EMUS G1 Manuale utente

G1 Battery Management System

User Manual


Table of contents 
 
G1 Battery Management System ................................................................................................................................................................................1 

Table of Contents 
G1 Battery Management System ................................................................................................................................................................................1 
Preface.........................................................................................................................................................................................................................8 
Introduction ........................................................................................................................................................................................................... 12 
Basics ........................................................................................................................................................................................................................ 13 
System structure overview ............................................................................................................................................................... 13 
1.1. Control Unit .................................................................................................................................................................................. 13 
1.2. Cell Modules..................................................................................................................................................................................17 
1.3. Cell Communication Adapters.................................................................................................................................................17 
1.4. Current Sensor ............................................................................................................................................................................19 
1.5. Smartphone Connectivity Module..........................................................................................................................................20 
1.6. Display Unit ..................................................................................................................................................................................20 
1.7. CAN Splitter ..................................................................................................................................................................................21 
1.8. Software........................................................................................................................................................................................23 
Functionality overview........................................................................................................................................................................23 
1.9. Cell Monitoring............................................................................................................................................................................23 
1.10. Current measurement.........................................................................................................................................................27 
1.11. SOC estimation............................................................................................................................................................................27 
1.12. Charging process and charging device control ............................................................................................................28 
1.13. Battery protections...............................................................................................................................................................35 
1.14. Power reductions..................................................................................................................................................................37 
1.15. Heater and cooling fan control ......................................................................................................................................... 38 
1.16. DC/DC converter control.....................................................................................................................................................39 
1.17. Statistics..................................................................................................................................................................................39 
1.18. Events...................................................................................................................................................................................... 42 
1.19. Vehicle speed measurement ............................................................................................................................................ 43 
1.20. Communication with external devices........................................................................................................................... 45 
1.21. Indication ................................................................................................................................................................................ 45 
Installation.............................................................................................................................................................................................................. 47 
Control Unit ............................................................................................................................................................................................47 
1.1. Choosing the power supply strategy ....................................................................................................................................47 
Cell Modules.......................................................................................................................................................................................... 50 
Current Sensor......................................................................................................................................................................................52 
Cell Communication Adapters......................................................................................................................................................... 54 
CAN Bus.................................................................................................................................................................................................. 54 
Centralized CAN group module ........................................................................................................................................................56 
Smartphone Connectivity Module....................................................................................................................................................57 
Display unit............................................................................................................................................................................................ 58 
Battery fuse........................................................................................................................................................................................... 58 
Contactor ................................................................................................................................................................................................59 
1.2. Pre-charge sub-circuit ............................................................................................................................................................59 


Charger....................................................................................................................................................................................................60 
1.3. CAN-based chargers ................................................................................................................................................................60 
1.4. Non-CAN chargers .....................................................................................................................................................................61 
1.5. Analog signal controlled chargers........................................................................................................................................62 
Cooling fan..............................................................................................................................................................................................62 
Heater ......................................................................................................................................................................................................63 
Indicators................................................................................................................................................................................................63 
Insulation fault detector .................................................................................................................................................................... 64 
Optimised Battery Charging Level...................................................................................................................................................65 
Configuration ........................................................................................................................................................................................................ 65 
Data interfaces......................................................................................................................................................................................65 
1.1. Serial..............................................................................................................................................................................................65 
1.2. CAN.................................................................................................................................................................................................65 
1.3. Cell communication...................................................................................................................................................................66 
CAN Cell Group Module configuration.......................................................................................................................................67 
Charging process .................................................................................................................................................................................68 
Protections.........................................................................................................................................................................................71 
Load power reductions..................................................................................................................................................................72 
Current measurement ...................................................................................................................................................................72 
SOC estimation.................................................................................................................................................................................73 
Heater control ..................................................................................................................................................................................75 
Cooling fan control..........................................................................................................................................................................76 
DC/DC converter control...............................................................................................................................................................76 
Pin mapping.......................................................................................................................................................................................76 
Display Unit .......................................................................................................................................................................................78 
Master/Slave .........................................................................................................................................................................................78 
Maintenance..........................................................................................................................................................................................................82 
Calibration of Cell Module temperature sensors ...................................................................................................................82 
Re-calibration of current sensor............................................................................................................................................... 83 
Master Clear .................................................................................................................................................................................... 84 
Setting up password...................................................................................................................................................................... 84 
Exporting and importing configuration .................................................................................................................................... 85 
Control Unit firmware update ......................................................................................................................................................86 
CAN Cell Group Module firmware update.................................................................................................................................86 
Display Unit firmware update.......................................................................................................................................................87 
Exporting and importing statistics .............................................................................................................................................87 
Changing language of the Control Panel........................................................................................................................................87 
Technical information ........................................................................................................................................................................................ 88 
Control Unit ...................................................................................................................................................................................... 88 
1.1. Mechanical specification......................................................................................................................................................... 88 
1.2. Electrical characteristics.........................................................................................................................................................89 
1.3. Other specifications...................................................................................................................................................................90 
Cell Module........................................................................................................................................................................................90 
1.4. Mechanical specification..........................................................................................................................................................90 
1.5. Electrical characteristics........................................................................................................................................................ 94 


