Pit Station Maintenance Manual
Contents
1. It is possible that you have not yet installed the driver for the 12C to USB adaptor Click http www ftdichip com Drivers VCP htm Make sure you disconnect the USB and connect it back again after the driver is installed so that it actually shows up as a new Comm port Right click on My Computer and click on Manage or Device Manager to check if the adaptor does show up as a new COMM Port It is possible that the BMS boards are corrupted Please shut off the program by clicking Quit under File menu Wait for 12 seconds Now unplug the 12C wire and plug it into SCADA box Turn on SCADA if the BMS green LED light is still on that is good news You can now connect the 12C back to the Pit Station Box and start the Charging program again You should now expect now more of the warnings to appear If Cannot communicate with BMS or similar warnings still keep showing up then shut off the program by clicking Quit under File menu Wait for 12 seconds Now unplug the USB cable between the laptop and the Pit Station Box Wait for 5 seconds Reconnect the USB cable between laptop and the Pit Station Box Re launch the program If it still not connected check the USB cable inside box including the USB hub and see if any of them are compromised That s as far as can help you If those warnings still show up it is probably a bad day for you to buy lottery tickets 5 Why dol keep breaking the BMS a2. gladly grant you write access if receive an email about the request 3 Cannot communicate with Arduino warning keep showing up after starting up the charging program m hopoan If you haven t install the Arduino driver that is probably why You can find the file you need to download from here and you can follow the instruction to install the driver from here It is the instruction for a different type of Arduino board but you should be following the same procedure The Arduino software IDE zipfile is also in the deployment folder in the repository When driver is installed right click on My Computer and click on Manage or Device Manager to check if the adaptor does show up as anew COMM Port There is an easy fix Shut off the program by clicking Quit under File menu Wait for 12 seconds Now unplug the USB cable between the laptop and the Pit Station Box Wait for 5 seconds Reconnect the USB cable between laptop and the Pit Station Box Re launch the program Hover over Mode menu and Charging Mode submenu check if With Arduino is selected h If it still not connected check the USB cable inside box including the USB hub and see if any of them are compromised As long as the LED on the Arduino board is still on that means the Arduino board is alive The LED should also blink on start up 4 Cannot communicate with BMS or similar warnings keep showing up gt oO
3. b Once you have connected the 12C cable and started the program you may only unplug the 12C cable under one condition after a safe shutdown A safe shutdown is i Goto File menu and click on Quit ii Wait for 15 seconds 6 Any reading on the Charging Monitor is not expected Open the EventLog txt file on the desktop Press Ctrl F to search for keyword Error Go through the log items with Error printed at the front and check for the time stamp printed at the end of the corresponding line to find the error that might help explaining the invalid reading on the GUI 7 Cannot close the charging relay to start charging process a First of all you can monitor the charging relay s status by outputting constant current and observe the actual current readings on the power supply It should be a non zero value once the relay is closed assuming the power supply is outputting b When the Charging Program starts up check the Mode menu and the Charging Mode submenu if the selected item is Without Arduino then it is a connection problem with the Arduino board Check this solution c It is also that the Relay malfunctions and needs to be replaced What you can do is to disconnect the relay from the box Powering the input side with a power supply and check the conductance on the output side The multimeter should beep showing there is a connection With the current Relay closed the outpu
4. bus number on the 12C section Now write to the board with address 0x04 with command 0x0100 address 7 bits 2 hex For example 0x010002 for the first board 9 The Arduino board is corrupted smashed into pieces starting to rust a You can try to reprogram using the software IDE you can download here b You can then download the firmware code here or here e f g You can then open the firmware and click on Compile and Upload button to program a new board To test if the code is actually new code you just download open the Serial Monitor under Tools in the toolbar in the IDE Now connect a voltmeter across pin 13 and once of the GND pins Type in a the voltage should jump to a digital high Type in b the voltage should drop to 0 Type in d the serial monitor should spits out a Ardui message 10 Everything works fine It is just that when I click on the Start button when I want to start charging the GUI does nothing QaQoo0 9 Safely shut down the program first by hovering over File and click on Quit Now Wait for 15 seconds for the program to completely shut down Now disconnect the USB wait for several seconds and reconnect the USB back again Try re launching the program and see if that fixed it If not repeat from step a 11 The software is displaying the wrong number of cells but no warnings are showing First wait for several minutes It is possible th
