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User Guide

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Contents

Introduction 5
Main panel 7
Graphics display 8
Encoder 8
External clamp connection 8
USB Port 8
Emergency power off button (EPO) 9
External energy supply socket 9
Ports for connection to other MDB-IIs 9
Discharged current and alarm monitors LED bar 9
Main Status and Ready LED 10
Auxiliary I/O Contacts 10
Using the MDB-II 11
Connecting the power cables to the MDB-II 11
Choosing how to supply energy to the system 12
Connecting the power cables to the batteries 13
Supplying the device with energy 13
Understanding how to use the encoder to move around on the display 15
Setting discharge parameters 18
Which memory should be used? 19
What is the end of discharge voltage? 20
What current value should be used to discharge the battery? 22
How to set the end of discharge battery capacity 26
How much time should battery discharge take? 27
Starting up a discharge session 27
Pausing the discharge session 30
Stopping the discharge session 31
Items to remember 32
Navigating between internal menus 33
Reset System 34
Discharge mode 35
External Current 39
Saved Curves 42
System Alarms 44
Date and Time 46
System Language 46
Parallel functioning 47
How to set a MDB-II MASTER in SLAVE mode 47

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


How to reset a MDB-II MASTER in MASTER mode 48
How to START A DISCHARGE WITH UNITS IN PARALLEL 49
General safety information 51
Technical specifications 52
Specifications 53

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


IDENTIFICATION:

CODE REVISION REVISION DATE Reference

GU______ ___ __ 2.0.0 (draft) 14/04/2011 UNI EN ISO 9001:2000

REVIEW:

REVISIONED PARTS
REVISION REVISION DATE DESCRIPTION
Paragraph(s) Page(s)

3.0.0 14/04/2011 Emission

APPROVED:

DEPT. NAME SIGNATURE DATE

PREPARED BY R&D R.Prato

CONTROLLED BY R&D A.Boon

APPROVED BY DIR S.Farsetti

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Introduction

MDB-II is a device that is easy to use and practical, with advanced


technical characteristics.

MDB-II is a portable device, built with latest generation technology and elements, able to discharge
stationary batteries in an effective, controlled, and secure manner.

The technology utilised is exclusively digital, making broad use of microprocessors.


A graphic display, together with a single rotating encoder control, allow for complete control and command of
the device.

MDB-II allows for discharging banks of batteries with a nominal voltage from 24Vdc to 240Vdc.
The maximum dischargeable current depends on the working voltage range:

Voltage range Maximum current

24V - 120V 130 A

220V - 240V 65A

Obviously, it is possible to increase the maximum dischargeable current by connecting up to 10 MDB-II


devices in parallel: in this case, obviously, the maximum dischargeable current shall be given by multiplying
by the number of devices used. It is therefore possible to discharge up to a maximum of 1300 amperes.

Furthermore, MDB-II is also able to measure and take into account the current discharged from a further
external charge that is not directly controllable, so that it can evaluate the effective capacity drawn from the
battery.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


MDB-II is able to function autonomously, thanks to non-volatile on-board memories, to carry out and save all
parameters and measurements taken during the discharge session. Below are the characteristics of the
memories:

• number of saveable sessions: 8


• maximum session length: 15 hours
• temporal recording resolution: 15 seconds
• saved data: battery voltage and current

The content of the memories can obviously be exported onto a computer, thanks to the “MDB-II Manager”
software and the USB connection, in order to allow for viewing it in graph or number form, saving it on disk,
or printing it on paper.

MDB-II can function both with energy supply from the network, with ranges which range from 100Vac to
240Vac 50/60Hz, and with energy supply deriving from the same batteries being discharged.

Warning:
In normal operations, the MDB-II device forces the ouput of hot air from its upper back part.
The external metallic surface can reach very high temperatures!

Avoid direct contact with the hands until the automatic cool-down cycle has automatically finished.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Main panel

MDB-II’s main panel was created to be clear, simple, and practical. On


the front, all commands are available, as well as power connections,
graphics display and LED bar, and the only command knob, which is a
rotating encoder knob with an integrated button.

Below are the details of the main characteristics and functions made available by the front panel
components.
GRAPHIC
DISPLAY
ENCODER

USB PORT

AUXILIARY I/O
CONTACTS EXTERNAL CLAMP
PORT

EMERGENCY SUPPLY
POWER-OFF SELECTOR
BUTTON
LED READY

ALARM MONITOR
EXTERNAL AND DISCHARGED
ENERGY CURRENT LED BAR
SUPPLY AND
POWER-OFF LED MAIN STATUS
SOCKET

NEGATIVE POLARITY MDB-II SLAVE POSITIVE POLARITY


CONNECTION BATTERY CONNECTION
BATTERY CONNECTION
PORTS

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Graphics display
Through this liquid crystal graphics display, it is possible to view the device status, electric measurements of
the connected battery, and the voltage and current curves of a discharge saved in the on-board memory.
Through this single display, it is also possible to set the functioning modes and the internal parameters of the
MDB-II.

Encoder
The control, the command, and the user interface in general, are structured in such a way as to be used by a
single rotating encoder control, with an integrated “accept” button: simply rotating the encoder in a clockwise
or counterclockwise motion, it is possible to navigate through the various entries of the context menus. To
accept an option, simply push the encoder itself.

External clamp connection


The BNC sockets available for connection of a continuous current clamp, allowing for reading the current
discharged from an external device that cannot be controlled by the MDB-II itself. The value of the current
that is read is added in this way to the discharge setting in order to correctly evaluate the quantity of capacity
drawn from the battery. In the case of external current reading, the MDB-II discharges the current which is
the difference between the set value (total current to be discharged) and the current read by the clamp (or
shunt).

USB Port
The USB 2.0 port on the front of the panel allows for connecting the device to a computer in order to save on
disk, view, and print the contents of the MDB-II memories. The “MDB-II Manager” software notably facilitates
this operation.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Emergency power off button (EPO)
The mushroom push button allows for immediately powering off the MDB-II if necessary. This command
immediately cuts all sources of energy supply to the internal electronics, causing the immediate power-off of
the unit and consequently stopping the battery discharge. The unit can only be reset by resetting the button,
or by rotating the red knob in a clockwise motion and pulling it out towards you.

External energy supply socket


Through the external energy supply socket, it is possible to provide energy to the device from an auxiliary AC
source. This operation is practically necessary if, during discharge, the battery voltage should fall to under
the 105Vdc value. It is possible to connect any source of alternating voltage, starting from 110Vac up to
240Vac, 50Hz or 60Hz. To function correctly, it is important to check that the Power Source Selector, to the
right of the socket, is set correctly.

Ports for connection to other MDB-IIs


The two ports available on the unit front are for permitting more than one MDB-II to be connected, which is
necessary if the current that needs to be discharged is more than the nominal current of the single device.
The connection between various devices takes place by a simple RJ11 cable, which is commonly used for
telephone appliances. The maximum length of the cable should not be more than 2 meters. There are two
equivalent sockets, which allow for connecting another device in cascade connection. To function correctly, it
is important to correctly set the addresses assigned to the MDB-IIs through the rotating Address Selector,
just under the connection ports.

Discharged current and alarm monitors LED bar


The LED bar has 10 segments on the front panel and accomplishes two tasks: during normal functioning, it
indicates the percentage of discharged current in relation to the maximum allowed capacity; in the case of
failure of the devices within the MDB-II, erroneous clamp connection, or irregular battery, the LED offers a
detailed indication of the anomaly that has occurred.

irregular CAN-Bus communication


irregular convertor/controller
fans failure
high dissipator temperature
power surge/ irregular LEM
irregular battery voltage
high battery voltage
low battery voltage
fuse blown
high system temperature
fans failur

irregular
battery
voltage
high batte
Document: MDB-II User Rev.3.0.0 Date: 21/03/2011
voltage
low batter
voltage
Main Status and Ready LED
On the front of the panel, there are 2 LEDs which immediately indicate the device conditions.
The Ready LED, which is green, comes on when the power electronics have been correctly supplied from
the point of view of battery polarity and voltage range, and there are no problems with the functioning of the
internal power conversion statuses.

The second LED, Main Status, which is below the LED bar, can have 2 different colours:

Red, when there is at least one device or setting irregularity, which could impede the start-up of a
discharge session

Green, when all of the requirements for starting up the discharge session are fulfilled

Yellow, when a battery is disharging

Auxiliary I/O Contacts


In the upper part of the front panel, to the left of the main display, there are two panels within some red/black
bushings.
In the upper panel, the two Input Remote Control bushings act as:
• input command when the MDB-II is used together with a battery charger, so as to automate the charge-
discharge cycles.
• remote manual stop command during a single discharge session with the loop function deactivated.

