DEMO MANUAL DC1894B
LTC6804-1
Precision Battery Monitoring System
DESCRIPTION
Demonstration circuit 1894B is a daisy-chainable isoSPI
battery-stack monitor featuring the LTC®6804-1. These
boards can be linked through a 2-wire isolated serial
interface to monitor any number of cells on a stack.
Communication to a PC uses a DC590 USB interface
board. A control program for up to ten stacked boards
has a Graphical User Interface (GUI) to implement the
device command set.
Multiple DC1894B can be daisy-chained using RJ45 terminated Ethernet patch cables.
Design files for this circuit board are available at
http://www.linear.com/demo/DC1894B
L, LT, LTC, LTM, Linear Technology and the Linear logo are registered trademarks and
QuikEval is a trademark of Linear Technology Corporation. All other trademarks are the property
of their respective owners.
HARDWARE SETUP
Separate the screw-terminal section from J1 and wire cell
voltage connections or resistors into the clamping contacts
to provide the input stimulus for the ADC.
Cell voltages are wired from position 4 (most negative
potential of the group) with increasing potentials up to
position 16 (most positive potential).
Alternatively, resistors can be used to simulate battery
cells. For this, connect twelve 100Ω leaded resistors between each contact from position 4 to position 16. Provide
a stack-equivalent power supply connection to position
16 (positive) and position 4 (return). The supply may be
adjusted to provide the desired nominal cell voltage (ex.
40V will be 3.33V/cell).
Figure 1 shows the following connections for two boards
on a stack interfaced to a PC:
1. Connect a USB cable from the PC USB port to DC590.
2. Connect a 14-pin ribbon from DC590 to the SPI BOTTOM connector (J2) on the bottom DC1894B board.
PC Running GUI
Control Program
Connectors for Cells
USB Cable to PC
DC590B
Ribbon
Bottom Board
Ethernet
Cable
Top Board
Figure 1. Connecting a Two Board Stack to a PC
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DEMO MANUAL DC1894B
HARDWARE SETUP
3. Connect an RJ45 cable from the bottom DC1894B
isoSPI B RJ45 connector (J4) to the next DC1894B
isoSPI A RJ45 connector (J3).
Additional boards can be connected in the same manner, using RJ45 terminated Ethernet patch cables.
4. Set the jumpers on each DC1894B as shown in Figure 2
and Table 1.
Table 1.
JUMPERS
0 POSITION
1 POSITION
JP4-Discharge Timer
Timer Disabled
Timer Enabled
BOTTOM BOARD
UPPER BOARDS
SPI 14-Pin
isoSPI RJ45
JP1-Chip Select
JP2-Clock
SPI 14-Pin
isoSPI RJ45
JP3-Isolated Mode
Normal SPI
2-Wire isoSPI
5. Mate the J1 cell-voltage connectors.
J4: Isolated SPI Connection to
a Higher Board on Stack
J1: Cell-Voltage
Connector
J3: Isolated SPI Connection to
a Lower Board on Stack
Cells
(12 Max)
J2: 14-Pin SPI
Ribbon Connector
Figure 2. Connections and Jumpers
SOFTWARE SETUP
QUIKEVAL DRIVER
To use the DC590B USB Interface board, the PC must
first have the proper driver installed. To do this, download the QuikEval™ software from Linear Technology, at
www.linear.com:
http://www.linear.com/designtools/software/quick_eval.jsp
1) Install the QuikEval software by running the executable
ltcqev.exe. Follow the instructions to connect DC590B.
NOTE: You will be instructed to ensure that the DC590B
is not connected to the PC:
If you fail to unplug the DC590B, the DC590B driver
FTD2XX.DLL will not install!
2) When installation of QuikEval is complete, close the
QuikEval program.
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DEMO MANUAL DC1894B
SOFTWARE SETUP
3) Reopen QuikEval, and then connect the DC590B to
confirm that QuikEval software was installed correctly.
If properly installed, QuikEval will show the following
message:
If not properly installed, QuikEval will be unable to connect to the DC590B. Please retry the software installation,
with the DC590B disconnected.
4) Connect the LTC6804 Demoboard to the DC590B with
QuikEval software open.
5) The QuikEval software will recognize when the LTC6804
demo board has been found, and will offer to download
and install the module from the LTC website:
6) The QuikEval software will open and indicate that the
LTC6804 device has been found. It will also indicate
that there is no module for this device. This is normal
and indicates that QuikEval does not directly control
the LTC6804 demo boards:
7) Close QuikEval Software, as it is no longer needed for
this demosystem.
