SETUP INSTRUCTIONS
Contents
1. Time _ Update BMS Control Panel Cells configuration page Max Allowed Voltage Sets the critical maximum never exceed voltage of the cell that 1s specified by cell s manufacturer If Over Voltage Cutoff function is enabled the protection is engaged via pin with function PF12 assigned when some cell voltage exceeds this setting If BMS 1 charging it aborts charging with corresponding error code Additionally BMS records under voltage event and updates the according statistic Fully Charged Voltage The voltage which indicates that cell 1 fully charged and has 100 SoC This setting should be configured according to cell manufacturer s specification maximum voltage in normal usage conditions It should have some margin below critical maximum never exceed voltage stated by cells manufacturer BMS uses this value as a reference for calculations of 100 SoC When charging BMS uses this setting as the target voltage needed to reach with all cells in balanced condition When charging is finished all cells in the pack should have the voltages close this setting Allowed Disbalance Sets allowed dis balance voltage which defines what is the minimum difference between lowest and highest cell voltages When actual cells difference exceeds this setting cells are considered out of balance and early balancing function is engaged during main charging stage Early balancing function 1 engaged when cells voltage exceeds Early Balancing Threshold2. MOTOR CONTROLLER MOTOR Typical wiring diagram for nn Emus BMS TT INPUT1 INPUT2 28 Can be used if F F INPUTS 55 CHARGING LAMP INPUT4 gt 26 function is remapped sain 6 in Emus BMS software Fuel Gauge 24 SOC OUT SPEED IN 23 Tl 22 E IGNITION KEY SW CAN E my FAST CHARGE SENSE dh FAST CHG cere E ue MESE BUZZER S mend is T RY or FAN relay TA oe LOW LAMP 10 1 USB D o used GROUND 7 Bl B cable uetooth module eoa nd 56 Android device o CELL TX OR CELL RX 3 USB CELL RX Windows GROUND OR 1 asi USB Android device BROWN NEU BOT isolator NOTE functions HEATER BAT LOW BUZZER IND RX CHARGER FAST IGN IN AC SENSE SPEED IN and SOC OUT can be remapped in Control Unit software 11 PC Software We will supply the latest software with the BMS module You can install the software on a WINDOWS computer with USB Install the CONTROL PANEL SOFTWARE EMUS BMS exe Version 1 if no CAN Group modules are used Version 2 if CAN Group modules are used The EMUS BMS Control Unit connects to PC via USB port and uses VCP Virtual Com Port to communicate with the application VCP requires a special driver which executable installer which will be on the installation CD Drivers can also be downloaded here http www f
3. 3 4 volts depending on manufacturer and a certain capacity in Amps The supplier gives you the maximum discharge and charge rate usually in C figures C1 maximum rate in 1 hour Example 100 A cell with 0 5 charge and C2 discharge 50 A max charge rate and 200 A max discharge rate The single battery cells have to be assembled in cell blocks by fixing them with solid steel bands or frames to avoid any movement and expansion A basic rule is that 4 prismatic cells are mounted in one block for 200 Amp cells and 8 prismatic cells are mounted in one block for 100 Amp cells The blocks can be connected with flexible cables or with cell connectors if the blocks are fixed The cell connectors may not receive any tension from moving cells There are different options how to assemble the cells 128 gt T m ars um d DRM i y 3 j m C ui TAS Steel Epoxy Steel band only Solid aluminium frame Alu SS frame in Acrylic box 3 Connection of battery cells 4 cells in series 12 volt nominal 12 8 V 8 cells in series 24 volt nominal 25 6 V 16 cells in series 48 volt nominal 51 2 V 24 cells in series 72 volt nominal 76 8 V 32 cells in series 96 volt nominal 102 4 V The balancing capacity of a BMS system is usually 1 1 5 Amps per cell So we recommend to use one balancer for up to 200 Amp cell capacity You can use one balancer
4. another is focused on setting operation of CAN bus and the last one 1 for distance parameter configuration Parameters list are described below 19 Language Ogboni Menagment General Cel Hatters Pack Changer Pins Hap Functions Devices Set Dabe and Tine of BMS Data Transmission bo Dispiarg Perko En SE t 0 5 Iri Seen State 5 0 Broadcast on 5231258 v CAN Eus Enable CAM Speed She Paria Data Eroode ast Lit Serial Colis Coramunication v Lee Extended 730 ID y Send bo REZ3Z2ILISB CA ET Desk air Par ame Pulses per Cans 1 Distance Line Mame Update Estimate Safety Margin 98 53 BMS Control Panel general configuration page Set Date and Time of BMS Sets the date and time of BMS internal clock The internal clock is used by BMS to record statistics and events timestamps This clock does not support daylight savings time Data Transmission to Display Period In Active State Display update period which defines the frequency of broadcasting the parameters via RS232 USB interface and or CAN bus Active state is when either charger is connected or ignition key IGN input PF5 is in switched on This period depends on user s requirements how frequently the BMS operation information 1s needed to be received Good starting value is 1 second Minimum is 0 15 for very frequent updates which would generate and a lot of data for
5. 1 3 UP 4 CELL RX 3 oZ E GROUND Ce 1 4 ET di e 3 aX 0 i EO DN is ui GR BROW BOT isolator MA can be anywhere in the battery pack Twisted pair shielded cables The BOT isolator with the two cables on each side has to be connected to the negative end of the battery string GREEN cable to DN connection of last balancer module BLACK cable to negative of last battery cell BROWN cable to RX connection 3 BMS BLACK cable to RX connection 4 BMS Emus BMS Cell Module A CELL CELL Cell Module B CELL mus BMS isolator E CELL GREEN BLACK The BOT isolator with the three cables on each side has to be connected to the positive end of the battey string GREEN cable to DN connection of last balancer module BLACK cable to negative of the last battery cell RED cable to the positive of the last battery cell BROWN cable to TX connection 5 BMS BLACK cable to TX connection 6 BMS 10 6 BMS connections 7 Current Sensor The current sensor senses all current in and out of the battery and enables to display the capacity usage charge discharge etc on the display The current sensor has to be installed within the main power string of the battery It is supplied with a cable and a plug that can be directly connected to the BMS controller 11 8 CAN cell modules CAN cell modules can co
6. cell voltages enough for normal charging Discharge Over Current Cutoff Cutoff the battery protection contactor on output pin with function PF12 assigned in case when discharge current exceeds the Critical Discharge Current parameter setting Critical Discharge Current Sets the critical discharge current above which BMS engages protection function by disconnecting the contactor relay on output pin with function PF12 assigned if the Discharge Over Current Cutoff function is enabled Additionally BMS records discharge over current protection event and updates the according statistic Graceful Contactor Disconnection If this function is enabled and an undervoltage event has occured the battery contactor will not be disconnected instantly if discharge current is higher than 5 A to prevent damaging the contactor but delayed up to 10 seconds to wait for undervoltage reduction to take effect or the load to be manually disconnected reduced Charge Over Current Cutoff Cutoff the battery protection contactor on output pin with function PF12 assigned in case when charge current exceeds the Critical Charge Current parameter setting Critical Charge Current Sets the critical charge current above which BMS engages protection function by disconnecting the battery protection contactor relay on output pin with function PF12 assigned if Charge Over Current Cutoff function 1s enabled Additionally BMS records charge over current protection event and updates th
