Smart.IC2 V3 Installation and Use Manual
Contents
1. Fax 39 059 785 737 www alfaprogetti com 10 Programming Once installed Smart ON needs to get some information to work correctly For this purpose it is necessary to connect it to a PC equipped with the SmartViewII program for Windows This can be done through an infrared port 10 1 Making it ready Connect the infrared adapter to the PC AP160 adapter to a RS232 port or API60UIR adapter to an USB port Trigger the SmartViewII program Insert the Password for level 2 Press the Connect pushbutton 10 2 Setting of date time Select the Programming TAB Press the Set clock push button Select the Monitor TAB and check data in the box showing date and time 10 3 Programming of operating parameters The operating parameters allow Smart ON to collect data correctly during the normal operation Therefore they have to be compiled very carefully For more details please see the user manual of the SmartViewII program 4 OnLine SmartIC I1 3 a 5 xl Monitor Info Old Data OLD Data Info Diagram Daily Programming Associations Averages Statistics Communications Nominal Parameters Other Parameters Battery Voltage 240 Volts n External Temp Sensor Present C Yes No Battery Ah poo 2 Ah r Diagram Sampling Time 6 mim Battery charger current oo 4 Electrolyte Sensor fof vj Hall Sensor Curren2. During the discharge stage the Discharged Capacity is counted In addition two situations which may arise in case of excessive discharge are highlighted the Underdischarge Time which indicates the time when the voltage is below the Underdischarge Voltage configured see 10 3 Programming of operating parameters and the Discharged Capacity Under AhBS indicates the capacity used below the threshold of 100 AhBS of the nominal battery capacity During the discharge stage the Self discharged Capacity and the Recovered Capacity are also counted Within the charging stage there is a First Stage the charge before reaching the configured Voltage Threshold 2nd Stage the Second Stage the charge following the attainment of the Voltage Threshold 2nd Stage and the Capacity in Overcharging corresponding to any charge in excess over the hypothetical attainment of 109 of the nominal capacity Only in the case of controlled Chargers SmartEnergy is the Equalization count displayed For a detailed list of the information provided by SmartViewII Info TAB and OLD Data Info TAB see the relevant manual loxi Monitor Info Old Data OLD Data Info Diagram Daily Programming Associations Averages Statistics Communications SN B090C005583 Rated Voltage V 24 Cycle Number cus BIANCHI SPA Rated Capacity Ah 580 RET ROSSI SRL Charge Controlled By SmartlC No USE MARIO BAT BA
3. 39 059 785 737 www alfaprogetti com 1 Description and operation 1 1 Features smart IC2 V3 is a device designed for the monitoring and control of lead batteries Its main features are e Measurement of the instantaneous battery data including voltage current available Ah and temperature An indication of the amount of Ah available 1s provided by LEDs on the panel 1 4 LED Signals e Built in RTC Real Time Clock to build a log of the data collected with date and time e Storage of historical data The past activity of the battery can be accessed on a PC using the SmartViewll software application or through WEB The data collected can be viewed grouped by working cycle or by day For each working cycle the data 1s presented both in figures and graphics e Data download to a PC Through an IR connection all data can be sent to the SmartViewII PC program e Statistical analysis SmartViewII has numerous functions able to provide statistics to check the correct use of the battery and the charge reporting any anomaly e Management of the Smart Energy family battery chargers controlled charging system which reduces the costs of charging e Remote monitoring via the internet SmartService is a software application which collects data from Smart IC2 devices processes it and sends an email report regarding the entire set of devices The communication between the Smart IC2 units and SmartService occurs through GPRS technology e Possibility to us
4. FOR USA TYPE BATTERY CONNECTOR 1 P882B CABLE CLAMP FOR INSTALLATION OUTSIDE THE CONNECTOR 1I pM S2GPRS SMARTIC II WITH GPRS MEN AP882GPRS ELECTRONIC CARD FOR SMART IC WITH GPRS BERN ANT882 GPRS ANTENNA P882 PLASTICS CASE OF SMART IC II SMART IC CLAMP WITHOUT CONNECTOR FOR SMART CB P882C25 SMART IC ADAPTER FOR 25MM CABLE SMART IC ADAPTER FOR 70MM CABLE P882bEU SMART IC BRACKET ADAPTER FOR USA TYPE BATTERY CONNECTOR P882B CABLE CLAMP FOR INSTALLATION OUTSIDE THE CONNECTOR miD DODimi 5 m 14 Specifications Some useful technical information is reported below STORABLE DATA 400 Storable graph data 12 000 samples equal to 50 days with sampling every 6 minutes Storable daily data The unit stores the work data of the previous 30 days FIELD OF OPERATION Cut off switch T200 batteries from 100 to 340Ah Cut off switch T400 batteries from 350Ah to 740Ah Cut off switch T800 batteries from 750 to 1500Ah ELECTRICAL PHYSICAL SPECIFICATIONS S2 lt 1 5W S2GPRS lt 2W Fuse on the power input PHYSICAL SPECIFICATIONS Size external dimensions 100mm x 60mm x 142mm Overall antenna connector min 350g Degree of protection IP 42 smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 34 of 34
