BATTERY VOLTAGE MONITORING RELAY

GENERATOR AUTO START

GENERATOR AUTO START CONTROLLER TUTORIAL

 

Battery Voltage Monitoring Relay

VOLTAGE & CURRENT RS485 TRANSMITTER
USB CONFIGURABLE UP TO 400V
 HIGH PRECISION    STATIC & RELAY OUTPUTS    RAIL MOUNT
20 ADJUSTABLE SETTINGS    RS232 MODEM 
500V ISOLATED RS485 MODBUS RTU

 

SOLAR SYSTEM BATTERY PACK MONITORING

 

The Be48 and Be148 are the ideal choices when it is about battery voltage monitoring. The Be48 features basic, user-friendly settings for private medium power systems. Be148 features MODBUS-RTU and an RS232 interface capable of driving an 4G-5G compatible MODEM. By using the RS485 based serial interface you can connect up to 128 Be148 modules in a network. Each module can be placed as far as 1000 meters away. Software for remote monitoring is provided free of charge. Both versions feature an USB type 'B' rugged connector plug. The embedded software driver is compatible with all operating systems.  Measurement precision of Be48 and Be148 can be calibrated down to 0% error via USB connections.

IDEAL FOR SOLAR PANEL SYSTEMS

EMBEDDED GENERATOR AUTO START

 

The Be48 and Be148, in addition to the SOLAR BATTERY PACK voltage monitoring, offer battery voltage monitoring of the engine battery (usually 12V or 24V). You can set up the automatic start of the generator in order to prevent low battery voltage. A set of programmable parameters allows you to set Voltage Thresholds, delay timings and time-out timing. Be48/Be148 features programmable input/output in a way that you can implement a stand-alone generator AUTO START module. By using Be148 you can remotely display voltage and current measurements. The Auto Start Generator module can be programmed to start and stop your generator based on a scheduler. You can start, for example the generator every 72 hours for 10 minutes. This is the ideal way to maintain your home generator health.  Finally, if you have an automatic generator, it is really easy to interface your Auto Start module  by using the floating contacts relay outputs of the Be48/Be148.
Automatically Recharge Battery Bank

TYPICAL WIRING DIAGRAM

The Be48 Battery Voltage Monitoring Relay is a cost-effective, flexible solution for your battery pack [1]. You can adjust all settings by using the USB connection to a computer [3]. You can supply the relay by using an DC source in between 8 up to 30 Vdc connected to terminals JA1 and JA2 [6]. In case you need to supply an auxiliary equipment equipment, the JA3 and JA4 terminals can deliver an electronically limited 300mA current[7]. The inputs JA1 and JA2 are protected from reverse polarity for unlimited time. As far as battery voltage monitoring is concerned, you can connect to terminals JF2 and JF3 a voltage in between 0VDC up to 60VDC [1]. Does not matter the polarity because the processor will automatically detect plus and minus. If your battery is over 60Vdc, we recommend that you use the terminals  JF1 and JF4[1]. Again, polarity does not matter.
WARNING
IN ORDER TO PROTECT YOUR CABLES, EQUIPMENT AND WIRINGS, WE RECOMMENND THAT YOU INSERT, ON THE BATTERY SIDE, SUITABLE FUSES TO PROTECT AGAINST SHORT CIRCUITS. MINIMUM FUSE RECOMMENDED SIZE IS 10X38MM WITH MAXIMUM CURRENT RATING OF 1A.
BE48 Voltage Monitoring Relay Typical Wiring Diagram
After a good set up[3], the Be48 is able to energize the relay output connected to the terminals JD1 and JD2 [2]according to the battery voltage and bypass delay timers. You can connect an indicator or you can drive an AUTOSTART module to control a suitable generator. The geneator [5] will recharge the battery via battery charger[5]. When battery voltage is restored, the relay [2] will instruct the AUTO START module to shut down the generator. An additional relay can be used for alarm indication about voltage or current via a precise current sensor [4] able to provide a signal 4-20mA or 0-10vdc.

