BMS2405-EN-manual - EV
Contents
1. 1 Analog output vs SOC In example above parameter Analog voltage at SOC 0 is set to 10V Parameter Analog voltage at SOC 100 is set to 30V 2 4 Optional input output Pin 7 can be used configured in three different modes e Output o Output set when SOC gt 20 Output voltage is selected with jumper on PSB between 12V or BAT o Output reset when SOC lt 20 e Input function is not implemented e Analog input o If optional pin is configured as analog input then pin is used to measure voltage between case and BAT Pin must be connected to case of BMS or electric car look picture below If voltage is not on middle of ignition output voltage then BMS goes to error mode BMS2405 User Manual IGNITION_OUTPUT gt OPTION_PIN lt 2 5 Charge relay output Pin 4 can be used for connecting external charging relay 2 6 Charge detect input Pin 3 can be used only for charger that has special output to signal charging on or off 2 7 Charge relay Charge relay allows charging currents up to 30A Connect charger minus directly to Batl not to the BMS Charger plus connect to charger relay pin CHARGER IN 2 8 Battery balancing algorithm Resistors on Res O Off rd Battery balancer functionality Balancing algorithm is enabled during charging cycle Balancing algorithm is enabled when battery is full BMS2405 User Manual Each battery cell resistor is enabled if cell voltage is higher than minimum2. BMS 2405 M Cet Lion DMS and S TSS ECE No 041214000063 Made in EU GWL BMS2405 User manual http www ev power eu EV Power eu managed by i4wifi a s member of GWL Power group Prumyslova 11 CZ 10219 Prague 10 CZECH REPUBLIC EU phone 420 277 007 500 fax 420 277 007 529 email export i4wifi cz GWL POWER BMS2405 User Manual Table of contents 1 INTRODUCTION sesscacssccicsiscce ta cacaceecessve te sacs ceeesess eete sassceeclecsseecesesdecsesesseesesedescccecsseedesocdsesessoveeseee 3 2 BMS SYSTEM CONNECTOR o occcccccccoconononononononononononononononononononononoconononononononoconoconoconoconocenonenos 4 Zl ON LORE CON ROE Hcaicecheh IA 22 SGNITION OU ii dd e e 23 ANALOG OUTPU Po sand pel tias cta ZA OPTIONAL INPUT OUTPUT dia 25 CHARGE RELAY OUTPUT 3 mai ia idas 2 07 CHARGE DETECT INPUT tad Dol ACHARGE RELAY ad hai ideado peas da De e ca dolo SE ena 2 8 BATTERY BALANCING ALGORITHM ccccccccccccccsssssssececcccccsssssssscsscccssseeueesesccssssseuseeseecessseaes i 3 CELTS CONNECTIONS iis sccatincic ceicscacecceccsccecssecccececececeaecseccccecscecececsssecascescoscuscaceccscvsccectenseseace 8 3 1 CONNECTION ORDER FOR COMPLETE BMS ccsceccccsscececcescececcssceccacesceceacececcasesseceaneseecees 32 CELES CONFIGURATION ua ii as 4 PROCEDURE AFTER BMS CONNECTION ccocccccococononononononononononononononononononoconocococonocononenos 10 5 BMS STATES wiscecssccsccssssbecsves
3. Command HISTORY DES print history log syntax Date Urorar Umin vor Uinx_min_ vor Umax_ vor Uinx_max_voLr 1 SOC Ogar Table 2 History log syntax Date Day motnh year hour minute seconds UroTAL Total battery voltage mV Umin_voLT Minimum cell voltage mV Unx mm vor Index of minimum cell voltage 2 Umax voLT Maximum cell voltage mV Unx max voir Index of maximum cell voltage Tc Temperature of external sensor The BMS return 273 if C temperature sensor is not found SOC Battery capacity in percent This value is set to O when Umi voLr is lower as value of parameter Shut down voltage SOC is equal 100 when battery is full SOC is decreased to value of parameter Decrease SOC if min cell voltage is lower as value of parameter Decrease SOC because min cell is low SOC is always 100 if current sensor is not present Qerar Actual battery capacity 0 battery full 40000 battery is total mAh empty for 40Ah battery This counter is reset battery is full 17 BMS2405 User Manual 8 2 SOC history Log is stored when e SOC jumps to value of parameter Decrease SOC if min cell voltage is lower as value of parameter Decrease SOC when min cell is lower as and actually SOC value if higher as value of parameter Decrease SOC e Unin cenis bellow shutdown voltage Command SOC_HISTORY sends all SOC history logs SOC history syntax Date O y Type Table 3 SOC history Dat
