Xuji Group ·Xuji Power Co., Ltd.

FXJ-22 Cell Internal Resistance

Instruction for Use

Xuji Power Co., Ltd.

October 2,
2009
Version: v1.0
1 Overview

1.1 Scope

FXJ-22 Cell Internal Resistance Inspection Management Unit is a network-based measuring module
for 2V, 6V and 12V cells, which is produced by the Company with years of DC equipment
manufacturing experience, and can be used independently or jointly with WZCK-21 microcomputer
DC monitoring device.

2 Main Technical Performance and Parameters

2.1 Ambient Parameters

2.1.1 Ambient Temperature: -10 °C~+55 °C

2.1.2 Atmospheric Pressure: 80~110 Kpa.

2.1.3 Relative Humidity: no more than 90％ (25 °C).

2.1.4 Working Position: vertically with the maximum slope of no more than 5°.

2.1.5 The place where the device is used shall be provided with facilities for preventing sand, rain
and snow, free of corrosive and explosive gas.

2.1.6 The place where the device is used shall be free from strong shock or sharp pounding.

2.2 Performance and Characteristics

2.2.1 It is featured by rapid computing speed and high reliability with AVR single chip adopted.

2.2.2 The software watchdog and BOD used can significantly improve the stability and reliability of
the system.

2.2.3 Special chip used can ensure high accuracy and excellent anti-interference ability.

2.2.4 Tail cell parameters are set independently, which is convenient for grouping the cell and wiring.

3 Technical Data

3.1 Terminal Voltage/Internal Resistance Inspection Range: 2 V/10 mΩ; 12 V/50 mΩ. (Jumper
setting)

3.2 Voltage Inspection Precision: ≦full range ±0.2%

3.3 Internal Resistance Inspection Precision: ≦ full range ±5%

3.4 Isolation Voltage: 3,000 VDC (communication and input isolation)

3.5 Communication Interface: RS485, 1 start bit + 8 data bits + 1 stop bit

3.6 Communication Rate: 9,600 bps

3.7 Communication Method: question and answer

3.8 Communication Protocol: MODBUS RTU protocol is adopted, see Annex II for details.

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3.9 Communication Interval :> 200 mS

3.10 Power Supply: DC 90~260 V with the ripple factor of no more than 5%.

4 Device Structure (Schematic Diagram)

5 System Overview

5.1 Indicator Light

There are two indicator lights on the module, one for operation and the other for communication.
After the unit is powered up, the indicator light for operation flashes once every 500 mS. The
indicator light for communication flashes once when the unit receives the message sent by the upper
computer and reports the message to upper computer after processing.

5.2 Workflow

5.2.1 Terminal Voltage Inspection Workflow

After the unit is powered up, corresponding optical relays are switched in turn to introduce the
voltage of single cell to the unit for analog-digital conversion and data processing via special chip,
and then inform the CPU to read the data by means of interruption. The voltage of cell can be

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calculated according to the data read by CPU, and then compared with the overvoltage and
undervoltage set. The overvoltage and undervoltage alarm information will be generated if the value
is out-of-limit for 3 consecutive times. CPU will measure the temperature every minute if the unit is
provided with temperature probe.WZCK-21 microprocessor DC monitoring and detecting device is
capable of setting parameters of the measuring unit via RS485 or reading the voltage of cell and
alarm data. If the address set by the dial switch of the unit is changed, the measuring unit shall be
powered up again. After alarm values of overvoltage and undervoltage, number of cells acquired and
other operation parameters are acquired, the measuring unit shall be powered on again, or the
correctness of operation parameters cannot be ensured.

5.2.2 Internal Resistance Inspection Workflow

After the unit is powered up, corresponding optical relays are switched in turn to introduce the
internal resistance inspection excitation current of single cell, and introduce the inspection voltage to
the unit for analog-digital conversion and data processing via special chip, and then inform the CPU
to read the data by means of interruption. The internal resistance of cell can be calculated according
to the data read by CPU. After the gear setting of the unit is changed, the measuring unit must be
powered up again, or the correctness of operation parameters cannot be ensured.

