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1. fan f Full Syntax lt addr gt fan lt level gt Minimum Syntax lt addr gt f lt level gt Broadcast Command Yes Example Command 1f 4 Reply 01F 4 fan will force a minimum fan level Normally the fan is only controlled by the temperature The lt level gt must be 0 to 9 A fan lt level gt of 1 or more will force the fan to run Fan lt level gt 0 is the default automatic mode controlled by the temperature 21 gethighv g Full Syntax lt addr gt gethighv Minimum Syntax lt addr gt g Broadcast Command No Example Command 01g Reply 01G 3 792V gethighv gives the high voltage set point There is only one high set point per regulator so all bus addresses on one regulator will give the same response hmaclear hma Full Syntax lt addr gt hmaclear Minimum Syntax lt addr gt hm Broadcast Command Yes Example Command 1hma Reply hmaclear will clear the history for the maximum sensed voltage for the given bus address hmiclear hmi Full Syntax lt addr gt hmiclear Minimum Syntax lt addr gt hmi Broadcast Command Yes Example Command 1hmi Reply hmiclear will clear the history for the minimum sensed voltage for the given bus address hstclear h Full Syntax lt addr gt hstclear Minimum Syntax lt addr gt h Broadcast Command Yes Example Command 1h Reply hstclear will clear the history for the minimum and maximum sensed voltages for the give2. Approximate dimensions are 2 37 in x 7 in x 0 938 inches 60mm x 175mm x 23mm The Mk3x8 name signifies Mark 3 edition BMS digital with 8 channels for 8 cells All Mk3x8 systems are calibrated and fully tested before leaving Manzanita Micro MARK 3X8 DIGITAL LITHIUM ION BMS KEY FEATURES Real time voltage monitoring of 4 to 8 lithium cells Real time temperature sensing of up to 8 external temp sensors Additional temperature sensor included on BMS module s heat sink Small size is less than 1 inch thick and 7 inches long by 2 4 inches wide Quick automatic cell equalization and balancing with high and low voltage on board indicators and outputs to the charger Two high speed real time warning lines which can be relay buffered for external use All BMS modules connect together using readily available RJ cable BMS easily connects to a PC using the included USB adapter Includes free Windows based scanner and command software All commands are easily entered and read in simple ASCII text Easy user adjustable min and max voltage parameters allow flexibility for various types of lithium cells from 1 75 to 5 5 volts per cell Each BMS board can bypass up to 2 5 amps per cell channel 20A total equating to fast charging and equalization of unbalanced cells Dual RJ reg bus ports for easy connection to the charger or other BMS units in a simple daisy chain fashion Self regulating thermal protection and feedback to Manzanita Micro Charger
3. Mk3x8 circuit boards attached to each group of 8 cells These boards are able to sense the voltage across the cell and turn on a bypass resistor to bypass current around the cell instead of going through it Each of the 8 circuits has a blink feature that changes duty cycle in response to the needs of the individual cell allowing the user to see what is happening When using the regulators in conjunction with an appropriate charger it is possible to charge and equalize the batteries very quickly without worrying about damaging them Fast full charges coupled with individual cell equalization means less down time more range per charge better battery health and longer lifespan The digital communication bus allows detailed continuously updating graphical battery and BMS data display using the Manzanita Micro Mk3 Reg Scanner Software Additionally anyone with a PC a USB port and the included software can view text based important battery and regulator information This information includes up to 8 individual cell voltages or the total block voltage for that unit using Querytot command individual cell temperatures with up to 8 user installed temp sensors regulator internal heatsink temperature and other information The rest of this manual details these features as well as how to change settings Dimensions and Specifications END VIEW FRONT VIEW The Mk3x8 Digital Lithium BMS units weigh in at approximately 3 6 ounces 102 grams
4. addr gt This command is handy for visually locating regs as it will make the unit s lights flash Broadcast Command Yes but only supported on a single regulator system NOTE Only use this command to talk to one individual regulator at a time Do not use as a broadcast command ie 99 if there is more than one Mk3x8 regulator in the system Additionally do not use this command if there are any Mk3x4 four 20 channel regulators in the system Example Command 1 Reply Rudman MK3x8 Regulator V0 17 Unit 01 08 S N 00001 commandl changead disable enable fan gethighv hstclear hmaclear hmiclear lights minvolts maxvolts querytot readlowv status sethigh setlow setover temperat tempwarm temphot tempoff voltage xtrntemp command lists the valid commands the version number bus address range and serial number Although commandl is a broadcast command it will generate garbage data on a system with more than one regulator The lt addr gt is not used in the command but serves to ensure only one regulator responds disable d Full Syntax lt addr gt disable Minimum Syntax lt addr gt d Broadcast Command Yes Example Command 1d Reply 01Disable This command disables the BMS unit s ability to shunt enable e Full Syntax lt addr gt enable Minimum Syntax lt addr gt e Broadcast Command Yes Example Command 1e Reply 01Enable This command enables the BMS unit s ability to shunt
