BMS-200 Battery Monitoring System Technical Manual

Transcription

1 BMS-200 Battery Monitoring System Technical Manual Aquion Energy, Inc th Street Pittsburgh, PA AQ-OP-00014_A

2 2015 Aquion Energy, Inc. The information in this document is subject to periodic updates and changes. Upon any updates or changes to the above-described material, Aquion Energy will provide new drawings and/or associated documentation that will supersede those contained in this document. Contents are subject to change without notice. For the latest product documentation, visit or us at Warnings in This Document WARNING WARNING indicates a hazardous situation that, if not avoided, could result in death or injury. CAUTION CAUTION indicates a situation that, if not avoided, could damage equipment. AQ-OP-00014_A

3 Table of Contents 1 Introduction About This Manual Contact Information Aquion Products 1 2 Product Information Product Overview Product Specifications Communications Overview Safety, Precautions, and Warnings 3 3 Transportation and Receipt of Product Delivery Inspection Contents of Shipment and Required Accessories Hidden Damage 4 4 Installation and Configuration Site Requirements Exposure and Enclosure Dryness Ambient Temperature Hardware Installation Electrical Interfaces and Connections Set-up Instructions 7 5 Operation Display System Status Display and Reset Faults Manage and Plot System Logs Display System Logs Update Firmware Control Contactors Change Network Settings Enable or Disable Aquion Tunnel Reboot or Shut Down Perform Factory Reset 25 6 Technical Support 26 Appendix A: Glossary 27 i AQ-OP-00014_A

4 1 Introduction 1.1 About This Manual This manual provides technical information and safe practices regarding receiving, installing, operating, and servicing the Aquion Energy BMS-200 Battery Monitoring System. WARNING: Failure to follow the instructions in this document could result in fire, electric shock, and/or other injury or damage. 1.2 Contact Information Mail: Aquion Energy 32 39th Street Pittsburgh, PA Telephone: Web: Aquion Products S-Line Battery Stack: Smallest unit of Aquion s Aqueous Hybrid Ion (AHI TM ) batteries. To be monitored by a BMS-200, battery stacks must be connected to a SMI-100. M-Line Battery Module: Twelve palletized S-Line Battery Stacks pre-wired in parallel. Modules whose model number contains LS include an integrated sensing board that measures the voltage, current, and temperature of the battery system and relays that data to the BMS-200. Hereafter in this manual, module refers to the sensed, LS battery module. Stack Monitoring Interface (SMI-100): Enclosed sensing board that measures the voltage, current, and temperature of battery stacks and relays that data to the BMS-200. Battery Monitoring System (BMS-200): System that parses and processes the data from the module or SMI-100. The BMS-200 then stores the processed data for access by the site controller on request. 1 AQ-OP-00014_A

5 2 Product Information Any hard goods, weights, and dimensions described in this document are estimates and are subject to updates and changes. This includes any connectors, pin outs, or other similar materials. All specifications are preliminary and are subject to change without notice. Upon any updates or changes to the above described materials, Aquion will provide new drawings and/or associated documentation that will supersede those contained in this document. Estimated performance characteristics are based on testing by Aquion Energy. Performance may vary depending on use conditions and application. Aquion Energy makes no warranty explicit or implied with this preliminary technical information. Contents subject to change without notice. 2.1 Product Overview Aquion Energy s BMS-200 Battery Monitoring System works with systems based on either M-Line Battery Modules or on S-Line Battery Stacks connected to Aquion s SMI-100 Stack Monitoring Interface. The BMS-200 connects to as many as 16 modules or SMI-100 units and provides easy-toread, real-time performance data and status updates from connected Aquion batteries. The BMS-200 collects data from all battery module or SMI-100 units, stores the data, and relays it to the inverter or site controller. Up to 16 sensed M-Line battery modules or SMI-100 units can be daisychained together into a single system, which then connects to a master BMS-200. The BMS-200 communicates to the inverter or site controller via Modbus TCP/IP. For information on the Modbus TCP/IP communications protocol, contact Aquion Technical Support (see Section 6). Typical BMS-200 configuration 2 AQ-OP-00014_A