In the lower panel, the three Output Alarm Contact bushings, clean exchange contacts, allow for signalling
an alarm and/or end of discharge situation.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Using the MDB-II

In this chapter, the following shall be discussed: how to connect the


device to the battery, the operations to carry out to set the discharge
parameters in the device, and how to start up, pause, and stop a
discharge.

To make the MDB-II work, it is necessary to connect it as follows:


• to a battery, with a voltage included in the work range, by two cables, with crocodile clamps, included with
the equipment
• if necessary, to an external energy supply source, through the energy supply cord included with the
equipment

Connecting the power cables to the MDB-II

First of all, the power battery power cables are connected to the device, to the two connectors named
“Battery +” and “Battery –“, paying special attention to the polarities.

• the cable with the red crocodile clamp is connected to the “Battery +” connector
• the cable with the black crocodile clamp is connected to the “Battery -” connector

Cable with BLACK Cable with RED crocodile

crocodile clamp clamp

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Choosing how to supply energy to the system
To work, the MDB-II needs an energy supply.
There are two possibilities: through the battery itself or through an external AC current socket.
The following table helps to choose the most appropriate energy supply method:

Battery Battery energy External socket


nominal supply energy supply
voltage

24Vdc

48Vdc

110Vdc

120Vdc

220Vdc

240Vdc

Key:

Not usable

Usable, but not the preferred choice

Fully usable

Once the energy supply source to be used is chosen, the Power Source Selector has to be correctly set.

Move the switch to the left when choosing to


provide energy from an external source.

Move the switch to the right when choosing to


provide energy from the battery.
.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Connecting the power cables to the batteries

Once the power cables have been correctly connected to the device, begin connecting the black crocodile
cable to the negative of the battery; then connect the red crocodile cable to the positive of te battery.
Ensure that the connections are firm, in order to avoid that the clamps overheat at the maximum discharge
current.
Ensure that the connections do not have inverted polarities: in this case the device shall not allow for the
battery to be discharged.

If the system is to be supplied with energy from the battery itself, as soon as the power cables are
connected, MDB-II immediately follows the start-up routine and immediately provides for beginning the
discharge.

If the system is to be supplied with energy through the external AC socket, once the power cables are
connected, nothing happens: the device waits to receive energy supply from the socket on the front of the
panel.

Supplying the device with energy

If the MDB-II is to be provided energy from the battery being discharged, the device has already been
supplied in the same moment that the power cables were connected to the battery.

If the MDB-II is to be provided energy from the external energy supply socket, the energy supply cord needs
to be connected to the socket on the front and the switch on the energy supply chamber needs to be turned
on: the device is immediately supplied, and the start-up routine proceeds and provides for starting the
discharge.

When the MDB-II starts up, it automatically carries out various control operations on the internal devices:

- the connection of other MDB-IIs in the network and their functioning is controlled
- if present, all connected MDB-IIs are started up
- the battery voltage is shown, once the work range and the maximum current and power of discharge
that can be set are established
- the device prepares to carry out a new discharge using the same end of discharge control parameter
values as those of the last discharge session carried out

At this point, the display shows all necessary information to the user, as well as the measurements taken
from the battery. The display information is organised as follows.

System information bar


15:56 18-11-07 MEMORY MENU
120.0
1 V
Battery measurement bar
130 A
0.0Ah 00:00:00 SEC

System messages and end of discharge controls bar


STOP: 102V 18A 100AH 14:59
START BARS PAUSE STOP
Command bar

In detail, the information, the measurements, and the commands presented are organised in this way:
Document: MDB-II User Rev.3.0.0 Date: 21/03/2011
Memory in which the Command to go to the settings
system time and date
discharge will be saved menu

battery voltage read current presently


15:56 18-11-07 MEMORY MENU discharged from the
during operation
1 battery
120.0 V
130 A

capacity discharged time remaining to the


0.0Ah 00:00:00 SEC
from the battery end of discharge
during the discharge
session
Control parameters for end of discharge:
STOP: 102V 18A 100AH 14:59 C - end of discharge voltage
- setting of current to be discharged
START BARS PAUSE STOP - end of discharge capacity
- discharge session duration time
- discharge mode

Discharge commands

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Understanding how to use the encoder to move around on the display

Once the system has been supplied with energy and the batteries are connected (let’s suppose that there is
a battery voltage equal to 120.0Vdc), the interface arranges for the immediate start-up of a discharge. The
parameters that will be controlled by the system for the control and stop of the discharge shall be shown in
the “System Messages and End of Discharge Control” bar. The system immediately sets itself on the START
command, showing it in the field that is reversed compared with the others:

Rotating the encoder to the right, we move to the next entry, indicated with the BARS label:

By pushing the encoder knob, we can enter into the BARS menu:

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


The new menu that is shown shall be the one from which, in just the blink of an eye, we can divide the
discharge currents, temperature, and voltage read by the whole fleet of connected devices:

By pushing the encoder knob again, we return to the previous menu.

The system immediately sets itself on the next option:

By rotating the encoder two clicks to the left, we are brought to the START entry:

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Now the START command is highlighted again:

So, we can say that:

• moving the encoder clockwise:


we move onto the next menu entry
the numerical values increase
moving the encoder counterclockwise:
we move onto the previous menu entry
the numerical values decrease
Pushing the encoder:
we enter into the highlighted menu
the highlighted action is carried out
the set numerical value is chosen
the option shown in the display is chosen

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Setting discharge parameters

MDB-II makes various options available for discharging batteries, some which are particularly specialised,
reachable only after having entered into the more internal setting menus.

Normally, and in particular every time the MDB-II is turned on, the systems arranges for discharging the
battery in Constant Current mode (to change modes, please see the paragraph regarding setting discharge
modes); the discharge mode is shown with a letter, on the far right of the System Messages and End of
Discharge Control Bar.

Setting the main discharge parameters, those which will surely be used in the great majority of cases, takes
place in the main menu, that is, the one that is shown when the system is turned on:

The parameters which can be set in this screen are the following:

memory number to be used


voltage at the end of battery discharge
current (or power) of battery discharge
end of discharge battery capacity
time (hours and minutes separately) that the battery discharge will last

Of these parameters, only two are used to carry out the discharge: the current (power) of discharge and the
memory to be used.
The other parameters, instead, help to establish when the discharge should be stopped.

A discharge session is automatically stopped when at least one, or more, of these parameters is not satisfied
anymore:

when more than the set time has passed


when the battery voltage falls below the voltage value set for the end of the discharge
when the set battery capacity has been discharged
when contact that may be connected to the Input Remote Control bushings is closed (in the case of
deactivated loop function)

Obviously, a discharge can also be definitively stopped by the operator at any moment, by using the STOP
command.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Which memory should be used?

MDB-II has 8 internal memories available, which are not deleted when the device is powered off, and are
able to save the voltage and current values discharged from the battery every 15 seconds, for a maximum
duration of 15 hours. The presence of these memories makes the device particularly autonomous, in that it is
possible to carry out 8 discharge sessions before having to connect a computer to collect the data from the
memories.

Obviously, it is necessary to pay particular attention to not overwrite memories that have already been used
before transferring them to the computer!

At the end of each discharge session, MDB-II automatically sets itself to use the next memory.
However, the operator, if necessary, can manually choose the memory on which the curves should be
saved:

rotate the encoder until the curve number option is highlighted


push the encoder to enter into the menu to select the memory number
the curve selection menu is displayed
if the memory selected has never been used, a message indicates that the memory is empty
if the memory selected has already been used, the summary data about the curve is displayed: date,
time, and duration of the last execution
rotate the encoder to move to the desired memory number: as the coder is rotated, the summary
data of the memory is displayed
push the encoder to choose a memory and exit the menu

The pre-chosen memory is shown in the System Information Bar.

System information bar


15:56 18-11-07 MEMOR. 1 MENU
120.0 V
130 A
0.0Ah 00:00:00 SEC

STOP: 102V 18A 100AH 14:59 C


START BARS PAUSE STOP

At this point, the next discharge session shall be recorded on the selected memory, overwriting the data that
was already saved on it.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


What is the end of discharge voltage?

When a battery is discharged, it is always necessary to avoid that its voltage drops to below a certain level,
to prevent that it becomes damaged. This voltage value is commonly called the “end of discharge voltage”.
The end of discharge voltage and the type of battery are related; it is possible to say that:

for lead batteries, the end of discharge voltage is equal to about 1.8-1.7 V/ cell
for NiCd batteries, the end of discharge voltage is equal to about 1.1-1.05 V/ cell

The best choice for the end of discharge value is evaluated based on experience, on the requirements of the
facility, the temperature, etc.

To calculate the effective end of discharge voltage, then, the end of discharge value needs to be multiplied
by the number of cells that make up the entire battery.

