EMUS G1 Manuale utente

G1 Battery Management System

User Manual 2.7.1

 
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Table of contents 
 
PREFACE 8 
INTRODUCTION 12 
CHAPTER 1: SYSTEM STRUCTURE OVERVIEW 18 
CONTROL UNIT 18 
1 USB DATA INTERFACE 19 
2 RS232 DATA INTERFACE 19 
3 CAN DATA INTERFACE 20 
4 SERIAL CELL COMMUNICATION DATA INTERFACE 20 
5 GENERAL PURPOSE INPUTS AND OUTPUTS 20 
6 CURRENT SENSOR INPUTS 21 
7 SOC OUTPUT 21 
8 SPEED SENSOR INPUT 22 
9 CELL MODULES 22 
9.1 Cell Module Selection Recommendations 23 
10 CENTRALIZED CAN CELL GROUP MODULE 24 
11 CELL COMMUNICATION ADAPTERS 25 
11.1 Top and Bottom Isolators 25 
11.2 CAN Cell Grop Modules 26 
11.3 Tesla Module retrofit BMS 26 
12 CURRENT SENSORS 27 
12.1 Bus Bar Type 27 
12.2 Closed Loop Type 28 
13 3RD PARTY CAN CURRENT SENSORS 28 
14 SMARTPHONE CONNECTIVITY MODULE 29 
15 DISPLAY UNIT 29 
16 CAN SPLITTER /FILTER 30 
17 SOFTWARE 31 
17.1 EVGUI Android and iOS applications 31 
17.2 Control Panel 32 

 
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CHAPTER 2: FUNCTIONALITY OVERVIEW 34 
1 CELL MONITORING 34 
1.1 Distributed Regular Cell Monitoring 34 
1.2 Distributed Grouped Cell Monitoring 35 
1.3 Centralized Cell Monitoring 36 
1.4 Temperature measurement 38 
1.5 Tesla Module cell monitoring 38 
2 CURRENT MEASUREMENT 39 
2.1 EMUS current sensors 39 
2.2 3rd party CAN current sensors 39 
3 SOC ESTIMATION 39 
3.1 SOC legacy adjustment algorithm 40 
3.2 Integrated SOC/SOH estimator (gen1 algorithm) 40 
3.2.1 SOH algorithm 42 
4 CHARGING PROCESS AND CHARGING DEVICE CONTROL 42 
4.1 Charging Interlock 48 
5 BATTERY PROTECTIONS 48 
5.1 Contactor pre-charge 50 
5.2 External contactor deactivation 51 
6 POWER REDUCTIONS 51 
7 WARNINGS 52 
8 HEATER AND COOLING FAN CONTROL 53 
8.1 Climate Control 54 
9 DC/DC CONVERTER CONTROL 54 
10 PSU UNDER-VOLTAGE SENSE CONTROL 55 
11 BATTERY CONTACTOR CONTROL BY “IGNITION”56 
12 OPTIMISED BATTERY CHARGING 56 
13 STATISTICS 56 
14 EVENTS 60 
15 VEHICLE SPEED MEASUREMENT 61 
15.1 Energy consumption calculation 62 
15.2 Remaining distance estimation 63 
16 COMMUNICATION WITH EXTERNAL DEVICES 64 

 
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17 MASTER/SLAVE 64 
18 INDICATION 64 
18.1 Charging status indication 64 
18.2 Buzzer 65 
18.3 Low battery indication 65 
CHAPTER 3: INSTALLATION 67 
1 CONTROL UNIT 67 
1.1 Choosing the power supply strategy 68 
2 CELL MODULES 70 
3 TESLA MODULE 74 
4 CURRENT SENSOR 75 
4.1 EMUS current sensor 75 
4.2 3rd Party current sensor 76 
4.3 CAN Current Sensor 77 
5 CELL COMMUNICATION ADAPTERS 77 
6 CAN BUS 78 
7 CENTRALIZED CAN CELL GROUP MODULE 80 
8 CAN SPLITTER /FILTER 83 
9 SMARTPHONE CONNECTIVITY MODULE 84 
10 DISPLAY UNIT 85 
11 BATTERY FUSE 85 
12 CONTACTOR 86 
13 PRE-CHARGE SUB-CIRCUIT 86 
14 CHARGER 87 
14.1 CAN-based chargers 88 
14.2 CAN chargers/inverters 89 
14.3 Non-CAN chargers 90 
14.4 Analog signal-controlled chargers 90 
15 COOLING FAN 91 
16 HEATER 92 
17 INDICATORS 92 