5. address as two hexadecimal digits Bit First digit Meaning 0x80 89ABCDEF The shunt is disabled 0x40 4567CDEF The shunt is enabled and the bus address is above the high voltage set point 0x20 2367ABEF The bus address is below the low voltage set point 0x10 13579BDF The bus address is above the high voltage set point Also bit 0x08 which is a second digit of 8 means the bus address has been below the low voltage set point temperat t Full Syntax lt addr gt temperat Minimum Syntax lt addr gt t Broadcast Command No Example Command t Reply 01T 064F temperat gives the current temperature of the heat sink There is only one heat sink temperature per regulator so all bus addresses on one regulator will give the same response 25 temphot temph Full Syntax lt addr gt temphot lt temp gt Minimum Syntax lt addr gt temph lt temp gt Broadcast Command Yes Example Command 1temph 151 Reply 01TH 151F temphot sets the temperature that runs the fan at full speed The fan speed scales up from tempwarm to temphot lt temp gt must be from 32 to 181 and between tempwarm and tempoff tempoff tempo Full Syntax lt addr gt tempoff lt temp gt Minimum Syntax lt addr gt tempo lt temp gt Broadcast Command Yes Example Command 1tempo 171 Reply 01TO 171F tempoff sets the temperature that forces the regulator off lt temp gt must be from 32 to 181 and greater than temphot tempwarm te
6. sensors Manzanita Micro recommends using 22 guage stranded hookup wire Be sure to check that each wire goes into the 16 pin Molex connector exactly as shown in the photo in figure 04 Crimp the Molex end pins onto the wires and insert them into the connector plug until they latch Each pair should be placed exactly like the photo so that there are 8 vertical rows In order to easily distinguish the sensors from each other it is recommended to use pairs of similar colors Solder a wire to each temperature sensor lead and cover the exposed joint with heat shrink The temperature sensors are not polarity sensitive so it does not matter which side the the wires go to The temp sensors are Xicon thermistors These are available from Mouser The P N is 334 NTC103 RC 13 Reg bus Wiring All MK3x8 BMS units are connected with a 6 pin RJ data cable allowing them to communicate back to the charger These communication lines connect all of the BMS units in a daisy chain fashion Reqbus Cable Construction The 6 wire RJ cable which is used to connect the regulators is a common data transfer cable and is available at most electronics stores The 6 pin connector plugs are usually clear and it is easy to crimp them using an appropriate crimping tool with a 6 pin die These are also readily available NOTICE RJ cable is quite rugged but take care not to cut or sharply bend and fatigue the cable in order to avoid errors from broken internal wires Additi
7. A DC DC converter All measurements are made relative to the GND wire It is important to verify all six of the wires are continuous throughout the system On older PFC charger models the GND on REGBUS is not isolated from battery negative The primary functions of the REGBUS are 1 Supply power to the charger side of the BMS units 2 Support analog data exchange from BMS to charger and real time analog control 3 Support digital data transfer and control of BMS via the Rudman Bus modified EVILbus Optimally the charger will run at full current until the first regulator gets hot then it will cut back to save that regulator and also start the countdown timer With new sets of cells it can take several hours for the pack to go from the first one to top off until the last one tops off this is especially true if the cells were manufactured at different times As more charge and discharge cycles are performed the cells in a pack will become more closely synchronized and the equalization time will be much quicker As the cells near the end of their useful life the time to equalize usually gets longer and longer as some cells perform more poorly than others How hot to run the regulators during the absorption phase is a function of the ambient temperature and how fast the vehicle needs to get back into service Higher temperatures will make the absorption phase take less time but is more risky to the regulators When the upper thermal threshol
