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Overkill Solar 120A 4s 12V BMS, Instruction Manual

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Overkill Solar 120A 4s 12V BMS Instruction Manual Download Page 9

2.4 Assembly 

 

2.4.1 Arranging the Cells 

Lay out your cells in the correct orientation.   Do not install the bus bars yet.  
 
NOTE:​ In this section, the 12V 4-cell and 24V 8-cell configurations are shown.  Other configurations are 
covered in ​

Appendix A​

. 

 

Summary of Contents for 120A 4s 12V BMS

Page 1: ...Overkill Solar BMS Instruction Manual Version 0 1 0 Date August 31 2020...

Page 2: ...vity 13 2 4 7 1 Bluetooth Module 13 2 4 7 1 USB Interface 13 2 4 7 3 Arduino LCD Display 15 3 BMS Parameters 15 3 1 Protection Parameters 15 3 1 1 Cell over voltage 15 3 1 2 Cell under voltage 15 3 1...

Page 3: ...x A Recommended Parameters 28 A 1 General Settings 28 A 2 12V Pack 4 Cell Using One 12V BMS and 100Ah LiFEPO4 cells 29 Mechanical Drawing 29 Bill of Materials 29 Wiring Diagram 31 BMS Configuration Pa...

Page 4: ...Sensor Connector 50 Appendix E BMS Application Usage 50 E 1 XiaoxiangBMS iPhone 50 E 2 Xiaoxiang Android 51 E 3 JBDTools PC 54 Appendix F Wire and Lug Sizing 57 F 1 Wire Sizing Chart 57 F 2 Battery B...

Page 5: ...y pack Do not accidentally short circuit the battery pack Do not submerge the battery pack Do not purposely connect the battery pack to a load that dissipates more than the BMS is rated to handle 2 2...

Page 6: ...but ideally elevated up a few inches Sitting on a closet shelf is perfectly fine These cells do not offgas in normal operation so they may be placed inside a living space Admittedly this setup isn t f...

Page 7: ...ime the top balancing step can be skipped because it was done before they were shipped to you The top balancing procedure is covered in Section 2 3 A handheld voltmeter for troubleshooting and BMS cal...

Page 8: ...r supply does not have a voltage readout then connect a digital multimeter to the positive and negative bus bars This will need to be monitored throughout the test 6 If the power supply does not have...

Page 9: ...rranging the Cells Lay out your cells in the correct orientation Do not install the bus bars yet NOTE In this section the 12V 4 cell and 24V 8 cell configurations are shown Other configurations are co...

Page 10: ...when connecting and reconnecting things Also some batteries do not label the and terminals very well Consider using a red marker or red fingernail polish to mark the red terminal being careful not to...

Page 11: ...s must be crimped to bare stranded wire Strip the ends back If using 16 22 AWG ring terminals the red ones then strip about 3 8 of insulation off and fold the exposed wire in half in order to double t...

Page 12: ...If the B wires do not reach the BC0 terminal then they must either be lengthened or replaced with a longer cable Longer thicker pigtail cables are optional at the time of purchase 2 4 3 Add BMS Mount...

Page 13: ...ls Here are some guidelines to follow Tape the temperature sensor to the battery cell case Do not tape the sensor to the plastic bits that may be on the top side of the battery Placing the sensor betw...

Page 14: ...the switch see Section 3 4 1 for instructions 2 4 7 Connectivity For systems with multiple BMSs and battery packs it may be desirable to use an external battery monitor to visualize the complete syste...

Page 15: ...ipated to be released by end of Q4 2020 Before plugging in the USB interface install the applicable software see table above Do not run the software just yet A virtual COM port driver must be installe...

Page 16: ...Arduino LCD Display For the adventurous DIYer we ve written an Arduino library that is capable of displaying the following parameters on a 20x4 character LCD screen Voltage current power capacity sta...

Page 17: ...t if any cell voltage goes under the Trigger value Reconnects when all cells rise above the Release value 3 1 3 Battery over voltage Cuts off charging current if entire pack goes over the Trigger valu...

Page 18: ...rrent if entire pack falls under the Trigger value Reconnects when pack rises above the Release value 3 1 5 Charge over current Cuts off charging current if the current exceeds the trigger value for d...

Page 19: ...t if the probe temp drops below the trigger value Reconnects after the probe temp rises above the release value 3 1 9 Discharge over temperature Cuts off discharging current if the probe temperature e...

Page 20: ...et the cycle capacity to hook a known DC load up to the battery and measure the amount of time it takes from full charge down to cutoff Ensure that the protection parameters are set before starting Ch...

Page 21: ...ch converts into heat This value must be a compromise between those two extremes Please see the recommended values in Appendix A 3 3 3 Balancer Enabled The BMS will only perform its balancing routine...

