PTSP+ 12-84V

Pocket PC Reference Guide

4005 Felland Road, Suite 116 Madison, WI 53718 USA © Power Designers USA LLC

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TABLE OF CONTENTS

SYSTEM REQUIREMENTS .................................................................................................. 1 POWERTRAC™ SP+ SETUP ................................................................................................. 2 Using PowerTrac™ SP+ Pocket PC Software..................................................................... 15 DATA ACQUISITION ........................................................................................................ 26 TROUBLESHOOTING ....................................................................................................... 27 SOFTWARE LICENSE AGREEMENT ................................................................................... 31 CONTACTING POWER DESIGNERS USA ............................................................................ 32

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SYSTEM REQUIREMENTS Minimum System Requirements Windows® Operating systems: Communication port: Required preinstalled:

Pocket PC Operating systems:

Communication:

XP, Windows Vista®, Windows® 7 One serial or USB port .NET Framework 2.0 or greater Microsoft ActiveSync® Version 4.5 for Windows® XP or Windows® Mobile Device Center Version 6.1 for Windows Vista® or Windows® 7

Windows® Mobile 2003, Windows® Mobile 5.0 and above Pocket PC cable/cradle, IR

Reference Documents and Notes The PowerTrac™ SP+ requires setup and calibration before operation. A separate Installation and Reference Guide covers installation of the PowerTrac™ to the battery. A separate Software Reference Guide covers the desktop utilities for data analysis and reporting. This reference guide is for use in programming the PowerTrac™ and is for use only after the software for the desktop and Pocket PC has been installed and communications verified. The following manuals are listed for reference: Installation and Reference Guide

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Software Reference Guide

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POWERTRAC™ SP+ SETUP Setting Battery Parameters Before using the PowerTrac™ SP+ battery data logger, the battery specific parameters MUST be set. 1. Start the Pocket PC application by selecting the Start PowerTrac program icon on the Pocket PC home screen. Select the Setup menu at the bottom left corner of the screen, and then Settings.

2. Select Scan, and the Settings screen appears.

3. On the Settings screen, ALL PARAMETERS MUST BE SET. Set these parameters to match the specific battery ratings and location. Incorrect settings can affect recorded data. NOTE: It is not necessary to keep the Pocket PC device aligned with the PowerTrac™ InfraRed (IR) window while entering the various parameters.

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4. Align the Pocket PC device with the IR window of the PowerTrac™ and select the Save button at the bottom of the screen. Continue to hold the alignment. When the data transfer is complete, a confirmation window appears. If prompted for a password: the default password is “0000,” but may be changed via the password function in the Admin menu. Select the Proceed button to transfer data to the PowerTrac™. 5. To verify the new settings, select the Clear Screen button then select the Scan button while aligning the Pocket PC device with the IR window of the PowerTrac™. The settings of the battery data logger are displayed. 6. Select the Close button when complete. Parameter

Description

Default Value

Battery ID

A unique battery name to be programmed. The Battery ID can consist of no more than 12 characters and/or numbers.

AAA…AAA

Plant ID

A unique plant name to be programmed. The Plant ID can consist of no more than 12 characters and/or numbers.

PPP…PPP

Truck ID

A unique truck name to be programmed. The Truck ID can consist of no more than 12 characters and/or numbers.

TTT…TTT

Nominal Voltage

The nominal voltage of the battery.

48 (V)

Nominal Capacity

The nominal capacity in amp-hours.

500 (Ahrs)

Number of Posts1

The number of negative posts (intercell connectors) per cell of the battery.

Shunt Size

The current size used (e.g., 500 for 500 A shunt). Must be 50 mV type.

Present Date

Present date. Verify after installation.

Present Real Date

Present Time

Present time. Verify after installation.

Present Real Time

Install Date

The installation date of the unit. Need to set after installation.

Date of Factory Test

Batt MFG Date

Date battery was manufactured. Must be set for accurate SOC reporting.

Date Battery Produced

1 500

1. NOTE: If more than one negative post exists per cell, and since the shunt will replace only one intercell connector, the total battery current is computed by multiplying the measured current by the number of posts. PERFORMING THE SHUNT CALIBRATION PROCEDURE IS REQUIRED TO ENSURE AN ACCURATE CURRENT READOUT.

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Setting Alarm Parameters 1. Return to the file list then select View Files. 2. Select the Setup menu and then select Alarms.

