Revision changes

Contents

Revision changes

BMS Master, hardware

Lithiumate Pro, 2CN0000

Rev B*, May 2009 - Release, patched (2 units)
Rev C*, May 2009 - Patched (10 units)
Rev D*, June 2009 - Replaced Schottky diodes, patched(25 units)
Rev E, July 2009 - Updated PCB, improved bank inputs circuit (50 units)
Rev F, Sept 2009 - Changed pin-out of programming port to match PICkit programmer. Present production rev (since Sept 2009, 1650 units through 2014)

(*) NOTE: Not compatible with newer positive cell boards with 470 Ohm resistors

Lithiumate HD, 2CN0002

Rev B, Jan 2015 - Release

BMS controller, 2CN0000 software 1.xx

Rev 0.80

11/02/08

First beta

Rev 1.00

09/25/09

Release

Rev 1.01

09/25/09

Added status table screen

Rev 1.02

10/15/09

Fixed status table screen
Added support for the HVFE remote

Rev 1.03

11/29/09

Added the ability to change the configuration through the CAN bus
Pressing a digit in the cell status screen no longer results in a scrolling screen
Pressing the '<' key goes from cell 0 to cell N-1
Cell boards work down to 2.06 V

Rev 1.04

12/28/09

If the most charged cell voltage exceeds the Maximum Cell Voltage, clear the DOD
Heating using balance resistors
Removed Macros to preset cable mounted source current sensor, to make space for more menus
Hardware rev is placed on CAN bus and About screen
FAN can be controlled through the CAN bus

Rev 1.05

2/6/10

CAN:
- instantaneous cell voltage, not averaged
- fixed code to use a particular bit and polarity the contactor control CAN message
- now reads the pack voltage from the HVFE
- implemented PID support, including a way to clear the stored fault code and to clear the fault state through the CAN bus
- Pack Resistance units are now consistently 100 uOhm throughout the program
- removed the ability to reprogramm the EEPROM through address 7FFh, as it is now possible to do so through PIDs
- Added 1 Mb CAN rate
- Turn on red LED in case of warning
- Added CAN control of outflags
- Added support for the Prius
RS232
- added way to clear the stored fault code in the System Status screen
- added 'k' as a way to clear stored faults / fault state, and to clear numeric entries
- removed unused QSI codes
- removed DEL as an entry, as it wasn't usable
- removed test for Escape key, as it was duplicated, and the ESC key is already used to go back down one level
- added node to select method to read pack voltage: sum of cell voltages or from HVFE
- pack stats shows both methods of pack voltage: sum of cell voltages and from HVFE
- in any Status screen, Resistance is now shown with 1 decimal
- added load off temperature to the cell status screen
- 1 Mb CAN rate selector
- Added a selection to reverse the direction of the analog outputs
- Removed Clamp SOC option, no longer used
- In the pack status screen show actual capacity, as well as nominal capacity
- Added a couple of J1939 CAN messages to meet X-Prize requirements
- added programmable filtering time constant on averages
FAULTS
- cleaned up the current limit warning and faults, so that a CCL or DCL of 100 % (= FFh) will never fail when the current is exactly at the limit
CURRENT LIMITS
- without cells (and therefore a pack voltage of 0) the DCL was set to 0%, even if the Low and Min Pack Voltage settings were cleared
- changed the Low and Min Pack Voltage settings defaults to 0, and tweaked the Pack Voltage so that the comparison to the settings wouldn't trigger a 0 DCL
MISC
- improved the calculation of pack resistance: with only 1 battery, do a straight sum or cell resistances (no conversion to conductance)
- added 1 byte to the conductance, to get improved resolution
- increased the max power in power calculation above 160 kW. Now, max power is 3.2 MW
- operation with no cell boards (X-Prize) is now possible
- Removed code that drives the Current LED, as recent hardware does not use it
- Added low SOH warning
- Changed units for stateOfCharge from [%] to {0.5%}, to get increased resolution
- Totally rewritten the SOC and DOD algorithms
- Squeezed 2 nybbles in 1 byte in a few variables in EEPROM, which affects the EEPROM locations of a few settings
- Added PRIUS code

