Thornwave Labs Inc PowerMon-W WiFi IoT Advanced Battery Monitor User Manual

Thornwave Labs Inc PowerMon-W WiFi IoT Advanced Battery Monitor

BRIEF

PowerMon-W is a WiFi / IoT advanced battery monitor / DC power meter. This tool can be used in any battery or DC-powered circuit to monitor, analyze, and log the most important electrical parameters: two voltages (0-72V), current over 1,000A using any external shunt, power (W), energy (Wh), coulombs (Ah) and temperature. Many other parameters are computed: the battery state of charge (% SoC), the remaining time on the battery at the current load, and a multitude of battery / DC power statistics. The device can log the data for up to 3 years, allowing for advanced data analysis and troubleshooting. Logging is done inside an internal FLASH memory. The device can drive a mechanical or solid-state relay which allows it to function as a low-voltage disconnect, high-voltage disconnect, over-current disconnect, temperature controller, battery isolator in multiple battery systems, remote on/off switch, timer, and generator control. A mobile device running either Android or iOS and the PowerMonX app (available for free on Google Play Store and Apple App Store) is required for using this device.

FEATURES

• Measures two voltages, current, power (W), charge (Ah), energy (Wh), and temperature
• Operates at up to 72V
• Can sense up to 160mV of voltage drop across an external current shunt allowing current over 1,000A to be measured
• Fully differential input for the current shunt, allowing it to be mounted on either the positive or negative side
• Data logging (up to 3 years)
• Can drive one relay or SSR (solid-state relay)
• Low/high voltage disconnect
• Over-current disconnect
• Low/high-temperature disconnect
• Generator control
• Battery isolator for dual battery systems
• Battery monitor (battery fuel gauge), displays the state of charge in percentage and the remaining time on the battery at the current load
• Works with all types of batteries
• Lithium iron phosphate battery charge manager
• Timers
• Can use an external temperature sensor (DS18B20-based)
• Very low power consumption (see Performance Parameters)
• 2.4GHz WiFi radio with internal antenna and long range
• 8-pole terminal block for connecting to the system that will be monitored
• ABS plastic enclosure with mounting flanges, completely enclosed in epoxy potting compound
• Measures only 3.0” x 1.55” x 0.75” (76mm x 39mm x 19mm) including the mounting flanges.
• Weatherproof
• PowerMonX app is available free, for Android and iOS.
• Highly configurable. It achieves top performance with all kinds of current shunts and batteries

TYPICAL APPLICATIONS

• RVs, boats, off-the-grid cabins
• Solar and wind alternative energy systems
• Vehicle batteries, battery isolator
• Backup electrical systems
• Lithium Iron-Phosphate battery charge manager
• Automation: solar irrigation systems, solar streetlights, general-purpose DC timers

TERMINAL DESCRIPTION / INTERNAL DIAGRAM

sensor
3| RELAY| Relay output. It drives a mechanical or solid-state relay. To turn the relay

on, the device is grounding this terminal internally.

4| ES1| External shunt connection
5| ES2| External shunt connection

6

| ****

+5V

| 5V from the internal regulator. Can be used to supply external circuits. Can also be used to supply the monitor with 5V. Do not connect to the

battery!!! Should be left unconnected in most installations.

7| V2| Second monitored voltage. Can measure the voltage of a second battery.
8| V1| This is the main voltage that will be monitored. The device also draws its

own power from this terminal.

SPECIFICATIONS

Absolute Maximum Ratings 1,2

Maximum voltage at the V1 and V2 terminals| +72V
Maximum voltage at the RELAY terminal| +72V
Maximum voltage at the +5V terminal| +5V
Maximum current through the RELAY terminal

(maximum relay coil current)

| 2A
Maximum sensed current| depends on the external shunt

(can be over 1,000A)

Maximum differential current sense voltage ES1 to ES2| -72V to +72V
Maximum common mode current sense voltage (ES1 –

ES2)

| -2V to +72V
Operating temperature| -30°C to +85°C

1. Stresses greater than those listed under “Absolute Maximum Ratings” may cause permanent damage to the device.
2. All voltages are referenced to ground (terminal 1) unless otherwise specified.