 


EXANDING YOUR APPLICATIONS

By using the Be148 you can add more features to your system via the RS485 and RS232. The RS485 interface supports standard MODBUS-RTU at 9600 bit per second rate. On the same twisted pair you can connect up to 127 modules that may include other Be148 modules, computer or remote metering display devices. The distance in between modules can be as long as 1000 meters. The RS485 is totally isolated from the BE148 supply up to 500Vdc. This will avoid any error due to common voltage problems. If you need additional remote control, you may connect the F1403 industrial-grade modem. You can remotely start stop the generator, you can monitor all electrical parameters, you can get all kinds of notifications as well. You can use any AT-COMMAND compatible modem or you can purchase from us the modem F1403 (see specifications)
BE148 Voltage Monitoring Relay Typical Wiring Diagram

THE VOLTAGE COMPARATOR

 

When the battery voltage drops below the [VT-] setting, the BE48 energizes the output. You can connect terminals JD1 and JD2 to an AUTO START module input. In this way, the engine will start. Once the battery voltage will rise above the [VT+] setting, the output will de-energize. Consequently, the engine will stop. You can set timers to delay the start [T1] or to delay the stop [T2]. These timers can be adjusted from zero second up to 24 hours. By adjusting these 4 parameters ([VT-], [VT+], [T1], and [T2]) you can get a great system flexibility. A software that allows you to setup the parameters is provided free of charge. If necessary (for example the battery is not able to reach the [VT+] level) you can set up a TIME-OUT timer that shutdown the system. In this case a manual reset, by removing the DC supply, is necessary to restart the module.

BERNINI DESIGN ON-LINE PURCHASE

30-DAY MONEY BACK GUARANTEE (SALE TERMS)
SUPPORT 0039 335 70 77 148 BERNINI@BERNINI-DESIGN.COM

BE48

USB CONFIGURABLE
129.00 € FREE SHIPPING

5-YEAR WARRANTY

DUE TO SEMICONDUCTORS SHORTAGE, THE AVERAGE DELIVERY TIME IS 30 DAYS FORM ORDER

BE148

USB CONFIGURABLE
 INCLUDES RS485 & RS232 OPTIONS
149.00 € FREE SHIPPING

5-YEAR WARRANTY


F1403

INDUSTRIAL 2-3-4-5G MODEM
 INCLUDES RS232 CABLE & ANTENNA
119.00 € FREE SHIPPING

5-YEAR WARRANTY

MODEM SPECIFICATIONS

 LED INDICATORS & SETTINGS

The 4-poles DIP SWITCH [1] allows you to set up special hardware functions. Set the SW1 to its 'ON' position to enable the 4-20mA mode for the input JD6. Set SW1 to 'OFF' to enable the 0-10V mode. Calibration of'the full scale measurement is done by using the configuration software.The SW2-3-4-5 are uncommitted; reserved for custom made versions. The LED '2' repeats the status of the output relay connected to terminals JD1-JD2.This relay is normally used to instruct a generator to charge the batteries. The yellow LED indicator '2' turns on when the relay turns on. This relay energizes when the battery voltage drops below the low voltage battery setting. The bypass delay timings and miscellaneous settings are adjusted via USB.The yellow LED '3' turns on when a bypass delay timer is counting.The yellow LED '4' turns on when the battery voltage is over the relay disconnect set point. The LED'4'starts blinking when the battery voltage is lower that the set point. The [5] green LED indicator turns on when the internal CPU (or microcontroller if you will) runs. It might blink when data communication is established on a USB, RS485 or RS232 port. The red '6' LED indicator turns on in case of failure or alarm. In this case the BE48 energizes the output relay connected to the terminals JD3 and JD4. When you connect the suppy terminals JA1 and JA2 all LED indicators turns on for 3 seconds (automatic LED test).
Battery Voltage Relay LED Indicators

BE48 BE148 MECHANICAL DATA

 

The Be48 Battery Monitoring Relay is intended for DIN rail mount inside a control panel. We recommend that you choose the vertical position. The Be48 works in a wide operating temperature range of about -25 up to 70 degrees Celsius. Total weight is about 240 gr. The power supply onnector features removable 5mm pitch, female plug. Battery voltage measurement is connected to a removable 7.5mm pitch female plug  A cable, 1m long, with USB-A and USB-B is included in the box. A 6 poles female plug, pitch 3,81, is used for the INPUT/OUTPUT connections.

ELECTRICAL SPECIFICATIONS

POWER SUPPLY: 08VDC up to 30VDC
POWER SUPPLY CURRENT (STAND-BY): 30mA
MAX POWER SUPPLY CURRENT (RELAY ON): 70mA
POWER SUPPLY CURRENT OUTPUT: 300mA MAX.
OUTPUT RELAY RATING: 30V 1A
NPN STATIC OUTPUT: 300mA 30Vdc
RS 485 ISOLATION VOLTAGE: 500Vdc
RS232-USB MODEM PORT: NON-ISOLATED
BATTERY MONITORING RANGE JF1-4: 60-400Vdc/1M OHM
BATTERY MONITORING RANGE JF2-3: 0-60Vdc/200K OHM
INPUT VOLTAGE POLARITY: AUTOMATICALLY DETECTED
VDC/ADC MEASUREMENT RESOLUTION: 10 BIT
VDC/ADC MEASUREMENT PRECISION: +/- 1%
USER CALIBRATION RANGE: +/- 2%
COMMON MODE VOLTAGE TO JA2: +/- 250Vdc
CURRENT MEASUREMENT RANGE: 5Adc/50Adc/500Adc
MISCELLANEOUS SPECIFICATIONS