Page 22: ...icable has no effect on the behavior of the BMS However if the PIN protect option is used within the iPhone app it will use the name as a PIN passcode which could leave you locked out of your BMS We r...

Page 23: ...mended to check the cell voltages with a multimeter If they are low charge the battery pack until the voltages are around 50 80 Use the iPhone Android app and the bluetooth module to ensure that the c...

Page 24: ...gain 0 8 milliamps when the BMS is inactive So assuming your battery setup is 100 amp hours the BMS would run for 17 years This proves that the BMS can be connected for long periods of time without an...

Page 25: ...g is usually more effective because the cell delta is greatest at the top of the charge This is labelled confusingly in the iOS app Our recommendation is to leave it to the default value of Bal only w...

Page 26: ...rn the undervoltage parameters to their original value Q Why doesn t it charge high enough A The BMS does not control the charge voltage This needs to be configured in the settings of your charger Q C...

Page 27: ...t over charge because your smart charger stops at 13 8 unbalanced cells can and will over charge a single cell long before the overall pack voltage tops out at 13 8 In conclusion always use a BMS with...

Page 28: ...OverkillSolar gmail com for technical support Our BMS policy is quite simple If you need help I will help If it isn t working right I will replace it If it s totally fried I will refund your money Thi...

Page 29: ...lliamps multiply the amp hours of your pack by 1000 Examples 50 Ah pack 50000 60 Ah pack 60000 100Ah pack 100000 200 Ah pack 200000 280 Ah pack 280000 mAh Cycle capacity This should be roughly 80 of t...

Page 30: ...y default setting that ships with the BMS 12V BMS 4 cells 24V BMS 8 cells External switch Set this to True if you have an external switch wired to the 2 pin connector as detailed in section 2 2 6 Load...

Page 31: ...A 2 12V Pack 4 Cell Using One 12V BMS and 100Ah LiFEPO4 cells Mechanical Drawing Figure A 2 1 12V 4 cell pack assembly Bill of Materials Qty Description Notes 1 1 12V BMS JBD SP04S020...

Page 32: ...0A 10 1 Power distribution block negative 2 or more 3 8 lugs black Rated for 150A 11 1 Wire positive lead red current carrying cable between last battery cell positive and the power distribution block...

Page 33: ...acity 100000 100 amp hours mAh Cycle capacity 80000 mAh Full charge voltage per cell 3500 mV End of discharge voltage per cell 2800 mV Discharge rate 0 2 80 capacity voltage per cell 3400 mV 60 capaci...

Page 34: ...000 mV 2 Battery over voltage 14600 mV 14000 mV 2 Battery under voltage 10000 mV 12000 mV 2 Charge over current 130000 mA 32s 10 Discharge over current 130000 mA 32s 10 Charge over temp 65 55 2 Charge...

Page 35: ...A 3 12V Pack 8 Cell Using One 12V BMS Mechanical Drawing Figure A 3 1 12V 8 cell pack assembly...

Page 36: ...rs Capacity configuration Parameter Value Units Designed capacity 200000 200 amp hours mAh Cycle capacity 160000 mAh Full charge voltage per cell 3500 mV End of discharge voltage per cell 2800 mV Disc...

Page 37: ...tage 3650 mV 3500 mV 2 Cell under voltage 2500 mV 3000 mV 2 Battery over voltage 14600 mV 14000 mV 2 Battery under voltage 10000 mV 12000 mV 2 Charge over current 130000 mA 32s 10 Discharge over curre...

Page 38: ...A 4 24V Pack 8 Cell Using One 24V BMS Mechanical Drawing Figure A 4 1 24V 8 cell pack assembly Bill of Materials Qty Description Notes 1 1 24V BMS JBD SP10S009...

Page 39: ...1 Power distribution block negative 2 or more 3 8 lugs black Rated for 150A 11 1 Wire positive lead red current carrying cable between last battery cell positive and the power distribution block 4 AW...

Page 40: ...capacity This should be the rated capacity of your battery in milliamps multiply the amp hours of your pack by 1000 Examples 50 Ah pack 50000 60 Ah pack 60000 100Ah pack 100000 200 Ah pack 200000 280...

Page 41: ...0 mV Protection parameters Parameter Trigger Value Release Value Delay seconds Cell over voltage 3650 mV 3500 mV 2 Cell under voltage 2500 mV 3000 mV 2 Battery over voltage 29000 mV 28000 mV 2 Battery...

Page 42: ...hanical Drawing Bill of Materials Wiring Diagram BMS Configuration Parameters A 6 48V Pack 16 Cell Using Two 24V BMSs TBD Mechanical Drawing Bill of Materials Wiring Diagram BMS Configuration Paramete...

