Douglas DataTrac Manual
Contents
1. PE a Section 6 Optional Accessones 21 Data Trac units may be special ordered with several additional options that allow it to be used in custom applications All of these optional accessones require custom software on the Data Trac unit which is typically only provided for high volume custom applications Contact your sales representative for more information Power Leads External Relay Connection Electolyte Level sensor Current Sensor External Thermisor External Relay connection this connection can be used to sink up to 100mA for the purpose of driving a solid state relay The control voltage of the relay must not exceed 24V An inline fuse with a rating of 100mA max 24Vdc min must be added by the installer between the relay connection and the relay 22 Section 7 Reading DataTrac Battery Data Once the Data Trac unit has been initialized it will collect charge discharge and idle data forthe battery during the daily operations of the equipment After it hasbeen accumulating battery data you can download this data at any time aslong asthe Data Trac unit is powered and within range of the PC Thiscan be accomplished while the unit is still attached to the battery truck or by connecting the Data Trac unit to a power supply at any time after it hasbeen removed Follow the instructions in the Douglas Data Manager Users Manual for transfemng data into an Douglas Data Managerdata base and generating rep2. Protection Water and acid resistant UL 94V 0 Power Consumption Packaging 5 0 L 6 Physical Dimensions Classified by UL to UL 583 Compliance Table 1 Specifications for DataTrac Bluetooth isa registered trademark of Bluetooth SIG Inc Se ae Ene EP D PL IST NEE a I APC eT Da SAVE THESE INSTRUC TIONS This manual contains important safety and operating instructions A This danger symbol indic ates that personnel must practice safety procedures in order to prevent equipment damage bodily injury or death CAUTION Installation of DataTrac must be performed by qualified personnel only Section 3 Safety Precautions A A CAUTION Working in the vicinity of lead acid batteries is dangerous Batteries can generate explosive gases during normal battery operation For this reason it isof utmost importance that you read these instructions and follow them exactly Wearcomplete eye protection and clothing protection Avoid touching eyes while working nearthe battery If battery acid contacts the skin or clothing wash immediately with soap and water If acid enters eye immediately flood eye with running cold water for a minimum of 10 minutes and get medical attention immediately Make sure that the area in which you are working is well ventilated NEVER smoke or allow a spark or flame in vicinity of battery Be extra cautious to reduce risk of dropping a metal tool onto battery It is capabl
3. analysis tools Data Trac Software Tools The Douglas Data Manager application software is used to configure the 60 and analyze the data that it collects Douglas Data Manager communicates with Data Trac via Bluetooth and compiles and displays the data in different formats for the end users analysis such as ampere hours 6 6 temperature overtime and SOC overtime Douglas Data Manager usesa standard SQLdatabase to maintain Data Trac data so that it can be easly accessed by any third party application For more information on using Douglas Data Manager with DataTrac devices see the Douglas Data Manager Users Manual PLT 24V 10 4 F 1589 202C 70 C Allows for throughput data collection using a Hall effect sensor which can measure 600A Continuous monitoring of overall battery voltage Can be installed on truck or battery Nominal Battery Voltage Operating Voltage Operating Temperature Bi directional Current Measurement Voltage Measurement Internal sensor or optional external thermistor With optional electrolyte sensor Electrolyte Level Detection Bluetooth communication Real Time Clock Time keeping and stamping of data Data Collection Upload data to PC or ExpressLink via Bluetooth 4000 event log records Data Storage Up to 100 meters Wireless Range 1 Watt integrated 950mWhr backup Over voltage Reverse Polarity
