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
REVIEW:
REVISIONED PARTS
REVISION REVISION DATE DESCRIPTION
Paragraph(s) Page(s)
APPROVED:
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.
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:
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.
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.
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
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.
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.
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
In the lower panel, the three Output Alarm Contact bushings, clean exchange contacts, allow for signalling
an alarm and/or end of discharge situation.
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
24Vdc
48Vdc
110Vdc
120Vdc
220Vdc
240Vdc
Key:
Not usable
Fully usable
Once the energy supply source to be used is chosen, the Power Source Selector has to be correctly set.
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.
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.
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
Discharge commands
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:
By rotating the encoder two clicks to the left, we are brought to the START entry:
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:
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:
Obviously, a discharge can also be definitively stopped by the operator at any moment, by using the STOP
command.
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:
At this point, the next discharge session shall be recorded on the selected memory, overwriting the data that
was already saved on it.
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:
(*) 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:
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).
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:
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:
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:
130A 65A
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:
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:
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:
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:
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:
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
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
At this point, the next discharge session shall be carried out by constantly discharging the set current.
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:
The set end of discharge capacity value is displayed in the System Messages and End of Discharge control
bar.
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
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.
At this point, it is possible to set the MDB-II to discharge a battery using the required parameters.
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
Push the encoder, and a request will appear to confirm carrying out the command given:
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:
The most important electrical measurements, the discharge time, and the system status are shown on the
display.
In particular there are:
Allowing the system to work autonomously, the discharge session will go ahead until at least one of the
following conditions occurs:
During discharge execution, all settings that have been discussed up to now are disabled, including access
to the system settings MENUS.
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
Imagine that a discharge session is underway; the user needs to momentarily stop the discharge, but not
definitively stop it.
DISCHARGING BATTERY
Push the encoder, and a request will appear to confirm carrying out the command given:
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.
A discharge session is underway; the user wants to definitively stop the discharge.
DISCHARGING BATTERY
Push the encoder, and a request will appear to confirm carrying out the command given:
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.
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.
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
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.
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:
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
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:
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.
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.
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).
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.
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
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:
Current profile no
Manual no
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.
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
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:
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.
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:
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
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
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 #
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.
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.
English
Italian
French
German
Spanish
The MDB-II battery dischargers have the possibility to work together, up to a maximum of 10 units, to reach
extremely elevated discharge currents.
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.
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.
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.
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.
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.
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:
Suppose, furthermore, to have a nominal voltage battery of 220Vdc and to want to discharge 240 amperes.
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
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.
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.
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.
Parameter Value
Maximum number of systems to be used in parallel 10 units: 1 master unit + 9 slave units.
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)
Sonorous alarm when the end of discharge is Yes, with 5 different levels of sonorous warnings
reached
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.
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
Devices for emergency hardware stop, outside of Through mushroom emergency button, on
microprocessor control the front
Thermal protection intervention
Equipment Device
pair of suitable cables with crocodile clamps
USB cable
CD-ROM software and documentation
Energy supply cable