Manual de Operacion CellSure Ingles

CellSure
Installation Guide

Issue: IPN 997-00012-20F
Issue Date: July 2009

Eaton Corporation
Telecommunications Power Solutions
www.Eaton.com/telecompower
DCinfo@Eaton.com

Eaton Corporation disclaims any liability for direct, indirect, incidental, special or consequential damages arising
out of the application or use of any information contained in this document. The foregoing disclaimer applies to
damages or personal injury, property damage, loss of operation, loss of profits, loss of product or loss of time,
whether incurred by the purchaser, the purchasers employees or third party.
Information in this document does not constitute a warranty, representation or guarantee concerning the
suitability or performance of Eaton products. No such warranty, representation or guarantee is expressed or
implied.
Information contained in this document is subject to change without further notice.
Subject to the right to use its equipment, Eaton Corporation does not convey any right, title or interest in its
intellectual property, including, without limitation, its patents, copyrights and know-how.
No part of this document may be reproduced or transmitted in any form, by any means or for any purpose other
than the Purchasers personal use, without the express written permission of Eaton Corporation.
Eaton
, Powerware
, Intergy
TM
, CellSure
TM
, SiteSure
TM
, PowerManagerII
TM
and DCTools
TM
are trade names,
trademarks, and/or service marks of Eaton Corporation or its subsidiaries and affiliates. Unless otherwise noted,
brands, product names, trademarks or registered trademarks are the property of their respective holders.
Copyright 2001-2009 Eaton Corporation. All Rights Reserved.

About This Guide

Copyright 2001- 2009 Eaton Corporation. All Rights Reserved.
IPN 997-00012-20F J uly 2009
i

About This Guide
Required Software
The Eaton DCTools configuration software is required to install and operate CellSure battery
management systems.
DCTools can be downloaded free from www.powerquality.eaton.com/downloads. It is not
supplied with CellSure systems.

Scope
This guide covers the installation, configuration, operation and maintenance of CellSure
battery management systems with Eaton SC200 system controller, SM45/SM65 supervisory
modules, or in stand-alone mode.

This guide does not cover:
Installation and configuration of other Eaton products. For details, refer to the relevant
guide listed under Related Information on page ii.
Detailed instructions for setting up DCTools/PowerManagerII, except for the
DCTools/PowerManagerII communications settings.
Installation, commissioning and maintenance of batteries. Always consult the battery
manufacturer's relevant instruction manual before installing or servicing the batteries.
Installation of CellSure battery management systems with Eaton SM50 supervisory
modules. For full details see Worldwide Support on page 101.

Audience
This guide is intended for use by:
Installers competent in:
installing and commissioning dc power systems
safe working practices for dc powered equipment
the relevant local electrical safety regulations and wiring standards
Operators and maintenance staff competent in:
operation of dc power systems
safe working practices for dc powered equipment

CellSure Installation Guide

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IPN 997-00012-20F J uly 2009

Related Information
DCTools Online Help (DCTools is available for free download from:
www.powerquality.eaton.com/downloads)
PowerManagerII Online Help
SiteSure Installation and Configuration Guide IPN 997-00012-19
SM65 Supervisory Module Handbook - IPN 997-00012-35
SM60 Supervisory Module Handbook - IPN 997-00012-27
Access Power Solutions Installation Guide (SM40 Versions) - IPN 997-00012-37
Access Power Solutions Installation Guide (SM45 Versions) - IPN 997-00012-38
SC200 System Controller Operation Handbook - IPN 997-00012-50

Reporting Problems with this Guide
Please use this email address to report any problems you find in this guide:

Eaton DC Product Marketing Communications
EMAIL: DCMarketingNZ@Eaton.com

For Further Information and Technical Assistance
For further information and technical assistance see Worldwide Support on page 101.

Table of Contents

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Table of Contents

About This Guide
Required Software.....................................................................................................................i
Scope............................................................................................................................................i
Audience.....................................................................................................................................i
Related Information..................................................................................................................ii
Reporting Problems with this Guide .....................................................................................ii
For Further Information and Technical Assistance..............................................................ii
Chapter 1 General Description
Overview.................................................................................................................................... 1
CellSure Battery Controller (CBC).......................................................................................... 2
2V Battery System Modules .................................................................................................... 3
6V/12V Battery System Modules ........................................................................................... 4
Ambient Temperature Sensor ................................................................................................. 5
Current Shunts .......................................................................................................................... 5
Current Sensor (CS04-A11)...................................................................................................... 6
Auxiliary Power Module (APM) ............................................................................................ 7
Chapter 2 Preparation
Overview.................................................................................................................................... 9
Warnings.................................................................................................................................. 10
Inspecting the Equipment and Reporting Damage............................................................ 11
Battery System Types............................................................................................................. 11
Location and Environment.................................................................................................... 11
Chapter 3 Current Shunts/Sensors
Overview.................................................................................................................................. 13
Mounting Current Shunts ..................................................................................................... 14
Mounting CS04-A11 Current Sensors.................................................................................. 14
Chapter 4 2V System Installation
Overview.................................................................................................................................. 19
Task 1 - Mounting the Q.C. Tabs .......................................................................................... 20
Task 2 - Mounting the CBC and APM Modules................................................................. 21
Task 3 - Mounting the C2M-TS and C2M Modules ........................................................... 21
Task 4 - Mounting the Ambient Temperature Sensor ....................................................... 22
Task 5 - Numbering the Monoblocs..................................................................................... 22
Task 6 - Installing the Interconnecting Wiring ................................................................... 23
Single String Battery Systems.......................................................................................................24
Two String Battery Systems..........................................................................................................25
Three String Battery Systems........................................................................................................26
Four String Battery Systems .........................................................................................................27
Task 7 - Installing the Urgent and Non-urgent Alarm Relay Cabling ............................ 28
Task 8 - Powering the CBC.................................................................................................... 29
Powering the CBC from the system dc bus ................................................................................29
Powering the CBC from the SM65 RCP bus...............................................................................30

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Chapter 5 6V/12V System Installation
Overview.................................................................................................................................. 31
Task 1- Mounting the Q.C. Tabs ........................................................................................... 32
Task 2 - Mounting the C6M/C12M, CBC and APM Modules ......................................... 32
Task 3 - Mounting the TS8CM and SP8CM Modules........................................................ 33
Task 4 - Mounting the Ambient Temperature Sensor ....................................................... 34
Task 5 - Numbering the Monoblocs..................................................................................... 34
Task 6 - Installing the Interconnecting Wiring ................................................................... 35
48V Battery Systems consisting of 6V Monoblocs and 1 to 2 Strings ......................................36
48V Battery Systems consisting of 12V Monoblocs and 1 to 4 Strings ....................................38
24V Battery Systems consisting of 12V Monoblocs and 1 to 4 Strings ....................................40
Task 7 - Installing the Urgent and Non-urgent Alarm Relay Cabling ............................ 42
Task 8 - Powering the C6M/C12M Sensor Modules ......................................................... 43
Task 9 - Powering the CBC.................................................................................................... 43
Powering the CBC from the system dc bus ................................................................................44
Powering the CBC from the SM65 RCP bus...............................................................................44
Chapter 6 Commissioning
Overview.................................................................................................................................. 45
Task 1 - Connecting a PC to the CBC................................................................................... 46
General Notes on Editing the CellSure Configuration..............................................................47
General Notes on Using DCTools................................................................................................47
Task 2 - Configure the Hardware and Battery Settings..................................................... 48
Task 3 - Check Monobloc Numbering................................................................................. 49
Task 4 - Check Temperature Sensors ................................................................................... 50
Task 5 - Calibrate Current Shunts/Sensors......................................................................... 52
Task 6 - Characterize the Batteries ....................................................................................... 55
Task 7 - Using the Characterization Data............................................................................ 62
Task 8 - Configure the CellSure System for Operation ..................................................... 64
Task 9 - Repeat for Other CBCs (if required) ...................................................................... 67
Task 10 - Setup External Communications ......................................................................... 67
Stand-alone Mode..........................................................................................................................67
SC200 Serial Server Mode.............................................................................................................70
Passthrough Communications (with SM45/SM65 only)..........................................................72
Chapter 7 Troubleshooting
CBC Status Indication ............................................................................................................ 78
Troubleshooting...................................................................................................................... 78
Appendix A Specifications
Auxiliary Power Module (APM)..................................................................................................81
Appendix B Alarm Details
Appendix C RS485 Bus Power Limits
RS485 Bus Design Method..................................................................................................... 89
RS485 Bus Power Limits (Cat 5 cable).................................................................................. 90
RS485 Bus Power Limits with Other Cable Types ............................................................. 91
Appendix D Data Management
Copy string data.............................................................................................................................93
Copy data from another CBC.......................................................................................................95
Equipment Incident Report
Worldwide Support
Index

Chapter 1
General Description

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C h a p t e r 1
General Description
Overview

Topic Page
CellSure Battery Controller (CBC) 2
2V Battery System Modules 3
6V/12V Battery System Modules 4
Ambient Temperature Sensor 5
Current Shunts 5
Current Sensor (CS04-A11) 6
Auxiliary Power Module (APM) 7


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CellSure Battery Controller (CBC)
The CBC provides the monitoring and control functions for a CellSure battery system. The
CBC is fully configurable for complete operational flexibility. All battery system parameters
are stored in a software configuration file.
Alarms can be mapped to the urgent and non-urgent alarm relays which can be used to
activate an external fault indication device (such as a warning light or audible alarm).
The CBC communicates via a standard RS232 or RS485 serial interface. The standard
communication options are:
Standalone Mode:
RS232 direct to a PC
RS232 to a remote PC (via an Ethernet interface or modem)
Direct connection to an RS485 network.
SC200 Serial Server Mode:
To a local or remote PC through an Eaton SC200 system controller.
Passthrough Mode:
To a local or remote PC through an Eaton SM45 or SM65 supervisory module.
For more information see Setup External Communications on page 67.

Urgent and Non-Urgent alarm relay outputs (XB9)

String communications ports (XB8)

Ambient temperature sensor input (XB5)

Current shunt / sensor inputs (XB6 and XB7)

Bus reference input (XB3)

RS485 communications ports (XB1 and XB2)

RS232 serial communications port (XB4)

Controller OK and communications activity LED
(green)
W
Four String Alarm LEDs (Red)

For details of LED operation see CBC Status Indication on page 78.

General Description

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2V Battery System Modules
The C2M and C2M-TS sensor modules are used with battery strings consisting of 2V cells.
Each module measure a single 2V cell voltage.
The COMMS IN and COMMS OUT ports are used to daisy chain up to 50 sensor modules.
C2M-TS sensor modules are identical to C2M sensor modules apart from a temperature
sensor input. The black TSCM temperature sensor forms an integral part of the C2M-TS
sensor module as shown in the following diagram.
CellSure systems require one C2M-TS sensor module per battery string.

C2M

C2M-TS

Communications input port (COMMS IN)

Communications output port (COMMS OUT)

Cell voltage sense input (on C2M-TS the
negative lead connects to the temperature
sensor)

Negative cell voltage sense output (no short-
circuit protection included)

Nonpolar string temperature sense outputs

Positive cell voltage and string temperature
sense input


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6V/12V Battery System Modules
6V/12V Sensor Modules (C6M/C12M)
C6M (for 6V monoblocs) and C12M (for 12V monoblocs) sensor modules measure up to eight
monobloc voltages and accept up to four string temperature signals.

