Pilot Communications PBAT600 User manual

PBAT600 String Sensor
Installation & Operation Manual
V1.0
ZHUHAI PILOT (HENGQIN) CO., LTD.
珠海横琴派诺技术有限公司

Danger and warning!
This device can be installed only by professionals.
The manufacturer shall not be held responsible for any accident caused by the failure to
comply with the instructions in this manual.
Risks of electric shocks, burning, or explosion
This device can be installed and maintained only by qualified people.
Before operating the device, isolate the voltage input and power supply and
short-circuit the secondary windings of all current transformers.
Use appropriate voltage tester to make sure the voltage has been cut-off.
Put all mechanical parts, doors, or covers in their original positions before energizing
the device.
Always supply the device with the correct working voltage during its operation.
Failure to take these preventive measures could cause damage to equipment or
injuries to people.

Contents
Chapter 1 Product Overview.................................................................................................................1
Chapter 2 Installation and Wiring.........................................................................................................3
2.1 Environment...............................................................................................................................3
2.2 Order Information......................................................................................................................6
2.3 Power Supply ............................................................................................................................6
Chapter 3 Measuring Parameters........................................................................................................7
3.1 Voltage........................................................................................................................................7
3.2 Current........................................................................................................................................7
3.3 Cell Data Acquisition................................................................................................................7
3.4 Voltage Balancing.....................................................................................................................7
3.5 Internal Resistance test...........................................................................................................8
3.6 SOC Remaining Capacity.......................................................................................................8
3.7 SOH health status ..................................................................................................................9
3.8 RS485 interface........................................................................................................................9
Chapter 4 Description of Indicated LED.......................................................................................... 10
Chapter 5 Maintenance and fault remove....................................................................................... 11
Chapter 6 Technical Specifications................................................................................................... 12

1
Chapter 1 Product Overview
PBAT600 battery string sensor is specially designed as highly integrated smart sensor
module for VRLA batteries, can quickly and accurately measure the VRLA’s voltage,
charge and discharge current and other parameters. String sensor uses specified
isolated communication bus, equipped with PBAT61 battery cell sensor, to realize the
real-time monitoring of the entire string of batteries. Real-time control of the actual
operation of the battery string and health status, then promptly found problems during
use battery. Real-time know the actual operation of the battery pack and health status,
and discover the battery string existing problems during using, and realize automatic
maintenance functions. It helps the battery string to keep voltage balance under float
status, so that each unit of the battery to maintain the best active status, improve the
battery life, timely find out the problem battery and maintenance, reduces labor cost
and other maintenance costs, improve the safety of battery use to reduce the accident
rate.
The PBAT600 string sensor can fulfill following functions:
Real-time monitoring of the entire string of battery voltage, charge and
discharge current, Battery string of SOC, SOH.
PBAT600 and PBAT61 series with the use of a dedicated isolation bus
real-time monitoring of each battery voltage, internal resistance,
temperature, SOC, SOH.
Auto-sensing for S/N, without excessive manual intervention and
configuration, reducing engineering effort.
About the PBAT61 program upgrade, you can use the local 600 to upgrade.
Advanced measurement algorithm, no need for high current discharge, to

2
achieve non-destructive measurement.
Balancing function, the battery pack keep voltage balance under floating
status, this allows each battery to maintain the best active state, improve
the battery backup time and operating life.
With PBAT61 collector, it collects the collected data into the register for
use by the background device.
Using RS485 communication with isolated power, safely and stably
By the circular alarm LED with breathing light, users can quickly locate the
fault batteries in the machine room
With the external linked Hall sensor, PBAT61 could measure different
ranges of charge and discharge current
The isolation voltage of communication interface is AC 3750V

3
Chapter 2 Installation and Wiring
2.1 Environment
2.1.1 Environmental requirements
◇Standard operating temperature：0℃～+45℃
◇Operating temperature limit：-10℃~ +55℃
◇Storage temperature：-40℃～+70℃
◇Working humidity：5% ～95%RH，Non-condensing
2.1.2 Installation and Dimensions
Unit：mm
85.0
104.5
38.5
PBAT600
1
+24 2 -24
3
霍尔接口
4
-5
+
(0~600V) 6 7
-+8 9
COM1 COM2
Unit：mm

