bacs - battery analysis & care system 3 generation battery ... · bacs is a holistic battery...

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BACS®

BACS® - Battery Analysis & Care System

3rd

Generation Battery Management System

Copyright of the European Union is effective (Copyright EU) (c) 22020 GENEREX SYSTEMS Computervertriebsgesellschaft mbH, Hamburg, Germany, All rights reserved

TEL +49(40)22692910 - EMAIL [email protected] - WEB www.generex.de (This and all other product datasheets are available for download. 1

BACS is a management, balancing & alarm system for all kinds of batteries/

BACS allows the user to prevent unnoticed or unexpected battery failures

BACS extends battery life up to 50% and Battery Capacity up to 20% and

secures the reliability of UPS systems

… BACS is a holistic battery management system and market leader in Europe …

GENEREX’s 3rd

generation BACS®

(Battery Analysis & Care System) is the most advanced product of its kind on

the market today with more than 1 Million units installed. As an ethernet network integrated battery monitoring and

management system, BACS® uses web management technology to monitor the temperature, internal resistance,

and regulate the voltage of every single battery or even cell in string applications like UPS, storage systems etc.

Through our patented balancing process—called Equalization* in Europe and Balancing elsewhere—BACS®

calibrates the charging voltage of all batteries with the charger’s target value, keeping all batteries within optimal

voltage operating range.

… BACS is the ultimate all-in-one solution

BACS® is capable to monitor and manage all aspects of the infrastructure all around the batteries – starting with

monitoring environmental measurements temperature, humidity, acid fill level, hydrogen gas concentration,

pressure, air conditioning systems etc. and can even manage or trigger any 3rd

party sensors. BACS has a

interface for all kinds of UPS, UPS inverters, transfer switches, generators, and any other alarm dry contacts.

BACS is also capable to handle simultaneously other network structures like BACnet, SNMP and MODBUS.

… BACS is capable to manage complex emergency situations

As a fully featured programmable logic controller (PLC), BACS is capable to manage a complete full-automatic emergency procedure. BACS can operate as a standalone solution as well as a part of a complex management control service. Core features are holistic management of 3

rd party devices as well as a holistic emergency

notification system that can keep, store and provide all necessary informations that help emergency response teams to react as fast as possible.

BACS

® is the ideal system for lead-acid batteries (open/wet cell, maintenance free, gel, AGM, etc.), as well

as NiCad, NIMH and most types of Li-Ion batteries.

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BACS features at a glance

INDIVIDUAL CHARGING REGULATION

BACS® is designed to monitor and regulate the charging voltage

level and the distribution of charging current of all kinds of batteries

towards the ideal level given by the battery charger :

The screenshot shows the Equalization (Balancing) of a battery

(the bold violet line in the graphic) within a string of 32 batteries

during a discharge/recharging process. BACS®

Equalization

(Balancing) prevents overcharging the violet battery, while the

other batteries will continue to get charged until the full charge

state is reached. The available Float Current is distributed to those

batteries which need extra charge. After this the voltage is kept in

narrow windows of a few millivolts to avoid undercharge or overcharge of any battery within the string. With the

unique concept of constant monitoring and harmonization of the individual charging voltages of batteries, BACS®

ensures availability of the battery at all times.

INDIVIDUAL VOLTAGE REGULATION

BACS®

patented process called Equalization (or Balancing)

regulates the voltage supply from the charger or UPS for every

battery or cell. This process secures that the batteries/cells reach

full charge level and kept at this level for optimal capacity and

improved lifespan.

The Oscilloscope diagram at the right illustrates 3 batteries while

Equalization/Balancing process is in progress. The already fully

charged red battery receives less charging voltage than the

undercharged green battery. After a few minutes all 3 batteries

reach the perfect volt level at the same time.

This leads into an ideal harmonized charging curve for each battery string

ACTIVE OVERCHARGE / UNDERCHARGE PROTECTION

The Equalization (Balancing) process prevents the unintended

overcharging of batteries. By preventing overcharging, BACS®

helps to avoid gassing, dry-out, and thermal runaway. The

Equalization (Balancing) process also prevents unintended

undercharging. By preventing undercharging, BACS®

helps to avoid

sulfation and loss of capacity.

As the diagram demonstrates, the charging of Battery 3 is capped

to prevent overcharging and gassing. Supply of charging energy to

Battery 2 is continued and boosted until the target charging voltage

is obtained. Battery 1 performs ideally and is not regulated.

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INCREASE BATTERY CAPACITY AND SERVICE LIFE

Protection meets improved performance SOC

Undercharged batteries in a string cause that the total string capacity

can not reach 100% level. By increasing the charge level of the

undercharged batteries fulll charge state can be reached, up to 20%

more capacity compared against a system without balancing has been

measured.

BACS® guarantees through Equalization (Balancing) a 100% SOC -

full charge level - and the optimal functioning of the battery system.

Extended Service Life SOH

The constant avoidance of overcharge/undercharge by the Equalizing

(Balancing) process has a massive effect on the service life of the

batteries SOH:

The service life of a high voltage string of batteries depends on the

weakest cell of the weakest battery in the string. Typically, in a UPS,

the service life of such a battery string is 50-60% of the battery

manufacturers ―Design Life‖.

Since Equalizing (Balancing) maintains each single battery within the string optimal voltage levels, damaging

effects of improper charging is eliminated. By doing so, BACS allows to use batteries within a string application

now to reach Design Life and beyond!

Hundreds of Capacity Test results have demonstrated that an increase of 30% is in most cases visible,

sometimes up to 50% longer usage than without BACS is found. BACS® greatly exceeds the service life of all

batteries in high voltage string applications, the higher the voltage, the higher the number of batteries per string

=> the higher the effect of balancing and increased battery life!

PROTECT NEIGHBORED BATTERIES

By balancing the voltages of all batteries within a string, BACS®

prevents damages caused by defect batteries to their neighbors in

the string.

It is well known that after a few years a failing battery block can not

be replaced against a new block without damaging the remaining

older blocks in the battery string.

This effect made it impossible to swap out older used batteries

against new ones, the enduser had to replace all batteries against

new ones, although the majority of the remaining batteries were still

good.

