Franklin Electric CELLGUARD GEN III Installation Manual
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Franklin Electric CELLGUARD GEN III Installation Manual

Wireless battery monitoring system
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CELLGUARD
WIRELESS BATTERY
TM
MONITORING SYSTEM
GEN III
installation guide

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Summary of Contents for Franklin Electric CELLGUARD GEN III

  • Page 1 CELLGUARD WIRELESS BATTERY MONITORING SYSTEM GEN III installation guide...
  • Page 2 Copyright © 2021 Franklin Electric Co., Inc., Madison, WI 53718. All world rights reserved. No part of this publication may be stored in a retrieval system, transmitted, or reproduced in any way, including, but not limited to, photocopy, photograph, magnetic, or other record, without the prior written permission of Franklin Electric Co., Inc.

  • Page 3: Table Of Contents

    CONTENTS INTRODUCTION..........................1 SYSTEM TOPOLOGY........................1 BASE COORDINATOR UNIT (BCU) ....................2 SENSORS .............................4 SAFETY PRECAUTIONS ........................5 HARDWARE INSTALLATION: SENSORS & VTC ................7 SENSORS .............................7 REQUIRED TOOLS ........................7 PROPER PPE (SEE SAFETY PRECAUTIONS) ..................7 SENSOR INSTALLATION .......................8 INSTALLING THE SENSORS WITH STRAP RESISTANCE ..............15 VTC ............................17 CURRENT TRANSDUCER INSTALLATION ..................23 SOLID-CORE CURRENT TRANSDUCER INSTALLATION ..............26...
  • Page 4 Intentionally Blank...

  • Page 5: Introduction

    INTRODUCTION SYSTEM TOPOLOGY The Gen III Wireless Battery Monitoring System (BMS): • Provides accurate and reliable indication of battery state of health through monitoring and analysis of battery voltage, temperature, and conductance. • Detects specific battery deterioration and battery string failures and provides automatic alarms via;...

  • Page 6: Base Coordinator Unit (Bcu)

    BASE COORDINATOR UNIT (BCU) FEATURES • Supports up to 16 Battery Strings. • 600 cells/batteries total per BCU. • Network Communications via: • TCP/IP Ethernet/Intranet • Modbus over TCP/IP • MQTT • SNMP v3 • 2 Form C Dry Contacts. •...
  • Page 7 Examples of BCU String Configurations: • If 60 cells per string, then the max is 10 strings (60 x 10 = 600) • If 4 batteries per string, then the max is 16 strings (4 x 16 = 64) • If 24 cells per string, then the max is 16 strings (24 x 16 = 384) •...

  • Page 8: Sensors

    SENSORS FEATURES • One sensor per cell/battery. • Sensor Types: 2V, 6V-12V, 12V. • Sensor Measurements: Voltage, Temperature, Conductance, Strap Resistance. • Mesh Routing Communication. • Quick, fully hot swappable sensor and/or wiring harness. • Remote upgradable firmware. • Compatible with VRLA batteries and VLA cells. •...

  • Page 9: Safety Precautions

    SAFETY PRECAUTIONS IMPORTANT: Read this manual before installing the products. WARNING: To avoid electrical shock when testing jars, follow your company's safety practices and these guidelines: 1. IMPORTANT SAFETY INSTRUCTIONS. IT IS OF UTMOST IMPORTANCE THAT BEFORE INSTALLING YOUR SYSTEM YOU READ THIS MANUAL AND FOLLOW THE SAFETY AND OPERATING INSTRUCTIONS.
  • Page 10 c. Always have someone within range of your voice, or close enough to come to your aid, when working around lead acid batteries. d. Have plenty of fresh water and baking soda nearby in case battery acid contacts skin, clothing or eyes. e.

  • Page 11: Hardware Installation: Sensors & Vtc

    HARDWARE INSTALLATION: SENSORS & VTC SENSORS REQUIRED TOOLS • Insulated Torque Wrench • Insulated Sockets and Extension PROPER PPE (SEE SAFETY PRECAUTIONS) Use of Personal Protection Equipment (PPE) and Protective Clothing per NFPA 70E guidelines. Some examples of these, but not limited to, are: •...