7. configuration allows to assign different functions to different pins of BMS Control Unit This is useful for various installations which don t use all the default pins For example in hot climate areas battery heater 1 not needed and cooling fan would be required Then this function may be assigned to HEATER pin and BMS would control the fan via this pin In the picture of Emus BMS Control Unit connector remappable pins are marked in green and non remappable ones marked in red 31 Different pins have different hardware interfaces HEATER LOW BUZZER CHG IND and CHARGER pins are open drain outputs that can drive the pin to the ground with maximum 0 54 current These pins cannot be assigned to input functions FAST CHG AC SENSE IGN IN SOC OUT SPEED IN and INPUT 1 4 are small power pins that can be assigned either to inputs or small power outputs of static signals SOC OUT pin also has the possibility to assign specific State of Charge PWM output function which generates signal for displaying SoC to external display devices SPEED IN has the capability to count the number and frequency of external incoming speed sensor pulses INPUT 1 4 may be used for current sensor measurements Please note that if any of INPUT 1 to 4 pin has the PF14 Current Sensor Input assigned then all other INPUT pins must be assigned to this function as well because current sensor uses all 4 INPUT pins to dual range current sensing When this function is select
8. configuration of BMS from unauthorized change default on fresh BMS Control Unit the password 1 not set and therefore no login is required The user is always in logged in state when password 1 not set The user can set the password using Set Password button and then BMS Control Unit becomes password protected NOTE that password security has 10 minutes automatic logout period of the user if no configuration activities were made To enable configuration editing it you would need to log in again NOTE The login access is locked out after 3 sequential unsuccessful login attempts for 10 minutes If 3 unsuccessful login attempts were made then user must wait 10 minutes before trying to login again The configuration of BMS can also be saved to file loaded from file and reset to defaults To perform these operations the user must be logged in to BMS The configuration management page and its buttons are described below Management General Battery Pack Charger SL Ping CAN Devices nnd Update 25 BMS Control Panel configuration management page Login Logout Login or logout button When user 1s logged out the button shows Login pressing which shows password entry dialog After entering correct password the button shows Logout which indicates successful login If the login failed the button stays Login To logout simply press this button when it displays Logout Set password
9. correctly to the CAN bus NOTE When CAN group module configuration is committed successfully Number of Overall Cells and Number of Cells Strings parameters Battery Pack configuration tab will be updated automatically Configuration by Tasks Functions Cell temperature calibration EMUS BMS measures temperatures of each cell each of EMUS BMS Cell Modules have temperature probes These probes require initial calibration to work properly When all battery cells and EMUS BMS Cell Modules are installed user must initiate a temperature calibration command To do so connect the EMUS BMS Control Unit to PC s USB port start the EMUS BMS Control Panel application and navigate to Configuration page Battery Pack tab There you will find a Calibrate Temperature button After pressing the button type in a current temperature of the battery pack 1n the prompted window Ordinary household thermometer 1 sufficient for getting this reference temperature Use this calibration only 37 when all cells are at the same temperature This will set the temperature of all cells to the one specified The result can be checked at Status page Cells tab Temperatures graph Cell temperature probe is situated on Cell Module itself and does not represent accurate temperature of the cell Cell tabs do have a good inner thermal conductivity and usually Cell Module will report a bit lower temperature especially at high values Also keep in mind th
10. for balancing the cell depends capacity of cells disbalance and other parameters Default 2 hours setting should work in most cases but it sometimes might require longer time when the pack is deeply disbalanced SoC configuration nent Gerir al Cel Battery Pack Changer Pins Deski Sabe of Charge Sexo parameters Sgt Stabe of Change Current Sermo Use L Calibration ake 2340 H Calibration 27500 Dendzone 0 3 Reverse Direction Reset Current bo SUCK OUT Sagnal Paramsbers Pen So 0 To Soc 100 e il BMS Control Panel SoC configuration page Set State of Charge Sets initial state of charge of the pack When pressed it prompts to enter the current estimated SoC of the pack This function is useful if the initial SoC value needs to be set when installing fresh battery pack with BMS as by default BMS assumes 0 SoC as it has not observed the pack s behaviour during charging and use yet It is also possible to save the initial SoC value in configuration file Then it is set when configuration file 1 loaded L Calibration Value H Calibration Value These values are the gain calibration values of the current sensor which are written on the back label of the sensor Calibration values differ from sensor to sensor Deadzone 30 This is the dead zone of the current sensor reading to improve 0 current stabili
11. parameter Early Balancing Threshold 22 Sets the early balancing threshold voltage above which the early balancing starts It balances the cell charge differences while exceeding the configured Allowed Dis balance threshold Early balancing is used during main charging stage when charge current is kept constant Balancing Range This is the voltage margin below Fully Charged Voltage parameter in which the balancing of the cells is done when a non CAN charger charger not capable to adjust current according to BMS command is used in balancing stage BMS periodically balances down the cells voltages and charges them again within this range below Full Charged Voltage parameter until all cells are equally balanced NOTE This parameter does not correspond to any point on the cell charging curve Charge Restart Voltage Sets the voltage threshold below which charging is restarted charger is connected NOTE This parameter does not correspond to any point on the cell charging curve Pre Charge Threshold Cell s voltage threshold for selecting pre charge or normal charging mode It is useful when a charger with controllable current like most chargers with CAN inteface 1 used to charge deeply discharged cells When the minimum cell s voltage 1 below this threshold BMS uses small pre charge current to charge the pack When minimum cell voltage exceeds this threshold BMS selects normal charging current depending on Slow Fast current setting of c
