Thornwave Labs PowerMon BT-DCPM User Manual
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PowerMon
Model: BT-DCPM
Bluetooth LE Enabled
Advanced Battery Monitor / DC Power Meter
– USER MANUAL –
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BRIEF
PowerMon (BT-DCPM) is a Bluetooth Smart (LE) Swiss-army knife tool that can be used in any DC circuit.
Its primary function is advanced battery monitor / DC power meter. PowerMon allows monitoring of important
electrical parameters: two voltages (0-75V), one current (0-60A using the integrated current shunt or up to
10,000A using an external current shunt), peak current, power (W), energy (Wh), battery charge (Ah) and
temperature. Many other parameters are computed: the battery state of charge (SOC) as a percentage,
remaining battery runtime, battery statistics (number of cycles, total discharged capacity, …). The current
measurement can be either unidirectional or bidirectional. In bidirectional mode, PowerMon senses current
flow in both directions (positive and negative). The device can drive a mechanical or solid-state relay which
allows it to function as a low voltage disconnect, high voltage disconnect, over-current disconnect, battery
isolator in multiple battery systems, remote on/off switch and timer. A mobile device running either Android or
iOS and the PowerMon app (available for free on Google Play Store and Apple App Store) are required for
operating this device.
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FEATURES
• Measures two voltages, one current
(unidirectional or bidirectional), peak
current, power (W), charge meter (Ah),
energy (Wh) and temperature
• Operates at up to 75V and 60A of
continuous current (75A peak current) using
the integrated current shunt
• Can sense up to 160mV of voltage drop
across an external current shunt allowing
current of up to 10,000A to be measured
• Full differential input for the current shunt,
allowing it to be mounted either on the
ground or positive wire
• Can control one relay or SSR (solid state
relay)
• Low / high voltage disconnect
• Over-current disconnect (circuit-breaker)
• Battery isolator for dual battery bank
systems
• Battery monitor (battery fuel gauge),
displays the state of charge in percentage
and the remaining time on battery
• Lithium iron phosphate battery charge
manager
• Timers
• Can use an external temperature sensor
• User / master password protection
• Very low power consumption (see
Performance Parameters)
• Bluetooth Smart (LE) radio with internal
antenna and long range
• 8-pole terminal block for connecting to the
system that will be monitored
• ABS plastic enclosure with mounting
flanges, completely enclosed in epoxy
potting compound
• Measures only 3.0” x 1.55” x 0.75” (76mm x
39mm x 19mm) including the mounting
flanges.
• Weatherproof
• Free PowerMon app available for Android
and iOS
• Most parameters can be configured,
allowing it to achieve top performance with
a variety of current shunts and batteries
TYPICAL APPLICATIONS
• RVs, boats, off-the-grid cabins
• Solar and wind alternative energy
• Vehicle batteries
• Backup electrical systems
• Lithium Iron-Phosphate battery charge manager
• Automatization: solar irrigation systems, solar street lights, general purpose DC timers
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TERMINAL DESCRIPTION / INTERNAL DIAGRAM
No.
Name
Terminal Description
1
GROUND
System ground
2
MF
Multi-function (for hardware revision 2.2 and up) – call for details
3
RELAY
Relay output. It controls a mechanical or solid-state relay. This terminal is
connected to ground internally by the device when the power is turned ON.
4
ES+
External shunt connection. When using the internal current shunt connect
this terminal to ES- (terminal 5)
5
ES-
External shunt connection. When using the internal current shunt connect
this terminal to ES+ (terminal 4)
6
VS
Optional power supply. If available, connect this terminal to a power supply
of not more than 18V. This connection is optional.
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V2
Second monitored voltage. Can measure the voltage of a second battery.
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V1
Main power. This is the main voltage that will be monitored. The device
also draws its power form this terminal. If power is applied to terminal 6
(VS), the device will draw its power from VS instead of V1.
9
IS-
Internal shunt connection. The measured current is flowing from IS+ to ISor backwards. Do not connect if using an external shunt.
10
IS+
Internal shunt connection. The measured current is flowing from IS+ to ISor backwards. Do not connect if using an external shunt.
