DC1652A
1
DESCRIPTION
Evaluation circuit DC1652A is a Battery Monitoring
System to demonstrate the functional operation of the
LTC6803-2
integrated circuit. The
LTC6803-2
is a
complete battery monitoring IC that can measure as
many as 12 series connected cells with a total voltage
of 60V. A simple SPI serial interface is used to com-
municate battery state information to a system control
processor.
Use of an on-board discrete-device SPI-bus daisy-
chain or optional isolated serial interface allows moni-
toring of completely separate battery cell packs or a
series stack of cells. Stacking of cells permits the mon-
itoring of each individual cell in systems requiring
100’s of volts from the battery pack, such as those
used in Hybrid Electric Vehicles (HEVs). Each device
also has a built in high-accuracy reference.
In addition, each individual cell connection has a soft-
ware controlled discharge transistor. This allows the
implementation of precision cell charging algorithms
including charge shedding of over-voltage cells.
A group of up to ten DC1652A boards can be managed
through the USB port of a PC using an on screen con-
trol panel GUI available from LTC.
LTC6803-2 FEATURES
12-bit accurate voltage measurement of 12 battery
cells (60V maximum/board).
4-bit addressable serial interface for high cell count
systems (16 boards x 12 cells = 192 Cells).
Packet error checking (PEC) for all commands.
New commands allow measuring of individual or all
cell voltages, open wire connections and tempera-
ture sensors.
Option to measure cell voltages and perform open
wire detection with or without the cell discharge
transistors conducting.
Enhanced self test functions.
Thermal Shutdown built in and flagged.
Silicon revision code provided
DC1652A DEMO FEATURES
Graphical User Interface (GUI) for demonstrating
new features.
Optional isolated main SPI communication port.
External discrete circuitry for daisy-chained current
mode SPI communication up and down a stack of
monitors.
ESD and fault protection circuitry included.
DC1652A
April 8, 2011
LTC6803-2 Battery Monitor
HARDWARE/SOFTWARE USERS GUIDE
ADDRESS
JUMPERS
LTC6803-2
MAIN SPI
INTERFACE
CONNECTOR
CELLS CONNECTOR
TOP SPI
PORT
ISOLATED SPI PORT
DC1652A
2
GETTING STARTED WITH ONE BOARD CONNECTED
SINGLE BOARD CONNECTION TO PC AND GUI
Step 1.
Set jumpers on DC1652A to the default posi-
tions indicated in Table 1 (and Figure 1).
TABLE 1. JUMPER FUNCTIONS
JUMPER FUNCTION DEFAULT
POSITION
“1” POSITION “0” POSITION
JP1
Two Jumper Block to Select
Voltage or Current Mode for
Bottom SPI Port
Voltage
Mode
Labeled “V” on board. Sets bottom
port for voltage mode SPI commu-
nication.
Labeled “I” on board. Sets Top and Bottom
ports for Current Mode SPI communication
using external daisy-chain current source
circuitry.
JP6,JP7,JP8,JP9
SPI Daisy Chain Configura-
tion Jumpers:
(All Four Jumpers Must
be Moved Together)
1, 1, 1, 1
Top of Stack
(TOS)
Setting
For V Mode communication to all
boards (e.g. using isolators) set all
four jumpers to the 1 position.
For SPI daisy chain communication
this setting is required for only the
board at the top of a cell stack.
These settings connect the top
daisy chain current source transis-
tors to the top cell at the top of the
cell stack.
For SPI daisy-chain (current mode) com-
munication set all four jumpers to the 0
setting. This enables the top port on each
board for current mode communication
up/down the stack.
Use these settings also for the bottom
board in a daisy chain stack, which should
also be set to V mode (JP1) for the bottom
port communication to a system controller.
JP2,JP3,JP4,JP5
Board Address Setting
(0000 to 1111)
JP2 is MSB
JP5 is LSB
0, 0, 0, 0
(for address
0000)
Logic ‘1’ setting Logic ‘0’ setting
Step 2.
Before running the DC1652 GUI, a DC590
driver must be installed. To do this, install the
Quick Eval Software. Quick Eval can be down-
loaded from:
http://www.linear.com/designtools/software/
After installation
close the QuickEval program.
