tbs electronics E-Pro-Hv High Precision Battery Monitor Owner’s Manual

High Precision Battery Monitor
e-xpert pro-hv
Owner’s manual
Thank you for purchasing a TBS Electronics
Battery Monitor.
Please read this owner’s manual for information
about using the product correctly and safely.
Keep this owner’s manual close to the battery
monitor for future reference.
TBS ELECTRONICS BV
De Marowijne 3, 1689AR, Zwaag, The Netherlands
http://www.tbs-electronics.com

Before proceeding with this owner’s manual, please make sure you have carefully read the enclosed installation and quick start guide as well!

E-xpert pro-hv display and control overview

1. Charge battery indicator
2. Numeric value indicator field
3. Setup lock / Master lock indicator
4. Main battery or Auxiliary battery indicator
5. State-of-charge bar
6. Charging in progress indicator
7. Alarm activated indicator
8. Readout units
9. Synchronize indicator
10. Next value or Right key (>)
11. Menu key
12. Previous value or Left key (<)

Synchronization

In order to keep your battery monitor delivering accurate status information about your battery, it is important to regularly synchronize your battery monitor with your battery. As explained in the quick start guide, a synchronization step is also needed before you can actually use your battery monitor. During operation, the battery monitor automatically
indicates when synchronization is required, by displaying the message SYNCHRONIZE.
A synchronization step means nothing more than performing a complete charge cycle on your battery. A charge cycle will be considered complete when all discharged energy is
restored in the battery and Auto-sync parameters F1.0, F1.1, and F1.2 (see chapter 5) are met. This typically means: when the battery charger switches to float mode. By meeting
these conditions, the battery is considered full, which will be indicated by a flashing FULL message on the display. Besides this, the State-of-charge readout will be set to 100% and the Amp-hour readout reset to 0Ah. The FULL message will disappear when a key is pressed, or automatically when the battery starts discharging again.
Performing synchronizations regularly is also important to keep your battery healthy and to increase its lifetime. You will notice that if you are often performing full charge cycles yourselves, the battery monitor will most likely not display the SYNCHRONIZE message, since the battery is already kept in good sync with the battery monitor.
Besides automatic synchronizations based on meeting the Auto-Sync Functions, you can also manually synchronize the battery monitor with your battery when you are sure your battery is fully charged. This can be accomplished by pressing both < and > keys simultaneously for three seconds. After these three seconds, the flashing FULL message

Status menu

The Status menu is a read-only menu that shows the battery monitor’s current status of several items. This menu can be accessed by the following sequence:

When the Status menu is entered, you can use the < and > keys to browse through the different status items. By pressing the MENU key, the selected status item can be viewed.
Pressing the MENU key again will then step back to the Status menu. From any menu position, the Normal Operating Mode can be accessed again by pressing the MENU key
for 3 seconds. The following Status menu items are available :

St.1 Alarm Status. When multiple alarms are activated, use the < or > keys to browse through the currently active alarms. When no alarms are activated, this item displays “—-“.
St.2 Days running. The number of days the battery monitor is operating to monitor your battery. This item resets when a battery reset is executed (see Reset menu).
St.3  Days since last synchronized. The number of days the battery monitor has not been synchronized. This item resets when the battery monitor is synchronized or when a battery reset is executed (see Reset menu).
St.4 Charge Efficiency Factor (CEF). The charge efficiency factor is used by the battery monitor. Depending on the value set in Function F5.6, this item displays the automatically calculated CEF or the manually set CEF.

History menu

The History menu is a read-only menu that shows the battery monitor’s History data. History data are special events that are stored in internal memory. This menu can be  accessed by the following sequence :

When the History menu is entered, you can use the < and > keys to browse through the different History items. By pressing the MENU key, the selected History item can be
viewed. Pressing the MENU key again will then step back to the History menu. From any menu position, the Normal Operating Mode can be accessed again by pressing the MENU key for 3 seconds. The following History menu items are available :

