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BQMS Installation Manual  

052319

 

 

5.5 Sensing Cable Connections 

Parts: 

Voltage, Current, and Temperature Cable Harnesses 

Tools: 

2/16” (2-3mm) flathead, duct, cable ties/zip ties, wire cutter, wire stripper 

 

The Sensing Cables must be connected to each Module and terminated at each clamp (C-Clamp or O-

Clamp) on the battery system.  

 

 

 

5.5.1 Sensing Cable Overview 

There are three Sensing Cable Harnesses which connect to the clamps: Voltage Sensing 

(Vs)

, Current 

Sensing 

(Is), 

and Temperature Sensing 

(Temp)

. Each cable harness contains smaller color-coded 

wires.  

 

    

   

 

 5-Pin Voltage (Vs) Harness           3-Pin Current (Is) Harness            8-Pin Temp. Sensing Cable 

 

 

 

In some cases, sensing cables may be provided at different lengths. It is important to organize cables 

before installation as longer cables may be needed for batteries separated by rack tiers.  

 

Prior to installing the Sensing Cables, it is important to understand the differences between the cable 

types and how they are installed.  

 

- 

Voltage Sensing Cables

 measure cell voltage and connect to the Vs termination on every

 

clamp.  

- 

Current Sensing Cables

 measure cell resistance and provide DC power to each Module. They 

connect to specific clamps only (the placement of clamps varies depending on the system). 

TIP: 

Follow any diagrams or drawings provided with the system for exact wiring instructions. 

 

NOTE: 

The  number  of  wires  per  harness  varies  depending  on  the  cell  voltage  being 

measured.  

 

Содержание BQMS

Страница 1: ...1 Eagle Eye Power Solutions LLC BQMS Battery Monitoring System Installation Manual 052319 www eepowersolutions com Tel 1 877 805 3377 Fax 1 414 962 3660 info eepowersolutions com...

Страница 2: ...5 1 Overview of Workflow 14 5 2 Mount CCU or Cabinet Enclosure 15 5 3 Check Mount Modules 16 5 4 Clamp Installation 18 5 4 1 Prepare for Connection 18 5 4 2 Connection of Clamps C Type 19 5 4 4 Connec...

Страница 3: ...T Clamp 37 5 8 1 Connect CT Cable Harness to BQMS CCU 37 5 8 2 Connect CT Cable to CT 38 5 8 3 Attach CT to Battery System 38 5 9 Ambient Temperature Connection 39 5 10 Verify Connections 40 5 10 1 Ch...

Страница 4: ...se and functionality of the BQMS If the BQMS is used in a way not specified in this manual the safety of the equipment personnel and property cannot be assured Please read this manual carefully to avo...

Страница 5: ...ons come complete with battery management software which allows all battery systems to be monitored 24 hours a day 365 days a year via remote computer s This software offers comprehensive battery diag...

Страница 6: ...ttery bank 2 Each bank has Modules which connect from the CCU to the battery cells in daisy chain 3 The CCU s communicate with the Server PC via Ethernet over a company private network 4 The CCU can a...

Страница 7: ...a is stored on the server Item Description POWER Power input termination LED Power LED and alarm LED TCP IP Ethernet port CAN PORT CAN communication port connects with Modules ON OFF Power ON OFF swit...

Страница 8: ...or LED CH Set Cell Quantity Measured by Module OFF OFF 1 cell measured OFF ON 2 cells measured ON OFF 3 cells measured ON ON 4 cells measured CAN ID CAN ID dial sets can ID number Ex Module 14 would h...

Страница 9: ...alarms Alarm Relays Form C output contacts Dry Contact Ratings Nominal 2A at 60V AC DC Max 0 5A at 250VAC 0 27A at 220VDC Measuring Interval Adjustable from 10 min to 24 hours Data Transfer TCP IP Mo...

Страница 10: ...processing unit for BQMS system Measures total voltage current ambient temperature Measurement Module Measures cell unit voltage resistance temperature C Type Clamp Clamp used for connection between...

