General Description. BADICHEQ 3000 (Battery Diagnostic & Charge Equalizing) The compact solution for perfect battery management

Transcription

1 General Description BADICHEQ Chapter1: Introduction I: The problem General Description BADICHEQ 3000 (Battery Diagnostic & Charge Equalizing) The compact solution for perfect battery management Lead acid batteries are employed for energy storage since more than 100 years. However the use of traction- and stationary batteries causes trouble until to-day. - Short lifetime of cells or blocs, - Short operating period in spite of correct charging and handling, - Controversial discussions with regard to reasons and responsibility in case of battery failure. In this document battery stands for cells or blocs of the same nominal voltage connected in series. Cell stands for an individual cell but also for a battery bloc. The reasons for failures are in general an inadequate technology of battery charging, that is still prevalent until to day. The total voltage is used to determine the charge current. Even if the correct voltage is respected overcharging of individual cells cannot be avoided. The result is loss of time, energy and electrolyte. Furthermore the charge indication is wrong because the Ahs supplied to the overcharged cells are not completely chemically transformed. Another problem consists because the cells suffer a consecutive difference of their respective charge levels. The equalizing of the charge levels demands voluntary overcharging of the whole battery from time to time, (Equalizing charge) which results in losses of time, energy and electrolyte. In case of omission of the equalizing charge deep discharges may occur and even polarity changes of cells are possible. If one cell fails by a short cut, other cells will be severely overcharged because a standard charger cannot detect the lacking voltage of one cell. II: Requirements The following requirements must be fulfilled for an economic operation of a battery installation composed of several cells connected in series: - Max. operating time - The capacity should remain the same during the whole operating time, independent of ambient conditions.

2 General Description BADICHEQ Min. maintenance costs Units connected in series have divergent capacities due to fabrication tolerances. New batteries have only % of their nominal capacity. They reach the full capacity just after a determined number of cycles or operation under charge conservation. Furthermore the capacity depends on the ambient temperature. Different temperatures may occur within an arrangement of batteries but also in various groups of batteries. Under consideration of these facts it is necessary to do the following, when individual blocs or cells are connected in series: - all units have to be charged to the same level, - all units have to be maintained at the same temperature - the weakest unit has to be protected against overcharging or deep discharge. III: Problem solution The battery management system BADICHEQ monitors all cells during charging and discharging and considers always the weakest or strongest cell. As soon as one cell reaches the preset final voltage the charge current is reduced by an optional PWM signal and the charge continues according to a given characteristic curve, if the charger is able to use the signal. To protect the battery the discharge current can be reduced as soon as the battery reaches a preset voltage or if the capacity reaches a preset level. The BADICHEQ with an integrated small charger applies an additional charge to individual cells. During voltage measuring, the temperature is considered within the various groups of batteries. It is possible by help of an analogue or digital instrument to measure the capacity level and the charge current. The battery status is indicated in % of the nominal capacity. Three LEDs show the general condition of the battery. The behaviour and the voltage status of three cells are recorded during 128 cycles and can be analysed for servicing and in case of guaranty problems. The experience made with the BADICHEQ during 1000 applications has shown that this device takes care of the battery and extends its lifetime. BADICHEQ however cannot substitute the physical laws and facts. When operating the batteries one has to take care that great temperature differences are avoided between the individual batteries. Chapter 2: Description, Structure, Action I: General In September1992 the BADICHEQ 3000 has been first presented to the public. 2 patents now protect its technical features and the unit has been installed since more than 1000 times. The BADICHEQ 3000 has proofed that it is a compact fully automatic system for a reliable battery management:

