ALIARO AL-4010 User manual

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Overview
This document is a quick start guide on how to use the AL-4010 Battery Cell Emulator / Battery
Cell Simulator board from ALIARO. It is intended to be used by industry professionals to:
-Understand what steps need to be taken when purchasing an AL-4010 board
-Provide an overview of what software/hardware is required for the AL-4010 board
-Be a practical step-by-step guide for engineers working with the AL-4010 board
This document is not intended to provide a list of all the product features (this is provided by the
device’s specification sheet). It is also not a software guide for controlling the board (this is
provided by specific software manuals or help documentation).
The AL-4010 is a SLSC module designed to be used with a NI SLSC chassis (SLSC-12001). It
provides a total of 6 channels that are capable of emulating 6 battery cells and the dielectric
strength between the channels is 60V and the dielectric strength between the board and the NI
SLSC chassis is 1500V, so the number of cells connected in series is therefore only limited by
the sum of single cell voltages.
The AL-4010 can sink and source in all quadrants and to minimize internal power losses the
positive and negative operation voltages are variable and operating dependent on the output
voltage.
Cell Voltage
Range
Cell Voltage
Accuracy
Current Load
Range
Current Load
Accuracy
Power
0-7V
±1mV
±2A
2mA
±14W
Table 1 - Cell Output Specifications
-In the case of short circuit, the board can handle 5A (10A peak for 100ms).
-In the case when the voltage from external source / BMS is higher than the voltage
output in the cell that results in that the current will flow from the external source / BMS
to the AL-4010 current sink.
-In the case when the voltage in AL-4010 is higher than the voltage from the external
source / BMS that results in that the current will flow from the AL-4010 into the external
source / BMS.
It is possible to calibrate the system and calibration and adjustment are both possible without
removing the system from its installation. Measurement accuracy is guaranteed within the
specified operating- and temperature range. All system channels, referring to cell voltages, and
sensing channels (cell voltage and cell current) are synchronized.
Sensing
Voltage
Range
Sensing
Voltage
Accuracy
Sensing
Current High
Range
Sensing
Current High
Accuracy
Sensing
Current Low
Range
Sensing
Current Low
Accuracy
±8V
±1mV
±2.2A
±2mA
<10mA
±10µA
Table 2 - Sensing Specifications

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System Architecture
The first diagram below shows how a system could look like with a real battery connected to the
battery management system, whereas the second diagram shows how a system could look like
when using ALIARO’s xMove Battery Cell Simulator.
Figure 2 - BMS when connected to real batteries, contactors etcetera.
Figure 3 - BMS when connected to ALIARO xMove Battery Cell Simulator

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Contents
Overview................................................................................................................................ 2
System Architecture ............................................................................................................... 3
Description............................................................................................................................. 6
Installation.............................................................................................................................. 6
Electromagnetic Compatibility ............................................................................................. 6
Unpacking the module ........................................................................................................ 6
Hardware Installation .......................................................................................................... 7
Maintenance .......................................................................................................................... 9
Safety Guidelines ................................................................................................................ 9
Before using the AL-4010...................................................................................................10
System Check ...................................................................................................................10
Calibration .........................................................................................................................11
Specification..........................................................................................................................12
Definition and conditions ....................................................................................................12
Environmental Characteristics ............................................................................................12
Physical characteristics......................................................................................................12
Setting Up The AL-4010 ........................................................................................................13
Software Setup ..................................................................................................................13
Product Setup....................................................................................................................13
Verifying The Setup............................................................................................................14
Features................................................................................................................................15
Block Diagram ...................................................................................................................15
LED Indicator.....................................................................................................................15
Cables and Accessories.....................................................................................................15
Pinout and Signal Descriptions ...........................................................................................16
J1 - DUT Connector (Front) ............................................................................................16
J2 - DUT Connector (Front) ............................................................................................16
J3 - DUT Connector (Front) ............................................................................................16
XJ1 –SLSC Interface Connector (Rear) ..........................................................................16
XJ2 - DUT Connector (Rear)...........................................................................................17
XJ3 - DUT Connector (Rear)...........................................................................................17
General Signal Capabilities.................................................................................................18
Fault Insertion Capabilities..................................................................................................18
Supply and Load Capabilities .............................................................................................18
Sensing / Measuring Capabilities ........................................................................................19
Additional Capabilities. .......................................................................................................19

