ALIARO AL-4010 User manual

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6 Cells Battery Cell Emulator Board
AL-4010 for SLSC
This document describes the SLSC AL-4010 for National Instruments SLSC-12001 chassis.
Figure 1: AL-4010

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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

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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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).