EnerSys iQ Mini Battery Monitor
User Manual and Installation Guide
Introduction
Information contained in this document is important for the safe handling and proper use of the iQ Mini™ battery monitoring device. It includes overall system specifications, related safety measures, codes of conduct, commissioning guidelines, and recommended maintenance. This document must be kept and made available to users who work with and are responsible for the battery monitoring device. All users are responsible for ensuring the system is always used appropriately and safely based on anticipated conditions or conditions that arise during operation.
This user manual contains important safety instructions. Before using the battery monitoring device and the apparatus into which it is installed, read and understand the sections on safety and device operation.
The owner is obliged to ensure that the use of this documentation and all related activities comply with applicable legal requirements that apply to them and relate to use in the respective countries.
This user manual is not intended as a substitute for training on the handling and operation of the iQ Mini™ battery monitoring device, which may be required based on local legal regulations and/or industry standards. Before any contact with the battery system, proper instruction and training of all users must be ensured.
For service, please contact your sales representative or call:
EnerSys EMEAEH Europe GmbH
Baarerstrasse 18
6300 Zug, Switzerland
Tel: +41 44 215 74 10EnerSys Global Headquarters
2366 Bernville Road
Reading, PA 19605, USA
Tel: +1-610-208-1991
Tel: +1-800-538-3627EnerSys APAC
No. 85, Tuas Avenue 1
Singapore 639518
+65 6558 7333
Website: www.enersys.com
Your safety and the safety of others is very important.
⚠️ WARNING: Failure to follow instructions may result in death or serious injury.
Features and Specifications
Features
- Real-time status
- Low voltage alarm
- iQ Mini™ battery monitoring device can be installed on multiple battery types
- Single polarity input, reverse polarity protection
- External voltage sensing – measures total battery voltage and cell count
- Super bright LED indicators
- iQ Mini™ battery monitoring device status indicators
- Multiple connection types
- Small and slim design
- Easy to use
- Simple installation
- Automatic data upload
Technical Specifications
| 300Q | 300B8 | 310Q | 310S | 301Q | |
|---|---|---|---|---|---|
| Battery Technology | TPPL Battery | Flooded Battery | TPPL Battery | ||
| Connection Type | FlexiTap (Q) | Bolt (B8) | FlexiTap (Q) | M4 Screw (S) | FlexiTap (Q) |
| Nominal Battery Voltage | 12 V, 24 V, 36 V, 48 V, 80 V *Voltage locks after 30 minutes. | ||||
| Operating Voltage | 4.5 V - 38 V MAX | ||||
| Voltage Sensing | 4.5 V - 120 V | ||||
| Operating Current | 1.6 mA - 10 mA | ||||
| Operating Temperature | -20 °C to +60 °C (-4 °F to +140 °F) | ||||
| Temperature Monitoring | Internal sensor | Internal sensor | External sensor | ||
| Wireless Range | Up to 100 m / 328 ft (unobstructed) | ||||
| Data Storage | Cumulative data and last 9 cycle data packets | ||||
| Data Acquisition | Via Gateway/App | ||||
| Current Consumption | Nominal Voltage | ||||
| Protection | Overvoltage and reverse polarity protection | ||||
| Physical Dimensions | 80 mm (D) x 29 mm (W) x 20 mm (H) / 3.14 in (D) x 1.14 in (W) x 0.79 in (H) | ||||
Compliance with Standards
2014/53/EU – Radio Equipment: Safety: EN 62368-1:2014+A11:2017; EMC: EN IEC 61326-1:2021; RF: EN IEC 62311:2020 / EN 50385:2017/EN 50665:2017, EN 300 328 V2.1.1 (2016-11), EN 300 328 V2.2.2, EN 301 489-17 - V3.2.0
2011/65/EU – Restriction of Hazardous Substances in Electrical and Electronic Equipment: RoHS: EN 62321-8:2017, EN 62321-3-1:2013, EN 62321-4:2013/AMD1:2017, EN 62321-5:2013, EN 62321-6:2015, EN 62321-7-1:2015, EN 62321-7-2:2017
Dimensions
The iQ Mini™ battery monitoring device has the following dimensions: 80 mm (3.15") length x 29 mm (1.14") width x 20 mm (0.79") height. All dimensions are in mm (inches).
