SM Bat - EnergyMaster™
User Manual
SM BAT Battery Supervision Module
User Manual
Document
Issue:
Release Date:
BOM:
V1.2
November 3, 2004
31011074
Revision History
Version
Date of Change
V1.0
July 13,2004
V1.1
November 1,
2004
V1.2
January, 2, 2005
Description of Change
Newly-created
document
Add more details in
battery connections
Add a picture in the
cover, correct the
grammar mistakes
Changed by
David Dai
David Dai
David Dai
Contents
Chapter 1 Introduction ............................................................................................1
1.1 Overview....................................................................................................1
1.2 Unpacking..................................................................................................1
1.3 Mechanical Features of SM BAT ...............................................................1
1.3.1 Appearance of SM BAT ...................................................................1
1.3.2 Sizes and Weight.............................................................................3
1.3.3 Overview of Terminals .....................................................................4
1.4 Function Overview .....................................................................................6
1.4.1 Hardware Functions ........................................................................6
1.4.2 Software Functions ..........................................................................8
1.5 Technical Specifications ............................................................................8
Chapter 2 Installation ............................................................................................12
2.1 Installation Environment ..........................................................................12
2.2 Installation Method...................................................................................12
2.2.1 Wall Mounting................................................................................12
2.2.2 Rack Mounting...............................................................................14
Chapter 3 SM BAT Hardware Configuration .........................................................15
3.1 Hardware Overview .................................................................................15
3.2 Earth Reference.......................................................................................16
3.3 RS485 Termination..................................................................................16
3.4 Analog Input AI3 ~ AI7.............................................................................16
3.5 Digital Input DI1 ~ DI8..............................................................................17
3.6 Cell Type Configuration ...........................................................................18
Chapter 4 Connections .........................................................................................19
4.1 Power Supply Connection .......................................................................19
4.2 Connection of Configuration Port.............................................................20
4.3 Connections for Cell Voltage Measurement ............................................22
4.4 Connection of Analog Input(AI) AI1 ~ AI7 ................................................23
4.4.1 Connection of AI1 and AI2 for System/Battery Voltage Input ........23
4.4.2 Connection of AI3,AI4,AI5,AI6 andAI7 for Shunt Current Input .....24
4.4.3 Connection of AI3,AI4,AI5,AI6 and AI7 for Temperature Sensor
Signal Input ...............................................................................................25
4.5 Connection of DI Terminal for Digital Input ..............................................25
4.6 Connections of RS485.............................................................................26
4.7 Typical Application...................................................................................27
4.7.1 2V Cell typical application..............................................................27
4.7.2 6V Cell typical application..............................................................29
4.7.3 12V Cell typical application............................................................30
Chapter 5 SM BAT Debugging .............................................................................31
5.1 Overview..................................................................................................31
5.2 Channel Configuration .............................................................................36
5.3 Date acquisiton and Output Control.........................................................43
5.4 Battery String Configuration.....................................................................47
5.5 Product Information .................................................................................48
5.6 System Voltage Reference ......................................................................50
Chapter 6 Troubleshooting and Maintenance .......................................................52
6.1 LED Indication Error ................................................................................52
6.2 Error Messages .......................................................................................52
6.3 Wrong Measurement ...............................................................................53
6.4 Invalid Data..............................................................................................53
6.5 No Action of Relay ...................................................................................53
6.6 RS232 Communication Failure ................................................................54
6.7 RS485 Communication Failure ................................................................55
Table List
Table 1-1
LED Functions ........................................................................................2
Table 1-2
Sizes and Weight....................................................................................3
Table 1-3
Signals of Pins ........................................................................................4
Table 1-4
General Technical Specifications of Power Supply.................................8
Table 1-5
General Technical Specifications of Cell Voltage Input ..........................9
Table 1-6
General Technical Specifications of Analog Input...................................9
Table 1-7
General Technical Specifications of Digital Input/Output ......................10
Table 1-8
General Technical Specifications of Communication Port ....................10
Table 1-9
Technical Specifications for Environments ...........................................10
Table 3-1
Analog Inputs of AI 3~AI7 .....................................................................17
Table 3-2
Digital Inputs of DI1~DI8.......................................................................18
Table 3-3
Cell Type Configuration ........................................................................18
Table 4-1
RJ45 Signal Definition ..........................................................................21
Table 4-2
Relationship between Pins of RJ45 and DB9 .......................................22
Figure List
Figure 1-1
Top View and Side View........................................................................2
Figure 1-2
Front View .............................................................................................3
Figure 1-3
Rear View ..............................................................................................3
Figure 1-4
SM BAT Terminals ................................................................................4
Figure 2-1
Brackets of SM BAT (Top View) ..........................................................12
Figure 2-2
Drill Screw Holes .................................................................................13
Figure 2-3
Insert Expansive Pipe into Reserve Hole ............................................13
Figure 2-4
