Superb BCI Manuel utilisateur

Manual

BATTERY COMMUNICATION

INTERFACE (BCI)

Version

March 2022

User Manual Battery Communication Interface (BCI)

Dear customer,

This manual contains all the necessary information to install, use and maintain the Battery

Communication Interface (BCI). We kindly ask you to read this manual carefully before using

the product. In this manual the Battery Communication Interface will be referred to as the

BCI. This manual is meant for the installer and the user of the BCI. Only qualied personnel

may install and perform maintenance on the BCI. Please consult the index at the start of this

manual to locate information relevant to you.

During the use of the product, user safety should always be ensured, so installers, users,

service personnel and third parties can safely use the BCI.

or its subsidiaries or suppliers, and are protected by national copyright laws and international

treaty provisions. Super B products are covered by Dutch and foreign patents, issued and

pending. Information in this publication supersedes that in all previously published material.

Specications and price change privileges reserved. Super B is a registered trademark of

Super B.

For more information please contact:

Super B Lithium Power B.V.

Europalaan 202

7559 SC Hengelo (Ov) The Netherlands

Tel: +31(0)88 00 76 000

E-mail: info@super-b.com

www: www.super-b.com

Be in charge. Super B.

Table of content

1. Safety guidelines and measures 5

1.1. General 5

2. Introduction 5

2.1. Product description 5

2.2. Intended use 6

2.3. Glossary of Terminology 6

2.4. Used symbols 7

3. Product speciﬁcations 7

3.1. Typical setup of the BCI 7

3.2. Product features 8

3.3. BCI functional behaviour 9

3.3.1. General 9

3.3.2. Functionality of the power inputs 9

3.3.3. BCI States 11

3.3.4. Driver behaviour 13

3.4. BCI control functions 15

3.4.1. Auto-on 15

3.4.2. SoC shutdown/Switch-OFF 15

3.4.3. Reset 15

4. General product speciﬁcations 16

4.1. Electrical specications 16

4.2. Mechanical specications 16

4.3. Environmental specications 17

4.4. Scope of delivery 18

4.5. Connections, indicators and controls 18

4.5.1. CAN connector pinout (Master/Slave) 19

4.5.2. J3 (I/O Connection 10) 19

4.5.3. J4 (I/O Connection 10) 20

4.5.4. Indicators 20

4.6. Peripheral equipment 21

5. Installation 22

5.1. General information 22

5.2. Unpacking 22

5.3. Required tools for installation 22

5.4. Placement of the BCI 22

5.5. Connection wires 22

5.6. Electrical installation 23

5.6.1. Electrical installation - BCI power from battery bank 23

5.6.2. Electrical installation - BCI externally powered 25

5.6.3. Manual control 26

5.6.4. Pre-charge selection 27

5.7. CAN Bus 29

5.7.1. General information 29

5.7.2. Connecting the CAN network cables 29

5.7.3. CAN Bus network topology 30

5.7.4. Termination Resistors 30

5.7.5. CAN bus power 30

5.7.6. Integrating CAN Protocol 31

5.7.7. General purpose I/O 31

6. BCI use 31

6.1. General information 31

6.2. Conguring the BCI and the battery bank 32

6.3. Battery ID’s 32

6.3.1. Battery ID renumbering procedure 32

6.3.2. Battery layout 36

6.3.3. Input level conguration 37

6.3.4. BCI Modules 38

6.3.5. Pre-charge adjustment 39

6.3.6. General settings: Automatic control 40

6.3.7. General settings: State-of-charge switch-OFF level 41

6.3.8. Saving a conguration 42

6.4. Status and control 43

6.5. Status of the battery bank 44

7. Inspection and cleaning 47

7.1. General information 47

7.2. Inspection 47

7.3. Cleaning 47

7.4. Maintenance 47

8. Storage 48

9. Transport 48

10. Disposal 48

11. Troubleshooting 49

12. Warranty and liability 50

Be in charge. Super B.

1. Safety guidelines and measures

1.1. General

• Treat the BCI as described in this manual.

• Do not disassemble, crush, puncture or shred the BCI.

• Never install or use a damaged BCI

• Do not expose the BCI to heat or re.

• Do not remove the BCI from its original packaging until required for use.

• The BCI shall not be used outside the electrical and mechanical specications as specied in

this manual.

• Do not mix Li-ion batteries of different capacity, size or type. Only use Super-B Li-ion traction

batteries with the BCI.

