Albér Universal Xplorer Industrial Monitor (UXIM) Battery Monitor Product Description Guide Albércorp 3103 North Andrews Avenue Ext. Pompano Beach, FL 33064 Tel: (954) 623-6660 Fax: (954) 623-6671 www.alber.com 4200-107 Copyright and Disclaimer Universal Xplorer Industrial Monitor (UXIM) Product Description Guide Document Revision 1.01 Part Number 4200‐107 Revision History Revision Date of Change Description of Change By 1.00 9/23/12 Initial Draft ED, MS 1.01 10/07/12 Final edits before release MS, ED Albér Universal Xplorer Industrial Monitor (UXIM) Battery Monitor Product Description Guide, Part Number 4200‐107 ©2012 Albércorp. All rights reserved. Albércorp, 3103 North Andrews Avenue Extension, Pompano Beach FL 33064. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording for any purpose, without the express written permission of Albércorp. Information in this document is subject to change without notice. Trademarks The first instances of registered trademarks or trademarks of Albércorp and other companies are annotated above using the ® and ™ symbols. For ease of reading, these symbols do not appear in the remainder of this Product Description Guide. Printed in the United States of America. 4200‐107 i Revision 1.01 Albér Customer Service Albér Customer Service is available Monday to Friday, 8:00AM to 4:30PM Eastern Time. Telephone: Fax: Email: Web site: (954) 623‐6660 (954) 623‐6671 [email protected] www.alber.com Corporate Office Address: Albércorp 3103 North Andrews Avenue Ext. Pompano Beach, FL 33064 USA 4200‐107 ii Revision 1.01 Table of Contents 1. Glossary of Terms ............................................................................................................1-1 2. Product Overview .............................................................................................................2-1 2.1 Product Description ..................................................................................................... 2-1 2.2 Supported System Configurations ............................................................................... 2-2 3. Features ............................................................................................................................. 3-1 4. Measurement Capabilities ............................................................................................... 4-1 5. Operating Modes ..............................................................................................................5-1 5.1 Normal Operating Mode .............................................................................................. 5-1 5.2 Discharge Mode .......................................................................................................... 5-1 5.3 Acceptance/Performance Test .................................................................................... 5-1 5.4 Resistance Test ........................................................................................................... 5-1 5.5 Ground Fault Detection ............................................................................................... 5-1 5.6 Alarm Mode ................................................................................................................. 5-1 5.7 Email Dispatcher ......................................................................................................... 5-2 6. Model Number Descriptions ............................................................................................ 6-1 6.1 Parts List...................................................................................................................... 6-2 7. Panel Controls and Indicators ......................................................................................... 7-1 7.1 Front Panel (All Models) .............................................................................................. 7-1 7.2 Rear Panel ...................................................................................................................7-2 8. UXIM Specifications ......................................................................................................... 8-1 8.1 UXIM System Specifications ....................................................................................... 8-1 8.2 Cell Measurements ...................................................................................................... 8-2 8.3 System Measurements ................................................................................................ 8-2 9. Index .................................................................................................................................. 