6 2.2 Product Specifications For more information on the BMS-200, download its Product Specification Sheet, available at See the S-Line and M-Line Technical Manual, available at for full guidance on receiving, installing, and operating Aquion battery modules and stacks. 2.3 Communications Overview Modules and SMI-100 units connect to the BMS-200 and each other using Amphenol SineCo DeviceNet cordsets (part number MN57B4BD02Mxxx). 1 The entire battery system s CANbus must be terminated with a 120-ohm CAN terminator (Amphenol part number P29319), as shown below. Aquion does not supply these parts. The BMS-200 can be controlled from either the unit s touchscreen or an online web interface: Operation Touchscreen Interface Web Interface Display System Status Yes Yes Display and Reset Faults Yes Yes Manage and Plot System Logs No Yes Display System Logs Yes Yes Update Firmware No Yes Control Contactors Yes No Change Network Settings Yes Yes Enable or Disable Aquion Tunnel Yes Yes Reboot or Shut Down Yes Yes Perform Factory Reset Yes No 2.4 Safety, Precautions, and Warnings Only qualified individuals are to install and service battery systems. The BMS-200 can communicate with up to 16 sensed M-Line battery modules or SMI-100 units. Never connect more than 16, as this may draw too much current, blow the internal BMS-200 fuse, and damage the BMS-200. Any power supply not provided by Aquion must be capable of supplying 22.9 W W of power (15 W for the BMS-200 plus 7.9 W per connected M-Line module or SMI-100). Be sure to account for losses due to cable length and wire gauge. Aquion recommends a maximum cable length of 10 meters for the power supply. The combined length of all power and CAN cables should not exceed 100 meters. Always follow local electrical codes. 1 In part numbers, xxx refers to cable length, which is determined by your installation s requirements. 3 AQ-OP-00014_A

7 3 Transportation and Receipt of Product 3.1 Delivery Inspection Immediately upon delivery, inspect all hard goods for signs of damage during transit, such as damaged enclosure or connectors, before signing for the delivery. Thoroughly document all instances of product damage on the bill of lading before accepting the shipment, and make a claim with the carrier as soon as possible. Contact Aquion immediately for further support (see Section 6). 3.2 Contents of Shipment and Required Accessories Shipments of the BMS-200 include two (2) items: 1. BMS-200 unit. 2. AC/DC power supply with cord. The AC/DC power supply converts standard IEC Vac at Hz outlet power to 24 Vdc. Installation, set-up, and operation of the BMS-200 and connected Aquion batteries involves additional parts not supplied by Aquion (see table below). They can be purchased through Amphenol distributors worldwide ( Image Part Name Optional, Recommended, Required Purpose Part Number Manufacturer Quantity per BMS-monitored system 4-pin miniboss Optional Alternate power supply connector if not using provided power supply MN47B4BC01Mxxx a Amphenol SineCo 1 DeviceNet Patch Cable Required CAN connection between BMS-200 and module or SMI-100 MN57B4BD01Mxxx Amphenol SineCo 1 16 (1 per module or SMI-100) 120-ohm Terminator Required Termination of CAN string P29319, Male Amphenol SineCo 1 RJ-45 Ethernet Connector Recommended Communication between BMS-200 and site controller and web varies varies 1 a In part numbers, xxx refers to cable length, which is determined by your installation s requirements. 3.3 Hidden Damage Within 10 days of receipt, connect the BMS-200 (see Section 4.4, steps 1 and 3) into to a power supply and confirm that it powers on and the touchscreen can be used. If the interface displays errors or does not load, request an inspection by the carrier and file a hidden damage claim. Do not delay this step. Delay may result in a loss of right of reimbursement for hidden damages. 4 AQ-OP-00014_A

