Conext™ Battery Monitor Owner’s Guide www.SEsolar.
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About This Guide Purpose The purpose of this Owner’s Guide is to provide explanations and procedures for installing, operating, configuring, maintaining, and troubleshooting the Conext Battery Monitor. Scope The Guide provides safety guidelines, planning, and setup information, procedures for installing the Battery Monitor, as well as information about configuring, monitoring, and troubleshooting the unit.
About This Guide Conventions Used The following conventions are used in this guide. DANGER DANGER indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a potentially hazardous situation, which, if not avoided, can result in death or serious injury. CAUTION CAUTION indicates a potentially hazardous situation, which, if not avoided, can result in moderate or minor injury.
Important Safety Instructions READ AND SAVE THESE INSTRUCTIONS - DO NOT DISCARD This guide contains important safety instructions for the Conext Battery Monitor that must be followed during installation and configuration procedures. Read and keep this Installation Guide for future reference. Read these instructions carefully and look at the equipment to become familiar with the device before trying to install, operate, service or maintain it.
DANGER HAZARD OF ELECTRIC SHOCK AND FIRE • Connect only to Safety Extra Low Voltage (SELV) circuits and power sources. • All wiring must be done by qualified personnel to ensure compliance with all applicable installation codes and regulations. • For Indoor Use Only. Install in a dry, indoor location away from direct sunlight. • To reduce the risk of electrical fire, replace fuses with same size, type, and rating only. • Do not disassemble. No user serviceable parts inside.
DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH • Remove watches, rings, or other metal objects. • This equipment must only be installed and serviced by qualified electrical personnel. • Keep sparks and flames away from the batteries. • Use tools with insulated handles. • Wear protective glasses, gloves and boots. • Do not lay tools or other metal parts on top of batteries. Failure to follow these instructions will result in death or serious injury.
NOTICE RISK OF EQUIPMENT DAMAGE • The Battery Monitor is intended for monitoring lead-acid batteries with a nominal voltage of up to 48 VDC. • Do not use the device with Lithium Ion batteries. Failure to follow these instructions can damage equipment.
Contents Contents 1 Overview Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Benefits of Monitoring the Battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Unpacking and Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Contents Mid-point Sensing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Mid-point Sensing Configurations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Trending Mid-point Voltages in Data Logs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Synchronization - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Upgrading Firmware - - - -
Contents Regulatory Standards - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A–57 Schneider Electric Products compatible with the Battery Monitor - - - - - - - - - - - - - - - - - - - - - - A–57 B Modbus Maps Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Supported Modbus Data Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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1 Overview Chapter 1 describes the features of the Battery Monitor and provides an overview of its physical features and user interface.
Introduction The Conext Battery Monitor is a meter for 24 V & 48 volt batteries designed for use in off-grid power systems as a wall/panel/DIN-rail mount device in stationary renewable energy applications. It features a local display to selectively show the voltage, current, consumed amp-hours, remaining capacity and remaining hours.
Features 1 2 4 3 Figure 1-1 Conext Battery Monitor front panel features 1. LCD (Liquid Crystal Display) screen 2. Navigation buttons (<, OK and > keys) 3. Mini-USB Port 4. Reset button 5 6 8 7 Figure 1-2 Conext Battery Monitor bottom panel ports 5.
6. BTS (Battery Temperature Sensor) Port 7. Battery Analog Signal Port 8. Xanbus Ports Functions The Battery Monitor features six data monitoring functions including: • Voltage (Battery voltage) • Amps (Real-time charge/discharge current) • Amp-Hours (Amount consumed. Displayed after Function F2.
Compatibility Other capabilities of the Battery Monitor include: • Configuration capability using the front panel, System Control Panel, Conext Configuration Tool, Conext ComBox or through 3rd party devices like PLC using RS485 Modbus. • Ability to connect directly to Xanbus devices using RJ45 connections. • Ability to control diesel generators using various triggers, including State-ofcharge triggers when used with the Conext Automatic Generator Start (AGS).
Note: Always use shunts that are scaled to 50 mV or 60 mV at rated current. Check with the manufacturer's data sheet to select the shunt rating. Select a shunt with an overcurrent margin of 25% over its rated current capacity, as matched to the continuous peak current expected on the system.
