BEU8636-12 Battery Electronic Unit

Cell Management Electronics for Lithium-Ion Battery
BEU8636-12
Balancing for 12-Cell Battery
Cell Voltage Monitoring and Telemetry
Reconditioning Load Control
Cell Bypass Relay Drivers
www.aeroflex.com/BEU
March 3, 2008
Description
The Aeroflex 8636-12 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 12 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
SCD8636-12 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 8636-12 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
ON
OFF
+30 VDC
CONTROLLER
XFMR
POWER
SUPPLY
BAL
CLK
BALANCING
CIRCUIT
CLOCK
DRIVER
RELAY
+5VDC
MON
CLK
BALANCING
CIRCUIT
1
+
-
BALANCING
CIRCUIT
2
+
-
BALANCING
CIRCUIT
3
+
-
BALANCING
CIRCUIT
4
+
-
BALANCING
CIRCUIT
12
+
-
PRECISION
REFERENCE
4.000V
+12VDC
(ISOLATED)
-12VDC
MUX
BATTERY RELAY DRIVER
BOARD
12 CELLS
& RELAYS
2 2 2
BATTERY
VOLTAGE
DIFF. AMPS
BATTERY
HI AND LO
( 3x )
+12VDC
SHARE BUS
RELAY DRIVER CONTROL SIGNALS
Block Diagram
8636-12 Operating Details
Battery Cell Balancing
Provides 12 individual continuous balancing circuits.
Cell Relay Bypass
Incorporates one bypass relay for each cell to remove a
malfunctioned cell from causing interference with the
operation of the remaining cells.
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.
Reconditioning Load Switching
Discretionary load switching is provided for reconditioning
(RECON).
Cell Balancing Accuracy
When connected to a battery, the 8636-12 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.
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.
Recovery from Cell Overvoltage Indication
The OVP latch is reset by a 1553B reset command or by
recycling the input power.
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.
Highest Battery Cell Voltage Telemetry
Provides highest battery cell voltage telemetry as specified in
Tables I & IV.
Battery Cell Voltage Monitoring
Measures cell voltages for up to 12-cells.
Lowest Battery Cell Voltage Telemetry
Provides lowest battery cell voltage telemetry as specified in
Tables I & IV.
4V and 0V References for Calibration
Provides 4V and 0V references for cell voltage telemetry
calibration.
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 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
SCD8636-12 Rev A 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.
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.
Table II – Bi-level Telemetry
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.
Item
The 12-bit data reply is left justified in the 16-bit 1553B data word
with the four LSBs set to "0".
1
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
6
Share Bus Voltage
0V to 122.88V
0809
0V to 5.12V
080A
7
Bypass Device Driver Power
0V to 51.2V
080C
8
Cell 1 Voltage
0V to 5.12V
0811
9
Cell 2 Voltage
0V to 5.12V
0812
10
Cell 3 Voltage
0V to 5.12V
0814
11
Cell 4 Voltage
0V to 5.12V
0817
12
Cell 5 Voltage
0V to 5.12V
0818
13
Cell 6 Voltage
0V to 5.12V
081B
14
Cell 7 Voltage
0V to 5.12V
081D
15
Cell 8 Voltage
0V to 5.12V
081E
16
Cell 9 Voltage
0V to 5.12V
0821
17
Cell 10 Voltage
0V to 5.12V
0822
18
Cell 11 Voltage
0V to 5.12V
0824
0827
19
Cell 12 Voltage
0V to 5.12V
20
Lowest Cell Voltage
0V to 5.12V
0871
21
Highest Cell Voltage
0V to 5.12V
0872
Telemetry Title
RECON Switch Status
Status
Reply
Bit
1st Data Word
of 1553B
Receive
Command
(Hex)
1 = Closed
D15
0C80
2
Discharge Inhibit Status
1 = Inhibit
D14
0C80
3
Overvoltage Latch Status
1 = Set
D13
0C80
4
Bypass Dev. 1 Arm Status
1 = Armed
D15
0C83
5
Bypass Dev. 2 Arm Status