Installation
This section provides installation instructions for various models.
Model 300Q Installation
The iQ Mini™ - 300Q is a battery life monitor that provides real-time status and is designed for use with 12 V to 80 V TPPL batteries. It monitors and records cycles, temperatures, and automatically sends this data to a gateway or app for online visualization. It provides LED indications for over-temperature and communication. If the battery status is OK and the device is functioning correctly, it blinks green every 10 seconds.
Installation Steps:
- Preparation: Ensure the voltage is between 2.0 and 2.25 V per cell before installation.
- Device Connection: Connect the iQ Mini™ battery monitoring device to the top of the battery.
- Positive Terminal: Connect the red cable to the positive terminal.
- FlexiTap Connection: Insert the FlexiTap into the center of the cable to ensure a good connection. Ensure it is centered and the pin is not bent.
- Secure FlexiTap: Secure the FlexiTap with a cable tie.
- Negative Terminal (12V/24V): Connect the yellow cable to the negative terminal for 12 V or 24 V systems. Note: For 24 V, connect only for 80 V batteries.
- Negative Terminal (Final): Connect the black cable to the negative terminal. The black cable must be connected last.
LED Status Checks:
Phase 1 LED Check: Upon power connection, observe the following LED sequence: 1 Green > 1 Red > 1 Yellow and 1 Blue. This blinking pattern repeats twice before the next phase.
Phase 2 Voltage Check: Check the number of blinks for voltage:
- x1 = 12V
- x2 = 24V
- x3 = 36V
- x4 = 48V
- x8 = 80V
Phase 3 LED Sequence on Startup: The LED blinks once to show the current battery status.
Model 300B8 Installation
The iQ Mini™ - 300B8 is a battery life monitor that provides real-time status and is designed for use with 12 V to 80 V TPPL batteries. It monitors and records cycles, temperatures, and automatically sends this data to a gateway or app for online visualization. It provides LED indications for over-temperature and communication. If the battery status is OK and the device is functioning correctly, it blinks green every 10 seconds.
Installation Steps:
- Preparation: Ensure the voltage is between 2.0 and 2.25 V per cell before installation.
- Device Connection: Connect the iQ Mini™ battery monitoring device to the top of the battery.
- Positive Terminal: Connect the red cable to the positive terminal.
- Remove Terminal Screw: Unscrew the terminal screw.
- Apply Lubricant: Apply lubricant between the screw and the terminal clamp.
- Secure Connection: Ensure the screw is firmly attached to the clamp. (Note: Tighten screw to the manufacturer's recommended torque.)
- Negative Terminal (12V/24V): Connect the yellow cable to the negative terminal for 12 V or 24 V systems. (Note: For 24 V, connect only for 80 V batteries.)
- Negative Terminal (Final): Connect the black cable to the negative terminal. The black cable must be connected last.
LED Status Checks:
Phase 1 LED Check: Upon power connection, observe the following LED sequence: 1 Green > 1 Red > 1 Yellow and 1 Blue. This blinking pattern repeats twice before the next phase.
Phase 2 Voltage Check: Check the number of blinks for voltage:
- x1 = 12V
- x2 = 24V
- x3 = 36V
- x4 = 48V
- x8 = 80V
Phase 3 LED Sequence on Startup: The LED blinks once to show the current battery status.
Model 310Q Installation
The iQ Mini™ - 310Q is a battery life monitor that provides real-time status and is designed for use with 12 V to 80 V flooded batteries. It monitors and records cycles, temperatures, and automatically sends this data to a gateway or app for online visualization. It provides LED indications for electrolyte status, over-temperature, and communication. If the battery electrolyte status is OK and the device is functioning, it blinks green.
Installation Steps:
- Preparation: Ensure the voltage is between 2.0 and 2.25 V per cell before installation.
- Device Connection: Connect the iQ Mini™ battery monitoring device to the battery and secure it with cable ties.
- Electrolyte Probe Installation: Install the electrolyte probe. The probe can be installed in any cell except the first three cells from the negative terminal of the battery.
