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System Installation

4200-088

4-1

Revision 1.03

System Installation

The following is a check list of the required steps to successfully install a BDSU system. Some of the
items may not apply because of optional accessories not purchased.

4.1.

Installation Checklist

Installation Task

Reference Manual Section

Verify materials ordered/received

Materials Received List, Page 5-1

Things to consider before system installation

System Installation Considerations, Page 6-1

De-energize and isolate the battery string

Isolate the Battery String, Page 6-2

Identify cell/monobloc number 1

Identify Cell/Monobloc Number 1, Page 6-2

Mount equipment

Mounting the Equipment, Page 8-1

Install wiring harness for each UXBM at
battery end only/ tab washer installation

UXBM Harness and Tab Washer Installation, Page 9-1

Connect 24VDC power to UXSM

UXSM Harness Installation, Page 10-1

Connect fiber optic cable to all system
components

Installing the Fiber Optic Cable, Page 11-1

Install string current transducer (if applicable)

String Current Transducer, Page 12-1

Install float current transducer (if applicable)

Float Current Transducer, Page 12-2

Install ambient temperature sensor (if
applicable)

Ambient Temperature Sensor, Page 12-4

Place cell number labels on each UXBM and
UXSM

Installing Label Identifiers, Page 13-1

Install communication cards (if applicable)

Installing Intellislot

Communication Cards, Page 14-1

Connect remote alarm reset and contacts (if
applicable)

Alarm Contacts and Remote Reset, Page 15-1

Table 1 - Installation Task List

Summary of Contents for BDSU

Page 1: ...Alb r Battery Diagnostic System Universal BDSU Installation Guide Alb rcorp 7775 West Oakland Park Blvd Sunrise FL 33351 Tel 954 377 7101 Fax 954 377 7042 www alber com 4200 088...

Page 2: ...umber 4200 088 2015 Alb rcorp All rights reserved Alb rcorp 7775 West Oakland Park Blvd Sunrise FL 33351 USA No part of this document may be reproduced or transmitted in any form or by any means elect...

Page 3: ...b r Customer Service is available Monday to Friday 8 00AM to 4 30PM Eastern Time Telephone 954 377 7101 Fax 954 377 7042 Email service alber com Website www alber com Corporate Office Address Albercor...

Page 4: ...u will not use the Software in violation of applicable laws and regulations or where such use detrimentally affects Alb r s rights in the Software or subjects Alb r to liability You assume responsibil...

Page 5: ...fy the Software are strictly limited to the specific rights provided in this Agreement or as may otherwise be required by applicable copyright law U S GOVERNMENT RESTRICTED RIGHTS This Software is dev...

Page 6: ...ge or modify this Agreement except an executive officer of Alb r Corporation and then only in writing The laws of the United States and the State of Florida shall apply to this Agreement and its inter...

Page 7: ...gnable without the prior written permission of Alb r Assignment of Warranties Alb r assigns to User any warranties which are made by manufacturers and suppliers of components of or accessories to the...

Page 8: ...AL WARRANTY PERIOD Limitations THIS WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE USER S SOLE AND EXCLUSIVE...

Page 9: ...tem Overview 3 1 3 1 Building Management System Integration 3 2 4 System Installation 4 1 4 1 Installation Checklist 4 1 5 Materials Received List 5 1 5 1 Battery Acquisition Module UXBM 5 1 5 2 Syste...

Page 10: ...ings with Cell Temperatures 9 10 9 7 Special Considerations when Installing UXBM s 9 11 10 UXSM Harness Installation 10 1 10 1 24 48VDC Battery Powered 10 1 10 2 AC Powered 10 4 10 3 Distributed Power...

Page 11: ...3 Figure 19 Improper connection method with disconnect switch 9 14 Figure 20 Proper Connection Method with Disconnect Switch 9 15 Figure 21 Intertier Connection on Last Cell within Group 9 16 Figure 2...

Page 12: ...ntory List 5 1 Table 3 UXSM Inventory List 5 3 Table 4 UXCM Inventory List 5 5 Table 5 Recommended Power Lead Connection 9 13 Table 6 Extender Lead Kits 9 14 Table 7 Intertier Inter row cable assignme...

Page 13: ...ipment voltage power ratings or capabilities Use of this product in a manner not specified could compromise the designed in safety if this product 1 2 Document Symbols The symbols below appear in this...

Page 14: ...zard the system chassis must be connected to an electrical protective earth ground if when required When AC mains are used for the power source the system must be connected to the AC power mains throu...

Page 15: ...uipment Due to the possibility of introducing additional hazards do not substitute parts or perform any unauthorized modification to the product For example all Current Transducers used with this prod...

Page 16: ...from AC and or DC power sources 2 3 Sense Leads When Applicable Ring Terminals On some applications cleaning the sense leads where they connect to the battery may be necessary This is normally needed...

