9 Summary of Port Usage ............................................................................................ 56
10 Resolving Common Problems................................................................................ 57
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PowerAgentTM SC3 Site Controller Document # 700-000014-01 Rev 2
Installation and Operation
1 Important Information
1.1 Revision History
Release Date Revision Description
Rev 1 04/27/2010 Draft for review, Firmware version 4.04, Web version 1.1
Rev 2 05/12/2010 On going revisions, Firmware version 4.10, Web version 1.3
1.2 Safety Notes
High currents and voltages may be present on the equipment terminals and on the
interior of the equipment. Make sure you understand and observe all appropriate
safety codes and regulations. Follow prudent electrical safety practices when
installing or servicing the equipment. Installation, maintenance and servicing of
the equipment should only be performed by qualified, trained and authorized
personnel.
Before installation, take measurements with a Volt Meter to ensure that no jar post in the
system has lethal AC or DC voltages relative to earth ground.
Except as explained in this manual, there are no user-serviceable parts inside the
PowerAgent Battery Monitoring System components. Opening the equipment could
expose you to dangerous voltages and void the product warranty. All product servicing
should be referred to factory-authorized personnel.
Use only interconnection cables supplied or authorized by Phoenix Broadband
Technologies. Use of user-made interconnection cable assemblies could result in
damage to equipment and potential safety hazards and voiding of equipment warranties.
Do not exceed the voltage specifications of the product.
Make sure the equipment is grounded properly.
The equipment should be protected from liquids, moisture, explosive, and corrosive
vapors.
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PowerAgentTM SC3 Site Controller Document # 700-000014-01 Rev 2
CAUTION!
NOTE:
Installation and Operation
1.3 Important Symbols
The following symbols are used in this document.
The use of CAUTION indicates safety information intended to prevent damage and/or injury
A NOTE to provide additional information to help complete a specific task or procedure
1.4 Definition of Terms
Admittance – The inverse of Impedance in units of Siemens. Admittance is a measure of how
easily a circuit or device will allow a current to flow. Resistance is a measure of the opposition of
a circuit to the flow of a DC current, while impedance takes in to account not only the resistance
but AC effects (known as reactance) as well. Likewise, admittance is not only a measure of the
ease with which a DC current can flow (conductance, the inverse of resistance), but also takes in
to account the AC effects of susceptance (the inverse of reactance).
Battery – A collection of jars connected in series. A battery is sometimes referred to as a Battery
String or String in this document.
Cell – A collection of plates connected to a single positive and single negative terminal immersed
in electrolyte in a single container. The cell may have multiple positive and negative connections
but they connect to a single set of plates. A lead acid cell produces approximately 2.1 volts.
Jar – A collection of one or more cells connected in series in a single housing. A 12 volt jar
contains 6 cells. A Jar is commonly and incorrectly referred to as a battery.
P-Bus – A Phoenix proprietary communications interface and protocol used to connect devices to
the Site Controller for the purpose of providing additional input, output, and measurement
capability.
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Installation and Operation
1.5 Contact Information
If you have any questions about the installation or use of the equipment described in this manual,
contact Phoenix Broadband Technologies (PBT) at (215) 997-6007 or
customerservice@phoenixbroadband.com.
When contacting Phoenix Broadband please have the following information available:
1. Site Controller Model Number and firmware version (from the Site Controller Web Page).
2. Battery Sensor Model Number, hardware version and firmware version. The version
numbers are shown on the Site Controller single Jar Web Page.
3. The Battery and String Voltage.
4. The battery model number.
5. UPS or DC power plant.
6. If a UPS the manufacturer and model number.
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PowerAgentTM SC3 Site Controller Document # 700-000014-01 Rev 2
Installation and Operation
2 System Overview
Network
Conn ectivity
MasterA gent
Site
Contro ller
Up To 6
Batter y
Batte ryAgent
Sensor
Units
Batt ery String # 1Batt ery String # 2
String s
RJ-11
“Dai sy Chain ”
area network. The Sensor modules are designed for use with 2 or 12 volt jars in DC power plants
and UPS power systems up to 600 volts DC and with several choices of mounting brackets for
different post configurations.
