World Class Charging Systems. Battery Controller BATCOM. Innovation by design

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Jasmine Lawson
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1 World Class Charging Systems Battery Controller BATCOM Innovation by design

Battery Controller BATCOM Innovation by Design The operators of large battery powered fleets of materials handling equipment usually have access to a high quantity of operational data.

The effective implementation and use of the BATCOM provides the operators with advanced information features.

2 Battery Controller BATCOM Innovation by Design The operators of large battery powered fleets of materials handling equipment usually have access to a high quantity of operational data. Compared with that, there is limited information available for the battery, which is one of the most important components of the truck system. The effective implementation and use of the BATCOM provides the operators with advanced information features. The BATCOM measures, stores and signals important operational data of the truck and the battery. The mechanical design is very compact, and it is well adapted to constant use in tough operational conditions on the battery. The data transmission via radio ensures a secure and interference free communication with the truck or the PC / laptop. Battery Controller BATCOM Special Features: Intelligent current probe (hall sensors) Interference free data transmission by radio (433 MHz) - Bi-directional to the truck (CAN-Bus compatible) - Bi-directional to the PC / laptop (B_Term2000 software) Compact design Degree of protection IP 65 Easy installation without special equipment Shock- and vibration-proof construction Integrated LED gauge for operation and battery capacity One device covers all major voltages

System Set-up The System: The BATCOM can be mounted easily on nearly any kind of traction battery without the need for special

The data read-out and programming during operation is possible by PC / laptop.

For evaluation by PC the service software B_Term2000 is an integral part of the system.

Charge-/Discharge data Logbook Measuring data Battery address BATCOM Software B_Term2000: The service software B_Term2000 is for

records B_Term2000 Console - BATCOM Residual battery capacity Logb

discharge current Average discharge current Used capacity End-of-charge temperature Used energy Residual capacity End-of-charge data

3 System Set-up The System: The BATCOM can be mounted easily on nearly any kind of traction battery without the need for special equipment. The battery information can be transferred by radio during operation and displayed in the truck if equipped with a receiver. The data read-out and programming during operation is possible by PC / laptop. BATCOM Further processing of the data in the truck depends on the applied system. For evaluation by PC the service software B_Term2000 is an integral part of the system. File Units Settings Window Help Battery reference Truck reference Bus synchronous Data read-out Console System data ZVEI data Charge-/Discharge data Logbook Measuring data Battery address BATCOM Software B_Term2000: The service software B_Term2000 is for programming and analysis of the recorded information: Truck and battery identification data 40 end-of-discharge and end-of-charge data records B_Term2000 Console - BATCOM Residual battery capacity Logbook data (e.g. capacity usage, idle times) Truck reference Battery reference Start End Long term data records Max. discharge current Average discharge current Used capacity End-of-charge temperature Used energy Residual capacity End-of-charge data Discharge time Idle time Minimum cell voltage Life expectancy analysis (acc. ZVEI) Event storage Record of measurements The battery data, information viewing and analysis functions can be achieved using the B_Term2000 software which includes a visualized database with a graphical analysis tools. Max. discharge current (A) Average discharge current (A) Residual capacity (%) Used capacity (Ah) Discharge diagram

Traction Management System Traction Management System When used with the Traction Management System the controller is the indispensable tool for recording all essential information of the batteries.

Therewith the charging system is set to achieve the optimum performance for the respective battery.

4 Traction Management System Traction Management System When used with the Traction Management System the controller is the indispensable tool for recording all essential information of the batteries. A charging system equipped with the BATCOM receives automatically the number of battery cells, the rated capacity and the charging characteristic to be applied. Therewith the charging system is set to achieve the optimum performance for the respective battery. Even different kind of batteries with different rated capacities and / or battery voltage could be charged with the same charging system. Moreover the BATCOM sends the last 40 end-of-charge and end-of-discharge records, the logbook, all measured data and the current condition of the battery to the charger. This data is forwarded to the Traction Management System for further storage, display and analysis. Truck ref. Battery ref. Start End Discharge time Idle time Logbook data Discharge time (s) Idle time (s) Discharge time Idle time Logbook diagram Type Table Type Part-No. Interface Current range 250 A 500 A 1000 A Battery capacity BATCOM Radio Radio (433 MHz, 9600 baud) BATCOM ASK ASK-modem Ah Ah >960 Ah BATCOM 2IN Radio and ASK-modem Technical Data Voltage range: V DC Temperature range: 0-60 C Degree of protection (EN 60529): IP 65 Mechanical construction: Dimensions (L x W x H): Shock- and vibration-proof (IEC & IEC ) 260 x 25 x 42 mm

Innovation by mechanical Design Mechanical Design For recording the current, the BATCOM is equipped with a current probe.

