Alber BDS-40 User manual

BDS–40
Battery Diagnostic System
Installation Instructions
7775 West Oakland Park Blvd
Sunrise, FL 33351
Tel: [phone]
www.Albér.com
4200–045

Table of Contents
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Table of Contents
1LEGAL INFORMATION............................................................................................1
1.1 FCC DECLARATION OF CONFORMITY...................................................................... 1
1.2 REGULATORY INFORMATION.................................................................................... 1
1.2.1 Type Of Service ...................................................................................................... 1
1.2.2 Telephone Company Procedures............................................................................ 1
1.3 SERVICE...................................................................................................................... 1
2SAFETY INFORMATION..........................................................................................2
2.1 General......................................................................................................................... 2
2.2 Before Applying Power.................................................................................................. 2
2.3 Ground the Equipment/Chassis..................................................................................... 3
2.4 Fuses............................................................................................................................ 3
2.5 Do Not Remove Equipment Cover ................................................................................ 3
2.6 Do Not Operate Damaged Equipment........................................................................... 3
2.7 Do Not Service or Adjust Alone..................................................................................... 4
2.8 Do Not Substitute Parts or Modify Equipment ............................................................... 4
2.9 Ensure Rack/Chassis/Shelving/Mounting Stability......................................................... 4
2.10 Radiated Immunity........................................................................................................ 4
2.11 Insulation Rating for Wires ............................................................................................ 4
2.12 Ventilation..................................................................................................................... 4
2.13 Drawings....................................................................................................................... 4
2.14 Warning......................................................................................................................... 4
2.15 Caution ......................................................................................................................... 5
2.16 Note:............................................................................................................................. 5
2.17 Safety Symbols............................................................................................................. 5
3EMERGENCY SHUTDOWN SWITCH/ DISCONNECT DEVICE..............................5
3.1 BDS–40 Disconnect Device .......................................................................................... 5
3.2 Uninterruptible Power Supply UPS................................................................................ 6
4PREVENTIVE MAINTENANCE................................................................................6
4.1 Visual Inspection........................................................................................................... 6
4.2 Cleaning System Components...................................................................................... 6
4.3 Fans and Vents............................................................................................................. 6
4.4 Sense Leads (When Applicable) ................................................................................... 6
4.5 Internal Components..................................................................................................... 6
4.6 Shipping, Storage, Normal Use Protection.................................................................... 7
5PRODUCT OVERVIEW............................................................................................7
5.1 Normal Operating Mode................................................................................................ 7
5.2 Discharge Mode............................................................................................................ 7
5.3 Resistance Test Mode................................................................................................... 8
5.4 BDS–40 Features.......................................................................................................... 8
5.4.1 Alarm Features........................................................................................................ 8
5.5 Materials ....................................................................................................................... 8

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5.5.1 Optional..................................................................................................................13
5.6 Tools............................................................................................................................14
5.7 Building Management System Integration....................................................................16
5.8 Panel Controls And Indicators......................................................................................16
5.9 BDS System Specifications..........................................................................................16
6BEFORE SYSTEM INSTALLATION ......................................................................16
6.1 Required Drawings.......................................................................................................16
6.2 System Configurations.................................................................................................17
6.3 Location Consideration.................................................................................................19
6.3.1 Check Service Access............................................................................................19
6.3.2 Maximum Wire And Cable Lengths........................................................................19
6.3.3 Fiber Optic Cable And BDS–40 Communication Information..................................19
6.3.4 Sense Lead Harness Routing From BDS–40 To The Battery.................................20
7BEGIN SYSTEM INSTALLATION..........................................................................22
7.1 Identify and Verify Cells, Markings, Load Steps, Configuration, etc..............................23
7.2 Prepare All Batteries ....................................................................................................23
7.2.1 Fit Tab Washers.....................................................................................................23
7.2.2 Check Sense Lead Routing From BDS–40 To The Battery....................................25
7.2.3 Sense Leads Connection .......................................................................................25
7.2.4 Internal Resistance Load Lead Cable Connecting..................................................25
7.2.5 Discharge Current Sensor (Optional) .....................................................................25
7.2.6 Temperature Sensor (Optional)..............................................................................26
7.2.7 Float Current Sensor (Optional) .............................................................................27
7.2.8 Alarm Contacts And Remote Alarm Reset..............................................................31
7.3 Base To Plus Unit Fiber Optic Connection ...................................................................32
8FINAL STEPS CONNECTING TO BATTERY TERMINALS ..................................33
8.1 Connect Cell Voltage Sense Lead Harness To BDS–40 ..............................................33
8.2 Installing The Cable Hood............................................................................................33
9FINAL STEPS COMMUNICATION CONNECTIONS .............................................33
9.1 Use With Local Computer ............................................................................................33
9.2 Use With No Local Computer.......................................................................................34
9.3 Communications Connections......................................................................................35
9.3.1 Modem...................................................................................................................35
9.3.2 USB .......................................................................................................................35
9.3.3 RS–232..................................................................................................................36
9.3.4 RJ–45 ....................................................................................................................36
10 DRAWINGS ............................................................................................................36

