Preface
PREFACE Thank you very much for choosing our battery management system of RS series (short for “one-unit
BMS”).For easily installation,use and maintenance, please read the User Manual (short for “manual”) carefully
before installation and use.
The one-unit BMS is new generation BMS for light trucks, mini vehicles , space vehicles and electric
motorcycles. Few cells batteries reach the requirements of the low voltage system for light trucks, mini vehicles ,
space vehicles.For the electric motorcycles whose volume is limited, smaller volume, more functions and more
stable BMS system is available.
The one-unit BMS has its own unique design framework, which including the collection and control in the
integration.The installation space is significantly re reduced according to the reduced volume. The wires are very
simple because of the high level collection.
The one-unit BMS also provide CAN concentration wires,RS485 concentration communication, perfect
charging protection and discharging control strategy.
Note
The manual contains very important information that customers must master. If the customer does not install ,
use and maintain the product according to the manual strictly ,our company will not bear the consequences and
responsibilities.
Statement
For being accurate, we have had validated and reviewed the manual. The guidance and description of the
one-unit BMS is accurate, and it may change due to the technical improvement. If it has changed , please make
the object as the standard.
Carl Clark
Security tag description:
Dangerous: if the operation is not according to the requirements, it will lead to fire , personal serious
injury and even death.
Warning: if the operation is not according to the requirements, it will lead to personal moderate injury
or minor injury, as well as the damage of the system.
Please read the manual carefully and operate according to the manual when install,use and maintain the system.
In case of any injuries and losses caused as a result of the error operation, our company will not bear the
consequences and responsibilities.
1.1 System Architecture
RS series battery management system (short for “one-unit BMS) is made of information display module(by on
choice),current sensor, wire harness and one unit module(which including the collection and control in the
integration).
1.2 System Function
This one-unit BMS use the acquisition, management integration design, has high precision, high accuracy of
information collection function, can get the core voltage of one cell battery, battery group voltage, body temperature,
and other data as well. It also can balance the core monomers, analyze and process the battery data, according to the
operation status of battery, alarm and control.
The one-unit BMS can get the current data through the current sensor, to judge the charging and discharging
state, complete the working current measurement and the battery charge and discharge control and, comprehensive
utilization of battery data estimates and discrete SOC evaluation.
It can also achieve the following functions by instruments, including the real-time display and convenient Settings
of the parameters, such as: the battery voltage, current, temperature, SOC, etc.
Temperature detection
Current sensor
Table 1-1 the technical parameter of the BMS
Function Technical Parameter Note
System power supply DC9~32V
System power dissipation ≤1W
±1% ±500A Current acquisition
precision ±2 85~125
max load current of Switch
signal ≤1A
Operating temperature
4090
NOTE: * monomer voltage collection scope only use the lithium iron phosphate battery as the
example, other types of battery based on customers' special requirements.
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2.1 The One- unit BMS Module Function
The one unit BMS module is the nucleus equipment of system data collection, process and control, followings are
the main functions:
information collect function
Real-time acquisition and high precision filtering processing for the Monomer voltage, 36way is the
max.
Real-time acquisition and process of the temperature sensor signal, 4 way is max
The acquisition and process of the charge and discharge current
the method of communication and control
1 way CAN general wire communication
2 way 485 communication
4 way switch signal
Fault alarm
heat management
Form2-1 the one-unit BMS basic protection parameter
Item Numerical Value

Overcharge
2.8V

Over-temperature
protection
temperature
65

Over-temperature
release
temperature
40
NOTE: * all the above parameter use the lithium iron phosphate battery as the example, other types
of battery based on customers' special requirements to make the personalized configuration.
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Pic 2-2 the one-unit BMS installation dimension schematic drawing
2.4 The One-unit BMS Interface Definition
RACERN_BMS_RSEV-36B
NO. 2
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NO.4 connector for voltage collection part
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NO.5 connector for voltage collection part Pic 2.3 one- unit module connector definition
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Form 2-2 the one-unit interface function