5. on the Start button when I want to start charging the GUI does nothing ccccssccecesssececeesneeeeeeseeeceesueeeceeaeeeceeqeeeeeeaeeeseeaeeeeeetueeeeeeneeeeeees 6 11 The software is displaying the wrong number of cells but no warnings are showing 6 12 What if the fan doesn t spin once the USB is CONNECtEM ccccecceessecessseeeseeesseeesseeseneeees 6 13 Whatis left to doicc areae n de a E ae veodeneeesteelssdsicccseatacbes vadeedees 6 Introduction The purpose of the Pit Station is to control and monitor the battery pack charging process After all the QA tests the Pit Station does satisfy most of the requirements but only under very specific circumstances It is essential for any users of the Pit Station to carefully read through the user manual before charging If any exceptions unexpected events occur please refer to this manual to find any possible solutions Foreseeable Problems 1 Having trouble deploy the software cannot run the Charger Program on a new desktop laptop a9 5 o Go to here to download the dist folder in a zip file called dist rar Unzip it and put it on your desktop Go to here to install the correct version of Java jdk based on the OS you are using For a 64 bit OS go to here to download the zip folder and extract rxtxSerial dll and rxtxParallel dll to C Program Files Java Jre6 or 7 bin For a 32 bit OS go to here to download the zip folder
6. Pit Station Maintenance Manual Siyuan Wang 05 11 13 Contents alel oye 0 cle a qltmecememaea sen mpm cniacere sae Qnew a SER FB a CPI CERP SE Ae YE Ue OE ATW TSR OER A ERT RES EET PD 2 1 Having trouble deploy the software cannot run the Charger Program on a new Cesktop laptop 3 i2ce s lt 2ecsc secon nees aeee an aeee ane eRe EAR atia AOE ed soneebtatedevstedexeenizaleeveut asteein neeeoes 2 2 Having trouble view edit compile run the code for the Pit Station Software 00068 3 3 Cannot communicate with Arduino warning keep showing up after starting up the charging PROB MAING siensa ccccctteTicaeewi vec cece sata Seews E E EREE a ube ch eacvauvode Genes EENE EEEN EEEa ES 3 4 Cannot communicate with BMS or similar warnings keep showing Up 0 ccssceeseeeees 4 5 Why dol keep breaking the BMS ccccccccsscceceesseeeceesneeecccsneeeescaeeeeseaeeeeeeceeeeeeseeeeeeseeeeeee 4 6 Any reading on the Charging Monitor is not expected ccccccccssseeeceessececessneeecessneeeesesneeeeeees 4 7 Cannot close the charging relay to start Charging process cccccssccccessseeeceesneeeeeesteeeeeesteeeeeees 5 8 What if the BMS boards are corrupted how to reprogram the BMS board c cscseseeeees 5 9 The Arduino board is corrupted smashed into pieces starting to rUuSt cccccseeseeseeseeeees 5 10 Everything works fine It is just that when I click
7. ancier screen about the team d Being able to save and load the most recent parameters e Solve the issue where one polling cycle has to be at least 12 seconds Right now the issue that is keeping the length of the polling cycle from shortening is the switching between two serial port and the limitation of writing consecutive commands to the BMS board One issue to keep in mind that you may never write to the BMS board set command consecutively without pausing It is very likely that it will break whatever board you are sending this command Maybe pinging the Arduino board is not necessary until charging is in progress That will shrink the polling cycle of non charging time f Conversion equation for current is still off but is close to be accurate enough g Having an XML parser to parse the XML data logged in the databaselog xml file one level above the dist folder Once the data is parsed any graph regarding cell voltages current cell temperatures can be generated
8. and extract rxtxSerial dll and rxtxParallel dll to C Program Files Java Jre6 or 7 bin Now is the most challenging part Hover over my Computer and click on properties Find Advanced System Settings this is different for different windows OS Then click on Environment Variables On the lower scrollarea scroll down to Path and click on it and then click on Edit Now append your jdk and jre library to the end of the line starting with a semicolon to separate the previous one i e C Program Files Java jre6 bin C Program Files Java jdk1 7 0_15 bin C Program Files Java jre7 bin Now click on OK OK Before you run the charging program by double clicking on the jar file in the dist folder try downloading it and run it in the terminal in case more error messages occur Navigate to the dist folder using Command window I assume you know how to do this with you bash skills from CS classes Use java jar ChargingController jar to run the jar executable If it worked GUI opened it is very likely that you can run the jar file by double clicking it If it still doesn t work copy down the exception printed in the terminal and search that exception in StackOverflow If you haven t install the Arduino driver you can find the file you need to download from here and you can follow the instruction to install the driver from here It is the instruction for a different type of Arduino board but you sh