2 Installation Chapter 2 describes how to install, wire, and connect the Battery Monitor to your network.
WARNING OVERHEATING OF DC TERMINALS AND CABLES Overheating of the DC terminals or DC cables to dangerous temperatures may occur due to improper installation of shunt. • Do not put anything between the cable lug and the terminal surface. • Do not over-tighten connections; observe all recommended torque values. • Do not apply any type of anti-oxidant paste until after the cable connection is tightened. • Do not under size cables; install cables sized in accordance with national electrical code requirements.
Planning and Choosing a Location Choose a clean, dry, protected and easily accessible indoor location. If you mount the Battery Monitor on a wall, the recommended height is at eye level so that you can clearly see the LCD display and have easy access to the data ports. All the communication ports on the Battery Monitor are accessible from the bottom of the device when mounted on a wall, panel or DIN rail. Clearance of at least 2 in.
Materials and Tools Required Materials List The materials supplied with the Battery Monitor package are listed in the section “Part List” on page 1–5. The following materials and tools are not supplied but are required to complete the installation: ❐ CAT5 or CAT5e network cable(s) for Xanbus connections - 6.
Wall Mount To mount the Battery Monitor on a wall: 1. Choose the location for mounting the device. 2. Using the template in the Conext Battery Monitor Quick Start Guide, mark the mounting holes on the wall with a pencil. Note: The holes must be at the same height and 2.36 in. (60 mm) apart. 3. Insert the two anchors and mounting screws supplied in the marked locations on the wall, leaving a space of approximately 0.13 in. (3.3 mm) between the wall and screw head.
4. Place the Battery Monitor on the mounting screws, and confirm a snug fit before going to the next step. Figure 2-3 Wall mounting the Battery Monitor (continued) 5. Connect the wiring and cables. See the Battery Monitor Quick Start Guide Section “Cable Connections” for correct wiring. Panel Mount The Battery Monitor has a front frame for slide-in mounting into a panel cutout. Standard dimensions of a panel mount meter are 3.6 x 3.6 in. (92 x 92 mm).
4. Remove the front panel plate from the Battery Monitor.
5. Place the Battery Monitor against the four drilled holes. 6. Connect the two Xanbus cables 7. Screw the Battery Monitor onto the wall. 8. Re-attach the front panel plate to the Battery Monitor. Figure 2-5 Panel mounting the Battery Monitor (Continued) DIN Rail Mount A standard 35-mm “top hat” DIN rail (EN50022) is required for DIN-rail mounting.
To mount the Battery Monitor on a DIN Rail: 1. Choose the location for mounting the device. 2. Use a Phillips head screwdriver to screw the DIN rail clip onto the back panel of the Battery Monitor. Figure 2-6 Attaching the DIN rail clip to the Battery Monitor 3. Mount the Battery Monitor on the DIN rail at an upward angle then push down and in to clip to the rail. Figure 2-7 DIN Rail mounting the Battery Monitor 4. Connect the wiring and cables. See “Electrical Wiring” on page 2–16 for details.
Mounting the Shunt NOTICE EQUIPMENT DAMAGE The shunt must be installed in the negative line. Installing the shunt in the positive line may result in damage to the Battery Monitor. Failure to follow these instructions can result in damage to equipment. The shunt connects between the inverter and batteries in the negative (–) battery power wire. To mount the shunt: 1. Mount the shunt on or near the battery enclosure close to the negative (–) battery terminal.
To Modbus via RS485 connector To battery bank OR To pre-scaler assembly port To Xanbus Figure 2-9 Wiring the Battery Monitor Wiring the Battery to the Shunt The shunt terminal labelled “BATTERY” must be wired to the negative battery terminal of the battery bank. The shunt terminal labelled “SYSTEM” connects to the inverter. To wire the shunt: 1. Disconnect the negative cable (that connects between the inverter and battery) from the battery’s negative (–) terminal. 2.
The included in-line 2AT voltage-sensing fuses are connected to the positive and negative endpoints and the positive midpoints of the battery bank as shown below. Refer to the Label column of Table 2-1 on page 2–19 for details about the lettered labels below.
Wiring the Battery Terminal to the Pre-scaler Board The pre-scaler board arrives pre-wired to the battery sense cable wires.
2AT Fuses are pre-wired to V+, Vm, VA1, VA2. L+, and L- are wired together as a twisted pair, while the remaining wires are individual. Pre-Scaler Port Pre-wired Connections Twisted Pair Battery Sense Cable Battery Sense Cable Wires H G F E D C B A Figure 2-11 Pre-scaler terminals To wire the battery terminal to the Pre-scaler Board: 1. Connect the black (V-) and grey (Vm-) wires to the negative (—) endpoint battery terminal. 2.
