Float Current Monitor Manual
Contents
1. 4 1 At the end of the string 4 2 Between two cells within a string Figure 3 Connecting the Core to the Battery Monitor SE Polytronics Engineering Ltd 2 1 1 Installing as Ground Fault Detector If the Float Current Monitor is being used as a ground fault detector it is installed such that the core goes through both the positive and negative leads of the charger as shown in Figure 5 Connecting the Battery Terminal to the FactStar on page 10 Ol E Sede T 1 2 TEMP idw Figure 4 Connected for Ground Fault Detection 2 2 Segment voltages Float Current Monitor monitors can measure up to four battery segments Install ring terminals with male fast on connectors to five battery posts can be either positive or negative Before connecting the segment sensing wire you need to install the appropriate voltage divider resistors see Figure 5 The resistors do not come with the FactStar but can be purchased from Polytronics b Battery to Factstar gt G l 5 dam a en ET N Voltage Divider Wire Connector IIl Ring Terminal Fast On Connector Resistor Connect to battery female i i i Sensing Wire Wire Connect2. 1 Enter 99 in the Last Device ID field in Figure 11 2 Check the Multiple Devices field in the top left corner of the main screen 3 Enter 31 in the Device ID field in the top right corner of the main screen 4 Click on Connect and then Detect in the main screen If you already know the device IDs on your network 1 Enter the highest ID number in the Last Device ID field in Figure 11 2 Check the Multiple Devices field in the top left corner of the main screen 3 Enter the lowest ID number in the Device ID field in the top right corner of the main screen 4 Click on Connect and then Detect in the main screen Float Current Monitor will scan from the lowest ID to the highest ID and it will only show the devices it finds in the Device ID field After the scan is complete select the device that you want to communicate with from the Device ID field and follow the same procedure outlined in the previous sections 19 a Polytronics Engineering Ltd 3 1 4 Changing Device ID After you detect the device and are able to read the correct serial number you can simply change the device ID by entering the new device ID in the New ID field and click on Update Note that the new device ID should be between 31 and 99 Important Make sure there are no duplicates in ID numbers on the network 3 1 5 Reading Device Upon successfully connection and detection you can now read your FactStar device through you
3. 10 070 10 07 10 07 High Ripple Current vm Ripple Current Slope Lirit Zeen xii p v JW High Ripple Current ius K SE Wa Minimum Discharge 1 000 WR Floating Limit A 1 000 Current s Battery Factory Rated ho Discharge End V 3788 VV JW String Exhausted Capacity 4H string V Current Averaging 37 Memory Cleared A ACE Equalize Voltage low 100 0 arms Sleep Mode mes Figure 12 Float Current Monitor Configuration Window There are four panels in the Configuration screen Limits Data Storage Adjustments and Rel Enabled Alarms which will be explained in the following sections The password to access this is dixie 3 1 9 1 Limits These limits will trigger an appropriate alarm Field Typical Value Comments Explanation Range Open Detection Limit 0 60 Current less than entered value in mA is considered as open state Depends on the Value which is considered as low Voltage Alarm battery at floating state Typically this value is specified Pow TV Hosp by battery manufacturer or if not known then 2 17 V per cell Low Segment V Depends on the Segment voltage below this value will trigger Low 21 V5 SEN SE Polytronics Engineering Ltd float battery and how the battery is segmented segment voltage alarm at floating state Typically if battery segments are equal size the value is LOW TV value divided by number of segments 1 4 Low Segme
4. Eet 20 Setting Time and Dci 20 Configure the DeVIDE ecserin ear E E RE Ra 21 K ypad E 25 First Level E 26 STEIRA DIS o K Daere 26 Alarmi DTS LM Eege 27 Segment delirium EO 28 Temperature Ripple Current Display eret a teer Dot etri ER Sete rabuES 28 System Time Device ID Display essa execute eu edd rg eda in NERA E DH ENRR 28 Second Level Menu Cycle Fable cniogetseetns idt ie uto peaux UE Fo bicidu beni t e Mpt 29 Third Level Menu Used CHDBOIDy iiie ce eege dE 29 Used capacity and event duration display eerta eret n eonun 20 Fourth Level Men Stored Data ii portio r I ctae yp aeo kRL dep YE pu FUP EN E Paca EYE 20 Number of Stored Data and A lenin ga ces rta rrt inire ra FA pent vecuienseedunacenvesies 29 Nuiber OL Stored TE 29 Clear Memory e D 29 Fifth Level Menu C apabiuty ag iert geed deeg ege 30 SERA 30 Sixth Level Menu Calibration Offset ci eo soscassescivenanccatdsaradeataaacaicensens 30 Calibration OffS t sca o RERO tU ex atte uiua Gear a dpt s ante i pa uM CONS cup 30 Inereasel Decrease EE tegen eege dree 30 Seventh Level Menu Device TD sue divegae sn hebr Fut ew 2d eese apa utu Fem inel d uta 30 Inorease Decrease Device ID oet rur rsen Eicpatbis tesa e npa Due breasts p hue 30 Alarmi File Format ee OEE aE ea R 30 Data e E 31 Hn Polytronics Engineering Ltd 3 3 6 1 6 2 6 3 6 4 6 5 Cyc
5. Float Current Monitor and therefore requires an external power supply For RS232 the power comes from the DTR and GND pins of a standard serial connector or a 5 VDC supply optional and are plugged into pins 22 and 23 Refer to Figure 9 RS232 Communication Connection on page 15 for wiring the Float Current Monitor to a RS232 DB 9 Female connector ota DB 9 Female Front View Pin 2 Received Data RX XKXXXEBBBX Pin 3 Transmit Data TX Pin 4 45VDC X Do not use Pin 5 Ground GN DTR TX RX Figure 9 RS232 Communication Connection 2 7 2 RS485 Communication The power for the communication is supplied through pins 22 GN and 26 P as shown in Figure 10 R 485 Communication Connection on page 15 below The voltage should be between 7 VDC and 15 VDC Figure 10 shows the communication terminal block with green connections that represent the connections to RS485 communication link RS 485 rr TD m TD RD RD GN 7 15V Figure 10 RS485 Communication Connection 2 7 3 Fiber Optics to Serial Converter Optional Fiber Optics communication can provide a safer and isolated communication link between the Float Current Monitor and the computer This connection requires you to have a fiber optics model of the Float Current Monitor You also have to optionally purchase a Fiber Optics to Serial Converter You must also have two pieces m