- Drilling Hole (Option 1): Make a hole using a hammer and a 12 mm (1/2") drill bit. Ensure the drill bit does not touch the electrolyte.
- Drilling Hole (Option 2): Alternatively, drill a hole.
- Probe Adjustment: Trim the probe to the correct length and insert it into the battery. Ensure the probe is at least 3-5 mm (1/8 inch) above the battery plate.
- Positive Terminal: Connect the red cable to the positive terminal.
- FlexiTap Connection: Insert the FlexiTap into the center of the cable to ensure a good connection. Ensure it is centered and the pin is not bent.
- Secure FlexiTap: Secure the FlexiTap with a cable tie.
- Negative Terminal (12V/24V): Connect the yellow cable to the negative terminal for 12 V or 24 V systems. Note: For 24 V, connect only for 80 V batteries.
- Negative Terminal (Final): Connect the black cable to the negative terminal. The black cable must be connected last.
LED Status Checks:
Phase 1 LED Check: Upon power connection, observe the following LED sequence: 1 Green > 1 Red > 1 Yellow and 1 Blue. This blinking pattern repeats twice before the next phase.
Phase 2 Voltage Check: Check the number of blinks for voltage:
- x1 = 12V
- x2 = 24V
- x3 = 36V
- x4 = 48V
- x8 = 80V
Phase 3 LED Sequence on Startup: The LED blinks once to show the current battery status.
Model 310S Installation
The iQ Mini™ - 310S is a battery life monitor that provides real-time status and is designed for use with 12 V to 80 V flooded batteries. It monitors and records cycles, temperatures, and automatically sends this data to a gateway or app for online visualization. It provides LED indications for electrolyte status, over-temperature, and communication. If the battery electrolyte status is OK and the device is functioning, it blinks green.
Installation Steps:
- Preparation: Ensure the voltage is between 2.0 and 2.25 V per cell before installation.
- Device Connection: Connect the iQ Mini™ battery monitoring device to the battery and secure it with cable ties.
- Electrolyte Probe Installation: Install the electrolyte probe. The probe can be installed in any cell except the first three cells from the negative terminal of the battery.
- Drilling Hole (Option 1): Make a hole using a hammer and a 12 mm (1/2") drill bit. Ensure the drill bit does not touch the electrolyte.
- Drilling Hole (Option 2): Alternatively, drill a hole.
- Probe Adjustment: Trim the probe to the correct length and insert it into the battery. Ensure the probe is at least 3-5 mm (1/8 inch) above the battery plate.
- Positive Terminal: Connect the red cable to the positive terminal.
- M4 Connection: Screw the M4 connection onto the terminal.
- Secure M4 Connection: Ensure the M4 connection is firmly attached to the battery.
- Apply Epoxy: Apply epoxy to the top of the screw.
- Negative Terminal (12V/24V): Connect the yellow cable to the negative terminal for 12 V or 24 V systems. Note: For 24 V, connect only for 80 V batteries.
- Negative Terminal (Final): Connect the black cable to the negative terminal. The black cable must be connected last.
LED Status Checks:
Phase 1 LED Check: Upon power connection, observe the following LED sequence: 1 Green > 1 Red > 1 Yellow and 1 Blue. This blinking pattern repeats twice before the next phase.
Phase 2 Voltage Check: Check the number of blinks for voltage:
- x1 = 12V
- x2 = 24V
- x3 = 36V
- x4 = 48V
- x8 = 80V
Phase 3 LED Sequence on Startup: The LED blinks once to show the current battery status.
Model 301Q Installation
The iQ Mini™ - 301Q is a battery life monitor that provides real-time status and is designed for use with 12 V to 80 V TPPL batteries. It monitors and records cycles, temperatures, and automatically sends this data to a gateway or app for online visualization. It provides LED indications for over-temperature and communication. This variant has an external temperature sensor.
Installation Steps:
- Preparation: Ensure the voltage is between 2.0 and 2.25 V per cell before installation.
- Device Connection: Connect the iQ Mini™ battery monitoring device to the battery and secure it with cable ties.
- Temperature Sensor Installation: Mount the temperature sensor.
- Positive Terminal: Connect the red cable to the positive terminal.
