PowerTrack 500 (PbS)

Device Image(s)

Device Identification

• Device name: PowerTrack 500

• Device model: S4PB-00C0187105

• Device SSID: PowerTrack500-XXXXXXXXXXXX

• BLE ID: 0x1125

• EAN: 3800600015612

Short Description

PowerTrack 500 is a high-current, low-voltage DC power and battery monitoring device designed for use in battery systems and DC power installations. The device measures electrical and thermal parameters and provides monitoring data via Wi-Fi network and RS485/Modbus interface.

⚠️ PowerTrack 500 is a monitoring device only. It does not disconnect power or provide protective isolation.

Intended Use

PowerTrack 500 is intended for:

• Measuring DC currents up to 500 A

• Measuring total battery pack voltage and individual battery voltages

• Measuring indivisual battery temperature

• Measuring the device temperature

• Estimating State of Charge (SoC) and State of Health (SoH) of the battery pack

• Providing alarms and monitoring data

Non-intended Use

PowerTrack 500 must NOT be used:

• As a protective or safety disconnect device

• As a fuse, breaker, or emergency cutoff

• In systems exceeding rated limits

• In life-critical or safety-critical applications

Main Features

Integrated High-Current Shunt

• Built-in precision shunt for direct DC current measurement up to 500 A.

High-Accuracy DC Power Monitoring

• Real-time measurement of:

• Current (bidirectional: charge / discharge)

• Voltage

• Power

• Energy (charge and discharge)

Battery Monitoring Capability

• Supports monitoring of battery systems from 6 V to 60 V nominal.

Individual Battery Voltage Measurement

• Up to 4 battery voltage inputs for individual battery monitoring.

Temperature Monitoring

• Device temperature monitoring

• Support for up to 4 external battery temperature sensors

State of Charge (SoC) Estimation

• Advanced SoC calculation using:

  • Coulomb counting

  • Peukert compensation

  • Charge efficiency factor

  • Synchronization logic

State of Health (SoH) Estimation

• Battery condition estimation based on:

  • Internal resistance trends

  • Cycle tracking

  • Temperature behavior

Configurable Battery Chemistry Support

• Compatible with:

  • LiFePO₄

  • Lead-acid (VRLA, AGM, Flooded, Gelled)

  • Li-Ion

Configurable Alarms and Thresholds

• Supports alarms for:

  • Charge and discharge over-current

  • Over-voltage / Under-voltage

  • Over-temperature / Under-temperature

  • Low / High SoC

  • Battery imbalance

RS485 / Modbus RTU Support

• Industrial integration via configurable Modbus register mapping.

Network Connectivity

• Local and cloud-based access for monitoring and configuration.

Energy and Cycle Tracking

• Tracks:

  • Cumulative charge/discharge (Ah)

  • Number of cycles

  • Remaining time estimation

Integrated Thermal Monitoring and Protection Awareness

• Continuous device temperature monitoring for safe high-current operation.

Designed for High-Current DC Applications

• Suitable for:

  • Energy storage systems

  • Off-grid installations

  • Marine and RV battery systems

Industrial DC monitoring

Use Cases

Battery System Monitoring (Single Battery)

Scenario:

Monitoring a single 12 V, 24 V, 36 V, or 48 V battery.

Purpose:

• Track charge and discharge current

• Monitor battery voltage

• Estimate State of Charge (SoC)

• Detect deep discharge or overcharge conditions

Typical Applications:

• Backup power systems

• Small energy storage systems

Battery Pack Monitoring (2–4 Batteries in Series)

Scenario:
Monitoring a battery pack consisting of 2 to 4 batteries connected in series.

Purpose:

• Measure total pack voltage

• Measure individual battery voltages

• Detect imbalance between batteries

• Monitor pack current and temperature

Benefits:

• Early detection of battery imbalance

• Prevention of premature battery failure

• Improved system reliability

Off-Grid Solar Energy Systems

Scenario:
Monitoring battery banks in off-grid photovoltaic installations.

