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Thanks for choosing Bestgo BMS1A EV BMS(Battery Management System). In order to install, use and
maintain the product better, please read this user manual (hereinafter called “manual”) carefully
before installing and using. BMS1A are new series BMS developed for Electric vehicle by Bestgo. Based on the demand features
as strong interference, high voltage and high stability of large electric vehicle, BMS1A are designed
with strong applicability. The product is configured with different components, which can meet various
application demands and provide outstanding performance.
BMS1A can well shield the strong electromagnetic interference of electric vehicles through effective
isolation and design mode and improves the safety, stability and reliability by virtue of automotive -class
processor chip, CAN bus communication and hardware and software designed with high redundancy.
1.1 Prompt
This manual includes important information that must be mastered by customers. Our company will not
undertake any related consequence or liabilities if customer doesn’t install, use and maintain the product
in strict accordance with this manual.
1.2 Qualification and Certification
1.3 Declaration
This manual has been reviewed and verified for accuracy. The guidance and description of BMS1A BMS
included in this manual are correct. However, the subsequent BMS1A BMS and manual may alter due to
technical improvement.
BMS1A User Manual
BMS1A Application BMS is an important component of electric control system of complete vehicle, which communicates with complete vehicle
controller; intelligent charger and instrument through CAN bus, realizing safe, reliable and effective management of battery
system. The complete vehicle controller reads BMS data through CAN bus, controls motor through intelligent motor controller,
displays data on instrument panel and communicates with intelligent charger through BMS to realize intelligent charging
control. The BMS anti-interference performance is very important for hybrid and pure electric bus. The strong electromagnetic
interference will influence the normal operation of BMS. In order to solve the problem fundamentally, BMS1A BMS adopts the
design of multiple electromagnetic compatibilities and isolations, which has effectively shielded the electromagnetic
interference and maintained the normal operation of system. The automotive class processor chip, automotive class CAN bus
and high redundancy circuit has improved the safety, stability and reliability of system remarkably.
The typical electric vehicle BMS is mainly composed of one Battery cluster-management unit (BCU), several (1-10) battery
monitoring units (BMU) and one insulation detection module (LDM).
System schematic diagram
BMS1A User Manual
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Safety Instructions n Description of Safety Signs：
Danger: danger caused by noncompliance with requirements, which may lead to fire hazard, serious personal
injury and even death.
Caution: danger caused by noncompliance with requirements, which may result to moderate or minor personal
injuries and system damages.
Please read this section carefully before installing, using and maintaining the system. Please be sure to operate the BMS
according to safety precautions in this section. Our company will not be responsible for damage or loss caused by violations.
Application
Danger
l BMS must be powered by defined voltage. Or system may be damaged.
l BMS is applied for information monitoring and management of battery pack only and cannot be used
for other purposes. Or system fault or fire hazard may be caused.
Arrival inspection
Caution
l BMS cannot be installed when system damaged or component missing. Or accident may occur.
l If components and packing list are inconsistent, please don’t install the system and contact with our
company in time (see appendix of this manual).
Installation
Caution
l Please move gently to avoid dropping on foot or product from being damaged when transporting and
installing.
l This system must be kept away from combustible objects and heat source.
l Don’t let foreign matters drop into system at the time of installation. Otherwise, system fault may be
caused.
l , do not get wet in the rain or water when installing the system, or you could lead to internal short
circuit, the system damage.
l The shell of insulation detection module must be well conducting with vehicle body. Otherwise, the
insulation detection module may be invalid.
Wiring
Danger
l The wiring work must be done by qualified operator of electric engineering. Otherwise, electric shock
or system damaged may be caused.
l The power supply must be disconnected before wiring. Otherwise, electric shock or fire hazard may
be caused. Caution
l The installation must be carried out in strict accordance with serial number of Battery monitor unit
address. Otherwise, the collected data may not be consistent with display on control platform.
l Check whether the battery quantity is same to that of Battery monitor unit. Otherwise, the collected
data may be incomplete.
l Check whether the connection order of voltage detection wiring harness is correct. Otherwise, the
system may be damaged.
l Check whether the wiring of control relay is correct. Otherwise, system and battery pack may be
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damaged.
l Check whether positive and negative poles wiring of power supply are correct. Otherwise, system
may be damaged.