Voltage inputs V1 to V4 and
temperature inputs T1 and T2
(XB22)

Power input (XB21)

Sensor module OK LED (Green)

String communications port (XB20)

Voltage inputs V5 to V8 and
temperature inputs T3 and T4
(XB23)

Short-Circuit Protection Module (SP8CM)
SP8CM modules are used on battery strings of 6V and 12V monoblocs.
SP8CM modules protect the monobloc voltage sense cabling against excessive current flow
during short-circuit conditions. The short-circuit protection device inside the SP8CM
automatically resets after removal of the fault condition.

Monobloc voltage sense output (short-circuit protected)

Monobloc voltage sense input

General Description

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6V/12V String Temperature Sensor (TS8CM)
The TS8CM temperature sensor combines temperature sensing and short-circuit protection in
one single module. Short-circuit protection is identical to the SP8CM. The TS8CM
temperature sensor measures the ambient temperature of one 6V or 12V monobloc in a
battery string.
CellSure requires one TS8CM temperature sensor per battery string of 6V or 12V monoblocs.

Monobloc voltage sense output (short-circuit protected)

Non-polar string temperature sense outputs

Monobloc voltage and string temperature sense input

Ambient Temperature Sensor
A CellSure battery monitoring system includes one TS2-A01 ambient temperature sensor
with 8m (26') of cable.
The TS2-A01 measures the ambient temperature of the battery.

Current Shunts
Resistive current shunts are available for measuring battery string current.
The maximum current ratings are:
CS600: 600A
CS02: 500A
CS300: 300A
CS03: 150A

The current shunts develop a current sense signal of 50mV at maximum rated current.
The current shunts are factory-calibrated for easy set-up, and should not require re-calibration
under normal conditions of use. However, if you observe significant measurement inaccuracies,
use the calibration potentiometer to re-calibrate the current shunt.


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The two RJ45 sockets are used to daisy chain current shunts. Each current shunt is supplied
with an 8m (26') long RJ45 cable. Mounting screws are not included.

CS600 CS02 CS300 CS03

RJ 45 input (XU2 - connection to other
shunts, if required)

Calibration potentiometer

RJ 45 current sense signal output (XU1)

Current Sensor (CS04-A11)
The CS04-A11 is a current transducer used for measuring current in a wide range of copper
and aluminum bus bar sizes. The CS04-A11 current sensor mounts directly onto a bus bar.
Because of the many different bus bar sizes in use, CS04-A11 current sensors are not factory
calibrated. Gain adjustment is by means of a jumper (located on the back of the sensor PCB)
and an external trim potentiometer. The maximum output signal amplitude of a CS04-A11
current sensor is 60mV.
Each CS04-A11 is supplied complete with mounting screws and an 8m (26feet) long RJ45
cable.
An optional CS04 Current Sensor Extension PCB is available for measuring current in very
large bus bars.

Extension PCB (optional)

Current sensor pickup contacts

Input inductor

Gain adjustment potentiometer

RJ 45 current sense signal output
(XU1)

RJ 45 input (XU2 - connection to other
CS04, if required)

General Description

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Auxiliary Power Module (APM)
The APM is a DIN-rail mounted twin output multi-purpose dc power supply used to:
Power the CBC module.
Except, an APM may not be required if the CBC is connected to an SM65 supervisory
module. See Powering the CBC (2V cells) on page 29 or Powering the CBC (6V/12V
monoblocs) on page 43.
Power auxiliary equipment such as modems, transducers and other user equipment.

The APM has a non-polar input voltage range of 18 to 60V dc. The twin outputs (9V and 12V)
are unregulated and isolated from each other. Both outputs feature overload protection with
automatic reset after removal of the overload condition.
A green status LED indicates Power On.
For comprehensive details see Specifications on page 81.

Power supply input (XE3)

RS485 serial comms output port (XE2) includes
9V output

RS485 serial comms input port (XE1)

12V output (XE4): three pairs of output terminals


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Chapter 2
Preparation

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C h a p t e r 2
Preparation
Overview

Topic Page
Warnings 10
Inspecting the Equipment and Reporting Damage 11
Battery System Types 11
Location and Environment 11


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Warnings

^
Batteries
The plastic cases of batteries installed in Eaton dc power system racks must have a
flammability rating of UL 94-V2 or better.
Flooded cell and VRLA lead acid batteries can emit explosive gases and must be installed with
adequate ventilation. Refer to the battery manufacturer or supplier for advice on minimum
ventilation levels.
Do not wear a synthetic dust-coat or overalls. Synthetic fabrics can hold static electric charges
that create sparks during discharge.
Remove rings, wristwatch and other metal jewelry that might be exposed to battery terminals,
before installing batteries.
Batteries are powerful sources of energy and present a potential electrical shock and energy
hazard. The energy hazard is always present, even if the batteries are not connected. Avoid
short circuiting terminals of opposite polarity.
Always use insulated tools.
Do not place tools, loose cables or metal objects (such as interconnecting bars) on top of
batteries.
Do not drop tools, loose cables or metal objects onto intercell connections or terminals of
opposite polarity.
Only terminate cables and interconnecting bars after confirming that the termination will not
create a short circuit.
Always tighten battery terminal bolts according to the battery manufacturers specification.
Failing to do so can cause erratic battery performance, possible damage to the battery, and/or
personal injury.
There is a risk of electric shock if a battery is replaced by an incorrect type.
Dispose of batteries according to the instructions.

^
EMC Compliance
This Eaton product ("the equipment") has been tested and found to comply with the limits for a
Class B digital device, pursuant to part 15 of the Federal Communications Commission (FCC)
Rules. These limits are designed to provide reasonable protection against harmful interference
in a residential installation.
The equipment generates, uses, and can radiate radio frequency energy and, if not installed and
used in accordance with the instructions in this installation guide, may cause harmful
interference to radio communications. However, there is no guarantee that the interference will
not occur in a particular installation.
If the equipment does cause harmful interference to radio or television reception, which can be
determined by turning the equipment off and on, the user is encouraged to try to correct the
interference by one or more of the following measures:
Reorient or relocate the receiving antenna.
Increase the separation between the equipment and receiver.
Connect the equipment into an outlet on a circuit different from that to which the receiver
is connected.
Consult the dealer or an experienced radio/TV technician for help.
Changes or modifications to the equipment not approved by Eaton Corporation could void the
FCC authority to operate the equipment.
Preparation

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11

^
Maximum Cable Lengths
EMC compliance is conditional on limiting the maximum length of the interconnecting cables
connected to the following ports:
CBC port XB4 (RS232) < 3m (9.8 feet)
CBC ports XB5, XB6 and XB7 < 10m (32.8 feet)
C6M/C12M ports XB20, XB22 and XB23 < 10m (32.8 feet)

Inspecting the Equipment and Reporting Damage
Unpack the equipment and inspect it carefully for possible damage that may have occurred
while in transit. Do not use any damaged equipment.
Report any damage immediately, using a completed Equipment Incident Report on page 98.
Keep the original packaging to use if any item needs to be returned for replacement or repair.

Battery System Types
CellSure provides real-time monitoring and fault prediction for both 24V and 48V battery
systems.
A single CellSure battery controller module can monitor up to four battery strings. Battery
strings can consist of 2V cells, 6V monoblocs or 12V monoblocs.
CellSure is not suitable for UPS or nickel-cadmium battery systems.

Location and Environment
CellSure is for use with 24V or 48V battery systems in telecommunication and other
applications.
CBC, APM, C6M and C12M modules must not be mounted in a location accessible to
operators. To maintain compliance with the applicable EMC and Safety standards, CBC,
APM, C6M and C12M modules can be mounted:
Inside an enclosed 19-inch cabinet
Inside a wall mounted enclosure

CellSure may be used in close proximity to other electronic equipment, provided the
installation is performed according to the instructions in this guide. However, CellSure may
still cause interference to other equipment or show performance degradation in the presence
of EM disturbances. In some cases, corrective action may be required. If you experience any
problems contact Eaton for advice. See Worldwide Support on page 101.
Always operate the CellSure modules within their rated ambient temperature range of
-10C to +70C (14F to 158F).
The CellSure algorithms provide accurate results within their rated ambient temperature
range of +10C to +40C (50F to 104F). Outside that range, the results may be less
accurate.


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Chapter 3
Current Shunts/Sensors

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C h a p t e r 3
Overview
Topic Page
Mounting Current Shunts 14
Mounting CS04-A11 Current Sensors 14


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Mounting Current Shunts
If CS04-A11 current sensors are used then go to Mounting CS04-A11 Current Sensors on page
14.
Mount one current shunt per battery string on the common bus.
The recommended torque setting for tightening the M10 termination bolts is 18.7 - 21.9Nm
(166 - 194 inch-pounds).
Ensure correct orientation (see following diagram) of the current shunts before tightening the
termination bolts.

Common bar

To battery strings

Mounting CS04-A11 Current Sensors
If current sensors are used then go to Mounting Current Shunts on page 14.
Using the CS04 Current Sensor Extension PCB
The CS04 current sensor extension PCB increases the distance between the two pickup points
of the CS04-A11 current sensor. Use the CS04 current sensor extension PCB if:
measuring current flow in very large bus bars, or
the required gain of the current sensor is greater than 40.

Current Sensor Preparation
Step 1 Calculate the required gain of the CS04 current sensor

Gain = - Constant x (CSA / IMAX)
Where: CSA = Cross sectional area of the bus bar (mm)
IMAX = Maximum expected current through the bus bar (A)
Constant = 68.24V.W
-1
.mm-
2
(for copper bus bars)

= 43.57V.W
-1.
mm-
2
(for aluminum bus bars)


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Step 2 Determine the need for a CS04 current sensor extension PCB

If the required gain of the current sensor is greater than 40, then calculate the new
required gain of the current sensor as follows:
Gain = - Constant x (CSA / IMAX) x (51/150)
And use the CS04 current sensor extension PCB.

Step 3 Resistance measurement

Measure the resistance of
the inductor located at the
back of the CS04 current
sensor PCB as shown.

Step 4 Set the gain range of the CS04 current sensor

The gain range of the CS04 current sensor depends on:
The required gain, as calculated in step 1 or step 2
The resistance value of the input inductor, as measured in step 3
1 Select the required gain range and jumper configuration for the CS04 current
sensor from the following table.
2 Connect the jumper(s) according to the selected jumper configuration.


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Gain Range for input inductor resistance values of
90W 110W 120W
Jumper Configuration
16 21 13 18 12 16

19 29 16 24 15 22

27 52 22 42 20 39

38 132 31 108 29 99

40 160 33 130 30 120

The jumper connection points are located on the back of the CS04-A11 current sensor PCB.
To obtain the required jumper configuration, you might have to break the track between
connection points 1 and 3 and solder additional jumpers between connection points.