It is typical to have the following end of discharge voltage for the following voltage ranges:

Battery Advised end of Deep end of Absolute


nominal discharge voltage discharge voltage minimum settable
voltage (minimum limit) limit (*)

24Vdc 22 Vdc 21 Vdc 20 Vdc

48Vdc 44 Vdc 41 Vdc 20 Vdc

110Vdc 99 Vdc 94 Vdc 20 Vdc

120Vdc 108 Vdc 102 Vdc 20 Vdc

220Vdc 198 Vdc 188 Vdc 20 Vdc

240Vdc 216 Vdc 204 Vdc 20 Vdc

(*) The absolute minimum limit could be not reached in some voltage ranges: in these case the unit could stop the discharge session
showing the “control failure” alarm

When it is turned on, the MDB-II analyses the battery voltage and tries to align it with the voltage range to
which the battery belongs; after this, it determines the typical end of discharge voltage, in accordance with
the table above.
Initially, the MDB-II tries to set the same end of discharge voltage value used in the previous discharge; if it
is impossible to use that value, the end of discharge value from the corresponding “advised” column will be
set.
However, the operator can intervene to select the most suitable end of discharge voltage:

rotate the encoder until the battery voltage measurement is highlighted


push the encoder to enter into the end of discharge voltage settings menu
the Vstop settings menu is displayed
the current end of discharge voltage value is displayed in Volts
rotate the encoder to choose the most suitable value: the voltage range on which it is possible to
work ranges from the battery’s nominal value to the lowest anticipated value of minimum voltage, so that it
does not damage the battery
when the set value is the correct one, push the encoder to exit the menu

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


The set end of discharge value is displayed in the System Messages and End of Discharge control bar.

15:56 18-11-07 MEMORY MENU


120.0
1 V
130 A
0.0Ah 00:00:00 SEC

System messages and end of discharge controls bar


STOP: 102V 18A 100AH 14:59 A
START BARS PAUSE STOP

At this point, the next discharge session shall be stopped if the battery voltage should reach and exceed the
set end of discharge voltage value.

NOTE: sometimes its possible that, even if the unit allows to set the absolute minimum limit as Vstop (20V),
the discharge session will stop before touching threshold; it happens when the internal power control device
reaches the its maximum modulation limit (normally it depends on the nominal beginning battery voltage).

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


What current value should be used to discharge the battery?

The reason for discharging the battery is to verify that it is able to supply the stated nominal capacity. It is
quite usual that the nominal capacity refers to a discharge current equal to one-tenth of the nominal capacity;
in this way, to be able to establish in a repeatable way the effective degree of battery reliability, it is advised
to discharge the battery for 10 hours with a current equal to one-tenth of the nominal capacity.

Practical example:
A nominal 110Vdc battery, with a 600Ah capacity, can be discharged setting a discharge current equal to:

600 Ah / 10h = 60A, for a duration of 10 hours

In this way, if at the end of 10 hours the battery voltage is still above the end of discharge voltage, it is
possible to confirm that the battery is in good condition. Obviously, it is also possible to discharge the
battery more “violently”, maybe in half the time, or 5 hours; in this case we will have:

600 Ah / 5h = 120A, for a duration of 5 hours

Obviously, it is also necessary to take into account the capacity of the device to discharge the desired
current, in the environmental conditions in which it is found.
In general, the maximum discharge current that can be set depends on:

the battery’s nominal voltage


environmental temperature

Each parameter is discussed below.


MDB-II is able to distinguish two work ranges based on the measured battery voltage:

range 24-120V range 220-240V

24V 48V 60V 110V 120V 220V 240V

130A 65A

The voltage difference of the work range is equal to 140V.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


It is possible that the nominal voltage of a 125Vdc battery can lead MDB-II to choose an unsuitable range
and so, an erroneous maximum discharge current. This choice depends on the battery voltage and, so, on
the voltage to which the battery was being recharged just before beginning to discharge it.
Therefore, it is possible that MDB-II limits the maximum dischargeable current to 65A for batteries with a
nominal voltage more than 120Vdc.
Vice versa, in the case that MDB-II assigns the battery to the first range (maximum dischargeable current
equal to 130A), the operator shall pay attention to ensure the effective dischargeable current is not
exceeded, which is given by the following formula:

maximum dischargeable current <=16000W/ nominal voltage

Practical example # 1:
With a lead battery with 62 cells, of nominal 125Vdc, at the environmental temperature of 25°C, a
maximum current can be discharged equal to:

16000 W / 125V = 128A

Practical example # 2:
With lead battery with 120 cells, of nominal 240Vdc, at the environmental temperature of 25°C, a maximum
current can be discharged equal to:

16000 W / 240V = 65A (limited to the maximum value which is 65A)

A second factor on which the maximum dischargeable current depends, in general, is given by
environmental temperature. For each range, the stated maximum dischargeable current is that which should
be set at an environmental temperature of 25°C.
As environmental temperature increases, the operator shall reduce the maximum current to be discharged
according to the following rule:

maximum dischargeable current=


nominal maximum dischargeable current- (environmental temperature- 25)

Practical example # 1:
With a battery of nominal 110Vdc and with an environmental temperature equal to 32°C, a maximum
current can be discharged equal to:

130 - (32-25) = 123A

Practical example # 2:
With a lead battery with 62 cells, of nominal 125Vdc, at the environmental temperature of 32°C, first the
maximum dischargeable nominal current should be evaluated, and then the derating due to excessive
temperature should be applied:

16000 W / 125V = 128A


128 - (32-25) = 121A

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


The grid below shows the the maximum discharge current in function of ambient temperature:

Battery
nominal
Maximum dischargeable current based on environmental temperature
voltage

25° 26° 27° 28° 29° 30° 31° 32° 33° 34° 35° 36° 37° 38° 39° 40°
C C C C C C C C C C C C C C C C

24Vdc 130 129 128 127 126 125 124 123 122 121 120 119 118 117 116 115
A A A A A A A A A A A A A A A A

48Vdc 130 129 128 127 126 125 124 123 122 121 120 119 118 117 116 115
A A A A A A A A A A A A A A A A

110Vdc 130 129 128 127 126 125 124 123 122 121 120 119 118 117 116 115
A A A A A A A A A A A A A A A A

120Vdc 130 129 128 127 126 125 124 123 122 121 120 119 118 117 116 115
A A A A A A A A A A A A A A A A

220Vdc 65A 64A 63A 62A 61A 60A 59A 58A 57A 56A 55A 54A 53A 52A 51A 50A

240Vdc 65A 64A 63A 62A 61A 60A 59A 58A 57A 56A 55A 54A 53A 52A 51A 50A

To increase the maximum dischargeable current, it is advised to make use of more than one MDB-II, until
reaching the maximum current to be discharged:

Battery
Maximum dischargeable current by number of MDB-IIs connected together at the
nominal
nominal environmental temperature (25°C)
voltage

1 2 3 4 5 6 7 8 9 10

24Vdc 130A 260A 390A 520A 650A 780A 910A 1040A 1170A 1300A

48Vdc 130A 260A 390A 520A 650A 780A 910A 1040A 1170A 1300A

110Vdc 130A 260A 390A 520A 650A 780A 910A 1040A 1170A 1300A

120Vdc 130A 260A 390A 520A 650A 780A 910A 1040A 1170A 1300A

220Vdc 65A 130A 195A 260A 325A 390A 455A 520A 585A 650A

240Vdc 65A 130A 195A 260A 325A 390A 455A 520A 585A 650A

In steps of 1 ampere, the operator can set the discharge current:

rotate the encoder until the battery current measurement is highlighted


push the encoder to enter into the end of discharge current settings menu
the discharge current settings menu is displayed (or the power in 100 Watt, if the constant power
discharge mode is selected)
the current discharge current is displayed in amperes (or the power in 100 Watt, if the constant
power discharge mode is selected)
rotate the encoder to choose the most suitable value: the current range on which it is possible to
work ranges from the 1A to the maximum current value that the system can discharge, based on the voltage
range and the number of MDB-IIs connected together (or from 100 Watt to the maximum possible power
value, if the constant power discharge mode is selected)
when the set value is correct, push the encoder to exit the menu

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


The set current, or power, value is displayed in the System Messages and End of Discharge control bar.

if the constant current, manual, or discharge profile discharge mode was set, the current is indicated
in amperes
if the constant power discharge mode is set, the power is indicated in kW

15:56 18-11-07 MEMORY MENU


120.0
1 V
130 A
0.0Ah 00:00:00 SEC

System messages and end of discharge control bar


STOP: 102V 18A 100AH 14:59 A
START BARS PAUSE STOP

At this point, the next discharge session shall be carried out by constantly discharging the set current.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


How to set the end of discharge battery capacity

Setting the end of discharge battery capacity is useful to automatically stop the discharge session, for
example, when the battery is completely empty, half empty, etc.

The most common setting is to set the same value as the nominal capacity of the battery as the end of
discharge capacity.

