BEU8635-24 Battery Electronic Unit

Cell Management Electronics for Lithium-Ion Battery
BEU8635-24
Balancing for 24-Cell Battery
Cell Voltage Monitoring and Telemetry
www.aeroflex.com/BEU
March 3, 2008
Description
The Aeroflex 8635-24 is a Lithium-Ion cell
balancing system. It controls the balancing
of one battery 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 24 Lithium-Ion battery cells in
series
●
Battery Drain Current at Balance
15mA maximum
●
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
SCD8635 Rev F
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 8635-24 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
1553B
Channel A
VIN
A/D
12-BIT
HIGH
CELL
LOW
CELL
12
MUX
SELECT
XFMR
7
XCVR
1553B
Channel B
CONTROLLER
XFMR
ON
OFF
+30 VDC
BALANCING
CIRCUIT
CLOCK
DRIVER
RELAY
POWER
SUPPLY
-12VDC
BAL
CLK
MON
CLK
BALANCING
CIRCUIT
1
+
-
BALANCING
CIRCUIT
2
+
-
BALANCING
CIRCUIT
3
+
-
BALANCING
CIRCUIT
4
+
-
BALANCING
CIRCUIT
24
+
-
PRECISION
REFERENCE
4.000V
+12VDC
(ISOLATED)
+5VDC
MUX
BATTERY
24 CELLS
2 2 2
BATTERY
VOLTAGE
DIFF. AMPS
BATTERY
HI AND LO
( 3x )
+12VDC
SHARE BUS
Block Diagram
8635-24 Operating Details
Battery Cell Balancing
Provides 24 individual continuous balancing circuits.
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.
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.
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.
Cell Balancing Accuracy
When connected to a battery, the 8635-24 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.
Recovery from Cell Overvoltage Indication
The OVP latch is reset by a 1553B reset command or by
recycling the input power.
Highest Battery Cell Voltage Telemetry
Provides highest battery cell voltage telemetry as specified in
Tables I & IV.
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.
Lowest Battery Cell Voltage Telemetry
Provides lowest battery cell voltage telemetry as specified in
Tables I & IV.
Battery Cell Voltage Monitoring
Measures cell voltages for up to 24-cells.
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.
4V and 0V References for Calibration
Provides 4V and 0V references for cell voltage telemetry
calibration.
Aeroflex Plainview
SCD8635 Rev F 3/3/08
2
MIL-STD-1553B Telemetry & Commands
Analog or bi-level telemetry can be requested from the controller
and reported over the dual redundant 1553B interface with the
RT addresses configurable at the J1 connector.
Bi-Level Telemetry
Bi-level telemetry can be requested on sub-addresses 18, 19 or
22.
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 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.
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
Item
Telemetry Title
Telemetry Reply
Scale
1st Data Word of
1553B Receive
Command (Hex)
1
4V Reference
-0.40V to 4.89V
0800
2
0V Reference
-0.40V to 4.89V
0803
3
Total Battery Voltage 1
0V to 122.88V
0805
4
Total Battery Voltage 2
0V to 122.88V
0806
5
Total Battery Voltage 3
0V to 122.88V
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
0V to 5.12V
0817
11
Cell 5 Voltage
0V to 5.12V
0818
12
Cell 6 Voltage
0V to 5.12V
081B
13
Cell 7 Voltage
0V to 5.12V
081D
14
Cell 8 Voltage
0V to 5.12V
081E
15
Cell 9 Voltage
0V to 5.12V
0821
16
Cell 10 Voltage
0V to 5.12V
0822
17
Cell 11 Voltage
0V to 5.12V
0824
18
Cell 12 Voltage
0V to 5.12V
0827
19
Cell 13 Voltage
0V to 5.12V
0828
20
Cell 14 Voltage
0V to 5.12V
082B
21
Cell 15 Voltage
0V to 5.12V
082D
22
Cell 16 Voltage
0V to 5.12V
082E
23
Cell 17 Voltage
0V to 5.12V
0830
0833
24
Cell 18 Voltage
0V to 5.12V
25
Cell 19 Voltage
0V to 5.12V
0835
26
Cell 20 Voltage
0V to 5.12V
0836
27
Cell 21 Voltage
0V to 5.12V
0839
28
Cell 22 Voltage
0V to 5.12V
083A
29
Cell 23 Voltage
0V to 5.12V
083C
30
Cell 24 Voltage
0V to 5.12V
083F
31
Lowest Cell Voltage
0V to 5.12V
0871
32
Highest Cell Voltage
0V to 5.12V
0872
1
Overvoltage Latch Status
1 = Set
Aeroflex Plainview
SCD8635 Rev F 3/3/08
3
32-Word Telemetry
To reduce data bus bandwidth usage, the 8635-24 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 8635-24 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
Telemetry Title
Telemetry Reply
Type
Word
Reply Bits
Item
Telemetry Title