Rev 1.06

3/6/10

Prius: DCL and CCL were swapped

Rev 1.07

3/24/10

Added support for Elcon charger's CAN bus
Completely redefined SOH
Added a way to select IR drop compensation, through the Resistance set-up menu
Fixed error in the CAN dump message: since I added the table with the temperature with the load off in rev 0.97, the bytes in the dump were wrong
Completely changed the SOH menu: now it only has a single item: minimum SOH, below which a warning is issued
Added a comma between items in the list of faults and warnings
Added as way to select the current below which we don't calculate SOC and DOD
The Monitor screen for the A/D inputs used to show only 3 digits, now shows 5
When resetting factory defaults, reset the relative capacity and the SOC as well
If no data on the Source or Load current, clear its value (such as after the CAN messages end)
Updated the message ID to the Morey for the X-Prize

Rev 1.08

4/4/10

Changed the default for X-Prize: CAN speed to 250 kHz, external Load current sensor on, 0 to 100 % SOC regardless of cell voltage, no unnecessary messages on the CAN bus
Corrected the Pack Voltage sent to the Morey: the Alternate Pack Voltage, from the HVFE

Rev 1.09

4/12/10

Added a delay before charging is enabled, to keep the Brusa from generating an error, and to allow the cell boards to read the resistance correctly

Rev 1.10

4/21/10

Gave "ElCon" a separate flag than "Overcurrent can start a fault"
Receive ElCon CAN messages only if ElCon is disabled
Able to work with a "Fault Delay" = 0
Interlock now causes immediate fault (within 120 ms), regardless of "Fault Delay"
In the PID for min and max temperature, show both "load off" and "all"
Added DOD as an option to custom CAN message
In the System Status screen, pressing the 'K' key also clears a relay fault

Rev 1.11

5/21/10

Turn on K3 first, K1 afterward

Rev 1.12

5/26/10

Programmable charger turn on delay (by direct manipulation of a EEPROM bit); default is on

Rev 1.13

6/1/10

Changed the turn-on order of relays: Turn on K1 first, K3 afterward
Improved instructions in Nominal Capacity screen
Improved the resolution in the SOC calculation when pack capacity < 100 Ah
Power-up charge delay is now programmable on and off

Rev 1.14

6/14/10

Cell readings rate can be varied (default is still 1/s)
SOC shown in event log screen was twice the actual value
HLIM cause shown in status / system screen started with "Power Up Delay" even if the Power Up delay was disabled, now fixed
Two bytes shown for nybble variables ("0 to 15", such as Number of batteries in parallel) instead of just one ("0 to 9")
Number of batteries in parallel now can go up to 15
Custom CAN message data length now limited to valid values
In RS232 dump, number of banks missing / number of a missing bank now works
In CAN PID support, number of a missing bank now works
Missing banks code in RS232 dump was always 0, now works
When using multiple batteries in parallel, pack voltage is computed correctly {WRONG: see below}

Rev 1.15

6/15/10

Restored code to calculate pack voltage for multiple batteries in parallel, which was correct before

Rev 1.16

6/30/10

Reduced the possibility of Over-current faults: when HLIM/LLIM is disabled, over-current fault occurs if the Pack Current is more than the setting of Minimum Current for SOC calculations
While charging, if the SOC reaches 100 % , it is set in EEPROM immediately (so that, if the BMS is not able to detect when the charger is unplugged, it can still store it in EEPROM)
During regen, do only Coulomb Counting, and never Voltage Translation, to avoid setting the SOC to 100 % during high regen

Rev 1.17

8/8/10

Save the SOC is EEPROM more often, in case the BMS controller is not able to see when the power goes away
Significantly rewritten the SOC / DOD code, automatically distinguishing between EV, HEV, PHEV, UPS and Peak Shaver, and calculating SOC in the best way for each application
Warning flag set if discharging, and any cell voltage is below V-low
- Warning flag turns on Red LED in SOC display (Red LED is turned on in case of Fault or in case of Low Voltage Discharge)
- Added way to use FLT output to reflect Warning flag instead of Fault state.
"cell number with max resistance" byte in standard messages now shows the right value
Added rounding to the Power calculation, to improve the accuracy at low power levels
Fixed bug that resulted in the wrong value occasionally appearing in the RS232 terminal when checking the settings
Added a screen that lists all the settings and their values
Removed "VS NOT USED" setting, as it is no longer used
Red LED in SOC display now flashes
Removed nominal capacity from pack status screen, as it is available elsewhere (now just shows actual capacity)
Cleaned up a few messages in RS232 user interface

