Summary of Contents for Power Designers PowerTrac SP Series
- Page 1 PowerTrac SP PTSP 24-84V Operation and Installation Manual Ver. 1.1 Battery Management Solutions by...
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Page 2: Table Of Contents
TABLE OF CONTENTS SAFETY......................1 DEFINITIONS AND ABBREVIATIONS ............3 PRODUCT DESCRIPTION................4 TECHNICAL SPECIFICATIONS ..............6 PROCEDURE FOR INSTALLATION AND OPERATION ......7 ..................7 ACKAGE ONTENT SP I ............10 OWER NSTALLATION ROCESS 5.2.1 Sealed Battery ..................10 5.2.1.1 Shunt Mounting.................. - Page 3 LIST OF FIGURES Figure 1: PowerTrac SP block diagram ..............4 Figure 2: PowerTrac SP package ................7 Figure 3: Close up top view of the PowerTrac SP unit..........8 Figure 4: PowerTrac SP leads ................... 8 Figure 5: Bolt-On shunt....................9 Figure 6: Clamp-On shunt..................
- Page 4 Figure 44: Record Menu ..................43 Figure 45: Records List Screen ................44 Figure 46: Settings Screen ..................45 Figure 47: Administration Screen................46 Figure 48: Password Screen..................47 Figure 49: “Battery Info” Screen................48 Figure 50: “Battery Summary” Screen ..............48 Figure 51: “Curr Event Info”...
- Page 5 LIST OF TABLES Table 1: PowerTrac Tool Bar Icons................21 Table 2: Batt Settings Screen Parameters............... 23 Table 3: Admin Settings Screen Parameters ............26 Table 4: Chart Selection Options ................35 Table 5: PowerTrac Report - Event Summary Data..........38 Table 6: PowerTrac Report - Battery Settings Data ..........
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Page 6: Safety
SAVE THESE INSTRUCTIONS -- This manual contains important instructions for PowerTrac SP series product line that shall be followed during installation and maintenance of the charger. Before attempting to install and begin charging with PowerCharge, please read this manual. - Page 7 Federal Codes: 29CFR1926.441 "Safety Requirements for Special Equipment" 29CFR1910.151(c) "Medical Services and First Aid" 29CFR1910.305(j) "Wiring Methods, Components and Equipment" STD 1-8.2(e) "OSHA Standing Directive" PoweTrac SP ©...
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Page 8: Definitions And Abbreviations
2. Definitions and Abbreviations The following abbreviations and abbreviations are used extensively throughout this document. Amp-Hours. This is a measure of energy in the battery system. It is a simple accumulation that assumes 1 amp for 1 hour is equal to 1 Ahr. Battery Pack Individual cells configured in a series connection. -
Page 9: Product Description
3. Product Description PowerTrac SP is a battery-monitoring system designed specifically to meet the needs of motive and stationary batteries. PowerTrac SP monitors and logs various data of interest including battery voltage, battery temperature, and battery current. A conventional current shunt is used to provide continuous battery current sensing. The PowerTrac SP is equipped with an Infra Red (IR) port for wireless interface through PDA devices, such as a Palm Pilot. - Page 10 In addition, the PowerTrac SP stores out-of-bounds conditions such as over-voltage, over-current, and over-temperature during charge and discharge events. A host device can communicate with the PowerTrac SP via the infrared (IR) interface. An optional isolated RS-232 interface can be also provided. This communication with the host is exclusive: it allows for only one host and one PowerTrac SP.