5. LEDs are lit 1n the Battery mimic panel indicating that the battery 1s fully charged It is recommended that the alignment procedure be run with the battery not fully charged IMPORTANT Normally the alignment is very easy to execute It is enough to recharge the battery with a conventional battery charger Nonetheless it 1s not always possible to recharge a battery in the aforementioned conditions This may be due to various reasons including The battery 1s already charged and the battery charger performs a charge that 1s too short The battery voltage does not reach the Voltage Threshold 2nd Stage configured this happens for instance for gel battery chargers The battery charger has a particular kind of charging curve In these cases it 1s possible to change the Voltage Threshold 2nd Stage and or 2nd Stage Charging Time parameters by reducing their values to facilitate the achievement of the alignment However it is good practice not to deviate much from the default values to avoid providing the smart IC2 V3 unit incorrect information about the real state of the battery NOTE As long as the Smart IC2 V3 is misaligned The red low battery LED flashes on the Mimic panel unless the battery charge was forced using the procedure described in 1 8 With SmartView Inthe Monitor TAB the battery charge status is replaced by the message Ah Alignment not performed Inthe OLD Data info TAB the graphic representation of
6. The programming of the associations can also be executed in advance in the workshop if all parameters are known NOTE To configure an S2 GPRS device it 1s possible to execute all the operations above through WEB after enabling the GPRS connection via SmartService In this case instead of an IR adapter and the SmartView software program the user needs a PC with internet access The S2 GPRS device must have a SIM card installed and the GPRS connection parameters already set smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 31 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com 11 Alignment To make Smart IC2 V3 fully operational and therefore collect and subsequently supply all the data it must acquire the real state of the battery This 1s called ALIGNMENT and must be performed only once after connecting the device to the battery During normal operation the Smart IC2 V3 device stays aligned by measuring and counting the inbound and outbound charge of the battery The alignment procedure involves the execution of a traditional full charge that 1s The battery voltage reaches the value indicated in the configured Voltage Threshold 2nd Stage parameter default 2 4V el The charge continues after reaching this voltage for a period not shorter than that established with the configured 2nd Stage Charging Time parameter default 2 hours After the alignment procedure all
7. default 1 Ah method Charging mode selection capacity Yes or time No default YES Smart CB monitoring Battery charger selection SmartCB SmartEnergy Opportunity charging Selection of scheduled counting of working cycles opportunity charging mode default No Self Alignment Ah Access button to set the Self alignment parameters Recharging Incr 96 Percentage of energy dissipated during charging stage default 7 Voltage Threshold 2nd Stage Gas production voltage threshold Determines the transition from the first to the second charging stage and related counts default 2 40 V el timed recharges and in the alignment cycle default 2 00 hours If the voltage has not reached the Voltage Threshold 2nd Stage within this time period an alarm is generated default 10 00 hours Safety timer 2nd Stage If the capacity has not reached the nominal value within this time period starting from the achievement of the Voltage Threshold 2nd Stage an alarm is generated default 6 00 hours enabled only available when SmartCB is selected smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 29 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com The Self alignment function automatically corrects the indication representing the charge available in the battery Ah The configurable parameters indicate the threshold beyond which the correction is performed the
8. maximum possible alignment and the number of samples on which the Self Alignment is based The Self Alignment is allowed only if the alignment has already been done see SErrore L origine riferimento non stata trovata Default parameters Alignment Threshold Max Alignment Num of Samples aa Self Alignment Programming Alignment Thresh ig Ah Nom Max Alignment 0 Ah Nom Num of Samples le Jf OK X Cancel Press the button Send data to SmartIC for the changes to take effect for greater security check the operation by pressing the button Read data from SmartIC and verify that the parameters read are those entered NOTE The work parameters can also be set in advance before installing the device on the battery NOTE To configure an S2 GPRS device it is possible to execute all the operations above through WEB after enabling the GPRS connection via SmartService In this case instead of an IR adapter and the SmartView software program the user needs a PC with internet access The S2 GPRS device must have a SIM card installed and the GPRS connection parameters Web section of the Programming TAB already set smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 30 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com 10 4 Programming of associations Associations are memory parameters which working cycles and diagrams coll