5.3 Description of Terminal

See Annex I for schematic diagram of FXJ-22 terminal.

Sample terminals 1 and 20 are used to connect with 19 cells, with terminal 1 connecting to the
positive electrode of cell 1, terminal 2 connecting to negative electrode of cell 1 and positive
electrode of cell 2, and so forth, terminal 20 shall be connected to the negative electrode of cell 19.

Signal terminals 31 and 50 are used to connect with 19 cells, with terminal 31 connecting to the
positive electrode of cell 1, terminal 32 connecting to negative electrode of cell 1 and positive
electrode of cell 2, and so forth, terminal 50 shall be connected to the negative electrode of cell 19.

When the temperature probe is provided, the red wire of temperature probe shall be connected with
terminal 21, the green one with terminal 22 and blue one with terminal 23.

Terminal 25 shall be used to connect with positive input of working power, and terminal 27 with
negative input of working power and terminal 29 with ground wire.

Terminal 30 shall be used to connect with A of RS485 communication interface, terminal 31 with B of
RS485 communication interface and terminal 32 with the ground wire of RS485 communication
interface.

5.4 Unit Setting

⚫ Address: 0x60~0x6f, wherein 0x6f is a universal address.

⚫ Type of measuring voltage: 12 V single, 6 V single, 2 V single

The Local address of FXJ-22 measuring unit can be set by 4-bit dial switch from No.2 to No.5 in
Element U19:

Fig.1 Functional Diagrams of Dial Switch in Element U19

Unit Address U19-No.2 U19-No.3 U19-No.4 U19-No.5

0x60 OFF OFF OFF OFF

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 0x61 OFF OFF OFF ON

0x62 OFF OFF ON OFF

0x63 OFF OFF ON ON

0x64 OFF ON OFF OFF

0x65 OFF ON OFF ON

0x66 OFF ON ON OFF

0x67 OFF ON ON ON

0x68 ON OFF OFF OFF

0x69 ON OFF OFF ON

0x6a ON OFF ON OFF

0x6b ON OFF ON ON

0x6c ON ON OFF OFF

0x6d ON ON OFF ON

0x6e ON ON ON OFF

0x6f ON ON ON ON

Whether the FXJ-22 measuring unit can be used for monitoring the ambient temperature can be set
via No.1 dial switch in Element U19.

⚫ Note! when the module is used separately, the address shall be set as: 0x60; When
modules are used in combination, the address shall be set as follows in turn: 0x60
0x61…etc.

No.1---ON --- Enable the ambient temperature monitoring function

No.1---OFF--- Disable the ambient temperature monitoring function

6 Installation and Commissioning

Inspection before Powering on

6.1 Inspection of loose plugging, damaged machinery and disconnected wire.

6.2 Inspection of incorrect and unreliable cable connection of devices.

6.3 Inspection of disconnected and broken wires in the back.

Any faults found shall be solved as per the drawings.

7 Transportation and Storage

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7.1 Products have been packed before leaving factory. Products shall be prevented from strong
collision and bump during transportation to avoid damages to the external packing.

7.2 Storage Conditions

Products shall be stored in a rain- and snow-proof room with the ambient temperature of
-20 °C∽+60 °C, relative humidity of no more than 80% and free from acid, alkaline or other
corrosive and explosive gas.

8 Unpacking and Check

After equipment are delivered to installation site, unpack them carefully and check whether drawings
and spares are complete and the packing are all right and register the process.

9 Attached Documents

Documents attached with products include one piece of Instruction for Use and one piece of
certificate.

10 Warranty Services

10.1 Warranty Conditions

⚫ In case of any quality problems even though the user complies with regulations for storage,
installation and use specified in this instruction after delivery;

⚫ In case of any product or accessories damage caused by transportation found by the user in
unpacking inspection after delivery.

10.2 Warranty Period

⚫ The warranty of the quality of products is 12 month after the delivery of the products.

10.3 Warranty Measures

⚫ The manufacturer is responsible for replacing or repairing the products free of charge within the
warranty period.

⚫ The user shall consult with the manufacturer for paid replacement or repair beyond the warranty
period.

