Advanced Information Subject to Changes High Efficiency 30/60V, 100 Amps Active Management System for Lithium Ion Batteries Roboteq s is a battery management system designed for building cost-effective, ultra-efficient and high current power sources using low cost Lithium Polymer, or Lithium Ion Phosphate (LiFePO4) battery cells. The BMS connects to arrays of battery packs at one end, and to a user load at the other. Available in a 24V and 48V versions, it is optimized for direct connection to 6-cell battery packs although it can be used with any other serial and parallel cell arrangements, depending on the desired max current and capacity. Precision voltage sensors monitor the voltage of every cell. Multiple current sensors keep track of the current flowing in and out of every cell maintaining an accurate image of the battery's State of Charge and State of Health. A high efficiency switch array continuously moves energy from high charged cells to lower charge cells. Balancing takes places during both charge and discharge. The BMS support regenerative loads, such as motor controllers in electric vehicles or mobile robot application. A builtin bidirectional high power solid state switch will disconnect the regenerative current source from the cells in case the later are fully charged and cannot accept more current. A secondary built-in switch will optionally connect the auxiliary power port to an external brake resistors, in case braking is still required while the batteries are full. Charge/discharge current, voltages, internal and battery temperatures are continuously monitored. The internal switch will disconnect the load in case of overload, over or under voltage, or over temperature. The BMS will act as a programmable circuit breaker in case of short circuit or continuous overload. The battery cells will also be disconnected in case of over/under voltage, over temperature, or other abnormal condition. The BMS is highly configurable: Temperature limits, voltage thresholds, current overload levels can all be viewed and changed using a provide PC utility. The utility can also be used to view and chart in real time the BMS internal parameter while the system is running, providing the user with useful data during system development and tuning State of Charge, voltage, current, temperature and other vital parameters are available on a front connector using selectable communication schemes, including TTL Serial or RS485 with user-selectable baud rate, I2C or PWM. A push button and LEDs are also provided for quick visualization of battery charge level and system status. December 6, 2014 Page 1
Applications Electric vehicles, scooters, e-bikes Personal mobility system Mobile robots Electric boats Electric forklifts Storage for wind/solar generators Telecom tower backup Features List 6 cells (24V) or 12 cells (48V) version. 30V and 60V max operation to allow for fully charged batteries 100A max current to load. 250A peak Active Cell Balancing. Moves energy from high charge cells to low charge cells Ultra efficient operation. Up to 10A balancing current using ultra low resistance switching circuits Extends battery capacity by shifting load to the higher capacity cells Advanced State of Charge management for optimal battery life Built-in Current sensors on charger input, load output Built in temperature sensor. Connector for up to 4 external temperature sensors Built-in 100A switch with under voltage and overvoltage shutoff Built-in circuit breaker function in case of short circuit and continuous overload Field upgradeable firmware Optional SDCard for years of battery history data logging Separate input for charger with internal switch Connection to optional brake resistor 1A Digital Output for activating Fan, Cooling Circuit, Contactor or other user device RS485, I2C, TTL Serial, or PWM Output for communication of battery data LEDs for status and battery charge indication Efficient conductive cooling via bottom aluminum plate built in clock/calendar for data login time stamp Built-in programming language for scripting advanced power management strategies Direct interface with Roboteq motor controllers USB connector and PC Utility for setup, configuration, test and monitoring System Architecture The BMS uses an ultra-low power consumption, 32-bit Processor to monitor voltages, amperage and temperature (shown as V, A and T in the block diagram below) in order to control a switch matrix and solid-state contactors. The charge balancing switch matrix is designed to extract charge from higher voltage cells and transfer it to lower charge cells. A power management block ensures that the, switch matrix and other system components are turned off when they are not needed and so to keep the battery from needlessly discharging. December 6, 2014 Page 2
User Connections The front side includes the following elements Out+/Out- Power Connectors December 6, 2014 Page 3
These Faston/spade connectors are used to connect to the user load. A 100A switch built into the BMS will isolate these connection from the battery in case of over/under voltage, short circuit, over current, over temperature or other unsafe conditions. Current is allowed to flow back into the battery Charge/Aux+, Charge/Aux These Faston/Spade connectors are used to connect the BMS to a charger. A 50A built-in switch will disconnect these lines from the battery when the battery is fully charged or in any other unsafe condition occurs. Alternatively, these connections can be used to connect a brake resistor to absorb regenerative current from the main connectors, when the batteries are already full and therefore unable to accept the regenerated current. The Aux connection can also be used to power other elements of the user's system, as for example powering control elements that must always remain on, while the power elements are switched on/off on the main Out+/- connectors. User I/O A 8-pin connector contains the signal needed by the BMS to other system elements. Pin Signal Description 1 GND Ground 2 UserOut 1A Open Drain output 3 IO Tx Configurable as TTL Serial Tx, I2C SCL or PWM Output 4 IO Rx Configurable as TTL Serial Rx, I2C SDA or PWM Input 5 RS485A RS485 Direct 6 RS485B- RS485 Inverted Use Molex 2 rows x 3, 4.2mm pitch connector reference 0039012060, or equivalent Pushbutton and LEDs One push button an 3 LED are provided for quick diagnostics such as charge level, communication, and other useful information. Different flashing patterns are used to code the various information type. USB Connector A USB port is present for connecting the BMS to a PC running a dedicated PC Utility for configuring the BMS' various parameters (voltage, current, temperature thresholds,..), monitor in real time operating values, capture/save logs and editing user's scripts. December 6, 2014 Page 4
Battery Connections Two sets of connectors are provided for connection to battery cells. Four Faston/Spade are for high current connections. Two 7-pin connectors are for connecting to each individual cell for monitoring and balancing. In the 30V version of the BMS, the B1+ and B2+, the B2- and B2-, and the two 7-pin connectors, are wired to each other inside the BMS, effectively paralleling two sets of 6 cells batteries. If a single 6 cell battery is uses, it can therefore be connected to the B1 Faston/connectors, or to the B2 Faston/connectors In the 60V version of the BMS, the battery cells must be connected to both B1 and B2. An 8-pin connector provides the connections to up to 4 external temperature sensors for monitoring the batteries. Typical Batteries Arrangements The BMS supports many batteries arrangements depending on the desired voltage and capacity. The figure below shows two sets of 6S batteries. Using the BMS1060, the two sets are wired in series inside the BMS to deliver 50.4V at the output (assuming 4.2V charge). In the BMS1030, the two sets are paralleled to deliver 25.2V with double the capacity. The figure below shows an arrangement using 3S batteries that are first put in series to create a 6S battery, and then paralleled for higher capacity. December 6, 2014 Page 5
Mechanical Dimensions December 6, 2014 Page 6
Ordering References Model Number of Cells Max Voltage SDCard BMS1030 6 30 No BMS1030S 6 30 Yes BMS1060 12 60 No BMS1060S 12 60 Yes December 6, 2014 Page 7