ACTIVE BATTERY

MANAGEMENT SYSTEM
REC ACTIVE BMS

Novi trg 9, 6230 Postojna, Slovenia

mail: info@rec-bms.com; www.rec-bms.com
 Novi trg 9, 6230 Postojna, Slovenia
mail: info@rec-bms.com; www.rec-bms.com

Features:
- robust and small design
- 4 cells connections
- up to 8 temperature sensors
- 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
- under temperature charging protection
- active cell balancing up to 2.5 A DC per cell
- shunt current measurement (resolution 19.5 mA @ ± 500 A)
- galvanically isolated user defined multi-purpose digital output
- programmable relay (normally open or normally closed)
- galvanically isolated RS-485 communication protocol
- CAN communication (customizable)
- error LED + buzzer indicator
- 11 ERROR log on the device FIFO
- PC user interface for changing the settings and data-logging (optional accessory)
- hibernate switch
- one IP65 protected connector for all connections
- ISO16315, ISO10133, EN61558-1, EN61558-2 and EN50498 compliant

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INDEX:
General Description of the BMS Unit: ....................................................................................... 3
Hardware Parameters: ............................................................................................................... 4
ABMS Power Supply:.................................................................................................................. 4
Default Software Parameters: ................................................................................................... 5
System Overview: ...................................................................................................................... 6
BMS Unit Connections: .............................................................................................................. 7
Setting the RS-485 Address:....................................................................................................... 8
BMS Unit Connector: ................................................................................................................. 8
BMS Unit Connector, Cells Part: ................................................................................................ 8
BMS Unit Power Supply: ............................................................................................................ 9
BMS Unit Connection Instructions:............................................................................................ 9
RS-485 Communication Protocol: .............................................................................................. 9
CAN Communication (Hardware and Software on demand): ................................................. 14
BMS Unit Start Procedure: ....................................................................................................... 17
BMS Unit LED Indication: ......................................................................................................... 17
Cell Voltage Measurement: ..................................................................................................... 17
BMS Cell Balancing:.................................................................................................................. 17
Balancing START Voltage: ........................................................................................................ 17
Balancing END Voltage:............................................................................................................ 17
Cell Internal DC Resistance Measurement: ............................................................................. 18
Battery Pack Temperature Measurement: .............................................................................. 18
BMS Current Measurement: .................................................................................................... 18
Voltage-to-current Coefficient:................................................................................................ 19
Battery Pack SOC Determination: ............................................................................................ 19
Battery Pack’s Charging Algorithm: ......................................................................................... 20
Battery Pack’s Discharging Algorithm: ..................................................................................... 20
ABMS Outputs Settings: ........................................................................................................... 21
Digital Outputs: ........................................................................................................................ 22
Pre-charge Connection: ........................................................................................................... 23
Parallel Cells Connection: ........................................................................................................ 24
System Error Indication: .......................................................................................................... 25
BMS Unit Dimensions: ............................................................................................................. 28

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General Description of the BMS Unit:

The Battery management system (BMS) 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 4.16 - 4.20 V or 3.5 – 3.7 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 the 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 to the whole pack or from the whole pack to a lower voltage cells –
active balancing. The device’s temperature is measured to protect the circuit from over-heating due
to unexpected failure. Battery pack’s temperature is monitored by Dallas DS18B20 digital temperature
sensor/s. Current is measured by a 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 a new battery pack. The BMS default HW parameters are
listed in Table 1.

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Hardware Parameters:
Table 1: ABMS hardware parameters.
Parameter Value Unit
BMS maximum pack voltage 16.8 V
BMS minimum pack voltage 10 V
BMS minimum pack voltage (HW UVP) 10.85 V
BMS maximum cell voltage 5.0 V
Shunt common mode input voltage interval (Shunt+, Shunt -) V
-0.3 to 3.0
to the Cell 1 negative
Shunt sensor max differential input voltage interval (Shunt+ -0.25 to 0.25 V
to Shunt -)
Cell voltage accuracy +/-3 mV
Pack voltage accuracy +/-6 mV
DC current accuracy +/- 1 LSB
Temperature measuring accuracy +/-0.5 °C
DC Current sample rate 3 Hz
Cell voltage sample rate 0.8 Hz
Cell balancing current 2.5 A
Maximum operating temperature* 70 °C
Minimum operating temperature* -20 °C
Maximum storage temperature* 30 °C
Minimum storage temperature* 0 °C
Maximum humidity* 75 %
max DC current relay @ 60 V DC 0.7 A
max AC current relay @ 230 V AC 2 A
max DC current @ optocoupler 15 mA
max DC voltage@ optocoupler 62.5 V
BMS unit disable power supply <1 mW
BMS unit stand-by power supply < 60 mW
BMS unit cell balance fuse rating 3.15 slow A
internal relay fuse 3.15 slow A
dimensions (w × l × h) 105 x 135 x 44 mm
IP protection IP65
HW version 2.1 n.a.
*defined by internal RTC back-up 2032 battery

