Rozna ulica 20, 6230 Postojna, Slovenia

e-mail: info@rec-bms.com; www.rec-bms.com

BATTERY MANAGEMENT SYSTEM

4 – 16S

Features:

- robust and small design

- 4 – 16 cells
- single cell voltage measurement (0.1 – 5.0 V, resolution 1 mV)
- single cell - under/over voltage protection
- single cell internal resistance measurement
- SOC and SOH calculation
- over temperature protection (up to 8 temperature sensors)
- under temperature charging protection
- passive cell balancing up to 0.9 A per cell
- shunt current measurement (resolution 19 mA @ ± 500 A)
- galvanically isolated user defined multi-purpose digital input/output
- programmable relay (normally open)
- galvanically isolated RS-485 communication protocol
- CAN communication
- error LED + buzzer indicator (option)
- PC user interface for changing the settings and data-logging (optional accessory)
- hibernate switch
- one-year warranty
- NEW: reduced 1 s measuring interval
- NEW: balancing transistors defect check @ restart
- NEW: EEPROM memory data corruption check @ restart
- NEW: cell's voltage RMS voltage measurement
- NEW: self calibration @ restart
- NEW: BMS shutdown @ 0.98 x minimum cell disconnect threshold
- NEW: Ah counting

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General Description of the BMS Unit:

Battery management system (BMS) is a device that monitors and controls each cell in the battery pack by measuring
its parameters. The capacity of the battery pack differs from one cell to another and this increases with number of
charging/discharging cycles. The Li-poly batteries are fully charged at typical cell voltage 4.10 - 4.20 V or 3.5 – 3.6 V
for LiFePO4. Due to the different capacity this voltage is not reached at the same time for all cells in the pack. The
lower the cell’s capacity the sooner this voltage is reached. When charging series connected cells with a single
charger, voltage on some cells might be higher than maximum allowed voltage. Overcharging the cell additionally
lowers its capacity and number of charging cycles. The BMS equalizes cells’ voltage by diverting some of the
charging current from higher voltage cells – passive balancing. The device temperature is measured to protect the
circuit from over-heating due to the passive balancing. Battery pack temperature is monitored by Dallas DS18B20
digital temperature sensor/s. Maximum 8 temperature sensors per Slave unit may be used. Current is measured by
low-side shunt resistor. Battery pack current, temperature and cell’s voltage determine state of charge (SOC). State
of health (SOH) is determined by comparing cell’s current parameters with the parameters of the new battery pack.
The BMS default parameters are listed in Table 1.

Default Parameters:

Table 1: Default BMS parameter settings.

parameter value unit
balance start voltage 3.95 V
balance end voltage 4.148 V
maximum diverted current per cell up to 0.85 (4.7 Ohm) A
cell over voltage switch-off 4.17 V
cell over voltage switch-off hysteresis per cell 0.015 V
charger end of charge switch-off pack 4.153.6 V
charger end of charge switch-off hysteresis 0.1 V
charger end of charge SOC hysteresis 5 %
cell under voltage protection switch-off 3.0 V
cell under voltage protection when BMS switches-off after 30s 3.0*0.98 V
cell under voltage protection alarm 3.2 V
under voltage protection switch-off hysteresis per cell 0.05 V
cell under voltage protection switch-off timer 4 s
cells max difference 0.15 V
BMS maximum pack voltage 68.0 V
BMS over temperature switch-off 55 °C
BMS over temperature switch-off hysteresis 5 °C
cell over temperature switch-off 55 °C
under temperature charging disable -10 °C
max DC current relay @ 60 V DC 0.7 A
max AC current relay @ 230 V AC 2 A
BMS unit stand-by power supply < 90 mW
max DC current @ optocoupler 15 mA
max DC voltage@ optocoupler 68 V
BMS unit disable power supply <1 mW
Slave unit cell balance fuse rating (SMD) 2 A
internal relay fuse (Master unit) 2 slow A
dimensions (w × l × h) 190 x 104 x 39 mm
weight 0.650 kg
IP protection IP32

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System Overview:

Figure 1: System overview.

