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1. August 2011 Revision 1 0 1 2009 2011 Global Energy Innovations All rights reserved Printed in the USA All product names are trademarks of the respective companies Document EN 1005 1001 GLOBAL ENERGY INNOVATIONS Global Energy Innovations EC1000 amp EC2000 Handheld Battery Analyzers Firmware Version 2 0 0 Onward Users Manual Global Energy Innovations EC 1000 amp EC2000 Analyzers Users Manual Limited Warranty amp Limitation of Liability 1 LIMITED WARRANTY amp LIMITATION OF LIABILITY Subject to the exclusions contained below Global Energy Innovations warrants its EC1000 and EC2000 Analyzers Products Global Energy Innovations branded or certified accessories sold for use with these Products Accessories and Global Energy Innovations software contained on CD Roms or other tangible media and sold for use with these Products Software to be free from defects in materials and workmanship under normal consumer usage for the period s outlined below This limited warranty is a consumer s exclusive remedy and applies as follows to new Products Accessories and Software purchased by consumers which are accompanied by this written warranty One 1 year from the date of purchase by the Producto aS denned above first consumer purchaser of the product One 1 year from the date of purchase by the Accessories as defined above f
2. 51 52 Geographical Region 18 E E 20 Compact Die een 15 H Automobile Inverter En 15 COMP AMON SOMNATE tt 14 Hand Strap ibit eds 14 AUTO START DELAY EC 28 35 SOMPANT REGION Gt ten ee 32 Hard Carrying Case cocinas 15 B E i ene p HARDWARE tratada 24 BASELINE AGF eebe 47 Se eg 6 e DEENEN 18 Baseline Adjustment ssssss 49 e e rolg omaes a High Capacity Lithium lon Battery Pack 15 BASELINE IMP REF mi 47 Eege HIGH NOISE ice ae ute ore en enol de 51 CONTAQGT EE 24 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Index MAIN MENU 22 A m ii IBMS Seege t ere ates 17 46 MANUFACTURER 0 cccccecceceeesteeeeeees 27 34 REPEATABILITY UTILITY 51 IBMS BASELINE ADJUSTMENT 47 MASTER RESET sese 55 REPEATIBILITY UTIUITN 51 Impedance Voltage sesssneneeeeeeeeeenene nsere 24 MINI SD CARD 24 Replacement Teeth ooooooconnnococcccncncccccncanancnnnnn 15 IMPEDANCE ALARMS 29 35 Mini SD Memory cocococcccccccccccnconononnnnnnnnccnannn nono 14 Replacement Tips 15 IMPEDANCE HIGH sss 29 35 MODEL coe td 24 27 34 Representative or Distributor ii IMPEDANCE LOW 96 sese 30 35 N S OS 14 Needs Tesi tia 52 SAREE Yuet een cacy age 10 11 Infrared Thermometer
3. 11 STRAP S PER BATTERY Entry of the number of Straps per Battery or Cell in the String being tested The user can manually enter a value from 1 to 59 or use the RIGHT and LEFT navigation buttons to increment or decrement the numeric value 12 ELOAT CHARGE The user selects if the Batteries or Cells in the Sting being tested are on float charge or not The RIGHT and LEFT navigation arrows are used for selecting between YES or NO 13 VOLT REF CELL V The user enters the Voltage Reference Value for the Cell This value will be used for all of the Voltage Alarm calculations When data entry is completed the value for VOLT REF BATTERY V is automatically calculated Values are entered manually or with the RIGHT and LEFT navigation buttons There are no preset values on the Analyzer when entering this section 14 VOLT REF BATTERY V The user enters the Voltage Reference Value for the Battery This value will be used for all of the Voltage Alarm calculations When data entry is completed the value for VOLT REF CELL V is automatically calculated Values are entered manually or with the RIGHT and LEFT navigation buttons There are no preset values on the Analyzer when entering this section Note Either CELL or BATTERY reference values may be enter first and the other is automatically calculated 15 USE AUTO CALC BASELINE The user selects if the Analyzer will automatically calculate a baseline for the string being test
4. EC1000 8 EC2000 Analyzers User Manual Table of Contents AUTO CALIBRATION eec 54 MASTER RESE Tiida A A A i 55 Niere VM 55 SYSTEM DIAGNOSTIC S inenen tt ee tee beet ete ew e n e bte ete en e ec a t ede A ed 55 TEMPERATURE MEASUREMENTS amp CORRECTION iU re A tUe oig cd d eec t dese Abr Eua ela e c Ee nete lees 55 ANALYZER JBMS INTERAGCTION 1 tert ee ode te ehh e d ge ER Foe vel dete tede tu baee d eue dee ute bdo e oh eine ete eee i Hee deus 55 CHAPTER 6 TROUBEESHOOTING 3 3 e ert eb IR E Ge docte ie Male ire Gian Aba i Me e e E er eed 57 lee t E le TEE 57 FIRMWARE UPGRADES titi ha enn A A RA e I etd et eee ite A ae tee ee deed 57 CRASH RECOVERY E niae eda pta e a etin cda a e ein alia 57 ANALYZER SPECIFICATIONS ed 6 Intt eine editi A A ain ees 58 INDEX inicia A A dais m A da ham ect A ct d eet dm etia mti ER pt s 64 APPENDIGCES ette ince medendi ti ett nete iicet gts 67 Page 3 Global Energy Innovations EC1000 8 EC2000 Analyzers User Manual Declaration of Conformity 3 DECLARATION OF CONFORMITY Based on the test results using appropriate standards the EC1000 and EC2000 Handheld Battery Analyzers are in conformity with the following e Electromagnetic Compatibility Directive 2004 108 EC e Low Voltage Directive 2006 95 EC C Conformity is indicated by the CE symbol Conformit Europ enne e Subpart B of Part 15 of the FCC Rules CFR Title 47 FE e CES 003 Issue A
5. 2 25 VOLT REF BATTERY V 2 25 USE AUTO CALC BASELINE YES USE AUTO CAL STRAP REFERENCE No STRAP REFERENCE ma 0 985 Figure 2 8 Location selection screen Figure 2 9 String selection screen Figure 2 10 String configuration screen When using these three 3 String Configuration screens the user may selection from a host of function keys F1 F2 F3 and F4 to save copy edit delete and enter additional information When the user is entering information in the STRING CONFIGURATION screen Figure 2 10 there are three 3 Template entries that may be selected otherwise data may be entered manually into these section The three templates BATTERY TYPE TEST SETTING and ALARM SETTING are detailed in the sections below Details on each of the STRING CONFIGURATION data entry fields are described below Although many of these were previously covered in the QUICK TEST section they are repeated here for clarity and comprehensiveness 1 STRING I D This is the name or Identification I D of the string 2 BASELINE STATUS This indicates to the user if the string that will be tested has been baselined If YES is displayed this indicates that teh string has baseline values for each battery or cell Baselining is covered in detail in a later section of this Users Manual 3 NUMBER OF BATTERY S This indicates the number of batteries or cells that will be tested in the string Page 33 Global Energy Innovations
6. 8 EC2000 Analyzers Users Manual Chapter 1 Initial Analyzer Setup The SYSTEM PROFILE screen Figure 1 12 gives the user all of the Analyzer information This information is often required if your Analyzer is being upgraded or if you have a question regarding the features that have been activated Details are listed below GENERAL SETTINGS 1 FIMRWARE The firmware version running on the Analyzer Firmware is automatically updated when you connect to IBMS when your PC has a live internet connection and can access the Global Energy Innovations Activation Server 2 HARDWARE The Analyzer hardware version This is a code that indicates the versions of the various internal hardware modules 3 VERSION RELEASE DATE The date that the firmware was released from Global Energy Innovations to the field for use 4 IBMS COMPATIBLE The latest version of IBMS that is compatible with the firmware currently running on the Analyzer 5 COMM PROTOCOL SQLite The communication protocol used for transferring the SQLite data to and from the Analyzer and IBMS 6 SERIAL NUMBER Analyzer Serial Number Since all Analyzers start at the factor as EC1000 s even if you have an EC2000 the first six 6 characters will always be EC1000 7 MAC ADDRESS The MAC Media Access Control Address of the Single Board Computer inside the Analyzer This is a unique identifier and allows Global Energy Innovations to identify the Analyzer v
7. Chapter 4 Connecting the Analyzer to IBMS Software About this Chapter This Chapter describes how you connect the Analyzer to IBMS Intelligent Battery Management System Software Once connection is accomplished please reference the IBMS Users Manual for details on how to transfer and analyze your data using IBMS The user must first connect the Mini USB cable from the Analyzer to a PC where IBMS is installed and running Now navigate to the CONNECT TO PC from the MAIN MENU Figure 1 5 After several seconds you should see the screens shown in Figure 4 1 below MEMORY MEM O1JAN20101300 sii CH USB CONNECTION ACTIVE WARNING e DO NOT DISCONNECT DURING DATA TRANSFER Figure 4 1 USB Connection screen The Analyzer is now connected to the PC and is ready to communicate Page 46 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 5 Advanced Analyzer Features amp Functions CHAPTER 5 ADVANCED ANALYZER FEATURES amp FUNTIONS About this Chapter This Chapter covers all the Advanced Features and Functions of the EC Series Analyzers EC1000 and EC2000 There is also reference to IBMS Intelligent Battery Management System Software in this Chapter since there is a great deal of overlap between the two systems This Chapter also covers a number of the functions in the TOOLS menu under UTILITIES TOOLS BASELINING ANALYZER BASELINE UTILITY This se
8. Firmware update error Figure 6 2 Analyzer system recovery screen Figure 6 3 Analyzer restore screen CRASH RECOVERY If for any reason the Analyzer crashes the user will likely see the screen shown in Figure 6 2 when the Analyzer is rebooted Follow the instructions on the screen to recover If the Analyzer boots but does not properly recover i e The Analyzer continues to crash or exhibits abnormal behavior the user may use the recovery key strokes shown in Figure 6 3 After pressing the Power ON button press the SHIFT key first and then press the F1 key Hold both keys down together and you will see the screen in Figure 6 3 The Analyzer will display RESTORE BACKUP FILE if the recovery process has successfully started After booting the Analyzer should operate normally Page 57 Global Energy Innovations EC1000 amp EC2000 Analyzers Users Manual Analyzer Specifications ANALYZER SPECIFICATIONS Performance Specifications and Operating Conditions Test Method CELScan Frequency Response Analysis Completely non intrusive Available but not required for measurement and detection of battery Data Trending health degradation Battery health is determined from a single measurement 5 Ah to 2 000 Ah Specified Performance Range Amp Hour Capacity Range 1 Ah to 9 999 Ah Operating Range for Batteries Under Test Amp hour measurement capabilities depend upon whether or not the battery impedance is within the
9. Testing 3 When a double asterisk is shown next to the test result this indicates a FAIL Alarm condition STRING TESTING This section covers testing using the TEST STRING function When the user selects TEST STRING from the MAIN MENU the following screens are displayed These are presented below MEMORY ET on van 0101300 w MEMORY BT 01 JAN 203071900 IEN MEMORY BT 01 saN 20101900 3 LOCATION SITE STRING SELECTION TEST SERIES SITE ID SITE Telluride BASELINED TELLURIDE STRING 1 COMPLETE T MOBILE ROCKY MOUNTAINS NO lt NEW TEST SERIES gt Telluride String 2 2010 01 02 12 45 08 NO Bolder String 3 2010 01 03 10 30 02 String 4 2010 01 04 22 13 43 2010 01 05 08 45 09 Figure 2 18 Test String testing screen Figure 2 19 String Selection screen Figure 2 20 Test Series screen Figure 2 18 is the first screen that the user sees This screen allows the user to select the Site that will be tested Upon selection of the site the user is prompted to select from a list of string names as displayed in Figure 2 19 The baseline status is displayed for each string on the far right hand side of the screen A string that has been baselined YES cannot be retested Once a string is selected the user is prompted to select a Test Series A baselined Completed YES string cannot be tested because the after baselining is completed the string is permanently locked for testing A NEW TEST SERIES gt may be selected at any
10. 2 are used to scroll up and down 9 The four 4 function keys The text for these keys will change depending on which screen is being displayed The MAIN MENU The Analyzer MAIN MENU Figure 1 5 gives the user the following navigation options listed below In this Chapter only the QUICK TESTS TEST CONFIGURATION and UTILITIES MENUS are covered Some sub Menus in these sections are not covered because they do not directly apply to the basic setup and use of the Analyzer 1 QUICK TESTS 2 TEST STRING 3 4 TEST RESULTS 5 UTILITIES 60 CONNECT TO PC Page 22 Global Energy Innovations EC1000 amp EC2000 Analyzers Users Manual Chapter 1 Initial Analyzer Setup The UTILITIES MENU The Analyzer UTILITY MENU Figure 1 10 is the first Menu that the user should enter and configure In this Menu only the SYSTEM SETTINGS and SYSTEM PROFILE Menus are explored in this section In future Chapters the other UTILITY MENU options are reviewed in detail MEMORY E Jo JAN 2010 13 00 wii SYSTEM PROFILE PROFILE NAME VALUE FIRMWARE 2 0 0 HARDWARE 01010101 MEMORY mE O1JAN20101300 wii RE MEMORY fe 1 o1 JAn 20101300 wii mmm VERSION RELEASE DATE 2011 01 01 IBMS SOFTWARE COMPATIBLE 2 0 0 Build 33 UTILITIES SYSTEM SETTINGS COMMUNICATION PROTOCOL SQLite USB SERIAL NUMBER EC10000900014 MAC ADDRESS 00 11 22 33 44 55 SYSTEM SETTINGS TIME AND DATE EC2000 TOOLS TEMPERATURE FORMAT v SYSTEM PROFI
11. 55 BATTERY TYPE 27 34 E ADVANCED ANALYZER FEATURES amp BATTERY TYPE sss earth Ground sa once es 11 FUNTIONS 47 BATTERY TYPES oes 26 38 Ad dV imet EE EE EE 16 C EG1000M KIT e dern rer IE 14 EE me eee EJECT SD CARD sssi 55 ALARM GEIIING 29 35 Calibration Certification 16 i Electrical Conpechon neeese 18 ALARM SETTINGS eese 39 GAPAGITY tt o ius 27 34 me ALARMS 29 CAUTION dod environmental conditions seeeseseee esenee 12 MS HEH TION ern 9 Eds Warner 16 Algorithm Calibration Factor 47 49 Caution Symbols seen 9 ANALYZER IBMS INTERACTION 55 CAUTION S inh eka a heen ie eek 11 F N 13 o oP ee f exis dus waned i FCC Rules En 4 Analyzer Recovery cocooococcccccononccccononcccnnnancnnnnnnns 57 CD ROMS en engin E E aebesiebtae i ES 17 51 Analyzer Restore 57 GE iip rte e e dn ui 4 E IMISYVAISE ul c M 24 ANALYZER SET UP eo etie atte 18 CELSCAN ALARMS 3nd 30 36 Ee AUTO CALIBRATION ees 54 CELScan Sulfation Dryout EC1000 Firmware Update Emer en 57 AUTO SHUTDOWN aaan 23 Upgrade EE 16 FIRMWARE UPGRADES sese 57 PUNO Da SEMIN See tetas cct RN ERU CRUEL 47 CELScan Package eee 14 Flooded EE 27 34 Auto Calc Strap Reference s in 50 CHECMICAL PROPERTIES s 51 G AUTO CALCULATED STRAP REFERENCE 50 Coefficient of Variation
