CRM-2010 Battery Management System
July 2007 CRM-2010 Page 2 of 28 1 GENERAL 4 1.1 In One Word 4 1.2 Safety Requirements 5 1.3 General 6 1.3.1 Fundamental Functional Procedure 6 1.4 Validity of the s 7 1.5 Guarantee and Limitations 7 2 CRM-2010 COMPONENTS 8 2.1 Survey 8 2.2 Standard components and optional accessories 8 2.3 8 2.3.1 General Fundamentals 8 3 CRM-2010 EMPLOYMENT POSSIBILITIES 9 4 SETTING UP FOR OPERATION 10 4.1 Unpacking the Device 10 5 OPERATING ELEMENTS AND CONNECTIONS 11 5.1 Measuring Input Connection Jacks 11 5.2 Operating Switch Array Keys 12 5.2.1 Key Occupation 12 5.2.2 Switching On and Off of the Device 12 6 MENU LAYOUT 13 6.1 General Explanation of the Menus 13 6.2 The internal database 13 6.3 The Main Menu 13 6.3.1 The INFO entry 14 7 DESCRIPTION OF THE SELECTION MENUS MEASUREMENT AND DATA 14 7.1 Selection Menu Measurement 14
July 2007 CRM-2010 Page 3 of 28 7.1.1 Fundamental Operating Sequence 14 7.1.2 The Battery Definition menu 15 7.1.3 Viewing of Measured Values 15 7.2 The Individual Measurement functions 16 7.2.1 Tour 16 7.2.2 TEST 18 7.2.3 Temperature 18 7.2.4 RESISTOR 19 7.2.5 CONNECTOR 22 7.2.6 INTERVAL 23 7.2.7 INTERVAL U+I 23 7.3 The DATA MENU 24 7.3.1 SEND DATA 25 7.3.2 GET DATA 25 7.3.3 SHOW MEASUREMENTS 25 8 APPENDIX 27 8.1 Load the CRM Measuring Device 27 8.2 Connect the PC to the CRM-Measuring Device 28
July 2007 CRM-2010 Page 4 of 28 1 General 1.1 In One Word Battery systems mounted in permanent area units are ever gaining on significance. Measurements and tests are a must for maintaining and retaining operational readiness. Only in this way is it possible to determine the momentary system status, to determine the availability of the batteries, to detect hidden malfunctions and to carry out appropriate measures for their elimination before damage is caused. The computer integrated CRM-2010 supports the service staff in their tasks. It provides a system which features the following advantages: light, compact, portable non-sensitive membrane switch array, large surface TFT-display menu controlled, simple operation quick measured value determination universal employment the values need only be determined one time immediate and exact data information is possible at the site area computer integrated analysis of the measuring results by means of PC We appreciate the fact that in purchasing this measuring system you have been convinced of the advantages it offers and we wish to express our thanks for your decision. Naturally, a manual, describing the advantages offered, is a part of the system itself. We would request you to take the little time required to work yourself through the manual. Most important of all are chapter "Safety Requirements" and chapter "Fundamental Functional Procedure". Should you have any further questions, desire extensive information or, also, have any critical remarks please do not hesitate contacting your local sales representative.
July 2007 CRM-2010 Page 5 of 28 1.2 Safety Requirements Before you begin to deal more deeply with the device itself we would like to give you a few safety hints in advance. Please observe the respective DIN/VDE/EN/IEC/ANSI-guidelines, the rules and regulations for local operators and the instructions of the battery manufacturer. Battery systems are electrical equipment systems having high short-circuit currents. Avoid short-circuits which can cause current interruption, damage to the battery, station equipment and/or harm to personnel. Be sure to think about possible shortcircuit dangers which can be caused by incorrectly connected shunts! The CRM-2010, the safety measuring leads and the accessories should only be employed for those purposes described here. Incorrect use can cause damage to the measuring system. Damage or used components must be immediately replaced. Do not use force in plugging the components together. The CRM-2010 charging unit may only be connected to the power supply voltage indicated on the identification shield. The unit should not be covered up or exposed to dampness during charging operation. The DATALOGGER should not be operated on the charging unit while carrying out measurements. The CRM-2010 is optionally equipped with a transponder-module which will emit radio-frequencies. Please be sure that it is allowed to use this feature in your country! Contact your nearest sales-representative for more information. The safety measuring leads and also all external cabling are not allowed to be longer than 2 meters. Be sure to secure your data at regular intervals. This is valid for the measuring device stored measured values, as well as, for the data in your own PC. The device should not be exposed to direct sunshine or temperatures exceeding 40 degrees Celsius (e.g. lying onto heating units, radiators, etc.).
