STW MBMS Montageanleitung

mBMS Hardware Guide

Created: W. Putz / F.-J. Schuster

Page 2 of 28

Sensor-Technik Wiedemann GmbH, Am Bärenwald 6, 87600 Kaufbeuren, Tel.: 08341/95050, Fax: 08341/950555, www.sensor-technik.de

Table of content

1COPYRIGHT NOTICE ...................................................................................................................................... 3

2INTRODUCTION ............................................................................................................................................ 4

2.1 SCOPE ............................................................................................................................................................ 4

2.2 DOCUMENTS ................................................................................................................................................... 5

2.3 GENERAL RULES ............................................................................................................................................... 5

3OVERVIEW .................................................................................................................................................... 6

3.1 TOPOLOGIES.................................................................................................................................................... 6

3.2 KEY COMPONENTS ............................................................................................................................................ 7

3.3 ADDITIONAL COMPONENTS................................................................................................................................. 9

4MOUNTING AND WIRING ............................................................................................................................12

4.1 MOUNTING ELECTRONIC COMPONENTS............................................................................................................... 12

4.2 WIRE DIMENSIONS.......................................................................................................................................... 13

4.3 INSULATION COORDINATION ............................................................................................................................. 13

4.4 ACHIEVING EMC COMPLIANCE.......................................................................................................................... 14

4.5 BMS CONFIGURATION..................................................................................................................................... 15

4.6 CSCCONFIGURATION ...................................................................................................................................... 16

4.7 INTERLOCK .................................................................................................................................................... 21

4.8 CAN-INTERFACING ......................................................................................................................................... 22

5MULTI BATTERY TOPOLOGIES ......................................................................................................................23

5.1 MASTER/SLAVE NETWORKING .......................................................................................................................... 23

5.2 MULTI MASTER NETWORKING ........................................................................................................................... 23

6TECHNICAL DATA .........................................................................................................................................25

6.1 MAXIMUM RATINGS ....................................................................................................................................... 25

6.2 KEY DATA ..................................................................................................................................................... 25

7TERMS AND ABBREVIATIONS.......................................................................................................................28

Document History:

Version

Date

Name

Change

Ticket

V1.2

27.07.2015

F.-J. Schuster

New PMB variants description added

New BMS variants description added

15260

15261

V1.1

14.12.2015

15.12.2015

16.12.2015

21.12.2015

F.-J. Schuster

“Battery-CAN” renamed to “Sensor-CAN”

Documentation standard inserted

Chapter “BMS configuration” created

Chapter “Interlock” created

12874

13541

12636

13526

V1.0

21.04.2015

W. Putz

F.-J. Schuster

First Release

mBMS Hardware Guide

Created: W. Putz / F.-J. Schuster

Page 3 of 28

Sensor-Technik Wiedemann GmbH, Am Bärenwald 6, 87600 Kaufbeuren, Tel.: 08341/95050, Fax: 08341/950555, www.sensor-technik.de

1 Copyright Notice

This User Manual and its content is copyright of Sensor-Technik Wiedemann GmbH - ©

No part or all of the contents may be reproduced and used without the consent of Sensor-

Technik Wiedemann GmbH other than the following:

you may print or download to a local hard disk extracts for your personal and non-

commercial use only

you may copy the content to individual third parties for their personal use, but only if

you acknowledge the source of the material

You may not, except with our express written permission, distribute or commercially

exploit the content. Nor may you transmit it or store it in any other website or other form of

electronic retrieval system.

All product names, companies, logos and other brands which are referenced in this User

Manual are the property of their respective owners.

They are subject to change without prior notice.

In spite of careful development and extensive reviews it is not possible to guarantee

perfect correctness and completeness of our User Manuals. Therefore, liability for any

damage resulting from incompleteness or incorrectness cannot be accepted.

mBMS Hardware Guide

Created: W. Putz / F.-J. Schuster

Page 4 of 28

Sensor-Technik Wiedemann GmbH, Am Bärenwald 6, 87600 Kaufbeuren, Tel.: 08341/95050, Fax: 08341/950555, www.sensor-technik.de

2 Introduction

2.1 Scope

The Battery Management System mBMS

is an essential part of the high voltage battery

in an electric vehicle

. It ensures safe operation of the lithium-ion battery cells and it

interacts with the vehicle’s high voltage DC network (traction net) and the vehicle’s bus

system.

