Chapter 1 Introduction of EK-FT
Contents
1. f Fig 2 80 Back Interface of BCU BMU interface Interface for relay ower supply Interface for voltage detection Interface for temperature detection and CAN communication Figure 2 9 Front Interface of BMU 12 LDM interface Positive pole red Negative pole black Gao a RENS e Figure 2 10 Front Interface of LDM 20 13 User manual of EK FT 12 BMS 14 RS485 communication interface RS485 communication interface Figure 2 11 Back Interface of LDM m 5 7 LDC interface CS interface 21 15 User manual of EK FT 12 BMS 2 4 Wiring Diagram of System Figure 2 14 Schematic Diagram of Installation Note products of different models may have some difference in functions and settings The installation method of2. _ 100 E i 4 l M4 7 hs 9 2 al IE eL fay yp 1l Ros 165 43 0 User manual of EK FT 12 BMS amp 2 1 BCU Overall Dimension Battery monitor unit BMU 2 2 BMU Dimension mg insulation Detection Module LDM RI 2 30LDM Dimension m Display Screen LCD User manual of EK FT 12 BMS amp 2 40 Overall Dimension of 5 7 LCD B Current Sensor CS 10 User manual of EK FT 12 BMS B Heavy current Control Box Figure 2 6 Overall Dimension of Heavy current Control Box 2 3 Interface Description m BCU interface Internal interface S Ls card ccs am z Doo oo Ge Figure 2 7 Front Interface of BCU Communication and switching output interface 11 il User manual of EK FT 12 BMS 19 Interface for communication Interface for system power and switching output supply output and input Interface for weak voltage
3. 22 16 User manual of EK FT 12 BMS special connecting lines and adaptors will be provided by our company separately iring Description o B Connection of voltage detection wiring harness take 16 strings for example Bli connects with positive pole red line of first battery B1 B15 connect with negative pole black line of each battery in series successively B16 connects with negative pole green line of the last battery Positive pole of battery module Negative pole of battery module Figure 2 15 Schematic Diagram of Connection between Voltage Detection Wiring Harness and Battery El amp eal E EA Figure 2 16 Example Diagram of Connection between Voltage Detection Wiring Harness and Battery Caution the connection order of voltage detection wiring harness cannot be wrong Otherwise the voltage collection may be incorrect equalizing circuit may be burnt out and battery may be damaged m Fix temperature sensor onto battery pack Hi Figure 2 17 Example Diagram of Temperature Sensor Connection 17 User manual of EK FT 12 BMS Connect voltage detection cable harness and temperature detection cable to BMU Figure 2 18 Example Diagram for Connection of Voltage Detection Cable Harness and Temperature Detection Cable Connection of CAN Communication Cable CAN communication cable is the communication medium between BMU and BCM The system adopts 3 core shielding line to be commun
4. Model Selection Table of Power and Resistance of Heavy current Module Item Cod Detailed Parameters 00 SOW Powe 01 75W Model 02 100W 04 300W 01 500 Resistar ce 02 750 Model 03 1000 07 2400 1 9 Current Sensor CS m CS function The current of this system is detected with Hall open loop current sensor with optional range 50A 1000A Model Selection Table of CS 1000A Item Code Detailed Parameters 01 50A 02 100A Current 04 200A Type 05 300A 07 500A 1 10 Display Screen LCD m LDM function The display screen is human machine interface for displaying system operation status All its models are designed according to industrial standard and suitable for applying in various conditions The display interface of LCD can display all operation parameters and faults of system Status description of LCD The operation indicator of display screen includes three ones power supply PWR running RUN and communication COM When the display screen is powered on the power indicator PWR is normally on if the running indicator RUN is normally on in yellow it stands for normal running of display screen if the running indicator RUN is not on it means that the display screen has fault when the display screen has connected with BMS the communication indicator COM flashes in yellow User manual of EK FT 12 BMS Figure 1 3 Running Status Indicator e The following table shows the display st
5. manufacturer Maximum Set maximum allowed charging voltage of charger through CAN communication charging voltage Maximum Set maximum allowed charging current of charger through CAN communication charging current Over charge Set the maximum voltage threshold value that single cell battery can raise during charging Carry out protection over charge protection to battery and alarm when it is more than this value voltage Over charge Set to cancel the voltage threshold value of overcharge protection i e to cancel over charg protection protection and alarm when the maximum voltage of single cell battery drops to the value lower than release threshold value Under voltage Set threshold value of alarm for low voltage of battery single cell which is used to prompt low power alarm voltage of battery Under voltage Set to cancel the voltage threshold value of under voltage alarm i e to cancel under voltage alarm alarm release when the minimum voltage of single cell battery recovers to the value more than this parameter Over discharg Set the minimum voltage threshold that battery can drop to during discharging Carry out protection over discharge protection to battery when the voltage is lower than the value voltage Over discharg Set to cancel the parameter of battery over discharge protection i e to cancel battery over discharge protection protection when the minimum voltage of single cell battery recovers to the value m
