Junxy Energy JUNXY-TA CELLCHECK User manual

JUNXY (HK) ENERGY CO.,LTD www.junxypowersolutions.com
JUNXY-TA CELLCHECK
Battery Monitoring System
User Manual

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Table of Contents
Tools required for installation and Debugging.............................................................................1
1 Overview.................................................................................................................................... 4
2 System Components and Module Description....................................................................5
2.1 System Components....................................................................................................... 5
2.2 CELLCHECK Module...................................................................................................... 6
2.3 CM Module........................................................................................................................ 7
2.4 TC Module......................................................................................................................... 9
2.5 Converter.........................................................................................................................10
3 Installation and Mounting......................................................................................................12
3.1 Determining the Installation Based on Location....................................................... 12
3.2 Numbering the Batteries...............................................................................................12
3.3 Set the addresses of TA modules and TC modules.................................................13
3.4 CELLCHECK Module Mounting Instructions............................................................ 14
3.5 TC module, Converter and CM Module Wiring........................................................ 15
4 Settings.................................................................................................................................... 16
4.1 Main Interface.................................................................................................................16
4.2 Easy Setup......................................................................................................................16
4.3 Resistance Alarm Setting............................................................................................. 17
4.4 Other Settings.................................................................................................................17
5 Checking Voltage Readings................................................................................................. 18
6 Performing a Resistance Test..............................................................................................18
7 Connecting BMS to a Remote Computer.......................................................................... 19
7.1 Via RS485....................................................................................................................... 19
7.2 Via network port............................................................................................................. 19
8 Network card setup................................................................................................................19
9 Trouble shooting.....................................................................................................................23
10 Menu description............................................................................................................23

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Tools required for installation and Debugging
NO.
Picture
Description
Installation tools
1
Socket wrench
12902
Socket head
12307/309/311
2
Multimeter
VC9807A+
3
Clamp Meters
VC3266D
4
Stripper
91108

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5
Phillips-head
screwdriver
61213
6
Flat-head screwdriver
61311
7
Phillips-head
screwdriver
61211
8
Needle nose pliers
70124A
9
Diagonal pliers
70221A

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10
Crimping Pliers
G51303
11
Scissors
03131
12
Wrench
47222
Debugging tools
13
Lap top
14
485 Converter and wire
15
Engineering manual

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（this manual）
1 Overview
The CELLCHECK is a stand-alone monitor for UPS applications. The CELLCHECK
provides early warnings for backup battery problems. In a CELLCHECK system there is
one CM module and one or more CELLCHECK modules, TC modules and converters. In
some cases, the system may also include a remote computer.
Figure 1-1-1
The CELLCHECK BMS standard configuration has the following features and
functionality:
- Online monitoring of cell voltage, internal resistance, cell temperature, overall voltage,
charge and discharge current and ambient temperature.
- Automatic over-limit alarm
- Displays data on CM module
- Key data can be saved on CM module, and a remote computer or a device can access
CM module to read the data through over a RS485 port or RS232 port
- Comes standard with two dry contact outputs on CM module
Optional features:
- Comes with a network upload port
- 5.7 inch display
We provide the users with easy step-by-step installation plans, engineering drawings,
device configuration, wiring methods and wiring diagram.
Installation steps are as follows:
- Check inventory of equipment and accessories according to the packing list upon
arrival.
-A detailed explanation of Installation plan with step by step instructions following
the engineering drawings will be provided with on-site installation by our Engineer
or Agent. Conditions will be determined at the installation location as well as the
methods of alignment. Once the Engineer has properly installed and explained
instructions of operation and maintenance to the user and client, approval is
required by the client.

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- Mounting equipment.
- Wiring.
- Testing.
- Check before approval.
- Training
The above contents will be described in detail below.
2 System Components and Module Description
2.1 System Components
Standard configuration below：
Part Number
Picture
Descriptive
name
1
CELLCHECK
2
CM Module
3
TC Module
4
Converter
5
Current
Transfer (CT)
6
CELLCHECK
test cable
7
TC test cable

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8
CELLCHECK
communication
cable
9
Power cable
Optional parts：
Part number
Picture
Descriptive
name
1
Monitoring
Module
The system topology is below：
Figure 2-1-1
2.2 CELLCHECK Module
The CELLCHECK Module monitors cell voltage of a single battery, internal resistance
and temperature and uploads data via the communications port. The TA Module
doesn’t have an alarm function. It is powered by monitored battery. The module