- FlexiTap Connection: Insert the FlexiTap into the center of the cable to ensure a good connection. Ensure it is centered and the pin is not bent.
- Secure FlexiTap: Secure the FlexiTap with a cable tie.
- Negative Terminal (12V/24V): Connect the yellow cable to the negative terminal for 12 V or 24 V systems. Note: For 24 V, connect only for 80 V batteries.
- Negative Terminal (Final): Connect the black cable to the negative terminal. The black cable must be connected last.
LED Status Checks:
Phase 1 LED Check: Upon power connection, observe the following LED sequence: 1 Green > 1 Red > 1 Yellow and 1 Blue. This blinking pattern repeats twice before the next phase.
Phase 2 Voltage Check: Check the number of blinks for voltage:
- x1 = 12V
- x2 = 24V
- x3 = 36V
- x4 = 48V
- x8 = 80V
Phase 3 LED Sequence on Startup: The LED blinks once to show the current battery status.
Visual LED Indication
Automatic Voltage Detection: The iQ Mini™ battery monitoring device automatically detects battery voltage. This is indicated by a blinking green LED immediately after initial startup. The detected voltage can be found in the table below. IMPORTANT: For the iQ Mini™ battery monitoring device to detect the correct voltage, the per-cell voltage must be between 2.0 and 2.25 V during installation.
| Number of Blinks | Sensed Cells | Nominal Voltage (V) |
|---|---|---|
| 1 | 6 | 12 |
| 2 | 12 | 24 |
| 3 | 18 | 36 |
| 4 | 24 | 48 |
| 8 | 40 | 80 |
72 V must be ordered separately.
LED Indications
Models 300Q, 300B8, and 301Q (Figure 7):
- Status OK: Blinks green every 10 seconds.
- Data Connection: Blinks blue when actively receiving data.
- Over-Temperature: Solid red when temperature is > 37 °C (99 °F).
- Hardware Failure: Solid red with a warning symbol.
Models 310Q and 310S (Figure 8):
- Electrolyte Status OK: Blinks green.
- Needs Electrolyte Soon: Blinks yellow.
- Needs Electrolyte Immediately: Blinks red.
- Over-Temperature: Solid red when temperature is > 40 °C (104 °F).
- Data Connection: Blinks blue when actively receiving data.
Low Voltage Alarm Indications (Figure 9):
- Low Voltage: Blinks red twice, followed by a sound alert.
Connectivity
iQ Gateway™ Data Transmitter
The iQ GATEway™ battery data transmitter automatically acquires data from any iQ Mini™ battery monitoring device within range and transmits the data directly to an online portal. This data is available in real-time and displays the status of connected devices.
Gateway Dimensions:
The iQ GATEway™ has dimensions of approximately 201 mm (7.91") length x 171 mm (6.73") width x 158 mm (6.22") depth. Mounting dimensions are also provided.
Gateway Installation:
- Mounting: Mount the control box to the wall using four screws/anchors and a level. Ensure it is securely attached.
- Antenna Connection: Connect the antennas to the iQ GATEway™ battery data transmitter.
- Antenna Placement: Position both antennas as high as possible to maximize signal. Note: Maintain a minimum distance of 1 m between antennas.
- Power On: Connect the device to power.
LED Sequence on Startup:
- Phase 1 Power: Solid green when connected to power.
- Phase 2 Signal: Slow green blink when connecting to a signal.
- Phase 3 Signal: Solid green when the signal is good. (If the signal is unstable, refer to FAQ.)
- Phase 4 Uplink: Solid green when connected to the internet.
- Phase 5 Data: Slow blue blink when the receiver is active. (If the blue LED does not blink, refer to FAQ.)
If the red LED is on, refer to the FAQ.
Frequently Asked Questions (FAQ)
iQ Mini™ Battery Monitoring Device
- Q1: What data does the iQ Mini™ battery monitoring device monitor and record?
A1: The iQ Mini™ battery monitoring device monitors and records battery voltage, temperature, electrolyte level, and battery status (i.e., real-time charge/discharge status). It also monitors and records cycles, average and min./max. temperatures, min./max. voltages, battery life, and any improper battery usage – over-temperature, over-discharge, and low electrolyte status. This data can be visualized online or via the app and uploaded through the gateway. - Q2: We connected the cables, but no LEDs are lit on the iQ Mini™ battery monitoring device.
