Installation Guide

Battery Monitor

CAN Bus Node

Smartpack based DC Power Supply Systems
.
351507.033

351507.033

Issue 1.2e, 2010 Apr

Published 2010-04-09
MfM

Installation Guide Battery Monitor CAN Bus Node

351507.033, Issue 1.2e, 2010 Apr

Table of Contents
1.

Introduction ................................................................................. 4
About this Guide................................................................................................ 4
System Diagram CAN Bus Nodes ................................................................ 4

2.

Battery Monitor, CAN Bus Node ................................................ 5

Key Features ..................................................................................................... 5
Typical Applications .......................................................................................... 5

3.

Installation of Battery Monitors.................................................. 6

Safety Precautions ............................................................................................ 6

Basis Installation Steps ................................................................................... 6

Fastening the Battery Monitors ......................................................................... 7
Location of Connectors, Ports, LEDs ................................................................ 7
Connection Drawing .......................................................................................... 8
Battery Symmetry Connections ......................................................................... 9
Block Measurements ................................................................................................ 9
Mid-point Measurements ........................................................................................ 10

Battery Terminology ........................................................................................ 10

CAN Bus Termination ..................................................................................... 11
Removing the Smartpack Controller....................................................................... 11

Configuration................................................................................................. 12
CAN Bus Addressing ...................................................................................... 12
About PowerSuite Configuration ..................................................................... 13

4.

Technical Specifications........................................................... 14

Installation Guide Battery Monitor CAN Bus Node

351507.033, Issue 1.2e, 2010 Apr

1. Introduction
Congratulations on your purchase of the Battery Monitor, CAN Bus Node, an intelligent
plug-and-play module to decentralize and expand the functionality of your Smartpack
based DC power supply system.

About this Guide

This booklet provides you with the required information for installing the Battery Monitor,
CAN Bus Node in your Smartpack based DC power supply system. The booklet also
presents the Battery Monitors technical specifications.
For more detailed description of the Battery Monitor, CAN Bus Node, read the Users
Guide Smartpack Monitoring and Control Unit, Art. 350003.013.
For description of how to activate and configure the Battery Monitor, CAN Bus Node using
the PowerSuite PC program, refer to the PowerSuite online Help system.
Refer also to Installation Guide Battery Monitor Symmetry Kit, document number
351497.033, which is included with the kit.

System Diagram CAN Bus Nodes

The Battery Monitor, CAN Bus Node is used as a building block in Smartpack based power
supply systems, see Figure 1. Other CAN bus nodes, like the Load Monitor and the
I/O Monitor, may also be connected to the bus. The nodes are powered directly from the
CAN bus, and have dedicated inputs and outputs that expand the system monitoring and
control capability.
The Smartpack controller monitors and controls the whole system, and serves as the local
user interface between you and the system. The PowerSuite application enables you to
configure and operate the system from a personal computer.

USB A-B cable

(standard)
1
Smartpack Controller

120
End-of-Line
Resistor

CAN bus
(twisted-pair CAT5 cable)

Battery
Monitor

Load Monitor

Flatpack2 Rectifiers

01

ID Number
33

02

120

81
I/O Monitor

Battery string #1
Flatpack2
DC Power System

End-of-Line
Resistor

49

Temp, Fan Speed Mon & Ctrl

Alarm Outputs NC-C-NO

Shunts

Current Monitoring
Sense Inputs
Fuses

Config. Inputs

Fuse Monitoring
Configurable Inputs

Figure 1 Example of three CAN bus nodes connected in a Flatpack2 DC Power Supply System

Installation Guide Battery Monitor CAN Bus Node

351507.033, Issue 1.2e, 2010 Apr

2. Battery Monitor, CAN Bus Node

The Battery Monitor CAN Bus Node enables you to decentralize and increase the number
of battery symmetry measurements in your Smartpack based DC power supply system.
Also, it monitors the battery compartment temperature using the built-in sensor the
battery fuse with a fuse monitoring input and the battery current via a current sense
input.

Key Features
A wide range of features are implemented in the Battery Monitor CAN Bus Node, as
mentioned below:
Powered via the CAN bus; no external power supply required
Firmware upgrade via the CAN bus (see required SW Upload tools on page 14)
4 battery symmetry inputs
for battery strings symmetry measurements
1 fuse monitoring input
user configurable for fuse monitoring and other site equipment monitoring
1 battery current sense input
for bi-directional current monitoring through external current shunts
1 battery temperature sense input
via the built-in temperature sensor
Storage of calibration data and real time event log
Windows-based setup, configuration and calibration via PowerSuite
Flexible mounting using Velcroue adhesive tape on the bottom of the unit
Up to 14 the Battery Monitor modules may be connected the CAN bus
CAN bus addressing via DIP switches
Read also chapter Technical Specifications, page 14, for more details.

