Franklin Electric CELLGUARD User manual

CELLGUARD™
wired Battery monitoring system
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 © 2020 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:
Franklin Electric Grid Solutions
3760 Marsh Rd. • Madison, WI 53718, USA
Tel: [phone] • Fax: [phone]
Tel: USA & Canada [phone]
Cellguard and Celltraq are trademarks of Franklin Electric Company, Inc.
167-000800 r1
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
Introducon ......................................................................................................................................1
System components ......................................................................................................................2
Accessories .................................................................................................................................4
Baery sensor components .......................................................................................................5
String sensor components ..........................................................................................................5
The BC .........................................................................................................................................6
Specic funcons .....................................................................................................................6
Components ............................................................................................................................7
Indicator lighs ..........................................................................................................................7
Installaon.........................................................................................................................................9
Assembly ........................................................................................................................................9
Numbering baeries ...................................................................................................................9
Addressing .....................................................................................................................................11
Installing sensor cables ...............................................................................................................12
Crimping sensor cables ...............................................................................................................12
Addressing sensors .....................................................................................................................13
Addressing the TC .......................................................................................................................14
Connecng the BC and TC ..........................................................................................................15
The BC ......................................................................................................................................15
The TC ......................................................................................................................................15
Wiring the TA .................................................................................................................................16
TA 1 ...........................................................................................................................................16
Wiring mulple string sensors in series .....................................................................................17
Wiring mulple string sensors in parallel ...................................................................................17
Wiring the BC and TC .....................................................................................................................18
The TC .........................................................................................................................................18
The BC .........................................................................................................................................18
Mulple TCs ................................................................................................................................18
Connecng the current transducer ...............................................................................................19
Powering the BC ............................................................................................................................20
Commissioning the BC ......................................................................................................................21
Connecng the BC web interface ..................................................................................................21
Using the Integrator tool ...............................................................................................................22
Seng up string parameters ......................................................................................................23
Changing port sengs ................................................................................................................23
Changing IR sengs ....................................................................................................................25
Connecng the BC web interface ...............................................................................................26

Conguring network connecons ..............................................................................................26
Performing the Resistance Test ..................................................................................................28
Conrming IR values ................................................................................................................28
Conguring the Franklin Interface (FI) .......................................................................................29
Starng the FI .............................................................................................................................30
Commissioning the site .................................................................................................................32
Seng up baeries ........................................................................................................................33
Seng alert limits ..........................................................................................................................35
Seng discharge limits ...............................................................................................................35
Tesng and conrming communicaon ........................................................................................36
Eding IP address names ...............................................................................................................37

1
Introduction
Franklin Electric Grid Soluons Wired Baery Monitoring System (BMS) consists of baery
sensors (TA) that measure voltage, temperature, and the internal resistance of the baery. TC
sensors measure the baery string current and ambient temperature. Both sensors report data
to the Base Controller (BC) module:
• The BC:
• Communicates through Ethernet (RJ-45) or RS-485.
• Must have monitoring soware and middleware for you to view data.
• Uses Integrator soware to congure the BC during installaon.
• The standard conguraon:
• Allows you online monitoring of cell voltage, internal resistance, and temperature, as
well as string voltage, charge and discharge current, and ambient temperature.
• Provides automac over-limit alarms.
• Provides sata storage funcons and can upload data though an RS-485 or network port.
• Has one dry-contact input.

2
System components
1. BC.
2. Baery sensor module.
3. String sensor module.
4. Current transducer.
5. Celltraq™ data management soware.

3
• The TAs collect the voltage, internal resistance, and temperature of each cell.
• The TC collects the ambient temperature and the charge and discharge current of baery
strings.
• All sensors and TCs are connected though a UART bus, back to the BC.
• The BC is connected through Ethernet or a serial port to give you centralized management
and allow you to view the health of baery string.
• TAs monitor cell voltage, Internal resistance and temperature, and uploads data through
the COM port:
• TAs are powered by the monitored baery:
• 1V Ni-Cd, 13mA maximum.
• 6V, less than 7mA.
• 2V current absorpon, 7mA maximum (no more than 13mA).
• 12V current absorpon, 3mA maximum (no more the 7mA).
• Sensors must be installed on a baery with the appropriate voltage for the sensor or
the unit can be damaged:
• 1V Ni-Cd only.
• 6V baery only.
• 2V baery only.
• 12V baery only.
• TCs monitor charge and discharge current and ambient temperature for one string. The TC
communicates with the BC through the COM1 and COM2 serial ports. Each string must have
separate TCs.
• The current threshold is -3 Amp with a sample rate every 20 seconds.

4
Accessories
• Baery tabs (acquision terminal).
• The Address Modier-HA-6224AAAO is used to address TAs and TCs:
• The Interconnect cable is used to connect TAs and TCs to the BC and is included with
sensors: 13" and TC -8 m (25").
• The sensor-baery cable is included with TAs.