12. receiving device Data Transmission to Display Period In Sleep State Display update period which defines the frequency of broadcasting the parameters via RS232 USB interface and or CAN bus Sleep state is when charger is de activated and on IGN input is switched off In sleep state the updates could be very rare like once every minute or similar Enable CAN If the application uses CAN interface then it must be enabled with this option NOTE A BMS reset is required for change to take effect Speed Sets the bit rate from the selection of 50 125 250 500 800 and 1000 kbps NOTE When using CAN charger please make sure that this speed matches to CAN charger s speed NOTE A BMS reset is required for change to take effect Periodic Data Broadcast 20 Periodically broadcasts the special CAN messages of BMS operation parameters over CAN interface 1f enabled It uses the data transmission to display periods that are configured above Use Serial Cells Communication Check to use serial cell communication or uncheck to use CAN cell communication Use of Extended 29bit ID Check to use extended 29 bit CAN ids instead of basic 11 bits if enabled The ID 1 used for the broadcast CAN messages described above NOTE This setting does not affect the format of charger specific CAN messages format Send to RS232 USB Enables the transmission of received CAN messages to corresponding serial interface sentences see serial communication pro
13. 18 Sets the password of BMS Control Unit password The user must be in logged in state to be able to set new password Password must be from 4 to 8 characters long If empty password 1 left and confirmed twice then this disables the password Save Opens save configuration to file dialog for entering file name to save to After confirming the file name two questions are asked if user wants to save password and initial SoC value into configuration file If they are selected then setting SoC and or password commands are storred into configuration file CAUTION The password is stored in configuration file as plain text so use this option with care Load Opens load configuration file dialog for selecting file name to load It automatically sets the configuration parameters of BMS sets SoC and or password if they were stored in the file and resets the BMS to work with newly loaded configuration Defaults If the user confirms to load default configuration then factory default settings are loaded to BMS and it 1s reset NOTE The password is not cleared when loading default settings Reset BMS Does what it says resets BMS This operation is sometimes needed when changing configuration parameters requiring fresh BMS start to activate for example enabling CAN interface General configuration General parameters section allows to configure general parameters for BMS operation One section describes the timing parameters configuration
14. INPUT GROUND 5M OUT SOC QUT SPEED IN CAN CAN CZ CSENSE BMS Ju Can te ved 7 CHARGING LAMP NE function is remapped 2 ET i Emus BMG poffet em m al bd en s We recommend to use Android Version 4 x on a tablet like Nexus Google 14 Download the software on the Android device using Applications Playstore search for Emus EVGUI install pair via Bluetooh with BMS run the programm PAIRING PASSWORD with your Android Tablet 1234 15 10 Full wiring diagram 16 Li Cell n 2 255 Emus BMS Cell Module A nz a o 3 Li Cell n 1 72 23 EO ao lt es Li Cell 4 5 2 DN Li Cell 3 Cell Module B Emus BMS CELL Li Cell 2 Emus BMS Cell Module A CELL 2 c T Li Cell 1 Cell Module B Emus BMS CELL CELL CELL 2 GREEN CP and isolator CELL CELL CELL CELL DN UP DN can be anywhere in the battery pack GREEN Twisted pair shielded cables OV Emus BMS CHARGER ardente To AC line 1 N N VOUT G ES G Charger CAN enabled OR conventiona Pb CHARGER d CAN CHARGER VIN VOUT VOUT VIN VOUT VOUT x Vehicle s 12V battery FEM ey VBAT Man E VBAT EM Contactor n I ume w m IGNITION
15. Pre Funcbore Deccwer devices Configuration List Paraka 1 Duca ID Ease g Cei al Call Count 20 BMS Control Panel CAN devices configuration page CAN Devices configuration allows to discover and configure Emus CAN cell group modules by JSC Elektromotus The page consists of configuration section and unconfigured devices list The parameters in this page and the procedure of configuring Can cell group modules are described in detail below Discover devices Discovers the CAN cell group modules that are connected to BMS CAN bus The discovered devices appear in the Unconfigured List where the serial number and cell count of the CAN Cell Group Module is displayed as show in the image below CAUTION discovering CAN devices puts BMS Control Unit into configuration mode until the discovery is complete While this mode normal operation of the Control Unit 1s stopped therefore 1 advised to configure CAN cell group modules before the actual use of of Emus BMS system Parallel strings Number parallel cell strings 1n the configuration table Increasing this number will create more columns in the configuration table Adjust this parameter according to the configuration of the battery pack Device CAN ID Base CAN ID Base address for CAN Cell Group Modules Each group module s own CAN ID 1s configured according to this parameter This allows to resolve the possible addressing conflicts with
16. al Voltage parameter value Minimum Allowed Voltage The same parameter as in Cells configuration tab For more detail see Cells configuration above Fan On Temperature Sets the temperature threshold above which BMS enables fan or other battery pack cooling device output on pin with PF13 function assigned Set this temperature to ensure the optimal cells operation temperature range in hot climate conditions or intense battery use NOTE Fan will be enabled when this temperature is reached regardless of whether the battery climate control 1 enabled or not Over Voltage Cutoff Enables the battery cutoff contactor in case of over voltage when voltage exceeds Max Critical Voltage parameter value by using pin with function PF12 assigned Maximum Allowed Voltage The same parameter as in Cells configuration tab For more detail see Cells configuration above Battery Climate Control Enables the battery climate control feature which controls the battery temperature using heater output pin PF5 if assigned and fan output pin PF13 assigned Low Voltage Reduction Enables power reduction output on pin with function PF16 if some cells voltage drops below Low Voltage Warning parameter level Low Voltage Warning Sets the low voltage threshold reaching which causes Low Voltage indicator on pin with function assigned warning Periodic blinking shows that some cell with 25 minimal volage has dropped below this low voltage threshold Whe
17. at Cell Module heats up during balancing stage and reported temperature will be higher than actual Configuring the charger To configure charger used with the Emus BMS connect the Emus BMS Control Unit to PC s USB port start the EMUS BMS Control Panel application and navigate to Configuration page Charger tab Charger Type dropbox selects a type of charger with or without CAN interface Please note that following current settings are applicable for CAN charger only and can be located in Configuration page Cells tab Pre charge Current field sets a current for pre charge mode This mode 1 active when voltage at any of the cells is lower than the value specified in Pre charge Threshold field This field is applicable only for CAN charger NOTE this parameter is located in Configuration page Cells tab Pre charge Threshold field specifies lowest operating voltage of the cells Typically this value is 3 0 V for LiPO La Ion cells and 2 5 V for LiFePO4 The exact value should be specified in cell manufacturer s datasheet This field 1s applicable only for CAN charger Slow Charging Current sets a charging rate for charging the vehicle prom lower power often public outlets If for example the outlet is limited to 1 kW and your cell voltage is 100 V then Slow Charge Current should be set to 10 A 1 kW 100 V 10 A This field is applicable only for CAN charger Fast Charging Current value should be set according to combined ability of
