EMUS BMS Mini User Manual

Centralized battery management system
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EMUS BMS mini
User Manual v0.8
1

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Summary of Contents for EMUS BMS Mini

  • Page 1 EMUS BMS mini User Manual v0.8...
  • Page 2: Table Of Contents

    Contents 1 System structure overview 2 Setting up the BMS 2.1 Battery cells installation ....... . 2.2 Connecting temperature sensors .
  • Page 3 10.1 BMS mini ........
  • Page 4 ....... . 34 Table 10.2: BMS mini Electric Specifications ..... . . 35 Table 10.3: BMS mini Physical Specifications...
  • Page 5 ..... 33 Figure 10.1: BMS mini mechanical drawing ......34...
  • Page 6: System Structure Overview

    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:...
  • Page 7: Setting Up The Bms

    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.
  • Page 8: Figure 2.2: Example System 24 V (7 Battery Cells)

    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.
  • Page 9: Connecting Temperature Sensors

    Figure 2.3: Example system 36 V (10 battery cells) 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.
  • Page 10: Charger Installation

    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.
  • Page 11: Figure 2.6: Uncontrolled Non-Can Charger Installation Diagram

    BMS will trigger ’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.
  • Page 12: Figure 2.7: Controlled Non-Can Charger Installation Diagram

    Non-CAN charger is presented. In this scenario Non-CAN charger is directly connected to the battery pack and controlled using low and high power relays. For this set-up firstly connect battery to BMS mini: connect "Battery (-)" to "Battery (-) Figure 2.7: Controlled Non-CAN charger installation diagram terminal"...
  • Page 13: Can Based Charger

    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 "Battery (-)" to "Battery (-) terminal" and "Battery (+)" to "Battery (+) terminal" using power cables. Now charger can be connected: using power cables connect "Charger (-) terminal"...
  • Page 14: Load Installation

    120 Ω terminating resistor would be applied to CAN Bus. Load installation On the left side of EMUS 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.
  • Page 15: Core Bms Functionality

    Battery tab. 3.1.2 Current Measurement EMUS BMS mini dual range integrated current sensor is an analog, hall-effect based current mea- surement device. The hall-effect measurement method also provides an inherent galvanic isolation between sensor ant the conducting part. There are two functionally identical types of the EMUS BMS mini dual range current sensor: internal and external.
  • Page 16: Temperature Measurement

    3.2.1 Charge estimation State of Charge estimation in EMUS BMS mini is mainly based on the coulomb counting technique. The coulomb counting is done in sync with the current update process every newly determined momentary current value is multiplied by the update period, and the result, is accumulated as Battery Charge value (in Ah).
  • Page 17: Using Non-Can Charging Device

    3.3.1 Using Non-CAN charging device Basic charging devices that do not have any EMUS BMS compatible interface for controlling their output current and voltage (also referred to as Non-CAN charging devices) are controlled by utilizing a special algorithm to turn them on an off using a switching device that is driven by a general purpose output pin mapped with ”Charger Enable”...
  • Page 18: Configuration

    Maximum discharging current (continuous) — maximum allowed continuous discharging cur- rent. Battery Protections During charge and discharge EMUS BMS protects the battery cells from an operation beyond certain limits of its parameters: voltage, current, temperature. Description and configuration for each protection is described in the following chapters.
  • Page 19: Charge Over-Current Protection

    3.4.3 Charge Over-Current Protection Charge Over-Current protection disconnects charger contactor or disables charger itself if pin function "Charger enable" is activated whenever the measured charge current is above the threshold set by the corresponding "Activation Threshold” parameter value, thus preventing the high currents during regenerative processes from potentially damaging the battery cells.
  • Page 20: Contactor Pre-Charge

    Contactor pre-charge In a lot of different applications the battery that is managed by EMUS BMS connects to a load that has a substantial input capacitance. In such case, it is often desirable to limit the high in-rush current that occurs when the main contactor is closed in order to reduce stress to the internal components of the load device and prevent the contactor from welding.
  • Page 21: Data Interfaces