4. when changing the Data Trac time to avoid confusion when reading event reports 11 e a a PP a ITR CE Section 5 DataTrac Installation Installation of Data Trac must be performed by qualified personnel only Be sure to follow all Safety instructions descnbed in Section 3 L installation de l DataTrac doit tre effectu e uniquement par du personnel qualifi S assurer de suivre toutesles consignes de s curit d crites dansla section 3 Note For dual lead batteries make sure the Hall Effect goes around the positive cable that is used for BOTH charging AND discharging Note For all installation scenanos the red LED on the Data Trac unit should always be OFF If it is ON or blinking contact qualified service personnel For Battery Installation to Track Single Battery Usage Data 1 Gather Tools DatatTrac unit 2 6 self tapping screws with ring terminals 4 and 8 cable ties 1 4 socket amp ratchet or nut driver 1A inline fuse 1 8 drill bit and dnll 2 Attach the Hall Effect transducer Forthe solid core unit remove the battery SB SBX or Euro connectorand slide the postive battery cable through the Hall Effect unit so that the 2101 5 0 the HE unit point towards the positive battery post 12 ERA ET D ET AES TE ET OR rte FPE UFAULU AR AT ni or CAUT
5. 5 3 c shed ESE ES ES TE EN NN eI AE EE EI PEL If after carefully following the instructions in this manual you have difficulty installing or operating the Aba described contact technical support at www DouglasBattery com Note This document is based on information available at the time of its publication While efforts have been made to be accurate the information contained herein doesnot purport to cover all details or vanations in hardware or software norto provide for every possible contingency in connection with installation operation or maintenance Features may be described herein which are not present in all systems Aker Wade Power Technologies LLC T 434 975 6001 4035 Hunterstand Court F 434 975 0984 Chanottesville VA 22911 Copyright 2013 Aker Wade Power Technologies LLC All fights reserved All ttademarks and logos are the property of Aker Wade except Data Trac and Douglas Data Manager which are trademarks of EnerSys Subject to change without notice E amp O E PR e CR AR TES NE ERA RE DPI E nee E it Rie ls Toe E tee or ET iy CR DC abe EE SN PTE ET OOM N _ NB 18 19 21 22 23 Contents Introduc
6. ION Make sure that the battery lead does not come into contact with any part of the battery ortruck ATTENTION S assurer que le plomb de la batterie ne rentre pasen contact avec un composant quelconque de la battere ou du camion Note For dual lead batteries make sure the Hall Effect goes around the positive cable that is used for BOTH charging AND discharging 1 DOUGLAS Datalrac 7 L For the split core unit it isnot necessary to remove the battery SB or SBX connector Simply open the HE unit and snap it shut around the positive battery lead so that the anowson the HE unit point towards the positive battery post Note For dual lead batteries make sure the Hall Effect goes around the positive cable that is used for BOTH charging AND discharging Once the Hall Effect device hasbeen secured around the positive battery cable lay the Data Trac unit on top of the battery in a location where it will not interfere with the normal operation of the truck or battery Connect Power To attach the power leads to battery terminals first drill a pilot hole on the positive and negative battery terminals with a 1 8 drill bit Be careful to only dnill into the lead a little at a time and then remove the excess matenal from the bit Place the red wire ring terminal over pre dniled hole on the positive terminal and secure by screwing in 6 self fapping screw use 1 4 socket or nut driver Repeat this procedure forthe nega
7. base test db1 mom Batteries 0 Chargers 0 Records 0 Once the unit has been configured the get current values function can be used to make sure that the unit isreading voltage current and temperature If the Data Trac unit is being deployed in a new location you may also want to clear the event data on the unit DataTrac can store 4087 charge discharge events so it is generally not necessary to clear events Salve Power lanweper St orl er dat 1 Discover Toggle Adi Device Options Merge to Database LD Cancel Comms a E Database teat dbl mpm Batteries 0 Chargers 0 Records 0 Database test dbl mom Gateries 0 Chargers 0 Records 0 10 2 ER RE EE TENE NN EE If the Data Trac unit is being deployed in a new location you may also want to clear the event data on the unit DataTrac can store 4087 charge discharge events so it is generally not necessary to clear events ubie Power anager St artes telit our LI Battery Module Trandier Screen T Database teat dbl mem Batteries Chargers 0 Records 0 Database test dbl mpm Gateries Chargers 0 Records Note The intemal temperature sensor of the Data Trac unit will usually read a few degrees higher than the ambient temperature because of a Slight nse in temperature from components inside the unit case Note Generally it isa good idea to clear events