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comes in 2V type, with maximum power usage less than 0.15W and a 12V type, with
maximum power usage of less than 0.25W. The module should only be used with its
assigned battery type; otherwise, damage to the module may occur.
The module interface is described in the following figure below.
Figure 2-2-1
NO.
Name
Description
⑴
J1
Test port, connects with battery negative and positive
poles.
⑵⑶
COM1/COM2
port
This is an internal parallel UART Port, which are used in
communication between CELLCHECK Modules.
⑷
LED
A double colors LED with a yellow and green light, the
green light indicates power on, the yellow shows that
communication is connected.
2.3 CM Module
The CM Module connects with CELLCHECK modules via a convertor and receives
data including cell voltage, cell internal resistance and cell temperature. The CM
Module displays all battery data. One CM module can manage up to 4 battery strings
and each string is up to 200 batteries. The details of functionality are shown below：
a、Reads data from CELLCHECK module.
b、Comes with an LCD Display that checks real-time monitoring data and shows
history of alarm records.
c、Can set parameters for operation limitations.
d、Automatic alarm function. In the event of an alarm, an LED light will flash and
a buzzer will sound, the corresponding dry contact will automatically shut off.
e、Connects to a host computer through an RS485, RS232 or a network port.

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Figure 2-3-1
NO.
Name
Description
⑴
LCD display
Two lines of text are displayed，122X32.
⑵
Button
Total of four buttons, “Esc” for exit，“▲”“▼”for page
up/page down，“Enter” for confirmation.
⑶
LED
POWER: is the power light; A1: indicates an important
alarm; A2: indicates a general alarm；E1:indicates CM
module failure; E2: indicates that the CM Module and the
TA module have a communication error; Rx1/Tx1:COM1
is sending and receiving data; Rx2/Tx2、Rx3/Tx3、
Rx4/Tx4、Rx5/Tx5、Rx6/Tx6: corresponds with COM2、
COM3、COM4、COM5 and COM6.
⑷
Power switch
Controls CM Module power input.
⑸
Power Input
85～264VAC input，less than 15W for each CM module.
⑹
DIP switch
Sets the CM Modules address from 1 to 15.
⑺
ISP1 port
Updates CM Module firmware.
⑻
TEMP/ISP2 port
Connects ambient temperature sensor，also used as a
firmware update.
⑼
J1，J2，J3 ports
Pin1 and Pin2 of J1 are a dry contact output and will
automatically shut off in the event of equipment failure.
Pin3 and Pin4 are also a dry contact output that is used
for other alarms except equipment failure. The other Pins
are for the future.

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⑽
COM5 port
Data upload port that connects to a remote computer
through an RS485, Pin9 is + and Pin5 is -, the baud rate is
19200BPS。
⑾
COM6 port
Data upload port that connects to a remote computer
through an RS232, Pin2 receives data, Pin3 sends data
and Pin1 is connected to the ground, the baud rate is
19200BPS.
⑿
COM1 port
Connects with a converter to CELLCHECK Module via a 4
pin connector, the pins on COM1 from the left are B,A,+,-,
where B is – of the RS485 port and A is + of the RS485
port, and the baud rate is 9600BPS. +/- is a DC 12V
power output.
⒀
COM2 port
Connects with a converter to CELLCHECK Module via a 4
pin connector, the pins on COM1 from the left are B,A,+,-,
where B is – of the RS485 port and A is + of the RS485
port, and the baud rate is 9600BPS. +/- is a DC 12V
power output.
⒁
COM3 port
Connects MM module. The pins of COM3 from the left are
B、A、+、-,where B is – of RS485，A is + of RS485，baud
rate is 19200BPS, +/- is a 12VDC output.
⒂
COM4 port
The Data upload port connects to a remote computer via
RS422 from Pin1 to Pin4 are T-、T+、R+、R-，Baud Rate
is 19200BPS.
⒃
Network Port
10M/100M，RJ45,communicates with a LAN.
⒄
Ground
Connects to the ground.
2.4 TC Module
The TC Module monitors charge and discharge current and ambient temperature for
one string. The TC Module communicates with the converter module through the
COM1 and COM2 parallel port. One string needs one TC Module. The following
details are shown below.

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Figure 2-4-1
NO.
Name
Description
⑴
J1 port
Connects to the current transformer and the ambient
temperature sensor。
⑵
LED
A double colors LED with a yellow and green light, the
green light indicates power on, the yellow shows that
communication is connected。
⑶ ⑷
COM1/COM2
port
This is an internal parallel UART Port, which are used in
communication with a CELLCHECK Module and a
converter.
⑷
VIN port
Power input，DC8-13V，where the left is + and right is -，
Powered by the CM Module, where the maximum power
is less than 2 watts。
2.5 Converter
The Converter is used to connect the CELLCHECK Modules and convert the UART
bus to a RS485 bus. The CELLCHECK Module can not communicate directly with the
CM Module so the converter must be used. Every 200 CELLCHECK Modules require
a converter for configuration.
The following details are shown below.
Figure 2-5-1
NO.
Name
Description
⑴
COM3 port
It’s a RS485 port that connects to the COM1 or COM2 on
the CM Module. The pins of COM3 from the left are B、A、
+、-,where B is – of RS485，A is + of RS485，baud rate is
9600BPS, +/- is a 12VDC input with maxima 0.3W power
dissipation.
⑵
LED
POWER: indicates power on; R/T: indicates

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communication.
⑶
COM1/COM2
port
This is an internal parallel UART Port. These ports are
used in communication with CELLCHECK modules.

