to view the Manzanita SOC Head User Manual
Contents
1. Shunt Value Stop Charge Status Geer Sauna Page 26 Temperature Time Since Reset Pack Voltage SEN Page 27 Time Since Reset EEES of Pack Watt HOUMS ccceeeeeeeessteeessseeeee Page 28 CONFIGURATION ninian See d EE PAGES 26238 MANZ ANITA MICRO STATE OF CHARGE MEASUREMENT UNIT SOC HEAD General Overview One of the most important things to any electric vehicle user is knowing how full the battery pack is Manzanita Micro teamed up with Bruce Sherry Designs and is pleased to offer the SOC Head which is a stand alone State of Charge information device This single unit can be used with any Manzanita Micro BMS Battery Management System past and present or even with no BMS at all It is simple to hook up to the battery pack and even easier to hook up to a Windows based computer for accurate battery information and data logging The SOC Head can also be used with the compact Rudman Bus touch screen display The SOC Head does not monitor individual cells or batteries in a string like Manzanita s BMS but instead it looks at what is happening with the entire battery pack Note it does have the ability to communicate with Manzanita Micro BMS units and trigger its own built in relays based on high and low cell voltage information In addition to displaying the SOC as a percentage the unit can show instantaneous pack voltage instantaneous pack amperage in or out instantaneous power in Kilowatts Amp hours used since2. could type lcfinc 150 or 2 5 amps would be Lcfinc 25 17 cfinltim cfinl Full Syntax lt addr gt cfinltim Minimum Syntax lt addr gt cfinl Broadcast Command No Example Command lcfinl Reply O1CL 0000 27 cfinltim Charge Finish Last Time reports the time from when the voltage reached cfinvolt till the current decayed to cfincurr in minutes and seconds If this time is going up over several charge cycles it could indicate some of the cells in your pack are getting micro shorts and are about to fail cfinnumb cfinn Full Syntax lt addr gt cfinnumb 0 Minimum Syntax lt addr gt cfinn Broadcast Command No Example Command 1cfinn Reply OLCN 4 cfinnumb displays the number of the most recent charge cycle Each time the SOC Head resets to full after detecting the correct values for charge completion it increments this number Supplying c6 99 a numeric argument past the will update the charge number to the argument cfinsecs cfins Full Syntax lt addr gt cfinsecs lt newseconds gt Minimum Syntax lt addr gt cfins lt newseconds gt Broadcast Command No Example Command lcfins 9 Reply O1CS 0001 00 cfinsecs The Charge Finish Seconds command reports or changes the number of seconds required from when the charge current falls below cfincurr before the SOC Head declares the pack charged cfinvolt cfin Full Syntax lt addr gt cfinvolt lt newvoltage gt Minimum Syntax
3. lt addr gt ch lt newvoltage gt Broadcast Command No Example Command 1cfin 8600 Reply 01CV 085 99V 18 cfinvolt Charge Finish Voltage reports or changes the voltage which the pack must exceed before the SOC Head decides that the charge has completed If lt newvoltage gt is not present lt addr gt cfinvolt reports the current charge finish voltage setting 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 If lt newaddr gt is not present lt addr gt changead reports the current address current c Full Syntax lt addr gt current Minimum Syntax lt addr gt c Broadcast Command No Example Command 1c Reply 01C 0019 6A current The current reports the current flowing through the shunt Positive values indicate charging the pack negative numbers indicate discharging the pack gauge g Full Syntax lt addr gt gauge Minimum Syntax lt addr gt g Broadcast Command No Example Command 1g Reply 01G 97 3 gauge The fuel gauge command returns the current st
4. PANGANTA in cooperation with B oe SOC Head State Of Charge Measurement Unit User s Manual Rev 1 4 2011 Manzanita Micro LLC and Bruce Sherry Designs The information date is 08 11 2011 CONTENTS GENERAL OVERVIEW aee iai inaenea Nee dE dae EERE SAA AAEE EE Page 3 PRODUCT DIMENSIONS NENNEN ENNEN aaa sanaan PAGE A KEY FEATURES LIS Tice sccsvcincececveccalecetece ed EEN dee ENEE SE gg Page 4 SOFTWARE OPERATION biisstecieetecceaccedsceancetescetstteessed edesee eacnee vee aa a a cece essere Page 4 System Requirements cccccscccsseeceseeeeeeeeesseeseseeeenseeeeeeeeesnaeseseaeenseeeseeeeeseaesaseenenseeeees Page 5 SOU E Page 5 SOC HEAD UNIT LAYOUT ET Ge DEA Photo of SOC Head Unit With Callouts EE e CH Rudman BUS Rote eege Eege EENS EEN Page 6 THE Rudman Bus INTERFACE NEEN eens eens eeeeeneneeeeeeeenenesessnensnnsseenes Page 6 Pinout Description oii SEENEN EE EEN dontecdvsee ded a ceuenseseehtscecesducteesssereeseecee Pages 6 7 INSTAEEING THE UNE eseu a eaaa aeaa E a a eaaa aaa aa iaa EEN Page 7 WIRING THE SOC HEAD Ges E E Meter Power Voltage amp Current Sense Wiring EE RAGE O Relay Output Connectors EE 9 10 Reg BUS Wining NEESS O Nee Page 10 Reg Bus Cable Comstruction cccececeececeeeeeeeeeeeeseeeneeeeseseseesstrstsssesstssseeerts PAGES 10 12 CONNECTING WITH THE DIGITAL INTERFACE cccececeeeeeeseestersrssstetnsssterers PAJE 12 Connecting with a Laptop
