IVT-MOD Application Additional Features (optional) Over current signal (OCS) Hardware trigger Software trigger Watch-Dog The modules are: Log-data

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1 ISAscale IVT-MOD Application Hybrid drive/lithium-ion battery BMS Electric vehicle Charging station Full cell control Additional Features (optional) Over current signal (OCS) The module contains hardware over-current detection for both current directions. As soon as the over current is detected the alarm line OCS is activated which signals an over current condition to the external circuit. The current channel will extend the measurement range automatic. It is possible to set the overcurrent threshold and the hysteresis. Hardware trigger The module provides a hardware trigger. The trigger signal could be used to synchronize the measurement between the module and an external hardware. A low to high transition triggers a single measurement cycle. The over current signal is active low. All channels having the setting trigger respond after the trigger signal. The IVT-MOD is a high precision shunt measurement system measuring current, voltage and temperature. The module consists of a printed circuit board directly soldered onto an Isabellenhütte nickel-plated shunt from 5 to 300 µohm. The IVT has a modular design. So it can be modified to the most applications in the automotive and industrial area. The modules are: a) Isolation against high voltage b) Eight ranges of current measurement c) Up to three voltage measurement channels d) Temperature measurement e) Individually trigger of each channel f) Communication g) Over current detection Software trigger With the software trigger it is possible to trigger each channel individually. Find the trigger modes under Measurement description. Watch-Dog The watch-dog feature generates a one ms toggle in normal operation mode when no errors are detected. An error generates an over-current signal. Log-data Data can be logged as energy meter, electric meter, maximum temperature and operating hours. Bootloader A function for firmware updates. Issue IVT-MOD 01 / 05

2 ISAscale IVT-MOD Function description The IVT has a switch mode voltage regulator for wide supply voltage range. Is it not possible to set the module in a standby mode. Both power supply and digital signal lines are galvanic isolated using integrated digital isolators. The sensor is measuring voltage drop over shunt resistor. An automatic range extension is performed if the nominal current range is exceeded. The output transfer rate is adjustable as well as the number of channels. The current signal is directly connected to the ASIC current measurement input (input 1). MEASURement description Measurements are performed in Dual Mode. A primary channel and a secondary channel are measuring alternately at an internal sample rate of approx Hz. The primary channel always measures input 1 (current filtered). The secondary channel may be configured to measure one of the following inputs: Input 1 Current Input 2 Voltage 1 Input 3 Voltage 2 Input 4 Voltage 3 Input 5 Internal temperature The output rate depends on the number of active channels. Each message contains two data and every ms came one message. Data 1 is the current and is fixed. Data 2 depends on the settings (Voltage 1, Voltage 2, Voltage 3 and/or temperature). Each channel has three Trigger modes: Disabled Triggered Cyclic running No trigger A trigger command send a data Sending permanent data System Overview (Example: IVT with 3 voltage measurement input) Issue IVT-MOD 02 / 05

3 ISAscale IVT-MOD Technical data Operation conditions Operating temperature C Storage temperature C Supply voltage Depend from module: 5 12; 7 60 V Supply current Depend from module: ma Start up time 100 ms Current measurement nominal range Nominal measurement range depends from shunt A A A A A A A A Initial Error 0.1 % rdg Total error [ C] without temperature calibration 0.2 % rdg Total error [ C] without temperature calibration tbd % rdg Total error [ C] with temperature calibration tbd % rdg Total error [ C] with temperature calibration tbd % rdg Offset ma Noise ma pp Physical resolution ma HV voltage measurement parameters nominal range Nominal measurement range 800 V Initial Error 0.1 % rdg Total error [ C] without temperature calibration tbd % rdg Total error [ C] without temperature calibration tbd % rdg Total error [ C] with temperature calibration (optional) tbd % rdg Total error [ C] with temperature calibration (optional) tbd % rdg Offset ma Noise 300 ma pp Physical resolution 30 ma Output resolution 1 ma Issue IVT-MOD 03 / 05

4 ISAscale IVT-MOD Technical data Temperature measurement Measurement range C Resolution 1 C Error (0 to 85 ) 3 +3 C Error (40 to 105 ) 4 +4 C Mechanical dimension IVT Modular small IVT Modular long Issue IVT-MOD 04 / 05