4
35.0
2.1.3 Structure and Terminals
+
(0~600V)
67
+89
COM1 COM2
4
-5-

5
The main terminal definitions：
No.
Symbol
Definition
1
+24V
Positive power supply
2
-24V
Negative power supply
3
Hall Terminal
Interface for the string current sensor
4
-
Negative terminal for the string voltage measurement
5
+
Positive terminal for the string voltage measurement
6
485+
RS+485 communication port
7
485-
RS-485 communication port
8
COM1
DL-BUS communication，RJ11 interface
9
COM2
DL-BUS communication，RJ11 interface
Note:
a.The String voltage measurement negative terminal (-) and positive terminal (+)
can not be exchanged.
b. The RS485 negative terminal (-) and positive terminal (+) can not be
exchanged.

6
2.2 Order Information
Model：PBAT600
PBAT600
For battery string
real-time string voltage measurement
Charge and discharge current
measurement
DL-BUS communication
Collector information centralized
processing
2.3 Power Supply
PBAT600 is supplied by 24VDC with the range from DC 18V to DC 36V，and its
power loss is less than 1W.

7
Chapter 3 Measuring Parameters
3.1 Voltage
PBAT600 could measure the real-time voltage of VRLA battery string, with the range
from DC 0V to DC 800V
3.2 Current
PBAT600 could measure the real-time charge and discharge current of VRLA battery
string with the range from -1000 to +1000A.
3.3 Cell Data Acquisition
The PBAT600 communicates with the Cell using the DL-BUS bus, through COM1 and
COM2 two RJ11 port for collection, each COM port can be connected to the maximum
of 60 cell sensors. The collected data is stored in the internal registers.
Supports one-one cell sensor and one-two cell sensor. Specific configuration
reference “PBAT600 Software Application Manual”
3.4 Voltage Balancing
PBAT600 provides voltage balancing, let the battery string keep voltage balancing
under floating status, So that each cell of the battery to maintain the best active status,
improve the battery backup time and operating life. This function needs to meet
certain conditions to proceed.
1. The battery string status is floating.
2. Balancing function on (default is off).
3. The deviation of the group voltage is higher than the setting balancing deviation.
（Balancing deviation can be configured）
4、Meet time interval of the two balancing（default is 2 minutes）

8
When the battery string status is floating, if the balancing function is on, when the
balancing period is reached, PBAT600 will calculate the deviation of all battery
voltages in the string. If the deviation of the voltage is higher than the setting value,
then PBAT600 will send a balanced command to the battery cell sensor. After Cell
sensor receive balancing orders, its LED light will flashes three times in a row for
balancing discharge. The balancing current is 0.2A and the balancing process is
about 1 minute.
Note: Please refer to the "PBAT600 Software Application Manual" for the balanced
configuration.
3.5 Internal Resistance test
The battery is in floating state, PBAT600 regularly send a test command to the cell
sensor for internal resistance test.（Internal resistance only measure under floating
status）
At the same time PBAT600 debugging software also provides internal resistance test
command
Note: for manual test the internal resistance, please refer to " PBAT600 Software
Application Manual " .
3.6 SOC Remaining Capacity
PBAT600 support calculate cell and string SOC (remaining battery capacity)
estimates. SOC is an important basis for the battery characteristics of the parameters,
including battery voltage level, recovery voltage, cut-off voltage. Battery SOC
calculated using the default battery characteristic parameters:
Battery voltage level
2V
12V
Float range
-3A to +3A
-3A to +3A

9
Cut-off voltage
1.75V
10.8V
Recovery voltage
2.12V
12.68V
The characteristic parameters of the battery can be configured via the PBAT600
commissioning software.
The default value（Recovery voltage）is the optimal value from a large number of
experiments, if no special circumstances do not change.
Note：Note setting for voltage rank, float range, cut-off voltage, recovery voltage,
please refer to "PBAT600 software application manual”
3.7 SOH health status
PBAT600 support cell and string of SOH (remaining battery capacity) estimates. SOH
estimation is based on the internal resistance of the battery, the user needs to set the
internal resistance reference value of the battery according to the actual information of
the battery.
Note: Note: setting for battery internal resistance, please refer to "PBAT600 Software
Application Manual" .
3.8 RS485 interface
PBAT600 provides one RS485 interface, support the international common
MODBUS-RTU protocol. Please refer to the corresponding "PBAT600 MODBUS
communication protocol" for the specific agreement.