12. BATTERY TYPE TEMPLATES rrt gaa tes eee gal ah eat nae Ai ith eee ee A teeter eat alae 38 TEST SETTING TEMPLATES nde deele AA alain tet dated a tercie pl d e a 39 ALARM SETTING TEMPLATES tual Gane nie ain ee ee ainda eee ain ei Eee eles 39 TESTING undi eere A A te Hm be aed ace Le dean de ete dem etiem E tns 41 TESTING USING THE ANLAYZER ico Adel EES cet sae ted eei ee e TRE E Dr ti e n 41 CHAPTER 3 REVIEWING THE TEST RESUETS 5 iin ee a t tetuer tain Late d ng t EE cde ER eid e sett pt deos 44 Aboutithis Chapter a e tatit dite ned tette ated et tt natn diit eta titel e dete obs Lote idt lai ctetur e Eid 44 CHAPTER A CONNECTING THE ANALYZER TO IBSM SOFTWARE ssssssssssesseeene eneenrenree rsen e n trn nnn nne inni dtr ir nr irri ntes nne sn reser sn nnne trn nter n nnn nnn nnn nnn nnns 46 ee L t EE O aT le TEE 46 CHAPTER 5 ADVANCED ANALYZER FEATURES A FUNTIONS ccccceccceceeeeeeeeeeeeceaeeeaeeeeeeceeeeeeeeeeeeceeecaeecaaecaaecaaeecaaecaaeceaeceaesaeceaescaeeseeeseeeeeeeesaeeeseseeseueseieesaress 47 Aboutthis Chapter A A e A A A A AA A A A ts 47 TOD Sit AA A A AA e eet A AAA tte tem nds eiat 47 BASEEINING ANALYZER BASELINE UTITV s a ee ieee cei e a pd CE Me d E E e ER AE eed ret eo 47 REPEATIBIEN UTIL rc etr tro a n REIR Oe EE ode c n e de SU on sah AS O fest foh toes fex t deus 51 BATTERY REPEACEMENT UT IEUDTY narimo er rg eter te d ren ar e e dep edu aep d dores d teats veered RD er EE 52 Global Energy Innovations
13. DUT being testing The RIGHT and LEFT navigation arrows are used for selecting between YES or NO TEST VOLTAGE The user selects if the Analyzer will test the voltage of the DUT being testing The RIGHT and LEFT navigation arrows are used for selecting between YES or NO TEST SULFATION The user selects if the Analyzer will run the CELScan algorithm for determining the amount of capacity loss due to battery sulfation The RIGHT and LEFT navigation arrows are used for selecting between YES or NO This function is only active on EC2000 Analyzers Page 28 Global Energy Innovations EC 1000 8 EC2000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp Testing 9 TEST DRYOUT The user selects if the Analyzer will run the CELScan algorithm for determining the amount of capacity loss due to battery dryout The RIGHT and LEFT navigation arrows are used for selecting between YES or NO This function is only active on EC2000 Analyzers and only for Valve Regulated Lead Acid Batteries Cells Lead Acid AGM and Lead Acid Gel 10 ALARMS The user selects if the Alarms will be active during testing The RIGHT and LEFT navigation arrows are used for selecting between YES and NO 11 ALARM SETTING This screen lets the user enter the ALARM SETTINGS for the testing Figure 2 5 shows the ALARM SETTINGS screen The following data entry is required for this screen MEMORY 25 Jan 2005 18 25 CH VOLTAGE A
14. EC1000 8 EC2000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp Testing 4 BATTERY TYPE This screen lets the user enter the BATTERY DETAILS for the battery that is being tested The user can either manually enter the information listed below create a Template or select from an existing template MANUFACTURER Battery Cell Manufacturer MODEL This is the Model number of the Battery Cell being tested TYPE This is a predefined selection menu The user selects from the following types using the RIGHT and LEFT navigation buttons c Other Lead Acid AGM Absorbed Glass Mat gt Lead Acid Gel gt Lead Acid Flooded gt Li lon Lithium lon gt NiCd Nickel Cadmium gt NiIMH Nickel Metal Hydride CAPACITY Entry of the Capacity of the Battery Cell being tested The value is entered at the C 10 Capacity at a 10 Hour discharge rate in Amp Hours TEST LEVEL This is a predefined selection menu indicating if the user is testing a Battery or Cell The user selects from the following test levels using the RIGHT and LEFT navigation buttons c Battery Multi Cell unit c Cell Single unit CELLS S PER BATTERY Entry of the number of Cells in the Battery being tested If a single cell is being tested this value will be one 1 otherwise the user can manually enter a value from 1 to 31 or use the RIGHT and LEFT navigation buttons to increment or decrement the numeric value 5 TEST SETTIN
15. GENERAL SAFETY INFORMATION 11 11 UNPACKING THE ANALYZER KIT 2 2 a A AE edie Hebe eda T de v a ate EA e dos 13 12 INTRODUCTION oie et ote e Rete udi d i e eu 17 CEHAPTER 1 INITIAE ANALYZER SETUP te AA A Eed 18 Lee V BI Ee TREE TC uc 18 BackQrounnd Em 18 SETUP A MICI 19 Setup Method 1 Using IBMS ooii e etae tee de du 19 Setup Method 2 Using The Analyzer cete tegere tede eve tege ce he ee bee ENEE 19 Setting up the Analyzer Getting Started iror nicis edic c dd Ld e deed ctl e cei Lnd dedi eee dde hc 20 Powering ON cx cc E v 20 Eowerrg DEENEN lh add ited gd lee ne ded ee ied Madde etapa le eee MA ae 21 The Analyzer Display e EE 22 Global Energy Innovations EC1000 8 EC2000 Analyzers User Manual Table of Contents The MAIN MENU dete t A e e e eet eee edn ette dev deae du tele dou rod Pee a be etc Ae en e te deve tute e ae 22 The TIELITIES MENU Ave Eat bct et et eoe eec eet e e ete e le ee eo Feeder A ee oie e ee e ae ea 23 CHAPTER 2 ANALYZER TEST CONFIGURATION amp TESTING sse eene ene nennen nn trn iter dnet rri R nr sr EEES EEEn nnne nnne 25 Leien VIE ET LTE 25 TEST CONFIGURATIONS nici ore anni beaded A A oe ee ee ee Pe een e ala debo ete pe t o hes 25 QUICK TEST SETTINGS TEMPLATES Aceh lettere A aden heed aa naan ea ee o a eddie eel nach dee eee ne 26 COMPANY REGION EE 32 STRING 4CONEIG RATIGONS ition ee A A AA d e ee de et due eed Ete a 32
16. TYPE they are returned to the QUICK TEST SETTINGS and BATTERY TYPE now shows EDIT instead of UNDEF This indicates that data was successfully entered either from manually or from a predefined BATTERY TEMPLATE NOISE FILTERING This is a predefined selection menu for selecting the level of Noise Filtering used during testing The user selects from the following predefined settings using the RIGHT and LEFT navigation buttons Test time may vary depending on the level of noise filtering that is selected c Off No noise filtering gt Low c Medium gt High Auto The Analyzer will automatically determine the filtering level based on feedback from testing conditions TEST START This is a predefined selection menu for selecting how the test will start The user selects from the following predefined settings using the RIGHT and LEFT navigation buttons gt Manual The user must press the ENTER button to start each test c AUTO Once the Kelvin Clips are attached to a valid Device Under Test DUT Batter Cell or Strap Interconnect the test automatically starts AUTO START DELAY SEC When TEST START is set to AUTO the user must manually enter a value from 1 to 31 or use the RIGHT and LEFT navigation buttons to increment or decrement the numeric value This is the amount of time the user will wait once a Valid DUT is detected TEST IMPEDANCE The user selects if the Analyzer will test the single point impedance value of the
17. The user enters the Baseline Temperature This is the temperature at which the Baseline data was collected and is used in subsequent Sulfation and Dryout algorithm calibrations and adjustments Values are entered manually or with the RIGHT and LEFT navigation buttons There are no preset values on the Analyzer when entering this section 19 USE AUTO CALC STRAP REFERENCE The user selects if the Analyzer will automatically calculate a reference value for the straps being tests The RIGHT and LEFT navigation arrows are used for selecting between YES or NO When NO is selected a STRAP REFERENCE mQ filed will appear and a value must be entered BATTERY TYPE TEMPLATES When using the BATTERY TYPE TEMPALTE the user will the following two 2 screens When selecting a NEW template the user is prompted to enter the information shown in At any time the user may enter an existing template and edit copy or delete information related to the template Explanations of each entry field have previously been described BATTERY TYPE TEMPLATES BATTERY DETAILS lt NEW gt ABSOLITE 1 100G39 TEMPLATE NAME UNIGY U1HR1500 SONNENSCHEIN A512 40G6 SETTING NAME VALUE EAST PENN 1 MANUFACTURER EAST PENN MODEL U1HR1500 TYRE VRLA AGM CAPACITY C 10 Ah 56 8 TESTLCEVEL BATTERY CELL S PER BATTERY 1 Figure 2 11 Battery Type Template Figure 2 12 Battery Details Template Page 38 Global Energy Innovations EC1000 amp EC2
18. Warnings before operating your Analyzer GENERAL SAFETY INFORMATION A CAUTION Disassembling the Analyzer or removing parts is likely to expose live parts which can be dangerous to life WARNING AND SAFETY PRECAUTIONS GENERAL 1 a RON Do not use or operate the Analyzer unless you have been formally trained at servicing electrical power systems including battery and other energy storage devices Before using the Analyzer be sure to read all instructions and CAUTIONS in this manual printed on the unit and on the battery Before using the Analyzer read all instructions and cautionary markings on 1 the Analyzer 2 the battery and 3 the product that uses the battery The Analyzer must only be serviced by Global Energy Innovations approved service center DO NOT attempt to open the Analyzer Avoid contact with the metal surfaces of the Kelvin clips when testing batteries or cells The Analyzer emits current at various frequencies and current levels during a test sequence Although the impedance of the human body is very high with little risk of large currents passing through the human body the user should exercise caution when using the Analyzer as with all other AC emitting devices While testing NEVER connect the Analyzer to a PC or laptop via the USB port When the PC is using an AC power supply the USB port connection can cause a ground loop with dangerous potentials that can disrupt the operation of the Analyzer and poten
19. measurement range of the device Typically the larger a battery s Ah capacity the lower its impedance Measures Battery on Float Yes battery must be fully charged and at equilibrium Measures Batteries at Open Circuit Yes battery must be fully charged and at equilibrium Measurement Range 500 to 1 Q Resolution 0 001 mOhms for all measurable impedance values 1 0 for Impedance gt 1 mA to 19 1 0 for Impedance gt 100 pA to 1 mQ Accuracy Traceability Through NIST traceable standards Repeatability 1 0 for Impedance from 100 A to 1 Q Accuracy Range 0 to 17 VDC Resolution Display 10 mV Accuracy 0 5 Accuracy Traceability Through NIST traceable standards Repeatability 0 5 Page 58 Global Energy Innovations EC1000 amp EC2000 Analyzers Users Manual Analyzer Specifications Sulfation Battery Charge Capacity Loss specified for Impedance range 100 pQ to 10 Range Accuracy Accuracy Traceability Repeatability Dryout Battery Charge Capacity Loss _ specified for Impedance range 100 vi to 19 0 to 100 relative to the amount of battery charge capacity degradation due to Sulfation 125 Test methodology traceable to NIST standards DNK Oto 100 Range relative to the amount of battery charge capacity degradation due to Dryout Accuracy Accuracy Traceability Repeatability 125 Test methodology
20. of batteries showing small levels of chemical degradation Hence the ideal ACF should be a batter with a low Relative Degradation without being out of family Finally since the baseline values used at the time of the test are tracked in the Test Configuration tab any erroneous ACF change can be corrected returned to the original value by reviewing the historical ACF value displayed in the Test Configuration screen AUTO CALCULATED STRAP REFERENCE The integrity of the straps that connect the batteries or cells together is critical for good operation and health of the battery string Similar to the Autobaseline feature the Analyzer has an automated Auto Calc Strap Reference function that is used for automatically calculating a valid Strap Impedance Reference value when a string is first tested The user may enable this feature by selecting YES to USE AUTO CALC STRAP REFERENCE when configuring a string String Configuration Screen BASELINE UTILITY The BASELINE UTILITY is used to determine the reference values for Impedance and ACF as presented in Figure 5 1b below The main purpose of this tool is to permit the user to determine the Impedance Reference IMPEDANCE REF mQ and ACF in a situation where the Autobaseline function analysis failed was not reliable or in a situation where testing is being done in different locations on batteries with different state of health For example when the tested string consists of old aged batteries w
21. set to LOW 2 HIGH The noise level is high and the Analyzer must be set to HIGH so that it may adequately reject noise Often in high noise conditions the Analyzer cannot take accurate readings Page 51 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 5 Advanced Analyzer Features amp Functions 3 AUTO This setting will automatically set the Analyzer to the best setting it can based on signal processing and data analysis Note CV readings above 2 3 indicate that the analyzer may take inaccurate readings Beware of data when repeatability statistics are above 3 Equation 5 1 is the calculation CV performed on the data from the five 5 repeatability tests where CV is the Coefficient of Variation o the standard deviation and u the mean MEMORY E 0 1jAN2010 300 w REPEATABILITY TESTING NOISE LEVEL LOW REPEATABILITY STATISTICS IMPEDANCE 0 015 VOLTAGE 0 005 CHEMICAL PROPERTIES 0 272 zen LPEIUEN sTART CA Ee CV Iul Figure 5 2 Baseline Utility screen Equation 5 1 Coefficient of Variation definition BATTERY REPLACEMENT UTILITY The BATTERY REPLACEMENT UTILITY tools allows the user to replace batteries or cells in the sting for whatever reason without changing or editing the String Configuration In most situations the replacement is essential because the battery or cell is faulty warned or has failed ANALYZER OPERATION 1 To acces
22. shown on the Analyzer when entering this screen Warning Value This is the warning value as specified as a percentage above the baseline value c Warning ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms c Fail Value This is the fail value as specified as a percentage above the baseline value c Fail ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms 7 TEST VOLTAGE The user selects if the Analyzer will test the voltage of the DUT being testing The RIGHT and LEFT navigation arrows are used for selecting between YES or NO 8 TEST IMPEDANCE The user selects if the Analyzer will test the single point impedance value of the DUT being testing The RIGHT and LEFT navigation arrows are used for selecting between YES or NO 9 TEST SULFATION The user selects if the Analyzer will run the CELScan algorithm for determining the amount of capacity loss due to battery sulfation The RIGHT and LEFT navigation arrows are used for selecting between YES or NO This function is only active on EC2000 Analyzers 10 TEST DRYOUT The user selects if the Analyzer will run the CELScan algorithm for determining the amount of capacity loss due to battery dryout The RIGHT and LEFT navigation arrows are used for selecting between YES or NO This function is only active on EC2000 Analyzers and only for Valve Regulated Lead Acid Batteries Cells Lead Acid AGM and Lead Acid Gel
