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I+ME ACTIA BMS Master 4, Hardware Manual, Page: 5 / 76

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Page 1: ...4417 A 15 01 2018 Page 1 76 ACTIA I ME GmbH Dresdenstrasse 17 18 D 38124 Braunschweig Germany Tel 49 0 531 38701 0 Fax 49 0 531 38701 88 www ime actia com Hardware Manual BMS Master 4 4 5 Doc Template...

Page 2: ...ange Name A All 26 07 2016 Hardware Manual Master 4 4 5 Revision based on Hardware Manual Master 4 KA A All 05 08 2016 Minor lingual corrections JQU 21 10 2016 3 1 3 1 Switch OFF BMS Kl15 Kl30 KA 13 0...

Page 3: ...Communication connector CN106 19 3 1 3 7 RS232 Interface 20 3 1 3 8 Ethernet Interface 20 3 1 3 9 Internal Interfaces 21 3 1 3 10 LEDs 21 3 1 4 Electromechanics 21 3 1 5 Summary MASTER Connectors 22 3...

Page 4: ...face 46 3 5 4 5 Balancing Resistors 46 3 5 4 6 Serial RS 485 Interface and ERROR Signalling 47 3 5 4 7 2nd Level Overvoltage Detection 48 3 5 4 8 Long Time Watchdog 48 3 5 4 9 Configuration Addressing...

Page 5: ...Ref IR14417 A 15 01 2018 Page 5 76 3 6 9 Passive Cell Balance 65 3 6 9 1 Connection of external Balance Resistors 66 4 Bringing the Slave C Slave 5 into Service only for Cell Voltages 69 5 Connectors...

Page 6: ...installed Damaged components and such that have exceeded their lifetime have to be replaced immediately Only adequately qualified specialists trained in handling of batteries and skilled in safety re...

Page 7: ...ions regularly Use only appropriate cables especially for ampacity of power cables refer to DIN VDE 0276 1000 or corresponding national directives Cable dismantling attaching end sleeves etc must not...

Page 8: ...ks or similar are set between angle brackets Text Text or values for input are bold in angle brackets OK Command buttons in context with screen masks are put in square brackets 1 1 6 GLOSSARY SoC Stat...

Page 9: ...A Relay Drive Load Load Charger HV HV Slave Slave Slave Slave Slave Master Current Sensor VAC4645 Relay Drive Relay Precharge X Ohm Drive mode with optional charger in the load circuit Different circu...

Page 10: ...1 2 3 4 5 6 CAN1L Shield CAN3H CAN3L Shield CAN BUS_A 1 2 3 4 5 6 5V NET GND BUS_B FAIL_IN Shield Master CAN 2 LiYCY TP 2x2 0 25mm K1 K2 twisted S1 S2 twisted CAN 1 CAN 3 Master_Slave_BUS_A Master_Sl...

Page 11: ...control NTC NTC 1 2 3 4 5 6 NTC2 NTC1 PTC temperature control NTC NTC Communicating with external hardware via a high speed CAN interface The Master module is supplied either by the controlled batter...

Page 12: ...lance check The ANA module is internally supplied from the connected cells The CON module is supplied from the MASTER Cell connector SLAVE 6 ANA Modul 14 7 13 6 12 5 11 4 10 3 9 2 e g LiYCY TP 3x2 0 2...

Page 13: ...lash 1 x CAN 1 x UART 1 x Ethernet RS 232 Interface Ethernet Power Supply Voltage Limiter RTC Wake UP KL15 Wake UP CAN Wake UP RTC Ext Flash USB Port optional 2 x 4 MB SDFlash CAN Transceiver 3 CAN Mu...

Page 14: ...Hardware Manual BMS Master 4 4 5 Ref IR14417 A 15 01 2018 Page 14 76 3 1 2 ENCLOSURE VIEWS Front Rear...

Page 15: ...y switch off itself e g by a CAN command active 8 V input resistance 32 k Wake up Drive KL15S Signal to switch on the device 9 28 VDC switch function the device cannot switch off itself active 8 V inp...

Page 16: ...A SWO5 8 Switch outputs with same characteristic as outputs SWO1 4 Outputs SWO5 8 will be activated only when EMSRET is connected to KL30 in any way The outputs may be loaded with up to 2 5 A each pea...

Page 17: ...ated by voltage with more than half level of KL30 1 V deactivated by voltage with less than half level of KL30 1 V Input resistance 20 k FIN1 2 Frequency measurement inputs activated by voltage higher...