3 General Description BADICHEQ Up to 48 cells are analysed (with an additional card up to 288 cells can be monitored) - Needing cells are individually charged in addition, - The main charge current can be regulated per cell (CRCS), (Only possible with a charger controlled by the BADICHEQ) - The real available capacity which does not damage the battery is indicated either digital or analogue. - A deep discharge protection is provided (relay contact), - Relevant data during 128 cycles are stored and can be read by a PC through an interface RS 232. * cell stands for a unit of 2, 6 or 12V It is possible to monitor a greater number of batteries or cells by connecting several units. For example connecting 6 BADICHEQ 3000 can monitor 192 cells of 2V. Each unit serves 32 cells. All individual sectors can be visited by a WEB interface which is part of the delivery. The system can be used for different types of batteries. The parameters can be programmed for almost all applications. Until to day the unit has been used for batteries made by Sonnenschein, Hagen, Saft, Varta, Trojan, Deta, Bären, Hawker, Panasonic, Horizon (USA), Oldham, and CMP. Extensive experiences and a reliable control algorithm are available. No cell will be overcharged due to the cell related control of the charge current (CRCS). As soon as one cell reaches the final charge voltage the charge current is reduced... Additional charge will be applied individually to cells that have not yet reached the final voltage by help of an integrated charger (max 20W) of the BADICHEQ. The effect is that after a certain number of charge cycles each cell is fully charged in relation to its individual capacity. This condition is monitored and maintained. The indication of the remaining available capacity considers the dependence on current and temperature of the capacity. Three separate temperature sensors monitor the ambient temperature of the battery during all measurements. The WEB-Interface Badicheq 3000 All battery data can be displayed by help of an SNMP Adapter (separate order) and the integrated web interface via intranet or with a router also via the internet. Further information is given in the BADICHEQ 3000 Webinterface documentation. Synopsis of battery installations via web interface

4 General Description BADICHEQ The status functions A tailor made concept in combination with a control algorithm created after many trials made it possible to design an affordable device that is able to face severe technical, climatically and electromagnetic conditions and overcome all technical problems II: Structure and mode of action The nucleus of the BADICHEQ is a cell-selecting network controlled by a microprocessor. Each cell can be connected with a voltage meter and a BADICHEQ integrated charger. The status data and the consolidated data of 128 cycles (charge and discharge) are stored in a battery supported (S-RAM).

5 General Description BADICHEQ The charger integrated in the BADICHEQ consists of a blocking converter and develops 20W independent of the cell voltage. The output current is limited at 5A, the output voltage at 24V per measuring unit. Help of a 60mV Shunt and two measuring amplifiers measures the battery current. To measure the temperature 3 input terminals are provided for temp sensors with 10mV/K, Ib<1mA. The assignments of cells and sensors within the BADICHEQ software are made in the factory according to the specification given with the order. An analogue display with 3 LEDs can be provided that shows the remaining capacity, the actual current and possible system defects. The display connects easily with the BADICHEQ by means of a 2 or 3 core cables... The data exchange with a PC takes place via an RS 232 interface. The PC has to be IBM compatible with the following min. configuration: - Win9x, WinNT, Win2000, WinXP operating system, - free RS 232 interface (the interface must not be used by an internal modem or similar device), The necessary level adaptation for a data transfer by an RS 232 interface is made in an interface component that is incorporated between the PC and the BADICHEQ. This RS232- Interface is supplied with potential separation. The PC is connected with the negative battery terminal. To control the main charger (current, set value for CRCS) a second potential free PWMoutlet is available. (Opto coupled transistor outlet) A further PWM-signal can be used to influence the discharge current subject to the charge condition of the battery. (To be discussed when ordering) The battery only powers BADICHEQ. This means that additional charging of individual cells can be performed any time, not dependent on the external power supply. Therefore no backlash, no radio interference, no dangerous voltages appear. The BADICHEQ 3000 can be used for batteries up to 576V total voltage. All measuring lines are directly connected to the BADICHEQ. For the connection of the lines to the temperature sensors, the shunt, the display a 37-pin D-SUB plug is provided. III: Advantages Long lifetime of the battery - Avoidance of overcharging of individual blocs, overheating and loss of electrolyte

