Friwo 14S12P User manual

Motor-Control Experts
Manual
Battery Pack
Dipl.-Ing. (FH) Henrik Vogler, F IWO Gerätebau GmbH

Chapter: Table of Contents Manual Battery Pack
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1 Table of Contents
1 Table of Contents ............................................................................................................................................................. 2
2 Copyright .......................................................................................................................................................................... 4
3 Safety Information, Terms of Use and Liability Wai er ................................................................................................... 5
4 General information......................................................................................................................................................... 9
4.1 Usage ........................................................................................................................................................................... 10
4.2 Description of parameters and measured alues .................................................................................................. 11
4.3 Important notes on changing parameters .............................................................................................................. 12
5 Technical Data ................................................................................................................................................................ 13
5.1 Housing/Dimensions .................................................................................................................................................. 13
5.2 Electrical Data Battery Pack ....................................................................................................................................... 14
5.3 BMS Mk2...................................................................................................................................................................... 15
5.4 Runtime battery pack ................................................................................................................................................. 15
5.5 Power Connector ........................................................................................................................................................ 16
5.5.1 Connector Type ............................................................................................................................................. 16
5.5.2 Pin Assignment .............................................................................................................................................. 16
5.6 Foil Display .................................................................................................................................................................. 17
5.6.1 Layout ............................................................................................................................................................. 17
5.6.2 State of charge (SoC) display ........................................................................................................................ 18
6 Using the BMS/Battery Pack .......................................................................................................................................... 19
6.1 Discharging the Battery ............................................................................................................................................. 19
6.1.1 Switching ON/OFF pushbutton (Pushbutton Mode) .................................................................................. 19
6.1.2 Switching ON/OFF button (keylog mode) .................................................................................................... 19
6.2 Charging the Battery .................................................................................................................................................. 21
6.2.1 Battery charging (Non Grid FW) (general) ................................................................................................... 21
6.2.2 Battery charging (Non Grid FW) (FRIWO LEV500 ariant) .......................................................................... 21
6.2.3 Battery charging (Grid FW) (FRIWO LEV500 ariant) .................................................................................. 21
6.3 BMS Mk2 Protection and Safety features ................................................................................................................ 22
6.3.1 Short-circuit Protection ................................................................................................................................. 22
6.3.2 Protection on 12V output ............................................................................................................................. 22
6.3.3 O ercurrent Protection ................................................................................................................................. 22
6.3.4 Start-up safety check..................................................................................................................................... 23
6.4 Precharge characteristics and limitations ................................................................................................................ 24
7 Ad anced setup and Troubleshooting ........................................................................................................................... 25
7.1 BMS Basic Setup ......................................................................................................................................................... 26
7.2 Setup the charging beha iour of the Battery .......................................................................................................... 27
7.2.1 Non Grid FW ................................................................................................................................................... 27
7.2.2 GridFW ............................................................................................................................................................ 27
8 SOC/SOH module description ........................................................................................................................................ 28
8.1 General Functions ...................................................................................................................................................... 28
8.2 SOC calculation - Current Integration ...................................................................................................................... 29
8.2.1 Full charge correction ................................................................................................................................... 29
8.2.2 Pack depletion detection .............................................................................................................................. 29
8.2.3 SOC correction - Voltage measuring ........................................................................................................... 30
8.2.4 SOC correction – manual preset .................................................................................................................. 31
8.3 SOH calculation........................................................................................................................................................... 31
9 HW Code ......................................................................................................................................................................... 32
9.1 BMS Mk2...................................................................................................................................................................... 32
32
10 Using Battery Packs in parallel ....................................................................................................................................... 33
10.1 Using “Grid” - General Information ........................................................................................................................... 33
10.2 References................................................................................................................................................................... 34
10.3 Wiring Diagram “Grid Connection” ........................................................................................................................... 34
10.4 Acti ation Procedure using a “Key Switch”............................................................................................................... 35
10.5 Acti ation Procedure using a “CAN Bus message” .................................................................................................. 35
10.5.1 Settings in MC configuration to acti ate the solution CAN Bus messages .............................................. 35
10.5.2 Needed Messages ......................................................................................................................................... 35
10.5.3 Procedure ....................................................................................................................................................... 36
10.6 ICS Info Message ........................................................................................................................................................ 37