4. MS2405 User Manual 2 1 ON OFF control Power ON is triggered with e Ignition input 1 Voltage between 15 and 90V or e Charger is connected Power OFF is triggered when e Ignition 0 Voltage 0 o If charger is connected then BMS stays turned on e Charger is disconnected o when BMS doesn t recognize charger for 30 s e Minimum cell voltage is below value of parameter Shut down voltage o If BMS on power up detects that voltage cell is too low then BMS will be turned off after 10 s In this 10 s period user has an option to delay turning off for 10 min with sending any valid command to it This give user opportunity to check which cell is too low 2 2 Ignition output Ignition output is used for connecting controller DC DC converter or other smaller loads Ignition output logic Ignition output is always disabled if BMS is turned off Ignition output is enabled if e Ignition input 1 and e If parameter Turn on controller during charging is 1 during charging Maximum allowed current on ignition output is 5A Voltage on ignition output is always equal to ignition input 2 3 Analog output Analog output range e For BMS HW version 1 2 5V to battery voltage and e For BMS HW version above 1 2 0 10V BMS2405 User Manual Analog output is active only 1f ignition output is enabled Analog output shows value of SOC N o on a S lt x output V 40 60 soc Figure
5. The device does not distinguish between lower and uppercase characters All input data is converted to lowercase characters before command parsing 23 BMS2405 User Manual 10 Parameters Parameters are stored in EEPROM All parameters are 32 bit numbers integer Set parameter with command par_set and get parameter value with command par_get 10 1 List of parameters Print table below with command par_print Table 6 List of parameters UN f ted 0 Number of cells ua u connect 24 6 24 cells When max cell reach Batt FuLL this voltage then BMS 1 LS ON 3600 3000 4000 voltage mV goes to battery full state If external temperature A A te in range between min ange of ext temp 2 E ES and max temperature 5 20 30 min value then propose power 100 If external temperature E i E in range between min ange of ext temp 3 3 R and max temperature 60 0 80 max value then propose power 100 Power decr Decrease proposes 4 because power is temperature is 5 0 100 ext temp C out of range 5 Charge detect Enable disable 0 0 1 24 BMS2405 User Manual input active charger input Only for chargers with charger detect output Charge detect Inverted non inverted charger input Only for 6 0 0 1 input inverted chargers with charger detect output 7 Current sensor Enable disable 0 0 1 enable current sens
6. codes description 5 1 Discharge This state will occur when charger is disconnected and user starts ignition o Ignition output is enabled analog output shows SOC Depending the events that occurs later in this state BMS reacts differently o Ignition to 0 BMS turns off o Charger is connected BMS goes to charge state o Error occurred BMS goes to error state 11 BMS2405 User Manual 5 2 Charging This state will occur when charger is connected o Balancing algorithm is enabled o Ignition output is enabled if parameter Turn_on_controller_during charging is 1 Depending the events that occurs later in this state BMS reacts differently o Charger is disconnected BMS turns off o Battery is full BMS is still balancing but charger relay is disconnected After 1 hour charger relay is once more connected o Error occurred BMS goes to error state o Cells temperatures higher as parameter Range of ext temp max value or bellow parameter Range of ext temp min value Charging is disabled until temperature of external sensors is out of range When external temp sensors are not connected is charging disabled until minimum BMS internal temperature is bellow Range of ext temp min value 5 3 Error codes If error code occurs then BMS will be turned off after 2min This give user opportunity to check what went wrong BMS_ INFO o Current offset Wrong value of parameter Cur