 
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18 INSULATION FAULT DETECTOR 93 
CHAPTER 4: CONFIGURATION 94 
1 EMUS BMS CONTROL PANEL 94 
2 SERIAL DATA INTERFACE 95 
3 CHARGING DISABLE 96 
4 CAN DATA INTERFACE 96 
5 CELL COMMUNICATION DATA INTERFACE 97 
6 CAN CELL GROUP MODULE CONFIGURATION 98 
7 EXTERNAL TEMPERATURE BREAKOUT BOARD CONFIGURATION 100 
8 MAXIMUM BALANCING CURRENT PARAMETER 100 
9 CHARGING PROCESS 101 
9.1 CAN chargers / inverters 104 
10 PROTECTIONS 104 
11 LOAD POWER REDUCTIONS 105 
12 WARNINGS 106 
13 CURRENT MEASUREMENT 107 
14 SOC ESTIMATION 109 
14.1 SOC legacy adjustment algorithm 109 
14.2 SOC/SOH estimator (gen1 algorithm) 111 
14.2.1 Tuning parameters 111 
14.2.2 Cell model reference settings 112 
14.2.3 SOC-OCV dependency curve of cell 113 
14.2.4 SOC dependency on temperature 113 
15 HEATER CONTROL 114 
16 COOLING FAN CONTROL 114 
17 BATTERY CONTACTOR CONTROL 115 
18 DC/DC CONVERTER CONTROL 115 
19 I/O PINS 116 
20 DISPLAY UNIT 120 
21 DISTANCE PARAMETERS 120 
22 MASTER/SLAVE 121 
CHAPTER 5: MAINTENANCE 124 

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5.1 CALIBRATION OF CELL MODULE TEMPERATURE SENSORS 124

5.2 RE-CALIBRATION OF CURRENT SENSOR 125

5.3 MASTER CLEAR 126

5.4 SETTING UP PASSWORD 126

5.5 EXPORTING AND IMPORTING CONFIGURATION 127

5.6 CONTROL UNIT FIRMWARE UPDATE 128

5.7 CAN CELL GROUP MODULE FIRMWARE UPDATE 128

5.8 DISPLAY UNIT FIRMWARE UPDATE 129

5.9 EXPORTING AND IMPORTING STATISTICS 129

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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

Manual information updated. Chapters 5.2, 5.13 added.

Obsolete products removed from manual. New products

uploaded. New mechanical drawings made.

2020-12-08

1.6.0

Added new chapters (2.1.3, 2.1.4, 2.3.2, 2.3.2.1, 2.7, 4.1, 4.9,

4.11.2, 4.11.2.1, 4.11.2.2, 4.11.2.3, 4.11.2.4), added BMS battery

cells arrangements configuration examples,

all products technical information has been transferred to

separate datasheet documents.

2021-08-17

1.7.0

Added new chapters (1.12.3, 2.1.5, 3.3). Detail description of

the EMUS Tesla Module (TES011C) retrofit BMS.

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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 0-1 Distributed regular ......................................................................................................................................................................... 14

Figure 0-2 Distributed grouped ...................................................................................................................................................................... 15

Figure 0-3 Centralized CCGM ...........................................................................................................................................................................16

Figure 0-4 G1 Distributed Master/Slave redundancy ................................................................................................................................17

Figure 1-1 EMUS G1 Control Unit................................................................................................................................................................... 18

Figure 1-2 Control Unit’s pins - fixed in red, general purpose remappable in green, and special purpose remappable in

blue ...........................................................................................................................................................................................................................19

Figure 1-3 Example SOC Output connection circuit ..................................................................................................................................21

Figure 1-4 Speed IN connection diagram....................................................................................................................................................22

Figure 1-5 A standard 3A module Cell Module..........................................................................................................................................23

Figure 1-6 Centralized CAN group module CCGM022C......................................................................................................................... 24