8. ANZANITA MICRO Rudman Regulator Mark 3x8 Digital Lithium lon BMS Owner s Manual Rev 1 4 2011 Manzanita Micro LLC The information date is February 16 2011 CONTENTS GENERAL OVERVIEW sai eEeeeeeee EENEG ege Page 3 DIMENSIONS AND SPECIICATIONS ue Page 4 KEY FEATURES LIST eege Eege ege Page 5 OPERATION eeneg eege EE cco Page 6 Photo of BMS Board Face With Callouts NENNEN Page 6 LED Indicator Guid esi cz cc scecz vacecies cee siiac eos ce acces shea esse Page 6 Dissipation Heat Smmnk KENNEN EEN Page 7 SOERENSEN Page 8 GONNCCHONS EE Page 8 THE REGBUS INTERFACE ee severe ge Gos teense een Page 10 Pinout DESCHIP OM ee isc sess secs cee ee EN Page 10 BMS INSTALLATION siiccs sccie vie tev cccties dee E AE senses EE Page 12 WIRING THE MANZANITA MICRO MK3X8 BMS Page 12 Voltage Sense WIring ccecececeeeeeeeeeeeeeeeeeeeeeeeeaeeseeeeeeeeeeenes Page 12 Temperature Sense WIriNg ccceceeeee ee eee eee e nena ee eee ne eens nena saan Page 13 geg Bus Wiring eer EES ee dees devon denies Page 13 Reg Bus Cable Constructhon NEEN Page 14 CONNECTING WITH THE DIGITAL INTERFACE ANNE Page 16 Connecting with a Laptop or Windows Based Computer Page 16 Dongle Terminator DT BOX ceecee eee ENEE Page 17 REGULATOR ADJUSTMENT AND COMMANDG eeeeeeeees Page 18 Command Usage and Document Conventions c eceeeeeeees Page 18 Commands EE Page 19 Detailed Descri
9. an unplugged portion of the REGBUS the charger cannot communicate with the regs and this could lead to potentially damaging situation if there is an un matched battery cell in the pack The RJ connectors are similar to phone cord connectors and they are designed to snap into place and stay connected If a cable is disconnected insure that it is fully reconnected An audible click should be heard when the RJ plug is fully inserted and it should not be able to be pulled out without first pinching the small plastic tab underneath the plug For more information visit www manzanitamicro com Or for technical questions or other inquiries Manzanita Micro Rich Rudman PO Box 1774 Kingston WA 98346 Phone 360 297 1660 2T APPENDIX Voltage Sense Wiring With Bottom Mount Connection figure 09 Some custom Mk3x8 BMS units have been produced with special bottom mount connections Figure 09 shows the correct wiring for the custom bottom mounted connector The Molex part number for the 10 pin voltage sense connector in the picture is 44133 1002 The Molex part number for the pins themselves is 43030 0002 28
10. cell a bad cell or a damaged BMS unit The undervoltage set point on a Mk3x8 BMS unit is preset to 2 5 Volts per cell before leaving Manzanita Micro This set point can be adjusted by communicating with the unit from a computer For more information on this procedure refer to the Adjustments section later in this manual NOTICE When many BMS units are connected together to monitor a pack of batteries if one unit detects an undervoltage condition with any one of its cells and illuminates its yellow LED this will trigger all of the regulators to illuminate their yellow LEDs In this case one must look for the regulator with the red LED to find the offending battery Red LED Undervoltage Latch The red LED indicates that one or more of the cells attached to that reg has have gone below the undervoltage set point at some point since it was last brought to a full charge The red LED will remain lit until either the power is disconnected from the regulator or the battery is fully charged and all eight green LEDs blink This feature lets the user quickly spot the weakest batteries in the pack even if some of the individual cells are currently not below the undervoltage set point Blue LED Communication Indicator The blue LED indicates when the regulator is communicating on the Rudman Bus All of the blue LEDs should blink in sequence whenever an external device is communicating with a string of regulators and going through ea
11. ch valid bus address The blue LED will illuminate whenever the unit is being communicated with Dissipation Heat sink The long L shaped aluminum heat sink is the area on the BMS unit where energy is bypassed around a cell and dissipated as heat This sets the Manzanita Micro BMS apart from the competition and allows for maximum battery balancing in a short amount of time When the unit s heat sink temperature becomes too high the unit automatically tells the charger to cut back via the reg bus data cable system Bolting the BMS unit to a larger heat sink and or adding a cooling fan will allow for even higher performance and faster equalization The thermal threshold temperature for the heat sink is normally set to 180 degrees Fahrenheit upon leaving Manzanita Micro This threshold can be changed in order to push the regulators harder but be aware that higher heat sink temperatures may shorten the life of the regulator For more information see the Adjustments section later in this manual WARNING NEVER touch any of the heat sinks while the cells are being charged As the name implies the heat sinks get HOT Temperatures can be as high as 180 F and they can cause burns if touched while they are hot Connections P2 Voltage Sense Cells Connection P2 is the Molex 10 pin voltage sense connection which connects each individual cell to its respective BMS channel The Molex part number for the standard required female con
