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Balmar SG200, Installation & Operation Manual

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Table of Contents

Installation Overview 

     4

Introduction       6

What is a Battery Monitor, and Why is it Important? 

6

Installation 

       8

Included in the box     8

Installing the SmartShunt and Display  

 

8

Adding an additional device to the SmartLink Network  13

Setting up multiple SmartShunts on one bank  

13

SG200 Layout and Operation 

    14

Single Button Operation 

    14

Real-Time Data 

     15

Setting up the SG200 for the First Time  

 

16

Initial Accuracy 

     17

Display 

       17

History        18

BAT TYPE - Selecting the Battery Chemistry   19

CAPACITY - Selecting a Battery Design Capacity  

20

CHARGING - Charge Termination and Charge Efficiency  21

Advanced Settings      23

Faults and Alerts 

      24

Alerts 

      24

Faults 

      25

Comparing Faults and Alerts 

   26

Appendix:

Specifications   

 

 

 

 

 

27

Part Numbers 

      28

Fault Thresholds 

      29

Converting Reserve Capacity to Amp Hours   29

Factors Affecting Battery Life    30

State of Health 

     30

Sulfation and shedding 

    30

Cycle Life 

      31

Partial State of Charge (PSOC) Cycling  

 

31

Balmar Warranty 

      32

Summary of Contents for SG200

Page 1: ...SG200 BATTERY MONITOR Installation Operation Manual SUP 0250 REV A...

Page 2: ...p the SG200 for the First Time 16 Initial Accuracy 17 Display 17 History 18 BAT TYPE Selecting the Battery Chemistry 19 CAPACITY Selecting a Battery Design Capacity 20 CHARGING Charge Termination and...

Page 3: ...acelets rings or handing necklaces 4 Wear ANSI approved safety eye wear and protective gear 5 DO NOT attempt to modify the SmartShunt or Display Modifications could result in damage to your charging s...

Page 4: ...e SG200 Battery Monitor unit your system wiring or health The SG200 is designed to monitor a battery or battery bank which is used in deep cycling applications It relies on the battery being discharge...

Page 5: ...rom auxiliary batteries to the shunt are not needed in a common ground installation CAUTIONS WARNING DO NOT install any of the positive leads without proper fusing NOTE The fuse holder is shipped with...

Page 6: ...ank The State of Charge SoC is a percentage value showing what percentage of the battery s capacity is remaining The SG200 very accurately calculates the State of Charge and it does so by incorporatin...

Page 7: ...To loads Inaccuracy is introduced that is multiplied with each additional cycle that does not reach full 100 charge For more information about issues that effect battery health and capacity read the A...

Page 8: ...be located within 6 of the power source The SmartShunt should be located as close to the battery as possible preferably within 12 inches The SmartShunt should be mounted to a firm surface in a dry loc...

Page 9: ...NOTE Do not install any positive voltage carrying wires to the SmartShunt studs ONLY negative cables The SmartShunt will not work on the positive side of an installation The SmartShunt should be locat...

Page 10: ...ace 2 Remove all loads and charging sources from the battery before any other steps are taken This often is accomplished by turning off a battery switch If there are loads or chargers directly attache...

Page 11: ...the hole is cut remove the nut washer and mounting brace insert the display from the front and then replace the brace Tighten the nut by hand and then 1 2 turn or so If it is being mounted in a plasti...

Page 12: ...bing to lock it into place The tubing is not needed for water tightness but does provide chafe protection to the exposed wires When the wedgelock is in place you should just be able to see the ends of...

Page 13: ...accomplish this is to use high amperage carrying bus bars with correctly sized cables for each 2 Connect the two SmartShunts on the SmartLink Network via the Communications Cable 3 Virtually connect t...

Page 14: ...the screen you have made a long press and then release your finger EXAMPLE If you are looking at a list of devices on the SmartLink network you can use short presses to move from one device to the ne...

