Relat BM3000 User manual

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User Manual
BM3000 Battery Monitoring System

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Content
1. Product Overview..................................................................................................................................................................... 2
1.1. Functions........................................................................................................................................................................2
1.2. Range of Application......................................................................................................................................................2
2. BMS System Description........................................................................................................................................................... 3
2.1. General Specification.....................................................................................................................................................4
2.2. BMS Component List..................................................................................................................................................... 5
2.3. Control Module(BM00MC)............................................................................................................................................ 6
2.4. Battery Sensor(R-Sensor) BM3KRS................................................................................................................................9
2.5. Current Detector (I-Sensor) BM00IS............................................................................................................................10
3. Preparation for Installation.....................................................................................................................................................12
3.1. Preparation Work.........................................................................................................................................................12
3.2. Resource from Client................................................................................................................................................... 12
3.3. Required Tools & Accessories......................................................................................................................................12
3.4. Checking the Product Package.................................................................................................................................... 14
3.5. Quick Installation Guide...............................................................................................................................................14
4. Safety Information.................................................................................................................................................................. 15
5. Installation Guide....................................................................................................................................................................16
5.1. Personal Protective Equipment (PPE) requirements.............................................................................................. 16
5.2. Step 1: Determine battery numbers............................................................................................................................17
5.3. Step 2: Install the Kelvin washers................................................................................................................................ 18
5.4. Step 3: Connect the battery cables............................................................................................................................. 19
5.5. Step 4: Install battery sensor BM3KRS........................................................................................................................ 20
5.6. Step 5: Install Current Detector BM00IS..................................................................................................................... 22
5.7. Step 6: Connect R-bus communication cable..............................................................................................................23
5.8. Step 7: Install Control Module.....................................................................................................................................24
6. Configuration Tool...................................................................................................................................................................25
6.1. Reset IP.........................................................................................................................................................................25
6.2. Cable Connection.........................................................................................................................................................25
6.3. Configuration............................................................................................................................................................... 26
6.4. Alarm Setting List.........................................................................................................................................................28
7. Battery Management Software.............................................................................................................................................. 28
8. Integrated to the 3rd party software......................................................................................................................................29
8.1. RS485 Port....................................................................................................................................................................29
8.2. Ethernet Port............................................................................................................................................................... 30

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1. Product Overview
1.1. Functions
BM3000 Battery Monitoring System(BMS) is a multi-channel online-automatic battery test and monitoring
system, which is a newest generation of monitoring systems based on new research on battery
characteristics of battery industry and new technologies of industrial electronic monitoring equipment. And
compared to the conventional DC discharge performance test system for batteries, which have the
following features:
Process by AC test technology, further effectively reveals the battery performance characteristics and
aging trends;
Much smaller discharge current, no damage on battery;
No effect on battery pack assembling and operation environment;
Optical isolation technology and multiple level safety protection;
Real-Time monitoring individual block impedance, voltage, temperature and current
Automatic inspection, maintenance-free, high speed, reliable;
Internal resistance can be reported every day or even every hour as needed;
Diversified event management and alarm criteria for setting;
Detailed historical data record for maintenance analysis of the facts;
Ethernet network management is conducive to expansion and centralized monitoring;
Optional wireless alarms, use of cell phones and other mobile devices for maintenance;
Designed to allow IEEE1188 best practice
MODBUS TCP/IP Protocol for communication
The system have been properly tested and proved by CE certification.
Provide battery management software for measure, record and report, can display the analysis graphs.
1.2. Range of Application
BM3000 Battery Monitoring system can monitor the standard of 2V, 6V, 12V battery, battery capacity is up
to 3000Ah, battery total voltage can reach 48V,110V,220V, 400V and etc, it meets the requirements of most
users.
BM3000 Battery Monitoring System is using advanced testing technology, test internal resistance of battery
each day/week, can effectively reflect the performance of battery, comply with IEEE1188 Standard
recommendations, therefor especially suitable for high reliability requirements of UPS Users such as data
center, telecom base station, power plant, rapid transit railway, semiconductor,medicine, bank,
securities,insurance and etc.

