Renesas ISL94212EVKIT1Z User manual

USER’S MANUAL
UG048
Rev 0.00
August 26, 2015
ISL94212EVKIT1Z
Evaluation Kit User Guide
UG048 Rev 0.00 Page 1 of 24
August 26, 2015
Description
The ISL94212EVKIT1Z is a kit that facilitates use of the
ISL94212 BMS device. The ISL94212 monitors cell voltage and
temperature. It converts the cell voltages and temperatures to
14-bit digital values, provides cell balance control, It provides
significant fault detection. The ISL94212 can operate in a single
device configuration, or multiple kits can be cascaded using a
built-in daisy chain connection. The daisy chain hardware
provides robust, redundant board-to- board communications.
Specifications
This board has been configured and optimized for the following
operating conditions:
•V
BAT = 6V to 60V
•V
BAT daisy chain = 10V to 60V
•VC
n(for n = 1 to 12) = V(VCn-1) to V(VCn-1) + 5V
•CB
n(for n = 1 to 9) = V(VCn-1) to V(VCn-1) + 9V
•CB
n (for n = 10 to 12) = V(VCn) -9V to V(VCn)
• External inputs Ext1 -4 = 0V to 2.5V
• SPI communications refer to ISL94212 datasheet
•V
POR (VBAT) voltage (rising) typical 5.1V
Key Features
• Supports both stand alone and daisy chained configurations
• Daisy chaining with both connector only or wire jumper
options
•GUIprovidedexportoptionfor generation of detailed
register and/or SPI communications log files.
• USB dongle runs HID firmware for driver-less enumeration
and communications with Windows platforms
• GUI add-in chart generation tool supports real-time
graphing, zoom and export of captured data.
• Software provides checksum requirements associated with
daisy chain communications.
• Kit includes “Battery Emulation” board(s) for cell voltages
generation.
References
ISL94212 web page
ISL94212 datasheet
Ordering Information
PART NUMBER DESCRIPTION (Note)
ISL94212EVKIT1Z ISL94212 master
ISL94212EVZ ISL94212 slave/daisy chain kit to be
used as either “middle” or “top” device(s)
NOTE: See “What is inside” on page 2 for kit details.
FIGURE 1. SINGLE DEVICE CONFIGURATION FIGURE 2. DAISY CHAIN CONFIGURATION
MICROCONTROLLER
CURRENT MONITORING
COMMUNICATION
POWER FET CONTROL
PACK CAPACITY MONITOR
ANALOG FRONT END
LEVEL SHIFTING
VOLTAGE MONITOR
TEMP MONITOR
OV, OT DETECTION
OP EN WIRE DETECT
CELL BALANCING
VOLTAGE REGULATOR
ADC
SPI
FET DRIVER
CURRENT
MOTOR DRIVE ELECTRONICS
SYSTEM
ELECTRONICS
Applications requiring 12 cells or less can operate with a single device as
shown above.
Also the ISL94212 can also operate in a 2 to 14 device configuration (Daisy
Chain). See example to the right.
MONITORING
ELECTRONICS
MONITORING
ELECTRONICS
MONITORING
ELECTRONICS
MONITORING
ELECTRONICS
MONITORING
ELECTRONICS
MONITORING
ELECTRONICS
MONITORING
ELECTRONICS
MONITORING
ELECTRONICS
MICRO-
CONTROLLER

