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Xiaoxiang Solar BMS Manual

Date: July 7th, 2022

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Table of Contents
1. Introduction ...................................................................................................................................................................... 3
1.1 What is a BMS .......................................................................................................................................................... 3
1.2 Safety Precautions ................................................................................................................................................... 3
2 BMS Software (Iphone / Android )................................................................................................................................. 5
2.1. XiaoxiangBMS (iPhone) ......................................................................................................................................... 5
2.2 XiaoxiangBMS (Android) ......................................................................................................................................... 6
3. BMS Parameters ............................................................................................................................................................. 9
3.1 Protection Parameters ............................................................................................................................................. 9
3.1.1 Cell over voltage .............................................................................................................................................. 10
3.1.2 Cell under voltage ........................................................................................................................................... 10
3.1.3 Battery over voltage ........................................................................................................................................ 10
3.1.5 Charge over current ........................................................................................................................................ 11
3.1.7 Charge over temperature ............................................................................................................................... 11
3.1.8 Charge under temperature............................................................................................................................. 11
3.1.9 Discharge over temperature .......................................................................................................................... 11
3.1.10 Discharge under temperature ..................................................................................................................... 11
3.1.10 Hardware Protection Parameters ............................................................................................................... 12
3.2 Capacity Parameters.............................................................................................................................................. 12
3.2.1 Designed Capacity .......................................................................................................................................... 12
3.2.2 Cycle Capacity ................................................................................................................................................. 12
3.2.3 Full Charge Voltage ........................................................................................................................................ 13
3.2.4 End of Discharge Voltage .............................................................................................................................. 13
3.2.5 Discharge Rate ................................................................................................................................................ 13
3.2.6 80%, 60%, 40%, 20% Capacity Voltage Levels ......................................................................................... 13
3.3 Balance Parameters ............................................................................................................................................... 13
3.3.1 Start Voltage..................................................................................................................................................... 13
3.3.2 Delta to balance ............................................................................................................................................... 13
3.3.3 Balancer Enabled ............................................................................................................................................ 13
3.3.4 Balance only when Charging ......................................................................................................................... 14
3.4 Other Parameters / Features ................................................................................................................................ 14
3.4.1 Load Detect ...................................................................................................................................................... 14
3.4.2 BMS Name ....................................................................................................................................................... 14
3.4.3 NTC Settings .................................................................................................................................................... 14
3.4.4 Galvanometer resistance ............................................................................................................................... 14
4. Periodic Maintenance ................................................................................................................................................... 14
4.1 Periodic Cable Check ............................................................................................................................................ 14

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4.2. Periodic Voltage Check ........................................................................................................................................ 15

5. Troubleshooting & FAQ ............................................................................................................................................... 15
6. Technical Support ......................................................................................................................................................... 19
Appendix ............................................................................................................................................................................. 19
Appendix A: Recommended Parameters .................................................................................................................. 19
A.1 General Settings ................................................................................................................................................. 19
Appendix B: About Cell Balancing .............................................................................................................................. 21
Q: OK, so how would one go about top-balancing their cells? ...................................................................... 22
Appendix C: BMS Specifications ................................................................................................................................ 23
Appendix D: JBDTools (PC application) ................................................................. Error! Bookmark not defined.
Appendix E: Wire and Lug Sizing ............................................................................................................................... 24
E.1 Wire Sizing Chart ............................................................................................................................................... 24
E.2 Battery Bus Bar Sizing Chart ............................................................................................................................ 25
Appendix F: Glossary ................................................................................................................................................... 25

1. Introduction

1.1 What is a BMS

A battery management system, or BMS, is an electronic device that protects and manages rechargeable
battery cells.

1.2 Safety Precautions

Aka “How to ruin your batteries, amputate your fngers, and burn down your home”

NOTE: If after reading this you disagree with anything we said, please take the time to learn and get
comfortable with LiFePO4 technology

First, the good news. LiFePO4 batteries are one of the safest types available. They contain no hazardous or
noxious substances, and have superior thermal and chemical stability compared to other lithium battery
chemistries. That said…

The battery cells we sell will store A LOT of energy (that is the whole point) – more than enough to maim
and/or kill you, your friends and family, and burn down your house, RV, boat or whatever, if you do not know
what you are doing.

Here is a short list of ways to screw up. This list is not complete.

