SECTION 26 33 46

BATTERY MONITORING

NDSL, Inc. - Cellwatch

Battery Monitoring System

PART 1 - GENERAL

1.1SECTION INCLUDES

  1. A monitoring system for lead acid and nickel cadmium batteries used as back-up power. Monitoring system consists of a means for monitoring battery voltages, Ohmic value, temperature and current. Custom wiring harnesses shall not be used and no load greater than 4 amps shall be used for measuring Ohmic values.
  2. Windows 7embedded software, hardware, cabling and associated accessories shall be included with the system.

1.2REFERENCES

  1. Reference Standards:
  2. Underwriters Laboratory (UL)

1.UL 1015: Vertical Wire Flame Test, Class 1

2.UL 61010B-1: Electrical Measuring and Test Equipment;
Part 1: General Requirements.

  1. Canadian Standards Association (CSA)

1.CAN/CSA C22.2 No. 1010-1: Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use – Part 1: General Requirements.

  1. International Organization for Standardization (ISO)

1.ISO 9001: Quality management systems – Requirements for quality of manufactured goods.

  1. National Electric Code (NEC)
  2. National Fire Protection Association (NFPA):
  3. NFPA 70: National Electric Code.
  4. cTUVus
  1. Definitions:
  2. Battery: A DC electrical storage system consisting of cells or jars connected in series to achieve the required DC voltage. Strings are connected in parallel to achieve the required back up time.
  3. String: A sub-division of a battery. A group of cells or jars connected in series.
  4. Jar: A housing which contains multiple cells.
  5. Cell: The basic unit of a Jar, traditionally consisting of lead acid and delivers a nominal 2 VDC.
  6. Pilot Cell: One jar of a string selected to obtain temperature readings.

1.3ADMINISTRATIVE REQUIREMENTS

  1. Pre-installation meeting: Conduct a pre-installation meeting at the job site attended by Owner, manufacturer’s technical representative, installer, and contractors of related trades. Coordinate installation, and other requirements specific to the project.

1.4SUBMITTALS

  1. Refer to Section [01 33 00 Submittal Procedures][insert section number and title].
  2. Product Data: Submit manufacturer current technical literature for each type of product.
  3. Quality Assurance Submittals
  4. Warranty:
  5. Manufacturer Installation Instructions: Provide manufacturer’s written installation instructions including proper material storage, and maintenance instructions.
  6. Submit copy of manufacturer’s warranty.

1.5QUALITY ASSURANCE

  1. ManufacturerQualifications:
  2. Manufacturer shall have comparable Battery Management Systems (BMS) in operational service a minimum of ten (10) years.
  3. Manufacturer shall be registered and certified by ISO 9001.
  4. Manufacturer shall have a minimum of 2 sources for all major manufactured components, both shall be ISO 9001 registered and certified.
  5. Upgrades to the system shall have backward compatibility so that the major components are not required to be replaced.
  6. Installer Qualifications:
  7. Installer shall be authorized and trained to install BMS by the manufacturer.

1.6DELIVERY, STORAGE AND HANDLING

  1. Refer to Section [01 60 00 Product Requirements] [insert section number and title].
  2. Deliver materials and components in manufacturer’s original, unopened, undamaged packaging with identification labels intact.
  3. Store materials on dry, level, firm, and clean surface.

1.7WARRANTY

  1. Warranty:
  2. Standard form in which manufacturer agrees to repair or replace products that are defective in materials or workmanship within the specified warranty period.

1.Warranty Period: One (1) year from date product is placed in service, or 15 months from date of shipment from manufacturer, whichever occurs first.

PART 2 - PRODUCTS

2.1MANUFACTURER

  1. NDSL Inc. Raleigh, NC 27612;919 790-7877 (
  2. Basis of Design:
  3. Cellwatch Battery Monitoring System.
  4. Substitution Limitations:
  5. Submit written request for approval of substitutions to the [Architect] [Engineer]a minimum of [14] days prior to the date for receipt of bids [Insert bid date]. Include the following information:

1.Name of the materials and description of the proposed substitute.