12. commands to the BMS units over the Rudman Bus More information on that is contained in the next section The REGBUS interface The REGBUS communicates important information back to the charger such as whether any regs are regulating or not and whether any heat sink channels are too hot The charger uses this information to determine when to turn down the charge current and when to turn off the charger In addition the REGBUS also transmits the digital information to the terminator and dongle where an external digital device can be hooked up in order to view and or change the regulator information The REGBUS interface contains five wires connected as follows 1 Power supply 5 volt DC 2 Reg overvoltage condition reg ON or reg hot 5V on this line when active 3 Undervoltage condition OV on this line means undervoltage active 4 Power supply return Ground GND CAUTION The GND return is NOT isolated on older Manzanita Charger models 5 Rudman bus negative 6 Rudman bus positive 123456 figure 05 Note The pin count reads from left to right when looking straight on into the RJ receptacle refer to figure 05 Or when looking at the bottom of the board pin 1 is the square pin All of these wires are isolated from the battery being monitored to prevent faults The opto isolator components keep local Batt POS and Batt NEG isolated from the charger s Batt POS and Batt NEG The 5 and GND are powered from a 150 m
13. d on a regulator has been reached the blue and red LEDs will illuminate and the reg will pull the hot reg line to 5 volts This will tell the charger to stop charging until the temperature of the heat sink drops below the thermal limit Adding airflow across the regulators will dramatically help cooling the regs and speed up charge equalization BMS Installation The Mk3x8 BMS units have 3 mounting holes with threaded inserts These mounting points are spaced evenly on the back side of the long angled aluminum heat spreader More precisely the mounting holes are at 25mm 87 5mm and 150mm from the left edge It is recommended that the units are mounted to a larger heat sink or piece of aluminum or copper The dissipation resistors and the fan drive transistor are isolated from the heat sinks Wiring the Mk3x8 BMS Voltage Sense Wiring Battery wires to the BMS units should be kept as short as possible Each Mk3x8 BMS unit needs only 9 cell connection wires to monitor a block of 8 cells actually 10 wires since there are 2 black ground wires Refer to the wiring illustration shown in figure 03 in order to assure proper wiring Nine different colors of wire are recommended in order to color code for ease and accuracy of cell wiring Manzanita Micro recommends using 22 gauge stranded hookup wire in black brown red orange yellow green blue violet and gray Be sure to check that each wire goes into the 10 pin Molex connector exactly as sho
14. es per regulator phev p Full Syntax lt addr gt phev lt enable gt Minimum Syntax lt addr gt p lt enable gt Broadcast Command Yes Example Command 1p 23 Reply 01P 0 phev sets the PHEV mode There is only one PHEV mode per regulator so all bus addresses on one regulator are affected by the command lt enable gt must be 0 or 1 If lt enable gt is not present lt addr gt phev reports the current mode If enabled REG_TOO_MUCH is asserted whenever UNDERVOLT is asserted querytot q Full Syntax lt addr gt querytot Minimum Syntax lt addr gt q Broadcast Command No Example Command 1q Reply 01Q 12 19V querytot will reply with the total current sensed voltage for the regulator containing the given bus address readlowv r Full Syntax lt addr gt readlowv Minimum Syntax lt addr gt r Broadcast Command No Example Command 01r Reply 01R 2 496V readlowv gives the low voltage set point There is only one low set point per regulator so all bus addresses on one regulator will give the same response sethigh se Full Syntax lt addr gt sethigh lt voltage gt Minimum Syntax lt addr gt se lt voltage gt Broadcast Command Yes Example Command 01seth 3 792 Reply 01H 3 792V sethigh sets the high voltage set point There is only one high set point per regulator so all bus addresses on one regulator are affected by the command lt voltage gt must be from 0 000 t
15. gure 07 T D B R WHITE WIRE BLUE WIRE PLASTIC TANG TANG DOWN BLUE RIGHT figure 07 Step 6 Double check that the blue wire is to the right side with the tang down and then take the RJ crimping tool in your right hand With your left hand push the cable with un crimped plug into the 6 pin die on the crimping tool Step 7 While using your left hand to make sure that the RJ cable is firmly held all the way into the connector squeeze the crimping tool with your right hand and complete the crimp If you have a clear plug end you can look in and make sure that each of the 6 metal pins sunk all the way down into their respective wires Give the connector a slight tug to make sure that it is adequately fastened and now you have created a proper RJ cable end Follow the same steps on the other end of the cable and you are done NOTE When crimping the second end of the cable notice that you ll have to flip it over in order to again orient the blue wire to the right when the connector tang is facing down see figure 08 T D B R TANG DOWN BLUE RIGHT figure 08 Connecting With the Digital Interface Connecting With a Laptop or Other Windows Based Computer Any computer with a USB port and running Windows can plug into the regbus using a dongle terminator box which is available from Manzanita Micro These items in conjunction with the free software will allow you to view regulator data and
