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BDS/pro Installation Instructions (Battery Diagnostic System)
1. Safety Regulations
BDS/pro installation should be based on the law of electric works and standard specifications, Eagle Eye Power Solutions LLC will be not responsible for personnel safety by these instructions.
Safety Warning:
1.1. Work on batteries shall be performed only by knowledge personnel with proper safety tools and protective equipment.
1.2. If you cause a short circuit by shorting the both +, – terminals of battery posts, will become shorted and cause severe damage in both equipment and body. Therefore, to protect of any accident, do the insulated taping to all of metallic conducted parts except working area for installation tools (screw driver, wrench-spanner).
1.3. Avoid the wearing of metallic object such as jewelry, watch while working on the battery. Put on electrically insulated gloves, goggles and other protect equipments for safe handling.
1.4. In case of a short circuit of system DC voltage (+, – post terminals of battery strings) will cause fire, burning, etc. Therefore after do the final test, connect BDS/pro input and battery (+) post on witness of your supervisor.
Attaching 1:
Refer to Working Standard for Connection of Total DC Line Voltage
1.5. Should be fully aware of details about working safety
2. Requirement Materials and Tools
2.1 Install Equipment
(1) Main device (MPU Monitoring Control Device)
(2) RU (in case of iPQMS)
(3) Cable Types Source Line (Current Line), Signal Line (Voltage Line), Temperature Line Total Voltage Current Line, Control Power Line, LAN Line (if necessary)
(4) Clamp Types (O-type or C-type)
(5) Duct, Banding line (for temperate capture use)
(6) Preventing Electromagnetic Waves Band (25 or 20 ): Voltage Line Capture
(7) Lines (Flexible) Conduit
2.2 Required Tools Warning:
Every tool should be completely taped with insulating tape to prevent accidents by short except the indispensible part to execute the work.
(1) Tools for adhering MPU and RU
(2) Multimeter
(3) + / – Drivers
(4) Small Size (-) Driver (front part is 2~3mm)
(5) Wrench (Spanner)
(6) Stripper
(7) Nipper,
(8) Terminal, Terminal Compressor
(9) Cable tie, Large-sized DC.CT capture use, Medium-sized (), Small-sized ()
(10) Hacksaw (Duct cutter)
(11) Silicon, Silicon gun (hot melt)
(12) Insulating tape, Double-stick tape (Black)
(13) Cotton gloves
(14) Insulated scaffold (insulated ladder) when batteries are installed vertically 1.6M and more.
3. Application Directions
3.1 BDS/pro
(1) BDS/pro should be installed on suitable place easy to maintaining or inspection. Make short sensing cabling length by installing near to battery strings.
(2) After setup of BDS/pro on battery stand or appropriate locations, all sensing cables get together with cable ties.
(3) Current lines of measuring signal should be separated perfectly to the voltage sensing lines. (
4) Install the MPU and RU to the battery power line cable tray or the side or front of battery cabinet after consulting with client to make the sensing line short.
3.2 Clamp Setup
(1) Powertron has two kind of Clamps; C-type or O-type. It depends on the battery connection bar or cable. Each clamps of cable or bus-bar should be fixed on the easy position by directions.
(2) Selecting guide of the clamps to types of battery connections, and connecting sensing lines.
① In case of connected terminal post is bus-bar: Use C-type Clamp.
② In case of connected terminal post is cable (like WCT): Use O-type Clamp
③ Selecting and connecting method of clamps when the size of connection cable is 38SQ or less.
④ Adhesion and connection of Bus-bar clamp (C-type)
3.3 Connection of Current Sensing Line(Source) and Voltage Sensing Line(Signal) to Clamps.
Caution : Absolutely prohibited to connect sensing line(Source) and voltage sensing line(Signal) to Relaying Unit. Insert the connector after connecting all sensing line to battery clamp terminal. (In connecting MPU and RU could be damaged by sensing line short.)
(1) Before making cable, check the status of cable with millimeters to prevent sensing line short-circuit. (It can be omitted after completing the import inspection.) (
2) Each small terminal of clamp connects to end part (with solder about 5-6mm) of current sensing line(Source) and voltage sensing line(Signal). Be sure the status of connection sensing line with terminal because small terminal size is tiny. Caution : Total sensing line should be shortly worked as long as possible to decrease noise.
(3) First, connect current sensing line(Source) with small terminal (Is) of clamp. Second, arrange each sensing line group by tie with hook band, which is for prevent electromagnetic waves. Third, connect voltage sensing line(Signal) with small terminal
(Vs) connector of clamp and divide current sensing line(Source) from voltage sensing line(Signal) (see, Fig 5) (4) Divide current sensing line(Source) and voltage sensing line(Signal) by connecting voltage sensing line(Signal) to small terminal (Vs) connector of clamp to be prevented from electromagnetic waves and find it easily in next inspection. ※ It could not be used as current sensing line because only one, fuseresistance( 0.22Ω) or small fuse(1A), is soldered in voltage fuse PCB.
