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Wiki source code of 3.3 Control

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1 (% data-numbered-headings-start="3" style="--numbered-headings-start: 2;font-size: 0px;color: rgba(0, 0, 0, 0.0);margin-bottom: 0px; margin-top: 0px;" %)
2 = Settings =
3
4 (% data-numbered-headings-start="3" style="--numbered-headings-start: 2;font-size: 0px;color: rgba(0, 0, 0, 0.0);margin-bottom: 0px; margin-top: 0px;" %)
5 == Control ==
6
7 === Common settings ===
8
9 To change the common BMS settings, select the "Control → Common settings" section:
10
11 [[image:1735054851946-552.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="105" width="800"]]
12
13 In this section:
14
15 * Cell capacity – nominal capacity of cells, Ah;
16 * Cell resistance – nominal (maximum) internal resistance of the cells, Ohm;
17 * Relax time (after charging) – a relaxation time after charging, second;
18 * Relax time (atfer discharging) – a relaxation time after discharging, second;
19 * Reset parameters – a command to reset cells state of charge, capacity, and resistance;
20 * Method of calculating the battery voltage:
21 ** Summation of cell voltages – the overall voltage is calculated as on sum of all cells in the battery;
22 ** Using voltage before contactors – the overall voltage is estimated as voltage before contactors measured by BMS.
23
24 The values “Capacity”, “Resistance”, “Cycles” are used to calculate the SOC of cells and the battery.
25
26 The values of “Relax time” are used to determine the state of the battery. If the battery is in a state of relaxation, the system recalculates the voltage on the cells to the state of charge of the battery.
27
28 The “Reset parameters” will reset:
29
30 * state of charge (new cell SOC values will be calculated based on cell voltage and “Uocv (open-circuit voltage) table”: in the “Control → SOC estimation” section);
31 * cell resistance to “Cell resistance” value;
32 * battery capacity to “Cell capacity” value.
33
34 The “Reset parameters” command is used for starting-up and adjustment of the battery.
35
36 === SOC estimation ===
37
38 The BMS Main 3 device calculates the state of charge of the battery (SOC) using two algorithms:
39
40 * by open circuit voltage;
41 * by voltage and current.
42
43 It is recommended to use the algorithm of calculation of SOC by voltage and current.
44
45 To change the estimation algorithm for calculating the battery SOC, select the "Control → SOC estimation → Algorithm" section:
46
47
48 [[image:1735056107942-306.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="141" width="800"]]
49
50 The following estimation algorithms supported:
51
52 * Voltage – by open circuit voltage;
53 * Current and voltage (simplified) – recommended for LFP cells;
54 * Current and voltage (enhanced) – recommended for NMC cells.
55
56 The **“Voltage”** SOC calculation algorithm calculates cells SOC based on the tabular dependence Uocv = Uocv(SOC, t °C).
57
58 The **“Current and voltage (simplified)”** SOC calculation algorithm works as follows:
59
60 * if I = 0, the battery is in the state of relaxation and the cell voltage Uocv is outside the [U,,ocv[point 1],,; U,,ocv[point 2],,], the SOC calculation is based on the tabular dependency Uocv = Uocv(SOC, t °C);
61 * in any other cases, the SOC value is proportional to the charge (coulomb) passed through the battery (current time integral).
62
63 The **“Current and voltage (enhanced)” **SOC calculation algorithm differs from the simplified algorithm by online correction of the effective capacity. When using this algorithm, it is necessary to fine tune the tabular dependence Uocv = Uocv (SOC, t °C).
64
65 To change the algorithm for calculating the Final SOC, select the "Control → SOC estimation → Final SOC" section:
66
67 [[image:1733322611551-852.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="148" width="800"]]
68
69 The following calculation methods are supported (“Final SOC”):
70
71 * Minimal SOC – the battery SOC is assumed to be the minimum SOC among the cells;
72 * Average SOC – the battery SOC is taken equal to the arithmetic average of the cell SOC;
73 * Min-Max SOC – the battery SOC is calculated based on the minimum and maximum SOC of the cells. Final SOC will be a) 100% if any cell have 100% SOC, b) 0% if any cell have 0% SOC;
74 * Max-Min SOC – the battery SOC is calculated based on the minimum and maximum SOC of the cells. Final SOC will be a) 100% if all cells have 100% SOC, b) 0% if all cells have 0% SOC;
75
76 Other parameters:
77
78 * Scale the final SOC – a flag to scale the battery SOC by the following values;
79 * SOC corresponding to 0% – the battery SOC that sets to be 0%;
80 * SOC corresponding to 100% – the battery SOC that sets to be 100%.
81 * Uocv (open-circuit voltage) table – the dependence of the cell open circuit voltage Uocv on SOC and the cell temperature (selected for specific batteries);
82 * Linear zone - linear zone of the Uocv = Uocv(SOC, t°C) dependency, inside which the cell voltage changes insignificantly:
83 ** Linear zone: point 1 – starting point of the Uocv linear zone;
84 ** Linear zone: point 2 – ending point of the Uocv linear zone;
85 * Coulomb counting correction (temperature) – the dependence of battery capacity on temperature;
86 * Coulomb counting correction (cycles) – the dependence of battery capacity on the number of charge-discharge cycles.
87
88 === SOC correction ===
89
90 The BMS Main 3 device can recalculate the battery SOC after long-term storage or after long-term working in the case when the battery was not charged fully or discharged totally. Recalculation is done based on the tabular dependency Uocv = Uocv (SOC, t) (see [[SOC estimation>>doc:||anchor="HSOCestimation"]]).
91
92 To configure parameters for periodically correcting the battery state of charge, select the "Control → SOC correction" section:
93
94 [[image:1733322624656-766.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="121" width="800"]]
95
96 In this section:
97
98 * Enable – a flag to enable the SOC correction;
99 * Shutdown period – a time the battery is off, day. If the BMS detects on its startup that it was off during the “Shutdown period” time, the BMS recalculates the battery state of charge based on the tabular dependency Uocv = Uocv (SOC, t);
100 * Correction period – a period of correcting the battery SOC, day. If the BMS detects that the last correction was more than the “Correction period” ago, the BMS recalculates the battery state of charge based on the tabular dependency Uocv = Uocv (SOC, t) and tunes it gradually during the “SOC change time”.
