Cellwatch Frontier User manual

System Installation
& User Manual
VERSION 4.0.0

Cellwatch Frontier System Installation & User Manual
Cellwatch Frontier
Intended Use
Cellwatch Frontier is a battery monitoring system that monitors the state of health of batteries used to
power UPS systems by measuring the battery voltage, current, temperature, and ohmic value.
There are features planned for future releases that are currently not available in this version. Future
software updates will be available for download. If there are any questions on these features, please
contact NDSL.
Regulatory Compliances
The Frontier and Data Collection Modules are fully compliant with CE regulations for EMC and safety to
the following standards:
Emissions and Immunity
 EN 61326:1:2013
Safety
 EN 61010-1:2010 (3rd edition)
 EN 61010-2-030:2010 (1st edition)
 UL 61010-1:2012
 UL 61010-2-03:2012
 CAN/CSA-C22 No. 61010-1-12
 CAN/CSA-C22 No. 61010-2-030-12
 cTUVus

Cellwatch Frontier System Installation & User Manual
Cellwatch Frontier is manufactured by:
NDSL Inc.
4112 Blue Ridge Road
Suite 210
Raleigh, NC 27612
USA
[phone]
www.cellwatch.com

Cellwatch Frontier System Installation & User Manual

Cellwatch Frontier System Installation & User Manual
Contents
CELLWATCH FRONTIER .............................................................................................................. 2
Intended Use ......................................................................................................................................... 2
Regulatory Compliances ....................................................................................................................... 2
SECTION I – INSTALLATION GUIDE ............................................................................................. 10
Introduction ................................................................................................................................. 11
Trademarks ......................................................................................................................................... 11
Copyright ............................................................................................................................................. 11
Life Support ......................................................................................................................................... 11
Liability ................................................................................................................................................ 11
Specification ........................................................................................................................................ 11
Warranty ............................................................................................................................................. 11
Limitation of Warranty ........................................................................................................................ 11
Important Safety Information ....................................................................................................... 12
Cellwatch™ Service and Support......................................................................................................... 13
Installation Safety ............................................................................................................................... 14
Frontier Hardware Specifications .................................................................................................. 15
DCM Specifications ....................................................................................................................... 16
Critical Distances .......................................................................................................................... 23
Mounting Options ........................................................................................................................ 24
Exposed Installations .................................................................................................................... 25
Frontier Front Panel ..................................................................................................................... 25
Frontier Back Panel ...................................................................................................................... 27
Input Connections ............................................................................................................................... 27
Connection Strain Relief ..................................................................................................................... 32
Installation: Data Collection Modules (DCM) ................................................................................. 32
Rules for Placing DCMs ....................................................................................................................... 32
Preparing the Battery .......................................................................................................................... 33
Tabbing the Battery ............................................................................................................................ 33
Battery Configurations ........................................................................................................................ 36

Cellwatch Frontier System Installation & User Manual
Connecting a DCM .............................................................................................................................. 43
DCM Connection Order ....................................................................................................................... 55
Installation: Frontier Electrolyte Level Detectors ........................................................................... 56
Specifications ...................................................................................................................................... 56
How it Works ....................................................................................................................................... 56
Wiring .................................................................................................................................................. 57
Hardware Installation Process ............................................................................................................ 59
SECTION II – USER GUIDE ........................................................................................................ 62
Introduction ................................................................................................................................. 63
Connecting to Frontier .................................................................................................................. 63
Compatible Browsers .......................................................................................................................... 63
Using the USB Service Port ................................................................................................................. 63
Using the Ethernet Port ...................................................................................................................... 64
The Navigation Bar ....................................................................................................................... 64
Home Page ................................................................................................................................... 65
Alarm Viewer ............................................................................................................................... 66
History Graphing .......................................................................................................................... 69
Using the Graphing Functions ............................................................................................................. 70
Reports ........................................................................................................................................ 71
Battery Report ..................................................................................................................................... 71
Scheduled Battery Reports ................................................................................................................. 71
Frontier Settings ........................................................................................................................... 72
Battery Design ..................................................................................................................................... 72
Battery Profiles.................................................................................................................................... 72
General ................................................................................................................................................ 73
Network Settings ................................................................................................................................. 74
HTTPS Support .................................................................................................................................... 75
Commissioning Data ........................................................................................................................... 77
Configure TPs ...................................................................................................................................... 77
Configure CTs ...................................................................................................................................... 77
Hardware Relay ................................................................................................................................... 78