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Configuration and Accessories...............................................................................................20
RTI Backplane ...................................................................................................................20
AL-4010 RTI Backplane .....................................................................................................20
Safety Guidelines...................................................................................................................23
Product Certifications and Declarations..................................................................................23
CE Compliance ........................................................................................................23
Electromagnetic Compatibility Standards............................................................................23
Environmental Management...............................................................................................24
Waste Electrical and Electronic Equipment (WEEE) .............................................................24

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Description
The Board provides functions for:
Fault Insertion (All Channels)
-Open Circuit
-Short Circuit
-Reverse polarity (AL-4010 can output negative voltages)
Other features
The board is isolated to keep the test system and DUT separated to provide a high signal
integrity and minimize interference.
The board uses the SLSC interface (Ethernet) for setting and reading the status of the board.
The board uses standard industry connectors on the front and the back.
Installation
Electromagnetic Compatibility
This product is intended for use in industrial locations. However, harmful interference may
occur in some installations, when the product is connected to a peripheral device or test object,
or if the product is used in residential or commercial areas. To minimize interference with radio
and television reception and prevent unacceptable performance degradation, install, and use
this product in strict accordance with the instructions in the product documentation.
Furthermore, any modifications to the product not expressly approved by ALIARO
could void your authority to operate it under your local regulatory rules.
Caution To ensure the specified EMC performance, operate this product only with
Shielded cables and accessories.
Unpacking the module
The AL-4010 board ships in an antistatic box to prevent electrostatic discharge (ESD). ESD can
damage the device components. Users should be familiar with the steps to prevent ESD damage
when handling the device.
Warning - Never touch the exposed pins of the connectors.
To prevent ESD damage when handling the device, please take the following precautions:
-Ground yourself before handling. Use a grounding strap or by touching a grounded
object.

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-Touch the antistatic package to a grounded metal part before removing the device from
the package. A good example would be the metal part of your computer chassis.
Remove the device from the package and inspect it for damages such as loose components.
Contact ALIARO if the device appears damaged in any way. Do not use a damaged device with
any other components. Store the device in antistatic protection when not in use.
Hardware Installation
The AL-4010 board is shipped with the following components:
- An ESD protection box
- Declaration of conformity
Additional components which connect to the AL-4010 are shipped separately. These could
include:
Battery Cell Emulator
Cables
Cabling to connect the battery cell emulator to the device under test,
for an example a battery management system.
Rear Transitional
Interfaces (RTIs)
These are used to provide connection points on the rear of SLSC
boards
To set up and use the module you need the following items:
Hardware
•SLSC-12001 chassis
•SLSC AL-4010 module(s)
•RTI-12344 for AO 37DSUB (P/N 785376-01)
•Cell Power Rear Connector
•Cell Communication Rear Connector
Tools
•Screwdriver as needed for your application
•Wire stripper
Documentation
SLSC-12001 Chassis Getting Started Guide and Specifications
Caution:
Do not touch the contacts or remove the I/O boards or cables while the system
is energized.
The SLSC chassis and the AL-4010 do not support hot plug-in. The entire
chassis must be powered off when a module is inserted or removed.

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Procedure:
1. Power off the main DC power source or disconnect the power source from the chassis
before installing any modules or RTIs.
2. Ensure that the chassis is powered off. The POWER LED should be off. If the POWER
LED is not off, do not proceed until it is off.
3. Loosen the screws on the upper rear panel of the chassis.
4. Position the RTI backplane at the desired slot and insert the securing screws, but do not
fully tighten them.
5. Insert an AL-4010 module into the same slot as its corresponding RTI while firmly holding
the RTI in place until the RTI is firmly connected to the module.
6. Repeat steps 4 and 5 for all required RTIs.
7. Fully tighten the screws for all RTIs and the upper rear panel of the chassis. Note Waiting
until all RTIs and modules are installed to fully tighten the screws ensures proper
alignment for future connections between modules and RTIs.
8. Fully tighten the two module mounting screws on each newly installed module.
9. Power on the SLSC chassis

