Hardware Manual

BMS Master 4 / 4.5

ACTIA I+ME GmbH

Dresdenstrasse 17/18
D-38124 Braunschweig
Germany
Tel.: + 49 (0) 531 38701-0
Fax: + 49 (0) 531 38701-88
www.ime-actia.com

Hardware Manual
BMS Master 4 / 4.5

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Doc Template Erstellt von/am: R&D/19.01.2015 IR11262G
Hardware Manual
BMS Master 4 / 4.5

Document Reference

Classification Internal Mailing List External Mailing List

Name Department Name Department

Without DKU R&D

Confid. I+ME
Confid. Client

Status only for information Official Document

Release Date: 15.01.2018

Initials Ref. I+ME Index

1412000037
Author KA
IR14417 A
approved DKU
© ACTIA I+ME GmbH 2018

Document Histor y

Index Page Date Reason of Change Name

A All 26.07.2016 Hardware Manual Master 4 / 4.5, Revision based KA
on Hardware Manual Master 4
A All 05.08.2016 Minor lingual corrections. JQU
21.10.2016 3.1.3.1 Switch OFF BMS – Kl15 / Kl30 KA
13.03.2017 3.5.4.5, 3.6.9, Slave Types (Balance Board) KA
18.08.2017 3.6.8.6 Slave 6 A voltage range KA
09.10.2017 6. Certificate Master 4.5 KA
19.12.2017 3.6.8.6 Slave 6 A voltage range KA
15.01.2018 3.2.2.2 new KA

Client Approval

Data and Name: ...............................................................................

Sign .........................................................................................

© 2018 ACTIA I+ME GmbH All Rights reserved.

Any reproduction or distribution of this document,
or parts of this document is prohibited without a
written authorization of ACTIA I+ME GmbH.

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Hardware Manual
BMS Master 4 / 4.5

Content
1. Introduction ......................................................................................................... 6
1.1 Appliance and Safety Information for ACTIA I+ME Battery Management System (BMS)
Components ............................................................................................................. 6
1.1.1. Determined Use, Connection and Installation ................................................. 6
1.1.2. Warranty and Responsibility ........................................................................ 6
1.1.3. Checking, Transport and Storage ................................................................. 7
1.1.4. Remarks ................................................................................................... 7
1.1.5. Symbols und Writings ................................................................................. 8
1.1.6. Glossary ................................................................................................... 8
2. General System description .................................................................................... 9
2.1 Diagram „System components“ ............................................................................ 9
2.2 Scheme „MASTER“ ............................................................................................ 10
2.3 Schematic for Slave C, Slave 5 ........................................................................... 11
2.4 Schematic for Slave 6 ....................................................................................... 12
3. Hardware ........................................................................................................... 13
3.1 The Hardware of the MASTER ........................................................................... 13
3.1.1. Block Diagram ......................................................................................... 13
3.1.2. Enclosure views ....................................................................................... 14
3.1.3. Interfaces ............................................................................................... 15
3.1.3.1 Supply, connector CN101 ....................................................................... 15
3.1.3.2 Outputs, connector CN102 ...................................................................... 16
3.1.3.3 Inputs, connector CN103 ........................................................................ 16
3.1.3.4 Current Measurement and CAN2, connector CN104 ................................... 18
3.1.3.5 CAN Interface 1 & 3, connector CN105 ..................................................... 19
3.1.3.6 Slave Module Communication, connector CN106 ....................................... 19
3.1.3.7 RS232-Interface .................................................................................... 20
3.1.3.8 Ethernet- Interface ................................................................................ 20
3.1.3.9 Internal Interfaces ................................................................................. 21
3.1.3.10 LEDs ................................................................................................... 21
3.1.4. Electromechanics ..................................................................................... 21
3.1.5. Summary MASTER Connectors ................................................................... 22
3.1.6. Electrical Specification .............................................................................. 23
3.1.7. Housing .................................................................................................. 23
3.1.8. Environmental Conditions .......................................................................... 24
3.1.9. Certifications ........................................................................................... 24
3.2 Measurement of Current .................................................................................... 24
3.2.1. VAC-Sensor ............................................................................................. 24
3.2.1.1 Connection to the MASTER ..................................................................... 25
3.2.1.2 Current Divider 5:1 ............................................................................... 26
3.2.2. BAT-S 1000 1U Sensor ............................................................................. 27
3.2.2.1 System integration ................................................................................ 27
3.2.2.2 Measurement values .............................................................................. 28
3.2.2.3 Connecting the BAT-S 1000 1U Sensor to MASTER .................................... 28
3.2.2.4 Connecting the BAT-S 1000 1U sensor for voltage measurement ................. 29
3.2.2.5 Technical Specification BAT-S 1000 1U - Sensor ........................................ 29
3.2.3. IVT-B Sensor ........................................................................................... 30
3.2.3.1 System integration ................................................................................ 30
3.2.3.2 Connecting the Sensor to Master ............................................................. 30
3.2.3.3 Connecting the Sensor for Voltage Measurement ....................................... 31
3.2.3.4 Technical Specification IVT-B-Sensor ....................................................... 31
3.3 Insulation Monitoring IR155-3204 ...................................................................... 32
3.4 The Hardware of SLAVE_C ................................................................................. 33
3.4.1. Functional Overview ................................................................................. 33
3.4.2. Block Diagram ......................................................................................... 34
3.4.3. Printed Circuit Board and Connectors .......................................................... 34

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3.4.4. Functional Description............................................................................... 35

3.4.4.1 Power Supply ........................................................................................ 35
3.4.4.2 Single Cell Interface .............................................................................. 35
3.4.4.3 Connecting less than 10 cells .................................................................. 36
3.4.4.4 Balancing Resistors................................................................................ 37
3.4.4.5 Serial RS 485 Interface and Error Signalling ............................................. 37
3.4.4.6 Configuration Interface .......................................................................... 38
3.4.4.7 Sensor- and PTC-Interface ..................................................................... 38
3.4.4.8 Signalling LEDs ..................................................................................... 39
3.4.4.9 2nd Level Voltage Detection ................................................................... 39
3.4.4.10 Fault Messaging Interface ...................................................................... 39
3.4.4.11 Long Time Watchdog ............................................................................ 40
3.4.4.12 Interface Isolation ................................................................................ 40
3.4.5. Mechanical Dimensions ............................................................................. 40
3.4.6. Power Supply and Consumption ................................................................. 40
3.4.7. Environmental ......................................................................................... 41
3.5 The Hardware of SLAVE_5 ................................................................................. 42
3.5.1. Functional Overview ................................................................................. 43
3.5.2. Block Diagram ......................................................................................... 43
3.5.3. Board Layout and Connections ................................................................... 44
3.5.4. Functional Description............................................................................... 45
3.5.4.1 Supply ................................................................................................. 45
3.5.4.2 Connecting Battery Cells ........................................................................ 45
3.5.4.3 Connecting Less Than 10 Cells ................................................................ 45
3.5.4.4 Sensor- and PTC-Interface ..................................................................... 46
3.5.4.5 Balancing Resistors................................................................................ 46
3.5.4.6 Serial RS 485 Interface and ERROR Signalling ........................................... 47
3.5.4.7 2nd-Level Overvoltage Detection ............................................................. 48
3.5.4.8 Long Time Watchdog ............................................................................. 48
3.5.4.9 Configuration - Addressing ..................................................................... 48
3.5.5. Connecting External Balance Resistors ........................................................ 48
3.5.6. Interface Isolation .................................................................................... 51
3.5.7. Mechanical Dimensions ............................................................................. 51
3.5.8. Supply and Current Consumption ............................................................... 51
3.5.9. Environmentals ........................................................................................ 52
3.6 The Hardware of Slave 6 ................................................................................... 53
3.6.1. Functional Overview SL6_CON ................................................................... 53
3.6.2. Functional Overview SL6_ANA ................................................................... 53
3.6.3. Function Overview SL6_BAL ...................................................................... 53
3.6.4. System Block diagram .............................................................................. 54
3.6.5. Connecting the Slave 6 CON Module to MASTER ........................................... 55
3.6.6. Communication Connection to CON Module - ANA Module ............................. 56
3.6.7. SL6_CON Module ..................................................................................... 57
3.6.7.1 Layout and connectors ........................................................................... 57
3.6.7.2 Mechanical Dimensions .......................................................................... 58
3.6.7.3 Supply and Current Consumption ............................................................ 59
3.6.7.4 Environmentals ..................................................................................... 59
3.6.8. SL6_ANA Module ...................................................................................... 60
3.6.8.1 Board Layout and Connectors ................................................................. 60
3.6.8.2 Connect less than 12 cells ...................................................................... 62
3.6.8.3 Second Level Protection ......................................................................... 64
3.6.8.4 Configuration SL6_ANA module .............................................................. 64
3.6.8.5 Mechanical Dimensions .......................................................................... 64
3.6.8.6 Supply and Current Consumption ............................................................ 65
3.6.8.7 Environmental ...................................................................................... 65

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3.6.9. Passive Cell Balance ................................................................................. 65

3.6.9.1 Connection of external Balance Resistors .................................................. 66
4. Bringing the Slave C, Slave 5 into Service (only for Cell Voltages) ............................. 69
5. Connectors-Accessory .......................................................................................... 71
6. Certificates ......................................................................................................... 73

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Hardware Manual
BMS Master 4 / 4.5

1. INTRODUCTION

Please read the present operation and safety remarks carefully. The instructions
refer to all components of the BMS.
The name BMS Master applies both for the BMS Master 4 and Master 4.5. There are
differences they are separately described for Master 4 and Master 4.5.

1.1 APPLIANCE AND SAFETY INFORMATION FOR ACTIA I+ME BATTERY

MANAGEMENT SYSTEM (BMS) COMPONENTS

The BMS MASTER and Slave are two electronic components, which shall be used together in
Lithium Ion batteries to control the battery system and charge status of each cell.

1.1.1. DETERMINED USE, CONNECTION AND INSTALLATION

 Please always observe the corresponding DIN/VDE/EN/IEC/ANSI guidelines. Be informed with the
specification and guidelines of the user and the respective manufacturer of the cells and accordingly
of the battery.
 Batteries are electrochemical components with very high short-circuit currents. Under all
circumstances avoid short-circuits that endangers you, the whole construction and other operators.
 All BMS-components and the provided equipment have to be used only for purposes described in
the corresponding manuals. Incorrect use and operation of the components may damage the
construction where they are installed.
 Damaged components and such that have exceeded their lifetime have to be replaced immediately.
 Only adequately qualified specialists, trained in handling of batteries and skilled in safety
requirements for working with batteries may install the BMS.
 After implementation of the BMS in the system a qualified specialist has to check the function and
safety of the whole installation.
 Due to the high voltage a sufficient insulation of the Slaves, their cabling and connected sensors is
essential.

1.1.2. WARRANTY AND RESPONSIBILITY

 Fundamentally our standard business conditions apply which are available to our client since the
conclusion of the contract.
 The ACTIA I+ME Battery Management System Components are complex parts intended for
operation in powerful batteries. The components achieve a number of surveillance functions
necessary for the management of lithium-ion batteries. These functions are described in provided
manuals. The user may utilize these functions; however, the safety of the whole battery is in his
responsibility.
 We assume no liability and guarantee claims resulting from improper use of the system. The
producer is on no account responsible for direct or subsequent claims that may happen from
inappropriate or unprofessional use of BMS components.
 Should be any of our clauses not be valid the German law applies.
 We reserve our right to do further development of the system and modifications of this manual
without previous announcement.

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1.1.3. CHECKING, TRANSPORT AND STORAGE

 Please check the transportation and component package for any damages and compare the content
with the bill of delivery. In case of damages inform ACTIA I+ME GmbH immediately.
 The Components may only be stored in rooms where they are safe from dust, humidity, splash water
and dropping water and where the denoted storing temperatures are guaranteed.

1.1.4. REMARKS

Before placing into operation please carefully read the following

security instructions.
The correct on site installation methods and the proper handling
procedures for the Lithium Ion Cells, and the following usage and
service procedures cannot be controlled by ACTIA I+ME. Therefore
ACTIA I+ME will not accept any responsibility for damage or costs
Electricity Hazard
resulting from the incorrect installation or operation in any form.

- Use insulated tools, wherever possible. Voltages may exceed some hundreds volts DC.
- Always use qualified proper and, wherever applicable, polarity proof connectors.
- Especially the wiring of the cells has to be done with extreme precaution. See chapter
3.4.4.2. Inspect the connections regularly.
- Use only appropriate cables; especially for ampacity of power cables refer to DIN VDE
0276-1000 or corresponding national directives.
- Cable dismantling, attaching end sleeves etc. must not be done near the electronic boards
to avoid short circuits due to single wire strands.
- Special care has to be taken when measuring or testing with
equipment electrically referenced to mains protective earth (PE; e.g.
mains supplied scopes); especially when master and slave units are
connected and the master does not have an isolated power supply of
its own. Remember that a master unit connected to a PC via RS232
interface is connected to PE anyway. The master unit’s reference GND- Battery Hazard
level is the supply minus-pole (KL31), the slave unit’s reference GND-
level is cell contact 7!! There will be a voltage difference of 21 V with
ten cells at least, depending on the amount of single cells connected; with an 80-cell
system e.g. the voltage difference between KL15 and Slave GND can be up to 300 VDC and
more.
- A short between both reference levels will destroy the battery, the electronics and the test
equipment and may lead to fire or even explosion.
- BMS MASTER and Slave boards are ESD (electrostatic discharge) sensitive devices.
Therefore, proper ESD precautions are recommended to avoid performance degradation or
loss of functionality.

