EMSYS Wireless Monitoring System

Case Study
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Telecom
Case Study
EMSYS Wireless Monitoring System
Case Study
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1 PREFACE .......................................................................................... 4
COPYRIGHT NOTICE 4
OBJECTIVES 4
2 OVERVIEW ........................................................................................ 5
INTRODUCTION 5
EMSYS SENSORS 6
WIRELESS BATTERY MONITOR CELLSPY 6
WIRELESS CURRENT TRANSDUCER 7
WIRELESS AMBIENT MONITOR 7
WIRELESS DC BUS MONITOR 7
LOCAL AND CENTRAL GATEWAY 8
MINI GATEWAY 9
WIRELESS REPEATER 9
3 TELECOM REMOTE LOCATION MONITORING REASONING ...... 10
EMSYS SYSTEM PREVENTS UNPLANNED DOWNTIME 10
EMSYS SYSTEM PREVENTS MAJOR FAILURES 10
EMSYS SYSTEM EXTENDS BANK LIFETIME 11
EMSYS SYSTEM ELIMINATES NEED FOR MANUALLY PERFORMED PERIODIC
MAINTENANCES 11
4 SYSTEM DIAGRAM EXAMPLE ...................................................... 12
EXAMPLE SYSTEM 12
5 EXTERNAL SYSTEMS INTEGRATION ........................................... 13
OVERVIEW 13
ACCESSING EMSYS GATEWAY THROUGH MODBUS PROTOCOL 13
ACCESSING EMSYS GATEWAY THROUGH SNMP 13
6 EMSYS BMS SOFTWARE .............................................................. 15
INTRODUCTION 15
BMS APPLICATION 16
LATEST READINGS VIEW 17
HISTORY READINGS VIEW 17
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HISTORY LINE GRAPH 18
CONFIGURATION VIEW 19
WEBCONFIG APPLICATION 19
BATTERY BANK TESTING 19
BANK CAPACITY TEST 19
PERIODICAL BANK MAINTENANCE TEST 21
7 EMSYS BMS PROJECT SIZING ..................................................... 23
SIZING OVERVIEW 23
SIZING SUMMARY 23
8 SUPPORT AND TROUBLESHOOTING .......................................... 24




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1 Preface

In This Chapter

COPYRIGHT NOTICE 4
OBJECTIVES 4


Copyright Notice

The material in this document is the intellectual property of EMSYS Design Inc. We
take every care in the preparation of this document, but no guarantee is given as to
the correctness of its contents. Our products are under continual improvement and we
reserve the right to make changes without notice

Objectives

The aim of this document is to briefly describe the EMSYS Battery Monitoring System
for Telecom repeater stations (remote locations). All main features and functionalities
will be covered by this document.




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2 Overview

In This Chapter

INTRODUCTION 5
EMSYS SENSORS 6
WIRELESS BATTERY MONITOR - CELLSPY 6
WIRELESS CURRENT TRANSDUCER 7
WIRELESS AMBIENT MONITOR 7
WIRELESS DC BUS MONITOR 7
LOCAL AND CENTRAL GATEWAY 8
MINI GATEWAY 9
WIRELESS REPEATER 9


Introduction

Businesses that demand uninterruptible power rely on EMSYSs Battery Monitoring
System for monitoring and testing to ensure the integrity of their Battery backup
system. The Main purpose of the EMSYS Wireless Monitoring Solution for Telecom
repeater sites is to monitor all important sites backup power parameters, including
Batteries, DC Bus, Charger, DC Current (Charge & Discharge), Ambient
parameters (temperature, humidity, etc.). Additionally, the EMSYS Monitoring System
provides you a quick and easy solution for performing Bank Capacity Tests,
Periodical Maintenance tests and generating appropriate reports.

It consists of the following elements:

Sensors (various types)
Repeaters
Mini Gateway
Local and Central Gateway
Cloud Virtual Server (optional)

This chapter will describe all the devices and infrastructure requirements for
communication between.

