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V 2 operating instructions

1. 24 ODLUODS cocos nti o UP hob Cc Men tub dub E e e ie DUE 24 Brief Description and Displays for Each Option ssssssssssssseseeeeeneeeneene enne 25 Soak Period After Voltage Plateau Detected End of Charge Off On sss 25 Bank Qliar ioie an E RETA E EE RT AEE Re E Ea E AAE ican RS 25 Allow Charging at 10 degrees F colder than Normal Limits eee 25 Serial Output Only During Charging or Always eese eene nennen enne nne nnne 26 Parameters Viewing amp Changing Access Level cccccccccsssesseceseceseeeeseeeseecesecesecseceeeseecnaeeneeeees 26 Pass word Not Entered or Incorrect sedo dass ovra eaaet exp PRETI eq iE C Dae te NEM Spa 26 Change Temperature Degrees F or Casos tease ete Soviets eas uae enthuses ueste ien ec ts 27 l minute or 5 seconds Serial reporting interval 27 Charge before Discharge VES ING nis auae Ns bang tat qd TRI e br imn di a RM aka y 2T Reload Defaults 536 etu E dte PURI E EH qu ENTER a E IRAN YI eri ii 28 Press TOP 10 end SetUlps ac oh atra eh eeu io iab oun ees dah Pale 28 QUIS prts UM CE NS Hc NO METRE 28 Se al Qutp t s etui etin tren oan carabus dena Msc Dente Mdb ebd uud dies ut cU Ue o Dra An c sb LI 30 Setup Parameters and hardware soe das etr overdue dete d unite Cv av We dede dra 30 Input as well as output on the Serial Bottin ete tea o abet ha Ie Eee RERO RE DM in AREE 30 What is sent out from the Serial PORE
2. Switch power off amp on to activate If a key other than was pressed the charger will not proceed with restoring the factory defaults and will indicate on the LCD that this action has been cancelled due to the wrong key pressed Restore Defaults 26 cancelled Wr Key cancelled Wrong Key If you pressed STOP to cancel and see the above message and now want to end SetUp then press STOP again to exit Press STOP to end SetUp At this point either press STOP to end SetUp or press SETUP again to rotate around to Car Profile Always press STOP when finished with Setup except not required for Options Tech Edit so the charger will end Setup function and not make an unexpected change the next time that the Down Arrow key is pressed TEST This function is normally only used at the factory to test and adjust the power supplies It can also be used to check that each power supply is working and is still close to its original factory Voltage adjustment Test Function works only in Tech Access level Tech Extended Editing not in User Access level If TEST is pressed when not in Tech Extended level the LCD will warn Can t do TEST Md Can t do TEST Mode Needs TECH Level Only select TEST when the charger is disconnected from the car battery or any battery Note The Test Mode will not start if the charger sees battery Voltage In that case the charger will warn on the LCD Can t do TEST Md Can t do TEST Mode Batter
3. doro teet ot desde ese ERA otii es ies 30 Power on Seral O tput a eoo Re rto ated tuse Ue dens aea t sa ente 30 Start Charging Seral Outp t iuis pee bos sas extet edd eis E L s Pec M dud 30 Charge Datdt adatta on Tete tepidis i ics staan loan uet repa reich Ro br aa 31 Diela e Datis od eve med tdi lac weuscaaves esi om uada wae M tad us 31 Explanation and listing of the SysStatus Variable flag bits sse 32 Converting decimal to binary ese teo iecit e Hare ivo erbe iie o rs dvi bei qua diss 32 SEFEAEIBDUD ritus o sais wo that e tapar tu raton a tuts Radon dm ique ease op d det c dace tes 33 Pow r Fa HU ee uad e n see ais tust Lal E abd dl dest 35 Abnormal Conditions sami na pede a ne na a n o duse a e tates 35 Over Current i irrati 35 Unde arenas d M 35 Fan and Temperature Control and Shut down sss nnns 36 Notes on Cold Temperature Charging censa Came dtu ten ad adhibe ea oum Lac que 37 Variables and Parameters Tisti i euren tr rU a PR Oed ERN QA NO d aee Rn EAS e NET tases 37 Infarmatiotial Paramelets qu soe d ue atas tbtoa ttbi te b hod ea edd ve i e abad p indo tus dead 38 PSUR AMICU ets octies ein odo nep alis vod es ial sk E E M D DE E DE 38 Operating Parameters and EIS ses Lose Rte Net RE Mas equ NOM ue NUBE REA EU ifs 38 Protected Parameters Tech dt yey iscritti cacy E epa tenui matan att bus ute Ma duni Aa 39 Further Expl
4. START will also end over ride other modes such as Test Tech mode Red E AS Greon Finished When the STOP key is pressed If charging Stops ends cancels charging for all Run Modes If Editing a parameter Aborts exits without saving changes If pressed before EDIT was pressed for the second time to store the changed value If in Setup Ends Exits Setup and resets pointer to the first item CarProfile for the next time If in Test Tech mode Stops resets the Test mode and returns unit to normal standby Off mode PAUSE If charging Suspends charging power supplies turned off but retains the time charging and MilliAmp Hours accumulated up to this point and the Voltage at the start of charging Press Pause again or START to resume charging with this data continuing to advance from the point it was paused If in Test Tech mode Turns off the power supply s being tested and retains the place in the Test sequence ready to resume at the same place when START is pressed to resume ALARM On Off Turns on or off audible alerts alarms for events Over amp Undercurrent Discharge rapid sampling and AutoStop reminder beeps Audible alerts function Powers up On For Over and Under current alarms it controls the LCD display of the alarm as well as the audible beeper When AutoStop reminder is sounding pressing this key during the pauses between the beeps will silence it First press editing Switches display fr
5. Tech Extend Edit message indicates that Technician level access has been set after the Down arrow key was pressed Press it again to return to the previous choice Password Not Entered or Incorrect Note The password is reset to 0 each time the charger is powered off and will need to be re entered if access to the Tech parameters is required For all other charger operation and use except TEST and Pulsed Discharge Run Mode 7 the password is not needed If the correct password has not been edited in to the Password parameter this will be indicated on the LCD bottom line after the Down Arrow is pressed in Setup Tech Edit Invalid Password Wait for the Password variable to next be displayed on the bottom line Password 0 The Grid Charger will automatically set up EDIT ready to enter the correct Password using the arrow keys Once the password has been entered correctly press EDIT to save it If the password was entered correctly the charger will automatically select the Tech Edit choice and Stop Exit SetUp The display confirms this by showing Tech Extend Edit Exiting Setup Change Temperature Degrees F or C For changing the degrees C or F used for display the LCD prompts Temp gt degrees F Temp gt degrees C Options 00000000 Options 00000100 Pressing the Down Arrow key at the above screen will change the degrees C or F used for display and show the current setting on the top line This selection is remembered a
6. gt this Voltage Level Model_Year6 Model year and car name A HrCapac Amp Hour capacity of the battery being charged RunMode 1 7 selects charge or discharge mode Replaced With Restore Operating Parameters and Limits StartDelay Sets minutes to wait after START is pressed before charging IntervalHrs Delay in hours between charge cycles in Maint for long term storage MaintRunTme Maximum time to run charger in regular long term maintenance charging TopTimeMN Maximum time to remain in the toping zone before shutoff MaxChgTime Maximum time to run charger in Run Modes 1 to 4 MaxChg_mAH Total allowed mA Hrs of charge MaxPT CVal PTC value where the charging is stopped because of excessive PTC temp Bottom TDifMaxRaw Maximum inlet to outlet temp difference after charging enters topping zone line of SampleTime Interval in minutes sample delay when determining the end of charge display with 36 Tech Edit C_DcyclesMax The number of Discharge charge cycles to do in Run Mode 6 SlopeDifMax Adjusted Difference between Long amp Short Term Avg V to stop Discharge MinDischrgV Minimum Voltage allowed for discharging S ViewTime Time in seconds that splash messages stay in view Password 4 digit password required for Tech edit and Test mode cleared on power off Bottom Password required to enter the Tech variables section line of Protected Parameters Tech Edit n Smoothing of samples being averaged to give current displ
7. packs under certain charge states and pack condition define InitFastDischT 101 Less than this short time counting 5 bits V drop slope samples will trigger the end of discharge for reason 4 Protected Tech Edit Variables Parameters that affect the operation of this mode DischSmpFac Options to select before starting minute or 5 seconds serial reporting Do pre charge first or start in discharge 19 Run Mode 7 Pulsed Discharge no charge current User Variables Parameters that affect the operation of this mode None Protected Tech Edit Variables Parameters that affect the operation of this mode None This is a special testing mode that requires the Password and Tech Edit selected in SetUp before it will work There is a warning long beep and LCD message if there is an attempt to start operation in this Run Mode without being in Tech Extended Edit user level Can t PulseDisch Needs TECH Level When started in this RunMode the Grid Charger pulses the discharge load Aux Output on and off at a very fast rate of about 22 Hz 22 on and off cycles per second It is intended for use with an AC Voltmeter to provide an idea of relative internal resistance of the battery pack not for doing a discharge cycle of a charged battery pack This mode provides a means to indicate how the internal resistance compares with a good or bad battery pack whether it is improving as the pack is charge discharge cycled and which sub packs a
8. 3 and 4 Delayed Start of Charge High and Low current respectively Works one time once START has been pressed Only use Run Mode 4 for the Low Current Maintenance charger If you edit the Run Mode to 3 by mistake with a Current Maintenance Charger it will be corrected to 4 right after by the charger Starts charging after the programmable Start Delay minutes to hours has expired and stops automatically or by pressing STOP The Start Delay is programmable in Minutes from 1 to 9999 166 hours by editing the StartDelay parameter Not Charging R 0 StartDelay 60 After pressing START with Run Mode 3 or 4 selected the display shows the Run Mode description on the top line Start Delay Hi C or Start Delay Lo C and then the display shows Charging starts in 60 minutes The actual delay time will be shown Once started and waiting for the delay to count down the display will indicate every 5 seconds on the top line the time remaining in minutes before charging will be started Start 2 min Profil 1 RunMd 4 Run Mode 5 Long Term Storage Maintenance Charging Low current In this mode the charger cycles continuously between a waiting off interval and a charging time to keep the battery pack charged It works this way once START has been pressed until STOP is pressed It starts up in the Wait Interval not charging and indicates the time remaining before starting to charge on the LCD Charging begins after the
9. At the end of the SampleTime if the beginning and end Voltage samples are seen as identical the Topping Plateau has been detected and charging will be stopped if Extra Soak Time has not been set up If not the charger repeats this test after it waits again for another SampleTime period Note that some battery packs in poor health with some high internal resistance cells for example may not exhibit the normal plateau In that case the charge will get stopped by one of the other methods such as 38 exceeding the maximum set Topping Time TopTimeMN or Temperature Differential It is in this Topping Mode 9 that the cell balancing and the most improvement to battery pack health is likely to occur Soak The Soak period will last for the remainder of the maximum allowed Topping Time and used sparingly provides overcharging to bring up out of balance cells that are well below the average State of charge If selected by the Soak choice in Set Up Accessories and enhancements Discharge Load for RunMode 6 Operation An auxiliary output is available to operate a Discharge Load for discharge recharge cycling which can help condition an ailing battery pack This auxiliary output is accessed on a socket behind the hole plug on the charger s left side More details will be provided with the instructions of the Discharge Load Check the 99mpg website for information on availability and price 39 OBD II State of Charge SOC Rese
10. LCD the one which is active for scrolling Line 1 Active will be displayed for the ViewTime on the top line Suggestion Select items for display that are the most useful to see before charging For example Battery Volts for the top line and the PTC value or a temperature for the bottom line Scroll to check that the battery temperature readings are suitable for charging Inlet Temp 87 0 Inlet Temp 87 0 OutletTemp 91 1 TempDiff 4 1 For one second in five the LCD will flash a status message like the following Not Charging RO orR 1 or R2 R14 to indicate the reason it is not charging now Profil 1 RunMd 1 The Reason codes are listed in the Stopping Charging section below This provides an indication to the user of what last happened to the charger to stop the charging useful to know at a glance if you check the charger and it has stopped If the unit has not stopped a charging session since it was powered up the reason will show as R 0 Typical Operation Starting Charging RunMode 1 or 2 Plug the car battery harness to the charger Plug the power cord to a 120V or 240VAC 50 60 Hz outlet or extension cord in good condition A GFI 3 wire circuit is recommended for powering the charger Turn on the power switch on the back of the unit Check that the battery Voltage and temperatures displayed are in the range expected for this battery pack If the charger operation or battery pack is to be different from the l
