Emcotec RC Electronic DPSI BMS User manual

Operating Manual

DPSI BMS Operating Manual Version 1.0
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Contents
1. Preface .............................................................................................3
2. Features ...........................................................................................3
3. Properties of the DPSI BMS ...........................................................6
3.1. LC-Display...............................................................................7
4. Packing Contents............................................................................8
5. Optional Accessories .....................................................................9
5.1. DPSI BMS Accessory Set........................................................9
6. Mounting Instructions ..................................................................10
6.1. Mounting of the DPSI BMS....................................................10
7. Soldering of the Battery Connectors ..........................................13
8. Charging Instructions for Batteries............................................. 15
9. Initial Operation.............................................................................16
9.1. Automatically Switching On/Off .............................................16
9.2. Manually Switching On/Off ....................................................18
9.3. The DPSI BMS in Operation..................................................18
9.4. LC-Display Indications for the 2 Channel DPSI BMS............19
9.5. LC-Display Indications for the 1 Channel DPSI BMS............23
10. Resetting the Memorized Values...............................................25
11. Programming the DPSI BMS......................................................26
12. Safety Instructions......................................................................27
13. Technical Data of the DPSI BMS................................................ 29
13.1. Measuring Parameters of the DPSI BMS ............................30
14. Warranty.......................................................................................30

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1. Preface
With the DPSI BMS (Dual Power System Interface – Battery
Monitoring System) you purchased a high quality and reliable
measuring system for battery power supplies. We thank you for your
faith in EMCOTEC GmbH and assure you that you have made the right
decision! Years of experience in development and manufacturing of
electronic systems went into the DPSI BMS. All products are
manufactured completely in house at EMCOTEC GmbH in Germany.
In-house manufacturing, careful quality assurance and a 100% test of
all shipped systems assure you of the highest reliability and
functionality.
Please read this operating manual carefully in order to use all functions
of the DPSI BMS optimally. We wish you continued success and
enjoyment with this high quality product!
2. Features
The DPSI BMS (Dual Power System Interface – Battery Monitoring
System) is the first monitoring and displaying system for batteries of
twin power supplies for use in large model airplanes.
For operation, the DPSI BMS is simply put in between both batteries
and the already mounted battery switch. Switching on and off occurs
fully automatically as soon as current is drawn (when equipment turned
on) or no current is drawn (when equipment turned off).
The DPSI BMS displays all relevant measured values in plain text.
Besides the battery voltages and currents of the connected consumers
(minimum / average / actual / maximum values), withdrawn capacity as
well as turn on time is displayed.

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Due to the manifold information indicated by the DPSI BMS,
malfunctions in the receiver set can be detected:
- Sticky control rods or defective servos can be diagnosed due
to higher current consumption.
- Eventual malfunction of a battery or in the battery switch
(e.g. inbalanced discharge of the batteries) can be detected
as well.
- Programming of end stops of servos is simplified where no
optical control is possible (e.g. throttle servo), because the
increasing current will indicate mechanical end stop.
As a specialty, both battery circuits in the DPSI BMS are galvanically
separated! This means, no electrical connection between each other
exists. This allows you to use one battery for the ignition system and
another one for the receiver set and operate both without any
influence. Due to the galvanic separation, it is also possible to operate
the DPSI BMS in connection with all battery switches currently
available on the market.
The measured values are derived from high precision 12 bit A/D
converters. Due to this elaborate design, constant currents of 10 amps
are permissible for each channel. Peak currents of up to 30 amps per
channel are permissible, thus allowing the usage of the DPSI BMS
even in big model airplanes where many servos are in use.
In case only one battery is to be monitored, a single channel version of
the DPSI BMS is available. Here, just one battery is connected and its
parameters (voltage, current, capacity, etc.) are displayed.

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Three printed circuit boards, equipped on both sides with most modern
parts allow for optimal space usage and are integrated into a stable
and ergonomic housing. Usage of pin-and-socket connectors allow for
simple exchange of connector cables and guarantees maximum
flexibility.
DPSI BMS: intelligent solutions ergonomically packaged!

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Summary:
The DPSI BMS allows for full control of two independent batteries. This
means:
Two independent batteries connectable (galvanically
separated)
Two 12 bit A/D converters for high precision data
acquisition
Automatic On/Off switching; therefore only single
switch necessary
LC-Display with indication of voltage, current, capacity,
operating time of each battery or both batteries together
with min./max.- and average values
1 channel version and 2 channel version available
3. Properties of the DPSI BMS
Displaying system for two separate batteries in battery switches or
other applications
Easily fitted between battery and consumer
Discharges the battery with only 10 µA in turned off state
Automatically switches On/Off without additional switch
2-4 cell LiIon / LiPo batteries usable
5-12 cell NiCad / NiMH batteries connectable
Up to 10A constant current per channel permissible
Up to 30A peak current durable
Programmable user language (German / English)
Wireless system, i.e. all leads is pluggable and therefore
exchangeable at any time
High-quality plastic housing including bracket for the battery
connectors

