Single Cell Battery Board 4-Cell Battery Board
These boards monitor cell voltages, and :
- If a cell goes overcharged (over 3.7V), switches a bypass resistor across it, lights an LED and sends an alarm report.
- If a cell becomes under-discharged (below 2.6V), it lights up LED and sends remote alarm report
- If its temperature sensor detects hot battery, it lights LED and sends remote alarm report too.
ALARM REPORT PORT:
This port is optically-isolated i/o from battery boards and operates at EV accessory battery potential (referred ti chassis). As
described below, it connects to our Master Display unit or our Smart Charger and Smart Motor Controller.
These boards monitor cell voltages, and :
- If a cell goes overcharged (over 3.7V), switches a bypass resistor across it, lights an LED and sends an alarm report.
- If a cell becomes under-discharged (below 2.6V), it lights up LED and sends remote alarm report
- If its temperature sensor detects hot battery, it lights LED and sends remote alarm report too.
ALARM REPORT PORT:
This port is optically-isolated i/o from battery boards and operates at EV accessory battery potential (referred ti chassis). As
described below, it connects to our Master Display unit or our Smart Charger and Smart Motor Controller.
EVCraft Battery Management System (BMS)
& Battey Boxes
& Battey Boxes
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1. Resistor-Bypass type BMS:
- Switches a resistor to bypass charge current away from the overcharging cell
- Optically isolated report wires to Master Display and other remote units.
- LEDs to identity Troubled Cells
- Reduces Charge current when one cell is full ( for low-power balancing).
- Turns off the charger when all cells full.
- Turns OFF the Motor Controller after a timeout to move the vehicle to safety.
2. Combined Lithium Cell Charger / BMS
This innovative combined Charger / BMS features isolated parallel switch-mode Cell
Chargers and a BMS micro-controller on the battery boards. The micro-controller switches
OFF each Cell Charger when its cell is full (above 3.7V).
Similar to our traditional BMS, this system consists of Battery boards (say for 4-cell blocks)
and a Dash Master board. However, the bypass resistors of the traditional Resistor
System are replaced with the Cell Chargers. The Master Board is the same or the system
can be connected to our Smart Charger and Controller.
The input, to all battery boards, is either a common 115VAC (directly from AC line) or a
common 48VDC (from an input AC-DC converter).
In 48V version, A 48V solar panel can also be directly connected (without any
charge controller) to the 48VDC bus.
CELL-BMS System Wiring:
This innovative combined Charger / BMS features isolated parallel switch-mode Cell
Chargers and a BMS micro-controller on the battery boards. The micro-controller switches
OFF each Cell Charger when its cell is full (above 3.7V).
Similar to our traditional BMS, this system consists of Battery boards (say for 4-cell blocks)
and a Dash Master board. However, the bypass resistors of the traditional Resistor
System are replaced with the Cell Chargers. The Master Board is the same or the system
can be connected to our Smart Charger and Controller.
The input, to all battery boards, is either a common 115VAC (directly from AC line) or a
common 48VDC (from an input AC-DC converter).
In 48V version, A 48V solar panel can also be directly connected (without any
charge controller) to the 48VDC bus.
CELL-BMS System Wiring:
Our Modular BMS protects Lithium Battery from over-charge and
under-discharge, with minimum cost and minimum number of wires.
We also offer 12V Battery Boxes with internal Lithium cells, BMS and
Power Switch.
under-discharge, with minimum cost and minimum number of wires.
We also offer 12V Battery Boxes with internal Lithium cells, BMS and
Power Switch.
The system consists of:
Battery Board:
This board is installed on or close to each battery (either bolted to cell copper links or wired to cells). It is offered as a
Single Cell Board (1" x 3.5" size), 4-Cell (12V) or 5-cell (15V) Board; as seen below:
- Battery Board: installed on or close to the battery. It comes as a single-cell , 4-cell (12V) or 5-cell (15V) board.
- Remote Unit: It can be a smart Charger, Smart Load or a Master Display / Control unit.
Battery Board:
This board is installed on or close to each battery (either bolted to cell copper links or wired to cells). It is offered as a
Single Cell Board (1" x 3.5" size), 4-Cell (12V) or 5-cell (15V) Board; as seen below:
2. SMART CHARGER / LOAD:
The alarm report outputs of all battery boards can be connected to the
alarm inputs of our smart charger and smart Load (EV Motor Controller).
The firmware of smart charger, when one cell is full, lowers the charge
current. This reduces cell by-pass resistor heat. And, since cells charge
rapidly at the end of cycle, it does not increase overall charge time a lot.
The firmware of the smart load (Motor Controller) starts a timeout when one
cell is empty (to move EV to safety). After timeout, the load turns itself OFF.
We are offer Lithium version of our EVC203 and EVC207 chargers
with an alarm input and firmware to perform this task at no charge.
Also, our EVMTC Motor Controllers are offered with an alarm input
port and firmware to shutdown.
This makes our Charger, Controller and BMS family compatible.
They operate in the simplest way and offered at lowest price.
The alarm report outputs of all battery boards can be connected to the
alarm inputs of our smart charger and smart Load (EV Motor Controller).