6. 2x0 5 power line one end is MOLEX20PIN connector Charge relay cable assembly the other end is null 2x0 5 power line Pre charge relay one end is MOLEX20PIN con assembly the other end is null ector cable 2x0 5 power line Charge switching one end is MOLEX20PIN con assembly the other end is null ector signal cable 2x0 5 power line Discharge switching one end is MOLEX20PIN con assembly the other end is null ector signal cable 4x0 5 shielding line Connecting wire one end is MOLEX8PIN connector assembly current sensor the other end is 5569 2x2 ce terminal 4x0 5 shielding line USB communication one end is MOLEXS8PIN connector assembly the other end is USB interface lular cable 3x0 5 shielding line one end is MOLEX28PIN con cable between BC assembly the other end is AMPSPIN cellular connector assembly Communication ector and BMU 25 5x0 3 shielding line Screen one end is MOLEX28PIN connector assembly mmunication j communicatio the other end is DB9 terminal cellular cable and 2PIN plug 3x0 5 shielding line and 2 0 5 power cord LDM communication one end is MOLEX28PIN conmector assembly the other end is AMP6PIN pin type cable connector assembly Note 1 the cable length is determined through consultation between customer and our company 2 The type of charge and discharge cables is determined according to requirement of custom
7. Note all protection parameters in table can be configured User manual of EK FT 12 BMS 1 6 Battery monitor unit BMU BMU function BMU connects with battery pack through voltage detection wire collects voltage of 16 strings of battery cell at most and can equalize battery according to battery single cell voltage When the voltage of some single cell battery in battery box reaches to 2 8V and battery voltage difference is between 10mv 800mv the balance function will start automatically Each battery detection unit can switch on 2 channels of balance at the same time at most BMU collects box module temperature through 4 temperature sensors at most and can actively manage cooling and heating according to temperature status to ensure battery application capacity and prolong battery service life The working power supply of BMU has to be provided by the external 12V 9V 18V self adaption or 24V 18V 36V self adaption DC power source BMU transmits the collected battery voltage box temperature and other information to Battery cluster management unit through CAN bus Detection of single cell voltage realize the real time detection of each single cell voltage through isolated collection of series single cell voltage Temperature detection put 1 4 temperature sensors in box of battery module to realize the real time detection of box temperature CAN communication transmit the voltage box temperature and other information o
8. EK FT 12 Chapter 1 Introduction of EK FT 12 BMS 1 1 Product Structure With the distributed two level management system EK FT 12 electric vehicle BMS hereinafter called EK FT 12 system is composed of Battery cluster management unit BCU and multiple Battery monitor unit BMU display screen LCD insulation detection module LDM heavy current control system HCS current sensor CS and wiring harness 1 2 System Configuration Battery string Control Unet BCU pay Screen LCD Current Service gt r pa Heavy current Corral Module GAC Battery Monitor Unit BMU insulation Detection Module LOM Figure 1 2 System Configuration 1 3 Brief Introduction of Function In EK FT 12 system BCU module carries out real time communications with multiple BMU modules and LDM insulation detection module through CAN bus to gain system parameters such as single cell voltage box temperature and insulation User manual of EK FT 12 BMS resistance and so on collects charging and discharging current through current sensor calculates SOC dynamically and displays related data through touch screen BCU manages system after gaining comprehensive information of battery pack through calculation and analysis respectively interacts with ECU motor controller and charger and so on intelligently through independently CAN bus andcan realize the secondary protection of charging and discharging through relay control to meet diversi
9. Example Diagram for Connection of LCD and BCU take 5 7 one for example A Caution 1 the communication cable interface DB9 connector of LCD connects to COM1 communication interface of LCD If it is connected to COM2 interface the LCD communication will be interrupted 2 The connection of positive and negative poles of LCD power cannot be reversed Otherwise LCD will be burnt out 3 LCD is powered by DC24V The positive pole connects with 24V and negative one with 24V 2 9 Installation Conditions and Requirements Avoid installing the system under the condition with oil mist metallic dust and much dust 22 9 9 9 User manual of EK FT 12 BMS Avoid installing the system under the condition with harmful gas and fluid or corrosive flammable and explosive gas Reserve appropriate installation dimensions Cable installation shall be kept away from sharp objects Try best to keep away from conditions with strong electromagnetic interference Parameters of all parts related to his system shall be confirmed by our company 23 Chapter 3 Wiring of System 3 1 Type of Cable RE eee 1 099 ne eee eee 0 5 high temperature wire one end is MOLEX28PIN connector Voltage detection assembly Size of cold pressed terminal is cable the other end is 1 5 8 cold pressed 9 GURRhAGREAM ARMS actual terminal 2x0 5 high temperature wire Temperature one end is MOLEX28PIN connectar detection cable assembly the oth
