EnerSys Wi-iQ3 User manual

User Manual of Wi-iQ3 ENGLISH
Protective cover
Current sensor
1. Main unit
The Wi-iQ3 consists of:
• a core unit (for the measurement and communication
features).Therearetwomodels,oneforindustrialbatteries
from24Vto80Vandoneforindustrialbatteriesfrom96Vto
120V.
• acableclamp(formechanicalxationofDCcables)
• acurrentsensor(forcurrentmeasurement)
• anoptioncover(forCANcommunicationoption)
TheWi-iQ3canbeassembledonindustrialbatteriesfrom24V
to80V.TheWi-iQ3120Vcanbeassembledonbatteriesfrom
96Vto120V.
2. Main unit with cable clamp (no current sensor)
There are four core part-numbers depending on the DC cable
gauge:
Product DC cable gauge Designation
Wi-iQ3
16>50mm2Wi-iQ3 core cables up to
50mm2
70>120mm2Wi-iQ3 core cables 70mm2
to120mm2
Wi-iQ3120V
16>50mm2Wi-iQ3 core cables up to
50mm2
70>120mm2Wi-iQ3 core cables 70mm2
to120mm2
Thedifferenceisrelatedtothecableclampwhichtstothe
cablegauge:
Clamp-1 (16 > 50mm2)
Clamp-2 (70 > 120mm2)
NB: the cable clamp model number and the polarities are
engravedintheplasticpart.
3. Current sensors
There are three models of Hall Effect current sensor
depending on the DC cable gauge and the battery current
rating.
Product DC cable gauge* Internal diameter Truck class
recommendation
Max
DC current
Designation
Current
sensor
Upto35mm215.6mm Class 3 300A 35mm2&300Amax
Upto120mm2
25.2mm Class1and2 600A 120mm
2
&600Amax
Upto120mm2 25.2mm Class1and2 1000A 120mm2&1000Amax
*The DC cable gauge does not take account of the terminals
dimensions. Terminals may need to be assembled after
inserting the cable in the current sensor.
The Wi-iQ3 core unit is delivered with a protective plastic
cover that needs to be removed to assemble the selected
current sensor.
Optioncover
Current
sensor
Core unit
Cableclamp

4. Installation
Carefullyfollowtheinstallationprocedureasdescribedbelow.
4.1 Make sure the cables are not connected to the battery
before proceeding to the assembly.
4.2 Remove the current sensor protective cover and the cable
clamp from the main unit.
Cableclamp
Protective cover
O-ring
CAUTION: there is an O-ring seal between the Wi-iQ3 main
unit and the protective cover.
Make sure the O-ring is still
properly located in the main unit when assembling the
current sensor.
4.3 Insert the NEGATIVE battery cable in the current sensor.
CAUTION:makesuretoproperlyorientatethebatterycable
duringassemblyonthecurrentsensor(refertotheIDdecal
on the current sensor).
Thebatteryplugshallbelocatedon
thissideofthesensor.
Thebatteryshallbelocated
onthissideofthesensor.
IDdecalofcurrentsensor
4.4 Press the NEGATIVE cable on the pins.
Presscarefullyandperpendicularlythecableonthepins.
CAUTION:thecableshallbepressedcarefullyagainstthepins
perpendicularlytoavoidbendingthepins.
4.5 Assemble the current sensor on the main unit (torque
1.5Nm±0.1). Make sure to use the appropriate screws
(delivered with the current sensor).
Current sensor
14mmscrews
Towardsthebattery
Towards
theplug
CAUTION: using inappropriate screws (type and length) may
damagetheproductandimpactitsreliability.
4.6 Press the POSITIVE cable on the pins.
Presscarefullyandperpendicularly
thecableonthepins.
CAUTION: thecableshallbepressedcarefullyagainstthepins
perpendicularlytoavoidbendingthepins.

4.7 Assemble the plastic clamp on the main unit (torque
1.5Nm±0.1) using 16mm long screws.
16mmscrews
CAUTION: usinginappropriate screws(type andlength) may
damagetheproductandimpactitsreliability.
4.8 Fasten the DC cables with cable ties at each side of the
Wi-iQ3 to avoid stressing the connections during handling.
4.9 The Wi-iQ3 main unit should be securely installed in
order to avoid any shock and misuse during handling and
operation.
4.10 As soon as supplying the Wi-iQ3 unit with the battery
voltage, make sure that the LEDs lit according to the
initialization sequence:
•theBLEblueLEDislitfor7seconds,
•thenallLEDsareblinkingquicklyforafewseconds.
NB:
• When the Wi-iQ3 is connected to the battery voltage for
thersttime,theBLEblueLEDislitfor7secondsthenall
LEDs are blinking quickly for a few seconds (initialization
sequence).
• The button close to the LEDs has no function at
thisstage.
5. LEDs
ThereareveLEDsontheWi-iQ3forstatusindication.
LED Color Lit Slow blinking
(1s ON / 1s OFF)
Fast blinking
(0.3s ON / 0.3s OFF) Unlit
BLE
Green N/A Paired
toaBLEsensor
Paired
toaBLEsensor
AllLEDs
blinkingfast
during10s
=
Identication
sequence
NoBLE
communication
inprogress
Blue
N/A CommunicatinginBLE
(EconnectApp) N/A
ON Green N/A Normalstatus
Communicating
inZigbee(Wi-iQ
Report)
Misfunction
TEMP Red Hightemperature N/A N/A Normalstatus
DOD Red AlertDOD WarningDOD N/A Normalstatus
LEVEL/BAL Blue Lowelectrolyte
level Unbalancevoltage N/A Normalstatus