Measured differential voltage on shunt inputs (ES1,

ES2)

| -160mV to +160mV
Current monitoring accuracy| depends on external shunt precision, typically 0.25% (with

calibration)

Temperature resolution| 1°C / 1°F
Data logging sample rate| 1 sec – up to ~18 days 2 sec – up to ~36 days 5 sec – up to ~90 days

10 sec – up to ~180 days 20 sec – up to ~1 year 30 sec – up to ~1.5 years

1 min – up to ~3 years

Maximum current available at terminal 6 (+5V)| 100mA
Current consumed by the device (using the latest firmware version, access point off, client not connected)

at 12V at 24V at 36V at 48V

at 60V

| 10-minute averages ±5%

4.4mA

2.2mA

1.5mA

1.2mA

0.9mA

Current consumed by the device (using the latest firmware version, access point off, client connected)

at 12V at 24V at 36V at 48V

at 60V

| 10-minute averages ±5%

10.6mA

5.2mA

3.6mA

2.7mA

2.2mA

Current consumed by the device (using the latest firmware version, access point on, client connected)

at 12V at 24V at 36V at 48V

at 60V

| 10-minute averages ±5%

19.0mA

9.5mA

6.3mA

4.8mA

3.9mA

COMPLIANCE STATEMENTS

FCC

• ATTENTION: Changes or modifications not expressly approved by Thornwave Labs Inc. could void the user’s authority to operate the equipment.
• ATTENTION: This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference and (2) this device must accept any interference received, including interference that may cause undesired operation.

IC RSS-102 RF Exemption
This system has been evaluated for RF Exposure per RSS-102 and complies with the limits specified by Health Canada Safety Code 6.

IC RSS-Gen 8.4
This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device.

SAFETY INSTRUCTIONS

Warning!
Read all the instructions and cautions before using the PowerMon-W device. Thornwave Labs Inc. does not assume responsibility for any injury or property damage caused by improper installation, bad wiring, or use of PowerMon-W outside of its intended purpose. The device should be installed by a professional. Do not work on a live electrical system. Disconnect the power sources first (battery, shore power, solar panels, generator)!

Warning!
The PowerMon-W device should not be used for any medical purposes, life- sustaining equipment, safety applications, or any application where equipment failure can cause injury, death, fires, or any other hazard.

Warning!
There are no serviceable parts or fuses inside the device! Do not disassemble or attempt to repair it! The unit operates with voltages up to 72V which can be lethal or cause serious and permanent injury.

Warning!
Do not submerge under water or other liquids. The device is weatherproof but not waterproof.

Warning!
The device is to be connected to DC circuits only, not exceeding 72V. Failure to do so will result in equipment damage. Confirm that all connections are tight to avoid excessive heating, sparks, or fire. Never connect the V1 terminal to a power source without using a fuse or circuit breaker. A 0.1A to 2A fuse or circuit breaker is required.

Warning!
Batteries are dangerous! Do not short-circuit a battery or the battery monitor terminals. Batteries can produce flammable and explosive gases and can generate extremely high currents that can lead to serious consequences including explosion, fire, damage to equipment, personal injury, and even death. It is the user’s responsibility to operate the equipment safely. Do not charge batteries in an enclosed environment unless allowed by the manufacturer of the battery. Never connect a load to a battery without using fuses or circuit breakers, properly sized for the wires/equipment.

Warning!
Although PowerMon-W coupled with a relay can disconnect power if an over- current condition occurs, it should not be used to replace circuit breakers. A properly rated circuit breaker or fuse should be used to protect the load and the wiring!

Warning!
PowerMon-W cannot be used as a charge current limiter or LiFePO cell balancer. A properly sized battery charger is required to recharge LiFePO batteries. Thornwave Labs Inc. does not assume any responsibility for expensive battery damage.

