BEU8640-24 AEROFLEX | Alldatasheet
Document overview
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Technical content
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 24 Lithium-Ion battery cells in series
- Battery Drain Current at Balance 15mA Max for 24 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
- Dual redundant control and cell balancing 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 8640-24 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. BEU8640-24 Cell Management Electronics for Lithium-Ion Battery Dual Redundant Balancing for 24-Cell Battery Cell Bypass Relay Drivers Reconditioning Load Control Cell Voltage Monitoring and Telemetry www.aeroflex.com/BEU October 5, 2007
SCD8640 Rev C 10/5/2007 Aeroflex Plainview ON OFF +30 VDC Channel B 1553B LOW CELL OVP HIGH CELL Channel A 1553B +12VDC +12VDC -12VDC +5VDC (ISOLATED) SHARE BUS MON CLK BAL CLK SELECT MUX VIN CELL BALANCE BOARD 1CONTROL BOARD 1 4.000V REFERENCE PRECISION RELAY XFMR XFMR XCVR A/D 12-BIT MUX BALANCING CIRCUIT BALANCING CIRCUIT BALANCING CIRCUIT BALANCING CIRCUIT BALANCING CIRCUIT POWER SUPPLY ON OFF +30 VDC Channel B 1553B LOW CELL OVP HIGH CELL Channel A 1553B +12VDC +12VDC -12VDC +5VDC (ISOLATED) SHARE BUS MON CLK BAL CLK SELECT MUX VIN CONTROL BOARD 2 4.000V REFERENCE PRECISION RELAY XFMR XFMR XCVR BALANCING CIRCUIT CLOCK DRIVER Controller POWER SUPPLY Block Diagram A/D 12-BIT RELAY BOARD RELAY DRIVER CONTROL SIGNALS RELAY DRIVER CONTROL SIGNALS BALANCING CIRCUIT BALANCING CIRCUIT BALANCING CIRCUIT BALANCING CIRCUIT BALANCING CIRCUIT BALANCING CIRCUIT CELL BALANCE BOARD 2 BALANCING CIRCUIT DRIVER BATTERY & RELAYS RECON LOAD RECON FET SIGNALS RECON FET SIGNALS DIFF. AMPS VOLTAGE BATTERY (3 x) HI AND LO BATTERY 2 2 2 MUX DIFF. AMPS VOLTAGE BATTERY (3 x) HI AND LO BATTERY 2 2 2 DIFF. AMPS VOLTAGE BATTERY (3 x) HI AND LO BATTERY 2 2 2 CIRCUIT Controller BALANCING CLOCK DRIVER CIRCUIT
SCD8640 Rev C 10/5/2007 Aeroflex Plainview 8640-24 Operating Details Battery Cell Balancing Provides a dual redundant set of 24 individual continuous balancing circuits. 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. Cell Balancing Accuracy When connected to a battery, the 8640-24 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 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 24 cells. 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. 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. Reconditioning Load Switching Discretionary load switching is provided for reconditioning (RECON). 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. 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.
SCD8640 Rev C 10/5/2007 Aeroflex Plainview MIL-STD-1553B Telemetry & Commands 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. 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. The 12-bit data reply is left justified in the 16-bit 1553B data word with the four LSBs set to "0". 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. 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 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 Bypass Device Driver Power 0V to 51.2V 080C 8 Cell 1 Voltage 0V to 5.12V 081 1 9 Cell 2 Voltage 0V to 5.12V 0812 10 Cell 3 Voltage 0V to 5.12V 0814 1 1 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 1 1 Voltage 0V to 5.12V 0824 19 Cell 12 Voltage 0V to 5.12V 0827 20 Cell 13 Voltage 0V to 5.12V 0828 21 Cell 14 Voltage 0V to 5.12V 082B 22 Cell 15 Voltage 0V to 5.12V 082D 23 Cell 16 Voltage 0V to 5.12V 082E 24 Cell 17 Voltage 0V to 5.12V 0830 25 Cell 18 Voltage 0V to 5.12V 0833 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 Table II – Bi-level Telemetry Item Telemetry Title Status Reply Bit 1st Data Word of 1553B Receive Command (Hex)