Purpose:

• Track energy flow between charger, battery, and load

• Monitor cumulative charge and discharge

• Estimate remaining runtime (time-to-go)

• Detect abnormal current conditions

Typical Users:

• Remote cabins

• Agricultural installations

• Standalone solar systems

Industrial DC Power Monitoring

Scenario:
Monitoring high-current DC systems in industrial environments.

Purpose:

• Measure DC load current up to 500 A

• Track energy consumption

• Integrate monitoring data via RS485 / Modbus

• Provide alarm notifications

Typical Applications:

• DC distribution panels

• Telecom power systems

Energy Storage System (ESS) Monitoring

Scenario:
Integration within a larger battery energy storage system.

Purpose:

• Monitor pack performance

• Estimate SoC and SoH

• Track cycle count

• Provide data to automation or SCADA systems

Integration:

• RS485 / Modbus RTU

• Network-based monitoring

Marine and RV Battery Monitoring

Scenario:
Monitoring service batteries in marine or recreational vehicle installations.

Purpose:

• Monitor discharge during operation

• Track remaining battery capacity

• Detect abnormal current draw

• Improve energy management

Battery Health Tracking Over Time

Scenario:
Long-term battery performance analysis.

Purpose:

• Track internal resistance trends

• Monitor cycle count

• Estimate degradation

• Plan preventive battery replacement

DC Energy Metering (Without SoC Tracking)

Scenario:
Using PowerTrack 500 purely as a DC power and energy meter.

Purpose:

• Measure bidirectional DC current

• Monitor energy in/out (Wh)

• Integrate with automation systems

• Track load behavior

Main Applications

• DC Battery Monitoring Systems - Monitoring of single batteries and battery packs (6 V to 60 V nominal).

• Battery Energy Storage Systems (BESS) - Performance monitoring and energy tracking in stationary energy storage installations.

• Off-Grid and Solar Power Systems - Monitoring of battery banks in standalone photovoltaic installations.

• Industrial DC Power Distribution - High-current DC monitoring in telecom, automation, and control systems.

• Marine and Recreational Vehicle (RV) Systems - Service battery monitoring and energy management.

• Backup Power Systems - Monitoring of battery-based UPS and emergency backup installations.

• DC Energy Metering Applications - Bidirectional DC current and energy measurement in high-current installations.

• Battery Health and Lifecycle Tracking - Long-term monitoring of battery performance, cycle count, and degradation trends.

Integrations

• NA

Connectivity

• Wi-Fi

• Bluetooth

Safety functions

Overcurrent Monitoring

• Continuous measurement of bidirectional DC current.

• Configurable alarm thresholds for:

  • Charge overcurrent

  • Discharge overcurrent

• Alarm notification when configured limits are exceeded.

Overvoltage and Undervoltage Monitoring

• Continuous monitoring of:

  • Total battery pack voltage

  • Individual battery voltages (up to 4 inputs)

• Configurable high and low voltage thresholds.

• Alarm generation upon limit violation.

Battery Imbalance Detection

• Monitoring of voltage deviation between batteries in a pack.

• Configurable imbalance threshold.

• Early detection of uneven battery aging or failure.

Temperature Monitoring

• Device temperature monitoring.

• Support for up to 4 external battery temperature sensors.

• Configurable high and low temperature thresholds.

• Alarm notification upon thermal limit violation.

State of Charge (SoC) Monitoring

• Continuous estimation of battery State of Charge.

• Configurable low SoC alarm threshold.

• Helps prevent deep discharge conditions.

State of Health (SoH) Estimation

• Tracking of cycle count.

• Configurable warning and critical thresholds.

• Provides early indication of battery degradation.

Time-to-Go Estimation

• Remaining runtime calculation based on current load.

• Supports operational planning and preventive action.

IMPORTANT
PowerTrack 500 provides monitoring and alarm functionality only. It does not perform automatic shutdown, load disconnection, or protective isolation. External protective devices are required.

