OPERATING INSTRUCTIONS
gaus sts
POWER ELECTRONICS


Jurija Gagarina 167/41
11000 Belgrade
Yugoslavia / Mobile: (+381) 63 215-722
Tel./fax: (+381) 11 17-69-142
Tech.support: 025 461-095
e-mail:

Contents:

GTBM technical features 3

GTBM data read manual 4

GTBM report: example 10

GTBM mounting manual 11

GTBM technical features

Gaus Traction Battery Monitor (GTBM) is suited for displaying current state of traction battery and long-term tracking of its use.

GTBM displays current battery charge/discharge level on 8-level LED panel in 10 different positions - steady light of one LED and flashy light of uppermost LED (maximal recommended charge level) or most lower LED (minimal recommended discharge level).

GTBM controls lift of forklifter with relay, which can enable or disable the lift. In case of battery voltage dropping below minimal recommended discharge level, then relay disables lift and forklifter's battery has to be recharged. After the charging of battery, lift is enabled again.

GTBM tracks battery voltage and records in its permanent memory every case that is out of recommended area (overcharging and deep discharging) for some period of time (15 min).

GTBM detects charging time (important fact in maintainence of battery capacity), connection to high voltage (in case of connecting GTBM on wrong battery) and accurate time within GTBM was disconnected from the battery.

In case of eventual complaint GTBM gives you all informations about misuse of battery.

GTBM is based on: microcontroller (CPU, battery voltage measurement, data recording, RTC read/write, LED panel control, relay control, PC communication), permanent memory (E2PROM, for data storage), real time clock/calendar (separate battery power supply), power supply (enables connection to the batteries in range 12¸80V), relay (enable/disable the lift).

GTBM accomplishes its functions only if there is permanency in power supply from traction battery. If there is standstill longer than 15 minutes, then GTBM records it in its memory.

GTBM can be set for next battery voltages: 12V, 24V, 36V, 40V, 48V, 60V, 72V, 80V. Current consumption is 10¸30mA. GTBM is waterproof in according to IP-65 standard and is suited for industrial temperature range [-25°C,+85°C].

GTMB connection toward forklifter and traction battery is made over 4-pins plug. GTBM can be mounted on any flat surface with two screws, which are already fixed on GTBM.

GTBM data read manual


  1. Connect GTBMCOMM (RS-232 communication device), over serial cable, on serial port of PC. Serial cable, with its female 9-pin SUB-D plug, is connected to male 9-pin SUB-D plug on GTBMCOMM (see picture). Other end of serial cable (male 9-pin SUB-D plug) is connected on serial port of PC (female 9-pin SUB-D plug).

2.  Connect GTBMCOMM to mains (220V/50Hz).



  1. Open GTBM by unscrewing 4 cover screws.
  1. GTBM has warranty seal on right side. To open GTBM without breaking the seal, you need to pull out 2 screws on rigth side (as shown on picture below) and then remove cover.




  1. On lower rigth part of board you see 8xDIP-SW. You should the most right switch (1) turn from its upper position (OFF) in to lower position (ON). WARNING!!! YOU MUST NOT CHANGE POSITION OF ANY OTHER SWITCH ON BOTH DIP-SW's!!!


  1. On upper left part of board you see 4-pins male connector. You should connect 4-pins female connector form GTBMCOMM, as shown on pictures.




  1. Turn on GTBMCOMM (as shown on picture).
  1. Turn on PC and start application GTBM (double click on desktop icon).
  1. When LOGIN dialog appears, you should press ENTER key on keyboard or mouse click on OK button.


  1. You should click on COMM OFF button, in upper left corner of application window. After short time same button should alter its caption into COMM ON, next button on right side becomes enabled and status bar has text KOMUNIKACIJA SA UREDJAJEM USPOSTAVLJENA.
  1. If there is error message NEMA ODZIVA SA UREDJAJA you should recheck steps 1, 2, 5, 6 and 7, because there is no communication established between PC, GTBMCOMM and GTBM.
  1. Click on button START. Process of data transfer from GTBM memory to PC lasts around 20 seconds.
  1. After the transfer you should turn off GTBMCOMM, disconnect 4-pin connector from GTBM board and turn back most right DIP-SW into upper position. WARNING!!! YOU MUST NOT CHANGE POSITION OF ANY OTHER SWITCH ON BOTH DIP-SW's!!!
  1. Application turns itself on next page, where are two tables: upper, with readed data on battery use, and lower, with textual report. Report contains all relevant informations about battery,

owner, GTBM: serial numbers, dates, times and informations about use of battery. Right click



brings popup menu with options: printing report and saving it on disk or floppy.


