Data Sheet

ManualsBrandsRoboteQ ManualsMisc. AccessoriesRoboteq 40V, 100 Amps Management System for 6 to 10 Cells Lithium Ion Batteries

40/60V, 100 Amps

Management

System for Lithium

Ion Batteries

www.roboteq.com 1

BMS10x0

RoboteQ’s BMS10x0 is a battery management and

protection system for building cost-effective, ultra-efﬁcient

and high current power sources using Lithium battery cells.

The BMS connects to an array of battery cells at one end,

and to a user load at the other. Available in a 40V and 60V

versions, it is optimized for 6-cell to 15-cell battery packs.

Precision voltage sensors monitor the voltage of every

cell. Precise, built-in current sensors keep track of the

current flowing in and out of the pack, load and charge,

maintaining an accurate image of the battery’s State

of Charge and State of Health. Balancing takes places

during battery charge.

The BMS includes a separate connector for battery

charging. The charger’s voltage and current are monitored

and an internal switch will automatically stop the charging

when the battery is full or if a fault condition occurs. This

allows the load to be controlled separately.

The BMS10x0 supports regenerative loads, such as motor

controllers in electric vehicles or mobile robot application.

A built-in, bidirectional, high power solid-state switch will

disconnect the regenerative current source from the cells

in case the later are fully charged and cannot accept more

current. A secondary, built-in high power switch will connect

the auxiliary power port to an optional external brake

resistor, in case of braking while the batteries are full.

Charge/discharge current, voltages, internal and battery

temperatures are continuously monitored. The internal

switch will disconnect the load in case of overload, over or

under voltage, or over temperature. The BMS will act as

a programmable circuit breaker in case of a short circuit

or continuous overload. The BMS is highly conﬁgurable:

temperature limits, voltage thresholds, and current overload

levels can all be set and changed using a provided PC Utility.

The utility can also be used to view and chart in real time

the BMS internal parameters while the system is running.

This provides the user with useful data during system

development and tuning.

State of Charge, voltage, current, temperature and other

vital parameters are available on a front connector using

selectable communication methods. This includes USB,

CANbus, RS485 and PWM, or wirelessly via an optional

Bluetooth module. A push button and LEDs are also

provided for quick visualization of battery charge level and

system status.

Applications

• Personal mobility system

• Mobile robots, ROVs and AGVs

• Electric vehicles, scooters, e-bikes

• Electric boats

• Electric forklifts

• Storage for wind/solar generators

• Telecom tower backup

Features List

• Conﬁgurable for all Lithium battery types

• Can manage 6 to 10 cells (40V) or 11 to 15 cells (60V)

versions

Summary of content (26 pages)