Page 17: ...XCM Collects stores and manages battery data System Acquisition Module or UXSM Collect System related Information Battery Assessment Module or UXBM Collect battery related information The system archi...

Page 18: ...gh the IntelliSlots optional cards These optional cards are available to allow connection via Ethernet or RS 485 Both of these interfaces will communicate MODBUS and the Ethernet will permit SNMP and...

Page 19: ...age 8 1 Install wiring harness for each UXBM at battery end only tab washer installation UXBM Harness and Tab Washer Installation Page 9 1 Connect 24VDC power to UXSM UXSM Harness Installation Page 10...

Page 20: ...will be used during the installation process 5 1 Battery Acquisition Module UXBM Part Number Part Description 1005 XXX UXBM Battery Acquisition Module 1102 190 5 combined measurement harness One requ...

Page 21: ...2800 168 Female 22ga quick connects Used for extending sense leads 2800 179 Male 22ga quick connects Used for extending sense leads 2800 192 Female 12ga quick connect Used for extending power harness...

Page 22: ...country Only used on AC powered systems 6003 016 EU AC Power Cord Actual one is dependent on country Only used on AC powered systems 6003 017 UK AC Power Cord Actual one is dependent on country Only u...

Page 23: ...ruction of DC power harness 6002 037 50 Red 12GA wire used in construction of DC power harness 1100 433MPM Fuse holder assemblies used in construction of DC power harness 4301 004 1A Fuse used in cons...

Page 24: ...country Only used on AC powered systems 6003 008 US AC Power Cord Actual one is dependent on country Only used on AC powered systems KIT 1200 375 Mounting hardware 1102 199 No Picture 100 power cable...

Page 25: ...4A Fuse used in construction of 24 48VDC power cable 4302 031 2A Fuse used in construction of 120VDC power cable 2800 004 3 8 shrink tubing 2880 004 1 4 shrink tubing used in construction of DC power...

Page 26: ...can obtain power from three different sources depending on the particular application used 5VDC Wall plug Transformer optional 24VDC from a UXCM equipped with 24VDC output power connections 24 48VDC...

Page 27: ...be extended do not extend these longer than twenty feet If longer sense leads are required contact Alb r for further assistance All modules within the system are connected together using a fiber optic...

Page 28: ...label on the underside of the UXBM and locate the Model Number Figure 2 UXBM Model Number Label Verify the voltage range string configuration of the UXBM matches the rating of the battery being monito...

Page 29: ...ng it using tie wraps or banding As an alternative the back of the UXBM and UXSM has slots that can accommodate tie wraps or banding eliminating the need for the additional bracket previously describe...

Page 30: ...ing in the slots provided on the multi use bracket Ensure banding is routed through both sides of the bracket Alternate Mounting with Banding As an alternate the banding can be routed through the slot...

Page 31: ...ccommodate two types of mounting 19 rack mount or table top If the rack mount option is desired optional brackets included will need to be installed These UXCM brackets can also be used for a table to...

Page 32: ...Mounting the Equipment 4200 088 8 4 Revision 1 03 Figure 5 UXCM Configured for 19 Rack Mounting Figure 6 UXCM Configured for Table Top Mounting...

Page 33: ...n Installing UXBM s It is important to note that the maximum operating voltage of the UXBM is 95Vdc Connecting the UXBM s in a way that could expose them to voltage higher than this will result in per...

Page 34: ...with part number 1102 191 This type of harness will provide an individual reading of the internal resistance of the cell separate from the intercell or interconnect resistance reading providing two s...

Page 35: ...battery Make sure the UXCM and UXSM power leads are installed first they should be closest to the battery post Then the brass 2 tabbed washers flat washer and lock washer with nut are installed and sh...

Page 36: ...2 conductor power harness for use on 2V and 4V cells Cannot be used in conjunction with 1102 196 or 1102 197 on the battery being monitored 1102 196 5 2 conductor power harness for use on 6V 8V 12V an...

Page 37: ...ote If the power leads are not connected correctly this could result in inaccurate resistance readings of the cell that these leads are connected to Power leads must always be the closest connection t...

Page 38: ...UXBM Harness and Tab Washer Installation 4200 088 9 6 Revision 1 03 Figure 10 Mid UXBM with Combined Resistance Readings...

Page 39: ...provide a combined resistance reading of the cell and the adjacent connecting strap as one value Use the previous section to install the 1102 190 harness The 1102 192 has built in thermistors to monit...

Page 40: ...This type of harness will provide a discrete resistance reading of the cell and the adjacent connecting strap as individual values Reference the Figure below to identify where and what style of tab wa...

Page 41: ...UXBM Harness and Tab Washer Installation 4200 088 9 9 Revision 1 03 Figure 13 First UXBM with Discrete Resistance Readings Figure 14 Mid UXBM with Discrete Resistance Readings...

