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Charger Interface
User Manual
50 pgs2.6 Mb1

DC Power Technologies Charger Interface User Manual

Enatel Motive Power Ltd
Charger Interface
Software Description and User Manual
Revised October 2014
TABLE OF CONTENTS
Configuration Template ....................................................................................... 9 2.4.2.
Import CSV ........................................................................................................ 9 2.4.3.
Charger Configuration ......................................................................................... 9 2.4.4.
Print Label ....................................................................................................... 10 2.4.5.
Auto Equalise ................................................................................................... 11 2.4.7.
Auto Watering Configuration .............................................................................. 11 2.4.8.
Daily Charging Schedule .................................................................................... 11 2.4.9.
Start Time Delay ............................................................................................... 12 2.4.10.
Cool Down Period .............................................................................................. 12 2.4.11.
Real Time Clock ................................................................................................ 12 2.4.12.
Single and Dual Profile Charging ......................................................................... 25 3.2.1.
Dual Profile Charge Example .............................................................................. 26 3.2.3.
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© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors
exempt. Pictures may be representative, actual products may differ.
6.5. BMM ALARMS ........................................................................................................ 35
7. APPENDIX .............................................................................................................. 36
7.1. CHARGE PROFILE TYPES ............................................................................................ 36
IUIa ................................................................................................................ 367.1.1.
IUa ................................................................................................................. 387.1.2.
IUUa ............................................................................................................... 407.1.4.
Ia ................................................................................................................... 427.1.6.
7.3. CHARGE PROFILE DEFAULT PARAMETERS .......................................................................... 43
7.4. GLOSSARY ............................................................................................................ 46
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© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors
exempt. Pictures may be representative, actual products may differ.
1. Introduction to Charger Interface
1.1. Uses
The Charger Interface software allows configuration of any FSx series charger by PC connectivity via the charger’s front panel USB port.
Common uses for Charger Interface include:
Configuring a charger or battery module for first use.
Retrieving charge and alarm logs from a charger or battery module.
Reconfiguring a charger for a different battery type.
Adjusting charge profile parameters.
Upgrading charger or battery module firmware (bootloading).
1.2. System Requirements
Charger Interface has the following minimum system requirements:
Microsoft Windows XP(SP3)/Windows Vista/Windows 7/Windows 8
Microsoft .NET Framework
USB 1.0/1.1/2.0
Administrator privileges on the PC for installation.
1.3. Installation
Ensure the minimum system requirements are met before installing Charger Interface.
The software installer may be supplied on a CD, USB flash drive or other distribution method.
1.4. Connecting to the Charger
Power on the charger and connect the charger to the PC with a USB cable.
Ensure the Charger Interface software is installed before connecting the charger via USB.
Locate and run the software installer file. Follow the installer prompts to complete the install.
The installer will create a desktop shortcut to run Charger Interface.
A successful USB connection
can be confirmed by the charger serial number and firmware version displaying in the window title bar.
For example:
“(Charger: MPC35 0123456789 V51)”.
If a connection is not made
within 30 seconds, ensure the correct COM port is selected from the Serial Port menu (Figure 1). If connectivity is still not established, remove and reinsert the USB cable.
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© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors
exempt. Pictures may be representative, actual products may differ.
1.6. Operator Access Level Control
An incorrectly configured charger can cause irreversible damage to batteries. For this reason Charger Interface employs a three-level access control system to limit access to advanced features and parameters. The default level is Read Only.
To access levels beyond Read Only, a password is required (supplied by the distributor). This can be entered in the About Charger Interface box from the About menu.
Read Only Access
Read charger status, charger­battery configuration, start and delay times, and alarm and charger logs from the charger. Viewing the configuration of an attached battery module is also possible.
Configuration Access
User can modify battery configuration settings on the charger and any connected battery module using pre-defined template settings only.
Advanced Access ( )
Allows advanced control over the charger and battery module functions. Access to view and edit charge profiles, advanced control over charger controller and charger module settings is possible including charger firmware bootloading and relay configuration.
1.7. Charger Interface Read/Write Functionality
Charger Interface can read a charger or module configuration and display on screen and, depending on access levels, write any changes back to the charger.
Live Feed
It should be noted that only the Monitoring tabs for charger and battery modules provide a “live” feed of updating information.
Read/Write
In all operations involving modifying a charger or module
configuration, the “Read” or “Refresh” buttons should be used
first to ensure the visible parameters and settings accurately reflect the current configuration in the device.
