Eagle Eye BDS-Pro User manual

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BDS-Pro
Battery Monitoring System
Installation Manual 122118
www.eepowersolutions.com | Tel: [phone] | Fax: [phone] | [email protected]

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Contents
1. Introduction ............................................................................................................................. 3
1.1 Safety Information ............................................................................................................ 3
2. Product Overview ................................................................................................................... 4
2.1 Main Processing Unit (MPU) ............................................................................................ 5
2.2 Technical Specifications .................................................................................................. 7
3. Parts List ................................................................................................................................. 8
4. Installation Tools .................................................................................................................. 10
4.1 Required Tools ................................................................................................................ 10
4.2 Recommended Tools ...................................................................................................... 11
5. Hardware Installation ........................................................................................................... 12
5.1 Overview of Workflow .................................................................................................... 12
5.2 MPU Installation .............................................................................................................. 13
5.3: Clamp Installation .......................................................................................................... 14
5.4 Sensing Cable Layout & Connection ............................................................................ 17
5.5 Temperature Sensor Connection .................................................................................. 21
5.6 DC Voltage Cables .......................................................................................................... 22
5.7 Connect DC CT Clamp .................................................................................................... 24
5.8 Verify Connections ......................................................................................................... 26
5.9 Connect Cables to BDS-Pro MPU .................................................................................. 28
6. Initial Power Up ..................................................................................................................... 29
6.1 Status LEDs ..................................................................................................................... 29
6.2 Keypad Operation ........................................................................................................... 30
7. Parameter Setup & Measurement Verification ................................................................... 31
8. Network Communication Setup .......................................................................................... 36
8.1 Configure MPU IP Address ............................................................................................ 36
8.2 Connect BDS-Pro to Network ........................................................................................ 38

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1. Introduction
This manual provides guided steps on how to install the Eagle Eye BDS-Pro Battery Monitoring
System safely and effectively. Please read this manual carefully to fully understand the
functionality of the BDS-Pro.
1.1 Safety Information
Operation methods and safety measures described in this manual are only applicable to the
defined purpose and functionality of the BDS-Pro. If the BDS-Pro is used in a way not specified
in this manual, the safety of the equipment, personnel, and property cannot be assured.
•Please read this manual carefully to avoid accidental injury or misuse of product.
•Only qualified personnel with proper tools and equipment should work on batteries.
•To avoid damage and injury due to the short circuiting of battery terminals, wrap
insulating tape around all metallic parts.
•Do not wear metallic items such as jewelry, watches, & rings. Wear insulated gloves and
goggles when working around batteries.
•Ensure an installation supervisor is on hand when connecting the BDS-Pro and battery
post to avoid fire or personal injury.
•Make sure all personnel are fully aware of safety guidelines.

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2. Product Overview
The BDS-Pro is designed to monitor and analyze the state of health of up to (24) cells by
measuring and recording:
String: Voltage & DC Float / Discharge Current
Jar/Cell: Voltage, Internal Resistance / Connection Resistance, & Temperature
All BDS-Pro solutions come complete with battery management software which allows all
battery systems to be monitored 24 hours a day, 365 days a year via remote computer(s). This
software offers comprehensive battery diagnosis and reporting capabilities to ensure the
integrity of your critical backup power system.
Alternatively, systems can be configured for Modbus communication for integration to a third-
party building management system or SCADA (supervisory control and data acquisition).
The BDS-Pro is composed of the MPU (main processing unit), Sensing Cables, Connection
Clamps, & CT.

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2.1 Main Processing Unit (MPU)
The MPU receives battery data and communicates with the Server.
Internal Access
Terminal Strip
(DC Power, DC
Voltage Sensing, & CT
Connections)
Power Button
Controls
System Status
Indicator Lights
TCP/IP Port
(Network Communication)
RS232 Port
(Programming &
Diagnostics)
RS485/422 Ports
(Daisy Chain
Connections)

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2.2 Technical Specifications
Applications:
Flooded, Sealed, & NiCad battery types
Up to 24 jars / cells.
Battery Capacity Range:
Up to 6000 Ah
Cell Voltage:
1 – 16 VDC
Accuracy:
DC Voltage / Current: ±0.5% / ±1%
Temperature: ±2%
Internal Resistance: ±2%
Cell Voltage: ±1%
Resolution:
AC Voltage / Current: 0.1 V / 0.1 A
DC Voltage / Current: 0.1 V / 0.1 A
Cell Voltage: 10 mV
Internal Resistance: 0.001 Ω
Temperature: 0.5 °C
Test Speed:
3 – 4 seconds per cell
Test Load:
< 2 A per cell
Display:
LED Indicator Lights
Internal Storage:
Limited On-board memory
Measuring Interval:
Adjustable from 10 min to 24 hours (voltage & resistance)
Data Transfer:
TCP/IP, Modbus Protocol
Bandwidth Use:
< 10 Kbps
Operating Environment:
Temperature: 0 – 50 °C (32 – 122 °F)
Relative Humidity: Under 80% RH
AC Power Requirements:
110 – 220 VAC, 50/60 Hz
DC Power Requirements:
48V: 43 – 72 VDC
125V: 100 – 150 VDC
Power Consumption:
15 W
Connections:
RJ45
Dimensions L x W x D:
MPU: 231 x 270 x 55 mm (9.1 x 10.6 x 2.2 in)