Operation
Danger
l Power on only after all modules and display screen are connected correctly. The plug wire cannot be
unplugged when the power is on. Otherwise, electric shock may be caused.
l Parameters of setting page cannot be altered at will. Otherwise, battery may be damaged
irretrievably
Caution
l Before operation, check whether the system is within allowed range of application. Otherwise,
system may be damaged.
l Before operation, check whether the control strategy of system is right. Otherwise, battery may be
damaged.
Maintenance and
inspection
Danger
l The power supply must be disconnected if it is necessary to disassemble the shell. Otherwise,
electric shock may be caused.
l The circuit board includes a large number of high-accuracy elements.Strictly prohibited remove shell
if not our company designated personnel.
l Please designate qualified operators of electric engineering to maintain, check or replace
components.
Others Danger
l Self modification for the system is prohibited. Otherwise, serious accident may be caused.
BMS1A User Manual
Contents
Chapter 1 Introduction of BMS1A........................................................................................ 7
1.1 Product Structure ................................................................................................... 7
1.2 System Configuration ............................................................................................. 7
1.3 Brief Introduction of Function ................................................................................. 7
1.4 Technical Specifications ......................................................................................... 8
1.5 Battery cluster-management unit (BCU) ................................................................ 8
1.6 Battery monitor unit (BMU)..................................................................................... 9
1.7 Current sensor CS ............................................................................................... 10
1.8 Display (LCD) ........................................................................................................ 11
Chapter 2 System Installation ......................................................................................... 12
2.1 Installation Dimension .......................................................................................... 12
2.2 Appearance dimensions diagram......................................................................... 12
2.3 Interface description ............................................................................................. 15
2.4 System diagram ................................................................................................... 17
2.5 BMU wiring description ........................................................................................ 18
2.6 BCU wiring description ......................................................................................... 19
2.7 LCD wiring description ......................................................................................... 21
2.8 Installation Conditions and Requirements ........................................................... 21
Chapter 3 System wires .................................................................................................. 22
3.1 Cables list ............................................................................................................. 22
3.2 Cables photograph ............................................................................................... 22
Chapter 4 LCD Direction ................................................................................................. 24
4.1 Explanation of Parameters ................................................................................... 24
4.2 Display of Main Interface...................................................................................... 25
4.3 System Configuration ........................................................................................... 25
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4.4 Display of Single Cell Information ........................................................................ 26
4.5 Display of Charger Information ............................................................................ 27
4.6 Configuration Interface ......................................................................................... 28
Chapter 5 Fault Diagnosis ................................................................................................. 31
5.1 Fault and Alarm List ............................................................................................. 31
5.2 Procedure of Fault Diagnosis ............................................................................... 32
Chapter 6 Daily Maintenance ......................................................................................... 33 Chapter 7 Service Guide ...................................................................... 错误!未定义书签。
7.1 Contact information .................................................................... 错误!未定义书签。
Appendix: System Accessories list ................................................................................. 35
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Chapter 1 Introduction of BMS1A
1.1 Product Structure With the distributed two-level management system, BMS1A electric vehicle BMS (hereinafter called BMS1A system) is
composed of Battery cluster-management unit (BCU) and multiple Battery monitor unit (BMU), display screen (LCD),
insulation detection module (LDM), heavy-current control system (HCS), current sensor (CS) and wiring harness.
Figure1-1 Product structure
1.2 System Configuration
Figure 1-2 System Configurations
1.3 Brief Introduction of Function BCU module carries out real-time communications with multiple BMU modules and LDM (insulation detection module) through
CAN bus to gain system parameters, such as single cell voltage, box temperature and insulation resistance and so on, collects
charging and discharging current through current sensor, calculates SOC dynamically and displays related data through touch
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screen. BCU manages system after gaining comprehensive information of battery pack through calculation and analysis,
respectively interacts with ECU, motor controller and charger and so on intelligently through independently CAN bus and can
realize the secondary protection of charging and discharging through relay control to meet diversified safety control demands
of customers, ensuring stable and effective operation of system.
1.4 Technical Specifications
Item Specification Remarks
Voltage collection range 0～5V
Voltage collection accuracy ≤±0.5%
Accuracy of total voltage ≤0.2%(Keep 0.1V)
Current collection accuracy ≤±1%FSR Hall current sensor
Error of SOC estimation ≤5%
Temperature collection accuracy ≤±1℃ -30～75℃
Temperature collection range -40～125℃
Balance current ≤250mA(Normal temperature) Each 12S can open 3 channels balance.
