Download BtmGlobal System Controller User Manual

BtmGlobal System
Controller
User Manual
Version 4.0.3
Polytronics Engineering Ltd.
2010 All Rights Reserved
1
Table of Contents
Introduction....................................................................................................................... 3
Site Requirements ............................................................................................................... 3
Hardware Overview.......................................................................................................... 4
Hardware Installation ...................................................................................................... 5
Installation ......................................................................................................................... 6
Communication Path Installation............................................................................... 6
Terminating Fiber Optic Cables................................................................................. 6
Hardware Verification and Configuration ................................................................ 7
System Setup and Operation ........................................................................................... 8
Accessing Battery Data ................................................................................................ 8
Summary Page.............................................................................................................. 9
Appendix A: Local Data Access.................................................................................... 10
Connecting Using a Router (Dynamic Addressed Controller) .............................. 10
Appendix B: Controller Alarms and String Status .................................................... 11
Appendix C: Sample Controller System...................................................................... 13
Appendix D: Mechanical System Layouts................................................................... 14
2
Introduction
The controller is a real-time, stand-alone battery monitor with full networking support. It
is used for storing individual cells/jars and full string data, detecting abnormalities
coming from the battery measurements, warning about the changes in the battery
condition and alarming when critical conditions occur on an individual Jar(s) or the entire
string. Based on the collected data, the controller generates various comprehensive
reports for assessing the operational conditions and the health of the battery. The
generated reports are presented in Hyper Text Markup Language (HTML) and in Portable
Network Graphics formats (various graphs and plots) to utilize the Internet based World
Wide Web browsers. Currently, only Mozilla Firefox fully supports all the user
interface features.
The controller’s network support facilitates TCP/IP protocol over Ethernet. The system
is easily accessible (locally or remotely) over Modem for report viewing, data
downloading, configuration and system upgrading. The system can also be configured to
automatically upload the report-pages to a predefined Web Site and use Email for the
remote enunciation of alarms (local ISP access point or local network Gateway access is
required).
The System Controller supports the following services over TCP/IP network:
HTTP: serves battery report pages for WEB-browser
FTP:
file transfer service
SSH:
secure shell for remote system configuration/upgrade
Mail:
electronic mail agent (configured to send alarm messages)
Site Requirements
•
•
•
Ethernet access (optional)
Direct telephone line (optional if remote access/support is required)
Uninterruptible power supply 500VA or UPS protected AC outlet
3
Hardware Overview
The concentrators are configured either as low voltage or high voltage devices. The high
voltage concentrators can serve up to 20 Jars, and the low voltage concentrator can serve
up to 30 Jars.
There are a few small differences in the equipment depending on whether the system is
monitoring 2V or 12V Jars. Although concentrators may look the same, it is important to
check the nameplate to tell whether the concentrator has the proper voltage for your
application.
All concentrators are powered from the battery monitored. However, the controller uses
a 120/220 VAC outlet for power.
Note:
In order to maintain data acquisition during a power failure, the AC outlet must be UPS
protected or have an emergency generator as a backup.
4
Hardware Installation
Alarm contacts, may be connected to
light/bell if desired)
AL WD
OUT
IN
Float Current Montior
Fiber Optical Cable
Concentrator
Charger Negative
Concentrator
Jar #32
Jar #17
Charger Positive
Jar #16
Jar #1
Battery String #1
Float Current Montior
Concentrator
Charger Negative
Concentrator
Jar #32
Jar #17
Charger Positive
Jar #16
Jar #1
Battery String #4
Figure 1: System Connectivity
5
Installation
Communication Path Installation
Layout the devices and measure the distances between the connection points for the
communication loop. The devices are connected in a daisy chain format - from the fiber
optics output (blue) of one device and then connected to the fiber optics input (black) of
the next.
Plan your connections of fiber optical cable to minimize the length of the longest fiber
optical cable run. If multiple strings are connected to the single optical loop, then fiberoptical cable must connect across strings (sometimes in another battery room).
