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Global Energy Innovations EC1000 User Manual

Handheld battery analyzers
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™
™
Global Energy Innovations EC1000
& EC2000
Handheld Battery Analyzers
Firmware Version 2.0.0 Onward
Users Manual
October, 2011 Revision 1.0.2
© 2009-2011 Global Energy Innovations, All rights reserved.
Printed in the USA.
All product names are trademarks of the respective companies.
Document: EN-1005-1001

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  • Page 1 Global Energy Innovations EC1000 & EC2000 Handheld Battery Analyzers Firmware Version 2.0.0 Onward Users Manual October, 2011 Revision 1.0.2 © 2009-2011 Global Energy Innovations, All rights reserved. Printed in the USA. All product names are trademarks of the respective companies. Document: EN-1005-1001...
  • Page 2 Subject to the exclusions contained below, Global Energy Innovations warrants its EC1000™and EC2000™ Analyzers (“Products”), Global Energy Innovations- branded or certified accessories sold for use with these Products (“Accessories”) and Global Energy Innovations software contained on CD-Roms or other tangible media and sold for use with these Products (“Software”) to be free from defects in materials and workmanship under normal consumer usage for the period(s)
  • Page 3 Who is covered? This warranty extends only to the first consumer purchaser, and is not transferable. What will Global Energy Innovations Do? Global Energy Innovations, at its option, will at no charge repair, replace or refund the purchase price of any Products, Accessories or Software that does not conform to this warranty.
  • Page 4 Laws in the United States and other countries preserve for Global Energy Innovations certain exclusive rights for copyrighted Global Energy Innovations software such as the exclusive rights to reproduce and distribute copies of the Global Energy Innovations software. Global Energy Innovations software may only be copied into, used in, and redistributed with, the Products associated with such Global Energy Innovations software.

  • Page 5: Table Of Contents

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers User Manual Table of Contents TABLE OF CONTENTS LIMITED WARRANTY & LIMITATION OF LIABILITY ................................. i TABLE OF CONTENTS ..........................................1 DECLARATION OF CONFORMITY ......................................4 COPYRIGHT NOTICE ..........................................5 SAFETY INSTRUCTIONS –...
  • Page 6 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers User Manual Table of Contents The MAIN MENU ............................................22 The UTILITIES MENU ........................................... 23 CHAPTER 2 – ANALYZER TEST CONFIGURATION & TESTING ..............................25 About this Chapter ............................................. 25 TEST CONFIGURATIONS ..........................................
  • Page 7 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers User Manual Table of Contents AUTO CALIBRATION ............................................54 MASTER RESET ............................................... 55 EJECT SD CARD .............................................. 55 SYSTEM DIAGNOSTICS ..........................................55 TEMPERATURE MEASUREMENTS & CORRECTION ................................... 55 ANALYZER / IBMS INTERACTION ........................................55 CHAPTER 6 –...

  • Page 8: Declaration Of Conformity

    Analyzers User Manual Declaration of Conformity DECLARATION OF CONFORMITY Based on the test results using appropriate standards, the EC1000™ and EC2000™ Handheld Battery Analyzers are in conformity with the following:  Electromagnetic Compatibility Directive 2004/108/EC  Low Voltage Directive 2006/95/EC Conformity is indicated by the CE symbol ( Conformité...

  • Page 9: Copyright Notice

    Reproduction in any manner whatsoever without the written permission of Global Energy Innovations is strictly forbidden. No Warranty. This user manual is being delivered to you “as is” and Global Energy Innovations makes no warranty as to its accuracy or use. Any use of this documentation or the information contained therein is at the risk of the user.

  • Page 10: Safety Instructions - Introduction

    EC2000 Analyzer. ™ ™ The following paragraphs contain information, cautions and warning which must be followed to ensure safe operation and to keep the EC1000 and EC2000 Analyzer in safe condition. WARNING Servicing described in this manual is to be done ONLY by qualified service personnel.