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11 Error Handler ................................................................................................................................................................. 38
11.1 References................................................................................................................................................................... 38
11.2 O erall Description ..................................................................................................................................................... 38
11.3 Error Code Summary ................................................................................................................................................. 39
11.4 Errorcode beha ior .................................................................................................................................................... 39
11.5 Detailed Descriptions ................................................................................................................................................. 40
11.5.1 ERR_E_TEMP_Powerstage_1 ......................................................................................................................... 40
11.5.2 ERR_E_TEMP_Powerstage_2 ......................................................................................................................... 40
11.5.3 ERR_E_Charge_Current ................................................................................................................................. 41
11.5.4 ERR_E_Discharge_Current ............................................................................................................................ 41
11.5.5 ERR_E_Pack_Voltage_Max ............................................................................................................................. 41
11.5.6 ERR_E_Pack_Voltage_Min .............................................................................................................................. 42
11.5.7 ERR_E_Analog_O er oltage .......................................................................................................................... 42
11.5.8 ERR_E_Current_Sensor_Offset...................................................................................................................... 42
11.5.9 ERR_E_EEPROM .............................................................................................................................................. 43
11.5.10 ERR_E_Cell_Monitor_CRC .............................................................................................................................. 43
11.5.11 ERR_E_External_Enable ................................................................................................................................. 43
11.5.12 ERR_E_Cell_Monitor_Alert ............................................................................................................................. 43
11.5.13 ERR_E_Cell_Monitor_Fault ............................................................................................................................. 44
11.5.14 ERR_E_Powerstage ........................................................................................................................................ 44
11.5.15 ERR_E_PreCharge .......................................................................................................................................... 44
11.5.16 ERR_E_Output_Voltage_High ........................................................................................................................ 45
11.5.17 ERR_E_Pack_Voltage_Min .............................................................................................................................. 45
11.5.18 ERR_E_Pack_Discharge_Voltage_Acti e_State ............................................................................................. 46
11.5.19 ERR_E_Cell_Under oltage ............................................................................................................................. 46
11.5.20 ERR_E_Cell_O er oltage ................................................................................................................................ 46
11.5.21 ERR_E_Analog_O ercurrent .......................................................................................................................... 47
11.5.22 ERR_E_O ertemp_Charge ............................................................................................................................. 47
11.5.23 ERR_E_O ertemp_Discharge ........................................................................................................................ 47
11.5.24 ERR_E_Undertemp_Charge ........................................................................................................................... 48
11.5.25 ERR_E_Undertemp_Discharge ...................................................................................................................... 48
11.5.26 ERR_E_Current_Flow_Passi e_State ............................................................................................................. 48
11.5.27 ERR_E_CAN_Timeout ..................................................................................................................................... 49
11.5.28 ERR_E_Cell_Connection ................................................................................................................................. 49
11.5.29 ERR_E_12V_AUX_Under oltage .................................................................................................................... 50
12 Versioning ...................................................................................................................................................................... 50

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2 Copyright
The content of this document is protected and may not be used, not even in part, for own publications and
implementations. Exceptions require written approval.

Chapter: Safety Information, Terms of Use and Liability Waiver Manual Battery Pack
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3 Safety Information, Terms of Use and Liability Wai er
Warning!
Using the BMS referenced in this document can be dangerous. Please follow instructions it with extreme
caution. Stop your application work if you encounter unexpected behaviour.
Terms of use
The use of this program, further called "Enable-Tool", can be very dangerous, that means it can cause
damage to personal and property.
Use it with extreme care and make sure that you have received instructions for use of it by qualified
personnel.
With this software, you are able to influence or control a connected electronic control system such as motor-
controllers, battery-management-Systems or other general electronic control devices. Your actions may
result in serious personal injury or property damage. Therefore, you should only be using this software if you
understand the possible consequences of the actions with this software and if you have been specifically
trained to handle this software! Enable-Tool is currently under development and functionality might be
subject to change without prior notice or arrangement.
Liability wai er
This is a liability waiver (further called “waiver”) which is made between the parties F IWO Gerätebau GmbH
("Manufacturer") Von-Liebig-Strasse 11, 48346 Ostbevern and the user of Enable-Tool ("User"). For
purposes of this waiver, the definitions of the parties shall be deemed to include any parent, subsidiary,
affiliate of, or entity under common control with any entity constituting the parties consisting of
Manufacturer and User.
1. Purpose
User desires to get access to the online-network infrastructure of the Manufacturer to obtain a license to use
Enable-Tool. User desires to use Enable-Tool to work with one or more electronic-control-units of
Manufacturer. The parties acknowledge that advanced electronic-control-units are complex and proprietary
devices that require special knowledge, skills and equipment to program and commission. User declares that
he has all necessary special knowledge, skills and equipment to work with and apply to such devices.
2. No obligation
Neither party shall be legally obligated in any way as a result of this waiver. The execution of the waiver shall
not prevent either party from continuing its independent, ongoing development of technologies, products
and other business-related research and development.