BMS Unit Connections:

Figure 2: BMS unit function overview.

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Table 2: BMS unit connections.

connection description
Temperature DALLAS 18B20
GND + shield
connector temp. sensor pins (pin 2)
Temperature DALLAS 18B20
1-wire digital signal
connector temp. sensor pins (pin 3)
Temperature DALLAS 18B20
+5V
connector temp. sensor pins (pin 1)
Current
+ Shunt (pin 3) Analog signal
connector
Current
- Shunt (pin 1 ) Analog signal
connector
Current
Shield (pin 2) Analog signal
connector

7 Cell 1 ground Analog signal

8 Cell 1 positive Analog signal
9 Cell 2 positive Analog signal
10 Cell 3 positive Analog signal
11 Cell 4 positive Analog signal
12 Cell 5 positive Analog signal
13 Cell 6 positive Analog signal
14 Cell 7 positive Analog signal
15 Cell 8 positive Analog signal
16 Cell 9 positive Analog signal
17 Cell 10 positive Analog signal
18 Cell 11 positive Analog signal
19 Cell 12 positive Analog signal
20 Cell 13 positive Analog signal
21 Cell 14 positive Analog signal
22 Cell 15 positive Analog signal
23 Cell 16 positive Analog signal

24 Optocoupler collector Charger enable +

25 Optocoupler emitter (darlington + reverse Charger enable -
protection diode)
26 - -
27 Internal Relay Main relay control via pre-charge
28 Internal Relay Main relay control via pre-charge

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Setting Number of Cells and the RS-485 Address:

Number of cells connected to the BMS unit is selected via CELL DIP Switch pins at the back of the unit. Binary
addressing is used to enable setting up to 16 cells with 4 DIP Switches.

Figure 3: Address and cell selection DIP Switches.

Figure 4: Number of cell selection description.

BMS unit address is selected via Address DIP Switch pins (BMS) at the back of the unit. Binary addressing is used to
enable setting up to 15 addresses with 4 DIP Switches. ! If multiple BMS units are used distinguished addresses
should be set to avoid data collision on the RS-485 communication bus!

Figure 5: BMS unit address selection description.

BMS Unit Cell Connector:

Connect each cell to the BMS unit cell connector plug. Use silicon wires with cross section of 0.5 – 1mm2 ! Before
inserting the cell connector check voltages and polarities with voltmeter of each connection!
! If working on cells connections –BMS's cells connector should be unplagued otherwise the BMS is damaged !

Figure 6: Battery pack to BMS connection.

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BMS Unit Power Supply:

BMS unit is always supplied from the 16-th cell connection. ! When less than 16 cells are used in the battery pack,
an additional wire with Pack + voltage should be connected to the cell 16 connector !

Figure 7: BMS unit power supply.

BMS Unit Connection Instructions:

Connect the BMS unit to the system by the following order described in Fig. 8. It is important to disable all the BMS
functions by turning enable switch OFF before plugging any connectors. All cells should be connected last and
simultaneously. When all the system components are plugged in, the enable switch can be turned ON and the Slave
unit starts the test procedure.

Figure 8: BMS connection order.

When disconnecting the unit from the battery pack, the procedure should be followed in reverse order.

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RS-485 Communication Protocol:

Figure 9: RS-485 DB9 connector front view.

Table 3: RS-485 DB9 connector pin designator.

Pin Designator
1 -
2 GND
3 B + TERMINATION 470 OHM
4 A + TERMINATION
5 -
6 GND BMS
7 -
8 -
9 -

BMS unit is programmed as a Slave unit and responds only when asked. Galvanically isolated RS-485 (EN 61558-1,
EN 61558-2) serves for logging and changing BMS parameters. Dedicated PC BMS Control Software or another RS-
485 device may be used for the communication.