Device electrical interfaces

Inputs

• P- : Power source negative

• P+ : Power Source positive (used for PowerTrack 500 power supply)

• B- : Battery negative

• B1 - B4: Individual battery temperature/voltage input terminals

• GND: Ground

• VBUS: Optional power supply input

Outputs

• None

User interface

Inputs

• One (control) button

  • Press and hold for 5 seconds to enable Device access point and Bluetooth connection.

  • Press and hold for 10 seconds to factory reset the Device.

Outputs

LED (red) indication

• • AP (Access Point) enabled and Wi-Fi disabled: 1 second ON / 1 second OFF

  • Wi-Fi enabled, but not connected to a Wi-Fi network: 1 second ON / 3 seconds OFF

  • Connected to a Wi-Fi network: Constantly ON

  • Cloud enabled, but not connected: 1 second ON /5 seconds OFF

  • Connected to Shelly Cloud: Constantly ON

  • OTA (Over the Air Update): ½ sec ON / ½ second OFF

  • Button pressed and held for 5 seconds: ½ second ON / ½ second OFF

  • Button presses and held for 10 seconds: ¼ second ON / ¼ second OFF

The list above starts with the initial device status and the lowest priority. Every next state cancels the previous one.

Modes of Operation

Measurement Mode (Default Mode)

This is the default mode and allows PowerTrack 500 to function as a high-current DC power meter.

Description:

• Continuous measurement of:

  • DC current (bidirectional)

  • Total battery voltage

  • Individual battery voltages (if connected)

  • Temperature (device and batteries)

• Real-time reporting via:

  • Wi-Fi / Bluetooth

  • RS485 / Modbus RTU

Characteristics:

• Always active after power-up

• Can operate without SoC / SoH configuration

OTA (Over the Air Update)

This is remote firmware update mode.

Specifications

Physical

• Size (HxWxD): 45x82x68 mm ±0.5 mm / 1.77x3.23x2.68 in ±0.02 in

• Weight: 300 g / 0.66 lb

• Mounting: Screws

• Shell material: Plastic

• Shell color: Black & Red

Environmental

• Ambient working temperature: -20 °C - 50 °C / -5 °F to 122 °F

• Humidity: 10 % to 90 % RH

• Max. altitude: 2000 m / 6562 ft

Electrical

• Power supply: 6 - 60V DC

• Power consumption: < 3W

• Max shunt current: 500A (≤ 2 hours)

• Power metering: YES (DC)

• Dry contacts: NO

• Controlled elements: NO

• Controlling elements: NO

Sensors, meters

• Internal-temperature sensor: YES

• External-temperature sensor: YES (4 channels)

• External-voltage meter: YES (4 channels)

• Accelerometer: NO

Interfaces

• LAN: NO

• RS485: YES (Modbus)

Radio

• Radio signal power: 1 mW

• Wi-Fi

  • Protocol: 802.11 b/g/n

  • RF band: 2412 - 2472 МHz

  • Max. RF power: < 10 dBm

  • Range: Up to 50 m / 164 ft outdoors, up to 30 m / 98 ft indoors (depending on local conditions)

• Bluetooth

  • Protocol: 5.0

  • RF band: 2402 - 2480 MHz

  • Max. RF power: < 4 dBm

  • Range: Up to 10 m / 33 ft indoors and 30 m / 100 ft outdoors (Depends on local conditions)

Microcontroller unit

• CPU: ESP-Shelly-C6 IC RF TXRX BLE 40QFN

• Flash: 8 MB

Firmware capabilities

• Schedules: 50

• Webhooks (URL actions): 20 with 5 URLs per hook

• Scripting: YES

• MQTT: YES

• Encryption: YES

Installation instructions

Mechanical installation instructions

PowerTrack 500 is designed for mounting on a solid metal surface such as an electrical panel, mounting plate, or battery compartment wall.

Follow the instructions below.

Step 1 – Select installation location

Install the device in a location that is:

• close to the battery negative terminal

• protected from water, condensation, and direct sunlight

• protected from excessive dust and vibration

• accessible for wiring and service

• within the specified operating temperature range

Ensure sufficient space is available for cable routing and tightening of the power terminals.

