Wakespeed Offshore WS500 User manual

CONFIGURING THE WS500
REGULATOR WITH THE WAKESPEED
FILE TRANSFER UTILITY
Wakespeed’s WS500 Advanced Alternator Regulator provides
onboard support for multiple battery technologies, via selectable
DIP switches, including standard ooded (thin plate) and deep
cycle ooded, Gel, standard AGM, carbon foam AGM (Firey),
high-density AGM, and LiFePO4.
In addition, the WS500 offers the ability to upload pre-engineered
conguration les for a growing number of battery brands and
chemistries, based on the battery manufacturer’s charging
recommendations by using the Wakespeed File Transfer Utility.
With the use of a Windows PC and a Micro USB cable, these
conguration les are downloadable from the Wakespeed website,
and uploaded to the WS500 Regulator. Conguring the regulator
does not require that the WS500 is installed in the vehicle or
vessel. Software and rmware upgrades can be done at the
workbench or at the dining table, as well as in place.
The following guide is designed to walk the installer or end user
through the upgrade/conguration process.
These items are necessary for the upgrade process:
• Windows-based computer with available USB port
• Access to the internet to download conguration .ZIP les
• High-quality Micro-USB cable
• Phillips hand or cordless screwdriver
• A non-metallic tool for depressing RESET button (doweling or
end of a pen or unsharpened pencil work well) is helpful
©2020 Thomason Jones Co. LLC (Wakespeed Offshore)

PREPARING THE WS500
REGULATOR
Place the WS500 Alternator Regulator on your
work surface and carefully unscrew the four
retaining screws on the top of the regulator. The
screws don’t need to be completely removed
from the lid.
When they have been sufciently loosened, the
regulator’s lid will lift off. The lid may need to be
wiggled as it’s lifted to free the sealing gasket.
GETTING STARTED
Conguration/rmware upgrade les are included in a .ZIP folder, which may be
downloaded from the Wakespeed website, or may be received from your Wakespeed
dealer as a link or email.
For the sake of illustration, we’ll look at a conguration update le from the
Wakespeed website. Conguration les are accessed on the website’s Technical page
(www.wakespeed.com/technical.html). Under the table header “WS500 Conguration
Files” is a list of available les, broken down by manufacturer and product series.
When the desired battery prole is found, click on the hyperlink. A .ZIP folder will be
downloaded to your computer. Drag the .ZIP le to your desktop and double-click to
extract the folder. Inside that folder will be all of the components required to upgrade
your regulator’s battery conguration.
Note: Your Windows computer should automatically update the drivers required to
support the Wakespeed File Transfer Utility, particularly if you are connected to the
internet. If your computer will not allow you to open the utility, it may be necessary to
upgrade your driver le. Driver les can be downloaded from Wakespeed’s Technical
page.
Figure 1 — Location of Conguration les at www.wakespeed.com/technical.html
Figure 2 — Unscrewing regulator lid
PAGE 2

Remove the regulator’s lid and
place out of the way.
The open regulator box will provide
access to the micro USB port and
RESET button.
The USB connector is scaled for
use with a standard Micro USB
cable, like one would use with
an Android smartphone. Use a
high quality cable that’s as short
as possible. Disconnecting other
USB cables from the computer will
ensure faster conguration.
RUNNING
THE NEW
CONFIGURATION
PROGRAM
Once the desired
battery conguration
prole is found on the
Wakespeed website, and
is downloaded to your
computer, it should be
placed on the computer’s
desktop.
Depending on the Windows
system being used,double
click the .ZIP le, or right click
and select Extract, to provide
access to the contents of the
Conguration folder.
The Conguration folder
shown in this example would
be optimized for use with MG
Energy LFP-Series batteries. File
names indicate the brand and
battery series, as well as the le
revision number.
Figure 3 — Removing regulator lid
Figure 4 — Shows Conguration .ZIP le on Windows desktop
Figure 5 — Shows contents of the Conguration folder
PAGE 3