  • Page 12: Sensor Installation

    SENSOR INSTALLATION NOTE: When installing tabs on the first and last batteries, installation of the VTC string voltage cable and/or the DC to DC cable and solid core transducers should be done with ring terminals to prevent having to disconnect ring terminals multiple times. See the VTC Installation and Powering BCU sections.
  • Page 13 NOTE: The path of current flow to the battery string (conventional current flow, positive to negative). WARNING: When working on batteries, use proper PPE. • The bolt hardware MUST be arranged as follows (from bolt head to bottom): • Lock-Washer •...
  • Page 14 SPECIAL CONDITIONS: For deep well connections such as on OPz cells, spacers may be needed to obtain proper connection. TAB TERMINAL INSTALLATION The bolt hardware MUST be arranged as follows (from bolt head to bottom): Lock-Washer Washer FE GRID Solutions Tabbed Washer FE GRID Solutions spacer(s) (must use FE hardware) Inter-cell connector...
  • Page 15 BATTERY SENSOR TERMINAL INSTALLATION Two-Tab Terminal Installation 1. Remove bolt and washers. 2. Install tab terminal as shown. NOTE: Ensure wide tab (.250 wide tab) is on the bottom touching the strap and narrow tab (.187 wide tab) is on top touching the washer and bolt.
  • Page 16 Four-Tab Terminal Installation 1. Remove bolt and washers. 2. Install with orientation as follows: a. Bottom portion of terminal surface indicated, with the two .250 wide tabs, contacts the strap. (These are the wider tabs) b. Top portion of terminal surface indicated, with the two .187 wide tabs, contacts the washer and bolt.
  • Page 17 • Make sure the battery string is powered down. NOTE: For CELLGUARD™ BMS Battery 1 is always the most positive battery in the string regardless if it is a positive grounded battery system. • Always install the BLACK and BLUE wires first.

  • Page 19: Installing The Sensors With Strap Resistance

    INSTALLING THE SENSORS WITH STRAP RESISTANCE • First battery or cell: On Negative Post; install BLACK and BLUE • wire to the upper .187 narrow terminal. BROWN • On negative post; install wire to lower .250 wider terminal. ORANGE • On First battery Only;...
  • Page 20 NOTE: When the ORANGE YELLOW wires cannot make the reach for tier to tier or battery shelf to shelf connections, treat these connects like the first battery/cell. and YELLOW. • When first installed, Sensors will flash • Indication that sensors are on the factory RF channel and need to be commissioned to the BCU.

  • Page 21: Vtc

    REQUIRED TOOLS • Insulated Torque Wrench • Insulated Socket Set • Phillips-Head Screwdriver • Crimping tool • Wire stripper PROPER PPE Per site requirement • Verify Battery String is OFFLINE (Battery breaker/disconnect switch is open) before installing string voltage/VTC Power cable. •...
  • Page 22 • Remove power cable fuses. • On the Positive and Negative leads, hold the fuse holder and twist lock ring. • Once lock ring is loose, pull cable sections apart. • Fuse can be pulled out of fuse socket without twisting. •...
  • Page 23 • Stack the most positive hardware . • The bolt hardware MUST be arranged as follows (from bolt head to bottom): Lock-Washer Washer VTC Power Cable, wire ring terminal. FE GRID Solutions tabbed washer. • The FE GRID Tab must be closest to the battery to ensure accurate readings. •...
  • Page 24 • Install most positive connection. • Verify the battery string breaker is OPEN before installing the String Voltage Cable. • Attach the (Positive, +) wire of the string voltage cable to the positive terminal of battery/cell 1 or a positive termination on the battery side of the string breaker.
  • Page 25 • Repeat process for negative terminal. • Remove the Most Negative Bolt. • Ensure the Feeder cable is electrically safe. • Arrange the Negative hardware stack as previously arranged for the positive stack. Attach the BLACK (Negative, -) wire of the string voltage cable to the negative terminal •...
  • Page 26 • Repeat prior steps for the most negative connection. • Verify the battery string breaker is OPEN before installing the String Voltage Cable. Attach the BLACK (Negative, -) wire of the string voltage cable to the negative terminal • of the last battery/cell in the string, or a negative termination on the battery side of the string breaker.