NO.3-NO.5
(NTC+ -)
Temperature
examination
connector
NO.1
TV_IN (red) :system power + (9-32v DC)
GND(black):system power –
CV-(black)charge relay coil negative
DV+(red): discharge relay coil positive
DV-(black): discharge relay coil negative
Connect with the current sensor to real-time monitoring the battery
working current
R+,R-,P+,P-: reserved.
vehicle control system and charger.
485+,485-: communication general wire, communicate with the
motor controller(if you need)
monitoring the battery working current
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Chapter III information display module
3.1 Information Display Module Function
Display module is an interface for communication between man and machine, which shows the operation
condition of system, all of them according to industry standard design, suitable for all kinds of environment in use.
Display module interface can display all the various operation parameters and fault of the system.
State instruction: The display has three operating status indicators, which including the powerPWR runningRUNcommunicationCOM.
When the power is on, the power indicatorPWRis always light on; if the runningRUNindicator is always light on in yellow shows
the display works well; if the runningRUNlight off means there's fault with display; When connect with the BMS, communication
indicator light (COM) is the twinkle of the yellow.
Pic 3-1 operating status indicator
Listed below are the display state of the indicator in different kinds of lights state:
3-1
PWR
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3-2 3.5
3-3 5.7
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3.4.1 information display module main interface

When the system is power on, the display start working, then enter into the interface, as following:
3-6
NOTE*1. Following all the signs , they won't display when the system works
normal, only shows when there's fault in the system.
*2. All the protection and release will have 1~30sec delay.
*3. The display interface may appear some change, so please Please use the actual
show shall prevail.
Shows the current of
Parameter Name
Aggregate Capacity
The battery group can release the max capacity after full charging, General use of the
nominal capacity battery for initial configuration.

Surplus Capacity
The rest AH of the battery group. According to the battery manufacturers with the
parameters of the setting.
Calibration
Used for Current zero adjustment, and the default Current digital calibration value is 0.0 A,
if in the system stops running (not to charge or discharge), also from information display
module reads Current is not 0, then Current can be calibrated to 0 A by setting "the
Current Cal". But calibration range is from 20.0 A to 20.0 A. For example: if the system
stops operation, from information display module reads Current value of 0.6 A, through
setting the input "Current Cal" for 0.6 A, and click on "Settings", can be calibrated to
Current 0 A.
Define the allowed maximum charging current of CAN communication charger.

Overcharge
Protection Voltage
Definition the highest voltage values of monomer battery allow up to in the process of
charging, if higher than the value, the battery needs overcharge protection and warning.

Overcharge
Discharging
Voltage
Define the voltage threshold value of cancellation for overcharge protection, namely that
is when the monomer battery highest voltage below this threshold, will cancel the
overcharge protection and warning.
Under Voltage
Protection Voltage
Define the low voltage warning threshold value of monomer battery, use for warning the
customers that battery remaining power is not much.

Under Voltage
Release Voltage
Define the voltage threshold value of the cancellation for under charge warning, namely
that is when the monomer battery lowest voltage higher than this threshold, will cancel
the under charge warning.
Over Discharge
Protection Voltage
Define the lowest voltage which allowed to drop to while using the battery, if lower than
the value, will start the over discharge protection for the battery.

Over Discharge
Define the parameter of cancellation for the over discharge protection for the battery,
namely that is when the monomer battery lowest voltage is higher than the parameter
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Form 3-3 Parameter Paraphrase
3.4.3 Monomer Information Display
Choose to enter the each other page through “menu” button, click “monomer information”, the monomer
information of battery is as following:
3-7
Pic 3-7 Battery monomer information show interface
Make the 36S as an example, all voltage and temperature information of 36ells battery will be shown. Choose to
enter to the each other page through “menu” button.
3.4.4 Charging Information Display
Click “charger”, it will show charging information, as shown below:
Release Voltage will cancel the over discharge protection.

Protection
Threshold
Define the max battery allowed working temperature, when higher than it, will start the
over temperature protection for the battery and warning.