5 ISAscale IVT-MOD Pin configuration (Full modularity) PIN Description Remark (module or basic) 1 (a, b) Power IN Basic 1 (c, d) CAN IN Basic 2 (a, b) Power OUT Module 2 (c, d) CAN OUT Module 3 (a, b) Trigger Module PIN a for one sensor or PIN a/b for loop through (> one sensor) 3 (c, d) OCS (over current signal) Module PIN a for one sensor or PIN a/b for loop through (> one sensor) 4 Voltage measurement 1 Module 5 Voltage measurement 2 Module 6 Voltage measurement 3 Module Communication CAN SPI Warranty // All information regarding the suitability, workability and applicability of our products, all technical advice and other information are provided to the best of our knowledge and belief, but shall not discharge the buyer from his own examinations and tests. This document is subject to change without notice. Issue IVT-MOD 05 / 05

6 CURRENT, VOLTAGE AND TEMPERATURE MEASUREMENT MODULE FOR AUTOMOTIVE APPLICATIONS preliminary datasheet, version General description The fully calibrated advanced sensor module IVT-A has been designed for all applications in which high currents, voltages and temperatures have to be measured. It contains a precision resistor with 100 µohm, the ISA-ASIC and all analogue circuits for a complete 4-channel 16bit data acquisition system. The internal µc is supplying the clock and controls the measurements and communication with the ISA-ASIC. The module contains a SPI interface which allows a simple integration into an external system. IVT-A 4. Start-up and operation of the module After power up, the module automatically starts to measure current and voltage alternately. Every time both measurements are done, EOC goes low for 10µs indicating that measurement values are ready to be read. The EOC frequency can be changed by setting the average counter. However values can be read every time. Changing the measurement mode (e.g. temperature) requires an external set command. The IVT-A device is SPI slave. The communication is done by the 4 isolated SPI signals lines. 5. Over Current Detection (OCD) The IVT contains an independent hardware over current detection for the positive and negative current. As soon as the over current is detected the alarm line OCS is activated which signals the external circuit an error condition. The limit is given by design to 300A. Figure 1: Picture of IVT-A 2. Measurement functions Current by using the voltage drop over the shunt Voltage by using an internal voltage divider Temperature by using internal temperature of ISA-ASIC 3. Electrical characteristics Power supply Min Typ Max Unit Supply voltage V Supply current ma Current measurement Value Unit resistance value of the shunt 100 µω nominal current range ±300 A max. pulse current (1 sec) A internal sampling rate 1750 s/sec accuracy 2 ±(0.2% + 30 ma) - resolution 3 1 to 10 ma 3 noise p-p 15 to 100 ma 6. Pin configuration Solder pads with through hole connections for a standard 10 pin connector 2x5 (2.54 mm). PIN Name Function 1 GND module ground 2 VCC supply voltage 3 OCS Over Current Signal 4 SCK SPI signal 5 MOSI SPI signal 6 MISO SPI signal 7 SS SPI signal 8 EOC End Of Conversion 9 Not connected 10 Not connected 7. Additional information and options The IVT-A contains an isolation of power supply and communication signals by using icoupler. To customize the IVT-A for special applications, the additional options shown in the table on next page are available. Further customizing is available upon request. Voltage measurement Value Unit independent channels 3 - nominal voltage range ±600 V internal sampling rate 1750 s/sec accuracy 2 ±(0.2% mv) - resolution 3 1 to 20 mv 3 noise p-p 30 to 200 mv SPI interface Value Unit clock frequency 1 to 2 MHz EOC frequency 7 to 1750 Hz 1 for max. load capacity of shunt 2 over temperature range 0 C to +60 C 3 depends on EOC frequency IVT-A ISABELLENHÜTTE Heusler GmbH & Co. KG page 1 of 2 Dillenburg, HE/RS/BS

