Digitale Ausgabe 32 Kanal - MCD Elektronik GmbH · 2016-06-06 · Manual Platform for Handheld Testers . Elektronik GmbH Platform for Handheld Testers Manual ... Lithium polymer battery

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MCD Elektronik GmbH

Hoheneichstr. 52

75217 Birkenfeld

Phone 0 72 31/78 405-0

Fax 0 72 31/78 405-10

[email protected]

www.mcd-elektronik.de

Offices: Birkenfeld

CEO: Bruno Hörter

Mannheim Court of Registry

HRB 505692

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Manual

Platform for Handheld Testers

Elektronik GmbH Platform for Handheld Testers Manual

Page 2 of 23

Table of contents

1. GENERAL INFORMATION ............................................................................................................................................... 4

1.1. OVERVIEW ....................................................................................................................................................................... 4

1.2. APPLICATIONS ................................................................................................................................................................... 4

1.3. FEATURES ......................................................................................................................................................................... 5

1.4. BLOCK SCHEMATIC ............................................................................................................................................................. 6

2. HARDWARE OVERVIEW ................................................................................................................................................. 6

2.1. HOUSING ......................................................................................................................................................................... 7

2.2. HOUSING OPTIONS ............................................................................................................................................................. 8

2.3. CONNECTING THE PC.......................................................................................................................................................... 9

2.4. USE / SAFETY INSTRUCTIONS FOR LITHIUM POLYMER (LIPO) BATTERIES ....................................................................................... 10

2.4.1. Battery type ........................................................................................................................................................ 10

2.4.2. Possible hazards ................................................................................................................................................. 11

2.4.3. Composition, specifications of components ....................................................................................................... 12

2.4.4. First aid procedures ............................................................................................................................................ 12

2.4.5. Firefighting measures ......................................................................................................................................... 13

2.4.6. Measures to take in case of unintentional release ............................................................................................. 13

2.4.7. Handling and storage ......................................................................................................................................... 13

2.4.8. Limitation and monitoring of exposure / personal protective equipment ......................................................... 13

2.4.9. Physical and chemical properties ....................................................................................................................... 14

2.4.10. Stability and reactivity........................................................................................................................................ 14

2.4.11. Toxicological information ................................................................................................................................... 14

2.4.12. Environmentally relevant information ............................................................................................................... 14

2.4.13. Instructions for disposal ..................................................................................................................................... 15

2.4.14. Transport information ........................................................................................................................................ 15

2.4.15. General information ........................................................................................................................................... 16

2.4.16. Changing batteries ............................................................................................................................................. 17

3. FIRMWARE OVERVIEW ................................................................................................................................................ 18

3.1. TOUCH DISPLAY ............................................................................................................................................................... 18

3.2. TURNING ON/OFF ............................................................................................................................................................ 19

3.3. POWER SUPPLY................................................................................................................................................................ 20

3.4. CONFIGURATION.............................................................................................................................................................. 21


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3.4.1. General information ........................................................................................................................................... 21

3.4.2. Switching languages .......................................................................................................................................... 22

3.4.3. Display calibration .............................................................................................................................................. 22

3.4.4. Configuring using PC software ........................................................................................................................... 23

3.4.5. Display brightness .............................................................................................................................................. 23


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1. General information

1.1. Overview

The "Platform for Handheld Testers" provides the basis for development of customer-specific portable test

systems with existing modules for hardware and software.

The framework consists of a housing system by OKW and can be expanded as needed and customized for the

design needed. It is operated using a touch display. The test objects are connected using robust cables and

connectors assembled to customer specifications.

The touch display interface can be freely specified by the customer using standard components such as buttons

and text fields. The menu structure can also be customized to meet requirements.

1.2. Applications

Functional testing of assemblies and components with different controllers, with or without bus control

Flexible application scenario with battery operation

For example, handheld testers can be built for stepper motors, switch assemblies, lighting units,

controllers, cable harnesses, and many more possibilities.


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1.3. Features

Hardware

The hardware consists of a housing in different sizes and a touch display. There is also power supply from an

external source, lithium polymer batteries, or conventional batteries. Further features of the "Platform for

Handheld Testers" hardware include:

4.3" LCD touch panel with graphical user interface

STM microcontroller (depending on application, for example STM32F407ZE)

Control of the device under test using different bus types: CAN, LIN, RS232, etc.

