Nilar High voltage energy storage solutions

Transcription

1 Specifications Nilar High voltage energy storage solutions Nilar offers high power battery solutions that are easy to use, robust, resource efficient and have a low lifetime cost. High voltage energy storage systems from Nilar are optimised for industrial use with a nominal system voltage from 60 V up to 720 V.

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3 03 Contents Monitoring unit... 4 Architecture... 4 Functions... 4 Interfaces... 4 Jumper configurations... 5 Module jumper configurations... 5 CAN jumper configuration... 6 RS-485 jumper configurations... 6 Baud rate and address DIP switch configurations. 6 LED indicators... 7 Montoring unit hardware I/O... 8 Module voltages... 9 Pressure sensors... 9 Battery pack temperature... 9 Monitoring unit temperature... 9 Current sensor... 9 Communication bus CAN... 9 Communication bus RS Power... 9 Ground... 9 I/O Pinout and connector interfaces pin high density D-sub RJ Green PTSM_ Black PTSM_ Black PTSM_ Interface communication protocol CAN communications Standard data frame CAN SOF Identifier RTR IDE r DLC Data CRC ACK EOF IFS CANOpen messages System request Reset flags Indicators Datum index, sub-index, and data Calibration Calibration control Setpoint voltages Monitoring unit process data Pack voltages Pack current Pack pressure Pack temperature Pack status Monitoring status SOC Indicators Module voltage low Module voltage high Datum System limit information Software flow Hardware Electrical isolation boundaries... 23

4 04 Monitoring unit The monitoring unit is a part of Nilar High Voltage battery management system (Nilar High Voltage BMS). The monitoring unit is mounted on each battery pack in high voltage energy storage systems offered by Nilar. The unit is monitoring module potentials (every 10 cells) in the battery pack, pack temperature, pack pressure and bi-directional pack current. Pack condition data and other input to battery management algorithms are communicated via a field-bus interface to the Nilar High Voltage BMS. The monitoring units are powered by an external power supply of 24 VDC (not from the battery pack). As this system is connected to a common voltage bus, the monitoring unit will issue warnings if string isolation is warranted. The monitoring unit is using the CANopen application programming interface, ISO :2003 standard CAN with an 11-bit identifier. Nilar High Voltage energy storage solutions are optimized for industrial systems having a common voltage bus that the battery will charge and discharge on. The battery management software is downloaded in an industrial programmable logical controller (PLC). Nilar High Voltage BMS is controlling the battery by communicating with the central management system for the specific application. Managing the battery within the operating limits to meet the designed service life of Nilar High Voltage energy storage, in a specific application, is mastered by the Nilar High Voltage BMS and the communication and control functions of the PLC. The large amount of data measured and monitored at high frequency, by the monitoring unit, on pack level is processed by the BMS Architecture ARM Cortex M10 microprocessor (designed for a distributed and scalable topology in a slave unit configuration) Sensing 10 voltage channels with 8 to 18V range 1 external pack temperature 1 internal ambient temperature 2 external currents using hall sensor 1 external pack pressure Functions Limit flag reporting Module voltage Current Pressure Temperature Interfaces Isolation boundaries Power supply to AGND (500 VCD) CAN Bus to AGND (1.5 kvdc) Voltage monitors to AGND (3 kvdc) Input Power 24 V supply power range from 18 to 36 VDC 5 V CAN bus power (no CAN power supply installed) Communications interface CAN/CANOpen Connectors Input power: Phoenix PTSM_ (Green) 4 pin CAN: Shielded RJ-45 8 pin Current sensor connector High density 15 pin D-sub 10 pack voltages Pack temperature Pack pressure

5 05 Jumper configurations Module jumper configurations The monitoring unit can be adapted to monitor 10 module voltages connected in both series and parallel. This is accomplished with jumper pins. The modules can be configured in a number of different pack sizes with varying voltages and capacities. The number of modules in a pack can range between 1 and 10 with voltages between 12 V and 120 V nominal. Every module will have a voltage tap connected to its most positive terminal. Each voltage tap will have a differential to the other voltage taps. The following figure shows the location of the voltage monitoring jumpers. These jumpers are set based on if a module negative terminal is connected in or to the pack ground. MODULE PACK Module X in series with Module X+1 Configuration B Negative terminal of Module X referenced to the Pack GND Configuration B Figure 1. Module voltage jumper locations. Table 1. Module voltage jumper configurations. Module voltage potential Module 1 Module 2 Module 3 Module 4 Module 5 Module 6 Module 7 Module 8 Module 9 Module V 24 V 36 V 48 V 60 V 72 V 84 V 96 V 108 V 120 V 12 V 24 V 36 V 48 V 60 V 12 V 24 V 36 V 48 V 60 V 12 V 24 V 12 V 24 V 12 V 24 V 12 V 24 V 12 V 24 V 12 V 24 V 36 V 12 V 24 V 36 V 12 V 24 V 36 V 12 V 24 V 36 V 48 V 12 V 24 V 36 V 48 V

