.
• Incaseof abatterysystemwithseveral batteriesinparallelconnection, setthetotal of thecapacityvalues,
e. g. 120Ah+120Ah+120Ah=360Ah(see figureonpage5).
Proceedasdescribedbelow:

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Positiontherocker switchto„Ah“and press theredkey:
• Thenominal capacitybeingsetwill bedisplayed, e.g. 50 Ahfactoryadjustment(incaseof the400A
execution:100 Ahfactoryadjustment).
• Keepthekeypressed, andthedisplaywill beflashingquicklyfor5seconds. Afterthat, thesigns„-„and
„5„will beprecedingthedisplayedfigure, e.g. 50 Ahfactoryadjustment.
• Releasetheredkey. Nowthenominal capacitycanbeset. Ifthekeyhasbeenreleasedprematurelyduring
theflashingdisplay, thechangesarenottakenoverandtheunit continuesworkingnormally.
• Thedisplayedfigurewill beincreasedby1witheachkeypressure.
• Whenpressingthekeycontinuously, anautomaticquickincreaseof thefigureisexecuted. Iftheaimed
figure(e.g.320 Ah)shouldbeexceeded,theautomaticincreaseshouldbecontinued.As soonasthehighest
value(1000 Ahor1500 Ah)isreached, thelowestvalue(e. g. 50 Ahor100 Ah)will bedisplayed.
• Ifthecorrectvalueisdisplayed, positiontherockerswitchto"A"tofinishtheprocedure. Complete.
8. Full ChargingofBattery
Charginguntil theAhvaluebeingdisplayedisequal orneartothenominal capacity(chargingfor24 hourswith
automaticchargerorextendeddrivingmode). Thebatterycomputerautomaticallysearchesthepointof full
chargingof thebatteryandadaptsto„its“battery.
Theprocesses7. and 8. are absolutelyrequiredtoensure correctcapacity display. Theyhave
toberepeatedwhenever thebatterycomputer orthebatteryhasbeendisconnected.
Operation
Correspondingtotheswitchpositionfor„V“, „A“and„Ah“, thecorrespondingunit of thedisplayedvaluecan
berecognizedbyalternatingflashingof thevalueandthebarprecedingtheunit ontherightwindowmargin.
Thus, theunit of thepresentlydisplayedvaluecanberecognizedclearly, evenincaseof greaterdistance of
reading.
Display ModeNormalOperation:Example 70 Ah
Display ModeWarningFunction:Example-10.9A
Alsorefer totheparagraph „WarningFunctions“onpage5!

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The rocker switch isusedtoselecttheactual measuringvaluesfor:
Switchpositiontotheleft: Voltage, Volts(V)
Switchpositioninthemiddle:Current, Amperes(A)
Switchpositiontotheright: Residual capacity, Ampere-hoursbeingstill available(Ah)
a. Rocker switchinposition„V“(Volts), display ofthebatteryvoltagefrom 7.0Vto32.0V:
Allowsdrawingconclusionsfromthebatterybehaviourincaseof variationsinloadandservesasoperational
checkforthebatterycharger, thesolarsystem, thedynamoetc.
b. Rocker switchinposition„A“ (Amperes), display ofthebatterycurrent(charging/discharging+/-0.0A
uptomax.:
Controlof thedischargerates(load) bytheconsumers, indicatedbythesign“-“. Chargingcurrentratesare
identifiedbyanarrowsymbol.
c. Rocker switchinposition„Ah“(Ampere-hours), display oftheavailable batterycapacity
0Ah uptonominalcapacity (Ah):
Displayof thecapacitybeingstill storedinthebattery(theresidual chargeorthechargingstate). Thedisplayed
valuemightextendfrom0Ah(battery„empty“)tomaximumnominal capacity(battery„full“, see 8.).
Theredkeycanbeusedtodisplaythesetnominalcapacitymomentarilyfor
information.