1 = Armed
D14
0C83
6
Bypass Dev. 3 Arm Status
1 = Armed
D13
0C83
7
Bypass Dev. 4 Arm Status
1 = Armed
D12
0C83
8
Bypass Dev. 5 Arm Status
1 = Armed
D11
0C83
9
Bypass Dev. 6 Arm Status
1 = Armed
D10
0C83
10
Bypass Dev. 7 Arm Status
1 = Armed
D9
0C83
11
Bypass Dev. 8 Arm Status
1 = Armed
D8
0C83
12
Bypass Dev. 9 Arm Status
1 = Armed
D15
0C85
13
Bypass Dev. 10 Arm Status
1 = Armed
D14
0C85
14
Bypass Dev. 11 Arm Status
1 = Armed
D13
0C85
15
Bypass Dev. 12 Arm Status
1 = Armed
D12
0C85
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
Aeroflex Plainview
SCD8636-12 Rev A 3/3/08
3
32-Word Telemetry
To reduce data bus bandwidth usage, the 8636-12 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 8636-12 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
RECON Switch Status
Telemetry
Type
Reply
Word
Reply Bits
Bi-level
1
D15
1
4V Reference
Analog
1
D(15:4)
1
2
Total Battery Voltage 1
Analog
2
D(15:4)
2
Discharge Inhibit Status
Bi-level
1
D14
Overvoltage Latch Status
Bi-level
1
D13
3
Total Battery Voltage 2
Analog
3
D(15:4)
3
4
Total Battery Voltage 3
Analog
4
D(15:4)
4
Bypass Dev. 1 Arm Status
Bi-level
2
D15
Bypass Dev. 2 Arm Status
Bi-level
2
D14
5
Share Bus Voltage
Analog
5
D(15:4)
5
6
Master Bypass Power Status
Analog
6
D(15:4)
6
Bypass Dev. 3 Arm Status
Bi-level
2
D13
D(15:4)
7
Bypass Dev. 4 Arm Status
Bi-level
2
D12
D(15:4)
8
Bypass Dev. 5 Arm Status
Bi-level
2
D11
Bypass Dev. 6 Arm Status
Bi-level
2
D10
D9
7
8
Cell 1 Voltage
Cell 2 Voltage
Analog
Analog
7
8
9
Cell 3 Voltage
Analog
9
D(15:4)
9
10
Cell 4 Voltage
Analog
10
D(15:4)
10
Bypass Dev. 7 Arm Status
Bi-level
2
D(15:4)
11
Bypass Dev. 8 Arm Status
Bi-level
2
D8
Bypass Dev. 9 Arm Status
Bi-level
3
D15
Bypass Dev. 10 Arm Status
Bi-level
3
D14
11
Cell 5 Voltage
Analog
11
12
Cell 6 Voltage
Analog
12
D(15:4)
12
13
Cell 7 Voltage
Analog
13
D(15:4)
13
14
Cell 8 Voltage
Analog
14
D(15:4)
14
Bypass Dev. 11 Arm Status
Bi-level
3
D13
D(15:4)
15
Bypass Dev. 12 Arm Status
Bi-level
3
D12
D(15:4)
16
Reserved
-
4
-
0V Reference
Analog
5
D(15:4)
15
16
Cell 9 Voltage
Cell 10 Voltage
Analog
Analog
15
16
17
Cell 11 Voltage
Analog
17
D(15:4)
17
18
Cell 12 Voltage
Analog
18
D(15:4)
18
Lowest Cell Voltage
Analog
6
D(15:4)
Highest Cell Voltage
Analog
7
D(15:4)
Message Count
Analog
8
D(15:0)
19
Reserved
-
19
-
19
20
Reserved
-
20
-
20
21
Reserved
-
21
-
22
Reserved
-
22
-
23
Reserved
-
23
-
24
Reserved
-
24
-
25
Reserved
-
25
-
26
Reserved
-
26
-
27
Reserved
-
27
28
Reserved
-
28
-
29
Reserved
-
29
-
30
Reserved
-
30
-
31
Message Count
Analog
31
D(15:0)
32
RECON Switch Status
Bi-level
32
D15
33
Discharge Inhibit Status
Bi-level
32
D14
34
Overvoltage Latch Status
Bi-level
32
D13
Aeroflex Plainview
SCD8636-12 Rev A 3/3/08
4
Additional Commands
unit is ready to accept another command or 5000(Hex), to
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.
Table V – Commands
Item
1
2
Function Title
Recon SW1 & 2 disconnect
Recon SW1 connect
Supported Mode Codes
The 8636-12 supports the 1553B Mode Codes in Table VI.
1st Data Word
of 1553B
Sub-Address
Receive
Command
(Hex)
13
13
Table VI – 1553B Mode Codes
Mode Code Name
Mode Code Number
0200
Transmit Status Word
2
0080
Transmitter Shutdown
4
Override Transmitter Shutdown
5
Reset Remote Terminal
8
3
Recon SW2 connect
13
0100
4
Bypass commands (multiple)
14
as req’d
5
Reset OVP Latch
15
0400
1553B Status Flag Bits
The 8636-12 supports the following 1553B status flag bits:
1. Message Error bit
2. Broadcast Message Received bit
All other status bits are set to "0".
