SmartON / SmartON+ Installation and Use Manual
Contents
1. ALFA PROGETTI S r l Spilamberto MO Tel 39 059 785 726 Fax 39 059 785 737 www alfaprogetti com PROGETTI SmartON SmartON Installation and Use Manual Rev Date Ver Ver Notes document document SmartON SmartViewll 1 0 06 04 2007 3 08 2 30 Pre release 1 01 10 04 2007 3 08 2 30 Release 1 02 04 10 2007 3 09 2 31 05 Release 1 03 17 04 2008 3 09 2 31 05 Update 1 04 07 04 2010 Update and use SmartON_Installation and Use Manual_V1 04 GB doc Page 1 of 16 ALFA PROGETTI S r l Spilamberto MO Tel 39 059 785 726 Fax 39 059 785 737 www alfaprogetti com Index ss A E nn A O 3 1 Dackare COMLEME isa dessns taki sedi caatetach ici Di A ADE AAA A aida 3 A A E E E EEEE E Ea SEE 4 aL Workin A O 4 LAO a e edo as te do ad 5 23 LED SS a a a a a a A A E R 5 ZA Estimation of The recharge AN E E EA 6 2 5 Opportunity Chaipinga sesei eae Sch ol a E ele do e al e ala Sa Sale 6 2 6 Lock functions SmartON only escocia natalidad diia das add 6 2 7 Use of the button SmartON only sisi rr io idas T 3 Mounn sss oR PAE SR eR Ra on En RY SO on PND A RE osoasa dreet pedoo deoo sise soss ARY Pann asa Br er 8 Ss PES NVM APIS edades 8 32 WiN aloes aac San n tut od ensued Cinta ate ada Sal onal nd tad tot ate a ae us Sac teats al ah eae aa 9 9 Final STC A O NA 10 AS PRO STAM Gi csitiilaacisicsancigistanecacacascucinccecendesauscanvaczensdevecaedbess E ao serias ia E2. choose carefully names and codes avoiding to fill in the same parameters for different Smart ON s For more details refer to the user manual of the SmartViewlIl program OnLine SmartIC IPlus SmartON 5 xj Monitor Info Old Data OLD Data Info Diagram Daily Programming Associations Averages Statistics Association Data Customer A08AU00441 1L SmartlC Serial Num Retailer A08AU004411L User 09 Send Data 09 Reread Data Battery ID Forklift Truck ID Clear Table PREVIOUS USES OF SMARTIC Forklift Truck ID pntOld SmartViewlII programming of the associations Select the Associations TAB Fill in the following fields Customer Text identifying customer Retailer Text identifying dealer User Text identifying user Battery ID Text identifying battery serial number Forklift Truck ID Text identifying forklift truck serial number Press the Send data pushbutton and check if a string with the parameters put in appears in the table underneath NOTE The programming of the associations can also be executed in advance in the laboratory if all parameters are known SmartON_Installation and Use Manual_V1 04_GB doc Page 14 of 16 ALFA PROGETTI S r l Spilamberto MO Tel 39 059 785 726 Fax 39 059 785 737 www alfaprogetti com 5 Alignment To make SmartON fully operational and therefore collect and subsequently sup
3. traditional by time foresees that the battery is considered charged after the duration of the charge subsequent to the attainment of the Threshold Voltage 2nd Stage has reached the Safety Timer 2nd Stage see 4 3 Programming of operating parameters The second way Ah in contrast foresees that the charge is considered sufficient when the restored capacity added to that present at the time the battery charge is initiated equals the nominal capacity The Default setting is the Ah method see 4 3 Programming of operating parameters NOTES With the Ah method through the SmartEnergy family battery charger the battery is supplied only with the power strictly necessary to achieve the full charge thus saving energy and avoiding damage and waste of water Alignment see 5 Alignment occurs only after a full recharge cycle is conducted 2 5 Opportunity Charging The term Opportunity Charging means the mode of use with which the battery is repeatedly charged and discharged for short periods and small capacity as happens for example in the AGVs Automatic Guided Vehicle In this situation there would be a proliferation of working cycles that would lead to a rapid depletion of memory and substantially illegible data In these cases by setting the item Opportunity Charging in the programming 4 3 Programming of operating parameters it is possible to reduce the daily number of cycles in fact in this mode a