  1. Click on tab VREMENSKI DIJAGRAM brings up time chart with all relevant data about battery use. Chart can be zoomed by clicking and draging mouse pointer from upper left corner to lower right corner and unzoomed by draging mouse pointer in opossite direction.

Double click on chart brings up tool tips above data points: voltage, date and time or with no data. Right click brings up menu with printing options. Chart display exact moments of beginning and ending of charging, overcharging or deep discharging, with extreme value. Chart display exact moments of connecting/disconnecting to/from battery, and eventual cases of connecting to the battery of higher voltage than provided.


  1. Click on tab ARHIVA PODATAKA brings up page with two tables. Tables contain saved data from GTBMs. Upper table contains information about date and time of reading GTBM, its serial number and voltage. Lower table contains data from GTBM’s memory. Right click on upper table brings up popup menu with options: OBRADA PODATAKA (data extraction from

database and setting up tables, chart and report same as reading data from the same GTBM), FILTRIRANJE (filtering view of table) and SORTIRANJE (sorting data in table).


  1. Click on tab ARHIVA GTBM brings up page with two tables on it. Tables show data about


produced GTBM’s. Two selected rows in tables point to the one GTBM. Upper table contains GTBM’s programming data, with two important columns: Br.HHC (unique serial number of GTBM) and NAPON (battery voltage that is GTBM programmed for). Lower table contains information about battery: company name, capacity, serial number, date of buy, date of installation and notes. Right click shows popup menu with options: SORTIRANJE (sorting), FILTRIRANJE (filtering) and PROMENA PODATAKA (enables editing of data field). On

page bottom there is enabled button PRIJEM GTBM PODATAKA. Click on this button enables data import from floppy disc. Floppy contains information about new-programmed GTBM from manufacture, GAUS StS.

GTBM report: example

FABRIKA AKUMULATORA SOMBOR A.D.

GTMB IZVESTAJ

______

Datum : 1.4.2002 Vreme : 14:27

PODACI O UREDJAJU

Serijski broj : 40

Napon baterije = 48V

Datum programiranja : 16.01.2002.

Vreme programiranja : 11:48

GTBM datum = 26.3.2002

GTBM vreme = 11:23

PODACI O KUPCU

Naziv kupca : Eko tehnika, Curug

PODACI O AKUMULATORU

Serijski broj : 3456

Kapacitet : 550Ah

Datum prodaje : 18.01.2002.

Datum montaze : 21.01.2002.

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Detaljni podaci o nedozvoljenim stanjima

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Br. DATUM VREME UACCU OPIS

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1 25.03.2002 09:26 Prekid napajanja!

2 26.03.2002 09:43 Povratak napajanja!

3 26.03.2002 09:47 54.0V Pocetak punjenja!

4 26.03.2002 09:52 57.6V Maksimalni napon punjenja!

5 26.03.2002 09:53 48.0V Zavrsetak punjenja!

6 26.03.2002 09:55 Prekid napajanja!

7 26.03.2002 09:59 Povratak napajanja!

8 26.03.2002 10:02 68.7V Ulaz u opseg prepunjavanja!

9 26.03.2002 10:11 72.0V Maksimalni napon prepunjavanja!

10 26.03.2002 10:11 72.0V Izlaz iz opsega prepunjavanja!

11 26.03.2002 10:11 Prekid napajanja!

12 26.03.2002 10:33 Povratak napajanja!

13 26.03.2002 10:34 38.7V Ulaz u opseg dubokog praznjenja!

14 26.03.2002 10:41 36.6V Minimalni napon dubokog praznjenja!

15 26.03.2002 10:41 46.5V Izlaz iz opsega dubokog praznjenja!

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Ukupan broj prepunjavanja : 1

Ukupan broj dubokih praznjenja : 1

Ukupan broj prekida napajanja : 3

Ukupan broj ukljucenja pod previsokim naponom : 0

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UKUPAN BROJ NEDOZVOLJENIH STANJA : 5

GTBM mounting manual

1. 
You should bind GTBM to flat surface. You should drill two holes (4.5mm in diameter) on surface, as it shown on picture.

2. 
With two screws, that are already mounted on box, GTBM could be binded to the surface.

  1. GTBM needs to be connected to the traction battery and work machine. Connection is made over 4-pins plugs, as shown on picture.


  1. You should bring two wires from traction battery (+ and - poles) and two wires from lift power supply.



  1. WARNING!!! You should take care about pin assignment that is given on paper with GTBM. If you accidentally mix up some pins, you could destroy GTBM permanently.


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GAUS StS-Belgrade, Jurija Gagarina 167/41, tel/fax: +381 11 17 69 142, mob. +381 63 215 722