Heltec BMS 96V System Relay Smart BMS User Manual

1. Rhagymadrodd

This manual provides detailed instructions for the installation, operation, maintenance, and troubleshooting of your Heltec BMS 96V System Relay Smart BMS. This advanced Battery Management System is designed for 25S-32S LiPo and LiFePO4 battery packs, supporting high current applications such as forklifts and solar energy storage systems. It features Bluetooth, UART, RS485, and CAN communication interfaces for comprehensive monitoring and control.

2. Cynnwys Pecyn

Gwiriwch fod yr holl eitemau yn bresennol ac mewn cyflwr da wrth agor y pecyn:

• Heltec Smart Relay BMS Unit
• Wire Harnesses (with labeled cables)
• Current Sensor (Shunt or Hall Sensor, depending on configuration)
• DC Relays (quantity may vary, typically 2-4, customer-supplied for specific current needs)
• Modiwl Bluetooth
• NTC Temperature Sensors (3-4 sensors, 500mm length)

Figure 1: Heltec BMS package contents including the BMS unit, relays, current sensor, and wiring.

3. manylebau

Nodweddion Cyffredinol

• Cyftage Gofynion: 10V ~ 120V (depending on configuration)
• Dynamic Self-consumption: ≤1.5W
• Static Self-consumption: ≤50uA
• System Startup Mode: External soft switch signal trigger
• SOC Estimation Difference: ±5%
• Balans Cyfredol: 60mA
• Tymheredd Gweithio: -40 ° C ~ 85 ° C
• Supported Battery Packs: 25 32-
• Sengl Llinynnol Voltage Collection Range: 0V ~ 5V
• Sengl Llinynnol Voltage Collection Error: ±10mV FS
• Cyfanswm y Batri Voltage Collection Error: ±100MV FS
• Charge and Discharge Current Collection Range: >500A
• Charge and Discharge Current Collection Error: ±2%
• NTC Temperature Control Collection Range: -40 ° C ~ 125 ° C
• NTC Temperature Control Check Error: ±1°C

Rhyngwynebau Cyfathrebu

• UART: 1 interface, supports Modbus protocol
• Isolated RS485: 1 interface, supports Modbus protocol
• Independent CAN2.0B: 1 rhyngwyneb

Protection Parameters (Ternary Lithium Battery)

• Diogelu Gordal: 4.25V
• Charge Release Protection: 4.15V
• Charge Detection Delay: 1000mS
• Discharge and Power Failure Protection: 2.7V±0.1V
• Discharge Release Protection: 2.9V±0.1V
• Discharge Detection Delay: 1000mS
• Cyfredol Codi Tâl: Number of strings * 4.2V
• Cyfredol Parhaus: 200A ~ 500A
• Amddiffyniad Gorgyfredol: 200A * 3-8 Times
• Overcurrent Detection Delay: 3000mS
• Overcurrent Release Protection: Datgysylltwch y llwyth
• Amddiffyniad cylched byr: Load short-circuit through the protection board (no direct short-circuit BMS)
• Charging and Discharging Temperature: ≥75 ° C
• Reset Social Equipment: <50°C
• Condition Range: -20 ° C ~ 85 ° C
• Opening Conditions of Balanced Pressure Difference: 0.02V-0.05V

Protection Parameters (LiFePO4 Battery)

• Diogelu Gordal: 3.65V
• Charge Release Protection: 3.55V
• Charge Detection Delay: 1000mS
• Discharge and Power-off Protection: 2.4V±0.1V
• Discharge Release Protection: 2.6V±0.1V
• Discharge Detection Delay: 1000mS
• Cyfredol Codi Tâl: Number of strings * 3.6V
• Cyfredol Parhaus: 200A ~ 500A
• Amddiffyniad Gorgyfredol: 200A * 3-8 Times
• Overcurrent Detection Delay: 3000mS
• Overcurrent Release Protection: Datgysylltwch y llwyth
• Amddiffyniad cylched byr: Load short-circuit through the protection board (no direct short-circuit BMS)
• Charging and Discharging Temperature: ≥75 ° C
• Reset Social Equipment: <50°C
• Condition Range: -20 ° C ~ 85 ° C
• Opening Conditions of Balanced Pressure Difference: 0.02V-0.05V

4. Gosod a Gosod

Proper installation is crucial for the safe and efficient operation of your BMS. Please follow these steps carefully.

4.1 Gwifro Cysylltiadau

The BMS is designed to control 2-4 relays for power management and connects with a Hall sensor or shunt for current measurement. Ensure all connections are secure and correctly oriented.

Figure 2: Detailed connection diagram for 25S-32S BMS. This diagram illustrates the wiring of the BMS to the battery pack, relays, and communication modules. Pay close attention to the positive and negative terminals, balance leads, and communication ports.

Figure 3: 12V System Wiring Diagram. This schematic shows the connection of the BMS to a battery, Hall sensor, fuse, and high voltage DC relay for charge and discharge control.

Figure 4: Pre-charge and Pre-discharge Wiring Schemes. These diagrams illustrate different wiring configurations for managing discharge and pre-charge functions, including the use of resistors.

4.2 Balance Lead Connections

Connect the balance leads to your battery pack according to the cell count. Each cable is marked to assist with correct identification.