ABMS Power Supply:

Table 2: BMS power supply.
Battery voltage[V] Supply current [mA]*
11 25.6
12 23.3
13 21.4
14 19.8
15 18.3
16 17.1
*Normal mode (only main relay and charge optocoupler are active)

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Default Software Parameters:

Table 3: Default BMS parameter settings*.
Parameter Value Unit
chemistry 3 (LiFePO4) n.a.
capacity 200 Ah
balance start voltage 3.45 V
balance end voltage 3.58 V
maximum diverted current per cell up to 2.5 (5 pp) A
cell over-voltage switch-off per cell 3.85 V
over-voltage switch-off hysteresis per cell 0.25 V
cell end of charge voltage 3.58 V
End of charge hysteresis per cell 0.25 V
SOC end of charge hysteresis 5 %
cell-under voltage protection switch-off per cell 2.8 V
under voltage protection switch-off hysteresis per cell 0.1 V
cell under voltage discharge protection (CAN communication
2.9 V
only)
cells max difference 0.25 V
BMS over-temperature switch-off 55 °C
BMS over-temperature switch-off hysteresis 5 °C
cell over temperature switch-off 55 °C
cell over temperature switch-off hysteresis 2 °C
under temperature charging disable -10 °C
under temperature charging disable hysteresis 2 °C
voltage to current coefficient 0.01171875 A/bit
current measurement zero offset 0.0 A
maximum charging/discharging current per inverter/charger
120/250 A
device (CAN communication only)
number of inverter/charger devices (CAN communication only) 1 n.a.
charge coefficient (CAN communication only) 0.6 n.a.
discharge coefficient (CAN communication only) 1.5 n.a.
charge optocoupler 1 voltage level 3.58 V
charge optocoupler 1 voltage level hysteresis -0.2 V
optocoupler 2 voltage level 2.9 V
optocoupler 2 voltage level hysteresis 0.2 V
CAN communication frequency 250 kbit/s
SW version 5.0 n.a.
*all parameters values may be changed with PC user interface.

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System Overview:

Figure 1: System overview.

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BMS Unit Connections:

Figure 2: BMS unit front panel function overview.

Table 4: BMS unit male socket connections.

Cable Wiring
Connection Designator Description
Label
1 Charge relay 1 Normally closed
2 Charge relay 1 Fused input RELAY CH F
3 Discharge relay 2 Normally closed
4 Discharge relay 2 Normally open RELAY DCH NO
5 Discharge relay 2 Fused input RELAY DCH F
6 Hibernate switch signal -
7 Hibernate switch ground -
8 Cell 4 positive + Analog signal CELL 4+
9 Cell 3 positive + Analog signal CELL 3+
10 Cell 2 positive + Analog signal CELL 2+
11 Cell 1 positive + Analog signal CELL 1+
12 Cell 1 negative - Analog signal CELL 1-
13 Charge relay 1 Normally open RELAY CH NO
14 Charge optocoupler 1 – user defined collector - OPTO CH C
Charge optocoupler 1 – user defined emitter - OPTO CH E
15 (darlington + reverse protection diode +
polyfuse)
16 Optocoupler 2 – user defined collector - OPTO DCH C
Optocoupler 2 – user defined emitter - OPTO DCH E
17 (darlington + reverse protection diode +
polyfuse)
CAN Vcc 4.6 V output, max 10 CAN
18
mA
19 CANL - CAN
20 RS485 Vcc - RS485
21 RS485 A - RS485
22 RS485 ground - RS485
23 RS485 B - RS485
24 Shunt- -
25 Shunt+ -
26 Shunt shield -
27 Dallas 18B20 temp. sensor GND + shield
28 Dallas 18B20 temp. sensor +5V
29 Dallas 18B20 temp. sensor 1-wire digital signal
30 CANH - CAN

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CAN ground GND potential of the CAN

31
battery pack
32 - -
Address pin 3 Normally 0, connect to
33
pin 35 to change to 1
Address pin 2 Normally 0, connect to
34
pin 35 to change to 1
Address pin ground Fused ground for
35
Address pins

Setting the RS-485 Address:

Address of the BMS unit is selected via the Address pins. Factory address is 2. Formula for changing
the address is:

ActiveBMS 𝐴𝐷𝐷𝑅𝐸𝑆𝑆 = 22 ∗ ̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅

𝐴𝑑𝑑𝑟𝑒𝑠𝑠 𝑝𝑖𝑛 3 + 21 ∗ ̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅̅
𝐴𝑑𝑑𝑟𝑒𝑠𝑠 𝑝𝑖𝑛 2 + 20

! If multiple BMS units are used distinguished addresses should be set to avoid data collision on the
RS-485 communication bus!