RUNNING THE NEW CONFIGURATION PROGRAM
The Conguration folder provides all of the les required to update the regulator’s
rmware, and customize the battery program prole, CAN conguration
for BMS (if used), and alternator congurations.
To begin the conguration process:
1. Double-click the le labeled
Update.bat. This will open the
window which will guide you
through the rmware update
and upload of the conguration
parameters for the battery type
selected. In some Windows
environments, there may be a message
indicating tha Windows is not allowing
the batch le to be opened. This can be
overridden by clicking the “More info”
link and clicking on the “Run anyway”
button on the next window.
2. A new window will open on the desktop,
providing step-by-step conguration
instructions. See Figure 9 on the
following page for an example of the
conguration window.
3. Carefully connect the Micro USB
connector to the USB plug on the
regulator’s circuit board.
4. See Figure 7 for the location of the USB
plug and reset button. The Micro USB
Figure 6 — Close-up of contents in the Conguration folder
Figure 7 — Micro USB connector & reset button
Figure 8 — Micro USB cable connected
See instructions for customizing battery
proles starting on Page 7.
PAGE 4

cable will provide power for
the regulator’s processor
during the conguration
process.
5. The conguration program
will update the regulator’s
rmware before installing
the conguration les. To
start the rmware upgrade,
press and hold the reset
button for ve seconds and
release.
6. Press any key on the
computer’s keyboard after
releasing the reset button.
This will begin to test and
install the newest version
of the regulator rmware.
7. The batch le window (as
shown in Figure 10) will
upload rmware to the
regulator, and verify the
upload.
8. If the conguration window
indicates that the rmware
has been successfully
loaded and veried, press
and release the regulator’s
reset button.
9. Count to ve, then press
any key on the computer’s
keyboard to load the
conguration le for your
battery type.
10.As shown in Figure 11, the program will upload the ASCII commands into
the regulator’s processor. When the new conguration is successfully
loaded into the regulator, the batch le window will indicate “Finished”. Note
that in Figure 11, the computer tried multiple ports before successfully
connecting with the regulator. Disconnecting any unused USB devices from
the computer will minimize these error messages. Press any key to exit the
program.
11.Carefully disconnect the Micro USB connector from the regulator.
Figure 10 — Batch le window. Showing rmware update.
Figure 11 — Batch le window. Showing conguration update.
PAGE 5

MODIFYING THE CONFIGURATION PROGRAM
While the downloaded .ZIP le is designed to t a broad range of applications, there
may be certain values that the installer or user may want to modify. The following
instructions are intended to provide guidelines for some of the more commonly
changed values, additional information is provided in the Communication and
Programming Guide that’s available at www.wakespeed.com/technical.html.
In most instances, the installer/user will consider adjusting four main values in the
conguration code:
• The alternator temperature set point
• The duration of the warm up delay
• The percentage of alternator de-rate
• The actual capacity of the batteries being
charged.
ACCESSING THE
CONFIGURATION FILE
Within the .ZIP le is the folder containing the
data and Wakespeed File Transfer Utility required
to update the regulator’s rmware and charging
proles. Within the folder is a .txt le which
contains the ASCII strings required to control the
regulator’s behavior.
The .txt. can be opened with a standard text
editing application . To access the text le:
1. Open the folder extracted from the .Zip
le downloaded from the Wakespeed
Conguration table at www.wakespeed.com/
technical.html.
2. Using your preferred text editing or terminal
console, open the le in the folder with the .txt
sufx.
Figure 12 — Location of .txt le in
conguration folder.
PAGE 6

