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dc2064af

DEMO MANUAL DC2064A

DESCRIPTION

LTC3300-1/LTC6803-2

Bidirectional Cell Balancer

Demonstration Circuit DC2064A is a bidirectional cell

balancer using two LTC

3300-1 ICs to achieve active cell

balancing of up to 12 Li-Ion batteries. The board uses the

LTC6803-2 multi-cell addressable battery stack monitor to

measure cell voltages and two LTC3300-1 ICs to provide

active cell balancing. The demonstration circuit uses a two

window GUI developed for the

DC2064A. One window is

a modified version of the GUI for the LTC6803

-2 and also

contains a tab to control the LTC3300-1 ICs through the

DC590B USB Serial controller and the second window

L, LT, LTC, LTM, Linear Technology and the Linear logo are registered trademarks of Linear

Technology Corporation. All other trademarks are the property of their respective owners.

PERFORMANCE SUMMARY

BOARD PHOTO

reports the status of the LTC3300-1 devices. All the

functions of the LTC6803-2 GUI are supported except

that cell balancing is achieved through the LTC3300-1

ICs by transferring charge from one to six batteries per

LTC3300-1 to the stack or from the stack to one to six

batteries per LTC3300-1.

Design files for this circuit board are available at

http://www.linear.com

/demo

Specifications are at T

= 25°C

Battery Voltage Range 3.2V to 4.5V (2.5V to 4.5V)*

Stack Voltage 60V Max

Average Battery Balancing Charge Current (12 Cell) 2.6A (Typ) (4A)*

Average Battery Balancing Discharge Current (12 Cell) 2.4A (Typ) (3.6A)*

Average Battery Balancing Charge Current (6 Cell) 2.2A (Typ) (3.3A)*

Average Battery Balancing Discharge Current (6 Cell) 2.4A (Typ) (3.6A)*

Balancing Efficiency 92% (Typ)

*The battery voltage range may be expanded to 2.5V-4.5V by changing resistor

TONS

to 19.1k and resistor R

TONP

to 29.4k.

The demo board’s average balancing current is adjustable up to 4A by scaling and installing new values of RS1A and RS1B through RS12A and RS12B.

Summary of content (36 pages)