3. Select Scan and the Alarms screen appears.

4. Enter the desired values in the spaces next to the alarms, and then align the Pocket PC device with the IR window of the PowerTrac™ SP+ and select the Save button. A confirmation message appears.

5. To verify the new settings, select the Clear button then select the Scan button while aligning the Pocket PC device with the IR window of the PowerTrac™. The present alarm settings of the battery data logger are displayed. 6. Select the Close button when complete.

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Parameter

Description

Default Value

High Temp Alarm [F]

Battery high temperature alarm point above which a high temperature alarm is displayed and logged. This setting also triggers the Over Temperature (OT) relay if the PowerTrac™ is equipped with this feature. Battery high voltage alarm point above which a high-voltage alarm is displayed and logged.

140 (°F)

High Volt Alarm [VPC] Low Volt Alarm

High Curr Alarm [A] OT Relay On [F] / OT Relay Off [F] UV Relay Off VPC

Battery low voltage alarm point below which a low voltage alarm is displayed and logged. This value also triggers the Under Voltage (UV) relay if the PowerTrac™ is equipped with this feature. Battery high current alarm point above which a high current alarm is displayed and logged. If the PowerTrac™ is equipped with the optional relays, the High Temp Alarm is the relay ON value and Low Temp Alarm is the relay OFF value. If the PowerTrac™ is equipped with the optional relays, the Low Volt Alarm is the relay ON value and this setting is the relay OFF value.

EL Sensor Enable

Electrolyte sensor monitor: 0 = disabled, 1 = enabled

EL Sensor Delay

The time delay during which the electrolyte level must be low in order to record and display a low electrolyte alarm. This is to reduce false alarms due to splashing.

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2.60 (VPC) 1.70 (VPC)

1000 (A) On 140 (°F) Off 131 (°F) 1.9 (VPC)

0 (disabled) 120 (seconds)

Shunt Calibration and Zeroing—REQUIRED!!! Although each PowerTrac™ SP+ is calibrated at the factory, it is not calibrated with the shunt used in the installation. The shunt-calibration procedure is required for the greatest accuracy in measuring current and calculating amp-hours and state of charge. If the battery has more than one intercell connector, the shunt only replaces one of these connectors. The current will not divide equally between the remaining intercell connector(s) and the newly installed shunt. Three-post battery (three intercell connectors)

Battery with three intercell connectors 1. From the file list, select Setup, then Calibration.

2. A new window appears for use in calibrating the battery data logger.

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Shunt Zeroing To attain the greatest accuracy, it is necessary to first remove any offset current that may be present. 1. With no current into or out of the battery, select the Read Current button to read the present battery current as reported by the PowerTrac™ SP+. 2. If the current is not zero but less than 10 A (+ or -), align the Pocket PC with the IR window of the PowerTrac™ and select the Zero Shunt button. 3. An acknowledgment window appears confirming that the shunt was zeroed. 4. Proceed to shunt calibration. NOTE: If the current readout is greater than 10 A while no current is flowing, the zero-shunt procedure will not work. In this event, verify the shunt installation, then remove power from the battery data logger and wait at least 15 minutes before reapplying power and again reading the zero current value.

Shunt Calibration To calibrate the shunt, a known current must be passed through the battery by charging or discharging the battery.

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1. Discharge or charge the battery with a measured current. The current should be a typical charging or discharging current for the selected battery. 2. Align the Pocket PC device with the IR window and select the Read Current button to read the present battery current as reported by the PowerTrac™ SP+. 3. Use the clamp-on meter to measure the total battery current and enter the value on line 2. Always enter the measured battery current as a positive number. 4. Select the Calc Calibration button. “Current Correction Factor” is displayed. 5. Align the Pocket PC and the IR window on the PowerTrac™ and select the Calibrate button. Once the calibration is complete, an acknowledgment window appears. 6. To verify calibration, select the Read Current button and confirm the displayed value is within 2% of the clamp-on meter reading. If it is not, select the Clear Calib button and perform the calibration procedure again.

Changing Passwords 1. To change the default password go to the file list, then View Files; select the Admin menu at the bottom of the screen, and then Passwords.

2. A window appears; enter the new password.

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3. Type in the old and new passwords then select the Change button while aligning the Pocket PC and the IR window of the PowerTrac™ SP+. A confirmation window appears confirming the new password has been accepted. The default password is “0000.” NOTE: If the password is forgotten, record the Factory ID found in the window on the back of the enclosure and call Power Designers USA LLC to obtain a new password.

