BQ2000EVM

User's Guide SLUU270 – June 2007 Using the bq2000EVM 1 Introduction This user’s guide describes the bq2000EVM EVM (an evaluation module for the bq2000 and bq2000T). The EVM provides a convenient method for evaluating the performance of a charge management solution for portable applications using either the bq2000 or bq2000T. A complete and tested charger is presented. The charger is designed to deliver up to 1.0A of continuous output current. The DV2000S1 is shipped with a programmed default charging current of 1.0A. Refer to the bq2000/bq2000T data sheet (literature ID “bq2000”) prior to using this EVM for detailed information on the bq2000 or bq2000T device. 1.1 Device Background The bq2000 is a programmable, monolithic IC for fast-charge management of nickel cadmium (NiCd), nickel metal-hydride (NiMH), or lithium-ion (Li-Ion) batteries in single or multi-chemistry applications. The bq2000 detects the battery chemistry and proceeds with the optimal charging and termination algorithms. This process eliminates undesirable undercharged or overcharged conditions and allows accurate and safe termination of fast charge. Depending on the chemistry, the bq2000 provides a number of charge termination criteria. The bq2000 can terminate charge based on peak voltage detection (PVD) for NiCd and NiMH batteries, minimum charging current for Li-Ion batteries, maximum temperature, or maximum charge time. For safety, the bq2000 inhibits fast charge until the battery voltage and temperature are within user-defined limits. If the battery voltage is below the low-voltage threshold, the bq2000 uses trickle-charge to condition the battery. For NiMH batteries, the bq2000 provides an optional top-off charge to maximize the battery capacity. The integrated high-frequency comparator allows the bq2000 to be the basis for a complete, high-efficiency power-conversion circuit for both nickel-based and lithium-based chemistries. 1.2 EVM Differences In addition to this bq2000EVM EVM, there are also DV2000S1 and DV2000TS1 EVMs available for evaluating the performance of the bq2000 or bq2000T. The DV2000S1/TS1 boards make use of through-hole devices while the bq2000EVM board was later developed to utilize all surface-mount devices and reduce the physical size of the EVM. Both EVMs provide complete evaluation environments for the bq2000/bq2000T, support up to 4 Li-Ion or 10 NiCd/NiMH cells, are user-programmable for other cell counts, and can operate with or without a charge top-off period. To correctly operate each EVM, consult its corresponding user’s guide. 1.3 Performance Specification Summary Specification Input DC voltage, V(DC+) – V(DC–) Min Max Unit 25 V Battery voltage, V(BAT+) – V(BAT–) 18 V Battery charge current, I(BAT+) 1.0 A 5 V Thermistor voltage, V(TS) SLUU270 – June 2007 Submit Documentation Feedback 10 Typ 0 Using the bq2000EVM 1 www.ti.com Setup and Configuration 2 Setup and Configuration This section describes the jumper connections on the bq2000EVM along with the resulting operation. It describes the different ways this EVM can be used with a variety of battery packs. 2.1 Connection Descriptions Jumper Designator Description J1: DC+ DC input positive voltage from external supply J1: DC– DC input ground J2: BAT+ Positive terminal of the battery or battery pack J2: BAT– Negative terminal of the battery or battery pack J2: TS Thermistor connection J2: BAT– Negative terminal of the battery or battery pack, used for thermistor connection J3: C/4, 320, Y Place jumper here for a C/4 charge rate, 320 minute timeout, top-off mode selected J3: C/4, 320, N Place jumper here for a C/4 charge rate, 320 minute timeout, top-off mode not selected J3: C/3, 240, Y Place jumper here for a C/3 charge rate, 240 minute timeout, top-off mode selected J3: C/3, 240, N Place jumper here for a C/3 charge rate, 240 minute timeout, top-off mode not selected J3: C/2, 160, Y Place jumper here for a C/2 charge rate, 160 minute timeout, top-off mode selected J3: C/2, 160, N Place jumper here for a C/2 charge rate, 160 minute timeout, top-off mode not selected J3: C, 80, Y Place jumper here for a C charge rate, 80 minute timeout, top-off mode selected J3: C, 80, N Place jumper here for a C charge rate, 80 minute timeout, top-off mode not selected J3: USER, Y Place jumper here to select a user-defined charge rate and timeout, uses top-off mode J3: USER, N Place jumper here to select a user-defined charge rate and timeout, no top-off mode J4: Top off Y Place jumper between Y and COM to select top-off mode J4: Top off COM Connect to top-off Y or top-off N 2.2 J4: Top off N Place jumper between N and COM to not use top-off mode J5: USER Place jumper here for a user-defined NiCd/NiMH cell count J5: 10 Place jumper here when using a battery pack of 10 NiCd/NiMH cells in a series configuration J5: 8 Place jumper here when using a battery pack of 8 NiCd/NiMH cells in a series configuration J5: 6 Place jumper here when using a battery pack of 6 NiCd/NiMH cells in a series configuration J5: 5 Place jumper here when using a battery pack of 5 NiCd/NiMH cells in a series configuration J5: 4 Place jumper here when using a battery pack of 4 NiCd/NiMH cells in a series configuration J6: 4 Place jumper here when using a battery pack of 4 Li-Ion cells in a series configuration J6: 3 Place jumper here when using a battery pack of 3 Li-Ion cells in a series configuration J6: 2 Place jumper here when using a battery pack of 2 Li-Ion cells in a series configuration J6: 1 Place jumper here when using a battery pack of 1 Li-Ion cells in a series configuration Board Setup The bq2000EVM can be configured as described below. Number of Cells Selection (JP5, JP6): These jumpers select the number of cells for either Li-Ion or NiCd/NiMH batteries. These jumpers should be changed only if the battery is absent or if the DC supply is not connected to the board. Only one jumper should be placed on a J5 or J6 connection for proper circuit configuration. Note that there are two USER defined connections provided on J5. This connection can be configured for NiCd/NiMH or Li-Ion cell counts other than what are predefined on the bq2000EVM. Configuration is accomplished by placing an appropriate resistor in the USER Y or N position according to the desired battery pack voltage. 2 Using the bq2000EVM SLUU270 – June 2007 Submit Documentation Feedback www.ti.com Setup and Configuration 2.3 Setup Procedure – Testing With a Battery Pack The following procedure outlines how to set up the bq2000EVM when charging a battery pack: 1. Configure the bq2000EVM for the appropriate number and type of cells by placing a single jumper on one of the J5 or J6 connection points. 2. Place a jumper between J4’s COM and YES to utilize the bq2000’s top-off mode or between COM and NO to not use the top-off mode. 3. Place one jumper on one of the J3 connection points to select a charge rate and timeout duration. If top-off mode is being used, only a J3 connection labeled “Y” should be used. A J3 connection labeled “N” should be used if top-off mode is not being used. 4. Connect the thermistor between TS and the lower BAT–. If using a thermistor is not desired, a 10-kΩ resistor can be connected between TS and BAT–. 5. Connect the battery pack to BAT+ and BAT–. 6. Connect the charging supply to J1 while ensuring that it falls within the bq2000EVM’s recommended DC operating range. 2.4 Setup Procedure – Testing Without a Battery Pack Sometimes it is beneficial to test a battery charger without charging an actual battery due to the long time needed to charge/discharge battery packs. An ideal substitute for a battery is a four-quadrant power supply that can both sink and source current. If a four-quadrant power supply is unavailable, the load card shown below can be used in parallel with a standard two-quadrant power supply. The load card as shown is designed to charge a one-cell lithium-ion battery at 1A constant current charge. SETUP Load Card BQ2000EVM + DC+ 12 V Power Supply 1 BAT+ BAT(No Connect) - TS + 2.0 V- 4.5 V Power Supply 2 DCBAT- - 1. Configure the bq2000EVM for the appropriate number and type of cells by placing a single jumper on one of the J5 or J6 connection points. 