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Page 11: Technical Specifications
4. Technical Specifications Nominal Battery Voltage Rating 12V – 84V Operational Voltage Range 10V – 120V Voltage Resolution ± 50mV Operating Temperature Range C – 60 ± 1.0 Temperature Resolution Operating Current Draw < 50mA at 12V Current Resolution ± 1% Interface IR port RS232 (optional) -
Page 12: Procedure For Installation And Operation
5. Procedure for Installation and Operation 5.1 Package Content The PowerTrac SP package should contain the following items (Figure 2): 1 PowerTrac SP unit 1 Shunt: Clamp-On or a Bolt-On (per your order) 1 Shunt cover 1 CD: includes Windows & Palm S/W as well as the user’s manual 1 Quick Installation and Reference Guide manual 1 Clamp-On installation kit (for Clamp-On shunts) 2 Corrosion prevention felt washers (flooded batteries... -
Page 13: Figure 3: Close Up Top View Of The Powertrac Sp Unit
A close up of the PowerTrac SP module is shown in Figure 3. The IR receiver is accessed through the clear plastic cover shown in Figure 3. IR Window Figure 3: Close up top view of the PowerTrac SP unit The PowerTracSP unit has two battery voltage/power supply terminals/leads (separate leads), two current shunt leads (twisted and sleeved), and one temperature lead as shown in Figure 4. -
Page 14: Figure 5: Bolt-On Shunt
as shown in Figure 5. For a flooded battery, a Clamp-On shunt is included as shown in Figure 6. Figure 5: Bolt-On shunt Figure 6: Clamp-On shunt PoweTrac SP ©... -
Page 15: Powertrac Sp Installation Process
5.2 PowerTrac SP Installation Process Read the entire manual before installing or operating the unit. Make sure that you understand the functionality and operation of unit before connecting it to the battery. There are no user serviceable parts inside enclosure, and any attempt to service those parts may void any applicable warranties. -
Page 16: Powertrac-Sp Module Mounting
5.2.1.2 PowerTrac-SP Module Mounting 1. Locate a convenient area between cells where module will fit securely without protruding above the intercell connectors, with a clear line to the IR port (the IR window should be accessible, i.e. facing up). 2. Secure the module to intercell connector with nylon wire ties provided, Velcro, or magnetic tape. -
Page 17: Figure 7: Locating The Intercell Connector To Be Replaced
1. Locate the 3” intercell connector closest to the Negative post of the battery. Figure 7: Locating the intercell connector to be replaced 2. Position the shunt with nylon spacers (normally used to position replacement intercell connectors) so it is centered on the battery posts. Figure 8: Locating the intercell connector to be replaced PoweTrac SP ©... -
Page 18: Figure 9: Locating The Punch Holes
3. Using the ¼” transfer punch and hammer transfer a center point into each post. Figure 9: Locating the punch holes Figure 10: Marked punch holes PoweTrac SP ©... -
Page 19: Figure 11: Drilling Off The Intercell Connectors
4. Drill off the intercell connector. Figure 11: Drilling off the intercell connectors 5. Place a fiber washer over the posts. Figure 12: Placing the fiber washers PoweTrac SP ©... -
Page 20: Figure 13: Dropping The Shunt In Place
6. Drop the shunt over the posts and tighten clamp bolts Figure 13: Dropping the shunt in place 7. The hole in the shunt may be larger than the post. If necessary, fill the hole with lead so it flows and fills the entire hole. Figure 14: Filling the holes with lead if needed PoweTrac SP ©... -
Page 21: Powertrac-Sp Module Mounting
5.2.2.2 PowerTrac-SP Module Mounting 1. Drill a hole for #10-32 self-tapping screw on the negative post of the battery. 2. Drill a hole for #10-32 self-tapping screw on the positive post of the battery 3. Drill a hole for #10-32 self-tapping screw on the innermost cell connector. 4. -
Page 22: Figure 15: Powertrac Sp Installed
Failure to disconnect in this order may damage the module. Clamp-On Shunt PowerTrac SP Figure 15: PowerTrac SP installed PoweTrac SP ©... -
Page 23: Software Installation And Operation
6. Software Installation and Operation 6.1 Minimum System Requirements Windows Operating systems: 98, Me, 2000, XP, NT Minimum free disk space: 20MB Communication port: One serial Port Required pre-installed S/W Microsoft Excel Palm Operating systems 3.5 and above Communication Serial interface Notes: 1. -