7. e Date when jump SOC jump is occurred Day motnh year hour minute seconds Oz Used charge until SOC jump mAh Type S log is stored when Umin cen was bellow shutdown voltage J log is stored at SOC jump 18 BMS2405 User Manual 8 3 Status logs optional For status logs must be flash soldered otherwise the BMS return error on all 3 status log commands Log is stored each second if BMS is in discharge mode If charger is connected is streaming interval defined by parameter Data streaming interval Command LOG_START starts printing logs from newest to oldest log Stop printing with LOG_STOP Command LOG_STOP sends log syntax Utrorar Umi vor Uiwx_ min vor Umax_ vom Uinx max vorte Tg To SOC O zar Power Uc 0 Uc 1 Uc Number of cells Table 4 Status logs syntax UTOTAL Total battery voltage mV Umin_voLT Minimum cell voltage mV Umx mmn vorr Index of minimum cell voltage Umax voLT Maximum cell voltage mV Unx max voir Index of maximum cell voltage Ip Battery current Positive value when current A flows into battery Ts Temperature of BMS C Te C SOC Look table history log Qerar mAh Power Look table Contol data Uc 0 Cell 1 voltage mV Uc 1 Cell 2 voltage mV Uc Number of Voltage of top cell in the stack mV cells 1 19 BMS2405 User Manual 9 Serial interfaces The BMS has two serial interfaces control a
8. ecccasssesecescacoscosesssocesessoscssecesecescacasessosdsesesesdescesosdsesescesesedsessssecsessesese 11 Dl DISCHARGE a Dalila den cued S ii 11 2 CHARGING ais a a dada 12 1297 ERROR CODES tucanes ala da tds 12 o DEC A NR 13 6 MONTAGE OF CURRENT SENSOR ccccccssssssssssssssssssssssssssssssssssssssssssssssssssssssssssscsces 13 6 1 CURRENT SENSITIVITY do oe Ste ake E kl aly 15 7 STATE OF HEAL Ti isecccscccccccscccccccssccscccssccsccsscscoveccsccsecnstcsoesestccsesesessovevsdccsecnsdsdovsesdccsesssdsesvovse 15 FA SOH CALCULATION oi ia iniciada 15 Tiza SOHN TO DEFAULT VALUES OE aL debe o e e a eS 16 SS LOGS wasseecoessdeasiccectebicsischassssecsbesacdessccestesteseccbavcccelepeasaceusbecsctancesscebeasececebcesacecseceasdescessccbeuesseccdens 16 SL P ENSTORVEOG Saudi tddi tia 17 8 25 SS OCCHISTORY ANNO cede Sea chos E cede teaches E EE 18 8 3 STATUS LOGSCOPTIONALO s r ii e Ua SHON ats irte 19 9 SERIAL INTERFACES sinsscsccccccccscccsscecsvsstucsscocsvscovdcsscsccccscsssvsabecescocasousvdssscscossscauav udecesoacasoucuss 20 9 1 CONTROL INTERFACE iiviceccsssvesdessvcscrcessecveedevedcncsesvcedessvescacebsycdedesvdcecsesvcsdesvevscacebsecvseveevececetee 20 0 2 sPROPOSE POWER EE AEE EEEE td 22 9 3 CONFIGURATION PROGRAM INTERFACE ccsccccccccsesssssscecesececseeesssececececsesensssaseceseeeeeenensaaes 23 10 PARAMETERS sisisscescisadedsistaceccedeadeletecscceccdesdete leva cesselceCecelabecsedce sacs caleba teessdee
9. ent sensor is wrong connected or e Voltage at zero current is not correct parameter Sensor voltage at zero current could be in case that you use different sensor as recommended HASS 50 S 11 Compare cells voltages with values measured of BMS INFO command e Set date command SET DATE o Example set_date day month year hour min seconds set_date 8 12 2011 21 35 54 e Connect charger SOC value will be wrong at this point until battery is not filled to full then BMS will set SOC 100 Command BMS_INFO return values of next counters e Number of charging cycles o Counter is incremented when max cell voltage is above value of par Battery full voltage e Number of deep discharge cycles 10 BMS2405 User Manual o Counter is incremented when min cell voltage is bellow value of par Shut Down voltage and BMS is also turned off e Total battery charge out and e Charge out from last charging 5 BMS states BMS OFF Curr cons lt 0 5mA 2min elapsed ERROR chg relay OFF balancing OFF igntion out OFF snition OFF Charger ON Look Error codes description 1h elapsed Battery full Discharging Charge relay OFF Charging chg relay OFF balancing OFF chg relay ON balancing OFF balancing ON igntion out depends of igntion out depends of igntion out ON Ig input and par 10 Ig input and par 10 Ucet_max gt UBAT FULL Look Error
