User Manual - EV
Contents
1. User Manual 123electric Battery Management System 123 BMS Revision 1 1 December 2012 www 123electric nl Table of contents guigeie PTS R91 Cen tee Teer ee er cer RES 3 Systemi Str UCtUTE ccs cocncenpcospconncetqvannented ne enwnqsanpseneconmewuedonersietasanonqdenncourcoeoseuetoneeeeecorenstqnee 3 Keep the batteries in a perfect condition ALWAYS ccccccccceccceeseeseeeeeeeeeceesseanaeeeees 5 nS of eel or B Lo gic eee tres reer Narre eT ete re NP ce Een eT TE CN PE ty cm eS oca iac 6 BMS Board mounting eae EE 7 TC Elcon wiring diagram OVERVIEW vicazesccsssscacecensacauaresnacunntsaceusveiancvenagaeceanitaneanetsanenausioaes 9 Split pack Wiring OvervieWissssrsirisersissrisesineiers iisti nae i n oE ela pd EN ENE TEKS RANN 10 Controller COMMS COINS ire eode ddr evt Vn rud Qt evt Viduae eto Uia utn do ludo Udo 11 Boardret CONNECTIONS scccsscoseue se nesre ina pcu v vay Cx PA RR RRRA TH ARTE ASARR RASA YA E SP YAn EY M opc Fri n pru ud 13 Current sensor connections uo sssosoi on ORAS URRERIA NOU EROR EROS GERE FEKUPMaV C Non paR R Cp MUR RON omnes 14 TC Elcon charger connectlol iSi cesse carbs intu iui eap cad p tition Cul VE dva UC Mese OE 16 Software SCENES soceecacinenescconennndesnonnined o E sinentbddsinestinas E E E E O 17 Screen shots electronic dashboard essssesssssssssssssessssseseseeeseeerrrrrrrrrrerrerrrererrerrrerereeeeee 25 www 123electric nl 2 Introduction After the int2. 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 factory setting is 3 40 Volt 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 So if one of the cells gets below the recharge threshold a new charging cycle will start factory setting is 3 00 Volt www 123electric nl 21 os T iu i io Cell Temperature Minimum Celsius 40 99 Maximum 60 Celsius 40 99 Minimum If one of the cells gets below this threshold the L indicator on the electronic dashboard is switched on Both Balanced charge and Quick charge will be suspended as long as one of the cells are below the minimum temperature set some battery chemistries may not be charged below zero degrees Centigrade The charging process will re start immediately when the cell temperature is within the safe area selected factory setting is O degrees Celsius Maximum If one of the cells gets above this threshold the H indicator on the electronic dashboard is switched on and the error relay Ry3 will be activated provided the contact is on factory setting is 60 degrees Celsius Note 1 Ry3 will be activated when the communication with the
3. charge may come in handy Quick charge After the charging process begins the current slowly increases to the maximum charging current selected until one of the cells reaches the maximum voltage OR all cells reach the bypass voltage At that point the charging ends Emergency charge In a situation where BMS communication is lost Cell Voltage much to low or cable rupture it would become impossible to charge the battery pack For this situation emergency charge can be selected in the electronic dashboard Charging will start even without BMS communication Your supervision is vital here as you can imagine After a period of 30 minutes the charging process will be stopped anyway for this reason www 123electric nl 18 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 fashion The realtime clock will be kept up to date as long as 12 24 Volt will be supplied to the unit Charging starts Here you can enter the time after which charging is permitted Charging only will be enabled 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 will always be enabled www 123electric nl 19 Charging Current M
4. www 123electric nl 13 mm a 2 poen Ry3 closes when Ry2 closes when CONTACT z ON and mains is connected CONTACT ON and no BMS commun or T gt Tmax or Ry3 V Vmin or VoVmax YS USB charger control 1 1234506789 10 122 sensor BMS 4 NC 3 ou 2 1 2eiectricmi Control Unit Ground Analog input 5 Volt power NC ce M pc BMS controller OFFSET 1 GAIN 4 Current sensor 1 5 Volt power 2 NC 3 Analog output 4 Ground www 123electric nl 14 Notes e Connect everything correctly prevent making a wrong connection e Two potentiometers can be adjusted by turning slowly to the required accuracy with a small screwdriver www 123electric nl 15 To battery pack Control unit Enable Black Pin 4 12 Volt Red Pin 5 Ground Green Pin6 ELCON BATTERY CHARGER Ry3 Rye max max control 1A 1A 123456789 10 12 5 8 9 10 BMS 3 2 Oo 2 W 7 8 il 23 lectricnl f id BMS controller TC Elcon charger Standard TC Elcon connector amp cable supplied with the charger www 123electric nl 16 Charge settings Voltmeter scale 40 140 Volt Current sensor 100 Ampere Cell capacity 90 Ah Charging algorithm O Balanced charge Quick charge Emergency charge Voltmeter scale In this part of the settings menu you can select one of five different v
