BDS-256 with Controller Installation Guide
Contents
1. 3 Panel Controls and Indicators Items on the front and rear panels of the BDS Controller the DCM and the External Load Module which are the discrete components in a typical BDS system are described in the MPM 100 BDS 256 and BDS 40 Monitors Product Description Guide Additional descriptions may appear elsewhere in this manual or related manuals 3 1 Symbols AN This symbol which may appear on equipment panels and cabinets indicates CAUTION Refer to accompanying documents Be sure to read and understand the documents that relate to the particular unit If you do not understand the documentation stop and contact Alb r or an authorized Alb r representative 4 General Information The BDS 256 system consists of Data Collection Modules DCMs External Load Modules and a BDS Controller Additional hardware may include a personal computer PC a cabinet to house the computer and BDS Controller a LAN adaptor DCM tower enclosures a DCM external power supply and if using more than one BDS Controller a Serial Port Multiplexer Upon receipt of a site survey Alb r creates a customer drawing package that contains a system drawing with site specific information Refer to this package and verify all components are available before starting installation The following steps are required for system installation e Prepare the computer cabinet if included or the BDS Controller if no PC is included This includes unpacking mounting2. and connecting the modules e Mount the DCMs close to the battery making sure they are accessible for servicing e Install an insulated wire tray along the length of each battery tier making sure it does not interfere with cell replacement e Install the leads Install the sense leads test current leads 24V AC cable and fiber optic cable connections according to site drawings This manual describes how to terminate the wires at the DCM and cell ends 4 1 Maximum Wire and Cable Lengths Runs of wire cable and fiber optic cable have length limitations as follows e The maximum length for each sense lead resistance test cable and external load control cable is 100 feet 30 5 meters e The maximum length for any one length of plastic fiber optic cable is 50 meters 164 feet e The maximum length for any one length of HCS fiber optic cable is 500 meters 1640 feet 4 2 Fiber Optic Cable When installing the fiber optic cable in the system do not bend the cable in a radius tighter than 35mm Refer to the figure below r35mm 70mm Diagram Not To Scale Figure 1 Minimum Bend Radius of Fiber Optic Cable 5 Communication Connections Connection to a BDS can be via a modem or WAN wide area network from a remote location or on site using the RS 232 Local port or LAN local area network port Both methods let you check all battery parameters This section explains how to set the rear panel configuration DIP switch and
3. 8 9 discharge current sensor 0 0 eects see ee ee 13 disconnect device se se ee ee ee se ee ee 2 dual reading tit 12 earth STOuNnd u EO EE 2 ethernet port on BD 5 fiber Optic siie See also cable fiber optic interface 5 6 fiber optic amplifiers oe nennen 10 flame proof restetor ees ee see ee ee 11 12 float current sensor ee ee eee se se ee ee ee ee 14 form C alarm Contacts see se ee ee ee ee 14 grounding the equipment ees ee ee ee ee ee 2 indicators on panels iese ee ee se ee ee ee ee 3 installation of system with local computer 7 with no local computer ee ee se see se ee 9 intertier CONNECTIONS se see se ee ee ee ee 12 LAN connection ee ese ee ees ee Re Re ee ee ee 8 9 LAN port on BD 5 LEDS On panels u 3 local COMPUTED nennen 7 multiple BDS ee ee ee se ee ee ee ee ee ee 6 local port local port select switch on BDS 5 OD BDS EE ark a ER EE ET 5 Magnetic transducer eee se ee ee ee ee 13 ENEE ss Se ER SE ree n ee ek GR aet 15 MODBUS vet its Ge RE Ee 0288000 esse 9 Modem ss EER EE EE SE De 7 9 BDS EE EE EE HERE 5 port disabled tiese RES ESE EE eg ge di 2 telco cord AMWO AE 5 monitor MUL impida 5 6 multiple monitors ARE rienda 6 Tel HR 2 MUX TD coria 5 6 OV sense lead Sies se EES DE tie 12 preventive maintenance iese sees see se ee ee ee 15 remote reset contactos 14 repeater input output esse see see se ee ee ee 10 TESIS ee ege he e 11 12 E
