Battery Management System (BMS) Installation guide and manual

Transcription

1 Battery Management System (BMS) Installation guide and manual BMS manual with software version 3.32BT

2 General safety informations when operating with the Battery Management System BMS: Control the purchased parts package for completeness and correctness! Please read the installation guide and the manual carefully before operating and follow the instructions! The specified safety instructions need to be followed! All now following operations need to be done by electrically instructed persons. A single lithium-cell or the connected cell-packages are constructionrelated under voltage (DC). The height of the voltage depends on the type connection. Therefore, it is important to work with the corresponding instructions according to VDE0100! The cells are constructed under safety class IP 0x. Please take care for the necessary electric shock protection! Cells and BMS are part of a complete system. The responsibility to operate the system according to the recommended practices lies within the customer or system constructor/operator (Load disconnecting switch, fuse protection, etc.)! Before starting the work on energized parts the charging plug needs to be disconnected from the grid and the connection of the batteries needs to be interrupted! Before connecting or disconnecting a pin to a cell or the battery all consumers and charging devices need to be switched to zeropotential! Even a standby-potential can cause significant damage to the BMS-electronic! Allowed charging and discharging currents as well as final charging and discharging voltages are not allowed to be exceeded. The BMScomponents need to be included into the electric power and controlling system of the energy storage unit! BMS manual with software version 3.32BT

3 The lithium-cells are only allowed to be charged and discharged within the approved operating limit according to the battery-data sheets! When operating with the batteries, we are referring to the material safety data sheet and the manual of the particular battery type! Before the starting up the mechanical (e.g. installation position, ambience conditions, etc.) and electrical (e.g. wire-dimensions, polarity of the components, wire-connections, etc.) installation needs to be checked! Please take care, that no damaged components are being used! When the components are built in or used inappropriate, the Clean Energy GmbH is not extending any warranty or assuming any liability. Our Cells and BMS-components are excluded from the extended product liability. The ingredients of that manual are the explanation of the BMS, the installation guide and the data sheet of the used cell-type! Please consider actual additions to the guidelines on our homepage We are not taking any liability on technical or print technical failures and their consequences. The orders in the explanations are being checked regularly. Changes in consequence of a correction or a technical improvement can be made without a letter of indication! The copyright of the BMS installation guide and manual are lying within the Clean Energy GmbH. Duplication without a written authorization, also in parts, is not allowed! BMS manual with software version 3.32BT

4 GENERAL INFORMATION ABOUT THE OPERATION WITH LITHIUM-CELLS AND BMS: When connecting or wiring the lithium-cells the following parts need to be considered: All battery-terminals need to be cleaned (3M Bristle-Disc 120) and then be coated with battery terminal grease or vaseline (corrosion protection). After the installation and wiring of the cell-boards we recommend, for dirt and wetness protection, to spray them with spray paint. During the installation of the cells they need to be fixed mechanically with a tentering frame, to avoid a possible expansion of the cells through an over pressure, and to prevent a possible shifting. The cross sections of the battery-connection wires need to be dimensioned sufficient. Only lithium-cells with the same charging level are allowed to be connected. Otherwise the cells need to be charged separately or connected parallel in consideration of the allowed charging current. Before any operations on the cells, like connecting or disconnecting of the battery-connection wires, the following steps need to be made: - When using a BMS with central box, the main plug needs to be disconnected first! - When using cell boards, the battery current circuit needs to be disrupted first! Our specialized personnel will help you for any more questions. BMS manual with software version 3.32BT

5 Table of contents 1. Battery management system [BMS] BMS and charger components Construction with cell boards Overview about the standard BMS components BMS connection example with cell boards on an electric vehicle system BMS connection example with cell boards on a storage system Construction with central BMS box Overview about the standard BMS components BMS connection example with cell boards on a storage system Connecting the BMS and the charging components BUS (voltage supply) board Construction with power supply 230V AC/12V DC Construction with power supply or V DC/ 12V DC Voltage supply for BMS and charger, wiring example on an EV system With power supply 230V AC/12V DC and charger with max W With power supply DC/12V DC and charger with max. 2400W Charging circuit with current sensor BUS wire Preparation for the Display (BMS control) BUS connection BUS connection with a central box Connecting the BUS wire to the central box Connecting the BUS wire to the cells at the central box Connection of the BUS wire to the cells with cell board version Installation of the cell boards Pressing on of the red BUS plugs Connecting the cell boards via BUS wire Manual BMS control with software version 3.32BT Software description Controlling elements Menu structure BMS manual with software version 3.32BT