With BACS®, it is possible to support green IT by reducing operating costs

Why changing all batteries because of one single bad battery? With the most advanced battery management

concept on the market, BACS® provides a unique balancing act between the responsibility of environmental

protection,performance and economy. With BACS®, it ist possible to combine a new battery with old existing

batteries or an older battery with new batteries. Reduce down time for maintenance work, reduce unnecessary

battery scrap, reduce costs for new batteries, … save the planet for our children!

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DETECT IMMINENT BATTERY ISSUES

Typical battery problems like sulfation, corrosion, gassing, dry-out, thermal runaway are detectable by interpreting

the BACS measurings. Changes in impedance, temperature and current in a battery string indicate hidden

damages in your battery string.

DETECT / AVOID SULFATION

Sulfation is often a problem for UPS batteries given that they are consistently held at a

float charge level or subject to a charging principle that leaves them uncharged for

long periods of time. Without a proper charging regulation, there is no guarante that all

batteries have reached full charge level when the UPS charge switches from boost to

float charging, this causes that some batteries are kept undercharge in the string and

built up Sulfation, while some other batteries are kept at an overcharged level. The

Equalization (Balancing) process retards sulfation by maintaining ALL batteries at a

balanced voltage level and keep them at the ideal SOC— and, thus, in the ideal

SOH(State of Health).

DETECT / PREVENT STRATIFICATION

By visualizing an increase in impedance and drifting voltages,

the user can detect a battery stratification. From time to time,

in order to reverse stratification, a battery’s acid-gel-water mix

requires rectification. After a discharge the user can verify by

the lower impedance and improved Equalizing (Balancing)

performance that the stratification has been reversed and the

batteries are healthy again.

THERMAL RUNAWAY PREVENTION

BACS detects a thermal runaway risk by monitoring the

cell/block temperatures and the current acceptance of the

string. In case a thermal runaway is detected, the BACS

system can automatically trigger the battery break to open to

avoid a fire in the battery room. For this, the GX_R_AUX

terminal is connected between the battery breaker and the

BACS bus. This principle as according to the US firecode

608.3 and mandatory in most US battery installations.

The GX_R_AUX module provides 4 relay contacts and 4

digital inputs. It controls up to 4 breakers. The digital inputs

read the battery breaker status and display it in the BACS®

web interface. Other alarm devices (for example, audio alarms) may be connected to the outputs or digital inputs

of the GX_R_AUX.

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BATTERY REPLACEMENT NEEDED

By monitoring impedance trends, BACS® allows the user to detect weak or damaged batteries in early stages of

deterioration. Timely replacement of bad batteries is vital to improving the lifespan of the battery system as a

whole.

MODBUS/BACnet/PROFIBUS/LONBUS/SNMP

BACS® allows MODBUS/BACnet clients to read the system data through IP and RS232, RS485 as well as

through SNMP. Conversion to PROFBIS and LONBUS is possible through optional converters.

BACS® includes a full qualified UPS Manager, SNMP adapter and MODBUS and BACnet server. Users have the

freedom of choice which management platform to choose and how to link the BACS system with UPS,

generators, chargers, transferswitches or any other device to manage the site where the batteries are installed.

New : BACnet is standard at BACS / CS141 :

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BACS®

web server displays the battery status of 140 batteries, 16 dry contacts, 8

analogue measuring’s and 1 UPS – all on one screen and one network address.

Status LEDs (green/yellow/red) show a change of color if any battery drifts beyond

configured thresholds.

ADVANCE WARNING SYSTEM

Because it monitors key battery parameters and set

thresholds, BACS® is able to provide advance

warning—via audio, video, and network messages

of any system event that require attention.

BACS® monitors UPS system data and

environmental parameters (temperature, humidity,

hydrogen gas concentration, acid fill level, DC

current, dry contacts, etc.). Alerts can be set up,

and this information can be accessed via multiple

communication systems.

REMOTE MAINTENANCE : Monitoring without compromising IT security – EmailTraps ®

Eleminate blind spots in your monitoring concept even if network loss to remote networks is a regular problem in

your IT security concept :

BACS®

is a network product and designed to work with any VPN, IP forwarding or other remote access

configuration. Additionally BACS provides remote monitoring thru « EmailTrap ® », our email based remote

monitoring function with UNMS Software. Using the UNMS you can monitor any BACS installation worldwide thru

Email – without the security hazzle you have to go thru when setting up a VPN access. Very large networks can

be

monitored safely thru EmailTraps® and UNMS software.

Real time battery test using UPS functions

BACS® is designed to manage a UPS or charge in parallel to Battery Management. Thru this feature the enduser

may watch the effect of a UPS battery test in real time. No need to apply a dummy load, simply start a UPS test to

see the performance of your batteries.

- Test your emergency measures in real time

- Maintain all configurationes without a system reboot

- Plan scheduled test routines

Professional Tools for battery experts

The free BACS®

VIEWER software is a professional tool for deep battery

analyzing and error prediction.

o Discharge analysis

o Impedance trend of batteries

o Temperature and voltage analysis

o Reporting

Investigate and search for any problem before an incident occurs - the inner life of a battery is no longer a blind spot.

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BACS IN DETAIL

A modern uninterruptable power supply (UPS) consist of a charger (Rectifier) and a DC to AC converter

(Inverter) and its functionality depends highly on the performance of its battery pack. Every single

cell/battery is important to avoid a loss or power during a grid failure and to secure the applications

behind the UPS. Just one “lost” battery may reduce the effiency of the entire system and may cause a

catastrophic event.

BACS®

is designed to find faulty batteries

BACS®

battery modules are capable of taking precise measurements of a battery’s internal resistance,

temperature, and voltage. These measurements are essential to do a precise analysis of the batteries

within the system. BACS® transfers this data through a bus system to the BACS

® WEBMANAGER,

which is triggering alarms in case the values are out of configurable thresholds. Additional 3rd

party

sensors can be attached for a holistic overview of the complete system that includes all kind of

environmental sensors, dry contacts alarm inputs and relays outputs.

BACS®

is designed to manage the entire system

The BACS WEBMANAGER handles events involving the UPS, rectifiers, inverters, environmental

sensors, transfer switches, generators, dry contacts, and other devices. The BACS® WEBMANAGER

acts as the battery system’s central control unit. It gathers, evaluates, and stores the data on its internal

flash memory.

