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Pilot Communications PBAT-Gate Installation & Operation Manual Download Page 7

 

3 

1.1 System Structure 

 

 

PBAT battery monitoring system consists of a gateway module, single acquisition module, 

battery  pack  collection  module,  Hall  sensors,  temperature  and  humidity  sensors  and 

datacenters, each module functions as following:

 

 

 

Module Name 

Illustration 

Gateway 

Realization  battery  data  acquisition,  control,  alarm  and 
event logging upload

 

Single acquisition 

module

 

Measuring  single  cell  voltage,  temperature,  resistance 
and alarm indication

 

Pack collection 

module

 

Measuring the pack 

voltage and current parameters

 

Current sensor 

Current sensor 

Summary of Contents for PBAT-Gate

Page 1: ...PBAT Gate Battery Monitoring System Installation Operation Manual V3 3 PILOT HENGQIN CO LTD 珠海横琴派诺技术有限公司 ...

Page 2: ...qualified people Before operating the device isolate the voltage input and power supply and short circuit the secondary windings of all current transformers Use appropriate voltage tester to make sure the voltage has been cut off Put all mechanical parts doors or covers in their original positions before energizing the device Always supply the device with the correct working voltage during its ope...

Page 3: ... and Usage 5 2 3 Order Information 11 2 4 Power Supply 12 Chapter 3Display and Operation instruction 13 3 1 Summary 13 3 2 Key features 13 3 3 Data Query 13 Chapter 4 Webpage Illustration 16 4 1 Summary 16 4 2 Login 16 4 3 Real time Data 17 4 4 History data 18 4 5 Discharge Data 20 4 6 Reports 21 4 7 Fault Statistics 22 4 8 Real Time alarm 22 4 9 Alarm History 24 ...

Page 4: ...n 42 7 1 Summary 42 7 2 Forwarding table configuration 42 7 3 Data Forwarding Function 42 Chapter 8 Alarm System 44 8 1 Summary 44 8 2 Alarm Analysis 44 Chapter 9 Auxiliary Function 48 9 1 Communication 48 9 2 Clock 48 Chapter 10 SOC remaining capacity 49 10 1 SOC Remaining capacity calculating Description 49 Chapter 11 Maintenance and Trouble shooting 51 Chapter 12 Technical Specification 52 ...

Page 5: ...n the best active state improve the battery backup time and operating life timely detection of backward battery and automatic on line activation maintenance this greatly reduces the manpower material and other maintenance costs improve the safety of battery use to reduce the accident rate effective energy saving emission reduction for the use of units to create a good economic and social benefits ...

Page 6: ...nt can adapt to any environment seamlessly site 7 Detailed historical data recording sound alarm event management provide battery maintenance failure analysis report generation from data support 8 A variety of alarm linkage So quickly found unexpected events ...

Page 7: ...dity sensors and datacenters each module functions as following Module Name Illustration Gateway Realization battery data acquisition control alarm and event logging upload Single acquisition module Measuring single cell voltage temperature resistance and alarm indication Pack collection module Measuring the pack voltage and current parameters Current sensor Current sensor ...

Page 8: ...meet the battery network monitoring requirements PBAT measurement functions as following Items Support or not Note Single Cell Voltage Single Cell Temperature Single Cell Resistance Group average Single Cell Voltage Group average Single Cell Temperature Group average Single Cell Resistance Group Voltage Serial Current Record Maximum storage12monthshistory data Maximum storage12months history data ...

Page 9: ...5 RH Non condensing 2 2 Installation and Usage PBAT battery monitoring system is divided into a gateway module Cell Sensor module String Sensor module 2 2 1 Gateway module Use rail installation fixed on the rail The size of the installation must be strictly in accordance with the following figure in order to ensure the correct installation of equipment Model GateL4 1 Dimension ...

Page 10: ...4 4CG NO Symbol Definition 1 24V 24V DC power supply positive terminal input 2 24V 24V DC power supply negative terminal input 3 Null Null 4 Null Null 5 Null Null 6 Null Null 7 RS485A B RS485A 8 RS485A A RS485A 9 RS485A SHEL RS485A Shield 10 RS485B B RS485B ...

Page 11: ...N2 Port 2 10M 100M TF Cover TF Card Standard The main terminal definitions Gate L4 2ZG NO Symbol Definition 1 24V 24V DC power supply positive terminal input 2 24V 24V DC power supply negative terminal input 3 Null Null 4 Null Null 5 RL11 Relay output passive 6 RL12 Relay output passive 7 RS485A B RS485A 8 RS485A A RS485A 9 RS485A SHEL RS485A communication line shield 10 RS485B B RS485B 11 RS485B ...

