APC 4x12V Battery Management System
Contents
1. fe LLI an LLI 4 Set the DIP switches After disconnecting the input power reset the DIP switches to configure the change in your system The DIP Switches must be set to one of the following valid configurations If the DIP switches are set incorrectly your Note Battery Management System may not operate properly 00 TA Condition Switch Number gt 8 7 6 5 4 3 2 1 Nn Gel Batteries Off c AGM Batteries On 0 Four Batteries per string Off Off Three Batteries per string Off On p Two Batteries per string On Off Ambient Temp Compensation Off AV Battery Temp Compensation On 25 Amp Hour Batteries Off Off Off Off AT 30 Amp Hour Batteries Off Off Off On 35 Amp Hour Batteries Off Off On Off gt 40 Amp Hour Batteries Off Off On On AT 45 Amp Hour Batteries Off On Off Off 50 Amp Hour Batteries Off On Off On AT 60 Amp Hour Batteries Off On On Off le 70 Amp Hour Batteries Off On On On Default Setting 0 deel WY WY ded C 0 0 ey 0 z 2 0 ded send fe Condition Switch Number 8 7 6 5 4 80 Amp Hour Batteries On Off Off Off 90 Amp Hour Batteries On Off Off On 100 Amp Hour Batteries On Off On Off 115 Amp Hour Batteries On Off On On 125 Amp Hour Batteries On On Off2. Using the Battery Management System Capabilities of the System The Battery Management System BMS does the following e Monitors each battery in the system and optimizes the state of its charge e Identifies failing or failed batteries so that you can replace them before they cause damage to other batteries in the same string e Extends battery life and ensures that batteries are able to supply back up power on demand e Integrates new replacement batteries with older existing batteries Capacity You can use a Battery Management System to manage one or two strings of two to four batteries each The batteries must be six cell batteries that have a nominal 12 VDC The system can manage batteries that are manufactured by different vendors and show different voltages during charging 00 dad WY gt WY 40 C 0 U C 0 2 W Jad 2 Sensors The Battery Management System monitors electrical current and ambient temperature through current and temperature sensors probes Each current probe measures the charge and discharge current of its battery string The Battery Management System uses this measurement to assess the performance of individual batteries and to determine when the batteries are discharging APC Field Service personnel can use the information about the current of the battery string for diagnostic purposes The ambient temperature probe measures the temperature of the air i
3. Battery Fault Minor battery alarms are unfavorable conditions that usually do not result in the loss of the critical load but could develop into a major alarm or would prevent the detection of a major alarm condition Possible Causes Corrective Action Blown fuse e Replace the blown battery lead fuse Open circuit in the battery wiring harness e Check the battery wiring harness connections Short circuit in the battery wiring harness e Check the battery wiring harness connections Major Battery Fault Major battery alarms require immediate corrective action They usually result in the loss of the critical load during emergency battery operation Possible Causes Corrective Action Shorted cell e Replace affected battery Thermal runaway Replace affected battery Dryout suflation opens e Replace affected battery Very low capacity e Replace affected battery 0 deel WY WY ded C 0 0 ey 0 z 2 0 ded send fe Product Information 00 dad WY WY 40 lt 00 U D U C U D 00 dad 40 AV le Specifications Electrical Item Specification Operating voltage range 22 54 VDC Monitoring current 1 6 A Maximum Boost current 3 5 A Monitoring power 37 W Maximum Boost power 75 W Physical Item Specification Dimensions H x W x D 1 75 x 10 x 4 in 4 45 x 25 4 x 10
4. For detailed instructions on how to install temperature and current sensors and to set the DIP switches correctly see the See also Installation and Quick Start Manual Restart the Battery Management System After adding or removing a battery string restart the Battery Management System by reconnecting the power input cable that you disconnected At start up the Battery Management System integrates any new battery string and resets each battery s current acceptance response benchmark After the system restarts check the Batteries LEDs If the LED for each battery in the system is illuminated you connected the batteries and set the battery DIP switches Q correctly Once the start up LED check is complete and battery string discovery is complete if any configured battery s LED turns off recheck the connections and fuses for the associated battery Refer to the Troubleshooting section for additional help Note z T deel WY WY dd C U O C z D T oped dead 00 dad N gt WY 40 C 0 W C AS D 00 dad fe LLI an LLI 4 gt Troubleshooting LED Definitions The twelve LEDs on the front panel of the Battery Management System indicate the status of the system The Battery Management System does not require a computer The system notifies you of battery conditions and any system alarms through a set of LEDs and alarm relays
