Battery Monitor user manual

Transcription

1 ZTP s.r.l. Via Bertona, Poviglio (RE) ITALY Cod. Fisc. n VAT n IT Società del gruppo ZF TEL FAX Web Site : - info@ztp.it Battery Monitor user manual Publication ZDL1ZZ0CA PAG 1/27 Date of publication 01/07/2016 Battery Monitor user and

2 INDEX 1 DESCRIPTION BATTERY MONITOR DATA CLOUD DIAGRAM CHARGE AND DISCHARGE AMPERE/HOURS DIAGRAM TEMPERATURE DIAGRAM INITIAL AND FINAL SOC DIAGRAM EVENTS TABLE INTRODUCTION BENEFITS TECHNICAL SPECIFICATION OF THE DEVICE BLOCK DIAGRAM PARTS OF EQUIPMENT BOX CONTENTS: CD CONTENTS: MINIMUM PC REQUIREMENTS: INSTALLING ON THE BATTERY FIX THE BATTERY MANAGER: THERMAL SENSOR: FIXING OF THE HALL CURRENT SENSOR POSITIVE POWER SUPPLY NEGATIVE POWER SUPPLY ELECTROLYTE LEVEL SENSOR USB PORT CABLES WIRE DESCRIPTION CABLE CONNECTION CONNECTING THE DEVICE TO THE PC DRIVER INSTALLATION ZTP LINK CONNECTION TESTER PAG 2/27 Date of publication 01/07/2016 Battery Monitor user and

3 10.5 PARAMETER NETWORK SETTINGS BATTERY MONITOR STARTING THE DEVICE SIGNALS FROM THE LED FIRST CONNECTION GENERAL NOTES Rev. Date Reason Updates A 01/07/2016 First DRAFT issue PAG 3/27 Date of publication 01/07/2016 Battery Monitor user and

4 Annotation charts The symbol nearby is used in this publication to indicate a note or a suggestion for which to keep attention. The symbol nearby is used in this publication to indicate an action or a feature very important for security. Pay big attention to the annotations highlighted by this symbol. The contents of this publication are property of ZTP s.r.l. Any kind of total or partial copy are forbidden. By no means will ZTP s.r.l. be meant responsible towards third parties in case of damages caused by an improper use of this publication and the device described in it ZTP s.r.l. reserve the right to bring modifications and improvements to their products at any time and without any notice. PAG 4/27 Date of publication 01/07/2016 Battery Monitor user and

5 1.1 Battery Monitor 1 DESCRIPTION MULTIVOLTAGE SUPPLY (24V - 96V) DIMENSIONS: 140x48x20h (mm) 1 CAN BUS PORT 1 USB PORT 1 DIGITAL INPUT 2 DIGITAL OUTPUTS Wi-Fi COMMUNICATION SYSTEM INTEGRATED IP 67 INTERNAL MEMORY 64Mb SUPPLIED COMPLETE OF: CURRENT SENSOR; THERMIC SENSOR; ELECTROLYTE LEVEL SENSOR 1.2 Data WORKING SOC (INITIAL FINAL) CHARGING SOC WORKING TEMPERTURE CHARGING TEMPERATURE WORKING A/h PROVIDED REGENERATION BRAKING A/h RECEIVED CHARGING A/h IDENTITY CODE OF THE BATTERY ABSENCE OF ELECTROLYTE PAG 5/27 Date of publication 01/07/2016 Battery Monitor user and

6 2 CLOUD DIAGRAM 2.1 Charge and Discharge Ampere/Hours Diagram 2.2 Temperature Diagram PAG 6/27 Date of publication 01/07/2016 Battery Monitor user and

7 2.3 Initial and Final SOC Diagram 2.4 Events Table PAG 7/27 Date of publication 01/07/2016 Battery Monitor user and