9-1 4200‐107 iii Revision 1.01 List of Figures Figure 1 - System Connections (1X60X2V Configuration) ......................................................... 2-2 Figure 2 - UXIM Front Panel ...................................................................................................... 7-1 Figure 3 - UXIM Rear Panel ....................................................................................................... 7-2 List of Tables Table 1 - Glossary of Terms ...................................................................................................... 1-1 Table 2 - Supported System Configurations .............................................................................. 2-2 Table 3 - Model Number Description ......................................................................................... 6-1 Table 4 - Standard Parts List ..................................................................................................... 6-2 Table 5 - UXIM Front Panel Component Descriptions ............................................................... 7-1 Table 6 - UXIM Rear Panel Component Descriptions ............................................................... 7-2 Table 7 - Cell Measurement Specifications ............................................................................... 8-2 Table 8 - System Measurement Specifications .......................................................................... 8-2 4200‐107 iv Revision 1.01 Glossary of Terms 1. Glossary of Terms The following is a list of terms commonly used with respect to batteries and battery monitoring. Term Definition Battery Two or more cells connected together electrically in series or parallel. Cell The basic electrochemical unit, characterized by an anode and a cathode, used to receive, store and deliver electrical energy. Current transducer The component that measures current. DC resistance measurement A test method that places a load across a group of cells and measures the instantaneous voltage response to calculate the battery's state of health. Discharge rate The rate, in Amperes or Watts, at which current or power is delivered by a battery. Float current The current drawn by a cell that is being float charged. Intercell connector An electrical conductor used to connect adjacent cells on the same rack. Intertier connector An electrical conductor used to connect two cells on different steps of the same rack. Internal ohmic measurement A measurement of the electronic and ionic conduction path within a cell or unit using techniques commonly known as impedance, conductance or resistance tests. Jar The container that holds a cell or a group of cells. A battery container can be a single cell or multicell unit, also called a monobloc. Monobloc or multicell unit A multicell container in which cells are installed. (Multicell Unit US, Monobloc outside the US) Ohmic value The unit of measure that indicates resistance of a conductor (intercell or intertier) or a cell / monobloc. Ripple current A type of electrical noise characterized by a uniform waveform riding in the DC circuit, normally expressed as peak, peak to peak, or RMS (Root Mean Square) voltage or current. String A number of cells connected together in series to form a battery. Table 1 ‐ Glossary of Terms 4200‐107 1‐1 Revision 1.01 Product Overview 2. Product Overview 2.1 Product Description The Universal Xplorer Industrial Monitor (UXIM) is a stationary battery monitor designed for use in Industrial or Utility applications. With standard configurations specifically designed for Utility Substations, make it ideal for NERC compliancy. Each monitor is considered a stand‐alone system, in that no external computer is required for normal operation with standard provisions to integrate to customer owned Building Management or Enterprise Systems. Complete and comprehensive remote monitoring capabilities include features you expect. Remote access via Ethernet or RS‐485 using industry standard protocols such as Modbus or SNMP for simple BMS integration. Embedded Web servers permit Web browsing from any PC on the network for quick real‐time battery viewing to inspect data in easy to interpret graphical views for all cell and string level parameters, active monitor status and state of active or latched alarms. Embedded email clients for alarm notifications and data delivery of battery parameters (XML format) with priority handling of message sent to responsible service technicians. Local USB connectivity to view and analyze battery systems using laptop computers. With the UXIM, all your battery parameters are measured and constantly monitored against user defined thresholds. And what sets