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3. Parts List
The following parts come standard with each BDS-Pro package. The number and type of
connector clamps will depend on the application.
Part Name & Purpose
Picture
BDS-Pro MPU
Main processing unit for BDS-Pro system
C-Type Clamp
Clamp used for connection between batteries
with busbar inter-cell connections
O-Type Clamp
Clamp used for connection between batteries
with cable inter-cell connections
Clamp Covers: C-Type / O-Type
Placed over clamp PCB
CT Clamp
Measures DC current

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AC / DC Power Cable
Power cable for systems utilizing AC power
Total Voltage / DC Power Fuses
Fused lines between the Total Voltage & DC
Power cables
Total Voltage Jumpers
Allows total voltage measurement from DC
power terminations
CT Cable Harness
For connection between CT & BDS-Pro MPU
Temperature Cable Harness (4-pin)
Measures temperature of battery posts
Voltage Sensing Cable Harness (6-pin)
Measures DC voltage (Vs)
Current Sensing Cable Harness (4-pin)
Measures current (Is)

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4. Installation Tools
4.1 Required Tools
Tool Name & Purpose
Picture
Multi-meter
Verification of connection voltage &
resistance
#1 Phillips Insulated Screwdriver
Tightening of O-Type/C-Type clamp screws
2/16” (2-3 mm) Flathead Screwdriver
Tightening of sensing cable
Wire Cutter
Adjustment of cable length
US or Metric Socket Set
For mounting BDS-Pro
Wire Stripper
Adjustment of cable length

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Shop Snips
Adjustment of duct length, cable length
Zip Ties
Cable management
Cable Duct / Panduit
Cable routing
Electrical Tape
(Scotch Super 33+ Recommended)
Cable management
Cable Wrap
Bind multiple cables together
4.2 Recommended Tools
Tool Name & Purpose
Picture
IBEX Battery Tester
Verification of BDS-Pro measurement
readings

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5. Hardware Installation
This section will provide the correct workflow for installing the BDS-Pro Battery Monitoring
System and all of its components.
All necessary cables and clamps are provided at correct quantities and lengths based on
information provided from the Site Survey. Please be sure to have all the necessary tools and
parts listed in Section 3 and 4.
5.1 Overview of Workflow
The following is an overview of the complete workflow of what needs to be done on-site for the
BDS-Pro Installation:
1. Mount BDS-Pro MPU
2. Install clamps to battery connections
3. Run all sensing cables from the MPU to the clamps
4. Install temperature sensors
5. Connect total voltage cable and power connections
6. Install CT clamp
7. Verify all connections
8. Configure Parameters on the BDS-Pro menu screen
9. Configure BDS-Pro MPU IP address
10. Connect BDS-Pro to Network (if applicable)
NOTE: This guide should be used as an outline for installation, however it does not cover
every aspect of installation step-by-step. It is recommended that experienced personnel
familiar with electrical work and battery-room environments perform this installation. If a
section of this guide is unclear, please contact Eagle Eye Power Solutions directly for further
support.

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5.2 MPU Installation
Parts:
Main Processing Unit, Mounting Blocks
Tools:
Screwdriver, Socket Set, Drill
(1) Mount MPU Identify mounting locations (ex. battery rack, wall behind battery rack)
•The MPU should be mounted in the location which was determined during the Site
Survey process. This location is typically indicated on the provided connection map
BDS-Pro Mounted to Wall
TIP: All sensing cables are factory cut to lengths based on the MPU location from the cable
connection map.

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5.3: Clamp Installation
Parts:
C-Type/O-Type Clamps
Tools:
Drill/Phillips Screwdriver
The BDS-Pro includes clamps for installation to the inter-cell connections of the battery system.
There are two clamp types:
C-Clamp: Metal clamp which connects to the battery bus bars or terminal plate
O-Type: Plastic clamp which connects to cables (typically between rack tiers)
The purpose of the clamps to provide a non-intrusive, fused connection to the battery system for
measurement. The fuses are housed on a small PCB on each clamp. The placement of the
clamps is based on the PCB type. There are two types of PCBs:
Voltage (Vs): Houses a 1A fuse only for voltage measurement
Current (Is): Houses a 1A fuse for voltage measurement in addition to a 3A fuse for current
Clamp Type
PCB Type
C-Type
for Busbar
O-Type
for Cable
Voltage:
(Vs)
(1 fuse)
Current:
(Is)
(2 fuse)
(1) Prepare For Connection
1. Organize clamps based on type and verify all clamps are present
2. Reference the provided connection map to determine where each clamp is placed on
the system