5. commands like shown above This will be printed if no actual command is requested but the correct address is entered Iminamph Im Full Syntax lt addr gt lminamph Minimum Syntax lt addr gt lm Broadcast Command No Example Command 11m Reply 01LA 089 93AH Iminamph Last Minimum Amp Hours reports the amount of amp hours removed from the pack at the lowest point before the last charge completion cycle This value gets stored at the end of each charge cycle and will be valid till the next completion Iminwatt Iminw Full Syntax lt addr gt Iminwatt Minimum Syntax lt addr gt Iminw Broadcast Command No Example Command 11lminw Reply O1LW 05739 4WH Iminwatt Last Minimum Watt Hours reports the amount of watt hours removed from the pack at the lowest point before the last charge completion cycle This value gets stored at the end of each charge cycle and will be valid till the next completion maxvolts ma Full Syntax lt addr gt maxvolts Minimum Syntax lt addr gt ma Broadcast Command No Example Command Ima Reply O1CV 087 49V 22 maxvolts Reports the maximum voltage seen since the last hstclear or hmaclear command minvolts m Full Syntax lt addr gt minvolts lt newcapacity gt Minimum Syntax lt addr gt m lt newcapacity gt Broadcast Command No Example Command m Reply 01 Now 09 minvolts will reply with the minimum sensed voltage seen since the last h
6. factor of two There are two ranges 0 and 1 Range 0 measures from OV to about 100V Range 1 measures from OV to about 50V 25 shuntval sh Full Syntax lt addr gt shuntval Minimum Syntax lt addr gt sh Broadcast Command No Example Command 1sh Reply O1SH 500 shuntval The Shunt Value command allows you to view or set the value of the shunt The value returned or entered is the number of amps for a 50mV drop across the shunt The standard shunt that comes with the SOC Head is a 500A for 50mV shunt stopchrg sto Full Syntax lt addr gt stopchrg lt newstate gt Minimum Syntax lt addr gt sto lt newstate gt Broadcast Command No Example Command lreg Reply 01SC 1 Stop Charger when charging complete Either changes or reports whether finishing the charge acording to the charge parameters will force the chareger to stop charging or not If the state is reported as 1 when the SOC Head detects that the battery pack is full and enters state 5 it will activate the Rudman Bus high line to force the charger to stop charging If it is reported as 0 the SOC Head will not activate the Rudman Bus high line If lt newstate gt is not present lt addr gt stopchrg reports the current value status s Full Syntax lt addr gt status Minimum Syntax lt addr gt s Broadcast Command No Example Command 1s Reply 01S 0xa400 status Command reports the current status of the State of Charge Head The
7. 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 Commands This list of commands is current as of May eh 2011 Listemnd List available commands Current Show pack current in Amps Voltage Show pack voltage Amphours Show Amp hours used since last reset Watthour Show Watt hours used since last reset 14 Capacity Show Set pack capacity in Amp Hours Gauge Show remaining pack capacity S O C in Percent full Minvolts Maxvolts Time Temperat Reset Hstclear Hmaclear Hmiclear Show Minimum pack voltage since reset Show Maximum pack voltage since reset Display time since last reset in minutes and seconds Display SOC Head internal temperature Reset Amp Hours Watt hours min and max voltages and time History Clear clears min and max voltages Clear Maximum voltage Reset Minimum voltage Status Display SOC Head
8. it took to get through state 3 Then we progress to state 3 State 5 is to make sure the unit doesn t count extra charges if the charger decides to top off the pack again after completion if the charger stays on for a long period It does this by waiting till it sees about an 8A discharge before proceeding back to state 0 to start the whole process over again 31 If you want to make sure a Manzanita charger doesn t go into charge mode again you can force the high line on the Rudman Bus with the SOC during state 5 with the stopchrg command like Command 25sto 1 Reply 255C 1 If you just want to know were it is leave off the parameter and it will report where it currently is In order to disable it again provide the parameter 0 The relays can be configured for many purposes and each relay has two isolated sets of contacts which each have a normally open and a normally closed to enable many logic functions For example Relay0 could be wired to activate a reduced performance mode on your controller when the battery pack voltage drops to a certain level To configure it to be triggered by the pack voltage going low you would use the relay0 and the pminimum commands Say you wanted relayO to activate at 55V you would use the commands Command 25pmi 5500 Reply 25PI 055 00V Command 25relay0 4 Reply 25R0 4 If you also wanted it to activate when the remaining capacity went below 15 of your total yo
9. last reset Watt hours used since last reset miniumum and maximum pack voltages attained since last reset and a variety of other history and charging information see the Features or Commands section for more details Dimensions MANZANITA MICRO SOC HEAD KEY FEATURES eThe ability to be used with any battery pack voltage up to 500 VDC peak eAble to output battery pack State of Charge reading as a percentage eOutputs total battery pack current reading Outputs total battery pack voltage reading eOutputs total battery pack Ampere hour reading eOutputs total battery pack Watt hour reading eOutputs total battery pack power reading in Kilowatts eBuilt in temperature sensor mounted in the unit eCompact and durable enclosure is about H 1 375 x W 3 750 x L 4 75 not including the I O connections H 35mm x W 95mm x L 120mm eWarning output lines for signaling high and low battery conditions eCan be connected independently or in conjunction with other Manzanita Micro Mk3 Digital products using readily available six conductor RJ cable eEasily connects to a PC or Rudman Bus Display using the DT box USB adapter eWorks with Manzanita s free Windows based scanner and command software eAll commands are easily entered and read in simple ASCII text eEasy user adjustable min and max voltage parameters allow flexibility for just about any pack voltage signaling requirements eDual RJ reg bus ports for easy connection to t