BMS Unit Connector:

Before starting the assembly please go to website:

http://www.te.com/catalog/pn/en/776164-1?RQPN=776164-1

…and read the connector assembly datasheet:

AMPSEAL Automotive Plug Connector and Header Assembly in Application Specification and
AMPSEAL Automotive Plug Assemblies 776268… in Instruction Sheet (U. S.).

BMS Unit Connector, Cells Part:

Connect each cell to the BMS unit cell connector plug. Use silicon wires with cross section of 0.5 –
1.4 mm2 (20-16 AWG). ! Before inserting the connector check the voltage and polarity of each
connection!

Figure 3: Battery pack connection plug – front side.

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BMS Unit Power Supply:

BMS unit is always supplied from the 4-th cell connection.

BMS Unit Connection Instructions:

Connect all necessary connections to the BMS connector first, check the polarities and then plug the
female connector into the BMS. When the system components are plugged in, the enable switch can
be turned ON and the unit starts the test procedure. Connection instruction video link:
http://www.rec-bms.com/ABMS.html

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

RS-485 Communication Protocol:

Figure 4: RS-485 DB9 connector front view.

Table 5: RS-485 DB9 connector pin designator.

pin designator
1 -
2 AGND
3 B
4 A
5 -
6 +5V to AGND
7 -
8 -
9 -

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. Default RS-485 address is 2.
Unlock password: Serial without the first minus e.g. 1A-XXXX.

Messages are comprised as follows:

STX, DA, SA, N, INSTRUCTION- 4 bytes, 16-bit CRC, ETX
 STX start transmission <0x55> (always)
 DA - destination address <0x01> to <0x10> (set as 6)
 SA - sender address <0x00> (always 0)
 N – number of sent bytes

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 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 - big endian, for the whole message except STX in ETX -
https://www.lammertbies.nl/comm/info/crc-calculation.html
 ETX - end transmission <0xAA> (always)

Dataflow:
 Bit rate: 56k
 Data bits: 8
 Stop bits: 1
 Parity: None
 Mode: Asynchronous
 Little endian format when an array is sent

Table 6: RS-485 instruction set.

SETTING
INSTRUCTION DESCRIPTION BMS ANSWER
INTERVAL
Answer “REC - BATTERY
*IDN? Identification Read only
MANAGEMENT SYSTEM”
ARRAYS INSTRUCTIONS
First answer is 28 – how many
byte data will be sent and then
data message follows as 7 float
values:
LCD1 [0] = min cell voltage,
LCD1 [1] = max cell voltage,
LCD1? Main data LCD1 [2] = current, Read only
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%
First answer is 8 – how many
byte data will be sent and then
data message follows as 8 byte
values:
LCD3 [0] = min cell BMS address,
LCD3 [1] = min cell number,
LCD3 [2] = max cell BMS address,
LCD3? Main data Read only
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 connected,
CELL? Cell voltages Read only
then it sends the values of the
cells in float format

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BMS first responds with how

many BMS units are connected
PTEM? Cell temperatures then it sends the values of the Read only
temperature sensors in float
format
BMS first responds with how
Cells internal DC many BMS units are connected
RINT? Read only
resistance then it sends the values in float
format

BMS first responds with value 1,

then it sends the values of the
BTEM? BMS temperature Read only
BMS temperature sensor in float
format
First answer is 4 – how many
byte data will be sent and then
data message follows as 4 byte
values:
ERRO [0] = 0 – no error, 1 – error
Error number description
ERRO? ERRO [1] = BMS unit Read only
array
ERRO [2] = error number (1-16)
and
ERRO [3] = number of the cell,
temp. sensor where the error
occurred
CELL SETTINGS INSTRUCTIONS
BVOL? or
Balance end voltage Returns float voltage [V] 2.5 to 4.30 V
BVOL x.xx
BMIN? or
Balancing start voltage Returns float voltage [V] 2.5 to 4.30 V
BMIN x.xxx
CMAX? or Cell over-voltage switch-
Returns float voltage [V] 2.0 to 4.30 V
CMAX x.xx off
MAXH? or Over- voltage switch-off
Returns float voltage [V] 0.005 to 2.0 V
MAXH x.xx hysteresis per cell
CMIN? or Cell-under voltage
Returns float voltage [V] 1.8 to 4.00 V
CMIN x.xxx protection switch-off
MINH? or Over- voltage switch-off
Returns float voltage [V] 0.005 to 2.0 V
MIN x.xxx hysteresis per cell
CHAR? Or Cell End of charging
Returns float voltage [V] 2.0 to 4.30 V
CHAR x.xxx voltage
CHIS? Or End of charging voltage
Returns float voltage [V] 0.005 to 2.0 V
CHIS x.xxx hysteresis per cell
RAZL? or
Cells max difference Returns float voltage [V] 0.005 to 1.0 V
RAZL x.xx
TEMPERATURE SETTINGS INSTRUCTIONS
TMAX? or cell over temperature
Returns float temperature [°C] -20 to 65 °C
TMAX x.xxx switch-off
TMIN? or Under-temperature
Returns float temperature [°C] -30 to 65 °C
TMIN x.xxx charging disable
TBAL? or BMS over-temperature
Returns float temperature [°C] -20 to 65 °C
TBAL x.xxx switch-off
BMTH? or BMS over temperature
Returns float temperature [°C] 1 to 30 °C
BMTH x.xxx switch-off hysteresis