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EMSYS Sensors

EMSYS Design offers multiple
sensors that measure different
physical values for complete
site backup power monitoring.
All sensors communicate with
the EMSYS Gateway via
industry standard radio protocol
IEEE 802.15.4 on ISM radio
band.
To receive readings, EMSYS
Sensor is ideally not more than
100m away from the gateway,
with maximum one non-
concrete wall between the
Gateway and the sensors. In cases where the distance is more than this, EMSYS
Repeaters are used to boost the signal.

EMSYS Design currently offers the following sensors:

Wireless Battery Monitor - CellSPY

Wireless Battery Monitors (CellSPY) is
measuring the resistance of both metallic
and chemical paths. Unlike other monitors
on the market which are consuming 10s and
100s of Amps to determine internal battery
resistance, CellSPY gets the job done
using 1Amp of load current during a 400ms
period.

The CellSPY is invisible to your batteries
by consuming less than 20mA during normal
operations. The operator will not have to be
anywhere near the batteries to do the
readings. The Gateway gathers the
information, eliminating expensive reading
by technicians.
CellSPY is designed to operate in just about
any environment.
Parameters measured by CellSPY:
DC voltage - indicates state of charge. Undercharged or overcharged
batteries will be detected and appropriate alarms will be raised. This
parameter can point to bad battery cells.
Terminal temperature - used to generate alarms when there is potential for
battery to go into thermal run-away, preventing hazards within battery rooms.
Resistance - High ohmic values indicate faulty battery or inappropriate
connections on battery terminals.
AC Ripple voltage - indicates charger behavior. High AC Ripple
measurement indicates potential charger related problems.


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Wireless Current Transducer

EMSYSs Wireless TrueRMS and Non-Invasive Current Sensor provides an accurate
load/charge level monitoring of DC current loads. It uses unique Dual Core
Technology with field proven circuitry to
provide a superior solution to DC applications
with minimal risk of permanent magnetization,
thereby ensuring longer life and better
accuracy. Unlike other current transducers on
the market, EMSYS WCT-200 offers the
same unmatched, accuracy for both low
(trickle charge) and high (load) DC currents
thanks to its Dual Core Technology. Along
with this unique feature, our WCT-200 can be
powered directly from DC Bus, which makes
its installation a breeze.

Wireless Ambient Monitor

EMSYSs Ambient Monitor WAM-200 measures temperature and humidity inside the
battery backup room. Our, web based, application will compare ambient monitor
readings with the battery temperatures collected by CellSPY monitors. If thermal
runaway is detected it will
immediately alert users by
sending emails or SMS.
WAM-200 can be powered from
any USB host device or from an
included wall powered adapter.
By measuring room temperature
and comparing it to battery
terminal temperatures, its easy
to efficiently detect Battery
candidates for thermal run-
away.

Wireless DC Bus Monitor

The DC Bus monitor measures both, DC and AC ripple
voltage across the whole battery bank. The ground fault
detection feature continuously measures the voltages
between the DC Bus and the ground.

The DC and the AC ripple voltage measurements will give
us an early warning if the battery charger starts to operate
out of spec. Overcharged or undercharged battery banks
can reduce the overall battery life and put the battery
backup system in danger. Excessive AC ripple voltage will
reduce the battery life and inject unwanted noise into the
system. In many cases this causes supplied equipment
failure.






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Local and Central Gateway

EMSYS Local/Central Gateway, a standalone, ruggedized application Gateway is
Linux based server and receives measurements from EMSYS Sensors via IEEE
802.15.4.

This Gateway provides web
interface to access the BMS
application where the station
battery backup (sub)system can
be monitored.

In a highly distributed system with
a lot of geographically distributed
locations, EMSYS is also offering
a Central Gateway, which has the
role of data concentrator. It
collects all measurements from
the station, providing the comfort of having all data displayed at one location. Also,
companies often have separated network zones for internal server communications
and employer access. In that case, its easier to maintain the bridge between these
two zones for one (Central) Gateway, than to all local Gateways. The communication
between Local and Central Gateway is bidirectional, through UDP protocol (arbitrary
ports).
The Central Gateway must be able to access all local Gateways through an Ethernet
network, and it needs to be opened at SSH port (23) and one UDP port (by default
22354, but arbitrary). Also, to be able to access the BMS application, standard HTTP
port (80) must be opened (port number is also arbitrary). To access the WebConfig
configuration application, port 8080 must be opened for inbound TCP access (HTTP
communication).
Both, local and central Gateways, can serve measurement data to a SCADA system
using industry standard ModbusTCP and/or SNMP protocols.

