This document describes the JDI Battery Management System (BMS), specifically the BI51 TYPE series, which includes models BI5116, BI5132, and BI5148. This system is designed for electric vehicles (EVs) and hybrid vehicles, offering comprehensive battery management capabilities.
Function Description
The JDI BI series BMS is an integrated battery management system that detects, manages, and controls batteries. It is suitable for various cell chemistries, including LiCoMnNiO2, LiFePO4, Ni-MH, and super capacitors, with cell voltages ranging from 0 to 5V. The system can manage batteries in single boxes and can be extended to manage batteries across several boxes through Battery Module-management Units (BMUs).
The core unit of the BMS is the Battery Integrated-management Unit (BIU), which collects battery information and analyzes it for management. Key functions include:
- State Estimation: Dynamically estimates State of Charge (SOC), State of Health (SOH), and State of Power (SOP) based on total current, total voltage, temperature, and other parameters.
- Current Detection: Real-time charge and discharge current detection using a Hall current sensor or diverter.
- Voltage Detection: Real-time single cell voltage detection and total battery pack voltage detection.
- Temperature Detection: Collects battery module temperatures via NTC temperature sensors (1-4 sensors per 16 cells).
- Communication:
- CAN-bus: Equipped with three CAN-bus interfaces (CAN0 for CSU and real-time current, CAN1 for charger, CAN2 for VCU/MCU).
- RS485: Used for external display of SOC, voltage, and current, and for program updates.
- Internal Communication: Communicates with other modules, charging devices, and vehicle systems.
- Warning and Protection: Conducts alarms and protection based on sampling information and state estimation results through built-in control strategies.
- System Self-check: Checks the function and state of each unit to ensure system safety.
- Control Output: Six relay control interfaces for charge, discharge, and auxiliary equipment.
- Digital Input: Four digital input interfaces for external digital control signals (e.g., active High, ACC, ON, Charging awaken).
- Analog Input: Three analog input interfaces for external analog control signals.
- Insulation Detection: Tests total voltage and positive/negative leakage current of the battery pack, alarming when insulation resistance falls below a threshold.
- Pre-charge Module: Controls load charging by pre-charging the main circuit load. AUX+ can control external pre-charge.
- Key Information Power-down Saving: Saves critical system data (Max&Min voltage, corresponding cells, SOC, current, history errors) upon detecting battery pack power-down.
The system components include:
- BIU (Battery Integrated-management Unit): Necessary, 1 piece. Handles internal/external communication, state estimation, safety management, charge/discharge management, input/output control, total voltage detection, insulation detection, single cell voltage collection, and temperature collection.
- CSU (Current Sample Unit): Necessary, 1 piece. Supports current collection via Hall current sensor and diverter.
- Cables: Necessary, 1 set. For voltage detection, temperature detection, communication, power, sensor, and control connections.
- BMU (Battery Module-management Unit): Optional, Max ≤ 10 pieces. Collects cell voltage and temperature, and communicates via DCT. Suitable for multiple batteries in separated boxes.
- LCD (Liquid Crystal Display): Optional, 1 piece. For data display, parameter configuration, and failure warning.
- DTU (Data Transfer Unit): Optional, 1 piece. For data remote upload/download and mobile application.
- PDU (Power Distribution Unit): Optional, 1 set. Includes pre-charge circuit, charging/discharging relays, main circuit over-current protection, and other power protectors.
Important Technical Specifications
Electrical Environment:
- Supply Voltage: 9-18V (typical 12V DC).
- Detection Range of Total Voltage: 9-400V.
- Detection Range of Single Cell Voltage: 0-5V.
- Detection Range of Current: -500A to 500A.
- Series of Battery: 4-160 cells (each board collects 16/32/48 cells at most, cascade extension supported).
- Detection Accuracy of Total Voltage: ≤0.2%.
- Detection Accuracy of Single Cell: ≤0.2%, ±5mV error.
- Current Detection Error: ≤0.5%FSR, typical 0.5A.
- Temperature Detection Range: -40°C to 125°C.
- Temperature Detection Accuracy: 0-2°C (NTC, 100K).
- Detection Error Insulation Resistance: 0-200KΩ (error < 10KΩ); >200KΩ (error ≤ ±10%).
- Balance Current: 50-120mA.
- Min Voltage Difference of Starting Balance: 30-800mV (configurable).
- CAN-bus Channel: 3 (Charger/Vehicle/BIU&BMU, CAN2.0B).
- Serial Port: 1 (for programming software and display connection).