Sometimes, it can be useful to remove this type of end of discharge control, for example when the user
wishes to verify when the battery has effectively completely discharged. In this case, it is necessary to set a
value equal to 0 Ah.
When the value is set at 0, the system still measures the discharged capacity but this measurement is not
accounted for in the verification of when to automatically stop the discharge.

At steps of 1 ampere hours, the operator can set the end of discharge capacity value:

rotate the encoder until the battery capacity measurement is highlighted


push the encoder to enter into the end of discharge capacity settings menu
the discharge capacity settings menu is displayed
the current capacity value in ampere hour is displayed
rotate the encoder to choose the most suitable value: the capacity range on which it is possible to
work ranges from the 0Ah value (no control on the discharged capacity) to the maximum dischargeable
current value for the dischargeable time, based on the voltage range and the number of MDB-IIs connected
together
when the set value is correct, push the encoder to exit the menu

The set end of discharge capacity value is displayed in the System Messages and End of Discharge control
bar.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


How much time should battery discharge take?

The duration of a discharge session obviously depends on the battery, on the current that is to be
discharged, on the battery capacity, and on the maximum current dischargeable by the MDB-II.
It is not possible to establish a fixed rule, but considering that the best choice is to discharge the battery with
a current equal to one-tenth of the nominal capacity, it is quite common to set a duration equal to 10 hours.

Sometimes, it can be useful to remove this type of control on the end of the discharge, for example when it is
desired to discharge the battery for more time than 15 hours. In this case, a duration equal to 0 hours and 0
minutes shall be set.
When the value is set at 00:00, the system still measures the discharge time that has passed, but this
measure is not accounted for in the verification of when to automatically stop the discharge.

In unit steps, the operator can set both the number of hours and the number of minutes of discharge
duration:

rotate the encoder until the two numbers that represent the discharge duration hours are highlighted
push the encoder to enter into the discharge duration hours settings menu
the discharge duration hours settings menu is displayed
the current value of the hours is displayed
rotate the encoder to choose the most suitable value: the range of hours on which it is possible to
work ranges from the value 0 hours to 14 hours
when the set value is correct, push the encoder to exit the menu

The discharge minutes can be set by using the same method:

rotate the encoder until the two numbers that represent the discharge duration minutes are
highlighted
push the encoder to enter into the discharge duration minutes settings menu
the discharge duration minutes settings menu is displayed
the current value of the minutes is displayed
rotate the encoder to choose the most suitable value: the range of minutes on which it is possible to
work ranges from the value 0 minutes to 59 minutes
when the set value is correct, push the encoder to exit the menu

The total duration shall be given by the sum of the hours plus the minutes.

The set discharge session duration value is displayed in the System Messages and End of Discharge control
bar.

Starting up a discharge session

At this point, it is possible to set the MDB-II to discharge a battery using the required parameters.

The following have been set:

the memory number on which the discharge session should be saved, for example, MEMORY 1
the end of discharge battery voltage, for example, 102Vdc (allowing a battery bank of 110Vdc)
current if the battery discharge, for example, 60A
end of discharge battery capacity, for example, 600Ah
time that the battery discharge will last, for example, 10 hours and 0 minutes

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Rotate the encoder until the START entry is highlighted:

Push the encoder, and a request will appear to confirm carrying out the command given:

Highlight the choice NO to exit this menu and not do anything.


Highlight the choice YES to carry out the start of discharge command.

Push the encoder to confirm the choice.

The discharge is started up immediately and the system begins to discharge the set current.
At the same time, the system fans begin to allow for adequate cooling of the internal devices.
On the LED bar, the LEDs will light up in a manner proportional to the maximum admissible discharge
current: in our case, 60A represents 46% of the maximum dischargeable current and therefore, 5 red LEDs
will light up, starting from the lower part:

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


If various MDB-IIs are connected between each other, the same sequence of actions shall take place at the
same time on all devices, so that the total discharged current is divided equally.

In the meantime, the display will show:

15:56 18-11-07 MEMORY MENU


122.2
1 V
60 A
30.1Ah 09:29:45 SEC
DISCHARGING BATTERY
STOP: 102V 60A 600AH 10:00 A
START BARS PAUSE STOP

The most important electrical measurements, the discharge time, and the system status are shown on the
display.
In particular there are:

the battery voltage measurement (122.2 V)


the present discharged current (60 A)
the partial capacity discharged from the beginning of the session ( 30.1 Ah)
the time left until the end of the discharge session (09:29:45 sec)
the system status (BATTERY BEING DISCHARGED)
the parameters that cause automatic stopping and the discharge mode (STOP 102V 60A 600AH 10:00
C)

Allowing the system to work autonomously, the discharge session will go ahead until at least one of the
following conditions occurs:

the battery voltage falls to under 102V


the discharged capacity is more than 600Ah
the reverse counter will have counted 10 hours
the operator will have manually stopped the test

During discharge execution, all settings that have been discussed up to now are disabled, including access
to the system settings MENUS.

The operator, however, can still access the following functions:

BARS, to graphically view the discharge current distribution among the various MDB-IIs
PAUSE, to momentarily stop the test without resetting the reverse counter to zero
STOP, to definitively stop the test

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Pausing the discharge session

Imagine that a discharge session is underway; the user needs to momentarily stop the discharge, but not
definitively stop it.

Rotate the encoder so that the PAUSE command is highlighted:

DISCHARGING BATTERY

Push the encoder, and a request will appear to confirm carrying out the command given:

Highlight the choice NO to exit this menu and not do anything.


Highlight the choice YES to carry out the discharge suspension command.

Push the encoder to confirm the choice.


MDB-II, and all of those which may be connected, shall immediately suspend the discharge; the red LEDs on
the LED bar will all turn off and on the display it will be seen that the system has been set to pause:

DISCHARGE PAUSE

The system prepares for a possible definitive stop of the discharge session.

In the meantime, for a few minutes, the fans will continue to work, in order to cool down the internal system
components.

At this point, the discharge can be restarted from the point at which it was interrupted, or it can be definitively
stopped.

To restart the discharge underway, rotate the encoder to select the START command and push; confirm the
restart of the discharge, and push the encoder again; at this point the discharge session restarts from the
point at which it stopped.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Stopping the discharge session

A discharge session is underway; the user wants to definitively stop the discharge.

Rotate the encoder so that the STOP command is highlighted:

DISCHARGING BATTERY

Push the encoder, and a request will appear to confirm carrying out the command given:

Highlight the choice NO to exit this menu and not do anything.


Highlight the choice YES to carry out the stop discharge command.

Push the encoder to confirm the choice.


MDB-II, and others which may be connected, shall immediately and definitively suspend the discharge; the
red LEDs of the LED bar will all turn off and it will be indicated on the display that the system has effectively
prepared for the next discharge, having increased the memory index which will be used with the next
discharge session:

On the display, the discharged capacity value and the time remaining to the end of the discharge will remain
visible.

In the meantime, for a few minutes, the fans will continue to work, in order to cool down the internal system
components.

At this point, it is possible to start up a discharge again with the same settings following the procedure
described above.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Items to remember

Below are some important suggestions for correct use of the MDB-II system.

The correct start-up sequence provides for first connecting the battery cables to the battery and then, only
after, the system can be supplied with an external AC energy source (if it is necessary to use an external AC
source).

If the battery connections are inverted, the system will not start; if MDB-II is supplied with energy from an
external source, some red LEDs from the LED bar will light up to indicate that the battery voltage is irregular,
the “READY” LED will remain off and the “MAIN STATUS” LED will remain on with a red light.

If the “READY” LED remains off, it means that the internal capacities are not charged enough and, so, that
the battery’s voltage is too low or that it has been connected with inverted cables.

If the battery cables are disconnected, even during the discharge, the system shows a voltage alarm of
irregular battery, even if the cables are reconnected afterwards; in this case, it is necessary to turn the
system off and start it again from the beginning, or to give the RESET SYSTEM command from within the
main MENU.

During the discharge session, it is not possible to change any parameters; only the PAUSE, STOP, and
BARS commands are active; only in manual discharge mode is it possible to change the discharge current.

During the parameter setting phase, if the system will not allow for setting the end of discharge capacity
and/or the discharge duration time, the manual control or current profile discharge mode has probably been
set.

If it is not possible to view the main measurements of the discharge current measured from the external
current clamps, it is possible that its use needs to be activated by way of the external clamp menu, or the
manual control or current profile discharge mode has been set.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Navigating between internal menus

MDB-II offers various additional functions compared with the classic battery discharge devices.