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Maintenance
Power off all connected device before attempting any maintenance. After maintenance is
complete, ensure that the device is fully dry and installed correctly, before powering the system
back on.
Warning - Many components within the chassis are susceptible to static discharge
damage. Service the chassis only in a static-free environment. Observe standard
handling precautions for static-sensitive devices while servicing the chassis. Always
wear a grounded wrist strap or equivalent while servicing the chassis.
Clean dust from the chassis exterior and interior as needed, based on the operating
environment. Periodic cleaning increase’s reliability.
Use a dry, low-velocity stream of air to clean the interior of the chassis. Use a soft-bristle brush
for cleaning around components
Safety Guidelines
Operate AL-4010 only as described in this document, all warning and precautions must be
followed.
Terminology used to describe security levels.
DANGER –
Warns of imminent danger that might result in serious injury or death.
WARNING –
Potentially hazardous situation that might result in serious injury or
death.
CAUTION –
Warns of a potentially dangerous situation that could result in personal
injury or property damage.
WARNING - The emulated cells of the AL-4010 (Battery Cell Emulator) are not
grounded and the same applies for the Battery Management System (BMS). Neither
of the systems can be connected to earth during operation as this results in a severe
hazard at high voltages.
CAUTION - Running the system without an earth leakage monitor or with bridged
functionality is not allowed, the purpose of the earth leakage monitor (or Bender –
Isometer) is to verify and check the galvanic isolation.

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CAUTION - For systems with more than 120 cells the following precautions must be
followed.
-Limit the output voltage per cell to 5V.
-Ensure that the Battery Cell Emulator / Battery Cell Simulator System is used
in a secured and safe areas where it is not accessible during operation by
any humans.
WARNING - Do not operate the device in a manner not specified in this document.
Misuse of the device can result in a hazard. You can compromise the safety
protection built into the device if the device is damaged in any way. If the device is
damaged, contact ALIARO for repairs or replacement.
WARNING - Do not substitute parts or modify the device except as described in this
document. Use the device only with the chassis, modules, accessories, and cables
specified in the product specification.
WARNING - Do not operate the device in an explosive atmosphere or where there
may be flammable gases or fumes. If you must operate the device in such an
environment, it must be in a suitably rated enclosure.
Before using the AL-4010
All input characteristics are DC, ACRMS, or a combination unless otherwise specified. Every card
provides a fully capable fault insertion with external control during simulations or testing. Relays
can be configured with xMove Configurator, VeriStand and LabVIEW
Note Steady state voltages and currents applied to the AL-4010 between any two I/O
connector pins more than the voltage- or current specification may damage the module
Note - Signal connections through the AL-4010 are intended to go through the cell output pins
and the sensing pins.
System Check
This chapter requires LabVIEW development and installation of LabVIEW drivers.
To identify and control that the cards are inserted and work properly with the right firmware,
LabVIEW provides basic VI scripts to check SLSC cards mounted in chassis
1. Open LabVIEW and select “Help” in the top menu bar and press “Find Examples…”
(This opens a new window with pre-built VI (Virtual Instruments) for different
applications).
2. Switch to the “Search” tab and enter keyword “SLSC” and double click.
3. In the new filtered table (to the right) find and select VI called “Configuration.vi”. This VI
can located every card(s) that is online in SLSC chassis.
4. To find the newly inserted cards look for the SLSC chassis IP-address (in the table to the
right).

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Count the showing card(s) in the table and make up that there are as many mounted in
the SLSC chassis as there are in the VI table for that specific IP address. (Can be 1 up to
11 cards per SLSC chassis)
Calibration
Recommended warm-up time
30 min
Calibration interval
1 year
Contact ALIARO to schedule calibration services. Additionally, you may be entitled to calibration
if you have a service agreement.
If you have purchased a calibration system from ALIARO, we recommend using the system with
your complete ALIARO test system or device, after the specified interval. If you are interested in
purchasing or renting a calibration system, please contact ALIARO.