Rev 1.18

10/12/10

The menu "in case of Fault, turn off contactors ", now also affects HLIM/CCL and LLIM/DCL; the default is that, in case of Fault, contactors are turned off, and HLIM and LLIM are activated
Fixed overflow in max voltage to the Brusa
Added code special to the Helsinki University of Technology: use external thermistors, 4 kHz PWM frequency
Corrected bug introduced in rev 1.14: was not allowing 8-byte custom messages
Cleaned up a bit the way the cause for a limit is shown on the screen

Rev 1.19

10/29/10

Added support for the NetGain Warp-drive motor controller
CAN messages with 0 data bytes that are received, are ignored.
Changed the Helsinki temperature correction algorithm
Fixed a bug introduced in rev 1.05, that resulted in a 0 % DCL if the battery pack voltage was 255 V

Rev 1.20

11/08/10
Added a preference to disable capacity calibration
Added a test screen that dumps all the cell voltages
In order to make space for the 2 above nodes, removed the Max Reported SOC node and skipped one step to set the SOH threshold
Small changes to text in screens

Rev 1.21

11/16/10
Improvements to Helsinki code

Rev 1.22

4/19/11
Fixed bug in custom CAN message code: was reporting minimum cell voltage instead of max

Rev 1.23

5/20/11
University of Helsinki code: removed Hot cell board temperature during balancing test

Rev 1.24

7/15/11
Ability to select EV mode only (no HEV mode)

Rev 1.25

8/1/11
Added support for the Current Ways charger
Added support for the Eltek charger
Added more variables available for a custom message
Added blank time after the HLIM or LLIM become active, to disable over-current detection for a few seconds
Show the HVFE test voltage bit in the test dump screen
If overriding the outputs, clear the Relay State, so that, when the override is done, the relays start from off
Overriding the outputs now does prevent the normal code from setting a fault

Rev 1.26

8/30/11
Balancing can be disabled if powered by VL

Rev 1.27

9/7/11
Added support for 1 MHz CAN speed programmed through the CAN bus
Tweaked the Current Ways code
Loss of CAN messages from the HVFE results in a Contactor fault

Rev 1.28

9/13/11
Added very low temperature charging (at low current)
Used RESET instruction

Rev 1.29

11/29/11
Increased the number of digits shown in the Pack Status screen for the Capacity
Display the actual capacity with 5 digits i/o 3

Rev 1.30

1/5/12
Special for Orun: Slowed Baud rate, slowed data reporting rate

Rev 1.31

1/9/12
Special for Helsinki: Max precharge time set at 30 s

Rev 1.32

4/16/12
Extended the time-out for current messages from the Current Ways charger
Added display current limits in Amps and charger voltage limit in the system status screen

Rev 1.33

5/23/12
Support for the Elektro Automatik chargers
Integrated all chargers into 1 menu
If no cells, send the standard messages 1/s
Divorced the code for Helsinki
Moved program memory and removed macros to make space

BMS controller, 2CN0000 software 2.xx

Rev 2.01

6/12/12
Support for GUI
Self service software upgrades
Support for Torque PIDs on Android
Adjustable RS232 baud rate
Parallel charging / series discharging
Variable report rate for "Status, as a table" and for RS232 dump
Adjustable isolation test time
Repeated isolation tests
Added a test screen for the CAN bus
Removed all Orun Energy, Escape and Prius code
Removed HVFE A/D reading, as the local HVFE is obsolete
If overriding the outputs, the relay state stays stuck in test battery voltage
Better handling of end of over-current, to allow the fault to be cleared
Cell reading: speed up recovery: don't wait for the end of the aux data to restart
No longer refreshes the RS232 screen every 16 s
Load factory defaults at first power-up to avoid duplicating settings in eedata
Add a termination character at the end of a screen in plain RS232 screens
After restoring factory defaults, it resets the program