8. e of producing a spark or short circ uiting the battery or other elec tric al part and causing an explosion Tum off all the electncal 0205 on the vehicle and set the brake before installing or removing the Data Trac unit CONSERVER CES INSTRUC TIONS Ce manuel comporte des consignes importantes de s cunite et d utilisation A Ce symbole de danger indique que le personnel doit suivre les proc dures de s curit de fa on pr venir une d t roration de l quipement un dommage corporel ou la mort ATENTON L installation de 2 doit tre effectu e uniquement par du personnel qualifie ATTENTION Travailler proximit de batteries plomb acide est dangereux e 010061165 peuvent g n rer des gaz explosifs durant leur fonctionnement normal Pourcette raison iles de la plus grande importance de lire ces instructions et de les suivre la lettre e _ Porter deslunettes de protection et une combinaison de protection viter de se toucherles yeux pendant le travail proximit de la batterie e 6 6 de la batterie entre en contact avec la peau ou les v tements laver imm diatement avec du savon et de l eau Si l acide entre dans ceil incer imm diatement abondamment l eau froide en la laissant couler pendant un minimum de 10 minutes et consulter imm diatement un m decin e S assurerque l espace de travail est ventil e Ne JAMAIS fumer ou allumer d
9. e portability and with a solid core transducer which is designed to be installed permanently on a single battery for long term energy metering applications Data Trac hasan intemal sensor which it uses to monitor temperature If can also be configured with an external thermistor which can be inserted between two battery cells for more precise temperature measurements It can optionally be configured to monitor battery electrolyte level and to dnve a 24 solid state relay Data Trac can have one ortwo seral ports One serial port is used for host communication and is typically configured with a Bluetooth radio for wireless communications but can also be configured as an RS232 port for communicating with a truck based host computer The other seral port may be used in some applic ations to communicate with the charger via an isolated RS232 serial port It continuously monitors the state of the battery after being configured and started by the user Data is retained in onboard flash memory and events are recorded detailing the operating condition of the battery At all timesthe battery Is considered to be in one of three states Charging Discharging Idle When Data Trac determines that the state of the battery has changed an event record isgenerated and stored that recordsthe cumulative data ofthe state that hasjus ended and a new summary recording the data ofthe new state is started In addition key high and low values measured dur
10. ing the operating state are recorded with this event record Bluetooth isa registered trademark of Bluetooth SIG Inc Re IT pe ta pe orage HILL OR OC ITR Co a I LP SPST Data Available For Analysis e Start Time and Date Total Time and Total Ampere hours for each charge profile state Charge Discharge or Idle e Battery Temperature voltage and electrolyte sensor level for units with this option installed at beginning and end of each charge profile state e Summanes for total plug ins average charge duration average AHRS retumed calculated daily and averaged over entire measurement period e Battery or Truck Identification Serial Model Number can be configured on the Datatrac for easy report identification DataTrac data is divided into three types Configuration Data contains the data necessary to manage the operation of Datatrac including battery and truck serial numbers battery configuration and put in service date Event Data isa record of the operation of the battery to which Data Trac is attached Events are recorded foreach operating state of the battery charge discharge and idle Event data isused to compile an accurate record of battery use Summary Data contains aggregate usage data which is compiled by software