Step 3.
Connect the DC590 Quick Eval USB cable to
PC/Laptop USB port if not already. Connect a rib-
bon cable from DC590 to the Main connector of
DC1652A (H1).
Step 4.
Launch the GUI control program:
LTC6803-2-4_GUI_Vxx_yyyymmdd.exe
The version/year/month/day addition to the file name
identifies the version as changes are made. When the
DC590 Quick Eval board recognizes the String ID code
from the DC1652A board, the program will open and
present the control screen.
The program will not open
unless DC590 is connected to the computer and the
DC1652A board.
Step 5.
Connect the cells to be monitored to the cells
connector J1. This connector is in two pieces. The
setscrew piece can be unplugged to make it easier
to attach a wiring harness with an up to twelve cell
battery stack. The
LTC6803-2
demo circuit is in-
tended to measure from four to twelve individual
cells with a total stack voltage of 10V to 60V.
With fewer than 12 cells to be monitored, the bot-
tom cell of the stack should always be connected
as Cell 1 between terminals J1-5(+cell contact) and
J1-4(-cell contact). Terminals J1-4 and J1-1 are
the ground reference point for the battery cell stack
and for the DC1652A board. The second cell on the
stack connects between terminals J1-6(+cell con-
tact) and J1-5(-cell contact). All higher numbered
terminals on J1 not used for cell connections may
be shorted together. The V+ positive supply for the
DC1652A is the potential at terminal J1-16 and
DC1652A
3
therefore must connect to the top of the battery
stack. Figure 1 illustrates a connection for fewer
than 12 cells.
Step 6.
Apply power.
Inserting the setscrew piece into connector J1 will
apply power to the board from the battery cell
stack.
Figure 1.
Connection of four cells (cell voltages at least 2.5V)
DC1652A
4
THE CONTROL PROGRAM
THE GRAPHICAL USER INTERFACE (GUI) SCREENS
Figure 2 shows the control panel that appears on the
computer screen. Controls on this panel are used to
communicate with the
LTC6803-2
. Commands are is-
sued and information is retrieved and displayed on this
screen. This panel is useful not only for demonstrating
the operation of the
LTC6803-2
, but also for software
developers to observe the Hex codes exchanged with
the device.
Figure 2.
PC GUI Control Panel
Cell Voltage
Readings fo
r
Selected Board
Board Selection
Tabs
Clic
k
-Button
Controls for
All Commands
Hex Code Display for Confi-
guration, System Flags and
Packet Error Check
Tempe
r
ature
Readings
Configure I/O
and Operating
Modes
Programmable Over
and Under Voltage
Thresholds
Color Coded
Status Panel
for All Cells
Connected
Continuous Reading of
All Cells Function
Set Individual
Board Addresses
DC1652A
5
OPERATING THE CONTROL SCREEN
FIRST THINGS FIRST – ONLY ONE BOARD
CONNECTED
The GUI start-up screen appears when the program is
launched and the DC590 Quick Eval interface card re-
cognizes that the DC1652A board is connected. Once
power is supplied to the board from a stack of cells or
a power supply, the communication between the PC
and the board can be checked.
1: SET BOARD ADDRESS
A feature of the LTC6803-2 is that each device/board is
given a unique 4-bit address. Communication between
the GUI and a board will occur only when the address
set on the board with jumpers J2 through J5 matches
the address set in the GUI for that board. The default
selected board and address on power up is Board #1
with the address of 0x80. The actual address byte for
each board is 8-bits long, but only the 4 LSBs are pro-
grammable. Set the jumpers to the address on the GUI
or change the GUI to match the board (using the Set
Hex Address box in the lower left corner of the GUI) to
enable communication with the DC1652A.
2: READ CONFIGURATION
Click the command button labeled
READ CONFIG.
If all
is properly connected and operating the start-up de-
fault configuration of the
LTC6802-2
(standby mode)
will be read from the board. The Hex codes for the six
bytes of configuration setting will appear in the
CONFIGURATION REGISTERS
section in the boxes
labeled
CONFIGURATION READ FROM LTC6803-2
.
The initial configuration bytes should be 0xE0 for con-
figuration register 0 (CNFRG0) and 0x00 for the other
five bytes.
