BtmGlobal System Controller User Manual
Contents
1. FRONT VIEW E FLOAT CURRENT fe TRANSDUCER ENTRATOR T L GONG x FRONT VIEW 4 SYSTEMCONTROLLER 57 L E a MR ama maie BTM GLOBAL COMPONENTS i MECHANICAL LAYOUT UNDER BATTERY RACK MOUNTED COMPONENTS ALL DIMENSIONS ARE NOV 20 2006 Rev A IMPERIAL MILLIMETERS SCALE 1 4 2 2 Figure 7 Mechanical Layout 15 4 Polytronics Engineering Ltd FIBER OPTICS OUT TO BTM CONCENTRATOR FLOAT CURRENT TRANSDUCER ALL HOOK UP WIRES TINNED COPPER PVC INSULATED STRANDED AWG 18 600V 105C BELDEN STYLE 1015 OR EQUIVALENT Se OR FIBER OPTICS IN FROM BTMGLOBAL CONSOLE TEMPERATURE SENSOR LEAD 12V FROM SYSTEM CONTROLLER POWER GND FROM SYSTEM CONTROLLER CURRENT TRANSFORMER BLACK LEAD PLASTIC FIBER OPTICAL CABLE SMF SUPPLIED WITH THE SYSTEM TEMPERATURE SENSOR 12V DC 2A MAX POWER SUPPLY SWITCHING TEMPERATURE SENSOR LEAD CURRENT LONGEST FIBER OPTICAL SEGMENT TRANSFORMER MUST EXCEED100FT 30M MODBUS RED LEAD INTERFACE eT 2 OR 4 WIRE RS485 SECOND COM PORT TO MODBUS INTERFACE VGA INTERFACE OPTIONAL2. PARC EN ER US 10 Connecting Using a Router Dynamic Addressed Controller 10 Appendix B Controller Alarms and String Status 11 Appendix C Sample Controller System ecce esee eere ee eee eee eene eee 13 Appendix D Mechanical System Layouts eee eee eee ee eere eee 14 Polytronics Engineering Ltd Introduction The controller is a real time stand alone battery monitor with full networking support It is used for storing individual cells jars and full string data detecting abnormalities coming from the battery measurements warning about the changes in the battery condition and alarming when critical conditions occur on an individual Jar s or the entire string Based on the collected data the controller generates various comprehensive reports for assessing the operational conditions and the health of the battery The generated reports are presented in Hyper Text Markup Language HTML and in Portable Network Graphics formats various graphs and plots to utilize the Internet based World Wide Web browsers Currently only Mozilla Firefox fully supports all the user interface features The controller s network support facilitates TCP IP protocol over Ethernet The system is easily accessible locally or remotely over Modem for report viewing data downl
3. Polytronics Engineering Ltd Als Polytronics Engineering Ltd BtmGlobal System Controller User Manual Version 4 0 3 Polytronics Engineering Ltd 2010 Rights Reserved Va Polytronics Engineering Ltd Table of Contents Introducti T 3 Site 3 Hardware REM EH rU X DEI POT ERR DOEPR 4 Hardware Installation 5 liicilcien e 6 Communication Path Installation 4 eee eere eene sete seen setas etas ta sena 6 Terminating Fiber Optic 6 Hardware Verification and Configuration c eee eee ee e eee eee eerte 7 System Setup and 5 lt 5 8 ACCESSING Battery Data 8 Summary Paf t 9 Appendix Local Data A4G8SS csse snessnco eh etuer ti rok
4. MONITOR ETHERNET INTERFACE KBD MOUSE INTERFACE TINNED COPPER POLYOLEFIN XLPE INSULATED STRANDED AWG 18 UL AWM STYLE 3265 105 C 600 SUPPLIED BY INSTALLER WIRE LENGTH BETWEEN CONCENTRATOR TERMINAL AND BATTERY POST SHOULD NOT EXCEED 100FT 30M POWER CONVERTER OPTION OUTPUT 12V DC 2A MIN BimGlobal SYSTEM CONTROLLER TO AC OUTLET BATTERY 24VDC 48VDC 96VDC 120VDC 240VDC 100 240 VAC 50 60 HZ FIBER OPTICS OUT TO FLOAT CURRENT FIBER OPTICS IN FROM BTM CONCENTRATOR 7 12V FLOAT CURRENT TRANSDUCER OPTIONALLY TO RS485 CONVERTER RS485 CONVERTER NOT SUPPLIED WITH THE SYSTEM RECOMMENDED MODEL 4850T9L B amp B ELECTRONICS 12V FROM SYSTEM CONTROLLER POWER GND FROM SYSTEM CONTROLLER ALARM RELAY CONTACT RATING SWITCHING POWER 10W SWITCHING VOLTAGE 100VDC SWITCHING CURRENT 500 mA POWER GND TO FLOAT CURRENT TRANSDUCER OPTIONALLY TO RS485 CONVERTER SYSTEM CONTROLLER AND INTERNAL COM FAILED ALARM CONTACT FLOAT CURRENT TRANSDUCER BTMGLOBAL COMPONENT CONNECTIONS BATTERY ALARM CONTACT NOT TO SCALE JAN 10 2007 Rev B 1 Figure 8 Mechanical Layout 16
5. TN 5552 ms access remote configuration Workstations on IP network Internet Explorer E HTML Report Pages Ee Data access system configuration BTM Global Stand alone system 6 120 220 1 A protected power source LAN WAN Ethernet access point vumimmt Internet explorer HTML Report Pages On Site Mobile PC Laptop Data access ESES system configuration Figure 2 Connecting PC to the Controller Polytronics Engineering Ltd System Setup and Operation The controller you have received has been pre configured for your installation Reconfiguration of the controller box can be performed remotely over the telephone line dial in Ethernet or locally Further instructions on configuring and use of the system are incorporated into the monitoring controller web page Accessing Battery Data The controller system facilitates several means to access data All necessary battery data is stored in the controller and is also presented in an HTML formatted report file Any graphics are produced in the PNG Portable Network graphics format Complete access to all data including raw data can be achieved by establishing a dial in network connection or by connecting the System Controller to a local Ethernet network The System Controller has a built in web server capability and all HTML report pag