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3. General
This waiver shall inure to the benefit of and be binding upon the parties and their successors and assigns,
provided that the receiving Party may not assign all or a part of this waiver without the prior written consent
of the Disclosing Party. If any provision of the waiver is held invalid or unenforceable by a court of competent
jurisdiction, such invalidity or unenforceability will not effect any other provision of the waiver, which shall
remain in effect.
4. Governing Law
This waiver shall be construed, and the obligations, rights and remedies of the parties hereunder shall be
governed by the laws of and subject to the jurisdiction of Kornwestheim, Germany.
5. Entire waiver
This waiver constitutes the entire waiver between the parties with respect to the subject matter herein, and
supersedes all prior oral or written waivers, arrangements, and understandings related thereto. This waiver
may not be modified or amended except in writing signed by an authorized representative of each Party.
WHE EOF, in consideration for the mutual promises contained herein, the parties have caused this waiver to
be executed by their authorized representatives. F IWO Gerätebau GmbH assumes no liability for loss of
data, personal injury or damage of property caused by misuse of the program or by use of improper settings.
In particular, we expressly point out that Emerge Engineering GmbH under no circumstances warranty /
liability for data loss, personal injury or property damage resulting from the direct use of this software takes
over.
Disclaimer
1.)
F IWO (hereinafter includes its parents, affiliates, subsidiaries, partners and suppliers) as a supplier
of system components, such as motor controllers, BMS, display, etc. generally excludes any liability
or recourse claims in connection with system integration.
2.)
The manufacturer of the end product, e.g. vehicle, machine, etc., hereinafter referred to as system
integrator, is solely responsible for the correct system design and integration of the system
components. This applies in particular to the mechanical and electrical design of the overall system
and to the parameterization of the system components. Any liability for the overall system is
excluded by F IWO. Further, the system Integrator and/or end users shall indemnify F IWO from
any claims and damages resulting from the improper use of the components delivered by F IWO.
3.)
The system integrator is solely responsible for the parameterization of the overall system, its
validation, reliability and safety. F IWO shall not be liable for any claims or damages which may
arise in this connection.

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4.)
The system integrator guarantees that the end product complies with the standards and guidelines
applicable and/or required for the overall system before it is used on public roads. In case of a
market launch or commercial sale to customers, the system integrator ensures that the overall
system is certified and approved meeting all safety norms. Any liability for claims or damages on
the part of F IWO shall be excluded.
Examples for relevant standards and guidelines (no claim to completeness, to be checked by the
system integrator):
UN 38.3 ecommendations on the Transport of Dangerous Goods
(IEC62281) Safety of primary and secondary lithium cells and batteries during transport (UN 38.3)
UL 62133-2 Secondary Cells and Batteries Containing Alkaline or Other Non-Acid Electrolytes -
Safety equirements for Portable Sealed Secondary Cells, and for Batteries Made From Them, for
Use in Portable Applications
UL 2580 Standard for Batteries for Use In Electric Vehicles
UL 2271 Standard for Batteries for Use In Light Electric Vehicle (LEV) Applications
UL 1973 Standard for Batteries for use in Stationary, Vehicle Auxiliary Power, and Light Electric ail
(LE ) Applications for data centres, IT equipment, and grid-tied energy storage
UL 2595 General equirements for Battery-Powered Tools
UL 2054 Household and commercial batteries
5.)
If system components are explicitly provided / delivered to the system integrator without
approvals, the system integrator is obliged to obtain the necessary approvals. F IWO shall not be
liable for any claims or damages arising directly or indirectly from breach of the above mentioned
obligation by the system integrator.
6.)
If F IWO supplies system components with the designation "Prototypes" or “Engineering Samples”
to the system integrator in the course of the development process, the system integrator will
ensure that these system components are only operated under supervision and exclusively for the
verification of the use cases and are not placed on the market (end customer). These components
may not be used in public areas. F IWO shall not be liable for any claims or damages arising
directly or indirectly from the operation of these components.