    2.4 GHz integrated wireless interface is designed to connect with smart-phones and PCs supporting the same wireless technology. "EMUS BMS mini" application has to be installed in order to connect BMS mini device used for information display and configuration. Smartphone acts as a CANopen client and communicates through EMUS BMS mini object dictionary.
  • Page 22: L - Maximum Length Of All Unterminated Drop Lines Together. U

    Table are calculated based on the bit timing settings used in CAN-quipped Emus 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.
  • Page 23: Installation

    Emus BMS components, therefore they should be connected to the bus either at its ends, or by branching the bus cable somewhere in the middle. When using the latter method, each wire of the branch cable, including the shield, should be connected 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.
  • Page 24: Remappable Gpio Functions

    Remappable GPIO Functions Description BMS mini supports remappable pins, which can be mapped with various different functions during configuration. The default function of one pin can be remapped onto another pin. These pins are also further divided into input and output categories. Each pin depending on its category has a set of standard and special mappable functions.
  • Page 25: Configuration

    Figure 5.2: Input and output pin configuration: a) High voltage sensing input, b) Ground sensing input, c) High voltage output Configuration Using EMUS BMS mini mobile application each pin can be configured individually and effortless: In the main menu locate Configuration page Pin Functions tab;...
  • Page 26: Analytics

    Analytics Statistics For diagnostic purposes, system keeps track of various pre-defined battery and BMS operation statis- tics and stores them internally. Each statistic, depending on its type, can consist of a corresponding main value, additional value, and a timestamp. A list of all statistics is provided in Table 6.1. Table 6.1: List of statistics and their descriptions Statistic Description...
  • Page 27 Over-voltage protection count The number of times Over-Voltage protection has been activated. Additionally contains the timestamp of the last occurrence. Discharge over-current protection The number of times Discharge Over-Current protection has been count activated. Additionally contains the timestamp of the last occurrence.
  • Page 28: Events

    Events During operation, BMS keeps a log of the most recent events internally. It consists of 128 entries, each of which stores an event type identifier and occurrence timestamp. Once all 128 entries a filled, any new event replaces the oldest entry. All event types are described in the Table 6.2. Table 6.2: List of events and their descriptions Event Description...
  • Page 29: Status Parameters

    Status Parameters Main BMS monitoring statuses and states are grouped into 4 groups. Each of the groups are described in the following lists. Battery group: State of Charge — indicates remaining charge in the battery pack. Measured in %. Energy Left — remaining energy in the battery pack. Measured in Wh. Total Energy —...
  • Page 30 Charging cycle count — count of charging times. Max. Charging current — Maximum registered charging current supplied by charging device. CAN charger connection state — presence of CAN charging device. Connected CAN charger model — CAN charging device model. CAN charger set voltage — voltage set for CAN charging device. Displayed as V. CAN charger set current —...
  • Page 31: Maintenance

    You can view it by clicking "View release notes" button. Device firmware 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 button and wait until latest firmware file is downloaded.
  • Page 32: Enabling Password Protection

    "Login" Time and Date BMS mini system has it’s own time and date clock used to track exact occurrences of events and statistic values update. The time is displayed inside application menus or alongside related records. The main time details and configuration can be found in Profile menu -> Time window. This windows consist of these fields:...
  • Page 33 Item 1: displays current date and time that is known to BMS device. If "Time not set" or incorrect time is shown, it’s needed to be adjusted by pressing button (refer to Item 4). Set BMS time Item 2: displays uptime counter in seconds, started from device power up or restart. This indicates how long system is stable and correctly running.
  • Page 34: Software

    Software Mobile application EMUS BMS mini is a freely available application for Android and in near future iOS devices, designed specifically for mon- itoring the battery status in an electric vehicle or energy stor- age application. Using this application, any smartphone or...
  • Page 35: Technical Information

    Technical information 10.1 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 Negative potential tab Mounting holes...
  • Page 36: Electrical Specifications

    10.1.2 Electrical specifications Table 10.2: BMS mini Electric Specifications Item Value Number of cells 6 - 16 Battery cell voltage 1.000 V ... 4.950 V Battery pack voltage 12.0 V ... 67.2 V Operating temperature -40 C ... +80 C...

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