5. 999 Ah Charging Algorithm balanced quick or emergency charge Real Time Clock 24 h Charging start time Charging stop time Minimum Charging Current depending on charger used Maximum Charging Current depending on charger used www 123electric nl 3 Minimum Cell Voltage error level Maximum Cell Voltage error level Bypass Voltage balancing voltage Recharge Voltage charge refresh Minimum Cell Temperature error level Maximum Cell Temperature error level Gauge linearization for current and capacity gauge External current meter scale selection The 123 BMS controller can be connected with most chargers from the TC Elcon range via the three wire control connector No CAN option required To indicate an error condition two relay outputs are available one output Ry2 is active to indicate that the charger is still connected to the mains and the other output Ry3 tells you that the communication between the cell boards is lost and or that one cell exceeds maximum temperature and or the cell voltage is outside the specified range For those who convert a car into an electric vehicle the 123 BMS controller supplies an output that mimics the float resistor in a fuel tank With this feature one may decide to use the already existing gauge as a remaining capacity fuel indicator A second output is available to indicate the actual current The
6. ARGER apuu I _ e emm ppan Ry3 closes when Ry2 closes when 4 ET CONTACT ON and CONTACT ON and no BMS commun or mains is connected T gt Tmax or Ld V Vmin or V gt Vmax Rya USB 7 charger control 1A 123456789 10 UT 8 9 10 qil curent fee eee eo oo BMS GND ca FUEL CURRENT CONTACT iv 24V ENABLE sensor lg 2 3efectric nl BMS controller mod I idle 7 mA to motor controller S J CONTACT bild 12V 24V BATTERY FUSE 5Amp FIRST BOARD LAST BOARD BMS OUT MAIN FUSE BMS IN A OK KK ER At OOOoOOoOOooocoocooooooococec j FIRST CELL TRACTION BATT LAST CELL LOO ODOC KK KK e A E OK DE E DEC www 123electric nl 9 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 Charger nd 2 me 9o cw mi d dope e IS Not Connected Not Connected Not Connected Enable 12 Volt Input Ground Not Connected Not Connected Not Connected Not Connected Es E Sase LIE e for analog controlled TC Elcon charger for analog controlled TC Elcon charger for analog controlled TC Elcon charger www 123electric nl 11 BMS out BMS out BMS in BMS in ar Current Sensor 1 Ground 2 Analo
7. BMS boards is lost and or when the cell temperature exceeds the maximum and or when the cell voltage exceeds its limits provided the contact is on Note 2 On the electronic dashboard three red lamps are shown E L amp H The E lamp is active when there is no BMS communication The L lamp is active when V V MIN and or T T MIN The H lamp is active when V gt V MAX and or T2 T MAX www 123electric nl 22 J 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
8. electronic dashboard offers a simple way to linearise almost any gauge www 123electric nl 4 Keep the batteries in a perfect condition ALWAYS The drawing below shows that your expensive batteries are in good hands with 123 electric The 123 BMS system pre sets the Coulomb counter to 100 when either all cells get to V bypass or when one cell reaches V max You can change these voltage settings with the electronic dashboard by yourself Note the Coulomb counter is also set to 100 after a power down The left side of the green safe area can also be set by yourselves If you use 90 Ah cells for instance and you only want to use 60 of the capacity you can enter 60 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 and on top of that an error condition is issued when one cell gets lower then Vmin so you can be pretty sure you are never ruining your cells Cell 123Electric BMS Coulomb counter Voltage 0 25 50 75 100 4 00V 3 75V 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 V MIN www 123electric nl www 123electric nl 5 Specifications Supply voltage of BMS controller Idle current of the BMS controller inclusive current sensor Number of cells Balancing current Idle current BMS board Current sensor A D resolution Ce
9. g in 3 Switched power to sensor 4 Not Connected Control 1 Ground 2 Not Connected 3 Relay output 3 Closed if BMS comm is lost or if T gt Tmax or if 4 Relay output 3 V Vmin or V gt Vmax whilst contact is on 5 Analog fuel gauge output Coulomb counter 6 Relay output 2 Closed if Mains connected whilst contact is on 7 Relay output 2 8 Analog current gauge output 9 Switched 12 24 Volt power contact 10 Power supply 12 24 Volt permanent connection www 123electric nl 12 Boardnet connections s papa OS pna Ry3 closes when Ry2 closes when emer CONTACT ON and CONTACT ON and no BMS commun or mains is connected T Tmax or V Vmin or V Vmax Pya ye USB charger control 1A 123456789 10 12 8 9 10 sensor 4 A 2 m 5 5 3 x 5 R wS g a i 3 izi gt DION Y 2 SI v 1 23 Tectric ni X BMS controller A f AN Backlight Lo 12V Yellow 12V Red l CONTACT 12V Yellow Jf ff oe 12V Red 12 v 24 y FUSE 5Amp BATTERY In the above schematic the 123electric current and fuel gauges are drawn Might you want to use your existing fuel gauges instead 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 dashboard software you should be able to linearize the reading of your gauge