Power consumption of BMU operation ≤1W
Power consumption of BCU operation ≤2.8W
Working input voltage DC 12/24V
System operating temperature -30～75℃
Storage temperature -40～85℃
Charging control mode CAN communication, active/passive output Depend on actual conditions
Discharging control mode CAN communication, active/passive output Depend on actual conditions
1.5 Battery cluster-management unit (BCU)
n BCU function u SOC estimation: use Joint EKF algorithm to estimate SOC of battery pack dynamically
u Current detection: carry out real-time detection of current in charging and discharging circuits through Hall current
sensor.
u Communication function: externally installed 3 CAN interfaces, which can be used to communicate with BMU,
complete vehicle controller and charger and so on to exchange voltage, temperature, fault code, control
command and other information.
u Alarm and protection: when there is fault as over-charge, over-discharge and so on, BCU can perform the
corresponding alarm and protection according to fault status and display it on LCD screen.
u System expanding: BCU supports multiple channels of active/passive node output and can realize two-level
control management through CAN communication and relay to ensure effective isolation of strong and weak
current and meet diversified safety control demands of customers.
u Data storage: support 8G data storage capacity and can record all performance parameters of long-term
operation of power battery pack and dispatching and fault events of battery module.
u System self-check: the system checks itself and BMU working status after power on to ensure normal working of
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system.
u Remote management: BCU is equipped with wireless communication interface, which can realize four-remote
function through external DTU module.
u System upgrade: program downloading interface is installed externally, which can be used to upgrade system
within 30 seconds.
n BCU parameters
Item Performance
Working voltage DC 12V/24V Current detection range ±1000A (range optional) Current detection accuracy ≤±1%FSR Error of SOC estimation ≤5%
Display Total voltage, total current, maximum and minimum voltages and cell numbers, voltage of single battery, box temperature, charging and discharging status, over-charge alarm, under-charge alarm, over-discharge alarm, over-temperature alarm and insulativity alarm, etc.
Alarm
Level Ⅰ alarm: l Single cells voltage≤3.0V； l 100Ω/V≤insulativity≤500Ω/V
Level Ⅱalarm: display shows alarm and buzzer warns. Cut off charge&discharge circuits: l Single cell voltage ≤2.5V or ≥3.9V l Box temperature≥75℃； l Insulativity≤100Ω/V。
Charging control mode
Controlling through CAN-bus and relay: l When single cell≥3.65V, start communicating with charger through CAN-bus, the
current value gradually decreases according to smooth curve; l When single cell≥3.9V, disconnect charger output after 30S delay; l When single cell﹤3.4V, charger can be used again for charging; l When box temperature≥75℃,cut off charge circuit or charger stop charging;
Discharging control
Controlling through CAN-bus and relay: l When single cell≤3.0V,start communicating with motor controller to reduce motor
output power through CAN-bus; l When single cell≤2.5V, cut off motor power output after 5~10S delay; l When single cell >2.6V, the motor controller can continue to output power; l When box temperature≥75℃,cut off discharge circuit.
Remarks: *all protection parameters in this table can be configured.
1.6 Battery monitor unit (BMU) n BMU function BMU connects with battery pack through voltage detection lines, detect temperature through temperature sensors (10 sensors
at most, more sensors needs to be customized).Each BMU collects 60 cells battery at most and equalize battery according to
single cell voltage. When the max single cell voltage reaches to 3.55V and battery voltage difference is between 20mv~800mv,
the balance function starts automatically.Every BMU can open 3 channels balancing at most. BMU get power from external
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12v/24v (18v~31v self-adaption) power supply. BMU can transfer the voltage and temperature information to BCU through
CAN-bus.
u Single cell voltage detection: realize the real-time detection of each single cell voltage through isolated collection of
the series single cell voltage.
u Temperature detection: put 1~10 temperature sensors in battery box to realize the real-time temperature detection.
u CAN-bus communication: transmit the voltage, box temperature and other single cell information to BCU through
CAN bus.
u Balance function: balance management can be performed to battery cell according to agreed balance management control strategy to improve the consistency of single battery cell and application performance of battery pack.
u Heat management: BMU can manage the cooling and heating status of battery actively according to battery box
temperature to ensure battery application capacity and prolong battery service life.
u Error alarm: buzzer warning when error appears.