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CURRENT SETTINGS INSTRUCTIONS

IOFF? or Current measurement
Returns float current [A] -2.0 to 2.0 A
IOFF x.xxx zero offset
IOJA? Or Voltage to current
Returns float value 0.0005 to 0.5
IOJA x.xxx coefficient
BATTERY PACK SETTINGS INSTRUCTIONS
CYCL? or Number of full battery
Returns integer value 0 to 8000
CYCL xx pack cycles
CAPA? or
Battery pack capacity Returns float capacity [Ah] 1.0 to 3000.0 Ah
CAPA x.xxx
CHEM? or
Li-ion chemistry Returns unsigned char value 1 to 5
CHEM xx
SOC SETTINGS INSTRUCTIONS
SOCH? or SOC end of charge
Returns float value 0 – 1.0 0.005 to 0.99
SOCH x.xxx hysteresis
SOCS? or
SOC manual re-set Returns float value 0 – 1.0 0.01 to 1.00
SOCS x.xx
CHARGING/DISCHARGING CAN COMMUNICATION SETTINGS INSTRUCTIONS
CHAC? or CHAC Charge coefficient (0-5C) Returns float value 0-5.0 (default 0.01 to 5.0
x.xxx 0.6)
DCHC? or Discharge coefficient (0- Returns float value 0-5.0 (default 0.01 to 5.0
DCHCx.xxx 5C) 1.5)
Number of inverter Returns unsigned char value
STRN? or STRN xx 1 to 6
devices on the bus (default 1)
MAXC? or Maximum charge current
Returns float current [A] 5.0 to 280.0 A
MAXC x.xxx per inverter device
Maximum discharge
MAXD? or
current per inverter Returns float current [A] 5.0 to 400.0 A
MAXD x.xxx
device
CLOW? or cell under-voltage
Returns float voltage [V] 1.8 to 4.20 V
CLOW x.xxx discharge protection
CANF? or Returns unsigned integer value 100, 125, 200, 250,
CAN Frequency
CANF xx 100, 125, 200, 250, 500 or 1000 500 or 1000 kbit/s
Resets charge and discharge Wh
WHCL 1 Wh counter reset n.a.
counter
ERROR LOG INSTRUCTIONS
Returns error log data
(FIFO register of the last
12 errors). Returns “xx,zz;
By sending the same hh:mm:ss;dd.mm.yyyy”
ERRL? instruction the data xx-error number Read only
pointer shifts from the zz-number of the cell/temp
last error entry to the sensor
first error entry, then it
starts all over again
Returns unsigned char value. To
ERLD? or
Error log delete reset Error log set ERLD to 1 and 0, 1
ERLD 1
restart the ABMS.
VMAX? or Number of exceeded
Returns integer value 0 to 8000
VMAX xx values of CMAX
VMIN? or Number of exceeded
Returns integer value 0 to 8000
VMIN xx values of CMIN
OUTPUTS SETTINGS INSTRUCTIONS

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OP1L? or Optocoupler 1 voltage

Returns float voltage [V] 1.8 to 4.30 V
OP1L x.xxx level
Optocoupler 1 voltage -2.0 to 2.0 V
OP1H? or level hysteresis Returns float voltage [V] 0.0 V enables
OP1H x.xxx
charge control
OP2L? or Optocoupler 2 voltage
Returns float voltage [V] 1.8 to 4.30 V
OP2L x.xxx level
Optocoupler 2 voltage -2.0 to 2.0 V
OP2H? or
level hysteresis Returns float voltage [V] 0.0 V disables
OP2H x.xxx
output
ABMS SETTINGS INSTRUCTIONS
CAL1? or
Cell 1 calibration offset Returns float voltage [V] -0.030 to 0.030 V
CAL1 x.xxx
CAL2? or
Cell 2 calibration offset Returns float voltage [V] -0.030 to 0.030 V
CAL2 x.xxx
CAL3? or
Cell 3 calibration offset Returns float voltage [V] -0.030 to 0.030 V
CAL3 x.xxx
CAL4? or
Cell 4 calibration offset Returns float voltage [V] -0.030 to 0.030 V
CAL4 x.xxx
SERI? or
ABMS Serial number Returns unsigned integer 0 - 9999 1-9999
SERI xx
SWVR? ABMS software version Returns string Read only
HWVR? ABMS hardware version Returns string Read only
TIME? or ABMS RTC Time Returns/accepts “hh:mm:ss”
-
TIME xx:xx:xx format*
DATE? or ABMS RTC DATE Returns/accepts “dd.mm.yyy”
-
DATE xx.xx.xxxx format*
Which cell is being Returns cell number
WCIB? Read only
balanced
*BMS->Time/Date pop-up window can be used to set both values at once.