6. Number Of Initial Flt d battery state changes samples Charge Higher value is used for discharge to capture Charge 1 battery initial voltage response to the load Disch 1 Open 1 10 This is the significant delta voltage between Float 1 5 value stored and now which will trigger Sibsifica Detay Flt 3 10 96 recording a new data set Value is in percentage Charge Charge 3 10 46 Disch 1 5 Data Storage interval 3600 86400 Interval in seconds of how often the monitor will record data set if no changes detected Discharge Cycle 7 Interval in minutes of how often the monitor will Recording Period record data during a discharge min Table 3 Data storage 3 1 9 3 Adjustments Field Typical Value Comments Explanation Range Temperature Offset 0 Shifts ambient temperature reading by so many 1 10 degrees as specified String Voltage Range A D Select according to Voltage Ranges and Resistor Values Segment Voltage As given by software There should be no reason to change these values Slopes use String Voltage Range to change it Ripple Current Slopes 0 28 Does not change Floating Limit A 1 0 The point at which the state of the Float Current Monitor changes from Floating Battery Factory Rated Capacity Factory rating from battery spec sheet Value in AH recommended at 10A discharge rate if given in the battery spec This value is used by the FS firmware to calculate High Floating current alarm threshold an
7. default EFCM is configured to obtain its IP address from a DHCP server on the Local Area Network LAN it is connected to Practically all routers available on the marked are equipped with DHCP server While configuring your LAN for the first time please ensure your router DHCP server is enabled If changes to you EFCM network settings are required please refer to Section 6 5 Gaining Access to Ethernet enabled Float Current Monitor on page 34 for details EFCM can be used as a stand alone device connected directly to a PC In such a case it must be assigned a static IP address and the PC networking must be set up in a compatible manner i e to the same subnet Appendix 1 Changing network settings on Windows XP on page 37 gives an example on how to do it 6 5 Gaining Access to Ethernet enabled Float Current Monitor on a LAN via Web Browser EFCM can be operated on and or configured on its own web page by opening a web browser and typing in its IP address Dynamically assigned EFCM IP address can be easily identified by Finder exe utility executed on any PC on the LAN EFCM is connected to Finder exe is a stand alone executable that does not require Windows installation It can be downloaded from Polytronics Engineering Ltd web site at URL http www polytronicseng com support in Downloads section under link ME Finder Utility 34 SKI Polytronics Engineering Ltd To use it execute Finder exe All operational EFCMs on the LAN
8. reading respectively Save the adjustment by pushing ON CLR button S Log File Format 5 1 Alarm File Format The name convention for the alarm file is as following Alarm mmddyy a csv where mm month dd date yy year a can be from a to z assigns a new letter for duplicate data The format of the file is shown below in Table 9 Alarm Log Sample on page 31 Alarm Type numbers correspond to the following alarm ID and value Alarm Type Alarm Name ID Value 1 High Temperature 0 Temperature 0 1 deg C resolution 2 Thermal Runaway 0 Current 1 mA resolution 3 String Open 0 Current 1 mA resolution 4 Hi Ripple Current 0 Ripple Current 0 1 A resolution 5 Voltage High Segment Segment Voltage 6 String Exhausted 0 Total Voltage 7 Voltage Low Segment Segment Voltage 8 Pilot Temperature High 0 Temperature 0 1 deg C resolution 30 SE Polytronics Engineering Ltd 9 Discharge 0 Current 1 mA resolution 10 Reserved 11 Reserved 12 Ground Fault 0 Current 1 mA resolution 13 Alarms Silenced 0 0 14 Memory Cleared 0 1 data 2 alarms 4 cycles Table 8 Alarm Explination Time Alarm Type ID Value 1 66006 28 0 1 2 66253 8 0 19257 Table 9 Alarm Log Sample 5 2 Data File Format The name convention for the data file is as following Data mmddyy a csv where mm month dd date yy year a can be from a to z assigns
9. should be detected and listed in a window as shown below 57 Finder Sample To gain access to an EFCM via Ethernet do the following 1 Type in the Float Current Monitor s IP address into the address field of your browser You will be asked to log in Type in your user ID and password float and current respectively Authentication Required amp Figure 22 Log in window 2 Quick Summary page will be displayed 35 a Polytronics Engineering Ltd Hn Polytronics Float Current Monitor Engineering Summary History Log Maintenance About Quick Summary Segment Voltages Help i 2 3 4 Seg 1 41 13 V DC Seg 2 40 09 v DC Seg 3 40 09 v DC Seg 4 41 11 VDC Details Status Charge Current 4 2144 AC Ripple G OA Temperature 17 8 deg C Total Voltage 164 42 V Copyright 2008 2010 Polytronics Engineering Inc All rights reserved Figure 23 Quick summary page Ripple Voltages Seg 1 Seg 2 Seg 3 Seg 4 Alarms None 3 Select Maintenance link on the left side of the page and then Network one at the bottom The network setting panel will be shown Hn Polytronics Float Current Monitor Engineering Summary Maintenance History Log Maintenance About bAdiustments o Help bData Storage bLimits amp Alarms gt Settinas Network C Obtain an IP address automatically Use the following IP address IP vd Address i92168 0 77 Subnet Mask 25
