Eagle Eye Power Solutions VIGILANT VIG-MON-LV-02 Installation & User Manual

Battery monitoring system

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VIGILANT Installation User Guide

1.0 Introduction

2.0 Required Tools

3.0 Review BOM

3.1 Package BOM

3.2 Identify Components

4.0 Installation Preparation

4.1 Pre-Install Battery Checks

4.2 Battery Preparation

4.3 ELM Sensor Preparation

5.0 Identify Placement of Components

5.1 VIGILANT Monitor Placement

5.2 VIGILANT Sensor Placement

5.3 ELM Sensor Placement

6.0 Mount Components

6.1 VIGILANT Monitor Mounting

6.1.1 Grounding the Monitor

6.2 VIGILANT Sensor Mounting

6.3 ELM Sensor Mounting

6.4 Connection Hardware Mounting

6.4.1 Battery Terminal Preparation

6.4.2 Square-Post Clamp Installation

6.4.3 Round-Post Clamp Installation

6.4.4 Tab Washer Installation

6.4.5 Standoff Bolt Installation

7.0 Install Cable Clamps

7.1 Install Clamps to Charger Cables

7.2 Connect Power & Sense Wires

8.0 Install Tab Harnesses

8.1 Understanding the Harnesses

8.2 Connect Harnesses to Battery Connections

8.3 Connect Special Terminal Harness

9.0 Terminate Harness Wires

9.1 How to Use IDC Crimp Tool

9.2 Wire Management

9.3 Positive Cable Clamp & First Sensor

9.4 Middle Sensors

9.5 Negative Cable Clamp & Last Sensor

10.0 Test Connections

10.1 Test Cable Clamp Connections

10.2 Test Sensor IDC Connections

11.0 Make Longer Cable Runs

11.1 How to Use RJ12 Crimp Tool

11.2 Monitor to Sensors

Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com

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Summary of Contents for Eagle Eye Power Solutions VIGILANT VIG-MON-LV-02