July 2007 CRM-2010 Page 6 of 28 1.3 General 1.3.1 Fundamental Functional Procedure The CRM-2010 measuring system serves the determination of the condition of permanent mounted local batteries, logging and the determination of the operating safety of these battery systems by employing computer integrated evaluation. The measuring system can, based upon its conception, be used for opened lead-acid/electrolyte batteries, as well as, for closed battery systems. The system includes certain operational modes (also referred to as programs) for this purpose and the most important ones are listed below: Battery tour Battery test (check) Resistance Battery interval test Alongside these operational modes there are a series of extension programs, such as, for example a bridge connector test which rounds off the power scope. These tasks are supported and backed up by the battery management system stored in the PC. Battery data base file Hint: The battery database which is created and maintained in the CS-MANAGER software should be the fundamental base of the use of CRM-2010. If this database was not created yet it should be done now before the introduction into CRM-2010 is continued. For further information please refer to the CS-MANAGER-software manual which is separate from this one. A microprocessor integrated digital multimeter with integrated memory store (Data logger) serves as basis. The "Tour" is the simplest operational mode. During the tour the measurement of the individual cell voltages is carried out in the usual way. The value is measured, indicated on the display and internally stored. The device automatically allocates the date and time of day. The measured values are compared to previously entered tolerances and deviations are acoustically and optically signalized during measurement. Once measurement has been completed the number of measured cells, the average value, all individual cell voltages, as well as, the number of the cells having the highest and lowest voltages can be shown on the display. The system software makes a computer integrated evaluation and analysis of the results possible. The values of all measurements, which have been carried out during the operating time of a battery, are compared to each other. The "Test" and "Interval Test" are carried out in the same manner. Only here the number of measuring cycles and the time intervals of measured value recording are different. In the operation mode "TEST" the individual cell voltage is determined exactly the same as is described above. The specialty of this operational mode is that the measured values of each TEST tour following in a time sequence are compiled, so that a clear survey over the time specific development of each battery cell is obtained.
July 2007 CRM-2010 Page 7 of 28 The entire history of a battery can be followed using the "Battery Data Base File" on the PC. The file administrates all typical battery values, such as, nominal capacity, projected set-point capacity, allowable voltage tolerances, manufacturing and commissioning date and all exceptional occurrences. The file allows the immediate access to the historical data of the system and simplifies decision making in consideration to battery status in conjunction with the actual measured values. 1.4 Validity of the s The manual is valid for the CRM-2010 from serial number XXXXXX0001 upwards. 1.5 Guarantee and Limitations The manufacturer supplies a guarantee of 12 months after purchase for material and construction. The guarantee is not valid if the product is modified or altered in any way by the customer and, likewise, damaged by an act of God or by employment under unusual working conditions. The manufacturer reserves the right to replace the product by supplying a new or overhauled device. Please contact your local representative by guarantee claims. We reserve the right to impose the following limitations: We reserve the right to make alterations and changes in the said system and to make changes in the information included in this manual without notice. We do not accept responsibility for damages of any type occurring in the use of the test system and/or occurring due to the fact that employment purposes could not be performed. The manufacturer can, in no case, be held responsible for direct damages, indirect damages or subsequent damages which occur to the customer by employment or non-employment possibilities of the product. The programs may neither be copied nor duplicated. Even though we have taken the utmost care in the preparation of the program and this manual, malfunctions can still occur in the program sequence which we cannot take responsibility for. Should a part of the guarantee specification be invalid the laws and ordinances of the Federal Republic of Germany are valid. This is valid for the device and also for the evaluation of the software components employed in the computer.