In addition the
LTC6803-2
calculates a Packet Error
Code, PEC, and appends it to the data stream each
time it sends out data. For the six bytes sent by this
command and received by the GUI, the control pro-
gram calculates a PEC in the same manner. This byte
is compared with the appended byte to check that the
data transmission was properly executed. Both PEC
bytes are displayed in the top section labeled
PACKET
ERROR CODE
and both bytes should match. A PEC is
also sent to the LTC6803-2 with every command as
shown in the GUI. Commands received by the IC and
not validated internally with a correct PEC calculation
are not processed, thus avoiding corrupted control.
The oval located at the top of the color-coded status
panel for the one board will turn green if the PEC bytes
match on the read-back. Read-back data transmission
errors will produce red warning indications if the PEC
bytes do not match.
3: PROGRAM THE CELL MONITORING VOLTAGE
THRESHOLDS
In the section labeled
SET VOLTAGE LIMITS
click on
the boxes and enter voltage values for the over-voltage
and under-voltage thresholds required for the cells be-
ing monitored. After entry completion, the voltage val-
ue will be “rounded” to the actual value used by the
LTC6803-2
and displayed. The voltage ranges for these
thresholds is -0.74V to 5.3V and the program will not
allow the ‘under’ to be greater than the ‘over’ voltage
threshold.
These monitor thresholds can be applied globally to
each and every cell in the system or customized for the
cells connected to an individual board by clicking the
desired option button. Individual boards are selected
for programming or viewed by the left hand tabs in
multiple board systems.
4: SELECT AN OPERATING MODE
The power-on operating mode for the LTC6803-2 is
Standby. The GUI initializes to this state also to serve
as a reminder that the device must be configured be-
fore starting operation. Select one of the seven CDC
(Comparator Duty Cycle) options from the scroll box in
the
SET I/O MODE
section at the bottom of the screen.
5: WRITE CONFIGURATION
Nothing is changed in the LTC6803-2 until the Write
Configuration command is executed. Clicking the
WRITE CONFIG
command button does this. When the
command is sent, the six Hex bytes shown in the
CONFIGURATION REGISTERS
section in the boxes
labeled
CONFIGURATION WRITTEN TO LTC6803-2
will
become
bold
type. Software developers can note
the exact hex values required by the LTC6803-2 for
DC1652A
6
specific conditions in these boxes to facilitate their
control program development.
Clicking the
READ CONFIG
button can provide confir-
mation that the configuration change was actually
made. The six bytes read back should generally (un-
less special GPIO conditions exist) match the six bytes
sent and the PEC check bytes should be a match
(green PEC oval above the stack status display).
IMPORTANT NOTE
No configuration changes take effect until the
WRITE CONFIG button is clicked. A flashing
backlight serves as a reminder that this needs to be
performed.
Consult the LTC6803-2 data sheet for detailed informa-
tion concerning the variety of software configurable
functions possible. The following is a summary of
these functions:
Discharging individual cells,
Changing Over/Under voltage thresholds,
Preventing UV/OV interrupt flags from modifying
system operation through masking,
Systems status polling type; level or toggle polling,
Monitor comparator time interval,
GPIO pin functions -Inputs or Outputs,
10cell/12cell conversion mode,
Standby Mode-low current drain.
All of these can be implemented from the control panel
when selected from various points on the screen then
followed by a
WRITE CONFIG
button click.
6: READ TEMPERATURE
The LTC6803-2 has three ADC channels dedicated to
measuring temperature. The temperature indications
are for the internal die temperature of the LTC6803-2
and two externally connected thermistors. The display
returns a voltage measurement.
The internal die temperature sensor produces a voltag-
es that changes at a rate of 8mV/°C relative to absolute
zero. To convert the voltage reading to degrees Centi-
grade, divide the voltage by 8mV then subtract 273°C.
For example, 25°C is a nominal reading of 2.384V.
For external temperature measurements connect ther-
mistors across cells connector terminals J1-3 to J1-1
and J1-2 to J1-1. A thermistor with a 25°C value of
10K
Ω
will produce a half of V
REF
voltage reading at
25°C (approximately 1.55V). Any thermistor value may
be used but scaling the voltage measurement may re-
quire changing the values of resistors R55 and R56 on
the DC1652A circuit board.