4. Load Modules may be mounted in a 19 or 23 wide rack in a cabinet enclosure If using such a cabinet you must ground the cabinet and installed equipment The cabinet has several ground lugs of which at least one must be tied to earth ground The DCM and Load Module have protective earth grounding connections that must be connected to earth ground using 1OAWG copper wire The receptacle for the AC cord from the cabinet must have protective earth connection three prong Do not defeat the use of the earth connection prong When connecting equipment via modem to a telephone line use a minimum 26AWG Telco line cord Drawings in this manual may be for reference only or superseded by later drawings For the latest information refer to the drawings supplied with your system 2 3 Disconnect Device The three prong AC cord from the cabinet which connects to the 115V AC receptacle is considered the primary disconnect device 2 4 Ventilation You must provide adequate ventilation to prevent equipment overheating The cabinet has two ventilation fans that run when power is applied The external load module has a fan that runs when required to cool internal circuitry Allow at least 8 clearance on all sides of the cabinet for ventilation Do not block ventilation ports and ensure the equipment is operated within the temperature and humidity ranges in the MPM 100 BDS 256 and BDS 40 Monitors Product Description Guide 4200 039
5. Serial Port Multiplexer User s Guide Part Number Description 1000 290 8 channel RS 232 multiplexer 12V 1000 291 16 channel RS 232 multiplexer 12V 5 6 DIP Switch Configuration For the BDS to function with a Telco or RS 232 multiplexer you must set the configuration DIP switch on the BDS controller rear panel The switch is factory set for BDS 256 operation with the Telco RJ 11 and RS 232 local port enabled To change the switch do the following WARNING Do not use a pencil to change the DIP switch settings Graphite residue may harm the internal BDS components 1 Power off the BDS 2 Change the DIP switch positions 1 through 4 to select Modem or Telco multiplexer Telco fiber optic 3 Change positions 5 through 8 to select RS 232 local port or RS 232 multiplexer Local fiber optic 4 The new switch setting takes effect when power is applied Configuration Modem Rear Panel RS 232 DIP Switch Telco RS 232 Local Position Modem Fiber Optic Local Port Fiber Optic 1 ON OFF X X 2 ON OFF X X 3 OFF ON X X 4 OFF ON X X 5 X X ON OFF 6 X X ON OFF 7 X X OFF ON 8 X X OFF ON Figure 2 DIP Switch Settings 6 System with Local Computer If using a computer and cabinet install the system as follows Place the cabinet where it will be permanently mounted If using a BDS Controller and standard fiber optic cable locate the cabinet so the fiber optic cable run does not exceed 164
6. connect the BDS modem computer and multiplexer When connecting via modem use a minimum 26AWG Telco line cord 5 1 Modem Connection To communicate with a BDS from a remote location connect the BDS rear panel modem connector to a telephone line Connect the Central computer modem to the phone line according to the computer manufacturer s instructions 5 2 Local Port Connection There are two 9 pin RS 232 local ports BDS controller front and rear panels You may use only one port at a time The front panel Local Port Select switch selects the front or rear port When the switch is lit the front port is selected Use the rear port for connecting to a permanent Local computer use the front port when using a portable computer 5 3 Ethernet Port Connection There are two BDS Controller options for Ethernet connection The Controller can have a network interface and a rear panel RJ 45 connector installed If the RJ 45 is not installed you may purchase an Alb r conversion unit that connects to the DB 9 5 4 Telco Serial Port Multiplexer Multiple monitors on one telephone line When only one telephone line is available for multiple BDSs at the same location use the Alb r Telco Serial Port Multiplexer This optional accessory is available in two configurations that can connect up to eight or sixteen BDS monitors with different power requirements When using the Telco Serial Port Multiplexer you must set a DIP switch on the BDS
7. connections are made via the RS 232 DB 9 connectors on the Controller rear panel Either the Local port or LAN connection can be used The only connections made are Tx Pin 2 Rx Pin 3 and GND Pin 5 9 Installing the DCMs You will need the following tools or equivalents to install the DCMs e Panduit CT 260 crimper for fuse holders and terminals Amp crimper 58074 1 handle with 58063 2 head for DB 37 sense lead harness connectors 1 8 flat blade screwdriver for DCM power connectors e Anderson Power Products 1351G1 crimper for Anderson current lead connectors Consider the maximum wire lengths of 100 feet for sense leads resistance test cables and external load control cables when mounting the DCMs and the External Load Module Locate the DCMS and External Load Module as close to the batteries as possible and mount them to allow access for servicing WARNING Install DCMs so that each DCM connects to the cells or modules to which it is assigned Each DCM nameplate indicates the battery string number for multiple string installations and the position of the DCM within that string 9 1 Power and Communications Connections to the DCMs The DCMs communicate with the BDS Controller via fiber optic cable and form a communication ring network The Controller has seven amplified fiber optic repeater input output connectors which may be used to amplify signals before a long fiber optic cable run The maximum length of standard plastic f