  • Page 27: Current Transducer Installation

    CURRENT TRANSDUCER INSTALLATION Two Current Transducer Options: • Option #1; Solid Core...
  • Page 28 • Option #2; Split-Core • Verify the battery string breaker is OPEN before installing the Current Transducer. • Identify a location in the battery string on the battery side of the breaker where the current transducer can be safely and securely mounted. •...
  • Page 29 • The battery string cable, strap, or conductor must pass through the Current Transducer aperture with positive to negative current flow in the direction of the arrow on top of the Current Transducer (CT). • If installing the CT near a strap or cable that connects to a POSITIVE terminal, the arrow should point TOWARDS the positive terminal.

  • Page 30: Solid-Core Current Transducer Installation

    SOLID-CORE CURRENT TRANSDUCER INSTALLATION...
  • Page 31 • When multiple parallel current carrying cables cannot fit through the current transducer aperture, a current multiplier must be applied during commissioning > current multiplier, which is a parameter setting under the string configuration.

  • Page 32: Ground Cable Installation

    GROUND CABLE INSTALLATION Ground Cable • Crimp a ring terminal onto the silvered end of the ground cable. • Connect ground wire to a proper earth ground. • Attach the ground wire lug to the GROUND connector on the back of the VTC. Carefully tighten the screw upon completion so as not to strip the terminal threads inside of the VTC.
  • Page 33 • Plug in cables for Temperature and Current Transducer. • Connect the 4-pin connector for the Ambient Temperature Sensor cable to the TEMPERATURE port. (Optional) Connect the 6-pin connector for the CT cable to the CURRENT PROBE port. • • The 2-pin connector, “POWER TO BCU,”...

  • Page 34: Powering Up The Vtc

    POWERING UP THE VTC 1. First, Connect the 3 pin (2 wires) a. Connector from the VTC Power cable and/or the VTC Inductor Assembly to the STRING VOLTAGE port. 2. Next, install fuse into negative cable . a. Insert the fuse into the fuse holder and tighten twist lock ring. 3.

  • Page 35: Bcu Installation And Power

    BCU INSTALLATION AND POWER POWERING THE BCU BCU Can be powered in two different ways: • Option #1 - - AC Input, DC Output power supply into a wall outlet. • Option #2 - - DC to DC Converter from the battery string. In all cases to set up the BCU you must have: •...
  • Page 36 POWERING THE BCU (OPTION #2) • DC to DC Converter • Connect positive and negative terminals to the battery string. • Positive to most positive battery in the string. • Negative to the most negative battery in the string. • Connect wires to the connections on the converter. •...

  • Page 37: Wiring The 100Vdc-1000Vdc

    WIRING THE 100VDC-1000VDC CONNECTING THE HARNESS 1. Loosen terminal pins 1, 3, 4, 7, and ensure terminal pins 2, 5 and 6 are tightened closed. 2. Insert the red wire of harness P/N 10000006864 into terminal 3 (+Vin) and tighten. 3.

  • Page 38: 48Vdc To Dc Converter Installation

    48VDC TO DC CONVERTER INSTALLATION DC-DC Converter Specifications • Input Voltage Range: 42 - 65 Vdc • Output Voltage: 12 Vdc +/-1% Load Regulation • Output Power: 10 Watts Max • Power Consumption: 1.8 Watts • Power Efficiency: 86% Typical •...

  • Page 39: Setting Up A Connection To The Bcu

    SETTING UP A CONNECTION TO THE BCU CONNECTING TO A LAPTOP/PC • To access the BCU using a web browser interface, connect a PC to the BCU through the Ethernet port. • If BCU is already networked, you can access the BCU by directly connecting over the same network as the BCU using Chrome, Firefox , or Safari®.

