Studer BSP User Manual

Studer Innotec SA 2017 – V1.3

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Battery Status Processor BSP

User Manual

Studer Innotec SA

BSP

2 V1.3 User manual

BATTERY STATUS PROCESSOR BSP: USER MANUAL

V 1.3
Copyright © 2017 Studer Innotec SA

ABOUT THE SOFTWARE

This document applies to software versions V1.5.6 or higher of the BSP. It is possible to check the
currently used software version with the menu "Information on the system" or to update the
product with the latest software version available on "www.studer-innotec.com/en/downloads/".

LEGAL NOTICE

The use of Studer Innotec SA devices is the responsibility of the customer in all cases. Studer Innotec
SA reserves the right to make any modification to the product without prior notice.

PRODUCT RECYCLING

The BSP conforms to the European directive 2011/65/EU on
hazardous substances and does not contain the following
elements: lead, cadmium, mercury, hexavalent chrome, PBB
or PBDE.

To dispose of this product, please use the service for collection
of electrical waste and observe all applicable obligations
according to the place of purchase.

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TABLE OF CONTENTS

1 INTRODUCTION ................................................................................................................................. 5

1.1 General battery knowledge ........................................................................................................ 5

1.1.1 Definition of battery capacity ............................................................................................. 5

1.1.2 Capacity and temperature ................................................................................................. 5

1.1.3 Capacity and cell imbalance ............................................................................................. 6

1.1.4 Capacity and discharge current ........................................................................................ 6

1.1.5 Capacity and battery lifetime ............................................................................................. 6

1.2 Conventions .................................................................................................................................... 6

1.2.1 Symbols .................................................................................................................................... 6

1.2.2 Parameters .............................................................................................................................. 6

1.3 Warranty and liability..................................................................................................................... 7

1.3.1 Disclaimer of warranty .......................................................................................................... 7

1.3.2 Disclaimer of liability .............................................................................................................. 7

1.4 Safety precautions ......................................................................................................................... 7

1.4.1 Generalities ............................................................................................................................. 7

1.4.2 Warnings .................................................................................................................................. 8

1.4.3 Safety precautions working with batteries ........................................................................ 8

2 EU DECLARATION OF CONFORMITY ................................................................................................ 9

3 INSTALLATION ................................................................................................................................. 10

3.1 Mounting ...................................................................................................................................... 10

3.2 Shunt mounting ........................................................................................................................... 11

3.3 Cabling ......................................................................................................................................... 11

3.4 Connecting the communication bus ...................................................................................... 11

3.5 Signalisation LED .......................................................................................................................... 12

4 QUICK START GUIDE ....................................................................................................................... 13

4.1 Choosing the battery capacity ................................................................................................ 13

4.2 Choosing the shunt ..................................................................................................................... 13

4.3 Reset the battery history to zero ............................................................................................... 14

5 DISPLAY OF THE STATE OF THE BATTERY ......................................................................................... 14

5.1 Graph of the state of charge history ....................................................................................... 14

5.2 Values to display ......................................................................................................................... 14

6 SETTING OF THE PARAMETERS ........................................................................................................ 16

6.1 Generalities .................................................................................................................................. 16

6.2 Levels of use and of accessibility ............................................................................................. 16

6.3 Basic settings {6000} .................................................................................................................... 16

6.3.1 Voltage of the system {6057} ............................................................................................ 16

6.3.2 Nominal capacity {6001} ................................................................................................... 16

6.3.3 Nominal discharge time (C-rating) {6002} ...................................................................... 16

6.3.4 Nominal shunt current {6017} ............................................................................................ 16

6.3.5 Nominal shunt voltage {6018} ........................................................................................... 16

6.3.6 Reset of battery history {6003}........................................................................................... 17

6.3.7 Restore default settings {6004} .......................................................................................... 17

6.3.8 Restore factory settings {6005} .......................................................................................... 17

6.4 Advanced settings {6016} .......................................................................................................... 17

6.4.1 Reset of user counters {6031} ............................................................................................ 17

6.4.2 Manufacturer SOC for 0 % displayed {6055} .................................................................. 17

6.4.3 Manufacturer SOC for 100 % displayed {6056} .............................................................. 17

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6.4.4 Activate the end of charge synchronization {6042} ..................................................... 18

6.4.5 End of charge voltage level {6024} ................................................................................. 18

6.4.6 End of charge current level {6025} .................................................................................. 18