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● Take off all metal jewelry (rings, watches, chains). When they bridge the battery terminals, your
jewelry will instantly weld to the battery, get red hot and burn off your fngers, wrists, et cetera.
Search “burn-induced compartment syndrome”. Not fun.
● If you wire the batteries in any one of many wrong ways, they could be destroyed and/or burn down
your home. Follow instructions.
● AC inverters can electrocute you just like regular house wiring.
● De-energize your AC systems when working on them or you could get electrocuted and die (If you
don’t know this already you have no business using anything we sell).
● Even the cells by themselves, depending on how you wire them, can produce enough voltage to kill
you. A 16 cell 48v battery can electrocute you in the right circumstances.
● Using cheap inverters or other low-quality equipment can damage the BMS in a way that will not be
apparent until the batteries explode. This actually happened in our lab.
● Programming your BMS incorrectly can lead to a variety of disasters.
● Pinching a balance wire will cause a short circuit that melts the wires, and might damage your cells or
BMS. Pay attention when tightening the terminals.
● Dropping tools between two terminals will short circuit the batteries and lead to a variety of disasters.
● If you run your batteries in the sun, or in a sauna, or over a wood-burning stove, they may overheat
and be ruined. Operate them within their specified temperature range.
● Do not undersize you’re wiring for the loads in your system, or omit properly-sized circuit-breakers.
If you do, the wires can melt and burn down your house-boat-shed-camper.
● Do not connect equipment in a way that bypasses the BMS.
● Do not let the batteries or BMS get wet.
● Pay attention to your metal tools when working near the battery terminals.
● Do not work on electrical systems while drunk, high, stoned, or otherwise intoxicated.

The bottom line is, the only thing we guarantee is that the products we sell will be high quality and free of
material defects. If they turn out not to be, we will replace them. We will not replace connected equipment,
your house-boat-shed-camper, or anything else that we did not directly provide to you.

NOTE: Unless specified, these products have not been evaluated by a Nationally Recognized Testing
Laboratory, e.g. UL. Is it up to you to determine whether they are ft for your particular project, and what
regulations apply to that use.

Whatever stupid thing you do with our products after you buy them is 100% on you. There is no way to make
them completely safe.

We support you learning new things through research and experimentation, but a certain baseline level of
technical competence and sound judgement is absolutely required.

If you are completely confident in your abilities, turn back now. Fear keeps you alive.

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2 BMS Software (Iphone / Android )

2.1. XiaoxiangBMS (iPhone)

1. Download the iPhone application from the app store. Link:

https://apps.apple.com/us/app/xiaoxiang-bms/id1375405426
2. Open the app. Ensure that the phone’s bluetooth has not been disabled (Settings -> Bluetooth ->
enable the top Bluetooth radio button)
3. Ensure that your battery pack is fully assembled and operational.
4. The iPhone app communicates via Bluetooth. So ensure that the bluetooth module is present and
plugged in.
5. Open the app. Your BMS should be immediately enumerated in the list of devices found. Click on the
device.
6. The basic info for your BMS should now be displayed.

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7.

There are five configuration pages:

1. App Settings: In this screen, you can give each BMS in your system a descriptive name. You can
also change the battery temperature display units to Celsius or Fahrenheit.
2. BMS Settings: In this screen, you can read and write the BMS settings. To do this, first click the BMS
read button. This will populate the page with settings from the BMS. Then, after updating the settings,
click BMS write. This will update the BMS. See Appendix A for recommended settings. Settings may
also be saved and loaded to a file.
3. Current Calibration: In this screen, the charge and discharge current readings can be calibrated.
See Section 4.2 for calibration instructions.
4. Voltage Calibration: In this screen, the idle, charge, and discharge voltage readings can be
calibrated. See Section 4.1 for calibration instructions.
5. Notifications: In this screen, optional notifications may be added. This will send an alert to your
phone when something bad happens. However, it will only alert you if the app is running and the
BMS is within range of the phone. Which makes it impractical in the real-world.

Note that this app supports password protection of parameter settings, even though the actual BMS does not.
The app accomplishes this through a clever hack. The password is stored plain-text in the BMS name field,
which gets written to the BMS non-volatile memory. The app cross-checks the value stored in the BMS name
to the value stored in the app. More information can be found on the app developer’s github project.

2.2 XiaoxiangBMS (Android)

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This application was provided by the manufacturer of the BMS.

Download the application from here:

https://github.com/FurTrader/OverkillSolarBMS/blob/master/Android_app_xiaoxiangBMS_3.1.1026.apk

1. Install the application. You may have to configure the permission settings on your phone to allow this
application to be run. After it is installed, run the app.
2. Ensure that your battery pack is fully assembled and operational.
3. The Android app communicates via Bluetooth. So ensure that the bluetooth module is present and
plugged in. Note that you must grant the application access to the device’s location. Android requires
location access to grant the application access to the Bluetooth device. For more information on why
this is, please see the FAQ question “My Android device says “Pairing Rejected”. What does that
mean?” in Section 5.
4. Your BMS should be immediately enumerated in the list of devices found. Click on the device. Wait
momentarily while the app connects to the BMS.
5. The application will display a dialog window that allows the user to set the nominal capacity and the
cycle capacity. In the image below, the user customized the capacity to 280 Ah.
6. The application may display another dialog window, asking, “use GPS to test speed? Yes / No”.
This question is not applicable to this (some versions of the BMS from the manufacturer include
GPS, as they are intended to be installed in electric scooters). Simply click No.
7. The basic info for your BMS should now be displayed.