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Table Of Figures
Figure 1. Sense Lead Harness................................................................................................... 8
Figure 2. 2 Cond 16 GA Black Zip Cord..................................................................................... 9
Figure 3. Fiber Optic Cable........................................................................................................ 9
Figure 4. Fiber Optic Polishing Kit.............................................................................................. 9
Figure 5. BDS–40 System.......................................................................................................... 9
Figure 6. 2 POS/8 POS Pluggable Terminals............................................................................10
Figure 7. 7’ Telephone Cable–UL..............................................................................................10
Figure 8. Exterior USB Cable....................................................................................................10
Figure 9. Tab Washers..............................................................................................................11
Figure 10. Lock Washer............................................................................................................11
Figure 11. Screws.....................................................................................................................11
Figure 12.Controller Power Cord(s)...........................................................................................12
Figure 13. RS–232 Cable..........................................................................................................12
Figure 14. ¼” Heat Shrink Tubing .............................................................................................12
Figure 15. Multitel Float Charging Current Probe Kit.................................................................13
Figure 16. AC Wall Plug Transformer.......................................................................................13
Figure 17. Ambient Temperature Probe & Assembled pn 1101–745.........................................13
Figure 18. 600 Amp Current Transducer CT Assembly.............................................................14
Figure 19. Panduit CT–260 Crimper..........................................................................................14
Figure 20. Panduit CT–1525 Crimper........................................................................................14
Figure 21. Panduit CT–1550 Crimper........................................................................................15
Figure 22. Thomas & Betts WT–111–M For Crimper.................................................................15
Figure 23. #2 Phillips–Head Screwdriver With Insulated Handle..............................................15
Figure 24. Flat–Head Stubby Screwdriver.................................................................................15
Figure 25. Digital Voltmeter.......................................................................................................15
Figure 26. Molex Crimp Tool.....................................................................................................16
Figure 27. Computer/PC...........................................................................................................16
Figure 28. BMDM Software Icon...............................................................................................16
Figure 29. Minimum Bend Radius Of Fiber Optic Cable............................................................20
Figure 30. NOTES From Drawing BDS–5274–B1054...............................................................22
Figure 31. Snapshot BDS–1179–A581 .....................................................................................24
Figure 32. Snapshot CT BDS–1189–B985................................................................................26
Figure 33. Temperature Sensor Connections Snapshot BDS–1189–B985................................26
Figure 34. FCCP Snapshot Of BDS–1189–B985......................................................................27
Figure 35. Multitel FCCP pn 5610–051 Part Of KIT–1101–749.................................................27
Figure 36. FCCP Cable.............................................................................................................28
Figure 37. Multitel FCCP Rear Panel.......................................................................................28
Figure 38. FCCP Connections ..................................................................................................28
Figure 39. Multitel’s FCCP With The Power Source And Inline Fuseholder..............................28
Figure 40. From Multitel's FCCP Manual–Routing The Cable...................................................29
Figure 41. Float Current Sensor................................................................................................29
Figure 42. Section 6.3 Of Multitel’s FCCP Installation Manual Pg. 38 .......................................30
Figure 43. Section 6.3 Of Multitel’s FCCP Installation Manual Pg. 39 .......................................31
Figure 44. Snapshot BDS–1193–B986 .....................................................................................32
Figure 45. Base to Plus Unit Connection...................................................................................32
Figure 46. TELCO RJ–11 Modem Connection..........................................................................35
Figure 47. USB Cable...............................................................................................................35