SYSTEM INFORMATION

LiTHIUM BALANCE Scalable Battery Management System (s-BMS v6)

Housed and loose board battery management solutions and accessories

Litt. no. 6100-0010

INTRODUCTION

Lithium Ion batteries offer high performance and good longevity, but they do not tolerate abuse or misuse. Battery Management Systems (BMS) are required to ensure that Lithium Ion (Li-Ion) batteries or battery packs operate safely and reliably.The LiTHIUM BALANCE s-BMS is an exceptionally flexible and cost effective BMS suitable for industrial applications including material handling, automo-tive, marine and stationary applications.

System descriptionThe system is designed around a distributed archi-tecture with a master board (BMCU) communicating over a galvanically isolated RS485 bus with up to 32 slave boards (LMU). Each slave board can connect 3 - 8 cells in series and 2 temperature sensors. The system is available as loose PCB boards or housed units with IP 61 protection. The s-BMS supports all commercially available Li-Ion chemistries with no restriction on pack current.

FEATURES

Factory calibrated cell voltage measurement circuit (<2mV typical, <10mV max.)For battery packs ranging from 12 -1000V with up to 256 cells in series

Individual over/under voltage & over current protection

Measures cell voltages, cell temperatures, SoC, SoH, pack current, pack voltage and many other parameters

Onboard system operational log for warranty support

Contactor driver circuit including precharge function

Real time short circuit and isolation (leak) fault detection

Close loop charger control using PWM, analogue or CAN.

Up to 840mA balancing current dependent on cell voltage

Galvanic isolation on all major interfaces/connections*

Extremely high EMI resillience (>200V/m @ 80-2400MHz)

Real-time diagnostics via PC interface (RS232) or CAN

Fully configurable CAN bus supporting CAN 2.0A&B

Fully bootloadable firmware on all boards

Battery models for power prediction and SoC calculation

* Except CAN bus

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Figure 1s-BMS Control unit

capable of managing 16 cells in series

SYSTEM INFORMATION

ApplicationsThe LiTHIUM BALANCE s-BMS is suitable for all industrial applications using Li-Ion battery technology. For transport applications it provides the necessary EMI and environmental test performance for harsh vehicle environments. The precise and reliable SoC calculation helps to reduce range anxiety. Stationary applications are often unsupervised and may have long periods between operation. With all aspects of the BMS operation constantly self monitored and a low power consumption, the system can safely work autonomously for extended periods of time. The distributed intelligence architecture allows the LMUs to perform balancing in the absence of a dedicated charger.

HardwareThe s-BMS hardware has been designed with special consideration for EMC performance. All connections to and from the boards are protected by transient voltage suppression circuits (TVS). Cell monitoring circuits are additionally protected against ESD and voltage spikes. The communications bus is an RS485 bus galvanically isolated from the high voltage bus. The communications bus is also protected with TVS circuits. The result of these measures is EMC performance greatly exceeding any of the applicable automotive or industrial standards. The housed version includes the s-BMS Control Unit which contains a BMCU and 2 LMUs in an IP61 unit designed to dissipate heat from thepassive balancing circuit. The Control unit can manage up to 16 batterycells in series and provides all of the connection options of the loose boards via an easy to use family of dedicated cables. The s-BMS Control unit can daisy chain up to 15 Monitoring units, each of which can monitor up to 16 cells.

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SYSTEM INFORMATION

The PC SoftwareThe PC software is the gateway to the s-BMS providing an easy to use suite of system configuration tools as well as displays for monitoring battery and BMS performance. The Diagnostic Software allows the user to field update the system quickly and provides the interface for setting battery parameters such as limit volt-ages and temperatures, allowable charge and discharge rates.Other features such as the onboard battery model can be setup to provide intellingent rate control to the load or improve the SoC estimation by adding temperature and C - rate compensation. Cell and pack resistance can also be displayed.

CAN busTo simplify integration, a powerful, fully user-configurable CAN bus plat-form is included allowing CAN messages to be constructed at “Bit level“ to broadcast any of the parameters measured or calcuated by the BMS. A post processing module allows you to scale and manipulate values, so that can get the BMS to broadcast exactly what you want on the CAN bus with no custom programming. You can configure up to 15 messages each with up to 25 signals. SafetyA key function of any BMS is safety. The s-BMS provides notification and user-definable system responses for 27 different fault and 17 warning condi-tions in charge and discharge mode, separately.

Figure 2PC Software interface

showing battery pack status as well as providing the necessary configuration

options

www.lithiumbalance.comContact@lithiumbalance.com

Tel: +45 5851 5104

LiTHIUM BALANCE A/SBaldershøj 26C 2635 Ishøj Copenhagen, Denmark

PRODUCT SPECIFICATIONS

Maximum system operational limits: 1000V; No current limit

Board details: BMCU and LMU Standard Euro card format 100 x 160mm. Clearance height between the boards is 20mm

Power Requirements: BMCU 9-15V; Current consumption: <150mA (operating) 0mA - powered down LMU 6-40V; Current consumption: <10mA from cells (operating) <100µA (sleep mode)

System details: 3-8 cells/LMU, max. 32 LMUs/system, 256 cells in series, 2 temperature sensors/LMU

Measurement specifications: Cell voltage 0-5V, acc. <±10mV max. typical ±2mV Sampling 1HzTemp. acc. ±1.5°C (dependent on sensor) Pack voltage 0-1000V, acc. ±1V. Sampling 100Hz Pack current acc. 0.015A with 300A/150mV Class 0.5 shunt. Sampling 50HzData I/O options: 8 GP I/Os (monitored and SW. configurable) switching current 1A cont. 3A peak per IO current capacity, semi conductor switch driver (12V high)Charger control: Pulse width modulation (0-5V)* and Analog voltage control of charging current - chargingcontrol algorithms provided by BMCU. CAN support for Brusa, EDN, ElCon, Eltek Valere, Zivan and TC ChargersProtection modes: 27 error and 17 warning conditions including; short circuit, high/low cell voltage, comms. error and high/lowtemp.

Data Buses: CAN bus 2.0 A&B RS485 internal comms. RS232 PC diagnostics interface

TEST SPECIFICATIONS

EMC Emission: EN55022 Class BEMC Immunity: EN61000-4-3 (80 Mhz – 2.4 GHz) at >200 V/m ESD: SAE J113/13

Temperature: Operational -40o to 85oC; Storage -50o to 125oC

Vibration: EN60068-2-6 random vibration (10-1000Hz) according to SAE technical paper 2006-01-0729

CE COMPLIANCE

2006/95/EC Low-Voltage Directive (safety), 2004/108/EC Electromagnetic Compatibility Directive (EMC), 2006/42/EC; Machinery Directive (safety when installed in a machine)

SYSTEM INFORMATION

* 0-30volts with external powersupply

Additionally, warning levels are selectable for key parameters allowing the system to respond progressively, before an error state occurs. System behaviour has been developed with failure mode analysis techniques where the potential failure modes are analysed and steps taken in software and hardware to remove or minimise the effects of component or system failures. Special attention is paid to charging as this is a critical phase of operation and the s-BMS operates a separate charger contactor as a fail safe to isolate the battery pack in the event of any system malfunction.

The s-BMS has been used successfully, all over the World in passenger vehicle fleets, large buses and trucks, boats, submarines, materials handling vehicles, power storage systems and even a manned electric helicopter.We say: Universal, Safe and Affordable, no application is too big or small.