PowerShield 8 User manual

PowerShield 8
Installation Manual

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Table of Contents
1 Glossary 4
2 Introduction 5
3 Installation Quick Guide 6
4 The PowerShield 8 Battery Monitoring System 8
4 2 Controller 10
4 2 1 Power Supply 10
4 2 2 Front and Rear Panels 10
4 2 3 Hub Ports and BBus Communication 11
4 2 4 Installation 11
4 3 Hub 12
4 4 mSensor 13
5 Installation 14
5 1 Install Controller and Power-up 14
5 2 Number Blocks 14
5 3 Block Terminal Tags 15
5 4 Mounting Rail for Hubs and mSensors 15
5 5 mSensor Power Leads 16
5 6 Connect mSensors to Blocks 17
5 7 Install Hub 17
5 8 Connect BBus Cables 18
5 9 Install Current Transducer 19
5 10 Connect Ambient Temperature Probe(s) 20
5 11 Confirmation and Configuration 20
Appendix 1 – Controller Panels 21
Front Panel 21
Rear Panel 21
Appendix 2 – LED Behaviour 23
PowerShield Controller LEDs 23
mSensor and Hub LEDs 24
Appendix 3 – Controller LCD 25
Appendix 4 – Communication Options 26
RS-485 26
Cabling & Termination 26
Appendix 5 – Relays and Auxiliary Inputs 27
Relays 27
Auxiliary Inputs 27
Appendix 6 – mSensor Power Lead Connection 28
Dual mSensor and Blocks with 2 Terminals 28
Single mSensor and Block with 2 Terminals 29
Dual mSensor and Blocks with 4 Terminals 30
Single mSensor and Block with 4 Terminals 31
mSensor Power Leads with Block Temperature 32
mSensor Power Leads without Block Temperature 32
Appendix 7 – 4-Wire / Kelvin Connection 33
Resistance 33

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2-Wire Resistance Measurement 33
4-Wire/Kelvin Resistance Measurement 34
Appendix 8 – DC Model Controller Wiring 35
DC Model Plug 35
Appendix 9 – Controller Specifications 37
Appendix 10 – Hub Specifications 38
Appendix 11 – mSensor Specifications 39
Appendix 12 - PowerShield 8 Installation Forms 40
6300-107 Facility Information Form (FIF) 40
6300-108 PowerShield 8 Controller Information Form (CIF) 41
6300-109 PowerShield 8 String Information Form (SIF) 42
6300-110 PowerShield 8 Block Mapping Form (BMF) 43

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1 Glossary
Cell
The basic electrochemical unit that can receive, store, and deliver electrical
energy
Block
One or more cells in a container also known as a battery
The terms block and jar are interchangeable
For this manual the term has been standardised as block to avoid using the
somewhat unwieldy convention of "block/jar" throughout
String
Two or more blocks connected in series
Battery Bank
A complete system of parallel connected strings
PowerShield Controller
Data logger that periodically communicates with PowerShield Hubs and
PowerShield mSensors to obtain system measurements
PowerShield mSensor
A remote sensor that is connected to the blocks
It periodically measures the block voltage, ohmic value and temperature
PowerShield Hub
A remote sensor that can be used to measure string current and ambient
temperature of the battery bank
mSensors can be connected to it so that they share the same
communication cable from the PowerShield Controller
BBus
A daisy chain communication bus used between the PowerShield Controller
and PowerShield Hubs or PowerShield mSensors

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2 Introduction
This manual is intended for use with the PowerShield 8 battery monitoring system that uses the PowerShield Controller
data logger, PowerShield mSensor battery sensors and the PowerShield Hub This manual describes the installation of
the system hardware
bout this manual
PowerShield 8 Installation Manual
Part Number 6300-095D
14 Nov 2018
The information contained in this manual is copyright and is not to be reproduced without the written authority of
PowerShield Ltd
PowerShield Limited
PO Box 102-190
NSMC
North Shore City 0745
New Zealand
PowerShield is committed to being responsible to take care of our environment. PowerShield products and packaging
contain materials that are highly recoverable and recyclable. Please consider recycling through proper channels at your
local packaging recycler and e-waste recycler.