23. significant discussion and explanations about IBMS in this manual For a complete review of IBMS please reference the IBMS Users Manual Page 17 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 1 Initial Analyzer Setup CHAPTER 1 INITIAL ANALYZER SETUP About this Chapter This section describes how to initialize and initial setup the Analyzer so it is ready for setting up test configuration and use in the field This section starts by reference to the various options that are available in the UTILITIES MENU These allow the user to set the time and date temperature format and other setup parameters that are used throughout the testing sequences The UTILITIES MENU also contains the TOOLS sub Menu section that will not be covered in this chapter This Menu is covered in a separate Chapter of this users manual since this Menu contain advanced functions and does not directly pertain to the setup and initialization of the Analyzer Background This background section gives the user a brief overview of how the Analyzer is typically configured and used Advanced users may deviate from these typical use conditions as required If you however are using the Analyzer for the first time it is strongly recommended that you follow the steps and procedures in this Chapter The Analyzer was designed to be an integral part of a battery monitoring and maintenance process particularly for those industries wit
24. the RIGHT and LEFT navigation buttons gt Other gt Lead Acid AGM Absorbed Glass Mat gt Lead Acid Gel gt Lead Acid Flooded gt Li lon Lithium lon gt NiCd Nickel Cadmium gt NiMH Nickel Metal Hydride CAPACITY Entry of the Capacity of the Battery Cell being tested The value is entered at the C 10 Capacity at a 10 Hour discharge rate in Amp Hours TEST LEVEL This is a predefined selection menu indicating if the user is testing a Battery or Cell The user selects from the following test levels using the RIGHT and LEFT navigation buttons gt Battery Multi Cell unit gt Cell Single unit Page 27 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp Testing 3 CELLS S PER BATTERY Entry of the number of Cells in the Battery being tested If a single cell is being tested this value will be one 1 otherwise the user can manually enter a value from 1 to 31 or use the RIGHT and LEFT navigation buttons to increment or decrement the numeric value B gt Function 1 Return Returns the user to the previous screen without saving data entry DO Function 2 Save Saves the entered data and returns the user to the previous screen so they can continue with the QUICK TEST SETTINGS data entry B gt Function 1 Template Allows the user to select a predefined BATTERY TEMPLATE NOTE Once the user has completed data entry for BATTERY
25. the user selects a battery and then clicks on the REPLACE BATTERY button In the REPLACEMENT BATTERY window Figure 5 7 the user can optionally enter the Installation Date and Manufactured Date of the replaced battery and then confirm the battery replacement by clicking YES before clicking OK to exit the window The REPLACED box for the selected battery will now be checked Finally the user must SAVE CHANGES before exiting quitting the tab The modified string must be updated to the Analyzer via IBMS for future field testing When using the Analyzer the batteries to be replaced will now show NEEDS Page 53 Global Energy Innovations EC1000 amp EC2000 Analyzers Users Manual Chapter 5 Advanced Analyzer Features amp Functions TESTING in the BATTERY REPLACEMENT UTILITY screen More details on the use of I BMS Battery Replacement functions can be found in the IBMS Users Manual b Edit Battery String 9 b Edit Battery String Name Baguette01 Name Baguette01 String Configuration Test Settings Battery Details String Configuration Test Settings Battery Details Battery Details Battery Details Battery Installation Date Manufactured Date Replaced Battery Installation Date Manufactured Date Replaced 1 05 26 2011 05 01 2011 v Replace Battery 2 05 02 2011 05 01 2011 9 3 05 04 2011 05 01 201
26. traceable to NIST standards 110 Measurement Range Resolution Accuracy Accuracy Traceability 50 yQ to 1 Q 0 001 mOhms for all measurable impedance values 110 Through NIST traceable standards Repeatability Measurement Pass Warning Fail Indicators 1 0 for Impedance from 100 uA to 1 Q Yes visual and audio Specific Gravity Manual Logging Calibration T Automatic System Calibration upon Startup System Boot T Yes Standard Annual Instrument Calibration Automated Baselining Baseline Adjustement Utility Upgradeable Auto calibration routines build in Annual Calibration Certificate may be performed if required Automated baseline generation and adjustment utility for rapidly determining your baseline Impedance Sulation and Dryout baseline values for new and old batteries or battery strings Yes Oscilloscope Line Noise Detect Voltmeter Others as available Page 59 Global Energy Innovations EC1000 amp EC2000 Analyzers Users Manual Analyzer Specifications Display Type Color TFT LCD Display Viewing Area Display Format amp Color Depth 3 50 in 8 9 cm Diagonal 70 08 W x 52 56 H mm 320 W x 3 R G B x 240 H 16M Colors Backlight Memory Type Supported Size String Cell Data Storage Capacity LED Backlight White LED Read Write Flash RAM Mini SD 16 GB Depends on SD Card Si
27. 0 amp EC2000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp Testing value Otherwise the user may select F1 and return to the previous screen without saving updating the baseline For a complete explanation of the Auto Baseline function as well as Impedance and ACF Algorithm Calibration Factor functions please reference Chapter 5 The F3 Temps button shown in Figure 2 22 may be used to manually enter individual Battery or Cell temperature This temperature value is used for adjustments of the Battery or Cell impedance or CELScan values Sulfation and Dryout MEMORY BS gt on woo soo wi RH MEMORY Baer ov Jan 2010 ioco wii BED menor bes Jensen vil HEC START TESTING BATTERY 1 CELL 2 TESTING AUTO CALCULATED BASELINE DATA TEST SETTINGS VALUE 95 of 100 TESTED 90 PASS 3 WARN 2 FAIL 30 0 C 95 of 100 TESTED 90 PASS 3 WARN 2 FAIL SS O 0 TEST TEMPERATURE C on IMP mO VOLT V SULF DRY IMPEDANCE mQ 8 227 SITE BOULDER SE ACF 1 277 STRING ID STRING 1 4 STRAP 0 1 1 WARN TEST START DATE 2011 11 15 STRAP 0 1 2 PASS TEST END DATE BATTERY 1 CELL 1 PASS a BATTERY 1 CELL 2 PLEASE WAIT BASELINE CALCULATION IN PROGRESS BASELINE STATUS Figure 2 21 Start Testing screen Figure 2 22 Testing screen Figure 2 23 Auto Calculated Baseline screen The EXIT TESTING screen Figure 2 24 is shown whenever all of the DUTS have been tested and the user selects v
28. 0 blue reference line For more precise control 50 40 Current ACF 1 14 30 20 Updated ACF 1 14 100 000 10 M 1 2 3 4 5 6 7 8 9 10 11 12 Population referenced 110 Updated Values 100 Eo 2 3 s E 70 5 60 amp so 9 40 X 30 20 10 D Sulfation Updated Yalues Sulfation a 1 2 3 Figure 5 1b IBMS baseline adjustment feature Relative Degradation Relative Degradation is Global Energy Innovations universal parameter to follow the evolution of battery health based on its Chemical Properties e g CELScan Relative Degradation is set such that a 100 level corresponds to a healthy battery As the battery ages the Relative Degradation levels are expected to increase Levels below 100 often indicate battery conditions such as internal short circuit formation For any lead acid battery types AGM Gel and Flooded Relative Degradation readings can only be viewed when the Advanced User Setting is active and only in the Adjust Baseline tab as shown in Figure 5 1b For non lead acid battery type Such as Li lon NiMH and others Relative Degradation can be used as an indicator of the evolution of the battery chemical properties allowing the user to pinpoint defective batteries within a string Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manua
29. 000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp Testing TEST SETTING TEMPLATES When using the TEST SETTING TEMPALTE the user will the following two 2 screens When selecting a NEW template the user is prompted to enter the information shown in At any time the user may enter an existing template and edit copy or delete information related to the template Explanations of each entry field have previously been described MEMORY EE o JAN2010 13 00 a nun T MEMORY EEE 01JaN20 0 200 wii TEST SETTING TEMPLATES TEST SETTINGS lt NEW gt SETTING NAME VALUE DEFAULT LOW NOISE TEMPLATE NAME UPS 1 UPS NOISE FILTERING POLARITY CORRECTION STRAP TEST START BATTERY TEST START AUTO START DELAY SEC Figure 2 13 Test Setting Template screen Figure 2 14 Test Settings screen ALARM SETTING TEMPLATES When using the ALARM SETTING TEMPALTE the user will the following two 2 screens When selecting a lt NEW gt template the user is prompted to enter the information shown in At any time the user may enter an existing template and edit copy or delete information related to the template Explanations of each entry field have previously been described Page 39 Global Energy Innovations EC1000 amp EC2000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp Testing MEMORY EEE 01 JAN 2010 13 00 a ALARM SETTING TEMPLATES lt NEW gt ABSOLITE STAND
30. 015 1001 USB Cable 1 11 1010 1002 2 GB Mini SD Memory Card 1 EQUIPMENT EC2000 KIT Impedance Voltage CELScan Sulfation Dryout 8656 2000 1 8656 2000 EC2000 Handheld ElectroChemical Battery Analyzer 1 2 8740 0001 Sulfation Dryout CELScan Package 1 3 8600 0004 Kelvin Clips Standard 1 4 8600 1000 IBMS Companion Software Compact Disc 1 5 1010 1001 AC Wall Adapter Battery Charger 1 6 8520 0000 Standard Lithium lon Battery Pack 1 7 1010 0002 Infrared Thermometer 1 8 1010 1004 Soft Carrying Case 1 9 1010 1005 Hand Strap 1 10 1010 1006 Shoulder Strap 1 11 1015 1001 USB Cable 1 Page 14 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Unpacking the Analyzer Kit 12 1010 1002 2 GB Mini SD Memory Card EQUIPMENT OPTIONAL ACCESSORIES 1 8600 1002 Hard Carrying Case 1 2 8600 0011 Kelvin Probes Double Point 1 3 8600 0018 Kelvin Probes Single Point 1 4 8600 0016 Kelvin Probes Mini 1 5 8600 0010 Accessory Cable Set 1 6 1010 0005 175 Automobile Inverter 1 7 1010 0006 SD Card Reader 1 8 8520 0001 High Capacity Lithium lon Battery Pack 1 REPLACEMENT PARTS 1 8600 0004 Kelvin Clips Standard 1 2 4242 2009 Kelvin Clips Replacement Teeth 4 1 3 4242 0001 Kelvin Probes Double Point Pointed Replacement Tips A 1 4 4242 0002 Kelvin Probes Double Point Waffle Replacement Tips 4 1 5
31. 1 Si Replace Battery 4 05 10 2011 05 01 2011 v Installation Date Manufactured Date Battery Replaced 05 01 2011 Yes 0 No Comment g Replacement History a Copy Details to Al Si Replace Battery Edit Battery g 1 Battery Comment Ba v ox amp cancel L String Comment String Comment AA M eegesed paeem Messen Figure 5 6 Battery Details tab in the Edit Battery String screen of IBMS inventory Management Figure 5 7 Replace Battery screen AUTO CALIBRATION This function is used for performing a complete Analyzer Calibration If the Analyzer FAILS the calibration please contact support for assistance Page 54 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 5 Advanced Analyzer Features amp Functions MASTER RESET This function is used for restoring the Analyzer to its factory settings Please review the WARNING screen before confirming EJECT SD CARD This function is used to safely eject the Mini SD card SYSTEM DIAGNOSTICS This screen is only meant to be used by Technical Support for troubleshooting the Analyzer TEMPERATURE MEASUREMENTS amp CORRECTION Temperature values entered on the Analyzer are used for calculating and adjusting values of Impedance and the CELScan values Sulfation and Dryout Pay close attention to enter the correct temperature values to ensure accurate results The three 3 places w
32. 2 ANALYZER TEST CONFIGURATION amp TESTING About this Chapter This section describes how configure the Analyzer and begin testing Advanced testing functions are not covered in this Chapter Refer to Chapter 6 Advanced Features and Function for details on going beyond basic setup and testing This Chapter covers the following MAIN MENU topics 1 TEST CONFIGURATIONS 2 QUICK TEST 3 TEST STRING This Chapter begins with TEST CONFIGURATIONS because this function allows the user to fully configure and set up the Analyzer in preparation for testing QUICK TEST and TEST STRING follow as these functions utilize the previous setup conditions on TEST CONFIGURATIONS It is assumed that the user has already read the previous Chapter and has performed the basic Analyzer setup functions TEST CONFIGURATIONS Figure 2 1 shows the TEST CONFIGURATION screen This screen has the sub Meuns listed below All of these Menus are described in detail in this Chapter The sub Menus are not covers in the order listed below because they a first time user should get familiar with the logical flow first After the user has become proficient in setting up testing it is expected that they will deviate from the this description 1 QUICK TEST SETTINGS 2 3 COMPANY REGION 4 5 6 Page 25 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp Testing QUICK TEST SETTINGS TE
33. 2000 Analyzers Users Manual Chapter 1 Initial Analyzer Setup Setting up the Analyzer Getting Started Powering ON The Analyzer is powered OFF by pressing the green power button as shown in Figure 1 2 1 for several seconds After the button is pressed the Analyzer will boot and the welcome splash screen shown in Figure 1 3 will appear Almost immediately after the welcome screen the Analyzer will go through an automatic calibration process The progress of this calibration is shown in Figure 1 4 an will typically complete in several seconds If there are any faults in the Analyzer this screen will display an error with details explaining the fault The calibration is a multi stage auto calibration sequence that the Analyzer goes through each time it is turned on Once the Analyzer has finished calibration the MAIN MENU is displayed Figure 1 5 Funtion Keys SHIFT Changes abc Abc ABC ESC Back Escape S Navigation Space 0 or Space depending on use condition Escape Return Back OJ Power ON OFF O ENTER Save Locks Entry Value EC2000 ELECTROCHEMICAL BATTERY ANALYZER VERSION 2 0 0 2009 2011 GLOBAL ENERGY INNOVATIONS Navigation Figure 1 2 1 Analyzer keypad layout Figure 1 2 2 Keypad functions Figure 1 3 Analyzer welcome splash screen Page 20 Global Energy Innovations EC1000 amp EC2000 Analyzers Users Manual Chapter 1 Initial Analyzer Setup MEMO
34. 4242 0008 Kelvin Probes Single Point Replacement Tips 2 1 6 8600 1000 IBMS Companion Software Compact Disc 1 7 1010 1001 AC Wall Adapter Battery Charger 1 8 8520 0000 Standard Lithium lon Battery Pack 1 9 1010 0002 Infrared Thermometer 1 10 1010 1004 Soft Carrying Case 1 11 1010 1005 Hand Strap 1 12 1010 1006 Shoulder Strap 1 13 1015 1001 USB Cable 1 14 1010 1002 2 GB Mini SD Memory Card 1 HARDWARE amp FIRMWARE UPGRADES Page 15 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Unpacking the Analyzer Kit 1 8740 0001 CELScan Sulfation Dryout EC1000 Upgrade 1 2 8740 1001 Oscilloscope EC1000 amp EC2000 Compatible 1 3 8740 1002 Advanced Voltmeter 1 4 8740 1003 AC DC Current Clamp 1 5 8740 1004 AC DC Current Shunt 1 7 8740 1005 Thermocouple Probe Module 1 PRODUCT WARRANTY amp OTHER 1 8740 2001 Calibration Certification Yearly with Certificate 1 2 8740 3001 Extended Warranty 1 Year Extension 1 3 8740 3002 Extended Warranty 2 Year Extension 1 Table 1 The complete list of standard and options accessories as well as replacement parts product upgrade and warranty extension options for the EC1000 and EC2000 Analyzers Page 16 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Introduction 12 INTRODUCTION Technology Overview Effective management of a battery installation requires time
