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Please read the installation guide and the manual carefully before operating
and follow the instructions! The specified safety instructions need to be
followed!
The cells are constructed under safety class IP 0x. Please take care for
the necessary electric shock protection!
Before starting the work on energized parts the charging plug needs
to be disconnected from the grid and the connection of the batteries
needs to be interrupted!
When the components are built in or used inappropriate, the Clean Energy
GmbH is not extending any warranty or assuming any liability.
Our Cells and BMS-components are excluded from the extended product
liability.
The ingredients of that manual are the explanation of the BMS, the
installation guide and the data sheet of the used cell-type! Please consider
actual additions to the guidelines on our homepage
www.cleanenergygmbh.de!
We are not taking any liability on technical or print technical failures and their
consequences. The orders in the explanations are being checked regularly.
Changes in consequence of a correction or a technical improvement can be
made without a letter of indication!
The copyright of the BMS installation guide and manual are lying within the
Clean Energy GmbH. Duplication without a written authorization, also in parts,
is not allowed!
After the installation and wiring of the cell-boards we recommend, for dirt
and wetness protection, to spray them with spray paint.
During the installation of the cells they need to be fixed mechanically with a
tentering frame, to avoid a possible expansion of the cells through an over
pressure, and to prevent a possible shifting.
Only lithium-cells with the same charging level are allowed to be connected.
Otherwise the cells need to be charged separately or connected parallel in
consideration of the allowed charging current.
- When using a BMS with central box, the main plug needs to be
disconnected first!
- When using cell boards, the battery current circuit needs to be disrupted
first!
Our specialized personnel will help you for any more questions.
The battery management system of the Clean Energy GmbH was developed for the diagnoses
and the monitoring of lithium-iron-phosphate batteries. A special attribute of the BMS is that
all components are being linked with a BUS wire for the communication with each other. There
are two different types to monitor the cells: with a central box or with cell boards. The system is
mainly consisting of six different components:
- a load shedding relay, that is disconnecting the battery discharging circuit to prevent a total
discharge,
- the BMS cell board or the central box that are monitoring and balancing the single cells,
Moreover up to five temperature sensors and further BUS relays can be connected to the BMS.
Important data, like the address of a disrupted battery, the voltage level of a single cell,
temperatures or removed charging volumes can be shown in the display of the BMS control for
battery diagnosis.
When further external components are connected to the BMS (e.g.: power contactor, charging
device, battery heating and ventilation), it can be used as an automatic system to control the
charging- and discharging circuits in electric vehicles.
When connected to a PLC, the BMS is able to monitor the battery of a storage system and
control the charging and discharging progress. The integration in the superior system control is
possible through potential-free contacts and/or a communication interface adapter.
With power supply 230VAC/12VDC and 16A charger. Without temperature monitoring.
The control about the 12V on board supply system is not taken into account here! The
emergency flasher system and the parking lights need also to be usable after die disconnection
of the power-shedding relay. All other consumers need to be switched off to prevent the cells
from a possible total discharge.
With power supply 230VAC/12VDC and 16A charger. Without temperature monitoring.
The control about the 12V on board supply system is not taken into account here! The
emergency flasher system and the parking lights need also to be usable after die disconnection
of the power-shedding relay. All other consumers need to be switched off to prevent the cells
from a possible total discharge.
The voltage supply for the BMS/the BUS communication is made through the BUS boards that
are being connected to the power supply. Depending on the application it is possible to use
alternating voltage or direct voltage power supply.
The voltage supply is assured with the public grid (230V AC) or with a 12V DC voltage source.
The BUS board is screwed on the power supply as shown here.
+12
0V
The voltage supply is assured over the battery or a 12V DV voltage source. Different input
voltage ranges like 18-36V DC or 36-72V DC can be selected.
+ 12V
0V
3.2.1 With power supply 230V AC/12V DC and charger with max. 2400 W
The voltage supply is assured through 230V AC charging plug and 12V DC on-board electric
230V AC-wiring:
When using charging devices with input currents greater than 16A, the BUS charger relay is
not allowed to be used directly for the switching operation of the charging current. A power
contactor needs to be used in this case that is controlled by the BUS relay.
12V DC-wiring:
When connecting the 12V DC, the terminal description of the power supply needs to be
considered! The position of the V+ and V- 12V DC connectors is not identical on both
available versions.
Connecting example:
The voltage supply is assured through the traction battery or the 12V DC on-board electric.
Connecting example:
230VAC-Anschluss:
When using charging devices with input currents greater than 16A, the BUS charger relay
is not allowed to be used directly for the switching operation of the charging current. A
power contactor needs to be used in this case that is controlled by the BUS relay
12V DC-wiring:
When connecting the 12V DC, the terminal description of the power supply needs to be
considered! The position of the V+ and V- 12V DC connectors is not identical on both
available versions.
The current sensor is recording the actual complete current during the charging and discharging
progress.
The battery connection wire of the negative terminal is laid through the current sensor.
Moreover, the blue ring or the text of the current sensor needs to direct away from the negative
terminal.
After the current sensor has been connected to the BUS wire and the BMS has been activated,
the correct operation of the current sensor is shown through a positive prefix at the current
value (+0A) in the Display of the BMS control.
If no or a negative prefix is shown. The orientation of the current sensor and the wiring need to
be checked!
Current sensor
Negative terminal
BUS-connection
All BMS components are connected through a BMS wire for the communication among each
other.
The on-board display needs to be sliced on its back for the BUS plug.