Warning!
Do not use any other WiFi antenna than the one that was provided. Using a different antenna may violate emissions standards imposed by your local EMC regulatory body (FCC for the US, IC for Canada, …)

CONNECTIVITY

PowerMon-W requires a mobile device running the PowerMonX app (client). A connection is established from the client to the PowerMon-W device. Three types of connections are supported:

• Direct connection – from the client to the PowerMon-W which is acting as an access point. This requires the access point feature of the PowerMon-W device to be on. This is typically used for the initial configuration of the device. Since the AP has to be on, the PowerMon-W device is consuming more power, hence this mode should only be used for the initial configuration. The AP will stay on for the first 2 minutes after the device is powered up or continuously if a WiFi station is connected to it. The AP mode can be configured to stay on permanently.
• Local connection – from the client, via the local network (local access point) to the PowerMon-W device. This requires the PowerMon-W to be configured to connect to the local access point. This type of connection offers higher speed and lower latency, making it ideal for downloading the data log. It also requires the client to be in the same network as the PowerMon-W device (connected to the same access point). PowerMon-W is advertising its presence and monitoring data to the local network every 3 seconds.
• Remote connection – from the client, via the Internet to the PowerMon-W device. Lower speed and higher latency should be expected. This requires the PowerMon-W to be configured to connect to the local access point. It also requires both the client device and PowerMon-W to have Internet access.

OVERVIEW

Installation. PowerMon-W was designed to be installed inside an equipment bay, or inside a plastic enclosure where it will be protected from water, high humidity, condensation, and battery or other corrosive gases. The device should not be installed inside an all-metal enclosure since that will significantly reduce the WiFi range and performance. Although the device is potted using epoxy, which makes it resistant to humidity and corrosive battery gases, the terminal block is not.
Use 16-20 AWG wires to make all the required connections in the green terminal block. Use a 0.1A – 2A fuse on the V1 signal (terminal 1). This terminal is also supplying power to the device.

Device power. The PowerMon-W device is drawing its supply power from the V1 terminal. Make sure that V1 is always present. If the device loses power, it will forget the internal clock. Terminal 1 (GROUND) should be connected to the system ground (usually system/battery negative). If the available voltage is less than 8V, use terminal 6 to supply 5V directly. Do not supply more than 5V on terminal 6. This will cause permanent damage. If not used, leave terminal 6 unconnected.

External current shunt. To monitor a large current, an external current shunt is used. This method allows monitoring current over 1,000A. The external current shunt should be connected to the ES1 and ES2 inputs. To avoid electrical noise, the wires should be as short as possible. Twisting the sense wires reduces noise even further. The common-mode voltage at ES1 and ES2 can be between -2V and +72V relative to the ground, allowing the current shunt to be placed on either the positive side of the circuit or the ground wire (negative side). The current reading should be positive when charging the battery and negative when discharging. If the current sign is reversed, swap the ES1 – ES2 wires, or simply change the “Flip Current Sign” switch in the device configuration.

Zero the current offset. Due to the high sensitivity of the current measurement circuitry inside the PowerMon-W device, the value displayed may have a small offset (measurement is different than zero even when the actual current is zero). Typically, this is less than 0.1A. In situations where the measurement precision is critical, the offset can be reduced to zero. To do this, disconnect the wires from the load side of the shunt or make sure the actual current is zero (turn all the loads off). This can also be achieved by turning the power relay off from the mobile application (in case the system is wired with a relay). Long-tap on the “Current” tab and then “Zero Current”. The operation will take 3 seconds to complete during which do not allow any current to pass through the device. Also, do not zero the current offset if the actual current is different than zero. Doing so will introduce a very large offset. Any current that is flowing through the shunt when the Zero Current operation is performed will become the new indicated zero.

Current calibration. Typically, the device can measure current with better than 1% precision. If higher precision is required, the current measurement can be calibrated allowing up to 0.25% of precision. To calibrate the current reading, an amp-meter capable of measuring current with a precision better than 0.25% is required. Connect the amp-meter leads in series with the shunt and read the actual value of the current. Long-tap on the “Current” tab, tap on “Calibrate Current” and then type the actual value measured by the amp-meter. The sign of the current does not matter. Once calibrated, the only way to change the calibration is to reset the device to factory defaults or re-calibrate. The device will not accept a calibration current different from the actual current reading by more than 10%.