7 CURRENT, VOLTAGE AND TEMPERATURE MEASUREMENT MODULE FOR AUTOMOTIVE APPLICATIONS preliminary datasheet, version 1.2 IVT-A 8. Additional options Option Details Assembly option Redesign required Voltage measurement range 30 V to 900 V X X Voltage measurement channels 1 to 3 X Over current detection limit 50 A to 500 A X Current measurement range 300 A to 600 A X Disengageable voltage channels Photo MOS / transistor X Customized shunt resistance and mechanics X Anti aliasing filter for measurement channels X Temperature measurement with external sensor X Power supply without voltage regulator range 4.5 V to 5.5 V X Extended operating temperature range -40 C to +80 C X Soldered cables instead of standard 10 pin connector X 9. Drawings Voltage3 Voltage2 Voltage1 Supply voltage and SPI 35.5mm 84.0mm Figure 2: Dimensions of IVT-A Positive current direction Figure 3: Drawing of BAS-Shunt 10. Typical measurement error at room temperature error / A 1,0 0,8 0,6 0,4 0,2 0,0-0,2-0,4-0,6-0,8 IVT-A-R0001 error limit: ±(0.2% + 30 ma) typical error positive limit negative limit -1, current / A IVT-A ISABELLENHÜTTE Heusler GmbH & Co. KG page 2 of 2 Dillenburg, HE/RS/BS

8 IVT-B Brief datasheet Application Hybrid- and full electric drive/lithium-ion battery BMS Electric vehicle Stationary battery storage system Charging station Full cell control Function Description The IVT-B is a high precision shunt based current, voltage and temperature measurement system. The module consists of a printed circuit board directly connected onto an Isabellenhütte low resistor shunt. The measurement system is using a microcontroller. Communication is provided by an isolated CAN interface. System overview / installation Additional Features positive current direction HV Voltage Additional hardware features of the module are the OCS and the SYNC lines. Over current detection line (OCS) The IVT-B contains hardware over-current detection for both current directions. As soon as the over current is detected the alarm line OCS is activated which signals an over current condition to the external circuit. Threshold A Error A Positive over current detector parameters. Threshold A Error A Negative over current detector parameters. TRIGGER signal line The module provides a TRIGGER input signal line. The TRIGGER signal could be used to synchronize the measurement between the module and an external hardware like a battery management system. The TRIGGER input line is fed through a K-Line Driver, so the input signal is in the same range as the supply voltage. The signal is high active. A low to high transition triggers the measurement. Current SYNC OCD CAN Power supply Switch mode voltage regulator for wide supply voltage range. Standby mode is not possible. Isolation Both power supply and digital signal lines are galvanic isolated using integrated digital isolators. Current measurement Isabellenhuette proprietary ISA-ASIC measuring voltage drop over shunt resistor. Since FW revision an automatic range extension is performed if the nominal current range is exceeded. Voltage measurement Isabellenhuette ISA-ASIC measuring input voltage attenuated by a high impedance voltage divider. Input filtering The current signal is directly connected to the designated ISA- ASIC current measurement input (Input 1). The same signal is connected to the second ISA-ASIC input (Input 2) via a double RC filter. The voltage signal is directly connected to the third ISA- ASIC input (Input 3). The same signal is connected to the fourth ISA-ASIC input (Input 4) via a double RC filter. Issue IVT-B // Version / 5

9 IVT-B Over current detection Two Hardware comparators are directly connected to the shunt resistor, one for each current direction. Each comparator compares the voltage drop over the shunt to a threshold voltage provided by a fixed voltage divider or a software adjustable voltage. The over current signal is active low. It is isolated by the digital isolator and provided at the LV connector through a K-Line transceiver. Measurement function By power-on the device performs an internal diagnostic check. After that the user defined configuration, operation mode and overcurrent thresholds are loaded from nonvolatile memory. A Primary Channel and a Secondary Channel are measuring alternately at an internal sample rate of approx Hz. The Primary channel always measures Input 1 (current unfiltered). The Secondary Channel may be configured to measure one of the following inputs: Input 1 Input 2 Input 3 Input 4 Input 5 CU (current unfiltered) CF (current filtered) VU (voltage unfiltered) VF (voltage filtered) T (internal temperature) There are three options of triggering the transmission of measurement results: Free running measurement mode: Every time a measurement cycle has completed, result messages are transmitted. The number of average values determines the interval of transmitting result messages. Hardware triggered measurement mode: As soon as the TRIGGER signal is detected, a complete cycle, determined by configuration of secondary channel and average configuration, is performed and after completion one to three result messages are sent. A CAN message; containing measurement results, holds at least one of two possible measured values. There are up to three different measurement messages possible, separated by three different CAN-IDs. If the input signal of the current input exceeds the nominal measurement range, an automatic range switching to an extended range is performed. Message triggered measurement mode: As soon as the request message is received, a complete cycle, determined by configuration of secondary channel and average configuration, is performed and after completion one to three result messages are sent. Issue IVT-B // Version / 5