ALIARO reserve the right to vary from the description given in this data sheet and shall not be liable for any errors.
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Specification
Definition and conditions
Warranted specifications describe the performance of a model under stated operating conditions
and are covered by the model warranty.
The following characteristic specifications describe values that are relevant to the use of the
model under stated operating conditions but are not covered by the model warranty.
•Typical specifications describe the performance met by most models.
•Nominal specifications describe an attribute that is based on design, conformance
testing, or supplemental testing.
Specifications are Typical unless otherwise noted.
Specifications are valid under the following conditions unless otherwise noted.
The AL-4010 module is mounted in an SLSC chassis with the recommended cooling clearances
and using a power supply that meets the specifications provided in the chassis user guide. For
the entire temperature range of the chassis.
Note These specifications only apply to the product as provided by ALIARO.
Modifications to the module may invalidate these. Be certain to verify the performance of
modified modules.
Caution Observe all instructions and cautions in the user documentation. Using the
model in a manner not specified can damage the model and compromise the built-in
safety protection. Return damaged models to ALIARO for repair.
Environmental Characteristics
Temperature and Humidity
Operating temperature
10°C to 35 °C
Storage temperature range
-40 °C to 85 °C
Operating relative humidity range
10% to 90%, noncondensing
Storage relative humidity range
5% to 95%, noncondensing
Physical characteristics
Category
Condition
Value
Module Dimensions
Excluding front handle
144.32mm x 30.48mm x 281 mm
(H x W x D)
Front Panel Connector
1 x female Weidmüller 24 (2x12) high
density
2 x RJ45
Table 3 - Physical characteristics AL-4010

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Setting Up The AL-4010
Complete the following steps to get started with the AL-4010 Board.
Software Setup
The AL-4010 Battery Cell Emulator/Simulator Board is intended to be used with the following
pieces of control software:
NI VeriStand
The NI VeriStand application software helps you configure I/O
channels, data logging, stimulus generation, and host communication
for NI real-time hardware. If using VeriStand to control the AL-4010
Board, install the ALIARO SLSC Plugin from ALIARO’s website. NI
VeriStand can be installed from NI’s website.
xMove Configurator
(Optional)
xMove Configurator is a configuration tool used to quickly configure
test systems and test system components such as the AL-4010
Board. It achieves this by defining/editing VeriStand System definition
files. We recommend using xMove with either of these software
platforms for maximum efficiency. xMove can be download from NI’s
website. Contact ALIARO for more information.
Product Setup
When using the AL-4010 Board, the following hardware components are required:
-NI SLSC Chassis (SLSC-12001) and all associated components listed in the SLSC
Chassis manual. This manual is located on NI’s website.
-Cross Connection Board
-Rear Transitional Interface (RTI)
Use the following steps to setup the AL-4010 Board in an SLSC Chassis:
Warning –Please complete the following steps with all devices powered off and with
users and systems being safely grounded. F
Choose a slot in the SLSC Chassis to install the AL-4010 Board. Before inserting the board, any
RTIs and cross connection boards must first be mounted on the rear of the SLSC chassis. Both
components are optional and are not required to use the AL-4010 board.
Now that all optional components have been installed into the chassis, the module can be
inserted. Please refer to the specific SLSC Chassis Getting Started Guide and Specifications
from NI to understand how to Install and Remove SLSC modules safely.
In addition to the mentioned guide, the module should also align with the RTI on the rear of the
chassis. All pins should firmly connect to the corresponding position on the module without great
resistance or the pins/connectors being bent.

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Connect the RTI and the AL-4010 Board to any DAQ devices as defined by their manufacturer,
all communication through the RTI is done through SPI, for information about how to read from /
write to registers on the AL-4010 please read the AL-4010 Software Manual.
Verifying The Setup
The diagram below provides an overview of all product components required and optional for
performing verification. Please note, some components are only optional based on the SLSC
modules being used and the requirements of your system.
To verify that all software and product components have been correctly installed, perform the
following actions:
-Power on the SLSC Chassis and observe the front of the AL-4010 Board. The AL-4010
Board has 2 LEDs which are described in the LED Indicator section of this document.
Verify that both LEDs power solid green when the chassis is powered on. This verifies
that the AL-4010 Board has been installed in the chassis successfully.
-Using VeriStand –Once the custom device has been installed, add the SLSC chassis to
the system definition file under the Custom Devices section. Add the AL-4010 Board into
this chassis configuration. Deploy the configuration to a target and use the parameters
for the AL-4010 Board created by the VeriStand custom device.
This concludes the verification process

