Cell Management Electronics for Lithium-Ion Battery BEU8636-24 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 8636-24 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 SCD8636-24 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 8636-24 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 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 24 + - PRECISION REFERENCE 4.000V +12VDC (ISOLATED) -12VDC MUX BATTERY RELAY DRIVER BOARD 24 CELLS & RELAYS 2 2 2 BATTERY VOLTAGE DIFF. AMPS BATTERY HI AND LO ( 3x ) +12VDC SHARE BUS RELAY DRIVER CONTROL SIGNALS Block Diagram 8636-24 Operating Details Battery Cell Balancing Provides 24 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 8636-24 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. 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 24-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 SCD8636-24 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. 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) 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 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 1 RECON Switch Status 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 12 Cell 5 Voltage 0V to 5.12V 0818 13 Cell 6 Voltage 0V to 5.12V 081B 15 Bypass Dev. 12 Arm Status 1 = Armed D12 0C85 16 Bypass Dev. 13 Arm Status 1 = Armed D11 0C85 14 Cell 7 Voltage 0V to 5.12V 081D 15 Cell 8 Voltage 0V to 5.12V 081E 17 Bypass Dev. 14 Arm Status 1 = Armed D10 0C85 18 Bypass Dev. 15 Arm Status 1 = Armed D9 0C85 16 Cell 9 Voltage 0V to 5.12V 0821 17 Cell 10 Voltage 0V to 5.12V 0822 19 Bypass Dev. 16 Arm Status 1 = Armed D8 0C85 18 Cell 11 Voltage 0V to 5.12V 0824 20 Bypass Dev. 17 Arm Status 1 = Armed D15 0C86 19 Cell 12 Voltage 0V to 5.12V 0827 21 Bypass Dev. 18 Arm Status 1 = Armed D14 0C86 20 Cell 13 Voltage 0V to 5.12V 0828 22 Bypass Dev. 19 Arm Status 1 = Armed D13 0C86 21 Cell 14 Voltage 0V to 5.12V 082B 23 Bypass Dev. 20 Arm Status 1 = Armed D12 0C86 22 Cell 15 Voltage 0V to 5.12V 082D 24 Bypass Dev. 21 Arm Status 1 = Armed D11 0C86 23 Cell 16 Voltage 0V to 5.12V 082E 25 Bypass Dev. 22 Arm Status 1 = Armed D10 0C86 24 Cell 17 Voltage 0V to 5.12V 0830 26 Bypass Dev. 23 Arm Status 1 = Armed D9 0C86 25 Cell 18 Voltage 0V to 5.12V 0833 27 Bypass Dev. 24 Arm Status 1 = Armed D8 0C86 26 Cell 19 Voltage 0V to 5.12V 0835 27 Cell 20 Voltage 0V to 5.12V 0836 28 Cell 21 Voltage 0V to 5.12V 0839 29 Cell 22 Voltage 0V to 5.12V 083A 30 Cell 23 Voltage 0V to 5.12V 083C 31 Cell 24 Voltage 0V to 5.12V 083F 32 Lowest Cell Voltage 0V to 5.12V 0871 33 Highest Cell Voltage 0V to 5.12V 0872 Aeroflex Plainview SCD8636-24 Rev A 3/3/08 3 32-Word Telemetry To reduce data bus bandwidth usage, the 8636-24 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 8636-24 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 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 Bypass Dev. 13 Arm Status Bi-level 3 D11 Bypass Dev. 14 Arm Status Bi-level 3 D10 D9 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 Bypass Dev. 15 Arm Status Bi-level 3 D(15:4) 19 Bypass Dev. 16 Arm Status Bi-level 3 D8 Bypass Dev. 17 Arm Status Bi-level 4 D15 19 Cell 13 Voltage Analog 19 20 Cell 14 Voltage Analog 20 D(15:4) 20 21 Cell 15 Voltage Analog 21 D(15:4) 21 