8. feet 50 meters from the BDS Controller to the DCM Make sure the back of the cabinet is accessible You must completely fill the container at the bottom of the cabinet with ballast This provides stability to help prevent the cabinet from tipping over The recommended ballast is all purpose sand Sure Mix All Purpose Sand or equivalent available at most home improvement stores WARNING Do not energize the cabinet or any component with 115VAC or battery voltage until after the installation is complete Look at the system drawing and the physical facility and determine how the fiber optic and power cables to the DCMs should exit the cabinet Two 1 2 holes through which wires may be passed are on the left side of the cabinet Normally pass the AC power cord for the power strip mounted inside the cabinet through the lower left hole and plug it into a UPS protected 115V AC outlet after installation is complete The service required is less than 15 amps If using an internally mounted UPS uninterruptible power supply plug the power strip AC cord into the UPS pass the UPS power cord through the hole and plug it into a 115V AC outlet after installation is complete Optionally pass conduit through the lower left hole and mount an outlet box inside the cabinet This must be done by a qualified electrician and meet NEC requirements Install the remaining components as follows Refer to your copy of BDS 183 B597 1 If using an optional U
9. 0 Optional Sensors Optional current and temperature sensors are available for the BDS 256 system 10 1 Discharge Current Sensor The BDS 256 can be used with either a shunt or a magnetic current transducer to measure discharge current These items are specified at time of order When using a magnetic current transducer connect to the Current Transducer connector on the first DCM in the battery string Refer to BDS 173 589 When using a shunt to measure discharge current connect the shunt to the Overall Current connector on DCM 1 Shunts require 2 conductor shielded cable and current transducers require 4 conductor shielded cable Use 10KO 2 watt flameproof resistors to protect the sense wires connected to the shunt 10 2 Temperature Sensor Two types of temperature probes are available for the BDS One probe hangs free for ambient temperature measurement or mounts on a cell post surface The other a Teflon coated probe may be immersed in a flooded cell Using 4 conductor shielded cable wire these sensors to the DCM connector marked Sense Leads 16 24 for the first temperature sensing on the DCM and to 40 48 for the second temperature sensing on the DCM Up to ten temperature probes may be used per battery string and up to two temperature probes may be connected to any DCM associated with that string 13 10 3 Float Current Sensor There is one float current sensor channel available Connect to the DCM rear panel Curren
10. 02 Book Revision 4 02 UL 2015 Alb rcorp 7775 West Oakland Park Blvd Sunrise FL 33351 USA This manual may not be copied in whole or in part without express written permission from Alb rcorp Microsoft Windows is a registered trademark of Microsoft Corporation Pentium is a registered trademark of Intel Corporation Printed in the United States of America ii Table of Contents 1 SAFETY INFORMATION EE 1 LTL 1 You Have Questons rss N N OE OE AO N N Seege 1 De oS VSTEMNOTES NE OE ON N EE ED dit EE EO N 2 AE Equipment Notes ansehe O eain 2 Se O O EG 2 2 3 Disconnect Device oooocococononononononononononononononononononononononononononononononononono nono S oS POP no nono ee ee nono ee ee ee 2 P R e E O EE 2 3 PANEL CONTROLS AND INDICATORS use ee ee ee ee ee ee n se ee ee ee ee Re Re ee ee ee ER Re Re ee ee ee Re Re ee ee ee ER Re ee ee ee Ge Re ee 3 ED ORE EE EA N EE OE EE OE EE 3 4 GENERAL INFORMATION 4 4 1 Maximum Wire and Cable Lengtbs AAA 4 MAN sok SLEE EE EE RO OR AO 4 5 COMMUNICATION CONNECTIONS ccccccccccccsessssececececsesesececececseseeseceecesesenseaeeeeececsenaaeeeeeceesessaassesececeenes 5 5 1 Modem Connection ococococonononononononononononononononononononononononononononononononononononononononononononononono Re Re ge Re ge Re ee ee 5 5 2 Local Port Connecpon ee ee Re Re ee ee ee Ke ee Ke Re Re Re Re Re Ke Re ge Re ee ee 5 5 3 Ethernet Port COmNectiON oocococonononononononono
11. 10 safety pformatpon sees see esse ee ee ee ee ee ee ee ee 1 sense leads nea ee ee ke en Re Re Re Re EE 11 12 sense leads cleantng esse see ee ee Se ee 15 VER RE EN 13 serial port multiplexer eee ee ee ee 6 7 8 9 OK EE AE 5 DIPS Witch ss DAE SEE BEE Ge degt 6 serial port on BDS unsesseesnesnnesnnennnenn 5 servicing CQUIPMENE 0 ee eee eee se ee 15 UR EE EE EO 13 specifications keiten 14 switches on panels cece see ee ee ee Se ee 3 SYMDOIsS se ESE DELE Ee ED Ge pe 3 system diagram ees sees se ee ee ee ee ee ee ee ee 4 telco serial port multiplexer BDS 5 telco cord AMWO ee esse se ee ee RR ee 5 telco cord AWG see ee Re ee GR RA ee 2 temperature gengt 13 test current cable se se ee ee ee GR Re ee 12 ET eg AAR een Bestes 13 EE EE EE EE 10 UPS internal battery sees se see ee se ee ee ee 15 WINE EE EE EE Brass EE 7 yentlat RO RE EE EE 2 AE ee ee See cable tray
