User Manual - EV
Contents
1. _ meme Ry3 closes when error Ry2 closes when nz is detected and mains is connected and CONTACT ON CONTACT ON Ry3 Ry2 max max charger control 1 1A 1234567 8 9 10 Iu 5 8 9 10 current Oe ee sensor 5 m d esa lt 4 n e S 5 3 a NES ou S15 Y _ I T2 in 1 2 3electric nl 3 BMS controller P Backlight Backlight L 12V Yellow 12V Yellow 12V Red 12V Red hhh pe 12V CAR FUSE 5Amp BATTERY In the above schematic the 123Electirc current en fuel gauges are drawn Might you want to use your existing fuel gauges for instance you are free to do so The BMS controller mimics a variable resistor between 0 and 240 Ohms and therefore practically any fuel gauge can be used With the help of analog gauge calibration in the 123Electirc software you should be able to linearize the reading of your gauge www 123electric nl 13 r 9 charger 12345678910 12 sensor NC 4 3 2 1 Control Unit Ground Analog Output 5 Volt Power Not Connected m E um 00 ee ME mm t v MM t Ry3 closes when error Ry2 closes when is detected and mains is connected and CONTACT z ON CONTACT ON USB Ry3 max control 14 BMS ou 2 3 electric nl BMS controller OFFSET i GAIN 4 Current sensor 5 Volt Power Not Connected Analog Output Ground ee www 123electric nl 14 e Conne2. bl ite AF CAR FUSE 5Amp BATTERY FIRST BOARD BMS IN E LAST BOARD BMS OUT A OK KK ER At cocococjecooccoocococoococec FIRST CELL TRACTION BATT LAST CELL Ne 0000000 A M A A EO OC OC OS www 123electric nl Split pack wiring overview to battery charger to controller BMS IN to controller BMS OUT to motor controller LAST BOARD BMS OUT FIRST BOARD BMS IN BMS OUT BMS IN www 123electric nl 10 Es E Sase LIE e Charger 1 Relay output 1 only for on off charger 2 Relay output 1 only for on off charger 3 Not connected 4 Analog out for analog controlled charger 5 12 Volt In for analog controlled charger 6 Ground for analog controlled charger 7 Bus out 8 Bus out 9 Bus in 10 Bus in www 123electric nl 11 e UWD BMS out BMS out BMS in BMS in Current Sensor DS Ground Analog in 5 Volt power Not connected Control Ground Not connected Relay output 2 Close if one cell voltage is too low Relay output 2 Close if one cell voltage is too low Analog coulombcounter output Relay output 3 Close if mains connected Relay output 3 Close if mains connected Analog current output Switched 12 Volt power contact 10 12 Volt power always on www 123electric nl 12 Boardnet connections 77 oo
3. User Manual 123Electric Battery management system Electric Vehicle Revision 1 0 www 123electric nl Table of contents guigeie PTS R91 MSN RR RES 3 ei engctcgb uil ye PC 3 Keep the batteries in perfect conditiohiu uet iron taro aea E eun R Eo usua aeg SE e unen peus r ausa a Pega p npud 5 ie el or JB lo g NN M OR ove EDT nM een PT nT Vr Cn EC PE caia cmm 6 BMS Board gno IRA MONS 7 Wiring Diasram OvervieW siissrissercisrereviroreniiiie iio EYE ior NEA ENRE 9 Split pack Wiring OVSIVI EW a sssastesddqes n dat uada eas ein ENE EENDEN E N ENE TEKS RaKa 10 Controller Cone EIOS eode ddr evite TEOR 11 Boardnet connections scccsccosenevauapeu Ge inabcu av vay Cx FA s Ty MARTE AF ARR RARE YA REX RAV SP YAn Y Mo pc FP np u ud 13 Current sensor connections usssbasoi on ORAS UARERIA Na PER URERPRN RETE pER P PaV C No pER R Cb MUR R OR omnes 14 TC Charger connections NN D 16 Software settings sonsecesnexeinorsnenuncasnestinadsinenmncannentinod E E E E E E O 17 Software Dashboard siseses rnesa enaa E E EE EEEE EEEE a 25 www 123electric nl 2 Introduction After the introduction of affordable Lithium Ferro Phosphate batteries electric cars boats and motorcycles became feasible It is vital that such batteries are charged very carefully In other words they can easily be over charged or over discharged Cell temperature and current are also very important in order to guarantee a long