10. inimum 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 in a situation where only reduced current is available 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 accordingly 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 00 Minimum If one of the cells gets below this threshold the L indicator on the electronic dashboard is switched on and the error relay Ry3 will be activated provided the contact is on factory setting is 2 50 Volt Maximum If one of the cells gets above this threshold the H indicator on the electronic dashboard is switched on and the error relay Ry3 will be activated provided the contact is on factory setting is 3 75 Volt Bypass This is the voltage where you want all the
11. ll voltage Cell temperature Scan time per cell Factory settings 8 30 Volts DC 0 007 Amp 2 255 1 Amp regardless of cell voltage 100 micro Amp 100 200 or 400 Amp 1024 steps 10 bit in steps of 0 01 Volt 2 00 5 00 V in steps of 1 degree 40 to 99 Celsius 0 015 Seconds Vmin 2 50 Volt Vmax 3 75 Volt Vbyp 3 40 Volt Vchg 3 00 Volt Tmin 0 degrees Celsius Tmax 60 degrees Celsius 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 sparks and ultra high electro magnetic levels can easily damage the electronic circuits We therefore strongly recommend to connect all large current connections first and to connect the BMS boards later 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 using a good anti oxidant joint compound like NOALOX 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 7 Now prepare the BMS boards as shown on photo number two Use thick solid copper wire for this for optimum accuracy the bypass current has to flow through these
12. olt meters on the electronic dashboard for the correct reading of your 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 Note selecting another current sensor will automatically select another current scale on the electronic dashboard Note changing current sensor and or capacity results in the preset to 10096 of the Coulomb counter 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 70 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 When the charging process begins the current slowly increases to the maximum charging current selected until one of the cells reaches the bypass voltage At that point the charging current will ultimately be reduced to the minimum charging current selected Charging ends when one of the cells reaches the maximum cell voltage OR when all cells reach the bypass voltage 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 for instance balanced
13. perature Charging stops 00 00 MEA Minimum Celsius 40 99 m ripe 12 3 electric ni www 123electric nl
14. roduction of affordable Lithium Ferro Phosphate batteries finally electric cars boats and motorcycles have become feasible However LiFePO4 batteries can easily be over charged or over discharged It is therefore vital that these batteries are treated very carefully For a maximum range and a long life intelligent battery management is of utmost importance The 123electric Battery Management System or short 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 cell number cell voltage cell temperature and bypass current These boards send this data via a one wire interface to the BMS controller This controller collects all this data and displays that via a USB interface on a Windows Computer A free downloadable electronic dashboard http www 123electric nl software tells you in the blink of an eye what the status of the battery pack is In the settings menu of this program the user can adapt the system to his personal requirements Volt meter range 5 choices Current meter range 3 choices depending on the current sensor used Cell Capacity 10
15. to pin number 9 contact of the control connector and prevent short circuit 2 Switch on the contact key the gauges will get 12 Volt supply voltage 3 From gauge calibration mode select for instance 50 for the current meter The meter should now read 50 if it does not read 50 press the up or down arrow until it does read the required 50 4 Repeat step 3 for all the other values and once you re happy press Save Notes Make sure you do this procedure using the right battery voltage as analog gauges are quite sensitive for varying supply voltage Might you have a 24 Volt battery and you want to connect the analog 123electric gauges follow the instructions that come with the gauges www 123electric nl 24 Screen shots electronic dashboard dashboard Y settings PEOC TUJ YOO Amp re 25 y EEI hae 40 ML 50 40 4 EN 8 ORT 4 5 1i P 3 0 Relectric 5 0 z I23electric 80 min max V min max C Cereus Me VED PIE dashboard Q Charge settings Charging Current Voltmeter scale Volt Minimum 2 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 Tem
16. wires Take your time the end result has to look 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 the 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 individual 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 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 The quality of your work effects reliability greatly NOTE Make sure the BMS boards are located in a dry and dust free area otherwise we advise to use a PCB coating to be applied after the installation is completed www 123electric nl 8 ques MM M M M TC Elcon wiring diagram overview CONFIGURATION amp MONITORING SOFTWARE WINDOWS ELCON BATTERY CH
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