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Annex I Schematic Diagram of Terminal

J5

GND
PE
P+
17
18
19
20

P-
D
Q

A
B
P
1
2
J2 LED2 LED1
3
J4 1 2 3 4 5 6 4
5

EARTH
IN+

IN- 6
Programmer 1
J3
interface
编程器接口 2
6 5

4 3
J1
2 1
J6
ON S1

No.1
No.2
No.3
No.4
No.5
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16

S1 is a dial switch and the address of device can be set by setting No.2, No.3, No.4, and No.5 of S1.
The coding rule of address is: address of device

= No.2*0x08+No.3*0x04+No.4*0x02+No.5+0x60.

Terminal J1 is the cell voltage acquisition terminal. Port 01 shall be connected with positive electrode
of the first cell, port 02 with the negative electrode of the first cell, port 03 with the negative electrode
of the second cell, and so forth, port 20 of J2 terminal shall be connected with negative electrode of
the nineteenth cell.

P+ and P- of J2 terminal shall be respectively connected with positive electrode of power supply and
power ground. PE shall be connected with the ground. And port A and B are RS485 communication
ports.

RC reset circuit can be accessed into rest pin of single chip when J3 terminal shorts circuit with short
circuit ring. During the process of program burning, short circuit ring must be removed, or the
program cannot be burned. After the process of program burn, short circuit ring must be added for
increasing the reliability of system.

J4 terminal shall be connected with power panel of the device, and external input power shall be
provided to power panel. Port 1 is power +, and port 3 is the power supply GND, and port 6 is GND.

J5 terminal shall be connected with power panel to supply power for measuring plate. Port 1 is +5V1
and port 2 is GND1. These two ports are responsible for power supply of RS485 communications
chip. Port 4 is -5V, port 5 is GND and port 6 is +5V. These three ports are responsible for power
supply of single chip.

J6 terminal is the programming interface of the device.

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Annex Ⅱ Communication Protocol

Cell inspection supports 0.2H (remote signal command), 0.3H (command of reading definite value),
0.4H (command of remote measuring), 10H (writing definite value), 11H (report the ID of slave).

Address for Remote Signal Command of Cell Inspection

Data Address Parameter Name Data Remarks

0 Overvoltage alarm in channel 1 BIT

1 Overvoltage alarm in channel 2 BIT

2 Overvoltage alarm in channel 3 BIT

3 Overvoltage alarm in channel 4 BIT

4 Overvoltage alarm in channel 5 BIT

5 Overvoltage alarm in channel 6 BIT

6 Overvoltage alarm in channel 7 BIT

7 Overvoltage alarm in channel 8 BIT

8 Overvoltage alarm in channel 9 BIT

9 Overvoltage alarm in channel 10 BIT

10 Overvoltage alarm in channel 11 BIT

11 Overvoltage alarm in channel 12 BIT

12 Overvoltage alarm in channel 13 BIT

13 Overvoltage alarm in channel 14 BIT

14 Overvoltage alarm in channel 15 BIT

15 Overvoltage alarm in channel 16 BIT

16 Overvoltage alarm in channel 17 BIT

17 Overvoltage alarm in channel 18 BIT

18 Overvoltage alarm in channel 19 BIT

19 Undervoltage alarm in channel 1 BIT

20 Undervoltage alarm in channel 2 BIT

21 Undervoltage alarm in channel 3 BIT

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22 Undervoltage alarm in channel 4 BIT

23 Undervoltage alarm in channel 5 BIT

24 Undervoltage alarm in channel 6 BIT

25 Undervoltage alarm in channel 7 BIT

26 Undervoltage alarm in channel 8 BIT

27 Undervoltage alarm in channel 9 BIT

28 Undervoltage alarm in channel 10 BIT

29 Undervoltage alarm in channel 11 BIT

30 Undervoltage alarm in channel 12 BIT

31 Undervoltage alarm in channel 13 BIT

32 Undervoltage alarm in channel 14 BIT

33 Undervoltage alarm in channel 15 BIT

34 Undervoltage alarm in channel 16 BIT

35 Undervoltage alarm in channel 17 BIT

36 Undervoltage alarm in channel 18 BIT

37 Undervoltage alarm in channel 19 BIT

38 Temperature enabling BIT

For example: the host inquires data of register with input state beginning from 32 (20H) in 2200H
from the slave.