Cellwatch Frontier System Installation & User Manual
Electrolyte Levels ................................................................................................................................ 79
String/Channel Alarms ........................................................................................................................ 79
Temperature Probe Alarms ................................................................................................................ 80
Current Alarms .................................................................................................................................... 81
Digital Input Alarms ............................................................................................................................ 81
SNMP ................................................................................................................................................... 82
DNP3 ................................................................................................................................................... 82
Software Activation ............................................................................................................................. 82
Upgrade Software ............................................................................................................................... 82
Cellwatch Central ................................................................................................................................ 83
Backup and Restore ............................................................................................................................ 83
Diagnostics................................................................................................................................... 85
View Frontier Log ................................................................................................................................ 86
Device Data ......................................................................................................................................... 86
Activation and Features ...................................................................................................................... 86
Tests and Actions ................................................................................................................................ 87
Troubleshooting ........................................................................................................................... 87
Data Interpretation ...................................................................................................................... 88
Voltage Alarms .................................................................................................................................... 88
Temperature Alarms ........................................................................................................................... 88
Ohmic Alarms ...................................................................................................................................... 88
Current Alarms .................................................................................................................................... 89
SECTION III – CONFIGURATION BUILD AND HARDWARE INTEGRATION GUIDE ................................... 91
Introduction ................................................................................................................................. 92
Building a Battery Configuration ................................................................................................... 92
Hardware ............................................................................................................................................ 92
Batteries .............................................................................................................................................. 93
Saving your configuration ................................................................................................................... 96
Configuring Temperature Probes (TP) ........................................................................................... 97
Configuring Current Transducers (CT) ............................................................................................ 98
Terminology and Implementation ...................................................................................................... 98

Cellwatch Frontier System Installation & User Manual
Type and Assignment .......................................................................................................................... 98
Configuring Frontier Electrolyte Level Detectors (FEDs) ............................................................... 101
Configuration: Battery Design ........................................................................................................... 101
Calibration ......................................................................................................................................... 102
Alarm Status in User Interface .......................................................................................................... 103
Other FED Diagnostic Functions ........................................................................................................ 103
Common Errors ................................................................................................................................. 106
Configuration Build Examples ..................................................................................................... 107
Standard System with FEDs .............................................................................................................. 107
Inter-cell Straps ................................................................................................................................. 108
Charger Cables .................................................................................................................................. 110
DCM6-R ............................................................................................................................................. 111
Battery Configuration Troubleshooting ....................................................................................... 112
Incorrect Number of DCMs ............................................................................................................... 112
CT Readings Incorrect ....................................................................................................................... 113
TP Readings Incorrect ....................................................................................................................... 113
SECTION IV – INTEGRATION GUIDE .......................................................................................... 114
Introduction ............................................................................................................................... 115
Integration: Modbus TCP/IP ....................................................................................................... 115
Integration: SNMP ...................................................................................................................... 115
General .............................................................................................................................................. 115
SNMPv2c ........................................................................................................................................... 115
SNMPv3 ............................................................................................................................................. 117
Advanced........................................................................................................................................... 118
Integration: DNP3 ...................................................................................................................... 119
General .............................................................................................................................................. 119
Master ............................................................................................................................................... 119
Session .............................................................................................................................................. 121
Events ................................................................................................................................................ 122
Default Variations ............................................................................................................................. 122
Files ................................................................................................................................................... 124

Cellwatch Frontier System Installation & User Manual
Integration: Cellwatch Central .................................................................................................... 124