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1.1.5. SYMBOLS UND WRITINGS

Symbols and writings used in this manual:

Safety references and Warnings

are marked with this attention symbol in this manual. A signal word explains the
subject.

Special instructions are marked with this symbol.

References to other chapters or additional information are marked with this

symbol.

>Text< Text or values mentioned in context with screen masks or similar are set
between angle brackets.
>Text< Text or values for input are bold in angle brackets.

[OK] Command buttons in context with screen masks are put in square brackets.

1.1.6. GLOSSARY

SoC State of charge

DoD Depth of discharge
KL15 Input of MASTER - Wake up „Plug-IN“
KL15S Input of MASTER - Wake up „Drive“
HV High Voltage Contactor (e.g. HV+ between Battery+ and Load)
KV Contactor like HV (refers to KiloVac)
RTC Real Time Clock
VDR voltage dependent resistor, Varistor
ADC Analog Digital Converter
NTC negative temperature coefficient resistor, thermistors
PTC positive temperature coefficient resistor, thermistors
IMD Insulation Monitoring Device

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BMS Master 4 / 4.5

2. GENERAL SYSTEM DESCRIPTION

Loads, contactors, fuses and chargers may be connected in different ways. First of all the
battery has to fit to the requirements of the load. Next the charger will influence the order
of the components.

2.1 DIAGRAM „SYSTEM COMPONENTS“

„Drive“ mode with optional charger in the

. load circuit

Current Sensor Fuse Relay Load +

VAC4645 350 A Drive +

Battery +
270V -378V dc Relay
Slave Precharge
Slave Charger
Slave X Ohm
.
Slave Master HV+

HV-

- Slave
Relay Load -
Drive -

Different circuits for both „PlugIn“ mode and „Drive“ mode

Current Sensor Fuse Relay Load +
VAC4645 350 A Drive +

Battery +
270V -378V dc Relay
Slave Precharge
Slave
Slave X Ohm
Charger
.
Slave Master
HV+
Relay
Charge - HV-

- Slave
Load -
Relay
Drive -

Every lithium ion battery system consists of several single cells, one master unit and at
least one slave unit. Every slave unit can control 4 up to 12 single cells, and the master unit
can control up to 32 slave units and up to 384 cells. For batteries with more than 12 cells at
least two slave units are needed.

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The master software and its parameters have to be adapted to the special battery
configuration. In exceptional cases a slave module may be modified to control three or four
cells. Controlling less than three cells is not possible.

2.2 SCHEME „MASTER“

Example schematic diagram:

CANH
CANL
SW5-8 Current sensor
Power Supply PlugIn Drive OFF VAC4645

Master_Slave_FAIL_IN
Master_Slave_5V NET
Master_Slave_BUS_A

Master_Slave_BUS_B
LC2
LC1
S1
S2

K1
K2

Master_Slave_GND
Vbat GND
6 5 4 3 2 1
1 2 1 2 1 2 1 2 120Ω

LiYCY- TP 2x2 0,25mm² CAN 2 CAN 1 CAN 3

K1 & K2 twisted
S1 & S2 twisted

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 1 2 3 4 5 6
KL31
KL31
KL31
KL30
KL30
KL30
Plug In
Drive
EMSRET

7V
S1
K1
KL31
S2
K2
CAN2H
CAN2L
Shield

CAN1H
CAN1L
Shield

CAN3H
CAN3L
Shield

BUS_A
5V NET
GND
BUS_B
FAIL_IN
Shield
Supply Current CAN Slave Comm.

Master

Outputs Inputs

ICONst1

ICONst2
REL1A

REL1B

REL2A

REL2B

SS200
PWM0

AGND

AGND

AGND
SWO1
SWO2

SWO3
SWO4

SWO5
SWO6

SWO7
SWO8
AOUT

OIN1

OIN2

KL31
KL31
DIN1

DIN2

DIN3

DIN4
KL31
KL31

KL31
KL31
KL31

KL31
KL31

AIN1

AIN2

AIN3

AIN4
FIN1

FIN2
7V

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Anabg out

2,2 kΩ

2,2 kΩ
PWM out

PT100 PT100

+ + + + 1 2

SavOut Out1 Out2 Out3 Out4

Out1 = FAN - - - - PE
Out2 = ? Ext. 12V
1 kΩ

Out3 = Error Signal HV-Relay HV-Relay HV-Relay HV-Relay Security

8 7 6 5 4 3 2 1
Out4 = ? Charge ? minus precharge plus Switch
OK-
OK+
M+
M-
KE
E
A+
A-

IR 155-32-3201
2nd Level Error
2nd Level Error

Signal Error

Bat + L+
Bat - L-
IMD

The Master module covers the following functions:

 Communicating with the connected slave modules
 Providing and supervising time
 Measuring of the total current drawn from the battery
 Controlling the main power relay
 Switching of climatic equipment, e.g. fans, Peltier elements or similar devices

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 Communicating with external hardware via a high speed CAN interface

The Master module is supplied either by the controlled battery itself or it can be supplied by
an additional system battery, e.g. in mixed 12V/42V-systems.
System time and date are provided by a real time clock.

The Master supply voltage must not exceed 28 VDC.

2.3 SCHEMATIC FOR SLAVE C, SLAVE 5

Example schematic diagram based on Slave C modules; for the Slave 5 modules the
picture is valid analogously. The Slave C, Slave 5 is on Master Connector CN106 (Slave
Comm) wired connected.

VBAT+

VBAT-
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
Cell connector Cell connector Cell connector

temperature temperature temperature

control control control

NTC2- 1 NTC NTC2- 1 NTC NTC2- 1 NTC

2 2 2
SLAVE n NTC1- 3 NTC SLAVE n-1 NTC1- 3 NTC SLAVE 1 NTC1- 3 NTC

4 4 4
PTC+ 5 PTC+ 5 PTC+ 5
6 6 6
Failn 2
Failn 1
GND
5V
BUS B
BUS A
SHIELD
SHIELD
GND
5V
BUS B
BUS A
Failn 2
Failn 1
GND
5V
BUS B
BUS A
SHIELD
SHIELD
GND
5V
BUS B
BUS A

Failn 2
Failn 1
GND
5V
BUS B
BUS A
SHIELD
SHIELD
GND
5V
BUS B
BUS A

12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

e.g. LiYCY- TP 3x2 0,25mm²

Bus A & Bus B Twisted
4,7 kΩ … 5,1 kΩ 5V & GND twisted

Master_SlaveCom.5
Master_SlaveCom.3
Master_SlaveCom.2
Master_SlaveCom.4
Master_SlaveCom.1

The slave module can be connected to 5 up to 10 cells and covers the following functions:
 Communicating with the Master module
 Measuring of the single cell voltages
 Compensation of different cell charge states
 Controlling of the mechanical integrity of one or more batteries
 Measuring of temperatures
 Signalling overvoltage and over temperature conditions

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The slave module is internally supplied by three cells of the controlled battery, in 10 cell-
systems the cells number 6 to 8 (counting from minus pole to plus pole) are used. If less
cells are used, the slave module is supplied by the cells connected to the according cell
contacts.

2.4 SCHEMATIC FOR SLAVE 6

The Slave 6 is on the Master connector CN104 (Current) together with the Current sensor
connected. The Second Level Security is on connector CN106 (Slave Comm) wired.

Master_Slave Com.5
Master_Slave Com.4
Master_Slave Com.1
Master_CurrentMeas.8 VBAT+
Master_CurrentMeas.7
Master_CurrentMeas.4
Master_CurrentMeas.1
CAN L 10

FAIL B 11

SHIELD 12
VNet 1
7
Term H 2
Term L 8
CAN H 3
CAN L 9
CAN H 4

FAIL A 5

FAIL_ 6

1 8 2 9 3 10 4 11 5 12 6 13 7 14 1 8 2 9 3 10 4 11 5 12 6 13 7 14
Cell connector Cell connector
GND

Balance temperature Balance temperature

Master connector Connector Connector
connector connector
1 1 1 1
NTC 1 NTC 1
6 6
2 NTC 2 NTC
NTC 2 NTC 2
SLAVE 6 7
3 NTC
7
3 NTC
CON Modul SLAVE 6 NTC 3
8 SLAVE 6 NTC 3
8
4 NTC 4 NTC
ANA Modul NTC 4
9 ANA Modul NTC 4
9
5 NTC 5 NTC
24 NTC 5 24 NTC 5
10 10

Connector Top Connector Bottom Connector Top Connector Bottom Connector Top

SI-T
SI+T
EN-T
EN+T
SHIELD
SHIELD
T2
T1
SI-B
SI+B
EN-B
EN+B
SHIELD
SHIELD
B2
B1
SI-B
SI+B
EN-B
EN+B
SHIELD
SHIELD
B2
B1

SI-T
SI+T
EN-T
EN+T
SHIELD
SHIELD
T2
T1
SI-T
SI+T
EN-T
EN+T
SHIELD
SHIELD
T2
T1

8 4 7 3 6 2 5 1 8 4 7 3 6 2 5 1 8 4 7 3 6 2 5 1 8 4 7 3 6 2 5 1 8 4 7 3 6 2 5 1

e.g. LiYCY- TP 3x2 0,25mm²

Bus A & Bus B Twisted
5V & GND twisted

The slave module can be connected to 4 up to 12 cells and covers the following functions:
 Communicating with the Master module
 Measuring of the single cell voltages
 Compensation of different cell charge states
 Measuring of temperatures
 Over and under voltage detection, (second level security)
 Over and under temperature detection, (second level security)
 Error events, notify the MASTER to turn of the relay
 Self-monitoring (cell voltage open wire check, balance check)

The ANA module is internally supplied from the connected cells.

The CON module is supplied from the MASTER.

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3. HARDWARE

3.1 THE HARDWARE OF THE MASTER

3.1.1. BLOCK DIAGRAM

This diagram shows the basic components of the „MASTER“

2 x 16 kB
Ext. Flash ext .
USB Port EEROM SRAM
2 x 4 MB
optional SDFlash

Intern
Auxiliary Comm
Ethernet Microcontroller Slave Bus
512k Flash handshake RS485 Comm.
1 x CAN incl. Emerg
1 x UART Fail
1 x Ethernet

VAC Current
sensor Interface
Opt. for other
sensor types
CAN
Transceiver 3
Main
CAN
Mux
Microcontroller CAN
Transceiver 2

CAN 256kFlash
Transceiver 1 2 x CAN
2 x UART

IO Interface
RS 232
Interface
8 x Out HiSide
2 x Relay OUT
6 x DigIN
1 x PWMOUT
RTC I²C 4 x AnalogIN
Power Supply
1 x AnalogOUT
Voltage Limiter
2 x ConstCur
RTC Wake UP
KL15 Wake UP
CAN Wake UP

The BMS-MASTER is equipped with two microcontrollers: the main processor XC167CI (by
Infineon) and the auxiliary processor AT91SAM7 (by Atmel). Both processors
communicate via internal interface or CAN-Bus.

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3.1.2. ENCLOSURE VIEWS

Front

Rear

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BMS Master 4 / 4.5

3.1.3. INTERFACES

3.1.3.1 SUPPLY, CONNECTOR CN101

The BMS MASTER is supplied via connector KL30 (+) and KL31 (–) with typ. 12 VDC or 24
VDC, e.g. a vehicle’s board net; the connections are polarity proof and protected against
overvoltage transients with a varistors, suppressor diodes and against overload with two
5A Thermo-Fuses.
Connector pin assignment / View on the pins:

1 KL30 4 KL15 7 KL31 1 4 7

2 KL30 5 KL15S 8 KL31 2 5 8
3 KL30 6 EMSRET 9 KL31 3 6 9

Nomenclature:

KL30 Plus, 9 … 28 VDC;

Power requirement depends on output loads, maximum 11.5 A
KL31 Minus, Ground, reference level – for all loads connected to outputs SWOx
(relays, valves, motors etc.)
Wake up Signal to switch on the device, +9 … 28 VDC; push-button function - the
„Plug-IN“ device may switch off itself, e.g. by a CAN command
(KL15) active @ > 8 V, input resistance 32 kΩ
Wake up Signal to switch on the device, +9 … 28 VDC; switch function - the device
„Drive“; cannot switch off itself
(KL15S) active @ > 8 V, input resistance 32 kΩ
EMSRET Supply of the Relay Outputs SWO5 … 8;
has to be connected to KL30 either directly or via a contact e.g. operated
with relay output REL1A/B
Without connection to KL30 the outputs SWO5 … 8 are out of function
Remark:
To switch ON or OFF the BMS Master use only the Kl15 or Kl15S signal. After switch OFF
with Kl15 / Kl15S the electronic control unit is running up to 10 seconds. In this time are
important data stored in non volatile memory.
Should the BMS complete disconnected from the power supply, at first the Kl15/Kl15S is
switched OFF and then wait 10 seconds. After that the clamp 30 can disconnected from
the BMS Master.
To switch OFF with clamp 30 or not wait 10 seconds can to cause inconsistent data at next
session (wrong State of charge).

