Atmel ATmega32HVB, ATA6870 User Manual

APPLICATION NOTE
User Guide for Atmel ATA6870 and Atmel ATmega32HVB
Evaluation Kit Hardware
ATA6870-DK10

Features

Evaluation of Atmel
Monitoring of 12 battery cells
Monitoring:
Overvoltage (every cell)
Overheating
Overcurrent
Open clamp detection
12-bit battery cell measurement
12-bit temperature measurement
Controlling of charge/discharge FETs
Status LEDs for easy evaluation
Charge balancing
Coulomb counting for SOC determination
Figure 1. Atmel ATA6870-DK10
®
ATA6870
9228C-AUTO-02/15

1. Introduction

ATA6 870
Cell 12
Cell 11
ATA6 870
Monitoring (V,T)
Coulomb counting
ATmega32HVB
Charge/
Discharge
Control Unit
Cell 02
Cell 01
The Atmel® ATA6870-DK10 is a demonstration board for the Atmel ATA6870, which offers an easy way to start evaluation of battery applications using the Atmel ATmega32HVB in combination with the Atmel ATA6870. The included software demonstrates implementation of a 12 Cell Battery Management System. The supplied code serves as an example of how to use the Atmel ATMega32HVB and Atmel ATA6870 together. The example is not a complete application intended for use with smart batteries, and it is best to use the devices in a slightly different way in a smart battery application.

2. Safety Precautions When Using Li-ion Batteries

Please observe the safety guidelines supplied with the batteries. If improperly used or defective, li-ion and polymer batteries and packs may explode and cause a fire.

3. Demonstration Board

The Atmel ATA6870-DK10 was developed to allow easy evaluation of control software for a microcontroller which controls multiple Atmel ATA6870s. The sample code supplied demonstrates a simple permanent running measurement of voltages and temperatures.
Figure 3-1. Board Concept
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3.1 System Start

Follow these steps to launch the system.

3.1.1 Installing the Hardware

Connect the load/charger to be powered between pack+ and pack- on J1
For demonstration purposes it is possible to use a resistor to simulate a load
Connect the battery cell stack to the screw connectors on the demonstration board
Led 1 indicates the enabled status of the demonstration board (controlled by microcontroller SW)
In case of emulating cells such as a voltage divider, apply sufficient voltage (see Section 3.3 “Powering the Board” on
page 5)

3.1.2 Number of Cells

It is possible to run the board with a reduced number of cells. The minimum voltage for each IC is 6.9V. Cell 1 and cell 6 (MBAT) have to be connected. The missing cells should be connected to the upper cell potential of the module. For further information refer to the Atmel ATA6870 datasheet Section 7.3: Reduced Number of Battery Cells Configuration. For the voltage range see Section 3.3 “Powering the Board” on page 5. If fewer than 6 cells are used per IC, the config.h file should be adjusted (CELLSIC# under General Setting). See Section 4.1 “Supplied Code” on page 7 for further information on how to configure the supplied software correctly.

3.2 The Demonstration Board

Figure 3-2. Evaluation Board with 2 Stacked Atmel ATA6870 and Atmel ATMega32HVB
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3.2.1 On-board Features

The demonstration board includes the following items:
2 Atmel
®
ATA6870 QFN 7mm 7mm
Atmel ATMega32HVB
12 external N-channel MOSFETs for balancing of battery cells
Connectors
ISP connector for programming/debugging the Atmel ATMega32HVB
Screw connectors for connecting up to 12 battery cells
Table 3-1. Connector Overview
J7 Function J8 Function
1 CELL- 1 VDDHVM
2 PAC K- 2
3 3 VCC
4 VFET 4 GND
5 5 IRQ
6 GND 6 CLK
7 OD 7 MISO
8 OC 8 MOSI
9 RESET 9 SCK
10 GND 10 CS_N
J1 Connector for charger/device to be powered J2 ISP connector J3 Upper battery stack (cells 7-12) J4 Bottom battery stack (cells 1-6) J9 Jumper to enable/disable MISO line of Atmel ATA6870
J9 should never be set while the Atmel ATmega32HVB is being programmed or while it is entering debug mode. It can be mounted as soon as AVR Studio prompts for additional SPI lines to be connected in debug mode or after the device has been correctly programmed.
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Figure 3-3. Connectors

3.3 Powering the Board

3.3.1 Power Supply

The board supports supply voltages from 13.8V (6.9V per Atmel ATA6870) to 60V. However, to run the board on voltages below 24V the ZDiode D3 needs to be replaced with a jumper to supply the Atmel the jumper is mounted, the stack voltage should not exceed 48V! The Atmel ATmega32HVB supports operating voltage from 4V to 24V.