Wrong Method to Drill Holes................................................................14
Figure 3-1
Connectors and Jumpers.....................................................................15
Figure 3-2
Jumpers of AI 3~AI7 ............................................................................17
Figure 4-1
Connection of Power Terminals...........................................................19
Figure 4-2
Connection of POWER Terminals of Multi SM Modules ......................20
Figure 4-3
Structure and Pin Definition of RJ45....................................................21
Figure 4-4
Wiring Diagram of RS232 ....................................................................22
Figure 4-5
Connections for Cell Voltage Measurement(CELL1~CELL25) ............23
Figure 4-6
Connection of AI1 for System/Battery Voltage Input............................24
Figure 4-7
Connection of AI3 for Shunt Current Input...........................................24
Figure 4-8
Connection of AI for Temperature Sensor Signal Input .......................25
Figure 4-9
Connection of DI Terminals for Digital Input ........................................26
Figure 4-10
RS485 Connection ............................................................................26
Figure 4-11
Typical Application Diagram of SM BAT(2V Cell) ..............................28
Figure 4-12
Typical Application Diagram of SM BAT(6V Cell) ..............................29
Figure 4-13
Typical Application Diagram of SM BAT(12V Cell) ............................30
Figure 5-1
Hardware Test Tools of SM BAT .........................................................32
Figure 5-2
Acquire Equipment Address Step 1.....................................................33
Figure 5-3
Acquire Equipment Address Step 2.....................................................33
Figure 5-4
Acquire Equipment Address Step 3.....................................................33
Figure 5-5
Serial Port Parameter Setting ..............................................................34
Figure 5-6
Read Baud Rate ..................................................................................34
Figure 5-7
Select Baud Rate.................................................................................35
Figure 5-8
Write Baud Rate ..................................................................................35
Figure 5-9
Self-test Information ............................................................................35
Figure 5-10
Measurement Range Conversion ......................................................37
Figure 5-11
Read CFG Step 1 ..............................................................................38
Figure 5-12
Read CFG Step 2 ..............................................................................38
Figure 5-13
Read CFG Step 3 ..............................................................................39
Figure 5-14
Load Configurations ..........................................................................40
Figure 5-15
Write CFG Step1 ...............................................................................40
Figure 5-16
Write CFG Step 2 ..............................................................................41
Figure 5-17
Write CFG Step 3 ..............................................................................41
Figure 5-18
Refreshing Single Channel Configurations Step 1.............................42
Figure 5-19
Refreshing Single Channel Configurations Step 2.............................42
Figure 5-20
Saving Configurations .......................................................................43
Figure 5-21
Acquired Data of Battery Voltage 1~25 and AI 1~7 ...........................43
Figure 5-22
Stopping Data Acquisition..................................................................44
Figure 5-23
Acquire Data of 8 Digital Input Channels...........................................44
Figure 5-24
Value of 8 Digital Input Channels ......................................................45
Figure 5-25
Relay Output Control Panel ...............................................................45
Figure 5-26
SM BAT Output Control: Level Mode ................................................46
Figure 5-27
SM BAT Output Control: Pulse Mode Step 1.....................................46
Figure 5-28
SM BAT Output Control: Pulse Mode Step 2.....................................46
Figure 5-29
SM BAT Output Control: Pulse Mode Step 3.....................................47
Figure 5-30
Read Battery String Configuration .....................................................47
Figure 5-31
Modified Battery String Configuration Step 1.....................................48
Figure 5-32
Modified Battery String Configuration Step 2.....................................48
Figure 5-33
Read Product Information..................................................................49
Figure 5-34
Set Product Information Step1:Revise Product Information ..............49
Figure 5-35
Set Product Information Step2:Select Product Information ...............49
Figure 5-36
Set Product Information Step3:Write Product Information .................50
Figure 5-37
Read System Positive Voltage Reference .........................................50
Figure 5-38
Step 1:Revise System Voltage Reference Value...............................51
Figure 5-39
Step 2:Set System Voltage Reference ..............................................51
Chapter 1 Introduction
1
Chapter 1 Introduction
1.1
Overview
SM BAT is a supervision module that supervises both –48V and +24V
batteries. The unit measures 25 channels of cell voltage, 2 channels of
battery string total voltage, 2 channels of charge/discharge current, and 3
channels of battery temperature. It also has 8 digital inputs and 2 digital
outputs to accomplish the supervision and control functions. It can also
estimate the capacity of battery string.
1.2 Unpacking
When the equipment arrives, make sure that all the boxes listed in the
shipping specification are delivered, and that they have correct serial
numbers.
The final unpacking of each module (or unit) shall not be done until just
before the installation. Otherwise there is a great risk of loose parts getting
lost. When handling printed board assemblies, be sure to wear suitable
ESD-protected gloves.
1.3
Mechanical Features of SM BAT
1.3.1
Appearance of SM BAT
SM BAT hardware mainly consists of a box, a box cover and a circuit
board. The box cover is fixed to the box through screws. The circuit board
is also fixed to the box through screws. See the following Figures.
SM BAT Battery Supervision Module User Manual
2
Chapter 1 Introduction
(a) Outline
(b) Top View
(C) Side View
Figure 1-1
Top View and Side View
In Figure 1-1, there are two LEDs on the box cover. The functions of LEDs
are described in Table 1-1:
Table 1-1
LED Functions
LED
Color
Description
Run LED
Green
The LED turns on to indicate the unit is operating normally.
SM BAT Battery Supervision Module User Manual
Chapter 1 Introduction
Alarm LED
Red
The LED turns on to indicate when the unit has an alarm.
Note
SM BAT has another green LED that indicates the communication status. This
LED is on the circuit board. It flashes if the communication is normal.
Figure 1-2
Front View
Figure 1-2 illustrates that all the terminals and the console port (RJ45
connector) are located in the front panel of SM BAT.
Figure 1-3
Rear View
From Figure 1-3 we can see that there are ventilation holes that are
located in the rear panel of SM BAT.
1.3.2 Sizes and Weight
The sizes and weight of SM BAT unit are given in Table 1-2.
Table 1-2
Unit
Sizes and Weight
Parameters
Tolerance
Height
43mm
<±1.0 mm
Width
300mm
<±1.0 mm
Depth
150mm
<±1.0 mm
Weight
<2 Kg
SM BAT Battery Supervision Module User Manual
3
4
Chapter 1 Introduction
1.3.3
Overview of Terminals
Terminals of SM BAT are illustrated in Figure 1-4.
SM BAT
DI1 DI2 DI5 DI6
+-+- +-+-
Console
Power
ABAB +-+- +-+DI3 DI4 DI7 DI8
+-+- +-+-
Cell Voltage
RS485
+- +-
AI1 AI2 AI5 AI6
DO1
DO2
Figure 1-4
27
15 13
1
28
16 14
2
+-+- +-+AI3 AI4 AI7
SM BAT Terminals
The functions of the terminals are introduced in Table 1-3.
