WhizBang Jr Manual

WhizBang Jr Manual
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Whizbang Jr. – Installation Instructions
The Whizbang Junior provides highly accurate current sensing when used with
compatible Midnite Solar products. However, for our customers that already own
similar products, the Whizbang Jr. has been designed for cooperative
attachment. If you already own another battery-monitoring product and wish to
continue using it, skip down to step 1.2.
Step 1.1 (Whizbang Jr. only): Attach Whizbang Jr. to 500A/50mV Deltec MKB Shunt
or equivalent (see Figure 1).
WARNING: The Whizbang Jr. is designed for low-side shunt measurement. Make
certain shunt is attached to battery-negative, not battery-positive.
A. Remove sensing screws from shunt, including lock-washer and flat-washer.
Put flat washers to the side, they will not be used.
B. With lock-washers attached, guide both screws through the Whizbang
terminals.
C. Slide on provided 1/8” long spacers over screws on the back-side of the
Whizbang Jr.
D. Carefully guide the Whizbang Jr. to the shunt. The Whizbang Jr.’s purple
wire should be pointing toward the battery cable side of the shunt. Handtighten screws to provide a solid connection. Loosen and retighten screws
to ensure a snug fit. Skip to 2.1.
Step 1.2 (Cooperative): Attach Whizbang Jr. to 500A/50mV Deltec MKB Shunt or
equivalent (see Figure 2).
WARNING: The Whizbang Jr. is designed for low-side shunt measurement. Make
certain shunt is attached to battery-negative, not battery-positive.
A. Remove sensing screws from shunt. Gather their attached lock-washers. The
pre-mounted screws and flat-washers will not be used. Put them to the
side.
B. Place provided 1/4" long spacers into Whizbang terminal recesses.
C. Attach lock-washers to included stainless-steel 3/4” screws, then slide
on #8 ring terminals w/attached 3rd party wiring.
D. Guide both screws through the spacers and Whizbang terminals.
E. Slide on provided 1/8” long spacers over screws on the back-side of the
Whizbang Jr.
F. Carefully guide the Whizbang Jr. to the shunt. The Whizbang Jr.’s purple
wire should be pointing toward the battery cable side of the shunt. Handtighten screws to provide a solid connection. Loosen and retighten screws
to ensure a snug fit.
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NOTE: WHIZBANG JR. CAN BE MOUNTED ON SHUNT
BACKWARDS, BUT MEASURED CURRENTS WILL BE OF
INCORRECT POLARITY!
Figure 1 – Whizbang Jr. Only
Included Hardware:
2x
2x
2x
6-218-1
6-210-1
6-239-1
1/8” long, 1/4" O.D., .171” I.D. Alum. Spacer
1/4" long, 1/4" O.D., .171” I.D. Alum. Spacer
3/4" long #8-32 Phillips, Stainless.
Not-Included Hardware:
1x
2x
9-004-1
None.
Deltec MKB Series, 500A, 50mV Shunt.
#8 Ring Terminals.
Figure 2 – Whizbang Jr. and
rd
3 party connections
Step 2.1: Attach Whizbang Jr. to Midnite Classic.
A. Strip approximately 3/16” from the end of the 22AWG purple
Whizbang Jr. wire. Twist the strands together to reduce fraying.
B. Feed wire through preferred conduit opening.
C. Secure wire to Classic AUX2+ input, see Fig. 3 below.
Figure 3 – Whizbang Jr., connection to Classic.
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The Whizbang Junior will need newer firmware loaded into the Classic and MNGP
(MidNite Graphics Panel). You will want to make sure you have Software Revision
1758 or newer. To check your revision press the status button 6 times and look
at the Classic Revision. Or if you are using a Classic Lite you can check the
revision by going to the INFO tab on the Local Status Panel. Visit the
following link and follow directions to bring your Classic/MNGP up to date.
http://www.midnitesolar.com/firmware.php?firmwareProduct_ID=1
SET UP:
From the Main Menu, highlight “AUX” and press Enter. Press the right arrow to
highlight the current AUX-2 mode. Press the soft-right key to enter the AUX-2
setup submenu. Cycle using the up/down arrows until “WHIZBANG JR.” is
highlighted. Press Enter to select this mode. The MNGP will save this mode to
the Classic. Press the Status button to return to the Home status screen.