2. Place a jumper between J4’s COM and YES to utilize the bq2000’s top-off mode or between COM and NO to not use the top-off mode. 3. Place one jumper on one of the J3 connection points to select a charge rate and timeout duration. If top-off mode is being used, only a J3 connection labeled “Y” should be used. A J3 connection labeled “N” should be used if top-off mode is not being used. 4. Connect the load card as shown above. A 10-kΩ thermistor or 10-kΩ resistor can be added to the load card for convenience. The JP1 header and 4.99-kΩ resistor are added to demonstrate the temperature sensing feature of the bq2000EVM. When the jumper is removed, the EVM will charge as normal. Installing the jumper simulates an over-temperature condition and the charger will turn off. 5. Connect the second power supply to the load card as shown. The series diode is added to protect the power supply from sinking current and potential damage. Turn power supply two on so that it is within the voltage range set in step one (4.2V/cell if simulating a lithium-ion battery is desired, or 1.2V/cell if a nickel-based battery is desired). 6. Connect the charging supply to J1 while ensuring that it falls within the bq2000EVM’s recommended DC operating range. The load card allows a two-quadrant power supply to be used because it sinks current to BAT– through the shunt resistors. The above load card is designed for charging a single lithium-ion battery at 1A constant current. The charge range for a one-cell lithium-ion battery is 2.7 V to 4.2 V. Whenever the voltage on power supply two is less than 2.7 V, the bq2000EVM will be off and power supply two will SLUU270 – June 2007 Submit Documentation Feedback Using the bq2000EVM 3 www.ti.com Setup and Configuration source current through the shunt resistors. The charging algorithm for the bq2000EVM depends on the charge voltage that it sees on BAT+. As the voltage on power supply two is increased to within the set charge range of the bq2000EVM, the bq2000EVM will turn on into constant current mode and will source its set charge current (1A) into the load card. As the voltage provided by power supply two is increased, it will source enough current into the load card such that: Vps2 = Rload x (Ips2 + Icharge), where Icharge is the constant current charge sourced by the bq2000EVM, Ips2 is the current sourced by power supply two, Rload is the parallel resistance between BAT+ and BAT–, and Vps2 is the voltage on power supply two. Once the voltage on power supply two goes above the termination point set on the bq2000EVM, the bq2000EVM will shut off and all current will be sourced by power supply two. To design a load card for an arbitrary battery pack, the following procedure can be used. 1. Determine the minimum (Vmin) and maximum (Vmax) charging voltages for the desired battery pack. 2. Determine the desired constant current charge (Ichg) 3. Calculate the resistance (Rload) needed between BAT+ and BAT– by the following equation: Rload = Vmin / Ichg 4. Calculate the power that will be dissipated by the shunts resistance (Pshunt): Pshunt = Vmax2 / Rload 5. Choose a combination of parallel resistors that meet the equivalent resistance and overall power dissipation rating needed to satisfy the above equations. NOTE: Make sure power resistors are heat sunk properly to handle the amount of power to avoid overstressing the components. 4 Using the bq2000EVM SLUU270 – June 2007 Submit Documentation Feedback www.ti.com Schematic 3 Schematic SLUU270 – June 2007 Submit Documentation Feedback Using the bq2000EVM 5 www.ti.com Physical Layouts 4 Physical Layouts Top Assembly 6 Using the bq2000EVM SLUU270 – June 2007 Submit Documentation Feedback www.ti.com Physical Layouts Layer 1 SLUU270 – June 2007 Submit Documentation Feedback Using the bq2000EVM 7 www.ti.com Bill of Materials Layer 2 5 Bill of Materials Table 1. HPA250A Bill of Materials 8 Count RefDes Value Description Size Part Number 2 C1, C2 0.1µF Capacitor, Ceramic, X7R, 0.1 µF 0603 {std} MFR 1 C10 0.15µF Capacitor, Ceramic, X7R, 0.15 µF, 16V 0603 {std} 2 C3, C5 10µF Capacitor, Aluminum, 10µF, 25V, 20% 0.177 × 0.177 EEV-FK1E100R Panasonic 2 C4, C9 1000pF Capacitor, Ceramic, 1000pF, 50V, X7R 0805 {std} {std} 8 × 10 mm EEV-FK1E331P Panasonic {std} 1 C6 330µF Capacitor, Aluminum, SM, 330µF, 25V, 0.16Ω (FK series) 1 C7 4.7pF Capacitor, Ceramic, 4.7pF, 50V, NPO 0603 {std} 1 C8 0.047µF Capacitor, Ceramic, X7R, 0.047µF, 25V 0603 {std} 1 D1 Red Diode, LED, Red, 1.7V, 40mcd, SM 1210 SML-LX2832SRC-TR Lumex 2 D2, D4 B230-13 30V, 2A Diode, Schottky, 2A, 30V SMB B230-13 Diodes, Inc. 2 D3, D5 BAT54 Diode, Schottky, 200mA, 30V SOT23 BAT54 Vishay-Liteon 1 D6 5.6V Diode, Zener, 5.6V, 350mW SOT23 BZX84C5V6T Diodes, Inc. 1 D7 MMSZ5234BT1 Diode, Zener, 6.2V, 500mW SOD-123 MMSZ5234BT1 On Semi 1 J1 Terminal block, 2pin, 6A, 3,5 mm 0.27 × 0.25" ED1514 OST 1 J2 Terminal block, 4pin, 6A, 3,5 mm 0.55 × 0.25" ED1516 OST 1 J3 Header, 