6 7.4 Showing the submenu Parameters of the battery condition Failure treatment Service address BMS manual with software version 3.32BT

7 1. Battery management system [BMS] The battery management system of the Clean Energy GmbH was developed for the diagnoses and the monitoring of lithium-iron-phosphate batteries. A special attribute of the BMS is that all components are being linked with a BUS wire for the communication with each other. There are two different types to monitor the cells: with a central box or with cell boards. The system is mainly consisting of six different components: - the BMS control with display for the control, - a relay that is regulating the charging device, - a load shedding relay, that is disconnecting the battery discharging circuit to prevent a total discharge, - the current sensor to measure the charging-/discharging-currents, - the BMS cell board or the central box that are monitoring and balancing the single cells, - the power supply for the energy supply of the BMS. Moreover up to five temperature sensors and further BUS relays can be connected to the BMS. Important data, like the address of a disrupted battery, the voltage level of a single cell, temperatures or removed charging volumes can be shown in the display of the BMS control for battery diagnosis. When further external components are connected to the BMS (e.g.: power contactor, charging device, battery heating and ventilation), it can be used as an automatic system to control the charging- and discharging circuits in electric vehicles. When connected to a PLC, the BMS is able to monitor the battery of a storage system and control the charging and discharging progress. The integration in the superior system control is possible through potential-free contacts and/or a communication interface adapter. BMS manual with software version 3.32BT

8 Schematic diagram with all BMS components: BMS manual with software version 3.32BT

9 2. BMS and charger components 2.1 Construction with cell boards Overview about the standard BMS components 01 BMS control with display optional build-up or build-in 02 Power supply 230V AC/12V DC or power supply V DC/12V DC 03 BUS board for power supply AC/DC or DC/DC 04 Current sensor 05 Cell boards (Version depending on cell type) 06 BUS relay charger 07 BUS relay load shedding veined BUS wire 09 BUS plug grey & red BMS manual with software version 3.32BT

10 2.1.2 BMS connection example with cell boards on an electric vehicle system With power supply 230VAC/12VDC and 16A charger. Without temperature monitoring. The control about the 12V on board supply system is not taken into account here! The emergency flasher system and the parking lights need also to be usable after die disconnection of the power-shedding relay. All other consumers need to be switched off to prevent the cells from a possible total discharge. BMS manual with software version 3.32BT

11 2.1.3 BMS connection example with cell boards on a storage system BMS manual with software version 3.32BT

12 2.2 Construction with central BMS box Overview about the standard BMS components 01 BMS control with display 07 BUS relay load shedding optional build-up or build-in 02 Power supply 230V AC/12C DC veined BUS wire or power supply V DC/12VDC 03 BUS board for power supply 09 BUS plug grey & red 04 Current sensor veined Bus wire 05 BMS central box 11 3 veined BUS wire 06 BUS relay charger BMS manual with software version 3.32BT

13 2.2.2 BMS connection example with cell boards on a storage system With power supply 230VAC/12VDC and 16A charger. Without temperature monitoring. The control about the 12V on board supply system is not taken into account here! The emergency flasher system and the parking lights need also to be usable after die disconnection of the power-shedding relay. All other consumers need to be switched off to prevent the cells from a possible total discharge. BMS manual with software version 3.32BT

14 3. Connecting the BMS and the charging components 3.1 BUS (voltage supply) board The voltage supply for the BMS/the BUS communication is made through the BUS boards that are being connected to the power supply. Depending on the application it is possible to use alternating voltage or direct voltage power supply Construction with power supply 230V AC/12V DC The voltage supply is assured with the public grid (230V AC) or with a 12V DC voltage source. The BUS board is screwed on the power supply as shown here V Construction with power supply or V DC/ 12V DC The voltage supply is assured over the battery or a 12V DV voltage source. Different input voltage ranges like 18-36V DC or 36-72V DC can be selected. The BUS board is screwed on the power supply as shown here. + 12V 0V BMS manual with software version 3.32BT

