www.xtalin.com lagler@xtalin.com Xtalin Accumulator Monitoring System and Xtalin Accumulator Balancing System devices Datasheet - Public
Table of content 1. List of abbreviations... 4 2. List of all AMS and ABS versions... 5 3. Consistent general attributes... 6 4. Differing general attributes... 7 5. Electrical characteristics and absolute maximum ratings... 8 6. Simplified one-line block diagram and short operational description of a complex e-drivetrain.. 9 6.1. Descriptions of the main blocks... 10 6.1.1. HV accumulator container... 10 6.1.2. LV accumulator... 10 6.1.3. X_UCU_v1 (CAN logger +GPS, +WiFi, +GPRS)... 10 6.1.4. Charger... 10 6.1.5. DCDC converter... 10 6.1.6. Motor controller unit... 10 6.1.7. Motor... 10 6.2. Descriptions of the HV accumulator parts... 11 6.2.1. Accumulator stack... 11 6.2.2. Drive contactor... 11 6.2.3. Drive fuse... 11 6.2.4. Charge contactor... 11 6.2.5. Charge fuse... 11 6.2.6. X_AMS... 11 6.2.7. X_ABS (optional)... 11 6.2.8. X_EM (Energy Meter)... 11 6.2.9. X_IRM (Isolation Resistance Measurement)... 12 7. Three-pack accumulator system with junction box /example/... 13 7.1. IRM LED... 14 7.2. UV warning LED... 14 7.3. PDM... 14 7.4. State of Charge analog output... 14 7.5. Charger Interrupt function... 14 7.6. Charger Control function (optional)... 15 8. Accumulator pack with X_AMS_35S_v1 /general example, not an existing device at the moment/ 16 9. Accumulator pack with X_AMS_12S_v2 /general example, no need for separate junction box/ 17 10. X_AMS_18S_v2... 18 10.1. Picture(s)... 18 10.2. Different stack configurations... 18 10.3. CAN configuration... 18 10.4. Further information... 18 11. X_AMS_4S_v1... 19 11.1. General description... 19 11.2. Picture(s)... 19 11.3. CAN configuration... 19 11.4. Further information... 19 12. X_AMS_12S_v1... 20 12.1. General description... 20 12.2. Picture(s)... 20 12.3. CAN configuration... 20 2
12.4. Further information... 20 13. X_ABS_18S_v1 (Accumulator Balancing System)... 21 13.1. Development status... 21 13.2. Box size... 21 13.3. CAN configuration... 21 13.4. Further information... 21 14. X_AMS_12S_v2... 22 14.1. General description... 22 14.2. Picture(s)... 22 14.3. Box size... 22 14.4. CAN configuration... 22 14.5. Further information... 22 15. X_AMS_18S_v4... 23 15.1. General description... 23 15.2. Picture(s)... 23 15.3. Box size... 23 15.4. CAN configuration... 23 15.5. Further information... 23 16. List of pictures... 24 3
1. List of abbreviations AMS ABS S P HV LV DC AC Accu EM SOC SOH BIN 0b DEC HEX 0x AIR UCU EM IRM LED PDM PWM UV OV OT OC CC CV Accumulator Management System Accumulator Balancing System Number of series cells, for example 18S means 18 series cells Number of parallel cells, for example 4P means 4 parallel cells High Voltage Low voltage Direct current Alternating current Accumulator Energy Meter device State of Charge State of Health Binary Binary Decimal Hexadecimal Hexadecimal Accumulator Isolation Relay Universal Control (and Communication) Unit Energy Meter Isolation Resistance Measurement Light Emitting Diode Power Distribution (Electronic) Module Pulse Width Modulation Undervoltage Overvoltage Overtemperature Overcurrent Constant Current Constant Voltage 4
2. List of all AMS and ABS versions Name Released Used in Comments X_AMS_18S_v1 2013 Q3 EV-Sport Association Electric gokarts Experimental, no longer available X_AMS_18S_v2 2014 Q2 Technological Center Zalaegerszeg Electric Formula Renault car X_AMS_18S_v3 2014 Q2 EV-Sport Association Electric gokarts Experimental, not for production X_AMS_4S_v1 2015 Q2 PannonPorto Kft. - Electric street sportscar used in lightweight 12V sportscar battery X_AMS_12S_v1 2015 Q2 Antro Kft. - Moveo foldable electric scooter X_ABS_18S_v1 2016 Q2 Unnamed project, BME Motostudent Team Electric Motorbike X_AMS_12S_v2 2016 Q3 BME Motostudent Team Electric Motorbike used in large capacity battery packs with external X_ABS_18S_v1 devices X_AMS_18S_v4 2016 Q4 Unnamed project used with X_ABS_18S in large capacity battery packs 5
3. Consistent general attributes Main functions: monitoring, balancing, protecting Supported types and chemistries: All form factor of lithium chemistry cells, configurable limits and warnings Default limits LiFePO4 LiPo Charge enable Max voltage [V] 3,63 4,2 /also depends on the actual state Min voltage [V] 1,0 1,0 of the charging procedure/ Max temperature [ C] 60 60 Drive enable Min voltage [V] 2,6 3,0V Max temperature [ C] 60 60 Feedback output /Status OK/ if Charge enable and Drive enable are true /Different limit values and operation could be implemented upon request./ Communication: standards (on demand): CAN 2.0A, CAN 2.0B speed (on demand): 125 khz 1 MHz 6