Setting PowerTrac™ SP+ Parameters The advanced setup submenu parameters should not be altered unless the use and operation of each parameter is thoroughly understood. 1. From the file list View Files, select the Admin menu at the bottom of the screen and then Advanced Setup.

2. Select Scan to view existing settings and enter desired values in the spaces next to the settings. 3. Align the Pocket PC device with the IR window of the PowerTrac™ SP+ and select the Save button.

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Parameter

Description

OpenCD Delay

The delay time from an open circuit state to a charge or discharge mode. NOTE: A new charge/discharge event will only be recognized if it lasts for a period of time longer than the Open Delay.

CDOpen Delay

The delay time from a charge or discharge state to an open circuit state. NOTE: A new open circuit event will only be recognized if charging/ discharging stops for a period of time longer than the COpen Delay or DOpen Delay.

CDDC Delay

The delay time from a charge or discharge state to an inverse (discharge or charge) circuit state. NOTE: A new circuit event will only be recognized if the direction of current flow reverses for a period of time longer than the CDDC Delay.

Open Circ Limit

The current level below which the battery is considered to be in open circuit state. NOTE: This limit is used by the PowerTrac™ SP+ to detect the onset of charge, discharge, and open circuit events.

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Default Value 5 (seconds)

600 (seconds)

30 (seconds)

10 (A) (Minimum recommended value: 1% of shunt rating)

Setting Charge Parameters When a PowerTrac™ SP+ with RS-485 communications is used in conjunction with a Power Designers battery charger, the PowerTrac™ sets the charger to the appropriate parameters used during the battery charge. 1. From the file list View Files, select the Admin menu at the bottom of the screen, then Charge Parameters.

2. Select Scan to view the existing parameters in the PowerTrac™ or enter the desired values in the spaces next to the settings.

3. Align the Pocket PC device with the IR window of the PowerTrac™ and select the Save button.

Charge Parameter Definitions When used with the Power Designers battery charger and RS-485 communications, all of the charge parameters may be programmed into the PowerTrac™ SP+. The PowerTrac™ adjusts the charger to the connected battery parameters.

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Trickle Voltage (TV) Trickle Voltage—Voltage limit used to ensure an excessively discharged battery will not be subjected to a high current charge. Trickle Current (TC) Trickle Current—A low current used to bring an excessively discharged battery to a level where a more aggressive charging current may be used. Constant Current (CC) CC Current—When the charger determines the battery is ready for the CC charge, the charger starts the CC charge at the CC current until the CV voltage is reached (~50% SOC). Constant Voltage (CV) CV Voltage—During a charge, when the CC charge is running, the battery voltage climbs slowly. When the CV voltage value is reached, the CC charge stops and the CV charge starts. The CV charge holds a constant voltage allowing the current to decrease to the CV finish current, which terminates the charge. CV Finish Current—The CV charge continues to run until the charger current decreases to this value. Finish Finish Voltage—During the finish charge the voltage will rise and the battery will theoretically reach 100% SOC. The finish charge terminates when the battery voltage reaches the finish voltage. Finish Current—This is the CC rate during the finish charge. Finish Each Cycle Always—Battery will have finish charge each cycle. Custom—Selected on one or more days as the application requires. Equalize (EQ) Equalize Voltage—An equalize charge is an intentional overcharge to bring all of the cells to the same voltage. The equalize charge terminates when the battery voltage reaches this limit. Equalize Current—This is the maximum constant current delivered by the charger during an equalize charge.

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The following image illustrates the various charge modes for a typical charge cycle.

Finish voltage

Equalization voltage

CV

VB VB ,

Trickle voltage

Ich

CC

Ich

Trickle current

Trickle

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CV

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CC finish current Equalization current

Finish Equal.

t

USING POWERTRAC™ SP+ POCKET PC SOFTWARE Pocket PC/PowerTrac™ SP+ Operation Start the PowerTrac™ SP+ application by selecting the icon indicated.

File List Selecting the View Files button opens the events file list.

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Files are saved in the downloaded order using the Battery ID as the file name followed by the date of download and the number of events in the file. Present Status Quick Look To obtain present status of the battery, align the Pocket PC and the IR window and select the Quick Look button. This opens the Battery Status screen.

Battery Summary The battery summary screen is accessed from the Battery Status screen after performing a quick look.

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Downloading Events Download stored events from the PowerTrac™ SP+ to a Pocket PC. 1. Perform a quick look, then select the Download button.