2.Drawings, cutsheets, performance.

3.List of projects of similar scope.

4.Other information necessary for evaluation.

5.List ofall exceptions and Deviations to this specification.

  1. After evaluation by [Architect] [Engineer], if approved, approval will be issued via addendum. No verbal approval will be given.
  2. Substitutions following award of contract are not allowed except as stipulated in Division 01 – General Requirements.

2.2PERFORMANCE CRITERIA

  1. Battery Monitoring System (BMS):
  2. Battery types monitored by semi-permanent connection to battery system:

1.Valve regulated lead acid (VRLA) Sealed batteries: Ohmic value range of 200µΩ to 25.9mΩ.

2.Flooded cellsor Valve regulated lead acid and 2v VRLA: Ohmic value range of 5 µΩ to 65mΩ.

3.Ni-CAD batteries. Ohmic value range of 50 µΩ to 20 mΩ.

4.Straps from 1 micro ohm to several hundred micro ohms.

  1. Components shall have the following regulatory approvals:

1.The following listings are for electrical safety:

1)UL 61010-1 2012

2)cTUVus

3)CAN/CSA C22.2 No. 61010-1-12

4)EN 60101-1:2010 (3rd edition)

2.Listings for electrical noise emissions and susceptibility.

EN 61326:1:2006

  1. System Capacity:

1.Voltage value measurement points: 1 to 30,000.

2.Ohmic value measurement points: 1 to 30,000.

3.Ripple Voltage measurement.

4.Supports different voltage cells, from 2vdc to 16vdc on the same system.

5.Current Sensors: 1 to 124.

6.Temperature Sensors: 1 to 124.

7.IntegratedBattery Monitoring Unit (iBMU) – Component capacity: 31 Control Units (CU).

8.Control Unit (CU) – Component capacity:

1)254 Data Collection Modules (DCMs) or 4 strings.

2)4 current measurement inputs.

3)4 temperature measurement inputs.

4)4 volt free relay contact for external alarms.

5)For Control Units with the Thermal Runaway option:

1.The system will meet IFC 608.3.

2.Additional relays will be incorporated to disconnect each string. The relays will be rated up to 30vdc or 250vac and 5amps.

3.Visual indicators will be used on each Control Unit to indicate when one of its strings is in Thermal Runaway.

  1. Measurement ranges:

1.Point Voltages: 2vDC to 16vDC nominal.

2.Temperature measurement: plus 36 to 176 degrees F.

3.Ohmic value range: 50 to 25,000 µΩ. (1 to 65,000 micro ohms for DCM 5)

4.Current measurement: Scalable10–5000 amps depending on number of conductors used.

  1. The system shall not require any calibration at installation, yearly intervals or when jars are replaced.
  2. Components of the BMS shall be reconfigurable to allow for changes in battery layouts and have the ability to add or remove BMS components without changing the entire system. New components or revisions shall be backward compatible.
  1. Software:
  2. System shall operate using Windows 7 embedded operating system and shall be capable of loading operating system without user intervention.
  3. Monitoring capabilities:

1.Monitored Data: Provide for each [Cell],[Jar][or][String where indicated], in the BMS. Each operation listed shall be capable of being programmed with upper and lower alarm operating limits.

1)Voltage (The BMS shall be able to support different voltage cells on the same system).

2)Ohmic value (including inter-cell link resistance).

3)Charge/Discharge current.

4)Pilot jar and individual jar temperatures.

5)Ambient temperature.

2.Alarm conditions: Program shall be capable of indicating the following either by visual alarm indicatororaudible alarm. Alarms shall be able to be set globally or individually and shall adjust automatically after 35 days:

1)Voltage out of tolerance

2)Ohmic value out of tolerance

3)Current out of tolerance

4)Temperature out of tolerance

5)Ripple voltage out of tolerance

6)String voltage out of tolerance

7)Current Discharge Event: Occurs when the current discharge exceeds the predetermined or programmed limits set.