BACS®

is designed for a strucured presentation of complex measuring data

The user has access to three groups of devices through the webserver of the BACS system:

o Display the Battery status : Everything you need to know about the condition of the batteries is

provided in real time. BACS®

will provide a general overview about the output quality as well as

information about the strings or even single batteries inside a string.

o Display the UPS/Transferswitch/Charger/Generator/Alarmcontact status : A UPS (or other

device for charging, discharging etc.) provides a lot of real time system information about the

current operating state, power input/output and alarms. BACS® has a UPS interface which

manages every UPS alarm/event and can automatically secure a grace network computer

shutdown in case the UPS runs of of battery autonomytime.

o Display environmental data : A 3rd

screen shows a complete overview of all environmental or 3rd

party sensors, inputs, switching states of actuators and relays, etc.

BACS®

is designed for easy configuration and maximum flexibility

A flexible programming interface – similar to a PLC - known as the EVENT MANAGER coordinates a

system response to significant events (alarms, notifications, etc.). The web browser interface of the

system is designed for easy configuration. It provides the user with access to all system values and

events and allows the configuration of an autonomous system which responds to any alarm by itself, fully

preprogrammed.

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Balancing

Balancing/Equalizing is a unique function of BACS and the key to a long and healthy battery system, here how it

works: The BACS® WEB-MANAGER reads individual battery voltages and compares them to the battery system’s

target voltage. The target voltage is sent to each BACS®

module, which steers voltage levels of the batteries

under its control towards this target voltage.

This is the process we call ―equalization‖ or ―balancing‖. By virtue of it, the voltages of all batteries in a given

system can be calibrated to within 0.01 volts of that system’s target voltage.

BACS®

effectively mitigates the possibility of overcharging batteries. In this way, it helps to prevent gassing and

drying. It also mitigates the possibility of undercharging.

Through Equalization (Balancing), system batteries are kept at an optimal charging voltage and SOC (State of

Charge) at 100%, and, therefore, in an optimal SOH (State of Health).

By managing a battery system’s charging voltages, BACS® vastly improves its durability and reliability.

BACS® has the ability to send out alarms via email, email-to-SMS, emailTrap®, network message, SNMP,

RCCMD, MODBUS, BACnet, PROFIBUS, LONBUS and thru UNMS messages. All alarm parameters can be

configured by the user to match battery type. For instance, discovering a rising internal resistance in a battery—

an indicator of corrosion or sulfation— BACS® triggers an alarm. (Sulfation, when caught in time, can be reversed

by means of a series of charging and discharging cycles.) Given early warning of the issues that such a rise

indicates, the user is able to investigate and take action in advance. The effects of corrective actions taken are

immediately observable. In addition to internal resistance, BACS® monitors voltage, temperature, the Equalizing

(Balancing) process, the system’s charging/discharging cycles as well as DC current and AC ripple current. When

preset thresholds pertaining to any of these categories are crossed, an alarm is tiggered.

In addition to sending above mentioned network alarms, BACS® also warns users via acoustical and visual

signals (a buzzer on the BACS® MANAGER and alarm LEDs on the module and BACS

® MANAGER) and thru

dry-contact output.

Realtime clock and large internal memory for exact data logs

A complete time line of an incident may help to improve operating security. Due to this fact, the BACS®

MANAGER provides internal memory to store all common log data for a long time.

The time line stored on the BACS® Managers flash rom depends on the number of modules and number of

alarms. Even with a huge system with eg. 330 batteries/modules, the BACS is capable to store battery log data

for up to 122 day.

With deleting only the oldest data log entry, the BACS Webmanager ensures there is always a continous time line

present that can be achieved for battery analyzis and error prediction. These log files can be easily downloaded

and stored in case of an incident or even for deep battery data lifetime analyzis that ranges for up to the complete

service life of each single battery.

No. Of BACS

Modules

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

250

260

270

280

290

300

310

320

330

Log range of the flash ROM in days.

4045

2022

1348

1011

808

674

578

505

449

404

367

336

310

288

270

253

237

224

213

202

192

183

175

169

161

156

149

144

139

135

130

126

122

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The BACS VIEWER - powerful free software tool included

The unique BACS® VIEWER software can do more than just fetching data from the Manager and free local

memory for data logging. After downloading the battery data, the BACS® VIEWER software is a powerful tool for

analyzing and archiving. It can be used to add useful documents like wiring descriptions, billets, guarantee

certificates, maintenance plans, handouts for technical staff, analyze battery data and timelines and many more.

BACS® VIEWER software can be used to manage maintenance work for an infinite number of BACS

® Systems:

Analyse the battery data and trends

Discharge analysis and faulty battery detection

Plan maintenance windows to shorten down time

Determine required spare parts

Create automatic status reports

Example: Finding a damaged battery:

The BACS® VIEWER shows the

individual battery voltage of all

accumulators at the end of a discharge.

The red dotted line shows the voltages

when power has returned. The lower bar

graph indicates those accumulators that

have collapsed early and have been

discharged to a very low level. These

batteries are a risk to the entire system.

With this important information, it is

possible to plan replacing only damaged

batteries – without BACS® all batteries

must be replaced which means a long

down time and enormous extra costs because not only replacing all batteries must be paid, it is also a eminent

downtime of the complete UPS system.

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Batteries in UPS applications

In a typical UPS battery installation, a large number of batteries are connected in series to produce a high string

voltage. Modern UPS systems, augmented with IGBT rectifiers, work very efficiently, but require this high string

voltage compared to older systems. (With larger strings, it’s not unusual to see voltages of 800V or higher.) At the

same time, in data centers, space is an increasingly precious commodity. Managers will often choose space

saving Valve Regulate Lead Acid (VRLA) batteries over their Flooded Lead Acid (FLA) counterparts. Where

VRLA batteries are smaller, they run hotter—and therefore tend to gas and dry out—often resulting in a shortened

lifespan.

More batteries in a string… this means higher voltage, but it also means more cables, more connectors, greater

impedance, and significant voltage deviation and charging issues. Up to 2V voltage differences in such battery

strings from battery to battery are not unusual and it worsen over time. It becomes increasingly difficult to maintain

the ideal float voltage of e.g. 13.6V for a typical lead acid battery. Thus, for years, it has been commonly accepted

in the UPS industry that such issues and the ill-effects they bring about (sulfation, drying out, shorter and shorter

battery life, etc.) were unavoidable. Lacking a technical solution, rather than focusing on the problem, UPS

makers have simply recommended replacing batteries earlier than their expected lifetime. Users wanting to avoid

the risk of UPS failure have simply had to accept replacing batteries at 50-60% of the lifetimes specified by

manufacturing designs.