9. the cycle is replaced by the message Ah Alignment not performed Elsewhere no battery charge reference values are displayed Even when Smart IC2 V3 is not aligned all parameters measured during the cycle voltages currents temperatures date and time and the graphs are logged NOTE The alignment procedure must be repeated each time the Smart IC2 V3 is disconnected from the power supply smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 32 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com 12 TA1 Codes for fastening components screws and accessories PHOTO RE COMPONN SIZE Vi jPBAF 29x65countersunk IU de P882EU P882C25 P882C70 P882EU m Pesu 0O Rm 00 wm P883U160 P883U320 smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 33 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com 13 TV2 KIT components materials lists Unit Coe BDescipion Qty S2 2 swncn OoOO O AP882 ELECTRONIC CARD FOR SMARTICH gt PR PLASTICS CASEOFSMARTICH O To P882CU SMARTIC CLAMP WITHOUT CONNECTOR FOR SMARTCB P882C25 SMARTIC ADAPTER FOR 25MM CABLE P882C70 SMARTIC ADAPTER FOR 70MM CABLE P8S82EU SMARTIC BRACKET ADAPTER
10. 1 Allen wrench 3 mm 4 A Locate the battery side and the connector side Connector Rm N of the Smart IC2 module side s Pass the positive pole cable red wire inside the hole of the Smart IC2 S2 or S2GPRS Module Note If the cable is so small as not to allow the punches to pierce the insulating sheath use the supports B provided and position them in the special location as shown in the sequence A Smart IC2 S2 or S2GPRS Module B Thickness P882C smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 14 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com A Smart IC2 S2 or S2GPRS Module B USA type connector 160A or 320A C Clamp cover P882B Connect the battery connector B by fastening the and wires to the PINs Fasten the adapter block D code P882EU to the USA type connector with the 4 screws E and washers D Adapter code P882EU E 4 screws 3 5x16 code V4 4 washers 4x12 code R2 smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 15 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com Fasten the adapter block D code P882EU to the SMART IC2 with the 4 screws F and washers F 4 screws 3 5x13 code V3 4 washers 4x9 code R1 Fasten the clamp G with the Allen screws H supplied 4x20mm code V10 G Clamp code P882A H Allen scre
11. ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com PROGETTI Smart IC2 V3 Installation and Use Manual Dae Notes Official Documentation o S qs o S o S a a Rs Page 1 of 34 smartIC2 V3 Installation and Use Manual V1 41 GB doc ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com INDEX I D sctipHon dd Opera O arnesses cod eset uet taque oa ned T ERU s Socal aed uut ree Reden ripd ed 3 Isl Pea DHT S obostesecobtodaiberttiot bet i eo tuc Mon Sure EE e d se nian UD anne mE co Mcd ttu RIDE gout tat Ord 3 EZAN OU CCN need miei Mn Ea erecta Saas eae ae 4 I5 ATOLDHALIOS das tercer or iot hss wo det ist aac ele nai te oi v fout bh aan Iss tu te Pa eb tds qur real detti ew octane iei 5 IP NB DUDEN Tui m RT 5 1 5 Estimation ot Ihe Tecldt Pes doo Ec oa ud pt morbis cu hada d pt me Rao dcc uh US 7 LG Opportunity lar 918 asninn se ee e iet rn ma pd tas deeem ms tes esM E nq Mens 7 I BOCK TODOS a aoc unde n o ba de tise seeidata assed optet eb diem 7 1 5 USE OP THO OD ULLON eiri aee E AE TEE EE ETE A TE E EEEE 8 2 Irisertinp replactie the SIM Card uie eine tin eee NOR bi abb AN 9 3 Mounting the Smart IC2 V3 on the battery side of the DINxxx type connector 11 4 Mounting on battery side of connector USA type ssssssssseeeeesessseeeeeeeeeeeeeennn nennen nennen 14 5 Mounting outsid
12. TOOOO1 FLT FLOOD Discharge Data rCharge data Discharge Start 03 04 10 04 05 43 Start Of Charging 03 04 10 04 27 40 Discharge Time 0 00 hh mm Stages Time Ist 0 00 2nd 0 00 hh mm Underdischarge Time 0 00 hh mm Total Charging Time 0 00 hhimm Pause Time in Discharge 0 21 hh mm Pause Time in Charging 0 00 hh mm Number of Discharges 1 l Number of Recharges 0 Capacity at Cycle Start 550 Ah 948 Capacity at the Start of Charging 550 Ah 948 Discharged Capacity 0 Ah 0 0 Reinstated Capacity 1st Stage 0 00 9 Capacity Discharged Under AhBS 0 Ah 0 0 Reinstated Capacity 2nd Stage OR oop Self discharged Capacity 0 Ah 0 0 x Total Reinstated Capacity 0 h 00 79 Recovered Capacity 0 Ah 0 0 75 Recharge Increase 00 gt Capacity at Discharge End 550 Ah 948 Total Input Capacity OMM 0 0 C9 Equalization 0 00 hhmm 0 An 0 0 4 Capacity in Overcharging 0 Ah 00 9 Extra Data Overcharging Time 0 00 hh mm z Capacity at End of Cycle 550 Ah 948 Minimum Voltage 0 00 Volt 0 00 V ce Maximum Voltage 0 00 Volts 0 00 Vice Maximum Current oo A 0 0 79 Maximum Current 00 A 00 Current at the End of Charging 00 AW 00 C9 SmarliC Maxim
13. ard is accessible tee Unlock the slot for the SIM by sliding it S ELA up and open it Insert the SIM card Close the slot and lock it by sliding it down Replace the electronic board in the container connect the flat cable to the current sensor card Close the back cover and tighten the 6 screws previously removed code V1 smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 10 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com 3 Mounting the Smart IC2 V3 on the battery side of the DINxxx type connector WARNING The DEVICE AND THE BATTERY CABLES SHOULD NOT BE CONNECTED TO THE POWER SOURCE during the following activities Required materials No 1 Phillips screwdriver type PHI No 1 Allen wrench 3mm No 1 Allen wrench 5mm Locate the battery side and the connector side Connector of the Smart IC2 module side Pass the positive pole cable red wire inside the hole of the Smart IC2 S2 or S2GPRS Module Note If the cable is so small as not to allow the punches to pierce the insulating sheath use the supports B provided and position them in the special location as shown in the sequence A Smart IC2 S2 or SZGPRS Module B Thickness P882C smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 11 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com Press the clamp u