To take a temperature reading simply click the
START
TEMP
command button to make the LTC6803-2 ADC
conversion followed by clicking the
READ TEMP
command button to download the data from the board
and display the voltage readings for temperature.
7: READ CELL VOLTAGES
The essential function of the LTC6802-2 is to measure
and report the voltage on each battery cell when com-
manded. Once again this is accomplished from the
control screen with two command button clicks. First
click on the
START CELL VOLT
button. This com-
mands an A/D conversion of all 12 cell-voltages.
NOTE:
All 12 cell-voltages are converted every time
regardless of the number of cells actually connected to
the LTC6803-2. Unused cell connections, if shorted
together, will return nominal voltage readings of 0.000
volts.
The actual cell voltage measurements are not displayed
until the
READ CELL VOLT
command button is clicked.
8: READ FLAGS
When any cell in a stack exceeds the programmed
over- or under-voltage threshold limit, one of two flag
bits is set in an internal register for that cell to serve as
a warning. This is simple feedback for battery charging
algorithms to know simply when to start or stop charg-
ing. To read the state of these warning flags at any
time is a simple click of the
READ FLAG
command
button. The Hex code for the three flag bytes appears
in the
FLAGS
section of the control panel at the top of
the screen.
One of the configuration options is to mask these flags
from appearing in the register bytes that are read from
the LTC6803-2. This feature can be used to either pre-
vent or allow these flags to report warnings to a con-
DC1652A
7
trol algorithm. A check box is provided for each cell in
a stack to select the mask option for that cell. To im-
plement the masking requires checking the box(es)
and then writing the new configuration with a
WRITE
CONFIG
button click.
9: DISCHARGE CELLS
Another major feature of the LTC6803-2 is the ability to
remove charge from individual cells. In connection
with a user control algorithm, this can distribute cell
charge evenly over a stack of batteries. DC1652A con-
tains a P-channel MOSFET in series with a 33
Ω
resis-
tor across each cell connection. When enabled, a cell is
loaded and charge is pulled from the cell with energy
dissipated in the switch and resistor.
A DCC check box is provided for each cell to be dis-
charged. Checking this box and then writing the new
configuration with a
WRITE CONFIG
button push will
begin discharging the selected cell(s).
IMPORTANT NOTE:
The discharge transistors are au-
tomatically turned off momentarily while the A/D con-
verter is measuring the cell voltage. This prevents any
voltage drop errors caused by the discharge current
flowing through the cell inter-connection wiring. An
accurate indication of the cell voltages is then obtained.
The command set and GUI offer the option of keeping
the discharge transistors on while measuring the cell
voltages. This is done by using the STARTCELL hold
DCC command button. A blue indicator is illuminated
when this command is in effect. If established by deli-
berate resistances, the lower voltage reading due to the
discharge current can serve a useful diagnostic pur-
pose.
OTHER CONTROL FEATURES
Three additional command buttons are provided on the
control screen. The
POLL ADC
and
POLL INT
com-
mand buttons are used to test if the ADC is busy mak-
ing conversion and to test if any of the LTC6803-2 de-
vices in a system have an interrupt condition respec-
tively. The result of these commands can be observed
by monitoring the serial data output line of the SPI in-
terface at pin 5 of the SPI BOTTOM connector, H1.
There is no indication provided on the control screen.
The
START OPENWIRE
command button connects the
built in open wire detection circuitry to all cells. A
START CELL VOLT
and
READ CELL VOLT
command
button click sequence must follow to determine the
result. Ideally an open wire connection to any cell will
be indicated by an abnormally high voltage measure-
ment for the cell above the open wire and a near zero
measurement for the cell with the open wire.
CONTINUOUS OPERATION
For convenience, the control panel allows for conti-
nuous operation of the DC1652A board. The command
button labeled
START
CONTINUOUS READ CELLS
can
be clicked and the board control is placed in a conti-
nuous loop executing the following commands auto-
matically in the following sequence:
Start cell voltage
Read cell voltage
Start temp
Read temp
Read flags
All values are updated continually. While running, the
configuration can be changed on the fly. Simply chang-
ing a configuration item (Discharge cells for example)
and clicking the
WRITE CONFIG
button will implement
the new configuration and return to continuous opera-
tion.