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7.)
The system integrator ensures that the end product is safe for the end customer and that no
danger emanates from it. F IWO shall not be liable for any claims or damages for the safety of end
product.
8.)
The system integrator shall be liable for any operating errors that may lead to personal injury,
serious injury or death. The system integrator ensures that the integration and validation is carried
out by personnel trained in the relevant technology areas (electrical, electronics, mechanical etc.).

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4 General information
Note: Battery application should only be done by well-trained persons with deep knowledge of battery
systems. Wrong handling of batteries could cause injuries and death. Under wrong handling Lithium- on
batteries could cause fire. Changing parameters can have a negative effect on the behaviour of the BMS
and could cause fatal errors.. Please observe the following notes when connecting a BMS or making
adjustments. n case of questions contact the FR WO Team.
Note: USB is not available in a fully assembled Battery Pack. For parametrization CAN Bus can be used.
Note: Do not open fully assembled Battery Pack. Opening a Battery Pack could cause injuries, fire and
death.
n case of changes of the factory setup the warranty expires. f the parameterset is changed the costumer
is responsible for all kind of errors or dangers that may result out of the change.
Note: Technical data and documentation subject to change without notice.
Note: The BMS is equipped with a precharge functionality to avoid hot plug events. t is recommended to
use this function to power up external or connected systems. Hot plugging an external system could cause
damages

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4.1 Usage
Note: This document is not related to the end costumer!
This document describes the functionality and parametrazion of the F IWO Gerätebau Battery Pack,
equipped with BMS Mk2
To setup the BMS you need a Windows PC on which the F IWO Enable Tool NG is installed in the latest
Version.
Parameters on the BMS can be changed or measured during operation using the Enable-Tool software. A
description of the Enable tool is provided separately.

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4.2 Description of parameters and measured alues
This document describes parameters and measured values that influence or make measurable the behaviour
of the software at runtime and assumes that you understand the Parameter names according to the
following nomenclature:
The formation of variable names follows the following principle:
Figure 1: Variable education.
Variables can be adjusted or measured with the F IWO Enable tool. ead the appropriate instructions before
using the Enable tool. The view of the Enable tool is customer-specific configured and can vary depending on
the application.
It is therefore possible that not all parameters and measured values described in this document are available
to you.

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4.3 Important notes on changing parameters
Note: Changing parameters can have a negative effect on the behaviour of the BMS. Please
observe the following notes when making adjustments:
Note: Fully assembled Battery Packs are not intended to change any factory settings. With any
change of parameters the warranty will expire .
Note: Changing parameters of a fully assembled Battery Packs could cause injuries, fire and
death. Changing parameters can have a negative effect on the behaviour of the BMS and the
Battery Pack and could cause fatal errors.
 Start your application work only after you have read this document completely and understood how
the parameters work.
 Change parameters in the smallest possible steps.
 Great importance was attached to the safety during the development of the BMS software.
Incorrect entries are usually intercepted and parameter changes are limited to safe values.
 However, a residual risk cannot be ruled out with certain changes. You should always use a USB
isolator to protect your PC from possible overvoltages and to prevent ground loops in your
laboratory or test bench.
 Some critical parameters are monitored by superimposed protective functions, so that only limited
changes are possible during peration.
 Confirm the entry of the parameter values by pressing Enter. Save parameters by clicking on "Store
Parameters". When restarting the BMS, the stored parameters are retained.

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5 Technical Data
5.1 Housing/Dimensions
Weight: approx. 11.05kg
Volume: approx. 8.1l

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5.2 Electrical Data Battery Pack
Configuration 14S12P
Cells 18650 Type (Samsung IN 18650-35E; BAK 18650-CP)
nominal voltage 50.4V
nominal capacity 40.2 Ah(0.2C, 2.5V discharge)
nominal energy 2026Wh
Charging voltage 58.8V
Charging method CC-CV (constant voltage with current limit)
Max. charging current 20A
ecommended charging current 12A
Min. charging current 1A
Max. cont. discharge current 70A
Max. discharge current Depending on temperature and cooling (see chapter 5.4)
Short circuit detection level 153A (<10μµsec)
Discharge cut off voltage 42V recommended, depending on the application and
parametrization of the BMS , min. 37.1V not for cycle life
Operation temperature Charge: 0 to 45°C
Discharge: -10 to 60°C
Power Density 250Wh/l
183,41Wh/kg

