BEU8637-08 Battery Electronic Unit

Cell Management Electronics for Lithium-Ion Battery
BEU8637-08
Independent Balancing for Two 8-Cell Batteries
Cell Voltage Monitoring and Telemetry
www.aeroflex.com/BEU
March 21, 2008
Description
The Aeroflex 8637-08 is a Lithium-Ion cell
balancing system. It controls the balancing
of one or two batteries, each consisting of
a series stack of Lithium-Ion cells to ensure
that each cell is precisely charged to its
proper level of energy and to monitor each
cell's operational voltage.
The cell balancing circuitry uses a set of
bilateral DC-DC converters which tie each
cell of a battery to a common share bus.
Cell charge is distributed among the
multiple cells so that the charge of each
cell is automatically matched to the
average charge of the other cells.
Features
●
Cell Balancing to within ±5.0mV
●
Cell Voltage Monitoring Accuracy
±10.0mV (±20.0mV Space Mission Life)
●
Total Battery Voltage Monitoring
Accuracy ±0.3% of Full Scale
●
Supports up to 8 Lithium-Ion battery cells
in series per stack
●
Battery Drain Current at Balance
15mA Max for each 8 cell stack
●
Discrete output lines for critical signaling
with user definable thresholds:
Overvoltage Protection 4.40V typ
Cell Voltage High
4.20V typ
Cell Voltage Low
3.20V typ
●
MIL-STD-1553B telemetry for data
logging and monitoring
SCD8637-08 Rev A
Safety
The safety of Lithium-Ion battery
technology requires that extreme care be
taken in the provisions made for cell
charging and cell monitoring.
Precision measurements of each of the
individual cell voltages in the battery stack
and precise charge balancing to each
individual cell are critical.
The Aeroflex 8637-08 provides the
necessary precision of control and
monitoring to ensure that safety.
Discrete logic outputs are provided for
critical signaling, enabling the user to
initiate load shedding and/or to halt
charging.
Low operating losses enable continuous
operation. Continuous balancing provides
maximum protection against any one cell
becoming overcharged.
CELL BALANCE
BOARD
CONTROL BOARD
OVP
A/D
12-BIT
HIGH
CELL
LOW
CELL
1553B
Channel A
12
MUX
SELECT
XFMR
7
XCVR
1553B
Channel B
ON
OFF
+30 VDC
VIN
CONTROLLER
XFMR
BALANCING
CIRCUIT
CLOCK
DRIVER
RELAY
POWER
SUPPLY
+12VDC
(ISOLATED)
+5VDC
MUX
BAL
CLK
MON
CLK
BALANCING
CIRCUIT
1
+
-
BALANCING
CIRCUIT
2
+
-
BALANCING
CIRCUIT
3
+
-
BALANCING
CIRCUIT
4
+
-
BALANCING
CIRCUIT
8
+
-
PRECISION
REFERENCE
4.000V
2 2 2
BATTERY
VOLTAGE
DIFF. AMPS
-12VDC
BATTERY
8 CELLS
BATTERY
HI AND LO
( 3x )
+12VDC
SHARE BUS
CONTROL BOARD
BATTERY
8 CELLS
OVP
A/D
12-BIT
HIGH
CELL
LOW
CELL
1553B
Channel A
12
MUX
SELECT
XFMR
7
XCVR
1553B
Channel B
ON
OFF
+30 VDC
VIN
CONTROLLER
XFMR
BALANCING
CIRCUIT
CLOCK
DRIVER
RELAY
POWER
SUPPLY
+12VDC
(ISOLATED)
+5VDC
-12VDC
MUX
BAL
CLK
MON
CLK
BALANCING
CIRCUIT
13
+
-
BALANCING
CIRCUIT
14
2
+
-
BALANCING
CIRCUIT
15
+
-
BALANCING
CIRCUIT
16
+
-
BALANCING
CIRCUIT
20
+
-
PRECISION
REFERENCE
4.000V
2 2 2
BATTERY
VOLTAGE
DIFF. AMPS
BATTERY
HI AND LO
( 3x )
+12VDC
SHARE BUS
Block Diagram
Aeroflex Plainview
SCD8637-08 Rev A 3/21/08
2
8637-08 Operating Details
Battery Cell Balancing
Provides 8 individual continuous balancing circuits per stack.
