0BDESCRIPTIONEvaluation circuit DC1654B is a Battery Monitoring System to demonstrate the functional operation of the LTC6803-4 integrated circuit. The design includes the ability to bus up to 10 devices with built-in board-to-board ribbon-cable interconnects (direct or optionally isolated) and selectively apply resistive loading to any cell for purposes of “Passive Balancing.” Additionally, the board includes an available DC-DC boost conver-sion section to power the IC from an isolated external 5V supply.

1BLTC6803-4 KEY FEATURES • Separate Cell 0 ADC input (bottom-cell connection). • Conversion range down to –300mV per cell. • Addressable SPI interface (up to 16 devices). • Packet Error Checking on command writes. • 6X lower standby current than LTC6802. • Power-down mode for “no battery drain”. • Active pullup on discharge-control outputs (S pins). • Extensive diagnostic commands.

2BDC1654B DEMO FEATURES • Controllable discharging for Passive Balancing. • Enhanced protection circuitry for IC and external

discharge transistors during hot plugging of cells. • Graphical User Interface (GUI) screen for demon-

stration of new features and program code devel-opment.

• Available 60V boost supply from isolated 5V exter-nal supply.

• Jumper configuration offers –5V offset for V– to support negative cell readings (Note that due to device ratings on C1, this operation is not rec-ommended).

• Footprint for LTC6655-3.3 calibration reference. • Footprint for SPI isolator with host bus extension

(NOTE corrected SPI connections to isolator).

Demo Circuit 1654BDemo Manual

LTC6803-412-Cell Battery Stack Monitor

February 25, 2013

CELLS CONNECTOR

DISCHARGE SWITCHES

DIRECT SPI PORT

LTC6803-4 ISOLATED SPI-BUS PORTS

DC-DC BOOST

ADDRESS BITS

DC1654B

2

3BGETTING STARTED WITH ONE BOARD CONNECTED

5BSINGLE BOARD CONNECTION TO PC AND GUI

Step 1. Set jumpers on DC1654B to the default posi-tions indicated in Table 1.

6BTABLE 1. JUMPER FUNCTIONS

JUMPER FUNCTION DEFAULT POSITION

DEFAULT POSITION ALTERNATIVE POSITION

JP7 Top of Stack (TOS) Active Indicates that the cells monitored by the board are at the top of the battery stack to provide primary toggle polling. Only one de-vice should form the toggle frequency.

Forces device into the secondary toggle polling mode. Note that due to a pcb design flaw that GPIO1 commanded low will also set TOS low, which could cause problems demon-strating toggle polling.

JP8 General Purpose I/O (GPIO1)

Active Output connected to pull-up resistor to Vreg. Can be programmed as an input or an output. Note that due to a pcb design flaw that TOS set low by JP7 low will also load the GPIO1 signal, which may cause input mode arti-facts.

Forces GPIO1 to a logic low level. Note that due to a pcb design flaw that GPIO1 forced low will also set TOS low, which could cause problems demonstrating toggle polling.

JP9 General Purpose I/O (GPIO2)

Active Output connected to pull-up resistor to Vreg. Can be programmed as an input or an output.

Forces GPIO2 to a logic low level.

JP3-JP6 A0, A1, A2, A3 (address)

0 Sets hexadecimal address nibble to 0x0 Setting bits to 1 configures different device addresses, Used in the event there are multiple LTC6803-4 in a SPI bus.

JP2 -POWER Stack Connects V- of the LTC6803 to the Cell 0 potential of the stack.

Forces V- to be at a potential 5V below Cell 0. Only usable if separate external power is ap-plied. Permits all cells to properly measure down to -300mV. This 5V shift is not recom-mended due to C1 input rating (a lower shift might be usable however).

JP1 +POWER Stack Connects V+ of the LTC6803 to the Cell 12 potential of the stack.

Connects V+ to the isolated boost power supply. Only usable if separate external power is applied. Permits full power-down of the LTC6803 when external power is removed.

Step 2. Connect DC590B Quick Eval USB cable to PC/Laptop USB port. Connect ribbon cable from DC590B to the SPI Direct port of DC1654B (J2). Make sure that the driver for DC590B has been downloaded from HUwww.linear.comUH and installed on the computer. This can be verified by running Quick Eval and seeing the message that there is a missing module for this board type. Close the Quick Eval program and then launch only the con-trol program:

LTC6803-2-4_GUI_Vxx_yyyymmdd.exe

When the DC590B Quick Eval board recognizes the String ID code from the DC1654B board, the pro-gram will open and present the control screen. This sometimes requires two launches of the GUI program to properly initialize.

A DC590B board has a required pull-up resistor for the SDO line already connected. If a system other than DC590 is driving the SPI interface, there must be a 5KΩ pull-up resistor added between

DC1654B

3

the SDO line (J2, PIN 5) and the 3V/5V logic supply rail of the driving system. This pull-up re-sistor was not added to the DC1654 because it cannot be present when the port is configured for bussed operation on a multiple board setup.

