AutarcTech JOULIE-4c User guide

JOULIE-4c Application Guide
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JOULIE-4c
Application Guide
Version 2.0 (DRAFT)
May 2019
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Copyright products are not explicitly indicated in this manual. The absence of the trademarks (™ or
®) and copyright © symbols does not imply that a product is not protected.
AutarcTech does not take responsibility for any inaccuracy, nor does it give any guarantee nor
excepts any liability whatsoever for consequential damages resulting from the use of this manual or
it’s associated product.
AutarcTech also o"ers no guarantee from the improper usage or installation of the hardware or
software.
© Copyright 2019 AutarcTech GmbH, D-91522 Ansbach, Technologiepark 1, [phone],
[email protected], www.autarctech.de,
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Preface
JOULIE-4c is the name of a cascadable Battery Management System (BMS) that
allows to monitor batteries from 12V up to 900V (high voltage) with high
capacities up to 400Ah per cell with a balancing current of 5A average (10A peak).
The BMS - JOULIE-4c - is designed to use for both as Master unit and as Slave
units, setup by the DIP switch settings (Master = 0, Slaves > 0).
Every JOULIE-4c board is a standalone operating BMS with active cell balancing for
4 cells battery packs.
The on-board serial interface (RS485) is used for an isolated inbound connection
to the next JOULIE in a chain and to an external unit like a PC.
The relay interface is used to drive a bi-stable relay.
It has two additional, galvanically isolated outputs for "Disable charge / discharge”.
SOC is indicated by a blinking LED and an analog (0..5V) output.
JOULIE units can be extended by an optional PBAL-Ext (passive balance extension)
in order to increase the balance power for cells up to 600Ah. - Not developed yet.
This documentation describes the function of a dedicated Battery Management
System. It does not describes what the function of a BMS is, nor does it present
dedicated parameters for a dedicated set of cells.
Because of the limitations of the used chip sets it allows the voltage and
temperature monitoring of 4 cells in a 4S arrangement in between 1.8V and 4.5V,
independent of any chemistry. Voltage range is between 1.8V and 4.5V.
Samples in the below chapters are just samples and not aligned to any cell type.#
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Table of Contents
Important notice 5
What you get 6
Optional Components 7
Usage 8
1. Hardware Overview 9
1.1. Technical Data 9
1.2. Hardware 11
1.3. Board Overview 11
1.4. Connectors Overview 12
1.5. DIP switch, Jumpers and receptacles 14
1.6. Meaning of the LEDs 14
2. PBAL-Ext 15
3. Applications 16
3.1. One JOULIE for a single 12V block 16
3.2. Chained JOULIE’s for a 24V battery 17
3.3. Chained JOULIE’s for a high voltage battery - up to 900V 18
4. Installation steps for a 12V battery 19
5. Installation steps for batteries higher than 12V 22
6. Software 25
6.1. BMS Graphical User Interface (GUI) 25
6.2. BMS Shell program 29
6.3. Parameters overview 32
6.4. Parameters limitations 32
6.5. EEPROM fields 33
6.6. Error Handling 34
6.7. SOC Calculation 35
7. RESET and ON/OFF 36
Q&A 37
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Important notice
Copyright products are not explicitly indicated in this manual. The absence of the
trademarks (™ or ®) and copyright © symbols does not imply that a product is not
protected.
AutarcTech does not take responsibility for any inaccuracy, nor does it give any guarantee
nor excepts any liability whatsoever for consequential damages resulting from the use of
this manual or it’s associated product.
AutarcTech also o"ers no guarantee from the improper usage or installation of the
hardware or software.
© Copyright 2019 AutarcTech, D-91522 Ansbach, Technologiepark 1, [phone]
7374, [email protected], www.autarctech.de,
The JOULIE must not be used without the express permission of the manufacturer in
safety-critical areas, e.g. hospitals.
The JOULIE must not be used in open or unprotected rooms. It has neither a contact
protection nor a protection against the penetration of water or other foreign objects
(protection class IP00).
The JOULIE is intended for use with lithium cells only, but it should operate with any cell
from 1.8 - 4.5V.
It is essential that the appliance is used as intended. The manufacturer assumes no
liability for damage resulting from improper use.
No modifications, either mechanical or electrical, are permitted without the manufacturer's
approval. Only the parts specified by the manufacturer may be used for conversions and
accessories. In the case of infringements, the manufacturer 's conformity and warranty are
void. The risk is then borne by the user alone.
The RJ45 (UP/DOWN) wires are galvanically isolated to the BMS.