8 3 INTRODUCTION The ZTP BM is a Battery logger connected to an industrial vehicle battery, It monitors the main battery parameters, recording all essential values then ensuring its utmost care and efficiency. By external sensors (bidirectional current sensor, thermic sensor, liquid level sensor) all battery data can be read, recorded and broadcasted along working and charging cycle of the machine Data can be collected: WORKING SOC (INITIAL FINAL) CHARGING SOC WORKING TEMPERTURE CHARGING TEMPERATURE WORKING A/h PROVIDED REGENERATION BRAKING A/h RECEIVED CHARGING A/h LIQUID PRESENCE IDENTITY CODE OF THE BATTERY In case of absence of the liquid a specific digital output is activated For monitoring the state of the battery, the device constantly reads the battery voltage and determines the amount of charge in dynamic conditions, by means of a current sensor Hall effect. The data will be stored in a database and each record will be closely linked to the serial number of the battery. 4 BENEFITS Highly accurate State-of-Charge calculation based on battery voltage, current, temperature and time to maximize the machine uptime because the ZTP BM is permanently connected to the battery. Installation of ZTP BFM is friendly and non-invasive with low impact cost. No need for special hardware. No modification into the battery is needed. The peculiar battery data are automatically uploaded to Ztp cloud, or to the customer s cloud, through Wi-Fi connectivity. The ZTP BM may connect to local Wi-Fi otherwise dedicated access point. ZTP BM provides info to determine if operations on the battery has been performed according to its warranty conditions. ZTP BFM guarantees max efficiency of a battery fleet in a way to achieve the machine best productivity. PAG 8/27 Date of publication 01/07/2016 Battery Monitor user and

9 Installed on a laptop, the ZTP configuration software allows ZTP BFM, duly set up, to match with specific battery. The peculiar battery data recorded by ZTP BFM are constantly uploaded to the ZTP cloud, or to the customer s cloud, for checking and analysis. The cloud web page translates the battery data into easy-to-read performance data. It also calculates the actual battery capacity, comparing it to the nominal value. 5 TECHNICAL SPECIFICATION OF THE DEVICE Voltage supply: VDC Internal memory: With the 64Mbytes memory; Internal battery: Lithium 3,3V; internal modem: Wi-Fi Communication port: Nr.1 USB port type A; Can bus: Nr.1 Digital inputs: Nr.1 for negative signals. Digital outputs: Nr.2 digital open drain exits to negative battery (max.1a); Working temperature: C; Protection grade: IP67 Compliances: Radio device directive 1999/5/ o EMC directive 2004/108/CE PAG 9/27 Date of publication 01/07/2016 Battery Monitor user and

10 6 BLOCK DIAGRAM 7.1 Box contents: 7 PARTS OF EQUIPMENT Battery Monitor Connection cable with current sensor, temperature sensor and liquid level sensor PC Installation CD with drivers and necessary tools. 7.2 CD contents: ZTP Link Battery Monitor USB driver 7.3 Minimum PC requirements: Pentium IV 2.0 GHz processor RAM memory 512MB Minimum hard disk space 200MB Software tested on Windows XP, Vista, 7, 8 PAG 10/27 Date of publication 01/07/2016 Battery Monitor user and

11 8 INSTALLING ON THE BATTERY 8.1 FIX THE BATTERY MANAGER: FIX THE Battery Manager to the cell interconnection by using plastic wrappers as for the picture 8.2 Thermal Sensor: Insert the thermal sensor among the cells in the middle of the battery at a depth of around 20Cm as well as fix cabling by plastic wrappers 8.3 Fixing of the hall current sensor Usher the battery positive cable running across the hall current sensor always insuring the arrow printed on is opposite direction of the positive battery pole and fixing with plastic wrappers PAG 11/27 Date of publication 01/07/2016 Battery Monitor user and

12 8.4 Positive power supply Connect the red wiring to the positive tip of the battery pole and fix it by using a plastic wrapper 8.5 Negative power supply. Connect the black wiring to the negative tip of the battery pole and fix it by using a plastic wrapper. 8.6 Electrolyte level sensor Make a hole in the central element. Insert the appropriate seal cup. Cut the rod of the sensor to the necessary length. Insert the sensor on the cup. Fix it by using a plastic wrapper. PAG 12/27 Date of publication 01/07/2016 Battery Monitor user and

13 8.7 USB Port A USB Port is available for connection with the PC for the installation, eventual further flashing or upgrading. 9 Cables The first part of the wiring to connect is the Hall effect sensor. This part is very important cause it allows the Battery Monitor to take over the power from the battery at each working cycle. The latter is installed on the negative battery cable or on the positive battery, that brings the power to all the machine systems. In the following picture you can see the Hall effect sensor in a ring shape. PAG 13/27 Date of publication 01/07/2016 Battery Monitor user and