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3 Installation Quick Guide

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4 The PowerShield 8 Battery Monitoring System
The PowerShield 8 battery monitoring system is a permanent battery monitoring system that can monitor one or more
strings of blocks Parameters measured include:
• DC & AC voltage of each block
• Ohmic value of each block
• Temperature of each block
• DC string voltage
• DC & AC string current
• Ambient temperature
• Ambient humidity
The diagram on the following page shows an overview of the system which consists of the following hardware:
• PowerShield Controller
• PowerShield Hubs
• PowerShield mSensors
• Current Transducers
• Ambient Temperature sensors
• Hub-to-BBus adaptors (where applicable)
The PowerShield Hub is used to connect external sensors for measuring string current and ambient temperature and has
an on board ambient humidity sensor The PowerShield mSensor is used to monitor each block The PowerShield
Controller periodically interrogates each Hub and mSensor and processes the data, logging the information into memory
at predefined intervals
The distributed system architecture using local Hubs and mSensors installed at the battery bank, connected to the
PowerShield Controller using a single CAT5 cable, allows one PowerShield Controller to monitor multiple remote strings
A single system can also monitor different voltage blocks and strings using appropriate mSensors
PowerShield provides ink software for automated multi-site battery management

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4.2 Controller
The PowerShield Controller is supplied in a 1U high 19" rack case The PowerShield Controller can be mounted in a
19" rack, on a wall, shelf, or similar using the mounting brackets provided Ensure there is safe access to the rear
connector panel and cable tray
4.2.1 Power Supply
The PowerShield Controller is available in AC input or DC input models
The AC input model has a standard 3-pin male IEC 60320 C14 appliance inlet
The D C input models have a male 3-pin input socket and are supplied with a mating female screw terminal plug
• Both AC and DC models must be installed by a service person and connected to a socket outlet or fixed
wiring with a protective earth conductor or connector
• A readily available disconnect device shall be incorporated in the building wiring or the socket outlet near
the PowerShield Controller that is readily accessible
• The power source for the DC models must be fused with a circuit breaker of no greater than 20A rating
The connection must be installed in a service access area
• To ensure that the system operates during a power failure, it is recommended that the PowerShield
Controller is powered by a battery backed supply that has sufficient backup time
4.2.2 Front and Rear Panels
The front and rear panels of the PowerShield Controller are shown below
Refer to Appendix 1 for a description of the front and rear panel features Refer to Appendix 2 for a description of the
front panel LED behaviour
PowerShield Controller Front Panel
PowerShield Controller Rear Panel

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4.2.3 Hub Ports and BBus Communication
The PowerShield Controller communicates with the PowerShield Hubs and PowerShield mSensors via the hub ports on
the rear panel of the Controller The hub ports use the BBus daisy chain communication bus with the devices being
connected in series, one after another
The hub port connectors are 8-pin RJ45 connectors Standard CAT5 cabling is used to connect the PowerShield Hubs
to the PowerShield Controller via the RJ45 connectors on each device The PowerShield Hub should be the first device
on each bus The cable distance between the PowerShield Controller hub port and PowerShield Hub should not extend
more than 50m (165ft) Contact PowerShield if longer distances are required
The PowerShield mSensors should be connected to the PowerShield Hub using 4-core BBus interconnect cable via the
4-pin Modular Jack connectors on each device The total cable length between the PowerShield Hub and last
PowerShield mSensor, including the short interconnecting BBus cables between each device, should not extend more
than 25m (82ft) Contact PowerShield if longer distances are required
Each PowerShield Controller hub port is capable of supporting 1 Hub and up to 32 mSensors For strings with a large
number of blocks, additional mSensors will need to be used These can be connected to spare Controller hub ports
using an adaptor available from PowerShield that converts the Controller hub port CAT5 cable to 4-core BBus
interconnect cable
4.2.4 Installation
The PowerShield 8 battery monitoring system must be correctly installed and configured in order to obtain accurate
results The installation of the system must be carried out only by suitably trained personnel Installation must be in an
adequately ventilated environment or the warranty may be invalidated
The PowerShield 8 battery monitoring system operates in a potentially hazardous environment making it imperative that
all installation personnel have adequate training and experience The system must be installed in a Service Access
area
Pay particular attention to the following points:
A) Elevated Operating Ambient Temperature – If installed in a closed or multi-unit rack assembly, the operating
ambient temperature of the rack environment may be greater than room ambient Therefore, consideration
should be given to installing the equipment in an environment compatible with the maximum temperature
specified in Appendix 9 – PowerShield Controller Specifications
B) Reduced Air Flow – Installation of the equipment in a rack should be such that the amount of air flow
required for safe operation of the equipment is not compromised
C) Mechanical Loading – Mounting of the equipment in the rack should be such that a hazardous condition is
not achieved due to uneven mechanical loading
D) Circuit Overloading – Consideration should be given to the connection of the equipment to the supply circuit
and the effect that overloading of the circuits might have on over-current protection and supply wiring
Appropriate consideration of equipment nameplate ratings should be used when addressing this concern
E) Reliable Earthing – Reliable earthing of rack-mounted equipment should be maintained Particular attention
should be given to supply connections other than direct connections to the branch circuit (e g use of power
strips)