Page 12: ...A I1 input 14 COM 4 20mA I1 2 input 15 I2 4 20mA I2 input 16 S1 Switch input 1 17 S2 Switch input 2 18 S3 Switch input 3 19 S4 Switch input 4 20 Scom Common port of switch port LAN1 Ethernet 1 10M 100M LAN2 Ethernet 2 10M 100M 2 2 2 Cell Sensor module 1 Dimension ...

Page 13: ... Temperature terminal 5 V Sense Positive voltage terminal 6 V Bat DC Power supply input 7 COM 1 Series 1 8 COM 2 Series 2 4 Indicate light illustration NO Symbol Color Definition 1 RUN Green Device running indicator 2 ALARM Yellow Alarm indicator When the user defined event alarm occurs the alarm is triggered and the alarm light is on Stickers Disassemble Installation ...

Page 14: ...tion 3 Definition of main terminal No Symbol Definition 1 24V 24V DC power supply positive terminal input 2 24V 24V DC power supply negative terminal input 3 Hall Terminal Group Current Hall Sensor connect 4 Group voltage measure 5 Group voltage measure ...

Page 15: ...Gate Gateway Module Support 1 4 group string battery maxim 120 units cell sensors 4CG 4 RS485 pick one of two 4CG support up to 4 groups of battery 2ZG support up to 2 groups of battery 2ZG 2 RS485 4 Passive switch input 2 Analog input DC 4 20mA 1 Relay output Model 600 600 String Sensor each group should be equipped with 1 piece Required Model 61 Cell Sensor one battery for one unit xx refers to ...

Page 16: ...12 2 4 Power Supply Module Power Supply Note Gate 18V 36V DC 5W 24VDC power supply 600 12V 36V DC 24VDC power supply 61 02 2V DC 2V battery unit power supply 61 12 12V DC 12V battery unit power supply ...

Page 17: ...ll be displayed again 3 2 Key features Gate panel has only one button to control the screen switch you can press the button to achieve the screen cycle display 3 3 Data Query Following is GATE display menu structure Display ETH1 ETH2 Default GPRS Gate Info FW TF capacity Port1 Conf Port2 Conf Port3 Conf Port4 Conf Time display OFF ...

Page 18: ...the current battery gateway time 3 3 2 Network port configuration Display interface IP address gateway address subnet mask The network port 2 is displayed in the same way as the network port 1 3 3 3 Default gateway interface Data Display Default gateway IP ...

Page 19: ...terface Data Display Software version number 3 3 6 SIM Status Info Data Display SIM Status SIM signal 3 3 7 Serial port display interface Data Display Sequentially displaying the number of the baud rate number of data bits parity and data bit settings Serial 2 3 4 configuration display and serial port 1 is the same ...

Page 20: ...Login Connect the gateway to a PC if there is LAN wireless router you can use your tablet or smart phone to log in open the IE browser supportsIE9 Firefox chrome and other browsers enter the gateway IP address on address bar Factory default setting User Name admin Password admin Notice If you are modify the user name or password and forgot the password the following super Account can be used for s...

Page 21: ...how the battery management information page Real time data page manage battery voltage current temperature internal resistance and battery collector connection status Click the switch TAB to switch group information cell information and digital input information as shown in the figure below ...

Page 22: ...18 Group info Cell info Digital input info 4 4 History data Click the left menu bar Historical data display the battery history data page ...

Page 23: ... red point sign Query historical data base on time period and parameter type time period can t longer than 30 days and the final date should late than the starting data the rectangle will judge whether is normal or abnormal of the measure value When it is abnormal the testing point will have red point sign Note PBAT Gate can Max storage history alarm record for 2 years For those record that longer...

Page 24: ...e historical data of string monitor in a time period including string voltage string current Query discharge historical data of cell monitor in a time period including voltage temperature internal resistance The default curve shows less than 3cells data curve The curve for more than 3cellsis hidden click on the line can be displayed Note PBAT Gate can Max storage history alarm record for 2 years F...

Page 25: ...rts User can select day month year as date type When select day can display any one of the day s detail data When select Month can display each day s average data of one month When select year can display each month s average data of one year Can select multi string sensor for query data Can select any one of the measure point string voltage string current SoC When select day then customer can sel...

Page 26: ...hen select month can select 12 months of the year When select year can only select year time Click Query then it will display the period of the present alarm quantity When click Download then it will download the present data as excel format files 4 8 Real Time alarm Click the menu in the left side Real Time alarm display detail information for the present alarm battery the alarm which is not deal...

Page 27: ...23 The second page shows the recent 200 untreated alarm information When the gateway is restarted or reconfigured the real time alarm display will be reset ...

Page 28: ...larm of the choosing string is queried The end time must be greater than or equal to the start time with maximum support for the cross one year query data Click the query button to display the data in the current condition to the table and support sorting and paging Click the download button to download the data from the current condition to the excel file Click the switch TAB to switch alarm mess...