  • Page 11: Safety Precautions

    SAFETY PRECAUTIONS ™ ™ For the correct and safe use of the EC1000 and EC2000 Analyzer, it is essential that both operating and service personnel follow generally accepted safety procedures in addition to the safety precautions specified in this manual. Specific warning and caution statements, where they apply, will be found throughout the manual.

  • Page 12: Caution & Warning Statement

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Caution and Warning Statement CAUTION & WARNING STATEMENT WARNING Used to alert the user to the possibility of performing an incorrect maneuver which could lead to damage or destruction of the equipment or other property.

  • Page 13: Warnings & Other Symbols

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Warnings and Other Symbols WARNINGS & OTHER SYMBOLS Nomenclature and Formatting in this Manual The following safety symbols are used in the Users Manual. Notes, Warnings and Caution Symbols...

  • Page 14: Impaired Safety

    Whenever it is likely that safety has been impaired or compromised, the Analyzer must be turned off. The matter should be referred to a qualified technician. ™ ™ Safety is likely to be impaired if, for example, the EC1000 and EC2000 Analyzer fails to perform the intended procedure or shows visible damage.

  • Page 15: List Of Warnings & Safety Precautions - General Safety Information

    3. Before using the Analyzer, read all instructions and cautionary markings on 1) the Analyzer, 2) the battery and 3) the product that uses the battery. 4. The Analyzer must only be serviced by Global Energy Innovations' approved service center. DO NOT attempt to open the Analyzer.
  • Page 16 2. Use only Global Energy Innovations supplied chargers and cables. 3. Use only replacement battery packs supplied by Global Energy Innovations. 4. Please contact Global Energy Innovations, or your local dealer if you wish to replace the battery pack in your Analyzer. Page 12...

  • Page 17: Unpacking The Analyzer Kit

    Figure 1 shows all standard EC1000 and EC2000 Analyzer Kit parts. For images of optional accessories and replacement parts please refer to the Global Energy Innovations Online Store or contact your local distributor. ™ ™...
  • Page 18 & EC2000 Analyzers Users Manual Unpacking the Analyzer Kit Item Part # Description Quantity EQUIPMENT – EC1000™ KIT (Impedance / Voltage): 8656-1000 8656-1000 EC1000™ Handheld ElectroChemical Battery Analyzer 8600-0004 Kelvin Clips – Standard IBMS™ Companion Software – Free Download 8600-1000 1010-1001...
  • Page 19 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Unpacking the Analyzer Kit 1010-1002 2 GB Mini SD Memory Card EQUIPMENT – OPTIONAL ACCESSORIES 8600-1002 Hard Carrying Case Kelvin Probes - Double Point 8600-0011 8600-0018 Kelvin Probes – Single Point 8600-0016 Kelvin Probes –...
  • Page 20 Extended Warranty – 1 Year Extension 8740-3002 Extended Warranty – 2 Year Extension ™ ™ Table 1. The complete list of standard and options accessories as well as replacement parts, product upgrade and warranty extension options for the EC1000 and EC2000 Analyzers. Page 16...

  • Page 21: Introduction

    Effective management of a battery installation requires timely information not only about which battery units are about to fail but also about the cause(s) of those failures. In aggregate, this information defines the battery state of health (SOH). The EC1000™ and EC2000™ (EC-Series) Analyzers determine SOH from a battery's response to a series of electrical excitation signals.

  • Page 22: Chapter 1 - Initial Analyzer Setup

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 1 – Initial Analyzer Setup CHAPTER 1 – INITIAL ANALYZER SETUP About this Chapter This section describes how to initialize and initial setup the Analyzer so it is ready for setting up test configuration and use in the field. This section starts by reference to the various options that are available in the UTILITIES MENU.

  • Page 23: Setup Methods

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 1 – Initial Analyzer Setup For this reason, the user must either manually enter the required information, or pre-load (via IBMS™) the Analyzer before testing takes commences. Pre-loading (pre-programming) the Analyzer is normally the preferred method of inputting the required information, however, this assumes that the user has prior knowledge of some or all of the information before arriving at the Site where testing will occur.