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3.1.3.2 OUTPUTS, CONNECTOR CN102

1 4 7 10 13 16 19
The device has 12 outputs with different characteristics. 2 5 8 11 14 17 20
Connector pin assignment / View on the pins: 3 6 9 12 15 18 21

1 REL1A 4 REL1B 7 REL2A 10 REL2B 13 KL31 16 PWMO 19 AOUT

2 SWO1 5 KL31 8 SWO3 11 KL31 14 SWO5 17 KL31 20 SWO7
3 SWO2 6 KL31 9 SWO4 12 KL31 15 SWO6 18 KL31 21 SWO8

Nomenclature:

KL31 Minus, Ground, reference level – for all loads connected to outputs SWOx
(relays, valves, motors etc.)
SWO1…4 Switch outputs; if activated the voltage level corresponds to KL30 level; if
not activated the output level is 0 … 7 V depending on load resistance, due
to a test current of some micro amps to detect open loads in OFF-state.
The outputs may be loaded with up to 2.5 A each (peak 4 A for 1 second).
Total of outputs SWO1…4 must not exceed 5 A.
SWO5…8 Switch outputs with same characteristic as outputs SWO1…4.
Outputs SWO5…8 will be activated only, when EMSRET is connected to
KL30 in any way.
The outputs may be loaded with up to 2.5 A each (peak 4 A for 1 second).
Total of outputs SWO1…4 must not exceed 5 A.
REL1A-B potential free relay contact, can carry 30V / 2A resistive and inductive.
The relay will be cut off, when
- input DIN1 is deactivated or
- a FAIL-signal from any of the cell monitoring slave moduls is pending
The relay can/should be included together with the emergency stop switch
into a security chain .
REL2A-B potential free relay contact, can carry 30V / 2A resistive and inductive
PWMO pulse width modulated output;
output voltage UPWM (KL30-level – 3.5V, max 10V), max.50 mA,
min. pulse width tmin 50 µs
AOUT analog output UAOUT 0… (KL30-level – 3.5V, max 10V), max.50 mA

3.1.3.3 INPUTS, CONNECTOR CN103

1 4 7 10 13 16 19
2 5 8 11 14 17 20
The device has 12 inputs with different characteristics. 3 6 9 12 15 18 21

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Maximum input voltage like KL30.

Connector pin assignment / View on the pins:

1 OIN1 4 OIN2 7 7V / 10 SS200 13 FIN1 16 FIN2 19 KL31

12V
2 DIN1 5 DIN2 8 DIN3 11 DIN4 14 IConst1 17 IConst2 20 KL31
3 AIN1 6 AGND 9 AIN2 12 AGND 15 AIN3 18 AGND 21 AIN4

Nomenclature:
SS200 Sensor supply output; KL30 level, max. current 100 mA, (fuse 350 mA)
OIN1…2 Optical isolated current sink inputs;
activated at voltage > 5VDC, internal limited current 4.5 mA
DIN1…2 Digital current sink inputs;
- activated by current > 3 mA,
- deactivated by current < 2.5 mA, internal limited current 4.5 mA
An open or deactivated input DIN1 cuts off relay output REL1 !
DIN3…4 Digital voltage inputs;
- activated by voltage with more than half level of KL30 +1 V
- deactivated by voltage with less than half level of KL30 –1 V
Input resistance 20 kΩ
+ +
FIN1…2 Frequency measurement inputs
- activated by voltage higher than 25% level of KL30
- deactivated by voltage lower than 15% level of KL30
Hysteresis 0,2 V, input resistance 44 kΩ
The FIN inputs should be connected to sources switching between high
and low, they should not be connected to sources switching between low
and open. fmax 20 kHz
AIN1…2 Analogue input, range 0…10 V, Input resistance 44 kΩ
AIN3…4 Analogue input, range 0…5 V, Input resistance ≥ 1 MΩ
AGND Analogue Ground, reference level for AIN1…4
IConst1…2 Constant current outputs for PT100 sensors, 22 mA
- active only while measuring –
PT100 sensors have be connected to AIN3, AGND and IConst1 - or -
AIN4, AGND and IConst1 -2.
KL31 Minus, Ground
7V Master 4: 7 Volt sensor supply, max. 350 mA
12V Master 4.5: 12 Volt sensor supply, max. 350 mA

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3.1.3.4 CURRENT MEASUREMENT AND CAN2, CONNECTOR CN104

Connector CN104 can be used to connect Current sensor and Slave 6.

Following current sensors are possible:
- Shunt based sensor with isolated CAN interface from ACTIA I+ME GmbH
- Current compensation sensor from Vacuumschmelze
Other sensors with analog output may be used only with proper replacement of some
resistor elements; proper software provided.
Connector pin assignment / View on the pins:

1 4 7
1 7V / 12V 4 KL31 7 CAN2H
2 5 8
2 S1 / OVC 5 S2 / AGNC 8 CAN2L
3 6 9
3 K1 / SIG 6 K2 / REF2V5 9 Shield

Nomenclature:

For sensors with Shunt and CAN interface (BAT-S1000 1U, IVT-B)
7V Master 4: Sensor supply +7 VDC, 350 mA max.
12V Master 4.5: Sensor supply +12 VDC, 350 mA max.
KL31 Sensor supply Minus, Ground
CAN2H, CAN bus connections
CAN2L,
Shield
Only for Sensors VAC_T60404_M4645-X201
Details see Document IR11758A_BMS_HW_Descr_VAC_PCB
S1 / S2 High Current Sense
K1 / K2 Compensation Current
Do not connect the sensor lines LC1 und LC2 for low current
OVC Only Master 4:
Overcurrent signal, active high
activated by voltage > 2.5 VDC, input resistance 1.1 kΩ
Only Master 4:
Only with proper board assembly
(in connection with proper software, optional)
for sensors with analog output 2,5 V ± 2 V (e.g. LEM HAB)
AGNC Reference level Sensor Ground
SIG Input Analog-Signal
REF2V5 Input or output reference voltage 2,5V

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3.1.3.5 CAN INTERFACE 1 & 3, CONNECTOR CN105

For the communication with other devices CAN interfaces are integrated according to CAN
specification V2.0B. Each CAN node is able to transmit and receive standard frames with
either 11-bit- or 29-bit-identifiers.
Interface CAN 1 is operated by the XC167 processor.
Interface CAN 3 is operated by the AT91 processor.
Connector pin assignment / View on the pins:

1 4
1 CAN1H 4 CAN3H 2 5
2 CAN1L 5 CAN3L 3 6
3 Shield 6 Shield

Nomenclature:

CAN1H, Controller Area Network channel 1

CAN1L For communication with external devices, e.g. host computer.
CAN3H, Controller Area Network channel 3
CAN3L for communication with battery control specific units
Shield Shield connection

The use of shielded and twisted pair cable is strongly recommended.

The termination of CAN-Bus № 1 and № 3 has to be done externally.

3.1.3.6 SLAVE MODULE COMMUNICATION, CONNECTOR CN106

Slave C, Slave 5 module communication is done via an RS485 interface. The interface is
not optical isolated, optical isolation is implemented on the slave modules; communication
baud rate is 19200 Bd. Single cell voltages, temperature values and commands for bypass
resistors are communicated.
Connector pin assignment / View on the pins:
1 4
1 BUSA 4 BUSB
2 5
2 5VNET 5 FAIL
3 GND 6 Shield 3 6

Nomenclature:

5VNET Slave communication supply 5 V +40/-5 %, 350 mA max.

GND Ground
BUSA, RS485 bus lines

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BUSB
Shield cable shield
FAIL Input for failure signals from any slave module caused by over
temperature on any slave module or by overvoltage of > 4.4V at any
single cell for longer than 1 second;
Activated by voltage < 2.4 V, input resistance 22 kΩ;
all FAIL outputs of all slave modules are connected together, a 5V/1mA-
current source must be realized with a resistor of 4.7 kΩ … 5.1 kΩ
connected to 5VNET on the last slave module in the chain.

The use of shielded and twisted pair cable is strongly recommended.

3.1.3.7 RS232-INTERFACE

The RS232-interface for software development, firmware download and diagnostics is

realized with a DSUB-9 female connector at the front side with standard pinning using
signals TXD, RXD, DTR, RTS und GND.
An active DTR-signal (> 2V) generates a system reset (RESET Mode).
An active RTS-signal (> 2V) in connection with reset leads the XC167 into bootstrap
mode.
1 – DCD
Connector pin assignment:
2 – RXD
3 - TXD
4 – DTR
5 – Ground
Masse
1 6 – DSR
5 6 7 – RTS
9 8 – CTS
9 - RI
Remark:
Is the serial Interface for monitoring used, the DTR signal line (Pin 4) should inactive set
or not connect (to prevent to keep the processor in the reset state). For a safe inactive
DTR signal put DTR signal line to Ground (e.g. EMC problems).

3.1.3.8 ETHERNET- INTERFACE

The Ethernet-interface is realized as 10/100 Base TX RJ45 tab-down 8-pin with internal
magnetics at the front side; the connector is suitable for AutoMDI(X). On both sides of the
jack a status-LED is placed.

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green LED, left RJ45 yellow LED, right

link active Jack speed

3.1.3.9 INTERNAL INTERFACES

For software development and test purposes only there are interfaces on the board, which
are accessible only with opened case:
- JTAG-interface to XC167-processor
- JTAG-interface to AT91- processor
- RS232-interface to AT91- processor
- USB-interface to AT91- processor
These interfaces are of no concern for the user and must not be operated for any purpose.

3.1.3.10 LEDS

There are 5 + 2 LEDs at the front side right of the RS232-jack with software dependent
meanings.

3.1.4. ELECTROMECHANICS

The supply- and the I/O-interfaces are realized with the MCP 2.8 mm interconnection
system by TYCO-AMP. The tab housing cavities mate with Junior Power Timer crimp
contacts without single wire seal with maximum wire size of 2.5 mm².
TYCO-AMP order for the connector:
- TYCO Fem-Cable-Connector 21POL: 1-967625-2
- TYCO Fem-Cable-Connector 6POL: 1-965640-3
- TYCO Fem-Cable-Connector 9POL: 1-967621-4

TYCO-AMP order numbers for JPT-contacts spare parts

(loose piece, ‘x’ and ‘y’ depend on material and finish):
- 1.0…2.5 mm² x-927777-y
- 0.5…1.0 mm² x-927779-y
- 0.2…0.5 mm² x-927776-y
- extraction tool 1-1579007-6

ATTENTION:
The tab housings are not coded. Take care to avoid misconnections of tab housings
with same pin count.

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3.1.5. SUMMARY MASTER CONNECTORS

TYCO Connector Pinning Summary

Supply Outputs Inputs Current CAN Slave Comm.

CN101 POWER

1 KL30 4 KL15 7 KL31

2 KL30 5 KL15S 8 KL31
3 KL30 6 EMSRET 9 KL31

CN102 OUTPUTS

1 REL1A 4 REL1B 7 REL2A 10 REL2B 13 KL31 16 PWMO 19 AOUT

2 SWO1 5 KL31 8 SWO3 11 KL31 14 SWO5 17 KL31 20 SWO7
3 SWO2 6 KL31 9 SWO4 12 KL31 15 SWO6 18 KL31 21 SWO8

CN103 INPUTS

1 OIN1 4 OIN2 7 7V / 10 SS200 13 FIN1 16 FIN2 19 KL31

12V
2 DIN1 5 DIN2 8 DIN3 11 DIN4 14 IConst1 17 IConst2 20 KL31
3 AIN1 6 AGND 9 AIN2 12 AGND 15 AIN3 18 AGND 21 AIN4

CN104 CAN2 Sensor connection

1 7V / 12V 4 KL31 7 CAN2H

2 S1 / OVC 5 S2 / AGNC 8 CAN2L
3 K1 / SIG 6 K2 / 9 Shield
REF2V5

CN105 CAN1 + CAN3

1 CAN1H 4 CAN3H
2 CAN1L 5 CAN3L
3 Shield 6 Shield

CN106 SLAVE Communication

1 BUSA 4 BUSB
2 5VNET 5 FAIL
3 GND 6 Shield

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3.1.6. ELECTRICAL SPECIFICATION

Supply Condition min typ max Unit
Usuppsl Sleep Mode, Master OFF, KL 30 6.0 28.0 V
Usuppop Standby/Operating, Master ON, KL 9.0 28.0 V
30, KL 15 ON
Usuppdr Voltage Real Time Clock Data 2.0 V
Retention
tret RTC data retention time with no 12 h
KL30 supply
Isuppsl Sleep Mode, mA
KL15 OFF, CAN-Wakeup OFF
@12V Master4 0.5 0.6 0.7
@12V Master 4.5 7.0 8.0 9.0
Isupp Standby, mA
no communication,
no output activated
@12V Master4 100 150 200
@12V Master 4.5 110 160 210
Isupp Operating, mA
CAN & RS485 communication,
no output activated
@12V Master4 200 250 300
@12V Master 4.5 210 260 310
Isuppmax Operating 11.5 A
maximum load input current
CAN and Slave communication
All Outputs ON

3.1.7. HOUSING

The housing is made of two parts of tinned and powder coated steel plate, degree of
protection IP30 (apertures < 2.5 mm), total size approximately 120 x 230 x 36 mm
(without connectors).
Device mounting with 6 screws or bolts M3;
Drilling plan: 214.7
49.75
49.75

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Provide a space of min. 180 x 230 x 40 mm for the device with all connectors plugged.

