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2. Functional and Safety Tests

2.1. Cell Voltage Measurement

Operational Mode Operating mode 2.2
Test objective DUT detecting cell temperature over complete measurement range
Test Definition
  1. DUT shall be in operating mode 2.2
  2. GUI is connected to BMS over RS485
  3. Sweep cell voltages from 1.5V to 4.5V via BMS tester
  4. Observe Cell voltages in GUI
Monitored Signals
  1. All Cell Voltages should be recorded
Test Criteria - DUT shall be able to measure cell voltages with +/- 5mv accuracy
Test Results

- DUT is able to measure cell voltages over complete measurement range with +/- 5mV accuracy.

Cell No Gui Values Measured Value Difference
Cell 1 4.1 4.097 0.003
Cell 2 4.113 4.11 0.003
Cell 3 4.104 4.1 0.004
Cell 4 4.1 4.097 0.003
Cell 5 4.104 4.1 0.004
Cell 6 4.1 4.097 0.003
Cell 7 4.1 4.097 0.003
Cell 8 4.097 4.094 0.003
Cell 9 4.101 4.099 0.002
Cell 10 4.093 4.09 0.003
Cell 11 4.099 4.096 0.003
Cell 12 4.111 4.108 0.003
Cell 13 4.098 4.095 0.003
Cell 14 4.099 4.096 0.003

2.2. Cell Temperature Measurement

Operational Mode Operating mode 2.2
Test objective DUT detecting cell voltages over complete measurement range
Test Definition
  1. DUT shall be in operating mode 2.2
  2. GUI is connected to BMS over RS485
  3. Observe cell temperature in Rest Condition in GUI
  4. Vary 1 cell temperature via potentiometer from 500kohms to 2kohms
  5. Observe cell Temperature in GUI
Monitored Signals All Cell Temperature should be recorded
Test Criteria - DUT shall be able to measure cell voltages with +/- 1C accuracy
Test Results

- DUT is able to measure cell voltages over complete measurement range with +/- 1C accuracy.

Cell No GUI Measurement Measured Values on Thermometer Difference
Temp 1 26.019 27 0.981
Temp 2 27.669 27 -0.669
Temp 3 26.019 27 0.981
Temp 4 26.019 27 0.981
Temp 5 26.019 27 0.981
Temp 6 26.019 27 0.981
Temp 7 26.019 27 0.981
Temp 8 26.019 27 0.981
Temp 9 26.019 27 0.981

Expected Temperature at 2kohms: 66.12675

Measured Temperature at 2kohms: 66.598

2.3. Battery and Load Voltage Measurement

Operational Mode Operating mode 2.2
Test objective DUT detecting pack voltage, battery voltage and load voltage in rest mode
Test Definition
  1. DUT shall be in operating mode 2.2
  2. GUI is connected to BMS over RS485
  3. Turn On Ignition
  4. Contactors should be on
  5. Observe Pack Voltage, battery voltage and Load voltage in GUI
Monitored Signals - Pack Voltage, Battery Voltage and Load Voltage
Test Criteria - DUT shall be able to measure cell voltages with +/- 1V accuracy
Test Results

- DUT is able to measure voltages over complete measurement range with +/- 1V accuracy.

Item Gui Values Measured Values Difference
Load Voltage 56.369 56.9 -0.531
Battery Voltage 56.369 56.9 -0.531
Pack Voltage 57.153 56.9 0.253

2.4. Charge and Discharge Current Measurement

Operational Mode Operating mode 2.2
Test objective DUT detecting charge and discharge current
Test Definition
  1. DUT shall be in operating mode 2.2
  2. GUI is connected to BMS over RS485
  3. Turn On Ignition
  4. Contactors should be on
  5. Sweep load from 5A to 200A
  6. Observe Discharge current in GUI
  7. Turn Off Ignition
  8. Contactor should be off
  9. Connect Charger
  10. Observe Charge Current in GUI
Monitored Signals - Discharge Current and Charge Current
Test Criteria - DUT shall be able to measure current with +/- 1A accuracy
Test Results

- DUT is able to measure current over complete measurement range with +/- 1A accuracy.