The functions which are surely used the most are all directly reachable from the main screen. Other
functions, which are perhaps more sophisticated and not less important, are reachable by way of the MENU
command, on the upper right of the display:

Rotate the encoder until the MENU command is highlighted, and press it.
You are immediately “behind the scenes" of the MDB-II. From here, you can access various sub-menus;
below is a brief description of the menu structures, organised in a tree diagram:

Reset System
Discharge mode
Constant current
Constant power.
Memory Profile
Manual
Loop activated
Loop pause
See Profile
Exit
External Current
Ext.Current
Input A
Output mV
Clamp / Shunt
Exit
Saving Curves
Select Memory
Memory Info
Graph V (t)
Graph I(t)
Delete Memory
Send Memory to Computer
Exit
System Alarms
Date and Time
Set hour
Set minute
Set day
Set month
Set year
Exit
Version Info
System Language
Italian
English
French
German
Spanish
Master/Slave
Slave Mode
Slave Address
EXIT

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Reset System

This function is to be used with caution because it carries out a general reset of the MDB-II and any
connected devices.

The use of this function is essentially to restart the system when it has been supplied with energy, and so
avoiding the necessary disconnection of the battery cables (if the system is set up for battery energy supply)
or of the energy supply cord from the external AC socket.

To carry out a total system reset, it is necessary to follow the steps below.
Rotate the encoder until the MENU command is highlighted, and press it.

Rotate the encoder until the RESET SYSTEM entry is highlighted and press:

MAIN MENU

SYSTEM RESET
SYSTEM RESET
DISCHARGE MODE
DISCHARGE MODE
EXTERNAL CLAMP
EXTERNAL CURRENT
SAVE CURVE
SAVE CURVE
SYSTEM ALARMS
SYSTEM ALARMS

The procedure confirmation is requested; select the YES option and press the encoder:

SYSTEM RESET

NO
YES

the entire system is reset and it will restart from the beginning.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Discharge mode

In this menu, it is possible to indicate to the MDB-II the execution mode for the battery discharge session;
there are 4 modes:

constant current: by selecting this mode, the system control will act in such a way as to draw, for the
entire duration of the discharge, the same current from the battery, even of the battery voltage varies; in this
mode, it is easy to arrange for the duration of the discharge session since it will be given by the division of
the battery capacity by the discharge current. This is generally the operator’s preferred discharge mode;
every time the system is turned on, it automatically prepares to work in this mode; when this operating mode
is selected, the letter C will be displayed in the bars of System Messages and end of discharge Control Bar.
constant power: by selecting this mode, the system control will act in such a way as to maintain the
power drawn from the battery constant; this means that, while the discharge proceeds, when the voltage
varies, the drawn current will be such so that it maintains the product constant. This battery discharge mode
is that which better simulates discharge behaviour when the connected charge is an inverter; when this
operating mode is selected, the letter W will be displayed in the bars of System Messages and end of
discharge Control Bar
current profile: by selecting this mode, the control carries out a discharged based on a predefined
sequence, built with the computer and saved within the on-board memories. This sequence can be built of a
maximum of 10 steps; each step has a minimum resolution of 1 ampere for a minimum time of 1 minute. This
battery discharge mode is that which better simulates dynamic behaviour of the battery when the charge
changes; when this operating mode is selected, the letter P will be displayed in the bars of System
Messages and end of discharge Control Bar
manual: by selecting this mode, the discharge current can be changed in real time during the test
execution; when this operating mode is chosen, the letter M will be displayed in the bars of “System
message Bar and end of discharge Control"

The following table shows the main characteristics of the 4 MDB-II operating modes:

Operating Control Indicator Operations


mode

Constant Controls the C It is possible to set the discharge current, the end of discharge
current discharged current voltage, the maximum capacity to be discharged, the maximum
duration time; it is possible to activate the loop function.

Constant Controls the W It is possible to set the discharge power at 100 Watt steps, the end of
power discharged power discharge voltage, the maximum capacity to be discharged, the
maximum duration time; it is possible to activate the loop function.

Current Controls the P It is only possible to set the end of discharge voltage; it is possible to
profile discharged current activate the loop function.
based on saved
time-current pairs

Manual Manually controls M It is possible to set the discharge current and the end of discharge
the current to be voltage.
discharged

To choose one of the discharge modes, follow the following steps.


Rotate the encoder until the MENU command is highlighted, and press it.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Rotate the encoder until the DISCHARGE MODE entry is highlighted and press:

MAIN MENU

SYSTEM RESET
DISCHARGE MODE
EXTERNAL CURRENT
SAVE CURVE
SYSTEM ALARMS

To choose one of the discharge modes, rotate the encoder until highlighting it, then push: the selected mode
will have YES written to the right of it, and the others will have NO:

DISCHARGE MODE

CONSTANT CURRENT NO
COSTANT POWER YES
MEMORY PROFILE NO
MANUAL NO
LOOP ACTIVATED NO

If the user continues to rotate the encoder, below three more options are shown: LOOP ACTIVATED, LOOP
PAUSE, and SEE PROFILE.

The loop function was introduced for integrated battery discharge - battery charge systems, where the
automation of cyclic and unattended management is necessary in the charge-discharge cycles.

In the majority of cases, this function is not utilised, and therefore it shall remain OFF.

If, instead, the user has a battery charger available equipped with sufficient input and output contacts to stop
or launch a new recharge, it is possible to interface it to the MDB-II by way of exchange contacts with no
voltage.
The following temporal diagram can help to understand how to take advantage of this function:

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


It is analysed as follows.

Suppose to have activated the loop function and set a loop


delay of 60 minutes.

Refer to the figure on the side, which shows which


bushings are involved in the explanation.

When the MDB-II is started up, if no alarm starts, the


COMMON and N.C. output contacts will be closed.

When the discharge begins, for the whole duration of the


discharge, the COMMON and N.C. output contacts will be
closed.

When a condition for stopping the discharge occurs, the


COMMON and N.C. contacts will open; since the loop
function was activated, immediately after opening, the
COMMON and N.C. contacts will close again for about 1
second, and will then reopen immediately after.

At this point, the battery charger should be provided with a


device able to distinguish this positive impulse; after
distinguishing this impulse, the recharging of the battery
can being and, for the whole duration of the recharge, the
contacts which drive the INPUT REMOTE CONTROL bushings shall remain open.

When the battery charger determines that the charging is finished, it shall close the INPUT REMOTE
CONTROL input contacts for about 10 seconds and then reopen them.

Starting from the reopening, the MDB-II will wait for a time equal to the set loop delay to allow the battery to
cool down and stabilise (the reverse timer is highlighted on the display); once this time has passed, a new
battery discharge will automatically take place, with the same settings previously utilised.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


The SEE PROFILE entry, on the other hand, allows for viewing on the display the discharge profile that was
saved in the MDB-II. The discharge profile cannot be edited by the MDB-II; it is necessary to create and/or
modify it with a computer. After, through the USB connection on the front panel, everything can be loaded
into the on-board memory.

The saveable current memory shall have the following characteristics:

it can be made up of 10 steps at the most


in each of the steps, the operative discharge mode is constant current
the maximum current for each step shall not exceed the maximum dischargeable from the
configuration being used
the maximum length of each step is, at the most, 600 minutes
the minimum duration of each step is equal to 1 minute (or 0 if the step is not used)

The current profile is built with the computer; the current and duration values are entered into a table for
each step; at the same time, on the side, a graph immediately shows the temporal trend and the calculation
of total duration and total capacity which shall be discharged at the end of execution.

Choosing the SEE PROFILE option, the display will show:

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


External Current

In this menu, it is possible to indicate to the MDB-II if there is a DC current clamp (or a shunt) or not, used to
measure an external discharge current, not controllable by the MDB-II, and its characteristic parameters.

During a battery discharge, it often occurs that a non-removable charge (for example an inverter) is
connected in parallel to the battery; in this way the battery discharge current measured by MDB-II is surely
incomplete, in that it does not take into account the further share of current drawn from this external charge.
On the other hand, connecting a DC current clamp (or a shunt) onto the cables that supply the energy to this
external charge, it is possible to correctly calculate the total discharged current.
When an external current measure is taken, the MDB-II shall regulate its internal discharge current so that,
added to the current read from the clamp (or shunt), the total current set on the display is discharged.
For this reason, pay attention so that, during the discharge, the MDB-II does not come to non-controllable
conditions (for example, an external current higher than that which was set).

With this menu, it is possible to indicate to the system:

if it should take into account the external reading or not


indicate the relationship between the read current (in amperes, with a resolution of 1 ampere and a
maximum value of 10 amperes) and the output voltage (in mV, with a resolution of 1mV)
select the appropriate hardware input circuit for DC clamp or shunt

The clamp (or shunt) is connected to the MDB-II by way of the appropriate bushings on the right side of the
display:

To activate the reading of the external current, it is necessary to follow these steps:

ensure that the clamp is turned on or the shunt has been connected
set the correct end-of-range current value, if there is a manual switch
note the equivalent output voltage value with a set range
ensure that the clamp is closed correctly and that it is not clamped over any cable through which
energy is flowing

NOTE:
1. Avoid setting the clamp output voltage equal to 1mV/A; only if the user needs to measure a current of more than 400A,
choose this capacity; if not, the resolution of the clamp current reading could be inaccurate.
2. The external current socket is electrically isolated from the unit and main circuits ONLY if SHUNT option has been
selected: only with this configuration will be allowed to take the current signal directly from shunt legs, with maximum
output voltage of 60mV when full current range; the voltage reading is unidirectional, please respect polarity.