LTC6804 Graphic User Interface
The LTC6804 Graphic User Interface (GUI) is provided in
a zipped file, LTC6804_GUI_Vxx_yyyymmdd.zip.
1) Unzip this folder
2) Run the setup.exe file to start installation
3) Ignore the security warning by selecting Install.
At this point, select cancel (Remember, QuikEval will
not be used to communicate with the LTC6804 demo
board). If you select OK, instead of cancel, QuikEval
will report that the module is not available on the LTC
website.
4) The GUI control panel appears immediately after installation. Subsequent starts of the GUI are done through the
Windows Start menu or the optional Windows Desktop
shortcut icon.
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DEMO MANUAL DC1894B
SOFTWARE SETUP
Figure 3. GUI Control Panel Start-Up Screen
OPERATING THE CONTROL SCREEN
FIRST
Figure 3 shows the GUI initial start-up screen. 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: READ CONFIGURATION
Click the command button labeled READ CONFIG. If all
is properly connected and operating, the start-up default
configuration of the LTC6804-1 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
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DEMO MANUAL DC1894B
OPERATING THE CONTROL SCREEN
boxes labeled CONFIGURATION READ FROM LTC6804-1.
The initial configuration bytes should be 0xD9 for register
0 and 0x00 for the other five bytes. This default configuration is the sleep mode for the LTC6804-1 on DC1894B.
The LTC6804 calculates a 15-bit Packet Error Code, PEC15,
as a 16-bit word and appends it to the data stream each
time it sends out data. The LTC6804 responds to the READ
CONFIG command by sending six bytes. For the six bytes
sent by a READ CONFIG command and received by the
GUI, the control program also calculates a PEC15. The
received PEC15 word and the calculated PEC15 word are
displayed in the top section labeled PACKET ERROR CODE
15-BIT. The oval located at the top of the color coded status
panel for the one board will turn green if the received and
calculated PEC15 words match. Data transmission errors
will produce red warning indications when the PEC15 words
do not match. There is also a display of the PEC15 that
was sent with the most recent command to the LTC6804,
which had to match an internally calculated value to be
accepted as a valid command.
NOTE: To get started, it is recommend to set REFUP to 1,
followed by a WRITE CONFIG command. The Watchdog
Timer (WDT) will now be continually serviced with the POLL
ADC command and the stack is ready to be monitored.
Leaving REFUP at the default setting of 0, the WDT times
out in 2 seconds and all configuration information is reset.
3: PROGRAM THE CELL MONITORING VOLTAGE
THRESHOLDS
2: WRITE CONFIGURATION
The GUI allows the user to configure the LTC6804, such as
the undervoltage and overvoltage levels, and the operating
state. However, setting the configuration within the GUI
does not change anything within the LTC6804 until the
Write Configuration command is executed. Clicking the
WRITE CONFIG command button sends the configuration
to the LTC6804. When the command is sent, the six Hex
bytes shown in the box labeled CONFIGURATION WRITTEN
TO LTC6804 will become bold type. This box provides the
exact hex values required by the LTC6804 and can be used
to facilitate control program development.
Clicking the READ CONFIG button can see confirmation
that the configuration change was actually made. The six
bytes read back should match the six bytes sent and the
PEC15 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 illuminated. This serves as a reminder that this command
still needs to be executed.
In the section labeled SET VOLTAGE LIMITS the user can
enter voltage values for the overvoltage and undervoltage
thresholds. The voltage value entered will be rounded to
the actual value used by the LTC6804 and displayed in
the box. The voltage ranges for these thresholds is 0V
to 6.5520V.
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.
4: READ CELL VOLTAGES
The essential function of the LTC6804 is to measure and
report the voltage on each battery cell. This is accomplished
in two steps. First, click on the STARTCELL button. This
commands an A/D conversion of all 12-cell voltages in the
bit-resolution configured from the selected CONV MODE
(Conversion Mode) in the ADC SETTINGS box. The actual
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DEMO MANUAL DC1894B
OPERATING THE CONTROL SCREEN
cell voltage measurements are displayed in groups of 3
when each command button inside the READ CELLS box
is clicked.
Another major feature of the LTC6804 is the ability to remove charge from individual cells. This can help to ensure
even charge distribution over a stack of batteries. Across
each cell connection, the DC1894B contains a P-channel
MOSFET in series with a 33Ω resistor. When enabled,
charge is pulled from the cell and energy is 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 screenshot)
and then writing this new configuration (with the WRITE
CONFIG button) the cell will begin discharging.