35. ACTOR RETURN START E Figure 5 1b Baseline Utility screen REPEATIBILITY UTILITY The REPEATABILITY UTILITY tool allows the user to rapidly check how repeatable testing is on a battery cell strap or other electrical conductor DUT Device Under Test Repeatability is affected by noise and other disturbances that may be present across the DUT The Analyzer uses FFTs and other advanced signal processing techniques to reject noise however some noise will still cause reading inaccuracies and ultimately may lead to incorrect results Whenever the user suspects HIGH NOISE conditions such as around old UPS systems or whenever reading seem inaccurate or odd using this tool will allow for rapid assessment of the condition The REPEATABILITY UTILITY tool Figure 5 2 is fully automated and should be performed in the conditions representative of the normal test conditions The simply connects the Analyzer to a DUT and presses the F2 Start button The Analyzer then performs a series 5 of measurements and reports the noise level and repeatability statistics CV Coefficient of Variation measure for IMPEDANCE VOLTAGE and CHECMICAL PROPERTIES Sulfation and Dryout Based on the reported CV values the Analyzer calculates a noise level of LOW or HIGH When setting up the Analyzer for testing the Noise Level may be set as shown in Figures 2 3 and 2 9 1 LOW The noise level is low enough that Noise Filtering should be turned off or
36. ARD LI ION NIMH Figure 2 15 Alarm Setting Template screen MEMORY E 25Jan2005 18 25 CDN ALARM SETTINGS SETTING NAME IMPEDANCE ALARMS IMPEDANCE HIGH Warning Value Warning ON OFF Fail Value Fail ON OFF IMPEDANCE LOW Warning Value Warning ON OFF Fail Value Fail ON OFF VOLTAGE ALARMS VOLTAGE HIGH V Warning Value Warning ON OFF Fail Value Fail ON OFF VOLTAGE LOW V Warning Value Warning ON OFF Fail Value Fail ON OFF SULFATION Warning Value Warning ON OFF Fail Value Fail ON OFF DRYOUT 96 Warning Value Warning ON OFF Fail Value Fail ON OFF STRAP 96 Warning Value Warning ON OFF Fail Value Fail ON OFF VALUE A 70 0 ON 50 0 ON 2 30 ON 2 35 ON 2 20 ON 2 15 ON 15 ON 20 ON 15 ON 20 ON 150 0 OFF 200 0 OFF Figure 2 16 Alarm Settings screen Page 40 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp Testing TESTING Now that the use is familiar with configuring the Analyzer these configurations can now be used for testing The following section covers how to use either Analyzer or IBMS configurations to perform testing TESTING USING THE ANLAYZER Configurations may be used that were directly done on the Analyzer This includes both QUICK TESTS and STRING TESTING These configurations were previously covered in prior sections Th
37. FF Allows the user to turn this alarm ON or OFF independent of the other alarms 12 VOLT REF CELL V The user enters the Voltage Reference Value for the Cell This value will be used for all of the Voltage Alarm calculations When data entry is completed the value for VOLT REF BATTERY V is automatically calculated Values are entered manually or with the RIGHT and LEFT navigation buttons There are no preset values on the Analyzer when entering this section 13 VOLT REF BATTERY V The user enters the Voltage Reference Value for the Battery This value will be used for all of the Voltage Alarm calculations When data entry is completed the value for VOLT REF CELL V is automatically calculated Values are entered manually or with the RIGHT and LEFT navigation buttons There are no preset values on the Analyzer when entering this section Note Either CELL or BATTERY reference values may be enter first and the other is automatically calculated 14 STD IMP REF VALUE mO This is the Standard Impedance Reference Value in mOhms that will used for all Impedance Alarm calculations Values are entered manually or with the RIGHT and LEFT navigation buttons There are no preset values on the Analyzer when entering this section 15 STD ACF REF VALUE The user enters the Standard Algorithm Calibration Factor used with the CELScan Algorithms Sulfation and Dryout This value will be used for Sulfation and Dryout algorithm
38. G ID TEST DATE TEST TIME BOULDER STRING 1 TELLURIDE 2010 01 01 17 34 00 STRING 2 2010 01 02 18 34 00 pararlo EE STRING 3 2010 01 03 19 34 00 Reech STRING 4 2010 01 04 20 34 00 MEMORY E osyanzoio1300 wii MH MEMORY fe oryanzoro1300 wii MO MEMORY RT o JAN 20101300 CH RESULTS STRING 1 BOULDER RESULTS STRING 1 BOULDER RESULTS STRING 1 BOULDER 90 OF 96 TESTED 84 PASS 5 WARN 1 FAIL BATTERY 4 CELL 3 of 3 RESULT WARN STRAP 0 1 1 4 BATTERY ABSOLITE 1 100G39 STRAP 0 1 2 PASS STRAP RESULT WARNING BATTERY 1 CELL 1 FAIL VOLTAGE V PASS IMPEDANCE mO 0 1450 BATTERY 1 CELL 2 PASS q IMPEDANCE 0 1480 PASS BATTERY 1 CELL 3 PASS GE SULFATION 2 PASS STRAP 1 2 1 WARNING EN STRAP 1 2 2 PASS DRYOUT 39 WARNING Jen TEMPERATURE C 28 8 MEASURED VALUE mO 0 045 Figure 3 1 Various user screens for navigating TEST RESULTS Menu At most points data may be deleted The user is always prompted with a WARNING screen to ensure that the deletion of data was intended Pay close attention to the Function Buttons F1 F2 F3 and F4 at the bottom of the screens These functions allow the user to view various setup parameters that were used for testing Additionally some data entry options are available to the user at various points during navigation Page 45 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual CHAPTER 4 CONNECTING THE ANALYZER TO IBSM SOFTWARE
39. GS This screen lets the user enter the TEST SETTINGS for the string that is being tested The user can either manually enter the information listed below create a Template or select from an existing template NOISE FILTERING This is a predefined selection menu for selecting the level of Noise Filtering used during testing The user selects from the following predefined settings using the RIGHT and LEFT navigation buttons Test time may vary depending on the level of noise filtering that is selected c Off No noise filtering gt Low Medium gt High c Auto The Analyzer will automatically determine the filtering level based on feedback from testing conditions Page 34 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp Testing POLARITY CORRECTION This is a predefined selection menu for selecting if the Analyzer will operate with correction ON or OFF The user selects from the predefined settings using the RIGHT and LEFT navigation buttons When ON POLARITY CORRECTION automatically stores the absolute value of the voltage of the battery or cell being tested This allows the user to rapidly test batteries or cells without worrying about the polarity This features should typically be turned OFF if the user is commissioning a new string and wants to know if any of the batteries or cells were installed in a reversed order gt On gt Off STRAP TEST S
40. ION O PLEASE WAIT OPTIONS 1 BOOT NORMALLY 2 CONNECT TO PC VIA USB 3 RESTORE LAST KNOWN GOOD DATA FILES 4 REBUILD DATA FILES SECTION FOR 1 Text Messages 8 2 Data 3 Menu Options NOTE POSSIBLE DATA LOSS WITH 3 COMPLETE DATA LOSS WITH 4 Figure 1 7 Power off sequence Figure 1 8 System recovery screen Figure 1 9 Screen layout descriptions Page 21 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 1 Initial Analyzer Setup The Analyzer Display Screen The Analyzer has a number of various screen types that display menus results calculations etc Although these screens vary somewhat in their layout they all share a number of common elements that the user will grow accustomed to during Analyzer operation Figure 1 9 illustrates these common elements 1 This icon shows the amount of used and available memory on the SD Card The user is alerted when memory is near full 2 The time and data are displayed 3 The sound level for the audible alarms and notifications 4 The battery status state of charge of the internal lithium ion battery 5 The title of the screen 6 The abridged data section Often other notices are also displayed in this area 7 This section is where most of the text messages data and menu options are displayed 8 UP and DOWN arrows are shown when there is additional data to see in either scroll direction The navigation buttons Figure 1
41. LARMS a VOLTAGE HIGH V ALARM SETTINGS Warning Value 2 30 Warning ON OFF ON SETTING NAME VALUE Fail Value 2 35 A Fail ON OFF ON IMPEDANCE ALARMS VOLTAGE LOW V IMPEDANCE HIGH Warning Value 2 20 Warning Value Warning ON OFF ON Warning ON OFF Fail Value 2 15 Fail Value Fail ON OFF ON Fail ON OFF SULFATION Warning Value 15 Warning ON OFF ON Fail Value 20 IMPEDANCE LOW Fail ON OFF ON Warning Value 70 0 DRYOUT Warning ON OFF ON Warning Value 15 Fail Value 50 0 Warning ON OFF ON Fail ON OFF ON Fail Value 20 Fail ON OFF ON STRAP Warning Value 150 0 Warning ON OFF OFF Fail Value 200 0 Fail ON OFF OFF Figure 2 5 Alarm Settings screen IMPEDANCE ALARMS Alarms for single point impedance testing results The following sub alarms fall under this section Default values are shown on the Analyzer when entering this screen IMPEDANCE HIGH This is the impedance alarm above greater than the baseline value Values are entered manually or with the RIGHT and LEFT navigation buttons Default values are set on the Analyzer when entering this section gt Warning Value This is the warning value as specified as a percentage measured from the baseline value gt Warning ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms Page 29 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp Tes
42. LE POWER MANAGEMENT LANGUAGE SOUND AND DISPLAY CAPACITY 20GB AVAILABLE 1 8GB ACTIVATION IMPEDANCE VOLTAGE ON SULFATION amp DRYOUT ON CONTACT www globalei com SUPPORT support globalei com Figure 1 10 Utility Menu Figure 1 11 System Settings Menu Figure 1 12 System Profile Screen The following SYSTEM SETTINGS Figure 1 11 in the UTILITY MENU Figure 1 10 should be configures at this step of setting up the Analyzer A brief description of each are outlined however most are fairly self explanatory 1 TIME AND DATE The user should set the date format that they prefer here This format may later be altered when data is imported into IBMS 2 TEMPERATURE FORMAT Using the RIGHT and LEFT navigation buttons the user can select either C Celsius or F Fahrenheit 3 POWER MANAGEMENT It is recommended that that AUTO SHUTDOWN feature be turned ON so that the internal lithium ion battery will not discharge if the power button is accidentally depressed in the Analyzers carrying case If the Analyzer shuts down all data is saved so there is not risk of data or configuration loss with this function enabled 4 LANGUAGE To change language a custom firmware load is required as indicated on this screen Please contact your local distributor for details on obtaining language specific firmware 5 SOUND AND DISPLAY These parameters are set per user preferences Page 23 Global Energy Innovations EC1000
43. MPLATES We will first cover QUICK TEST SETTINGS because in the process of running a QUICK TEST the user will be guided through the most basic setup parameters required for testing a batter or cell In later discussion on setting up STRING CONFIGURATIONS BATTERY TYPES ALARM SETTINGS and TEST SETTINGS the user may run QUICK TEST with greater ease because some of the Templates will have already been configured for use In the standard QUICK TEST setup the user does not access the Templates but may if desired Details on setting up Templates may be found in this Chapter under the Templates Figure 2 2 and 2 3 show the two 2 screen required for setting up a QUICK TEST MEMORY ew 01 JAN 2010 13 00 QUICK TEST SETTINGS SETTING NAME CONFIG NAME T Mobile London BATTERY TYPE lt UNDEF gt NOISE FILTERING TEST START TEST IMPEDANCE TEST VOLTAGE MEMORY fe O1JAN201013 00 mf Dm MEMORY a Joryanzo101300 wii mr TEST CONFIGURATION TEMPLATES QUICK TEST TEMPLATES QUICK TEST SETTINGS STRING CONFIGURATIONS COMPANY REGION BATTERY TYPES ALARMS ON ALARM SETTINGS ALARM SETTING lt UNDEF gt TEST SETTINGS VOLT REF CELL V 2 25 VOLT REF BATTERY V 2 25 STD IMP REF VALUE mQ 1 225 STD ACF REF VALUE 2 25 STD TEMP C Figure 2 1 Test Configuration Menu Figure 2 2 Quick Test Template screen Figure 2 3 Quick Test Settings screen When arriving at the QUICK TEST TEMPLATES screen Figure 2 2
44. ORMAT Mas deridet e LL oy 23 TYPE sasasasasssauasuanasansauasaaaasaasasuanauauauaacuanauanacana 27 34 Ww TEST CONFIGURATION canes 25 U WARNING unreal 8 9 11 TEST CONFIGURATIONS e 25 SI d curar os etes cns an 13 WARNINGS LLL 9 11 TEST DRY OU Tiida ias 29 37 Update of frmmware 55 A i TEST IMPEDANCE A 28 37 upgrade 16 WARRANTY eese i TEST HEV E Lar ee 27 34 EE 51 SEENEN 20 TEST RESULTS ias 44 USB abla illo 14 TEST SE TING Steet ate obscene 39 USB Connection n tette 46 Page 66 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Appendices APPENDICES NONE Page 67
45. Page 4 Global Energy Innovations EC1000 8 EC2000 Analyzers User Manual Copyright Notice 4 COPYRIGHT NOTICE Information in this document is subject to change without notice O Global Energy Innovations All rights reserved Reproduction in any manner whatsoever without the written permission of Global Energy Innovations is strictly forbidden No Warranty This user manual is being delivered to you as is and Global Energy Innovations makes no warranty as to its accuracy or use Any use of this documentation or the information contained therein is at the risk of the user This documentation may include technical or other inaccuracies or typographical errors Global Energy Innovations reserves the right to make changes without prior notice Although every effort has been made to assure the accuracy of the representations of the EC1000 and EC2000 Analyzer screen displays within this manual last minute changes and alterations may lead to slight differences in the information held within this manual and the actual display Trademarks Global Energy Innovations The GEI logo Dynapulse IBMS CELScan are trademarks of Global Energy Innovations Page 5 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Safety Instructions Introduction 5 SAFETY INSTRUCTIONS INTRODUCTION Read these pages carefully before beginning to unpack or use the EC1000 and EC2000 Analyzer The following para
46. R erase 12 E aa geg E b thiini ring Copflguratlon sa QUICK TEST SETTINGS eren fe ee m ta Location Hierarchie 18 AO ti T STRING CONFIGURATIONS 111111ririnren 32 R String E Lu 19 ae ADDRESS 24 GCOVOly geed eii ie 21 String selection sseeese 33 KM SERI QM GP EL Relative Degradation ssssseeseenereneee erreneren 48 SULFATION 96 30 36 Main Men 21 Page 65 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Index Sulfation DEVQUEEs trail edem ta e ct 24 TEST START Conc Ma ash eee 28 USE AUTO CALC BASELINE 47 SUPPORT Esa caracas 24 TEST SULEATION 28 37 UTILITIES MENU 18 Synchronization of the Clock 55 TEST VOLTAGE imerodioibaireearaio hn 28 37 Utility Mem 23 SYSTEM DIAGNOSTICS 55 TESTING units aet tcs les de 25 41 V System Profile Screen eese 23 TESTING USING THE ANLAYZER 41 VERSION RELEASE DATE 24 System Settings Men 23 Thermocouple Probe Module 16 VOLT REF BATTERY V e 31 37 T TIME AND DATE rct etn 23 VOLT REF CELLY V eene 31 37 TABLE OF CONTENTS x2 odes 1 TOOLS 18 47 VOLTAGE ALARMS 30 36 technical specification sess 63 Trademarks 5 VOLTAGE HIGH V ecce 30 36 Technology Overview s 17 TROUBLESHOOTING eene 97 VOLTAGE LOW V 30 36 TEMPERATURE F
