Installation Guide
Battery Monitor
CAN Bus Node Smartpack based based DC Power Supply Systems . 351507.033
351507.033
Issue 1.2e, 2010 Apr
Published 2010-04-09 MfM
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Installation Guide Battery Monitor CAN Bus Node
351507.033, Issue 1.2e, 2010 Apr
Table of Contents 1.
Introduction ................................................................................. 4 About this Guide............................... ................................ ................................ . 4 System Diagram — CAN Bus Nodes ............................... ................................ . 4
2.
Battery Monitor, CAN Bus Node ................................................ 5 Key Features ............................... ................................ ................................. ..... 5 Typical Applications ................................... ................................ ....................... 5
3.
Installation of Battery Monitors.................................................. 6 Safety Precautions ...................................................... ................................ ...... 6
Basis Installation Steps ................................................................................... 6 Fastening the Battery Monitors ......................................................... ................ 7 Location of Connectors, Ports, LEDs ............................... ................................ . 7 Connection Drawing ............................... ................................ ........................... 8 Battery Symmetry Connections .............................................................. ........... 9 Block Measurements ................................................................................................ 9 Mid-point Measurements ........................................................................................ 10
Battery Terminology .............................................. ................................ .......... 10 CAN Bus Termination ..................... ................................. ............................... 11 Removing the Smartpack Controller....................................................................... 11
Configuration................................................................................................. 12 CAN Bus Addressing ...................... ................................. ............................... 12 About PowerSuite Configuration ................................. ................................ .... 13
4.
Technical Specifications...........................................................14
Installation Guide Battery Monitor CAN Bus Node
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1. Introduction Congratulations on your purchase of the Battery Monitor, CAN Bus Node, an intelligent “plug-and- play” module to decentralize and expand the functionality of your Smartpack based DC power supply system.
About this Guide This booklet provides you with the required information for installing the Battery Monitor, CAN Bus Node in your Smartpack based DC power supply system. The booklet also presents the Battery Monitor ’s technical specifications. For more detailed description of the Battery Monitor, CAN Bus Node, read the “User’s Guide Smartpack Monitoring and Control Unit ”, Art. 350003.013. For description of how to activate and configure the Battery Monitor, CAN Bus Node using the PowerSuite PC program , refer to the PowerSuite online Help system. Refer also to “ Installation Guide Battery Monitor – Symmetry Kit ”, document number 351497.033, which is included with the kit.
System Diagram — CAN Bus Nodes The Battery Monitor, CAN Bus Node is used as a building block in Smartpack based power supply systems, see Figure 1. Other CAN bus nodes, like the Load Monitor and the I/O Monitor , may also be connected to the bus. The nodes are powered directly from the CAN bus, and have dedicated inputs and outputs that expand the system monitoring and control capability. The Smartpack controller monitors and controls the whole system, and serves as the local user interface between you and the system. The PowerSuite application enables you to configure and operate the system from a personal computer.
USB A-B cable (standard) 1 Smartpack Controller
120
End-of-Line Resistor
CAN bus (twisted-pair CAT5 cable) 01
ID Number Battery Monitor
Load Monitor
Flatpack2 Rectifiers
33
02
n
120
81 I/O Monitor
Battery string #1 Flatpack2 DC Power System
End-of-Line Resistor
49
Temp, Fan Speed Mon & Ctrl Alarm Outputs NC-C-NO
Shunts
Current Monitoring Sense Inputs Fuses
Config. Inputs
Fuse Monitoring Configurable Inputs
Figure 1 Example of three CAN bus nodes connected in a Flatpack2 DC Power Supply System
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Installation Guide Battery Monitor CAN Bus Node
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2. Battery Monitor, CAN Bus Node The Battery Monitor CAN Bus Node enables you to decentralize and increase the number of battery symmetry measurements in your Smartpack based DC power supply system. Also, it monitors the battery compartment temperature – using the built-in sensor – the battery fuse – with a fuse monitoring input – and the battery current – via a current sense input.
Key Features A wide range of features are implemented in the Battery Monitor CAN Bus Node, as mentioned below:
Powered via the CAN bus; no external power supply required
Firmware upgrade via the CAN bus (see required “SW Upload tools” on page 14)
4 battery symmetry inputs for battery strings’ symmetr y measurements
1 fuse monitoring input user configurable for fuse monitoring and other site equipment monitoring
1 battery current sense input for bi-directional current monitoring through external current shunts
1 battery temperature sense input via the built-in temperature sensor
Storage of calibration data and real time event log
Windows-based setup, configuration and calibration via PowerSuite
Flexible mounting using Velcroue adhesive tape on the bottom of the unit
Up to 14 the Battery Monitor modules may be connected the CAN bus
CAN bus addressing via DIP switches
Read also chapter “Technical Specifications”, page 14, for more details.