14 In the following picture you can see the complete set of cable 9.1 Wire Description Table 1 Wires description COLOR FUNCTION DESCRIPTION Red Positive supply Must be connected directly to the positive pole of the battery. Black Negative supply Must be connected to the negative pole of the battery. Brown Can High Must be connected to the plug imput for the Zivan Battery charge control Blue Can Low Must be connected to the plug imput for the Zivan Battery charge control Blue Liquid level Insert the liquid level sensor on the cap of the first battery element White Digital Output Digital Output (ELECTROLYTE LEVEL) Green Digital Input Optional Brown Digital Output Optional PAG 14/27 Date of publication 01/07/2016 Battery Monitor user and

15 9.2 Cable Connection PAG 15/27 Date of publication 01/07/2016 Battery Monitor user and

16 10 Connecting the device to the PC 10.1 Driver installation Install the USB drivers included on the given CD. Install them without the device being connected to the PC Ztp Link ZTP Link (ZDCT) is the instrument to setup the Battery Monitor After inserting the disk, install the software ZDCT on the PC that will be used to setup the devices Connection The procedure below can be done on a machine with the device already connected to the battery, or in the office with the device connected to a stand-alone power supply or battery with a voltage between 24 and 96V Follow these operations: 1. Power up the device; 2. Connect the device to the USB port of the PC; 3. Open the software ZTP Link; 4. Press to scan and select the comm port. 5. after press Connect and read. PAG 16/27 Date of publication 01/07/2016 Battery Monitor user and

17 10.4 Tester With this menu can read and adjust the sensor readings. 1. Press the start button and measure the voltage with a tester between the + and - battery, adjust Battery (by increasing or decreasing the value of 1000) in order to have the same voltage reading. 2. Press the button Acquire 0 AMP for acquire the zero of the current sensor after it has been connected to the battery cable. Make sure that during this adjustment there are no consumption of current from the battery. 3. With a thermometer read the temperature between the cells of the battery, adjust TEMPERATURE SENSE (by increasing or decreasing the value of 1000) in order to have the same temperature reading 4. Press the write button. PAG 17/27 Date of publication 01/07/2016 Battery Monitor user and

18 10.5 Parameter The options in this menu will allow you to set the kind of battery available on your machine 1. BATTERY TYPE You can choose the Lead acid or gel battery, each of these options will use a different calculation to establish the correct battery charge. 2. BATTERY VOLTAGE Sliding the drop down menu you can set the voltage of the battery 3. RECONNECT EACH TIME This sets the automatic reconnection time of the Battery Monitor to the CLOUD, to download data. 4. INVERTING INPUTS AND OUTPUTS This programming mask defines the status of the input and output commands when the machine is not in use. It establishes if the inputs are normally closed or if the outputs are normally active. This function makes the usage of the commands very flexible meaning the device can be easily integrated in any electrical switchboard 5. Battery Monitor CAN BUS NODE: The option in this menu allows you to change the number of the can-bus node of the Battery Monitor. Application with Zivan must be After choosing the settings, press the write button. PAG 18/27 Date of publication 01/07/2016 Battery Monitor user and

19 10.6 Network settings 1. Open Network settings ; 2. Set the correct parameters depend on the choice of connection (WI-FI whit static or dynamic IP); 3. Press Write to save everything to the memory Battery monitor This menu allows you to set and control variables in the compilation of records that will be shipped to the cloud. AVAILABLE VOICES: 1. BATTERY SERIAL NUMBER 2. BATTERY REFERENCE 3. BATTERY CH. CAN BUS NODE N of can bus node charger which must communicate to the Battery Monitor. PAG 19/27 Date of publication 01/07/2016 Battery Monitor user and