Battery Cell Overvoltage Latch Output
The status of the OVP latch is provided by telemetry as
specified in Tables II, III & IV and also as a discrete output.
Maximum Cell Balancing Current Limit
Each cell is provided with a 1Amp fuse for overload interrupt
in the event of a shorted cell to protect the remaining cell
balance functionality.
Recovery from Cell Overvoltage Indication
The OVP latch is reset by a 1553B reset command or by
recycling the input power.
Cell Balancing Accuracy
When connected to a battery, the 8637-08 provides
balancing currents into each of the battery's cells. The
directions and the magnitudes of the individual currents are
proportional to the deviations of the cell voltages from the
average cell voltage. The transfer ratio of voltage to current is
1.0 Ohm nominal and is satisfied for cell voltages of up to
4.2V.
Highest Battery Cell Voltage Telemetry
Provides highest battery cell voltage telemetry as specified in
Tables I & IV.
Lowest Battery Cell Voltage Telemetry
Provides lowest battery cell voltage telemetry as specified in
Tables I & IV.
Test Points
Provides test points for total battery voltage, low cell
indicator and high cell indicator. Access to the total battery
voltage is provided to permit pre-charging before connection
to the battery.
Battery Cell Current Drawn in Off State
In the off state, the differential mode battery cell current
drawn by each cell balancing circuit is less than 50μA.
Battery Cell Voltage Monitoring
Measures cell voltages for up to two 8-cell batteries.
4V and 0V References for Calibration
Provides 4V and 0V references for cell voltage telemetry
calibration.
Battery and Cell Protection
Incorporates overvoltage protection (OVP) circuits. These
circuits monitor all of the battery cell voltages and only
register the highest of all cell voltages monitored. When a
cell voltage threshold of 4.40V is reached, the protection
circuit output changes state and latches within 50mS.
Aeroflex Plainview
SCD8637-08 Rev A 3/21/08
3
MIL-STD-1553B Telemetry & Commands (Each 8-cell battery)
Analog or bi-level telemetry can be requested from either
the primary or the redundant controller and reported over
the dual redundant 1553B interface with the RT addresses
configurable at the J1 and J4 connectors.
Bi-Level Telemetry
Bi-level telemetry can be requested on sub-addresses 18, 19
or 22.
First a 1553B receive command with one data word as
defined in Table II, which specifies the telemetry item being
requested, must be issued. After a minimum delay of 1.2ms,
the data can be retrieved by sending a 1553B transmit
command for one data word on the same sub-address on
which the request was initiated.
Analog Telemetry
Each analog telemetry item can be requested individually on
sub-addresses 18, 19 or 22.
First a 1553B receive command with one data word as
defined in Table I, which specifies the telemetry item being
requested, must be issued. After a minimum delay of 1.2ms,
the data can be retrieved by sending a 1553B transmit
command for one data word on the same sub-address on
which the request was initiated.
Table II – Bi-level Telemetry
The 12-bit data reply is left justified in the 16-bit 1553B data
word with the four LSBs set to "0".