11. Mode 6 the battery is discharged completely and then recharged completely Each set of discharge followed be recharge is one cycle DisChrg Time Real time total discharge time DegTempDiff Temperature rise of the air passing through the pack DischSmpFac No to divide the initial slope count by to get the period for a 1 bit drop to end the discharge in Run Mode 6 EndChargeV Voltage at end of charge EndDisChgV Voltage at end of discharge GFCI Ground Fault Current Interrupter a safety device to detect leakage current to ground which could be hazardous if it causes a metal part to be Hot or is passing through a person s body Inlet Temp Temperature in F or C of the inlet air 46 IntervalHrs InTemp 2Cal InTemp 3Cal InTemp 4Cal InTemp 5Cal InTemp 6Cal Last Chg mAh Last Chg WHr LCD Delay in hours between charge cycles in Maint for long term storage Inlet temperature calibration offset for Car Profile 2 Inlet temperature calibration offset for Car Profile 3 Inlet temperature calibration offset for Car Profile 4 Inlet temperature calibration offset for Car Profile 5 Inlet temperature calibration offset for Car Profile 6 mAh of the last charge WHr of the last charge Liquid Crystal Display The Grid charger uses an LCD that shows 2 lines of 16 alphanumeric characters letters and numbers MaintRunTme MaxChgTime MaxChg mAH MaxPTCVal MaxInTmpRaw MaxOutTpRaw MilliAmp Hours MinInTmpRaw MinOutTpRaw MinDischrg
12. On indicating that the battery is probably a little colder than that too cold for safe amp efficient charging It is tested against a Tech editable parameter MinOutTpRaw with a default of 510 The LCD message is Cold OutTmp Stop Try Delayed Chg When the unit is not charging the Grid charger temperature sensors and the battery pack PTC sensor if applicable are still monitored and may cause the fan to run for a while or cycle on and off Notes on Cold Temperature Charging From Mike s post on Insight Central November 18 Got this from a NIMH battery manual Low temperatures e g 15C 5F will obviously reduce Ni Cd and Ni MH battery discharge rate At 20C electrolyte is at its freezing point charge speed will greatly slow down At low temperature under 15C 5F charge will raise the internal gas pressure and probably unseal the safety vent Ambient temperature of 5C 41F to 30C 86F is the best range to get effective charge Generally with temperature rising charge efficiency will become higher But when the temperature rises to 45C 113F or higher the materials performance in the battery will be degenerated and battery service life will be shorten greatly If we want to charge in the cold take the car for a ride to get both the car and the pack heated up If the ambient is very cold one could put a small electric heater in the car since we have an AC cord for the charger going in anyways The pack heat and the electri
13. Soak Time On Off Store Discharge Cycles Data in Memory Bank 0 1 Cold Charge Yes No Serial output only when charging or Always User Tech edit Change Temperature Degrees F C 1 minute or 5 seconds Serial reporting interval Charge before Discharge Yes No Only 2 of these options are remembered after a power off Memory Bank 0 1 amp Temperature Deg F C When the Options function has been selected in SetUp the LCD will display Options Display Chg press Down The LCD 2nd line message reminds the user to press the Down Arrow Key to toggle the Option Bit between the 0 and 1 choices After the ViewDelay the Options Display page is then shown on the LCD The current state of all 8 Options choices 8 Options Bits is displayed as a series of 0 or 1 indications on the bottom line of the LCD Initially the cursor will be on the first one to the left and the LCD top line will show the description and current state of the first option The default state is all options at the 0 choice Xtra Tm Soak Off The extra time for soak charging is turned off Options 00000000 Press the Down Arrow if you want to toggle the choice The up arrow is not active for this function and will prompt a reminder to use the Down arrow As the bit is toggled between 0 and 1 the top line of the LCD will update to display the current choice Xtra Tme Soak On Options 10000000 Use the Left and Right Arrow keys to scroll through the 8 Options on the b
14. Wait Interval IntervalHrs counts down to zero or if low battery Voltage is detected Low Voltage is calculated based on 88 of the edited Cut backVPr about 147V for a First Gen Insight or Civic and 161V for a Second Gen Civic or an Accord The Grid Charger then charges for a programmable Maintenance Charging Time MaintRunTme or until charging is suspended automatically due to a full or hot battery The charger then returns to the Wait Interval to start over It will continue cycling off and on indefinitely until STOP is pressed The Wait interval is programmable in hours from 1 to 9999 416 days by editing the IntervalHrs parameter This is the interval between the end of the previous charge and the start of the next The maximum Maintenance mode charging time is programmable in minutes from 1 to 9999 166 hours by editing the MaintRunTme parameter It is usually set to a shorter time than the other single operation Run Modes 14 Not Charging R 1 Not Charging R 1 IntervalHrs 168 MaintRunTme 360 StopAlarm reminder beeps are not activated for Long term Maintenance RunMode 5 as the user is likely not nearby to hear them while the continuing beeping could annoy other people After pressing START with RunMode 5 selected the display shows the RunMode description on the top line Storage Maintain and then the display shows Starting long Term Maintain Then the LCD will indicate the time remaining in hours and min
15. a good time to end charging The Cut back point that starts Topping Mode 9 is determined by the Cut back Voltage for Profiles 1 to 6 whichever is in use Cut back VP1 Cut back VP2 Cut back VP6 Even if the charger is a Maintenance model or an Overnight model set for Run Mode 2 or 4 with the current always at only 350mA this Cut back change point signals the time for a switching to the final Topping mode M 9 This charger mode has different behavior from the previous bulk charging modes in that it is looking for other conditions besides Maximum allowed Voltage reached Maximum Amp Hours delivered to the battery Maximum Total Time spent charging or temperature to end charging In Charger Mode 9 Topping Mode it can determine if the battery Voltage has plateaued and either stop charging or allow it to continue for a soak period To detect this leveling off of Battery Voltage at full charge the charger first looks for a minimum Voltage to have occurred and the Voltage to be rising or at least stable for five minutes reduced from the 10 minutes setting in Ver 1 2 Then it takes a snap shot of the Battery Voltage waits for the SampleTime to elapse and compares the battery Voltage now with the snap shot Sometimes decimal digit dithering at the instant of sampling could cause this sample to be rejected During the wait for the sample time if the Voltage is seen to still be increasing the Sample Timer will be reset and start over
16. beep response for SETUP pressed when in the middle of Edit mode 1 Added blocking amp recovery for wrong keys pressed in SetUp or Edit TEST PAUSE RUN MODE f in Setup amp editing Profile STOP press ends Edit amp returns to SetUp Revised Serial headings IDs SSET HCHG HDIS Added LTAVx10 STAVx10 to Discharge serial data output Corrected position of amp amp Batt Volt lt SamplStartV 1 condition in averages calculation Changed Discharge Serial output to only the averages difference Moved averages amp difference discharge stop detection to 5 sec AltDisplay Added averages amp Diff calculation to Charging AltDisplay code section also Added averages difference to charge serial output headings amp data SlopeStopDisable will now also prevent stop due to averages difference detection Added ASD AvgStopDetect flag to give distinct DischTAVG LCD message Starting minimum averages difference point determination Did code to detect the minimum averages difference point Changed Long term average initial calculation Testing for Option 7 amp low Voltage separately at start of Disch Pre charge Optn new LCD message Added SmpStartV to end of Discharge data serial output Added Md7Run timer for Run Mode 7 Pulse Discharge Revised AvgDifMinV code to update DifAvgVminRaw on rising DifAvg if low by 10 or more 44 BattV lt FactorD_SmpStartV CutBakV will start tests for AvgDiff
17. discharge if not stopped sooner by one of the other methods Charge Data First the charge data headings line is sent HCHG BattV ChgCur S ysSt StopR ChgMode ChgT mAHrs InT OutT TempDiff PTC TScntr DifAVx10 n This output starts with HCHG and then provides the abbreviations for Battery Volts Charge Current SysStatus Charge Stop Reason ChargerMode Charge Time Minutes milliAmpHrs Inlet Temp Outlet Temp Temperature Differential PTC Temperature Sensor Topping Sample Counter and an indicator of the current difference between the Long term and Short term Voltage averages The charge data headings line described above is sent before the first line of charge data Then comma separated CSV charge data in the same order as the charge data headings is output every minute or 29 5 seconds while actively charging or always when the charger is On if Serial Always was selected in SetUp This output starts with DATA This charge data line is also sent for some changes in status such as switching to Topping Mode 9 In other words an additional line of serial data is output at the time the Topping condition has been satisfied with the actual Battery Snapshot value tested for this decision just before charging is about to be ended for that reason Discharge Data First the discharge data headings line is sent HDIS BattV SysSt DischR DisChgT InT OutT TempDiff PTC TScntr DischgST DifAVx10 SmpStartV AvgMinFound MinCnt
18. or press a key to speed up the transition to the next step Watch the display to see whether your key press was acted on or whether it only ended the ViewTime and you need to press it again The delay time is now entered as whole seconds not milliSeconds for example 3 instead of 3000 The following information applies to the Standby Not Charging state Initially the top line of the LCD is active for scrolling the possible items for display This means that pressing the Left or Right Arrow key will change the item displayed on the top line and the bottom line is unaffected The top line can display from a smaller list of the favourite items that are not editable for faster access to the one you want to see In other words these items are values and times that the charger has measured rather than parameters that set limits i e parameters that can be changed to modify charger behaviour Pressing the Down Arrow key will make the bottom line of the LCD active for scrolling and editing instead There will be a brief indication of Line 2 Active to confirm that the charger has reacted to the key press The bottom line is for editing parameters as well as viewing measured values and times It can be scrolled to display all the items available to the User or Factory Technician editable and not according to the current User or Tech level Tech Extended Level Off or On Press the Up Arrow key to again make the top line of the
19. removed ClockAdjust as editable variable Removed the less useful HighCurrent and Pause status info from the bits 0 and 1 of the SysStatus output in the serial data and used these freed up bits to provide status information for the new Discharge RunMode 6 InitSlopeDone SysStatus 0 and DischargeSampleTarget has been calculated SysStatus 1 Automatic setting to 1 of invalid Run Mode or Car Profile entered while editing them Added handling of wrong changed password in SetUp Options Tech Revised Car Profile defaults taking advantage of the increase in Car Profiles from 3 to 6 Aligned TempCal messages for easier fast scrolling in the Tech Edit sectio Automatic Testing and storing of Power Supplies output Voltages when upgrading firmware from 1 2 to 2 0 Added hold down repeat for L R arrow keys through Cycles display Added hold down repeat for Up amp Down arrow keys in Edit display Revised STOP to end SetUp without STOP actions If EDIT pressed with Setup gt 1 no action amp redirected back to Setup Added SlopeStopDisable for testing discharge beyond normal stop Fan always on in Discharge Added variables amp code for 2 Battery Voltage averages Disch stop Added SamplStartV 1 condition for doing V averages Increased size of Short Term Samples buffer to 5 for future use Revised display of CarProfile in start of SetUp Changed to DisplayProfile 0 when Setup first pressed Invalid Key long