July 2007 CRM-2010 Page 8 of 28 2 CRM-2010 Components 2.1 Survey 2.2 Standard components and optional accessories Standard components Item Management-System CRM-2010 data logger CS-MANAGER-Software CD Version (must be downloaded until further notice) Charging unit USB-B cable, for use with CRM-2010 exclusively Measuring leads Article-no. Options Item Transponder RF-ID Transponder tags Temperature sensor Specific Gravity sensor Article-no. 2.3 2.3.1 General Fundamentals This symbol refers to situations or procedures which could cause danger to persons and/or damage to objects. Important hints and sequential steps are designated by "Hint". Important test sections in the manual are accentuated by bold type. Practice examples are indicated as follows: Practice Example While working in the management program commands have to be entered using the normal and functional keys. The following appears in the manual: The letters which are to be typed in capitals (e.g. CRM). Keys occupied by permanent functions, for example, the key " is written out as <Return> and set in arrow brackets. File names are in capitals and in quotation marks, for example, "CONFIG.SYS".
July 2007 CRM-2010 Page 9 of 28 3 CRM-2010 Employment Possibilities The measuring system features the following main aspects: Battery Tour, whereby the cell voltages of a battery system are recorded, for example, in a monthly measurement of the charge retention. Testing, whereby the cell voltages of a battery system are recorded, for example, during discharging. Resistance, whereby the resistance values (Rel; Rct) are recorded, for example, in a monthly measurement interval. Interval, voltages or current sequences can be recorded in freely defined time intervals. A battery file is opened covering the entire lifetime of a battery using the PC and its installed analysis software. In this file all the activities concerning a battery (measurements, substitution of cells etc.) are stored and can be evaluated in graphic and/or table form. The measuring system supports all operational sequences known in the past. The measuring results and/or inputs serve as unified data base for further processing on the PC or for on the spot output. The various different functional modes are selected in a menu system. The build-up of this menu system corresponds to the operational sequence. During measured value store the measured values are simultaneously monitored for high and low limit value violation of voltage tolerances and, when required, indicated as such. The time of day and the date are automatically inserted. The operational status of a battery system can be evaluated exactly by utilizing the battery file. The evaluation can be followed over a period of years. Thus, an extraordinary survey covering the individual battery tours and tests is established.
July 2007 CRM-2010 Page 10 of 28 4 Setting Up for Operation 4.1 Unpacking the Device Before delivery the device and its components are given an extensive final test, the accumulators in the multimeter are charged and all components are carefully packed for shipment. When unpacking the equipment please make a visual check in order to determine that none of the components have been damaged during transport. Should a damage be determined please contact the freight company. If the CRM-2010 has been stored in a cold place allow the unit some time to adjust to room temperature in order to avoid the formation of condensation. The device is already configured and ready for operation. Only the management system software need be installed into your computer. Following a longer storage period it may be necessary to charge the accumulators.
July 2007 CRM-2010 Page 11 of 28 5 Operating Elements and Connections 5.1 Measuring Input Connection Jacks The measuring device features five connection jacks for the measuring leads and/or sensors included in delivery. The measuring signals refer to the reference and/or ground potential of the [COM]-jack. The measuring inputs are not galvanically isolated. Figure 5: Connections on the Multimeter Measuring Ranges The measuring ranges depend upon the occupation of the input jacks. [COM / P-] [S+] Ground (earth)-/reference potential of each particular range Input for DC Measurement. Cell/block voltages or complete battery voltages are measured over these jack inputs. This input is also used as the positive sense for the resistance measurement. Range 1: ±24.50 V Range 1: ±600.00 V 600V CAT III DC - Input impedance: 1 MΩ resolution: 0.001 V resolution: 0.100 V [S-] This input is used as the negative sense for the resistance measurement. [AUX] [P+] can DC - Input impedance: >1 MΩ Inputs for DC Measurement The signal of a DC clip-on current transformer or a temperature sensor be processed at this input. range 1: ±2450.0 mv DC - Input impedance: >1 MΩ resolution: 0.10 mv This input is used together with P- to establish the power path for the resistance reading. Be extremely careful with the voltage range you use here. There is a maximum of 18V allowed to this input, otherwise the instrument will be destroyed.