Take care to keep the radius on all bends at least 2 inches or 40 mm. Care should be
taken to run all lengths prior to cutting.
Warning:
The fiber optical loop must be planned very carefully before cutting the fiber optic cable
because there is no way to join cut pieces of fiber optic cable together without any extra
equipment. Also, neither the sequence nor the total length of the cable is important. The
only important aspect is the length of the longest piece of the cable is. The longest fiber
optic cable must not exceed 60 meters.
Terminating Fiber Optic Cables
The fiber optic cable from the concentrators should be terminated in the appropriate
socket in the controller. Prepare the end of the fiber optic cable by cutting it at a right
angle with a sharp utility knife. Do not strip the fiber-optic wire. With limited force, a
stripped wire can damage the internal receiver and transmitter. Position the prepared end
of the fiber optic cable in the input (or output) of the special fiber optic’s connector, be
sure the connector is loosened. Push the end of fiber optics cable into the housing;
tighten the connector with finger force as much as would be used to close a toothpaste
container.
6
Hardware Verification and Configuration
Workstations on IP network
Remote Workstation
Windows Hyperterminal SW
Dial-in / Remote data
access / remote configuration
Data access
system configuration
BTM-Global Stand-alone system
120/220 Vac (1 A Max)
protected power source
LAN / WAN
PSTN line
Internet Explorer
HTML Report Pages
PWR
COM1
KM
LAN1
CRT
Ethernet access-point
Modem
Ethernet Cable
Internet explorer HTML Report
Pages
On Site Mobile PC / Laptop
Data access
system configuration
Figure 2: Connecting PC to the Controller
7
System Setup and Operation
The controller you have received has been pre-configured for your installation.
Reconfiguration of the controller box can be performed remotely over the telephone-line
(dial in), Ethernet or locally.
Further instructions on configuring and use of the system are incorporated into the
monitoring controller web page.
Accessing Battery Data
The controller system facilitates several means to access data. All necessary battery data
is stored in the controller and is also presented in an HTML formatted report file. Any
graphics are produced in the PNG (Portable Network graphics) format.
Complete access to all data (including raw data) can be achieved by establishing a dial-in
network connection, or by connecting the System Controller to a local Ethernet network.
The System Controller has a built-in web-server capability and, all HTML report pages
can be browsed using a local network connection or over a dial-in network. Raw data,
ASCII text tables and other relevant files, can be retrieved using an FTP site.
Note:
The System Controller is configured for dynamic IP address and should work with any
existing network.
8
Summary Page
Figure 3: Controller Summary Page
The Summary page summarizes data and provides links to all the other areas of the
system. It displays information about the batteries themselves: the status, alarms, charge
level, voltages, current, ripple current, ambient and pilot temperatures of the string are
displayed.
Clicking on the logo in the top right side opens up a FAQ for the controller.
9
Appendix A: Local Data Access
Connecting Using a Router (Dynamic Addressed Controller)
1. Connect the PC, router and Controller(s) as shown in Figure 4.
To Other Equipment
Local PC
Ethernet Cable
Ethernet Cable
Ethernet Cable
Ethernet Cable
Figure 4: Connection of Controller, Router and PC
2. Start your web browser (Mozilla Firefox and in the address bar type
btmGlobalXX, where XX is digits 01 – 99. The Controller name is recorded on
the front label.
10
Appendix B: Controller Alarms and String
Status
Alarm
String Exhausted
Bit Position
1
String Open
2
Pending Jar Reversal
3
Low Capacity
5
Jar Internal resistance High
6
Jar Voltage Below set limit
7
Jar voltage Above set limit
8
Jar High Float Mobility
10
Jar High Noise during Float
Temperature Abnormalities
Discharge Warning
Charge Warning
Equalization Warning
Jar Parameters Degraded
9
12
13
15
14
16
Ground Fault
17
Description
Battery total voltage is below discharge
end voltage (during discharge)
String is at open potential, charger not
connected or malfunctioning
A jar terminal voltage is near its end
voltage during discharge. This jar does not
support the load any longer.