10. ND Figure 2 25 Example Diagram for Connection of CAN Communication Cable Caution 1 Confirm that the connection of H and L of CAN bus is correct Otherwise CAN bus cannot communicate with other devices 2 Confirm that the matched resistance of CAN bus is correct Otherwise CAN bus cannot communicate with other 26 20 User manual of EK FT 12 BMS devices B Connect the power supply cord of BCU red line connects with positive pole of power supply and black one with negative pole Figure 2 26 Example Diagram for Connection of BCU Power Cord 2 Wiring Description of LDM Connect communication cables between LDM and BCU Figure 2 27 Example Diagram for Connection of Communication Cables between LDM and BCU Connect LDM to the master positive pole and master negative pole of battery pack and make LDM shell contact with vehicle body and keep well conducting between them LDM shell grounded s 7 21 User manual of EK FT 12 BMS Figure 2 27 Example Diagram for Connection of Communication Cables between LDM and battery positive and negative terminals Caution LDM shell must well contact with vehicle body Otherwise functions of LDM will be invalid Dangerous it is necessary to wear insulation gloves when connecting positive negative pole wire of detection Otherwise electric shock may be caused 2 8 Wiring Description of LCD m Wiring description of display screen Figure 2 29
11. Single Cell Informatio The system will enter the corresponding interface after clicking Single Cell Information as shown in the following figure 4 5 Hattery Management System TES Voltage value of module 1 Temperature value of module 1 Page down Voltage value of module 2 Temperature value of module 2 Figure 4 5 Single Cell Information Remarks above figure gives the corresponding information of modules 1 and 2 Each module includes the information of 16 single cell voltages and 3 module temperatures 4 5 f Display of Charger Information The system enters into corresponding charger interface after clicking Charger 34 Battery Management Figure 4 6 Charger Information Remarks the interface displays some information of charger Receive the corresponding messages of charger through CAN communication and display them on the touch screen B Explanation of parameters Online status communication status of charger it displays online when charger is communicating with BMS otherwise it is offline the default status is offline Starting status indicate whether the charger has started to charge it indicates starting after starting to charge otherwise it is stopping the default status is normal Hardware fault malfunction of charger itself default to normal Input voltage indicate the status of charger input voltage default to normal Temperature status indicate the temperature status of
12. and discharging status over charge alarm prompt under charge alarm prompt over discharge alarm prompt over temperature alarm prompt and insulativity alarm prompt etc rade la no control measures are taken e Single cell voltage lt 3 0V e 1000 Vs insulativity x5000 V rade alarm prompted alarm intormation appears on bumming disconnect charging and discharging circuits e Single cell voltage lt 2 5V or single cell voltage 23 9V delay 5 309 Box temperature 275 C e Insulativity lt 1000 V a Display Alarm charger and the current value gradually decreases according to smooth curve e When the cell voltage of single battery 23 9V disconnect charger output Charging delay control mode When the cell voltage of single battery lt 3 4V charger can be used again for continue charging e When the box temperature 275 C charger is abnormal or charging circuit is disconnected Use CAN and high voltage relay to control when cell voltage of single battery lt 3 0V communicate with motor controller by CAN communication to reduce motor output power Discharging When the cell voltage of single battery lt 2 5V disconnect motor power output after 5 control 10S delay e When single core voltage gt 2 6 V festival the motor controller can continue to output power When battery box temperature 275 C disconnect discharging circuit
13. ation files or fill in the data need configuration and selected in front of the check box then click setting S 44 L mar i A m MAFFE ae ERE Me MEE iE mna peris x a Lt ee ae L T aren Fig 5 11 Parameter setting interface You can also click Getting parameter G to get all the parameters of BMU and adjust according to requirement When batch configuration click Save parameters A to create files like BMU 03 2011 09 01 02 44 Igpara Then load again After finishing the configuration click Getting parameter G or back to BMU parameter clicking Read R to check the modified parameter After finishing the configuration click Exit E to back to main interface Click Getting G to get the parameters of BMU Select automatic acquisition then setting the interval time click Getting G again you could periodically obtain information from BMU B 5 12 Upper computer software configuration display interface 2 45 5 3 LDM Upper Computer Leakage detecting module can be independently testing by upper computer Procedure is as follows Step 1 Positive and negative of LDM respectively connect the battery total positive and negative Step 2 Connect LDM and PC through USB RS485 adapter Step 3 Power supply for LDM is DC12V or DC24V Y VV Y Step 4 Open upper computer software fig 5 13 Initialize setting m H slect COM1 free configuration according to the
14. atus of three LED indicators under various conditions Equipment Status Green LED PWR Yellow LED RUN Yellow LED COM No power supply Oo O Oo e e e Power on no 3 9 screen communication 5 7 screen e Communicate with connected j e o xX equipment o LED off e LED on X Flash B Display description of LCD The integrated interface information of display screen is as shown in the figure below Display alarm information Displa i MIRA Display SOC Display Display voltage temperature Figure 1 4 Figure of LCD Display Interface m Model Selection Table of LCD Item Cod Detailed Parameters Display screen 02 Display screen 5 7 Chapter 2 Installation of System 2 1 Installation Dimension and Weight of Product Overall and Installation Dimensions unit mm Weight Product Type W H D wil m bi d KG BCU 165 106 43 100 50 4 0 6 User manual of EK FT 12 BMS BMU 124 91 40 100 40 M4 0 48 LDM 165 120 25 105 5 85 15 4 5 1 05 HCS 260 240 100 130 225 26 6 96 81 47 90 15 o 4 0 186 LCD 17 140 40 160 6 130 5 6 4 0 5 Note W H and D are dimensions of external structure W1 H1 and D1 are installation dimensions of internal structure d is width of mounting hole 2 2 chematic Diagram of Overall Dimensions m Battery cluster management unit BCU