8 4 Installation and Configuration The BMS-200 is designed for simple hardware installation, software updating, and logging control. 4.1 Site Requirements Environmental specifications must be followed to optimize the performance of Aquion AHI batteries Exposure and Enclosure The BMS-200 should be installed indoors or otherwise protected from the elements. Install, operate, and store the BMS-200 out of direct exposure to sunlight. Exposure to sunlight can cause material degradation and potential failure of the BMS Dryness Install the BMS-200 in a dry, clean environment only. Direct exposure of the BMS-200 to water ingress may cause shorting. The unit may be installed in humid or coastal regions with atmospheric salt Ambient Temperature The BMS-200 must be operated in temperatures between -5 C and 40 C. The BMS-200 must be stored in temperatures between -5 C and 50 C. 4.2 Hardware Installation The BMS-200 should be mounted to a wall with standard drywall anchors and screws via the two mounting holes shown at right. 4.3 Electrical Interfaces and Connections The mating connector and cable for the 24 Vdc in (connector 1 below) are part of the AC/DC power supply included with the BMS-200. The mating connectors and cables for the BMS 24 Vdc out and CANbus (connector 2) and RJ-45 Ethernet (connector 3) are not included with the BMS-200 but can be purchased through Amphenol distributors worldwide. Find your nearest authorized distributor at All dimensions in millimeters. The USB and auxiliary power connectors are used for Aquion diagnostics only. The 3.5 mm audio connector is not used. 5 AQ-OP-00014_A

9 1 24 Vdc In Function: BMS-200 unit power Part: Amphenol SineCo miniboss MN44PW02M005 Female Receptacle Pin # Name Wire Color Description 1 24V_IO_NEG Black 24 V I/O Negative 2 24V_IO_POS White 24 V I/O Positive (for driving contactors) 3 INTLK_RLY_OUT Red Interlock Relay Out (normally open) 4 RLY_RTN_OUT Green Interlock Relay Return Out Mating connector: 24 Vdc connector on the Aquionprovided AC/DC power supply Alternate mating connector: Amphenol SineCo MN47B4BC01Mxxx 4-pin miniboss 2 Vdc Out & CANbus Function: DeviceNet cable, provides power and CANbus communication Part: Amphenol SineCo DeviceNet MN54PD01M005 Female Receptacle, Internal Threads Pin # Name Wire Color Description 1 CAN_GND Bare Isolated CAN Ground 2 24V_LOGIC_POS Red 24 V Logic Positive 3 24V_LOGIC_NEG Black 24 V Logic Negative 4 CAN_H White CAN High Signal 5 CAN_L Blue CAN Low Signal Mating connector: Amphenol SineCo DeviceNet MN57B4BD01Mxxx Patch Cable Terminating connector: 120-ohm Terminator P29319, Male 3 RJ-45 Ethernet Connection Function: cloud reporting, web page interface, engineering GUI Part: RJ-45 female receptacle Mating connector: standard RJ-45 Ethernet Part not supplied by Aquion. In part numbers, xxx refers to cable length, which is determined by your installation. 6 AQ-OP-00014_A

10 4.4 Set-up Instructions CAUTION: Set up the BMS-200 as shown below before connecting together any modules or SMI-100 units. 1. Plug the 24 Vdc end of the AC/DC power supply into the 24 Vdc In (connector 1) of the BMS-200. Leave the other end of the power supply unplugged. 2. If available, connect the Modbus/TCP port (RJ- 45 Ethernet, connector 3) to the Site Controller Network and the internet. An internet connection will allow the BMS-200 to download the latest firmware update. The BMS-200 may still be set up without an internet connection. If the internet is not available, continue to next step. 3. Plug the 120 Vac end of the AC/DC power supply into a 120 Vac power outlet. The BMS-200 screen may flicker or be blank for 1 2 minutes while the unit automatically boots up. When the Setup Wizard screen appears, continue to the next step. If the Modbus/TCP port is connected to the internet: The BMS-200 will connect to a DHCP server. If the system does not detect a DHCP server, it will boot up to the static IP address (default: ). 7 AQ-OP-00014_A

