Webasto BMID I User manual

BMID I Installation Manual
Battery Management Tool
BMID I
Rev Feb 2023
These commodities, technology, or software were exported from the United States in accordance
with the Export Administration Regulations. Diversion contrary to US law prohibited.

BMID I Installation Manual
IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS
5912853 A01 2 of 12 Webasto Charging Systems, Inc.
PLEASE NOTE:
Webasto Charging Systems, Inc., the Webasto logo, PosiCharge™, and the PosiCharge logo are
trademarks of Webasto Charging Systems, Inc.
WEBASTO PROPRIETARY INFORMATION: This manual contains information that is confidential
and proprietary to Webasto Charging Systems, Inc. (“Webasto”), constitutes “Confidential
Information,” and is subject to Non-Disclosure Agreements. The intended users of this manual are
service technicians certified by Webasto's installation network. This manual shall not be disclosed
in whole or in part to any other party without Webasto’s prior written permission. Each recipient's
acceptance of this manual and use of the information contained herein shall be deemed to be an
acceptance of this non-disclosure obligation.
This BMID Installation Manual includes the latest information available at the time of printing.
Webasto Charging Systems, Inc. reserves the right to make changes to this product without further
notice. Changes or modifications to this product by other than an authorized service provider could
void the product warranty.
© 2019 Webasto Charging Systems, Inc. All rights reserved. No portion of these materials may
be duplicated, used or disclosed without prior written permission from Webasto Charging
Systems, Inc.
FCC Information
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two
conditions:
1. This device may not cause harmful interference.
2. This device must accept any interference received, including interference that may cause
undesired operation.
This product has been designed to protect against Radio Frequency Interference (RFI). However,
there are some instances where high powered radio signals or nearby RF producing equipment
(i.e. digital phones, RF communications equipment, etc.) could affect operation.
If interference to your charge station is suspected, Webasto recommends the following steps be
taken prior to contacting customer support for assistance.
1. Relocate nearby electrical appliances or equipment during charging.
2. Turn off nearby electrical appliances of equipment during charging.
WARNING
Changes or modifications to this product by other than an
authorized service provider could void FCC compliance.
Save These Instructions
This document is your guide to installation and use of the PosiCharge BMID products.
The installation examples shown are for batteries in material handling and tug/tow vehicles.

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CONTENTS
1 BMID INSTALLATION...................................................................................................... 4
2 INSTALLATION PROCEDURE ........................................................................................ 5
2.1 Flooded Batteries ............................................................................................................. 5
2.2 Sealed Batteries ............................................................................................................... 5
2.3 Welded Battery Terminal Posts ........................................................................................ 6
2.4 Bolted Battery Terminal Posts .......................................................................................... 6
3 BMID INITIALIZATION ..................................................................................................... 9
3.1 BMID Initialization Procedure ........................................................................................... 9
4 COMMUNICATION WIRING.......................................................................................... 11
4.1 Single Anderson Euro Connector Communication Wiring, Battery Side........................ 11
4.2 Single Schaltbau Euro Connector Communication Wiring, Battery Side ........................ 11
4.3 Dual SBX Connector Communicating Wiring, Charger and Battery Side ....................... 12
4.4 Dual Anderson Euro Connector Communication Wiring, Battery Side …………………..12

