Zeva Electric Vehicle Management System V3 User manual

ELECTRIC VEHICLE MANAGEMENT SYSTEM V3 ZERO EMISSION VEHICLES AUSTRALIA
ZERO EMISSION VEHICLES AUSTRALIA
http://www.zeva.com.au
Electric Vehicle Management System V3
Multifunctional, integrated control system for your EV
Table of Contents
Introduction 2
Safety Warning 2
  Specications    3
  Installation    4
  DescriptionofConnections  5
  CANBusWiring    6
  ChargerIntegrationOptions  7
EVMS Monitor 8
  ConguringSettings   10
  ListofSettings    10
  MultiPurposeInputsandOutputs  14
  ErrorDetection    15
  VoltageThresholds   17
  StateofChargeSynchronisation  19
  StationaryMode    19
  UseWithBatteriesOver350VDC  20
  IsolationFaultDetection   20
  TechnicalSupportandWarrantyInformation 20
Introduction
Thank you for purchasing ZEVA’s ElectricVehicle Management System. The EVMS was
developedtoaddresstheneedforsafer,morereliableandbetterintegratedEVconversions.
Itcombinesmanycommonfunctionsandarangeoffaultdetection,providingwarningsof
operatingerrorsandautomaticallyrespondingtoseriousfaults.
Instrumentationincludingvoltage,current,power,batterycharge,temperature,and•
isolationintegrity.
Batterymanagementincludingcellvoltageandtemperaturemonitoringwithauto-•
maticresponsetounder/over-chargedbatteries,andautomaticpackbalancing.
Analoggaugeoutputstore-useOEMfuelgauge,tempgaugeandtachometer.•
Contactorcontrolformanagementofauxiliarycontactors,allowingbatterypack•
break-upandisolationforsafetywhenvehicleisnotinuse.
Optional2-stageprechargerwithfaultdetectionforsoft-startingmotorcontrollers•
Detectionofmanydifferentoperatingerrors/warnings.•
AcompleteinstallationconsistsofanEVMS,usuallyinstalledinthevehicle’senginebay,
communicatingoverCANbuswithaMonitormoduleinthevehiclecabin,andacurrent
sensorandbatterymanagementmoduleslocatedwithinyourbatteryboxes.TheCANbus
mayalsoincludeuptothreeTCChargersandaZEVAmotorcontroller.
ThismanualdescribestheinstallationandoperationofboththeEVMSandMonitordevices.
Please refer to documentation supplied with your BMS modules, motor controller and
chargerforfurtherinformationrelatingtothosedevices.
Safety Warning
Electricvehiclesarehighpoweredmachineswhichinvolvepotentiallylethalvoltagesand
currents.Properprecautionsand electricalsafetyproceduresshouldalwaysbeobserved,
voltages above 110VDC should be considered dangerous, and vehicles should never be
worked on while power contactor(s) are engaged. Please read this manual carefully to
ensurecorrectinstallationandoperation.Ifyouareunsureofanything,pleasecontactus
beforeproceeding.
Wehaveendeavouredtomakeasafeandreliableproductwhichperformsasdescribed,
howeversinceZEVA hasnocontrolovertheintegrationofits products intoavehicleor
batterysystem,wecanassumenoresponsibilityforthenalsafetyorfunctionalityofthe
completedvehicle.Itisuptotheendusertodeterminethesuitabilityoftheproductsforthe
purposeemployed,andtheenduserassumesallrisksassociated.Productsshouldonlybe
installedbysuitablyqualiedandexperiencedpersons,andshouldalwaysbeusedinasafe
andlawfulmanner.
21
12VDC Main
Contactor
Main Ctr Cathode Ground Aux
Contactor
HV+ Fuel
Gauge
MPO2 MPO1
Ground
Charge
Enable
MPI Charge Sense Key In HV– Tach
Gauge
ZEVA EVMS3 www.zeva.com.au
Electric Vehicle Management System
+ –

ELECTRIC VEHICLE MANAGEMENT SYSTEM V3 ZERO EMISSION VEHICLES AUSTRALIA
Specications
Powersupply:12Vnominal(8-16Vmaximum)•
Powerconsumption:Approx35mAwhenactive(EVMSonly),3mAwhensleeping•
Fusing:InternalPTCtype,5Aforpoweroutputs,200mAforlogicI/O•
Tractionpackvoltagerange:12-350VDCnominal•
Tractionpackcapacity:5-1250Ah(5Ahsteps)•
Currentmeasurement:ViaCANbuscurrentsensor,upto±1200A•
CANbusformat:250kbps29-bit(CAN2.0B).Otherformatsbyrequest.•
Dimensions:EVMS120x100x40mm,Monitor96x62x17mm+mountingfoot•
Housing:ABSplastic,approxIP44rating(weatherresistant,notwaterproof)•
Installation
TheEVMSshouldbemountedsecurelyusingscrewsthroughthefour4mmholesonthecase
anges,inalocationprotectedfromdirectwater.Please note that although the housings
provide some weather protection, they are not fully waterproof, so should not be exposed
to rain or submerged in water.
The EVMS has 16 screw terminal connections on top of the case, plus dual CAN ports
andatemperaturesensorinputononeside.Wiregaugeformostconnectionsshouldbe
around16-20AWG forsuitablecurrent ratingandmechanicalstrength. Ensureallwiring
hasappropriatevoltage(insulation)ratings–bewarethatmostautomotiveinsulated wire
isnotratedforthehighervoltageofEVtractioncircuits.Thesuppliedforkcrimplugsare
recommendedforthemostreliableconnectionstothescrewterminals.