Typical Applications
The Battery Monitor CAN Bus Node is employd in Smartpack-based DC power systems, to
implement flexible expansion and distribution of system functionality.
The Battery Monitor CAN Bus Node is suitable for distributed monitoring of battery
symmetry, fuse, current and temperature of local and remote located battery banks.

Installation Guide Battery Monitor CAN Bus Node

351507.033, Issue 1.2e, 2010 Apr

3. Installation of Battery Monitors

You can install the Battery Monitor CAN Bus Node if your DC power system meets the
following requirements:
1. The systems Smartpack controller has firmware version 2.03 or higher installed
Version
Sensitive

2. You have a PC with PowerSuite application version 2.3 or higher installed

You need standard installation tools and equipment used by an authorized electrician.
NOTE: All tools must be insulated.

Safety Precautions
Follow these precautions during installation, commissioning and general handling of the
Smartpack-based power supply system.

Qualified
personnel

Electric
shock

CAUTION: For safety reasons, the commissioning and configuration of the equipment is
only to be performed by Eltek s personnel or by authorized and qualified persons;
otherwise the warranty may be invalidated.
Please, read the user documentation carefully before installing and using the equipment,
as installation and operation is to be performed as described in it.
WARNING: The batteries represent a major energy hazard. To avoid short-circuit of
battery poles, you must always remove metallic objects uninsulated tools, rings,
watches, etc. from the vicinity of the batteries.

Basis Installation Steps

Carry out these steps to install the Battery Monitor CAN Bus Node in your DC power
system.
Refer also to Installation Guide Battery Monitor Symmetry Kit, document number
351497.033, which is included with the kit.
Power is ON!
1. Assign the Battery Monitors CAN bus address, by
setting the Battery Monitors DIP switches. Read to chapter CAN Bus
Addressing, page 12
2. Terminate the CAN bus, by
e.g. removing the CAN bus termination plug from the controller and plugging it on
the last connected Battery Monitor or node. Read CAN Bus Termination, page 11
3. Attach the Battery Monitor to a battery block;
Read chapter Fastening the Battery Monitors, page 7
4. Connect the required input cabling to the terminals;
Read chapter Connection Drawing, page 8
5. Configure the Battery Monitor nodes operation,
using the PowerSuite application, read chapter About PowerSuite Configuration,
page 13

Installation Guide Battery Monitor CAN Bus Node

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Fastening the Battery Monitors

You mount the Battery Monitor CAN Bus Node on a battery block, using the Velcroue
adhesive tape on the bottom of the module. Thus, the built-in temperature sensor will
monitor the battery temperature accurately.
For more exact measurements, attach the monitor on the front of a battery block. If not
possible, you can fix it on the side of the outer battery block, or on top, or on the cabinets
inner side wall

Location of Connectors, Ports, LEDs

Warning

Alarm

LED Lamp (yellow)

LED Lamp (red)

CAN port 1&2

Power

Pin 8

Electrically identical

LED Lamp (green)

Pin 1

Battery Monitor

DIP switches
CAN ID address

Battery Monitor

Monitor Inputs
Terminal Block

DIP switch #1

Figure 2 Location of terminals, DIP switches, CAN ports and LED indicators in the Battery Monitor

CAN port 1 and 2 are electrically identical, and are used to enable connection of the CAN
bus incoming and outgoing CAT5 cables, or the RJ45 CAN bus termination plug.

LED
Indicator
Power
Warning
Alarm
Other

Illumination
Status
OFF
ON green
OFF
ON yellow
OFF
ON red
Green ON & Red Flashing
Green OFF & Red Flashing

Description
The monitor has NO supply
The monitor has supply
No Warning
Warning (Non-critical alarm)
No Alarm
Alarm (Critical Alarm)
Supply voltage too low
Firmware boot-loading

Table 1 Description of the Battery Monitors LED illumination status

Installation Guide Battery Monitor CAN Bus Node

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Connection Drawing

To next CAN bus

node

Use this drawing as a connection reference for all cabling. You find the exact location of
connection terminals, plugs and DIP switches, by referring to chapter Location of
Connectors, Ports, LEDs, page 7.

Battery Monitor Connections

Part 242100.300
Battery
Monitor

FUNCTION

SIGNAL PIN-OUT

X:*
+
+
+
+
Batt. Fuse +

Batt. Current +

CAN port 1&2

1.5 mm , max.
wire section

From previous CAN

bus node

RJ45, 8 pins
Built-in Battery
Temperature Sensor

(From the current shunt)

(From the battery fuse)

Or
RJ45 CAN bus
termination plug,
if the Battery
Monitor is the
last node in the
CAN bus

(From the
batteries)

1
2
3
4
5
6
7
8

Batt. Symmetry 1
Batt. Symmetry 2
Batt. Symmetry 3
Batt. Symmetry 4

Figure 3 Connection Drawing Battery Monitor CAN Bus node

Electric
shock

WARNING: Switch the battery fuses OFF before connecting the symmetry wires!
1st Fasten the wires to the battery monitor. 2nd Fasten cable lugs to the other cable ends.
3rd Connect the cable lugs to the battery terminals.