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Features
Block Diagram
The figure below shows the key functional components of the AL-4010 Board.
Figure 4: AL-4010 Simplified Block Diagram
LED Indicator
The AL-4010 Board has 2 LEDs which indicate the status of the board. All states are shown I the
table below.
LED Name
LED Behavior
Definition of Behavior
Power
Off
No power present on module
Solid Green
Module powered
Solid Red
Module fault
Ready
Off
Module is not powered
Solid Green
Module is ready to be used
Solid Red
Module fault
Table 4 - LED Indicator States
Cables and Accessories
The table below contains information about all cables and accessories available for the AL-4010.

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Accessory
Description
Piggyback Boards
N/A
Rear Transitional Interfaces
(RTIs)
RTI-12344 for AO 37DSUB (P/N 785376-01)
Cross Connection Boards
N/A
Table 5 - Compatible Cables and Accessories
Pinout and Signal Descriptions
The following section describes the connectors located on the AL-4010 Board. Please note that
Connector XJ3 and XJ2 are primarily designed with a Rear Transitional Interface in mind.
Connector XJ1 will connect with the SLSC Chassis and does not require any action from the
user.
J1 - DUT Connector (Front)
This is the connector used to access the cell outputs and sensing lines available on each cell,
see pinout below.
Pin
Left
Right
1
Cell 1, Sense -
Cell 1, Sense +
2
Cell 1, Out -
Cell 1, Out +
3
Cell 2, Sense -
Cell 2, Sense +
4
Cell 2, Out -
Cell 2, Out +
5
Cell 3, Sense -
Cell 3, Sense +
6
Cell 3, Out -
Cell 3, Out +
7
Cell 4, Sense -
Cell 4, Sense +
8
Cell 4, Out -
Cell 4, Out +
9
Cell 5, Sense -
Cell 5, Sense +
10
Cell 5, Out -
Cell 5, Out +
11
Cell 6, Sense -
Cell 6, Sense +
12
Cell 6, Out -
Cell 6, Out +
Table 6 - Front Connector Pinout
J2 - DUT Connector (Front)
This is a RJ45 Ethernet port, currently not used by the AL-4010 board. Prepared for EtherCAT
slave functionality.
J3 - DUT Connector (Front)
This is a RJ45 Ethernet port, currently not used by the AL-4010 board. Prepared for EtherCAT
slave functionality.
XJ1 –SLSC Interface Connector (Rear)
This is the SLSC interface connector, and we highly recommend not connecting directly to this
connector and instead use a RTI backplane such as RTI-12344 for AO 37DSUB (P/N 785376-
01).

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XJ2 - DUT Connector (Rear)
This is one of the I/O connectors and we highly recommend not connecting directly to this
connector and instead use a RTI backplane such as RTI-12344 for AO 37DSUB (P/N 785376-
01).
Through this connector various signals are sent to the AL-4010 / received from the AL-4010, for
an example the SPI communication interface takes place through this connector. It is most easily
accessed by using an optional RTI Board. ALIARO do not recommend soldering or attaching
jumpers directly to these pins, as this may cause damage to the AL-4010 Board.
Row
E
D
C
B
A
1
SPI_MOSI
SPI_CSn
SPI_Clk
2
3
4
SPI_MISO
5
6
7
8
9
10
11
15
16
17
18
19
20
21
22
23
24
25
Table 7 - Pinout on XJ2 Connector.
XJ3 - DUT Connector (Rear)
This is one of the I/O connectors and we highly recommend not connecting directly to this
connector and instead use a RTI backplane such as RTI-12344 for AO 37DSUB (P/N 785376-
01). Power provides the supply and load capabilities on the board.