Table 1-3
Connector
Power
Console
RS485
Pin
Signal
Type
1
Power1 +
Input
2
Power1 -
Input
3
Power2 +
Input
4
Power2 -
Input
3
RS232-TXD
Output
4,5
RS232-GND
Signal Gnd
6
RS232-RXD
Input
1
RS485 A
2
RS485B
3
RS485 A
4
RS485B
Signals of Pins
Remark
Power input
Debug terminal
Communicaton terminal
SM BAT Battery Supervision Module User Manual
Chapter 1 Introduction
Connector
DI
DI
DO1
DO2
CELL
VOLTAGE
Pin
Signal
Type
1
DI1+
Input
2
DI1-
Input
3
DI2+
Input
4
DI2-
Input
5
DI3+
Input
6
DI3-
Input
7
DI4+
Input
8
DI4-
Input
1
DI5+
Input
2
DI5-
Input
3
DI6+
Input
4
DI6-
Input
5
DI7+
Input
6
DI7-
Input
7
DI8+
Input
8
DI8-
Input
1
Relay1-NO
Output
2
Relay1-COM
Output
3
Relay1-NC
Output
4
Relay2-NO
Output
5
Relay2-COM
Output
6
Relay2-NC
Output
1
BAT1
Input
2
BAT2
Input
3
BAT3
Input
4
BAT4
Input
5
BAT5
Input
6
BAT6
Input
7
BAT7
Input
8
BAT8
Input
9
BAT9
Input
10
BAT10
Input
11
BAT11
Input
12
BAT12
Input
13
BAT13_T1
Input
14
BAT13_T2
Input
15
BAT13
Input
Remark
Digital input channels can be configured
into voltage inputs and 2k current
inputs.resistance alarm type
24VDC/250VAC 5A
100mS~2600mS to be set (200mS as a
step, error less than 100ms)
Battery voltage measurement interfaces
SM BAT Battery Supervision Module User Manual
5
6
Chapter 1 Introduction
Connector
Pin
Signal
Type
CELL
VOLTAGE
16
BAT14
Input
17
BAT15
Input
18
BAT16
Input
19
BAT17
Input
20
BAT18
Input
21
BAT19
Input
22
BAT20
Input
23
BAT21
Input
24
BAT22
Input
25
BAT23
Input
26
BAT24
Input
AI
27
BAT25
Input
28
BAT26
Input
1
AI1+
Input
2
AI1-
Input
3
AI2+
Input
4
AI2-
Input
5
AI3+
Input
6
AI3-
Input
7
AI4+
Input
8
AI4-
Input
9
AI5+
Input
10
AI5-
Input
11
AI6+
Input
12
AI6-
Input
13
AI7+
Input
146
AI7-
Input
Remark
Battery voltage measurement interfaces
AI1 and AI2 measure total voltage of
battery string;
AI3,AI4,AI5,AI6 and AI7 Measure four
types of signals:
(1) 0 ~ 10 V Voltage; (2) 0 ~ 20 mA
Current; (3) 0 ~ 100m V Voltage
(Shunt current); (4) temperature (current
1 µA/K)
1.4 Function Overview
1.4.1
Hardware Functions
SM BAT measures battery cell voltage, battery string total voltage,
charge/discharge current, battery surface temperature and ambient
SM BAT Battery Supervision Module User Manual
Chapter 1 Introduction
7
temperature, and have the ability of digital inputs and relay control
outputs.
SM BAT measures 25 channels of cell voltage, 2 channels of battery
string total voltage, 5 configurable AI channels which can measure
charge/discharge battery string current, battery surface temperature,
ambient temperature and shunt current.
SM BAT has 2 relay outputs with normally opened contact (NO),
normally closed contact (NC) and common contact (COM). It receives
commands from the host to control the action of relays by means of
level or pulse. In level mode the relays work as they work in general
applications, while in pulse mode the relays output pulse whose width
rates between 100ms and 2600ms with a step of 200ms.
SM BAT has 8 digital inputs. These inputs can be configured for two
modes, one for voltage signal input and the other for contact closure
resistance input. Each of them has two 2-pin jumpers, which shall be
set according to what kind of signal that shall be measured.
SM BAT has two green LEDs and one red LED. Lighting the first green
LED indicates the unit is ok. Flashing the second green LED indicates
the communication status. The second green LED is un-visible on the
enclosure. Lighting the red LED indicates the self-test failure on power
up.
The unit uses a hardware watchdog to supervise its operating. The
watchdog can reset the system when the watchdog timer overflows
due to some severe failure. And the watchdog is also used as a
method by the software to reset the system for some special purpose.
SM BAT has one communication port that accords with the RS485
standard. Via the port SM BAT can exchange data with PCU/ACU and
fulfill the functions of data transmission, remote control as well as
remote update.
SM BAT has one console port that accords with the RS232 standard
that is convenient for local maintenance personnel to configure and
diagnose SM BAT at sites. Through the port all information can be
inspected, which includes configuration information, measured data,
SM BAT Battery Supervision Module User Manual
8
Chapter 1 Introduction
product information and firmware vision as well. This port has higher
priority than the communication port, that is, when it is used the
communication port will be disabled.
1.4.2 Software Functions
On power up SM BAT is able to do self-test, which includes RAM test,
EEPROM test and watchdog test. Once fail in self-test SM BAT will
indicate the problem through red LED.
The active input and output channels can be selected by configuration
information.
All analog inputs have the settable offset and factor except the cell
voltage channel. Default settings for total voltage channel are offset = 0
and factor = 48.046 and for 5 configurable AI channels are offset =
-273.1 and factor = 196.1.
YDN23 protocol is used for access to the unit.
The baud rates of the communication port and the console port are
able to be selected according to the configuration information.
All settings and configurations parameters (i.e. analog/digital, offset
and factor) are stored in a non-volatile memory in SM BAT and not be
lost in the case of power failure.
All configuration information can be downloaded and uploaded locally
and remotely.
The following product information can be retrieved from SM BAT:
Product number, Product Revision (HW), Product Revision (SW),
Serial number, Manufacturing Date, Installation Date, Service Date,
Factory Code.