Network parameters of both, local and central EMSYS Gateways (IP address, subnet
mask and gateway IP address), are configurable through the WebConfig application.





















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For central Gateway deployment, there are various options offered by EMSYS Design:
A Gateway machine can be provided by EMSYS Design as a physical server
in a ruggedized enclosure.
A Gateway machine can be deployed on the clients cloud infrastructure. In
this case EMSYS Design will provide VM image, so the client is in charge of
deploying the machine into the cloud infrastructure.
A Gateway machine can be deployed on cloud infrastructure on Amazon
Cloud Service. In this case EMSYS Design will maintain the cloud machine.



Mini Gateway

EMSYS Mini Gateway is
primarily designed to serve
small and remote sites as a
Wireless to IP and IP to
Wireless Bridge. Its compact
size, variety of power sources,
and effortless installation
makes it a perfect solution for
many types of installations.

With its built in high power
transceiver, it receives the
sensor readings via IEEE 802.15.4 and forwards them to central EMSYS Gateway
through Ethernet network. Using Mini Gateways, customer can cover multiple remote
sites with only single central Gateway.

Mini Gateway is fully compatible with POE - IEEE Alternative B. If POE is not
available, Mini Gateway is shipped with POE injector which can be connected to any
DC power source from 12 to 60 VDC.



Wireless Repeater

Repeater is used in environments where
room structure and wall configuration
make it hard for Gateway and sensors to
communicate. EMSYS Repeater acts as
an intelligent signal repeater, preventing
package loops and filtering packages
while repeating only what is needed.
Repeater also significantly boosts signal
strength.



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3 Telecom remote
location monitoring
reasoning

In This Chapter

EMSYS SYSTEM PREVENTS UNPLANNED DOWNTIME 10
EMSYS SYSTEM PREVENTS MAJOR FAILURES 10
EMSYS SYSTEM EXTENDS BANK LIFETIME 11
EMSYS SYSTEM ELIMINATES NEED FOR MANUALLY PERFORMED PERIODIC
MAINTENANCES 11


EMSYS System prevents unplanned downtime

Since batteries can fail in a few days, CellSPY is designed to monitor your battery
backup system every hour, not just when the periodic/quarterly maintenance occurs.
In case of any failure indication, the Gateway alarm is generated and presented to
operators on the BMS application - as an email or SMS message, or through Modbus
and/or SNMP protocols for external SCADA systems.
This way CellSPY detects possible failures before a single battery cell is able to
become an operational risk, but also months before a technician would discover it
during a regular quarterly maintenance.


EMSYS System prevents major failures

EMSYS does not monitor only batteries - it monitors the whole site Battery Backup
system, indicating problems with the charger, the single battery jar, the air conditioner
or the ventilation.
By automating battery monitoring youre preventing a lot of potential failure situations.
By monitoring battery terminal temperatures, and the ambient temperature, the
EMSYS BMS is preventing thermal runaway which can potentially destroy the whole
Battery Backup room. The measured temperature can also indicate problems with air
conditioning or Battery Backup room ventilation.
By monitoring the battery internal resistance, the EMSYS BMS is maximizing the
Battery Backup uptime by indicating Cells for replacement before failure.
By monitoring the DC Bank Voltage and AC Ripple Voltage on Bank Bus, the EMSYS
BMS can monitor Charger status.

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Potential problems are reported to the operator by multiple alarms:
If the charger breaks down, the Current Sensor will report zero current for a
long period of time. The DC Bus monitor and CellSPY Battery Monitor will
report zero AC Ripple Voltage.
If the air conditioner fails, the Ambient monitor will set off the Ambient
temperature alarm and the CellSPY Battery Monitor will report a High
Temperature alarm on Battery Terminals.