Read chapter Battery Symmetry Connections on page 9.

Refer also to Installation Guide Battery Monitor Symmetry Kit, document number
351497.033, which is included with the kit. The Battery Fuse and Battery Current cables
are not shipped with the Battery Monitor ~ Symmetry Kit.
You find more information on chapter Technical Specifications, page 14.

Installation Guide Battery Monitor CAN Bus Node

351507.033, Issue 1.2e, 2010 Apr

Battery Symmetry Connections

Block Measurements
Block Measurement
Four measurements per string

Four measurements per string

Battery Monitor
Part 242100.300
ID# <33>

Block3

Block4

Intercell Links

Battery
String 2

Four measurements per string

Block1

Intercell Links

Block3

Block4

+
0V Outer
Terminal

Symmetry 4.2

Symmetry 4.1

Symmetry 3.4
+

- + - + - + - +

(-48V) Outer
Terminal

Battery Monitor
Part 242100.300
ID# <36>
Set DIP switch 1 2 3 4
1&2 ON (down),
the rest OFF
(up)

Symmetry 3.3

Symmetry 3.2

Symmetry 3.1
Battery
String 3

Symmetry 2.4

0V Outer
Terminal

Four measurements per string

Set DIP switch 1 2 3 4

2 ON (down),
the rest OFF
(up)

Block4

Battery Monitor
Part 242100.300
ID# <35>

Block3

Block1

Intercell Links

0V Outer
Terminal

- + - + - + - +

(-48V) Outer
Terminal

+
Battery
String 4

- + - + - + - +

(-48V) Outer
Terminal

Symmetry 4.4

Block1

Symmetry 2.3

Symmetry 2.1

Symmetry 1.4
+

- + - + - + - +

(-48V) Outer
Terminal

Symmetry 4.3

Figure 4 Example of
battery symmetry
connections. Block
measurements 48VDC
power systems

Symmetry 1.3

Symmetry 1.2

Symmetry 1.1
+
Battery
String 1

Set DIP switch 1 2 3 4

1 ON (down),
the rest OFF
(up)

1234

Symmetry 2.2

Set all 4
DIP
switches
OFF (up)

Battery Monitor
Part 242100.300
ID# <34>

Block1

Intercell Links

Block3

Block4

+
0V Outer
Terminal

Notice:
Always connect Battery Monitor with ID#<33> to battery string 1 (lowest), with
ID#<34> to string 2, and so on. PowerSuite will then refer to the correct battery
string.

Installation Guide Battery Monitor CAN Bus Node

351507.033, Issue 1.2e, 2010 Apr

Mid-point Measurements
Battery Symmetry String 1 to 4
Mid-point Measurement
One measurement per string, four strings
Battery Monitor
Part 242100.300
ID# <33>
DIP
switches
for CAN
bus addr.

1234

+
Battery String 4
Symmetry 1.4

Symmetry 1.3
Battery String 3
Symmetry 1.2
Battery String 2
Symmetry 1.1
Battery String 1
- + - + - + - +

(-48V) Outer
Terminal

Block1

Intercell Links

Block4

Block3

+
0V Outer
Terminal

Notice:
Always connect Battery Monitor with ID#<33> to battery strings 1 (lowest),
2, 3 and 4. Then Battery Monitor with ID#<34> to string 5, 6, 7 and 8. And
so on. PowerSuite will then refer to the correct battery string.

Figure 5 Example of battery symmetry connections. Mid-point measurements 48VDC power systems

Battery Terminology
Battery Terminology
Battery Block, Battery String and Battery Bank
Battery
Block (12V)

48V Battery Bank

Battery
String #2
(48V)Batt.
Symmetry
7
Battery
Batt.
String #1
Symmetry
(48V)
6

Figure 6 Battery block, battery string and battery bank definitions

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Installation Guide Battery Monitor CAN Bus Node

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CAN Bus Termination

To ensure a correct bus communication and avoid data reflection, you must always
terminate the CAN bus with two 120 resistors, one at each end of the line (60 bus
impedance).
Smartpack based systems are shipped from factory with the CAN bus already terminated
with 120 resistors. The CAN bus termination is implemented with a special RJ45 plug
with built-in 120 end-of-line resistor.
USB A-B cable
(standard)
1
120

CAN bus
(twisted-pair CAT5 cable)

End-of-Line
Resistor

ID
Number
Battery
Monitor

01
33

Battery string #1

02

34

n
120
End-of-Line
Resistor

Battery string #2

Flatpack2
DC Power System

Figure 7
Example of CAN bus addressing and termination in a Flatpack2 system with two
Battery Monitors connected the CAN bus

When connecting Battery Monitor nodes (max. 14 nodes) to the CAN bus, you have to
remove the CAN bus termination plug from the Smartpack controllers rear CAN port, and
plug it on one of the CAN ports on the last connected Battery Monitor node. See chapter
Removing the Smartpack Controller, page 11.