Parameter accepted and changed value is responded with 'SET' answer.

Example: proper byte message for 'LCD1?' instruction for BMS address 2 is:

<0x55><0x02><0x00><0x05><0x4C><0x43><0x44><0x31><0x3F><0x53><0x90><0xAA>

RS-485 message is 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.
Little endian format is used for all sent float or integer values. In case of single data is sent ASCII
characters are used e.g. -1.2351e2
Custom made instructions can be added to the list to log or set the parameters that control the BMS
algorithm or its outputs.

Video instruction link for settings change: https://www.youtube.com/watch?v=sRr_5vBKupw

Video instruction link for firmware update: https://www.youtube.com/watch?v=2di-Dpv2Nf8

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CAN Communication (Hardware and Software on demand):

Figure 5: CAN female DB9 connector front view.

Table 7: CAN DB9 connector pin designator.

pin designator
1
2 CANL + TERMINATION*
3 GND
4
5 -
6
7 CANH + TERMINATION*
8 -
9 + 4.6V
* Termination plug with 120 R

No termination is used inside ABMS connector. Terminate pins 2 and 7 with 120 Ohm resistor to
prevent ABMS to reset. Additional RJ45 connector with 120 Ohms across CANL and CANH should be
used for the end device on the CAN bus for end termination. When the CAN frequency is changed via
RS-485 instruction, BMS has to be reset to enable the new setting.

Pre-programmed CAN communication

11-bit TX identifiers: 0x031, 0x032, 0x033, 0x034, 0x035, 0x036, 0x037.

Table 8: CAN message 0x031 structure description (charging/discharging restrictions).

Byte Description Type Property
1 Max charge voltage low byte
Unsigned integer LSB = 0.1 V
2 Max charge voltage high byte
3 Max charging current low byte
Signed integer LSB = 0.1 A
4 Max charging current high byte
5 Max charging current low byte
Signed integer LSB = 0.1 A
6 Max charging current high byte
7 Max discharge voltage low byte
Unsigned integer LSB = 0.1 V
8 Max discharge voltage high byte

Table 9: CAN message 0x032 structure description.

Byte Description Type Property
1 Battery voltage low byte
unsigned integer LSB = 1 mV
2 Battery voltage high byte
3 Battery current low byte
Signed integer LSB = 0.02 A
4 Battery current high byte
5 SOC Unsigned char LSB = 1 %
6 SOH Unsigned char LSB = 1 %
Bit 1: Charge relay 1
Bit 2: Discharge relay 2
7 Outputs status Unsigned char
Bit 3: Charge optocoupler 1
Bit 4: Optocoupler 2

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Table 10: CAN message 0x033 structure description (charging/discharging restrictions).

Byte Description Type Property
1 Cell 1 voltage low byte
Unsigned integer LSB = 1 mV
2 Cell 1 voltage high byte
3 Cell 2 voltage low byte
Unsigned integer LSB = 1 mV
4 Cell 2 voltage high byte
5 Cell 3 voltage low byte
Unsigned integer LSB = 1 mV
6 Cell 3 voltage high byte
7 Cell 4 voltage low byte
Unsigned integer LSB = 1 mV
8 Cell 4 voltage high byte

Table 11: CAN message 0x034 structure description.

Byte Description Type Property
1 MAX temperature Signed char LSB = 1° C
2 MIN temperature Signed char LSB = 1° C
3 Capacity low byte
Unsigned integer LSB = 1 Ah
4 Capacity high byte
5 Remaining capacity high byte
Unsigned integer LSB = 1 Ah
6 Remaining capacity low byte
7 Error number Unsigned char 0 - 16
8 Error number element Unsigned char 0-4

Table 12: CAN message 0x035 saved Wh structure description.

Byte Description Type Property
1 Charged Wh first byte
2 Charged Wh second byte
Unsigned long LSB = 100 Wh
3 Charged Wh third byte
4 Charged Wh forth byte
5 Discharged Wh first byte
6 Discharged Wh second byte
Unsigned long LSB = 100 Wh
7 Discharged Wh third byte
8 Discharged Wh forth byte

Table 13: CAN message 0x036 HW and SW structure description.