Step 3. 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 safer to attach wiring from a four to twelve cell battery stack. The LTC6803-4 is intended to measure from four to twelve individual cells with a total stack vol-tage of 10V to 50V.

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). Terminal J1-4, is the Cell 0 ref-erence point for the battery cell stack. The second cell on the stack connects between terminals J1-6(+cell contact) and J1-5(-cell contact). All higher numbered terminals on J1 not used for cell con-nections may be shorted together. If the V+ posi-tive supply for the DC1654B is to be the cell stack, then the terminal J1-16 must connect to the top of the battery stack. Figure 1 illustrates a connection for fewer than 12 cells.

7BSPECIAL NOTE FOR DEMONSTRATION PURPOSES

DC1654B and the GUI program are useful to serve as a demonstration tool to highlight the features of the LTC6803-4. If actual battery cells are not available, a series string of 150Ω resistors connected between each of the J1 connector terminals can be used in-stead. Each resistor will serve as a cell voltage. A lab power supply voltage of 10V to 50V can be connected across the resistor string between terminals J1-16(+) and J1-4(-).

When using resistors instead of cells, the discharge indicating LEDs on the DC1654B board will not light due to limited available current in the resistor-string.

Step 4. Apply power.

Inserting the setscrew piece into connector J1 will apply power to the board from the battery cell stack. For the demo set up simply turn on the lab power supply preset to a voltage between 10V and 50V.

Figure 1. Connection of four cells (cell voltages at least 2.5V)

DC1654B

4

THE CONTROL PROGRAM

8BTHE GRAPHICAL USER INTERFACE (GUI) SCREEN

Figure 2 shows the control panel that appears on the computer screen. The DC1654B board must be con-nected to the DC590 interface card for the program to open. The control screen will close if any of the boards are disconnected. Controls on this panel are used to communicate with the LTC6803-4. 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 LTC6803-4, but also for software developers to observe the Hex codes exchanged with the device.

The control screen makes good use of color to provide cell status and operating conditions at a glance. White indicates non-existent or stale data. A step by step procedure for one board connected to a stack of cells follows to explain the operation of the control panel. Sections are highlighted for each procedure.

Figure 2. GUI Control Panel Start-up Screen

DC1654B

5

4BOPERATING THE CONTROL SCREEN 9BFIRST THINGS FIRST

Figure 2 is the initial start-up screen that appears when the program is launched and the Quick Eval interface card recognizes that the DC1654B 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.

10B1: READ CONFIGURATION

Click the command button labeled READ CONFIG. If all is properly connected and operating the start-up de-fault configuration of the LTC6803-4 will be read from the board. The Hex codes for the six bytes of configu-ration setting will appear in the CONFIGURATION REGISTERS section in the boxes labeled CONFIGURATION READ FROM LTC6803. The initial configuration bytes should be 0xE0 for register 0 and 0x00 for the other five bytes. This default configura-tion is the standby mode for the LTC6803. To enable the device and begin taking cell voltage measure-ments, a CDC (Comparator Duty Cycle) setting other than Standby must be selected from the SET I/O MODE set CDC selection box at the bottom of the GUI screen. Once chosen, a WRITE CONFIG com-mand must be executed.

In addition the LTC6803 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 receive byte to check that the data transmission was properly executed. The Received PEC byte and the calculated PEC from the received data are displayed in the top section labeled PACKET ERROR CODE and both bytes should match. The oval located at the top of the color-coded status panel for the one board will turn green if the PEC bytes match. Data transmission errors will produce red warning indications if the PEC bytes do not match. There is also a display of the PEC that was sent with the most recent command to the LTC6803, which had to match an internally calculated value to be accepted as a valid command.

11B2: WRITE CONFIGURATION

Nothing is changed within the LTC6803 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 will become bold type. Software developers can note the exact hex values required by the LTC6803 for specific conditions in these boxes to facilitate their control pro-gram development.

Clicking the READ CONFIG button can see confirma-tion that the configuration change was actually made. The six bytes read back should match the six bytes sent and the PEC/CRC check bytes should be a match (green PEC oval on stack display).

When any configuration information is changed on the screen the WRITE CONFIG command button will be back-lit illuminated. This serves as a reminder that this command still needs to be executed.

12BIMPORTANT NOTE

32BNo configuration changes take effect until the WRITE CONFIG button is clicked. The GUI provides a periodic background command so that watchdog does not trigger a CDC reset back to 0.

DC1654B

6

13B3: 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. The voltage value entered will be rounded to the actual value used by the LTC6803 and displayed in the box. The voltage ranges for these thre-sholds is -0.74V to 5.35V and the program will not al-low the under-voltage 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 by the left hand tabs in multiple board systems.