1.6. Other specifications` ................................................................................................................................................................ 94 
Cell Communication Adapters.................................................................................................................................................... 94 
1.7. Mechanical specification......................................................................................................................................................... 94 
1.8. Electrical characteristics.........................................................................................................................................................97 
1.9. Other specifications...................................................................................................................................................................98 
Current Sensor.................................................................................................................................................................................99 
1.10. Mechanical specification.....................................................................................................................................................99 
1.11. Electrical characteristics.......................................................................................................................................................102 
1.12. Other specifications............................................................................................................................................................102 
Smartphone Connectivity Module............................................................................................................................................. 102 
1.13. Mechanical specification...................................................................................................................................................102 
1.14. Electrical characteristics .................................................................................................................................................103 
1.15. Other specifications............................................................................................................................................................103 
Display Unit .....................................................................................................................................................................................103 
1.16. Mechanical specification...................................................................................................................................................103 
1.17. Electrical characteristics .................................................................................................................................................104 
1.18. Other specifications............................................................................................................................................................104 
CAN Splitter.....................................................................................................................................................................................105 
1.19. Mechanical specification...................................................................................................................................................105 
1.20. Electrical characteristics .................................................................................................................................................105 
1.21. Other specifications............................................................................................................................................................106 
 
Preface ...................................................................................................................................................................................................................................8 
Introduction ........................................................................................................................................................................................................... 12 
Basics ........................................................................................................................................................................................................................ 13 
1. System structure overview .......................................................................................................................................................... 13 
1.1. Control Unit .................................................................................................................................................................................. 13 
1.2. Cell Modules..................................................................................................................................................................................17 
1.3. Cell Communication Adapters.................................................................................................................................................17 
1.4. Current Sensor ............................................................................................................................................................................19 
1.5. Smartphone Connectivity Module..........................................................................................................................................20 
1.6. Display Unit ..................................................................................................................................................................................20 
1.7. CAN Splitter ..................................................................................................................................................................................21 
1.8. Software........................................................................................................................................................................................23 
2. Functionality overview...................................................................................................................................................................23 
2.1. Cell Monitoring............................................................................................................................................................................23 
2.2. Current measurement ..............................................................................................................................................................27 
2.3. SOC estimation............................................................................................................................................................................27 
2.4. Charging process and charging device control .................................................................................................................28 
2.5. Battery protections....................................................................................................................................................................35 
2.6. Power reductions.......................................................................................................................................................................37 
2.7. Heater and cooling fan control............................................................................................................................................... 38 
2.8. DC/DC converter control..........................................................................................................................................................39 
2.9. Statistics .......................................................................................................................................................................................39 
2.10. Events...................................................................................................................................................................................... 42 