16. hangesn commandl debug disable enable fan gethighv hmaclear hmiclear hstclear lights maxvolts minvolts numchan phev querytot readlowv sethigh setlow setover status temperat temphot tempwarm temphigh tempoff voltage xtrntemp watchdog NOTE Commands marked with an asterisk are not available on production units changead ch Full Syntax lt addr gt changead lt newaddr gt Minimum Syntax lt addr gt ch lt newaddr gt Broadcast Command No Example Command 1ch 9 Reply 01 Now 09 changead changes the current bus address lt addr gt to the new address lt newaddr gt The other bus addresses on the same regulator are adjusted respectively The new address must always be from 0 to 255 Additionally the new address must not force any other bus address on the same regulator to exceed 0 to 255 changesn changes This command is not available on production units Full Syntax lt addr gt changesn lt level gt Minimum Syntax lt addr gt changes lt level gt Broadcast Command Yes Example Command 1changesn 100 Reply Rudman MK3x8 Regulator V0 17 Unit 01 08 S N 00100 commandl changead disable enable fan gethighv hstclear hmaclear hmiclear lights minvolts maxvolts querytot readlowv status sethigh setlow setover temperat tempwarm temphot tempoff voltage xtrntemp changesn changes the internal serial number command Full Syntax lt addr gt commandl Minimum Syntax lt
17. mmand is one that responds to the broadcast address The broadcast address is a single asterisk i e or 99 NOTE The latest version of the regulator supports the two digit bus address 99 as the broadcast address To use 99 as a bus address that does not mean broadcast but instead exactly one bus address specify at least one leading zero E g 099 A broadcast command will not reply with any report or status command is the only exception to this rule however command should never be invoked with the broadcast address A descriptive word representing one field will be set off in lt angle brackets gt The brackets are not included in the actual command E g lt addr gt may be replaced by 1 2 99 etc An optional field will be set of in square brackets The brackets are not included in the actual command E g lt voltage gt may be replaced by 2 500 or left empty Commands may be specified using their full syntax abbreviated to their minimum syntax or anything in between An abbreviated command ends with a period A command that takes an argument after the command must end with a single period whether or not it is abbreviated All commands must be in lower case letters E g 1e but not 1E NOTICE The commands will not work if there are any uppercase letters used All letters must be entered in lowercase characters only Commands List This list of commands is current as of August 6th 2010 changead c
18. mpw Full Syntax lt addr gt tempwarm lt temp gt Minimum Syntax lt addr gt tempw lt temp gt Broadcast Command Yes Example Command 1tempw 120 Reply 01TW 120F tempwarm sets the temperature to start the fan The fan speed scales up from tempwarm to temphot tempwarm must be from 32 to 181 and less than temphot watchdog w This command is not available on production units Full Syntax lt addr gt watchdog lt flags gt Minimum Syntax lt addr gt w lt flags gt Broadcast Command Yes Example Command 1w 0 Reply Unit 01 Wir watchdog controls the watchdog timer lt flags gt may contain 0 or 1 to disable or enable the watchdog lt flags gt may contain r or t to reset or test the watchdog timer If the watchdog is enabled test mode will cause a reset 26 xtrntemp x Full Syntax lt addr gt xtrntemp Minimum Syntax lt addr gt x Broadcast Command No Example Command 1x Reply 01X Cold xtrntemp gives the current temperature of the external temperature sensor There is only one external temperature sensor per regulator so all bus addresses on one regulator will give the same response NOTICE Ensure that the REGBUS data cable is fully plugged into the charger whenever the vehicle is charging The communication data cables are hooked to the regulators in a daisy chain fashion Make sure that each of the smaller data cables are all plugged in where they should be before charging If there is