String capacity near exhaustion, a few
minutes reserve time remaining
The internal resistance of a jar has
increased drastically.
During float operation, the jar terminal
voltage is below preset limit.
During float operation, the jar terminal
voltage is above preset limit.
Jar terminal voltage drifts significantly
during battery floating
High ripple voltage during float operation
Ambient/Pilot temperature outside limits
String is discharging
String is charging
String is at Equalization potential
Jar calculated parameters during discharge,
charge or Float have been degrading.
When using a ground fault detector, the
limit at which it alarms has been passed
and ground fault condition is present.
Note:
Each alarm can be individually enabled or disabled. The controller can send an e-mail
when an alarm is detected if it is connected to the LAN or has a dial-out to the ISP
capabilities enabled.
String Status
NA
OPEN
FLOATING
FLOAT-CHARGING
Description
String status unknown. During a system
start-up or communication failure
String is at open potential
String is fully charged and floating at its
nominal voltage
Battery capacity is not fully restored.
11
CHARGING
EQUALIZING
DISCHARGING
Charging current to the battery detected.
Battery at equalizing potential (prolonged
application will be harmful to the battery).
Load is on the battery.
12
Appendix C: Sample Controller System
Local Workstations
Internet Explorer
HTML Report Pages
Remote Workstation
Windows Hyperterminal SW
PSTN line
Dial-in / Remote data
access / remote configuration
Ethernet interface
(RJ-45 for 10/100Mbs):
TCP/IP protocol:
- HTML server
- FTP server
PWR
PSTN Interface:
external modem
(optional)
COM1
KM
LAN1
CRT
LAN
120/220 Vac (1 A Max)
protected power source
Ethernet access-point
Rs232 cable
Cross-over
network cable
Internet explorer HTML Report
Pages
On Site Workstation
Out
BTM4000I
Concentrator
ID #3
In
T Sensor
Charger Negative
Jar #32
Jar #17
BTM4000I
Concentrator
ID #1
Charger Positive
Jar #16
Jar #1
Battery String #4
Current Shunt
(not required if current is
less than 400A and Factstar
option is selected)
Figure 5: Sample System Setup
13
11.65 (296)
0.63 (16)
0.39
(10)
7.4 (188)
4.61
(117.1)
2.32
(59)
0.197 (5)
PLASTIC
FIBRE OPTICS
3.94
(100)
2.17
(55)
TOP VIEW
BTM GLOBAL
CONSOLE
0.39
(10)
FACTSTAR
CURRENT
TRANDUCER
0.24
(6)
TOP VIEW
1.77
(45)
1.65
(42)
TOP VIEW
7.52 (191)
0.24 (6)
0.24 (6)
ALARM
CONTACTS
1.34
(34)
3.58
(91)
18 CONNECTOR
TERMINAL BLOCK
3.19
(81)
16 CONNECTOR
TERMINAL BLOCK
9.84 (250)
0.39
(10)
0.31
(8)
2.48 (63)
BTM
CONCENTRATOR
4.88
(124)
WALL MOUNTED CONCENTRATOR
Appendix D: Mechanical System Layouts
3.35
(85)
0.24 (6)
3.54 (90)
TEMPERATURE
SENSOR
0.197 (5)
2.05 (52)
CT
ALL DIMENSIONS ARE
IMPERIAL (MILLIMETERS ARE IN BRACKETS)
BTM GLOBAL COMPONENTS
MECHANICAL LAYOUT
NOV 20,2006
SCALE 1:4
Rev. A
1 OF 2
Figure 6: Mechanical Layout
14
SIDE VIEW
SIDE VIEW
SIDE VIEW
1.25
(31.75)
1.42 (36)
0.25
(6.35)
FLOAT CURRENT
TRANSDUCER
FRONT VIEW
FRONT VIEW
B- 28 26 24 22 20 18 16 14
12 10
8 6 4 2 B1+ B+
29 27 25 23 21 19 17 15 13
11 9
7
5 3 1
BC HC
CONCENTRATOR
FRONT VIEW
SYSTEM CONTROLLER
BTM GLOBAL COMPONENTS
MECHANICAL LAYOUT
UNDER BATTERY RACK MOUNTED COMPONENTS
ALL DIMENSIONS ARE
IMPERIAL (MILLIMETERS)
NOV 20,2006
SCALE 1:4
Rev. A
2 OF 2
Figure 7: Mechanical Layout
15
ALL HOOK-UP WIRES:
TINNED COPPER, PVC INSULATED, STRANDED, AWG 18, 600V ,105C
(BELDEN STYLE 1015 OR EQUIVALENT)
OR
TINNED COPPER, POLYOLEFIN (XLPE) INSULATED, STRANDED, AWG 18,
UL AWM STYLE 3265 105°C, 600V.