15. charger default to normal Output current indicate present charging current of charger 9 9 gt 9 Output current indicate present charging voltage of charger 4 6 Display of Battery Statistical Information The information is mainly used for analysis of battery performance and application status Step 1 change user information to senior user gt Step2 click Battery Information Step 3 click Statistical Information 35 Battery Management System 4 7 Configuration Interface In order to evaluate all parameters of battery accurately it is necessary to re configure BMS before its initial running The configurable content includes total capacity of battery pack nominal capacity current surplus capacity of battery pack maximum charging voltage maximum charging current over charge voltage of single cell battery over charge release voltage of single cell battery under voltage protection voltage of single cell battery under voltage release voltage of single cell battery over discharge protection voltage of single cell battery over discharge release voltage of single cell battery over temperature protection temperature and over temperature release temperature gt gt Steps of parameter configuration Step 1 change user information to senior user Step 2 click Configure Information of main interface The system displays a configuration interface as shown in figure 4 7 1 St
16. code control command and other information X Alarm and protection when there is fault as over charge over discharge and so on BCU can perform the corresponding alarm and protection according to fault status and display it on LCD screen User manual of EK FT 12 BMS System expanding BCU supports multiple channels of active passive node output and can realize two level control management through CAN communication and relay to ensure effective isolation of strong and weak current and meet diversified safety control demands of customers Data storage support 8G data storage capacity and can record all performance parameters of long term operation of power battery pack and dispatching and fault events of battery module System self check the system checks itself and BMU working status after power on to ensure normal working of system Remote management BCU is equipped with wireless communication interface which can realize four remote function through external DTU module System upgrade program downloading interface is installed externally which can be used to upgrade system within 30 seconds Parameters of BCU module Item Performance orking voltage DC 12V 24V urrent detection rang 00 Optional urren detection 1956 accuracy Iror o estimation 9 otal voltage total current maximum and minimum voltages and serial numbers voltage of single battery box temperature charging
17. ction 3 Surplus capacity lt total capacity Recover configuration parameters to default value gt Stepi click the button Restore Default The dialog box to inquire whether confirm the restoration pops up gt Step 2 Click OK in the popped up dialog box Then the configuration information restores to default value gt Step 3 click Write in to write default value into BMS 37 Chapter 5 Application of Upper Computer Software 5 1 BCU data show Upper Computer Software 5 1 1 Function of Upper Computer Software Communication with BCU through designated model CAN USB converter Analyze the data information transmitted by all modules and then display voltage temperature and configuration value and so on Configure information for each module through upper computer Can request data automatically 5 1 2 Software Installation System requirement all systems above WinXP Vista or Win 7 is better X Software running operate EXE file directly 5 1 3 Application of BCU Upper Computer BCU can be tested and configured independently through using upper computer software 1 Main interface ONES ME SF e Setter t Pant CAN e Uu CAN indes CAN mamie Fig 5 1 System Login Form Choose applicable communication optional according to communication protocol between BMS and upper computer 38 software Default value of equipment index number is O appointed CAN USB converter Defa
18. ep 3 click Read to read the default configuration parameters of host The system doesn t support automatic reading of configuration parameter Therefore it is required to click Read after entering the configuration interface Step 4 click the corresponding parameter column to modify the corresponding parameter Step 5 Click Write in to enter the password 8888 Configuration parameters are related to the running status of system Therefore they cannot be altered at will After clicking if you didn t operate step 3 previously the dialog box for reading will pop up If you have operated step 3 system will pop up a dialog box for write in confirmation The configuration parameter can be read before writing in Step 6 When writing into the dialog box click Write in and wait for 5 seconds around It means that the setting operation has been finished when the COM indicator light flashes normally If the indicator displays abnormally you can click Write in again and then click Return 36 Battery Management System onha Read Return configuration to main information menu from BMS ar sali Figure 4 8 Configuration Information Remarks the relationship between configuration parari Se Blagg valle 1 over charge voltage gt over charge release gt under voltage release gt under voltage voltage gt over discharge release gt over discharge protection 2 Over temperature release lt over temperature prote