47. RY ES on aw 2070 1300 a HO MEMORY ER 07 SAN 20101300 aD MEMORY Be Torsanzoro130o D HO START UP CALIBRATION ROUTINE CONFIRM POWER OFF QUICK TEST POWER OFF BUTTON WAS PRESSED TE T teg y PLEASE CONFIRM POWER OFF TEST CONFIGURATIONS CALIBRATING EST ULT BY PRESSING CONFIRM COROT TOKE PRESS RETURN TO GO BACK TO THE PREVIOUS METER STATE Figure 1 4 Calibration screen Figure 1 5 Main Menu Figure 1 6 Confirm power off screen Powering OFF The Analyzer is powered OFF by pressing the green power button as shown in Figure 1 2 for several seconds After the button is pressed a Confirm Power Off screen Figure 1 6 will show to ensure that the user wants to power the Analyzer OFF The F1 key Return may be pressed to abort Power OFF and return to the previous screen During the power off sequence Figure 1 7 any unsaved data is saved and the analyzer properly shuts down If for any reason the Analyzer is shut down improperly i e The battery is removed there is a system crash etc data is normally saved in memory and recovered on the next power ON sequence Figure 1 8 shows the system recovery screen that is displayed after an improper Analyzer shut down o o 989 MEMORY MEAE O1JAN20101300 4 RECH per orsanzoro1300 w D HH ABNORMAL ANALYZER SHUT DOWN ANALYZER SHUT DOWN e SCREEN TTLE THE ANALYZER ENCOUNTERED A FAULT PLEASE SELECT ONE OF THE FOLLOWING ABRIDGED DATA SECT
48. TART The user selects from the predefined settings MANUAL or AUTO using the RIGHT and LEFT navigation buttons When MANUAL is selected the test will automatically start once a Valid strap is detected The delay time between the detection of the valid DUT and the start of the test is defined by the AUTO START DELAY SEC setting described below BATTERY TEST START The user selects from the predefined settings MANUAL or AUTO using the RIGHT and LEFT navigation buttons When MANUAL is selected the test will automatically start once a Valid battery or cell is detected The delay time between the detection of the valid DUT and the start of the test is defined by the AUTO START DELAY SEC setting described below AUTO START DELAY SEC The user must manually enter a value from 1 to 31 or use the RIGHT and LEFT navigation buttons to increment or decrement the numeric value This is the amount of time the user will wait once a Valid DUT is detected 6 ALARM SETTING This screen lets the user enter the ALARM SETTINGS for the testing The following data entry is required for this screen IMPEDANCE ALARMS Alarms for single point impedance testing results The following sub alarms fall under this section Default values are shown on the Analyzer when entering this screen IMPEDANCE HIGH This is the impedance alarm above greater than the baseline value Values are entered manually or with the RIGHT and LEFT navigation buttons Defa
49. The Adjust Baseline Screen presents several graphs depending of the battery type selected in the string 1 Relative Degradation Population Referenced Adjustment Utility This graph is used to select the level of Relative Degradation that should correspond to 100 based on the collected dataset e g using the original ACP 2 Relative Degradation Population Referenced Updated Values The changes made on the Adjustment Graph are immediately reflected in this graph to the user Based on this graph the user can decide if the new baseline is adequate or not 3 Sulfation Updated Values The changes made on the adjustment graph will be immediately reflected on the Sulfation level to the user Based on this graph the user can decide if the new baseline is adequate or not This graph is only displayed for Lead Acid Battery Strings 4 Dryout Updated Values The changes made on the adjustment graph are immediately reflected on the Dryout level to the user Based on this graph the user can decide if the selected baseline is adequate or not This graph is only displayed for Lead Acid Battery Strings consisting of AGM or Gel type batteries There are three methods for performing an ACF adjustment with the Relative Degradation Population Referenced Adjustment Utility Graph 1 Input an ACF value in the Updated ACF box at the left of the graph Changes will cause automatic updating of the other graphs as well as movement of the blue line in the A
50. also have other rights that vary from state to state or from one jurisdiction to another Laws in the United States and other countries preserve for Global Energy Innovations certain exclusive rights for copyrighted Global Energy Innovations software such as the exclusive rights to reproduce and distribute copies of the Global Energy Innovations software Global Energy Innovations software may only be copied into used in and redistributed with the Products associated with such Global Energy Innovations software No other use including without limitation disassembly of such Global Energy Innovations software or exercise of the exclusive rights reserved for Global Energy Innovations is permitted iii Global Energy Innovations EC1000 8 EC2000 Analyzers User Manual Table of Contents 2 TABLE OF CONTENTS 1 LIMITED WARRANTY 8 LIMITATION OF LIABILITY a a ae ar naa aan Rain nennen 2 TABLE OF GONTENITS oq init nnde tied t dept tei dde in ethanol ud adeste meten natem dte Dr edt 1 3 DEGLARATIONOF CONFORMITY EE 4 4 EI A EIN Le NEE debole te bte e e D Ue red t ate tiet epe tic lade cee 5 5 SAFETY INSTRUCTIONS INTRODUGTION 5 ceeds rt titt ERRORI tiradas 6 6 SAFETY PRECAUTIONS sects o etate i iet deo d iia diia 7 7 GAUTION amp WARNING S TAT ME N T ttt tet ee RD ia 8 8 WARNINGS amp OTEHER SYMBOBLS ricette RR PDC e eim eate ettet iiec bte nea iet E RE 9 9 IMPAIRED SAFETY EEN 10 10 LIST OF WARNINGS amp SAFETY PRECAUTIONS
51. arranty Who is covered This warranty extends only to the first consumer purchaser and is not transferable What will Global Energy Innovations Do Global Energy Innovations at its option will at no charge repair replace or refund the purchase price of any Products Accessories or Software that does not conform to this warranty We may use functionally equivalent reconditioned refurbished pre owned or new Products Accessories or parts No data software or applications added to your Product Accessory or Software including but not limited to personal contacts site data configurations will be reinstalled To avoid losing such data software and applications please create a back up prior to requesting service How to Obtain Warranty Service or Other Information To obtain service or information please contact Your Local Representative or Distributor e http www globalei com distributorsAndReps html Global Energy Innovations Customer Services Main Phone Number 1 415 354 5688 Facsimile 1 415 354 5738 Email supportOalobalei com Or visit us online at http www globalei com You will receive instructions on how to ship the Products Accessories or Software at your expense to a Global Energy Innovations Authorized Repair Center To obtain service you must include a a copy of your receipt bill of sale or other comparable proof of purchase b a written description of the problem c the name of your distributor or representa
52. as specified as a discrete value gt Fail ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms VOLTAGE LOW V This is the voltage alarm below less then the pre entered reference value Values are entered manually or with the RIGHT and LEFT navigation buttons Default values are set on the Analyzer when entering this section Warning Value This is the warning value as specified as a discrete value gt Warning ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms gt Fail Value This is the fail value as specified as a discrete value gt Fail ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms CELSCAN ALARMS Alarms for CELScan testing results Sulfation and Dryout Default values are shown on the Analyzer when entering this screen SULFATION These values represent the percentage 96 of capacity loss due to battery cell sulfation For example if a value of 10 was entered this would mean that after 1096 of capacity loss in the battery or cell due to battery cell sulfation the alarm would be reached Values are entered manually or with the RIGHT and LEFT navigation buttons Default values are set on the Analyzer when entering this section Warning Value This is the warning value as specified as a percentage c Warning ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms Page 30 Global E
53. ation Impedance Alarms Yes Sulfation Capable Capacity Loss Reading Yes Dryout Capable Capacity Loss Reading Yes Safety Features Manual Push Button Test Mode and Hands Free Auto Start Test Mode Yes t Overvoltage Warning 17 VDC Over Voltage Auto Reset Breaker Danger Warning 50 VDC High Voltage Protection Reverse Polarity Protected Yes Damage Point Protection Failure 600 VDC max Weight 2 8 lb 1 27 kg Dimensions 4 25 x 10 05 x 2 30 in 108 x 267 x 58 mm Warranty 1 Year Limited Warranty Cable Connector Assemblies Standard Kelvin Clips Yes with removable jaws Double Point Kelvin Probes Yes with removable tips Single Point Kelvin Probes Yes with removable tip Optional Accessories SD Card Reader For use with PC DC Vehicle Adapter Charger For use with AC Adapter Charger Preminum Hard Carrying Case Heavy duty case for protection of handheld device Accessory Cable Set For use with Oscilloscope Voltmeter Other Service Support 4 Instrument Training Yes Customer Support Website Yes Technical Support Hotline Yes Warranty Extension Available 1 and 2 Year Yes Instrument Calibration Program Yes Page 61 Global Energy Innovations EC1000 amp EC2000 Analyzers Users Manual Analyzer Specifications EC1000 amp EC2000 PRODUCT IMAGES PARTI SIDE VIEW Carryi
54. ation the alarm would be reached Values are entered manually or with the RIGHT and LEFT navigation buttons Default values are set on the Analyzer when entering this section Warning Value This is the warning value as specified as a percentage c Warning ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms c Fail Value This is the fail value as specified as a percentage c Fail ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms DRYOUT These values represent the percentage 96 of capacity loss due to battery cell dryout For example if a value of 10 was entered this would mean that after 1096 of capacity loss in the battery or cell due to battery cell dryout the alarm would be reached Values are entered manually or with the RIGHT and LEFT navigation buttons Default values are set on the Analyzer when entering this section c Warning Value This is the warning value as specified as a percentage c Warning ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms c Fail Value This is the fail value as specified as a percentage Page 36 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp Testing c Fail ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms STRAP ALARMS These are alarms for strap testing results Default values are
55. calibrations and adjustments Values are entered manually or with the RIGHT and LEFT navigation buttons There are no preset values on the Analyzer when entering this section Page 31 Global Energy Innovations EC 1000 8 EC2000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp Testing This value is typically calculated using the BASELINE UTILITY in the UTILITIES TOOLS Menu Details on the ACF and proper ACF generation procedure please reference the Chapter 7 The user has now completed the QUICK TEST setup COMPANY REGION COMPANY REGION is covered next because this value is used in the STRING CONFIGURATION This section allows the user to manually entera COMPANY name i e The name of the Company that owns the sites that are being tested Example Southern California Edison The REGION is the name of the Region where testing occurs COMPANY REGION NEW COMPANY REGION lt NEW gt NEW COMPANY NAME DEFAULT DEFAULT NEW REGION NAME Figure 2 6 Company Region screen 1 Figure 2 7 Company Region screen 2 Figure 2 6 and 2 7 show the two screen for entering the appropriate data Follow the screens for appropriate data entry The correct COMPANY and REGION must be entered prior to testing otherwise these values will not properly load to IBMS for review and archiving STRING CONFIGURATIONS The STRING CONFIGURATION Menu and accompanying screens are the most complex and all encompass
56. ction covers both the Baseline Utility in the Tools Menu as well as Autobaselining and the theory and principles behind baselining on the Analyzer Since IBMS Software Advanced User Setting may be used to adjust baseline values this concept is covered briefly in this section 1 AUTOBASELINE The baseline and Algorithm Calibration Factor ACF are derived values that are used to accurately calculate adjust compensate the level of battery sulfation and dryout as well as impedance reference values The Autobaseline feature on the Analyzer is used to automatically calculate a valid baseline value ACF and Impedance for the string of batteries or cells being tested Each battery or cell carries its own baseline value in addition to a string level baseline value When the user selects YES for USE AUTO CALC BASELINE in the String Configuration setup the Analyzer will automatically arrive at a baseline value for the string of batteries or cells during normal testing Figure 2 10 shows where the user selects this information Autobaseline YES is the default option on the Analyzer It is recommended to keep this feature enabled unless you have suitable prior knowledge of the battery or cell to be tested in which case the following BASELINE values may be manually entered BASELINE IMP REF mQ BASELINE ACF BASELINE TEMP C or F Note Entering values manually is an advanced user function and should be done by trained experie
57. djustment Utility Graph according to the new ACF value The percentage number next to the box indicates what current Relative Degradation level is considered to be 10096 after accepting the change 2 Select a Relative Degradation Levels in the Adjustment Utility Graph The ACF value in the Updated ACF box percentage value and the blue line in the graph will be automatically changed to reflect the selection The other graph will be updated as well to reflect the new ACF value Page 49 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 5 Advanced Analyzer Features amp Functions 3 3 Drag the blue line in the Adjustment Utility Graph By dragging the blue line up or down the Updated ACF box Value percentage will be updated accordingly The other graphs will be updated as well to reflect the new ACF value After selection of a new ACF the user can immediately see the effect of this new baseline on the CELScan levels Based on the CELScan updated graphs the user can decide if the new baseline is adequate and by clicking Save Changes the new ACF value is saved into the Test Configuration If the new ACF value does not seem adequate the user can either click on the Cancel Changes button to reset the ACF value or continue adjusting the ACF appropriately The ideal ACF is one that removes outlier batteries having an excessively low Relative Degradation whilst not compromising the detection