20. repeat this process until you cannot divide by 2 anymore For example let s take the decimal value 157 157 2 78with a remainder of 1 78 2 39with a remainder of O 39 2 19with a remainder of 1 19 2 9with a remainder of 1 9 2 4with a remainder of 1 4 2 2with a remainder of O 2 2 1with a remainder of O lt to convert write this 1 2 Owith a remainder of 1 remainder first Next write down the value of the remainders from bottom to top in other words write down the bottom remainder first and work your way up the list which gives 10011101 157 Serial Input The charger accepts a number of 4 character commands over the serial link to a PC lap top or other computing device with an RS 232 port or a USB port and USB to Serial converter These commands will usually only be sent from a computer program such as the data logging graphing and control program from Genesis One However most can be sent by typing them in manually with a terminal program like HyperTerminal provided the command is entered within the 5 seconds time out window The Serial Charger Control Commands are The commas between the characters in single quotes are for clarity only and are not sent over the serial connection The characters are case sensitive 1 e lower case only as shown s t a r for START to do the equivalent of pressing the START key on the charger s t o p for STOP to do the equivalent of pre
21. start of charging The headings line is DATA StartCharging Profile RunMd CutBakV VMax TopTime Max CGTm MaxAH SampleTm TDMax Soak ColdChrg SmplStrtV CDcycles DeSmplF MinDcV followed by a line of the corresponding data 42 Added a new Serial Output report type and corresponding headings line for during Discharge Added SerialAlways Option in SetUp to cause serial output also when not charging Added Options bit for 1 min or 5 seconds interval for serial output reports Added TempDiff PTC amp DischgST to the Serial data output Added TIME TIME to the beginning of serial headings and DATA TIME to the beginning of data output for compatibility with Parallax DAQ data acquisition program Pressing Pause will now output a line of serial data providing a trace of this event An additional line of serial data is output at the time the Topping condition has been satisfied with the Battery Voltage Snapshot value tested for this decision just before charging is about to be ended for that reason New Serial Control Input Accepts commands for START STOP dumping of Parameters Variables values and setting of Parameters Variables values Write to EEPROM get to get6 serial input commands for Bank 0 amp 1 and Cycles 1 2 amp 3 info Added Serial input commands g e 1 address amp g e 2 address to get 1 or 2 Bytes from EEPROM starting at address Improved flexibility for working at cold tempe
22. there is a safeguard limit of 9999 as the maximum value that will be retained 20 Exceptions are the calibration Tech Edit parameters This is done so that the user will not inadvertently enter a higher number by incrementing the thousands digit past nine to raise the not displayed 10 thousands digit above zero When another press of the UP arrow would have raised the parameter past 9999 it will be held at this maximum When another press of the DOWN arrow would have wrapped around the parameter value past 0000 to 65535 the maximum value of a 16 bit number it will be constrained to 0000 Move the cursor to another digit to be changed if required using the Left and Right Arrow keys and then change its value again using the Up and Down Arrow keys When the correct value for the parameter is displayed press the EDIT key a second time to save the new value and exit Edit returning to Display mode If you want instead to abandon the changes made and not save them then press STOP instead of pressing EDIT the second time For the Tech calibration parameters with negative values allowed such as CurrentCal a down arrow press below 0000 will show 5535 Press EDIT to end and save the change and it will be displayed as Pressing edit again to go back and re edit this value will display 0255 now for editing Press the down arrow a number of times and the 0255 value will decrement by that number Press EDIT to complete the session and the val
23. 2 3 4 5 and 6 so the the Grid Charger can be calibrated at the factory to best match the temperature sensors of each different car harness Calibration offset for the Inlet temperature sensor on each car harness Factory Tech Editable InTemp2Cal InTemp3Cal InTemp4Cal InTemp5Cal InTemp6Cal Calibration offset for the Outlet temperature sensor on each car harness Factory Tech Editable OutTemp2Cal OutTemp3Cal OutTemp4Cal OutTemp5Cal OutTemp6Cal Run Modes The Run Mode is selectable by the User to match the need for charging immediately only after a delay or for continuously scheduled charging with long intervals between topping up These choices provide flexible operation to suit varying circumstances like returning home with a hot pack and charging later when it has had some time to cool down In addition there are two run Modes for discharging the battery pack The Run Modes available are Run Modes 1 and 2 Manual Charge with No Delay High and Low current respectively Works one time once START has been pressed Only use Run Mode 2 for the Low Current Maintenance Charger If you edit the Run Mode to 1 by mistake with a Current Maintenance Charger it will be corrected to 2 right after by the charger Starts charging immediately and stops automatically or by pressing the STOP The 13 operation and LCD information are as described in the earlier section on Typical Operation Starting Charging Run Modes
24. DifVmin DifVmin2 AvgMinFd2 n These are abbreviations for Battery Volts SysStatus Discharge Stop Reason Discharge Time Minutes Inlet Temp Outlet Temp Temperature Differential PTC Temperature Sensor Topping Sample Counter Discharge Samples Target an indicator of the current difference between the Long term and Short term Voltage averages a flag to indicate that a Voltage averages minimum has been found the current value of a counter requiring 48 consecutive samples without going below the minimum found up to now to declare that a minimum has been found the minimum value found and if a second minimum is found later in the discharge the second minimum value and the flag indicating that the second minimum was declared found The discharge data headings line described above is sent before the first line of discharge data Then comma separated CSV discharge data in the same order as the discharge data headings is output every minute or 5 seconds while actively discharging This output starts with DDAT Serial Output in response to serial input commands This will be described and explained in the section on Serial Input below Explanation and listing of the SysStatus Variable flag bits This 1 Byte 8 bits variable is the third item transmitted in the charge data and the second item of the discharge data It provides 8 status or On Off conditions of the charger s operation Bit Description Function Value if True On 0 InitS
25. Genesis One Grid Charger Operation Manual Version 2 2 1 Manual Revision 2 2 1 Junell 2012 Power supplies Isolated RS232 E ast Power switch adjustment adjustment openings and fuse Introduction Got a hybrid car with a High Voltage battery pack that is acting up The Genesis One universal battery charger balancer may be the answer This charger can charge any battery from 7V to 240V at a constant current The Overnight Charger can charge at 1 05A and 350ma and the Maintenance Charger no longer available can charge at 350ma Charger is configurable to charge with seven different Run Modes charge charge discharge or discharge profiles and six car profiles The charger has an isolated RS232 port that reports the state of the charge and other relevant data into a remote computer for data logging Charge parameters can be reprogrammed by the user Either from the charger or from a remote PC The hardware specific parameters and test mode are password protected Charger mates with custom in car harnesses so the same charger can be used for 6 different cars each with a unique harness Charging a multi cell series battery in this way has been shown to condition the pack for better performance and at the same time as a cell balancer to get all of the cells to the fully charged state and to recover from many battery related error codes A Discharge Load is available that plugs between the car and charger harness It is used with t
26. OBDIIC amp C Programming adapter kit RJ 12 to RI 12 Adapter allows the ICP 1 to pro gram the grid charger or MIMA Adapter also allows Microchip IDC 2 or 3 to program the OBDIIC amp C andthe new SOC reset device fm RAMMER TS aporia o 2010 Comments and Feedback Welcomed We encourage and look forward to your comments and feedback concerning this Instruction Manual and your experience using your Grid Charger We would like to learn from shared experience and data and make this information available to the user community and incorporate it in any future enhancements if applicable What is New amp Improved in Version 2 2 Firmware A more compact method of storing LCD text only messages and sending them to the display made program space available for more features A larger memory version of the microcontroller now doubles the program space and made possible all the improvements listed below The changed display view delay method allows the user to press a key to end the display time for a message and quickly move on In many cases where the next LCD information page is not required for the user to see what a key press will do the Grid Charger will act on a key entry as well as cutting short the present LCD message As a consequence of these changes the View delay is now entered as seconds not milliSeconds for example 3 instead of 3000 Improvements have been made to the Topping detection routines inc
27. V Model Year1 Model Year2 Model Year3 Model Year4 Model Year5 Model Year6 Outlet Temp OutTemp2Cal OutTemp3Cal OutTemp4Cal OutTemp5Cal OutTemp6Cal Password Pre Charge Profiles charged PTC value RunMode SampleTime S ViewTime SlopeDifMax Smoothing StartChrgV StDisChrgV StartDelay TDifMaxRaw Maximum time to run charger in regular long term maintenance charging Maximum time to run charger in Run Modes 1 to 4 Total allowed mA Hrs of charge PTC value where the charging is stopped because of excessive PTC temp Inlet temperature maximum value that allows charging Outlet temperature maximum value that allows charging Inlet temperature minimum value that allows charging Outlet temperature minimum value that allows charging Minimum Voltage allowed for discharging Model year and car name Model year and car name Model year and car name Model year and car name Model year and car name Model year and car name Temperature in F or C of the outlet air Outlet temperature calibration offset for Car Profile 2 Outlet temperature calibration offset for Car Profile 3 Outlet temperature calibration offset for Car Profile 4 Outlet temperature calibration offset for Car Profile 5 Outlet temperature calibration offset for Car Profile 6 4 digit password required for Tech edit and Test mode cleared on power off Doing a charge before the first Discharge Charge cycle of Run mMde 6 begins A group of settings or value
28. amp Slope point Removed Options from LoadUserVariables to avoid clearing Options when EEPROM is reloaded after a serial write If BattV gt 170 M7RunTime will be divided by 2 Added 20mS delay in Pulse Discharge loop to slow pulse frequency to about half the original Revised AvgDifMin detection code for case where too high i e false minium Added SmpStartV AvgMinFound CountStableTopVmin DifAvgVminRaw to Labview discharge serial output a Auto change to corresponding MinDischrgV default FactorMinDischrgV CutBakV when Car Profile is changed At the start of each Discharge cycle set SmpStartV FactorD_SmpStartV CutBakV Added second averages minimum detect amp variables to Serial Output 45 Glossary A HrCapac Amp Hour capacity of the battery being charged Batt Volts Smoothed real time battery Voltage C DcyclesMax The number of Discharge charge cycles to do in Run Mode 6 Charge mA Smoothed real time current mA CarProfile Select the Profile that best matches your car s 1 to 6 Cell of battery Smallest element of a battery Usually cells are combined in series to make a battery battery pack of higher Voltage than a single cell For the NiMH batteries used in most hybrid car batteries the nominal Voltage is 1 2 Volts per cell 120 Cells are needed to make a 144V nominal Voltage battery pack 144 1 2 Charge Time Real time total charge time Chargermode The charger operates in various mod
29. anation of Operation and chargermodes M1 M2 M9 sssssssssseee 40 Paramietel 9 us edet EE ese oed eter n I Mte ae a A Uude itc me LE 40 OTN secte cd E a nc i M M ad M M De 40 Topping MOE i sedet ti e rie rebate tele en tle dus kahuna rerit rudes pe odas 40 IUE quM REN TAI MEET NEUE US ROME 4 AC COSSOTICS and enhancements esc essa ose tetas Een d tei e luis dm eode ha late ier ub Rust epe eed 41 Discharge Load for RunMode 6 Operation cccccccsscceseceseeeeseeececeseceeeeeaeessaecaecneeeeeeenseeenaeens 41 OBD II State of Charge SOC Reset and Diagnostic Flash Code Trigger Device 42 Programming A Captaris cis scies aee uates toc e aia oie i Efe ve bee Cet dva a cabanas 42 Comments and Feedback Welcomed 5s eoe oet tor ede eet toe bap ex eta es dax buda ase bep sa Vies 45 What is New amp Improved in Version 2 2 Firmware eeeeeeeeeee eese ee ente nth etin sata stante eae 45 EET yt ue entrato toas a end M due e ead vata SUD tree dede drea Ca vn a d koe d E FebR eene e Potrai ated 49 Care Handling and Use of the Grid Charger Read the reminder list on the right side of the Grid Charger front panel each time before preparing to use it Always turn off the AC power before connecting or disconnecting charger from the vehicle battery pack or any other battery pack being charged Make certain that charging has stopped before disconnecting the charger connection to the battery Correct seq