When connecting external systems, be aware that there may be high voltages
depending on the connections. Please avoid connecting multiple Serial-to-USB
converters to multiple JOULIE boards on the same external system, e.g. a PC.
The GND level is the plus level of the predecessor board! Only within the same
JOULIE you can use GND as reference potential.
If you have questions regarding the BMS which have not been answered by this manual,
please contact AutarcTech before you connect the BMS with the battery:
AutarcTech GmbH, Technologiepark 1, 91522 Ansbach, Ph.: [phone],
[email protected]#
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What you get
JOULIE-4c - Active Balance BMS 12V/4S
CellCon Balance - ERNI balancer cable with coloured wires, 1m, open end for ring
connectors
This Documentation
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Optional Components
CellCon NTC - cell boards with NTC 10k, (42 x 29 mm²) for 4x M5, 1x M8,
1x M14
CAT5 cable - 1m to connect CellCon NTC to JOULIE
Relay - LAYHER, bi-stable, 12V/200A, 6A / 80ms switch impulse
Current Sensor - LEM HASS 100-S with cable 0.20 m
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Usage
The JOULIE Active Balance BMS is used to monitor the charging and discharging of Lithium
cells, and to balance cells with di"erent SoC (State of Charge) in a series connected
battery.
Lithium cells react very sensitively to lowering the minimum cell voltage (deep discharge)
and exceeding the maximum cell voltage (overload), so monitoring is mandatory.
The JOULIE ensures that individual cells in series connected battery are neither
overcharged or deep discharged. If one of the cells is too high or too low voltage, the
JOULIE will open the external bi-stable or normal relay.
Lithium cells connected in series charge and discharge due to manufacturing tolerances
never exactly equal. To compensate this, the JOULIE contains an Active Balancer based on
flyback converters.
The Active Balancer acts in charge, discharge and idle mode always in order to minimise
the dis-balance of the battery.
In these cases the energy of one cell will be transferred to the block or from the block to a
cell. The systems works bi-directional and balances 2 cells at the same time.
This principle is very e%cient, the balance performance is about 92% (http://
www.linear.com/product/LTC3300-1#overview).
The balance di"erence parameter allows to control and optimise the balancing process.
Via serial interface parameter changes can be performed.
The very high contact reliability of the balancer cables is ensured by ERNI color coded
cables.
It's possible to increase the balance security and power of the active one by a stacked
passive extension.
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1. Hardware Overview
1.1. Technical Data
•Battery Management System for 4S Lithium cells from 1.8-4.5V
•Protects and active balances cells
•Active balancing also with disconnected charger, in order to get a very good balanced
block
•Adjustable parameters
•permanent voltage and temperature control of each cell in a block
•input for 4 temperature sensors (NTC, 10k)
•galvanic isolated input for centralised ON (several JOULIE's can be turned on/o"with
one external switch)
•LED indicators for RS485 communication and SOC (also used for error indication)
•a multi-channel 12bit ADU measures cell voltages, cell temperatures and performs active
(and optional passive) balancing
•Values and errors are transferred via serial interface to other JOULIE's and to any
external unit
•SOC is indicated by 1 blinking LED
•Connectors for balancer cables (4 cells, 10 A per cannel), for 4 temperature resistors
(10k NTC), for extension board PBAL_EXT (not yet ready)
•The JOULIE has an isolated RS485 serial interface accessible at RJ45 jack
•via DIP switches 64 JOULIE's are addressable#
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Dimensions
120 mm x 80 mm x 15 mm (WxDxH)
Weight
60 g
Class
IP00
Input Voltage per cell
1.8 - 4.5 V
Balancing current peak / average
10 A / 5 A
Voltage measurement
0.0016 V (12 Bit ADC)
Temperature / current
measurement
12 Bit ADC
Performance
92 % (http://www.linear.com/product/
LTC3300-1#overview)
Relay output
12 V / 6 A / 80 ms impulse for bi-directional relay,
or permanent up to 0.23A on Relay ON output only
Galvanic isolated outputs
Disable charge / discharge,
ALERT
0,4 A (http://www.mouser.com/ds/2/205/
CPC2014N-13500.pdf), on customer request 2.2A
Interface
RS485
Safety
4 inputs for NTC temperature sensors
outputs for relay and external switches
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1.2. Hardware
•active balancing with 4 independent bi-directional fly-back converters
•active balance power 10 A peak / 5 A average per channel, 2 channels at the same time
•extendable by PBAL-Ext 3 W / channel
1.3. Board Overview
clamp connector for IN/OUT TOS for chaining JOULIEs
ERNI connector for -BLOCK, Cell1 .. Cell4
clamp connector for Current Sensor
RJ45 connector for 4 temperature sensors (NTC, 10k)
RJ45 connector for RS485 (DOWN)
RJ45 connector for RS485 (UP)
clamp connector for Relay/Disable charge/Disable discharge/SOC
DIP switch for SLAVE addresses, SPI Interface, isolated RS485 IN
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TOS
Cell
Connector
Temp.