(5) All cable of current sensing line(Source) and voltage sensing line(Signal) arrange to use appropriate size of duct or cable tie.
(6) In case of connect a clamp with two line of current sensing line(Source) and voltage sensing line(Signal), divide per source line or per signal line and connect cable by twist. (When connecting sensing line to small terminal, use small (-) driver which has 2~3mm in front part)
3.4 Temperature Line Connection
(1) After connect temperature sensor to near negative terminal post, set it with adhesive tape or hot melt.
(2) After final test, fix or adhesion with transparency silicon.
(3) After setup, arrange cable with cable tie and duct. (7)
7 3.5 Total Voltage, Current Line(CT) Connection
(1) Total voltage cable(VDC) is assembled to perfect contact with using of lug or clamp to connect with battery string/charger(rectifier) + − terminal post (it is consisted of bus-bar or more than 2 cables in case of mass storage).
(2) Connect total voltage cable with + terminal post to using of fuse. Caution : First, connect with BDS/pro and then connect battery terminal post. If you do not it, occurs fire, burning, blind by short.
(3) When battery charges, insert current line(CT) to turn on current to the arrow direction in the positive post line(if it is impossible − line), set CT with tie lab at the appropriate place, check correct polarity of control power + − 12V, and connect CT signal
4 line with BDS/pro connector. It is recommendable to put the terminal connection part of current sensing line(Source) and voltage sensing line(Signal) in the small dipping machine and solder in the stripped part to make it easy to insert into terminal.
3.6 Control Power Line Connection
(1) Use AC power or battery groups +, − power as the installed location
(2) Connect the distributing wires after checking MPU power is OFF. At this time check the polarity and connect battery groups +, − power after connecting MPU terminal (check the wires) not to be Short.
(3) Connect the wires between IPQMS aand RU refer to interior wiring diagram of IPQMS and RU.
(4) The detail connecting process should be followed as says in Attachment 1 “working standard for connection of total DC line voltage”
3.7 Inspecting the Statue of Other Connection Lines
(1) Put power into MPU after confirmed the state of connection lines is normal.
(2) Make sure signal, source and temperature line connectors are inserted in the regular sequence as designated. (
3) Check the connection order of signal lines and source lines. Signal Line:
①Gray, ②Green, ③Blue + Blue, ④Orange, ⑤Brown Source Line: ①Gray, ②Green, ③Blue
(4) Make all signal and source lines easy to inspect hereafter by attaching identification tag of CH number of RU and battery cell number.
(5) Check the jumper position in RU after checking JP1 jumper in the main PCB when installing more than 2 RU cabinets.
4 Other Installing Directions (1) Battery monitoring system should be installed with facility in maintenance test and installing method should be based on the plan. (2) Work with a driver after taping except the end part of driver. (3) Avoid the partial rise in temperature and a direct ray of light. (4) Attendance at Working and Inspection Execute an efficiency test according to standard requirements after installing equipment and completing wiring and submit the result of test to obtain inspector’s approval. Local supervisor’s attendance and inspection are required if necessary in the process.
4 Other Installing Directions
(1) Battery monitoring system should be installed with facility in maintenance test and installing method should be based on the plan. (
2) Work with a driver after taping except the end part of driver.
(3) Avoid the partial rise in temperature and a direct ray of light.
(4) Attendance at Working and Inspection Execute an efficiency test according to standard requirements after installing equipment and completing wiring and submit the result of test to obtain inspector’s approval. Local supervisor’s attendance and inspection are required if necessary in the process.
Attaching 1 Warning Working Standard for Connection of Total DC Line Voltage Edited Version, Dec. 2007 1. Purpose: Execute it according to the installing standard in the condition of supervisor’s present to prevent accidents as this process could cause major accidents in client’s equipment and worker‘s safety. (※This standard has to be prior to product manual or working directions.) 2. Installing Standard
3. Sequence of Operations
① Connect total voltage measuring line to iPQMS, BDS. (as short as possible)
② Install clamp separately for connecting the sensing line and control power line to the cathode(-) of DC booth.
③ Install clamp separately for connecting the sensing line and control power line to the anode(+) of DC booth (install after connecting a wiring fuse to the anode(+) of control power line shortly.)
④ Connect the wiring fuse holders and check whether the voltage is permitted or not.
Attaching 2 iPQMS –
Diagram of Connection among Battery Strings Cycle: Current lines are connected as 2V for every 4 cells and 12V for every 2 cells.
Attaching 3
BDS/pro – Diagram of Connection among Battery Strings Cycle: Current lines are connected as 2V for every 6 cells or 12 cells, 12V 20/16 cells type for every 3 cells (#1~#8 is for every 2 cells), and 12V 24/18 cells type for every 3 cells.
Attaching 5
Attaching 6
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