101 * SOC change time – a duration of the linear changing the battery SOC to the value calculated by the correction algorithm, minute;
102 * Ignore the linear zone – a flag to ignore linear SOC zone while correction (recommended to be unset);
103 * Last correction timestamp – time when last correction was made.
104
105 === Resistance estimation ===
106
107 Calculation of the resistance of cells is carried out in two ways. The first method is used when the battery passes from a relaxation state to a charge or discharge state, wherein the cell resistance value
108
109 {{formula fontSize="SMALL" imageType="PNG"}}
110 R = \frac{U-U_{ocv}}{I_{stable}}
111 {{/formula}}
112
113 where U — the cell voltage measured in the charge or discharge state, V; U,,ocv,, — cell voltage measured in the state of relaxation (before switching to the state of charge or discharge); I,,stable,, — stabilized current through the cell in the state of charge or discharge.
114
115 The second method is used for a stepwise change in the current through the cell, while the value of the cell resistance:
116
117 {{formula fontSize="SMALL"}}
118 R = \frac{U_2-U_1}{I_{stable2}-I_{stable1}}
119 {{/formula}}
120
121 provided that
122
123 {{formula fontSize="SMALL"}}
124 | I_{stable2}-I_{stable1} | > 0.2 × Qmax
125 {{/formula}}
126
127 where Q,,max,, — the maximum cell capacity,U,,2,, — voltage on the cell at the moment when the stabilized current I,,stable2,, is flowing through it; U,,1,, — the voltage on the cell at the moment when the stabilized current I,,stable1,, flowing through it.
128
129 The stabilized current I,,stable,, = I, if during the stabilization time the instantaneous current I is in the range from 0.95 × I to 1.05 × I.
130
131 To change parameters of the algorithm for calculating the cell resistance, select the "Control → Resistance estimation" section:
132
133 [[image:1733322624659-473.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="108" width="800"]]
134
135 In this section:
136
137 * Current stabilization time, millisecond;
138 * Maximum calculation period – maximum time between resistance measurements. If more time has elapsed since the last determination of the stabilized current I,,stable,, than is determined in this field, the resistance calculation is not performed, second;
139 * Maximum resistance factor – the coefficient of calculation of the maximum acceptable resistance of the cell;
140 * Minimum SOC – minimum cell SOC value for resistance calculation;
141 * Maximum SOC – maximum cell SOC value for resistance calculation.
142
143 The calculated resistance is accepted by the system as valid (and therefore updated) if its value is in the range from Resistance / 2 to “Maximum resistance factor” × Resistance, where "Resistance" is the nominal resistance of the cell (see [[Common settings>>doc:||anchor="HCommonsettings"]]). If the calculated resistance value is greater than the value (Maximum resistance factor × Resistance), the updated resistance value will be equal to the value (Maximum resistance factor × Resistance).
144
145 === Low SOC (signal) ===
146
147 To change the parameters of the generation a signal about low battery level, select the "Control → Low SOC (signal)" section:
148
149 [[image:1733322624660-513.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="116" width="800"]]
150
151 In this section:
152
153 * Enable – a flag to enable signal generation;
154 * Minimum SOC, %;
155 * Tolerant SOC, %;
156 * Delay before setting the signal, second;
157 * Delay before clearing the signal, second;
158 * Lock – lock the signal until the device is reset.
159
160 Signal generation conditions:
161
162 * the battery SOC is less than the “Minimum SOC” value during the “Delay before setting the signal” time.
163
164 Conditions for clearing the signal:
165
166 * the battery SOC is greater than the “Tolerant SOC” during the “Delay before clearing the signal” time.
167
168 The "Low SOC signal" is indicative and can be output to a discrete output or a power switch.
169
170 === High charging current (signal) ===
171
172 To change the parameters of the generation high-current signal, select the "Control → High charging current (signal)" section:
173
174 [[image:1733322624661-915.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="107" width="800"]]
175
176 In this section:
177
178 * Enable – a flag to enable signal generation;
179 * Maximum charging current, А;
180 * Tolerant charging current, А;
181 * Delay before setting the signal, second;
182 * Delay before clearing the signal, second;
183 * Lock – lock the signal until the device is reset.
184
185 Signal generation conditions:
186
187 * the measured current is greater than the “Maximum charging current” value during the “Delay before setting the signal” time.
188
189 Conditions for clearing the signal:
190
191 * the measured current is less than the “Tolerant charging current” value during the “Delay before clearing the signal” time.
192
193 The "High charging current" signal is indicative and can be output to a discrete output or a power switch.
194
195 === Charge map ===
196
197 The BMS Main 3 device calculates the maximum allowable charge current values in respect to SOC, battery temperature, contactor temperature and cell voltage.
198
199 Calculated current values are sent to a charger or an intellectual load over the CAN bus. External devices based on received data provide correct battery operation.
200
201 To configure parameters for determining the charge current limit, select the "Control → Charge map" section:
202
203 [[image:1735064362593-844.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="153" width="800"]]
204
205 In this section:
206
207 * Enable – a flag to start calculation of the charge current limit;
208 * Maximum charge current – a maximum allowable value of the charge current (under normal conditions), A;
209 * Rate of change – a rate of change the current limit to a new value (0 is for immediate change), A/s;
210 * Option 1: Limit charge current by the battery SOC and temperature – a flag to enable correction of maximum allowable charging current Kcs depending on SOC and battery temperature;
211 * Option 1: SOC x Temperature x Factor – the dependence of the correction factor on SOC and battery temperature;
212 * Option 2: Limit charge current by the contactor temperature – a flag to enable correction of maximum allowable charging current Kcc depending on contactor temperature;
213 * Option 2: Contactor temperature x Factor – the dependence of the correction factor on SOC and contactor temperature;
214 * Option 3: Limit charge current by the maximum cell voltage - a flag to enable correction of maximum allowable charging current Kcv depending on maximum cell voltage;
215 * Option 3: Cell voltage x Factor – the dependence of the correction factor on maximum cell voltage;
216 * Option 4: Limit charge current by the cell temperature - a flag to enable correction of maximum allowable charging current Kct depending on maximum cell temperature;
217 * Option 4: Cell temperature x Factor – the dependence of the correction factor on maximum cell temperature.