NOTE: Before initiating cell measurements, the user can
set the bit-resolution by selecting the desired mode within
the box ADC SETTINGS CONV MODE.
The READ DISPLAY box has options to display Cell Voltages in VOLTS or HEX. First select VOLTS or HEX then click
on one of the command buttons inside READ CELLS box.
Every time a command button inside the READ CELLS box
is clicked; new data is downloaded from the board and
displayed as selected in VOLTS or HEX.
5: DISCHARGE CELLS
NOTE: The discharge transistors are automatically turned
off momentarily when measuring cell voltages via the
STARTCELL command. This prevents voltage drop errors
caused by the discharge current and ensures that the true
cell voltage is obtained. The LTC6804 offers the option of
keeping the discharge transistors on while measuring cell
voltages, using the STARTCELL DCC command button.
This command button is illuminated blue when executed.
In this mode, the lower voltage reading includes I*R errors introduced by cabling and connectors, as well as the
load on the cell.
OTHER CONTROL FEATURES
Additional command buttons are provided on the control
screen. The POLL ADC command button is used to determine if the ADC is busy (in the process of converting).
The result of this command can be observed by monitoring the serial data output line of the SPI interface to the
Bottom Port, J2. There is no indication provided on the
control screen.
The START OPEN (WIRE) command button connects the
built in open wire detection circuitry to all cells. This command must be followed by any command buttons inside
the READ CELLS box click to see the result. The OPEN
ISOURCE box provides options to use either PULLUP or
PULLDOWN Open Wire Test Currents. An open wire connection to any cell will be indicated by an abnormally high
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DEMO MANUAL DC1894B
OPERATING THE CONTROL SCREEN
voltage measurement for the cell above the open wire and
a near 0V measurement for the cell with the open wire.
CONTINUOUS OPERATION
All values are updated continually (update rate is ~500ms
in FAST or NORMAL and ~750ms in FILTERED Conversion
Mode). While running, the configuration can be changed on
the fly. Simply changing a configuration item (Discharge
cells for example) and clicking the WRITE CONFIG button will implement the new configuration and return to
continuous operation.
A green box with the label ON in the lower right corner
of the GUI indicates that the system is running continuously. A red box with the label OFF means that the system
is stopped and waiting for a new command to be sent.
DATALOGGING OPERATION
For convenience, the control panel allows for continuous
operation of the DC1894B board. Using the command
button labeled START CONTINUOUS READ CELLS the
board control is placed in a continuous loop executing
the following command sequence automatically:
The GUI program can datalog or store cell voltage results
in a CSV (Comma Separated Value *.csv) file. This feature
is useful for characterizing cell voltages over time. Datalogging operates similarly to continuous operation but has
the added functionality of storing results in a CSV file.
1. At the upper left of the GUI, click on the Datalog Menu,
then Enable Datalog.
Start cell voltage
Read cell voltage groups A (1-3) , B (4-6), C (7-9), and
D (10-12)
Options available are the READ DISPLAY box, ADC
SETTINGS box, OPEN ISOURCE box, and the CONTINUOUS box. The CONTINUOUS box allows the selection of
STARTCELL, STARTOPEN, STARTCELL DCC, and STARTOPEN DCC commands to be executed during continuous
operation. This is useful for monitoring the cell voltage
measurements under different ADC Test Conditions.
Datalog mode is enabled when a maroon box appears to
the left of the START CONTINUOUS READ CELLS command button and the red box label changes from OFF to
DATALOG OFF. Datalog mode is disabled when the maroon
box disappears and the red box label reverts to OFF.
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DEMO MANUAL DC1894B
OPERATING THE CONTROL SCREEN
NOTE: The *.csv filenames are based on the time created
and are stored by default into the C:\Datalog6804\ folder.
More details about datalogging are in the file AboutCurrentVersion.txt inside the GUI’s installation folder (normally
C:\Program Files\LTC\MultiCellBatteryMonitor\LTC6804).
5. View the CSV file in a compatible spreadsheet software
program such as MS Excel.
2. Click on the START CONTINUOUS READ CELLS command button to start datalogging onto a new CSV file.
Elapsed Time = Total time of Datalog from start to finish.
Total Data Points = Total data points of Datalog from
start to finish.
Refresh = Time in seconds (s) between each Read Cells
command; also known as Sample or Update Rate.
3. Click on the STOP CONTINUOUS READ CELLS command
button to stop datalogging and close the CSV file.