19. er end is temperdture sensor 2x0 5 power line Heating relay control one end is MOLEX16PIN conrector assembly the other end is null 2x0 5 power line Refrigeration rela one end is MOLEX16PIN connector assembly control line the other end is null power line one end is MOLEX16PIN connecto BMU power line 1 Power supply into BMU assembly the other end is3PINAMP pin type connector assembly g i Communication one end is MOLEX16PIN connector assembly cable among the other end is AMP3PIN connectbrcommunication among BMUs modules assembly cellular type and pin type 6x1 0 high temperature wire 2x0 5 i AMP cellular connector assembly is qqual power line to the number of BMU quantity Main line BMU power line 2 one end is 30A connection assembly the other end is AMP2PIN cellular connect with several AMP2PIN cellular connector connector assembly 2x0 5 power line one end is MOLEX12PIN connector Power line assembly the other end is null 24 2x0 5 power line one end is MOLEX12PIN connector assembly the other end is null Discharge relay cable 2x0 5 power line one end is MOLEX12PIN connector Input signal cable assembly the other end is null 3 0 5 shielding line CAN cable of whole one end is MOLEX20PIN con assembly the other end is null ector 3 0 5 shielding line one end is MOLEX20PIN con Charge CAN cable assembly ector the other end is null
20. erature Configuration according to the xi dn situation Maximum temperature Factory configuration is25 C ie Minimum temperature Factory configuration is 25 C Releasevalue3000mV Oftempeatue49C mE Sta ingvotage 2800mV fi Battery balancing Starting differential pressure t0mV S Overtemperature 600 Disable maximum differential pressure 800mV Fig5 7 Upper computer software configuration display interface 3 43 2 Configuration parameters method Operation PC software Enter the PC connection interface 1 connect USB CAN translator PBLOERL ie ewe La co m H on LIGOO E gr TE EER 2 oF ome SEPA GC eA aes st i Fig 5 8 PC connection interface 1 Click Connect C to enter equipment connection interface 2 Fig 5 9 Select the corresponding device number the channel number and baud rate click connection O LI bh gau Eau a WE gi Fig 5 9 Equipment connection interface 2 After entering the equipment connection interface3 slect FT BMU S to enter PC configuration display interface EE LIGOO Boii STE eR EAER rx EPEOcEBNEASSTER S l TT Em aB bu sim idum e Fig5 10 Upper computer software connection interface 3 Parameter setting Click Parameter setting O enter parameter settings interface slect BMU setting click Loading parameters L to lead parameters configur
21. ere the improvement of is any damage It is necessary to cut off power supply before replacement component service life Check whether any connector assembly is loose If yes please fix it Check whether any cable is worn If yes replace it in time Check the communication between BCU and BMU If the communication is abnormal please check it by yourself according to appendix If the problem still cannot be solved please contact technical support center of our company in time Check module collection accuracy mainly refer to voltage accuracy and temperature accuracy It is Regula necessary to check whether the voltage is within normal range with special instrument when measuring maintenance voltage Also use special instrument to detect whether the battery temperature is consistent with the value displaying on console Please check it by yourself according to appendix if there is any abnormality If the problem still cannot be solved please contact technical support center of our company in time Regularly check whether LCD display is normal Please check it by yourself according to appendix if there is any abnormality If the problem still cannot be solved please contact technical support center of our company in time Regularly check whether any module is loose If yes please tighten it in time 49
22. ers 3 For wiring mode please refer to instructions for system installation 4 If special cables are needed please contact technical support center of our company 5 n the above listed cable type based on standard system according to the demand of customer and system application different occasions will different with objects 3 2 Diagram of Cables m Following pictures show common cables produced by our company Diagram Name Applicatio Interface Connect battery an BMU detect voltage detection cable information of battery Control external Heating relay control line equipment 23 26 Refrigeration Control external Communicatio Communication AARRAMONG ByATONG al Connection BMU power external power supply and BMU Power cord9upply power red black for BCU vehicle CAN controller co 27 Charge CAN Connect charger Charge relay control cables of charge relay and BCU Connect Pre charge control cables relay cable of pre charge relay and BCU Output charge to motor controller or others Current senso cable _ Download communication saved data BMU and BCU Communication communication cables be BMU and BGU 28 Communication Insulation communicatio cable power cord 3 3 Cable Quantity In the following table a set of EK FT 12 system is take