6 06 CAN jumper configuration The CAN bus jumper configuration allows for termination and power isolation. See Figure 2 and Table 2 for configurations. Jumper positions 1 and 2 are not used. They are a bypass for the TTL level CAN interface and used only for monitoring unit servicing. Jumpers 3 and 4 are used to terminate the bus. If the monitoring unit is the last in the chain, then both jumpers should be installed. Installing these jumpers on multiple monitoring units will cause the bus to stop working. Jumpers 5 and 6 are used if an external 5 V supply is not available. Using the internal 5 V supply is only recommended on systems with a nominal voltage above 120 V. RS-485 jumper configurations The 4 position switch set the type of RS-485 node for the monitoring unit. The supported node types are master, slave, and interstitial node. See Figure 2 and Table 3 for configurations. Baud rate and address DIP switch configurations The 8 position DIP switch is used to set both the baud rate and monitoring unit address. Addresses are set via switches 1 to 6 and baud rate is set on switches 7 and 8. Addresses numbering is arbitrary however it is suggested that the method shown in Table 4 should be followed. Table 2. CAN bus jumper configurations. Jumper position Definition x x x x TTL level CAN bypass for monitoring unit servicing only x x 1 1 x x End of CAN cable termination x x x x 1 1 CAN power 5 V isolation bypass Table 3. RS-485 jumper configurations. Jumper position Definition Set monitoring unit as master node Set monitoring unit as end node Set monitoring unit as an interstitial node Table 4. Baud rate and address jumper settings String address in binary starting at 1. EX: String 10 would be 1=0, 2=1, 3=0, 4= Position address in binary starting at 0. EX: String 10, Position B would be 5=0, 6=1 Position Switch 5 Switch Baud rate settings A = Off B = On C 0 1 X = Don't Care if it is On or Off D 1 1 Rate Switch 7 Switch kbs kbs kbs kbs 1 1 NOTE: Per ISO1050 standard recommends less than 30 CAN nodes and less than 40 meters cable length.

7 07 LED indicators Table 5. LED indicators Limit Flags will cycle once a second, when values are return to normal they will clear from the cycle Switch 1 Switch 2 Switch All OK, will transition to this state between limit(s) reported 1 x x Voltage limit out of range x 1 x Temperature limit out of range x x 1 Pressure limit out of range 4..5 CAN NMT state indication Switch 4 Switch Initialize 1 0 Pre-operational 0 1 Stopped 1 1 Operational 6 CAN message transmission (TX). LED is lit whenever a CAN message is transmitted and remains on for at least 1/10 second. 7 CAN message reception (RX). LED is lit whenever a CAN message is received and remains on for at least 1/10 second. 8 Main loop and timer execution. Flash at one second rate indicates proper operation. CAN Settings Use Internal +5 V Supply Terminate Do NOT Connect DIP Switches ON OFF 8 Baud Rate Configuration Node ID/Address RS 486 Termination LEDs Figure 2. Jumper configurations. Node Slave Master Heartbeat CAN RX CAN TX State Limit Flags