Telemetry
Type
Reply
Word
Reply Bits
Bi-Level
1
D13
1
4V Reference
Analog
1
D(15:4)
1
Overvoltage Latch Status
2
Total Battery Voltage 1
Analog
2
D(15:4)
2
Reserved
-
2
-
D(15:4)
3
Reserved
-
3
-
D(15:4)
4
Reserved
-
4
-
0V Reference
Analog
5
D(15:4)
3
4
Total Battery Voltage 2
Total Battery Voltage 3
5
Share Bus Voltage
6
Reserved
Analog
Analog
3
4
Analog
5
D(15:4)
5
-
6
-
6
Lowest Cell Voltage
Analog
6
D(15:4)
Highest Cell Voltage
Analog
7
D(15:4)
Message Count
Analog
8
D(15:0)
7
Cell 1 Voltage
Analog
7
D(15:4)
7
8
Cell 2 Voltage
Analog
8
D(15:4)
8
9
Cell 3 Voltage
Analog
9
D(15:4)
10
Cell 4 Voltage
Analog
10
D(15:4)
11
Cell 5 Voltage
Analog
11
D(15:4)
12
Cell 6 Voltage
Analog
12
D(15:4)
13
Cell 7 Voltage
Analog
13
D(15:4)
14
Cell 8 Voltage
Analog
14
D(15:4)
D(15:4)
15
Cell 9 Voltage
Analog
15
16
Cell 10 Voltage
Analog
16
D(15:4)
17
Cell 11 Voltage
Analog
17
D(15:4)
18
Cell 12 Voltage
Analog
18
D(15:4)
19
Cell 13 Voltage
Analog
19
D(15:4)
20
Cell 14 Voltage
Analog
20
D(15:4)
21
Cell 15 Voltage
Analog
21
D(15:4)
22
Cell 16 Voltage
Analog
22
D(15:4)
23
Cell 17 Voltage
Analog
23
D(15:4)
24
Cell 18 Voltage
Analog
24
D(15:4)
25
Cell 19 Voltage
Analog
25
D(15:4)
26
Cell 20 Voltage
Analog
26
D(15:4)
27
Cell 21 Voltage
Analog
27
D(15:4)
28
Cell 22 Voltage
Analog
28
D(15:4)
29
Cell 23 Voltage
Analog
29
D(15:4)
30
Cell 24 Voltage
Analog
30
D(15:4)
31
Message Count
Analog
31
D(15:0)
32
Overvoltage Latch Status
Bi-level
32
D13
Aeroflex Plainview
SCD8635 Rev F 3/3/08
4
Additional Commands
indicate that the unit is busy and cannot accept another
command.
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.
1553B Data Wrap Around
Sub-address 30 is dedicated to data wrap around as
specified in MIL-STD-1553B.
Supported Mode Codes
The 8635-24 supports the 1553B Mode Codes in Table VI.
Table V – Commands
Item
Function Title
1
Reserved
2
Reserved
3
Reset OVP Latch
1st Data Word
of 1553B
Sub-Address
Receive
Command
(Hex)
Table VI – 1553B Mode Codes
Mode Code Name
Mode Code Number
Transmit Status Word
2
-
Transmitter Shutdown
4
14
-
Override Transmitter Shutdown
5
15
0400
Reset Remote Terminal
8
13
Telemetry Frame Sync Command
1553B broadcast command on sub-address 17 (any data
word) commands the 8635-24 to refresh its RT address.
1553B Status Flag Bits
The 8635-24 supports the following 1553B status flag bits:
1. Message Error bit
2. Broadcast Message Received bit
All other status bits are set to "0".
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
Aeroflex Plainview
SCD8635 Rev F 3/3/08
5
Connector P1
26 Pin Subminiature-D Plug
Cell Sense
Connector J2 for Control Board
Triaxial
1553B Bus A
CHA_DATA_H
Pin
#
Function Name
Pin
#
Function Name
23
CELL_12+
17
CELL_24+
9
CELL_11+
7
CELL_23+
CHA_DATA_L
SHIELD
3
CELL_10+
14
CELL_22+
19
CELL_9+
1
CELL_21+
10
CELL_8+
20
CELL_20+
13
CELL_7+
12
CELL_19+
16
CELL_6+
18
CELL_18+
Connector J3 for Control Board
Triaxial
1553B Bus B
26
CELL_5+
8
CELL_17+
CHB_DATA_H
5
CELL_4+
4
CELL_16+
CHB_DATA_L
2
CELL_3+
21
CELL_15+
SHIELD
15
CELL_2+
22
CELL_14+
24
CELL_1+
6
CELL_13+
11
CELL_1-
25
CELL_13-
Connector J1 for Control Board
51 Pin Micro-D Receptacle
Control & Test Points
Pin
#
Function
Pin
#
Function
Pin
#
Function
1
30V_RTN
18
V_BAT_3
35
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_24
8
CELL_CHG_12
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
Aeroflex Plainview
SCD8635 Rev F 3/3/08
6
3-D View
2x 0.25
2x 11.00
2x 0.40
2x 1.00
4x
0.20
J3
0.76
J2
P1
5.250
J1
3.25
2.50
1.50
11.50
2.01
Outline
Aeroflex Plainview
SCD8635 Rev F 3/3/08
7
Standard Configuration
Power Dissipation
9.0 Watts from 30V Supply
1.5 Watts from battery
Operating Base Plate Temperature
BEU8635-24-S
-34°C to +71°C
BEU8635-24
0°C to +70°C
Storage Temperature
-34°C to +71°C
Dimensions
11.5'' L x 2.01'' W x 5.25'' H
Weight
3.5 lbs (1.59 kg)
Ordering Information
MODEL NUMBER
SCREENING
BEU8635-24-S
High Reliablilty Space Grade
BEU8635-24
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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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.
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SCD8635 Rev F 3/3/08
8