Power relay control. PowerMon-W can drive a power relay (either mechanical or solid-state) using the RELAY output (terminal 3). When active (relay turned on), the RELAY terminal is internally connected to the ground by the device. The relay coil should be connected between the power supply (battery positive, typically) and the RELAY terminal. The low/high voltage disconnect, temperature disconnect, over-current disconnect, and generator control functions require the use of a relay / SSR (Solid State Relay).

Low voltage disconnect. When this feature is enabled and the battery voltage drops below a specified threshold, the device turns the relay off, disconnecting the loads to protect the battery from over-discharge. To disconnect the load the voltage must be below a threshold for a configurable amount of time. This feature helps in situations like cranking an engine or a short high current load that causes the battery voltage to momentarily drop. The device will re-engage the power relay for a configured amount of time after the voltage goes back above the connect threshold. This feature also allows the PowerMon-W to operate as a battery isolator. The relay is used to connect the house battery in parallel with the starting battery (see wiring diagrams at the end of this document). The LVD filter value should be set to 5000ms. The disconnect threshold should be set to 13.2V and the connect threshold to 13.6V. When the engine is started and the alternator charges the starting battery, the voltage will start increasing. When the voltage reaches 13.6V (the connect threshold) the relay engages and connects the house battery to the starting battery, allowing all batteries to be charged. When the engine is stopped the voltage will drop below 13.2V (the disconnect threshold) and the relay disengages, isolating the house battery from the starting battery. The house battery voltage can be monitored using the V2 input. Note that the thresholds (13.6V and 13.2V) are just an example. They can be configured to best fit the application.

High voltage disconnect. This function is similar to the low voltage disconnect, but as the name suggests it will disconnect the load when the voltage goes above the disconnect threshold and will reconnect the load when the voltage goes below the reconnect threshold. This mode can be used together with the low-voltage disconnect.

Over-current disconnect. When this feature is enabled and the measured current increases above a user-specified trip value, the device disconnects the load, protecting the batteries and load from over-current. The device will re-engage the power relay for a configured amount of time after the current drops below the trip threshold.

Battery fuel gauge. PowerMon-W computes the battery state of charge and various statistics. This is accomplished by using coulomb counting. For the battery fuel gauge to work properly, the charging current should display positive, and the discharging current should display negative. If the displayed current sign is wrong, it can be swapped by changing the “Flip Current Sign” switch in the device configuration. Small errors in measurement and integrating current over long periods will introduce errors in the state- of-charge estimation. This is normal. For this reason, the device will re- synchronize its SoC counter with the battery every time a full charge is performed. A full charge is detected based on the chemistry of the battery but in general, it requires the voltage to be higher than a threshold while at the same time the charging current is lower than a threshold. The battery fuel gauge will also take into consideration the Peukert effect. The next table shows the Peukert coefficients used for various battery chemistries.

LiFePO charge manager. PowerMon-W can manage the charging of a lithium- iron-phosphate battery. This function cannot be used together with the other disconnected functions. If enabled, the mobile app will automatically disable the other disconnect functions. A relay must be placed in between the battery and the charger, or power source used for charging (the vehicle alternator for example). The function of this relay is to disconnect the charger from the battery if a full charge is detected or the charger is turned off (the engine is turned off for example). To use the LiFePO charge manager, connect the V1 input to the battery positive and the V2 input to the charger positive. The internal shunt and the relay should be wired in between the charger and the battery (see wiring diagrams at the end of this document).

The battery voltage and the total capacity of the battery in Ah should be properly configured. At least one disconnect condition has to be true for at least 2 seconds for the disconnect to take place. The connect conditions must be true for the time specified in “Connect Time” for the connect to take place (default is 10 seconds). The following table shows the conditions used by PowerMon-W to decide whether to connect or disconnect the charger from the battery (turn the relay ON/OFF). Current refers to the current flowing in between the battery and the charger. “C” refers to the battery capacity. Care should be exercised to ensure that the current is positive when the battery is being charged and negative if it is being discharged. If wired backward, use the “Flip Current Sign” option to fix it.