PAGE 1
DEMO MANUAL DC2064A LTC3300-1/LTC6803-2 Bidirectional Cell Balancer DESCRIPTION Demonstration Circuit DC2064A is a bidirectional cell balancer using two LTC®3300-1 ICs to achieve active cell balancing of up to 12 Li-Ion batteries. The board uses the LTC6803-2 multi-cell addressable battery stack monitor to measure cell voltages and two LTC3300-1 ICs to provide active cell balancing. The demonstration circuit uses a two window GUI developed for the DC2064A.
PAGE 2
DEMO MANUAL DC2064A DESCRIPTION Power Stage Discharge Efficiency Power Stage Charge Efficiency 100 100 95 95 EFFICIENCY (%) EFFICIENCY (%) 6-CELL 12-CELL 90 85 80 75 6-CELL 12-CELL 90 85 80 2.6 2.8 3.0 3.2 3.4 3.6 CELL VOLTAGE (V) 3.8 4.0 75 2.6 2.8 3.0 3.2 3.4 3.6 CELL VOLTAGE (V) 3.8 4.0 Figure 1. DC2064A Size 5.5" × 12.
PAGE 3
DEMO MANUAL DC2064A OPERATING PRINCIPLE Operation of the LTC6803-2 is detailed in the LTC6803-2 data sheet and the operation of the DC2064A GUI is similar to the DC1652A GUI except additional functionality was added to control the LTC3300-1 balancing devices. Refer to the Quick Start Guide for the DC1652B for operation of the LTC6803-2 GUI.
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DEMO MANUAL DC2064A QUICK START PROCEDURE The Voltage Comparator box must be turned off and the VREF must remain on during balancing. Set window by using the Up/Down arrows to the right of the box. See Figure 3. Click the START CELL VOLT button followed by the READ CELL VOLT to verify that the batteries are connected and that the LTC6803-2 can read the battery voltages. Figure 3. Voltage Comparator Box The DC2064A GUI periodically checks for OV and UV measured on the cells when balancing.
PAGE 5
DEMO MANUAL DC2064A QUICK START PROCEDURE To do this, select the DISCHARGE or CHARGE button for the desired cell, then enter the time in seconds into the cells “BALANCE TIME” text box. Press the enter key on the key board or select another button in the GUI to load the time. When all the desired balance actions and times have been entered, select the “Balance Cells” START button to start the balancing sequence. Figure 9.
PAGE 6
DEMO MANUAL DC2064A QUICK START PROCEDURE Cell Balancer Efficiency Measurements: Cells 7-12 Figure 28 shows the proper connections for measuring the efficiency of a cell balancer. The secondary of the cell balancer connects to the top of stack. This connection needs to be to an isolated power source through a current sensing resistor (0.10Ω).
PAGE 7
DEMO MANUAL DC2064A QUICK START PROCEDURE 12 Cell Discharge 6 Cell Discharge Table 2. Typical 12 Cell Discharge Data Table 4. Typical 6 Cell Discharge Data Cell I (A) Stack I (A) Frequency (kHz) Efficiency Cell I (A) Stack I (A) Frequency (kHz) Efficiency 2.444 0.188 127.7 92.21% 2.448 0.277 126.1 92.33% Figure 12. 12 Cell Discharge Waveforms Figure 14. 6 Cell Discharge Waveforms 12 Cell Charge 6 Cell Charge Table 3. Typical 12 Cell Charge Data Table 5.
PAGE 8
DEMO MANUAL DC2064A 4.0 4.0 3.5 3.5 CELL CHARGE CURRENT (A) CELL DISCHARGE CURRENT (A) QUICK START PROCEDURE 3.0 12-CELL 2.5 6-CELL 2.0 1.5 1.0 2.6 2.8 3.6 3.0 3.2 3.4 CELL VOLTAGE (V) 3.8 3.0 12-CELL 2.5 6-CELL 2.0 1.5 1.0 2.6 4.0 0.50 0.50 0.45 0.45 0.40 6-CELL 0.35 0.30 0.25 12-CELL 0.20 0.15 0.10 2.6 3.6 3.0 3.2 3.4 CELL VOLTAGE (V) 3.8 4.0 Figure 18. Cell Charge Current STACK CHARGE CURRENT (A) STACK DISCHARGE CURRENT (A) Figure 16. Cell Discharge Current 2.8 6-CELL 0.
PAGE 9
DEMO MANUAL DC2064A QUICK START PROCEDURE Two Board Setup and Operation: As a result of communication latency to the PC, the system only supports two series DC2064A boards When connecting two DC2064A boards together, the interface cables must be connected in sequence as shown in Figure 20 to avoid large inrush currents. The DC590B DC2064A must be connected to the PC USB port and the bottom DC2064A board first and then the top DC2064A board may be connected.