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2. BMS System Description
BM3000 Monitoring system using modular level designed, which is easy for the installation and expansion.
BM3000 hardware composed with
→ Control Module,
→ Current Detector,
→ Battery Sensor,
→ Battery Management Software
System configuration as below:
Control Module is the brain of battery monitoring system, it management of battery sensor and current
detector and process all the collecting battery data.
Battery Sensor is measuring individual battery voltage, internal resistance, temperature and transmit these
data to control module via R-BUS port.
Current Detector is measuring battery string current and transmit the data to control module via R-BUS
port.
Battery Management Software

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Battery Management Software is installed at laptop or desktop, allows for remote viewing and data
management of all connected battery monitoring systems. Report generation, graph and trending curves,
detailed alarms can all be viewed on multiples of laptop or desktop on the same network.
2.1. General Specification
Table 1. BMS Specification List
Operating Specification
Power Supply Range
DC12V
Power Supply Rating
Max.3.6 Watts
Operating Temperature
-5℃to 50 ℃(23°F ~ 122°F)
Operating Humidity
5% ~ 90%
General Specification
Battery Type
VRLA,SLA,Vented and Nicad Battery
Nominal Battery Voltage
2V, 6V, 12V battery
Max. Connected Battery
254 blocks of battery
Max. Connected Strings
6 battery strings
Measurement Range
Individual Battery Voltage
1.5V to 5V or 5V to 16V
Individual Battery Resistance
0.01mΩ to 40mΩ & 0.1mΩ to 80mΩ
Individual Battery Temperature
-10°C to 70°C (14°F ~ 158°F)
String Voltage
0 to 1500V
Ambient Temperature
-10°C to 70°C (14°F ~ 158°F)
String Current
0 to 1000A
Measuring Accuracy
Individual Battery Voltage
± 0.2%
Individual Battery Resistance
2%
Individual Battery Temperature
±1°C
String Voltage
± 0.3%
String Current
± 1A
Ambient Temperature
±1°C

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2.2. BMS Component List
Please check the BMS Component List below,
Table 2.BMS Component List
No.
Product Picture
Product Name
Description
1
Control Module
BM00MC
Max connected with 254 block
batteries and 6 battery strings.
2
Battery Sensor
BM3KRS
One block battery require one
R-Sensor
3
Current Detector
BM00IS
One string batteries require one
I-Sensor
4
Current Transducer
100A – 1000A
One string batteries require one
current transducer
5
Battery Cable with
temperature probe
Accessory of R-Sensor
6
R-bus Communication Cable
Accessory of R-Sensor and
I-Sensor
7
Communication Cable of
Current Transducer
Accessory of Current Transducer
8
Power Cable for Control
Module
Accessory of BM00MC
9
Power Cable of I-Sensor
Accessory of I-Sensor

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10
Kelvin Washer
One block battery require 2 PCS
Kelvin Washer
11
RJ11 Connector
Fixed length of Telephone cable
with RJ11 connector.
2.3. Control Module(BM00MC)
Control Module (BM00MC) is the core component of battery monitoring, allowed to wall mounting.
Designed to receive transmitted signals from the Battery Sensor and Current Detector.
Continuously monitors, analyzes, and uploads battery measurements to BMS software
Provides RS-485 or Ethernet communication for remote monitoring.
Table 3. Control Module (BM00MC) Specifications
Model
BM00MC
Operating Temperature
-5℃to 50 ℃(23°F ~ 122°F)
Relative Humidity
5% ~ 90%
Operating Voltage
DC 12V±10%
Power Consumption
3.6 Watt
Communication Ports
Ethernet x 1
RS-485 x 2
Reserved Interface
USB x 1 (Loading firmware)
Monitoring Nodes/Battery
Maximum 254 nodes of batteries and
6 battery strings
Communication Protocol
Modbus
Dimensions (H x W x D)
90*152*27mm(3.54’’x5.98’’x1.06”)
Weight
420 g

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Dimensional Drawing as below,
Interface Description
① ② ③ ④ ⑤ ⑥
1LAN : Ethernet interface connect to computer or network switch, allow for web configuration or
connecting to SCADA software via Modbus TCP. (Baud rate is 9600)
2RESET: Long press 5 seconds to reset the device IP address to 192.168.1.100
3Loading: loading the firmware
4RS485: RS485 interface connect with monitoring software, uploading battery data. (Baud rate is
9600)
5DC12 V Input: DC12v Power Supply input
6Dual R-Bus Port : Connect with R-sensors and I-Sensors in a link loop communication

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LED Description
① ② ③ ④
⑤ ⑥
① RUN: If BM00MC control module is power on, the green light should be on.
②FAULT: Hardware detection indicator, if there’s any fault component, the red light should be on.
③ALARM: Alarm indicator, if there’s any alarms, the red light should be on.
④IR TEST: If the system is measuring the battery internal resistance, the blue light should be on. IR is short
for internal resistance.
⑤RS485: Communication indicator, the green blinking light should be on when there’s RS485
communication.The right LED is RXD means received data, left LED is TXD means transmit data.
⑥RBUS: When control module is communicated with R-Sensors and I-Sensors, the green light should be
on and blink. The right LED is RXD means received data, left LED is TXD means transmit data.

