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Installation Guide

Battery Monitor

CAN Bus Node


Smartpack based DC Power Supply Systems .
351507.033

Information in this document is subject to change without notice and does not represent a commitment on the part of Eltek Valere. No part of this document may be reproduced or transmitted in any form or by any means electronic or mechanical, including photocopying and recording for any purpose without the explicit written permission of Eltek Valere. Copyright : Eltek Valere, 2008

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351507.033
MfM

Issue 1.1, 2008 Aug

Published 2008-08-08

Installation Guide Battery Monitor CAN Bus Node

351507.033, Issue 1.1, 2008 Aug

Table of Contents
1. Introduction ................................................................................. 4
About this Guide................................................................................................ 4 System Diagram CAN Bus Nodes ................................................................ 4

2.

Battery Monitor, CAN Bus Node ................................................ 5


Key Features ..................................................................................................... 5 Typical Applications .......................................................................................... 5

3.

Installation of Battery Monitors.................................................. 6


Safety Precautions ............................................................................................ 6

Basis Installation Steps ................................................................................... 6


Fastening the Battery Monitors ......................................................................... 7 Location of Connectors, Ports, LEDs ................................................................ 7 Connection Drawing .......................................................................................... 8 Battery Symmetry Connections ......................................................................... 9
Block Measurements ................................................................................................ 9 Mid-point Measurements ........................................................................................ 10

Battery Terminology ........................................................................................ 10 CAN Bus Termination ..................................................................................... 11


Removing the Smartpack Controller....................................................................... 11

Configuration................................................................................................. 12
CAN Bus Addressing ...................................................................................... 12 About PowerSuite Configuration ..................................................................... 13

4.

Technical Specifications........................................................... 14

Installation Guide Battery Monitor CAN Bus Node

351507.033, Issue 1.1, 2008 Aug

1. Introduction
Congratulations on your purchase of the Battery Monitor, CAN Bus Node, an intelligent plug-and-play module to decentralize and expand the functionality of your Smartpack based DC power supply system.

About this Guide


This booklet provides you with the required information for installing the Battery Monitor, CAN Bus Node in your Smartpack based DC power supply system. The booklet also presents the Battery Monitors technical specifications. For more detailed description of the Battery Monitor, CAN Bus Node, read the Users Guide Smartpack Monitoring and Control Unit, Art. 350003.013. For description of how to activate and configure the Battery Monitor, CAN Bus Node using the PowerSuite PC program, refer to the PowerSuite online Help system. Refer also to Installation Guide Battery Monitor Symmetry Kit, document number 351497.033, which is included with the kit.

System Diagram CAN Bus Nodes


The Battery Monitor, CAN Bus Node is used as a building block in Smartpack based power supply systems, see Figure 1. Other CAN bus nodes, like the Load Monitor and the I/O Monitor, may also be connected to the bus. The nodes are powered directly from the CAN bus, and have dedicated inputs and outputs that expand the system monitoring and control capability. The Smartpack controller monitors and controls the whole system, and serves as the local user interface between you and the system. The PowerSuite application enables you to configure and operate the system from a personal computer.

USB A-B cable (standard) 1 CAN bus (twisted-pair CAT5 cable) ID Number Battery Monitor 33 01 81 I/O Monitor Battery string #1 Flatpack2 DC Power System Temp, Fan Speed Mon & Ctrl Alarm Outputs NC-C-NO Config. Inputs 02 n 49
Smartpack Controller

120

End-of-Line Resistor

Flatpack2 Rectifiers

Load Monitor 120


End-of-Line Resistor

Shunts

Current Monitoring Sense Inputs


Fuses

Fuse Monitoring Configurable Inputs

Figure 1 Example of three CAN bus nodes connected in a Flatpack2 DC Power Supply System

Installation Guide Battery Monitor CAN Bus Node

351507.033, Issue 1.1, 2008 Aug

2. Battery Monitor, CAN Bus Node


The Battery Monitor CAN Bus Node enables you to decentralize and increase the number of battery symmetry measurements in your Smartpack based DC power supply system. Also, it monitors the battery compartment temperature using the built-in sensor the battery fuse with a fuse monitoring input and the battery current via a current sense input.