Messages are comprised as follows:

STX, DA, SA, N, INSTRUCTION- 4 bytes, 16-bit CRC, ETX

 STX start transmition <0x55> (always)
 DA - destination address <0x01> to <0x10> (set as 6)
 SA - sender address <0x00> (always 0)
 N – number of sent bytes
 INSTRUCTION 4 bytes for example.: 'L','C','D','1','?', - (combined from 4 ASCII characters, followed by ‘?’, if
we would like to receive the current parameter value or ‘ ’,’xx.xx’ value in case we want to set a new value
 16-bit CRC, for the whole message except STX in ETX
 ETX - end transmition <0xAA> (always)

Dataflow:
 Bit rate: 56k
 Data bits: 8
 Stop bits: 1
 Parity: None
 Mode: Asynchronous

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Table 4: RS-485 instruction set.

INSTRUCTION DESCRIPTION BMS ANSWER

'*','I','D','N','?' Identification Answer “REC - BATERY MANAGEMENT SYSTEM”
Returns 7 float values
LCD1 [0] = min cell voltage,
LCD1 [1] = max cell voltage,
LCD1 [2] = current,
'L','C','D','1','?' Main data LCD1 [3] = max temperature,
LCD1 [4] = pack voltage,
LCD1 [5] = SOC (state of charge) interval 0-1-> 1=100%
and
LCD1 [6] = SOH (state of health) interval 0-1-> 1=100%
Returns 8 unsigned char values
LCD3 [0] = min cell BMS address,
LCD3 [1] = min cell number,
LCD3 [2] = max cell BMS address,
'L','C','D','3','?' Main data LCD3 [3] = max cell number,
LCD3 [4] = max temp. sens. BMS address,
LCD3 [5] = max temp. sens. number,
LCD3 [6] = Ah MSB,
LCD3 [7] = Ah LSB
BMS first responds with how many BMS units are
'C','E','L','L','?' Cell voltages connected, then it sends the values of the cells in float
format
BMS first responds with how many BMS units are
'P','T','E','M','?' Cell temperatures connected then it sends the values of the temperature
sensors in float format
BMS first responds with how many BMS units are
'R','I','N','T','?' Cells internal DC resistance
connected then it sends the values in float format
BMS first responds with value 1, then it sends the values
'B','T','E','M','?' BMS temperature
of the BMS temperature sensor in float format
Responds with 4 bytes as follows
ERRO [0] = 0 – no error, 1 – error
ERRO [1] = BMS unit
'E','R','R','O','?' Error
ERRO [2] = error number (1-13) in
ERRO [3] = number of the cell, temp. sensor where the
error occurred
'B','V','O','L', '?'/
Cell END balancing Returns float voltage [V]
'B','V','O','L', ' ','xxx'
'C','M','A','X','?'/
Max allowed cell voltage Returns float voltage [V]
'C','M','A','X',' ','xxx'
'M','A','X','H', '?'/
Max allowed cell voltage hysteresis Returns float voltage [V]
'M','A','X','H', ' ','xxx'
'C','M','I','N', '?'/
Min allowed cell voltage Returns float voltage [V]
'C','M','I','N', ' ','xxx'
'M','I','N','H', '?'/
Min allowed cell voltage hysteresis Returns float voltage [V]
'M','I','N','H', ' ','xxx'
'T','M','A','X', '?'/
Maximum allowed cell temperature Returns float temperature [°C]
'T','M','A','X', ' ','xxx'
'T','M','I','N', '?'/ Minimum allowed temperature for
Returns float temperature [°C]
'T','M','I','N', ' ','xxx' charging
'B','M','I','N', '?'/
Balancing START voltage Returns float voltage [V]
'B','M','I','N', ' ','xxx'
'C','H','A','R', '?'/
End of charging voltage per cell Returns float voltage [V]
'C','H','A','R', ' ','xxx'

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'C','H','I','S', '?'/ End of charging voltage hysteresis