8 08 Monitoring unit hardware I/O The follow section describes the hardware I/O between the monitoring unit and its peripherals. Table 6. Monitoring unit I/O electrical specification. Voltage monitor sensor 10 Input Analog Differential V See Figure V Ref: Pack GND 12 bit +/- 5 mv Offset 10 mv Accuracy NOTE: Each module (Mn) can have different voltages, as referenced to GND. Please look at Table 1 for possible configurations. Pressure sensors Battery temperature Monitoring unit temperature 1 Input Analog PSIA 0..6 V Ref: AGND 8 bit +/-2 PSI offset +/-0.05 PSI accuracy 1 Input Analog -40 to 85 C 0..6 V Ref: AGND 8 bit +/- 0.5 C offset +/- 0.5 C accuracy 1 Input Analog -40 to 85 C 0..6 V Ref: AGND 8 bit +/- 0.5 C +/- 0.5 C accuracy Current sensor 1-2 Input Analog LEM DHAB 14S +/- 30 A Channel A Channel 2 LEM DHAB 34S +/- 50 A Channel 1 +/- 200 A Channel 2 LEM DHAB 44S +/- 20 A Channel A Channel V Ref: AGND 12 bit Open Loop Hall effect sensor Temperature range: -40 C to +125 C Bus CAN 1 Bi-directional Digital Isolated CAN Differential > 5 V V Ref: Ext CAN GND ISO ISO1050DW ISO1050DUB Loop Delay 210 ns (Max) 50 kv / μs Transient Immunity IEC (VDE 0884, Rev. 2) IEC UL 1577 IEC RS Bi-directional Digital Isolated RS-485 Differential > 2 V V Ref: AGND ANSI TIA/EIA-485-A ISO 8482:1987(E) Input power 1 Input Power Isolated monitoring unit power V V Isolated Ref: Input GND Hz Ripple (< 500 mv) Input GND 1 Input Power 0 V Isolated +/-100 mv

9 09 Table 6. cont. Ext CAN +5 V 1 Input/ Output Power Isolated CAN power 5 V 0..6 V Isolated Ref: Ext CAN GND +/-300 mv Ext CAN GND 1 Input/ Output Power +5 V 1 Output Power 5 V Isolated sensor power 0..6 V Isolated Ref: AGND AGND 1 Output Power Reset 1 Input Digital 0..5 V 0..6 V Opto isolated Ref: Ext CAN GND ISP mode Input Digital 0..5 V 0..6 V Opto isolated Ref: Ext CAN GND ISP select Input Digital 0..5 V 0..6 V Opto isolated Ref: Ext CAN GND Module voltages These are signals that measure the voltage at the highest potential of each model to pack GND or series connected module, see Figure 1 and Table 1 for more information. These signals provide reference for battery management algorithms. They also provide diagnostic information regarding internal resistance and battery balance. Since the pack voltage can exceed 60 VDC the modules need to be isolated from the ucontroller for measurement. In addition, the voltage at each tap is determined by the type of battery pack it is connected to. Table 1 shows the common combinations that are possible. Calibration is required with variables stored in the ucontroller s upper 4k memory block. The voltage that the monitoring unit requires is the differential value between the positive and negative potential of the 10 cell module. This range is between 8 V and 16 V and should be scaled to full range at the ucontroller. Pressure sensors Internal battery pressure sensing is a unique feature of Nilar battery packs. The charge and discharge functions use pressure as a means to indicate end of charge, discharge, and abuse. Battery pack temperature The battery pack temperature is an accurate indication of the temperature of the battery pack at the location of the sensor. This value is used for battery models used to determine charge limits, abuse limits, SOC and SOH. Monitoring unit temperature This will monitor the air temperature inside the monitoring unit. Current sensor The current is measured via an isolated hall effect sensor. This signal gives the bi-directional current flow used for battery management algorithms such as Coulomb counting for SOC. The measurement between reads is integrated and averaged. Communication bus CAN Communications between the monitoring unit and the PLC. Bus communications will use the CANOpen standard. See section CAN communications for more information. Communication bus RS-485 This communication bus is not available on some systems. It is available upon request. This bus can write passively measurement data and limit flags. Power Main power for the monitoring unit. The monitoring unit has a resettable fuse for reverse polarity protection however it is suggested that a master fuse or circuit breaker be installed at the appropriate fuse block. This power is not switched in normal operation. The connector is designed to daisy chain power from one connector to the next. For more than 15 monitoring units in a system, it is recommended that the power is connect from both ends of the monitoring unit chain. Ground Chassis ground of the electrical system. An adequately sized wire must be presented that is free of any ground loop problems. The connector is designed to daisy chain power from one connector to the next. For more than 15 monitoring units in a system, it is recommended that the power is connect from both ends of the monitoring unit chain.

