INSTALLATION INFORMATION BMS ZE6000i-PCBT.xxxx / ver. 2 Programmable battery management system for Lithium Ion battery cells, for up to 32 round or prismatic cells, 10 to 400Ah NOTE: This installation guide applies to the micro lithium ion battery management system, part number ZE6000i, and associated modules. For explanation of terms used, acronyms & a glossary, refer the the lithium ion battery management system application note, document code 146156. You are strongly advised to read through this application note before attempting system installation. Also, be sure that you are fully conversant with the safety issues surrounding lithium-ion batteries. There are some notes in the application note to assist understanding, but these should not be considered to be a complete & authoritative source of information. You are entirely responsible for ensuring that you understand these issues & comply with best practice when putting together a battery system. Only technically competent persons should attempt to install this system!
Table of Contents Description This BMS comprises one master module, along with a range of additional expander modules. The battery management system is organized into groups of four cells, this being referred to as a bank. The master is configured to manage either one or two banks, with additional banks being catered for by the addition of expander modules. Any added expander modules are also managed by the master BMS, with a maximum capacity of 32 cells in total. The primary user interface is a 20 character x 4 line OLED display with a touchscreen style user input key. The display also houses a light sensor for automatic adjustment of the display to suit the ambient light level. BMS configuration parameters may be changed by authorized users through a configuration webpage. The configuration webpage has two permission levels allowing parameter changes. These are engineer & system integrator. Module identification BMS master module User display
Lithium-ion battery safety Lithium ion batteries are capable of both absorbing & delivering extremely high current. Excess current may cause overheating or burning of connected circuits, the battery itself can also suffer damage with fire & toxic emissions a possible outcome. Although the BMS includes overcurrent detection, the external contactors may not be capable of breaking the short circuit current without welding in the closed position. It is vital to provide fail-safe protection of last resort. A conventional fuse is one appropriate means of providing this protection. The fuse must be capable of breaking the fault current & the fault current must always be able to rupture the fuse. Information provided by both the battery & fuse manufacturer should enable correct part selection. Wiring loom BMS wiring looms are included with the complete BMS system. The BMS wiring looms are also available separately. The installer may also make up looms based on the information supplied in this manual. Connection sequence The BMS must be connected to the battery pack in the sequence set down below. Failure to follow this sequence may cause damage to the BMS. The sequence assumes that the individual cells have already been assembled into the battery stack and wired together and that the component parts such as relays & contactors have been mounted into the pack. More complete wiring details are provided in the sections that follow & it is advisable to refer to them before commencing installation. 1. Connect one side of the current shunt power terminals to the battery stack negative terminal. 2. Connect the BMS common 0V to the ground side power terminal of the current shunt. 3. Before plugging the current shunt loom into the BMS, wire it to the current shunt sense terminals. 4. The following looms may be wired next; the connection sequence of these looms is not critical, but do not plug them into the BMS at this stage unless stated: temperature sensors - can be plugged into the BMS at this point cell monitors - wire to individual cells as shown in the wiring diagram display - can be plugged into the BMS at this point (if used) external relays & contactors - wire to relays & contactors as shown in the wiring diagram 5. The load & charger sense wires may now be connected to the BMS terminal block. There are two terminal blocks on the BMS, marked Cn2 & Cn3. Cn2 (lo) is used when a four cell stack (12V) is to be managed.cn3 is used when an eight cell stack (24V) is to be managed. If the system includes expander modules to cater for more than eight cells, then the terminal block on the highest expander in the stack is used. For details, refer to the expander installation manual. 6. First connect the load wire from the BMS to the load connection point - refer to the wiring diagrams. 7. Next, connect the charger wire from the BMS to the charger connection point - refer to the wiring diagrams. 8. Finally plug the cell monitor ribbon cable connector into the BMS - at this point the BMS will power up & is ready for configuration, if required. 9. Configuration instructions are provided in document no. 136156-C