ThefollowingdiagramshowsatypicalschematicforacompleteEVMSinstallationinan
electricvehicle,otherthangaugeoutputsandMultiPurposeterminals.Itmaylookalittle
intimidatingatrstbutshouldbecomeclearasyoustarttowireupyourownvehicle.Note
thatthediagramdoesnotshowaninertiaswitch(crashsensor),whichshouldbeinstalled
betweenthe12VbatteryandtheEVMS‘s12Vsupply.Youwillalsousuallyneedtousethe
keysignaltoswitcharelayforpoweringauxiliary12Vdevicessuchasbrakevacuumpump,
powersteeringpump,watercoolingpump,cabinheater,etc.
Make sure all power wiring has appropriate current and voltage (insulation) ratings, and
thatfuseshaveappropriateDCvoltageandcurrentratings.TheEVMShasaninternalself-
resettingfusewhichlimitsthetotalcombinedcurrentofalloutputsto5Acontinuous,butup
to10Aisneintermittently(e.gwhencontactorsareenergising).
Withmotorcontrollerswhichmanagethemaincontactorthemselves,theMainContactor
outputfromtheEVMScanbewiredtothecontroller’sKeySwitchInput(KSI)sothattheEVMS
isabletoturnthemotorcontrolleroffinthecaseofalowcelldetected,forexample.
Example Wiring Diagram
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ELECTRIC VEHICLE MANAGEMENT SYSTEM V3 ZERO EMISSION VEHICLES AUSTRALIA
Description of Connections
Terminal name I/O Description
+12VDC Input To 12V battery positive (permanent supply, not key
switched).8-16Vmaximumrange.
Ground Input Tovehiclechassisor12Vbatterynegative
KeyIn Input Tokeysignal,shouldbe+12Vwhenkeyisturnedon
ChargeSense Input Connecttoyourchargedetectionswitch,suchasafuel
doorswitchor240Vdetectrelay/circuit.Shouldconnect
toground/chassiswhentheswitchison.
MPI Input Multi-PurposeInput,assignabletoarangeofadditional
functions.
MainCtrCathode Input Connecttothepowerterminalonthemotorcontroller
side(i.eoutput/cathode)ofyourmaincontactor
HV+ Input Connecttothemostpositivepotentialofyourbattery,or
theinput/anodeofyourmaincontactor.
HV- Input Connecttothemostnegativepotentialofyourbattery.
MainCtr Output Connecttothepositivewireofyourmaincontactorcoil.
Thecontactorcoilnegativewireshouldbeconnectedto
ground/chassis.
AuxCtr Output Connecttothepositivewireofyourauxiliary/secondary
contactor(s).Thecoilnegativewireshouldbeconnected
toground/chassis.
ChargeEnable Output Connecttothe+12terminalofarelaywhichcanenable
yourcharger(usuallyturningtheACsupplyon,orcharge
enableinputpinssupportedbysomechargers).Theother
sideoftherelayshouldbeconnectedtoground/chassis.
Ground Asparegroundconnectionpoint,oftenusedasaground
forcontactorwiring.
MPO1 Output Multi-Purpose Outputs 1 and 2, assignable to a range
of additional functions. Please refer to section Multi-
Purpose Input and Outputsformoreinformation.
MPO2 Output
FuelGauge Output To the fuel gauge input connection on your vehicle’s
OEMinstrumentcluster(oraftermarketfuelgauge).
TachGauge Output To the tachometer input connection on your vehicle’s
OEMinstrumentcluster(oraftermarkettachometer).
CAN Bus Wiring
TheEVMSusesCANbustocommunicatewithotherdevicesinthevehiclesuchasBMS
modules,EVMSMonitor,CANcurrentsensor,TCChargersandZEVAmotorcontrollers.
NotethateverymanufacturertendstoimplementtheirownprotocolonCANbussothe
EVMSwillnotbeabletocommunicatewithCAN-enableddevicesfromothermanufacturers
(otherthanTCChargers).NormallyitisbestforZEVAdevicestousetheirowndedicated
CANbusratherthanshareanexistingCANbuswithotherdevices,toavoidthepossibility
ofbandwidthlimitationsandIDconicts.
The EVMS itself has two CAN bus connectors, joined to the same bus internally, which
can be connected in either order in any location along the CAN bus.The EVMS3 and
mostassociateddevicesuseMolexEurostylepluggablescrewterminalsfortheCANbus.
Connectorwiringisshowninthediagrambelow:
Shield
Ground
CAN L
CAN H
12VDC
Note that while connectors into most devices go screw side
up, due to the orientation of the internal circuit board in the
EVMS3, its CAN plugs are inserted with screw side down.
CANbusesworkbestwhenwiredasasingledaisychainofdevices,with120ohmtermination
resistorsateachendtopreventsignalreection.MostZEVACAN-enableddeviceshavedual
CANplugsforeasydaisy-chaining.Theorderofdevicesisunimportant-usuallytheshortest
pathbetweendevicesisbest.TheEVMSMonitorismostcommonlyinstalledatoneendof
theCANbussoonlyhasasingleCANport,andabuilt-ininternalterminationresistor.The
monitormaybeinstalledinthemiddleofaCANbusbycreatingashortY-branchoffthebus
totheMonitor’sCANplug,andremovingthesmallpinjumperontherightoftheCANplug
todisabletheinternalterminationresistor.
