EMUS BMS Mini, User Manual

Page 1: ...EMUS BMS mini User Manual v0 8 1 ...

Page 2: ...vice 16 3 3 2 Using CAN charging device 16 3 3 3 Configuration 17 3 4 Battery Protections 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 Co...

Page 3: ...0 8 2 2 Enabling password protection 31 8 2 3 Logging in 31 8 3 Time and Date 31 9 Software 33 9 1 Mobile application 33 10 Technical information 34 10 1 BMS mini 34 10 1 1 Mechanical specifications 34 10 1 2 Electrical specifications 35 10 1 3 Other specifications 35 2 ...

Page 4: ...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...

Page 5: ... 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 4 ...

Page 6: ...e 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 5 ...

Page 7: ...ts 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...

Page 8: ...ntial 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 Wiri...

Page 9: ...erature 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...

Page 10: ...ion 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 perfo...

Page 11: ...rigger Over voltage protection and internal contactor will disconnect a charger which will finish charging process For this set up firstly connect battery to BMS mini connect Battery to Battery terminal and Battery to Battery terminal using power cables Now charger can be connected using power cables connect Charger terminal to Battery and Charger terminal to Power terminal 10 ...

Page 12: ...minal to Battery and Charger terminal to Power terminal Now we will setup control indication components Low power AC Sense Relay of type NC normally closed should be connected in series to the AC Mains which purpose is to signal whenever power is present Connect one output of this relay to I1 pin of pin function connector which is displayed in figure 2 8 Other output connect to pin of the safe 10 ...

Page 13: ...2 3 2 CAN based charger Provided wiring connection between BMS mini and CAN Charger in figure 2 9 is only for reference and should be done according to the general rules of correct CAN bus setup that are described in section 4 2 CAN charger is directly connected to a battery but its control is performed over CAN Bus Wiring diagram is shown in figure 2 9 Firstly connect battery to BMS mini connect ...

Page 14: ...S BMS mini refer to figure 2 11 there are 2 power terminals one is dedicated to connect battery and another one is for connecting load Before connecting any device load you must power up the BMS mini itself Therefore connect battery pack power cables to BMS mini Battery with Battery terminal and Battery with Battery terminal and BMS should be up and running Make sure that device load will not draw...

Page 15: ...sub type Current measurements have an accuracy of 1 digit after decimal point e g 15 7 A for all types of current sensors Table 3 1 External current sensor operating current range From A To A 200A 200A 800A 800A Table 3 2 External current sensor current update rate Communication type Update rate Hz CAN 100 LIN 10 Either internal or external current sensor module continuously measures the analog si...

Page 16: ...gulates output current of the charging device according to feedback of measured battery parameters It ensures that the battery is charged safely and the battery cell voltages are correctly balanced after the charging process is finished Regardless of the charging device type charging process is divided into six stages 1 Pre Heating stage is entered when the minimum temperature value of all system ...

Page 17: ...ging stage persists until its entering condition is valid The order in which charging stages take place is not strictly defined Naturally they follow the order as they are listed above but it can vary depending on the situation For safety reasons BMS does not allow to change any configuration parameters during the charging process 3 3 1 Using Non CAN charging device Basic charging devices that do ...

Page 18: ...tion and configuration for each protection is described in the following chapters 3 4 1 Cell Over Voltage Protection Cell Over voltage protection prevents the battery cells from being overcharged during regenerative process and is activated if the voltage of at least one of the battery cells is above the threshold set by Maximum Cell Voltage When protection is triggered integrated external contact...

Page 19: ...easured by one of the external temperature sensors is below Activation threshold parameter value which indicates that environment is too cold for battery exploitation 3 4 7 Internal Over Temperature Protection Internal Over Temperature protection prevents the device from being operated under high tem perature which could build up if heat dissipation is not performed well due to unexpected heat dev...

Page 20: ... from 20 to 155 C Recom mended value is 60 C For External Under Temperature parameter can have a value from 40 to 10 C Recom mended value should be set according to minimum operating temperature value that is defined in the manufacturer provided specification sheet of the battery cells The optimal values for these parameters as well as the necessity of each type of protection should be assessed ac...

Page 21: ...mizable names and serial number for easier identification It s worth notice that only one wireless client e g smart phone can be connected at the time BMS mini will not be discoverable until primary device disconnects However other interfaces will still be available 4 2 CAN The CAN bus has be widely adopted in industrial automotive and instrumentation applications due to the inherent strengths of ...