EMSYS System extends bank lifetime

By industry standards, to ensure uptime, batteries are routinely replaced at a 5-year
(10-year for some battery types) interval. With automated battery monitoring,
operators are aware of each battery cells health daily, providing information about
weak cells, replacing individual cells showing signs of weakness, eliminating the need
for total battery bank replacement, avoiding major expenses.


EMSYS System eliminates need for manually
performed periodic maintenances

By having an automated system for monitoring and testing, there is no need for
periodic sending of technicians for maintenance. This fact alone contributes to quick
ROI.






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4 System Diagram
Example

In This Chapter

EXAMPLE SYSTEM 12


Example system

The diagram represents one project with four remote locations (repeater sites), each
having its own collection of sensors (of various types). Mini Gateways collect
measurements from a sites sensors and all four Mini Gateways forward the
measurements to the regional EMSYS Gateways/Servers, which processes and
stores them. As an option, regional Gateways can be configured to forward the data to
EMSYS Cloud Virtual Machine with BMS software installed. VM can be hosted on
Amazon Cloud Service and managed by EMSYS, or it can be deployed on customers
host server. Processing power and storage of VM can be increased in matter of
minutes, which makes scaling of entire BMS system easier, cheaper and more
productive.

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5 External systems
integration
In This Chapter

OVERVIEW 13
ACCESSING EMSYS GATEWAY THROUGH MODBUS PROTOCOL 13
ACCESSING EMSYS GATEWAY THROUGH SNMP 13


Overview

To be able to integrate currently installed systems with the EMSYS Battery Monitoring
System, local and central Gateways provide all measured data through industry
standard protocols like Modbus and SNMP.


Accessing EMSYS Gateway through ModBus
protocol

Modbus is an industry standard protocol in RTU and SCADA systems. Local and
central Gateways behave as Modbus slaves, and they are accessible by Modbus
master applications. They are providing Modbus via TCP and Serial (RS232 and
RS485) port.

Values served by Gateway are:
All measurements from sensors (as input registers)
Low and high limits for all sensors (as input registers)
Measurement timestamps (as input registers)
Alarm states for low-low, low, high, high-high alarms for each measurement
(as discrete inputs)


Accessing EMSYS Gateway through SNMP

Often companies have developed internal SNMP infrastructure, so EMSYS Gateway
exposes all valuable information through SNMP protocol. Alarms generated on
Gateways can be sent to SNMP Manager asynchronously as SNMP traps. Multiple
trap destinations are supported. Also, its configurable which alarms will be sent as
traps.

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Values served through SNMP protocol are:
All measured data
All high and low alarm limits
Timestamps for each sensor indicating time of last measurement

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6 EMSYS BMS Software

In This Chapter

INTRODUCTION 15
BMS APPLICATION 16
LATEST READINGS VIEW 17
HISTORY READINGS VIEW 17
HISTORY LINE GRAPH 18
CONFIGURATION VIEW 19
WEBCONFIG APPLICATION 19
BATTERY BANK TESTING 19
BANK CAPACITY TEST 19
PERIODICAL BANK MAINTENANCE TEST 21


Introduction

Beside sensors, state of the art software that is running on Central and Local
Gateways represents the heart of the Battery Monitoring System, as it processes all
data received from the sensors and provides applications with visual monitoring of
Battery Backup system and system configuration.
The main applications used by system operators and administrators are BMS and
WebConfig applications.

