Studer BSP 1200, BSP 500 User Manual

Battery Status Processor BSP

User Manual

Copyright © 2011 Studer Innotec SA - V1.0.3

Battery Status Processor BSP : User Manual

V1.0.3
Copyright © 2011 Studer Innotec SA

About the software

This document applies to the version of software V1.4.0 or higher of the BSP. It is possible to check the software with the menu "Information on the
system" or update it with the latest version available on "www.studer-innotec.com/support".

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 2002/95/EC 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 the collection of electrical waste and observe all applicable obligations according to the place
of purchase.

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BSP

Table of Contents

1. Introduction ............................................................................................................................................... 7

1.1. General ideas over batteries ......................................................................................................... 7

1.1.1. Defining the capacity .......................................................................................................... 7

1.1.2. Capacity and temperature .................................................................................................. 7

1.1.3. Capacity and cells imbalance ............................................................................................ 7

1.1.4. Capacity and discharge current ......................................................................................... 7

1.1.5. Capacity over the battery lifetime ....................................................................................... 8

1.2. Conventions ................................................................................................................................... 8

1.2.1. Symboles ............................................................................................................................ 8

1.2.2. Regarding the parameters ................................................................................................. 8

1.3. Warranty and liability ..................................................................................................................... 8

1.3.1. Warranty and liability .......................................................................................................... 8

1.3.2. Exclusion of warranty ......................................................................................................... 9

1.3.3. Exclusion of liability ............................................................................................................ 9

1.4. Safety precautions ........................................................................................................................ 9

1.4.1. Generalities ......................................................................................................................... 9

1.4.2. Warnings ............................................................................................................................ 9

1.4.3. Precautions while using batteries ..................................................................................... 10

2. EC declaration of conformity ................................................................................................................. 11

3. Dimensions ............................................................................................................................................. 12

3.1. Views of different sides with dimensions .................................................................................... 12

3.2. Exploded view ............................................................................................................................. 13

4. Installation .............................................................................................................................................. 14

4.1. Mounting ...................................................................................................................................... 14

4.2. Shunt mounting ........................................................................................................................... 14

4.3. Cabling ........................................................................................................................................ 15

4.4. Connecting the communication bus ............................................................................................ 15

5. Quick Start guide ................................................................................................................................... 16

5.1. Choosing the battery capacity .................................................................................................... 16

5.2. Choosing the shunt ..................................................................................................................... 17

5.3. Reset the battery history to zero ................................................................................................ 17

6. Display of the state of the battery ......................................................................................................... 18

6.1. Graph of the state of charge history ........................................................................................... 18

6.2. Values to display ......................................................................................................................... 18

7. Setting of the parameters ...................................................................................................................... 20

7.1. Generalities ................................................................................................................................. 20

7.2. Levels of use and of accessibility ............................................................................................... 20

7.3. Basic settings {6000} .................................................................................................................. 20

7.3.1. Nominal capacity {6001} .................................................................................................. 20

7.3.2. Nominal discharge time (C-rating) {6002} ........................................................................ 20

7.3.3. Nominal shunt current {6017} ........................................................................................... 20

7.3.4. Nominal shunt voltage {6018} .......................................................................................... 20

7.3.5. Reset of battery history {6003} ........................................................................................ 20

7.3.6. Restore default settings {6004} ........................................................................................ 20

7.3.7. Restore factory settings {6005} ........................................................................................ 20

7.4. Advanced settings {6016} ........................................................................................................... 21

7.4.1. Reset of user counters {6031} ......................................................................................... 21

7.4.2. Self discharge rate {6019} ................................................................................................ 21

7.4.3. Nominal temperature {6020} ............................................................................................ 21

7.4.4. Temperature coefficient {6021} ........................................................................................ 21

7.4.5. Charge efficiency factor {6022} ........................................................................................ 21

7.4.6. Peukert's exponent {6023} ............................................................................................... 21

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7.4.7. Activate the end of charge synchronization {6042} .......................................................... 21

7.4.8. End of charge voltage level {6024} .................................................................................. 21

7.4.9. End of charge current level {6025} .................................................................................. 21

7.4.10. Minimum time before end of charge {6026} ................................................................... 21

8. Factory setting values ............................................................................................................................ 23

9. Technical data ........................................................................................................................................ 24

Index ........................................................................................................................................................... 25

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1. Introduction

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

The BSP offers voltage measurement for 12, 24 and 48 V nominal batteries as well as current measurement
with a resistive shunt. Thanks to the Xtender communication bus, the BSP is able to communicate with the
other devices of the system. The remote control RCC-02/-03 makes it possible to configure the BSP and to
display the values that it measures. More than this, the Xtender inverters can react according to various data
given by the BSP.

1.1. General ideas over batteries

The lead-acid batteries are energy storage with a complex behaviour. They consist of 2 Volt (V) nominal cells
in series to reach the required voltage. Due to different physical and chemical phenomenons they can show,
depending on the conditions, a behaviour quite far from the reservoir that simply fills up and empties out. This
is the reason why the battery state of charge is complex to determine and why a lead-acid battery monitor
is not as precise as, say, a petrol gauge.

The different values that affect a battery are described here below.

1.1.1. Defining the capacity

The battery capacity is defined as the quantity of electrical charge that a full battery can supply at given current
before reaching a certain voltage. The unit generally used is the Ampere-hour (Ah). An ideal battery of 100 Ah
will for instance supply 10 Amperes (A) during 10 hours or 1 A during 100 hours.

The capacity is usually given for a new battery, at 20 °C, with a discharge down to 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 given by the letter C followed by
the duration in hours, like C10 for 10 hours.

To make them reach the given capacity, the 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 lower than what is given by the manufacturer.

1.1.2. Capacity and temperature

The capacity varies according to the temperature of the active substance of the battery. A decrease of the
temperature will lead to a decrease of the capacity and an increase of the temperature to an improvement
of the capacity.

1.1.3. Capacity and cells imbalance

Despite the fact that always the same current 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 formula.

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The exponent n

varies in every battery and is on average approximately 1.25. C

peukert

and I

ref

refers to

ref

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

Table 1.1. Capacity ratio with a Peukert exponent of 1.25

1.1.5. Capacity over the 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. Symboles

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. Regarding the 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 this parameter are specified in the
defaults parameter table Chapter 8: “ Factory setting values ” (p. 23) .

1.3. Warranty and liability

1.3.1. 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.

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1.3.2. Exclusion 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 ? 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.

1.3.3. Exclusion of liability

Installation, commissionning, use and maintenance of this device can not be supervised by the company
Studer Innotec SA. For this reason, we do not accept any liability for the damages, the costs or the losses
generated either by an installation that is not conforming to the prescriptions, by a defectuous operation or
by a poor maintenance. The use of this device is under the responsibility of the end-user. 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 commissionning of the
device. Not respecting these instructions might constitute a lethal physical danger but can also damage the
functionnalities of the device. Therefore do keep this manual close to the device.

Do, for any installation, follow strictly the local and national norms and regulations in
force.

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 striclty too!

• Wherever the installation, the person in charge of installation and commissionning 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.

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