Forthesakeofnoiseimmunity,CANbusestypicallyusetwistedpaircable.Sinceelectric
vehiclescaninvolvehighelectromagneticinterference(EMI)fromthetractioncircuit,we
recommendusingshieldedtwistedpairwireformaximumnoiseimmunity.Veryshortspans
areusuallyOKwithuntwistedand/orunshieldedcable.
CANbusesandtheattacheddevicesdoconsumesomepower(anEVMSwithafewBMS
modules and an EVMS Monitor will use in the order of 200mA), so in order to reduce
quiescentdrainontheauxiliarybattery,theEVMSwillnormallyswitchofftheCANbusafter
acongurablenumberofminutesinIdlestate(i.eneitherdriving,charging,orinsetup)to
savepower.SetupmodecanonlybeenteredfromIdlestate,soneedstobedoneduringthe
timewindowbeforetheCANbuspowersdown.Thesleepdelayiscongurableinsettings,
andsleepcanbedisabledaltogether.
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ELECTRIC VEHICLE MANAGEMENT SYSTEM V3 ZERO EMISSION VEHICLES AUSTRALIA
Current Sensor
TheEVMS3communicateswithacurrentsensorontheCANbustoreceiveinstantaneous
current,andusesthistocalculatebatteryStateofChargethroughintegrationovertime.Two
typesofcurrentsensorareavailable,HallEffectorShunt.
HallEffectcurrentsensorsareavailablefor300A,600Aor1200Amaximum,and•
areinstalledsimplybyslippingthebatterycablethroughthebluetorusofthehall
sensor.Smallerratedsensorsofferproportionallyhighermeasurementaccuracyso
aremoreappropriateforlowercurrentsystems.Hallsensorsarenormallyeasierto
installandgeneratenoheat,butarealittlemoreexpensiveandhaveslightlyless
accuratezeropoint.
TheShuntInterfacemeasurescurrentowthroughashuntinstalledonthebattery•
cableandoutputsittotheCANbus.TheShuntInterfacecanworkwith50A,100A,
200Aor500Ashunts,either75mVor50mV.Smallershuntsofferproportionately
highermeasurementresolution.Note that the current ratings for the shunts are
maximum continuous ratings, but the shunt interface can measure up to twice the
shunt’s nominal rating intermittently - limited by heat buildup in the shunt.Ashunt
interfaceplusshuntworksoutalittlecheaperthantheHallEffectsensorandhasa
slightlymoreaccuratezeropoint(betteraccuracywithverylowcurrents),butcan
bealittlemoreefforttoinstall,andgeneratessomeheat.
Asageneralguide,halleffectsensorsaremoresuitableforhighpowersystems,andshunts
aremoresuitableforlowerpowersystems.
Inbothcasesthecurrentsensororshuntmaybeinstalledoneitherthepositiveornegative
batterywire.TheHallSensorshouldbeorientedsuchthatdischargecurrentowsfromthe
back(black)sidetothefront(blue)side.Ensurethattherearenodevicesinstalledbetween
thebatteryandthecurrentsensororshunt,ortheEVMSwillnotbeabletocalculatestateof
chargecorrectly,sincethecurrentowto/fromthosedeviceswouldnotbemeasuredbythe
currentsensor.Note: If the status light is blinking when no current is owing, hold down the
button until it stops blinking to recalibrate the sensor’s zero point.
Charger Integration Options
Toenablecharging,theEVMSneedstoswitchintochargingmodebyconnectingtheCharge
Senseinputtoground/chassis.Thiswillwakeitfromsleepifneeded,poweruptheCAN
bustocommunicatewithBMSmodules,andstartthecharger.Itwillalsopreventthevehicle
frombeing accidentallydrivenoffwhileplugged into charge.Thereare severalwaysto
implementchargedetection:
Amagneticreedswitch(orsimilar)canbewiredbetweenChargeSenseand•
ground/chassis,andsetuptocloseitscontactswhenthedoor/covertothecharging
portisopened.
AnACrelaywithitscoilwiredinparallelwiththecharger’sACinput,sothatwhen-•
everthechargerhaspower,therelaywillalsoclosetoenableEVMSchargemode.
Somechargers(e.gnewerTCChargers)haveanoutput12Vsupplywhichcanbe•
usedtoswitchasmallsignalrelaytojoinChargeSensetoground/chassis.
ItisalsoessentialthattheEVMSisabletoswitchoffthechargerifanycellsexceedsafe
voltage,topreventdamagefromover-charging.Thereareseveralwaystoimplementthis:
IfusingCANintegrationwithaTCCharger,theEVMSisabletodisablethecharger•
overCANbussonoadditionalcontrolrelaysarerequired,andtheChargeEnable
outputcanbeleftunused.ToconnectaTCChargertoaZEVACANbus,join only
the CANGND, CANL and CANH pins.(Thechargeralsohasa12Vpinbutthis
shouldnotbejoinedtotheZEVACANbus,sinceitisa12Voutput,andonlythe
EVMSshouldmanage12VpowertotheCANbus.)
Manychargershaveapairofcontrolpinsthatgetjoinedtoenablethecharger.To•
usethismechanism,useasmall12VrelayswitchedbytheChargeEnableoutputof
theEVMS,withthenormallyopencontactswiredtotheenablepins.