  • Page 40: Gen 3 Bcu Web Interface To Windows® 10

    GEN 3 BCU WEB INTERFACE TO WINDOWS® 10 • Update connection properties for ability to direct connect to BCU module using Ethernet(RJ-45) Cat 5-6 cable. NOTE: See Windows® 7 Connection to BCU for information about connecting the BCU to Windows® 7. •...

  • Page 41: Accessing The Web Browser Interface

    ACCESSING THE WEB BROWSER INTERFACE NOTE: The first time you login you must create a password for user: ADMIN. • Using laptop or PC, open a web browser. • Setup of network parameters covered in previous section. • Type in HTTPS://192.168.168.168 . YOU MUST USE HTTPS: •...
  • Page 42 • Once logged in, navigate to Settings-Configuration and set time out to a minimum of 8 hours. • Date/ Time: NOTE: Navigate to Configuration, and set the time zone before setting the correct date and time under date and time section. •...

  • Page 43: Hardware Commissioning Sensors And Vtc

    HARDWARE COMMISSIONING SENSORS AND VTC SENSOR COMMISSIONING QR CODE SCANNER Ensure BCU and QR code scanner are attached to laptop and powered. NOTE: The scanner must have the ability to scan a QR code. Simple bar scanners will not scan sensor data.

  • Page 44: Scanning Sensor Data

    SCANNING SENSOR DATA • Label each sensor with a sting number and sensor number prior to scanning sensors with the QR code scanner. NOTE: Sensors must be scanned in order. • Example: 24 battery sting > string 1/sensor 1 is first to scan, string 1/Sensor 2 is next, then string 1/sensor 3, then string 1/sensor 4, and so on until all 24 sensors for string 1 are successfully scanned.

  • Page 45: Configure System Parameters

    CONFIGURE SYSTEM PARAMETERS >> • Click " " to expand a group to see the full programming section. • Click " " to add a String Battery. • Click " " to delete a String, Battery. • Navigate to Settings > Configuration. •...

  • Page 46: Battery Data Entry

    BATTERY DATA ENTRY ENTERING BATTERY MAC ADDRESS • String > “Add string” will appear if a battery string has not been configured. You can start scanning sensors and this will be configured as String 1. • Click on Battery 1 •...
  • Page 48 • Navigate to Settings. • Configuration > Cell Guard > String > Batteries • Confirm all MAC addresses are populated. Save the configuration. Attach the sensors to the wire harnesses and terminals, or attach the sensor to terminals (2 Volt, 12 Volt).

  • Page 49: Vtc Commissioning

    VTC COMMISSIONING • Under settings, Navigate to VTC discovery. • Click, “start VTC Autodiscover”. • When the VTC is discovered, it will appear in the list under MAC address. • Configure the VTC for the system you are working on.
  • Page 50 • Configuring the VTC for the system you are working on. Clicking “Configure” will take you to the configuration page where the selected VTC MAC address will be automatically filled in for you. Once you add details, if needed, save the configuration and the system will commission the VTC to the system channel and pan id.
  • Page 51 CONFIGURING MULTIPLE VTCS • You can only configure one VTC a time. • To add another VTC, go back to the VTC discovery page and get the next MAC address before you save the configuration so that they all get commissioned together. •...

  • Page 52: Bcu Configuration Setting System Parameters

    BCU CONFIGURATION SETTING SYSTEM PARAMETERS SETTING SYSTEM PARAMETERS • Navigate to Settings > Configuration. • To set system parameters, click the appropriate menu selection and edit the selection as needed and hit enter to save. • Once all parameters are configured, click the confirmation option SAVE in upper right corner.

  • Page 53: System Id

    SYSTEM ID • Site Name: Physical name of site; typically will have store number or other unique identifier. • ID Line: These lines will contain physical address of site. This information will appear as header on reports and used to identify the site. •...