218
219 Value of the charge current limit at given SOC, temperature, contactors temperature, maximum cell voltage and maximum cell temperature is calculated as follows:
220
221 Charging current limit = Maximum charging current × Kcs × Kcc × Kcv × Kct
222
223 === Discharge map ===
224
225 The BMS Main 3 device calculates the maximum allowable discharge current values in respect to SOC, battery temperature, contactor temperature and cell voltage.
226
227 Calculated current values are sent to a charger or an intellectual load over the CAN bus.
228
229 To configure parameters for determining the discharge current limit, select the "Control → Discharge map" section:
230
231 [[image:1735064399985-526.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="152" width="800"]]
232
233 In this section:
234
235 * Enable – a flag to start calculation of the discharge current limit;
236 * Maximum discharge current – a maximum allowable value of the discharge current (under normal conditions), A;
237 * Rate of change – a rate of change the current limit to a new value (0 is for immediate change), A/s;
238 * Option 1: Limit discharging current by the battery SOC and temperature – a flag to enable correction of maximum allowable discharging current Kds depending on SOC and temperature;
239 * Option 1: SOC x Temperature x Factor – the dependence of the correction factor on SOC and battery temperature;
240 * Option 2: Limit discharge current by the contactor temperature – a flag to enable correction of maximum allowable discharging current Kdc depending on contactor temperature;
241 * Option 2: Contactor temperature x Factor – the dependence of the correction factor on SOC and contactor temperature;
242 * Option 3: Limit discharge current by the cell voltage - a flag to enable correction of maximum allowable discharging current Kdv depending on minimum cell voltage;
243 * Option 3: Cell voltage x Factor – the dependence of the correction factor on minimum cell voltage;
244 * Option 4: Limit discharge current by the cell temperature - a flag to enable correction of maximum allowable discharging current Kdt depending on maximum cell temperature;
245 * Option 4: Cell voltage x Factor – the dependence of the correction factor on minimum cell temperature.
246
247 Value of the discharge current limit at given SOC, temperature, contactors temperature, minimum cell voltage and maximum cell temperature is calculated as follows:
248
249 Discharging current limit = Maximum discharging current × Kds × Kdc × Kdv × Kdt
250
251 === Charge map (PEAK & CONTINUOUS) ===
252
253 The BMS Main 3 has an alternative algorithm for the maximum allowed charging current based on peak and continuous battery operating modes.
254
255 To configure parameters for determining the charge current limit, select the "Control → Charge map (PEAK & CONTINUOUS)" section:
256
257 [[image:1735064434321-430.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="124" width="800"]]
258
259 In this section:
260
261 * Enable – a flag to start calculation of the charge current limit;
262 * Maximum PEAK charge current – a maximum peak charge current (under normal conditions), A;
263 * Maximum CONTINUOUS charge current – a maximum continuous charge current (under normal conditions), A;
264 * PEAK: SOC x Temperature x Factor – the dependence of the correction factor for peak current K,,cp,, on SOC and battery temperature;
265 * CONTINUOUS: SOC x Temperature x Factor – the dependence of the correction factor for continuous current K,,cc,, on SOC and battery temperature;
266 * PEAK time – a time for peak current to be allowed, s;
267 * Sliding time – a time of linear change of the maximum charging current from peak to continuous and from continuous to peak value, ms;
268 * Waiting time – a time for peak current to be prohibited, s.
269
270 The maximum charging current value equals to the peak or continuous current according to the following diagram:
271
272 [[image:1733322717451-608.png||data-xwiki-image-style-alignment="center"]]
273
274 I,,peak,, = Maximum PEAK charge current × K,,cp,,
275
276 I,,continuous,, = Maximum CONTINUOUS charge current × K,,cc,,
277
278 === Discharge map (PEAK & CONTINUOUS) ===
279
280 The BMS Main 3 has an alternative algorithm for the maximum allowed discharging current based on peak and continuous battery operating modes.
281
282 To configure parameters for determining the discharge current limit, select the "Control → Discharge map (PEAK & CONTINUOUS)" section:
283
284 [[image:1735064454708-345.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="124" width="800"]]
285
286 In this section:
287
288 * Enable – a flag to start calculation of the discharge current limit;
289 * Maximum PEAK discharge current – a maximum peak discharge current (under normal conditions), A;
290 * Maximum CONTINUOUS discharge current – a maximum continuous discharge current (under normal conditions), A;
291 * PEAK: SOC x Temperature x Factor – the dependence of the correction factor for peak current K,,dp,, on SOC and battery temperature;
292 * CONTINUOUS: SOC x Temperature x Factor – the dependence of the correction factor for continuous current K,,dc,, on SOC and battery temperature;
293 * PEAK time – a time for peak current to be allowed, s;
294 * Sliding time – a time of linear change of the maximum charging current from peak to continuous and from continuous to peak value, ms;
295 * Waiting time – a time for peak current to be prohibited, s.
296
297 The maximum discharging current value equals to the peak or continuous current according to following diagram:
298
299 [[image:1733322753429-968.png||data-xwiki-image-style-alignment="center"]]
300
301 I,,peak,, = Maximum PEAK discharge current × K,,dp,,
302
303 I,,continuous,, = Maximum CONTINUOUS discharge current × K,,dc,,
304
305 === Main contactor ===
306
307 The BMS Main 3 device controls the main contactor. The main contactor is usually placed in the common (minus) battery line for opening the charge and discharge circuits in case of sealing of the charging or discharging contactors.
308
309 The Main contactor algorithm supports the following modes:
310
311 * Always on;
312 * Automatic;
313 * On demand.
