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AutarcTech JOULIE-4c Application Manual

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JOULIE-4c Application Guide
JOULIE-4c
Application Guide
Version 2.0 (DRAFT)
May 2019
Page
1
of
38
3. May 2019
Joulie-4c_Documentation_2.0_en.pages

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Summary of Contents for AutarcTech JOULIE-4c

  • Page 1 JOULIE-4c Application Guide JOULIE-4c Application Guide Version 2.0 (DRAFT) May 2019 Page 3. May 2019 Joulie-4c_Documentation_2.0_en.pages...
  • Page 2 ®) and copyright © symbols does not imply that a product is not protected. AutarcTech does not take responsibility for any inaccuracy, nor does it give any guarantee nor excepts any liability whatsoever for consequential damages resulting from the use of this manual or it’s associated product.
  • Page 3 400Ah per cell with a balancing current of 5A average (10A peak). The BMS - JOULIE-4c - is designed to use for both as Master unit and as Slave units, setup by the DIP switch settings (Master = 0, Slaves > 0).

  • Page 4: Table Of Contents

    JOULIE-4c Application Guide Table of Contents Important notice What you get Optional Components Usage 1. Hardware Overview 1.1. Technical Data 1.2. Hardware 1.3. Board Overview 1.4. Connectors Overview 1.5. DIP switch, Jumpers and receptacles 1.6. Meaning of the LEDs 2. PBAL-Ext 3.

  • Page 5: Important Notice

    (™ or ®) and copyright © symbols does not imply that a product is not protected. AutarcTech does not take responsibility for any inaccuracy, nor does it give any guarantee nor excepts any liability whatsoever for consequential damages resulting from the use of this manual or it’s associated product.

  • Page 6: What You Get

    JOULIE-4c Application Guide What you get JOULIE-4c - Active Balance BMS 12V/4S CellCon Balance - ERNI balancer cable with coloured wires, 1m, open end for ring connectors This Documentation Page 3. May 2019 Joulie-4c_Documentation_2.0_en.pages...

  • Page 7: Optional Components

    JOULIE-4c Application Guide Optional Components CellCon NTC - cell boards with NTC 10k, (42 x 29 mm²) for 4x M5, 1x M8, 1x M14 CAT5 cable - 1m to connect CellCon NTC to JOULIE Relay - LAYHER, bi-stable, 12V/200A, 6A / 80ms switch impulse Current Sensor - LEM HASS 100-S with cable 0.20 m...

  • Page 8: Usage

    JOULIE-4c Application Guide Usage The JOULIE Active Balance BMS is used to monitor the charging and discharging of Lithium cells, and to balance cells with different SoC (State of Charge) in a series connected battery. Lithium cells react very sensitively to lowering the minimum cell voltage (deep discharge) and exceeding the maximum cell voltage (overload), so monitoring is mandatory.

  • Page 9: Hardware Overview

    JOULIE-4c Application Guide 1. Hardware Overview 1.1. Technical Data • Battery Management System for 4S Lithium cells from 1.8-4.5V • Protects and active balances cells • Active balancing also with disconnected charger, in order to get a very good balanced block •...
  • Page 10 JOULIE-4c Application Guide Dimensions 120 mm x 80 mm x 15 mm (WxDxH) Weight 60 g Class IP00 Input Voltage per cell 1.8 - 4.5 V Balancing current peak / average 10 A / 5 A Voltage measurement 0.0016 V (12 Bit ADC)

  • Page 11: Hardware

    JOULIE-4c Application Guide 1.2. Hardware • active balancing with 4 independent bi-directional fly-back converters • active balance power 10 A peak / 5 A average per channel, 2 channels at the same time • extendable by PBAL-Ext 3 W / channel 1.3.

  • Page 12: Connectors Overview

    JOULIE-4c Application Guide 1.4. Connectors Overview https:// www.showmecables.com/blog/post/rj45-pinout/ Page 3. May 2019 Joulie-4c_Documentation_2.0_en.pages...
  • Page 13 JOULIE-4c Application Guide Connecting LEM HASS 100 current sensor (or comparable) and relay In order to use a regular relay instead of a bi-stable one (default) close the Relay Jumper. The current may not exceed 200mA. Page 3. May 2019...