July 2007 CRM-2010 Page 12 of 28 5.2 Operating Switch Array Keys The measuring device is operated using the membrane switch array. 5.2.1 Key Occupation The buttons are self explaining. You can scroll or change number settings with the arrowkeys. The X is used for exiting menus, or for an early stop of a function in use. The red key is special, it is a symbol for securepulse and is used for initiating a single measurement, mainly resistance and temperature readings. 5.2.2 Switching On and Off of the Device The device is switched on [I/O] key. The CRM-2010 has a complete build in LINUX system. So please allow 8 seconds to power on the device. The switch-off command can only be given when the main menu is displayed and takes place by selecting the POWER OFF function in the main menu.
July 2007 CRM-2010 Page 13 of 28 6 Menu Layout 6.1 General Explanation of the Menus The device has three different menu sequences available. 1) The measurement menu 2) The database menu 3) The system menu The desired selection menu is selected, from the main menu, by pressing the appropriate menu key. The sequence or sub-menus located below the main menu are paged using the [ ], [ ] keys. After the last sub-menu-point the row begins again from the start. The desired sub-point is selected using [RET]. Changing between the various different selection menus can only take place over the main menu. 6.2 The internal database The internal database enables a simple and efficient identification of battery banks. The database will be transferred from the CS-MANAGER-Software into the CRM-2010 data logger. On-site the user can fall back upon up to 1-10000 different site and battery definitions. The database is can be activated inside the measurement setup functions Please note that all inputs/data such as limits, site no., battery no., were done in the Windows-Software and will be used when executing the measurements. 6.3 The Main Menu After the measuring device has been switched on the main menu always appears on the display first: All functions of the CRM can be reached using this main menu.
July 2007 CRM-2010 Page 14 of 28 6.3.1 The INFO entry Only in the main menu it is possible to get an overview about some system parameters. It is always a good idea to look at the INFO function first. 7 Description of the Selection Menus Measurement and Data 7.1 Selection Menu Measurement After the selection of Measurement, you do have the choice of several menu entries: 7.1.1 Fundamental Operating Sequence 1) Selection of the desired function to use (Tour, Test ) 2) Program sequence. 3) Viewing of the measured values. Ending of the programs Programs are ended with the [RET] or automatically. A so ended program ensures the correct storage of the measured values. Running programs can also be interrupted by pressing the [X]-Key. In this case the measured values recorded are not stored.
July 2007 CRM-2010 Page 15 of 28 7.1.2 The Battery Definition menu After you have selected a desired function an input menu is shown. Here you can edit all inputs simply by moving the selection box over the entry to change. Klick on [RET] and you will see, that the numbers are simply changed by the use of the arrow keys. With [RET] you will go to the next figure to change. After processing the last figure you will be put back into the box selection you had before. Holding down the [RET]-key for about two seconds will also stop the input routine. The limit values help in the recording of measured values and subsequent processing so that the operator is drawn attention to bad measuring values. Each sequence menu has its own limit value which is separately administrated and called up by the system. After all inputs are made, you must select PROCEED. to measure the desired values. 7.1.3 Viewing of Measured Values The recorded measured data are indicated on the display as soon as the program run has been completed: With the red [SP]-key you can change between absolute and relative values. With the [RET]-key you will switch between graphic and text display. The arrow keys will go through all blocks with an increment of 12.
July 2007 CRM-2010 Page 16 of 28 With the [X]-key you will leave the viewing function. 7.2 The Individual Measurement functions The following chapters will describe most of all programs and functions which can be reached via the [Measurement]-selection menu. 7.2.1 Tour Application: Measuring of the cell voltages of a battery system. A TOUR is a recording of cell voltages in large time intervals (e.g. repeating measurements of charge retention according to individual time plans). Indication on the display: Measuring Range ±24.50V, is set automatically.
July 2007 CRM-2010 Page 17 of 28 Connections [COM]-jack, [S+]-jack. Acoustic alarm indication by high/low violation of freely definable limit values. Key Functions [X] Interruption of the TOUR without memory store. [ ] Go back to the cell from which the new measurement should be carried out. The indication "-------" appears on the display. [RET] End of the TOUR with measured value memory store. The storage is done automatically if the battery was selected from the internal database before! The cells of a battery system are measured after ending of the following run sequence: Press the measuring leads firmly on the cell poles. Wait for the "high" pitched tone, perhaps the tone sequence for alarm signals will sound (recording of the measured values). Remove the measuring leads from the cell poles. Wait for the single tone (ready for the next measurement). This procedure is repeated until all cells of the battery system have been measured. After each recorded value measurement the cell voltage is indicated on the display. The recorded cell voltages along with date and time are stored and are ready for transfer. Hint: Should you wish to additionally measure temperatures, gravity and bridge connections, in one tour, be sure to carry out the TOUR program first. In order to be sure of the measurements the measured values can be viewed once again and when required also cancelled under [DATA] - [SHOW MEASUREMENT].