314
315 In “Always on” mode main contactor closes if all the following is true:
316
317 * Charging contactor is open;
318 * Discharging contactor is open;
319 * There are no errors from the list below:
320 ** Overcurrent;
321 ** Undervoltage;
322 ** Overvoltage;
323 ** High temperature (CH);
324 ** High temperature (DCH);
325 ** Unallowable charging;
326 ** Critical error.
327
328 In “Always on” mode main contactor opens if all the following is true:
329
330 * Charging contactor is open;
331 * Discharging contactor is open;
332 * There is an error from the list below:
333 ** Overcurrent;
334 ** Undervoltage;
335 ** Overvoltage;
336 ** High temperature (CH);
337 ** High temperature (DCH);
338 ** Unallowable charging;
339 ** Critical error.
340
341 In “Automatic” mode, the main contactor closes by internal charging and discharging algorithms at the same time with Precharging, Charging and Discharging contactors.
342
343 In “On demand” mode, the main contactor closes by external the “Close Main contactor” request.
344
345 (% class="box infomessage" %)
346 (((
347 **Note: **when errors occur in the system, the **Main **contactor opens either immediately or with the delay T,,off,, (depends on the settings described below).
348 )))
349
350 To change the parameters of the main contactor, select the "Control → Main contactor" section:
351
352 [[image:1735064488658-863.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="112" width="800"]]
353
354 In this section:
355
356 * Enable – a flag to enable the main contactor control;
357 * Algorithm – main contactor control algorithm:
358 ** Always on – contactor is always closed;
359 ** Automatic – contactor closes by internal charge and discharge algorithms;
360 ** On demand – contactor is closed by an external request;
361 * Time to keep the contactor closed before closing the others – a time for other contactors to be open after the main contactor is closed;
362 * Delay before opening the contactor – a time which is used to detect conditions for opening the contactor, s;
363 * Keep the contactor open until the device is restarted – a flag for keeping the main contactor open until the system is reset;
364 * Errors 1, 2 to open the main contactor – bitfields to choose the errors which will open the main contactor.
365
366 === Charging status ===
367
368 To change the parameters of charging process status, select the "Control → Charging status" section:
369
370 [[image:1735064935499-941.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="110" width="800"]]In this section:
371
372 * Current to set the "Charging current present" – a current level to generate the "Charging current present" signal, A;
373 * Current to clear the "Charging current present" – a current level to clear the "Charging current present" signal, A;
374 * Voltage to clear the “Ready to charge” – a threshold voltage level on the cell, V; if the voltage of any cell is above this level, the “Ready to charge” (hence, the “Allow charging”) signal is cleared;
375 * Voltage to reset the “Ready to charge” – a tolerant voltage level on the cell, V; if all cell voltages are below the tolerant level, the “Ready to charge” (hence, the “Allow charging”) signal is set;
376 * Delay before recharging – a time after which the previously opened the allow charging contactor closes again, minute; to disable the operation by timeout set "Delay before recharging" to 0;
377 * Errors 1, 2 to clear the "Ready to charge" – bitfields to choose the errors which will clear the "Ready to charge" signal.
378
379 (% class="box infomessage" %)
380 (((
381 **Note:** The "Allow charging" signal activates under two independent conditions:
382 1) the voltage on the cells reaches the “Voltage to reset the “Ready to charge"” level and
383 2) the "Delay before recharging" time has passed since the opening of the allow charging contactor.
384 )))
385
386 === Discharging status ===
387
388 To change the parameters of charging process status, select the "Control → Discharging status" section:
389
390 [[image:1735064980481-209.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="102" width="800"]]In this section:
391
392 * Current to set the "Discharging current present" – a current level to generate the "Discharging current present" signal, А;
393 * Current to clear the "Discharging current present" – a current level to clear the "Discharging current present" signal, А;
394 * Voltage to clear the “Ready to discharge” – a threshold voltage level on the cell, V; if the voltage of any cell is below this level, the “Ready to discharge” signal is cleared;
395 * Voltage to reset the “Ready to discharge” – a tolerant voltage level on the cell, V; if all cells voltages are above the tolerant level, the “Ready to discharge” signal is set;
396 * Errors 1, 2 to clear the "Ready to discharge" – bitfields to choose the errors which will clear the "Ready to discharge" signal.
397
398 === Precharge ===
399
400 The BMS Main 3 device can control the precharge contactor. The precharge contactor is used to charge the intermediate capacity with low current and usually placed with the limiting resistor in parallel to charging or discharging contactor.
401
402 BMS Main 3 device detects errors while pre-charging the load capacity by monitoring the current and voltage difference before and after contactors. Also BMS can measure the power dissipated on precharge resistor and generate an error if it greater than configured limit.
403
404 To change the parameters of precharge contactor, select the "Control → Precharge" section:
405
406 [[image:1735065073836-743.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="160" width="800"]]
407
408 * Precharge current threshold to finish precharging – a minimum current value at which precharging process assumed to be finished, A;
409 * Check voltages before and after contactors to finish precharging – a flag to check the voltages before and after contactors to ensure that precharge process has finished and it is allowed to close the discharging contactor;
410 * Minimum voltage difference to finish precharging – minimal voltage difference before and after contactors at which precharge process is meant to be finished, V;
411 * Number of precharging attempts – maximum number of precharging attempts before setting the "Precharge error";
412 * Precharge time – a duration of closing the precharge contactor before closing the discharging contactor, millisecond;
413 * Relaxation between attempts – a duration between precharge attempts, millisecond;
414 * Check the power dissipated in the preacharge resistor - a flag to enable the calculation of power dissipated in precharge resistor;
415 * Precharge resistor resistance, Ohm;
416 * Maximum allowable power dissipated in the resistor, W;
417 * Delay before setting the "Precharge error" when checking power, millisecond;
418 * Delay before clearing the "Precharge error", second;
419 * Lock the "Precharge error" – a flag to block the error until the device is restarted.