10
Chapter 4 Description of Indicated LED
Indicated LED
Status
LED
Running LED L1（Green）
Normal working
Breathing
mode
String Voltage/Current surpass high limit or low limit
String SOC surpass low limit
OFF
Alarm LED L2（Red）
Normal working
OFF
String Voltage/Current surpass high limit or low limit
String SOC surpass low limit
Hall connection abnormal
on

11
Chapter 5 Maintenance and fault remove
Problems
Causes
Solutions
Running LED is off after
power on.
Power can not input to
the device
Check whether the proper power is
supplied on the sensor.
Master device can’t
communicate with the
sensor.
Unit ID of the sensor is
wrong
Check whether unit ID of the sensor is the
same as the master.
Baud rate is not match.
Check whether the baud rate of both sides
is same.
Communication line is
disturbed.
Check whether the shielding layer of
RS485 is grounded.
Communication is
interrupted.
Check whether the communication cable
is disconnected.
Unable to see the
collection of data
Communication line
interruption
Check the communication wire PBAT600
is disconnected with the Cell sensor
Point table configuration
error
Re-configure the PBAT600 point table
Parameter
configuration
Protocol: Extended protocol and standard
protocol
Cell sensor type：one-one or one-two
setting
Whether the COM unit number is correctly
SOC
Battery characteristic
parameter is incorrect
Voltage level, cut-off voltage, recovery
voltage, float current is set incorrectly
SOH
Battery characteristic
parameter is incorrect
Battery internal resistance reference value
is wrong

12
Chapter 6 Technical Specifications
Dimension
Main-body：104.5mm（L）×85mm（W）×38.5mm（H）
Power
Supply
Rated voltage is DC 24V with the normal range from DC18V to DC36V power
loss：<=1W
Item
Range
Accuracy
Note
Voltage
DC 20~800V
±0.5%
Resolution：0.01V
Current
DC-1000A~1000A
±2%（15℃~35℃）
Resolution：0.01A
Item
Test Conditions
Insulation
Insulation voltage: DC1000V, Insulation resistance > 10MΩ
Dielectric strength
Test voltage AC 2kV，Test time 1minute，leakage current < 5mA
Impulse with stand
voltage
Test voltage 5kV, 1.2/50us, ±3 times each

13
Item
Reference Standard
Class
Electrostatic discharge
immunity
GB/T17626.2-2006
(IEC61000-4-2:2001)
IV
RFEMS
GB/T17626.3-2006
(IEC61000-4-3:1998)
IV
Electrical fast transient
burst immunity
GB/T17626.4-2008
(IEC61000-4-4:1998)
III
Surge Immunity
GB/T17626.5-2008
(IEC61000-4-5:2005)
III
RF conducted immunity
GB/T17626.6-2008
(IEC61000-4-6:1998)
III
Power frequency magnetic
field immunity
GB/T17626.8-2008
(IEC61000-4-6:2001)
IV
Electromagnetic emission
limits
GB/T14598.16-2002
(IEC60255-25:2000)
OK

14
Notice:
PILOT reserves the right to modify this manual without prior notice in view of
continued improvement.
Email: [e-mail]
Tech Support Email: [e-mail]
PILOT (HENGQIN) CO., LTD
Add: No. 15, Keji 6 Road, Chuangxin Haian, Tangjia High-tech Zone, Zhuhai, Guangdong,
519085 China
Tel: [phone]
Fax: [phone]
http://en.pmac.com.cn
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