Byte Description Type Property
1 BMS HW number main version
2 ASCII ‘.’ ASCII 2.1
3 BMS HW number sub version
4 BMS SW number main version
5 ASCII ‘.’ ASCII 5.0
6 BMS SW number sub version

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Table 14: CAN message 0x037 BMS serial number structure description.
Byte Description Type Property
1 ASCII ‘1’ 1
2 ASCII ‘A’ A
3 ASCII ‘-’ -
ASCII
4 BMS serial MSB (1000)
5 BMS serial (100)
e.g. 1305
6 BMS serial (10)
7 BMS serial LSB (1)
8 Not used - 0 Unsigned char 0
CAN messages are sent every 200 ms.

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BMS Unit Start Procedure:

When the BMS unit is turned ON it jumps into a boot-loader and checks if the user tries to upload a
new firmware. Then it commences the test procedure by checking the balancing fuses and
temperature sensors. After the test procedure red error LED turns off and the BMS unit starts working
in normal mode.

BMS Unit LED Indication:

Power LED (green) is turned on for 0.2 s every 2 s signaling that the BMS powered. When the battery
pack is fully charged and SOC/end of charge hysteresis are set POWER LED is turn 100% on. Error LED
(red) is turned on in case of system error and signals the error number with 50 % duty cycle. Between
repeated error number 1 s timeout is introduced.

Cell Voltage Measurement:

Cell voltages are measured every second. The cell measurement performs 4 ms cell measurement by
Sigma Delta ADC. 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 actively with very high efficiency in opposite to passive balancing, where all energy
is lost in heat. Another benefit of active balancing is charging of dangerously low cell, if other cells are
above dangerous level, consequently longer pack usage is possible.

Balancing START Voltage:

If errors 2, 4, 5, 8, 10, 12 are not present and the highest cell voltage rises above Balance 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 any cell is above balance END voltage are balanced regardless
the battery pack current.

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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 20 A, cells internal resistance
is calculated. Moving average is used to filter out voltage spikes errors.

Battery Pack Temperature Measurement:

Battery pack temperatures are measured by Dallas DS18B20 digital temperature sensor/s. Up to two
sensors can be used in parallel connected directly to the wiring. Up to 8 sensors may be used with a
junction box. BMS should be turned off and main connector disconnected before adding sensors. If
the temperature sensors wiring is placed near the power lines shielded cables should be used.

BMS Current Measurement:

Low-side only precision shunt resistor for current measurement is used. A 4-wire Kelvin connection is
used to measure voltage drop on the resistor. 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 Sigma-Delta 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. Two more 300 ms measurements are performed through the whole ABMS measurement
interval Shunt connection is shown in Fig. 6. If the BMS measures charging/discharging current that is
higher than the double value of the rated shunt for more than 2 consecutive cycles error 12 is
triggered. This serves for shunt, contactor and fuse protection in case of short circuit.

Figure 6: 300 A/50 mV shunt resistor connection.

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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 IOJA x.xxxx 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 𝐼currentx
𝑘𝐿𝑆𝐵 = 0.01171875 ∙ ∙
300 A 𝑉dropx
where the Vdropx represents the voltage drop on shunt resistor at current Icurrentx.

Battery Pack SOC Determination:

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

Table 15: Li-ion chemistry designators.

Number Type
1 Li-Po Kokam High power
2 Li-Po Kokam High capacity
3 Winston/Thunder-Sky/GWL LiFePO4
4 A123
5 Li-ion NMC/ LiMn2O4

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 connected to the battery pack for the first time, SOC is set to 50 %. SOC is reset to 100
% at the end of charging. Charging cycle is added if the coulomb counter had reached the battery
pack’s capacity.

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Battery Pack’s Charging Algorithm:

If the highest cell reaches the cell over-voltage switch-off per cell CMAX threshold Charge relay 1 is
turned off. Relay turns back on after the highest cell is balanced down under the cell over-voltage
switch-off per cell - cell over-voltage switch-off hysteresis.
When the last cell rises to the End of Charge Voltage, End of Charge SOC hysteresis and End of charge
cell voltage hysteresis is set. SOC is calibrated to 100 % and Power LED lights ON 100 %.
SOC is also calibrated to 96 % when the maximum open circuit cell voltage rises above the 0.502 x
(Balance start voltage + balance end voltage), minimum open circuit voltage above balance start
voltage and system is in charge regime (current > 2 A).

If the Charge optocoupler 1 hysteresis is set to 0, this digital optocoupler output functions like charger
enable. Charge optocoupler 1 is turned ON until the last cell reaches END of charge voltage. If a single
or multiple cell reach the voltage level between cell over-voltage switch-off and end of charge, output
is turned OFF, until this/these cells are balanced down to end of charge voltage. Some of the errors
also turn the output off. See Error table 16.