Страница 11: ...es String VDC and DC Power Cables Positive and negative cable sets for string voltage measurement and DC voltage input CCU Module CAN Cable 4 pin Data communication between CCU and Modules CCU CCU CAN...

Страница 12: ...wer to Module 4 Installation Tools 4 1 Standard Installation Tools Tool Name Purpose Picture Multi meter Verification of connection voltage resistance 1 Phillips Insulated Screwdriver Tightening of O...

Страница 13: ...ed to mount the BQMS Wire Stripper Adjustment of cable length 12 to 22AWG required Shop Snips Adjustment of duct length cable length Cable Ties Cable management Wire Tray Optional Cable routing and ma...

Страница 14: ...Mount BQMS CCU 2 Install Clamps to battery connections 3 Install Sensing Cables 4 Install Temperature Sensors 5 Check mount Modules 6 Connect Total Voltage Cable and power connections 7 Install CT 8 V...

Страница 15: ...The CCU Cabinet should be mounted in the same location indicated during the Site Survey process Provided cabling is cut to length based on this location 2 Observe areas around the CCU Cabinet to ensur...

Страница 16: ...ould be checked for accuracy against the Unit No printed on the face of the Module a The face of each Module has a Unit No b Check that the CAN ID matches the Unit No c Check the CH Switches are set c...

Страница 17: ...Cables will need to be connected to the Modules in the coming steps If the Module s mounted location makes the connector ports difficult to access consider setting the Module in the general location...

Страница 18: ...nection to the battery system for measurement The fuses are housed on a small PCB on each clamp The placement of the clamps is based on the PCB type There are two types of PCBs Voltage referred to as...

Страница 19: ...lace the clamp in the center of the bus bar and tighten down using the provided screws 4 If the bus bar has a cover cut out an area so the cover sits snugly against the clamp 5 Attach additional clamp...

Страница 20: ...he wire terminations should be facing the direction the sensing cable s will come from 3 Place the clamp over the center of the cable and tighten the screws into the cable NOTE If the cable is too lar...

Страница 21: ...Temp Sensing Cable In some cases sensing cables may be provided at different lengths It is important to organize cables before installation as longer cables may be needed for batteries separated by ra...

Страница 22: ...e Module measures up to four 2V cells 1 The Voltage Harness includes 5 wires colored gray green blue orange brown 2 The Current Harness includes 2 wires colored red for positive black for negative o N...

Страница 23: ...oltage Harness includes 4 wires colored gray green blue orange 2 The Current Harness includes 2 wires colored red for positive black for negative 3 The Temperature Harness includes up to 8 colored wir...

Страница 24: ...ts 1 The Voltage Harness includes 3 wires colored gray green blue 2 The Current Harness includes 2 wires colored red for positive black for negative 3 The Temperature Harness includes up to 8 colored...

Страница 25: ...units only This configuration is only applicable to 12V 1 The Voltage Harness includes 2 wires colored gray green 2 The Current Harness includes 2 wires colored red for positive black for negative 3 T...

Страница 26: ...and Temp Sensing cable to the corresponding Module so that it is ready to be connected after the wires are routed and connected to the batteries 2 The number on each Cable Harness always refers to th...

Страница 27: ...he Molex connector end of each cable harness should be secured at each Module but not yet connected The colored wires from each harness can now be routed to each clamp that they will connect to Follow...

Страница 28: ...ly 3 16 4mm of the 22AWG sensing wire 4 Insert the stripped wire into the termination 5 Screw the wire tight using a 2 16 2 3mm flathead firmly pull on the wire to ensure the connection is tight ensur...

Страница 29: ...to up to four Temperature Sensors Connecting Temp Sensors to Cable Harness Each Temp Sensing Harness has cables which are labeled per the cell unit they will be adhered to Each of these numbered cabl...

Страница 30: ...e correct cell unit 2 Stick the adhesive pad close to the negative cell as shown below 3 Using silicone or hot glue adhere the sensor right next to the base of the negative post Try to keep the placem...