Similarly, any modifications or adjustments should always be followed by clicking the appropriate “Write” button ensuring the parameters are written back to the charger.
1.8. Battery Modules
A battery module generally describes a device installed on a battery to provide varying levels of functionality depending on the module model. Some features of the Charger Interface software discussed in this manual may only apply to certain battery module types.
Unless otherwise stated, reference to a battery module is assumed to be the APC/BMID module.
APC/BMID Module
APC (Automatic Profile Configuration) Module and BMID (Battery Monitoring and Identification) provide identification to the charger of battery type and required charge profile as well as basic battery status including temperature, electrolyte level, and voltage imbalance monitoring.
© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors
exempt. Pictures may be representative, actual products may differ.
BMM/BMID ‘Current Sensing’
BMM (Battery Monitoring Module) provides the functionality of the APC/BMID module, as well as charge/discharge current monitoring and data logging features.
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1.9. Software License for Battery Module Data Access
In order to retrieve the full range of BMM and Current Sensing BMID data, Charger Interface requires activation by the purchase of a software license. Purchase will result in supply of a license file. See below for instructions to activate the Charger Interface for BMM.
Charger Interface allows as standard access to the BMM Data Log. The addition of the Software License provides access to the following logs by enabling tabs dedicated to each:
BMM Alarm Log
BMM Charge Log
BMM Daily Log
See Section 2 for details and use of each of these tabs.
Activating the Battery Module License
1. Click Software Licensing under the About menu.
2. Click Import License File and select the supplied license file.
A valid license file will display the licensing details,
including Name, Company in the Current License area.
1.10. Diagnostics
Troubleshooting issues may be aided by saving a diagnostic file for review by an expert. The file contains the full configuration as read by Charger Interface and allows the charger configuration to be loaded and viewed on a separate PC.
Create Diagnostics File
1. Click the About option in the menu bar.
2. Click Prepare Diagnostic File.
A prompt requests
confirmation to include battery module data (if connected). Battery module data can take up to 1 hour to fully download. If the issue does not involve a battery module, click No.
The diagnostic file is prepared
and saved in the default Documents folder of the currently logged in user. The file name incorporates the charger serial and current date in an XML file.
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© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors
exempt. Pictures may be representative, actual products may differ.
2. Charger Interface Tabs
2.1. Tab Overview
Charger Interface displays the various charger data in a series of tabs within the main window. Tabs may be closed from view or reopened using the Charger and Battery Module menus in the main window title bar.
Depending on the user access level, some tabs may not be available.
Indicates a tab accessible only at the Advanced Access level.
Indicates a tab available with additional Software License purchase.
Some tabs such as the Monitoring Tab are undocked by default. These tabs may be docked to the main window by double-clicking the tab title bar.
Charger Tabs
Charger Status
View recent charge cycles for insight into the health and usage of the battery. If the charger is used to charge multiple batteries, the battery ID can be selected. Also available on this tab is the ten most recent alarms recorded.
Configuration
View the current configuration of the charger, including battery type, equalise, scheduled start, and start delay options. Changing these options requires Configuration access.
Charge Log
Displays the charge cycle log for saving to PC. Useful for determining usage trends, battery health.
Alarm Log
Displays all recorded charger and battery alarms for analysis and saving to PC.
Monitoring
A live display of the current charge cycle parameters including battery, charger module and alarm status.
Charge Profiles
View and edit charge profiles for each battery and charge type.
Bootloader
Update the charger and battery module firmware.
Alarm Configuration
Configure or re-define alarms according to urgent/non-urgent status. On-board relays to activate according to specified alarm states.
Controller Settings
Advanced control of the charger low-level control functions, including setting service mode, temperature compensation, fast charge, auto water and battery module enable.
Battery Module Tabs
Battery Module Monitoring
Monitor battery status via a battery module.
Battery Module Configuration
Configure battery module for battery type and ratings as well as set charge profile types and sequences for a battery module.
Battery Module Settings
Additional module settings and functionality control.
© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors
exempt. Pictures may be representative, actual products may differ.
BMM Alarm Log
View and save the alarm log from a BMM battery module.
BMM Charge Log
View and save the charge log from a BMM battery module.
BMM Data Log
View and save the data log from a BMM battery module.
BMM Daily Log
View daily summaries of battery activity.
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2.2. Charger Status Tab
Gain a quick overview of the most recent charge cycles, the charger configuration and recent alarms.
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© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors
exempt. Pictures may be representative, actual products may differ.
2.4. Configuration Tab
The Configuration tab allows the charger configuration to be viewed, modified and saved back to the charger.