Main features of BMS Software are:

Processing measurement data received from the sensors
Alarms: alarm and event engine processes measurement data and generates
alarms when a certain alarm condition is met. There are value based alarms
(LowLow, Low, High and HighHigh) as well as time based alarms which are
generated when a sensor does not send any reading within a configured
amount of time. The alarm acknowledgement mechanism is present and it
requires the operator to give attention to each alarm, by acknowledging it.
Events: All important events are stored within the Gateway. Stored events
provide the operator a way to recreate a series of sequences that happened
during a period of time.
Bank Capacity Test: BMS application provides a Bank Capacity Test feature.
With artificial load (optionally provided by EMSYS Design Inc.) the test can be
performed by the EMSYS System. The output of the Bank Capacity test is
automatically generated into report files in both, PDF format (with graphically
presented data) and CSV format (with raw data).
Periodic Maintenance Test: Batteries are typically tested quarterly, on basic
parameters (voltage, internal resistance). The EMSYS System can perform
bank maintenance tests on demand and automatically generate PDF reports
in a matter of minutes.
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Easy sensor configuration & reconfiguration: Sensor configuration is done
easily, and once the client needs to add new sensors to the system or to
replace the existing ones, its a task that can be done in a few minutes.
Easy system administration: All system parameters are easily configurable
through the WebConfig application. Configurable parameters include: network
interface configuration, SNMP and Modbus configuration, scheduling data
backup, data download, system software automatic updates, user
management, etc.
Multiple user privileges: There are three predefined user groups with
different privileges: operators, configurators and system administrators.
Data backup: Data backups can be scheduled periodically and also can be
done on request. All backups are stored locally on a Gateway but can also be
configured to be uploaded to the FTP server
Periodic reporting: Measurement reports contain all readings, like regular
reports, but also measurements that meet alarm conditions in case of an
alarm report. Reports can be sent to a preconfigured email address.
Email/SMS alarming: When an alarm is created the operator can be alerted
by an email that contains information about the alarmed measurement. In US
all mobile operators have their own Email2SMS gateway. Emails can be sent
to these gateways so the user can receive a SMS message when the alarms
are created. SMTP parameters are fully configured and usually a customers
internal email infrastructure (SMTP server) is used for emailing purposes.
Accessibility from external systems: All measurements on the Gateway are
accessible, by using industry standard protocols such as Modbus (TCP or
Serial) or SNMP.


BMS Application

EMSYS BMS Application is a web-based Gateway application that provides HMI
functionality to EMSYS System operators, configurators and administrators.

BMS Application is used to perform a set of defined tasks.

As a Operator, you can use the BMS application to:
View geographical positions of installed remote sites
View the latest measurements received from installed sensors (CellSPY
sensors, Current Sensors, etc.)
Monitor and acknowledge alarms generated on the Gateway
Monitor events generated on the Gateway
View historical data for each group, from each remote site for different
historical time periods, separately.
View all measurements for each sensor and for different historical time
periods, both separately.

Additionally, as a Configurator or Administrator, you can use the BMS application to:
View and modify Gateway configuration of sites and groups (Sensor arrays)
within the same Site.
View and modify Gateway reporting configuration
View and modify Email Alarming configuration
Run battery load/recover tests

BMS Application is a flash application that requires a browser (IE, Chrome, Firefox or
Safari) with a Flash Plugin 10.0, or a newer version. No installation process is required
on the client machine.

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All measurements are presented in two ways, tabular and graphical.
Briefly described below are the most important views of the BMS application.
Latest readings view

It contains the latest measured values from each sensor separately.
This view also shows alarm regions and indicates if any of measurements are in an
alarm condition.




















History readings view

One of the main features of the BMS Application is its ability to view and analyze the
history of battery measured data. That way some atypical battery behavior can be
detected and batteries can be replaced on time to prevent Bank failure.






















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Similar to the latest readings view, data is presented in both ways, tabular and
graphical. Graphically, data on history view is presented as a CandleStick Chart
Graph.

CandleStick charts are typically used in stock trading related graphs. It is a type of bar
graphs where each bar represents the range of a measured value movement over a
given time interval.
As it is shown on the image above, each bar shows the maximum and the minimum
(in form of bar) of the battery, as well as the maximum and the minimum (in form on
black line below bar) of the bar.
Left clicking on any of the bars will open the history of the line Graph view for the
selected battery.

It is also possible to download all history data in the form of a csv file for further
analysis and/or archiving purposes.