23. f each single cell in battery pack to BCU through CAN bus Balance function balance management can be performed to battery cell according to agreed balance management control strategy to improve the consistency of single battery cell and application performance of battery pack Heat management BMU can manage the cooling and heating status of battery actively according to battery box temperature to ensure battery application capacity and prolong battery service life System upgrade program downloading interface is installed externally which can be used to upgrade system within 30 seconds Parameters of BMU module Item Parameter Remarks aximum quantity of collection string 16 strings Working voltage DC9V 32V oltage collection range 07 5V onection accuracy of single cell voltage siomV collection ang 40 125 C detection acna y stc 30 75 C interface CAN ets 200ms 16S PERTON b 1 2A Peak value 5A User manual of EK FT 12 BMS 1 7 Insulation Detection Module LDM LDM function LDM is used to detect whether the battery pack has electricity leakage on vehicle body LDM receives the command from BCU through serial bus and transmits the detected data information to BCU which then will deliver LDM status to display screen Method to judge whether the battery leaks electricity onto vehicle body respectively detect whether the insulativity between positive negative pole of vehicle mounted battery and body shell is more t
24. fied safety control demands of customers ensuring stable and effective operation of system 1 4 Technical Specifications Type Specification Remarks Voltage collection range Nd Voltage collectipn 45mV accuracy i Accuracy of total lt 0 29 voltage ret Current collection ET accuracy lt 00A current sensor Error of SO 59 estimation nous Temperature collection 41 C 30 75 C accuracy Temperature collection E range 40 125 C Balance current gt 1A normal temperature 2 channels of balance can be switched on at the same time Power consumption of p AET BMU operation lt 1W One BMU module 4 FFA Power consumption of lt 2 8W BCU operation Working input voltae DC 12 24V System operating mn Storage temperature 40 85 C Weight BCU 480 5g BMU 640 5g One module CAN communication a Charging control mode active passive output Depend on actual conditions Discharging control CAN communicati Merenda oniinn mode active passive output PEVA AA EES 1 5 Battery cluster management unit BCU m BCU function SOC estimation use Joint EKF algorithm to estimate SOC of battery pack dynamically Current detection carry out real time detection of current in charging and discharging circuits through Hall current sensor Communication function externally installed 3 CAN interfaces which can be used to communicate with BMU complete vehicle controller and charger and so on to exchange voltage temperature fault
25. han 100Q V Insulativity System Status Display Screen Insulativity21000 V Normal system display No icon Total pressure testing System alarm Bus abnormal abnormalities Insulativitys1000 V System alarm Il Display insulation leakage Red system cuts off circuit 1 8 Heavy current Control System HCS Heavy current control system includes heavy current control module charging and discharging control circuits and pre charge circuit etc m HCS function Charge and discharge control charging discharging of battery is controlled through switching on off high voltage relay to prevent over charge and over discharge of battery besides the function of relay contact detection is also equipped to prevent sticky point of relay in circuit Pre charge circuit before switching on the discharging high voltage relay of main circuit it is necessary to switch on the pre charge circuit firstly to charge capacitance Then switch on the high voltage relay of main circuit when the voltage at both terminals of capacitance has reached to setting threshold value to ensure the reliability of high voltage relay of main circuit CAN and RS485 communication use CAN or RS485 bus to communicate with BCU upload relay status and other information and receive the control command from BCU m Table of Relay Model Selection Item Code Detailed Parameters 01 EV200AAANA 02 400V 10A E 1 400V 80A 04 400V 120A User manual of EK FT 12 BMS
26. ication cable MOLEX12pin connector assembly and AMP 6PIN automobile connector cellular type and pin type are used for joint The BMU farthest away from BCU connects to No 2 line and others connect to No 1 line Figure 2 19 Example Diagram for Connection of Communication cables among BMUs Connect the BCU power line red line to connect power positive black line across the connect power Figure 2 20 Example Diagram for Connection of BMU power line User manual of EK FT 12 BMS 18 User manual of EK FT 12 BMS 2 6 Wiring Description of BCU Connect communication cable s between BCU and BMU Connect current sensor The current sensor is strung onto the circuit cable of output positive negative pole of battery pack and has two kinds of wiring modes as shown in the figure below pay attention to the arrow on current sensor Figure 2 22 Schematic Diagram for Connection of Current Sensor Installation Connection method 1 onnection method 2 19 User manual of EK FT 12 BMS Figure 2 22 Example Diagram for Connection of Current Sensor Connectthe control cable of charge discharge relay red line connects with positive pole of relay coil and black one with negative pole of relay coil Figure 2 24 Example Diagram for Connection of Relay Control Cable B Connect CAN communication cables of charger and complete vehicle system motor controller For 3 core shielding line red is H yellow is L and black is G
27. lease refer to LCD introduction part 47 6 2 Procedure of Fault Diagnosis Start system NO Use normall Troubreshoot according to NO Consult technical 6 1 List of Fault and Alarm Information and check whether it is includgg in the uu support center 400 0551 B06 FintNagossible cause and Consult technical solutions according to the the system haddBl amp og gr check whet to normal a support center ef adjustment Fault reset check whether support center Consult technicalthe fault has been eliminated q End Chapter 7 Daily Maintenance Factors as service environment such as temperature humidity dust and interference and so on aging and abrasion of internal components and so on will increase the fault occurrence rate of system It is necessary to carry out daily maintenance to decrease fault occurrence rate and prolong system service life 48 Caution e Only trained professional operators can disassemble and replace the internal components litis necessary to switch off the power supply before checking and maintaining e Prevent metal or other matters being left in system Otherwise system may be short circuited and damage e n order to improve the function realization and prolong the service life of system it is necessary to keep good installation environment Generally it is required to avoid direct high light for long time or other