Figure 5: Balance Lead Connection Examples. This image provides visual guidance for connecting balance leads for various cell configurations (e.g., 6S, 13S, 16S).

Figure 6: Labeled Cables. Each cable in the harness is clearly marked to simplify the connection process and ensure correct functionality.

4.3 Current Sensing

• For 3S-4S battery configurations, current is collected by a shunt.
• For 6S-24S battery configurations, current is collected by a Hall sensor.

Figure 7: Current Collection Methods. This diagram shows the different methods for current collection based on the number of series cells.

4.4 DC Relays

Customers are required to provide their own DC relays, selecting the appropriate current rating for their application. The BMS supports various mainstream relays and allows for cutting off either the positive or negative wire.

Ffigur 8: Examples of Compatible DC Relays. This image displays different types of DC relays that can be used with the BMS.

4.5 NTC Temperature Sensors

The product includes 3-4 NTC temperature sensors (500mm length) to monitor battery temperature. Install these sensors in appropriate locations within your battery pack to ensure accurate temperature readings.

5. Gweithrediad

The Heltec Smart BMS offers multiple ways to monitor and configure your battery system.

5.1 Mobile App (Bluetooth)

The BMS includes a Bluetooth module for wireless communication with a mobile application. This allows you to view battery status and adjust BMS parameters.

Figure 9: Bluetooth Module. This module enables wireless communication between the BMS and your smartphone.

Figure 10: SmartBMS Mobile Application Interface. The app displays real-time battery data such as voltage, current, temperature, and State of Charge (SOC).

• Ap Android: Yn caniatáu viewing battery status and adjusting BMS parameters.
• iOS App (iPhone): Currently, the iPhone app can only view parameters; parameter adjustment is not supported.
• Pellter Effeithiol: The Bluetooth signal has an effective range of approximately 10 meters.

5.2 Meddalwedd PC

Dedicated PC software is available for monitoring parameters, modifying configurations, and other advanced functions. This software requires a UART or RS485 module to USB converter (sold separately).

5.3 Balance Function

The BMS features an automatic balance function. When the battery cell voltage difference is detected to be between 0.02V and 0.05V, the balancing will automatically activate with a current of 60mA.

6. cynnal

Regular monitoring and proper care will extend the lifespan and performance of your BMS and battery pack.

• Monitro Tymheredd: Utilize the NTC temperature sensors and the mobile app/PC software to regularly monitor battery temperatures. Ensure the battery pack operates within the specified working temperature range (-40°C to 85°C).
• Cydbwyso Celloedd: While the BMS provides an auxiliary balancing function, for significant cell voltage deviations, a specialized external balancing instrument may be required for optimal battery health.
• Diweddariadau Cadarnwedd: Check with Heltec BMS Official Store for any available firmware updates to ensure your BMS operates with the latest features and improvements.

7. Datrys Problemau

This section addresses common issues you might encounter with your Heltec BMS.

7.1 Protection Triggers

The BMS is equipped with various protection mechanisms. If the system shuts down unexpectedly, check for the following conditions:

• Overcharge/Over-discharge: Verify individual cell voltages using the app or PC software. Ensure they are within the safe operating range (e.g., 2.7V-4.25V for Ternary Lithium, 2.4V-3.65V for LiFePO4).
• Overcurrent: If an overcurrent event occurs (e.g., 200A * 3-8 times), the BMS will disconnect the load. Reduce the load or check for short circuits in the system.
• Cylchdaith byr: The BMS provides short-circuit protection by detecting a load short-circuit through the protection board. Avoid directly short-circuiting the BMS itself.
• Tymheredd: Check the NTC sensor readings. If the charging or discharging temperature exceeds 75°C, the BMS will trigger protection. Allow the battery to cool down.

7.2 Problemau Cyfathrebu

• Cysylltedd Bluetooth: Ensure your mobile device is within 10 meters of the BMS. Restart the app and/or the BMS if connection issues persist.
• UART/RS485/CAN: Verify physical connections and ensure the correct communication module (e.g., UART to USB) is properly installed and drivers are up-to-date on your PC.

7.3 Cell Imbalance

Os cell cyftages show a significant difference, the internal balancing function may not be sufficient. Consider using an external battery balancer to bring cells back into equilibrium.

8. Awgrymiadau Defnyddiwr

• Cydnawsedd Batri: This BMS is designed for LiPo and LiFePO4 battery types. It is not compatible with NiMh batteries or other chemistries outside its specified voltage amrediad.
• Addasiad Paramedr: For full control and parameter adjustment, use the Android mobile app or the PC software with the appropriate communication module. iPhone users can only monitor parameters.
• Serial Port Module: If you intend to use RS485 or CAN communication, you will need to purchase a separate serial port module.
• Relay Selection: For heavy-duty applications like truck startup, consider using 4 high-current relays for robust performance.

9. Gwarant a Chefnogaeth

For technical support, troubleshooting assistance, or warranty inquiries, please contact the Heltecbms Official Store directly. Ensure you have your product model and purchase details available when contacting support.

Figure 11: Heltec BMS Production and Quality Assurance. Heltec BMS is committed to stable products through rigorous manufacturing processes.