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By clicking on the top-right nav icon, you can navigate to the app’s sub-pages:

1. Dashboard: This navigates back to the main menu

2. Battery State: In this screen, you can view individual cell voltages
3. Parameter View: In this screen, you can read the BMS settings. See Appendix A for recommended
settings.

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4. Params Setting: In this screen, you can read and write the BMS settings. See Appendix A
for recommended settings.
5. Function Setting: In this screen, the general BMS settings, can be set (external switch on/off,
load check on/off, balance enable on/off, charge balance on/off, and NTC temp sensors on/off).
6. App Setting: In this screen, you can change the name of your bms. Simply change the “device
Model” i.e. name of your bms, then unlink and close the app and relaunch the app, you should see
your name for the bms instead of “lh-sp3903569854”
7. About XiaoXiang: In this screen, you can view information about the author of this app.

NOTE: Avoid pressing the giant padlock on the main screen. If you touch it, it engages the “mosfet software
lock” without confirmation. Then it disappears. To find it again, you must switch the app mode from driving
mode to monitor mode and back. Avoid clicking it.

3. BMS Parameters

3.1 Protection Parameters

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3.1.1 Cell over voltage

Disconnects charging current if any cell
voltage goes over the Trigger value.
Reconnects when all cells drop below the
Release value

3.1.2 Cell under voltage

Cuts off discharging current if any cell
voltage goes under the Trigger value.
Reconnects when all cells rise above the
Release value.

3.1.3 Battery over voltage

Cuts off charging current if entire pack goes
over the Trigger value.
Reconnects when pack drops below the
Release value.

3.1.4 Battery under voltage

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Cuts off discharging current if entire pack falls under the Trigger value.
Reconnects when pack rises above the Release value.

3.1.5 Charge over current

Cuts off charging current if the current
exceeds the trigger value, for [delay]
seconds.
Reconnects after [release value] seconds.

3.1.6 Discharge over current

Cuts off discharging current if the current
exceeds the trigger value, for [delay]
seconds.
Reconnects after [release value] seconds.

3.1.7 Charge over temperature

Cuts off charging current if the probe

temperature exceeds the trigger value.
Reconnects after the temp drops below the
release value.

3.1.8 Charge under temperature

Cuts off charging current if the probe temp
drops below the trigger value.
Reconnects after the probe temp rises above the release value.

3.1.9 Discharge over temperature

Cuts off discharging current if the probe temperature exceeds the trigger value.
Reconnects after the temp drops below the release value.

3.1.10 Discharge under temperature

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Cuts off discharging current if the probe temp drops below the trigger value.
Reconnects after the probe temp rises above the release value.

3.1.10 Hardware Protection Parameters

These parameters are the last line of defense between the outside world and your batteries. They will shut off
charging and/or discharging if the limits are exceeded. These settings should never be changed. Resist
the temptation to change them. They were set this way to prevent physical damage to your batteries and
BMS.

Note: Hardware parameters are only accessible from the Android and PC app. They are not available from
the iPhone app.

3.2 Capacity Parameters

These parameters are used to display the battery capacity and to calculate the state of charge..

3.2.1 Designed Capacity

This should be set to the battery pack’s capacity, in amp hours (Ah). It is not used to calculate the state of
charge. It’s simply used when displaying the intended capacity of the cells. The actual capacity of the pack is
defined as the cycle capacity, which is described in the next section. Designed capacity can be calculated as
follows:

Designed capacity=Cell capacity Parallel cell count of pack

NOTE: This parameter is displayed in milliamp hours in the iPhone app.

3.2.2 Cycle Capacity

This parameter is used to calculate state of charge. In the real world, batteries do not meet the designed
capacity printed on the cells. It can be higher, if the cell was underrated, or it can be lower (especially true for
used or B- or C-grade cells).

Ideally, the capacity of the battery pack should be measured, and the actual number should be programmed
into the BMS. Therefore:

Cycle capacity =Actual measured capacity of the pack

There are several ways to measure the pack’s total capacity. The easiest way is to set the cycle capacity to
hook a known DC load up to the battery, and measure the amount of time it takes from full charge down to
cutoff. Ensure that the protection parameters are set before starting. Charge up to 100% (see the section on
top-balancing). Note the start time. Record the pack voltage in 15 minute intervals (this info may be used to
set the percent capacity voltages, later in this section). Record the time when the BMS protection circuitry cuts
off the discharge current.

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Cycle capacity = Test load current (A) Total run time (h)

NOTE: This parameter only affects the state of charge. If it is set too low, the state of charge will hit zero
percent before the battery is actually at zero percent. The state of charge percentage will never go negative.

3.2.3 Full Charge Voltage

This should be set to the cell’s voltage at full charge. This information typically comes from the battery cell’s
datasheet, but the recommended values in Appendix A may be used.