18. cribed in detail below Language Option Marinated General Cal Battery Peck Changer Soc Fi Battery Pack Number of Over all Calls 45 humba of Cells hrec Masten Balancing Current 20 Capacity 100 0 Ah C abbrabs Cels Temperature Cel Cubort irre Alea Voltage 250 Fan On Temper at un 20 deg c Creer ioksge y Animum Yokege 3 80 v Ashery Chrate Contra 7 Reduction y Loew Aamin 5 00 y Cinste Normal Temperature E deg J High Temp abun 50 wy C Control Charging Temperature 30 deg 1 Update Creer Heat J Maz Crixal Temp deg Control SOC e High Current Reduction y Current Warning 1000 Cel Comm Restore Diechange Cher Curnent Critical Deochange Current rme Contactor Deeconnection Pi Charge Cuba af CHEA Charge currani A Cells Communicston Cutoff a BMS Control Panel Battery Pack configuration page Number of Overall Cells The total number of cells that you have in your battery pack The battery pack may consist either of one string of cells connected in series or several of these strings connected in parallel This setting allows BMS to verify 1f it has detected correct number of cells and if the communication with cells is ok It will raise an alert and 24 engage other prote
19. ction functions if the actual number of cells does not match this setting Number of Cells String This parameter sets the number of parallel strings It is used when calculating the charge voltage for a controlled charger and when displaying individual cell parameters Max Balancing Current Sets the maximum allowed balancing current of the cell modules to reduce dissipated heat during balancing stage Reduce this value if cell modules temperature is getting too high during balancing stage Cell modules can work in balancing mode without communication to Control Unit and will not exceed this setting When charging Control Unit reduces maximum balancing current when needed even further to not exceed Warning Temperature Capacity Defines the nominal capacity of the cell This parameter is used in State of Charge SoC calculation to determine the SoC level If you are using sever parallel strings of cells multiply the cell capacity by the number of parallel strings for correct state of charge calculation Calibrate Cells Temperature Sends the calibration command to cell modules to set the temperature value on all modules to temperature on the right as reference This needs to be done only once when all modules are installed and are at the same temperature conditions Under Voltage Cutoff Engage the battery protection contactor in case of under voltage by using output pin with function PF12 assigned when lowest cell voltage drops below Min Critic
20. e according statistic No Cells Communication Cutoff Enables the cutoff of battery protection contactor on output pin with function PF12 assigned in event of loss of cells communication for over 10 seconds Minimum Charging Temperature 27 Sets the minimum allowed charging temperature in degrees of Celcius of cell modules If the minimum cell temperature is below this value and charger 1 connected then BMS starts with pre heating stage which enables heater output pin Pin Function 5 PF5 enabled that is controlling external heater which should be heating up the cells until they reach this minimum temperature As most of Lithium chemistry cells are sensitive to charging in low temperatures charging should be done in above zero temperatures To be on the safe side set a value of say 2 C to give it a little margin of error EMUS BMS will turn on the battery heater 1f one exists and controlled via PF5 and wait until cell temperatures reaches the value set before charging the pack To disable pre heating and charge delay enter a value of 100 Charger configuration Emus BMS supports operation using non CAN and CAN chargers Non CAN charger is basically the charger which has no digital data transfer capability over CAN line and can be controlled by only switching it on or off via relay or contactor CAN charger is the charger which can communicate and can be controlled via CAN communication bus There is no unified and widely acc
21. ed and committed the control unit automatically updates other INPUT pin functions When some INPUT function is changed to something else from PF14 then other INPUT pins have this function removed as well Management bensa Cel Esterp Pack Charger jo Pins Bap Pin herme Assie Pin Irveert IMFLIT 1 PFL4 Current Sensor Input 2 PFI4 Current Sensor Input 3 PPL Current Sensor Input Current Sensor input SENSE Charger Mains AC Sense Input PFA ignition key Int FAST OHG PFE Fast Change Switch CHARGER PFl ChargerEnabie Output HEATER PFS Heater Enable a 4 3 4 4 4 Low Battery Low indication BUER PF Sound Euzzer Output Configuration ING Charging Indication Output SPEED IM PFI Seed Sensor rpi C E ste s d 18 Lal 3 LS SOC OUT State of Charge Output BMS Control Panel pins re map configuration page Not all pins can be assigned to all functions and the best is to see what configuration options each pin has on the BMS Control Panel software In the Pins Map configuration page each remappable pin is listed with function that 1 assigned to it and along with inversion flag Each function assignment drop down box has a list of choices of functions that are pos
22. epted charger communication specification standard and therefore the support of various manufacturers and models 1 being added to the supported chargers list gradually At the current moment Emus BMS supports Elcon chargers that are produced by Hztiecheng However the number of supported chargers will soon grow to more models Brusa NLGS new Zivan line NetGain are coming soon The charger parameters are configured via charger configuration tab 28 een Germir al Cal Battery Pack Charger Soc Pins Charger Type Ekor charger piti Siaga Duraliong Pre change 120 min Main 6I mini Balancing 120 min 22 BMS Control Panel charger configuration page Charger Type Allows you to select the charger type that 1s controlled by BMS It may be non CAN charger which is controlled via the relay using output pin with function PF10 assigned The sensing that charger is connected to some power supply is made via input pin which has PF3 function assigned Chargers of this type do not allow BMS to control the charging current and therefore perform somewhat worse as exact optimal current mode cannot be selected as it depends on only how the charger was setup When CAN type charge 1 selected then all communication is done via the CAN bus using special messages compliant to specific charger type For this type of chargers BMS selects optimal charging current and ta