30. as mentioned above the Cut backVPn is also used to determine the Low Voltage Start Point in Long Term Maintenance charging calculated as 0 88 X Cut backVPn Maximum Voltage This is the highest Battery Voltage allowed and when reached charging will be stopped User Editable ChgStopVP1 ChgStopVP2 ChgStopVP3 ChgStopVP6 ChgStopVP1 180 12 Car model and year This parameter is interpreted to display the Car model and year as explained below User Editable Model_Yr1 Model Y12 Model Yr3 Model Yr1 100 Model Yr4 306 This will display as InsightGen1 2001 and this as Civic HCH2 2006 and ToyotaPrius 2006 for CarProfile5 in this example Model Yr5 506 Here are the choices and what number to enter by editing for each Model Yrn parameter Car Model Coding where the 2 digit year is entered in place of xx Oxx Custom Car This allows for a car or Battery Pack not on the list of models 1xx InsightGen1 Typical Default Cut backVPx 166 ChgStopVPx 180 2xx Civic HCH1 Typical Default Cut backVPx 166 ChgStopVPx 180 3xx Civic HCH2 Typical Default Cut backVPx 183 ChgStopVPx 200 4xx Accord Typical Default Cut backVPx 166 ChgStopVPx 180 5xx ToyotaPrius Typical Default Cut backVPx 233 ChgStopVPx 245 6xx InsightGen2 Typical Default Cut backVPx 116 ChgStopVPx 126 In addition sets of temperature offsets are associated with CarProfiles
31. ast use edit the Run Mode and Car Profile settings as required See instructions on how to do this below Press the START key and observe the displayed indications of Chargermode Battery Voltage Charge Current Charge Time so far in minutes and seconds and milliAmp Hours charge accumulated M6 159 2V 1056mA CH 0 13 OmAH Press the Down Arrow key to see another page of information PTC value Inlet Temperature Ti Outlet Temperature To and the Difference between outlet and inlet Temperatures Td PTC 8271 64 1 To 68 3 Td 4 3 Press the Down Arrow key again to go back to the first display page and to toggle between pages Charger models and Specifications All chargers will operate on 90 264 VAC 47 63 HZ GCIMI no longer available 198V max 350MA Constant Current 1 12V 1 2A RS 15 12 3 48V 57A RS 25 48 1 5 48V 350ma Constant Current LPC 20 350 GCM1 no longer available 250V max 350MA Constant Current 1 12V 22 1A RS 25 12 4 48V a 57A RS 25 48 1 5 48V 350ma Constant Current LPC 20 350 GCOI 250V max 350MA and 1050 ma Constant Current 1 12V 3A RS 35 12 4 48V 1 1A RS 50 48 1 5 48V 350ma Constant Current LPC 20 350 1 5 48V 700ma Constant Current LPC 35 700 How the Grid Charger Works It contains a 350mA Constant Current power supply and a 700 mA CC power supply to make 1050 mA total in High Current operation and 4 nominal 48V adjustable Constant Voltag
32. aximum Voltage comana at ARE EEE tena edt aas tab itu aa ioca fu d pase epa a Edd 14 Car model and year ds ue ot Ae egisse al Gat tale vi tek Maer cata oases alas 14 Pun IVES so coros e ca ane uut tlt sme detent a caters iS at cie UE 15 R n Modes I and 2 ous ode ato seid pudet nens tede uses the pda Rae dos om b M UE cate 15 Run Modes 5 and 4 ice oie eun cus naa eee ui e NE es REX NU E USA ERRARE DETUR NAE VER 15 Run Mode 5 Long Term Storage Maintenance Charging Low current ssssssss 15 Run Mode 6 Discharge Charge Cycling c soo ponte heats cts deci Sae te ee ou gu tos ridet ees eid sus 17 Stop Discharging list Of reasons esse dete kleben rte ern ar tree o e x a vovv da PR ER 19 Discharge Charset veles Display irean Ralaten ter Pot a heec o qd n es a deu d tease 19 Disabling Automatic Stop of Discharge mode Slope Stop Disable sesssssss 20 Variables and defined factors that affect this mode sse 20 Options to select before starting iussit tet e aoro t l aeta iege dea 21 Run Mode 7 Pulsed Discharge no charge current cccccceceseceseceseeeeeceeseeceueceeeeeeeeeseecsaeeneenees 21 Using th EDIT Butte OBS tae oot bee sate e UI IURE ANNI MIRARI Nt Ae M odi a etat UN Sunes es 22 Changing the Run MOG s 4c isle okt as cde tan iade Dated E a aa E ie ta dc Eat 23 Using the SETUP PUInCUDDS uccisi e i P t P eR n D HD E naa pex uve Vere vtl ROTOR 23 Car Profle MT
33. ay like a low pass filter Tech DischSmpFac No to divide the initial slope count by to get the period for a 1 bit drop Edit to end the discharge in Run Mode 6 InTemp 2Cal Inlet temperature calibration offset for Car Profile 2 OutTemp2Cal Outlet temperature calibration offset for Car Profile 2 InTemp 3Cal Inlet temperature calibration offset for Car Profile 3 OutTemp3Cal Outlet temperature calibration offset for Car Profile 3 InTemp 4Cal Inlet temperature calibration offset for Car Profile 4 OutTemp4Cal Outlet temperature calibration offset for Car Profile 4 InTemp 5Cal Inlet temperature calibration offset for Car Profile 5 OutTemp5Cal Outlet temperature calibration offset for Car Profile 5 InTemp 6Cal Inlet temperature calibration offset for Car Profile 6 OutTemp6Cal Outlet temperature calibration offset for Car Profile 6 MinInTmpRaw Inlet temperature minimum value that allows charging MaxInTmpRaw Inlet temperature maximum value that allows charging MinOutT pRaw Outlet temperature minimum value that allows charging MaxOutTpRaw Outlet temperature maximum value that allows charging CurrentCal Calibration constant for low current in Overnight charger T 37 Further Explanation of Operation and chargermodes M1 M2 M9 Parameters On the page above is the listing of the charger variables and the parameters that can be edited in User and in Tech Level Access They are shown in the order they will be presented when scrolling
34. c heater will keep the car and the pack in the 41 86F range We also need to consider the situation where the pack is frozen but the car has warmed up in the sun I still advise taking a ride to warm up the pack before charging as the warm air will take some time to thoroughly thaw the pack We do not allow charging when the ambient inlet air temp is lt 40F or gt 97F or when the outlet temp battery temp is lt 48 F or gt 107F these conservative values will minimize the chances of the pack being charged when in a temperature zone that could damage or otherwise reduce the effectiveness The Max inlet and max outlet temps are adjustable via the tech edit but the minimums are fixed constants at this point Corrections and changes since then The minimum Outlet Temperature allowed for charging when the ColdChrg option is not selected is about 42 degrees F The ColdChg option in Setup allows the charger to be operated at inlet and outlet temperatures about 10 degrees F colder than the standard limits Variables and Parameters List On the next 2 pages are the Informational Variables User level editable parameters and Tech Extended level editable parameters 35 j Informational Parameters Batt Volts Smoothed real time battery Voltage Charge mA Smoothed real time current mA Inlet Temp Temperature in F or C of the inlet air Outlet Temp Temperature in F or C of the outlet air DegTempDiff Temperature rise of the air pas
35. d cut off rate the minimum Voltage has been reached or the Averages Difference method has its rapid change threshold met or the time out not likely then discharging ends The discharge load is disconnected Aux Output switched off If enabled the stop alarm beeps will alert the user to the end of the discharge period The reason for i e the method for deciding the end of discharge is stored and indicated as DisR At this time the charger will start the charge part of the Discharge Charge cycle The recharge will start at the high 1 Amp rate if the charger is the Overnight type Temperature out of limits either the Inlet or Outlet temperature sensor reads too high or too low during RunMode 6 charging will cancel operation turning the charger off After the battery has been recharged the grid charger will check whether the maximum number of cycles has been done up to now and if so stop operation and change to standby Not Charging condition requiring user action before doing anything else or if one or 2 cycles remain to be done automatically start the next discharge cycle This number of Discharge Charge cycles is entered by editing the C_DcyclesMax User parameter to a value of 1 2 or 3 cycles The data for each of the Discharge Charge cycles is displayed on 3 pages in a special LCD top line scrolling region next to the left of the Battery Voltage position This set of data is stored for later recall and viewing in one of 2
36. e decimal value associated with each character if the commands are sent from a computer keyboard For example pressing the Space Bar will send 32 The GET commands request several variables or values at once The first 3 characters of the GET commands are always g e t The 4th character is u for the USER variables The serial output in response to this command starts with USER and then sends the value stored for each variable in the sequence CarProfile Cut backVP1 ChgStopVP1 Model Yr1 Cut backVP2 ChgStopVP2 Model Y12 Cut backVP3 ChgStopVP3 Model Yr3 Cut backVP4 ChgStopVP4 Model Yr4 Cut backVP5 ChgStopVP5 Model Yr5 Cut backVP6 ChgStopVP6 Model Yr6 MinDischrgV RunMode StartDelay IntervalHrs MaintRunTme TopTimeMN Max CGTime Maxchg mAH MaxPTCVal SampleTime TDifMaxRaw S ViewTime A HrCapac C DcyclesMax SlopeDifMax Password t for the TECH variables The output starts with TECH and then sends the value stored for each variable in the sequence Smoothing DischSmpFac InTemp2Cal OutTemp2Cal InTemp3Cal OutTemp3Cal InTemp4Cal OutTemp4Cal InTemp5Cal OutTemp5Cal InTemp6Cal OutTemp6Cal MinInTmpRaw MaxInTmpRaw MinOutTpRaw MaxOutTpRaw CurrentCal SysStatus p for the EEPROM program Version and Revision Bytes The output starts with PROG and then sends the two Bytes values l for the get last command retrieves stored valu
37. e power supplies identified as P48A P48B P48C and P48D P48D is not present in the GCIMI charger P48A is adjusted near its minimum at 41V The other 3 are adjusted to near their maximum Voltage around 54V These power supplies are switched in and out of operation so as to be able to provide any charging Voltage from 7V up to about 245V One or both of the Constant Current power supplies are always used so that the charging is done in a Constant Current manner For batteries conditions requiring a Voltage between 7 and about 42V only the Constant Current power supply s are required as they can output their full current over this range For a Voltage range of about 42 to 69V P48A will be switched on as 10 well by the microcontroller detecting the SwitchV1 threshold of 42V and operating a solid state relay to add P48A s Voltage in series The Constant Current power supply s will initially reduce their output Voltage as required to maintain their set Constant Current output of 350 or 1050 mA The CC power supplies will gradually raise their output Voltage as the battery charges to maintain their target current When a little higher Voltage is required over 69V given by SwitchV2 the microcontroller will switch off P48A and switch on P48B which can provide 54V instead of 41V For the next Voltage range of 69V to 96V P48A will be switched back on and add its 41V to the equation This continues if higher Voltage is required depending on CarProfile
38. es from the last charger operation The output starts with LAST and then sends the value stored for each variable in the sequence Chg Time Topping Time EndChargeV StartChrgV 1 27 3 4 5 or 6 for the Stored Cycles Discharge and Charge Data Enter 1 2 or 3 for Cycles 1 2 or 3 of Bank 0 data Enter 4 5 or 6 for Cycles 1 2 or 3 of Bank 1 data The output starts with CYO and the Cycle No requested then sends mAH WtH ChT TpT ECV ChSR SCV DCT EDV DisR SDV values as shown on the LCD 32 EEPROM Memory Read Commands g e GET 1 or 2 Bytes of data at a specific EEPROM address The first 2 characters of the Memory Read commands are always g e The four characters of this command are g e 1 or 2 address In other words the 3rd character of this command can be only either a 1 or a 2 This Serial Input Command gets reads 1 or 2 Bytes from the specified EEPROM address or address pair After receiving g followed by e the program checks to see if 1 or 2 is the third character received If so it will do a 1 or 2 Bytes internal EEPROM read starting at the EEPROM address given by the 4th character received For the 1 Byte command the response back will be EEP1 Address Value stored at Address For the 2 Bytes command the response back will be EEP2 Address Value stored at Address Value stored at Address 1 Note that with this protocol
39. es or stages according to the Charging Voltage required to push the set constant current into the battery kind of like shifting gears on a car This allows the charger Chargermode 0 is off Chargermode 1 is the lowest Voltage range with only the constant current power supply ies on 8 allows the highest Voltage range and 9 is the Cut back stage where end of charge conditions are detected ChrgStopVP1 Stop charging if Voltage is gt this Voltage ChrgStopVP2 Stop charging if Voltage is gt this Voltage ChrgStopVP3 Stop charging if Voltage is gt this Voltage ChrgStopVP4 Stop charging if Voltage is gt this Voltage ChrgStopVP6 Stop charging if Voltage is gt this Voltage Comma Separated Values CSV A format for exporting spreadsheet files where each data item is separated by a comma Constant Current A method of charging that maintains a constant current into the battery until the Voltage level or other condition is detected to stop charging CurrentCal Calibration constant for low current in Overnight charger Cut backVP1 Cutback to 350mA when crossing this Voltage Cut backVP2 Cutback to 350mA when crossing this Voltage Cut backVP3 Cutback to 350mA when crossing this Voltage Cut backVP4 Cutback to 350mA when crossing this Voltage Cut backVP5 Cutback to 350mA when crossing this Voltage ChrgStopVP5 Stop charging if Voltage is gt this Voltage Cut backVP6 Cutback to 350mA when crossing this Voltage Discharge Charge cycles In Run