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 D1 1 0C83 9 Bypass Dev. 6 Arm Status 1 = Armed D10 0C83 10 Bypass Dev. 7 Arm Status 1 = Armed D9 0C83 1 1 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. 1 1 Arm Status 1 = Armed D13 0C85 15 Bypass Dev. 12 Arm Status 1 = Armed D12 0C85 16 Bypass Dev. 13 Arm Status 1 = Armed D1 1 0C85 17 Bypass Dev. 14 Arm Status 1 = Armed D10 0C85 18 Bypass Dev. 15 Arm Status 1 = Armed D9 0C85 19 Bypass Dev. 16 Arm Status 1 = Armed D8 0C85 20 Bypass Dev. 17 Arm Status 1 = Armed D15 0C86 21 Bypass Dev. 18 Arm Status 1 = Armed D14 0C86 22 Bypass Dev. 19 Arm Status 1 = Armed D13 0C86 23 Bypass Dev. 20 Arm Status 1 = Armed D12 0C86 24 Bypass Dev. 21 Arm Status 1 = Armed D1 1 0C86 25 Bypass Dev. 22 Arm Status 1 = Armed D10 0C86 26 Bypass Dev. 23 Arm Status 1 = Armed D9 0C86 27 Bypass Dev. 24 Arm Status 1 = Armed D8 0C86
SCD8640 Rev C 10/5/2007 Aeroflex Plainview 32-Word Telemetry To reduce data bus bandwidth usage, the 8640-24 supports a 32-word telemetry request on sub-address 20 as defined in Table III. 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. 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".. 8-Word Telemetry To reduce data bus bandwidth usage, the 8640-24 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 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 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 Item Telemetry Title Telemetry Type Reply Word Reply Bits 1 4V Reference Analog 1 D(15:4)
2 Total Battery Voltage 1 Analog 2 D(15:4)
3 Total Battery Voltage 2 Analog 3 D(15:4)
4 Total Battery Voltage 3 Analog 4 D(15:4)
5 Share Bus Voltage Analog 5 D(15:4)
6 Master Bypass Power Status Analog 6 D(15:4)
7 Cell 1 Voltage Analog 7 D(15:4)
8 Cell 2 Voltage Analog 8 D(15:4)
9 Cell 3 Voltage Analog 9 D(15:4)
10 Cell 4 Voltage Analog 10 D(15:4)
1 1 Cell 5 Voltage Analog 1 1 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)
15 Cell 9 Voltage Analog 15 D(15:4)
16 Cell 10 Voltage Analog 16 D(15:4)
17 Cell 1 1 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 RECON Switch Status Bi-level 32 D15
33 Discharge Inhibit Status Bi-level 32 D14
34 Overvoltage Latch Status Bi-level 32 D13
Table IV – 8-Word Telemetry Item Telemetry Title Telemetry Type Reply Word Reply Bits
1 RECON Switch Status Bi-level 1 D15
2 Discharge Inhibit Status Bi-level 1 D14
3 Overvoltage Latch Status Bi-level 1 D13
4 Bypass Dev. 1 Arm Status Bi-level 2 D15 5 Bypass Dev. 2 Arm Status Bi-level 2 D14 6 Bypass Dev. 3 Arm Status Bi-level 2 D13 7 Bypass Dev. 4 Arm Status Bi-level 2 D12 8 Bypass Dev. 5 Arm Status Bi-level 2 D1 1 9 Bypass Dev. 6 Arm Status Bi-level 2 D10 10 Bypass Dev. 7 Arm Status Bi-level 2 D9 1 1 Bypass Dev. 8 Arm Status Bi-level 2 D8 12 Bypass Dev. 9 Arm Status Bi-level 3 D15 13 Bypass Dev. 10 Arm Status Bi-level 3 D14 14 Bypass Dev. 1 1 Arm Status Bi-level 3 D13 15 Bypass Dev. 12 Arm Status Bi-level 3 D12 16 Bypass Dev. 13 Arm Status Bi-level 3 D1 1 17 Bypass Dev. 14 Arm Status Bi-level 3 D10 18 Bypass Dev. 15 Arm Status Bi-level 3 D9 19 Bypass Dev. 16 Arm Status Bi-level 3 D8 20 Bypass Dev. 17 Arm Status Bi-level 4 D15 21 Bypass Dev. 18 Arm Status Bi-level 4 D14 22 Bypass Dev. 19 Arm Status Bi-level 4 D13 23 Bypass Dev. 20 Arm Status Bi-level 4 D12 24 Bypass Dev. 21 Arm Status Bi-level 4 D1 1 25 Bypass Dev. 22 Arm Status Bi-level 4 D10 26 Bypass Dev. 23 Arm Status Bi-level 4 D9 27 Bypass Dev. 24 Arm Status Bi-level 4 D8 28 0V Reference Analog 5 D(15:4)
29 Lowest Cell Voltage Analog 6 D(15:4)
30 Highest Cell Voltage Analog 7 D(15:4)
31 Message Count Analog 8 D(15:0)