20 4. NOMINAL CAPACIT Nominal capacity of the battery in ampere / hour. The charger fits a particular charging curve according to the value in ampere / hour set 5. SOC COULOMB COUNTING % Percent state of charge 6. DISCHARGE CAPACITY Current in amperes / hour recorded during the discharge process 7. CHARGED CAPACITY Current in amperes / hour loaded during the charging process 8. REGENERATIVE BRAKE CAP. Current generated during the phase of electric braking of the carriage 9. BATTERY CHARGING RECORD NUMBER Amount of records (one record is created after a discharge and charge cycle) in the memory of Battery Monitor not yet been sent to the server 10. INITIAL BATTERY DISCHARGING TEMPERATURE Initial temperature detected during the discharge phase (event reported in the record) 11. MAX CHARGING DISCHARGING TEMPERATURE Maximum temperature detected during the discharge phase (event reported in the record) Attention: for the correct acquisition of the parameters you need to restart the device by pressing the button REBOOT DEVICE. PAG 20/27 Date of publication 01/07/2016 Battery Monitor user and

21 11 Starting the device 11.1 Signals from the led State of the led Green led Orange led Orange led slow blinking Orange led fast blinking Red led blinking Signification Power ON Presence of event to send to the cloud WI-FI Connection Transmission of the data Alarm 11.2 First Connection At the first start up you need to check the functionality of the wireless connection of the device. The Orange LED on the cover of the box will start blinking (if it were not so, check the electrical connections). The first phase of the modem initialization takes about 60 seconds and it coincides with a slow flashing yellow 1 second blink. Then it passes to the cloud connection emitting a flashing fast light. Do not disconnect the power during this stage. It all ends after another 60 sec with the led turning off. Be sure that in the cloud the machines database has been updated. If the flashing is red instead of orange check that: - The network security configurations in the program ZTP link are not correct; - The WI-FI signal does not reach the Battery Monitor. On the cover of the box there Is a button that allow to force the BM connection, this system must be used in the case where the connection to the server is carried out through a mobile connection. Warning: the modem of the Battery Monitor is not able to manage a company proxy. In the case of antivirus ensure that you can reach the server on ports 80, 8000, 8001, 8020 with TCP-IP protocol. This means that the network must be configured accordingly. PAG 21/27 Date of publication 01/07/2016 Battery Monitor user and

22 12 General notes The Battery Monitor cannot handle the security of the operating machine or of the electronic parts set on it. The connection of the device to the machine must be done in compliance with the already existing security devices present on the machine, avoiding to do any by-pass on the original control systems. The usage of the controls that the Battery Monitor has onboard is bonded to the reduction of performance, to a visive/acoustic signal in the case of a specific event, or to the lock of the machine, excluding any kind of rehabilitation of the functions in case of a lock caused by the original electronics. Do not use the Battery Monitor instead of the key of the machine. Do not use the Battery Monitor to handle power contactors set in series to the engine or battery cables, cause the opening of these contacts could happen during the pass of electricity creating and electric arc. The handling of a machine block must be done in the respect of security and avoiding slow downs or blocking the production. Check the paragraph regarding risks evaluation and Emergency handling. No operation, which changes the behavior of the truck, can be done remotely, without having previously informed the customer and the operator of the machine. This is absolutely necessary in order to prevent any dangerous situations for the driver and for the operators present in the range of action of the machine. In any case, the operations of remote connection must be made only by authorized people responsible of the management of the system. PAG 22/27 Date of publication 01/07/2016 Battery Monitor user and