A green box in the lower right hand corner indicates
that the system is running continuously. A red box
means that the system is stopped and waiting for a
new command to be sent.
DC1652A
8
DATA TRANSFER VALIDATION
Each time data is transferred from the LTC6803-2 by
the four READ commands (Cell Voltage, Configuration,
Flag Status and Temperature), a Packet Error Code,
PEC, is calculated based on the data stream sent. The
control program also calculates a PEC value based on
the data it receives. If the calculated PEC matches the
transmitted value the data transfer is assumed to be
error free and therefore the data is valid.
If the two PEC values do not match, the transmitted
data stream has been somehow corrupted. This type of
data error becomes more of a concern when boards
are stacked and the transmit data stream is leng-
thened. The transmitted and calculated PEC values are
displayed on the GUI and turn red when a mismatch
occurs.
A PEC byte must also be appended to a command is-
sued to the LTC6803-2 which then must pass an inter-
nal check to be processed. In this way corrupted
commands will not effect operation. The PEC is auto-
matically calculated and sent by the GUI for each
command. The PEC hex codes for both write and read
operations are shown in the PACKET ERROR CODE
area.
LOW CURRENT STANDBY
An important system consideration is the ability to put
the monitoring circuitry into a low current drain condi-
tion. This is done by setting the LTC6803-2 into its
standby configuration. A command button in the lower
right corner of the screen is provided to facilitate this
function. Once clicked, all data and configuration set-
tings are restored to initial values and the screen goes
white on all indicators. Also in this condition, SPI sig-
nals are set to static logic high so that the watchdog
timer will trip and external SPI transistors go to an off
state.
24B
SELF TEST FUNCTIONS
The LTC6803-2 has built in self test functions. These
commands apply test signals to the ADC to check that
the internal cell voltage and temperature connections
are functioning. The cell voltage and open wire test
signals can be applied with or without the discharge
transistors active. Checking the functionality of each bit
in the internal data registers for cell voltages and tem-
peratures can also be seen by choosing which test
code (0x555, 0xAAA, or 0xFFF) to expect to be re-
turned from the device when a self test command is
issued.
25B
OTHER CONFIGURATION OPTIONS
The SET I/O MODE CFGR0 group of checkboxes can be
used to adjust other features of the LTC6803-2. Confi-
guring the general purpose I/O pins and setting the
polling mode can be set by checking the appropriate
boxes, and sending the command with a WRITE
CONFIG button push.
DC1652A
9
ADDING BOARDS TO
MEASURE MORE CELLS
An important function of the LTC6803-2 is the ability to
communicate with devices connected to up to 16 indi-
vidually addressable battery cell stacks. Likewise 16
DC1652A boards, monitoring up to 12 cells each, can
be controlled and read individually.
The control GUI is
limited to only 10 boards (120 cells) maximum
. The
battery cell stacks can be completely separate from
each other with an isolated digital control interface or
stacked on top of each other. To control more than one
board requires the following hardware and software
modifications:
HARDWARE ADJUSTMENTS
1.
Each board needs a unique 4-bit binary address
between 0 (0000) and 15 (1111). The LSB of the
address is A0 and is set with jumper J5 (1 or 0).
Bits A1 through A3 (the MSB), are set with jum-
pers J4, J3 and J2. Any address can be used with
any board so long as no two are the same. The
GUI can also be programmed to match the address
of each board.
2.
Refer to the following configuration drawings (A
through E) for connecting to multiple battery
stacks. Just a three-board example is shown for
simplicity; more boards will require other individu-
al address settings.
3.
Pay close attention to the jumper settings for each
board in a stack depending on the configuration
chosen. It is essential that the current/voltage I/V
Communication Mode and Top-of-Stack (TOS) set-
tings be correct for communication to work prop-
erly.
EXTERNAL DIGITAL ISOLATOR SUPPLY
The DC590 interface is electrically isolated from the
controlling computer power. This can allow communi-
cation from a PC with full isolation from the main AC
power. Several battery stacks which have a common
ground connection can be controlled by a single bot-
tom port SPI bus as shown in configuration B.