The mBMS key functions are:

Enter Safe state by disconnecting the battery from the traction net in case of:

oCell Over voltage events

oCell Under voltage events

oCell Over temperature events

oOver Current events

oLoss of interlock signal

Battery Health Measures:

oKeep all cells in a balanced state

oPrevent battery abuse

Determination of the battery’s state:

oSelf-diagnostics including insulation monitoring

oState of Charge (SOC)

oInner resistance determination and prediction of deliverable power

oBattery capacity

Vehicle interfacing:

oControlled pre-charge of inverter’s capacitance

oDetermination of vehicle’s insulation status

oOptional interlock signal generation

oCommunication via the ESS-CAN bus

This document describes the 2nd generation of STW’s mBMS

The term “vehicle” is used throughout this document, although the mBMS may be part of a high voltage

battery system of a non-vehicle application.

mBMS Hardware Guide

Created: W. Putz / F.-J. Schuster

Page 5 of 28

Sensor-Technik Wiedemann GmbH, Am Bärenwald 6, 87600 Kaufbeuren, Tel.: 08341/95050, Fax: 08341/950555, www.sensor-technik.de

2.2 Documents

You can find the latest release of this document and related documents online:

STW Cloud: https://cloud.sensor-technik.de/

Download area on www.sensor-technik.de

Related documents include:

mBMS Toolchain Guide

ESS-CAN Matrix (in .dbc format and as an export in .xlsx format)

Diagrams describing:

obasic interconnections

odetailed wiring and

oMaster/slave wiring

Pin assignment of key components: BMS, PMB, CSC

Component drawings

2.3 General Rules

This document was created to give the ambitious technician a compact set of information.

Please take the time to read this issue carefully to prevent the setup from malfunction and

the environment/user from harmful injuries or death.

Building a battery system means working on voltages present.

This should be done only by specially trained personnel.

Even if a single cell has a low voltage, the current can be very

high in short circuit condition.

Use insulated tools.

Pay attention towards the separation of high- and low voltage

parts. For creeping and clearance, refer to related normative

standards like EN 60664.

If the component is used in a manner not specified, the protection

supported by the component may be impaired.

Most components of this system are bare electronic devices

without a cover. Therefore, they are sensitive to electric

discharge. Personal ESD protection and an ESD protected area

are necessary.

Inverters cause high electromagnetic fields.

Inside the housing, communication wires (CAN, CSC-Bus) should

be a pair of twisted wires (at least).

Outside the housing, use shielded wires suitable for high voltage

wiring.

The pre-charge resistor, the shunt and as well the cell sensor

circuit might get hot during operation.

mBMS Hardware Guide

Created: W. Putz / F.-J. Schuster

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Sensor-Technik Wiedemann GmbH, Am Bärenwald 6, 87600 Kaufbeuren, Tel.: 08341/95050, Fax: 08341/950555, www.sensor-technik.de

3 Overview

3.1 Topologies

Lithium-ion batteries are the preferred energy storage system (ESS) for modern electric

drive systems. The mBMS permits safe operation of lithium-ion batteries up to 800 volts.

The mBMS supports various ESS topologies –single battery systems as well as multi

battery systems for larger installations.

Master

ESS-CAN

CAN1

Figure 1 –single battery topology

The single battery approach (standalone) is the most common system topology consisting

of one serially connected string of battery cells. A stack comprises one or more cell

modules with cell sensor circuits (CSC), a single current sensor (PMB), a single main

supervisor (BMS) and a pair of main switches.

For an ESS with a high demand for energy, power, availability or maintainability, it may be

more appropriate to connect multiple batteries in a parallel topology.

See chapter 5 for further information.

mBMS Hardware Guide

Created: W. Putz / F.-J. Schuster

Page 7 of 28

Sensor-Technik Wiedemann GmbH, Am Bärenwald 6, 87600 Kaufbeuren, Tel.: 08341/95050, Fax: 08341/950555, www.sensor-technik.de

3.2 Key components

Figure 2 –Connection overview

Figure 2 shows the devices for a battery management system and their interconnection.

This diagram can be found as a separate file in a larger format and higher resolution.

The key components (marked green) can only be purchased from STW. The additional

components (marked yellow) may be obtained from 3rd parties.

BMS –Battery Main Supervisor

The BMS is the main device of the battery system. It contains three controllers for a

maximum of reliability and safety. It collects all information from its sensors, determines

the state of the battery system and decides whether main switches are allowed to be

close or need to be opened. An insulation measurement device may be installed as a

piggy-pack to the BMS.

It´s very important for the function of the insulation measurement

device that the mounting hole of the BMS is connected to the

chassis of the system (car body, system rack, etc.) in a low

impedance way.

There are four hardware variants of the BMS.

CAN Wakeup or KL15 Wakeup (Imprint on nameplate: CAN1 or KL15)

Precharge with Relay or with CDR-Module (Imprint on nameplate: RELAY or

CDR)

Exemplary imprint on the nameplate:

mBMS Hardware Guide

Created: W. Putz / F.-J. Schuster

Page 8 of 28

Sensor-Technik Wiedemann GmbH, Am Bärenwald 6, 87600 Kaufbeuren, Tel.: 08341/95050, Fax: 08341/950555, www.sensor-technik.de

PMB –Power Measurement Board / current sensor

The PMB measures the current (shunt resistor) which flows in or out of the battery, the

voltage value of the battery stack and the traction net. The PMB is equipped with a unique

redundant safety circuit which enables the PMB to directly signal a current limit violation.