Charge Current:

GUI Value Measured Value Error
10.311 10 0.311
20.622 20 0.622
30.765 30 0.765
40.673 40 0.673

Discharge Current

GUI Value Measured Value Error
5.552 5.3 0.252
10.752 10.4 0.352
21.188 20.78 0.408
41.134 40.6 0.534
100.765 100.2 0.565
151.35 150.89 0.46
201.105 200.345 0.76

2.5. SD Card

Operational Mode Operating mode 2.2
Test objective BMS writing logs and events in sd card
Test Definition
  1. DUT shall be in operating mode 2.2
  2. GUI is connected to BMS over RS485
  3. Turn On Ignition
  4. Contactors should be on
  5. Contactor should be on for 30sec
  6. Turn Off Ignition
  7. Contactor should be off
  8. Give command from gui to read event and logs for current date
  9. Event file and log file will be saved in gui folder
Monitored Signals - Logs and Event file
Test Criteria - GUI shall be able to read logs and event from DUT sd card
Test Results

GUI is able to read logs and event file from DUT sd card


Snapshot of log file

- All Cell voltages, Cell temperature, Pack voltage, Pack Curren, BMS State, SOC, SOH are recorded in SD Card in every 10sec interval

- Every day new csv file is created to keep logs

00:03:17 3.333 3.333 3.334 3.333 3.334 3.333 3.333 3.333 3.333 3.333 3.333 3.334 3.334 3.334 3.333 3.334 26.686 27.1 26.274 27.1 26.686 26.686
00:03:27 3.333 3.333 3.334 3.333 3.334 3.333 3.333 3.333 3.333 3.333 3.333 3.334 3.334 3.334 3.333 3.334 26.686 27.1 26.274 27.1 26.686 26.686
00:03:37 3.333 3.333 3.334 3.333 3.334 3.333 3.334 3.333 3.333 3.333 3.333 3.333 3.334 3.334 3.334 3.334 26.686 27.1 26.274 27.1 26.686 26.686
00:03:46 3.333 3.333 3.334 3.333 3.334 3.333 3.333 3.333 3.333 3.333 3.333 3.333 3.334 3.334 3.333 3.334 26.686 27.1 26.274 27.1 26.686 26.686
00:03:56 3.333 3.333 3.334 3.333 3.334 3.333 3.333 3.333 3.333 3.333 3.333 3.333 3.334 3.334 3.334 3.334 26.686 27.1 26.274 27.1 26.686 26.686

Snapshot of Event file

- All BMS state machine events are recorded in event file

- Every day new csv file is created to keep events

65924705 28 1 0 0 90 0
65924713 58 1 0 0 86 0

2.6. CAN and RS485 Communication

Operational Mode Operating mode 2.2
Test objective BMS communicating over CAN and RS485
Test Definition 1. DUT shall be in operating mode 2.2
2. GUI is connected to DUT over RS485
3. DUT CAN is connected to system PCAN
4. Check if GUI is getting parameter from DUT in scan mode
5. Check if PCAN is getting CAN parameter from DUT as per CAN DBC
Monitored Signals GUI Parameters and PCAN trace
Test Criteria - GUI shall be able to communicate over RS485 and CAN
Test Results - DUT is able to communicate over RS485 and CAN

GUI Screenshot:
GUI Screenshot

PCAN Screenshot:
PCAN Screenshot

2.7. State Machine

Operational Mode Operating mode 2.2
Test objective DUT states and state transition
Test Definition
  1. DUT shall be in operating mode 2.2
  2. GUI is connected to BMS over RS485
  3. Test state Transition as per below
OFF Maintenance Balancing Precharge Discharge CAN Charge CAN_Fully_Charged CAN_Charge_Balancing Sleep Reset Balancing
OFF TBT TBT TBT TBT
Maintenance Balancing TBT
Precharge TBT
Discharge TBT TBT TBT
Rest Balancing TBT
CAN Charge TBT TBT
CAN_Fully_Charged TBT
CAN_Charge_Balancing TBT
Sleep TBT TBT
Monitored Signals - DUT State on GUI
Test Criteria - DUT shall be able to make all state transition
Test Results - DUT is able to make all state transition
OFF Maintenance Balancing Precharge Discharge CAN Charge CAN_Fully_Charged CAN_Charge_Balancing Sleep Reset Balancing
OFF OK OK OK OK
Maintenance Balancing OK
Precharge OK
Discharge OK OK OK
Rest Balancing OK
CAN Charge OK OK
CAN_Fully_Charged OK
CAN_Charge_Balancing OK
Sleep OK OK