4. Differing general attributes Name Nr. of meas. (series) cell voltages Nr. of meas. cell temp. Cell ballancing current [A] Cell ballancing method State of Charge meas. Max. nominal system voltage [V] IP rating X_AMS_18S_v1 18 2 0,15 passive separated 66,6 IP65 X_AMS_18S_v2 18 6 0,15 passive separated 600 PCB only (series conn.) X_AMS_18S_v3 18 2 0,15 passive separated 66,6 IP67 X_AMS_4S_v1 4 2 0,3 passive separated 14,8 PCB only X_AMS_12S_v1 12 4 0,15 passive integrated 44,4 PCB only X_ABS_18S_v1 (Accumulator Balancing System) - - 5,0 active - 600 (series conn.) IP65 X_AMS_12S_v2 12 4 0,15 passive + external active X_AMS_18S_v4 18 6 0,15 passive + external active separated 150 (series conn.) separated 600 (series conn.) IP67 IP67 7
5. Electrical characteristics and absolute maximum ratings Name LV supply voltage min [V] LV supply voltage max [V] X_AMS_18S_v1 18 70 75 X_AMS_18S_v2 7 15 18 X_AMS_18S_v3 15 70 76 X_AMS_4S_v1 9 15 18 X_AMS_12S_v1 7 15 18 X_ABS_18S_v1 (Accumulator Balancing System) X_AMS_12S_v2 X_AMS_18S_v4 LV supply voltage absolute max [V] Typical LV supply current [ma] 8
6. Simplified one-line block diagram and short operational description of a complex e-drivetrain /Note: does not contain all necessary connections and devices./ 1. Picture: Simplified one-line block diagram of a complex e-drivetrain 9
6.1. Descriptions of the main blocks Attention: there are several standards which must be taken into account during designing any part of an electric vehicle. This document is not a guideline, and contains only short descriptions regarding some basics. The author does not take responsibilty for the content of this document. 6.1.1. HV accumulator container Contains the accumulator stacks, and all necessary components to protect the accumulator cells from unwanted situations, and to handle the high voltage and currents in a safe way. Accumulator voltage usually depends on system requirements. E-bikes, e-scooters are usually ranging from 30V to 60V system voltage, and 50 (100) Amps. E-motorbikes, e-cars, and bigger vehicles usually have higher system voltages with 600V upper limit. 6.1.2. LV accumulator The definition claims that an LV accumulator s/lv battery s voltage is lower than 60 VDC. (Small vehicles, for example electric bikes, electric scooters usually do not contain a separate LV accumulator, because in these cases the AMS can be supplied directly from the traction accumulator.) LV accu is the power supply of the LV electronics, including AMS, ABS, etc. The needed capacity depends on the charging possibilities (for example: presence of a sufficient sized DCDC converter). 6.1.3. X_UCU_v1 (CAN logger +GPS, +WiFi, +GPRS) This is an Xtalin developed universal electronics with several opportunities, which can be used as the project requires it. It handles 2 CAN buses, logs data to a µsd card, contains built in GPS, WiFi, GPRS, has an optional LAN connector, internal LV accumulator, several current limited digital outputs, digital inputs for different voltages, analog inputs and outputs. There is an optional 3 axis accelerometer and 3 axis gyroscope (inertial measurement unit), it also contains an optional second microcontroller, and built-in AMS unit. Please contact Xtalin Ltd. for further information. 6.1.4. Charger Generally the charger is an inverter, which converts the AC line voltage to the DC charge voltage of the accumulator pack. There are on-board and off-board versions. 6.1.5. DCDC converter As conventional combustion engined vehicles are using a generator to charge the 12V lead-acid battery, electric vehicles are using DCDC converters to charge the LV accumulator from the energy of the HV accumulator pack. 6.1.6. Motor controller unit This unit is connected to the DC bus of the HV battery. It handles the AC or DC motor as the torque demand requires it. 6.1.7. Motor Rotating machine, converts the electrical energy to kinetic (mechanical) energy. 10