12. BDS 256 Battery Diagnostic System with BDS Controller Installation Instructions Alber Wees SEN nd Pa A e FL 3335 Tel 954 a 7101 Fax 05 377 7042 R4200 028R4 02 BDS 256 Battery Diagnostic System with BDS Controller Installation Instructions Alber wa SEN Kand Pa Zeg d e FL 3335 Tel 954 a 7101 Fax SC 377 7042 www alber com 1 WARRANTY AND LIMITATION OF LIABILITY LIMITED WARRANTY Alb rcorp warrants that the software product will perform in accordance with the accompanying written materials for a period of ninety 90 days from the date of receipt Some states and jurisdictions do not allow limitations on duration of an implied warranty so the above limitation may not apply to you To the extent allowed by applicable law implied warranties on the software product if any are limited to ninety 90 days CUSTOMER REMEDIES Alb rcorp s entire liability and your exclusive remedy shall be at Alb rcorp s option either return of the price paid or replacement of the software product that is returned to Alb rcorp with proof of purchase This Limited Warranty is void if failure of the software product has resulted from accident abuse or misapplication Any replacement software product will be warranted for the remainder of the original period or thirty 30 days whichever is longer Alb rcorp shall not be liable for any data or programs stored in or used in conjunction with this software product Without pr
13. OFF ON ON Multiplexer Figure 3 Configuration DIP Switch Settings If using two or more BDS Controllers with one local computer connect the Serial Port Multiplexer to the local computer then connect the BDS Controllers to the Serial Port Multiplexer using fiber optic cable Refer to the System Block Diagram and to the Serial Port Multiplexer manual If connecting through a LAN connect the TCP IP adaptor to the BDS Controller RS 232 connector labeled LAN Refer to the System Block Diagram and the network interface adaptor manual NOTE Make certain the DIP switch is set for the configuration being used Installing the fiber optic and 24 volt power cables from the BDS Controller to the DCMs is the last step but do not do this until the DCMs have been physically mounted in place 7 System with No Local Computer If a local computer and cabinet are not being used install the BDS Controller as follows 1 Provide UPS protected 115V AC power to the location where each BDS Controller will be installed Unpack the BDS Controller and if mounting it in the 19 rack or tower enclosure install 1t below the computer Connect the AC power cord to the UPS protected outlet If using a modem to dial out connect the phone line to the RJ 11 jack on the Controller rear panel Use a minimum 26AWG Telco line cord If using two or more BDS Controllers with one telephone line connect the Serial Port Multiplexer to the phone line then conn
14. PS install it towards the bottom of the rack 2 Install the computer video display monitor on the cabinet top shelf Connect the power cord to the power strip 3 Install the computer PC on the shelf below the display Connect the power cord to the power strip 4 Connect the display to the computer Install the keyboard in the keyboard drawer and connect it to the computer 6 Unpack the BDS Controller If mounting it in the 19 rack install it below the computer Connect an RS 232C cable from the BDS Controller to a COM port on the computer Plug the power cord into the power strip 7 If using a modem to dial out connect the phone line to the RJ 11 jack on the Controller rear panel Use a minimum 26AWG Telco line cord If using two or more BDS Controllers with one telephone line connect the Serial Port Multiplexer to the phone line then connect the BDS Controllers to the Serial Port Multiplexer using fiber optic cable Refer to the System Block Diagram and the Serial Port Multiplexer manual The BDS Controller has a rear panel DIP switch that allows the Controller to be used with up to two Serial Port Multiplexers The DIP switch settings are as follows DIP Switch Number 1 2 3 4 5 6 7 8 Telco Port Line ON ON OFF OFF x x x x Telco Port Fiber Optic to Serial Port OFF OFF ON ON x D D D Multiplexer Rear Local Port RS X x x X ON ON OFF OFF 232 Rear Local Port Fiber Optic to Serial Port x x x x OFF