3.2.4 End of Discharge Voltage

This should be set to the cell’s voltage and end of discharge. This information typically comes from the
battery cell’s datasheet, but the recommended values in Appendix A may be used.

3.2.5 Discharge Rate

Leave this at the default setting.

3.2.6 80%, 60%, 40%, 20% Capacity Voltage Levels

This should be set to the cell’s voltage at each of the four indicated state of charge levels. This information
typically comes from the battery cell’s datasheet, which may involve interpreting the discharge curve graph.
However, the recommended values in Appendix A may be used.

3.3 Balance Parameters

3.3.1 Start Voltage

The BMS will not begin its balancing routine until the cell voltage(s) are above this voltage. Typically this
parameter should be set towards the top of the battery’s voltage curve.

3.3.2 Delta to balance

The BMS will not balance unless the delta exceeds this level. Setting this value too coarse will result in
possible cell damage; setting this value too fine will result in the BMS dissipating considerable heat as it
attempts to equalize the cell voltages. Recall that the passive balancing circuit works by routing the excess
voltage into resistors within the BMS, which converts into heat. This value must be a compromise between
those two extremes. Please see the recommended values in Appendix A.

3.3.3 Balancer Enabled

The BMS will only perform its balancing routine if this option is enabled.
There are very few reasons why this would ever be turned off. We recommend keeping it enabled.

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3.3.4 Balance only when Charging

When enabled, the balancing routine will only be performed when charging.
When disabled, the BMS will enter Static Balance mode, where it will balance when both charging and
discharging.

NOTE: Charging while balancing is usually more effective, because the cell delta is greatest at the top of the
charge. We recommend keeping this setting enabled.

3.4 Other Parameters / Features

3.4.1 Load Detect

When enabled, you will need to disconnect the load after a short-circuit before the battery pack can be used
again.

3.4.2 BMS Name

Not applicable; has no effect on the behavior of the BMS. However, if the PIN protect option is used within
the iPhone app, it will use the name as a PIN passcode, which could leave you locked out of your BMS. We
recommend to leave this alone, and to not use the iPhone app’s PIN protect function.

3.4.3 NTC Settings

Leave these at their default setting.

3.4.4 Galvanometer resistance

In the context of the BMS, the galvanometer refers to the current sense resistor used to calculate current. A
galvanometer is an ammeter that is capable of displaying both the magnitude and direction of measured
current. Leave this at its default setting. Do not change. The current sensor resistors used are high-
precision, low-tolerance, and therefore will not drift.

Note: This setting is only accessible from the Android and PC app; not the iPhone app.

4. Periodic Maintenance

4.1 Periodic Cable Check

Periodically perform a cable check:
1. Ensure that the cables have not loosened. Use a wrench or socket to tighten any connections or
terminals that have come loose.
2. Ensure that no wires have pinched or frayed; especially the balance wires.

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4.2. Periodic Voltage Check

If the battery pack has gone unused for more than 6-12 months, it is recommended to check the cell voltages
with a multimeter. If they are low, charge the battery pack until the voltages are around 50-80%.

Use the iPhone / Android app and the bluetooth module to ensure that the cell voltages are not different by
more than 50 millivolts when fully charged. If the cells are off by more than this amount, first verify with an
external voltmeter. If the voltmeter doesn’t agree, then the BMS may need calibration (follow the steps in
Section 4). Otherwise, a top-balance might be necessary to bring them closer together. See the
troubleshooting section for top-balancing procedure.

5. Troubleshooting & FAQ

Q: Why is this so complicated?
A: Because it is. This equipment was not designed to be a consumer item or DIY project, but here we
are. Lithium batteries demand this level of control.

Q: I have a charge under-temperature warning. The sensor says -30 degrees Celsius?
A: Make sure that your temperature sensor is plugged in. An open-circuit temperature probe always reads as
-30c. If your probe is damaged you can set the under-temperature protection parameter to -40. This will allow
the BMS to operate until a new probe can be obtained.

Q: I don’t understand the wiring diagram. Why is the negative terminal the way it is?
A: This is a common question. The BMS is a glorified high-current automatic switch. It needs to be in series
with the battery somewhere in order to interrupt the current when it senses an issue with voltage, current, or
temperature. Your load (and charger(s) must therefore be placed after the BMS in the circuit.

Q: What is the quiescent current? What can I do for long-term storage?

A: The quiescent current is as follows: (this was measured on a 4 cell BMS)
● 5.5 milliamps with everything off, when the BMS is active, but no bluetooth.
● 15 milliamps with the bluetooth active (after about 10 seconds it drops to 0.8 milliamps.
Reconnecting it wakes it up again).
● 0.8 milliamps when the BMS is inactive.

So, assuming your battery setup is 100 amp hours, the BMS would run for 17 years. This proves that the
BMS can be connected for long periods of time without any fear of it draining the battery.