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2.4. Battery Sensor(R-Sensor) BM3KRS
Battery sensor(R-Sensor) BM3KRS can measure the battery cell voltage, temperature and internal
resistance, and transmit the measurement to the Control Module for analysis and storage.
Table 4. Battery Sensor BM3KRS Specifications
Model
BM3KRS-LV
BM3KRS-HV
Cell Voltage
2V/3.7V
6V/12V
Cell Voltage Measurement Range
1.5 - 5V
5 - 16V
Accuracy
±0.2% Full Scale
Internal Resistance Measurement Range
0.01 - 40mΩ
0.1 - 80mΩ
Internal Resistance Repeat Accuracy
±2%
Temperature Measurement Range
-10 - 70°C
Accuracy
± 1 °C
Operating Temperature
0 - 50°C
Humidity
≤ 95%
Power Consumption
< 0.4 W
Isolation Characteristic
Input /Output > 4kV
Communication Interface
RJ10
Communication Protocol
R-bus
Dimensions (H x W x D)
60x59x28mm
Weight
50g

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Description,
1Battery Cable Plug: Place in battery cable and connect to battery positive and negative pole
2RBUS Port: Place in RBUS cable and connect to neighbouring sensors for communication
3RBUS Port: Place in RBUS cable and connect to neighbouring sensors for communication
4Led indicator: Run is Green, Alarm is Red.
2.5. Current Detector (I-Sensor) BM00IS
The Current Detector(I-Sensor) BM00IS could be connected to a current transformer to measure the
battery string current, and transmit the data transmit the measurement to the Control Module for analysis
and storage.

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Table 5. Current Detector BM00IS Specifications
Model
IS-100/200/300/400/1000
Current Measurement Range*
0~100/200/300/400/1000A
Accuracy
±1% Full Scale
Operating Temperature
0-50°C
Humidity
≤ 95%
Power Supply
DC 24/48V
Power Consumption
< 1.6 W
Communication Interface
RJ10
Communication Protocol
R-bus
Dimensions (H x W x D)
60x59x28mm
Weight
56g
*The current measurement range depend on the current transformer.
Description,
1DC12V Power Supply: DC24 V power supply from controller or other current detector
2CT Port: Place in communication cable and connect to current transducer
3RBUS Port: Place in RBUS cable and connect to neighbouring sensors for communication
4RBUS Port: Place in RBUS cable and connect to neighbouring sensors for communication
5Led indicator: Run is Blinking Green

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3.Preparation for Installation
3.1. Preparation Work
Installation drawing and BMS layout should be completed before installation, all anticipating technician
should familiar with all the installation procedure, make sure all component mounting position and the
wiring methods. All the installation process should follow with the installation guide.
3.2. Resource from Client
Kindly check and confirm the following resource is ready,
a. AC 100V/110V/220V/230V input power supply
b. Assign the IP address for each set of control module
c. Confirm the panel box of control module mounting position
3.3. Required Tools & Accessories
All required tools & accessories should be ready before installation.
Kindly find the tool list below,
Item
Tool
Picture
Description
1
Ratchet wrench
Loose or tight the battery terminal bolts and nuts,
insulating treatment
2
Electric screwdriver
Loose or tight the battery terminal bolts and nuts,
insulating treatment
3
Adjustable wrench
Mounting the panel box, insulating treatment
4
Multimeter
Measure voltage, current, and resistance. After
MC annual verification.
5
Network cable tester
Verify the electrical connections in a RJ45/RJ11
network cable

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6
Internal resistance
tester
Measure battery internal resistance. After MC
annual verification.
7
Current clamp
Measure the current, and check the UPS status.
After MC annual verification.
8
Electrical outlets
Access AC power for installation jobs
9
Laptop
Testing and Commission
10
Diagonal pliers
Cutting wire
11
Needle-nose pliers
Used to bend, re-position and snip wire
12
Wire stripper
Used to strip the electrical insulation from electric
wires.
13
Crimping Tool
Makes crimping RJ45/RJ11 network cables
14
Slot Head/Cross Head
Screwdriver
Settle the control module,current transformer
15
AC Electric Voltage
Detector
Electrical testing

