Battery Manager 3EL Printable User Manual
Contents
1. by the BatMan looks like this 007 29 054 7A 24 06V 006 84AH 007 29 054 7A 24 06V 006 84AH 007 29 054 7A 24 06V 006 84ABH 007 30 054 7A 24 06V 006 85ABH 007 30 054 7A 24 06V 006 85AH 007 30 054 7A 24 06V 006 85AB 007 30 054 7A 24 06V 006 86AH 007 31 055 5A 24 14V 006 86AH 00022 024 92 007 31 054 7A 24 06V 006 87ABH 007 31 054 7A 24 06V 006 87AH 007 31 054 7A 24 06V 006 87ABH 007 32 054 7A 24 06V 006 88AB 007 32 054 7A 24 06V 006 88AH 007 32 054 7A 24 06V 006 88AH 007 32 054 7A 24 06V 006 89ABH 007 33 054 7A 24 06V 006 89AH The data is pretty self explanatory the first column is the Race Time followed by the Battery Current with negative discharging the battery Then comes battery voltage and amp hours used You will notice that time changes every fourth sample This is because the BatMan updates four times a second There is one line longer than the others and this extra data is the lap number and lap time when there is a Lap Beacon Receiver and Transmitter present This line indicates lap 22 with a lap time of 24 92 seconds The data presented here was recorded using the standard Windows program HyperTerminal 13 4 21 2005 BSDesigns Battery Manager 3EL Trouble Shooting If your meter Possible Problem Remedy Always Reads about 450A The shunt may be on the positive side of the battery Move shunt to negative side of battery The white wire2. if you have used too much Drain Mode This mode is intended to help you determine what the capacity of your batteries are before race day It can be used with or without the optional 50A load and Load Switch When used with the Load Switch it will turn on the load when you are ready and turn it off again when the battery voltage has gotten down to your selected Target Voltage The test goes through four states e Target Voltage e Ready e Drain e Done The Target Voltage can be adjusted by turning the knob and when your preffered voltage is displayed pushing the knob will step to Ready state Ready state will display the voltage of the battery along with the test duration which will be 000 00 and ask you to Push to Start Once the knob has been pressed the Battery Manager will turn on the Load Switch and proceed to Drain state The Drain state displays the same four values in Page 0 of Race Mode I E Battery Current Battery Voltage Amp Hours since start Time since start When the voltage of the battery under test gets down to the selected target voltage the Battery Manager will turn off the load and step to the Done state where it will display Done Battery Voltage Final Amp Hours used 10 4 21 2005 BSDesigns Battery Manager 3EL Final Test Duration Pressing the knob again brings you back to the Target Voltage screen so you can charge your battery and play again You can exit Drain Mode
3. is not connected Connect the white wire to the side of the shunt toward the battery Reads OA at 0A but stops at about 40A The shunt sense wires are reversed Swap the two sense wires on the small shunt Screws Always reads about 35A The green wire is not connected Connect the green wire to the side of the shunt with the black wire If your unit fails for any reason send it to Bruce Sherry Designs Repair 15621 N E 164 Street Woodinville WA 98072 We will repair it and send it back the same way it comes to us Fed Ex UPS or US Mail Please understand the Battery Manager 3EL is intended for racing and if it is damaged there will be a repair charge If it can reasonably blamed on faulty materials or workmanship there will be no charges Controls There is one knob which can be turned or pushed Display contrast full dark is all the way clockwise When the unit is very warm as on a hot summer day you may need to turn the contrast control counter clockwise a bit to be able to read the display 14 4 21 2005 BSDesigns Battery Manager 3EL Specifications Dimensions 3 26 High by 5 63 Wide x 0 91 Thick not including the knob The display characters are 4 84mm 0 2 wide by 9 66mm 0 38 high Current 450A discharge to 45A charge Voltage 10 to 45V Clock starts after 25A or more are drawn from the battery Accurate to within about 5 seconds
4. monitor This wire goes to the 3 8 9 16 headed bolt of the shunt that the negative side of the controller connects to The green wire is the controller side current sense wire and goes to the same side of the shunt as the black wire but to the little screw terminal instead The white wire is the battery side current sense wire and goes to the other little screw terminal on the shunt The 3 8 bolt on the same side as the white wire should go to the negative side of the battery with no other connections on the battery on the shunt or the little screw terminal Finally the red wire goes to the positive side of the battery The green and white wire connections are very sensitive as 10 MicroVolts there equals one tenth of an Amp of current PLEASE make no other connections to their screw terminals Once the connections have been made you are ready to go You can use the BatMan to test your batteries on the bench before you go racing so you know what to expect If you are testing your batteries the clock will start counting within a second or two of applying a 50 Amp load Then you can record what values you get every 2 to 5 minutes as you drain each battery Your batteries should be at the temperature they will be at during a race 120 degrees F is a good starting temperature You should check each battery individually so you can pick a pair of fairly evenly matched ones to race with You should expect 40 to 45 Amp Hours capacity fr