TheAuxiliaryContactoroutputisdisabledaswellastheChargeEnableoutputif•
anycellsgoover-voltage,soifyourtractioncircuithasanyauxiliarycontactors
(andyourchargeristolerantofhavingitsDCsideinterruptedmid-charging),there
isnoneedtoaddfurtherrelays/contactorstostopthecharger,astheopeningofthe
auxiliarycontactorwillnecessarilyinterruptchargecurrent.
Thenaloption,whichcanbesafelyusedwithanycharger,istouseapowerrelay•
switchedbytheChargeEnableterminalfromtheEVMS,withtherelay’sNormally
OpenoutputswiredtointerrupttheACinputtothecharger(asshownontheex-
amplewiringdiagramonthepreviouspage).
Auxiliary Contactors
Auxiliarycontactors(asshownontheexamplecircuitdiagram)areoptionalbutcanserve
severalfunctionsinanEV.
Splituphighvoltagebatterypacksintosmallergroupsofnon-lethalvoltage,orto•
isolateseparategroupsofcellsdistributedaroundthevehicle,forsafety.
Switchon/offotherHVloadsthatarebeforethemaincontactor,eitherdirectly(us-•
ingarelayswitchingpowertothedeviceitself)orindirectly(bybreakingthemain
tractioncircuit).ThemostcommonexampleistheDC/DCconverter,sothatitisnot
permanentlyin-circuit.
Effectivelyfunctioningasanautomaticmaintenanceswitch.(Ifyoudon’thavean•
auxiliarycontactorbreakingthetractioncircuitwhenthekeyisoff,itisadvisable
tohaveamanualmaintenanceswitchtodothesamejobwheneverworkingonthe
vehicle.)
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ELECTRIC VEHICLE MANAGEMENT SYSTEM V3 ZERO EMISSION VEHICLES AUSTRALIA
Remember not to have any BMS module’s wiring harness span any auxiliary contactor (or
maintenance switch), or the BMS module becomes the only conduction path for the traction
circuit when the contactor opens, which exposes the module to damaging voltages!
EVMS Monitor
TheEVMSMonitorisusedtoremotelyinteractwithotherdevicesontheCANbus,both
forviewingoperatingdataandtoeditsettings.TheMonitorhasvariousdifferentpagesof
informationasdescribedbelow.
EVMS: Running
Voltage
Current
Power
Aux V Temp Isol SoC
13.5V 25C 100% 90%
148V
42A
6.2kW
The main display, showing EVMS status at the top,
instantaneous voltage, current, power, auxiliary
battery voltage, temperature, isolation, and State of
Charge(SoC).
Touchingtheleftorrighthalfofthedisplaywillswap
tothepreviousornextdisplaypagerespectively.
EVMS: Running
Pack Voltage Temperature
Aux voltage Isolation
148V 25˚C
13.5V 100%
If no current sensor is present on the CAN bus, the
EVMSisunabletoshowcurrentorcalculatepoweror
stateofcharge,soadifferentpageisshownwithonly
packvoltage,temperature,auxvoltage,isolation,and
abargraphofallindividualcellvoltages.
BMS Summary: 45 cells
Avg voltage Avg temp
Min voltage Max voltage
M0 C4 M2 C8
3.32V 28˚C
3.31V 3.33V
BMS summary page, showing the total number of
cells being monitored, the average voltage per cell,
theaverageofanyBMStemperaturesensors,andthe
voltage and location of both the lowest and highest
cells.MisModuleID,Cisthecellnumber.
Alongthebottomisagraphofallcellvoltages.Green
barsindicate cellswithin range.Barswill changeto
blue for undervoltage cells, orange for cells being
balanced,andredforovervoltagecells.
BMS Details: Module 1
Cell voltages
3.323 3.336 3.321 3.317
3.332 3.316 3.327 3.323
3.318 3.322 3.331 3.327
Temp1: 23˚C Temp2: 25˚C
Prev Next
Detailed information for a single BMS module,
showingvoltageofeachcell(to3decimalplaces)and
two temperatures if available. Orange bars beneath
thevoltagesindicateifcellshuntsarecurrentlyon.
Tap the Prev or Next buttons to change which BMS
module is being viewed, or anywhere else in the
displaytochangeMonitorpagesasusual.
TC Charger Status
Output Volts Output Amps
Target Volts Target Amps
Charger Status: OK
149V 19.4A
154V 20.0A
IfaTCChargerispresentontheCANbus,itwillbe
autodetectedandanewpageofdatamadeavailable
ontheMonitorshowingcharger’soutputvoltageand
current,thetargetvoltageandcurrentbeingrequested
bytheEVMS,andthechargerstatusatthebottom.
MC600C Status
Batt Volts Batt Amps
Motor Volts Motor Amps
Temp Throttle
Status OK
149V 150A
75V 300A
42˚C 60%
IfaZEVAmotorcontrollerispresentontheCANbus,
itwillbeautodetectedandanewpageofdatamade
available on the Monitor showing battery voltage,
battery current (into the motor controller only),
motorvoltage,motorcurrent,thecontroller’sinternal
temperature, the current throtttle position, and the
statusatthebottom.
Warning:
Charge ended by BMS
If the EVMS detects an error, a warning page will
be displayed. In most cases, the error can be
acknowledged/resetbypressingSelect.Somecritical
errorscannotbedismisseduntiltheerrorcondition
iscorrected.
Forafulllistoferrorsyoumightsee,pleasereferto
sectionError Detection.