19. n bus address lights I Full Syntax lt addr gt lights Minimum Syntax lt addr gt l Broadcast Command No This command is handy for visually locating regs as it will make the unit s lights flash 22 NOTE Only use this command to talk to one individual regulator at a time Do not use as a broadcast command ie 99 if there is more than one Mk3x8 regulator in the system Additionally do not use this command if there are any Mk3x4 four channel regulators in the system Example Command 11 Reply Rudman MK3x8 Regulator V0 17 Unit 01 S N 00001 lights will flash the lights on the regulator that contains the bus address and reply with the sign on message maxvolts m Full Syntax lt addr gt maxvolts Minimum Syntax lt addr gt m Broadcast Command No Example Command ima Reply 01MA 1 524V maxvolts will reply with the maximum sensed voltage for the given bus address minvolts mi Full Syntax lt addr gt minvolts Minimum Syntax lt addr gt mi Broadcast Command No Example Command 1mi Reply 01MI 1 510V minvolts will reply with the minimum sensed voltage for the given bus address numchan n This command is not available on production units Full Syntax lt addr gt numchan lt channels gt Minimum Syntax lt addr gt n lt channels gt Broadcast Command Yes Example Command 1n 6 Reply Unit 01 06 Numchan is used to artificially limit the number of bus address
20. nector plug is 43025 1600 and the pins are p n 43030 0008 For further instructions refer to Wiring the Mk3x8 BMS in the Installation section of this manual If you happen to have one of the custom bottom mounted voltage sense connections then refer to the Appendix at the end of this manual for a specific diagram of the bottom mount connection figure 0 3 Standard Voltage Sense Plug J1 External Fan Connection J1 is the 2 pin molex plug right next to the fuse This provides power to drive an external 12 volt fan The part number for this connector plug is 22 01 3027 Red and black 22 awg stranded hook up wire is recommended Crimp on the Molex end pins p n 08 50 0114 and insert them into the connector plug until they latch The red positive wire should be inserted into the RIGHT side of the Molex connector so that it is on the side nearest to the heat sink on the BMS unit CAUTION Do not short out these pins as they can have 12 volts potential between them at any time Also when an external fan or fans are hooked up to this connection be aware that it they may turn on and off at any time The external fan uses PWM control allowing 8 different fan speeds 1 9 and an automatic mode O For more information on controlling an external fan refer to the Fan command description on page 21 of this manual P3 Eight Channel 16 pin Molex Temperature Sense Connection P3 is a 16 pin Molex connection which allows up to 8 indi
21. o 9 999 and must contain exactly four digits If lt voltage gt is not present lt addr gt sethigh is the same as lt addr gt gethighv setlow setl Full Syntax lt addr gt setlow lt voltage gt Minimum Syntax lt addr gt setl lt voltage gt Broadcast Command Yes Example Command 01setl 2 496 Reply 01L 2 496V 24 setlow sets the low voltage set point There is only one low set point per regulator so all bus addresses on one regulator are affected by the command lt voltage gt must be from 0 000 to 9 999 and must contain exactly four digits If lt voltage gt is not present lt addr gt setlow is the same as lt addr gt readlowv setover seto Full Syntax lt addr gt setover lt voltage gt Minimum Syntax lt addr gt seto lt voltage gt Broadcast Command Yes Example Command 01seto 3 984 Reply 010 3 984V setover sets the over voltage set point There is only one over voltage set point per regulator so all bus addresses on one regulator are affected by the command lt voltage gt must be from 0 000 to 9 999 and must contain exactly four digits If lt voltage gt is not present lt addr gt setover reports the current set point If any bus address exceeds the over voltage set point the shunt is turned on status s Full Syntax lt addr gt status Minimum Syntax lt addr gt s Broadcast Command No Example Command 1s Reply 01S 28 Status gives the current status of the given bus
22. off time As the cell becomes more fully charged the on time increases and the off time decreases thereby increasing the bypass current through the regulator and preventing the battery from being overcharged So the faster the individual green LED blinks the more fully charged that cell is The set point voltage controls the voltage level when this regulation occurs On a Mk3x8 reg this set point high voltage limit is preset to 3 8 Volts per cell before leaving Manzanita Micro This set point can be adjusted by communicating with the regulator from a computer via a USB cable and the DT box or the Manzanita Micro Regscanner The high and low set points can be adjusted in 0 024 volt increments For more information on this procedure see the Adjustments section later in this manual NOTICE If any green LED stays on steady this means that at least one of the channels in the BMS unit is regulating at full bore If this happens frequently the charger should be turned down or the regs need more cooling When the reg bus is connected to a Manzanita Micro battery charger and a green LED remains steady on one or more regs the charger should cut back or shut down automatically as necessary In this case the blue Timer LED on the charger will be lit Yellow LED Undervoltage Real time The yellow LED indicates that one or more of the cells in the string is are currently below the undervoltage set point This can indicate a discharged