H1: BATTERY HISTORY :
H1.0 Average discharge in Ah. This number will be recalculated after each synchronization.
H1.1 Average discharge in %. This number will be recalculated after each synchronization.
H1.2 Deepest discharge in Ah.
H1.3 Deepest discharge in %.
H1.4 Total Amphours removed. The total number of Amphours removed from the battery. When exceeding 10000Ah, the units are kAh and the value displayed
must be multiplied by 1000.
H1.5 Total Amphours charged. The total number of Amphours charged to the battery These Amphours are not compensated by the Charge Efficiency Factor (CEF).
When exceeding 10000Ah, the units are kAh and the value displayed must be multiplied by 1000.
H1.6 Number of cycles.
H1.7 Number of synchronizations. This is the number of times the battery is fully charged meeting the Auto-sync Functions.
H1.8 Number of full discharges. The number of times the battery has been fully discharged reaching a State-of-charge of 0.0%.
H2: ALARM HISTORY
H2.0 Number of Low Battery alarms.
H2.1 Number of Main battery low voltage alarms.
H2.2 Number of Auxiliary battery low voltage alarms.
H2.3 Number of Main battery high voltage alarms.
H2.4 Number of Auxiliary battery high voltage alarms.

Function setup menu

In the Function setup menu, your battery monitor can be adjusted to fit into your system. Lots of parameters, called Functions, can be set according to your needs. This menu can be accessed by the following sequence :

When the Function setup menu is entered, you can use the < and > keys to browse through the different Functions. By pressing the MENU key, the selected Function value
can be viewed. The < and > keys can now be used to change this value. Pressing the MENU key again will then step back to the Function menu. From any menu position, the
Normal Operating Mode can be accessed again by pressing the MENU key for 3 seconds. This will also save any Function value changes to internal memory. When no keys are
pressed for 90 seconds while operating in the Function setup menu, the battery monitor will automatically return to the Normal Operating Mode again without saving any Function value changes. The following functions are available :