4. Its main features are e Measurement of the instantaneous battery data including voltage current available Ah and temperature An indication of the amount of Ah available is provided by LEDs on the panel 2 3 e Built in RTC Real Time Clock to build a log of the data collected with date and time e Storage of historical data The past activity of the battery can be accessed on a PC using the SmartViewll software application or through WEB The data collected can be viewed grouped by working cycle or by day For each working cycle the data is presented both in figures and graphics e Data download to a PC Through an IR connection all data can be sent to the SmartViewIl PC program e Statistical analysis SmartViewlIlI has numerous functions able to provide statistics to check the correct use of the battery and the charge reporting any anomaly 2 1 Working Cycle A working cycle is intended as a sequence comprising a discharge stage followed by charging stage Given that a change of cycle is forced in the case of a new association power failure or long period of inactivity after a charge this definition should be understood as a guideline Another exception of the definition occurs when the option Opportunity Charging is set see 2 5 Opportunity Charging The transition from discharge to charge occurs after 2 minutes of charging to avoid misinterpretations due to the presence of a charge recovery device during braking in this ca
5. a oarece o Se iess oaasis 11 AL MARIO LEA A Aaa ace Gn AA A toes 11 42 A a a a dae Get 11 4 3 Programming of operating PardMEtelS vu coiacinudn israel ed aaa redee idad 11 4 4 Programming of associations sas 14 SATIN isco sca sess in sa ona vn xassicniosalew ce esser oean sE eras osi esr e SKEE SEEE EEE OEN SKANE E EE 15 O Specifications 5 ch sco O A RES 16 SmartON_Installation and Use Manual_V1 04_GB doc Page 2 of 16 ALFA PROGETTI S r l Spilamberto MO Tel 39 059 785 726 Fax 39 059 785 737 www alfaprogetti com Foreword This installation manual refers both to Smart ON and Smart ON devices When Smart ON is indicated both devices are meant If instructions refer to only one of the 2 devices this will be specified To install Smart ON battery connector has to be equipped with at least 2 auxiliary contacts 1 Package content The package contains the following parts The Smart ON device of the size required equipped with wire terminals and conical fairleads 2 fairleads for cables with a reduced cross section area Protection adhesive for the bottom side Package content Smart ON to the left Smart ON to the right SmartON_Installation and Use Manual_V1 04_GB doc Page 3 of 16 ALFA PROGETTI S r l Spilamberto MO Tel 39 059 785 726 Fax 39 059 785 737 www alfaprogetti com 2 Operation SmartON is a device designed for the monitoring and control of lead batteries
6. arameter Forks Lock is 80 The Smart ON PLUS device also foresees the following lock function SmartON_Installation and Use Manual_V1 04_GB doc Page 6 of 16 ALFA PROGETTI S r l Spilamberto MO Tel 39 059 785 726 Fax 39 059 785 737 www alfaprogetti com Forklift Lock For each day of the week it is possible to set the time start and end with which to impose a lock on the forklift If the two times coincide the lock does not occur The Lock Timeout parameter indicates the forklift downtime that must elapse before the lock is operational 4 FORKLIFT TRUCK LOCK lol x Scheduler Lock Timeout 255 min Forks lock hours Monday _ fo00 lt Ifo 00 Tuesday o00 fo 00 Wednesday 0 00 lt fo 00 Thursday fo 00 lt fo00 Friday joo foo Saturday fo 00 ooo Sunday jooo foot J OK 2 7 Use of the button SmartON only e If during discharge the Forks Lock situation is reached the pressure on the button ensures an additional bonus of usable capacity equal to 4 of the nominal capacity e If during a working cycle the different power points are blocked for Anti opportunity Charging pressing the button disables the lock for that cycle e Within 6 minutes of providing the power supply repeatedly pressing the button forces the amount of Ah present in the battery with an increase of 20 of the nominal capacity each time note it does not perform the alignment This featur
7. attery connector Connect the terminal of the previously removed wire again to the negative pole Only Smart ON plug the auxiliary contact pins inserted into the wires ends into the connector and connect it to the battery negative cable Connect the red wire of Smart ON to battery positive pole TAKING CARE TO PLACE AND FIX IT PROPERLY IN ORDER TO PREVENT IT FROM BEING ACCIDENTALLY CUT OFF A few seconds after connection the red LED will blink showing battery presence on Smart ON SmartON_Installation and Use Manual_V1 04_GB doc Page 10 of 16 ALFA PROGETTI S r l Spilamberto MO Tel 39 059 785 726 Fax 39 059 785 737 www alfaprogetti com 4 Programming Once installed Smart ON needs to get some information to work correctly For this purpose it is necessary to connect it to a PC equipped with the SmartViewII program for Windows This can be done through an infrared port 4 1 Making it ready Connect the infrared adapter to the PC AP160 adapter to a RS232 port or AP160UIR adapter to an USB port Trigger the SmartViewll program Insert the Password for level 2 Press the Connect pushbutton 4 2 Setting of date time Select the Programming TAB Press the Set clock push button Select the Monitor TAB and check data in the box showing date and time 4 3 Programming of operating parameters The operating parameters allow Smart ON to collect data correctly duri