Each sensor in a PowerAgent
TM
Battery Management System
measures its associated cell or jar’s terminal voltage, post or
case temperature, and internal cell impedance (admittance).
Multiple sensors within a string of monitored jars are
interconnected in a “daisy-chain” utilizing CAT-5 cabling and RJ45 connectors. Each daisy-chain of sensors is connected via
another CAT-5 cable to one of the six string ports on the Site
Controller. Each site controller can manage up to six strings of
batteries with a maximum of 40 batteries in any string and a site
total of 240 batteries. The site controller has extensive user-definable set-up capabilities,
including labels for every monitored jar and alarm thresholds for voltage, temperature and
admittance on each individual jar.
The site controller has several user interface mechanisms built-in, including a configurable web
server that displays site, string, and individual jar
information, as well as an SNMP (Simple Network
Management Protocol) interface that allows any SNMP
compliant management software to collect data and
perform jar tests. Other features of the site controller
include a password protected Telnet port for remotely
configuring the unit, A DHCP (Dynamic Host
Configuration Protocol) client that automatically obtains
an IP (internet protocol) address from a DHCP server,
and TFTP (Trivial File Transfer Protocol) server for
uploading firmware changes remotely.
The Phoenix Broadband Technologies (PBT)
PowerAgentTM Battery Management System is
a comprehensive solution for remotely
monitoring the state of health for individual cells
or jars within the battery bank of a UPS or DC
power plant system.
The system consists of a series Sensor modules
which are electrically and mechanically affixed to
the terminal posts of the jars being monitored,
and a PowerAgent TM Site Controller unit which
collects readings from the individual sensors and
makes the information available for
management purposes via an Ethernet local
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PowerAgentTM SC3 Site Controller Document # 700-000014-01 Rev 2
Installation and Operation
2.1 Sensor Description
Sensor modules are small, inexpensive units designed to
mount in close mechanical, electrical, and thermal
proximity to the monitored jar’s terminal posts. The sensor
takes a very small amount of “idling” power from the
monitored jar (typically less than 10ma). Internally, a
programmable microcontroller chip provides an optically
isolated communications interface for the site control unit.
Sensors are connected to the Site Controller using a
CAT5 cable daisy chain.
The sensor continuously monitors the voltage and
temperature of the jar. At user-defined intervals, the
microcontroller generates a digitally synthesized AC test
signal of approximately 0.5 to 6.0 amps (depending on
sensor type) which drives the jar’s terminals for testing
purposes. This test current causes a small AC voltage,
proportional to jar impedance, to be superimposed on the
jar’s DC terminal voltage. This AC voltage is separated from the DC terminal voltage and
amplified inside the sensor module. It is then fed to an analog-to-digital converter inside the
microcontroller chip. The microcontroller digitally samples the AC waveform and performs a DSP
(digital signal processing) algorithm that filters out noise and measures the amplitude of the AC
signal. These measurements and subsequent calculations determine the jar’s internal AC
impedance, which is the basis for Admittance measurements.
Mechanically, the sensor consists of a nickel-plated copper mounting bracket which fits on the
jar’s negative terminal post, a short wire terminated in terminal lug that connects to the jar’s
positive terminal post, and an electronics assembly that contains the test signal generation and
measurement circuitry. Sensors with two wires are also available.
The sensors with brackets have the advantage of being able to more accurately measure the
temperature of the electrolyte in the cell. The two wire sensors have the advantage of working
with a wide variety cell and jar mechanical configurations that could requires several different
bracket types. Refer to the Sensor Selector Guide later in this section for more details.
Each sensor is shipped with a 1 foot CAT5 cable to connect the sensor to the daisy chain. This
cable is the proper length for most applications. Longer cables are available from PBT.