Section I – Installation Guide

Cellwatch Frontier System Installation & User Manual
Section I – Installation Guide-11
Introduction
This guide will walk through the installation of the Cellwatch Frontier unit, the Data Collection Modules
(DCM), Temperature Probes (TP), Current Transducers (CT) and Frontier Electrolyte Detectors (FEDs).
Instructions on accessing and configuring the Frontier unit can be found in the User Guide and Battery
Configuration Guide.
Trademarks
All brand and product names are the trademarks of their respective owners. Cellwatch™ is the registered
trademark of NDSL Group Limited in the UK and the USA and a trademark of NDSL Group Ltd. in the rest
of the world.
Copyright
© All rights reserved. No part of this manual shall be stored in a retrieval system, or transmitted by any
means, electronic, mechanical, photocopying, recording or otherwise without the written permission of
NDSL Group Limited.
Life Support
NDSL products cannot ensure performance for life-support devices or systems since the end user is
responsible for monitoring and management of the system.
Liability
Neither NDSL nor any of its employees shall be liable for any direct, indirect, incidental or consequential
damages arising from the failure of the battery monitoring system due to the failure of a proprietary
part of the battery monitoring system, even if NDSL had been advised in advance except for as provided
by law.
Specification
NDSL makes every effort to ensure that the specifications and details in this manual are accurate and
complete. NDSL reserve the right to alter or improve the specification, design or manufacturing process
at any time, without notice.
Warranty
Please contact your Cellwatch installer/provider for warranty issues.
Limitation of Warranty
This warranty does not apply to defects arising from system modification performed without NDSL’s
written approval, or misuse of the system or any part of the system. The warranty excludes defects or
malfunctions resulting from failure by the customer, or his designated personnel, to maintain and
upkeep the batteries to which the system is fitted.

Cellwatch Frontier System Installation & User Manual
Section I – Installation Guide-12
This warranty does not apply to any part of the system supplied by the customer or problems arising
from normal wear and tear or failure to follow instructions.
Important Safety Information
READ THE FOLLOWING INFORMATION CAREFULLY. SAVE ALL INSTRUCTIONS FOR FUTURE REFERENCE!
 Read these instructions.
 Keep these instructions.
 Heed all warnings.
 Follow all instructions.
 Clean only with a dry cloth.
 Do not expose this apparatus to rain, liquids, or moisture of any type.
 Do not block any ventilation openings.
 Never push objects of any kind into ventilation slots on the equipment casing.
 Install in accordance with the manufacturer’s instructions.
 Do not install near any heat sources such as radiators, heat registers, stoves, or other apparatus
that produces heat.
 Ensure the unit is Installed so that it is easy to operate and disconnect power by removing the
power cord.
 This equipment should be connected to an electrical outlet with a protective ground connection.
 Use only the supplied power cord. Contact NDSL for a replacement if required. Do not use
inadequately rated cords.
 Power supply cords should always be handled carefully and should be replaced if damaged in
any way.
 Do not defeat the safety purpose of the polarized or grounding-type plug.
 Never break off the earth (ground) pin on the power supply cord.
 Protect the power cord from being walked on or pinched particularly at plugs, convenience
receptacles, and the point where they exit from the apparatus.
 Only use attachments and accessories specified by NDSL.
 Servicing is required when the apparatus has been damaged in any way, such as power-supply
cord or plug is damaged, liquid has been spilled or objects have fallen into the apparatus, the
apparatus has been exposed to rain or moisture, does not operate normally, or has been
dropped. Do not open the equipment case. There are no user serviceable parts in this
equipment. Refer all servicing to qualified service personnel.
 Operation of the product outside of the recommendations in this manual can cause the
protection provided by the equipment to be impaired.
 Unauthorized modification of this equipment is expressly forbidden by NDSL.
 Always replace damaged fuses with the correct rating and type.
 Follow all warnings and instructions marked on the product!

Cellwatch Frontier System Installation & User Manual
Section I – Installation Guide-13
To completely disconnect this apparatus from the AC mains, disconnect the power supply cord from
the AC receptacle.
WARNING: To reduce the risk of fire or electric shock, do not expose this apparatus to rain or
moisture.
Beware!
Check the manual for important operation and
maintenance instructions.
Danger Live Electrical Equipment
Danger Du Matériel Électrique
Cellwatch™ Service and Support
If during the use of the NDSL product any cracks, breaks, or defects are found in any of the units then
please contact NDSL. You will be advised on the necessary action to be taken.
Visit http://www.cellwatch.com for the latest contact information and locations.