2.8. Cell High Voltage Warning and Cell Over Voltage Fault

Operational Mode Operating mode 2.2
Test objective DUT detecting cell high voltage warning and cell over voltage fault for single cell or multiple cells and taking protective measures
Test Definition
  1. DUT shall be in operating mode 2.2
  2. GUI is connected to BMS over RS485
  3. Turn off Ignition
  4. Manipulate Cell High voltage and Cell Over Voltage settings through gui such that DUT detects high voltage warning and over voltage fault within 1min of charging
  5. Connect Charger
  6. Observe Cell High Warning and Cell Over voltage fault bit in gui
  7. Function of DUT shall be observed
  8. Disconnect Charger and Turn on Ignition
  9. Function of DUT shall be observed
Monitored Signals
  1. Status of contactor shall be recorded
  2. Cell high voltage warning bit and cell over voltage fault bit in gui shall be recorded
  3. External communication of DUT shall be recorded [Error code]
Test Criteria

- DUT shall be able to detect cell high voltage warning, cell over voltage fault and prohibit further charging

- Load Contactor should open

- After Disconnecting charger and turning on ignition warning and fault shall reset and contactor should turn on
Test Results

- DUT is able to detect cell high voltage warning and cell over voltage fault within configured time

- DUT is able to reset warning and fault after ignition is turned on and charger is disconnected

2.9. Pack High Voltage Warning and Pack Over Voltage Fault

Operational Mode Operating mode 2.2
Test objective DUT detecting pack high voltage warning and pack over voltage fault and taking protective measures
Test Definition
  1. DUT shall be in operating mode 2.2
  2. GUI is connected to BMS over RS485
  3. Turn off Ignition
  4. Manipulate pack High voltage and pack Over Voltage settings through gui such that DUT detects high voltage warning and over voltage fault within 1min of charging
  5. Connect Charger
  6. Observe pack High Warning and pack Over voltage fault bit in gui
  7. Function of DUT shall be observed
  8. Disconnect Charger and Turn on Ignition
  9. Function of DUT shall be observed
Monitored Signals
  1. Status of contactor shall be recorded
  2. pack high voltage warning bit and pack over voltage fault bit in gui shall be recorded
  3. External communication of DUT shall be recorded [Error code]
Test Criteria

- DUT shall be able to detect pack high voltage warning, pack over voltage fault and prohibit further charging

- Load Contactor should open

- After Disconnecting charger and turning on ignition warning and fault shall reset and contactor should turn on
Test Results

- DUT is able to detect pack high voltage warning and pack over voltage fault within configured time

- DUT is able to reset warning and fault after ignition is turned on and charger is disconnected

2.10. Cell Low voltage warning and Cell Under voltage fault

Operational Mode Operating mode 2.2
Test objective DUT detecting cell low voltage warning and cell under voltage fault for single cell or multiple cells and taking protective measures
Test Definition
  1. DUT shall be in operating mode 2.2
  2. GUI is connected to BMS over RS485
  3. Turn on Ignition
  4. Manipulate Cell low voltage and Cell under Voltage settings through gui such that DUT detects low voltage warning and under voltage fault within 1min of discharge
  5. Connect load for 50A discharge
  6. Observe Cell low Warning and Cell under voltage fault bit in gui
  7. Function of DUT shall be observed
  8. Disconnect load, turn off Ignition and connect charger
  9. Function of DUT shall be observed
Monitored Signals
  1. Status of contactor shall be recorded
  2. Cell low voltage warning bit and cell under voltage fault bit in gui shall be recorded
  3. External communication of DUT shall be recorded [Error code]
Test Criteria

- DUT shall be able to detect cell low voltage warning, cell under voltage fault and prohibit further discharge

- Load Contactor should open

- After Disconnecting load, turning off ignition and turning on charger warning and fault shall reset and contactor should turn on
Test Results

- DUT is able to detect cell low voltage warning and cell under voltage fault within configured time

- DUT is able to reset warning and fault after ignition is turned off and charger is connected

2.11. Pack Low Voltage Warning and Pack Under Voltage Fault

Operational Mode Operating mode 2.2
Test objective DUT detecting pack low voltage warning and pack under voltage fault and taking protective measures
Test Definition
  1. DUT shall be in operating mode 2.2
  2. GUI is connected to BMS over RS485
  3. Turn on Ignition
  4. Manipulate pack low voltage and pack under Voltage settings through gui such that DUT detects low voltage warning and under voltage fault within 1min of discharge
  5. Connect load for 50A discharge
  6. Observe pack low Warning and pack under voltage fault bit in gui
  7. Function of DUT shall be observed
  8. Disconnect load, turn off Ignition and connect charger
  9. Function of DUT shall be observed
Monitored Signals
  1. Status of contactor shall be recorded
  2. Pack low voltage warning bit and pack under voltage fault bit in gui shall be recorded
  3. External communication of DUT shall be recorded [Error code]
Test Criteria