23. for a higher capacity by using larger cells or connect multiple cells in series have to be similar cells We do not recommend to use capacities of more than 400 Amp per balancer Two 100 Amp 3 2 volt cells connected parallel 3 2 Volts 200 Amps ONE balancer required Two 100 Amp 3 2 volt cells connected in series 6 4 Volts 100 Amps TWO balancers required First design your final setup and let us know we can confirm the number of balancers and material you need and if the setup configuration is correct for your use Example for 48 volt battery pack 4 Connection of balancers Example for 4 cells in series Li Call 3 E E MAIN _ NEGATIVE amp gt m Li CONTROLLER CABLE DOWN CONTROLLER CABLE UF m h m lt BALANCER 1 4 p nn BALANCER4 If a ofa ES n bw J E 1 n wo s UN ip Ww p A ES 3 3 E SST t CABLE U m pt 3 pU UU E V CE Uf zi Cable from flat part to negative cell connector and cable besides resistor white block to positive cell connector UP control cable to DN of next balancer etc 5 Connection of isolators On each end of the battery a BOT isolator has to be installed and connected to the last cell of the string and the BMS controller I S CELL AX
24. h EMUS Balancer e BMS controller EMUS digital e Setup plug with cables USB for BMS included with EMUS BMS e DC DC converter to 12 V DC for BMS e Fuse for power to BMS 12 V DC e Software to setup and monitor BMS included with EMUS BMS e Plug amp cables for final cable connections included with EMUS BMS e BOT isolators negative positive Included with EMUS BMS CAN Bus Group Module e Blue Tooth Module e Main switch for power supply on off e Main switch for charger on off e Main switch for load on off for status with cable e Android tablet with preinstalled EMUS app e Main contactor load 100 300 A switched by relay max 0 5 A e Main contactor charge 50 100 A switched by relay max 0 5 A conventional charger CAN Bus charger You can setup and wire the whole system or we can pre wire the system for you The pre wiring does not include the main cables if those are not ordered separately The pre wiring includes the pre wiring of all the balancer units the cables to the controller and the marking of all cables to be connected to the battery cells charger etc 1 Safety Warning Handling LiFePo4 batteries requires knowledge and safety precautions Incorrect handling can damage batteries and attached systems and cause serious injury Read all manuals from the battery cell supplier 2 Preparation of batteries LiFePo4 cells usually have a certain nominal voltage 3 2
25. harger configuration parameters Setting this parameter to very low value like 2 0V disables the pre charging feature Empty Voltage The voltage which indicates that cell 1s fully discharged and has 096 SoC left This setting should be configured according to cell manufacturer s specification minimum voltage in normal usage conditions It should have some margin above critical minimum never drop below voltage stated by cells manufacturer BMS uses this value as a reference for calculations of 0 SoC Minimal Allowed Voltage Sets the critical minimum never drop below voltage of the cell that 1s specified by cell s manufacturer Below this voltage the protection 1s engaged by disconnecting battery contactor via pin which has pin function PF12 assigned if activated For this protection to work Under Voltage Cutoff function must be enabled and battery protection contactor connected to output pin which has PF12 function assigned If BMS 1 charging it aborts charging with corresponding error code Standard value for LiPO and Li Ion cells is around 3 0V for LiFePO4 2 5V Please use cells manufacturer s datasheet to get exact needed value Additionally BMS records under voltage event and updates the according statistic Fast Charging Current This setting configures the fast charge current for CAN chargers when Fast Charge selection input with function PF2 assigned is active and the charger can be used at its full available power Slow Charging Cur
26. harging should start 4 Ignition Key Input Input for ignition key of the vehicle which controls the power state of BMS it is driven or in idle state OV vehicle idle 25V vehicle is in active driving state Cells poll and display communication rate are depending on this sleep and active state Active state 1s also considered when CAN or non CAN charger is connected to mains regardless of Ignition Key position In addition this state information 1s used by graphical interface device such as EVGUI for Windows Mobile or Android to switch the screen on or off automatically when ignition key 1s switched on or off PF5 Heater Enable Output This pin function is active when BMS enters pre heat stage if the battery pack s temperature is below minimum Heater On Temperature setting If this function is assigned to open drain output then in active state the pin is pulled low to the GROUND pin On other types of pins the active state is 5 V on the output PF7 Sound Buzzer Output Designed to sound a sound buzzer for driver in case of warning or error PF8 Battery Low Indication Output An indicator lamp for driver informing that battery is getting low starting blinking and when battery is very low it is always on PF9 Charging Indication Output An indicator lamp for driver to show various stages of charging process When it 1s off charger is not connected When it is displaying one to several pulses in around 2 seconds intervals it indicates that charg
27. ing 1s ongoing where number of pulses means the charging stage pulse pre heat 2 pre charge 3 main charge 4 balancing When charging is finished ok it displays this by constant indicator on with short interrupts every few seconds A charging error is indicated by rapid flashing PF10 Charger Enable Output Output which controls the non CAN charger during charging process When charger is connected to AC mains or other power source this must be inidicated to BMS by 33 activating Charger Mains AC Sense Input Then BMS enables the charger activating this PF10 Charger Enable Output During balancing stage BMS may periodically enable and disable the charger until all cells 1n the pack are balanced Once charging is complete BMS disables the charger PF11 State of Charge Output This is the Pulse Width Modulation output signal which has TTL levels of 0 and 5V switched at base frequency of 7 8kHz The width of the pulse is controlled from 0 to 100 duty by the value of State of Charge This signal may be converted to analog voltage by filtering it with externally attached gt luF capacitor between the pin and ground This analog voltage may be measured voltage meter which is graded to display fuel levels Alternatively this pin ouptut may control a MOSFET gate to drive fuel gauges which require higher current and work on principle of measuring a resistance to the ground which is common in many cars fuel tank gauges Due to the specific
28. mperatures above 45 50 and most LiPO Li Ion cells in addition to shorter life can catch fire if operated above 60 C If any cell in the battery pack reaches specified temperature load and charger are disconnected and error code shown Use this setting responsibly If Over Heat Cutoff function is enabled then battery protection contactor is engaged via output pin with function PF12 assigned Additionally BMS records over heat protection event and updates the according Statistic Climate Control Minimum SOC Minimum battery state of charge value below which battery climate is no longer controlled even if enabled to prevent deep discharge High Current Reduction Activates power reduction output pin with function PF16 assigned when discharge current exceeds warning level specified by Current Warning parameter value Current Warning Sets the warning discharge current above which BMS enables buzzer warning output pin function PF7 and power reduction output pin function PF16 if High Current Reduction function is enabled Additionally BMS records discharge high current warning event and updates the according statistic Cell Comm Restore If this function is enabled when cells are deeply discharged and there is either no cell communication or an undervoltage event has occurred and a charger of any type has been connected no charging error will be registered for 30 seconds to charge the battery a bit to restore cell communication and to raise