Returns float voltage [V]
'C','H','I','S', ' ','xxx' per cell
'I','O','F','F','?'/
Current measurement zero offset Returns float current [A]
'I','O','F','F',' ','xxx'
'T','B','A','L','?'/
Max allowed BMS temperature Returns float temperature [°C]
'T','B','A','L',' ','xxx'
'B','M','T','H','?'/ Max allowed BMS temperature
Returns float temperature [°C]
'B','M','T','H',' ','xxx' hysteresis
'V','M','A','X','?'/ Number of exceeded values of
Returns integer value
'V','M','A','X',' ','xxx' CMAX
'V','M','I','N','?'/ Number of exceeded values of
Returns integer value
'V','M','I','N',' ','xxx' CMIN
'T','H','I','S','?'/ Number of exceeded values of
Returns integer value
'T','H','I','S',' ','xxx' TMAX
'C','Y','C','L','?'/
Number of battery pack cycles Returns integer value
'C','Y','C','L',' ','xxx'
'C','A','P','A','?'/
Battery pack capacity Returns float capacity [Ah]
'C','A','P','A',' ','xxx'
'I','O','J','A','?'/
Voltage to current coefficient Returns float value
'I','O','J','A',' ','xxx'
'R','A','Z','L','?'/
Package cell difference Returns float voltage [V]
'R','A','Z','L',' ','xxx'
'C','H','E','M', '?'/
Li-ion chemistry Returns unsigned char value
'C','H','E','M', ' ','xxx'
'S','O','C','S','?'/
State of charge Returns float SOC [0-1.0]
'S','O','C','S',' ','xxx'
'R','E','L','V','?'/ Cell under voltage protection
Returns float voltage [V]
'R','E','L','V',' ','xxx' switch-off
'R','E','L','H','?'/ Cell under voltage protection
Returns float voltage [V]
'R','E','L','H',' ','xxx' switch-off hysteresis
'R','E','L','T','?'/ Timer for min cell < RELV before
Returns unsigned char value (1-200 means 2-400 s)
'R','E','L','T',' ','xxx' under-voltage relay turns off

'C','R','E','F','?' Reference calibration – read only Returns float voltage [V](4.996 typ.)

'O','D','D','C','?'/
Odd cells calibration coefficient Returns float value (0.0003 typ.)
'O','D','D','C',' ','xxx'
'E','A','V','C','?'/
Even cells calibration coefficient Returns float value (0.0003 typ.)
'E','A','V','C',' ','xxx'
'S','O','C','H','?'/
Charger SOC hysteresis Returns float value 0 - 0.99
'S','O','C','H',' ','xxx'
Parameter accepted and changed value is responded with 'SET' answer.

Example: proper byte message for 'LCD1?' instruction for BMS address 1 is:
<0x55><0x01><0x00><0x05><0x4C><0x43><0x44><0x31><0x3F><0x01><0xD9><0xAA>
RS-485 message are executed when the microprocessor is not in interrupt routine so a timeout of 350 ms should
be set for the answer to arrive. If the timeout occurs the message should be sent again.

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CAN Communication Protocol (not programmed):

Figure 10: CAN DB9 connector front view.

Table 5: CAN DB9 connector pin designator.

Pin Designator
1 TERMINATION
2 CANL +TERMINATION
3 GND
4
5 -
6 GND
7 CANH
8 -
9
Bitrate: 250 kbs
11-bit identifier: 0x031
Default settings TX only
8 byte message structure:

Table 6: CAN message structure description for ID=0x031

Byte Description Type

1 State of charge [%] Unsigned char 0-200 LSB = 0.5 % SOC
2 Battery pack voltage high byte
Unsigned integer 0-65535, LSB = 2 mV
3 Battery pack voltage low byte
4 Battery pack current high byte
Signed integer −32768 to 32767 LSB = 20 mA
5 Battery pack current low byte
6 Battery pack max temperature Signed char -127 to 127 LSB = 1° C
7 Error number Unsigned char 0-15
Number of the cell or temp. sensor
8 Unsigned char 0-16
where the error occurred

Table 7: CAN message structure description for ID=0x032.