Figure 1-7 Top and Bottom Isolators.............................................................................................................................................................25

Figure 1-8 CAN Cell Group Module...............................................................................................................................................................26

Figure 1-9 Tesla Module (TES011C) retrofit BMS.......................................................................................................................................27

Figure 1-10 EMUS G1 Dual Range Current Sensor: Bus Bar type..........................................................................................................28

Figure 1-11 EMUS G1 Dual Range Current Sensor: Closed Loop type................................................................................................28

Figure 1-12 EMUS G1 Smartphone Connectivity Module.......................................................................................................................29

Figure 1-13 EMUS G1 Display Unit................................................................................................................................................................ 30

Figure 1-14 EMUS G1 CAN Splitter (Chogori connectors) ...................................................................................................................... 31

Figure 1-15 EMUS G1 CAN Splitter (Molex connectors).......................................................................................................................... 31

Figure 1-17 Get it on Google Play..................................................................................................................................................................32

Figure 1-17 Download on Apple App Store ................................................................................................................................................32

Figure 1-18 EMUS Control Panel.....................................................................................................................................................................33

Figure 2-1 Cell communication data flow: when using Top and Bottom Isolators......................................................................... 34

Figure 2-2 Cell communication when using CAN Cell Group Modules. .............................................................................................35

 
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Figure 2-3 Cell communication when using Centralized CAN Cell Group Modules. ......................................................................37 
Figure 2-4 CCGM Temperature status.......................................................................................................................................................... 38 
Figure 2-5 EMUS Equivalent circuit model................................................................................................................................................... 41 
Figure 2-6 Formula for SOH ............................................................................................................................................................................ 42 
Figure 2-7 Contactor pre-charge timing diagram.................................................................................................................................... 50 
Figure 2-8 Power supply unit voltage sense example circuit schematic............................................................................................ 55 
Figure 2-9 PSU under-voltage sense control ..............................................................................................................................................56 
Figure 2-10 Battery contactor control by "Ignition" sequence..............................................................................................................56 
Figure 2-11 Charging indicator timing..........................................................................................................................................................65 
Figure 2-12 Sound indicator timing...............................................................................................................................................................65 
Figure 2-13 Low battery indicator timing.....................................................................................................................................................66 
Figure 3-1 Correct installation of Control Unit and distribution of power supply to other EMUS G1 BMS components ...68 
Figure 3-2 Power supply strategy 1 ...............................................................................................................................................................68 
Figure 3-3 Power supply strategy 2 ...............................................................................................................................................................69 
Figure 3-4 Power supply strategy 3 ...............................................................................................................................................................70 
Figure 3-5 Correct way of wiring a cell communication daisy chain: (a) Top and Bottom Isolators; (b) CAN Cell Group 
Module.....................................................................................................................................................................................................................71 
Figure 3-6 3MTM ScotchlokTM butt connector..............................................................................................................................................72 
Figure 3-7 Cell Modules Wires Positioning..................................................................................................................................................73 
Figure 3-8 EMUS Tesla Module (TES011C) connectors............................................................................................................................74 
Figure 3-9 Installed EMUS Tesla Module (TES011C) .................................................................................................................................75 
Figure 3-10 EMUS G1 Current Sensor connection diagram. ..................................................................................................................75 
Figure 3-11 Correct EMUS G1 Bus Bar Current Sensor installation......................................................................................................76 
Figure 3-12 Correct EMUS G1 Closed loop type Current Sensor installation....................................................................................76 
Figure 3-13 CAN current sensor......................................................................................................................................................................77 
Figure 3-14 Correct way of connecting the TOP/BOT Isolator to the Control Unit.........................................................................77 
Figure 3-15 High-speed CAN network specified in ISO-11898-2 standard.......................................................................................78 
Figure 3-16 Cells connection, with e.g 8 cells in series ............................................................................................................................ 81 
Figure 3-17 CCGM Battery, Ext. Temperature Sensors installation....................................................................................................... 81 
Figure 3-18 CCGM CAN port pinout..............................................................................................................................................................82 
Figure 3-19 Power supply connection for CCGM.......................................................................................................................................82 
Figure 3-20 Temperature Breakout Board connection possibility to CCGM .................................................................................... 83 
Figure 3-21 CAN Splitter connection............................................................................................................................................................ 83 
Figure 3-22 EMUS G1 Smartphone Connectivity Module connection diagram.............................................................................. 84 
Figure 3-23 EMUS G1 Display Unit wiring................................................................................................................................................... 85 
Figure 3-24 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.............................................86 
Figure 3-25 Contactor pre-charge sub-circuit connection diagram....................................................................................................87 
Figure 3-26 Correct CAN charger and charger contactor connection in respect of the battery, battery fuse, and main 
contactor ............................................................................................................................................................................................................... 88 
Figure 3-27 CAN Charger/Inverter system...................................................................................................................................................89 
Figure 3-28 Correct connection of a non-CAN charger in respect of the battery, battery fuse, and main contactor: using 