11 4. Use the BMS Setup Wizard to configure the BMS-200 and address each module or SMI-100. a. Select your product type and battery model. Currently, S20-P is the only battery model available for use with the BMS-200. Click Next. b. Select your inverter type. Click Next. c. Select your system s size and layout. If you selected a named type of inverter: Select the total number of modules or stacks (not SMI-100 units) to be connected to the BMS-200. Click Next. -OR- If you selected Other for inverter type: Select the total number of modules or stacks (not SMI-100 units) to be connected to the BMS-200. Select your system configuration. Click Next. 8 AQ-OP-00014_A

12 d. The Setup Wizard will install the BMS-200 firmware (see below). When complete, click Next. If the BMS-200 is connected to the internet, the Setup Wizard will download the newest firmware and install it. -OR- If the BMS-200 is not connected to the internet, the Setup Wizard will install the firmware version saved in the BMS unit. e. Using a DeviceNet Patch Cable, connect the CAN Out of the BMS-200 to the CAN In of the first module or SMI-100. Insert the CAN Terminator into the CAN Out of the same module or SMI-100. f. In the Setup Wizard, click Begin. When the Setup Wizard has addressed the first module or SMI-100, go to the next step. If your system has only one module or SMI-100: Click Finished. The set-up will complete, and the system will reboot to the Home screen. Ignore the remaining set-up steps. g. Remove the CAN Terminator from the CAN Out of the first module or SMI-100 and insert it into the CAN Out of the next module or SMI AQ-OP-00014_A

13 h. Using a DeviceNet Patch Cable, connect the CAN Out of the first module or SMI-100 to the CAN In of the next module or SMI-100. i. In the Setup Wizard, click Next. When the Setup Wizard has addressed the next module or SMI-100, go to the next step. If you want to restart the addressing phase: Disconnect all CAN connections between modules or SMI-100 units. Remove the CAN Terminator. Click Restart Addressing, and go to step 4e. j. Repeat steps 4g through 4i until all modules or SMI-100 units are connected and the Setup Wizard has addressed the last one. Leave the CAN Terminator inserted in the CAN Out of the last module or SMI-100. k. In the Setup Wizard, click Finished. The system will reboot to the Home screen. 10 AQ-OP-00014_A

14 5 Operation The BMS-200 can be operated through the integrated touchscreen interface or through the web interface. To use the web interface, the Modbus/TCP port of the BMS-200 must be connected to the internet, and the IP address must be configured for the network. 5.1 Display System Status Key values for the system are displayed in real time and updated at 1 Hz. (See table on page 12 for definitions.) These values will change based on state of charge. Touchscreen 1. Press the Home button. The Home screen displays the voltage, SOC, current, and power. The system s fault status, either Active or Faults, is indicated at the bottom of the screen. 2. Press the Statistics button. The Statistics screen displays the IMD/IMR, PMD/PMR, VMD/VMR, temperature, input energy, and output energy (see next page for definitions), as well as the system s fault status. 11 AQ-OP-00014_A

15 Web 1. Click the Status button. The Status screen displays all of the system s key values. Value Definition Unit Charging kwh Energy that has been put into battery since commissioning. kilowatt hours Discharging kwh Energy that has been taken out of the battery since commissioning. kilowatt hours State of Charge (SOC) Present amount of energy stored in the battery as a percentage of battery total capacity (0%-100%) percentage Battery Voltage Voltage output from the battery volts System Current Current input to the battery amperes System Power Power output from the battery kilowatts IMD/IMR Maximum discharge (IMD) and charge (IMR) currents amperes PMD/PMR Maximum discharge (PMD) and charge (PMR) power kilowatts VMD/VMR Maximum discharge (VMD) and charge (VMR) voltage volts System Temperature Ambient temperature around the battery system degrees Celsius 12 AQ-OP-00014_A