Cellwatch Frontier System Installation & User Manual
Section I – Installation Guide-14
Installation Safety
The following safety precautions should be observed before any work is performed on the
system containing the NDSL product.
 This system is intended for installation by personnel who are trained and qualified to
recognize the hazards associated working with such systems and are familiar with the safety
precautions required to avoid possible injury.
 Never work on any system that threatens life
or injury through hazardous voltages. Even
when safety precautions have been taken.
 NEVER WORK ALONE. Always ensure that
two properly trained personnel are on site.
 NDSL recommends that when performing
any work concerned with batteries, that the
safety procedures and safe working practices
as described in the appropriate battery
manufacturers documentation should be
followed at all times.
 Never make unauthorized changes or
modifications to equipment. This may create
unsafe or even hazardous situations.
 Where the battery documentation
recommends that links are removed for safe
working, it is important to totally remove any
Cellwatch unit which is connected across
any link to be broken prior to separation and
subsequent removal of the link. FAILURE
TO DO SO WILL RESULT IN THE STRING
NOT BEING TOTALLY ISOLATED.
 After servicing of the battery, any removed links must be fitted and reconnected before the
Cellwatch™ modules are reconnected.
 Safety glasses should be worn at all times.
 Ensure all equipment and tools are safe and in good working order.
 Ensure electrical tools have been tested for proper insulation and grounding.
 Do not wear loose clothing, jewelry, long hair when working near rotating machinery.
 Appropriate PPE should be utilized depending upon the application and hazards present.
 Observe all CAUTIONS, WARNINGS and DANGER notices on equipment, tools, and
buildings whether internally or externally displayed.

Cellwatch Frontier System Installation & User Manual
Section I – Installation Guide-15
Frontier Hardware Specifications
Power Supply
AC Input 100-240 VAC @ 50-60Hz, 10W
(Alternative) DC Input
Option 1: 20-70 VDC, 10W
Option 2: 70-150 VDC, 20W
Option 3: 100-240 VDC, 20W
Permitted Mains Supply Variations 10%
Transient Overvoltage Category 2
Fuse Rating 250V 1A Slow-Blow
Environmental (Indoor use only)
Operating Temperature 0-65°C
Relative Humidity 5-90% non-condensing
Maximum Altitude 3,000 m (~10,000 ft.)
Pollution Degree 2
Dimensions
Wall Mount Model 9.75 in. x 5 in. x 2.5 in.
Rack Mount Model (1U) 1.75 in. x 19 in. x 6 in.
Weight
Wall Mount Model 1.6 lbs. / 0.73 kg
Rack Mount Model 2.2 lbs. / 1.00 kg
Fiber Optics
Optical Cable Acrylic
Outside Diameter 2.2 mm
Wavelength 400-700 nm
Range 150 mm – 50 m (6 in. – 150 ft.)
Digital Inputs
Isolated Digital Inputs 4
Relay Outputs
Quantity 4
Type Dry Contact (NO/NC) 30VDC 5A
Relays
Battery Alarm (programmable)
System Alive
String 1 Disconnect (Thermal Runaway only)
String 2 Disconnect (Thermal Runaway only)
Capacity
Max. Number of Measurement Points 256
Max. Number of DCMs 64
Temperature Probe
Quantity 4

Cellwatch Frontier System Installation & User Manual
Section I – Installation Guide-16
Temperature Sensor Range 2-80°C +/- 1°C
Current Transducer
Quantity 2 (Wall Mount)
4 (Rack Mount)
Float Only Range 5A
Supported Directional / Bi-Directional
Ranges (+/-) 50A, 100A, 300A, 600A, 1000A
Ethernet Ports
Quantity 1 on Wall Mount or Rack Mount units
Option: 2 ports on Rack Mount only
Rate 10/100 Mbps
DCM Specifications
DCM 5
DCM 5 Specifications
Description DCM 5
Environment
Operating Temperature 0-60°C
Relative Humidity 5-95% non-condensing
Maximum Altitude 3,000 m (10,000 ft.)
Power Supply (full functionality) 4.5-80 VDC
Power Supply (voltage, temperature &
ripple) 4.0-80 VDC
Protection
Transient Suppression 600W
Short Circuit Protection Internal 3A fuse
Reverse Polarity Protection Any combination
Insulation Resistance 1000 Ms >1Kv
Operating Current
Quiescent Current 22mA
Sleep Current < 2mA
During Ohmic Testing 0.5A or 2A
Standard Measurement Characteristics Range Resolution Accuracy
Voltage 0 to 60V 15mV 0.1% +/- 15mV
Ohmic Value 0 to 25.9mΩ 6.3µΩ 2% +/- 12 µΩ