6. UPS protected or have an emergency generator as a backup Polytronics Engineering Ltd Hardware Installation Alarm contacts may be connected to light bell if desired Float Current Montior Pay Sal e aa e Fiber Optical Cable 9 Brn mn Terr Concentrator Charger Negative Bs Concentrator Jar 32 Jar 17 Charger Positive Jar 16 Battery String 1 DM Tom TT Concentrator Charger Negative m mass Concentrator Jar 32 Jar 17 Charger Positive wem T Battery String 4 Figure 1 System Connectivity Va Polytronics Engineering Ltd Installation Communication Path Installation Layout the devices and measure the distances between the connection points for the communication loop The devices are connected in a daisy chain format from the fiber optics output blue of one device and then connected to the fiber optics input black of the next Plan your connections of fiber optical cable to minimize the length of the longest fiber optical cable run If multiple strings are connected to the single optica
7. es can be browsed using a local network connection or over a dial in network Raw data ASCII text tables and other relevant files can be retrieved using an FTP site Note The System Controller is configured for dynamic IP address and should work with any existing network Polytronics Engineering Ltd Summary Page 2 btmGlobal Mozilla Firefox 4 loj x File History Bookmarks Tools CYS E cx o a http btmglobal99 we L btmetobat 5 BIMGLOBAL a E Polytronics Engineering Ltd SITE NAME Serial Number DEMO Data Last Updated 16 55 27 01 31 2006 Quick summary System status report Monitor Status Voltage bar graph Voltage numeric table Current profile Voltage profile Temperature profile String Name Status String DC Ripple Ambient Pilot Charge Level Duration Voltage Current Current Temperature Temperature g String 1 100 160 Battery alarm listing System alarm listing Event listing Data profiles Cycle report High Low report Degradation analysis Detailed report Maintenance CRITICAL Battery Alarms Start Date amp Time String None Detected 0 0 Figure 3 Controller Summary Page The Summary page summarizes data and provides links to all the other areas of the system It displays information about the batteries themselves the status alarms charge level voltages current ripple current ambien
8. l loop then fiber optical cable must connect across strings sometimes in another battery room Take care to keep the radius on all bends at least 2 inches or 40 mm Care should be taken to run all lengths prior to cutting Warning The fiber optical loop must be planned very carefully before cutting the fiber optic cable because there is no way to join cut pieces of fiber optic cable together without any extra equipment Also neither the sequence nor the total length of the cable is important The only important aspect is the length of the longest piece of the cable is The longest fiber optic cable must not exceed 60 meters Terminating Fiber Optic Cables The fiber optic cable from the concentrators should be terminated in the appropriate socket in the controller Prepare the end of the fiber optic cable by cutting it at a right angle with a sharp utility knife Do not strip the fiber optic wire With limited force a stripped wire can damage the internal receiver and transmitter Position the prepared end of the fiber optic cable in the input or output of the special fiber optic s connector be sure the connector is loosened Push the end of fiber optics cable into the housing tighten the connector with finger force as much as would be used to close a toothpaste container Polytronics Engineering Ltd Hardware Verification and Configuration Remote Workstation Windows Hyperterminal SW Dial in Remote data PS
9. oading configuration and system upgrading The system can also be configured to automatically upload the report pages to a predefined Web Site and use Email for the remote enunciation of alarms local ISP access point or local network Gateway access is required The System Controller supports the following services over TCP IP network serves battery report pages for WEB browser FTP file transfer service SSH secure shell for remote system configuration upgrade Mail electronic mail agent configured to send alarm messages Site Requirements e Ethernet access optional e Direct telephone line optional if remote access support is required Uninterruptible power supply 500VA or UPS protected AC outlet Polytronics Engineering Ltd Hardware Overview The concentrators are configured either as low voltage or high voltage devices The high voltage concentrators can serve up to 20 Jars and the low voltage concentrator can serve up to 30 Jars There are a few small differences in the equipment depending on whether the system is monitoring 2V or 12V Jars Although concentrators may look the same it is important to check the nameplate to tell whether the concentrator has the proper voltage for your application All concentrators are powered from the battery monitored However the controller uses a 120 220 VAC outlet for power Note In order to maintain data acquisition during a power failure the AC outlet must be