Item
Telemetry Title
Status
Reply
Bit
1st Data
Word of
1553B
Receive
Command
(Hex)
D13
0C80
Table I – Analog Telemetry (Each 8-cell battery)
1
Telemetry Reply
Scale
1st Data Word of
1553B Receive
Command (Hex)
4V Reference
-0.40V to 4.89V
0800
2
0V Reference
-0.40V to 4.89V
0803
3
Total Battery Voltage 1
0V to 61.44V
0805
4
Total Battery Voltage 2
0V to 61.44V
0806
5
Total Battery Voltage 3
0V to 61.44V
0809
6
Share Bus Voltage
0V to 5.12V
080A
7
Cell 1 Voltage
0V to 5.12V
0811
8
Cell 2 Voltage
0V to 5.12V
0812
9
Cell 3 Voltage
0V to 5.12V
0814
10
Cell 4 Voltage
11
Cell 5 Voltage
12
Cell 6 Voltage
13
Cell 7 Voltage
14
Cell 8 Voltage
15
Cell 13 Voltage
Item
1
Telemetry Title
16
Cell 14 Voltage
17
Cell 15 Voltage
18
Cell 16 Voltage
19
Cell 17 Voltage
20
Cell 18 Voltage
21
Cell 19 Voltage
22
Cell 20 Voltage
23
Lowest Cell Voltage
24
Highest Cell Voltage
⎫
⎬
⎭
⎫
⎬
⎭
0V to 5.12V
0817
0V to 5.12V
0818
0V to 5.12V
081B
0V to 5.12V
081D
Overvoltage Latch Status
1 = Set
1/
0V to 5.12V
081E
0V to 5.12V
0828
0V to 5.12V
082B
0V to 5.12V
082D
0V to 5.12V
082E
0V to 5.12V
0830
0V to 5.12V
0833
2/
1/ For Battery A.
0V to 5.12V
0835
0V to 5.12V
0836
0V to 5.12V
0871
0V to 5.12V
0872
2/ For Battery B.
Aeroflex Plainview
SCD8637-08 Rev A 3/21/08
4
32-Word Telemetry
To reduce data bus bandwidth usage, the 8637-08 supports
a 32-word telemetry request on sub-address 20 as defined
in Table III.
8-Word Telemetry
To reduce data bus bandwidth usage, the 8637-08 supports
an 8-word telemetry request on sub-address 24 as defined
in Table IV.
First a 1553B receive command with one data word of
AAAA(Hex) must be issued. After a minimum delay of
1.2ms, the data can be retrieved by sending a 1553B
transmit command for 32 data words on sub-address 20.
First a 1553B receive command with one data word of
5555(Hex) must be issued. After a minimum delay of 1.2ms,
the data can be retrieved by sending a 1553B transmit
command for 8 data words on sub-address 24.
Reply word 31 is a modulo-16 message count. This counter
increments by one for each valid telemetry request.
The 12-bit analog data reply is left justified in the 16-bit
1553B data word with the four LSBs set to "0"..
Reply word 8 is a modulo-16 message count. This counter
increments by one for each valid telemetry request.
The 12-bit analog data reply is left justified in the 16-bit
1553B data word with the four LSBs set to "0".
Table III – 32-Word Telemetry
Table IV – 8-Word Telemetry
Item
1
2
Telemetry Reply
Type
Word
Telemetry Title
4V Reference
Analog
Total Battery Voltage 1
1
Analog
2
Reply Bits
Item
Telemetry Title
D(15:4)
1
Overvoltage Latch Status
D(15:4)
2
Reserved
Reserved
Telemetry
Type
Reply
Word
Reply Bits
Bi-level
1
D13
-
2
D15
-
3
D15
3
Total Battery Voltage 2
Analog
3
D(15:4)
3
4
Total Battery Voltage 3
Analog
4
D(15:4)
4
Reserved
-
4
D15
0V Reference
Analog
5
D(15:4)
5
Share Bus Voltage
6
Reserved
7
Cell 1 Voltage
8
Cell 2 Voltage
9
Cell 3 Voltage