14B4: READ CELL VOLTAGES

The essential function of the LTC6803 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 VOLTAGE button. This com-mands an A/D conversion of all 12-cell voltages in the time configured from the selected Set CDC option in the SET I/O MODE box. The actual cell voltage mea-surements are not displayed until the READ CELL VOLTAGE command button is clicked.

15B5: 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 important feedback for battery charg-ing algorithms to know when to start or stop charging. 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 FLAG REGISTERS section of the control panel.

One of the configuration options is to mask these flags from appearing in the register bytes that are read from the LTC6803. This feature can be used to prevent or allow these flags to affect a control algorithm. A check box is provided for each cell in a stack to select the mask interrupt option for that cell. To implement the masking requires checking the box and then writing the new configuration with a WRITE CONFIG button push.

If the measured voltage of a cell is within the monitor-ing thresholds all indications for the cell appear green.

DC1654B

7

16B5: READ TEMPERATURE

The LTC6803 has three ADC channels dedicated to measuring temperature. The temperature indications are for the internal die temperature of the LTC6803 and two externally connected thermistors. The display re-turns a voltage measurement.

The internal die temperature sensor produces a voltage that changes at a rate of 8mV/°C relative to absolute zero. To convert the voltage reading to degrees Cel-sius, divide the voltage by 8mV then subtract 273°C. For example, 25°C is a 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 10KΩ will produce a voltage reading of ~VREF/2 at 25°C. Other thermistor values may be used but scaling the voltage measurement may require changing the values of resistors R31 and R32 on the DC1654B cir-cuit board.

To take a temperature reading simple click the START TEMP command button to make the LTC6803 ADC conversion followed by clicking the READ TEMP command button to download the data from the board and display the voltage readings.

17B6: READ AN INDIVIDUAL CELL OR TEMPERATURE

18BEach cell and each temperature channel has a check box to allow individual measurements. Checking these “Only” boxes sends the command (STARTCELL VOLT then READCELL VOLT, START TEMP then READ TEMP) to read only that channel and display its status. Cell 8 and Internal Temp are shown in the example screen above. Older or stale readings for all other cells and temperatures are faded out.

DC1654B

8

19B8: DISCHARGE CELLS

Another major feature of the LTC6803 is the ability to remove charge from individual cells. This can help to distribute the cell charge evenly over a stack of batte-ries. DC1654B contains a P channel Mosfet in series with a 33Ω resistor 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 check box is provided for each cell to be discharged. Checking this box (Cell 3 in the above example screen shot) and then writing the new configuration with a WRITE CONFIG button push will load the cell.

IMPORTANT NOTE: The discharge transistors are au-tomatically turned off momentarily while the A/D con-verter is measuring the cell voltage using the normal STARTCELL VOLT command. This prevents any vol-tage drop errors caused by the discharge current flow-ing through the cell inter-connection wiring. An accu-rate indication of the true state of charge of the cells is then obtained.

The LTC6803 offers the option of keeping the dis-charge transistors on while measuring the cell voltag-es. This is done using the STARTCELL hold DCC command button. A blue indicator is illuminated when this command has been executed. This lower voltage reading also includes I*R errors introduced by cabling and connectors.

20BOTHER CONTROL FEATURES

Three additional command buttons are provided on the control screen. The POLL ADC and POLL INTERRUPT command buttons are used to test if the ADC is busy making conversion and to test if any of the LTC6803 devices in a system have an interrupt condition respec-tively. The result of these commands can be observed by monitoring the serial data output (SDO) line of the SPI interface at J2 (or J3 or J4 if a data isolator is used as described on pg. 10). There is no indication pro-vided on the control screen.

The START OPENWIRE command button connects the built in open wire detection circuitry to all cells. This command must be followed by READCELL VOLT command button click to see the result. An open wire connection to any cell will be indicated by an abnor-mally high voltage measurement for the cell above the open wire and a near 0V measurement for the cell with the open wire.

21BCONTINUOUS OPERATION

For convenience, the control panel allows for conti-nuous operation of the DC1654B 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 (~800ms update rate). While running, the configuration can be changed on the fly. Simply changing a configuration item (Dis-charge cells for example) and clicking the WRITE CONFIG button will implement the new configuration and return to continuous operation. 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.

DC1654B

9

22BDISPLAYING VALID DATA TRANSFERS ONLY

Each time data is transferred from the LTC6803 by the four READ commands (Cell Voltage, Configuration, Flag Status and Temperature), a Packet Error Code, PEC, is appended 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.

23BLOW 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 into its standby configuration. A command button in the lower right corner of the screen is provided to facilitate this function. Once pushed all data and configuration set-tings are reset and the screen goes white on all indica-tors.

