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ELECTRIC VEHICLE MANAGEMENT SYSTEM V3
Z
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V
E R O
M I S S IO N
EHI C LE S
http://www.zeva.com.au
Electric Vehicle Management System V3
Multifunctional, integrated control system for your EV
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Table of Contents
Introduction
Safety Warning
Stationary Mode
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U STRA LIA
ZEVA EVMS3
www.zeva.com.au
Electric Vehicle Management System
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Introduction
Thank you for purchasing ZEVA's Electric Vehicle Management System. The EVMS was
developed to address the need for safer, more reliable and better integrated EV conversions.
It combines many common functions and a range of fault detection, providing warnings of
operating errors and automatically responding to serious faults.
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Instrumentation including voltage, current, power, battery charge, temperature, and
isolation integrity.
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Battery management including cell voltage and temperature monitoring with auto-
matic response to under/over-charged batteries, and automatic pack balancing.
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Analog gauge outputs to re-use OEM fuel gauge, temp gauge and tachometer.
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Contactor control for management of auxiliary contactors, allowing battery pack
break-up and isolation for safety when vehicle is not in use.
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Optional 2-stage precharger with fault detection for soft-starting motor controllers
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Detection of many different operating errors/warnings.
A complete installation consists of an EVMS, usually installed in the vehicle's engine bay,
communicating over CAN bus with a Monitor module in the vehicle cabin, and a current
sensor and battery management modules located within your battery boxes. The CAN bus
may also include up to three TC Chargers and a ZEVA motor controller.
This manual describes the installation and operation of both the EVMS and Monitor devices.
Please refer to documentation supplied with your BMS modules, motor controller and
charger for further information relating to those devices.
Safety Warning
Electric vehicles are high powered machines which involve potentially lethal voltages and
currents. Proper precautions and electrical safety procedures should always be observed,
voltages above 110VDC should be considered dangerous, and vehicles should never be
worked on while power contactor(s) are engaged. Please read this manual carefully to
ensure correct installation and operation. If you are unsure of anything, please contact us
before proceeding.
We have endeavoured to make a safe and reliable product which performs as described,
however since ZEVA has no control over the integration of its products into a vehicle or
battery system, we can assume no responsibility for the final safety or functionality of the
completed vehicle. It is up to the end user to determine the suitability of the products for the
purpose employed, and the end user assumes all risks associated. Products should only be
installed by suitably qualified and experienced persons, and should always be used in a safe
and lawful manner.
ZERO EMISSION VEHICLES AUSTRALIA
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Table of Contents
Summary of Contents for Zeva Electric Vehicle Management System V3
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Page 1: Table Of Contents
Error Detection before proceeding. Voltage Thresholds We have endeavoured to make a safe and reliable product which performs as described, State of Charge Synchronisation however since ZEVA has no control over the integration of its products into a vehicle or Stationary Mode battery system, we can assume no responsibility for the final safety or functionality of the Use With Batteries Over 350VDC completed vehicle. It is up to the end user to determine the suitability of the products for the Isolation Fault Detection purpose employed, and the end user assumes all risks associated. Products should only be... -
Page 2: Specifications
ELECTRIC VEHICLE MANAGEMENT SYSTEM V3 ZERO EMISSION VEHICLES AUSTRALIA Specifications Example Wiring Diagram • Power supply: 12V nominal (8-16V maximum) • Power consumption: Approx 35mA when active (EVMS only), 3mA when sleeping • Fusing: Internal PTC type, 5A for power outputs, 200mA for logic I/O • Traction pack voltage range: 12-350VDC nominal • Traction pack capacity: 5-1250Ah (5Ah steps) • Current measurement: Via CAN bus current sensor, up to ±1200A • CAN bus format: 250kbps 29-bit (CAN 2.0B). Other formats by request. • Dimensions: EVMS 120x100x40mm, Monitor 96x62x17mm + mounting foot • Housing: ABS plastic, approx IP44 rating (weather resistant, not waterproof) Installation The EVMS should be mounted securely using screws through the four 4mm holes on the case flanges, in a location protected from direct water. Please note that although the housings provide some weather protection, they are not fully waterproof, so should not be exposed to rain or submerged in water. -
Page 3: Description Of Connections