Page 18: ...lature For sensors with Shunt and CAN interface BAT S1000 1U IVT B 7V 12V Master 4 Sensor supply 7 VDC 350 mA max Master 4 5 Sensor supply 12 VDC 350 mA max KL31 Sensor supply Minus Ground CAN2H CAN2L...

Page 19: ...g host computer CAN3H CAN3L Controller Area Network channel 3 for communication with battery control specific units Shield Shield connection The use of shielded and twisted pair cable is strongly rec...

Page 20: ...INTERFACE The RS232 interface for software development firmware download and diagnostics is realized with a DSUB 9 female connector at the front side with standard pinning using signals TXD RXD DTR R...

Page 21: ...the RS232 jack with software dependent meanings 3 1 4 ELECTROMECHANICS The supply and the I O interfaces are realized with the MCP 2 8 mm interconnection system by TYCO AMP The tab housing cavities ma...

Page 22: ...WO1 5 KL31 8 SWO3 11 KL31 14 SWO5 17 KL31 20 SWO7 3 SWO2 6 KL31 9 SWO4 12 KL31 15 SWO6 18 KL31 21 SWO8 CN103 INPUTS 1 OIN1 4 OIN2 7 7V 12V 10 SS200 13 FIN1 16 FIN2 19 KL31 2 DIN1 5 DIN2 8 DIN3 11 DIN4...

Page 23: ...Master4 12V Master 4 5 0 5 7 0 0 6 8 0 0 7 9 0 mA Isupp Standby no communication no output activated 12V Master4 12V Master 4 5 100 110 150 160 200 210 mA Isupp Operating CAN RS485 communication no o...

Page 24: ...2007 3 1 9 CERTIFICATIONS The BMS MASTER in combination with other battery components is in compliance with following legal regulations RoHS directive CE 3 2 MEASUREMENT OF CURRENT 3 2 1 VAC SENSOR T...

Page 25: ...as short as possible Current Direction The BMS measuring system interprets a negative current as a discharge current and a positive one as a charge current The load wiring has to be installed accordi...

Page 26: ...current though the sensor When only one broad bar is bolted down it becomes a 3 1 divider maximum current then is 300 A The divider may be mounted mirror inverted Before remounting the divider take c...

Page 27: ...th isolated CAN interface Air and creepage distances provide isolation up to 1500 VDC Additionally the sensor has a quasi synchronous voltage measurement interface and an internal temperature measurem...

Page 28: ...alue is positive Is the current sensor mounted in plus path of the battery and the voltage connector connected to battery minus the measurement value is negative 3 2 2 3 CONNECTING THE BAT S 1000 1U S...

Page 29: ...sical Resolution 15 mA nominal 37 mA extended Voltage Meas Range nominal 1200 V Physical Resolution 50 mV Temperature Meas Range 40 105 C Physical Resolution 0 1 C For further and detailed information...

Page 30: ...ement The CAN2 interface of the MASTER is reserved for this sensor Range current 320A 1500 A for 1 second Range voltage 620V 3 2 3 1 SYSTEM INTEGRATION The sensor may be connected either in the positi...

Page 31: ...urrent Meas Range extended 1500 A Offset 50 mA 250 mA ext phys Resolution 10 mA nominal 40 mA extended Voltage Meas Range nominal 620 V Offset 100 mV Physical Resolution 30 mV Temperature Meas Range 4...

Page 32: ...tance Detection of ground faults and lost ground line Short protected outputs for o Fault detection high side output o Measurement Value PWM 5 95 Status f 10 50Hz at high and inverted low side output...

Page 33: ...irements 3 4 1 FUNCTIONAL OVERVIEW The slave module covers the following functions communication with the master module measuring the voltages of the single cells balancing different cell charge state...

Page 34: ...nterface PIN 1 RS 485 Interface 1 1 1 1 1 3 4 2 BLOCK DIAGRAM Single Cell Interface Power Supply 2nd Level Over voltage and temperature Detection Voltage and Temperature Measuring Balancing Resistors...

Page 35: ...ll 8 cell 6 cell 7 cell 5 cell 6 cell 4 cell 5 cell 3 cell 4 cell 2 cell 3 cell 1 cell 2 cell 1 n c The edge connector provides pre mating contacts to assure the proper connecting sequence Do only con...

Page 36: ...Z1 n c ONLY WITH MODIFIED HARDWARE The dashed connections are realized on the board When connecting only three cells the connection between contacts 11 and 10 must be realized outside on the edge conn...

Page 37: ...t up to 1A In both circumstances the external balancing must be realized on a separate PCB with adequate power dimensioning 3 4 4 5 SERIAL RS 485 INTERFACE AND ERROR SIGNALLING The optically isolated...