Cellwatch Frontier System Installation & User Manual
Section I – Installation Guide-17
Enhanced Measurement
Characteristics (Requires Activation) Range Resolution Accuracy
Voltage 0 to 80V 2mV 0.1% +/- 5mV
Ohmic Value 0 to 1mΩ 1µΩ 2% +/- 8µΩ
1 to 65mΩ 1µΩ 1.5%
Cell Temperature (requires DCM5T) 2 to 80°C 0.01°C +/- 1°C
Ripple Voltage across 4 channels
(40Hz – 1KHz)
0
to
4V

2mV

2% +/
-
5
mV

Fiber Optic Specification
Optic Cable Acrylic
Sheathing Fluorine containing polymer
Core Diameter 1.0 mm
Outside Diameter 2.2 mm
Wavelength 400-700 nm
Communication Rate 9600 baud
Fiber Optic Range Min: 150 mm (6 in.) to Max: 50 m (150 ft.)
Mechanical
Dimensions 4.2 in. x 3.1 in. x 0.9 in. (107 mm x 80 mm x 23 mm)
Mounting Pads 3M™ Dual Lock™
Base Plate with Mounting Holes Optional
Base Plate with DIN Rail Mount Optional
Enclosure Material ABS
Lead Length 36-72 in.
DCM6-L
The DCM6-L is designed for use with 2-volt jars. It can operate up to a maximum power supply voltage
of 12 volts between the white and brown wires. Unlike previous DCMs, the white and blue must be at
the same DC voltage (connected to the same cell terminal post). Note the DCM6-L will not power up,
flash the LEDs and play its startup song until the white, blue and brown wires are connected.
The DCM6-L cannot measure Ripple Voltage. A DCM6-R will be required to measure Ripple Voltage on a
system utilizing DCM6-L units.
The DCM6-L has a lower quiescent current than previous DCMs and so must not be mixed on the same
string of cells, it can however operate on the same fiber optic loop as previous DCM models.

Cellwatch Frontier System Installation & User Manual
Section I – Installation Guide-18
DCM6-L Specifications
Description DCM6-L
Environment
Operating temperature 0 to 60ºC
Relative Humidity 5 - 85% non-condensing
Maximum Altitude 3,000 meters (10,000ft)
Power supply full functionality 4 - 12 Volts DC
Power supply voltage &
temperature 3 - 12 Volts DC
Protection
Transient suppression 600W
Short circuit protection Internal 4-amp fuse
Reverse polarity protection Any combination
Insulation resistance 1000 MΩs >1Kv
Operating current
Quiescent current 12mA
Sleep current after 25 hours <2ma
During ohmic testing 1.5 amps
Standard Measurement
Characteristics Range Resolution Accuracy
Voltage 0 to 12 volts 15 mV 0.1% +/-15mv
Ohmic Value 0 to 5mΩ 6.3µΩ 2% +/- 15 µΩ
Enhanced Measurement Characteristics Requires Activation
Voltage 0 to 12 volts 2mV 0.1% +/-5mv
Ohmic Value 0 - 5mΩ 1µΩ 2% +/- 8 µΩ
Temperature -ve post (optional) 2 to 80ºC 0.01ºC +/- 1ºC
Mechanical
Fiber optic range Min: 150mm (6”) to Max: 50meters (150 ft)
Dimensions 4.2" x 3.1" x 0.9" 107mm x 80mm x 23mm
Mounting pads 3M Dual Lock™
Base plate with mounting holes Optional
Base plate with DIN rail mount Optional
Enclosure Material ABS
Wire lead length 40 - 72 inches
DCM6-H
The DCM6-H is designed to work from 12- 80 volts. It will work on 4, 6, 8, 12, 16-volt containers
provided the total voltage between the white and brown wires is >12 volts. Use the DCM6-L on 2-volt
cells. The container voltage restriction is the only installation difference between the DCM6-H and the
DCM5.