10. 5 255 255 0 Default Gateway i92 166 0 254 Primary DNS ann Secondary DNS poo0 Apply Reboot gt Upload Firmware Copyright amp 2008 2010 Polytronics Engineering Inc All rights reserved Figure 24 Network maintenance page 4 Change network setting as required click the Apply button and then Reboot 36 SE Polytronics Engineering Ltd Appendix 1 Changing network settings on Windows XP 1 Open up Windows Explorer and navigate to My Computer gt Control Panel gt Network Connections gt Local Area Connection refer to Figure 25 Computer Network Connection on page 37 flit Network Connections E 2 0 x File Edit View Favorites Tools Advanced Help ay de r d JO Search 17 Folders b gt e x id GZ Address e Network Connections DI Go Folders x 3 Ga Data E a ug DVD RAM Drive F e Control Panel 09 Administrative Tools Fonts e Network Connections Printers and Faxes ES Scanners and Cameras EJ Scheduled Tasks Shared Documents Realtek RTL8168 8111 PCI E Gigabit Ethernet NIC A Figure 25 Computer Network Connection internet Connection Internet Gateway Connected LAN or High Speed Internet Local 4rea Connection LAN or High Speed Inter Connected Wizard 5 New Connection Wizard Wizard 9 Network Setup Wizard Wizard 2 Right mouse click on Local Area Connec
11. Float Current Monitor FS3 User Manual Version 4 2 1 Copyright Polytronics Engineering Ltd 2009 2013 All Rights Reserved SE Polytronics Engineering Ltd 2 1 2 1 1 22 2 3 2 4 25 2 6 2 7 2 7 1 2 14 2 7 3 2 7 4 3 1 3 1 1 3 1 2 3 1 3 3 1 4 3 1 5 3 1 6 3 1 7 3 1 8 3 1 9 4 1 4 2 4 2 1 4 2 2 4 2 3 4 2 4 4 2 5 4 3 4 4 4 4 1 4 5 4 5 1 4 5 2 4 5 3 4 6 4 6 1 4 7 4 7 1 4 7 2 4 8 4 8 1 5 1 5 2 Table of Contents Installing th e 9 Installing as Ground Fault Detector occid reprehe atom rigen neut Uh rees 10 Segment Volta T eed 10 Tempertat r SEUSOK d 12 Pilot Temperature Sensor OpLBOal usse sauren ra tab n temi sete terea 12 Analog Voltage Output Optional 22 tei natin nen 12 T rning th Unt ON wem 12 Deyi Communicati EE 14 R5232 CommuniCallOtl scien deed SENE E a E REA Roa E 15 RS439 COMI MMIC ALON NT 15 Fiber Optics to Serial Converter Optional eene 15 Ethernet Optional e 16 Installations resien S 17 COMM NG oeste am ede utar a esr EEO ee 17 Communicating Over a Modem Bthernet esee 18 Communicating With Multiple Devices secuestro are eseu 19 Changing Device dp 20 R ading OVC cars 20 Downloading Dat E 20 Clearing Data on Device o retia M ui est i tain tn iR equa
12. a new letter for duplicate data The format of the data log file is shown in Table 10 Data Log Sample on page 31 Explanations of Event Type and Record Type are described below Table 9 Alarm Log Sample on page 31 describes the Pending Alarm by converting the pending alarm to a binary representation and using positions of the ones to correspond to an alarm in Table 8 Alarm Explination on page 31 Event Record Pending Current AC Current Total SEG1 SEG2 SEG3 SEG4 Time sec Type Type Alarm mA 1 10A Tempr V V V V V 323560 4 2 0 53500 251 0 0 0 0 324200 5 2 O 11348 251 0 0 0 0 Table 10 Data Log Sample Time represents number of seconds elapsed since January 1 2000 at 00 00 00 Event type is defined as follows 0 Unknown 1 Open 2 Floating 3 FloatChrg 4 Charge 5 Discharge 6 Equalize device cannot determine the status device fault start up current is less than minimum floating current value string is fully charged and floating current is detected string is not fully charged recharge current is small positive current is flowing into the string negative current is flowing from the string the string is charging to an equalization voltage Record type is defined as follows 31 SE Polytronics Engineering Ltd Start of event Delta current Delta total voltage Delta segment voltage Initial sampling after event change Discharge cycle counter r
13. d Table 7 Float Current Monitor Alarms When an alarm is detected it is logged into the alarm memory with a time stamp Individual alarms can be enabled disabled using the utility software Additionally when an alarm is detected the alarm relay is closed for local alarm enunciation Pressing the CLR button while alarms are displayed will acknowledge the alarm and the relay contact will open The acknowledgment message with a time stamp is logged into the alarm memory Silenced alarm marker is also displayed on the LCD Alarms remain acknowledged silenced until a new alarm condition is detected or the CLR button is pressed again toggles silence function ON OFF 27 SE Polytronics Engineering Ltd Figure 16 Segment Voltages Display 4 2 3 Segment Voltages Segment voltages are displayed in precision of 0 1V if voltage range A is used otherwise the display is limited to precision of 1V 4 2 4 Temperature Ripple Current Display Figure 17 Temperature Ripple Current Display If the temperature sensor is not connected temperature reads 200C If the sensor is shorted the device displays 100C Ripple current is measured with precision of 0 1A rms 4 2 5 System Time Device ID Display Device ID Figure 18 Time Device ID Display Float Current Monitor keeps its internal time in seconds elapsed since 12 AM at the reference date All records are stamped with a count in seconds The display conv
14. d thermal runaway duration Current Averaging 37 Averages the current reading 23 SE Polytronics Engineering Ltd Equalize Voltage As specified by the Segment voltage above which the battery is low battery manufacturer considered being in Equalization state 120 3600 The Float Current Monitor goes into power saving Sleep Mode mode for the duration entered Table 4 Adjustments 3 1 9 4 Rel Enabled Alarms The first column is for enabling the relay for a particular alarm The second column is for displaying the alarm on the Float Current Monitor LCD For example suppose that a buzzer is connected to the Float Current Monitor alarm contacts Then according to Figure 12 Float Current Monitor Configuration Window on page 21 if the temperature is above the limit an alarm notice will be displayed on the Float Current Monitor LCD and the buzzer will be activated To silence acknowledge an alarm press the CLR button when an alarm is displayed for further information see section 4 2 2 Alarm Display on page 27 24 SE Polytronics Engineering Ltd 4 Float Current Monitor LCD and Keypad 4 1 Keypad The Float Current Monitor keypad has 4 buttons under the LCD screen The SEL ALT key will take you from one menu level to another The Reset ft and the Funct keys are used to scroll through the sub menus on the same menu level The ON CLR button is an exit button While in a menu you ca