Sensor
RS485
DOWN
CPU
DIP
SPI
PBAL-Ext
RS485
UP
Current
Sensor
Relay
Connector
Iso
Balancer Area
12 bit ADC
PBAL-Ext

JOULIE-4c Application Guide
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1.4. Connectors Overview
https://
www.showmecables.com/blog/post/rj45-pinout/
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Connecting LEM HASS 100 current sensor (or comparable) and relay
In order to use a regular relay instead of a bi-stable one (default) close the Relay Jumper.
The current may not exceed 200mA.
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1.5. DIP switch, Jumpers and receptacles
Dip switch for addressing the Jumper Power ON/OFF
JOULIE’s in a chain; close: 12V Joulie only
0 = Master, 1 <= Slave <= 63 open: for a chain of Joulie’s
Receptacle for PBAL_EXT:
Bal_Extension, from left: CELL1..CELL4
P_2 (to cells) from left (attention!): Cell4 .. Cell1, -Block
1.6. Meaning of the LEDs
4 green LEDs close to the ERNI balancer plug indicates the connection of the 4 cells.
1 green LED on the rightmost indicates the SOC by blinking SOC/10 times, f.e. 8x
blinking means SOC >= 75% and < 85%. Flashing in case of error.
1 yellow LED close to the green one indicates the RS485 communication between the
Slaves and the Master in a chain.
4 green LEDs close to the transformers indicate balancing between the cells. There is
no indication possible which cell is charged and which discharged. This could be read
by the trace output using the command *gMxxx. See chapter Software#
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2. PBAL-Ext
•optional extension for JOULIE-4c, increases the balance power by 3 A per cell
PBAL_Ext (not yet developed)
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3. Applications
The BMS can be used in di"erent ways (see schematics):
3.1. One JOULIE for a single 12V block
JOULIE setup for a 12V battery
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Important Notice:
All RJ45-IN wires are galvanically isolated. The RJ45-OUT lines do not.
When connecting external systems, be aware that there may be high voltages
depending on the connections. Please avoid connecting multiple serial-to-USB
converters to multiple JOULIE boards on the same external system, e.g. a PC.
The GND level is the plus level of the predecessor board!
Only within the same JOULIE you can use GND as reference potential.
3.2. Chained JOULIE’s for a 24V battery
This shows a setup for a 24V battery.
All GND connections are local to the dedicated JOULIE !
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3.3. Chained JOULIE’s for a high voltage battery - up to 900V
The CTRL units act in the same way like the JOULIE's does: the first one is the
“Master”, the communication is serial as well. All chains (CTRL boards) can be
connected to LiMaster (see Manual for Master). (CTRL not developed yet).
Setup for up to 8 chains of up to 64 JOULIE’s in every row.
Important Notice again:
All RJ45-IN wires are galvanically isolated. The RJ45-OUT lines do not.
When connecting external systems, be aware that there may be high voltages
depending on the connections. Please avoid connecting multiple Serial-to-USB
converters to multiple JOULIE boards on the same external system, e.g. a PC.
The GND level is the plus level of the predecessor board!
Only within the same JOULIE you can use GND as reference potential.
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4. Installation steps for a 12V battery
Connect 4 cells in series to a 12 V (14 V) block.
On top of every + pole mount the CellCon NTC boards (do not mount
below the cell connectors).
Connect fuse, current sensor and relay (see chapter Connectors Overview).
Connection schema for CellCon boards, current sensor, relay.
Be aware of the current direction from + to -.
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Connect the CAT5 temperature sensor wires to the clamp connectors on
the CellCon NTC - ensure you use paired wires (orange, blue, green,
brown).
Bridge the TOS clamp connectors right most:
DO NOT PLUGIN THE ERNI CABLE into the JOULIE board! Follow these steps first.
Connect the black wire of the ERNI cable to the - pole of the 1st cell.
Connect the other wires of this ERNI cable with the + pole of cells 1- 4.
For best contact of the balancer wires it’s recommended to use ring
connectors.
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