  • Page 24: Setting Up The Analyzer - Getting Started

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 1 – Initial Analyzer Setup Setting up the Analyzer – Getting Started Powering ON The Analyzer is powered OFF by pressing the green power button as shown in Figure 1.2.1 for several seconds. After the button is pressed, the Analyzer will boot and the welcome splash screen shown in Figure 1.3 will appear.

  • Page 25: Powering Off

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 1 – Initial Analyzer Setup Figure 1.4. Calibration screen. Figure 1.5. Main Menu. Figure 1.6. Confirm power off screen. Powering OFF The Analyzer is powered OFF by pressing the green power button as shown in Figure 1.2 for several seconds. After the button is pressed, a Confirm Power Off screen (Figure 1.6) will show to ensure that the user wants to power the Analyzer OFF.

  • Page 26: The Analyzer Display Screen

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 1 – Initial Analyzer Setup The Analyzer Display Screen The Analyzer has a number of various screen types that display menus, results, calculations, etc... Although these screens vary somewhat in their layout, they all share a number of common elements that the user will grow accustomed to during Analyzer operation.

  • Page 27: The Utilities Menu

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 1 – Initial Analyzer Setup The UTILITIES MENU The Analyzer UTILITY MENU (Figure 1.10) is the first Menu that the user should enter and configure. In this Menu, only the SYSTEM SETTINGS and SYSTEM PROFILE Menus are explored in this section.
  • Page 28 AVAILABLE – The available (remaining) capacity of the Mini SD Card is displayed here. FEATURES Impedance / Voltage – This is the standard EC1000™ feature set for the Analyzer. When this feature is enabled, the Analyzer is capable of testing the electrical properties of batteries only.

  • Page 29: Chapter 2 - Analyzer Test Configuration & Testing

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing CHAPTER 2 – ANALYZER TEST CONFIGURATION & TESTING About this Chapter This section describes how configure the Analyzer and begin testing. Advanced testing functions are not covered in this Chapter. Refer to Chapter 6 (Advanced Features and Function) for details on going beyond basic setup and testing.

  • Page 30: Quick Test Settings (Templates)

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing QUICK TEST SETTINGS (TEMPLATES) We will first cover QUICK TEST SETTINGS because, in the process of running a QUICK TEST, the user will be guided through the most basic setup parameters required for testing a batter or cell.
  • Page 31 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing Figure 2.4. Battery Type Manu (Battery Details) screen. (2) BATTERY TYPE – This screen lets the user enter the BATTERY DETAILS for the battery that is being tested. Figure 2.4 shows the BATTERY TYPE screen.
  • Page 32 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing  # CELLS(S) PER BATTERY: Entry of the number of Cells in the Battery being tested. If a single cell is being tested, this value will be one (1), otherwise the user can manually enter a value from 1 to 31 or use the RIGHT and LEFT navigation buttons to increment or decrement the numeric value.
  • Page 33 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing (9) TEST DRYOUT: The user selects if the Analyzer will run the CELScan™ algorithm for determining the amount of capacity loss due to battery dryout.
  • Page 34 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing  Fail Value: This is the fail value as specified as a percentage measured from the baseline value.  Fail ON/OFF: Allows the user to turn this alarm ON or OFF independent of the other alarms.
  • Page 35 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing  Fail Value: This is the fail value as specified as a percentage.  Fail ON/OFF: Allows the user to turn this alarm ON or OFF independent of the other alarms.