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Proof recognition of erroneous linkages (through increased
current consumption)
Proof recognition of defective or decrepit batteries
Three double side populated printed circuit boards for highest
packing density and therefore small dimensions
Each system 100% tested
3.1. LC-Display
The LC display shows all information in plane text using 2 lines, 8
characters each:
- Actual voltage battery 1 and battery 2
- Actual current battery 1 and battery 2
- Minimum voltage battery 1
- Minimum voltage battery 2
- Maximum voltage battery 1
- Maximum voltage battery 2
- Maximum current battery 1
- Maximum current battery 2
- Average current battery 1
- Average current battery 2
- Maximum current battery 1 + battery 2
- Average current battery 1 + battery 2
- Withdrawn capacity battery 1
- Withdrawn capacity battery 2
- Withdrawn capacity battery 1 + battery 2
- Flight time (Operating time in minutes)
The withdrawn capacity (in mAh) and the operating time (in minutes)
can be reset on demand.

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4. Packing Contents
Included in delivery of the DPSI BMS
DPSI BMS basis device
Screwing frame for M3 stop nuts
2 pieces of screws M3x20 with stop nuts
Bracket for securing the MPX connectors
Operating manual
EMCOTEC sticker
Carrying case

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5. Optional Accessories
5.1. DPSI BMS Accessory Set
The DPSI BMS accessory set contains two connector cables, 30 cm
(11.8”) each, which are put in between the DPSI BMS and the battery
switch (1 cable for the 1 channel version). Therefore, no soldering work
is necessary if MPX connectors are already in use (from the battery to
the battery switch).
The accessory set also contains a bracket (for spare) which serves as
a lock for the MPX connectors.

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6. Mounting Instructions
6.1. Mounting of the DPSI BMS
The DPSI BMS is designed as a cockpit instrument and therefore can
be mounted as such (especially interesting for scale models). Of
course, mounting on a small board inside the fuselage is also possible.
The mounting place should not be exposed to extreme vibrations (as is
the case at a fuselage’s side wall without a strengthening frame). The
DPSI BMS is solid mounted by the accompanying frame which serves
as a counter bearing. By the way, the frame can serve as a positioning
device for the cutout of the DPSI BMS.
The screwing connection is accomplished with the delivered M3
screws and stop nuts, which do not get loose even when exposed to
vibrations.
Dimensions for mounting:
After mounting, the connector cables can be put into their
corresponding plugs/sockets. In order to avoid loosening of the
connections caused by vibrations, the accompanied bracket is fed in
between the positive and negative pole of the connection cable and
locked at the sides of the housing of the DPSI BMS. Herewith, the
connectors are secured against vibrating loose.

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Connector clamping with bracket:
When using battery switches, the DPSI BMS is simply put in between
the batteries and the battery switch. This means: both batteries are
disconnected from the battery switch and connected to the inputs of
the DPSI BMS. The DPSI BMS outputs are then connected to the twin
power supply (e.g. a DPSI RV system) using appropriate patch cables
(e.g. out of the accessory set).
Abmessungen des DPSI BMS:

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7. Soldering of the Battery Connectors
In case connector cables are manufactured by the user for connection
to the DPSI BMS, correct implementation must be observed. The MPX
high current connectors are marked + and – on their soldering side.
This marking must be strictly observed! The cables are first stripped
(approx. 5 mm / 0.2”) and then tin-plated. Before soldering the cables
to the connectors don’t forget to put the shrink hoses to the cable ends.
The cable is then soldered to all 3 pins, so it is located in their midst
(see photo). When using thin cables, the 3 pins can be bend to their
center (see photo). Sufficient tin has to be provided in order to connect
the cable to all 3 pins. The shrink hoses are then shrunk using a heat
gun.

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Soldering Multiplex connectors:
Hint:
It is necessary to use one shrink hose per cable (see photo) for isolation and not
to put a shrink hose over both cables! There must be enough space between the
positive and negative wire to accommodate the bracket.

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Hint:
Due to its design, the DPSI BMS is not polarity proof! Please make
sure, that the batteries are always correctly connected, i.e. the red
wire corresponds to positive and the black wire to negative.
Better double check!
8. Charging Instructions for Batteries
If batteries are to be charged while they are connected to the DPSI
BMS a second cable must be soldered to the batteries or the batteries
must be connected by a V-cable (LongGo batteries already do have a
charging connector integrated).
If in doubt, it is more reasonable and safer to disconnect the batteries
from the DPSI BMS for charging. Here, the bracket has to be released
(if mounted).
Hint:
Batteries, which are connected to the DPSI BMS during charging and having an
additional charging input (e.g. V-cable or charging connector), must be charged
separately, if the DPSI BMS is connected to a battery switch! Please observe the
operating manuals of the corresponding manufacturer of the battery switch.
Hint:
If the batteries are connected to the DPSI BMS during charging, a charger has to
be used which output voltage (charging voltage) never exceeds 20 volts (=>
limited step up converter). This is the case for all chargers of “ORBIT Electronic”.
Using an unlimited step up converter can cause damage to the DPSI BMS. Ask
your charger’s manufacturer if in doubt!
Hint:
Because batteries do not have any electrical connection among each other if
connected to the DPSI BMS, they can be of totally different types and can supply
their own consumers. Thus, a 2 cell LiPo battery can supply a receiver set and a
5 cell NiMH battery can be used to supply the ignition system for a gasoline
engine.