29. n this indicator is constantly on then the average voltage of whole pack cells has decreased below this setting In general use this 1 a voltage threshold at which alarm light buzzer will start during discharge state when driving operating etc This value highly depends on battery cell type and manufacturer and should be chosen from discharge graph in manufacturer s datasheet Usually for Li Ion LiPO cells it is around 3 6V and for LiFePO4 around To get the warning sooner increase this value If Low Voltage Reduction function 1s activated then signal on output pin with function PF16 assigned 1s activated which can be used for vehicle s motor controller to reduce the power BMS also records a low voltage warning event and updates corresponding statistic counter Climate Control Normal Temperature The battery temperature which will be maintained when not charging if battery climate control is enabled If the average temperature measured by the cell modules drops below this threshold heater output pin PF5 if assigned will be enabled and if the average temperature is above this threshold fan output pin PF13 if assigned will be enabled High Temp Reduction Activates power reduction output pin with function PF16 assigned when maximum cell temperature exceeds warning level specified by Warning Temperature parameter Warning Temperature Sets the temperature threshold above which BMS indicates warning and activates power
30. nature of this function 1t may only be assigned to SOC OUT pin PF12 Battery Contactor Output This is a battery protection contactor outptut which disables the battery in the event of protection error configured on BMS For information about protection functions configuration look at Cells configuration section PF13 Battery Fan Output This output 1s enabled once the maximum cell temperature of battery pack exceeds the Fan On Temperature setting of Cells configuration This function pin may drive a fan or other battery pack cooling device PF14 Current Sensor Input Current sensor input which uses all pins from INPUT 1 to INPUT 4 together to work with analog dual range current sensor If at least one INPUT X pin is changed to this function other INPUT pins are changed to this function as well As this 1s specific function it may only be assigned to INPUT X pins PF15 Leakage Sensor Input This function is designated for detecting a battery pack leakage event using a leakage sensor The leakage sensor is external device that should generate a signal of at least 5V in the event of high voltage battery pack circuit leakage to car s chassis or low voltage subsystem PF16 Power Reduction Output This function is intended to signal a power reduction requirement to motor controller of the vehicle in the event of low voltage high discharge current and overheat CAN Devices configuration 34 MMamegement General Battery Pack Changer soc
31. nnect several battery batteries to one single BMS via CAN bus For example 2 battery banks of 16 x 100 Amp cells 48 Volts Each bank has 16 balancers Both banks require a CAN cell module DN Bottom Cell Top Cell UP Top Cell All CAN Group modules are connected to the CAN high and CAN low connection of the BMS controller see section 6 and to the negative and positive of a 12 V DC power source The BOT modules are not required 12 Control Unit CAN High pack CAN Group a Moule Moule Serial Number 2 2 CAN Group CAN Charger serial Humber 1 Sertal Number 4 d ANGES Tt Serial Numtrer 3 EAMUS oe Moule pepe pack wih Cul 13 9 Blue Tooth Module To connect to Android Tablet Emus Bluetooth module operates from 12V supply and communicates with Emus Control Unit via RS232 port DISP TX and DISP RX pins Connection is as follows ad doom Black OV BMS controller GROUND 12 V negative Red 12 BMS controller USB PWR 12 V positive White DISP RX BMS controller DISP RX Pin 12 Green DISP TX BMS controller DISP TX Pin 11 Shield not connected Please note that RS232 port is shared with USB port internally Bluetooth will be not accessible while USB is connected Bluetooth module can be powered from ignition key if energy saving is required yg Emus BMS al INPUT INPUT2 INPUTS
32. other devices on the same CAN bus NOTE CAN Cell Group Modules use extended 29 bit CAN ID s and the Base ID represents upper 13 bits of ID For example the Base ID 0001 is also 0001 h in hexadecimal and BMS 35 broadcast the messages to CAN Cell Group Modules starting from 000100008 and so on Configuration table Configuration table consists of columns that represent strings of cells connected in series and of rows that represent CAN Cell Group Modules in the cell string For example if the battery pack consists of two strings connected in parallel each one of them having 40 cells connected to two CAN cell group modules then configuration table will have two columns and two rows After the device discovery to assign a particular CAN cell group module to a cell Unconfigured List Serial Cell Count 191 20 201 20 193 20 201 20 d BMS Control Panel CAN devices configuration page Unconfigured List with some discovered CAN Cell Group Modules string simply drag the entry from the unconfigured list to the configured table and drop on the desired column This entry will then appear in the configured table with a yellow question mark icon The column headers will be updated and will display the total cell count of the string in parentheses next to the string number This total cell count corresponds to the number of cells of in the string Configuration Parallel 2 string 0 Cells 40 string 1 Cells 40 1 9 CGM
33. reduction if High Temp Reduction function 1s enabled and pin with function PF16 is assigned During charging the balancing current of cell modules is gradually reduced when max cells temperature starts exceeding this threshold because during charging the temperature increase usually caused by shunts on cell modules when balancing BMS also records a high temperature warning event and updates corresponding statistic counter Climate Control Charging Temperature The battery temperature which will be maintained when charging if battery climate control is enabled If the average temperature measured by the cell modules drops below this threshold heater output pin PF5 1f assigned will be enabled and if the average temperature 1s above this threshold fan output pin PF13 if assigned will be enabled Over Heat Cutoff Cutoff the battery contactor in case of maximum cell temperature exceeding Max Critical Temp value by using activating the output pin with function PF12 assigned Max Critical Temp 26 Sets the maximum allowed temperature in degrees of Celcius of cell modules If this temperature is reached on some cell module then BMS switches off the charging and indicates an error This parameter depends on battery type For most lithium based cells it 1 around 60 C This value is not a strict one but hence that the higher the temperature the shorter battery life is Usually LiFePO4 cells start to degrade much faster when used at te