15. dvanced COM Port Settings WindoW iue eese apre ru up sr nebuS 18 Float Current Monitor Configuration Wimndow eee 2 Neger stirpe edu Ria una 25 Variations of the Status Display eie reiege 26 Variations of the Alarm Display oda oot tue het Ee ie ax SPIRI Eae e imu bean 27 Segment Voltases DIsplady iiuieeoe pi ite E Ert mai aa E ee p rUEd MU pR 28 Temperature Ripple Current Display eene 28 Time De yice ID Display eet Etage Po uas o ipe ER toe eti etu band 28 Cycle Display c es 29 Connecting Ethernet equipped FCM to a network sess 33 Ethernet external power connection seeseeseereerreriserrerrsreseresresressresrensessres 34 Log in WAG OW P E e Re 35 Quick sumidry PARE eeben eege 36 Network maintenance Dae eoe petro Edge 36 Computer Network Connection iiec etie tna e Rode be CECR 37 Local Area Conection Properties osi osadeos cepas etna ponia ie atibus esses Ende panauE 38 Internet Protocol TCP IP Properties eege hee eie Pn cR Re dae ois 39 SE Polytronics Engineering Ltd Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 List of Tables Voltage Ranges and Resistor Values eeeeeeeeneene 11 IEN 22 Dad SOR E 23 Fen CETUS s PTT A snes E 24 Ming DE 27 DD GSC E 27 Float Current Monitor Alarms uk 27 Ala
16. e battery float current High Float Current long battery has to be remains slightly higher for 2 12 hours period Detection Time at floating state before alarm is activated By setting this field accordingly high float current alarm after recharge can be avoided Minimum Discharge Current Value in milliamps If negative current in absolute value exceeds this limit the Float Current Monitor enters into discharge mode Thermal Runaway Detection Time sec 86400 minimum This value sets the time current must be over a limit calculated based on the battery capacity to trigger the associated alarm Ground Fault Limit mA 25 100 The limit at which the associated alarm will trigger Note Entering zero in any of these fields will disable the alarm Table 2 Limits 22 SE Polytronics Engineering Ltd 3 1 9 2 Data Storage Field Typical Value Range Comments Explanation Open 3 5 Current change last saved value and present Float 5 15 96 reading greater than this value in the Significant Current Fit 10 20 corresponding state will force the data being Change Charge recorded This value is adjusted internally Charge 10 20 depending on the current value and current ripple Disch 5 20 Open 0 Defines how many samples are recorded with Float 0 maximum speed approx 0 2 s per sample when
17. ecording Timer elapsed E a a Pending alarm is defined by the following bit values 14 13 12 9 s 7 6 5 4 3 2 1 High temperature Thermal runaway String open High ripple current Voltage high String exhausted Voltage low Pilot temperature high Discharge 12 Ground fault 13 Alarms silenced 14 Memory cleared Q9 uo tRUOM 5 3 Cycle File Format The name convention for the data file is as following Cycle mmddyy a csv where mm month dd date yy year a can be from a to z assigns a new letter for duplicate data The format of the data log file is shown in Table 11 Cycle Log Sample on page 32 Explanations of Event Type and Record Type are described below Type Start Duration AHrs Start End Temperature Time 1 10 Voltage Voltage 1 10 1 Discharge 2068542 57 153 130 120 253 2 Equalization 2069985 2564 155 125 133 254 Table 11 Cycle Log Sample 32 SE Polytronics Engineering Ltd 6 Ethernet enabled Float Current Monitor EFCM 6 1 Summary Ethernet Enabled Float Current Monitor provides Ethernet as en alternative means of communication between FCM and external devices Both BTM mode and RS232 communication are not available on EFCM The following EFCM specific functionality is supported Local Area Network connectivity Network wide user interface via web browser Numeric and graphical current data pres
18. ent duration display shows the time the current event has lasted in minuets if the event is less than 60 minutes and in hours otherwise 4 5 Fourth Level Menu Stored Data 4 5 1 Number of Stored Data and Alarms Shows memory usage of alarms and data records that are be stored 4 5 2 Number of Stored Cycles Shows memory usage of cycle records that are be stored This contains a count of the discharges and equalizations 4 5 3 Clear Memory It is recommended that the memory be cleared using the utility software after downloading data The memory for the alarms and data can be cleared by pushing the Funct l button followed by the ON CLR button 29 SE Polytronics Engineering Ltd 4 6 Fifth Level Menu Capability 4 6 1 BTM Mode To change the BTM mode capability of the Float Current Monitor push the Funct f button followed by the ON CLR button 4 7 Sixth Level Menu Calibration Offset 4 7 1 Calibration Offset This function is only for specialized service personnel 4 7 2 Increase Decrease Offset To change the calibration offset of the Float Current Monitor push the Funct U or Funct fl to decrease or increase the current reading respectively The adjustment is by 10 mA increments Save the adjustment by pushing the ON CLR button 4 8 Seventh Level Menu Device ID 4 8 Increase Decrease Device ID To change the Device ID of a Float Current Monitor push Funct l or Funct f button to decrease or increase the current