5
Battery sensor components
1. Indicator light.
2. Baery connecon port.
3. COM port.
String sensor components
1. Indicator light.
2. Baery sensor connecon port.
3. COM port.
4. Power input.

6
The BC
The BC can read the monitoring values, one-by-one, from TAs and TCs. This includes:
• Analysis and processing of data received from TAs and TCs.
• A maximum of six baery strings for each BC and 2 strings per COM port.
Specific functions
The BC reads each sensor in series to the end strings or strings including a TC.
• Parameters for string(s) set up in the Integrator soware cover upper and lower alarm
limits.
• An automac alarm funcon. (When an alarm happens, the E2 light illuminates.)
• The COM port is an RJ-45 (Ethernet) RS-485 Serial.
• Power Opons:
• CGBC-300-WD(BC) 85 to 246VAC/110VDC to 370VDC, 10W.
• CGBC-300-WD-48V(BC) 36VDC-72VDC (DC ONLY), 15W.

7
Components
1. Alarm indicator lights.
2. Power input.
3. Power output.
4. Dry contact.
5. Upload port.
6. LAN port.
7. Communicaon ports.
Indicator lighs
• P–Power light.
• A–Alarm light.
• E1–Commuincaon failure.
• E2–Baery alarm.
• R1/T1–Transmit and receive for COM1.
• R2/T2–Transmit and receive for COM2.
• R3/T3–Transmit and receive for COM3.
• R4/T4–Transmit and receive for COM4.

8
Intenonally Blank

9
Installation
Assembly
Numbering batteries
Before you connect the TAs to the baeries, label and number both the TAs and baeries clearly.
• The rst baery, or baery NO.1, must be the rst one on the string's posive terminal, the
NO.2 is the baery following the NO.1 baery, and so on:
• Mulple strings with separate ports and sensors in parallel:
• Each string starts with 1 and connues to last baery in string.
• Each string requires a TC.
• Example: 120 Baeries consisng of 2 strings of 60:
• String 1: 1-60 (addressing).
• String 2: 1-60 (addressing).
• Mulple strings that use the same port (maximum 2 strings) with sensors in series:
• String 1: 1-30 (addressing).
• String 2: 31-60 (addressing).
• Second TC (has an address dierent from the rst TC).
• The last baery is the one aached closest to the string negave terminal. Number the
baeries according to this pracce.
The BMS is a mulple string system. COM ports 1-3 on the BC are capable of supporng two
strings (six strings maximum) for each COM port.

10

11
Addressing
Install the U-type acquision terminals (provided) on each post on top of the baeries to be
monitored. Install the terminals in the following order:
U-type acquision terminals > Flat washer > Spring washer > Nut (or bolt)
Baery connector Flat washer
Spring washer
Nut
U-type acquision terminal

12
Installing sensor cables
Aach the appropriate end of the sensor cable to the tabs on the U-type acquision terminal,
and then plug the sensor cable into the sensor module connector.
Crimping sensor cables
IMPORTANT: You must use an RJ-22 crimping tool.

13
Addressing sensors
Power light
COM1
1. Make sure the sensor is secured on the baeries, and conrm the power light in the lower
le corner is green.
2. Use the TA address modier (provided) to:
• Connect the connector wire to the TA address modier and COM1 of the sensor.
• Press the up or down arrow at the boom of the TA address modier unl the desired
address number appears on the TA address modier display (1-240).
• Press Enter. The Acve light ashes green.
• The address is changed, and the TA address modier changes to the next address
automacally.
• Connect the TA address modier to the next sensor, and press Enter unl the enre
string is addressed.
IMPORTANT: Sensors will not address if the cable is connected to COM2. Make sure only the TA
address modier is connected to the sensor when you aempt to the address the sensor.

14
Addressing the TC
The default TC address is 241, but you can choose an address from 241 to 247. If you are
monitoring only one baery string, the address can remain the default.
To change the address:
1. Connect the address modier to COM1 on the TC.
2. Turn on the address modier power switch.
3. Press the ESC buon.
4. Use the arrow buons to change the address.
5. Press Enter to select the next digit. Aer you set the last digit, press Enter.
6. Press the arrow to select H-C, and then press Enter.
7. When “96” appears in the address modier display, press Enter. The address will be appear
in the display.
8. Press Enter. When the ACTIVE lamp turns green, the change is complete.

15
Connecting the BC and TC
The BC
• COM1 on the BC:
• Le side to either COM port on the TC.
• Right side from COM2 of the last baery in string 1 or string 2, if you use two strings for
each COM port.
The TC
• COM1 and COM2 operate idencally once the TC is addressed.

16
Wiring the TA
TA 1
• COM1 and COM2 act idencally once they are addressed.
• The last sensor in the string, COM2, has a home run back to the right port on COM1 on the
BC.
BC
TC
Last sensor in string