POLYBESS1500V1 User Manual

Document Information

Keywords: Polycarbonate support, demonstrator, HVBMS, high-voltage battery management system, RD-BESS1500BUN

Abstract: This user manual aims to help users build their POLYBESS1500V1 HVBMS polycarbonate support. This platform is used for BESS1500BUN HVBMS hardware reference design.

1 Kit Content

The polycarbonate structure POLYBESS1500V1 for RD-BESS1500BUN kit contains:

Table 1. POLYBESS1500V1 kit contents

Required Tools:

• A Phillips screwdriver
• A 3 mm Allen key
• Pliers
• Cutting pliers

1.1 Content Pictures - Polycarbonate

Table 2. Polycarbonate structure combo of 93915

Table 3. Content pictures

Top plate (800-10075)

Image shows the top polycarbonate plate with markings for component placement, including areas labeled 'Battery Management Unit' and 'Battery Junction Box'.

Bottom plate (800-10076)

Image shows the bottom polycarbonate plate with markings for component placement, including areas labeled 'Cell Monitoring Unit board based on MC33774 91653 RDBESS774A3EVB'.

Short hinges, 50 mm (800-76229)

Image shows two clear polycarbonate pieces shaped as short hinges.

Long hinges, 95 mm (800-76228)

Image shows two clear polycarbonate pieces shaped as long hinges with mounting holes.

Supports, 145 mm (800-76232)

Image shows two clear polycarbonate pieces shaped as support structures with mounting slots.

1.2 Content Pictures - HW Accessory

Table 4. Hardware accessory

Image Description: A collection of small plastic bags containing various fasteners, screws, nuts, standoffs, and cable ties, as listed in Table 4.

2 Guidelines for the construction of the base structure

This section details the steps for the construction of the base structure.

2.1 Required Components

For this part of the construction, the required components are:

Table 5. Required components

2.2 Adding hinges and supports to the top plate

Figure 1: Mount the long hinges to the top plate using four M4-0.7 X 14 mm screws (280-78013).

Image Description: A clear polycarbonate top plate with four M4 screws (280-78013) being used to attach two long hinges (800-76228) to designated mounting points. The screws are shown inserted into the hinges and the plate.

Figure 2: Mount the supports to the top plate using two M4-0.7 X 14 mm screws (280-78013).

Image Description: A clear polycarbonate top plate with two M4 screws (280-78013) being used to attach two support structures (800-76232) to designated mounting points.

2.3 Adding hinges and adhesive feet to the bottom plate

Figure 3: Mount the short hinges to the top plate using four M4-0.7 X 14 mm screws (280-78013).

Image Description: A clear polycarbonate bottom plate with four M4 screws (280-78013) being used to attach two short hinges (800-76229) to designated mounting points.

Figure 4: Add the adhesive feet to the bottom plate (280-76689).

Image Description: A view of the bottom polycarbonate plate showing six circular adhesive feet (280-76689) being attached to the underside at the designated corner positions.

2.4 Connecting top and bottom plates

Figure 5: Connect the top and bottom plates using two M4-0.7 X 20 mm screws (280-78014) and two wingnuts (280-78017).

Image Description: The assembled top and bottom polycarbonate plates are shown connected by two M4 screws (280-78014) and two wingnuts (280-78017) at the rear hinge points, forming an angled structure.

2.5 Completed base structure

The base structure is now complete. To mount the boards on the structure, see Section 3.

3 Guidelines for the specific setup of the RD-BESS1500BUN

This section details the steps for the construction of the specific setup for RD-BESS1500BUN. The RD-BESS1500BUN kit is composed of:

• A RD-BESSK358BMU battery management unit (BMU)
• A RDBESS774A3EVB cell monitoring unit (CMU)
• A RDBESS772BJBEVB battery junction box (BJB)
• A BATT-18EMULATOR battery emulator
• A 5 V power supply
• A 12 V power supply

Note: One of the two supplies can be fastened to the support.

3.1 Components required

For this part of the construction, the components required are:

• 1 RD-BESS1500BUN kit
• A RD-BESSK358BMU battery management unit (BMU)
• A RDBESS774A3EVB cell monitoring unit (CMU)
• A RDBESS772BJBEVB battery junction box (BJB)
• A BATT-18EMULATOR battery emulator
• A 5 V power supply
• A 12V power supply

Table 6. One set of polycarbonate HW accessory

3.2 Adding support for the battery emulation system

1. Mount both 95 mm side parts (800-76228) using two M4-0.7 X 14 mm screws (280-78013) according to Figure 1 and Figure 2.

2. Mount both 145 mm supports (800-76232) to the top plate using two M4-0.7 X 14 mm screws (280-78013) according to Figure 1 and Figure 2.

Long hinges, 95 mm (800-76228)

Image shows two clear polycarbonate pieces shaped as long hinges.