Albér monitors apart from others is the ability to provide early warning of potential battery problems by performing a proactive, patented resistance test, a proven technology to reliably predict battery performance. To complement the resistance proactive test, other parameters monitored to ensure optimal battery performance and life is the following: Cell Level Measurements o Individual Cell Resistance o Individual Cell Voltage o Individual Intercell Resistance o Electrolyte Level (Optional) System Level Measurements 4200‐107 o Overall Volts o String current (Discharge/Float) o Ripple Current o Ambient Temperatures o Charger Cable Resistance o Ground Fault Currents 2‐1 Revision 1.01 Product Overview 2.2 Supported System Configurations Refer to the following table to identify supported systems. As the table shows, the monitor has the ability to monitor up to 62 cells and can be used in five different common configurations. If the desired configuration is not in the table, contact Albér for further information. Technology 2V cells, VLA/VRLA Nominal Volts Battery/String Configuration (Number of strings) x (Number of data points) x (Nominal voltage of data point) 116V 1X58X2V 118V 1X59X2V 120V 1X60X2V 122V 1X61X2V 124V 1X62X2V Table 2 ‐ Supported System Configurations The figure below shows a typical system connection for a single string of 60 cells. Figure 1 ‐ System Connections (1X60X2V Configuration) 4200‐107 2‐2 Revision 1.01 Features 3. Features All system configurations are field configurable Continual real time scanning of the following parameters: o Individual cell voltage o String discharge current o String float current o String ripple current o Ambient temperatures Automatic/ scheduled testing of internal resistance, intercell and intertier connection measurements Stores discharge events to allow playback of recorded data including cell voltages, currents and temperatures Fiber optic connectivity for BDSU system network integration Form C contact for battery parameter or hardware alarm Embedded Web server for viewing battery data via Web browsers Embedded email manager for delivery of alerts and battery data on a defined priority to service technicians. Isolated RS‐485 interface for third party vendor integration Ethernet connectivity for connection to company network Compact 1U, 19" rack mount enclosure USB connectivity for PC to allow real time data viewing and configuration Local status indicators and alarm reset Maintenance override ‐ global disable of all alarms Self calibrating Supports MODBUS (via RS‐485 & Ethernet) and SNMP (via Ethernet) protocols The system is compatible with the BDSU architecture. For a full description of features used with that system, refer to the BDSU Product Description Guide. 4200‐107 3‐1 Revision 1.01 Measurement Capabilities 4. Measurement Capabilities The UXIM has the following measurement capabilities. Cell or Monobloc Level Measurements (Max) 62 voltages, 2 volt 62 internal resistances 61 intercell resistances String Level Measurements Overall voltage (cumulative value of cell measurements) Discharge current Float current Ripple current ± Charge cable resistance Ground fault currents 4 intertier resistances System Level Measurements 2 ambient temperatures 4200‐107 4‐1 Revision 1.01 Operating Modes 5. Operating Modes Although the monitoring system excels as a maintenance tool, the real advantage is knowing the current status of the batteries at a glance or being notified via email when there is an issue. By using status lights and extensive graphics when used with the Battery Explorer software, pertinent status and alarm events are easily accessible. 5.1 Normal Operating Mode In normal operating mode, the system continuously scans all parameters within a one‐second time frame. As readings are taken, they are compared to user‐programmed alarm thresholds. Each parameter is constantly compared to the previously scanned value and, if the value exceeds an alarm threshold, the unit triggers an alarm event, causing the Form C alarm contact to activate. If Email Dispatcher is configured, a message will be sent to the first priority responder. Up to five levels of priorities and the amount of repeat messages sent to each priority responder is configurable. 5.2 Discharge Mode If a discharge is detected, the system goes into a data logging mode and stores discharge start and end times, lowest overall voltage reached, highest string current reached during the event, and all cell voltages during the discharge event. These discharge events can then be played back later for further analysis. 