PAGE 10
DEMO MANUAL DC2064A QUICK START PROCEDURE Figure 21.
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DEMO MANUAL DC2064A QUICK START PROCEDURE On the LTC6803-2 tab on the DC2064A GUI, the Number of Boards in the System drop down box will need to be changed to 2. Make sure the address for each board in the Hex Address box matches the address set by the A0 to A3 jumpers on the respective DC2064A board. The board selection buttons on the bottom left side of the GUI highlight which board is selected in maroon, as shown and the set hexadecimal address is displayed under each board.
PAGE 12
DEMO MANUAL DC2064A QUICK START PROCEDURE Cell Bypass Capacitors The DC2064 contains bypass capacitors between the cell connections and the stack connections. These capacitors are intended to smooth the high current triangular wave before they travel down the interconnection wires to the cells within the stack and the secondary stack connections. The RMS current rating of these capacitors is a critical parameter as well as their capacitance with applied voltage and their physical size.
PAGE 13
DEMO MANUAL DC2064A QUICK START PROCEDURE Figure 25. DC2064A LTC3300-1 Setup Screen with Timed Balance Controls Figure 26.
PAGE 14
DEMO MANUAL DC2064A QUICK START PROCEDURE System Setup Requirements: LFP or Li-Ion Battery ≥ 10AHr Internal Resistance < 30mΩ Recommended Battery Simulator: Power Supply 2V to 5.0 V ±10A Interconnect Resistance < 25mΩ Figure 27. Proper Measurement Equipment Setup for Bidirectional Cell Balancer Note: All connections from equipment should be Kelvin connected directly to the Board Pins which they are connected to on this diagram and any input, or output, leads should be twisted pair, where possible.
PAGE 15
DEMO MANUAL DC2064A QUICK START PROCEDURE System Setup Requirements: LFP or Li-Ion Battery ≥ 10AHr Internal Resistance < 30mΩ Recommended Battery Simulator: Power Supply 2V to 5.0 V ±10A Interconnect Resistance < 25mΩ Figure 28.
PAGE 16
DEMO MANUAL DC2064A QUICK START PROCEDURE System Setup Requirements: LFP or Li-Ion Battery ≥ 10AHr Internal Resistance < 30mΩ Recommended Battery Simulator: Power Supply 2V to 5.0 V ±10A Interconnect Resistance < 25mΩ Figure 29.
PAGE 17
DEMO MANUAL DC2064A QUICK START PROCEDURE System Setup Requirements: LFP or Li-Ion Battery ≥ 10AHr Internal Resistance < 30mΩ Recommended Battery Simulator: Power Supply 2V to 5.0 V ±10A Interconnect Resistance < 25mΩ Figure 30.
PAGE 18
DEMO MANUAL DC2064A QUICK START PROCEDURE System Setup Requirements: LFP or Li-Ion Battery ≥ 10AHr Internal Resistance < 30mΩ Recommended Battery Simulator: Power Supply 2V to 5.0 V ±10A Interconnect Resistance < 25mΩ Figure 31.
PAGE 19
DEMO MANUAL DC2064A QUICK START PROCEDURE System Setup Requirements: LFP or Li-Ion Battery ≥ 10AHr Internal Resistance < 30mΩ Recommended Battery Simulator: Power Supply 2V to 5.0 V ±10A Interconnect Resistance < 25mΩ Figure 32.
PAGE 20
DEMO MANUAL DC2064A QUICK START PROCEDURE System Setup Requirements: LFP or Li-Ion Battery ≥ 10AHr Internal Resistance < 30mΩ Recommended Battery Simulator: Power Supply 2V to 5.0 V ±10A Interconnect Resistance < 25mΩ Figure 33.
PAGE 21
DEMO MANUAL DC2064A QUICK START PROCEDURE System Setup Requirements: LFP or Li-Ion Battery ≥ 10AHr Internal Resistance < 30mΩ Recommended Battery Simulator: Power Supply 2V to 5.0 V ±10A Interconnect Resistance < 25mΩ Figure 34.
PAGE 22
DEMO MANUAL DC2064A QUICK START PROCEDURE System Setup Requirements: LFP or Li-Ion Battery ≥ 10AHr Internal Resistance < 30mΩ Recommended Battery Simulator: Power Supply 2V to 5.0 V ±10A Interconnect Resistance < 25mΩ Figure 35.
