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BCT-2000 Software and BCT-128 and BCT

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1. Selected Input DMM Input Overall Battery DMM Input Overall Battery Reading As Found Reading As Left 75V 350V 600V INTERTIER Before Calibration After Calibration 0 1 of reading 1mV Selected Input DMM Input Reading Intertier As Found DMM Input Reading Intertier As Left INTERTIER 1 150mV 100mV 50mV INTERTIER 2 150mV 100mV 50mV INTERTIER 3 150mV 100mV 50mV INTERTIER 4 150mV 100mV 50mV 74 INTERTIER Before Calibration After Calibration Selected Input Intertier As Found DMM Input Reading DMM Input Reading Intertier As Left INTERTIER 5 150mV 100mV 50mV INTERTIER 6 150mV 100mV 50mV INTERTIER 7 150mV 100mV 50mV INTERTIER 8 150mV 100mV 50mV PREAMP OFFSET AND GAIN Before Calibration After Calibration Selected Input Current Count As Found DMM Input Reading DMM Input Reading Current Count As Left 100mV 100mV 75 19 Run Time Error Messages Run Time Error Message Probable Cause No battery OV detected Clip leads fell off VV IT board malfunctioning Unable to control load No load detected Check shunt connections Veri
2. 53 54 add battery button 18 add button 25 28 Add cell button aii 35 add site button eR 18 add step button 36 adjust active row duration sess 36 adjust active row target 36 adjust alarm levels button 35 adjust test steps button 36 alarm Cells an CRDI Seen AE 33 ijo E 33 nr R 34 ARE EE lina 34 values in reportg ee esse esse se see se Ge ke ee 43 view during test esse ese ee ee se ee 33 37 alarm levels change during test 35 alarm levels aen 24 alarm levels screen sese 35 alarm threshold values area 43 all button 4 in nette 42 all off button 33 46 all on button 46 ambient temperature fest 13 amps Column 25 36 amps per TOV geed 28 with calibration eee 59 amps per weight value ese ese se see ee ee 29 aimps ALES oes eo ee SEENEN 30 archive files eee eee ging tees 50 OPENING eects din eas 51 archive reader sss 52 ASCI format iis SEE ee eee 50 auto button 32 auto button on graph screen 46 auto detect step resistance ee se se ee ee 29 auto select button 46 B back up of data 5 68 battery manufacturer sesse esse se ee ee ee ee 17 battery name essere 17 iS URE EE riens 49 battery strings screen 18 battery voltage on diagnostics screen 55 BBR dIE nnne tein 41 50 BCT 128 BCT 256 3 8 12
3. Adjust the CS 2000 for a DMM reading of 100mV Record the voltage under DMM Input In the Present Readings area observe the value in the IT 1 box Record the value under Intertier As Left Repeat steps 13 and 14 for Intertiers 2 through 8 Adjust the CS 2000 for a DMM reading of 50mV Record the voltage under DMM Input In the Present Readings area observe the value in the IT 1 box Record the value under Intertier As Left Repeat steps 16 and 17 for Intertiers 2 through 8 Remove the DMM from the CS 2000 67 15 14 Print a Calibration Report After you calibrate the unit print a calibration report and keep it as proof of timely calibration and as a reference should any equipment need repair in the future The calibration report contains the Calibration K constants If the calibration file becomes corrupted refer to the report and re enter the Calibration K values on the Calibration dialog box This will save having to recalibrate the BCT To print the calibration report open the Calibration dialog box and click Print 15 15 Disconnect Equipment Observe electrical safety precautions when disconnecting cables and replacing the BCT cover High voltages may be present Close the BCT 2000 software Power off the BCT and the CS 2000 Disconnect the Cell cable and the System cable from the CS 2000 and BCT Replace the BCT 128 or BCT 256 cover if required Do p 15 16 Calibration Backup During the calibrat
4. Calibrating the preamp affects the overall current and intertier calibration If after completing the as found readings you determine that the preamp needs calibration then the overall current and intertiers will also have to be calibrated The following is required for equipment calibration Alb rcorp CS 2000 calibration source recommended A 41 digit calibrated digital multimeter DMM Two 37 pin ribbon cables for connecting the CS 2000 to the BCT If a CS 2000 is not available use a O to 12VDC source for cell calibration a 100mV source for current calibration and a 0 to 600VDC source for OV calibration This may be a combined 0 to 600VDC source The original sense lead harness must be used WARNING High voltages exist inside the BCT 2000 system components and on the CS 2000 terminals Calibration must be performed only by technically qualified persons Observe electrical safety precautions when removing and installing the BCT cover and when connecting leads and making adjustments 58 15 1 Shunt Rating Under Setup open the Load Bank dialog box At the Shunt Rating Amps and per mV boxes type the shunt value from the load banks For example if the shunt is stamped 600 100 600 amps at 100mV type 600 in the Shunt Rating Amps box then type 100 in the per mV box Refer to Load Bank 15 2 BCT 2000 Calibration Source When calibrating the BCT 2000 the use of the CS 2000 calibration source is recommended If the CS 20
5. GOVERNMENT LICENSEE If you are acquiring the software on behalf of any unit or agency of the United States Government the provisions of Section 3 apply to are incorporated in and are made a part of this Software License Agreement GENERAL This Software License Agreement will be governed by the laws of the State of Florida except for that body of law dealing with conflicts of law Should you have any questions concerning this Software License Agreement or if you desire to contact Alb rcorp for any reason please contact Alb rcorp 990 South Rogers Circle Suite 11 Boca Raton FL 33487 email alber Q alber com 3 Government Provisions The Government acknowledges the representations of the Alb rcorp software as Restricted Computer Software as the term is defined in Clause 52 227 19 of the Federal Acquisition Regulations FAR and is Commercial Computer Software as that term is defined in Clause 52 227 7013 a 1 of the Department of Defense Federal Acquisition Regulation Supplement DFARS The Government agrees that 1 if the software is supplied to the Department of Defense DOD the software is classified as Commercial Computer Software and the Government is acquiring only restricted rights in the software and its documentation as that term is defined in Clause 252 227 7013 c 1 of the DFARS and ii if the software is supplied to any unit or agency of the United States Government other than DOD the Government s r
6. 55 When the test is complete click Edit View to display the Steps Resistance box Steps Resistance ES Step 1 00000 Step 9 2 0208 Step 2 0 0000 Step 10 1 0302 Step3 0 0000 Step 11 0 5268 Step 4 Step 12 0 0000 Step5 330189 Step 13 0 0000 Step 6 161164 Step 14 0 0000 Step 83252 Step 15 0 0000 Step 8 41029 Step 16 0 0000 OK RE Figure 47 Steps Resistance After running the load bank resistance test the Step n boxes display the resistance values that were read To edit steps with no resistance values read the resistance value on the panel of the load bank and type it into the box for each step NOTE Not all load banks will have this information You should run the load bank resistance test periodically especially if there is a problem controlling the load The test verifies that no step resistance is too high or low Each step should be approximately half the resistance of the previous step unless its weight value is not double the weight value of the previous step Refer to Load Bank IMPORTANT NOTE If the load bank is used in low and high voltage modes the values displayed are for the currently selected mode of operation See the load banks panel for different voltage settings If using both modes of the load bank add another load bank to the setup in Setup Load Bank and repeat the test Name the load banks Low Voltage and High Voltage Assign the load bank used for each test type Rem
7. Print To print site battery configuration contact and test information for the currently selected test click Print 11 2 Battery Strings On the Setup menu click Battery Strings The Battery Strings dialog box identifies how many strings and cells per string the BCT 2000 is configured for Each string has an entry identifying the start test lead and end test lead Bct Setup x Location Battery String s Test Setup Intertier Load Bank Contact Number of Cells Per String 60 String 3 Startlead 124 End Lead 184 Config Battery Figure 5 Battery String Config Battery To change the number of strings and cells click Config Battery The Configure Battery dialog box appears 18 Number of Strings 7 OK Number of Strings v OK Total Cell Humber T Cells per String i n Cancel AE eee ee r weg S e wesen SC Call Voltage el Valtaga M mt st Er St SES Fa c4 6 CB C18 0c 12 Figure 6 Configure Battery Number of Strings Type the number of strings in Number of Strings If Multiple Strings is not selected the Number of Strings box defaults to 1 and cannot be changed Multiple Strings If using multiple strings select the Multiple Strings box then type the number of strings in Number of Strings Total Cell Number If Multiple Strings is not selected type a value in Total Cell Number Cells per String If Multiple Strings is selected type a value in C
8. sse 29 W warning level ecd td 19 24 warning SCTEEN eene 33 watts Column 25 37 weight b ttons erase dieto een 32 width DUO ca 49 Z Zoom on cell axis button 37 ZRF file EA EE EE 41 50
9. 71 ETER AA N EE 30 L load battery isolated ee ee ee ee 14 load bank S N ID 28 load bank screen see se se ee ee ee ee 28 load button 41 51 load data filter tete 47 load scaling area eee 46 load step weights eee 32 load test control sene 31 load test setup ese ese ee ee ee ee Re 17 supplemental eene 14 SM ELE 14 load bank configuration from DOS 71 diagnOSHCS sies eere retener 55 high voltage mode 56 load bank manual control 32 load bank screen sesse esse se ee ee ee ee ee 28 low voltage mode esee 56 near fire system 12 location screen iresi Re Re ee ER Ke Re 17 low cell criteria Jabel 46 low cell threshold cococonnoonocnncnccnnnnononoss 43 low OV criteria Jabel 46 low OV threshold eie se ee ee ee ee ee Re Re 43 low voltage warning esse se see se see see ee ee 43 M main menu 10 calibration screen 11 communications screen ee ee ese ee ee ee 11 diagnostics screen 11 EE 10 Setup ed RN 10 TOS ESC AE EG 10 Version SCIeen eie se ee ee ee ee ee Re Re ee ee 11 maintenanCe sesse ees ee ee ee ee ee ee Re ee 69 manual button 32 manual button on graph screen 46 manual control test screen sesse ss se se ee ee 32 manual mode 32 manual select button
10. Gp Start ard End of Test for enot i E End SS stat 00 00 00 E El oso 4 4 El I Enable Figure 35 Options Report Title and Report Footer Edit or add text in these boxes if required The Report Title always prints unless there is no title text but you must select the Footer Text Printed check box to print the footer To print the page number and date select the Footer Page Number and Footer Date Printed check boxes Expand All Test Results Graphs Select this box to display a Drill Down Report for each cell that fails minimum voltage threshold level This report graph appears on screens under the Results tab on the View Reports Form screen To have the Results tab appear select Test Results on the Summary dialog box Refer to Drill Down Reports Include Power in Report Select this box to list power in reports in addition to voltage and current This box is available when the test data is not for constant power Start Capacity Calculation at Target Select this box to calculate the capacity when the target value is found All the test times in the report are adjusted by this time For example if it takes four seconds to find the target then all the times in the test report will be minus four seconds NOTE If Calculate Capacity at Target was selected during test setup this option is not available 44 Ignore Zero Target Steps in Capacity Calculation Select this box to ignore steps when the load is targ
11. Items on View Reports Form Non Charger Report Charger Report Test Site Info Site Site Battery Name Info Battery Battery Test Setup Setup Setup Test Results Results Test Activity Activity Activity Intertiers Intertiers S Cell Summary Cell Summary Standard General Standard Cell Detail Text Cell Detail Tabular General Tabular Cell Detail Graph Detail Graph Battery Graph or Charger Graph Battery Graph Charger Graph Battery Text or Charger Text Battery Text Charger Text Notes Notes Notes Figure 33 Items on View Reports Form Each item selected in the Summary box results in a tab appearing on the View Reports Form screen which opens when Preview is clicked Refer to View Reports Form Preview Screen 42 13 5 Criteria Screen Click the Criteria tab to display the Criteria dialog box y Henntr Figure 34 Criteria Time Interval and OV Deviation Click Time Interval or OV Deviation and type a value or click the time or voltage buttons next to the boxes The Report Interval determines the frequency of report sampling Specify time in hours minutes and seconds 10 second minimum or OV deviation in volts 0 2 volt minimum Low Cell Threshold and Low OV Threshold The Alarm Threshold Values area is enabled for all tests except Charger The thresholds are the cell and OV shutdown levels entered in test setup or the last levels entered during the test On the report values that violate these threshold
12. and voltage If the A D count varies outside the range determined by the A D Threshold Deviation value an error is recorded in the error count box To stop the test click Stop 14 2 VWIT Use the I V IT test for diagnosing intertier connection and voltage problems WARNING A CS 2000 must be used for this test When using the CS 2000 source disconnect the batteries and the load control cable before connecting the CS 2000 System connector to the board At the A D Deviation Threshold box type the number of A D counts that can vary before an error is declared The default value is 10 counts The Reference box indicates the A D reference voltage A count other than 0 in the Reference Error Count box indicates a problem with the system Figure 45 I V IT Diagnostics To start the test click Start The boxes display the A D count and voltage If the A D count varies outside the range determined by the A D Threshold Deviation value an error is recorded in the error count box To stop the test click Stop 54 14 3 Load Bank Diagnostic Load bank diagnostics may be used in two ways Click a single step On to display the load current battery voltage and step resistance or perform a cumulative resistance test which saves the individual step resistance to the setup file If you do not enable Auto Detect Step Resistance refer to Load Bank you must enter the resistance for each step There are two methods to obtain this inf
13. 00 Elapse Time 0 01 35 00 01 35 Amps 150 RemainingTime 00 58 25 00 58 25 F3 Manual Figure 28 Charger Test The red curve displays the load in amps The green curve displays charger voltage 38 12 7 Hardware Failure If the computer senses a board failure or loses communication with the BCT the test pauses and the screen displays an error message If load banks are being used the system shuts them down Upon communication failure all selected levels are voided Before doing any diagnostics verify the load banks are powered off and no load is being applied to the battery During the pause mode check all cable connections and equipment After the problem is resolved the testing may be resumed 39 13 Report Generator The BCT Report Generator program reads the test data files generated by the BCT 2000 test software and creates customized reports After the BCT 2000 system performs a load test the test data is saved to a file and it is this data presented in report format that battery test personnel rely on to analyze battery system performance Using the Report Generator you can display graphs edit site information add notes and customize report pages The Report Generator can save reports in several file formats One format lets you open the report at a later date and modify site information or appearance Or you may save the report in the archive format which protects the document against chan
14. 46 micro ohmmeter Test 12 misc diagnostics oo ee ee eee se cee ee Re ee ee ee 57 modified performance test screen 21 modify graphs sse 37 momentary area see ee ee ee ee ee ee ee nennen 28 multiple strings check box 19 N none button 24 42 notes button eene 48 OES dIE RE iS 48 nudge button 30 number Of Strings essere 19 O open archive button ooooccccnonccnoncninnccnonnninnccnnno 51 options button 44 OpORSSCTEEN o Leere Te cete eei tren 44 OV alarm EE 34 SHUTAO EE 24 WAInDInDg ande teet ee Te PIPER HUE 24 OV data filter EE tee RS 47 OV deviation button 43 OV scaling area eer oen 46 AER 20 P parella ii 49 page size in reports oo ee eee inosine 49 parts St EE 78 79 80 password eee 6 pause button reme 31 performance test screen ese ee ee se se ee 20 polarity sensing 29 polling cells rome 10 power scaling area esse see se ee ee ee ee 46 power type AAA eorr Dr ek e 23 preamp offset and gain 62 63 preview button iieri 49 preview screen nei metere 49 print all button siese once 50 print current button sss 50 properties button 48 R rated time ote tes 23 43 recharge Ours ost epe totes 26 recharge test SCI ici totes 23 SS EA A S E 54 reference error Count iisisti 54 report Oria 44 report generator iesi 40 archive UE 50 BBR fil toe 50 binary file hen 50 DB UE 5