Byte Description Type

1 High cell voltage high byte
Unsigned integer 0-65535, LSB = 1 mV
2 High cell voltage low byte
3 Low cell voltage low byte
Unsigned integer 0-65535, LSB = 1 mV
4 Low cell voltage low byte
5 High cell number Unsigned char 1-16
6 Low cell number Unsigned char 1-16
7 Battery pack min temperature Signed char -127 to 127 LSB = 1° C
8 State of health [%] Unsigned char 0-200 LSB = 0.5 % SOH

CAN message is sent every second with refreshed values.

Short pins 1 and 2 for CAN communication termination.

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BMS Unit Start Test Procedure:

When the Slave unit is turned ON it commences the test procedure. BMS checks if the user tries to uplod a new
firmware by turning on the Power LED. After the timeout Red error LED turns on to signal the system’s test
procedure. The procedure starts by testing balancing switches, BMS address and cells number, temperature
sensor/s detection, self calibration, EEPROM memory parameters, buzzer and internal relay. The test completes in
10 seconds. In case of no Errors red LED turns off and the BMS unit starts working in normal mode.

In case of Address=0 or cell number <4, error 6 informs the user to properly set the DIP switches. BMS has to be
turned off before the pins are changed.
In case if the BMS does not detect any temperature sensors on the bus, error 8 appears.
Error 10 indicates that the self calibration rutine detected error while calibrating due to reference failure.
Error 15 indicates balancing transistor/s failure.

BMS Unit LED Indication:

Power LED (green) is turned on in 2 s intervals, if the BMS is powered. Error LED (red) is turned on in case of system
error. Number of Error LED blinks/sound alarm indicates Error number.

BMS Unit Low Voltage Disable:

If the lowest cell’s voltage drops under MIN Vcell ('C','M','I','N') set value (2.9 V per cell default), the BMS signals
Error 2. If the lowest cell’s voltage drops further under the relay under-voltage threshold ('R','E','L',’V') for more
than set Timer for min cell ('R','E','L',’T') internal relay turns off. This feature prevents switching off the system at
higher load spikes. When the lowest cell’s voltage drops further under the relay under-voltage threshold
('R','E','L',’V') x 0.98 for more than 30 s, BMS goes to sleep.

Cell Voltage Measurement:

Cell voltages are measured every second. The cell measurement algorithm performs several measurements to
digitally filter the influence of 50, 60, 100 and 120 Hz sinus signal. Each cell voltage is measured after the balancing
fuse, in case the fuse blows BMS signals error 10 to notify the user.

BMS Cell Balancing:

Cells are balanced passively by a 4.7 Ω power resistor. Since the balancing resistors dissipate a lot of heat, there
must be an additional temperature measurement inside the enclosure of the BMS unit to prevent overheating the
integrated circuits. If the BMS temperature rises above the set threshold, charging and balancing is stopped. BMS
error 5 is indicated until the temperature drops under the set hysteresis.

Balancing START Voltage:

If errors 2, 4, 5, 8, 10, 12 are not present, highest cell voltage rises above Balancing START voltage and current is >
0.2 A (charging stage) the BMS initiates balancing algorithm. A weighted cell voltage average is determined
including cells’ DC internal resistance. Balancing algorithm calculates the voltage above which the cells are
balanced. The lowest cell voltage is taken into account determining balancing voltage.

Balancing END Voltage:

If errors 2, 4, 5, 8, 10, 12 are not present, the cells above balancing END voltage are balanced regardless the battery
pack current. A special charging-balancing algorithm is programmed. If the highest cell’s voltage rises above the

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middle value between end of charge voltage and maximum cell’s voltage the charger is turned off. BMS measures
the weighted average value of the battery pack and sets this value as balancing voltage END. BMS balances all the
cells that are above this value. When the highest cell is balanced down below this value, the charger is enabled
again. Process is repeated until all the cells are @ end of charge voltage.