2.1.1 “High Voltage” and “Low Voltage” Sensors
Sensors are typically used in DC power plant and UPS applications. DC power plant applications
commonly utilize two volt cells and twelve volt jars wired in series with total nominal string
voltages typically ranging from 24 to 48 VDC nominal. In many UPS systems, voltages can be
significantly higher (480 volts or more). Because of the specific requirements of high voltage
systems, Phoenix Broadband has developed two types of sensors to accommodate each
environment.
When working in environments where string voltages are greater than 64 VDC, always use the
High Voltage sensors. “High voltage” (HV) sensors are completely optically isolated from the
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PowerAgentTM SC3 Site Controller Document # 700-000014-01 Rev 2
PBT
-
PA
-
BS1
-12-2
Installation and Operation
controller and each other, with no string-level voltages present in the interconnecting CAT5
cables. This architecture was designed to ensure safety and prevent damage. For environments
where string voltages are 64 VDC and lower Low Voltage sensors are appropriate, however
either sensor (High or Low voltage) can be used low voltage strings.
CAUTION: Installing Low Voltage sensors on a high voltage string will damage the
sensors and may present a shock hazard.
Both sensor types will be auto-discovered by the controller. The Low Voltage sensor has the
advantage that its position in the string is automatically discovered. This means the sensors can
be connected in any order and the controller will automatically discover upon which cell or jar the
sensor was installed. High Voltage sensors have an address. The address and cell or jar
number must be recorded when the sensor is installed. These addresses are then entered into
the Site Controller Web page so that the ordering of the cells or jars will be correct.
High Voltage and Low Voltage sensor should not be mixed in the same string.
Each sensor has a bi-color red/green LED that indicates the operational state of the sensor and
its communications status with the site controller. Each sensor is also is internally fused so that
improper connection to the jar will not damage the jar, the jar cabling, or the sensor. Again, the
sensors are fully optically isolated from the site controller.
2.1.2 Sensor Selector Guide
Selecting a sensor requires first determining if a Low or High voltage sensor is required. Then a
jar voltage is selected, either 2 or 12 volts. Finally the bracket style is selected. The sensor
model number is constructed as shown below.
String Voltage
-BS1- Low Voltage (< 64 Volts)
-BS2- High Voltage (> 64 Volts)
-BS1B- Series B Low Voltage
-BS2B- Series B High Voltage
-BS3B- Series B Low Voltage, High Current
Jar Voltage
-2- 2 Volt Jars
-12- 12 Volt Jars
Series B sensors should be used for all new installations, they offer improved noise immunity and
an enhanced feature set including battery balancing. These sensors require a B series
SiteController.
When selecting a bracket be sure to consider the clearance above the jar. This is particularly
important when the jars are installed in a cabinet as is typical with most UPSs. Be sure there is
enough space for the CAT-5 cables to exit the sensor without kinking.
Bracket Type
-1 L Bracket
-2 Z Bracket
-3 Front Mount Bracket
-4 2 Wire Sensor
-5 12 mm Z Bracket
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PowerAgentTM SC3 Site Controller Document # 700-000014-01 Rev 2
Installation and Operation
Type 1 Bracket
This bracket commonly referred to as
the “L” bracket, is typically used on Jar
terminals where the sensor must stand
up from the jar. An example is the
vertical blade type terminal where the
bolt is parallel to the top of the Jar.
The maximum bolt size for the terminal and bracket is 5/16 inch.
Type 2 Bracket
This bracket, commonly referred to as the “Z” bracket, is
typically used jars that are connected together with straps.
It is also used when the jar cables are secured by bolts
that extend into the jar. The maximum bolt size for the
terminal and bracket is 5/16 inch.
Type 3 Bracket
This bracket, commonly referred to as the “Front
Mount” bracket, is used front terminal Jars. While
specifically designed for the Marathon, the bracket
will fit most front terminal Jars. This bracket was
designed for a M6 (6 mm) bolt.