Naturally, UPS users have never been satisfied with this solution. Entire systems may collapse given a single

point of failure. Changing batteries more often does not completely mitigate the risk of UPS failure. New batteries

have been known to fail without warning. And no high voltage UPS can tolerate missing batteries

So, UPS makers have offered another solution: Redundant UPS – such systems feature two or more parallel

strings of batteries. This reduces the risk of UPS failure, but has several disadvantages: increased cost, increased

space requirements, increased service costs. And it is still no guarantee. The user has no idea what is going on in

any battery string at any given time. The reduction in risk accomplished by adding more strings is only theoretical.

To counteract the risk of unnoticed battery failures and loss of backup, UPS users began installing automatic

transfer switches to redundant UPS systems and using emergency generators as a backup in case of power

failure. This is both an extremely costly solution and one that involves a further risk. Emergency generators on

standby require at least a ten-second startup time—time enough to lose data in the event of battery failure. The

uncontrolled generator’s starter battery is still another risk factor.

The battery was and will ever be the Achilles’ heel of any backup system! All you can do is minimizing the

risk and being prepared for a worst-case scenario

BATTERY MANAGEMENT SYSTEMS

In light of this fact, the Battery Management System (BACS) has become fashionable as the superior system to a

Battery Monitoring System (BMS) which was just watching the batteries fading, but such a monitoring system was

not able to avoid the cause of the problem.

A Battery Management System should not only detect imminent battery failure, tell the user why batteries are

failing, and provide a reliable Advance Warning System, but it should automatically initiate actions to counteract

battery issues. In a word, a good BMS should not only monitor but regulate – ―manage‖ all batteries!

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BACS®

VIEWER SCREENSHOT

As seen by BACS®, the same 5 year old system as shown in the

previous graphic, this time, after the application of the patented

Equalization (Balancing) process. Within a few hours, this process

brings the variance in float voltage to within 1/100th of a volt of the

level recommended by the manufacturer.

BACS

® is the only BMS on the market that does both - monitor and regulate/manage all batteries !

Standard battery behavior in any UPS today:

The graphic at the right shows the battery history in a UPS that

might be found in any data center today. It is using a five-year-

old battery system; the float voltages of the batteries in the

string it contains vary within an eminent range of +/- 1.8V. This

means the deviation from the ideal voltage of such batteries

(13.60 Volt) is at some batteries at 14.50 Volt, some are at

12.70 Volt).

The longer such differences remain uncorrected, the more the

voltage patterns start drifting. In the long term this is the cause

why batteries in UPS applications cannot reach the design life

and become unstable.

A few hours after enabling BACS…

Applying the patented Equalization (Balancing) process used

by BACS® to this system solves the voltage difference problem

within a few hours: The screenshot at the right with the green

frame shows the same batteries and the progress of the

Equalization (Balancing) process. All batteries in the string are

kept within the ideal voltage. BACS® keeps each of the

batteries at 100% charge level and at the float voltage

recommended by the manufacturer.

Looking for more information?

A general description about the principle of equalization and

an explanation of the reasons it extends battery life drastically

and extends cycle life by at least a factor of 3 is scientifically is explained in the INTELEC Paper 32.1:

―Life Extension through charge Equalization of Lead-Acid Batteries‖ by Philip T. Krein, Member of IEEE.

The BACS® patent has been established based on scientific principles and investigations conducted by

GENEREX research since 2002. Now, with more than 18 years of research how to balance batteries within high

voltage applications, GENEREX has earned to be the market leader in Europe and the number 3 all over the

world.

http://www.google.de/url?sa=t&rct=j&q=intelec%20paper%2032.1&source=web&cd=1&ved=0CB0QFjAA&url=http%3A%2F%2Fenergy.ece.illinois.edu%2Fbalog%2Fimages%2Fintelec02.pdf&ei=NVHLTpX3JuyO4gTo9vBD&usg=AFQjCNHrwk1whWNj8ISSKSo-sYiqTc8DxQ

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Features of the BACS WEBMANAGER product family

High-tech made in Germany / Made in the USA

The most powerful and flexible UPS management card worldwide is the CS141 – the basis of the BACS

WEBMANAGER. Running on an ARM Cortex A8 CPU, 10/100Mbit Auto-sensing Ethernet, 3 serial RS-

232 Interfaces, 1 USB Port, AUX port for connecting an external interface Card with 4 dry-contact,

external alarms output/input and connecting the BACS modules. Available also as MODBUS RS485

interface at COM2.

Grafical interfaces

The in-build web server is designed for inutuitive monitoring and configuration via the network, to

configure the extensive functions of the BACS WEBMANAGER and perform even the most powerful

statistical analysis in the BMS market. Statistical values of all connected devices are displayed

graphically - UPS, temperature, humidity, etc. Additionally, the BACS WEBMANAGER provides options

to communicate with UNMS (UPS Network Management System) - or any type of other 3rd

part

management software based on SNMP, MODBUS or BACnet. Thanks to the GENEREX API, the BACS

WEBMANAGER offers additional interfaces for customers who wish to program the settings on the

device using self-defined scripts.

Universal suitable for nearly type of UPS

Beside the capabilty to manage up to 510 Batteries of almost any chemistry, it supports at the COM1

more than 1400 UPS types from 120 UPS manufacturers. The incorporation of native UPS RS-232

protocols and support of dry contacts makes the monitoring of any device possible and allows the

interaction with such devices in case of battery or other alarms. Besides batteries, te BACS

WEBMANAGER is a fully qualified manager for the monitoring/management of UPS, Transfersswitches,

Rectifiers, Inverters, Generators and Fuel Cells – plus Batteries.

Scheduler

Use the intuitive task scheduler to plan recurring tasks such as UPS battery tests, AUX output switching,

or any other tasks the devices connected to the BACS WEBMANAGER can offer.

Data logging

Measurement values and alarms are logged to the non-volatile storage of the BACS WEBMANAGER.

The time synchronization function through NTP ensures that all log entries are precise.

Email/SMS

Integrated email client via SMTP can be configured to relay either all or specific messages. The email

client can use of public email servers and local email servers to distribute information. Compatible with

SMTP email systems such as MS Exchange/Outlook, Lotus, and many others. Support for GSM Modem

through COM2 for transmitting SMS Textmessage in case the system is not part of a network with

Emailserver access.