10. some analog signals over the Rudmanbus lines These communication lines can connect the SOC Head charger and or all of the BMS units in a daisy chain fashion The SOC Head has its own unique bus address so it does not matter where in the chain it is connected as long as it is programmed with a bus address different from any other unit s on the bus Rudman Bus 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 Additionally follow the proper cable construction techniques listed below and make sure that all the wires are installed in the correct orientation See figure 06 Proper Rudman Bus 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 Rudman Bus 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 recept
11. status is reported as a 16 bit hexadecimal value not all bits currently have meaning The right most digit indicates the current state of the charge sequence 0x000X where X indicates 0 not currently charging The SOC Head needs to see positive current for 5 minutes before progressing to state 1 1 Charging has started waiting for all the amp hours to be returned to the pack 2 Waiting for CFINVOLT voltage to be reached 3 Waiting for the current to decrease to the value specified by CFINCURR 26 4 Waiting for the current to stay below CFINCURR for CFINSECS After CFINSECS it will reset the time amp hours watt hours state of charge and store how far pack was discharged in both amp hours and watt hours how long it took to get from state 2 to finish state 4 and how many extra amp hours were required to get the pack fully charged 5 Wait to see a discharge current to avoid resetting again 0x0100 indicates that the low voltage warning relay is activated 0x0200 indicates that the high voltage warning relay is activated 0x0800 indicates the ignition switch is on 0x2000 shows that the Manzanita Micro charger power is on 0x4000 indicates the Manzanita Rudman Bus low voltage line is active 0x8000 indicates the Manzanita Rudman Bus high voltage line is active temperat te Full Syntax lt addr gt temperat Minimum Syntax lt addr gt te Broadcast Command No Example Command 1te Reply OLTM 24C temperat Repo
12. way the ports mount to the inner SOC Head board makes them appear backwards so refer to figure 03 to be sure The 5 and GND are powered from a 150 mA 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 the Rudman Bus is not isolated from battery negative The primary functions of the Rudman Bus are 1 Supply power to the charger side of BMS units 2 Support analog data exchange from BMS to charger and real time analog control 3 Support digital data transfer and control of the SOC Head and or BMS via the Rudman Bus modified EVILbus Installing the Unit The SOC Head is built into a sturdy metal case It is the responsibility of the user to fashion a suitable mount for the unit Brackets straps or even strong velcro may be suitable Wiring the SOC Head Meter Power Voltage amp Current Sense Wiring Ten feet of Shielded 4 conductor wire is provided with the unit for connecting to the large 8 pin connector on the SOC Head the shorter this cable is the better This 8 pin connector should be wired as follows SHUNT SENSE WIRES SHIELD WIRE 12 VOLT POWER MAIN PACK POSITIVE figure 04 Pin 1 Red Wire 12 Volt Positive usually from vehicle s 12V system Pin 2 Other Color Vehicle Key On usually from vehicle ignition switch Pin 3 White Wire Shunt LOAD
13. Command linv 9e Reply OLIV 285 99V involtag The Instantaneous minimum voltage command displays the voltage seen when the maximum discharge current seen in a single sample is recorded This value is reset by the hstclear or hmiclear commands kill ki Full Syntax lt addr gt kill Minimum Syntax lt addr gt ki Broadcast Command No Example Command 1k 9 Reply BSD State of Charge Head2 V1 09 UNIT 01 S N 1026002 kill The Kill command forces the unit to go through a complete reset about 2 seconds after issuance of the command Since this command is a bit dangerous it is protected You must add the parameter 9 or it won t have any effect kwatt k Full Syntax lt addr gt kwatt Minimum Syntax lt addr gt k Broadcast Command No Example Command 1k Reply 01K 001 1KW kwatt The KiloWatt command returns the instantaneous power being used listcmnd Full Syntax lt addr gt listemnd Minimum Syntax lt addr gt l Broadcast Command No Example Command 1 Reply BSD EMeasurement Head2 21 V1 12 UNIT 01 S N 1026002 LISTCMND CURRENT VOLTAGE AMPHOURS WATTHOUR CAPACITY GAUGE MINVOLTS MAXVOLTS TIME TEMPERAT RESET HSTCLEAR HMICLEAR HMACLEAR STATUS CHANGEAD KWATT PMINIMUM PMAXIMUM CFINVOLT CFINCURR CFINSECS CFINAMPH CFINLTIM CFINNUMB LMINAMPH LMINWATT SETCRNGE SETVRNGE SHUNTVAL KILL INCURRNT INVOLTAG STOPCHRG Rudman BusEC listcmnd Prints a brief list of all the customer
14. The communication data cables are hooked to the various devices 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 an unplugged portion of the Rudman Bus the charger cannot communicate with the regs and this could lead to a 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 ensure 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 33
15. acles 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 figure 06 T D B R WHITE WIRE BLUE WIRE PLASTIC TANG TANG DOWN BLUE RIGHT figure 06 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 pi
16. ate of charge based on the amp hours you have selected with the capacity command This will be reset to 100 when the unit resets based on the charge finish parameters or you issure the reset command 19 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 given bus address incurrnt i Full Syntax lt addr gt incurrnt Minimum Syntax lt addr gt 1 Broadcast Command No Example Command 1i Reply O1IC 0819 6A incurrnt The Instantaneous maximum current command displays the highest discharge current seen in a single sample since the last hstclear or hmiclear command The instantaneous minimum voltage is recorded at the same time for later display by the involtag command 20 involtag inv Full Syntax lt addr gt involtag Minimum Syntax lt addr gt inv Broadcast Command No Example