Unplugging the balance connector would ensure complete shutdown

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NOTE: The cell’s self-discharge rate will always cause the battery to drain over time, which may be several
percent per month. This is simple chemistry and physics; there’s nothing that you or the BMS can do to avoid
the battery cells from self-discharging over time, other than to occasionally top up the batteries.

Q: I can’t get the bluetooth paired to my phone. Help!

A: In all cases, the bluetooth module should be selected from the monitoring app. NOT paired with the phone
or tablet device.

Q: My Android device says “Pairing Rejected”. What does that mean?

A: This can be resolved by setting the device’s location sensitivity to “High”. Also, make sure GPS location is
enabled.

Q: I can’t charge or discharge after I used the Android app

A: Avoid pressing the giant padlock on the Android app main screen. If you touch it, it engages the “mosfet
software lock” without confrmation. Then it disappears. To fnd it again, you must switch the app mode from
driving mode to monitor mode and back. Avoid clicking it. If you’ve inadvertently pressed it, switch the modes
and see if that fxes it.

Q: One of my cells is reading high, and one of my cells is reading low.

A: If one cell is reading very high and another cell is reading very low, the balance leads are connected in the
wrong order, or not connected at all. Check the order and check the connections. Pinching the insulation in
the crimp connector can have this effect also.

Q: Should I balance while charging or discharging?

A: Charging while balancing is usually more effective, because the cell delta is greatest at the top of the
charge.

This is labelled confusingly in the iOS app. Our recommendation is to leave it to change the default value of
“Bal only when charging” = disabled.

Q: What about fuses?

A: The BMS itself is a solid state circuit breaker that protects the battery cells. Fuses and/or circuit breakers
should be used and sized as appropriate to protect your wire size outside the battery pack

Q: My battery pack depleted to the point of under-voltage cutoff. And now I can’t charge from solar, because
my MPPT controller is powered from the battery pack, which is in under voltage protection cutoff. How do I
recover from this?
A: There are three methods to recover from this catch-22 scenario:

But first, turn off all loads (inverters, lights, etc) because we need to revive the battery to the point where the
under-voltage cutoff protection releases. This can be several volts above the point where the cutoff occurred
(refer to Section 3.1.2 and Section 3.1.4 for a description of the two applicable protection modes, and refer to
Appendix A for recommended values.

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The first method is to simply charge the battery pack using an AC-DC charger on shore power. The AC-DC
charger will have no problem charging the battery, whereas the solar MPPT will only charge if the battery
isn’t in discharge protection mode. If you don’t have access to shore power, then use either the second or the
third method below.

The second method is to “jump-start” the battery pack with another battery, which can be a lead-acid car or
deep-cycle battery (if you’ve got a large-capacity lithium battery laying around, that would work too, but lead
acid batteries are more common). Just ensure that the voltage of the jump-start battery has the same nominal
voltage as the battery pack in need of the charge.

The third method is a bit more clever, and doesn’t require lugging a battery around. You can do it from your
smartphone, if you have the optional Bluetooth module. Pull up the BMS configuration app (XiaoxiangBMS on
iPhone). Go into the protection parameter settings page. Write down the under voltage protection numbers or
take a screenshot of them. Temporarily lower the cell under voltage release value. For example, for
LiFePO4, lower it from 3000 to 2800). This will allow the discharge FET to activate (remember we disabled all
loads, so the only thing that should be allowed to discharge is the MPPT controller). This should give the
MPPT charge controller power, which will start charging your battery pack, assuming that the panels are in full
sunlight. Wait until the batteries have recovered a bit of charge, and then go back into the BMS configuration
app, and return the under voltage parameters to their original value.

Q: Why doesn’t it charge high enough?

A1: The BMS does not control the charge voltage. This needs to be configured in the settings of your charger.
If you’ve ruled out the charger as a possible issue, then it could also be a balance problem.
A2: If the BMS is cutting off the charge current before the target voltage, the reason may be a single cell
overvoltage cutoff, due to unbalanced cells. See Appendix C.

Q: Can I use a lead-acid charger to charge a LiFePO4 battery pack? Or do I need one that supports LiFePO4?
A: Well that’s a deep subject.

"a lead acid charger" can be a lot of different things.

smart, dumb, adjustable/programmable....

Short answer is yes, the battery will tolerate it.

Long answer, possible failures:

● Some won’t charge to a high enough voltage.
● Some will be overloaded by the low internal resistance of the battery(similarly to alternators.)
● Some will charge too high if they do an equalization cycle.
● Dumb unregulated chargers will charge too high.

Charging too high could damage connected equipment. Because this is a common port BMS, everything in
the system is connected together. When the BMS disconnects for overvoltage, the charger is still active and
connected to the rest of the system, possibly resulting in a damaging unregulated voltage spike.

We suggest only using regulated chargers and/or power supplies. Set the upper voltage limit to 14-14.4v

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If the charger only offers battery profiles, choose the setting for AGM batteries.