28. n for example to explain cable quantity required by product One of products takes one BCU and N 316 BMUs for example to explain the quantity of each cable as shown in the table below Quantity of each set of voltage detect cable is equal to that of Voltage detection cable There are 3 temperature sensors on each set of cable Temperature detection Heating relay control Set N Optional Refrigeration rela Optional Communication cable m Communication cables among BMUs Each system of BMU corresponding a connection of th BMU power line 2 BMU and BCU Connecting wire o Pcs 29 cable Discharge switching The corresponding discharge mode and harness correspanding Discharge CAN cable to one cable are selected by customers Discharge relay cable 1 Pcs Charge relay cabl Charge CAN cable to one cable are selected by customers Charge switching cable 1 Pcs Pre charge relay cable 1 Pcs Optional USB communication Pcs Optional cable Input signal cable 1 Pcs Optional Insulation Pcs Optional communication cable 30 Chapter 4 LCD Application and Parameter Setting 4 1 Explanation of Parameters Capacity of battery pack after being fully charged Usually it is initially configured to nominal capacity Total capacity of battery pack Currently surplus ampere hours of battery pack It is set according to parameters provided by battery Surplus capacity
29. ommunication interrupted 3 Check communication interface Femperature difference e Stop charging anddischaraing anc restart Buzzer alarms But LCD temperature detection point is joo after temperature recovery 3 K has no fault display 2 sof s aw manele battery or correct configuration multiple batteries or two consecutive batteries 7 Voltage display of partial collection cable for the corresponding Check and reconnect voltage collection caple batteries is abnormal battery urrent displays positive when discharging and Incorrect installation direction of Change the direction and re install curren 8 l displays negative when current sensor sensor charging ted 9 No current display Incorrect connection of current sensorin good stations 10 when system is static Current digital calibration is not set parameters i H Heck whetherthe curret GTTSOTF T original B when system is operated Incorrect matching of current sensor or geraten of system TE NOS as SUDDITed power 12 LCD doesn t work No power supply voltage 2 Check whether the ped cord between host p FEM 9 and wk connect d correctly 1 maximum current of Maximum charging current is set too h Reset parameter of maximum charging X charger low 14 or over discharge Incorrect parameter setting Reset parameter SD card cannot write in SD card write in is protected Switch off SD card write in protection Remark for detailed fault icons of LCD p
30. ord it will display like following picture 41 Pari cl E new 5 2 1 Functio er Com uten Softw re 5 2 Kiinction TERY EON ion Upper Computer software Communicate with BMU BCU data storage module and leakage detecting module Analysis data from modules shown the voltage temperature and configuration value etc Configure information for BMU module through upper computer 9 9 Can request data automatically 5 2 2 Software Installation System requirement all systems above Win98 X Software running operate EXE file directly 5 2 3 Application of Upper Computer BMU can be tested and configured independently through using upper computer software 1 Main interface 42 Fig 5 6 Main interface of BMU configuration parameters BMU configuration the default configuration parameters in the list below Configuration according to the practical S 1 BMU address Scope 1 255 Configuration according to the practical situatior s Ad Scope 1 16 strings 3 Voltage calibration Configuration according to the practical situation value Scope 5000 5000mV Protection value 60 C Release value 40 C BE var charming vollade Protection value 3850mV di g Release value 3400mV Protection value 2600mV 6 Over discharge voltage J g Release value 2800mV Starting temperature Configuration according to the 7 Heating control practical situation Off temp
31. ore than this release parameter Over temperat Set allowed maximum operating temperature of battery pack Carry out battery over temperature protection protection and alarm when the temperature is higher than the value temperature Over temperature Set the temperature threshold of over temperature alarm release i e to cancel over temperature protection protection and alarm when the maximum temperature of battery drops to the value lower than the release threshold 31 42 Main interface of LOD Display alarm information Display current Display SOC Display Display voltage temperature Figure 4 1 Main Interface of Terminal User Remarks It displays in gray when alarm information is normal it displays in red and flashes when there is alarm 2 For advanced user Display alarm information Display SOC Display current Display Display voltage temperature Figure 4 2 Main Interface of Senior User sat tary Statistical Fits 188 Charger Remarks at this moment click battery information to pop up the window Compared with terminal user interface statistical information and configuration information are newly increased in senior user interface 32 4 3 User Permission The touch screen has the function to set user permission The terminal user can only browse general information For senior user statistical information and configuration information of battery are increased When the touch screen is powered on