Страница 31: ...nnection Parts CCU Module CAN Cable Module Module CAN Cable Tools N A The CAN Cables connect the following components CCU to the first or last Module Module to Module The diagram below illustrates how...

Страница 32: ...the closest Module 3 Connect all the remaining Modules together with the provided CAN Cables There are 2 CAN ports on each Module CAN 1 and CAN 2 It does not matter which port the cables are connecte...

Страница 33: ...ections on the BQMS CCU 5 7 1 Voltage Connections Directly to CCU The sections below outline the various ways system voltage may be connected to the BQMS CCU NOTE If installing an EE NERC BMS kit were...

Страница 34: ...the CCU will connect to a terminal block The terminal blocks are connected to the appropriate voltage inputs on the CCU 1 Locate the fused terminal blocks inside the enclosure 2 Refer to the system sp...

Страница 35: ...the DC input cables 2 If connecting from an enclosure run the positive and negative cables to the clamps installed on the main positive bus the first and last clamp 3 After routing the cables to the c...

Страница 36: ...t to the most positive and negative clamps 2 Connect the Total Voltage Cable to the Vs screw on the clamp 3 Connect the DC Power Cable to the Is screw on the clamp Total Voltage DC Power Total Voltage...

Страница 37: ...t CT Cable Harness to BQMS CCU 1 The CT Cable has three colored wires which connect the CT to the BQMS CCU red black and white 2 The CT Cable is wired to three or four inputs on the BQMS 12V Ground 12...

Страница 38: ...ound Ground Black 12 White Output 5 8 3 Attach CT to Battery System 1 Typically the CT is attached to the positive bus of the battery system but it can also be installed anywhere else on the string as...

Страница 39: ...ambient temperature This sensor connects directly to the CCU To connect the ambient Temperature Sensor insert the two ends of the wires into the ambient temperature terminal block The wires are not se...

Страница 40: ...robe from the meter into the pin with the gray Sensing Wire on the Molex 3 Insert the negative probe from the meter into the pin with the green Sensing wire on the Molex The voltage of cell unit 1 sho...

Страница 41: ...ive lead of the meter to the pin with the red wire and the negative lead to the pin with the blue wire 7 The voltage displayed should match the voltage displayed in Fig 6 1 Voltage of Cells 1 4 Tested...

Страница 42: ...should be connected to the clamps and checked for correct voltage Module Connections for Sensing Cables Connect all Sensing Cables to the Module The Module has 3 types of connections 1 Input refers t...

Страница 43: ...output There are 8 additional inputs and outputs for external hardware BQMS Dry Contact Outputs BQMS CCU BQMS Outputs External Hardware Output External Hardware Input Output Output Output Output Input...

Страница 44: ...44 BQMS Installation Manual 052319 5 12 2 Dry Contact Overview...

Страница 45: ...ain alarm conditions They are labeled per alarm type models prior to August 2018 are labeled as LED 1 to LED 8 Models after July 2018 Models prior to August 2018 LED 1 String Voltage LED 2 String Curr...

Страница 46: ...clamp is facing the correct direction 4 All voltages have been verified from the Sensing Cables including current voltage and total voltage 5 All Modules are connected in the correct order and are po...

Страница 47: ...efer to the steps below to configure the BQMS 1 Connect the computer with the WIZ100SR tool installed directly to the Ethernet port on the BQMS using an Ethernet or Crossover cable and power on the BQ...

Страница 48: ...s set to Client 11 Click Setting to save all changes 7 2 Connect BQMS to Network With the BQMS installed and the IP configured it can be connected to the company network 1 Run the Ethernet directly in...

Страница 49: ...uses the same measurement technology as the BQMS so it is the only other method to determine measure the resistance It is recommended to measure all the cells units in the battery bank with the IBEX...

Страница 50: ...n By default all Revised Values should be 0 meaning the cell has no compensation value b For BQMS v1 0 or v1 1 click Odd Module Measurement and Even Module Measurement to perform a complete measuremen...

Страница 51: ...ement is complete the compensated resistance value will appear under the R column Note that internal resistance values change slightly with each measurement so it is possible the new measured value wi...

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