Page 24: Figure 16: Installation Files Window
Figure 16: Installation Files Window The installation procedure has been successful if you are able to see the “PowerTrac” icon on the handheld desktop as shown in Figure 17. Figure 17: PowerTrac Software Icon PoweTrac SP ©... -
Page 25: Palm Installation Check
6.2.1 Palm Installation Check To verify proper installation, do the following: 1. Start the Palm application by clicking on the “PowerTrac” program icon on the Palm desktop as shown in Figure 17. 2. Aim the Palm device towards PowerTrac SP IR port and tap the “Quick Look” button at the bottom of the screen. -
Page 26: Powertrac Sp Setup
Exit Program Print PowerTrac-SP Open Database Connection Report Palm Connection Figure 19: PowerTrac Windows Startup Screen Table 1 shows a brief description of the tool bar icon buttons at the top of the screen. Table 1: PowerTrac Tool Bar Icons Parameter Action Open Database... -
Page 27: Figure 20: Powertrac Menu Bar - Selecting Batt Settings Submenu
1. Start the Palm application by clicking on the “PowerTrac” program icon on the Palm home screen (Refer to the Installation Check procedures shown earlier) 2. Tap the “PowerTrac” label at the top of the screen. A menu bar will appear with “Connection”, “Record”... -
Page 28: Table 2: Batt Settings Screen Parameters
Table 2: Batt Settings Screen Parameters Parameter Action Battery Enter a unique battery name. It is used to distinguish the data that will be collected from PowerTrac SP. The battery name can consist of characters and numbers. Number of Cells Enter the number of cells of your battery Nominal Voltage Enter the nominal voltage of your battery... -
Page 29: Setting Powertrac Configuration Parameters
Figure 22: Saving Battery Settings 6.4.2 Setting PowerTrac Configuration Parameters 1. Tap the “PowerTrac” label at the top of the screen. A menu bar will appear with “Connection”, “Record” and “Help” pull down menus and shown in Figure 23. Figure 23: PowerTrac Palm Menu Bar – Selecting Admin Settings Submenu 2. -
Page 30: Figure 24: Powertrac Palm Admin Settings Screen
Figure 24: PowerTrac Palm Admin Settings Screen 4. The PalmOS device screen should now show factory pre-set data for each of the configuration parameters as shown in Figure 25. Figure 25: Admin Settings Screen - Saving Battery Settings The user can now view and set a number of configuration parameters as explained in Table 3. -
Page 31: Table 3: Admin Settings Screen Parameters
Table 3: Admin Settings Screen Parameters Parameter Action Battery Battery name as set previously (see Batt Settings screen parameters) Factory ID Factory assigned battery ID. This value is not field programmable. Warranted Ahrs Enter the Ahrs warranted by the battery OEM Installation Date Enter the installation date of the unit Installation Time... -
Page 32: Data Acquisition
Once all parameters are set, at close proximity, aim the Palm device at the IR port on the PowerTrac-SP module and tap the “Save” at he bottom of the screen. As before, you will be prompted for a password. Enter the default password “0000”... -
Page 33: Figure 27: Downloading Events File - Password And Progress Screens
Tap the “Proceed” button to transfer data to your Palm. The “IR Download in progress” screen will appear as shown in Figure 27. Figure 27: Downloading Events File - Password and Progress Screens Once download is complete, a screen showing all the downloaded files will appear as shown in Figure 28. -
Page 34: Viewing Palm Summary Data
6.5.2 Viewing Palm Summary Data There are two summary screens that can be easily accessible from the palm main screen. These are the Battery Status and Battery Summary screens. To view these screens, follow these steps: Select a file from the list of files listed in the PowerTrac main menu by first highlighting the file as shown above. -
Page 35: Viewing Palm Detailed Data
The Battery Summary screen lists the accumulated battery data since installation. These include: Installation date and time Total amp-hours of charge and discharge since installation Hours of charge and discharge since installation Events counter (total events logged since last time events were cleared). 6.5.3 Viewing Palm Detailed Data There are three additional data screens that can provide users with additional... -