10 Circuit Breaker Fuse LMUCurrent sensor 10 LMU-pack LMU PLC LMU DC/DC Converter LMU I/O Pinout and connector interfaces Field bus The following HMI section shows the pin interfaces LMU for the various LMU monitoring unit connectors. Common voltage bus Current sensor LMU-pack DC/DC Converter Common voltage bus Field bus High LMU-packs 15-pin high density D-sub The 15 pin male high density D-sub connector receives module voltage, pack temperature, and pack pressure signals. It also include the temperature and pressure power and AGND reference. This connector is located on the same side as the CAN communications. The pinout for this connector is shown in Figure 3. RJ-45 CAN, see Figure 3. r Out D +5V Power Out Battery GND mperature essure 2) V Module 5 ) V Module 4 ) V Module 3 3) V Module 2 (6) V Module 10 (1) V Module 9 (11) V Module 8 (7) V Module 7 (2) V Module 6 Battery Temperature Battery Pressure AGND ) V Module 1 Figure 3. High voltage and CAN connector pin outs. (12) V Module 5 (8) V Module 4 (3) V Module 3 (13) V Module 2 (9) V Module 1 CAN H CAN L CAN Vcc CAN GND System Reset ISP Mode ISP Select Pass Through CAN H CAN L CAN Vcc CAN GND System Reset ISP Mode ISP Select Pass Through Green PTSM_ This connector is for the 24 V input power, see Figure 4. Black PTSM_ This connector attaches to a LEM HB series Current sensor. Black PTSM_ The RS-485 interface is available upon request, otherwise this connector is not populated on the monitoring unit s PCB. +24 V Power In +24 V Power In 0 V Power In 0 V Power In +24 V Power In +24 V Power In 0 V Power In 0 V Power In AGND Out Current Signal B In Current Signal A In +5 V Out AGND Out Current Signal B In Current Signal A In +5 V Out Figure 4. Power and current sensor connector pin outs.

11 High LMU-packs 11 Interface communication protocol CAN communications The main communication between the battery management system and the monitoring unit is a CAN bus using the CANOpen API. CANOpen uses ISO-11898:2003 Standard CAN with an 11-bit identifier. The bus signaling rates from 125 kbps to 1 Mbps. The monitoring unit bus rate is set to 250 kbs. This section will define the messages between the monitoring unit and Nilar High Voltage BMS. Standard data frame CAN Table 7. CAN frame. SOF 11-bit identifier RTF IDE r0 DLC 0 8 Bytes of data CRC ACK EOF IFS 0 11b b 0b.. 64b 16b 2b 7b 7b SOF The single dominant start of frame (SOF) bit marks the start of a message, and is used to synchronize the nodes on a bus after being idle. Identifier The Standard CAN 11-bit identifier establishes the priority of the message. The lower the binary value, the higher its priority. RTR The single remote transmission request (RTR) bit is dominant when information is required from another node. All nodes receive the request, but the identifier determines the specified node. The responding data is also received by all nodes and used by any node interested. In this way, all data being used in a system is uniform. IDE A dominant single identifier extension (IDE) bit means that a standard CAN identifier with no extension is being transmitted. r0 Reserved bit (for possible use by future standard amendment). DLC The 4-bit data length code (DLC) contains the number of bytes of data being transmitted. Data Up to 64 bits of application data may be transmitted. CRC The 16-bit (15 bits plus delimiter) cyclic redundancy check (CRC) contains the checksum (number of bits transmitted) of the preceding application data for error detection. ACK Every node receiving an accurate message overwrites this recessive bit in the original message with a dominate bit, indicating an error-free message has been sent. Should a receiving node detect an error and leave this bit recessive, it discards the message and the sending node repeats the message after rearbitration. In this way, each node acknowledges (ACK) the integrity of its data. ACK is 2 bits, one is the acknowledgment bit and the second is a delimiter. EOF This end-of-frame (EOF), 7-bit field marks the end of a CAN frame (message) and disables bit-stuffing, indicating a stuffing error when dominant. When 5 bits of the same logic level occur in succession during normal operation, a bit of the opposite logic level is stuffed into the data. IFS This 7-bit interframe space (IFS) contains the time required by the controller to move a correctly received frame to its proper position in a message buffer area.