15. ance readings are combined in one measurement Most battery installations have cables connecting groups of cells on different levels tiers within a battery string Because these intertier cables normally have higher resistance than intercell connections additional sense leads are used to monitor the resistance of these cables Up to ten intertier channels per DCM are provided The software accommodates up to 15 intertier connections per battery CAUTION The sense leads monitoring an intertier connection must be from the DCM measuring the cell that has its negative post connected to the beginning of the intertier cable Dual Readings defined Internal cell resistance and intercell resistance readings are separate There are no additional sense leads required Select the intertiers under Battery Setup in the BMDM program 9 5 Internal Resistance Test Current Cable Connections Resistance test current cables connect from the External Load Modules to certain cells in the battery string Cable is supplied based on an average of 35 feet per lead unless a special length is ordered Cut these cables to the proper length before termination WARNING Before making any connections ensure that the fuses are removed from the fuse holders Do not install the fuses until the time that the entire system is commissioned Connect the first resistance test current cable to the positive post of the first cell The last lead connects to the negative post
16. controller This activates a fiber optic interface that replaces the modem and connects to the multiplexer With this option the RJ 11 modem port is disabled but still present Each unit connected to the multiplexer requires a unique MUX ID This setting is under SetuplSystemlLink on the BMDM program Refer to the BMDM manual and the Serial Port Multiplexer User s Guide Part Number Description 1000 292 8 channel Telco multiplexer 12V 1000 293 16 channel Telco multiplexer 12V 5 5 RS 232 Serial Port Multiplexer Multiple monitors on one Local computer When only one Local computer is available for multiple BDSs at the same location use the RS 232 Serial Port Multiplexer This optional accessory is available in two configurations that can connect up to eight or sixteen BDS monitors with different power requirements When using the RS 232 Serial Port Multiplexer you must set a DIP switch on the BDS controller rear panel This activates a fiber optic interface that replaces the rear RS 232 Local port and connects to the multiplexer With this option the BDS front panel Local port is still available however if you connect a Service computer to this port for servicing or setup set the BDS Local Port Select switch to select the front port NOTE The rear RS 232 connector is still present but should not be used Each unit connected to the multiplexer requires a unique MUX ID This setting is under SetuplSystemlLink Refer to the BMDM manual and
17. ect the BDS Controller to the Serial Port Multiplexer using fiber optic cable Refer to the System Block Diagram and the Serial Port Multiplexer manual The BDS Controller has a rear panel DIP switch that allows the Controller to be used with up to two Serial Port Multiplexers The DIP switch settings are as follows DIP Switch Number 1 2 3 4 5 6 7 8 Telco Port Line ON ON OFF OFF x x x x Telco Port Fiber Optic to Serial Port OFF OFF ON ON x D D D Multiplexer Rear Local Port RS X x x X ON ON OFF OFF 232 Rear Local Port Fiber Optic to Serial Port x x x x OFF OFF ON ON Multiplexer Figure 4 Configuration DIP Switch Settings If connecting through a LAN connect the TCP IP adaptor to the BDS Controller RS 232 connector labeled LAN Refer to the System Block Diagram and the network interface adaptor manual NOTE Make certain the DIP switch is set for the configuration being used Installing the fiber optic and 24 volt power cables from the BDS Controller to the DCMs is the last step but do not do this until the DCMs have been physically mounted in place 8 Connecting to a Building Management System The BDS 256 system can be connected to building management systems This integration requires writing software that can communicate with the BDS The communication protocol is MODBUS ASCII You may obtain a register map from Alb r or download it from the Alb r Web site technical library at www alber com The
18. ejudice to the foregoing generality Alb rcorp shall not be liable for the loss or corruption of data or programs stored in or used in conjunction with this or any other software product nor shall Alb rcorp be liable for the cost of retrieving or replacing lost or corrupted data Alb rcorp s sole and exclusive liability for any and all losses and damages arising out of any cause whatsoever shall in no event exceed the purchase price of the software product purchased NO LIABILITY FOR CONSEQUENTIAL DAMAGES ALB RCORP SHALL NOT IN ANY CASE BE LIABLE FOR ANY DAMAGES INCLUDING SPECIAL INCIDENTAL INDIRECT EXEMPLARY COLLATERAL OR CONSEQUENTIAL ARISING FROM BREACH OF WARRANTY BREACH OF CONTRACT NEGLIGENCE OR UNDER ANY OTHER LEGAL THEORY ARISING FROM THE WARRANTY HEREIN STATED OR THE PURCHASE OF PRODUCT INCLUDING WITHOUT LIMITATION LOSS OF PROFITS USE OR GOODWILL NO LIABILITY FOR UPDATES IN PRODUCT WARRANTY Some states and countries do not allow the exclusion or limitation of incidental or consequential damages therefore the above exclusion or limitation may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary state to state and country to country Alb rcorp 7715 West Oakland Park Blvd Sunrise FL 33351 Information in this document is subject to change without notice BDS 256 Battery Diagnostic System with BDS Controller Installation Instructions Part Number 4200 028R4