1.5 Technical Specifications
Table 1-4
type
Input
General Technical Specifications of Power Supply
Description
Input voltage range: 18V-60V; Input current range: <0.5A
SM BAT Battery Supervision Module User Manual
Chapter 1 Introduction
Table 1-5
Type
Working mode
General Technical Specifications of Cell Voltage Input
Description
Range: 0~2.45V Tolenrance <5‰ RG
2V
endurable input: 75 VDC(in –48 V systems)
channel quantity: 25channels(two groups: cell1,12
channels;cell2,13channels)
Total input voltage of each groups: <29.5V
Range: 0~7.35V Tolenrance <5‰ RG
input
6V
endurable input: 75 VDC(in –48 V systems)
channel quantity: 8 channels(two groups: cell1,4
channels;cell2,4channels)
Total input voltage of each groups: <29.5V
Range: 0~14.5V Tolenrance <5‰ RG
12V
endurable input: 75 VDC(in –48 V systems)
channel quantity:4 channels(two groups: cell1,2
channels;cell2,2channels)
Total input voltage of each groups: <29.5V
Table 1-6
Type
General Technical Specifications of Analog Input
Working mode
AI1
AI2
total voltage of
battery string
0 ~ 10 V Voltage
0 ~ 20 mA
Current
input
AI3~AI7
0 ~ 100m V
Voltage
(Shunt current)
1 µA/K
Description
Range: 0~75V Tolenrance <5‰ RG
endurable input: 90 VDC(in –48 V systems)
Range: 0~15V Tolenrance <5‰ RG
endurable input: 75 VDC(in –48 V systems)
Range: 0~20mA Tolenrance <5‰ RG
endurable input: 32mA
Sample resistance: 100 ohm
Range: 0~100mV Tolenrance : ≤1% RG
Max. endurable input :75VDC
Range: -25 °C ~ +85 °C
Error: ≤ 2 °C
SM BAT Battery Supervision Module User Manual
9
10
Chapter 1 Introduction
Table 1-7
Type
General Technical Specifications of Digital Input/Output
Working mode
Input(DI1~DI8)
Voltage
> 4 V => true (1)
< 1 V => false (0)
Max endurable input:60V
Open/close circuit
Alarm at < 2 kΩ
Output(RLY1,RLY2)
Output capacity: 24VDC/250VAC/5A
Table 1-8
type
One communication port
One console port
Description
General Technical Specifications of Communication Port
Description
RS485 isolated asynchronous port
Baud rate: 1200bps/2400bps/4800bps/9600bps/19200bps set by software.
Data format: 8, N, 1
Fulfill the functions of data transmission, alarm report, remote control as well
as remote update.
RS232 isolated asynchronous port
Baud rate:
1200bps/2400bps/4800bps/9600bps/19200bps set by software;
Data format: 8, N, 1
Table 1-9
Technical Specifications for Environments
Description
Operating
Item
Site
Indoor
Ambient
temperature
-10℃~ +70℃(Irregular)/ -40℃~70℃(Non destructive )
Relative humidity
Environment
Environment
Storage
Altitude
Cooling mode
Site
Ambient
temperature
Relative humidity
Installation
Rack and wall mounting.
Protection level IP20 of IEC 529
0℃~ +50℃(Normal)/-5℃~ +60℃(Reduced)/
10%~80%(Normal)RH/5%~95%RH(Reduced)
Free of dust, erode gas, ignitable gas, oil fog, vapor,
water dropping, salinity and etc
Under 3000m
Air cooling without fan
Indoor
-40℃~70℃
5%~95%RH
SM BAT Battery Supervision Module User Manual
Chapter 1 Introduction
Item
11
Description
≥ 10×10 Ω , Ambient Temperature: 25±5
6
Insulation
Resistance
Insulation
EMC
Safety
DC-Enclosure
℃, Relative Humidity: 90％(no
condensation), Testing Voltage: 500VDC
Be able to withstand 50Hz AC voltage with
effective value of 500V for 1 min, without
Dielectric Strength
DC-Enclosure
arc or breakdown; The leakage current
should be less than 30mA.
Comply with EN 55022, EN 61000-4-6, EN 61000-4-2, EN 61000-4-4, EN
61000-4-5, and EN 61000-4-29
Comply with the safety standard: EN60950, UL60950, GR-63, GR-1089.
Safety certifications: CE, UL.
SM BAT meet the requirement of NEBS level 3.
SM BAT Battery Supervision Module User Manual
12
Chapter 2 Installation
Chapter 2 Installation
2.1
Installation Environment
Recommended ambient temperature should be within the range of 0℃
~50℃. The performance of SM BAT will be reduced if the temperature
is higher than 50℃;
Humidity should be lower than 80% without condensation;
Mount unit in area free of direct sunlight, dust, metal powder, and
corrosive gas.
If there are any special requirements for installation, please contact us in
advance.
2.2
Installation Method
2.2.1
Wall Mounting
Bracket
Figure 2-1
Brackets of SM BAT (Top View)
SM BAT Battery Supervision Module User Manual
Chapter 2 Installation
13
The SM BAT module is mounted on a wall through its two brackets that are
mounted at the top. Installation Procedures:
Step 1: Use a pencil to mark the location of screw holes on the wall;
Step 2: Use a Φ6mm drill bit to drill holes in the wall, depth 60mm. To avoid
being off center, make sure drill remains steady, and is kept vertical
position (perpendicular to the wall). See Figure 2-2.
Wall
Hand drill
Figure 2-2
Drill Screw Holes
Step 3: Insert the expansive pipe into the reserve hole, and knock it gently
using a hammer until top of the expansive pipe is flush with the wall. See
Figure 2-3.
Wall
Figure 2-3
Insert Expansive Pipe into Reserve Hole
SM BAT Battery Supervision Module User Manual
14
Chapter 2 Installation
Step 4: Align the screw holes of the SM BAT unit to the reserve holes in the
wall;
Step 5: Fasten the SM BAT with a screw (M6X60mm) and a washer. Min
torque: 50Nm, Max torque: 80Nm.
Note
To avoid damage to SM BAT, it is recommended to pre-drill holes prior to
installation. Do not use the SM BAT unit as a guide to drill holes in wall.
Wall
SM BAT Bracket
Figure 2-4
Wrong Method to Drill Holes
2.2.2 Rack Mounting
The SM BAT module can also be mounted in a rack vertically or
horizontally with a tray underneath it through its two brackets if the rack
has been previous prepared with the installation space and screw holes for
the module. The mounting process is simple. First align the screw holes of
the module to the reserve holes in the rack. Then fasten the module to the
rack with a screw and a washer.
SM BAT Battery Supervision Module User Manual
Chapter 3 SM BAT Hardware Configuration
15
Chapter 3 SM BAT Hardware Configuration
3.1 Hardware Overview
SM BAT has one power port for input and one for output, one RS232 port
for debugging and one RS485 port for networking, three relay output ports
with NO, NC and common contacts, one frequency input port, seven
digital/ analog input ports and five galvanically isolated analog digital input
ports.
The connectors and jumpers are shown in Figure 3-1.
Figure 3-1
Connectors and Jumpers.