To communicate with multiple boards connected to
stacked cells requires the addition of an isolator circuit
on each DC1652A board for device U5 and connection
to the alternative bottom port isolated connector, H3.
Power for the isolators can be provided through the
DC590 connector at H3 up to 30mA total. If the operat-
ing current required by all of the isolators exceeds the
available current from this supply, an external 5V pow-
er supply connected to terminals E3 and E2 (ground)
will ensure proper data communication. Make sure to
disconnect the power supplied by DC590 to pin 2 of
connector H3. An external supply is shown in the iso-
lated configuration schematics but is not required if the
DC590 isolated port and supply are used.
CAUTION! CAUTION! CAUTION!
As battery cells are stacked on top of each other, great
care must be taken to prevent damage and personal
injury from the very high voltage potentials that may be
present. Do not allow short circuit connections, wheth-
er electrical or human, between a high voltage point
and the system or chassis ground at the bottom of the
stack. Be very careful and respect the potential danger
of high voltage & energy!
DC1652A
10
DC1652A
DC1652A DC1652A DC1652A
DC1652A
11
DC1652A
DC1652A
DC1652A
DC1652A
12
DC1652A
DC1652A
DC1652A
DC1652A
DC1652A
DC1652A
DC1652A
13
INITIAL SOFTWARE ADJUSTMENTS
The GUI program can control up to ten boards.
Select the number of boards connected from the list
box located in the lower left corner of the screen.
A tab will appear on the left edge of the control panel
for each board on the stack.
Click each board tab separately and set the following
parameters for the selected board:
1.
Select the address for each board to match its
jumper-set value. Values range from 0 to F. Make
sure that each board has a unique address.
2.
Select whether the Over/Under voltage thresholds
for each board are to be the same (GLOBAL) or dif-
ferent (CUSTOM) and set the voltage limits accor-
dingly. If Global, the limits need to be entered only
once.
3.
Since the default power up state of the LTC6803-2
is Standby, the GUI starts up this way to serve as a
reminder that the device must be configured be-
fore any other operations. Select an operating
mode from the Set CDC scroll box at the bottom.
4.
Click
WRITE CONFIG
to configure the board for
basic operation.
5.
Click
READ CONFIG
to verify that the proper word
was written to the board.
6.
Select another board tab on the left and repeat
steps 1 to 5.
BROADCAST COMMANDS-BE CAREFUL
Each LTC6803-2 controlling command has the option
to be broadcast to all boards in the system simulta-
neously. This can be quite convenient, but it can also
make unintended changes to some of the boards.
When the
WRITE CONFIG
command B’Cast check box
is checked, the settings currently visible on the screen
will be sent to all boards and will change their configu-
ration for voltage monitoring threshold and operating
mode. If unpredictable results are seen from a board it
could be due to the configuration change. Making a
READ CONFIG
on that board will indicate the present
configuration.
CONTINUOUS READING OF ALL CELLS IN A SYSTEM
When put into continuous mode each board is exer-
cised in succession. The moving LTC logo indicates
which board is being measured. The cell voltage and
temperature readings are for the Tab selected board
only. When stopped, all readings are cleared.
DC1652A
14
COLOR CODED STATUS PANEL
The color-coded status panel will expand to include all
boards connected in a stack. Each small square in this
array represents an individual battery in the stack of
boards. The intent of this display is to provide a way to
see the status of all cells at a glance. The meaning of
the colors used is explained in the legend on the
screen.
Any grayed box indicates that the cell’s interrupt flag
has been masked so the LTC6802-2 is no longer re-
porting this status. The cell voltage value measured for
this cell however is still accurate.
The GUI is quite sophisticated with many adjustable
variables. As items are changed displayed values may
become stale or inaccurate. These will be flagged by
either being cleared or grayed. If an item looks differ-
ent, repeat the desired command to refresh the dis-
played information.
The schematics for DC1652A follow. Consult the data
sheet for detailed information on the operation of the
LTC6803-2 battery monitoring system.
Figure 3.
GUI screenshot showing 3 boards being continuously monitored. Cell voltages and Temperature readings shown are for board 1
only. Color-coded cell status is for all boards connected.
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