Rotate the encoder until the MENU command is highlighted, and press it.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Rotate the encoder until the EXTERNAL CURRENT entry is highlighted and press:

MAIN MENU

SYSTEM RESET
DISCHARGE MODE
EXTERNAL CURRENT
SAVE CURVE
SYSTEM ALARMS

The menu regarding the external clamp appears; rotate the encoder to highlight the EXTERNAL CURRENT
option:

EXTERNAL CLAMP

EXTERNAL CURRENT NO
INPUT A 10
OUTPUT MV 1
CLAMP / SHUNT CLMP
EXIT

To change the option, just push the encoder; for example, to activate the external current reading, after
pushing the encoder, the display looks like this:

EXTERNAL CLAMP

USE EXTERNAL CLAMP YES


INPUT A 10
OUTPUT MV 1
CLAMP / SHUNT CLMP
EXIT

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


If the use of a DC external current is activated, once the user returns to the main measurement screen, the
change will be immediately obvious; in the “Battery measurements bar”, on the line in which the battery
current is normally indicated, two current measurements will be indicated:

The external current measurement can play a fundamental role in the battery discharge session; on one
hand it allows for extending the capacity of the discharge current; on the other hand, however, it can stop the
discharge session if the control is not able to continue working correctly to maintain the discharge current at
the set value, exactly because this current is not controllable by the MDB-II, but it enters into play in the
regulation process. So, be very careful when using this option.

Since the discharged current from a charge external to the MDB-II is not controllable, the use of the external
current is possible only in some discharge modes:

Operating mode External Current Option usable

Constant current yes

Constant power yes

Current profile no

Manual no

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Saved Curves

With this menu, it is possible to choose, view, delete, and send to the computer the discharge curves saved
in the memory bank of the MDB-II.

MDB-II has an autonomous memory bank, that is not volatile and is able to save up a maximum of 8
discharge sessions, lasting 15 hours each, with a saving frequency of 4 times per minute.

In general, for each discharge session, the following are recorded:

general information on the discharge session: date and time the discharge began, date and time the
discharge ended, total duration in minutes, resolution of end of recording, mode of test execution,
reason for discharge stopping, machine settings, and discharge stop parameters
the whole set of voltage and current measurements taken

When the user decides to carry out a battery discharge test, the first thing to do is establish which memory
the data should be recorded in. This is possible in two equivalent ways: from the main measurement screen,
choosing the memory option, or from the curve menu:

Rotate the encoder until the MENU command is highlighted, and press it.

Rotate the encoder until the SAVE CURVE entry is highlighted and press:

MAIN MENU

SYSTEM RESET
DISCHARGE MODE
EXTERNAL CURRENT
SAVE CURVE
SYSTEM ALARMS

The menu regarding the curves saved in the MDB-II is shown:

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


MEMOR.CURVE

SELECT MEMORY 2
MEMORY INFO
GRAPH V(T)
GRAPH I(T)
DELETE MEMORY

The SELECT MEMORY option, on the right, shows which memory will currently be used with the next
discharge session; to change the memory in which to record the next curve:

highlight the SELECT MEMORY option


push the encoder
the characteristic data of the curve saved in the selected memory is shown on the display: if it is
empty or otherwise, the date, time, and duration of the execution
rotate the encoder to select a new memory
push the encoder to set the new memory as the one to be used and exit the menu

Warning: when an already-utilised memory is selected, the next discharge session will overwrite the
memory, irreversibly deleting that which was previously saved; to avoid losing data, save the curves on the
computer ahead of time.

The MEMORY INFO option allows for viewing the main electrical parameters of the beginning and end of the
saved discharge curves. If a memory in which nothing has yet been saved is chosen, the "(!)" symbol will be
shown.

The GRAPH V(t) and GRAPH I(t) options allow for rapidly viewing on the display the voltage and current
curves related to the discharge session saved in the selected memory. The curves are shown on the classic
Cartesian plane, with the axis of the ordinates scaled in such a way as to allow for better viewing of the curve
in question. If a memory in which nothing has yet been saved is chosen, the "(!)" symbol will be shown.

The MEMORY DELETE option allows for completely cleaning out the selected memory.
Warning: the deletion of the memory does not allow for a successive restoration of the saved data; to avoid
losing data, save the curves on the computer ahead of time. If a memory in which nothing has yet been
saved is chosen, the "(!)" symbol will be shown.

In manual and unattended mode, the SEND MEMORY TO COMPUTER option allows for sending the data
relative to the curves saved in the currently selected memory to the computer. The data is sent to the
computer in CSV format, to allow for manipulating it in a common spreadsheet. In all cases, the best way for
transferring data onto the computer is to use the “MDB-II Manager” software; it is an easy interface which
allows for automatically choosing which memory to receive, and for numerically and graphically representing
the received data. If a memory in which nothing has yet been saved is chosen, the "(!)" symbol will be
shown.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


System Alarms

With this menu, it is possible to quickly view the alarms present in the system, if there are alarms. In reality, if
MDB-II has one or more alarms, in the main unit or in the auxiliary expansion units, an alarm warning would
be presented in the “System messages and end of discharge Control bar”, as running text, so as to cyclically
highlight all alarms that have been sensed.
The entirety of the alarms found and their characteristics are indicated in the table below:

Alarm Characteristics of alarm found Possible Causes

High The temperature within the device is more than The environmental temperature has risen
temperature 80°C There is not adequate air exchange
The device is found in direct sunlight

SCR fuse blown Input fuse blown Failure in power modules

Fan failure One or more system fans are not working in the Excessively dirty fans
appropriate manner Mechanically blocked fans
Fan without power supply

Irregular Vbatt The battery voltage is out of the allowed or was Battery connected with inverted polarities
connected with inverted polarities Battery voltage too low
Battery voltage too high

Power surge A not allowed current is discharging Failure in power modules


External charge measured by the clamp is excessive

High dissipator The dissipater in the power modules reached a The environmental temperature has risen
temperature temperature of more than 60°C There is not adequate air exchange
The device is found in direct sunlight

Not controllable The device control does not allow for External charge measured by the clamp is excessive
discharging the current indicated with the External charge measured by the clamp is reduced
current electrical parameters IGBT module failure
IGBT output fuse blown

Power failure Failure of one or more system power modules Failure in power modules

Irregular CAN- Irregular or missing CAN connection between Defective connection cable
Bus devices or failure of the CAN microprocessor Failure in CAN microcontroller
controller Failure in internal CAN connection

Irregular USB Irregular USB controller or attempted access to Access to USB device with elevated frequency
the USB in unsupported manners and/or times

Irregular LEM Irregular input battery current sensor High mechanical shock in the instrument

Irregular CAN Setting of a mistaken CAN address, or two or The same address set on more than one device
address more devices wih the same CAN address set on
the rotating address switch on the front of the
panel

EEprom error Failure of one or more memory banks Failure of the EEprom memories

Irregular Two or more devices are connected with Lack of homogeneity between connected devices
firmware incompatible firmware versions

To see in detail which device has the alarm, proceed in this way:
Document: MDB-II User Rev.3.0.0 Date: 21/03/2011
Rotate the encoder until the MENU command is highlighted, and press it.

Rotate the encoder until the SYSTEM ALARMS entry is highlighted and press:

MAIN MENU

SYSTEM RESET
DISCHARGE MODE
EXTERNAL CURRENT
SAVE CURVE
SYSTEM ALARMS

The user can see the lis of possibilities; rotate the encoder to go through the whole list of alarms; if an alarm
is taken from a device, the identification address of the device will be shown (address set on the front panel
switch):

ALARM MDB-II #

HIGH TEMPERATURE :--2-------


SCR FUSE BLOWN :----------
MANUAL BLOCK :----------
FAN FAILURE :----------
VBatt ABNORMAL :----------

Press the encoder again to exit the alarm menu.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Date and Time

From this menu it is possible to set the correct date and time within the MDB-II clock.

The date and time are also automatically updated every time the device is set through the computer.

It is important that the dates are correct, so that the discharge curves saved in the MDB-II can be easily
distinguished.

The settable parameters are:

hour, from 0 to 23
minute, from 0 to 59
day, from 1 to 31
month, from 1 to 12
year, from 2007 to 2100

The clock and calendar are autonomous and conserve dates even when the device is off. The number of the
day of the month is automatically updated based on the months. The leap year is also taken into account.