8)The system shall provide four volts free alarm relays to permit interface to third party devices.

9)Thermal Runaway (optional) shall be able to meet the requirements of IFC 608.3 and shall include an audible and visual alarm capabilities including LEDs on the Control Unit, a warning state with programmable delay to isolate the string from the UPS. The Thermal Runaway condition shall be dependent upon current, temperature of string or jar and jar voltage. The BMS shall provide advanced notification so issues can be addressed without putting mission critical loads at risk.

10)E-mail Alert Alarm Notification. The BMS shall have the ability to send an e-mail when an alarm occurs. Each e-mail send will include details about the side location, battery, string, date, time and type of alarm event: voltage, ohmic value, current, thermal runaway or discharge.

3.Monitoring frequency: The customer shall have the ability to set the frequency of data collection for voltage and ohmic value. Voltage data shall be able to be logged constantly, every hour or every 6 hours. Ohmic value shall be logged every 12 or 24 hours.

1)Continuously measure the following at an interval of more than once per minute:

1.Charge current.

2.Discharge current.

3.Pilot jar and individual jar temperatures.

4.Ambient temperature.

5.Individual Jar voltage during discharge.

2)Float voltage measurement: Measurement set between [4] [24]times each day.

3)Ohmic measurement: Measurement set to [1][2]time[s] each daybut no less than one a day.

  1. Monitored Data and Analysis: All retrieved data shall be stored and may be displayed as a spreadsheet in most formats (e.g. Microsoft Excel).The system shall have the ability to store multi-year historical data on the iBMU. All files except the .xcfg can be modified to a CSV file for easy viewing.

1.Daily Archival:

1)Monitored data shall be averaged.

2)A trend analysis of monitored data.

3)Ability to display archived averaged data and trend analysis.

2.Analysis Graphs: Displayed as line or bar charts, except trend analysis and discharge graphs which shall be displayed as line graphs.

1)Each cell or jar’s monitored data for the current day.

2)Each cell or jar’s monitored complete historical data.

3)Most recent voltage and ohmic reading for each string.

4)A trend analysis of monitored data for each year of operation.

5)An analysis of the best and worst performing cells, jars or strings in a system discharge. Provide the capability of adding all cells, jars in the system.

6)Alarm condition – Current outflow event: Discharge analysis showing all battery voltage curves for performance analysis. Graph shall be able to show from one to all cells or jars in the system.

3.Analysis graphs shall be capable of allowing user defined colors.

4.Analysis graphs shall be printable, each graph individually or all graphs.

  1. The system shall support Modbus TCP/IP and SNMP interfaces.
  2. The system shall incorporate a separate program to manage alarm data. It shall include the ability to sort events by type, alarm value, time and start or end date. All reports can be generated and exported to a CSV file. All active alarms shall be shown in red, acknowledged alarms shall be shown in blue. Users must be able to filter alarm events by using the battery, string or cell/probe selections. Only batteries, strings and cells/probes that have alarmed will be available for filtering.
  3. The system shall be able to provide reports for:

1.Total String/Battery Float Voltage

2.Individual Jar/Cell Float Voltage

3.Discharge Voltage per Jar/Cell

4.String Current

5.Ambient Temperature

6.Pilot Temperature

7.Per Cell Temperature

8.Ripple Voltage

9.Thermal Runaway Conditions

1)Dependent upon Current, String Temperature and Jar Voltage

  1. The system shall be able to physically identify any jar(s) under investigation via a ping feature which will cause an audible alarm and flash an LED at the DCM(s) indicating which jar(s) under investigation.