40. file The display briefly shows the information describing the Car Profile including car model and model year for example InsightGen1 2000 21 144V Profile 1 Then the LCD will prompt EDIT to change CarProfile 1 Each press of SETUP will move to display the next Set Up item and at the bottom of the list will return to the first item SetUp Navigation Diagram CarProfile SS Options Restore User Defaults Car Profile Car Profile is a 6 choice item with the current choice shown on the bottom line of the LCD When the LCD prompts EDIT to change CarProfile 1 Press EDIT and the LCD shows for example InsightGen1 2000 CarProfile 0001 Use the Up or Down Arrow Keys to select the desired Car Profile from 1 to 6 As soon as the Car Profile number has been selected the corresponding description will be shown Once EDIT has been pressed the second time the Car Profile will again be displayed including the calculated nominal battery pack Voltage for example ToyotaPrius 2005 202V Profile 5 Always press STOP when finished with Setup Except for the Tech Extended level option which has an automatic exit once completed If you want to cancel editing before the second press of EDIT press STOP Then to exit Setup press STOP again 22 If you want to change a SetUp item other than CarProfile press SETUP again to point next to Options Options The Options which the user can change are
41. fter the unit is powered Off 1 minute or 5 seconds Serial reporting interval I min Serial data 5sec Serial data 25 Options 00000000 Options 00000010 Change to the 5 seconds interval for serial data output only if fine detail and lots of data is desired and can be accomodated by the receiving data logger program This selection is not remembered after the unit is powered Off Charge before Discharge Yes No Charge B4 Disch No Precharge Options 0000000 Options 00000001 If the charger should automatically recharge the pack before starting the first discharge charge cycle leave this option at 0 For no pre charge press the arrow key down to select Yes instead of the default No This selection is not remembered after the unit is powered Off Reload Defaults The third and last SetUp function is Reload Defaults accessed by pressing the SETUP key when at Options Reload Defaults press now To restore the User parameters to the factory defaults press the left arrow key The User parameters are the items with an at the end of the name that are editable on the bottom line of the display in User Mode This function will not over write the Tech parameters section of memory to avoid losing the factory calibrations A brief message will indicate that the restore has been prepared Restore Defaults has been setup Then the next LCD page will be displayed giving the instruction to switch the AC power off amp on
42. gh power supplies R11 Too HOT Outlet Temperature R12 Too COLD Inlet Temperature R13 Too HOT Inlet Temperature R14 Too Cold Outlet Temperature Pausing Charging Press PAUSE to suspend charging This works while actively charging not while in a Delay Wait Run Modes 3 or 4 or Delay Interval Run Mode 5 period or discharging Run Mode 6 The LCD indicates PAUSE Charging Keeps Chg data This Pause Mode will allow a parameter to be changed without losing track of information on the charging process up to that time such as the charge time and milliAmp hours delivered to the battery The LCD will flash the status message on the top line Pause Charge R 0 11 every 5 seconds so long as the charger remains paused Press START to resume charging The charger may back down by a chargermode for example from M6 to M5 if the battery Voltage has decayed below a boundary switch point while charging was paused Car Profiles Matching Battery Pack Charging Requirements Six programmable Car Profiles are available for selection in Setup These allow the charger to be quickly switched between 6 different car models or battery pack types They can also be used set to the same battery car type for people with 2 or 3 Insights or Civics but with a different year edited for each description for the best match between each car harness and the charger In other words associate each car and its harness and temperature sensors wit
43. h a different CarProfile even though the cars are the same model Which CarProfile the charger is now using is selected in Setup How each CarProfile will control the charging and the description displayed for it are determined by editing 3 parameters for each CarProfile explained below Following are examples of typical CarProfile descriptions seen when the charger is turned on and in Setup InsightGen1 2000 Civic HCH2 2006 144V Profile 1 158V Profile 2 ToyotaPrius 2006 202V Profile 3 CarProfiles have their descriptions automatically generated from the Model Yrn parameters where n is 1 2 3 or 6 to match the CarProfile number and from the corresponding programmed Cut back Voltages This gives the user an approximate indication of the nominal battery pack Voltage each CarProfile can be used to charge CarProfile 4 is usually factory set for for a 158V pack for Honda Civic 2nd generation and Accord cars while CarProfile 5 is usually factory set for Toyota Prius 2004 and CarProfile 6 is usually factory set for Honda Insight II The following parameters are programmable for each CarProfile using EDIT Cut Back Voltage This is the Voltage level at which the charger switches to low current topping charging User Editable Cut backVP1 Cut backVP2 Cut backVP3 Cut backVP6 Cut backVP1 166 Note In addition to creating the nominal pack Voltage value for display calculated as 0 862 X Cut backVPn
44. h subsequent press of TEST will move to the next Test step selecting only one of the power supplies to be on for testing and adjustment There are 7 steps in total If PAUSE is pressed during Test the power supply s will be turned off and the position in the sequence remembered Press START to resume testing at the same step as before when PAUSE was pressed Press STOP to end Testing and reset the step counter to step 1 for the next time this function is used Or if TEST is pressed enough times to cycle though all the steps the following screen will be displayed End of TEST Mode TEST to restart Press TEST only if you need to get back into the Test mode Otherwise just wait a couple of seconds for the display to indicate that the charger has returned to the Off not charging condition Serial Output Setup Parameters and hardware The configuration required for the receiving computer or data logger is 9600 Baud 8 bits No Parity 1 Stop bit 9600 8 N 1 The RS 232 interface is isolated from the high Voltage connections and the vehicle Voltages by opto couplers Input as well as output on the Serial Port From program version 2 0 the Grid Charger is able to receive commands from a serial connected PC or lap top These are described in the Serial Input section a few pages below What is sent out from the Serial Port The Grid charger outputs data 1 Regularly at set intervals according to charger operation and its Option se
45. he automatic Discharge Charge programmable from 1 to 3 Cycles of Run Mode 6 which further improves this process of balancing the cells of a battery Table of Contents Genesis One Grid Charger Operation Manual Version 2 2 1 c ccccescesseceseceeeceeseeeeseceseeeeeecaecneenseeenanes 1 EnttoduetionE s oarenien cise cuss ot om edu a ep enema aot EM LM RM E 1 Care Handling and Use of the Grid Chat Serica eas dcteiiakeaedsnattess stapnatdistesatesianssedansacmaanieaduceoasta quias 4 What is Displayed on PoWeOE Up steer i Y NU UG UM HERD PATRE aware aa vani t eii eats 4 Front Panel Key Functions and LED Indicator 24er mere tse nra nua eta ok iran ene ee Epe scie e eR ae 6 Keypad Keys CDS 6 LED incer 9 Viewing Values and Parameters on the Liquid Crystal Display essseseeeeene 9 Typical Operation Starting Charging RunMode 1 or 2 essssseeeeeeerenen enn 10 Charger models and Spec rHeatloHs ss ac aene etse aoc siete slate t vi ud io tti teg oA des 11 How th Grid Charger Works Sensi cists das oculata a rex EARS EENAA AAEE Ue PA PNIS EES aiaa 12 Stopping Charging aae c a a e iiec E bera Pee d a a a aS 12 Pasme Charting us celata a auta dde a aE acta Mead ies aa a eee Dasa os ea 13 Car Profiles Matching Battery Pack Charging Requirements essen 13 Cut Back Voltage deae eto Ped qu Gh Ee oce RR I iR NAP blue CORO Pr ERR ote 14 M
46. ing the SETUP Function below RUN MODE Press to select RUN MODE choice editing The current Run Mode will be displayed on the bottom line of the LCD and can then be edited like the other parameters This is a shortcut key provided as a quicker way to select Run Mode for editing than by scrolling See Using the EDIT Function below Press to select Test Function and point to the next Test pattern in the sequence The first one switches all the power supplies on Each subsequent press of TEST will move to the next Test step If PAUSE is pressed during Test the power supply s will be turned off and the position in the sequence remembered Press START to resume testing at the same step as before when PAUSE was pressed If a key is not interpreted or active in the charger s current mode of operation or in the User Access Level usually a beep and a message like the following will warn about this and no action occurs In some situations such as during Editing a long Bad beep will instead be used to warn that a key is inappropriate and will not be processed Repeat Action In most modes of operation holding one of the Arrow Keys Up Down Left or Right pressed will cause a repetition of that key s action for as long as it is pressed This can be used to easily scroll quickly through a selection or change a value LED Indicator On Red during charging until the last stage Topping On Amber during the last topping bala
47. isplayed Prod Gridcharger V 2 2 Code 05 01 Then the previously selected Car Profile information is displayed and finally the Off mode display initially set to show Battery Volts and Charging Current on the top and bottom LCD lines respectively Only on power up after an upgrade from version 1 2 you will then hear a distinct series of beeps and see the message Doing AutoPStest Do Not Disturb The Grid Charger will now measure and record the Voltage output of all and then each one of the power supplies This will take about two minutes and you will be able to see the progress up to step 7 on the LCD Be sure that the charger is disconnected from the battery and do not press any key or turn off the charger until this has completed Red Charging Amber Topping Green Finished Universal Constant Current Battery Charger HIGH VOLTAGE ELECTRICAL EQUIPMENT User Operating Instructions Grid Charger Overnight 1 05 Amp High Current and Maintenance 350mA Low Current models June 11 3 2012 Program Version 2 2 indicates Overnight charger model only Front Panel Key Functions and LED Indicator Keypad Keys 5 Ecc Amber Topping Green Finished Press this key to Start Charger operation Charger behaviour at this time depends on the Run Mode selected amp the charge characteristics of the Car Profile choice amp its programming See Run Modes and Car Profiles below for details Note
48. le This is a special testing mode that requires the Password and Tech Edit selected in SetUp before it will work The two principle methods used to detect the end point for stopping discharge can be disabled if the discharge operator is watching the discharge using the Labview program and wants to take it further with manual intervention This feature is recommended only for experienced operators after the battery pack has been characterized using the normal automatic discharge The automatic safety stop methods Minimum Voltage reached and Falling too rapidly through the test Voltage Zone are not disabled and remain in effect These would not be triggered for almost all normal ranges of battery pack conditions but would stop discharge if the operator failed to do so before conditions became too extreme To activate Slope Stop Disable Press TEST when discharging The display will show 18 SlopeStopDisable now turned ON The Discharge time message on the second line will now change from Discharge 23 13 to DischTEST 23 13 Then later if the Slope method determines that the condition has been satisfied that normally would automatically stop the discharge the Discharge time message on the second line will now change to DischT 23 13 and a long beep will sound at every 6 seconds sample interval If the Voltage Averages Difference method determines that the condition has been satisfied that normally would automatically stop the di
