EM1402 Evaluation Module - TI.com

1 1 SNOU143 February2017 SubmitDocumentationFeedbackCopyright 2017,TexasInstrumentsIncorporatedEM1402 EvaluationModuleUser's GuideSNOU143 February2017EM1402 EvaluationModuleThisuser'sguidedescribes the generalfeatures,theoryof operation,hardwaresetup,and use of user'sguide,the abbreviationsEVM, EM1402 EVM, and the termevaluationmoduleare synonymouswith theEM1402 EvaluationModule, anevaluationboardof theActiveBalancechipsetfor use in largeformatLithium-ionbatteriesthat providesmonitoring,balancing,and of (ReferenceImageOnly)..63 Molex22-12-4062(ReferenceImageOnly)..74 TycoElectronics43045-1601(ReferenceImage Only)..85 TycoElectronics1452625-1(ReferenceImageO nly).. of February2017 SubmitDocumentationFeedbackCopyright 2017,TexasInstrumentsIncorporatedEM1402 EvaluationModuleTrademarksLaunchPad,Code ComposerStudioare trademarksof othertrademarksare the propertyof (TI HV EVM)UserSafetyGuidelinesWARNINGW arning:To minimizerisk of fire hazard,alwaysverifyand followanyspecificsafetyinstructionsandap plicationconsiderationsrelatedto the batteriesbeingusedin conjunctionwiththis s set-upand applicationinstructions,includinguse of all interfacecomponentswithintheirrecommende delectricalratedvoltageand electricalsafetyprecautionsto helpensureyourpersonalsafetyand the safetyof thoseworkingaroundyou.

2 ContactTI s ProductInformationCenterhttp:// warningsand instructionsfor followwarningsand instructionsmayresultin personalinjury,propertydamage,ordeathdue to termTI HV EVMrefersto an electronicdevicetypicallyprovidedas an openframed, is intendedstrictlyfor use in developmentlaboratoryenvironments,solely for qualifiedprofessionalusershavingtraining ,expertise,and knowledgeof electricalsafetyrisksindevelopmentand applicationof otheruse or applicationare strictlyprohibitedby you are not suitablyqualified,you shouldimmediatelystop fromfurtheruse of the HV :1. Keepworkareacleanand Qualifiedobserver(s)mustbe presentany time circuitsare Effectivebarriersand signagemustbe presentin the areawherethe TI HV EVMand its interfaceelectronicsare energized,indicatingoperationof accessiblehigh voltagesmay be present,for thepurposeof All interfacecircuits,powersupplies,evaluati onmodules,instruments,meters,scopesand otherrelatedapparatususedin a developmentenvironmentexceeding50 VRMSor 75 VDCmustbeelectricallylocatedwithina protectedEmergencyPowerOff (EPO) Use a stableand Use adequatelyinsulatedclampsand wiresto attachmeasurementprobesand.

3 As a precautionarymeasure,it is alwaysa goodengineeringpracticeto assumethatthe entireEVMmay havefully accessibleand activehigh De-energizethe TI HV EVMand all its inputs,outputs,and electricalloadsbeforeperforminganyelectr icalor TI HV EVMpowerhas Withthe EVMconfirmedde-energized,proceedwith requiredelectricalcircuitconfigurations, wiring,measurementequipmenthook-upsand otherapplicationneeds,whilestill assumingtheEVMcircuitand measuringinstrumentsare OnceEVMreadinessis complete,energizethe EVMas February2017 SubmitDocumentationFeedbackCopyright 2017,TexasInstrumentsIncorporatedEM1402 EvaluationModuleWARNING:whilethe EVMis energized,nevertouchthe EVMor its electricalcircuitsas theycouldbe at highvoltagescapableof :1. Wearpersonalprotectiveequipment,for example,latexglovesor safetyglasseswith side shieldsor protectEVMin an adequatelucentplasticbox with SafeUse:1. EVMsare not to be usedas all or part of a TexasInstrumentsEM1402 EVMB atteryManagementSystem(BMS)is an evaluationboardof theActiveBalancechipsetfor use in largeformatLithium-ionbatteriesthat providesmonitoring,balancing,and robustactivebalancing,theActiveBalanceBM Sis capableof bi-directionalpowertransferat eachcell.