Uses:
View or edit charger configuration depending on access level.
Print charger rating label using configuration parameters.
Configure Auto Equalise, Daily Charging Schedule, Start Time Delay, Cool Down Timer. Set charger internal clock.
Section Overview:
Configuration Template
Select battery, charger model and AC supply type to generate the charger configuration automatically. A CSV file with the appropriate parameters must first be loaded using the Import CSV button.
Charger Configuration
View the current configuration of the charger, print a rating label. Changing these options requires Configuration access.
Print Label
Print a rating label once the charger is configured. Options for what parameters to print and print designation are available.
Auto Equalise Settings
Set the charger to perform equalise charges according to defined rules: profile, cycle or time based. Requires Configuration access.
Auto Watering Settings
Set duration and number of charge cycles per watering event. Auto Water activation is via Relay 2 by default.
Daily Charging Schedule
Daily lockout periods can be set by dragging three bars horizontally. Green and red sections indicate go and no-go periods respectively.
Start Time Delay
Set a delay in hours:minutes to delay charging after the charger switch is set to Start. Charger displays a count-down timer to charge.
Real-Time Clock
Read or set the charger’s internal clock. An internal cell battery maintains the RTC in the event of a power outage.
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© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors
exempt. Pictures may be representative, actual products may differ.
Configuration Template2.4.2.
Configuration templates simplify charger configuration and allow for accurate configurations with minimal user input. The templates are pre-set configurations that may be selected for certain battery types. A template may be used as­is (Configuration Access) or loaded
Import CSV 2.4.3.
Charger Interface software packages ship with a Configuration Template CSV file included. The CSV file contains the ratings and related charge configuration data for known battery types.
and details fine tuned (Advanced Access required to adjust parameters).
Template data is contained in a CSV formatted file that needs to be imported into Charger Interface when using a template for the first time.
To import a CSV, click Import CSV and locate the CSV file. Typically a dealer-supplied CSV file is located in the Charger Interface installation folder within the Program Files folder.
Charger Configuration 2.4.4.
The Charger Configuration section displays the set parameters for a charger configured for a single battery type. See Section 3: Charger Configuration for a description of the various charger/battery module configuration options, and step-by­step example configurations.
The Charger Configuration section displays the fundamental charge parameters of the charger as determined by the battery it is configured for. Modifying these parameters requires Advanced
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© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors
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Access.
Click Read Configuration to
retrieve current values from the charger.
Always click Write
Configuration to save these
settings to the charger. Failure to do so will leave the charger with the previous settings.
Nominal Voltage
As defined by the battery, typically 24V/36V/48V
Start Current
Defines the maximum current delivered in the first stage of the charge, as recommended by the battery manufacturer.
Battery Rating
Capacity of the battery, measured by discharge rate x discharge time. Typical motive batteries are measured at a 5 hour (“C5”) rate, e.g. a 500Ah battery can be discharged for 5 hours at 100A.
Typical Battery Temperature
An indicative value of the battery temperature that assists in managing parameters during a charge.
Typical Cable Temperature
An indicative value of the battery cable temperature that assists in managing parameters during a charge.
Charge Profile
Profile as selected according to the battery type and requirements. Profiles are defined in the Charge Profiles tab.
Charger Cable Length
Length of cable from charger to battery. An indicative value used to
manage parameters while charging.
Cable Cross-Sectional Area
Gauge of cable from charger to battery. An indicative value used to manage parameters while charging.
Verify Configuration
When enabled during Write Configuration the charger checks
that the installed modules can meet the requirements of the chosen configuration.
Should the required configuration exceed the capacity of the installed modules, install further modules or a larger capacity charger is required.
Print Label2.4.5.
Label printing options include printer selection, label size and orientation selections. A layout preview allows selection or removal of fields from the resulting printout. A grey field indicates a field that will not be printed.
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© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors
exempt. Pictures may be representative, actual products may differ.
Auto Equalise 2.4.7.
An automatic equalise charge can be programmed to begin automatically according to defined parameters: Profile, Cycle or Time based.
Set By Profile
Any equalise settings are controlled within the set charge profile, configurable in the Charge Profile tab. See Section 2.11.
Cycle Based
Cycle based equalise parameters apply to a charger configured with a dedicated profile, as the number of charge cycles that charger performs.
Auto Watering Configuration 2.4.8.
Auto watering functions are triggered primarily by a charge cycle frequency count configured on the Configuration tab.
