Franklin Electric CELLGUARD GEN III User manual

CELLGUARDTM WIRELESS BATTERY
MONITORING SYSTEM
GEN III
installation guide

The informaon in this publicaon is provided for reference only. While every eort has been made to ensure the reliability and accuracy of
the informaon contained in this manual at the me of prinng, we recommend that you refer to the appropriate website for the most current
version of this manual. All product specicaons, as well as the informaon contained in this publicaon, are subject to change without noce.
Franklin Electric Co., Inc. does not assume responsibility and expressly disclaims liability for loss, damage, or expense arising out of, or in any way
connected with, installaon, operaon, use, or maintenance by using this manual. Franklin Electric Co., Inc. assumes no responsibility for any
infringement of patents or other rights of third pares that may result from use of this manual or the products. We make no warranty of any kind
with regard to this material, including, but not limited to, the implied warranes of merchantability and tness for a parcular purpose.
Copyright © 2021 Franklin Electric Co., Inc., Madison, WI 53718. All world rights reserved. No part of this publicaon may be stored in a retrieval
system, transmied, or reproduced in any way, including, but not limited to, photocopy, photograph, magnec, or other record, without the prior
wrien permission of Franklin Electric Co., Inc.
For technical assistance, please contact:
franklinfueling.com
3760 Marsh Rd. • Madison, WI 53718 • USA
Tel: USA & Canada [phone] • Fax: [phone]
Tel: UK [phone] • Tel: Mex 001 800 738 7610
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CONVENTIONS USED IN THIS MANUAL
This manual includes safety precauons and other important informaon presented in the following format:
NOTE: This provides helpful supplementary informaon.
IMPORTANT: This provides instrucons to avoid damaging hardware or a potenal hazard to the environment, for example: fuel leakage from
equipment that could harm the environment.
CAUTION: This indicates a potenally hazardous situaon that could result in minor or moderate injury if not avoided. This may also be used to
alert against unsafe pracces.
WARNING: This indicates a potenally hazardous situaon that could result in severe injury or death if not avoided.
DANGER: This indicates an imminently hazardous situaon that will result in death if not avoided.
OPERATING PRECAUTIONS
WARNING: IMPORTANT SAFETY INSTRUCTIONS. BEFORE INSTALLING ANY FRANKLIN ELECTRIC GRID SOLUTIONS EQUIPMENT, READ THIS GUIDE
AND FOLLOW SAFETY AND OPERATING INSTRUCTIONS. SAVE THESE INSTRUCTIONS.
WARNING: Risk of explosive gases: Baeries generate explosive gases during normal operaon, and when discharged or charged.
WARNING: To reduce risk of baery explosion, follow these safety instrucons and those published by the baery manufacturer and the
manufacturer of any equipment you intend to use in the vicinity of a baery. Review cauonary marking on these products and on the baery
cabinets, baery racks, baery rooms, and on equipment containing the baery.
WARNING: Do not disassemble any equipment; contact Franklin Electric Grid Solutions when a repair is required. Incorrect reassembly may
result in a risk of electric shock or re.
WARNING: Use Franklin Electric Grid Solutions equipment in a dry, well-venlated area.
WARNING: Do not expose Franklin Electric Grid Solutions equipment to rain or snow.
WARNING: To avoid electric shock when tesng jars, abide by your company’s safety pracces and the following guidelines:
WARNING: Perform service work only for which you have been trained.
WARNING: Refer to NFPA 70E for electrical safety requirements.
WARNING: Use of Personal Protecon Equipment (PPE) and Protecve Clothing per NFPA 70E guidelines is required. Some examples of these,
but not limited to, are: Electrical-insulang, acid-resistant, and protecve gloves and sleeves per ASTM D 120, OSHA 29 CFR 1910.137, and NFPA
70E requirements; Protecve footwear; Aprons (acid-resistant); Insulang blankets; On-site spill kits; Protecve clothing for voltage levels, level
of corrosive protecon, and the amount of arc-ash protecon provided; Insulated rescue hooks or other means for pulling personnel from live
circuits; Eyewash staons or portable eyewash boles; Class “C” dry chemical re exnguishers instead of water around baery systems.
WARNING: Always have someone within range of your voice, or close enough to come to your aid, when working around lead acid baeries.
WARNING: Have plenty of fresh water and baking soda nearby in case baery acid contacts skin, clothing or eyes.
WARNING: If baery acid contacts skin or clothing, wash immediately with baking soda and water. If acid enters the eye, immediately ush
with cold running water for at least 10 – 15 minutes, and seek medical aenon.
WARNING: Never smoke or allow a spark or ame in the vicinity of a baery or engine.
WARNING: Be extra cauous to reduce risk of dropping a metal tool onto the baery. It might spark or short circuit the baery or other
electrical part that may cause an explosion.
WARNING: Before working with a lead-acid baery, remove personal metal items such as rings, bracelets, necklaces, watches, etc. A lead-acid
baery can produce a short circuit current high enough to weld such items causing a severe burn.
WARNING: Always wear safety glasses with side shields in the vicinity of baery work per 29CFR1910.133 (OSHA).
WARNING: Do not disconnect the baery cables from power systems during the test without authorizaon.
WARNING: Do not place yourself in an electrical circuit.
WARNING: Avoid simultaneous contact with the jar and with the baery cabinet, racks, or hardware that may be grounded.
WARNING: Baery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to cause cancer and birth
defects or other reproducve harm. Wash hands aer handling.