u System upgrade: program downloading interface is installed externally, which can be used to upgrade system within
30 second.
n BMU parameters
Item Parameters Remarks Max collection
strings 60 strings 10 temperature sensor
Working voltage DC 12V/24V Voltage collection
range 0～5V
Collection accuracy of single cell voltage ≤±0.5%
Temperature collection range -40～125℃
Temperature detection accuracy ≤±1℃ -30～75℃
Communication interface CAN
Voltage sampling period 200ms
Cooling/heating current ≤1A Peak value 2A
1.7 Current sensor CS
n CS function
The current of this system is detected with Hall open-loop current sensor with optional range 50A～1000A.
n CS type
Item Code Parameters
Type 01 50A
02 100A
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04 200A
05 300A
07 500A
10 1000A
1.8 Display (LCD)
n LCD function The display screen is HMI for showing system operation status. All the models are designed according to industrial standard
and can be applied to various conditions. LCD can display all operation parameters and faults of system.
n LCD Status description The operation indicator of display includes three lights: power supply (PWR), running (RUN) and communication (COM). The
power indicator (PWR) is normally on when the display power on; if the running indicator (RUN) is normally on in yellow light, it
stands for normal running of display screen; if the running indicator (RUN) is not on, it means that the display screen has fault;
when the display screen has connected with BMS, the communication indicator (COM) flashes in yellow light.
Figure 1-3 Indicator light status
n LCD description The integrated interface information of display screen is as shown in the figure below:
Figure 1-4 LCD Display Interface
n LCD type
Item No. Specification
LCD type 01 LCD display 3.5 inch
02 LCD display 5.7 inch
SOC
Temperature
Current
Voltage
Alarm
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Chapter 2 System Installation
2.1 Installation Dimension
Component Dimensions(mm)
W H D W1 H1 D1 d
BCU 165 130 44.5 100 118 M4
BMU
BM5112A 132 96 32 120 60
BM5124A 170 96 32 158 60
BM5136 208 96 32 196 60 M4
BM5148 246 96 32 234 60
BM5160 284 96 32 272 60
LCD 96 81 47 90 75 5 4
177 140 40 160.6 130.5 6 4
Remarks: W, H and D are dimensions of external structure; W1, H1 and D1 are installation dimensions of internal
structure; d is width of mounting hole.
2.2 Appearance dimensions diagram
n BCU
Figure 2-1 BCU dimensions
n BMU
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Figure 2-2 BM5112A dimensions
Figure 2-3 BM5124A dimensions
Figure 2-4 BM5136A dimensions
BMS1A User Manual
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Figure 2-5 BM5148Adimensions
Figure 2-6 BM5160Adimensions
n LCD display（LCD）
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Figure 2-7 5.7 ’LCD dimensions
n Current Sensor（CS）
Figure 2-8 CS dimensions
2.3 Interface description
n BCU interface
Figure 2-9 Front Interface of BCU
Figure 2-10 Back Interface of BCU
1
2
19
20 11
12
1 2
7
8
1
2
C-P2, interface for system power supply, output and input
1
2
11
12
13 14
27 28
card
C-P4 inner interface
C-P3, interface for weak voltage
C-P1, interface for communication and switching output
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n BMU interface
Figure 2-11 Front Interface of BM5060A
n 5.7”LCD interface
Figure 2-12 5.7”LCD interface
n CS interface
Figure 2-13 CS interface
Power, CAN communication, cooling, heating
12 strings voltage detection, 2 temperature sensors
12 strings voltage detection, 2 temperature sensors
12 strings voltage detection, 2 temperature sensors
12 strings voltage detection, 2 temperature sensors
12 strings voltage detection, 2 temperature sensors
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2.4 System diagram
Figure 2-14 System diagram
Discharge relay
Current sensor
LCD communication line
LCD screen
BCU DC/DC
LDM
DC input+
DC input-
Pre-charge relay Charge relay Refrigeration relay Discharge switch signal Charge CAN
Temperature detection line Temperature detection line
Current sensor
Voltage detection line Voltage detection line
Module communication cable
Switch signal line
Switch signal line
Fuse Power resistor
Load Charger Connect to charge CAN line
Connect to charge relay line Connect to discharge CAN line
Charge relay Discharge relay
Connect to pre-charge relay
Pre-charge relay
Pack positive Pack negative
LDM communication cable
BCU power line
LDM power line
BMU power line
Module communication cable
Module communication cable
Matched resistance
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2.5 BMU wiring description
n Voltage detection wiring u Method 1: When the cells No. =12*n, please connect the wires according to figure 2-15.
u Method 2: When the cells No. is between 6 and 12, please connect the wires according to figure 2-16.