Configuration overview Figure 1: overview of system connectors
Configuration overview - continued Figure 2: overview of system connectors which have configuration options
Configuration overview - continued Figure 3: generic power system architecture Charger disconnect: For safe & proper management of lithium-ion battery packs, both the loads & the charging source must be controlled so as to restrict battery operation to within prescribed limits. There is no float charge condition, as there is with lead-acid batteries. Charging must be terminated when the battery reaches 100% state of charge; any overcharging will cause irreversible damage. Hence, some form of charge disconnect must be provided. Some chargers designed for use with lithium ion may have appropriate built-in charge management, but be aware that this must be configured for the specific cell in use. Variations of cell electrode composition between manufacturers means that there is no one-size-fits-all regime. The BMS may be used with a suitable intelligent charger, configured for the specific battery cell type. The BMS may also be used with a suitably set constant voltage source for charging; the BMS provides a charge on/off capability to protect the battery pack. This may be accomplished using a relay or contactor which may be located at the charger output, as shown above. The relay or contactor may instead be located at the charger input, provided the charge source is able to operate with the battery permanently connected and without any significant reverse loading. If the charger has an on/off control input, the BMS charger control output may be used to drive it.
Load disconnect: Load disconnection is required to protect the battery. The BMS can be configured to drive both normal contactors or relays, or twin-coil latching types. If the load has an on/off control input, the BMS consumers control output may be used to drive it, but be aware that the overcurrent disconnect relies on a reliable method of removing the load. If non-priority load shed is configured, a second relay or contactor will be required for the priority loads. Configuration overview - continued Figure 4: alternative charger control options, when not using an output side disconnector
Configuration overview - continued Figure 5: alternative DC/DC charger control options, when not using an output side disconnector
Configuration overview - continued Figure 5: alternative charger control options, when not using an output side disconnector
Wiring diagrams Figure 6: connectors right hand end of BMS
Wiring diagrams - continued Figure 7: connectors left hand end of BMS
Wiring diagrams - continued Figure 8: connectors right hand end of BMS
Wiring diagrams - continued Figure 9: overall wiring diagram for four-cell 12V systems, using charger output side relay and latching loads contactor
Wiring diagrams - continued Figure 10 & 11: overall wiring diagram for eight-cell 24V systems, using charger output side relay and latching loads contactor
Wiring diagrams - continued Figure 12 & 13: overall wiring diagram for four-cell 12V systems, using intelligent charger & latching loads contactor
Wiring diagrams - continued Figure 14 & 15: overall wiring diagram for eight-cell 24V systems, using intelligent charger & latching loads contactor
Wiring diagrams - continued Figure 17: general information, relay & contactor pin-out Wiring diagrams - continued Figure 18: user display & on/off control
Wiring diagrams - continued Figure 19: temperature sense & current shunt connections required for all systems
Wiring diagrams - continued Figure 20: cell monitoring connections, required for all systems 24 volt systems: This wiring diagram shows the connections for an 8 cell 24 volt pack. 12 volt systems: For 12 volt systems, there are two wiring options: 1. Simply leave the upper bank sense wires disconnected; cut back & insulate the ends. 2. The upper & lower bank sense wires may be parallel connected, so cell 5 sense wires go to cell 1 & so on. The parallel option doubles the balancing current, since the controllers now operate in tandem. The BMS must be configured to recognise the parallel connection as follows: Using the configuration tool, set up all parameters as if there were two banks; stack size set to 2, Then re-configure all parameters with exactly the same values, but with stack size set to 1. Note: Since incorrect settings for the BMS may damage the battery with the risk that the battery may rupture, only qualified persons may change settings using the configuration tool.
Powering up the system Figure 21: inserting the cell sense connector powers up the BMS. Only do this once all other connections are in place and have been checked.