Step 5 Apply heat sink compound as shown

Input inductor

Heat sink compound to ensure good thermal
contact between the input inductor and the busbar.
Procedure complete

Mounting the CS04-A11
The CS04-A11 is supplied with M3x35mm screws to attach the CS04-A11 current sensor to a
bus bar.
This section covers the following mounting options:
Through-hole mounting
Threaded-hole mounting


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Step 1 CS04-A11 placement and orientation

CS04-A11 current sensors must always be mounted onto the Common bus bar. (See
following diagram.)
Wherever possible, do not mount the CS04-A11 current sensor closer than 150mm
(6") from:
A bus bar joint
Termination bolts
Bolts joining laminated bus bars
Ensure correct orientation of the CS04-A11 current sensor before drilling the
mounting holes into the bus bar. (See following diagram.)

Common bus

To battery

To rectifiers

Step 2 Drill the mounting holes

Drill two mounting holes according to the template below and tap if the threaded-
hole mounting option is used.

Through-hole Threaded-hole
Drill size M3.5 M2.5
Thread size and
pitch
- M3 x 0.5 ISO
Coarse


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Step 3A Mounting a CS04-A11 through-hole mounting option

Mount the CS04-A11 current sensor as shown in the following diagrams.
Ensure correct orientation of the CS04-A11 (see Step 1 for details).

Without Extension PCB With Extension PCB

Step 3B Mounting a CS04-A11 threaded-hole mounting option

Mount the CS04-A11 current sensor as shown in the following diagrams.
Ensure correct orientation of the CS04-A11 (see Step 1 for details).

Without Extension PCB With Extension PCB

Procedure complete

Chapter 4
2V System Installation

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C h a p t e r 4
2V SystemInstallation
Overview

Topic Page
Task 1 - Mounting the Q.C. Tabs 20
Task 2 - Mounting the CBC and APM Modules 21
Task 3 - Mounting the C2M-TS and C2M Modules 21
Task 4 - Mounting the Ambient Temperature Sensor 22
Task 5 - Numbering the Monoblocs 22
Task 6 - Installing the Interconnecting Wiring 23
Task 7 - Installing the Urgent and Non-urgent Alarm Relay Cabling 28
Task 8 - Powering the CBC 29


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See instructions on page 32 for installation of 6V/12V battery system modules.

Task 1 - Mounting the Q.C. Tabs
Step 1 - Mount Q.C. tabs

^
Always tighten battery terminal bolts according to the battery manufacturers
specification. Failing to do so can cause erratic battery performance, possible
damage to the battery or personal injury.

Mount a Q.C. tab onto
each battery terminal
Step 2 Ensure that equalizing bars are fitted

Equalizing bars must be fitted as shown in the example below, to allow accurate
monobloc voltage measurement.

Inter-cell bars

Equalizing bars
Procedure complete


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Task 2 - Mounting the CBC and APM Modules
CellSure modules mount on standard DIN rail.

Place the lower clip of the module under
the bottom of the rail.

Move in top of the module until it clicks into
position on the rail.

To remove, push module up and pull top
forwards away from rail.
It is recommended that the modules are mounted in their numbered sequence and in a
location that is not accessible to operators.

Task 3 - Mounting the C2M-TS and C2M Modules
Step 1 - Mount the C2M-TS module

1 Install only one C2M-TS module per battery string.
The C2M-TS can be installed on any monobloc in the battery string. However,
we recommend installing the C2M-TS module on the battery monobloc
connected to the live bus bar.
2 Push the TSCM temperature sensor onto the Q.C. tab of the negative battery
terminal as shown in the following diagram. This ensures direct thermal
contact with the internals of the battery.
If space constraints prevent connecting the TCSM directly onto the negative
terminal, attach the TSCM to any other appropriate place close to the negative
terminal.
3 Attach the C2M-TS sensor module to the side of the monobloc as shown or any
other appropriate place such as the battery support framework.

TSCM temperature sensor


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Step 2 - Mount the C2M sensor modules

Attach a C2M sensor module to the side of each monobloc (as shown) or to any
other appropriate place, such as the battery support framework.

Procedure complete

Task 4 - Mounting the Ambient Temperature Sensor
Mount the temperature sensor at a convenient location to measure the ambient temperature
of the battery.

Task 5 - Numbering the Monoblocs
Step 1 - Locate the monobloc connected to the common bus bar

Step 2 - Number the monoblocs

Numbering must start at the monobloc connected to the common bus bar and end
at the monobloc connected to the live bus bar.
The following diagram is an example of numbering the monoblocs of a battery
string, in this case battery string 1.


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23

Connection to common busbar

Connection to live busbar

Step 3 - Repeat these steps for each battery string

Procedure complete

Task 6 - Installing the Interconnecting Wiring

^
Compliance with EMC immunity standards is conditional on limiting the length of the
interconnecting cables, connected to the following ports:
CBC port XB4 < 3m (9.8 feet)

Use the following table to select the appropriate interconnection diagram for your battery
system and interconnect the CellSure modules accordingly.

Number of strings See
1 Diagram on page 24


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Single String Battery Systems
Use this interconnection diagram (in conjunction with the layout diagram on page 28) for
single string battery systems with 2V cells.

Battery string 1

Live bus bar

Common bus bar

VF1 or VF2 (common) voltage feed module.
Must be connected for accurate current readings.
Always connect the black wire to "common".

Battery ambient temperature sensor

CBC. For other connections:
RS485 comms:
- see Powering the CBC on page 29
- see Setup External Communications on page 67.
RS232 comms:
- see Connecting a PC to the CBC on page 46
Alarm relays - see details on page 28.


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25

Two String Battery Systems
two-string battery systems with 2V cells.

Battery string 1

Live bus bar

Common bus bar



RS485 comms:
RS232 comms:


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Three String Battery Systems
three-string battery systems with 2V cells.

Battery strings 1, 2 and 3

Live bus bar

Common bus bar



RS485 comms:
RS232 comms:


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27

Four String Battery Systems
four-string battery systems with 2V cells.

Battery strings 1, 2, 3 and 4

Live bus bar

Common bus bar



RS485 comms/power:
RS232 comms
Alarm relays - see details on page 28


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How to connect CellSure modules to monoblocs
Use the following diagram to connect:
the C2M modules to the cells
the communication wiring between the C2M modules, and to the CBC

CellSure Battery Controller (CBC) connected to
C2m on cell 1

TSCM on cell 24

Task 7 - Installing the Urgent and Non-urgent Alarm Relay Cabling
The CellSure Battery Controller (CBC) has an Urgent and a Non-urgent alarm relay with the
following specifications and connector pin assignments.

Relay Outputs
Contact Arrangement One changeover contact per relay
Maximum Switching Voltage 60V dc
30V ac
Maximum Switching Current 500mA
Maximum Continuous Current 500mA
Maximum Power Rating 30W (dc Voltage)
15VA (ac Voltage)
Maximum Cable Size 1.5mm

States and Conditions
Active State Energized or de-energized
State during CBC Start-up De-energized
On Condition Urgent Alarm Relay Any urgent alarm active
On Condition Non-urgent Alarm Relay Any Non-urgent alarm active
Off Condition Urgent Alarm Relay No urgent alarm active
Off Condition Non-urgent Alarm Relay No Non-urgent alarm active


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29

Connector Pin Assignment

Task 8 - Powering the CBC
There are two options for powering the CBC:
Power the CBC from the system dc bus
For all installations except SM65-based Eaton dc power systems, use an Auxiliary Power
Module (APM) to power the CBC from the system dc bus.
Power the CBC from the SM65 RCP bus
Use this option only when installing CellSure with an SM65-based Eaton dc power
system.

Powering the CBC from the system dc bus
Power the CBC as shown in the wiring following diagram. Over-current protection of the
APM power cable is required to prevent excessive current flow during accidental short-
circuit conditions.

Common bus

Live bus

Over-current protection*.

Auxiliary Power module (APM)

CellSure battery Controller (CBC)
* Use an Eaton Voltage Feed Module or a 2A (maximum) fuse or MCB (for Live feed only).


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Powering the CBC from the SM65 RCP bus
Power the CBC from the rack communications port (XS11) of the SM65 supervisory module.
The same cable provides the communications link from the SM65 to the CBC.
For details refer to the relevant section of the SM65 supervisory module handbook. See
Related Information on page ii.
It may be necessary to use an Auxiliary Power Module (APM) to power the CBC depending
on the number and type of other devices connected to the RS485 (RCP) bus. See RS485 Bus
Power Limit Calculations on page 89.

Chapter 5
6V/12V System Installation

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C h a p t e r 5
6V/12V SystemInstallation
Overview

Topic Page
Task 1- Mounting the Q.C. Tabs 32
Task 2 - Mounting the C6M/C12M, CBC and APM Modules 32
Task 3 - Mounting the TS8CM and SP8CM Modules 33
Task 4 - Mounting the Ambient Temperature Sensor 34
Task 5 - Numbering the Monoblocs 34
Task 6 - Installing the Interconnecting Wiring 35
Task 7 - Installing the Urgent and Non-urgent Alarm Relay Cabling 42
Task 8 - Powering the C6M/C12M Sensor Modules 43
Task 9 - Powering the CBC 43


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See instructions on page 20 for installation of 2V battery system modules.

Task 1- Mounting the Q.C. Tabs
Step 1 - Mount Q.C. tabs

^
Always tighten battery terminal bolts according to the battery manufacturers
specification. Failing to do so can cause erratic battery performance, possible
damage to the battery or personal injury.

Mount a Q.C. tab onto
each battery terminal
Procedure complete

Task 2 - Mounting the C6M/C12M, CBC and APM Modules
CellSure modules mount on standard DIN rail.

Place the lower clip of the module under
the bottom of the rail.

Move in top of the module until it clicks into
position on the rail.

To remove, push module up and pull top
forwards away from rail.
It is recommended that the modules are mounted in their numbered sequence and in a location
that is not accessible to operators.


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Task 3 - Mounting the TS8CM and SP8CM Modules
Step 1 Mount the TS8CM temperature sensor

1 Install only one TS8CM temperature sensor per battery string.
The TS8CM can be installed on any monobloc in the battery string. However,
we recommend installing the TS8CM module on the battery monobloc connected
to the live bus bar.
2 Push the TS8CM onto the Q.C. tab of the negative battery terminal as in the
following diagram. This ensures direct thermal contact with the internals of
the battery.
If space constraints prevent connecting the TS8CM directly onto the negative
terminal, attach the TS8CM to any other appropriate place close to the negative
terminal.

TS8CM temperature sensor


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Step 2 Mount the SP8CM short-circuit protection modules

Push the SP8CM modules onto the Q.C. tabs of the battery terminals as shown.
If space constraints prevent connecting the SP8CM modules directly onto the battery
terminals, attach the SP8CM modules to any other appropriate place close to the
battery terminals.

TS8CM temperature sensor

SP8CM short-circuit protection module
Procedure complete

Task 4 - Mounting the Ambient Temperature Sensor
Mount the temperature sensor at a convenient location to measure the ambient temperature
of the battery.

Task 5 - Numbering the Monoblocs
Step 1 - Locate the battery monobloc connected to the common bus bar

Step 2 - Number the battery blocs

Numbering must start at the battery monobloc connected to the common bus bar
and end at the battery monobloc connected to the live bus bar.