8. cases it is possible to change the Voltage Threshold 2nd Stage and or 2nd Stage Charging Time parameters by reducing their values to facilitate the achievement of the alignment However it is good practice not to deviate much from the default values to avoid providing the SmartON unit incorrect information about the real state of the battery NOTE As long as the SmartON is misaligned The red low battery LED flashes on the Mimic panel unless the battery charge was forced using the procedure described in 2 7 Use of the button SmartON only With SmartView Inthe Monitor TAB the battery charge status is replaced by the message Ah Alignment not performed In the OLD Data info TAB the graphic representation of the cycle is replaced by the message Ah Alignment not performed Elsewhere no battery charge reference values are displayed Even when SmartON is not aligned all parameters measured during the cycle voltages currents temperatures date and time and the graphs are logged NOTE The alignment procedure must be repeated each time the SmartON is disconnected from the power supply SmartON_ Installation and Use Manual_V1 04_GB doc Page 15 of 16 ALFA PROGETTI S r l Spilamberto MO Tel 39 059 785 726 Fax 39 059 785 737 www alfaprogetti com 6 Specifications Some useful technical information is reported below STORABLE GRAPH DATA Storable Working cycles 200 Storable gra
9. e is useful if the Forks Lock function is selected to allow normal use of the fork lift after the installation of SmartON before the alignment charge is executed SmartON_Installation and Use Manual_V1 04_GB doc Page 7 of 16 ALFA PROGETTI S r l Spilamberto MO Tel 39 059 785 726 Fax 39 059 785 737 www alfaprogetti com 3 Mounting Smart ON has to be mounted on the battery negative cable This cable has to be cut so as to place the shunt inside the Smart ON between the 2 cut ends 3 1 Preliminaries Disconnect the negative cable from the battery negative pole and from connector so as to work without taking any risks Unscrew the Smart ON cover and remove conical fairleads and wire terminals If necessary cut the conical fairleads in order to allow the cable with the desired cross section area to go through Select the wire terminals most suitable to the cable cross section area among the ones available Choose the position on the battery where you want to install Smart ON so as to determine the cable lengths between Smart ON and negative pole and between Smart ON and connector SmartON_Installation and Use Manual_V1 04_GB doc Page 8 of 16 ALFA PROGETTI S r l Spilamberto MO Tel 39 059 785 726 Fax 39 059 785 737 www alfaprogetti com 3 2 Wiring Connector side Cut the battery negative cable so as to have Smart ON in the previously fixed position Insert the conical
10. fairleads into the 2 cut cable crop ends and insert the wire terminals Wire terminals have to be put between the plastics case and the shunt in the same position as they were originally Screw the cable with the terminal to the shunt PLEASE NOTE CONNECT THE BATTERY SIDE END TO THE SHUNT NEGATIVE SIDE shown by the adhesive Stick the protection adhesive on its seat on the bottom of Smart ON Close the cover of Smart ON after placing the cable fairleads and the red wire in the right position Fasten the cover with screws Equip the terminal of the red cable coming out of Smart ON with a wire terminal not on issue or any other system suitable for making a connection to the battery positive pole Only Smart ON cut the Forks Lock control cable coming out of Smart ON at a length which allows to reach battery connector Insert the auxiliary contact pins not on issue into the wires ends Battery side Wirings The auxiliary contacts on liftruck side shall be wired to interrupt the forks circuit or any other circuit which limits the functions of the forklift truck Note Smart ON delivers a clean closed contact if the function is enabled an open contact in the case of lock SmartON_Installation and Use Manual_V1 04_GB doc Page 9 of 16 ALFA PROGETTI S r l Spilamberto MO Tel 39 059 785 726 Fax 39 059 785 737 www alfaprogetti com 3 3 Final Steps Connect the previously removed pin to the b