10. full voltage Propose Power Propose power is calculated from parameters Ucell power decreasing and Ucell power decreasing gain Propose is decreased also if temperature of external sensor is out of range parameter Temp range min value and Temp range max value 21 BMS2405 User Manual 9 2 Propose Power Propose power is calculated from minimum cell voltage of battery stack and external temperature If minimum cell voltage below value of parameter Ucell power decreasing then the BMS starts decreasing of power Also if temperature is out of range the BMS decreasing propose power In example are used next settings of parameters temperatures are in range e Ucell min mV power decreasing 2900 e Power decreasing gain V 90 UCELL_MIN mvV Propose Power Figure 5 Power decreasing because cell voltage 22 BMS2405 User Manual 9 3 Configuration program interface Configuration interface is used for setting of parameters reading of logs monitoring of battery and FW upgrade Use next settings of serial port on your terminal program HyperTerminal TeraTerm Baud Rate 115200 Parity None Data Bits 8 Stop Bits 1 Flow Control None The device accepts text commands which are terminated with CR hex code 0D Optional LF characters are ignored The device accepts one command at time All responses begins with OK or ERROR
11. ge 1 i voltage mV SOC 0 when SOC is zero 0 0 20000 Analog display Anal 1 1 19 voltage mV nalog display voltage i Baas SOC 100 when SOC is 100 When Ucell_min is lower as this value Ucell min mV 20 q then BMS starts 3000 2000 3600 power decreasing decreasing of propose power Power decreasing Power decreasing 21 100 0 300 Gaim a v gain V Cell internal 2 e internal resistance 3 0 100 resistance mQ UceLL Umeasurep Reezz Ip Enable disable use of Use SOH by SOC 23 state of battery health 1 0 1 calculation by SOC calculation State of State of health 24 health SOH according to nominal 100 0 100 value 5 capacity 0 used as output Oj o a Olla 25 l input 0 0 2 definition 2 analog input http www ev power eu EV Power eu managed by i4wifi a s member of GWL Power group Prumyslova 11 CZ 10219 Prague 10 CZECH REPUBLIC EU phone 420 277 007 500 fax 420 277 007 529 email export i4wifi cz GWL POWER 26
12. h battery capacity used in SOC measurement Qnom Ah parameter Battery capacity SOH value is 100 if parameter Use SOH by SOC calculation is disabled 7 1 SOH calculation SOH calculation is always executed on power up and is stored as parameter SOH e SOH calculation from logs when Umin cen was bellow shutdown voltage at least 3 logs are needed SOH Qineas Qnom 100 wher Qmeas used charge until Umin cen Was above shutdown voltage Qnom parameter Battery capacity 15 BMS2405 User Manual e SOH calculation from SOC jumps at least 3 logs are needed SOH Qmeas QNom 100 SOC value after jump wher Qmeas used charge until SOC jump was occurred Qnom parameter Battery capacity 7 2 SOH to default value To set back SOH value back to default is needed e Erase SOC history logs with command Erase SOC history e Set parameter SOH to 100 8 LOGS History logs 300 SOC history logs 10 HW 1 2 3000 Status logs optional HW above 1 2 6000 History and SOC history logs are stored into EEPROM Status logs are stored into flash When no more space for log is then oldest log is replaced with new log 16 BMS2405 User Manual 8 1 History logs Log is stored before BMS is shutting down Logs can be read over configuration serial interface Command HISTORY START starts printing history logs from newest to oldest log To stop printing send HISTORY STOP
13. nd configuration interface Over control interface the device sends data to PC or the controller Configuration interface is used for adjusted of parameter streaming data and read logs 9 1 Control interface Control interface is galvanic isolated RS232 interface Over control interface the BMS sends data to PC or the controller The data are sent each second The BMS does not accept any command over this interface Control interface serial settings e Baud Rate 115200 e Parity None e Data Bits 8 e Stop Bits 1 e Flow Control None 20 BMS2405 User Manual DATA SYNTAX e String when ignition goes to 1 BMS2405 r n e Each line is terminated with r n UTOTAL UMIN_VOLT Uiwx min vor Umax vor Uinx max _vottslpar 1 SOC CHG O gar Table 5 Control data syntax UroraL Total battery voltage mV Umin_vott Minimum cell voltage mV Uix min vor Index of minimum cell voltage UMAX VOLT Maximum cell voltage mV Uimx max voir Index of maximum cell voltage IBaT Battery current Positive value when current flows into mA battery T Temperature C SOC Look table History log CHG Charge present 1 charge is connected 0 charger is not connected always send O if par Turn on controller during charging is set to 2 QBAT Actual battery capacity 0 battery full 40000 battery mAh is total empty for 40Ah battery This counter is reset when Umax vourr is higher as parameter Battery