Lithium polymer battery with a 3000 mAH capacity (conventional batteries also possible if necessary)

External power connection (9 to 17V, typically 12V)

Serial RS-232 interface for remote control

Miniature speaker

Standby mode with start button

Robust test cables for the various connectors

Firmware

The firmware consists of multiple modules that can easily be used to produce a new application to customer

specifications. These include:

Power management (battery monitoring, automatic shutoff)

Components for configuration of the touch display interface (buttons)

Bilingual user's manual and user guidance (German/English, other languages possible)

Software

MCD Toolmonitor for operation of the remote interface

The software can be extended for data logging or other visualizations.


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1.4. Block schematic

The block schematic shows how the modules of the platform are connected. The interfaces to the device under

test can be custom-designed. By varying the microcontroller with pin-compatible modules, a wide variety of

communication, stimulus, and measurement interfaces can be implemented. All sorts of connected electronics

can also be implemented on the application circuit board, for example to adapt signal levels.

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Hardware overview

2.1. Housing

The following pictures show an example implementation using the "Platform for Handheld Testers". The

connections in this case are on the bottom, but can be moved if necessary. The touch display is used for both

operation and display of results.

RS232 PC Test cable Power supply

Button to turn the

handheld tester on

and off

Touch display


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2.2. Housing options

The OKW housing used is available with different options. MCD can process the housing to customer

specifications.

Source: OKW Gehäusesysteme / www.okw.com/de


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2.3. Connecting the PC

The device is connected to the PC with a serial cable (RS232). If the PC has no RS232 connection, an additional

USB adapter (USB to serial) can be used.

The remote interface can be used to transmit different parameters to the device. Especially for large numbers of

parameters, this has the advantage that parameters can be entered much more quickly on the PC.

MCD can also provide data storage. The measurement can then be transmitted to a PC. It is also possible to

remote control a mobile test device from a PC if the application requires it.

Figure 1 Example implementation of the handheld test platform in the field


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2.4. Use / safety instructions for lithium polymer (LiPo) batteries

2.4.1. Battery type

All specifications in this data sheet as well as references to the battery refer to the following battery type:

<Type selected by MCD based on the application>

Manufacturer:

<Manufacturer name>

<Contact data>

Instructions and data sheets for the batteries described are included in the delivery, or can be requested from

MCD Elektronik GmbH.


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2.4.2. Possible hazards

Lithium batteries are sealed gas-tight and are harmless as long as the manufacturer's instructions for use and

handling are followed.

Warning!

Do not charge batteries if the battery system is not rechargeable!

Never use chargers on rechargeable batteries that are not suitable for the battery type. Do not short

circuit!

Do not mechanically damage batteries (puncture, deform, dismantle, etc.)!

Do not heat batteries above the permissible temperature or burn them!

Keep batteries out of the reach of children!

Always store batteries in a cool, dry place!

When properly handled under the conditions specified by the manufacturer, lithium batteries are safe during use.

Improper handling or circumstances that lead to abnormal operation can cause leaks of battery contents and

products of decomposition, which can in turn lead to serious reactions that can endanger health and the

environment.

Since a wide variety of chemical materials are used, in case of an accident always follow the manufacturer's

instructions for immediate actions and first aid measures.

Contact with escaping battery components can in principle always represent a hazard to health and the

environment. Sufficient body and breath protection is therefore required when handling suspicious batteries

(escaping contents, deformation, discoloration, bulges, etc.). Lithium batteries can react very powerfully in

combination with fire, for example. Battery components with significant energy can be emitted.

Handling and operational safety:

Lithium batteries must be handled in accordance with the manufacturer's specifications at all times. This

particularly applies to compliance with limits on maximum current load, charge and discharge voltages, and

mechanical or thermal stress.

The product package provided (portable tester and battery) match one another. Under no circumstances may the

products be modified or manipulated, since this can lead to significant safety risks.

Charging procedures appropriate to the specific call type of rechargeable batteries must be used.

As with any batteries, lithium batteries can still be a hazard even when they are believed to be in a discharged

state. On the one hand, they can still deliver a very high short circuit current.

Excessively deep discharge will damage most products permanently. Deeply discharged lithium batteries may no


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longer be charged or operated.