Over Temperature
Release Threshold
Define the over temperature warning release threshold value, namely that is when the
battery max temperature is lower than it, will cancel the over temperature protection and
warning.
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Pic 3-8 charging information interface
Online state: charger communication status, when it is communicate with BMS, it shows online, otherwise
it shows off, the default state is off.
Start: status: when it starts charging, it shows start, otherwise it shows stop, the default state is normal.
Hardware failures: the failure status of the charger itself, the default state is normal.
Input voltage: shows charger input voltage state, the default state is normal.
Temperature state: shows charger temperature state, the default state is normal.
Output current: shows charging current.
Output voltage: shows charging voltage.
3.4.5 Charging Control Explication
The one-unit BMS control the charger charging through the CAN connector. The related charging configuration
parameters are: the maximum charge current (refers to the current when the charger is in the constant charging stage),
overcharge protection voltage, overcharge release voltage.
The charger charging process is divided into constant current charging and constant pressure charging.
Constant current stage can be set through the configuration page "charge maximum current" item, the setting
range of the charge current is 1 A to 0.3 C (C is battery capacity, which is 0.3 times the rated charge current). If the
nominal current of the charger is less than the charge configuration current, that means in constant current charging
stage, the actual output current for charger is the same as the nominal current chargers of nominal current.
For the lithium iron phosphate battery, the system for controlling the charging process is as follows:
Step 1: When the system self-check, if the system is working normal, will send the start signal to charger,
when the charger receives the start signal will turn to step two.
Step 2: Constant current stage, the charger current value is the minimum value between charge
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configuration current and charge nominal current. In the power supply allowed power situation, generally,
we set the the maximum charger current the same as the charger nominal current.
Step 3: If the one cell battery's max voltage is higher than 3.65V, then the BMS will send a control signal to
adjust the charger current through the CAN wire, avoid the one cell battery voltage rapid up to the
overcharge voltage.
Step 4: When the monomer battery max voltage is higher than the overcharge voltage, delay 1~10 sec,
BMS will send the control signal to close the charger output through CAN wire.
Step 5: When the one cell battery max voltage below the overcharge release voltage, delay 1~10 sec, BMS
will send the control signal to restart the charger through CAN wire.
3.5 Information Display Module Parameter Configuration
In order to be able to precisely the parameters of the battery assessment, when first run in BMS, we can
reconfigure the BMS, the configuration includes: the total capacity battery (nominal capacity), the residual capacity of
the battery, current digital calibration, voltage calibration, monomer battery over charge voltage, monomer battery
overcharge release voltage, monomer battery under-voltage protection voltage, monomer battery under-voltage
release voltage, monomer battery over discharge protection voltage, monomer over discharge release voltage,
thermal protection temperature and thermal release temperature.
Step 1: Click the "setting" in the display interface, input the password "8888" enter the BMS configuration
interface;
Pic 3-9 BMS configuration interface
Step 2: Start the system first enter into the configuration interface, we must click "Read" to get the actual
parameters of the BMS, therefore, when we enter into the configuration interface read the BMS configuration
parameter first;
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Step 3: Click on the corresponding parameter bar, according to the actual battery parameters to set the
initialization of the BMS;
Step 4: Set the configuration parameters for BMS. Click on "Settings", wait for five seconds or so, until the COM
indicator lights flashing normal, means the set operation has been completed
Step 5: Verify configuration changes success. Click on the "read", if shown parameters and the set of all the same,
says configuration tasks success, or repeat steps 2 ~ 5;
Step 6: Click "main interface" button back to the information main interface.
NOTE: *1 Parameters of the interface configuration parameters can be customized, modified and add
according to the customers.
*2 When finish the settings and start running, The parameters not allowed to modify, matching
parameters is not correct may lead to battery protect function failure.
3.6 The battery Group Number Configuration
RS-36E SAMI system can manage the 8-36S of lithium battery system, and its internal voltage acquisition
module can be divided into 3 groups (M1-M3M4 stand for BMS ID), each group can be collected 4-12 cells of lithium
battery voltage. In order to guarantee the normal work of the management system, it is necessary to set the number
correctly for each battery acquisition group need the battery number collection.
Step 1: Click the "settings" in the display interface, input the "8888" as the password enter into the BMS
configuration interface.
Step 2: According to the steps of "3.5 Information Display Module Parameter Configuration" to operate, enter
into the following interface.
Step 3: According to each battery group that corresponding to the number of the battery. Make the Lithium
battery to 24 cells as an example, beginning distribute from M1 to M3, each number of battery group
distribution is between 4 to 12. As for 24 cells, allocation methods are: M1 sets 8, M2 sets 8, M3 sets 8, M4 sets
0 or M1 sets 12, M2 sets 12, M3 sets 12, M4 sets 0. As for 32 cells Lithium batteries , is set according to the M1
12, M2 set 12, M3 set 8, M4 sets 0 for setting.
Step 4: Set the configuration parameters to the BMS. Click on the "settings", wait for 5 sec, until the COM
indicator flashing normal, means the setting operation is finished.
Step 5: Verify configuration changes success. Click on the "read", if shown parameters and the set of all the same,
says configuration tasks success;
Step 6: Click "main interface" return the main interface. Shut down the power for the system, restart the power,
configuration results take effect. Otherwise, the configuration parameters invalid (only for battery acquisition
group configurations)
3-11 32
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Chapter IV Current Sensor
4.1 Current Sensor Function
Current sensor is an very important part of battery management system current collection and SOC count
function, main effect is to collect the battery the current value of charging and discharging state, to provide
parameters foundation for management system in analysis, calculation and judgment. The system of current sensor is
the open loop hall current sensor , the electric current detection range is 500 A ~ 500 A.
4.2 Current Sensor Type