2x10pin, 100mil spacing (36-pin strip) 0.100 × 10 × 2" PTC36DAAN Sullins 1 J4 Header, 3pin, 100mil spacing, (36-pin strip) 0.100 × 3" PTC36DAAN Sullins Using the bq2000EVM SLUU270 – June 2007 Submit Documentation Feedback www.ti.com References Table 1. HPA250A Bill of Materials (continued) Count RefDes Value Description Size Part Number MFR Header 2x6 pin, 100mil spacing (36-pin strip) 0.100 × 2 × 6" PTC36DAAN Sullins Header 2x4 pin, 100mil spacing (36-pin strip) 0.20 × 0.40 PTC36DAAN Sullins Inductor, SMT, 100µH, 1.3A, 160mΩ 0.472 sq CDRH125-101 Sumida Si3455DV MOSFET, Pch, –30V, 2.3A, 190mΩ Micro6 Si3455DV Vishay-Liteon Q2 MMBT3906 Bipolar, PNP, 40V, 200mA, 0.22W SOT23 MMBT3906-7 On Semi 2 Q3, Q4 MMBT3904 Bipolar, NPN, 40V, 200mA, 250mW SOT23 MMBT3904 Fairchild 1 R1 100kΩ Resistor, Chip, 100kΩ, 1/16W, 1% 0603 Std Std 1 R11 330Ω Resistor, Chip, 330Ω, 1/16W, 1% 0603 Std Std 1 R12 499Ω Resistor, Chip, 499Ω, 1/16W, 1% 0603 Std Std 1 R13 604Ω Resistor, Chip, 604Ω, 1/16W, 1% 0603 Std Std 1 R14 249kΩ Resistor, Chip, 249kΩ, 1/16W, 1% 0603 Std Std 2 R15, R32 187kΩ Resistor, Chip, 187kΩ, 1/16W, 1% 0603 Std Std 1 R16 150kΩ Resistor, Chip, 150kΩ, 1/16W, 1% 0603 Std Std 1 R17 107K Resistor, Chip, 107kΩ, 1/16W, 1% 0603 Std Std 1 R18 681kΩ Resistor, Chip, 681kΩ, 1/16W, 1% 0603 Std Std 2 R19, R31 143kΩ Resistor, Chip, 143kΩ, 1/16W, 1% 0603 Std Std 1 R2 2kΩ Resistor, Chip, 2kΩ, 1/16W, 1% 0603 Std Std 1 R20 232kΩ Resistor, Chip, 232kΩ, 1/16W, 1% 0603 Std Std 1 R21 102kΩ Resistor, Chip, 102kΩ, 1/16W, 1% 0603 Std Std 1 R22 82.5kΩ Resistor, Chip, 82.5kΩ, 1/16W, 1% 0603 Std Std 1 R24 47.5kΩ Resistor, Chip, 47.5kΩ, 1/16W, 1% 0603 Std Std 1 R25 95.3kΩ Resistor, Chip, 95.3kΩ, 1/16W, 1% 0603 Std Std 1 R27 14.7kΩ Resistor, Chip, 14.7kΩ, 1/16W, 1% 0603 Std Std 1 R28 29.4kΩ Resistor, Chip, 29.4kΩ, 1/16W, 1% 0603 Std Std 1 R29 44.2kΩ Resistor, Chip, 44.2kΩ, 1/16W, 1% 0603 Std Std 1 R3 0.05Ω Resistor, Chip, 0.05Ω, 1/10W, 1% 0805 Std Std 1 R30 59kΩ Resistor, Chip, 59kΩ, 1/16W, 1% 0603 Std Std 1 R4 14.7kΩ Resistor, Chip, 14.7kΩ, 1/16W, 1% 0603 Std Std 1 R10 10kΩ Resistor, Chip, 10kΩ, 1/16W, 1% 0603 Std Std 1 R5 31.6kΩ Resistor, Chip, 31.6kΩ, 1/16W, 1% 0603 Std Std 1 R6 750kΩ Resistor, Chip, 750kΩ, 1/16W, 1% 0603 Std Std 0 R7, R23, R26 spare Resistor, Chip, Ohms, 1/16W, 1% 0603 Std Std 1 R9 1kΩ Resistor, Chip, 1kΩ, 1/16W, 1% 0603 Std Std 1 U1 BQ2000PW IC, Fast Charge, Multi-chemistry TSSOP-8 BQ2000PW TI 1 Circuit board HPA250 Circuit board HPA250 Any 1 RT1 NTC103AT Semitec 1 J5 1 J6 1 L1 100µH 1 Q1 1 Thermister, 10kΩ 0.095 x 1.150 In Notes: 1. These assemblies are ESD sensitive, ESD precautions shall be observed. 2. These assemblies must be clean and free from flux and all contaminants. Use of no clean flux is not acceptable. 3. These assemblies must comply with workmanship standards IPC-A-610 Class 2. 4. Ref designators marked with an asterisk ('**') cannot be substituted. All other components can be substituted with equivalent MFG's components. 5. After testing RT1 is taped to the bottom of UUT with ESD tape. 6 References 1. bq2000 data sheet, http://focus.ti.com/lit/ds/symlink/bq2000.pdf 2. Using the bq2000/T to Control Fast Charge, http://focus.ti.com/lit/an/slua064b/slua064b.pdf SLUU270 – June 2007 Submit Documentation Feedback Using the bq2000EVM 9 www.ti.com References FCC Warning This evaluation board/kit is intended for use for ENGINEERING DEVELOPMENT, DEMONSTRATION, OR EVALUATION PURPOSES ONLY and is not considered by TI to be a finished end-product fit for general customer use. It generates, uses, and can radiate radio frequency energy and has not been tested for compliance with the limits of computing devices pursuant to part 15 of FCC rules, which are designed to provide reasonable protection against radio frequency interference. Operation of this equipment in other environments may cause interference with radio communications, in which case the user at his own expense will be required to take whatever measures may be required to correct this interference. - SSZZ017A February 2006 EVALUATION BOARD/KIT IMPORTANT NOTICE Texas Instruments (TI) provides the enclosed product(s) under the following conditions: This evaluation board/kit is intended for use for ENGINEERING DEVELOPMENT, DEMONSTRATION, OR EVALUATION PURPOSES ONLY and is not considered by TI to be a finished end-product fit for general consumer use. Persons handling the product(s) must