AXIOMATIC AX090690 User manual

USER MANUAL UMAX090690
Version V1.3
Dual 12V Li-ion BATTERY CHARGER
With SAEJ1939
USER MANUAL
P/N: AX090690

UMAX090690. Version: 1.2 Preliminary Documentation –May Be Subject To Change 2-37
ACCRONYMS
ACK Positive Acknowledgement (from SAE J1939 standard)
CAN Controller Area Network
DM Diagnostic Message (from SAE J1939 standard)
DTC Diagnostic Trouble Code
EA Electronic Assistant, p/n AX070502 (A Service Tool for Axiomatic ECUs)
ECU Electronic Control Unit (from SAE J1939 standard)
FMI Failure Mode Identifier
NAK Negative Acknowledgement (from SAE J1939 standard)
PDU1 A format for messages that are to be sent to a destination address, either specific
or global (from SAE J1939 standard)
PDU2 A format used to send information that has been labeled using the Group
Extension technique and does not contain a destination address.
PGN Parameter Group Number (from SAE J1939 standard)
PropA Message that uses the Proprietary A PGN for peer-to-peer communication
PropB Message that uses a Proprietary B PGN for broadcast communication
PWM Pulse Width Modulation
OC Occurrence Count
SPN Suspect Parameter Number (from SAE J1939 standard)
VPS Voltage Power Supply

UMAX090690. Version: 1.2 Preliminary Documentation –May Be Subject To Change 3-37
TABLE OF CONTENTS
1. INTRODUCTION.......................................................................................................................6
2. BATTERY CHARGER THEORY OF OPERATION...................................................................7
2.1. BATTERY CHARGER MODES ............................................................................................................................... 7
Charger Temperature...................................................................................................................................................8
2.2. BATTERY CHARGER STATE DIAGRAM ................................................................................................................. 9
2.3. BATTERY PROTECTION....................................................................................................................................... 9
3. OVERVIEW OF J1939 FEATURES........................................................................................11
3.1. INTRODUCTION TO SUPPORTED MESSAGES....................................................................................................... 11
3.2. NAME,ADDRESS AND SOFTWARE ID................................................................................................................. 12
J1939 Name................................................................................................................................................................ 12
ECU Address ............................................................................................................................................................... 12
Software Identifier .....................................................................................................................................................13
4. BATTERY CHARGER FUNCTION BLOCKS.........................................................................15
4.1. CHARGING PROFILE FUNCTION BLOCKS............................................................................................................ 15
4.2. MISCELLANEOUS INPUT FUNCTION BLOCK ........................................................................................................ 15
4.3. J1939 NETWORK FUNCTION BLOCK ................................................................................................................. 15
4.4. DIAGNOSTIC INPUT FUNCTION BLOCKS ............................................................................................................. 15
4.5. CAN TRANSMIT FUNCTION BLOCK.................................................................................................................... 18
4.6. CAN RECEIVE FUNCTION BLOCK...................................................................................................................... 19
5. ECU SETPOINTS ACCESSED WITH ELECTRONIC ASSISTANT .......................................21
5.1. NETWORK SETPOINTS ...................................................................................................................................... 21
5.2. COMMON CAN SETPOINTS............................................................................................................................... 21
5.3. CHARGING PROFILE SETPOINTS........................................................................................................................ 22
5.4. MISCELLANEOUS INPUT SETPOINTS .................................................................................................................. 24
5.5. DIAGNOSTIC INPUT SETPOINTS ......................................................................................................................... 24
5.6. CAN RECEIVE SETPOINTS................................................................................................................................ 25
5.7. CAN TRANSMIT SETPOINTS.............................................................................................................................. 26
6. BATTERY CHARGER ERROR CODES.................................................................................28
6.1. BATTERY ERROR CODES.................................................................................................................................. 28
7. REFLASHING OVER CAN WITH EA BOOTLOADER.......................................................29
8. INSTALLATION INSTRUCTIONS...........................................................................................34
9. TECHNICAL SPECIFICATIONS.............................................................................................35
9.1. INPUT SPECIFICATIONS..................................................................................................................................... 35
9.2. OUTPUT SPECIFICATIONS ................................................................................................................................. 35
9.3. GENERAL SPECIFICATIONS ............................................................................................................................... 35
10. VERSION HISTORY................................................................................................................37