July 2007 CRM-2010 Page 18 of 28 7.2.2 TEST Application: Cyclic measurement of cell voltages of a battery system during controlled charging or discharging. The TEST program is called up before each cell voltage measurement. As opposed to a tour a "Battery Test", or in short "Test or CHECK" is measured here during a charging or discharging process. An essential difference to a tour is that in the testing procedure the cell/block voltages of a battery system are measured several times. In order to be able to make a statement concerning a test, a minimum of two measuring sequences are required (measuring of all cell/block voltages). If a test has less than two measuring sequences the recorded values are not stored. Please do refer to the function Tour for the use of the display and keys. In order to be sure of the measurements the measured values can be viewed once again and when required also cancelled under [DATA] - [SHOW MEASUREMENT]. 7.2.3 Temperature Application: Measuring of the individual cell temperaturesof a battery system. The system expect an IR-Temperature probe. Measuring Range Connections ±24.50V, is set automatically. [COM]-jack, [AUX]-jack. Acoustic alarm indication by high/low violation of freely definable limit values. Key Functions [X] Interruption of the TOUR without memory store. [SP] Executes a single temperature reading.
July 2007 CRM-2010 Page 19 of 28 [ ] Go back to the cell from which the new measurement should be carried out. The indication "-------" appears on the display. [RET] End of the TOUR with measured value memory store. The storage is done automatically if the battery was selected from the internal database before! In order to be sure of the measurements the measured values can be viewed once again and when required also cancelled under [DATA] - [SHOW MEASUREMENT 7.2.4 RESISTOR Application: Recording of the electrical and chemical resistance of a single cell. With the use of this function, the values of the cell voltages are also examined. You will have as a result three measurement files stored on the internal flash disk, the cell voltages, Rel and Rct. These files will have the same date and time stamp and can be easily viewed under [DATA] - [SHOW MEASUREMENT]. Indication on the display: Measuring Range 0 mohm 280 mohm The value shown in the middle of the display is Rel, which is the electrical resistance of the cell in [mohm]. In the line below you will see the value of Rct. The sum of Rel and Rct is the total resistance of the battery cell. It is recommended to use the Kelvin-clamps. Please be aware that it is a must to use twisted cables to achieve the correct resistor readings. Wrong and correct lead connection are shown in the following pictures:
July 2007 CRM-2010 Page 20 of 28 WRONG : CORRECT: Please do use the following connection scheme. Connection schematic: P+ S+ S- P- + - + - CAUTION : Do never connect a voltage greater than 18V on the P+ input!
July 2007 CRM-2010 Page 21 of 28 The cells will be examined with the following steps: - wait until the display shows Connect to cell > 2V - - connect the clamps like in the diagram shown above. - wait until the display shows ----- - press the [SP]-key - wait until the resistor reading is displayed - disconnect the clamps to proceed the procedure again It can happen that the device is overheating. Normally you can process 60 times a 12Vcell or for instance 108 times a 2V-cell without overheating. If overheating occurs, the following screen appears: It can take some minutes until you can proceed with the measurement. Please do always have a look into the INFO menu on the main screen, to be sure that the system is not overheated. Internally temperatures of 45 C are the maximum allowed (at the moment). Key Functions [SP] [X] [ ] Do a single resistance reading. Interruption of the function without memory store. Go back to the cell from which the new measurement should be carried out. The indication "-------" appears on the display. [RET] End of the TOUR with measured value memory store. The storage is done automatically if the battery was selected from the internal database before!