Type 4 Bracket
This bracket is not a bracket at all
but a sensor with two wire
connections. This is the universal
sensor that will work with most
jars. The maximum bolt size for
the terminals is 5/16 inch. The
one disadvantage of this sensor is
that it does not directly measure
the jar post (electrolyte)
temperature like the bracketed sensors. When the sensor is mounted to the top of the jar, and
not in the direct cooling air flow, the sensor will read the approximate jar case temperature. The
sensor is equipped with a self adhesive industrial velcro strip for fastening the sensor to the jar.
Type 5 Bracket
This bracket is similar to the Type 2 bracket but is designed for a larger bolt. The maximum bolt
size for the terminal and bracket is ½ inch or M12 (12mm). Because of the higher torque
required for the larger bolt this bracket has a round hole rather than a slot. This prevents
distorting the bracket when tightening the bolt.
Contact PBT if none of these brackets fit your requirements.
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PowerAgentTM SC3 Site Controller Document # 700-000014-01 Rev 2
Installation and Operation
2.2 Site Controller Description
The Site Controller is a small, rack-mountable unit that monitors the sensor modules and makes
the data collected by them available via a local area network or the internet. The SC3 Site
Controller has 6 string ports for connection to strings of up to 40 jars each for a total capacity of
240 jars. Two P-Bus ports provide expansion capability for connection to current sensors, RIMs
and ROMs for additional input and output capability. A USB setup port allows direct connection
to a PC for configuration. A USB thumb drive provides storage of logged data and additional
USB ports provide expansion capability.
The SC3 Site Controller has most of the connections on the rear panel and indicators on the front
panel.
The SC3 Site Controller can be
powered directly from a battery
string voltage of 24-48VDC, or it
can be powered from an
optional small wall-mount
24VDC wall transformer. The
voltage range is 18 to 65 VDC
and power consumption is about
5 watts, with current draw
dependent on the input voltage.
Power is supplied to the unit via
a rear-panel screw-type terminal
block. The power supply input is
floating. The terminal block also
provides a chassis ground
connection.
A Front panel USB connection provides access to configure the Site Controller IP address and
other parameters during installation. Setup can also be performed over the network connection.
The site controller has six RJ-45 connectors on the rear panel for interfacing to up to six strings of
monitored jars. Each string has a front panel indicator. The LED lights when the string is being
polled. A green LED indicates everything is normal, a red LED indicates abnormal conditions
within that string.
An Rear Panel Ethernet connection provides a TCP/IP (internet protocol) interface to a local area
network or to the internet. A built-in web server is accessible via this interface, with no need for
any software other than a common PC web browser. More sophisticated monitoring and control
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PowerAgentTM SC3 Site Controller Document # 700-000014-01 Rev 2
Installation and Operation
of the site controller can be performed remotely using any SNMP-capable network management
software system. These systems are described in additional detail in the SNMP section of this
Manual.
Upon power-up, the site controller automatically begins a search sequence to determine which of
its string ports are attached to battery sensors and discovers each sensor module.
When a string of High Voltage sensors is discovered, the controller discovers the factoryprogrammed address of the sensor module as part of this discovery process. The HV sensor is
also assigned to one of the jars in the string, but the user can change these assignments after
installation is complete.
When a string of Low Voltage sensors is discovered the controller automatically discovers each
sensor and its correct position in the string (no factory programmed address is necessary with low
voltage sensors).
Once the “auto-discovery” process is finished, the site controller can individually address each
sensor, collect its readings, and display those reading in the hierarchical web page display.
Except for the final user assignment of High Voltage sensors to jars, this process is ‘plug & play’.
All sensor assignments and configuration information are saved in non-volatile memory, so the
system automatically reconfigures itself if power is lost or if the system is turned off for
maintenance.
The site controller can be mounted in any small, inconspicuous location that is available, or it can
be rack-mounted in a standard 19” (or 23” with adapter ears) equipment
rack by using the optional rack-mount bracket. One rack bracket can hold
one or two site control units. Rubber feet, screws for mounting the site
controller to the rack bracket, and extra sensor fuses are included with the
Site Controller.