5.3 Acceptance/Performance Test Real time data viewing allows the user to monitor the individual cell voltage, cell temperature, overall voltage and discharge currents during a discharge. Seeing real‐time data during acceptance testing is critical in identifying faulty connections or cells. 5.4 Resistance Test A battery resistance test may be performed at user‐set intervals or on demand. The test utilizes a patented technology that can identify failing cells or monoblocs, allowing service to be performed on a proactive schedule. Additional measurements taken include intercell, intertier/inter‐row, and charger cable resistance measurements for identifying bad connections due to improper torque or corrosion at the connections. 5.5 Ground Fault Detection With Alber’s patent pending ground fault detection measures ground currents periodically throughout the entire string. Fault currents are identified and displayed graphically to identify what cell or area of the battery has a fault to highlight potential leaking cells creating shorts to ground. 5.6 Alarm Mode Every monitored parameter can have an assigned alarm threshold. When any parameter goes outside the normal range, the Alarm LED lights and a Form C contact energizes. The event can be programmed to stay latched until the alarm is reset. 4200‐107 5‐1 Revision 1.01 Operating Modes 5.7 Email Dispatcher The Email Dispatcher is a configurable embedded email service that can be set up in a couple of different modes. One is the email notification of alarms handled by a priority manager. This priority manager can have up to five emails assigned in a priority with the ability to set the amount of message reattempts and how often. The second mode is an automatic data delivery mode that will automatically send an email with the latest set of data available within the UXIM. This data is delivered in an XML format. 4200‐107 5‐2 Revision 1.01 Model Number Descriptions 6. Model Number Descriptions The model number is in the format of PPPP‐COB, where PPPP is 1010 and C, O, and B are described below. PPPP– C O B Description Choices 1010 C Communications 0 = RS‐485 Only 1 = Network 2 = Fiber Optic 3 = Network and Fiber Optic 1010 O Options 0 = None 1–9 = Reserved 1010 B Branding 0 = OEM 1–9 = Reserved Table 3 ‐ Model Number Description 4200‐107 6‐1 Revision 1.01 Model Number Descriptions 6.1 Parts List The following items are included with each order of a UXIM. Name Part Number Description Requirements UXIM Battery Monitor Module 1010‐### ###=options UXIM Battery Monitor Module. One supplied per system Sense lead harness (standard) 1102‐560‐XX Harness for monitoring internal cell voltage/internal resistance, and intercell resistance Eight supplied per system. Load lead harness (standard) 1102‐550‐XX Single Ambient temperature sensor harness 1102‐553‐XX XX=length 25’ standard XX=length 25’ standard XX=length 25’ standard 1102‐554‐XX XX=length 25’ standard Harness for connecting power and One supplied per system load module for internal resistance testing One Ambient temperature sensor used to monitor room or cabinet temperature. Optionally, a double ambient temperature sensor can be ordered. Contact your Alber Sales representative for details. One supplied per system. Double Ambient Temperature Sensor harness is (optional) USB Cable 2025‐108 3 meter USB communication cable One supplied per system Load Fuse Holder 1102‐551 Fuse holder for connecting the load fuse Seven supplied per system Load fuse 4301‐015 Fuse used in fused load lead Seven supplied per system 4 Position Connector 2140‐047 4 position plug connector for connecting digital inputs, RS‐485 communication and alarm contacts Five supplied per system Charger cable resistance harness (standard) 1102‐552‐XX Harness for monitoring charger cable resistance measurements. One supplied per system 10K Resistor Sense Lead Assembly 1102‐555 10K Resistor sense leads assembly connectors 136 supplied per system Single Tab Washer 2120‐164 5/16 single tab washer 140 tab washers are supplied per system Software CD 2027‐029 UXIM software installation CD 1 CD is supplied Flush Mounting Kit KIT 1400‐531 Optional flush mounting kit The flush mounting kit is sold separately. Contact your Alber Sales representative. XX=length 25’ standard Table 4 ‐ Standard Parts List 4200‐107 6‐2 Revision 1.01 Panel Controls and Indicators 7. Panel Controls and Indicators This section describes the front and rear panels of the UXIM. Additional descriptions may appear elsewhere in this guide or in related manuals. 7.1 Front Panel (All Models) This section describes the components on the front panel of the UXIM. Figure 2 ‐ UXIM Front Panel The UXIM front panel has the following components. The numbers in the table refer to the callout numbers in the preceding figure. Number Description Function 1 Alarm Reset Button Reset button for resetting active or latched alarms. 