58. ed or if manually entered values will be used The RIGHT and LEFT navigation arrows are used for selecting between YES or NO If the user selects YES then BASELINE IMP REF mQ BASELINE ACF and BASELINE TEMP C are not selectable for data entry Page 37 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp Testing Details on the methods and technology of the Automatic Baseline Feature on the Analyzer can be found in Chapter 5 16 BASELINE IMP REF mQ The user enters the Baseline Impedance Reference Value for the Battery or Cell being tested This value is used for calculating the alarm values Values are entered manually or with the RIGHT and LEFT navigation buttons There are no preset values on the Analyzer when entering this section 17 BASELINE ACF The user enters the Baseline ACF Algorithm Calibration Factor used with the CELScan Algorithms Sulfation and Dryout This value will be used for Sulfation and Dryout algorithm calibrations and adjustments Values are entered manually or with the RIGHT and LEFT navigation buttons There are no preset values on the Analyzer when entering this section When the Auto Calculated Baseline is not used this value is typically calculated using the BASELINE UTILITY in the UTILITIES TOOLS Menu Details on the ACF and proper ACF generation procedure please reference Chapters 6 and 7 18 BASELINE TEMP C
59. form on and inside the casing Allow the Analyzer sufficient time to acclimatize and all condensation to evaporate before powering it on WORKING IN THE VICINITY OF A LEAD ACID BATTERY IS DANGEROUS BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION FOR THIS REASON IT IS OF THE UTMOST IMPORTANCE THAT EACH TIME BEFORE USING YOUR ANALYZER YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY INTERNAL LITHIUM ION ANALYZER BATTERY PON A The handling of the Lithium lon Battery pack inside the Analyzer requires caution and misuse or mishandling of the battery pack may cause harm to the user Failure to follow the instructions below may result in high temperatures fire or explosion Do not expose the battery to temperatures above 60 C 140 F Do not disassemble or mistreat the battery Use only Global Energy Innovations supplied chargers and cables Use only replacement battery packs supplied by Global Energy Innovations Please contact Global Energy Innovations or your local dealer if you wish to replace the battery pack in your Analyzer Page 12 Global Energy Innovations EC1000 amp EC2000 Analyzers Users Manual Unpacking the Analyzer Kit 11 UNPACKING THE ANALYZER KIT The following items are included in the EC1000 and EC2000 test tool kit Table 1 is a complete list of standard and options accessories as well as replacement parts product upgrade and warranty extension option
60. graphs contain information cautions and warning which must be followed to ensure safe operation and to keep the EC1000 and EC2000 Analyzer in safe condition WARNING Servicing described in this manual is to be done ONLY by qualified service personnel To avoid electrical shock DO NOT service the EC1000 or EC2000 Analyzers unless you are qualified to do so WARNING DO NOT use the EC1000 or EC2000 Analyzers unless you have been formally trained at servicing electrical power systems including battery and other energy storage devices Page 6 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Safety Precautions 6 SAFETY PRECAUTIONS For the correct and safe use of the EC1000 and EC2000 Analyzer it is essential that both operating and service personnel follow generally accepted safety procedures in addition to the safety precautions specified in this manual Specific warning and caution statements where they apply will be found throughout the manual Page 7 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Caution and Warning Statement 7 CAUTION amp WARNING STATEMENT WARNING Used to alert the user to the possibility of performing an incorrect maneuver which could lead to damage or destruction of the equipment or other property CAUTION Used to call attention to a potential danger that requires correct procedures or practices to prevent property da
61. h battery powered back up systems in multiple locations and regions When testing multiple batteries it is important know which test data is from which battery For this reason the Analyzer must be configured so that it knows the following information This information is part of the hierarchy outlined below Figure 1 1 shows the Configuration Screen in the Analyzer s companion software IBMS Intelligent Battery Management System Software It is displayed her to both graphically show the information hierarchy as well as illustrate the similarities between the Analyzer and the IBMS configuration options Location Hierarchy TT x 9 9 Configuration Company or User Company Inventory Options Chart Display Geographical Region Location Region AS Location Level 1 Company Site Location Site Location Level 2 Regon Location Level 3 Site 5 x TestGroup String String of Batteries being Tested String Ty Eegen B A Region Testable Parts and Connections ES NI sting Testable Parts and Connections Multiple Cell Unit Battery Multiple Cel Unit Batey Single Cell Unit Cell Electrical Connection Strap Single Cell Unit Cell v oc 88 conce Electrical Connection Strap Figure 1 1 IBMS Inventory hierarchy setup screen Page 18 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 1 Initial Analyzer Setup For this reason the user mu
62. here temperature is most often entered are listed below 1 Sting Configuration BASELINE TEMPERATURE 2 Start Testing Screen TEST TEMPERATURE 3 Testing Sequence F3 TEMPS Individual Battery or Cell Temperatures may be entered during testing The Analyzer ships with a precision Fluke Model 62 Infrared Thermometer P N 1010 0002 for accurately measuring battery temperature Battery or Cell temperature is best taken by measuring the temperature of the Positive or Negative terminal Please reference the Fluke Model 62 Infrared Thermometer data sheet on the Global Energy Innovations website for details on using the thermometer http www globalei com bms accessories replacement parts infrared thermometer html ANALYZER IBMS INTERACTION The Analyzer has been designed to interact with IBMS to facilitate easy operation and configuration Although the Analyzer may be used in a stand alone fashion Without IBMS it is recommended that IBMS be used for configuration There are also a number of advanced functions that are only accessible via IBMS Please reference the IBMS Users Manual and Quick Start Guides for details on this subject Some of the critical features are as follows 4 Update of firmware 5 Addition of new features 6 Synchronization of the Clock Page 55 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 5 Advanced Analyzer Features amp Functions Whenever connecting to IBMS
63. ia pressing F1 to RETURN While in this screen the user can CONFIRM F1 RETURN F2 or select TEMPS F3 When CONFIRM is selected this strings test sequence can no longer be opened for future testing It is permanently locked and can only be reviewed deleted or transferred to IBMS Page 43 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 3 Reviewing the Test Results CHAPTER 3 REVIEWING THE TEST RESULTS About this Chapter This Chapter shows the user how to review the test results and test settings configurations that were used during testing After testing is completed or during testing before or after a test sequence is locked the user may navigate to the TEST RESULTS screen to review test results in detail The following functions may be accomplished in the TEST RESULTS section 1 Test results may be deleted 2 Limited battery and site specific information may be entered and or modified 3 Test Configurations and the settings associated with them may be viewed The following six 6 screens shown in Figure 3 1 illustrate the navigation for reviewing test data Page 44 Global Energy Innovations EC1000 amp EC2000 Analyzers Users Manual Chapter 3 Reviewing the Test Results MEMORY NMJ O1JAN 20107300 wii DCH MEMORY NN O1JAN201013 00 4 Rm MEMORY Jot Aan 20101300 wii i RESULTS SELECT SITE RESULTS BOULDER RESULTS BOULDER COMPANY REGION STRIN
64. ia the activation server 8 MODEL The Model of your Analyzer This can change depending on the features that have been activated or deactivated on the Analyzer MINI SD CARD 9 CAPACITY The total capacity of the Mini SD Card that is installed in the Analyzer is displayed here Note The Mini SD Card must be configured formatted with an appropriate setup backing file to operate in the Analyzer Instructions on how to format a standard Mini SD Card can be found on the Customer Support Site http support globalei com 10 AVAILABLE The available remaining capacity of the Mini SD Card is displayed here FEATURES 11 Impedance Voltage This is the standard EC1000 feature set for the Analyzer When this feature is enabled the Analyzer is capable of testing the electrical properties of batteries only 12 Sulfation Dryout CELScan module for Sulfation and Dryout advanced health algorithms When ACTIVATION is ON this feature is enabled and will work on the Analyzer This is only ON for EC2000 Analyzers This CELScan module also provides additional signal processing capabilities such as Fast Fourier Transform FFT analysis and enhanced noise rejection SUPPORT 13 SUPPORT website for support related matters 14 CONTACT Contact details for support related matters Page 24 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp Testing CHAPTER
65. ing screen flow in the Analyzer A user can select STRING CONFIGURATION and use this Menu exclusively to set up and entire test STRING CONFIGURATION accesses most all of the other critical setup functions on the Analyzer with the exception of QUICK TEST Although STRING CONFIGURATION accesses COMPANY REGION BATTERY TYPES ALARM SETTINGS and TEST SETTINGS these Templates have already been covered in Chapter 2 and will not be repeated in this section TEST SETTINGS will however be covered in this section Figure 2 1 shows the TEST CONFIGURATION TEMPLATES screen When STRING CONFIGURATION is selected the user is prompted through the three 3 screens shown in Figure 2 8 2 9 and 2 10 Page 32 Global Energy Innovations EC1000 amp EC2000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp Testing MEMORY orAN2o10 13 00 wii DCH MEMORY EEE oran 2010 13 00 sii MEMORY e TI 01 Jan 201013 00 wii LOCATION SITE STRING SELECTION STRING CONFIGURATION SITE ID SITE BOULDER BASELINED SETTING NAME VALUE EE SIE CE ROSE E lt NEW gt YES BASELINE STATUS YES amp Rocky Mountain Telcom Central Region YES NUMBER OF BATTERY S PES FLAGSTAFF NE 3 NO BATTERY TYPE lt UNDEF gt BOULDER STRING 4 TEST SETTING lt VIEW gt ALARM SETTING lt VIEW gt TELLURIDE TEST VOLTAGE TEST IMPEDANCE TEST SULFATION YES TEST DRYOUT YES STRAP S PER BATTERY 1 FLOAT CHARGE YES VOLT REF CELL V
66. irst consumer purchaser of the product The balance of the original warranty or for ninety 90 Days from the date returned to the consumer whichever is longer Products or Accessories that are Repaired or Replaced Software as defined above Applies only to physical defects in the media that embodies Ninety 90 days from the date of purchase the copy of the software e g CD ROM What is not covered Exclusions Normal Wear and Tear Periodic maintenance repair and replacement of parts due to normal wear and tear are excluded from coverage Ornamental Decorations Ornamental decorations such as emblems and graphics and other decorative elements are excluded from coverage Batteries Only batteries whose fully charged capacity falls below 60 of their rated capacity and batteries that leak are covered by this limited warranty Abuse amp Misuse Defects or damage that result from a improper operation storage misuse or abuse accident or neglect such as physical damage cracks scratches etc to the surface of the product resulting from misuse b contact with liquid water rain extreme humidity or heavy perspiration sand dirt or the like extreme heat or food c Subjecting the Product or Accessory to abnormal usage or conditions or d other acts which are not the fault of Global Energy Innovations are excluded from coverage Use of Non Global Energy Innovations Products and Accessories Defects or da
67. is section covers the use of these configurations QUICK TESTS This section covers testing using QUICK TEST MEMORY NN 01 JAN2010 4300 wii QUICK T NAME STATUS 2 Tested 1 Pass 0 Warn 1 Fail 25 C IMP mQ VOLT V SULF DRY 1 024 2 056 o 5 2 04AT 2 320 Figure 2 17 Quick Test testing screen The screen shown in Figure 2 17 shows the full test mode for QUICK TEST All alarms and setting for QUICK TEST testing come from the QUICK TEST SETTINGS that were previously discussed in the TEST CONFIGURATIONS section of this Chapter Details on each mode are listed below IMPEDANCE METER This is a preset template on the Analyzer and allows the user to test impedance only 1 2 VOLTAGE amp IMPEDANCE METER This is a preset template on the Analyzer and allows the user to test impedance and voltage only 3 VOLTAGE METER This is a preset template on the Analyzer and allows the user to test voltage only 4 CUSTOM TEMPLATE This is a user entered template that allows for setup of CELScan Sulfation and Dryout in addition to impedance and voltage measurement Note 1 When the user presses the RETURN key and exits QUICK TEST mode no data is stored in memory 2 When a single asterisk is shown next to the test result this indicates a WARNING Alarm condition Page 41 Global Energy Innovations EC 1000 8 EC2000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp
68. ithout a baseline value history whilst new batteries of the same make and model are available elsewhere to test and acquire valid baseline data Note There is no baseline utility for strap impedance If the user wants to determine the strap reference value without using the Auto Calc Strap Reference feature they can do it manually by performing a QUICK TEST Impedance on the strap When using the BASELINE UTILITY the user must input the following information a Battery Type b Capacity Amp hours c Number of Cells per Post Pair d Temperature Battery of Cell Upon completion of this data entry the user starts the test by pressing the F2 button Start Note There is no baseline utility for strap impedance If the user wants to determine the strap reference value without using the Auto Calc Strap Reference feature they can do it manually by performing a QUICK TEST Impedance on the strap Page 50 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 5 Advanced Analyzer Features amp Functions Warning Since the Baseline Test is done on a single battery or cell it is strongly recommended to use the BASELINE UTILITY only in particular circumstances where the Autobaseline function cannot be used MEMORY on JAN 20101300 m DCH BASELINE UTILITY BATTERY TYPE lt UNDEF gt CAPACITY Ah 200 NUMBER OF CELLS PER POST PAIR 6 TEMPERATURE C IMPEDANCE REF mQ ALGORITHM CALIBRATION F