17. connected to the same communications bus With the dongle terminator box hooked up to the SOC Head and the USB plug going into a Windows based computer all that is really needed to send commands read from and communicate with the SOC head is a simple terminal program Many versions of Microsoft Windows up until VISTA came with a program called Hyperterminal Another free terminal program available online is called PuTTy The correct com port number must be identified and the serial communication must be set to 9600baud 8 bits no parity An easy alternative is to download the free Manzanita Micro Reg Scanner software or the Manzanita Perl Scanner software for even easier communication and graphical battery info These programs are all available in the aforementioned Downloads section of the Manzanita Micro website SOC Head Unit Layout 12V POWER HIGH VOLTAGE INPUT FOR UNIT INPUT a RELAY OUTPUT CONNECTOR KEE 2468 1012 REGBUS PORTS figure 02 Rudman Bus Ports RJ Connections On the end of the unit next to the relay output connector are the In Out ports for the reg bus communication line These are standard 6 pin RJ data connections Either one or both of these ports allow the SOC head to be connected into the Rudman Bus Even if there are other units connected on the Rudman Bus the precise order does not matter as each unit is individually programmed with a specific bus address identification number that does
18. e voltage go above cfinvolt while in state 2 it goes on to state 3 where it looks for the current to decrease below the value you set with the cfincurr command or Charge Finish Current You might guess that you could check where this was set by Command 25cfinc Reply 25CC 0002 9A If that wasn t what you wanted you could change it to 5A by Command 25cfince 50 Reply 25CC 0004 9A Yes these numbers aren t coming out exactly what we wanted but they are close It is again an ingeter math thing coupled with being able to measure up to 1000A the 100mA pieces sometimes get lost To continue on with our charging the current has to stay below our charge finish current for some time before we decide we are done That time is set with the function cfinsecs It reports the time in minutes and seconds but you have to feed it integer seconds To find where it is set you do this Command 25cfins Reply 25CS 0005 00 This says that the charge current MUST stay below cfincurr for 5 minutes in order to declare the charge complete If you wanted to change it to 2 minutes you would need to give the command 120 seconds like Command 25cfins 120 Reply 25CS 00002 00 When this has been met we reset the time reported by the time command to 0 clear the Amp Hours and Watt Hours used to 0 We increment our charge cycle count record how many Amp Hours extra we had to put into the pack and how long
19. er is installed USB PORT REG BUS PORTS 12 VOLT INPUT figure 08 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 SOC Head and any Mk3 digital BMS units using the Rudmanbus system The other end of the dongle has two Ru 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 12 volts to power it 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 Parameter Adjustment and Commands Using Commands Unlike the old analog Rudman Regulators the SOC Head does not require adjusting potentiometers in order to change voltage settings Instead the SOC Head can be asked to feedback information or have settings such as voltage limits changed using simple ASCII commands The SOC Head should be talked to individually by using its specific bus address Some commands can be sent to all Mk3 based units on the Rudman Bus at once by entering a bus address of 99 or This is useful for commands like clearing history or setting all of the voltage limits A command
20. ese two shunts is still the same they both have a value of 100 micro ohms The number we use is how many Amps result in 50mV The difference in the shunts is what current they can handle continuously The shunts that come with the unit are rated to handle 2 3 of their rated current continuously so if you expect to spend lots of time above 333A you should go to a bigger shunt Our Zenn would be fine with a 500A 50mV shunt but a converted Cadillac Escalade would probably need a bigger shunt If you needed the 1200A 50mV shunt you would reconfigure the SOC like this Command 25sh 1200 Reply 25SH 1200 Now for the current range The normal range of currents that the unit can measure with a 500A 50mV shunt is about 350A charge to about 1000A discharge Our little Zenn wouldn t know what to do with 1000A except possibly catch fire so that probably isn t very useful A little better resolution in the 350A 350 area might be useful We can do this with the setcrnge command We can see where the unit is currently set by Command 25setc Reply 255C 0 This is set for the standard asymmetric range We can change it to the symmetric range by Command 25setc 1 Reply 255C 1 Something to note as we go along here is that all commands we send to Rudman Bus devices are in lower case and all replies from the units are in UPPER case This is so the units can tell the difference between commands we send and responses from other units T