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ELECTRIC VEHICLE MANAGEMENT SYSTEM V3 ZERO EMISSION VEHICLES AUSTRALIA
Reset SoC
Enter Setup
Display Off
Exit Options
Youcanbringupthisoptionsmenubyholdingyour
ngerdownonthescreenfor1second.Fromhereyou
candoamanualresetoftheStateofCharge(backto
100%), enter the Setup mode, or switch the display
off.
Whenthedisplayisoff,touchandholdanywherefor
1secondtoturnitbackon.Displaywillautomatically
wakeifthereisanewwarningtodisplay.
Setup mode can only be entered from Idle state, i.e
whenthevehicleisnotchargingorbeingdriven.
Conguring Settings
TheEVMSMonitorcanbeusedtoconguresettingsforallZEVAdevicesontheCANbus.
EVMS: Setup
General Settings
Parameter:
Pack capacity
Value:
100Ah
Exit Setup
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<
<
>
>
>
The Setup mode has three rows. The top row
toggles between the General Settings and the BMS
Congurationsections.Tapthearrowseithersideto
navigatebetweenthese.IntheGeneralSettingspage,
thesecondrowselectstheparametertobemodied,
andthethirdrowmodiestheparameteritself.TheExit
Setupbuttonwilldistributenewsettingstoalldevices
ontheCANbusthenreturntonormaloperation.
EVMS: Setup
BMS Configuration
Module ID:
0
Num cells:
12
Exit Setup
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<
<
>
>
>
Thispageisforconguringyourbatterypack(sothe
BMSknowshowmanycellstomonitor).
Tapthe arrowseitherside oftheModule IDrowto
selectthemoduleinquestion,andthearrowseither
sideofNumcellsareusedtomodifyhowmanycells
thatBMSmoduleshouldexpectatthatID.
List of Settings
The following table describes the parameters available in the General Settings page.The
numberofsettingscanbeabitoverwhelmingatrst,butmostofthemcanbeleftattheir
defaultvalueunlessyouneedtoadjustaspecicfunctiontosuityourinstallation.
Ifyouwishtolockthesettingsafterthesystemhasbeencommissioned,simplyremovethe
smalljumperontheleft-handsideoftheMonitor’sCANport.(Theright-handjumperisfor
disconnectingtheMonitor’sinternalCANterminationresistor,incaseswherethemonitoris
notatoneendoftheCANbus.)
Name Range Description
PackCapacity 5-1250Ah Theratedcapacityofyourtractionbatterypack,
inAmpHours.
SoCWarning 0-99% TheEVMScanraiseawarningwhenthetraction
battery’s SoC reaches a predetermined level.
Use0%todisable.
FullVoltage 1-400V The EVMS uses a “full voltage” threshold to
detect charge approaching completion. One
hourafterreachingthisvoltage,theEVMSwill
resettheSoCto100%andpowerdown.
WarnCurrent 0-1200A TheEVMSwillprovideawarningifthecurrent
inthetractioncircuitexceedsthisthreshold.Set
above1200Atodisable.
TripCurrent 0-1200A The EVMS will provide a warning and
automatically shut down the traction circuit if
currentexceedsthisthreshold.
EVMSTempWarning 0-150C
/OFF(151)
The EVMS will provide a warning if its
temperature sensor exceeds this threshold.
It will not shut the vehicle down, but it is
recommended that you stop to investigate as
soonaspossible.Notethatthisisindependent
fromBMStemperaturesensorsandwarnings.
MinAuxVoltage 0-14V If the 12V supply drops below this threshold
for more than 5 seconds, a warning will be
provided. It may indicate a weak 12V battery
and/orfaultyDC/DCconverter.
MinIsolation 0-100% A warning will be raised if isolation integrity
fromtractioncircuittochassisdropsbelowthis
threshold, indicating compromised insulation
or an unexpected conduction path. See also
sectiononIsolation fault detection.
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TachoPPR 1-6 The EVMS can drive your vehicle’s OEM
tachometer as an ammeter, displaying
hundredsofampsinsteadofthousandsofRPM.
Tachometers typically expect a number of
PulsesPerRevolution,beinghalfthenumberof
cylindersthattheoriginalenginehad.
FuelGaugeFull 0-100% Because every vehicle’s OEM gauges use
different scaling, these four parameters allow
theEVMStotuneit’soutputstosuityourgauges.
Whentheseparametersareselectedforediting,
theEVMS willdrivetheappropriate gaugefor
thecurrentparameter,allowingyoutotunethe
gauge visually. (Note that you may need the
keyintheOnpositiontopowertheinstrument
cluster–butenterSetupmoderst.)
FuelGaugeEmpty 0-100%
TempGaugeHot 0-100%
TempGaugeCold 0-100%
BMS:MinVoltage 1.50-4.00V Adjusts the low voltage warning threshold for
eachcellinyourtractionpack.
BMS:MaxVoltage 2.00-4.50V Adjuststhehigh voltage warning thresholdfor
eachcellinyourtractionpack.
BalanceThreshold 2.00-4.50V,
Dynamic
orOFF
Adjusts the voltage threshold at which BMS
moduleswillbeinstructedtobalancehighcells.
EitheraxedVoltage(usuallyequaltoaverage
maximum charge voltage) for “top of charge”
balancing,Dynamictosetbalancethresholdto
beequaltotheaveragecellvoltageatanytime,
or Offtodisablebalancing.
