3. How to Set-up and Connect the ZBM
Before using and operating a ZBM, it must be set-up by a qualified electrician and connected in the following
way. See the ZBM Installation and Operating Manual for more detailed information.
Step 1
Ensure the ZBM may be properly operated by checking for things such as loose fittings,
damaged tubes around the system and leaks that may have occurred during transport.
Ensure that the masking tape has been removed from the Catch Can.
Step 2
Using a multi-meter, check that the ZBM is fully discharged by ensuring the voltage across the
terminals is 0V when disconnected from any bus.
Step 3
Using a forklift, crane or lifting device with the lifting straps provided, place the ZBM into the
prepared location. It is recommended that Steps 1-2 be repeated once the ZBM is in its
required location.
Step 4
Ensure all sensors of the Analog Loom are in their correct positions. Connect the Analog
Loom to the MMS via the 12-pin UT connector if not already connected.
Step 5
If not already connected, connect the pumps and fan Power Cables of the ZBM to the MMS.
See specified labelling on the ZBM for the pumps and fan power cable connection points.
Step 6
Connect any external systems or controllers to the COM ports on the MMS (if necessary).
Either or both COM ports may be used. The ZBM uses the MODBUS RTU protocol, with
details as below:
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If using a laptop, this can be done by using an RJ45/USB converter and Ethernet cable. The
laptop should be running Redflow's ClusterMonitor software (which also requires the
Labview Runtime Engine, which is downloadable online) and configured as per the
ClusterMonitor Manual referenced in Step 10.
Step 7
Connect the positive and negative bus terminals on the MMS to the available external DC
terminals. On the ZBM side, both the positive and negative terminals of the ZBM are
terminated in 8mm eyelet lugs. It is important to size the cable for the expected currents of
up to 120A. It is recommended that a circuit breaker also be used for this connection (not
provided with the ZBM). If performing initial testing on a ZBM or ZBM2, a 48V nominal
power supply capable of supplying at least 10-40A at 54-58VDC is required. For ZBM3 a 60V
nominal power supply capable of supplying at least 10-40A at 59-63VDC is required. These
must both be capable of handling short periods with ~0VDC connected on the battery side.
Protocol: MODBUS RTU
Physical Connection: RS485 (Half Duplex)
Bit Rate: 19200
1 Stop Bit
No Parity Bit
8 Data Bits
No Handshake
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