Lead-acid Battery Monitoring Solution

Lead-acid battery online monitoring system, data centers and base stations will use a large number of batteries as backup power sources. By collecting battery voltage, temperature, internal resistance, charge and discharge current and other parameters in real time, the remaining capacity (SOC) and remaining life (SOH) can be estimated.
The above parameters, especially the internal resistance, allow operation and maintenance personnel to understand the health status of the battery in real time and replace the deteriorated battery in time to ensure that the battery pack can meet the discharge time and ensure reliable, stable and continuous power supply.

 

This lead-acid battery monitoring solution was majorly designed for monitoring SOH,SOC, inner resistance, temperature, current, voltage and etc of lead-acid battery pack used in UPS. Generally, some places like data center, hospital, telecommunications base station will have UPS of which the lead-acid battery pack need such a monitoring solution.

Reason why that we need such a lead-acid battery monitoring solution was due to following major pain points of customer including:

[1]Power Outage will cause severe Loss: In some scenario like data center, hospital and etc, any minutes of power outage will cause severe loss. Thus the UPS will be necessary for such scenario as back-up power supply when girds go down. But if UPS also failed, power outage will be inevitable.

[2]37% of UPS Failure was due to Battery Failure: According to the report, nearly 37% percent of UPS failure was caused by battery failure. Thus we need to first ensure the battery pack always in healthy status for running the UPS.

[3]Battery Failure mostly related with Battery Inner Resistance: Inner resistance is a crucial monitoring targer for judging the SOH of battery pack.

 

(1)A single battery pack is connected to the Acrel gateway, and then connected to the Acrel BMS platform + local HMI display topology diagram

(2)Multiple battery groups local HMI display + access to third-party BMS system

Following was a sample SLD for a data center which has 6 pcs UPS system. Each UPS system has 1 battery pack group. Thus there are totally 6 pcs battery pack group of UPS system need to be monitored:

[1]UPS #1 - Battery Pack Group #1: 1 pcs UPS with battery group pack #1 which has 40 pcs lead-acid single cell battery [12Vdc single cell battery].

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[6] UPS #6 - Battery Pack Group #6: 1 pcs UPS with battery group pack #6 which has 40 pcs lead-acid single cell battery [12Vdc single cell battery].

 

Below was hardware deployment for monitoring 6 UPS's battery pack.

[0]For display&alarm data for Battery Pack Group #1~6 of UPS #1~6:

-1* ATP007kT Smart HMI [For display and alarm all battery data collected by 6 ABAT100-HS data colletor via RS485 connection]

[1]For monitoring Battery Pack Group #1 of UPS #1:

-1* ABAT100-HS Data Collector [For collecting the data from 1*ABAT100-C and 40*ABAT100-S- 12 and further upstream the data to ATP007kT smart HMI]

-1* ABAT100-C Group Cell Current Monitor [for monitoring the charging&discharging current and ambient temperature of battery pack group #1]

-40* ABAT100-S-12 Single Cell Monitor [each monitor for monitoring inner resistance, temperature and voltage of single battery cell]

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[6] For monitoring Battery Pack Group #6 of UPS #6:

-1* ABAT100-HS Data Collector [For collecting the data from 1*ABAT100-C and 40*ABAT100-S- 12 and further upstream the data to ATP007kT smart HMI]

-1* ABAT100-C Group Cell Current Monitor [for monitoring the charging&discharging current and ambient temperature of battery pack group #6]

-40* ABAT100-S-12 Single Cell Monitor [each monitor for monitoring inner resistance, temperature and voltage of single battery cell]

[1]Between ABAT100-C group cell current monitor, ABAT100-S-12 single cell monitor and ABAT100-HS data collector, we are using RJ12 port based communications [Self- defined protocol].

[2]Between ABAT100-HS data collector and ATP007Kt smart HMI, we are using RS485 communications based on MODBUS-RTU protocol. Communication distance within 300m when using RVSP 2x1.5mm² cable.

Note: 1 ATP007kT can support up to 6 pcs ABAT100-HS via RS485 [MODBUS-RTU].