Typical Applications The Battery Monitor CAN Bus Node is employd in Smartpack -based DC power systems, to implement flexible expansion and distribution of system functionality. The Battery Monitor CAN Bus Node is suitable for distributed monitoring of battery symmetry, fuse, current and temperature of local and remote located battery banks.
Installation Guide Battery Monitor CAN Bus Node
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3. Installation of Battery Monitors You can install the Battery Monitor CAN Bus Node if your DC power system meets the following requirements: 1. The system’s Smartpack controller has firmware version 2.03 or higher installed Version Sensitive
2. You have a PC with PowerSuite application version 2.3 or higher installed
You need standard installation tools and equipment used by an authorized electrician. NOTE: All tools must be insulated.
Safety Precautions Follow these precautions during installation, commissioning and general handling of the Smartpack -based power supply system.
Qualified personnel
Electric shock
CAUTION : For safety reasons, the commissioning and configuration of the equipment is only to be performed by Eltek ’s personnel or by authorized and qualified persons; otherwise the warranty may be invalidated. Please, read the user documentation carefully before installing and using the equipment, as installation and operation is to be performed as described in it.
WARNING: The batteries represent a major energy hazard. To avoid short-circuit of battery poles, you must always remove metallic objects — uninsulated tools, rings, watches, etc. — from the vicinity of the batteries.
Basis Installation Steps Carry out these steps to install the Battery Monitor CAN Bus Node in your DC power system. Refer also to “ Installation Guide Battery Monitor – Symmetry Kit ”, document number 351497.033, which is included with the kit. Power is ON!
1. Assign the Battery M onitor ’s CAN bus address , by setting the Battery Monitor ’s DIP switches. Read to chapter “CAN Bus Addressing”, page 12 2. Terminate the CAN bus, by e.g. removing the CAN bus termination plug from the controller and plugging it on the last connected Battery Monitor or node. Read “CAN Bus Termination”, page 11 3. Attach the Battery M onitor to a battery block ; Read chapter “Fastening the Battery Monitors”, page 7 4. Connect the required input cabling to the terminals ; Read chapter “Connection Drawing”, page 8 5. Configure the Batter y M onitor node’s operation, using the PowerSuite application, read chapter “About PowerSuite Configuration”, page 13
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Installation Guide Battery Monitor CAN Bus Node
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Fastening the Battery Monitors You mount the Battery Monitor CAN Bus Node on a battery block, using the Velcroue adhesive tape on the bottom of the module. Thus, the built-in temperature sensor will monitor the battery temperature accurately. For more exact measurements, attach the monitor on the front of a battery block. If not possible, you can fix it on the side of the outer battery block, or on top, or on the cabinet’s inner side wall
Location of Connectors, Ports, LEDs Warning
Alarm
LED Lamp (yellow)
LED Lamp (red)
CAN port 1&2
Power
Pin 8
Electrically identical
LED Lamp (green) Pin 1
Battery Monitor
DIP switches CAN ID address
Battery Monitor
Monitor Inputs Terminal Block
DIP switch #1
Figure 2 Location of terminals, DIP switches, CAN ports and LED indicators in the Battery Monitor
CAN port 1 and 2 are electrically identical, and are used to enable connection of the CAN bus incoming and outgoing CAT5 cables, or the RJ45 CAN bus termination plug.
LED Indicator Power Warning Alarm Other
Illumination Status OFF ON green OFF ON yellow OFF ON red Green ON & Red Flashing Green OFF & Red Flashing
Description The monitor has NO supply The monitor has supply No Warning Warning (Non-critical alarm) No Alarm Alarm (Critical Alarm) Supply voltage too low Firmware boot-loading
Table 1 Description of the Battery Monitor ’s LED illumination status
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Connection Drawing Use this drawing as a connection reference for all cabling. You find the exact location of connection terminals, plugs and DIP switches, by referring to chapter “Location of Connectors, Ports, LEDs”, page 7. s u b
Connections B a t t e ry M o n i t o r
N A C t x e n e d o o T n
Part 242100.300 Battery Monitor
FUNCTION
SIGNAL PIN-OUT
X:* + + + + Batt. Fuse +
Batt. Symmetry 1 Batt. Symmetry 2 Batt. Symmetry 3 Batt. Symmetry 4
Batt. Current +
Or RJ45 CAN bus ermination plug, if the Battery Monitor is the last node in the CAN bus
CAN port 1&2
1.5 mm , max. wire section
RJ45, 8 pins
N e d A o C n s s u u o b i v e r p m o r F
1 2 3 4 5 6 7 8
Built-in Battery Temperature Sensor
) e s h e t i r m e t t o r a F b ( ) e s u f ) t y n r u e h t s t a t b n e e r h r t u c m o e r h t F ( m o r F (
Figure 3 Connection Drawing Battery Monitor CAN Bus node
Electric shock
WARNING: Switch the battery fuses OFF before connecting the symmetry wires! 1st Fasten the wires to the battery monitor. 2 nd Fasten cable lugs to the other cable ends. 3rd Connect the cable lugs to the battery terminals.