  • Page 36: Company / Region

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing This value is typically calculated using the BASELINE UTILITY in the UTILITIES → TOOLS Menu. Details on the ACF and proper ACF generation procedure, please reference the Chapter 7.
  • Page 37 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing Figure 2.8. Location selection screen. Figure 2.9. String selection screen. Figure 2.10. String configuration screen. When using these three (3) String Configuration screens, the user may selection from a host of function keys (F1, F2, F3 and F4) to save, copy, edit, delete and enter additional information.
  • Page 38 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing (4) BATTERY TYPE – This screen lets the user enter the BATTERY DETAILS for the battery that is being tested. The user can either manually enter the information listed below, create a Template, or select from an existing template.
  • Page 39 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing  POLARITY CORRECTION – This is a predefined selection menu for selecting if the Analyzer will operate with correction ON or OFF. The user selects from the predefined settings using the RIGHT and LEFT navigation buttons.
  • Page 40 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing VOLTAGE ALARMS: Alarms for voltage testing results. The following sub-alarms fall under this section. Default values are shown on the Analyzer when entering this screen.
  • Page 41 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing  Fail ON/OFF: Allows the user to turn this alarm ON or OFF independent of the other alarms. STRAP ALARMS: These are alarms for strap testing results. Default values are shown on the Analyzer when entering this screen.

  • Page 42: Battery Type Templates

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing Details on the methods and technology of the Automatic Baseline Feature on the Analyzer can be found in Chapter 5.

  • Page 43: Test Setting Templates

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing TEST SETTING TEMPLATES When using the TEST SETTING TEMPALTE, the user will the following two (2) screens. When selecting a <NEW> template, the user is prompted to enter the information shown in .
  • Page 44 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing Figure 2.15. Alarm Setting Template screen. Figure 2.16. Alarm Settings screen. Page 40...

  • Page 45: Testing

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing TESTING Now that the use is familiar with configuring the Analyzer, these configurations can now be used for testing. The following section covers how to use either Analyzer or IBMS™...
  • Page 46 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing (3) When a double asterisk (**) is shown next to the test result, this indicates a FAIL Alarm condition. STRING TESTING – This section covers testing using the TEST STRING function.
  • Page 47 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 2 – Analyzer Test Configuration & Testing value. Otherwise, the user may select F1 and return to the previous screen without saving (updating) the baseline. For a complete explanation of the Auto Baseline function as well as Impedance and ACF (Algorithm Calibration Factor) functions, please reference Chapter 5.

  • Page 48: Chapter 3 - Reviewing The Test Results

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 3 – Reviewing the Test Results CHAPTER 3 – REVIEWING THE TEST RESULTS About this Chapter This Chapter shows the user how to review the test results and test settings / configurations that were used during testing.
  • Page 49 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 3 – Reviewing the Test Results Figure 3.1. Various user screens for navigating TEST RESULTS Menu. At most points, data may be deleted. The user is always prompted with a WARNING screen to ensure that the deletion of data was intended.

  • Page 50: Chapter 4 - Connecting The Analyzer To Ibsm™ Software

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 4 – Connecting the Analyzer to IBMS Software CHAPTER 4 – CONNECTING THE ANALYZER TO IBSM™ SOFTWARE About this Chapter This Chapter describes how you connect the Analyzer to IBMS™ (Intelligent Battery Management System™) Software. Once connection is accomplished, please reference the IBMS Users Manual for details on how to transfer and analyze your data using IBMS™.

  • Page 51: Chapter 5 - Advanced Analyzer Features & Funtions

    About this Chapter This Chapter covers all the Advanced Features and Functions of the EC-Series Analyzers (EC1000™ and EC2000™). There is also reference to IBMS™ (Intelligent Battery Management System) Software in this Chapter since there is a great deal of overlap between the two systems.
  • Page 52 Figure 5.1b. IBMS™ baseline adjustment feature.  Relative Degradation – Relative Degradation is Global Energy Innovations’ universal parameter to follow the evolution of battery health based on its Chemical Properties (e.g. CELScan™). Relative Degradation is set such that a 100% level corresponds to a healthy battery.
  • Page 53 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 5 – Advanced Analyzer Features & Functions  Baseline Adjustment – The Baseline cannot be adjusted on the Analyzer during use in the field. Baselines, however, may be adjusted using IBMS™...
  • Page 54 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 5 – Advanced Analyzer Features & Functions 3. Drag the blue line in the Adjustment Utility Graph: By dragging the blue line up or down, the Updated ACF box Value, percentage will be updated accordingly.