Excessive charge currents and overcharging must be avoided under all circumstances. They can lead directly to

critical situations, and can also have negative effects on battery lifetime.

2.4.3. Composition, specifications of components

The specific contents can be found in the manufacturer- and product-specific data sheets for lithium batteries.

Note: Lithium batteries are products from which no material escapes when they are used properly.

2.4.4. First aid procedures

Skin or eye contact:

Should this type of contact occur, rinse the areas affected thoroughly with water for at least 15 minutes. In case

of eye contact, in addition to thorough rinsing with water a doctor must in any case be contacted.

Burns:

Should burns be caused, treat them appropriately. It is also urgently recommended that a doctor be contacted.

Breathing passages:

If intensive smoke develops or gas escapes, leave the room immediately. In case of larger quantities and irritation

of the breathing passages, contact a doctor. If possible, ensure sufficient ventilation.

If swallowed:

Rinse in and around mouth with water. Obtain medical assistance immediately.

When properly handled and stored, lithium cells and batteries represent no damage. Since different materials are

used depending on the manufacturer, in case of damage always follow the manufacturer's instructions provided

in their product-specific documentation.


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2.4.5. Firefighting measures

Fires in lithium batteries during operation can in principle be fought with water. Differentiation between different

systems in the lithium battery is generally impossible as well as unnecessary during a fire.

Due to the construction and battery characteristics, no additional or special extinguishing agents need to be

provided, since the batteries are protected appropriately. Fires in the vicinity of batteries must be fought with

conventional extinguishing agents. A fire in a battery cannot be treated separately from the surrounding fire.

Due to the cooling effect of water, the spread of a fire to battery cells that have not yet reached critical

temperature for ignition ("thermal runaway") is effectively prevented.

As in any fire, the combustion gases released can damage health when breathed in. Be sure there is sufficient

ventilation, therefore.

2.4.6. Measures to take in case of unintentional release

If the battery housing is damaged, electrolyte can escape. Batteries must be enclosed in an air-tight plastic bag,

then dry sand, chalk dust (CaCO3), or vermiculite added. Traces of electrolyte can be picked up with dry paper

towels. Avoid direct skin contact by wearing protective gloves. Rinse with sufficient water.

Personal protective equipment appropriate to the situation (safety gloves, protective clothing, face mask,

respiration protection). Concrete specifications for the personal protective equipment can be found in the

manufacturer- and product-specific information.

Always proceed in accordance with the instructions of the manufacturer. If needed, information should be

obtained from the manufacturer.

2.4.7. Handling and storage

Use only the battery type recommended and/or provided.

A short circuit of the battery pole must be effectively prevented by means of suitable insulation.

Lithium batteries should preferably be stored at room temperature in a dry place (details can be found in the

manufacturer information for the storage temperature range). Large temperature fluctuations should be avoided.

(For example, do not store near heaters, do not expose to long-term sunlight). Should damage or improper

handling lead to the release of materials, always follow the instructions of the manufacturer. This particularly

includes the use of personal protective equipment.

When storing large quantities of lithium batteries, coordinate with local authorities. In general, and

independently of batteries: A construction permit is required for warehouses.

2.4.8. Limitation and monitoring of exposure / personal protective equipment

Lithium batteries are products from which no materials are released under normal and reasonably foreseeable

conditions of use.


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2.4.9. Physical and chemical properties

Please refer to the properties of the materials used, described in the manufacturer- and product-specific data

sheets for lithium batteries.

2.4.10. Stability and reactivity

If an upper temperature limit is exceeded (see product-specific data sheets from the manufacturer), there is a risk

that the battery could burst. When charging a rechargeable system, always ensure compliance with the upper

voltage limit. If limits are exceeded, the battery could burst or even explode. Impermissible charging of a non-

rechargeable system can cause the battery to burst or explode. The final discharge voltage may also not go too

low. There is a risk of bursting in this case as well.

2.4.11. Toxicological information

Please refer to the toxicological information for the materials used, described in the manufacturer- and product-

specific data sheets for lithium batteries.

2.4.12. Environmentally relevant information

Please refer to the toxicological information for the materials used, described in the manufacturer- and product-

specific data sheets for lithium batteries.


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2.4.13. Instructions for disposal

Lithium batteries are marked with the symbol of a crossed-out waste container (see figure).

