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1 Tutorial for Using Power Report Processor and Archive System Developed by Linchpin Programming in Partnership with DC Power Technologies 0. The site has been developed by Linchpin Programming in partnership with DC Power Technologies. To request a site, or see more about Linchpin, tap Partnership icon. 1. Browse your device and locate chargelog of interest. It must be in.csv format. The chargelog is retrieved from battery monitor via Bluetooth, a process described elsewher re. 2. Upload chargelog. It will be sent to Report Processorr on web and checked for errors. A clean chargelog gives no warning messages. 3. For batteries that are new to system and to check upload status, click this icon. It creates an upload table describing chargelog and allows a battery to be configured for reporting purposes. 4. Once a battery has been configured, it can be sent to Report Processor through Create Report icon. But first, let s look at Upload Table and associated utilities, revealed with Upload Status icon. 8. Without wishing to get ahead of ourselves, an archive system holds all of recent battery reports, and is accessed through this portal. Obviously we have some explaining to do before we can hit submit button.

2 3.a. The Upload Status icon sends you to this page, which shows aspects of upload and battery configuration. Utilities below Upload Table allow for configuringg a new battery or changing battery identifiers. 3.b. The Table indicates date when chargelogg was taken, total number of days of dataa in log, number of battery states (Charge, Discharge or Idle) ), number of battery cells, amp/hour rating and warranty. 3.c. New batteries to system must be configured before reports are meaningful. This utility allows a technician to input number of cells in battery, amp/hour rating of battery and warranty (in months). Clicking Submit, shows new configuration in upload table so it can be checked for accuracy. 3.d. Each battery has a unique serial number thatt drives all of memory in system. This identifier is module number that names chargelog. But batteries can be given two informal identifiers that allow batteries to be referenced and to be grouped with archive system. Neir is required for system to operate. The first identifier is battery handle. The handle can be a nick name like Hyster-1 are shown on reports for easy reference. The second identifier is a group ID. The group ID allows batteries to be grouped in archive for or Bat-23. These handles comparison and ease of retrieval. The archive can select all batteries in a group and so forth. Group ID can be names like Warehouse East or Cold Storage or a Client name like Ashley Furniture. Submit adds this info to memory.

3 4.a. Once a battery has been configured, you are ready to accesss reporting system through Create Report icon. A set of four reports is produced, starting with Power Report. 4.b. The Power Report describes battery and n shows 35 separate statisticss covering all aspects of battery s performance. A separate tutorial describes exact formulas underlying se statistics, but names of statistics are intendedd to be descriptive. The first statistic is Months of Activity, which is self-explanatory. The second showss ratio of total charge amps put into battery divided by total discharge amps pulled out of battery. It reflects factors like efficiency of charging system and ability of battery to take a charge. Stats 7 and 8 show lifetime EBU and Discharge Amps, whichh feed into Warranty calculations. Stat 10, calculates wher battery is within its warranty process or is being used harder than statutory 1 EBU per day. If battery is being used beyond warranty allowances projected use warranty shows actual warranty projected (e.g. 55 months rar than 60 month warranty under normal use). Stats 13 through 35 focus on latest 30 days of data. Shown are statistics like minimum and average end voltages s, battery temperatures, number of equalize charges per week and so on. Each statistic is designed to help paint a comprehensive picture of how battery is being used and how it is handling loads under which it is operating. The last statistic is Battery Discharge Indicator (BDI), a proprietary indicator of how voltage drops during discharges align with predicted drops from a battery in perfect health. The BDI does a very good job of predicting weak and failing cells along with routine deterioration of battery performance. New batteries willl generate BDI s above 95, while weak batteries will drop into 60 s and below. Batteries below 70 typicallyy perform poorly on traditional load tests, often having one or more dropped cells. BDI s below 50 are a clear sign that a traditional load test will fail. The battery shown here, at 77.1, is probably an old battery that is just barely able to pass a warra anty loadtest.

4 5. Second is Alarm Report. It shows nature and frequency of alarms like low electrolyte and highh temperatures. Notice that this battery has a number of low electrolyte levels (over 30 in past 30 days when you add up combined alarms. This may well be contributing to low BDI. Hey, this battery needs water, man. The monitor itself also needs some attention because Temperature Sensor has failed. We can t trust temperature statistics if sensor isn t working properly. 6. Third is Charge Termination Report. It provides an important summary of state of battery at charge termination. At termination, re is an indication of low electrolyte on this battery, consistent with Alarm Report. But minimumm dv/dt suggests that change in volts during charge isn t behaving as it should with a healthy battery. 7. A graph of daily EBU over past two weeks is also available behind this Daily EBU Graph icon. It shows how evenly EBU load is being spread over week.