PAGE 1
BMS10x0 40/60V, 100 Amps Management System for Lithium Ion Batteries RoboteQ’s BMS10x0 is a battery management and protection system for building cost-effective, ultra-efficient and high current power sources using Lithium battery cells. The BMS connects to an array of battery cells at one end, and to a user load at the other. Available in a 40V and 60V versions, it is optimized for 6-cell to 15-cell battery packs. Precision voltage sensors monitor the voltage of every cell.
PAGE 2
BMS10x0 • • • • • • • • • • • • • Centralized design. No cell boards – All BMS electronics contained within the unit 100A max current to load. 200A peak Automatic, intelligent cell voltage balancing during charge Advanced State of Charge monitoring and management for optimal battery life State of Health monitoring and reporting Built-in bi-directional current sensors for monitoring flow from/to battery pack, load and charger. Built in temperature sensor.
PAGE 3
BMS10x0 System Architecture The BMS10x0 uses an ultra-low power consumption, 32-bit Processor to monitor voltages, amperage and temperature (shown as V, A and T, as seen in the diagram in Figure 1, below) to control the internal balancing array and solid-state switches. The balancing array is designed to extract charge from multiple higher voltage cells during the charge cycle and smoothing the uneven stresses on the battery.
PAGE 4
BMS10x0 User Connections The BMS electronics board is mounted on top of an aluminum cooling plate and under an ABS plastic cover. Figure 2, below, shows the position of its connectors. Temp Cell Balancing Pack Load LEDs Charge+ Brake+ BrakeCharge- CAN RS485 PWM DOUT USB Button FIGURE 2. BMS Board Connectors Optional Brake Resistor or other high current accessory LOAD BrakeLoad e.g.
PAGE 5
BMS10x0 Load+/Load-Power Connectors to Load Two high current screw terminals are used to connect to the user load. A 100A switch built into the BMS will isolate these connections from the battery in case of over/under voltage, short circuit, over current, over temperature or other unsafe conditions. Current is allowed to flow back into the battery from regenerative loads if operating in the safe operation area.
PAGE 6
BMS10x0 The CAN and RS485 pins can be connected to a twisted pair cable. The BMS can be configured to operate in either of these communication modes. Two Open Drain Digital Outputs are availalbe for connecting low-power accessories. The BMS10x0 also implements a RoboteQ proprietary single wire PWM communication protocol for exchanging the most vital battery information with RoboteQ’s motor controllers. When using the PWM mode, external ground and 5V supply must be connected to the GND and VCC pins.
PAGE 7
BMS10x0 TABLE 2. Signals Pin BMS1040 BMS1060 Description 1 TC1P TC1P Thermistor 1 terminals 4 TC1N TC1N 2 TC2P TC2P 5 TC2N TC2N 3 NC TC33P 6 NC TC3N Thermistor 2 terminals Thermistor 3 terminals Cell Connections In order for the system to successfully measure, monitor and balance each individual cell in the battery pack, the cells must be properly connected to the BMS.
PAGE 8
BMS10x0 B0 B3 B4 B7 B8 NC NC NC B0 B3 B4 B7 B8 NC NC NC B1 B2 B5 B6 B9 B1 B2 B5 B6 B9 B9 NC NC NC NC 10 Cells B0 B3 9 Cells B6 B7 NC NC NC B1 B2 B4 B5 B8 NC NC B0 B3 B6 NC NC NC B1 B2 B4 B5 B7 NC NC 8 Cells 7 Cells B5 NC NC NC B1 B2 B3 B4 B6 NC NC B0 6 Cells FIGURE 7.
PAGE 9
BMS10x0 Absolute Maximum Ratings TABLE 4. Model VI Input voltage Bn+1 - Bn, with n = 0…10 BMS1040 Bn+1 - Bn, with n = 0…15 BMS1060 B5 - B0, B10 - B6 BMS1040 B5 - B0, B10 - B6, B15 - B11 BMS1060 TSnP - TSnN, with n = 1, 2 BMS1040 TSnP - TSnN, with n = 1, 2, 3 BMS1060 Pack+ - PackVI & VO Input and Output voltage Load+ - LoadAux+ - Aux- (Break Resistor) Typ Max 7.2 V 36 V -0.3 V 3.
PAGE 10
BMS10x0 Considering balancing, the precision can be adjusted, minimizing cell voltage differences. Take care when altering the 10 mV default value because very low precision values may fail to satisfy the end of balancing condition. The BMS has by default the auxiliary output switch function set to Disabled. This means that the state of the switch does not automatically change and script may be written to control it.
PAGE 11
BMS10x0 Counting is considered the dominant indicator. When at least one of the cells reaches near the minimum or maximum cut off thresholds, where the voltage change is significant depending on the energy stored in the battery, this cell’s voltage becomes the dominant indicator for the battery’s SoC. Observing the SoC allows the user to know when the pack will be isolated from the load (0% SoC) and when it will be isolated from the charger (100% SoC).
PAGE 12
BMS10x0 conditions under which the charging was paused, different rest times will be set. Balancing will still be applied as long as the BMS recognizes a charger to be connected. For example, if one of the cells hits the overvoltage threshold while still charging with a fast speed (current close to maximum nominal current during charging), the system will let the battery rest for a longer time than if it were charging with a slow speed, allowing balancing to operate for more time before charging again.
PAGE 13