12 12 CANOpen messages There are 5 main PDO messages than are used to report measured sensor values, diagnostic information, and make/reset information on the monitoring unit. Table 8. Monitoring unit CANOpen PDO messages. TX RX Type CANOpen Object EDS Common object identifier (COB-ID) Bytes PDO 0x1400 Node_ID+0x Entries Name PDO 0x1401 Node_ID+0x Obsolete System request will reset limit flags reported in monitoring unit process data. Indicate to the monitoring unit the system state, and Request the monitoring unit send detailed data. PDO 0x1800 Node_ID+0x Pack data (V,I,P,T,alerts) PDO 0x1801 Node_ID+0x Module alerts (V,I,P,T) PDO 0x1802 Node_ID+0x Snapshot data monitoring unit variable data NOTE: Node ID is the same as the monitoring unit address set on the 8 position DIP switch, see section Baud Rate/Address DIP switch configurations. System request Table 9. CANOpen COB 0x200 system request message. Byte Field Name Value Description 0 Reset flags uint8: bit field Limits are sticky, once they are set they can only be reset via this PDO.0 Voltage low =reset limit.1 Voltage high =reset limit.2 Current low =reset limit.3 Current high =reset limit.4 Temperature low =reset limit.5 Temperature high =reset limit.6 Pressure low =reset limit.7 Pressure high =reset limit

13 13 Byte Field Name Value Description 1 Indicators uint8: bit field.0 Running =true.1 Charge =true.2 Forced run =true.3 Charging complete =true.4 SoH < 80 % =true.5 Contactors engaged =true.6 Request status PDO =true.7 Take data snapshot =Record snapshot and transmit via COB 0x Datum index 0x xFFFF For internal use only Contact Nilar for more details (set to 0x0000 for correct operation) 4 Datum sub-index 0x00..0xFF For internal use only Contact Nilar for more details (set to 0x0000 for correct operation) 5-7 Datum data 0x xFFFFFF Reset flags When a limit is crossed for any of the limit thresholds show in the system limit condition section, a flag is latched for the corresponding event. This flag is reported in the monitoring unit process data and monitoring unit status messages. To reset the flag state its corresponding reset flag must be set to 1 in the system request message. In the event that the monitoring unit process data shows the same flag being set after a reset, this should alert the battery management system of a potential problem warranting further investigation. In addition to resetting the limit flag(s), depending on the type of flag, the min or max measurements will also reset at the time of this request.

14 14 Indicators The following system indicators put the monitoring unit into a normal data capture state where data will be sent via a PDO with COB-ID 0x180. Running bit 0, a 1 indicates the PLC is in normal run mode. Charge bit 1, a 1 indicates the battery pack is in charge mode. Forced Run Charging Complete SoH < 80% bit 2, a 1 indicates that additional battery power is required and that some limits will be ignored while in this mode. bit 3, a 1 signals that the charger will disconnect and that the batteries have been fully charged. Please note this resets the internal SOC estimation to 100 %. bit 4, a 1 indicates that the battery is nearing its end of life and may require service. Contators engaged Contators disengaged Request status PDO Take data snapshot bit 5, when set to 1 the monitoring unit s battery string is connected to the main DC bus. bit 5, is set to 0 indicating that the battery string is not connected to the DC bus via the contactors. When bit 6 is 1 this will trigger the monitoring unit to send the 0x280 PDO. When bit 7 is high this will trigger the monitoring unit to capture and send voltage data from each module. When transmitting this data via COB-ID 0x380 this bit should be low if an additional request is sent to prevent a data recapture. The purposes for this message is calculating the module internal resistance. Taking 2 snap shots at different currents allows the battery management system to calculate internal resistance. Datum index, sub-index, and data This portion of the message will tell the monitoring unit to transmit or set specific data. This value will indicate the exact data to send. For more information regarding this message please contact Nilar for details. The only valid value to send in this part of the message is all zeros (0X ).

15 Calibration This message should never be used in normal operation. Please contact Nilar before attempting to use these messages. Improper use of this message will result in lost calibration. Table 10. CANOpen COB 0x300 calibration message. Byte Field Name Value Details 0 Calibration control Uint8: Setpoint low voltage 2 1=reset limit.1 Setpoint high voltage 3 1=reset limit.2 Calculate voltages 4 1=reset limit.3 Commit calibration 5 1=reset limit 1-2 Setpoint voltage =reset limit Calibration control This message is designed to calibrate module voltage monitors. Calibration is performed by setting a common voltage for all the modules. The jumpers should be configured for all modules referenced to pack GND, see Figure 1 and Table 1 for more information. The Nilar High Voltage BMS will perform this operation in the following flow: 1. BMS will set a low voltage ~10 V and allow the monitoring unit to sample all voltage channels 2. BMS will send a setpoint low voltage command along with the setpoint voltage value 3. Monitoring unit will store the sampled voltages and the setpoint voltage in a temporary register 4. BMS will repeat this for the setpoint high voltage at ~15 V 5. Then the BMS will send a calculate voltages to the monitoring unit 6. If the voltage coefficients are within a tolerance the BMS will send a commit calibration message to the monitoring unit and the monitoring unit will move the coefficients into flash memory. Setpoint voltages This is the value of the external voltage applied to the monitoring unit for calibration. This applied voltage and the setpoint voltage value need a tolerance within +/- 5 mv.