Figure 2-15 Method 1 of voltage detection wiring Figure 2-16 Method 2 of voltage detection wiring
Caution: please ensure the wires connected in order. If not, the voltage collection may be wrong, internal circuit
may be burnt out and batteries may be damaged!
n Fix temperature sensors to battery pack
Figure 2-17 Instance diagram of temperature sensors connection
n Insert the wires connectors into BMU ports.
Figure 2-18 Instance diagram of voltage and temperature detection wires
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n CAN communication wires connection CAN communication wires are used for communicating between BMUs and BCU.
Figure 2-19 Instance diagram among BMUs
2.6 BCU wiring description
n Communication wires between BCU and BMU
Figure 2-20 Connection diagram between BCU and BMU
n Connecting current sensor Thread the output line of the battery pack through the current sensor. There are two positions you can lay the current
sensor, as below diagram (please notice the arrow):
Figure 2-21 Current sensor connection diagram
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Figure 2-22 Instance diagram of current sensor
n Connect the relay control lines. The red cord connects with positive. The black cord connects with negative.
Figure 2-23 Instance diagram of relay control lines
n Connect the CAN-bus communication line(BMS communicate with charger/motor/vehicle). The three core line: red cord is CAN-high line, yellow cord is CAN-low line, black cord is GND.
Figure 2-24 Instance diagram of CAN communication
Caution: 1. Please confirms the connection of “H” and “L”. Otherwise, BMS can’t communicate with other
equipment through CAN-bus. 2. Please confirm matched resistance number, Otherwise, BMS can’t communicate with other
equipment through CAN-bus.
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n Connect power line of the BCU. The red cord connects with positive. The black cord connects with negative.
Figure 2-25 Instance diagram of BCU power line
2.7 LCD wiring description n Connect LCD and BCU with the communication/power line.
Figure 2-26 Instance diagram of LCD and BCU
Caution: 1.Connect communication line (DB9 connector) to COM1 port. If connected to COM2, LCD will be
communication outage.
2. The connection of positive and negative poles of LCD power cannot be reversed. Otherwise, LCD
will be burnt out!
3. LCD is powered by DC24V/DC12V. The positive pole connects with 24V+/12V+ and negative one
with 24V-/12V-!
2.8 Installation Conditions and Requirements u Avoid installing the system under the condition with oil mist, metallic dust and much dust.
u Avoid installing the system under the condition with harmful gas and fluid or corrosive, flammable and explosive
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gas.
u Reserve appropriate installation dimensions。
u Cables installation shall be kept away from sharp objects。
u Try best to keep away from conditions with strong electromagnetic interference.
u Parameters of all parts related to connection with this system shall be confirmed by our company.
Chapter 3 System wires
3.1 Cables list n In the following list, a set of BMS1A system is taken for example to explain cables required. One set of products takes
one BCU and N (≤20) BMUs to explain the quantity of each cable, as shown on the list below:
3.2 Cables photograph
n Following pictures show common cables:
Name QTY Unit Remarks
Voltage& temperature
detection cable N Set
QTY is equal to QTY of 12 cells acquiring board. Terminal
would be confirmed according to battery terminal.