14. or 8 a sensor Current SENS OF 12500 0 100000 sensitivity uV A sensitivity 9 Sensor voltage at Current sensor voltage 2500 0 5000 zero current mv at zero current 0 the controller is turned on only if ignition is on 1 the controller is always turned on vada vida on COMtO eje us os 10 0 1s not possible for 0 0 2 JULING Clacueojalimej Emsiso controllers 2 the controller is always turned on during charging and also drive is possible for Emsiso controller E If min cell voltage is own 11 i under this value then 2500 2000 3200 voltage mv BMS is turned off Interval for streaming to PC and store data 12 a streaming mo flash For values gt 1 600 interval ls bigger as 10 accept only values that are divided by 10 13 ge imit This parameter is set in 50 30 70 while balancing C EMSISO Lab If cell voltage is bigger 14 Cell voltage of min cell voltage for 5 5 500 difference mV value of this parameter then enable 25 BMS2405 User Manual discharge resistor on this cell Used only in charging mode 15 Battery Ban it m TA ee capacity mAh attery capacity Decrease SOC to value Decrease SOC when of par 17 if min cell 16 min cell is lower voltage is lower as this 2850 2400 3600 as value and SOC value is higher as par 17 Look iption of 17 Decrease SOC to Don 15 0 100 parameter 16 Analog display Analog display volta
15. pply voltage 5V and Output voltage is not higher as 3 3V Figure 3 Current sensor HASS 50 S 13 BMS2405 User Manual Current sensor is connected to 10 pin system connector Pin 1 of current sensor HASS 50 S is not connected Tabela 1 Current sensor HASS 50 S pinout 2 output 8 3 GND 9 4 5V 10 This current sensor is able to measure up to 200A DC current Increase accuracy of current measurement with more loops of wire through current sensor Battery Charger Figure 4 Two loop of wire through current sensor 1 200 100 2 50 3 only if charger current is lower as 15A For HASS 50S is needed Molex connector 22 01 2045 and Molex pins 08 50 0032 14 BMS2405 User Manual 6 1 Current sensitivity Parameter Current sensor sensitivity depends of number of turns Current sensor sensitivity uV A 12500uV A number of turns 7 State of health State of health SOH is relationship between measured actual capacity and nominal capacity An SOH of 100 means that the actual capacity matches nominal capacity parameter Battery capacity Read value of SOH with command BMS_INFO or read parameter SOH Actual capacity is stored in SOC logs when e SOC jump occurs or e Unin cen is bellow shutdown voltage If parameter Use SOH by SOC calculation is enabled then value of SOH is used for battery capacity calculation Qs Quom SOH 100 wher Qs A
16. rent sensor offset Wrong use of hall sensor o Wrong current sensor orientation Change sensor orientation o Cell under voltage Turn off BMS and then connect charger o Communication with balancers If this error occurs during charging then the reason can be noise of charger In this case on charger output connect splitting ferrite farnell code 74271222 Charger outputs plus and minus have to passed through ferrite o Charger detect input Charger detect input is active but no voltage detect on charger input 12 BMS2405 User Manual 5 4 LCD On power up all segments are showing for 1second 0 9 SOC value 9 SOC value between 90 100 C 0 9 C charging 0 9 SOC value F 0 9 F battery full 0 9 balancing voltage difference between maximum cell and minimum cell voltage subtracted for value of parameter Cell voltage difference Battery is full and BMS doesn t recognize charger any more Ucell lt Ucharger 0 6 BMS goes into sleep mode BMS turns off when charger is disconnected E error Character t blinking Inhibit charging until cells temperatures are out of range Dot on 7 segment LCD is blinking if date is not set 6 Montage of current sensor Current sensor has to be montage so that it returns positive value in case of charging battery current flows into battery Emsiso recommended HASS 50 S Use only current sensors with next properties Su