3.3.2 Emulating Cells

Battery cells can be emulated by connecting a voltage divider to the specified clamps. Section 3.1.1 “Installing the Hardware”
on page 3 describes how to connect cells. The voltage limits for this setup are the same as for real batteries. Section 3.3.1 “Power Supply” on page 5 specifies these limits.
®
ATmega32HVB with sufficient voltage. If
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4. Software Description: Monitoring of Up to 12 Battery Cells

The supplied code is documented and easy to adjust for verifying the functions of the Atmel® ATA6870 and start BMS application development work.
After the board has been connected as described above the microcontroller automatically starts a cyclic measurement of voltages, temperature, and current. LED 1 indicates these cyclic measurements. It toggles in default operation. A continuously illuminated LED1 indicates an open clamp. See Section 4.2 “Open Cell Check” on page 7 for more information about open clamp detection. LED 2 indicates that for some reason the MOSFETS have been disabled. The default software disables the FETs in case of these events:
Overvoltage (at least 1 cell exceeds the upper default threshold of 4.2V)
Undervoltage (at least 1 cell exceeds the lower default threshold of 2.5V)
Overcurrent (the current through the shunt exceeds the default threshold of 80mA)
Overheating (the temperature exceeds the upper threshold, default value is 60°C)
Low temperature threshold (the default threshold is -20°C)
LED 3 indicates whether the Atmel ATA6870s are turned on or not. An active LED indicates that the Atmel ATA6870s are enabled.
Table 4-1. LED Functions
LED Function
LED 1
LED 2 On indicates disabled MOSFETs for one of the reasons listed above
LED 3 On indicates active Atmel ATA6870
Indicates clamp is open when permanently illuminated Indicates cyclic measurements when blinking
The Atmel ATmega32HVB has no clock divider to provide an external slower clock than 1/2 CPU clock. Requirement of Atmel ATA6870 is f of the Atmel ATA6870 and 250kHz for SPI.
CLK
> 2 f
. Hence, the clock frequency of 1MHz is mandatory to provide a 500kHz clock for the ADCs
SPI
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4.1 Supplied Code

Voltage (Cell) 4V
V
acqVoffset
3031 V
offset
-------------------------------- -


=

4.1.1 config.h

This section refers to the config.h file provided in the zip archive with this Application Note. Only values in the User Setting paragraph should be changed!
------------- GENERAL SETTING-------------------------------­CELLSIC# Selecting which Cells are used Bits 0-5 -> Cells 1-6
------------- TEMPERATURE SETTING---------------------------­RES_REF# Value of the mounted reference resistor (default: 3300) T_TLS Temperature belonging to the first Value in the lookup
T_TLE Temperature belonging to the last value in the lookup
T_TLSZ Temperature step size used in the lookup table (default:
1) T_LOWERTHRESHOLD Lower temperature threshold T_UPPERTHRESHOLD Upper temperature threshold
------------- COULOMBCOUNTER SETTING------------------------­SHUNT_RESISTANCE Value of the shunt resistor in mOhm RCC_CONVERSIONPERIOD The cycle times for the Regular Current Check
0x11 - 2s RCC_DIVIDEDSZ 0x01 to enable divided Voltage (Current) stepsize RCC_CHARGETHRESHOLD Threshold for charging current, exceeding the
RCC_DISCHARGETHRESHOLD Threshold for discharging current, exceeding the
Other values should not be changed in the default HW setup!
table (index 0, default: -20)
table (default: 80)
0x00 - 256ms (default) 0x01 - 512ms 0x02 - 1s
threshold will turn off the Mosfets
threshold will turn off the Mosfets

4.2 Open Cell Check

The implemented function checks for open clamps by measuring the cell voltages two times. During the first check a normal measurement is completed and the values stored. During the second check the voltages are measured while the discharge function for all cells is active. If the two measurements for the same cell differ by more than 100mV it is very likely that one or more cells are not properly connected. The implemented method cannot be used to determine which cell is not properly connected. A continuously illuminated LED1 indicates an open clamp.