RS 485 CONFIGURATION: MODBUS RTU HALF DUPLEX
RS485 DATA RATE: 19200 (0-248 NODES)
USB CONNECTION: TYPE 'B' V2.0
OPERATING TEMPERATURE RANGE: -10 UP TO +50 CELSIUS
RELATIVE HUMIDITY: 95% at 40°C, NON-CONDENSING
STORAGE TEMPERATURE RANGE: -40 UP TO +85 CELSIUS

 

SETTING UP THE VOLTAGE MONITORING RELAY

 

We provide a free of charge software that allows you to set up the module. Make sure that the SUPPLY MINUS of the Be48 is at the same potential of your computer. In other words, the best safety condition is obtained when the DC supply is connected to the battery minus of the power generator (battery minus must be grounded). Before running the software you are required to connect your  computer to the Be48 MODULE (via USB cable) and turn on the DC supply (12Vdc-30Vdc). The USB cable features a USB-A plug for your computer and a USB-B mini for the BE48 module.  You can set Voltage thresholds and various timings. When the precision is mandatory, you can calibrate down to zero the measurement error. This will compensate ground loop errors, noise and miscellaneous error sources. The software provides accurate reading of the power supply as well.  Normally, the power supply voltage is connected to the battery of the power generator. Battery System is usually a backup battery pack of a solar system for example. This could be in the range 0 up to 400V isolated or non-isolated to ground. You can connect the computer at anytime without affecting the system only if the MINUS VDC supply terminal is grounded.  When you set up the system you can test the output by using the ON-SCREEN test button.
USB CONNECTION

 

After wiring the Be48 MODULE, you are required to connect the USB cable to your computer. Run the BE48 DC VOLTAGE MONITORING software. The computer will automatically search for the serial connection port. A green message 'CONNECTED' will indicate the communication between BE48 and your computer. The software provides measurements of the power supply voltage and battery system voltage.
VOLTAGE MONITORING RELAY OVERVIEW
BASIC SETTINGS

 

The basic available commands are SAVE (to store a parameter), DEFAULT (to use factory settings) and RELAOD (it cancels a modification and restore the previous setting). If you modify a parameter, a yellow backgroud will warn you. Once stored in the memory the yellow background wll disappear. Low Voltage Start is the voltage level of the battery that triggers the timer T1 (once T1 expires, the engine starts). High Voltage Stop is the voltage level of the battery that triggers the timer T2 (Once T2 expires, the engine will stop).
VOLTAGE MONITORING RELAY VDC SETTINGS
TIMIMG SETTINGS

 

START & STOP delay timers are used to provide flexibility to your application. You can use these two timer to avoid false start and stop commands. As a matter of fact the voltage comparator itself has no response delay. It works immediately. This may cause a system instability. You can put, if you wish, the timers to zero at anytime. This can be usefull in particualr applications in which you need a fast respomse of the voltage comapator or you need to carry out tests of the system without waiting for delays.
VOLTAGE MONITORING RELAY TIMING SETTINGS
SHUTDOWN SETTING

 

This additional timer is extremely important when you want to add security to your system. If there is a failure on the charger, you will never be able to charge the battery. The generator will run for hours and hours without benefit in return. This timers limits the run time of the engine. One the BE48 triggers the alarm, you are required to remove the power supply for a few seconds to restart the module.
VOLTAGE MONITORING RELAY SHUTDOWN SETTING
VOLTAGE CALIBRATION

 

Factory precision of the measurements is about 2%. If this error is not accettable, we recommend that you carry out the calibration. This is really simple. You will put a precise measurement instrument on the battery and yu will take note of the measurement. Then, you will type on the screen the value. After pushing the button 'SAVE', the Be48 will calculate the correction factor. You will get in a few seconds the reading with approximately 'NO ERROR'. A good calibration will allow you a 0,1% accuracy. The calibration is stored in a NON VOLATILE memory.
CALIBRATING THE MONITORING VOLTAGE RELAY
LOG HISTORY

 

If you want to carry out really accurate testing of the system, the BE48 provides real time data logger. By analyzing the TIME STAMP you can find out if the sysem works as you expect.
VOLTAGE MONITORING LOG HISTORY
 Bernini  Design Srl

Zona Industriale, 46035 Ostiglia Italy

email bernini@bernini-design.com
Tel 0039 335 7077148   24/7/365 support 0040 721 241 361