Rev 2.02

6/28/12
Adjustable CAN bus Rx timing
Tweak Torque support
CAN RX counters, from 5 ea to 6 ea
Isolation test now works
Fixed CAN rate selection
Enable setting the SOC while forcing analog outputs
Upgrade: rev level in immutable memory would fail upgrade

Rev 2.03

7/30/12
Fix to time-out for current messages from a charger
Doubled the time-out for receiving data from the GUI, to help when computer is too slow, and BMS times out and doesn't accept new settings

Rev 2.04

8/7/12
Forcing FLT output for testing now work even if the FLT output is used as a Warning output
Gain of load current sensor works (it was halved in rev 2.01)

Rev 2.05

9/28/12
Added DOD in 1/256 Ah to the custom message items list
Resistance is calculated and reported, but not used internally (not used for for IR compensation); nominal value is used instead
Nominal cell resistance can be compensated based on temperature and SOC (GUI is required to set-up compensation parameters)
Added support for TIM 600 motor driver, by CEBI / MES

Rev 2.06

10/28/12
Fixes (HLIM and LLIM were swapped, Discharge limit was controlled by CCL instead of DCL), changes (Vmax is now the same as the V-Pack_max setting) and additions (Vmin is now the same as the V-Pack_min setting) to TIM inverter support
Warning uses averaged instead instantaneous minimum cell voltage: slows down warning response

Rev 2.07

11/7/12
Support for the new Netgain WarP drive
Messages to the HVFE increased from 1/s to 1 /100 ms

Rev 2.08

1/5/13
Added a PID that resets the BMS (see Lithiumate PIDs)
Allow capacity calibration in EV only mode
Standard CAN messages are sent when faking banks
Don't integrate current below Min Current for SOC calculations
For BMS PIDs, dispatch table limited to 2 bits instead of 3 bits

Rev 2.09

1/10/13
Workaround for a bug in the NetGain Warp Drive motor controller

Rev 2.16

1/13/13
Was not checking the precharge resistor through the HVFE (since rev 2.01)
When turning on contactors, during the precharge test, request a message from the HVFE every 10 ms
If the pack voltage reading from the HVFE was selected as the pack voltage, the value shown was jumping between 0 and a high, bogus number
Contactor test for presence of battery voltage uses reading from the HVFE instead of the isolation sensors

Rev 2.17

2/5/13
On CAN bus, standard message ID 626h reports actual capacity instead of nominal capacity
Added PID 57h, to report actual capacity
Capacity is calculated when the average minimum cell voltage reaches a new setting, instead of the empty voltage in the SOC points

Rev 2.18

3/2/13
Support for the TM4 motor driver

Rev 2.19

3/17/13
Fixed EEPROM reading / writing through PIDs, broken in rev 2.08

Rev 2.20

4/15/13
Added many additional options for isolation detection, algorithm that may help in noisy situations
Added ability to keep LLIM off until precharge is completed

Rev 2.21

4/25/13
Fixed endianness for CAN messages to MES-CEBI TIM inverter

Rev 2.22

5/30/13
Fixed FAN PWM (broken in rev 2.02)

Rev 2.23

6/20/13
Added support for the HPEVS AC motor inverter

Rev 2.24

9/4/13
Added ability to wait 10 s before turning relays back on

Rev 2.25

10/15/13
Custom message gave minimum voltage for cell voltage, now gives average voltage

Rev 2.26

11/6/13
For strings in parallel, GUI histogram now shows all cells, not just the 1st string
Restored the proper format for the RS232 data dump for cell data
Cell voltage must remain below the threshold for a full 10 s (does not have to be consecutive) before capacity is recalculated

Rev 2.27

11/30/13
Added PIDs 6B and 6C to zero out the current sensor

Rev 2.28

Feb 21 2014
Support for ElCon chargers with various CAN IDs
HPEV messages are no longer on, out-of-the-box
Removed node to set isolation testing in the classic interface, as it was no longer used
Removed node to set isolation testing in the classic interface, as it was no longer used
Increased range of Temperature compensation of cell voltages