The LED on the WB Jr. circuit board will begin flashing approximately every 5
seconds if properly connected to the Classic.
STATUS:
Pressing the STATUS button three times will bring you to the Whizbang Jr.
status screen. There are 4 displayed items here, see Figure 4 below.
Instantaneous
Current
Whizbang Jr. Board
Temperature
Temperature
Compensated
Remaining Amp Hours
Figure 4 – Whizbang Jr. Status Screen (Classic)
State of Charge
percentage (SOC%)
This status screen updates live. It displays: Whizbang Jr. temperature,
instantaneous battery current, remaining temperature compensated Amp-hours and
SOC% (if SOC is flashing then the battery has not seen a full charge by going
to float for the first time after turning unit on) Pressing the upper Left
button (Left Soft Key) displays the accumulated Amp Hours screen as seen in
figure 5.
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Positive Amp Hours
Negative Amp Hours
Net Amp Hours
Figure 5 – Whizbang jr. “More” Screen
When the battery is receiving a charge, the accumulated positive Amp-hours
figure will increase, as will the total Net figure. When the battery is being
discharged, the accumulated negative Amp-hours will increase, and the total
(Net) Amp-hours will decrease. As battery charging is not 100% efficient, the
total accumulated Amp-hours or “NET AMP-HOURS” should remain positive after a
discharge-charge cycle. A typical battery efficiency is 94 to 96%.
The Net Amp-hours tally can be configured to reset every time the Classic goes
to float. To set this option, go to the “TWEAKS” menu and press “MORE” four
times. Select “WBRST” and press the UP or DOWN arrow keys to select “YES.”
Press Enter to save. “NO” (or no reset) is the default.
If set to “YES”, only the Net-Amp-Hours will reset. The accumulated +AH and –AH
will keep increasing. These values are stored into non-volatile memory every
night at midnight. If the Classic were to lose power, it would recover
accumulated Amp-hours from the previous day. These values can be cleared from
the Classics Logs menu, please consult the Classics owner’s manual for more
info.
From the WBjr main screen in figure 4 press the upper right button (Right Soft
Key) to take you to the first set up screen.
Battery Capacity
in Amp Hours
adjustment.
Name of the Classic
Charge Controller as set by
the user in the local App
Battery Efficiency
(Typically 94-96%)
Figure 6 – Whizbang jr. “Setup” Screen
On this screen we need to set the Capacity of the battery bank. Remember that
batteries in series do not add in Amp Hours, only batteries in parallel.
(Example- 2 strings of 4 6 volt golf cart batteries that are 220 Amp Hours each
wired for 24 volts would be 440Ah) Holding Shift while changing the Ah capacity
will change in steps of 100. The Default setting is 400Ah.
We need to set the Efficiency. Typically on a flooded battery this will be
between 94 and 96%. On a sealed battery it can be higher. If there is any
question you should shoot for a lower efficiency, not a higher one. You can
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also contact your battery supplier for help with that value. After both of
these are set, press Enter to save them. Next, press the upper right button,
(Right Soft Key) to continue with setup.
Percentage of Capacity change
per degree C of battery
temperature (User adjustable
from 0 to 3%, typically 1%)
The Temperature
reference where no
compensation occurs
Figure 7 – Whizbang jr. “Setup-2” Screen
On the second setup screen “figure 7” we need to set the battery temperature we
reference to for temperature compensation for capacity change and voltage
adjustment. As a battery changes in temperature, its apparent capacity changes
and the voltage we charge it to needs to change. If the battery temperature is
above the “Reference Point” (Hot) we gain capacity and lower the charge
voltage. If the battery temperature is below the reference point (Cold) we lose
capacity and raise the charge voltage. Most standard batteries use 25 Degrees
Celsius as their “Reference Point”. If your battery uses something other than
25C for a reference value, this is where you would set it.