CONTENTS
INTRODUCTION..............................................................................................................................1
SYSTEM TOPOLOGY.....................................................................................................................1
BASE COORDINATOR UNIT (BCU) ...............................................................................................2
SENSORS .....................................................................................................................................4
SAFETY PRECAUTIONS ...................................................................................................................5
HARDWARE INSTALLATION: SENSORS & VTC ................................................................................7
SENSORS .....................................................................................................................................7
REQUIRED TOOLS ........................................................................................................................7
PROPER PPE (SEE SAFETY PRECAUTIONS) ..................................................................................7
SENSOR INSTALLATION ...............................................................................................................8
INSTALLING THE SENSORS WITH STRAP RESISTANCE ................................................................15
VTC ...........................................................................................................................................17
CURRENT TRANSDUCER INSTALLATION .....................................................................................23
SOLID-CORE CURRENT TRANSDUCER INSTALLATION ................................................................26
GROUND CABLE INSTALLATION ..................................................................................................28
AMBIENT ZONE TEMPERATURE SENSOR INSTALLATION ...........................................................28
POWERING UP THE VTC .............................................................................................................30
BCU INSTALLATION AND POWER ...................................................................................................31
POWERING THE BCU ..................................................................................................................31
WIRING THE 100VDC-1000VDC .................................................................................................33
48VDC TO DC CONVERTER INSTALLATION .................................................................................34
SETTING UP A CONNECTION TO THE BCU ....................................................................................35
CONNECTING TO A LAPTOP/PC ..................................................................................................35
GEN 3 BCU WEB INTERFACE TO WINDOWS® 10 ........................................................................36
ACCESSING THE WEB BROWSER INTERFACE .............................................................................37
HARDWARE COMMISSIONING SENSORS AND VTC .......................................................................39
SENSOR COMMISSIONING .........................................................................................................39
SCANNING SENSOR DATA ...........................................................................................................40
CONFIGURE SYSTEM PARAMETERS ............................................................................................41
BATTERY DATA ENTRY .................................................................................................................42
SCANNING SENSOR DATA ...........................................................................................................42
VTC COMMISSIONING ................................................................................................................45
BCU CONFIGURATION SETTING SYSTEM PARAMETERS ................................................................48
SETTING SYSTEM PARAMETERS ..................................................................................................48
SYSTEM ID ...................................................................................................................................49
CELLGUARD™ ..............................................................................................................................50
DOWNLOADING A CONFIGURATION FILE ..................................................................................56
VERIFY INSTALLATION AND CONFIGURATION ............................................................................57
SETTING BCU OUTPUT COMMUNICATIONS ..................................................................................58
NETWORKING>ETHERNET ..........................................................................................................58
COMMUNICATIONS>PROTOCOLS ..............................................................................................59
CELLTRAQ™ COMMISSION .........................................................................................................61
TOOLS>MODBUS REGISTER ........................................................................................................62

