High-Power Battery Management System Solution Module

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Overview

Introduction

The EVKT-BMU1xx-HP is an evaluation kit for the EVBMU1xx-HP-R01A, a reference design board for a 7-cell to 16-cell in series battery management unit with high current support up to 100A DC and 150A Peak.

This board uses the MP279x ICs, a robust family of battery management analog front-ends (AFEs) that provide a complete AFE monitoring and protection solution. The MP279x supports up to 16 cells in series, and provides two separate analog-to-digital converters (ADCs) for synchronous voltage and current measurements. The high-side MOSFET (HS-FET) driver and robust HW protection functions come with configurable thresholds. Protections include over-current protection (OCP), short-circuit protection (SCP), battery and cell over-voltage protection (OVP), battery and cell under-voltage protection (UVP), over-temperature protection (OTP), and under-temperature protection (UTP). The MP279x also integrates internal balancing FETs to equalize mismatched cells while offering the option to control external FETs for a higher balancing current.

The board also features the MPF4279x, a standalone battery fuel gauge (FG) IC that performs state-of-charge (SoC), time-to-full, time-to-empty, and unavailable energy estimation using a custom battery model obtained through exhaustive characterization and voltage, current, and temperature readings. This solution is fast, simple, and easy to configure through the graphic user interface (GUI). Figure 1 shows the EVKT-BMU1xx-HP block diagram.

Figure 1: EVKT-BMU1xx-HP Block Diagram Design

Each EVKT-BMU1xx-HP evaluation boards offer different combinations of the MP279x AFE and the MPF4279x fuel gauge. See the Evaluation Kits section on page 5 for more details.

Evaluation Kits

Reference Design MPF4279x Part Number MPF4279x Short Description MP279x Part Number MP279x Short Description
EVBMU16S-HP-R01A MPF42790 2-Cell to 16-Cell FG with Level LEDs MP2797 7-Cell to 16-Cell BMS with I2C
EVBMU16SNL-HP-R01A MPF42792 2-Cell to 16-Cell FG MP2797 7-Cell to 16-Cell BMS with I2C
EVBMU14S-HP-R01A MPF42790 2-Cell to 14-Cell FG with Level LEDs MP2791 7-Cell to 14-Cell BMS with I2C
EVBMU10S-HP-R01A MPF42795 2-Cell to 10-Cell FG with Level LEDs MP2791 7-Cell to 14-Cell BMS with I2C
EVBMU10SNL-HP-R01A MPF42797 2-Cell to 10-Cell FG MP2791 7-Cell to 14-Cell BMS with I2C
EVBMU16S-HP-G1-R01A MPF42791 Next Generation 2-Cell to 16-Cell FG with Level LEDs MP2797 7-Cell to 16-Cell BMS with I2C
EVBMU14S-HP-G1-R01A MPF42791 Next Generation 2-Cell to 14-Cell FG with Level LEDs MP2791 7-Cell to 14-Cell BMS with I2C


Kit Contents

EVKT-BMU16S-HP

Items included with the kit (items below can be ordered separately):

# Part Number Item Quantity
1 EVBMU16S-HP-R01A MP2797DFP-0001-T and MPF42790DR-0B-0001 reference design and evaluation board 1
2 EVKT-USB_RS485/I2C-01 USB to RS-485/I2C adapter 1

EVKT-BMU16SNL-HP

Items included with the kit (items below can be ordered separately):

# Part Number Item Quantity
1 EVBMU16SNL-HP-R01A MP2797DFP-0001-T and MPF42792DR-0B-0001 reference design and evaluation board 1
2 EVKT-USB_RS485/I2C-01 USB to RS-485 / I2C adapter 1

EVKT-BMU14S-HP

Items included with the kit (items below can be ordered separately):

# Part Number Item Quantity
1 EVBMU14S-HP-R01A MP2791DFP-0001-T and MPF42790DR-0B-0001 reference design and evaluation board 1
2 EVKT-USB_RS485/I2C-01 USB to RS485 / I2C adapter 1

EVKT-BMU10S-HP

Items included with the kit (items below can be ordered separately):

# Part Number Item Quantity
1 EVBMU10S-HP-R01A MP2791DFP-0001-T and MPF42795DR-0B-0001 reference design and evaluation board 1
2 EVKT-USB_RS485/I2C-01 USB to RS485 / I2C adapter 1

EVKT-BMU10SNL-HP

Items included with the kit (items below can be ordered separately):

# Part Number Item Quantity
1 EVBMU10SNL-HP-R01A MP2791DFP-0001-T and MPF42797DR-0B-0001 reference design and evaluation board 1
2 EVKT-USB_RS485/I2C-01 USB to RS485 / I2C adapter 1

EVKT-BMU16S-HP G1 (Next Generation FG)

Items included with the kit (items below can be ordered separately):

# Part Number Item Quantity
1 EVBMU16S-HP-G1-R01A MP2797DFP-0001-T and MPF42791DR-0B-0001 reference design and evaluation board 1
2 EVKT-USB_RS485/I2C-01 USB to RS485 / I2C adapter 1

EVKT-BMU14S-HP G1 (Next Generation FG)

Items included with the kit (items below can be ordered separately):