3.1.8. ENVIRONMENTAL CONDITIONS

Operating temperature: -20°C ... +70°C

Storage temperature: -20°C ... +80°C
Humidity: max. 95% not condensing
EMC: EN 61000-6-1:2007; EN 61000-6-3:2007

3.1.9. CERTIFICATIONS

The BMS MASTER (in combination with other battery components) is in compliance with
following legal regulations:
- RoHS directive
- CE

3.2 MEASUREMENT OF CURRENT

3.2.1. VAC-SENSOR

The standard current sensor VAC T60404 M4645 X201 is mounted on a board VAC_PCB.
The current sensor works in two ranges:
1. -2A ...+2A
2. -100A ... +100A
For measuring current higher than 100A a current divider is needed. For the MASTER the
lower current range (-2A …..+2A) is basically not usable.
VAC-sensor connections and dimensions

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48.00

PTSA25-6

25.00
6 LC2
do not connect
5 LC1
Sense 1 4 S1
Sense 2 3 S2
Compensation 1 2 K1
Compensation 2 1 K2

54.00

3.2.1.1 CONNECTION TO THE MASTER

The picture shows the wiring between the Current sensor

VAC4645
VAC_PCB board and connector

LC2
LC1
S1
S2

K1
K2
CN104 on BMS_MASTER. 6 5 4 3 2 1

Wire gauge must not exceed 0.5 mm² (AWG20).

Total wiring length should be kept as short as possible. LiYCY- TP 2x2 0,25mm² CAN 2
K1 & K2 twisted
S1 & S2 twisted

1 2 3 4 5 6 7 8 9
7V
S1
K1
KL31
S2
K2
CAN2H
CAN2L
Shield
Master04 - CN 104

Current Direction:
The BMS measuring system interprets a negative current as a discharge current
and a positive one as a charge current. The load wiring has to be installed
accordingly.If necessary the measured current flow direction may be inverted by
interchanging the signal cables pairwise (K1 vs. K2 AND S1 vs. S2).Attention:
changing only one cable pair may result in sensor damage.

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3.2.1.2 CURRENT DIVIDER 5:1

The current divider is to be used together with the 100A current sensor from Vacuum-
schmelze in applications with currents up to 500 A. The sensor’s low current range cannot
be used with the divider.
The divider consist of three bended and bolted down copper bars of same length but
different width, which will lead only one fifth of the total current though the sensor. When
only one broad bar is bolted down, it becomes a 3 : 1 divider, maximum current then is
300 A.

Current
Sensor

Current

Sensor

Current direction for positive values

The divider may be mounted mirror inverted. Before remounting the divider take care to
clean all the contacting areas of the copper bars very well with finest emery cloth and
possibly treat them with a proper anticorrosive mean for copper. The M3-screws have to
be tightened thoroughly.
The 8.5mm-holes may be used to fasten the divider directly on the bolts of a KiloVac
relay; but some washers have to be used to avoid collision with the relay corpus.

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If the current divider is wrongly calibrated, the switch-off current may

not be reached. In this case there will be no safety switch-off! Due to
the electromechanical uncertainties the current divider should only be
used in prototypes and testing.

3.2.2. BAT-S 1000 1U SENSOR

The Current sensor BAT-S1000 1U is shunt based sensor with isolated CAN interface. Air
and creepage distances provide isolation up to 1500 VDC. Additionally the sensor has a
quasi-synchronous voltage measurement interface and an internal temperature
measurement. The CAN2 interface of the MASTER is reserved for this sensor.
Range current: ±1000A (rated); ±1200A (max.)
Range voltage: ±1000V (rated); ±1200V (max.)

3.2.2.1 SYSTEM INTEGRATION

Connector voltage

Voltage Ground Level

Connector current path

Connector Power/CAN

The sensor may be connected either in the positive current path or in the negative path as
well. The Ground Level of the voltage potential is the shunt.

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3.2.2.2 MEASUREMENT VALUES

current direction

Current Measurement:
 Is A connected to positive and B connected to negative the measurement values is
positive.
 Is A connected to negative and B connected to positive the measurement value is
negative.

Voltage Measurement:
 Is the current sensor mounted in minus path of the battery and the voltage
connector connected to battery plus the measurement value is positive.
 Is the current sensor mounted in plus path of the battery and the voltage
connector connected to battery minus the measurement value is negative.

3.2.2.3 CONNECTING THE BAT-S 1000 1U SENSOR TO MASTER

Molex MicroFit 10-pol (view of the connector at the device) CN104 Tyco 9-pol

10 9 8 7 6 1 VCC  1 7V /12V
Shield NC CAN L CAN L GND 6 GND  4 KL31 1 4 7
7 CAN-L  8 CAN2L 2 5 8
5
Shield
4
Term H
3
CAN H
2
CAN H
1
VCC
2 CAN-H  7 CAN2H 3 6 9
9 Shield

Shorting the Pin 3 and Pin 4 provides a 120Ω-bus termination, necessary only with long
cables as the MASTER-CAN2-interface has termination inside. For CAN-H and CAN-L usage

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of twisted pair cables is required. The shield is connected to the BMS Master only.

3.2.2.4 CONNECTING THE BAT-S 1000 1U SENSOR FOR VOLTAGE MEASUREMENT

For voltage measurement the 2-pole MicroFit-connector is used. The two pins are shorted
internally. The voltage measurement uses one side of the shunt as reference (see
3.2.2.1).

3.2.2.5 TECHNICAL SPECIFICATION BAT-S 1000 1U - SENSOR

Environmental Temp Range -40 / +85 °C

Current Meas. Range nominal ± 470 A
Current Meas. Range ext. ± 1200 A, max. 5 minutes
Offset ± 15 mA
Physical Resolution 15 mA nominal, 37 mA extended
Voltage Meas. Range nominal ± 1200 V
Physical Resolution 50 mV
Temperature Meas. Range -40 / +105 °C
Physical Resolution 0.1 °C

For further and detailed information on the BAT-S1000 1U refer to the product
specification by ACTIA I+ME GmbH.
The maximum current depends on the mechanical position and the heat dissipation
conditions. The high current cables connected provide a heat sink for the shunt. The
connections have to be made with a minimum contact resistance. The cable have to
be over dimensioned to achieve proper heat dissipation.
The inner heat resistance is approx. 2 K/W, the resistance is approx. 25µΩ and the
nominal power is approx. 15W. Ensure that under worst case operating conditions a shunt
temperature of 85 °C is not exceeded.

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3.2.3. IVT-B SENSOR

The current sensor IVT-B by Isabellenhütte is a shunt sensor with isolated CAN interface.
Air- and creepage distances are sufficient for 500 VDC.
Additionally the sensor has a quasi-synchronous voltage measurement interface and an
internal temperature measurement. The CAN2 interface of the MASTER is reserved for this
sensor.
Range current: ±320A (1500 A for 1 second)
Range voltage: ±620V

3.2.3.1 SYSTEM INTEGRATION

The sensor may be connected either in the positive current path or in the negative path as
well.

3.2.3.2 CONNECTING THE SENSOR TO MASTER

Molex MicroFit 8-pol (view of the connector at the device)

1 Usupp to 1 7V0
1 4 7
5 GND to 4 KL31
6 CAN-L to 8 CAN2L 2 5 8

2 CAN-H to 7 CAN2H 3 6 9
9 Shield

CN104 Tyco 9-pol

IVT-B-signals OCS und SYNC are not used. Shorting the CAN-T-lines provides a 120Ω-bus

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termination, necessary only with long cables as the MASTER-CAN2-interface has termination
inside. For CAN-H and CAN-L usage of twisted pair cables is required. The shield is connected
to the BMS Master only.

3.2.3.3 CONNECTING THE SENSOR FOR VOLTAGE MEASUREMENT

For voltage measurement the 2-pole MicroFit-connector is used. The two pins are shorted
internally. The voltage measurement uses one side of the shunt as reference voltage.

3.2.3.4 TECHNICAL SPECIFICATION IVT-B-SENSOR

Environmental Temp Range -40 / +85 °C

Current Meas. Range nominal ± 320 A
Current Meas. Range extended ± 1500 A
Offset ± 50 mA, ± 250 mA ext.
phys. Resolution 10 mA nominal, 40 mA extended
Voltage Meas. Range nominal ± 620 V
Offset ± 100 mV
Physical Resolution 30 mV
Temperature Meas. Range -40 / +105 °C
Physical Resolution 0.1 °C

For further and detailed information on the IVT-B-sensor refer to the product specification
by Isabellenhütte.

The maximum current depends on the mechanical position and the heat deviation
conditions. The connected high current cables are the heat sink for the shunt and the
connections have to be made with a minimum contact resistance. The cable has to be over
dimensioned to achieve proper heat deviation.
The inner heat resistance is 2 K/W, the resistance is 100 µΩ and the nominal power is
15 W. Be sure even under worst case conditions not to exceed a shunt temperature of
85°C.

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3.3 INSULATION MONITORING IR155-3204

The BMS MASTER is prepared for the cooperation with the Bender insulation monitor
IR155-3204.

Only one insulation monitoring device may be used in each interconnected

system. When insulation or voltage test are to be carried out, the device shall be
isolated from the system for the test period.
IR155-3204 Measurement Output Highside
 Measurement of insulation resistance with modified DCP method
o Response time <2s for first estimated insulation resistance
o Response time <20s for measured insulation resistance
 Detection of ground faults and lost ground line.
 Short protected outputs for:
o Fault detection (high side output)
o Measurement Value (PWM 5…95%) & Status (f=10..50Hz) at high and
inverted low side output

Connector XLA+
Pin 1+2 L+ Line Voltage

Connector XLA-
Pin 1+2 L- Line Voltage

Connector XK1A
Pin 1 KL31b Electronic ground
Pin 2 KL15 Supply voltage Master 4
Pin 3 KL31 Chassis ground
Pin 4 KL31 Chassis ground (sep. line) Inputs
ICONst1

ICONst2
SS200

Pin 5 M HS Data Out, f, PWM (high side)

AGND

AGND

AGND
OIN1

OIN2

KL31
KL31
DIN1

DIN2

DIN3

DIN4
AIN1

AIN2

AIN3

AIN4
FIN1

FIN2

Pin 6
7V

Pin 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Pin 8 OK HS Status Output (high side)

L-
1 2

Pilotline
PT100 PT100
L+

2 1 2 1

XLA- XLA+
XK1A

KL31
1 KL31b
2 KL15 Ext. 12V
3 E
4
KE
5 MHS
6
7
A - ISOMETER® iso-F1 IP155-3204 8 OKHS

KL31

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3.4 THE HARDWARE OF SLAVE_C

This chapter describes the following aspects of the BMS SLAVE_C hardware:
 external inputs and outputs
 internal structure
 environmental requirements

3.4.1. FUNCTIONAL OVERVIEW

The slave module covers the following functions:

 communication with the master module
 measuring the voltages of the single cells
 balancing different cell charge states on behalf of master messages
 detecting the mechanical status of one or more cells
 measuring of temperatures
 detecting of over voltages (second level detection)
 messaging fault conditions to the master unit to switch off the main relay

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3.4.2. BLOCK DIAGRAM

Power
Single Cell Interface
Supply

2nd Level Over Additional

Voltage and
voltage Balancing Balancing
Temperature
and temperature Resistors Resistor
Measuring
Detection Interface

Isolated Serial RS 485-

Communic.
Interface to BCS
CPU
Master

Config. Long Time External

Interface Watchdog Memory

3.4.3. PRINTED CIRCUIT BOARD AND CONNECTORS

Single Cell Interface

12 1

PIN 1
InCircuit progr.
Interface

PIN 1
2nd serial Port
1 1

PIN 1
Configuration
1 Interface
1 PIN 1
Sensor Interface

PIN 1 RS 485 Interface

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BMS Master 4 / 4.5

3.4.4. FUNCTIONAL DESCRIPTION

3.4.4.1 POWER SUPPLY

The CPU and peripherals are supplied by linear regulated 5VDC derived from the mid cell
voltages number 6 to 8, min. 5.4V to 12.6V, connected to cell contacts 7 … 10.
The power supply reference level is always at cell contact 7.

3.4.4.2 SINGLE CELL INTERFACE

The interface to the single battery cells is realized as 12 edge connector pads suitable for an
edge connector ZEC1, 0/12 made by Phoenix Contact (Order No. 18 93 78 2), additionally
12 solder pads in a 3,5mm-pitch for 10 cells with 11 connections; order with contact row at
top of board; pin1 is the last one right of the coding slot.

12 11 10 9 8 7 6 5 4 3 2 1
cell 10 +

cell 10 –
cell 9 +

cell 8 +

cell 7 +

cell 6 +

cell 5 +

cell 4 +

cell 3 +

cell 2 +

cell 1 +
cell 9 –

cell 8 –

cell 7 –

cell 6 –

cell 5 –

cell 4 –

cell 3 –

cell 2 –

cell 1 –
n.
c.