- DUT shall be able to detect pack low voltage warning, pack under voltage fault and prohibit further discharge

- Load Contactor should open

- After Disconnecting load, turning off ignition and turning on charger warning and fault shall reset and contactor should turn on
Test Results

- DUT is able to detect pack low voltage warning and pack under voltage fault within configured time

- DUT is able to reset warning and fault after ignition is turned off and charger is connected

2.12. Charge and Discharge High Current Warning and Over Current Fault

Operational Mode Operating mode 2.2
Test objective DUT detecting high current warning and over current fault in charge and discharge state and taking protective measures
Test Definition
  1. DUT shall be in operating mode 2.2
  2. GUI is connected to BMS over RS485
  3. Turn on Ignition
  4. Connect load for 350A discharge
  5. Observe discharge high current Warning and over current fault bit in gui
  6. Function of DUT shall be observed
  7. Disconnect load, turn off Ignition
  8. Function of DUT shall be observed
  9. Connect Charger with 120A charging current
  10. Observe charge high current warning and over current fault bit in gui
  11. Function of DUT shall be observed
  12. Disconnect charger and Turn on ignition
  13. Function of DUT shall be observed
Monitored Signals
  1. Status of contactor shall be recorded
  2. Discharge and Charge High current warning bit, over current fault bit in gui shall be recorded
  3. External communication of DUT shall be recorded [Error code]
Test Criteria

- DUT shall be able to detect Discharge High current warning, Discharge over current fault and prohibit further discharge

- Load Contactor should open

- After Disconnecting load, turning off ignition and turning on charger warning and fault shall reset and contactor should turn on

- DUT shall be able to detect Charge high current warning, Discharge over current Fault and prohibit further charge

- Load Contactor should open

- After disconnecting charger, turning on ignition warning and fault shall reset and contactor
Test Results

- DUT is able to detect Discharge High Current warning and over current fault within configured time

- DUT is able to reset warning and fault after ignition is turned off and charger is connected

- DUT is able to detect Charge High Current warning and over current fault within configured time

- DUT is able to reset warning and fault after charger is turned off and Ignition is turned on

2.13. Charge and Discharge High Temperature Warning and Over Temperature Fault

Operational Mode Operating mode 2.2
Test objective DUT detecting high temperature warning and over temperature fault in charge and discharge state and taking protective measures
Test Definition
  1. DUT shall be in operating mode 2.2
  2. GUI is connected to BMS over RS485
  3. Turn on Ignition
  4. Temperature signal for 1 of the thermistors should be continuously increased till DUT reacts due to high temperature
  5. Observe discharge high temperature Warning and over temperature fault bit in gui
  6. Function of DUT shall be observed
  7. Temperature signal for 1 of the thermistors should be continuously decreased till DUT resets warning and Fault
  8. Function of DUT shall be observed
  9. Turn off Ignition
  10. Connect charger
  11. Temperature signal for 1 of the thermistors should be continuously increased till DUT reacts due to high temperature
  12. Observe charge high temperature Warning and over temperature fault bit in gui
  13. Function of DUT shall be observed
  14. Temperature signal for 1 of the thermistors should be continuously decreased till DUT resets warning and Fault
  15. Function of DUT shall be observed
Monitored Signals
  1. Status of contactor shall be recorded
  2. Discharge and Charge High temperature warning bit, over temperature fault bit in gui shall be recorded
  3. External communication of DUT shall be recorded [Error code]
Test Criteria

- DUT shall be able to detect Discharge High current warning, Discharge over current fault and prohibit further discharge

- Load Contactor should open

- After decreasing temperature signal warning and fault shall reset and contactor should turn on

- DUT shall be able to detect Charge High temperature warning, over temperature Fault and prohibit further charge

- Load Contactor should open

- After decreasing temperature signal warning and fault shall reset and contactor should turn on
Test Results

- DUT is able to detect Discharge High temperature warning and over temperature fault within configured time

- DUT is able to reset warning and fault once temperature is decreased

- DUT is able to detect Charge High temperature warning and over temperature fault within configured time