Dimension: 300mm*150mm*43mm
Weight: <2Kg
SM BAT Battery Supervision Module User Manual
16
Chapter 3 SM BAT Hardware Configuration
3.2 Earth Reference
Set the jumper for internal earth reference to a suitable level.
Jumper (J4824) for internal earth reference:
1
2
3
When SM BAT is fed by a -48V system, this jump should be 1-2 on. When
SM BAT is fed by a +24V system, it should be 2-3 on. The former(1-2 on)
is factory setting.
3.3 RS485 Termination
Set the jumper for the proper termination of RS485 network.
Jumper (J485) for RS485 termination:
1
2
3
1-2 ON:Termination off
2-3 ON:Termination on
In most case the RS485 termination is not necessary, because the
maximum data rate is only 19200 bps. But the RS485 termination is
recommended if the network is over long distance.
The jumper should be 1-2 on for RS485 termination off, and it is the factory
setting. The 3-3 on is for RS485 termination on.
3.4 Analog Input AI3 ~ AI7
Set the jumpers for the analog input channels in their correct positions.
The SM BAT can be used for up to five analog inputs.
Each analog input channel has five 3-pin jumpers, which are set according
to what type of analog signal that shall be measured.
Jumpers for AI 3~7 are shown as below:
SM BAT Battery Supervision Module User Manual
Chapter 3 SM BAT Hardware Configuration
17
1-2
3-4
5-6
7-8
9-10
Figure 3-2
Table 3-1
Jumpers of AI 3~AI7
Analog Inputs of AI 3~AI7
0 ~ 10V (DC)
1-2
OFF
Jumper position
3-4
5-6
7-8
OFF
OFF
OFF
9-10
OFF
0 ~ 20 mA
OFF
ON
ON
OFF
ON
0 ~ 100 mVDC
1uA/K
OFF
ON
OFF
OFF
ON
OFF
OFF
ON
ON
ON
Type of input signal
Range
Voltaget
General-purpose
transducers
Shunt current
Temperature
Note
2
Note
1. AI1~AI2 :To get the real measured voltage, the four parameters in TOOLS99E
shall be set to: DC_CURRENT_SIGNAL and X1 = 0, Y1 = 0, X2 = 1.561, Y2 =
75.
2. To get the real measured temperature, the four parameters in TOOLS99E shall
be set to: DC_VOLTAGE_SIGNAL and X1 = 1.265, Y1 = -25, X2 = 1.928, Y2 =
105.
3. In other case, the four parameters in TOOLS99E shall be set to X1 = 0, y1 = 0,
X2 = 1, Y2 = 1 to get the measured value
Attention
If voltage is applied to an input set for current input, the input measurement
resistance will be overheated and damaged.
3.5 Digital Input DI1 ~ DI8
Set the jumpers for the digital input channels in their correct positions:
SM BAT Battery Supervision Module User Manual
18
Chapter 3 SM BAT Hardware Configuration
Each digital input channel has 2-pin jumpers, which are set according to
what type of digital signal that shall be measured.
Jumpers for DI1~DI8 are shown as below:
Table 3-2
Type of input signal
Voltaget
Open/close circuit
Range
Digital Inputs of DI1~DI8
Jumper position
1-2
3-4
> 4 V => true (1)
< 1 V => false (0)
OFF
OFF
Alarm at < 2 kΩ
OFF
ON
Note
Max endurable
input:60V
3.6 Cell Type Configuration
The voltage of 2V cell, 6V cell and 12V cell can be measured through jumper
setting: Jumper J174 and J171.
Table 3-3
Type of Cell input
signal
Range
2V
6V
12V
0-2.45V
0-7.35V
0-14.5V
Cell Type Configuration
Jumper position
J175
J171
1-2
NUll
2-3
1-2
2-3
2-3
SM BAT Battery Supervision Module User Manual
Note
Chapter 4 Connections
19
Chapter 4 Connections
4.1 Power Supply Connection
SM BAT is powered by a power supply with voltage range of 18 ~ 60 VDC.
The power is fed to SM BAT through its POWER terminal. Connection of
power terminals is very simple. Procedures are as following:
Step 1: Set the Jumper J4824 according to Section 3-2;
Step 1: Connect the plus power terminal (+) of SM BAT to the plus terminal
of power supply;
Figure 4-1
+
+
-
SM BAT
DC
Power
Supply
POWER
Step 2: Connect the minus power terminal (-) of SM BAT to the minus
terminal of power supply. See Figure 4-1:
-
Connection of Power Terminals
SM BAT has two other power supply terminals that are plus terminal and
minus terminal respectively. When SM BAT is used together with another
SM BAT or when it is used together with other SM modules such as SM IO,
the user can connect the POWER terminals of SM BAT or SM IO directly
to these other two terminals of SM BAT instead of connecting the POWER
terminals to the power supply if SM IO and SM BAT are set to the same
voltage input range. This is very convenient for installation and wiring. As
shown in the Figure 4-2:
SM BAT Battery Supervision Module User Manual
20
Chapter 4 Connections
DC
Power
Supply
DC Power
Supply
+
-
+
-
- +
- +
Power Supply Terminals
POWER
SM BAT
Figure 4-2
SM IO/SM BAT/SM AC
Connection of POWER Terminals of Multi SM Modules
Note
SM BAT is a DC-powered unit, polarity must be observed even though it is
protected against reverse connection of power supply terminals.
4.2 Connection of Configuration Port
Configuration port of SM BAT is a RS232 port. It uses RJ45 socket. The
structure and pin definition of RJ45 are shown in Figure 4-3:
SM BAT Battery Supervision Module User Manual
Chapter 4 Connections
RJ45 socket
RJ45 socket
RJ45 plug-in
Figure 4-3
Structure and Pin Definition of RJ45
Pin configurations of RJ45 are given in Table 4-1:
Table 4-1
RJ45 pins
Source
RJ45 Signal Definition
Abbreviation
Signal definition
1
DTE
RTS
NC(Not Connected)
2
DTE
DTR
NC
3
DTE
TD
Transmitting Data
4
SG
Signal Grounding
5
SG
Signal Grounding
6
DCE
RD
Receiving Data
7
DCE
DSR
NC
8
DCE
CTS
NC
RJ45 connector applies to RS-232 serial communication. Console cable
wiring diagram is shown as follows:
SM BAT Battery Supervision Module User Manual
21
22
Chapter 4 Connections
host
RS-232
RS232
console
RJ45 plug-in
DB9 female
Figure 4-4
Table 4-2
Wiring Diagram of RS232
Relationship between Pins of RJ45 and DB9
RJ45
Pin 6
Pin 5
Pin 4
Pin 3
DB9
Pin 3
Pin 5
Pin 5
Pin 2
4.3 Connections for Cell Voltage Measurement
SM BAT measures 25 channels of cell voltage signals.