Connect Conditions (10 sec. delay used)| Disconnect Conditions (2 sec. delay used)
---|---
battery voltage (V1) less than 3.32V / cell

AND

charger voltage (V2) at least 0.2V above the battery voltage (V1)

|

battery voltage (V1) greater than 3.65V / cell

–| charging current (I) less than C/100 or 1 Amp,

whichever is greater

–

| full charge is detected:

battery voltage (V1) greater than 3.5V /cell

AND

charging current (I) less than C/20

External temperature sensor. PowerMon-W can read the temperature from an external DS18B20-based sensor. The sensor has three terminals: VCC (red wire), GND (black wire), and DATA (yellow wire). Connect VCC and GND to terminal 1 (system ground). Connect DATA to the MF terminal (terminal 2). Configure the MF function for the temperature sensor in the general configuration. If the sensor is recognized by PowerMon-W, the temperature reading on the Live Data page will change to “Ext. Temperature”.

Internal clock. PowerMon-W keeps track of time internally. If the internal clock is not set the device is not logging data.

Timer function. The device supports controlling the relay using a set of up to 16 timers. Each timer contains a start time, stop time, and repetition. The start time specifies the time of day (HH: MM) when the relay turns on. Stop time specifies the time of day when the relay turns off. A timer does not need to have both the start and stop times. One of them can be disabled. This kind of timer should be used in pairs: one turns the relay on and the second one turns it off. ‘Repetition’ controls the days when a timer will trigger. This can be either DoW (Day of Week) where the timer repeats on specific days of the week or DoM (Day of Month) where the timer repeats on specific days of the month. Using multiple timers, users can create very complex time schedules.

Examples:

• Timer1: START 4:50 PM, STOP 5:10 PM, REPETITION DOW Mon Tue Wed Thr Fri Sat Sun  This timer will run every day and turn the relay on for 20 minutes, from 4:50 PM until 5:10PM
• Timer 2: START 8:00 PM. STOP: disabled, REPETITION DOW Mon Tue Wed Thr Fri Sat Sun
• Timer3: START disabled, STOP: 7:00 AM, REPETITION DOW Mon Tue Wed Thr Fri Sat Sun
• This set of timers used together will turn the relay on every day at 8:00 PM and turn it off the following day at 7:00 AM. The same effect can be achieved using a single timer. This is just an example.
• Timer4: START 12:00AM. STOP: disabled, REPETITION DOM: 1
• Timer5: START disabled, STOP: midnight, REPETITION DOM: 8

This set of timers used together will turn the relay on every 1st of the month at midnight and turn it off 7 days later, on the 8th of the month at midnight.