The edge connector provides pre-mating contacts to assure the proper connecting
sequence. Do only connect the single cell voltages to the edge connector, when it is not
plugged.

Attention:
If NOT using the edge connector, the single cells have to be connected in a
proper sequence to avoid damage to the multiplexers on the slave module. The
cells can be connected in two ways:
- either by soldering the wires directly into the pad holes
- or by using pin rows in 3.5 mm pitch in conjunction with pluggable miniature spring
cage clamps (e.g. PHOENIX CONTACT PST 1,0/12-3,5 (Order No. 19 45 19 3) with
clamps FK-MPT 0,5/12-ST-3,5 (Order No. 19 14 03 0))
For Phoenix connector details see product catalogue or visit www.phoenixcontact.com.
The following sequence must be strictly observed:
1. contact 12
Z10+

Z1-

2. contact 6
3. contact 9
4. contact 2
5. contact 7 10-cell-wiring
12 11 10 9 8 7 6 5 4 3 2 1
6. the remainder in any order

To remove the slave from the battery, disconnect in

reverse order.

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3.4.4.3 CONNECTING LESS THAN 10 CELLS

Cell-Contact 12 11 10 9 8 7 6 5 4 3 2 1
ONLY with NOT modified hardware. The connections between the
single contacts as depicted must be realized on the edge connector
10 Cells Z10 Z10- Z9- Z8- Z7- Z6- Z5- Z4- Z3- Z2- Z1- n.c.
+ Z9+ Z8+ Z7+ Z6+ Z5+ Z4+ Z3+ Z2+ Z1+
9 Cells Z9+ Z9- Z8- Z7- Z6- Z5- Z4- Z3- Z2- Z1- n.c.
Z8+ Z7+ Z6+ Z5+ Z4+ Z3+ Z2+ Z1+
8 Cells Z8+ Z8- Z7- Z6- Z5- Z4- Z3- Z2- Z1- n.c.
Z7+ Z6+ Z5+ Z4+ Z3+ Z2+ Z1+
7 Cells Z7+ Z7- Z6- Z5- Z4- Z3- Z2- Z1- n.c.
Z6+ Z5+ Z4+ Z3+ Z2+ Z1+
6 Cells Z6+ Z6- Z5- Z4- Z3- Z2- Z1- n.c.
Z5+ Z4+ Z3+ Z2+ Z1+
5 Cells Z5+ Z5- Z4- Z3- Z2- Z1- n.c.
Z4+ Z3+ Z2+ Z1+
ONLY WITH MODIFIED HARDWARE.The dashed connections are
realized on the board. When connecting only three cells, the
connection between contacts 11 and 10 must be realized outside
on the edge connector.
IMPORTANT: Connect Z4+ rsp. Z3+ always to contact 12 and
connect Z1- always to contact 6
Cell-Contact 12 11 10 9 8 7 6 5 4 3 2 1
4 Cells Z4 Z4- Z3- Z2- Z1- n.c.
+ Z3+ Z2+ Z1+
3 Cells Z3 Z3- Z2- Z1- n.c.
+ Z2+ Z1+

ATTENTION: Connecting 5 or more cells to a modified hardware for 3 or 4 cells will

destroy the hardware and possibly the battery, too.
Z10+

Z1-

Z6+
Z8+

Z1-
Z1-

10-cell-wiring 8-cell-wiring 6-cell-wiring

12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
Z9+

Z1-

Z5+
Z7+

Z1-
Z1-

9-cell-wiring 7-cell-wiring 5-cell-wiring

12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

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Hardware Manual
BMS Master 4 / 4.5

3.4.4.4 BALANCING RESISTORS

To achieve properly balanced cells a resistor of 68Ω/0.5W can be switched parallel to each
single cell to reduce the charging current with appr. 60 mA. The status of each of these
switches is visualised with 10 LEDs. Additionally, the centred four LEDs show the binary
coded Slave address after powering on the
Bit 3 Bit 2 Bit 1 Bit 0
Slave
when connecting the cell interface plug.
See sketch beside.
All balancing resistor connection points as
well as the cell connection points are lead
to Beispiel 1: 0 0 1 1 = Adresse 3
Beispiel 2: 0 1 1 0 = Adresse 6
a 22-pin micro-match connector. This gives
the possibility either to connect additional
balancing resistors ≥ 47 Ω in parallel to
increase the charging currents up to 150mA
or to connect external transistors with
appropriate resistors to increase the charging current
up to 1A. In both circumstances the external balancing must be realized on a separate PCB
with adequate power dimensioning.

3.4.4.5 SERIAL RS 485 INTERFACE AND ERROR SIGNALLING

The optically isolated RS485 interface is realized with air and creeping distances of 10 mm
at least. The interface is supplied from the BMS master unit with 5 VDC.
The RS485 pins are protected against electrostatic discharge up to 15 kV (human body
model).
The interface is a 12-pin cage clamp connector (PHOENIX PTSA 2.5) with following
assignment:

pin signal
12 FAILn (Fault Messaging Interface,
11 FAILn see next chapter)
10 NETGND
9 5V_NET
8 BUS_B
7 BUS_A
6 NET_Shield 1 Each shield input may be connected separately
5 NET_Shield 2 to NETGND via resistor and/or capacitor in 0805
4 NETGND form factor below the cage clamp connector on
PCB bottom side.
3 5V_NET
Default population: both shields contacts are
2 BUS_B
shorted and connected via 10kΩ || 10 nF to
1 BUS_A
NETGND

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Pin numbers counting from left to right with the PCB battery interface on top.
See chapter 3.4.3 page 34

Due to double pin assignment every signal may be connected twice to achieve proper
connections with one wire per cage only. Wire gauge must not exceed 0.5 mm². The
use of shielded twisted pair cable for the serial connection is strongly recommended
when the cabling distances are longer than a few centimeters.

Example connecting several slaves to one master see 2.3 Schema “Slaves”.

3.4.4.6 CONFIGURATION INTERFACE

Each SLAVE_C has to have its own slave address number to be identified by the MASTER.
The SLAVE_C may be configured via this port without being connected to any other power
supply. The configuration data will be stored in the serial E²ROM.

Connector assignment:
- Pin 1: 5V
- Pin 2: Datachannel (RX/TX)
- Pin 3: GND
See chapter 3.4.3 page 34

3.4.4.7 SENSOR- AND PTC-INTERFACE

An external 12-bit ADC measures the temperature of the connected NTC which has to be
according to the software an EPCOS B57703M0303G040 with a cold resistance of 30 k at
25°.
The voltage of the PTC is measured by the internal 8-bit AD-channel 0. These inputs may be
used to detect over-temperatures in each single cell. For this purpose each cell is supplied
with a PTC connected serially in a chain. The total cold resistance of all PTCs must be less
than 10 k. A proper example for a PCB would be EPCOS B59701C0070 in 0805-size to
detect over-temperatures above 70 °C. The total cold resistance of a chain of ten PTCs will
be less than 5 k at 25 °C.
If only one single PTC becomes high resistive due to over-temperature in one of the cells
(the total chain resistance must exceed 22 kΩ), the FAILn–output will be activated and the
event is signalled to the MASTER.
The PTC-interface for over-temperature is always active while there is communication traffic
on the RS485 interface and two seconds longer. The active state of the PTC-interface cannot
be changed by parameterizing. To disable the temperature control a resistor of 100 to 1000
 has to be connected to the PTC port.
The interface for temperature measuring and over-temperature control is realized as 6 cage
clamps (PHOENIX PTSA).

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Connector Assignments, 1 Temp Sensor 1 (NTC)

2 Temp Sensor 1 (NTC)
Pin numbers counting from
3 Temp Sensor 2 (NTC)
top to bottom with the 4 Temp Sensor 2 (NTC)
PCB battery interface on top. 5 Overtemp PTC
6 Overtemp PTC
See chapter 3.4.3

ATTENTION: Via the cell voltages the temperature sensor is

connected to the battery cells. So its potential to GND may exceed
several hundreds of Volts depending on the number of cells.
A sufficient insulation of the sensor and its cables is
Electricity Hazard
imperative!

3.4.4.8 SIGNALLING LEDS

Two signalling LEDs are connected to CPU-ports. 10 LEDs show the status of the balancing
resistors. The centred four of those display the Slave address.

3.4.4.9 2ND LEVEL VOLTAGE DETECTION

All single cell voltages are controlled by “second level security chip” activating the isolated
fault port when at least one cell voltage exceeds 4.40 V for longer than 1 second (other cut-
off voltages are possible depending on the selected chip type; feasibility depends on
quantities). This circuitry is always active and cannot be deactivated, though for test
reasons the fault output may be activated by software.

3.4.4.10 FAULT MESSAGING INTERFACE

The fault messaging interface is isolated and realized as an open collector output referenced
to NETGND level. Current sink capability is appr. 2 mA.
The FAILn–lines are to be connected in parallel from one slave module to the next resp. to
the appropiate master input (MASTER), so all FAILn–outputs are OR-wired together.
At the end of the Slave chain the FAILn-line has to be terminated with a resistor of 4.7 kΩ
or 5.1 kΩ to the +5VNET.

Connection sketch for the FAILn-lines (MASTER with SLAVE_C):

Master Module 1. Slave Module 2. Slave Module 3. Slave Module Letztes Slave Module
FAIL_IN Failn 1 Failn 2 Failn 1 Failn 2 Failn 1 Failn 2 Failn 1 Failn 2

GND GND GND GND GND GND GND GND GND

5V NET 5V 5V 5V 5V 5V 5V 5V 5V 4,7 kΩ … 5,1 kΩ

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BMS Master 4 / 4.5

3.4.4.11 LONG TIME WATCHDOG

On the Slave PCB a slow RC-generator (approximately 3 Hz) clocks a multistage divider IC
that has to be reset periodically by the MASTER. If no reset happens, e.g. caused by an
unsupplied MASTER, the divider IC cuts off all balancing circuitry to prevent totally
discharging of the battery.
The time-out will appear app. 40 minutes after the last reset.

3.4.4.12 INTERFACE ISOLATION

The interfaces to MASTER, RS485- and FAIL-interface, are optically isolated with air and
creepage distances of ≥ 10 mm, sufficient for voltages up to 1000 VDC at pollution level 1.

ATTENTION: The mounting holes do NOT comply with the

requirements of 10 mm air and creepage distances for high voltages.
If the slave modules are used under these conditions
non-conductive screws and/or bolts must be used.

Electricity Hazard

3.4.5. MECHANICAL DIMENSIONS

 PCB size 75 x 91.5 mm;
 four mounting holes for screws M3,
o symmetrically arranged one on each corner, distances 67 x 83,5 mm
 mounting height on top ≤ 14 mm including connectors.
 mounting height on bottom ≤ 7 mm including connectors.
 mounting height with no connectors (cables soldered directly) ≤ 4 mm on top and
bottom.

3.4.6. POWER SUPPLY AND CONSUMPTION

Operating voltage: 5.4 to 12.6V (by 3 cells of controlled battery)

Current consumption:
Average current consumption with BMS-master active, no bypass active ≤ 10 mA
Peak current consumption while transmitting data to master unit ≤ 20 mA
Standby/sleep with BMS-MASTER inactive ≤ 0.01 mA
Bypass current per cell with no external bypass resistor (voltage dependent) 50 ... 62
mA

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BMS Master 4 / 4.5

3.4.7. ENVIRONMENTAL

Operating temperature: -20°C ... +70°C (t.b.d)

Storage temperature: -40°C … +85°C
Humidity: max 95% not condensing.

At pollution level 1 the Slave C may be operated up to 1000V

At pollution level 2 the Slave C may be operated up to 650V
At pollution level 3 the Slave C must not be operated

At applications above 650 VDC non-conducting screws have to be used fixing the module
mechanically

Environmental tests:
 Temperature Test ISO16750-4
o 24 h at – 40 °C
o 96 h at +85 °C
o 4 x cycle with -40°C und 85°C
 Insulation Test: 300GΩ / 5kV DC
 EMC: EN 55022 and EN 55024 (industrial environment)

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3.5 THE HARDWARE OF SLAVE_5

The BMS SLAVE_5 is part of the modular Battery Monitoring System by ACTIA I+ME. With
one SLAVE_5-Modul from 5 … 10 single lithium cells may be controlled; up to 31 SLAVE_5-
Modules may be connected to one MASTER unit; the maximum amount of cells is 310.

SLAVE_5 and SLAVE_C are substantially identical with following differences:

- electronic board casted in a plastic case
- different connection technology; MicroFit crimp connectors instead of cage clamps
- Different temperature sensor system: NTC’s with 10 kΩ instead 30 kΩ @25°C
- separate piggyback balancing board with lower resistor values for higher balancing
currents

SLAVE_5-module with balance board, casted

Top: sense lines to cell voltages (black – 9 x blue – red)
Two temperature sensors (grey) and one PTC-dummy (blue)
Bottom: RS485-cable to MASTER unit

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BMS Master 4 / 4.5

3.5.1. FUNCTIONAL OVERVIEW

The SLAVE_5 modules cover following functions:

 Communication with master module
 Measurement of single cell voltages
 Balancing of different cell charges
 Control of the mechanical integrity of one or several cells
 Measurement of cell temperatures
 Detection of cell overvoltage (second level detection)
 Transmitting of faults to the master module to cut off the main contactors

3.5.2. BLOCK DIAGRAM

Power
Single Cell Interface
Supply

2nd Level Over Additional

Voltage and
voltage Balancing Balancing
Temperature
and temperature Resistors Resistor
Measuring
Detection Interface

Isolated Serial RS 485-

Communic.
Interface to BCS
CPU
Master

Config. Long Time External

Interface Watchdog Memory

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BMS Master 4 / 4.5

3.5.3. BOARD LAYOUT AND CONNECTIONS

Cell voltages and temp sensors Config-Interface

normal operation pin use configuration pin use

1 cell 1+/2- 13 cell 1- 1 n.c. 13 n.c.

