Whisper Power WPC-BSI 500 Battery Status Interface User Manual

Whisper Power WPC-BSI 500 Battery Status Interface

Product Information

Product Usage Instructions

• The battery capacity is defined as the quantity of electrical charge that a full battery can supply at a given current before reaching a certain voltage. The unit generally used is the Ampere-hour (Ah). An ideal battery of 100 Ah will, for instance, supply 10 Amperes (A) during 10 hours or 1 A during 100 hours.
• To reach the given capacity, the manufacturers charge their batteries according to standard procedures (for instance, as per the norm IEC-60896-11). This kind of charge can last up to many tens of hours at very high voltages, which is rather far from normal conditions of use. Therefore, the real available capacity is lower than what is given by the manufacturer.
• The capacity of the battery varies according to the temperature of the active substance. A decrease in temperature leads to a decrease in capacity, while an increase in temperature improves the capacity.
• The capacity also varies according to cell imbalance and discharge current. Big discharge currents lead to a decrease in capacity as the active substance needs time to spread into the cells. To convert the capacity from one discharge duration to another, you can use the Peukert formula.
• The capacity of the battery decreases along the charge-discharge cycles, with deep discharges having a particularly negative impact. High ambient temperatures also lower the lifetime of the battery.

INTRODUCTION

GENERAL
The BSI (Battery Status Interface) is designed to monitor lead-acid batteries used with inverter chargers of the WPC range. An advanced algorithm provides the battery state of charge in real-time to best optimize its use. The BSI offers voltage measurement for 12, 24, and 48 V nominal batteries as well as current measurement with a resistive shunt. Thanks to the WPC communication bus, the BSI can communicate with the other devices of the system. The remote control WPC-PSCP/RCC makes it possible to configure the BSI and display the values that it measures. More than this, the WPC inverters can react according to various data given by the BSI.

GENERAL IDEAS OVER BATTERIES
Lead-acid batteries are energy storage with complex behavior. They consist of 2 Volt (V) nominal cells in series to reach the required voltage. Due to different physical and chemical phenomena, they can show, depending on the conditions, a behavior quite far from the reservoir that simply fills up and empties. This is the reason why the battery state of charge is complex to determine and why a lead-acid battery monitor is not as precise as, say, a petrol gauge.

The different values that affect a battery are described below.

Defining the capacity

• The battery capacity is defined as the quantity of electrical charge that a full battery can supply at a given current before reaching a certain voltage. The unit generally used is the Ampere-hour (Ah). An ideal battery of 100 Ah will for instance supply 10 Amperes (A) during 10 hours or 1 A during 100 hours.
• The capacity is usually given for a new battery, at 20 °C, with a discharge down to 1.8 V per cell (10.8 V for 12 V nominal, 21.6 for 24 V, and 42.3 V for 48 V). The time of discharge is given by the letter C followed by the duration in hours, like C10 for 10 hours.
• To make them reach the given capacity, the manufacturers charge their batteries according to standard procedures (for instance as per the norm IEC-60896-11). This kind of charge can last up to many tens of hours at very high voltages, which is rather far from normal conditions of use. This is why the real available capacity is lower than what is given by the manufacturer.

Capacity and temperature
The capacity varies according to the temperature of the active substance of the battery. A decrease in the temperature will lead to a decrease in capacity and an increase in the temperature an improve the capacity.

Capacity and cell imbalance
The capacity varies according to the temperature of the active substance of the battery. A decrease in the temperature will lead to a decrease in capacity and an increase in the temperature an improve the capacity.

Capacity and discharge current
The capacity goes down when it comes to big discharge currents. The active substance in the battery needs time to spread into the cells and a quick discharge will lead to a capacity decrease. To convert the capacity from one discharge duration to another, one can use the Peukert formula.

Capacity over the battery lifetime

• The capacity decreases along the charge-discharge cycles.
• The deep discharges have a particularly negative impact.
• High ambient temperatures lower also the lifetime.

Capacity report with a Peukert coefficient of 1.25

CONVENTIONS

Symbols

• This symbol is used to indicate the presence of a dangerous voltage that is sufficient to constitute a risk of electric shock.
• This symbol is used to indicate a risk of material damage.
• This symbol is used to indicate information that is important or which serves to optimize your system.