MODIFYING A CONFIGURATION FILE
The conguration text le contains a string of command lines; each that modies the
behavior of the WS500 to optimize control of the alternator to match the needs of the
batteries and charging system.
The .txt le shown in Figure 12 is a good example of a typical conguration le. In
most cases, the le will provide all the settings the regulator requires to provide a
safe, effective prole for charging.
On the following several pages, we’ll look at the actual text le for a Lifeline AGM
battery, and consider some of the values that the user may want to alter to best
support his or her specic application. Note that in most cases, the only values
which may need modication are battery capacity, target alternator temperature,
percentage of alternator de-rate, and the duration of the start delay and charge ramp.
Other conguration values should be modied with caution.
Note that conguration les are carefully designed, based on
testing and manufacturer charging recommendations. Improper
modications can result in damage to the batteries, regulator
and alternator. DO NOT attempt to modify the conguration le
if you are not familiar with this process. Failure to properly follow
guidelines may void your warranty and damage your system.
The conguration le broken down in the next several pages is intended to provide
a generalized look at how the code is laid out. Note that different battery types,
different alternator types, battery capacity, and additional components like battery
BMS units may require command lines not shown in this example.
The Wakespeed Communication and Conguration Guide, which can be downloaded
from the Technical Page at www.wakespeed.com, provides a complete list of
available command lines, which can be used to modify the behavior of the WS500
Alternator Regulator.
If your battery, BMS, or alternator type are not supported by an existing command
line, you may nd a conguration le for a similar application and modify it to support
your needs. For additional assistance, contact suppor[email protected].
!
PAGE 7
IMPORTANT: The following information is provided to describe the numerous
user-congurable features available in the WS500 regulator. We have highlighted
the four most commonly adjusted values in the example. Those values are dis-
played in RED. For more information about advanced user congurations, please
refer to the Wakespeed Communication and Conguration Guide, which can be
downloaded in PDF format from the Technical Page at www.wakespeed com.

TRANSLATING THE .TXT PROFILE
When opened in a terminal program or text editor, the Lifeline Standard AGM program
will appear as follows:
#
# LIFELINE AGM cong le
#
# Based on details in: Lifeline Technical Manual, rev E
#
# Date: 3/17/2020
#
# Lifeline standard
# 100c alternator
#
# Lifeline AGM
$SCA: 0,100,1.00,0.75,0.50,0,0,0,10000,0,0,30,0@
$CPA:7 14.3,360,3,0@
$CPO:7 0, 0, 0.0, 0@
$CPF:7 13.3, -1, 0, 0, -50, 12.5, 0@
$CPE:7 15.5,25,600,0@
$CPP:7 0,0.0,0,0.0@
$CPB:7 0.022, -30, -40, 71, 0.0, -99, -99, 15, 2000@
$SCN: 0,Lifeline,1234@
$SCO: 0,0,0,0@
Each line of the .txt le provides commands and values specic to various aspects
of the charge program. The rst line of code, designated as $SCA, changes the
parameters of the alternator in the table of system congurations. Meanings for the
values are as follows (note that values are deliniated by commas):
$SCA: 0,100,1.00,0.75,0.50,0,0,0,10000,0,0,30,0@
12 3 4 5 6 7 8 9 10 11 12 13
1. Factory use only
2. Alternator target temperature (°C) – Temperature regulator will attempt to maintain at
alternator temperature sensor. Contact your alternator manufacturer for recommended
temperature setting and sensor location. For added system safety, consider setting your
value 10-20 degrees below the manufacturer’s recommendation.
3. Alternator Derate (Normal) – When no derate modes are selected.
4. Alternator Derate (Small Alternator Mode) – When DIP Switch #8 is selected.
5. Alternator Derate (Half Output) – Selected when alternator temperature sensor wires
are shorted.
6. Pull Back Factor (PBF) – Reduces eld at idle (Set “0” to disable) (Set “1” to enable).
7. Amp Cap – (-1500) Allows maximum amperage limit if current shunt is connected.
8. System Watts Cap – (-120000) Limits maximum wattage.
9. Amp Shunt Ratio – Indicates the current shunt’s ratio (Amps/mVolts) Default setting is
for a 500A/50mV shunt (500/0.050=10000)
PAGE 8
IMPORTANT: The following information is provided for reference, and is intended
to provide guidance required to tailor the configuration profile to your system.
Commonly adjusted settings are highlighted in RED. Please refer to the Wakespeed
Communications and Configuration Guide for detailed configuration instructions.