Name

Item

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4.4 Current Sensor Connector
Current Sensor Connector
5.1 48s system Wire Drawing
Pic 5-1 installation drawing
NOTE: *The product function and setting vary from different types, our company will provide individual
installation method for special connection lines and adapter.
*The charger, battery group, controller and motor are configured by the customers.
*The customers have their own choice on the charge and discharge relay. (coil current≤1A)
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Avoid installation in the mist , metal dust and dusty occasion.
Avoid installation in hazardous gas, liquid , corrosive , flammable and explosive gases occasion.
Installation size should be reserved to the right size.
Do not install cables close to sharp objects.
Away from strong electromagnetic interference environment.
All components involved in connection with this system parameters need to be confirmed with our
company.
5.3 Wiring Introduction (Read this section please)
36S one unit can detect 8-36 string of battery voltage information. Begin with the negative of the battery, group
from 1 to 36, each 12 string as a group. The first group of battery voltage wire is B1-, + B1, B2 +... B12 +; The second
group of battery wire is B1-(2), B1+(2), B2+(2)...... B12+(2)……
Connect with the battery voltage wire, start with the negative of the battery. First connect with the B1-, then
orderly connect the each rest battery positive of from B1 +, B2 +... Until the B12 +.
If one group batteries are fewer than 12 cells. For example, there's one group battery only have 4 cells battery,
when we connect B4+ with the fourth battery positive of this group, we also need connect B12+ with the fourth
battery positive, in order to supply the working voltage.
The rest of the voltage wire after insulation package (note that can not touch the other cell extremely column )
can impending processing.
NOTE: 1.The voltage wire terminal can't put into the wrong port, should put into the calibration insert
position, otherwise, it will cause the damage of the main unit.
2. Make sure the connect order between the voltage wire and battery are correct, or will cause the
other voltage collection appear mistake, when serious will cause damage of circuit board.
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5.3.1 Voltage Wire Connection Voltage wire connection (24cells,because of 48cells,we will use two RS36S units, each is 24s)
Start with the negative of the battery group, B1- connect with the negative (black wire) of the
first battery;
B1+~B11+ orderly connect with each battery's positive (white wire);
B12+ connect with the positive of the 12th battery (red wire);
B1-(2) connect with the negative of the 13th battery (black wire);
B1+2~B12+2orderly connect with each battery's positive (white wire);
B12+2connect with the positive of the last one cell battery (red wire).
Voltage Wire Connection (24cells,another way)
Start with the negative of the battery group, B1- connect with the negative (black wire) of the first battery;
B1+~B8+ orderly connect with each battery's positive (white wire);
B12+ connect with the positive of the 8th battery (red wire);
B1-(2) connect with the negative of the 8th battery (black wire);
B1+2~B8+2orderly connect with each battery's positive (white wire);
B12+2connect with the positive of the 16th battery (red wire).
B1-(3) connect with the negative of the 17th battery (black wire);
B1+(3) ~ B8+ (3) orderly connect with each battery's positive (white wire);
General negative
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B12+ (3) connect with the general positive of the battery group
B1-B1+B2+B3+B4+B12+
B1-(2) B1+(2)
Pic 5-5 24 cells voltage wire connection drawing with battery
5.3.2 Temperature Sensor Set
System Installation
General negative
5.3.3 Connect with the current sensor
Current sensor can be connected on the positive pole or negative pole of the batteries. There are two
connection ways showing as followings. ( Note arrow points, which on the top of the current sensor.)
Pic 5-7 current sensor install connection diagram.
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5.3.4 Information Display Module Connection
The display power connector and communication connector, both of them connect with the Master control
module, the connection drawing as following:
,CCM ,CCM
5.3.5 Two BMS Units Module Connection
In 48s system, we need two BMS units work together. As the picture show, BMS1(main unit
control discharge and charge) connect with BMS2 by CAN bus(include charger). BMS2 send
the battery’s information to BMS1.
Power connector for the touch
screen, connect with the CCM
power connector (LCD PWR)
the CCM general data
6.1 Wire Types
lead wire
terminals according to the
lead wire
4 Current Sensor Wires 4×0.5 Shielding wire
5 Discharge Relay Wires 2×0.5 power wire Discharge way use the relay
control method
Charge way use the CAN
communication control
method
7 Discharging CAN Wires 2×0.3 Shielding wire Discharge way use the CAN
communication method
8 Charge Relay Wires 2×0.5 power wire Charge way use the relay
control method
DISN,DISP supply the
communication method