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1 BMID Installation
This manual describes the installation of the Battery Monitor and ID module (BMID) on
a battery compatible with a Webasto PosiCharge charger. The BMID is located on the
forklift battery pack to monitor the condition of the pack and to communicate the type of
battery to the charger.
CAUTION An improperly installed BMID may cause the charger to
charge incorrectly, and may void your battery warranty.
DANGER Electric shock hazard. Only trained personnel should
install or maintain this equipment.
BMID Installation Kits
Part
Number Description
26131 KIT, UNIVERSAL INSTALL, BATTERY MONITOR, BASIC
26132 KIT, UNIVERSAL INSTALL, BATTERY MONITOR, ANDERSON
26133 KIT, UNIVERSAL INSTALL, BATTERY MONITOR, SCHALTBAU
26134 KIT, UNIVERSAL INSTALL, BATTERY MONITOR, SEALED BATTERY
26135 KIT, UNIVERSAL INSTALL, BATTERY MONITOR, DUAL SBX
26136 KIT, UNIVERSAL INSTALL, BATTERY MONITOR, GSE BURTON
26509 KIT, UNIVERSAL INSTALL, BATTERY MONITOR, ANDERSON COMM &
TEMP SENSOR
Please contact an authorized PosiCharge sales representative for kit details.
CAUTION
BMIDs are installed on electrically live battery packs.
Use insulated tools and DO NOT touch bare terminals of
the batter
y
with
y
our hands.
DANGER
Hydrogen gas may be present in battery compartments.
Be sure to work on equipment only in a well ventilated
environment.

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2 Installation Procedure
First select one of the center cells in the pack as an installation location (typically the hottest
cell). Secure the BMID to a nearby intercell connect with the provided polypropylene cable
ties and foam tape.
2.1 Flooded Batteries
Select one of the battery cells near the BMID where the temperature sensor will be installed.
This cell should be in the center of the pack so that it will read the warmest temperature.
Carefully drill a 0.5-inch hole in the center of the case of the cell. Insert the submersion type
temperature probe through the case and submerge it into the electrolyte.
Figure 1 – Temperature Sensor Installation
WARNING
Use only the submersion-type temperature probe with
flooded batteries. Do not use the non-submersion type,
black plastic temperature sensor, as it is not designed
for liquid electrolyte cells.
2.2 Sealed Batteries
Select one of the battery cells near the BMID where the temperature sensor will be attached.
It is very important to read the actual temperature of the battery. Using the non-submersible
black plastic temperature sensor, slide the probe between two cells. This is the preferred
method. If it does not fit between the cells, it can be placed under the battery post.
CAUTION
The temperature probe is fragile. Take extra care not
to damage it during installation. Also, select a location
it will not be damaged during normal operation or
maintenance.
Route the voltage sensing lines to the positive (red wire) and the negative (black wire)
terminals of the battery.

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2.3 Welded Battery Terminal Posts
Remove the plastic covers from the terminals. Install knurled brass inserts (Part # 06602) into
the pack’s positive and negative lead terminals of the battery pack – it must be the same
posts which the main positive and main negative power cables attach to the pack. Drill a
0.188-inch diameter hole in the center of the lead post, between 0.290 to 0.353 inch deep
(drill bit supplied in assembly kit). Press the knurled brass insert into the hole. Use the #6
screw, flat washer, and lock washer to attach the BMID voltage wires to the knurled insert.
Apply a small amount of terminal protective grease to completely encapsulate the screw and
ring lug of both the + red and –black terminals. Replace the plastic terminal covers.
Figure 2 – Knurled Brass Insert Installation
2.4 Bolted Battery Terminal Posts
Use the same procedure as above except install the brass insert in the center of the terminal
bolt head. After applying the grease, snap the caps onto the bolt head to insulate the
connection.
Figure 3 – Bolted Battery Installation

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Neatly bundle any excess wire length and fasten it securely to the battery using
polypropylene cable ties. Confirm all the wires are routed to prevent chafing or snagging
during normal operation and maintenance. Then secure all of the BMID communication lines
to intercell connects along their path with the provided cable ties. Use polypropylene cable
ties only – nylon cable ties are vulnerable to sulfuric acid attack. Figure 4 shows a typical
installation of the BMID in a single connector pack. Figure 5 shows a typical installation of the
BMID in a double connector pack.
Connect the BMID data line receptacle to the mating plug on battery patch cable.
(Figure 4 & Figure 5)
+
4/0 Battery Cable
Euro Connector, Female
SB350 Connectors
4/0 Battery Cable
BMID Data Connector
4/0 Battery Cable
4/0 Battery Cable
Battery Patch Cable, sized to fit vehicle
Voltage sense
wire, red, "+"
Voltage sense
wire, black, "-"
BMID Data and
Direction Wires
BMID,
secured to pack Temp. Sensor
Figure 4 - Typical BMID Installation on a Single Connector Battery Pack