Heating relay control cable N Set Optional
Refrigeration relay control
cable N Set Optional
Communication cable
among modules N Pcs Communication cables among BMUs
Power line 1 Pcs BCU power input
BMU and BCU
communication cable 1 Pcs
Current sensor wire 1 Pcs
Screen cable 1 Set
Discharge switching cable 1 Pcs
Choose either according to discharge control method. Discharge CAN cable 1 Pcs
Discharge relay cable 1 Pcs
Charge relay cable 1 Pcs
Choose either according to charge control method. Charge CAN cable 1 Pcs
Charge switching cable 1 Pcs
Pre-charge relay cable 1 Pcs Optional
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Picture Name Application Connector
Voltage& temperature detection cable
Connect batteries and BMU, to detect voltage and temperature
Heating relay control cable
Control external heating equipment(function indeterminate)
Refrigeration relay control line
Control external refrigeration equipment(function indeterminate)
Communication cable among modules
Communication among BMUs
Power Line(red”+”,blacn”-”) Power for BCU
Discharge relay cable Connect discharge relay and BCU
Input signal cable Input level signal to BCU
Vehicle CAN cable Connect motor controller/vehicle to BCU
Charge CAN cable Connect to charger
Charge relay cable Connect charge relay to BCU
Pre-charge relay cable Connect pre-charge relay and BCU
Charge switching cable Output switch signal to charger
Discharge switching cable
Output switch signal to motor controller or other equipment
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Current sensor wire Connect current sensor to BCU
USB communication wire
Download data from SD-card
BMU and BCU communication cable
Communication line between BCU and BMU
Screen cable Communication and power line between BCU and LCD
LDM communication cable
Communication and power line between BCU and LDM
Chapter 4 LCD Direction
4.1 Explanation of Parameters
Total capacity Fully charged Capacity of battery pack. Usually, it is initially configured according to nominal
capacity of battery pack.
Surplus capacity Currently surplus ampere-hours of battery pack; it is set according to parameters provided by
battery manufacturer.
Max charging
voltage Set maximum charging voltage of charger through CAN communication.
Max charging
current Set maximum charging current of charger through CAN communication.
Over-charge
protection voltage
Set the maximum voltage threshold that single cell battery can raise during charging. Carry out
over-charge protection to battery and alarm when voltage beyond this value.
Over-charge
protection release
Set to cancel the voltage threshold of overcharge protection, i.e. to cancel over-charge protection
and alarm when the maximum voltage of single cell battery drops to the value lower than
threshold value.
Under-voltage alarm
voltage
Set threshold of alarm for low voltage of battery single cell, which is used to prompt low power of
battery.
Under-voltage alarm Set to cancel the voltage threshold of under-voltage alarm, i.e. to cancel under-voltage alarm
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release when the minimum voltage of single cell battery recovers to the value higher than this parameter.
Over-discharge
protection voltage
Set the minimum voltage threshold that battery can drop to during discharging. Carry out
over-discharge protection to battery when the voltage is lower than the value.
Over-discharge
protection release
Set to cancel the parameter of battery over-discharge protection, i.e. to cancel battery
over-discharge protection when the minimum voltage of single cell battery recovers to the value
more than this parameter.
Over-temperature
protection temp
Set maximum operating temperature of battery pack. Carry out battery over-temperature
protection and alarm when the temperature is higher than the value.
Over-temperature
protection release
Set the temperature threshold of over-temperature alarm release, i.e. to cancel over-temperature
protection and alarm when the maximum temperature of battery drops to the value lower than the
threshold.
4.2 Display of Main Interface
Figure 4-1 Main Interface
Remarks: Alarm information shows in gray when normal; shows icon and flashes when alarm.
4.3 System Configuration Click “Menu”, then click”BMS Config” to enter system configuration interface. As shown in figure 4-2:
显示报警信息
Current SOC
Temperature
Voltage
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Figure 4-2 System Configuration information
You can set the voice, system language, page interface and time, etc
4.4 Display of Single Cell Information Click”Battery” to enter interface of single cell information, as figure4-3:
Figure 4-3 Single cell information
Remarks: this picture shows 16 cells voltage and 4 temperature sensors. The information may alter
according to applications.
Cell Voltage
Module Temperature
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4.5 Display of Charger Information Click “charger”, then click “Information” to enter charger interface.
Figure 4-4Charger information
Remarks: the interface displays some information of charger. Receive the corresponding messages of charger through CAN
communication and display the information on screen.
n Explanation of parameters
u Online status: communication status of charger; it displays online when charger is communicating with BMS; otherwise, it is offline; the default status is offline
u Starting status: indicate whether the charger has started to charge; it indicates starting after starting to charge;
otherwise, it is stopping; the default status is normal.
u Hardware fault: malfunction of charger itself, default to normal.
u Input voltage: indicate the status of charger input voltage, default to normal.
u Temperature: indicate the temperature status of charger, default to normal.
u Output current: indicate present charging current of charger.
u Output current: indicate present charging voltage of charger.
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Click “Charger”, then click “Configure” to enter interface of charger config.
Figure 4-5Charger configuration
User can set parameters in this interface, such as “Max charge current” and “Max total voltage”, etc.