15. KW or variable current user defined profile conditions and has programmable alarm warning and shut down levels The BCT controls battery discharge tests at currents up to 4000 amps and can print data reports upon completion of the discharge test Data logging is accomplished with a memory saving write by exception method which internally records monitored parameter changes that exceed 5 millivolts and stores all data on the hard drive The write by exception method increases data point resolution and updates data faster than other data collection methods The BCT 2000 is available as a BCT 128 or a BCT 256 model that tests up to 128 or 256 individual cells or modules respectively Each system includes two key components the BCT and a laptop computer The BCT 128 or BCT 256 data acquisition device incorporates the system and relay boards control boards for optional Alb rcorp load banks and boards to communicate with the laptop computer 3 System Requirements The following are the minimum requirements for BCT 2000 system operation Microsoft Windows 95 98 or NT4 0 Personal computer using a Penttum 200MHz or higher microprocessor 16M of memory 13M of hard disk space available CD Drive or a 3 5 high density 1 44MB disk drive SVGA monitor set to at least 800 x 600 Mouse or compatible pointing device d Software Installation and Backup The BCT 2000 program is loaded onto the laptop computer at the factory This pro
16. Load Bank SN ID box click Delete Step n For each load bank setup type the step weight information Momentary If the load bank has momentary load steps on steps 9 through 16 select the appropriate Step n boxes in the Momentary area Selecting Momentary protects the resistors in the load bank by limiting the load test on the step to a maximum of 60 seconds Shunt Rating Amps per mV Assign the shunt rating in amps per millivolt At the Shunt Rating Amps and per mV boxes type the shunt value from the load banks For example if the shunt is stamped 600 100 600 amps at 100mV type 600 in the Shunt Rating Amps box then type 100 in the per mV box 28 Auto Detect Step Resistance If selected the BCT calculates the average resistance of all steps with weight information The net effect of this occurs at the start of the test The BCT assumes 0 5 amps per weight value At 0 5 amps per weight value the BCT turns on the steps needed to achieve the target load Depending on the actual load banks the first attempt may be off target by as much as half the desired target load After these steps are set the BCT waits for the next load and OV reading Using the sum of the step weights first set the BCT calculates the actual amps per weight value then uses the OV to calculate each step resistance NOTE These resistances are calculated not actual If there is a problem controlling the load the actual resistance of one or more steps may be in
17. a DMM reading of 100mV Record the voltage under DMM Input Observe the Current Count reading on the I V IT dialog box Record the count under Current Count As Found Set the Reverse Polarity switch to minus and adjust the CS 2000 for a DMM reading of 100mV Record the voltage under DMM Input Observe the Current Count reading on the I V IT dialog box Record the count under Current Count As Found Remove the DMM from the CS 2000 62 15 9 Preamp Offset and Gain Calibration 1 GE 10 11 12 13 14 15 16 17 18 19 Calibrate if As Found readings are not within specification The current count at 100mV must be within 30 counts of the count at 100mV Power off the BCT remove the BCT cover and power up the BCT Locate the I V IT board in the BCT This board has two multiturn pots RV1 and RV2 on the rear of the top edge Complete the Preamp Offset and Gain After Calibration section of the Calibration Record as follows On the main menu click Diagnostics then click I V IT on the drop down menu Set the DMM to millivolts Connect the DMM to the CS 2000 0 200mV jacks Set the Reverse Polarity switch to plus and adjust the CS 2000 for a DMM reading of 100mV Observe but do not record the Current Count reading on the I V IT dialog box Set the Reverse Polarity switch to minus and adjust the CS 2000 for a DMM reading of 100mV Observe but do not record the C
18. and most of all high reliability using only quality components and products All of us at Alb rcorp are pleased that you have the confidence in our abilities and understanding of the type of system required to perform this critical and necessary battery testing Please don t hesitate to contact any of the Alb rcorp staff or your local representative if you require further information or clarification on the operation and control of your new system Once again thank you for your confidence in Alb rcorp Sincerely Derek Alb r President Vili 1 What s New This section describes the new features in Version 1 07 of the BCT 2000 program The following are software changes that do not affect the manual e All test setup information is now saved on test setup exit This ensures settings are saved and eliminates wrong alarm levels and target values e Float voltages for batteries of 256 cells or more are now saved to reports e Manual mode now steps linearly for all load bank types e Cells with intertier voltages greater than the cell voltage now show correct voltage e At midnight the BIOS occasionally advanced the time but not the date This caused the calculation for elapsed time to show 24 hours causing the test to end Tests no longer end at midnight e On some charger tests when the load was incremented during the test the load and voltage were recorded for the entire test instead of after the change The report now u
19. bar graph color is green yellow indicates a warning condition and red indicates a shutdown If a cell goes into negative voltage levels the bar graph for the cell changes to black Cell Warning When a cell falls below a warning level the BCT beeps but the test does not pause To silence the alarm click OK in the Warning message box If the Cell Warning level is lowered the cell comes out of warning and the bar graph returns to green but the event is retained in the alarm history Use the Adjust Alarm Levels toolbar button to change the level Refer to Alarm Levels String 1 Cell 5 in Warning Figure 19 Cell Warning Message Cell Shutdown When a cell falls below a shutdown level the BCT sounds a continuous tone the test pauses and the Cell Exclusion message box appears Cell Exclusion c 7 Exclude STRING 1 CELL 18 From Test Figure 20 Cell Exclusion Message 33 To silence the alarm and exclude the cell from the test click Yes in the Cell Exclusion box This also causes the bar graph for the cell to no longer be displayed To silence the alarm and keep the cell in the test click No Resume the test if desired The faulty cell can be jumpered out and the test resumed This allows all alarm parameters to disregard the faulty cell if it is excluded 12 4 2 Intertier Cable Alarm When an intertier goes into alarm the bar graph for the failing intertier changes color the BCT alarm sounds and the intertier de
20. be no battery on line to support designed operation Before switching the battery off line from the charger ensure that design criteria allows for the charger to carry full load Some organizations require placing a backup battery into service prior to load testing a critical battery 10 1 2 Optional Load Banks Supplemental Load A second recommended way to load test a battery is to supplement the service load on the battery with Alb rcorp load banks In this case the battery is left on line and a capacity test is performed using the load bank and system load as a combination total load on the battery This is done by reading the present load on the battery charger subtracting that from the discharge load required and programming the unit for the balance of the theoretical load 10 1 3 System Load Using the system load on the battery allows the system load to be placed directly on the battery with the BCT 2000 used as a data gathering device The BCT system will not read current unless a current shunt is installed and optional current sense leads are connected to the shunt Done as a rundown test on the BCT 14 10 2 BCT 128 BCT 256 Connection Steps After completing all preliminary test preparations connect the BCT 2000 system to the battery being tested This section describes how to connect equipment for a single string test Refer to drawing BCT 2436 D1110 for connection of the cables from the computer to the BCT 128 or BCT 2
21. box Record the value under Overall Current As Found Adjust the CS 2000 for a DMM reading of 100mV Record the voltage under DMM Input Observe the value in the Amps box Record the value under Overall Current As Found Adjust the CS 2000 for a DMM reading of 150mV Record the voltage under DMM Input Observe the value in the Amps box Record the value under Overall Current As Found Set the CS 2000 Reverse Polarity switch to minus Repeat steps 5 to 10 for negative inputs of 50mV 100mV and 150mV NOTE The BCT 2000 only displays positive numbers even though the input is negative Remove the DMM from the CS 2000 60 15 6 Overall Battery As Found 1 6 7 8 9 10 Complete the Overall Battery Before Calibration section of the Calibration Record as follows Set the DMM to volts Connect the DMM to the CS 2000 50V 600V jacks Adjust the CS 2000 for a DMM reading of 75V Record the voltage on the Calibration Record under DMM Input In the Present Readings area observe the value in the Battery OV box Record the value under Overall Battery As Found Adjust the CS 2000 for a DMM reading of 350V Record the voltage under DMM Input Observe the value in the OV box Record the value under Overall Battery As Found Adjust the CS 2000 for a DMM reading of 600V Record the voltage under DMM Input Observe the value in the OV box Record the value under Overall Battery As Found Rem
22. briefly described below refer to IEEE 450 for more information Descriptions of items on the dialog boxes follow the six test type descriptions The areas enabled on the dialog boxes depend on the test type selected 19 11 4 1 Performance Test Also known as a capacity test the performance test uses a programmed constant current or constant power load to project reliability and remaining battery life before replacement is necessary A performance test has only one step Figure 7 Test Setup Performance 20 11 4 2 Modified Performance Test A modified performance test tests battery capacity similar to a performance test and the ability of the battery to provide a high rate short duration load cycle This test may be done in place of a service test If you type 0 zero for Rated Time the test does not calculate battery capacity Figure 8 Test Setup Modified Performance 11 4 3 Service Test A service test determines the battery as found ability to satisfy the battery duty cycle Figure 9 Test Setup Service 21 11 4 4 Rundown Test A rundown test is similar to a service test except the test uses the system load instead of a controlled load Rundown has only one step and no shutdown levels Figure 10 Test Setup Rundown 11 4 5 Charger Test When the charger test is selected the only parameters recorded to the report file are Overall Voltage and Current Figure 11 Test Setup Charge
23. interval at the start and end of the test See the Options Screen section You can now optionally include the start and end step values on a multi step test See the Options Screen section There is now manual scale control for all graphs See the Graph Screen section A data filter option has been added to screen out abnormal values such as when a clip lead falls off See the Filter Screen section The Text Export feature is available again for reports See the Exporting in Text TXT Format section 2 BCT General Description The BCT 2000 Series battery capacity testing system helps ensure the reliability of the DC bus by determining weaknesses in the battery string and estimating when the battery should be replaced Capacity testing is the only proven way to determine where the battery is in its life curve The BCT 2000 lets you determine the amount of energy remaining in the battery The test system can also help detect faulty intercell connections and weak cells in the battery string During a battery discharge test the BCT 2000 continuously records and displays individual cell voltages overall battery voltage current intertier connections and alarm parameters Test data can be printed using the BCT report generator or exported to other programs The BCT 2000 monitors and displays the voltage of up to 256 cells or modules and up to eight strings It can be programmed to discharge a battery under constant current constant power
24. or Constant Current Power type determines if the programmed load is rated in watts or amps The power type selected applies to all steps you cannot switch between Constant Power and Constant Current between steps 23 11 5 3 Temperature and Correction Available for test types Performance Modified Performance Temperature F and C Click F or C Fahrenheit or Celsius then in the Temperature box type the average electrolyte temperature of the sample number of cells The program automatically calculates between C and F For example if you select C after typing a Fahrenheit value the value converts to Celsius To minimize rounding errors type the value in the known format For example if the temperature is in degrees C select C before typing the value Correction None and IEEE If you enter a temperature other than 77 F 25 C you may select IEEE temperature correction of the load To automatically correct to IEEE 450 click IEEE in the Correction area For no correction click None If the IEEE correction option is enabled and the temperature is later changed all programmed steps are automatically corrected and all loads are compensated throughout the test program For more information on temperature compensation refer to IEEE Std 450 11 5 4 Cell Voltage Available for test types Performance Modified Performance Service Rundown Recharge Click the button that corresponds to the voltage of an individual cell 11 5
25. socket closest to the front of the BCT is angled You must align the angled corner of the new chip with this corner before installation Failure to align the corners will damage the BCT 6 Using a PLCC chip puller carefully remove U21 from its socket CAUTION The socket can easily be broken if you are not careful during removal and installation of the chips Grasp the replacement U21 chip and install it in the socket making certain that the angled corner of the chip is aligned with the angled corner of the socket Replace the cover on the BCT replace the six screws and put the plastic caps over the Screws Reconnect the BCT to power 70 17 2 Calibration Constants and Load Bank Configuration After installing the new Windows BCT software you must properly configure the calibration constants and load banks before using the system Record this information from the existing DOS program configuration files as follows 1 Start the DOS BCT program From the main menu select F4 Hardware Diagnostics then select F1 Calibrate Record the shunt setting and calibration K constants below Shunt Rate Value Amps per millivolts Measurement Point Calibration K Cell Overall Current Overall Battery Intertier 1 Intertier 2 Intertier 3 Intertier 4 Intertier 5 Intertier 6 Intertier 7 Intertier 8 2 Press ESC to return to the previous menu 71 3 Select F2 Load Control Diagnostics and record the load bank step
26. steps alarm levels and load bank must be correctly entered for the BCT 2000 to run properly The BCT 2000 software polls the cells for data only when the Test Diagnostics or Calibration screens are open Polling causes the relays in the BCT 128 or BCT 256 to click Do not confuse polling with testing which has defined start and stop parameters The following are brief descriptions of the main menu items See full descriptions elsewhere in this manual 8 1 Setup Setup accesses the Location Battery Strings Test Setup Intertier Load Bank and Contact dialog boxes Setup determines system operation and control of tests Open the Setup dialog boxes before running a test or using the system for data logging Selections let you input information for the battery being tested and parameters such as cell voltage alarms overall voltage alarms number of cells tested intertier connections and test program 8 2 Test The Test screen displays information for monitoring test progress in real time The screen indicates battery OV overall voltage load in amps power in watts kilowatts and capacity if activated Individual cell or module activity is displayed as a bar graph The screen also displays step information presently active step duration value step number and total test times The status area indicates the currently selected cell voltage and test lead numbers The maximum minimum and average cell voltages appear below the sta
