JSC Elektromotus Emus Manuel utilisateur
BATTERY MANAGEMENT SYSTEM
User’s manual Revision 1
In this user‘s manual you will find a list of characteristics, setup and
installation steps and recommendations for the EMUS Battery
Management System. This document should be read before setting up
your EMUS BMS.
JSC Elektromotus, 2011
EMUS BMS User‘s manual
SC Elektromotus, 2011 Page 1
Table of Contents
Introduction ......................................................................................................... 2
System structure .................................................................................................. 2
Standard package contents ................................................................................. 3
Features ............................................................................................................... 3
Specifications ....................................................................................................... 5
Installation & setup ............................................................................................. 6
Connect 12V power source ............................................................................. 6
Connect the USB .............................................................................................. 6
Start the EMUS BMS Control Panel ................................................................. 7
Configure cell count and type .......................................................................... 8
Install Cell Modules ......................................................................................... 9
Connecting Charging and Battery low indication .......................................... 13
Connecting sound buzzer .............................................................................. 13
Connecting Ignition and Fast charge input switches ..................................... 14
Connecting non-CAN charger ........................................................................ 14
Connecting CAN charger ................................................................................ 15
Connection of IPAQ as display unit ............................................................... 16
Cell temperature calibration ......................................................................... 16
Cell voltage configuration .............................................................................. 17
Configuring the charger ................................................................................. 19
Configuring the timing ................................................................................... 20
Firmware updates .......................................................................................... 22
EMUS BMS User‘s manual
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Introduction
Recent development of rechargeable battery technology allowed wider use of
electric propulsion in electric vehicles, electric motorcycles, boats etc. Most
popular high performance batteries are based on Lithium chemistries. Such
batteries require systems to keep them in the specified usage range while
being used. The Battery Management System (BMS) is required for batteries
that are sensitive to their usage conditions such as current, voltage and
temperature. EMUS BMS is the product intended for use with LiIon, LiPO,
LiFePO4 and other chemistries prismatic battery cells which operating voltages
range is from 2V to 5V. EMUS BMS is a distributed type of digital BMS with
central Control Unit. It does the balancing of the cells by dissipating the excess
energy of cells as heat which is often referred to as passive balancing.
It's usage is explained further in this manual.
System structure
EMUS BMS is designed for batteries where cells are connected in series to
form a higher voltage battery pack. Each cell of the battery has a Cell Module
which monitors cell's parameters, controls the balancing current and
communicates with central Control Unit over 1 wire digital interface.
EMUS BMS Control Unit is connected to Cell Modules via double twisted-pair
optically isolated interface over which it communicates and collects cell
characteristic information and manages the battery. Control Unit also connects
to charger via CAN bus or via Solid State Relay (SSR) if non-CAN charger is used.
Collected data is sent via serial RS232 interface and CAN bus. The data can be
gathered and displayed to the user by Display Module (optional add-on).
Control Unit also has a USB interface for firmware updates, configuration,
which is used to connect it to a PC to configure the BMS via special EMUS BMS
Control Panel software.
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EMUS BMS Control Unit also has a connection to Current Sensor Module
(optional add-on) which enables the EMUS BMS to act as a State Of Charge
(SOC) meter allowing user to monitor remaining battery charge and plan a trip
or operation. To allow such trip planning there is an input for vehicle Speed
Sensor signal.
Control Unit connects to other user controls as well: Ignition Key and Slow/Fast
charge selection switch. Several output connections are intended to be used as
audio-visual indicators to the user: Charging and Low Battery indicators and
warning audio buzzer.
Standard package contents
1. EMUS BMS Control Unit – 1 unit
2. EMUS BMS Cell Module, one per cell:
a) Cell Module of “Bottom” type - 1 unit
b) Cell Module of “Top” type - 1 unit
c) Cell Modules of A and B type - number as per customer's requested
number of cells, minus 2 units
3. Cell Module inter-connection wires, pre-cut and ready to use - number as
per customer's requested number of cells
4. EMUS BMS Control Unit's 22-pin connection header with contacts - 1 unit
5. 120 Ohm CAN termination resistor - 1 unit
Features
•Suitable for wide range of battery chemistries with operating voltage 2 to 5
V per cell (LiPO, Li-Ion, LiFePO4 and others).
•Fully scalable: 2 to 255 cells, 8 to 1300 Volts battery pack.
•Measures voltage of each cell in real time.
•Measures temperature of each cell in real time.
•Controlled balancing current of each cell.
•Configurable maximum balancing current up to 1.5 A.
EMUS BMS User‘s manual
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•Configurable minimum cell temperature for charging (typically 0°C for
lithium cells).
•Battery heater control: the EMUS BMS will pre-heat the battery before
charging, if configured to.