23 WARNINGS ON WIRELESS Wi-Fi TRANSMISSION The used modem, Bluegiga WF121, meets the risks requirements related to wideband transmission. This device can be used only for "fixed" or "mobile" applications. It is not correct to use this device as a "portable"(like a mobile phone on the operator) The rule says that between the antenna and the person, there should be a minimum distance of 20 cm. For any questions please contact our technical office. RISK ASSESSMENT, EMERGENCY MANAGEMENT, SECURITY SYSTEM MANAGER OF THE APPLICATION The standard installation, which is normally used on the machines, may provide the reduction or interruption, by the Battery Monitor, of the traction function or lifting function, as well as an audible / visual signal on a specific event. It s clear that, in case the Battery Monitor has a malfunction, for internal defects or other causes, there may be a reduction or the block of the function without having the required conditions. The purpose of the system Battery Monitor is to monitor the use of the battery, for this reason all necessary measures must be used to prevent the tool becoming a source of disturbance to the normal production activities of the company, in case of functional problems. That s why it is absolutely necessary to create a system of rehabilitation of the functions at the exclusive use of the System Manager (security manager, department manager or the technical manager for internal maintenance etc.) chosen by the company. Through him, the restart operation of the machine caused by a fault in the Battery Monitor, must and will be done in a very short time, to limit the possible stop of the production. The "by-pass" can be achieved by inserting on the interrupt line managed by the Battery Monitor, the two wires to interrupt the micro-seat, for example, a key or a connector for canceling the block. Concerning the proper management of the system and the necessary precautions to be implemented, as shown in this manual, ZTP srl disclaims any liability for delays or stops of the production caused by the Battery Monitor. The system management is to be assigned only to trained personnel with the right skills for the treatment of data and possible malfunctions. The system operator, will then form the users of the machines, making them aware of the steps to take in relation to the use of the machine on which the Battery Monitor is installed. The information to be given to the operators is: 1) Who is the manager of the Battery Monitor 2) The purpose of the system installation 3) Purpose of use of the data acquired by the system 4) Possible risks caused by the malfunction of the system 5) Who to contact for system problems 6) How to use the system on the machine without damaging it PLEASE NOTE: This information will ensure that staff is aware of the changes made to the machine, putting them in a better reaction condition in front of possible problems. MANAGER OF THE SYSTEM, SAFETY AND RISK EVALUATION The system operator must be trained in order to use the software Battery Monitor (ZDCT and CLOUD), as well as being able to intervene on the machine in case of anomalies. The required competence is on the use of a PC and accessories, as well as competence on technical installation-maintenance of electronic equipment on electrical machines and diesel. In the case that the System Manager doesn t have specific skills, he can be supported by specialized PAG 23/27 Date of publication 01/07/2016 Battery Monitor user and

24 technicians for installation and activation of the machine, dealing only with data management. Anyway he will have to, while evaluating risks, make an environmental analysis to allow the usage of the equipment, reducing as much as possible the risks of damage to people or property. This means that, for example, if in an industrial environment there is an internal rail for freights, it s better to avoid the use of the traction lock of the machine by the Battery Monitor, as dangerous for the safety of the operator. He may be unable to move the machine from the rails as the train approaches. In this case it is necessary to block or restrict another function that is not the traction one. It's clear, however, that the possibility of undesired block of the vehicle still remains possible, due to any anomaly of the engine or the electronic control, but we would not increase the probability that such a situation could happen. The same thing could be applied in an environment in which, for various logistical reasons, the machine has to travel on roads with a very heavy load. For example it can be assumed that a sudden and unexpected interruption of traction, could generate oscillations on the pillar. Another case could be the use of the machines on airport runways or where the machine could constitute a real danger. In the case that the connection of the system was made in modality "traction lock", The Battery Monitor would not stop the machine, but only the interrupt enable signal (for example, the driving request or micro seat). If this happens during the usage of the machine, you would have the same condition of when the pedal is released or the micro seat is open. The stop of the machine would always be controlled by the existing braking system and the existing electronics. WARNING: Never connect the Battery Monitor, with traction lock function, to machines authorized for road usage. In the case of failure of operation on the system, with a traction block, you could generate traffic obstruction or danger. In general, before deciding which actions to do with the Battery Monitor to inhibit a service on a machine, it is mandatory to carefully analyze the environmental context in which the machine is used and the eventual risks it could cause (RISK ANALYSIS). The operator of the system, rather than the supervisor for internal security, will have to consider all the variables that could be introduced over the previous situation and control that the installation of the equipment is done in the correct way, preserving the safety of the operators. RISKS ANALYSIS RELATED TO THE USAGE OF THE Battery Monitor ON AN OPERATING MACHINE. As we stated earlier, the use of the Battery Monitor system on machines, can increase the level of security in the industrial departments, monitoring and empowering operators in the use of machines. Through proper use of this tool it is possible, therefore, to have greater control over the machines, in relation to the events that the Battery Monitor Can is able to detect. The action that the system can do, is to monitor and control how, and by whom, the machines are used, making it a deterrent to an hazardous behavior of the operator in industrial environments. It 's clear that the Battery Monitor, cannot prevent the incorrect action of the driver, so the possibility of an accident is always linked to action and responsibility of those who operate the machine. The Battery Monitor could possibly react to the event, recording the data related to the driver or by activating the related command output if specified from the customer. The work of prevention, in terms of quality of the results, comes from the way the system is introduced and managed within the departments, forming and informing the staff about the characteristics of the installed equipment and the effects of the data detected related to their conduct. Together with this preventive service, you will have all the recorded data, useful for an economic and managerial analysis of the machines, according to the quality of use on the work field. By analyzing all the possible situations that could be a danger to the safety of the operators, involved in the use of the machines and those that operate in their range, one can identify the main issues to be considered at the time of installation. PAG 24/27 Date of publication 01/07/2016 Battery Monitor user and