Charging is stopped in case of systems errors (See System Errors indication chapter). SOC is calibrated
to 96 % when the maximum open circuit cell voltage rises above the 0.502 x (Balance start voltage +
balance end voltage), minimum open circuit voltage above balance start voltage and system is in
charge regime.

Battery Pack’s Discharging Algorithm:

When the lowest cell voltage is discharged bellow the set threshold CLOW maximum allowed
discharging current starts to decrease down to 0.05 C (5 % of Capacity in A). After decreasing down,
maximum allowed discharging current is set to 0 A. SOC is reset to 3 % and Discharging SOC hysteresis
is set to 5 %. If the cell discharges below cell-under voltage protection switch-off per cell
CMIN, ABMS signals Error 2 and SOC is reset to 1 %. Discharge relay 2 is turned off with cell-under
voltage protection switch-off hysteresis to prevent relay ringing.

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ABMS Outputs Settings:

System devices can be controlled by digital outputs Charge optocoupler 1 and Discharge optocoupler
2.

Charge optocoupler 1

Charge optocoupler 1 may be programmed to function in three ways. As a charger enable signal
(Charge optocoupler 1 hysteresis OP1H is set to 0, OP1L is irrelevant in this case). If OP1H hysteresis
is set to a positive value, digital output functions as an under-voltage protection – OP1L should be set
to a threshold voltage level under which the output turns off.
If OP1H hysteresis is set to a negative value, digital output functions as an over-voltage protection –
OP1L should be set to a threshold voltage level over which the output turns off.

Discharge optocoupler 2

Discharge optocoupler 2 may be programmed to function in two ways only. If OP2H hysteresis is set
to a positive value, digital output functions as an under-voltage protection – OP2L should be set to a
threshold voltage level under which the output turns off.
If OP2H hysteresis is set to a negative value, digital output functions as an over-voltage protection –
OP2L should be set to a threshold voltage level over which the output turns off.
If OP2H hysteresis is set to 0, output is disabled.

EXAMPLE 1:
We want to use Charge optocoupler 1 as over - charge control. Charge optocoupler 1 should switch
off if the highest cell reaches 3.7 V with 0.15 V hysteresis. In communicate window we set:

OP1L 3.7
OP1H -0.15

EXAMPLE 2:
We want to use Discharge optocoupler 2 as discharge control. Optocoupler 2 should switch off if the
lowest cell drops under 2.70 V with 0.25 V hysteresis. In communicate window we set:

OP2L 2.70
OP2H 0.25

EXAMPLE 3:
We want to use Charge optocoupler 1 as charger enable control. In communicate window we set:

OP1H 0

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Digital Outputs:
Digital outputs are implemented with galvanic isolation. Optocouplers with diode reverse protection
are used. When closed, a 0.7 V voltage drop over the digital output should be taken into account.
Optocoupler outputs can drive a small signal relay or LED diodes. Fig. 7 shows two different connection
schematics. Both outputs can be used to drive LED diodes for charge/discharge relay indication.

Figure 7: BMS digital outputs schematics.

Current limit resistor R can be calculated as:

𝑉CC2 − 0.7 𝑉 − 𝑉FVLED

𝑅=
𝐼LED

VFVLED represents LED forward voltage drop (typ. 1.9 – 2.3 V) while ILED represents LED current (2-5
mA).

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Pre-charge Connection:
Charging/discharging contactors are driven by charge/discharge relays 1 and 2 inside the BMS. If a
high input/output capacity (> 2,000 µF) is used at the charging sources/discharging loads, a pre-charge
unit should be used to avoid high in-rush current spikes when the contactor is turned on. In-rush
currents degrade the contactor, cells and input capacitors in the electronic device. Fig. 8 shows
contactor connection with the pre-charge circuit in discharge DC-rail. In case the charging source also
use high output capacity a pre-charge unit should be used also in the charge DC-rail.

Figure 8: Contactor connection schematics.

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Parallel Cells Connection:

Capacity can be increased by connecting multiple cells in parallel and then connect these sub-packs in
series. Fig. 9 shows 2P4S connection with 2 cells in parallel and 4 pack like this in series. For proper
current distribution 2 connection bars should be used between each 2P to 2P sub-pack.

Figure 9: 2P4S battery pack connection.

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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. Each and every error number trigger algorithm has a normal delay time of 3 measuring cycles
with sensed/measured error – 3 x 1.25 s before the error is triggered.
Errors 2 and 10 are set to trigger @ the first measured error when the BMS is turned ON. If the two
errors are not present normal delay timer is set.

Table 16: BMS error states.

Number of
ERROR BMS OWNER
ON blinks

BMS will try to balance down the

Single or multiple cell problematic cell/cells to safe
voltage is too high voltage level (2.5 s error
(cell over voltage hysteresis + single cell voltage
 Wait until the BMS does its
1 switch-off per cell + hysteresis is applied).
job.
cell over-voltage Charge relay is disconnected.
switch-off hysteresis Discharge relay 2 is connected. In
per cell ). case charge optocoupler is set to
charger enable it is disconnected.