Cell Internal DC Resistance Measurement:

Cell internal DC resistance is measured as a ratio of a voltage change and current change in two sequential
measurement cycles. If the absolute current change is above 15 A, cells internal resistance is calculated. Moving
average is used to filter out voltage spikes errors. A time interval current-drop is introduced in the battery pack
charging current to perform the cell internal DC resistance measurement.

Battery Pack Temperature Measurement:

Battery pack temperatures are measured by Dallas DS18B20 digital temperature sensors. Up to eight sensors can
be used in parallel. BMS should be turned off before adding additional sensors. If the temperature sensors wiring
is placed near the power lines a shielded cables should be used.

BMS Current Measurement:

A low-side shunt resistor current measurement is used. A 4-wire Kelvin connection is used to measure the voltage
drop. As short as possible shielded cable should be used to connect the power shunt and BMS. The battery pack
current is measured every second. A high precision ADC is used to filter out the current spikes. The first current
measurement is timed at the beginning of the cell measurement procedure for a proper internal DC resistance
calculation. Shunt connection is shown in Fig. 11.

Figure 11: Shunt resistor connection.

Table 8: Shunt resistor connection.

Pin Signal
1 - Shunt
2 Shield
3 + Shunt

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Voltage-to-current Coefficient:

Different size and resistance shunts can be used, since the voltage-to-current coefficient can be changed in the BMS
Control software as 'I','O','J','A',' ','xxxxx'

Current is calculated by the voltage drop at the shunt resistor. 1 LSB of the 18 bit ADC represents different current
values according to the shunt resistance. The LSB coefficient can be calculated as:

0.05 V V dropx
k LSB  0.01171875   ,
300 A I currentx

where the Vdropx represents the voltage drop on different shunt resistor at current Icurrentx.

ADC has a pre-set gain of 8. With a maximum input voltage difference of 0.256 V.

Battery pack SOC Determination:

SOC is determined by integrating the charge in-to or out of the battery pack. Different Li-ion chemistries may be
selected:

Table 9: Li-ion chemistry designators.

Number Type
1 Li-Po High power
2 Li-Po High capacity
3 Winston/Thunder-Sky/GWL
4 A123
5 Li-NMC

Temperature and power correction coefficient are taken into consideration at the SOC calculation. Li-Po chemistry
algorithms have an additional voltage to SOC regulation loop inside the algorithm. Actual cell capacity is
recalculated by the number of the charging cycles as pointed out in the manufacturer’s datasheet.

When BMS is reconnected to the battery pack, SOC is set to 50 %. SOC is reset to 100 % at the end of charging. It
can be set to desired value by RS-485 communication protocol by 'S','O','C','S',' ','x.xx' instruction (0.0-1.0).

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Chargers Enable Connection:

Charger is controlled by internal Darlington optocoupler. When the charger should be enabled the
optocoupler output transistor is closed. Due to the Darlington output and additional reverse protection
diode there is 0.9 V voltage drop between the transistor’s collector and emitter. Optocoupler can drive a
small external transistor (coil up to 15 mA, 68 V). Connection schematic is shown in Fig. 12.

Figure 12: External relay connection schematics.

Pre-charge Circuit:

Pre-charge circuit is used to fill the input capacitors of the System. When the BMS turns the internal relay, battery
voltage starts to charge the capacitors via 33 Ohm power resistors inside the pre-charge circuit. After 4 s, the
contactor is turned ON. Fig. 13 below shows how to connect the pre-charge circuit in the system.

Figure 13: Pre-charge circuit connection schematics.

