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5. Installation

5.1. General information

!

Warning!

Never install or use a damaged BCI.

!

Caution!

Do not reverse connect the BCI.

!

Caution!

Use the BCI within the specifications.

5.2. Unpacking

Check the BCI for damage after unpacking. If the BCI is damaged, contact your reseller or
Super B. Do not install or use the BCI if it is damaged!

5.3. Required tools for installation

•

Screwdriver flat 5 mm

5.4. Placement of the BCI

Before it is used, the BCI must be positioned in such a way that it will not move during use.
The BCI may be fixed in place by using the mounting holes (Figure 9).

Figure 9. Mounting the BCI

5.5. Connection wires

Use appropriate wire for the connection wires to ensure no overheating or unnecessary
losses occur. Consult the SAE-J378 or ISO 10133:2012 standards to determine the appropriate
wire properties. Use appropriate fuses matching the wires and load.

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Summary of Contents for BCI

Page 1: ...Manual BATTERY COMMUNICATION INTERFACE BCI Version March 2022 ...

Page 2: ...he use of the product user safety should always be ensured so installers users service personnel and third parties can safely use the BCI Copyright Super B All rights reserved Licensed software products are owned by Super B or its subsidiaries or suppliers and are protected by national copyright laws and international treaty provisions Super B products are covered by Dutch and foreign patents issu...

Page 3: ... on 15 3 4 2 SoC shutdown Switch OFF 15 3 4 3 Reset 15 4 General product specifications 16 4 1 Electrical specifications 16 4 2 Mechanical specifications 16 4 3 Environmental specifications 17 4 4 Scope of delivery 18 4 5 Connections indicators and controls 18 4 5 1 CAN connector pinout Master Slave 19 4 5 2 J3 I O Connection 10 19 4 5 3 J4 I O Connection 10 20 4 5 4 Indicators 20 4 6 Peripheral e...

Page 4: ...ng the BCI and the battery bank 32 6 3 Battery ID s 32 6 3 1 Battery ID renumbering procedure 32 6 3 2 Battery layout 36 6 3 3 Input level configuration 37 6 3 4 BCI Modules 38 6 3 5 Pre charge adjustment 39 6 3 6 General settings Automatic control 40 6 3 7 General settings State of charge switch OFF level 41 6 3 8 Saving a configuration 42 6 4 Status and control 43 6 5 Status of the battery bank ...

Page 5: ...ndicates problems may occur if a procedure is not carried out as described It may also serve as a reminder to the user 2 Introduction 2 1 Product description The Battery communication Interface BCI is a device intended to control contactors or relays that must be used to protect Super B Li ion batteries from improper use The BCI collects data from one or multiple Li ion batteries by a CANopen comm...

Page 6: ... needs to be aligned with your sales and application engineering contact If this manual does not cover or address your application please contact Super B Only qualified personnel may install and perform maintenance on the complete system always refer to chapter 1 of this manual for safety guidelines The boundaries of the BCI use as described in this manual should always be upheld The BCI may not b...

Page 7: ...age to the user and or product may occur when a procedure is not carried out as described Caution A caution sign indicates problems may occur if a procedure is not carried out as described It may also serve as a reminder to the user 3 Product specifications 3 1 Typical setup of the BCI Figure 1 depicts a typical setup of the BCI The circuit shows the interconnections of the BCI in an installation ...

Page 8: ... connected to the BCI with use of external CAN power Drive a Pre charge contactor to switch a capacitive load and prevent inrush currents A mechanism that allows temporary reconnection of the Li ion battery bank to the DC bus in an undervoltage situation Logging function of diagnostics Complete power down in case of an undervoltage of the Li ion battery bank I 1 µA The BCI has an open collector ou...

Page 9: ...on battery bank However when powered from the Li ion battery bank the maximum number of Li ion batteries in series is limited to four Caution The BCI can only be powered by a Li ion battery bank if the bank consist of 4 or less Li ion batteries in series The BCI has two supply and one GND minus input see chapter 4 5 1 The battery supply input J4 pin 9 2 The DC bus external supply input J4 pin 10 3...

Page 10: ...trol battery bank externally supplied BCI DC bus external suppply input J4 pin10 GND J4 pin1 Figure 3 BCI supplied by external power supply Caution If Li ion battery banks with a setup depicted in figure 2 are put in parallel by connecting the DC bus the self shutdown functionality will only occur when all BCI s power is off Until that happens the BCI will be fed by the DC bus and is not able to s...