Key Features
A wide range of features are implemented in the Battery Monitor CAN Bus Node, as mentioned below: 9 Powered via the CAN bus; no external power supply required 9 Firmware upgrade via the CAN bus (see required SW Upload tools on page 14) 9 4 battery symmetry inputs for battery strings symmetry measurements 9 1 fuse monitoring input user configurable for fuse monitoring and other site equipment monitoring 9 1 battery current sense input for bi-directional current monitoring through external current shunts 9 1 battery temperature sense input via the built-in temperature sensor 9 Storage of calibration data and real time event log 9 Windows-based setup, configuration and calibration via PowerSuite 9 Flexible mounting using Velcroue adhesive tape on the bottom of the unit 9 Up to 14 the Battery Monitor modules may be connected the CAN bus 9 CAN bus addressing via DIP switches Read also chapter Technical Specifications, page 14, for more details.

Typical Applications
The Battery Monitor CAN Bus Node is employd in Smartpack-based DC power systems, to implement flexible expansion and distribution of system functionality. The Battery Monitor CAN Bus Node is suitable for distributed monitoring of battery symmetry, fuse, current and temperature of local and remote located battery banks.

Installation Guide Battery Monitor CAN Bus Node

351507.033, Issue 1.1, 2008 Aug

3. Installation of Battery Monitors


You can install the Battery Monitor CAN Bus Node if your DC power system meets the following requirements: 1. The systems Smartpack controller has firmware version 2.03 or higher installed
Version Sensitive

2. You have a PC with PowerSuite application version 2.3 or higher installed

You need standard installation tools and equipment used by an authorized electrician. NOTE: All tools must be insulated.

Safety Precautions
Follow these precautions during installation, commissioning and general handling of the Smartpack-based power supply system.
CAUTION: For safety reasons, the commissioning and configuration of the equipment is only to be performed by Eltek Valeres personnel or by authorized and qualified persons; otherwise the warranty may be invalidated. Please, read the user documentation carefully before installing and using the equipment, as installation and operation is to be performed as described in it. WARNING: The batteries represent a major energy hazard. To avoid short-circuit of battery poles, you must always remove metallic objects uninsulated tools, rings, watches, etc. from the vicinity of the batteries.

Qualified personnel

Electric shock

Basis Installation Steps


Carry out these steps to install the Battery Monitor CAN Bus Node in your DC power system. Refer also to Installation Guide Battery Monitor Symmetry Kit, document number 351497.033, which is included with the kit. Power is ON! 1. Assign the Battery Monitors CAN bus address, by setting the Battery Monitors DIP switches. Read to chapter CAN Bus Addressing, page 12 2. Terminate the CAN bus, by e.g. removing the CAN bus termination plug from the controller and plugging it on the last connected Battery Monitor or node. Read CAN Bus Termination, page 11 3. Attach the Battery Monitor to a battery block; Read chapter Fastening the Battery Monitors, page 7 4. Connect the required input cabling to the terminals; Read chapter Connection Drawing, page 8 5. Configure the Battery Monitor nodes operation, using the PowerSuite application, read chapter About PowerSuite Configuration, page 13

Installation Guide Battery Monitor CAN Bus Node

351507.033, Issue 1.1, 2008 Aug

Fastening the Battery Monitors


You mount the Battery Monitor CAN Bus Node on a battery block, using the Velcroue adhesive tape on the bottom of the module. Thus, the built-in temperature sensor will monitor the battery temperature accurately. For more exact measurements, attach the monitor on the front of a battery block. If not possible, you can fix it on the side of the outer battery block, or on top, or on the cabinets inner side wall

Location of Connectors, Ports, LEDs


Alarm Warning Power
LED Lamp (yellow) LED Lamp (green)

CAN port 1&2

LED Lamp (red) Pin 8 Pin 1

Electrically identical

Battery Monitor

DIP switches
CAN ID address DIP switch #1

Monitor Inputs
Terminal Block

Battery Monitor

Figure 2 Location of terminals, DIP switches, CAN ports and LED indicators in the Battery Monitor

CAN port 1 and 2 are electrically identical, and are used to enable connection of the CAN bus incoming and outgoing CAT5 cables, or the RJ45 CAN bus termination plug.