Page 29: ...the left side Setting General Setting Network Setting then it will display network parameter setting page Network port can be configured dual NIC IP address subnet mask gateway DNS information Please follow the correct network parameters to configure Note Dual network card network segment does not allow the same 4 10 2 Serial Port Setting Click the left menu bar Setting General Setting Serial Port...

Page 30: ... data bits 8 stop bit 1 parity none This setting changes the Gate s own serial parameter configuration not to change the PBAT600 serial port parameters to change the 600 serial parameters please contact the professional staff 4 10 3 Input setting Click the left menu bar Setting General Setting Input Setting to display the AI and DI port configuration page ...

Page 31: ...ied alarm settings file You can download the modified alarm settings file Make the modified or uploaded configuration file effective Upload and download function is only for the use of engineering staff configuration do not arbitrarily change the contents of the upload file Make the local configuration effective Read the configuration of 600 and cover the local configuration This function is conve...

Page 32: ... you want to send Set contact and tel on Project Details page Read 600 alarm Click to Get the page will pop up to read the 600 alarm configuration the user can confirm Alarm function ON or OFF Upper limit value Recovery value Normally is 0 Normally is 0 Select DO alarm or SMS SMS alarm content SMS alarm content SMS alarm content ...

Page 33: ...ment Click the left menu bar Setting General Setting Resistance Measurement to display the resistance measurement page Click the pop up prompt Are you sure you want to test the internal resistance manually Testing the internal resistance need to wait for a long time each monomer takes about 5 ...

Page 34: ...l Setting Time setting to display the time setting page Select the time zone the default Beijing time zone East 8 District The calibration time server can be the domain name or IP address of the NTP server time a nist gov Calibration time that gateway will connect NTP server for automatic calibration Click the Sync button to synchronize the gateway and computer time ...

Page 35: ...ds user identity surname name and contact information You can delete all users except the SuperAdmin and you will be prompted before deleting them Click Modify to modify a specified user Click Delete to delete the specified user there will be prompted before the deletion 4 10 8 Balancing Setup Click the left menu bar Setting General Setting Balancing Setup to display the setting page ...

Page 36: ...l resistance balance judgment used for data upload No effect on balancing 4 10 9 Gateway Firmware Upgrade Click the left menu bar Setting General Setting Gateway firmware upgrade to display the gateway firmware upgrade page Attention When the system needs to be upgraded perform a firmware upgrade on this page Be sure to consult a technician before upgrading 4 10 10 Project Details Click the left m...

Page 37: ... and affect the language used when sending text messages The timing record setting set the interval time of record historical data Logo settings for the login screen Logo display and the upper left corner of the user s Logo display 4 10 11 Battery Information Click the left menu bar Setting Project Setting Battery Information to display the battery information page ...

Page 38: ...34 ...

Page 39: ...ed group voltage value Cell superimposed value Accumulation of all cell voltages String voltage 4 10 12 Hall sensor Setup Click the left menu bar Setting Project Setting Hall Setup to display the Hall setup page Set Hall specifications and calibrate CT Read the Read button is to read the current set of 500 Hall specifications from the drop down box to modify the click settings can be set to select...

Page 40: ...llector Device Address Table for each COM in bulk Examples First add PBAT600 Second Auto Sensing all cell sensor SN address Final Enable the Config Click to Get the 600 configuration the pop up window prompts the current 600 address configuration the user can choose to confirm the writing to the gateway configuration or click to cancel the writing Regular function Read the configuration of 600 Con...

Page 41: ...ice Configuration Register List to display the ModbusTCP Forward Table page Can be loaded empty and export the collector table V3 1 support alarm information forwarding refer to Gateway protocol V3 1 Note Before uploading the gateway data please click Import List ...

Page 42: ...sually an operational parameter such as the connection state interface name and so on The most common default communication strings are public read only and private read write along with many vendor private default communication strings Almost all network devices running SNMP can find some form of default communication string This device only supports using the GET command from the security aspect...

Page 43: ... all child nodes such as a child node to traverse the group under all the data can use snmpwalk v 2c c public 192 168 1 XX 1 3 2 3 1 2 4 8072 1 3 2 3 1 2 4 49 Using the snmpget command you can obtain data for the specified node for example to obtain the data of the single voltage 1 under the group node can use snmpget v 2c c public 192 168 1 XX 1 3 2 3 1 2 4 8072 1 3 2 3 1 2 4 49 48 48 48 ...

Page 44: ... unit collector and 1 group collector 1 Single cell unit collector will charge each battery cell voltage temperature and inner resistance 2 Group collector will charge battery group s group voltage serial current group temperature 3 Each gateway equip with 4 channel RS485 port 4 Each RS485 channel connect maxim 60 pieces single cell collector 5 Each gateway support maxim 4 group battery connection...