Page 11: ... BCI boots in the OFF state In addition the BCI can be set in OFF state manually by the Be in Charge software 3 3 3 3 Pre charge state A contactor that must switch a large capacitive load can be exposed to high electric current during initial turn on This current if not limited can cause considerable stress or damage to the system components Pre charging is implemented to increase the lifespan of ...

Page 12: ...h the BCI will switch to the ON state The BCI will also go to the OFF state after 10 minutes spent in the undervoltage reboot state which implies that the Li ion battery bank should be charged with at least 1 Ah to avoid unnecessary shutdown 3 3 3 7 Shutdown state BCI battery bank powered In this state the main relays and the pre charge relay are disabled the BCI doesn t take any power from the Li...

Page 13: ...ously and the charger cannot supply enough current for the load the Li ion batteries will be discharged When the Li ion batteries are empty the BCI wants to shut down due to an undervoltage event but it can t since its powered by the charger on the load side of the BCI In this situation the BCI will remain in this state relays off but BCI on if it is powered from the load side by the charger It is...

Page 14: ... for a 48V system 4 Li ion batteries in series the voltage across the relay should be less than 5V The BCI will remain in overlap state 1 seconds after the main contactor has been enabled 3 3 4 3 Pre charge driver behaviour BCI externally powered For limiting the inrush current for systems 60Vdc an external pre charge relay should be connected to Pin 3 and 4 of connector J4 see Figure 12 However t...

Page 15: ...o into shutdown or OFF state It is activated only with descending SoC level If the BCI is in SoC shutdown OFF state it can be turned on again by power cycling it When the BCI is turned on again it s in the SoC recovery state during which it will not shutdown on SoC again unless the SoC of the Li ion battery bank is charged 1 above the set level This re enables the functionality Once the SoC shut d...

Page 16: ...excluding CAN power 1 W Current draw full shut down 1 µW Internal Relay switch current max all 4 4 A Internal Relay switch voltage max all 4 60 Vdc Internal Relay isolation voltage 60 Vdc Input voltage for manual control inputs 0 60 Vdc Input high level 6 4 6 8 Vdc Input isolation voltage 60 Vdc Generic IO open drain referring to BCI ground 60 Vdc 100 mA Table 4 Electrical specifications 4 2 Mecha...

Page 17: ... temperature range 40 C to 85 C 40 F to 185 F Relative humidity 5 85 non condensing Ingress protection IP20 Shock and vibration Tested according to DNV requirements Table 6 Environmental specifications Warning The BCI may only be used in conditions specified in this manual Exposing the BCI to conditions outside the specified boundaries may lead to serious damage to the product and or the user ...

Page 18: ...ery Figure 6 Scope of delivery 1 1x Battery Interface Box 2 2x Phoenix plug 10 MC 1 5 10 STF 3 81 1827787 3 3x CAN Cable male to male 0 6m 4 5 Connections indicators and controls Figure 7 Connections Indicators and controls ...

Page 19: ...Slave PIN Signal Master side Slave side 1 CAN_SHLD Optional CAN Shield Optional CAN Shield 2 CAN_V CAN bus supply voltage 12V Not connected 3 CAN_GND Ground OV Ground OV 4 CAN_H CAN_H bus line dominant high CAN_H bus line dominant high 5 CAN_L CAN_L bus line dominant low CAN_L bus line dominant low Table 7 CAN connector pinout Male Female 2 1 3 4 5 1 2 4 3 5 Figure 8 CAN Connections Male and Femal...

Page 20: ...ay NO 4 Pre charge relay common 5 Main relay low side NO 6 Main relay low side common 7 Main relay high side NO 8 Main relay high side common 9 Battery 10 Load Table 9 J4 I O Connection 10 4 5 4 Indicators LED 1 Yellow LED 2 Green LED 3 Red Mode Flashing Off Off Pre charge Off On Off Main relay On On On Off Main relay Off On On On Battery in error mode or communication error Off Flashing Off CAN n...

Page 21: ...1362031 Relay TBS RBS 24V500A 8718531362048 Relay LIR250 12V 24V 500A 8718531361126 CAN Terminator Female Low Profile 8718531362000 CAN Terminator Male Low Profile 8718531361997 CAN Cable 0 6m Male to Female 8718531360716 CAN Cable 1m Male to Female 8718531360723 CAN Cable 2m Male to Female 8718531360730 CAN Cable 5m Male to Female 8718531360747 CAN Cable 10m Male to Female 8718531360754 CAN Cable...

