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Alber Training and Education Product Tutorial

BDS-256XL Battery Diagnostic System

Tutorial Topics

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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

Tutorial Topics
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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

How Does the BDS256XL 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 BDS256 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 RS232, USB, modem and network methods depending upon the users requirements
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Applications
UPS Power generation stations Other battery types with large cell counts

BDS-256XL System Hardware


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

CM-XL8 Controller

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 lowvoltage 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

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-XLR Resistance Test Module

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RTM-XLR Resistance 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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Configuration Examples

2 strings, 240, 2V jars

5 DCM-XL48 and 1 RTM-XLR per string


1 CT and at least 2 temperature probes per string

1 CM-XL8 Controller

String 1 5 DCM-XL48 and 1 RTM-XLR per string


1 CT and at least 2 temperature probes per string

Fiber optics for data transfer and 24VAC power supply between DCM and Controller
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String 2

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


RTM-XLR connections

DCM-XL48 L O A D RTM-XLR

DCM-XL48 sense 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 inline splice to terminate it to the sense lead harness Each cell has a voltage sense lead

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BDS-256XL Installation Examples

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BDS-256XL 3 Strings of 240 Cells

Sense lead harnesses

DCM-XL48

RTM-XLR

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 this floor 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

Wire Termination Methods

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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

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)


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Shunt

Optional Equipment
Discharge current measurement
600 Amp hall-effect CT for smaller systems

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Discharge Current CT Installation

CT

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

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

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Inter-tier and inter-rack cable assemblies

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

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Downloads User manuals Installation instructions Product literature and more Service Bulletins

Sales Assistance
Alber Sales Team
3103 N. Andrews Ave. Extension Pompano Beach , FL 33064 Phone 954-623-6660 or 800-851-4632 Email 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

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