420
421 “Precharge error” generation conditions:
422
423 * the precharge current does not decrease after "Number of precharging attempts";
424 * voltages before and after contactors are not equal after "Number of precharging attempts";
425 * power dissipated on the precharge resistor is above the maximum value during the “Delay before setting the 'Precharge error' when checking power” time.
426
427 (% class="box warningmessage" %)
428 (((
429 Behavior of contactors at “Precharge error” is configured in corresponding contactor settings!
430 )))
431
432 === Charge ===
433
434 There are two contactors that serve charging the battery: a charging contactor and an allow charging contactor. With the help of the allow charging contactor, the BMS commands the charger to start or stop charging.
435
436 The device supports three charge control algorithms:
437
438 * Always on – charging is always allowed;
439 * On charger connected – charging is allowed when there is a signal “Charger connected”;
440 * On charge request – charging is allowed when there is a signal “Charge request”.
441
442 If the "**Always on**" algorithm is selected, the charging contactor and the allow charging contactor are always closed. If at least one of the errors appears:
443
444 * Overvoltage;
445 * Overcurrent;
446 * High temperature (CH);
447 * Low temperature (CH);
448 * HYG offline (optional);
449 * Combilift offline (optional);
450 * Spirit offline (optional);
451 * Spirit charger error (optional);
452 * Short circuit (optional);
453 * High contactor temperature (optional);
454 * CH contactor cycles error;
455 * Precharge error (optional);
456 * Critical error
457
458 or one of the signals:
459
460 * Service reset;
461 * Power down request;
462 * Inhibit charging,
463
464 both contactors are open (no current flows).
465
466 When the algorithm "**On charger connected**" is selected, the control is performed as follows:
467
468 * If there is a signal “Charger connected” and there are no errors (see the list above), then through the delay time T,,on,, the charging contactor and the allow charging contactor close;
469 * If the signal “Charger connected” disappears, the allow charging contactor opens and after the delay time T,,off,, the charging contactor opens;
470 * If in the process of charging the voltage on the cell exceeds the “Ready to charge” level, the allow charging contactor opens (while the charging contactor remains closed);
471 * If errors in the list above occur the charging contactor and allow charging contactor open.
472
473 When the "**On charge request**" algorithm selected, the control is performed as follows:
474
475 * If there is a signal “Charge request” and there are no errors (see the list above), then through the delay time T,,on,, the charging contactor and the allow charging contactor close;
476 * If the signal “Charge request” disappears, the allow charging contactor opens and after the delay time T,,off,, the charging contactor opens;
477 * If in the process of charging the voltage on the cell exceeds the “Ready to charge” level, the allow charging contactor opens (while the charging contactor remains closed);
478 * If errors in the list above occur the charging contactor and allow charging contactor open.
479
480 (% class="box infomessage" %)
481 (((
482 **Note: **when errors occur in the system, the **Charge **contactor opens either immediately or with the delay T,,off,, (depends on the settings described below).
483 )))
484
485 To change the parameters of the battery charge control algorithm, select the "Control → Charge" section:
486
487 [[image:1735063563460-549.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="262" width="800"]]
488
489 In this section:
490
491 * Enable – a flag to activate the charge control;
492 * Algorithm:
493 ** Always on – charging is always allowed;
494 ** On charger connected – charging is allowed when there is a signal “Charger connected”;
495 ** On charge request – charging is allowed when there is a signal “Charge request”;
496 * Allow charging only when the "Ready to charge" signal is set – charging contactor will open if "Ready to charge" signal is cleared;
497 * Delay before starting charging – a time delay T,,on,, before closing the charging contactor and the allow charging contactor, millisecond;
498 * Delay before stopping charging – a time delay T,,off,, before opening the charging contactor, millisecond;
499 * Control the precharging contactor – a flag that allows control of the precharging contactor while closing the charge contactor;
500 * Errors 1, 2 to open the charging contactor – bitfields to choose the errors which will open the charging contactor;
501 * Use custom delays before stopping charging (on errors) – a flag to enable manual settings of time delays T,,off,, for specific errors;
502 * Custom delay: <error> – delay for specific error, millisecond;
503 * Switch off the charging contactor on errors without delay – a flag to protectively open the charging contactor without a delay. In the opposite case, when an error is detected, the charging contactor opens always with the delay “Delay before stopping charging”;
504
505 === Discharge ===
506
507 The device controls the discharging contactor to connect battery to the load.
508
509 The device supports three algorithms to control battery discharging:
510
511 * Always on – load is always connected;
512 * On charger disconnected – load is connected when there is no signal “Charger connected”;
513 * On discharge request – load is connected when there is signal “Discharge request”.
514
515 When the algorithm "**Always on**" is selected, the discharging contactor is always closed. If at least one of the errors appears:
516
517 * Undervoltage;
518 * Overvoltage (optional);
519 * Overcurrent;
520 * High temperature (DCH);
521 * Low temperature (DCH) (optional);
522 * HYG offline (optional);
523 * Combilift offline (optional);
524 * Spirit offline (optional);
525 * Spirit charger error (optional);
526 * Short circuit (optional);
527 * High contactor temperature (optional);
528 * Unallowable charging;
529 * DCH contactor cycles error;
530 * Precharge error (optional);
531 * Critical error
532
533 or one of the signals:
534
535 * Service reset
536 * Power down request
537 * Inhibit discharging
538
539 the discharging contactor opens.
540
541 If the algorithm "**On charger disconnected**" is selected, the control is performed as follows:
542
543 * if there is no signal “Charger connected”, the charging contactor is open and there are no errors (see the list above), then through the delay time T,,on,, the discharging contactor closes;
544 * If the signal “Charger connected” appears or errors occur (see the list above), then after the delay time T,,off,, the discharging contactor opens.
545
546 When the "**On discharge request**" algorithm selected, the control is performed as follows:
547
548 * if there is signal “Discharge request”, the charging contactor is open and there are no errors (see the list above), then through the delay time T,,on,, the discharging contactor closes;
549 * If the signal “Discharge request” disappears or errors occur (see the list above), then after the delay time T,,off,, the discharging contactor opens.