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4.3 Hub
The PowerShield Hub is used to connect external sensors for measuring string current and ambient temperature and has
an on board ambient humidity sensor Each Hub can read from one Current Transducer and up to two Ambient
Temperature probes It also has two Dry Contact inputs that can be used to read the state of external devices
The PowerShield Controller communicates with the Hubs via the Controller hub ports, connected using CAT5 cable It
also supplies 24VDC power to the Hubs over this cable Up to eight Hubs can be connected to a single PowerShield
Controller, 1 per Controller hub port This allows up to eight strings to be monitored with one PowerShield Controller
The Hub is also the BBus link between the PowerShield Controller and mSensors The mSensors are connected to the
Hub using 4-core BBus interconnect cable
Each Hub has a factory set ID number in the range 221 to 230 Hub ID 221 should be used for the first string and
subsequent sequentially numbered Hubs are used for multiple string systems (where applicable)
The LED on the Hub indicates Hub state Refer to Appendix 2 for Hub LED behaviour

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4.4 mSensor
The PowerShield mSensor connects to the blocks and periodically measures the block voltage, temperature and ohmic
value Each mSensor is specific to the block voltage to which it will be fitted, e g 2V / 6V / 12V
Dual and single mSensors are available A dual mSensor is used to monitor a pair of blocks located one after another in
series A single mSensor is used to monitor only one block The single mSensor allows for installations containing
strings with uneven numbers of blocks or where physical layout makes pairing of blocks impossible The label on the
mSensor will show whether it is single or dual
Each mSensor has a factory set ID number Dual mSensors are numbered with IDs in the range 1 to 200 while single
mSensors are numbered 201 to 220 For ease of mapping of mSensors to blocks and subsequent system configuration,
it is recommended to connect the mSensors to the blocks in sequential order of ID starting at ID 1 Each block in a string
must be uniquely identified with a sequential number starting at 1 For correct automatic mapping of mSensors to blocks,
the block numbering should start at the most positive block in the string If single mSensors are used in a string, they
should also be installed in sequential order of ID starting at ID 201
The PowerShield Controller communicates with the mSensors via the Controller hub ports using the BBus daisy chain
communication bus The mSensors should be connected to the PowerShield Hub using 4-core BBus interconnect cable
via the 4-pin Modular Jack connectors on each device If a Hub is not used, it is possible to connect the mSensors to the
PowerShield Controller using a Hub-to-BBus adaptor that converts the Controller hub port CAT5 cable to 4-core BBus
interconnect cable
The LED on the mSensor indicates sensor state Refer to Appendix 2 for mSensor LED behaviour

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5 Installation
Complete the forms in Appendix 12 during the installation
5.1 Install Controller and Power-up
The PowerShield Controller is supplied in a 1U high 19" rack case Mount the PowerShield Controller securely into a 19"
rack (not supplied), wall, shelf, or similar using the mounting brackets provided Ensure there is safe access to the rear
connector panel and cable tray
When the PowerShield Controller is powered up, it will emit an audible alert and the green Power LED will light Other
LEDs on the front panel may also light
NOTE: Ensure the PowerShield Controller is unable to move when installed – cables and connections must not be
put under strain
5.2 Number Blocks
Each block in string must be uniquely identified with a sequential number starting at 1, e g 1-32, 1-40 etc For ease of
mapping of mSensors to blocks and subsequent system configuration, it is recommended to start numbering at the most
positive block in the string