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35

Step 3 - Repeat these steps for each battery string

Procedure complete

Task 6 - Installing the Interconnecting Wiring

^
Compliance with EMC immunity standards is conditional on limiting the length of the
interconnecting cables, connected to the following ports:
CBC port XB4 < 3m (9.8 feet)
C6M/C12M ports XB20, XB22 and XB23 < 10m (32.8 feet)

Use the following table to select the appropriate interconnection diagram for your battery
system and interconnect the CellSure modules accordingly.

48V Battery Systems consisting of
1 to 2 strings See the diagram on page 36
6V monoblocs and
3 to 4 strings See the diagram on page 37
12V monoblocs and 1 to 4 strings See the diagram on page 38
24V Battery Systems consisting of


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48V Battery Systems consisting of 6V Monoblocs and 1 to 2 Strings
Use this interconnection diagram (in conjunction with the layout diagram on page 41) to
connect CellSure to a 48V battery system consisting of 6V monoblocs and 1 to 2 strings.

Battery strings 1 and 2

Live bus bar

Common bus bar

VF1 or VF2 (common) voltage feed module


RS485 comms:
RS232 comms:


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Live bus bar

Common bus bar



RS485 comms:
RS232 comms:


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IPN 997-00012-20F J uly 2009



Live bus bar

Common bus bar



RS485 comms:
RS232 comms:


IPN 997-00012-20F J uly 2009
39



Live bus bar

Common bus bar



RS485 comms:
RS232 comms:


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IPN 997-00012-20F J uly 2009



Live bus bar

Common bus bar



RS485 comms:
RS232 comms:


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41

How to interconnect monoblocs, TS8CM, SP8CM and C6M/C12M
modules
Use the following diagram to connect:
TS8CM and SP8CM modules to monoblocs
The wiring between TS8CM and C6M/C12M and SP8CM and C6M/C12M modules in
two battery strings.

String 1

C6M or C12M sensor module

String 2

SP8CM short circuit protection modules

TS8CM temperature sensor modules


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Task 7 - Installing the Urgent and Non-urgent Alarm Relay Cabling
The CellSure Battery Controller (CBC) has an Urgent and a Non-urgent alarm relay with the
following specifications and connector pin assignments.

Relay Outputs
Contact Arrangement One changeover contact per relay
Maximum Switching Voltage 60V dc
30V ac
Maximum Switching Current 500mA
Maximum Continuous Current 500mA
Maximum Power Rating 30W (dc Voltage)
15VA (ac Voltage)
Maximum Cable Size 1.5mm

States and Conditions
Active State Energized or de-energized
State during CBC Start-up De-energized
On Condition Urgent Alarm Relay Any urgent alarm active
On Condition Non-urgent Alarm Relay Any Non-urgent alarm active
Off Condition Urgent Alarm Relay No urgent alarm active
Off Condition Non-urgent Alarm Relay No Non-urgent alarm active

Connector Pin Assignment


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43

Task 8 - Powering the C6M/C12M Sensor Modules
C6M/C12M sensor modules are powered from the system dc bus. Over-current protection of
the C6M/C12M power cable is required to prevent excessive current flow during accidental
short-circuit conditions.
Use the following diagram to connect power to a C6M/C12M sensor module.

Common bus

Live bus


C6M or C12M sensor module

Task 9 - Powering the CBC
There are two options for powering the CBC:
Power the CBC from the system dc bus
For all installations except SM65-based Eaton dc power systems, use an Auxiliary Power
Module (APM) to power the CBC from the system dc bus.
Power the CBC from the SM65 RCP bus
Use this option only when installing CellSure with an SM65-based Eaton dc power
system.


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Powering the CBC from the system dc bus
Power the CBC as shown in the wiring following diagram. Over-current protection of the
APM power cable is required to prevent excessive current flow during accidental short-
circuit conditions.

Common bus

Live bus


Auxiliary Power module (APM)

CellSure battery Controller (CBC)

Powering the CBC from the SM65 RCP bus
Power the CBC from the rack communications port (XS11) of the SM65 supervisory module.
The same cable provides the communications link from the SM65 to the CBC.
For details refer to the relevant section of the SM65 supervisory module handbook. See
Related Information on page ii.
It may be necessary to use an Auxiliary Power Module (APM) to power the CBC depending
on the number and type of other devices connected to the RS485 (RCP) bus. See RS485 Bus
Power Limit Calculations on page 89.

Chapter 6
Commissioning

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45

C h a p t e r 6
Commissioning
Overview

Topic Page
Task 1 - Connecting a PC to the CBC 46
Task 2 - Configure the Hardware and Battery Settings 48
Task 3 - Check Monobloc Numbering 49
Task 4 - Check Temperature Sensors 50
Task 5 - Calibrate Current Shunts/Sensors 52
Task 6 - Characterize the Batteries 55
Task 7 - Using the Characterization Data 62
Task 8 - Configure the CellSure System for Operation 64
Task 9 - Repeat for Other CBCs (if required) 67
Task 10 - Setup External Communications 67


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Task 1 - Connecting a PC to the CBC
Step 1 Check that the CBC is powered

Green status LED on the CBC is on.
If not see Troubleshooting on page 78.
Step 2 - Install the DCTools software

Download DCTools from www.powerquality.eaton.com/downloads and install.
Step 3 Connect the null-modem cable (supplied)

Connect from the CBC RS232 socket (XB4) to a serial port (COM1 or COM2) on the
PC/laptop.

Step 4 Start DCTools

Double-click on the DCTools icon to display the DCTools Connection List.

Step 5 Check that the PC port is specified correctly

Check the Comms Properties column for the COM port to be used. Settings must be:
COM1 (or COM2 as appropriate); S3P Addr: 0
To change, right-click the name and select Properties.

Step 6 Enable the connection

Select
:
the connection check box. The CellSure Battery Monitoring System
Summary screen is displayed.
If the connection is unsuccessful, the message TPC Session Failed: Connection
Error 201 will appear in the Status column. For more information see
Troubleshooting on page 78.
Procedure complete

Commissioning

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47

General Notes on Editing the CellSure Configuration
Each CellSure battery management system is supplied with a pre-programmed default
configuration file.
The default configuration file can be re-configured on-site for the specific battery system
using DCTools.

General Notes on Using DCTools
DCTools is an easy-to-use software tool for:
Monitoring CellSure alarms and discharges
Diagnosing CellSure installation faults and identifying battery failures
Changing CellSure configuration values
You can connect only to one CellSure battery-management system at a time. For continuous
remote management, use PowerManagerII.
Other very useful buttons and controls are described in the table below.

Buttons and Controls Description

Changes to the configuration file are held and
are not downloaded to the CBC.

Downloads changes to the configuration file to
the CBC.
Most editable items will reset the CBC.

Select a battery string position to display the
graph of that string.

Highlight a specific graph.

Zoom in and out on all graphs.


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Task 2 - Configure the Hardware and Battery Settings
Step 1 - Edit Hardware and Battery Setup

1 In DCTools, click Configuration to display the CBC Configuration view.
2 Under Hardware and Battery Setup, edit the following fields to match the
battery system:
Operator Notes (text)
Installer Notes (text)
Monobloc Type (text)
System Polarity
Number Of Strings
Monoblocs Per String
Monobloc Voltage

Do not configure any other configuration parameters at this stage.

Step 2 - Return to Summary view

Click Summary to return to the Summary view.

Procedure complete

Commissioning

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49

Task 3 - Check Monobloc Numbering
Step 1 Disconnect one voltage sense wire from monobloc 2 of string 1

At battery string 1 disconnect a voltage sense wire from monobloc 2.

Step 2 Check the monobloc voltages in DCTools

1 In DCTools, click Realtime.
2 Check that the monobloc voltage of monobloc 1 is displayed. (If not, see
Troubleshooting on page 78.)
After removing the voltage sense wire from monobloc 2, expect a 30-second delay
before DCTools displays the monobloc voltage.

2V Systems 6V/12V Systems

Step 3 Repeat these steps for the remaining strings

Procedure complete


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Task 4 - Check Temperature Sensors
Step 1 Check string temperatures in DCTools

In DCTools, click Realtime and check that the string temperatures are correct. If not,
see Troubleshooting on page 78.

Commissioning

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51

Step 2 Check that the ambient and string temperatures are similar

Click Summary and check that the ambient temperature is correct. If not see
Troubleshooting on page 78.)

Procedure complete


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Task 5 - Calibrate Current Shunts/Sensors
Step 1 Configure the Current Shunt Scaling in DCTools

1 Determine the correct scale factor from the following list:
CS03 3A/mV
CS300 6A/mV
CS02 10A/mV
CS600 12A/mV
CS04-A11 Maximum Current per String (A)/60mV
2 In DCTools, click Configuration.
3 Enter the current shunt scale factor in the Current Shunt Scaling field.

Step 2 Enable Current metering

Commissioning

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53

Step 3 Connect a test load

1 Select a suitable calibration current.
For the highest measurement accuracy select a calibration current as close as
possible to the maximum current to be measured per battery string.
2 Disconnect the battery string from the LIVE bus.
Do NOT disconnect the current sensor/shunt from the COMMON bus.
3 Connect a test load to that battery string.
Do not switch on the load at this stage.
4 Attach a high accuracy clamp-on dc ammeter around the battery cable.

Step 4 Switch on the load

1 In DCTools, click Realtime to view the string current.
2 Switch on the load. Ensure that a negative current is shown on both the clamp-
on dc ammeter and the laptop PC display, indicating current flow out of the
batteries (discharge).
If a positive current is displayed, then the orientation of the current shunt/sensor
is incorrect. For correct orientation and mounting see Current Shunts/Sensors
on page 13.
3 All current shunts/sensors must be fitted the same way around.


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Step 5 Adjust the calibration potentiometer on the current shunt/sensor

1 If there is significant difference between the current readings in DCTools and on
the clamp-on dc ammeter then adjust the calibration potentiometer on the
current shunt (see details on page 5) or sensor (see details on page 14).
2 If you run out of adjustment range when calibrating a CS04-A11 current sensor,
do the following:
Ensure that the gain range is set correctly (see details on page 14).
Change the current shunt scale factor in DCTools.
Changing the current scale factor in DCTools is no substitute for an incorrect
gain range setting on the CS04-A11 current sensor.
3 Switch off then disconnect the test load from the battery string.

Step 6 Set the Current Shunt Offset for each string

1 Use a clamp-on dc ammeter to confirm that there is no current flow through
the current shunt/sensor.
2 In DCTools, click on Realtime.
3 Scroll to the bottom of the Realtime values screen and click
"
to the left of
Current Shunt Adjustment to view a table of the Raw String Current and
Current Shunt Offset for each battery string fitted.
4 If Raw String Current is approximately 0.0A then no change is needed. Go to the
next step.
5 If Raw String Current is not approximately 0.0A then ensure that the
Current Shunt Offset is 0. If not, set it to 0 and click Apply Changes.
6 Double-click on the Current Shunt Offset field and change its value to be the
opposite of the Raw String Current value. Press Enter.
For example, if the Raw String Current equals 7.6A, enter 7.6A in the
Current Shunt Offset field.
7 Click Apply Changes. The offset will now take effect and the Raw String Current
will show 0.0A.
The value may not be exactly zero because there is usually a small amount of
noise present at the current shunt/sensor input.
8 Recheck the current reading by passing a known current through the current
shunt/sensor and adjust the calibration potentiometer, if required. See Step 3
and Step 4.