6. BLE peripheral sensors
The Wi-iQ3 can be associated to a peripheral sensor allowing
battery temperature measurement, electrolyte level and
unbalancedvoltagedetections.Twomaintypesofsensorsare
availabledependingonthebatteryconguration:
•2V sensors for assembly on 2V cells (with or without
electrolytelevelprobe)
•12Vsensorsforassemblyon12Vblocs
Product Electrolyte
level
probe
Temperature
probe
Unbalance
detection
Designation
2V
sensor
Yes Yes Ye s
BLET°/LEV
2V(EMEA/
ASIA)
No Yes Yes
BLET°2V
(EMEA/ASIA)
12V
sensor No Yes Yes BLET°12V (EMEA/ASIA)
ThesensorscommunicatewiththeWi-iQ3unitviaBluetooth
LowEnergy(BLE)process(theyarealsocalledBLEsensors).
The pairing process with the Wi-iQ3 unit is described in the
Pairingsection.
Wire Function Length
Red POSITIVEvoltage 300mm
Black(small) NEGATIVEvoltage 300mm
Black(large) Temperatureprobe 300mm
7. BLE peripheral sensor installation
TheBLEsensorsshouldbeinstalledaccordingtothesketches
below.
• 2V cell setting:
The2VsensorisonlyconnectedtoONEcell(2Vnominal
voltage–redandblackmainsupplywires).Itisrecommended
toinstalltheBLEsensorclosetothemiddleofthebattery.The
2VBLEsensorwithoutelectrolytelevelprobeshallbesecured
onaharnessusingcableties.
CAUTION:  DO NOT CONNECT  the sensor to more than ONE cell,
a voltage above 4V would cause a permanent product failure.
Forconnectingeachwireonthebattery,useonlythegenuine
partssuppliedwiththeBLEsensor:
•blackvoltagetapforANY wire
•heat-shrinkablecrimpingsplice
Wireconnectionassemblydetails
NB:theBLEsensorincludesitsownprotectivefusesthenthe
connectionmaterialsshallnotincludeanyadditionalfuse.
Unbalance detection is made by comparing the average
bloc voltage measured by the Wi-iQ3 with the bloc voltage
measured by the BLE sensor. It is possible to deactivate the
unbalancedetectionbyuntickingthe“Balance”selectionbox
intheApporinWi-iQReport.
CAUTION: onBLEsensorswithelectrolyteleveldetection:
•the level probe shall be cut in order to be located 5mm
abovetheseparatorandshallnottouchtheseparatorsor
theinternalcellsplates.
•make sure that the level probe is fully protected by
the plastic housing over its entire length (no hole, no
deformation)toavoidfalsedetection.
• 12V bloc setting:
The12Vsensorisonlyconnected toONEbloc(12Vnominal
voltage – red and black main supply wires). The 12V BLE
sensorshallbesecuredonaharnessusingcableties.
CAUTION:  DO NOT CONNECT  the sensor to more than ONE bloc,
avoltageabove24Vwould causeapermanent productfailure.
Forconnectingeachwireonthebattery,useonlythegenuine
partssuppliedwiththeBLEsensor:
•blackvoltagetapforANY wire
•heat-shrinkablecrimpingsplice
Wireconnectionassemblydetails
NB:theBLEsensorincludesitsownprotectivefusesthenthe
connectionmaterialsshallnotincludeanyadditionalfuse.
Unbalance detection is made by comparing the average
bloc voltage measured by the Wi-iQ3 with the bloc voltage
measured by the BLE sensor. It is possible to deactivate the
unbalancedetectionbyuntickingthe“Balance”selectionbox
intheApporinWi-iQReport.
Sensor
without
electrolyte
probe
8. BLE sensors LEDs
TherearetwoLEDsonthetopofeachsensorforstatusindication.
Color Lit Confidence blinking
(every 32s)
Slow
blinking Alternate blinking Unlit
Red Hightemperature N/A Misfunction Identication
sequence
Normal
status
Blue Lowelectrolytelevel Normalstatus
(unitinfunction) N/A
Sensor
with
electrolyte
levelprobe