2 Front Panel Indicators Used for showing system alarm status and mode of operation. 3 USB Connection Allows connectivity of computers for setup, configuration, and real time data viewing. Table 5 ‐ UXIM Front Panel Component Descriptions 4200‐107 7‐1 Revision 1.01 Panel Controls and Indicators 7.2 Rear Panel This section describes the components on the rear panel of the UXIM. Figure 3 ‐ UXIM Rear Panel The UXIM rear panel has the following components. The numbers in the table refer to the callout numbers in the preceding figure. Number Description Function 1 Alarm Contact Form C alarm contact for remote parameter or hardware alarm notification. 2 RS‐485 Connection Two ports available; One used for remote communications using a MODBUS protocol and the second is used for communicating to optional accessories. 3 Digital Inputs Used for monitoring wet or dry contact inputs. 4 Ambient Temperature Inputs Ambient temperature probe connection. 5 LAN Connection Ethernet connection for network connectivity. This is optional and is only available on the 1009‐1XX or 1009‐3XX models. 6 Fiber Optic Connections Used for communication to the BDSU network. This is optional and only available on the 1009‐ 2XX or 1009‐3XX models. 7 Load Inputs Load connections for performing internal resistance measurements. 8 Charger Cable Resistance Inputs Sense lead connection for monitoring charge cable resistance. 9 Cell Voltage Inputs Sense lead connections for making voltage measurements. Table 6 ‐ UXIM Rear Panel Component Descriptions 4200‐107 7‐2 Revision 1.01 UXIM Specifications 8. UXIM Specifications 8.1 UXIM System Specifications Safety Approvals UL61010‐1 EN61010‐1 IEC61010‐1 EMC Approvals EN61326‐1 FCC part 15 class A Operating Environment Temperature Range: 0ºC to 40ºC (32ºF to 104ºF) Humidity Range: 0% to 80% RH (non‐condensing) at 5ºC to 31ºC, 0% to 50% RH (non condensing) at 31ºC to 40ºC Indoor Use Only Installation Category I Pollution Degree 2 Altitude: 0 to 2000 meters above sea level Alarms 2 ‐ Form C relay contact, 2A at 30Vdc Input Power DC Power, 95 to 145VDC, 7.5W max. Communications RS485/1 ‐ MODBUS RS‐485/2 ‐ Proprietary for optional accessories Ethernet ‐TCP/IP MODBUS, SNMP, SMTP USB Fiber optic for BDSU integration Packaging 1U chassis 17.0" W x 1.75" H x 12.00" D 4.0 lbs. Wall or 19" Rack Mount 4200‐107 8‐1 Revision 1.01 UXIM Specifications 8.2 Cell Measurements This section describes cell measurement specifications. Parameter Tolerance Cell Voltage 0 to 3V, 0.1% 2mV Internal Cell Resistance 0 to 32,000µ, 5% of reading ±2 Intercell Resistance 0 to 5000µ, 5% of reading ±5 Intertier/charge cable Resistance 0 to 5000µ, 5% of reading ±5 Cell/Monobloc Temperature 0C to 80C ±0.1C (32F to 176F) Table 7 ‐ Cell Measurement Specifications 8.3 System Measurements This section describes system measurement specifications. Parameter Tolerance Number Of Inputs String Voltage 85Vdc to 150 Vdc ± .5% Calculated String Current 0 to 2000ADC ±1% of full scale Calculated Ripple Current 0 to 250 Amperes RMS, ±5% of full scale Calculated Float Current 0 to 5000mADC, ±50mA Calculated Ambient Temperature 0C to 80C±0.1C (32F to 176F) 1 Table 8 ‐ System Measurement Specifications 4200‐107 8‐2 Revision 1.01 Index 9. Index Intertier connector 1‐1 Jar 1‐1 Load Inputs 7‐2 Load lead harness (standard) 6‐2 Measurement Capabilities 4‐1 Model Numbers 6‐1 monoblocs 2‐2 Normal Operating Mode 5‐1 Ohmic value 1‐1 Operating Environment 8‐1 Packaging 8‐1 Panel Controls 7‐1 Product Description 2‐1 Resistance Test 5‐1 Ripple current 1‐1 Ripple Current 8‐2 Safety Approvals 8‐1 String 1‐1 String Level Measurements 4‐1 String Voltage 8‐2 Supported System Configurations 2‐2 System Level Measurements 4‐1 System Measurements 8‐2 Terms 1‐1 UXIM Features 3‐1 Front Panel 7‐1 Operating Modes 5‐1 Rear Panel 7‐2 UXIM Parts List 6‐2 UXIM System Specifications 8‐1 Alarm Contact 7‐2 Alarm Mode 5‐1 Alarm Rest Button 7‐1 Alarms 8‐1 Ambient Temperature 8‐2 Ambient Temperature Input 7‐2 Battery 1‐1 Cell 1‐1 Cell Measurements 8‐2 Cell or Monobloc Level Measurements 4‐1 Cell Voltage Inputs 7‐2 Cell/Monobloc Temperature 8‐2 Communications 8‐1 Current transducer 1‐1 DC resistance measurement 1‐1 Digital Inputs 7‐2 Discharge Current 8‐2 Discharge Mode 5‐1 Discharge rate 1‐1 Discrete Reading Sense lead harness (standard) 6‐2 EMC Approvals 8‐1 Fiber Optic Connections 7‐2 Float current 1‐1 Float Current 8‐2 Front Panel Indicators 7‐1 Fused load lead 6‐2 Glossary of Terms 1‐1 Input Power 8‐1 Intercell connector 1‐1 Internal Cell Resistance 8‐2 Internal ohmic measurement 1‐1 4200‐107 9‐1 Revision 1.01