ZERO EMISSION VEHICLES AUSTRALIA
8-16 CELL LITHIUM BATTERY MANAGEMENT SYSTEM
Z
ERO
E
MISSION
V
EHICLES
A
USTRALIA
http://www.zeva.com.au
BMS16
v2
8-16 cell Lithium Battery Management System
Introduction
The ZEVA BMS16 is an integrated battery management system for lithium battery packs
containing 8-16 cells in series and 5-1200 Ah capacity. It is suitable for both electric vehicle
and battery storage applications. The BMS16 includes an internal power supply to allow it to
run directly from the battery pack, internal shunt resistors for automatic pack balancing, dual
solid state relay outputs for switching power contactors to protect charging and discharging
of batteries, built-in current shunt interface for measuring current and calculating battery
state of charge, and a CAN bus port for optional colour touchscreen interface or integration
with third party control systems.
The BMS16 Monitor provides information such as voltage, current, power, battery state of
charge, and all individual cell voltages. It can also be used for configuring the operating
parameters of the BMS16. It may be installed up to 50m from the BMS16 (if correct shielded
twisted pair cable is used).
Battery management systems are the last line of defence for your battery pack. In normal
circumstances it should not interfere with the battery pack’s operation, only intervening
when something goes wrong and protection is required.
Safety Warning
Although 8-16 cell lithium battery packs do not involve lethal voltages, they frequently
involve dangerous amounts of current and power. Proper precautions and electrical
safety procedures should always be observed. Please read this manual carefully to ensure
correct installation and operation. If you are unsure of anything, please contact us before
proceeding.
We have endeavoured to make a safe and reliable product which performs as described,
however since ZEVA has no control over the integration of its products into a battery system,
we can assume no responsibility for the final safety or functionality of the completed
installation. It is up to the end user to determine the suitability of the products for the purpose
employed, and the end user assumes all risks associated. Products should only be installed
by suitably qualified and experienced persons, and should always be used in a safe and
lawful manner.
Specifications
Number of cells: 8-16
•
Battery types: LiFePO4, LiCo, LiMn, NMC, etc
•
Accuracy: Within 0.002V per cell
•
Battery capacity: 5-1200Ah
•
Current measurement: 0-500A via shunt interface, 0-1200A with external sensor
•
Dimensions: 120x80x16mm, 2x Ø4mm mounting holes 116mm apart
•
Outputs: Dual solid state relays, 60V 1.3A max, internally fused
•
Power consumption: Approx 30mA when running (with both output relays closed and a
•
monitor connected to the CAN bus), 8mA when sleeping
Installation
The BMS16 should be mounted securely using screws through the holes on the case flanges.
Install the BMS16 in a location protected from direct sun and water, and close to the cells if
possible to minimise cell wiring lengths (under 1m recommended).
The BMS16 has a pluggable screw terminal block for the cell connections, with the most
negative point of the battery pack connected to terminal
00
, and successive positive
terminals connected to
01–16. Wire gauge around AWG20-26 is recommended for sufficient
mechanical strength and suitable current rating. We recommend wiring up the plug and
verifying all voltages before connecting to the BMS. The plug requires a significant amount
of force to fully engage; ensure it is plugged all the way in for reliable connections.
If you need to disconnect the cell plug from the BMS, significant force is required for removal
as well. For easier removal, a flat blade screwdriver may be used to lever the positive end of
the plug out first, which should then be loose enough to remove by hand.
Ensure that all wiring is secured so it will not become damaged from vibration or abrasion.
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