15 3.2 Voltage supply for BMS and charger, wiring example on an EV system With power supply 230V AC/12V DC and charger with max W The voltage supply is assured through 230V AC charging plug and 12V DC on-board electric 230V AC-wiring: When using charging devices with input currents greater than 16A, the BUS charger relay is not allowed to be used directly for the switching operation of the charging current. A power contactor needs to be used in this case that is controlled by the BUS relay. 12V DC-wiring: When connecting the 12V DC, the terminal description of the power supply needs to be considered! The position of the V+ and V- 12V DC connectors is not identical on both available versions. Connecting example: BMS manual with software version 3.32BT

16 3.2.2 With power supply DC/12V DC and charger with max. 2400W The voltage supply is assured through the traction battery or the 12V DC on-board electric. Connecting example: 230VAC-Anschluss: When using charging devices with input currents greater than 16A, the BUS charger relay is not allowed to be used directly for the switching operation of the charging current. A power contactor needs to be used in this case that is controlled by the BUS relay BMS manual with software version 3.32BT

17 DC connection from the battery: To disconnect the BMS from the voltage supply, a break-switch needs to be installed in the current circuit. 12V DC-wiring: When connecting the 12V DC, the terminal description of the power supply needs to be considered! The position of the V+ and V- 12V DC connectors is not identical on both available versions. 3.3 Charging circuit with current sensor The current sensor is recording the actual complete current during the charging and discharging progress. The battery connection wire of the negative terminal is laid through the current sensor. Moreover, the blue ring or the text of the current sensor needs to direct away from the negative terminal. After the current sensor has been connected to the BUS wire and the BMS has been activated, the correct operation of the current sensor is shown through a positive prefix at the current value (+0A) in the Display of the BMS control. If no or a negative prefix is shown. The orientation of the current sensor and the wiring need to be checked! Current sensor Negative terminal BUS-connection BMS manual with software version 3.32BT

18 4. BUS wire All BMS components are connected through a BMS wire for the communication among each other. 4.1 Preparation for the Display (BMS control) The on-board display needs to be sliced on its back for the BUS plug. The build-in display is ready to mount. For the operation in the CityEL there is a special version available Standard build-in display CityEL build-in display Before the display is built in, the jumper configuration to select the background lightning needs to be selected on the rear side of the board: Rear side build-in display Jumper Color table BMS manual with software version 3.32BT

19 Jumper set red-green-blue red green blue red-green red-blue green-blue no Jumper... equals background lightning white red green blue yellow purple turquois unlighted 4.2 BUS connection BUS control, BUS relay, power supply and current sensor are connected through the grey BUS plugs with the 10 veined BUS wire. Therefore, it is important that the grey BUS plugs are pressed at right angles to the BUS wire. The BUS wire is laid out symmetric, so that the red marking is not having any importance. The named components are having an assured participant address. Consequently, the order within the BUS circuit is for free choice. 5. BUS connection with a central box 5.1 Connecting the BUS wire to the central box The bridge between the BUS wire and the BUS central box entry is being soldered according to the following terminal diagram and isolated individually. Therefore, two individual wires of the BUS wire are united. Consequently, the BUS wire is laid out symmetric and protected from reverse voltage. BMS manual with software version 3.32BT

20 5.2 Connecting the BUS wire to the cells at the central box The cells are connected individually with the BMS central box. Therefore, the grey outside isolation is being removed so far, that the single wires can be laid to the cells of the battery package. The ends of the wires need to be equipped with flat-pin plugs. The green-yellow wire is being connected to the negative terminal of the first cell. The black wires are numbered from 1 to 17. These are connected to the positive terminals of the first cell and the following. The wire No. 17 can be sliced through as it is not disposed in the plug. All other unused wires need to be isolated (see also connecting diagram point 2.2.2) BMS manual with software version 3.32BT

21 Inside the central box the wires are dedicated to a BUS address. To address the cells with the BMS control the menu-point Auto addressing is being started with 1 in the BMS control. When having reached the last connected cell the addressing stops. Through plugging the spring-return button the addressing is quitted and the BMS switches back to the main-menu. 6. Connection of the BUS wire to the cells with cell board version 6.1 Installation of the cell boards As the cell boards can be used for multiple cell sizes, it might be affordable to shorten the cell boards according to the distance between the positive and the negative terminal of the battery. After the cell connectors are laid down, the cell boards are being screwed frontal on the cells (with washer and spring washer). Here it is essential to take care for the parallel polarity of the lithium cell and the cell board (+ and polarity are marked on the cell)! Special feature of cells with about 200 Ah and more: The cell boards cannot be directly installed on the battery terminals. In this case two connecting wires are soldered to the boards and fitted to the battery terminals with cable lugs. The board is fixed on the cell with four gluey basements. BMS manual with software version 3.32BT