UMAX090690. Version: 1.2 Preliminary Documentation –May Be Subject To Change 4-37
Table 1 - Charger LED State Values............................................................................................6
Table 2 –Charger Mode Values .................................................................................................8
Table 3 –CAN Transmit Data Sources ......................................................................................18
Table 4 –Default CAN Transmit Messages................................................................................19
Table 5 –Default Network Setpoints ........................................................................................21
Table 6 –Default Common Control Setpoints............................................................................22
Table 7 –Default Charging Profile Setpoints .............................................................................23
Table 8 –Default Display Board Setpoints ................................................................................24
Table 9 –Default CAN Receive Setpoints..................................................................................25
Table 10 –Default CAN Transmit Setpoints ..............................................................................27
Table 11 –Error Codes............................................................................................................28

UMAX090690. Version: 1.2 Preliminary Documentation –May Be Subject To Change 5-37
Figure 1. Battery Charger Algorithm Profile.................................................................................7
Figure 2 . Voltage-Current Charging Profile ..................................................................................7
Figure 3 . Battery Charger State Diagram ....................................................................................9

UMAX090690. Version: 1.2 Preliminary Documentation –May Be Subject To Change 6-37
1. INTRODUCTION
The battery charger is designed to autonomously charge dual sided batteries. The AX090690
model can charge dual 12V batteries with a maximum charging current of 1.25A
Once programmed, the charger does not require any operator’s involvement in the charging
process; the charger automatically recognizes the presence of the battery, charges the battery to
the maximum capacity, and automatically maintains the battery charge if the charger is connected
to the power line. The charger will continue to charge the battery even if disconnected from the
J1939 CAN network.
When the charger is disconnected from the power line it automatically switches off, protecting the
batteries from discharge.
There are three main charge modes –Precharge Mode, Bulk Charge Mode, and Constant Voltage
Charge Mode –along with Float Mode for maintaining charge. Temperature sensing using an
auxiliary temperature sensor or through the J1939 network protects batteries from overheating,
shutting down the charging process if the battery temperature exceeds a certain level.
An internal red-green LED indicator on the front panel of the charger is used to monitor the internal
state of the charger. The charger states and corresponding LED indications are described in Table
1.
LED State
Description
Red/Green (Flashing)
Idle.
Green (Flashing)
At least one charger is in the precharge, bulk
charge, or constant voltage stage.
Green (Solid)
Both Chargers have completed charging and
are in the Charge Termination (Float) stage.
Red (Solid)
At least one charger has experienced a fault.
Table 1 - Charger LED State Values
Note that the LED indication prioritizes Fault state above all else, followed by active charging. This
means that for example, if Charger 1 is finished charging, but Charger 2 is still charging its battery,
the LED will stay blinking green until both are finished.
If connected to the J1939 CAN network, the charger continuously transmits its internal state,
charging current and the battery voltage. It can also use the J1939 network to acquire the battery
temperature and to perform any user specific functions on demand. The battery charger also
supports J1939 regular node functions, including address claiming, PGN responses, etc.
The RS232 interface of the charger allows the user to change the battery type, program battery
charger setpoints, flash the new software, and watch an internal state of the charger using one of
the standard terminal emulation software (Tera Term, Hyperterminal, etc.).

UMAX090690. Version: 1.2 Preliminary Documentation –May Be Subject To Change 7-37
2. BATTERY CHARGER THEORY OF OPERATION
The battery charger implements a three-stage charging algorithm with an additional charge stage
for maintenance.
Constant
voltage
Voltage
Time
Precharge
Stage
Bulk Charge Stage
Absorption
Stage
Float Stage
Current
Constant
current
Constant
current
Constant
voltage
Voltage, Current
Charging
Maintaining
Charge
Figure 1. Battery Charger Algorithm Profile
The charging process starts from the Precharge Stage, then, when the battery voltage reaches a
certain point, the charger switches to the Bulk Charge Stage, and the charging process is finalized
in the Absorption (Constant Voltage Charge) Stage.
After the battery is fully charged, the charger maintains the battery charge in Float Mode.
2.1. Battery Charger Modes
Each stage of the charging process corresponds to one or two battery charger modes. There are
also modes reflecting an idle or an error condition of the charger and a special power supply mode
used for testing.
The charger starts functioning from Idle Mode. It stays in Idle Mode until the Charger is enabled,
and a battery is connected to the charger.
Ich
Ibc
Vbc_start
Vbat
Vpc_start
Vbc_rst
Vfl_start
Vfl
Vcv_start
Vcv
Veq_stop
Ipc
Ieq
Icv_stop
Ifl_stop
Figure 2. Voltage-Current Charging Profile