19. entation via user interface Historic data download via user interface Network wide Modbus access Device configuration via user interface oe er Warning Even though Device ID is relevant only in BTM mode EFCM must always be configured to ID 31 Please ensure device ID of 31 remains unchanged on EFCMs at all time 6 2 Connecting to Local Area Network Each EFCM is equipped with an RJ45 receptacle located in the back of its enclosure and is identified by a unique number encoded by 12 hex numbers referred to as MAC Media Access Control address The device s MAC address is written on the label positioned just above the RJ45 receptacle To connect an EFCM to a network use Cat5 or above Ethernet cable with an RJ45 plug S 40 82 06 404700 Buasajuo Ajod Jopuop Asayeg A 183524 mess E Figure 20 Connecting Ethernet equipped FCM to a network 33 SE Polytronics Engineering Ltd 6 3 Ethernet Communication Port Power Supply Ethernet communication circuit is isolated from the rest of the EFCM and therefore requires an external 5 VDC power supply The Ethernet external power is to be connected to pins 22 and 23 as shown in Figure 21 below GND 5VDC XXXXEEXXX X Do not use Figure 21 Ethernet external power connection It is not possible to communicate with EFCM via Ethernet without external power as described above 6 4 Ethernet enabled Float Current Monitor Network Configuration By
20. erts the seconds into an appropriate date time string The reference date is stored in the device configuration memory and can be changed using the utility Clock synchronization function If multiple Float Current Monitor installations are required a unique ID number must be assigned to each individual device The recommended that the range for the Float Current Monitor IDs is from 31 to 99 The ID number can be changed using the utility software IMPORTANT Do not perform any configuration functions on multi device installation if there are two or more devices with the same ID number Results in such a case can be unpredictable Always check the installation for ID numbers first 28 SE Polytronics Engineering Ltd 4 3 Second Level Menu Cycle Table Figure 19 Cycle Display Cycle table reports total number of discharge hits and cumulative capacity used AHrs detected for the string The discharges are grouped into 4 categories e Cycles shorter than 30 seconds Cycles shorter than one minute Cycles shorter than five minutes Cycles longer than five minute To clear the cycle display as well as the alarms and data records push the Funct button until the erase memory message is displayed followed by the ON CLR button 4 4 Third Level Menu Used Capacity 4 4 1 Used capacity and event duration display Used capacity display shows the energy in AH taken from battery during discharge and energy restored during charge Ev
21. f the unit See below for connections Warning Do not plug the device in until you have completed all the connections to the battery that is being monitored RS485 5 dH 4 Be AARM AMENT PILOT COIL KR 1 2 TEMP TEMP i o Do E GE ef 27a 27b 12345 67 8 9 10 11 12 1314151617 1819 20 21 22 23 24 25 26 1 Power Supply Input 60VDC ABS MAX 2 Voltage Segment Input 3 Voltage Segment Input DC Power Source in Center 4 Voltage Segment Input Recommended 15V 1000mA 5 Voltage Segment Input 6 Voltage Segment Input 7 Not Used DO NOT CONNECT 18 RS485 Port TD 8 Power Supply Input 60VDC ABS MAX 19 RS485 Port TD 9 Alarm 1 Contact 48VDC 0 5A 20 RS485 Port RD 10 Alarm Common 21 RS485 Port RD 11 Alarm 2 Contact Optional 22 RS485 and RS232 Ground 12 Ambient Temperature Sensor Input 23 RS232 DTR or 5V Supply Optional 13 Ambient Temperature Sensor Input 24 RS232 TX 14 Analog Voltage Output Optional or 25 RS232 RX Pilot Temperature Sensor Input Optional 26 7 15V Communication Supply 15 Analog Voltage Output Optional or 27a Optical OUT Optional Pilot Temperature Sensor Input Optional 27b Optical IN Optional 16 Current Sensing Coil Red 17 Current Sensing Coil Black Figure 1 Float Current Monitor Pin Assignments SE Polytronics Engineering Ltd 2 1 Installing the Core The Float Current Monitor ships with a current sensing core Install the core anyw
22. here in the battery string by opening the battery string and putting the wire that connects to the battery through the core see Figure 2 Extending the core and temperature sensor for more than 6 feet optional on page 9 The core is polarity sensitive so check the label on it to be sure to that it is facing the right direction Once the core is installed its sensing wires should be connected to the terminal as shown in Figure 3 Connecting the Core to the Battery Monitor on page 9 The cable can be extended if necessary up to 30 feet with standard 18 gauge insulated cable as shown in Figure 2 Warning Do not drop break or damage the core Damage can result in incorrect readings When installing the core on the multi post battery do not install the core between posts of the same polarity b Battery to Hoat Curent Monitor ep Wire Connector Sensing Wire to be Wire from Core connected to Float Monito Not included Figure 2 Extending the core and temperature sensor for more than 6 feet optional RS485 Rg3 P SR E E 5 EN P ES 34 E ALARM CUT cob aaga TARRA TI 12 PT ER o ALARM OUT Go del hh T 52 masse OH OH oe H OH 909 oo
23. inimum 12 each of fiber optic cabling 15 SE Polytronics Engineering Ltd First connect the serial cable to your computer and power on the converter through the supplied adapter Once the converter is connected to the computer and powered on connect a piece of fiber optic cable to the output white or blue of the converter into the input black of the Float Current Monitor Then connect the other piece of fiber optic output of the Float Current Monitor white of blue into the input of the converter black 2 7 4 Ethernet Optional For information regarding setup and operation of Ethernet enabled Float Current Monitor please refer to Section 6 Ethernet enabled Float Current Monitor on page 33 16 SE Polytronics Engineering Ltd 3 Float Current Monitor Utility Software Float Current Monitor Utility software is provided for these functions e Downloading stored data and alarm list Clearing memory Changing Float Current Monitor ID number Setting Float Current Monitor clock Configuring Float Current Monitor and adjusting settings The utility software runs on a Windows XP operating system and uses a serial port to communicate with the device A Float Current Monitor device is addressable and has a unique ID number in the range of 31 to 99 Hence multiple Float Current Monitor devices max 30 may be installed on the same RS485 communication network or optic cabling full duplex 9600 Baud 8 data bits 1 stop bit The uti