Remarks: 4.5 is referenced only when charger communicates with BMS through CAN-bus. Please don’t consider 4.5 if
there is no CAN-bus communication between charger and BMS.
4.6 Configuration Interface In order to evaluate all parameters of battery accurately, it is necessary to re-configure BMS before its initial running. The
configurable content includes: total capacity of battery pack (nominal capacity), current surplus capacity of battery pack,
maximum charging voltage, maximum charging current, over-charge voltage of single cell battery, over-charge release voltage
of single cell battery, under-voltage protection voltage of single cell battery, under-voltage release voltage of single cell battery,
over-discharge protection voltage of single cell battery, over-discharge release voltage of single cell battery, over-temperature
protection temperature and over-temperature release temperature.
Steps of parameter configuration:
Ø Step 1: Click “Menu” on main interface.
Ø Step 2:Click”BMS Config” to enter config interface as figure 4-6
Ø Step 3: Click “Read” to read the default value. System supports automatic reading also.
Ø Step 4: Click the column you want to change.
Ø Step 5: Click”Write”, then enter the code”8888”.The parameters will influence the system operation, please don’t
modify them casually.
Ø Step 6: Click “Write” in the writing dialog. After 5 second ,the configuration is finished when the COM icon show
normally. If the light shows abnormally, please click “Write” again, then click “Back”.
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Figure 4-6 Configuration information
Remarks: the relationship of configuration parameters as following:
1. over-charge voltage > over-charge release > under-voltage release > under-voltage voltage >
over-discharge release > over-discharge protection
2. Over-temperature release < over-temperature protection
3. Left capacity < total capacity
n Recover configuration parameters to default value:
Ø Step 1: Click “Default”. The dialog box pops up to inquire whether confirm the restoration, as figure 4-7:
Read the configuration information.
Back to main interface
Write the configuration value into BMS
Reset to defaults
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Figure 4-7 Restore defaults
Ø Step 2:Click “OK” to restore default value.
Ø Step 3:Click”Write”,enter the default value into BMS. If you have questions about the parameters, click “Help” to enter help interface as figure 4-8:
Figure 4-8 Help information
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Chapter 5 Fault Diagnosis
5.1 Fault and Alarm List BMS1A has impeccable management function, which can extend battery life. Fault tips may appear when using BMS. Please
analyze and solve the fault according to the following table. (If system damaged or meet insoluble problems, please call
400-0551-306 for getting solutions.)
No. Fault Description Possible Cause Solutions
1 System doesn’t work
1.Working voltage incorrect
2.No power supply
3.DC power supply damaged
1. Check whether the working voltage is
within normal voltage range. 2. Supply power for system.
3. Maintained by professional technician.
2 Buzzer alarms and LCD
displays fault.
1.Over-charge, over-discharge or
under-voltage
2.Over-temperature
3.Communication interrupted
1. Check parameter setting of battery
protection.
2. Disconnect charger or stop supplying
power for battery.
3. Check communication interface.
3 Buzzer alarms. But LCD
has no fault display.
1. Temperature difference at temperature
detection point is too large.
2.SOC too low
1. Stop charging and discharging and restart
after temperature recovery.
2. Charge battery or correct configuration
manually.
4 LCD displays
communication error
Incorrect connection of communication
cable
Check whether the power interface of LCD is
loose or has fallen off.
5
LDC displays voltage=0
(multiple batteries or
two consecutive
batteries)
Incorrect connection of voltage cable
Check whether the voltage detection cable
harness is connected in good stations.
6
The maximum
temperature
indicates -40℃.
Incorrect connection of temperature
sensor Check and reconnect temperature sensor.
7 Partial batteries voltage
display abnormally.
Incorrect connection of voltage
collection cable for the corresponding
battery
Check and reconnect voltage collection
cable.
8 No current display Incorrect connection of current sensor
Check whether the current sensor is
connected
in good stations.
9 Current displays when ”Current digital calibration” is not set. Refer to "explanation of configuration
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system is static. parameters".
10
Current display is
incorrect when system
is operated.
Mismatch of current sensor Check whether the current sensor is original
configuration of the system.
11 LCD doesn’t work No power supply
1. Check whether the BCU has supplied
power.
2. Check whether the power cord between
BCU and LCD is connected correctly.
12
Charging current ＜
maximum current of
charger
Maximum charging current is set too low. Reset parameter of maximum charging
current.