Specifications These specifications are subject to change without notice & do not form part of any contract. Parameter Default value Range (configuration) Notes Engineer Permissions Cell undervoltage threshold 2.55 volts 2.0 to 4.7 volts Cell overvoltage threshold 3.50 volts 2.0 to 4.7 volts Balancer forced on voltage 3.60 volts 2.0 to 4.7 volts Charge high temperature limit 45ºC 1ºC to 70ºC Discharge high temperature limit 55ºC 1ºC to 70ºC Charge low temperature limit 0ºC -20ºC to +5ºC Discharge low temperature limit -20ºC -30ºC to +5ºC Fan start temperature 35ºC 20ºC to 50ºC Fan stop temperature 30ºC 20ºC to 50ºC SOC for charger on 90.00% 10 to 100% note 4 Current for SOC synchronisation 18 amps 1 to 40 amps note 5 Charger volts per cell 3.7 volts per cell 3 to 5 volts per cell note 6 Rated battery capacity 100Ahr 20 to 400 Ahr Contactor configuration 6 7 options note 7 Stack size 1 1 = 12V up to 8 = 96V Remote display fitted fitted/not fitted Battery monitor fitted fitted/not fitted Current shunt mv 50mV 1 to 60mV note 8 Current shunt amps 500 amps 1 to 800 amps note 8 Maximum peak charging current 100 amps 10 to 800 amps note 9 Maximum mean charging current 100 amps 10 to 800 amps note 10 Maximum peak discharge current 200 amps 10 to 800 amps note 11 Maximum mean discharge current 100 amps 10 to 800 amps note 12 COM port number 6 COM 1 to COM 12 note 13 Configuration reference 1 integer, 1 to 200 note 14 Notes: Integrator The BMS settings are installed using the configuration webpage, which is only available for qualified persons. The BMS reports its settings, along with present battery status information via the serial port or via bluetooth if
installed. These data may be viewed by any user by logging in as Guest in the configuration web-page. Configuration permissions - the configuration webpage has two permission levels allowing parameter changes; these are engineer & installer. Engineers can change all configurable parameters, whereas installers (system integrators) have limited options. Guests can view all details, but not make changes. Once the battery has been charged, recharge is not enabled until the battery state of charge has fallen to this level. Once the recharge current has fallen to this level, the state of charge is reset to 100% The open-circuit or off load charger voltage This parameter defines the configuration of the output power drivers. The ratings for the external battery current shunt, used to track state of charge, Threshold for the peak battery charging current, above which the charger will be disconnected. Threshold for the mean battery charging current, above which the charger will be disconnected; short term peaks are disregarded unless they exceed the maximum peak charging current setting. Threshold for the peak battery discharge current, above which the loads will be disconnected. Threshold for the mean battery discharge current, above which the loads will be disconnected.; short term peaks are disregarded unless they exceed the maximum peak discharge current setting. This is the COM port that will be used for serial connection with a PC. This a number that can be used to identify the BMS system & is appended to the bluetooth identity so that a particular pack can be identified when a connection is established. Serial port These are the COM port settings that are used by the BMS: Baud: 38400 Parity : none Databits : 8 Stop bits : 1 Flow control : none Encoding : ASCII.For complete information, consult the BMS configuration guide. BMS monitoring - using the optional bluetooth module First pair your monitoring device with the BMS bluetooth by searching for nearby devices. The BMS identity begins BMS followed by the BMS type & configuration reference. The bluetooth default passcode is all zeros ie 0000, although this may have been changed on your system. If 0000 is rejected, ask your system installer for the new passcode. Once paired & connected, you can monitor the bluetooth transmissions using either the bluetooth monitor webpage, or third party serial port capture software. Data can be received on Windows PC's, Android devices & other equipment that can receive the bluetooth data stream. The data is broadcast in plain English, but some control codes are also transmitted which may be displayed as text or symbols - these can be ignored
These are the settings that are used by the BMS for bluetooth: Baud: 38400 Parity : none Databits : 8 Stop bits : 1 Encoding : ASCII