Page 1 9.5 Negative Cable Clamp & Last Sensor 10.0 Test Connections 10.1 Test Cable Clamp Connections 10.2 Test Sensor IDC Connections 11.0 Make Longer Cable Runs 11.1 How to Use RJ12 Crimp Tool 11.2 Monitor to Sensors Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 2: Required Tools
Bore hole in charger Cable boring No specific cable for connection tool model of cable clamp Crimp RJ12 cables Klein Tools / RJ12 cable for sensor VDV226-011- crimper communications Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 3 Eagle Eye IBEX resistance & voltage readings or similar tester for verification 3.0 Review BOM Prior to starting installation it's important to review the included BOM and ensure all components are included. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 4: Identify Components
LV-02 VIGILANT sensor, cable clamps, manual Monitor for Medium Voltage (100-365VDC) - VIG-MON- Includes: DIN rail, DIN rail clips, ambient sensor, Similar to VIG-MON-LV-02 MV-02 +1 VIGILANT sensor, cable clamps, manual Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 5 Negative Charger Cable Clamp - Includes: 3- VIG-CBL- way jelly crimp, inline fuse, backplate, 2x cable CLP-NEG-02 ties VIGILANT Sensor - Includes: (2) IDC connectors, VIG-SEN-01 mounting cradle, 12" RJ12 cable, isolation sticker Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 6 Mounting cradle, connector cable VIG-CLS-ST- Small steel C-Clamp with single tab for square posts VIG-CLM-ST- Medium steel C-Clamp with single tab for square posts VIG-CLL-ST- Large steel C-Clamp with single tab for square posts Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 7 Steel long-legged clamp for round posts VIG-TAB-M8 M8 Tab Washer VIG-TAB- M10 Tab Washer VIG-TAB- M12 Tab Washer VIG-TAB- Bent Brass M10 Tab Washer for BAE Cells M10-BENT VIG-STO- M8x22 Bolt with Threaded Tap M8X22 Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 8: Installation Preparation
Successful operation of the VIGILANT requires certain parts of the battery system to be cleaned and prepped: 1. Clean any excessive corrosion off the battery terminals and jars. 2. Remove excessive grease from the terminals if present. Grease can affect the resistance measurement accuracy. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 9 (EnerSys specifically). For either cleaning solution, clean each jar first, then go through again with a dry rag and buffer the jars. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 10 There needs to be at least 2" (50mm) above and below the sensor. If 2 sensors are mounted side- by-side, there should be at least 3" between them. If space does not allow this, contact Eagle Eye regarding drop down hardware that staggers the height of every other sensor. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 11 Placement for Flooded/VLA battery systems: It's recommended to mount the sensor inline with each cell, so that the sensor is in front of the cell. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 12 For example, if mounting sensors on the top of the battery bank, ensure the 3.3 ft (100 cm) harness for that sensor can reach cells at the bottom of the battery bank. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 13 ELM sensors connect to the VIGILANT sensors with the provided 12" ribbon cable. Ensure the VIGILANT sensors are close enough to where the ELM sensors will be mounted to account for this. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 14: Mount Components
1. Remove the 2 front covers from the monitor by loosening the screws. Back the screws out as far as you can without completely unscrewing them, then pull the covers out. 2. Mount the DIN rail to determined location (hardware not included). Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 15 5. Install the DIN Rail Stops on each side of the monitor. Ensure the stop is pushed all the way in before tightening so that both ends grip the DIN rail. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 16 The wire should then be grounded to the appropriate location. If possible, this will be determined during the site survey process. Steps to Ground 1. Crimp the ground wire to the lug on the monitor. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 17 Cable (30 per box) Black Dot For covering cradle mounting Inside the leaflet included with Stickers hardware each sensor box Installation Steps 1. Mount the cradles as determined from Step 5.2: Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 18 2. If using ELM Sensors, attach the ribbon cable to the back of each VIGILANT sensor, this will be needed for the ELM installation steps (Section 4.3). 3. Slide the VIGILANT sensor into the cradle, there is no locking mechanism. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 19 Wrapped with each ELM sensor ELM Ribbon Connects ELM sensor to VIGILANT Bundled in ELM Sensor box (30 Cable sensor per box) Confirm ELM sensors will not be ELM Template obstructed Installation Steps Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 20 8. After the cradles are mounted, slide the sensor into the cradle and click it into place. 9. On the front of the ELM, remove the cover by squeezing both sides. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 21 8. Go through all sensors again and firmly press the cradles on to the battery jar to ensure maximum adhesion. 9. When complete, all ELM sensors should be securely mounted with the covers in place and ribbon cables connected to the VIGILANT sensors. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 22 1. Place each clamp on the battery terminals and ensure they are consistently facing the same direction per each row of batteries. The adjustment screw should be facing a direction that is accessible with the tool used to tighten. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 23 3. If Using Torque Tool - With the clamp hand tightened, continue to tighten the adjustment screw with the torque tool until the tool 'breaks'. Push down on the top of the clamp while tightening. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 24 When completed, the clamps should be consistently installed across the battery. 6.4.3 Round-Post Clamp Installation If the battery has round posts the C-Clamp is not used. Instead, either a J-Clamp or Long-Legged Clamp is used. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 25 This guide does not cover all the steps required on the battery system to fit tab washers. It simply explains what the options are and how they should be distributed on the battery. Be sure to follow safety and procedural steps for work on the specific battery. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 26 The other washer should be between the standard washer and the bolt head. If a spring washer was installed, place it between the standard washer and spring washer. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 27 2. Install a standoff bolt on the positive post of the last cell/unit (at the negative end of the string). 3. Install a single tab on every standoff bolt installed. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 28 These clamps power the monitor (if not using the 24V input), measure the charger float voltage, and provide terminal connection resistance measurement points. Parts & Tools Needed Part/Tool Where to Find Positive Cable Clamp Positive battery connection In monitor box Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 29 2. Determine where on the charger cable the clamps will be installed, take into consideration the following: The clamps should be as close to the battery terminals as possible. They are also limited by the length of wire attached (3.3ft). Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 30 The size of the bit should not exceed 2mm (5/64"). Do not use the grub screws to bore the holes. The grub screw should not penetrate the cable more than 9mm (3/8") from the base of the mold. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 31 Start by inserting the cable ties into the holes on the clamp main body. Note the position of the cable tie heads, the cable should feed into the head from the wire side of the clamp. Next, slide the backplate into the cable ties. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 32 7. Pull the cables ties as tight as possible - it works best to have the cable tie head flush with the clamp bracket as shown below. Tighten the grub screws into the cable and cut the excess zip tie. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 33 Using pliers, squeeze the crimp together until it's firmly closed. It may need to be pressed down in several places to ensure a good connection. WARNING: Remove the fuse from the fuse holder before proceeding. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 34 The fitted cable clamp should look like the below when done. 4. Repeat the same steps for the negative cable clamp and wiring. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 35 The tab harnesses connect each VIGILANT Sensor to the connection hardware on the cell. Parts & Tools Needed Part/Tool Where to Find Connect sensor to connection Positive Tab Harness In harness box (12 per box) hardware Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 36 Measures the strap voltage between it and the red wire connected to the negative post of the previous cell. Blue Wires - Measures the negative post temperature of the connected cell. Gray Pulse Connector: Connects to negative post. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 37 3. Connect the gray pulse connector to the tab washer installed on the negative post. The tab washer can be in various location such as on the excess bolt thread or between the bus bar and the washer and nut of the bolt. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 38 3. Connect the gray pulse connector to the bottom tab washer on the negative post. 4. In some cases, the tab washers may be installed on standoff bolt hardware. In this case, follow the same connection sequence. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 39 1. Connect the tab connector as follow depending on the clamp type: C-Clamp: Connect to the tab on the clamp. Tab washer: Connect to the bottom tab washer closest to the post. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 40 2. Insert the wire into the hole, be sure to push and hold the wire all the way in. 3. Squeeze the crimp handle to crimp the connection. The IDC should automatically move to the next termination point. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 41 The wiring should be cut as short as possible while not pulling on the components - a bit of slack is recommended. If possible, route the wiring between cells. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 42 Position 2: Crimp the red sense wire from the red sense connector installed on the positive post. Position 3: Crimp the gray pulse wire from the positive cable clamp installed on the charger cable. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 43 CAUTION: Do not plug any crimped IDC connectors into the sensors. The picture below is for example only. The IDCs should not be plugged into the sensors until the commissioning. If they are it could damage the sensor. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 44 4. Finally, the completed wiring for the positive cable clamp and first sensor should look like shown below. All wires are terminated except a single black sense and gray pulse from the negative post. These will be terminated in the next main step. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 45 3. As mentioned in 8.2, do not plug the sensor IDC connectors into the sensors yet. This is done during the commissioning process. 4. Repeat this process for every sensor up to the last sensor. The sequence of wiring from sensor to sensor should look like below. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 46 Position 2: Crimp the blue sense wire from the negative cable clamp installed on the charger cable. Position 3: Crimp the gray pulse wire from the negative cable clamp installed on the charger cable. 3. When completed, the wiring should look like shown below. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 47: Test Connections
2. For any measurement at the IDC connector, the test lead should make contact with the exposed pins on the front of the connector as shown below. Further steps will not make this clarification. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 48 Negative post to the gray wire - less than 0.15 Ω Negative post to the blue wire - approximately 8=12 kΩ Negative post to the gray wire - less than 0.15 Ω Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 49 1. With the crimp tool in hand, strip back cable to expose the 6 colored wires. 2. Insert the RJ12 connector into the "6P" slot on crimp tool, then insert the cable into the connector. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 50 2. Route the second cable from the monitor to the last sensor and cut to length. 3. With the cables cut to length, crimp the RJ12 connectors to both ends. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 51 Relay 2: Watchdog Alarm For both relays, the maximum power rating is 300 watts, not to be exceeded. If the breaking voltage is 300V then the breaking capacity could be as high as 1A. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 52 This could occur if the system is powered off, reset, or there is some type of internal failure with the CPU. Relay 2 is Normally Closed, so wire the alarm cabling to NC and C. Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 53: Post Installation Checklist
There are no obstructions between the sensor and the battery jar such as battery labels, debris, etc. The ELM ribbon cable is connected to the VIGILANT sensor System Wiring Input voltage wiring between the cable clamps and monitor is managed and secured Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...
Page 54 All harness wires are terminated to the sensor IDCs correctly All harness wires are routed and managed neatly for a clean look Any wiring between battery racks/steps/tiers is managed and secured Eagle Eye Power Solutions, LLC | 1-414-877-3377 | www.eepowersolutions.com...

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Vigilant vig-mon-mv-02 Vigilant vig-mon-hv-02

Eagle Eye Power Solutions VIGILANT VIG-MON-LV-02 Installation & User Manual

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Summary of Contents for Eagle Eye Power Solutions VIGILANT VIG-MON-LV-02

Page 2: Required Tools

Page 4: Identify Components

Page 8: Installation Preparation

Page 14: Mount Components

Page 47: Test Connections

Page 53: Post Installation Checklist

This manual is also suitable for:

Table of Contents