49. lly need to charge now and cannot warm up the car amp battery pack sufficiently to work with the standard low temperature limits This selection is not remembered after the unit is powered Off It reverts to the standard low temperature limits the next time the charger is powered up turned On Serial Output Only During Charging or Always For the choice of when to send serial reports at the 1 minute or 5 seconds interval selected by the last option 0 Only when charging or while operating in Run Mode 6 Discharge Cycles or 1 All the time the charger is powered On Serial gt Chg Only Serial gt Always Options 00000000 Options 00010000 Pressing the Down Arrow key at the above screen will toggle the Serial Always operation on off and show the current setting on the top line This selection is not remembered after the unit is powered Off and then reverts to the standard behaviour of sending serial output only when charging Parameters Viewing amp Changing Access Level For the choice of Access Level Regular User Level or Technician Level the LCD prompts 24 Tech Edit Off Tech Extend Edit Options 00000000 Options 00001000 If the correct password has been entered Technician Level Extended Editing Capability can be selected Only select Tech Access when the charger is disconnected from the car battery or any battery Without the valid password the Access Level can only be User Level Tech Extended Edit Off The
50. lopeStarted in Discharge RunMode 6 indicates that discharge has 1 advanced to the fast sampling portion of the curve where the bulk discharge slope is determined was HighCurrent True for RunModes 1 and 3 in program Ver 1 2 1 DischargeSampleTarget has been calculated meaning that the Voltage 2 has dropped a further 1 2V from the start of the fast sampling was Pause indicates charging or Test has been paused in program Ver 1 2 2 Test indicates if in Test mode 4 3 DelayedCharge True if Delayed Charging is active 8 4 MaintCharging in charging period of Maintenance cycle RunMode 5 16 5 MaintWaiting indicates waiting to start the next Maintenance charging 32 6 Toppingflag in Topping the last phase of charging at low current 64 7 ChargeFlag charging in progress 128 Total of all values 255 30 From an interpretation of the SysStatus value reported from 0 to 255 the state of the charger can be almost completely determined Example If SysStatus 128 this must be from bit 7 being On and all others off This means it is charging now Bit 7 but not Delayed Charge or MaintCharging or in chargermode 9 Topping as those bits are zero Conclusion the charger is in RunMode 1 or 2 Immediate charging before the Topping phase Converting decimal to binary To convert decimal to binary is very easy you simply divide the decimal value by 2 and then write down the remainder
51. luding resetting the Topping Counter as soon as the battery Voltage rises about 5V from the previous reference snapshot A Battery Voltage Snapshot variable has been added and used for the serial output The benefit is that the Voltage indicated can now be the actual value used for Topping tests and not the value read a second or so later as the serial data is being transmitted Automatic selection of Tech user level is completed once an incorrect or zero password has been edited to the correct value Also an automatic end of SetUp is done at this time New Discharge Charge Run Mode 6 Discharge charge cycles with 1 to 3 cycles programmable before stopping Data stored in two EEPROM memory Banks for later viewing and comparison New Drop down top line LCD viewing range shows 12 data items for each Discharge charge cycle New arrow keys navigation for Discharge Charge data display Option for charge first or go directly to do the programmed Discharge charge cycles Test for safe MinDischrgV at START of Mode 6 Discharge Allow Discharge with a low MinDischrgV by an over riding 2nd press of START Added Discharge Reasons and other variables to store Discharge data Pulse Discharge RunMode 7 for Tech level users fast pulsing allows AC Voltmeter method of estimating and comparing pack and module internal resistance For the Serial Output New Start Charging headings and data lines provide information about charger settings at the
52. memory banks selected in SetUp Options as either Bank 0 or Bank 1 This means that a previous or first set of data can be saved in one memory bank while recording the latest data in the other bank This Options choice of to which active Bank to next save data is remembered after the unit has been powered off so there is less chance of over writing the set of data you want to keep In addition this data is available to be read out the Serial Port from the EEPROM storage Data Bank Stop Discharging list of reasons DischR 1 Manual Stop STOP key was pressed DischR 2 End of discharge slope drop off detected Battery Voltage graph dropping rapidly signals a cell drop out or overall pack nearing end of safe Discharge DischR 3 Low Voltage reached the MinDischrgV level DischR 4 Discharging too fast Voltage dropped too quickly through the slope sampling region at D SmpStartV This could indicate a low capacity or otherwise damaged pack DischR 5 Time out discharging reached the IntervalHrs Time This is not likely to ever occur unless IntervalHrs is changed to a low value like 2 hours DischR 6 End of discharge determined by the difference between the Long term and Short term Voltage Averages exceeding the SlopeDifMax set value Battery Voltage graph dropping rapidly signals a cell drop out or overall pack nearing end of safe Discharge 17 Discharge Charge Cycles Display There are six special 4 page displa
53. ncing stage of charging Mr On Green when the charge has been completed and or unit is ready to charge Green Finished Viewing Values and Parameters on the Liquid Crystal Display The Liquid Crystal Display LCD is the Transflective type that is viewable in bright light as well as low light with its back light It has 2 lines of 16 characters each There is a Contrast Adjustment potentiometer accessible through a hole on the back of the unit See Photo page 1 should the factory setting ever need changing The display screens have a user adjustable presentation time the time an information or alert page stays on display before moving on to the next one or back to the usual screen for the mode the charger is in The presentation time S ViewTime is set slow enough 3 seconds default for most new users who can speed it up later as they get used to seeing what is displayed With program Version 2 0 a key press is now seen during the ViewTime delay Depending on the position in the program or the message displayed this key press may only immediately end the view delay In that case another press will be required for the key to be interpreted and acted upon when the next LCD page is displayed and the user can see what the next key pressed will do As with the previous program version typically a beep is sounded each time a key press is seen and another beep when the ViewTime has finished You can either wait for the ready beep
54. ng RunMode 5 When charging is about to start at each Charge of a Discharge charge cycle Run Mode 6 This Start Charging Headings line is SSET Profile RunMd CutBakV VMax TopTime Max CGTm MaxAH SampleTm TDMax Soak ColdChrg VSmpDif CDcycles DeSmplFE MinDcV n Refer to the next page and the Variables and Parameters List a few pages ahead for a description of each of the variables Next the line of data corresponding to these headings is sent This output starts with SDAT and then provides the values for Car Profile Run Mode the Cut back Voltage of this Car Profile the Maximum Charging Voltage of this Car Profile the Maximum Topping Time the Maximum Total Charging Time the Maximum milliamp Hours of charge allowed the Sample Time of minute counts for the Topping test the Maximum Temperature Differential allowed to continue charging whether Soak is enabled and whether Cold Charging is enabled Soak and ColdChrg are flags Options that have either the value of 0 for Off or 1 for On Following these Options come the values of the variables added for Discharge the raw data number of bits difference required between the Long term and Short term Voltage averages to stop discharge the number of Discharge charge cycles to perform the factor to divide the test slope samples count by to determine the no of samples to use in testing for the end of discharge slope and the minimum Voltage to stop the
55. om DATA display to DATA edit Resch Second Press editing Saves the change and returns to DATA display When Charging the first press switches the 2nd line display to one parameter display for viewing editing with Car Profile selected Then the edit key functions as above See Using the EDIT Function below a in EDIT Increment data increase the value by one at the cursor position in regular DISPLAY Switch to top line of display for selecting data to display in Discharge charge Cycles Display Changes page in Charging Toggles between the 2 available LCD charging display pages Lv in Charging Toggles between the 2 available LCD charging display pages in EDIT Decrement data decrease the value by one at the cursor position in regular DISPLAY Switch to bottom line of display being active for selecting data to display in Discharge charge Cycles Display Changes page in SetUp Toggles 2 choice items Soak No Yes Discharge Data Storage in Bank 0 1 Cold Charge No Yes Serial Always No Yes User Tech level access F C degrees Pre Charge Yes No in Test Tech Turns off PCCHI power supply indicates Overnight charger model only M in EDIT move edit field one digit right in DISPLAY scroll right for the next data item to display a in EDIT move edit field one digit left in DISPLAY scroll right for next data to display Press to select Setup Function or move to the next Setup item in the rotation See Us
56. or this mode so that key data will also be sent out the 15 serial port during the discharge half of the cycle This will enable monitoring and graphing the discharge curve when connected to a data logger computer program The Option bit for 1 minute 5 seconds serial reporting should be set on to 5 seconds for the best detail when monitoring the discharge using the Labview program A separate discharge time variable DisChgT is used by the program to count up and indicate the minutes of time spent discharging From 1 to 3 discharge charge cycles can be selected by editing the User parameter C DcyclesMax At the end of this programmed number of discharge charge cycles the Grid Charger will stop once it has completed the final re charge The data from all of the cycles was stored in non volatile memory Bank 0 or Bank1 depending on the Options choice and is available to view on the top line of the LCD An Option in SetUp is provided to choose between doing a pre charge before starting the first cycle or skipping the pre charge and going straight into the start of discharge After pressing START with RunMode 6 selected the display shows the RunMode description on the top line Discharge Cycles and then the display shows Starting Dischrg Charge Cycling Then the LCD will indicate information like Batt Volts 155 3 Discharge 0 05 indicating the time counting up in minutes and seconds on the bottom line Besides C DcyclesMax there a
57. oth over and under temperature conditions which are reasons to cause a shut down of charging If this happens a message will show on the LCD that lasts for the ViewTime and a Reason Code is generated Here is a listing of the 4 temperature out of safe range conditions that will cause a shut down along with the Reason Code and LCD message indicated for each one R11 Too HOT Outlet Temperature This is an indication that the battery may be too hot for safe charging It is tested against a Tech editable parameter MaxOutTpRaw with a default of 850 about 107 degrees F The LCD message is HOT OutTemp Stop Try Delayed Chg R12 Too COLD Inlet Temperature This triggers below about 40 deg F if the Cold Charge Option is not On where there is concern that very cold air entering the battery pack could over chill the cells nearest the inlet It is tested against a Tech editable parameter MinInTpRaw with a default of 500 The LCD message is COLD InTemp Stop Heat car inside R13 Too HOT Inlet Temperature This triggers above about 97 deg F where there is concern that very warm air entering the battery pack would prevent adequate cooling of the battery pack It is tested against a Tech editable parameter MaxInTmpRaw with a default of 800 about 97 degrees F 34 The LCD message is HOT InTemp Stop Cool car inside R14 Too Cold Outlet Temperature This triggers below about 42 deg F if the Cold Charge Option is not
58. ottom line to select the one to view and change As each one is selected the corresponding description and state of the Option will be shown on the LCD top line When you get to the end the cursor will wrap around and go from the last to the first item or from the first to the last Brief Description and Displays for Each Option Soak Period After Voltage Plateau Detected End of Charge Off On Provides extra charging time in the Topping Phase up to the value of the TopTimeMN parameter The default value is 540 minutes Detection of the usual Voltage Topping Plateau ending will be ignored and charging will be continued until either the maximum Topping Time or the Maximum Total Charging 23 time have been achieved See the section above for the LCD screens See the explanation of Soak in the section Further Explanation of Charger Operation Bank 0 1 Selects in which of the 2 Memory Banks to store the data such as Start Voltage Stop Voltage Stop Reason etc for the next Discharge Charge cycle s when using the Grid Charger in Run Mode 6 Bank 0 Selected Bank 1 Selected Options 00000000 Options 01000000 Allow Charging at 10 degrees F colder than Normal Limits For the choice of allowing charging at temperatures 10 degrees F about 5 5 degrees C colder than the standard low temperature limits the LCD prompts Cold Charge No Cold Charge Yes Options 00000000 Options 00100000 Use this option only if you rea