22 Suggestion: To avoid possible discharging currents over the cell board, which can occur during the connecting or disconnecting of the main negative terminal, it should be connected to the main negative terminal of the battery with a flat-pin plug. Before disconnecting the power-wire, the connection to the board needs to be interrupted. When connecting it needs to be handled the other way round. Possible interruption point 6.2 Pressing on of the red BUS plugs The red BUS plug needs to be pressed on the BUS wire in the same way as explained before with the grey plugs. Here it is important to take care for enough space between the plugs to make the installation as easy as possible and not to put the BUS wire under tensile stress. Because of the simpler installation the noses at the plugs can be broken away, as seen on the following picture. BMS manual with software version 3.32BT

23 6.3 Connecting the cell boards via BUS wire Please connect the BUS plugs individually after having activated the BMS and after the Auto addressing (see point 7) Line of action: 1. The cells get numbered according to the constructed series connection. The cell with No. 1 should be the cell with the main positive terminal of the battery pack for a better overview. 2. As soon as the BMS is activated, the BUS plugs can be plugged on all boards one after another. Here it is important to start with the cell No. 1. If the BMS has identified the cell, a hearable signal will appear and the cell will be shown in the BMS. Afterwards, in the sense of a rising voltage according to the series connection, the cells are linked to the BMS one after another. If a cell is not identified (no hearable signal appears), the cell board needs to be exchanged. Connected battery package BMS manual with software version 3.32BT

24 7. Manual BMS control with software version 3.32BT 7.1 Software description The now following descriptions of the BMS functions can differ in earlier software versions. An update for the latest versions can be made by the CleanEnergy GmbH. The suggestion for the option of the shunt-voltage (see point 7.4) is also guilty for earlier software versions >3.25 and should be readjusted (with software up to 3.25 we suggest a shunt-voltage of 3.60V). The battery management system is activated by the connection of the supply voltage. After adjusting all data sets, the BMS control is reading the cell values and optional the temperatures. If all criteria are fulfilled, the charging and discharging mode is being unlocked. The charging as well as the discharging mode is being supervised by the BMS and steered by the BUS relay. The charging/discharging is only active during the Standard display, Temperature and Service display. The charging/discharging progress is being interrupted in all other menus for safety reasons. A switch between the operation displays is possible without any interruption. 7.2 Controlling elements The BMS control of the BMS includes a display to show the information and a spring-return button to choose the functions or data sheets and to adjust the values. 7.3 Menu structure After starting the BMS there it is a short system test and the installed software version is shown Now the display is changing to the Standard display. Through a short push on the spring-return button the display is changing into the main menu. BMS manual with software version 3.32BT

25 When turning the button right the following menus can be selected: Main menu standard display Main menu service display Main menu temperature display Main menu single display Main menu setting the Ah to 0 Main menu Auto addressing Main menu current comparison Main menu Shunt voltage The last three menu points are only available if the spring-return button is not only pushed short in the standard display, but held for min. 4s (Signal appears). From each main menu point it is possible to come to the next sub menu through pushing the spring return button (in the following shown with a ). Through turning it is possible to see different values or to adjust them. With a short push it is possible to get back to the main menu standard display. A second short push is setting back again onto the standard display with total battery voltage, charging quantity and momentary current. BMS manual with software version 3.32BT

26 7.4 Showing the submenu Main menu service display Display in the sub menu: Cell with lowest voltage: ID-Nr., cell voltage [ V ]; Cell with highest voltage: ID-Nr., cell voltage [ V ]; Momentary current [ A ] With the difference between the cell voltages it is possible to calculate the maximum difference between the cells of the traction battery. Main menu temperature display Display of the first temperature sensor 1. All other temperatures can be shown by pushing the spring-return button. Main menu setting the Ah to 0 Pushing the spring return button is setting the Ah counter back to 0. This function is only useful after the installation of a traction battery. During the circuit operation the display is showing the received charging value (+). With the first following removal of energy (during the driving mode), an automatic recalibration is made. The counter is set back to 0 and is then starting to count to the negative (-). Main menu - single display Starting with the cell No.1 the cell voltages of the single cells are shown. Turning the button is changing to the next cell.!the charging mode is interrupted in the single display! Main menu standard display Display: Total voltage [ V ] Actual current [ +/- A ] charging quantity [+/- Ah ] A negative prefix is showing a discharging operation. A positive prefix a charging operation. BMS manual with software version 3.32BT