Regarding the parameters
All values mentioned hereafter, followed by a parameter number indicate that this value may be modified using the WPC-PSCP/RCC remote control. In general, the default values are not mentioned and are replaced by a parameter number in the following format: {xxxx}. The default values for this parameter are specified in the defaults parameter table Chapter 8: “ Factory setting values ” (p. 17).

WARRANTY AND LIABILITY

Warranty and liability
During production and assembling, each BSI gets several controls and tests. They are carried out in full respect of fixed procedures. Each BSI is given a serial number allowing a perfect follow-up of the controls, in conformity with the specific data of every device. For this reason, it is very important to never remove the descriptive sticker bearing the serial number. The production, the assembling, and the tests of each BSI are entirely carried out in our supplier factory. The warranty of this product depends on strictly following the instructions in this manual. The warranty period for the BSI is 5 years.

Exclusion of warranty
No warranty will be applied for damages caused by handling, operation, or actions that are not described in this manual. Damages arising from the following events are not covered by the warranty:

• Overvoltage on the device.
• Reverse polarity while connecting the battery.
• Liquid in the device or oxidation due to condensation.
• Failures due to a fall or to a mechanical shock.
• Modifications made without the explicit authorization of Whisper Power BV.
• Nuts or screws are partially or insufficiently tight during installation or maintenance.
• Damages due to atmospheric overvoltage (lightning).
• Damages due to transport or improper packaging.
• Disappearing of original marking items.

Exclusion of liability
Installation, commissioning, use, and maintenance of this device cannot be supervised by Whisper Power. For this reason, we do not accept any liability for the damages, the costs, or the losses generated either by an installation that is not conforming to the prescriptions, by a defectuous operation, or by poor maintenance. The use of this device is under the responsibility of the end-user. This device is neither designed nor guaranteed for the supply of life support applications or any other critical application with potential risks for human beings or the environment. We shall assume no liability for patent infringement or other third-party rights involved in the use of this device.

SAFETY PRECAUTIONS

Exclusion of liability
Do read carefully all safety instructions before proceeding to the installation and commissioning of the device. Not respecting these instructions might constitute a lethal physical danger but can also damage the functionalities of the device. Therefore keep this manual close to the device. Do, for any installation, follow strictly the local and national norms and regulations in force.

Warnings

• This device is used together with a permanent energy source (battery bank) and can also receive an alternative source at its input. Before any handling, it is then necessary to disconnect all energy sources from the device.
• Even when the device has been disconnected from its supply source, there might remain a dangerous voltage at the outputs. To avoid any accident, it is necessary, after disconnection, to wait at least 30 seconds before operating on the device
• Never use this device in a place where explosions might occur. Do refer to the indications of the battery manufacturer to ensure the compatibility of the battery with the device. The safety instructions of the battery manufacturer have to be followed strictly too!
• Wherever the installation is, the person in charge of installation and commissioning must know perfectly the safety measures and the prescriptions in force in the country. Therefore, the whole maintenance must be carried out by a qualified
• All components connected to this device must conform to the laws and regulations in force. The persons without written authorization from Whisper Power BV are forbidden to make any change, modification, or repair whatsoever. Regarding authorized modifications and replacements, only genuine components shall be used.
• This device is meant for use only indoors and must under no circumstances stand in the rain, the snow, or any other humid or dusty
• In case of use in motor vehicles, this device must also be protected against vibrations by absorbing

Precautions while using batteries
Lead acid batteries with liquid electrolytes produce a highly explosive gas during normal operation. No source of spark or fire should be present in the closeness of the batteries. The batteries must be installed in a well- ventilated space and mounted to avoid accidental short circuits while connecting them.

Never charge frozen batteries! During any work on batteries, a second person must be present in case a problem occurs that requires assistance. There should be within reach enough fresh water and soap for an immediate washing of the skin or the eyes in case of accidental contact with acid. Should it happen, they must be washed carefully for at least 15 minutes with cold water. It is then necessary to immediately consult a doctor.