5 7.a. This screen shot does not show coloring on graph, which reflects EBU level. The daily EBU are for last 10 periods, each coming close to a single day. States such as idle, that cut across a weekend, can not be separated into exact daily intervals. Thesee are intervals closest to daily moving back from last state recorded. In this examplee last interval started days before end of most-recent state. There were two weekends of approximately two days each, with little or no use. The last panel is a hypotical EBU of 1.75, to show how coloring works. The coloring is not shown here, however.

6 8. The archive system is accessed through submit button on report-processing page. The archive holds all of battery data that have been uploaded through Create Report icon across alll of batteries that are being processed in system. Only most recent report on older batteries is saved because report summarizes entire battery history. Beforee moving into archive, a group ID can be inserted into access Icon. If an ID is submitted, n archive shows only batteries with this group ID. Later analysis of batteries is n concentrated on se batteries alone. If group ID is left blank, entiree archive is shown later and can be manipulated in various ways to be describedd next. We are looking at what you ll see upon entering archive system. In this case, group ID was left blank and entiree archive is made available in dropdown box shown. 8.a. The dropdown box shows all of batteries in archive or all of batteries with group ID of interest. Clicking dropdown shows batteries and, selecting one, allows it to be sent to Report Processor. This creates Power Report on battery selected. 9. The sort utility is very powerful. Any of 35 statistics in Power Report can be analyzed with this dropdown. Select a statistic from dropdown. Use Sort Archive icon to create a table that sortss entire archive (or group ID) on basis of statistic selected. It is possible to sort batteries on lifetime EBU, age, Total Discharge Amps, BDI or any or statistic. At a glance, technicians, clients or dealers can see which batteries are working hardest and which are getting little use. Which batteries are pulling largest peak amps and which are reaching highest temperatures. Wow. That s a lot of knowledge to help manage a fleet of batteries, evaluate chargers and assesss battery utilization.

7 10. In this example, all of batteries in archive have been sorted by statistic #1, Months of Activity. The table shows row number in archive of each battery, months of activity and battery handle (if one was assigned) or battery ID. It is now possible to select any of se rows and run Power Report on battery to see entire picture of how battery has been performing and how it has been used. Just identify this same row number in dropdown feeding into Archive System and send that ID to Report Processorr 11. The archive system can be managed throughh anor set of utilities. To this point, what went into archive is protected and stored re forever.. Hit Portal to Archive Manager to gain access. This set of utilities (or any or part of system) can be password protected. For now, this feature has been disabled.

8 13. Billing for system is throughh Paypal. We will describe billing later. 11.a. This page has two main features. It allows access to archive so that handles and group IDs can be updated on existing batteries. Old batteries can also be deleted or killed in system. For example, if a battery is replaced under warranty, system administrator should delete old battery from archive. The monitor can n be reused on new battery and a new history started. To alter a battery in archive, insert archive number, shown in archive dropdown. It is n possible to delete battery or alter handle and/or group ID. To delete battery, type word Yes into form. Any or word will not delete battery, including leaving this field blank. To change handle or group ID, leave delete-battery field blank and insert a new handle or group ID. Use Update Archive icon to effect desired changes. 11.b. Notice that archive can be backed up before attempting modifications. This step is highly recommended. Tap Backup Archive beforee modifications. If something goes wrong, you can restore original archive with Restore Archive backup icon. Any archive backup stays in backup until a new backup is created. 12. We are doing research on viability of battery discharge indicator as a predictor of battery health. The BDI uses nonlinear relationships between discharge draw, amp capacity, temperature and voltage drop to assess a battery s ability to do work. Each discharge state is a tiny experiment that is like a field test equivalent of a load test traditionally performed in industry. We are collecting data on load-test resultss and how y correlatee with BDI of a given battery. We are hoping to partner with users of this site to collect data on load tests. These tests will help us refine BDI until it is best possible tool to predict battery health. To provide data, fill out fields as indicated. We are collecting average cell voltage after 4 hours of a standard load test (including voltage of cells that have to be dropped). The number of dropped cells is also important, of course. Include that too. Input BDI from latest Power Report, date and send it all to our database. You will be helping us build best diagnostic tool in industry. That is our goal.

9 13. Billing for system is through Paypal. Enter system through archive manager page as shown above. We are endeavoring to keep costs of running Report Processor and Archive System as low as possible and still have a viable enterprise. The fee structure is described on this page. To make a payment, tap Buy Now icon and you ll be sent to Paypal. You can use a credit card or Paypal account. An invoice is created for you and we receive a copy for our files. It s that simple. If Linchpinn can avoid office staff, we all save money. When you reach Paypal site, it shows $1 per unit. Enter number of batteries in archive to get your invoice. For initial build-out fee, enter 250 for number of units and invoice will calculate $250, cost of build out Your paypal