21. gbus High Active 2 4 Pack Voltage under Minimum pminimum 3 8 Pack Voltage over Maximum pmaximum 4 16 Manzanita Charger is On 5 32 Charge Cycle Complet in charge state 5 6 64 Amp Hour below Low Warning level ahwarnin 7 128 Amp Hours below Low Shutdown level ahshutdn relayO relay0 Full Syntax lt addr gt relay0 Minimum Syntax lt addr gt r relay0 Broadcast Command No Example Command lrelay0 1 Reply OLRO 1 relay0 The RelayO command displays or alters which conditions affect the actuation of Relay0 The conditions that can be used to activate the relay can be seen in the description of the relaycnd command above The example shows setting relay 0 to activate when the regbus low signal activates This can be used to put your controller into a slow mode to protect your battery pack In addition to the values shown in the relaycnd command you may enter the value 256 to force the relay on to test your wiring Setting the relay value to O will force the relay off If you force the relay on be sure to put it back to the proper value afterward relay1 relay1 Full Syntax lt addr gt relay Minimum Syntax lt addr gt relay1 Broadcast Command No Example Command lrelayl 8 Reply O1R1 8 relayl The Relayl command displays or alters which conditions affect the actuation of Relay The conditions that can be used to activate the relay can be seen in the description of the relaycnd command above The example
22. he charger and or other Manzanita Micro BMS units and accessories eSeamless integration with Manzanita Micro Perl Scanner program which has extra graphics already programmed in for displaying the SOC Head information System Requirements Currently the Manzanita Micro SOC head has been designed to work with software that runs on Windows based computer or display systems Operating system Windows XP or newer recommended The reality is that anything Windows 95 or newer is likely to run the software Processor Anything capable of running Windows XP should run the software Connectivity A USB port and the appropriate dongle terminator box will be required in order for the program to receive the digital data from the regulators Setup Software Acquisition and Installation Go to www manzanitamicro com Go to the Downloads section and then to the Software sub heading Then go to the Mk3 Digital Regulators There are various software options and documentation available from this sub section Click on the Download button to download and save the files to your computer If the computer is not already equipped with the proper drivers start by downloading the DT USB Driver installer program This is an exe file that will automatically install the correct drivers allowing the computer to connect to the DT box dongle terminator box and communicate with the SOC Head and any other Manzanita Micro digital devices that are
23. he relay connector is organized as four quadrants with a single pole double throw relay contact in each of the four quadrants The left side of the diagram has the contacts for relayO pins 1 6 and the right side pins 7 12 has relay1 Each SPDT relay contact has three pins NC normally closed Common and NO normally open The connections are organized as follows Relay Connector RegBus Connectors Figure 05 Pin 1 Blue RelayO NC When Relay is activated this line opens Pin 2 Black RelayO NO2 When Relay0 is activated this line closes Pin 3 Green RelayO COM1 This is the common line for RelayO contact 1 Pin 4 Red RelayO COM2 This is the common line for RelayO contact 2 Pin 5 Yellow RelayO NO1 When Relay0 is activated this line closes Pin 6 Orange RelayO NC2 When Relay0 is activated this line opens Pin 7 Orange Relay1 NO1 When Relay1 is activated this line closes Pin 8 Yellow Relay1 NC2 When Relay1 is activated this line opens Pin 9 Red Relay1 COM1 This is the common line for Relay1 contact 1 Pin 10 Green Relay1 COM2 This is the common line for Relay1 contact 2 Pin 11 Black Relay1 NC1 When Relay1 is activated this line opens Pin 12 Blue Relay1 NO2 When Relay1 is activated this line closes Reg bus Wiring All Manzanita Micro Mk3 digital hardware products are connected with a 6 pin RJ data cable allowing them to communicate both digitally and with
24. he relay outputs First we should find out the address of the Device We can do this by connecting to the Rudman Bus using a terminal emulator like HyperTerminal or Putty then plugging in the main power plug to the device It should sign on and display its revision unit number and serial number Once we know the unit number we can move it to where we want it to live usually after all the cells in our pack The factory default is that the SOC comes as unit address 1 so we will have to move it We do this with the change address command like this Command lcha 25 Reply 01 Now 25 Notice I used the shortened version of the command cha I will use the short versions of the commands during this tutorial Now we can plug in the rest of the units on the Rudman Bus There are three parameters we use to do some basic setup We need to tell the unit what value of shunt we are using Most units come with a 500A 50mV shunt This allows us to measure currents up to around 1000A discharge If we need more than that there is a 1200A 50mV shunt available for a slight additional charge This allows measurement of currents above 2500A Voltage and Current ranges can be adjusted over a factor of 2 28 So for checking what value of shunt the unit is set for we use the shuntval command Command 25sh Reply 25SH 500 This means that the unit is set for a 500A 50mV shunt or possibly a 10004A 100mV shunt Note that the ratio of th