EmailTrap® for UNMS Remote Monitoring

Every BACS WEBMANAGER can send its data packages via ―Email Trap” to the UNMS Software with

TELESERVICE module. This allows a remote monitoring via email, without compromising the customers

network security systems.

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Multiserver Shutdown and Restart Management

Each BACS WEBMANAGER comes with a full featured RCCMD Network Management server – The

according RCCMD client is available for more than 40 different operating systems. Since RCCMD is

more than just another shutdown client, each BACS system is able to trigger shutdowns, messages,

scripts, etc. to run even most complex shutdown and restart control with time-scheduled manual scrip-

based routines.

BACS can manage all kinds of system states:

o Cold boot (computers are directly cut-off from or connected to the power supply).

o System reset and warm boot

o Wake On LAN (Use magic packets to start the hardware or virtual machines).

o Custom scripting and local shutdown-sequences

o Trigger physical switches and acuators …

Network Services

The BACS system has full qualified UPS manager on board and supports all kinds of network protocols

like SNMP V2/V3, IPv4/IPv6, HTTP/HTTPs, DNS, DHCP, SMTP, NTP, SFTP, UPSTCP (UNMS),

MODBUS over IP, MODBUS/PROFIBUS over RS232 or RS485, BACnet and GENEREX proprietary

network protocols like UPSTCP (for UNMS) and RCCMD for network computer shutdown management.

Network Security

The BACS WEBMANAGER provides manifold security features to ensure a maximum of network

security. The BACS WEBMANAGER uses industrial standards to provide HTTPs and SSL encrypted

communication with user created certifcates, it can be configured to deny outdated or invalid certificates

and is provides encrypted SNMP communication (V3), but alsso less secured systems are supported.

Advanced password security and hard-coded user management provides configuration menues

according to user level. To prevent unauthorized access, the webserver can be disabled after

configuration – the hardened operating system does not support a ROOT access so that no change is

possible. An intelligent build-in watchdog will reboot the BACS WEBMANAGER in case of unexpected

incidents causing a hang-up. As a special feature, the BACS WEBMANAGER provides tools to assist

network administrators during network security auditings of a network segment.

SNMP/MODBUS/BACnet

Fieldbussupport: The BACS WEBMANAGER supports the SNMP V2/V3 using RFC1628 MIB (Standard

UPS MIB) and MIB extensions for use with the SITEMANAGER 4,5,6, BACS and SENSORMANAGER.

Also several private MIBs are supported (APC).

All GENEREX products support MODBUS-over-IP and BACnet, which enables the BACS

WEBMANAGER to incorporate PLC devices (SPS) like those from Schneider Group or any other

MODBUS or BACnet based management system. Additionally the BACS WEBMANAGER provides at

the COM2 port MODBUS over RS232 (or RS485).

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PROFIBUS/LONBUS (option)

More Fieldbuskonverters are available as option.

SENSORMANAGER (option)

The optional SENSORMANAGER offers 8 analog inputs for almost all kinds of analogue sensors on the

market. In addition, the sensor manager provides 4 digital inputs for alarm sensors (e.g., for smoke, fire,

water, etc.) and 4 digital outputs (e.g., for visual and visual alarms).

Analog IO (option)

It is possible to connect an Interfaceboard (CON_AUX4/CON_R_AUX4) to the COM3/AUX-port to

control 4 analog Inputs or Outputs with the BACS WEBMANAGER.

Third party UPS SNMP card communication

The BACS WEBMANAGER offers communication with UPS and other devices using RS232 or slots for

almost any UPS systems on the market. In some cases, this direct RS232 connection is not possible due

to a missing or blocked interface on the UPS - e.g. if the UPS manufacturers prevent this and use their

own SNMP cards. This is not an obstacle for the BACS WEBMANAGER:

The intelligent third-party UPS communication assistant integrates these third-party SNMP cards via

TCP / IP using SNMP in accordance with the RFC1628 standard (or private MIBS e.g. APC) and thus

uses existing infrastructures to query data from a UPS. This allows the BACS WEBMANAGER to read

UPS/Charger input data for triggering its own battery management processes. The BACS

WEBMANAGER now ensures compatible communication methods to formerly incompatible UPS

solutions. All UPS makers SNMP solutions can be harmonized using BACS or CS141.

The BACS WEBMANAGER

will query the UPS data via

network.

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FUNCTION OVERVIEW: BACS WEBMANAGER

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BACS®

System Components

BACS® WEB-MANAGER in 5 versions

3 external versions incl. a Rack model plus 2 UPS slot versions Management of up to 510 BACS

® C modules

in up to 16 parallel strings. Includes a full-qualified UPS-SNMP & MODBUS and BACnet manager at COM 1 and over Network for the monitoring of a UPS/inverter/rectifier/generators or other devices with a serial interface or network SNMP interface. COM2 for optional environmental sensors (e.g. temperature, humidity, current, acid fill level, etc.). One programmable alarm relay output, one alarm-LED, one alarm buzzer, mute button. Integrated web server for status display configuration of all alarm thresholds (battery impedance, voltage, temperature, UPS alarms, environmental alarms, etc. network messaging system (email, SMS, SNMP, RCCMD, MODBUS, BACnet and (optional) PROFIBUS and LONBUS. Data logger for all measuring data, current sensors (optional) for charge- and discharge current measuring. Compatible to UNMS monitoring software

BACS® C MODULE & CABLE

Diagram of a BACS® module installation:

A calibrated measuring cable with two high-voltage fuses connected to the positive and the negative Battery poles uses a 4-string wire for measuring the individual battery data. The BACS

® module measures through an

integrated sensor the surface temperature of the accumulator, the voltage and the impedance. The BACS

® module is available in 5 different

types: 16 volt, 12 volt, 6 volt, 4 volt, 2 volt for Lead/Acid, NiCd, NiMH and Lithium Ion batteries.

BACS® VIEWER

Remote monitoring software for deep battery

analyzing and maintenance management.