A2: Check that the connections were made in the correct order and at the correct voltage. If everything is correct, the device may be faulty. Contact your local EnerSys service center. - Q3: What is the purpose of the green LED blinking during the initial startup sequence?
A3: The purpose of the green LED blinking during the initial startup sequence is to indicate the detected battery voltage. The number of green LED blinks corresponds to the battery voltage. For example, one green blink indicates a 12 V battery, two green blinks indicate a 24 V battery, and so on, up to eight green blinks indicating an 80 V battery. This LED indication helps users verify that the iQ Mini™ battery monitoring device has correctly detected the battery voltage and is ready for operation. This must be checked during the installation of the iQ Mini™ battery monitoring device. - Q4: We connected the device, and the iQ Mini™ battery monitoring device turns on, but the number of green blinks does not match the battery voltage.
A4: This may mean the iQ Mini™ battery monitoring device was turned on in the wrong order. Disconnect the cables and reconnect them, ensuring the yellow cable is connected before the red and black cables. The iQ Mini™ battery monitoring device must be installed when the voltage is between 2.0 and 2.25 V per cell. - Q5: We installed the electrolyte probe, but the LED indication is incorrect.
A5: First, verify that the electrolyte probe is not installed in the first 3 cells from the negative terminal. The probe must not touch any plates or separators inside the cell. If this is verified and the problem persists, contact your local EnerSys service center. - Q6: The yellow LED on the iQ Mini™ battery monitoring device is blinking rapidly – what does this mean?
A6: Rapid blinking yellow means the voltage range is incorrect. Verify that the red and black cables are connected only to 12 V, 18 V, or 24 V. It may also mean the voltage is unstable. Verify that the charger is disconnected and that the battery has had enough time to reach a voltage between 2.0 and 2.25 V per cell. - Q7: The red indicator on the iQ Mini™ battery monitoring device is blinking – what does this mean?
A7: Blinking red indicates a low electrolyte level. - Q8: The red LED on the iQ Mini™ battery monitoring device is solid – what does this mean?
A8: A solid red LED indicates a fault – contact your local EnerSys service center for assistance. - Q9: We installed the gateway and the iQ Mini™ battery monitoring device, but we do not see real-time online status.
A9: Before installation and power-up, the gateway must be assigned to the online page. Your local EnerSys service center can provide further information.
iQ GATEway™ Battery Data Transmitter
- Q1: The signal LED is not green.
A1: This means the signal is insufficient. Move the gateway to a location where the signal is better. - Q2: The red LED on the gateway is lit – what does this mean?
A2: A continuously lit red LED means the gateway is faulty. Contact your local EnerSys service center. - Q3: We powered on the gateway, but none of the LEDs are lit.
A3: Check that the plug is properly connected and powered on. If the problem persists, contact your local EnerSys service center. - Q4: The blue LED is not blinking – what does this mean?
A4: This means the receiver has not been activated and data is not being uploaded. Contact your local EnerSys service center.
Spare Parts
iQ Mini™ Battery Monitoring Device
| Part Number | Description |
|---|---|
| IQ-300 | iQ Mini™ TPPL battery monitoring device without external temperature sensor |
| IQ-310 | iQ Mini™ flooded battery monitoring device without external temperature sensor |
| IQ-301 | iQ Mini™ TPPL battery monitoring device with external temperature sensor |
FlexiTap Connector Kits
| Part Number | Description |
|---|---|
| IQ-RFQ | FlexiTap Connector |
| IQ-RFQ | Q Connector - FlexiTap |
Bolt Connector Kits
| Part Number | Description |
|---|---|
| IQ-RFB8 | M8 Bolt Connector |
M4 Screw Connector Kits
| Part Number | Description |
|---|---|
| IQ-RFS | M4 Screw Connector |
iQ GATEway™ Battery Data Transmitter
| Part Number | Description |
|---|---|
| IQ-GATE-CW10 | Global 4G mobile gateway with Wi-Fi support |
Notes
Placeholder for notes.