27. 0 EXPONO ion oer 50 loading ATC orte 41 opening a repott aienee cete 40 sample file esee 40 saving a Teport aceti 49 EXT file nendum PR 50 ZIRE OR EE DEE i 50 report interval area sesse esse esse esse ee ee se ee ee 43 report properties screen iese ee ee se se ee 48 report ttle cao ether 44 reports button 40 reports SCHeCH osinn ee ee esse ee ee ee ee 10 40 resistance test area ese see se ee ee ee Se se 55 resume button 0 cece se ee ee ee ee ee ke 31 run time error messages uu ee eee eee ee ee 76 rundown test screen oe ee see ee ee se ee ee 22 S safety information sse 111 sample dia init 40 save archive button esee 50 save button in report 50 Service COD fact A eerte ciet 29 service test screen ees ee se see ee se ee ee ee 21 Tn OR EE N 17 battery strings ese se eee eee ee ee se ee ee 18 inr GE AE 27 A casters 28 load test cg eee a 17 location eerte Herten 17 IER 19 test DES eener geg 19 SETUP eis di EE RE RE 10 shunt rating fun RE ROT EE 28 with calibration eese 59 shunt rating amps per MV eee se 28 shutdown level esses 19 24 SA Se EER SEE SR de Ge VERG Ni 29 EA OE EE EE EER 17 ID TepOFts AA EEN 49 sonalert button esse 57 specifications eec rette retener el TI start capacity calculation at target check box 44 Start Step mtt e tert er 55 start test button ees
28. 0 01 15 00 01 30 00 01 45 00 02 00 00 02 15 00 02 30 00 02 37 58 TestTime The Following Cells Failed the CAPACITY TEST BELOW 80 Cell Capacity None E Figure 43 Results with Drill Down Report To automatically display the Drill Down Reports select Expand All Test Results Graphs on the Reports Options dialog box To manually display a report click Preview on the Reports dialog box then click the Results tab to display the Test Results page This page lists cells that fell below the minimum threshold voltage Click on a cell description line to display a Drill Down Report for that cell The report appears under the description line of the selected cell You may display a report for each failing cell listed To close a report click on the same description line 13 19 Archive Reader Program The BCT 2000 Archive Reader program is a separately distributed program that is used to view and print archive files when the Report Generator program is not available The Archive Reader is typically distributed with archive files when these files are sent to locations that do not have the Report Generator program The Archive Reader is packaged with the Report Generator and may be freely copied and distributed with archive files 52 14 Running Diagnostics The DAM Data Acquisition Module I V IT Current Voltage Intertier Load Bank Bus and Misc diagnostic screens reside under Diagnostics on the main menu The
29. 00 00 Figure 26 Change Axis and Zoom Axis Results When more than one X axis is displayed you may click Zoom on Cell Axis to increase the size of an axis display 12 5 5 View Alarms View Alarms Q Click the View Alarms button to open a box that lists all cell intertier and OV alarms that are occurring or have occurred during the test 37 Interlier DN 53 9 Amps 9 0 Kw 0 00 Capacity 2 6 3 IT ETT 2 25 2 30 String 1 Cell 3 2 0 000 Vs Step Number 1 Step 00 01 32 Test 00 01 32 Cell ShutDown String 1 Cell 3 2 0 000 Vs Step Number 1 Step 00 01 32 Test 00 01 32 Step Test Time String 1 Cell 2 m Test 1 of 1 Step Total E Leads 1 fe P Duration 51 00 00 Elapse Time 00 01 32 00 01 32 Voltage 2 248 F2 Resume T Max Cell Min Cell Avg Cel F3 Manual Amps 150 RemainingTime 00 58 28 00 58 28 228 222 225 Figure 27 View Alarms 12 6 Charger Test Screen When the Charger test is running the Charger screen displays a Voltage Load History graph Data on this graph enters from the right and moves to the left This history data is limited to ten minutes on the X axis time display BCT 2000 Test Type Charger 10 51 59 am Buell O Interlier VOLTAGE Charger Low Warning Step Test Time 1 off 1 Step Total Duration 01 00
30. 00 is not available use the original sense lead harness to connect to an alternate voltage source Not using the original cables will result in inaccurate calibration because all input signals are current limited by a resistor in each lead The CS 2000 simulates these resistive leads CAUTION Using a source other than the CS 2000 without the original sense leads will result in inaccurate calibration Make a photocopy of the BCT 2000 Calibration Record each time the equipment is calibrated Retain these records in the event the equipment needs servicing in the future 15 3 Calibration Setup Prepare the BCT and CS 2000 as follows 1 Power off the BCT 128 or BCT 256 and the CS 2000 2 Connect a ribbon cable from the CS 2000 Cell connector to the BCT Cell 1 connector 3 Connect a ribbon cable from the CS 2000 System connector to the BCT System connector 4 When using the CS 2000 or equivalent calibration source calibrate the BCT 2000 system without any battery cables or load control cables connected to the BCT 128 or BCT 256 5 Key points to remember before power up e If using a source other than the CS 2000 use the original sense lead harness to avoid inaccurate calibration e When using any calibration source remove all battery cables and load cables from the BCT e Calibration must be performed only by technically qualified persons Dangerous voltages are present e Ifall as found parameters are within specification ca
31. 000 series O Rh ke aa Laptop computer with power cable and manuals Computer to BCT cable 10ft Cell sense lead labeled 1 32 Cell sense lead labeled 32A 64 Cell sense lead labeled 64A 96 Cell sense lead labeled 96A 128 Sense lead labeled OV IT1 8 Sense lead extender cables 25 ft Flight approved shipping cases Program disks 1 to 7 UD DD DD DUDU DU Certificate of calibration Rh SB SB N OU ke a ha ha onm n Printer with power adapter ink jet cartridges and manual o O Printer cable O 1 Printer paper package Optional Equipment 1 CS 2000 calibration source 1 Power cable for CS 2000 2 37 pin I V IT test cable 3 ft 1 Load control cable 50 ft 00 0 0 Checked By 78 22 Appendix B BCT 256 Parts List Quantity Description Checked BCT 256 data acquisition logging unit O Power cable for BCT O Operating manual for BCT 2000 series O Rh ke aa Laptop computer with power cable and manuals Computer to BCT cable 10ft Cell sense lead labeled 1 32 Cell sense lead labeled 32A 64 Cell sense lead labeled 64A 96 Cell sense lead labeled 96A 128 Cell sense lead labeled 128A 160 Cell sense lead labeled 160A 192 Cell sense lead labeled 192A 224 Cell sense lead labeled 224A 256 Sense lead labeled OV IT1 8 Sense lead extender cables 25 ft Flight approved shipping cases Program disks 1 to 7 umnuuuumumumumsumumsurmt r Certificate of calibration Rh Se ma ND VO FF HA HA e e 2 HA
32. 15 59 87C52 processor ee see ese ee ee ee 70 binary leonesa napa ndo 50 BTRhfle nahin 41 C calculate capacity at target check box 26 Caldero 58 DacklD tasas 5 68 Cl 60 64 CODStAants ii 5 68 71 CS 2000 SOUL CE sk eet teo 59 SO RTE 61 67 overall pattery aiii 61 66 overall Current esse sesse se ee ee ee ee 60 65 PREAMP s RA ED 62 63 EE OE NR NE 73 TEDOLLS SEE SG cc 68 SD iia EE EE EN 59 calibration screen 11 capacity test either 20 CAPACILY A eee 30 cell eXClUSIOD E 35 shutdown sss 24 33 vpn 24 33 Cel Fo failute tete 44 COM ata filter eere 47 cell detail button seen 45 cell detail Screen iem 45 cell exclusion screen 33 cell exclusions screen sees 35 cell n n buttons esee 27 cell scaling area wo eee ee esee 46 cell voltage area esee 24 cell voltage buttons sess 19 24 cells per string cet 19 change button 49 change cell axis count button 37 change password button 6 charger high low voltage warning 26 charger screen 38 charge test eege ee 38 charger test screen rriservata eis 22 charger warning levels area 43 clip start and end of test check box 45 clip values determining eie eret 45 colors of graphs eeeeeeeeeeeeeee 33 34 38 COM button N EE EG 7 communication settings screen ee ese ee 7 communications SCTeEH
33. 37 Figure 26 Change Axis and Zoom Axis Results 37 Figure 27 View AVE EE teo RE OE OER OR ERROR N 38 Figure 28 Charger Testseite ceo ne PUE eI eR eI ge gre erc ete dels 38 Figure 29 Reports Main Screen Top 40 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 OPIO si RR OER RE KEER EA A ak i ER ada 44 Cell Detail ene ae eI S E a ae 45 Figure 39 RE RE RE ER EHE is 48 Figure 40 Report Properties s d Ret Ule et Rr te orte itio 48 Ligure 41 View Reports Porm one ite tica 49 Figure 42 Typical Archive File oue dip een Ee cst eet 51 Figure 43 Results with Drill Down Report 52 Figiire 44 DAM Diagnosis Ee UHR NU RORIS neptem ui isti A 53 Ligure 45 VAT Dag BOSUCS ciet iaa 54 Figire 46 Toad Bank DIA ROSI 2 astu ipee Ee el GEN Ge Pep ge E ee see ee ek ee A 55 Figure 47 Steps Resistance 5 eo idt tet RU Het eti A 56 Fig re 48 BUS eC c EE Se Ee ER oe eg ee Se Re ee E lia 57 Figure vk RE OR EE EE OR ER OR EO OE EE 57 Figure OE ER EE EE EEN Ee 58 Vii Dear Customer Congratulations on the purchase of the BCT 2000 Series testing system The BCT 2000 Series is the latest generation test system engineered by the Battery Test Experts at Alb rcorp Alb rcorp has taken its experiences from the field of battery testing since 1973 to develop this new product line This state of the art test system is designed with the user in mind with on line help repeatable readings
34. 5 Alarm Levels Area Available for test types Performance Modified Performance Service Rundown Recharge In the Alarm Levels area type voltage levels that issue warnings or shutdown during testing This area lets you set warning and shutdown levels for cells OV and intertiers When an alarm condition occurs an alarm sounds the failing cell is logged and the graph or display area changes color A beeping alarm from the BCT indicates a warning and a solid tone indicates a shutdown Refer to View Alarms During Test You may change the warning and shutdown test levels for cells OV and intertiers when the test is running Changes are recorded in the test activities portion of the report Refer to Alarm Levels NOTE When cell warning or shutdown levels are changed the OV warning or shutdown levels are automatically adjusted by the number of cells in the string times the changed level NOTE To disable any of the following warning or shutdown levels type a 0 zero in the box Warning Cells Type the alarm voltage level of the individual cell or module to be alarmed For example if testing to an average end voltage of 1 75 volts per cell type 1 75 When any cell falls below 1 75V an alarm condition occurs If values are set to 0 the warning is not active 24 Shutdown Cells Type the voltage of an individual cell to pause the test For example if discharging to 1 75 volts per cell average you may want to pause the test if
35. 56 Refer to drawing BCT 350 D1105 for connection to the cells 1 Before making any connections ensure all equipment is powered off 2 Connect one end of the 9 pin to 9 pin cable to the serial port of the computer 3 Connect the other end of the cable to the BCT computer port 4 Connect the AC power cable to the BCT 128 or BCT 256 and plug the other end into a 120V AC 60Hz receptacle 5 If printing of test results is desired unpack the printer Plug the AC adapter into the small power receptacle on the printer and the other end into a 120V AC 60Hz receptacle Wait until completion of the test before printing 6 Connect the male end of the six foot printer cable to the printer cable port near the AC adapter input Connect the other end to the computer 25 pin D Sub female connector on the rear of the unit 7 Load paper into the printer 8 Connect the DB37 end of the 25 foot sense lead extender cable DB37 on one end Amphenol round 37 pin on other end to the BCT Cell 1 32 port 9 Connect the black connector end of the red individual cell wire small numbered clips on one end Amphenol 37 pin on the other to the sense lead extender cable Open end from above step 10 Repeat above two steps for all other extender cables and sense lead cables until there are enough clips for all the cells 11 Connect one end of another sense lead extender cable to the System connector on the rear of the BCT and connect the individual red
36. BCT 2000 Software and BCT 128 and BCT 256 User s Guide 990 South Rogers Circle Suite 11 oca Raton 3487 Tel 561 997 2299 Fax 561 997 5588 http www alber com 1 Warranty and Limitation of Liability LIMITED WARRANTY Alb rcorp warrants that the software product will perform in accordance with the accompanying written materials for a period of ninety 90 days from the date of receipt Some states and jurisdictions do not allow limitations on duration of an implied warranty so the above limitation may not apply to you To the extent allowed by applicable law implied warranties on the software product if any are limited to ninety 90 days CUSTOMER REMEDIES Alb rcorp s entire liability and your exclusive remedy shall be at Alb rcorp s option either return of the price paid or replacement of the software product that is returned to Alb rcorp with proof of purchase This Limited Warranty is void if failure of the software product has resulted from accident abuse or misapplication Any replacement software product will be warranted for the remainder of the original period or thirty 30 days whichever is longer Alb rcorp shall not be liable for any data or programs stored in or used in conjunction with this software product Without prejudice to the foregoing generality Alb rcorp shall not be liable for the loss or corruption of data or programs stored in or used in conjunction with this or any other software product no
37. EEEE 46 13 9 EU EE 47 13 10 NOTES SCfeens c aoo ote el EE 48 13 11 Report Properties Steen eee etre EENS 48 13 12 View Reports Form Preview Screen 49 13 13 Saving a Report epe et N OE dte cr qe 49 13 13 1 Binary GBBR Oe E 50 13 13 2 Archive CZRP Format 2 ene ec etes ee RR E c rt ec ters 50 13 14 Exporting in Database DB Format 50 1345 Exporting in Text TXT Format etes cer eint EH ed ee eb ee de bes Eee 50 13 16 Prn ngaRepOfFt z mie eee see e Re RUE aii 50 13 17 Opening an Archive File va iei enter e tiii ete eade eedem 51 13 18 Drill Down oi AE EE EE te Pe etri eae ems 52 13 19 Archive Reader Propia iode toe edet cti iii rae ed due deiere 52 14 RUNNING DIAGNOSTICS seeren EO EE EE 53 14 1 DAM Data Acquisition Module 53 14 2 IA RRE 54 14 3 Load Bank Diagnostic onem ege EE ES Raia 55 14 4 RR RE AE RR ER 57 14 5 EE ER EE EE leia 57 15 SYSTEM CALIBRATION EE OE EE RE 58 15 1 Shunt TE 59 15 2 BCT 2000 Calibration SOULCE E 59 15 3 do tte SA RR EE NEESS ENEE 59 15 4 Cell As Found x AA AE HERE EE EE RR EG 60 15 5 Overall Current Se EE EE ret e Prem rei EE HOS 60 15 6 Overall Battery AS dT RE EO N ot etae rers 61 15 7 Inter er As Pound RE XE ER Ee EE ER EG 61 15 8 Preamp Offset and Gain As Found 62 15 9 Preamp Offset and Gain Calibration eese eene nre nenne 63 15 10 Cell Calibration cnt EE er RR Rer t EYE PEREAT PR 64 LI Overall Current Calibr
38. able between the CS 2000 Cell Outputs rear connector and the BCT Cells 1 32 connector Connect the other 37 pin cable between the CS 2000 System connector and the System connector on the BCT Power on the four devices The BCT 128 or 256 the laptop computer the printer and the CS 2000 Verify the Windows desktop appears Click the BCT2000 icon to start the program On the main menu select DAM Verify the BCT relays are clicking On the DAM dialog box at Display Board select 1 17 18 19 20 On the DAM dialog box observe A D counts of at least 10000 if no CS 2000 is connected Varying the CS 2000 causes the A D counts to vary Close the DAM dialog box and exit the BCT program To test the printer open a word processing program select the printer driver then send output to the printer After verifying operation power off the equipment and disconnect the cables Place all the cables and components back into the shipping cases as found when unpacking 8 Main Menu The main menu is where all BCT 2000 operations begin BCT 2000 BET Setup Test Reports Diagnostics Communications Calibration Help Figure 3 BCT 2000 Main Menu To start the program and display the main menu double click the BCT 2000 icon on the Windows desktop The Setup Test Reports Diagnostics Communications Calibration and Help screens are accessed from the main menu Setup information which includes battery configuration test
39. able of Figures PASS ion EE EE EO RE N 6 W eu ene E H BET 2000 Maln Men EE 10 TQ Caton cs sis sis sh RE RE RR E mm 17 Battery Strmpg eR nno nea EE N AR EE 18 Configure Battery onines ome crece mp eeh Regen 19 Test Setup Performance iris nitor ceo pere eo terra D T o Eee tree ee Eed Rees ee 20 Test Setup Modified Performance uei ge Se BE gees o ee Dedit tet eser rrr de Fee Regs dee 21 Test Setup Service cies eb peeite cue DER SO DO I RT HE reU den 21 Test Setup AA rata Ta retara pae oe Eea EEE EE EEEE E EOTS EEO RESE PE SERS b EREE Er Eai 22 Test Setup Charger RR epe tu EO oe dece 22 Test Setup Recht ii eee GE GE RERO en 23 ren E 27 Load Bank uer rep erm eg NEE KEER ci 28 EE 29 BE E KEE 30 BET Test Eu E Rule EE 32 Figure 18 Manual Toolbar eese eren enne ennt nennen trennen trente eter GRA GRA Gee enne 32 Figure 19 Cell Warning Message eise ese ee se ee Ge Ge r RA nono no nn nn Ge ee ee ee ee Gee Ge trennen rennen enne 33 Figure 20 Cell Exclusion Message sienien ee ee Se Ge Ge Ge p Re Ge Gee Ge ee ee ee ee Ge ee Ge Se ee enne ee ens 33 Figure 21 BCT Test Toolbar esee oh ie 35 Figure 22 Cell Exclusions i eie ENEE oe 35 Figure 23 Alarm levels iae epe dek ee SS RS DER dd 36 Figure 24 Test Steps Constant Curemt eee se se se Ge RA GR Ge ee Ge ee ee ee Ge Se Ge Re RA RA RA Gee ee ee 36 Figure 25 Test Steps Constant POWer ssie eien eeen eer ee ee Ge ee ee ee Ge See Ge Re ee ee oe Gee ee ee