Step 7 Reconnect the battery string to the system dc bus

Commissioning

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55

Step 8 Repeat steps 3 to 6 for the remaining battery strings

Do NOT change the current scale factor in DCTools after the first current
shunt/sensor has been calibrated correctly. There is only one current scale factor for
all shunts/sensors used. The remaining current shunts/sensors must be calibrated
accordingly.
Step 9 Fully recharge all batteries after calibration

Procedure Complete

Task 6 - Characterize the Batteries
Characterization data management
DCTools has a Characterization Data Management feature that enables characterization data
to be copied for other strings of the same type and size. This can reduce the time needed to
characterize batteries. For details see Data Management on page 93.

Before you start
Ensure that the batteries are fully charged.
Disable the LVD (if fitted) or reduce its disconnect voltage below the Monobloc End
Voltage.


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Step 1 Configure the Discharge Conditions in DCTools

1 Click on Configuration to display the CBC Configuration view.

2 Edit the Discharge Conditions parameters using the following configuration
guidelines.

Parameter Configuration Guidelines
Bloc End Voltage Select the appropriate end voltage in Vpc (Volt per cell) from the battery
manufacturers specification.
This is normally 1.8Vpc. For example, the monobloc end voltage of a
12V monobloc, assuming an end voltage of 1.8Vpc, is 1.8 Vpc x 6 =
10.8V or 10800mV.
Rated Bloc
Capacity
Determine the Rated Monobloc Capacity for the characterization
discharge from the battery manufacturers specification. Ensure that the
Rated Monobloc Capacity relates to the expected discharge rate.
Discharge Rate Determine the Discharge Rate from the discharge time and the discharge
current according to the battery manufacturers discharge tables.
If the average discharge current at the end of a battery discharge is
outside the range, defined by the Discharge Rate Discharge Rate
Tolerance, the battery characterization will fail.
Discharge Rate
Tolerance
Set to 25%. The Discharge Rate Tolerance can be reduced, once the
behavior of the batteries is known.

Commissioning

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57

Discharge Temp Controlled Discharges
(such as an offline discharge in an air-conditioned room)
Set Discharge Temp equal to the ambient temperature of the battery.
Uncontrolled Discharges
(such as an offline discharge in a non-air conditioned room or an
ac supply outage)
Set Discharge Temp 5-10C higher than the ambient temperature of
the battery. The ambient temperature of the battery will rise during a
discharge test because of heat dissipated by the load into the
surrounding atmosphere. The internal temperature of the batteries
will also rise during the discharge.
If the average temperature at the end of a battery discharge is outside the
range, defined by the Discharge Temp Discharge Temp Tolerance, the
battery characterization will fail.
Discharge Temp
Tolerance
Set to 15C. The Discharge Rate Tolerance can be reduced, once the
behavior of the batteries and the environment is known.
Partial Discharge
Depth
Set to 30%.
Minimum
Recharge Time
Set to zero. A full discharge is only valid, after recharging the batteries
for the configured minimum recharge time. By setting the Minimum
Recharge Time to zero, a battery characterization can be performed
immediately.

The parameters Reserve Time Low Urgent Threshold and Reserve Time Low NonUrgent
Threshold are alarm settings and are not used at this stage.


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Step 2 Set the date and time in DCTools

The CBC has no battery back-up real-time clock. Every time the CBC resets or the
configuration file changes, date and time return to 01/01/70 00:00:00.
If the CBC is connected to an SM45 or SM65, date and time of the CBC will be
updated to that of the SM45 or SM65.
To set the date and time in DCTools, follow the following steps.
1 Click Apply Changes and wait for the CellSure system to reset.
2 Click Summary then edit the date and time in the Values view.

3 Click Apply Changes. The CBC resets and the new date and time is displayed.

Step 3 Enable data logging (optional)

This is an optional step and does not affect the outcome of the battery
characterization. Logging the CBC data during a discharge can be useful for
troubleshooting or for later analysis.
Do NOT open the data log file during the active logging process, as this will prevent
the logs from being updated. If you need to edit or review the data log file, you must
first create a copy. Open this copy to do any editing or reviewing of the data log file.
To enable data logging:
1 Click PC Log to display the Data Log view.
2 Click to display the Save As dialog.
3 Select a file location and save the CBC Data Log file.
4 Select and set the data log time interval.
The recommended setting is 30 seconds.
5 Click Start. The data logging process starts and data is saved in the data log file
specified in 3.
This data log differs from the data log stored in the CBC.

Commissioning

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59

Step 4 Check the Running string status field in DCTools

1 From the Available Forms panel, select Realtime to display the Realtime
values view.
2 If the Running string status field is set to false (-), then go to the next step.

3 If the Running string status field is true (
v
):
Disconnect then reconnect power from the CBC, to reset it.
Wait approximately 5 minutes, then check that the Running string status
field is false (-).
Set the date and time (see Step 2 for details).

Step 5 Discharge the batteries

Instead of discharging one string at a time, it is possible to discharge all strings into
the telecommunications load, if permitted under your regulations.
A completed discharge characterization and a further 30% discharge are required
before both Battery Estimated Capacity and Battery State of Health will show
realistic values.
1 Disconnect the battery string from the system dc bus.
2 Connect the load to the battery string(s) under test.
3 Switch on the load.


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4 In DCTools click Realtime. Check the displayed string current corresponds to
the selected discharge current and that it is negative. If not, see Troubleshooting
on page 78.

5 Ensure that the string Running status field has changed to true (
v
).
There is a time delay (typically up to 1 minute) between switching on the load
and DCTools recognizing the start of a battery discharge.
6 Check that the individual monobloc voltages are in fact dropping.
It is recommended to switch between Trend Graph and Realtime in DCTools
during a discharge.
7 Check that the string status fields Partial Complete and Partial Valid change
to true (
v
), after about 30 to 50% of the selected discharge time has elapsed.
(See Step 1 Configure the Discharge Conditions in DCTools for the exact value.)

8 At the end of the selected discharge time, check that Full Complete has
changed to true (
v
). This indicates that the discharge test is complete and the
CellSure system has collected enough data.
Also, check that the string Full Valid status field changes to true (
v
).
Full Valid only changes to true (
v
), if the following string status fields are false
(-):
Discharge Interrupted (The discharge was interrupted during the test)
Average Current Fail (The average current during the test was outside the set
limits)
String Temp Fail (The average temperature during the test was outside the set
limits)
Recharge Too Short (The minimum recharge time has not elapsed before the test
started)
If any of the listed string status fields are true (
v
), repeat the discharge after
fully recharging the batteries.

Commissioning

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Step 6 Disconnect the load and recharge the batteries offline

Step 7 Check the string status fields

Check that the string Running status field changes to false (-), after the batteries
have recharged for approximately 5 minutes.

Step 8 Stop data logging (optional)

This step is only required, if data logging has been enabled in step 3.
Select PC Log and click Stop.
To view the data log file, open it in Microsoft Excel.

Step 9 Reconnect the battery string to the system dc bus

Step 10 Repeat this procedure for the remaining battery strings

Your regulations may require delay between discharges.
Procedure complete


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Task 7 - Using the Characterization Data
Each CellSure battery-monitoring system is supplied with a default characterization based on
a 100Ah battery system. Use the following procedure to configure CellSure with the exact
battery characterization for your specific battery system.
Step 1 - Open Characterization Algorithm view

In DCTools click Tools to display the Characterization Algorithm view.

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63

Step 2 - View most recent full discharge

Click
"
to the left of Graph. The most recent full discharge is then displayed.

Step 3 - Check graph

Look at the graph and ensure that this is what you expect as a discharge for your
batteries.
If you are satisfied, close the Graph view by clicking
"
to the left of Graph.
You can check individual values by opening the Data view.

Step 4 - Select string to characterize

1 Click the relevant Characterization Algorithm button for the
string you wish to characterize. The following confirmation dialog is displayed.

2 Confirm overwrite only if you are satisfied with the discharge graph and data.


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Step 5 - Repeat for other strings

Repeat Steps 1 to 4 to characterize the other strings in the system.
Procedure complete

Task 8 - Configure the CellSure System for Operation
Step 1 Configure the CBC for operation

1 In DCTools click Configuration to display the CBC Configuration view.
2 Edit the listed parameters using the following configuration guidelines.

Relay Active State Set as appropriate.
Bloc End Voltage Ideally, the Monobloc End Voltage should be set to the same value as
Point 19 of the CBC Discharge Characterization table for each string.
To view Point 19 of the CBC Discharge Characterization table, select
CBC Logs then click on Data and Discharge Characterization.
Rated Bloc Capacity
Discharge Rate
Change only if the discharge rate of the telecommunications load
differs from that used during the battery characterization.
For example, the total discharge current of a battery system into the
telecommunications load during an ac supply failure is 100A,
providing a backup time of 3 hours.
Therefore: Rated Monobloc Capacity = 300Ah, and
Discharge Rate = 100A
Minimum Recharge
Time
Ideally, this should be set to 72 hours to fully recharge the batteries.
The Minimum Recharge Time prevents multiple ac supply failures
(over a number of hours or days) from being used as characterization
data.
Reserve Time Low
Urgent Threshold
Reserve Time Low
NonUrgent
Threshold
Set these thresholds as appropriate. The CBC generates an alarm once
the set threshold is reached.

If CellSure is used in conjunction with Eaton dc power system, ensure that all control and
alarm functions are compatible.

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Step 2 - Configure the alarm settings in DCTools

Each CellSure battery-monitoring system is supplied with pre-programmed default
alarm configuration settings, suitable for most applications. If required, these
default settings can be re-configured using DCTools.
Ensure that the alarm configuration settings are compatible with the power system.
For example, to re-configure the String Temperature High Absolute alarm:
1 In DCTools click Alarms then Alarm Configuration. The Alarm Configuration
view is then displayed.
2 Re-configure the State and Alarm Report settings of the String Temperature
High Absolute alarm. For example, to enable the Urgent State of the String
Temperature High Absolute alarm, double-click Disabled in that row, then
click
Z
and select Enabled from the popup list box.

3 Click
"
to the left of String Temperature High Absolute and edit the threshold
and alarm time fields.

For alarm details see Appendix on page 83.


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Step 3 Configure the CBC communication settings

Set the CBC communications settings to suit the external communications option to
be used. See Setup Communications on page 67 for the available options.
1 In DCTools select Configuration > Communications.

2 For stand-alone mode set:
Protocol Port RS485: S3P
CBC S3P Address: in the range 1 to 65279
(For multi-drop, each CBC must have a different
address.)
Modem: Configure the modem settings if required.
3 For Pass-through communications set:
Protocol Port RS485: Rcp
CBC RCP Slave Address: 150 (151, 152, 153 for other CBCs if required)
Procedure complete

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Task 9 - Repeat for Other CBCs (if required)
Repeat tasks 1-8 for other CBCs if required.
Up to four CBCs can be connected together to monitor up to 16 battery strings. This requires
multidrop communications (stand-alone or SC200 Serial Server mode) or an Eaton SM45 or
SM65 supervisory module (using Passthrough communications). See Setup External
Communications on page 67.