2.11. Vehicle speed measurement ............................................................................................................................................ 43 
2.12. Communication with external devices........................................................................................................................... 45 
2.13. Indication ................................................................................................................................................................................ 45 
Installation.............................................................................................................................................................................................................. 47 
1. Control Unit .......................................................................................................................................................................................47 
1.1. Choosing the power supply strategy ....................................................................................................................................47 
2. Cell Modules..................................................................................................................................................................................... 50 
3. Current Sensor.................................................................................................................................................................................52 
4. Cell Communication Adapters.................................................................................................................................................... 54 
5. CAN Bus............................................................................................................................................................................................. 54 
6. Centralized CAN group module ...................................................................................................................................................56 
7. Smartphone Connectivity Module...............................................................................................................................................57 
8. Display unit....................................................................................................................................................................................... 58 
9. Battery fuse...................................................................................................................................................................................... 58 
10. Contactor ...........................................................................................................................................................................................59 
10.1. Pre-charge sub-circuit .......................................................................................................................................................59 
11. Charger...............................................................................................................................................................................................60 
11.1. CAN-based chargers ................................................................................................................................................................60 
11.2. Non-CAN chargers ................................................................................................................................................................61 
11.3. Analog signal controlled chargers...................................................................................................................................62 
12. Cooling fan.........................................................................................................................................................................................62 
13. Heater .................................................................................................................................................................................................63 
14. Indicators...........................................................................................................................................................................................63 
15. Insulation fault detector ............................................................................................................................................................... 64 
Configuration ........................................................................................................................................................................................................ 65 
1. Data interfaces.................................................................................................................................................................................65 
1.1. Serial..............................................................................................................................................................................................65 
1.2. CAN.................................................................................................................................................................................................65 
1.3. Cell communication...................................................................................................................................................................66 
2. CAN Cell Group Module configuration.......................................................................................................................................67 
3. Charging process ............................................................................................................................................................................68 
4. Protections.........................................................................................................................................................................................71 
5. Load power reductions..................................................................................................................................................................72 
6. Current measurement ...................................................................................................................................................................72 
7. SOC estimation.................................................................................................................................................................................73 
8. Heater control ..................................................................................................................................................................................75 
9. Cooling fan control ..........................................................................................................................................................................76 
10. DC/DC converter control...............................................................................................................................................................76 
11. Pin mapping.......................................................................................................................................................................................76 
12. Display Unit .......................................................................................................................................................................................78 
13. Master/Slave ....................................................................................................................................................................................78 
Maintenance..........................................................................................................................................................................................................82 
1. Calibration of Cell Module temperature sensors ...................................................................................................................82 
2. Re-calibration of current sensor............................................................................................................................................... 83 
3. Master Clear .................................................................................................................................................................................... 84 


4. Setting up password...................................................................................................................................................................... 84 
5. Exporting and importing configuration .................................................................................................................................... 85 
6. Control Unit firmware update ......................................................................................................................................................86 
7. CAN Cell Group Module firmware update.................................................................................................................................86 
8. Display Unit firmware update.......................................................................................................................................................87 
9. Exporting and importing statistics .............................................................................................................................................87 
10. Changing language of the Control Panel...................................................................................................................................87 
Technical information ........................................................................................................................................................................................ 88 
1. Control Unit ...................................................................................................................................................................................... 88 
1.1. Mechanical specification......................................................................................................................................................... 88 
1.2. Electrical characteristics.........................................................................................................................................................89 
1.3. Other specifications...................................................................................................................................................................90 
2. Cell Module........................................................................................................................................................................................90 
2.1. Mechanical specification..........................................................................................................................................................90 
2.2. Electrical characteristics........................................................................................................................................................ 94 
2.3. Other specifications` ................................................................................................................................................................ 94 
3. Cell Communication Adapters.................................................................................................................................................... 94 
3.1. Mechanical specification......................................................................................................................................................... 94 
3.2. Electrical characteristics.........................................................................................................................................................97 
3.3. Other specifications...................................................................................................................................................................98 
4. Current Sensor.................................................................................................................................................................................99 
4.1. Mechanical specification..........................................................................................................................................................99 
4.2. Electrical characteristics.......................................................................................................................................................102 
4.3. Other specifications.................................................................................................................................................................102 
5. Smartphone Connectivity Module............................................................................................................................................. 102 
5.1. Mechanical specification........................................................................................................................................................102 
5.2. Electrical characteristics.......................................................................................................................................................103 
5.3. Other specifications.................................................................................................................................................................103 
6. Display Unit .....................................................................................................................................................................................103 
6.1. Mechanical specification........................................................................................................................................................103 
6.2. Electrical characteristics.......................................................................................................................................................104 
6.3. Other specifications.................................................................................................................................................................104 
7. CAN Splitter.....................................................................................................................................................................................105 
7.1. Mechanical specification........................................................................................................................................................105 
7.2. Electrical characteristics.......................................................................................................................................................105 
7.3. Other specifications.................................................................................................................................................................106 
 

Release notes:

Revision Date

Revision

Author

Changes

2018-11-11

1.2.1

Fixed some mistakes and inaccuracies in chapters 3.2.13.1,

3.2.13.2, 3.2.13.3, 4.13, and 4.14.

2018-12-07

1.3.0

Updated company name and links. Updated information about

new and obsolete products.

2019-08-11

1.4.0

Martyna

Dulevičiūtė

Manual information updated. Chapters 5.2, 5.13 added.

Obsolete products removed from manual. New products

uploaded. New mechanical drawings made.