6.2. Descriptions of the HV accumulator parts Attention: there are several standards which must be taken into account during designing any part of an electric vehicle. This document is not a guideline, and contains only short descriptions regarding some basics. The author does not take responsibilty for the content of this document. 6.2.1. Accumulator stack It is strongly recommended to sub-divide the accumulator into smaller segments, which are also called as stacks. The maximum voltage of one stack should be less than 120 VDC to reduce risks during assembling or working on the accumulator pack. 6.2.2. Drive contactor A contactor is also called as accumulator isolation relay (AIR), is able to interrupt the battery current even at full load, or in an emergency situation. Each HV accumulator container must contain at least 2 drive contactors, that way both poles of the accumulator can be isolated from the outside of the container. 6.2.3. Drive fuse A Drive fuse or main fuse must be sized to protect all other parts of the system. Each accumulator container must contain at least 1 main fuse. 6.2.4. Charge contactor The charge contactor is an optional component. This is also an accumulator isolation relay (AIR), but could be sized to different currents, and could be controlled separately. A container contains 2 or 1 or 0 charge contactor, depending on the operation of the charging system. 6.2.5. Charge fuse It is connected in series with the charge contactor, and must be sized to protect all parts of the charging system. 6.2.6. X_AMS Can be used in all kinds of lithium accumulators, and at any voltage levels under 600 VDC. An Xtalin Accumulator Management System protects the cells from unwanted voltage levels, and temperatures. One device handles maximum 12 or 18 or 35 series cells, and 4 or 8 or 12 temperature sensors, but different versions are available on demand. Some versions of the X_AMS are containing passive cell voltage balancer circuits. The measured AMS data is available on the CAN bus, and can be logged with an X_UCU device. 6.2.7. X_ABS (optional) Xtalin Accumulator Balancing System handles maximum 18 cells in series. X_ABS units can be used in all kinds of accumulators, and at any voltage levels under 600 VDC. It is an active balancer circuit, which means that during the cell balancing procedure the energy is pumped from one cell to another. This method is much more efficient than the passive balancing, where the energy is wasted as dissipated heat. 6.2.8. X_EM (Energy Meter) Xtalin Energy meter (X_EM) measures the current and voltage of the whole accumulator pack. This data may also be used to protect the accumulator cells from overcurrent. The energy meter measures the energy which is flowing from the accumulator to the other components of the HV system, and from the other components into the accumulator, so the X_EM is able to determine the State of Charge value of the accumulator. 11
6.2.9. X_IRM (Isolation Resistance Measurement) The HV system must be totally isolated from the LV system. (The chassis of the vehicle is connected to the LV GND.) The first fault (conduction between HV and LV parts) must be detected by the isolation measurement circuit as soon as possible, the vehicle must be stopped, the driver must be warned, with all of these actions the second fault can be prevented. Thanks to the X_UCU_v1, the isolation measurement data is also logged, and may be monitored via GPRS mobile internet. 12
7. Three-pack accumulator system with junction box /example/ /Note: does not contain all necessary connections and devices./ Xtalin Engineering Ltd. 2. Picture: Three-pack accumulator system with junction box /example/ 13
7.1. IRM LED If the isolation measurement value decreases under a critical value, the IRM feedback LED turns off. It is recommended to place the IRM feedback LED in a well-visible position in the vehicle. 7.2. UV warning LED The UV_WARNING pin of the X_UCU_v3 is a 3A current limited digital output. It can be configured to warn the Vehicle Control Unit, or the Motor Controller Unit, that the vehicle should switch to a low power mode, because the accumulator is close to the undervoltage switch off limit (Drive Enable minimum voltage). 7.3. PDM The Power Distribution Module is the modern solution instead of the old fashioned fuse-boxes. A PDM can be controlled via CAN bus, all output channels CAN be switched on/off. Also PWM-outputs can often be really useful, for example when using water-pumps or ventillators in the vehicle. 