Task 10 - Setup External Communications
The CellSure Battery Controller (CBC) communicates with a PC (with DCTools or
PowerManagerII), either:
directly, via its RS232 or RS485 serial interface (Stand-alone mode), or
via an Eaton SC200 system controller (Serial Server mode), or
via an Eaton SM45 or SM65 supervisory module (Passthrough communications).
Install one of the following external communication options to communicate with the CBC.
These are the standard communication options. Contact Eaton for other options. See Worldwide
Support on page 101.

Stand-alone Mode

Direct Connection Option

CBC

PC/laptop with PowerManagerII*
and/or DCTools*.

RS232 null-modem cable (S3P
protocol).

Auxiliary Power module (APM).

RJ 45 cable.

Modem Option

CBC

PC/laptop with
PowerManagerII* and/or
DCTools*.

RS232 modem cable (straight
through).

Modem

PSTN network. S3P protocol.


RJ 45 cable.


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Ethernet Option

CBC

and/or DCTools*.

protocol).

RS232-Ethernet interface.

TCP/IP network. S3P-TCP/IP
protocol.


RJ 45 cable.

Multidrop Option

Up to four CBCs. (Multiple
CBCs must have distinct S3P
Addresses.)

and/or DCTools*.

RJ 45 cable.

RS485-RS232 interface. S3P
Protocol.

* For setup details see Configure the Communications Settings on page 67.

Configure Communications Settings for Stand-alone Mode
Step 1 Configure the communication settings for DCTools

1 Double-click on the DCTools icon to display the Connection List.

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2 Click to create a new connection. The Comms Properties dialog is
displayed.

Step 2 - Configure the properties

1 Configure the properties according to the following table.
2 Click OK.

Properties Direct
Connection
Modem Ethernet Multidrop
Comms Enabled True True True True
Protocol S3P S3P S3P S3P
Connect Using COM1 COM1/Modem
(Note 1)
Local Network COM1
S3P Address
(Note 2)
0 0 0 Individual CBC
address
Phone Number User specific
Server IP
Address
xxx.xxx.xxx.xxx
(Note 3)

Server Port Note 4

Notes
1 If an internal modem is fitted then select from drop down list. For an external modem
select COM1.
2 0 = Broadcast, 1-65279 = individual address. For Multidrop communications the CBCs
must have distinct S3P Addresses.
3 Allocated by network supervisor.
4 As specified in the documentation for the Ethernet interface.


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Step 3 - Repeat for other CBCs (if applicable)

If there is more than one CBC then create and configure a separate connection for
each CBC.
Procedure complete

SC200 Serial Server Mode

Single CBC Option

CBC

and/or DCTools*.

protocol).

SC200 system controller.

protocol.


Multidrop Option

Up to four CBCs. (Multiple
CBCs must have distinct S3P
Addresses.)

and/or DCTools*.

RJ -45 cable.

RS485-RS232 interface. S3P
Protocol.

SC200 system controller.

protocol.

* For setup details see Configure the Communications Settings on page 67.

Configure Communications Settings for SC200 Serial Server Mode


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71

displayed.


2 Click OK.

Properties Single CBC Multidrop
Comms Enabled True True
Protocol S3P S3P
Connect Using Local Network Local Network
S3P Address (Note 1) 0 Individual CBC
address
Server IP Address (Note 2) xxx.xxx.xxx.xxx xxx.xxx.xxx.xxx
Server Port 15000 15000

Notes
1 0 = Broadcast, 1-65279 = individual address. For Multidrop communications the CBCs
must have distinct S3P Addresses.
2 IP address of the SC200 (allocated by network supervisor). Refer to Ethernet
Communications in the SC200 Operation Handbook (see Related Information on page
ii).


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each CBC.
Procedure complete

Passthrough Communications (with SM45/SM65 only)

Direct Connection Option

Up to four CBC connected via
XB1/XB2 (Note 1).

PC/laptop with PowerManagerII
and/or DCTools (Note 2).

RJ -45 patch cable connected to
RCP bus in dc power system.
RCP protocol. (Note 3).

SM45 or SM65.

RS232 null-modem cable
(protocol: S3P).

(Note 4).

Modem Option

XB1/XB2 (Note 1).


RJ -45 cable connected to RCP
bus in dc power system. RCP
protocol (Note 3).

SM45 or SM65.

RS232 modem cable (straight
through).

PSTN Modem.

PSTN network (protocol: S3P).

(Note 4).

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Ethernet Option

XB1/XB2 (Note 1).


RJ -45 cable connected to RCP
bus in dc power system. RCP
protocol. (Note 3).

SM45 or SM65 (Note 5).

Communications network
(protocol: S3P/IP).

(Note 4).

Notes
1 Multiple CBCs must have distinct RCP Slave Addresses.
2 For setup details see Configure the Communications Settings on page 67.
3 Communication with the SM45 or SM65 is via the RCP bus in the dc power system.
Connection to the RCP bus is usually made at the last rectifier backplane in the system.
Refer to the supervisory module handbook for details (see Related Information on page
ii).
4 APM may not be required with SM65. See Powering the CBC (2V cells) on page 29 or
Powering the CBC (6V/12V monoblocs) on page 43.
5 Refer to the supervisory module handbook for Ethernet setup details (see Related
Information on page ii).

Configure Communications Settings for Passthrough Mode



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displayed.


2 Click OK.

Properties Direct Connection Modem Ethernet
Comms Enabled True True True
Protocol (Note 1) S3P-Passthrough S3P-Passthrough S3P-Passthrough
Connect Using COM1 COM1/Modem
(Note 2)
Local Network
S3P Address (Note 3) 1:150 1:150 1:150
Phone Number User specific
Server IP Address xxx.xxx.xxx.xxx
(Note 4)
Server Port 14000

Notes
1 Ensure that Comms is enabled on the SM45/SM65.
2 If an internal modem is fitted then select from drop down list. For an external modem
select COM1.
3 The format is SM45/SM65 S3P Address : CBC RCP Slave Address (150, 151 etc).
4 Allocated by network supervisor.

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each CBC.

Step 4 - Configure the SM45 or SM65 for CellSure

1 Connect to the supervisory module from DCTools. Refer to the supervisory
module handbook for details (see Related Information on page ii).
2 From the DCTools System Summary (Home) screen, go Configuration >
External I/O to display the External Input/Output Communications view.
3 Scroll down to CellSure Battery Controller (CBC) and set Fitted to True.
4 From the DCTools System Summary (Home) screen, go to CBC to display the
CellSure Battery Controller (CBC) Summary view.
5 Set Number of CBCs as appropriate.
6 To allow the supervisory module to use the average string temperature from
the CellSure battery temperature sensors (instead of its own battery
temperature input) click
Z
next to Batt Temp Source and select CBC Average
from the list.
Procedure complete

Chapter 7
Troubleshooting

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C h a p t e r 7
Troubleshooting
Topic Page
CBC Status Indication 78
Troubleshooting 78


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CBC Status Indication
Use the following table to confirm operation and identify alarms.

LED State Indicates
On Power on and CellSure is operational
Flashing Reception of communications data
Green Status
LED
Off No power or CBC faulty
On
Non-Urgent String Alarm or faulty sensor
module(s)
Flashing Urgent String Alarm
Red String
Alarm LEDs
Off No active alarms
All LEDs On (for at least 1s) CBC start-up
Off No power or CBC faulty

Troubleshooting
Use the table to troubleshoot minor installation and operational problems. Troubleshoot one
string at a time.
For additional assistance see contact details on page 101. Return items for replacement or
repair with a completed Equipment Incident Report on page 98.

Problem Possible Cause Required Action
CBC not powered. Check that the APM (or SM65 supervisory module,
if used) is powered.
Check the power/RS485 cable is plugged into either
XB1 or XB2.
Check the cable.
CBC green status LED is
off.
CBC faulty. Replace and return faulty unit for service.
Incorrect or disconnected
cable
Use a null-modem cable.
Check cable is plugged into the PC COM port and
XB4.
Communications port of PC
does not match that of
DCTools.
Reconfigure the port properties in DCTools. See
Connecting a PC to the CBC on page 46.
Incorrect baud rate specified. Check that the baud rate is 19,200.
No communications
between CBC and PC.
Incorrect S3P Address Check that the S3P address in DCTools is either 0 (for
broadcast) or the specific S3P address of that CBC.
The voltage of monobloc 1 is
less than 1.4V.
Measure the voltage of monobloc 1. DCTools does not display
the monobloc voltage of
monobloc 1.
Sensor module of monobloc 1
not connected to CBC.
Check connection.
Troubleshooting

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79

Problem Possible Cause Required Action
Polarity of string
communications cabling
between CBC and first sensor
module incorrect.
Check the polarity of the string communications
cabling between the CBC and the first sensor
module (C2M, C6M or C12M).
Polarity of monobloc voltage
sense cabling incorrect.
Check the polarity of the monobloc voltage sense
cabling.
Number of strings incorrectly
configured in DCTools.
Check that the Number Of Strings setting. See
Configure the Hardware and Battery Settings on
page 48.
Number of blocs per string
incorrectly configured in
DCTools.
Check that the Blocs Per String setting in DCTools is
configured correctly. See Configure the Hardware
and Battery Settings on page 48.
No string temperature sensor
installed.
Install a C2M-TS or TS8CM. DCTools does not display
the correct string
temperature.
Wiring between temperature
sensor and sensor module
incorrect.
Check wiring. (The spade connector on the
temperature sensor may need to be removed.)
Faulty or disconnected
temperature sensor cable.
Check cable.
Check cable is plugged into XB5.
DCTools does not display
the correct ambient
temperature.
Faulty temperature sensor. Replace and return faulty unit for service.
The system will operate without an ambient
temperature sensor connected.
Current shunts/sensors not
connected to the Common
bus bar.
Check that all current shunts/sensors are connected
to the Common bus bar.
String current is positive.
Orientation of current
shunt/sensor incorrect.
If the orientation of all the current sensors is the
same, change the current shunt scale factor in
DCTools. See Calibrate the Current Shunts/Sensors
on page 52.
If this shunt/sensor is different from the others, turn
the shunt/sensor around to be the same as the
others.
String current is negative.

Calibration of a current shunt/sensor incorrect. See
calibration procedure on page 13.
String current floats higher Bus reference connection missing or incorrect. Check
the Bus Reference cable is connected correctly to
XB3.
The displayed string
current in DCTools does
not match the selected
discharge current.
Daisy-chaining of current
shunts/sensors incorrect.
Check that the RJ45 cables for daisy chaining the
current shunts/sensors are plugged into the correct
ports.


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Appendix A
Specifications

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A p p e n d i x A
Specifications
Auxiliary Power Module (APM)

Input
Input Voltage Range 18 to 60V (non-polar)
Maximum Input Current 900mA (at 18V)
Typical Input Current 300mA (at 54V)
Auxiliary Supply Output
Nominal Output Voltage 12V
Output Voltage Range 11.7 to 15V (unregulated)
Maximum Output Current 500mA (total at 12V)
Overload Protection
2A (typical) (Automatic reset after
removal of fault condition)
RCP Bus Supply Output
Nominal Output Voltage 9V
Output Voltage Range 8.7 to 11.3V (unregulated)
Maximum Output Current 400mA

Overload Protection 2A (typical) (Automatic reset after
removal of fault condition)
Isolation
Isolation (Input to Output) 1.5kV ac (1 minute)
Isolation ( 12V Outputs to 9V Output) 1.0kV ac (1 minute)


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Appendix B
Alarm Details

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A p p e n d i x B
AlarmDetails
Use the following tables to find the appropriate alarm details (configurable parameters and
description) for a specific event.