Page 15: ...ection Initial Accuracy State of Health SoH Percent SoH is the battery s existing or actual aged capacity compared to the initial design capacity Current Amps A Shows the NET of simultaneous charge mi...

Page 16: ...e correct battery chemistry and the capacity of the battery bank Each SmartShunt on a SmartLink Network has it s own menu If you only have one SmartShunt it is automatically selected for you Otherwise...

Page 17: ...lied upon and you may see significant changes in these values during this time NOTE The accuracy of the voltage and current measurements are calibrated at the factory and do not change over time Displ...

Page 18: ...of those parameters Viewing HISTORY steps the user through the minimum and maximum values recorded of the real time data parameters An additional set of values is shown here for POWER expressed in wat...

Page 19: ...ect the chemistry that most closely represents the batteries being monitored All batteries on the bank being monitored by the SmartShunt should be the same size age and chemistry If they are not the S...

Page 20: ...acity of the battery bank This is the total design capacity of the entire bank regardless of the battery s condition or previously measured capacity Typically the capacity is expressed as the 20 hour...

Page 21: ...ystem resets and any battery learning described in Initial Accuracy is lost CHARGING Charge Termination and Charge Efficiency The CHARGE VOLTAGE and TAPER CURRENT are used together by the SG200 to det...

Page 22: ...ery PEUKERT PEUKERT QUOTIENT VALUE The default value for each chemistry should only be changed if a different value is provided by the battery manufacturer If the CHARGE VOLTAGE has been reached AND t...

Page 23: ...NETWORK Resets the SmartLink network Learning chemistry faults etc are retained FACTORY RST FACTORY RESET Performs a FULL reset of the device ALL history including faults chemistry capacity learning...

Page 24: ...User Defined Min Max State of Charge SoC Min Max Current A Min Max State of Health SoH Min Max Voltage V Min Max Aux 1 Aux 2 Voltage V Min Max Mins Left minutes Generally Alerts are used to notify the...

Page 25: ...d the set value for the ALERT to be triggered When a LOW value is configured the parameter must fall below that value for the ALERT to be triggered Faults Faults are triggered when specific values hav...

Page 26: ...ser know when potentially battery damaging voltages are sensed Comparing Faults and Alerts Here is a summary of some differences between Faults and Alerts 1 Alerts are user configurable you can enable...

Page 27: ...for 10 minutes Display Values State of Charge SoC State of Health SoH Voltage V Charge Discharge Current A Time Remaining Hrs Minutes History Faults and Alerts Communications Cable 4 wire 22AWG Shiel...

Page 28: ...SmartLink Network SG2 0300 Gateway SG200 Bluetooth Optional 39 Bluetooth Gateway for Smartphone App SG2 0400 Com Cable SG200 10m Optional SmartLink Com Cable 10 meter for Longer Cable Runs NOTE If equ...

Page 29: ...y to Amp Hours The following formula converts Reserve capacity typically expressed in min utes drawing a 25 amp load to Amp hours at the 20 HR rate RC 60 25 3600 Multiply Reserve Capacity to 60 to con...

Page 30: ...chemical level there are two primary conditions that reduce the life or State of Health of a battery They are Sulfation and Shedding Sulfation occurs when lead sulfate formed naturally during battery...

Page 31: ...in real life applications most batteries never reach the cycle life proposed by manufacturers Partial State of Charge PSOC Cycling All lead acid batteries benefit from being fully charged back to 100...

Page 32: ...90 days whichever is greater Not Covered Under Warranty Balmar s Warranty does not cover any problem that is caused by a an accident abuse neglect exposure to shock electrostatic discharge heat or hum...

Page 33: ...RMA number on the outside of the package 4 Please send the product postage prepaid via a carrier that can track the package Balmar LLC 353 James Record Road SW Huntsville AL 35824 Attention Warranty...

Page 34: ...34 NOTES...

Page 35: ...35 NOTES...

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