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ISL94212EVKIT1Z
Document Overview
The following are three key portions of this document:
Software Installation
The software is necessary to use this evaluation kit. This section
guides you through the installation and verification of both the
GUI / Windows software and also the USB enumeration of the
HID firmware/dongle device for PC to device(s) communication.
Quick Hardware Setup Guide
This section provides information regarding the connection of the
various boards and the settings of the configuration options.
Quick GUI Setup Guide (Using the GUI)
The section steps the user through fundamental use of the GUI
software. Enough information is provided to establish and verify
communications are working properly and enable the user to
observe measurements in real time and export data as well.
Functional Description
The ISL94212 evaluation Kit, coupled with the associated GUI
provides the means to familiarize oneself with the various
instructions capability and operation of the device. A single
ISL94212 Li-ion battery manager IC supervises up to 12 series
connected cells. The part provides accurate monitoring, cell
balancing and extensive system diagnostics functions.
The kit enables the user to activate and data log voltage and
temperature measurements. Cell voltages are supplied via a
resistor ladder network in the MCB_PS2_Z multi-cell power
supply test board.
The ISL94212 has three cell balancing modes incorporated:
Manual Balance mode, Timed Balance mode and Auto Balance
mode. The auto balance mode terminates balancing functions
when a charge transfer value specified by the host
microcontroller has been met. Note: Cell balancing will require
the removal of the MCB_PS2_Z multicell power supply test board
and attachment of Cell devices that are capable of sourcing and
sinking current.
The ISL94212 communicates to a host microcontroller via an SPI
interface and to other ISL94212 devices using a robust, two-wire
daisy chain system. The primary evaluation board provides
configuration options that can be set via switches. These are
discussed in detail later in this document.
Connecting multiple Intersil boards allows the user to setup
communications and measurement capability of many packs
and up to 185 battery cells. However, one should review the
“Quick Hardware Setup Guide” on page 3. There will be safety
concerns as voltage levels increase with multiple packs.
What is inside
The ISL94212EVKIT1Z (Master) evaluation kit contains:
• ISL94212EV1Z evaluation board
• MCB_PS2_Z multicell power supply test board
• MCB_MICRO_EVZ multicell power supply test board
• USB cable, connects PC to evaluation board
• 16 conductor flat cable (connects power supply board to
evaluation board)
• One daisy chain cable
The ISL94212EV1Z (Slave(s)) evaluation kit contains:
• ISL94212EV1Z evaluation board
• MCB_PS2_Z multicell power supply test board
• 16 conductor flat cable (connects power supply board to
evaluation board)
• One daisy chain cable
What is needed
The following instruments will be needed to perform testing:
• 60V/1A adjustable power supply
• Wires to connect power supply to MCB_PS2_Z board
• Precision multimeter
• Oscilloscope (optional)
• Cables and wires (Optional)
• Windows computer with USB port
Operating Range
Single device setup (non-daisy chain) mode can operate with a
battery voltage of 6V to 60V. When using less than 12 cells, the
user should consult the datasheet regarding cell connections.
However, caution should be employed during daisy chain
operation. In this mode, up to 14 boards can be connected. While
each board is operating on a relative voltage of up to 60V, this
“floating” is accomplished via the AC coupling of the daisy chain
circuits. (see below)
DHI
DLO
DGND
R
2
R
2
R
1
C
2
C
2
R
1
C
1
C
2
C
1
C
1
DHI
DLO
DGND
CONNECTOR
CONNECTOR
R
2
R
2
R
1
R
1
C
2
C
1

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ISL94212EVKIT1Z
As mentioned in the “Quick Hardware Setup Guide” on page 3,
while each board is operation in 60V range, total voltage across
multiple packs can be dangerous.
PCB Layout Guidelines
The ISL94212 layout has been optimized for electrical and
protection during hot plug conditions.
During layout the designer should consider:
• While the ISL94212 does not dissipate much power itself, the
internal temperature sensor might be more functional if a
thermal array is incorporated under the QFN thermal slug. The
user is invited to review Intersil’s Technical Brief TB389
regarding the thermal vias and the package pad.
• The user should review closely the artwork, component values
and routing of the daisy chain circuitry.
• The standard evaluation board accommodates both
connector-to-connector or cabled communication paths. If
multiple devices are being used, physical placement/size of
the cells should be reviewed in starting you product’s layout.
• Finally, the mechanical aspects of the battery pack should be
considered. Much as been written regarding damaged BMS
PCBs as a result of slight shifting of battery cells. (Cells tend to
be heavy and therefore can impart significant force)
Software Installation
This version of software supports both ISL94212 or ISL78600
devices. It has been tested on XP, Win7 and Win8 platforms.
Step 1: Run the Intersil_BMS_Vxxx.exe file. This installs the
BMS GUI software to the PC. Depending on your IT
department there are a couple of items to address
when performing an installation.
Select “Run As Administrator” option when available (Right click
in installation program)
When setting up project installation and shortcut paths, consider
using Users\Public instead of program directory.
Step 2: Connecting the evaluation board will result in
automatic USB enumeration under the Human
Interface section of the Windows device manager.
Quick Hardware Setup Guide
Single Board
Step 1: A “Startup” screen in the GUI (will wait for you to select
the combo box. Compete steps below.)
Step 2: Connect the MCB_MICRO_EVZ board (J1) to the
ISL94212EVZ board (J2). (See Figure 3)
Step 3: Set the power supply voltage to 39.6V (3.3V per cell). If
there are fewer cells being tested, reduce the power
supply voltage such that it equals 3.3V times the
number of cells.)
Step 4: Connect the power supply to the MCB_PS2_Z board.
The positive terminal of the MCB_PS2_Z board is
J5/J11 and the negative terminal is J8/J12. Connector
J7 can also be used to provide power to the board. The
J7 tip is positive and the ring is negative. Check that the
voltages on the J3 connector of the board are +3.3V
from PIN(n) to Pin(n-1).

