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WS 500 charge profile

After startup at low engine rpm the system goes to bulk and  charges at 20 to 30 amps.

When rpm is raised the amps increase as does the voltage to 14.1 volts. That is the VBat set point in line

$CPA. The unit goes to Float and stops charging. The SOC is well below 100 %. How to keep charging without

raising the Kilovault battery set point above the max setting ?  The alternator is a Balmar 60 - 120 amp which is

more than adequate.

Don

Don, the WS500 is doing exactly what it is supposed to be doing, so lets look more closely at your battery pack.

The problem seems to be with your SOC reading.  Remember that SOC is just a calculation of what comes in vs what goes out and an allowance for efficiency losses.

A couple of things to try:

  1.  Research how your BMS calculates and resets its SOC reading.  Most BMSs will do a reset to 100% when it reaches its maximum pack voltage(which yours seems to be doing)
  2.  If there is a slight difference in readings between your cell pack and the WS500 you might try increasing your VBAT setting by a tenth or two of a volt and monitor it closely while charging, just to get it to its 100% reset trigger point.

The big thing to remember here is that SOC is just a calculation and can easily get out of whack over time with just the smallest of error in sensing values.

Hope this helps,

 

Rick

OGSS Tech support

Have been monitoring SOC with the Balmar SG 200 and Kilovault bluetooth app.

The Kilovault app  reads consistently higher by 7 to 15 % so I have been switching to internal regulation at the alternator  in order to raise the  charge up to 90/95 %  of the battery capacity without having the WS 500 shut down.

Most battery packs are set to 14.4 and fine up to 14.6 volts, provided they are fairly well balanced.  You are likely better off using your WS500 and increasing the VBAT setpoint vs relying on an internal regulator with no proper shutoff or temperature safety cutoffs.

Hello Don,

from KiloVault manual.

Absorb Voltage 14 Volt

Absorb End Amps 2 A
Absorb Time 2 minutes or less

Not clear for me, is what they like, 14.0V only for 2 minutes, or 14.0 till the amps drop below 2Amp.

The WS500 can be programmed for both charge profiles.

This means as Rick mention, the WS500 is doing what it should do.

If there is 14V, for 2minutes on the battery pole, the internal software, should reset the SOC reading to 100%.

If thats not happen, you need to ask Kilovault when there SOC should reset to 100%.

 

Iam curious how the Kilovault is doing his internal balancing, because most off the other brands do balancing between 14.0 and 14.4 volt.  My personal test show that balancing below 14.0V is not efficient, and created in some cases a bigger imbalance.

Lower charge voltage seams better for lifetime from the  lifepo4 cells, but higher voltage are needed to keep the cells in balance.

Anyway I think you need to follow the manufacture charge advise, higher as 14.0 I would discuss with manufacture.

 

Your internal regulator will keep the batteries longer as 2 minutes in Bulk, not good.

As your charge voltage is maximum 14.0V, the Balmar battery monitor should reset to 90 or 100% also. Check there manual how to archive this.

 

Another point thats important, is your voltage sense from the ws500 installed at the correct position.

 

Ben

Forum reader

Have contacted Kilovault and received a reply that is basically what they have printed in their brochure.

Limit  the voltage to 14.1 v. Since then I have raised the VBat set point to 14.2 volts. anyway.

This resulted in a slight improvement. The  system stayed in bulk longer , then went to acceptance and stayed for several minutes until the rpm was raised to about 1500rpm , then went to float and quit charging. When the rpm was raised the voltage at the alternator and battery sense increased slightly to 14.3/14.4 volts. It does appear that the WS 500 is working properly but there does not seem to be a way to allow the battery  to reach full charge. Since Kilovault says not to raise the set point , the other alternative is to somehow lower the max amperage of the alternator. How ? I have difficulty understanding when and how the the battery will reach full charge. The Balmar SG 200 has never gone above 65% and the Kilovault App  90 %

 

This is a great example of what happens when the Smart regulator can not talk with the BMS.  With an integrated system the BMS will send a signal to the WS500 to start to taper back as it approaches 100%.

In your case you will have to go to a semi-automatic method.  The WS500 has an option, using the feature IN input to reduce its output when a switch is closed.

From what it seems, your Battery pack may be out of balance and even though it is not 100% full, you have a cell that is going over voltage, while other cells are not yet full, but the total voltage goes above 14.1 because when a cell reaches 100% full its voltage will start to rise exponentially as compared to the other cells.  Your idea to slow feed it while it approaches 14.1v may work, all depending on how the internal BMS will try to top balance your cells.  Kilovault may be able to assist with a maximum input amp rating while balancing.

This is from page 11 of the manual

http://wakespeed.com/Wakespeed%20%20Communications%20and%20Configuration%20Guide%20v2.4.3.pdf

A NOTE ON FEATURE-IN PORT
The Feature-in port allows a wide range of optional capabilities in the WS500 to be selected in real time. Throughout
this configuration guide there are a number of places where the Feature-In port may be enabled to be looked at to
select a given capability. There are also options to modify the behavior of the Feature-In port from its normal behavior.
Care should be exercised when configuring the WS500 to assure that the desired behavior of the Feature-in port is
selected, and that some other expected use has not inadvertently been disabled. Example, by utilizing the Feature-In
port to allow to selection of an alternative DC-DC converter set point, the default behaviors of forcing the regulator
mode to Float with CPE #8 will be overridden; this could cause unexpected behaviors if the system design expects to use
the Feature-in port for a legacy BMS integration.

Feature-In can be used as

1. Force Equalize (when using CPE #7)
2. Force Float (when using CPE #8)
3. Force whitespace (setting RMP to positive value in CNG when in CPE #8. Negative value of RPM in CNG forces
whitespace on all the time ignoring Feature-In. Pos/New values of RPM in CNG are ignored when in CPE 7.)
4. Force regulator power (setting dHalf 0 in SCA)
5. Feature-In polarity change for any of the above.

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