11. harge Self discharged capacity every 24 hours default 1 Ah method Charging mode selection capacity Yes or time No default YES Opportunity charging Selection of scheduled counting of working cycles opportunity charging mode default No Self Alignment Ah Access button to set the Self alignment parameters Recharging Incr Percentage of energy dissipated during charging stage default 7 Voltage Threshold 2nd Stage Gas production voltage threshold Determines the transition from the first to the second charging stage and related counts default 2 40 V el 2nd Stage Charging time Safety timer Ist Stage Time after exceeding the Voltage Threshold 2nd Stage to end the charge for timed recharges and in the alignment cycle default 2 00 hours If the voltage has not reached the Voltage Threshold 2nd Stage within this time period an alarm is generated default 10 00 hours Safety timer 2nd Stage If the capacity has not reached the nominal value within this time period starting from the achievement of the Voltage Threshold 2nd Stage an alarm is generated default 6 00 hours The Self alignment function automatically corrects the indication representing the charge available in the battery Ah The configurable parameters indicate the threshold beyond which the correction is performed the maximum possible alignment and the number of samples on which the Self Alignment is based The Se
12. lf Alignment is allowed only if the alignment has already been done see 5 Alignment Default parameters Alignment Threshold 10 Max Alignment 10 Num Of Samples 8 SmartON_Installation and Use Manual_V1 04_GB doc Page 12 of 16 ALFA PROGETTI S r l Spilamberto MO Tel 39 059 785 726 Fax 39 059 785 737 www alfaprogetti com lol Self Alignment Programming Alignment Thresh Ah Nom Max Alignment 10 Ah Nom Num of Samples 8 Y OK X Cancel Press the button Send data to SmartIC for the changes to take effect for greater security check the operation by pressing the button Read data from SmartIC and verify that the parameters read are those entered NOTE The work parameters can also be set in advance before installing the device on the battery SmartON_Installation and Use Manual_V1 04_GB doc Page 13 of 16 ALFA PROGETTI S r l Spilamberto MO Tel 39 059 785 726 Fax 39 059 785 737 www alfaprogetti com 4 4 Programming of associations Associations are memory parameters which working cycles and diagrams collected by Smart ON during normal operation refer to Every time cycles and diagrams will be downloaded onto a PC they will be identifiable and selectable thanks to the above mentioned parameters Therefore these parameters too need to be compiled very carefully NOTE filling in the association parameters is not binding If you do it
13. new cycle is generated only if there is a discharge after the sum of cycle charge times has already exceeded the time 2 6 Lock functions SmartON only The Smart ON PLUS device foresees two functions based on measurement of the battery capacity level to inhibit the operation of the forklift and or lock the forks through the NO contact Normally Open of a relay These functions require that the relay contact is wired to a circuit of the forklift which can limit the functionalities for example the circuit that stops operation when the operator is not seated Anti opportunity Charging After being charged if the percentage of Ah in the battery is higher than that which is programmed in Anti Opportunity Charging see 4 3 Programming of operating parameters the forklift is enabled for normal use the NO contact is closed Conversely if the battery capacity drops below the programmed percentage use is prevented the NO contact remains open Setting the parameter to 0 as a default the function is disabled Forks Lock When discharging until the battery level drops below the 100 Forks Lock normal operation is permitted the NO contact is closed In contrast when the capacity drops below this threshold normal use is prevented the NO contact is left open NOTE To avoid disrupting manoeuvres during a period of intensive use the lock is executed 30 seconds after the last manoeuvre The default value of the programmable p