DECLARATION OF CE CONFORMITY

EC Declaration of Conformity/Incorporation

By EN ISO 17050-1:2004, We Whisper Power BV, Kelvinlaan 82, 9207 JB Drachten, The Netherlands hereby declare that:

BSI

• Model number: 500/1200
• Serial Number: All serial numbers are in conformity with the applicable requirements of the following documents:

Ref. No. Title

• EN 60950 2005  Low voltage directive 2006/95/EC
• EN 61000-6-2 2005 Generic Emission directive 2004/108/EC EN 61000-6-3 2007
• RoHS  RoHS directive 2002/95/EC Signed by:

Name: Dr. R.E.Bosman, Technical Director, Drachten Date: Document ref. BSI The technical documentation for the machinery is available from Whisper Power BV, Kelvinlaan 82, 9207 JB Drachten, The Netherlands

DIMENSIONS

VIEWS OF DIFFERENT SIDES WITH DIMENSIONS

EXPLODED VIEW

INSTALLATION

MOUNTING
The BSI must be mounted as close as possible to the battery. In this way, the measurement perturbations are minimized and the temperature sensor integrated in the box gives a more accurate measure of the battery temperature. If the BSI has to be installed in another room, it is possible to use the temperature sensor BTS that will be connected to the WPC. In that case, the temperature of the BTS will be automatically taken into account for the state of charge calculation. Ideally, the BSI can be stuck directly to the battery. It can also be mounted close to the battery using the fixing plate supplied with (see Figure 2). The direct mounting on the battery offers a more precise measurement of the battery temperature. While changing the battery bank, the BSI will have to be stuck again with a new double-sided adhesive.

The BSI must be mounted to avoid any contact with acid from the battery. It should be taken care of fixing it vertically with the communication bus connectors downwards.

SHUNT MOUNTING
The shunt supplied with the device allows the measurement of the battery current. It must imperatively be installed in series with the negative terminal of the battery. The connection (a) of figure 3 must be as short as possible. For a good operation of the charge estimating algorithm, all the current must go through the shunt. No other conductive component shall be connected to the negative terminal of the battery.

The shunt must be exclusively mounted on the negative terminal of the battery

The cabling schematic is available in Figure 4.1. The cabling procedure is as follows:

1. Connect the shunt to the negative terminal of the battery
   • Beware of the cable cross-section! All current (WPC + solar module(s) or consumer(s) directly connected to the DC side) will go through this cable for the charge and discharge of the battery.
2. Connect the white and yellow wires of the BSI cable to the screw of the shunt on the battery side (b).
3. Connect the green wire of the BSI to the second screw of the shunt (c).
4. Connect the red wire with a fuse to the positive terminal of the battery (d). It might happen while connecting the red wire to the battery that a spark is generated. No damage is likely to happen or to damage the device.
5. Connect the negative cables of the inverter, the solar regulator, and/or DC consumers to the free bolt of the shunt. The positive cables are connected straight to the positive terminal of the battery (e).
6. Connect the communication cable to the communication bus of the WPC system and activate, if necessary, the linkend (f). For more information see Section 4.4.

CONNECTING THE COMMUNICATION BUS

The devices of the WPC range are equipped with an owned communication bus (WPCbus) for data exchange, configuration, and updating of the system. Connection is being made by linking the devices with the communication cables. One gets then a bus online where a link end must be activated on the devices on each end, to obtain the configuration of the Figure 3. Each device is equipped with a switch offered to choose between open “O” or terminated “T”. The devices at the end of the line must be set on “T” and all the others on “O”.

A wrong setting of the link ends can lead to an erratic running of the installation or impede its updating.

QUICK START GUIDE
You will find in this chapter the procedure to follow to configure the BSI during installation. For the major part of the systems, this is good enough. For a full list of the parameters that can be set refer to Chapter 7.

CHOOSING THE BATTERY CAPACITY
The battery capacity must be configured. The manufacturer gives it at various discharge times (see Section 1.1). If several capacities at different times are supplied, the discharge time in 10 hours (C10) must be chosen because these are the reference conditions for the state of charge calculation. From the initial display of the RCC and using the keys UP and DOWN, move to the configuration menu of the BSI parameters, then push SET.

To modify the parameter “Battery Capacity” {6001}, move with the arrows UP and DOWN to the general menu.

Then push on SET to enter the menu. With the arrow DOWN, move to the parameter “Battery Capacity”.

To modify its value push on SET. The value turns in reverse video.

Change the value for one of your batteries with the keys UP and DOWN. Confirm by pushing on SET. Then, configure the parameter “Nominal Discharge Time(Crating)” {6002} the same way as for the battery capacity.

CHOOSING THE SHUNT
If you are using a shunt supplied with the BSI-500, the BSI is configured for it and you can go directly to the next section. Otherwise, the measuring shunt must be configured. The shunts are meant to supply a measuring nominal voltage at a nominal current. If you use the BSI-1200 shunt, the nominal current is 1200 A at 50 mV. If you use your shunt, the current and the nominal voltage are given by the manufacturer and are often printed on the shunt. The parameters “Nominal Current of the shunt” {6017} and “Nominal Voltage of the shunt” {6018} of the advanced menu enable configuring the BSI for a given shunt.