10. on the jar terminal voltage is below preset limit Jar voltage Above set limit 8 During float operation the jar terminal voltage is above preset limit Jar High Float Mobility 10 Jar terminal voltage drifts significantly during battery floating Jar High Noise during Float 9 High ripple voltage during float operation Temperature Abnormalities 12 Ambient Pilot temperature outside limits Discharge Warning 13 String is discharging Charge Warning 15 String is charging Equalization Warning 14 String is at Equalization potential Jar Parameters Degraded 16 Jar calculated parameters during discharge charge or Float have been degrading Ground Fault 17 When using a ground fault detector the limit at which it alarms has been passed and ground fault condition is present Note Each alarm can be individually enabled or disabled The controller can send an e mail when an alarm is detected if it is connected to the LAN or has a dial out to the ISP capabilities enabled String Status Description NA String status unknown During a system start up or communication failure OPEN String is at open potential FLOATING String is fully charged and floating at its nominal voltage FLOAT CHARGING Battery capacity is not fully restored 11 Polytronics Engineering Ltd CHARGING Charging current to the battery detected EQUALIZING Battery at equalizing potential prolonged application
11. t and pilot temperatures of the string are displayed Clicking on the logo in the top right side opens up a FAQ for the controller Polytronics Engineering Ltd Appendix A Local Data Access Connecting Using a Router Dynamic Addressed Controller 1 Connect the PC router and Controller s as shown in Figure 4 To Other Equipment Local PC BE Ethernet Cable EI TY TEE i Ethernet Cable Ethernet Cable Ethernet Cable Figure 4 Connection of Controller Router and PC 2 Start your web browser Mozilla Firefox and in the address bar type btmGlobalXX where XX 15 digits 01 99 The Controller name is recorded on the front label 10 Polytronics En gineering Lta Appendix B Controller Alarms and String Status Alarm Bit Position Description String Exhausted 1 Battery total voltage is below discharge end voltage during discharge String Open 2 String is at open potential charger not connected or malfunctioning Pending Jar Reversal 3 A jar terminal voltage is near its end voltage during discharge This jar does not support the load any longer Low Capacity 5 String capacity near exhaustion a few minutes reserve time remaining Jar Internal resistance High 6 The internal resistance of a jar has increased drastically Jar Voltage Below set limit 7 During float operati
12. tem Setup 13 Polytronics Engineering Ltd Appendix D Mechanical System Layouts WALL MOUNTED CONCENTRATOR 0 31 527 LL LLL L 8s 4 i T TOP VIEW ff i E i i EE L EE T E 88 1 ae i i AN BE gt i lt 25 2 i 22 39 i 039 oca i i 949 11 65 296 gt 10 955 i 2 i 0 63 16 ror i ES 1 i i 7 4 188 0 197 5 232 3 94 i PLASTIC E X gt FIBRE OPTICS 4 A atts Z A did ie e 8 20 24 6 g jou E dE ALARM S3 aem CONTACTS vo p g 2 amp Y amp 1 18 CONNECTOR TERMINAL BLOCK TERMINAL BLOCK CA gt 2 0 24 6 53 54 90 X TEMPERATURE M y SENSOR yo 2 0 197 5 ALL DIMENSIONS ARE IMPERIAL MILLIMETERS ARE IN BRACKETS BTM GLOBAL COMPONENTS MECHANICAL LAYOUT NOV 20 2006 Rev SCALE 1 4 10F2 Figure 6 Mechanical Layout 14 Polytronics Engineering Ltd SIDE VIEW
13. will be harmful to the battery DISCHARGING Load is on the battery 12 Polytronics Engineering Ltd Appendix C Sample Controller System Remote Workstation Windows Hyperterminal SW 28A EC ES ff Soe spr Dial in Remote data Resonate Local Workstations Internet Explorer HTML Report Pages Em PSTN line access remote configuration 120 220 Vac 1 A Max protected power source zu z Ne Ethernet interface 4 ES PWR RJ 45 for 10 100Mbs PSTN Interface 5 TCP IP protocol external modem Gui HTMLserver optional FTP server S e Ethernet access point Cross over network cable Internet explorer On Site Workstation HTML Report 5 EE REA 40001 Sensor Concentrator J ID 3 Charger Negative BTM4000 a ll N Concentrator lt lt SJ Jar 32 T E gt Charger Positive dando Current Shunt Battery String 4 not required if current is less than 400A and Factstar option is selected Figure 5 Sample Sys
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