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5.3 Block Terminal Tags
Ensure that all blocks have appropriate terminal tags fitted for connection to the mSensors as follows For simplicity, it
may be easier and more efficient to fit two tags to every terminal
• Where a dual mSensor is to be used with a pair of blocks, fit two tags on the negative (-) terminal of the
most negative block and two tags on the positive (+) terminal of the most positive block
Fit one tag on each of the remaining terminals
• Where a single mSensor is to be used on a single block, fit two tags on all block terminals
NOTES: The terminal tags must be suitable for 6 3mm x 0 8mm receptacles The tag material is important for
accurate measurements PowerShield can supply a range of approved tags
Place the tags on the top of the block interlinks and below any lock washers otherwise the current flow
between the interlink and the battery may be reduced and could result in a 'hot spot'
Do not bend the tags as this can damage the connector crimp and/or result in poor or loose connections with
the mSensor power leads Poor connections can have significant impact on impedance measurement
PowerShield reserves the right to void warranties where terminal tags are bent or modified
5.4 Mounting Rail for Hubs and mSensors
The mounting rail for the Hubs and mSensors can be fitted in any orientation and can be used with both battery racks
and cabinets Drill to suit and fasten with screws or cable ties

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5.5 mSensor Power Leads
Fit the mSensor power leads to the block terminal tags with the correct polarity Ensure the dual power leads are
connected across an ‘in series’ pair of batteries Power leads are available with or without Block Temperature sensors
Refer to Appendix 6 for the recommended method of connecting the mSensor power leads
mSensor Power Leads with Block Temperature
Dual mSensor Single mSensor
mSensor Power Leads without Block Temperature
Dual mSensor Single mSensor

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5.6 Connect mSensors to Blocks
Dual mSensors are numbered with IDs in the range 1 to 200 while single mSensors are numbered 201 to 220 For ease
of mapping of mSensors to blocks and subsequent system configuration, it is recommended to connect the mSensors to
the blocks in sequential order of ID If single mSensors are being used for a string, install these as required but follow
the sequential ID order approach
Plug the mSensors onto the power leads of the blocks The mSensor LED should light solid green when the mSensor is
connected correctly If the LED lights red, check the connections of the power lead at each block A full list of mSensor
LED states is available in Appendix 2
Insert the mSensor into the mounting rail when done
5.7 Install Hub
A PowerShield Hub is required per string to measure string current and ambient temperature Hubs are numbered with
IDs in the range 221 to 230 Use Hub ID 221 for the first string and subsequent sequentially numbered Hubs for
multiple string systems (where applicable)
Insert the Hubs into the same mounting rail as the mSensors and connect CAT5 cable from the PowerShield Controller
hub ports to each Hub The Hub LED should flash orange if all is correct A full list of Hub LED states is available in
Appendix 2

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5.8 Connect BBus Cables
Connect the mSensors and Hub using suitable lengths of BBus interconnecting cables in a daisy chain fashion Note
that each PowerShield Controller hub port must not have more than 33 devices connected to it (1 Hub and up to 32
mSensors) In addition, the IDs of all devices on a single hub port must be different The same IDs can be used on
other hub ports
For strings with a high number of blocks and mSensors, mSensors can be connected directly to additional PowerShield
Controller hub ports using a CAT5-to-BBus adaptor which is available from PowerShield
The mSensor LEDs should flash orange if all is correct A full list of mSensor LED states is available in Appendix 2

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5.9 Install Current Transducer
A current transducer (CT) is required per string to measure string current Install the current transducer anywhere on
the primary string conductor and plug the current transducer cable into the Current connector of the PowerShield Hub.
NOTE: Ensure the current transducer selected has the appropriate rating for the expected string charge and
discharge currents The nominal rating of the current transducer should be similar to the typical maximum
expected current flow The current transducer has a measurement range of ±150% of the nominal rating
IMPORT NT: The direction of the current transducer is important The transducer has an arrow on it to show the
direction of current flow
• If the current transducer is installed with its arrow pointing in the direction that current flows during a
discharge event, the current transducer direction is considered to be Standard
• If the current transducer is installed with its arrow pointing in the direction that current flows during a charge
event, the current transducer direction is considered to be Reversed

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5.10 Connect mbient Temperature Probe(s)
Up to two ambient temperature sensors can be used with each Hub to measure local ambient temperature(s)
Secure the ambient temperature sensor(s) in appropriate locations in or around the battery rack or cabinet but be aware
of other factors that may affect the local environment such as HVAC, fans or other devices
5.11 Confirmation and Configuration
Check that all installed parts are performing as expected and secure all cables with appropriate strain relief
Complete the forms as in Appendix 12, connect to the Service Port Ethernet connector on the front of the PowerShield
Controller and configure the system
Refer to the PowerShield Controller User Manual (part number 6300-103) for more details on configuring the system
NOTE: All Hub and mSensor LEDs should flash green if the system is installed and configured correctly