4. 00 Minimum If one of the cells gets below this threshold the E and L indicator on the electronic dashboard are switched on and the error relay Ry3 will be activated provided the contact is on Maximum If one of the cells gets above this threshold the E and H indicator on the electronic dashboard are switched on and the error relay Ry3 will be activated provided the contact is on Bypass This is the voltage where you want all the cells to end up When you have selected balanced charging you will get to this situation every charging cycle In quick charge mode however it may take several cycles Recharge Threshold Assume you leave your electric vehicle connected to the mains for a long time Obviously you don t want to start a charging cycle every day but you want to keep your battery pack up to date If one of the cells gets below the recharge threshold a new charging cycle will start www 123electric nl 21 Cell Temperature Minimum Celsius 40 99 Maximum 60 Celsius 40 99 Minimum If one of the cells gets below this threshold the E and L indicator on the electronic dashboard are switched on and the error relay Ry3 will be activated provided the contact is on Maximum If one of the cells gets above this threshold the E and H indicator on the electronic dashboard are switched on and the error relay Ry3 will be activated provided the contac
5. Note Selecting another current sensor will automatically select another current scale on the electronic dashboard www 123electric nl 17 Cell capacity The cell capacity can of course be set to the capacity of the cells used We advise however to take only 7096 of the rated capacity to comply with cell aging and temperature effects Example if you have 90 Ah cells enter 65 Ah in the capacity field Charging algorithm Balanced charge After the charging process begins the current slowly increases to the maximum charging current until one of the cells reaches the bypass voltage At that point the charging current will ultimately be reduced to the minimum charging current Charging ends when one of the cells reaches the maximum cell voltage OR when all cells reach the bypass voltage Quick charge After the charging process begins the current slowly increases to the maximum charging current until one of the cells reaches the maximum voltage OR all cells reach the bypass voltage At that point the charging ends Note We advise to use balanced charge at least regularly but certainly when the battery pack is new When you replace one of the cells in a pack or for priming balanced charge may come in handy www 123electric nl 18 os o E E ud er Time settings Device Time 14 01 Bieri Charging starts 23 00 WIEP Charging stops 23 00 WIEP in Device time Here you can enter the time in a 24h fashi
6. controller Idle Current of the BMS controller inclusive current sensor Number of Cells Balancing Current Idle Current BMS board Current sensor Resolution 8 15 Volt 15 mA 2 255 1 Amp 100 uA 100 200 or 400 Amp 1024 steps www 123electric nl WARNING be aware that your battery pack contains a large amount of energy which can be potentially lethal Use isolated spanners to prevent any short circuits High inrush currents causing arc ing sparks and ultra high electro magnetic levels can easily damage electronic circuits We therefore strongly recommend to always FIRST connect the so called large current connections in a new setup and THEN separately connect the BMS boards A good way of doing this is indicated on photo number one Standard M8 bolts are modified with an M4 threaded hole in the top After thorough cleaning of the cell poles the copper strips are bolted on Don t forget to also attach wires to the first and last cell in the same way and connect these to the charger and the motor controller www 123electric nl Fi Now prepare the BMS boards as shown on photo number two Use thick solid copper wire for this Use the right length so that the end result looks good Connect all the boards as shown in photo number three The BMS board always to be mounted on the plus pole of the cell This is also indicated on the board Remember to use an IN board for th