LED Indicator Power Warning Alarm Other

Illumination Status OFF ON green OFF ON yellow OFF ON red Green ON & Red Flashing Green OFF & Red Flashing

Description The monitor has NO supply The monitor has supply No Warning Warning (Non-critical alarm) No Alarm Alarm (Critical Alarm) Supply voltage too low Firmware boot-loading

Table 1 Description of the Battery Monitors LED illumination status

Installation Guide Battery Monitor CAN Bus Node

351507.033, Issue 1.1, 2008 Aug

Connection Drawing
Use this drawing as a connection reference for all cabling. You find the exact location of connection terminals, plugs and DIP switches, by referring to chapter Location of Connectors, Ports, LEDs, page 7.
To next CAN bus node

Battery Monitor Connections


Battery Monitor Part 242100.300
FUNCTION SIGNAL PIN-OUT

Batt. Symmetry 1 Batt. Symmetry 2 Batt. Symmetry 3 Batt. Symmetry 4

CAN port 1&2


RJ45, 8 pins

From previous CAN bus node

Built-in Battery Temperature Sensor

Figure 3 Connection Drawing Battery Monitor CAN Bus node

Electric shock

WARNING: Switch the battery fuses OFF before connecting the symmetry wires! 1st Fasten the wires to the battery monitor. 2nd Fasten cable lugs to the other cable ends. 3rd Connect the cable lugs to the battery terminals.

Read chapter Battery Symmetry Connections on page 9. Refer also to Installation Guide Battery Monitor Symmetry Kit, document number 351497.033, which is included with the kit. The Battery Fuse and Battery Current cables are not shipped with the Battery Monitor ~ Symmetry Kit. You find more information on chapter Technical Specifications, page 14.

Installation Guide Battery Monitor CAN Bus Node

(From the current shunt) (From the battery fuse) 351507.033, Issue 1.1, 2008 Aug

Or RJ45 CAN bus termination plug, if the Battery Monitor is the last node in the CAN bus

+ + + + Batt. Fuse + Batt. Current +

X:*

1 2 3 4 5 6 7 8
2

1.5 mm , max. wire section

(From the batteries)

Battery Symmetry Connections


Block Measurements
Battery Symmetry String 1 to 4 Block Measurement
Four measurements per string Battery Monitor Part 242100.300 ID# <33> DIP switches for CAN bus addr. 1234 DIP switches for CAN bus addr. Four measurements per string Battery Monitor Part 242100.300 ID# <34> 1234

Symmetry 1.1

Symmetry 1.2

Symmetry 1.3

Symmetry 1.4

Symmetry 2.1

Symmetry 2.2

Symmetry 2.3 + +
Block3

+ Battery String 1 (-48V) Outer Terminal

+ Battery String 2 (-48V) Outer Terminal

Symmetry 2.4 +
Block4

Figure 4 Example of battery symmetry connections. Block measurements 48VDC power systems

- + - + - + - +
Block1 Block3 Block4

- + - + - + - +
Block1

Intercell Links

0V Outer Terminal

Intercell Links

0V Outer Terminal

Four measurements per string Battery Monitor Part 242100.300 ID# <35> DIP switches for CAN bus addr. 1234

Four measurements per string Battery Monitor Part 242100.300 ID# <36> DIP switches for CAN bus addr. 1234

Symmetry 3.1

Symmetry 3.2

Symmetry 3.3

Symmetry 3.4

Symmetry 4.1

Symmetry 4.2

Symmetry 4.3 + +
Block3

+ Battery String 3 (-48V) Outer Terminal

+ Battery String 4 (-48V) Outer Terminal

Symmetry 4.4 +
Block4

- + - + - + - +
Block1 Block3 Block4

- + - + - + - +
Block1

Intercell Links

0V Outer Terminal

Intercell Links

0V Outer Terminal

Notice: Always connect Battery Monitor with ID#<33> to battery string 1 (lowest), with ID#<34> to string 2, and so on. PowerSuite will then refer to the correct battery string.