Page 42: ...vide a discrete resistance reading of the cell and the adjacent connecting strap as individual values Use the previous section to install the 1102 191 harness The 1102 192 has built in thermistors to...

Page 43: ...when the total number of cells do not evenly divide by five For example if the string uses 241cells this would require 49 UXBM s with the last UXBM only monitoring one cell If this or a similar case a...

Page 44: ...considering the lowest level reached during a discharge For example if 2 volt cells are being monitored then the power leads must be connected across at least five cells This is considering an end vo...

Page 45: ...er Connection for UXBM Monitoring with a Split Load of 4 x 12V The following table will illustrate recommended minimum cells or monoblocs required to power the UXBM Cell Monobloc nominal unit voltage...

Page 46: ...not extend these longer than twenty feet If longer sense leads are required contact Alb r for further assistance Part Number Description KIT 1102 180 25 25 of green 22 awg wire and 5 connector sets fo...

Page 47: ...DC max and if connected across an open circuit on a battery the entire battery voltage could be present across the open connections if the charging circuit is still energized This will result in perma...

Page 48: ...monitor one cable The UXBM sense lead harness 1102 190 has a white violet wire that is used in conjunction with the regular cell sense lead The drawings below will help illustrate how this wire is co...

Page 49: ...on Cell in Middle of Group Using the chart below fill in the cell before and after each Intertier or inter row cable to help facilitate configuring the software Cable Cell before Intertier Cell after...

Page 50: ...n 6002 121 50 black 12GA wire used in construction of DC power harness 6002 037 50 Red 12GA wire used in construction of DC power harness 1100 433MPM Fuse holder assemblies used in construction of DC...

Page 51: ...the fuse holder The following illustration only gives one possible scenario of how the actual power supply leads are connected to the battery Make sure the UXCM and UXSM power leads are installed firs...

Page 52: ...power leads are installed first they should be closest to the recessed battery post Then the brass 2 tabbed washers flat washer and lock washer with bolt are installed and should be located on top of...

Page 53: ...ered 10 2 AC Powered When the UXSM is powered from a 100 240VAC source a wall plug power supply is used This power supply must be powered by a protected power source Use the appropriate power cord sup...

Page 54: ...feature is commonly used when two or more UXSM s are required with one UXCM There is a 2 conductor 16ga zip cord included in the install kit This cable can be routed as a daisy chained through each U...

Page 55: ...is important Every battery string that is monitored will have one UXSM module This must be the first module of each string when connecting the fiber optic Depending on what type of system is being ins...

Page 56: ...us should not be less than 35mm or 1 4 and maximum length between modules cannot exceed 250 or 76 meters Doing so will cause degradation in the signal which will manifest itself as intermittent or no...

Page 57: ...core design and requires to be installed across one of the battery cables that will be carrying all of the current going into or out of the battery There are two dots on the casing that indicate the...

Page 58: ...to better understand the requirements When installing this option a specific harness will be included in the installation kit separate from the FCCP packaging One of two standard lengths supplied is...

Page 59: ...rangement Figure 36 String Current Connection on Rear of UXSM or UXCM The sensor as shown below is a split core device and must be placed across the battery cable There is an arrow on the casing that...

Page 60: ...s part number 1102 187 12 for 12 or 1102 187 50 for 50 To connect the temperature sensor simply connect the four pin connector directly into the TEMP connection on UXSM or UXCM depending on which comp...

Page 61: ...uded for each string being monitored The UXBM will require each section of numbers to be cut to the appropriate cell numbers that are actually monitored by the UXBM For example if the first UXBM is mo...

Page 62: ...Table 9 Intellislot Card Parts List There are two slots on the rear of the UXCM to accommodate two types of communications simultaneously There must be at least one card with an Ethernet connector to...

Page 63: ...ons has a Common COM Normally Closed NC and Normally Open NO terminal Connection can be made directly to the facility s alarm reporting system via these connections These contacts can be connected in...

Page 64: ...Alarm Contacts and Remote Reset 4200 088 15 2 Revision 1 03...

Page 65: ...4 1 tasks 4 1 Installing Fiber Optic Cable 11 1 Installing Intellislot 14 1 Installing Optional Sensors and Transducers 12 1 Insulation Rating For Wires 1 3 IntelliSlots 3 2 Internal Components 2 1 I...

Page 66: ...NI_STRUT 8 1 UXBM 8 1 UXCM 8 1 UXSM 8 1 Uninterruptible Power Supply 1 3 UPS 1 3 UXBM 3 1 5 1 UXBM Monitoring Less Than 5 Cells 9 11 UXCM 3 1 5 5 5 6 6 1 UXCM Power Lead Connections 10 3 UXSM 3 1 5 3...

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