2.3 Accessories
Various optional accessories are available to aid in the system installation.
2.3.1 Cable Kits
A Cable kits provides the cables necessary to connect a string of jars to the site controller. Each
string requires a Cable Kit. The Cable Kit contains the cables most commonly required to
NOTE: We strongly recommend that you order the appropriate Cable Kit for each string
and not make your own sensor cables. A single improperly made cable can destroy an
entire string of sensors.
Phoenix Broadband Technologies, LLC 10/28/2010
available for common string sizes. Contact PBT
for any special requirements. The Cable Kit
contains the cables most commonly required to
connect the string of jars.
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Installation and Operation
2.3.2 Power Transformer
The Site Controller is normally powered from the Rectifier or UPS battery
charger (24 to 60 VDC). In cases where this power is not available a 24 VDC
wall mount transformer is required to power the Site Controller. This
transformer can be ordered from PBT as model number WT-3.
2.3.3 Rack Mount Bracket
A bracket that mounts up to
2 Site Controller in a 1U
space in a 19” rack is
available by ordering model
PBT-RK-1.
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PowerAgentTM SC3 Site Controller Document # 700-000014-01 Rev 2
Installation and Operation
3 Initial Bench Evaluation
If the user has no previous experience with the PowerAgent TM Battery Management System, it is
recommended that a small local test and evaluation of the system components be set up prior to
field deployment of the equipment. This approach can save a significant amount of time before
connecting to a much larger network. It will allow you to verify proper operation of the site
controller’s web server; telnet configuration, and DHCP client without having to troubleshoot
larger network issues (firewalls, router, and connectivity etc.).
The above diagram shows a low cost networking router (D-Link™, NetGear™, or other)
connected to a laptop/Desktop and the Site Controller. In this scenario the installation steps are
as follows:
1. Power up router
2. Power up laptop and connect laptop to router
3. Verify that the laptop has acquired an IP address from the router (view the router’s
configuration web page and write the address down)
4. Connect controller to router (via Ethernet connection)
5. Power up controller (upon power up, the controller will seek an IP address from the
router)
6. Connect sensors to the each other (via CAT 5 cables daisy chained from sensor to
sensor)
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Installation and Operation
7. Connect last sensor in the daisy chain to one of the six controller’s sensor input ports
8. View the router’s web page to determine which IP address has been given to the
controller (write it down)
9. Type the IP address of the controller into your laptop’s web browser and verify that the
web page displays properly. Verify that all sensors have been auto-discovered. Verify
that the parameter information displayed in the web page appears reasonable
10. Verify telnet connectivity by connecting to the controller via telnet (remember Phoenix
Broadband uses port 9999 for our telnet connection)
11. If you are using an SNMP manager, verify proper SNMP operation (gets, sets & traps)
This bench evaluation can also be performed using the free Lookout software described in the
SNMP section of this manual.
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Installation and Operation
4 Sensor Installation
Refer to the Battery Management System Manual (700-000006-02) for detailed information
before installing the battery sensors.
CAUTION! Lethal voltages may be present on the battery strings. If you are not sure of
what you are doing leave the installation to a certified technician. Read the sensor
installation instructions carefully.
CAUTION! Be sure to disconnect the Rectifier or Charger before installing the Sensors.
Failure to do so could result in sensor damage.
5 Site Controller Installation
NOTE: Before any sensor strings are connected to the Site Controller, it should be
mounted (either in a rack or shelf), connections should be made to the network (Ethernet
connection) and it should be powered up and checked out for network connectivity.
Select a location for the Site Controller. The location should be central to the strings being
monitored. It should be dry and free of corrosive or explosive vapors.
The maximum cable length between the SC3 Site Controller and the battery string varies with the
number of battery sensors on the string. With 40 sensors a maximum total cable length of 200
feet is recommended. This includes the sensor to sensor cables. With 24 sensors this increases
to 300 feet.
Mount the Site Controller in an equipment rack using the optional rack mount bracket, or place
the Site Controller on a shelf.