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SPECIFICATIONS
Absolute Maximum Ratings
1,2
Maximum voltage at V1 and V2
+65V (hw rev 2.00)
+75V (hw rev 2.20)
Maximum voltage at VS
+18V
Maximum voltage at RELAY
+18V (hw rev 2.00)
+30V (hw rev 2.20)
Maximum current through RELAY terminal (maximum
relay coil current)
0.5A
Maximum current through IS+ and IS- (using the
integrated current shunt)
60A continuous, 75A peak
Maximum current (using an external current shunt)
depends on external shunt
(up to 10,000A)
Maximum differential input sense voltage ES+ to ES(using an external shunt)
-75V to +75V
Maximum common mode input sense voltage (ES+, ES-,
IS+, IS-)
-2V to +75V
Operating temperature
-30°C to +85°C
1. Stresses greater than those listed under “Absolute Maximum Ratings” may cause permanent damage to the device.
2. All voltages are referenced to ground unless otherwise specified.
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Performance Parameter
Value
Measured voltage (V1, V2)
0 to 60V (hw rev 2.00)
0 to 75V (hw rev 2.20)
Measured voltage accuracy
0.5%
Measured current (using integrated shunt IS+, IS-)
0 to 60A
Current monitoring accuracy (using integrated shunt)
2% - without calibration
1% - with calibration
Integrated current shunt resistance
0.5 mOhm / ±1%
Voltage at external shunt input (ES+ to ES-)
0 – 160mV / ~20µV resolution
Current monitoring accuracy (using external shunt)
depends on external shunt
precision, typically better than 1%
with calibration
Minimum external current shunt resistance
0.1 mOhm
Power (using integrated shunt)
max. 4500W
Power meter
more than 1000 MWh
Charge meter
more than 1000 MAh
Battery state-of-charge monitor
0% – 100%
Temperature
1°C / 1°F resolution
Current draw (current consumed by the device)
at 12V
at 24V
at 36V
at 48V
at 60V
at 75V
7.2 mA
7.5 mA
7.8 mA
8.1 mA
8.5 mA
8.9 mA
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COMPLIANCE STATEMENTS
FCC
ATTENTION: Changes or modifications not expressly approved by Thornwave Labs Inc could void the
user's authority to operate the equipment.
ATTENTION: This device complies with Part 15 of the FCC rules. Operation is subject to the following two
conditions: (1) this device may not cause harmful interference and (2) this device must accept any interference
received, including interference that may cause undesired operation.
ATTENTION: Cet appareil est conforme à la Partie 15 des règlements de la FCC. L'opération doit se
conformer aux deux conditions suivantes: (1) cet appareil ne peut causer d'interférences nuisibles et (2) cet
appareil doit accepter toute interférence reçue, y compris les interférences qui peuvent provoquer un
fonctionnement indésirable.
IC RSS-102 RF Exemption
This system has been evaluated for RF Exposure per RSS-102 and is in compliance with the limits specified
by Health Canada Safety Code 6.
L’exposition aux radiofréquences de ce système a été évaluée selon la norme RSS-102 et est jugée
conforme aux limites établies par le Code de sécurité 6 de Santé Canada.
IC RSS-Gen 8.4
This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to the
following two conditions: (1) this device may not cause interference, and (2) this device must accept any
interference, including interference that may cause undesired operation of the device.
Le présent appareil est conforme aux CNR d'Industrie Canada applicables aux appareils radio exempts
de licence. L'exploitation est autorisée aux deux conditions suivantes: (1) l'appareil ne doit pas produire de
brouillage, et (2) l'utilisateur de l'appareil doit accepter tout brouillage radioélectrique subi, même si le
brouillage est susceptible d'en compromettre le fonctionnement.
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SAFETY INSTRUCTIONS
Warning !
Read all the instructions and cautions before using the PowerMon device. Thornwave Labs Inc does not
assume responsibility for any injury or property damage caused by improper installation, bad wiring or use of
PowerMon outside of its intended purpose. The device should be installed by a professional.
Warning !
The PowerMon device should not be used for any medical purposes, life sustaining equipment, safety
applications or any application where equipment failure can cause injury, death, fires, or any other hazard.