# Part Number Item Quantity
1 EVBMU14S-HP-R01A MP2791DFP-0001-T and MPF42791DR-0B-0001 reference design and evaluation board 1
2 EVKT-USB_RS485/I2C-01 USB to RS485 / I2C adapter 1

Figure 2: EVBMU1xx-HP-R01A Evaluation Kit Set-Up

Features and Benefits

  • High-Side Charge and Discharge (Including Pre-Charge Function) MOSFETs
  • 7 Cells, Up to 16 Cells in Series
  • Up to 100A of Constant Charge/Discharge Current and Up to 150A of Peak Current
  • True Hardware Protections
  • 5V, CAN Bus and UART Availability for External Devices (e.g. Displays)
  • External Fault Indicator LED and Pack Voltage Status LED
  • High-Accuracy Analog-to-Digital Converter (ADC) with the Option of Simultaneous Voltage and Current Measurements
  • Configurable Alarm Reactions and Thresholds:
    • Configurable Over-Voltage Protection (OVP) and Under-Voltage Protection (UVP)
    • Configurable Charge and Discharge Over-Current Protection (OCP) and Short-Circuit Protection (SCP)
    • PCB and Configurable Battery Over-Temperature Protection (OTP)
    • Self-Functionality Test Options
  • Cell-Balancing with Internal MP279x FETs with Option of External Balancing FET for Higher Currents
  • Open-Wire Detection
  • Sleep Mode with Standby Discharge FET for Lower Current Consumption with Automatic Wake-p when a Load/Charger is Detected
  • Load/Charger Detection Option in Safe Mode
  • Accurate Battery Pack State-of-Charge (SoC) Estimate (see Figure 3)
  • Simple Configuration through MPS’s GUI
  • Supports any Lithium-Based Cell Type Using a Dedicated Battery Cell Model

Figure 3: EVBMU16S-HP-R01A Performance Example


Kit Specifications

Features Specifications
Max series cell supported EVKT-BMU16Sxx-HP: 16 cells in series
EVKT-BMU14Sxx-HP: 14 cells in series
EVKT-BMU10Sxx-HP: 10 cells in series
Battery pack voltage range EVKT-BMU16Sxx-HP: 18V to 70.4V
EVKT-BMU14Sxx-HP: 18V to 65.8V
EVKT-BMU10Sxx-HP: 18V to 44V
Cell voltage range Up to 4.5V (configurable cell UV and OV thresholds)
Charge current range 0A to 196.605A (configurable charge OC threshold) (1)
Discharge current range 0A to 196.605A (configurable discharge OC threshold) (1)
Total high-side protection resistance (connectors + PCB traces + 1 parallel FETs) 4mΩ to 5mΩ
Operating systems supported Windows 7 or later
System requirements Minimum 350MB free
EVB size (L x W) 123mmx121mm (FETs board)
97mmxx61mm (control board)

Note:
1) It is not recommended to exceed 120A of continuous current for the 10 parallel FET configuration. Up to 150A of peak current is supported.


Hardware Limitations Affecting Testing and Usage

EVKT-BMU16S-HP, EVKT-BMU16S-HP-G1, EVKT-HP-BMU16SNL Limitations

The EVKT-BMU16x-HP uses an engineering sample of the MP2797. The microcontroller (MCU) and GUI are designed to provide a simplified experience to overcome some of the sample limitations. Review the MP2797 datasheet and related application note to be aware of such limitations. Contact and MPS FAE for the application note.

To ensure a robust set-up, excellent performance, and optimal BOM, note the changes related to the MP2797’s engineering pre-sample. Changes that deviate from what is suggested in this guide are not advised; before doing so, contact an MPS FAE.

EVKT-BMU10S-HP, EVKT-BMU10SNL-HP, EVKT-BMU14S-HP, EVKT-BMU14-HP-G1 Limitations

The EVKT-BMU10x-HP and EVKT-BMU14S-HP use an engineering sample of the MP2791. The MCU and GUI are designed to provide a simplified experience to overcome some of the sample limitations. Review the MP2791 datasheet and related application note to be aware of such limitations. Contact and MPS FAE for the application note.

To ensure a robust set-up, excellent performance, and optimal BOM, note the changes related to the MP2791’s engineering pre-sample. Changes that deviate from what is suggested in this guide are not advised; before doing so, contact an MPS FAE.

Section 1. Hardware Specifications

1.1 Personal Computer Requirements

The following minimum conditions must be met to use the EVKT-BMU1xx-HP GUI:

  • Operating System of Windows 7 or later
  • Net Framework 4.6.1
  • PC with a minimum of one available USB port
  • At least 350MB of free space

1.2 EVBMU1xx-HP-R01A Specifications

The EVBMU1xx-HP-R01A is a reference design and evaluation board for the MP279x and the MPF4279x.

Figure 4: Reference Design

Feature Specifications
Battery pack voltage 18V to 70.4V (16-cell battery)
18V to 65.8V (14-cell battery)
18V to 44V (10-cell battery)
Charger voltage 18V to 72V (16-cell battery)
18V to 67.8V (14-cell battery)
18V to 46V (10-cell battery)
Parallel protection N-channel MOSFETs 1 to 10
EVB size (L x W) 123mmx121mm ; 97mmx61mm