14. ately sized cable gland is already installed on the back cover smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 26 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com 9 1 Communication with SmartKey and SmartEnergy Communication with the SmartKey display and the SmartEnergy family battery chargers occurs by means of the RS485 serial port The connection is made by means of a two wire cable One end of the cable is connected to the smart IC2 V3 the other to the battery connector s auxiliary contacts The connection with Smart IC2 V3 1s shown below For the connection to the external devices end refer to the relative manuals making sure that on both ends the couplings are between corresponding signal pairs RS485 A with RS485_ A RSA85 B with RS485_ B Remove the lid remove the electronic board from its plastic casing until the terminal is accessible The wiring connections to the terminal must be made according to the following diagram see screen printed numbers next to the terminals SmartKey SmartEnergy Connections Pole6 brown wire RS485 A blue white wire RS485 B Colors refer to SmartKey SmartEnergy provided by Alfa Progetti Replace the lid and tighten it with the screws Tighten the cable gland smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 27 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726
15. e threshold electrolyte level low Probe wired to terminals 8 signal and 10 common Presence of water Select whether the probe generates a signal if the electrolyte level is above the ISO2 threshold electrolyte level OK Probe wired to terminals 9 signal and 10 common No water ISO2 Select whether the probe generates a signal if the electrolyte level is below the threshold electrolyte level low Probe wired to terminals 9 signal and 10 common smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 23 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com 8 Antenna installation Required materials Wrench no 8 Cable bands Identify the connection for the corrugated conduit on the back of the Smart IC2 plug On the side of the Smart IC2 screw the antenna cable on the connector Tighten the connector slightly with a no 8 wrench Insert the corrugated conduit into the connection A GPRS antenna cable side of smart IC2 B GPRS antenna C Connector for corrugated conduit D Corrugated conduit smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 24 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com Place the antenna on top of a ferrous part of the forklift preferably in an area not shielded by other metal parts The antenna base is composed of a magnet thereby favouring i
16. e the SmartService functions which like the SmartViewII program provide statistical data and report anomalies also enabling the visualisation of the list of anomalies and data grouped by cycle e Analysis of battery efficiency thanks to the SmartService monitoring e Ability to interface with SmartKey devices system that controls access to the forklifts and stores events and collisions and send data to SmartService via GPRS NOTE WEB SmartService services are available only for the GPRS version Optional accessories e External temperature immersion sensor e Electrolyte level sensor SmartIC2 V3 Installation and Use Manual V1 41 GB doc Page 3 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com 1 2 Working Cycle A working cycle is intended as a sequence comprising a discharge stage followed by charging stage Given that a change of cycle is forced in the case of a new association power failure or long period of inactivity after a charge this definition should be understood as a guideline Another exception of the definition occurs when the option Opportunity Charging is set see 1 6 Opportunity Charging The transition from discharge to charge occurs after 2 minutes of charging to avoid misinterpretations due to the presence of a charge recovery device during braking in this case it is intended as energy recovery and the input charge will be added to the Recovered Capacity
17. e the connector battery side sss 17 O EOFrKHE Control MOS densin a A E O TE 19 FORME CH ONCOL ACCESS OTIES Shensi oaea n a e a E 21 TAI External temperatule proDQu ep ee hd E Rp CIPRIANI UN 21 T2 plectrolyte Eversons neie adeb uds adu bU da UAE Ua esee 27 SANDA ATS CAA OM a see iret e e O A ia nescientes 24 9Comimumcadon witrotherdeVT6e Susselsesbidenticomb E bates palo o deudor doti uoo etam eee 26 9 1 Communication with SmartKey and SmartEnergy eessseeeeeeeseseseeeeeeeeeeeeennnnnn nnns 2 LO PEOSEITHITIIDE T eee ane eee eee nee rete een A EE AAA ed i ei E Dele ear treme o sete oe 28 o NIAKIN OE TCAOY TR D ca hea inasii echt hs nae Gere ieecet hate 28 10 2 Setung or Cale d MNS ssena tento TIR fufca ar on me td tafucn reme far antral 28 10 3 Programming of operating parameters do mede o aed etn er vtt reete o tb det om edv tus 28 10 4 Programming OF associations s cogere a RODEO eel tme testa ules teda a d E 3l Pik ATG RET m 32 12 TAI Codes for fastening components screws and accessories seen 33 19 TV2 KIT components materials TISIS seeds coit heb us EP dete Eo HORE Ie opa e routes Pres toa reta teet ies 34 I4 Pe CTC AU OLN eoe tert ted alba iati niat seuss toute bios tu CEOMis et ten iten t Fa te t u tne UM ac Lac atomes 34 smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 2 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax
18. ected by Smart ON during normal operation refer to Every time cycles and diagrams will be downloaded onto a PC they will be identifiable and selectable thanks to the above mentioned parameters Therefore these parameters too need to be compiled very carefully NOTE filling in the association parameters is not binding If you do it choose carefully names and codes avoiding to fill in the same parameters for different Smart ON s For more details refer to the user manual of the SmartViewII program iBixi Monitor Info Old Data OLD Data Info Diagram Daily Programming Associations Averages Statistics Communications Association Data Customer BIANCHI SPA SmartlC Serial Num Retailer ROSSISRE B09OCO005583 User MARIO e Send Data e Reread Data Battery ID BATOO001 Forklift Truck ID FLOO001 Clear Table PREVIOUS USES OF SMARTIC ID ustomr Retailer fuser Battery ID Forklift TruckID pntOld BIANCHI SPA 0 0 0 0 0 5 0 0 0 0 0 0 SmartViewII programming of the associations Select the Associations TAB Fill in the following fields Text identifying customer Text identifying dealer Text identifying user Battery ID Text identifying battery serial number Forklift Truck ID Text identifying forklift truck serial number Press the Send data pushbutton and check if a string with the parameters put in appears in the table underneath NOTE
19. f providing the power supply repeatedly pressing the button forces the amount of Ah present in the battery with an increase of 20 of the nominal capacity each time note it does not perform the alignment This feature is useful if the Forks Lock function is selected to allow normal use of the fork lift after the installation of Smart IC2 V3 before the alignment charge is executed e While charging with charger controlled by Smart IC2 V3 SmartEnergy the button performs the ON and OFF functions of the charge smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 8 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com 2 Inserting replacing the SIM card The following is a description of the operations to insert remove or replace the SIM card in the GPRS module of the device only for GPRS versions WARNING The DEVICE SHOULD NOT BE CONNECTED TO THE POWER SOURCE during the following activities Required Supplies No 1 Phillips screwdriver type PHI Remove the back cover by unscrewing the 6 screws code V1 Locate the connector with a flat cable smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 9 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com Disconnect the flat cable connector from the current sensor card Remove the electronic board from the container until the slot for the SIM c
20. he capacity drops below this threshold normal use is prevented the NO contact is left open NOTE To avoid disrupting manoeuvres during a period of intensive use the lock 1s executed 30 seconds after the last manoeuvre The default value of the programmable parameter Forks Lock 1s 80 SmartIC2 V3 Installation and Use Manual V1 41 GB doc Page 7 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com The device also foresees the following lock function to prevent the use of the forklift outside working hours Forklift Lock For each day of the week it 1s possible to set the time start and end with which to impose a lock on the forklift If the two times coincide the lock does not occur The Lock Timeout parameter indicates the forklift downtime that must elapse before the lock 1s operational o x Scheduler Lock Timeout 255 min Forks lock hours Monday ron Tuesday 0 00 Wednesday 0 00 Thursday 0 00 Friday 0 00 Saturday 0 00 Sunday 0 00 Jf OK 1 8 Use of the button e If during discharge the Forks Lock situation 1s reached the pressure on the button ensures an additional bonus of usable capacity equal to 4 of the nominal capacity e If during a working cycle the different power points are blocked for Anti opportunity Charging pressing the button disables the lock for that cycle e Within 6 minutes o
21. hrough the clamp collar G using screws H and fastening nuts I Wiring complete and connector ready for use A DINxxx type connector C Smart IC2 S2 or S2GPRS Module Wiring complete and connector ready for use B USA type Connector C Smart IC2 S2 or S2GPRS Module smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 18 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com 6 Forklift Control Mode Locking or limiting the activities of all powered devices requires wiring the contact of the relay on the device The operations are indicated below WARNING The DEVICE SHOULD NOT BE CONNECTED TO THE POWER SOURCE during the following activities NOTE It is assumed that an appropriately sized cable gland 1s already installed on the back cover Required materials No 1 Phillips screwdriver type PH1 No 1 flat screwdriver type SL2 5 Remove SA ae ae back cover by unscrewing the 6 screws code V1 Locate the connector with flat cable Disconnect the flat cable connector from the current sensor card smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 19 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com Remove the electronic board from the container until the green terminals next to the Hall sensor are accessible Connect the wires to the terminal in poles 1 and 3 see screen