 

Model 1: ABAT100-HS Data Collector

-Application: Support collecting data from up to 120 pcs battery cell monitor and further upstream data via RS485 [MODBUS-RTU]; analysing remaining battery capacity [SOC, SOH]. -Upstream Methods: RS485 [MODBUS-RTU protocol] -Downsteam Methods: RJ12 (Self-defined protocol) -Power Supply: 24Vdc -Certificate&Standard: CE        Learn More +

Model 2: ABAT100-C Group Cell Current Monitor

-Application: Monitor charge&discharge current data of one group of battery; moniotr ambient temperature. -Measuring Current Range: Max 1000A AC -Measuring Temperature Range: -5℃～+105℃ -Accuracy: ±1% [Current]; ±1°C [Ambinet temperature] -Upstream Methods: RJ12 (Self-defined protocol) -Power Supply: 24Vdc -Certificate&Standard: CE Learn More +

Model 3: ABAT100-S Single-cell Monitor

-Application: Monitor inner resistance, voltage, negative pole           temperature of single cell. -Supported battery type: 2Vdc, 6Vdc, 12Vdc lead acid battery[Capacity less than 3000AH] -Measurement Range: 2&6&12Vdc [Voltage]; 50～65535uΩ [Inner resistance]; -5℃～+105℃ [Temperature] -Accuracy: ±0.1% [Voltage]; 1uΩ [Inner resistance resolution]; ±1°C [Temperature] -Upstream Methods: RJ12 (Self-defined protocol) -Power Supply: From monitoring single cell -Certificate&Standard: CE Learn More +

Model 4: ATP007kT Series Smart Touch Screen

-Application: Display and alarm real-time battery data from cell monitor. [Support up to 6 pcs ABAT100-HS data collector]       all AMC100 series Energy Meter -Communications: 2-channel RS485 [MODBUS-RTUprotocol]; 1-channel RJ45/Ethernet [MODBUS-TCP] -Size: 7 inches -Power Supply: 24Vdc              -Certificate&Standard: CE

Model 5: AHKC-EKC Split-core Hall Sensor

-Application: Paired with ABAT100-C for current input                      -Current Input Range: 0~(500~1500)A DC -Current Output Range: ±5Vdc -Aperture: φ55.5mm -Auxiliary Power Supply: ±12~±15Vdc -Advantage: Safety with electricity isolation Learn More +

 

#1 - Homepage

Homepage for battery management software:

[1]Can check all major software function in homepage.

[2]Can check total alarm status of overall battery system.

[3]Can check voltage, current, charge/discharge status, SOC %, SOH % of overall battery group.

#2 - Data Query - General Data & Battery Group Voltage

Data query page for battery management software:

[1]Can check battery group voltage, current, charge/discharge status, SOC % and SOH % of certain battery group.

[2]Can check battery group voltage in histogram format.

#3 - Data Query - SOC & Total Battery Data Overview

Data query page for battery management software:

[1]Can check SOC % of battery group.

[2]Can check temperature, inner resistance, voltage, discharge&charging current, SOC %, SOH % of battery group.

#4 - Data Query - Single Cell Data List & Histogram

Data query page for battery management software:

[1]Can check SOC % of battery group.

[2]Can check data histogram of single cell. [Voltage, inner resistance, temperature]

#5 - Alarm Management

Alarm management page for battery management software:

[1]Can check currently happened alarm and mute the alarm sound.

[2]Can check history alarm and event record.

#6 - User Management - Login

User page for battery management software:

[1]Can login in as administrator for further configuration. 

Noted: Login password is "10000".

#7 - User Management - Parameter Setting

Parameter setting page for battery management software:

[1]Can set the number of batteries, voltage, battery voltage, battery pack name, battery capacity. Can test internal resistance of single battery or battery pack group.

[2]Can set various alarm threshold.

#8 - User Management - Parameter Setting

Parameter setting page for battery management software:

[1]Can set acquisition mode [default use Serial port mode to directly collect data from ABAT100-HS via RS485 serial port], IP address, numbers of ABAT100-HS collector connected to HMI, ABAT100-HS meter address, HMI RS485 forwarding address.

[2]Can set battery equalization, internal resistance reference value, current direction, device reset and low power consumption mode.