- Relay Output Channel: 4 (Active, continuous current 1A, instantaneous 5A).
- Input Channel Number: 4 (Active High, ACC, ON, Charging awaken).
- Charging Connect Confirmation: 3 (CC2, CC, CP).
- Max Cascade of BIU and BMU: 10 units.
- SOC Estimation Error:
- SOC≤20%, SOC≥80%: 3%.
- 80%>SOC>20%: 5%.
- SOH Estimation Accuracy:
- SOH>80%: error within 5%.
- SOH ≤ 80%: error within 10%.
Environmental Parameters:
- Operating Temperature: -30°C to 85°C.
- Storage Temperature: -40°C to 125°C.
- Altitude: 4000m.
- Humidity: 95%RH (no droplet).
- Atmosphere Pressure: 57-101kPa.
- Salt Spray (Continued Atomization Time): 16h.
Mechanical Parameters:
- Vibration (Amplitude or Acceleration):
- 30 m/S² (Amplitude 1.2mm when 10-25Hz).
- Max 30 m/S² when 26-500Hz.
- Drop (Height): 1.5m (Horizontal vertical direction).
- Impact (Acceleration): 150 m/S² (Adopting half sin shock wave).
- Dustproof & Waterproof (IP Degree): 54 (GB 4208).
Physical Dimensions and Weight:
- BI5116: 184x 108.1x 31.2 mm, 490g.
- BI5132: 230x 108.1x 31.2 mm, 620g.
- BI5148: 276x 108.1x 31.2 mm, 750g.
- BM5116: 117.76 x 80.73 x 24.88 mm, 120g.
Usage Features
First Installation Guide:
- Open-package Checking: Verify quantity and specifications against the packing list; inspect surfaces of modules, cables, and accessories.
- Safety Confirmation: Read the manual thoroughly; prepare instruments and installation environment.
- Environment Confirmation: Ensure the operating environment meets requirements; contact service staff if unsuitable.
- Function Confirmation: Understand module functions and interfaces from the system overview.
- Components Installation: Install hardware near batteries, charger, or motor controller, ensuring fastening meets vibration and impact demands.
- Cables Installation:
- Cut off power to high and low voltage circuits.
- Connect communication, control, and temperature cables.
- Connect voltage collection cables to cells orderly and correctly (very important).
- Connect insulation detection and high voltage detection cables (optional).
- Check all cable connections against the system diagram for correctness and reliability.
- Notice: All connectors must be locked; avoid conductive impurities; ensure power is off before connecting cables.
- Adjusting Confirmation: After connecting components, power on the BMS. Observe display information and relay state. If errors occur, check connections or contact service staff.
- Power-on Test: Perform a charge-discharge experiment to observe system operation. Record any errors; confirm normal operation if no errors.
Operating Environment:
- Avoid water, dust, and strong electromagnetic environments.
- The operator must be an electric engineer.
- The system is for monitoring and managing battery packs.
- Check power supply voltage (9-32V).
- Install cables strictly according to battery order.
Software Introduction:
- Main Interface ("Overview"): Displays basic battery and BMS information, function windows, and system error information.
- Cell Information Interface: Displays individual cell voltage and temperature data.
- Calibration Interface: Configures BMS parameters and simulates failures. Supports manual modification and batch import/export of parameters. Changes require "Flash" to be saved.
- Software Upgrade: Use the "Upgrade" function in the upper computer software to burn new programs.
Maintenance Features
Safety Notice (Danger Levels):
- Caution: Ignoring notices or not taking measures may lead to unexpected results or property loss.
- Carefully: Not being careful may cause personal injury or significant property loss.
- Danger: Not being careful may cause serious injuries or death.
Reminders (Before Installation):
- Do not install if components are missing or hardware/cables are damaged.
- Do not install if water is found on the box or if water has entered.
- Handle gently during unpacking and moving to prevent equipment damage.
Reminders (Installation):
- To avoid accidents, power supply should be shut down during installation.
- Use insulating tools.
- Carefully check voltage collecting cables for damage or loose connectors.
- Ensure relay cables are installed correctly to prevent serious battery pack damage and fire.
Reminders (Maintenance):
- Unauthorized persons should not repair or maintain the system.
- Do not repair or maintain when the system is powered on.
- Non-authorized persons should not break the module box.
- Prevent static electricity; do not touch high-accuracy devices.
- Unauthorized changing of the system is forbidden.
- Unauthorized persons should not test signals during system operation to avoid personal injury and system damage.
- Protect the system from water-drop, dust, or other particles to avoid serious accidents.
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