24BSELF TEST & DIAGNOSTIC FUNCTIONS

The LTC6803 has built in self test and diagnostic func-tions. These commands apply a test signal 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 temperatures can also be seen by choosing which test code (0x555, 0xAAA, or 0xFFF) to expect to be returned from the device when a self test command is issued.

25BOTHER CONFIGURATION OPTIONS

The SET I/O MODE group of checkboxes can be used to adjust other features of the LTC6803. Configuring the general purpose I/O pins and setting the type of activity polling scheme can be selected then configured with a WRITE CONFIG button push.

EXTERNAL POWERING OPTION

The DC1654B includes circuitry that can power the LTC6803 separately from the monitored cells. A low-power isolated DC-DC conversion function accepts a 5.0V input and provides about 60V between V+ and V-. To enable this mode, the +POWER jumper JP1 must be set to the EXTernal setting. This disconnects V+ from the battery stack and allows the LTC6803 to completely power-down with removal of the external energy source, dropping battery drain to mere nA lea-kage levels for best long-term storage conditions. The external 5V supply will have to provide about 50mA in normal operation. When using the external power option, there is also a choice of configuration for the biasing point of V-. The –POWER jumper JP2 will tie the bottom cell potential (cell 0) to either V- (the STACK position) or to 5V above V- (the EXTernal position). The latter provides the needed common-mode headroom the ADC re-quires to support negative cell-voltage readings by forcing V- to be 5V below cell 0.

DC1654B

10

EXTERNAL CALIBRATION OPTION

The DC1654B provides a solder-pad footprint (U6) to accept the LTC6655 high-accuracy reference. The ref-erence is powered from the external DC-DC function through the local 5V regulator provided (which also creates the biasing for the –POWER EXT option). The reference voltage is digitized by the VTEMP1 ADC channel (instead of a thermistor signal) and may be used to provide corrective information on the battery readings. A 3.300V or 4.096V model is recommended. The reference is enabled by setting GPIO1 to “0” using a configuration command, or placing the GPIO1 jum-per JP5 to the GND position. DATA ISOLATION OPTION

The DC1654B provides a solder-pad footprint (U7) to accept an SPI data isolator. The side of the isolator connecting to the LTC6803 is powered from the exter-nal DC-DC function through the local 5V regulator pro-vided, while the host side is powered from the external 5V directly. The footprint is industry-standard and will accept several different isolator models. STACKING BOARDS TO ADD MORE BATTERY CELLS

When multiple DC1654B are equipped with optional data isolators, the circuits have the ability to communi-cate to the host along with up to 15 other DC1654B boards, monitoring up to 12 cells each. The control GUI however is limited to only 10 boards (120 cells maximum). To stack and control more than one board requires the following hardware and software modifica-tions: 27BMULTI-BOARD HARDWARE ADJUSTMENTS

1. Data isolator ICs must be installed on each DC1654B. Silicon Labs Si8441AB-D-IS is suitable. All boards will require the use of external 5V power applied at EXT+5V and EXT RTN (host GND). The external power can be shared amongst boards, as the host interfaces will all be at the same potential.

2. The bottom board on the stack, which connects to a system controller or to a DC590 Quick Eval link to a PC, must use the SPI BUS IN connector (J3)

as the primary interface. If not using DC590, a 5KΩ pull-up resistor must be connected from the SDO output line (connector J3, pin 5) to the 3V/5V logic power rail of the circuit driving the SPI port.

3. The final board on the top of the stack must have JP7 (TOS) set to ACTIVE. Connect JP7 (TOS) on all other boards to the GND position.

4. A ribbon cable must connect the SPI BUS OUT (J4) of a lower board to the SPI BUS IN (J3) of the next board up on the stack. The daisy chain link-ing with ribbon cables from the output port of a lower board on the stack to the input port of the next board above it establishes the data link bus for the entire stack.

28BCAUTION! 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!

DC1654B

11

30BSOFTWARE ADJUSTMENTS

The GUI program can control up to ten boards on a stack.

1. Select the number of boards on the stack from the pop up window located near the command buttons at the bottom of the screen.

2. A tab will appear on the left edge of the control panel for each board on the stack. Clicking on any of these tabs will transfer control commands and data to and from the display screen to that selected board. Each board must have a unique address nibble selected. The address nibble must match the settings of the address jumpers JP3-JP6 (in hexadecimal).

3. Select whether the Operating Configuration (CDC Comparator) and Over/Under voltage thresholds for each board are to be the same (GLOBAL) or dif-ferent for each board (CUSTOM) and set the duty cycle and voltages accordingly.

31BCOLOR 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 significance 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 LTC6803 is no longer report-ing this status. The cell voltage value measured for this cell however is still accurate.

The next page shows the schematic for DC1654B. Consult the data sheet for detailed information con-cerning the operation of the LTC6803-4.

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