10 IVT-B Technical Data Operation conditions // The module may be used in both 12 V and 24 V power supply systems, but there is no additional load dump protection above 32 V! Operating temperature C Storage temperature C Supply voltage V Supply current ma Start up time 50 ms Current measurement characteristics nominal range Nominal measurement range A Extended measurement range A Initial Error % rdg Total error [ C] without temperature calibration % rdg Total error [ C] without temperature calibration % rdg Total error [ C] with temperature calibration opt % rdg Total error [ C] with temperature calibration opt % rdg Offset (not included in error) ma Noise 120 ma pp Physical resolution 10 ma HV voltage measurement parameters nominal range Nominal measurement range V Initial Error % rdg Total error [ C] without temperature calibration % rdg Total error [ C] without temperature calibration % rdg Total error [ C] with temperature calibration % rdg Total error [ C] with temperature calibration % rdg Offset (not included in error) mv Noise 120 mv pp Physical resolution 30 mv Input resistance 3.3 mohm Issue IVT-B // Version / 5

11 IVT-B Technical Data Temperature measurement The internal temperature measurement is performed on the PCB which is thermally connected to the shunt by the direct solder joint. It does not represent the hot spot temperature of the shunt but more likely the average temperature of the module (PCB and shunt). Measurement range C Resolution 0.1 C Error (0 C to 85 C) 2 +2 C Error ( 40 C to 105 C) 4 +4 C Mechanical Dimension Issue IVT-B // Version / 5

12 IVT-B Connectors The module is equipped with two Molex Micro Fit 3.0 male connectors. A 8 pin connector is used for the connection to the LV side. The HV voltage can be connected to a 2 pin connector. These two pins are shorted together internally. Connector pin assignment HV measurement inputs The module has one high voltage inputs. The common reference point is the negative side of the shunt. The voltage divider may be switched off to minimize current drawn from the battery. It has bipolar measuring capability. Interface / Power Supply Power Supply Isolated CAN Isolated signal lines +12V DC GND CAN-H CAN-L CAN-T-A (termination connector) CAN-T-B (termination connector) OCS (over current detect output) SYNC (synchronization input) If Pins 8 (CAN-T-B) and 4 (CAN-T-A) are shortened externally, the module s internal CAN bus termination is activated. Package / Housing The module is supplied in an open version without housing but with a conformal coating. Communication CAN communication description Communication consists of a small amount of CAN messages with different CAN IDs at a speed of 500kbits/s. There is one transmit message (named Command) and four receive messages (named Message) seen from the host s point of view. Different commands are realized by a Command-ID-byte on position DB0. A message is reported as a response to a command. The other three messages contain measurement results. Since FW revision all five CAN IDs may be permanently changed by a user command. Since FW revision the CAN speed may be permanently changed to several bitrates. Warranty // All information regarding the suitability, workability and applicability of our products, all technical advice and other information are provided to the best of our knowledge and belief, but shall not discharge the buyer from his own examinations and tests. This document is subject to change without notice. Issue IVT-B // Version / 5

13 IVT-C Brief datasheet Function Description System integration By power-on the device performs an internal diagnostic check. After that the user defined configuration, operation mode and overcurrent thresholds are loaded from nonvolatile memory. A Primary Channel and a Secondary Channel are measuring alternately at an internal sample rate of approx Hz. The IVT-C is a high precision shunt based current, voltage and temperature measurement system. The module consists of a printed circuit board directly connected onto an Isabellenhütte low resistor shunt. The measurement system is using a microcontroller. Communication is provided by an isolated CAN interface. Additional Features (optional) Over current detection line (OCS) The module contains hardware over-current detection for both current directions. As soon as the over current is detected the alarm line OCS is activated which signals an over current condition to the external circuit. TRIGGER signal line The module provides a TRIGGER input signal line. The TRIGGER signal could be used to synchronize the measurement between the module and an external hardware like a battery management system. The TRIGGER input line is fed through a K-Line Driver, so the input signal is in the same range as the supply voltage. The signal is high active. A low to high transition triggers the measurement. The Primary channel always measures Input 1 (current input). The Secondary Channel may be configured to measure one of the following inputs: Input 1 Current Input 2 Voltage 1 Input 3 Voltage 2 Input 4 Voltage 3 Input 5 Internal temperature Each measuring cycle consists of at least one Primary channel measurement (always current) and one secondary channel measurement. The measurement cycle may be configured to consist of up to 5 different secondary channel measurements. The secondary measurements are performed in a circle style. Application Hybrid- and full electric drive/lithium-ion battery BMS Electric vehicle Stationary battery storage system Charging station Full cell control Issue IVT-C // Version / 05