16 5.2 Display and Reset Faults The Faults screen displays present system faults or warnings, coded by color: + Fault - Red + Warning - Yellow + Normal function - Green Fault indicators will latch closed and can be reset to normal only by using the Reset Faults button. Warnings will not latch and will automatically reset once the value returns to normal. Touchscreen 1. Press the Faults button. The Faults screen displays the status for all monitored system faults. 2. To reset all system faults, press the Reset Faults button. Web 1. Click the Faults button. The Faults screen displays the status for all monitored system faults. 2. To reset all system faults, click the Reset Faults button. 13 AQ-OP-00014_A

17 5.3 Manage and Plot System Logs Log files recorded on the BMS-200 report the operations that the BMS-200 has performed. The log files are used for diagnostic purposes. Touchscreen Operation not available. Web 1. Click the Logging Control button. The Logging Control screen allows the user to create CSV and binary logs of system performance. The CSV logs (.csv files) use comma-separated variables that can be easily read by spreadsheet applications such as Microsoft Excel. The binary logs (.txt files) are compressed, high-resolution files containing more detailed information on system performance. a. To view CSV data logging status, set the CSV log name stub, set the CSV sampling interval, and start or stop CSV data logging, use the CSV Logging section of the Logging Control screen. b. To view binary data logging status, set the binary log name stub, set the binary sampling interval, and start or stop binary data logging, use the Data Logging section of the Logging Control screen. 14 AQ-OP-00014_A

18 5.4 Display System Logs Touchscreen 1. Press the Console button. The System Console screen displays the recorded log of all operations the BMS-200 has performed, as well as the fault status of the system. Web 1. Click the View Logs button. The View Logs screen displays all the log files recorded on the BMS-200. Past records can also be selected and plotted. a. The Console Log section displays the most recent set of logged operations. To refresh the list, click the Refresh button. You can also download the full console log as a.txt file. 15 AQ-OP-00014_A

19 b. The Log Files section lists the CSV (.csv) and binary (.txt) log files recorded on the BMS-200. Click the links to download the CSV files (plot, filtered Microsoft Excel comma-separated values, gzip, or.csv formats) or binary files (gzip or.txt formats). Example plot of CSV data c. The Cloud Log Files section shows the log files to be uploaded to the Aquion cloud. BMS-200 units connected to the internet will automatically upload stored files to the Aquion cloud and delete them from the BMS-200 memory. 16 AQ-OP-00014_A

20 5.5 Update Firmware CAUTION: Do not upload new firmware if the contactors are closed, as doing so will reboot the system, open the contactors, and suddenly stop battery charging or discharging. Touchscreen Operation not available. Web 1. Click the Firmware button. The Firmware screen allows the user to upload the latest required firmware updates to the BMS-200. If the BMS-200 is connected to the internet: a. Click Check for Update to automatically find and download the most recent version of the BMS-200 firmware. If an update is found, the system will download it automatically. b. Once the download is complete, click Upload Firmware to automatically install the new firmware. The system will then reboot. -OR- If the BMS-200 is not connected to the internet: a. Contact Aquion and request a copy of the updated firmware. b. When you receive the file, save it to your local system. c. In the Upload New Firmware section, click Choose File. Navigate to your locally saved firmware file and select it. d. Click Upload Firmware to automatically install the new firmware. The system will then reboot. 17 AQ-OP-00014_A

21 5.6 Control Contactors CAUTION: Opening the contactors will suddenly stop battery charging or discharging. Touchscreen 1. Press the Control button. The Control screen displays the current status of the contactors, the options to close or open them, log management storage device, and the fault status of the system. 2. To close open contactors, press the Close button. You will be asked to confirm your choice. 3. To open closed contactors, press the Open button. You will be asked to confirm your choice. Web Operation not available. 18 AQ-OP-00014_A

22 5.7 Change Network Settings CAUTION: Changing network settings will force the system to reboot, open the contactors, and suddenly stop battery charging or discharging. Touchscreen 1. Press the System button. The System screen displays system performance, system settings, and system fault status. 2. Change the system s static IP address. a. Press the button displaying the address. c. Change the static IP address or netmask. 19 AQ-OP-00014_A