FunctionsoftheCapacityDisplay:
Themicrocomputercontrolwill countaccuratelyeveryampere-hour(Ah)of capacityduringchargingand
discharging, eveninsplits.
Theautomaticevaluationof thebatteryloadiseffectedbymeansof theprogrammedcharacteristicdiagramsof
thebattery. So, acurrentrateof e.g. 100 Amperesrepresentsaninferiorloadfora600 Ahbattery, whilethisis
anextremelyhighloadfora70 Ahbattery. Correspondingly, thelargestoragebatteryprovidesalmostitsfull
capacity, butthesmall 70 Ahbatteryonly42 Ahor60% of theimprintedvalue, at best.
Theresultisacorrectindicationoftheavailable capacity inthebattery, whichcanbedrawn (residual
capacity, chargingstate), suchasitisknown from a“fuel gauge”.

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Itisamatterof coursethat theself-dischargeof thebatteryincaseof longdowntimeswill beconsidered.
Duringchargingof thebattery, thefull chargingstatewill berecognizedautomatically, andit will becorrected,
ifrequired. Dependingonthequalityof theusedcharger, thechargedcapacitymaybebetween80% and100%
(pleasereferalsotothedescriptionof theVOTRONIC AutomaticChargers).
Stand-byoftheDisplay:
Whenpressingthe redkey inposition„V“and„A“, thedisplaycanbeswitchedON orOFF. Inposition„Ah“
thesetnominal capacityof thebatterycanbedisplayed.
Incaseof extendeddowntimes(weekendoperation, winterbreak), thedisplaycanbeswitched-off withthis,
whichresultsinafurtherdiminutionof theverylowcurrentconsumption. Theinternal measuringand
calculationprocesseswill becontinuedtoensurethat noampere-hourat all will belost.
Thestand-bydisplay incaseof„Off“ istheflashingpoint.
WarningFunctions:
Batterychargingstate<20%, completedisplay isflashingslowly:
Toavoiddamageof thebatterybytotal discharge, theunit indicatesthat chargingof thebatteryisrequiredin
caseof anydischargebelow20% byslowflashingof all displaysegments.
Batterychargingstate<10%, completedisplay isflashingquickly:
Shouldtheresidual capacitybeonly10 %, all displaysegmentswill beflashingquicklytoarouseattention.
Batterychargingisrequiredimmediately!
Thedisplaywill return tonormal state, assoonasthebatteryischarged.
Excess voltageofbattery, completedisplay isflashingslowly:
Excess voltageof thebatteryexceeding15.0V/30.0Vduringcharging(gassing), will clearlybeindicatedby
flashingof all displaysegments.
Once ayear:
• Checktheconnectingscrewsat themeasuringshuntfortightness.
• Checktheconnectioncableforcorrectcontactanddamage.
• Agedbatteries:
Leadbatteriesaresubjecttowear, whichwill begrowingwiththeageof thebattery, thenumberof
charging/dischargingcycles, therateof discharge(frequenttotal discharge)andotherfactors, suchasextreme
temperatures, vibrationetc. Thisresultsinadecreaseof theavailablecapacity.
Thebatterycomputerisabletoconsiderthisloss of capacityincalculationwithincertainlimits. However, we
recommendtocorrectingthesetnominal capacitytoalowervalue(e. g. 5%, dependingonthebatterytypeand
theoperatingcondition), once ayear.
BatterySystems (Examples)
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-- 6--
Failure CorrectiveAction:
Nodisplay at all:
a)Wrongpolarizationof battery:Check
b)Batteryistotallydischarged, below7volts:Rechargeimmediately!
c)Connectioncableisinterrupted, punctured, squeezedorit isnotinserted:Check
„Hieroglyphs“onthedisplay:
a)Theinternal checkprogramsof theunit havefoundan(memory)error:
Withdrawthecableconnectorfor10 secondsandrestartasdescribedintheparagraphs7.-8.