F1: SYSTEM PROPERTIES

F1.0 Charger’s float voltage (Auto-sync parameter). This value must be equal to your battery charger’s float voltage. which is the last stage of the charging process. In this stage, the battery is considered full.
Default : 52.8V Range : 16.0V – 66.0V Step size : 0.2V
F1.1 Charger’s float current (Auto-sync parameter). When the charge current is below this percentage of the battery capacity (see Function F5.0), the battery will be considered fully charged. Make sure this Function value is always greater than the minimum current at which the charger maintains the battery or stops charging.
Default : 2.0% Range : 0.5 – 10.0% Step size : 0.1%
F1.2 Auto-sync time (Auto-sync parameter). This is the time the Auto-sync parameters F1.0 and F1.1 must be met in order to consider the battery as fully charged.
Default : 240sec Range : 5 – 300sec Step size : variable
F1.3 Discharge floor. This is the reference point at which the battery needs to be recharged. When the State-of-charge percentage falls below this value the Charge battery indicator starts flashing while the time remaining readout shows 0:00 and the State-of-charge bar is empty.
Default : 50% Range : 0 – 99% Step size : 1%
F1.4 Battery temperature. In this Function, the average battery temperature can be adjusted. The value AU enables the automatic temperature measurement, provided that an external temperature sensor is connected to the battery monitor. Also, the temperature readout in the Normal Operating Mode is enabled.
Default : +20°C Range : -20..+50°C / AU Step size : 1°C
F1.5 Time remaining averaging filter. Specifies the time window of the moving averaging filter. There are three settings, where setting 0 gives the fastest Time remaining readout response and setting 2 the slowest. The best setting will depend on the type of battery load and your personal preference.
Default : 1 Range : 0 – 2 Step size : 1
F1.6 Auto-sync sensitivity. Only change this setting when F1.0, F1.1, and F1.2 are set correctly and automatic synchronization still fails. If automatic synchronization takes too long or does never occur, lower this value. When the battery monitor synchronizes too early, increase this value.
Default : 5 Range : 0 – 10 Step size : 1
F2 : LOW BATTERY ALARM SETTINGS
F2.0 Low battery alarm On (% SOC). When the State-of-charge percentage has fallen below this value, the alarm relay will be activated (depending on F2.6).
Default : 50% Range : 0 – 99% Step size : 1%
F2.1 Low battery alarm On (Volts). When the battery voltage has fallen below this value, the alarm relay will be activated (depending on F2.6).
Default : 42.0V Range : 16.0 – 66.0V Step size : 0.2V
F2.2 Low battery alarm Off (% SOC). When the State-of-charge percentage has risen above this value and the alarm relay was activated, the alarm relay will deactivate again. When “FULL” is selected, the alarm relay is deactivated when the Autosync parameters are met.
Default : 80% Range : 1 – 100% / FULL Step size : 1%
F2.3 Low battery alarm On delay time. This is the time the Low battery alarm On conditions, F2.0 and F2.1, must be met before the alarm is activated.
Default : 10sec Range : 0 – 300sec Step size : variable
F2.4 Minimum ‘Alarm On’ time. The minimum time that the alarm relay stays activated even if the State-of-charge percentage has risen above the Low battery alarm Off setpoint (F2.2). Function units are hours: minutes.
Default : 0:00 Range : 0:00 – 12:00 Step size : variable
F2.5 Maximum ‘Alarm On’ time. The maximum time that the alarm stays activated even if the State-of-charge percentage is still below the Low battery alarm Off setpoint (F2.2). The value “-:–“ indicates an unlimited time, and the relay will stay activated until the State-of-charge percentage has risen above the Low battery alarm Off setpoint (F2.2). Function units are hours: minutes
Default : -:- – Range : 0:00 – 12:00 / -:- – Step size : variable
F2.6 Enable Low battery alarm / Use contact. Select “OFF” to disable the low battery alarm. Select “[1]” to use the battery monitor’s internal alarm relay. Select “[ ]1” to “[ ]8” to use an external alarm contact (only for use with optional Alarm output expander).
Default : [1] Range : OFF / [1] / [ ]1..[ ]8
F3 : LOW VOLTAGE ALARM SETTINGS
F3.0 Main battery low voltage alarm On. When the Main battery voltage falls below this value, the message “Lo” will appear on the display, and the selected alarm relay will be activated (depending on F3.2).
Default : 42.0V Range : 16.0 – 66.0V Step size : 0.2V
F3.1 Main battery low voltage alarm Delay. This is the time the Main battery low voltage alarm On condition, F3.0, must be met before the alarm is activated.
Default : 10sec Range : 0 – 300sec Step size : variable
F3.2 Enable Main battery low voltage alarm / Use contact. Select “OFF” to disable the Main battery low voltage alarm. Select “[1]” to use the battery monitor’s internal alarm relay. Select “[ ]1” to “[ ]8” to use an external alarm contact (only for use with optional Alarm output expander).
Default : OFF Range : OFF / [1] / [ ]1..[ ]8
F3.3 Auxiliary battery low voltage alarm On. When the Auxiliary battery voltage falls below this value, the message “Lo” will appear on the display and the selected alarm relay will be activated (depending on F3.5).
Default : 10.5V Range : 8.0 – 33.0V Step size : 0.1V
F3.4 Auxiliary battery low voltage alarm Delay. This is the time the Auxiliary battery low voltage alarm On condition, F3.3, must be met before the alarm is activated.
Default : 10sec Range : 0 – 300sec Step size : variable
F3.5 Enable Auxiliary battery low voltage alarm / Use contact. Select “OFF” to disable the Auxiliary battery low voltage alarm. Select “[1]” to use the battery monitor’s internal alarm relay. Select “[ ]1” to “[ ]8” to use an external alarm contact (only for use with optional Alarm output expander).
Default : OFF Range : OFF / [1] / [ ]1..[ ]8
F4 : HIGH VOLTAGE ALARM SETTINGS