5. Off 150 Amp Hour Batteries On On Off On 175 Amp Hour Batteries On On On Off 200 Amp Hour Batteries On On On On Default Setting 00 dad WY WY 40 lt 00 00 lt U 2 00 dad 40 AV le Install a current sensor If you add a second battery string to a system that had only one string you need to install a second current sensor The system needs one sensor per string to measure the current throughout the string 1 Set the DIP switches on the new current sensor to identify its location correctly Plug the ambient temperature sensor into the unused port on the current sensor to be located at the warmest area of the enclosure Connect the two current sensors to each other with the supplied cable Use the remaining cable to connect the sensor string to the sensor port at the back of the Battery Management System Unless at least one current sensor is connected to the sensor port neither current sensor will be able to report information If a current or temperature sensor is not functioning always check this connection first Calibrate the new current sensor eS See the nstallation and Quick Start Manual for detailed instructions on calibrating the current sensors See also Install the current sensor in the new string ensuring that the current sensor is oriented correctly with a load carrying conductor passing through it
6. 16 cm Net weight 2 2 Ib 1 0 kg Shipping dimensions H x W x D 5 3 x 11 5 x 8 3 in 13 46 x 29 21 x 21 08 cm Shipping weight 6 Ib 2 7 kg Environmental Item Specification Elevation above MSL Operating 10 000 ft 3000 m Storage 50 000 ft 15 000 m Temperature Operating 40 to 140 F 40 to 60 C Storage 40 to 149 F 40 to 65 C Relative humidity operating and storage 5 95 RH non condensing Approvals Standards Approvals CE EN55024 FCC part 15 ICES 003 CISPR22 VCCI C Tick z T deel WY WY dd C 0 U O C z D T ded dd Warranty and Service Limited warranty APC warrants the Battery Management System to be free from defects in materials and workmanship for a period of two years from the date of purchase Its obligation under this warranty is limited to repairing or replacing at its own sole option any such defective products This warranty does not apply to equipment that has been damaged by accident negligence or misapplication or has been altered or modified in any way This warranty applies only to the original purchaser Warranty limitations Except as provided herein APC makes no warranties express or implied including warranties of merchantability and fitness for a particular purpose Some jurisdictions do not permit limitation or exclusion of impl
7. See LED states and Interpreting alarms As a test all LEDs turn on for 3 seconds when the system starts up Observe this test carefully at start up An LED could be off because it has failed rather than for the reasons cited in the Note following table LED states The state of each LED indicates the following LED Action Meaning On Function is active and normal Flashing 1 second Function has a Minor Fault Slow Flashing 4 second Function has a Major fault Fast Off Function is inactive due to either failure to detect it or to indicate non configured batteries Alarm indicators Refer to the following table to determine the status of your system and follow the link for each event for more information Event Status LEDs Alarm Relays Battery LEDs System Sensor Charger Battery Major Minor Normal Operation On On On On Open Open Active batteries on Sensor calibration Slow Slow Slow Slow Open Open Affected Strings Flashing Slow Loss of System Off Off Off Off Open Open All Off Power Sensor Input Fault Slow Off Off Off Open Closed All Off String Polarity On On On On Open Open All String B Off Mismatch Battery String A Slow On Off Off Open Closed All Off Missing Blown Fuse or Open Slow On On On N A Closed Affected batteries Circuit on Battery Slowt Off String Connector Discharge or On On Off On N A Closed N A Charger I
8. address RMA number and daytime phone number a copy of the sales receipt and a check as payment if applicable Mark the RMA number clearly on the outside of the shipping carton Ship by insured prepaid carrier to the address provided by the Customer Support technician Life Support Policy General policy American Power Conversion apc does not recommend the use of any of its products in the following situations e In life support applications where failure or malfunction of the apc product can be reasonably expected to cause failure of the life support device or to affect significantly its safety or effectiveness e In direct patient care APC will not Knowingly sell its products for use in such applications unless it receives in writing assurances satisfactory to Apc that a the risks of injury or damage have been minimized b the customer assumes all such risks and c the liability of American Power Conversion is adequately protected under the circumstances Examples of life support devices The term life support device includes but is not limited to neonatal oxygen analyzers nerve stimulators whether used for anesthesia pain relief or other purposes autotransfusion devices blood pumps defibrillators arrhythmia detectors and alarms pacemakers hemodialysis systems peritoneal dialysis systems neonatal ventilator incubators ventilators for adults and infants anesthesia ventilators infusion pumps and any