4.3 Voltage Measurements

The standard software loop measures the voltage ADC value and the offset ADC value for every cell and checks for overvoltage and undervoltage once per cycle. Further information about the acquiring of voltages can be found in the Atmel ATA6870 datasheet Section 7.5.1. The formula for calculating the voltage:
®
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4.4 Temperature Measurements

adc (out) 2048 1
RES_NTC(1)
(RES_NTC(1) + RES_REF(1))
-------------------------------------------------------------------------- -
8
15
----- -
8
10
----- -
+


=
The default software only measures channel 1 of chip 1. The temperature sensors are based on a resistor divider using a standard resistor and an NTC resistor. This resistor divider is connected to the reference of the ADC for temperature measuring. Because the ADC is sharing the same reference value, the output of temperature measurement with ADC is ratio metric. Further information is found in the Atmel ATA6870 datasheet Section 7.5.3: Temperature Channel.
For this application Atmel recommends using Res_Ref1 = 3.3k and RES_NTC1 R25 = 10k, B = 3435. The software supplied for this board uses these values as default. The function uses a lookup table to determine the temperature. This table has to be edited if an NTC other than the recommended one is used. The values in the lookup table range from –20°C (index 0) to +80°C (index 100). These values can be edited via the config.h file in the User Settings section. More Information about this file can be found in Section 4.1 “Supplied Code” on page 7. The calculation of RES_NTC is carried out based on the formula provided in the Atmel ATA6870 datasheet Section 7.5.3:
When using another NTC, the LookupADC.txt has to be edited to match the NTC used.

4.5 State of Charge Measurements

Highly precise SOC measurement is possible by combining the features of the Atmel ATmega32HVB and the Atmel ATA6870. The coulomb counting feature of the Atmel ATmega32HVB enables highly precise measurements of the change in the state of charge. Frequent reading of the current in a shunt is used to update the SOC frequently. The acquired cell voltages and temperatures can be used to determine the SOC without the Atmel ATmega32HVB. The easiest way is to compare the SOC measured by the added/extracted charge with the calculated SOC using the cell voltage, temperature, and the data provided by the manufacturer of the cells. Further information regarding the coulomb counting ADC as well as an implementation suitable for the Atmel ATmega16HVA is found in Application Note AVR352.

4.6 Overcurrent Protection

The current through the shunt is calculated by measured voltage drop. The limit can be set via the CADRDC/CADRCC register. The step size depends on the settings of the CADCSRC register and the shunt used. For further information about limiting current see the Atmel ATmega32HVB datasheet Section 19.4: Regular Current Detection Operation. The supplied software allows the feature to be tested by adjusting the values in the config.h file. More Information about this file can be found in Section 4.1 “Supplied Code” on page 7. Values/part of the code should only be changed if you are aware of possible consequences. The default implementation continuously measures the current and generates an interrupt if the entered thresholds are exceeded. The thresholds are defined in the config.h file. The thresholds are written to the registers in the function CCinit in the Atmel ATA6870_func.c file. Refer to the features of the Atmel ATmega32HVB in the coulomb counter section to learn more about the time the controller waits for the values to be written.
C Code Example
CADRCC = RCC_CADRCC; while(CADCSRA & (1 << CADUB)); CADRDC = RDC_CADRDC; while(CADCSRA & (1 << CADUB));
// Charge Threshold // Wait values to be written // Discharge Threshold // Wait values to be written
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5. Features of the Atmel ATmega32HVB

Since the Atmel® ATmega32HVB is a part of the Atmel AVR® family which is dedicated to battery management there are several special features such as coulomb counting and the control of the two charge/discharge MOSFETs.

5.1 Coulomb Counter

The coulomb counter ADC runs on a different clock than the CPU. This clock is slower and therefore several things have to be kept in mind before using it. Writing several registers in sequence takes a long time depending on the delays between each write cycle. A possible solution is given in the supplied software example:
C Code Example
void CCinit(){
CADRCC = RCC_CADRCC; while(CADCSRA & (1 << CADUB)); CADRDC = RDC_CADRDC; while(CADCSRA & (1 << CADUB)); SETBIT(CADCSRB,1<<CADRCIE); while(CADCSRA & (1 << CADUB));
SETBIT(CADCSRC,RCC_DIVIDEDSZ<<CADVSE);
while(CADCSRA & (1 << CADUB)); SETBIT(CADCSRA,((1<<CADEN)|(1<<CADSE)|(RCC_CONVERSIONPERIOD<<1)));
while(CADCSRA & (1 << CADUB));
}
The Update Busy (CADUB) bit in CADSRA is cleared and written by hardware.