6 General Description BADICHEQ no over-all equalization charge that damages all blocs by overheating and loss of electrolyte - Avoidance of deep discharges because the necessary additional charge is computed - no loss of lifetime through cycling - Charge procedure: The total battery is charged with an optimised charger as an individual bloc Reduction of the operating costs Other advantages Conditions - use and exchange of uncycled blocs is possible - increased efficiency because no over-charging - no waste of time and energy for equalizing charges - economy of maintenance costs and capacity tests in a workshop - economy of service costs due to rapid failure analysis - appraisal and testing of the installation via optional data lines with internet or LAN - optional incident information to service personnel via GSM - max. availability because of permanent optimal charge balance - maintenance free and fully automatic operation - Reduction of the mean charge time with a charger controlled by the system - comprehensive information with regard to the history of the battery - rapid clarification of guaranty problems Each battery terminal must be connected to the BADICHEQ via lines of 0,75qmm. The lines must be fused near to the battery (max 5A with according voltage) Chapter 3: Technical characteristic main values Max number of cells: 48, with extension module up to 288 Measuring range of cell voltage: 0-1.5x cell nom. voltage Resolution: 0.1% final value of the effective range Max. error: 1% final value of the effective range Temperature drift during voltage measurement: <0.3% of the total temperature range Effective range charge/discharge current: 0-0.7x / 0-1.5x (60mV ) shunt, nom. current Resolution, total error: 0.1% / 0.5% effective range +1%rdg Temperature drift during current measurement: <0.5% of the total temperature range Effective range temperature measurement: - 20 up to +75 C Resolution, total error: 1K/3K (LM235) PWM outputs / frequency: 3 / 2kHz

7 General Description BADICHEQ PWM output voltage and current Relay terminals deep discharge PC coupling: Range of supply voltage: Power consumption: Current of the additional charge: Temperature range Calculated lifetime: Weight/dimensions (HxWxD): 27V / 5mA 220V~ / 2A RS 232, 9.6kBaud 30V up to 660V DC ca. 2,5W, 6W with active display 20W / cell voltage, max. 5A - 0 C to +45 C ambient temperature >15 years with 300 cycles ca. 5 kg / 600x300x150mm (up to 62 cells) ca.20kg / 700x550x350mm (at 288cells) Chapter 4: Scope of delivery All BADICHEQs 3000 in their standard version are designed to monitor 32 cells. It is possible to increase or decrease the number of cells by additional components to screen from 12 up to 288 cells. The max nom. total voltage is 576V. This means that max 48 blocs of 12V or 288 blocs of 2V can be supervised. The exact number of cells should be indicated when ordering. All BADICHEQs are installed in plastic housings. Units for12 up to 28 cells meet the requirements of safety class IP 20, units for 30 up to 288 cells are supplied with a housing that meets the safety class IP 54. The measuring lines to the individual cells are directly connected with the BADICHEQ. Display, shunt, additional temperature sensors, interface adapters and appraisal software are not included in the unit price. They should be ordered separately. Order The BADICHEQ can be adapted to almost any battery type, due to its hardware configuration. This is also valid for the charge procedure, if the cell related charge characteristic (CRCS) is selected and the charger can be controlled accordingly. Each BADICHEQ is preset by the factory for the wanted application. Your order must include the following information: - Nom. Voltage and number of cells or groups of cells to be monitored - Type of battery and manufacturer - Nom. current and voltage for the shunt - Number and allocation of the temp. sensors (max. 3) To prepare the measuring lines we need in addition: - Number of temp. sensors (max 3) and the respective cable lengths, - For each sensor the allocated cell numbers, - Length of the shunt cable. A personal conversation should be held to determine i.e. a specific charge characteristic etc. Technical information/contribution of the customer:

8 General Description BADICHEQ A fused 230 VAC supply per data cabinet near to the BADICHEQ 3000 has to be provided, - A network interface is needed at the installation place near to the BADICHEQ A fused 230 VAC supply and a network interface is needed for each data cabinet in each room if the batteries are located in different rooms!

9 General Description BADICHEQ Chapter 5: Wiring diagrams Example: BADICHEQ 3000, model for 32 batteries of 12V, incl. one temp. sensor and an integrated LED display - LED green: power charge / trickle charge - LED yellow: battery discharge / low voltage of the bloc - LED red: battery fault / unit fault

10 General Description BADICHEQ Sample, graphical representation of the housing

11 General Description BADICHEQ Wiring diagram BADICHEQ 3000 and SNMP

12 General Description BADICHEQ Sample Representation of the LED display