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Technical data and dimensions

BACS® WEBMANAGER BUDGET SC (slot version)

Order No. BACSKIT_BSC4

Processor and memory ARM Cortex A8 800MHz CPU, 30 MB storage for battery history

(range: pls. refer to the example table above). Power consumption At 12V default power supply consumption approx. 150mA. BACS

CONVERTER is included. Interfaces 3x RS-232 interfaces, (COM1= UPS/power device,

COM2 =Multipurpose, COM3=BACS battery bus) 1x RJ12 for battery bus converter 1x RJ45, 10/100Mbit Ethernet

Display 2x LED (Manager status, UPS/device alarm) Housing Slot card ―SC format‖ for UPS devices witch compatible slots

UL- Certification Dimensions 60 x 29 x 120mm = 2,36 x 0,79 x 5,12 in. (L x W x H) – Slot card

„SC format― Weight 90g

Operating condition Temperature 0 - 70°C, max. humidity 20 - 95%, not condensing MTBF (calculated) 849192 hours; 96,9 years

BACS® WEBMANAGER BUDGET L

Order No. BACSKIT_LB4

Processor and memory ARM Cortex A8 800MHz CPU, 30 MB storage for battery history (range: pls. refer to the example table above).

Power consumption At 12V default power supply consumption approx. 150mA. BACS CONVERTER is included.

Interfaces 3x RS-232 interfaces, (COM1= UPS/power device, COM2 =Multipurpose, COM3=BACS battery bus) 1x RJ12 for battery bus converter 1x RJ45, 10/100Mbit Ethernet

Display 2x LED (Manager status, UPS/device alarm) Housing Aluminium, RAL 7035 (light gray) CE, UL/NEMKO certification

Dimensions 69 x 126 x 35mm = 2,72 x 4,96 x 1,38 in. (L x W x H) Weight 210 g


BACS® WEBMANAGER BUDGET SCM RS485

(slot version) Order No. BACSKIT_SCMB4

Processor and memory

ARM Cortex A8 800MHz CPU, 30 MB storage for battery history (range: pls. refer to the example table above).


Interfaces 2x RS-232 interfaces, (COM1= UPS/power device, COM3=BACS battery bus), 1 * RS485 = COM2 1x RJ12 for battery bus converter 1x RJ45, 10/100Mbit Ethernet

Display 2x LED (Manager status, UPS/device alarm) Housing Slot card ―SC format‖ for UPS devices witch compatible slots

UL- Certification Dimensions 60 x 29 x 120mm = 2,36 x 0,79 x 5,12 in. (L x W x H) – Slot card

„SC format― Weight 66g


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BACS®

WEB-MANAGER – modular and flexible

BACS® WEBMANAGER BUDGET LM RS485

Order No. BACSKIT_LMB4

Processor and memory ARM Cortex A8 800MHz CPU, 30 MB storage for battery history (range: pls. refer to the example table above).


Interfaces 2x RS-232 interfaces, (COM1= UPS/power device, COM3=BACS battery bus), 1x RS485 1x RJ12 for battery bus converter 1x RJ45, 10/100Mbit Ethernet

Display 2x LED (Manager status, UPS/device alarm) Housing Aluminium, RAL 7035 (light gray) CE, UL/NEMKO

certification Dimensions 69 x 126 x 35mm = 2,72 x 4,96 x 1,38 in. (L x W x H)

Weight 210 g Operating condition Temperature 0 - 70°C, max. humidity 20 - 95%, not

condensing MTBF (calculated) 844138 hours; 96,4 years

BACS – All-in-One - solution

SITEMANAGER 6 Order No. SITEMAN_6

Processor and memory ARM Cortex A8 800MHz CPU, 30 MB storage for battery history (range: pls. refer to the example table above). Non-volatile memory for alarm notification after power loss

Power consuption 40 watts max. Interface RS-485 interface for other devices / Adapter for RS232 support

Inputs 8 digital inputs (opened / closed configurable) 8 analog inputs (0 - 10V, 4 - 20mA, 0 - 20mA configurable via jumpers)

2 x RJ10 for BACS battery bus

Outputs 8 relay outputs (changer, max. 230V/ 4A AC/DC)

Network 10/ 100Mbit LAN

Supported protocols Email, Telnet, HTTP, SNMP, SNTP, RFC868, MODBUS Over IP, UPSTCP,DHCP, DNS, FTP, TELNET

Front Display LED alarm display, LED operating status display Dimensions 483 x 162 x 44mm, (483 x 212 x 44mm incl. SM_LOOM)

19,00 x 6,38 x 1,73in, (19,02 x 8,35 x 1,73in incl. SM_LOOM) Weight 2262 g

Operating condition Temperature 0 - 70°C, max. humidity 20 - 95%, not condensing

Network management UNMS II Network Management software Network Adapter BACnet, PROFIBUS, LONBUS network adapter

Additional sensors Smoke/fire alarms, motion detectors, door contacts etc., connection of any other alarm contact indicator, which output signal is between 0 - 10V,4 -20mA or rather 0 - 20mA (configurable via jumpers)

Actuators flash light, alarm buzzer, relay-switches, external switches, etc.

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BACS®

Webmanager Budget

BACS® WEBMANAGER BUDGET - 12V

Order No. BACSKIT_B4

Processor and memory ARM Cortex A8 800MHz CPU, 30 MB storage for battery

history (range: pls. refer to the example table above). Power consumption At 12V default power supply consumption approx. 150mA.

Plus 1830 mA for BACS modules (up to 366 BACS modules).

Number of modules Standard Power supply grants power for up to 366 BACS C modules. For more Modules and sensors, ask for larger power supply.

Interfaces 3x RS-232 interfaces, (COM1= UPS/power device, COM2 =Multipurpose, service port for Windows BACS READER and PROGRAMMER software) USB 2x battery bus converter outputs internal 1x RJ45, 10/100Mbit Ethernet 1x potential-free contact (2 pole screw wiresize 1,0 mm², rated load 24 VDC /1A)

Display/Signal 3x LED (Manager status, UPS/device alarm, BACS alarm) 1x Buzzer with mute button

Housing Aluminium, RAL 7035 (light gray) UL/NEMKO certification in preparation

Dimensions 130 x125 x 30mm = 5,12 x 4,92 x 1,18 in. (W x L x H) Weight 180g

MTBF (calculated) 849192 hours; 96,9 years

BACS®

WEBMANAGER BUDGET 18V - 72V Order No. BACSKB4_72

Description Identical to BACSKIT_B4, but designed for power supply

directly from the 24Volt or 48Volt batterie group. The external pluggable power supply is replaced by a TRACOPOWER TCL 024-112DC DIN rail power supply

Number of modules Standard Power supply grants power for up to 330 BACS C modules and BACS bus sensors Für up to 510 Modules and sensors, an alternative power supply is available.