Preface

List of Abbreviations

BMS

Battery Management System

Control Unit

Cell Module

CGM

CAN Group Module

CCGM

Centralized CAN Group Module

Carrier Return

Line Feed

USB

Universal Serial Bus

Control Panel

PWM

Pulse Width Modulation

List of Figures

Figure 3.1 EMUS G1 BMS System 13

Figure 3.2 EMUS G1 Control Unit14

Figure 3.3 Control Unit’s pins - fixed in red, general purpose remappable in green, and special purpose

remappable in blue 14

Figure 3.4 A standard 3A module Cell Module 17

Figure 3.5 Top and Bottom Isolators 18

Figure 3.6 CAN Cell Group Module 18

Figure 3.7 Centralized CAN group module 19

Figure 3.8 EMUS G1 Dual Range Current Sensor: Bus Bar type 20

Figure 3.9 EMUS G1 Dual Range Current Sensor: Closed Loop type 20

Figure 3.10 EMUS G1 Smartphone Connectivity Module 20

Figure 3.11 EMUS G1 Display Unit 21

Figure 3.12 Master/Slave system structure diagram 21

Figure 3.13 EMUS G1 CAN Splitter 22

Figure 3.14 EMUS EVGUI Application 23

Figure 3.15 Download on Apple App Store 23

Figure 3.16 Get it on Google Play 23

Figure 3.17 Cell communication data flow: when using Top and Bottom Isolators 24

Figure 3.18 Cell communication when using CAN Cell Group Modules. 25

Figure 3.19 Location of "Maximum balancing current" parameter 26

Figure 3.20 CCGM Temperature status 27

Figure 3.21 Contactor pre-charge timing diagram 37

Figure 3.22 Charging indicator timing 46

Figure 3.23 Sound indicator timing 46

Figure 3.24 Low battery indicator timing 46

Figure 4.1 Correct installation of Control Unit and distribution of power supply to other EMUS G1 BMS

components 47

Figure 4.2 Power supply strategy 1 48

Figure 4.3 Power supply strategy 2 49

Figure 4.4 Power supply strategy 3 49

Figure 4.5 Correct way of wiring a cell communication daisy chain: (a) Top and Bottom Isolators; (b) CAN Cell

9 
Group Module. 50 
Figure 4.6 Correct EMUS G1 BMS Cell Module 51 
Figure 4.7 3MTM ScotchlokTM butt connector 52 
Figure 4.8 EMUS G1 Current Sensor connection diagram. 53 
Figure 4.9 Correct EMUS G1 Bus Bar Current Sensor installation 53 
Figure 4.10 Correct EMUS G1 Closed loop type Current Sensor installation 54 
Figure 4.11 Correct way of connecting the TOP/BOT Isolator to the Control Unit. 54 
Figure 4.12 High-speed CAN network specified in ISO-11898-2 standard 55 
Figure 4.13 CCGM Battery installation 57 
Figure 4.14 CCGM CAN port pinout 57 
Figure 4.15 EMUS G1 Smartphone Connectivity Module connection diagram 58 
Figure 4.16 EMUS G1 Display Unit wiring 58 
Figure 4.17 Connecting contactor to EMUS G1 Control Unit: (a) directly, when the rated current of the contactor 
coil is less than 0.5A; (b) through a relay, when the rated current of the contactor coil is 0.5A or more. 59 
Figure 4.18 Contactor pre-charge sub-circuit connection diagram 60 
Figure 4.19 Correct CAN charger and charger contactor connection in respect of the battery, battery fuse, and 
main contactor 61 
Figure 4.20 Correct connection of a non-CAN charger in respect of the battery, battery fuse, and main contactor: 
(a) using EMUS G1 Solid State Relay; (b) using a third-party electromechanical contactor. 62 
Figure 4.21 Correct analog signal controlled charger and charger contactor connection in respect of the battery, 
battery fuse, and main contactor62 
Figure 4.22 : Cooling fan connection diagram 63 
Figure 4.23 Heater connection diagram 63 
Figure 4.24 Examples of connecting visual or audial indicators to the Control Unit (left to right): an indication 
lamp, a self-oscillating buzzer, and an LED. 64 
Figure 4.25 Example of connecting a third-party insulation fault detector to the Control Unit. 65 
Figure 5.1 Data Transmission to Display parameters 65 
Figure 5.2 CAN communication parameters 66 
Figure 5.3 Cell communication parameters 67 
Figure 5.4 CAN Devices in unconfigured list 67 
Figure 5.5 CAN Devices in configuration table before commit 68 
Figure 5.6 CAN Devices in configuration table after commit 68 
Figure 5.7 CAN Devices in configuration table after committing failed 68 
Figure 5.8 Single reduction example 72 
Figure 5.9 Current measurement parameters 73 
Figure 5.10 "Capacity" parameter box 74 
Figure 5.11 State of Charge parameters 75 
Figure 5.12 Heater and Fan parameters 76 
Figure 5.13 DC/DC Converted Control parameters 76 
Figure 5.14 Pin mapping settings 78 
Figure 5.15 Display Unit settings in Control Panel78 
Figure 5.16 Master/Slave parameters 79 
Figure 5.17 Master/Slave Configuration parameters 79 
Figure 5.18 Master/Slave BMS list table 80 
Figure 5.19 CAN Splitter Configuration button 80 
Figure 5.20 Master/Slave Protection and Reduction table 80 
Figure 6.1 External temperature sensor calibration window, 83 
Figure 7.1 EMUS G1 Control Unit mechanical drawing and connector’s pinout. All dimensions in millimeters