69. l Chapter 5 Advanced Analyzer Features amp Functions Baseline Adjustment The Baseline cannot be adjusted on the Analyzer during use in the field Baselines however may be adjusted using IBMS when the user is in the Advanced User Mode Configuration Options Test View Results The Adjust Baseline tab See Figure 5 1b must first be selected This advanced tool is NOT intended to be used to make a string of batteries look healthy by adjusting the Algorithm Calibration Factor ACF to a frivolous value however its intended use is to increase the accuracy level of baseline determination of the string Hence the utility should only be used by expert uses who intimately understand the consequences of changing the baseline values Additionally Baseline Adjustment should only be done once or twice for any strings In particular the purpose of Adjust Baseline is to allow the user to adjust ACF and CELScan readings when an error was made such as 1 The Baseline Values were manually entered and after testing appear to be incorrect 2 An Auto Baseline value was determined by the Analyzer that appears to be inaccurate or faulty The new ACF value saved from the Adjust Baseline should be used for all future tests on the string e g changes of the baseline value in the Test Configuration It is the responsibility of the User to ensure that the Configuration is loaded back to the Analyzer for future testing of the same string
70. ly information not only about which battery units are about to fail but also about the cause s of those failures In aggregate this information defines the battery state of health SOH The EC1000 and EC2000 EC Series Analyzers determine SOH from a battery s response to a series of electrical excitation signals Interpretation of the response is performed in real time by Global Energy Innovations impedance based CELScan Chemical Electrical Layer Scanning algorithms At the heart of the EC Series Analyzers is a single board computer running Linux that works together with analog digital and measurement boards to accomplish noise rejection using fast Fourier transforms FFT and other advanced signal processing tasks The technology incorporated in these Analyzers is the most advanced of its kind today About this Users Manual This Users Manual covers all of the features function and operation of the EC Series Analyzers Often there are detailed descriptions of how a function works with examples The manual is intended to cover a large amount of information not all of which may be immediately relevant to your successful operation of the Analyzer For this reason you may want to read only key parts and reference others at a later date when appropriate or when a feature or function is not clear Since the EC Series Analyzers were designed to work intimately with the IBMS Intelligent Battery Management System Software there is
71. mage personal injury or death Page 8 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Warnings and Other Symbols 8 WARNINGS amp OTHER SYMBOLS Nomenclature and Formatting in this Manual The following safety symbols are used in the Users Manual Notes Warnings and Caution Symbols NOTE A note indicates important information that helps you make better use of your equipment incorrect maneuver which could lead to damage or destruction of the equipment or Q WARNING A WARNING used to alert the user to the possibility of performing an other property CAUTION A CAUTION calls attention to a potential danger that requires correct procedures or practices to prevent property damage personal injury or death Page 9 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual 9 IMPAIRED SAFETY Whenever it is likely that safety has been impaired or compromised the Analyzer must be turned off The matter should be referred to a qualified technician Safety is likely to be impaired if for example the EC1000 and EC2000 Analyzer fails to perform the intended procedure or shows visible damage Impaired Safety Page 10 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual List of Warnings amp Safety Precautions General Safety Information 10 LIST OF WARNINGS amp SAFETY PRECAUTIONS GENERAL SAFETY INFORMATION Please read all of the following
72. mage that result from the use of Non Global Energy Innovations branded or certified Products Accessories Software or other peripheral equipment are excluded from coverage Unauthorized Service or Modification Defects or damages resulting from service testing adjustment installation maintenance alteration including without limitation software changes or modification in any way by someone other than Global Energy Innovations or its authorized service centers are excluded from coverage Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Limited Warranty amp Limitation of Liability Altered Products Products or Accessories with a serial numbers or date tags that have been removed altered or obliterated b broken seals or that show evidence of tampering c mismatched board serial numbers or d nonconforming or non Global Energy Innovations housings cases or parts are excluded from coverage Software Embodied in Physical Media No warranty is made that the software will meet your requirements or will work in combination with any hardware or software applications provided by third parties that the operation of the software products will be uninterrupted or error free or that all defects in the software products will be corrected Software NOT Embodied in Physical Media Software that is not embodied in physical media e g software that is downloaded from the internet is provided as is and without w
73. nced users Baseline Temperature must be entered correctly or results may be calculated incorrectly on the Analyzer IBMS BASELINE ADJUSTMENT IBMS may be used to adjust baseline values that have been acquired determined by the Analyzer This function is important because the user may want to manually adjust override the baseline value if the auto calculated value is determined to be less accurate than one determined by the user When the Adjust Baseline Advanced User function is used the new baseline value must be loaded back to the Analyzer for subsequent testing Figure 5 1a shows the IBMS screen where the baseline may be adjusted You must be running IBMS Version 2 1 0 Build 40 or later to use this Advanced function Page 47 Global Energy Innovations EC1000 amp EC2000 Analyzers Users Manual Chapter 5 Advanced Analyzer Features amp Functions Test Result on 2010 10 26 17 44 46 Global Energy Field Testing Hopland The Raven String 2 Test Results Test Configuration string Report Cell History Adjust Baseline 943 Y Save Changes amp Cancel Changes Show All Relative Degradation Auto Calc ACF 0 00 H Relative Degradation Relative Degradation Ei Population referenced 110 Adjustment Utility 100 oru Click on a Battery in the chart to compute s 80 anew ACF based on that Battery being 70 100 Relative Degradation Or drag the 6
74. nergy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp Testing gt Fail Value This is the fail value as specified as a percentage gt Fail ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms DRYOUT These values represent the percentage 96 of capacity loss due to battery cell dryout For example if a value of 10 was entered this would mean that after 1096 of capacity loss in the battery or cell due to battery cell dryout the alarm would be reached Values are entered manually or with the RIGHT and LEFT navigation buttons Default values are set on the Analyzer when entering this section Warning Value This is the warning value as specified as a percentage c Warning ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms gt Fail Value This is the fail value as specified as a percentage gt Fail ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms STRAP ALARMS These are alarms for strap testing results Default values are shown on the Analyzer when entering this screen Warning Value This is the warning value as specified as a percentage above the baseline value gt Warning ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms gt Fail Value This is the fail value as specified as a percentage above the baseline value gt Fail ON O
75. ng Strap Hole Santoprene Protective Power amp Digital UO Connector Fan Vents Boot Panel Cover BACK VIEW FRONT VIEW Cooling Fan Color TFT Removable Display Carrying ZP Silicon Rubber Keypad Tilt Stand Lithium lon Battery Removable Page 62 Global Energy Innovations EC1000 amp EC2000 Analyzers Users Manual Analyzer Specifications EC1000 A EC2000 PRODUCT IMAGES PARTII TOP VIEW Kelvin Oscilloscope Connector p Probe Input POWER amp DIGITAL 1 0 CONNECTOR PANEL Mini SD Card DC Power Slot Charger Mini USB Ethernet Table AS 01 Analyzer technical specification and product images Page 63 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Index INDEX A BASELINE TEMP C or F 47 COPYRIGHT NOTE 5 Absorbed Glass Mat 27 34 Baseline Utility ssssssesssssse 47 Customer Services oooooocococccncccccnnccnonononccnnnnnnnns ii AC DC Current Camp 16 BASELINING ANALYZER BASELINE D AC DC Current Ghunt neeese 16 B I Pe A O O cue DECLARATION OF CONFORMITY 4 GENEE 14 ee QC A TEE 17 Accessory Cable Get 15 dpi DETAILS 27 34 Disassembling ssssssssssss 11 AGE m AI Tuc e i dae UN OT CIMA UR Ir ano DRYOUT 96 1 eie tenis 31 36 e BATTERY REPLACEMENT UTILITY 52 Addition of new features
76. ove to the testing flow and test all of the batteries that were ADDED flagged for replacement and then confirm F3 locking the string At any point the user can return to the BATTERY REPLACEMENT UTILITY and ADD more batteries for replacement Note These tests are required to update the individual battery or cell baseline values used in the ADVANCED USER mode in IBMS however these values DO NOT change the general Reference Impedance and ACF values associated with the entire string MEMORY RS Joiyamzoio13 00 sii CH MEMORY RS Joiyamzoio13 00 9 CH MEMORY MENS Joiyamzoio13 00 90 CH SELECT SITE ID SELECT STRING ID ID Flagstaff String 2 STRING 1 BASELINE DATA COLLECTION caius BATTERY 1 T MOBILE ROCKY MOUNTAINS SIRINGS BATTERY 2 BOULDER STRING 4 TELLURIDE BATTERY 3 BATTERY 4 Needs Testing BATTERY 5 Needs Testing Figure 5 3 Battery Replacement Utility Screen 1 Figure 5 4 Battery Replacement Utility Screen 2 Figure 5 5 Main Battery Replacement Screen Using IBMS the user may review battery details and schedule eventual battery replacement in the inventory management section To schedule battery replacements the user selects the string where batteries will be replaced using the INVENTORY MANAGEMENT window This will cause a pop up of the EDIT BATTERY STRING window and the batteries to be replaced can be flagged Checked Replaced in the BATTERY DETAILS tab Figure 5 6 To schedule a battery to be replaced
77. pre entered reference value Values are entered manually or with the RIGHT and LEFT navigation buttons Default values are set on the Analyzer when entering this section Warning Value This is the warning value as specified as a discrete value Warning ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms c Fail Value This is the fail value as specified as a discrete value c Fail ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms VOLTAGE LOW V This is the voltage alarm below less then the pre entered reference value Values are entered manually or with the RIGHT and LEFT navigation buttons Default values are set on the Analyzer when entering this section Warning Value This is the warning value as specified as a discrete value c Warning ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms c Fail Value This is the fail value as specified as a discrete value c Fail ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms CELSCAN ALARMS Alarms for CELScan testing results Sulfation and Dryout Default values are shown on the Analyzer when entering this screen SULFATION 9 5 These values represent the percentage 96 of capacity loss due to battery cell sulfation For example if a value of 10 was entered this would mean that after 1096 of capacity loss in the battery or cell due to battery cell sulf
78. s Figure 1 shows all standard EC1000 and EC2000 Analyzer Kit parts For images of optional accessories and replacement parts please refer to the Global Energy Innovations Online Store or contact your local distributor EC1000 EC2000 Analyzer 8656 1000 2000 Hand Strap 1010 1005 Shoulder Strap 1001 1006 AC Wall Adapter USB Cable Mini SD Memory Card Battery Charger 1015 1001 1010 1002 1010 1001 3 Standard Lithium ion AB 5 Sytem Intelligent Windows XP 7 Vista Software Download Th e Battery Pack IBMS Companion Software 8520 0000 1010 0002 Soft Carrying C Free Download Kelvin Clips Standard oft Carrying Case 8600 1000 ponte 1010 1004 Figure 1 0 EC1000 and EC2000 Analyzer Kit Page 13 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Unpacking the Analyzer Kit Item Part Description Quantity EQUIPMENT EC1000 KIT Impedance Voltage 8656 1000 1 8656 1000 EC1000 Handheld ElectroChemical Battery Analyzer 1 2 8600 0004 Kelvin Clips Standard 1 3 8600 1000 IBMS Companion Software Free Download 1 4 1010 1001 AC Wall Adapter Battery Charger 1 5 8520 0000 Standard Lithium lon Battery Pack 1 6 1010 0002 Infrared Thermometer 1 7 1010 1004 Soft Carrying Case 1 8 1010 1005 Hand Strap 1 9 1010 1006 Shoulder Strap 1 10 1
79. s the BATTERY REPLACEMENT UTILITY screen the user must first navigate through two 2 screens Figure 5 3 and 5 4 to locate the batteries or cells to be replaced 2 In the main BATTERY REPLACEMENT UTILITY screen Figure 5 5 all of the batteries that can be replaced are listed and batteries that have not been tested yet are flagged as Needs Testing The Needs Testing is also displayed alongside the untested batteries flagged for replacement in IBMS 3 While in the main BATTERY REPLACEMENT UTILITY screen Figure 5 5 the user may select a replacement battery to test by pressing ADD F2 When ADD is selected the use is prompted to select the ID of the battery Only ID values related to the battery Page 52 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 5 Advanced Analyzer Features amp Functions or cell may be selected For example if 10 was selected but there were only 5 batteries in the string Battery 1 2 3 4 5 an error screen would show prompting the user to select a valid battery number You may use the RIGHT and LEFT navigation buttons on the keypad to increment or decrement the values 4 The user can start testing any of the replacement batteries by pressing TEST F3 When testing begins the user is taken to the main testing flow and must manually return to the BATTERY REPLACEMENT UTILITY to review replacement data and status of untested batteries Typically the user will m
80. sess 95 Nickel Cadrhi m octets 27 34 SAFETY INSTRUCTIONS sss 6 Inventory Management senene 19 Nickel Metal Hydride ssssssss 27 Screen layout is cals at di 21 K Ill EE 48 SD Caldo ii 22 Kelvin CPS ci Ee 11 Noise Filtering aaeseerrresesrinssrrrnierrresrna 51 SD Card Reader 15 Kelvin BET detti Mete 14 NOISE FILTERING nceroinhean n ea 28 34 SERIAL NUMBER a 24 Kelvin Probes Double Point 15 noise rejection eet ede ctc ed 17 SEIVICE t tont ache er ge Let ut ears Kelvin Probes Mim 15 NOTE eit teni eot et ot esate eR s 9 Setup Methode sss 19 Kelvin Probes Single Point 15 O SHIFT iet aD 26 keypad oa 20 OPTIONAL ACCESSORIES o 15 Shoulder Strap Fee ee ee Sec 14 Keypad diia nda 20 A E 16 Site Local iii in Ada 18 L A eek S 27 34 Site Name 19 Eege e 23 p sites stipite ot coU 19 LANGUAGE ccoo 23 Poterat ue NA 11 46 p LE ML M b Lead Acid AGM HEEL 27 34 POLARITY CORRECTION 35 SW eege id iie l Lead Acid Gel E AA 27 34 POWER MANAGEMENT 23 SOUND AND DISPLAY en 23 OS 27 34 48 power Off ee o He 21 GE i EAUX e ee eee eee SA 17 POWOFOE ro uis nins ir tired darter Tose S RU S As 21 STD ACF REF VALUE seee 31 38 Lithium lon 27 34 precautiOns n endete tn etd todas 12 Sr MP REE aee uiid tuens 3l Blo UfTu e lu BEE 14 PRECAUTIONS ces 7 11 STRAP ALARMS eee 31 37 DEIE