Technical data: TRACOPOWER TCL 024-112DC

Input 18V – 72V DC

Output 12V 2000mA DC stabilized

Notes Input safeguarding fuse (recommended circuit breaker 6-16A / characteristic C) is not included.

BACS® WEB-MANAGER BUDGET 120V -

370V Order No. BACSKB4_370

Description Identical to BACSKIT_B4, but designed for power supply directly from the 24Volt or 120Volt to 370 Volt batterie group. The external pluggable power supply is replaced by a MEANWELL SNT MW-MDR20-12 DIN rail power supply

Number of modules Standard Power supply grants power for up to 330 BACS C modules and BACS bus sensors Für up to 510 Modules and sensors, an alternative power supply is available.

Technical data of the MEANWELL SNT MW-MDR20-12:

Input 120V – 370V DC (or 85V-264V AC)

Outuput 12V 2000mA DC stabilized

Notes Input safeguarding (input fuse) is not included

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BACS®

accessories

BACS® BUS CONVERTER 5

Order No. BACS_BUS_CONV_V

Construction Conversion and galvanic separation of the BACS battery bus to the BACS WEBMANAGER BUDGET plus real time clock (RTC) timer for the BACS WEBMANAGER.

Power Supply Stabilized external 12V/2000mA Number of modules Standard Power supply grants power for up to 366 BACS C

modules. Für up to 510 Modules and sensors, a larger power supply is available.

Interface 2x RJ10 for BACS battery bus 1xRJ12 for COM3 BACS WEBMANGER BUDGET 1xMiniDin8/RS232 interface for serial connection to workstation. For CONVERTER 3 an adapter is required (see below) 1x2,1mm DC connector socket for power supply via external wall wart power supply 1x potential-free contact (2 pole screw terminal for 1,0 mm² /24 VDC /1A)

Display Optical display (LED) Alarm Internal alarm buzzer with acknowledge button

Housing Polystyrene Optional parts Optional: Adapter from mini-8 to RS232 for the BACS

CONVERTER 3, with junction cable mini-8 1.5m Dimension 91,5 x 67 x 25 (W x H x D)

Weight 120g Operating condition Temperature 0 - 60°C, max. humidity 90%,

not condensing

BACS® SPLITTING BOX

Order No. BCII_SPLITT Construction Passive splitter for BACS communication cables, designed

to optimize the overall cable lenghts and to create an optical pleasant wiring. In addition to the extension of the 2 BACS bus inputs of the BACS CONVERTER.

Power supply Passive element, no additional power supply required Interfaces 5* RJ10 for BACS bus cables

1x RJ10 input connector for BACS bus data input Housing Polysterene

Dimension 91,5 x 67 x 25 (B x H x T) Weight 90g

Operating condition Temperature 0 - 60°C, max. humidity 90%, not condensated

BACS® DC current sensor

50/200/400/1000/2000 Ampere Ord. No: BACS_CSH50, BACS_CSH200, BACS_CSH400,

BACS_CSH1000, BACS_CSH2000

Construction

DC current sensor for measuring battery string discharge and charging process +/-50A, +/-200A, +/-400A, +/-1000A, +/-2000A DC Current transducer diameter hole : 21mm [0,82in] (BACS_CSH50) /40 mm [1.57in]

Power supply Intern powered by BACS bus Power consumption 60mA

Interfaces 2x RJ10 for BACS bus cable, pluggable system Housing DIN Rail

Dimension (LxWxH) 110 x 82 x 125 mm = 4,33 x 3,22 x 4,92 in. (LxWxH) Weight 420g

Operating condition Temperature 0 - 60°C, max. humidity 90%, not condensated

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BACS® bus interface GX_R_AUX

Order No. GX_R_AUX

Description Input alarms and Output relay management. A typical application is the control of a battery breaker in case of ―thermal runaway‖ alarm in the battery system. Applies to US Norm International Fire Code IFC 608.3 for isolating UPS batteries in case of a thermal runaway. In case of a high battery temperature and increasing voltages during float charge, the GX_R_AUX may open the battery breaker to stop a further increase of the temperatures in the batteries. Individual programming of the relays through web interface.

Inputs 4 digital inputs (configurable NO/NC) Outputs

4 Relay potential-free outputs (NO/NC) / 50VAC – 2A, 30VDC – 1A

Power supply Powered by BACS bus, no external power supply Power consumption Apporx 170mA

Housing Polamid, plugable system DIN rail Dimension 75 x 75 x 45mm = 2,95 x 2,95 x 1,77 in. (LxWxH)

Weight 170g Operating condition Temperature 0 - 60°C, max. humidity 90%, not condensated

BACS® external temperature sensor

Order No. BACS_TS1L23, BACS_TS1L90

Construction

External temperature sensor for BACS REV 3 (Optional). If this sensor is attached, the internal temperature sensor of the BACS module will be automatically switched off.

Cable lentght 23cm (9.06in) / 88cm (34,65in) cable

Delivery content Sensor only, has to be attached to the BACS C module by a qualified BACS service engineer

Housing UL certified material, voltage proofed up to 1000V Measuring range -10°C - +90°C,

precision +/- 1°C dimension 2cm x 1.5cm x 1cm) ( 0.87 x 0.58 x 0.37 Inch ―)

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Modules and cables

BACS®

modules REV 3

Construction Measuring modules with passive balancing/equalisation BACS patent no.: DE 102004013351.4

current consumption from battery

normal operation: 15 - 20mA (C20, C23, C30) 35 - 40mA (C40, C41) „Sleep Mode―: < 1mA

Measuring precision Internal resistance : < 10 % at C40, < 5% at C20/30 Voltage : < 0,5 % Temperature: < 15 %

Interfaces 2x RJ10 for BACS battery bus

Internal RS232 bus interface 1x button for the addressing Temperature sensor -35 bis + 85 °C Optical display LED (alarms red/green, mode red/green)

Housing ABS housing (UL certified, flame retardant, cooling fins) Dimensions, weight 55 x 80 x 24 mm = 2,17 x 3,15 x 0,94 in. (B x H x T), 45g Operating condition Temperature 0 - 60°C, max. humidity 90%, not condensin Int. protection rating IP 42 coated against dust and condensate