34. rent This setting configures the slow charge current for CAN chargers when Fast Charge selection input with function PF2 assigned is inactive This slow charge allows to charge the vehicle from lower power electrical sockets For example some 230V sockets could be rated 10A which would require to charge the battery with lower current than when charged from 164A socket Charge Finished Current 23 This setting defines what should be the minimum set current for CAN charger in balancing stage BMS starts gradually decreasing the requested current from charger when cells reach the Fully Charged Voltage setting If the cells are balanced and current has decreased to this point charging 1 considered finished This current 1 set as a percent of the nominal charging current which can be either Fast Charging Current or Slow Charging current Pre charge Current Allows to setup the pre charge current for CAN chargers when cells that are deeply discharged below Pre charge Threshold voltage This current 1s set as a percent of the nominal charging current which can be either Fast Charging Current or Slow Charging current and 1 used during Pre charging stage When the pre charge voltage threshold is exceeded BMS goes to the next main charging stage Battery Pack configuration Battery pack parameters allows you to set the configuration of the whole battery pack and to set thresholds for various battery pack protection features These parameters are des
35. rget voltage for different stages of charging Maximum Pre charge Stage Duration Sets the maximum allowed to time for pre charge stage with CAN charger to allow cells to reach the Pre charge Threshold voltage and enter normal charging stage If this time is exceeded a charging error is raised and charging is stopped Default 2 hours value should be more than enough in most scenarios If this time 1s exceeded it usually indicates some issue with the battery Maximum Main Charge Stage Duration 29 Sets the maximum allowed to time for main charge stage to allow cells to reach the Fully Charged Voltage and enter balancing stage If this time 1s exceeded a charging error is raised and charging 15 stopped The time for charging the cell depends capacity of cells and charging current Default 10 hours setting should work in most cases If for example total cell capacity 1s 100 Ah and the pack 1s being charged with current of 20 A the pack should be fully charged in 5 hours Give it a bit of reserve and set say 7 hours 420 minutes Too long charging time may indicate a bad cell and big energy leak heat in the battery pack If the problem occurs check cell voltages on Status page Cells tab Maximum Balancing Stage Duration Sets the maximum allowed to time for balancing stage to allow cells to reach the balanced state and complete the charging cycle If this time is exceeded a charging error is raised and charging is stopped The time
36. s would be sorted in a downwards ascending order in every column and also from column to column see images on the right This way cells will displayed correctly in Status page Cells tab cell of the most negative potential the one connected to the minus terminal in the string will be displayed as the first cell on the left and cell with of the most positive potential the one connected to the plus terminal will be the first one on the right For more detail on how to connect CAN cell group modules see Installation instructions Commit configuration After all entries from unconfigured list have been put in the configured table make sure that every CAN cell group module reports correct cell count NOTE If some CAN cell group modules report incorrect cell count please check that the cell modules are installed and connected correctly and that the cell voltages are high enough to power up the cell modules If cell count 1s reported correctly from all CAN cell group module entries press Commit configuration button Doing so will send the finished configuration to Control Unit and if everything is ok the yellow question mark icons will turn to green check icons indicating that CAN cell group module configuration was completed successfully If some error occurred while committing the configuration some of the yellow question mark icons will turn to red x icon indicating an error In such case check that CAN cell group modules are connected
37. sible to assign to each pin The first choice on top of the list is always a default pin function and is assigned when factory defaults are loaded Other assignable functions choices depend on hardware capabilities of each pin The last choice PFO No Function disables any function of the pin 32 NOTE To ensure correct pins operation please make a BMS Reset after configuring pin functions The list of pin functions 15 described below PFO No Function Disables any function of the pin PFI Speed Sensor Input Sets the pin to receive speed sensor pulses to determine the speed and distance of the vehicle This function can only be assigned only to SPEED IN pin Please note that speed and distance function 1 not enabled in BMS software yet PF2 Fast Charge Switch Input Sets pin to act as an input a charge rate switch If the nvert flag 1s not set then OV voltage of this pin will be treated as slow charge setting while voltage more than 5V will be treated as Normal Fast charge choice This pin can be connected to 12V signals directly PF3 Charger Mains AC Sense Input Sets pin to act as a sense for non CAN charger connection to AC mains or other source and as a command to BMS to start and control the charging process This input may be used with Charger Control Relay supplied by JSC Elektromotus or input from other signal With inversion flag off OV charger is not connected to AC mains and 25V charger is connected to power source and c
38. sn 197 cells 20 9 sn 200 cells 20 CGM sn 199 cells 20 CGM sn 201 cells 20 3 BMS Control Panel CAN devices configuration page Configuration table with four CAN cell group module entries two in String 0 and two more in String 1 The yellow question mark icon indicates that this configuration has not been committed yet Configuration Parallel 2 string 0 Cells 40 string 1 Cells 40 1 9 CGM sn 197 cells 20 COM sn 200 cells 20 2 9 sn 199 cells 20 9 CGM sn 201 cells 20 J m BMS Control Panel CAN devices configuration page Configuration table with four CAN cell Group Module entries after the configuration has been successfully committed and sent to BMS Control Unit The green check icons indicate no errors 36 Configuration Parallel 2 string 0 Cells 40 string 1 Cells 40 1 9 sn 197 cells 20 e sn 200 cells 20 2 CGM sn 199 cells 20 C CGM sn 201 cells 20 3 BMS Control Panel CAN devices configuration page Configuration table with four CAN cell Group Module entries after committing configuration has failed and one of the group modules is not responding The red x icon indicates a communication error In such case check that the indicated CAN cell group module is connected to the CAN bus correctly NOTE For purpose of clarity it is advised to set up the configuration in such way that serial numbers of the CAN cell group module