RESET THE BATTERY HISTORY TO ZERO
If you install the BSI for the first time or if the battery has been changed, you must reset the battery history to zero, using the parameter {6003}.

DISPLAY OF THE STATE OF THE BATTERY

BATTERY MONITOR
On installations with a BSI, the view over information on the battery of Figure 6.1 is added to the WPC-PSCP/RCC. In area (A), four values of the BSI are displayed. The symbol of the battery in (B) gives a quick overview of the state of charge (SoC). The direction of the current is given in (C). An arrow upwards means the charge, and downwards, the discharge.

GRAPH OF THE STATE OF CHARGE HISTORY
It is possible to see the battery state of charge for the last 5 days on the WPC-PSCP/RCC. For that purpose, from the view over the battery information, you enter selection mode with the key SET. The battery is then selected as in Figure 6.2. The key SET allows them to display the graph. The graph of the state of charge in Figure 6.3 is then displayed. On the horizontal scale are today and the last 4 days. The graduations indicate every hour from midnight to midnight. Each horizontal pixel means one hour. The vertical axis gives the state of charge of the battery. The graduations mean 20, 40, 60, 80, and 100 %, and one pixel means 2 %.

VALUES TO DISPLAY
It is possible to modify the values to display on the battery view. For that, from the basic view of Figure 6 push on  SET. The battery is then selected as in Figure 7. Go to the first value displayed with the key DOWN. The keys UP and DOWN allow going to the field to configure. With the key SET, enter the menu corresponding to the value to display. Then, choose the value to displayusingf UP and DOWN and push on SET to validate. At any time, to quit, use the key ESC that will bring you to the previous view.

The values available are the following:

Displayable values on the BSI view

battery charge reaches 100 %. During discharging, it indicates the time before it reaches 0 %. This value is calculated based on the present current. What it gives is an indication. A variable energy consumption

has of course a big impact on this value.

Battery temperature| °C| Temperature is used to calculate the battery state of charge. Unless a BTS is connected to the WPC and therefore its value is taken into account, this is the temperature measured inside the BSI that will be used.
Relative capacity| –| The ratio between the effective capacity of the battery and its nominal capacity.
Ah charged today| Ah| Charge supplied to the battery from midnight until now.
Ah discharged today| Ah| Charge supplied by the battery from midnight until now.
Ah charged yesterday| Ah| –
Ah discharged yesterday| Ah| –
Total kAh charged| Kah| Charge supplied to the battery from the last reset to zero of the battery history. See “Reset to zero of the battery history {6003}” (p. 20).
Total kAh discharged| Kah| Charge supplied by the battery from the last reset to zero of the battery history.
Total time| Days| Time since the last reset of the battery history.
Charge counting on the user side| Ah| This value offers the user a charge and discharge measurement according to his needs. This counter, as the following two, can be reset to zero using the parameter “Zero resetting of users

counters {6031}” (p. 21).

Discharge counting on the user side| Ah| –
Duration of the counting on the user side| Hours| –

SETTING OF THE PARAMETERS
A full list of accessible parameters can be found in Chapter

GENERALITIES
The configuration is carried out on the WPC-PSCP/RCC using the BSP parameters menu. Generally, the settings described in Chapter 5: “Quick Start Guide” are enough for a good operation of the BSI. It is however possible to modify many other parameters described in this chapter.

LEVELS OF USE AND ACCESSIBILITY
The functions described below correspond to the level EXPERT. As per the user level selected, access to all these functions might not be possible. Do refer to the chapter user level setting in the remote control manual for more information about this matter.

GENERAL MENU {6000}
The parameters for a basic configuration of the BSI are in this menu.

Nominal capacity {6001}
Battery nominal capacity. It is given for the nominal discharge time defined by the parameter {6002}.

Nominal discharge time (C-rating) {6002}
Discharge time is used to give the battery nominal capacity of the parameter {6001}.

Nominal current of the shunt {6017}
This parameter enables to adjustment of the BSI measurement to the shunt. It must be set according to the nominal voltage ofthe shunt (parameter {6018}). For instance, for the shunt 1200 A supplied with the BSI-1200, the setting will be 1200 A and 50 mV.