Bypass Dev. 18 Arm Status Bi-level 4 D14 22 Cell 16 Voltage Analog 22 D(15:4) 22 Bypass Dev. 19 Arm Status Bi-level 4 D13 D(15:4) 23 Bypass Dev. 20 Arm Status Bi-level 4 D12 D(15:4) 24 Bypass Dev. 21 Arm Status Bi-level 4 D11 Bypass Dev. 22 Arm Status Bi-level 4 D10 D9 23 24 Cell 17 Voltage Cell 18 Voltage Analog Analog 23 24 25 Cell 19 Voltage Analog 25 D(15:4) 25 26 Cell 20 Voltage Analog 26 D(15:4) 26 Bypass Dev. 23 Arm Status Bi-level 4 D(15:4) 27 Bypass Dev. 24 Arm Status Bi-level 4 D8 0V Reference Analog 5 D(15:4) Lowest Cell Voltage Analog 6 D(15:4) 27 Cell 21 Voltage Analog 27 28 Cell 22 Voltage Analog 28 D(15:4) 28 29 Cell 23 Voltage Analog 29 D(15:4) 29 30 Cell 24 Voltage Analog 30 D(15:4) 30 Highest Cell Voltage Analog 7 D(15:4) 31 Message Count Analog 8 D(15:0) 31 Message Count Analog 31 D(15:0) D15 32 RECON Switch Status Bi-level 32 33 Discharge Inhibit Status Bi-level 32 D14 34 Overvoltage Latch Status Bi-level 32 D13 Aeroflex Plainview SCD8636-24 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 8636-24 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 8636-24 supports the following 1553B status flag bits: 1. Message Error bit 2. Broadcast Message Received bit All other status bits are set to "0". Telemetry Frame Sync Command 1553B broadcast command on sub-address 17 (any data word) commands the 8636-24 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 SCD8636-24 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 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 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 SCD8636-24 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 KDL13 3 KDH9 29 NC_ISOLATION 55 KDL10 4 NC_ISOLATION 30 KDL23 56 ISO_1MEG 5 30V_RTN 31 KDL2 57 KDH16 6 NC_ISOLATION 32 KDL22 58 KDH20 7 CHASSIS GND 33 KDL9 59 KDH24 8 CELL_CHG_12 34 KDL19 60 KDH4 9 SPARE 35 KDL4 61 KDH8 10 KDL1 36 ISO_1MEG 62 KDH12 11 KDL8 37 KDH13 63 RELAY_CURRENT_MON 1 KDL6 12 KDL17 38 KDH17 64 ISO_1MEG 13 KDL3 39 KDH21 65 ISO_1MEG 14 KDL16 40 KDH2 66 ISO_1MEG 15 KDL11 41 KDH6 67 RECON_LOAD_RTN 16 KDL20 42 KDH10 68 RESERVED 17 ISO_1MEG 43 RECON_LOAD 69 ISO_1MEG 18 KDL24 KDH15 44 RECON_LOAD 70 19 KDH19 45 RESERVED 71 KDL14 20 KDH23 46 RESERVED 72 KDL21 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 KDL18 76 KDH14 25 RECON_LOAD 51 KDL7 77 KDH18 26 RESERVED 52 KDL15 78 KDH22 Aeroflex Plainview SCD8636-24 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 SCD8636-24 Rev A 3/3/08 8 Standard Configuration Power Dissipation 9.5 Watts from 30V Supply 1.5 Watts from battery Operating Base Plate Temperature BEU8636-24-S -34°C to +71°C BEU8636-24 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 BEU8636-24-S High Reliablilty Space Grade BEU8636-24 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.) PLAINVIEW, NEW YORK Toll Free: 800-THE-1553 Fax: 516-694-6715 INTERNATIONAL Tel: 805-778-9229 Fax: 805-778-1980 NORTHEAST Tel: 603-888-3975 Fax: 603-888-4585 SE AND MID-ATLANTIC Tel: 321-951-4164 Fax: 321-951-4254 WEST COAST Tel: 949-362-2260 Fax: 949-362-2266 CENTRAL Tel: 719-594-8017 Fax: 719-594-8468 www.aeroflex.com [email protected] 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: solution-minded, performance-driven and customer-focused SCD8636-24 Rev A 3/3/08 9