Installation Guide Battery Monitor CAN Bus Node

351507.033, Issue 1.1, 2008 Aug

Mid-point Measurements
Battery Symmetry String 1 to 4 Mid-point Measurement
One measurement per string, four strings Battery Monitor Part 242100.300 ID# <33> DIP switches for CAN bus addr. + 1234

+ Battery String 4 Symmetry 1.4

Symmetry 1.3 Battery String 3 Symmetry 1.2 Battery String 2 Symmetry 1.1 Battery String 1 (-48V) Outer Terminal

- + - + - + - +
Block1 Block3 Block4

Intercell Links

0V Outer Terminal

Notice: Always connect Battery Monitor with ID#<33> to battery strings 1 (lowest), 2, 3 and 4. Then Battery Monitor with ID#<34> to string 5, 6, 7 and 8. And so on. PowerSuite will then refer to the correct battery string.

Figure 5 Example of battery symmetry connections. Mid-point measurements 48VDC power systems

Battery Terminology
Battery Terminology
Battery Block, Battery String and Battery Bank Battery Block (12V)

Battery String #2 (48V)Batt. Battery String #1 (48V)

48V Battery Bank

Figure 6 Battery bock, battery string and battery bank definitions

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Installation Guide Battery Monitor CAN Bus Node

351507.033, Issue 1.1, 2008 Aug

CAN Bus Termination


To ensure a correct bus communication and avoid data reflection, you must always terminate the CAN bus with two 120 resistors, one at each end of the line (60 bus impedance). Smartpack based systems are shipped from factory with the CAN bus already terminated with 120 resistors. The CAN bus termination is implemented with a special RJ45 plug with built-in 120 end-of-line resistor.
USB A-B cable (standard) 1 CAN bus (twisted-pair CAT5 cable) ID Number Battery Monitor 33 01 34 02 n 120
End-of-Line Resistor

120

End-of-Line Resistor

Battery string #1 Flatpack2 DC Power System

Battery string #2

Figure 7 Example of CAN bus addressing and termination in a Flatpack2 system with two Battery Monitors connected the CAN bus

When connecting Battery Monitor nodes (max. 14 nodes) to the CAN bus, you have to remove the CAN bus termination plug from the Smartpack controllers rear CAN port, and plug it on one of the CAN ports on the last connected Battery Monitor node. See chapter Removing the Smartpack Controller, page 11.

Removing the Smartpack Controller


To access the CAN bus termination plug from the Smartpack controllers rear CAN port, release (1) both handle springs see Figure 8, page 11 and use both handles to cautiously pull out the module. Be careful, as cables are connected to its rear.
Hole to release the handles spring mechanism

Smartpack controller

Handle in locked position

Figure 8 Removing the Smartpack controller

Installation Guide Battery Monitor CAN Bus Node

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11

Configuration
When connecting Battery Monitor nodes to the CAN bus of the Smartpack based DC power system, you have to configure each of the Battery Monitors by: 1. Setting the DIP switches with the correct CAN bus address, to assign a unique ID number to the Battery Monitor, read chapter CAN Bus Addressing, on page 12 2. Configuring the Battery Monitor nodes operation, using the PowerSuite application, read chapter About PowerSuite Configuration, page 13

CAN Bus Addressing


The Smartpack controller dynamically software-assigns ID numbers to rectifiers. The controller registers the rectifiers ID numbers or CAN bus address (01, 02) together with their Serial Numbers. The ID numbers (1, 230) on Smartpack controllers and Smartnode units and Battery Monitors ID numbers (33, 3446) are assigned by DIP switches on the nodes side. A maximum of 14 Battery Monitors and or 28 controllers and Smartnode units may be connected to the CAN bus. Note that if only one Battery Monitor is connected, you have to assign it with ID# 33.
Battery Monitor DIP switch configuration Smartpack controller DIP switch configuration