Inquire Response

Functional Domain Sample Functional Domain Sample

HEX ASCII HEX ASCII

Sub-site Address 01 Sub-site Address 01

Function Code 02 Function Code 02

Beginning register H 22 Number of bytes 04

Beginning register L 00 Data (07-00) 03

Register data H 00 Data (15-08) 00

Register data L 20 Data (23-16) 01

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CRC L - Data (31-24) 00

CRC H - CRC L -

CRC H -

Note: ON is checked when the slave responds the voltage to the host, the temperature enabling is
ON and the overvoltage alarm of channel 15 is ON.

Address for Reading Definite Value (03H) of Cell Inspection

Data Address Parameter Name

00 Overvoltage value of single cell

02 Undervoltage value of single cell

04 Overvoltage of tail cell

06 Undervoltage value of tail cell

08 Number of cell acquired

0A Zero drift of channel 00

0C Zero drift of channel 01

0E Zero drift of channel 02

10 Zero drift of channel 03

12 Zero drift of channel 04

14 Zero drift of channel 05

16 Zero drift of channel 06

18 Zero drift of channel 07

1A Zero drift of channel 08

1C Zero drift of channel 09

1E Zero drift of channel 10

20 Zero drift of channel 11

22 Zero drift of channel 12

24 Zero drift of channel 13

26 Zero drift of channel 14

28 Zero drift of channel 15

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2A Zero drift of channel 16

2C Zero drift of channel 17

2E Zero drift of channel 18

30 Factor of channel 00

32 Factor of channel 01

34 Factor of channel 02

36 Factor of channel 03

38 Factor of channel 04

3A Factor of channel 05

3C Factor of channel 06

3E Factor of channel 07

40 Factor of channel 08

42 Factor of channel 09

44 Factor of channel 10

46 Factor of channel 11

48 Factor of channel 12

4A Factor of channel 13

4C Factor of channel 14

4E Factor of channel 15

50 Factor of channel 16

52 Factor of channel 17

54 Factor of channel 18

One set of data shall be expressed by two registers, with the data format described as follows:

BIT31 BIT30 BIT29 BIT28 BIT27 BIT26 BIT25 BIT24 BIT23 …… BIT00

Sign bit Decimal digit Data

Description of sign bit: 0 shows that the item is a positive number, while 1 stands for negative
number;

Description of decimal digit: 000-111 refers to decimal from 0 to 7

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 Actual transmission value = (-1) symbol bit x data x 10 (- decimal digits)

For example: the host inquires contents of ten definite values beginning from 2400H from the slave.

Inquire Response

Functional Domain Sample Functional Domain Sample

HEX ASCII HEX ASCII

Sub-site Address 01 Sub-site Address 01

Function Code 03 Function Code 03

Beginning register H 24 Number of bytes 14

Beginning register L 00 8 bit H in register 1 03

Register data H 00 8 bit L in register 1 00

Register data L 10 8 bit H in register 2 0A

CRC L -- 8 bit L in register 2 F0

CRC H -- 8bit H in register 3 03

8bit L in register 3 00

8bit H in register 4 06

8bit L in register 4 40

8bit H in register 5 03

8bit L in register 5 00

8bit H in register 6 0A

8bit L in register 6 F0

8bit H in register 7 03

8bit L in register 7 00

8bit H in register 8 06

8bit L in register 8 40

8bit H in register 9 00

8bit L in register 9 00

8bit H in register 10 00

8bit L in register 10 13

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 CRC L --

CRC H --

Description: The definite values responded from the slave are respectively:

