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Alber Training and Education Product Tutorial

BDS-256XL Battery Diagnostic System

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Tutorial Topics• What is a BDS-256XL?• How Does the BDS-256XL Work?• Introduction• Product Application• BDS-256XL Hardware Descriptions• Configuration Example• System Level Input/Output Capabilities• Communication Methods• Wire Management• Installation Examples• Wiring Termination Methods

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Tutorial Topics• Options• Technical Assistance• More Tutorials

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What is a BDS-256XL?• The Alber BDS-256XL is a complete battery

diagnostic system well suited for a variety of monitoring applications

• The BDS-256XL can measure and store the following data– Cell voltage– Battery voltage– Cell resistance– Ambient and electrolyte temperature– Discharge current– Float current– Battery discharge data

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How Does the BDS-256XL Work?• The BDS-256 is permanently connected to

a battery via sense lead wiring described later in this tutorial

• The BDS-256 continuously scans key operating parameters for unacceptable deviations from defined limits

• When a threshold is exceeded, the BDS-256 can be programmed to alert the user with a number of reporting methods

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Introduction• The BDS-256XL Battery Diagnostic System

is designed for a variety of batteries of up to and including 256 cells. A single system can monitor 8 strings of batteries simultaneously

• The system can communicate using RS-232, USB, modem and network methods depending upon the user’s requirements

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ApplicationsUPSPower generation stationsOther battery types with large cell counts

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BDS-256XL System Hardware

• CM-XL8 System Controller• DCM-XL48 Data Collection Module• RTM-XLR Resistance Test Module

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CM-XL8 Controller

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CM-XL8 Function

• Each Controller can manage up to 8 strings of up to 256 cells/channels

• The controller holds all system setup information and test data in non volatile RAM

• It communicates to the DCMs via visible-light fiber optic cable

• The controller is also the source of low-voltage AC power to additional system components

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CM-XL8 Com Ports• There are three ports to communicate

to PCs– Local Port

• Front and Rear RS232• Switched – only one active at a time

– Telco Port (standard modem)– Network Port

• RJ45 Standard Ethernet card

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CM-XL8 Communication Protocols

• Modbus (ascii) • Via RS232• Via TCP/IP

• SNMP• TCP/IP

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CM-XL8 I/O and Control Options• Optional digital I/O board provides16

inputs & 8 outputs– Provides connection from ancillary sources

such as door switches and other alarm contacts

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• Monitor load control• Permits complete control of an Alber DC load bank

with a BDS-256XL for conducting capacity tests per IEEE recommendations

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DCM-XL48 Data Collection Module

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DCM-XL48 Data Collection Module Function

• Connected to each cell in the battery to allow measurement of cell voltage and resistance

• 48 input channels• Powered via 24VAC sourced at CM-XL8• Communicates with CM-XL8 via fiber optic

loop• Power Output

– Provides DC power for temperature, float current and discharge current sensors

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DCM-XL48 Data Collection Module

• The DCM controls the RTM-XLR during resistance testing

• These outputs are opto isolated for safety and measurement reliability

• Power is sourced from the RTM-XLR

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RTM-XLRResistance Test Module

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RTM-XLRResistance Test Module

• Provides the resistive load for internal cell resistance testing

• One RTM-XLR per string• The source of power for the load

control circuit in the DCM• Powered by 24VAC• No microprocessor, only switching logic

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2 strings, 240, 2V jars

1 CM-XL8 Controller

String 1

String 2

Fiber optics for data transfer and 24VAC power supply between DCM and Controller

5 DCM-XL48 and1 RTM-XLR per string1 CT and at least 2 temperature probes per string

Configuration Examples

5 DCM-XL48 and1 RTM-XLR per string1 CT and at least 2 temperature probes per string

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System Level I/O

• System inputs–Remote alarm reset–16 digital inputs - optional

• System outputs (dry form C contacts)–Maintenance alarm–Critical alarm–8 programmable control outputs

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Communication Capabilities

• Two RS-232 ports for a local computer

• RJ-11 for modem connection

• RJ-45 for network connection

• Standard Modbus protocol

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System Hook-up with RTM-XLR and DCM-XL48

LOAD

RTM-XLR

DCM-XL48

DCM-XL48 sense connections

RTM-XLR connections

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Wire Management

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Wire Management• Management of all installation wiring and

fiber optics can be accomplished through the use of plastic wire channel

• The channel can be easily installed on the battery rack

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Wire Management

• The sense lead pigtail is supplied assembled and requires the use of an in-line splice to terminate it to the sense lead harness

• Each cell has a voltage sense lead

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BDS-256XL Installation Examples

RTM-XLRDCM-XL48

BDS-256XL – 3 Strings of 240 Cells

Sense lead harnesses

RTM-XLR control cables

Installation in a Standard 19”Cabinet Rack

Should service become necessary, a hinged rack enclosure easily permits access to all wiring.

Front View of Previous Slide

System Computer and Controller Enclosure

Alber offers a variety of installation enclosures including thisfloor mounted cabinet that can be used to house the system computer, CM-XL8 controller, monitor and keyboard

RTM and DCM Installation Methods

The RTM-XLR and DCM-48XL are frequently mounted adjacent to the battery they serve. This minimizes wire lengths, and reduces installation time.

Sense Lead Harness, Discharge CT, Panduit, DCM and RTM Installation

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Wire Termination Methods

Tab Washer Connection Method for Sense Leads

Post Clip Connection for Sense Leads

C-Clamp Connection for Sense and Resistance Test Leads

Resistance Test and Sense Wring Installation

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Optional Equipment• Temperature Sensors

Ambient Temperature Sensor

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Optional Equipment

• Discharge current measurement– Up to 4000 amps

Hall-effect Current Transducer (CT)

Shunt

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Optional Equipment• Discharge current measurement

– 600 Amp hall-effect CT for smaller systems

Discharge Current CT Installation

The BDS system can measure up to 4000 amps using a hall-effect CT or a shunt based on customer needs.

CT

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Optional Equipment

• Intertier and inter-rack cable resistance measurements– Discrete wiring can be installed to permit

monitoring the resistance of all inter-tier cable connections throughout the battery

Inter-tier and inter-rack cable assemblies

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Technical Assistance• Product support is available Monday-Friday,

8:00a.m.-5:00p.m. ET• Main Phone – 954-623-6660• Email support – support@alber.com• Web – www.alber.com

– Downloads– User manuals– Installation instructions– Product literature and more– Service Bulletins

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Sales Assistance• Alber Sales Team

3103 N. Andrews Ave. ExtensionPompano Beach , FL 33064Phone – 954-623-6660 or 800-851-4632Email – sales@alber.com

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More Tutorials from Alber• Please visit our website at

www.alber.com/training for additional tutorials about monitoring products and software– Battery monitoring theory– Monitoring system basics– BDS-40 monitor– BDS-256 monitor– MPM-100 monitor– Battery monitor data manager software