2 cell 3+/4- 14 cell 2+/3- 2 n.c. 14 n.c.
3 cell 5+/6- 15 cell 4+/5- 3 n.c. 15 n.c.
4 cell 7+/8- 16 cell 6+/7- 4 n.c. 16 n.c.
5 cell 9+/10- 17 cell 8+/9- 5 n.c. 17 n.c.
6 PTC-GND 18 cell 10+ 6 n.c. 18 n.c.
7 PTC 19 do not connect 7 n.c. 19 n.c.
8 NTC-GND 20 NTC-GND 8 n.c. 20 n.c.
9 NTC1 21 NTC2 9 n.c. 21 n.c.
10 n.c. 22 n.c. 10 GND 22 5V-CFG
11 n.c. 23 n.c. 11 TXD 23 CFGRX
12 n.c. 24 n.c. 12 RXD 24 n.c.

Connections for single cell voltages and temperatures in normal operation

rsp. config connection for setting up
pin 1
Connection for external
balancing resistors

pin 1

pin 1 pin 1

dual RS485 connection to master

module rsp. neighboured slave
module

RS485-Interface to Master
Pin use for both connectors

1 FAIL_ 4 BUS-B
2 NETGND 5 BUS-A
3 5VNET 6 Shield

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3.5.4. FUNCTIONAL DESCRIPTION

3.5.4.1 SUPPLY

CPU and peripherals are supplied with a linear regulator with 5V DC out of cells 6, 7 und 8,
(connector pins 3, 16, 4, 17) from 5.4 to 12.6 VDC.
The internal reference point for all voltages is always connector pin 3; except the
isolated region of the RS485 interface which is referenced to NETGND.

3.5.4.2 CONNECTING BATTERY CELLS

The interface to the single battery cells is part of the 24-pole connector. Only pins 1 to 9
and pins 13 to 18 and pins 20/21 may be used connecting cell voltages and temp sensors.
Slave_5 pin assignment 24-pole connector
view on cable side

standard assignment for cell voltages and temperature sensors

21 20 19 18 17 16 15 14 13
24 23 22
NTC2 NTC-GND (testpoint) Z10+ Z8+/9- Z6+/7- Z4+/5- Z2+/3- Z1-

9 8 7 6 5 4 3 2 1
12 11 10
NTC1 NTC-GND PTC PTC-GND Z9+/10- Z7+/8- Z5+/6- Z3+/4- Z1+/2-

3.5.4.3 CONNECTING LESS THAN 10 CELLS

For connecting less than 10 cells, the non-existing cells have to be replaced by shorting
wires according following scheme:

Pin 18 5 17 4 16 3 15 2 14 1 13
10 Z10+ Z9+/10- Z8+/9- Z7+/8- Z6+/7- Z5+/6- Z4+/5- Z3+/4- Z2+/3- Z1+/2- Z1-
Cells
9 Z9+ Z8+/9- Z7+/8- Z6+/7- Z5+/6- Z4+/5- Z3+/4- Z2+/3- Z1+/2- Z1-
Cells
|-----------|
8 Z8+ Z7+/8- Z6+/7- Z5+/6- Z4+/5- Z3+/4- Z2+/3- Z1+/2- Z1-
Cells
|-----------| |---------|
7 Z7+ Z6+/7- Z5+/6- Z4+/5- Z3+/4- Z2+/3- Z1+/2- Z1-
Cells
|-----------|----------| |---------|
6 Z6+ Z5+/6- Z4+/5- Z3+/4- Z2+/3- Z1+/2- Z1-
Cells
|-----------|----------| |---------|---------|
5 Z5+ Z4+/5- Z3+/4- Z2+/3- Z1+/2- Z1-
Cells
|-----------|----------| |---------|---------|---------|

As the crimp contacts are not suitable for crimping two or more wires the short circuits
have to be realized outside the connector housing. The shorting wires have to be as short
as possible; best by soldering and insulated with heat shrink.

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3.5.4.4 SENSOR- AND PTC-INTERFACE

According to the slave software an NTC-resistor with a cold resistance of 10 k at 25 °C

has to be used as temperature sensor.
To supervise the cells on over temperature a PTC-resistor may be mounted on each cell
surface. All PTCs will have to be connected in series. The cold resistance of the chain must
be smaller than or equal 10 k. A suitable PTC e.g. is EPCOS B59701C0070 in size 0805
to detect temperatures above 70°C. A chain of 10 of those PTCs would have a resistance
of less than 5 k at 25°C.
If only one PTC in the chain becomes high resistant because of over temperature (the
total chain resistance must exceed 22 kΩ), the FAILn-output will be activated and
signalled to the master module. The PTC-over temperature interface is active while there
is data traffic on the RS485-interface and 2 seconds further on. This time delay cannot be
altered by parameters.
When this supervision interface shall not be used, the PTC chain must be replaced by a
single resistor of 100 to 1k. The temperature and over-temperature interface is part of
the 24-pole connector. Pin assignment see above: pins 6 and 7 for the PTC’s and pins 8
and 9 rsp. 20 and 21 for the NTC’s.

ATTENTION: Because the slave module is supplied out of the battery cells,
the temp sensors are connected with a cell voltage as well. The voltage
difference between slave modules and sensors may exceed some hundreds
of volt depending on total battery size!
Electricity Hazard
A sufficient insulation of sensors and cables is mandatory!

3.5.4.5 BALANCING RESISTORS

Depending on the cell voltage, there are various slave 5 A module. The types are shown in
the following table:
Slave 5 Module Balance resistor Voltage range
balance current
cell type
Slave 5 LTO 20,5 Ohm U [mV]: 1500 … 2800
I [mA]: 73 … 137
Cell type: LTO cell
Slave 5 STD 45 Ohm U [mV]: 2800 … 4200
I [mA]: 62 … 93
Cell type: NCA cell

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The resistor values are adapted on the voltage range of the cell voltages. Thus an
optimum between maximum balance current and maximum board temperature is reached.
All resistor connection points rsp. all cell connection point are led to a 22-pole MicroFit-
connector, to give the possibility for balancing currents of up to 500 mA using an external
balancing resistor board or even only one resistor near every cell.

3.5.4.6 SERIAL RS 485 INTERFACE AND ERROR SIGNALLING

The RS485-interface is optical isolated with air and creeping distances of 10 mm at least.
The interface is supplied by the master with 5 VDC. The electrical reference point of the
interface is line NETGND.
The interface is ESD-protected up to 15 kV (human body model).

Pin assignment with view on the cable side of the connectors; the assignment is for both
connectors identical. With several slave modules in a system only one slave will be
connected directly to the master module, the remaining slave modules are connected one
to the next.
The pin assignment nomenclature corresponds to that of the

6 5 4
BMS MASTER.
Shield BUS-A BUS-B
Due to the dual connector layout each wire may be crimped
separately. The wire gauge must correspond with the selected
3 2 1
5V-NET NETGND FAIL crimp contact.

When the distances are longer than a few centimeters it is strictly recommended to
use shielded twisted-pair-cable e.g. LiYY 3x2tp.

The FAIL-interface is optically isolated and realized as open-collector-output referenced to

NETGND. The output may sink approximately 2mA.
The slave modules have to be connected in chain, all open-collector-outputs paralleled in
OR-function. At the end of the slave chain the interface has to be terminated with a
resistor of 4.7 kΩ or 5.1 kΩ to +5VNET.

Schematic sketch for FAIL-cabling (one MASTER and several SLAVE_5):

Slave 1 Slave 2 Slave n

__________________ ___________________ _________________

6 5 4 6 5 4 6 5 4 6 5 4 6 5 4 6 5 4
Shield BUS-A BUS-B Shield BUS-A BUS-B Shield BUS-A BUS-B Shield BUS-A BUS-B Shield BUS-A BUS-B Shield BUS-A BUS-B

3 2 1 3 2 1 3 2 1 3 2 1 3 2 1 3 2 1
5V-NET NETGND FAIL 5V-NET NETGND FAIL 5V-NET NETGND FAIL 5V-NET NETGND FAIL 5V-NET NETGND FAIL 5V-NET NETGND FAIL

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 to MASTER

3.5.4.7 2ND-LEVEL OVERVOLTAGE DETECTION

Every single cell voltage is supervised by a “second level security chip”, activating the
FAIL-output if only one cell voltage exceeds 4.4 V for more than one second (other threshold
voltages are possible, but the realization depends on quantity.
This circuitry is always active and cannot be deactivated, though it is possible to activate it by
software for test reasons.

3.5.4.8 LONG TIME WATCHDOG

A slow RC-oscillator with ca. 3 Hz clocks a multistage counter which has to be reset by the
master periodically. If the counter will not be resetted, all balancing resistors are cut off after
ca. 40 minutes to prevent a total discharge of the cells.

3.5.4.9 CONFIGURATION - ADDRESSING

To assign each SLAVE_5 a unique address number in a system a „capture/compare”-

processor-port is used. Each SLAVE_5 in a system must have an own address number for the
master to be allocated.
While being configured the slave has to be supplied via the configuration-interface and must
not be connected to battery cell voltages. Slave configuration must be done using configurator
SC-CONFIG2, a proper interface cable belongs to the configurator. Configuration data are
stored in the serial E²ROM.
Using accordant PC-software E2ROM data and thus the module address may be altered via the
2nd serial port.
The configuration interface uses 6 pins of the 24-pole connector; pins 10, 11, 12, 22, 23, 24
(see Chap. 3.5.3).
Using this connector as configuration interface, all other pins (1…9 und 13…21) must not be
used.

3.5.5. CONNECTING EXTERNAL BALANCE RESISTORS

External balance resistors may be mounted and connected directly at the cell contacts in
conjunction with an additional cable to the 22-pole connector. The cell voltage sense lines in
the 24-pole connector (see chap.3.5.3) are not affected.
Special care has to be taken on correct mounting and connecting the resistors to the cells,
as depending on cell number they have to be attached either to cathode or anode.
The resistor value must not be lower than 8.2 Ω, power rating must be greater than 2.5 W,
heat dissipation has to be adequate.
Together with the piggyback balance board a current of ~ 570 mA will be achieved with

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BMS Master 4 / 4.5

8.2 Ω and 4 V cell voltages.

When connecting external balancing resistors in applications with less than 10 cells it has to
be considered to adapt the schematics below relatively to line Z5+/Z6-. Those cells replaced
by a short connection (see 3.5.4.3) have to be removed from the schematics

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22pol Stecker 24pol Stecker

+
22pol Conn. 24pol Conn.

18 Z10+
1
Cell 10
R10 12
5 Z9+/10-
2
Cell 9
R9 13
17 Z8+/9-
3
Cell 8
R8 14
4 Z7+/8-
4
Cell 7
R7 15
16 Z6+/7-
24pol
R6 16
Cell 6 5

22pol
3 Z5+/6- SLAVE 5

R5 17
Cell 5 6

15 Z4+/5-
R4 18
Cell 4 7

2 Z3+/4-
R3 19
Cell 3 8

14 Z2+/3-
R2 20
Cell 2 9

1 Z1+/2-
R1 21
Cell 1 10

13 Z1-

Anschluss externer Balance-Widerstände an Slave 5

- Connecting external balance resistors to Slave 5

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The sense lines to the single cell voltages may be connected ONLY to the 24-pole connector;
external balance resistors may be connected ONLY to 22-pole connector. The pins 1 … 10 of
the 22-pole connector may be used only, when there is no other possibility to connect the
balance resistors directly to the cell contacts.

SLAVE_5 pin assignment 22-pole connector

view on cable side

assignment for cell voltages and external balance resistors

22 21 20 19 18 17 16 15 14 13 12
do not use R1 R2 R3 R4 R5 R6 R7 R8 R9 R10

11 10 9 8 7 6 5 4 3 2 1
do not use Z1+/2- Z2+/3- Z3+/4- Z4+/5- Z5+/6- Z6+/7- Z6+/7- Z7+/8- Z8+/9- Z9+

3.5.6. INTERFACE ISOLATION

The interfaces to MASTER, RS485- and FAIL-interface, are optically isolated with air and
creepage distances of ≥ 10 mm, sufficient for voltages up to 1000 VDC at pollution level 1.

ATTENTION: The mounting holes do NOT comply with the

requirements of 10 mm air and creepage distances for high voltages.
If the slave modules are used under these conditions
non-conductive screws and/or bolts must be used.