Cellwatch Frontier System Installation & User Manual
Section I – Installation Guide-19
Please note that the DCM6-H has a lower quiescent current than other DCM models and so must not be
mixed on the same string of containers. It can however operate on the same fiber optic loop as previous
DCM models.
DCM6
-
H Specifications
Description
DCM6
-
H
Environment
Operating temperature
0 to 60ºC
Relative Humidity
5
-
85% non
-
condensing
Maximum Altitude
3,000 meters (10,000ft)
Power supply full functionality
12
-
80 Volts DC
Protection
Transient suppression
600W
Short circuit protection
Internal 1
-
amp fuse
Reverse polarity protection
Any combination
Insulation resistance
1000 M
Ω
s >1Kv
Operating current
Quiescent current
12mA
Sleep current after 25 hours
<2ma
During ohmic
testing
0.5 amps
Standard Measurement
Characteristics Range Resolution Accuracy
Voltage
0 to 80 volts
15 mV
0.1% +/
-
15mv
Ohmic Value
1 to 25.9mΩ
6.3µΩ
1.5%
Enhanced Measurement Characteristics Requires Activation
Voltage
0 to 80 volts
2mV
0.1% +/
-
5mv
Ohmic Value
1 to 50mΩ
1µΩ
1.5%
Ripple Voltage
0
-
400 mVAC
rms 1 mv 2% +/-5mv
Temperature
-
ve post (optional)
2 to 80ºC
0.01ºC
+/
-
1ºC
Fiber Optic Specification
Optic cable
Acrylic
Sheathing
Fluorine
containing polymer
Fiber optic range
Min: 150mm (6”) to Max: 50meters (150 ft)
Mechanical
Dimensions
4.2" x 3.1" x 0.9" 107mm x 80mm x 23mm
Mounting pads
3M Dual Lock™
B
ase plate with mounting holes
Optional
Base
plate with DIN rail mount
Optional
Enclosure Material
ABS
Wire lead length
40
-
72 inches

Cellwatch Frontier System Installation & User Manual
Section I – Installation Guide-20
DCM6-R
The DCM6-R is designed to measure string ripple voltage on 2 volts cells up to a maximum string voltage
of 300 volts. The white wire should be connected to the negative side of the Frontier cabinet fuse and
the brown wire to the positive side. The DCM6-R is usually configured to be the last DCM on the fiber
loop. You should null all the DCM6-R channels so that Frontier does not try to read voltage or Ohmic
value.
DCM6-R Specifications
Description DCM6-R
Environment
Operating temperature 0 to 60ºC
Relative Humidity 5 - 85% non-condensing
Maximum Altitude 3,000 meters (10,000ft)
Power supply full functionality 24 - 300 Volts DC
Protection
Transient suppression 600W
Short circuit protection Internal 4-amp fuse
Reverse polarity protection Any combination
Insulation resistance 1000 MΩs >1Kv
Operating current
Quiescent current 12mA
Sleep current after 25 hours <2ma
Standard Measurement
Characteristics Range Resolution Accuracy
Ripple voltage 0 - 5 VAC rms 1 mv 2% +/- 5 mv
String voltage 24 - 300 VDC 10 mv 0.5% +/- 100 mv
Mechanical
Fiber optic range Min: 150mm (6”) to Max: 50meters (150 ft)
Dimensions 4.2" x 3.1" x 0.9" 107mm x 80mm x 23mm
Mounting pads 3M Dual Lock™
Base plate with mounting holes Optional
Base plate with DIN rail mount Optional
Enclosure Material ABS
Wire lead length 72 inches
DCM6-L-CC
The DCM6-L-CC is designed to monitor charger cable connections. It is built using DCM6-L technology
with a special cable harness that supports two power supply feeds to the device. It has built-in over-