The nominal voltage of the shunt {6018}
See parameter {6017}.

Reset to zero of the battery history {6003}
This parameter enables resetting to zero all counters of Section 6.2 and the algorithm during installation on a new battery. This parameter should normally not be used if the battery has not been changed, because then the history (total current, estimated capacity) is lost.

Restore the default settings {6004}
Use this parameter to restore the initial settings of the BSI. If your installer has made some settings at the “installer” level while commissioning your installation, this function restores his settings and not the factory ones.

Restore the factory settings {6005}
With this function, you can find the factory settings. For each parameter, not only the factory value is restored but also the limits and the user level. This function is only accessible with the level installer.

ADVANCED MENU
The advanced parameters for a BSI configuration.

Zero resetting of uusercounters {6031}
This parameter allows reset to zero the charge, discharge, and time user counters of Section 6.2.

Self-discharge coefficient {6019}
A battery gets discharged over time even when no current is consumed. This parameter allows us to take thisphenomenon into account.

Nominal temperature {6020}
The battery parameters are specified for a given temperature, which can be set using this parameter.

Temperature coefficient {6021}
The available capacity diminishes with the decrease of the temperature. This coefficient enables us to take this factor into account.

Factor of charge efficiency {6022}
During charging, less Ah is stored in the battery than during discharging. The ratio discharge/charge can be set with this parameter.

Peukert exponent {6023}
The capacity varies according to the discharge current (see Section 1.4). With this parameter, one can set the Peukert exponent that goes along with the nominal capacity {6001} and nominal discharge time.

Activating the end of charge synchronization {6042}
This parameter activates the function of synchronization at 100 % of SOC under certain conditions of end of charge.

For the synchronization to occur:

• the voltage shall be above parameter {6024}
• the current shall be below parameter {6025}
• and this during a period defined by the parameter {6026}

This function is generally not necessary because the BSI adjusts automatically the state of charge as per the voltage.

End of charge voltage threshold {6024}
See explanation at parameter {6042}.

End of charge current threshold {6025}
See explanation at parameter {6042}.

Minimum time before the end of charge {6026}
See explanation at parameter {6042}.

FACTORY SETTING VALUES

Factory setting values

TECHNICAL DATA

Specification

5 mA @ 24 V
3 mA @ 48 V
Input voltage range

Shunt measurement input range

| 7..85 Vdc
±195 mV
RMS continuous current @ 25 °C| ±500 A (BSI 500)
±1200 A (BSI 1200)
Maximum measurable peak current| ±1950 A (BSI 500)
±4680 A (BSI 1200)
Voltage measurement accuracy| 0.3 %
Current measurement accuracy| 0.5 %
Battery capacity| 20..20000 Ah
Operating temperature range| -20..55 °C
Packed weight| 900 g (BSI 500)
1500 g (BSI 1200)
Displayable values| see chapter 8
Protection degree| IP20
Conformity| LVD 2006/95/EC, EMC 2004/108/EC, RoHS 2002/95/EC EN 60950:2005, EN 61000-6-2:2005, EN 61000-6-3:2007

Readout resolution

±0.1 (10..100)
±1(100..9999)
State of charge| ±0.1 %
Temperature| ±0.1 °C
Time to go| ±1′

INDEX

SYMBOLS

• {6000} General menu, 15
• {6001} Nominal capacity, 15
• {6002} Nominal discharge time (C-rating), 15
• {6003} Reset to zero of the battery history, 15
• {6004} Restore the default settings, 15
• {6005} Restore the factory settings, 15
• {6016} Advanced menu, 15
• {6017} Nominal current of the shunt, 15
• {6018} Nominal voltage of the shunt, 15
• {6019} Self discharge coefficient, 15
• {6020} Nominal temperature, 15
• {6021} Temperature coefficient, 15
• {6022} Factor of charge efficiency, 15
• {6023} Peukert exponent, 15
• {6024} End of charge voltage threshold, 16
• {6025} End of charge current threshold, 16
• {6026} Minimum time before end of charge, 16
• {6031} Zero resetting of users counters, 15
• {6042} Activating the end of charge synchronization, 15

Kelvinlaan 82, 9207 JB Drachten, Netherlands www.whisperpower.com / sales@whisperpower.nl

References

• WhisperPower - Enjoy Green Energy | For a better world
• Solcon Internetdiensten B.V.

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