SM BAT Battery Supervision Module User Manual
Chapter 4 Connections
Figure 4-5
23
Connections for Cell Voltage Measurement(CELL1~CELL25)
The incoming feeding cables shall be plugged into the terminal blocks
according to the symbols on the enclosure.
This chart shows the connections of 2V-cell, see section 4.7 for the wiring
of battery and the requirement.
4.4 Connection of Analog Input(AI) AI1 ~ AI7
4.4.1
Connection of AI1 and AI2 for System/Battery Voltage Input
AI1 is input with system/battery voltage input (0~75V), connect the
terminals according to Figure 4-6:
SM BAT Battery Supervision Module User Manual
24
Chapter 4 Connections
Figure 4-6
Connection of AI1 for System/Battery Voltage Input
AI2 is also input with system/battery voltage input (0~75V). Connection of
AI2 is the same with that of AI1.
4.4.2
Connection of AI3,AI4,AI5,AI6 andAI7 for Shunt Current Input
When the AI3 is input with shunt current input (0 ~ 100 mVDC), set the
corresponding jumper for shunt current input. See Chapter 3 for details of
jumper setting. After setting the jumper, connect the terminals according to
Figure 4-7:
Figure 4-7
Connection of AI3 for Shunt Current Input
AI4 can also be configured for shunt current input. Under this situation,
connection of AI4 is the same with that of AI3.
SM BAT Battery Supervision Module User Manual
Chapter 4 Connections
25
4.4.3 Connection of AI3,AI4,AI5,AI6 and AI7 for Temperature Sensor
Signal Input
When the AI5 is input with temperature sensor signal input, set the jumper
for temperature sensor signal input. See Chapter 3 for details of jumper
setting. After setting the jumper, connect the terminals according to Figure
4-8:
Temperature
Sensor
Signal Input
Differential
Amplifier
SM BAT
AI5
+
5.1k Ω
-
5.1k Ω
GND
+24V
SM BAT Module
Figure 4-8
Connection of AI for Temperature Sensor Signal Input
The recommended model of temperature sensor is AD592. The parameter
of the sensor is 1µk/°C. AI3, AI4, AI6 and AI7 can also be configured for
temperature sensor signal input. Under this situation, connection of AI3,
AI4, AI6 and AI7 is the same with that of AI5.
4.5 Connection of DI Terminal for Digital Input
When the DI is input with digital signal (maximum input is 65VDC), set the
corresponding jumpers for digital input. See Chapter 3 for details of jumper
setting. After setting the jumper, connect the terminals according to Figure
4-9:
SM BAT Battery Supervision Module User Manual
26
Chapter 4 Connections
SM BAT
DI
+
Digital
Signal Input
A/D
Converter
-
GND
Operation
Amplifier
SM BAT Module
Figure 4-9
Connection of DI Terminals for Digital Input
Pay attention to the polarities of the DI terminals when connecting cables.
Reverse connection will damage the DI channels.
4.6 Connections of RS485
SM BAT also communicates to controller and reports the data to the
controller such as ACU through RS485 when ACU queries these data.
SM BAT has four RS485 terminals. When SM BAT is used together with
another SM BAT or other supervision modules such as SM IO and SM AC,
these modules can form a network through RS485 ports. See Figure 4-10.
DC
Power
Supply
Controller
A
B
A
B AB
RS485 Terminals
SM BAT
Figure 4-10
A
B
RS485 Terminals
SM IO (Or SM AC)
RS485 Connection
SM BAT Battery Supervision Module User Manual
Chapter 4 Connections
27
Available standard baud rates are 1200, 2400, 4800, 9600 and 19200. The
unit operates up to 19200 baud. For a smaller number of units over a long
distance, use a lower baud rate. Optimal recommended baud rate is 9600
baud, if noisy conditions exist
4.7 Typical Application
4.7.1 2V Cell typical application
SM BAT Battery Supervision Module User Manual
28
Chapter 4 Connections
Figure 4-11
Typical Application Diagram of SM BAT(2V Cell)
AI1 of SM BAT measures one battery string total voltage. AI4 measures the
shunt current, AI6 measures the ambient temperature and AI7 measures
the battery temperature. Cell voltage terminals measure the battery cell
voltages. Figure 4-11 shows the connection. Before connecting the cables,
be sure to set the corresponding jumpers according to Chapter 3. The
incoming feeding cables shall be plugged into the terminal block according
to the symbols on the unit.
SM BAT Battery Supervision Module User Manual
Chapter 4 Connections
4.7.2 6V Cell typical application
Figure 4-12
Typical Application Diagram of SM BAT(6V Cell)
SM BAT Battery Supervision Module User Manual
29
30
Chapter 4 Connections
4.7.3
12V Cell typical application
Figure 4-13
Typical Application Diagram of SM BAT(12V Cell)
SM BAT Battery Supervision Module User Manual
Chapter 5 SM BAT Debugging
31
Chapter 5 SM BAT Debugging
5.1
Overview
SM BAT module can acquire 25-channel battery cell voltage, 2-channel
battery string total voltage, 5-channel configurable analog voltage (or
current) signal, 8-channel digital input signal, and provide 2-channel digital
output control.
SM BAT is debugged through TOOLS99E V1.00 or higher.
Before debugging SM BAT with TOOLS99E, you should first set
“Communication Port” and get “Local Address”, and then click [Read CFG]
(read configuration) to view or modify the configurations of SM BAT, as
shown in Figure 5-1:
SM BAT Battery Supervision Module User Manual
32
Chapter 5 SM BAT Debugging
Figure 5-1
Hardware Test Tools of SM BAT
The local address of SM modules is from 0 to 255, which address of 0 1,
255 reserved. Firstly, make sure that the communication cable was
connected to the SM BAT module. Secondly, click [Address] to acquire the
equipment address and communication protocol version, See Fig5-2 and
Figure 5-3:
SM BAT Battery Supervision Module User Manual
Chapter 5 SM BAT Debugging
Figure 5-2
Acquire Equipment Address Step 1
Figure 5-3
Acquire Equipment Address Step 2
33
Click “ok” to execute the acquire address operation, See Figure5-4:
Figure 5-4
Acquire Equipment Address Step 3
Baud rates: 1200bps/2400bps/4800bps/9600bps/19200bps set by software.