- DUT is able to reset warning and fault once temperature is decreased

2.14. Charge and Discharge Low Temperature Warning and Under Temperature Fault

Operational Mode Operating mode 2.2
Test objective DUT detecting low temperature warning and under temperature fault in charge and discharge state and taking protective measures
Test Definition
  1. DUT shall be in operating mode 2.2
  2. GUI is connected to BMS over RS485
  3. Turn on Ignition
  4. Temperature signal for 1 of the thermistors should be continuously decreased till DUT reacts due to high temperature
  5. Observe discharge low temperature Warning and under temperature fault bit in gui
  6. Function of DUT shall be observed
  7. Temperature signal for 1 of the thermistors should be continuously increased till DUT resets warning and Fault
  8. Function of DUT shall be observed
  9. Turn off Ignition
  10. Connect charger
  11. Temperature signal for 1 of the thermistors should be continuously decreased till DUT reacts due to low temperature
  12. Observe charge low temperature Warning and over temperature fault bit in gui
  13. Function of DUT shall be observed
  14. Temperature signal for 1 of the thermistors should be continuously increased till DUT resets warning and Fault
  15. Function of DUT shall be observed
Monitored Signals
  1. Status of contactor shall be recorded
  2. Discharge and Charge low temperature warning bit, under temperature fault bit in gui shall be recorded
  3. External communication of DUT shall be recorded [Error code]
Test Criteria

- DUT shall be able to detect Discharge low current warning, Discharge under current fault and prohibit further discharge

- Load Contactor should open

- After increasing temperature signal warning and fault shall reset and contactor should turn on

- DUT shall be able to detect Charge low temperature warning, over temperature Fault and prohibit further charge

- Load Contactor should open

- After increasing temperature signal warning and fault shall reset and contactor should turn on
Test Results

- DUT is able to detect Discharge low temperature warning and under temperature fault within configured time

- DUT is able to reset warning and fault once temperature is increased

- DUT is able to detect Charge low temperature warning and over temperature fault within configured time

- DUT is able to reset warning and fault temperature is decreased

2.15. Fuse Open

Operational Mode Operating mode 2.2
Test objective DUT detecting Fuse open and taking protective measure
Test Definition
  1. DUT shall be in operating mode 2.2
  2. GUI is connected to BMS over RS485
  3. Connect switch/contactor [FS] in series with fuse to simulate fuse open condition
  4. Turn on FS
  5. Turn on Ignition
  6. Turn off FS
  7. Observer fuse open bit in gui
  8. Function of DUT shall be observed
Monitored Signals
  1. Status of contactor shall be recorded
  2. Fuse open bit in gui shall be recorded
  3. External communication of DUT shall be recorded [Error code]
Test Criteria

- DUT shall be able to detect Fuse open and contactor should open
Test Results

- DUT is able to detect Fuse open within configured time

2.16. Cell Voltage Sensing Open

Operational Mode Operating mode 2.2
Test objective DUT detecting Cell wire open and taking protective measure
Test Definition
  1. DUT shall be in operating mode 2.2
  2. GUI is connected to BMS over RS485
  3. Connect switch/contactor [FS] in series with fuse to simulate fuse open condition
  4. Turn on FS
  5. Turn on Ignition
  6. Turn off FS
  7. Observer fuse open bit in gui
  8. Function of DUT shall be observed
Monitored Signals
  1. Status of contactor shall be recorded
  2. Cell open bit in gui shall be recorded
  3. External communication of DUT shall be recorded [Error code]
Test Criteria
  1. DUT shall be able to detect Cell open and contactor should open
Test Results
  1. DUT is able to detect Cell open within configured time

2.17. Cell Temperature Sensing Open

Operational Mode Operating mode 2.2
Test objective DUT detecting thermistor open and taking protective measure
Test Definition
  1. DUT shall be in operating mode 2.2
  2. GUI is connected to BMS over RS485
  3. Connect switch/contactor [FS] in series with thermistor to simulate thermistor open condition
  4. Turn on FS
  5. Turn on Ignition
  6. Turn off FS
  7. Observer thermistor open bit in gui
  8. Function of DUT shall be observed
Monitored Signals
  1. Status of contactor shall be recorded
  2. Thermistor open bit in gui shall be recorded
  3. External communication of DUT shall be recorded [Error code]
Test Criteria
  1. DUT shall be able to detect Thermistor open and contactor should open
Test Results
  1. DUT is able to detect Thermistor open within configured time