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XJ3 Pin
H
Positive Voltage 1
G
Negative Voltage 1
F
Positive Voltage 2
E
Negative Voltage 2
D
Positive Voltage 3
C
Negative Voltage 3
B
Positive Voltage 4
A
Negative Voltage 4
Table 8 - Pinout on XJ3 Connector.
General Signal Capabilities
-The AL-4010 Board is isolated to keep the test system and DUT electrically separated.
This ensures high signal integrity and minimizes interference.
-The board utilizes the SLSC interface for setting and reading the status of the board.
-The board utilizes a SPI bus through the RTI backplane for setting and reading desired
cell voltages, sense voltages and currents etcetera in a deterministic and fast manner.
-EtherCAT through the RJ45 connectors on the front of the card will be added later,
potentially in a new revision of the card.
Parameter
Value
Comments/Additional
Synchronization between cells
<50µs
Control Interface
SPI
EtherCAT
EtherCAT support will be
added in the future.
Table 9 - General Properties
Fault Insertion Capabilities
Fault insertion is the process of sending a known error (fault) to a Device Under Test (DUT) to
understand the reaction from the device. This includes several types of simulated failures such
as short or open circuits.
AL-4010 supports the following fault insertion mechanisms, short circuit, open circuit, and
reverse polarity.
Parameter
Value
Comments/Additional
Current, short circuit
5A (10A peak for 100ms)
Table 10 - Fault Insertion Properties
Supply and Load Capabilities
AL-4010 has the following supply and load capabilities:
Parameter
Value
Comments/Additional
Voltage Supply, Range
0-7V
Voltage Supply, Accuracy
±1mV
Voltage Supply, Ripple
2mVrms

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Voltage, Step Response 1-4V
0.1ms
Voltage, Step Response 4-1V
<1ms
Dependent on load
Maximum External Load
2000mA
Current Load, Range
0-2000mA
Current Load, Accuracy
2mA
Current Load, Step
Response (10-90%)
Table 11 - Supply and Load Properties
Sensing / Measuring Capabilities
The AL-4010 has the following sensing / measuring capabilities:
Parameter
Value
Comments/Additional
Voltage Measurement,
Range
±8V
Voltage Measurement,
Accuracy
±1mV
Current Measurement,
Range (Low Range)
±10mA
Current Measurement,
Accuracy (Low Range)
±10µA
Current Measurement,
Range (High Range)
±2200mA
Current Measurement,
Accuracy (High Range)
±2mA
Coulomb Measurement,
Samples / Calculation
100 Samples, 250 Samples,
500 Samples, or 1000
Samples
Number of samples for
Coulomb Measurement
Coulomb Measurement,
Accuracy
Needs to be calculated and
verified.
Table 12 - Sensing / Measuring Properties
Additional Capabilities.
The AL-4010 Board can do everything in a bipolar fashion, in other words output positive,
negative voltages, and measure the same, this results in that we offer reverse polarity on all
cells.

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Configuration and Accessories
For most applications, the AL-4010 needs to be configured with a backplane.
RTI Backplane
RTIs are used to format signals into common bus types and are mounted onto SLSC chassis
using screws. These screws will be provided with the RTI board and will have a corresponding
threaded hole on the top rear of the SLSC chassis. The RTI board will have several holes which
the screws will fit through.
Mount the RTI with the external connectors (to measurement devices) and external references,
facing away from the chassis. The available connectors will vary depending on which RTI is
being used. The figure below shows an example RTI and how it is mounted on the SLSC
Chassis.
Figure 5: Example RTI
Cross connection boards are used to route/reorganize signals before being sent to DAQ
equipment. They are placed over RTI boards and connect onto bus terminal points. Please refer
to your specific cross connection board instructions to install the board.
AL-4010 RTI Backplane
For AL-4010 use the SET-12344 backplane, it passes on all signals from the XJ2 and XJ3
connectors on the AL-4010 to connectors that are easier to interface with.
▪JR1 connector, handles power, positive voltages upper row, negative voltages lower
row.
▪JR2 connector, SPI bus
▪SPI_Clk = RTI_IO_1 = A1 = P0.0 = DSUB Pin 1, Signal is low when idle
▪SPI_CSn = RTI_IO_2 = B1 = P0.1 = DSUB Pin 20, Signal is high when idle
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Digilent Pmod Con1 Module Board Reference manual

IFM
IFM QHA200 Instructions for setup