Do not mount the shunt on conductive surfaces/materials.

Choose the mounting position of the shunt carefully because it´s

getting hot during operation at high currents. The dissipated

power is    .

There are two hardware variants of the PMB: PMB1000 and PMB2000.

The PMB2000 is designed for higher currents than the PMB1000. For details, see the

chapter Technical Data.

Exemplary imprint on the nameplate:

CSC –Cell Sensor Circuit

The CSC is directly contacted to the cells of the battery. It measures the cell voltages and

temperatures and converts this data in a way suitable for the BMS. Each CSC is equipped

with a passive discharge path for balancing the charges of the battery cells.

While balancing, the CSC is getting hot.

To prevent overheating, the CSC will reduce the balancing current

Filter

Optional filter devices reduce the electrical noise originating from the power converters on

the traction net. They include special Y-Capacitors for EMC suppression.

Filters should be mounted directly on the battery output (near HV

connector).

Filters have to be connected with low impedance (short wires) to

chassis ground.

mBMS Hardware Guide

Created: W. Putz / F.-J. Schuster

Page 9 of 28

Sensor-Technik Wiedemann GmbH, Am Bärenwald 6, 87600 Kaufbeuren, Tel.: 08341/95050, Fax: 08341/950555, www.sensor-technik.de

3.3 Additional components

Main switches

The main switches are connecting and disconnecting the power source or load to/from the

battery. They must be able to interrupt the flowing current in short circuit situation to

prevent uncontrollable situations.

It´s important to use the correct fixing torques at the contacts to ensure good connection

and low connecting resistances. For the EV200 the torque should be 10Nm. Refer to the

owner’s manual if different main switches are used.

The BMS supports main switches with 12V or 24V coils as well as types without internal

power reduction (economizer). Please keep in mind that the BMS has to be provided at

least with the lowest voltage level the main switches require for closing.

The main switches shall be selected in accordance with the

maximum system voltage, the maximum short circuit current as

well as the number of cycles the main switch can do in these

situations.

CDR –Pre-charge Module

The CDR pre-/dis-charge module may be used as an alternative solution for pre-charging

traction net capacitors usually included in inverters. It is able to provide an economic

replacement of a mechanical pre-charge relay (up to 800 V). The CDR combines a small

mechanical relay with a semiconductor device.

Pre-charge relay

The pre-charge relay bypasses the positive main switch with a resistor. This is to prevent

high current flows into the traction net capacity.

The pre-charge relay has to fit to the maximum pre-charge current

(limited by the pre-charge resistor) and the system voltage.

Attention: When using the CDR, a special variant of the BMS (Battery Main Supervisor)

has to be used.

mBMS Hardware Guide

Created: W. Putz / F.-J. Schuster

Page 10 of 28

Sensor-Technik Wiedemann GmbH, Am Bärenwald 6, 87600 Kaufbeuren, Tel.: 08341/95050, Fax: 08341/950555, www.sensor-technik.de

Pre-charge resistor

The pre-charge resistor has to limit the current rushing into the traction net capacitor.

It must be ensured that the resistance is capable to handle the impulse energy which

occurs during pre-charging. Use special “braking resistors” with high impulse energy

capability.

The suitable resistance value “R” depends on the traction net capacity “C”, the pre-charge

time “t”, the maximum allowed current “IShort” as well as on the maximum system voltage

“U”. The value “∆U” is the voltage difference between the traction net voltage and the

system voltage “U” after pre-charge time “t”.

   

  󰇡

󰇢

The current  has to be within the switching capability of the pre-charge relay.

 



The impulse energy “E” for the resistor to dissipate is calculated with

  

   

The pre-charge resistor gets hot during the pre-charge process.

After one pre-charge cycle, the resistor needs a time-interval

sufficiently for cooling down.

The pre-charge resistor has to be mounted on a heat dissipation

surface.

The BMS dynamically manages the pre-charge process in order

to prevent overheating.

HV connector

This connector is the Interface to the traction net. The HV connector may include

additional contacts carrying an interlock signal.

Temperature sensor

The two temperature sensor inputs are intended to measure the coolant temperature.

The internal look up table is configured for an NTC type with 10 kand the characteristic

EPCOS 8016. If you use a different type, the look up table has to be adapted to the

sensor used. The adaptions necessary on mBMS side are subject to a customer specific

development. Please call STW for a commercial offer.

The used temperature sensors (10 kNTC, characteristic 8016)

must be electrically isolated types.

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