The default setting of serial port is: 9600, N, 8, 1.The serial port parameter
setting is shown as Figure 5-5:
SM BAT Battery Supervision Module User Manual
34
Chapter 5 SM BAT Debugging
Figure 5-5
Serial Port Parameter Setting
Baud rate can be read and modified respectively, See Figure5-6:
Figure 5-6
Read Baud Rate
SM BAT Battery Supervision Module User Manual
Chapter 5 SM BAT Debugging
Figure 5-7
Select Baud Rate
Figure 5-8
Write Baud Rate
35
On power up and system running SM BAT will do self-test, which includes
CPU test, EEPROM test, watchdog test, and voltage reference test.
Self-test result can be read for SM BAT, see Figure5-8:
Figure 5-9
Self-test Information
SM BAT Battery Supervision Module User Manual
36
Chapter 5 SM BAT Debugging
5.2 Channel Configuration
The options on the configuration interfaces are described below.
1. Channel Number
SM BAT has 40 input channels and 2 output channels, among which
battery voltage 1~25 are used to measure battery cell voltage, AI 1~2(Total
Volt1~2) are used to measure battery string total voltage, AI 3~7 are used
to measure different kinds of analog signals such as shunt current,
system/battery voltage, general transducers (4~20mA or 0~20mA) and
temperature (using AD592, 1uA/k), DI 1~8 are used to measure digital
input signal, output channels 1~2 are used for remote control,
2. Status
The status values of battery voltage 1~25 are:
Disabled
DC voltage signal
The status values of AI1~2 (Total Volt 1~2) are:
Disabled
DC voltage signal
The status values of AI3~7 are:
Disabled
DC voltage signal
DC current signal
No configuration for DI channels
SM BAT Battery Supervision Module User Manual
Chapter 5 SM BAT Debugging
37
Attention
Channels without being connected with signals are set at “Disable”.
The AI 1~2(Total Volt 1~2) are fixed for battery string total voltage. You should
first confirm that the battery string voltage signal has been installed and then set
the channel at “DC voltage signal” if you want to acquire battery string total
voltage.
3. X1, Y1, X2,Y2
The four parameters are for measurement range conversion, i.e., to
convert the acquired voltage value into a value with physical meaning.
They determine two points on a 2-dimension coordinate axis, and thus
define a line. X1 and X2 are in unit of Volt or Amp. X1 must not equal X2
and neither do Y1 and Y2. Take the current sensor with 4~20mA output for
an example, the sensor outputs 4mA when current input is zero and output
20mA when current input is 1000A. See Figure 5-8:
Current
（X2，Y2）
X1=0.004A
Y1=0.0A
X2=0.020A
Y2=1000A
（X1，Y1）
0.004
Figure 5-10
0.020
Current
Measurement Range Conversion
So, the parameters can be configured as X1=0.004, Y1=0, X2=0.020,
Y2=1000. Since the digital value is acquired in the form of analog value,
for digital value, the parameters should be set at X1=0.0, Y1=0.0, X2=1.0,
Y2=1.0.
SM BAT Battery Supervision Module User Manual
38
Chapter 5 SM BAT Debugging
Attention
No parameters for cell voltage channel
The parameters of AI1~2 (Total Volt 1~2) channel must be: X1=0.0, Y1=0.0,
X2=1.561, Y2=75.0.
For AI 3~7, when select analog input signal of the temperature sensor (1uA/K),
the parameters of channel must be: X1 = 1.265, Y1 = -25, X2 = 1.928, Y2 = 105.
In other case, the four parameters in TOOLS99E shall be set to X1 = 0, y1 = 0, X2
= 1, Y2 = 1 to get the measured value
Figure 5-11
Read CFG Step 1
Figure 5-12
Read CFG Step 2
SM BAT Battery Supervision Module User Manual
Chapter 5 SM BAT Debugging
Figure 5-13
39
Read CFG Step 3
When maintaining SM BAT or the data measured by two SM BAT modules
are exactly the same, you may not reset the configuration. Click [Load
CFG], you will see the interface shown in Figure5-14:
SM BAT Battery Supervision Module User Manual
40
Chapter 5 SM BAT Debugging
Figure 5-14
Load Configurations
Select the file to be configured and then click [Open] and [Write CFG] to
complete the configuration.
Figure 5-15
Write CFG Step1
SM BAT Battery Supervision Module User Manual
Chapter 5 SM BAT Debugging
Figure 5-16
Write CFG Step 2
Figure 5-17
Write CFG Step 3
41
If you modify only one channel and the others remain unchanged, you may
just send the changed configurations to SM BAT, no need to press [Write
CFG] button. Move the mouse to the channel to be modified and right click
it to enter the interface as shown below. Then point the mouse at “Refresh
channel setting” and left click it.
SM BAT Battery Supervision Module User Manual
42
Chapter 5 SM BAT Debugging
Figure 5-18
Refreshing Single Channel Configurations Step 1
Figure 5-19
Refreshing Single Channel Configurations Step 2
Click the “ok” button to refresh the single channel configurations.
Click [Save CFG], Your new configuration will be saved in the pre-created
directory, as shown in Figure5-19:
SM BAT Battery Supervision Module User Manual
Chapter 5 SM BAT Debugging
Figure 5-20
Saving Configurations
5.3 Date acquisiton and Output Control
You can click [Acquire] to see the quantified data of Battery voltage 1~25
and AI 1~7.
Figure 5-21
Acquired Data of Battery Voltage 1~25 and AI 1~7
After confirming all data are normal, click [Acquire] again to stop data
acquisition.
