Eagle Eye BMS-icom User manual

1
Eagle Eye Power Solutions, LLC
BMS-icom
Battery Monitoring System for 48V
Installation Manual 062918
www.eepowersolutions.com | Tel: [phone] | [email protected]

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Contents
1. Introduction ............................................................................................................................. 2
2. Safety Overview ...................................................................................................................... 2
3. Package Contents ................................................................................................................... 3
4. Required Tools ........................................................................................................................ 5
5. Installation Instructions ......................................................................................................... 6
Step 1: Mount BMS Unit ........................................................................................................... 6
Step 2: Clamp Setup ................................................................................................................. 6
Step 3: Sensing Cable Connection ........................................................................................... 8
Step 4: Control Power Cable .................................................................................................... 9
Step 5: Temperature Cable ..................................................................................................... 10
Step 6: Connect Current Clamp .............................................................................................. 10
Step 7: Verify Connections ..................................................................................................... 11
Step 8: Connect Cables to MPU ............................................................................................. 12
6. Communication Setup .......................................................................................................... 13
Step 1: Cable Connection to Computer/Network .................................................................... 13
Step 2: Configure MPU IP ....................................................................................................... 14
Step 3: Configure Centroid Snet ............................................................................................. 15
7. Specifications ....................................................................................................................... 16
8. Support .................................................................................................................................. 17

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1. Introduction
Thank you for choosing Eagle Eye Power Solution’s BMS icom. The BMS icom is designed to
monitor and analyze the aging status of up to (24) cells (4) jars by measuring and recording:
§ STRING: Voltage & Current
§ JAR / CELL: Voltage, Internal Resistance, Connection Resistance & Temperature
The BMS icom comes complete with the battery management software package that allows ALL
battery systems to be monitored 24 hours a day, 365 days a year via remote computer(s). This
software offers the most comprehensive battery diagnosis and reporting capabilities to ensure
the integrity of your critical battery backup.
BMS icom MPU
2. Safety Overview
Eagle Eye Power Solutions is not responsible for personnel safety issues.
§ Only qualified personnel with proper tools and equipment should work on battery
systems.
§ To avoid damage and injury due to the short circuiting of battery terminals, wrap
insulated tape around all metallic-conducted parts. This is not necessary for the
installation tool area.
§ Do not wear metallic items such as jewelry and watches while working around batteries.
Be sure to use insulated gloves and goggles when handling batteries.
§ Ensure an installation supervisor is on hand when connecting the BMS and battery post
to avoid fire or personal injury.
§ Make all personnel fully aware of safety guidelines.

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3. Package Contents
The following parts come standard in the BMS icom package. Each package will come with
either O-Type clamps or C-Type clamps.
Part Name & Purpose
Picture
BMS icom
Main body of the unit.
C-Type Clamp
Clamp used for connection to bus bars.
O-Type Clamp
Clamp used for connection to cables.
Clamp Cover: C-Type
Placed over clamp PCB
Clamp Cover: O-Type
Placed over clamp PCB
CT Clamp
Measures current

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Power Cable (3-Pin)
Positive(+) red
Negative(-) blue
Temperature Cable (8-pin) & Sensors
Measures temperature of battery posts
Voltage Sensing Cable (6-pin)
Measures voltage (Vs)
Current Sensing Cable (4-pin)
Measures current (Is)
Temperature Sensors

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4. Required Tools
Tool Name & Purpose
Picture
Multimeter
Verification of connection voltage &
resistance
#1 Phillips Screwdriver
BMS clamp installation
(2-3 mm) Flathead Screwdriver
Termination of sensing cable to clamps
Wire Stripper (16, 22 AWG req.)
Adjustment of cable length
Crimp Tool
Crimp temp sensors to cable
Cable Ties
Cable management

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5. Installation Instructions
The following steps will provide the correct workflow for installing the BMS icom battery
monitoring system and all of its components to a battery string.
Step 1: Mount BMS Unit
Parts:
BMS MPU, mounting hardware (not included)
Tools:
Drill, screwdriver
Mount the BMS icom close to the batteries which it will monitor using the mounting brackets on
the side of the unit.
Step 2: Clamp Setup
Parts:
O-Type and/or C-Type Clamps
Tools:
Phillips screwdriver
The BMS uses two different types of clamps based on the battery connection. C-Type clamps
are used for batteries connected by bus-bar; O-Type clamps for batteries connected by cable.
Connector Type
Board Type
C-Type
for Bus-bar
O-Type
for Cable
Voltage
(1 fuse)
Voltage + Current
(2 fuse)
There are two board types for clamps: voltage and voltage+current. The voltage clamp reads
voltage whereas the voltage+current clamp reads voltage in addition to resistance. The
connection pattern for the clamps is as follows:
Connection Number
Clamp Type
1
Voltage+Current
2
Voltage
3
Voltage+Current
4
Voltage
5
Voltage+Current