4. The CSV file is ready to view. Go to C:\Datalog6804\
folder and open file.
SOFTWARE ADJUSTMENTS
The GUI program can control up to ten boards on a stack.
1. Select the number of boards on the stack by sliding the
track bar up or down; this slider is located on the far
left side of GUI.
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.
3. Select whether the ADC’s voltage reference powered
state (ref up) and over/undervoltage thresholds for
each board are to be the same (GLOBAL) or different for
each board (CUSTOM) and set the Ref Up and voltages
accordingly.
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 significance of
the colors used is explained in the legend on the screen.
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DEMO MANUAL DC1894B
OPERATING THE CONTROL SCREEN
COMMANDS SUPPORTED (V03 VERSION)
POLLADC
WRITE CONFIG (REFUP, VUV, VOV, Discharge
selected cells)
READ CONFIG
START CELL and OPEN WIRE conversions with and without
discharge connected (ADC Settings: Conversion Mode,
Open Wire Test Current (Open Isource))
READ CELL GROUPS (A, B, C and D. Read Volts/Hex)
START CONTINUOUS read all cells every 500ms.
COMMANDS NOT SUPPORTED (V03 VERSION)
SELFTEST
For the latest software, contact your local LTC sales office.
READ FLAGS
GPIO FUNCTIONS
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DEMO MANUAL DC1894B
PARTS LIST
ITEM
QTY
REFERENCE
PART DESCRIPTION
MANUFACTURER/PART NUMBER
Required Circuit Components
1
0
C1, C2, C3, C4, C5, C6, C7, C8, C9, C10, C11, CAP., 0805, OPT
C12, C14, C15
2
2
C13, C23
CAP, 0805 100nF 10% 100V X7R
3
0
C16, C18, R65, R66
CAP., 1206, OPT
MURATA, GCM21BR72A104KA37
4
4
C17, C20, C21, C22
CAP, 0603 1µF 10% 16V X7R
MURATA, GCM188R71C105KA64D
5
1
C19
CAP, 0603 100nF 10% 25V X7R
MURATA, GCM188R71E104KA57D
6
13
C24, C25, C26, C27, C28, C29, C30, C31,
C32, C33, C34, C35, C36
CAP, 0603 10nF 10% 25V X7R
MURATA, GRM188R71E103KA01
7
1
D2
DIODE, SHOTTKY
DIODES INC., BAT46W-7-F
8
9
E1-E8, E10
TURRET
MILL MAX, 2308-2-00-80-00-00-07-0
9
4
JP1, JP2, JP3, JP4
HEADER, 3-PIN, 2mm
SAMTEC, TMM-103-02-L-S
10
4
XJP8, XJP9, XJP10, XJP11
SHUNT
SAMTEC, 2SN-BK-G
11
1
J1
HEADER, 1X16 3.5mm, HORIZ.
WEIDMULLER, 1761682001
12
1
J2
HEADER, 2X7 2mm
MOLEX, 87831-1420
CONNECTOR RJ45, CACE CODE 00779
13
2
J3, J4
14
12
LED1, LED2, LED3, LED4, LED5, LED6, LED7, LED, 0603 GREEN
LED8, LED9, LED10, LED11, LED12
LITE-ON, LTST-C190KGKT
TE CONNECTIVITY, 5406298-1-ND
15
1
P1
CONN. MATING 1X16 3.5mm HORZ
WEIDMULLER, 1615770000
16
12
Q1, Q2, Q3, Q4, Q5, Q6, Q7, Q8, Q9, Q10,
Q11, Q12
XSTR, MOSFET, P-CHANNEL
INFINEON, BSS308PE
17
1
Q13
XSTR, NPN, SOT223
CENTRAL SEMI., CZT5551
18
15
R1, R2, R3, R4, R5, R6, R7, R8, R9, R10,
R11, R12, R49, R56, R64
RES., CHIP, 100Ω 1% 0603
VISHAY, CRCW0603100RFKEA
19
12
R13, R14, R15, R16, R17, R18, R19, R20,
R21, R22, R23, R24
RES., CHIP, 3.3k, 5% 0603
VISHAY, CRCW06033K30JNEA
20
12
R25, R26, R27, R28, R29, R30, R31, R32,
R33, R34, R35, R36
RES., CHIP, 475Ω, 1% 0603
VISHAY, CRCW0603475RFKEA
21
12
R37, R38, R39, R40, R41, R42, R43, R44,
R45, R46, R47, R48
RES., CHIP, 33Ω, 1% 2512
VISHAY, CRCW251233R0FKEG
22
2
R50, R51
RES., CHIP, 110Ω 1% 0603
VISHAY, CRCW0603110RFKEA
23
2
R52, R53
RES., CHIP, 1k, 1% 0603
VISHAY, CRCW06031K00FKEA
24
5
R54, R55, R62, R71, R72
RES., CHIP, 1M, 1% 0603
VISHAY, CRCW06031M00FKEA
25
2
R57, R58
RES., CHIP, 4.99Ω, 1% 0603
VISHAY, CRCW06034R99FKEA
VISHAY, CRCW06030000Z0EA
26
1
R61
RES., CHIP, 0Ω, 1% 0603
27
2
R63, R73
RES., CHIP, 0603 OPT
28
1
R67
RES., CHIP, 10k, 1% 0603
VISHAY, CRCW060310K0FKEA
29
1
R68
RES, 0603 10k, NTC, 1% 1/10W