6.4.7 Minimum time before end of charge {6065} .................................................................. 18

6.4.8 Temperature correction of the end of charge voltage {6048} ................................... 18

6.4.9 Activate the state of charge correction by the open circuit voltage {6044} ........... 18

6.4.10 Battery current limitation activated {6058} ..................................................................... 18

6.4.11 Max battery charge current {6059} ................................................................................. 18

6.4.12 Self-discharge rate {6019} .................................................................................................. 18

6.4.13 Nominal temperature {6020} ............................................................................................. 19

6.4.14 Temperature coefficient {6021} ........................................................................................ 19

6.4.15 Charge efficiency factor {6022} ....................................................................................... 19

6.4.16 Peukert's exponent {6023} ................................................................................................. 19

6.4.17 Use C20 capacity as reference value {6049} ................................................................. 19

6.5 Configuration as simple counter .............................................................................................. 19

7 FACTORY SETTING VALUES ............................................................................................................. 20

8 INDEX OF THE PARAMETERS {XXXX} .............................................................................................. 20

9 BSP SPECIFICATIONS ...................................................................................................................... 21

9.1 Technical data ............................................................................................................................ 21

9.2 Readout resolutions .................................................................................................................... 21

9.3 Dimensions ................................................................................................................................... 22

9.4 Mounting ...................................................................................................................................... 23

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1 INTRODUCTION

The BSP (Battery Status Processor) is designed to monitor lead-acid batteries when used together
with inverter-chargers from the Xtender series. An advanced algorithm provides the BSP with the
battery’s state of charge in real time in order to optimize its use.

The BSP offers voltage measurement for 12, 24 and 48 V batteries as well as current measurement
with a resistive shunt. By using the Xtender communication bus, the BSP is able to communicate
with the other devices in the system. It is possible to configure the BSP and to display its values with
the remote control RCC-02/-03.

Moreover, the Xtender inverter/chargers have the ability to adapt their functioning according to
the data given by the BSP.

1.1 GENERAL BATTERY KNOWLEDGE

Lead-acid batteries constitute energy storage with complex behaviour. They consist of a
collection of 2 Volt (V) cells connected in series to obtain a specific voltage. Depending on the
conditions, lead-acid batteries exhibit behaviour far more complicated than a tank that simply
fills and empties, due to different physical and chemical phenomena. For this reason it is more
difficult to precisely determine a battery’s state of charge than, for instance, that of a petrol
gauge.

The different values that affect a battery are described below.

1.1.1 Definition of battery capacity

A battery’s capacity is defined as the amount of electrical charge that a full battery can supply
at given current before reaching a certain voltage. Normally the unit Ampere-hour (Ah) is used
for its measurement. An ideal 100 Ah battery should for instance supply 10 Amperes (A) during 10
hours or 1 A during 100 hours.

The capacity is usually given at 20 °C for a new battery, with a discharge until 1.8 V per cell (10.8
V for 12 V nominal, 21.6 for 24 V and 43.2 V for 48 V). The time of discharge is indicated by the
letter C followed by the duration in hours, for example C10 for a discharge in 10 hours.

To reach a battery’s stated capacity, manufacturers charge their batteries according to standard
procedures (for instance as per the norm IEC-60896-11). This kind of charge can last up to many
tens of hours at very high voltages, which is rather far from normal conditions of use. This is why the
real available capacity is often lower than what is stated by the manufacturer. The parameters
{5055} and {5056} allow the BSP to measure a state of charge corresponding to the real available
capacity.

1.1.2 Capacity and temperature

A battery’s capacity varies according to the temperature of its active substance. A decrease of
temperature diminishes the capacity and an increase of temperature improves the capacity.

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1.1.3 Capacity and cell imbalance

Despite the fact that it’s always the same current that goes through the 2 V cells of a battery,
factory differences, even small, might make their state of charge uneven. In case of imbalance,
the most discharged cell determines the end of discharge.

Therefore, the cells in series must always be of the same model and have the same history of use. One
of the objectives of the absorption and equalization steps is to even out the charge of the cells in series.

1.1.4 Capacity and discharge current

The capacity goes down when it comes to big discharge currents. The active substance in the
battery needs time to spread into the cells and a quick discharge will lead to a capacity decrease.

To convert the capacity from a discharge duration to
another, one can use Peukert’s formula.

The exponent n

peukert

varies in every battery and is on

average approximately 1.25. C

ref

and I

ref

refer to the given

capacity at a known current.

Discharge speed

Capacity at C10 (100 Ah at 10 A during 10 hours)

C3

0.74

C20

1.19

C50

1.50

C100

1.78

Capacity ratio with a Peukert exponent of 1.25

1.1.5 Capacity and battery lifetime

The capacity decreases along the charge-discharge cycles. The deep discharges have a
particularly negative impact. High ambient temperatures lower also the lifetime.