  • Page 55: Repeatibility Utility

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 5 – Advanced Analyzer Features & Functions Warning: Since the Baseline Test is done on a single battery or cell, it is strongly recommended to use the BASELINE UTILITY only in particular circumstances where the Autobaseline function cannot be used.

  • Page 56: Battery Replacement Utility

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 5 – Advanced Analyzer Features & Functions (3) AUTO – This setting will automatically set the Analyzer to the best setting it can based on signal processing and data analysis.
  • Page 57 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 5 – Advanced Analyzer Features & Functions or cell may be selected. For example, if 10 was selected, but there were only 5 batteries in the string (Battery 1, 2, 3, 4, 5), an error screen would show prompting the user to select a valid battery number.

  • Page 58: Auto Calibration

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 5 – Advanced Analyzer Features & Functions TESTING in the BATTERY REPLACEMENT UTILITY screen. More details on the use of IBMS™ Battery Replacement functions can be found in the IBMS™ Users Manual.

  • Page 59: Master Reset

    Battery or Cell temperature is best taken by measuring the temperature of the Positive or Negative terminal. Please reference the Fluke Model 62 Infrared Thermometer data sheet on the Global Energy Innovations' website for details on using the thermometer (http://www.globalei.com/bms/accessories-replacement-parts/infrared-thermometer.html).
  • Page 60 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 5 – Advanced Analyzer Features & Functions Whenever connecting to IBMS, you must first navigate to the CONNECT TO PC at the MAIN MENU and select this function. This puts the Analyzer in its communication mode so that it is ready to communicate with a Personal Computer (IBMS) via the USB port.

  • Page 61: Chapter 6 - Troubleshooting

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Chapter 6 – Troubleshooting CHAPTER 6 – TROUBLESHOOTING About this Chapter This Chapter covers troubleshooting for the Analyzer. The various sections covers various common problems that you might encounter and how to resolve these problems.

  • Page 62: Analyzer Specifications

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Analyzer Specifications ANALYZER SPECIFICATIONS Page 58...
  • Page 63 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Analyzer Specifications Page 59...
  • Page 64 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Analyzer Specifications Page 60...
  • Page 65 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Analyzer Specifications Page 61...
  • Page 66 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Analyzer Specifications Page 62...
  • Page 67 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Analyzer Specifications Table AS-01. Analyzer technical specification and product images Page 63...

  • Page 68: Index

    Firmware ............1 ANALYZER SETUP ......... 18 CELSCAN ALARMS ........30, 36 Firmware Update Error ........57 AUTO CALIBRATION ........54 CELScan™ – Sulfation / Dryout: EC1000™ FIRMWARE UPGRADES ........ 57 Upgrade ............16 AUTO SHUTDOWN ......... 23 Flooded ............27, 34 CELScan™...
  • Page 69 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Index MAIN MENU ............ 22 Repair ..............ii IBMS ............17, 46 MANUFACTURER ........27, 34 REPEATABILITY UTILITY ......51 IBMS™ BASELINE ADJUSTMENT ....47 MASTER RESET ..........55 REPEATIBILITY UTILITY ........
  • Page 70 ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Index Sulfation / Dryout ..........24 TEST START ........... 28 USE AUTO-CALC BASELINE ......47 SUPPORT ............24 TEST SULFATION ........28, 37 UTILITIES MENU ..........18 Synchronization of the Clock ......55 TEST VOLTAGE ........

  • Page 71: Appendices

    ™ ™ Global Energy Innovations – EC1000 & EC2000 Analyzers Users Manual Appendices APPENDICES [NONE] Page 67...

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