  • Page 54: Cellguard

    CELLGUARD™ CELLGUARD™ NOTE: If multiple units are in the same area, randomize the PAN ID and channel for each unit. • Wireless PAN ID • Wireless channel • Enable Discharge Detection: Yes or No • Plant-Wide Conductance Reference: Yes or No NOTE: If battery manufacturer and/ or model is not selectable in drop down menu, custom must be selected from battery type and battery information entered manually •...
  • Page 55 INTERVAL TESTS • Conductance (G Interval): Number days between Conductance tests. • Voltage/Temperature (VT Interval): number of hours between Voltage and Temperature tests. STRINGS • Click “+” to add string . • Strings will list in order they are programed. •...
  • Page 56 Battery Sensor: 2V (NERC), 6-12V UPS BATTERIES • Select “+” to add batteries. • MAC Address NOTE: this section will auto populate using battery Data entry screen. • Updating data on all batteries in string. • Make updates to parameters at string level. •...
  • Page 57 BATTERY THRESHOLDS • Conductance • High Alarm, High warning, low warning, low alarm –level of conductance that will trigger alarms. • Strap resistance • High Alarm, High warning, low warning, low alarm –level of strap resistance that will trigger alarms. •...
  • Page 58 STRING THRESHOLDS • Voltage • High Alarm, High warning, low warning, low alarm –level of voltage that will trigger alarms. • Current • High Alarm, High warning, low warning, low alarm –level of current that will trigger alarms. TEMPERATURE ZONES •...
  • Page 59 • High alarm- temperature to trigger high temperature alarm. • Low Alarm- temperature to trigger low temperature alarm. ELS STRANDS • Name- Name of ELS Strand • Digital Input # - 1 or 2 To configure additional battery strings with the same parameters, click Drag and drop >...

  • Page 60: Downloading A Configuration File

    DOWNLOADING A CONFIGURATION FILE...

  • Page 61: Verify Installation And Configuration

    VERIFY INSTALLATION AND CONFIGURATION • Go to; Tools > Manual Operations • Manual operations tab can be used to test individual sensors and to test entire string. • VT - Voltage / Temperature testing. • G - Conductance testing. NOTE: Once tests are initiated, navigate to Monitoring>Status to see new readings populate.

  • Page 62: Setting Bcu Output Communications

    SETTING BCU OUTPUT COMMUNICATIONS NETWORKING>ETHERNET IPV4 • Method: • Manual: Enter IP address manually. • DHCP: Obtain a valid IP address. • Address: IP address must either be address on network or static IP provide by service provider. • Network Mask: The mask must match that of the network the BCU is connected to. •...

  • Page 63: Communications>Protocols

    COMMUNICATIONS>PROTOCOLS CELLTRAQ™ • Enabled : Yes or NO (Must be set to Yes and at least one battery string must be created for “CELLTRAQ™ commission” to appear in the settings list). • Site Serial Number: serial number of BCU. (Sites with multiple BCUs reporting to CELLTRAQ™ require programming same serial number in each BCU.) •...
  • Page 64 SNMP V3 NOTE: Set the SNMP Configuration to match the protocol of the device the BCU will communicate to using SNMP. MQTT • Click “+” to add connection. • Connection 1 • Name- Name of connection. • Service-select service for connection. •...

  • Page 65: Celltraq™ Commission

    CELLTRAQ™ COMMISSION • Commission site to CELLTRAQ™ • Complete programming in CELLTRAQ™ section under configuration. • This should then populate in the CELLTRAQ™ commission screen. • Once all data is confirmed, click on Commission site to CELLTRAQ™. • Verify in CELLTRAQ™ the site was created. NOTE: CELLTRAQ™...

  • Page 66: Tools>Modbus Register

    TOOLS>MODBUS REGISTER 1. Click Tools>Modbus Registers. 2. Click the string to display the battery register. 3. The Modbus register map is provided upon request.
  • Page 67 Intentionally Blank...
  • Page 68 10000008420 r2...

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