59. ratures Added ColdChrg SetUp option that shifts the permissible minimum input and output temperatures down by10 degrees F Added MinIn tempRaw and MinOut tempRaw to the Tech variables that can be edited with the password in Tech Edit Mode Revamped SetUp to 3 items and replaced 5 SetUp options with 1 Options variable providing 8 Options choices changeable on one line Descriptions now provided for Run Mode and Car Profile at each step in editing and which update as they are being edited Added Profile amp RunMode to second line of Alt Display every 5 seconds when not charging when in Delayed Start waiting and for Maint Waiting Run Mode 5 Edit allowed during charging The first Editable item CarProfile is automatically selected If Edit then pressed again on a non edit item charger warns amp exits Edit to normal charge display Auto entry to EDIT password for wrong PW change to Tech level Adjusted SETUP to work while charging amp discharging 2nd PAUSE press sets kp 9 to reSTART Revised the order of variables display to a more logical grouping and to include the new variables Minor Fixes amp Changes fix for blank LCD after PAUSE was pressed in Edit and the warning message was displayed Now a 43 long Bad Beep is used as a warning that the PAUSE key does not apply here removed some duplicate beeps Revised Car Profile SetUp message Faster complete Run Mode display on both lines
60. re likely sub par There is a time limit on operation to avoid overheating the solid state relay in the discharge load 90 seconds for battery packs below 170V and 45 seconds above 170V Toyota Prius After pressing START with RunMode 7 selected the display shows the RunMode description on the top line Pulsed Discharge and then the display shows Starting Dischrg Pulsed Aux load Press STOP when your test is complete to end this Pulsed Discharge operation Using the EDIT Function First make the Bottom display line on the LCD active by pressing the Down Arrow key if the charger is not operating If charging press EDIT to change the bottom line from the charging display to the single parameter display Be careful what you Edit change while charging Scroll to select the item to edit using the Left and Right Arrow keys Note More items are available to edit in Tech Access than in User Access These additional parameters are mostly calibrations that should not be changed by the user Altering these except as directed by Genesis One can cause the charger to overcharge undercharge or otherwise malfunction and risk damage to the battery pack Press EDIT to make the value field editable Using the Left and Right Arrow keys move the cursor to the digit position to be changed Press the Up and Down Arrow keys to Increment increase and decrement decrease the value of the digit to arrive at the desired number For most parameters
61. re two other User editable variables that affect Discharge MinDischrgV and SlopeDifMax MinDischrgV is provided to set the minimum allowed Voltage threshold at which discharge will be stopped if not stopped sooner by one of the other methods The factory default value is 130V intended for the Honda Insight 1 There is only one MinDischrgV not one per Car Profile as with the Cut back and ChgStopV While there are several other detection methods that will almost always stop the discharge before reaching this safety limit minimum Voltage it is strongly recommended that this value be changed for discharging a battery pack other than the 144V nominal default Suggested values are 143V for a 158V pack 182V for a Prius 201V pack A second higher threshold or switch point is calculated from the Cutback Voltage of the chosen Car Profile The formula is 0 9 X Cut backVPx which is about 153V for 144V Insight packs This determines a lower limit for starting testing by the two methods for detecting a good point in the discharge curve to stop This lower limit for starting testing backs up the usual start point determined by finding a minimum in the difference between the Long term and short term Voltage Averages the flattest portion of the discharge curve Which ever start point Voltage value is higher reached first is stored as SmpStartV displayed in the discharge serial output and used to start the sampling testing for determining
62. s that match the requirements of the battery being Number from 80 to 2048 representing 20 1500 ohms 1 7 selects charge or discharge mode Interval in minutes sample delay when determining the end of charge Time in seconds that splash messages stay in view Adjusted Difference between Long amp Short Term Avg V to stop Discharge of samples being averaged to give current display like a low pass filter Voltage at start of charge Voltage at start of discharge Sets minutes to wait after START is pressed before charging Maximum inlet to outlet temp difference after charging enters topping 47 zone Tech mode Allows access to viewing and changing certain variables settings and to using 2 special discharging Run Modes that are not available in the standard User Mode Requires the password to access Tech Mode Topping Time Real time spent in the topping zone Top TimeMN Maximum time to remain in the toping zone before shutoff ViewTime The time that a message stays on the LCD screen before moving to the next message to be displayed See S ViewTime above 48
63. scharge the Discharge time message on the second line will change to DischTAVG 23 13 and a long beep will sound at every 6 seconds sample interval Press TEST again while discharging to turn off this Slope Stop Disable feature Then it will no longer inhibit automatic detection of when to stop discharge The display will show SlopeStopDisable now turned OFF Variables and defined factors that affect this mode User Variables Parameters that affect the operation of this mode C DcyclesMax SlopeDifMax MinDischrgV Cut backVP1 2 3 6 depending on the Car Profile selected A HrCapac IntervalHrs Derived variables using the above user variables and pre defined multiplier factors D_SmpStartV 0 90 define FactorD_SmpStartV multiplied by the CutbackV If the sampling start point was not already found by the minimum of Voltage Averages difference method then sampling for determining the end of discharge will start anyway at this Voltage Defined constants pre determined fixed define AvgDifMinCnt 48 The number of 5 second samples that DifAvgVminRaw must not change to have found the minimum value for the difference of the Long term amp Short Term Averages define MaxDifForMin 40 If VbitsSmpDifX10 is still higher than this when minimum AvgDif is found don t accept it as the minimum to start Averages difference and Slope point methods for Discharge Stop This will eliminate the false early minimum found with some Prius 2004
64. settings up to the point that all of the 48V nominal Power Supplies P48A to P48D are on Stopping Charging There are many ways or Reasons for the charger to stop charging in order to automate and optimize the process of charging and protect the battery The reason the charger stops charging is displayed briefly as it happens on the LCD sent out on the serial port with the regular status reports and kept and displayed as the R indication on the Not Charging flash message This message is shown one second out of 5 seconds Reason indicated as R 1 or R 2 etc There are fourteen of these reason codes at present which advise the reason why the Grid Charger last stopped charging R1 Manual Stop STOP key was pressed R2 The maximum allowed Voltage has been reached ChgStopVP1 ChgStopVP2 ChgStopVP6 depending on the CarProfile selected R3 The maximum allowed total charging time has occurred MaxChgTime R4 The timed end of topping mode occurred TopTimeMN R5 Battery now too hot to continue MaxPTCVal R6 The TEST button was pressed R7 The maximum allowed milliAmp Hours charge was supplied to the battery MaxChg mAH R8 End of Topping charge due to Voltage plateau detected R9 Temperature Differential Outlet Inlet Temperature target reached meaning the charging energy received by the battery is now going into heat rather than raising the state of charge R10 Higher current than expected throu
65. sing through the pack PTC value Number from 80 to 2048 representing 20 1500 ohms Charge Time Real time total charge time Topping Time Real time spent in the topping zone DisChrg_Time Real time total discharge time To StartChrgV Voltage at start of charge 9p EndChargeV Voltage at end of charge Line StDisChrgV Voltage at start of discharge Of EndDisChgV Voltage at end of discharge Display Last Chg mAh mAh of the last charge Last Chg WHr WHr of the last charge j Setup parameters CarProfile Select the Profile that best matches your car s 1 to 6 Cut backVP1 Cutback to 350mA when crossing this Voltage ChrgStopVP1 Stop charging if Voltage is gt this Voltage Model Year1 Model year and car name Cut backVP2 Cutback to 350mA when crossing this Voltage ChrgStopVP2 Stop charging if Voltage is gt this Voltage Model Year2 Model year and car name Cut backVP3 Cutback to 350mA when crossing this Voltage ChrgStopVP3 Stop charging if Voltage is gt this Voltage Model Year3 Model year and car name Cut backVP4 Cutback to 350mA when crossing this Voltage ChrgStopVP4 Stop charging if Voltage is gt this Voltage Model_Year4 Model year and car name Cut backVP5 Cutback to 350mA when crossing this Voltage Bottom ChrgStopVP5 Stop charging if Voltage is gt this Voltage line of Model Year5 Model year and car name Display in Cut backVP6 Cutback to 350mA when crossing this Voltage User ChrgStopVP6 Stop charging if Voltage is
66. ssing the STOP key on the charger The EEPROM Memory Write Commands are used to write a new value for a variable directly into the EEPROM non volatile memory instead of Editing the value on the Grid Charger keypad The two EEPROM write commands are w h Address Value gt Writes the high Byte of a 2 Byte variable This command is not used when sending a single Byte variable such as a Tech calibration value 31 w l Address Value gt Writes the low Byte of a 2 Byte variable or writes a single Byte variable like the Tech calibration values After this low Byte command has written the Byte to the EEPROM it will then cause a read back update to the corresponding variable SRAM memory the same as if the change was done on the keypad using EDIT The new value can be seen on the display and will be used from now on in the charger operation Send first the high Byte of a 2 Byte variable and then the low Byte so the read back will be done only after both Bytes have been written to the EEPROM If sent electronically put a delay greater than 5 seconds between the two commands so that the program will have time to process the first one and write the Byte to the EEPROM before the data in the buffer gets over written by the next command To use these EEPROM write commands you need to have 1 a listing of the addresses corresponding to the EEPROM locations for each variable available on request 2 an ASCII chart showing th
67. t and Diagnostic Flash Code Trigger Device A small module that plugs in to the OBD II diagnostic port should be used to set the battery SOC to a high level after a grid charge has been completed Then the car will know to expect the battery to be at its high SOC instead of where it last thought it was A second push button will be provided to trigger the diagnostic code indication A prototype of this module has been tested and the production version is now being produced Check the 99mpg website for information on availability and price Reset SOC Blink Codes Programming Adapter If you have a compatible programmer for the PIC series microcontrollers you will be able to update the program version and features of the Grid Charger and other PIC based devices Pic programmers can have different programming connectors The Microchip units have a 6 pin RJ 12 connector which directly matches the programming socket on the Grid Charger using the RJ 12 jumper cable usually supplied with these programmers e g ICD 3 Other programmers use a 5 pin single row inline connector SIP and will need an adapter to plug to the Grid Charger Programming socket Conversely you may have a programmer with RJ 12 format output and devices to program such as the OBD II C amp C that need a 5 pin SIP programming connector This set of components lets the RJ 12 type program the SIP and the SIP program the RJ 12 See photos on the following page 40
68. the Grid charger echoes back the address requested and then the value s accessed at this address Power Failure AC mains grid Power Failure or AC power disconnect or switch off while in operation What happens when power fails during operation In RunModes 1 to 4 Immediate and Delayed Start charging Once power is re applied the charger powers up OFF waiting for manual intervention Push START to restart In RunMode 5 Long Term Maintenance Charging If the charger was in between charging periods in the waiting interval it will power up at the beginning of the waiting time while watching as usual for a low battery Voltage to prompt an earlier start of active charging If the charger was charging at the time of the power failure it will start up with 1 minute of waiting interval to allow it to get a good reading of the battery Voltage and the appropriate chargermode to use then start charging As it charges it watches the battery Voltage and looks for the usual conditions to determine when to end the charging period and go to the waiting interval In RunModes 6 or 7 Discharge or Pulsed Discharge Once power is re applied the charger powers up OFF waiting for manual intervention Push START to restart Abnormal Conditions Over Current If more current is measured than expected for the present charger operation Run Mode Charger Mode etc this could indicate a mis adjustment or failure of a power supply If this condi