4 EachEM1402 EVMcan manage6 to 16 cells(70-Vmax)for EM1402 EVMmodulescan be stackedup to 1300V. The systemprovidesfastcell balancing,diagnostics,and moduleto EM1402 EVMis equippedwith precisionmeasurementand synchronouscommunicationto enableamastercontrollerto performStateof Charge(SOC)andStateof Health(SOH) voltagesand a fast samplingtime for the entirebatterypackallowsmoreefficientoper ationof batterymodulesand moreaccurateSOCand userwill be able to extendthe availablecapacityof the batteryand will benefitfromlongerpacklifetimesversuspass iveor EM1402 EVMis equippedwith eventssuchasundervoltage,overvoltage,and systemis also capableof packtemperatureand fault flaggingsystemshelp protectthe batterymoduleand alertthe FeaturesThis EVMincludesthe followingfeatures: Activebi-directionalcell balancing Multi-cellchargeand dischargecapability Isolatedcommunications(5 kV) Flexiblearchitecturefor up to 16 cells UART interface Highaccuracycell voltagemeasurement ElectricalParametersThe followingtableidentifiesthe key electricalparameters.

5 Maximumbatterypackvoltage1300 VMaximumoperatingvoltage70 VMinimumoperatingvoltage12 VMaximumcell opencircuitvoltage5 VAmbienttemperature-40 C to 85 CNominaloperatingtemperature-20 C to 60 CCell balancingcurrentup to +/- 5 A-+-+-+Switch Matrix871-+16 Differential MUXADC116 Vtop116 GPIOS witch Matrix3 5 A (max)91 Active Cell Balancing (3x EMB1428Q + EMB1499Q)Cell Fault DetectionCell Monitoring (Voltage)Power Module 1 Cell Module nPack +Pack -BMS Module 1 UART TX/RXWAKEUPBMS Module 2 Cell Module 2+-+-OVUV7+-OTIC Temp127 Remote Temp InputsMicrocontrollerFAULT_NCOMM busFAULT busMUXbq76PL455A-Q1 Monitor + Protector2 Switch Matrix1016 SPID aisy-Chain CommsIsolated 12 VBMS Module 1 Isolated 12 VVP RegulatorDaisy-Chain Comms12 VFCOMM busFAULT busCopyright 2017, Texas Instruments IncorporatedTheoryof February2017 SubmitDocumentationFeedbackCopyright 2017,TexasInstrumentsIncorporatedEM1402 EvaluationModule3 Theoryof OperationFigure1 showsthe Operation5 SNOU143 February2017 SubmitDocumentationFeedbackCopyright 2017,TexasInstrumentsIncorporatedEM1402 EvaluationModuleThe BMSsystemis designedto prolongthe usefullife of Lithium-ioncellsin batterypackis brokeninto a seriesof modules.

6 Eachof whichcontainsup to 16 monitorvoltagesof individualbatterycellsand transferchargefromthe modulestackto anunder-chargedcell or take chargefroman over-chargedcell and transferit to the BMSallowsbatterypoweredelectricmachinest o use smallerbatterypacksand use fewerchargingcyclestoperformthe sameamountof also improvesthe overalllifetimeof Li-ionbatterypacksbypreventingunder-and BMSsystemhas threemainsub-systems,as shownin Figure1: Cell voltagemonitoringcircuitry Cell fault detection Activecell balancingengineThe cell-monitoringarchitectureis basedon the bq76PL455A-Q1(16 cell monitorand protection).EachEMB1428 Qis designedto controlaccessto up to 7 cellsof a typical16-cellbatterymodule;the full 16-cellmoduleutilizesthreeEMB1428 Qand one to threeEMB1499 QICs. The EM1402 EVMis designedwithone EMB1499 QIC to allowsimultaneouschargeand dischargeof a singlecell (of the up to 16 cellsattached)at up to 5 commandsand dataare communicatedwith a host via eithera UARTor EM1402will not do anythingwithoutbeingfirst commandedfromthe EM1402can supporta host PC or microcontroller(via the UART connectionheader)or a daisy-chaininterfacefroma bq76PL455A-Q1implementedas a EMB1428 Qis controlledvia an SPIinterfaceimplementedon the EM1402 EVMhas threeEMB1428 Qdevicessharingcontrolof a singleEMB1499 Qbi-directionalDC-DC EM1402 EVMhas connectedthe cellsthe EMB1428 Qdevicesas follows: EMB1428Q1 (U2): cells1 and 2 EMB1428Q2 (U3): cells3 to 9 EMB1428Q3 (U4): cells10 to 16 The typicalflow is for the host to go throughthe followingsequence:1.