Single or multiple cell BMS will try to charge the battery

voltage is too low (2.5 s error hysteresis + single cell
(cell under voltage voltage hysteresis is applied). SOC
protection switch-off is reset to 1 %  Plug in the charging
2
per cell + under Charging relay 1 is enabled, sources.
voltage protection discharging relay 2 is disabled. In
switch-off hysteresis case charge optocoupler is set to
per cell). charger enable it is connected.

BMS will try to balance the cells if  Wait until the BMS does its
Cell voltages differs balancing is enabled (20 mV job. If the BMS is not able
3 more than set (cells voltage difference hysteresis). to balance the difference in
max difference) Charging relay 1 is enabled, a few hours, contact the
discharging relay 2 is enabled. service.

Cell temperature is Cells temperature or cell inter-

too high (cell over connecting cable temperature in
temperature switch- the battery pack is/are too high.  Wait until the pack cools
4
off + cell over (2.5 s error hysteresis 2°C down.
temperature switch- hysteresis).
off hysteresis). All outputs are disabled.

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BMS temperature is
Due to extensive cell
too high –internal
balancing/hardware error the
error (BMS over
BMS temperature rose over the  Wait until the BMS cools
5 temperature switch-
upper limit (2.5 s error hysteresis down.
off + BMS over-
+ 5 °C temperature hysteresis).
temperature switch-
All outputs are disabled.
off hysteresis).

Number of cells,
6 address is not set All outputs are disabled.  Set proper ABMS address
properly.

If cells are charged at

temperatures lower than
The temperature is operating temperature range,
too low for charging cells are aging much faster than
(under temperature they normally would, so charging  Wait until the battery’s
7 charging disable + is disabled (2 °C temperature temperature rises to
under temperature hysteresis). usable range.
charging disable Charge relay is disconnected.
hysteresis). Discharge relay 2 is connected. In
case charge optocoupler is set to
charger enable it is disconnected.

 Turn-off BMS unit and try

to re-plug the temp.
Temperature sensor is un-plugged
sensor. If the BMS still
Temperature sensor or not working properly (2.5 s
8 signals error 8, contact the
error. error hysteresis).
service. The temperature
All outputs are disabled.
sensors should be
replaced.

Communication RS-485 Master-Slave

9
error. communication only.

 Turn-off the BMS and

Single or multiple cell voltage is
Cell in short circuit or check the cells connection
close to zero or out of range,
BMS measurement to the BMS and fuses.
indicating a blown fuse, short
error (Max cell Restart the BMS.
10 circuit or measuring failure
voltage > 4.5 V or
(15 s error hysteresis + 10 mV
Min cell voltage <  If the same error starts to
voltage difference hysteresis).
0.8 V). signal again contact the
All outputs are disabled.
service.

If the discharge relay 2 should be  Restart the BMS unit. If the

opened, all the other outputs are same error starts to signal
Discharge relay 2 is
set to control charging and again examine the
11 in short circuit.
current < -0.5 A, the BMS signals discharge relay 2 output on
error 11. the BMS, pre-charge unit
All outputs are disabled. and contactor.

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Current
 Check the system
measurement ABMS is not able to measure
settings/HW configuration.
disabled or current or current is too high for
12 If the BMS still signals error
charging/discharging charging or discharging.
12, contact the service or
current >2 x shunt All outputs are disabled.
change the BMS settings.
max current
In some application the chemistry
Wrong cell chemistry  Use PC Control Software to
13 pre-set is compulsory. All outputs
selected. set proper cell chemistry.
are disabled.

During start-up or shut-down

EEPROM read/write was
interrupted. The corrupted
setting/settings was/were set to a
EEPROM data  Use PC Control Software to
14 default value. If the
corruption set proper settings
setting/settings was/were
changed after the first installation
it/they should be corrected. All
outputs are enabled.

 Use PC Control Software to

ABMS CAN bus Set CAN baud rate is not correct.
set proper settings. 100k,
15 communication baud All outputs are enabled. CAN is
125k, 200k, 250k, 500k or
rate error disabled.
1M may be set.

I2C or SPI communication failure.

ABMS internal  Restart the BMS unit. If the
BMS signals error 16 and does not
16 communication same error starts to signal
start normal procedure.
failure again contact the service.
All outputs are disabled.

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BMS Unit Dimensions:

Figure 10: BMS dimensions.

M4 bolts are preferred to use for mounting. BMS unit can be also supplied without the enclosure, if
an application is weight or space limited. The dimensions of the BMS (including connector) without
the enclosure are 109 mm x 100 mm x 38 mm. The PCB has four 3.2 mm mounting holes.

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