The voltage is measured at the end terminals of the battery. Additionally a temperature sensor mounted in between the battery cells measures the battery temperature.

The radio module uses a 433 MHz frequency with a transmission rate of 9600 baud. The ASKmodem interface complies to the ZVEI standard.

5 Innovation by mechanical Design Mechanical Design For recording the current, the BATCOM is equipped with a current probe. For the installation it is not necessary to open the battery circuit, as the current probe can be opened easily and be mounted at any inter cell connector. The voltage is measured at the end terminals of the battery. Additionally a temperature sensor mounted in between the battery cells measures the battery temperature. The BATCOM is also equipped with a real time clock. For the data transmission the BATCOM is equipped with a radio and / or ASK module. The radio module uses a 433 MHz frequency with a transmission rate of 9600 baud. The ASKmodem interface complies to the ZVEI standard. Current probe Hall sensors Iron core Antenna Radio interface Service LED s Capacity gauge Power supply ASK-Modem Storage and processing unit Cable compartment Cable connection +/- battery and temperature sensor LED Display The LED display indicates the current operational conditions of the system. The LEDs signal the battery capacity, charging, discharging, identification with the truck or charger or if an error occured. Identification with the truck, the charger or the PC / laptop is ok (green LED) Current flow, charging or discharging (yellow LED) Error (red LED) Battery capacity gauge (1 green, 3 yellow, 1red LED)

6 BENNING worldwide Austria Benning GmbH Elektrotechnik und Elektronik Eduard-Klinger-Str. 9 A-3423 St. Andrä-Wördern Tel / Fax / info@benning.at Ireland Theo Benning GmbH North Industrial Estate Whitemill North IRE-Wexford / Rep. Ireland Tel / Fax 053/ benning@benning.ie South East Asia Benning Power Electronics Pte Ltd 1, Kaki Bukit View # 05-03/04 Techview SGP-Singapore Tel. (65) Fax (65) benning@singnet.com.sg Belgium Benning Belgium Power Electronics Z. 2 Essenestraat 16 B-1740 Ternat Tel. 02 / (85) Fax 02 / info@benning.be Italy Benning Conversione di Energia S.r.l. Via E. Mattei, 7 I Bologna Tel / Fax 0 51 / benning.energia@libero.it Sweden Eldaco AB Box 990, Hovslagarev. 3B S Sollentuna Tel. 08 / Fax 08 / power@eldaco.se Czech Republic Benning CR s.r.o. Zahradní ul. 894 CZ Kosmonosy (Mladá Boleslav) Tel Fax benning@benning.cz Netherlands Benning NL Power Electronics Peppelkade 42 NL-3992 AK Houten Tel. 030/ Fax 0 30 / info@benning.nl Switzerland Benning Power Electronics GmbH Industriestrasse 6 CH-8305 Dietlikon Tel. 01/ Fax 01/ info@benning.ch France Benning Conversion d énergie 43, avenue Winston Churchill B.P. 418 F Louviers Cedex Tél. 0 / Fax 0 / info@benning.fr Poland Benning Power Electronics Sp.z.o.o. Korczunkowa 30 PL Glosków Tel / / Fax 0 22 / biuro@benning.biz Spain Benning Conversión de Energía S.A. C/Pico de Santa Catalina 2 Pol. Ind. Los Linares E Humanes, Madrid Tel. 91/ Fax 91/ benningcde@ret .es ISO Germany Theo Benning Elektrotechnik und Elektronik GmbH & Co.KG Münsterstr D Bocholt Tel / 93-0 Fax 02871/ info@benning.de Great-Britain Benning Power Electronics (UK) Ltd. Oakley House Hogwood Lane Finchampstead GB-Berkshire RG 40 4QW Tel Fax info@benninguk.com Hungary Benning Kft. Power Electronics Rákóczi út 262 H-2541 Lábatlan Tel. 033/ Fax 033/ benning@vnet.hu P. R. of China Benning V. GmbH Shanghai Repr. Office 1233 Si Ping Rd., Rm. 006 PRC Shanghai Tel Fax benning@public8.sta.net.cn Russian Federation OOO Benning Power Electronics Scholkovskoje Chaussee, 5 RF Moscow Tel. 095/ Fax 0 95 / benning@benning.ru Slovakia Benning Slovensko, s.r.o. Kukuričná 17 SK Bratislava Tel. 02 / Fax 02 / benning@internet.sk Ukraine Benning ul. Solomenskaja, 3B UA Kiew Tel. 044 / Fax 044 / benning@benning.com.ua U.S.A. Benning Power Electronics, Inc Grader Street USA-Dallas, TX Tel Fax sales@benning.us /2004 paus Design & Medien, Bocholt Subject to alterations. Printed on chlorine free paper.

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