9. Option
It is possible to communicate with the Wi-iQ3 unit through
CANcommunicationprotocol.ItisdonethroughaCANoption
devicewhichhastobeconnectedtotheWi-iQ3.
The Wi-iQ3 main unit is delivered with a protective plastic
coverthatneedstoberemovedtoassembletheCANoption.
Protective cover
9.1 Remove the current sensor protective cover from the
main unit.
O-ring
CAUTION: thereisanO-ringsealbetweentheWi-iQ3mainunit
andtheprotectivecover.MakesuretheO-ringisstillproperly
locatedinthemainunitwhenassemblingthecurrentsensor.
9.2 Assemble the CAN option on the main unit (torque 1.5Nm
±0.1). Make sure to use the appropriate screws (delivered
with the CAN option).
CAN
option
14mm
screws
CAUTION: usinginappropriatescrews(typeandlength)may
damagetheproductandimpactitsreliability.
9.3 The female pin connector is described below.
GND(optional) CANLOW
CANHIGH
9.4 The loose male connector is included in the option (ITT-
CANON SURE-SEAL IP68 3-contact receptacle with 2 pins
and 1 socket adapted for 0.75-1.5mm2wires).
Product Receptacle
part number
Contact part number
Wire gauge Pin (qty 2) Socket (qty 1)
ITT-CANON
SURE-SEAL 120-8551-001(SS3R)
0.5–1.0mm2330-8672-001(SS20) 031-8703-001(SS20)
0.75–1.5mm2330-8672-000(SS10) 031-8703-000(SS10)
10. Communication / Download
There are two modes of communication available on the
Wi-iQ3devices:
•Zigbee: this is the existing protocol already in use on
Wi-iQ1 and Wi-iQ2 devices. It will continue to provide
communicationtoexistingLifeiQchargers.
•BLE:thisisanewfeaturewhichprovidescommunicationto
aSmartphone.
TheWi-iQ3canalsobeconguredandprovidedataviaZigbee
(Wi-iQReport–v5.1.Xminimum)orBLE(EconnectApp).
11.“E connect” App
A Mobile App is developed for iOS and Android
Smartphones.TheAppnameis“Econnect”andwill
beavailable fromAppStore andPlayStore.Access
isprotectedbylogin/password.Severalaccesslevels
willbeavailablethroughpasswords.TheAppiscombiningthe
existing COMpact App features (for on-board chargers) with
the new Wi-iQ3 ones.
ThisApprequirestobeconnectedtoInternet(3G/4GorWIFI)
totakeadvantageoffullfeatures.ThisAppallowsmainly:
•toscan1andthenassociatetheWi-iQ3toacustomersite(list
ofdevicesisautomaticallyrecordedonaremoteserver2)
•tosetthe Wi-iQ3 batteryparameters(such as technology,
capacityetc)
•todownloadtheWi-iQ3historydata(datadownloadedare
automaticallytransferredtoaremoteserver*-thereis no
datastoredontheSmartphone)
•topairaWi-iQ3devicewithaBLEsensor
Notes:
(1)When launching the App, Bluetooth is automatically
activated.
(2)IftheSmartphoneisnotconnectedtoInternetduringscan
anddatadownload,thetransfertotheremoteserverwill
bedoneassoonastheInternetconnectionisrestored.
The main screens of the App with the main parameters are
showninthenextpages.

Notes:
(3)The ‘Share’ button allows to share the site data with
another user (through his e-mail address). By default, a
customersiteisonlyvisiblebyitsowner(whocreatedit).
(4)The ‘Export’ button allows to export data in a .xrp le
formatwhichcanbeimportedintheWi-iQReportsoftware
for deeper analysis. A web link to download the le is
providedorsenttoanyusere-mailaddress.
(5)The ‘Open’ button allows to access to the list of devices
alreadyrecordedinthecustomersiteinOff-linemode.
(6)The ‘Identication’ button allows to visually identify the
selected device through the identication sequence of its
LEDs.
(7)AslongastheWi-iQ3isconnectedtotheApp,thereisno
communicationwiththeBLEsensor(i.e.temperaturedata
isnotrefreshed).
Customer page
Share3Export4
Scanthe
devices
on site
Open5the
site without
scanningthe
devices
Numberof
chargersonsite
(history)
Numberof
Wi-iQ3 on site
(history)
Status page
Realtime
SOC
BatteryID
FW revision
Warnings
Settings(writting
ispasword
protected)
Temperature7if
connectedtoa
BLEsensor
Realtimedata
(V,A,V/c,
remainingAh)
Cyclesdata
Warning
Status page (with low DOD)
Scan page Directaccess
toadevice
viaQRcode
Deviceselection
lter(chargers,
sensors,Wi-iQ3)
SerialNumber
MACaddress
Device
identication6
Wi-iQ3
Warning
Charger
SerialNumber
MACaddress
BLEsensor
SOC