Page 45: ...0 Number of 4 groups cannot be more than 480 The total quantity of batteries cannot be more than 960 RS485 B 1 120 61 Group 2 1 240 62 RS485 C 1 120 61 Group 3 1 240 62 RS485 D 1 120 61 Group 4 1 240 62 2ZG Group 1 Group 2 Group 1 battery number 1 50 Group 2 battery number 1 50 RS485 A 1 120 61 Group 1 1 240 62 The gateway connect with 2 group battery Number of each group cannot be more than 120 N...

Page 46: ...point Click on the Setting Service Configuration Register List Display the forwarding point table page click the load forwarding table you can select the required points to generate Click the export the table to generate the EXCEL file 7 3 Data Forwarding Function Configuration the forwarding table base on Chapter 5 2 the user can read the real time data by the software which connect with gateway ...

Page 47: ...equentially to read the battery real time data one message can read maxim 512 measuring point When a larger number of measuring points need to get real time data can divide into several sections 5 If there are several data center need to read the data from gateway at the same time can connect all of them to port 502 on the gateway Suggest maxim number no more than 20 ...

Page 48: ... the value can be customized 8 2 2 Alarm Object Type Analogue setting system can monitor all electrical parameter totally 22 items as following Over Limit Type Parameter Type Upper Limit Single Cell unit voltage Single Cell unit temperature Single Cell unit inner resistance over than group average percentage Battery group voltage Battery group current SOC Lower Limit Single Cell unit voltage Singl...

Page 49: ...ion Condition After define monitoring parameters need to set the action condition For example define single cell unit voltage upper limit action Set the battery group number event type set as upper limit limit value 2 5V trigger action is Event Record The Hysteresis value hold time recovery time is 0 If the voltage over than 2 5V there will be one event record information ...

Page 50: ...arm at 2 4V alarm not cancel return back to 2 5V will not repeat alarm Until the voltage 2 3V alarm be cancelled Hysteresis value be set according to measuring point on site environment if setting value is 0 it means at the moment the real time value within the limit range and Alarm return time is 0 Revert is yes will cancel alarm immediately Because of collector s repoll time interval is long so ...

Page 51: ...ger Activation Illustration LED Light Alarm ON Cancel OFF Alarm light including gateway panel light and collector light Event Record record alarm and cancel DO 2ZG version Can be connected to sound and light alarm for alarm Attention If use the 2ZG version only support 2 RS485 ...

Page 52: ...ng 9 1 2 Communication Protocol RS485 port to support the international common MODBUS RTU protocol Please refer to the corresponding _MODBUS communication protocol manual for the specific agreement 9 1 3 Communication Parameter Whether the instrument can communicate with the master is the premise of whether the communication parameters are set correctly Communication Parameter including 1 Meter ad...

Page 53: ...V 12 68V The default battery parameters can be configured by Setting Project settings Battery information Battery recovery voltage in actual use after a complete charge and discharge process you can update by calculation Take the average value of the recovery voltage of all the batteries in each group general requirements to remove the maximum and minimum modify the configuration parameters for us...

Page 54: ...ature parameters the original parameters will be lost be sure to understand this risk when switching battery voltage levels The default recovery voltage value for a large number of experimental access to the optimal value if no special circumstances Such as battery manufacturers to provide reference value etc do not change ...

Page 55: ...onnection 2 Check whether measurement voltage compatible with device rated parameter Current measurement wrong 1 Check whether measurement current compatible with device rated parameter 2 Check Hall sensor setting Cannot communication with UP side device Communication address wrong Check device address Baud rate wrong Check device baud rate Did not add resistor by the end of network Check whether ...

Page 56: ...06 IEC61000 4 2 2001 III RFEMS GB T17626 3 2006 IEC61000 4 3 1998 IV Electrical fast transient burst immunity GB T17626 4 2008 IEC61000 4 4 1998 III Surge Immunity GB T17626 5 2008 IEC61000 4 5 2005 III RF conducted immunity GB T17626 6 2008 IEC61000 4 6 1998 III Power frequency magnetic field immunity GB T17626 8 2008 IEC61000 4 6 2001 III Electromagnetic mission limits GB T14598 16 2002 IEC60255...

Page 57: ...king pmac com cn Tech Support Email systemtech pmac com cn PILOT HENGQIN CO LTD Add No 15 Keji 6 Road ChuangxinHaian Tangjia High tech Zone Zhuhai Guangdong 519085 China Tel 86 756 3629166 3639029 Fax 86 756 3631718 http en pmac com cn Please pay attention to our WeChat public number Open WeChat to scan our two dimensional code ...

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