5. per hour The Battery Manager EL gives you the information you need to get the most out of the batteries in your electric race car Let s go racing Right after you fill out and mail in your registration card Bruce Sherry Bruce Sherry Designs 15621 N E 164 Street Woodinville WA 98072 8176 206 909 3409 bruce brucesherrydesigns com www brucesherrydesigns com 15 4 21 2005
6. BSDesigns Battery Manager 3EL Battery Manager 3EL User Manual Bruce Sherry Designs 15621 N E 164 Street Woodinville WA 98072 8176 1 4 21 2005 BSDesigns Battery Manager 3EL Table of Contents Battery Manager 3 i Push to Select Dark Hold for Mode PURPOSE cscsscssssssscsssrssssssssssscsssessscsssessscsssessecsesessesseseseens 3 INSTALLATION ccscssssscsssscsescssscsssssesesssessssssessssnerseses 4 OPERATION sccccsssccsssccescsscscrsscncsscsssssesesssescssenessseneeseses 8 RACE Mode o cetus nid ote 8 Drain Mode vu cte e Eu 10 Senine s mode sea er REPE ERE R 11 Amp Hours SChedule ua teet 11 Target Voltage ote ett rents 12 Save MOC 12 DATA COMMUNICATIONS scsscssessssssssesessesseeseees 13 TROUBLE SHOOTING eere cesses eese entes assii 14 SPECIFICATIONS eeeeeee sees ense teens tastes enses enata tn 15 2 4 21 2005 BSDesigns Battery Manager 3EL Purpose The purpose of this document is to describe the intended use of the Bruce Sherry Designs Battery Manager 3 Electrathon Version The Battery Manager 3EL is a battery monitoring and measuring instrument It s intended use is to measure the performance of batteries used in electric racing applications and to provide a few other useful numbers to the racers It mainly measures and displays four quantities Battery current 450 to 45A Battery Voltage 10 to 45V Amp Hour
7. by pressing the knob for more than 4 seconds If you would like a different default Target Voltage you can change what the default is in Settings Mode If you haven t obtained you Drain Switch as yet you can still use drain mode to test your batteries but you will have to manually connect your load after starting the test and disconnect it after the Battery Manager changes to Done state Settings mode This mode allows you to adjust the default Amp Hours Schedule for Race Mode and Target Voltage for the Drain Mode Changing these values will be effective while the unit remains powered unless they are saved to EEPROM with Save Mode Once they have been saved they will be used every time until changed and saved again Amp Hours Schedule The Amp Hours Schedule is how many Amp Hours you want to use during the course of the one hour Electrathon race The Battery Manager 3 updates an internal value based on this every 1 4 second and subtracts the actual amp hours used from this internal value and displays the difference in Page 1 of Race Mode The resulting value will be positive if you can use more power than you have been and negative if you have used too much In Settings Mode you can adjust what you expect to be able to get out of your batteries during the race This value can be saved to EEPROM in the Save Mode 11 4 21 2005 BSDesigns Battery Manager 3EL Target Voltage The Target Voltage is the voltage to sto
8. der and actually use your brakes rather than coasting In trying to estimate how many Amp Hours you might expect to use during a race remember that the higher currents you draw the fewer Amp Hours you can expect to get This means that on a nearly constant speed course like a big oval or a velodrome you can expect to get more from your batteries than on a road course with slow corners and a lot of braking 7 4 21 2005 BSDesigns Battery Manager 3EL Operation Mode selection is performed by pressing the knob for more than four 4 seconds which will bring up the mode select menu Once your selection has been made by turning the knob you chose your mode by pressing the knob for more than 4 second but less than 4 seconds This also has the added feature of resetting any accumulated values like time or Amp Hours Race Mode This mode is intended for use in the race car on race day It has two different screens which are exchanged by pushing the knob for more than 4 second Page zero is the old familiar page like the previous versions of Battery Managers and Page 1 has new information Page 0 This page displays four things Battery Current Battery Voltage Amp Hours since start Time since start Amp Hours and Time start automatically when current exceeds 25 Amps If the time starts counting in error it can be reset by pushing the knob for 5 8 4 21 2005 BSDesigns Battery Manager 3EL seconds to get to