23. onally follow the proper cable construction techniques listed below and make sure that all the wires are installed in the correct orientation See figure 07 Proper Regbus cable construction is not difficult but it requires keen attention to detail on the part of the person installing the plug ends onto the RJ cable The following steps tell how to correctly make a regbus cable suitable for use with any 6 Pin Manzanita Micro product Step 1 Cut the RJ cable to the desired length It is advisable to err on the long side because each of the cable s ends will be pushed to the back of their respective RJ receptacles Step 2 Strip about a quarter inch of the thick flat outer jacket off of each end of the cable in order to expose the 6 colored wires inside Most RJ crimping tools will have a special wire stripping section with a guide which will allow you to quickly strip the correct length of cable jacket off Step 3 Hold the flat RJ cable in front of you in your left hand with one end pointing towards you and one away from you Step 4 Looking down at the cable in your hand make sure that the end facing away from your body has the blue wire to the right side Step 5 Now take an un crimped plug end in your right hand and with the tang oriented on the bottom side slide the outward facing end of the flat RJ cable into the slot in the un crimped plug Make sure it is not crooked and push it all the way into the un crimped plug see fi
24. ors the Mk3x8 regs do not require adjusting potentiometers in order to change voltage settings Instead the Mk3x8s can be calibrated asked to feedback information or have settings such as voltage limits and changed using simple ASCII commands Each reg can be talked to individually by using its specific bus address Some commands can be sent to all regs at once by entering a bus address of 99 This is useful for commands like clearing history or setting all of the voltage limits The first two bytes are the devices bus address in ascii decimal ie 00 to 99 These are followed by the specific command to be executed To ask for regulator 1s battery voltage reading the command would be O1voltage and then hit the return key To ask for regulator 7s battery voltage reading the command would be O7voltage and then hit the return key NOTICE The commands will not work if there are any uppercase letters used All letters must be entered in lowercase characters only Document Conventions Again ASCII numbers from 000 to 999 are valid device bus addresses Address 99 is reserved for an all device broadcast which is only valid for settings such as minvolts maxvolts hstclear etc The bus address is a string of decimal digits and is always in the range 0 to 255 inclusive Leading zeroes are allowed When the regulator replies with a bus address it will always send two or three digits E g 01 099 or 200 A broadcast co
25. ption of Each Commande NEEN Page 20 MANZANITA MICRO CONTACT INFO Page 27 BPP EN DIK specced exten psncnes vera vests a aa ARETA nE REELS SEE TRENSA Page28 Voltage Sense Wiring With Bottom Mount Connection Page28 Mk3x8 DIGITAL BMS FOR 8 LITHIUM CELLS General Overview The Mk3x8 Digital Lithium Regulator is a feature rich battery management board capable of individual voltage and temperature monitoring and equalization of up to 8 cells Each Mk3x8 is less than 1 inch tall and has a footprint of only 7 x 2 4 inches yet they have incredible dissipation capacity for quick equalization Furthermore they have simple RJ reg bus ports for quick and simple communication back to any Manzanita Micro Charger When lithium cells are connected in series even if they are closely matched when new over time their exact capacities and voltages will drift apart With the many varieties of sealed lithium ion batteries permanent capacity loss can result if cells are overcharged to the point of venting Furthermore with some lithium polymer batteries as well as certain other chemistries thermal runaway or explosion can occur if there is no intelligent BMS to keep the cells in their safe operational range The intent of the Mk3x8 regulator is to bypass current around a fully charged lithium cell so that all the other cells in a long series string can get fully charged without any one becoming overcharged This is accomplished with individual