11. ll of the battery Insert the level sensor into the cell Connect the blue retum wire to the negative post of battery cell which is immediately adjacent to and 2V lessthan the cell with the sensor Note Pay careful attention to the onentation of the cellswhen connecting the EL sensor wires The voltage acrossthe two wires must not exceed 4V 16 17 1 1 CE is Secure all wires from the Data Trac using Velcro 0 66 0165 ties ensuring no loose orslack wires are left hanging Tuck Installation for Trac king Throughput Measurements in Battery Change Out Operations 1 Gather Tools DataTrac unit 2 6 self fapping screws with ring terminals 4 and 8 cable ties 1 4 socket and ratchet or nut driver small Phillips screwdriver electncal tape Position the Data Trac on the lift tuck in a location where it will not be damaged norcreate interference during normal operation and battery change out Attach the Hall Effect transducer Forthe solid core unit remove the SB connectorthat goesto the battery and slide the positive cable through the Hall Effect unit so that the arowson the HE unit point towards the positive battery post For the split core unit clamp the Hall effect sensor around the positive cable of the truck You will feel a click as the two halves of the Hall Effect sensor snap together Attach the Data Trac power leadsto a terminal block where the battery leads are
12. nk rapidly asthe Data Trac unit powers up After a delay of several seconds you will see the green light of the unit begin to blink indicating that it iscollecting data and ready to communicate with a host PC Note Only the green LED should be blinking on the Data Trac unit If the Data Trac unit is configured with an Electrolyte level sensor and the sensor is either not installed ordetectsa low Electrolyte level the red LED will blink steadily Any other blink pattems are indicative of an enor If the unit displays any of the following LED pattems please call customer service e Red and green LED flashing simulfaneously Real time clock error Battery may need to be replaced e Red and green LED flashing alternating Unit has not been calibrated or has lost calibration e Red LED flashing 3 short bursts followed by long burst hardware error ARTE TS TENE E AEE ER FTE PN PT EH APT IE 2 Data Trac Follow the instructions in the Douglas Data Manager Users Manual for Creating an Douglas Data Manager database and Configuring the DatatTrac unit i x tune a i olive Power Hanoger Starter Edition a Battery Module Transfer Screen js SOE i Discover Toggle AddDevice Options Marge ta Database Cancel Comms Danse test dh nem Bateries O Chargers O Records O_ Data
13. orts 1 2 19 ecu tee ee ee eae En ae pee ee Le meng gE ee een pee Pee ee 23 EEA itl TE EE RTE Accessones 21 Battery Temperature 5 C Communications between PC and Data 0 Communications Interface 9 D Data Available for Analysis 5 Data Collection 6 Data Storage Amount and Time 6 Electrolyte Level Sensor 16 Electrolyte Sensor 16 Extemal Relay Connection 21 F Featuresand Capabilities 4 Ha 6 ct Sensor 12 18 Initializing DataTrac 10 Installation of Data Trac 12 M Douglas Data 3 5 Nominal Battery Voltage 6 O Operating Temperature 5 Operating Voltage 5 one 11 o rE a i RL A eT TT ON TT 0 Power Consumption 5 Power Leads 14 R Reading Data Trac Battery Data 22 Real Time Clock 9 Removing the DataTrac Unit 19 RS232 Host Communication Cable 21 S Safety Precautions 7 Setup and Initialization 9 Software Toolsfor DataTrac 5 Specifications 6 T Thermistor 15 Tracking Single Battery Usage Data 4 Tracking Throughput Measurements in Battery Change Out Operations 4 V Voltage Measurement 6
14. terminated For front panel truck ha mess installation make sure that if there is a truck kill switch that the Data Trac is insta led between the kill switch and battery otherwise if the kill switch is hit the Data Trac will record that a battery change out occured Secure all wires from the Data Trac using Velcro or cablesties ensuring no loose or sla ck wires are left hanging 4 QT HET TE A 19 Removing the DataTrac Unit for All Installations To move the Data Trac unit to a different truck or battery follow the reverse of the Instructions for installation To remove a solid core Hall Effect sensor remove the SB SBX or Euro connector and slide the HE unit off the end of the cable CAUTION Make sure that the battery lead does not come into contact with any part of the battery k ATTENTION S assurer que le plomb de la batterie ne rentre pasen contact avec un composant quelconque de la battene ou du camion 1 For the split core Hall Effect unit insert a flat blade screwdriver into the pry point at the side of the unit where the two halves snap together 20 TN 2 Keeping the blade of the screwdriver against the pry point raise the sc to unlock the two halves of the Hall effect unit SP eT LEE PR A