7 Wakeupthe EM1402boardby sendinga WAKEUP pulsewhenusingthe UART interface,or sendinga WAKE tonewhenusingthe EM1402in a stackof otherEM1402boardsfor a largebatterypackor abq76PL455A-Q1configuredas a bq76PL455A-Q1to be readyfor Senda samplecommandto the bq76PL455A-Q1to readthe cell The host will use the cell measurementdatato calculatean averageand determinethe highestorlowestcellsand determinetheonecell that shouldbe chargedor Sendcommandsto the bq76PL455A-Q1to initializethe EMB1428 Qcommunicationinterfaceon Sendcommandsto the bq76PL455A-Q1to initializethe SN74 AHC595QI/O expanderto enablethechip selectfor the 8-bitDACon the Sendcommandsto the bq76PL455A-Q1to initializethe 8-bitDACon the EM1402 EVMwhichis usedto set the chargeor dischargecurrentlevel(an inputto EMB1499Q).7. Sendcommandsto the bq76PL455A-Q1to initializethe SN74 AHC595QI/O expanderto enablethechip selectfor the EMB1428 Qconnectedto the targetcell (determinedin step 3).

8 8. Sendcommandsto the bq76PL455A-Q1to sendthe startcommandto the EMB1428 Qto chargeordischargethe Whenchargeor dischargeis to be stopped,sendcommandsto the bq76PL455A-Q1to sendthe stopcommandto the EMB1428 Qto stop the chargeor dischargeof the targetcell. If no stop commandis sent,the EMB1499 Qhas a built-intimeoutof 8 seconds,afterwhichtimethe chargeor dischargewill be stoppedautomatically. If a longeramountof chargeor dischargetime is needed,the host will needto senda stopcommand,followedby a startcommandat leastevery<8 The host can thendecideto repeatthe process(backto step 2) or sendcommandsto shutdowntheEM1402 EVMand February2017 SubmitDocumentationFeedbackCopyright 2017, a singleboardthe BMScan activelybalanceup to 16 cellsup to 70 V of total the EM1402 EVMis handledby the daisy-chaincommunicationsbus fromanotherbq76PL455A-Q1orthe UART host BMSboardsmay be stackedup to 1300V.

9 Communicationto the EM1402 EVMis handledby thedaisy-chaincommunicationsbus batterycell connectionsare madefromconnectorJ1. Cell voltagemeasurementsand balancingcurrentsuse the top cell connectionin the wiringharnesstosupportless than16 TycoElectronics175785-1(ReferenceImageOn ly)Table1. ConnectorInformationDesignatorManufactur erPartNumberMatingConnectorJ1 TycoElectronicsManufacturer:175785-1 Digi-Key:175785-1-NDManufacturer:174952- 1 Digi-Key:1-174952-1-NDContacts:Manufactu rer:175027-6(16-20 AWG)Digi-Key:175027-6-NDTable2. Pin DescriptionPinNameComments1 BAT16 Positiveterminalof BAT162 BAT13 Positiveterminalof BAT13,negativeterminalof BAT12,negativeterminalof BAT11,negativeterminalof BAT10,negativeterminalof BAT5,negativeterminalof BAT4,negativeterminalof BAT3,negativeterminalof February2017 SubmitDocumentationFeedbackCopyright 2017,TexasInstrumentsIncorporatedEM1402 EvaluationModuleTable2.

10 Pin Description(continued)10 BAT15 Positiveterminalof BAT16,negativeterminalof BAT14,negativeterminalof connected14 BAT9 Positiveterminalof BAT9,negativeterminalof BAT8,negativeterminalof BAT7,negativeterminalof BAT6,negativeterminalof BAT1,negativeterminalof BAT1620 BAT2 Positiveterminalof BAT2,negativeterminalof 6-pinJ3 - Serialconnectoris usedto connectthe bq76PL455 EVMto a PC runningthe GUI or to ahost the J3 - Serialconnectorare 5-V TTL s USB-to-TTLserialconvertercableto allowconnectionwith a PC s availablefromFTDI( ),and the appropriatepart numberforthe Molex22-12-4062(ReferenceImageOnly)Table 3. ConnectorInformationDesignatorManufactur erPartNumberMatingConnectorJ3 MolexManufacturer:22-12-4062 Manufacturer:22-01-2061 Digi-Key:WM1579-NDContacts:Manufacturer: 08-55-0101(22-30 AWG)Digi-Key:WM2312CT-NDTable4. Pin DescriptionPinNameMatingCableColor1 GroundBlack2 FAULT signalfrombq76PL455A-Q1 Black35-V inputfromPCRed4RX fromPC to bq76PL455A-Q1 Orange5TX frombq76PL455A-Q1to February2017 SubmitDocumentationFeedbackCopyright 2017, 7 boardprovidesa 20-k pullupto TycoElectronics43045-1601(ReferenceImage Only)Table5.