10
Cell 4 Voltage
11
Cell 5 Voltage
12
Cell 6 Voltage
13
Cell 7 Voltage
14
Cell 8 Voltage
15
Reserved
16
Reserved
17
Reserved
18
Reserved
19
Cell 13 Voltage
20
Cell 14 Voltage
21
Cell 15 Voltage
22
Cell 16 Voltage
23
Cell 17 Voltage
24
Cell 18 Voltage
25
Cell 19 Voltage
26
Cell 20 Voltage
27
Reserved
28
Reserved
29
Reserved
30
Reserved
⎫
⎬
⎭
⎫
⎬
⎭
1/
2/
Analog
5
D(15:4)
5
-
6
D(15:4)
6
Lowest Cell Voltage
Analog
6
D(15:4)
Highest Cell Voltage
Analog
7
D(15:4)
Message Count
Analog
8
D(15:0)
Analog
7
D(15:4)
7
Analog
8
D(15:4)
8
Analog
9
D(15:4)
Analog
10
D(15:4)
Analog
11
D(15:4)
Analog
12
D(15:4)
Analog
13
D(15:4)
Analog
14
D(15:4)
-
15
D(15:4)
-
16
D(15:4)
-
17
D(15:4)
-
18
D(15:4)
Analog
19
D(15:4)
Analog
20
D(15:4)
Analog
21
D(15:4)
Analog
22
D(15:4)
Analog
23
D(15:4)
Analog
24
D(15:4)
Analog
25
D(15:4)
Analog
26
D(15:4)
-
27
D(15:4)
-
28
D(15:4)
-
29
D(15:4)
-
30
D(15:4)
31
Message Count
Analog
31
D(15:0)
32
Overvoltage Latch Status
Bi-level
32
D13
1/ For Battery A.
2/ For Battery B.
Aeroflex Plainview
SCD8637-08 Rev A 3/21/08
5
Additional Commands
Data Load Command
1553B receive commands consist of 2 data words to the
sub-address specified in Table V. Only the first data word is used.
Table V – Commands
Item
Function Title
1
Reset OVP Latch
1st Data Word
of 1553B
Sub-Address
Receive
Command
(Hex)
15
0400
Telemetry Frame Sync Command
1553B broadcast command on sub-address 17 (any data word)
commands the 8637-08 to refresh its RT address.
Remote Terminal State Command
1553B transmit command on sub-address 21 for one data word.
The reply word will be 4000(Hex), to indicate that the unit is ready
to accept another command or 5000(Hex), to indicate that the
unit is busy and cannot accept another command.
1553B Data Wrap Around
Sub-address 30 is dedicated to data wrap around as specified in
MIL-STD-1553B.
Supported Mode Codes
The 8637-08 supports the 1553B Mode Codes in Table VI.
Table VI – 1553B Mode Codes
Mode Code Name
Mode Code Number
Transmit Status Word
2
Transmitter Shutdown
4
Override Transmitter Shutdown
5
Reset Remote Terminal
8
1553B Status Flag Bits
The 8637-08 supports the following 1553B status flag bits:
1. Message Error bit
2. Broadcast Message Received bit
All other status bits are set to "0".
Aeroflex Plainview
SCD8637-08 Rev A 3/21/08
6
Connector P1
26 Pin Subminiature-D Plug
Cell Sense
Pin
#
Function Name 1/
Connector J2 for Control Board
Connector J5 for Control Board
Triaxial
1553B Bus A
Pin
#
Function Name 2/
CHA_DATA_H
CHA_DATA_L
23
RESERVED
17
RESERVED
9
RESERVED
7
RESERVED
3
RESERVED
14
RESERVED
19
RESERVED
1
RESERVED
10
CELL_8+
20
CELL_20+
13
CELL_7+
12
CELL_19+
16
CELL_6+
18
CELL_18+
26
CELL_5+
8
CELL_17+
SHIELD
5
CELL_4+
4
CELL_16+
Connector J3 for Control Board
Connector J6 for Control Board
Triaxial
1553B Bus B
2
CELL_3+
21
CELL_15+
CHB_DATA_H
15
CELL_2+
22
CELL_14+
CHB_DATA_L
24
CELL_1+
6
CELL_13+
SHIELD
11
CELL_1-
25
CELL_13-
1/ For Battery A.