• Monitor. PowerMon-W monitors the following parameters in real-time (two times a second) except when connected via the cloud, in which case the date is updated once every 2 seconds:
• Voltage 1 / Voltage 2 : These are the voltages measured at the V1 and V2 terminals (referenced to terminal 1 – GROUND)
• Current: This is the current flowing through the external shunt. The value can be zeroed to eliminate any offset. If higher accuracy is required, it can also be calibrated. The current reading should be positive when charging the battery and negative when discharging. If the sign is wrong, it can be flipped using the “Flip Current Sign” switch in the general configuration.
• Power: This value is computed as voltage multiplied by current. Depending on the configuration, either V1 or V2 is used to compute the power.
• Energy Meter: This value is the electrical energy that passes through the shunt. It counts in Wh (Watt-hour), and it can be reset to zero. The measurement is purely informational. It is not used for any other purpose by the device.
• Coulomb Meter: This value is the accumulated coulombs. It counts in Ah (Ampere-hour), and it can be reset to zero. The measurement is purely informational. It is not used for any other purpose by the device.
• Battery SoC: The battery state-of-charge is displayed in percentage, from 0% to 100%. If the value displays “unset” is because the battery fuel gauge component inside the PowerMon-W is not yet synchronized with the battery. The fuel gauge will synchronize automatically when a full charge is detected. It is important that the current sign is correct, and that the battery fuel gauge is configured correctly (battery chemistry, battery voltage, and battery capacity). For Lithium batteries, a small discharge is required (about 10%) before applying a full charge to initially synchronize the SoC reading.
• Battery Remaining: The time left before the battery is completely discharged assuming the current rate of discharge. This value is only shown when the discharge current is higher than -0.1A.
• Power Status : Displays the current power status of the device (RELAY output status). Possible values are: OFF, ON, LVD (Low Voltage Disconnect – the device is OFF due to an LVD condition), HVD (High Voltage Disconnect), OCD (Over-Current Disconnect), LTD (Low-Temperature Disconnect), HTD (High-Temperature Disconnect) and NCH (Not CHarging – only in LiFePO Charge Manager mode – the relay is OFF, and the Li battery is not being charged). The power can be manually turned off. For all disconnect functions to operate the power must be manually set to on.
• Generator Status: This is shown only when the generator control feature is enabled in the device configuration. It displays the generator state (the relay state: ON / OFF)
• Temperature: This is the internal device temperature. If an external temperature sensor is connected and configured properly this will change to “Ext. Temperature” indicating that this is now the external sensor temperature.
• Device Clock / Device Date : The internal clock and date of the device. It can be set from the system time and date.
• Device Signal Strength : The strength of the WiFi signal received by the PowerMon-W device. It is measured in dBm, and it will be a negative value. The higher the value (closer to zero) the stronger the signal is. If this value is lower than about -80dBm it will become more difficult to have a reliable, fast connection to the device.
• Configuration. The device configuration can be changed using the PowerMonX app. The configuration parameters are grouped into categories based on the function affected by these parameters.

General

• Keep Access Point On  If enabled, the PowerMon-W will keep its access point feature turned on. If off, the access point will stay on for 2 minutes after the device receives power or since the last time a client was connected to the device directly (using the AP feature). This allows the device to be initially configured. When the AP is on, the device consumes significantly more power. It is advised to keep this option off to reduce power consumption.

• Shunt Specifications: The characteristics of the shunt used.

• Max. Shunt Current (amperes): The maximum current that the shunt is expected to see. Typically, this is set to the maximum rated current of the shunt. It can be set lower to potentially increase the resolution of the reading. To do this it has to be set lower than the current that causes a voltage drop of 40.96mV on the shunt. For example, a 500A / 75mV shunt would develop a 40.96mV voltage drop when the current passing through it is 273A. If this value is set to less than 273A, the current resolution is increased by 4 times. This is done at the expense of the range of measurement. The maximum current PowerMon-W would now measure is only 273A.

• Disable Voltage 2 : Disable the V2 voltage input. Use this option if you don’t use the V2 voltage input and desire to not have it displayed at all.

• Power Meter Voltage Source : The voltage used to calculate power and energy. Voltage1 or Voltage2 can be selected.
  Flip Current Sign: This allows the current sign to be flipped by software. Can be used to correct the shunt being wired backward. Should be set such that the discharge current is displayed as a negative value and the charge current shows a positive. This is a requirement for the fuel gauge to work correctly.

• Turn On at Startup: The default power status when powering the device. If set to on, the relay will be turned on automatically when the device is first powered up.

• Latch Relay On  If enabled, the device will turn the power on as a response to the RELAY terminal being temporarily pulled to the ground using a push button.

• Invert Relay Logic : Enabling this option will invert the behavior of the RELAY terminal: when the power is on, the RELAY terminal will be floating and when the power is off it will be driven to the ground. When this option is enabled “Trigger on Relay Active” is ignored (disabled).

• Connect Filter (milliseconds): The duration of time in milliseconds the LVD (Low Voltage Disconnect), HVD, and OCD (Over-Current Disconnect) conditions must be removed for the PowerMon-W to re-engage the power relay.

• MF Terminal Function: Select the function of the MF terminal: push-button input, data output, or external temperature sensor. The external temperature sensors are only available for hardware revision 2.2 or higher.