17. t connected if not used SN GND for NTC not connected if NTC not used MI Negative minus terminal of cell number 1 11 11 2 3 24 cells Notes BMS2405 User Manual 4 Procedure after BMS connection Connect the BMS to PC with provided serial cable Open device configuration tool or other terminal hyperterminal teraterm Ignition to 1 IES By default cell number is 24 If you use different cell number the BMS goes into error In 10s after power up you have to send any valid command so that BMS stays alive Otherwise the BMS is turned off because of cell undervoltage Nn Set number of cells parameter Number_of_cells and set date command SET DATE Restart ignition to 0 and back to 1 the BMS 7 If cells are correct connected and all cells have voltage higher as 2 5 default D Shut_down_voltage then BMS shows number between 0 9 If the BMS is still in error then send command BMS_INFO inside 10s after power up In first line the BMS return description of error Possible errors e One of cell is not connected or bad connected e Cell voltage bellows 2 5V check this cell also with V meter e HW internal error contact info Oemsiso com 8 If current sensor is not used skip next point 9 Enable current sensor parameter Current sensor enable and set current sensitivity look chapter Current sensitivity Restart the BMS 10 If the BMS goes into error state check reason with command BMS INFO e Curr
18. telelessescscucadecsdestes 24 1 1 LISTOFPARAMETER Sid a a A E Os 24 BMS2405 User Manual 1 Introduction Battery balancer is an advanced battery management solution for Li based battery cell that is measuring and monitoring battery cells during the complete charge and discharge cycle that protect cells against under voltage or over voltage that is balancing during the whole duration of the charging cycle that is capable of measuring charge in out from battery state of charge SOC For SOC measuring is required current sensor That is capable calculating State of health of cells For complete understanding and usage of BMS use also datasheet for Emsiso BMS 2405 and user manual for device configuration tool that is used for changing parameters of BMS and analyzing monitoring variables logs inside BMS BMS2405 User Manual 2 BMS system connector On BMS front side there is 10 pin connector that is signed as SYSTEM 1 Ignition input 15 90 2 Ignition output 15 90 5A 15 90 This is only for special 3 Charger detect input en ee ae chapter detect input 4 Charge relay output 12 0 3A 5 Ground connected to i f BAT1 6 Analog output ee 0 02A analog output Optional input 12 90 7 onda 12V or ignition input 025A voltage 8 Current sensor input 0 5 Ground of current sensor 10 Current sensor supply 5 0 3A B
19. voltage for voltage that is presented with parameter Cell voltage difference Balancing current is 500mA 3 Cells connections Current BAT Ignition sensor switch ystem Fuse connector Battery pack connectors 1 ee 2 3 DC DC 12V 4 relay out 5 6 7 8 Hall 9 sensor 10 CHG IN Can be used as input or ouput Charger Some chargers have power detect output Figure 2 24 cells schematic 3 1 Connection order for complete BMS Connect in next order e Connect 20 pins cell connector e Connect 8 pins cell connector e Connect system connector e Connect BAT and e Connect charger e Connect serial cable if you want to communicate with device PROGRAM connector e Connect control cable if you want connect other devices to BMS BMS sending status to PC or eDrive controller CTRL connector When disconnect the connectors use reverse order BMS2405 User Manual two connectors to BMS Always first connect th tion 3 2 Cells configura 8 pin connector Battery pack configuration 18 18 19 20 18 19 20 20 Not Connected AN Positive plus terminal of cell number 7 NC 12 T S b a ajaja Saa NINA NS N mim N 5 EN NIM NIN SRI NINJ NININ ojojo aja x x x x x x ajaja a 300 PO DU a www aja vom mon ne ajaj a r a A mimim lr bry N aS Temp sensor 2 not connected if not used Temp sensor 1 no
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