25. he units that Bruce Sherry Designs manufactures come in two voltage ranges 250V and 500V A 72V Zenn doesn t have a lot of use for either of those so the voltage range of the SOC can be halved in the configuration We do this with the setvrnge command like this Command 25setv 1 Reply 25SV 1 This configures the unit so it can measure from 0 to about 125V so its calculations can be a bit more accurate If we wanted to change it back we merely have to say 29 Command 25setv 0 Reply 255V 0 Next we need tell the device what our battery pack capacity is This is what the Fuel Gauge is based on If we have a 100AH pack we might set it to 100 or we might set it to 80AH to give ourselves some margin We might first check where it is currently set like this Command 25ca Reply 25CA 100 00AH This might be what you would have in a 72V Zenn NEV with 24 prismatic cells If you had 200AH cells you might want to set your capacity to 175AH and you would do it like this Command 25ca 17500 Reply 25CA 175 02AH Yes you have to type all the digits from the right You may or may not include the period as a decimal point the unit will ignore it where ever you put it it wants the digits This is because the unit does all its calculations with integer numbers and what we are looking for is 17500 Now in order to reset itself at the end of charge so the fuel gauge function will work properly we have to tell it what
26. not change The SOC head can have its own bus address assigned just to it The dongle terminator DT for the Manzanita Micro Rudmanbus Display or a laptop can be plugged into the same Ru connection at either end of the chain to read information and send commands to the SOC Head over the Rudman Bus More information on that is contained in The Rudman Bus Interface section of this manual The Rudman Bus Interface The Rudman Bus 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 Rudman Bus 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 Rudman Bus interface contains five wires connected as follows 1 Power supply 5 volt DC 2 Battery overvoltage condition reg ON or reg hot 5V on this line when active 3 Battery 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 8 654321 65432 figure 03 Note The pin count reads from left to right when looking straight on into the RJ receptacle but the
27. ns 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 11 to again orient the blue wire to the right when the connector tang is facing down see figure 06 and figure 07 TANG DOWN BLUE RIGHT figure 07 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 Rudman Bus using a dongle terminator box which is available from Manzanita Micro These items in conjunction with the free software will allow you to view SOC Head and BMS data and 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 Make sure that the proper driv
28. or Windows Based Computer 21s Page 12 Dongle Terminator DT BOX ccecececeeeeeeeeeeeeeeeeeeeseseseseseeeessasstsssasstsssers PAGE 13 PARAMETER ADJUSTMENT AND COMMAND ccecceeeeeeeeeseeesteeeesteeeseeeePage 13 Command Usage and Document Conventions ecceceeeeeeeeeeesteesteesstereees PageS 13 14 Commande List ecco ease ace eslececetcetevgeces asuceddesdenuecdedge gdicdewtecsestceeredaeceezesinee Pages 14 15 Command Details AH Shutdown AH Warn Capacity cccccceceeeeeeeeeeeeeeeeeeeeeetseeeeseeePage 16 Chrg Finish AH Chrg Finish Current c cccesccsseceseeeeeseeessseeesseeeeseeeeeeees Page 17 Chrg Finish Last Time Chrg Finish Number Chrg Finish Seconds Chrg Finish Voltage ccccccecscceceeseneeeeeeneeeeeeeneeeesecneeeeseeneeesseeneeeeseeeenseeeeenees Page 18 Change Address Current GaUQe cssecceseeeeeeeeeseeeeeseeeeneeeeseeeseseaeenseeeeees Page 19 History Max V Clear History Min V Clear History Clear All Instant Current Mag eege deeg REENEN Sec Page 20 instant Voltage Min Kill Full Reset kW Instant Pwr List Commandes Page 21 Last Min AH Last Min Watts Max Volts E Ge Ce Min Volts Pack Max Voltage Pack Min Voltage e Page 23 Relay Conditions RelayO Relay1 ccseccessesseeesseeeeseeeeeeeeseaeeeseeeenseeeeeas Page 24 Reset Soft Reset Set Current Range Set eee eee settee Page 25
29. rts the internal temperature of the State of Charge Head in degrees Celsius time t Full Syntax lt addr gt time Minimum Syntax lt addr gt t Broadcast Command No Example Command 1t Reply 01T 0325 36 time Reports the time since the last reset command or charge completion reset in minutes and seconds The example shows 5 hours 25 minutes and 36 seconds voltage v Full Syntax lt addr gt voltage Minimum Syntax lt addr gt v Broadcast Command No Example Command 1ch 9 Reply 01V 081 57V voltage Reports the current pack voltage 2I watthour w Full Syntax lt addr gt watthour Minimum Syntax lt addr gt w Broadcast Command No Example Command 1w Reply OW 05739 4WH watthour The watt hour command displays the watt hours used since the last reset or charge completion cycle The minimum this reaches is stored upon charge completion and can be read with the Iminwatt command Configuration The SOC Head needs to be configured for your specific battery pack and charger This involves telling the unit the pack capacity in amp hours what the pack voltage should be above in order to enable charge completion what the current should come down to and how long to wait before deciding that the charge is complete You should also configure the voltages to activate the low and high relays Other things you should decide on is whether the Rudman Bus high and low signals should be echoed to t