Overvoltage value of single cell AF0H * 0.001 2.80

Undervoltage value of single cell 640H * 0.001 1.60

Overvoltage of tail cell AF0H * 0.001 2.80

Undervoltage value of tail cell 640H * 0.001 1.60

Number of cell acquired 13H * 1 2.80

Address of Remote Measuring (04H) of Cell Inspection

Data Address Parameter Name

0 Temperature

2 Cell voltage of channel 0

4 Cell voltage of channel 1

6 Cell voltage of channel 2

8 Cell voltage of channel 3

0A Cell voltage of channel 4

0C Cell voltage of channel 5

0E Cell voltage of channel 6

10 Cell voltage of channel 7

12 Cell voltage of channel 8

14 Cell voltage of channel 9

16 Cell voltage of channel 10

18 Cell voltage of channel 11

1A Cell voltage of channel 12

1C Cell voltage of channel 13

1E Cell voltage of channel 14

20 Cell voltage of channel 15

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22 Cell voltage of channel 16

24 Cell voltage of channel 17

26 Cell voltage of channel 18

One set of data shall be expressed by two registers, with the data format described as follows:

BIT31 BIT30 BIT29 BIT28 BIT27 BIT26 BIT25 BIT24 BIT23 …… BIT00

Sign Decimal digit Data

Description of sign bit: shows that the item is a positive number, while 1 stands for negative number;

Description of decimal digit: 00-111 refers to decimal from 0 to 7

Actual transmission value = (-1) symbol bit x data x 10 (- decimal digits)

For example: the host inquires contents of two registers beginning from 2800H from slave 1.

Inquire Response

Functional Domain Sample Functional Domain Sample

HEX ASCII HEX ASCII

Sub-site Address 01 Sub-site Address 01

Function Code 04 Function Code 04

Beginning register H 28 Number of bytes 04

Beginning register L 00 8 bit H in register 1 04

Register data H 00 8 bit L in register 1 00

Register data L 02 8 bit H in register 2 5F

CRC L -- 8 bit L in register 2 2D

CRC H -- CRC L --

CRC H --

The host inquires contents of two registers (measuring data of channel 00) beginning from 2800.
The measuring data of the response channel 00 of the slave is 5F2DH * 0.0001 = 2.4365.

Address of Definite Value (10H) of Cell Inspection

Data Address Parameter Name

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00 Overvoltage value of single cell

02 Undervoltage value of single cell

04 Overvoltage of tail cell

06 Undervoltage value of tail cell

08 Number of cell acquired

0A Calibration value of channel 00

0C Calibration value of channel 01

0E Calibration value of channel 02

10 Calibration value of channel 03

12 Calibration value of channel 04

14 Calibration value of channel 05

16 Calibration value of channel 06

18 Calibration value of channel 07

1A Calibration value of channel 08

1C Calibration value of channel 09

1E Calibration value of channel 10

20 Calibration value of channel 11

22 Calibration value of channel 12

24 Calibration value of channel 13

26 Calibration value of channel 14

28 Calibration value of channel 15

2A Calibration value of channel 16

2C Calibration value of channel 17

2E Calibration value of channel 18

One set of data shall be expressed by two registers, with the data format described as follows:

BIT31 BIT30 BIT29 BIT28 BIT27 BIT26 BIT25 BIT24 BIT23 …… BIT00

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Sign Decimal digit Data
bit

Description of sign bit: 0 shows that the item is a positive number, while 1 stands for negative
number;

Description of decimal digit: 000-111 refers to decimal from 0 to 7

Actual transmission value = (-1) symbol bit x data x 10 (- decimal digits)

Inquire Response

Functional Domain Sample Functional Domain Sample

HEX ASCII HEX ASCII

Sub-site Address 01 Sub-site Address 01

Function Code 10 Function Code 10

Beginning register H 2C Beginning register H 2C

Beginning register L 00 Beginning register L 00

Register data H 00 Register data H 00

Register data L 02 Register data L 02

Number of bytes 04 CRC L -

8 bit H in register 1 03 CRC H -

8 bit L in register 1 00

8 bit H in register 2 0A

8 bit L in register 2 F0

CRC L -

CRC H -

Note: the host requests that the address of 2C00H and 2C01H of slave 1 shall be respectively
0300H and 0AF0H, i.e., definite value of overvoltage for single cell shall be 2.800 V. After the slave
receives and executes the command, the origin address and number of register which have been
revised shall be responded.

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