32. radiation and prevent water other Service environment Check input voltage and input current with voltmeter and ampere meter to see whether they are within normal range You can refer to description of system parameters The output voltage and output current also can be checked with voltmeter and ampere meter to see whether they are within rated range It is Daily maintenance BCU and BMU modules possible to perform intuitive judgment through touching smelling and visual e t is necessary to clean LCD frequently to keep it clean Don t crash or abrade it Otherwise the sight line will be interfered which will cause incorrect judgment Different components have different service e Wires of various plugs e g air plug PIN connector and serial port easily fall off life The service life of from their welding spot causing open circuit Please replace them in time if there components is is any damage It is necessary to cut off power supply before replacement Component influenced by e DC DC is easily short circuited or damaged under high voltage Please replace it replacement environment and in time if there is any damage It is necessary to cut off power supply before application conditions replacement Keeping good operating Various wires are easily of short circuit or open circuit due to vehicle vibration environment is good for aging or falling off of plug from welding point Please replace them in time if th
33. the default user is terminal user B Steps for modification of user permission gt Step 1 click Menu to pop up the window as shown in figure 4 3 1 gt Step 2 click User Information to pop up the window as shown in figure 4 3 2 gt Step 3 click Modify and enter password to change user name If the entered password is 1111 the user is terminal user If the entered password is 5555 the user is senior user Step 4 click Return The main interface can alter automatically according to user name lleer TOR beens Figure 4 4 User Information 4 3 User Permission The touch screen has the function to set user permission The terminal user can only browse general information For senior user statistical information and configuration information of battery are increased When the touch screen is powered on the default user is terminal user B Steps for modification of user permission gt Step 1 click Menu to pop up the window as shown in figure 4 3 1 gt Step 2 click User Information to pop up the window as shown in figure 4 3 2 gt Step 3 click Modify and enter password to change user name If the entered password is 1111 the user is terminal user If the entered password is 5555 the user is senior user gt Step 4 click Return The main interface can alter automatically according to user name 33 Iser informatica rj que 4 4 User Information 4 4 Display of Battery
34. ult value of CAN channel is O appointed CAN USB converter Choose suitable CAN Baud rate according to communication protocol between BMS and upper computer software Choose the language 9999 Click Yes and enter BCU interface after connecting with BMS Remark It will show following information if BMS and upper computer software is not connected 2 BCU Interface 39 LIGOO J MS RE Ss EA Thege tocherg mbon nyvterm ctwatarcs Madibtiati bespot slate Maarama betje atis n mm Marire wage Meh eben UE s Momm wm mage Moaute Marber tre amm am T Wareng ieto Fig 5 3 BCU Interface BCU interface will display the systems working condition information 3 BMU Interface Fig 5 4 BMU Interface 40 BMU interface will display the collection voltage and temperature information of each module 4 Configuration Information Interface r LUIGO soo ew MEME EN UM Fig 5 5 Configuration Information Interface Enter configuration information interface and click Read it will display each parameter of system Input parameter if need any modification Click Configuration and enter password default password is 8888 then press Enter to confirm refer to following picture System will display the information of configuration success or configuration failure Darky dece pei is Corfaysralurr Ipher Remark If entering wrong passw
35. upper machine interface RFR ic F4 9600 PIAL zik None AL XepE S SEEN ART A ARA R O ia EGLI Fig 5 13 Initialize setting gt Step 5 After connecting the power line click read to read the display value Fig 5 14 Parameters to check Insulation monitoring the condition of normal detection e Positive insulation resistance 1MO Negative insulation resistance gt 1MQ Total voltage effective when above 100V Fault code 00 means normal operation 01 means offline state 02 means leakage state Working code 00 46 Chapter 6 Fault Diagnosis 6 1 List of Fault and Alarm Information EK FT 1 BMS has perfect management functions which can prolong the service life of battery Some fault tips may appear during application Please carry out analysis judge causes and eliminate fault according to the following table If system damaged or meet problems that cannot be solved please contact the technical support center 400 0551 306 of our company to obtain solutions ib Fault Description Possible Cause Solutions jr in 1 working voltage incorrect ROT ERAN range System doesn t work 2 no power supply 2 Supply power for system 3 DC power supply damaged 3 Maintained by professional technicist 1 Over charge over discharge or protection 2 Buzzer alarms and LCD under voltage 2 Disconnect charger or stop supplying power displays fault 2 over temperature for battery 3 c
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