• Retain the original product documentation for future reference.

• Always take safety precautions when working on battery systems.

• Never short circuit the Li-ion battery.

Warning! Only trained experts shall handle or install a BCI and/or the related battery

systems. These systems can deliver very large currents and/or high voltages.

Caution! A caution sign indicates problems may occur if a procedure is not carried out as

described. It may also serve as a reminder to the user.

2. Introduction

2.1. Product description

The Battery communication Interface (BCI) is a device intended to control contactors or

relays that must be used to protect Super B Li-ion batteries from improper use. The BCI

collects data from one or multiple Li-ion batteries by a CANopen communication bus. This

data contains information about the status and the current use of the Li-ion batteries. If one

or more Li-ion batteries reports an issue, the BCI will turn off the contactors and protect

the Li-ion batteries. Although the BCI can be used to manage a single Li-ion battery, it is

intended to collect data from multiple Li-ion batteries in series and/or parallel for controlling

contactors. Other typical functions are:

• Control pre-charge functionality. Therefore, an additional contactor and resistor is needed tailored to

the application.

• Protocol conversions (depending on BCI software version).

• Control charger by CAN or charge enable signal (depending on BCI software version).

2.2. Intended use

Potential applications to use the BCI in combination with Li-ion batteries from Super B are:

• Off grid applications

• Marine applications

• Medium for (renewable) energy storage (traction)

• Battery for vehicles.

Depending on the application it can be necessary that additional components are used to

assure that the installation is compliant with the applicable regulations. See chapter 5.6 for

information on electrical installations.

The BCI is sold as a single device, the customer is expected to source necessary

components for protecting the Li-ion batteries. Super B cannot be held responsible for

installations made by the customer.

Super B also offers the option of supplying the complete installation. This can be a standard

solution or a custom solution. The standard solution can be found on our website or by

contacting sales. The custom solution needs to be aligned with your sales and application

engineering contact.

If this manual does not cover or address your application, please contact Super B.

Only qualied personnel may install and perform maintenance on the complete system -

always refer to chapter 1 of this manual for safety guidelines.

The boundaries of the BCI use, as described in this manual should always be upheld. The

BCI may not be used in medical, or in aviation related applications. The BCI may not be used

for any purposes other than described in this manual. Using the BCI for any other purposes

will be considered improper use and will void the warranty of the product. Super B cannot

be held responsible for any damage caused by improper, incorrect, or unwise use of the

product. Please read and understand this entire manual carefully before using the product.

2.3. Glossary of Terminology

BMS Battery Management System

BIB Battery Interface Box

BCI Battery Communication Interface

LiFeP04 Lithium Iron Phosphate

Be in Charge Software PC application for monitoring control and conguration

Be in charge. Super B.

DC-bus Load / charger side of main contactor(s)

SoC State of charge

CANopen CAN bus protocol

48V system A system that consists of 4 batteries in series

24V system A system that consists of 2 batteries in series

Table 1. Glossary of Terminology

2.4. Used symbols

The following icons will be used throughout the manual:

Warning! A warning indicates severe damage to the user and/or product may occur when a

procedure is not carried out as described.

Caution! A caution sign indicates problems may occur if a procedure is not carried out as

described. It may also serve as a reminder to the user.

3. Product specications

3.1. Typical setup of the BCI

Figure 1, depicts a typical setup of the BCI. The circuit shows the interconnections of the BCI

in an installation to protect the Li-ion battery (bank).

main relay high

pre charge relay

main relay low

CANbus

DC bus -

DC bus +

control

fuse

BCI

CANbus

to other systems

Figure 1. Typical BCI setup

3.2. Product features

• Three dry outputs to control the minus, the plus, and the pre-charge contactor of the Li-ion

battery bank.

• Four galvanic isolated inputs for manual operation (not shown in Figure 1).

• Collecting the status and alarm messages of all the Li-ion batteries connected to the CAN

bus. In case of an alarm from one of the Li-ion batteries the BCI will control the contactors to

disconnect from the DC bus.

• Scanning the CAN bus to see if all the Li-ion batteries that are congured are present. In

case of a missing Li-ion battery, the BCI will go in alarm state and will control the contactors

to disconnect the Li-ion battery bank from the DC bus.

• Collecting information of all Li-ion batteries in the battery bank and presenting it as one Li-ion

battery on the CAN bus.

• Programmable power down on user adjustable Li-ion battery (bank) SoC level.