  • Page 14: Dip Switch, Jumpers And Receptacles

    JOULIE-4c Application Guide 1.5. DIP switch, Jumpers and receptacles Dip switch for addressing the Jumper Power ON/OFF JOULIE’s in a chain; close: 12V Joulie only 0 = Master, 1 <= Slave <= 63 open: for a chain of Joulie’s Receptacle for PBAL_EXT: Bal_Extension, from left: CELL1..CELL4...

  • Page 15: Pbal-Ext

    JOULIE-4c Application Guide 2. PBAL-Ext • optional extension for JOULIE-4c, increases the balance power by 3 A per cell PBAL_Ext (not yet developed) Page 3. May 2019 Joulie-4c_Documentation_2.0_en.pages...

  • Page 16: Applications

    JOULIE-4c Application Guide 3. Applications The BMS can be used in different ways (see schematics): 3.1. One JOULIE for a single 12V block JOULIE setup for a 12V battery Page 3. May 2019 Joulie-4c_Documentation_2.0_en.pages...

  • Page 17: Chained Joulie's For A 24V Battery

    JOULIE-4c Application Guide Important Notice: All RJ45-IN wires are galvanically isolated. The RJ45-OUT lines do not. When connecting external systems, be aware that there may be high voltages depending on the connections. Please avoid connecting multiple serial-to-USB converters to multiple JOULIE boards on the same external system, e.g. a PC.

  • Page 18: Chained Joulie's For A High Voltage Battery - Up To 900V

    JOULIE-4c Application Guide 3.3. Chained JOULIE’s for a high voltage battery - up to 900V The CTRL units act in the same way like the JOULIE's does: the first one is the “Master”, the communication is serial as well. All chains (CTRL boards) can be connected to LiMaster (see Manual for Master).

  • Page 19: Installation Steps For A 12V Battery

    JOULIE-4c Application Guide 4. Installation steps for a 12V battery Connect 4 cells in series to a 12 V (14 V) block. On top of every + pole mount the CellCon NTC boards (do not mount below the cell connectors).
  • Page 20 JOULIE-4c Application Guide Connect the CAT5 temperature sensor wires to the clamp connectors on the CellCon NTC - ensure you use paired wires (orange, blue, green, brown). Bridge the TOS clamp connectors right most: DO NOT PLUGIN THE ERNI CABLE into the JOULIE board! Follow these steps first.
  • Page 21 JOULIE-4c Application Guide Check the correct connection and rank with a voltmeter or an (optional) test adaptor (please ask us for such equipment). CellLog is no longer available. Connection schema of balancer cables; check with a test adapter or voltmeter...

  • Page 22: Installation Steps For Batteries Higher Than 12V

    JOULIE-4c Application Guide 5. Installation steps for batteries higher than 12V Important Notice again: All RJ45-IN wires are galvanically isolated. The RJ45-OUT lines do not. When connecting external systems, be aware that there may be high voltages depending on the connections. Please avoid connecting multiple Serial-to-USB converters to multiple JOULIE boards on the same external system, e.g.
  • Page 23 JOULIE-4c Application Guide Connecting 2 boards only Connecting more than 2 boards, use RJ45 cable splitter Page 3. May 2019 Joulie-4c_Documentation_2.0_en.pages...
  • Page 24 Slave. When disconnecting go in reverse order, starting from the last Slave to the Master. If you are not sure please contact AutarcTech. Wrong wiring can damage the JOULIE units and can also cause high voltage hazards! Page 3.