Intenonally Blank

1
INTRODUCTION
SYSTEM TOPOLOGY
The Gen III Wireless Baery Monitoring System (BMS):
• Provides accurate and reliable indicaon of baery state of health through monitoring and
analysis of baery voltage, temperature, and conductance.
• Detects specic baery deterioraon and baery string failures and provides automac
alarms via; dry alarm contacts, modbus TCP/IP, email, SNMP traps, and text messages.
• Collects and analyzes baery health indicators to provide detailed baery health status
reports.
• Eliminates the manual me and cost consuming maintenance programs with programmed
baery performance tesng and reporng through the web/intranet.
• CELLGUARD™ System-Gen-3 provides local applicaon access and immediate baery
health informaon. Baery state of health indicators are reported to a remote
server with outgoing email. Wireless sensors reduce me and cost of installaon and
maintenance.
• CELLGUARD™ System-Gen-3 eliminates the need for dedicated computers to monitor
each baery system.
• Lowers cost of ownership from installaon to its product life cycle.

2
BASE COORDINATOR UNIT (BCU)
FEATURES
• Supports up to 16 Baery Strings.
• 600 cells/baeries total per BCU.
• Network Communicaons via:
• TCP/IP Ethernet/Intranet
• Modbus over TCP/IP
• MQTT
• SNMP v3
• 2 Form C Dry Contacts.
• Embedded Internal Webserver.
• Field Upgradable Firmware.
• 2 Ambient Temperature Sensors.
• Remote Conguraon and Hardware Commissioning.
• Captures String & Baery data including baery discharge data.
• Sends data to CELLTRAQ™ Enterprise soware at scheduled frequency.
SPECIFICATIONS
Baery Strings:
• Max strings is 16.
• Max sensors per string is 300.
• Max sensors per BCU is 600 (irrespecve of how they are divided by strings).
• Test Measurement Intervals:
• Baery Voltage and Temperature.
• Range: 1 – 24 Hours (Default: 4hrs).
• Baery Conductance and Strap Resistance.
• Range: 1 – 30 Days (Default: 7 Days)

3
Examples of BCU String Conguraons:
• If 60 cells per string, then the max is 10 strings (60 x 10 = 600)
• If 4 baeries per string, then the max is 16 strings (4 x 16 = 64)
• If 24 cells per string, then the max is 16 strings (24 x 16 = 384)
• If 240 cells per string, then the max is 2 strings (240 x 2 = 480)
• Power Input: 9-12Vdc @ 800mA.
• Operang Temperature: 0⁰C - 65⁰C.
• Storage Temperature: -10⁰C - 80⁰C.
• Processor: Quad Core @ 1250MHz.
• RAM: 1Gb SDRAM @ 400MHz.
• Storage: 16GB micro SD card.
• USB Type A: 2.0.
• UART: Baud Rate: 57.6Kbps; Data Bits: 8; Parity Bit: None; Stop Bit: 1.
• Ethernet: RJ45; 10/100Mbps; Auto-Negoate; 802.3 Compliant.
• Analog Alarm Input: 0.2Vdc – 10Vdc.
• Binary Alarm Input: Dry contact only.
• Major/Minor Alarm Output: Close/Open Form C Dry Contacts.
• Wireless RF Radio Band: 802.15.4 Compliant; 2.4GHz @ 8mW (6.3dBm).
• Modbus: Ethernet TCP/IP UDP.
• Regulatory Compliance: FCC, CE, RoHS, IEEE.
• Physical Dimensions: L:7.8in, W:4.47in, H1.44in.