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(2) Connection of Clamps (C-Type)
1. Connect clamps according to the provided connection map.
2. Determine how the clamp will be placed. Generally, the cable terminations should be
facing the direction the sensing cable(s) will be ran from
3. Place the clamp in the center of the busbar and tighten down using the provided
screws
4. If the busbar has a cover, cut out an area so the cover sits snugly against the clamp
5. Attach additional clamps, keep the direction and placement of all clamps consistent
C-Type Clamps Installed to Busbars

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(3) Connection of Clamps (O-Type)
1. Connect clamps according to the provided connection diagram.
2. Determine how the clamp will be placed. Generally, the cable terminations should be
facing the direction the sensing cable(s) will come from
3. Place the clamp over the center of the cable and tighten the screws into the cable
NOTE: If the cable is too large for the clamp it can cut down to accommodate the
size
4. Attach additional clamps, keep the direction and placement of all clamps consistent
O-Type Clamp Connections
Breaking Points

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5.4 Sensing Cable Layout & Connection
Parts:
Voltage Sensing Harness, Current Sensing Harness, Connection Map
Tools:
2/16” (2-3mm) flathead, duct, cable ties/zip ties, wire cutter, wire stripper
The sensing cables must be laid out from the MPU to each individual connection (C-Clamp or
O-Clamp) on the battery system. It is highly recommended to follow the cable connection map
provided with the system while performing this step.
There are two labeled sensing cable harnesses which connect to the clamps: Voltage Sensing
(V)& Current Sensing (I). Each cable harness is split into smaller color-coded wires.
6-Pin Voltage Sensing Cable 4-Pin Voltage Sensing Cable
(1) Sensing Cable Overview
Prior to installing the sensing cables it is important to understand the differences between the
cable types and how they are installed.
Voltage sensing cable:
Voltage sensing cables measure cell voltage and connect to each clamp in the following order
per harness from left to right:
Grey, Green, Blue, Orange, Brown
Example:
Clamp #1 = Grey
Clamp #2 = Green
Clamp #3 = Blue
Clamp #4 = Orange
Clamp #5 = Brown + Grey
Clamp #6 = Green

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The last wire (brown) of the harness will always connect to the same (Vs) termination of the first
wire (grey) of the next harness.
Current Sensing Cable:
Current sensing cables measure cell resistance and connect to specific clamps only (the
placement of clamps varies depending on the system) in the following order from left to right:
Black, Red, White
Example: (for installation to 48V system with (24) 2V cells)
Clamp #1 = Black
Clamp #13 = Red
Clamp #25 = White
The last wire (white) of the harness will always connect to the same (Is) termination of the first
wire (black) of the next harness if multiple harnesses are used.
(2)Prepare Cable Routing
1. The first step to installing the sensing cabling is to plan the routing of the cabling.
Sensing cables are provided in lengths based on information determined from the
site survey process.
2. Start by securing the connector ends of the sensing cables to the BDS MPU by
running the cable up into the MPU and fastening it using a zip-tie or tape as shown
below:

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(3) Install Cable Duct
1. For a clean installation it is recommended to route cables efficiently using cable
ducts that are properly measured for the battery system
2. Mount cable ducts along all areas that sensing cables will be laid out
3. Be sure not to attach the cable ducts in a manner that will not prevent batteries from
being removed during replacement (Ex. Laying cable ducts across front facing
battery systems)
Duct Installation on (8) 6V Jars
(4) Lay Sensing Cables to Each Clamp
1. At this point the connector end of the cables should be secured at the MPU
2. Run the sensing cables from the MPU to the battery string
3. Starting with the voltage (V) sensing cables, lay each colored cable in the correct
sequence 4 to 6 inches past each clamp so that there is some slack once the cable
is connected (Ex. GreyàClamp 1, GreenàClamp 2, Blue àClamp 3,
OrangeàClamp 4, Brown+GreyàClamp 5)
4. Next lay all current (I) sensing cables in the correct sequence 4 to 6 inches past
each clamp (I.e. BlackàClamp 1, RedàClamp 13, WhiteàClamp 25)
NOTE: Cable ducts are included with Eagle Eye serviced installations. If performing the
installation without Eagle Eye, ducts must be purchased separately.
WARNING: Do not connect any cables to clamps yet, wait until all cables are laid out and the
steps to verify voltage have been completed.

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5. For all clamps with multiple cables running to them, twist the cables together to
minimize exposed cabling
(5) Connect Sensing Leads to Clamps
1. Observe carefully which slot to is used for each sensing cable
(Vs) Board
(Is) Board
2. Using a wire stripper, cut ¼” (4mm) of shield away from the wire
3. Twist the exposed wire together, then fold in half and attach to appropriate
termination on the clamp
4. Screw the cable tight using a 2/16” (2-3mm) flathead, firmly pull on the cable to
ensure the connection is tight, ensure that none of the cable is exposed.
Connection of (Vs) Cable to C-Type Clamp
(Vs)
(Vs)
(Is)