9. om a good set of race batteries During practice you can read the current to see if you have a chance of using the battery properly during the race and maybe adjust you gearing or driving style to end up with just dying batteries as the checkered flag falls If you think you can get 40AH from your race batteries you should be averaging about 40Amps over the course of a whole lap When the unit is powered up it should display it s software revision and serial number for two seconds then start measuring the current and voltage of the battery pack While waiting for the race to start press the Clear button for more than four seconds and the the Amp Hours and clock will 6 4 21 2005 BSDesigns Battery Manager 3EL clear to zero when you let go When the race starts the clock should start in the first second due to the high currents used to get the car going all it takes is more than 25 Amps to start it off Then as the race progresses check your Amp Hours at points you might be able to figure in your head like every 15 minutes If you expect to use 40AH during the race you should have used 10 of them in the first 15 minutes 20 in the first half hour and so on If you are using too much slow down a bit or maybe speed up if you are not using enough If you are using too much you might let off the throttle a little earlier and coast farther into the corners If you aren t using enough you might dive into the corners a bit har
10. p the drain test at This menu along with Save Mode will allow you to adust this value for a series of tests Save mode This mode is used to save four values to EEPROM so they will persist over power cycles The four values are Race mode Amp Hours Schedule Drain Test Target Voltage Contrast Default Mode The first two have already been described the contrast and default mode have not Most screens which are not adjusting values or selecting modes can be used to adjust the contrast This contrast value can be saved to EEPROM so that next time the unit powers up that contrast value will be used The default mode is the mode Race or Drain that was in use before mode selection was entered If you want the BM3 to come up in Drain Mode each time it powers up start from Drain Mode select Save Mode and push the knob Changing back can be accomplished by starting from Race Mode and following the same procedure 12 4 21 2005 BSDesigns Battery Manager 3EL Data Communications The Battery Manager 3EL comes with RS 232 outputs and includes a six foot straight through RJ 11 phone cord and an RJ 11 to DB 9F connector Connection from the BatMan to your computer is simple Your computer should have a DB 9M connector on the back somewhere or you will need a USB to RS 232 adapter All you need to do is to plug in the DB 9F from the Batman into your RS 232 DB 9M connector and you should be ready to go The data transmitted
11. s used Time since 100A or greater has been drawn usually the first second of a race Boc It also can display where the battery is compared to a preset schedule for amp hour use in relation to the one hour race In addition with optional accessories it can receive signals from a Lap Beacon to give the driver lap times counts and beacon crossing times during the race and be used to control a battery load switch for testing batteries It has an RS 232 output for logging purposes 3 4 21 2005 BSDesigns Battery Manager 3EL Installation BatMan 3EL H H Od 4 4 21 2005 BSDesigns Battery Manager 3EL The shunt goes on the negative side of the battery Red Battery Positive This wire connects to the positive side of the battery usually before the disconnect and fuse Black Meter Negative This wire has the 3 8 lug to go on the big bolt where youhook up the negative lead to your controller Green Meter Load side sense This wire goes to the little screw terminal on the same side of the shunt as the black wire White Meter battery negative This wire goes on the other little screw terminal on the shunt The 3 8 bolt goes to the NEGATIVE side of the battery Make no other connections to these two points 5 4 21 2005 BSDesigns Battery Manager 3EL It is connected to the battery to monitor with four wires and a 500A 50mV shunt The black wire with the 3 8 ring lug is the negative return for the
12. the mode select menu and pushing it again to get back to Race Mode Page 1 This page displays Lap Count Lap Time Battery usage versus Schedule zx acon crossing ti M S BSDesigns Hold for Mode BSD RS 232 Not Isolated j Push to Select Dark gt If you have the optional Lap Beacon Receiver connected and there is a Lap Beacon Transmitter near the Start Finish that can be seen by the receiver each time the car passes the transmitter it will increment the lap count compute the lap time and display those along with the race time the beacon was crossed The first two lap values are self explanatory with the exception that the lap count may increment right at the start if the transmitter is very near the start finish line The crossing time is useful in the case of having a set schedule that you might be wanting to maintain during the course of the race A prime example would be at Portland Oregon and having a 25 lap schedule taped to the dash when is search of race records The Amp Hours Schedule is how many Amp Hours you want to use during the course of the one hour Electrathon race The Battery Manager 3 updates an 9 4 21 2005 BSDesigns Battery Manager 3EL internal value based on this every 1 4 second and subtracts the actual amp hours used from this internal value and displays the difference here The resulting value will be positive if you can use more power than you have been and negative
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