Battery
technology&
capacity
Multiple graphs are available (SOC, temperature, Ah…) with
variousperiodlters(day,week,year).
Settings page (4) Warning page
Off-line
status when
displayinga
Wi-iQ3 which is
outofrange
Onlysettings
parameterscan
bedisplayed
Password
Batterys/n
Nbofcells
Status page (Off-line) Settings page (1)
Settings page (2) Settings page (3)
SettoONif
connectedto
BLEw/level
probe
Customer
data
BLEpairing
Warning
Normal
status
SettoON
todetect
unbalancing
SetWi-iQ3
mode

12. Pairing a Wi-iQ3 with the BLE sensor
Theprocesstoassociate(i.e.topair)aBLEsensortoaWi-iQ3
unitisdescribedbelow:
12.1 With the E connect Mobile App (using Bluetooth)
•AfterinstallingtheWi-iQ3andBLEunitsonthebattery
•LaunchtheMobileApp
•ScantheWi-iQ3units
•AccesstotheselectedWi-iQ3
•EnterintheSettingssection
•Enterthepassword
•ScrolldowntotheBLESensorsection
•SettheSensorActiveparametertoON
•EntertheBLESensorAddress(MAC)–youcaneitherllit
manuallyorreaditviatheBLEQRcode
EntertheBLEsensoraddress
(MAC#ontheBLEIDdecal)
SetSensor
Active
toON
QRcode
reading
Savethe
change
Manual
enter
NB: how to get the BLE sensor address in case the decal is
missingornotreadable:
•LaunchtheSCANprocesstodetectthesurroundingBLEsensors
•ActivatetheIDENTIFICATIONmodeofthedetectedsensors
andidentifytherightone
•RecorditsMACaddress
Toverifythatpairingiseffective,itisneededtodisconnectthe
AppfromtheBLEsensorthen:
•ExitfromthesettingssectionandreturntotheSCANpage
(orExitfromtheApp)
•Check that the green BLE LED is blinking on the Wi-iQ3
(refertosection5)
12.2 With the Wi-iQ Report Software (using Zigbee dongle)
•AfterinstallingtheWi-iQ3andBLEunitsonthebattery
•LaunchWi-iQReportwiththeUSBdongleconnected(v5.1.X
minimum)
•ScantheWi-iQ3units
•AddandaccesstotheselectedWi-iQ3
•EnterintheBLEsection
•TicktheActivebox
•EntertheBLESensorAddress(MAC)
•Tick the appropriate boxes and set cells balance number
dependingontheBLEsensormodel
•ClickonWrite
IDdecalonaBLEsensor
Enterthe
number
of cells
Ticktheappropriate
boxesdependingon
BLEmodel
EntertheBLE
sensoraddress
(MAC#onthe
BLEIDdecal)
Tick the
Activebox
Clickon“Write”
•Verifythatpairingiseffectivebycheckingthatthe
greenBLELEDisblinkingontheWi-iQ3(referto
section5)

www.enersys.com
Subject to technical modification without any prior notice. E.&O.E.
Thisdevicecomplieswithpart15oftheFCCrules.Operationissubjecttothefollowingtwoconditions:
(1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause
undesiredoperation.InaccordancewithFCCrequirements,changesormodicationsnotexpresslyapprovedbyEnerSyscouldvoidtheuser’sauthority
tooperatethisproduct.
13. Use conditions
1.TheWi-iQ3is abatterycontrollerexpectedtobemounted
onanindustrialbattery.
2.Theassemblyhastobemadeinanon-connedplace.
3.InputVoltagerange:[15Vdc;120Vdc]
4.Batteryvoltage:24,36,48,72&80V(Wi-iQ3)
   96&120V(Wi-iQ3120V)
5.Currentmeasurementrange:[+/-300A][+/-600A][+/-1000A]
6.Temperaturerange:[0;70°C]
7.Altitude <2000m, Pollution level protection: 3 (dusty
environment)
8.Measurement level:I (measuresunconnected tonetwork),
donotuseinlevelII,III,IV
9.Technical support: Refer to our website: www.enersys.com
tondyourlocalcontact.
10.Standards:
*RadioSpectrum(Directive2014/53/EU-RED)
*FCC ID: T7V4561HM (Panasonic industrial 802.14.4
modem–2.405-2.475GHz)
*FCCID:WAP2001(CypressBLEPRoC–2.402-2.48GHz)
Publication No. EN-AC-WQ-IU-002 - 07.2019