550
551 (% class="box infomessage" %)
552 (((
553 **Note: **when errors occur in the system, the **Discharge **contactor opens either immediately or with the delay T,,off,, (depends on the settings described below).
554 )))
555
556 The device supports controlling the precharging contactor. The duration of switching on the precharging contactor before closing the discharging (load) contactor is adjusted.
557
558 To change the parameters of the battery discharge control algorithm, select the "Control → Discharge" section:
559
560 [[image:1735064038329-836.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="273" width="800"]]
561
562 In this section:
563
564 * Enable – a flag to activate the discharge control;
565 * Algorithm:
566 ** Always on – load is always connected;
567 ** On charger disconnected – load is connected when there is no signal “Charger connected”;
568 ** On discharge request – load is connected when there is signal “Discharge request”;
569 * Allow charging only when the "Ready to discharge" signal is set – discharging contactor will open if "Ready to discharge" signal is cleared;
570 * Delay before starting discharging – a time delay T,,on,, before closing the discharging contactor, millisecond;
571 * Delay before stopping discharging – a time delay T,,off,, before opening the discharging contactor, millisecond;
572 * Control the precharging contactor – a flag that allows control of the precharging contactor while closing the discharge contactor;
573 * Errors 1, 2 to open the discharging contactor – bitfields to choose the errors which will open the discharging contactor;
574 * Use custom delays before stopping discharging (on errors) – a flag to enable manual settings of time delays T,,off,, for specific errors;
575 * Custom delay: <error> – specific error delay, millisecond;
576 * Switch off the discharging contactor on errors without delay – a flag to protectively open the discharging contactor without a delay. In the opposite case, when an error is detected, the discharging contactor opens always with the delay “Delay before stopping discharging”.
577
578 === Charge/Discharge ===
579
580 The BMS Main 3 device can control the charge/discharge contactor, which combines algorithms of charging and discharging contactor.
581
582 Charge/Discharge contactor has three algorithms of operation:
583
584 * Dependent (on Charging and Discharging signals) - Charge/Discharge contactor depends on Charge and Discharge algorithms and their signals and behaves as Charging contactor if Charging signal is set, otherwise – as Discharging contactor;
585 * Independent (Always) - Charge/Discharge contactor is always closed if there is no errors;
586 * Independent (on Charge request or Discharge request) - Charge/Discharge contactor is based on its own controller that listen to Charge and Discharge requests and closes if one of these signals occurs.
587
588 (% class="box infomessage" %)
589 (((
590 **Note: **when errors occur in the system, the **Charge/Discharge **contactor opens either immediately or with the delay T,,off,, (depends on the settings described below).
591 )))
592
593 The charging/discharging contactor control is configured in the “Control – Charge/Discharge” section:
594
595 [[image:1735122153011-166.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="162" width="800"]]
596
597 In this section:
598
599 * Enable – a flag to enable the charge/discharge controller.
600 * Algorithm:
601 ** Dependent (on Charging and Discharging signals) - Charge/Discharge contactor depends on Charge and Discharge algorithms and their signals and behaves as Charging contactor if Charging signal is set, otherwise – as Discharging contactor;
602 ** Independent (Always) - Charge/Discharge contactor is always closed if there is no errors;
603 ** Independent (on Charge request or Discharge request);
604 * Delay before starting charging or discharging, millisecond;
605 * Delay before stopping charging or discharging, millisecond;
606 * Control the precharging contactor – a flag that enables control of precharging contactor while closing the charge/discharge contactor;
607 * Emulate the "Charging" and "Discharging" signals – a flag to enable generation of "Charging" and "Discharging" signals when closing charge/discharge contactor;
608 * Errors 1, 2 to prevent CHARGING through charging/discharging contactor, Errors 1, 2 to prevent DISCHARGING through charging/discharging contactor – bitfields to choose the errors which will open the charging/discharging contactor. This bitfields are combined by bitwise OR and intended to separate settings for charging and discharging processes;
609 * Errors 1, 2 which affect the contactor only if battery CHARGING is detected – a bitfield to choose the errors which will trigger only if charging current is present. This bitfield is combined with "Errors 1, 2 to prevent CHARGING through charging/discharging contactor" by bitwise AND;
610 * Errors 1, 2 which affect the contactor only if battery DISCHARGING is detected – a bitfield to choose the errors which will trigger only if discharging current is present. This bitfield is combined with "Errors 1, 2 to prevent DISCHARGING through charging/discharging contactor" by bitwise AND;
611 * Switch off the charging/discharging contactor on errors without delay – a flag to protectively open the charging/discharging contactor without a delay. In the opposite case, when an error is detected, the charging/discharging contactor opens always with the delay “Delay before stopping discharging”.
612
613 === Discharge (AUX) ===
614
615 The BMS Main 3 device can control the power supply of external equipment using the auxiliary (AUX) discharging contactor. An example of external equipment can be an inverter that converts DC to AC to power a service laptop and other devices.
616
617 The power supply circuit of the external equipment using the auxiliary (AUX) discharging contactor is independent of the battery load circuit. The closing and opening of the auxiliary (AUX) discharging contactor is performed according to its program.
618
619 If the power supply function of the external equipment is enabled, the auxiliary (AUX) discharging contactor closes. The opening of this contactor occurs on three independent conditions:
620
621 * the battery has low SOC;
622 * the battery voltage is out of range;
623 * the battery system errors are detected.
624
625 (% class="box infomessage" %)
626 (((
627 **Note: **when errors occur in the system, the **Discharge (AUX) **contactor opens either immediately or with the delay T,,off,, (depends on the settings described below).