Telemetry Frame Sync Command
1553B broadcast command on sub-address 17 (any data
word) commands the 8636-12 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
Aeroflex Plainview
SCD8636-12 Rev A 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
RESERVED
9
CELL_11+
7
RESERVED
CHA_DATA_L
SHIELD
3
CELL_10+
14
RESERVED
19
CELL_9+
1
RESERVED
10
CELL_8+
20
RESERVED
13
CELL_7+
12
RESERVED
16
CELL_6+
18
RESERVED
Connector J3 for Control Board
Triaxial
1553B Bus B
26
CELL_5+
8
RESERVED
CHB_DATA_H
5
CELL_4+
4
RESERVED
CHB_DATA_L
2
CELL_3+
21
RESERVED
SHIELD
15
CELL_2+
22
RESERVED
24
CELL_1+
6
RESERVED
11
CELL_1-
25
RESERVED
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
RESERVED
8
CELL_CHG_12
25
LOW_CELL
42
SPARE
9
SPARE
26
DISCHARGE_INH
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
SCD8636-12 Rev A 3/3/08
6
Connector P2
78 Pin Subminiature-D Plug
Bypass Relay Driver
Pin
#
Function
Pin
#
Function
Pin
#
Function
KDH1
27
RECON_LOAD_RTN
53
2
KDH5
28
RESERVED
54
RESERVED
3
KDH9
29
NC_ISOLATION
55
KDL10
4
NC_ISOLATION
30
RESERVED
56
ISO_1MEG
5
30V_RTN
31
KDL2
57
RESERVED
6
NC_ISOLATION
32
RESERVED
58
RESERVED
7
CHASSIS GND
33
KDL9
59
RESERVED
8
CELL_CHG_12
34
RESERVED
60
KDH4
9
SPARE
35
KDL4
61
KDH8
10
KDL1
36
ISO_1MEG
62
KDH12
11
KDL8
37
RESERVED
63
RELAY_CURRENT_MON
1
KDL6
12
RESERVED
38
RESERVED
64
ISO_1MEG
13
KDL3
39
RESERVED
65
ISO_1MEG
14
RESERVED
40
KDH2
66
ISO_1MEG
15
KDL11
41
KDH6
67
RECON_LOAD_RTN
16
RESERVED
42
KDH10
68
RESERVED
17
ISO_1MEG
43
RECON_LOAD
69
ISO_1MEG
18
RESERVED
RESERVED
44
RECON_LOAD
70
19
RESERVED
45
RESERVED
71
RESERVED
20
RESERVED
46
RESERVED
72
RESERVED
21
KDH3
47
RECON_LOAD_RTN
73
KDL12
22
KDH7
48
RESERVED
74
KDL5
23
KDH11
49
ISO_1MEG
75
ISO_1MEG
24
ISO_1MEG
50
RESERVED
76
RESERVED
25
RECON_LOAD
51
KDL7
77
RESERVED
26
RESERVED
52
RESERVED
78
RESERVED
Aeroflex Plainview
SCD8636-12 Rev A 3/3/08
7
3D View
NOTES - UNLESS OTHERWISE SPECIFIED
DIMENSIONS ARE IN INCHES.
TOLERANCE: .XXX ±.010
.XX = .03
2x .425
J3
J2
P1
P2
5.25 MAX.
4.010
3.250
J1
2.250
2.525
1.502
.441
1.464
11.500
2.424
3.3 MAX.
3X 11.000
3x .250
6x
.200
2x 2.423
2x 1.000
2x .403
Outline
Aeroflex Plainview
SCD8636-12 Rev A 3/3/08
8
Standard Configuration
Power Dissipation
7.65 Watts from 30V Supply
0.75 Watts from battery
Operating Base Plate Temperature
BEU8636-12-S
-34°C to +71°C
BEU8636-12
0°C to +70°C
Storage Temperature
-34°C to +71°C
Dimensions
11.5'' L x 3.30'' W x 5.25'' H
Weight
5.3 lbs (2.4 kg)
Ordering Information
MODEL NUMBER
SCREENING
BEU8636-12-S
High Reliablilty Space Grade
BEU8636-12
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
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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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SCD8636-12 Rev A 3/3/08
9