Page 36: Figure 31: Pam Pc Connection Menu - Pc Transfer
On your PC, exit from the Hot Sync software, as it will hold the COM port, and start the PowerTrac software. On your Palm, press the “PowerTrac” menu button and select the “Connection” menu at the top of the screen as shown in Figure 31. Figure 31: Pam PC Connection Menu –... -
Page 37: Figure 33: Powertrac Windows Menu Bar - Palm Connection
Figure 33: PowerTrac Windows Menu Bar – Palm Connection A dialog box will appear as shown in Figure 34. The user can set the port number (default is 1) and the port speed (default is 115200). Figure 34: PowerTrac Windows Connection Screen Click the “Connect”... -
Page 38: Figure 35: Powertrac Windows File Download Screen
Figure 35: PowerTrac Windows File Download Screen Select the files to be downloaded and hit the “Get File List” button. These files will then be loaded into the PowerTrac Windows database as shown in Figure Figure 36: PowerTrac Database Files PoweTrac SP ©... -
Page 39: Building Charts & Generating Reports
Note: All files having the same name with an “underscore” suffix refer to subsequent downloads from the same battery. Once these files are downloaded into the PowerTrac Windows database, they will be combined into a single file name corresponding to that specific battery as shown in Figure 36. 10. -
Page 40: Figure 37: Powertrac Chart Selection Screen
Figure 37: PowerTrac Chart Selection Screen Table 4: Chart Selection Options Parameter Action Max Voltage Builds a bar chart that shows the maximum voltages for all Charge charge events that occurred during the selected time interval Min Voltage Builds a bar chart that shows the minimum voltages for all Charge discharge events that occurred during the selected time interval Event Voltage... -
Page 41: Generating Reports
A sample chart showing the minimum battery voltage recorded over a period of two months is shown in Figure 38. The chart shows that the minimum battery voltage kept decreasing until the battery was charged on 3/5/02. Discharge events following the charge event have sharply higher minimum event battery voltages. -
Page 42: Figure 39: Generating Reports Screen
Figure 39: Generating Reports Screen 2. Hit the “Report” button at the bottom of the screen. A report window will appear as shown in Figure 40. Figure 40: A Sample Report PoweTrac SP ©... -
Page 43: Table 5: Powertrac Report - Event Summary Data
Each report has three sections: 1. Event Summary: summarizes the events in the database for the user selected time interval. Table 5 lists the data reported in the event summary section. Table 5: PowerTrac Report - Event Summary Data Parameter Description Total Ahr Charge Total amp-hours of charge of all the events within the... -
Page 44: Table 6: Powertrac Report - Battery Settings Data
2. Battery Settings: shows the most recent settings of the PowerTrac SP module. Table 6 lists all of the data reported. Table 6: PowerTrac Report - Battery Settings Data Parameter Description Battery ID The user programmed battery ID (name) Factory ID Factory installed battery ID Number of Cells Number of cells in the battery... -
Page 45: Browsing Events
3. PowerTrac SP Battery Lifetime Accumulated Summary: shows a summary of the PowerTrac accumulated parameters since installation. Table 7 lists all of the data reported. Table 7: PowerTrac Report – PowerTrac SP Lifetime Accumulated Summary Parameter Description Battery ID The user programmed battery ID (name) Factory installed battery ID Factory ID Amp Hours of Charge... -
Page 46: Figure 41: Browsing Events Window
Figure 41: Browsing Events Window 3. Select the events to display then click the “Show Events” button to display the event table as shown in Figure 42. Figure 42: A Sample Events Table PoweTrac SP ©... - Page 47 Note: The event table will contain events that occurred in the selected time interval. 4. The event table can be saved as a comma delimited file (CSV) file or it can be transferred to Excel by selecting the “Data” menu then the ” Export Events to Excel”...