Wrongcurrentdisplay:
a)Permanentdisplayof veryhighcurrent(A):Checktheconnectioncableforcorrectcontactanddamage.
b)Thedisplaydoesnotshow0.0Aafterdisconnectionof all consumersandchargers:
Check, ifhiddencurrentconsumersareconnectedtothebattery
-Check, ifthecontactof theconnectioncableiscorrectandifit isdamaged
-Check, ifcondensationwaterorhumiditymightexistinthedisplayunit.
ConnectingPlan
Nofurther connection, neither aconsumer noracharger, shouldexistatthenegativepoleofthe
battery (-battery)toensure correctbatterymeasurement!
Theseare alwaystobeconnectedtothegroundsideofthemeasuringshunt(-Load)!

--7--
TechnicalData: BatteryComputer BatteryComputer BatteryComputer
incl. MeasuringShuntincl. MeasuringShuntincl. Meas. Shunt
100A200 A400A
Nominal VoltageBattery:12Vand24V12Vand24V12Vand24V
MeasuringRangeVoltage:7,0V–34,0V7,0V–34,0V7,0V–34,0V
Nominal Capacityof Battery
(adjustable):50Ah–1000Ah50Ah–1000Ah100Ah–1500Ah
MeasuringRangeCapacity:0Ah–1000Ah0Ah–1000Ah0Ah–1000Ah
MeasuringRangeBattery
ChargingCurrent: 0.0A–300A0.0A–600A0.0A–1.200A
MeasuringRangeBattery
DischargingCurrent: 0.0A–450A0.0A–900A0.0A–1.800A
Max. AdmissibleCurrent
MeasuringShunt:
Nominal Current: 100A200A400A
ConstantCurrent(Well Cooling:)120A240A480A
Max. Current15 Minutes:150A300A600A
Max. Current7Minutes:200A400A800A
Max. Current4Minutes:250A500A1.000A
Max. Current90 Seconds:300A600A1.200A
Max. Current20 Seconds:450A900A1.800A
Max. Current5Seconds:1.000A2.000A4.000A
LCD BatteryComputer:
CurrentConsumption(12V):0.009A0.009A0.009A
Dimensions:85 x80 x21mm 85 x80 x21mm 85 x80 x21mm
AssemblyDimensions:70 x65mm 70 x65mm 70 x65mm
MountingDepth:max. 16mm max. 16mm max. 16mm
Weight: 62g 62g 62g
MeasuringShunt:
Dimensions:135 x30 x41mm 135 x30 x41mm 135 x30 x41mm
Weight: 160g 180g 200g
DeliveryScope:Available Accessories:
• 1ea. BatteryComputer(Display)ControlCableExtension, Length5m, OrderNo. 2005
• 1ea. MeasuringShunt100A, 200Aor400A
• 1ea. GroundStrap
• 1ea. ControlCable, Length5m
• 1ea. FuseHolder
• 1ea. Flat Plug Fuse3A
• 4ea. FasteningScrews
• 1ea. OperatingManual
• 1ea. DrillingJig
InstallationoftheFuse
Holder
1Insertcable0.75-1.5mm²
2Closethefuseholderand
useplierstopress thetwo
partstogetheruntil it snaps.
3 Complete.
DeclarationofConformity
Accordingtothestipulationsoftheregulations
73/23/EWG, 89/336/EWG, 92/31/EWG, 93/68/EWG.
Weherewithdeclareonsoleresponsibility, that thisproduct
correspondstothefollowingstandardsorstandardizeddocuments:
EN50081-1, EN55014, EN50082-1, EN55104
Subjecttomisprints, errorsand technicalmodificationwithoutnotice.
All rightsreserved, particularlytherightofreproduction. Copyright VOTRONIC 6/02.
MadeinGermanybyVOTRONICElectronic-SystemeGmbH &Co. KG, Ilbeshäuser Str. 4, D-36355 Grebenhain
Phone:[phone]Fax:[phone] e-mail: [e-mail] internet: www.votronic.de