25 The Battery Monitor must not, under any circumstances, be used to rehabilitate the functions of the machine, if these have been inhibited due to an action of the electronic existing control. The Battery Monitor must never have the by-pass function for blocks determined by the safety devices of the other electronic controls, originally installed on the machine. For example, if we use the signal man present (Micro seat, button foot or micro rudder), to block the traction of the machine in the absence of Smart Card, the Battery Monitor can only be put in series with this signal and never in parallel. In this way if I swipe the smart card and do a correct login into the system, but I am not sitting on the seat or have not pulled into an active position the rudder arm, I will have the machine exactly like before the system Battery Monitor was installed. Please note that the Battery Monitor be just a Supervisor of machine functions, without interfering with the existing electronic system, but would not oblige the operator to log-in. In any case, the Battery Monitor will at most, reduce the performance of the machine, in case of speed reduction, or block it, but never restore the functionality of the machine if it has been interrupted by the original electronics. Before installing the system on the machines, it is absolutely necessary to establish what functions will be assigned to the command outputs of the Battery Monitor on the management system of the machine. This means that you will have to define the actions that the system will execute on the machine functions in the various step detections. In the case of a crash, and the detection by the Battery Monitor, you can decide if the reaction of the system should be to: 1) stop the machine 2) reduce the traction speed 3) reduce or inhibit the lifting function 4) activate an audible and / or visual signal 5) simply record the event without acting 6) activate an audible and / or visual warning and then terminate a function These are examples of the usage of the "crash alarm" and, on the basis of the decision taken by the user, you will define the risks and safeties related to these actions in relation to the use of the machine and the environmental context in which it is used. It is important that these assessments are carried out before installation, following our advices, allowing to properly inform the operators that will use the system. POSSIBLE DANGER SITUATIONS CAUSED BY THE BATTERY MONITOR: - In an airport environment The interruption of traction on a runway takeoff / landing may cause obstruction to the air traffic. - In industrial environments with internal rail The interruption of traction on tracks may constitute an obstacle to the train. - Handling high loads If the truck travel long distances in this condition, it is possible that the unexpected loss of traction determines oscillations on the load (in any case it would be like interrupting the micro seat, the release of the breaks electronic control would act in a standard way). - Handling materials If the machine suffered an unexpected release of traction, it could constitute an obstacle to the other vehicles circulating during loading operations. PAG 25/27 Date of publication 01/07/2016 Battery Monitor user and

26 - On machines with negative brake The unexpected release of traction on machines with a negative brake, can generate sudden blocks. In these cases it would be appropriate to manage the output of the Smart Card in order to avoid a dangerous behavior of the machine. Important: Before applying the system, and activating it, it is recommended to take all the necessary assessments so that the machine can give the best possible contribution to the security in the departments and save on maintenance costs in case of wrong use of the machine. The system must be seen as an additional element, of support, for security, and not as a substitute to existing systems, so its application must not limit the securities already present on the machine. For any question or doubt about the installation and application of the system, you can contact our technical department at WARNING: Never connect the Battery Monitor, with traction lock function, on vehicles used on the roads. In case of failure of the system, with traction block, you could generate traffic obstruction or danger. EMC EMC and ESD performances of an electronic system are strongly related to the installation methods. Particular attention must be paid to the length and to the electrical path of the connections and shields. This situation is out of ZTPs control. ZTP can offer assistance and recommendations, based on years of experience, on topics related to EMC. However, ZTP declines any responsibilities for malfunctions and failures in the event that the tests were not performed correctly. The machine manufacturer is responsible for the safety of the machine and related approvals, based on current regulations. PAG 26/27 Date of publication 01/07/2016 Battery Monitor user and

27 NOTE PAG 27/27 Date of publication 01/07/2016 Battery Monitor user and

28 PAG 28/27 Date of publication 01/07/2016 Battery Monitor user and