Page 38: ...NTC which has to be according to the software an EPCOS B57703M0303G040 with a cold resistance of 30 k at 25 The voltage of the PTC is measured by the internal 8 bit AD channel 0 These inputs may be us...

Page 39: ...on the selected chip type feasibility depends on quantities This circuitry is always active and cannot be deactivated though for test reasons the fault output may be activated by software 3 4 4 10 FAU...

Page 40: ...ts of 10 mm air and creepage distances for high voltages If the slave modules are used under these conditions non conductive screws and or bolts must be used 3 4 5 MECHANICAL DIMENSIONS PCB size 75 x...

Page 41: ...be operated up to 1000V At pollution level 2 the Slave C may be operated up to 650V At pollution level 3 the Slave C must not be operated At applications above 650 VDC non conducting screws have to b...

Page 42: ...10 SLAVE_5 and SLAVE_C are substantially identical with following differences electronic board casted in a plastic case different connection technology MicroFit crimp connectors instead of cage clamps...

Page 43: ...or several cells Measurement of cell temperatures Detection of cell overvoltage second level detection Transmitting of faults to the master module to cut off the main contactors 3 5 2 BLOCK DIAGRAM S...

Page 44: ...cell 5 6 4 cell 7 8 5 cell 9 10 6 PTC GND 7 PTC 8 NTC GND 9 NTC1 10 n c 11 n c 12 n c 13 cell 1 14 cell 2 3 15 cell 4 5 16 cell 6 7 17 cell 8 9 18 cell 10 19 do not connect 20 NTC GND 21 NTC2 22 n c 2...

Page 45: ...s have to be replaced by shorting wires according following scheme Pin 18 5 17 4 16 3 15 2 14 1 13 10 Cells Z10 Z9 10 Z8 9 Z7 8 Z6 7 Z5 6 Z4 5 Z3 4 Z2 3 Z1 2 Z1 9 Cells Z9 Z8 9 Z7 8 Z6 7 Z5 6 Z4 5 Z3...

Page 46: ...there is data traffic on the RS485 interface and 2 seconds further on This time delay cannot be altered by parameters When this supervision interface shall not be used the PTC chain must be replaced b...

Page 47: ...nnected directly to the master module the remaining slave modules are connected one to the next The pin assignment nomenclature corresponds to that of the BMS MASTER Due to the dual connector layout e...

Page 48: ...supplied via the configuration interface and must not be connected to battery cell voltages Slave configuration must be done using configurator SC CONFIG2 a proper interface cable belongs to the confi...

Page 49: ...4 V cell voltages When connecting external balancing resistors in applications with less than 10 cells it has to be considered to adapt the schematics below relatively to line Z5 Z6 Those cells repla...

Page 50: ...l 1 R1 R2 R3 R4 R10 R5 R7 R9 R8 R6 12 13 14 15 16 17 18 19 20 21 13 18 5 17 4 16 3 15 2 14 1 22pol Stecker 22pol Conn 24pol Stecker 24pol Conn Anschluss externer Balance Widerst nde an Slave 5 Connect...

Page 51: ...comply with the requirements of 10 mm air and creepage distances for high voltages If the slave modules are used under these conditions non conductive screws and or bolts must be used 3 5 7 MECHANICA...

Page 52: ...20 C 70 C Storage temperature 40 C 70 C At pollution level 2 the Slave may be operated at voltages up to 650 VDC At pollution level 3 the Slave must not be operated In applications with voltage differ...

Page 53: ...nctions Communication with a BMS Master via CAN Isolated communication with SL6_ANA modules Transmission of the hardware monitoring status second level detection Isolated stimulation of the hardware m...

Page 54: ...dule SL6_ANA module SL6_ANA module SL6_BAL module Batt 4 12 cells 10 60V Batt 4 12 cells 10 60V Sec Level Hardware Configuration 2 x Temperature 3 x Temperature Sec Level Hardware Configuration Second...

Page 55: ...kOhm resistor to 5VNET pullup resistor Usage of more than one CON Module Molex MicroFit 12 pol view of the connector at the device CN106 Tyco 6 pol The FAIL Pin is connected with a 4 7 5 1 kOhm resist...

Page 56: ...eld 5 T2 4 SI T 3 EN T 2 Shield 1 T1 7 EN T 8 SI T 6 Shield 5 B2 4 SI B 3 EN B 2 Shield 1 B1 7 EN B 8 SI B 6 Shield 5 T2 4 SI T 3 EN T 2 Shield 1 T1 7 EN T 8 SI T SL6_CON SL6_ANA Top SL6_ANA Bottom 6...