23 Web 1. Click the System button. The System screen allows the user manage system network and tunneling settings, as well as reboot or shut down the system. 2. In the Network Settings section, change the static IP address or netmask. Click Update. 20 AQ-OP-00014_A

24 5.8 Enable or Disable Aquion Tunnel The Aquion tunnel allows Aquion system engineers to remotely log into the BMS-200 and diagnose and troubleshoot problems. The tunnel is disabled by default. For security, Aquion recommends disabling the Aquion tunnel when not needed. CAUTION: Disabling the Aquion tunnel will force the system to reboot, open the contactors, and suddenly stop battery charging or discharging. Touchscreen 1. Press the System button. The System screen displays system performance, system settings, and system fault status. 2. Press the button displaying the tunnel status. The button toggles the Aquion tunnel on (enabled) or off (disabled). 3. Confirm your choice. 21 AQ-OP-00014_A

25 Web 1. Click the System button. The System screen allows the user to manage system network and tunneling settings, as well as reboot or shut down the system. 2. In the Aquion Tunnel section, click the button to either enable or disable the Aquion tunnel. The button toggles the Aquion tunnel on (enabled) or off (disabled). 22 AQ-OP-00014_A

26 5.9 Reboot or Shut Down To prevent file system corruption, always use this option to shut down or restart the BMS-200. Power loss while the BMS-200 is running can corrupt the file system. CAUTION: Rebooting or shutting down the BMS-200 will open the contactors and suddenly stop battery charging or discharging. Touchscreen 1. Press the System button. The System screen displays system performance, system settings, and system fault status. 2. Press the Reboot or Shut Down button. Rebooting will open the contactors, power down the system, and restart it. Shutting down will open the contactors and power down the system. 3. Confirm your choice. 23 AQ-OP-00014_A

27 Web 1. Click the System button. The System screen allows the user to manage system network and tunneling settings, as well as reboot or shut down the system. 2. In the Reboot BMS or Shutdown BMS section, click the appropriate button. 24 AQ-OP-00014_A

28 5.10 Perform Factory Reset A factory reset opens the contactors and reboots the system to the factory settings. All system setup parameters will be erased. To use the BMS-200 again, disconnect all CAN connections from the modules or SMI-100 units and run the BMS-200 Setup Wizard from the beginning (see Section 4.4). Touchscreen 1. Press the System button. The System screen displays system performance, system settings, and system fault status. 2. Press the Factory Reset button. 3. Confirm your choice. Web Operation not available. 25 AQ-OP-00014_A

29 6 Technical Support If you need technical support, visit us on our website at If you purchased your products from an authorized Aquion Energy dealer, please contact the dealer for assistance. If you require immediate assistance AND if you purchased your products directly from Aquion Energy, call our support line at Please have your Aquion Energy order number ready. 26 AQ-OP-00014_A

30 Appendix A: Glossary A Ah Battery Monitoring System (BMS) CAN port CSV logging I IMD/IMR kw kwh Modbus/TCP port PMD/PMR S ampere amp-hour System that parses and processes the data from the battery module or SMI-100. The BMS-200 then stores the processed data for access by the site controller on request. Port used for communications between the BMS-200 and the battery module or SMI-100. Data logging stored as comma-separated variables (CSV) in a.csv file that can be easily read by spreadsheet applications. current Maximum discharge (IMD) and charge (IMR) currents (A). kilowatt kilowatt-hour Port used for communications between the BMS-200 and site controller. Maximum discharge (PMD) and charge (PMR) power (kw). system temperature sensing board Board that measures the voltage, current, and temperature of a battery module (built into the M-Line sensed modules) or stack (via the SMI-100) and relays that data to the BMS-200. state of charge (SOC) V VMD/VMR Present amount of energy stored in the battery as a percentage of battery total capacity (0%-100%). volts Maximum discharge (VMD) and charge (VMR) voltage (V). 27 AQ-OP-00014_A