BMS:Hysteresis 0-0.50V OnlyapplicableinStationaryMode,toprevent
rapid oscillation of self-resetting outputs by
addingahysteresisband.Pleaserefertosection
Stationary Modeformoreinformation.
BMS:MinTemp OFF(-40)or
-39-100˚C
A temperature exceeding these values will
automaticallyshutdownthesystem.InRunning
mode, there will be 10 seconds of warning
beforean automaticshutdown.Shutdowncan
be suppressed by acknowledging the warning
within10seconds.
BMS:MaxTemp -40-100˚Cor
OFF(101)
LowTempChgRest. Yes/No Low Temperature Charge Restriction setting
candisablechargingifthebatterytemperature
is below the programmed LowTempWarning
threshold,ratherthanjustprovideawarning.
MaxChargeVoltage 0-500V OnlyapplicablewhenusingaTCChargerwith
CAN integration to the EVMS, these set the
target voltage and current that are sent to the
charger(for itsCCCVchargingalgorithm).The
“Alt”settingsareonlyusediftheMPIfunction
is set to “Alt charge”, and the MPI terminal is
connectedtoground/chassis.
MaxChargeCurrent 0-120A
AltChargeVoltage 0-500V
AltChargeCurrent 0-120A
SleepDelay 1-5min/OFF SetsthetimedelaybeforetheEVMSwillgoto
sleepwhen inIdle mode.Can bedisabled by
setting to Off, but note that the CAN bus and
otherperipheralswillremainpoweredupwhich
resultsinhigherquiescentpowerconsumption,
whichcanattenbatteriesmorequickly.
MPIFunction Various Sets the function of the Multi-Purpose Input
terminal and the two Multi-Purpose Output
terminals.PleaserefertosectionMulti-Purpose
Inputs and Outputsbelowforfurtherdetails.
MPO1Function
MPO2Function
ParallelStrings 1-20 The EVMS normally uses the sum of cell
voltagestocalculatetheoverallbatteryvoltage.
Ininstallationswithmultiplestringsofcellsand
BMS modules in parallel, this setting can be
usedtocorrectthevoltagecalculation.
Enableprecharge Yes/No The EVMS’s internal precharger (if present)
can be disabled – but make sure your motor
controller does not require it, or contactor
damagemayresult!
Stationary Mode Yes/No Switches the EVMS into Stationary Mode,
for battery backup and off-grid power type
applications. Please refer to the Stationary
Applicationssectionformoreinformation.
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RevCurrentDisp. Yes/No ReverseCurrent Display.By default,current is
displayedwithdischargeampspositive.Insome
applicationsitispreferableormoreintuitiveto
displaychargeampspositiveinstead.
NightBrightness 0-100% Adjusts the brightness of the LCD display in
low light mode, to reduce screen glare at
night.Togglebetweenfullbrightnessandnight
brightnessbyeitherswipingangerup/down,
orusingtheMPIpinasaheadlightsense.
BuzzerOn Yes/No Selects whethertheMonitor shouldsoundthe
buzzerforalerts.(Safesttoleavethison.)
UseFahrenheit Yes/No Changes display of temperature units to
FahrenheitinsteadofCelcius.
SoCDisplay Percentor
Amp-Hours
ThebatteryStateofChargevaluedisplayedon
theMonitorcaneitherbeshownasapercentage
offull charge, orasthe numberof amp-hours
remaining.
Multi-Purpose Input and Outputs
TheEVMShasoneMulti-PurposeInput(MPI)terminalandtwoMulti-PurposeOutput(MPO)
terminals,whichcanbeassignedtoarangeofadditionalfunctionality.
TheMPIterminalhasahighinputimpedancesowillneverdrawmorethanafractionofa
milliamp.TheMPOterminalsarelimitedtoabout0.5Acontinuouscurrent(eitherinorout
oftheterminal),butcanhandleseveralampsshorttermsoarecompatiblewithdrivingfull
sizecontactors,solongastheyincludeacoileconomizertoreduceholdingcurrentbelow
0.5A.
MPI Function Description
Wakeup Jointerminaltoground/chassismomentarilytowaketheEVMSfrom
sleepmode(withoutenteringRunningorChargingmode).
Note:OtherMPIfunctionswillstillperformanEVMSwakeuptoo.
Altcharge Jointerminaltoground/chassistoswitchTCChargertosecond(“Alt”)
setofvoltageandcurrentsettings.Usefulifyousometimesusetwo
differentsizedchargers,orifyousometimesneedtorestrictalarge
chargerfromoverloadingasmallACsocket.
HdlightIn HeadlightInput.ConnectMPIterminaltotheheadlightsignalinyour
car(+12Vwhenheadlightsareon)tohavetheEVMSautomatically
dimtheMonitorbrightnessatnight,basedontheNight Brightness
setting.
CtrAuxSw ContactorAuxiliarySwitch.WiretheMPIterminaltotheauxiliary
switch of your main contactor (with the other side of the switch
connectedtoground)tohavetheEVMSmonitorthestateoftheaux
switch.ThisallowstheEVMStoprovideawarningifthecontactor
is not working correctly (not closing when it should close, or not
openingwhenitshouldopen).
MPO Function Description
Ground Defaultstatefortheoutput,canbeusedasasparegroundterminal.
Tempgauge Can be connected to the temperature sensor input of many OEM
instrument clusters, to view the EVMS temperature input on the
original temp gauge (calibrated to the gauge in the settings and
scaledbetween0˚Candthe“overtemp”setting).