30. shows setting relayl to activate when the pack voltage goes over 24 Pack Maximum pmaxium This can be used to disable your charger on overvoltage to protect your battery pack In addition to the values shown in the relaycnd command you may enter the value 256 to force the relay on for testing Setting the relay value to 0 will force the relay off If you force the relay on be sure to put it back to the proper value afterwards reset r Full Syntax lt addr gt reset lt newcapacity gt Minimum Syntax lt addr gt r lt newcapacity gt Broadcast Command No Example Command 1r Reply 01R 0000 00 reset Resets the state of charge to 100 and zero amp hours and watt hours It also resets the time to zero and reports it setcrnge se Full Syntax lt addr gt setcrnge Minimum Syntax lt addr gt se Broadcast Command No Example Command 1se Reply O1SC 0 setcrnge The Set Current Range command allows you to view or set the range for current over a factor of two There are two ranges 0 and 1 Range 0 has asymetric range with the standard 500 50 shunt it measures about 300A charge and 900A discharge Range 1 is symmetric with 300A for both charge and discharge setvrnge setv Full Syntax lt addr gt setvrnge Minimum Syntax lt addr gt setv Broadcast Command No Example Command 1setv 1 Reply O1SV 1 setvrnge The Set Voltage Range command allows you to view or set the range for voltage measurement over a
31. side small terminal on side of shunt load end Pin 4 Black H V Wire amp the Plain Cable Shield These two wires can go to the main large terminal of the shunt on the LOAD side The shield wire is non insulated Pin 5 Black Wire 12 Volt Negative usually from vehicle s chassis 12V ground Pin 6 NOT USED Pin 7 Green Wire Shunt BATTERY side small terminal on side of shunt batt end Pin 8 Red Wire Main Battery Pack Positive from the most positive point in the pack Information on assembling and servicing the main 8 pin connector can be found on page 31 of the PDF document at the following web address http rhu004 sma promail com SQLImages kelmscott Molex PDF_Images 987650 21 81 PDF Relay Output Connectors The SOC Head has some internal relays which can be triggered under various circumstances such as when the state of charge falls below a certain point or when pack or cell voltage goes above or below a preset level How the relays are used is completely up to the end user The SOC head will function just fine even with nothing hooked up to the relay connections A variety of useful connection points are made available on the 12 pin connector on the end of the unit The unit is shipped with the proper connector plug and at least 12 pins These pins are designed for use with 20awg through 24awg stranded wire An example color scheme is shown in figure 03 as well as listed in the description below T
32. starts with the bus address in ascii decimal ie 0 to 254 These are followed by the specific command to be executed Since address 99 can be a broadcast command in order to talk to unit 99 the address must be preceeded with a 0 as in 099 Assuming the SOC Head is programmed with a bus address number of 50 to ask for the total battery pack voltage reading the command would be SO0voltage and then hit the return key The SOC head would then reply with the full pack voltage it is currently reading This command can be shortened to 50v Document Conventions Again ASCII numbers from 000 to 254 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 254 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 command 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 instead of a broadcast signal specify at least one leading zero E g 099 this would mean actual bus address 99 A descriptive word representing one field will be set off
33. status Changead Kwatt Pminimum Pmaximum Cfinvolt Cfincurr Cfinsecs Cfinamph Cfinltim Cfinnumb Lminamph Lminwatt Setcrnge Setvrnge Shunt Kill Incurrnt Involtag Stopchrg Ahwarnin Ahshutdn Relaycnd Change SOC Head Rudman Bus address Display Instantaneous Power in Kilo Watts Display Set Pack minimum voltage warning Display Set Pack Maximum voltage warning Display Set Charge Finish Voltage level Display Set Charge Finish Current level Display Set Charge Finish Time Show Amp Hours required to finish last charge cycle Show charge current taper time for last charge cycle Show Clear Charge Cycle Number Show Amp Hours used before last charge cycle Show Watt Hours used before last charge cycle Set Display Current Range Set Display Voltage Range Display Modify Shunt Value Force Reset of unit Instantaneous maximum Current Instantaneous minimum Voltage Stop Charger when charging complete Show Change Amp Hours Low Warning level Show Change Amp hours Low Shutdown level Display current relay conditions RelayO Show Change conditions for relay Relay1 Show Change conditions for relay1 15 ahshutdn ahs Full Syntax lt addr gt ahshutdn Minimum Syntax lt addr gt ahs Broadcast Command No Example Command lahs 5 Reply OLAS 5 ahshutdn The Amp Hours Low Shutdown command displays or alters the percentage of full capacity that is used for controlling the actua
34. stclear or hmiclear command pmaximum pm Full Syntax lt addr gt pmaximum lt newpackmaximum gt Minimum Syntax lt addr gt pm lt newpackmaximum gt Broadcast Command No Example Command 1pm 8600 Reply OLPA 085 99V pmaximum Either reports or changes the current maximun pack voltage before the SOC Head will switch its high voltage warning relay You must enter all digits to the right as displayed by the command with no argument If lt newpackmaximum gt is not present lt addr gt pmaximum reports the current value pminimum pmi Full Syntax lt addr gt pminimum lt newpackminimum gt Minimum Syntax lt addr gt pmi lt newpackminimum gt Broadcast Command No Example Command 1pmi 5000 Reply O1PI 085 99V pminimum Either reports or changes the current minimum pack voltage before the SOC Head will switch its low voltage warning relay You must enter all digits to the right as displayed by the command with no argument If lt newpackminimum gt is not present lt addr gt pmaximum reports the current value relaycnd rel Full Syntax lt addr gt relaycnd 23 Minimum Syntax lt addr gt rel Broadcast Command No Example Command lrel Reply OLRC relaycnd Relay Conditions displays the current state of the conditions that can be used to control the relays The conditions are defined as follows Bit Value Condition 0 1 Regbus Low Active 1 2 Re