22. il the terminal 1s accessible Insert the wires B through the cable gland C and connect the wires to the terminal D The wiring connections to the terminal must be made according to the following diagram see screen printed numbers next to the terminals Connections Pole 11 Pole 12 gray white wire Cover code P882CU Wires for temperature sensor PT1000 A B C Cable gland D Connection terminal for external temperature probe J3 Replace the cover and tighten it with the screws Tighten the cable gland SmartIC2 V3 Installation and Use Manual V1 41 GB doc Page 21 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com 7 2 Electrolyte level sensor smart IC2 V3 supports the electrolyte level sensors that provide a LED indication of the status Level OK or Low Level via remote cable To be used with Smart IC2 V3 the sensor must be adapted contact the SmartIC vendor IMPORTANT This SmartIC2 V3 device unlike the prior model has a galvanically isolated input for the electrolyte level sensor The following instructions apply only to the V3 series For the prior series refer to the relevant Installation Manual Remove the cover remove the electronic board from the container until the terminal is accessible Connect the level sensor SL to terminals 8 and 10 input ISOI or 9 and 10 ISO2 input The wiring connections to the terminal must be
23. ing cycles that would lead to a rapid depletion of memory and substantially illegible data In these cases by setting the item Opportunity Charging in the programming 810 3 Programming of operating parameters it is possible to reduce the daily number of cycles in fact in this mode a new cycle is generated only if there 1s a discharge after the sum of cycle charge times has already exceeded the time 1 7 Lock functions The Smart IC2 V3 device foresees two functions based on measurement of the battery capacity level to inhibit the operation of the forklift and or lock the forks through the NO contact Normally Open of a relay These functions require that the relay contact 1s wired to a circuit of the forklift which can limit the functionalities for example the circuit that stops operation when the operator is not seated Anti opportunity Charging After being charged if the percentage of Ah in the battery is higher than that which is programmed in Anti Opportunity Charging see 10 3 Programming of operating parameters the forklift 1s enabled for normal use the NO contact 1s closed Conversely if the battery capacity drops below the programmed percentage use is prevented the NO contact remains open Setting the parameter to 0 as a default the function 1s disabled Forks Lock When discharging until the battery level drops below the 100 Forks Lock normal operation is permitted the NO contact is closed In contrast when t
24. iven that some sensors provide a delayed signal the actual timing of activation and deactivation of the anomaly depends on the sensor used 1 4 LED Signals The LEDs on the unit provide useful information including an indication of the battery charge and possibly some anomalies LEDs can signal the following situations LED 1 flashing Battery charge not exceeding 100 AhBS of the nominal battery capacity smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 5 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com down sequence from LED 5 to LED 1 bottom up sequence from LED 1 to LED 5 Forks Lock due to the Anti opportunity charging activated see 1 7 Lock functions LED 4 Flashing Forklift Lock activated due to scheduling see 1 7 Lock functions Communication via IR or via GPRS Led 7 2nd STAGE THRESHOLD It turns ON when the battery voltage is greater than the Voltage E Threshold 2nd Stage see 10 3 Programming of operating parameters Anomaly detected in the current cycle Note AhBS is a programmable parameter through SmartView If the value assigned is lower than 60 the signalled events will differ from those reported in the table with regard to the first LED from the bottom that will flash with battery charge below 100 AhBS Led 8 Led 7 Led 6 Button smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 6 of 34 ALFA PROGETTI S
25. lamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com Select the Programming TAB Fill in the following fields Battery Voltage Nominal voltage of the battery Battery Ah Nominal capacity of the battery Battery charging current Nominal current of the battery charger Hall Sensor Current Nominal value of the current sensor Diagram sampling time Voltage and current log sampling times for graphs 1 127 min 1 127 sec default 6 min NOTE If expressed in seconds the duration of cycles will be one hour at most External Temp Sensor Present External temperature sensor selection Electrolyte Sensor Input and operation of electrolyte level sensor selection Working current threshold by See manual SmartViewlII default 10A contract Anti opportunity charging Forks lock setting for anti opportunity charging See 1 7 Lock functions Forks Lock Forks lock setting for low battery charge See 1 7 Lock functions Forklift Lock Forklift Lock schedule setup button See 1 7 Lock functions Under Discharge If the voltage is below the specified value V el for the specified time minutes the capacity is forced to 100 AhBS of the nominal capacity Ah Battery if greater than said value default 1 70 V el 30 minutes Battery discharged threshold Discharging below 100 AhBS of the nominal capacity the battery is AhBS considered discharged default 80 Self discharge Self discharged capacity every 24 hours
26. made according to the following diagram see screen printed numbers next to the terminals Pole 8 9 Pole 10 Colors refer to the electrolyte level sensor supplied by Alfa Progetti WARNING The two inputs are not isolated from each other do not install two probes on two different battery cells Replace the cover and tighten it with the screws Tighten the cable gland SmartIC2 V3 Installation and Use Manual V1 41 GB doc Page 22 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com Place the level sensor within a cell of the battery in the figure the automatic refilling cap m was used alternatively a hole can be made on the cell cap For the power supply positioning and setting ag Aem the threshold level refer to the probe NZ manufacturer s instructions Depending on the type of probe used and to which input it is connected it 1s necessary to programme the Electrolyte Sensor parameter via the SmartView Programming TAB see 10 3 Programming of operating parameters The table shows the selectable options in the dropdown menu Probe is not installed Presence of water Select whether the probe generates a signal if the electrolyte level is above the ISOI threshold electrolyte level OK Probe wired to terminals 8 signal and 10 common No water ISOI Select whether the probe generates a signal if the electrolyte level 1s below th