Alarms common to all states

String Temp High Absolute Alarm
Type Urgent or Non-urgent
Urgent and Non-urgent Threshold Range -20C to +70C

Urgent Alarm Time Range 2 to 510 minutes (2 minute
steps)
Non-urgent Alarm Time Range 1 to 240 hours (1 hour steps)

The temperature of the pilot cell in a string exceeds the set threshold and alarm time limits.
The string and ambient temperatures should be similar when the batteries are on float.
If the string temperature exceeds the normal operating temperature of the battery, the
battery is being thermally stressed resulting in reduced life.

Bloc Voltage Failure Alarm
Non-urgent Threshold 1,000 to 13,000mV

A monobloc in a string has failed. This alarm provides a warning before imminent loss of
string communication occurs in C2M sensor modules.
C2M sensor modules do not operate below 1.4V. C6M and C12M sensor modules
are not affected as they are powered from the system dc bus.

Alarms while on float

Bloc Volt Divergence Float Alarm
Non-urgent Threshold Range 1 to 1,500mV

The voltage of an individual monobloc differs significantly from the average monobloc
voltage of that string for the alarm time limit set. The alarm is used to identify blocs that do
not regain their expected charge while on float. After further discharges, this information is
useful to determine which blocs need to be replaced.


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Bloc Volt High Float Alarm
Non-urgent Threshold Range 1,500 to 18,000mV

Stressed cells/blocs. This alarm is based on the absolute voltage of the individual blocs for the
set alarm time. To prevent excessive gas build-up, Cells/blocs must not be float charged at a
high float voltage for too long.
A cell/monobloc with a high float voltage does not always indicate that it is faulty. That
cell/monobloc may be pressurized by another.

Bloc Volt Low Float Alarm
Non-urgent Threshold Range 1,500 to 18,000mV

A cell/monobloc is being undercharged. This alarm is based on the absolute voltage of the
individual blocs for the set alarm time. Low float is the opposite of high float. In this case,
Many cells/blocs fail if undercharged by a too low float voltage.

String Temp High Ambient Float Alarm
Urgent and Non-urgent Threshold Range 0C to +70C
Urgent Alarm Time Range 2 to 510 minutes (2 minute steps)

The string temperature exceeds the ambient temperature for the set threshold and alarm time
limits. The alarm indicates that the temperature of the pilot cell in a string has increased
significantly. This in turn indicates thermal run away or overcharged cells.

Alarms while in discharge

Bloc Volt Divergence Discharge Alarm

The voltage of an individual monobloc is significantly below the maximum monobloc voltage
of that string.
The alarm is used to identify blocs that drop away during a discharge, indicating reduced
capacity of that monobloc and the need for replacement. Several of these alarms generated
during a discharge may indicate replacement of the whole string is required.

Alarm Details

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String Current Divergence Discharge Alarm
Urgent and Non-urgent Threshold Range 5 to 50% of Average String Current
Urgent and Non-urgent Alarm Time Range 1 to 60 minutes (1 minute steps)

The individual string currents differ significantly for the alarm time limit set.
String current divergence indicates state of charge or capacity imbalances between strings.
Further analysis of the discharge data will indicate what caused it.

Reserve Charge Low Discharge Alarm

Urgent and Non-urgent Threshold Range 0 to 100% of Rated Monobloc
Capacity

Only a limited amount of backup capacity remains. A warning to find an alternative power
source if required.

Reserve Time Low Discharge Alarm
Urgent and Non-urgent Alarm Time Range 0 to 65,535 minutes

Only a limited amount of backup time remains. A warning to find an alternative power
source if required.

Start of Discharge Alarm

Urgent and Non-urgent Threshold 0 to 100% of configured Discharge
Rate
The string is discharging, if the string current exceeds the set threshold.

Alarms after discharge

Bloc Capacity Low Alarm

Non-urgent Threshold Range 20 to 100% of Rated Monobloc
Capacity

The capacity of an individual bloc is below the set threshold limit.
Capacity alarms are generated after completing a valid discharge. A valid discharge is
defined as a completed discharge within a specific discharge rate and temperature range
down to or beyond a partial discharge depth (full discharge or partial discharge depth). The
capacity is calculated according to the built-in algorithm. By detecting low capacity in blocs,
these poor-performing blocs can be removed before healthy blocs are affected.


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String Capacity Low Alarm

Urgent and Non-urgent Threshold Range 20 to 100% of Rated Monobloc
Capacity

The capacity of a string is below the set threshold limit.
The alarm indicates that the capacity of a number of blocs in that string is low. This in turn
prompts further investigation and possible replacement of the blocs affected.

Battery Capacity Low Alarm

Urgent and Non-urgent Threshold 20 to 100% of Rated Monobloc
Capacity

The battery capacity is below the set threshold limit.
Battery capacity is the most critical. If the battery capacity is low, the reliability of the
standby power system is endangered.

Bloc State of Health Low Alarm

Bloc Low Non-urgent Threshold Range 0 to 1.00 (1.00 indicates a healthy
monobloc)
The condition of the blocs is poor or requires extended float charging or a boost recharge.

Bloc State of Health Poor Alarm

Type
Urgent or Non-urgent

Bloc Poor Non-urgent Threshold Range 0 to 1.00 (1.00 indicates a healthy
monobloc)
An early warning that a monobloc is in poor condition and may need replacing soon.

Bloc State of Health Fail Alarm

Bloc Fail Non-urgent Threshold Range 0 to 1.00 (1.00 indicates a healthy
monobloc)
A warning that the monobloc may need to be replaced.

String State of Health Low Alarm

String Low Non-urgent Threshold Range 0 to 1.00 (1.00 indicates a healthy
monobloc)
The condition of the strings is poor or requires extended float charging or a boost recharge.

Alarm Details

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String State of Health Poor Alarm

String Poor Non-urgent Threshold Range 0 to 1.00 (1.00 indicates a healthy
monobloc)
An early warning that a string is in poor condition and may need replacing soon.

String State of Health Fail Alarm

String Fail Non-urgent Threshold Range 0 to 1.00 (1.00 indicates a healthy
monobloc)
A warning that the string may need to be replaced.

Battery State of Health Low Alarm

Battery Low Urgent Threshold 0 to 1.00 (1.00 indicates a healthy
monobloc)
The condition of the battery is poor or requires either a boost recharge or replacing.

Battery State of Health Poor Alarm

Battery Poor Urgent Threshold Range 0 to 1.00 (1.00 indicates a healthy
monobloc)
An early warning that a string is in poor condition and may need replacing soon.

Battery State of Health Fail Alarm

Battery Fail Urgent Threshold Range 0 to 1.00 (1.00 indicates a healthy
monobloc)
A warning that the battery may need to be replaced.

Partial Discharge Completed
Type Information only

A logged event used to maintain a history of discharges and to indicate that a partial
discharge has been completed.

Full Discharge Completed
Type Information only

A logged event used to maintain a history of full discharges and to indicate that a full
discharge has been completed.


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Alarms while on charge

Bloc Volt Divergence Charge Alarm
Non-urgent Alarm Time Range 2 to 510 minutes (2 minute steps)

The voltage of an individual monobloc differs significantly from the average monobloc
voltage of that string for the alarm time limit set. The alarm is used to identify blocs that do
not regain their expected charge. These blocs may not be healthy and may fail soon.

String Current Divergence Charge Alarm
Urgent and Non-urgent Threshold Range 5 to 50% of the average string current
Urgent and Non-urgent Alarm Time Range 1 to 60 minutes (1 minute steps)

The individual string currents differ significantly for the alarm time limit set. String
current divergence indicates state of Charge or capacity imbalances between strings.
Further analysis of the recharge data will indicate what caused it.

String Temp High Ambient Charge Alarm
Urgent and Non-urgent Threshold Range 0C to +70C
Urgent Alarm Time 2 to 510 minutes (2 minute steps)
Non-urgent Alarm Time 1 to 240 hours (1 hour steps)

The string temperature exceeds the ambient temperature for the set threshold and alarm time
limits. The temperature of the pilot cell in a string has increased significantly. Indicates
thermal run away or overcharged cells.

Start of Charge Alarm
Event Threshold 0 to 100% of Discharge Rate
Indicates the string is charging, if the string current exceeds the event threshold.

Start of Float Alarm
Event Threshold 1 to 240 hours (1 hour steps)

Indicates the string is float charging.
This is determined by the fact that the string has been charging for longer than the time
given by the Event Threshold and the string current does not exceed either the charge event
threshold or discharge event threshold.

Appendix C
RS485 Bus Power Limits

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A p p e n d i x C
RS485Bus Power Limits
RS485 Bus Design Method
Use the following table to calculate the total RS485 bus load current by summing the load
current for each RS485 slave device.
RS485 Slave Devices Load current
per device
(mA)
Number of
devices
Total load
current (mA)
APR24, APR48, APU48 rectifiers 0 - -
NPR24, NPR48 rectifiers 8
CS04 current sensor 3
IOM-CS master module 60
SS-GP master module 50
SS-DI expansion module 5
SS-DO expansion 50
CBC (only SM65 systems) 170

Total:

Actual cable length: _____m (ft x 0.305 = length in meters)

Plot the load current and cable length on the appropriate graph on page 90 if using CAT 5
cable, or use the information for other cable types on page 91.
Be careful to use the correct limit line if one or more SS-DO or a CBC modules are connected to
the bus.

Conclusion: Plotted point is within limit line - design ok
Plotted point is outside limit line - segment bus and use
additional APM(s)


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RS485 Bus Power Limits (Cat 5 cable)
The RS485 bus must comply with the load current and cable length limits shown in the
following graphs. The limits depend on the RS485 source device (supervisory module or
APM) and whether any SiteSure SS-DO modules or CellSure controllers (CBC) are connected
to the bus.
The graphs are based on the use of Cat 5 cable (0.089/m impedance). For other cable types see
RS485 Bus Power Limits with Other Cable Types on page 91.

SM40 and SM45 supervisory modules

RS485 Bus Load
Current (mA)

Maximum cable length (m)

Without SS-DO or CBC

With one or more SS-DO or CBC

SM60 and SM65 supervisory modules, Auxiliary Power Modules (APM)

RS485 Bus Load
Current (mA)

Maximum cable length (m)

Without SS-DO or CBC

With one or more SS-DO or CBC

RS485 Bus Power Limits

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RS485 Bus Power Limits with Other Cable Types
For other cable types use one of the following formulae to calculate the maximum allowable
cable distance:

Devices on the RS485 bus: Maximum
allowable cable
distance (m)
Maximum
allowable cable
distance (feet)
One or more SS-DO or a CellSure CBC
modules
= 1000 / (Z x L) = 3280 / (Z x L)
No SS-DO and CellSure CBC modules = 2000 / (Z x L) = 6560 / (Z x L)

Where: Z = cable impedance (ohms/m)
L = RS485 load current (mA)

Subject to the following overall limits:

RS485 source device Maximum cable
distance
Maximum RS485
load current
SM40 or SM45 (without SS-DO) 500m [1640 ft] 200mA
SM40 or SM45
(with one or more SS-DO modules)
225m [740 ft] 200mA
SM60, SM65, or APM (without SS-DO or
CBC*)
500m [1640 ft] 400mA
SM50, SM60, SM65, or APM
(with one or more SS-DO or CBC* modules)
225m [740 ft] 400mA

* CellSure CBC modules only connect to an SM65.