Read chapter “Battery Symmetry Connections” on page 9.
Refer also to “ Installation Guide Battery Monitor – Symmetry Kit ”, document number 351497.033, which is included with the kit. The Battery Fuse and Battery Current cables are not shipped with the Battery Monitor ~ Symmetry Kit. You find more information on chapter “Technical Specifications”, page 14.
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Installation Guide Battery Monitor CAN Bus Node
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Battery Symmetry Connections Block Measurements Block Measurement Four measurements per string
Four measurements per string
Battery Monitor Part 242100.300 ID# <33> Set all 4 DIP switches OFF (up)
Battery String 1
Figure 4 Example of battery symmetry connections. Block measurements 48VDC power systems
Set DIP switch 1 2 3 4 1 ON (down), the rest OFF (up)
1 23 4
1 . 1 y r t e m m y S
2 . 1 y r t e m m y S
3 . 1 y r t e m m y S
4 . 1 y r t e m m y S
1 . 2 y r t e m m y S
2 . 2 y r t e m m y S
3 . 2 y r t e m m y S
4 . 2 y r t e m m y S
+
+
+
+
+
+
+
+
- + - + - + - +
—
(-48V) Outer Terminal
Battery Monitor Part 242100.300 ID# <34>
Battery String 2
- + - + - + - +
—
Block1
Block3
Block4
+
Intercell Links
(-48V) Outer Terminal
Block3
Block1
+
Intercell Links
0V Outer Terminal
Four measurements per string
0V Outer Terminal
Four measurements per string
Battery Monitor Part 242100.300 ID# <35> Set DIP switch 1 2 3 4 2 ON (down), the rest OFF (up)
Battery String 3
Battery Monitor Part 242100.300 ID# <36> Set DIP switch 1 2 3 4 1&2 ON (down), the rest OFF (up)
1 . 3 y r t e m m y S
2 . 3 y r t e m m y S
3 . 3 y r t e m m y S
4 . 3 y r t e m m y S
1 . 4 y r t e m m y S
+
+
+
+
+
- + - + - + - +
—
(-48V) Outer Terminal
Block4
Battery String 4
2 3 . . 4 . 4 4 4 y y y r r t r t t e e e m m m m m m y y y S S S
+
+
+
- + - + - + - +
—
Block1
Intercell Links
Block3
Block4
+ 0V Outer Terminal
(-48V) Outer Terminal
Block1
Intercell Links
Block3
Block4
+ 0V Outer Terminal
Notice: Always connect Battery Monitor with ID#<33> to battery string 1 (lowest), with ID#<34> to string 2, and so on. PowerSuite will then refer to the correct battery string.
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Mid-point Measurements Battery Symmetry — String 1 to 4 Mid-point Measurement One measurement per string, four strings Battery Monitor Part 242100.300 ID# <33> DIP switches for CAN bus addr.
1 23 4
+
+
+
+ Battery String 4 Symmetry 1.4
Symmetry 1.3 Battery String 3 Symmetry 1.2 Battery String 2 Symmetry 1.1 Battery String 1 - + - + - + - +
—
(-48V) Outer Terminal
Block1
Intercell Links
Block4
Block3
+ 0V Outer Terminal
Notice: Always connect B attery Monitor with ID#<33> to battery strings 1 ( lowest), 2, 3 and 4. Then Battery Monitor with ID#<34> to string 5, 6, 7 and 8. And so on. PowerSuite will then refer to the correct battery string.
Figure 5 Example of battery symmetry connections. Mid-point measurements 48VDC power systems
Battery Terminology Battery Terminology Battery Block, Battery String and Battery Bank Battery Block (12V)
Battery String #2 (48V)Batt.
