Elite Power Solutions EMS Operation And Installation Manual

EMS OPERATION AND INSTALL A T I O N M A N U A L

Energy Management System Operation

and Installation Manual

Elite Power Solutions 21411 N. 11th Ave, Suite 3 Phoenix, AZ 85027

www.elitepowersolutions.com

EMSOPERATION AND INST A L L A T I O N M A N U A L

Table of Contents

1 Introduction ______________________________________________________ 1

2. Packing List _______________________________________________________ 3

3. Specifications _____________________________________________________ 4

4. Installation _______________________________________________________ 6

Heartbeat LED ____________________________________________________________ 7

Isolated Battery & Shunt Connections _________________________________________ 7

12v Car Battery ___________________________________________________________ 8

Page Select Switch Input____________________________________________________ 8

Sense Board Wiring ________________________________________________________ 9

Making your own cables ___________________________________________________ 12

Video Output ____________________________________________________________ 13

5. Programming ____________________________________________________ 14

6. Usage __________________________________________________________ 15

Video Display ___________________________________________________________ 16

Home Page _____________________________________________________________________ 16

Detail Page _____________________________________________________________________ 19

Alarms and Warnings _____________________________________________________ 20

Controlling Other Devices with Alarm Outputs _________________________________ 21

Battery Balancing ________________________________________________________ 22

7. Capacity Algorithm ________________________________________________ 23

8. CAN Interface ____________________________________________________ 24

EMSOPERATION AND INST A L L A T I O N M A N U A L

9. Trouble Shooting _________________________________________________ 26

Appendix A. Enclosure Mounting ______________________________________ 28

Warning! Read ALL of the instructions before attempting

installation. All connections should be made when the system is

OFF. No connections of energized wires should be made.

Revised 3/3/11

EMS OPERATION AND INSTALLATION MANUAL

Section

1

T

1 Introduction

NOTE: It is important that you read this manual before

installing or operating any of these components.

Thank you for purchasing Elite Power Solutions Energy Management System
(EMS). This manual covers operating and installation information for the Elite
Power Solutions Energy Management System.

he EMS system has everything needed to display the condition and maintain
the health of your lithium batteries. It consists of two major components, the

computer and the cell sense boards. The computer will tell you many things
about the condition of your batteries. It will tell you overview information like the
battery state-of-charge, battery current, battery voltage as well as the voltage and
temperature of individual cells.. The cell sense boards mount on each individual cell
to read voltage and temperature. They also have a battery balancing circuit to
equalize the charge of all the cells in a battery pack. There are programmable outputs
from the computer for battery over voltage and battery under voltage interlocks.
These can be used to control other systems in the vehicle such as battery chargers
and motor controllers. In addition, there are warnings to let you know that error
conditions are approaching.

One of the important safety features of the EMS is ground fault detection. When an
inadvertent connection is made between the battery pack and the vehicle chassis, it
is detected and a warning is shown on the screen.

The EMS is designed so that the battery monitoring is completely isolated from the
regular vehicle 12V system. The EMS is powered by a powerful, 8 core 32-bit

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EMS OPERATION AND INSTALLATION MANUAL

microprocessor that is capable of outputting composite video. A CAN interface
option is available to display the EMS information on a CAN display. Many options in
the EMS are programmable and can be customized for your car.

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EMS OPERATION AND INSTALLATION MANUAL

Section

2

2. Packing List

1x – EMS Computer
1x – Composite video cable
1 per cell - Battery Sense Boards
Wiring Harness(es)
1x- Current Shunt
1x – Installation Guide & User’s Manual

Note: The number of battery sense boards and the wiring harness
vary based on the number of cells in your system.

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4

Section

3

EMS OPERATION AND INSTALLATION M A N U A L

3. Specifications

Items Displayed............................Voltage, Current, Battery Capacity (Main Screen)

Cell number, cell voltage, cell temperature (Detail
Screen)

Computer Power…………….......8 - 20V, 20mA or 8 - 85V as an option

Battery Voltage…………..…......36-500V

Shunt Input…………..………….500A = 50mV
Voltage Resolution………………0.01V
Current Resolution ………………1A

Temperature Measurement Range -99°F to +199°F or -146°C to +92°C

Battery Types Supported…...……Lithium Iron Manganese Phosphate

Video Output…………………....Composite Video, Color, NTSC

RS-170

Programming Port………….........Asynchronous Serial, TTL levels,

Measurement accuracy………….. Better than 1%

115200, n, 8, 1

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EMS OPERATION AND INSTALLATION M A N U A L

Measurement speed …………….. Voltage and current 3 times per second main screen
Voltage and Temperature 1 time per second detail screens

Number of cells supported ………128

Cell Voltage………………………2.5 to 4.5
Balancing Threshold ……………..3.6V
Balancing Current ………………..0.5A
Digital Output Current……………200mA
Output Delay (default)……………30 seconds
Optional Display Interface……….CAN
Connection Fault Detection ………2mA (5000 Ohm/Volt)

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Section

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EMS OPERATION AND INSTALLATION M A N U A L

4. Installation

ALWAYS USE HIGH CAUTION WHEN WORKING ON AN
ELECTRIC VEHICLE. ALWAYS DISABLE THE CIRCUIT BREAKER
WHEN THE ENGINE BAY IS OPEN (THIS WILL HELP MINIMIZE
RISK OF SHOCK). ALWAYS TAKE NOTE WHERE THE HIGH
VOLTAGE LINES ARE.

he Elite Power Solutions EMS is designed to make installation easy. All of the
connections to it are made with convenient pluggable ¼” quick disconnect terminals.
The EMS computer should be installed as close to the shunt as possible. The shunt

sense wires should be less than 1’ long and twisted around each other. Mounting holes
for the computer box are shown in Appendix A. After the installation is complete, you
must completely charge the car before the capacity will read correctly (see Section 7.
Capacity Algorithm for more details).
On models equipped with Connection Fault Detection, it is important that the screw with
the chassis wire be attached to the metal chassis of the car. This will enable the
Connection Fault Detection to work properly.

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EMS OPERATION AND INSTALLATION M A N U A L

Heartbeat LED

When the EMS is correctly connected to 12V, the heartbeat indicator will blink about once
per second.

Isolated Battery & Shunt Connections

The Terminals on the left side of the computer are used for making the High-Voltage and
shunt connections. Refer to the figure below for these connections. The connections
between the battery bank, shunt and high voltage loads are usually large wire like 2/0.
The connections to the EMS from the battery and the shunt can be smaller gauge like 18
or 20.

High Voltage Connections