Battery Monitor 1st Monitor 2nd Monitor 3rd Monitor 4th Monitor 5th Monitor 6th Monitor 7th Monitor 8th Monitor 9th Monitor 10th Monitor 11th Monitor 12th Monitor 13th Monitor 14th Monitor

ID # 33 34 35 36 37 38 39 40 41 42 43 44 45 46

DIP Switch Position 1 2 3 4 OFFOFFOFFOFF ON OFFOFFOFF OFF ONOFFOFF ON ONOFFOFF OFFOFFON OFF ON OFF ONOFF OFFON ON OFF ON ON ONOFF OFFOFFOFFON ON OFFOFFON OFFON OFFON ON ON OFFON OFFOFFON ON ON OFF ON ON

ID <33>

(All switches OFF)

Note: The monitors ID # corresponds to the DIP switchs binary value plus 33

ID <1> Smartpack ID DIP Switch Position (All switches OFF) Controller # 1 2 3 4 Master 1 OFFOFFOFFOFF Slave 1 2 ONOFFOFFOFF Slave 2 3 OFF ONOFFOFF Slave 3 4 ON ONOFFOFF Note that the controllers ID # corresponds to the DIP switchs binary value plus one.

Table 2 Smartpack DIP switch addressing

Table 3 Battery Monitor DIP switch addressing

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Installation Guide Battery Monitor CAN Bus Node

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About PowerSuite Configuration


You have to connect a PC to the systems Smartpack controller and start the PowerSuite application, version 2.3 or higher, to activate and configure the Battery Monitor nodes. Read the PowerSuite applications Online Help for information on how to configure the CAN Bus nodes. In general, the connected Battery Monitor node(s) are displayed in the PowerSuites Power Explorer pane, under the Control System node and under the Battery node. For configuring the Battery Monitor specific settings such as its software alarm monitors for fuse monitoring and current sense inputs, symmetry measurementes inputs, etc open the Battery Monitors icon under the Battery node. Open the Battery Monitors icon under the Control System node to reas the status of the Battery Monitor.
Battery Monitor icon displayed in the Power Explorer pane, under the Battery node

Battery Monitor icon displayed in the Power Explorer pane, under the Control System node

Installation Guide Battery Monitor CAN Bus Node

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4. Technical Specifications
Battery Monitor
Inputs o 4x Symmetry Voltage o 1x Configurable (Fuse failure) o 1x Current sense o Voltage: 76mV o Current (200A): +/- 1A o Symmetry measurement 2, 6, 12, 24, 30 or 36V o Fuse failure NO, NC or Diode Matrix o Current sense 50mV or 60mV shunt o Temperature measurement Embedded in unit 402086.009 90mA

Accuracy based on resolution (calibrated) Functionality

SW Part number Max. CAN Power consumption

CAN Nodes
Max. nodes Mounting Visual Indication 14 units of same type can be added a single CAN bus Slotted groove for post mounting or DIN rail 3xLED (1xLED CAN Power) o GREEN: Power o YELLOW: Warning o RED: Alarm (Flashing LED: insufficient power) FWLoader v3.25 or newer and IXXAT USB-to-CAN Converter (p/n: 208565) Plastic - V0 rated / Steel (CAN Power) -40 to 70C (-40 to 158F) Storage temp -40 to 85C (-40 to 185F)

SW Upload tools Casing material Operating temp

Applicable Standards
Electrical safety IEC 60950-1 UL 60950-1 CSA C22.2 IEC 61000-6-1 IEC 61000-6-2 IEC 61000-6-3 /A1 IEC 61000-6-4 ETSI EN 300 386 v1.3.3 FCC Part 15B Subpart 109 2002/95/EC (RoHS) & 2002/96/EC (WEEE) ETS 300 019-2-1 Class 1.2 ETS 300 019-2-2 Class 2.3 ETS 300 019-2-3 Class 3.2

EMC

Environment

Specifications are subject to change without notice 242100.CAN.DS3 v2(part)

Ordering Information Part no. Description


242100.300 Battery Monitor

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Installation Guide Battery Monitor CAN Bus Node

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Installation Guide Battery Monitor CAN Bus Node

351507.033, Issue 1.1, 2008 Aug

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