SUPPLIED BY INSTALLER. WIRE LENGTH BETWEEN CONCENTRATOR
TERMINAL AND BATTERY POST SHOULD NOT EXCEED 100FT (30M).
FLOAT CURRENT TRANSDUCER
FIBER OPTICS OUT
TO BTM CONCENTRATOR
+12V FROM SYSTEM CONTROLLER
POWER GND FROM SYSTEM CONTROLLER
FIBER OPTICS IN
FROM BTMGLOBAL
CONSOLE
CURRENT TRANSFORMER
BLACK LEAD
TEMPERATURE SENSOR LEAD
TEMPERATURE SENSOR LEAD
TEMPERATURE SENSOR
CURRENT
TRANSFORMER
RED LEAD
CT
SECOND COM PORT TO MODBUS INTERFACE
PLASTIC FIBER OPTICAL CABLE (SMF)
SUPPLIED WITH THE SYSTEM.
LONGEST FIBER OPTICAL SEGMENT
MUST NOT EXCEED 100FT (30M) .
TO MODBUS
INTERFACE
2 OR 4 WIRE
RS485
VGA INTERFACE (OPTIONAL MONITOR)
ETHERNET INTERFACE
12V DC, 2A MAX
POWER SUPPLY
(SWITCHING)
DC-DC POWER
CONVERTER
OPTION,
OUTPUT:
12V DC, 2A MIN
KBD/MOUSE INTERFACE
RS485 CONVERTER
NOT SUPPLIED WITH THE SYSTEM
RECOMMENDED MODEL: 485OT9L
B&B ELECTRONICS
BtmGlobal SYSTEM CONTROLLER
+12V FROM SYSTEM CONTROLLER
POWER GND FROM SYSTEM CONTROLLER
TO AC OUTLET:
100 - 240 VAC 50/60 HZ
BATTERY:
24VDC
48VDC
96VDC
120VDC
240VDC
FIBER OPTICS OUT
TO FLOAT CURRENT
TRANSDUCER
FIBER OPTICS IN
FROM BTM CONCENTRATOR
+12V TO FLOAT CURRENT
TRANSDUCER (OPTIONALLY
TO RS485 CONVERTER)
POWER GND TO FLOAT CURRENT
TRANSDUCER (OPTIONALLY
TO RS485 CONVERTER)
INTERNAL COM FAILED ALARM CONTACT
BATTERY ALARM CONTACT
ALARM RELAY CONTACT RATING:
SWITCHING POWER: 10W
SWITCHING VOLTAGE: 100VDC
SWITCHING CURRENT: 500 mA
BTMGLOBAL COMPONENT CONNECTIONS:
SYSTEM CONTROLLER AND
FLOAT CURRENT TRANSDUCER
NOT TO SCALE
JAN 10,2007
Rev. B
1 OF 1
Figure 8: Mechanical Layout
16