27 Main menu auto addressing Selecting the starting No. with the spring-return button. When adjusting the cell-addresses in a BMS control for the first time it is useful to with 1. When using a BMS central box each wire is having its own address (see description BMS with central box) The cell boards need to be handled the following: With activated BMS the BUS plug of the cell No.1 is connected. Then the start is activated when pushing the button once. When the BMS has identified the cell, an audio signal appears and the cell is shown in the BMS display. Furthermore the next BUS address is shown in the display. Afterwards, in the sense of a rising voltage according to the series connection, the BUS plugs are connected. When the highest cell number or the last connected cell is reached the addressing stops. Pushing the button finishes the addressing and changes the display back to the main menu. The BUS component address is now saved on the cell board. A later change of the address is not possible. When the auto addressing is started later again, the BMS is automatically identifying the cell boards that are connected to the BMS-BUS. This can be seen by the ramping up of the counter. Main menu current comparison Pushing the spring-return button is recalibrating the current sensor (i.e. set to 0). Consequently, a misusage means that the actual current and the charging quantity display are not correct. Main menu - shunt voltage Adjusting the voltage level, where the balancing shall start. Suggestion for SP-LFP and WB-LYP cells Higher than SW3.26: 3,50 V. up to SW3.25: 3,60V. A special feature of our BMS is the balancing of the single cells, which is made at the end of the charging mode. With a BUS charger relay the charging mode of the connected charging device is interrupted. At the same time the cells, which fulfill the criteria, are balanced. A load resistance on the cell boards is reducing the cell energy, so that their cell voltage is declining. During that progress the cells with low voltages are continuing their charging operation. If the threshold for the end of BMS manual with software version 3.32BT

28 the Balancing is reached, the charging mode is starting again. The balancing continues until the switch off criteria is reached. 7.5 Parameters of the battery condition Nominal cell voltage: 3,25 V, at 25 C BMS voltage registration: +/- 0,01 V BMS activity Advance warning Low Discharge => Interrupted audio signal Main warning Low Discharge => Constant audio signal Discharging off switch active => BUS load shedding relay is deactivated Charging active => BUS charging relay active Balancing => LED on the cell board is lightning. When using charging currents >10A the BUS charging relay is deactivated and reactivated automatically after the charging adjustment. Charging off/ charging off switch => BUS charger relay deactivated BMS manual with software version 3.32BT

29 7.6 Failure treatment Breakdown of a cell board. Here e.g. cell address 3. A registered defect cell leads to an off switch of the charging and load-shedding relay. When switching on the single cell supervision the faulty cell board is shown with the value 2,50 V. The real cell voltage needs to be controlled with a voltage meter. When the connection between the cell boards and the complete BUS wire is interrupted, the service display is showing 2,50 V as the value for the lowest cell voltage and the BUS supply voltage 5,00 V for the highest cell. All cells are showing 2,50 V on the single display and the actual current value is displayed without a prefix: Short circuit on the BUS system: Possible reason: Damage on the first or the last cell board, because of an over current by connecting the battery power wire under load with connected BMS. No prefix at the current value: Missing signal of the current sensor. When the temperature sensor is damaged or the connection interrupted the display is showing -20 C. Here e.g. the temperature sensor for the first battery pack. Advice for the change of a cell board: When a damaged cell board is exchanged it needs to be programmed with the correct cell address first. The other way is to build in the new, not addressed cell board. The BUS plug is not connected to the cell yet. After the auto addressing has been started, the counter will stagnate at the number of the new cell. Connecting the BUS plug will recalibrate the address. The counter is than continuing up to the last component. BMS manual with software version 3.32BT

30 8. Service address Clean Energy GmbH Etzelstrasse Aub Tel: ++49 (0)9335 / Fax: ++49 (0)9335 / info@cleanenergygmbh.de BMS manual with software version 3.32BT