9. at the software just failed to pin some boards for certain polling cycle this is common to happen when bypass is occurring If this issue still occurs after several minutes keep reading this It is possible for you to have some loose connection in one of the BMS boards Check if the 12C connection is strong on all BMS boards The only plausible explanation is that the second BMS board 0x04 or even the third BMS board is corrupted Please follow this solution to reprogram and reassign the address of the boards 12 What if the fan doesn t spin once the USB is connected ao 7 Open the lid Replace the fan with a new fan specifications can be found on BOM Try connecting the USB cable and see if that helped to get the fan started If that still doesn t work start from step a 13 What is left to do a b Control the power supply using the charging program i Using the spare USB port on the USB hub to connect to the RS232 input of the power supply via a USB to RS232 adaptor ii Learn how to interface RS232 iii Add code to control the power supply Having a non BMS mode In addition to the without Arduino charging mode the charging software also needs to have a without BMS mode where it doesn t check the address of the BMS board but still acquire cell data from the boards although taking any data from the BMS boards will require knowing the board address It is absurd know c Welcome screen f
10. ould be following the same procedure The Arduino software IDE zipfile is also in the deployment folder in the repository When driver is installed right click on My Computer and click on Manage or Device Manager to check if the adaptor does show up as a new COMM Port It is possible that you have not yet installed the driver for the 12C to USB adaptor Click http www ftdichip com Drivers VCP htm Make sure you disconnect the USB and connect it back again after the driver is installed so that it actually shows up as a new Comm port Right click on My Computer and click on Manage or Device Manager to check if the adaptor and Arduino show up as two new COMM Ports 2 Having trouble view edit compile run the code for the Pit Station Software highly recommend you to download Java JDK with Netbeans from this site http www oracle com technetwork java javase downloads jdk 7 netbeans download 432126 html Afterwards suggest you download Git Bash from here and go to a new folder your created Now enter git clone https github com MrAlwaysRight SeniorDesignProject git to clone the project to your local directory Now open Netbeans go to open project in the tool bar and open this project from the directory you clone the code into Now you should have the source code and you can either port the code into a different repository or request the write access so you can also push the code into Github will
11. t resistance should be zero If it still have close to infinite resistance then that means it is a broken relay and it needs to be replaced d Ifthe Relay seems to be fine What might have happened is that in the charging circuit some connection is loose You will need to use a multimeter and the flukes to probe around the charging circuit inside the box from the Anderson connector to the charging supply to the relay Rewire and reinforce the wiring if any loose connection is found 8 What if the BMS boards are corrupted how to reprogram the BMS board a If you plug the I2C cable into SCADA box and the LED for BMS on SCADA is still red it probably means that the BMS boards are corrupted b Please follow the following instructions to reprogram BMS boards i Following the BMS subsystem instructions to download firmware to the board ii Connect the BMS board to the I2C adaptor iii Connect the I2C adaptor to PC iv If the device driver cannot be automatically installed please install it www ftdichip com Drivers VCP html v Now launch RealTerm which should be available in most lab machines If not install Realterm at http www i2cchip com realterm vi Now follow instructions here http sites lafayette edu ece492 sp13 files 2013 03 Instructions for l2C Operation1 pdf to configure the serial port vii Select the bus number based on the connection between your BMS and the 12C adaptor It is most likely to be 3 so click on 3 on the
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