 
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a third-party electromechanical contactor...................................................................................................................................................90 
Figure 3-29 Correct analog signal controlled charger and charger contactor connection in respect of the battery, battery 
fuse, and main contactor....................................................................................................................................................................................91 
Figure 3-30 : Cooling fan connection diagram............................................................................................................................................91 
Figure 3-31 Heater connection diagram.......................................................................................................................................................92 
Figure 3-32 Examples of connecting visual or audial indicators to the Control Unit (left to right): an indication lamp, a 
self-oscillating buzzer, and an LED.................................................................................................................................................................93 
Figure 3-33 Example of connecting a third-party insulation fault detector to the Control Unit.................................................93 
Figure 4-1 Data Transmission to Display parameters...............................................................................................................................95 
Figure 4-2 Disable Charging Button ..............................................................................................................................................................96 
Figure 4-3 CAN communication parameters...............................................................................................................................................96 
Figure 4-4 Cell communication parameters ................................................................................................................................................98 
Figure 4-5 CAN Devices in unconfigured list ..............................................................................................................................................98 
Figure 4-6 CAN Devices in configuration table before commit ............................................................................................................99 
Figure 4-7 CAN Devices in configuration table after commit ................................................................................................................99 
Figure 4-8 CAN Devices in configuration table after committing failed.............................................................................................99 
Figure 4-9 External Temperature Breakout board configuration........................................................................................................100 
Figure 4-10 Location of "Maximum balancing current" parameter....................................................................................................100 
Figure 4-11 Single protection example.......................................................................................................................................................105 
Figure 4-12 Single reduction example ........................................................................................................................................................ 106 
Figure 4-13 Single warning example ........................................................................................................................................................... 107 
Figure 4-14 Current measurement parameters........................................................................................................................................ 107 
Figure 4-15 Isabellenhütte sensor configuration....................................................................................................................................108
Figure 4-16 State of Charge estimation type ............................................................................................................................................ 109 
Figure 4-17 "Battery Pack" parameter box..................................................................................................................................................110 
Figure 4-18 SOC at low voltage warning.....................................................................................................................................................110 
Figure 4-19 State of Charge parameters .....................................................................................................................................................110 
Figure 4-20 Tuning Parameters......................................................................................................................................................................112 
Figure 4-21 Cell Model Reference Settings ................................................................................................................................................113 
Figure 4-22 SOC-OCV dependency curve of cell......................................................................................................................................113 
Figure 4-23 Heater and Fan parameters......................................................................................................................................................114 
Figure 4-24 Battery Contactor Control parameters..................................................................................................................................115 
Figure 4-25 DC/DC Converted Control parameters ................................................................................................................................. 116 
Figure 4-26 Pin mapping settings ................................................................................................................................................................ 119 
Figure 4-27 Display Unit settings in Control Panel.................................................................................................................................. 120 
Figure 4-28 Distance Parameters................................................................................................................................................................... 121 
Figure 4-29 Master/Slave parameters .......................................................................................................................................................... 121 
Figure 4-30 Master/Slave Configuration parameters ............................................................................................................................. 122 
Figure 4-31 Master/Slave BMS list table..................................................................................................................................................... 122 
Figure 4-32 CAN Splitter Configuration button ....................................................................................................................................... 122 
Figure 4-33 Master/Slave Protection and Reduction table................................................................................................................... 123 
Figure 5-1 External temperature sensor calibration window................................................................................................................ 125 