EV-POWER BCU-PPAK Manuale utente
BCU-PPAK INSTALLATION MANUAL 1.0
EV Power BCU-PPAK
Battery Control Unit Installation.
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BCU-PPAK INSTALLATION MANUAL 1.0
BCU-PPAK Features
- Simple to install and use, microprocessor control.
- Low power requirement, just 15mA when switched on with relay active.
- Prevents overcharge and over-discharge o LFP batteries.
- 12V (4 cell) operation.
- 240A (or 3 x 80A) capacity with normal relay, 500A capacity with optional high power relay.
- Capable o controlling multiple batteries in parallel.
- Plug and play with EV Power Pak 12V batteries.
- Works with any charger that is suitable or LFP batteries.
BCU-PPAK+4C Specifications
- Supply Voltage - 8 - 15VDC
- Power Consumption - <5mA (o ), 15mA (on) @ 13VDC
- Switching current - 240A (80A per pole)
- Dimensions - 150 x 90 x 55mm : control enclosure
- Weight - 520g
- Environmental - -20 to +60 Celsius
bjective of this manual
This manual will help with installation and operation o the PPAK-4C battery control unit in conjunction with EV Power
PowerPaks.
An understanding o electrical principles and competence with electrical tools is required. Ability to use the volts, amps
and Ohms setting o a multimeter is a prerequisite.
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BCU-PPAK INSTALLATION MANUAL 1.0
Disclaimer
This is a guide only. Potentially lethal voltages and currents are involved when working with batteries. It is the
responsibility of the installer to have the appropriate qualifications and skills for working with high voltages. No
liability whatsoever will be assumed by EV Power for injury, accidents or damage resulting from the use of these
instructions.
Read these instructions several times be ore commencing installation.
Do not try to charge or discharge Lithium (LFP) batteries without the BCU installed. One over-charge or
over-discharge WILL cause permanent damage.
Every e ort has been made to make this apparatus as reliable and robust as possible. However electronics can ail. The
BCU-PPAK is designed to be the last line o battery protection and should not be relied upon to disconnect the battery
under normal operating conditions. Connected loads and chargers should have inbuilt low/high voltage cuto mecha-
nisms. EV Power assumes no responsibility or battery damage resulting rom ailure o the BCU other than statutory
warranty requirements.
Introduction
The EV Power Battery Control Unit is designed or Lithium Iron Phosphate (LiFePO4, LFP) batteries o capacity 40-
400Ah and nominal voltage o 12.8V. These batteries are generally used in applications where light weight, high power
and long li e are required.
The BCU-PPAK+4C is designed to control 4 cell (12V) battery packs. It monitors overall battery voltage and also the con-
dition o each cell via the patented one wire link to BMS cell modules.
It is designed to be the simplest possible method o providing complete LFP battery protection.
This overall system consists o a single Battery Control Unit (BCU) and multiple cell modules that bolt directly on top o
each cell. The cell modules per orm the cell balancing unction during charging and connect together via a one wire inter-
ace. The BCU controls a relay that interrupts power to/ rom the load/charger in the event o a battery problem.
No battery uel gauge unctions are incorporated in the system and there are no digital outputs available to inter ace with
external devices. No temperature monitoring is done.
In combination with an approved switch mode charger the BCU-PPAK+4C will provide automated charging o EV Power
Paks or LFP cells with EV Power BMS modules attached.
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BCU-PPAK INSTALLATION MANUAL 1.0
How it works - Usage
The BCU per orms a number o unctions:
1) It monitors the battery voltage, i the voltage alls below 11.6V or rises above 15.0V (4 or 5 red LED lashes) or more
than 15-20 seconds the relay will open. Then will be no LEDs and the BCU will revert to a low power mode.
2) It monitors the BMS cell module loop. I any cell goes below 2.5V or above 4.0V (2 lashes red LED) or more than 15-
20 seconds the relay will open. Then will be no LEDs and the BCU will revert to a low power mode.
3) I the battery voltage is below 11.6V or above 15.0V and the BMS cell loop signals an error on one cell the relay will
immediately open, no delay. Then will be no LEDs and the BCU will revert to a low power mode.
The BCU is operated by pressing the ON/OFF button on the ront.
- One press to switch on
- One press to switch o
- Press and hold to override and engage relay a ter a dropout. Use this only i necessary and only to enable charging.
The BCU ON/OFF button has a Red LED to indicate that the relay is switched ON.
This LED will lash to indicate battery error conditions.