Page 22: ... 3 Required tools for installation Screwdriver flat 5 mm 5 4 Placement of the BCI Before it is used the BCI must be positioned in such a way that it will not move during use The BCI may be fixed in place by using the mounting holes Figure 9 Figure 9 Mounting the BCI 5 5 Connection wires Use appropriate wire for the connection wires to ensure no overheating or unnecessary losses occur Consult the S...

Page 23: ...ays be evaluated especially in installations which include high frequency drives 4 Manual battery switch is necessary during maintenance to isolate the battery voltage from the rest of the system during human intervention If the BCI is used with a Li ion battery bank that consists of 4 or less Li ion batteries in series 48V or less the battery supply power input of the BCI and its functionality ca...

Page 24: ...e pre charge driver and the main contactor high driver of the BCI D3 and D4 are to absorb the back EMF of the contactor coils Some contactors have built in back EMF diodes or transient diodes In that case it is advised not to install D3 and D4 D1 and D2 are needed to provide power for the contactor coils Fuses F1 and F2 should be placed close to the main contactor s terminals The pre charge resist...

Page 25: ...8 V Figure 11 BCI externally powered Circuit description The BCI Is powered by the external power supply through pin 1 minus and pin 10 plus The coils of contactors K1 K2 and K3 are connected to the pre charge driver the main contactor low and the main contactor high drivers of the BCI D1 D2 and D3 are to absorb the back EMF of the contactor coils Some contactors have built in back EMF diodes or t...

Page 26: ...d Table 13 Circuit description 5 6 3 Manual control The BCI can be controlled manually with external hardwired control buttons The manual inputs can be normally open contacts or normally closed contacts A typical setup is depicted in Figure 12 The manual inputs are default configured for active high so normally open contacts can be used This can be configured under Input level configuration see ch...

Page 27: ...s about the behavior When pre charging a DC bus usually not only the capacitive load needs to be considered Often the DC bus has a more complex impedance and there is some resistive load that has to be taken into account choosing the pre charge resistor Figure 13 Simplified circuit In Figure 13 a possible load configuration is depicted The purpose of the pre charge circuit is to charge the DC bus ...

Page 28: ...r a system consisting of 32 batteries in series Considering System voltage 460V 32 charged batteries in series at end of charge voltage A capacitive load of 10mF A resistive load of 1 kOhm The maximum switching current of the contactor is 600A The battery bank total internal resistance is 160mΩ The maximum acceptable voltage difference across the contactor is 96V 600A x 160mΩ The pre charge resist...

Page 29: ...aster bus needs to be connected to the Super B Li Ion batteries More information on the CANopen bus can be found at the CiA website www can cia org The required documentation can be found in the following CiA documents or in a future version of these documents CiA 301 CiA 303_1 V1 8 0 Sections 5 AC and DC parameters and 7 2 5 pin micro style connector 5 7 2 Connecting the CAN network cables The Li...

Page 30: ...e done up to 16 Li ion batteries If more Li ion batteries are connected the CAN bus must be powered externally using a CAN power cable The CAN bus power should be at least 10V and should not exceed 30V Therefore in any 12V or 24V system the CAN bus can be powered directly by the system power A 12V system always needs an additional CAN power cable The CAN slave bus is not powered by the BCI There a...

Page 31: ...B for the right software version This mechanism controls chargers by using the pin IO1 to allow to charge if it is pulled low by the BCI The BCI will inquire the Li ion batteries if charging is allowed This function does not control the state of the BCI like ON state or OFF state should charging not be allowed it only signals towards the charger Refer to 4 1 or the electrical specification Pin 1 J...

Page 32: ...g can be done manually Any Node ID number between 2 and 100 can be assigned to a Li ion battery Node ID 1 should not be used for Li ion batteries as it is reserved for the BCI We recommend not to use Node ID 10 for multi battery configurations as it may be confusing in case a Li ion battery is added to the system Multiple Li ion batteries with the same number will result in unpredictable behavior ...

Page 33: ...the Scan button to start scanning for devices You can also select the scan refresh icon in the top left corner Figure 16 Figure 16 Scan for devices 3 In order to make changes to battery node ID it is necessary to set the user level to Expert User Figure 17 and 18 ...

Page 34: ...34 Figure 17 Set user level to Expert user Figure 18 Confirm user level change 4 Navigate to the Details page and make sure to change the battery node ID of the first battery to 11 Figure 19 and 20 ...