The build-in display is ready to mount. For the operation in the CityEL there is a special version
available
Before the display is built in, the jumper configuration to select the background lightning needs
to be selected on the rear side of the board:
Jumper
Color table
BMS manual with software version 3.32BT - 18 - 23.03.2012
© clean energy gmbh
Jumper set … ... equals background lightning
red-green-blue white
red red
green green
blue blue
red-green yellow
red-blue purple
green-blue turquois
no Jumper unlighted
BUS control, BUS relay, power supply and current sensor are connected through the grey BUS
plugs with the 10 veined BUS wire. Therefore, it is important that the grey BUS plugs are
pressed at right angles to the BUS wire. The BUS wire is laid out symmetric, so that the red
marking is not having any importance. The named components are having an assured
participant address. Consequently, the order within the BUS circuit is for free choice.
The bridge between the BUS wire and the BUS central box entry is being soldered according to
the following terminal diagram and isolated individually. Therefore, two individual wires of the
BUS wire are united. Consequently, the BUS wire is laid out symmetric and protected from
reverse voltage.
The cells are connected individually with the BMS central box. Therefore, the grey outside isolation is
being removed so far, that the single wires can be laid to the cells of the battery package.
The ends of the wires need to be equipped with flat-pin plugs. The green-yellow wire is being
connected to the negative terminal of the first cell. The black wires are numbered from 1 to 17.
These are connected to the positive terminals of the first cell and the following. The wire No.
17 can be sliced through as it is not disposed in the plug. All other unused wires need to be
isolated (see also connecting diagram point 2.2.2)
When having reached the last connected cell the addressing stops. Through plugging the
spring-return button the addressing is quitted and the BMS switches back to the main-menu.
6. Connection of the BUS wire to the cells with cell board version
As the cell boards can be used for multiple cell sizes, it might be affordable to shorten the cell boards
according to the distance between the positive and the negative terminal of the battery.
After the cell connectors are laid down, the cell boards are being screwed frontal on the cells (with
washer and spring washer). Here it is essential to take care for the parallel polarity of the lithium cell
and the cell board (+ and – polarity are marked on the cell)!
The cell boards cannot be directly installed on the battery terminals. In this case two connecting
wires are soldered to the boards and fitted to the battery terminals with cable lugs. The board is
fixed on the cell with four gluey basements.
To avoid possible discharging currents over the cell board, which can occur during the
connecting or disconnecting of the main negative terminal, it should be connected to the main
negative terminal of the battery with a flat-pin plug. Before disconnecting the power-wire, the
connection to the board needs to be interrupted. When connecting it needs to be handled the
other way round.
The red BUS plug needs to be pressed on the BUS wire in the same way as explained before
with the grey plugs. Here it is important to take care for enough space between the plugs to
make the installation as easy as possible and not to put the BUS wire under tensile stress.
Because of the simpler installation the noses at the plugs can be broken away, as seen on the
following picture.
Please connect the BUS plugs individually after having activated the BMS and after the
“Auto addressing” (see point 7)
Line of action:
1. The cells get numbered according to the constructed series connection. The cell with No. 1
should be the cell with the main positive terminal of the battery pack for a better overview.
2. As soon as the BMS is activated, the BUS plugs can be plugged on all boards one after
another. Here it is important to start with the cell No. 1. If the BMS has identified the cell, a
hearable signal will appear and the cell will be shown in the BMS. Afterwards, in the sense of a
rising voltage according to the series connection, the cells are linked to the BMS one after
another. If a cell is not identified (no hearable signal appears), the cell board needs to be
exchanged.
The now following descriptions of the BMS functions can differ in earlier software versions. An
update for the latest versions can be made by the CleanEnergy GmbH.
The suggestion for the option of the shunt-voltage (see point 7.4) is also guilty for earlier
software versions >3.25 and should be readjusted (with software up to 3.25 we suggest a
shunt-voltage of 3.60V).
The battery management system is activated by the connection of the supply voltage.
After adjusting all data sets, the BMS control is reading the cell values and optional the
temperatures. If all criteria are fulfilled, the charging and discharging mode is being unlocked.
The charging as well as the discharging mode is being supervised by the BMS and steered by
the BUS relay.
The charging/discharging is only active during the “Standard display”, “Temperature” and
“Service display”. The charging/discharging progress is being interrupted in all other menus for
safety reasons. A switch between the operation displays is possible without any interruption.
Through a short push on the spring-return button the display is changing into the main menu.
BMS manual with software version 3.32BT - 24 - 23.03.2012
© clean energy gmbh
When turning the button right the following menus can be selected:
The last three menu points are only available if the spring-return button is not only pushed
short in the standard display, but held for min. 4s (Signal appears).
From each main menu point it is possible to come to the next sub menu through pushing the
spring return button (in the following shown with a „“ ).
With a short push it is possible to get back to the main menu – standard display. A second
short push is setting back again onto the standard display with total battery voltage, charging
quantity and momentary current.
Starting with the cell No.1 the cell voltages of the single
cells are shown. Turning the button is changing to the next
cell.
Display:
Total voltage [V]
Actual current [ +/- A ]
charging quantity [+/- Ah ]
When using a BMS central box each wire is having its own
address (see description BMS with central box)
A special feature of our BMS is the “balancing” of the single cells, which is made at the end of
the charging mode. With a BUS charger relay the charging mode of the connected charging
device is interrupted.
At the same time the cells, which fulfill the criteria, are balanced. A load resistance on the cell
boards is reducing the cell energy, so that their cell voltage is declining. During that progress the
cells with low voltages are continuing their charging operation. If the threshold for the end of
BMS activity
Charging active
Balancing