2. Select the Proceed button to download data. The downloaded file appears in the file list.

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NOTE: To erase all saved events in the PowerTrac™ after the download is complete, check the Erase events check box before selecting Proceed.

Real Time Data Files Selecting the Real Time Data Files button opens the real time data file list.

Files are saved in the downloaded order using the Battery ID as the file name followed by the date of download and the number of events in the file.

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Downloading Real Time Data Downloading real time events from the PowerTrac™ SP+ to a Pocket PC. 1. Perform a quick look, then select the Download button.

2. Select the Real Time Data button and select the Proceed button to download data. The downloaded file appears in the real time data file list.

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Battery Information The battery info page is accessed either by using the button on the file list, the real time data file list, or from the info submenu Battery Info.

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Deleting Files from the Pocket PC File List The number of files stored in the Pocket PC is limited only by the amount of memory in the handheld device. To free up memory, it may be necessary to delete files occasionally. Deleting files is permanent, therefore it is important to regularly transfer files from the Pocket PC to a PC. 1. From the PowerTrac™ SP+ home screen, select View Files for PowerTrac™ events or Real Time Data Files for PowerTrac™ real time data.

2. Select the file and select the Admin menu at the bottom of the screen. Select Delete File.

3. A Confirmation Alert window appears. Select Yes or No. A Yes answer will permanently delete the file from the file list. A No answer will return to the file list without deleting the file.

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2.2

Erasing Events from the PowerTrac™ SP+ Battery data logger Erasing the events in the PowerTrac™ SP+ is not necessary due to the First-In, First-Out (FIFO) memory-management method. It is possible to delete events on demand. NOTE: This clears the events and does not clear the global registers. 1. Select the Admin menu at the bottom of the screen, and then select Erase Events.

2. A “Confirmation Alert” window appears. Select Yes or No. To erase the events, align the Pocket PC and the PowerTrac™ IR window and select Yes. A No answer will return to the previous screen.

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Battery Information Following a quick look, the battery info page is accessed either by using the button on the file list, real time data file list, or from the info submenu Battery Info.

Viewing Settings The Battery Info submenu reveals the settings of the battery and PowerTrac™ SP+, the current or last event info, and warranty info. 1. Battery Info. Programmed battery parameters.

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2. PowerTrac Settings. Programmed PowerTrac™ battery data logger settings.

3. Current Event Info. This is the event in progress at the time of download.

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4. Warranty Information. Describes battery manufacturer warranty in amp-hours.

Help Menu The About submenu under the Help tab contains copyright information, a description of the software, and the software version number.

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DATA ACQUISITION Transferring Files from the Pocket PC to the PC 1. Connect the Pocket PC to the PC through the USB cable or cradle. 2. Press the synchronize button on the Pocket PC or cradle if auto synchronize is not enabled on the PC. 3. The ActiveSync application launches the PowerTrac™ SP+ software, and the “PowerTrac Sync” window opens. File Names, which starts with RT_, stores Real Time Data

PowerTrac event files.

4. Select the files to download by checking the corresponding boxes and then selecting the Download button at the bottom of the PowerTrac Sync window. A progress bar is displayed. NOTE: The downloaded data files are automatically saved into the default PowerTrac™ Database file “PowerTracSPDB”. 5. Once the download is complete, select the Exit button.

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TROUBLESHOOTING The following is a summary of the most common errors encountered while using the PowerTrac™ SP+ Pocket PC Application. 1. Neither Light Emitting Diode (LED) Lit After installing the PowerTrac™ SP+, neither the red nor the green LEDs are on. Possible Causes  The RED 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 

The inline fuse in the yellow, weatherproof fuse holder may be open. Replace with a two-amp, time-delay 3 AG type fuse



Battery voltage is below ten volts

2. Red LED Illuminated After installing the PowerTrac™ SP+, the red LED is on. Possible Causes  The nominal voltage (e.g., 24, 36, 48, etc.) has not been set. The PowerTrac™ series battery data logger alarms are set on a VPC basis. Set the nominal voltage following the setup instructions. 

The battery voltage is lower than the programmed low-voltage alarm



The battery voltage is higher than the programmed high-voltage alarm



The battery temperature is higher than the programmed high-temperature alarm



The battery current is higher than the programmed high-current alarm



The electrolyte sensor is enabled without an electrolyte sensor present



The battery electrolyte level is low

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3. Communication Timeout Error The Pocket PC device requested information and did not receive a response from the PowerTrac™ SP+ battery data logger. A communication timeout popup window appears. Possible Causes  The Pocket PC is not aligned at the PowerTrac™ IR port. 

