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Installations in Power Plants and Substations

Installation can be performed by your electricians or certified contractors with the training from BatteryDAQ.
A written MOP (method of procedure) must be approved by Operations Manager before working on battery.

Prepare MOP

Order correct model and accessories

Following the site survey to specify battery and rack information

Order pre-made harness

Default length 20FT, suitable for battery cells on one rack, and the BMS unit is mounted on rack or nearly wall.

For split racks, it may require 30FT.

Try to keep the unit close to the battery. Max length is 50FT.

mount on rack

Mount on rack

Unit can be mounted on the rack with brackets or strut.

Mount on wall

Wall mount hole distance 7.5″ (W) and 13.25(H).

A stainless durable template is available for more efficient multi-sites installation.

Choose the center area if the rack is split around for short wiring distance.

Pass through cables

Cut flexible 2-inch pipe to proper length, install the pipe.

Pass cables through pipe one-by-one, ensure each cable has 3 numbering labels on the plug end, 6ft away from plug and the other end.

Plug cables to correct terminals from #1 to #12, matching the numbers. (VERY IMPORTANT)

Power on unit with AC adapter

Use BatteryDAQ provided AC adapter to power on the unit.

Unplug 8-pin IR terminal during the wiring.

Plug HMI to read data as you go.

Connect DTU to Laptop, access web page on DTU.

Temperature probe

Install temperature probes

Identify correct wires for 3 temperature probes. Ambient probe can be secured to rack to sense air temperature. 2 pilot probes are to be attached to cell surface secured with stainless tape.

Crimp and connect probes, read temperature on HMI to confirm.

Connect Current Transducer

Install CT to battery loop, the arrow goes with the charging current direction. Crimp and connect 4 wires to CT cable.

Verify current, calibrate zero if necessary.

Bring Battery to Offline

Following the planned procedure to bring the battery offline.

Plan for post connection

For two post cells, connect sensing lead to each post.

For multiple sets of posts per cell, connect sensing leads to far diagonal posts.

Loosen bolts and install leads

Install sensing (0.5A) leads and IR (10A) leads.

Tools for leads connection

Cowboy, fast draw!

Only two tools are needed for stripping (20 AWG wire) and crimping.

A strong magnet has been added to the tool bag for holding the stripper securely, while easy to take off.

Crimp leads with correct wires

Following the printout for leads connections.

Start from BAT#1, read voltage from HMI as you go.

IR Leads (10A)

A 60x2V bank is divided to 4 sections. 5 (10A fuse) leads are utilized to generate current for IR and CR measurement, following Four-terminal principle.

IR lead and sensing lead must be two separate leads, can not be shared.

When IR lead and sensing lead go to the same post, put IR lead on top of sensing lead.

Bus Plate

IR leads (RM+ and RM-) can be on bus plate (recommended) or battery terminal.

Verify Connection with Data

Read out voltage with HMI or Laptop.

Bring Battery Online and BMS Commission

When Voltage, Internal Resistance and Connection Resistance all look good, bring battery online.

Fill in commission report