81. st either manually enter the required information or pre load via IBMS the Analyzer before testing takes commences Pre loading pre programming the Analyzer is normally the preferred method of inputting the required information however this assumes that the user has prior knowledge of some or all of the information before arriving at the Site where testing will occur Since this is not always the case the Analyzer has been designed such that either method will work adequately The primary benefit of pre loading the Analyzer with its configuration information is that this allows the maintenance personnel to simply call up the Site and String information and rapidly move into testing In addition to the information listed above the user is prompted to enter additional String Configuration Test Setting Battery and other Site and Test specific information prior to testing Again all of this information can be either created using the Analyzer or in IBMS and loaded to the Analyzer There are some a limited amount of setup parameters that are only accessible via IBMS however these do not affect the usability of the Analyzer These features fall into the category of enhanced function features Setup Methods Setup Method 1 Using IBMS The quickest and easiest method of setting up the Analyzer is to use the Inventory Management utility in IBMS This has additional benefits in that a library of configuration files can be developed and
82. stored ready for use at any time In this way the configuration of one or more Analyzers is easy and rapid Simply connect the Analyzer to a PC running IBMS load in the appropriate configuration file or files and load them to any number of Analyzers connected via USB with a few clicks of the mouse Multiple pre programmed sites can be entered into any Analyzer in a matter of seconds This method of device configuration has the following significant benefits Once a configuration has been defined and stored it can simply be re used saving significant administration time The continuity and integrity of the test data taken by the Analyzer is preserved since each subsequent maintenance visit to each site will be based on exactly the same Site Name String Name etc Setup Method 2 Using The Analyzer The Analyzer can be fully programmed and configured using the keypad shown in Figure 1 2 Similar to a mobile or smart phone the keypad can be used to access and navigate menus enter data switch options ON and OFF etc This flexibility allows the user to configure the Analyzer anywhere simply by following the on screen menus The following section explains in detail how the Analyzer is manually programmed lt is recommended that all users read these procedures fully so as to obtain the maximum benefit from the Analyzer and a complete understanding of the necessary set up procedures Page 19 Global Energy Innovations EC1000 amp EC
83. the user will see lt NEW gt Press the ENTER button to move to the QUICK TEST SETTING screen You will now need to enter the following information as indicated in Figure 2 3 Details on each entry are described in the list below After completing data entry for all of the sections listed below you will return to Figure 2 2 however a new QUICKTEST name will appear under NEW 1 CONFIG NAME This is the name of the QUICK TEST configuration Entry is accomplished using the Alpha Numeric keys Use the ESC Back Arrow to move back and the SHIFT keys as needed A complete description of the key functions are shown in Figure 1 2 2 Page 26 Global Energy Innovations EC 1000 8 EC2000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp Testing MEMORY BEEN 01 JAN 2010 13 00 a pu BATTERY DETAILS SETTING NAME VALUE MANUFACTURER EAST PENN MODEL U1HR1500 IY PE VRLA AGM CAPACITY C 10 Ah 56 8 TEST LEVEL CELL S PER BATTERY Figure 2 4 Battery Type Manu Battery Details screen 2 BATTERY TYPE This screen lets the user enter the BATTERY DETAILS for the battery that is being tested Figure 2 4 shows the BATTERY TYPE screen The following data entry is required for this screen MANUFACTURER Battery Cell Manufacturer MODEL This is the Model number of the Battery Cell being tested TYPE This is a predefined selection menu The user selects from the following types using
84. tially harm the operator Even if the PC is a laptop that is not connected to the AC mains and is using only its own internal battery it is possible for high voltages to appear between the laptop s GROUND e g any exposed metal parts and the actual earth ground potential at the test site While testing NEVER disconnect the Analyzer from the battery or cell that is being tested and reconnect the Analyzer to a voltage source that is greater than 20V When the Analyzer starts a test cycle the high voltage protection is disabled Connecting to voltage sources greater than 20V in this state may damage the unit Hydrogen gas can be present near batteries that are charging and operating with the Analyzer Always operate your System in a well ventilated area NEVER smoke or allow a spark or flame in the vicinity of the battery It is recommended that you have baking soda NaHCOs3 and water available to absorb neutralize any battery electrolyte that may leak or bubble from the battery 10 Have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes Page 11 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual List of Warnings amp Safety Precautions General Safety Information 11 12 13 14 15 16 17 18 19 20 Wear complete eye protection and clothing protection and always avoid touching your eyes while working near lead acid batteries If battery acid contac
85. time The screen shown in Figure 2 21 is displayed when a New Test Series is selected or whenever an unbaselined string is selected for testing The Test Temperature is a required entry field for this screen Once a valid temperature is entered the Start F2 button may be pressed to begin testing The user may start testing when arriving at the screen shown in Figure 2 22 The user can scroll UP and DOWN and select the DUT to test Testing begins by pressing the ENTER button Test results are displayed on the far right as PASS WARN or FAIL These values are determined by pre entered baseline and or alarm values Setup of these values can be found in a previous section of this manual When the user scrolls UP and DOWN test values are displayed for Impedance Imp mQ Voltage VOLT V Sulfation SULF and Dryout DRY Often no values are displayed under these headings This indicates that no values were taken or reported Function keys may become active at different times during testing as required When Pending is displayed this indicates that the alarm condition has not yet been calculated via the automatic baseline calculator The user must wait until a valid baseline is reached Often F2 Base Line is shown and the user may select to manually calculate a baseline value for the string using this function Figure 2 23 The Apply button may be used to apply the newly calculated baseline Page 42 Global Energy Innovations EC100
86. ting gt Fail Value This is the fail value as specified as a percentage measured from the baseline value gt Fail ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms IMPEDANCE LOW This is the impedance alarm below less than the baseline value Values are entered manually or with the RIGHT and LEFT navigation buttons Default values are set on the Analyzer when entering this section gt Warning Value This is the warning value as specified as a percentage measured from the baseline value c Warning ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms gt Fail Value This is the fail value as specified as a percentage measured from the baseline value gt Fail ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms VOLTAGE ALARMS Alarms for voltage testing results The following sub alarms fall under this section Default values are shown on the Analyzer when entering this screen VOLTAGE HIGH V This is the voltage alarm above greater than the pre entered reference value Values are entered manually or with the RIGHT and LEFT navigation buttons Default values are set on the Analyzer when entering this section Warning Value This is the warning value as specified as a discrete value gt Warning ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms gt Fail Value This is the fail value
87. tive if applicable and most importantly d your address and telephone number What Other Limitations Are There ANY IMPLIED WARRANTIES INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE SHALL BE LIMITED TO THE DURATION OF THIS LIMITED WARRANTY OTHERWISE THE REPAIR REPLACEMENT OR REFUND AS PROVIDED UNDER THIS EXPRESS LIMITED WARRANTY IS THE EXCLUSIVE REMEDY OF THE CONSUMER AND IS PROVIDED IN LIEU OF ALL OTHER WARRANTIES EXPRESS OF IMPLIED IN NO EVENT SHALL GLOBAL ENERGY INNOVATIONS BE LIABLE WHETHER IN CONTRACT OR NOT INCLUDING NEGLIGENCE FOR DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE PRODUCT ACCESSORY OR SOFTWARE OR FOR ANY INDIRECT INCIDENTAL SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY KIND OR LOSS OF REVENUE OR PROFITS LOSS OF BUSINESS LOSS OF INFORMATION OR DATA SOFTWARE OR APPLICATIONS OR OTHER FINANCIAL LOSS ARISING OUT OF OR IN CONNECTION WITH THE ABILITY OR INABILITY TO USE THE PRODUCTS ACCESSORIES OR SOFTWARE TO THE FULL EXTENT THESE DAMAGES MAY BE DISCLAIMED BY LAW Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Limited Warranty amp Limitation of Liability Some states and jurisdictions do not allow the limitation or exclusion of incidental or consequential damages or limitation on the length of an implied warranty so the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may
88. ts your skin or clothing wash immediately with soap and water If acid enters your eyes immediately flood eyes with running cold water for at least 10 minutes and get medical attention immediately DO NOT expose the Analyzer to rain snow or other harsh environmental conditions Remove all personal metal items i e necklaces rings watches bracelets etc when working with lead acid batteries and the Analyzer Batteries can produce a short circuit current high enough to vaporize or melt a ring or similar Take precautions to NOT drop any metal tools onto the battery or battery terminals Metal can cause sparking or short circuit battery or other electrical devices All tools used in or around a battery should be properly insulated Before using the Analyzer ensure that someone is within range of your voice or close enough to come to your aid when you work near a lead acid battery Before cleaning the Analyzer disconnect the unit from all cables computer connection cable Kelvin clips charger cable Clean your unit using a soft cloth that has been dampened with water Do not use liquid or aerosol cleaners which may contain flammable substances Avoid subjecting your Analyzer to hard knocks or mechanical shocks such as dropping it on hard surfaces When travelling store the Analyzer in the supplied carrying case to avoid damage When moving your Analyzer between environments of differing temperature and humidity levels condensation may
89. ult values are set on the Analyzer when entering this section c Warning Value This is the warning value as specified as a percentage measured from the baseline value c Warning ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms c Fail Value This is the fail value as specified as a percentage measured from the baseline value c Fail ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms IMPEDANCE LOW This is the impedance alarm below less than the baseline value Values are entered manually or with the RIGHT and LEFT navigation buttons Default values are set on the Analyzer when entering this section Warning Value This is the warning value as specified as a percentage measured from the baseline value c Warning ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms c Fail Value This is the fail value as specified as a percentage measured from the baseline value c Fail ON OFF Allows the user to turn this alarm ON or OFF independent of the other alarms Page 35 Global Energy Innovations EC1000 8 EC2000 Analyzers Users Manual Chapter 2 Analyzer Test Configuration amp Testing VOLTAGE ALARMS Alarms for voltage testing results The following sub alarms fall under this section Default values are shown on the Analyzer when entering this screen VOLTAGE HIGH V This is the voltage alarm above greater than the
90. you must first navigate to the CONNECT TO PC at the MAIN MENU and select this function This puts the Analyzer in its communication mode so that it is ready to communicate with a Personal Computer IBMS via the USB port Page 56 Global Energy Innovations EC1000 amp EC2000 Analyzers Users Manual Chapter 6 Troubleshooting CHAPTER 6 TROUBLESHOOTING About this Chapter This Chapter covers troubleshooting for the Analyzer The various sections covers various common problems that you might encounter and how to resolve these problems FIRMWARE UPGRADES When upgrading the firmware on the Analyzer IBMS communicates to the Analyzer and through USB Occasionally the communication between Linux Analyzer Operating System and the PC Windows will encounter an error If this occurs the user will see the screen below Figure 6 1 Simply follow the instructions on the screen and reload the firmware SHIFT Press First ABNORMAL ANALYZER SHUT DOWN RESTORE BACKUP FILE SW pros Second FIRMWARE UPDATE ERROR AN UNKNOWN ERROR OCCURED IN THE LAST ATTEMPT TO UPDATE THE FIRMWARE FOR THIS ANALYZER THE ANALYZER ENCOUNTERED A FAULT PLEASE SELECT ONE OF THE FOLLOWING OPTIONS PLEASE RECONNECT THE ANLAYZER TO IBMS AND TRY AGAIN BOOT NORMALLY CONNECT TO PC VIA USB RESTORE LAST KNOWN GOOD DATA FILES HIT ANY KEY TO CONTINUE REBUILD DATA FILES NOTE POSSIBLE DATALOSS WITH 3 COMPLETE DATALOSS WITH 4 Figure 6 1
91. ze and String Configuration Communications Internal Battery USB Ethernet Mini SD Card Type Voltage Capacity Lithium Ion Standard and High Capacity Options 12 VDC Standard 5 4 Ah High Capacity 8 0 Ah Typical Instrument Battery Run Time Charge Time Standard 6 to 10 hrs High Capacity 8 to 12 hrs depending on use 3 0 to 4 5 hrs more for High Capacity AC Adapter Charger Input Voltage Output Voltage Output Current Frequency 90 264 VAC 15 VDC 1 67 Amps 47 63 Hz DC Vehicle Adapter Charger Input Voltage 12 0 VDC Input Current Output Voltage Output Frequency 8 Amp max 115 VAC 60 Hz Output Power Environment Conditions 60 Watts Continuous 75 Watts 5 Min Operating Temp Range Storage RH Non Condensing Key Pad Upload New Software from Internet or CD 0 to 45 C 20 to 60 C 90 Silicone Rubber Yes Using IBMS Intelligent Battery Management System Interface and Reporting Software Data Collection and Reporting Software Yes Using IBMS Intelligent Battery Management System Interface and Reporting Software Page 60 Global Energy Innovations EC1000 amp EC2000 Analyzers Users Manual Analyzer Specifications User Programmable Functions Number of preset battery string configurations that can be stored Voltage Alarms Yes Depends on SD Card Size and String Configur

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