5.1 Powering
Connect a source of 18 to 65 volts DC to the rear panel power connector. This can be DC power
from a DC power plant or it can be 24 VDC from the optional WT-3 plug-in transformer. For UPS
installations the Site Controller should be powered from the WT-3 or other DC source. The WT-3
should be plugged into a outlet that is running on the UPS. Never power the Site Controller from
UPS batteries. The SC3 Site Controller can also be powered from low voltage AC. Consult PBT
for the voltage range limitations. There is a power input fuse inside the Site Controller. It is
extremely rare for this fuse to blow.
The power supply input is floating on the SC3 Site Controller. To ground the Site Controller
connect the center ground pin on the power connector to an earth ground.
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Installation and Operation
5.2 Network Connections
Connect the rear panel Ethernet connector to the network through a hub or switch. On a
managed switch, make sure that the switch port has been enabled.
Set the IP Address of the Site Controller as described in the following section.
Verify network communications by accessing the Web page and telnet setup menu over the
network.
5.3 Connecting Battery Sensors
Connect the cable from the battery sensor daisy-chain to an available “BATTERY STRINGS”
connector on the Site Controller rear panel.
NOTE: We strongly recommend that you order the appropriate Cable Kit for each string
and not make your own sensor cables. A single improperly made cable can destroy an
entire string of sensors.
The site controller will begin to auto-discover the sensors connected in each of the daisy-chains.
You will notice the String LEDs on the front panel flashing in sequence left to right. This indicates
that the controller is polling each string and looking for sensors on that string. Once a string has
been discovered it will be visible in the Web page.
5.4 Connecting RIMs and ROMs
RIMs and ROMS are connected to one of the P-BUS connectors on the rear of the Site Controller
using CAT-5 cables. Up to 200 feet of cable can be connected each of the two P-BUS ports. Up
to 4 RIMs and 4 ROMs can be connected to each P-Bus port, for a total of 8 RIMs and 8 ROMs.
Refer to the RIM and ROM installation manual for information on mounting and configuring the
RIM and ROM.
5.5 Connecting Current Sensors
Up to 6 Current Measurement Interfaces (CMI) can be connected to P-BUS port A. These 6 units
correspond to the 6 strings. Each CMI must be set to a unique addresses, from 1 to 6. The
Addresses correspond to the 6 strings. For example; current measurements made on CMI
address 2 are displayed with string 2.
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Installation and Operation
5.6 Setting the IP Address
In order to communicate over the network, the Site Controller must be assigned an IP address.
There are several ways the IP address can be assigned.
•You can pre-configure your DHCP server to assign a reserved IP address to the Site
Controller based on the Site Controller MAC Address. The MAC address is printed on
the Site Controller label. This method is commonly used for field installations.
•You can let your DHCP server assign an address and then interrogate the DHCP server
to determine what address was used. This technique works well in the lab environment
where the DHCP server may be in a router. This method is not very practical for field
installations since the IP address can change if the Site Controller resets or the DHCP
server decides there is a reason to change the address.
•You can program a static IP address in the Site Controllerusing a temporary connection
to a router with a built-in DHCP server and the Site Controller Telnet configuration port.
•You can program a static IP address in the Site Controllerdirectly using the USB
interface and a PC as described in the next section.
•You can program a static IP address in the Site Controller using an Ethernet Crossover
cable and a PC as described in the next section.
Generally, static IP addresses are used so that the Network Manager can associate the IP
address with a physical location. Contact your network administrator or IT department to obtain a
static IP address, gateway address, and sub net mask that will work on your network.
The Site Controller is shipped from the factory configured to obtain an IP address automatically
from a DHCP server.
5.7 Configuring the Site Controller
The Site Controller can be configured over the network through a telnet connection or through a
USB connection directly from a PC. Support of telnet is a standard part of Windows so virtually
any PC can configure the Site Controller.
There are several ways of connecting your PC to the Site Controller to access the configuration
program.
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