Rev 2.29

Feb 22 2014
With 256 cells in series, reports correct pack voltage

Rev 2.30

March 3 2014
Removed test code in the default table
Powerful Battery Solutions tag

Rev 2.31

March 24 2014
Cleared Temperature compensation of cell voltages

Rev 2.32

Feb 5 2015
Support for HD master

Rev 2.33

Apr 1 2015
Ability to disable faults in case of HVFE lost comm
Added support for strings in parallel in the Lithiumate HD Master

Rev 2.34

Apr 29 2015
Added support for back-to-back MOSFET switch
Reverted to 2.32: removed support for strings in parallel in the Lithiumate HD Master, removed any differentiation on the Pro vs HD software
HVFE comm timeout defaults to 2 s (was 0)
Fixed bug: if the cause of a fault was fixed, even if faults were not cleared, it allowed CCL and DCl to increase, and HLIM and LLIM to be re-enabled

Rev 2.35

Jul 1 2015
Relay task uses instantaneous current instead of averaged

Rev 2.37

Dec 17 2015
Added support for Brusa NLG6 charger

Rev 2.38

Mar 20 2016
Added support for SMA SunnyBoy inverter

Rev 2.39

May 25 2016
Added support for Zivan SG3 charger

Rev 2.40

Jun 2016
Fix to Zivan support

Rev 2.41

Aug 9 2016
Fix to Zivan support

Rev 2.44

Aug 11 2016
Fix to Zivan support
Current below the SOC current threshold will not cause an over-current fault

Rev 2.47

Feb 8 2017
Fix for masters without an HVFE (hvVtgAbsent)

Rev 2.56

Oct 12 2017
Small fixes for SMA inverter: from 100 ms to 1 s, moved SOC to byte 0 of message 0x355

Rev 2.57

Oct 25 2017
Clamp current limit for Brusa NLG6 charger to max it can handle
If bank comm error, wait 2 seconds for cell boards to go to sleep, then start from scratch

Rev 2.71

Nov 11 2017
Fix comm for Brusa NLG6 charger

Rev 2.72

Jan 3 2018
Fixed Number of Missing Banks
Bank comm fault issued after a number of cycles with comm faults

Rev 2.73

Jan 8 2018
Increased time off while cell boards reset after a bank comm error

Rev 2.74

Jan 13 2018
Support for Vinci cell modules

Rev 2.76

Feb 22 2018
Bank comm error restarts bank comm machine in BMS

Rev 2.78

Mar 3 2018
Added configurable "Limit recovery time" and "Over-current blank time"
Over-current warnings are now based on CCL and DCL

Rev 2.80

Mar 4 2018
Reduced the amount of initialization of the bank comm machine in BMS in case of bank comm error

Rev 2.81

Mar 4 2018
Clean up of cell code

Rev 2.82

Mar 22 2018
Issue faults to the SMA inverter only if the BMS Fault line is active

Rev 2.83

Mar 25 2018
Improved resilience to register corruption, in particular to avoid random clearing the number of cell in bank 0

Rev 2.84

Mar 31 2018
Fixed bug introduced in previous rev: received only the first CAN message, then no more

Rev 2.89

Jul 1 2018
LLIM output may be configured as a Low Voltage Fault output
SMA: Clear current limit while HLIM or LLIM is active, changed SoH in message 0x355, alarms and warnings, 45 s blank time for overcurrent
Improved robustness against electromagnetic interference
Version 'A' for HD, test only 8 banks for the HD
Source current CAN message time-out timer was not decremented if no charger was selected
Improved 10 ms time base accuracy
Improved balancing algorithm

Rev 2.90

8/31/19
Requires GUI rev dated at least 8/31/19
Added enable/disable for writing to BMS
Controlling the BMS done through codes (rather than writing directly to RAM)

Rev 2.91

9/19/19
Automatic threshold detection for bank communications

Rev 2.92

7/25/20
Added a PID message to get the serial number

Remote HVFE, 2HR0xxx