48V Battery Bank
Battery String #1 (48V)
Figure 6 Battery block, battery string and battery bank definitions
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Installation Guide Battery Monitor CAN Bus Node
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CAN Bus Termination To ensure a correct bus communication and avoid data reflection, you must always terminate the CAN bus with two 120 resistors, one at each end of the line (60 bus impedance). Smartpack based systems are shipped from factory with the CAN bus already terminated with 120 resistors. The CAN bus termination is implemented with a special RJ45 plug with built-in 120 end-of-line resistor. USB A-B cable (standard) 1 120
CAN bus (twisted-pair CAT5 cable)
End-of-Line Resistor
ID Number Battery Monitor
01 33
Battery string #1
02
34
n 120
End-of-Line Resistor
Battery string #2
Flatpack2 DC Power System
Figure 7 Example of CAN bus addressing and termination in a Flatpack2 system with two “Battery Monitors” connected the CAN bus
When connecting Battery Monitor nodes (max. 14 nodes) to the CAN bus, you have to remove the CAN bus termination plug from the Smartpack controller’s rear CAN port, and plug it on one of the CAN ports on the last connected Battery Monitor node. See chapter “Removing the Smartpack Controller ”, page 11.
Removing the S m a r t p a c k Controller To access the CAN bus termination plug from the Smartpack controller’s rear CAN port, release (1) both handle springs — see Figure 8, page 11 — and use both handles to cautiously pull out the module. Be careful, as cables are connected to its rear.
Smartpack controller
Hole to release the handle’s spring mechanism
Handle in locked position
Figure 8 Removing the Smartpack controller
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Configuration When connecting Battery Monitor nodes to the CAN bus of the Smartpack based DC power system, you have to configure each of the Battery Monitors by: 1. Setting the DIP switches with the correct CAN bus address, to assign a unique ID number to the Battery Monitor , read chapter “CAN Bus Addressing”, on page 12 2. Configuring the Batter y M onitor node’s operation, using the PowerSuite application, read chapter “About PowerSuite Configuration”, page 13
CAN Bus Addressing The Smartpack controller dynamically software-assigns ID numbers to rectifiers. The controller registers the rectifiers’ ID numbers — or CAN bus address (01, 02…) — together with their Serial Numbers. The ID numbers (1, 2…30) — on Smartpack controllers and Smartnode units — and Battery Monitor ’s ID numbers (33, 34…46) are assigned by DIP switches on the nodes’ side. A maximum of 14 Battery Monitors and or 28 controllers and Smartnode units may be connected to the CAN bus. Note that if only one Battery Monitor is connected, you have to assign it with ID# 33. Battery Monitor DIP switch configuration
Battery ID Monitor # st 1 Monitor 33 2n Monitor 34 3r Monitor 35 4th Monitor 36 5th Monitor 37 6th Monitor 38 7th Monitor 39 8th Monitor 40 9t Monitor 41 10t Monitor 42 11th Monitor 43 12th Monitor 44 13th Monitor 45 14th Monitor 46
DIP Switch Position 1 2 3 4 OFF OFF OFF OFF ON OFF OFF OFF OFF ON OFF OFF ON ON OFF OFF OFF OFF ON OFF ON OFF ON OFF OFF ON ON OFF ON ON ON OFF OFF OFF OFF ON ON OFF OFF ON OFF ON OFF ON ON ON OFF ON OFF OFF ON ON ON OFF ON ON
ID <33> (All switches OFF)
Note: The monitor ’s ID # corresponds to the DIP switch’s binary value plus 33
Smartpack controller DIP switch configuration
ID <1> Smartpack ID DIP Switch Position (All switches OFF) Controller # 1 2 3 4 Master 1 OFF OFF OFF OFF Slave 1 2 ON OFF OFF OFF Slave 2 3 OFF ON OFF OFF Slave 3 4 ON ON OFF OFF Note that the controller’s ID # corresponds to the DIP switch’s binary value plus one.
Table 2 Smartpack DIP switch addressing
Table 3 Battery M onitor DIP switch addressing
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About PowerSuite Configuration You have to connect a PC to the system’s Smartpack controller and start the PowerSuite application, version 2.3 or higher, to activate and configure the Battery Monitor nodes. Read the PowerSuite application’s Online Help for information on how to configure the CAN Bus nodes. In general, the connected Battery Monitor node(s) are displayed in the PowerSuite’s Power Explorer pane, under the Control System node and under the Battery node. For configuring the Battery Monitor specific settings — such as its software alarm monitors for fuse monitoring and current sense inputs, symmetry measurementes inputs, etc — open the Battery Monitor ’s icon under the Battery node.
Battery Monitor icon displayed in the Power Explorer pane, under the Battery node
Open the Battery Monitor ’s icon under the Control System node to reas the status of the Battery Monitor.
Installation Guide Battery Monitor CAN Bus Node
Battery Monitor icon displayed in the Power Explorer pane, under the Control System node
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4. Technical Specifications o o o
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Ordering Information
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Installation Guide Battery Monitor CAN Bus Node
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