2/ For Battery B.
Connector J1 for Control Board 2/
Connector J4 for Control Board 1/
51 Pin Micro-D Receptacle
Control & Test Points
Pin
#
1
Function
30V_RTN
Pin
#
18
Function
V_BAT_3
Pin
#
35
Function
V_BAT_2
2
NC_ISOLATION
19
NC_ISOLATION
36
NC_ISOLATION
3
NC_ISOLATION
20
+30V_POWER
37
NC_ISOLATION
4
NC_ISOLATION
21
+30V_POWER
38
NC_ISOLATION
5
30V_RTN
22
NC_ISOLATION
39
SPARE
6
NC_ISOLATION
23
NC_ISOLATION
40
CHASSIS GND
7
CHASSIS GND
24
CHASSIS GND
41
CELL_CHG_20
8
CELL_CHG_8
25
LOW_CELL
42
SPARE
9
SPARE
26
RESERVED
43
BEU_ON_CMD_1
10
BEU_OFF_CMD_2
27
BAL_ON_1
44
BEU_ON_CMD_2
11
BEU_OFF_CMD_1
28
BAL_ON_2
45
HIGH_CELL
12
RTA_2
29
RTA_0
46
RTA_4
13
RTA_GND
30
RTA_GND
47
RTA_GND
14
RTA_GND
31
RTA_GND
48
RTA_GND
15
RTA_1
32
RTA_3
49
RTPTY
16
OV_PROT
33
V_BAT_TP
50
V_BAT_RTN1
17
V_BAT_RTN3
34
V_BAT_RTN2
51
V_BAT_1
1/ For Battery A.
2/ For Battery B.
Aeroflex Plainview
SCD8637-08 Rev A 3/21/08
7
3D View
2.892
2x 2.270
2x .425
J3
J6
.760
J2
J5
5.250 MAX.
P1
2x 3.250
3.156
J1
J4
1.844
2x .895
.441
1.464
2.286
NOTES - UNLESS OTHERWISE SPECIFIED
1. DIMENSIONS ARE IN INCHES.
.800
TOLERANCE: .XXX ±.010
.XX = .03
8x .200
4.125 MAX.
2x 3.456
3.750
2x .928
2.817
2x 1.000
2x .403
3x 11.000
4x .250
11.500
Outline
Aeroflex Plainview
SCD8637-08 Rev A 3/21/08
8
Standard Configuration
Power Dissipation
11.08 Watts from 30V Supply
0.96 Watts from battery
Operating Base Plate Temperature
BEU8637-08-S
-34°C to +71°C
BEU8637-08
0°C to +70°C
Storage Temperature
-34°C to +71°C
Dimensions
11.5'' L x 4.125'' W x 5.250'' H
Weight
4.80 lbs (2.18 kg)
Ordering Information
MODEL NUMBER
SCREENING
BEU8637-08-S
High Reliablilty Space Grade
BEU8637-08
Commerical Flow
EXPORT CONTROL:
EXPORT WARNING:
This product is controlled for export under the International Traffic in
Arms Regulations (ITAR). A license from the U.S. Department of
State is required prior to the export of this product from the United
States.
Aeroflex’s military and space products are controlled for export under
the International Traffic in Arms Regulations (ITAR) and may not be
sold or proposed or offered for sale to certain countries. (See ITAR
126.1 for complete information.)
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Tel: 719-594-8017
Fax: 719-594-8468
www.aeroflex.com
info-ams@aeroflex.com
Aeroflex Microelectronic Solutions reserves the right to
change at any time without notice the specifications, design,
function, or form of its products described herein. All
parameters must be validated for each customer's application
by engineering. No liability is assumed as a result of use of
this product. No patent licenses are implied.
Our passion for performance is defined by three
attributes represented by these three icons:
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SCD8637-08 Rev A 3/21/08
9