The firmware of smart charger, when one cell is full, lowers the charge
current. This reduces cell by-pass resistor heat. And, since cells charge
rapidly at the end of cycle, it does not increase overall charge time a lot.
The firmware of the smart load (Motor Controller) starts a timeout when one
cell is empty (to move EV to safety). After timeout, the load turns itself OFF.
We are offer Lithium version of our EVC203 and EVC207 chargers
with an alarm input and firmware to perform this task at no charge.
Also, our EVMTC Motor Controllers are offered with an alarm input
port and firmware to shutdown.
This makes our Charger, Controller and BMS family compatible.
They operate in the simplest way and offered at lowest price.
Prices are as follows:
- Single cell Resistor-Bypass BMS Battery board......................$39 each (minimum 10 order)
- 4-Cell Resistor Bypass BMS Battery Board.............................$110 each
- 5-Cell Resistor Bypass BMS Battery board..............................$140 each
- 4-cell Cell Charger BMS board................................................$300 each
- BMS Master Disp;ay/ Control Board.........................................$150 each
- EVC207 Charger with BMS Alarm input....................................$1150
- EVC203 Charger with BMS Alarm input....................................$920
- EVMTC800A with BMS Alarm input...........................................$1190
3. Lithium Battery Boxes with BMS:
These boxes contain 4 LiFePO4 cells plus resistor-bypass BMS
and internal solid-stare switch. They are equivalent to common
12V battery. We have 2 types:
1. Backup 12V Battery box: This unit contains 4 lithium
cell, resistor-bypass type BMS and a low current (2 A) charger
regulator inside. This battery is used in applications requiring a
back-up battery; such as UPS. It is charged by an standard
16V-40VA class-2 bell transformer via a charge plug.
2. Standard 12V Battery Box: This unit contains 4
Lithium cells, Resistor-bypass BMS,a 2A charge current limiter
and bidirectional power switch.
It can be charged (up to 10A) and discharged up to 100A via its
power terminals ( just like a normal 12V battery). However, it
has internal switches to control the charge-discharge currents.
Upon charge, it first limits the charge current to 2A when one
cell is full then switches off this current when all 4 cells are full.
Upon discharge, BMS will switch off the load (through the power
switch) if one cell becomes under-discharged (empty).
Both of these battery boxes are available with 20, 40 and 100
AH cells; contact us for prices.
These boxes contain 4 LiFePO4 cells plus resistor-bypass BMS
and internal solid-stare switch. They are equivalent to common
12V battery. We have 2 types:
1. Backup 12V Battery box: This unit contains 4 lithium
cell, resistor-bypass type BMS and a low current (2 A) charger
regulator inside. This battery is used in applications requiring a
back-up battery; such as UPS. It is charged by an standard
16V-40VA class-2 bell transformer via a charge plug.
2. Standard 12V Battery Box: This unit contains 4
Lithium cells, Resistor-bypass BMS,a 2A charge current limiter
and bidirectional power switch.
It can be charged (up to 10A) and discharged up to 100A via its
power terminals ( just like a normal 12V battery). However, it
has internal switches to control the charge-discharge currents.
Upon charge, it first limits the charge current to 2A when one
cell is full then switches off this current when all 4 cells are full.
Upon discharge, BMS will switch off the load (through the power
switch) if one cell becomes under-discharged (empty).
Both of these battery boxes are available with 20, 40 and 100
AH cells; contact us for prices.
1. The Master Display / Control Board:
This board is installed in operator dash. It displays each battery board statefor 15 seconds and advances to the next. A
numeric display identifies which battery board is shown. It also sounds a buzzer if f the displayed battery has an alarm.
The cell status display is by color coded LEDs. LED color is Green in safe range (2.9V to 3.5V), Red for unsafe range
(below 2.7V or above 3.6V) and Yellow in near unsafe (2.6 to 2.7V or 3.5 to 3.6V).
The Battery Boards and Master Display are connected with an optically isolated daisy-chain network.
Optionally, the unit has relays to reduce charger current (after one cell full), to switch the charger OFF (once all cells are full)
or to switch Motor Controller key OFF (after a timeout following one cell empty).
NOTE: The above voltage thresholds are temperature compensated and can be programmed to different values for other
battery chemistries.
This board is installed in operator dash. It displays each battery board statefor 15 seconds and advances to the next. A
numeric display identifies which battery board is shown. It also sounds a buzzer if f the displayed battery has an alarm.
The cell status display is by color coded LEDs. LED color is Green in safe range (2.9V to 3.5V), Red for unsafe range
(below 2.7V or above 3.6V) and Yellow in near unsafe (2.6 to 2.7V or 3.5 to 3.6V).
The Battery Boards and Master Display are connected with an optically isolated daisy-chain network.
Optionally, the unit has relays to reduce charger current (after one cell full), to switch the charger OFF (once all cells are full)
or to switch Motor Controller key OFF (after a timeout following one cell empty).
NOTE: The above voltage thresholds are temperature compensated and can be programmed to different values for other
battery chemistries.
