EXCAR Battery Pack

EX51.2-78

Manual

0. Preface

Warmly welcome for choosing Excar Lithium battery. As a professional golf cart
manufactutor more than 10 years, we sincesely hope our new Battery Product can
provide you the best golf cart energy solution.
1. Specification

Model: EX 51.2-78
Type: Power Pack
Cell: Lithium Iron Phosphate
Rated Voltage: 51.2V
Rated Capacitor: 78AH (3,993WH)
Cycles：> 2,000 cycles, > 80% rated capacitor

The whole battery system is composte by two case and 3 components, They are the
cell case , and the control case, indicator and its hardness and ON-OFF-START switch.
Please refer to the following picture.

[在此插入电池的照片，电池箱的和电控箱的]

Dimensions:
Cell Case： 14-12/16 * 13-6/16 * 11-7/16 （375 * 340 * 290 mm）
Control Case：13-12/16 * 9-3/16 * 4-15/16 （350 * 250 * 125 mm）

Electric Characterist:
Cont.Discharge Current : 120A
Max Discharge Current : 350A （15min）
Max Allow Charge Current : 50A
Charge Cutoff Voltage : 58.4 V
Discharge Cutoff Voltage : 43.2 V
Charge Current : 17A
Charge Time : ~5h
Working Temperature : -20℃- 60℃
Storage Temperature : -40℃- 60℃
Storage Capacitor : 70% SOC
SOC Indicator By CAN communication
Heating Device : -20℃-20℃ 1 hour

2. Schematic

START Sw
350A Fuse P+
To BMS To BMS
ON Sw Relay 1
Relay 2
To BMS
B16
60AFuse C+
B15
To BMS Relay 3 To BMS

B2

B1

Current Sensor P-
Figure 1 - Battery Pack Schematic

As show on the above picture, the P+ terminal and C+ terminal is controlled by Relay 1 and Relay 3
individually, which are connectted to the main B+ of the cart and B+ of the charger. P- terminal is
connected to the main B- of the cart.
3. Connection Guide

Figure 2 - Battery Pack Connection Guide

BMS system contain 2 CAN chanels, one for program, called Inner CAN, another for cart
communicaton, called Outer CAN. With specify PC software <Excar BMS Soft> and USBCAN adapter,
all the BMS setting can be modify and all the BMS status can be monitored on line. Whie the outer
CAN is used to communicate with controller, charger and battery indicator. All the CAN cable inside
the cart hardness are twisted and shielded.

4. Cell Specification

In EXCAR pack, we equiped with HighStar cells, model IFP32115220-78 , which specification are list
below:
Table 1 - Cell specification
No Items Specifications
1 Charge Voltage 3.65V
2 Norminal Voltage 3.2V
3 Rated Capacity 78AH
(Discharge at 1C to voltage of 2.5V
at 25ºC ± 2ºC
4 Standard Charging Current 0.5C
5 Standard Discharging Current 1C
6 Discharge cut-off voltage 2.5V
7 Operatin temperature Charging: 0ºC - 45ºC, 65% ± 20% RH
Relative humidity % Discharging: -20ºC - 60ºC, 65% ± 20% RH
8 Recommended Storage 15ºC - 35ºC
temperature
9 Cell Weight Approx. 1.7kg
10 Impedance ≦0.6mΩ
11 Cell Dimension Thick: 36.2±0.3mm
Width: 115.2±0.5mm
Length: 213±1.0mm

5. BMS Fault Catalog

According to the severity, BMS define 3 class fault to do coresponding actions.Class 1 is the most
severe, Class 2 less and Class 3 is the most lightly fault.

During discharging, once the BMS raise a class 3 fault, it will inform controller and battery indicator.
Controller will respones the class 3 fault due and reduce driving speed to 50% of maximum speed, and
accroding to the type of the fault, controller will limit the driving current as well. At the mean time,
the battery indicator bar will flash at a lower frequency to give driver a warning.

While the BMS detect a class 2 fault, controller will do a more aggressive action to reduce the speed
to 20% of maximum speed and limit the driving current deeper. At the mean time, the battery
indicator will flash the bar at a higher frequency.

Once the BMS detect a class 1 fault, it means the battery now is in a very urgent sitruation, controller
will stop the cart and the battery indicator will show a special bar to imply the error code. Please refer
to the next chapter to decode the fault code.

If the battery fault continue and become worse and worse, the BMS will shut off itself to protect the
battery. At this state, no any indicator or display will have in the cart. Please refer to the Trouble
shooting for more information.

Please find the fault code in the following table.