Electricity Hazard

3.5.7. MECHANICAL DIMENSIONS

 Module size 80.5 x 97 x 17 mm
 four mounting holes for M3-screws, symmetrically arranged in the corners, distances
67 x 83.5 mm

3.5.8. SUPPLY AND CURRENT CONSUMPTION

Supply voltage: 5.4 to 12.6 V (by three cells of the supervised battery)
Current consumption:

Average consumption with MASTER active, no balancing ~ 10 mA

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Peak consumption while communicating with MASTER ~ 20 mA

Stand-by/sleep-mode with MASTER inactive ≤ 0.03 mA
Balancing current per cell without external resistors (voltage dependent) 70 ... 90 mA

3.5.9. ENVIRONMENTALS

Humidity: max 95%, non-condensing

Working temperature: -20°C ... +70°C
Storage temperature: -40°C ... +70°C

At pollution level 2 the Slave may be operated at voltages up to 650 VDC

At pollution level 3 the Slave must not be operated
In applications with voltage differences > 650 VDC non-conducting screws (e.g. Nylon)
have to use for fixing the molded module.
Maximum insulation voltage must not exceed 1000 VDC.

Environmental testing:
 Temperature Test acc. ISO16750-4:
o 24 h at –40 °C
o 96 h at +85 °C
o 4 x Cycles at -40°C and +85°C
 Insulationtest: 300GΩ / 5kV DC.
 EMC: according EN 55022 and EN 55024 (industrial)

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BMS Master 4 / 4.5

3.6 THE HARDWARE OF SLAVE 6

Slave 6 is a part of the modular Battery Management System of ACTIA I+ME. The Slave 6
hardware consists of 3 different modules.
 1x SL6_CON module (control module) communication interface to the Master and
to the SL6_ANA modules
 Up to 32 SL6_ANA modules (analog module) monitoring 4…12 cells
 Up to 32 SL6_BAL modules (resistor modules) for passive cell balancing. The
balance modules are connected to the SL6_ANA modules
 The maximum number of cells is 384
The SL6_ANA module is powered by the connected cells. The minimum supply voltage is
10V.

3.6.1. FUNCTIONAL OVERVIEW SL6_CON

The SL6_CON module covers following functions:

 Communication with a BMS Master via CAN
 Isolated communication with SL6_ANA modules
 Transmission of the hardware monitoring status (second level detection)
 Isolated stimulation of the hardware monitoring (second level detection)
 Check the status of the hardware monitoring (second level detection)

3.6.2. FUNCTIONAL OVERVIEW SL6_ANA

The SL6_ANA module covers following functions:

 Measuring single cell voltages
 Control the passive cell balancing
 Measuring the temperature
 Detection of over and under voltage (second level detection)
 Detection of over and under temperature (second level detection)
 Isolated communication to other SL6_ANA and SL6_CON modules

3.6.3. FUNCTION OVERVIEW SL6_BAL

The SL6_BAL module is connected with the SL6_ANA module. Balance modules consist of
resistors for the passive balancing of cells. It is possible to adapt the value of the balance
resistors with respect to the cell type.

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3.6.4. SYSTEM BLOCK DIAGRAM

SL6_ANA-module

Second Level
Hardware
dection

2 x Temperature
Sec. Level
Hardware
Configuration

Batt.
SL6_BAL-module

4...12 cells
10...60V Voltage
Temperature
Measureing
Cell Balance

3 x Temperature

SL6_ANA-module

Second Level
Hardware
dection

2 x Temperature
Sec. Level
Hardware
Configuration

Batt.
SL6_BAL-module

4...12 cells
10...60V Voltage
Temperature
Measureing
Cell Balance

3 x Temperature To CON Modul

To ANA Modul Fail Output

(Open collector)
Master Connector

Fail Output
(RS485)

SPI / ISO SPI PowerSupply

Converter CPU
CAN

SL6_CON-module

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BMS Master 4 / 4.5

3.6.5. CONNECTING THE SLAVE 6 CON MODULE TO MASTER

Molex MicroFit 12-pol (view of the connector at the device) CN104 Tyco 9-pol

12 11 10 9 8 7
1 VNET  1 7V /12V
Shield FAILB CANL CANL TERML GND 7 GND  4 KL31 1 4 7

6 5 4 3 2 1
9 CAN-L  8 CAN2L 2 5 8
FAIL_ FAILA CANH CANH TERMH VNET
3 CAN-H  7 CAN2H 3 6 9
9 Shield

For CAN-H and CAN-L usage of twisted pair cables is required. The shield is connected to
the BMS Master only.

Usage of one CON Module

Molex MicroFit 12-pol (view of the connector at the device) CN106 Tyco 6-pol

5 FAIL A  1 BUS A
12
Shield
11
FAILB
10
CANL
9
CANL
8
TERML
7
GND
11 FAIL B  4 BUS B 1 4
2 5VNET 2 5
6
FAIL_
5
FAILA
4
CANH
3
CANH
2
TERMH
1
VNET
5 FAIL 3 6

For Fail A and Fail B are twisted pair cables used. The FAIL Pin is connected with a 4.7 …
5.1 kOhm resistor to 5VNET (pullup resistor).

Usage of more than one CON Module

Molex MicroFit 12-pol (view of the connector at the device) CN106 Tyco 6-pol

6 FAIL _  5 FAIL
12
Shield
11
FAILB
10
CANL
9
CANL
8
TERML
7
GND
2 5VNET 1 4
2 5
6 5 4 3 2 1 3 6
FAIL_ FAILA CANH CANH TERMH VNET

The FAIL Pin is connected with a 4.7 … 5.1 kOhm resistor to 5VNET (pullup resistor).

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BMS Master 4 / 4.5

3.6.6. COMMUNICATION CONNECTION TO CON MODULE - ANA MODULE

SL6_ANA Top

T2

T1
5

1
Shield

Shield
6

2
EN+T
EN-T
7

3
SI+T
SI-T
8

4
B2

B1
5

1
Shield

Shield
6

8 7 6 5
SI-B EN-B Shield B2
EN+B
EN-B
7

4 3 2 1
SI+B EN+B Shield B1
SI+B
SI-B
8

SL6_ANA Bottom
T2

T1
5

1
Shield

Shield
6

2
EN+T
EN-T

1 2 3 4
7

T1 Shield EN+T SI+T

SI+T
SI-T

5 6 7 8
8

T2 Shield EN-T SI-T

B2

B1
5

1
Shield

Shield
6

Typical cable between:

EN+B

- SL6_C and SL6A module

EN-B
7

- SL6_A and SL6_A module

- Shield only one connection on the
SI+B
SI-B
8

bottom connector
- LiYCY 3x0.5 TP

SL6_CON
T2

T1
5

1
Shield

Shield
6

2
EN+T
EN-T
7

3
SI+T
SI-T
8

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BMS Master 4 / 4.5

The communication cables must be shielded twisted pair. The signal pairs B1/B2 and
T1/T2 may not be exchanged; T1 connects to B1 and T2 connects to B2 of the next
module. The return signals (signal SI+-B) are only present if the hardware error detection
recognizes no error.

3.6.7. SL6_CON MODULE

3.6.7.1 LAYOUT AND CONNECTORS

8-pole connector to the lowest A module, view of 4 pole connector to the lowest B module, view of
the connector at the device the connector at the device (future development)

8 7 6 5 4 3
SI-T EN-T Shield T2A Shield T2B

4 3 2 1 2 1
SI+T EN+T Shield T1A Shield T1B

6 pole connector for programming,

view of the connector at the device
(only development)

6 5 4
MD0 GND RES

3 2 1
+5V TxD RxD

5
8 7 6 12 11 10 9 8 7
KL30
GND SW 2 SW 1 Shield FAILB CANL CANL TERML GND
(+)

1
4 3 2 6 5 4 3 2 1
KL30
GND GND GND FAIL_ FAILA CANH CANH TERMH VNET
(+)

8 pole connector for relay outputs, view of the 12 pole connector to BMS Master, view of the
connector at the device connector at the device

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BMS Master 4 / 4.5

CON module, 12 pole connector to BMS Master

Pin Signal Description

1 VNET Power Supply from Master, typical 12VDC (9…16)
2, 8 TERM L/H Activation CAN termination resistor 120 Ohm (short Pin 2- 8)
3, 4 CAN H Signal CAN high, communication to Master
5, 11 FAIL A, B Differentially error signal line RS485 to Master, only Master 4.5
(second level detection)
6 FAIL_ Static error signal to Master (second level detection)
7 GND Ground (Minus) from Master
9, 10 CAN L Signal CAN low, communication to Master
12 SHIELD

CON Modul, 8 pole connector for relay output

Pin Signal Description

1, 5 KL30 (+) Power supply for outputs, (9 … 28V)
2, 3, 4, 8 GND Ground (Minus)
6 SW1 Output 1
7 SW2 Output 2

CON module, 8 pole connector to 1. SL6 ANA module

Pin Signal Description

1, 5 T1A, T2A Differentially ISO SPI signal to the lowest ANA module
2, 6 SHIELD
3, 7 EN-T, EN+T Differentially stimulation signal to the lowest ANA module (ca.
10kHz)
4, 8 SI-T, SI+T Differentially Return signal from the lowest ANA module (ca.
10kHz)

3.6.7.2 MECHANICAL DIMENSIONS

• Module size 80.5 x 97 x 17 mm;

• For mounting holes for M3-screws, symmetrically arranged in the corners, distances 67
x 83.5 mm

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BMS Master 4 / 4.5

Attention: The mounting holes do NOT comply with the

requirements of 10 mm air and creepage distances for high
voltages.
If the slave modules are used under these conditions non-
conductive screws and/or bolts must be used.

3.6.7.3 SUPPLY AND CURRENT CONSUMPTION

The SL6_CON module must be powered from the BMS Master.

Description Value Unit

Voltage 9…16 V
Current (Master active) ≤ 100 mA
Current (Master active max.) ≤ 150 mA

3.6.7.4 ENVIRONMENTALS

Environmental testing:
 Temperature Test acc. ISO16750-4:
o 24 h @ – 40 °C
o 96 h @ +85 °C
o 4 x cycles at -40°C and 85°C
 Insulation test: 300GΩ / 5kV DC.
 EMC: acc. EN 55022 and EN 55024 (industrial)

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BMS Master 4 / 4.5

3.6.8. SL6_ANA MODULE

3.6.8.1 BOARD LAYOUT AND CONNECTORS

14-pole connector, cell voltage, view of the 10-pole connector, temperature sensor, view of the
connector at the device connector at the device

13 12 11 10 9 8 10 9 8 7 6
14
Sensor Sensor Sensor Sensor Sensor
n.c. CV11 CV9 CV7 CV5 CV3 CV1 5 4 3 2 1

5 4 3 2 1
7 6 5 4 3 2 1
Sensor Sensor Sensor Sensor Sensor
CV12 CV10 CV8 CV6 CV4 CV2 CV0 5 4 3 2 1

SL6_R- module with balance resistors

Connector for external balance

app. 90 mA
board 500mA max.

8-pole connector to previous module, 8-pole connector to the next module, view of the
view of the connector at the device connector at the device

8 7 6 5 8 7 6 5
SI-B EN-B Shield B2 SI-T EN-T Shield T2

4 3 2 1 4 3 2 1
SI+B EN+B Shield B1 SI+T EN+T Shield T1

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BMS Master 4 / 4.5

ANA module, 14 pole connector – cell voltage

Pin Signal Description
1 CV0 Cell 1 Minus
8 CV1 Cell 1 Plus, Cell 2 Minus
2 CV2 Cell 2 Plus, Cell 3 Minus
9 CV3 Cell 3 Plus, Cell 4 Minus
3 CV4 Cell 4 Plus, Cell 5 Minus
10 CV5 Cell 5 Plus, Cell 6 Minus
4 CV6 Cell 6 Plus, Cell 7 Minus
11 CV7 Cell 7 Plus, Cell 8 Minus
5 CV8 Cell 8 Plus, Cell 9 Minus
12 CV9 Cell 9 Plus, Cell 10 Minus
6 CV10 Cell 10 Plus, Cell 11 Minus
13 CV11 Cell 11 Plus, Cell 12 Minus
7 CV12 Cell 12 Plus
14 n.c. No connection

ANA module, 10 pole connection - Temperature sensors

Pin Signal Description
1, 6 Do not use, detection over temperature balance board
2, 7 Sensor 2 NTC Temperature sensor 1, 10kOhm at 25°C
1. Sensor for measurement data
3, 8 Sensor 3 NTC Temperature sensor 2, 10kOhm at 25°C
2. Sensor for measurement data
4, 9 Sensor 4 NTC Temperature sensor 4, 10kOhm at 25°C
Second Level Protection, detection under temperature
5, 10 Sensor 5 NTC Temperature sensor 5, 10kOhm at 25°C
Second Level Protection, detection over temperature

ANA module, 8 pole connection Bottom – communication to previous module

Pin Signal Description
1, 5 B1, B2 Differentially ISO SPI signal to CON module or to the previous
ANA – module
2, 6 Shield
3, 7 EN+B, Differentially stimulation signal from CON or previous ANA module
EN-B (ca. 10kHz)

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BMS Master 4 / 4.5

4, 8 SI+B, Differentially Return–Signal to CON module or to previous ANA-

SI-B module (ca. 10kHz)

ANA module, 8 pole connection Top – communication to the next module

Pin Signal Description
1, 5 T1, T2 Differentially ISO SPI signal to the next ANA – module
2, 6 Shield
3, 7 EN+T, Differentially stimulation signal to the next ANA module (ca.
EN-T 10kHz)
4, 8 SI+T, Differentially Return signal from next ANA module (ca. 10kHz)
SI-T

The single cell voltages are connected to 14 pole connector. The wire gauge should be 0.5
mm².
For the Temperature Measurement in the battery are connected 5 sensors to the SL6 ANA
module. The sensors 1…3 are used for the accurate temperature measure in the battery.
The sensors 4, 5 are used for the second level Hardware detection (Over and under
Temperature). The sensors are connected to the 10 pole connector.