Page 22: ...s BMS Components which were chosen according to the recommendations in CiA CAN in Automation 301 standard and are optimal when nodes from different manufacturers are connected to the same CAN network According to high speed transmission specification in ISO11898 2 standard both ends of the CAN bus must be terminated in order to minimize reflections and ensure that both lines are correctly returned...

Page 23: ...d to corresponding wire of the main bus cable by using a T connector wire tap splices or in the worst case by soldering the wires together and covering them in heat shrink tube The shield should be grounded at a single point only ideally as close as possible the output of the power supply that powers the nodes connected to the CAN network in order to avoid ground loops 4 2 1 Installation TBD 4 2 2...

Page 24: ...d set input functions Pin function Description Ignition Used for reading ignition state When active BMS enables additional fea tures and or changes function priorities AC Sense Used for sensing when AC Mains is present to supply power for Non CAN charger Protection Reset Used when user wants to clear all occurred protections Table 5 2 List of special set input functions Pin function Description No...

Page 25: ...ions tab There will be all available input and output pins with programmable functions Select a pin which function you would like to change In the resulting drop down window a list of all currently available functions for this pin will be listed Simply select new function and it will be automatically configured and enabled Each pin function has additional parameters e g functionality inversion inp...

Page 26: ...ent The highest recorded charge current value This statistic also contains the timestamp of when the value was recorded 10 Min Cell Voltage The lowest recorded cell voltage Additionally contains the cell number and timestamp of when this value was recorded 11 Max Cell Voltage The highest recorded cell voltage Additionally contains the corresponding cell ID and timestamp of when this value was reco...

Page 27: ...g process has been entered 27 Charging stage count The number of time the Charging stage of the charging process has been entered 28 Balancing stage count The number of time the Balancing stage of the charging process has been entered 29 Charging finished count The number of time the Charging Finished stage of the charging process has been entered 30 Charging error occurred The number of time the ...

Page 28: ...External Over Temperature protection has been deactivated 11 External temperature critically low External Under Temperature protection has been activated 12 External temperature recovered External Under Temperature protection has been deactivated 13 Internal temperature critically high Internal Over Temperature protection has been activated 14 Internal temperature recovered Internal Over Temperatu...

Page 29: ... External temperature minimum temperature of external temperature sensors Dis played in C Max External temperature maximum temperature of external temperature sensors Dis played in C Average external temperature average temperature of all external temperature sensors Displayed in C Internal temperature internal temperature of device itself Displayed in C Charging group Charging stage current batte...

Page 30: ...N charger set voltage voltage set for CAN charging device Displayed as V CAN charger set current current set for CAN charging device Displayed in A CAN charger error last CAN charging device charging error Protections group consist of Under voltage Over voltage Charging over current Discharging over current Ext over temperature Ext under temperature Int over temperature Int under temperature Each ...

Page 31: ... can only be updated using user with administrative privileges Follow these steps in order to update to the last available firmware version 1 In EMUS mobile application navigate to Menu Update page 2 Press Download button and wait until latest firmware file is downloaded 3 Press Install button and wait until device firmware is updated It is recommended to always use the latest firmware version but...

Page 32: ... user optional 7 Mark Password protected check box to protect Guest user with a password optional 8 Type in Guest User password After selecting required authentication configuration click Submit button to apply changes On next connection device authentication will behave differently according to chosen configuration 8 2 3 Logging in If password authorization is enabled device could request Guest s...

Page 33: ...nd sent to a device After this process all already occurred records will be set to correct time in the past and their track won t be lost Each time after device is powered on or firmware update it s required to manually set a correct time In case of software restarts or internal device malfunction correct time won t be lost If device is operating without time and date set it will still track exact...

Page 34: ... the device via Smartphone wire less connectivity eliminating the need for a dedicated dis play Emus BMS mini application displays the most rele vant statuses such as battery cells voltages state of charge estimated remaining distance power consumption provides configuration for every parameter performs firmware updates etc More detailed diagnostic information can be found in separate menus Mobile...

Page 35: ...0 1 BMS mini 10 1 1 Mechanical specifications Figure 10 1 BMS mini mechanical drawing Table 10 1 Fastening screws Fastening screw location Screw diameter Positive potential tabs M5 Negative potential tab M3 Mounting holes M4 34 ...

Page 36: ...oltage 1 000 V 4 950 V Battery pack voltage 12 0 V 67 2 V Operating temperature 40 C 80 C Supply power active 50 mW Supply power sleep 0 5 mW Balancing current 200 mA Maximum inner contactor current 75 A 10 1 3 Other specifications Table 10 3 BMS mini Physical Specifications Item Value Dimensions 97 67 15 mm Weight 125 g 35 ...