40. ae Baan Eed 41 RE 41 ZREJ e ikea Shel RE EE 41 filter b tton iii oerte tt ER 47 ll EE 47 firmware Upgrade 2 0 0 eee cece se Se ke ee ee 70 footer date printed check box 44 footer page number check box 44 footer text printed check box 44 full button rin nina 49 G general descrptton ee ee se see Se Se Re ee 3 graph DUO se sege EE eg EE Ge eg Ee ee 46 graph SCLEOM s s EE ER 46 A e negate ere eden D eg 30 changing during test 37 GOOSE T eet 33 34 38 AM TepOTts iicet erre 52 H hardware failure see 39 high voltage warning iese esse esse ese ee se se ee 43 history graph for charger 38 history of tests 13 hydrometer test sse 12 I AR 54 IEEE button ionem ens 24 IEEE standard iii 12 13 19 ignore zero target steps check box 26 45 include power in report check box 44 include steps start and end values check box 45 e EIN 8 insert button N 25 installation se 5 intertier alarm dis eri pep 24 bar gr phi is eee 34 Cable IERE RE OER ds 34 cell assignment eese 27 graph on test screen ees sees ee ee se ee ee 30 string assignment sse 27 EVER AR Ee tei iste rr err EE EO 24 intertier cell assignment buttons 27 intertier screen oe eee cece ee ee Se ee ee 27 K ET N 5 68
41. any cell falls below 1 65V In this case type 1 65 to pause the test when any cell falls below this voltage If values are set to 0 the shutdown is not active Warning OV This box defines the overall battery voltage warning level Type the overall voltage warning level For example if testing 60 cells to an average of 1 75 volts per cell you may want to be warned when battery voltage is approaching shutdown If values are set to 0 the warning is not active Shutdown OV In most cases this value determines the end of the test Type the overall battery end voltage For example if testing a 60 cell battery to 1 65 volts per cell type 99 0 in the box 60 cells x 1 65 volts per cell 99 0 volts The system pauses the test when the overall voltage falls below 99 0 volts If values are set to 0 the shutdown is not active Warning Intertier and Shutdown Intertier Each intertier can have a warning and or shutdown level set To select an intertier click an Intertier button then type alarm and warning levels in the Intertier Warning and Shutdown boxes Select values for each intertier as required If values are set to 0 the warning or shutdown is not active 11 5 6 Test Steps Area Available for test types Performance Modified Performance Service Rundown Charger Step Each step is programmed individually with a maximum of 99 steps allowed If Step 1 or another desired step is not displayed scroll to the step then click the step
42. arm levels by changing the OV warning and shutdown values by one cell level All items on the cell exclusion list are cleared when the test is exited Cell Exclusions Alarm Levels Test Steps MEscluda Seng 1 Call 1 HE ncluda Enaing 1 Call 12 IER Figure 22 Cell Exclusions 12 5 2 Alarm Levels Adjust Alarm Levels H You may change the warning and shutdown levels for cells OV and intertiers while the test is running Click the Adjust Alarm Levels toolbar button After changing a level use the TAB or ENTER key or mouse to move to the next box The new alarm level takes effect immediately Changes are recorded in the test activities portion of the report 35 CAUTION Changes made to the alarm levels and test steps using the Test Adjustments dialog boxes are valid only for the presently running test and do not permanently change the test setup information Teat dhs slomrnl Figure 23 Alarm Levels 12 5 3 Test Steps Adjust Test Steps E Click Adjust Test Steps to add new steps or change the duration or load of the presently running step or subsequent steps NOTE You cannot change the duration of a presently running step to less than the elapsed time of the step Also steps that have already run cannot be changed To add a new step click Add Step IEEE iljuni Figure 24 Test Steps Constant Current If Constant Current is selected the Test Steps dialog box has buttons for 20 10 5 an
43. ation cer rer EE OR eer ee eroe DE 65 15 12 Overall Battery Calibration nette tert terrore e RED Ee Sage ba reges 66 A IA mH SF CREE N e N 67 15 14 A O o emerit Street ridere erbe 68 15 15 a A dnt t pete ido e eres o Ra te ope BR Gegee De sted 68 15 16 Calibration Backup EE RE Ret ete et e proe Dea teri prep rhe 68 16 MAINTENANCE E 69 17 UPGRADING BCT 2000 SOFTWARE nennen trennen rene GRA enne ee enne nennen 70 17 1 Replace the 87C52 Processor eese nennen eene enne Ge ee ee ee ee ee tren 70 17 2 Calibration Constants and Load Bank Configuration essere 71 18 BCT 2000 CALIBRATION RECORD ee eene nene teen then trennen retener enne Gee tenet ee ee see 73 19 RUN TIME ERROR MESSAGES isse enne ese ese ee Gee ee Re enne eed eterne bee tenete retener 76 20 SYSTEM SPECIFICATIONS ENEE SEENEN ese Dee eg TI 21 APPENDIX A BCT 128 PARTS LIST ee see see se eee nennen nenne rn neon nr enne nest tnn 78 22 APPENDIX B BCT 256 PARTS LIST ee see see se see see se ee ee ee ee Re ER nenne ener enne enne meer tene 79 23 APPENDIX C SPARE PARTS ee eee EEN 80 Table of Drawings BG E RAR RA System Block Diagram BCT System BCT 350 D1105 net metet Gen Arrangement Sense Lead Connections vi Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 T
44. ay be viewed without a password but not modified To view a screen click Cancel or press ESC If the password is changed without authorization or lost contact Alb rcorp to obtain a code to unlock the system Type this code in the Enter Factory Backup Code box and click OK This puts the password back to the default password alber Change the password as previously described 6 Communication Settings If the computer does not communicate with the equipment you may need to select a new COM port To display the Communication Settings screen click Communications on the main menu z LCommuncalon Siling Conmmuncabon Part P Comi Coma C Com Com o ems Figure 2 Communication Settings Click a button for the COM port setting then click OK If the reguired COM port is not known you may have to try all four selections to determine which setting establishes communication between the computer and the eguipment The BCT program communicates with the unit only when in the Test Diagnostics and Calibration screens 7 BCT 2000 Initial Test Before connecting equipment for an actual test check all the BCT components for functional operation First test the laptop computer Remove the computer from its shipping case and connect the power cable Refer to the laptop computer manual Power up the computer and verify the screen displays the Windows desktop and the BCT 2000 icon If it does not contact Alb r
45. before selecting other options Select the subdirectory and the file name then click Open 13 3 Loading a File Load When certain functions are selected and no file is open a message indicates a file must be opened To open a file after the Report Generator is started click Load and select a file You do not need to close the old file as only one text or binary file can be open at a time However you may open an archive file while a text or binary file is open Refer to Opening an Archive File 13 4 Summary Screen After a file is opened the Reports dialog box appears Click the Summary tab to display the Summary dialog box Items in this box depend on the type of report selected E E Ki x as 1311440407 k z M zd dd zi al Fa Figure 31 Summary 41 T Henmt s Preis Coen ze Load Properties Summary criteria Options Graph Fiter Motes F Teel Site Info EI F Battery Mame Info E Geller 1 F Tesi Selup E ett E Ee pt E Tesi Activity F Charger Graph fe redler E Charger Text ar j FF Hates Figure 32 Summary for Charger Report On the Summary box select the items to include in the report If a Charger test report is selected Battery Graph and Battery Text change to Charger Graph and Charger Text To select all the items in the Summary box click All To clear all the items click None Items in Summary Box Items on View Reports Form
46. box observe the value in the Amps box Record the value under Overall Current As Left Adjust the CS 2000 for a DMM reading of 100mV Record the voltage under DMM Input Observe the value in the Amps box Record the value under Overall Current As Left Adjust the CS 2000 for a DMM reading of 150mV Record the voltage under DMM Input Observe the value in the Amps box Record the value under Overall Current As Left Set the CS 2000 Reverse Polarity switch to minus Repeat steps 9 to 14 for negative inputs of 50mV 100mV and 150mV NOTE The BCT 2000 only displays positive numbers even though the input is negative Remove the DMM from the CS 2000 65 15 12 Overall Battery Calibration N e DN Ld PS TOR 10 11 12 13 14 Calibrate if As Found readings are not within specification 0 1 of reading 0 4V Complete the Overall Battery After Calibration section of the Calibration Record as follows Set the DMM to volts Connect the DMM to the CS 2000 50V 600V jacks Adjust the CS 2000 for a DMM reading of 350V Type the actual reading into the Overall Battery Voltage Measured box Tab to the Intertier box The Calibration K value changes Adjust the CS 2000 for a DMM reading of 75V Record the voltage on the Calibration Record under DMM Input In the Present Readings area observe the value in the Battery OV box Record the value under Overall Battery As Left Adjust
47. ceed equipment voltage or power ratings and capabilities e Make sure that equipment is properly grounded e Do not let unauthorized persons operate the equipment References The following IEEE standards are referenced in this manual IEEE Std 450 1995 IEEE Recommended Practice for Maintenance Testing and Replacement of Vented Lead Acid Batteries for Stationary Applications IEEE Std 1188 1996 IEEE Recommended Practice for Maintenance Testing and Replacement of Valve Regulated Lead Acid VRLA Batteries for Stationary Applications 111 Table of Contents lo WHAT S E 1 2 BCT GENERALE DESCRIPTION serere ri eer et toe e e e eren scri deii 3 3 SYSTEM REQUIREMENTS ececdeasesevechccstvsvedesecochcesdesdesesevedseoses ee EN oe Eee e FERE e eve eve eee exse pres vede 4 4 SOFTWARE INSTALLATION AND BACKUP ENEE gt DE 3PASSWORD EE 6 6 COMMUNICATION SETTINGS tror ORE TR EE OE EE HO EE ss 7 T IBGIS2000 INITIAL TEST EE OE OE OO OU EE EE EE N 8 T l Im alSystem Iest esee OR ene Dee UDIN UD OE EE 8 AE E BCEE 10 8 1 KE DE 10 5 2 TeSE EE 10 ad OER cis sie NAS LE C AR RN ER ee 10 8 4 Di gnostics eene EE EE EO 11 5 COMO OS D EO EE E 11 6 A AE AE EER EE EE N EN 11 8 7 MASIA as RORIS ERE Re eet E SR ee ee eg 11 O REGOMMENDED TESTS i ES EE DR Ee GE Ge EG Ee ee eege 12 9 1 Micro Ohmimeter uc NN 12 9 2 Hydromet fs eet DR ee GE Ge e RR ee ee ee is a 12 9 3 Temperature Electrolyt ie ER ese
48. corp for technical assistance Power off the computer to end the test 7 1 Initial System Test Refer to drawing BCT 2436 D1110 System Block Diagram for connection of the cables from the computer to the BCT 128 or BCT 256 data logging acquisition device The system has a serial interface which uses a 9 pin to 9 pin cable The following steps describe the connections for proper operation 1 2 3 4 10 11 12 13 14 15 16 Before making any connections ensure all equipment is powered off Connect one end of the 9 pin to 9 pin cable to the serial port of the laptop computer Connect the other end of the cable to the BCT computer port Connect the AC power cable to the BCT 128 or BCT 256 and plug the other end into a 120VAC 60Hz receptacle Unpack the printer Plug the AC adapter into the small power receptacle on the printer and the other end into a 120VAC 60Hz receptacle Connect the male end of the six foot printer cable to the printer cable port near the AC adapter input Connect the other end to the computer 25 pin D Sub female connector on the rear of the unit Load paper into the printer NOTE The printer is not required during an actual load test Unpack the CS 2000 if available Locate the two test cables and one power cable for the unit The parallel cables each have a female and male D Sub 37 pin connector Connect the power cable to the CS 2000 and to a 120V AC 60Hz receptacle Connect one 37 pin c
49. correct Refer to Load Bank Diagnostic If Auto Detect Step Resistance is selected the BCT corrects the load steps at least one more time at the start of the test If you do not want this to occur do not select Auto Detect Step Resistance In this case select Diagnostics from the main menu open the Load Bank dialog box and measure or type the load bank resistance values into only the active Steps boxes Steps 1 to 16 as required 11 8 Contact On the Setup menu click Contact to display the Contact dialog box Location Battery Etringis Test Setup Intestier Load Bank Contact Bite Contact Contact P hena Er o Est EE Eye cf Fax ki Emil E Figure 15 Contact The Contact dialog box is an information screen and has no effect on tests Type the names of persons responsible for the system at the site and for service and their telephone numbers and e mail addresses 11 9 Voltage Polarity The BCT 2000 systems features automatic polarity sensing and no user input is required The system senses when Cell 1 is the most positive or the most negative cell in the string 29 12 Running the Test At this point the BCT 2000 must be connected as described in Connecting the System and the main menu displayed On the main menu click Test The BCT Test screen displays all relevant information for monitoring test progress and parameters in a real time mode OV Amps KW and Capacity The top o
50. d To return to automatic mode click F3 Auto T 2000 Test Type PerFormance 10 14 31 am lu N Eli ol TN ov 49 4 amps 150 9 Kw 7 45 Capacity 1 9 DES Manual Control Ai Of ooooommomoooomoof 420 2410 2 5 E E woe feet Time String 1 Cell 1 EI Sto Test e Step Total Test Leads 0A 1 P E 01 00 00 lapse Time 00 01 08 00 01 08 Voltage 2 065 Erre a MaxCel Min Cell Awg Cel ff Amps 150 RemainingTime 99 58 52 00 58 52 207 2 05 06 i Figure 17 BCT Test in Manual Mode Typically select manual mode to control a charger test or if there is a load bank problem Manually selecting load step weights may help determine which step in the load bank is causing the problem NOTE Do not confuse step weights in the load bank with test steps in the program When F3 Manual is selected a toolbar on the screen allows control of the load bank Manual Control ANOFf DOOODODOMMBMOOOMODO m 20105 Sech a Figure 18 Manual Toolbar User Defined Weight Buttons The larger arrows to the left of 20 on the toolbar are user definable To increase or decrease their load weight per step type a weight in the box or click the smaller arrows adjacent to the box The maximum weight value is 200 To increase or decrease the load applied click the larger arrows As the value is changed the 16 square step indicators change The step enabled in th
51. d 1 amp or you may type a new value in the Amps column 36 TT ET TER Aust Active Bei Target 2000 1000 j 500 aj 100 8 Aust Acti Flow Duration 15 00 2d SE 120 2 amm Figure 25 Test Steps Constant Power If Constant Power is selected the Test Steps dialog box has buttons for 2000 1000 500 and 100 watts or you may type a new value in the Watts column 12 5 4 Modify Graph Change Cell Axis Count ES Zoom on Cell Axis Di Use the Change Cell Axis Count or the Zoom on Cell Axis buttons to change the number of X axis lines graphs displayed or to zoom in on a graph Click Change Cell Axis Count to spread the cells over more than one X axis This is useful when there are more than 60 cells in a test BCT 2000 Test Type PerFormance 09 53 28 am BCT 2000 Test Type Performance 10 00 37 am fia ele e ED nl E i el ov 53 9 amps 0 04 Kw 0 00 Capacity 0 096 PERSPSER lev 54 0 Amps vos 0 00 Capacity 0 0 220 220 Step CTestTime er ml Duration 01 00 00 Elapse Time 00 00 00 00 00 00 e Maxell Min Cell Avg Cell Amps o RemainingTimeo1 00 00 01 00 00 zaa iz Por Step Total St Test Time Tat Step Total Duration 01 00 00 Elopse Time on n0 00 00 00 00 Amps E RemainingTime 01 00 00 01
52. d the battery be allowed 72 hours of float condition prior to testing This charging action should provide optimum capacity results Contact individual battery companies for their recommendations on this practice In an effort to test the battery in an as found state occasionally load test the battery in its normal float state without any prior charging or preparation This as found testing checks the effectiveness of the battery maintenance program Done as a service test on the BCT 9 6 Test History Analyze test results from previous tests to determine faulty conditions that may become apparent during the load test Doing this permits closer observation of cells or connections that were weak the cause of problems or possible failures Correct any problems that stop tests prior to putting the battery back into service and before further testing 13 10 Connecting the System After performing all preliminary tests prepare and connect the BCT 2000 Series system 10 1 Determine Load Type The BCT 2000 System can operate in three different types of load configurations 10 1 1 Optional Load Banks Battery Isolated One recommended way to load test a battery is with the battery completely isolated from the system or its associated load using optional Alb rcorp Load Banks In this instance the charger carries the load until the test ends WARNING When using this method if a loss of power occurs during the load test there will