• Data Logging Mode : Configure the data logging sample rate. Possible values are disabled, every second, 2 seconds, 5 sec, 10 sec, 20 sec, 30 sec, or 1 minute.

Low Voltage Disconnect

• LVD Voltage Source : The voltage used by the low voltage disconnect feature. Voltage1 or Voltage2 can be selected.
• LVD Disconnect Threshold (V): The voltage in volts below which the power relay will disengage.
• LVD Connect Threshold (V): The voltage in volts above which the power relay can re-engage (after the connect filter time has passed). This must be higher than the LVD Disconnect Threshold.
• LVD Disconnect Filter (milliseconds): The duration of time the voltage must be below the disconnect threshold for the relay to disengage. It is used to filter voltage spikes.

High Voltage Disconnect

• HVD Voltage Source : The voltage used by the high voltage disconnect feature. Voltage1 or Voltage2 can be selected.
• HVD Disconnect Threshold (V): The voltage in volts above which the power relay will disengage.
• HVD Connect Threshold (V): The voltage in volts below which the power relay can re-engage (after the connect filter time has passed). This must be lower than the HVD Disconnect Threshold.
• HVD Disconnect Filter (milliseconds): The duration of time the voltage must be above the disconnect threshold for the relay to disengage.

Over-Current Disconnect

• OCD Disconnect Threshold (A): The current in amperes above which the power relay disengages.
• OCD Disconnect Filter (milliseconds): The duration of time the current must be above the disconnect threshold to disengage the relay.

Low Temperature Disconnect

• LTD Disconnect Threshold: The temperature below which the power relay will disengage.
• LTD Connect Threshold: The temperature above which the power relay can re-engage (after the connect filter time has passed). This must be higher than the LTD Disconnect Threshold.
• LTD Disconnect Filter (milliseconds): The duration of time the temperature must be below the disconnect threshold for the relay to disengage.

High Temperature Disconnect

• HTD Disconnect Threshold: The temperature above which the power relay will disengage.
• HTD Connect Threshold: The temperature below which the power relay can re-engage (after the connect filter time has passed). This must be lower than the HTD Disconnect Threshold.
• HTD Disconnect Filter (milliseconds): The duration of time the temperature must be above the disconnect threshold for the relay to disengage.
• Auto-off Timer : If enabled the power will turn off automatically after a specified time since it was turned on has passed. This effectively becomes a turn-off timer.
• Auto-on Timer : If enabled the power will turn on automatically after a specified time since it was turned off has passed. This effectively becomes a turn-on timer.

Battery Fuel Gauge

• Battery Voltage Source : The voltage used by the battery fuel gauge feature. Voltage1 or Voltage2 can be selected.
• Battery Chemistry: The chemistry of the battery used (Lead Acid – Flooded, Lead Acid – AGM, LiFePO4, Li-Ion, Li-Poly).
• Battery Voltage: The battery voltage (can be the standard 12V, 24V, 48V, … or custom, in which case the number of cells in the battery can be configured).
• Number of Cells: Number of cells in the battery. 12V Lead Acid batteries have 6 cells. 12V LiFePO4 batteries have 4 cells. If you have batteries connected in series, add the number of cells in each of them. If batteries are connected in parallel the number of series cells does not change. This is the number of cells that contribute to the battery’s nominal voltage.
• Total Battery Capacity: Battery capacity in Ah. If batteries are connected in parallel, add their capacities. If batteries are connected in series the capacity does not change.
• Disconnect on Battery SoC Threshold (%): The device will disconnect power (turn the relay OFF) when the battery state of charge becomes lower than this threshold (in percentage).
• Connect on Battery SoC Threshold (%): The device will re-connect power (turn the relay ON) when the battery state of charge becomes higher than this threshold (in percentage).