19. em component panels controls and connectors If you detect any damage remove the equipment from service until the damage is repaired WARNING Before cleaning equipment ensure the system is disconnected and power to the units has been shut off You must disconnect the BDS system cabinet and system components controller DCM load module UPS etc from any DC voltage sources and from any AC power sources Cleaning System Components The BDS system will provide years of service if properly maintained Clean system components using a soft cloth slightly moistened with water Do not use commercial or industrial cleaners that may attack the computer display and housing Never expose the computer or any system component to water high humidity or dampness Fans and Vents Remove dust from fans and vents using a small brush or hand held vacuum Sense Leads Clean the sense leads as required The acid to which the sense lead clips are exposed during testing should be neutralized often using a water and baking soda mixture Brush this mixture onto the sense lead clip then rinse well with clean cool tap water Before cleaning the sense lead clips ensure the system is disconnected and power to the system has been shut off Dry with a clean soft cloth Internal Components The BDS system has no user replaceable components Because high voltage exists in several areas in each unit only knowledgeable users should remove the covers or cowling f
20. es BDS 1116 A479 Sub Assembly Temperature Connections BDS eee se se ee ee Re ee ee ee cnn ee Se ee BDS 136 A397 1v 1 Safety Information Except as explained in this manual do not attempt to service Alb r equipment yourself Opening the equipment may expose you to dangerous voltages Refer servicing beyond that described in this manual to authorized personnel Do not allow liquids or moisture to get into the equipment If liquid does get into the equipment unplug it immediately and contact your nearest authorized service center or Alb r directly Ensure equipment is provided adequate ventilation Do not block equipment ventilation openings Do not exceed equipment voltage or power ratings and capabilities Make sure that equipment is properly grounded Do not let unauthorized persons operate the equipment Do not energize the cabinet or any component with 115VAC or battery voltage until after the installation is complete Use of this product in a manner not specified could compromise the designed in safety of this product High voltage or current may be present inside the equipment and on the equipment terminals Only qualified personnel should perform the operations described in this manual Calibration must be performed only by technically qualified persons Observe electrical safety precautions when removing and installing equipment covers and when connecting leads and making adjustments Proper installation is essen
21. iber optic cable that may be used is 164 feet 50 meters The maximum length using HCS fiber optic cable is 1640 feet 500 meters The transmit TX FO of the BDS Controller connects to the receive RX FO of a DCM The transmit of this DCM connects to the receive of the next DCM and so on until the transmit of the last DCM returns to the receive of the BDS Controller BDS CONTROLLER 1 2 3 4 5 7 RX TX RX TX RX TX RX TX RX TX RX TX RX RX FO TX FO Figure 5 DCM Connection Without Repeater Amplifiers IMPORTANT NOTE Unlike the requirement for connecting DCMs to battery strings the string and address assignments on the DCM nameplates do not determine the order in which DCMs are connected within the fiber optic ring of the system 10 Another way to connect the fiber optic cables is to make an individual connection home run between each string to the repeaters on the BDS Controller This is recommended when possible to simplify the troubleshooting of communication problems BDS CONTROLLER 1 2 3 4 5 7 TX RX TX RX TX RX TX RX TX RX TX RX TX RX RX FO TX FO Figure 6 DCM Connection Using Repeater Amplifiers A pair of 16 AWG wires supplying 24V AC power connects from the BDS Controller to the External Load Module and to the DCMs of each string There are four 24 volt output connectors on the BDS Controller The first two connectors can supply a combined total of 12 amps and the last two can su