Wiring the Shunt to the Pre-Scaler Board The Pre-scaler board is connected to the shunt via the twisted wire pair which is wired to the inner screws on the shunt. Connect Blue wire here Connect Violet wire here Figure 2-12 Wiring the shunt to the Pre-scaler board Wiring the Pre-Scaler Board to the Battery Monitor The Pre-scaler board is connected to the Battery Monitor using the orange RJ45 cable provided.
3. Insert the three wires into the connector terminals as shown in Figure 2-13. D N G 0 D 1 3/8 in. (10 mm) D Figure 2-13 Wiring the RS 485 modbus connector 4. Secure the wires by tightening the screw on the terminal. Note: The right terminal is not connected internally but is provided for the ground connection of the cable. 5. Plug the connector into the rear RS485 port on the Battery Monitor.
To connect the BTS cable to the battery: 1. Connect the RJ11 connector to the back of the Battery Monitor as indicated in Figure 2-9, “Wiring the Battery Monitor” on page 2–17. 2. Connect the BTS connector either by bolting it directly to a battery terminal along with the other connections or by removing the sticker on the bottom of the BTS connector and sticking it directly to a surface on the battery. The two methods are shown in Figure 2-14.
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3 Configuration Chapter 3 describes how to configure settings for the Battery Monitor and perform tasks such as extracting data logs upgrading device firmware.
Initial Startup of the Battery Monitor Figure 3-1 Location of front panel power LED indicator Note: Use the front panel display for first installation. Do not connect the Xanbus cables initially because system functions on other Xanbus devices could be affected as the Battery Monitor initializes. To turn on the Battery Monitor: 1. Insert the pre-scaler cable into the RJ45 analog-signal port. The Battery Monitor will power on using battery power. 2.
8. The default State-of-charge at startup is 75%. Before synchronizing the Battery Monitor to a State-of-charge of 100%, charge the batteries completely and allow the batteries to remain in float state for at least 2 hours. Refer to “Synchronization” on page 3–36 for synchronization instructions. Battery Sizing The amp-hour setting on the Battery Monitor should be set to a value equal or lower than the actual amp-hour capacity of the system’s battery bank.
Function Menu In the FUnc (Function) setup menu, the Battery Monitor can be adjusted to fit your system. Parameters called Functions can be set according to your needs. This menu can be accessed by following the sequence in “Changing Settings from the Front Panel” on page 3–27. The Function menu is divided into three types of settings: System Property Settings (represented by F1), Main Battery Settings (represented by F2), and Battery Monitor settings (represented by F3).
F1.6 1 0-2 1 Auto-sync sensitivity. Changes sensitivity of the auto-sync function. If it takes too long to activate the synchronization function, lower this value. If it synchronizes too early, increase this value for a later synchronization. Default Range Step size 5 0-10 1 Main Battery Settings F2.0 Battery capacity. Your Main battery’s capacity in Amp hours (Ah). Default F2.1 975-0691-01-01 Revision B Step size Range Step size Range Step size 1.25 1-1.50 0.01 Self-discharge rate.
Battery Monitor Settings F3.0 F3.1 Internal firmware version. (Reserved, Read-only value) Shunt Amp Rating. This Function is linked to F3.2 and represents the Amp rating of your shunt at the given sensing voltage as set in F3.2. Included with your Battery Monitor is a 500 Amp/50 mV shunt, meaning that at 500 A flowing through the shunt, a voltage of 50 mV is generated across the small ‘Kelvin’ screw terminals of the shunt. This voltage is used by the Battery Monitor to measure the battery current.
Battery History Settings H1.0 H1.1 H1.2 H1.3 H1.4 H1.5 H1.6 H1.7 H1.8 Average discharge in Ah. This number will be recalculated after each synchronization. Average discharge in %. This number will be recalculated after each synchronization. Deepest discharge in Ah. Deepest discharge in percent. Total Amp-hours removed. The total number of Amp-hours removed from the battery. When exceeding 10000 Ah, the units are kAh and the value displayed must be multiplied by 1000. Total Amp-hours charged.
Hold the OK key for 3 sec until StAt appears on the LCD display, then press the right arrow button three times. rSt appears on the LCD display. Press the OK key again, then use the arrow keys to toggle the various items. The default value for all Reset menu settings is “OFF”. If required, use the < and > keys to change the value from “OFF” to “ON”. Pressing the OK key again will step back to the Reset menu.