10 
 88 
Figure 7.2 EMUS G1 Cell Module 1.5A (CM011A) mechanical drawing. All dimensions in millimeters. 90 
Figure 7.3 EMUS G1 Cell Module Small (CM021A-8mm) mechanical drawing. All dimensions in millimeters. 91 
Figure 7.4 EMUS G1 Cell Module GBS (CM031B) mechanical drawing. All dimensions in millimeters92 
Figure 7.5 EMUS G1 Control Module 200-400Ah (CM051A) mechanical drawing. All dimensions in millimeters.
 92 
Figure 7.6 EMUS G1 Cell Module CALB CAM 72Ah (CM060A) mechanical drawing. All dimensions in millimeters.
 93 
Figure 7.7 EMUS G1 Cell Module 3A (CM071A) mechanical drawing. All dimensions in millimeters 93 
Figure 7.8 EMUS G1 Top Isolator (CCA010D) mechanical drawing. All dimensions in millimeters. 95 
Figure 7.9 EMUS G1 Bottom Isolator (CCA020D) mechanical drawing. All dimensions in millimeters. 95 
Figure 7.10 EMUS G1 CAN Cell Group Module (CGM020A) mechanical drawing. All dimensions in millimeters
 96 
Figure 7.11 EMUS G1 Centralized CAN Group Module (CCGM020A) mechanical drawing and connector’s pinout. 
All dimensions in millimeters 96 
Figure 7.12 EMUS G1 Bus Bar Type Dual Range Current Sensor (CS010B) mechanical drawing. All dimensions in 
millimeters. 100 
Figure 7.13 EMUS G1 Closed Loop Type Dual Range Current Sensor (CS020A) mechanical drawing and connectors 
pinout. All dimensions in millimeters. 100 
Figure 7.14 Smartphone Connectivity Module mechanical drawing (applies to both SCM030A). All dimensions in 
millimeters. 102 
Figure 7.15 EMUS G1 Display Unit (DU010A) mechanical drawing. All dimensions in millimeters. Electrical 
characteristics 104 
Figure 7.16 CAN Splitter (CSL020A) mechanical drawing 105 
 
List of Tables 
Table 3.1 List of statistics and their descriptions 39 
Table 3.2 List of events and their descriptions 42 
Table 4.1 Recommended cell terminal bolt 51 
Table 4.2 Maximum bus line lengths 55 
Table 7.1 EMUS G1 Control Unit (CU021A) connector pin 88 
Table 7.2 EMUS G1 Control Unit electrical characteristics 89 
Table 7.3 EMUS G1 Control Unit other specifications 90 
Table 7.4 EMUS G1 Cell Module A/B terminal assignment 90 
Table 7.5 EMUS G1 Cell Module Small terminal assignment 91 
Table 7.6 EMUS G1 Cell Module GBS terminal assignment 92 
Table 7.7 EMUS G1 Cell Module 200-400Ah terminal assignment 92 
Table 7.8 EMUS G1 Cell Module CALB CAM 72Ah terminal assignment 93 
Table 7.9 EMUS G1 Cell Module 3A terminal assignment 93 
Table 7.10 EMUS G1 Cell Module electrical characteristics94 
Table 7.11 EMUS G1 Top Isolator (CCA010D) wire assignment 95 
Table 7.12 EMUS G1 Bottom Isolator (CCA020D) wire assignment 95 
Table 7.13 EMUS G1 CAN Cell Group Module (CGM020A) cell communication wire assignment 96 
Table 7.14 EMUS G1 CAN Cell Group Module (CGM020A) connector pin assignment 96 
Table 7.15 EMUS G1 Centralized CAN Group Module (CCGM020A) connector pin assignment 96 
Table 7.16 EMUS G1 Top Isolator (CCA010D) electrical characteristics 97 
Table 7.17 EMUS G1 Bottom Isolator (CCA020D) electrical characteristics 97 
Table 7.18 EMUS G1 CAN Cell Group Module (CGM020A) electrical characteristics 98 