22. nonononononononononononononononononononononononono nono nonono ee ee ee ee ee ee 5 5 4 Telco Serial Port Multiplexer AAA 5 5 5 RS 232 Serial Port Multiplexer A 6 5 6 DIP Switch Configuration 2 22422442 se ee ee Ge ee ee ee ere GR GR RA Rd Ge eror Ge ee ee ee ee ee ee 6 6 SYSTEM WITH LOCAL COMPUTER 7 7 SYSTEM WITH NO LOCAL COMPUTER ese ese ee ee ee ee se ee ese ee ee ee ER Re ee ee ee ER ee ee ee ee RR nn ee ee ee Re Re ee ee ee 9 8 CONNECTING TO A BUILDING MANAGEMENT SYSTEM esse ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee se ee ee ee ee ee ee ee ee ee ee eke ee 9 9 INSTALLING THE DEMS 2 82 22 ann ed be ves Gee EE de ee et th bape De det Ge ee Gee ee Vee tenes bee r es 10 9 1 Power and Communications Connections to the DCMs eie ese sees ee Re Re Re Re Re Re Re Re Re Re Re Re ke ee ee 10 9 2 Sense Lead Harness Routing from DCMS to the Batter 11 9 3 Cell Voltage Sense Lead Connectong nono no cono Ge ee be crac ee ee cnn non Re ee recono 11 9 4 Antertier Conne A ee 12 9 5 Internal Resistance Test Current Cable ConnectiONS o oooooconononononononononononononononononononononononononononos 12 9 6 Overall Voltage Sense Leads 00 eee cee ee ee ee ee Ge Ge GR GR GR GRA Re ee ee ee ee ES a VEs ee 12 9 7 External Load Module Control Cable ConnectOnS iese ese ese ee ee ee ee Re Re Re Re Re Re Re Re Re Re Re Re Re ee ke 13 10 OPTIONAL SENSORS id ee See oe se eb see baa Yoh Gee ee SE ee ee Ge 13 10 1 Discharge C
23. of the last cell Other connections depend on the battery configuration Refer to the drawing DCM to Battery Connections for a connection diagram Again verify fuses are removed from fuse holders before making any battery connections Refer to your drawings for resistance test current cable construction details Identify each cable at the External Load Module to facilitate servicing 9 6 Overall Voltage Sense Leads Connect the Overall Voltage sense leads to DCM 1 The OV wires run from the Overall Voltage connector to the most positive and the most negative posts of the battery string Be sure to install 10K 1 2W flameproof resistors at the battery connection points 12 9 7 External Load Module Control Cable Connections The DCM External Load Module for each string is controlled by the DCMS assigned to monitor that string Connect the DCMs and the Module using the 15 conductor cable supplied with the installation kit Connect the cable from the DCM Load Control connectors to the External Load Module rear panel connectors starting with connector DCM 1 WARNING Before making any connections to the battery verify the fuses have been removed from the fuse holders Do not install the fuses until the time that the entire system is commissioned WARNING In hazardous voltage applications where battery voltage is greater than 60VDC remove the load cable fuse before disconnecting the load cable connector from the BDS load module 1
24. pply a combined total of 12 amps Each DCM consumes 400mA Do not exceed the total current for either group of connections 9 2 Sense Lead Harness Routing from DCMs to the Battery The installer normally determines the wire routing Do not route the wires in the same conduit as other wires in the facility A Panduit or equivalent slotted cable tray with cover is normally used to distribute wires to the cells Suggested slotted cable trays and covers are Panduit E1X1L66 with C1L66 or ESX3L66 with C5L66 9 3 Cell Voltage Sense Lead Connections Voltage sense leads connect from each DCM to the individual cells Cut each sense lead to the appropriate length and assemble it using BDS 120 A373 The sense lead resistor assemblies include a 10K 2W 1 flameproof resistor that reduces the risk of a short circuit during installation and maintenance Drawing DCM to Battery Connections has a schematic of these connections Properly identify each sense lead to simplify the connection process When connecting a sense lead to the same battery terminal as the load cable the load cable must be closest to the cell post Refer to your copy of BDS 123 A380 NOTE The last sense lead on a DCM connects to the same point as the first sense lead of the next DCM within a battery string Refer to the DCM to Battery Connections drawing in your drawing package 11 9 4 Intertier Connections Combined Readings defined Internal cell resistance and intercell resist
25. rom system components controller DCM load module UPS etc when required Failure to comply with this restriction could pose a safety hazard and or void the system warranty WARNING High voltages exist inside the BDS system components and on the terminals Calibration must be performed only by technically qualified persons Observe electrical safety precautions when removing and installing equipment covers and when connecting leads and making adjustments UPS Uninterruptible Power Supply If you are using an optional UPS with the BDS system be certain the UPS internal battery is functional Follow instructions in the UPS manufacturer manual Shipping Protect the BDS system from bumps and bangs during normal use or storage and provide protection during shipment between test sites 15 Index ZAVAC POWER sans 11 AC power receptacle i e se EES RE EN 2 Alarm Contacts 14 building mgt system ees sesse ee ee ee ee ee ee 9 Cabinet WINING ete 7 cable Cabl Mina 11 fiber optic length esse see see se ee ee ee ee 10 fiber Optic radiUS see se se ee RA ee ee 4 maximum length 4 10 sensedeads init siii 11 t st CUM iii 12 combined readmngs ese ee ee GR ee ee 12 configuration settings ees sesse ese ee ee ee 8 9 connectors on panels se see ee ee se ee ee 3 control cables ecos REEDE 004 13 current transducer eee ee se se se ee ee ee ee 13 DIPS Witch RE ER 80855 6 DIP switch settings iese se see see ee se ee ee