Extracting data logs To extract data logs, a Mini-USB to USB cable is used to connect from the Battery Monitor’s Mini-USB port to the computer’s USB port. The data logs are available in a spreadsheet comma separated values (.csv) format. Figure 3-2 Mini-USB to USB cable To extract data logs: 1. Plug the Mini-USB to USB cable directly from the Battery Monitor’s Mini-USB port directly to the computer’s USB port. 2.
5. Find the .csv file for the current day and open the file in your preferred spreadsheet software. The data file is formatted by using a comma to delimit items. The file can be opened and viewed by most popular spreadsheet programs such as Microsoft® Excel® or a text editor (i.e. Notepad). Figure 3-5 Example log file (CSV format) Mid-point Sensing Mid-Point voltage sensing is a technique used to detect unbalanced battery strings.
Method 1: Vm 2x 2AT fuse Va1 2AT fuse Va2 2AT fuse Each battery icon represents a 6 V cell. Method 2 (parallel battery banks): Vm 2x 2AT fuse Va1 2AT fuse Va2 2AT fuse Figure 3-6 Mid-point sensing configurations To display the mid-point voltages on the Battery Monitor, press the right arrow key until the AUX Voltage label is shown. The voltage display on the LCD display will alternate every 5 seconds between VA1 and VA2 voltages.
It is not practical to monitor the mid-point voltage throughout the day. Therefore, a more practical approach is to look at periodic log files stored inside the Battery Monitor and examine the minimum values recorded for Va1 & Va2. If they differ beyond 1.5 V, maintenance may be required. Another option is to compare these minimum voltages to double (two times) the value of Vm. If these are close in value, it can reasonably be inferred that the batteries are healthy.
A synchronisation step means performing a charge cycle on the battery. A charge cycle will be considered complete when all discharged energy is restored in the battery and Auto-sync parameters F1.0, F1.1 and F1.2 are met (see “System Property Settings” on page 3–28). This typically occurs when the battery charger switches to float mode. By meeting these conditions, the battery is considered full, which will be indicated by a flashing Full message on the display.
SCP Menu Map The Conext System Control Panel (SCP) provides remote configuration and monitoring capability for the Battery Monitor and other Xanbus-enabled devices in the network. Below is a map of Battery Monitor menu functions. Conext System Control Panel Battery Monitor Menu Map Conext BM 00 : Basic Capacity [450Ah] Discharge Rate Nominal Temp [20h] [25øC] Shunt Amps [500A] Conext BM 00 : Meters Shunt mV [50mV] Battery 31.7A 75% Self Disch [3.
duplicated, which could cause system-wide battery bank status readings to be inaccurate. Be sure to manually configure a unique DC association number for each Battery Monitor when multiple Battery Monitors are present in a system to avoid this issue.
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4 Monitoring Chapter 4 describes how the Battery Monitor can monitor system components and explains how displays and functions are calculated.
Indicators and Controls The Battery Monitor contains the following controls and indicators: 1 2 3 Figure 4-1 Conext Battery Monitor Controls and Indicators 1. LCD display screen 2. Navigation buttons (<, OK and > keys) 3. Reset button The LCD display screen displays alphanumeric messages with a three-digit resolution (0.00). The screen will flash amber when the battery is in an emergency state requiring attention.
Meters When not being actively configured, the Battery Monitor is operating in display mode. By default, it displays the main battery voltage readout. To display one of the other meters: • Press the OK button repeatedly until the desired indicator illuminates. • The LCD display will indicate the values for the currently selected function. All readout selections can be navigated by using the < and > keys.
Theory of Operation How State-of-charge and Amp-hours are Calculated The capacity of a battery is rated in amp-hours (Ah). A battery that can deliver a current of 5 A for a period of 20 hours is rated at 100 Ah (5 × 20 = 100) at a C20 discharge rate. The Battery Monitor continuously measures the current flow in or out of the battery and calculates the amount of energy removed from or added to the battery. However, battery age, discharge current, and temperature all influence the battery’s capacity.
based on the load at the time of readout. Therefore, it should be used as a guide only. The use of the state-of-charge readout generally gives a more accurate indication of the overall percentage of battery life remaining. Time Remaining is still an important readout in certain cases. For example, when there is a heavy and sustained load, it can be useful to know how much longer the load can be operated.
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5 Troubleshooting Chapter 5 describes troubleshooting for common issues that might be encountered when installing or operating the Battery Monitor. It also describes how the Battery Monitor works with other Xanbus Devices.