UMAX090690. Version: 1.2 Preliminary Documentation –May Be Subject To Change 8-37
When the charger recognizes the battery, it starts analyzing the battery state. If the battery is
deeply discharged and its voltage is between Vpc_start and Vbc_start (See section 2.2), the
charger will start the precharging process, charging the battery with a relatively small constant
current Ipc. The small current prevents a deeply discharged battery from damage, which otherwise
could occur due to gas emission from the battery electrolyte at high current. The charger will stay
in the Precharge Mode until the battery voltage reaches the Vbc_start voltage.
When the battery reaches Vbc_start voltage, the charger will enter the Bulk Charge Mode
increasing the charging current to Ibc. It will charge the battery with the Ibc current until the battery
voltage reaches Vcv_start. At this point the battery is around 75% charged and the charger can go
to the Constant Voltage Charge Mode limiting the charging voltage to Vcv. This will cause a
gradual drop of the charging current. When the charging current drops to Icv_stop, the battery is
considered fully charged, and the charger will stop the charging process and go to Standby Mode.
In Standby Mode the charger only monitors the battery voltage. It will maintain the battery charge
either by periodically recharging the battery when the battery voltage drops below Vbc_restart, or
by maintaining the charge in Float Mode, if the voltage drops below Vfl_start voltage.
In Float Mode the charger limits the charging voltage to Vfl and the charging current Ibc. When the
charging current drops below Ifl_stop, the charger returns to Standby Mode, keeping the battery
voltage at a predefined level.
The charger stages can be used as signal sources for transmitting over CAN. The corresponding
values to the stages are given in Table 2.
Value
Charger Mode
0
Idle Mode
1
Charge Termination (Float) Mode
2
Precharge Mode
3
Constant Current Mode
4
Constant Voltage Mode
5
Recharge Mode
Table 2 –Charger Mode Values
Charger Temperature
In addition to the charging profile parameters, each charger has a temperature sensor. The
charger will turn off its output and go to Idle state if the temperature threshold is exceeded. The
charger will remain in Idle state until the Temperature Hysteresis value is cleared.
In case of electronics failure, the charger will be locked in Module Error Mode until either the
battery or the power is disconnected, and the charger goes to the initial Idle Mode.
Battery Temperature
Battery temperature can be measured using the RTD inputs. By default, the firmware is configured
to use a PT1000 temperature sensor. The maximum battery temperature is configured through the

UMAX090690. Version: 1.2 Preliminary Documentation –May Be Subject To Change 9-37
Miscellaneous Input setpoint “Shutdown Temperature”. If no RTD is connected, ensure the RTD
Enable setpoint is set to ‘Disabled’.
2.2. Battery Charger State Diagram
A complete set of the charger modes and their relations to each other are shown on the Battery
Charger State Diagram (Figure 3).
Figure 3. Battery Charger State Diagram
In order to avoid accidental switching of the charger from one mode to another due to noise,
transients, etc., the condition causing the transition must stay on for at least 3 seconds.
2.3. Battery Protection
To prevent a battery from damage, the battery charger has a time-out condition of 48 hours. The
charger will return to Idle state if the charge time exceeds this value.
By default, the battery charger will not start charging a battery with a voltage less than the
Precharge Mode Start Voltage. However, some batteries may contain a safety feature which
disconnects the output when not charging. In this case, the battery may hold a charge, but the
battery charger will read no voltage from the battery terminals. For this reason, the battery charger

UMAX090690. Version: 1.2 Preliminary Documentation –May Be Subject To Change 10-37
contains an additional function, Precharge Mode Force Enable. When enabled, the charger will
bypass the battery voltage check, and attempt to charge the battery in Precharge mode.