EMUS BMS Mini User manual

EMUS BMS mini

User Manual v0.8

Contents

1 System structure overview 5

2 Setting up the BMS 6

2.1 Batterycellsinstallation................................ 6

2.2 Connecting temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.3 Chargerinstallation .................................. 9

2.3.1 Non-CANbasedcharger............................ 9

2.3.2 CANbasedcharger .............................. 12

2.4 Loadinstallation.................................... 13

3 Core BMS functionality 14

3.1 BatteryMonitoring................................... 14

3.1.1 VoltageMonitoring .............................. 14

3.1.2 CurrentMeasurement ............................. 14

3.1.3 Temperature measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.2 StateofBattery .................................... 15

3.2.1 Chargeestimation ............................... 15

3.2.2 Healthestimation ............................... 15

3.3 Chargingprocess.................................... 15

3.3.1 Using Non-CAN charging device . . . . . . . . . . . . . . . . . . . . . . . . 16

3.3.2 Using CAN charging device . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.3.3 Conﬁguration ................................. 17

3.4 BatteryProtections .................................. 17

3.4.1 Cell Over-Voltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.4.2 Cell Under-Voltage Protection . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.4.3 Charge Over-Current Protection . . . . . . . . . . . . . . . . . . . . . . . . 18

3.4.4 Discharge Over-Current Protection . . . . . . . . . . . . . . . . . . . . . . 18

3.4.5 External Over-Temperature Protection . . . . . . . . . . . . . . . . . . . . 18

3.4.6 External Under-Temperature Protection . . . . . . . . . . . . . . . . . . . . 18

3.4.7 Internal Over-Temperature Protection . . . . . . . . . . . . . . . . . . . . . 18

3.4.8 Conﬁguration ................................. 18

3.5 Contactorpre-charge.................................. 19

4 Data interfaces 20

4.1 Wireless smartphone connectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.2 CAN .......................................... 20

4.2.1 Installation................................... 22

4.2.2 Conﬁguration ................................. 22

5 Remappable GPIO Functions 23

5.1 Description....................................... 23

5.2 Conﬁguration...................................... 24

6 Analytics 25

6.1 Statistics........................................ 25

6.2 Events ......................................... 27

7 Status Parameters 28

8 Maintenance 30

8.1 FirmwareUpdate.................................... 30

8.2 Passwordprotection .................................. 30

8.2.1 Usertypes ................................... 30

8.2.2 Enabling password protection . . . . . . . . . . . . . . . . . . . . . . . . . 31

8.2.3 Loggingin ................................... 31

8.3 TimeandDate..................................... 31

9 Software 33

9.1 Mobileapplication ................................... 33

10 Technical information 34

10.1BMSmini ....................................... 34

10.1.1 Mechanical speciﬁcations . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

10.1.2 Electrical speciﬁcations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

10.1.3 Otherspeciﬁcations .............................. 35

List of Abbreviations

BMS Battery Management System

PWM Pulse Width Modulation

RPM Revolutions per minute

LIN Local Interconnect Network

CAN Controller Area Network

GPIO General Purpose Input Output

PC Personal Computer

AC Alternating Current

NC Normally Closed

List of Tables

Table 3.1: External current sensor operating current range ................ 14

Table 3.2: External current sensor current update rate .................. 14

Table 4.1: Maximum bus line lengths, calculated based on the used CAN bit timing

setting, considering that a twisted-pair cable with a typical propagation delay

of 5 ns/m is used. LU- maximum length of a single unterminated drop line,

PLU- maximum length of all unterminated drop lines together. ....... 21

Table 5.1: List of standard set input functions ...................... 23

Table 5.2: List of special set input functions ....................... 23

Table 5.3: List of standard set output functions ..................... 23

Table 5.4: List of special set output functions ...................... 24

Table 6.1: List of statistics and their descriptions .................... 25

Table 6.2: List of events and their descriptions ...................... 27

Table 10.1: Fastening screws ................................ 34

Table 10.2: BMS mini Electric Speciﬁcations ....................... 35

Table 10.3: BMS mini Physical Speciﬁcations ....................... 35

List of Figures

Figure 1.1: System structure ............................... 5

Figure 2.1: Battery connection diagram ......................... 6

Figure 2.2: Example system 24 V (7 battery cells) .................... 7

Figure 2.3: Example system 36 V (10 battery cells) ................... 8

Figure 2.4: External Temperature Sensor ......................... 8

Figure 2.5: External Temperature Sensor installation diagram .............. 9

Figure 2.6: Uncontrolled Non-CAN charger installation diagram ............. 10

Figure 2.7: Controlled Non-CAN charger installation diagram .............. 11

Figure 2.8: 10-pin Pin Function connector ........................ 11

Figure 2.9: CAN charger wiring diagram ......................... 12

Figure 2.10: CAN connector ................................ 13

Figure 2.11: Load installation diagram ........................... 13

Figure 4.1: High-speed CAN network speciﬁed in ISO-11898-2 standard ......... 20

Figure 5.1: Pin function connector pinout ........................ 23

Figure 5.2: Input and output pin conﬁguration: a) High voltage sensing input, b) Ground

sensing input, c) High voltage output .................... 24

Figure 9.1: EMUS BMS mini mobile application ..................... 33

Figure 10.1: BMS mini mechanical drawing ........................ 34

1 System structure overview

EMUS BMS mini is a centralized battery management system that consists of a main controller

and optional components that serve diﬀerent purposes or ampliﬁes the integrated ones. All of the

populated pins and tabs of the main controller are described below:

•pins dedicated to connecting battery cells

•5 connectors for external temperature sensors

•9 multi-purpose input/output programmable pins

•CAN Bus

•LIN Bus

•Battery power tabs

•Load/Charger power tab

Figure 1.1: System structure

2 Setting up the BMS

2.1 Battery cells installation

There are two dedicated connectors for battery pack’s power terminals and two for direct connection

with batteries.