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9. Initial Operation
Initial operation, On/Off, Status Display:
The DPSI BMS is simply put in between battery and consumer (e.g.
between two LongGo batteries and a DPSI RV system).
Turning On/Off can take place in two different ways:
- Automatically turning On/Off
- Manually turning On/Off
9.1. Automatically Switching On/Off
Automatically turning on of the DPSI BMS always works. As soon as
the connected consumer (e.g. a receiver set connected to a battery
switch) draws current from battery 1 which exceeds approx. 100 to 150
milli amps, the DPSI BMS turns on automatically. Current drawn by a
receiver set using several servos usually clearly exceeds more than
150 milli amps per battery.

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However, automatic turning on only functions if current flows from
battery 1! If battery 1 is not loaded (but battery 2), the DPSI BMS is not
turned on.
Hint:
Whenever the current from battery 1 exceeds 100 to 150 milli amps, the DPSI
BMS automatically turns on. If the current is less (e.g. only a receiver without
servos is connected), the DPSI BMS does not turn on.
As soon as the current from battery 1 and battery 2 drops below 100 to
150 milli amps, the DPSI BMS turns off after approx. 10 seconds!
Hint:
As soon as the receiver set is turned off and the current from battery 1 drops
below approx. 100 to 150 milli amps, the DPSI BMS turns off automatically after
approx. 10 seconds.
Hint:
If the DPSI BMS turns itself on due to a short current pulse and the current
immediately drops below 100 to 150 milli amps, the DPSI BMS does not
necessarily turn off automatically, because the internal logic does not know
where the turn on command came from (automatic or push button).
Hint:
Current consumption of the DPSI BMS when turned off is just several µA.
Connected batteries therefore are not discharged!

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9.2. Manually Switching On/Off
In order to control the voltages of the batteries without turning on the
receiver set or the consumers (e.g. in winter), the DPSI BMS can be
turned on by a pushbutton (button “I”). A DPSI BMS turned on by the
button stays on until turned of by the off button (button “O”).
Hint:
If the DPSI BMS is turned on by the on button it stays on until turned off by the
off button.
An automatically turned on DPSI BMS can be turned off using the off button (but
will immediately turn on again if the current is higher than 150 milli amps).
9.3. The DPSI BMS in Operation
Hint:
For operation, battery 1 has to be connected because the electronics of the DPSI
BMS are supplied by battery 1. The micro controller and the LC display get their
voltage from battery 1!
As soon as the DPSI BMS is turned on, “EMCOTEC Germany” is
displayed for approx. 2 seconds in the LC display. Thereafter, both
voltages of the batteries are displayed (BMS 2 channel version) and
the DPSI BMS is in normal operating mode. The 1 channel version
displays the actual voltage as well as the actual withdrawn current of
the battery (battery 1).
Using both arrow keys (left side of housing) different information can
be retrieved.
If in sequence the button is pressed, values are displayed as
follows.

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9.4. LC-Display Indications for the 2 Channel DPSI BMS
This standard display in normal
operating mode shows the actual
voltages of both connected
batteries.
If battery 2 is not connected or its
voltage is too low, the value
“< 4.0V” is displayed.
If the voltage of one connected
battery exceeds 20 volts, “> 20V” is
displayed. CAUTION: only a max.
of 16 volts are allowed!
Display of actual current withdrawn
from battery 1 and battery 2.
If the DPSI BMS is turned on
(manually) for testing without any
consumer, the display indicates a
current of < 150 milli amps (0.15A).
Minimum battery voltage of battery
1 since last turned on.

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Minimum battery voltage of battery
2 since last turned on.
Maximum battery voltage of battery
1 since last turned on (maximum
value 20.0V).
Maximum battery voltage of battery
2 since last turned on (maximum
value 20.0V).
Maximum current from battery 1
since last turned on. If the value I is
< 150mA this is indicated
accordingly.
Maximum current from battery 1
since last turned on. This value
indicates the peak current which
was reached in the equipment and
can reach up to 13.00 amps.
Higher values are displayed as
“> 13.00A”.
Maximum current from battery 2
since last turned on. If there is no
current flow, the value “<0.15A” is
displayed.