A lab CC/CV (constant-current, constant-voltage) power supply also makes a good charger. Set CV to
14-14.4v

If there are absolutely no other options but a dumb charger, connect a healthy lead acid battery in parallel
with the system. If the lithium pack disconnects, the lead acid battery will continue to regulate the system.

Q: Someone told me that you don’t need a BMS.

A: Below on the left is a picture from one of our customers that wasn’t using a BMS. It was over-charged,
which creates gasses, and can cause the outer case to bulge (this kills the battery). One of the jobs of a BMS
is to prevent overcharging. We’ve also seen batteries that have been discharged down to zero volts,
rendering them useless, but the photographs are not as interesting.

Even if you think you can’t over-charge because your smart charger stops at 13.8, unbalanced cells can and
will over-charge a single-cell, long before the overall pack voltage tops out at 13.8.

In conclusion, always use a BMS with lithium batteries.

Q: I fully charged my cells to 3.6 each and overnight they discharged down to 3.4v. How am I losing so much
power??
A. This doesn’t necessarily indicate a discharge. LiFePO4 chemistry just takes some time to equalize. If the
cell delta is more than a few millivolts, then you may have a problem with one or more of the cells. Keep in
mind that the steep top end of the charge curve represents a very small percentage of the cell’s capacity, so a
discharge down to 3.4v can happen with a very small load overnight.
Q: Someone told me that bottom-balancing is better than top-balancing.
A: Always top-balance. Will Prowse explains why in this informative video. Also, see Appendix C, About
Cell Balancing.

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6. Technical Support

Our Battery warranty policy is quite simple:

If you need help, we will help.

Appendix

Appendix A: Recommended Parameters

General settings are listed below, in Subsection A.1.

Specific settings for common battery configurations are given in the following subsections:

Max
Sub- Total Pack # of Cell Battery Pack Battery Pack Inverter
section Voltage Cells Capacity Capacity Current Rating BMS Size

A.2 12 volt 4 100 Ah 100 Ah 120 A 1x 12V 1500W

(1200 Wh)

A.3 12 volt 8 100 Ah 200 Ah 120 A 1x 12V 1500W

(2400 Wh)

100 Ah
A.4 24 volt 8 100 Ah 100 A 1x 24V 2500W
(2400 Wh)

100 Ah
A.5 48 volt 16 100 Ah 100 A 1x 48V 5000W
(4800 Wh)

A.1 General Settings

Recommended generic settings can be found below. These settings assume LiFePO4 batteries. They can be
used as a starting point.

Capacity configuration:

Parameter Value Units

This should be the rated capacity of your
battery in milliamps (multiply the
amp-hours of your pack by 1000)

Examples:
Designed capacity 50 Ah pack: 50000 mAh
60 Ah pack: 60000

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100Ah pack: 100000

200 Ah pack: 200000
280 Ah pack: 280000

This should be roughly 80% of the value

above.
Cycle capacity mAh
Examples:
50 Ah pack: 40000

60 Ah pack: 48000
100Ah pack: 80000
200 Ah pack: 160000
280 Ah pack: 224000

Full charge voltage (per cell) 3500 mV

End of discharge voltage (per cell) 2800 mV

Discharge rate 0.2 %

80% capacity voltage (per cell) 3400 mV

60% capacity voltage (per cell) 3300 mV

40% capacity voltage (per cell) 3200 mV

20% capacity voltage (per cell) 3100 mV

Protection Parameters:

Delay
Parameter Trigger Value Release Value (seconds)
Cell over voltage 3650 mV 3500 mV 2

Cell under voltage 2500 mV 3000 mV 2

Cell count × cell Cell count × cell

Battery over voltage over-voltage trigger [1] over-voltage release [1] 2
Cell count × cell Cell count × cell
over-voltage trigger [1] over-voltage release [1] 2
Battery under voltage

Charge over current Rated amps + 10 [2] 32s 10

Discharge over current Rated amps + 10 [2] 32s 10

Charge over temp 65℃ 55℃ 2

Charge under temp -1℃ 5℃ 2

Discharge over temp 75℃ 70℃ 2

Discharge under temp -10℃ 0℃ 2

[1]See individual sections below; trigger/release voltages for popular setups are given

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[2]See individual sections below; trigger/release currents for popular setups are given

Balance Configuration
● Balancer start voltage: 3400 mV (Note: in the Android app, this is called “Balanced turn-on voltage,
and the units are volts, not mV”)
● Balancer delta-to-balance: 15 mV (Note: in the Android app, this is called “Balancing precision, and
the units are volts not mV”)
● Balancer enabled: True
● Balance only when charging: False

Appendix B: About Cell Balancing

Q: But Mac’s, doesn’t the BMS have a built-in balancer?

A: Yes, the BMS has a built-in balancing function. HOWEVER no, it is not capable of doing an initial balance
on new cells.

The balancer works by connecting a tiny bleed resistor (see Figure C.1 below) to the cells with the highest
voltage, and the excess energy in those cells turns into waste heat. This is a slow process. The intention is
that the BMS can maintain the balance on the cells as they slowly drift over their lifetime.