39. stance unit name for easier display in status screens and for further reference Name can be up to 2 characters long Estimate Safety Margin Defines the percentage of battery capacity to subtract from left capacity that 1 used estimated remaining distance calculation Recommended value 1 around 10 but may depend on application Cells configuration Emus BMS is designed to work with wide range of battery cells with operating voltages in between 2 and 5 V including LiPO Li Ion LifePO4 and others Different cell types operate at different voltages and these parameters must be set for proper operation of Emus BMS To configure cell type connect the Emus BMS Control Unit to PC s USB port start the Emus BMS Control Panel application and navigate to Configuration page Cells tab For 21 visual reference of the cell parameters most of them are aligned to an image of a cell charging curve pr m ia Language Opbani Managment General Battery Pack Changer Sc Fire CAR Devices Cell Charging Parameters Masimum Aksan Woltage 3 80 4 A Fast Changing Curent Fully Charged 2 80 debalance 0 05 Em badain Threshold 3 50 y Bari Range 0 09 Charge Restert voltage 3 30 y h Change Finished Current Configuratio g Precharge Threshold 3 00 Precharge Current Empty 2 70 v A Slew Charging Gurren Minimal woltage 2 50
40. tdichip com Drivers VCP htm The latest firmware is installed on the BMS unit Introduction to configuration Once Emus BMS is installed it must be configured to work properly Configuration includes various types of parameters from cells count protection parameters to pins re mapping configuration parameters have a popup hint tool tip text which appears when mouse is hovering above the configuration parameter entry element Configuration parameters change can be done only in logged in state as described in configuration management section below When user is not logged in then all configuration parameters and buttons except Login are disabled and grayed out and parameter entry 1s not possible When a parameter is changed its background turns yellow which means that parameter was edited but has not been committed and saved to BMS yet Committing the parameter 1s done when user deselects parameter entry field Once parameter is committed successfully the yellow background is removed If for some reason the parameter was not committed and it still shows yellow then select and deselect the entry field to try again NOTE When charger is connected and charging parameter configuration will be blocked and yellow background will not be removed Configuration management Since version 1 6 configuration of BMS has new features were introduced enhancing usability and the security of parameters 17 The password can be set to protect the
41. the cells charger and power outlet whitch one 1s the lowest If for example the charger can give a 50 A current but battery cells are 100 Ah and rated at only 0 3 C charge rate this 1s a limiting factor and Normal Charge Current value should be set to 30 A 100 Ah 0 3 C 2 30 A This field 1s applicable only for CAN charger Early Balancing Threshold value sets a minimum cell voltage at which cell balancing starts By lowering this value faster balancing and overall charge time can be achieved but this increases power losses dissipated as heat in Cell Modules Usually threshold of 3 4 V 1s optimal LiFePO4 cells and 3 7 V for LiPO La Ion cells Allowed Dis balance value sets the minimum difference between cell voltages at which it 1 considered that cells are at balance and cell balancing is turned 38 12 Android device Android devices can download the an application via Google Store EVGUI This application allows a connection to the BMS unit via Blue Tooth BT Module required to monitor all data from you battery 39
42. tocol description for exact format This may be useful if a device connected via serial interface would need to see and manage the CAN devices over serial interface CAUTION This function is not intended to be fully functional CAN Serial converter because of BMS CAN messages processing and serial interface speed limitations It could be used when there are not many messages on the CAN network CAN ID Base CAN ID Base address which allows to set an arbitrary base address for periodic broadcast CAN messages generated by BMS This allows to use several BMSes on the same CAN bus or resolve the possible addressing conflicts with other devices For extended 29 bit ID it represents upper 13 bits of ID For example the default extended ID 6581 is 19B5h in hexadecimal and BMS broadcast the messages starting from 19B50000h and so on For basic 11 bit ID it this a base address number which must be added to the broadcasted messages IDs For example if this number 15 entered 800 then BMS will broadcast messages with standard 11 bit IDs starting from 800 Pulses per Distance Unit Sets the number pulses that are required to be registered on SPEED IN input to count one distance unit For example if your car s service manual says that gearbox VSS Vehicle Speed Sensor is producing 600 pulses per one kilometer then you should enter value of 600 for BMS to measure the distance in kilometers and speed in kilometers per hour Distance Unit Name Allows to set the di
43. ty This allows to eliminate the SoC drift over time due to electric or magnetic noise of current sensor surrounding media and other factors Use small values up to around 10 A default value 3 is good starting point If sometimes the reading shows tendency to show small current in either direction when actually no current 1 flowing then Reset Current to 0 should be used first and additionally this Deadzone could be increased Reverse Direction Reverses the direction of current sensor Use this setting to ensure positive current reading when charging and negative current reading when discharging Reset Current to 0 Resets current sensor reading to zero to compensate for sensor s offset and surrounding static magnetic influence Min SoC Output Sets the SOC OUT output PWM signal duty period which corresponds to 0 SoC This setting is useful when analog fuel gauge 1s used for displaying the SoC As analog sensors have some range in which they show values of Empty at some voltage above 0 Therefore for example it might be required to define a value of 10 SOC OUT PWM signal to display a SoC value of 096 Max SoC Output In similar way as described above it is set to define the PWM signal duty period which corresponds to 100 SoC charge estimated by BMS As a result the SOC OUT PWM signal duty cycle will swing from Min and Max values for displaying 0 and 100 SoC accordingly Pins Map configuration h BMS control unit pins Pins map
44. www all4solar com au 4s last update 01 01 2014 electric boat engines amp solar power EMUS BMS battery management system for LiFePo 4 batteries SETUP INSTRUCTIONS Note The BMS module is manufactured in Europe The systems are assembled in Australia This document only applies to the EMUS BMS system setup offered in Australia One year limited warranty applies to all products supplied via all4solar Contense Material reguired partiy Optional 2 5 2i Preparan 5 NN e or palan ETS E E 8 S Connection of BOT 10 SBI SCOTS GU ONG A E EEE 11 SONS OM TNT mms 11 NOT 12 S Blue MOG UO CUS 14 TO UN MAGI LIS 16 TPC ONT n 17 E Tm 39 Material required partly optional Prismatic battery cells with 8 or 10 mm connectors Cables usually 32 70 mm2 elugs for main cable connections 8 10 mm 47 e Suitable sized cable e Cell connectors With bolts and washers eG Antioxydant e Cell balancers EMUS digital Standard with one cable and 8 mm connector or e Cell balancers EMUS digital all prewired in blocks of 4 on a acrylic board with cover plate for balancers 8 10 mm included with EMUS Balancer e Cable to connect balancers 1 2 mm2 included wit
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