27. ntil the punches completely pierce the cable sheath Make sure the insulation has been pierced by the two tips at the bottom A Smart IC2 S2 or SZGPRS Module B DINxxx type connector C Clamp cover P882B Secure the Smart IC2 to the DINxxx type connector B with the screws supplied D 4 Allen screws M6x50 code V8 E Cylindrical nut 6MA code D2 Place the power supply wires inside the cable clamp compartment P882A so that they are not damaged during closure F Clamp P882A smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 12 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com Secure the clamp F with the Allen screws G supplied 4x20mm code V10 G Allen screws 4x20 mm code V10 Close the clamp with the special cover C and secure it with the screw H supplied 3 5x16 mm code V4 H Screw 3 5x16 mm code V4 Wiring complete and connector ready for use A USA type connector 160A or 320A B Smart IC2 S2 or SZGPRS Module smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 13 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com 4 Mounting on battery side of connector USA type WARNING The DEVICE AND THE BATTERY CABLES SHOULD NOT BE CONNECTED TO THE POWER SOURCE during the following activities Required materials No 1 Phillips screwdriver type PHI No
28. opped below the Battery AhBS discharged threshold AhBS see 10 3 Programming of operating parameters Low Battery Efficiency The battery has been in an underdischarging state for a time gt Under Discharge time when the remaining battery capacity is gt Battery Ah Battery discharged threshold AhBS see 10 3 Programming of operating parameters Electrolyte minimum level Wrong Programming Relay With SmartCB selected see 10 3 Programming of operating Failure parameters there is a charging current even though Charge Relay is open EEPROM RTC Failure A failure in the memory of the SmartIC device or RTC was detected The Xs in the LED Anom column indicates that a LED warning is foreseen for the anomaly indicated The Low Battery Efficiency anomaly must not be confused with the Battery Efficiency indication provided by SmartService which is evaluated over a long operational period of the battery and not on single cycles The Low Level Of Battery Electrolyte anomaly is indicated by activating the LED anomaly and reported on SmartView Info TAB for the entire time and only the time it 1s active Nonetheless the anomaly is logged and can be viewed in the Old Data Info TAB NOTE The Low Level Of Battery Electrolyte anomaly state appears after the sensor detects the anomaly for 3 consecutive minutes The anomaly is deactivated when the sensor detects no anomalies for 10 consecutive seconds G
29. printed numbers next to the terminals The wiring connections to the terminal must be made according to the following diagram see screen printed numbers next to the terminals Colours refer to the wire supplied by Alfa Progetti Reposition the electronic board in the container connect the flat cable to the current sensor card Close the back cover by tightening the 6 screws previously removed code V1 Tighten the cable gland smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 20 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com 7 Connection of accessories The operations for installing the following external accessories are described below Immersion temperature sensor two wire type PT1000 Electrolyte level sensor The two operations are optional and independent of each other For simplicity in the following images only the mounting of the accessory discussed in the corresponding paragraph will be shown If both accessories are mounted it will be necessary to ensure that a cable gland is used which 1s large enough to hold all the cables to be used WARNING The DEVICE SHOULD NOT BE CONNECTED TO THE POWER SOURCE during the following activities NOTE It is assumed that an appropriately sized cable gland 1s already installed on the back cover 7 1 External temperature probe Remove the cover A remove the electronic board from the container unt
30. r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com 1 5 Estimation of the recharge Thanks to the features described above Smart IC2 V3 1s able to accurately estimate the charge in the battery There are two different ways to determine the attainment of a full charge The first traditional by time foresees that the battery 1s considered charged after the duration of the charge subsequent to the attainment of the Threshold Voltage 2nd Stage has reached the Safety Timer 2nd Stage see 810 3 Programming of operating parameters The second way Ah in contrast foresees that the charge is considered sufficient when the restored capacity added to that present at the time the battery charge 1s initiated equals the nominal capacity The Default setting 1s the Ah method see 10 3 Programming of operating parameters NOTES With the Ah method through the SmartEnergy family battery charger the battery 1s supplied only with the power strictly necessary to achieve the full charge thus saving energy and avoiding damage and waste of water Alignment see 811 Alignment occurs only after a full recharge cycle is conducted 1 6 Opportunity Charging The term Opportunity Charging means the mode of use with which the battery is repeatedly charged and discharged for short periods and small capacity as happens in the AGVs Automatic Guided Vehicle In this situation there would be a proliferation of work