The Pocket PC is too far from the PowerTrac™ IR port.



A barrier exists between the two devices.

4. CRC Error The PowerTrac™ SP+ communication process is error protected by incorporating a Cyclic Redundancy Check (CRC) code in every data packet that is transmitted. Possible Causes  There is a source of infrared noise such as high-bay lighting, fluorescent lighting, computer InfraRed Data Association (IRDA) devices, or Liquid Crystal Display (LCD) screens. 

The handheld Pocket PC OS computer software is not compatible with the PowerTrac™ battery data logger firmware. If any newer software for the PDA has been downloaded, please make sure it is compatible with the PowerTrac™ battery data logger’s firmware revision.

5. NAK Packet Received The communication protocol that is used in the PowerTrac™ SP+ system is request and response based. When a request is sent and no response is received, “not acknowledged” (NAK) is displayed. Possible Causes  This error occurs when the handheld Pocket PC OS computer software is not compatible with the PowerTrac™ battery data logger’s firmware.

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6. The Application Cannot Detect the IR Port The application attempts to detect the IR port automatically. When an IR Port detection failure occurs, it is then necessary to set the port manually.

Possible Causes  The method that the application uses is not working with the operating system or Pocket PC. Troubleshooting a. Set the IR port manually: i. Select OK to close the warning message. The main form loads. ii. Select Port Settings from the bottom of the screen.

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iii.

Port Settings window is displayed. Select the Manual button and select the correct COM port from the pull down menu. It may be necessary to try more than one port.

b. Select Apply. c. Test the infrared communication: i. From a distance of 3–24 inches, align the Pocket PC device and the PowerTrac™ SP+ IR windows and select the Quick Look button in the center of the screen. ii. If a “Communication Problem” error message appears, select another port. iii. There is no associated COM port with the device IR. This indicates that the Pocket PC IR does not support raw IR, or the Pocket PC does not have an IR device. In this case, the IR communication cannot be accomplished. 7. Parse Error This error occurs when transferring data from the Pocket PC to a PC that does not have the latest version of Windows® software installed.

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SOFTWARE LICENSE AGREEMENT This license agreement is a legal agreement between Power Designers USA LLC of Madison, Wisconsin, the author and licensor of the software, and the end user licensee of the software. Installation or other use of this software by the licensee constitutes agreement to all terms and conditions of this license. In the event the licensee does not agree to all terms and conditions of this agreement the software may not be installed or otherwise used. The following terms apply: 1. Licensee may not redistribute any files, including but not limited to any setup or installation files created by this software. 2. Licensee may not disassemble or reverse engineer any part of this software. 3. Licensee may not resell, rent or lease the software. 4. Licensor owns all rights in the software including any incorporated images or text. 5. Should the licensee fail to comply with any terms or conditions of this agreement this agreement will immediately and automatically terminate without notice. 6. The licensor of this software does not guarantee that this software is free from bugs or free from viruses. To the maximum extent permitted by applicable law, the software and documentation are provided "as is" and the licensor disclaims all other warranties and conditions, expressed or implied, including, but not limited to, implied warranties of merchantability, fitness for a particular purpose, conformance with description, title and non-infringement of third party rights. To the maximum extent permitted by applicable law, in no event shall the licensor be liable for any indirect, incidental, consequential, special or exemplary damages or lost profits whatsoever (including, without limitation, damages for loss of business profits, business interruption, loss of business information, or any other pecuniary loss) arising out of the use or inability to use the software product, even if the licensor has been advised of the possibility of such damages. In any case, the licensors’ cumulative and entire liability to the licensee or any other party for any loss or damages resulting from any claims, demands or actions arising out of or relating to this agreement shall not exceed the purchase price paid for this license. Should any term of these terms and conditions be declared void or unenforceable by any court of competent jurisdiction, such declaration shall have no effect on the remaining terms hereof.

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CONTACTING POWER DESIGNERS USA Power Designers USA LLC 4005 Felland Road, Suite 116 Madison, WI 53718 USA www.powerdesigners.com [email protected] [email protected]

Main Office Phone: 608.231.0450 Main Office Fax: 608.231.9979 Service Department: 608.216.9295

Phones are answered between 9 a.m. and 5 p.m., Monday through Friday Central Time. After-hours calls are answered by voice mail and returned on the next business day. Questions and comments can also be submitted via fax or email.

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