NOTE *1. The length of wires should be confirmed by customer and our company.
*2. According to customer’s requirement to make sure the type of charge wires and discharge wires.
*3. Wiring method please see the System Installation Instruction.
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*4. If you need special wires, please contact with our technical support center.
6.2 Wire Harness Icon Followings are our normal wire harness comparison chart.
Form 6-2 wire harness picture
Picture Name Use Connector
system for power
Charge wire charger
Display wire Information display
7.1 Faults and the Warn Information List
It has perfect protection function, can prolong the service life of the battery, the use of process may encounter
some troubleshooting tips, please use the table below for the analysis, to judge the cause and clear the fault.
(If there's the problem about the system or others cannot solve, please technical support center to get help.)
Table 71 faults and the warn information list
NO. Fault Description Possible reason Solution
Wrong working voltage To make sure whether the working
voltage is in the normal range
No power supply Supply the power to the system 1 The system stop working
DC power damage Need to repair by the professionals &
technical
protecting the battery
power supply for battery when it's
safe.
module showing something
Temperature testing point
shows the temperature
Stop charging and discharge, restart it
when the temperature is back normal. 3 Buzzer alarm and the display
module no showing
4 display module showing
5 display module showing voltage
is zero
connect well
“-20 ”
sensor
voltage
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when charge shows negative
9 Current shows nothing The current sensor connect
wrong
connect right
calibration"
current sensor
whether is the same with the current
range 11 Dynamic status, showing current
is inaccuracy The output voltage of the
charger is not steady check and change the charger
check whether the BMS has power
going through 12 the display stop working No power supply
Check the power wire between BMS
and display is correct or not
13 while charging, the current is less
than the max charging current
The setting for the max
charging current is low
parameter of charger
or over discharge
The wrong parameters
to the "parameter setting"
8.1 The CP Function CP
There are multiple functions provided by CP, including data recording, power cutoff, generator control, and power steering control. Data Recording CP CAN BMS 10s
2GB SD
EXCEL Through CAN communication, data will be collected from BMS. All single cell voltages, temperature number, current value, and system status will be recorded in every 10 seconds into 2GB SD memory chip. It can be reviewed as Excel file. CP EXCEL CP
There is a time chip within CP which establishes a new Excel file for user to review. The time can be adjusted by Touch Screen, which has English version as well.
power cutoff
CP 1
When vehicle status meet (1) criteria (or customer request) as following, CP will activate Power Cutoff function to cut off power supply from batteries, which is to prevent batteries been damaged due to power stay on for long hours.
1CP
45 One cell battery voltage value
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lower than certain default value AND system is at rest condition (current is lower than certain value), CP will shut down the power supplier from batteries in 45 seconds.
2 0.6mAWhen power has been shut down, the internal power friction for whole vehicle system will be lower than 0.6mA.
3KEY RELAY KEY RELAY
5-6s KEY RELAYWhen power has been shut down, the Key Relay is still in “on” position, which allow operator to turn off Key Relay manually. After 5-6 seconds off, re-start Key Relay will bring whole system back to normal. Generator control
Generator can be started or shut down in according to battery voltage condition (can be re-set by operator through Touch Screen). Power steering control CAN
In particular vehicle, CP can control power steering with reasonable force in according to information from CAN communication. 8.2 System Wiring Drawing
8.2.1 Wiring Introduction
10-CAN_H
20-CAN_L
1020 can CP can BMSCP can
can 10and 20 are CAN communication ports. CP
obtains and records BMS information through CAN. In vehicle, the CAN of charger
and CAN of controller are together.
18-485+
17-485-
18,17 485 485 17 and 18 are for 485
communication, which 485 is for communication with display.
9-CHOKE
8-CHOKE
9.8 9 and 8 are for generator fan
control wires, which has not been used. No positive or negative need to be
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identified.
7-GEN_S
6-GEN_S
7.6 7 and 6 are for generator
control wires. No positive or negative need to be identified. Just put them with
generator together.
16,15,14,5,4 16,5,4, 14 and 15 are reserved
for tow output and tow input wires. Not been used currently.
12-POW+
11-GND
1112 CP 9-24 12 11 11 and 12 are power wires
for CP. 9 - 24 voltage power supplier, 12 is positive and 11 is negative (ground).
1-B12+
2-RELAY
3-B-
B12+
RELAY B+2-Relay is for
Solenoid contact wire. One contact point of solenoid should be connected with
2-Relay wire, and another contact point of solenoid should be connected with 1-B12+
wire.