4
SENSORS
FEATURES
• One sensor per cell/baery.
• Sensor Types: 2V, 6V-12V, 12V.
• Sensor Measurements: Voltage, Temperature, Conductance, Strap Resistance.
• Mesh Roung Communicaon.
• Quick, fully hot swappable sensor and/or wiring harness.
• Remote upgradable rmware.
• Compable with VRLA baeries and VLA cells.
• Conductance technology for Ohmic tesng.
• Non-Invasive to the baery.
• Accurate baery state-of-health results.
• Wireless system minimizes wiring, installaon cost, and maintenance.
SPECIFICATIONS
• Wireless RF Radio Band: 802.15.4 Compliant; 2.4GHz @ 8mW (6.3dBm).
• Wireless Range: 0 – 30 meters (Unobstructed).
• Operang Temperature: 0⁰C - 65⁰C
• Storage Temperature: -10⁰C - 80⁰C
• Test Current: 1100 – 4500mA depending on baery/cell oat voltage.
• Voltage Resoluon: 1mV
• Conductance Resoluon: 1
Ω
• Regulatory Compliance: FCC, CE, RoHS, IEEE
• Physical Dimensions: L:2.63in, W:2.64in, H1.06in

5
SAFETY PRECAUTIONS
IMPORTANT: Read this manual before installing the products.
WARNING: To avoid electrical shock when tesng jars, follow your company's safety pracces
and these guidelines:
1. IMPORTANT SAFETY INSTRUCTIONS. IT IS OF UTMOST IMPORTANCE THAT BEFORE
INSTALLING YOUR SYSTEM YOU READ THIS MANUAL AND FOLLOW THE SAFETY AND
OPERATING INSTRUCTIONS. SAVE THESE INSTRUCTIONS.
a. TO REDUCE RISK OF BATTERY EXPLOSION, FOLLOW THESE SAFETY INSTRUCTIONS
AND THOSE PUBLISHED BY THE BATTERY MANUFACTURER AND THE MANUFACTURER
OF ANY EQUIPMENT YOU INTEND TO USE IN THE VICINITY OF A BATTERY. REVIEW
CAUTIONARY MARKING ON THESE PRODUCTS AND ON THE BATTERY CABINETS,
BATTERY RACKS, AND BATTERY ROOMS, OR EQUIPMENT CONTAINING THE BATTERY.
IF YOU ARE UNCERTAIN AS TO THE TYPE OF BATTERY YOU ARE WORKING ON, THEN
CONTACT THE SELLER OR BATTERY MANUFACTURER.
b. DO NOT INSTALL THIS EQUIPMENT IF IT HAS BEEN DROPPED OR OTHERWISE DAMAGED
IN ANY WAY; CONTACT FRANKLIN GRID TECHNICAL SERVICES OR CUSTOMER SERVICE.
c. DO NOT DISASSEMBLE ANY PARTS; CONTACT FRANKLIN GRID TECHNICAL SERVICES
OR CUSTOMER SERVICE WHEN A REPAIR IS REQUIRED. INCORRECT REASSEMBLY MAY
RESULT IN A RISK OF ELECTRIC SHOCK OR FIRE.
d. INSTALL EQUIPMENT IN A DRY, WELL-VENTILATED AREA.
e. DO NOT EXPOSE EQUIPMENT TO RAIN OR SNOW.
2. Perform service work only for which you have been trained.
a. Refer to NFPA 70E for electrical safety requirements.
b. Use of Personal Protecon Equipment (PPE) and Protecve Clothing per NFPA 70E
guidelines. Some examples of these, but not limited to, are:
• Electrical-insulang, acid-resistant, and protecve gloves and sleeves per ASTM D
120, OSHA 29 CFR 1910.137, and NFPA 70E requirements.
• Protecve footwear.
• Aprons (acid-resistant).
• Insulang blankets.
• On-site spill kits.
• Protecve clothing for voltage levels, level of corrosive protecon, and the amount
of arc-ash protecon provided.
• Insulated rescue hooks or other means for pulling personnel from live circuits.
• Eyewash staons or portable eyewash boles.
• Class “C” dry chemical re exnguishers instead of water around baery systems.