Figure C.1: Bleed Resistors within the 12V BMS

A batch of new cells needs to be top-balanced before they can be expected to charge properly as a battery
pack.

Q: Why?
A: Because of the nature of the LiFePO4 voltage curve. At the top end of a charge cycle, the cell voltage
spikes quickly, and charging must be stopped to prevent damage to the cells. If one cell is at a higher state of
charge, (in terms of amp-hours or coulombs), even by a small amount, it will spike while the other cells are still
in the "bulk" phase of their charge cycle (See Figure C.1 below). On the linked graph, the red line is the highest
cell, which triggers a "cell overvoltage" alarm before the pink/green cells get to a full charge. The BMS must

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then disconnect to protect the high cell, and the battery pack will be at a lower voltage than expected. You want
all the cells to spike up at the same time, and the only way this can happen is for them to be well balanced.

Figure C.1: LiFePO4 Cell Spikes During Charging

Q: OK, so how would one go about top-balancing their cells?

A: There are several ways to manually balance cells, depending on what equipment you have access to:

The best way in my opinion, is to use a regulated power supply to charge the cells to 3.65 volts each.
● Set the power supply to a voltage limit of 3.650. Resist the urge to bump it up to save time.
● Connect the cells in parallel as a single cell and charge together (without the BMS).Re-assemble into
the series-connected pack with the BMS.
● Will Prowse demonstrates in this video: https://youtu.be/x5ABvbbics8

If the pack is already assembled in series, and you are unable or unwilling to start over, you can still balance
it with the regulated power supply.
● Connect a charger to the battery with the BMS installed normally. (charger positive to BC[max] and
negative to C-).
● Charge the battery until the BMS reaches a cell overvoltage cutoff.
● Open your Bluetooth app or desktop app and navigate to the individual cell voltages.
● Find the lowest cell and connect your 3.650v regulated to that cell only, in the correct polarity.
● Allow the cell to charge up to 3.650v.
● Repeat this process until every cell is fully charged to 3.650v.
● Now cycle the battery with a load then a charger to verify that the cells are sufficiently balanced.
● If the BMS still reaches a cell overvoltage before the battery is fully charged, repeat this process.

Cheapest way: Connect a load to the high cell in your pack to quickly bleed off the excess energy. I tried this
method using a random car light bulb with some alligator clips on the leads. (see Figure C.3 below) You need
to watch the cell voltages closely because it’s easy to go too far.

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Figure C.3: Using a car light bulb to bleed off excess cell voltage

What does NOT work is the old recommendation of connecting your new cells in parallel and letting them
passively equalize for hours or days. This does not work because of the fat charge curve. They are at almost
the same voltage even if they are far apart in state-of-charge. Basically the cells don't know that they aren't
balanced unless you can push them into the very top end of the charge cycle.

Appendix C: BMS Specifications

12V (4s) 24V(8S) 48V (16s)

# of cells supported 4 8 16

Battery pack voltage 12V 24V 48V

(nominal)

Maximum charge current 120A (confgurable) 100A (confgurable) 100A (confgurable)

(continuous)

Maximum discharge current 120A (confgurable) 100A (confgurable) 100A (confgurable)

(continuous)

No-load current 5.5 mA Similar to 12V BMS Similar to 12V BMS

(BMS active, no Bluetooth)

No-load current 15 mA Similar to 12V BMS Similar to 12V BMS

(BMS active, Bluetooth)

No-load current 0.8 mA Similar to 12V BMS Similar to 12V BMS

(BMS inactive)

Pack over-voltage cutoff? Yes (confgurable) Yes (confgurable) Yes (confgurable)

Pack under-voltage cutoff? Yes (confgurable) Yes (confgurable) Yes (confgurable)

Individual cell over-voltage Yes (confgurable) Yes (confgurable) Yes (confgurable)

cutoff?

Individual cell Yes (confgurable) Yes (confgurable) Yes (confgurable)

under-voltage cutoff?

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Current over-discharge Yes (confgurable) Yes (confgurable) Yes (confgurable)

cutoff?

Current over-charge cutoff? Yes (confgurable) Yes (confgurable) Yes (confgurable)

High-temperature cutoff? Yes (confgurable) Yes (confgurable) Yes (confgurable)

Low-temperature cutoff? Yes (confgurable) Yes (confgurable) Yes (confgurable)

Bluetooth? Optional Optional Optional

Communications port? Yes (5V TTL serial, 9600 Yes (5V TTL serial, 9600 Yes (5V TTL serial, 9600 8n1,
8n1, via JST XH 4-pin 8n1, via JST XH 4-pin via JST XH 4-pin connector)
connector) connector)

Wire length 6” (152mm) 6” (152mm) 6” (152mm)

(12” or 24” optional) (12” or 24” optional) (12” or 24” optional)