Page 35: ...ed new node ID from the dropdown menu 5 Verify if the correct number is assigned to the Li ion battery by selecting the scan refresh icon on the top left corner 6 Connect the next Li ion battery and repeat step 4 and 5 until all Li ion batteries have been assigned a unique Node ID 7 Continue with the battery layout ...

Page 36: ...ection as described in chapter 5 7 2 2 Perform a scan by selecting the scan button or refresh icon on the top left corner The Be in Charge software request the BCI to scan for connected Li ion batteries When the scan is completed the number of Li ion batteries connected will be shown in the configuration tab in the Total batteries field see Figure 21 3 Configure the battery bank with the slide bar...

Page 37: ...s four hardware inputs Reset Pre charge OFF and ON see Figure 22 The inputs can be used to control the BCI With the Input level configuration box you can select whether the inputs should be active high or active low Figure 22 Be in Charge Software Input level configuration ...

Page 38: ...nication protocol The default setting is CANOpen CiA418 and Super B features There is also an option to use proprietary protocols This list is subject to change therefore the list may look differently depending on the software version Figure 23 BCI Modules and communication protocol ...

Page 39: ...harge adjustment When the BCI is powered externally paragraph 5 6 2 it is possible to adjust the pre charge duration in the below section see Figure 24 This can only be adjusted when External power is enabled Figure 24 BCI Precharge time ...

Page 40: ...matic start up option chapter 3 4 1 The main relay s will be engaged automatically when the BCI starts up or all the alarms are cleared see Figure 25 When Auto On is disabled the Control buttons in the control tab or the external control inputs can be used Figure 25 Auto ON ...

Page 41: ...level The State of charge switch off level is a function that makes it possible to put the BIB in shutdown state see 3 4 2 at a certain level of state of charge This level can be set by the user see Figure 26 By default this function is disabled Figure 26 SoC switch OFF level ...

Page 42: ...42 6 3 8 Saving a configuration To save a configuration select the Apply button on the bottom right corner see Figure 27 Figure 27 Saving a configuration ...

Page 43: ...he BCI is is indicated by the indication bar as depicted in Figure 28 Figure 28 BCI Control tab The state of the BCI can be manually controlled by using the buttons underneath the BCI Control tab The reset button can be used to reset the BCI when the BIB and or a Li ion battery is in error state More information about the different state and the corresponding behaviour can be found in chapter 3 4 ...

Page 44: ...information shown in the image is subject to change depending on the Be in Charge software version They show respectively the BCI in ON state OFF state due to battery error warning state only available as of BCI SW version 2 35 or later and 1Ah undervoltage reboot state Figure 29 BCI Status tab ON Figure 30 BCI Status tab OFF battery in overvoltage ...

Page 45: ...45 Be in charge Super B Figure 31 BCI Status tab OFF battery in overcurrent while charge Figure 32 BCI Status tab undervoltage warning ...

Page 46: ...46 Figure 33 BCI Status tab undervoltage complete shutdown Figure 34 BCI Status tab 1Ah undervoltage reboot state ...

Page 47: ...fore performing cleaning and maintenance activities 7 2 Inspection Inspect for loose and or damaged wiring and contacts cracks deformations or damage of any other kind If damage to the BCI is found it must be replaced Do not attempt to use a damaged BCI 7 3 Cleaning If necessary clean the BCI with a soft dry cloth Never use liquids solvents or abrasives to clean the BCI 7 4 Maintenance The BCI is ...

Page 48: ...ange of electronic and electrical products WEEE encourages the collection treatment recycling and recovery of waste electrical and electronic equipment WEEE makes producers and importers responsible for financing of the collection treatment and recovery of WEEE Reference The Waste Electrical and Electronic Equipment WEEE Directive 2012 19 EU RoHS The RoHS Directive will ban placement into the EU m...

Page 49: ...ED ON Main contactor s open Check if BCI is configured for Automatic startup option Chapter 6 3 6 Red LED is on One or more Li ion batteries are reporting an error or the BCI is not configured first bootup Determine which Li ion battery is reporting the error Check for excessive heat any damage short circuits etc Take appropriate safety precautions If the problem has been resolved reset the system...

Page 50: ...anty granted to you Please refer to the sales agreement for warranty and other provisions applicable to your purchase If the product is defective please contact the dealer reseller or retailer that you purchased the product from Super B s liability for any of its products is limited to the corresponding provisions under mandatory applicable law ...

Page 51: ...For more information please contact Super B Lithium Power B V Europalaan 202 7559 SC Hengelo Ov The Netherlands Tel 31 0 88 0076 000 E mail info super b com www www super b com Manual March 2022 ...

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