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Figure 5 - Typical BMID Installation on a Dual SBX Battery Pack
+
+
-
-
SBX Connector, Yellow
SBX Connector, Blue
SB Connectors Data wire connector (4 wire)
Temperature Sensor
Battery Patch Cable Assemblies
See document #09441-76
Battery Modification Instructions
BMID Data/
Direction/Pilot Wires
BMID - Secured to Pack
Voltage Sense Wire "-"
Voltage Sense Wire "+"

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3 BMID Initialization
NOTE: When using BMID Is with Procore chargers, skip the initialization step.
Before a battery can be charged, the BMID must be initialized and the battery
parameters written to the BMID. This is done the first time the battery is connected to a
PosiCharge fast charger. At a minimum, the following parameters must be entered:
1. Battery ID
2. Battery type - Choose from a list of batteries by manufacturer
3. Number of cells
4. Battery capacity in AHrs
5. Vehicle ID is optional.
Equalization is scheduled for Sundays by default. Enter the EQ start and end days and
times if another scheduled is required.
Use the default settings for the other parameters unless instructed otherwise by
PosiCharge.
3.1 BMID Initialization Procedure
WARNING: This procedure deletes all warranty data and should ONLY be performed
on new BMIDs when they are first placed into service.
1. Press the Select button until BMID Configuration is displayed,
then press the Enter button.
2. The Enter Key Code will be displayed – enter the initial key code
by pressing the Enter and Down Arrow buttons until Key Code
Accepted is displayed on the screen, followed by Initialize BMID.
3. Press the Select button until Initialize Date is displayed.
4. Enter the secondary key code (Up Arrow and Down Arrow for
10 seconds). There will be no indication that the key code has
been accepted.
5. Press the Select button until Initialize BMID is displayed, the
press the Enter button.

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6. Erase all BMID data? is displayed with Cancel flashing – press
the Up Arrow or Down Arrow button to change Cancel to OK.
Then press the Enter button.
7. Initializing BMID – please wait… is displayed followed by BMID
Initialization OK and Battery ID.
8. The default Battery ID type is 8 alphanumeric characters. Some
older PosiCharge software does not support alphanumeric and
requires a 5-digit numeric Battery ID. If a 5-Digit Numeric ID is
required, press the Select button until the Battery ID Type is
displayed, then press Enter, and use Up Arrow or Down Arrow
keys to toggle between Alphanumeric Batt ID and 5-Digit
Numeric. Then press Enter to accept.
9. Press the Enter button and input the Battery ID.
NOTE: If the Charger did not accept the secondary key code,
pressing the Enter button at the Battery ID screen will cause
Access Denied to display. Return to the Initialize Date screen,
enter the secondary key code again, and proceed with step 5
above.
10. Enter the remaining BMID parameters.
NOTE: The BMID S/N is not editable. The Initialize Date
parameter is automatically set to the date configured in the
charger and is not editable.

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4 Communication Wiring
4.1 Single Anderson Euro Connector Communication Wiring, Battery Side
The communication wiring provides the safety interlock signal (called the pilot), the
communication between the BMID and the charger. The communication wiring must be
connected properly for the charger to initiate a charge.
Figure 6 - Wiring for Anderson Euro A32
4.2 Single Schaltbau Euro Connector Communication Wiring, Battery Side
Figure 7 - Wiring for Schaltbau Euro LV320

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4.3 Dual SBX Connector Communicating Wiring, Charger and Battery Side
Figure 8 – Wiring for Dual SBX 320 Connector
4.4 Dual Anderson Euro Connector Communication Wiring, Battery Side
Figure 9 - Wiring for Dual Anderson Euro
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