System Language

With this menu, it is possible to set the language used by the MDB-II to write the display messages.

The available languages are:

English
Italian
French
German
Spanish

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Parallel functioning

The MDB-II battery dischargers have the possibility to work together, up to a maximum of 10 units, to reach
extremely elevated discharge currents.

Parallel functioning is only possible by using:


a single MDB-II MASTER unit, to which up to 9 MDB-II SLAVE units can be connected
a MDB-II MASTER set as MASTER, to which up to 9 MASTER units can be connected, set as
SLAVE units with different addresses among them
a MDB-II MASTER set as MASTER, to which up to 9 MASTER and SLAVE units can be connected,
set as SLAVE units each with a different address

System configuaration is totally automatic and takes place thanks to a connection cable (RJ11 type),
included with each slave unit. During the discharge session, the master unit provides for collecting all of the
necessary information coming from all of the units connected togetherr, in order to carry out the necessary
calculations.

How to set a MDB-II MASTER in SLAVE mode

Any MDB-II MASTER can function in either MASTER or SLAVE mode.


It is always set in two steps: set the mode by way of the display and select the address.
To set the SLAVE mode, proceed in this way:
enter into the main menu
select the MASTER/SLAVE menu and push the encoder
once entered into the new menu, the first option allows for choosing the function mode simply by
pushing the encoder on it
push the encoder to activate SLAVE mode
if the SLAVE mode is chosen, a numerical address to assign to the unit has to be chosen
when setting is finished, exit the menu

After exiting from the menu, if the setting carried out is different from the initial setting, the machine will
request the user to set a new address manually, using the rotating switch on the lower part of the front panel.

To set the desired address, proceed in this manner:


insert a small flathead screwdriver in the hole and try to delicately find the switch draft
rotate the screwdriver until feeling a small click
in this way, the address changes and, that which was just set will be shown on the LED bar thanks to
a LED that will flash for about 4-5 seconds
if the set address is not the desired one, rotate the screwdriver until the number of desired clicks is
felt

After all, if the user wished to set address 1, the LED corresponding to number 10 should flash for 4-5
seconds; if the user wished to set address 6, the LED corresponding to the number 60 should flash for 4-5
seconds;

When finally the right address is set, the encoder needs to be pushed, as requested on the display: the
MDB-II shall carry out a total reset and will restart with the requested set-up

The MDB-II unit set as a SLAVE always shows the label SLAVE #n on the display, where n is the assigned
address.

The functioning mode settings, such as the address, do not change if the unit is powered off.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


How to reset a MDB-II MASTER in MASTER mode

Any MDB-II MASTER can function in either MASTER or SLAVE mode.


It is always set in two steps: set the mode by way of the display and select the address.
To set the MASTER mode, proceed in this way:
enter into the main menu
select the MASTER/SLAVE menu and push the encoder
once entered into the new menu, the first option allows for choosing the function mode simply by
pushing the encoder on it
push the encoder to deactivate SLAVE mode
if the MASTER mode is chosen, the unit address is automatically set to 0
when setting is finished, exit the menu

After exiting from the menu, if the setting carried out is different from the initial setting, the machine will
request the user to set a new address manually, using the rotating switch on the lower part of the front panel.

To set the desired address, proceed in this manner:


insert a small flathead screwdriver in the hole and try to delicately find the switch draft
rotate the screwdriver until feeling a small click
in this way, the address changes and, that which was just set will be shown on the LED bar thanks to
a LED that will flash for about 4-5 seconds
if the set address is not the desired one, rotate the screwdriver until the number of desired clicks is
felt

After all, if the user wished to set address 1, the LED corresponding to number 10 should flash for 4-5
seconds; if the user wished to set address 6, the LED corresponding to the number 60 should flash for 4-5
seconds;

NOTE: the address 0, which is to be set for MASTER units, is highlighted by the flashing LED corresponding
to the number 100

When the right address is finally set, the encoder shall be pushed, as requested on the display: the MDB-II
shall carry out a total reset and will restart with the requested set-up

The MDB-II unit set as MASTER always shows in its display the electrical measures and the various
possible commands; if, at the end of the initial start-up phase, the display remains empty, without anything
written, it is probably that the address set with the rotating switch was not equal to 0; in this case, set the
correct address, power off the unit and restart it.

The functioning mode settings, such as the address, do not change if the unit is powered off.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


How to START A DISCHARGE WITH UNITS IN PARALLEL

Following are the instructions of how to make the MDB-IIs work in this configuration.
As an example, let's assume we have 4 total units: 1 master unit and 3 slave units.

If, in place of SLAVE units, MASTER units in SLAVE configuration are used, they should be set to function in
SLAVE mode (see above).
Initially verify that the SLAVE units have different addresses among
them:

On the panel of the first slave unit, using a small flathead


screwdriver, rotate the rotating “Address Selector” switch so that the
LED on the LED bar corresponding to the number 10 flashes for 4-5
seconds.
On the panel of the first slave unit, using a small flathead
screwdriver, rotate the rotating “Address Selector” switch so that the
LED on the LED bar corresponding to the number 20 flashes for 4-5
seconds.
On the panel of the first slave unit, using a small flathead screwdriver, rotate the rotating “Address
Selector” switch so that the LED on the LED bar corresponding to the number 30 flashes for 4-5 seconds.

Suppose, furthermore, to have a nominal voltage battery of 220Vdc and to want to discharge 240 amperes.

It works in this way:

connect each unit, both slave and master, to the battery to be discharged by way of its own crocodile
connection cables; respect the battery connection polarities and ensure that the connections are very firm
arrange all of the units aligned in the same way, in order to allow for hot air to exit from the back part
in the same direction
the master unit is placed at one or the other end (the right or left end); for simplicity, suppose that it
is the first unit on the left of the line
take the RJ11 cable of the first slave unit and connect it to one end of the MDB-II master, in the
“Output” port of the “Connection to external load” panel; the other end is connected to the “Input” port of the
“Connection to external load” panel of the first slave unit, at the right of the master unit
take the RJ11 cable of the second slave unit and connect it to one end of the first slave unit, in the
“Output” port of the “Connection to external load” panel; the othter end is connected to the “Input” port of the
“Connection to external load” panel of the second slave unit, at the right of the first slave unit
take the RJ11 cable of the third slave unit and connect it to one end of the second slave unit, in the
“Output” port of the “Connection to external load” panel; the other end is connected to the “Input” port of the
“Connection to external load” panel of the third slave unit, at the right of the second slave unit
Connect the energy supply cable from all of the units to an adequate AC energy supply source (keep
in mind that each MDB-II uses about 150W during each discharge).
Set the energy supply switch to the AC source.
Turn on the slave units first, one at a time; then turn on the master unit last
When the master unit starts up, all of the slave units will be reset (all of the LEDs of the LED bars on
all of the slave units will briefly turn on)
Scanning of units present will be immediately started up and, on the master unit display, a progress
bar that indicates that research will be visible
Once the research has finished, the master unit display will show the battery’s electric parameters
Bring the cursor over the BARS entry and push the knob: the electrical data of the 4 MDB-II units, or
the voltages, currents, and temperatures returned by all of the individual units should appear on the display
Set the discharge parameters, as described above
Start up the discharge
All of the MDB-II units should start up at the same time and each should discharge the same current
discharged by the other units so that the total amount is equal to the requested discharge current; in this
case, each unit should discharge about 60 amperes; this value will be immediately correspondant to the
number of LEDs that light up in each LED bar of each unit, both master and slave
Document: MDB-II User Rev.3.0.0 Date: 21/03/2011
At the end of the discharge all of the units should stop at the same time
Wait until the end of the automatic cool-down cycle
Power off all of the units
Remove the battery connections
Remove the RJ11 connection cables
Remove the energy supply cables

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


General safety information

The MDB-II device was designed to allow for thte operator to use it in absolute safety.

Various circuit parts constantly control all of the parts of the convertors, interrupting their functioning
immediately in the case of irregularities.