53. dialog boxes perform diagnostics on the BCT system the I O control board the load control board used with load banks and the load control system 14 1 DAM Data Acquisition Module Use the DAM test for testing boards that may have stuck relays bad A D counts or bad A D reference If not using the CS 2000 calibration source leave the batteries connected to the BCT during the test CAUTION Make certain there is no load on the batteries and no charger is connected so the A D counts do not drift If using the CS 2000 source disconnect the batteries before connecting the CS 2000 Cell connector to the board The source is capable of driving one board at a time If it is connected to more than one board loading of the source may occur At the A D Deviation Threshold box type the number of A D counts that can vary before an error is declared The default value is 10 counts mmm E Ue d ee Wm 8 ma D ia MET 1i Ul Hi Figure 44 DAM Diagnostics At the Display Board box select the board to monitor on the screen The highest number is 8 with a fully loaded BCT 256 If you select an invalid board number the display shows zeroes when the test is running 53 The Reference box indicates the A D reference voltage A count other than O in the Reference Error Count box indicates a problem with the system To start the test click Start The boxes next to each cell number display the cell A D count
54. e Calibration dialog box Record the DMM voltage on the Calibration Record under DMM Input Tab to the Overall Current Voltage Measured box The Calibration K value changes In the Present Readings area of the Calibration dialog box observe the value in the Cell 1 box Record the value under Cell As Left Set the CS 2000 Cell 1 switch to 2V Observe the DMM voltage reading Record the voltage under DMM Input Observe the value in the Cell 1 box Record the value under Cell As Left Remove the DMM from the CS 2000 64 15 11 Overall Current Calibration 1 DE O 10 11 12 13 14 15 16 17 Calibrate if the preamp was calibrated or if As Found readings are not within specification 0 1 of reading 3A Complete the Overall Current After Calibration section of the Calibration Record as follows Set the DMM to millivolts Connect the DMM to the CS 2000 0 200mV jacks Set the Reverse Polarity switch to plus Adjust the CS 2000 for a DMM reading of 100mV Record the voltage on the Calibration Record under DMM Input Type the actual reading into the Overall Current Voltage Measured box NOTE Type the reading in volts for example for 100 millivolts type 1 Tab to the Overall Battery Voltage Measured box The Calibration K value changes Adjust the CS 2000 for a DMM reading of 50mV Record the voltage under DMM Input In the Present Readings area of the Calibration dialog
55. e Summary box Refer to Summary Screen 13 13 Saving a Report The Report Generator can save a report as a binary file and an archive file Either file type may be opened later and viewed or printed Reports are saved by default in the folder last opened unless a different folder is selected 49 13 13 1 Binary BBR Format Save in Reports You may use the Report Generator to open a binary file and customize a report Select options in the Reports dialog box to create different styles of reports for the same data To save a report in BBR format click Save in the Reports box In the Save As box select the folder type the file name then click Save NOTE BBR files saved with BCT 2000 software Version 1 07 cannot be read by earlier versions of the program 13 13 2 Archive ZRF Format Save Archive in View Reports Form The Report Generator and the Archive Reader can open archive files An archive file cannot be changed after it is saved Archive format lets you distribute the report file while ensuring the integrity of the data To save a report in ZRF format click Preview in the Reports box When the View Reports Form box appears click Save Archive In the Save Archive box select the folder type the file name then click Save 13 14 Exporting in Database DB Format Export in Reports The Report Generator can export a report as a comma delimited text file for use by commercial database programs Files saved as c
56. e load bank is displayed as a binary count along the toolbar when a square is black that step is on in the load bank NOTE The value in amps of the load change depends on the type of load bank used Typically this value is less than one amp per step For a larger increment change the user defined step size on the toolbar To determine the actual amp value for each weight divide the load bank s total amp capacity by the total weight count Refer to the Load Bank screen to determine the total weight count 32 20 10 5 1 and All Off You may also use the 20 10 5 and 1 buttons to change the total weight applied to the load To turn off all the steps click All Off When the test is running you may click F2 Pause to pause the test and remove the load NOTE Instead of using the manual mode to change step weights you may use the Test Steps dialog box to change the actual load current or power Refer to Test Steps 12 4 View Alarms During Test The Test screen indicates real time alarm conditions for cells intertiers and OV During testing to view the alarm history click the View Alarms button Refer to View Alarms 12 4 1 Cell Alarm When a cell goes into alarm the bar graph for the failing cell changes color the BCT 128 or BCT 256 alarm sounds and the cell number and string designation are logged in the alarm history A cell alarm occurs when the cell voltage drops below the programmed Cell Warning voltage level The normal
57. ee ses ee ee ee 11 config battery button 18 connecting the BCT 2000 14 15 constant current button ee esse ee ee ee ee ee 23 constant power button 23 contact personnel screen sss 29 COTTECTION ATEA ii ee Ee ier i eee 24 RRE e AAA i Ea 43 Ve EE 53 54 59 cursor ball on graph seeeess 31 D DA EE 53 data acquisition module iese see See DAM database format 50 DB Tie ee ES DE Ge ee 50 delete battery button esses 18 delete button 25 28 delete site button 18 diagnostiCs oL erectos b e Cen d 53 DUS tet ertt eto Ro Dane te as 57 RE 53 OUE EN ES 54 load bankies GER SE GR Ee teret 55 EIS EE EE EE 57 diagnostics screen 11 disable on filter screen 47 display board see se ee eene 53 DOS software upgrade iese se ee ee ee 70 drill down report 52 d rationiateas eee erre 30 duration column 25 E edit view button 56 electrolyte temperature fest 12 enable on filter screen 47 enable check box eere 45 enter factory backup code 6 enter password o eoo eon 6 equalize chareng sese 13 CTO COUTE iicet oerte ERE Exe REO EE 54 error TESSABES iier Get DR GE Se See eb ev 76 exclude cells button 35 expand all test results graphs check box 44 52 export button ge Taten 50 F F1 buttons on screens See the button names factory backup code 6 file type BB ie Sits d
58. ee xL Printer with power adapter ink jet cartridges and manual o O Printer cable O 1 Printer paper package Optional Equipment 1 CS 2000 calibration source 1 Power cable for CS 2000 2 37 pin I V IT test cable 3 ft 1 Load control cable 50 ft 0000 Checked By 79 23 Appendix C Spare Parts BCT 2000 Series Recommended Spare Parts List Part Number Description Suggested Quantity 1100 457 Cell Board is EE ettet een 2 1100 462 VIT ore RE ortas 1 1100 234 System Board Serial sess 1 1100 477 Interface Board 1 1100 468 Power Supply erstens niniin 1 1100 450 Mother Board Assembly se 1 1100 458 VO Harness ei nett ERE EE ENEE 1 1100 463 Low Voltage Harness eee 1 1100 464 High Voltage Assembly esses 1 1100 469 Fan Assembly ss o mee ee 1 1100 457 Input Harness stented i CERN 2 1100 459 Load Control Hamess esses 1 1100 453 Sense Lead Extender Cable Assembly 25ft 2 1100 452 Load Control Cable Assembly SOft 1 2025 012 Computer Interconnect Cable 37P 37P 1 2025 116 Computer Interconnect Cable 37P 9P 1 2025 200 Computer Interconnect Cable 9P 9P 1 6003 001 AC Power Cable Im 2 2120 012 Sense Lead Che 25 4707 002 LOK ResietOr EE Sk ed EE terrre enis 25 2025 107 Printer Cable attt emitte N 1 80 A A D deviation threshold
59. ees see see se ee ee ee Se ee ee 31 step column peteret tette 25 step n buttons on diagnostics screen 55 56 ON setup screen oo ee ee cess ee ee ee ee ee 28 Step resistance tese nr teret eee 55 Step WEI SDE se Reese eg ek Ee teres 28 32 ii iese OO ER rep nhe 33 steps resistance Screen 56 Ste A E 55 stop test button 31 summary button 41 summary SCTEEN enne ee 41 system A ei a aesae S ENE 14 A es inn a Ee ut 4 T taskbar aen a 5 temperature ambient eie ES E 13 Core SE ti iba 24 RE 24 US EE 12 test controlling rete 31 ia ARE EE EE E a Er 13 Starting eee Eee E 31 test adjustments screen 35 test leads aren sees ee se ee ee ee ee ee ee 31 CA einari i 10 30 test screen toolbar iese ee ee ee ee ee Ge 35 IesCSetuD cce RE Eege 19 WII PE 36 change during test 36 test Ste E 25 test steps screen ee see ee ee ee ee ee ee ee be ee 36 test time are EE EO a IE 30 SERS EE 19 dolus ASE que ree rer IS 22 modified performance 21 performance ee see se ee se ee Se ee ee ee 20 Techarge eet aaae Ee 23 ak lee cene tert eere Reto YER 22 EE 21 time interval button 43 toolbar on test Screen ese ee ee ee 31 total cell number eene 19 EXD EES 50 V VETSION SCIOCD EE IE NG 11 view alarms button 37 view reports form items eee 42 view reports form screen iese eee eee eens 49 voltage area on test screen oe eee eee eee 31 voltage polarity
60. ells per String NOTE When using multiple strings this value is the number of cells per string not the total number of cells NOTE If using multiple strings the program automatically drops one test lead between strings Cell Voltage Click the appropriate Cell Voltage button then click OK NOTE Battery cell voltage initiates the warning and shutdown levels in the test setup For every two cell volts the cell warning level is set to 1 75 V and cell shutdown to 1 60V The OV overall voltage alarm levels are a multiple of these levels times the number of cells per string For example a 6 volt cell voltage defaults to a warning level of 5 25 volts and a shutdown level of 4 80 volts NOTE When a battery is reconfigured all previously set intertier assignments are cleared 11 3 Test Setup On the Setup menu click Test Setup The Test Setup dialog box allows selection of test type discharge to perform length of the discharge and load to be applied Single string applications test a single string multiple string applications test up to eight strings at one time charger testing performs a test on the battery charger and recharge mode monitors the battery during recharging 11 4 Test Types You may configure six test types Performance Modified Performance Service Rundown Charger and Recharge Each type saves specific parameters and test steps Select a test from the Test Type drop down list before running a test Each test is
61. ember that values only need to be entered if Auto Detect Step Resistance is not enabled Click OK to exit the Steps Resistance dialog box Click the appropriate Step 1 to 16 on the Load Bank dialog box to turn on the step corresponding to the step number If power is supplied to the load the step resistance is displayed Toggle the button to turn the step on or off With no power to the load bank you may use an ohmmeter to read each step resistance Results of the load bank diagnostics may be needed by Alb rcorp to assist in troubleshooting 56 14 4 Bus Typically this option is used only at the factory during product manufacturing and test A special bus analysis board is required The screen displays technical diagnostics for circuit boards in the BCT 2000 system It is not a user diagnostic screen and should only be used with the assistance of Alb rcorp technical personnel Ch p PETERET fI i E TEE Figure 48 Bus 14 5 Misc The Misc dialog box permits testing of the audible alarm inside the BCT To test the alarm click the Sonalert button to toggle the alarm on and off Don War Eoad Euri Bar r Figure d9 Misc 57 15 System Calibration This section describes the calibration of the BCT 2000 system First check the system in the as found condition If all as found parameters are within specification calibration does not have to be performed Calisratinn Figure 50 Calibration
62. eted to 0 zero in the capacity calculation For any steps targeted to zero the time of that step will not be used in the calculation Include Steps Starting and Ending Values For a multi step test select this box to see the starting and ending values of the steps The starting and ending times are included in the report Clip Start and End of Test for Report In the Start and End boxes type the clip values for the start and end of a report in hh mm ss format This is used when the BCT does not control the load or there is no load interval or low load at the start and end of the test To determine the clip values on the Criteria box enable OV Deviation On the Summary box select only the battery text txt report To compile the report click Preview From the report determine the time where the voltage drops or current is detected This is the start clip time The time where the voltage rises or current is no longer present is the end clip time Set the end clip time on the Options box to one second less than the actual value found For example if the voltage rises at 13 minutes 00 seconds type 12 minutes 59 seconds for the end clip time Enable Select this box to clip the start and end times for the report 13 7 Cell Detail Screen Click the Cell Detail tab to display the Cell Detail dialog box This box lets you automatically or manually select the cells included in the cell detail report Pre Export Save Load Pro
63. etup file Complete all text boxes before performing any test or reports may have incorrect or missing data Location Battery Strings Test Setup Intertier Load Bank Contact Sibe Rang slbercog d Add Sita Address 30 Soup Rogers Circle Dulete Site ES 11 Boca Rabon FL 33457 Battery Mame Battery 1 D Add Battery Battery Installation 3 zm Dalsie Battery Mex Scheduled Test 3 57155 Battery Manufacturer Battery Model im Battery ID Figure 4 Location Site Name and Address Information in the Site Name text box creates a subdirectory in the BCT Reports directory Battery Name and Dates Type the battery installation date and next test date in mm dd yy format NOTE The present date appended to the battery name is the default file name of the report generated at the time of test Battery Manufacturer Model and ID At Battery ID note any specific identification number associated with the battery being tested 17 Add Site Delete Site To add a site click Add Site To delete a site select the site name from the Site Name drop down list then click Delete Site Deleting a site deletes all the battery information assigned to the site Add Battery Delete Battery To add a battery click Add Battery To delete a battery select the battery name from the Battery Name drop down list then click Delete Battery Deleting a battery deletes all the test information assigned to the battery
64. f the screen indicates battery OV overall voltage load in amps power in kilowatts and the present capacity of the battery The capacity is calculated only during a Performance or Modified Performance test Intertier The Intertier area displays the voltage of each intertier Single click on a bar to display the value of an intertier Double click the graph to increase it to full screen In this mode the graph does not update To return to normal view press ESC BCT 2000 Test Type PerFormance 10 12 48 am Aj ele el l 2 05 Step Test Time SungiCeli FF Sg 1 of 1 Step Total Test Leads 0A Duration 91 00 00 Elapse Time 00 00 36 00 00 36 Voltage 2 044 F2 Pause ram Max Cell Min Cell Avg Cell Amps 150 RemainingTime 00 59 24 00 59 24 z05 294 ET F3 Manual Figure 16 BCT Test Nudge Next to the Amps value are arrows that slightly increase or decrease nudge the load within target when in the auto mode When controlling the load the BCT is considered on target when the target current plus 1 5 of target current plus 1 5 amps is achieved For example on a load of 500 amps the BCT 2000 could set the load at 500 amps plus 1 5 7 5 amps plus 1 5 amps or as high as 509 amps The Nudge control lets you change the load to move the current closer to 500 amps Duration and Test Time Individual cells or modules are displayed in a bar grap
65. fy load bank has power 1 V IT board malfunctioning Unable to control load Steps missing or resistance too high or too low Resume the test in manual mode and adjust specific loads to determine problem 76 20 System Specifications Power Consumption BCT 128 65 Watts BCT 256 trente 75 Watts Input Voltage BCT 128 and BCT 256 120V AC 60Hz or 220V AC 50Hz Input Number of Channels Reading Range Accuracy Cells Up to 256 0 to 20V 0 1 of reading 0 01V Overall Volts 1 0 to 300V 0 1 of reading 0 2V 0 to 600V 0 1 of reading 0 4V Current 1 0 to 3000A 0 1 of reading 3A Intertiers 8 0 to 3V 0 1 of reading 1mV Alarms Warning Shutdown Cell 0 to 20V 0 to 20V Overall Volts 0 to 600V 0 to 600V Current N A 20 of program current for 10 sec Intertiers 200mV N A Hardware N A Immediate Input Data Points Stored At Reading Changes Cell Voltages 10mV Overall Volts 0 17 of reading Current 1A Intertiers End of test reading only RAM Update Every 10 minutes or 1K buffer Accuracy guaranteed from 40 F to 120 F to 95 relative humidity non condensing Beyond the rated temperature range accuracy may be degraded by 0 05 per F 77 21 Appendix A BCT 128 Parts List Quantity Description Checked BCT 128 data acquisition logging unit O Power cable for BCT O Operating manual for BCT 2