Troubleshooting Common Issues To troubleshoot commonly encountered issues, look up the issue in the troubleshooting table below for possible solutions. If you’re unable to find the issue, Contact Customer Service for further assistance. Please be prepared to describe details of your system installation and provide the model and serial number of the unit. See page 1–i for contact information.
Problem Possible cause Solution(s) Battery voltage readout is inaccurate Voltage drop within the circuit. Check connections and verify that the cable lengths are within the limits. See “Planning and Choosing a Location” on page 9 for correct cable lengths. Battery State-ofCharge displays 100% when voltage is low. Amp-hour setting is too low. Reconfigure the Amp-hour setting using Function F1.1 (Charger float current) to an appropriate value.
2. SCP (if ComBox is not present) Temperature The Battery Monitor can be connected to a Battery Temperature Sensor (BTS) to provide status information on the temperature (in °C) at which the connected battery is operating. This information is used in SOC% and reserve capacity calculation.
Table 5-2 Device Compatibility with Conext Battery Monitor Device Name Firmware Version Conext ComBox 1.04 and higher Conext ComBox App 1.0.
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A Specifications Appendix A contains the electrical, mechanical, and physical specifications for the Conext Battery Monitor. It also contains regulatory standards, supplementary data and information about compatible devices. Note: All specifications are subject to change without notice.
Electrical Specifications Supply Voltage 18 to 66 VDC Supply Current (backlight Off, loggingdisabled) 80 mA @ VIN=48 VDC, 150 mA @ Vin=24 VDC Input Voltage Range (main battery) 0 to 70 VDC Input Current Range -9999 to +9999A Battery Capacity Range 20 to 10,000 Ah Operating Temperature Range -20 to +50°C (-4 to 122°F) Power Consumption <4 W Voltage 0 to 70 V (+0.01 V) Current 0 to 200 A / 200 to 9999 A (+0.1 A / +1 A) Amp-hours 0 to 200 AH / 200 to 9990 AH (+0.
ModBus Isolated RS-485, half-duplex, 2-wire serial Data Logging 10 data points every 10 minutes for 10 years Display Backlit LCD User interface 3 front panel menu buttons, 1 power button Battery stringimbalance detection Two-point sensing Temperature Sensor (included) 762 cm (300 in.
Mechanical Specifications Dimensions (H x W x D) 8.5 x 8.5 x 9.0 cm (3.3 x 3.3 x 3.5 in.) Product/Shipping Weight 0.2 kg (0.4 lb) / 1.95 kg (4.
Regulatory Standards Markings CE EMC Directive 2004/108/EC, IEC/EN61000-6-3, IEC/EN61000-61, FCC Part 15 Class B, Industry Canada ICES-003 Class B Schneider Electric Products compatible with the Battery Monitor • • • • • • • • • • • • • 975-0691-01-01 Revision B Conext XW+ 5548 NA (865-5548-01) Conext XW+ 6848 NA (865-6848-01) Conext XW+ 7048 E (865-7048-61) Conext XW+ 8548 E (865-8548-61) Conext SW 2524 230 (865-2524-61) Conext SW 4024 230 (865-3524-61) Conext SW 2524 120 (865-2524) Conext SW 4024 12
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B Modbus Maps Appendix B contains the Modbus register address maps. Note: All data is subject to change without notice.
Modbus Maps WARNING UNINTENDED OPERATION The use of this product with Modbus communications requires expertise in the design, operation, and programming of the device. Only qualified persons should program, install, alter, and commission this product. When writing values to the device, ensure nobody else is working with the device. Failure to follow these instructions can result in death or serious injury, and/or equipment damage.
Converting Data to Units of Measurement Converting Data to Units of Measurement Data from a Modbus register is converted to units of measurement using the following algorithm: result = [(data @ Modbus Register) * scale] + offset Example: Read the Nominal Temperature The following example shows a conversion of the nominal temperature located at Modbus Address 0x0400. Modbus Address = 0x0400 Scale = 0.01 Offset = -273.
Modbus Maps Modbus Address Name Type 0x0206 Battery State of Charge uint16 r % 1 0 0x0207 Battery Midpoint VA1 sint32 r V 0.001 0 0x0209 Battery Midpoint VA2 sint32 r V 0.
Battery Monitor Device Modbus Map Modbus Address Name Type 0x0503 Time Remaining Filter uint16 rw 0x0504 Auto Synchronization Sens uint16 rw 1 0 0x0505 Battery Peukert Expo uint16 rw 0.
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