Supports, 145 mm (800-76232)

Image shows two clear polycarbonate pieces shaped as support structures with mounting slots.

Figure 6: Top plate - BATT-18EMULATOR support mounting holes

Image Description: The top polycarbonate plate with two long hinges (800-76228) and two support structures (800-76232) attached. Red circles highlight the mounting points for the supports.

Figure 7: Top plate - BATT-18EMULATOR support mounting holes

Image Description: The top polycarbonate plate with two long hinges (800-76228) and two support structures (800-76232) attached. Red circles highlight the mounting points for the hinges.

Figure 8: Top plate - Final structure

Image Description: The top polycarbonate plate with the long hinges and supports attached, showing the structure ready for further component mounting.

3. Mount both 50 mm side parts (800-76229) using two M4-0.7 X 14 mm screws (280-78013) according to Figure 3 and Figure 4.

Short hinges, 50 mm (800-76229)

Image shows two clear polycarbonate pieces shaped as short hinges.

Figure 9: Bottom plate short hinges support mounting holes

Image Description: The bottom polycarbonate plate with two short hinges (800-76229) attached. Red circles highlight the mounting points for the hinges.

3.3 Mounting the power supplies (optional)

One of the two power supplies can be fastened on the back of the top plate. The other power supply needs to be placed around the polycarbonate support, but cannot be fastened to it.

Figure 10: Mount the short hinges to the top plate using four M4-0.7 X 14 mm screws (280-78013).

Image Description: The top polycarbonate plate with two short hinges (800-76229) attached using M4 screws.

Figure 11: Power supply mounting

Image Description: A diagram showing the top plate with two rectangular areas marked for power supply placement. One area is labeled 'Battery Management Unit' and the other 'Battery Junction Box'.

Figure 12: Fastened power supply

Image Description: A view of the top plate with one power supply unit attached using nylon cable ties (600-77772) through designated holes. Green marks indicate the fastening points.

Use the two nylon cable ties (600-77772) to fasten one of the power supplies to the top plate according to the highlighted holes. Green marks on Figure 11 and Figure 12.

3.4 Mounting the battery management unit

Mount the BMU to the top plate using four screws (280-78008), four washers (280-78015) and four nuts (280-76566) according to Figure 13.

Figure 13: Battery management unit mounting procedure

Image Description: A circuit board labeled 'Battery Management Unit' is shown being mounted onto the top plate. Four screws (280-78008), washers (280-78015), and nuts (280-76566) are indicated for securing it.

3.5 Mounting the cell monitoring unit

Mount the CMU to the bottom plate using four screws (280-78008), four washers (280-78015) and four nuts (280-76566) according to Figure 14.

Figure 14: Cell monitoring unit mounting procedure

Image Description: A circuit board labeled 'Cell Monitoring Unit' is shown being mounted onto the bottom plate. Four screws (280-78008), washers (280-78015), and nuts (280-76566) are indicated for securing it.

3.6 Mounting the battery junction box

Mount the BJB to the top plate using four screws (280-78008), four washers (280-78015), and four nuts (280-76566) according to Figure 15 and Figure 16.

Figure 15: Battery junction box mounting procedure

Image Description: A diagram showing the top plate with red circles indicating the mounting locations for the Battery Junction Box.

Figure 16: Battery junction box mounting procedure with Plexiglass

Image Description: A circuit board labeled 'Battery Junction Box' is shown mounted onto the top plate, secured by screws and nuts. A clear protective cover (Plexiglass) is also indicated.

3.7 Mounting the battery emulation system

Mount the battery emulator to the 78 mm side parts using four screws (280-76355) according to Figure 17.

Figure 17: Battery emulator mounting procedure

Image Description: A battery emulator unit is shown being mounted. Four screws (280-76355) are indicated for attachment. A note specifies that the J1 connector should face the right side.

3.8 Connect the top and bottom plates

Connect the top and bottom plates using two M4-0.7 X 20 mm screws (280-78014) and two wingnuts (280-78017).

Figure 18: Connect the top and bottom plates

Image Description: The assembled structure, showing the top and bottom plates connected via screws and wingnuts, creating the final angled configuration.

3.9 Completed structure

The RD-BESS1500BUN structure is now complete. To learn how to connect the boards together, refer to the reference design user manual available on the RD-BESS1500BUN web page.

Figure 19: Final structure for RD-BESS1500BUN

Image Description: A detailed 3D rendering of the fully assembled RD-BESS1500BUN structure, showing all components mounted on the polycarbonate frame.

4 References

[1] RD-BESS1500BUN -- 1500 V Battery Energy Storage Reference Design -- detailed information on the RD-BESS1500 BUN, https://www.nxp.com/part/RD-BESS1500BUN

5 Revision History

Table 7. Revision history

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