16 16 Monitoring unit process data Table 11. CANOpen COB 0x180 monitoring unit process data message. Byte Field name Value 0-1 Pack voltage unit16: / V 2-3 Pack current uint16: / A 4 Pack pressure Unit8: / PSIA 5 Pack temperature Unit8: 0.255/ C 6-7 Pack status uint16: bit field Limit value reached.0 Voltage low 0..1 See System Limit Condition section.1 Voltage high 0..1 See System Limit Condition section.2 Current low 0..1 See System Limit Condition section.3 Current high 0..1 See System Limit Condition section.4 Temperature low 0..1 See System Limit Condition section.5 Temperature high 0..1 See System Limit Condition section.6 Pressure low 0..1 See System Limit Condition section.7 Pressure high 0..1 See System Limit Condition section.8 Cell fault 0..1 Detect cell drop via dv/dv (module to module).9 Power failure 3.3 V V power supply out of range +/-200 mv.10 Power failure 5 V V power supply out of range +/- 200 mv.11 Power failure 12 V V power supply out of range +/- 500 mv.12 Charging complete 0..1 Detect full charge.13 Reserved Stale time update 0..1 Indicates time code reception time-out.15 Node guard 0..1 Toggles once per second Calibration control This is the summation of all 10 module voltages reported in 100 mv (2000 = 200 V). Pack current This is the average current between reported samples reported in 10 ma (1000 = 10 A). A value of 300 indicates that the sensor is not connected. Pack pressure This is the average pressure between reported samples (13 = 13 PSI absolute). A value of 200 indicates the sensor is not connected. Pack temperature This is the measured temperature between 1 second measurements reported as a linearly scaled integer (0 = -25 C 255 = 75 C) Pack status This is a list of limits flags. If at any time a system limit condition threshold is reached, its corresponding limit is latched until a system request is send to reset the flag.

17 17 Monitoring status Table 12. CANOpen COB 0x280 monitoring unit status message. Byte Field name Value Description 0 SOC uint8: (0-100 %) Battery pack estimated SOC 1 Indicators uint8: bit field -.0 Reserved Reserved Reserved Reserved Reserved Reserved Reserved Node guard 0..1 Toggles once per second 2-3 Module voltage low uint16: bit field Indicates individual modules that have tripped low voltage limits. These are stick bits and are reset via COB 0x200 byte 0 Reset Flags.0 Low voltage module indicates voltage was below low limit.1 Low voltage module indicates voltage was below low limit.2 Low voltage module indicates voltage was below low limit.3 Low voltage module indicates voltage was below low limit.4 Low voltage module indicates voltage was below low limit.5 Low voltage module indicates voltage was below low limit.6 Low voltage module indicates voltage was below low limit.7 Low voltage module indicates voltage was below low limit.8 Low voltage module indicates voltage was below low limit.9 Low voltage module indicates voltage was below low limit.10 Reserved Reserved Reserved Reserved Reserved Reserved

18 18 Table 12. cont. Byte Field name Value Description 4-5 Module voltage high Uint16: bit field Indicates individual modules that have tripped high voltage limits.0 High voltage module indicates voltage was above high limit.1 High voltage module indicates voltage was above high limit.2 High voltage module indicates voltage was above high limit.3 High voltage module indicates voltage was above high limit.4 High voltage module indicates voltage was above high limit.5 High voltage module indicates voltage was above high limit.6 High voltage module indicates voltage was above high limit.7 High voltage module indicates voltage was above high limit.8 High voltage module indicates voltage was above high limit.9 High voltage module indicates voltage was above high limit.10 Reserved Reserved Reserved Reserved Reserved Reserved SOC When the system is turned on for the first time, an estimated SOC based on voltage and temperature is calculated. Once the battery pack is in operation, SOC is adjusted via coulomb counting. SOC will limit to 100 % and will use the System Request > Indicators > Charging Complete to reset the SOC value to 100 %. Note it is important not to set the Charging Complete flag if only a partial charge is accomplished. Indicators This message sends a cyclic node-guard bit every second. This bit will toggle to ensure communication for the monitoring unit as a network node. Note this is not the present CANOpen standard and does not use the objects [1017] or [1016]. Module voltage low Reports each module s low voltage limit flag state. If a module has a value of 1, this indicates that a low voltage condition was observed and latched. These values can only be reset by System Request > Reset Flag > Voltage Low being set to 1. Module voltage high Reports each module s high voltage limit flag state. If a module has a value of 1, this indicates that a high voltage condition was observed and latched. These values can only be reset by System Request > Reset Flag > Voltage High being set to 1.