MURATA, NCP18XH103F03RB
30
2
R69, R70
RES., CHIP, 22k, 1% 0603
VISHAY, CRCW060322K0FKEA
31
1
T1
TRANS., TG110-AE050N5
HALO ELECTRONIC, TG110-AE050N5
32
1
U1
IC, BATTERY MONITOR, SSOP-48, 5.3mm
LINEAR TECH., LTC6804IG-1
33
1
U2
IC, 24AA01, SOT23-5, MARKING CODE B1
MICROCHIP TECH., 24AA01
34
1
U3
IC, 24LC025-I/ST
MICROCHIP TECH., 24LC025-I/ST
35
1
MH1, MH2, MH3, MH4
STANDOFF, SNAP ON
KEYSTONE_8831
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A
B
C
5
4
1%
4
3
2
2
3
1
TECHNOLOGY
1
Information furnished by Linear Technology Corporation is believed to be accurate and reliable.
However, no responsibility is assumed for its use. Linear Technology Corporation makes no representation that the interconnection of its circuits as described herein will not infringe on existing patent rights.
D
5
A
B
C
D
DEMO MANUAL DC1894B
SCHEMATIC DIAGRAM
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DEMO MANUAL DC1894B
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. As such, the DEMO BOARD herein may not be complete
in terms of required design-, marketing-, and/or manufacturing-related protective considerations, including but not limited to product safety
measures typically found in finished commercial goods. As a prototype, this product does not fall within the scope of the European Union
directive on electromagnetic compatibility and therefore may or may not meet the technical requirements of the directive, or other regulations.
If this evaluation kit does not meet the specifications recited in the DEMO BOARD manual the kit may be returned within 30 days from the date
of delivery for a full refund. THE FOREGOING WARRANTY IS THE EXCLUSIVE WARRANTY MADE BY THE SELLER TO BUYER AND IS IN LIEU
OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED, OR STATUTORY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS
FOR ANY PARTICULAR PURPOSE. EXCEPT TO THE EXTENT OF THIS INDEMNITY, NEITHER PARTY SHALL BE LIABLE TO THE OTHER FOR
ANY INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES.
The user assumes all responsibility and liability for proper and safe handling of the goods. Further, the user releases LTC from all claims
arising from the handling or use of the goods. Due to the open construction of the product, it is the user’s responsibility to take any and all
appropriate precautions with regard to electrostatic discharge. Also be aware that the products herein may not be regulatory compliant or
agency certified (FCC, UL, CE, etc.).
No License is granted under any patent right or other intellectual property whatsoever. LTC assumes no liability for applications assistance,
customer product design, software performance, or infringement of patents or any other intellectual property rights of any kind.
LTC currently services a variety of customers for products around the world, and therefore this transaction is not exclusive.
Please read the DEMO BOARD manual prior to handling the product. Persons handling this product must have electronics training and
observe good laboratory practice standards. Common sense is encouraged.
This notice contains important safety information about temperatures and voltages. For further safety concerns, please contact a LTC application
engineer.
Mailing Address:
Linear Technology
1630 McCarthy Blvd.
Milpitas, CA 95035
Copyright © 2004, Linear Technology Corporation
dc1894bfa
12 Linear Technology Corporation
LT 1014 REV A • PRINTED IN USA
1630 McCarthy Blvd., Milpitas, CA 95035-7417
(408) 432-1900
●
FAX: (408) 434-0507 ● www.linear.com
LINEAR TECHNOLOGY CORPORATION 2013