24. ken from the battery 6 Equalization positive current is flowing into the string String is reaching equalization voltage max floating voltage limit 7 FloatRip the string is floating but the value being read is negative due to ripple on the string Float Current Monitor devices are capable of measuring currents by two modes float current and large current mode The switching point of the modes is around 30A The method change is indicated on the LCD display with character which means it is in large current mode 26 a Polytronics Engineering Ltd 4 2 0 Alarm Display Alarms Acknowledged Silenced Marker Figure 15 Variations of the Alarm Display Table 5 S Table 6 Description tring None No alarm Tempr Lim Temperature outside limits T RunAway Thermal runaway has been detected Str Open String is at open condition no float current detected Hi Ripple Ripple AC current value exceeds pre configured limit High Volt One or more segment voltage values are too high Exhausted String total voltage is equal or less than pre configured end of discharge voltage during discharge Low Volt One or more segment voltage values is lower than pre configured limit Pilt Temp Pilot temperature is high DISCH The batteries are discharging GND Fault A ground fault has been detected ALMR ACK Alarms have been silenced alarm relay contact opens MEM CLR Memory has been cleare
25. le Fil Format E 32 SEENEN 33 Connecting to Local Area INGISVOTE aieo qp d ege 33 Ethernet Communication Port Power Supply eene 34 Ethernet enabled Float Current Monitor Network Configuration 34 Gaining Access to Ethernet enabled Float Current Monitor on a LAN via Web oes oA P 34 SE Polytronics Engineering Ltd Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 List of Figures Float Current Monitor Pin Assignments eeseseeeeeseeseerreressirsresrersererrerersess 8 Extending the core and temperature sensor for more than 6 feet optional 9 Connecting the Core to the Battery Monitor eene 9 Connected for Ground Fault Detection istoc eerte retain 10 Connecting the Battery Terminal to the FactStar esses 10 Four Cell Configuration Setups Total Voltage Measurement or Segment uice onere s 11 Eight Cell Configuration Setup Segment Measurements 11 Bv vdd cs m 14 RS232 Communication Connection uice ient eo oett bts ph rh obse e ede Tun 15 RS485 Communication Connection suono tete rau tae retur qp pee pp MoR eb Nine dics 15 A
26. lity software could also be used remotely using a modem or TCP IP to serial communication module IMPORTANT Itis highly recommended to perform any Float Current Monitor reconfiguration modification of its non volatile memory over a local communication link 3 1 Installation The up to date version of the utility software please download it from URL http www polytronicseng com support and save it in a folder of your choice then double click on the downloaded file icon and follow the on screen instructions to complete the installation process After installing the utility software on your PC the software will have a shortcut on the desktop 3 1 1 Connecting After connecting the Float Current Monitor to the computer open the software utility Select the COM port which you are using on the drop down list If you are connecting through TCP IP select it on the bottom of the drop down list If you are using a modem select the associated radio button and enter the phone number If you have multiple Float Current Monitors check Multiple Devices If you are communicating through a Fiber Optics to serial converter check Fiber Optics Check the Delay checkbox if connecting to the Float Current Monitor doesn t always work Click the Connect button after checking that the Device ID is set correctly If the serial number S N and firmware 17 SE Polytronics Engineering Ltd revision number Rev both show up the c
27. n press this button to return to the default status screen The menu structure for the Float Current Monitor is presented in Figure 13 LCD Menu Structure on page 25 Status Alarms Temperature Segment System Time Total V Ripple Current Voltages Date amp ID Cycle Scroll through Clear Data Alarm Cycle Report 4 cycle categories memory Used Capacity Event Duration Data and Alarm Cycle Memory Usage Clear Data Alarm Cycle Memory Usage memory Capability BTM Mode Increase Decrease Calibration Offset Value Offset Increase Decrease Unit ID ID Value Figure 13 LCD Menu Structure 25 SE Polytronics Engineering Ltd 4 2 First Level Menu 4 2 1 Status Display N High current market Figure 14 Variations of the Status Display Current is displayed in the following format 0 00 9 99 A precision 0 01 A 10 0 25 0 A precision 0 1 A 25 600 A precision 1 A String status can be one of the following 0 Unknown device cannot determine the status device fault start up Open current is less than minimum floating current value 2 Floating string is fully charged and floating current is detected 3 FloatChrg string is not fully charged recharge current is small 4 Charge positive current bigger than threshold value is flowing into the string Energy is being put back in the battery 5 Discharge negative current bigger than threshold value is flowing from the string Energy is being ta
28. nt V Depends on the battery and how the battery is segmented Segment voltage below this value will trigger segment outside limits alarm during discharge Typically if battery segments are equal size the isthaiee value is Discharge End V divided by number of segments 1 4 Depends on the Absolute minimum voltage which is permitted by batter Manufacturer of the battery to be discharged to Disgharge Eno y g Discharge below this Ste may damage battery Typical values are 1 67V cell Depends on the Segment voltage above this value will trigger High Segment V battery and how the Segment Voltage Outside Limit alarm at floating float battery is segmented state Typically if battery segments are equal size the value is High Total V value divided by number of segments 1 4 e Depends on the Total voltage above this value will trigger Total EE SE Voltage GERS Limit alarm at GE state If battery is installed Temperature values above this limit will trigger in air conditioned Temperature Outside Limits Alarm High Tempr Limit C environment typically limit is 28 32C If battery is installed Temperature values above this limit will trigger e in air conditioned Pilot Temperature Outside Limits Alarm E gh Puen Temp environment Pome typically limit is 28 32 C Ripple current values above this limit will trigger SE High Ripple Current Alarm Time period for how Typically right after recharg