7.4. State of Charge analog output Xtalin devices (X_UCU_v3 in the current example) are capable of providing an analog signal, to control an analog display to indicate the SOC value of the accumulator. The SOC value can be sent by: - 1 (-100) Hz CAN message, or - galvanically isolated 4-20mA current signal, or - other (on demand) SOC minimum, and maximum values: - CAN value: 0-100 (0-100%) - 4-20mA value: 4-20 ma (0-100%) 7.5. Charger Interrupt function Generally, the charging of the accumulator is switched on and off with the charge relays. These are powered by the LV accumulator, and the control signal can be interrupted by several devices in the vehicle, for example; safety switches, interlocks, the X_IRM device, the charge enable outputs of the AMS devices, etc. 14
7.6. Charger Control function (optional) Better handling of the accumulator cells and charge contactors can be achieved by using a Charge Control function. Xtalin devices (X_UCU_v3 in the current example) are capable of providing a signal to control the vehicles charger. If the charger is able to handle this signal, it decreases the charging current as the charging procedure requires it. The Charger Control signals value is proportional to the maximum allowed charging current. This value can be sent by: - 1 (-100) Hz CAN message, or - galvanically isolated 4-20mA current signal, or - other (on demand) Example with default values: 3. Picture: Charger Control signal /example/ Axis Y: charger control signal value I1: charger control signal s minimum value - CAN value: 10-4-20mA value: 4 ma I2: charger control signal s maximum value - CAN value: 100-4-20mA value: 20 ma Axis X: special events/conditions during charging C1 (condition 1): the lowest cell voltage is equal to the charge enable minimum limit C2 (condition 2): the lowest cell voltage is equal to the drive enable minimum limit C3 (condition 3): the highest cell voltage is equal to the charge enable maximum limit minus 0,1V C4 (condition 4): the highest cell voltage is equal to the charge enable maximum limit 15
8. Accumulator pack with X_AMS_35S_v1 /general example, not an existing device at the moment/ /Note: does not contain all necessary connections and devices./ 4. Picture: Accumulator pack with X_AMS_35S_v1 /general example, not an existing device at the moment/ 16
9. Accumulator pack with X_AMS_12S_v2 /general example, no need for separate junction box/ /Note: does not contain all necessary connections and devices./ If the accumulator container contains all the minimum required devices, then the use of a separate junction box is not needed. In this example the charger is capable of charging a 12S accumulator segment only. In that case there are separate charge relays for the separate segments. These relays are controlled by the corresponding AMS device of the accumulator. 5. Picture: Accumulator pack with X_AMS_12S_v2 /general example, does not need separate junction box / 17
10. X_AMS_18S_v2 10.1. Picture(s) 6. Picture: X_AMS_18S_v2 PCB design, prototypes, and accumulator stacks 7. Picture: X_AMS_18S_v2 prototypes in an electric racecar 10.2. Different stack configurations X_AMS_18S_v2 is used in the six accumulator stacks of the racecar. The 60V stacks can be connected in series and in parallel also. This way it is easy to form packs with different system voltages; 360V, (180V, 120V, and 60V) nominal. 8. Picture: Series and parallel connection of six stacks 10.3. CAN configuration The X_AMS_18S_v2 uses the following CAN configuration: CAN 2.0A, 500kBaud 10.4. Further information Further information (CAN messages, etc.) can be found in the device specific datasheet. Please contact Xtalin Ltd as required. 18
11. X_AMS_4S_v1 11.1. General description Lightweight 12V sportscar battery s AMS. Specially designed to the PannonPorto Amber One prototype taking into account the special requirements caused by the car s operation modes. 11.2. Picture(s) 9. Picture: X_AMS_4S_v1 PCB design and prototype 10. Picture: X_AMS_4S_v1 prototype in the PannoPorto Amber One car 11.3. CAN configuration The X_AMS_4S_v1 uses the following CAN configuration: CAN 2.0B, 1 MBaud 11.4. Further information Further information (CAN messages, etc.) can be found in the device specific datasheet. Please contact Xtalin Ltd as required. 19