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3 Installation and Mounting
3.1 Determining the Installation Based on Location
The Module may be mounted in 3 ways:
1) The CELLCHECK Module can be glued directly onto the side of the battery
(A) or the railing of the battery rack (B).
2) The TC Module and converter can be mounted to the battery rack.
3) The CM Module can be mounted inside a 19”rack (C) or on a battery rack (D).
Note: Installation of the CM modules should be no more than 400 meters
from the batteries themselves.
Figure 3-1-1
3.2 Numbering the Batteries
Before connecting the CELLCHECK Modules to the batteries, the batteries should be
numbered and labeled correctly by using a label to paste on the surface of the battery
where the labels are easy to be seen. The first battery, or, battery NO.1 must be the
first one on the string positive terminal, the NO.2 is the battery following the NO.1
battery, and so on. The last battery is the one attached closest to the string negative
terminal. The batteries must be numbered in accordance with this method.
Figure 3-2-1
D
C
A
B

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Figure 3-2-2
3.3 Set the addresses of TA modules and TC modules
The initial address is 1 for all modules and need to set to comply with the application
before installation. The max address which may be set is 200, all modules with
different address connected to a same communication bus.
Using CM module to set TA/TC module address
Connects the TA module to the COM1 of CM module via a converter, and then follow
below steps:
Enter the menu ‘ 5 Addr. Wr.’:
Choose ‘ 5.2 TA Addr’
Then choose ‘Yes’
The CM module will restart after choosing ‘Yes’ and enter address changing mode.
Choose the menu ‘5.2 TA Addr’ again and enter the new address for the TA module
to finish the process.
The same steps for changing TC module address but choose ‘5.3 TC Addr’.
Note: Need to restart CM module for quitting from address changing mode.
Using address module to set TA/TC module address
If a lot of modules need to be set, using a address module will be more convenient.
Just connect the address module to the TA/TC module, and set the new address on
the address module then enter, the address will be changed to new one.
5 Addr. Wr.
6Erase Data
5.2 TA Addr
5.3 TC Addr
Change TA addr?
Yes No

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3.4 CELLCHECK Module Mounting Instructions
Each battery must be connected to the CELLCHECK Module. The TA Module may be
mounted to the side of the battery according to the following diagram as seen below.
Figure 3-3-1
Instruction
Steps
Detailed Description
⑴
Connect the black test cable to the battery negative pole.
⑵
Connect the red test cable to the battery positive pole.
⑶
Plug in the other end of the test cable to the J1 Port of the
CELLCHECK Module.
⑷
Tear away the protective film from the adhesive tape and
mount the module to the side of the battery.
⑸
Uses a communication cable to connect this module to the
module in front of it in order or succession.
Following the above steps, install the CELLCHECK Modules on each battery and
connect each adjacent module by a communication cable (see figure 3-4-1). The
battery numbers should be consistent with the CELLCHECK module’s addresses. If a
battery number is 1, for example, the battery must be connected to a module with an
address of 1.
After the CELLCHECK test cable is installed, the module will automatically boot and

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the LED will light up.
The CELLCHECK module’s address ranges from 1 to 200. There are two COM ports on
the CM module to connect to the CELLCHECK Module; therefore, up to 400 CELLCHECK
modules can be connected to one CM module to monitor 400 batteries.
3.5 TC module, Converter and CM Module Wiring
The TC module and converter requires a 12 Volts power supply to operate which is
received through the CM module’s COM1 or COM2. Follow the steps below for wiring
instructions.
Figure 3-4-1
Instruction
Steps
Detailed Description
⑴
Connect the first or last CELLCHECK module’s COM1 on one
battery string to the TC module’s COM1 by a communication
cable
⑵
Connect the TC module’s COM2 to the converter’s COM1 by a
communication cable
⑶
Connect the TC module’s VIN port to the converter’s ‘+ -’ port by a
power cable
⑷
Connects the converter’s COM3 to the CM module’s ‘B A+-’by a
4-core cable.
A CT Module measures string discharge & charge current and may be connected to
the TC module by a TC test cable where there is a temperature sensor for measuring
ambient temperature on the end of said sensor. Connect one end of the TC test cable
to the J1 port of the TC module, then connect the other end of the cable to a CT which
may be installed between two batteries (see diagram below). It should be noted that
installation of wires must have the same same current direction between the arrow
markings on the CT and the direction of the battery charge current.