31. t 400 A Working Current Threshold LINE A 5 Current circuit Circuit 1 Direct Y Discharge Anti opportunity charging 9 0 OF Charge Forks Lock Forklift Lock o i 64 0 Off Ahmethod Yes C No Under Disch 1 70 Vice so min 0 0ff Smart CB monitoring C Yes No F 2wires control Batt discharged Thresh AhBS a0 zi 26 Opportunity charging C Yes No Self discharge fioo 9 0 O0ff Self Alignment Ah Sampling Time V Min Max fo sec Recharging Incr PF H c9 Web Voltage Threshold 2nd Stage 240 gt Vice Ban 0 GSM 300MHz DCS 1800MHz z 2nd Stage Charging time zoo 2 hh mm APN wEBOMNTELIT Safety Timer Ist Stage i00 2 hhomm User ID Password Safety Timer 2nd Stage e 00 2 hh mm Servlet smartview AlfaManager Web Site smartw alfaprogetti com Autostart C Hours 0 05 HERR HTTP Port 8888 Self Scheduling C Seconds 5 Sec Alternative Web Site 85 47 105 98 Power Saving Setup Alternative HTTP Port 8888 wEB Timeout 140 Zl sec es e Send data to SmartlC ey Read data from Smartic OY Default 7 SmartViewII programming of the operating parameters The AP160UIR device needs to be previously installed through a driver for Windows The process transfers date and time on PC to Smart ON check that the PC dater is correctly set smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 28 of 34 ALFA PROGETTI S r l Spi
32. ts positioning Lay the corrugated conduit along the battery cables Fasten the corrugated conduit with bands without putting it under tensile stress Sometimes it may be useful to wrap the corrugated conduit of the antenna to a battery cable with insulating tape Note Make sure that the corrugated conduit of the antenna and the cable inside 1t are not damaged when closing the hood or by any other mechanical part of the forklift smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 25 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com 9 Communication with other devices smart IC2 V3 has the following serial interfaces to communicate with external devices e Galvanically isolated RS485 e Galvanically isolated CAN bus NOTES RS485 and CAN bus are on the same galvanic area both the CAN line and the RS485 line terminate in the SMART IC2 unit with a 120 resistor The signals are available on terminals in the Smart C2 V3 unit The signals and relative terminals are presented in the table Other Devices CAN oe 4 CAN Poles 0 RS485 A RS485 B Pole7 Blue white wire Colors refer to SmartKey SmartEnergy provided by Alfa Progetti Some connections are described below WARNING The DEVICE SHOULD NOT BE CONNECTED TO THE POWER SOURCE during the following activities NOTE It is assumed that an appropri
33. um Temperature Internal 0 0 External 0 SmartlC Maximum Temperature Intemal 0 0 External _ BN Safety Timer 1st Stage O2nd Stage O Wrong Programming Relay Failure Q End of Charging Ah O End of Charging Time Safety Ah C EEPROM RTC Failure Charge 1stStage Equalizing Charge Battery Discharged Under AhBS Charge 2nd Stage Equalizing Charge Pause Low Battery Efficiency Pause Floating Charge Ol Low Level Of Battery Electrolyte i O Overcharging CyclestoDownload gS 30 Store Cycles Cycle no 2 gt ec 4 E SmartViewII Old Data Info smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 4 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com 1 3 Anomalies The SmartViewII program provides information about anomalies found in the cycle LED Anom Safety Timer Ist Stage While charging the battery voltage did not reach the Voltage Threshold 2nd Stage by the Safety Timer Ist Stage see 10 3 Programming of operating parameters Safety Timer 2nd Stage While charging during the 2nd Stage the battery charge did not reach the nominal capacity by the Voltage Threshold 2nd Stage see 10 3 Programming of operating parameters safety Ah While charging the battery reached 11096 of the nominal capacity before reaching the 2nd Stage Battery Discharged Under While discharging the battery capacity dr
34. ws 4x20 mm code V10 Close the clamp with the special cover C and secure it with the screw I supplied 3 5x16 mm code V4 D Screws 3 5x16 mm code V4 Wiring complete and connector ready for use A Smart IC2 S2 or SZGPRS Module B USA type connector 160A or 320A smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 16 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 89 059 785 726 Fax 39 059 785 737 www alfaprogetti com 5 Mounting outside the connector battery side Required materials No 1 Phillips screwdriver type PHI No 1 Allen wrench 3mm No 1 Allen wrench 4mm Pass the positive pole cable red wire inside the hole of the Smart IC2 S2 or S2GPRS Module o DINxxx type connector U S A type connector Smart IC2 S2 or S2GPRS Module Clamp code P882A 2 screws 4x20 for clamp code V10 Screw 3 5x16 for clamp cover code V4 Clamp for 25 mm cable code P882C25 or 70 mm cable code P882C70 2 screws 5x30 for clamp code V5 2 nuts 5MA code D1 EE I Qnmuous N N o iell z Elele F E Secure the clamp collar D to the module C using the screws E F Make sure the insulation has been pierced by the two tips in the lower part smartIC2 V3 Installation and Use Manual V1 41 GB doc Page 17 of 34 ALFA PROGETTI S r l Spilamberto MO Tel 39 059 785 726 Fax 39 059 785 737 www alfaprogetti com Also fasten the battery cables to the module C t
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