6
c. Always have someone within range of your voice, or close enough to come to your aid,
when working around lead acid baeries.
d. Have plenty of fresh water and baking soda nearby in case baery acid contacts skin,
clothing or eyes.
e. If baery acid contacts skin or clothing, wash immediately with baking soda and water.
If acid enters the eye, immediately ush with cold running water for at least 10 – 15
minutes and seek medical aenon.
f. Never smoke or allow a spark or ame in the vicinity of a baery or engine.
g. Be extra cauous to reduce risk of dropping a metal tool onto the baery. It might spark
or short circuit the baery or other electrical part that may cause an explosion.
h. Before working with a lead-acid baery, remove personal metal items such as rings,
bracelets, necklaces, watches, etc. A lead-acid baery can produce a short circuit
current high enough to weld such items causing a severe burn.
i. Always wear safety glasses with side shields in the vicinity of baery work per
29CFR1910.133 (OSHA).
j. Do not disconnect the baery cables from power systems during the installaon
without proper authorizaon.
k. Do not place yourself in an electrical circuit.
l. Avoid simultaneous contact with a baery and with the baery cabinet, racks, or
hardware that may be grounded.
m. Baery posts, terminals, and related accessories contain lead and lead compounds,
chemicals known to cause cancer and birth defects or other reproducve harm.
NOTE: WASH HANDS AFTER HANDLING.

7
HARDWARE INSTALLATION: SENSORS & VTC
SENSORS
REQUIRED TOOLS
• Insulated Torque Wrench
• Insulated Sockets and Extension
PROPER PPE (SEE SAFETY PRECAUTIONS)
Use of Personal Protecon Equipment (PPE) and Protecve Clothing per NFPA 70E guidelines.
Some examples of these, but not limited to, are:
• Electrical-insulang, acid-resistant, and protecve gloves and sleeves per ASTM D 120,
OSHA 29 CFR 1910.137, and NFPA 70E requirements.
• Protecve footwear.
• Aprons (acid-resistant).
• Insulang blankets.
• On-site spill kits.
• Protecve clothing for voltage levels, level of corrosive protecon, and the amount of arc-
ash protecon.
• Insulated rescue hooks or other means for pulling personnel from live circuits.
• Eyewash staons or portable eyewash boles.
• Class “C” dry chemical re exnguishers instead of water around baery systems.
• Always wear safety glasses with side shields in the vicinity of baery work per
29CFR1910.133 (OSHA).
• Make Sure Baery String is disconnected from charging circuit.

8
SENSOR INSTALLATION
NOTE: When installing tabs on the rst and last baeries, installaon of the VTC string voltage
cable and/or the DC to DC cable and solid core transducers should be done with ring terminals to
prevent having to disconnect ring terminals mulple mes. See the VTC Installaon and Powering
BCU secons.
NOTE: Torque all baery terminals to baery manufacturer specicaons.
MONITORING APPLICATIONS
• Telco- two-tab ring terminals if no strap resistance.
• Data Center – Four-tab ring terminals - Strap Resistance.
• Ulity (NERC)- Four-tab ring terminals - Strap Resistance.
Terminal Cross Reference Table
Post Size Compability
Metric US
M4 4mm #8 0.176"
M6 6mm 1/4" 0.250"
M8 8mm 5/16" 0.3125"
M10 10mm 3/8" 0.375"
M10 10mm 7/16" 0.4375"
429-000062-6mm 429-000064-10mm
• Electrically isolate the baery string and reduce the voltage to <60VDC.
• Note the inial torque value of the baery/cell.