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Page 48: Palm Menu Descriptions
6.7 Palm Menu Descriptions Connection Menu: The “Connection” menu shown in Figure 43 has the following selections: “PC Transfer” submenu initiates transfer of the stored battery data file(s) to the PC for analysis “Batt Settings” submenu is used for initial set-up of the PowerTrac-SP module “Admin Settings”... -
Page 49: Palm Screen Descriptions
6.8 Palm Screen Descriptions PowerTrac Main Screen: The PowerTrac main screen is shown in Figure The first column shows the filename where the battery events are stored. The filename will be the same as the battery ID. If two or more files from the same battery ID exist in the system then the second file name will contain the battery ID plus underscore ‘number’... -
Page 50: Figure 46: Settings Screen
The Batt Settings screen shown in Figure 46 allows users to program the following parameters: Battery – Enter a unique battery name. It is used to distinguish the data that will be collected from PowerTrac SP Present Date: Enter the date of installation Present Time: Enter the time of installation Number of Cells –... -
Page 51: Figure 47: Administration Screen
The Administration screen shown in Figure 47 allows users to program the following parameters: Battery ID: User defined battery name (see Batt Settings screen) Factory ID: PowerTrac-SP factory ID Warranted Ahr - Enter the battery warranty in Amp Hours Install Date and Time – Enter the PowerTrac SP installation date and time Open Delay –... -
Page 52: Figure 48: Password Screen
The Password screen shown in Figure 48 allows users to program the their own passwords Enter the old password (if the default, use “0000”) first and enter your new password next Click the “Change” button to make the password change. If you loose your password, call PowerDesigners with your Factory ID. -
Page 53: Figure 49: "Battery Info" Screen
Battery Info Screen – Record Menu: The Battery Info screen shown in Figure 49 displays the following battery parameters: Battery: Customer assigned battery name Factory ID: PowerTrac-SP factory ID Number of cells: number of cells in the battery (2V cells) Nominal Voltage: nominal battery voltage Nominal Capacity: nominal battery Amp-hour capacity... -
Page 54: Figure 51: "Curr Event Info" Screen
The Current Event Info screen shown in Figure 51 displays the following unit settings: Battery: Customer assigned battery name Event Type: Type of present event or state of the battery Event Start Date: Start date of the present event Event Start Time: Start time of the present event Max Event Volt: Maximum voltage for the present event that has been logged thus far... -
Page 55: Figure 52: "Powertrac Settings" Screen
PowerTrac Settings Screen – Record Menu: The PowerTrac Settings screen shown in Figure 52 displays the following settings: Battery: Customer assigned unique battery name Factory ID: PowerTrac-SP factory ID High Volt Alarm: The high voltage alarm set point above which an over voltage alarm is logged Low Volt Alarm: The low voltage alarm set point below which an over voltage alarm is... -
Page 56: Troubleshooting
7. Troubleshooting The following is a summary of the most common errors encountered while using PowerTrac SP. 1. After installing the PowerTrac SP, neither the nor the green LEDs are on. Possible Causes: and/or BLACK single wires are not properly connected. Ensure that both wires are properly connected and firmly bolted to the positive and negative posts, respectively. -
Page 57: Figure 53: Communication Timeout Error
Figure 53: Communication Timeout Error 4. The PalmOS PDA receives an invalid response from the PowerTrac-SP module. A line error pop-up dialog appears as shown on Figure 54. Possible Causes: There is a source of infrared noise such as luminescent light, computer IRDA devices or LCD screens. -
Page 58: Figure 54: Line Error
Figure 54: Line Error 5. The PowerTrac-SP communication process error protected incorporating a Cyclic Redundancy Check code (CRC) in every data packet that is transmitted. The PalmOS handheld device is verifying the calculated CRC code from the received data with the CRC code calculated from the PowerTrac-SP module. -
Page 59: Figure 55: Crc Error
Figure 55: CRC Error 6. The communication protocol that is used in the PowerTrac-SP system is request – response base. This means the devices (PowerTrac-SP module and PalmOS handheld device) are not sending any data through their IR ports unless there is a request for that from the user. For example if an user wants to obtain a “Quick Look”... -
Page 60: Figure 56: Not Acknowledged (Nak) Packet Received Error
Figure 56: Not Acknowledged (NAK) packet received Error PoweTrac SP ©... -
Page 61: Warranties
8. Warranties PowerDesigners, LLC (“PD”) hereby warrants its PowerTrac SP battery data logger (the “Product”) pursuant to the following terms and conditions: 1. PD warrants the Product against any defects in materials and workmanship for a period of one (1) year commencing on the date of purchase of the Product (the “Warranty Period”);... -
Page 62: Contacting Powerdesigners
9. Contacting PowerDesigners Calls are answered 9 a.m. – 5 p.m. Monday – Friday central time. After hour calls will be answered by voice mail and returned on the next business day. Phone: +1.608.231.0450 All mail, including shipping and returns can be sent to our office address: PowerDesigners, LLC 931 E. -
Page 63: Powertrac Sp Software License Agreement
PowerTrac SP Software License Agreement License agreement for: PowerTrac Windows Software and PowerTrac Palm Software This license agreement is a legal agreement between you (either an individual or a single entity) and the author of this software package (PowerDesigners, LLC, Middleton, WI).
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