2.3COMPONENTS

  1. IntegratedBattery Monitoring Unit (iBMU): The iBMU will control all aspects of the monitoring process including: retrieving, displaying and saving data; indicating alarm activation; processing data for historical trending; real time calculations; and control outputs to trigger external functions. The data will be presented on a customer supplied and connected color screen or over an Ethernet network connection using PCAnywhere, Remote Desktop, or a customer supplied and connected KVM over IP. A KVM over IP option allows the iBMU to be accessible via the network but isolated from the network as the KVM connects directly to the Video, Monitor, and Mouse ports on the iBMU.
  1. iBMU hardware – minimum requirements:

1.1.6 GHz Atom Processor

2.1 GB Memory

3.16 GB CF Solid State Hard Drive

4.Windows 7embedded operating system

5.Fanless Mother Board

6.2 Network Interface Connector (NIC) 10/100/1000 MHz Ethernet Connections

1)One static service port (192.168.0.128/255.255.255.0)

2)One dynamic (DHCP enabled)

7.1 VGA Video Port

8.1 RS 485 Port for connections to the Control Unit(s)

9.6 USB Ports

10.2 RS 232 Com Ports

11.1 Modem

12.Communicates with up to 31 Control Units

  1. Power: [110] [240] VAC, 300 Watts, must be powered from a UPS backed supply
  2. Mounting: [Wall] [Rack] mounted.
  3. Component connections: RS485 cable, Belden 8102 or 88102.
  4. Standard connections for external components:

1.Ports: Printer, [1 USB port].

2.Modem: Integral modem for standard subscriber trunk dialed analog line (V90-56K). Customers requiring remote monitoring capability will require a dedicated analog phone line to be available. The modem can be used to connect to the iBMU via Remote Desktop in secure sites where a phone connection is made available. It can also be used to dial an internet connection to send email notifications through Email Alert or Cellwatch.net.

3.Optional Keyboard Interface Type (Customer Supplied) Standard PC PS/2 or USB keyboard and mouse. Optionally KVM or KVM over IP devices may be used.

B. Control Unit (CU): The Control Unit shall communicate to the DCMs via a fiber optic loop.The functions of the Controller include; conversion between digital RS485 and optical signals, up to four independent current readings per Control Unit, up to four independent temperature reading per Control Unit for ambient and/or pilot cell temperatures and the facility for four volt free contacts to be used as alarm and control outputs. A total of 31 RS-485 Addresses can be connected to a single IBMU. The last Control Unit must be within 2000’ of the iBMU. For Control Units with Thermal Runaway protection, additional relays will be incorporated to allow the disconnect of battery cabinet circuit breakers by either UVR or shunt trip.

1.Power: [110] [240] VAC, 20 Watts,must be powered from a UPS backed supply

2.CU hardware – controls 254 DCMs, includes 4 current inputs, 4 temp. probe inputs and 4 volt free relay contacts (10 relays for the Thermal Runaway option)

3.Maximum number of CUs per RS 485 bus is 31

4.Interface for generator extension kit to be RJ45

5.Component connection: RS485 cable, Belden 8102 or 88102.

6.Mounting: Wall mounted.

7.Sensing inputs:

1)Temperature- Solid state probe

2)Resolution- 0.05 degrees C

3)Accuracy- +/- 1 degree C

4)Range- 2 to 80 degrees C

5)Current- Solid state magnetic core sprung clamp 2” (50mm) capacity 1,000 amps or 4.5” (112mm) 2,500 amps

6)Resolution- 0.5 amps

7)Useful Range- +/- 10 to maximum amps of clamp

8)Communication rate- 9600 baud

  1. Data Collection Module (DCM): Data collection modules are voltage and Ohmic Value (O.V.) measurement instruments that can measure the voltage and O.V. of up to four measurement points to which they are connected. DCM’s with the temperature option will also be able to monitor the jar temperature at the negative post. They are designed to be connected in a serial data loop. This loop will utilize fiber optic cable for reliability, noise elimination and safety. Electrical wiring between DCM’s is NOT acceptable. Each DCM has a transmitter (white or blue connector) and a receiver (black connector) that is fiber cabled to the next DCM and continues until a loop is formed returning to the Controller. Maximum distance to each DCM will be no longer than 150’. The maximum rating of any DCM is 80VDC.
  2. Mounting: Dual Lock
  3. EachDCM can measure up to 4 jars or cells data. Data collection includes:

1.Voltage

2.Ohmic Value

  1. DCM shall have a sleep mode that after 25 hours of no communication with the Control Unit it shall reduce the power requirement to less than 2ma to conserve battery life.
  2. Maximum current draw during ohmic testing shall be 2 amps.
  3. Voltage range shall be 0 to 80vdc with 2mv resolution with accuracy of 0.1%, +/-5mv.
  4. Ohmic value range 0 to 65 milliohms with accuracy of 2%, +/- 8 micro ohms (For DCM 5s accuracy shall be 1.5%).
  5. Ripple voltage (across 4 jars, 40 Hz to 1K Hz) range 0 to 4 v rms with resolution of 2mv rms and an accuracy of 2%, +/-5mv rms.
  6. Component connection:

1.Factory installed terminators on wire harness to Jars 40” standard length

2.Fiber optic cable for data communication between DCM’s and the CU

  1. Cable Specifications:

1.Conductors shall be minimum 22 and maximum 14 AWG, 300 v rated, 15 amp maximum, insulated wire meeting the requirements of UL 1015

2.Conductors shall be color coded

3.All wiring that connects to the battery should be acid resistant.

4.Fiber optic cable shall be acrylic, 1.0mm core diameter and 2.2mm outside diameter with a 400-700 nm wavelength. The primary function of the fiber optic network is to supply a highly efficient medium, which allows for ease of installation and safety in operation. The supplied cable must be acid resistant, highlyisolated, and immune to electrical noise. The fiber optic network enables serial connection or ‘daisy chaining’ of the DCMs. The fiber optic cable joins each DCM serially to the Control Unit.

  1. Current Transducers (CT):
  2. Mounting: Battery lead
  3. Component connections: Standard 35’cable provided by manufacturer. Maximum distance is 150’.
  4. Solid state, magnetic core sprung clamp. 2” (50mm) capacity, 1,000 amp or 4.5’ (112mm) 2,500 amp.
  5. Maximum of 4 CT’s per CU
  6. Communication rate 9600 baud
  7. Range +1000 to -1000A
  8. Sensitivity 1mV/A
  9. Resolution 0.5A
  1. Temperature Transducer
  2. Mounting: Adhesive provided by manufacturer
  3. Component connections: Standard 35’ cable provided by manufacturer. Maximum distance is 150’.
  4. Maximum of 4 temperature transducers per CU
  5. Range 2C to 80C
  6. Accuracy +/- 1C

2.4Additional system capabilities.

  1. Generator Kit: The system shall be capable of monitoring remote batteries typically used for generators up to 4000ft from the CU.

CAT5 cable provided by electrical contractor.

PART 3 - EXECUTION

3.1EXAMINATION

  1. Equipment: Install to facilitate service, maintenance, and repair or replacement of components of electrical equipment. Connect in such a way as to facilitate future disconnecting with minimum interference with other components.
  2. Verify that power source for all equipment is as required by manufacturer.

3.2PREPARATION

  1. Coordinate external enunciator’s location and connection to BMS.
  2. Conduit installation:
  3. Listing and Labeling: Metal conduits, tubing, and fittings shall be listed and labeled as defined in NFPA 70, by a qualified testing agency, and marked for intended location and application.
  4. Electrical Contractor to install conduit and provide 120VAC circuit with duplex outlet from the UPS output to provide power to the iBMU and Control Units.
  5. Electrical Contractor to add a network drop and coordinate with end user for provisioning an IP address.

3.3INSTALLATION