26. t Transducer connector on the first DCM in the battery string This connector is shared with the discharge current sensor Refer to your copy of BDS 1124 A493 and the Float Charging Current Probe User s Manual for termination details 11 Alarm Contacts and Remote Alarm Reset There are two sets of Form C alarm contacts labeled Critical and Maintenance on the BDS Controller rear panel Each set of connections has a COM Common NC Normally Closed and NO Normally Open terminal These alarms are software configurable under the Setup selection on the Main Menu Connection can be made directly to a facility s alarm reporting system If there is more than one BDS at the same location and only one set of contacts can be monitored the alarm contacts can be wired in parallel The remote reset contact is on the BDS Controller rear panel A connection can be made directly to a local alarm reporting system that provides active voltage from 12VDC to 32VDC for reset If there is more than one BDS at the same location and only one set of contacts is available for reset these inputs can be wired in parallel 12 BDS System Specifications Specification sheets for the discrete components in a typical BDS system are in the MPM 100 BDS 256 and BDS 40 Monitors Product Description Guide 14 13 Preventive Maintenance Visual Inspection Visually inspect all BDS system components for damaged or frayed power cords and cables and damaged BDS syst
27. tial to the correct functioning of your system If you have any questions about installation please contact Alb r for assistance This manual describes the general installation and use of the BDS 256 system If your system has features or accessories not addressed in this manual please contact Alb r Drawings in this manual may be for reference only or superseded by later drawings For the latest information refer to the drawings supplied with your system 1 1 If You Have Questions Proper installation and testing are essential to the correct functioning of your system If you have questions contact Alb r at 954 377 7101 or fax 954 377 7042 Request BDS assistance 2 System Notes The following are notes for a typical BDS system 2 1 Equipment Notes Only equipment that is part of the BDS system should be installed in the BDS cabinet The four corners of the cabinet must be securely mounted to the floor In this manual the term cell refers to either cell or module where appropriate 2 2 Wiring WARNING The BDS system is designed to connect to UPS systems that are 600VDC or less and a maximum of 300V with respect to earth ground The voltage with respect to earth ground must be verified before connecting the system This can be done by measuring the voltage from each battery post referenced to earth ground The voltage cannot exceed 300V A BDS 256 system which includes a BDS Controller DCMs and External
28. urrent Sensor unseren air ni BEE 13 10 2 Temperature EE ER OR RE OE OE ES ON EE eed ved 13 10 3 Float Current SENSOL iiss es ee 8225er en ng Se Ee ee ee ee 14 11 ALARM CONTACTS AND REMOTE ALARM RESET iese ee ese se ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ge ee ee ee ee ee Re ee ee ee 14 12 BDS SYSTEM SPECIFICA REENEN 14 13 PREVENTIVE MAINTENANCE EE 15 111 Required Drawings IMPORTANT NOTE The following drawings are required for BDS 256 installation The drawings in this manual may not be of the latest revision and are included for reference only Refer to the Engineering Drawing Package included with your system for drawings with the latest revisions General Assembly BDS Controller cursi bien BDS 183 B597 General Assembly DEM ASOR o 2 32 82 essen rs BDS 173 B589 General Assembly BDS 256 External Load Module BDS 165 B583 Fabrication Detail Resistor Lead Assembly BDS sesse se ee ee Re ee GR Re ee GR Re ee ee BDS 1202 A598 600V Fused Load Lead BOS cirio is BDS 193 A453 Quick Connect Post Clip Leads BD BDS 163 A424 Quick Connect Sense Load Leads BDS ee se ee RR GR ee ER Re GE RA GR ee ee ER nennen BDS 123 A380 Quick Connect C Clamp Leads BDS A BDS 127 A381 Current Transducer Connection DCM 480 eise se se ee ee ee ER Re ee ee ee ee ee ee ee ee ee ee BDS 1132 A501 Current Transducer Float Connections DCM A0 BDS 1124 A493 Overall Voltage Cable DEMEA8O ee see ESE EG SEGE EE EE egg on GE gee see s
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