13
Cannot protect from
over-charge
or over-discharge
Incorrect parameter setting Reset parameter
14 SD card cannot be
written in SD card write-in is protected. Switch off SD card write-in protection.
Remark: for detailed fault icons of LCD, please refer to LCD introduction part.
5.2 Procedure of Fault Diagnosis
Fault appears
Troubleshoot according to 5.1 List of Fault and Alarm
Information and check whether it is included in
the table.
Start system
Consult technical support center 400-0551-306
Yes
No
Yes
No Use normally
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Chapter 6 Daily Maintenance Factors as service environment (such as temperature, humidity, dust and interference and so on), aging and abrasion of
internal components and so on will increase the fault occurrence rate of system. It is necessary to carry out daily maintenance
to decrease fault occurrence rate and prolong system service life.
Caution:
l Only trained professional operators can disassemble and replace the internal components.
l Switch off the power supply before checking and maintaining.
l Prevent metal or other matters being left in system. Otherwise, system may be short circuited and damaged
Daily
maintenance
Service environment
l In order to improve the function realization and prolong the service life
of system, it is necessary to keep good installation environment.
Generally, it is required to avoid direct high light for long time or other
radiation and prevent water, other fluid, dust or dirt from entering.
BCU and BMU modules
l Measuring voltage with voltmeter and current with ampere meter to
check whether they are within normal range. Please refer to
description of system parameters. It is possible to perform intuitive
judgment through touching, smelling and visual inspection to prevent
these factors influencing functions.
LCD l Clean LCD frequently to keep it clean. Don’t crash or abrade it.
Consult technical support center 400-0551-306
No Find possible cause and
solutions according to the table and check whether the system has recovered
to normal after adjustment.
Finish
Yes
Fault reset; check whether the fault has
been eliminated
Yes
Consult technical support center 400-0551-306
No
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Otherwise, the view will be interfered, which will cause incorrect
judgment.
Component
replacement
Different components have
different service life. The
service life is influenced by
environment and operating
conditions. Keeping good
operating environment will be
good for improving
components service life.
l Wires of various plugs (e.g. air plug), PIN connectors and serial ports
may fall off from their welding spot, which may cause open circuit.
Please replace them in time if there is any damage. Please cut off
power supply before replacement.
l DC-DC is easily to short circuited or damaged under high voltage.
Please replace it in time if there is any damage. It is necessary to cut
off power supply before replacement.
l Various wires are easily to short circuit or open circuit due to vehicle
vibration, aging or falling off of plug from welding point. Please replace
them in time if there is any damage. It is necessary to cut off power
supply before replacement.
Regular
maintenance
l Check if any connector assembly loose. Please fix it if there is.
l Check if any cable worn. Please replace worn cable in time.
l Check the communication between BCU and BMU. If the communication abnormal, please check it
according to appendix. If the problem still cannot be solved, please contact technical support center of
our company in time.
l Check module collection accuracy; mainly refer to voltage accuracy and temperature accuracy. Please
check if the voltage within normal range with special instrument when measuring voltage. Also, use
special instrument to detect whether the battery temperature is consistent with the value displaying on
console. Please check it according to appendix if any abnormality. If the problem still cannot be solved,
please contact technical support center of our company in time.
l Regularly check whether LCD display is normal. Please check it according to appendix if there is any
abnormality. If the problem still cannot be solved, please contact technical support center of our company
in time.
l Regularly check if any module loose. Please tighten loose module in time.
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Appendix: System Accessories list
n Accessories list
No. Item Specification Qty Remarks
1 BCU BCU 1 PCS
2 BMU BMU,6-60 strings M PCS
3 Module communication cable （ ）meter M PCS Connect BMU and BCU, among
BMUs
4 CAN-bus cable （ ）meter 1 PCS Connect charger to BCU
5 BCU power cord （ ）meter 1 PCS Supply power for BCU
6 Voltage and temperature
detection cables N strings M（N+1）PCS
1 set of voltage detection cable
harness includes N+1 pieces of
voltage detection cable
7 Current sensor 0-1000A 1 PCS
8 Current sensor cables （ ）meter 1 PCS Connect current sensor to BCU
9 LCD communication cable （ ）meter 1 PCS Connect LCD to BCU
10 LCD display 3.5/5.7inch 1 PCS Optional
11 Outgoing inspection report 1 copy
12 Certificate of conformity 1 copy
13 Bill of sales 1 copy