19 19 Datum This section is for custom data reporting per application. Please contact Nilar for more information. Table 13. CANOpen COB 0x380 send datum message. Byte Field name Value Description 0 Reserved 0x00..0xFF Index 0x xFFFF - 3 Sub-index 0x00..0xFF Value 0x xFFFFFFFF Data value in HEX, may require conversion/ transfer function System limit information These values are defaults and subject to change per application. Please contact Nilar for more information. Table 14. Monitoring unit default system limits. Signal High limit Low limit Notes Voltage 15.5 V / module 11 V / module Subject to change per application Current 16 A -16 A Subject to change per application Temperature 55 C -10 C Subject to change per application Pressure 65 PSIA 0 PSIA Subject to change per application

20 RS Software flow Main Program Main program Main Loop Set Unique Serial Number From CPUD NEW CAN Sync mode_id 0x080 Send CANOpen Data PDO mode_id 0x180 Start Timers (1ms) Init SPI Bus Loop_Timer Incremented? Read DIP Switch Settings Acquire =10ms Init RS-485 Bus Reset Acquire Timer Init ADC Ports ADC Acquire Heartbeat = period Toggle Node Guard Init CAN Bus Print Data Header On RS-485 Set Timeout Alert Timeout >1min NEW CAN SYNC COB 0x100 Reset Heartbeat Timer Update UI LEDs Reset Timeout Timer Main Loop Send Data to RS-485 Main Loop Figure 5. Main software flow chart.

21 21 Main Program cont. ADC Acquire Measure V Modules Update Min V Update Max V Update V Limits Measure Current Measure Min Current Measure Max Current Update SOC Update Current Alerts Measure Pressure Update Pressure Alerts Check Power Supplies Check Power Alerts Return Figure 6. Main software flow chart continued. CANOpen Interrupts CAN RX Turn On UI CAN RX LED PLC State Start NMT COB 0X000 Data (0) Byte = 0x81 PLC State Pre Op Return BYNC COB 0x80 Increment Sync Count Figure 7. CAN message interrupt.

22 22 CANOpen Interrupts cont. TIME COB 0x100 Reset Timeout Status Update Monitoring Unit Time PDO1 COB 0x200 System Request PDO2 COB 0x300 Calibration System Request Running Charge Forced Rus Limits = 0 Update Indicators SOC Update Normal Reset Limit Flags SOC = 100% Charge Complete Not Used SoH < 50% Full Operation TX COB 0x180 Contactor Engaged Lower Bus Traffic Turn Off TX COB 0x180 Request Status PDO Status PDO COB 0x280 Bend Module Voltages (10x) COB 0x380 Store Module Voltages Take Snapshot Send Detailed Data Datum PDO COB 0x380 Figure 8. CAN message interrupt continued. Return

23 +24 V Power In +24 V Power In 0 V Power In 0 V Power In AGND Out Current Signal B In Current Signal A In +5 V Out 23 Hardware Electrical isolation boundaries Module 1 Pressure and temperature sensors Temperature sensors ucontroller CAN Power supply Module 2 Module 3 Module 4 Module 5 Module 6 Module 7 Module 8 Module 9 Module 10 RS-485 Figure 9. Electrical isolation boundaries.

24 Nilar AB Sales and Distributor Stockholmsvägen 116 B SE Täby Sweden Phone: +46 (0) sales.europe@nilar.com Nilar Inc. Sales and Distributor Suite 525, E. Bethany Drive Aurora, CO USA Phone: sales.america@nilar.com Nilar AB Production unit Bönavägen 55 Box 8020 SE Gävle Sweden Phone: +46 (0) production@nilar.com Nilar Doc. No.: 73-F005-R01