7. ct the power source and output correctly never make a wrong connection e Two potentiometers can be adjusted by turning slowly to the required accuracy with a small screwdriver Normally factory calibrated only necessary if the idle current isn t zero www 123electric nl 15 NIE ELCON BATTERY CHARGER a mm M R Ry3 closes when error Ry2 closes when cas is detected and mains is connected and CONTACT ON CONTACT ON Ry3 Ry2 ine ma USB charger control 1 1A 123456789 10 12 5 8 9 10 al cwrent eeeeeeeees eoeeceeees sensor 4 5 a2 85 Zs 3 ix 5 T Es a E 5 ou Ww 10 Y 2 SIS f in 1 2 3eiectric ni 2 BMS controller H To battery pack Control unit TC charger Enable Black Pin 4 Standard TC connector 12 Volt Red Pin 5 Ground Green Pin 6 www 123electric nl 16 Charge settings Voltmeter scale 40 140 v MU Current sensor 100 a Ampere Cell capacity 90 Ah Charging algorithm Balanced charge Quick charge Voltmeter scale In this part of the settings menu you can select one of five different volt meters on the electronic dashboard for the reading of the pack voltage 10 60 Volt 40 140 Volt 100 200 Volt 150 300 Volt 250 500 Volt Current sensor The 123BMS can work in conjunction with one of three different current sensors Chose the one that you ordered 100 Ampere 200 Ampere 400 Ampere
8. e first cell and an OUT board for the last cell see wiring diagram overview Might you have two battery packs like one in front and the other in the back of a car you will have to equip each pack with its own IN and OUT board see split pack wiring overview For optimum noise immunity the wiring from and to the IN and OUT boards will have to be so called twisted pair see wiring diagram overview and or split pack wiring overview It speaks for itself that if you would plan to use for instance three packs that you will have to order three IN boards and three OUT boards For optimum reliability the one wire interconnect should be soldered as indicated in the diagrams Use a small soldering iron and take your time to do this job VERY carefully NOTE Make sure the BMS boards are located in a dry and dust free area otherwise we advise to use a special PCB coating www 123electric nl 8 Wiring Diagram Overview CONFIGURATION amp MONITORING SOFTWARE WINDOWS ELCON BATTERY CHARGER A 07 p B ES Ry3 closes when error Ry2 closes when pm is detected and mains is connected and 77 CONTACT ON CONTACT ON d Ry3 ms max USB charger ouno 1A T DOE EHI EXEYTYTINXS qil current x CURRENT E enu h I idle lt 15mA i j sensor Ud E Jem Li BMS controller to motor controller ex
9. life The 123electric Battery Management System or BMS is primarily intended for prismatic LiFePO4 cells but can also be adapted by the end user for other cells like Li lon and LiPo provided the cell voltage is in the range of 2V to 5V System structure The 123electric BMS is designed for battery packs that have many cells in series to form a high voltage battery pack Each cell is equipped with a small BMS board that monitors cell parameters like current voltage and bypass current and communicates over a one wire interface with the BMS controller This BMS controller collects this data and displays that via a USB interface on a Windows Computer The electronic dashboard tells you in the blink of an eye what the status of your battery pack is In the settings menu the user can adapt the system to his requirements Voltmeter 5 choices Current Sensor used 3 choices Cell Capacity 10 999 Ah Charging Algorithm balanced or quick charge Real Time Clock 24 h Charging starts Charging stops Minimum Charging Current depending on charger used Maximum Charging Current depending on charger used Minimum Cell Voltage error level Maximum Cell Voltage error level Bypass Voltage balancing voltage www 123electric nl 3 Recharge Voltage Minimum Cell Temperature error level Maximum Cell Temperature error level Gauge linearization for curre
10. nt and capacity gauge Current scale selection The BMS controller can be connected with most chargers from the TC range via the three wire control connector No CAN option required To indicate an error condition two relay outputs are present that can be wired to the motor controller and or to a dashboard indicator www 123electric nl 4 Keep the batteries in perfect condition The drawing below shows that your expensive batteries are in good hands with 123 electric The system sets the coulomb counter to 10096 when either all cells get to V bypass or one cell reaches V max You can change these settings with the PC software by yourself Calibrating the coulomb counter to 10096 is important as otherwise small