15. tincelle ou de flamme proximit de la battene e Etre extr mement prudent pour ne pas laisser tomber un outil en m tal sur la batterie Ceci pourait produire une tincelle ou un court circuit au niveau de la batterie ou d un autre composant lectrique et provoquer une explosion e Eteindre toutes les charges lectriques sur le v hicule et serer le frein main avant d installer ou de retirer l unit Data Trac ae AT TE EE PT n aE DEH Section 4 Setup and Initialization Configuring a PC to Communicate with the DataTrac To communicate with the Data Trac from a PC the PC must have a Bluetooth radio installed supplied with the Douglas Data Manager product and be running the Douglas Data Manager software Referto the Douglas Data Manager Users Manual for installing the software and the Bluetooth radio Testing Communications with the DataTrac To venfy that PC can communicate with DataTrac pnorto installing the Data Trac ona truck or battery 1 Gather Tools Data Trac unit DC power supply with output of at least 12 volts and no more than 100 volts such as bench power supply or 12V DC transformer PC with Douglas Data Managersftware and Bluetooth radio 2 Attach the red wire power lead of the Data Trac unit to the positive connection of the DC power supply and the black wire power lead to the negative connection Apply powerto the DC supply 3 The red and green LEDs will bli
16. tion Section 1 Features and Capabilities Data Available for Analysis Data Trac Software Tools Section 2 Specifications Safety Precautions Setup 20 Section 3 Section 4 Configuring a PC 10 Communicate with the DataTrac Testing Communications with the Data Trac Initializing the Data Trac DataTrac Installation Section 5 For Battery Installation to Track Single Battery Usage Data Truck Installation for Tracking Throughput Measurements in Battery Change Out Operations Removing the DataTrac Unit for All Installations Optional Accessones Reading DataTrac Battery Data Section 6 Section 7 Index id sor Pee al Rte E ot ey 0 E eee PER EP Re eI RT ET LEP EN Section 1 Introduction Connect the Data Trac and enhance your ability to manage battery usage maintenance and overall life Start tracking daily usage charge retum temperature water level and equalization events With the Data Trac you ll collect data needed to Confirm operator compliance charging and equalizing Identify battery maintenance needs Easily optimize fleet size and truck operation Features and Capabilities Data Trac isan intelligent battery data collection device for use with industna battery applications It contains instrumentation to continuously measure temperature Current and voltage Data Trac is availa ble with a split core current transducer forapplications which requir
17. tive terminal 3 4 SAR Sia eR ae ee bette sie me RE cee le TES rie fl i AD EC AR TEE ER EE TEE PD PUR AO RE PO TT CAUTION A 1 Amp 250V inline fuse must be added atthe termination point of the Data Trac positive power connection so that in the event that the Data Trac powerlead isdamagegd it doesnot create a possible current path ATTENTION Un fusible en s rie de 250 V 1 A doit tre ajout au point de termina ison de la connexion lectrique positive de l Data Trac afin qu un passage de courant ne soit pas cr dansle casou le c ble d alimentation est endommag 5 For units configured with external thermistor only To install the thermistor locate a position nearthe middle of the battery between four cells This location should not have a metal plate running between the cells Use the Phillips 0 make a small passage forthe battery thermistor Holding the battery thermistor at the top slide it down and into the passage made by the screwdnver 15 ts Te ee ae ee Le E 2 PP RTC QUE TE E TRE Le EE gE aiee 6 For units configured with electrolyte level sensor only To install the electrolyte level sensor dnill a Winch diameter hole in the top of the cell to be monitored This must not be the first lowest voltage ce
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