ELECTRIC VEHICLE MANAGEMENT SYSTEM V3 ZERO EMISSION VEHICLES AUSTRALIA Description of Connections CAN Bus Wiring The EVMS uses CAN bus to communicate with other devices in the vehicle such as BMS Terminal name Description modules, EVMS Monitor, CAN current sensor, TC Chargers and ZEVA motor controllers. +12VDC Input To 12V battery positive (permanent supply, not key Note that every manufacturer tends to implement their own protocol on CAN bus so the switched). 8-16V maximum range. -
Page 4: Charger Integration Options
ELECTRIC VEHICLE MANAGEMENT SYSTEM V3 ZERO EMISSION VEHICLES AUSTRALIA Current Sensor • An AC relay with its coil wired in parallel with the charger’s AC input, so that when- ever the charger has power, the relay will also close to enable EVMS charge mode. The EVMS3 communicates with a current sensor on the CAN bus to receive instantaneous • Some chargers (e.g newer TC Chargers) have an output 12V supply which can be current, and uses this to calculate battery State of Charge through integration over time. Two used to switch a small signal relay to join Charge Sense to ground / chassis. types of current sensor are available, Hall Effect or Shunt. It is also essential that the EVMS is able to switch off the charger if any cells exceed safe • Hall Effect current sensors are available for 300A, 600A or 1200A maximum, and voltage, to prevent damage from over-charging. There are several ways to implement this: are installed simply by slipping the battery cable through the blue torus of the hall sensor. Smaller rated sensors offer proportionally higher measurement accuracy so • If using CAN integration with a TC Charger, the EVMS is able to disable the charger are more appropriate for lower current systems. Hall sensors are normally easier to over CAN bus so no additional control relays are required, and the Charge Enable install and generate no heat, but are a little more expensive and have slightly less output can be left unused. To connect a TC Charger to a ZEVA CAN bus, join only accurate zero point. the CANGND, CANL and CANH pins. (The charger also has a 12V pin but this should not be joined to the ZEVA CAN bus, since it is a 12V output, and only the •... -
Page 5: Evms Monitor
ELECTRIC VEHICLE MANAGEMENT SYSTEM V3 ZERO EMISSION VEHICLES AUSTRALIA Remember not to have any BMS module’s wiring harness span any auxiliary contactor (or B M S D e t a il s : M o d u l e 1... -
Page 6: Configuring Settings
ELECTRIC VEHICLE MANAGEMENT SYSTEM V3 ZERO EMISSION VEHICLES AUSTRALIA disconnecting the Monitor’s internal CAN termination resistor, in cases where the monitor is You can bring up this options menu by holding your not at one end of the CAN bus.) finger down on the screen for 1 second. From here you Reset S o C can do a manual reset of the State of Charge (back to Name Range Description Enter Se t u p 100%), enter the Setup mode, or switch the display Pack Capacity 5-1250Ah The rated capacity of your traction battery pack, Display O f f off. - Page 7 ELECTRIC VEHICLE MANAGEMENT SYSTEM V3 ZERO EMISSION VEHICLES AUSTRALIA Tacho PPR The EVMS can drive your vehicle’s OEM Low Temp Chg Rest. Yes/No Low Temperature Charge Restriction setting tachometer as an ammeter, displaying can disable charging if the battery temperature hundreds of amps instead of thousands of RPM. is below the programmed Low Temp Warning Tachometers typically expect a number of threshold, rather than just provide a warning.
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Page 8: Multi Purpose Inputs And Outputs
ELECTRIC VEHICLE MANAGEMENT SYSTEM V3 ZERO EMISSION VEHICLES AUSTRALIA Rev Current Disp. Yes/No Reverse Current Display. By default, current is Hdlight In Headlight Input. Connect MPI terminal to the headlight signal in your displayed with discharge amps positive. In some car (+12V when headlights are on) to have the EVMS automatically applications it is preferable or more intuitive to dim the Monitor brightness at night, based on the Night Brightness display charge amps positive instead. setting. Night Brightness 0-100% Adjusts the brightness of the LCD display in Ctr Aux Sw Contactor Auxiliary Switch. Wire the MPI terminal to the auxiliary low light mode, to reduce screen glare at switch of your main contactor (with the other side of the switch night. Toggle between full brightness and night... -
Page 9: Error Detection
ELECTRIC VEHICLE MANAGEMENT SYSTEM V3 ZERO EMISSION VEHICLES AUSTRALIA Error Detection Over-Temperature The EVMS’s temperature sensor has reported a temperature The EVMS monitors a wide range of operating parameters for your electric vehicle and can above the programmed warning level. notify you if any exceed their safe range or any faults are detected. In most cases, errors Isolation Fault A chassis leakage above the programmed threshold has been can be acknowledged/dismissed by tapping on the screen. Critical errors are responded to... -
Page 10: State Of Charge Synchronisation
Technical Support and Warranty Information backup and off-grid power applications. In this mode, the Key input enables both Main All ZEVA products are covered by a 12 month warranty against manufacturing faults or Contactor and Charge Enable outputs concurrently. An undervoltage cell will disable the failures under normal operating conditions. The warranty does not cover misuse of the...