SM BAT Battery Supervision Module User Manual
43
44
Chapter 5 SM BAT Debugging
Figure 5-22
Stopping Data Acquisition
SM BAT has 8 digital input channels. You can [Switch] to see the value of
each channel. The value of 8 digital input channel are displayed in Switch
signal list, see Figure5-23
Figure 5-23
Acquire Data of 8 Digital Input Channels
SM BAT Battery Supervision Module User Manual
Chapter 5 SM BAT Debugging
Figure 5-24
Value of 8 Digital Input Channels
SM BAT has 2 output control channels (relay output channel 1~2). The
relay output control panel is shown as Figure 5-25:
Figure 5-25
Relay Output Control Panel
There are 4 output types on the remote control interface. Refer to Figure
1-12:
A. Constant low level
B. Constant high level
C. High-level pulse (set in the Pulse Width box)
D. Low-level pulse (set in the Pulse Width box)
The unit time of pulse width is ms, ranging from 100ms to 2600ms, with
increment of 100ms at a click.
SM BAT Battery Supervision Module User Manual
45
46
Chapter 5 SM BAT Debugging
Select the relay output channel and the output type, Click [Control] execute
the operation.
Figure 5-26
SM BAT Output Control: Level Mode
Figure 5-27
SM BAT Output Control: Pulse Mode Step 1
Figure 5-28
SM BAT Output Control: Pulse Mode Step 2
SM BAT Battery Supervision Module User Manual
Chapter 5 SM BAT Debugging
Figure 5-29
47
SM BAT Output Control: Pulse Mode Step 3
5.4 Battery String Configuration
There are 5 battery string configurations for SM BAT: Typical configuration
1~4 and user defined configuration.
Battery string configuration can be read and modified by tools99e
respectively, See Figure5-30 and Figure5-31:
Figure 5-30
Read Battery String Configuration
SM BAT Battery Supervision Module User Manual
48
Chapter 5 SM BAT Debugging
Figure 5-31
Modified Battery String Configuration Step 1
Figure 5-32
Modified Battery String Configuration Step 2
5.5 Product Information
The following product information can be retrieved from SM BAT (“*”
indicates which items can be revised):
Product Number
Factory Code
Product Revision, HW*
Product Revision, SW
Serial Number*
Manufacturing Date*
Installation Date*
SM BAT Battery Supervision Module User Manual
Chapter 5 SM BAT Debugging
49
Service Date*
Figure 5-33
Read Product Information
Enter the product information in the edit box, and then select the type of
product information, refer to Figure5-34:
Figure 5-34
Set Product Information Step1:Revise Product Information
Figure 5-35
Set Product Information Step2:Select Product Information
SM BAT Battery Supervision Module User Manual
50
Chapter 5 SM BAT Debugging
Click “Write” to revise the product information.
Figure 5-36
Set Product Information Step3:Write Product Information
5.6 System Voltage Reference
There are 2 positive voltage references in SM BAT, which can be read and
write respectively, see Figure
Figure 5-37
Read System Positive Voltage Reference
SM BAT Battery Supervision Module User Manual
Chapter 5 SM BAT Debugging
Figure 5-38
Step 1:Revise System Voltage Reference Value
Figure 5-39
Step 2:Set System Voltage Reference
SM BAT Battery Supervision Module User Manual
51
52
Chapter 6 Troubleshooting and Maintenance
Chapter 6 Troubleshooting and Maintenance
6.1 LED Indication Error
Requirement
Run LED blinks and Alarm LED turns off during the initialization process
after the SM BAT is switched on. After the initialization process is over, Run
LED turns on to indicate normal operation and Alarm LED turns on when
self-test failure occurs.
Issue
When SM BAT is powered on, Run LED does not blink
Solution
Check whether the power input wiring of SM BAT is correct or not and use
a multimeter to check whether the power supply voltage meets the
requirement or not.
Check whether the wiring of other terminals is correct.
6.2 Error Messages
Issue
Error Messages are shown when using the TOOLS99E software to view
the information of the SM BAT.
Solution
Watchdog error: The watchdog is damaged and the unit should be
replaced.
EEPROM error: The EEPROM is damaged and the unit should be
replaced.
SM BAT Battery Supervision Module User Manual
Chapter 6 Troubleshooting and Maintenance
53
System voltage reference error: The voltage reference is error and the unit
should be replaced.
6.3 Wrong Measurement
Issue
The SM BAT is unable to obtain correct data when doing measurement.
Solution
Check if the software configuration for every channel such as channel
parameter setting is correct;
Check if the hardware configuration such as jumper setting is correct.
Make sure that the hardware configuration complies with the software
Check if the input cable is well connected to the wiring terminal;
Check if the voltage of the power supply is normal.
6.4
Invalid Data
Issue
During Data Configuration of SM BAT, an Error Message “Invalid Data”
appears.
Solution
Check if the following requirements are met when configuring data for the
SM BAT module:
X1 cannot be equal to the X2;
Y1 cannot be equal to the Y2.
6.5 No Action of Relay
Issue
The relays of SM BAT for digital output do not act.
SM BAT Battery Supervision Module User Manual
54
Chapter 6 Troubleshooting and Maintenance
Solution
Check whether the Run LED indication is correct or not. See Section
2.1 for the correct Run LED indication.
Check whether the power supply voltage of SM BAT is normal.
Replace the SM BAT module if above solutions do not work.
6.6 RS232 Communication Failure
Issue
When configuring SM BAT, the communication of configuration port
(RS232) fails.
Solution
Check if the connections between computer RS232 serial port, the console
cable and the console port of the tested module, are correct.
Make sure the debugging software “Serial port configuration” has the same
communication baud rate setting as that of the module and that port
number is the same as the actually used computer serial port number.
Confirm that the debugging software “Serial port configuration” has the
same slave address as the hardware setting of the module.
Use the “Equipment address” command button to read the address of
tested module. If the operation fails, the module may be damaged or the
computer serial port is damaged or the setting of the serial port in
computer “Control panel” is wrong.
Check if the address obtained by using the “Local address” command
button is the same as the preset address. If the answer is no, carefully
check the address switch to see if it is put in the desired position or if the
address switch is damaged.
SM BAT Battery Supervision Module User Manual
Chapter 6 Troubleshooting and Maintenance
6.7 RS485 Communication Failure
Issue
The communication of RS485 port fails.
Solution
Check whether the wiring of the RS485 port is correct:
RS485 A is connected to RS485 A
RS485 B is connected to RS485 B
SM BAT Battery Supervision Module User Manual
55
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