• Programmable Auto-On function.

• Up to sixteen Li-ion batteries can be connected to the BCI Master side CAN bus without

the need of external CAN power (Super B Li-ion batteries need power on their CANOpen

Interface).

• Up to 100 Li-ion batteries can be connected to the BCI with use of external CAN power.

• Drive a Pre-charge contactor to switch a capacitive load and prevent inrush currents.

• A mechanism that allows temporary reconnection of the Li-ion battery bank to the DC-bus in

an undervoltage situation.

• Logging function of diagnostics.

• Complete power down in case of an undervoltage of the Li-ion battery bank (I < 1 µA).

• The BCI has an open collector output/input for various additional applications.

• The BCI is a standalone device.

• The BCI must be congured using a CAN-USB (see Table 11) converter and the Be in Charge

software.

• Three status LEDs to indicate the status of the BCI and the Li-ion battery bank.

• Two power supply inputs

1. To power the BCI from an external supply or supply from the DC bus.

2. To power the BCI from the battery bank, this power input has a self-disconnect feature.

• Two CAN communication ports

1. The master port indicated by J1. This port is dedicated for the Li-ion batteries. The communication

protocol is CANopen.

2. The slave port indicated by J2. This port is to communicate with an external network. It can also

be used for other CAN protocols.

All the Li-ion battery (bank) values can be monitored on both ports. The Li-ion battery bank

can also be controlled by both ports. If the slave port (J2) is used for another protocol than

Be in charge. Super B.

CANopen, monitoring and control of the Li-ion battery bank using the Be in Charge software

can only be done on the master port (J1). Though controlling on both sides is possible,

changes are not forwarded to the other port. Hence, this is not advisable.

3.3. BCI functional behaviour

3.3.1. General

The BCI monitors all connected Li-ion batteries through the CAN bus. Whenever one or more

Li-ion batteries reports an alarm, or is missing on the bus, the BCI will drive the contactors to

disconnect the Li-ion battery (bank) from the DC bus to avoid misuse of the Li-ion battery or

to prevent an unsafe situation. The alarms from the Li-ion battery can differ with each battery

type. Because the alarm is indicated to the BCI as a general alarm, any Super B Li-ion battery

with CANopen communication can be used in combination with the BCI. For alarms detected

and signaled by the Li-ion battery consult the manual of the Li-ion battery.

3.3.2. Functionality of the power inputs

The BCI can be powered by an external power supply or, by the Li-ion battery bank. However,

when powered from the Li-ion battery bank, the maximum number of Li-ion batteries in series

is limited to four.

Caution! The BCI can only be powered by a Li-ion battery bank if the bank consist of 4 or less

Li-ion batteries in series.

The BCI has two supply and one GND/minus input, see chapter 4.5:

1. The battery supply input, J4 pin 9

2. The DC-bus / external supply input, J4 pin 10

3. GND/minus, J4 pin 1

The DC-bus / external supply input can be used if the Li-ion battery bank consists of more

than 4 Li-ion batteries in series or when the self-shutdown functionality is not used. In that

case the Li-ion battery supply input is not to be connected.

The Li-ion battery supply input has internal disconnect functionality to minimize self-

consumption in case of a shut down. If the Li-ion battery bank is drained and there is a risk of

damaging the Li-ion batteries, the BCI disconnects the Li-ion battery bank from the DC-bus

and shuts down itself to no longer drain the Li-ion batteries. Refer to Figure 2 and Figure 3

simplied connection diagrams, depicted with focus on how to supply the BCI.

Only when the BCI is powered from the Li-ion battery bank the self-shutdown functionality is

used. For this functionality, refer to chapter 5.6.

main relay ...

DC bus -

DC bus +

control

battery bank

battery

supply

input

(J4, pin9)

BCI

DC-bus / external

suppply input ( J4, pin10)

GND(J4, pin1)

Figure 2. BCI supplied by the Li-ion battery bank

main relay...

DC bus -

DC bus +

control

battery bank

externally

supplied

BCI

DC-bus / external

suppply input ( J4, pin10)

GND(J4, pin1)

Figure 3. BCI supplied by external power supply

Caution! If Li-ion battery banks with a setup depicted in gure 2 are put in parallel by

connecting the DC-bus, the self-shutdown functionality will only occur when all BCI’s power

is off. Until that happens the BCI will be fed by the DC-bus and is not able to self-shutdown.

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