628 )))
629
630 To change the parameters of the powering of external equipment, select the "Control → Discharge (AUX)" section:
631
632 [[image:1735066190419-838.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="161" width="800"]]
633
634 In this section:
635
636 * Enable – a flag to activate the auxiliary discharge control;
637 * Switch off the discharging (AUX) contactor if the SOC is too low;
638 * Minimum SOC – a minimum SOC value, when reached, the auxiliary (AUX) discharging contactor opens, %;
639 * Tolerant SOC – a permissive SOC value, upon reaching which the auxiliary (AUX) discharging contactor re-closes, %;
640 * Switch off the discharging (AUX) contactor if the battery voltage is out of the range;
641 * Minimum voltage – minimum battery voltage, V;
642 * Maximum voltage – maximum battery voltage, V;
643 * Switch off the discharging (AUX) contactor on errors – the auxiliary (AUX) discharging contactor opens if the following errors occur: Undervoltage, Overcurrent, High temperature (DCH), Short circuit, Critical error;
644 * Minimum battery voltage, V;
645 * Maximum battery voltage, V;
646 * Errors 1, 2 to open the auxiliary discharging contactor – bitfields to choose the errors which will open the auxiliary discharging contactor;
647
648 === Cell balancing ===
649
650 Balancing makes the voltage of all cells equal to the minimum cell voltage.
651
652 The following balancing rules are supported:
653
654 * when the battery is charging (current I > 0) and time after until the battery is relaxed;
655 * when the battery is charging (current I > 0) or when the battery is in a state of relaxation;
656 * always (regardless of battery state).
657
658 A balancing resistor is connected to the cell if the following conditions are simultaneously met:
659
660 * the voltage on the cell is higher than the balancing start voltage;
661 * the difference between the voltage on the cell and the minimum voltage among the battery cells is greater than the balancing start threshold.
662
663 A balancing resistor is disconnected from the cell if any of the following conditions are met:
664
665 * the voltage on the cell is less than the balancing start voltage;
666 * the difference between the voltage on the cell and the minimum voltage among the battery cells is less than the balancing stop threshold.
667
668 If the “High logic temperature” occurs, then the balancing of the cells connected to the overheated BMS Logic device will not be performed.
669
670 The BMS Main 3 can enable the cell balancing by the external “Balancing request” signal. Balancing process will be started to cells which the voltage is higher than the balancing start voltage and the difference between the cell voltage and the minimum voltage among all the cells is greater than the balancing stop threshold.
671
672 To change the cell balancing parameters, select the "Control → Cell balancing" section:
673
674 [[image:1735065702806-422.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="130" width="800"]]
675
676 In this section:
677
678 * Enable – a flag to enable cell balancing;
679 * Balancing rule:
680 ** Balance on charge – balancing is performed while and after the charging (in the “Charge ON” and “Charge OFF” states);
681 ** Balance on charge or relaxed - balancing is performed while and after the charging and in the relaxed state (in “Charge ON”, “Charge OFF”, “Relaxed (after charging)” and “Relaxed (after discharging)” states);
682 ** Balance always – balancing is always performed regardless the battery state;
683
684 [[image:1735065666891-686.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="132" width="800"]]
685
686 * Balancing condition:
687 ** Automatic – balancing will be performed automatically if needed conditions are met;
688 ** On balancing request – balancing will start only if a remote request is received. In this case cells will start to balance regardless the "Voltage deviation to start balancing" value;
689 * Minimum cell voltage to start balancing, V;
690 * Voltage deviation to start balancing;
691 * Voltage deviation to stop balancing;
692 * Voltage for forced balancing – if cell voltage is above this value, it will start discharging through balancing resistor;
693 * Maximum allowable temperature of BMS Logic devices, ºC;
694 * Command to discharge all cells – a flag to force the balancing of all cells.
695
696 === Series balancing ===
697
698 The BMS Main 3 device supports work with two independent (galvanically unrelated) cell series. To monitor the status of two series, two current sensors are used. A series of cells must be equivalent: they must have the same number of cells and the same capacity.
699
700 Since the series of cells can operate at different loads, they must be balanced. For this, the BMS Main 3 provides two signals to power switches: “Balancing series 1” and “Balancing series 2”, as well as a combined algorithm that considers both the voltage of each series and the charge that these series gave load. The “Balancing series 1” and “Balancing series 2” signals are used to connect high-power balancing resistors in parallel with cell series 1 and 2.
701
702 When charging the battery, balancing is performed based on the voltage of the series. A balancing resistor is connected to the cell series if:
703
704 * the series voltage is higher than the start balancing voltage;
705 * the difference between the voltage of a series of cells and the minimum voltage among the battery series is greater than the balancing threshold.
706
707 When the battery is discharging (work on load), balancing is turned on if one of the series gives the load a charge (Ah), which is more by the amount Qthr of the charge given off by another series.
708
709 To change the series balancing parameters, select the "Control → Series balancing" section:
710
711 [[image:1733322892811-410.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="126" width="800"]]
712
713 In this section:
714
715 * Enable – a flag to enable series balancing;
716 * Number of Logics in a series;
717 * Minimum series voltage to start balancing, V;
718 * Balancing threshold, V;
719 * Coulomb threshold – the difference of the charges Qthr, given by a series of cells, above which balancing to be started, Ah;
720 * Period – a period to reset of charge counters for each series (to avoid accumulation of error), second;
721 * Do not sum series voltages – a flag to disable the summing of series voltages.3
722
723 === Power down ===
724
725 The BMS Main 3 device can shut down itself if the battery voltage is low or the battery is idle for a long time.
726
727 Shutting down the battery system is performed according to the following conditions:
728
729 * the battery voltage is below the minimum level;
730 * the “Charger connected” signal is cleared for 60 seconds.
731
732 The BMS Main 3 device also shuts down the battery if it stays in the “Charging OFF”, “Discharging OFF”, “Relaxed (after charging)” or “Relaxed (after discharging)” for the configured time.
733
734 To change the parameters of the power down control, select the "Control → Power down" section:
735
736 [[image:1733322892813-562.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="103" width="800"]]
737
738 In this section:
739
740 * Minimum voltage to power down – a minimum voltage level of the battery below which the BMS commands to shut down the battery, V;
741 * Idle time to power down – a time of battery inactivity after which the battery is shut down, minute;
742 * Wait the "Power up/down request" is cleared (on startup) – a flag to enable delay for clearing the “Power up/down request” signal while starting the BMS.