F4.0 Main battery high voltage alarm On. When the Main battery voltage rises above this value, the message “Hi” will appear on the display and the selected alarm relay will be activated (depending on F4.2).
Default : 64.0V Range : 20.0 – 70.0V Step size : 0.2V
F4.1 Main battery high voltage alarm Delay. This is the time the Main battery high voltage alarm On condition, F4.0, must be met before the alarm is activated.
Default : 5sec Range : 0 – 300sec Step size : variable
F4.2 Enable Main battery high voltage alarm / Use contact. Select “OFF” to disable the Main battery high voltage alarm. Select “[1]” to use the battery monitor’s internal alarm relay. Select “[ ]1” to “[ ]8” to use an external alarm contact (only for use with optional Alarm output expander).
Default : OFF Range : OFF / [1] / [ ]1..[ ]8
F4.3 Auxiliary battery high voltage alarm On. When the Auxiliary battery voltage rises above this value, the message “Hi” will appear on the display and the selected alarm relay will be activated (depending on F4.5).
Default : 16.0V Range : 10.0 – 35.0V Step size : 0.1V
F4.4 Auxiliary battery high voltage alarm Delay. This is the time the Auxiliary battery high voltage alarm On condition, F4.3, must be met before the alarm is activated.
Default : 5sec Range : 0 – 300sec Step size : variable
F4.5 Enable Auxiliary battery high voltage alarm / Use contact. Select “OFF” to disable the Auxiliary battery high voltage alarm. Select “[1]” to use the battery monitor’s internal alarm relay. Select “[ ]1” to “[ ]8” to use an external alarm contact (only for use with optional Alarm output expander).
Default : OFF Range : OFF / [1] / [ ]1..[ ]8
F5: ‘MAIN’ BATTERY PROPERTIES
F5.0 Battery capacity. Your Main battery’s capacity in Amphours (Ah).
Default : 200Ah Range : 20 – 9990Ah Step size : variable
F5.1 Nominal discharge rate (C-rating). The discharge rate (in hours) at which the battery manufacturer rates your battery’s capacity.
Default : 20h Range : 1 – 20h Step size : 1h
F5.2 Nominal temperature. The temperature at which the battery manufacturer rates your battery’s capacity.
Default : 20°C Range : 0 – 40°C Step size : 1°C
F5.3 Temperature coefficient. This is the percentage that your battery’s capacity changes with temperature. The unit of this value is percent capacity per degree Celsius. The setting “OFF” disables temperature compensation.
Default : 0.50%cap/°C Range : Step size : 0.01%cap/°C OFF / 0.01 – 1.00
F5.4 Peukert’s exponent. Peukert’s exponent represents the effect of reducing battery capacity at higher discharge rates. When the Peukert value of your battery is unknown, it is recommended to keep this value at 1.25. A value of 1.00 disables the Peukert compensation and could be used for Lithium-based batteries.
Default : 1.25 Range : 1.00 – 1.50 Step size : 0.01
F5.5 Self-discharge rate. This is the rate at which the battery loses capacity by itself, even when it is not used. The unit of this value is percent capacity per month at the Nominal temperature (F5.2). The setting “OFF” disables self-discharge compensation and could be used for Lithium-based batteries.
Default : 3.0%/month Range : OFF / 0.1 – 25.0%/month Step size : 0.1%/month
F5.6 Charge Efficiency Factor (CEF). CEF is the ratio between the energy removed from a battery during discharge and the energy used during charging to restore the original capacity. It is recommended to keep this value at “AU” (automatic calculation). The setting “100” disables charge efficiency
Default : AU Range : 50 – 100% / AU Step size : 1%
F6 : BATTERY MONITOR PROPERTIES
F6.0 Firmware version. Displays the firmware version of the battery monitor (read-only).
Default : x.xx
F6.1 Shunt Amp Rating. This Function is linked to F6.2 and represents the Amp rating of your shunt at the given voltage indicated by F6.2. Included with your battery monitor is a 500Amp/50mV shunt, meaning that at 500A flowing through the shunt, a voltage of 50mV is generated across the small ‘Kelvin’ screw terminals of the shunt. This voltage will be used by the battery monitor to measure the amount of current.
Default : 500A Range : 10 – 9000A Step size : variable
F6.2 Shunt milliVolt Rating. This Function represents the milliVolt rating of your shunt at the given current indicated by F6.1. The battery monitor supports 50mV and 60mV
shunts.
Default : 50mV Range : 50 / 60mV
F6.3 Backlight mode. Represents the duration of backlight activation in seconds after key-press. The backlight can also be set to be always “ON” or always “OFF”. Function setting “AU”, activates the backlight automatically when charge/discharge current exceeds 1Amp or when a key is pressed.
Default : 30sec Range : OFF / 5…300 / ON / AU Step size : variable
F6.4 Alarm contact polarity. Enables selection between a normally open (NO) or normally closed (NC) contact.
Default: NO Range: NO / NC
F6.5 Not available.
Default : – – – – Range : – – – –
F6.6 Temperature unit selection. Enables selection between degrees Celsius (°C) and degrees Fahrenheit (°F) in the temperature readout.
Default : °C Range : °C / °F
F6.7 Auxiliary input mode. This Function is used to configure the VA input terminal on the rear side of the battery monitor and can be set in two modes. In mode “0”, the
VA input operates in normal voltage measurement mode. In mode “1”, the VA input can be used to control the backlight. In this mode, the backlight is switched ON at an input voltage higher than 2V and switched OFF again if the voltage is
below 1V. Default : 0 Range : 0 / 1
F6.8 Communication mode. This Function is used to configure the data output mode.
There are four data output modes :
Mode “0” : E-xpert pro-hv (broadcasting)
Mode “1” : E-xpert pro-hv (request mode)
Mode “2” : E-xpert 501 compatibility mode (broadcasting)
Mode “3” : E-xpert 501 compatibility mode (request only)
Default : 0 Range : 0 / 1 / 2 / 3
F6.9 Setup lock. When set to “ON”, all functions (except this one) are locked and cannot be altered. The Reset menu is also locked.
Default: OFF Range: OFF / ON