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Step 5: Turn off the power to the power supply.
Step 6: Connect the flat cable between the MCB_PS2_Z board,
connector J1 and the ISL94212EVZ board, connector J1.
Step 7: Check the jumpers and switches on the board. Since
this is a single board configuration, the board should be
configured as follows:
• SPI/daisy switch set to SPI.
• EN0 and ENR should contain jumpers.
• LEDEN should contain a jumper.
• CMSSel1 (left) and CMSel2 (right) switches both set
to “0”. This sets single board operation.
• CMRSel1 (left) and CMRSel0 (right) should have
jumpers to “1”. These set the daisy chain speed and
are not used in the single board operation, but it is
OK to leave the jumpers in place.
Step 8: Turn on the power to the supply and notice that there is
a green LED (VDD), indicating the LDO regulator on the
ISL94212 is operating.
The voltages at various points should be:
VDD = 3.3V ±3%
VCC = ~3.3V ±5%(a little lower than VDD)
V2P5 = 2.5V ±2%
VREF = 2.50V ± 0.5%
Step 9: Connect the USB port of the PC to the USB port of the
MCB_MICRO_EVZ board.
VBAT
V12
V11
V10
V9
V8
V7
V6
V5
V4
V3
V2
V1
V0
GND
6V to 60V
CMSSel
1
0
1
0
DAISY CHAIN
SETTINGS
CMSSel1 = 0
CMSSel2 = 0
ISL94212
Enable
CMRSel0 = 1
CMRSel1 = 1
(Not used in
single board
application)
CMRSel
1
0
1
0
MCB_MICRO_EVZ
MCB_PS2_Z BOARD
FIGURE 3. ISL94212EVKIT1Z SINGLE BOARD SETUP
ISL94212EVZ
SPI
Daisy
SPI/daisy CHAIN SELECT
(SET TO SPI IN SINGLE BOARD APPLICATION)

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ISL94212EVKIT1Z
Step 10: Open the ISL94212 GUI software, select the “BMS
Evaluation Board Connected” in the “Select Option” box
as seen in step one. The software will automatically
take you to the Configuration Screen. Select “non-daisy
chain” and device type, then click “OK.” GUI will return
to the main screen. Use the software to read the cell
voltages and registers
Daisy Chain
Step 1: To Connect all boards, complete steps below. Specify
“daisy” chain when configuration screen appears.
Step 2: Connect the MCB_MICRO_EVZ board (J1) to the Master
ISL94212EVZ board (J2). (See Figure 5)
Step 3: Set the power supply voltage to 39.6V (3.3V per cell). If
there are fewer cells being tested, reduce the power
supply voltage such that it equals 3.3V times the
number of cells.)
Step 4: Connect the power supply to all MCB_PS2_Z boards in
parallel. There should be one MCB_PS2_Z board for
every evaluation board. This connection is not typical of
a battery installation, where the ground of one board is
the VBAT of another, but it easily facilitates testing of
the communication and allows a safer environment for
initial testing.
The positive terminal of the MCB_PS2_Z board is
J5/J11 and the negative terminal is J8/J12. Connector
J7 can also be used to provide power to the board. The
J7 tip is positive and the ring is negative. Check that the
voltages on the J3 connector of all boards are +3.3V
from PIN(n) to Pin(n-1).
Step 5: Turn off the power to the power supply.
Step 6: Connect the flat cable between each MCB_PS2_Z
board, connector J1 and an ISL94212EVZ board,
connector J1.
FIGURE 4. ISL94212EVZ
USE CAUTION when connecting the MCB_PS2_Z
boards in series, since voltages quickly reach
hazardous levels. BE CAREFUL!