Step 2 – Mount the device using M5 screws

PowerTrack 500 must be mounted using two M5 screws through the mounting holes of the enclosure.

Installation requirements:

• Use two M5 screws

• Screw length must be appropriate for the thickness of the metal mounting surface

• Screw length must be not less than 20 mm

• Use flat washers if necessary to ensure proper mechanical support

Tighten the screws securely so that the device is firmly attached to the mounting surface. Ensure the enclosure is not deformed during tightening.

Step 3 – Install in correct orientation

Install the device with the front panel facing outward and the cable terminals accessible.

Recommended orientation:

• current terminals facing upward or sideways

• communication and signal terminals easily accessible

Avoid installing the device in positions that obstruct wiring or create mechanical stress on the terminals.

Step 4 – Connect high-current cables securely

The B− and P− terminals carry the full system current.

Ensure that:

• cable lugs are properly crimped

• contact surfaces are clean

• terminal bolts are securely tightened

Loose connections may cause:

• overheating

• inaccurate measurements

• permanent damage

Use cables with appropriate cross-section for the system current.

Step 5 – Provide strain relief for cables

Ensure that heavy cables do not apply mechanical force to the device terminals.

Use:

• cable clamps

• cable ties

• or mounting supports

to secure cables independently of the device. The device terminals must not support cable weight.

Step 6 – Ensure proper ventilation

PowerTrack 500 generates heat during operation.

Do not:

• cover the device

• install near heat sources

• install in sealed, unventilated enclosures without airflow

Ensure adequate airflow around the device.

Step 7 – Final mechanical inspection

Before electrical connection, verify that:

• the device is securely mounted using two M5 screws

• the mounting surface is stable and rigid

• cables are properly supported

• terminals are accessible

• the enclosure is not mechanically stressed

Electrical connection instructions

PowerTrack 500 must be installed in series with the negative conductor of the battery system, so that all charge and discharge current flows through the internal shunt. This ensures accurate measurement of current, energy, and State of Charge (SoC). Follow the steps below:

Step 1 – Disconnect power

Before installation:

• Disconnect the battery or open the main DC breaker.

• Ensure no current is flowing in the system.

• Verify that the installation voltage is within the supported range (6–60 V DC).

Step 2 – Connect the main current terminals

The device must be installed in the negative path between the battery and the system load. Connect as follows:

B- terminal → Battery negative

• Connect the battery negative terminal directly to the B- terminal of PowerTrack 500.

P- terminal → System negative

• Connect the P- terminal to the system negative bus.

• This includes all loads and chargers.

IMPORTANT:

• All current entering or leaving the battery must flow through PowerTrack 500.

• Do not connect any loads or chargers directly to the battery negative bypassing the device.

Incorrect installation will result in inaccurate measurements.

Step 3 – Connect the power supply

PowerTrack 500 is powered from the battery voltage.

Connect:

P+ terminal → Battery positive

Use the red cable supplied with the product for this connection.

This cable must be connected between the battery positive terminal and the P+ terminal of PowerTrack 500.

This connection provides operating power and enables battery voltage measurement.

Important:

• Ensure the cable is securely fastened.

• Do not use this connection to power external loads.

• Use only the supplied cable or a cable with equivalent specifications.

Step 4 – Connect battery sense and temperature cables (combined voltage and temperature measurement)

PowerTrack 500 uses combined sense cables to measure both the individual battery voltage and the battery temperature.

Use the green cables supplied with the product for these connections.

Each green cable contains:

• a voltage sense conductor connected to the battery positive terminal

• an integrated thermistor that measures the battery temperature

Connect the cables as follows:

• B1 → Positive terminal of Battery 1 (green cable)

• B2 → Positive terminal of Battery 2 (green cable)

• B3 → Positive terminal of Battery 3 (green cable)

• B4 → Positive terminal of Battery 4 (green cable)

Each green cable must be connected to the positive terminal of the corresponding battery. The device will automatically measure:

• the individual battery voltage via the sense conductor

• the battery temperature via the thermistor integrated in the cable

This combined measurement enables:

• individual battery monitoring

• temperature monitoring

• imbalance detection

• improved State of Charge (SoC) and State of Health (SoH) estimation

Important:

• Use only the original green PowerTrack sense cables with integrated temperature sensor.