BMS10x0 The BK+ terminal is connected internally to the Load+ terminal. The BK- goes to a MOSFET transistor which will internally connect to the Load- terminal when the resistor is enabled. The figures below show the current flow under the various load and regeneration conditions FIGURE 11. Current Flow from Pack to Load FIGURE 12. Regenerating Energy from Motor FIGURE 13. Excess Energy Out to Brake Resistor By default, the Brake output is deactivated and may be controlled by user command or script.
PAGE 14
BMS10x0 during charging in a significantly cold environment or makes charge/discharge safer in hot environments. Fan or Heater FIGURE 14. Configuration for Guaranteed Temperature Balance State of Health The State of Health in a battery is a vague measurement to infer its wellbeing. In other words, there is no exact way to specify how many years or days the battery has left until one of its cells fail.
PAGE 15
BMS10x0 capacity. If the battery is then charged back to 100% and is discharged to 90%, we would have a total of 20% the nominal capacity delivered. When this process is repeated 10 times, the total energy delivered would be equal to 100% the nominal capacity, thus one full battery cycle.
PAGE 16
BMS10x0 pack. The temperature thresholds are configurable so, as long as the values set define a safe operating area, the Circuit Breaker will do the job. In the BMS1040, two external sensors are supported, whereas the BMS1060 has three. The temperature sensors should be NTC thermistors of 10k resistance. A sensor example is NTCALUG03A103G by Vishay, digikey number BC2385-ND, or any similar sensor. Dout1 & Dout2 The BMS provides two general purpose digital outputs suitable for any application.
PAGE 17
BMS10x0 If an external power source is utilized, users must make sure that the external GND is connected to the negative terminal of the pack. TABLE 7.
PAGE 18
BMS10x0 TABLE 9. System State Bit 7 Bit 6 Bit 5 Bit 4 - NOCONNECT FAIL LOCK Bit 3 Bit 2 Bit 1 Bit 0 RGN DCH BALANCE CH TABLE 10. Command Description Examples ?BMC Arguments Read BMS SoC ?BMC ?BMF Read BMS Status Flags ?BMF ?BMS Read BMS Operational State ?BMS USB USB is the most reliable method for communication with the BMS. When users connect the system to a PC, the PC Utilitywill automatically recognize the BMS model. At that time all internal variables can be accessed.
PAGE 19
BMS10x0 RoboCAN is a RoboteQ proprietary meshed networking protocol allowing multiple RoboteQ devices to operate together as a single system. This protocol is extremely simple and lean, yet practically limitless in its abilities. It is the preferred protocol to use by users who want to make multiple controllers work together with the minimal effort. RS485 RS485 is implemented for a half duplex communication user configurable baud rate.
PAGE 20
BMS10x0 TABLE 12. Command Arguments Description Examples ^DMOD xx Modbus Mode Set Modbus Mode ^DMOD 4 xx 0: Off 3: RS232 ASCII 4: RS485 ASCII ^MNOD xx Node ID Set Modbus Node ID ^MNOD 1 Bluetooth BLE RoboteQ offers the option of an embedded low energy Bluetooth module in the BMS10x0. With Bluetooth, all variables are accessible using our Smartphone application which is a simplified version of the PC Utility.
PAGE 21
BMS10x0 FIGURE 16. Capacity LED Display Status LED The flashing pattern provides operating and exception status information. The Status LED is indicated by a GREEN and RED LED. The first half of the duty cycle includes operating information using the GREEN light. The second half indicates hazardous conditions detected in regards to the pack or the board. FIGURE 17. Status LED Display Additional status information may be obtained by monitoring the controller with the PC Utility. www.roboteq.
PAGE 22
BMS10x0 Communication LED The communication LED gives information about CANbus and USB communication status. FIGURE 18. Communication LED Display Mechanical Dimensions 0.25" 0.98" (6.3 mm) (25mm) 0.3" (7.6 mm) 0.16" (4.0mm) FIGURE 19. BMS10x0 Side Dimensions 4.45" ( 113.0mm) 5.10" ( 129.7mm) 5.50" ( 139 .7mm) 0.20" (5.0mm) 0.19" (5.0mm) FIGURE 20. BMS10x0 Top Dimensions 22 www.roboteq.com Version 1.
PAGE 23
BMS10x0 Appendix BMS Command Reference Summary The BMS10x0 is highly configurable and accepts a number of commands via the USB port and optional Bluetooth interfaces. This is useful for reading operational data, setting configuration sending commands and performing maintenance. The commands are categorized in four groups depending on their functionality and can be found in Tables 13-16, below.
PAGE 24
BMS10x0 Real Time Commands A Real Time Command is used for instructing the BMS10x0 to perform an action. This type of command is executed by typing the “!” character before the name of the command. In Table 14, below, examples are shown for each command. TABLE 14.
PAGE 25
BMS10x0 Command Arguments Description Examples DINL Input Index, Active Level Digital Input Active Level (If inverted) ^DINL 2 1 (Din 2 inverted) DOA Output Index, Trigger Digital Output Active When ^DOA 1 0 0: Never 1: Over Temp 2: Over Volt 3: Overload/Short DOL Output Index, Level Digital Output Level Logic ^DOL 1 1 ATRIG Channel, Amps Amp Trigger Level ^ATRIG 1 150 ATGD Channel, Delay ms Amp Trigger Action Delay ^ATGD 1 500 MicroBasic Auto Start ^BRUN 1 BRUN CEN CAN Mode Opti
PAGE 26
BMS10x0 Command Arguments Description Examples CCHT Chemistry Option Cell Chemistry Type ^CCHT 1 0: LiPo 1: LiFePO4 2: Custom BPRC Value mV Balance Precision ^BPRC 10 ISRG Aux Output Option Aux Output Function ^ISRG 0 0: Disable 1: Brake Resistor 2: Fan 3: Heater CRES Value in uOhm Cell Internal Resistance ^CRES 1 (0.