•Full charger control: ON/OFF and AC sense for conventional chargers, full
charge characteristics for CAN chargers, slow/fast charge modes.
•Load control: switches off the load when critically low voltage is reached
on any of cells.
•State-Of-Charge (SOC) indication: conventional analogue gauge or LCD
with statistical information (requires optional add-on).
•Additional indication: „Battery low“ light and buzzer, „Charging“ light.
•USB-configurable: free EMUS BMS Control Panel application for Windows
OS is supplied to update the firmware of the EMUS BMS, configure it, read
statistical data and observe each cell in real time.
•One-wire digital interface between Cell Modules: the minimum of wires
used, lowest risk of mechanical wire failure.
•Optically isolated interface between EMUS BMS Control Unit and Cell
modules: no risk of electric shock.
•Forward-Error-Correction: greatly improved data transfer liability even in
harsh EMI environments.
•Moisture resistant: the EMUS BMS Control Unit is hermetically sealed and
the Cell Modules are treated to resist any moisture.
•Easy and tool-less installation: the only tool needed to install the Cell
Modules is a wrench for your battery cell tabs. Once the Cell Module is
connected, it starts to blink a green LED to indicate a live communication
with the Control Unit – speeds up the installation process.
•Engineered and manufactured in European Union.
EMUS BMS User‘s manual
SC Elektromotus, 2011 Page 5
Specifications
Parameter
Value
Control Unit supply voltage
8
–
20 V
Battery pack voltage
4
–
1300 V
Series cell count
2
–
255 pcs.
Cell operating voltage
2
–
5 V
Cell balancing current
1.5 A
Balancing
type
Passive/dissipative
Power consumption of
t e
Control Unit
50 mA
EMUS BMS User‘s manual
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Installation & setup
The installation of BMS is covered in the following chapters as step by step
guide.
Connect 12V power source
The EMUS BMS Control Unit needs 12 Volts DC power from vehicle's auxiliary
battery or other 12V source. Connect 12V battery's negative (-) tab to
“GROUND” and battery’s positive (+) tab to “+12V” wires of the 22-pin
connector on EMUS BMS Control Unit.
Connect t e USB
To verify basic EMUS BMS operation, connect the EMUS BMS Control Unit's
USB socket to a Windows PC via mini-USB cable. Please use the drivers for your
version of Microsoft Windows from USB Flash drive which is supplied with
EMUS BMS or download them from FTDIChip site
http://www.ftdichip.com/Drivers/VCP.htm. Make sure that a new device is
found and is installed successfully without errors.
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Start t e EMUS BMS Control Panel
EMUS BMS Control Panel software application can be found on USB Flash drive
supplied with the EMUS BMS or downloaded from our website
www.elektromotus.eu. When started, application will initiate a connection to
the EMUS BMS. When connected, EMUS BMS Control Panel application will
indicate “Connected” on the title bar and show some basic BMS status
parameters.
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Cells tab will indicate the Number of Cells is “0” as you don't have any cells and
Cell Modules connected to your Control Unit yet.
Configure cell count and type
The connection of the cells will be covered in the next chapter, but before that
we will configure the number of cells for EMUS BMS that it would expect to
see on the battery after installation. The Number of Cells is configured by
selecting Configuration age and Cells tab. In our example we enter Number of
Cells equal to 4 for demonstration purposes.
In the Number Of Cells field, specify the amount of series cells in the battery
pack. Cells can be connected in series and parallel configuration, for example
16 series and 3 parallel. Only a number of series cells should be specified here.
Note how the Number of Cells field background color changes to yellow which
indicates that the parameter is updated, but has not been written into EMUS
BMS Control Unit yet. When you press Tab key or select other parameter field
the color changes back to white, which means that parameter has been
written to BMS.
In the Ca acity field, enter a rated cell’s capacity in Amp-hours, specified in
manufacturer’s datasheet. If multiple cells are used in parallel, specify a total
capacity here. For example, three parallel cells of 100 Ah is a total of 300 Ah.
Change all other parameters as per your requirements.
EMUS BMS User‘s manual
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Install Cell Modules
There are 4 types of EMUS BMS Cell Modules to allow nice and tidy installation
on the battery pack: Bottom, types A and B, Top. The type of the module is
printed on the module itself. Bottom cell module is dedicated to be installed
on the cell which has negative (-) terminal of the whole battery pack. Top
module is installed on the cell which has positive (+) terminal of the pack. Type
A and B modules are installed on the cells in between, as illustrated below.
HINT: it is recommended to start the installation of the modules from the
Bottom Cell Module, connect it to the Control Unit and go up the battery stack
installing other modules up to the Top one. This is because when starting from
Bottom module which is connected to powered-up Control Unit you should see
green LED flashing once every second indicating that cell module connection is
OK. Then going up every next Cell Module connected to the chain should start
flashing as well.
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