This symbol reminds the end user that batteries may not be disposed of with household waste,

but must instead be collected separately. Used batteries must be returned (free of charge) to the

point of sale or sent to a disposal system (industrial, commercial).

To prevent short circuits and associated heating, lithium batteries may never be stored or transported in loose

piles without protection. Suitable measures against short circuits include, for example:

Placement of batteries in original packaging or in a plastic bag

Taping the poles

Embedding in dry sand

2.4.14. Transport information

The commercial transport of lithium batteries is subject to hazardous goods transportation regulations. Transport

preparations and transport may only be carried out by appropriately trained personnel or the process must be

supervised by appropriate experts or qualified companies.

Transport guidelines:

Lithium batteries are subject to the following hazardous goods regulations and exceptions to them, in their

currently valid editions:

Class 9

UN 3090: LITHIUM METAL BATTERIES

UN 3091: LITHIUM METAL BATTERIES IN EQUIPMENT, or

LITHIUM METAL BATTERIES PACKAGED WITH EQUIPMENT

UN 3480: LITHIUM ION BATTERIES (including lithium ion polymer batteries)

UN 3481: LITHIUM ION BATTERIES IN EQUIPMENT, or

LITHIUM ION BATTERIES PACKAGED WITH EQUIPMENT

(including lithium ion polymer batteries)

Packaging group: II, tunnel category E

Special and packaging regulations:

ADR, RID:188, 230, 310, 636, P903, P903a, P903b

note: For ADR, see

www.bmvbs.de/SharedDocs/DE/Artikel/Ul/Gefahrqut/qefahrqut-recht-vorschriften-strasse.html

IATA: A88, A99, A154, A164, P965, P966, P967, P968, P969, P970

Note: IATA Guidance Document "About lithium batteries", see

www.iata.org/whatwedo/cargo/dangerous__goods/Pages/lithium_batteries.aspx


Page 16 of 23

IMDG Code: 188, 230, 310, P903

Ems: F-A, S-1

Stowage category A

Used batteries are also subject to these regulations. For intact, undamaged used batteries, the regulations for

new batteries can generally be used.

Defective of damaged batteries are subject to stricter regulations that can even include the complete prohibition

of transport. This transport prohibition applies for air cargo (ICAO T.I., IATA DGR -

Special decision A154).

The transport of used - but undamaged - batteries, however, is also governed by the corresponding special

regulations (636) and/or packaging instructions (P903a and P903b / ADR).

Waste batteries and batteries sent for recycling or disposal are prohibited from air cargo (IATA special decision A

183).

Exceptions must be approved by the competent national authorities of the sending company and the country of

the airline.

2.4.15. General information

In Germany, the Law governing the sale, return, and environmentally responsible disposal of batteries (the

Battery Act, "Batteriegesetz", or BattG) of 25 June 2009 applies. This law implements Directive 2006/66/EC

(Battery Directive).

The instructions in this document represent a guide to compliance with legal requirements, but do not replace

them.

The information above has been gathered to our best knowledge and conscience.


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2.4.16. Changing batteries

WARNING: The handheld tester does not contain a built-in charger. As a result, the battery must be removed

and charged with an appropriate charging unit. Only chargers may be used that are suitable for lithium polymer

batteries and suitable charge monitoring. When using the adapter, there is a danger of short circuiting the

battery! Always connect to the charger first, then to the battery!

1. Loose screws (Phillips head) on the back

2. Remove the cover and battery

3. Disconnect the battery at the yellow plug connector

4. The battery can remain mounted in the holder on the back wall during charging

5. The battery can now be connected to a charger using the adapter cable provided

Figure 2 Handheld tester with back wall removed


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3. Firmware overview

3.1. Touch display

The figure shows an example implementation of a customer-specific touch display interface. The arrangement

and color may be freely selected. Existing modules can be used.

Display of the power source

in use Status display

Configuration and

parameters

Results display Buttons


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3.2. Turning on/off

The handheld tester is turned on using the red button on the right side. To turn it on, actuate it briefly, then the

unit starts and shows the main menu after it starts. During the start phase, the device checks whether a valid

power supply is connected. Should a valid power supply be connected (external with correct voltage or charged

battery), the unit will not start.

To turn it off, press the button briefly. The button is periodically polled and must therefore be pressed for at most

1 second before releasing it turns the unit off. If the button is pressed for a longer time, a red battery symbol

appears in order to indicate that the shut-down phase has started.