If a battery module is installed with an electrolyte sensor, the module can be configured to monitor
A charger set as APC Enabled uses the battery module charge cycle
count to determine a battery’s
need for an equalise charge.
Time based
The equalise charge can be set to occur at a specific time, weekday and at a week-based interval.
electrolyte levels, triggering an auto watering cycle if required.
See your auto watering kit installation manual for full hardware and software configuration.
Auto Water Activation
1. Connect to the charger and select the Configuration tab.
2. Check the Auto Watering Enable option and enter the required values for Duration and Frequency and click Write to program the settings into the charger.
Daily Charging Schedule 2.4.9.
The charging schedule provides a graphical representation of a 24 hour period, with markers at 1 and 4 hour intervals.
Duration (seconds)
determines the length of time the auto watering circuit is open and providing water to the battery.
Frequency (cycles)
determines the number of charge cycles per watering activation.
Dragging the three white vertical bars allows setting of lockout periods (red) preventing charging. This is useful where power providers offer discounted power pricing during off-peak demand periods.
If a battery is connected and
the start/stop switch activated during a lockout period, a Start Time Delay counter on the charger display will count
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© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors
exempt. Pictures may be representative, actual products may differ.
down to the charge start.
If a charge is interrupted by a
lockout period, the Daily Schedule Stop alarm is
Start Time Delay 2.4.10.
flagged and the charge will resume at the end of the lockout period.
A start time delay may be set in hours:minutes to start the charge after the specified delay.
Cool Down Period 2.4.11.
A period following a charge may be set to allow the battery to cool before the charger indicates charge completion.
A start delay is typically used to
allow heavily used batteries to cool before charging begins.
The charger Start/Stop switch must
be activated to begin the delay timer.
A user may over-ride the Start Time
Delay by holding the Enter button on the front panel for approximately 10 seconds. The delayed charge will begin immediately.
If enabled, the cool down period
begins at the end of the charge, with the charger display counting down the specified cool down time in Hours:Minutes. The front panel green LED alternates on/off during this period.
When the cool down period is
complete, the green LED remains steady on, and the charger display counter indicates the total time the battery has cooled.
Real Time Clock 2.4.12.
The charger’s internal clock allows charge and alarm logs to accurately timestamp records as well as the Daily Charging Schedule and other features to perform as required.
It is important that the Real Time Clock is accurately set for the local time zone.
The date format is dd/MM/yyyy
The time format is hh:mm:ss
Ensure the connected PC has the
correct local time and click Set To Computer Time.
Click Read to confirm the charger’s
clock is now set accurately.
The real time clock will display in
12hr format regardless of the PC’s 12/24hr setting.
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© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors
exempt. Pictures may be representative, actual products may differ.
2.6. Charge Log Tab
The Charge Log tab displays a number of details for each charge cycle for analysis and troubleshooting. Records can be viewed in the tab by clicking Read, and downloaded to a PC in CSV or XML formats using the Save button. Erase will clear all records currently stored on the charger.
Each charge cycle is recorded with profile type, durations of the various charge phases, start and
finishing voltages, as well as charge returned.
Charge logs are retained in the charger memory by an internal battery and are not subject to erasure due to power loss.
When the 2400 charge cycle record maximum is reached, the charger retains only the most recent records. Logs should be retrieved from the charger regularly to maintain charge cycle records.
2.7. Alarm Log Tab
The Alarm Log tab displays the last 200 alarms recorded during the operation of the charger. Records can be viewed in the tab by clicking Read and downloaded to a PC in CSV or XML formats using the
Save button. Erase will clear all records currently stored on the charger.
Refer to Section 6: Alarms for charger alarm definitions.
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© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors
exempt. Pictures may be representative, actual products may differ.
2.9. Monitoring Tab
The monitoring tab provides real­time updates on the parameters of the charge, charger alarm states and per-module status indicators
Sections
Charge Status
View current charge parameters as delivered to the battery and elapsed times. Charge parameters reflect all variables entered into the Configuration tab including cable and battery variables.
Alarms
Real-time view of alarm states – green indicates clear state, red indicates alarm state is currently triggered.
Charger Modules
Click on a module label to view individual module reports displaying current, input and output air temperatures per charger module. Green indicates charging state, red indicates alarm or failure, grey indicates module deactivated or not in use.
for the charge in progress. Detailed logging directly to the file on the connected PC is available.
Charge Detail Log
The Start Logging button initiates collection of detailed charging data directly to a connected PC. Sample rate, log filename and location and log start time can be customised.
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© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors
exempt. Pictures may be representative, actual products may differ.
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