  • Page 25: Software

    JOULIE-4c Application Guide 6. Software 6.1. BMS Graphical User Interface (GUI) The Graphical User Interface is available for OSX, LINUX and Windows. Access to data and parameters is possible ONLY in Command Mode! For this the communication in between the boards is interrupted, nevertheless, balancing is continued.
  • Page 26 JOULIE-4c Application Guide In the list box at the left corner you can choose the board you want to monitor, For the Master choose 000, for the Slaves choose 001..063. The GUI automatically sends 2 commands permanently, where xxx stands for the board number:...
  • Page 27 JOULIE-4c Application Guide As you can see, there is a light blue line in the middle of the cell voltages area. This shows the median voltage value which is the common one of all connected boards in the chain. It allows you to control the behaviour of the balancing process. After a dedicated time all cells voltages should be pretty close to this line.
  • Page 28 JOULIE-4c Application Guide The GUI can be swapped between English and Deutsch. Page 3. May 2019 Joulie-4c_Documentation_2.0_en.pages...

  • Page 29: Bms Shell Program

    JOULIE-4c Application Guide 6.2. BMS Shell program The shell is accessible via the RS485-UP connector pins 1 and 2. - Baudrate: 38400 - Databits: 8 - Stopbits: 1 - Parity: Non - Xon/Xoff: No Shell commands (max. 64 JOULIE's, executable from any external unit with RS485) Periodically the trace stops for a few seconds in order to allow to go to a command mode.
  • Page 30 JOULIE-4c Application Guide - balance status cell1..4; I-Idle, C-Charge active, D-Discharge active, B-Balance passive … 3431 - median voltage of the 4 cells … 20.5; - temperature cell 1..4 [°C] … -30.5; - current (negative - discharge) [A] - SOC [%] 100;...
  • Page 31 JOULIE-4c Application Guide 200; - charge current limit -200 - discharge current limit see also chapter Parameters overview other valid commands: *gM012 - reads the measured values from JOULIE no. 012 *gP004 - gets parameters from JOULIE 004 *vers - prints out the software version...

  • Page 32: Parameters Overview

    JOULIE-4c Application Guide 6.3. Parameters overview *gP000;100;3800;3600;3500;3450;3100;2900;2800;60;1;0;0;50;-50 //reads the parameters *sP000;100;3800;3600;3500;3450;3100;2900;2800;60;1;0;0;50;-50 //sets the parameters There is a limit of 70 characters for the entire string! Validation is performed via GUI only. CellCapaci = 10..1000 [Ah] RelayHiOFF = 3600 [mV] //Relay OFF Limit...

  • Page 33: Eeprom Fields

    JOULIE-4c Application Guide Parameter Meaning valid value error DisableCHR Disable charge voltage, triggers the appropriate port 0 .. 9 DisableDCH Disable discharge voltage, triggers the appropriate 0 .. 9 DDCH port Currnt_CHR Charge current limit >= 0 CurrntDCHR Discharge current limit <= 0...

  • Page 34: Error Handling

    JOULIE-4c Application Guide 6.6. Error Handling R000 - generic relay errors • - relay off by hardware • RCOM - relay off by terminal command • - relay off after 5x retry • - relay is on • ROFF - relay is off •...

  • Page 35: Soc Calculation

    JOULIE-4c Application Guide 6.7. SOC Calculation For the calculation of the SOC (State Of Charge), the reference point is 100%. This is determined by the following conditions: After the BMS is switched on, the SOC is estimated based on the SOC table stored in EEPROM.

  • Page 36: Reset And On/Off

    JOULIE-4c Application Guide 7. RESET and ON/OFF Use the ICSP port to reset the BMS by short cut RESET to GND for 1s. releasing the Jumper ON/OFF switches the CPU off, AD goes to power down mode Use also the RS485-UP connector and connect Pin3 with GND and Pin8 with +5V (see chapter Connectors Overview).

  • Page 37: Q&A

    JOULIE-4c Application Guide Q&A • What is the most important thing when the BMS will be connected to the battery block? First connect the balancer cables to the cells THEN connect them to the board. Ensure the balancer wires are connected in the correct order.
  • Page 38 • What similar products does AutarcTech offer? AutarcTech offers a 16S/48V Active Balance BMS, that is technically based on the same components like described for JOULIE in this manual. This BMS is named JOULIE-16, a separate Manual describes the features and it’s use.

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