Page 57: ...e view of the connector at the device 6 Shield 5 T2A 4 SI T 3 EN T 2 Shield 1 T1A 7 EN T 8 SI T 4 pole connector to the lowest B module view of the connector at the device future development 4 Shield...

Page 58: ...Master 9 10 CAN L Signal CAN low communication to Master 12 SHIELD CON Modul 8 pole connector for relay output Pin Signal Description 1 5 KL30 Power supply for outputs 9 28V 2 3 4 8 GND Ground Minus...

Page 59: ...non conductive screws and or bolts must be used 3 6 7 3 SUPPLY AND CURRENT CONSUMPTION The SL6_CON module must be powered from the BMS Master Description Value Unit Voltage 9 16 V Current Master activ...

Page 60: ...ltage view of the connector at the device 10 pole connector temperature sensor view of the connector at the device 8 pole connector to previous module view of the connector at the device 8 pole connec...

Page 61: ...e connection Temperature sensors Pin Signal Description 1 6 Do not use detection over temperature balance board 2 7 Sensor 2 NTC Temperature sensor 1 10kOhm at 25 C 1 Sensor for measurement data 3 8 S...

Page 62: ...emperature measure in the battery The sensors 4 5 are used for the second level Hardware detection Over and under Temperature The sensors are connected to the 10 pole connector Sensor Types Sensor 2 5...

Page 63: ...V8 4 CV6 3 CV4 2 CV2 8 CV1 7 CV10 6 CV10 11 CV7 10 CV5 12 CV9 9 CV3 1 CV0 14 n c 13 CV9 5 CV8 4 CV6 3 CV4 2 CV2 8 CV1 7 CV9 6 CV9 11 CV7 10 CV5 12 CV9 9 CV3 1 CV0 14 n c 13 CV8 5 CV8 4 CV6 3 CV4 2 CV2...

Page 64: ...set the configuration the jumpers on all ANA moduls must be set The description how to set the configuration you can find in the document IR14131_Slave6_InitialOperation pdf After the configuration th...

Page 65: ...alance resistors 70 115 mA 3 6 8 7 ENVIRONMENTAL Humidity max 95 not condensing Operating temperature 20 C 70 C Storage temperature 40 C 85 C At pollution level 2 the Slave may be operated up to 650V...

Page 66: ...module to connect on the ANA module 3 6 9 1 CONNECTION OF EXTERNAL BALANCE RESISTORS All resistor respective cell connections are connected to a 24 pole MicroFit connector At this connector it is poss...

Page 67: ...ling is to ensure The cell voltage measurements wires are only connect to 14 pole connector To connect the external Balance Resistors use only the 24 pole Connector The pins 1 12 should only use if it...

Page 68: ...ll 1 1 6 12 5 11 4 10 3 9 2 8 14pol connector Sense Lines 24pol connector Balance Lines External connection of balance resistors to SL6_ANA SL6_ANA 24pol CV9 CV10 CV8 CV7 CV6 CV5 CV4 CV3 CV2 CV1 CV0 1...

Page 69: ...l voltages at each cell plug before connecting it to the Slave The pictures show the connections of a 10 cell battery to Slave_5 rsp of an 8 cell battery to Slave_C The MASTER has to be connected to t...

Page 70: ...8 cell wiring Accordingly one Slave after the other has to be connected to the RS485 bus and be taken in function For the Slave_5 module this picture is valid analogously 12 1 12 11 10 9 8 7 6 5 4 3...

Page 71: ...ole connector MPE Garry 433 2 012 X KSO Molex 43025 1200 Nexus 2300P 12 W rth 6620126113322 Order Numbers 10 pole connector MPE Garry 433 2 010 X KSO Molex 43025 1000 Nexus 2300P 10 W rth 662010113322...

Page 72: ...er 4 4 5 Ref IR14417 A 15 01 2018 Page 72 76 Nexus 2300T B F T W rth 66210113722 Order Numbers Crimp Tool MPE Garry 454 1 05 The articles by Molex Nexus and W rth are not guaranteed to be fully compat...

Page 73: ...Hardware Manual BMS Master 4 4 5 Ref IR14417 A 15 01 2018 Page 73 76 6 CERTIFICATES...

Page 74: ...Hardware Manual BMS Master 4 4 5 Ref IR14417 A 15 01 2018 Page 74 76...

Page 75: ...Hardware Manual BMS Master 4 4 5 Ref IR14417 A 15 01 2018 Page 75 76...

Page 76: ...Hardware Manual BMS Master 4 4 5 Ref IR14417 A 15 01 2018 Page 76 76...

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