July 2007 CRM-2010 Page 22 of 28 7.2.5 CONNECTOR Application: Recording of all the bridge connector losses of a battery system. Measuring Range 0 mohm 20 mohm Please do use the following connection scheme. It is possible to use the Kelvin-clamps or you can establish connections with separate leads, which makes it easier to measure multiple connectors between cells. Connection schematic: P+ S+ S- P- AUX + - + - CAUTION : Do never connect a voltage greater than 18V on the P+ input! Key Functions [SP] [X] [ ] Do a single resistance reading. Interruption of the function without memory store. Go back to the cell from which the new measurement should be carried out. The indication "-------" appears on the display. [RET] End of the TOUR with measured value memory store. The storage is done automatically if the battery was selected from the internal database before!
July 2007 CRM-2010 Page 23 of 28 7.2.6 INTERVAL Application: Recording and display of measured values with storage. These measured values are continuously recorded in freely definable time intervals (e.g. for the recording of one total voltage curve during discharging). CRM measures a certain electrical variable at equal "Interval Measurement" time intervals. In the CRM the time intervals are adjustable, starting with the smallest time interval of 2 seconds. Thus, it is possible to record the entire voltage of a battery during charging or discharging in intervals of 5 seconds. Measuring Range The measuring range is 600V. Key Functions [X] Interruption of the function without memory store. [RET] End of the function with measured value memory store. The storage is done automatically if the battery was selected from the internal database before! Input connection used: [COM] Ground reference [S+] The voltage input signal, mainly the total voltage of the battery The charging component cannot be used to extend the recording time by interval measurements, since fault signals can access and destroy the device. 7.2.7 INTERVAL U+I Application: Recording and display of measured values with memory storage. The measured values are continuously recorded in freely definable time intervals. (E.g. for the recording of an entire voltage curve and current curve during discharging). Measuring Range The measuring range for the voltage measurement is 600V. The measuring range for the current measurement is set via the current/voltage-ratio. Key Functions [X] Interruption of the function without memory store. [RET] End of the function with measured value memory store. The storage is done automatically if the battery was selected from the internal database before!
July 2007 CRM-2010 Page 24 of 28 The charging component cannot be used to extend the recording time by interval measurements, since fault signals can access and destroy the device. Again, the inputs are not galvanically isolated. Use a transformer coupled current-probe! Input connection used: [COM] Ground reference [S+] The voltage input signal, mainly the total voltage of the battery [AUX] The voltage input signal, mainly the output voltage of a current clamp. Danger! Please only use a current clamp! Short-circuit danger exists by incorrect connection when employing a shunt. All interval programs are limited to the acceptance of 10 000 measured values. This limitation has been made in order to guarantee perfect processing of the measured values with the system software. 7.3 The DATA MENU These functions contain the sub-menus for handling and further processing of gained measured values.
July 2007 CRM-2010 Page 25 of 28 7.3.1 SEND DATA Application: This function is used to activate the USB-port of the CRM. Display: Before this function can be called, the USB cable must be connected between the PC and the CRM. After the USB-port is activated, the CRM can be viewed using the Windows Explorer (TM of Microsoft). A disk drive called CRM-2010 appears in the Explorer. All files are stored in a subdirectory called mdata. For example, under E:\CRM-2010\mdata, all measurement files of the CRM are accessible. If you do a double-click on such a file, the values can be examined using EXCEL (Trademark of Microsoft). 7.3.2 GET DATA Application: This function is used to activate the USB-port of the CRM. After activating, software updates and databases can be transferred to the CRM. Before this function can be called, the USB cable must be connected between the PC and the CRM. After the USB-port is activated, a disk drive called CRM-2010 appears in the Explorer (Trademark of Microsoft). Simply by drag and drop operations, files can be uploaded to the CRM. 7.3.3 SHOW MEASUREMENTS Application: This function provides a high efficiency aid for subsequent viewing of stored programs. With the call-up of a function a menu is opened which presents all stored programs on the display.
July 2007 CRM-2010 Page 26 of 28 Display: Key Functions [SP] [ ] [ ] [RET] [X] Deletes the displayed programs. Goes back to a program entry. Goes forward to a program entry. Views the measured values of the displayed program. Returns to the main menu. At this point the user can select the stored program point, in which viewing or deletion is to be carried out, by using the direction keys. After a stored program is selected, use the following key functions to switch between different viewing styles: With the red [SP]-key you can change between absolute and relative values. With the [RET]-key you will switch between graphic and text display. The arrow keys will go through all blocks with an increment of 12.