5.2 Charging/Discharging FETs

The two FETs are controlled by an N-channel FET driver. The pins (OC and OD) are designed for outputting a high voltage of approx. 13V. The status of the pins is controlled by software via the FCSR - FET control and status register.
C Code Example
void Configure_Fet(unsigned char Fet){
if(Fet&0x01)
SETBIT(FCSR, (1<<DFE));
else
CLEARBIT(FCSR,(1<<DFE));
// Charge Threshold
// Discharge Threshold
// Interrupt Enable
// Voltage Scaling
// ADC Enable, RCC Mode, Sampling // Interval
if(Fet&0x02)
SETBIT(FCSR,(1<<CFE));
else
CLEARBIT(FCSR,(1<<CFE));
}
The example above implements an easy method to enable or disable the two FETs independently of each other. For more information, see the Atmel ATmega32HVB datasheet page 148ff.
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6. Power Consumption

There are several ways to reduce the power consumption of the Atmel ATA6870 and the Atmel ATmega32HVB. Sleep modes are documented in the datasheet of the Atmel ATA6870 Section 7.1.1 and in the Atmel ATmega32HVB datasheet Section 10. This board allows the Atmel ATA6870 to be enabled/disabled using the Atmel ATmega32HVB software. The pin PB2 is used to control a transistor for activating/deactivating the Atmel ATA6870. Other options which are not implemented are the use of interrupts and a timer (sleep between cycles).
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7. Schematic

