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HORNER
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XL4
Operation Manual
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HORNER XL, RCC, HE-RCC1410, HE-RCC8842, HE-RCC2414 Operation Manual

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MAN1142-06-EN_Batt_Man
4/22/2019 Page 1 of 9
Horner Rechargeable Battery Operation Manual
XL and RCC series controllers running 15.20 Firmware and Later
Table of Contents
1. Overview of Rechargeable Battery Function
The OCS Controllers with rechargeable batteries maintain register data in high-speed RAM when connected to DC power. When DC power is switched off or lost, critical circuits switch over and run on battery power for around 100mS. During this time register and other retentive data is saved to FLASH memory. After this time the real-time clock continues to run on the battery at a very low power level. The battery is designed to maintain the real-time clock for a year or more in the powered-down state. When powered, the OCS controller recharges the battery as necessary. Recharging the battery can take up to 8 to 40 hours depending on temperature and the state of charge.
Rechargeable Lithium Battery Table
Controller
Horner Part Number
Battery Description
HE-RCC1410
BAT00028F
3.7V LI-RECH 340mAH 4.5x40x24mm Bare Cell LF
HE-RCC2414
BAT00028F
3.7V LI-RECH 340mAH 4.5x40x24mm Bare Cell LF
HE-RCC8842
BAT00028F
3.7V LI-RECH 340mAH 4.5x40x24mm Bare Cell LF
XL4
BAT00019
3.7V LI ION Rechargeable 800mAH 14500 AA
XL7
BAT00019
3.7V LI ION Rechargeable 800mAH 14500 AA
EXL6
BAT00019
3.7V LI ION Rechargeable 800mAH 14500 AA
EXL10
BAT00019
3.7 V LI ION Rechargeable 800mAH 14500 AA
2. Battery Life
The battery is designed to last 300 full charges to 1000 partial charges or 7 to 10 years. Because typical operation does not drain the battery, the 1000 charge cycles should never be reached, and the 7 to 10-year aging of the battery would limit its useful life. The battery is designed to be replaced.
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3. Lithium Battery Safety
Many of the publicized battery issues are a result of using multiple batteries or flexible battery pack. The OCS uses a small single cell in a metal enclosure, and the battery is UL recognized and comes from quality suppliers. The OCS has safety circuitry built into the charging IC and additional external protection including fusing. These circuits were closely evaluated by UL and Horner engineering for use in hazardous environments.
4. OCS Battery Charging Cycle
There are various charging states that are executed based on battery temperature, level of battery charge, and self-test results. The battery temperature can be determined by checking the CPU temperature in the controller System Menu: View Battery Status or by monitoring System Register %SR195.
The battery temperature is equal to the CPU temperature minus 30°C.
Refer to Table 1 for charge states and definitions.
1. When power is applied to the OCS, the unit always goes to State 11; Waiting, for the first
two minutes.
2. After two minutes have expired, the OCS wil begin charging the battery based on battery
temperature. In this step, charging will ensue even if the battery is already fully charged. In this step charging does not ensue if the battery temperature is outside of the acceptable hot or cold limits.
3. The battery is charged fully to 4.2 volts in the Normal Charging or Cold Charging states or
to 4.1 volts in the Hot Charging state.
4. Once fully charged to 4.2 volts, state 0, the Wait Discharging state is executed, state 12.
The battery is allowed to discharge to 4.0 volts for however long that takes. Powering up the OCS will reset the charge cycle to step 1.
5. If the battery was charged to 4.1 volts under state 2, Hot Charging; 4.1 volts is maintained
until Normal or Cold Charging can be executed.
Note: If the battery voltage is too low, less than 2.5 volts, or if the battery is missing, charging is
suspended. In this condition, the OCS unit fails self-test. Diagnostics will show a battery warning. %SR55.13 will be ON.
Note: If the battery is not missing and the voltage is 2.5 volts or greater but will not fully charge in
8 to 40 hours, the charge cycle is suspended for 5 minutes and then tried again.
Note: Because the OCS is designed to maintain the Real Time Clock for a year or more in a powered
down state, this translates as; the battery requires up to 8 to 40 hours of recharging time in a year.
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5. Battery Charging Status
Viewed in the System Menu under “View Battery Status” or read as a numeric value in %SR196. The battery temperature, Tb, is equal to the CPU temperature minus 30°C: Tb = CPU° - 30°C.
Table 1 – Charging State Table
State -
%SR196
Name
Description
Additional Information
0
Final Charge to 4.2V
The battery is fully charged
Next step, State 12 – Wait Discharging
1
Normal Charging
Battery is fast charging Tb: 11-45°C
@100mA to 4200mV Up to 8 hrs charge time
2
Hot Charging
Battery is slow charging Tb: 45-60°C
@20mA to 4100mV Up to 40 hrs charge time
3
Battery Won’t Charge
Battery has not completed charging in 8/40 hours
Charging is suspended for 5 minutes and then tried again.
4
Battery Too Hot
Not Charging Tb: > 60°C
Charging cycle resumes when battery temperature falls to 60°C or less.
5
Cold Charging
Battery is slow charging Tb: 0-10°C
@20mA to 4200mV Up to 40hrs charge time
6
Battery Too Cold
Not Charging Tb: < 0°C
Charging cycle resumes when battery temperature climbs to 0°C or greater.
7
Error No Battery
No battery was detected at power up. It will not attempt to charge until the next power cycle.
%SR55.13 = ON
8
Final Charge to 4.1V
The battery has fully charged to 4.1V in Hot Charging mode.
4.1V is maintained until Normal or Cold charging can execute.
10
Error: Voltage Too Low
The battery voltage was too low at power up. It will not attempt to charge until the next power cycle. Make sure a proper battery is installed.
%SR55.13 = ON
11
Waiting
The unit has powered up and is waiting 2 minutes before attempting to charge.
After 2 minutes, charging begins even if the battery is fully charged.
12
Wait Discharging
The battery has been charged and the system is waiting for the voltage to drop before charging again.
Charging resumes when battery voltage has dropped below 4000mV.
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