Webasto BMID III-B Battery Management Tool Instruction Manual

Webasto BMID III-B Battery Management Tool

Product Information

Specifications

• Product Name: BMID III-B (BatteryRxTM) Battery Management Tool
• Manufacturer: Webasto Charging Systems, Inc.
• Interfaces : Voltage sensor, Current sensor, Temperature sensor
• Compliance : FCC Part 15

Product Usage Instructions

Installation

1. Read and understand the installation manual thoroughly before proceeding.
2. Ensure the battery is disconnected from the power source before installation.
3. Mount the BatteryRx on top of the battery using the provided hardware.
4. Connect the voltage sensor, current sensor, and temperature sensor to their respective terminals.
5. Follow the wiring diagram provided in the manual for proper connections.

Operation

1. Once installed, the BatteryRx will record performance data and monitor battery health continuously.
2. During charging, the BatteryRx will transmit charging requirements to the battery charger.
3. Refer to Webasto battery charger manuals for more information on BMID function.

Scope

This manual describes the installation procedures for the BatteryRx.

Overview

WARNING

Read and follow the instructions and warnings in this Manual before attempting to install or service this product. Failure to do so can result in serious injury or death. Keep this Manual for future reference.The BatteryRx Battery Charging Monitoring System, referred to in this manual as BatteryRx, performs several functions. The Battery Rx:

• Records performance data for the life of the battery
• Monitors battery health continuously

During a charge cycle, the BatteryRx transmits charging requirements to the battery charger. Webasto battery charger manuals refer to this function as a BMID.

The BatteryRx is installed on the top of the battery and includes all hardware required to perform the installation. The BatteryRx has three interfaces:

1. Voltage sensor
2. Current sensor
3. Temperature sensor

Symbol Usage

Take special note of the information marked with the following symbols throughout this manual:

• DANGER
• Contains information about safety practices necessary to prevent personal injury or death.
• WARNING
• Contains information about safety practices necessary to prevent fire or equipment overheating.
• NOTE
• Offers helpful information for installation or usage, but does not contain personnel or equipment safety-related information.

Installing the BatteryRx

• WARNING An improperly installed Battery Rx may cause the charger to charge incorrectly, and may void your battery warranty.
• DANGER Electric shock hazard. Only trained personnel should install or maintain this equipment.
• DANGER Hydrogen gas may be present in battery compartments. Be sure to work on equipment only in a well-ventilated environment.
• DANGER Battery Rx modules are installed on electrically live battery packs. Use insulated tools during the installation

The Battery Rx should be located near the centre of the battery pack.

IMPORTANT:
All of the sensor wires must be installed correctly in order for the BMID III-B to connect to the charger. If any of the sensor wires (including the current sensor wires) are not installed correctly, the BMID III-B WILL NOT CONNECT to the charger.

Wiring for Voltage, Current, Battery Temperature and Shunt Temperature Sensor

1. Battery Negative – attach to the negative battery terminal.
2. Battery Positive – attach to the positive battery terminal.
3. Battery Temperature Sensor – attach to a cell interconnect near the center of the battery.
4. Current Sensor Shunt (Brown) – attach to the negative (-) end of the cell interconnect, which is the side farthest from the negative terminal.
5. Current Sensor Shunt Temp (Black) – attach to the centre of the interconnect.
6. Current Sensor Shunt (Blue) – attach to the positive (+) end of the cell interconnect, which is the side nearest the negative terminal.

BatteryRx – BMID III-B Installation

IMPORTANT NOTE:
The brown and blue current sensors MUST be connected with the polarity shown in the illustration above. Unless these wires are correctly connected, the BMID III-B WILL NOT CONNECT TO THE CHARGER.

1. Remove the plastic cover from the appropriate terminal or interconnect bar.
2. Drill a 0.188-inch diameter hole between 0.290 to 0.350 inches deep (a drill bit is supplied in the hardware kit). Using a drill stop is recommended.
3. Gently tap the knurled brass insert into the hole flush with the terminal/interconnect bar surface. Refer to the images below.
4. Use the #6 screw, flat washer and lock washer to attach the sensor wire to the insert. Torque the screw to 9.60 in-lb (1.085 Nm).
5. Apply a small amount of terminal protective grease to completely coat the screw and ring terminal.
6. Replace the plastic cover.
7. Repeat the procedure for each sensor wire.

Final Assembly

1. Secure the BatteryRx to a convenient interconnect bar with the supplied polypropylene tie-wrap.
2. Notify Customer Support when the installation is complete.

LED Status Indicators

BMID III-B status indicators visible from the top of BMID III-B:

1. Green LED – ON when power is supplied to the BMID III.
2. Orange LED – blinks during wireless communication with the charger.
3. Red LED – blinks if software error.

Pressure Wash Limitation

BMID III-B has been designed to withstand high-pressure washing up to 120PSI.

WARNING

Exposure to Pressure Washing above 120PSI voids the warranty.

Available Webasto Accessories:

Battery Rx Installation/Validation Data Sheet See next page.

Battery Rx Installation

/Validation Data Sheet See next page.

1. Thermistor/Temp Sensor installed on the centre-most inter-cell connector?
2. Are current Sense Shunt blue and brown leads installed correctly? (Blue lead nearest to negative battery post)
3. Are all wires bundled and routed neatly?
4. Date and Time set correctly?

NOTES: (Report unit failures, changes to default parameters, etc.)

• BatteryRx S/N or Battery ID:
• BatteryRx S/N or Battery ID:
• BatteryRx S/N or Battery ID:

1. Place S/N sticker here (1)
2. Place S/N sticker here (1)
3. Place S/N sticker here (3)
4. Place S/N sticker here (4)
5. Place S/N sticker here (5)
6. Place S/N sticker here (6)
7. Place S/N sticker here (7)
8. Place S/N sticker here (8)
9. Place S/N sticker here (9)
10. Place S/N sticker here (10)
11. Place S/N sticker here (11)
12. Place S/N sticker here (12)

Emai l the form to IPCServices@Webasto.com

IMPORTANT INFORMATION – SAVE THESE INSTRUCTIONS
PL EASE NOTE
Webasto Charging Systems, the Webasto logo, PosiCharge™, and the PosiCharge logo are trademarks of Webasto Charging Systems, Inc.
WEBASTO PROPRIETARY INFORMATION: This manual contains information that is confidential and proprietary to Webasto Charging Systems, Inc. (“Webasto”), constitutes “Confidential Information,” and is subject to Non-Disclosure Agreements. The intended users of this manual are service technicians certified by Webasto’s installation network. This manual shall not be disclosed in whole or in part to any other party without Webasto’s prior written permission. Each recipient’s acceptance of this manual and use of the information contained herein shall be deemed to be an acceptance of this non- disclosure obligation. This BMID Installation Manual includes the latest information available at the time of printing. Webasto Charging Systems, Inc., reserves the right to make changes to this product without further notice. Changes or modifications to this product by other than an authorized service provider could void the product warranty.

© 2022 Webasto Charging Systems, Inc. All rights reserved. No portion of these materials may be duplicated, used or disclosed without prior written permission from Webasto Charging Systems, Inc.

FCC Information

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions:

1. This device may not cause harmful interference.
2. This device must accept any interference received, including interference that may cause undesired operation.

WARNING

Changes or modifications to this product by other than an authorized service provider could void FCC compliance.

Save These Instructions
This document is your guide to the installation and use of the PosiCharge BMID products. The installation examples shown are for batteries in material- handling vehicles.

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