History line graph

A history line graph provides a way for operators to monitor the state of health of a
single battery, through a selected period of time in the form of a Line graph.
This dialog is depicted in the picture below:
























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Configuration View

This is the part of BMS application where the main configuration is monitored and
updated. It provides a way to update your configuration on the Gateway, easily and
quickly. This is necessary if you want to add more sensors to the system or to replace
existing ones.


WebConfig Application

EMSYS WebConfig is a web-based application that provides functionalities for
administrating EMSYS Gateways.

Administrator can use WebConfig application to:
Set common operating system parameters (time related parameters,
networking, etc.)
Configure CommServer parameters including Modbus and SNMP parameters
Configure WebService parameters
Configure BMS Application parameters
Configure Database backup process
Monitor Gateway functionality by examining log files (by watching live log tail
on the WebConfig page or downloading log files to the local computer for
viewing)
Perform System Monitor reconfiguration (sensor replacement, adjusting alarm
limits, etc.)


Battery Bank Testing

EMSYS Battery Monitoring System provides you two types of battery tests, as
described in following chapters.
Bank capacity test

Upon Battery Backup installation, initial battery commissioning is necessary. Also, a
battery capacity check is usually performed on a defined time interval. The EMSYS
BMS is capable of performing these tests without any additional mechanical
installations on batteries just by using the Gateways software, eliminating risk factors
introduced by human cell handling.
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This also significantly reduces costs, as there is no need to hire an external company
for bank capacity tests.
During a bank capacity test the following parameters are measured on a 10 second
interval:
Discharge current
Battery DC voltage
Battery AC Ripple voltage
Battery terminal temperature
DC Bus voltage
Bus AC Ripple voltage

After the test is finished, report files are created automatically in both PDF (for
graphical and tabular data visualization) and CSV (containing raw data) formats.
Below is a graphic sample of a Bank Capacity Test report:


Also, on the same page with graphics, tabular data containing all measured values is
displayed for easier analysis. Sample measurement table is shown below:
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Periodical bank maintenance test

Another advantage to using the automated monitoring system is a reduced cost
needed for quarterly maintenance.
The EMSYS BMS is capable of performing battery tests easy on clients computer
using BMS software, without any additional mechanical installation on batteries. Once
again, risk factors introduced by human cell handling are eliminated.
In a matter of minutes after the test is started, report files in PDF and CSV formats are
generated with the following measured values:

Battery DC voltage
Battery AC Ripple voltage
Battery terminal temperature
Battery ohmic value

Measurements in report are shown in both tabular and graphical presentations.
Tabular presentation is shown below:



A
l









Also, every measured data is displayed in report in form of bar charts, as is shown on
images below:






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Voltage graph









Resistance graph


.





Temperature graph

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7 EMSYS BMS Project
sizing

In This Chapter

SIZING OVERVIEW 23
SIZING SUMMARY 23


Sizing overview

This chapter will provide the sizing guidelines in the form of bullets for all devices
included in typical project installation, based on examples:

The whole project is centered on Central Gateway or users SCADA system.
The project is divided into remote sites/locations.
Each site has its own collection of sensors, repeaters and one Mini Gateway
One site can contain multiple Battery Backup systems with Battery
strings/banks.
Each Battery bank should contain a current sensor. Thanks to EMSYSs Dual
Core Wireless Current Transducers only one current sensor is needed. It will
provide the same high accuracy for both charge and discharge currents.
Each Battery bank should contain one DC Bus Monitor.
Each cell within the battery bank should have one Wireless Battery Monitor
connected for cell measurements.
Each room within the site should have one Ambient Monitor.
One or more Wireless Repeaters may be installed if required.


Sizing summary

One Central Gateway in project.
One Mini Gateway per site/repeater station.
One Current Sensor per Battery Bank.
One DC Bus Monitor per Battery Bank.
One CellSPY per Battery (Cell).
One Ambient Monitor per room (where needed).
May possibly need one Repeater per site, depending on building/room
configuration.


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8 Support and
troubleshooting

If you encounter any problem, or have CellSPY System related questions please feel
free to contact EMSYS Design Inc. any time:

by email: [email protected]
by phone: (+1) 858-4927240 ext. 3