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Appendix D
Data Management

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A p p e n d i x D
Data Management
DCTools provides easy management of battery characterization data. Characterization data
can be copied between strings within a CellSure Battery Controller (CBC) and copied to
another CBC by saving /loading a characterization data file.
There are two benefits of this feature. It allows quicker setup and configuration of CellSure
systems with multiple strings of the same battery type. It is also useful when only off-line
battery discharge characterizations are allowed.
The initial accuracy of the installed CellSure system may be reduced. This is because the
referenced data has been copied from other characterized batteries and may not accurately
represent the installed batteries. This will be corrected after the next partial discharge test.

Copy string data
The Characterization Data Management feature allows the data to be copied from the first
string to the second, third and fourth strings. This saves time and eliminates the need to take
the individual strings offline for characterization.
Step 1 - Characterize the first string

Follow the instructions in Characterize the Batteries on page 55.

Step 2 - Connect to the CBC with DCTools

See Connecting a PC to the CBC on page 46.
Ensure the Hold Changes button is enabled. This will ensure multiple data
changes can be made prior to updating the CBC.


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Step 3 - Copy characterization data

1 In DCTools go to Characterization then click on + beside Management.

2 Select String 1 from the drop down list on the left of Copy to >>.
3 Select String 2 from the drop down list on the right of Copy to >>.
4 Press Copy to >>.

Step 4 - Repeat for additional strings (if required)

1 Select String 3 / String 4 (as required) from the drop down list on the
right of Copy to >>.
2 Press Copy to >>.

Data Management

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95

Step 5 - Verify copied data

1 Click on + beside Graph. The graph for string 1 is displayed.

2 Moved the String: slider control to view the graphs for the other
strings.
The new data is displayed in blue. This indicates that the change is still
pending. The copied data will be updated when Apply Changes is enabled.

Step 6 - Update CBC

Select Apply Changes to update the CBC's database.
Procedure complete

Copy data from another CBC
The Characterization Data Management feature allows data to be copied from one CBC to
another.
Step 1 - Connect to the CBC with DCTools

See Connecting a PC to the CBC on page 46.
Ensure the Hold Changes button is enabled. This will ensure multiple data
changes can be made prior to updating the CBC.


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Step 2 - Save the characterization data

1 In DCTools go to Characterization then click on + beside Management.
2 Select All Strings, String 1 etc (as required) from the drop down list on
the left of Save to File ....

3 Press Save to File ... select a file name and location and click Save.

The file extension will depend on whether "All" strings or a "Single" string
characterization data was saved. (All = .sca; Single = .scs)

Step 3 - Load data into new CBC

1 Connect to the new CBC with DCTools.
Ensure the Hold Changes button is enabled. This will ensure multiple
data changes can be made prior to updating the CBC.
2 Go to Characterization then click on + beside Management.
3 Select All Strings, String 1 etc (as required) from the drop down list on
the left of Load from File ....
4 Press Load from File ... navigate to the saved file and click Open.

Data Management

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Step 4 - Verify copied data

1 Click on + beside Graph. The graph for string 1 is displayed.

2 Moved the String: slider control to view the graphs for the other
strings.
The new data is displayed in blue. This indicates that the change is still
pending. The copied data will be updated when Apply Changes is enabled.

Step 5 - Update CBC

Select Apply Changes to update the CBC's database.
Procedure complete

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IPN 997-00012-20F J uly 2009

Equipment Incident Report

EQUIPMENT INCIDENT REPORT

Please enter as much information as you can. Send the completed form, together with the item for repair to your
nearest authorized service agent. NOTE: Only one fault to be recorded per form.
For further information contact your local Eaton dc product supplier or Eaton (see contact details on page 101). Or
email: CustomerServiceNZ@Eaton.com

Date:

Customer Information
Company:
Postal Address:

Return Address:
(Not PO Box)

Telephone: Fax: Email:
Contact Name:

Location of Failure
Product code: Serial number: Document number:
System type installed in: Serial number:
Site name or location:

Fault discovered Delivery Unpacking Installation
Initial test Operation after _____ years Other ___________

Failure source Design Manufacturing Documentation
Transportation Installation Handling
___________

Effect on system operation None Minor Major _________________

INFORMATION (fault details, circumstances, consequences, actions)

Internal use only.
Reference No: __________ RMA: __________ NCR: __________ Signature: _________________ Date: __________

IPN 997-00012-20F J uly 2009
99

INFORMATION continued (fault details, circumstances, consequences, actions)

SG/03 ISS06

Worldwide Support

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101

Worldwide Support
For product information and a complete listing of worldwide sales offices, visit Eaton's
website at: www.Eaton.com/telecompower or email: DCinfo@Eaton.com
For technical support contact either your local Eaton dc product representative, the closest
office from the following list, telephone (+64) 3 343-7448, or email
CustomerServiceNZ@Eaton.com

Australia 1300 877 359
Canada 1-800-461-9166
Central America +52 55 9000 5252
China +86-571-8848-0166
Europe / Middle East / Africa +44-1243-810-500
Hong Kong / Korea / Japan +852-2745-6682
India +91-11-4223-2325
New Zealand 0800 DC Power (327-693)
Singapore / South East Asia +65 6825 1668
South America +54-11-4124-4000
South Pacific +64-3-343-7448
Taiwan +886-2-6600-6688 or free call 0800-038-168
United States of America
(Toll Free)
1-800-843-9433


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Index

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103

Index
A
Alarms 2
Alarm Messages 79
Alarm Relays 2, 28, 42
LED States See Status LEDs
Troubleshooting 74
Ambient Temperature Sensor 5, 22
Check Temperature Readings 50
Mounting the TS2-A04 22
Ambient Temperature Sensor (TS2-A04) See
Ambient Temperature Sensor
Auxiliary Power Module (APM) 7
Mounting the APM Modules 21, 32
Powering the CBC 29, 43
RS485 Load, Bus Length and need for APMs
7, 85
Specifications 77
B
Battery Capacity Low Alarm 82
Battery State Of Health Fail Alarm 83
Battery State Of Health Low Alarm 83
Battery State Of Health Poor Alarm 83
Bloc Capacity Low Alarm 81
Bloc State Of Health Fail Alarm 82
Bloc State Of Health Low Alarm 82
Bloc State Of Health Poor Alarm 82
Bloc Volt Divergence Charge Alarm 84
Bloc Volt Divergence Discharge Alarm 80
Bloc Volt Divergence Float Alarm 79
Bloc Volt High Float Alarm 80
Bloc Volt Low Float Alarm 80
Bloc Voltage Failure Alarm 79
C
C2M and C2M-TS 2V Sensor Modules 3, 21
Mounting the C2M-TS and C2M Modules 21
C6M/C12M 6V/12V Sensor Modules 4
Mounting the C6M/C12M Modules 32
Powering the C6M/C12M Sensor Modules
43
Cable Lengths for EMC Compliance 10
Cautions See Warnings
CellSure Battery Controller (CBC) 2
Mounting the CBC 21, 32
PC Connection to CBC 46
Characterize the Batteries 53
Copy Characterization Data 89
Default Characterization Data 59
Circuit Diagrams (2V Cells)
1 String 24
2 Strings 25
3 Strings 26
4 Strings 27
Circuit Diagrams (6V/12V Monoblocs)
24V, 12V, 1-4 Strings 40
24V, 6V, 1-4 Strings 39
48V, 12V, 1-4 Strings 38
48V, 6V, 1-2 Strings 36
48V, 6V, 3-4 Strings 37
Communications
CBC Communications 2
Communications Settings 64, 69
Direct Connection Option 64, 69
Ethernet Option 64, 69
Modem Option 64, 69
Multidrop Option (RS485) 64
Passthrough Communications (with
SM45/SM65 only) 69
Serial Server Communications (SC200) 67
Setup External Communications 64
Stand-alone Mode 64
TPC Session Failed Error 46
Troubleshooting 74
Configuration File 2
Configuration File Updating 47, 48, 60
Copy Characterization Data 89
Current Shunts/Sensors 5, 6
Calibration 51
Current Sensor (CS04-A11) 6
Current Shunts 5
Installation 14

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Mounting CS04-A11 Current Sensors 14
Mounting Current Shunts 14
D
Damage (transport) 11
DCTools i, 47
Download DCTools 46
E
EMC Compliance See Warnings
Equalizing Bars (required on 2V cells) 20
F
Full Discharge Completed Alarm 83
L
LED States See Status LEDs
Lengths of Cables
Cable Lengths for EMC Compliance 10
Length of RS-485 Bus Cable 85
N
Nickel-cadmium Battery Systems 11
P
Partial Discharge Completed Alarm 83
SM45/SM65 only) 69
Problems See Troubleshooting
R
Relays (alarm) 2, 28, 42
Repair and Return 93
Reserve Charge Low Discharge Alarm 81
Reserve Time Low Discharge Alarm 81
RS232 Communications
Direct Connection Option 64, 69
Modem Option 64, 69
RS232 Connector (on CBC) 2
RS485 Communications
Multidrop Communications Option 64
RS485 Connector (on CBC) 2
RS485 Load, Bus Length and need for APMs
7, 85
S
SC200 System Controller
Sensor Modules
2V (C2M and C2M-TS) See C2M and C2M-
TS 2V Sensor Modules
6V/12V Sensor Modules (C6M/C12M) See
C6M/C12M 6V/12V Sensor Modules
Short-Circuit Protection Module (SP8CM) 4
Mounting the SP8CM Modules 33
SM45/SM65 Supervisory Modules
Configure the SM45 or SM65 for CellSure 69
SM45/SM65 only) 69
Software Required i
SP8CM Short-Circuit Protection Module 4
Specifications
APM 77
Stand-alone Mode 64
Start Of Charge Alarm 84
Start Of Discharge Alarm 81
Start Of Float Alarm 84
Status LEDs 2, 74
String Capacity Low Alarm 82
String Current Divergence Charge Alarm 84
String Current Divergence Discharge Alarm 81
String State Of Health Fail Alarm 83
String State Of Health Low Alarm 82
String State Of Health Poor Alarm 83
String Temp High Absolute Alarm 79
String Temp High Ambient Charge Alarm 84
String Temp High Ambient Float Alarm 80
T
Technical Assistance 95
Temperature Range 11
Temperature Sensor
2V (C2M-TS) See C2M and C2M-TS 2V
Sensor Modules
6V/12V (TS8CM) See TS8CM 6V/12V
String Temperature Sensor
Index

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105

Ambient (TS2-A04) See Ambient
Temperature Sensor
Troubleshooting 74
TPC Session Failed Error 46
Troubleshooting 74
Damage (transport) 11
Repair and Return 93
Technical Assistance 95
TS8CM 6V/12V String Temperature Sensor 5
Mounting the TS8CM 33
U
UPS Battery Systems 11
W
Warnings 10

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