9. anagement System is in this mode After five flashes the sensor is calibrated Do not perform sensor calibration while there is current flowing through the sensor Remove the sensor from the battery cable Caution before performing a sensor calibration Possible Causes Corrective Action The Battery Management Set the current sensor s DIP switch number four to Off System is in sensor calibration mode 00 dad WY WY 40 lt 00 00 C U 2 00 dad 40 AV le eS See the nstallation and Quick Start Manual for instructions on how to calibrate the sensors See also 0 dex WY WY head C 0 z 0 O C 0 z 2 0 ded dead fe Loss of System Power The Battery Management System is not powered Possible Causes Corrective Action Power leads are swapped or backwards Power leads are not connected to a power source e Reverse the power leads e Connect the Battery Management System to a power source Blown power lead fuse e Check the Battery wire harness for pinched or frayed wires e Replace the fuse Monitor the Battery Management System for more blown power lead fuses as this is a sign of an internal problem with the Battery Management System Sensor Input Fault Minor Alarm The number of sensors the BMS detects does not match the number of battery strings Possible Causes Corrective Action Current sens
10. ctor If you are using only one battery string it must be connected to the String A input Blown battery lead fuse on String A Battery 1 e Replace the blown battery lead fuse Blown Fuse or Open Circuit on Battery String Connector Minor Alarm The BMS detects an individual battery voltage of less than 3 VDC Possible Cause Corrective Action Blown battery lead fuse e Replace the blown battery lead fuse Open circuit in the battery wiring harness e Check the battery wiring harness connections 00 dad WY WY 40 lt 00 00 lt U 2 00 dad 40 AV le Discharge or Charger Inactive Minor Alarm The BMS detects 5 amps of continuous discharge current on either battery string for more than 5 seconds Possible Causes Corrective Action Loss of AC to power supply e Restore AC input before batteries are exhausted Power supply overloaded e Check for short circuits on load e Remove excess load on system Current sensor entered calibration mode during a battery charge e Re calibrate current sensor s by performing calibration with no current flowing Current sensor installation reversed e If a discharge is indicated while the batteries are charging reverify orientation of sensor and reverse if not installed correctly Charger Voltage Low Minor Alarm After a discharge or application of power the Charger V
11. ied warranties therefore the aforesaid limitation s or exclusion s may not apply to the purchaser Except as provided above in no event will APC be liable for direct indirect special incidental or consequential damages arising out of the use of this product even if advised of the possibility of such damage Specifically APC is not liable for any costs such as lost profits or revenue loss of equipment loss of use of equipment loss of software loss of data costs of substitutes claims by third parties or otherwise This warranty gives you specific legal rights and you may also have other rights which vary according to jurisdiction 00 dad WY gt N 40 C 0 U AV C 0 D 00 dad 40 A 2 z T de WY WY dd C U z O C z D T oped dead Obtaining service To obtain support for problems with your Battery Management System 1 Note the serial number and date of purchase The serial number is on the bottom of the unit Contact Customer Support at a phone number at the end of this user s guide A technician will try to help you solve the problem by phone If you must return the product the technician will give you a return material authorization RMA number If the warranty expired you will be charged for repair or replacement Pack the unit carefully The warranty does not cover damage sustained in transit Enclose a letter with your name
12. m you purchased your apc product for information on how to obtain local customer support 0 dex WY WY head C 0 z 0 ey C 0 z 2 0 ded dead fe 21 Copyright Entire contents copyright 2003 American Power Conversion All rights reserved Reproduction in whole or in part without permission is prohibited APC and the APC logo are trademarks of American Power Conversion Corporation and may be registered in some jurisdictions All other trademarks product names and corporate names are the property of their respective owners and are used for informational purposes only 990 1230B 06 2003 0 deel WY WY ded C 0 0 ey 0 z 2 0 ded send fe 22
13. nactive Charger Voltage Low On On Slow On N A Closed N A Charger Voltage High On On Fast On Closed N A N A Minor Battery Fault On On N A Slow N A Closed Affected battery flashing slow Major Battery Fault On On N A Fast Closed N A Affected battery flashing fast 00 dad WY WY 40 lt 00 00 lt U 2 00 dad 40 AV le N A LED or Relay not affected see other criteria for indications t A blown fuse or other open circuit in the battery string connectors may cause a Charger Voltage Low alarm Interpreting alarms The Battery Management System can generate Major or Minor alarms e A Major alarm requires immediate action to ensure that the batteries are able to provide back up power e A Minor alarm indicates a condition that is not likely to result in the batteries being unable to provide back up power but could develop into a major alarm or could prevent the detection of a major alarm Each alarm type will close an associated normally open alarm relay The alarm relays can be connected to a device that monitors normally open and normally closed sensors Sensor calibration The Battery Management System is in sensor calibration mode You can set this mode by setting DIP switch 4 on each sensor to On The Battery Management System will then obtain a new zero value The LEDs will flash at a rate of once per second while the Battery M