In order to safely connect batteries follow these instructions step by step. Also please refer to the

wiring diagram in ﬁgure 2.1 for detailed overview of described connections.

1. Connect BMS mini "Terminal (-)" with "-" of #1 Battery;

2. Connect BMS mini "Terminal (+)" with "+" of highest battery cell in a string;

3. Connector BAT1 has 9 pins and connects ﬁrst 8 batteries of a battery pack. Connector BAT2

has 8 pins and connects remaining 8 batteries. Batteries must be connected to connectors

from right to left side in a sequence from lowest potential to the highest potential.

Note! When connecting less than 16 battery cells all unused wires must be connected to the

highest battery cell in a string.

Figure 2.1: Battery connection diagram

Example 24 V system

In this example 7 Lithium Ion (Li-ion) battery cells are used to reach nominal total voltage of 25.9

V. In order to connect 7 battery cells only 8 pins of BAT1 connector is used. Remaining 9th pin

and all BAT2 connector pins must be tied to positive potential of #7 Battery. Refer to ﬁgure 2.2.

Wiring steps:

1. Connect BMS mini "Terminal (-)" with "-" of #1 Battery;

2. Connect BMS mini "Terminal (+)" with "+" of #7 Battery;

3. Connect wires from BAT1 connector to battery cells in a series. From lowest (#1) to highest

(#7) potential.

4. All remaining (unused) wires from BAT1 and BAT 2 connectors must be connected to positive

potential of #7 Battery;

Figure 2.2: Example system 24 V (7 battery cells)

Example 36 V system

In this example 10 Lithium Ion (Li-ion) battery cells are used to reach nominal total voltage of 37.0

V. In order to connect 10 battery cells 9 pins of BAT1 connector and 2 pins of BAT2 connector must

be used. Remaining 6 pins of BAT2 connector must be tied to positive potential of #10 Battery.

Refer to ﬁgure 2.3.

Wiring steps"

1. Connect BMS mini "Terminal (-)" with "-" of #1 Battery;

2. Connect BMS mini "Terminal (+)" with "+" of #10 Battery;

3. Connect wires from BAT1 and BAT2 connectors to battery cells in a series. From lowest (#1)

to highest (#10) potential.

4. All remaining (unused) wires from BAT2 connector must be connected to positive potential

of #10 Battery;

Figure 2.3: Example system 36 V (10 battery cells)

2.2 Connecting temperature sensors

On the bottom of the BMS mini (refer to ﬁgure 2.5) there are ﬁve 2-pin connectors dedicated to

external temperature sensors. External temperature sensor is shown in a Figure 2.4.

Figure 2.4: External Temperature

Sensor

Temperature sensors are easy to set-up, because they are

designed to support "Plug and Play" functionality. You just

simply need to connect provided external temperature sensors

to any of these slots and no further conﬁguration is needed.

Sensors are hot-swappable meaning installation can be per-

formed while system is powered. Use the same steps when

you need to remove or replace these sensors. In Figure 2.5 is

it shown that external temperature sensors can be mounted on

battery cells or between them.

Figure 2.5: External Temperature Sensor installation diagram

2.3 Charger installation

Charging process control is one of the most important tasks that a battery management system

must perform to ensure safe lithium battery operation, therefore it is very important to correctly

select and connect a charging device in order allow EMUS BMS mini to control it. The selection

of a particular charging device should be done considering various aspects of the application, yet its

output parameters are the most important from the battery management system’s point of view. The

maximum charger’s output voltage should be slightly higher than the cell charge voltage speciﬁed

in the cell speciﬁcation sheet multiplied by the number of cells connected in series. The maximum

charger’s output current should not exceed the maximum charging current speciﬁed in the same

speciﬁcation sheet. Correct connection of diﬀerent charging devices types supported EMUS BMS

mini is described in the following chapters.

2.3.1 Non-CAN based charger

Non-CAN charger can be integrated with EMUS BMS mini in 2 diﬀerent scenarios: using additional

components to control the charger or without control. Main diﬀerences of these two scenarios are

described below:

1. When using Non-CAN charger without control BMS cannot perform charger switching, also

battery pack does not reach full potential of balanced cells.

2. When using Non-CAN charger with additional components for control, BMS can perform

charger switching, and total battery cell balance is reached, but with relatively slower balancing

process.

Scenario 1 (uncontrolled Non-CAN charger)

In the following ﬁgure 2.6 a system using uncontrolled Non-CAN charger is presented. In this

scenario Non-CAN charger is directly connected to the battery pack. BMS has no control over

charger’s output voltage or current. Therefore, when the battery pack is nearly fully charged these

events will happen: because this type of charging is uncontrolled, balancing is not eﬃcient and

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