12. X_AMS_12S_v1 12.1. General description This Accumulator Management System was specially designed into the Moveo foldable electric scooter. It handles 12 cells in series, measures voltages of every cell, and the temperature of the pack at 4 different locations. This AMS also measures the current flowing out of, and into the accumulator pack, so it calculates the SOC [Ah] and SOC [Wh] values. Due to the special shape of the PCB, it s installation into the Moveo s accumulator container is really easy. 12.2. Picture(s) 11. Picture: X_AMS_12S_v1 PCB design and prototypes 12. Picture: X_AMS_12S_v1 prototypes in the Moveo foldable electric scooter 12.3. CAN configuration The X_AMS_12S_v1 uses the following CAN configuration: CAN 2.0A, 500kBaud 12.4. Further information Further information (CAN messages, etc.) can be found in the device specific datasheet. Please contact Xtalin Ltd as required. 20
13. X_ABS_18S_v1 (Accumulator Balancing System) 13.1. Development status X_ABS_18S_v1 is under development. (2015 march: prototype production.) Please contact Xtalin Ltd for further information. 13.2. Box size One electronics box contains two X_ABS_18S_v1 devices. Dimension Size [mm] A 188 B 188 C 63 E 171,5 F 171,5 13. Picture: X_ABS_18S_v1 box sizes 13.3. CAN configuration The X_ABS_18S_v1 uses the following CAN configuration: CAN 2.0A, 500 kbaud 13.4. Further information Further information (CAN messages, etc.) can be found in the device specific datasheet. Please contact Xtalin Ltd as required. 21
14. X_AMS_12S_v2 14.1. General description Designed for the BME Motostudent Teams electric motorbike, and also can be used in any other system, where excellent IP protection and relatively low number of cells (max 12) per AMS device is required. /Note: at the Motostudent competiton the maximum allowed system voltage is 110VDC. X_AMS_12S_v2 is designed for 150V maximum system voltage. For further information on Motostudent you can visit: http://www.motostudent.com/ / 14.2. Picture(s) 14. Picture: X_AMS_12S_v2 14.3. Box size Length (with connectors, and 25mm space for wires) Width Height Mounting 160 mm 120 mm 36 mm 4x M6, DIN912, 101.6mm 15. Picture: X_AMS_12S_v2 box sizes 14.4. CAN configuration The X_AMS_12S_v2 uses the following CAN configuration: CAN 2.0A, 500 kbaud 14.5. Further information Further information (CAN messages, etc.) can be found in the device specific datasheet. Please contact Xtalin Ltd as required. 22
15. X_AMS_18S_v4 15.1. General description Designed for a specific vehicle, and also can be used in any other system, where excellent IP protection and high number of cells is required. /Note: It is strongly recommended to sub-divide the accumulator into smaller segments, which are also called stacks. The maximum voltage of one stack should be less than 120 VDC to reduce risks during assembling or working on the accumulator pack./ 15.2. Picture(s) 16. Picture: X_AMS_18S_v4 15.3. Box size Length (with connectors, and 30mm space for wires) Width Height Mounting 245 mm 160 mm 55 mm 4x M6, DIN912, 70x144mm 17. Picture: X_AMS_18S_v4 box sizes 15.4. CAN configuration The X_AMS_18S_v4 uses the following CAN configuration: CAN 2.0A, 500 kbaud 15.5. Further information Further information (CAN messages, etc.) can be found in the device specific datasheet. Please contact Xtalin Ltd as required. 23
16. List of pictures 1. Picture: Simplified one-line block diagram of a complex e-drivetrain... 9 2. Picture: Three-pack accumulator system with junction box /example/... 13 3. Picture: Charger Control signal /example/... 15 4. Picture: Accumulator pack with X_AMS_35S_v1 /general example, not an existing device at the moment/... 16 5. Picture: Accumulator pack with X_AMS_12S_v2 /general example, does not need separate junction box /... 17 6. Picture: X_AMS_18S_v2 PCB design, prototypes, and accumulator stacks... 18 7. Picture: X_AMS_18S_v2 prototypes in an electric racecar... 18 8. Picture: Series and parallel connection of six stacks... 18 9. Picture: X_AMS_4S_v1 PCB design and prototype... 19 10. Picture: X_AMS_4S_v1 prototype in the PannoPorto Amber One car... 19 11. Picture: X_AMS_12S_v1 PCB design and prototypes... 20 12. Picture: X_AMS_12S_v1 prototypes in the Moveo foldable electric scooter... 20 15. Picture: X_ABS_18S_v1 box sizes... 21 16. Picture: X_AMS_12S_v2... 22 17. Picture: X_AMS_12S_v2 box sizes... 22 13. Picture: X_AMS_18S_v4... 23 14. Picture: X_AMS_18S_v4 box sizes... 23 24