14. ng the normal operation Therefore they have to be compiled very carefully For more details please see the user manual of the SmartViewlIl program zix Monitor Info Old Data OLD Data Info Diagram Daily Programming Associations Averages Statistics Nominal Parameters Other Parameters Battery Voltage 48 al Volts ya Battery Ah 600 al Ah r Diagram Sampling Time 6 lt min y Battery charger current 100 3 A SHUNT Current 160 x A Working Current Threshold 10 q A Discharge Anti opportunity charging 0 Y 0 0ff Charge Forks Lock Forklift Lock Al 0 0ff Ah method Under Disch 1 70 Vice 30 y min 0 Off C No Batt discharged Thresh AhBS 80 4 9 Opportunity charging Yes No Self discharge oo 0 01 Self Alignment Ah Sampling Time V Min Max 360 sec Recharging Incr pP Voltage Threshold 2ndStage 240 y Vice 2nd Stage Charging time jzo0 hh mm Safety Timer 1st Stage fo 00 2 hh mm Safety Timer 2nd Stage 6 00 hhimm 69 Send data to SmartIC a Read data from SmartlC Set clock ow Default 5 xose SmartViewll programming of the operating parameters Select the Programming TAB Fill in the following fields The AP160UIR device needs to be previously installed through a driver for Windows The process transfers date and time on PC to Smart ON check that the PC dater is correctly set SmartON_In
15. ormation about anomalies found in the cycle Anomalies Description Safety Timer Ist Stage While charging the battery voltage did not reach the Voltage Threshold 2nd Stage by the Safety Timer Ist Stage see 4 3 Programming of operating parameters Safety Timer 2nd Stage While charging during the 2nd Stage the battery charge did not reach the nominal capacity by the Voltage Threshold 2nd Stage see 4 3 Programming of operating parameters Battery Discharged Under AhBS While discharging the battery capacity dropped below the Battery discharged threshold AhBS see 4 3 Programming of operating parameters Low Battery Efficiency The battery has been in an underdischarging state for a time gt Under Discharge time when the remaining battery capacity is gt Battery Ah Battery discharged threshold AhBS see 4 3 Programming of operating parameters EEPROM RTC Failure A failure in the memory of the SmartIC device or RTC was detected 2 3 LED Signals Led 5 Led 4 Led 3 Led 2 Led 1 The five LEDs on the unit provide useful information including an indication of the battery charge LEDs can signal the following situations LED 1 flashing Battery charge not exceeding 100 AhBS of the nominal battery capacity LED 1 ON Battery charge over 100 AhBS and below 40 of the battery capacity LED 1 and 2 ON Battery charge over 40 and below 60 of
16. ph data 4 800 samples equal to 20 days with sampling every 6 minutes Storable daily data The unit stores the work data of the previous 30 days FIELD OF OPERATION Current cut off switch 40A batteries up to 170Ah Current cut off switch 80A batteries from 180Ah to 345Ah Current cut off switch 160A batteries from 350Ah to 740Ah Current cut off switch 320A batteries from 745 to 1300Ah Voltage cut off switch L batteries 24 48V Voltage cut off switch H ELECTRICAL PHYSICAL SPECIFICATIONS batteries 50 96V Power supply min max Size L 18V 72V Size H 36V 144V Average power consumption S ON 0 5W S ON 0 8W Protection from internal breakdown Fuse on the power input Contact Relay SmartON only 1A Y 30Vdc Vmax 50Vdc Vac Protection from external causes Electronic components protected by H2SO4 resistant resin Operating temperature SmartON_Installation and Use Manual_V1 04_GB doc 20 C to 50 C Page 16 of 16
17. ply all the data it must acquire the real state of the battery This is called ALIGNMENT and must be performed only once after connecting the device to the battery During normal operation the SmartON device stays aligned by measuring and counting the inbound and outbound charge of the battery The alignment procedure involves the execution of a traditional full charge that is The battery voltage reaches the value indicated in the configured Voltage Threshold 2nd Stage parameter default 2 4V el The charge continues after reaching this voltage for a period not shorter than that established with the configured 2nd Stage Charging Time parameter default 2 hours After the alignment procedure all LEDs are lit in the Battery mimic panel indicating that the battery is fully charged It is recommended that the alignment procedure be run with the battery not fully charged IMPORTANT Normally the alignment is very easy to execute It is enough to recharge the battery with a conventional battery charger Nonetheless it is not always possible to recharge a battery in the aforementioned conditions This may be due to various reasons including The battery is already charged and the battery charger performs a charge that is too short The battery voltage does not reach the Voltage Threshold 2nd Stage configured this happens for instance for gel battery chargers The battery charger has a particular kind of charging curve In these