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(1) Prepare for Connection
1. Organize clamps based on type and verify that all clamps are present
2. Ensure all intercell connections are secure and torqued to spec
(2) Connection of Clamps (C-Type)
1. Place the clamp in the center of the bus-bar and tighten down using the provided
screws
2. If the bus-bar has a cover, cut out an area so the cover sits snugly against the clamp
3. Attach additional clamps, be sure all clamps are facing the same direction
C-Clamp on Busbar
(3) Connection of Clamps (O-Type)
1. Place clamp in center of cable and tighten sensing screw into the cable
2. Ensure that the screw has penetrated sufficiently into the cable
NOTE: If the cable is too large for the clamp it can cut down to accommodate the
size
3. Attach additional clamps, be sure all clamps are facing the same direction
Breaking Points

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Step 3: Sensing Cable Connection
Parts:
Clamps, clamp covers, voltage sensing cables, current sensing cables
Tools:
Phillips screwdriver, 2-3mm flathead, duct, duct tape, cable ties/zip ties, wire cutter,
wire stripper (22 AWG)
(1) Connection Order
There are two sensing cables, voltage and current, which connect to the clamps. Each cable
has a number of sensing leads which are color coded to help with installation. The connection
order for the sensing cable leads is:
Connection of Vs & Is Leads
Connection
Voltage
Current
Clamp 1
Grey
Black
Battery 1
Clamp 2
Green
Battery 2
Clamp 3
Blue
Red
Battery 3
Clamp 4
Orange
Battery 4
Clamp 5
Brown
White
NOTE: Total sensing cable length should be as short as possible to decrease noise, if cable
length is longer than needed, shorten its length (see step 2)
WARNING: Do not plug connectors for any cable into BMS icom until all sensing leads have
been connected to the clamps on the battery string
(2) Connect Sensing Leads to Clamps
1. Observe carefully which slot on the board is used for each cable.
Voltage Board
Voltage+Current Board
2. Insert the end of the sensing lead into the correct slot following the sequence in the
“Connection of Vs & Is Leads” table above
3. Using a 2-3mm flathead driver, tighten the screw down all the way until you can
firmly pull on the sensing lead without it coming out
4. Place protective covers over the clamps
Vs
Vs
Is

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Step 4: Control Power Cable
Parts:
Control Power Cable, C-Clamp (if applicable)
Tools:
Phillips driver, cable/zip ties
The BMS icom is powered by the batteries which it is connected to. The control power cables
are also used to monitor string voltage.
(1) Remove Fuses
1. Each control power cable has a fuse built in.
2. Remove each fuse prior to connecting cables to the batteries
1A Fuse in Holder
(2) Verify Connection Location
1. Determine the best place to connect the control power cables
2. If using bus-bar connections, use the c-clamp to connect to the bus-bar
3. If using cable connections, connect directly to the post
C-Clamp for Control Power Cable O-Clamp for Control Power Cable
(3) Connect Control Power Cables
1. Connect the red positive (+) cable to the most positive connection of the battery
string
2. Connect the blue negative (-) cable to the most negative connection of the battery
string.
NOTE: The connector for both cables is colored red, ensure that the correct colored cable is
connected to the correct polarity of the string

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Step 5: Temperature Cable
Parts:
Temperature sensors, TS cable
Tools:
Tape, silicone
Each BMS unit comes standard with (2) temperature sensing leads. The lead is used to
measure temperature near the battery post.
(1) Place Temperature Leads
1. Place the temperature lead near the negative post of each jar/cell
2. Adhere the lead as close to the post as possible using tape or hot glue
3. If possible, place the lead under a cover or in a tight place as close to the post as
possible
Secure Temperature Lead
Step 6: Connect Current Clamp
Parts:
CT, CT cable
Tools:
Phillips screwdriver
The CT is used to measure the flow of current passing through the battery string.
(1) Attach Current Clamp
1. The CT can be placed anywhere on the battery string
2. The clamp hook is labeled with a small arrow, connect the clamp so that the arrow is
pointing from positive to negative
Current Flow