Warning !
There are no serviceable parts or fuses inside the power meter! Do not disassemble or attempt to repair!
The unit operates with voltages up to 75V which can be lethal or cause serious and permanent injury.
Warning !
Do not submerge under water or other liquids. The device is weatherproof but not waterproof.
Warning !
The device is to be connected to DC circuits only, not exceeding 75V and 60A (using the integrated
current shunt). Failure to do so will result in equipment damage. Higher currents are supported when using an
external current shunt. Confirm that all connections are tight to avoid excessive heating and sparks. Never
connect the V1 or VS terminals to a power source without using a fuse or circuit breaker. A 0.1A to 5A fuse or
circuit breaker is required.
Warning !
Batteries are dangerous! Do not short-circuit a battery or the power meter. Batteries can produce
flammable and explosive gases and can generate very high currents that can lead to serious consequences
including explosion, fire, damage to equipment, personal injury and even death. It is the user’s responsibility to
operate the equipment in a safe manner. Do not charge batteries in an enclosed environment unless allowed
by the manufacturer of the battery. Never connect a load to a battery without using fuses or circuit breakers.
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FUNCTIONAL OVERVIEW
Device power. The PowerMon device is drawing its supply power from the V1 terminal and using an
internal voltage regulator it creates an internal supply voltage of 9V. This internal supply voltage is available at
the VS terminal but should not be used to supply any external load. Attempting to power external loads from
VS will damage the device. If a power supply of maximum 18V is available it is recommended to connect it to
the VS terminal. This will turn the internal regulator off and provide the power for the device, improving
efficiency (only if V1 is higher than 24V). When the device is used to monitor 12V batteries, V1 and VS can be
wired together to the positive side of the 12V battery. If an appropriate power supply voltage is not available
the VS input should be left unconnected.
Integrated current shunt. When using the integrated current shunt, the ES+ and ES- pins should be
connected together using a wire bent in a U shape and attached to the supplied terminal block. The current to
be monitored should be routed through the IS+ and IS- terminals. An internal current shunt of 0.5mOhm exists
in between these two terminals. The aluminum, hex screw terminal blocks (IS+ and IS-) can accept wires up to
6AWG in size. In order to minimize the voltage drop on wires and connections, use the thickest wires that can
support the required current. The common mode voltage at IS+ and IS- can be in between -2V and +75V relative
to ground, allowing the current shunt to be placed either on the positive side of the circuit or on the ground
wire. Current flowing from IS+ to IS- will display as a positive value and current from IS- to IS+ will display as a
negative value. The current sign can be flipped from the device configuration.
External current shunt. To monitor a large current or a very small current more accurately, an external
current shunt can be used. This method allows monitoring current up to 1,000A with reasonable resolution or
even higher current if resolution can be sacrificed. Using a higher resistance current shunt, current in the milliamp range can be measured accurately. The external current shunt resistor should be connected to the ES+ and
ES- inputs. To avoid noise the wires should be as short as possible. Twisting the sense wires reduces noise even
further. The IS+ and IS- terminals should be left unconnected. The common mode voltage at ES+ and ES- can be
in between -2V and +75V relative to ground, allowing the current shunt to be placed either on the positive side
of the circuit or on the ground wire. Current flowing from the ES+ to ES- sides of the external shunt will be
displayed as a positive value and current from ES- to ES+ will be displayed as a negative value. The current sign
can be flipped from the device configuration.
Operation. Once the device receives power it will start advertising its presence to other Bluetooth
devices. Using a cell-phone or tablet running the PowerMon app (found on the App Store / Play Store) the user
can scan for PowerMon devices and connect to one of them at a time (if multiple devices are present). Multiple
PowerMon devices can be distinguished after changing their Bluetooth name using the mobile app. This will be
displayed by the app upon scanning for Bluetooth devices. The factory default name is “DCPM”. Once the mobile
app is connected to a power monitor device, the app will display all the measured electrical parameters and
update them in real-time. Tapping on a measurement value for longer than 1 second will open a menu that
allows operations and configuration specific to that measurement.
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