35. the end of charge should look like so it knows what to look for Let me first describe the process it uses to determine charge completion The SOC uses what is called a state machine to figure out where it is in the process The first state state 0 is the normal driving state In this state the unit watches for the current to go positive continuously for 5 minutes This is just in case your vehicle has regenerative braking and you might get charge current for short periods of time Once it has seen this for 5 minutes it figures that you are probably charging the vehicle and goes on to state 1 In state 1 the unit is waiting for all the amp hours that you had removed from the pack while driving to be put back in This would most likely correspond to your chargers bulk charge state When they are all back in we progress to state 2 State 2 watches for the pack voltage to get up to a certain point which we tell the SOC Head with the cfinvolt command This in the Charge Finish Voltage If you had 24 Winston Battery 100AH cells like our theoretical Zenn you would probably have your charger set to finish at 87 6V or 3 65V per cell We can tell the SOC Head that we are in the voltage range of charging finish at about 86V which we do like this Command 25cfinv 8600 Reply 25CV 085 99V 30 If we just wanted to find out where it was we would do Command 25cfinv Reply 25CV 085 99V Once the SOC Head sees th
36. the gauge command will report 0 Issuing the command without a new capacity number will display the current setting Decimal points in the lt newcapacity gt are ignored so you must enter all digits to the right of the value you want To set the capacity to 180 amp hours enter 1ca 18000 or 1ca180 00 cfinamph cfina Full Syntax lt addr gt cfinamph Minimum Syntax lt addr gt cfina Broadcast Command No Example Command lcfina Reply 01CA 000 93AH cfinamph Charge Finish Amp Hours reports the state of the amp hour counter when the last charge cycle was completed That is to say how many more amp hours were put into the pack than were taken out If this number starts to increase over similar amounts of discharge it could indicate deteriorating pack health cfincurr cfinc Full Syntax lt addr gt cfincurr lt newcurrent gt Minimum Syntax lt addr gt cfinc Broadcast Command No Example Command 1cfinc Reply 01CC 0002 9A cfincurr Charge Finish Current reports or alters the value below which the current must fall during charge in order for the SOC Head to declare the pack charged Cfincurr will report the existing setting if no current is specified If a current is specified it will be changed to the new value The input format ignores period characters so you must enter all numbers to the right of what you need as reported by not supplying a parameter So in order to set the value to 15 amps you
37. tion of the relays In order to use this value to control a relay bit 7 value 128 of the relay0 or relay command must be set The current value can be read by leaving off the new percentage value ahwarnin ahw Full Syntax lt addr gt ahwarnin Minimum Syntax lt addr gt ahw Broadcast Command No Example Command lahw Reply 01AW 15 The Amp Hours Low Warning command displays or alters the percentage of full capacity that is used for controlling the actuation of the relays In order to use this value to control a relay bit 6 value 64 of the relay0 or relay command must be set The current value can be read by leaving off the new percentage value amphours a Full Syntax lt addr gt amphours Minimum Syntax lt addr gt a Broadcast Command No Example Command la Reply 01AH 000 93AH amphours The Amp Hour command displays the amp hours used since the last reset or charge completion cycle The minimum this reaches is stored upon charge completion and can be read with the Iminamph command capacity ca Full Syntax lt addr gt capacity lt newcapacity gt Minimum Syntax lt addr gt ca lt newcapacity gt Broadcast Command No Example Command lca Reply 01CA 100 00AH Command 1ca 50 00 Reply 01CA 050 00AH 16 capacity The capacity command displays or alters the amp hour value that is used for calculating the gauge value When you have discharged your pack this many amp hours
38. u would need to configure the Amp Hours Low Warning ahwarnin and change the relay0 command like Command 25ahw 15 Reply 25AW 15 Command 25relay0 68 Reply 25R0 68 The RelayO command has bit 6 count of 64 and bit 2 count 4 for both Amp hours Low Warning and below Pack Minimum If you had Manzanita Micro regulators you might want to add the regbus low line into the mix with Command 25relay0 69 Reply 25R0 69 That way you would be protected three ways any cell going too low the overall pack voltage going low and getting near the end of your pack capacity 32 You might want to set up relay to disable your controller completely if your remaining pack capacity went under the 10 you would use the Amp Hours Low Shutdown command ahshutdn Just to make sure you might want to also disable the controller when your Manzanita Micro charger was powered up You could do this by Command 25ahs 10 Reply 25AS 10 Command 25relayl 144 Reply 25R1 144 The value 144 is comprised of 128 Amp Hours Low Shutdown and 16 Manzanita Charger On All of the relay conditions are logically OR ed together to activate the relay That is to say that any of the contitions in the mask will activate the relay if they are true NOTICE If you are using a Manzanita Micro charger and the SOC Head or a Manzanita Micro BMS system ensure that the Rudman Bus data cable is fully plugged into the charger whenever the vehicle is charging
Download Pdf Manuals
Related Search