LowSoCSignal Willoutput12Vifthebattery’sstateofchargepercentageisbelow
the“SoCWarning”setting.Canbeusedforawarningsystem,orto
turnonadditionalchargingsystems(suchasagenset).
Overtempsignal Willoutput12VifanyBMStemperaturesensorsexceedthe“BMS
Overtemp”setting.Canbeusedasanadditionalwarningortoturn
onbatterycoolingsystems.
UndertempSignal Willoutput12VisanyBMStemperaturesensorsarebelowthe“BMS
Undertemp”setting.Canbeusedtoenablebatteryheatingsystems
incoldclimates.
ErrorBuzzer Will output 12V if any error is pending in the EVMS, to drive
additionalwarningbuzzers.MaybeusedtosupplementtheEVMS
Monitor’sinternalbuzzer,orifnoMonitorispresent.
StatusLight CanbeusedtodriveanexternallighttoshowEVMSstatus.Offwhen
thesystemisidleorsleeping,on(12V)whenrunningorcharging,
andashingifanyerrorispending.
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Error Detection
TheEVMSmonitorsawiderangeofoperatingparametersforyourelectricvehicleandcan
notifyyouifanyexceedtheirsaferangeoranyfaultsaredetected.Inmost cases,errors
canbeacknowledged/dismissedbytappingonthescreen.Criticalerrorsarerespondedto
automatically(suchasbyshuttingdownthetractioncircuitduetoanundervoltagecell),
whileothersareatthedriver’sdiscretiontorespondto(suchasover-temperaturewarnings).
Thefollowingtabledescribestheerrorsyoumayencounter.
Error Description
OvercurrentWarning Ifbatterycurrentexceedstheprogrammedthresholdformore
than1second,thiswarningwillappear.
OvercurrentShutdown Asabove,excepttheEVMSwillalsoautomaticallyshutdown
the traction circuit if this threshold is exceeded. Note that
for safety reasons this system cannot replace a physical fuse,
though it can be used to prevent blowing the fuse rst.
BMS-LowCell ABMSmodulehasreportedacellvoltagebelowtheminimum
threshold.Thiserrorwilllikelyrststartappearingunderheavy
acceleration,thenwithincreasingfrequency.Itisrecommended
thatyoupullthevehicleoverassoonassafetoavoidaforced
shutdown.
ShutdownbyBMS Alowcellconditionhasbeenpresentformorethan10seconds,
sotheEVMShasshutdownthetractioncircuittoprotectthe
batteries.
BMS-HighCell ABMSmodulehasreportedacellvoltageabovethemaximum
threshold.
ChargeEndedbyBMS A high cell condition has been present for more than 1
second,sotheEVMShasshutdownthechargertoprotectthe
batteries.
BMS-Overtemp A BMS module has reported a temperature above the
programmedthreshold,andthesystemwillbeshutdownfor
protection.
BMS-Undertemp A BMS module has reported a temperature below the
programmedthreshold,andthesystemwillbeshutdownfor
protection.
LowBatteryCharge The battery’s State of Charge has reached the programmed
warningthreshold.
Over-Temperature The EVMS’s temperature sensor has reported a temperature
abovetheprogrammedwarninglevel.
IsolationFault Achassisleakageabovetheprogrammedthresholdhasbeen
detected.(Mayindicateaninsulationfaultwithtractioncircuit
wiringorevenwateringressintothemotororotherdevice.)
Low12VBattery Thevoltageofthe12Vauxiliarybattery(powersupplyforthe
EVMS) has dropped below the programmed threshold. May
indicateaweakbatteryorfaultyDC/DCconverter.
PrechargeFailed Displayedifanerrorisdetectedduringtheprechargesequence,
eitherfailingtostart(usuallyawiringfault)ortakingtoolongto
nish(usuallyanunexpectedload“downstream”fromthemain
contactor).Thestartupsequenceiscancelledautomatically.
Contactorfault Ifusingcontactorswithauxiliary switchesanda discrepancy
isdetected(contactorclosedwhenitshouldbeopen,orvice
versa),thiserrorwillbedisplayed.
BMS-Commserror IftheEVMShasn’treceiveddatafromaBMSmoduleforawhile
(about1second),thiserrorwillappearandthetractioncircuit
willbeshutdownforsafety.
NocommstoEVMS If the Monitor hasn’t received data from the EVMS for more
than1second, thiserrorwillappear. Mostcommonlythisis
duetoawiringfaultontheCANbus.
CorruptSettings OccursifmemorycorruptionhasbeendetectedintheEVMS
orMonitor’ssavedsettings.Theywillautomaticallyberesetto
defaults.Contactusifyouseethisone.
Voltage Thresholds
Bydefault the EVMSwill come withBMS voltagethresholds conguredto suit LiFePO4
cells,butthethresholdscanbechangedtosuitanylithiumchemistry.Thefollowingtable
listsrecommendedvoltagethresholdsforLithiumIronPhosphate(LiFePO4),LithiumCobalt
(LiCo)andLithiumTitanate(LTO)cells.Mostotherlithiumchemistries(LiPo,NMC,etc)are
variationsofLithiumCobaltandsharethesamevoltagerange,butifindoubtpleasereferto
thedatasheetforyourbatteriestoconrm.