14. nside the battery cabinet The system uses the ambient temperature and proprietary algorithms to derive the internal battery temperature Front panel LED Legend Off inactive Steady On ok Flash l sec minor fault Flash 4 sec major fault Configure Batteries Ont EEEEEEEN OOOO OOOO 8 1234 1234 String String wn fas cot E val wWww ape com Battery Management System System CE Sensors O Charger O Battery O 1 Status LEDs 2 Configuration DIP switches Battery LEDs 0 dex WY WY head C 0 z 0 O 0 z 2 0 ded dead fe Adding or Removing Components Adding or Removing a Battery String Disconnect power to the system When adding or removing a battery string first disconnect power to the Battery Management System by unplugging the power input cable to avoid causing sparks that could cause a battery to explode Warning Connect the new battery string See the installation guide 990 1224B which came with your system for battery string connection instructions It is also See also available on the APC Web site www apc com The Battery Management System auto detects the new battery string Verify that the polarities of the two strings match If they do not the Battery Management System will Note not be able to detect the second string 00 dad N gt WY 40 C 0 W C AS D 00 dad
15. oltage Low alarm condition is ignored for 60 minutes After the 60 minute delay the Charger Voltage Low alarm occurs if the string voltage value the sum of all battery voltages in the string is below the string voltage limits Possible Causes Corrective Action Power supply charger setting too low or failure of charger temperature compensating circuit e Check charging system e Reset charger voltage or repair if required Incorrect temperature compensation selected e Verify that the configured temperature compensation method ambient or battery matches the power supply s compensation method 0 dex WY WY head C 0 z 0 O C 0 z 2 0 ded dead fe Charger Voltage High Major Alarm After a discharge or application of power the Charger Voltage High alarm condition is ignored for 60 minutes After the 60 minute delay the Charger Voltage High alarm occurs if the string voltage value the sum of all battery voltages in the string is above the string voltage limits Possible Causes Corrective Action Power supply charger setting too high or failure of charger temperature compensating circuit Incorrect temperature compensation selected e Check charging system e Reset charger voltage or repair if required e Verify that the configured temperature compensation method ambient or battery matches the power supply s compensation method Minor
16. or is not installed on each battery string e Install a current sensor for each battery string connected to the Battery Management System Current sensors not correctly addressed e Check DIP switch settings for each current sensor String A s sensor should have DIP switch 1 set to On all others Off and String B s sensor should have DIP switch 2 set to On all others Off Ambient temperature sensor missing Install an ambient temperature sensor in the open port on one of the current sensors 00 dad WY WY 40 lt 00 00 lt U 2 00 dad 40 AV le String Polarity Mismatch The second battery string s polarity is reversed from the polarity of the first battery string The Battery Management System will not detect the second string if its polarity is reversed Possible Causes Corrective Action Second battery string s polarity does not match the first string s polarity e Reverse the order of the battery leads connected to one of the battery strings Battery String A Missing Minor Alarm At start up the Battery Management System twice attempts to detect the polarity of Battery String A If both attempts fail the Battery Management System generates a Battery String A missing fault Possible Causes Corrective Action Single battery string is connected to the String B input e Connect the battery string to the String A conne
17. other devices designated as critical by the u s FDA Hospital grade wiring devices and leakage current protection may be ordered as options on many Arc ups systems Apc does not claim that units with these modifications are certified or listed as hospital grade by apc or any other organization Therefore these units do not meet the requirements for use in direct patient care 00 dad WY gt N 40 00 U D U C 0 D 00 dad 40 AV le 20 APC Worldwide Customer Support Customer support for this or any other Apc product is available at no charge in any of the following ways e Visit the Apc Web site to find answers to frequently asked questions FAQs to access documents in the apc Knowledge Base and to submit customer support requests www apc com Corporate Headquarters Connect to localized Apc Web sites for specific countries each of which provides customer support information www apc com support Global support with Faas knowledge base and e support Contact an apc Customer Support center by telephone or e mail Regional centers APC headquarters u s Canada 1 800 800 4272 toll free Latin America 1 401 789 5735 USA Europe Middle East Africa 353 91 702020 Ireland Japan 0 35434 2021 Local country specific centers go to www apc com support contact for contact information Contact the arc representative or other distributor from who
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