66. ges to ensure the integrity of the information In Export mode the Report Generator exports files in formats that can by used by commercial database programs or text editors Sample Data Use the file reportdemo btr performance test or betdemo btr modified performance test to try the features in the Report Generator 13 1 Starting the Report Generator After the system performs a Load Test you may generate a report for battery data analysis To generate a report from a completed test click Reports on the main menu then open the file The Reports main dialog box has five buttons and seven tabs Preview Export Save Load Properties Summary Criteria Options Cell Detail Graph Fiter Notes Figure 29 Reports Main Screen Top Click a tab or button to open dialog boxes The following sections describe the items in each dialog box To exit the Report Generator click the x in the upper right corner of the Reports main dialog box 13 2 Opening a Report When the Report Generator is started the Open dialog box appears S ben ia 3 Seed IP EI S Baar TH pi ETA S Een ig 25 33H TR ml ET Dinan AFR we 1 3 rm Fia pe ESCT OM Fari Pref med Figure 30 Open 40 The Files of Type drop down list lets you select BCT 2000 text BTR binary BBR or archive ZRF files The BCT 2000 test software generates BTR format the Report Generator generates BBR and ZRF formats You must open a file
67. gram controls all aspects of the BCT 2000 system During the calibration process data is saved to the BCT2000setup mdb file located under programfiles alber bct2000 setup This file contains calibration setup configuration and password information Refer to Calibration Backup At a minimum back up BCT2000setup mdb upon receipt of equipment or whenever the unit is calibrated or the password is changed so the data can be reloaded if the file becomes corrupted Use Microsoft Explorer to back up the file from the hard drive to a 3 5 inch disk If the program becomes corrupted re install it from the CD program disk or the 3 5 inch disks The program does not overwrite an existing BCT2000setup mdb file upon re install To start installation insert the CD or Disk 1 into the computer and select StartlRun from the Windows desktop At the Run dialog box type d setup or other appropriate drive letter then follow the on screen instructions After installation if the data is still corrupt copy the backup BCT2000setup mdb file from the 3 5 inch disk over the existing file on the hard drive If the backup file is not available delete BCT2000setup mdb from the hard drive and re install the program again When no BCT2000setup mdb file is present the program creates one At this point either recalibrate the BCT system or re enter the calibration constants K factors from the calibration report before using the BCT system for testing To star
68. h format Presently active step duration and target value in amps or watts are in the lower left of the screen The Test Time area displays the present step total test times 30 Test Leads and Voltages Click a bar on the graph to cause a cursor ball to appear above the bar The cursor denotes the cell on which the status area to the right of Test Time is reporting The status area indicates the cell voltages and test lead numbers The maximum minimum and average cell voltages are displayed below the status area Toolbar Toolbar items at the top of the screen are for excluding or including cells that went into shutdown changing alarm levels changing test step duration and load changing the number of graph bar lines zooming in on a bar line and viewing the alarms list At the BCT Test screen all connected cells are displayed in a bar graph format Verify the displayed readings of two or three cells and OV overall volts with a digital voltmeter If the display and the DVM do not agree refer to System Calibration in this manual 12 1 Start the Test Verify equipment connections are secure and equipment is in operating mode If using Alb rcorp load banks ensure the step weights are configured properly Refer to Load Bank F1 Start Test If load banks are being used set the load bank AC power switches to ON If no problems are apparent to start the test click F1 Start Test on the BCT Test screen or press the F1 key Dur
69. ights in the software and its documentation will be as defined in Clause 51 227 19 c 2 of the FAR RESTRICTED RIGHTS LEGEND Use duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph c 1 ii of the Rights in Technical Data and Computer Software clause at DFARS 252 227 7013 Alb rcorp 990 South Rogers Circle Suite 11 Boca Raton FL 33487 Information in this document is subject to change without notice BCT 2000 Series and BCT 2000 Software User s Guide Book Revision 4 0 P N 4200 003 1999 2000 Alb rcorp 990 South Rogers Circle Suite 11 Boca Raton FL 33487 This manual may not be copied in whole or in part without express written permission from Alb rcorp Microsoft Microsoft Windows and Microsoft Explorer are either trademarks or registered trademarks of Microsoft Corporation Pentium is a trademark of Intel Corporation Safety Information e Except as explained in this manual do not attempt to service Alb rcorp equipment yourself Opening the equipment may expose you to dangerous voltages Refer servicing beyond that described in this manual to authorized personnel e Do not allow liquids or moisture to get into the equipment If liquid does get into the equipment unplug it immediately and contact your nearest authorized service center or Alb rcorp directly e Ensure equipment is provided adequate ventilation Do not block equipment ventilation openings e Do not ex
70. ing the test the cells degrade as the load is applied to the battery Click a bar graph to cause a cursor to appear above the bar The cursor denotes the cell on which the status area to the right of Test Time is reporting The status area indicates the minimum and maximum cell voltages average cell voltage and the test clip lead numbers If the graph is in the active screen press the left or right arrow keys to move the cursor to the previous or next cell bar At the end of the test a message indicates the load test is complete When disconnecting any equipment power down the continuous load bank first then power down the rest of the system WARNING When disconnecting equipment power down the load bank first then the rest of the system 12 2 Load Test Control While the test 1s running several options are available Stop Test Pause Resume and Manual F1 Stop Test To stop the test click F1 Stop Test or press Fl A message appears to confirm the test should be stopped F2 Pause and F2 Resume To pause the test click F2 Pause or press F2 Pause lets you make changes Do not pause the test for extended periods of time during load testing because the cells will recover during the idle period When the test is paused F2 Pause changes to F2 Resume 31 12 3 Manual Load Bank Control F3 Manual and F3 Auto The system defaults to automatic control For manual control click F3 Manual or press F3 after the test has starte
71. ion process calibration data is saved to the bet2000setup mdb file under programfiles alber bct2000 setup It is strongly recommended that you back up this data file to a 3 5 inch disk to save having to recalibrate the system if the BCT software must be re installed Refer to Software Installation and Backup 68 16 Maintenance The BCT 2000 Series test system should provide years of service if properly maintained Clean the laptop computer screen and case using a soft cloth slightly moistened with water Do not use commercial or industrial cleaners that may attack the computer display and housing Never expose the computer or the BCT 128 or BCT 256 to water high humidity or dampness WARNING Before cleaning any component ensure the system is disconnected and power to the unit has been shut off Sense Leads Clean the BCT 2000 sense leads after each use The acid to which the sense lead clips are exposed during testing should be neutralized often using a water and baking soda mixture Brush this mixture onto the sense lead clip then rinse well with clean cool tap water When cleaning the sense lead clips with any water or water based solution ensure the system is disconnected and power to the unit has been shut off Dry with a clean soft cloth The BCT 2000 is microprocessor based and has no user replaceable components Also because high voltage exists in several areas in each unit only knowledgeable users should remove the covers
72. libration is not required e Ifthe preamp needs calibration then the overall current and intertiers must be calibrated Power on the BCT and the CS 2000 Start the BCT 2000 software 59 15 4 Cell As Found DEE O UR E 8 9 10 11 Complete the Cell Before Calibration section of the Calibration Record as follows On the main menu click Calibration to open the Calibration dialog box Set the DMM to volts Connect the DMM to the CS 2000 Cell 1 banana jacks Set the CS 2000 Cell 1 switch to 12V Observe the DMM voltage reading Record the voltage on the Calibration Record under DMM Input In the Present Readings area of the Calibration dialog box observe the value in the Cell 1 box Record the value under Cell As Found Set the CS 2000 Cell 1 switch to 2V Observe the DMM voltage reading Record the voltage under DMM Input Observe the value in the Cell 1 box Record the value under Cell As Found Remove the DMM from the CS 2000 15 5 Overall Current As Found 1 Ud MES e 10 11 12 13 Complete the Overall Current Before Calibration section of the Calibration Record as follows Set the DMM to millivolts Connect the DMM to the CS 2000 0 200mV jacks Set the CS 2000 Reverse Polarity switch to plus Adjust the CS 2000 for a DMM reading of 50mV Record the voltage on the Calibration Record under DMM Input In the Present Readings area observe the value in the Amps
73. may be typed in this area Figure 39 Notes You may add notes to the report by typing them in this dialog box Notes may include details about test results or equipment used and appear on the last page of the report To make the notes permanent save the file as a BBR file 13 11 Report Properties Screen Properties Click the Properties button to display the Report Properties dialog box a HE m Figure 40 Report Properties 48 Change Use the Properties dialog box to edit site information then click Change to cause the changes to take effect Click the x in the upper right to close the window To close without saving the changes do not click Change To make the changes permanent save the file as a BBR file 13 12 View Reports Form Preview Screen Preview After all report parameters are selected to view the report on the screen click Preview Each section of the report is displayed one page at a time To change the size of the page display click Page Width or Full To view different pages in one section click the first previous next or last page buttons at the top of the screen f e ator atm ema Aca mmn A Cus Gras Seiten rm rn Teri Hans Cell General Starting Fleet Voltages Nn load Batler Voltage i whips Figure 41 View Reports Form To view different sections of the report click the tabs along the top of the screen A tab appears for each item selected in th
74. mmed intertier warning level You can program a warning level and shutdown level for each intertier For no shutdown set the intertier shutdown level to 0 zero AMMESSI e CRW Figure 13 Intertier Intertier Cell Assignment Intertiers are assigned by string and cell Select the intertier needing assignment by clicking the appropriate Intertier Cell Assignment button 1 to 8 String and Cells Assign a string to the intertier from the String drop down list then determine the cell pair the intertier is on and click the appropriate Cell n n button Repeat the above steps for all required intertiers To remove an intertier assignment double click the Cell n n button for the intertier If no Cell button is selected then no cell pair is assigned to the presently selected intertier To view more cell pairs click the left or right arrows 27 11 7 Load Bank On the Setup menu click Load Bank The Load Bank dialog box appears Load Bank 1 a a a BR z a Figure 14 Load Bank Load Bank SN ID Add and Delete The BCT can configure multiple load bank setups To select a setup click a name in the Load Bank SN ID drop down list To add a setup name click Add The name Load Bank n appears in the Load Bank SN ID box and in the drop down list To change this name overwrite the name in the box with a new name You can assign ratings and step weights to each load bank setup name To delete a name in the
75. ng alarm indicates a warning and a solid tone indicates a shutdown To silence the alarm click Yes in the Warning or Shutdown message box If the OV Warning level is lowered the OV comes out of alarm and the OV display returns to background color but the event is retained in the alarm history Use the Adjust Alarm Levels toolbar button to change the level Refer to Alarm Levels 34 12 5 Test Screen Toolbar The Toolbar buttons that appear along the top of the BCT Test screen are shown below Js ES EB e Figure 21 BCT Test Toolbar Use the buttons to exclude or include cells that went into shutdown change alarm levels change test step duration and load change the number of graph grid lines zoom in on a bar axis and view the alarms list These buttons are described in the following sections 12 5 1 Cell Exclusion Exclude Cells fra To remove a cell from the test click the Exclude Cells button In the Cell Exclusions dialog box click Add Cell type the string and cell number then click Exclude The string and cell appear in the list in the Cell Exclusions dialog box A box with a check mark indicates the cell is excluded from the test To include an excluded cell back into the test clear the check box You can exclude cells before a test and during a test without pausing the test You can include them back during a test without pausing Excluding and including a cell from the test automatically adjusts battery al
76. nstallation or use of this software product constitutes your acceptance of and agreement with the terms of this Software License Agreement LICENSORS All software on this media is licensed to you by Alb rcorp GRANT OF LICENSE You are granted the right to use the Alb rcorp Software on a single personal computer You may copy the software to use with this personal computer to any one hard disk drive of this personal computer and to the memory of this personal computer provided that you reproduce all copyright and trademark notices restricted rights legends and other proprietary markings RESTRICTIONS You may not sublicense rent or lease the Alb rcorp Software You may not reverse engineer decompile disassemble modify translate or create derivative works of the Software LIMITED WARRANTIES AND LIMITATION OF LIABILITY The limited warranties and limitation of liability in Section 1 of this file apply to are incorporated in and are made a part of this Software License Agreement EXPORT LAW ASSURANCES You acknowledge and agree that the Software is subject to restrictions and controls imposed by the United States Export Administration Act the Act and the regulations thereunder You agree and certify that neither the Software nor any direct product thereof is being or will be acquired shipped transferred or exported directly or indirectly into any country or used for any purpose except as authorized by the Act and the regulations
77. omma delimited text have the extension DB To save a report in database format click Export in the Reports dialog box In the Save In box select the folder under which the file will be saved Reports are exported by default to the folder last opened unless you select a different folder In the File Name box type the file name In the Save As Type box select DB Format To save click the Save button In the DB format data is in the following stream Line 1 Header Information Test Location Test Date Test Start Time Test End Time Battery ID Battery Type Installation Date Line 2 Test Information Time Overall Voltage Current Cell 1 Cell 2 Cell 3 Cell x 13 15 Exporting in Text TXT Format Export in Reports The Report Generator can export a report as an ASCII text file for use with a text editor Files saved as ASCII text have the extension TXT To save a report in text format click Export in the Reports dialog box In the Save In box select the folder under which the file will be saved In the File Name box type the file name In the Save As Type box select Text Format To save click the Save button 13 16 Printing a Report Print Current and Print All To print only the pages under the currently selected tab click Print Current on the View Reports Form screen To print all the pages under all the tabs on the screen click Print All When Print All is clicked a print dialog box appear