We also have to set the percentage of capacity lost or gained for every degree
Celsius we are below or above the reference point. This value can be set from 0
to 3%, where 0 is disabled. Typically a lead acid battery is 1% per degree C.
When both values are set press Enter to save these changes and then press
Status to return to the home screen.
For help with any of these battery specific values, please contact your battery
supplier/manufacturer.
Also note that on the Home screen the Charge stage message in the bottom right
corner will toggle between the current stage and the actual state of charge
percentage after it goes to float for the first time.
WHIZBANG JR. ASSISTED CHARGING:
One feature of the Whizbang Jr. is the ability to end an Absorb charge based on
Ending Amps. In this mode, if the battery current falls below a programmable
threshold for one minute, the Classic will go to Float, meaning that the
batteries have been fully charged.
To enable Whizbang
Select “ADVANCED.”
“SHUNT” (selecting
Enter to save your
Jr. assisted charging, select “CHARGE” from the main menu.
Press the soft-left key until the annunciator above it reads
“CLASC” uses the Classic’s internal shunt instead). Press
choice.
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Setting the Ending Amps value properly is important. Setting this value too
high will lead to under-charged batteries. Setting it too low may make it
impossible to reach. In which case, the Classic will transition to Float based
on Absorb time. Similarly, an Ending Amps setting of “<0.0” will disable this
feature, causing the Classic to transition to Float based on Absorb time only.
Consult your battery manufacturer’s literature to determine recommended Ending
Amps.
Note: If you have two or more Classics connected using Follow-Me mode, the
other Classics should follow the Classic connected to the Whizbang Jr.
TROUBLESHOOTING:
If the Classic’s Whizbang Jr. status screen (see Fig. 4) shows the Whizbang
Jr.’s board temperature sitting at -50°C after initial setup, then the Whizbang
Junior is NOT communicating with the Classic’s AUX-2 circuitry. Here are some
tips in troubleshooting this scenario.




Is the Classic firmware up to date? Check the Classic’s status display
for main firmware/MNGP firmware versions.
Does the Whizbang Jr’s purple wire make a solid connection with the
Classic AUX2+ input? Is the Whizbang Jr. securely attached to the shunt?
Is the shunt attached to battery-negative? Is the Classic tied to
battery-negative?
Is the Classic’s AUX-2 setup mode set to “WHIZBANG JR.”?
Check the Whizbang Jr.’s LED
Behavior
Blinks ON every 5 seconds.
Meaning
The Whizbang Jr. is
receiving data-requests and
responding.
Suggests
The Whizbang Jr. is
receiving data. Check
Whizbang status screen.
Solid ON
The Whizbang Jr. has power,
but there appears to be no
communication.
AUX2 mode misconfigured.
Revisit page 2.
Solid OFF
The Whizbang Jr. has no
power.
Improper wiring and/or AUX2
mode misconfigured.
Blinks rapidly
Hardware Fault
Device may be damaged. Try
cycling Whizbang Jr.’s
power.
Note: To manually reset accumulated Whizbang Jr. Amp-hour tallies, go to “LOGS”
menu and press Enter. There are three entries related to the Whizbang Jr.: “WB
Jr. NET Amp-Hours”, “WB Jr. (+AH)”, and “WB Jr. (-AH)”. To erase, select one
and use the soft-left or soft-right keys to confirm “YES”, or “NO”. Once
confirmed, the Classic will display “Clearing Data” for a few seconds and then
return to the main log menu.
MidNite Solar 17722 – 67th Ave NE Arlington, Wa 98223
PH 360.403.7207 Fax 360.691.6862
www.midnitesolar.com
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