29. ommunication with the Float Current Monitor has been established Note If you need to find out the device ID for a particular device you can press on the Funct key on the device itself several times until you get to the screen that displays the reference date time and device ID see section 4 2 First Level Menu 3 1 2 Communicating Over a Modem Ethernet Selecting modem on the main screen automatically enables the text window next to it where you enter the telephone number of the modem you are trying to communicate with You can also change the settings for modem communication by clicking on the Advanced button in the top left corner of the main screen The Advanced COM Settings window will display see Figure 11 Advanced COM Port Settings Window on page 18 Once the communication is established the procedure for reading data is the same as connecting directly to the device Advanced COM Settings EN m Timeouts amp Delays Dial Timeout sec 45 Reply Timeout ms 250 Max receive timeout ms 70 Le Command delay ms 25 Delay between bytes ms Last Device ID 3 E ECE Figure 11 Advanced COM Port Settings Window The functions of each of the fields in Figure 11 are explained below Dial Timeout sec The amount of the time the software waits to connect to the device Reply Timeout ms The maximum time period for reply the utility should wait before issuing an error message Thi
30. or Voltage Divider Est Dot incon a dear Resistor 8 Pin Voltage Divider Figure 5 Connecting the Battery Terminal to the FactStar Depending on the voltage levels of the batteries that are being monitored different resistor values are required Below is a table of resistor values for a specific voltage range Range Total String Voltage Resistor Value Segment Voltage Slope A 60V 1K0 1 Red 4 380 B lt 150 V 415k 1 White 10 07 C lt 450 V 2x IM5 1 Black 40 02 10 SE Polytronics Engineering Ltd D lt 600 V 2x IM5 1 Black 40 02 E lt 1000 V 2 x 2M43 1 Green 60 80 Ranges A and B need only one resistor per connection either at the Float Current Monitor or at the battery post Table 1 Voltage Ranges and Resistor Values If the battery string does not evenly divide into 4 segments try to keep the segments as equal as possible For example a 10 cell string can be divided into 4 segments of 4 2 2 2 cells or 4 segments of 3 3 2 2 cells Either configuration is acceptable Once you have determined the correct resistor to use follow the diagrams in Figure 6 Four Cell Configuration Setups Total Voltage Measurement or Segment Measurements on page 11 and Figure 7 Eight Cell Configuration Setup Segment Measurements on page 1 1to complete the connections Each connection on the battery posts should be done according to Figure 5 Lp ALARU SUT COL e eps E x 12 mu
31. ov gt BERESS CS E LLL Qo ol Git OQ OO D 9 Ol Oleo ole o Figure 6 Four Cell Configuration Setups Total Voltage Measurement or Segment Measurements RS485 RS232 _ a ALARM OUT coL a T 12 Mit ECKER Figure 7 Eight Cell Configuration Setup Segment Measurements 11 SE Polytronics Engineering Ltd 2 3 Temperature Sensor The temperature sensor is built into the core It can also be purchased separately if position of the sensor is critical 2 4 Pilot Temperature Sensor Optional This temperature sensor connects where the analog voltage output is connected This option gives the Float Current Monitor the ability to monitor and alarm ambient and pilot temperatures 2 5 Analog Voltage Output Optional The voltage output is proportional to the measured current within these limits Low current 0 1 50 V equivalent to 0 10A High current 1 55 3 V equivalents to 10 001 600 A 2 6 Tu
32. r computer screen By pressing Read Data you will receive a real time battery monitoring data regarding Current Large Current difference Large Current AC Ripple Temperature Total Voltage and string voltages respectively Select Segment V if you want to see the segment voltages What you are reading on the screen is the same as going on the FactStar and looking off the LCD Reading the device on the computer is a great way to monitor your batteries without stepping into the battery room 3 1 6 Downloading Data Click the Download button you will be given the option to select where you would like to download It is a good idea to note where you download your data so you can easily remember and access these files When downloading data there are two files that are downloaded alarm and data Both types of files are CSV which can be opened with Excel See Log File Format for more detailed information on contents of files 3 1 7 Clearing Data on Device After downloading data it is a good habit to clear the data to allow more memory space on the Float Current Monitor to store and collect more data The Float Current Monitor is capable of holding up to year of average data collection To clear data on the Float Current Monitor click on Clear Memory to delete the alarms data and cycles 3 1 8 Setting Time and Date To set the time and date on the FactStar check Synch on the bottom right corner of the utility