- Two red lashes, one or more cell modules is registering a cell ault. (< 2.5V or > 4.0V)
- Four red lashes, low battery voltage, <11.6V
- Five red lashes, high battery voltage, > 15.0V
- No LEDS, BCU has dropped the contactor and switched itsel OFF.
The relay is a special type called a magnetic latching relay. It consumes no power when switched on. The downside o
this is that it can remain on i power to the BCU is removed or i the BCU ails or any reason. Check that the relay is op-
erating correctly occasionally by switching o and on the BCU.
S ME L ADS AND CHARGERS HAVE INTERNAL CAPACIT RS WHICH DRAW LARGE INRUSH
CURRENTS WHEN C NNECTED. THIS MAY CAUSE THE RELAY C NTACTS T FUSE CL SED. SUITABLE
PRE-CHARGE CIRCUITS SH ULD BE INC RP RATED IN THIS CASE.
D N T DISC NNECT P WER T THE BCU WHILE THE RELAY IS IN THE N STATE, battery protec-
tion will be removed.
I the BCU cuts o the battery during discharge the battery is most likely nearly empty. DO NOT RESET AND CONTIN-
UE DISCHARGE! Reset and charge the battery immediately.
I the relay is pulsing on/o that would mean it is hitting the low voltage threshold under load. More likely on cold days
and with cold batteries.
Note that the 11.6V cuto threshold equates to approximately 2-5% remaining battery capacity, more or less. The battery
should be considered to be lat at this level to allow or a sa ety bu er.
Note that even when switched o the BCU consumes a small parasitic current. It will take some months to drain a ull
battery at this rate but it is best to either leave the battery on continuous loat charge 13.6-13.8V or to disconnect the
BCU i the battery is to be stored or long periods.
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BCU-PPAK INSTALLATION MANUAL 1.0
I the relay opens during charging it means either the charge voltage has gone to high or the cells are unbalanced. Try
reseting and charging a ew times. I one red LED on the BMS cell modules on the battery comes on long be ore the oth-
ers then that cell is running too high. Contact EV Power or advice in this instance.
The BCU is the last line of defence for the battery pack. It should not be relied upon to disconnect the
battery every time it is used. It is there as a safety backup.
Battery Storage
When a battery is to be le t unused or a period it is important to make sure it is ully charged irst.
Lithium batteries last longer i stored not ully charged but this is not a problem as the BCU will provide a small current
draw to ensure it is not quite ull.
Continuous charging is not recommended during storage.
The new BCU-PPAK+4C (or 8C) is meant to be set to 11.6V low voltage cut on the main contactor.
It should be calibrated +/- 0.1V.
We do a ull QC burn-in test on all units.
The low voltage cutout is adjustable via a small trimpot next to one o the terminal blocks. Anticlockwise to turn it down
lower.
The new BCU also has a hardware cutout that inhibits power to the BCU itsel i it drops below ~7.5V.
This helps prevent total battery discharge i the unit is orgotten about or weeks or months.
It does also mean that some external trickle charge may be required to get the battery back up to the switch on thresh-
old.
When storing a battery, ully charge it irst, then switch
o the BCU and ensure a ull recharge is done every two or
three months.
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BCU-PPAK INSTALLATION MANUAL 1.0
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BCU-PPAK INSTALLATION MANUAL 1.0
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BCU-PPAK INSTALLATION MANUAL 1.0
High Power Applications
For batteries in parallel one pole o the relay is required per battery to prevent high current damage i one cell ails in one
pack. The standard relay has three poles which may be used to control up to three battery packs in parallel. Just remove
the copper bus bar rom the battery side o the relay.
Current drain may be 80A per parallel pack. So two batteries in parallel = 160A capability.
For applications which require more than 80A continuous per battery a high power contactor option is available. It can
supply up to 500A . Please advise when purchasing.
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BCU-PPAK INSTALLATION MANUAL 1.0
Remote Enable Chargers
A very ew types o charger have a remote enable connection. This is a two pole terminal block. I the poles are bridged
then the charger will activate. I open circuit then the charger is disabled. It is a use ul unction which the BCU-PPAK can
used to enable the charger. This means the charger may be connected directly to the battery terminals, via a suitable
use or circuit breaker.
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BCU-PPAK INSTALLATION MANUAL 1.0
General Battery Guidelines
LFP cells should be housed in a battery box away rom dust, excessive heat and moisture. Appropriate restraints should
be used that are capable supporting at least 5 times the battery weight in the event o a vehicle rollover. All restraints
should be well insulated so as not to short out battery terminals.
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