Gen4

Application
Note
Title App Note - BMS Interfacing
Filename App Note - BMS Interfacing.docx
Date of Creation 10/05/2011 14:46:00 by Matthew Karas
Last Updated 10/05/2011 22:05:00 by Matthew Karas
Revision 1

Contents
1. Introduction .................................................................................................................................... 2
2. Interfacing Gen4 to BMS Outputs ................................................................................................. 3
3. Extras............................................................................................................................................... 6

Sevcon Ltd
TVTE
Gateshead
Tyne & Wear
England NE11 0QA

Tel +44 (0)191 4979000

Fax +44 (0)191 4824223
www.sevcon.com

Commercially confidential You are authorised to open and view any

electronic copy we send you of this document within your organisation and
to print a single copy. Otherwise the material may not in whole or in part be
copied, stored electronically or communicated to third parties without the
prior written agreement of Sevcon Limited.
App Note - BMS Interfacing Commercially Confidential

1. Introduction
An application may have a sophisticated BMS system that controls lithium battery packs. The
Gen4 can be configured to interface with the BMS in a few ways.
This app note assumes that the reader has:
1. Knowledge of configuring VPDOs on the Gen4
2. Knowledge of setting up RPDOs on the Gen4
3. Confidence in using DVT and DVT Helper
4. Read through the Gen4 product manual
If this is not so, the app note will still give you some idea of what you would like to request from
a Sevcon application engineer.

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App Note - BMS Interfacing Commercially Confidential

2. Interfacing Gen4 to BMS Outputs

The BMS may have three types of outputs that can interface with the Gen4.
1. Digital outputs
2. Analog outputs
3. CAN or CANOpen Communication

2.1. Digital Outputs

If the BMS has digital outputs capable of pulling to ground when active, then you can configure
one or two of the Gen4’s driveability profile switches.
It is recommended that the drive profile for baseline, drive profile 1, and profile 2 are identical
except for torque limit in drive. That way, speed limits do not cause unexpected drive feel for EV
applications.
For example, you may limit the torque level on drive profile 1, so that the battery current limit is
cut by a percentage. Note that battery current doesn’t directly translate to a torque, but cutting
the torque by a half or more will definitely lower the battery current draw of the application.
You may set drive profile 1 as a limp mode - and drive profile 2 as a complete shutdown (zero
drive torque). Or you may just want to open the circuit when you want the battery to shut down
completely.

2.2. Analog Outputs

For a BMS that is capable of outputting an analog voltage in the 0-5V or 0-10V range, you would
configure the economy pot on the Gen4. This would give the BMS a refined control of the draw
of the motor.
For EV applications using torque mode you would set the economy function to “Max Torque”
Set up the economy pot as you would a standard throttle – where economy value of one is equal
to a total loss of torque.

Note: You may want to configure the analog input range on the gen4 to fault in the case of the
BMS outputting an erroneous voltage – or if the wire falls off. A fault analysis should be done to
understand the effects of a hardware fault.

Figure 1: A voltage input that exceeds the chosen range will cause a very severe fault.

2.3. CAN or CANOpen Communication

The BMS must only send out standard size Cob-ids to be compatible with the gen4. Take note
the battery cutback range should be configured correctly and the master battery current limit
should be disabled.

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App Note - BMS Interfacing Commercially Confidential

The BMS should be able to send out two 16 bit values for the positive and negative limits for
battery current. Discharge current is a positive number and recharge current is a negative value
(2’s compliment). One bit is equal to one amp.
The transmission rate should 250ms or faster so that CAN timeouts do not occur.
Here is an example configuration on the Gen4 where the CAN device sends out a message with
COB-ID of 0x0205

Here the message id is 0x0205 and in the first 16 bits is sent the negative charge current limit and
next the positive charge current. If the Gen4 properly receives this message it will try to limit the
current.
Note the cutback will start at the limit minus the cutback range – so if the limit is 100 and the
cutback range is 20 – torque will start dropping off at 80 Amps of draw.

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App Note - BMS Interfacing Commercially Confidential

If the BMS is CANOpen compliant, ensure that the heartbeat protocol is set up on the Gen4 and
BMS. NOTE: A heartbeat fault is a severe fault that will stop the application and open the line
contactor. If the BMS is not CANOpen compliant, then the customer must decide how the Gen4
should behave under a failure of the CAN bus.

For non-CANOpen systems configure the RPDO Timeout scheme to fault if the message takes
longer than 500 ms to send to the Gen4.
• Disabled – Use the last successful transmission value and continue running.
• Warn and Slow Down – A warning will be emitted to the CANOpen bus and the control
will switch to drive profile 2 (Set the profile 2 to something with much less drive torque
than the baseline profile)
• Inhibit drive – Stop the vehicle and if the fault clears you can put the drive into neutral
and then try to drive again.
• Severe – only a key recycle and working CAN bus will permit the drive operate correctly.
This setting will open the line contactor if configured and a timeout fault occurs.

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App Note - BMS Interfacing Commercially Confidential

3. Extras

A NOTE indicates important information that helps you make better use of your
computer system.

A CAUTION indicates either potential damage to hardware or loss of data and tells you
how to avoid the problem.

A WARNING indicates the potential for bodily harm and tells you how to avoid the
problem.

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