14 IVT-C Additionally all measurements may be averaged over a configurable number of measurement cycles. There are three options of triggering the transmission of measurement results: Free running measurement mode: Every time a measurement cycle has completed, result messages are transmitted. The number of average values determines the interval of transmitting result messages. Hardware triggered measurement mode: As soon as the TRIGGER signal is detected, a complete cycle, determined by configuration of secondary channel and average configuration, is performed and after completion one to three result messages are sent. Message triggered measurement mode: As soon as the request message is received, a complete cycle, determined by configuration of secondary channel and average configuration, is performed and after completion one to three result messages are sent. A CAN message containing measurement results, holds at least one of two possible measured values. There are up to three different measurement messages possible, separated by three different CAN-IDs. If the input signal of the current input exceeds the nominal measurement range, an automatic range switching to an extended range is performed. Technical Data Operation conditions Operating temperature C Storage temperature C Supply voltage V Supply current ma Start up time 50 ms Current measurement characteristics nominal range Nominal measurement range A Extended measurement range A Initial Error % rdg Total error [ C] without temperature calibration % rdg Total error [ C] without temperature calibration % rdg Total error [ C] with temperature calibration opt % rdg Total error [ C] with temperature calibration opt % rdg Offset (not included in error) ma Noise 120 ma pp Physical resolution 10 ma Issue IVT-C // Version / 05

15 IVT-C Technical Data HV voltage measurement parameters nominal range Nominal measurement range V Initial Error % rdg Total error [ C] without temperature calibration % rdg Total error [ C] without temperature calibration % rdg Total error [ C] with temperature calibration % rdg Total error [ C] with temperature calibration % rdg Offset (not included in error) mv Noise 120 mv pp Physical resolution 30 mv Input resistance 3.3 mohm Temperature measurement The internal temperature measurement is performed on the PCB which is thermally connected to the shunt by the direct solder joint. It does not represent the hot spot temperature of the shunt but more likely the average temperature of the module (PCB and shunt). Measurement range C Resolution 0.1 C Error (0 C to 85 C) 2 +2 C Error ( 40 C to 105 C) 4 +4 C Issue IVT-C // Version / 05

16 IVT-C Mechanical Dimension Issue IVT-C // Version / 05

17 IVT-C Pin Configuration HV measurement inputs The module has three high voltage inputs capable of bipolar measurement. The common reference point of all of them is the negative side of the shunt. Voltage 1 and 2 inputs may be switched off to minimize current drawn from the battery. Due to a MOSFET transistor switch Voltage 2 input is able to switch off only positive voltages. If a negative voltage the switch is always on. Voltage 3 input cannot be switched off. Interface / Power Supply Power Supply Isolated CAN Isolated signal lines +12V DC GND CAN-H CAN-L CAN-T-A (termination connector) CAN-T-B (termination connector) OCS (over current detect output) SYNC (synchronization input) If Pins 8 (CAN-T-B) and 4 (CAN-T-A) are shortened externally, the module s internal CAN bus termination is activated. Connectors The module is equipped with four Molex Micro Fit 3.0 male connectors. An 8 pin connector is used for the connection to the LV side. The three HV voltages can be connected to 2 pin connectors. The two pins of each HV connector are shorted together internally. Connector pin assignment Communication CAN communication description Communication consists of a small amount of CAN messages with different CAN IDs at a default speed of 500 kbits/s. There is one transmit message (named command message) and four receive messages (one response message and three result messages) seen from the host s point of view. Different commands are realized by a Command-ID-byte on position DB0. The response message is reported as a response to a command. The three result messages contain measurement results. All five CAN IDs may be permanently changed by a user command. The CAN speed may be permanently changed to several bitrates. Warranty // All information regarding the suitability, workability and applicability of our products, all technical advice and other information are provided to the best of our knowledge and belief, but shall not discharge the buyer from his own examinations and tests. This document is subject to change without notice. Issue IVT-C // Version / 05