Removing the Smartpack Controller

To access the CAN bus termination plug from the Smartpack controllers rear CAN port,
release (1) both handle springs see Figure 8, page 11 and use both handles to
cautiously pull out the module. Be careful, as cables are connected to its rear.

Smartpack
controller

Hole to release the

handles spring
mechanism

Handle in locked position

Figure 8 Removing the Smartpack controller

Installation Guide Battery Monitor CAN Bus Node

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11

Configuration
When connecting Battery Monitor nodes to the CAN bus of the Smartpack based DC
power system, you have to configure each of the Battery Monitors by:
1. Setting the DIP switches with the correct CAN bus address,
to assign a unique ID number to the Battery Monitor, read chapter CAN Bus
Addressing, on page 12
2. Configuring the Battery Monitor nodes operation,
using the PowerSuite application, read chapter About PowerSuite Configuration,
page 13

CAN Bus Addressing

The Smartpack controller dynamically software-assigns ID numbers to rectifiers. The
controller registers the rectifiers ID numbers or CAN bus address (01, 02)
together with their Serial Numbers.
The ID numbers (1, 230) on Smartpack controllers and Smartnode units and
Battery Monitors ID numbers (33, 3446) are assigned by DIP switches on the nodes
side.
A maximum of 14 Battery Monitors and or 28 controllers and Smartnode units may be
connected to the CAN bus. Note that if only one Battery Monitor is connected, you have to
assign it with ID# 33.
Battery Monitor
DIP switch configuration

Battery
Monitor
1st Monitor
2nd Monitor
3rd Monitor
4th Monitor
5th Monitor
6th Monitor
7th Monitor
8th Monitor
9th Monitor
10th Monitor
11th Monitor
12th Monitor
13th Monitor
14th Monitor

ID
#
33
34
35
36
37
38
39
40
41
42
43
44
45
46

DIP Switch Position

1 2 3 4
OFFOFFOFFOFF
ON OFFOFFOFF
OFF ONOFFOFF
ON ONOFFOFF
OFFOFFON OFF
ON OFF ONOFF
OFFON ON OFF
ON ON ONOFF
OFFOFFOFFON
ON OFFOFFON
OFFON OFFON
ON ON OFFON
OFFOFFON ON
ON OFF ON ON

ID <33>
(All switches OFF)

Note:
The
monitors
ID #
corresponds
to the DIP
switchs
binary value
plus 33

Smartpack controller
DIP switch configuration

ID <1>
Smartpack ID
DIP Switch Position
(All switches OFF)
Controller
#
1 2 3 4
Master
1
OFFOFFOFFOFF
Slave 1
2
ONOFFOFFOFF
Slave 2
3
OFF ONOFFOFF
Slave 3
4
ON ONOFFOFF
Note that the controllers ID # corresponds to
the DIP switchs binary value plus one.

Table 2 Smartpack DIP switch addressing

Table 3 Battery Monitor DIP switch addressing

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Installation Guide Battery Monitor CAN Bus Node

351507.033, Issue 1.2e, 2010 Apr

About PowerSuite Configuration

You have to connect a PC to the systems
Smartpack controller and start the PowerSuite
application, version 2.3 or higher, to activate
and configure the Battery Monitor nodes.
Read the PowerSuite applications Online
Help for information on how to configure the
CAN Bus nodes.
In general, the connected Battery Monitor
node(s) are displayed in the PowerSuites
Power Explorer pane, under the Control
System node and under the Battery node.
For configuring the Battery Monitor specific
settings such as its software alarm monitors
for fuse monitoring and current sense inputs,
symmetry measurementes inputs, etc open
the Battery Monitors icon under the Battery
node.

Battery Monitor icon

displayed in the Power
Explorer pane, under the
Battery node

Open the Battery Monitors icon under the

Control System node to reas the status of the
Battery Monitor.

Installation Guide Battery Monitor CAN Bus Node

Battery Monitor icon

displayed in the Power
Explorer pane, under the
Control System node

351507.033, Issue 1.2e, 2010 Apr

13

4. Technical Specifications
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Ordering Information

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Installation Guide Battery Monitor CAN Bus Node

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Installation Guide Battery Monitor CAN Bus Node

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