Chemistry Nom Voltage Min Voltage Max Voltage Charge To Temp Range
LiFePO4 3.2V 2.5V 3.8V 3.65V -20˚C–60˚C
LiCo 3.7V 3.0V 4.2V 4.1–4.2V -20˚C–60˚C
1817

ELECTRIC VEHICLE MANAGEMENT SYSTEM V3 ZERO EMISSION VEHICLES AUSTRALIA
2019
LTO 2.4V 1.6V 2.8V 2.7V -30˚C–60˚C
Quick tip: LiCo chemistry cells may be charged to 4.2V, but will achieve almost double the
cycle life if slightly undercharged to 4.1V instead – though at the loss of about 10% available
capacity. It also leaves some margin between peak charge voltage and maximum allowable
voltage, for tolerance of pack imbalance.
State of Charge Synchronisation
TheEVMSreceivescurrentdataoverCANbusfromeitherahalleffectsensororashunt
interface. By integrating current ow over time, it is able to calculate battery SoC. But
becausethis calculationisan integrationover time,itis possiblefor smallmeasurement
errorstoaccumulate,resultinginpossibleinaccuracyinthestateofchargevalue.
Tomitigatethis,theEVMSincludesamechanismtoautomaticallyresynchronisetheSoCat
theendofanyfullchargecycle,usingthecongurableFull voltagesettingtotelltheEVMS
whatvoltagethepackiswhenfullycharged.Ideally,setthistoavoltortwobelowthepeak
chargevoltageofyourchargerforasmalltolerance.Whenthisvoltageisreachedduring
achargecycle,aonehourtimerisstartedtoallowtheConstantVoltagephaseofcharging
tocomplete.Afteronehour,thetheSoCwillbesynchronisedbackto100%,thecharger
willbeturnedoff,thenaftertheprogrammedSleep Delaytimethesystemwillgotosleep
tosavepower.
TheSoCcanalsobemanuallyresetto100%viatheOptionsmenuoftheEVMSMonitor.
Stationary Applications
TheEVMScongurationincludesasettingforStationaryMode,intendedforuseinbattery
backup and off-grid power applications. In this mode, the Key input enables both Main
ContactorandCharge Enableoutputsconcurrently.An undervoltage cellwilldisablethe
MainContactoroutput(toremoveanyloadsonthebattery)and anovervoltagecellwill
disabletheChargeEnableoutput(todisableanychargingsources).
Outputs will automatically be re-enabled once the cell voltage has recovered by a
congurablemargin,knownashysteresis.Forexample,ifBMS Hysteresisissetto0.20V,the
MainCtroutputwillnotturnoffuntilacellis0.20VbelowtheMin Voltagethreshold,and
willresetwhencellis0.20VabovetheMin Voltagethreshold.
CommonsettingsforLiFePO4cellsareaMin Voltagesettingof2.80V,Max Voltageof3.60V,
and Hysteresisof0.20V,givinga2.6V-3.0VbandfortheMainCtroutputand3.4V-3.8V
bandfortheChargeEnableoutput.LiCocellshaveamorelinearchargecurvesotypically
needasmallerhysteresisbandaround0.05V-0.10V,withaMin Voltagesettingabout3.00V
and a Max Voltagesettingabout4.1V.
In Stationary Mode, the Charge Sense input is no longer used, and precharging is not
supported.TheAuxCtroutputwillbeonpermanentlywheneverthesystemisinRunning
mode.
Use With Batteries Over 350VDC
TheEVMS’sinternalvoltagemeasurementandisolationmonitoringcircuithasanabsolute
maximumvoltageratingof400VDC,makingitsuitablefornominalbatterypackvoltages
uptoabout350VDC.TheEVMSmaybeusedwithhighervoltages,buttheHV+,HV- and
Main Ctr-connectionsmustbeomitted.Prechargingandisolationmonitoringarenolonger
supported,andsystemvoltagecanonlybecalculatedfromthesumofallcellsconnected
toBMSmodules.
Isolation Fault Detection
The EVMS has an internal high resistance connection (200Kohm) between the traction
circuit and the vehicle chassis. By monitoring microamps of current owing across this
resistor,theEVMScandetectiftheisolationbetweentractioncircuitandthevehiclechassis
iscompromised,suchasfromdamagedwiringinsulation,excessivecarbonbuildupinDC
motors,orevenahumantouchingaHVterminal.
Thisisquantiedasa0-100%range,where0%representsaverylowresistancepathbetween
thetractioncircuitandthechassis,and100%representsnodetectableleakage.Thedefault
warningthresholdforleakageis50%,whichisusuallysensitiveenoughtodetectifahuman
touchesanyoftheHVterminals.Ideally,youshouldseeatleast90%atalltimes.
Technical Support and Warranty Information
All ZEVA products are covered by a 12 month warranty against manufacturing faults or
failures under normal operating conditions.The warranty does not cover misuse of the
product,includingbutnotlimitedto:excessivevoltageorreversedpolarityonterminals,
shortcircuitsonoutputs,openingofhousingsand/ormodicationofinternalelectronics,
severeimpactdamage(e.gduetovehiclecrashes),submersioninwater.
Wehavetakengreatcaretodesignasafeandreliableproduct,butfaultscanhappen.If
youbelieveyourproducthasafault,pleasecontactusviaourwebsitetodiscuss.Ifitis
determinedthatahardwarefaultisthelikelycause,wewillprovideRMAinformationanda
returnaddresstoproceedwithrepairs.
Ifyouhaveanyquestionsnotcoveredbythismanual,pleasecontactusviaourwebsite:
http://www.zeva.com.au/Contact