1.2 CONVENTIONS

1.2.1 Symbols

This symbol is used to indicate the presence of a dangerous voltage that is sufficient

to constitute a risk of electric shock.

This symbol is used to indicate a risk of material damage.

This symbol is used to indicate information that is important or which serves to
optimize your system.

1.2.2 Parameters

All values mentioned hereafter, followed by a parameter number indicate that this value may be
modified using the RCC-02/-03 remote control. In general, the default values are not mentioned
and are replaced by a parameter number in the following format: {xxxx}. The default values for these
parameters are specified in the defaults parameter table chapter 7: “Factory setting values” (p. 20).

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1.3 WARRANTY AND LIABILITY

During production and assembling, each BSP gets several controls and tests. They are carried out
in full respect of fixed procedures. Each BSP is given a serial number allowing a perfect follow-up
of the controls, in conformity with the specific data of every device. For this reason, it is very
important to never remove the descriptive sticker bearing the serial number. The production, the
assembling and the tests of each BSP are entirely carried out in our factory in Sion (CH). The
warranty of this product depends on strictly following the instructions in this manual. The warranty
period for the BSP is 5 years.

1.3.1 Disclaimer of warranty

No warranty will be applied for damages caused by handling, operation or actions that are not
described in this manual. Damages arisen from the following events are not covered by the
warranty:

 Overvoltage on the device (Applying a voltage higher than 85 Vdc).
 Reverse polarity while connecting the battery.
 Liquid in the device or oxidation due to condensation.
 Failures due to a fall or to a mechanical shock.
 Modifications made without the explicit authorization of Studer Innotec SA.
 Nuts or screws partially or insufficiently tight during installation or maintenance.
 Damages due to atmospheric overvoltage (lightning).
 Damages due to transport or improper packaging.
 Disappearing of original marking items.

1.3.2 Disclaimer of liability

Installation, commissioning, use and maintenance of this device cannot be supervised by the
company Studer Innotec SA. For this reason, we do not accept any liability for damages, costs or
losses generated either by an installation that is not conforming to the prescriptions, by a defective
operation or by poor maintenance. The use of this device is under the responsibility of the end­user. This device is neither designed nor guaranteed for the supply of life support applications or
any other critical application with potential risks for human beings of for the environment. We shall
assume no liability for patent infringement or other third party rights involved in the use of this
device.

1.4 SAFETY PRECAUTIONS

1.4.1 Generalities

Do read carefully all safety instructions before proceeding to the installation and commissioning
of the device. Not respecting these instructions might constitute a lethal physical danger but can
also damage the functionalities of the device. Therefore, do keep this manual close to the device.

Strictly follow the local and national norms and regulations in force. This is valid for all
installations.

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1.4.2 Warnings

Danger of electrical shock!

 This device is used together with a permanent energy source (battery bank) and can also

receive an alternative source at its input. Before any handling it is then necessary to
disconnect all energy sources from the device.

 Never use this device in a place where explosions might occur. Do refer to the indications

of the battery manufacturer to ensure of the compatibility of the battery with the device.
The safety instructions of the battery manufacturer have to be followed strictly too!

 Wherever the installation, the person in charge of installation and commissioning must

know perfectly the safety measures and the prescriptions in force in the country. Therefore,
the whole maintenance must be carried out by a qualified staff.

 All components connected to this device must be conforming to the laws and regulations

in force. The persons without a written authorization from Studer Innotec SA are forbidden
to do any change, modification or repair whatsoever. Regarding authorized modifications
and replacements, only genuine components shall be used.

 This device is meant for a use only indoor and must under no circumstances stand in the

rain, the snow or any other humid or dusty environment.

 In case of use in motor vehicles this device must also be protected against vibrations by

absorbing components.

1.4.3 Safety precautions working with batteries

Lead acid batteries with liquid electrolyte produce a highly explosive gas during normal
operation. No source of spark or of fire should be present in the closeness of the batteries. The
batteries must be installed in a well-ventilated space and mounted so as to avoid accidental short
circuits while connecting them.

Never charge frozen batteries!

During any work on batteries, a second person must be present in case a problem occurs that
requires assistance. There should be within reach enough fresh water and soap for an immediate
washing of the skin or the eyes in case of accidental contact with acid. Should it happen, they
must be washed carefully during at least 15 minutes with cold water. It is then necessary to
immediately consult a doctor.