18. se it is intended as energy recovery and the input charge will be added to the Recovered Capacity During the discharge stage the Discharged Capacity is counted In addition two situations which may arise in case of excessive discharge are highlighted the Underdischarge Time which indicates the time when the voltage is below the Underdischarge Voltage configured see 4 3 Programming of operating parameters and the Discharged Capacity Under AhBS indicates the capacity used below the threshold of 100 AhBS of the nominal battery capacity During the discharge stage the Self discharged Capacity and the Recovered Capacity are also counted Within the charging stage there is a First Stage the charge before reaching the configured Voltage Threshold 2nd Stage the Second Stage the charge following the attainment of the Voltage Threshold 2nd Stage and the Capacity in Overcharging corresponding to any charge in excess over the hypothetical attainment of 109 of the nominal capacity Only in the case of controlled Chargers SmartEnergy is the Equalization count displayed For a detailed list of the information provided by SmartViewI Info TAB and OLD Data Info TAB see the relevant manual SmartON_Installation and Use Manual_V1 04_GB doc Page 4 of 16 ALFA PROGETTI S r l Spilamberto MO Tel 39 059 785 726 Fax 39 059 785 737 www alfaprogetti com 2 2 Anomalies The SmartViewlIl program provides inf
19. stallation and Use Manual_V1 04_GB doc Page 11 of 16 ALFA PROGETTI S r l Spilamberto MO Tel 39 059 785 726 Fax 39 059 785 737 www alfaprogetti com Battery Voltage Nominal voltage of the battery Battery Ah Nominal capacity of the battery Battery charger current Nominal current of the battery charger Shunt Current Nominal value of the Shunt Diagram sampling time Voltage and current log sampling times for graphs 1 127 min 1 127 sec default 6 min NOTE If expressed in seconds the duration of cycles will be one hour at most Working current threshold by contract See manual SmartViewll default 10A Anti opportunity charging SmartON only Forks lock setting for anti opportunity charging See 2 6 Lock functions SmartON only Forks Lock SmartON only Forks lock setting for low battery charge See 2 6 Lock functions SmartON only Forklift Lock SmartON only Forklift Lock schedule setup button See 2 6 Lock functions SmartON only Under Discharge If the voltage is below the specified value V el for the specified time minutes the capacity is forced to 100 AhBS of the nominal capacity Ah Battery if greater than said value default 1 70 V el 30 minutes Battery discharged threshold AhBS Discharging below 100 AhBS of the nominal capacity the battery is considered discharged default 80 Self disc
20. the battery capacity LEDs 1 3 ON Battery charge over 60 and below 80 of the battery capacity LEDs 1 4 ON Battery charge over 80 and below 95 of the battery capacity LEDs 1 5 ON Battery capacity over 95 of the battery capacity Periodic shut OFF of the LEDs from top Discharge Stage down sequence from LED 5 to LED 1 Periodic turning ON of the LEDs from Charging Stage bottom up sequence from LED 1 to LED 5 LED 3 Flashing Forks Lock due to the Anti opportunity charging activated see 2 6 Lock functions SmartON only LED 4 Flashing Forklift Lock activated due to scheduling see 2 6 Lock functions SmartON only LED 5 Flashing Forks Lock activated due to low battery charge see 2 6 Lock functions SmartON only SmartON_Installation and Use Manual_V1 04_GB doc Page 5 of 16 ALFA PROGETTI S r l Spilamberto MO Tel 39 059 785 726 Fax 39 059 785 737 www alfaprogetti com NOTE AhBS is a programmable parameter through SmartView If the value assigned is lower than 60 the signalled events will differ from those reported in the table with regard to the first LED from the bottom that will flash with battery charge below 100 AhBS 2 4 Estimation of the recharge Thanks to the features described above SmartON is able to accurately estimate the charge in the battery There are two different ways to determine the attainment of a full charge The first
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