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Figure 3-4-2
4 Settings
All parameters may be set on the Main Module.
4.1 Main Interface
The CM Module will be shown, as below, after power on.
During this interface, in the event of an alarm, please press the “Enter” key to view the
details, use “▲” “▼” arrow keys to view options and press “ESC” to quit.
Press the ”Enter” key to enter the main menu.
Enter “A. Mon Data” to view the real-time voltage data and internal resistance data,
and enter “B Alarm Hist” to view the alarm record. All parameters can be set in menu
C, and the password is “2022”.
The setup menu has the following features:
- Setting the parameter
- Resistance test
- Erase data
- Recover to default
4.2 Easy Setup
Enter “3 Easy Setup” and the system will automatically guide you through setup. We
advise you to use this menu to set parameters for your first installation.
After entering the setup menu, use the “▲” “▼” keys to set string quantity. The
maximum string quantity is no more than 6.
1# :Alarm 2#:OK
3#:None 4#:None
S1 A/T alarm
S1 R alarm
A.Mon. Data
B.Alarm Hist.
C.Setup
Str. Qty
2

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222
After inputting the string set value, press the “Enter” key to enter the following step to
set “Basic Set”.
After finishing these initial parameters settings, the system will automatically set the
other parameters to the same format.
If the string quantity is set to two or more, it will be asked to continue the parameters
setting for the second string.
The changes will take effect only after restarting the CM Module.
Note: After completing easy setup, resistance alarm values   must be set
individually, see the specific "resistance-related parameter set."
4.3 Resistance Alarm Setting
The resistance alarm level must be set separately, even if easy setup has been
selected and completed. Setting the level is required prior to the resistance test, and
then set a standard resistance for each individual battery. The highest level, as
default, is 1.3 times the standard resistance.
The method for getting the standard resistance is different for different battery string.
For New Batteries
After performing a resistance test, the values can be used as a standard resistance
for those specific batteries. See the steps below to set a standard resistance setting.
‘2 Setup’ →“2.3 1#IR Set”→“2.34 R Reset”
Enter ‘Enter’ then choose ‘Yes’, the module will copy the last resistance values as the
standard resistance setting.
For Old Batteries
After performing a resistance test on the old batteries, you may work out the average
value as a standard resistance set. See the steps below to set a standard resistance
setting for old batteries.
‘2.33 Initial R’ → ‘001: XXX uΩ
Enter the average value for each battery instead of XXX. Then the standard
resistance for each battery will be an average value set.
4.4 Other Settings
All the parameters can usually be modified in the menu of “2 Setup”, and the
followings are samples for how to modify these parameters which may be used.
Check Firmware Version
Select “1 Data Ing” → “1.3 GL set” → “1.31 Version”, and then press “Enter” to check
the current firmware version.
Setting the Quantity of the String
Select “2 Setup” → “2.1 GL set” → “2.14 Str. Qty”, and then use “▲” “▼” to change
the quantity.
Set Quantity String 1 Batteries
Select “2 Setup” → “2.2 String 1” → “2.21 Basic Set”, and then use “▲” “▼” to change
the parameters.
12V，300AH，24

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Set High & Low Level Cell Voltage of String 1
Select “2 Setup” → “2.2 String 1” → “2.23 C_Volt”, and then use “▲” “▼” to change
the values.
Set High & Low Level String Voltage of String 1
Select “2 Setup” → “2.2 String 1” → “2.25 C_S_Volt”, and then use “▲” “▼” to
change the values.
5 Checking Voltage Readings
The module will automatically start to monitor cell voltage after resetting the module.
Usually, the module requires one or two minutes to collect the cell voltage data at the
initial setup and then you may enter menu “A. Mon. Data” to check if the data is correct.
NO.
Item
Requirements
Tool
1
Cell voltage
1.5～2.5V，0.1%±1mV；
9～15V，0.1%±10mV；
Multimeter
2
String voltage
20～700V，0.3%±0.2V
Multimeter
3
Ambient
temperature
±0.5℃
Thermometer
4
Cell
temperature
±1.5℃
Thermometer
4
Current
2%±2A
Clamp Meters
After the procedures are finished, all data should be filled into the "check table" menu.
6 Performing a Resistance Test
By default, the module will test battery resistance once a month, but, it also can be done
manually.
Please follow the steps below to perform a resistance test for string 1.
Select “C Setup” → “4 R test”, and then it will show:
Select “Yes” and press the “Enter” key.
Then the module will take about one minute to start a resistance test.
Usually it will take about 15 minutes to finish one string of a resistance test. After the test is
complete, it will show as below.
To test R of S1?
Yes No
Wait,Normal
1：Normal
Completed