78. or cowling from devices when required Failure to comply with this restriction could void the system warranty WARNING High voltages exist inside the BCT 2000 system components and on the CS 2000 terminals Calibration must be performed only by technically qualified persons Observe electrical safety precautions when removing and installing the BCT cover and when connecting leads and making adjustments The shipping cases will protect the BCT 2000 from normal bumps and bangs when stored properly and will provide protection during shipment between test sites 69 17 Upgrading BCT 2000 Software Upgrading the BCT 2000 software from the DOS to the Windows version involves the following steps If you need assistance contact Alb rcorp Technical Support 17 1 Replace the 87C52 Processor Before the Windows BCT 2000 program can communicate with a BCT 128 or BCT 256 that was being used with the DOS BCT 2000 program the 87C52 processor must be changed in the BCT 128 or 256 1 2 3 4 Power down the BCT and disconnect it from AC power Remove the six screws under plastic caps located along the sides of the BCT cover Remove the cover The 87C52 U21 processor is located in a socket on the right most vertically mounted board At this point the technician you should be connected to ground with a ground strap or you should discharge any static electricity by touching a grounded object WARNING Notice that the top corner of the
79. ormation and a combination of the two may be necessary After resistance values are entered the data is saved with the load bank setup information for the currently selected load bank RA O OOOO OOOO E ne DAM over od Basies Jus Laut Carat iw Bahai Vitara Dio Blas Baihiunra Zoe Step 1 OF TE Sip n IF Sep OM AT seines hane E up iia ep 400 eg Se Step 7 CH Suy 11 OF m Eng Sep IE OM m napa DT Sep OT 12 08 Se IE OM Five Figure 46 Load Bank Diagnostics To set up the load bank resistance first select a Start Step in the Resistance Test group Depending on shunt rating selecting Start Step 3 or 4 is recommended because lower steps produce very low voltages across the shunts which may result in inaccurate readings Select a Stop Step in the Resistance Test group Ensure there is sufficient current to drive the stop step selected Verify the Battery Voltage box displays battery or charger voltage If the voltage is not displayed fix the electrical connections before continuing with the test To begin the load bank resistance test click Start The graph fills with resistance values Observe the bottom axis of the graph labeled 1 2 3 1 3 4 and so on Plots on the graph alternately indicate the resistance of an individual step and the cumulative parallel resistance of the steps up to that step Double click the graph to maximize it NOTE If you did not enter the password the test runs but values are not stored
80. ose issued by IEEE you can help ensure a safe effective load test Before performing a load test determine the type of test to perform the length of the test and where to locate the equipment during testing If the test includes the use of Alb rcorp DC load banks a well ventilated area is required to disperse heat from the resistive load bank In most cases the BCT 128 or BCT 256 is placed near the battery being tested and the load bank is within 50 feet of the battery and BCT WARNING Do not place the load bank in a room that has an automatic halon or other fire system The heat generated by the load bank could inadvertently trigger the fire system Either locate the load banks in a safe area without such a system or take other measures to prevent the inadvertent activation of the automatic system Before connecting the BCT 2000 to the battery being tested and prior to any load testing Alb rcorp recommends performing the following tests on the battery 9 1 Micro Ohmmeter During the battery discharge test the test system discharges the battery at a high current rate Ohm s Law shows that a high rate of current through a high resistive connection results in a large amount of power being dissipated through the connection This could cause excessive heat build up and result in premature termination of the test Therefore use a micro ohmmeter to ensure there are no high resistive connections between individual cells modules or inter
81. ove the DMM from the CS 2000 15 7 Intertier As Found 1 2 3 4 10 11 12 13 Complete the Intertier Before Calibration section of the Calibration Record as follows Set the DMM to volts Connect the DMM to the CS 2000 0 200mV jacks Adjust the CS 2000 for a DMM reading of 150mV Record the voltage on the Calibration Record under DMM Input In the Present Readings area observe the value in the IT 1 box Record the value under Intertier As Found Repeat steps 4 and 5 for Intertiers 2 through 8 Adjust the CS 2000 for a DMM reading of 100mV Record the voltage under DMM Input In the Present Readings area observe the value in the IT 1 box Record the value under Intertier As Found Repeat steps 7 and 8 for Intertiers 2 through 8 Adjust the CS 2000 for a DMM reading of 50mV Record the voltage under DMM Input In the Present Readings area observe the value in the IT 1 box Record the value under Intertier As Found Repeat steps 10 and 11 for Intertiers 2 through 8 Remove the DMM from the CS 2000 61 15 8 Preamp Offset and Gain As Found 1 Oy ue HE d Complete the Preamp Offset and Gain Before Calibration section of the Calibration Record as follows On the main menu click Diagnostics then click I V IT on the drop down menu Set the DMM to millivolts Connect the DMM to the CS 2000 0 200mV jacks Set the Reverse Polarity switch to plus and adjust the CS 2000 for
82. ow Voltage Warning sese neen rennen 26 11 5 10 Recharge Hours nte ERO nra RD PR ER OE 26 11 6 riel ien rre d enee AE ovens EA EE DE Seet 27 iv 11 7 Load SE 28 11 8 COMA E 29 11 9 Voltage MET EE 29 12 RUNNING THE SE ET ER EE 30 12 1 Startthe OE EE 31 12 2 PRES ESE RE EO NE EE ER EE ET 31 12 3 Manual Load Bank Control es n eret ter e RR e TO eR ESPERE REET 32 12 4 View Alarms During Test RE OE EE rer Rete ree EUER Rentas 33 TZAT o INA EE eet HE RE EE RE EG 33 12 452 Intertier Cable Alarm E 34 12 4 3 Overall Voltage Alarm see se ee ee Ge ee ee nennen nennen nooo rennen nn non eene enne enne 34 12 5 Test Screen Toolbar esee etr E GER Re ee VERG DERS De DER Ge RR Ge Ge DERE Ee ER Oe SE VER EN GR Ee 35 12 5 l ell EU Ee 35 12 32 Alarm Levels eene DERE DE Ee EV RE GED Ee Ge Ge ARE RSG eg VER Ge RR oa Ge er DERE Seep ER Oe gek Ee eg es 35 12 5 3 Tes EE 36 12 5 4 le e Graphite nette tertie e EE EE HERE 37 T2 5 5 PAIN ET 37 12 6 Charger Test Screen e eae OR EE desea OE EEN 38 12 7 Hardware Cinca Lc 39 13 REPORT GENERATOR aere 40 13 1 Starting the Report Generator 40 13 2 Opening Report ie OE EE EE OE EE Ee 40 13 3 Loading a File at Estee EO EE EE AE EK OE 41 13 4 SUMMALY SCHESD M REDDE 41 13 5 GUIDE INIMICI oa 43 13 6 GI CIR miii EEEE E E E E E T E E EEE E 44 13 7 Cell DetallScteeu iE eee EE OE EE N GR IE 45 13 8 Graph Screens e eao E oE EEEE EE E EEE E E E A ETE I
83. perties Summary Criteria Options Cell Detail Graph Fitter Notes f Bubs Selec Siring 1 Cel 12 E EJ51nng 1 Cal 13 E Manual Select 15trina 1 Cel 14 OSinng 1 Cali 15 All Oni OString 1 Cell 16 E Bing 1 Sell 17 LlISting 1 Cell 18 All Off ElSiring 1 Cell 19 O ining 1 Cel 20 OSiing 1 Celi 21 Omring 1 Cel 33 OSting 1 Cell 23 EN Figure 36 Cell Detail 45 Auto Select Click Auto Select to automatically select cells that were at or below the low threshold level In auto select mode you may manually select additional cells for the report by selecting check boxes in the list To clear a selection select the box again If you later change the low cell threshold on the Criteria box cells that meet the new criteria are automatically selected and cells manually selected before the threshold change are not selected Manual Select Click the Manual Select button to manually select cells for the report Add cells to the report by selecting the check boxes To clear a selection select the box again Changing the low cell threshold does not change selected cells when in the manual mode All On and All Off Click All On to select all cells in the list Click All Off to clear all cell selections You may use this feature in auto or manual mode 13 8 Graph Screen Click the Graph tab to display the Graph dialog box The values displayed are 10 below the minimum and 10 above the maximum values found during the
84. r 22 11 4 6 Recharge Test The recharge test monitors the battery system while it is being recharged For every two cell volts the cell warning level is set to 2 33V The OV warning levels are a multiple of these levels times the number of cells per string On this test the levels are high level maximum values Location Saiten Stringa Test Sea intarticr Load Bank Comtact Test Type Recharge Cell Valage FP f ur a FA foi 2 Alarm Levels Dobei E CNN 71 bieter Cal Warming 13 z ss 7 F1 DEER Let s ch 9 8 Recharge Hours Figure 12 Test Setup Recharge 11 5 Test Setup Parameters The following items are available on the Test Setup dialog boxes depending on the test type selected 11 5 1 Rated Time Available for test types Performance Modified Performance Type the manufacturer s specified rated time in the Rated Time box This value is important for the on line capacity calculation performed during a single step capacity test The format is hh mm ss If doing a Modified Performance test you may leave Rated Time blank You may type 0 zero for Rated Time on a Modified Performance test If this is done the test does not calculate battery capacity at test time You may enter a Rated Time at report generation 11 5 2 Power Type Available for test types Performance Modified Performance Service Charger Constant Power and Constant Current To define power type click Constant Power
85. r shall Alb rcorp be liable for the cost of retrieving or replacing lost or corrupted data Alb rcorp s sole and exclusive liability for any and all losses and damages arising out of any cause whatsoever shall in no event exceed the purchase price of the software product purchased NO LIABILITY FOR CONSEQUENTIAL DAMAGES Alb rcorp shall not in any case be liable for any damages including special incidental indirect exemplary collateral or consequential arising from breach of warranty breach of contract negligence or under any other legal theory arising from the warranty herein stated or the purchase of product including without limitation loss of profits use or goodwill Some states and countries do not allow the exclusion or limitation of incidental or consequential damages therefore the above exclusion or limitation may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary state to state and country to country 2 Software License Agreement THIS IS A LEGAL AGREEMENT PLEASE READ BEFORE INSTALLING SOFTWARE Any use of this media other than to review this Software License Agreement constitutes your acceptance of and agreement with the terms of this Software License Agreement with respect to the Alb rcorp Software If you do not accept and agree to these terms you must return the full product with proof of purchase to Alb rcorp within thirty 30 days for a full refund I
86. rformance test can now optionally ignore steps when the load is targeted to zero See the Ignore Zero Target Steps section A High Low voltage warning has been added to Charger test See the Charger High Low Voltage Warning section Manual mode now has four fixed weight buttons 1 5 10 and 20 These buttons manually control the load to the desired target more quickly than the one button in previous versions Also the Manual mode user defined weight has been increased from 32 to 200 weights per increment See the Manual Load Bank Control section You can now manually exclude cells prior to and during testing without pausing See the Cell Exclusion section The duration and target of the presently running test step and all following test steps can now be modified without pausing the test See the Test Steps Area section On the Charger test a Voltage Load History graph replaces the cell graph History is limited to 10 minutes See the Charger Test Screen section A charger and battery text report of voltage and load is now available See the Summary Screen section Brackets and in reports indicate values that violate thresholds A color printer is no longer required See the Criteria Screen section The Percentage of Cell Failure in reports is now user definable instead of fixed at 8096 See the Criteria Screen section You can now clip the start and end of a report when the BCT doesn t control the load and there is no load
87. s Performance Modified Performance Select this box to calculate the capacity when the target value is reached The test time advances only when the target is reached The test time but not the test stops if the load falls below target and resumes when the target is reached 11 5 8 Ignore Zero Target Steps Available for test types Modified Performance Ignore Zero Target Steps in Capacity Calculation Select this box to ignore steps when the load is targeted to 0 zero in the capacity calculation For any steps targeted to zero the time of that step will not be used in the capacity calculation 11 5 9 Charger High Low Voltage Warning Available for test types Charger Charger High Voltage Warning and Charger Low Voltage Warning Type values in these boxes to activate a warning when high or low voltage levels are exceeded If values are set to 0 the warning is not active 11 5 10 Recharge Hours Available for test types Recharge Recharge Hours Type the number of hours that the recharge will be monitored 26 11 6 Intertier On the Setup menu click Intertier This dialog box defines the location of intertier and interrack connections so the BCT can add the voltage back to the cell that the intertier follows Otherwise the cell just before an intertier connection would appear lower in voltage than it actually is When using intertier monitoring an alarm occurs when the intertier voltage drop is greater than the progra
88. s do the following Connect the 50 load control cable two Amphenol 37 pin connectors on each end from the BCT Load Control port to the Load Control Input on the side of the optional load bank This connector is usually labeled J2 however refer to the drawings that came with the load banks Connect the heavy load cables from the load banks to the battery as shown in the drawings that came with the load banks The BCT 2000 is now mechanically ready to perform the desired load test Power on all the equipment at this time except the Alb rcorp continuous load banks After the BCT 2000 system has initialized and the main menu appears on the computer power on the load banks When disconnecting any equipment power down the continuous load bank first then power down the rest of the system 16 11 Setting Up the BCT 2000 for Load Test The BCT 2000 program lets you use the computer to set up all test parameters Refer to the following Setup dialog box descriptions to program the test parameters At this point the BCT 2000 main menu must be displayed The computer does not need to be connected to the BCT 128 or BCT 256 unit On the main menu click Setup A drop down menu with Location Battery Strings Test Setup Intertier Load Bank and Contact appears Complete each item as described 11 1 Location On the Setup menu click Location Site and battery information is saved with each test report and permanently saved in the BCT S
89. s which lets you specify print all pages the current page or specific pages the number of copies and the printer setup 50 13 17 Opening an Archive File Load in Reports and Open Archive in View Reports Form A BCT 2000 Archive ZRF file is the only file type that may be opened while a text or binary file is open Archive files cannot be changed To open an archive file click Load on the Reports dialog box In the Open box at Files of Type select BCT 2000 Archive from the drop down list select the file name then click Open Figure 42 Typical Archive File The archive file opens and is displayed Use the buttons along the top of the screen to change the page size and view different pages To print the report click the Print button at the top left To close the file click the Close button 51 13 18 Drill Down Reports A Drill Down Report graph displays the cell voltage versus test time A report for each cell that fails minimum voltage threshold level can be automatically or manually displayed on the Test Results pages ViewReportsForm x Print An Print Current 14 4 NN SaveArchive Page Width Full Open Archive BCT 2000 Battery Load Test Report Test Results The Following cells dropped below the low threshold level of 0 850 Vs Cell Step Step Time Test Time Capacity 4 1 02 37 54 02 37 54 87 7 String 1 Cen 4 START 00 16 00 00 30 00 00 45 00 01 00 0
90. s are printed in color and with brackets lt gt for black ink printers These values may be changed if desired High Voltage Warning and Low Voltage Warning For the Charger test the Alarm Threshold Values area changes to Charger Warning Levels These are the warning levels entered in test setup or the last levels entered during the test On the report values that violate these thresholds are printed in color and with brackets gt for low threshold violation and for high threshold violation for black ink printers These values may be changed if desired Rated Time Rated Time is used by Capacity test reports and may be modified at report time 43 Cell Failure The percentage of cell failure is used by Capacity test reports and may be modified at report time The value was previously fixed at 80 for reports but may now be changed NOTE Changing the threshold rated time and percentage failure values affects which cells are indicated on the report as failing 13 6 Options Screen Click the Options tab to display the Options dialog box Summary Criteria Options Cel Datail Graph Fitter Notes Report Tile 367 2000 Battery Load Test Report Expard All Test Resulis Graphs F Footer Text Printed Includa Power in Report F Footer Page Mumbar Gan Capacity Calculation al amer 9 Footer Date Printed Ignora Zero Target Steps in Capacity Calculation T Include Steps Starting and Ending values