33. rm ExXplinatioN EE 31 Alarm Los Sample nyissa erria ta iaee od EE eae 31 Data Log Sample geet eege Ee Ee 31 Cycle Log Sample T 32 da Polytronics Engineering Ltd SE Polytronics Engineering Ltd 1 General Float Current Monitor also known as FactStar FCM or FS3 is a real time stand alone battery monitoring system which is capable of monitoring float current temperature charge discharge current string voltage and 4 segment voltages The system is also capable of detecting a variety of alarms such as high or low voltages pending thermal run away low capacity in the event of discharge The Float Current Monitor System is composed of one or numerous monitoring devices depending on the system The Float Current Monitoring package includes the following Float Current Monitor device Power Supply Sensing Core current transformer with temperature sensor CD Includes FactStar Utility amp Manual Options Resistive Clips Fuse Clips Power Converter Pilot temperature sensor Built in Ethernet web server Modem SE Polytronics Engineering Ltd 2 Installing the Float Current Monitor Find a suitable place to mount the Float Current Monitor in the battery room Standard units will require a 120V AC outlet nearby If an AC outlet is not close by the Float Current Monitor can be powered off the batteries using a power converter optional The Float Current Monitor may be mounted using the mounting brackets on the back o
34. rning the Unit ON Once you have completed all the relevant connections plug the Float Current Monitor unit into an AC power source using the power supply provided from the batteries being monitored optional or power converter optional 12 a Polytronics Engineering Ltd RS485 PA a dioe epp zB ze a filter ale ai or Connect to 15V DC 1A AC Adapter A Powered from AC adapter a Polytronics Engineering Ltd B OUT COIL TEMP 0 2 5V ii B Powered from measured battery optional The image shows power connection via CUI Inc isolated DC DC converter model VYB10W Q48 S15 T Figure 8 Device Power Configuration 2 7 Device Communication The Float Current Monitor can work alone with information displayed on the LCD For most applications this is sufficient However the full utilization of the Float Current Monitor is only possible where communication between the Monitor and a computer is utilized There are several ways to connect to the Float Current Monitor to the computer e RS485 to serial USB converter RS232 Fiber optics to serial converter optional RS485 to Ethernet converter optional Ethernet optional with or without wireless connectivity 14 SE Polytronics Engineering Ltd 2 7 1 RS232 Communication Serial communication is isolated from the rest of the
35. s value depends on the communication link e Direct link 100 300 ms e Modem link 250 500 ms e TCP IP link 250 900 ms Max Receive Timeout ms This field defines what the maximum time period the software should wait to receive the next data packet when transmission has started This 18 SE Polytronics Engineering Ltd value should be in the range of 1 2 of the reply timeout This field primarily applies to Float Current Monitor data downloading Command Delay ms This field defines the silence period between receiving a reply from the Float Current Monitor and issuing the next command This value depends on the communication link type e Direct link 50 100 ms e Modem link 100 200 ms e TCP IP link 100 500 ms Delay Between Bytes ms This field defines the silence period between command bytes This value depends on the communication link type e Direct link 0 5ms e Modem link 2 7 ms e TCP IP link 2 30 ms Last Device ID This field is the last device ID that a Float Current Monitor can have on the communication link 3 1 5 Communicating With Multiple Devices If you have a network of devices you can communicate with any of them by simply connecting to any device on the network either directly or through a modem The devices on the network must have different device IDs You can only read data or download records from one device at a time If you do not know the device IDs on your network
36. tion and select properties Under the General tab select Internet Protocol TCP IP and click Properties button refer to Figure 26 Local Area Conection Properties on page 38 37 Ha Polytronics Engineering Ltd 4 Local Area Connection Properties ivi A File and Printer Sharing for Microsoft Networks M Network Monitor Driver Internet Protocol TCP IP Uninstall Figure 26 Local Area Conection Properties 3 Change the dialog box such that it looks like the settings shown in Figure 27 Internet Protocol TCP IP Properties on page 39 Then press OK until the dialogs are all closed 38 A Polytronics Engineering Ltd Internet Protocol TCP IP Properties 192 168 0 254 182 168 0 254 Obtain DNS server address automatically fe Figure 27 Internet Protocol TCP IP Properties The Float Current Monitor web page will be accessible once you connect it directly to the computer The computer settings may be reverted back to the original settings after the Float Current Monitor network settings are changed for the network 39
37. window Click Update Clock to update the time of the Float Current Monitor with the time on the computer The offset function allows you to offset the time in one hour intervals For instance if the time on your computer is 5pm and you input an offset of 3 the FactStar time will be 8pm Negative numbers are also permitted in the offset function Note FactStar is not equipped with daylight saving If you are collecting precise data either note the time differential when reading data or set the time again 20 SE Polytronics Engineering Ltd 3 1 9 Configuring the Device x J Device 20110531 Confiquration gt ID 31 LIMITS REL ENABLED ALARMS DATA STORAGE Str Open Detection eo Limit rn amp 60 lv v String Open Open Float Che Chige Disch Thermal Runaway Significant Current po ps Rho fe Detection Time sec 72000 T Thermal Runaway i enge e 0 20 j25 0 Je umber of Inital iem rens p Ground Fault EE io jo jo jo t 7 change High Total V float V 500 d T High Volage Significant delta V SI 25 fio fis 15 15 High S tV wa 150 0 Data storage interval s eo Low TV float V 81 0 M v Low Voltage Discharge Cycle Recording Period min 5 Low Segment V float V 20 0 ADJUSTMENTS Low Segment V RES 30 0 Temperature Offset o E mod t ig 1z High Tempr Limit C 4 v M Temperature High String Voltage Range C C C C idle EMEND V Ed t Segment Voltage Slopes 10 070
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