Sensor Types:
- Sensor 2 … 5: VISHAY NTCLE100E3103 with 10 kΩ resistor at 25 °C
Or types with similar temperature characteristic

Second Level detection:

- Sensor 4 triggers an Under temperature signal at lower than -40 °C,
- Sensor 5 triggers an Over temperature signal at higher than +90 °C

3.6.8.2 CONNECT LESS THAN 12 CELLS

To connect less than 12 cells, the not presented cells must be replaced by shorting to the
connector. The allowed voltage range of the Slave6 A module is describe in chapter
3.6.8.6.
The crimp contacts are not able to use more than 1 wire in one contact; short circuit
connection should be realized outside of the connector. The short circuit wires must be
short as possible, e.g. with isolated shrink hose solder connections.

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BMS Master 4 / 4.5

14 13 12 11 10 9 8
n.c. CV11 CV9 CV7 CV5 CV3 CV1
11 cells
7 6 5 4 3 2 1
CV11 CV10 CV8 CV6 CV4 CV2 CV0

14 13 12 11 10 9 8
n.c. CV10 CV9 CV7 CV5 CV3 CV1
10 cells
7 6 5 4 3 2 1
CV10 CV10 CV8 CV6 CV4 CV2 CV0

14 13 12 11 10 9 8
n.c. CV9 CV9 CV7 CV5 CV3 CV1
9 cells
7 6 5 4 3 2 1
CV9 CV9 CV8 CV6 CV4 CV2 CV0

14 13 12 11 10 9 8
n.c. CV8 CV8 CV7 CV5 CV3 CV1
8 cells
7 6 5 4 3 2 1
CV8 CV8 CV8 CV6 CV4 CV2 CV0

14 13 12 11 10 9 8
n.c. CV7 CV7 CV7 CV5 CV3 CV1
7 cells
7 6 5 4 3 2 1
CV7 CV7 CV7 CV6 CV4 CV2 CV0

14 13 12 11 10 9 8
n.c. CV6 CV6 CV6 CV5 CV3 CV1
6 cells
7 6 5 4 3 2 1
CV6 CV6 CV6 CV6 CV4 CV2 CV0

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BMS Master 4 / 4.5

14 13 12 11 10 9 8
n.c. CV5 CV5 CV5 CV5 CV3 CV1
5 cells
7 6 5 4 3 2 1
CV5 CV5 CV5 CV5 CV4 CV2 CV0

14 13 12 11 10 9 8
n.c. CV4 CV4 CV4 CV4 CV3 CV1
4 cells
7 6 5 4 3 2 1
CV4 CV4 CV4 CV4 CV4 CV2 CV0

3.6.8.3 SECOND LEVEL PROTECTION

The SL6 ANA module contains a hardware circuit to check the cell voltage of every cell and
cell temperature (sensor 4, 5). Are the values over the limits, the FAIL signal of the SL6
CON module becomes active.
The circuit is always active and cannot switch off.

3.6.8.4 CONFIGURATION SL6_ANA MODULE

The hardware second level detection must be configuring depending cell type (over and
under cell voltage) and number of cells. The configuration must be write only once and is
saved in the SL6 ANA module. To set the configuration, the jumpers on all ANA moduls
must be set. The description, how to set the configuration you can find in the document
“IR14131_Slave6_InitialOperation.pdf”. After the configuration the jumpers must be
removed.

3.6.8.5 MECHANICAL DIMENSIONS

• module size 80,5 x 97 x 17 mm;

• 4 mounting holes for screws M3, symmetrically arranged one on each corner, distances
67 x 83.5 mm
Attention: The mounting holes do NOT comply with the
requirements of 10 mm air and creepage distances for high
voltage.
If the slaves modules are used under these conditions non-
conductive screws and/or bolts must be used.

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BMS Master 4 / 4.5

3.6.8.6 SUPPLY AND CURRENT CONSUMPTION

The SL6 ANA is powered from the connected cells.

Description Value Unit

Max. Supply voltage (from the cells) 12…55 V
Connection CV0 - CV12
Max. voltage between connections (CV0 – CV1) -0.3 … 8 V
Measurement range 5 V
Cell voltage accuracy (@3.3V) 2 mV
Current consumption (Master active) ≤ 10 mA
Current consumption (Master active max.) ≤ 20 mA
Current consumption in Standby/Sleep Mode 0.2 mA
Balance current without external Balance resistors 70…115 mA

3.6.8.7 ENVIRONMENTAL
Humidity: max. 95%, not condensing
Operating temperature: -20°C ... +70°C
Storage temperature: -40°C ... +85°C

At pollution level 2 the Slave may be operated up to 650V

At pollution level 3 the Slave must not be operated
At applications above 650 VDC non-conducting screws have to be used fixing the module
mechanically

Environmental tests:
 Temperature Test ISO16750-4:
o at – 40 °C
o 96 h at +85 °C
o 4 x cycle with -40°C und 85°C
 Insulation test: 300GΩ / 5kV DC
 EMC: EN 55022 and EN 55024 (industrial environment)

3.6.9. PASSIVE CELL BALANCE

Depending on the cell voltage, there are various slave 6 A module. The types are shown in
the following table:

Slave 6 ANA Balance resistor Voltage range

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BMS Master 4 / 4.5

Modul Balance current

cell type
Slave 6 A 2X 20,5 Ohm U [mV]: 1500 … 2800
I [mA]: 73 … 137
Cell type: LTO cell
Slave 6 A 3X 27,5 Ohm U [mV]: 2500 … 3600
I [mA]: 91 … 131
Cell type: LFP cell
Slave 6 A 4X 37,5 Ohm U [mV]: 2800 … 4200
I [mA]: 75 … 112
Cell type: NCA cell

The resistor values are adapted on the voltage range of the cell voltages. Thus an
optimum between maximum balance current and maximum board temperature is reached.

View of a Balance module to connect on the ANA module:

3.6.9.1 CONNECTION OF EXTERNAL BALANCE RESISTORS

All resistor respective cell connections are connected to a 24 pole MicroFit connector. At
this connector it is possible to connect external balance resistors to use higher balance
current max. 600mA. External resistors can be connected of 2 ways.
 One connection direct at the cell, one connection with a separate wire at the 24
pole connector.
or
 With 2 wires at the 24 pole connector
The cell voltage connections of the 12 pole connector must not use for the external
balance resistors. Wire gauge should be minimum 0.5 mm².
Resistor value is set depending to cell type, so that the balance current lower than

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Hardware Manual
BMS Master 4 / 4.5

600mA. The resistor load must be enough.

For sufficient cooling is to ensure!

The cell voltage measurements wires are only connect to 14 pole connector.
To connect the external Balance Resistors use only the 24 pole Connector.
The pins 1…12 should only use, if it is not possible to connect the balance resistors direct
at cell contact.
24-pole connector, view of the connector at the device:

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Hardware Manual
BMS Master 4 / 4.5

14pol
24pol connector
+ connector Sense Lines
Balance Lines
7 CV12
1
Cell 12
R6 13
13 CV11
2
Cell 11 R6 14
6 CV10
3
Cell 10
R6 15
12 CV9

4
Cell 9
R6 16
5 CV8

5
Cell 8
R6 17
11 CV7
6
Cell 7
R6 18
4 CV6
14pol
7
Cell 6
R6 19

24pol
10 CV5 SL6_ANA

8
Cell 5
R6 20
3 CV4

9
Cell 4
R6 21
9 CV3

10
Cell 3
R6 22
2 CV2

11
Cell 2
R6 23
8 CV1

12
Cell 1
R6 24
1 CV0

- External connection of balance resistors to SL6_ANA

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BMS Master 4 / 4.5

4. BRINGING THE SLAVE C, SLAVE 5 INTO SERVICE (ONLY FOR CELL VOLTAGES)

A startup example of Slave5 and Slave C is represented.

VBAT-
24-pol Conn.
VBAT+
18 13

5 1

8-cell-wiring
12 11 10 9 8 7 6 5 4 3 2 1
VBAT-
VBAT+

Slave_5 Slave_C

After connecting the cell plugs to the battery it has to be controlled whether all wires have
the proper contact to the cells (screws tight?) and the cabling is correct. With a wrong
connection the Slave may be destroyed — ACTIA I+ME will disclaim all warranties. So it is
strongly recommended to measure all voltages at each cell plug before connecting it to the
Slave. The pictures show the connections of a 10-cell battery to Slave_5 rsp. of an 8-cell
battery to Slave_C.

The MASTER has to be connected to the supply and a switch to the drive input. The first
Slave has to be connected via RS485 interface to the SlaveCom interface of the MASTER
and the checked cell plug has to be plugged on the Slave. The MASTER has to be connected
to a PC via RS232 interface and the Monitor program to be started. After switch-on the
Drive input, the display of the cell voltages shall confirm the function of the Slave and of the
RS485 interface.

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BMS Master 4 / 4.5

VBAT-
VBAT+

8-cell-wiring
12 11 10 9 8 7 6 5 4 3 2 1

12 1

1 4 7
Power

EMSRET
Plug In
KL30

KL30
KL30

Drive

KL31

KL31

KL31
2 5 8
3 6 9 1 2 3 4 5 6 7 8 9

Slave Com.
1 4

5V NET
BUS_A

BUS_B
FAIL_IN
Shield
GND
2 5
3 6 1 2 3 4 5 6

1 2 1 2

Vbat GND

Power Supply Drive

Failn 2
Failn 1
GND
5V
BUS B
BUS A
SHIELD
SHIELD
GND
5V
BUS B
BUS A

12 11 10 9 8 7 6 5 4 3 2 1

e.g. LiYCY- TP 3x2 0,25mm²

Accordingly one Slave after the other has to be connected to the RS485 bus and be taken
in function. For the Slave_5 module this picture is valid analogously.

8-cell-wiring 8-cell-wiring
12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1

12 1 12 1

MASTER

Here can only be described how to bring the Slave modules in operation for the
measurement of the cell voltages which is the same in each application. We thought it
important to refer to the proper connection between Slave and battery that often showed
difficulties for some first users.
All starting ups happen in the responsibility of the system manufacturer.

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BMS Master 4 / 4.5

5. CONNECTORS-ACCESSORY

Order Numbers 24-pole connector:

MPE-Garry 433-2-024-X-KSO
Molex 43025-2400
Nexus 2300P-24
Würth 662024113322

Order Numbers 22pole connector:

MPE-Garry 433-2-022-X-KSO
Molex 43025-2200
Nexus 2300P-22
Würth 6620226113322

Order Numbers 14-pole connector:

MPE-Garry 433-2-014-X-KSO
Molex 43025-1400
Nexus 2300P-14
Würth 6620146113322

Order Numbers 12-pole connector:

MPE-Garry 433-2-012-X-KSO
Molex 43025-1200
Nexus 2300P-12
Würth 6620126113322

Order Numbers 10-pole connector:

MPE-Garry 433-2-010-X-KSO
Molex 43025-1000
Nexus 2300P-10
Würth 662010113322

Order Numbers 8-pole connector:

MPE-Garry 433-2-008-X-KSO
Molex 43025-0800
Nexus 2300P-08
Würth 662008113322

Order Numbers 6-pole connector:

MPE-Garry 433-2-006-X-KSO
Molex 43025-0600
Nexus 2300P-06
Würth 662006113322

Optional:
Order Numbers 4-pole connector:
MPE-Garry 433-2-004-X-KSO
Molex 43025-0400
Nexus 2300P-04
Würth 662004113322

Order Numbers Crimp-contact für AWG20 – 24 (0.5 – 0.2 mm²):

MPE-Garry 604-1-TX-XL (Bulk), ...-XR (Reel)
Molex 43025-0007

Ref.: IR14417 A 15.01.2018 Page 71/76

Hardware Manual
BMS Master 4 / 4.5

Nexus 2300T-B/-F/-T
Würth 66210113722

Order Numbers Crimp-Tool:

MPE-Garry 454-1-05

The articles by Molex, Nexus and Würth are not guaranteed to be fully compatible; use is on
own risk.

Ref.: IR14417 A 15.01.2018 Page 72/76

Hardware Manual
BMS Master 4 / 4.5

6. CERTIFICATES

Ref.: IR14417 A 15.01.2018 Page 73/76

Hardware Manual
BMS Master 4 / 4.5

Ref.: IR14417 A 15.01.2018 Page 74/76

Hardware Manual
BMS Master 4 / 4.5

Ref.: IR14417 A 15.01.2018 Page 75/76

Hardware Manual
BMS Master 4 / 4.5

Ref.: IR14417 A 15.01.2018 Page 76/76