743 * Power down if KEYRUN and CHARGE_ON are cleared – a flag to power down the device if KEYRUN and CHARGE_ON signals are cleared;
744 * Delay before setting the internal power down signal – a delay before turning off the device power when removing KEYRUN and CHARGE_ON or receiving the “Power down request” command, ms.
745
746 === Heater ===
747
748 To change the parameters of the heater control algorithm, select the "Control → Heater" section:
749
750 [[image:1733322901923-144.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="108" width="800"]]
751
752 In this section:
753
754 * Enable – a flag to enable the heater control;
755 * Minimum cell temperature, °C;
756 * Tolerant cell temperature, °C;
757 * Delay before starting the heater, millisecond;
758 * Delay before stopping the heater, millisecond;
759 * Switch off the heater on errors (Undervoltage, Overcurrent, High temperature, Short circuit or Critical error).
760
761 As a result of operating the heating algorithm, the “Heater” signal is generated.
762
763 Conditions for signal generation:
764
765 * the minimum temperature among all cells of the battery is less than the “Minimum cell temperature” value during the “Delay before starting the heater” time.
766
767 Conditions for clearing the signal:
768
769 * the minimum temperature among all cells of the battery is greater than the “Tolerant cell temperature” value during the “Delay before stopping the heater” time.
770
771 If there is the "Heater" signal, the heater contactor closes and/or a signal is output to the corresponding digital output.
772
773 === Cooler ===
774
775 To change the parameters of the cooler control algorithm, select the "Control → Cooler" section:
776
777 [[image:1733322901924-962.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="107" width="800"]]
778
779 In this section:
780
781 * Enable – a flag to enable the cooler control;
782 * Maximum cell temperature, °C;
783 * Tolerant cell temperature, °C;
784 * Delay before starting the cooler, millisecond;
785 * Delay before stopping the cooler, millisecond;
786 * Switch off the cooler contactor on errors (Undervoltage, Overcurrent, Low temperature, Short circuit or Critical error).
787
788 As a result of operating the cooling algorithm, the "Cooler" signal is generated.
789
790 Conditions for signal generation:
791
792 * the maximum temperature among all cells of the battery is greater than the “Maximum cell temperature” value during the “Delay before starting the cooler” time.
793
794 Conditions for clearing the signal:
795
796 * the maximum temperature among all cells of the battery is less than the “Tolerant cell temperature” value during the “Delay before stopping the cooler” time.
797
798 If there is the "Cooler" signal, the cooler contactor closes and/or a signal is output to the corresponding digital output.
799
800 === High voltage ===
801
802 The BMS Main 3 device has an ability to measure high voltages before and after contactors.
803
804 To change the parameters of high voltage fault, select the "Control → High voltage" section:
805
806 [[image:1733322914683-203.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="87" width="800"]]
807
808 In this section:
809
810 * Enable – a flag to enable High voltage control;
811 * Delay before clearing the High voltage fault, second;
812 * Lock the High voltage fault.
813
814 The BMS Main 3 implements a self-diagnostics of high-voltage measurement lines. If measurement line breaks or high-voltage polarity is wrong, “High voltage fault” is generated.
815
816 (% class="box warningmessage" %)
817 (((
818 If there is the “High voltage fault”, **the “Critical error” is generated.**
819 )))
820
821 === Cell analysis ===
822
823 The battery discharge characteristic – the dependence Uocv = Uocv(DOD) – is used to determine the tabular dependence Uocv = Uocv(SOC, t°C), which is necessary for calculating the battery charge level.
824
825 The BMS Main 3 device can automatically determine the battery discharge characteristic.
826
827 Before starting the process of determining the discharge characteristic, it is necessary to prepare a BMS:
828
829 1. Charge the battery.
830 1. Connect a resistive load to the discharging contactor, which will provide a discharge current of 0.5C (where C is the cell capacitance).
831
832 To configure parameters for determining the discharge characteristic of the battery, select the "Control → Cell analysis" section:
833
834 [[image:1733322914685-558.png||data-xwiki-image-style-alignment="center" data-xwiki-image-style-border="true" height="107" width="800"]]
835
836 In this section:
837
838 * Enable – a flag to enable cell analysis;
839 * Discharge step, Ah;
840 * Delta voltage – a maximum allowable voltage drop for the cell, V;
841 * Logic index, Cell index – a position of the analyzed cell;
842 * Analyse the most discharged cell – a flag to analyse of the least charged cell (in this case, the values “Logic index” and “Cell index” are ignored).
843
844 Discharge step should be set equal to
845
846 Discharge step= С/21,
847
848 where C is the cell capacity.
849
850 The discharge characteristic will be constructed for the given cell (its position is determined by the fields “Logic index” and “Cell index”).
851
852 The algorithm for determining the discharge characteristic of the battery will be started if the “Enable” flag is set. From this moment, the control of the discharge contactor is performed by this algorithm.
853
854 Algorithm steps:
855
856 1. DOD = 0.
857 1. Opening the discharging contactor.
858 1. Waiting for the relaxation of the battery.
859 1. Measuring Uocv = U.
860 1. Saving the point of the discharge characteristic (Q, U,,OCV,,).
861 1. Closing of the discharging contactor. DOD,,1,, = DOD + Discharge step, U,,1,, = U
862 1. If DOD = DOD,,1,, or U < (U,,1,, – Delta voltage), then go to step 2.
863 1. If the "Undervoltage" error is detected, then the end of the algorithm.
864
865 During the operation of the algorithm, a file with the name "CELLANALYSIS.TXT" in the CSV format will be created on the SD card.
866
867 File structure:
868
869 |**Time**|**DOD**|**Logic**|**Cell**|**OCV**|**Resistance**
870 |**10.11.2017 12:28:34**|0.0|1|1|4.180|0.080000
871 |**...**|...| |…|...|...
872
873 Parameter names:
874
875 * Time – date and time;
876 * DOD – depth of discharge, Ah;
877 * Logic - position of the Logic device to which the analyzed cell is connected;
878 * Cell – position of the analyzed cell for which OCV and Resistance values are provided;
879 * OCV – cell voltage Uocv, V;
880 * Resistance – cell resistance, Ohm.