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A C1 C2 C1 C1 C2 C2 C3 1210 6.3V 1210 6.3V 1210 6.3V 1210 6.3V I1P C1G 2.2nF OPT D1C G1P C1B 100uF C1A 100uF D1F SBR10U200P5 20 4 3 4 20 R1C 4 5.1 Q1A SiR882DP 20 1206 4 3 T2 4 5 6 7 OPT D3B DFLS1100 9 10 1 2 T1 4 5 6 7 OPT D2B DFLS1100 V- WURTH-750312504 OPT OPT D1A D1B DFLS260 DFLS1100 470pF 100V 0603 C1E RS1A 0.008 20 1206 R1A 4 5 6 7 WURTH-750312504 9 10 1 2 OPT D2A DFLS260 100V 0603 RS2A 0.
PAGE 24
A C7 C8 C7 C7 C8 C8 C9 1210 6.3V 1210 6.3V 4 4 3 20 4 20 4 5.1 Q7A SiR882DP CMOSH-4E R7G 3 R7C 1210 6.3V OPT C7C 100uF 4 CMOSH-4E R8G 3 Q8A 5.1 SiR882DP R8C 1210 6.3V OPT C8C 100uF PLACE RC CLOSE TO LTC3300 I7P C7G 2.2nF OPT D7C G7P C7B 100uF C7A 100uF D7F SBR10U200P5 20 PLACE RC CLOSE TO LTC3300 I8P C8G 2.2nF OPT D8C 1210 6.3V 1210 6.3V G8P C8B 100uF C8A 100uF SBR10U200P5 D8F 4 5.1 Q9A SiR882DP CMOSH-4E R9G R9C 1210 6.3V PLACE RC CLOSE TO LTC3300 I9P C9G 2.
PAGE 25
16V 0603 C20 A 1.0uF I5S G4S 0 R2 U1 I1S G1S V- 12 11 10 9 8 7 6 5 4 3 2 1 49 V- R7 15.4k LTC3300ILXE-1 I2S 1 VREG1 WDTA G6S I6S G5S G2S I3S G3S I4S C1 4.7uF 16V 1210 WDTA E19 BSS123W Q13 D23 CMOSH-4E CMPT3906E Q15 I1S G1S I2S G2S I3S G3S I4S G4S I5S G5S I6S G6S GND OPT R3 0 1 1 R1 1M 0805 R14 845k D21 CMHZ4689 R8 20.5k 45 2 2 3 2 1 3 2 1 2 SDO SDII 39 I1P V- SCKI CSBI C2 0.1uF 10V 0402 BOT6_TS C6 D25 PDZ5.
PAGE 26
A C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 100 0603 R1K 100 0603 R2K 100 0603 R3K 100 0603 R4K 100 0603 R5K 100 0603 R6K 100 0603 R7K 100 0603 R8K 100 0603 R9K 100 0603 R10K 100 0603 R11K 100 0603 R12K V- V- V- V- V- V- V- V- V- V- V- V- V- V- C12_FILTER C11_FILTER C11L 0.1uF 100V 1206 C10_FILTER C10L 0.1uF 100V 1206 C9_FILTER C9L 0.1uF 100V 1206 C8_FILTER C12L 0.1uF 100V 1206 1 2 1 2 1 2 1 C8L 0.
PAGE 27
A D12 BAT46W C12_CLAMPED C2_FILTER C3_FILTER C4_FILTER C5_FILTER C6_FILTER C7_FILTER C8_FILTER C9_FILTER C10_FILTER C11_FILTER SDI SCKI A3 A2 A1 S12 C11 S11 C10 S10 GPI01 GPI02 VREF VREG TOS NC WDTB C2 S3 C3 S4 C4 V- V- 44 43 D14 100 R26 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 CMHZ5265B S2 C1 S1 V- NC S5 VTEMP1 C5 VTEMP2 S6 C6 S7 C7 S8 C8 S9 A0 SDO C12 C9 CSBI V+ D13 BAT46W 22 21 20 19 18 17 16 15
PAGE 28
DEMO MANUAL DC2064A PCB LAYOUT Figure 41.
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DEMO MANUAL DC2064A PCB LAYOUT Figure 42.
PAGE 30
DEMO MANUAL DC2064A PCB LAYOUT Figure 43.
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DEMO MANUAL DC2064A PCB LAYOUT Figure 44.
PAGE 32
DEMO MANUAL DC2064A PCB LAYOUT Figure 45.
PAGE 33
DEMO MANUAL DC2064A PCB LAYOUT Figure 46.
PAGE 34
DEMO MANUAL DC2064A PARTS LIST ITEM QTY REFERENCE Required Circuit Components 1 24 C1A-C12A, C1B-C12B 2 12 C1G-C12G 3 12 C1H-C12H 4 12 C1R-C12R 5 14 C1K-C12K, C20,C21 6 4 C2, C4, C8, C14 7 1 C7 8 3 C11, C12, C15 9 2 C18, C19 10 2 D23, D24 11 4 D1, D5, D19.
PAGE 35
DEMO MANUAL DC2064A PARTS LIST ITEM QTY REFERENCE Components and Hardware for Demo Board Only 1 12 C1E-C12E 2 12 C1, C3, C22-C31 3 13 C1L-C12L, C6 4 2 C5, C13 5 12 D1D-D12D 6 15 F1-F15 7 1 L1 8 12 R1A-R12A 9 12 R1K-R12K 10 4 R22-R25 11 8 R43-R50 12 12 R1J-R12J 13 18 E1-E18 14 5 E19-E23 15 2 J17,J18 16 1 J1 17 1 J1 (MATE) 18 3 J1 (MATE CONTACT) 19 4 JP1-JP4 20 4 JP1-JP4 21 1 U6 22 1 U7 23 5 MH1-MH5 Optional Components 1 0 C1C-C12C 2 0 C1F(OPT)-C12F(OPT) 3 0 C1S-C12S, C1T-C12T 4 0 C5, C13 5 0 C9(OPT), C10(OPT
PAGE 36
DEMO MANUAL DC2064A DEMONSTRATION BOARD IMPORTANT NOTICE Linear Technology Corporation (LTC) provides the enclosed product(s) under the following AS IS conditions: This demonstration board (DEMO BOARD) kit being sold or provided by Linear Technology is intended for use for ENGINEERING DEVELOPMENT OR EVALUATION PURPOSES ONLY and is not provided by LTC for commercial use.