Reset menu

In the Reset menu, you can reset a number of items of your battery monitor This menu can be accessed by the following sequence :

When the Reset menu is entered, you can use the < and > keys to browse through the different reset items. By pressing the MENU key, the selected reset item can be viewed.
The default value for all reset items is “OFF”. To actually reset the selected item, use the < and > keys to change the value from “OFF” to “ON”. Pressing the MENU key again will step back to the Reset menu. All reset items set to “ON” will only be reset once the Normal Operating Mode is accessed again by pressing the MENU key for 3 seconds. The following Reset menu items are available :
rSt.a Reset alarms. Use this reset item to reset or ignore all current alarms.
rSt.b Reset Battery status. Use this reset item to reset your current battery status (CEF, State-of-charge, and battery history). You can use this reset item after you have installed a fresh battery of the same specifications as the previous one.
rSt.F Reset Functions. This reset item can be used to reset all Function values to factory default values.
rSt.c Reset zero-offset current. Use this reset item to remove small current readings on the display when no current is flowing in or out of the battery. When performing this reset action, please be 100% sure that all DC consumers/chargers are disconnected or turned off.

Troubleshooting guideline

connections.
– Make sure the inline fuses are installed and not blown.
– Check the battery voltage. The battery might be flat. Vbatt must be >14VDC.
– Try to restart the monitor by removing/placing the fuses again.
Current readout gives wrong polarity (positive current instead of negative when discharging)| – Current sense leads from the shunt are reversed. Check the installation guide.
The monitor resets all the time| – Check the wiring for corrosion and/or lose contacts.
– Battery might be flat or defective.
No changes can be made in the Function setup| – Check if the setup-lock is OFF (Function F6.9)
– Your E-xpert pro-hv might be locked by the superblock. Ask the installer for the password to unlock the monitor using the PC link.
“CHARGE” or “SYNCHRONIZE” keeps on flashing| – Charge battery full (synchronize your battery with the monitor)
– Check the Auto-sync parameters in Functions F1.0, F1.1, and F1.2 for possible wrong settings.
State-of-charge and/or time-to-go readout not accurate| – Check if all current is flowing through the shunt (the negative terminal of the battery may only contain the wire going to the battery side of the shunt!).
– Current sense leads from the shunt are reversed.
– Check all Battery properties Functions (F5)
– Check if the battery monitor is synchronized.
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Display returns ‘- – – -‘ in temperature readout|     – Connection with the temperature sensor is lost. Check for failed connections and/or cable damage.

Warranty conditions

TBS Electronics (TBS) warrants this product to be free from defects in workmanship or materials for 24 months from the date of purchase. During this period TBS will repair the defective product free of charge. TBS is not responsible for any costs of the transport of this product.
This warranty is void if the product has suffered any physical damage or alteration, either

1. internally or externally, and does not cover damage arising from improper use or from use in an unsuitable environment.
   This warranty will not apply where the product has been misused, neglected, improperly installed, or repaired by anyone other than TBS. TBS is not responsible for any loss,
   damage or costs arising from improper use, use in an unsuitable environment, or improper installing, setup, and malfunctioning of the product.
   Since TBS cannot control the use and installation (according to local regulations) of their products, the customer is always responsible for the actual use of these products. TBS
   products are not designed for use as critical components in life support devices or systems, that can potentially harm humans and/or the environment. The customer is always responsible when implementing TBS products in this kind of application. TBS does not accept any responsibility for any violation of patents or other rights of third parties, resulting from the use of the TBS product. TBS keeps the right to change product specifications without previous notice.
   Examples of improper use are :

• too high input voltage applied
• wrong shunt connection
• applying battery voltage to shunt input
• mechanically stressed enclosure or internals due to harsh handling and/or incorrect packaging
• contact with any liquids or oxidation caused by condensation

Technical specifications

–  Expert quick connection kits
–  Expert pro temperature sensor kits
–  Expert pro communication kit RS232
–  Expert pro communication kit USB
–  Expert pro alarm relay expansion kit

Note: the given specifications are subject to change without notice.

1. If needed, take additional isolation measures when the voltage exceeds 60VDC.
2. Measured with backlight and alarm relay turned off.
3. Depends on selected shunt. With standard delivered 500A/50mV shunt (350A continuous), the range is limited to -600..+600A.
4. Only available when an optional temperature sensor is connected.

E-pro-hv TBS Manual Rev6e / Printed in The Netherlands

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