• Do not connect external voltage sources to these inputs.

• Do not modify or extend the cables.

If individual battery monitoring is not required, leave the inputs unconnected.

Step 5 – Connect communication interface (optional)

For RS485 / Modbus communication connect:

• RS485 A → Bus A

• RS485 B → Bus B

• GND → Signal ground (recommended)

Ensure correct polarity and proper bus termination.

If the device is located at the end of the RS485 line:

• Set the termination switch to ON

If the device is located in the middle of the RS485 line:

• Set the termination switch to OFF

Step 6 – Verify installation

Before powering the system verify:

• All terminals are properly tightened

• Polarity is correct

• No wires bypass the device

• Sense wires are connected correctly (if used)

Step 7 – Power up the system

Reconnect the battery or close the main breaker. After power-up:

• The device will start automatically

• Measurement mode is active immediately

• Data becomes available via Wi-Fi, Bluetooth, or RS485 interface

Step 8 – Connect optional external power supply (optional backup power)

PowerTrack 500 provides an optional external power input that allows the device to remain operational independently of the monitored battery system.

This connection is shown on the diagram as PSU 6–60 V DC (optional).

Connect the external power supply as follows:

• Positive (+) terminal of the external power supply → VBUS terminal of PowerTrack 500

• Negative (−) terminal of the external power supply → GND terminal of PowerTrack 500

The external power supply voltage must be within the range 6 to 60 V DC.

This optional external power supply allows the device to:

• continue operating in case of failure of the main batteries

• remain powered if the main battery is disconnected

• continue communication via Wi-Fi, Bluetooth, or RS485

• maintain monitoring capability during service or emergency conditions

When the external power supply is connected, the device remains powered even if the monitored battery voltage is not present at the P+ terminal or if the current path through the shunt is interrupted.

Important:

• Ensure correct polarity when connecting the external power supply.

• Do not exceed the specified voltage range.

• The GND terminal of the external power supply must be connected to the GND terminal of the device.

This connection is optional. If no external power supply is connected, the device is powered from the monitored battery via the P+ terminal.

RS485 Termination Switch

Case 1 - End position - The termination switch should be in position "ON"

Case 2 - Intermediary position - The termination switch should be in position "OFF"

Troubleshooting

This section provides guidance for diagnosing and resolving common issues.

1. Device Does Not Power On

Possible causes:

• No battery voltage present

• Incorrect wiring

• Loose terminals

• Blown external fuse

Recommended actions:

1. Verify battery voltage is within specified limits.

2. Check polarity of all connections.

3. Ensure all high-current terminals are properly tightened.

4. Inspect external fuse and wiring integrity.

2. No Current Reading

Possible causes:

• Incorrect installation in the DC path

• Loose high-current terminals

• Current below threshold setting

• Configuration issue

Recommended actions:

1. Verify the device is installed in series with the negative conductor.

2. Check that all terminals are tightened to the specified torque.

3. Verify that the current threshold setting is not suppressing low readings.

4. Confirm that the device is properly configured in the interface.

3. Incorrect Voltage Reading

Possible causes:

• Miswired voltage sense inputs

• Incorrect battery order in string

• Loose sense wiring

Recommended actions:

1. Verify voltage inputs (B1–B4) are connected in correct order.

2. Confirm that battery string configuration matches actual wiring.

3. Inspect all low-voltage sense connections.

4. SoC Value Appears Incorrect

Possible causes:

• Battery parameters not configured

• No recent full-charge synchronization

• Incorrect battery capacity setting

• Charge efficiency misconfigured

Recommended actions:

1. Verify battery chemistry and capacity settings.

2. Fully charge the battery.

3. Ensure tail current and charged voltage parameters are correct.

4. Perform synchronization if required.

Note: SoC estimation accuracy improves over time and with proper configuration.