Wire gauge 10 AWG (6mm²) 10 AWG (6mm²) 10 AWG (6mm²)

(8 AWG optional) (8 AWG optional) (8 AWG optional)

Dimensions (not including 4” W x 5.4” H x 0.65” T 4” W x 5.9” H x 0.7” T 4.75” W x 5.71” H x 0.65” T
wires) (102mm W x 138mm H x (102mm W x 150.5mm H x (120mm W x 145mm H x
16.5mm T) 18mm T) 17mm T)

Weight 10 ounces 12 ounces 17 ounces

(290 grams) (340 grams) (481 grams)

Appendix D: Wire and Lug Sizing

D.1 Wire Sizing Chart

We’ve provided the table below for convenience; it only lists common sizes and lengths in the context of
wiring a battery pack. For a more complete guide, we recommend Blue Sea System’s page on choosing the
correct wire size for a DC circuit.

For lengths of wire less than six feet (1.8 meters):

Desired current (amps) Freedom Units Closest metric size

5 16 AWG 1.5 mm²

10 16 AWG 1.5 mm²

15 14 AWG 2.5 mm²

20 14 AWG 2.5 mm²

25 12 AWG 4 mm²

30 10 AWG 6 mm²

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40 8 AWG 10 mm²

50 6 AWG 16 mm²

60 6 AWG 16 mm²

80 4 AWG 25 mm²

90 4 AWG 25 mm²

100 4 AWG 25 mm²

120 2 AWG 35 mm²

150 1 AWG 50 mm²

200 2/0 AWG 70 mm²

D.2 Battery Bus Bar Sizing Chart

If your batteries did not come with bus bars, they may be fashioned from 1” wide copper bar material (110
alloy is 99.9% pure is recommended). Use the chart below to determine the correct thickness.
Note that these are general guidelines and may not be appropriate in all circumstances.
Our 100ah cells are supplied with 1”x1/16” tinned copper bus bars.
The standard bus bars can also be stacked for higher currents.

Desired current (amps) Bar Size McMaster Carr P/N

120A or less 1" x 1/16" 8964K3

Over 120A 1" x 1/8” 8964K78

Cut the bar to the proper length, and drill slightly-oversized holes at the correct distance for your batteries.
Optionally place heat-shrink tubing over the bare middle section, but ensure that it will not interfere with the
electrical connection.

Appendix E: Glossary

AC: Alternating current. In the context of this document, this means wall power (or shore power, in the
marine / RV parlance).

Balancing: The process of equalizing the voltages between series cells within a battery pack. This process
can be passive (as is the case with our BMS), or active.

BMS: Battery management system.

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Bus bar: Short, thick pieces of metal that connect individual cells together within a battery pack. Ideally
made out of copper. Bus bars should be sized to the maximum expected current in the circuit, and
should always be fully tightened, and checked periodically.

CC/CV: Constant-current, constant-voltage. This is a topology of power supply with the ability to regulate both
current and voltage (though only one of these modes would be activated at a time). The supply will
have controls for both, usually knobs, that defne the maximum voltage and current. When on, the
power supply will be in one of two modes: constant-current, or constant-voltage. Usually the mode will
be indicated by LEDs. When in constant-voltage mode, the voltage will be regulated, and the current
will vary depending on the load’s needs. When in constant-current mode, the current will be regulated,
and the voltage may vary depending on the load’s needs. These power supplies are typically
advertised as lab power supplies, and are typically used during the electronics prototyping process.
They’re great to have around, and have many uses. Every DIYer should consider having at least one.

Cutoff: A feature of the BMS, which will disconnect the battery from the charger and/or load when an error
condition occurs.

Charge: When electric current is fowing into the batteries.

DC: Direct current. Batteries operate on direct current.

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Discharge: When electric current is fowing out of the batteries, into the load.

Load: The portion of a circuit which consumes electric power. In this context of this document, a load is
typically the items that are being powered by the battery and/or solar panels (e.g. lights, cooking
equipment, computers, and phones).

Parallel: In the context of batteries, a parallel circuit is when multiple battery cells are connected with their
positive terminals connected together, and their negative terminals connected together. This
increases the current capacity of the battery, but not the voltage.

Self discharge: A battery’s natural tendency to lose charge over time, even when no load is applied. It is
caused by chemical reactions within the positive electrode, negative electrode, and/or the electrolyte.
All rechargeable batteries exhibit this behavior, although certain chemistries are less susceptible to it.
Higher temperatures can accelerate self-discharge.

Series: In the context of batteries, a series circuit is when multiple battery cells are connected in a chain, so
each cell’s positive terminal is connected to the next cell’s negative terminal. This increases the
voltage, but not the current capacity.

Thermal runaway: A dangerous feedback cycle that occurs when batteries turn excess energy into heat,
which in turn releases oxygen, which in turn makes more heat. This can result in venting, bulging, fre,
and explosions, depending on the battery chemistry.

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