69. the end of discharge More about this later The grid charger will begin the 5 seconds Voltage sampling when the battery Voltage has dropped to this SmpStartV value In other words as the battery is getting more discharged this SmpStartV Voltage is reached and the Grid Charger will watch it more closely and check whether the rate of discharge indicates the discharge should be stopped At the instant of each 5 seconds sample there is a beep unless disabled by the ALARM key and the indication Smpl at the top left of the LCD so the user can be aware of the progress and faster sampling At the end of the first 5 bits drop from the start 16 of rapid sampling about 1 2 Volts further drop a determination of the rate or slope of discharge is stored This reference value is used to later stop the discharge before the minimum TestDischgV if a relatively too fast rate of Voltage drop indicates a weak cell reversal may be about to occur In addition there is a further sanity check if the Voltage is seen to be dropping abnormally fast in the slope determining region around the D SmpStartV Voltage the discharge will be quickly stopped Usually this indicates a battery in very poor health that will need to have some cells replaced before a satisfactory capacity can be achieved Once the pack discharge has been stopped by any of the 4 methods fast dropping Voltage the discharge slope has started accelerating down to the calculate
70. tion is detected the charger will stop charging and display this message plus alarm beeps to alert the user Stop Overcurrent Charge mA 395 33 Under Current If less current is measured than expected for the present charger operation this will cause an audible and visual warning as shown below but not a stop of charging Warn Lowcurrent Charge mA 325 Detection of this condition only works if Alarm is ON The power up default is On but it can be switched Off and back On using the ALARM On Off key In either case contact Genesis One describing the circumstances for advise on how to correct it Fan and Temperature Control and Shut down At the start of charging the fan is turned on and the Grid Charger s microprocessor waits for a set time 2 minutes before using the information from the Inlet and Outlet Temperature sensors After the delay the air flow through the battery pack and over the sensors will now enable the sensors to post useable values for the Inlet ambient Temperature and the Outlet battery warmed air Temperature The Grid Charger s microprocessor uses the raw corrected data before conversion to deg F or deg C so that it will work the same regardless of the User s preference for degrees F or C The raw data is about 5 points per degree F giving a resolution for temperature testing of about 0 2 degree F These temperature readings are used when charging after the initial 2 minutes delay to test for b
71. ttings 2 On demand in response to commands received on the serial port The Grid charger outputs data providing the status and values of key variables every minute during charging and discharging and at significant changes in operation like an automatic stop The RS 232 interface is provided on a DB9 Female connector that can be hooked to a computer serial port or USB to Serial adapter using a standard DB9 Male to DB9 Female straight through serial cable A terminal program in the computer such as Hyper Term can be used to receive and display the data Alternately the serial port can be coupled to a data logging device for later viewing and analysis A custom program is available from Genesis One to do data logging graphing and control of charger operation plus reading and editing of the parameters from a PC instead of using the unit s keypad and LCD 28 Power on Serial Output At program start up the Grid Charger outputs a message like Prod Gridcharger V2 0 Code 03 22 This is the ID and Program Version message Start Charging Serial Output A new Start Charging Headings line and then a line of corresponding data is sent When START is pressed When charging is about to start at the end of the delay start of charging in Delayed Charge RunModes 3 amp 4 When charging is about to start at the end of the Wait Interval in Long Term Maintenance Charging RunMode 5 At low Voltage start in Long Term Maintenance Chargi
72. ue will be displayed as a negative number Be careful about changing parameters if you are not sure about what you intend to accomplish the effect of changing a each parameter and the correct value to use for your battery pack and environment For example reducing the SampleTime too much from its default 30 minutes to below about 10 minutes for an Overnight charger could result in a false detection of the Voltage Plateau Voltage no longer increasing and a premature end of charging Changing the Run Mode Press the RUN MODE key The RunMode variable will automatically be selected for display and editing on the second line ofthe LCD RunMode 1 Press the EDIT key to place a cursor in the RunMode value field for editing RunMode 000 Follow the EDIT instructions above to change the value choice of RunMode and save it RunMode 0008 If an invalid RunMode such as 8 or 0 is entered the warning Invalid RunMode will be displayed The Run Mode will be forced to 1 to prevent an invalid Run Mode being saved When EDIT is pressed to end and save the change the value will be checked for suitability with the charger model Ifa 1 or 3 was chosen for a 350 mA charger model the charger is not an Overnight 1 05 Amp model the a 1 will be changed to 2 and a 3 changed to 4 and the corrected values over written Using the SETUP Function Pressing the SETUP key places the charger in Setup Mode starting with the first item Car Pro
73. uence STOP charger turn off the AC power switch disconnect the AC cord disconnect the battery cable e Do not use this equipment where it could get wet or experience condensation e Only use a properly grounded GFCI protected 3 wire AC circuit to power this charger e Do not use this equipment in enclosed spaces without adequate ventilation If the ambient temperature is warm to hot to prevent overheating Be sure before starting a charge that the Car Profile matches the car when using the default settings Pay extra attention if you have customized any settings Consult Genesis One about any unexpected behaviour not covered by this user manual What is Displayed on Power up First the unit checks that the EEPROM version matches what is expected by the program and displays it EEPROM V 4 000 Parameters Read Parameters Read means that they match and the parameters stored in non volatile memory including those changed by the user have been read into RAM memory to use in operation Defaults Written on the second line instead would mean the unit sees a mismatch of versions and will instead take the default values contained in the program code and load them into EEPROM memory This happens with a new unit at the factory when the user activates Restore Defaults or when a newly updated program version requires new or re arranged parameter locations in the EEPROM After the ViewTime the program Version Number and Date is d
74. using the Left and Right Arrow Keys Note The Tech level items include calibrations done when the charger was first built and tested These are not likely to require field adjustment If one of these parameters requires changing access the Tech Level using Setup and edit the Password to the correct number as directed by Mike at Genesis One General Knowing the meaning and function of the parameters that control charger operation will be helpful to your understanding of how it works and what it can do Consequently some time spent to read through this listing will be time well spent As indicated in the introduction section How the Grid Charger Works this charger consists of several power supplies that can be switched on and off individually under microprocessor control to build a rising Voltage at one of two available constant current values As a result it is able to charge almost any battery from below 12V up to a little over 200V nominal Prius 2004 to present Topping Mode After doing the bulk of the charging as determined by the Voltage of the battery some of the cells will have reached full charge before the others It will now be necessary to cut back the charge current if it is an Overnight charger to a value these full or nearly full cells can tolerate without damage while the lower charge cells continue to charge at the lower current rate 350 mA Also from this time onward additional methods are started to determine
75. utes on the top line of the Alternate Display every 5 seconds Start in 168H00 Profil 1 RunMd 4 Once the IntervalHrs waiting off time between charges has expired charging will start and the LCD will indicate WaitTime expired Starting charge If the charging is started because of low Voltage before the Maintenance wait time interval expired the LCD will indicate Voltage too low Starting charge Usually no one is present and looking at the LCD when these starting messages pop up After the WaitTime Expired or Voltage too low reason for starting charge message the usual charging display will be shown with the option available to press the down arrow for the alternate charge display Run Mode 6 Discharge Charge Cycling Mode 6 is intended for use in discharging a battery pack to optimize the battery capacity and performance It is also a good diagnostic aid in determining the battery condition and in finding specific sticks modules that require refurbishing i e cell replacement The charger is designed to be used in Mode 6 and mode 7 described later with an accessory discharge load so that the pack is being discharged during the period between charges When started in Mode 6 the Auxiliary Output available from a connector behind a hole plug on the side of the charger case once installed is turned on to enable the solid state relay to connect the discharge load The Serial Always option is automatically set f
76. y detected Insulate any battery wire connection leads or plug so no short circuit can occur Press TEST to select Test Function and point to the first next Test step in the sequence The first step switches all the power supplies on Briefly after TEST has been pressed the LCD shows Test Mode Now 1 on the top line and a message like Saved PS V 198 8 on the bottom The display then looks like Batt Volts 198 5 1198 8VS OmA The Batt Volts 198 5 shows what is being measured now in this step The bottom line indicates 1 for step 1 198 8VS for the Voltage measured and saved to non volatile memory during a previous test or the factory calibration and 0mA as the current now When done as a factory test with a resistor load drawing current the actual current will be shown instead of 0 Press EDIT once only to replace the previously stored test value with the present value Be sure that you want to over write the original stored value and also to wait for the Voltage reading to stabilize before pressing EDIT to take the Voltage sample Unless a power supply output has been re adjusted or a power supply replaced stay with the initial sample to keep as a reference for comparison Press the Down Arrow key in this step 1 to turn off the PCCHI power supply to test at 350 mA ifa 27 test load is being used Press the Up Arrow key in this step 1 to turn the PCCHI power supply back on indicates Overnight charger model only Eac
77. y items 2 Banks of 3 Cycles per Bank for viewing of the Discharge charge Cycles information These are accessed on the LCD Top Line to the left of the Batt Volts item Scrolling with the left and right arrows over this area selects the first Title Page of each Bank0 Cyclel P1 Bank0 Cycle2 P1 Bank0 Cycle3 P1 Bankl Cyclel P1 Bank Cycle2 P1 Bank Cycle3 P1 Select Pg v amp Select Pg v amp Select Pg v amp Select Pg v amp Select Pg v amp Select Pg v amp When the display is on one of these 6 Bank and Cycle display items pressing the Up or Down arrow will select another page of data to view There are 3 data pages with 4 data items on each plus the Title Page for a total of 4 pages for each of the 6 Bank and Cycle display items Pressing the Down or Up Arrow navigates from page to page and wraps around at each end of the list of pages Bank1 Cycle3 Pl Indicates which cycle and Bank are being displayed Select Pg V amp Reminds about the Down and Up Arrows used to select pages Ud DCT 125 SDV160 4 Discharge Time Start Discharge Voltage DisR 2 EDV 139 6 Discharge Stop Reason End Discharge Voltage t PAH 35 SCV139 3 Percent Amp Hours capacity charged Start Charge Voltage ChSR 8 ECV171 2 Charge Stop Reason End Charge Voltage uf mAH 2275 WtH 342 milli Amp Hours charged Watt Hours charged ChT 360 TpT 35 Charge Time Topping Time Disabling Automatic Stop of Discharge mode Slope Stop Disab

V 2 operating instructions

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