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Kindly find the accessory list below,
Item
Accessory
Description
1
RJ45/RJ11 Connector
Makes communication cable (Relat Supply)
2
2 pair/4 core telephone cable
Long communication cable between the control module and
sensors.(Relat Supply)
3
Nylon cable tie
Tie the cable
4
Cable trunking
Cable wiring
5
Label for battery
Identify the number to all the battery (Relat Supply)
6
Insulating tape
Used to insulate electrical wires/battery terminal
7
Clean Rag
Clean battery surface and the battery rack
3.4. Checking the Product Package
Step 1, Appearance Inspection
Open the package, please check and confirm all the inner & outer packages and the components are intact,
confirmed all packages are no damage, moisture and deformation.
Step 2, Quantity Inspection
Please check and confirm the quantity of the equipment, cables and accessories if in conformity with the
product list!
3.5. Quick Installation Guide
Step 1, Cut off all the battery breaker from the battery bank to the UPS
Step 2, Cut off and segment the batteries connected in serial
Step 3, Stick all the battery labels on visible place of each cell/block
Step 4, Mounted all kelvin washers in accordance with specification
Step 5, Mounted all battery cable and make sure all red wires are post in positive terminal and blacks post
in negative.
Step 6, Positioned all R-Sensors in accordance with specification
Step 7, Positioned all CT and I-Sensors in accordance with specification
Step 8, Mounted the communication cable from CT to I-Sensors and mounted their power cable in serial.
Step 9, Wall/Rack mounted all control module and the power supply in accordance with specification
Step 10, Mounted all fixed length communication cable to all R-Sensors and I-Sensors and connecting in
serial.
Step 11, Handed make and mounted the fittest long distance communication cable from sensors to the
control module
Step 12, Handed make and mounted the fittest long distance communication cable from different tier of
the battery rack.

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Step 13, Power on the Control module and inquiry and verify the reading of block voltage and temperature
if correct.
Step 14, Manual performance An Internal Resistance Test and verify the reading of block impedance if
correct.
Step 15, Revised the impedance high limit(the impedance reading plus 1.5 times )
Step 16, Save the Impedance Reference.
Step 17, Connected RJ45 cable from the control module to the Laptop computer and install the BMS
Software.
4.Safety Information
Batteries are potentially dangerous, and proper precautions must be observed in handling and
maintenance of batteries and monitoring systems. Maintenance shall be done only by personnel with
knowledge of batteries and the monitoring system and trained in the safety precautions involved. Properly
insulated tools and adequate personal protective equipment should be used when working with batteries.
The following precautions shall be observed when installing or servicing a battery:
a) Prohibit smoking and open flames in the immediate vicinity of the battery.
b) Avoid wearing metallic objects, such as jewelry.
c) Keep the top of the battery clear of tools and other foreign objects.
d) Provide unobstructed egress from the battery area.
e) Verify that the battery area and/or cabinet ventilation is operable.
f) Neutralize static buildup just before working on the battery by having personnel contact the nearest
effectively grounded surface.
It is recommended that a battery disconnection means be used to isolate a battery from the system. If a
battery disconnect is not provided, use extreme caution when removing the battery from the system. The
entire string voltage will appear across any two open points when the string is disconnected from the
system. Arcing will occur when the circuit is opened or closed if the charger/rectifier is not capable of
supporting the existing loads. This also will occur if the battery voltage and the system voltage are not
properly matched prior to the opening or closing action. For example, if the terminals are opened at the
individual cell level while the string is connected to a load, lethal voltages may be present across the open
circuit that is created by removing one side of the connection. Specialized training is required to perform
work on live battery systems
Electrical Hazard: Risk of electric shock: battery cabinets contain potentially lethal voltages!
A short-circuit can result in injury or death. Do not work alone.
Caution: Only qualified personnel, trained in battery operation and safety, may install the
harnesses. Keep unauthorized personnel away from the batteries.
--`,,```,,,,````-`-`,,`,,`,`,,`---

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5. Installation Guide
5.1. Personal Protective Equipment (PPE) requirements
The following personal protective equipment shall be available to personnel who perform battery
maintenance work: goggles and face shields, acid-resistant gloves, protective aprons, portable or stationary
water facilities for rinsing eyes and skin in case of contact with electrolyte, class C fire extinguisher, acid or
alkaline neutralizer, and adequately insulated tools. Personnel shall wear protective equipment suitable for
the voltage of the battery when installing or servicing a battery.

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5.2. Step 1: Determine battery numbers
Designate a battery number for each battery in the system. Before connecting the Battery Sensor BM3KRS
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 negative 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 positive terminal. The batteries should be numbered in
accordance with this method.
Battery Bank
UPS/Charger

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5.3. Step 2: Install the Kelvin washers
Electrical Hazard: A short-circuit can result in injury or death. Do not work alone.
Perform a battery disconnection from the UPS system. Use Multimeter measures and confirms there’s no
voltage difference between battery and battery rack.
1) Remove the bolt from a battery;
2) Place the Kelvin Washer above the existing battery connection, behind the hex-head of the bolt.
3) Replace the bolt in the battery, and adjust its torque according to the specifications of the battery
manufacturer.

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5.4. Step 3: Connect the battery cables
1) Use an insulated pair of pliers (Important: Do not use your bare hands!) to slide the receptor end
of each cable over the tab portion on the washers that you installed on the positive and negative
terminals of each battery.
2) Remove the backing from the adhesive patches on the temperature sensor then position and
mount it onto the top or side of the battery block (Important: Make sure the surface is clean!).