26. s Built in active variable speed 12V DC fan control output on each BMS unit The fan settings can be viewed and changed using the included software Large heat spreader is totally isolated from the cells and is already threaded for easy mounting to a larger heat sink Each unit can dissipate up to 110 watts Mark 3x8 Lithium BMS Operation Heatsink Green Regulation intemal ge LED bes Temp Large Dissipation Heat Sink With Mounting Holes Fully solated Fan Drive Transistor 10 pin Molex Reg Bus In Out Green LED Temp Sense Dissipation Active Blue LED 16 pin Molex Low Voltage Low Indicator Real Time Voltage Latch figure 02 Indicators There are twelve LED indicators on a fully populated Mk3x8 regulator When the regulator is first connected to at least 4 cells the green yellow red and blue LEDs will illuminate briefly to let the user know that they are all functioning 8 Green LEDs Regulation Indicators The eight green LEDs indicate that the BMS unit is regulating Each of the eight LEDs in the middle of the board correspond to their own independent dissipation channels They come on when the cell they are attached to is above the regulation set point and the reg load is activated The green LED next to the yellow LED blinks any time any of the eight cells are at their upper regulation voltage limit This is a brief transient event at first with a brief blink followed by a much longer
27. send commands using a text based program The files are available from www manzanitamicro com and they are located in the Downloads section Simply open the file and follow the simple setup wizard to install the program on your computer Once installed open the program and if the regs are properly connected through dongle terminator and you should be able to read information from them More specific instructions for the application can be found in the README file included with the software itself Details on hooking up the dongle terminator DT box is in the section below USB PORT REG BUS PORTS 12 VOLT INPUT figure 09 Dongle Terminator Box DT Box The dongle terminator box is a black adapter box with a USB plug which plugs into the computer that will be used to communicate with the Mk3 regulators using the Rudmanbus system The other end of the dongle has two RJ jacks which allow it to be connected with cables to the reg bus system The reg bus alone will not function correctly without a supply of 12v power The new DT box receives its power from the USB plug itself On older models there is actually a separate 12 volt power jack as in figure 09 The center pin requires 12 volts and is a 2 1mm post NOTE Communication over the digital Rudmanbus will not be possible if the DT box is not receiving a solid 12 15 volts Regulator Adjustment and Commands Using Commands Unlike the old analog Rudman Regulat
28. vidual temperature sensors to be connected to the regulator These external temperatures can then be displayed on any laptop or computer running the supporting software These external temperature sensors will be in addition to the unit s own internal heat sink temperature readout The Molex part number for the required 16 pin female connector plug is 43025 1000 and the pins are p n 43030 0008 For proper temperature sensor wiring order the sensors from Manzanita Micro or refer to Wiring the Mk3x8 Regulators in the Installation section of this manual Figure 04 below shows a properly constructed temperature sense harness Figure 04 P1 Programming Header P1 is the 6 pin JTAG programming header This is where the chip programmer is attached in order to load the firmware when the regulator is initially programmed at Manzanita Micro Users should never attempt to attach anything to this header J2 and J3 Regbus I O RJ Connections J2 and J3 are the In Out ports for the reg bus communication line These are standard 6 pin RJ data connections The Mk3x8 units are to be connected to each other in a daisy chain fashion The precise order does not matter as each unit is individually programmed with a specific bus address identification number that does not change The dongle terminator DT for the Manzanita Micro Regscanner or a laptop can be plugged into the same RJ connection at either end of the chain to read information and send
29. wn in the wiring diagram figure 03 and that each wire goes to the appropriate connection between cells When wired as shown in the diagram the cell voltages will be in the correct order The Digikey part number for the Molex connector pins is WM 1125 CT ND Crimp the Molex connector pins and insert them into the connector plug until they latch The other ends of the wires connect to the cells Simply attach an appropriately sized ring terminal and bolt the terminal onto the cells placing it on top of the lug or bus bar The two black wires are both attached to the negative terminal of the 1 cell in the group of 8 cells The gray wire is the most positive wire so it is connected to the positive terminal of the 8 cell in the group of 8 cells The other wires connect in order at each interconnect point between the cells as shown in figure 06 12 NOTE In some cases the number of cells in a battery pack may not be divisible by eight If this is the situation please continue to use all 9 cell voltage sense wires when wiring the cells When the last cell in the group is reached simply place all the extra ring terminal connections on the last most positive terminal of the group 8 Lithium Cells figure 06 Standard Voltage Sense Connector Diagram Temperature Sense Wiring Temperature sensor wires must be twisted pairs and should be kept to 18 inches or less The Mk3x8 regulators use 8 pairs of wires to monitor up 8 external temperature
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