91. sense leads labeled OV OV IT 1 IT 2 and so on to the open end of the sense lead extender cable 12 Connect the clip labeled OV Overall Voltage to the most positive post on the battery Connect the clip labeled OV to the most negative post on the battery 13 Connect Clip 0 from the first set of red sense leads to the positive post of Cell 1 This is the same point the OV lead was placed in the previous step 14 Place Clip 1 on the positive post of Cell 2 unless Cell 1 is the most negative cell If it is the most negative cell then connect the lead to the negative post of Cell 2 Continue this step until the entire battery has been outfitted 15 In installations of more than 32 cells or modules it is necessary to use another set of sense leads Connect the A lead of each new set to the same post as the last lead from the previous set 16 The last cell will have two leads the overall voltage lead and sense lead Place the clip with the Cell Number minus 1 count on the positive post and the Cell Number on the negative post of the final cell 15 17 18 19 20 21 22 Connect the leads labeled IT 1 and IT 1 to the first intertier connection Follow this sequence with the remaining IT sense leads Leave the unused IT sense leads free Refer to Drawing BCT 350 D1105 for sense lead connection to the individual cells intertier cables and overall volts connections If using Alb rcorp load bank
92. ser emper dee Pene De oe be Ee ERG ee see 12 94 Temperature Ambient ener peer EE Ge BED Ge GE KG ee Ee Gee Ge EE Ge GE epe EN EEN Gee he 13 9 5 Equalize Charen RE EA oil 13 9 6 Test HIStory EE 13 10 CONNECTING THE SYSTEM EE 14 10 1 IRC ER KE 14 10 1 1 Optional Load Banks Battery Isolatedt AAA 14 10 1 2 Optional Load Banks Supplemental Load esee 14 10 1 3 System Load ii tesis EER ES BE ig EE ES se Se Ee RR ed Peis pee aia asa 14 10 2 BCT 128 BCT 256 Connection Steps iese see se ee ee ee ee GR RA Ge Gee Ge ee Se ee ee eene 15 11 SETTING UP THE BCT 2000 FOR LOAD TEST 17 11 1 LOC AUN EE 17 11 2 Battery SINES iie MERE ORE ede aie ete a i eet 18 11 3 KEE 19 11 4 TEST EE 19 RS ES Performance Tests EE 20 11 4 2 Modified Performance Test 21 11 4 3 Service Test EE 21 11 44 ie MEER EER OE HE OER EE OE 22 IB AEN Gru MET 22 11 4 6 Recharge E 23 11 5 Test Set p Parameters ss ox oet tie rte iN ERU RA iN IU es 23 TT Debs Rated RL 23 11 5 2 ROWER TYDE REGSES Ee Re EE Se eg SG NE EES 23 1153 Temperature and Correction cete ii 24 L b Cell Voltage SEE SEE EG OR NER CERERI UTE IRE Ee DE Se 24 11 53 Alarm ievels Area iuo ire Ee Ee SE GE eed eet tese cutie ub SE ge ee bete evt ee 24 11 36 Test Steps ATea eot Re IE OR ii rens 25 11 5 7 Calculate Capacity at Target ooo eoo Uie ai 26 11 38 Ignore Zero Target Steps Eeer ee ER REN RUNE Ee 26 11 5 9 Charger High L
93. ses the last known value for time interval e Load control has been improved for load banks that have multiple steps with the same weight value Previously the scaling factor was incorrectly calculated when a load bank had multiple steps with same weight value This caused the BCT to take extra time to achieve target value The following are changes that affect the manual or the program operation e The manual is now available in HTML Web page viewer and PDF Adobe Acrobat viewer formats on the program disk The manual has more screen shots Items on the screens are in bold type and followed by full descriptions Most items on the screens are indexed e All cells in reports are now referenced by string name not string number e You can now configure multiple sites with multiple batteries See the Location section e Attest time the capacity can now optionally be calculated when the target value is reached See the Calculate Capacity at Target section e There are now nudge buttons to nudge the load to within target when in the auto mode When controlling the load the BCT is considered on target when the target value plus 1 596 of target value plus 1 5 amps is achieved For example on a load of 500 amps the BCT could set the load at 500 amps plus 1 5 7 5 amps plus 1 5 amps or as high as 509 amps The Nudge control lets you move the load closer to 500 See the Running the Test section In the capacity calculation the Modified Pe
94. signation is logged in the alarm history The normal bar graph color is green yellow indicates a warning condition and red indicates a shutdown The intertier bar graph is on the upper right of the Test screen Double click the graph to increase it to full screen In this mode the graph does not update To return to normal view press ESC An intertier cable connection alarm condition occurs when the intertier exceeds the programmed level The Intertier bar graph indicates the failing intertier A beeping alarm indicates a warning and a solid tone indicates a shutdown To silence the alarm click Yes in the Intertier Warning or Shutdown message box Carefully examine the intertier and its connections to determine if it is safe to continue the test If the Intertier Warning level is raised the intertier comes out of alarm and the bar graph returns to green but the event is retained in the alarm history Use the Adjust Alarm Levels toolbar button to change the level Refer to Alarm Levels 12 4 3 Overall Voltage Alarm When the overall voltage goes into alarm the OV display changes color the BCT alarm sounds and the OV event is logged in the alarm history An OV alarm occurs when the overall voltage drops below the programmed Warning voltage level The normal OV display color is the screen background color yellow indicates a warning condition and red indicates a shutdown The OV V display is on the upper left of the Test screen A beepi
95. t the BCT 2000 program double click the BCT icon on the desktop On an 800 x 600 screen the Windows taskbar hides a portion of some BCT screens Either drag the taskbar to minimize it or right click on the taskbar then select PropertieslAuto Hide to hide the taskbar WARNING The computer power management feature which automatically shuts down the computer hard drive and display after a specified time of inactivity must either be disabled or set to a time long enough to allow testing without going into the suspend mode Also check the computer BIOS to determine if power management features have been set WARNING For Windows 95 and 98 under Control PanellSystemlPerformancelFile System in the File System area confirm that at Typical role of this machine Desktop Computer is selected WARNING Under Control PanellSystemlPerformancelApplication Performance on Windows NT set the Boost control to None 5 Password When you select certain functions a password dialog box appears The default password from the factory is alber Entiat Pasawornd to modify CALIERATION FACTORS Press ESC to wiew only Entar Password Change Enter Factory Backup Code fy o Cancel Enter Password H lost call dectory dor Backup Code Figure 1 Password Type the password in the Enter Password box and click OK To change the password click Change and follow screen instructions Some screens that require a password m
96. test Preview Export _ Save Ln Properties Sumenary Criteria Options Cell Detail Graph Fater Notes Cel Scang OW Scaling Caso Merl 24 Cono Mel 553 amp Manual Min Sal Manual Mm Ga Lead Sealing Power Being C Ada Max 1552 C Ano Mel 31 e Manual Min 22 al E Manual Min ona Low Cel Crtena Label Ka ShutDown Low UN Entera Label Battery ShutDown Figure 37 Graph Manual To change the minimum and maximum values displayed on report graphs click Manual and select values The Cell Scaling and OV Scaling values are in volts Load Scaling is in amps and Power Scaling is in watts Auto If Auto is selected the graphs are plotted to within 3 of the values Low Cell Criteria Label and Low OV Criteria Label You may type new graph names in these areas for report graphs 46 13 9 Filter Screen Click the Filter tab to display the Filter dialog box The values displayed are the minimum and maximum values found during the test This dialog box lets you eliminate bad values such as those caused when a clip lead falls off Figure 38 Filter Disable is the default selection To change values click Enable then type a value or select a value Cell Data Filter and OV Data Filter values are in volts The Load Data Filter is in watts 47 13 10 Notes Screen Click the Notes tab to display the Notes dialog box Motes lo be added to the rapor
97. the CS 2000 for a DMM reading of 350V Record the voltage under DMM Input Observe the value in the Battery OV box Record the value under Overall Battery As Left Adjust the CS 2000 for a DMM reading of 600V Record the voltage under DMM Input Observe the value in the Battery OV box Record the value under Overall Battery As Left Remove the DMM from the CS 2000 66 15 13 Intertier Calibration 1 AD EA ge 10 11 12 13 14 15 16 17 18 19 Calibrate if the preamp was calibrated or if As Found readings are not within specification 0 1 of reading 1mV Complete the Intertier After Calibration section of the Calibration Record as follows Set the DMM to volts Connect the DMM to the CS 2000 0 200mV jacks Click the Intertier 1 button on the Calibration dialog box Adjust the CS 2000 for a DMM reading of 100mV Type the actual reading into the Intertier Voltage Measured box NOTE Type the reading in volts for example for 100 millivolts type 1 Press ENTER to increment to the next intertier Repeat steps 6 and 7 for Intertiers 2 through 8 Click Intertier 1 on the Calibration dialog box Adjust the CS 2000 for a DMM reading of 150mV Record the voltage on the Calibration Record under DMM Input In the Present Readings area observe the value in the IT 1 box Record the value under Intertier As Left Repeat steps 10 and 11 for Intertiers 2 through 8
98. tier connections Refer to the battery manufacturer s maintenance instructions for a safe range of readings 9 2 Hydrometer Prior to load testing read the specific gravity of the sample electrolyte to confirm the battery is fully charged Reading cannot be performed on sealed cells but can easily be done on wet cell batteries Although this data is not entered into the BCT program you may want to record it separately and attach it to the final test report Specific gravity is a good indicator of the present charge of the battery If all cell float voltage readings are within normal limits you may limit the hydrometer readings to a 1096 sample 9 3 Temperature Electrolyte While taking specific gravity readings measure the electrolyte temperature of each cell Record this data and then calculate the average temperature of the electrolyte in the cells being tested The BCT 2000 requires that the temperature be entered for certain tests Use this average value for temperature correcting the load during test setup 12 9 4 Temperature Ambient Record the ambient temperature of the battery room prior to testing This data is entered into the BCT 2000 program and the load can be temperature corrected to IEEE standards 9 5 Equalize Charging IEEE Std 450 for flooded cells and Std 1188 for VRLA cells and most battery manufacturers recommend that a battery be equalize charged at least seven days before performing a discharge test an
99. to highlight it Exiting a field or pressing ENTER saves the data entered Duration Double click on the Duration field for the desired step and type the time the step is to operate in hh mm ss NOTE If running a capacity test where the battery must perform for a certain time at a single discharge rate select a time at least 50 longer than Rated Time The time must be longer than the theoretical run time so the test shuts down on voltage rather than time for a more accurate capacity test For example if the test is one hour enter a time of at least 1 hour 30 minutes This ensures testing to at least 100 of capacity Amps or Watts Use TAB or the mouse to move to the Amps or Watts field The column heading depends on the test type Type the amps or watts required when using optional load banks If using the BCT 2000 as a portable data logging unit without load banks and the system load or other load control is being used type 0 in this field Add Delete and Insert If this is a performance or rundown test there is only one step If this is a modified performance charger or service test program the additional required steps To add more steps click Add A new step appears in the list To delete a step highlight the step to be deleted by clicking the step then click Delete To insert a step highlight the step that will follow the new step then click Insert 25 11 5 7 Calculate Capacity at Target Available for test type
100. tus area 8 3 Reports The Report Generator creates a report of a completed test This is the only screen that provides a final report or transfers test data to a file The types of reports and options for creating reports are described in the section Report Generator Report options include Summary Criteria Options Cell Detail Graph Filter and Notes Report files reside in the Reports site name subdirectory unless a different subdirectory was selected at time of test 10 8 4 Diagnostics Diagnostics allows selection of the DAM I V IT Load Bank Bus and Misc dialog boxes from which BCT 2000 and load control system diagnostics are performed Use Diagnostics when a problem is encountered or when performing technical checks with the assistance of Alb rcorp 8 5 Communications Select Communications to select the COM port for the computer 8 6 Calibration Select Calibration when BCT 2000 system calibration is required 8 7 Version Select Version to access the help files or determine the software version number 11 9 Recommended Tests Prior to performing any type of battery test you should review battery theory and the battery manufacturer s maintenance and test procedures Alb rcorp strongly recommends following the IEEE Std 450 1995 publication on battery maintenance and testing for flooded cells and IEEE Std 1188 1996 for VRLA batteries By using the battery manufacturer s suggested testing procedures and th
101. urrent Count reading on the I V IT dialog box Adjust RV2 rear pot on the I V IT board so that the current count at plus polarity is within 30 counts of the current count at minus polarity Repeat steps 8 to 12 several times until count between plus and minus does not vary more than 30 counts This sets the preamp offset When the counts are within specification set to 100mV and record the DMM Input and Current Count As Left then set to 100mV and record the DMM Input and Current Count As Left Set the Reverse Polarity switch to plus and adjust the CS 2000 for a DMM reading of 100mV Adjust RV1 front pot on the I V IT board for a Current Count of 20001 430 counts on the I V IT dialog box Record the Current Count under Current Count As Left This sets the preamp gain Remove the DMM from the CS 2000 Close the I V IT dialog box After preamp calibration the overall current and intertiers must be calibrated 63 15 10 Cell Calibration mU Oy Ue PR PD uem 9o 10 11 12 13 14 Calibrate if As Found readings are not within specification 0 1 of reading 0 01V Complete the Cell After Calibration section of the Calibration Record as follows On the main menu click Calibration Set the DMM to volts Connect the DMM to the CS 2000 Cell 1 jacks Set the CS 2000 Cell 1 switch to 12V Observe the DMM voltage reading Type the actual reading into the Cell Voltage Measured box on th
102. weights Step Number Step Weight 1 OO N OO So ND eo 11 12 13 14 15 Press ESC to return to the previous menu 5 Press ESC to return to the main menu and press ESC to exit the program 6 Start the Windows BCT program by double clicking the BCT icon To open the calibration dialog box select Calibration from the main menu and enter the password alber Type the Calibration K values recorded above 7 To open the Load Bank setup dialog box select Load Bank from the Setup menu and enter the password alber Type the shunt rating value recorded above Type the load bank step weights recorded above 8 If more than one load bank configuration is required click the Add button and configure a second load bank Repeat as necessary to complete the load bank configurations 9 The Windows BCT program is now ready for operation 72 18 BCT 2000 Calibration Record Customer CELL Before Calibration After Calibration 0 1 of reading 0 01V Selected Input DMM Input Cell DMM Input Cell Reading As Found Reading As Left 12V 2V OVERALL Before Calibration After Calibration CURRENT 0 1 of reading 3A Selected Input DMM Input Overall Current DMM Input Overall Current Reading As Found Reading As Left 50mV 100mV 150mV 50mV 100mV 150mV 73 OVERALL BATTERY Before Calibration After Calibration 0 1 of reading 0 4V

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