R59
1kΩ
R34
100Ω
DISCH5
MBAT6ODMBAT7
VDDHV
IRQ_IN
CLK_OUT
CS_N_OUT
SCK_OUT
MOSI_OUT
CS_N
1314151617181920212223
24
4847464544434241403938
37
SCK
MOSI
MISO
MFIRST
DTST
SCANMODE
CS_FUSE
VDDFUSE
DVSS
DVDD
GND
GND
DISCH6
MISO_IN
PD_N
VDDHVP
1
2
3
4
5
6
7
8
9
10
12
11
MBAT5
DISCH4
MBAT4
DISCH3
MBAT3
DISCH2
MBAT2
MBAT1
DISCH1
IC2
Atmel
ATA6870
IRQ
CLK
36
1
2
3
J5 0Ω
D
S
G
35
34
33
32
31
30
29
28
27
26
25
VDDHVM
PD_N_OUT
POW_ENA
PWTST
BIASRES
TEMPREF
TEMP2
TEMP1
TEMPVSS
AVSS
AVDD
ATST
R40
C6
51kΩ
nc (33μF/50V)
+
Q6
FMMT620
121kΩ
GND_2
GND_2
GND_2
GND_2
GND_2
R55
R38
7.5kΩ
R4
10Ω/0.25W
R41
PB2
4.7kΩ
R58
1kΩ
R45
1kΩ
R46
1kΩ
R96
D2
MM3Z13VC
56kΩ
R109
56kΩ
R93
56kΩ
PACK+
R94
56kΩ
T18
ZXMN2F34FH
CELL+
CELL-
J3-7
R30
100Ω
T14
ZXMN2F34FH
R33
100Ω
T17
ZXMN2F34FH
R32
100Ω
T16
ZXMN2F34FH
R31
100Ω
R29
100Ω
T15
ZXMN2F34FH
T13
ZXMN2F34FH
J3-6
J3-5
J3-4
J3-3
J3-2
J3-1
J1-3
R27
R86
10Ω/0.25W
C3+
10μF 30V
C19
100nF 30V
C8
2.2μF 25V
C5
100nF 50V
C1+
10μF 30V
C32
100nF 30V
R39
10Ω/0.25W
R12
tbd
R37
150Ω
R14
4.7kΩ
R10
4.7kΩ
D4 LL4148
C10
100nF
Q7 SQ2301ES
Q5 IRF5210SPBF
Q4 IRF5210SPBF
C33
10nF
R66
100kΩ
C38
220nF
C11
100nF
C12
100nF
C13
100nF
C14
100nF
C15
100nF
GND_2
GND_2
GND_2
GND_2
GND_2
R49
R57
3.3kkΩ
3.3kkΩ
R52
R56
NTC
NTC
R47
1kΩ
R53
1kΩ
R54
1kΩ
R25
1kΩ
R19
R11
100Ω
D1
D
G
G
S
S
D
MM3Z13VC
DISCH5
MBAT6
MBAT7
VDDHV
IRQ_IN
CLK_OUT
CS_N_OUT
SCK_OUT
MOSI_OUT
CS_N
1314151617181920212223
24
4847464544434241403938
37
SCK
MOSI
MISO
MFIRST
DTST
SCANMODE
CS_FUSE
VDDFUSE
DVSS
DVDD
GND
GND
DISCH6
MISO_IN
PD_N
VDDHVP
1
2
3
4
5
6
7
8
9
10
12
11
MBAT5
DISCH4
MBAT4
DISCH3
MBAT3
DISCH2
MBAT2
MBAT1
DISCH1
IC1
Atmel
ATA6870
IRQ
CLK
LED1
J9
PB2
RESET
CLK
SCK
MOSI
MISO
IRQ
CS_N
LED_0603
LED3
LED2
36
1
2
3
J6 0Ω
35
34
33
32
31
30
29
28
27
26
25
7
PA1 (ADC1/SGND/PCINT1)
PA2 (PCINT2/T0)
PA3 (PCINT3/T1)
PB0 (PCINT4/ICP00)
PB2 (PCINT6)
VCC
IC3 ATMEGA32HVB
VCC
VREG
VREF
VFET
PB3 (PCINT7)
PB4 (SS/PCINT8)
PB5 (SCK/PCINT9)
PB1 (PCINT5/CKOUT)
PA0 (ADC0/SGND/PCINT1)
8
9
10
14
36
6
4
12
13
11
5
15
35
3
44
43
1
2
42
18
OC
OD
16
37
17
27
20
21
22
23
24
25
26
28
29
30
31
2 4 6
VCC
3x2M
MOSI
MISO
SCK
RESET
J2
1 3 5
32
33
34
41
40
39
38
19
VDDHVM
PD_N_OUT
POW_ENA
PWTST
BIASRES
TEMPREF
TEMP2
TEMP1
TEMPVSS
AVSS
AVDD
ATST
C7
nc (33μF/50V)
+
+
121kΩ
R21
R24
1kΩ
R18
nc
opt. ext.supply
TP1
R3
1kΩ
R5
1kΩ
T12
ZXMN2F34FH
Q2
MMBT2222A
OC
J1-2
J1-1
J1-4
R95
4.7kΩ
Q1
MMBT2222A
Q2
NSS60601MZ4
D3 BZV55C6V8-TP
J4-7
R6
100Ω
T8
ZXMN2F34FH
R10
R22 nc
100Ω
T11
ZXMN2F34FH
R9
100Ω
T10
ZXMN2F34FH
R8
100Ω
R1
100Ω
R2
1kΩ
T9
ZXMN2F34FH
T7
ZXMN2F34FH
J4-6
J4-5
J4-4
J4-3
J4-2
J4-1
C16
100nF
C20
10nF
R44
100kΩ
R17
5.1kΩ
C24
C24
nc
220nF
C17
100nF
C18
100nF
C21
100nF
C22
100nF
C23
100nF
VDD_HVM
VCC
VCC
R20
5.1kΩ
VCC
R13
R23
3.3kΩ
3.3kΩ
R77
R76
NTC
NTC
R7
1kΩ
R15
1kΩ
R16
C30 100nF
C27
100nF
C31
C34
100nF
100nF
C2 2.2μF
1kΩ
100ΩR89
R113
RSENSE
1kΩR99
100ΩR91
1kΩR100
PACK-
VFET
R88 1kΩ
R28 1kΩ
R35 1kΩ
R36 1kΩ
R26
10/0.25WΩ
PB6 (MOSI/PCINT10)
PB7 (MISO/PCINT11)
PC0 (INT0/EXTPROT)
PC1 (INT1)
PC2 (INT2)
PC4 (SCL)
PC5
PV1
PV2
PV3
PV4
RESET/DW
PC3 (INT3/SDA)
BATT
VCLMP10
GND
GND
GND
PI
PPI
NI
NNI
1
CELL-
RSENSE
10x1F
J7
10x1F
J8
Piggypack Board
for other Microcontroller
VDD_HVM
VCC
CLK
IRQ
CS_N
SCK
MOSI
MISO
PACK -
VFET
OD
OC
RESET
2
3
4
5
6
7
8
9
10
NV
OC
OD
PVT
NC
NC
VREFGND
1
2
3
4
5
6
7
8
9
10
Figure 7-1. Schematic
ATA6870-DK10 [APPLICATION NOTE]
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Figure 7-2. PCB Top
12
ATA6870-DK10 [APPLICATION NOTE]
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Figure 7-3. PCB Bottom
ATA6870-DK10 [APPLICATION NOTE]
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13

8. Revision History

Please note that the following page numbers referred to in this section refer to the specific revision mentioned, not to this document.
Revision No. History
9228C-AUTO-02/15 Put document in the latest template 9228B-AUTO-10/12 Section 4.4 “Temperature Measurements” on page 8 updated
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X
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© 2015 Atmel Corporation. / Rev.: 9228C–AUTO–02/15
®
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