5. SoH Value Appears Incorrect

Possible causes:

• Insufficient historical data

• Internal resistance baseline not properly configured

• Temperature influence

Recommended actions:

1. Allow sufficient operational time for data accumulation.

2. Verify internal resistance configuration.

3. Ensure temperature sensors are functioning correctly.

4. Note: SoH is an estimation and may vary depending on operating conditions.

6. Overcurrent Alarm Triggered

Possible causes:

• Load exceeds configured threshold

• Threshold configured too low

• Short-duration high inrush current

Recommended actions:

1. Verify actual system current.

2. Adjust alarm thresholds if appropriate.

3. Inspect load behavior.

7. Overtemperature Alarm Triggered

Possible causes:

• Sustained high current

• Insufficient ventilation

• Ambient temperature too high

Recommended actions:

1. Verify current load is within rated limits.

2. Improve ventilation.

3. Reduce continuous high-current operation.

8. Communication Issues (Network or RS485)

Possible causes:

• Incorrect network configuration

• RS485 wiring polarity reversed

• Incorrect Modbus parameters

Recommended actions:

1. Verify communication settings.

2. Check RS485 A/B wiring.

3. Confirm Modbus address and baud rate configuration.

FAQs

Q1: Does PowerTrack 500 disconnect the battery if a fault occurs?

• No. PowerTrack 500 is a monitoring device only and does not perform automatic disconnection or protection. External protective devices are required.

Q2: Can it replace a fuse or circuit breaker?

• No. It does not provide overcurrent protection.

Q3: Can it be used without battery monitoring?

• Yes. The device can operate as a DC current, voltage, and energy meter without enabling SoC or SoH tracking.

Q4: What battery chemistries are supported?

• PowerTrack 500 supports:

• LiFePO₄

• Lead-acid (Flooded, AGM, Gel)

Q5: How accurate is the SoC estimation?

• SoC accuracy depends on:

• Correct configuration

• Proper synchronization

• Battery condition

• Operating temperature

• Short-term accuracy is typically high, but long-term drift may occur without periodic synchronization.

Q6: Is SoH a certified battery health measurement?

• No. SoH is an estimation based on internal resistance trends and operational history.

Q7: Can it be used in 48 V systems?

• Yes, within the specified voltage range.

Q8: Is it suitable for outdoor installation?

• No. The device must be installed in a dry and protected environment unless placed in a suitable enclosure.

Q9: Does it support industrial integration?

• Yes. RS485 / Modbus is supported.

Components and APIs

This device (TBD)

All Shelly devices and services

Compliance

Safety Standards

The device is evaluated according to applicable safety standards for measurement equipment in DC systems, such as:

• IEC / EN 61010-1 (Safety requirements for electrical equipment for measurement, control, and laboratory use)

The device is intended for installation in accordance with national and local electrical regulations.

EMC Compliance

The device complies with applicable electromagnetic compatibility (EMC) standards, including:

• EN IEC 61000-6-1 (Immunity for residential, commercial, and light-industrial environments)

• EN IEC 61000-6-3 (Emission standard for residential environments)

Additional radio compliance standards apply where wireless communication is enabled.

CE Marking

PowerTrack 500 meets the essential requirements of applicable European directives, including:

• Low Voltage Directive (where applicable) - 2014/35/EU

• EMC Directive - 2014/30/EU

• Radio Equipment Directive (if wireless communication is enabled) - 2014/53/EU

The Declaration of Conformity is available upon request.

UL Considerations

The device is designed to meet the requirements for safety and EMC applicable to high-current DC measurement equipment in North American markets. Certification status may vary by region and product version.

Environmental Compliance

The device complies with:

• RoHS (Restriction of Hazardous Substances) - 2011/65/EU

• WEEE requirements for proper disposal

Printed user guide

TBD