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System Error Indication:

System errors are indicated with red error LED by the number of ON blinks, followed by a longer OFF state.
Table 10: BMS error states.
Number of
ERROR BMS OWNER
ON blinks
BMS will try to balance down the
problematic cell/cells to safe voltage
Single or multiple cell level (10 s error hysteresis + single  Wait until the BMS does its
1 voltage is too high (cell over cell voltage hysteresis is applied). job.
voltage switch-off).
Internal relay is opened, charger is
disabled.
BMS will try to charge the battery
(10 s error hysteresis +single cell
Single or multiple cell voltage hysteresis is applied).
voltage is too low (cell
2  Plug in the charger.
under voltage protection Internal relay is opened to disable
switch-off). discharging (if cell’s voltage is below
CLOW for more than TREL), charger is
enabled.
BMS will try to balance the cells
 Wait until the BMS does its
(10 s error hysteresis + 20 mV voltage
job. If the BMS is not able to
Cell voltages differs difference hysteresis).
3 balance the difference in a few
more than set.
hours, contact the service.
Internal relay is closed, charger is
enabled.
Cells temperature or cell inter-
connecting cable temperature in the
Cell temperature is battery pack is/are too high. (20 s  Wait until the pack cools
4 too high (over temperature error hysteresis 2°C hysteresis). down.
switch-off).
Internal relay is opened, charger is
disabled.
Due to extensive cell balancing the
BMS temperature rose over upper
BMS temperature is too limit (10 s error hysteresis + 5 °C  Wait until the BMS cools
5 high (BMS over temperature hysteresis). down.
temperature switch-off).
Internal relay is closed, charger is
disabled.
Number of cells at the back of the
BMS unit was changed from the
Number of cells, address is default manufacturer settings.  Set the proper number of
6
not set properly. cells, address.
Internal relay is opened, charger is
disabled.
If cells are charged at temperatures
lower than operating temperature
The temperature is too low range, cells are aging much faster  Wait until the battery’s
for charging (under than they normally would, so temperature rises to usable
7
temperature charging charging is disabled (2 °C temperature range.
disable). hysteresis).
Internal relay is opened, charger is
disabled.

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Temperature sensor is un-plugged or  Turn-off BMS unit and try to

not working properly (6 s error re-plug the temp. sensor. If
hysteresis). the BMS still signals error 8,
8 Temperature sensor error.
contact the service. The
Internal relay is opened, charger is temperature sensors should
disabled. be replaced.

RS-485 Master-Slave communication

9 Communication error.
only.

Single or multiple cell voltage is close  Turn-off the BMS and check
to zero or out of range, indicating a the cells connection to the
Cell in short circuit or blown fuse, short circuit or measuring BMS and fuses. Restart the
BMS failure (10 s error hysteresis + 10 mV BMS.
10
measurement/calibration voltage difference hysteresis).
error.  If the same error starts to
Internal relay is opened, charger is signal again contact the
disabled. service.

If the main relay should be opened

and current is not zero or positive,
the BMS signals error 11. When the
Main relay is in short error is detected, the BMS tries to un-  Restart the BMS unit. If the
11 circuit. shorten the main relay by turning it same error starts to signal
ON and OFF for three times. again contact the service.

Internal relay is opened, charger is

enabled.

 Turn-off the BMS and check

Current sensor is disconnected or not
the sensor connections, re-
working properly.
Error measuring current. plug the current sensor
12
connector. Turn BMS back ON.
Internal relay is opened, charger is
If the BMS still signals error 12,
disabled.
contact the service.

Wrong cell chemistry In some application the chemistry  Use PC Control Software to set
13
selected. pre-set is compulsory. proper cell chemistry.

EMC interference can change the

data in the EEPROM memory. When
the BMS is switched on all the data is
checked. If corrupted data is found,
 Use PC Control Software to
14 EEPOM data corruption BMS sets its values to default and
reset the parameters.
signals error 14.

Internal relay is opened, charger is

disabled.

Single or multiple transistors for

balancing failure detection  Restart the BMS unit. If the
15 Balancing transistors failure same error starts to signal
Internal relay is opened, charger is again contact the service.
disabled.

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BATTERY MANAGEMENT SYSTEM 4-16S - preliminary

BMS Unit Dimensions:

Figure 14: BMS dimensions.

BMS unit can be supplied without the enclosure, if an application is weight or space limited. The dimensions of the
BMS without the enclosure are 160 mm x 100 mm x 27 mm. Sufficient contact surface for cooling the balancing
resistors should be provided (aluminum recommended).

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