errors will appear because of changes in the charging efficiency aging of the batteries etc etc The width of the green safe area can also be selected by yourselves If you use 90 Ah cells for instance and you only want to use 6096 of the capacity you can enter 6096 of 90 Ah 54 Ah in the field for Cell capacity Conclusion the upper limit is safe guarded by entering V max V bypass and the lower limit by Cell capacity Cell 123Electric BMS Coulomb counter Voltage 0 25 50 75 100 4 00V 3 79v 3 50V 3 25V 3 00V 2 75V 2 50V 2 25V 2 00V 0 20 40 60 80 100 SOC V MAX V BYPASS www 123electric nl www 123electric nl 5 Specifications Supply Voltage of BMS
11. on The BMS controller keeps this time as long as 12 Volt will be supplied to the unit Charging starts Here you can enter the time after which charging is permitted Charging only starts at the moment that the device time equals the start time Charging stops Here you can enter the time after which charging is not permitted Charging only stops at the moment that the device time equals the stop time Important If the start and stop time are equal charging is always permitted www 123electric nl 19 Charging Current Minimum Maximum Minimum The final current after balanced charging should approach the 1 ampere bypass current of the BMS boards The minimum can be set from 2 to 17 of the maximum charging current supplied by your charger Example Maximum charging current is 30 Ampere 1 Ampere would be 3 3 gt Select 4 as minimum charging current Maximum The maximum charging current can be set to 20 40 60 80 and 100 This feature may come in handy when you are on a camping and they only supply reduced current Example assume that you have only 230 Volt 6 Ampere available 1380 Watt and you have a 3000 Watt charger If you set the maximum current to 40 you will only use 1200 Watt Take into account that charging time will increase www 123electric nl 20 Cell Voltage Minimum Volt 2 00 5 00 Maximum 3 75 EALE AN ERA Bypass Volt 2 00 5 00 Recharge Treshold Volt 2 00 5
12. s Save Note Make sure you do this procedure using the right 12 Volt battery voltage www 123electric nl 24 dashboard Y settings PEOC TUJ 0 o un Amp re a9 ce 25 C 14 ZEILE 40 P 50 P4 d N f3 40 y 2 3 5 719 14 N P 3 0 Relectric 5 0 z I23electric 80 min max V min max C R Me VED PIE dashboard Q Charge settings Charging Current Voltmeter scale Volt Minimum 26 v Current sensor 100 v Bes Maximum cal apaty an Charging algorithm Balanced charge Cell Voltage Quick charge Minimum Volt 2 00 5 00 char dag dae Maximum Volt 2 00 5 00 Time settings Bypass Volt 2 00 5 00 Recharge Threshold 3 00 MYSTTeXBERI Device Time 20 04 WEA Charging starts 00 00 MEA Cell Temperature Charging stops 00 00 MEA Minimum Celsius 40 99 m ripe 12 3 electric ni www 123electric nl
13. t is on www 123electric nl 22 JJ electric nl je producto for electric vehicles 9 Analog Gauge Calibration Current meter Kela 100A excl regen current 25A excl regen current 50A excl regen current 75A excl regen current 125A excl regen current 25A incl regen current 50A incl regen current 75A incl regen current 100A incl regen current 125A incl regen current Analog Gauge Calibration By pressing the Gauge Calibration button in the settings menu you will see the above calibration window After having selected the proper current sensor in the settings menu you can now select the scale of the current meter on the car dashboard The pull down menu will speak for itself the first five options do not display regenerative current whilst the last five do Note that the regenerative current will be displayed as a positive current www 123electric nl 2 3 In order to linearize your specific gauge the following procedure is necessary 1 Remove the wire to pin number 9 contact of the control connector and prevent short circuit 2 Switch on the contact key gauges get 12 Volt supply voltage 3 From gauge calibration mode select for instance 5096 for the current meter The meter should now read 50 if it does not read 5096 press the up or down arrow until it does read the required 5096 4 Repeat step 3 for all the other values and pres
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