9
NOTE: The path of current ow to the baery string (convenonal current ow, posive to
negave).
WARNING: When working on baeries, use proper PPE.
• The bolt hardware MUST be arranged as follows (from bolt head to boom):
• Lock-Washer
• Washer
• FE GRID Soluons Tabbed Washer
• The FE GRID Tab must be closest to the baery to ensure accurate readings.
• Tesng is sensive enough to pick up resistance created by a misplaced washer.

10
SPECIAL CONDITIONS: For deep well connecons such as on OPz cells, spacers may be needed
to obtain proper connecon.
TAB TERMINAL INSTALLATION
The bolt hardware MUST be arranged as follows (from bolt head to boom):
1. Lock-Washer
2. Washer
3. FE GRID Soluons Tabbed Washer
4. FE GRID Soluons spacer(s) (must use FE hardware)
5. Inter-cell connector

11
BATTERY SENSOR TERMINAL INSTALLATION
Two-Tab Terminal Installaon
1. Remove bolt and washers.
2. Install tab terminal as shown.
NOTE: Ensure wide tab (.250 wide tab) is on the boom touching the strap and narrow tab (.187
wide tab) is on top touching the washer and bolt.

12
Four-Tab Terminal Installaon
1. Remove bolt and washers.
2. Install with orientaon as follows:
a. Boom poron of terminal surface indicated, with the two .250 wide tabs, contacts the
strap. (These are the wider tabs)
b. Top poron of terminal surface indicated, with the two .187 wide tabs, contacts the
washer and bolt. (These are the narrower tabs)
Installing the Sensors (without strap resistance test)
Sensor wire denions:
• Orange: Input signal lead
• Red: Posive baery post sense lead
• Brown: Negave baery post signal return lead
• Blue: Negave baery post temperature
• Black: Negave baery post sense lead

13
• Make sure the baery string is powered down.
NOTE: For CELLGUARD™ BMS Baery 1 is always the most posive baery in the string
regardless if it is a posive grounded baery system.
• Always install the BLACK and BLUE wires rst.
NOTE: BLACK and BLUE wires are treated with Heat shrink and are not fully insulated.
IMPORTANT: Any variance from these steps can cause injury or damage the sensor
• On Negave Post; install BLACK and BLUE wire to the boom most .187 narrow
terminal.
• On negave post; install the BROWN wire to the .25 wide terminal.
• On Posive Post; install the ORANGE wire to the boom most .25 wide terminal.
• On the posive post; install the RED wire to the boom most .187 narrow terminal.
• Repeat unl all sensors are installed.

14

15
INSTALLING THE SENSORS WITH STRAP RESISTANCE
• First baery or cell:
• On Negave Post; install BLACK and BLUE wire to the upper .187 narrow terminal.
• On negave post; install BROWN wire to lower .250 wider terminal.
• On First baery Only; On Posive post Connect ORANGE wire to .250 wide terminal .
• On rst baery Only; On posive post connect YELLOW wire to .187 terminal.
• On Posive Post Connect RED wire to .187 terminal.
NOTE: On all other baeries, the orange
and yellow wires connect to the negave
post of the previous baery on the proper
size terminals.
• On Negave Post; install BLACK and BLUE wire to the top .187 narrow terminal.
• On negave post; install BROWN wire to lower .250 wider terminal .
• Install ORANGE wire to .250 wide terminal on the negave post of the previous
baery/cell.
• Install YELLOW wire to .187 terminal on the negave post of the previous baery/cell.
• On Posive Post install RED wire to .187 terminal.

16
NOTE: When the ORANGE and YELLOW wires cannot make the reach for er to er or baery
shelf to shelf connecons, treat these connects like the rst baery/cell.
• When rst installed, Sensors will ash RED and YELLOW.
• Indicaon that sensors are on the factory RF channel and need to be commissioned to the
BCU.
Sensor wire denions:
• Orange: Input signal lead
• Yellow: Strap resistance sense lead
• Red: Posive baery post sense lead
• Brown: Negave baery post signal return lead
• Blue: Negave baery post temperature
• Black: Negave baery post sense lead