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Step 7: Verify Connections
Parts:
Sensing Cables, Clamps
Tools:
Multimeter or voltmeter
Before plugging cable connectors into the MPU, be sure to check each connection using a
multimeter.
(1) Check Voltage & Current Sensing Connections
1. With the connector end of the cable in hand, insert the positive lead from the
multimeter into the grey port
2. Insert the negative test lead into the green port
3. The Multimeter should display the same voltage as jar 1
Test Connection between Clamp 1 & Clamp 2
4. Move the negative test lead down the connector and verify each connection
5. The final connection (brown) should read the total voltage of the string
Test Connection for Entire String

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(2) Troubleshooting Incorrect Voltage
1. If voltage is incorrect, connections will need to be checked
2. Set the Multimeter to measure resistance and test the connection between the
sensing screw and the sensing cable
3. If the Multimeter displays zero resistance (0.00Ω) then the connection is good. If the
connection has resistance, replace the fuse (1A)
Check to Verify Fuse
Step 8: Connect Cables to MPU
Parts:
BMS MPU, Cables Connected to Batteries
Tools:
N/A
With all cables connected to the batteries and verified for correct voltages, they can be
connected to the MPU.
(1) Plug Connectors to MPU
1. Connect the current, voltage, and temperature cables
2. Connect current clamp
3. Connect the control power cable
Current
Cable
Voltage
Cable
Temp.
Cable
CT
Clamp
DC Power
Cable

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6. Communication Setup
The BMS icom can communicate directly to a server PC or over a network for remote
monitoring of battery systems. The following steps will provide the correct workflow for
connecting the BMS icom to a PC or network.
Step 1: Cable Connection to Computer/Network
Parts:
BMS MPU, Ethernet Cable
Tools:
N/A
The MPU communicates directly to a computer or network using TCP/IP over Ethernet cable
connection.
(1) Connect Ethernet Cable to BMS
1. Plug the Ethernet cable into the TCP/IP port on the side of the MPU
2. Do not use the RS-232 or RS-485 ports for communication
3. Connect the other end of the Ethernet cable to the computer or network
4. Flip the power switch to “ON”

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Step 2: Configure MPU IP
Parts:
BMS MPU, Computer
Tools:
N/A
For communication, the BMS MPU needs to be assigned an IP address. Use the provided
WIZ100SR configuration utility to establish connection. This configuration tool can be found on
the provided USB drive.
Connection steps will vary depending on whether or not the BMS is connecting to a network or
directly to a computer.
(1) Determine Computer and Network IP
A. Direct Connection to Computer
1. Disable the computer’s firewall or open ports 9000, 9001
2. Set a static IP as shown below
B. Connection to Network
1. Contact the network administrator computer and server IP
2. Disable firewall
Static IP Settings

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(2) Configure MPU IP Address
1. Launch “WIZ1x0SR_105SR_CFG.exe”
2. Click “Search” to locate the MPU
3. The MPU MAC address will appear under “Board List”
4. Local IP refers to the MPU IP address. To change the IP, enter it in this field
5. “Gateway” refers to the Network’s IP address
6. “Server IP” refers to the IP address of the server computer (computer with Centroid
Snet)
7. Ensure “Operation Mode” is set to “Client” and “IP Configuration Method” is set to
“Static”
8. Click “Setting” to save the settings
Step 3: Configure Centroid Snet
Parts:
BMS MPU, Computer
Tools:
N/A
To setup the BMS icom in Centroid Snet 2 battery management software, please refer to the
software manual for steps to configure.
3
7
4
5
6
2
8

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7. Specifications
Battery Types:
VLA, VRLA
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
Measuring Interval:
Adjustable from 5 min to 24 hours (voltage & resistance)
Data Transfer:
TCP/IP (proprietary protocol)
Bandwidth Use:
Less than 3 Kbps peak
Operating Environment:
Temperature: 0 – 50 °C (32 – 122 °F)
Relative Humidity: Under 80% RH
Power Requirements:
~44 VDC (from connected batteries)
Connections:
Ethernet, RS-232, RS-422
Dimensions:
140 x 121 x 44.5 mm (5.5 x 4.75 x 1.75 in)
Weight:
70 g (1.5 lbs)

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8. Support
For further support or additional questions, please contact Eagle Eye via phone or email.