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Step 7: Check the jumpers and switches on the board. Since
this is a daisy chain configuration, the boards should be
configured as follows:
• SPI/Daisy switch set to SPI on the master. For all
other boards, this switch should be set to Daisy.
• EN0 and ENR should contain jumpers.
• LEDEN should contain a jumper.
• CMS1 and CMS2 should have switches set as
follows:
This sets daisy chain operation and locates the boards within the
daisy chain.
• CMRSel1 and CMRSel0 should have jumpers set to
1. These set the daisy chain speed at the maximum
500kHz.
Step 8: Connect the daisy chain wires.
The boards can plug together to complete the daisy
chain connections, or the enclosed twisted pair cable
can connect the boards. Connect as shown in Table 2.
See also the 36-cell daisy chain connection Figure 5 on
page 7. For a 24-cell connection, drop out the Middle
board.
Step 9: Turn on the power to the supply and notice that there is
a green LED (VDD) on each board, indicating the LDO
regulators on the ISL94212 are operating.
The voltages at various points should be:
VDD = 3.3V ±3%
VCC = ~3.3V ±5% (a little lower than VDD)
V2P5 = 2.5V ± 2%
VREF = 2.50V ±0.5%
Step 10: Connect the USB port of the PC to the USB port of the
ISL94212EVZ daisy chain master board.
Step 11: Open the ISL94212 GUI software.
Select Daisy Chain Mode in the Device Menu at the top
left of the screen. Click Connect. Use the software to
read the cell voltages and other register content.
TABLE 1. DAISY CHAIN COMMUNICATIONS DATA RATE SELECTION
COMMS RATE 0 COMMS RATE 1
DATA RATE
(kHz)
00 62
01 125
1 0 250
1 1 500
TABLE 2. COMMUNICATIONS MODE CONTROL
COMMS
SELECT 1
COMMS
SELECT 2
PORT 1
COMM
PORT 2
COMM
COMMUNICATIONS
CONFIGURATION
00 SPI
(Full Duplex)
Disabled Standalone
01 SPI
(Half Duplex)
Enabled Daisy Chain,
Master device setting
1 0 Daisy Chain Disabled Daisy Chain,
Top device setting
1 1 Daisy Chain Enabled Daisy Chain
Middle device setting
If boards are connected in series, be aware of the
voltage potentials between the different boards
when measuring and monitoring signals with a
meter or a scope.

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ISL94212EVKIT1Z
FIGURE 5. ISL94212EVZ IN 36-CELL DAISY CHAIN CONFIGURATION (SHOWN 1 ISL94212EVKIT1Z (MASTER) AND 2 ISL94212EV1Z (SLAVES)
SPI
DAISY
DAISY
OPTIONAL TWISTED PAIR DAISY CHAIN
CONNECTION
NORMAL
DAISY CHAIN
CONNECTION
TO PC
USB
6V to 60V
6V to 60V
6V to 60V

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ISL94212EVKIT1Z
Quick GUI Setup Guide (Using the
GUI)
Step 1: Once the board is powered up and connected to the PC
through the USB cable, start the GUI program.
Step 2: Choose the communication mode (stand-alone or daisy
chain). If the GUI is already running, select the
operating mode in the device menu (upper left of the
screen.)
Step 3: The GUI program identifies the devices connected,
either in a single board, or a daisy chain configuration,
(See Figure 6). NOTE: Figure 5 on page 7 shows the
daisy chain configuration.
In a daisy chain configuration, the top bar provides an
indication of the boards connected and allows selection
of any ISL94212EVZ board for monitoring and control.
Select the specific device in the daisy chain. Device 15
selects all devices. Device 0 selects devices that are not
yet identified. For a single board, these boxes are not
shown.
Step 4: Use the various tabs and buttons to monitor and
control the operation of the device.
Step 5: The “Device Commands” buttons along the bottom of
the main tab are commands sent to all boards in the
system. So, selecting “Scan Volts” then “Read Volts”
causes all boards to read the cell voltages,
temperatures and update the ISL94212 register values
and the GUI display boxes. (Note: these buttons send
separate commands to each board. It does not send a
“Scan All” or “Read All” command.)
Step 6: At the bottom of the screen there are activity logs
showing the USB communications and the SPI
communications to the master board.
Step 7: To clear fault indications, the fault first needs to be
cleared. When the fault is no longer active, do a “Read
Faults” command, then read the Faults register and
click on each individual bit to change the setting (or
write 0 to the register value). Then click on Write to
send the value to the device.
Using the “Read Group or Write Group” button sends
commands to all registers on the page.
Step 8: Use the “Show Chart” button to view various voltages
and status in real time (See Figure 7).
FIGURE 6. MAIN GUI WINDOW - TWO CASCADED DEVICES

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ISL94212EVKIT1Z
Chart Window
The charting function of the GUI provides real time viewing of the
critical voltages in the battery pack. The chart updates results as
long as the GUI is polling. If the GUI stops polling (or there is a
communication interruption) the chart maintains the last valid
value.
At the end of a sample period, the captured data can be exported
to a file that can be loaded into Excel for further analysis by
clicking on the “Export” button.
Using the controls at the left of the screen, various charts can be
turned off and the specific cells being monitored can be chosen.
At this time, the cell voltages of only two packs can be monitored
on one screen and only the temperatures of board 1 can be
monitored.
FIGURE 7. CHART WINDOW

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ISL94212EVKIT1Z
Monitor Tab
The monitor tab shows the voltages and status of the first 4
boards in the daisy chain. (See Figure 8)
At this time, it is not possible to select the results for any other
boards in the stack. Individual boards can be monitored in the
main window, one board at a time.
If there are more than 4 boards, only boards 1 through 4 are
shown in this tab.
FIGURE 8. MONITOR TAB