PowerMon-5S Bluetooth LE 500A Advanced Battery Monitor / DC Power Meter – USER MANUAL – 1
BRIEF PowerMon-5S is a Bluetooth Low Energy Swiss-army knife tool that can be used in any DC circuit. Its primary function is advanced battery monitor / DC power meter. PowerMon-5S allows monitoring of important electrical parameters: voltage (0-65V), current (0-500A bidirectional), peak current, power (W), energy (Wh), battery charge (Ah) and temperature.
FEATURES • • • • • • • • • • • Measures voltage, current (bidirectional), peak current, power (W), charge meter (Ah), energy (Wh) and temperature Operates at up to 65V, allowing it to work in 12V, 24V and 48V systems Measures up to 500A using the integrated high precision shunt Data logging for up to 3 years Can control one relay or SSR (solid state relay) Low / high voltage disconnect Over-current disconnect Low / high temperature disconnect Generator control Battery monitor (battery fuel gauge), displa
TERMINAL DESCRIPTION 3 1 5 2 No. 1 2 3 Type 10mm hex bolt ¼” blade male terminal 10mm hex bolt 4 Name BATT+ BATTLOAD 4 ¼” blade male terminal RELAY 5 connector MF Terminal Description Battery positive. PowerMon-5S takes its power from this terminal. It also measures the voltage at this point. Battery negative. Usually also the chassis ground. Connect using the supplied black wire. Connect to the loads / charger / solar charge controller Relay output. It drives a mechanical or solid-state relay.
SPECIFICATIONS Absolute Maximum Ratings 1,2 Maximum voltage at BATT+ /LOAD terminals Maximum voltage at RELAY Maximum current through the RELAY terminal (maximum relay coil current) Maximum current through the shunt Operating temperature 1. 2. +32V (hw rev 3.0) +65V (hw rev 3.1) +32V (hw rev 3.0) +65V (hw rev 3.1) 2A 500A continuous -30°C to +85°C Stresses greater than those listed under “Absolute Maximum Ratings” may cause permanent damage to the device.
Performance Parameter Measured voltage (BATT+) Measured voltage accuracy Measured current Current monitoring accuracy (using integrated shunt) Integrated current shunt resistance Power Power meter Charge meter Temperature Data logging sample rate Current draw (current consumed by the device) (using the latest firmware version) at 12V at 24V at 32V at 48V at 65V Value 7 ~ 32V (hw rev 3.0) 7 ~ 65V (hw rev 3.1) max 0.5%, typ. 0.25% (hw rev 3.0) max 0.2%, typ. 0.1% (hw rev 3.1) -500A to 500A 0.
COMPLIANCE STATEMENTS FCC ATTENTION: To satisfy RF exposure requirements, this device and its antenna must operate with a separation distance of at least 20cm (8 inches) from all persons and must not be collocated or operating in conjunction with any other antenna or transmitter. 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.
SAFETY INSTRUCTIONS Warning ! Read all the instructions and cautions before using the PowerMon-5S device. Thornwave Labs Inc does not assume responsibility for any injury or property damage caused by improper installation, bad wiring or use of PowerMon-5S outside of its intended purpose. The device should be installed by a professional.
FUNCTIONAL OVERVIEW Device power. The PowerMon-5S device is drawing its supply power from the BATT+ / BATT- terminals. If the device loses power, it will forget the internal clock. The device also monitors the voltage between the BATT+ and BATT- terminals. Current shunt. PowerMon-5S contains an integrated 500A / 0.25% precision current shunt. The current shunt accepts 3/8” ring terminals.
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. Possible uses are to protect the load from high voltage conditions, start external chargers or generators, connect to the grid and so on. Over-current disconnect.
Battery fuel gauge. PowerMon is a battery monitor so it can keep track of a battery state of charge. This is accomplished by using coulomb counting. Charging current is displayed as a positive value while discharging current as a negative value. Due to the complex nature of chemical batteries, small errors in measurement and integrating current over long periods of time will introduce errors in the state-of-charge estimation. This is normal and expected.
Timer5: START disabled, STOP: 12:00AM, REPETITION DOM: 8 This set of timers used together will turn the relay on every 1 st of the month at 12:00AM and turn it off 7 days later on the 8th of the month at 12:00AM. Configuration. The following parameters can be configured using the PowerMon app: Initial Power Status: The default power status when powering the device. If set to on the relay will be turned on automatically when the device receives power.
Over-Current Disconnect OCD Trip Threshold: The current in amperes above which the power relay disengages. OCD Filter (ms): The duration of time the current has to be above the trip value in order to disengage the relay. In order to function as a circuit breaker this should be set to a very low value between 0ms .. 20ms. Larger values will slow down the reaction to over-current. In some instances, this could be useful.
MOBILE APPLICATION – POWERMON The PowerMon device requires a mobile device running Thornwave Labs’ PowerMon app which is available free of charge for both Android and iOS platforms and can be found on Google Play Store and Apple App Store. The mobile device used needs to be equipped with a Bluetooth Smart (LE) adapter. The app will not install on devices that are too old to support Bluetooth Smart (4.0).
Measurement limits. The app allows setting measurement limits. When a measurement value is in between the specified limits it will be displayed with black. If the measurement is outside of the specified limits (less than the low limit or more than the high limit) it will be displayed in red. This feature allows for easy identification of parameters that are not within normal limits. In order to configure the limits, tap on the top right corner menu button when on the scan screen.
Battery Fuel gauge. The device implements a fuel gauge functionality for lead-acid, LiFePO4 and other lithium batteries. When the device is first powered on, the fuel gauge will display “-----” meaning that it is not synchronized with the battery. A full charge is required to bring the SOC in sync with the battery. By tapping on the Battery tab for longer than one second a few options relating to the fuel gauge will be shown.
WIRING DIAGRAM 17
DIMENSIONS Dimensions are in mm.
ORDERING Part Number Description PowerMon-5S - Bluetooth smart DC power meter / battery monitor with PowerMon-5S low/high voltage disconnect, over-current disconnect, timers, and data logging 19
Changelog: Date Revision Description 12/17/2019 3/6/2020 3/23/2020 6/16/2020 Initial preliminary version. Updated wiring diagram. Updated dimensions. Corrected text. Corrected minor issues.