High voltages security tested Protection against high ohmic batteries fault voltages up to 150 Volt /per module (fuse opens). At higher voltages the fuse opens, but BACS module is damaged. All REV 3.1 modules are designed for fault voltages up to 600 Volt

MTBF (calculated) 87.600 hours (10 years)

Module BACS® C20

Order No. BACSC20 REV 3 module for 12Volt 7-600Ah lead, NiCd, NiMH, Lithium batteries (UL certified)

Voltage range 9.7V – 17V RI range 0.5-60mOhm

Equalisation power 0.15 A

Module BACS® C23

Order No. BACSC23 REV 3 module for 16Volt 7-600Ah lead, NiCd, NiMH, Lithium batteries

Voltage range 9.7V – 17V RI range 0.5-60mOhm


Module BACS® C30

Order No. BACSC30 REV 3 module for 6Volt 7-900Ah lead, NiCd, NiMH, Lithium batteries

Measuring value 4.8V – 8.0V RI range 0.5-60mOhm


Module BACS® C40

Order No. BACSC40 REV 3 module for 2Volt 7-5000Ah lead, NiCd, NiMH, Lithium batteries (UL certified)


Equalisation power 0.9 A (at 2.27V)

Module BACS® C41

Order No. BACSC41 REV 3 module for 4Volt 7-900Ah lead, NiCd, NiMH, Lithium batteries (UL certified) (ULd)



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BACS Cables

BACS® measuring cables

Order No. BC4B-xxxxx

Description Measuring cables made of UL certified material for BACS

sensors type C40 REV 3. Unique high voltage precision fuses for system protection and precise measurements

cable cross section 2x1,50mm² nominal voltage U0/U 300V/500V

fuses 1000V/10A und 1000V/1A temperature range -25°C – 70°C


Order No. BC4B-xxxxxH

Description Measuring cables made of halogen free, extremely fire

resistant and oil resistant material, for BACS sensors type C40 REV 3. Unique high voltage precision fuses for system protection and precise measurements.


fuses 1000V/10A und 1000V/1A temperature range -15°C – 70°C

Cable coating halogen free in acordance with VDE0281 part 14


Order No. BC5-xxxxx

Description Measuring cables made of UL certified material for BACS

sensors type C20 REV. 3, C23 REV. 3, C30 REV. 3 and C41 Rev. 3. Unique high voltage precision fuses for system protection and precise measurements

cable cross section 2x0,75mm nominal voltage U0/U 300V/300V

fuses 1000V/2A und 1000V/500mA temperature range -25°C – 70°C


Order No. BC5-xxxxxH

Description Measuring cables made of halogen free, extremely fire

resistant and oil resistant material, for BACS sensors type C20 REV. 3, C23 REV. 3, C30 REV. 3 and C41 Rev. 3. Unique high voltage precision fuses for system protection and precise measurements


fuses 1000V/2A und 1000V/500mA temperature range -15°C – 70°C

Cable coating halogen free in acordance with VDE0281 part 14

BACS® bus cables

Order No. B4BCRJx

Description High quality communication BACS bus communication cable Cable coating halogen free in acordance with VDE0281 part 14

Contacts twisted pair RJ10 Cable length Various lengths available.

See latest BACS price list for details

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BACS®

CONTROL CABINETS: Technical data and dimensions

Control cabinet for BACS® systems. Plug-play, with AC input plug (Euro) ready to install. With optical and audible display on the

outside door, protection class IP 56. Easy connection of inputs and outputs through a strip terminal.

BACS® CONTROL CABINET Type 1

Order No. BACS_CC1

Controller 1 BACS WEBMANAGER BUDGET

Power 1 12V Power supply (100 – 240V, 50/60Hz)

LAN 1 CAT 6 Ethernet socket

Contacts 1 Alarm contact (potential-free) , 230VC / 30VDC / 8A

Front door 1 POWER LED

Front door 1 BACS ALARM LED Spare parts 6 Spare bus communication cable Dimension WHD 400 x 500 x 210 mm = 15,75 x 19,69 x 8,27 in.


Order No. BACS_CC2

Controller 2 BACS WEBMANAGER BUDGET





Front door 2 BACS ALARM LED

Spare parts 8 spare bus communication cable

Dimension WHD 500 x 500 x 210 mm = 19,69 x 19,69 x 8,27 in.


Order No. BACS_CC3 Controller 3 BACS WEBMANAGER BUDGET





Front door 3 BACS ALARM LED

Spare parts 10 Spare bus communication cable

Dimension WHD 500 x 500 x 210 mm = 19,69 x 19,69 x 8,27 inch

Need some more space? BACS®

CONTROL CABINET Type 4 Order No. BACS_CC4

BACS® CONTROL CABINET

Type 5 Order No. BACS_CC5

BACS® CONTROL CABINET

Type 6 Order No. BACS_CC6

- 4 * BACS WEBMANAGER BUDGET - 5 * BACS WEBMANAGER BUDGET - 6 * BACS WEBMANAGER BUDGET - 4 * 12V Power 100 – 240V, 50/60Hz - 5 * 12V Power 100 – 240V, 50/60Hz - 6 * 12V Power 100 – 240V, 50/60Hz - 4 * CAT 6 Ethernet socket - 5 * CAT 6 Ethernet socket - 6 * CAT 6 Ethernet socket - 4 * Alarm contact (potential-free) 230VC, 30VDC, 8A

- 5 * Alarm contact (potential-free) 230VC, 30VDC, 8A

- 6 * Alarm contact (potential-free) 230VC, 30VDC, 8A

- 4 * POWER LED, - 4 * BACS ALARM LED



12 * spare bus communication cable 14 * spare bus communication cable 16 * spare bus communication cable

- Dimension: 600 x 760 x 210 mm 23,62 x 29,92 x 8,27 in

- Dimension: 760 x 760 x 210 mm 29,92 x 29,92 x 8,27 in.

- Dimension: 760 x 760 x 210 mm 29,92 x 29,92 x 8,27 in.

NEW: All cabinets are also available with integrated door touch panel computer – marked with ―TP‖ in the Partnumber.

Order No.: BACS_CC1_TP, BACS_CC2_TP, BACS_CC3_TP, BACS_CC4_TP, BACS_CC5_TP, BACS_CC6_TP

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The BACS Control Cabinets are also available as:

bacs - battery analysis & care system 3 generation battery ... · bacs is a holistic battery...

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