10. Shunt Reversal – Allows user to compensate if a shunt is installed backward. “0” is
normal polarity. “1” will reverse the polarity of the readings.
11. Idle RPMs – Used in conjunction with Pull Back Factor (PBF). Determined in whole
numbers (0 1500). Default zero setting enables regulator to automatically deter-
mine idle RPM.
12. Warmup Delay – Determined in whole numbers (15 600), controls the number of
seconds the regulator will wait before moving into ramp mode.
13. Required Sensors – Determined in whole numbers (0 255) controls regulator
response to missing alternator temperature, battery temperature and current sen-
sors. Default value is “0”. See Communication and Conguration Guide for detailed
programming instructions.
The second line of code, designated as $CPA, updates the parameters of the
ACCEPT (and BULK) portions of the charge prole. Meanings for the values are as
follows (note that values are deliniated by commas):
The third line of code, designated as $CPO, updates the parameters of the Over-
Charge (or nish) portion of the charge prole. Meanings for the values are as
follows (note that values are deliniated by commas):
$CPA: 7,14.3,360,3,0@
$CPO: 7,0,0,0.0,0@
1
1
2
2
3
3
4
4
5
5
1. Charge Prole Table Entry – Identies the Prole number being modied by the new
conguration. Select 7 or 8.
2. VBat Set Point – Identies the voltage set point that the regulator will use during the Ac-
ceptance phase of charging. Value is a oating point number, and is entered for a normal-
ized 12V system.
3. Exit Duration – Value represents the timer duration between entry into acceptance and
exit to over-charge phase. Setting the value at “0” will disable time-based exiting and will
activate current-based monitoring. Range is 0 600 (10 hours).
4. Exit Amps – Represents the minimum amperage allowed before regulator advances
from acceptance to over-charge. Range is whole numbers -1 200. See Communication
and Conguration Guide for details on special settings.
5. Factory Only
1. Charge Prole Table Entry – Identies the Prole number being modied by the new
conguration. Select 7 or 8.
2. Limit Amps – After entering over-charge, the delivered amps will be monitored and regu-
late to the value set. Range is 0 50. Zero setting will disable over-charge mode.
3. Exit Duration – Value represents the timer duration between entry into over-charge and
exit to oat. Setting the value at “0” will disable time-based exiting and will activate cur-
rent-based monitoring. Range is 0 600 (10 hours).
PAGE 9

4. Exit VBat – Represents the minimum amperage allowed before regulator advances from
acceptance to over-charge. Range is oating point numbers 0.0 20.0. Setting Exit V
Bat at zero will disable over-charge mode.
5. Exit Amps – Ranging in whole numbers from 0 50, this value will keep the regulator
in over-charge until acceptance current falls to or below the set value. A zero setting will
disable this option.
The fourth line of code, designated as $CPF, updates the parameters of the Float
portion of the charge prole. Meanings for the values are as follows (note that values
are deliniated by commas):
The fth line of code, designated as $CPE, updates the parameters of the Float
portion of the charge prole. Meanings for the values are as follows (note that values
are deliniated by commas):
$CPF: 7,13.3,-1, 0, 0, -50, 12.5, 0@
$CPE: 7,15.5,25, 600, 0@
1
1
2
2
54
4 5
3
3
6 7 8
1. Charge Prole Table Entry – Identies the Prole number being modied by the new
conguration. Select 7 or 8.
2. VBat Set Point – Floating point value (0.0 20.0) for target oat voltage in a normal-
ized 12V system.
3. Limit Amps – After entering oat, the delivered amps will be monitored and regulate to
the value set. Range is 0 50. Zero setting will disable over-charge mode.
4. Exit Duration – Whole number (0 30000) controls timer duration once oat stage
is started. A “0” will cause the regulator to remain in oat until triggered by other exit
criteria.
5. Revert Amps – Whole number (-300 0). Value of negative current, indicating large
system load, will cause regulator to revert to restart charge cycle. “0” will disable fea-
ture.
6. Revert Amps-Hours – Whole number (-250 0). Indicates accumulated number of amp
hours removed from the battery to restart charge cycle. “0” will disable this feature.
7. Revert Volts – Floating point value (0.0 20.0) establishes low voltage in oat which
will cause regulator to revert to restart charge cycle. “0” will disable this feature.
8. Revert SOC – Whole number (0 100). Will restart charge cycle from oat if BMS or
other RBM indicates drop below battery SOC level. “0” will disable this feature.
1. Charge Prole Table Entry – Identies the Prole number being modied by the new
conguration. Select 7 or 8.
2. VBat Set Point – Floating point value (0.0 20.0) for target equalization voltage in a
normalized 12V system.
3. Maxs Amps – Whole number (0 50). Caps the allowable amps in equalization mode.
“0” will disable this feature.
PAGE 10