In any case, when working with high-value voltages and corrents, it is necessary to pay attention to some
factors:

the back part of the MDB-II emits high-temperature air: avoid being directly hit by that air flow.
avoid positioning objects that are sensible to heat in the immediate vicinity of the battery discharger,
especially if they are directly hit by the air flow emitted by the MDB-II.
During functioning, ensure that there is a minimum distance of 2 meters from any obstacle and the
back air output.
Do not place any object on top of the batter discharger: the upper grill acts as a aeration conductor
and obstructing it, even partially, could cause it to malfunction.
Always keep the battery discharger placed in a horizontal position and far away from surfaces that
are dusty or that have objects which could impede, even partially, the suction of air from the lower part of the
battery discharger.
Do not keep the battery discharger directly exposed to sunlight, especially during months of higher
environmental temperature.
Once the discharge session has finished, do not immediately poweer off the MDB-II; rather, wait
for the automatical cool-down cycle to finish, until the fans automatically stop.
Do not use the battery discharger with energy supply cables and battery connections in poor
conditions.
Ensure that the crocodile clamps included with the equipment are connected in an adequate manner
both to the clamps on the MDB-II and to the terminals used for the battery.
Always connect a grounding cable, with a length of 25mmq or more, to the grounding point near the
back part of the frame.
Do not touch any internal part of the battery discharger, neither directly nor with metallic objects,
even when the device is turned off.
Do not carry out any operations that are not described in this manual.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Technical specifications

The MDB-II device can discharge batteries that belong to various voltage ranges: from 24Vdc to 240Vdc.
The discharge current can be up to a maximum of 130A, for batteries from nominal 24Vdc to 120Vdc, and
65A, for batteries with a higher voltage.
To extend the maximum dischargeable current, it is enough to connect more than one device together, until
reaching a maximum of 10 units.

Using the MDB-II system is extremely simple:

connect the cables to the battery to be discharged


supply the device with energy
choose the memory on which to record the discharge session
set the discharge current
set the discharge duration
verify the end of discharge voltage
set the maximum capacity to be discharged
push start

During the discharge, all paramenters are saved in the selected memory.
If the user has the “MDB-II Manager” software, it is possible to set the discharge paramenters and start up
and monitor the discharge session situation in real time.

During the discharge, if at least one of the pre-set protections turns on, the discharge will be definitively
stopped.

When the discharge stops, the user can view the voltage and current curves directly on the display, or, using
the “MDB-II Manager” software, the user can download the data onto a computer to view it, record it, and
create a more professional final report.

Warning:
In normal operations, the MDB-II device forces the ouput of hot air from its upper back part.
The external metallic surface can reach very high temperatures!

Avoid direct contact with the hands until the automatic cool-down cycle has automatically finished.

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Specifications

The specific techniques indicated below refer to a single unit.


The functioning ranges and the maximum dischargeable currents are valid for an environmental temperature
of 25°C. For higher temperatures, a derating factor must be used for the maximum dischargeable current
equal to: -1A/°C.
In all cases:
the maximum operating environmental temperature should not exceed 40°C
the device should not operate if it is located in direct sunlight or any other heat source

Parameter Value

Maximum number of systems to be used in parallel 10 units: 1 master unit + 9 slave units.

Maximum battery voltage 270 Vdc

Minimum battery voltage 20 Vdc

Maximum dischargeable power (with maximum 16 kW (max 160 kW with 10 parallel systems)
current based on the battery’s voltage range)

Maximum dischargeable current in the 24 Vdc 130 A (max 1300 A with 10 parallel systems)
range (max 25°C)

Maximum dischargeable current in the 48 Vdc 130 A (max 1300 A with 10 parallel systems)
Maximum dischargeable current in the 72 Vdc 130 A (max 1300 A with 10 parallel systems)
range (max 25°C)

Maximum dischargeable current in the 110 Vdc 130 A (max 1300 A with 10 parallel systems)
Maximum dischargeable current in the 120 Vdc 130 A (max 1300 A with 10 parallel systems)
range (max 25°C)

Maximum dischargeable current in the 220 Vdc 65 A (max 650 A with 10 parallel systems)
Maximum dischargeable current in the 240 Vdc 65 A (max 650 A with 10 parallel systems)
range (max 25°C)

Discharge mode: constant current, constant power, 4


current profile, manual adjustment

Resolution of discharge current regulation 1A

Resolution of discharge power regulation 100 W

Determining battery range Automatic, on 4 ranges, established when the tests


begin

Voltage limits, 24 Vdc range 20 - 34 Vdc

Voltage limits, 48 Vdc range 34 - 60 Vdc


Voltage limits, 72 Vdc range 60 - 84 Vdc

Voltage limits, 110/120 Vdc range 84 - 140 Vdc

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Parameter Value

Voltage limits, 220/240 Vdc range 140 - 270 Vdc

Limits of voltage acceptance from functioning in 24 20 - 35 Vdc


Vdc range

Limits of voltage acceptance from functioning in 48 34 - 65 Vdc


Vdc range
Limits of voltage acceptance from functioning in 72 58 - 97 Vdc
Vdc range

Limits of voltage acceptance from functioning in 84 - 140 Vdc


110/125 Vdc range

Limits of voltage acceptance from functioning in 169 - 250 Vdc


220/240 Vdc range

Accuracy of voltage measurement +/- 1% of the end-of-range of the maximum value


(270V)

Accuracy of current measurement +/- 1% of the end-of-range of the maximum value


(200A)

Resolution of voltage measurement 100mV on the entire range

Resolution of current measurement (internal and 1 A on the entire range


from the external source)

Resolution of time measurement 1 second

Input to measure the external current through a DC 1 – 100 mV with 1 – 10 A


clamp or shunt can be set from the display
NOTE: the 1mV capacity is to be used ONLY when the
Note: electrically isolated input ONLY with shunt currents to be measured exceed the value of 400
option selected amperes
Shunt, unidirectional, 0-60mV max

Frequency of voltage and current measurements 15 seconds


during the discharge

Setting the device Recorded in the internal non-volatile memory

Number of discharges recordable in the memory 8

Maximum duration of a recordable discharge 15 hours, with a 15-second resolution

Maximum duration of a discharge not recorded in infinite


the memory

Sonorous alarm when the end of discharge is Yes, with 5 different levels of sonorous warnings
reached

SPDT contact for alarm signalling Yes

Charge-discharge loop mode commanded from the Yes


outside and delayable

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Parameter Value

Number of savable discharge profile steps 10

Resolution of time and current for each memory 1 minute/ 1 ampere


step

Maximum values of time and current for each 600 minutes / 1300 amperes
memory step

Operator interface at the front of the system 128 x 64 pixels, backlighted graphic display.
Rotating encoder with integrated button.
LED bar to view the current and alarms.
On-Off button for manual energy supply
Buzzer.
LED for general system status.

System control mode. Display navigation menu through the encoder and
its integrated button.

Calendar and clock Integrated in the system, with back-up battery

Measurements visible on the display: Date


Time
Internal discharge current
External discharge current
Battery voltage
Discharged capacity
Discharge time

Stop discharge parameters minimum voltage


maximum discharged capacity
discharge duration
system alarms
manual stop from remote contact

System control Completely digital, by dual microprocessor

Interconnection mode for devices that operate in By way of RJ11 cable (4/6)
parallel

Energy supply mode of triple system Through the battery to be discharged (110-
240V)
Through an external auxiliary AC energy
supply: 100-240Vac 50/60Hz.
Through an external auxiliary DC energy
supply: 120-270Vdc

Device energy use About 10W in standby


About 150W in discharge phase

Devices for emergency hardware stop, outside of Through mushroom emergency button, on
microprocessor control the front
Thermal protection intervention

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Parameter Value

Implemented protections: High temperature dissipator


Blown fuse
Fan failure
Minimum battery voltage
Maximum battery voltage
Irregular battery voltage
Power surge
High system temperature
Out of control regulator
Failure in power modules
Irregular CAN-Bus
Irregular LEM input current
Manual block
Irregular USB
Irregular EEprom
Irregular firmware

Dimensions (width x length x height) 283 x 803 x 420 mm

Degree of protection IP20

Acoustic noise <75 dBA at full power

Applicable standards Conforms with EEC directives regarding


Electromagnetic Compatability and tools for low
voltage

Electromagnetic Compatability EEC 89/336 Directive


Applicable standard EN61326 + A1 + A2
Issue:
EN 61000-3-2, class A
EN 61000-3-3 (EN 55011 class A)
Immunity:
EN 61000-4-2
EN 61000-4-3
EN 61000-4-4
EN 61000-4-5
EN 61000-4-6
EN 61000-4-8
EN 61000-4-11

Low voltage directive EEC 73/23 Directive


Applicable standards: CEI EN 61010-1, in
particular:
Dielectric rigidity: 2.0kV per 1 minute
Insulation resistence: > 100 MΩ to 500Vdc
Ground resistence: < 0.1Ω
Current leekage: < 5mA
Degree of protection: IP20
Operating temperature: 0°C - 40°C
Warehousing temperature: -25°C - 70°C
Relative humidity: 5 - 95% not condensing
Vibration: IEC 68-2-6
Altitide: less than 2000m above sea level

Weight 48 kg (without carrying case)


54 kg (with optional accessories included)

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011


Parameter Value

Equipment Device
pair of suitable cables with crocodile clamps
USB cable
CD-ROM software and documentation
Energy supply cable

Optional accessories External current clamp


Carrying case

System Languages Italian, English, French, German, Spanish

Document: MDB-II User Rev.3.0.0 Date: 21/03/2011