Table 2 - BMS fault code catalog

Level 1 Level 2 Level 3

Description
Fault Code Fault Code Fault Code
Battery high temperature 1 51 101
Insulation failure 2 52 102
Cell over voltage 3 53 103
Cell low voltage 4 54 104
Total over voltage 5 55 105
Total low voltage 6 56 106
Over charge current 7 57 107
Over discharge current 8 58 108
Over feedback current 9 59 109
Low SOC 10 60 110
High voltage connector failure 11 61 111
Fire Alarming 12 / /
Charging socket over temperature 13 64 112
Battery low temperature 14 65 113
Cell voltage difference is huge 15 66 114
Battery temperature difference is huge 16 67 115
Insulation module failure / 62 /
Collection module failure / 63 /
VCU failure / 68 /

6. Controller Setting

We do integrated the BMS information into Curtis hand held program for maintance. In the Monitor
menu, Lithium battery, all the battery information can be found there. Please refer to the following
picture.
 Figure 3 - Battery information on hand held programmer

7. Battery Indicator Decoding

Battey Indicator is a CAN receiver,and power by system volage 51.2V. So, please be careful to do the
connection and never short circuit of the B+ to any of the CAN terminal, it will destroy the CAN
receiver inside the inidcator.

Like a usual battery indicator, each bar indicate 10% of the battery. The most left bar indicator 0% and
the most right position bar indicate 100%. When during chargsing, the bar will move accrodingly
unlike the acid battery indicater which reset at the last moment.

As we mentioned before, the indcator works at the following status:

Table 3 - Indicator LED Bar Description

NO LED Bar display Description
1 Any position of the Bar solid light Indicate the SOC status of the battery
2 At Any position, the bar flash at 1Hz BMS detect a class 3 fault
frequency, slower
3 At Any position, the bar flash at 2Hz BMS detect a class 2 fault
frequency, faster
4 At the most left position, i.e. position 1, the SOC < 10%, and give the driver a warning
bar flash
5 Special position Show the class 1 fault , plz refer to Table 4
for more information. Please noted at this
status driving prohibited.
 Table 4 - Led Bar Decode to Fault Code
Level 1
Description Battery Indicator Show
Fault Code
Battery high temperature 1
Insulation failure 2
Cell over voltage 3
Cell low voltage 4
Total over voltage 5
Total low voltage 6
Over charge current 7
Over discharge current 8
Over feedback current 9
Low SOC 10
High voltage connector failure 11
Fire Alarming 12
Charging socket over temperature 13
Battery low temperature 14
Cell voltage difference is huge 15
Battery temperature difference is huge 16
Insulation module failure /
Collection module failure /
VCU failure /

8. Excar Gauge Setting

For the Excar gauge, it will show the controller fault code in real time. During driving, if more than one
fault raised , it will display the fault code one by one. And here below is the fault code table related to
the battery.

Table 5 - Fault code comments

Fault Code explaination solution
47 HPD fault Release throttle and put F/R
switch to neutral then restart
key
51 CAN communications fault This fault raised because the
controller and BMS stop
communication for more than
10 minutes. Please check cable
continuity.
52 BMS PDO Timeout CAN message do not
continusely. Please check the
cable continuity.
53 BMS Heart beat Timeout CAN message do not
continusely. Please check the
cable continuity.
84 or 54 Battery Class 1 Fault If the SOC also low, please
charge the battery, or check the
BMS fault code by hand held
programmer
85 or 55 Battery Class 2 Fault If the SOC also low, please
charge the battery, or check the
BMS fault code by hand held
programmer

9. Charger Indicator

For the Charger, it is a CAN charger which only operated accroding to the CAN message sent by the
BMS. With some special controll logic, BMS will required charger to adjust the output voltage and
current during charging process. The whole process are automoatically.

For the Charger indicator information, please refer to the follow table.

Table 6 - Charger Indicator information

Normal Charging Information

1 Normal charging Green -

2 Charge Full Solid Green
3 Charger Waiting
（1）Normal Solid Yellow
（2）BMS send shuting down
Solid Yellow
message
（3）Battery Connect Well Solid Yellow

Warning Information

1 CAN communication fail Solid Red

2 Battery Not Connected Red - Green - - -
3 Over Temperature Protection Red - Green - Yellow- - -
4 Input Circuit Fail Red - Green - Yellow - Yellow - - -
5 Under Temperature Protected Red - Green - Yellow - Yellow - Yellow - - -
Red - Green - Yellow - Yellow - Yellow - Yellow -
6 Hardware Fail
--
7 Over Current Protection Red - Yellow - - -
Remarks
If the charging gun is not plug in, the charger do not know if it is CAN commnucation fail
1
or not, so will indicate Solid Red.
If the Charging Gun plug in the cart for long term, it is acceptable, the charger will
2
power on the BMS and when the battery soc drop, it will start automatically.
3 "-" means flash

For the short term storage of the vehicle, it is recommended to plug and keep the charging gun on the
cart, the charger will start charging automatically. While during long term storage of the vehicle, it is
not suggested to keep the charging gun on the cart, instead, it is recommended to shut off the battery
pack and unplug the charging gun after one complete full charged, then charge the battery every
three months.

10. Maintance

Bascially, Lithium battery no need to do the weekly and even monthly maintance. Only one rule for
the battery pack, keep it full charged all the time is the best maintance, what’s more, keep it charged
after each use no matter how long driving. Besides, every months do check the cables connection
situation and make sure all the cables are working in good position.