Page 43: ...ields install them These are typically used when working around high voltage However they re also handy when working around low voltage high current There will be less chance of short circuiting adjac...

Page 44: ...ure that it will measure DC current Cheaper models only measure AC current Note At the time of writing calibration can only be done via the iPhone app or the JBDTools USB Windows application These ins...

Page 45: ...use several chargers simultaneously just do not exceed the maximum charge current of the BMS or the batteries At this point turn on the charger s and verify that they are running in the correct mode...

Page 46: ...asured amperage by 1000 Enter this into the app s text box see image below Click the Charge Current Calibration button This step will fail if the BMS is discharging or not charging If successful the a...

Page 47: ...s for 40A or 400A the 400A range was selected Turn on the load for a few seconds and ensure that the current is displayed on the meter and on the iPhone app Make sure that the current is in the right...

Page 48: ...5 Keep the load on do not turn it off yet 6 Click the Discharge Current Calibration button 7 Wait for a message that indicates whether the BMS successfully wrote the value to memory or not 8 Finally...

Page 49: ...the 12V BMS A batch of new cells needs to be top balanced before they can be expected to charge properly as a battery pack Q Why A Because of the nature of the LiFePO4 voltage curve At the top end of...

Page 50: ...ight bulb with some alligator clips on the leads see Figure C 3 below You need to watch the cell voltages closely because it s easy to go too far Figure C 3 Using a car light bulb to bleed off excess...

Page 51: ...ter cells and this puts them at a lower state of charge If you are trying to use crappy cells like this you will only be able to charge them up to 80 to avoid constant cell over voltages This might be...

Page 52: ...delta is 29 9 millivolts No need to top balance these cells right They re almost identical right The customer figured as much because he didn t top balance them He was in a hurry Here was the output f...

Page 53: ...ly but the voltage won t change much We can actually see in the measurements from the vendor that the delta was 30 millivolts Consulting the discharge curve for the battery above a 30 millivolt delta...

Page 54: ...Figure C 7 LiFePO4 battery discharge curves are extremely flat...

Page 55: ...idual cell under voltage cutoff Yes configurable Yes configurable Current over discharge cutoff Yes configurable Yes configurable Current over charge cutoff Yes configurable Yes configurable High temp...

Page 56: ...negative White 3 BC2 Balance tap Cell 2 positive Cell 3 negative White 4 BC1 Balance tap Cell 1 positive Cell 2 negative White 5 BC0 Balance tap Cell 1 negative Black Part Numbers Female housing JST X...

Page 57: ...hite 7 N C No connection N A 8 BC3 Balance tap Cell 3 positive Cell 4 negative White 9 BC2 Balance tap Cell 2 positive Cell 3 negative White 10 BC1 Balance tap Cell 1 positive Cell 2 negative White 11...

Page 58: ...SXH 001T P0 6 Male connector through hole vertical JST B4B XH A Male connector through hole right angle JST S4B XH A 1 D 1 3 BMS Switch Connector Connector type JST XH Pin Function Wire color 1 Switch...

Page 59: ...the iPhone application from the app store Link https apps apple com us app xiaoxiang bms id1375405426 2 Open the app Ensure that the phone s bluetooth has not been disabled Settings Bluetooth enable...

Page 60: ...file 3 Current Calibration In this screen the charge and discharge current readings can be calibrated See Section 4 2 for calibration instructions 4 Voltage Calibration In this screen the idle charge...

Page 61: ...mediately enumerated in the list of devices found Click on the device Wait momentarily while the app connects to the BMS 6 The application will display a dialog window that allows the user to set the...

Page 62: ...igate to the app s sub pages 1 Dashboard This navigates back to the main menu 2 Battery State In this screen you can view individual cell voltages 3 Parameter View In this screen you can read the BMS...

Page 63: ...the drivers if necessary see Section 2 4 7 1 3 Plug in the USB adapter see Section 2 4 7 1 Use Device manager to take note of what the COM port is If you unplug the USB interface the port should disa...

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Page 66: ...10 16 AWG 1 5 mm 15 14 AWG 2 5 mm 20 14 AWG 2 5 mm 25 12 AWG 4 mm 30 10 AWG 6 mm 50 6 AWG 16 mm 60 6 AWG 16 mm 80 4 AWG 25 mm 90 4 AWG 25 mm 100 4 AWG 25 mm 120 2 AWG 35 mm 150 1 AWG 50 mm 200 2 0 AWG...

Page 67: ...t voltage mode the voltage will be regulated and the current will vary depending on the load s needs When in constant current mode the current will be regulated and the voltage may vary depending on t...

Page 68: ...e terminal This increases the voltage but not the current capacity Thermal runaway A dangerous feedback cycle that occurs when batteries turn excess energy into heat which in turn releases oxygen whic...

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