Generator Control

• Generator Control Voltage Source: The voltage used by the generator control feature. Voltage1 or Voltage2 can be selected.
• Turn On Based on Voltage : If enabled the generator will be turned on when the battery voltage drops under a specified threshold.
• Turn On Voltage Threshold (V): The threshold in volts below which the generator will be turned on.
• Turn On Voltage Filter (milliseconds): The duration of time the voltage must be below the turn-on threshold for the generator to be turned on.
• Turn On Based on SoC: If enabled the generator will be turned on when the battery SoC (State-of-Charge) drops under a specified threshold.
• Turn On SoC Threshold (%): The threshold in percentage below which the generator will be turned on.
• Turn Off Based on Voltage: If enabled the generator will be turned off when the battery voltage increases above a specified threshold.
• Turn Off Voltage Threshold (V) : The threshold in volts above which the generator will be turned off.
• Turn Off Based on SoC : If enabled the generator will be turned off when the battery SoC (State-of-Charge) increases above a specified threshold.
• Turn Off SoC Threshold (%): The threshold in percentage above which the generator will be turned off.
• Turn-Off Delay (minutes): A delay applied between the conditions to turn the generator off becomes true and turns the generator off. For example, if set to 1 minute, the generator will stay on for an extra minute after the voltage or SoC increases above the turn-off threshold. LiFePO Charge Manager
• Battery Voltage: The battery voltage (can be the standard 12V, 24V, 48V, or custom, in which case the number of cells in the battery can be configured).
• Number of Cells: Number of cells of the battery. 12V LiFePO4 batteries have 4 cells. If you have multiple batteries connected in series, add the number of cells in each of them. If batteries are connected in parallel the number of series cells does not change. This is the number of cells that contribute to the battery’s nominal voltage.
• Total Battery Capacity: Battery capacity in Ah. If batteries are connected in parallel, add up their capacities. If batteries are connected in series the capacity does not change (only the number of cells in series does).
• Default Factory Settings. The device can always be reset to the default configuration using the PowerMonX app. To do this, connect to a device, tap the top right corner menu, and then “Device Information”. Tap on Factory Reset.
  WARNING: When resetting to the factory defaults, all custom settings, and timers will be erased, including the device calibration, the battery fuel gauge internal state, and the data log. Radio performance. The device contains an internal WiFi radio operating in the 2.4GHz ISM band and an internal antenna. For best performance, the device should be installed in such a way as to offer a path for radio waves to reach it. Metal walls or enclosures can attenuate or completely shield the device. Installation on non-metallic surfaces is preferred. The mobile device app displays the RSSI value (Received Signal Strength Indication) in real time. Renaming the device. Renaming the device can be achieved using the top-right menu button and taping on “Device Information”. The maximum name length is 32 characters.

WIRING DIAGRAMS

Typical application without a relay

• The disconnect functions are not available (there is no relay).
• V2 can be used to monitor a second battery, the midpoint between two batteries in series, or the solar panel input voltage (max. 72V). Leave unconnected if not used.
• The sense wires from the shunt to ES1 and ES2 should be as short as possible and twisted to minimize noise
• The main fuse should be sized based on the maximum system current and the wire size

Typical application using a relay

• V2 can be used to monitor a second battery, the midpoint between two batteries in series, or the solar panel input voltage (max. 72V). Leave unconnected if not used.
• The charging sources are connected before the relay. This is done so they cannot be disconnected from the battery during a low voltage or other disconnect events (very important for an MPPT charge controller).
• The main fuse should be sized based on the maximum system current and the wire size

Typical application of a battery isolator

• The disconnect functions are not available
• V1 is monitoring the starting battery voltage
• V2 is monitoring the house battery voltage
• The house battery SoC is monitored. Set the fuel gauge voltage source to V2 (see device configuration)

DIMENSIONS

• Dimensions are in inches.

ORDERING

Meter**

Documents / Resources

| Thornwave Labs Inc PowerMon-W WiFi IoT Advanced Battery Monitor [pdf] User Manual
PowerMon-W, PowerMon-W WiFi IoT Advanced Battery Monitor, WiFi IoT Advanced Battery Monitor, IoT Advanced Battery Monitor, Advanced Battery Monitor, Battery Monitor, Monitor
---|---

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>