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5.3 BMS Mk2
Type: 1960815 or Variants
BMS cell configuration: 14S Li-Ion (HW Coded)
Max pack voltage: 60V
Max continuous Current: 70A (with Heatsink, 60A open Frame)
Peak current 150A (short Circuit protection @ 153A)
Idle power consumption: 20mA
Deep sleep consumption: 78µA
Max current 12V link: 2A
Note: BMS Mk2 is available in HW Coded to a cell configuration. Other variants from 10S up to 15S are
available. Changing the HW code is not possible. Please contact the FR WO Sales Team.
Note: Technical data and documentation subject to change without notice.
5.4 Runtime battery pack
The runtime of battery pack is dependent on mounting and cooling situation in application. The
temperature of cells and BMS is continuously monitored and operation is limited to values
mentioned in chapter 5.2.
Typical runtimes of battery pack starting at 20°C:
70A 20min (limited by cell temperature)
60A 30min (limited by cell temperature)
50A 45min (limited by capacity)
35A 60min (limited by capacity)

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5.5 Power Connector
5.5.1 Connector Type
Type: WY28K8BZZ1
ated current: 70A
5.5.2 Pin Assignment
PIN 1 BAT-
PIN 2 BAT+
PIN 3 Charge sense
PIN 4 CAN low
PIN 5 CAN high
PIN 6 BAT enable
PIN 7 12V
PIN 8 n.c.

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5.6 Foil Display
Note: The functionality and the behaver of the Battery pack is depending on the software version and the
parametrization. The described functionality may differ depending on the application!
5.6.1 Layout
Note: Example Layout of a Foil display. The Layout may differ. Main functionality will remain the same.
Subject to change without notice.

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5.6.2 State of charge (SoC) display
The current state of charge (SoC) is indicated by the LEDs as follows:
>80 to 100% -> 5 LED`s light up
>60 to 80% -> 4 LED`s light up
>40 to 60% -> 3 LED`s are on
>20 to 40% -> 2 LEDs are on
>5 to 20% -> 1 LED is on
0 to 5% -> No LED is lit
In addition, the LEDs generate different signals in the following applications:
When waking up the battery, the 5 LED`s generate a running light.
In case of error detection, all 5 LEDs flash several times simultaneously.
When switching to sleep mode (deepsleep), all 5 LEDs flash briefly, then generate a running light
and go out.

Chapter: Using the BMS/Battery Pack Manual Battery Pack
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6 Using the BMS/Battery Pack
Note: The functionality and the behaver of the Battery pack is depending on the software version and the
parametrization. The described functionality may differ depending on the application!
6.1 Discharging the Battery
6.1.1 Switching ON/OFF pushbutton (Pushbutton Mode)
The pushbutton is used to switch the system on and off with the following realizations:
Short press (short press) t < 1s: wakes up the BMS and activates the communication on the CAN
interface, this is indicated by a green backlit ring around the ON/OFF symbol. In addition, the 5 bars
of the charge level indicator are backlit. The output voltage is not enabled.
Long press 1s< t < 5s: Activates the output voltage. This is indicated by the HV LED.
A long press in the activated state (HV switches the output voltage off again and the HV LED goes
out.
Super long press (t= >5s): Deactivates the battery. The output voltage is switched off, if it was
switched on, and the battery goes into sleep mode (Deepsleep). This is additionally indicated by a
flashing of the SoC-LEDs and a running light from top to bottom, at the same time the HV-LED
goes out, shortly afterwards also the backlit ring around the ON/OFF symbol.
6.1.2 Switching ON/OFF button (keylog mode)
In "Keylog Mode", the button is used only secondarily for switching the system on and off. In this
mode, the system is primarily activated via the "Bat Enable" pin.
Pressing the button activates the battery analog to the "Bat Enable" pin (pulled to BAT-) and wakes
up the BMS, activates the communication on the CAN interface and the 12V and HV output
voltage. This is indicated by a green backlit ring around the ON/OFF symbol and the HV symbol.

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When the button is released or the "Bat Enable" pin is opened, the communication on the CAN
interface, the HV and 12V output voltage is deactivated again and the battery goes into sleep mode
(Deepsleep).