SCD8640 Rev C 10/5/2007 Aeroflex Plainview Additional Commands Data Load Commands 1553B receive commands consis t of 2 data words to the sub-address specified in Table V. Only the first data word is used. Telemetry Frame Sync Command 1553B broadcast command on sub-address 17 (any data word) commands the 8640-24 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 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 8640-24 supports the 1553B Mode Codes in Table VI. 1553B Status Flag Bits The 8640-24 supports the following 1553B status flag bits: 1. Message Error bit 2. Broadcast Message Received bit All other status bits are set to "0". Table V – Commands Item Function Title Sub-Address 1st Data Word of 1553B Receive Command (Hex)
1 RECON SW1 & 2 Disconnect 13 0200
2 RECON SW1 Connect 13 0080
3 RECON SW2 Connect 13 0100
4 Bypass Commands (multiple) 14 as req’d
5 Reset OVP Latch 15 0400
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
SCD8640 Rev C 10/5/2007 Aeroflex Plainview Connector P1 for Cell Balance Board 1 Connector P3 for Cell Balance Board 2
26 Pin Subminiature-D Plug
# Function Name Pin # Function Name
23 CELL_12+ 17 CELL_24+
9 CELL_11+ 7 CELL_23+
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+
26 CELL_5+ 8 CELL_17+
5 CELL_4+ 4 CELL_16+
2 CELL_3+ 21 CELL_15+
15 CELL_2+ 22 CELL_14+
24 CELL_1+ 6 CELL_13+
11 CELL_1- 25 CELL_13-
Connector J2 for Control Board 1 Connector J5 for Control Board 2 Triaxial 1553B Bus A CHA_DATA_H CHA_DATA_L SHIELD Connector J3 for Control Board 1 Connector J6 for Control Board 2 Triaxial 1553B Bus B CHB_DATA_H CHB_DATA_L SHIELD Connector J1 for Control Board 1 Connector J4 for Control Board 2
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_R TN2 51 V_BAT_1
SCD8640 Rev C 10/5/2007 Aeroflex Plainview Connector P2
78 Pin Subminiature-D Plug
# Function Pin # Function Pin # Function
1 KDH1 27 RECON_LOAD_RTN (Side1) 53 KDL6
2 KDH5 28 RECON_LOAD_RTN (Side2) 54 KDL13
3 KDH9 29 ISO_1MEG 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
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 (Side1)
16 KDL20 42 KDH10 68 RECON_LOAD_RTN (Side2)
17 ISO_1MEG 43 RECO N_LOAD (Side 1) 69 ISO_1MEG
18 KDH15 44 RECON_LOAD (Side 1) 70 KDL24
19 KDH19 45 RECON_LOAD (Side2) 71 KDL14
20 KDH23 46 RECON_LOAD (Side2) 72 KDL21
21 KDH3 47 RECON_LOAD_RTN (Side1) 73 KDL12
22 KDH7 48 RECON_LOAD_RTN (Side2) 74 KDL5
23 KDH11 49 ISO_1MEG 75 ISO_1MEG
24 ISO_1MEG 50 KDL18 76 KDH14
25 RECON_LOAD (Side 1) 51 KDL7 77 KDH18
26 RECON_LOAD (Side2) 52 KDL15 78 KDH22
SCD8640 Rev C 10/5/2007 Aeroflex Plainview Outline .250 5x 5x 11.500 11.000 .402 2x 1.0002x 2.423 2x 3.442 2x 1.000 2x 10x .200 THRU 5.25 1.502 2x 2.525 2x 3.250 2x 4.010 2x 2.500 5.25 .250 NOTES - UNLESS OTHERWISE SPECIFIED 1. DIMENSIONS ARE IN INCHES. TOLERANCE: .XXX ±.010 .XX = .03 3-D View
PLAINVIEW, NEW YORK Toll Free: 800-THE-1553 Fax: 516-694-6715 SE AND MID-ATLANTIC Tel: 321-951-4164 Fax: 321-951-4254 INTERNATIONAL Tel: 805-778-9229 Fax: 805-778-1980 WEST COAST Tel: 949-362-2260 Fax: 949-362-2266 NORTHEAST Tel: 603-888-3975 Fax: 603-888-4585 CENTRAL 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: solution-minded, performance-driven and customer-focused EXPORT CONTROL: EXPORT WARNING: This product is controlled for expor t 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.) Standard Configuration Power Dissipation 33 Watts (30 Watts from 30V, 3.0 Watts from battery at balance) Operating Base Plate Temperature -34°C to +71°C Storage Temperature -34°C to +71°C Dimensions Weight 8.20 lbs (3.73 kg)
ORDERING INFORMATION
BEU8640-24-S High Reliablilty Space Grade BEU8640-24 Commerical Flow, -34°C to +71°C operating base plate temperature