If the battery voltage is too high or if the voltage on the input for the external power supply is too low, the unit

turns off automatically. It is particularly important to avoid a shut-off in battery mode, to prevent damage to the

lithium polymer battery and the unit.

Figure 3 Handheld tester with button to turn on and off


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3.3. Power supply

General information

The power supply for the handheld tester is checked periodically once per second. In this cycle, then, the power

source is switched or the unit turned off.

Battery operation

WARNING: The handheld tester does not contain a built-in charger. As a result, the battery must be removed

and charged with an appropriate charging unit. Only chargers may be used that are suitable for lithium polymer

batteries and suitable charge monitoring.

If the battery is being used, the information line at the upper right shows the charge status display as a battery

symbol. If the battery is low, the battery symbol appears in red. If the lower voltage limit of the battery has been

reached, the unit is automatically turned off in order to avoid damaging the battery and the unit. It is

recommended that the battery be recharged before the automatic shutoff, if possible, to reduce wearout.

If the unit is in battery operation, a direct switch to external power can take place using a power supply. In this

case, the power supply must be plugged into the corresponding jack. During the cyclical detection, the unit then

switches automatically to external power.

Operation with external power supply

For stationary operation, the handheld tester can be connected to an external power supply. This is indicated on

the information line at the upper right by the "EXT" symbol. The external power supply always takes priority over

use of the battery, to protect it.

If a sufficiently charged battery is inserted, the unit can switch from external power to battery during operation.

To do this, remove the power supply from the connection jack.

To ensure problem-free operation, a power supply with sufficient capacity should be provided. A 12 VDC power

supply with a current capacity appropriate to the application is recommended.


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3.4. Configuration

3.4.1. General information

The basic settings can be made for the handheld tester in the configuration user interface:

Language

Display calibration

Activation of the configuration from the PC

Display brightness

The configuration menu (Figure 5) can be called up from the CONFIG button (Figure 4) on the main menu. The

configuration can then be adjusted using the corresponding buttons.

Figure 4 Main menu with button to open configuration

To return to the starting screen, press the blue HOME button on the lower right edge of the screen. Pressing the

HOME button saves all the configuration values to the memory of the unit so they will be available after a restart

as well. If the unit is turned off beforehand, the configuration values will be discarded.

After pressing the HOME button, the connection to the device under test is also reestablished in order to make

use of any changed configuration of versions.

Figure 5 Configuration menu


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3.4.2. Switching languages

The "Language" button can be used to switch languages. The button always displays the language to which the

unit should be switched. This simplifies use for people who do not speak the current language. The menu system

can currently be switched between German and English.

The platform permits the addition of new languages for the development or further development of a handheld

tester.

3.4.3. Display calibration

It is possible to change the calibration of the display at any time. This is recommended, for example, when the

position at which a button is activated is not in the desired location. The unit is delivered with a working standard

calibration.

The calibration can be started by pressing the "Calibration" button. Three flashing dots are then displayed one

after the other and must be touched on the display. It is important to touch the dots in the same way as during

the normal operation situation. This permits differences such as operation with the thumb or index finger to be

taken into consideration.

Figure 6 Start menu for display calibration

WARNING: An incorrectly performed calibration can make the unit inoperable and will require a reset by the

manufacturer. A calibration should therefore only be carried out when absolutely necessary.


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3.4.4. Configuring using PC software

A connection can only be established to a connected PC if the button "Start PC mode" is set to "Active" (Figure 7).

The HOME button is disabled to prevent use of the device during configuration. Once the mode is switched to

active, the PC software can be used to read out the parameter set, change it, then transmit it back to the unit.

Figure 7 Activate button for PC mode in the configuration menu

A change to this functionality is possible, depending on the application (for example remote control).

3.4.5. Display brightness

The display brightness can be adjusted using the slider (Figure 8). To do this, slide the red dot on the white bar. A

change is recommended, for example, when the unit is used in a very bright or very dark environment. The

battery life can also be extended by a dark display.

Figure 8 Slider for display brightness in the configuration menu

Documents

Digitale Ausgabe 32 Kanal - MCD Elektronik GmbH · 2016-06-06 · Manual Platform for Handheld Testers . Elektronik GmbH Platform for Handheld Testers Manual ... Lithium polymer battery