have electronics training and observe good engineering practice standards. As such, the goods being provided are not intended to be complete in terms of required design-, marketing-, and/or manufacturing-related protective considerations, including product safety and environmental measures typically found in end products that incorporate such semiconductor components or circuit boards. This evaluation board/kit does not fall within the scope of the European Union directives regarding electromagnetic compatibility, restricted substances (RoHS), recycling (WEEE), FCC, CE or UL, and therefore may not meet the technical requirements of these directives or other related directives. Should this evaluation board/kit not meet the specifications indicated in the User’s Guide, the board/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 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. The user assumes all responsibility and liability for proper and safe handling of the goods. Further, the user indemnifies TI 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. EXCEPT TO THE EXTENT OF THE INDEMNITY SET FORTH ABOVE, NEITHER PARTY SHALL BE LIABLE TO THE OTHER FOR ANY INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES. TI currently deals with a variety of customers for products, and therefore our arrangement with the user is not exclusive. TI assumes no liability for applications assistance, customer product design, software performance, or infringement of patents or services described herein. Please read the User’s Guide and, specifically, the Warnings and Restrictions notice in the User’s Guide prior to handling the product. This notice contains important safety information about temperatures and voltages. For additional information on TI’s environmental and/or safety programs, please contact the TI application engineer or visit www.ti.com/esh. 10 Using the bq2000EVM SLUU270 – June 2007 Submit Documentation Feedback www.ti.com References EVALUATION BOARD/KIT IMPORTANT NOTICE (continued) No license is granted under any patent right or other intellectual property right of TI covering or relating to any machine, process, or combination in which such TI products or services might be or are used. FCC Warning This evaluation board/kit is intended for use for ENGINEERING DEVELOPMENT, DEMONSTRATION, OR EVALUATION PURPOSES ONLY and is not considered by TI to be a finished end-product fit for general consumer use. It generates, uses, and can radiate radio frequency energy and has not been tested for compliance with the limits of computing devices pursuant to part 15 of FCC rules, which are designed to provide reasonable protection against radio frequency interference. Operation of this equipment in other environments may cause interference with radio communications, in which case the user at his own expense will be required to take whatever measures may be required to correct this interference. Mailing Address: Texas Instruments, Post Office Box 655303, Dallas, Texas 75265 Copyright © 2007, Texas Instruments Incorporated EVM WARNINGS AND RESTRICTIONS It is important to operate this EVM within the input voltage range of 10 V to 25 V. Exceeding the specified input range may cause unexpected operation and/or irreversible damage to the EVM. If there are questions concerning the input range, please contact a TI field representative prior to connecting the input power. Applying loads outside of the specified output range may result in unintended operation and/or possible permanent damage to the EVM. Please consult the EVM User's Guide prior to connecting any load to the EVM output. If there is uncertainty as to the load specification, please contact a TI field representative. During normal operation, some circuit components may have case temperatures greater than 50°C. The EVM is designed to operate properly with certain components above 50°C as long as the input and output ranges are maintained. These components include but are not limited to linear regulators, switching transistors, pass transistors, and current sense resistors. These types of devices can be identified using the EVM schematic located in the EVM User's Guide. When placing measurement probes near these devices during operation, please be aware that these devices may be very warm to the touch. Mailing Address: Texas Instruments, Post Office Box 655303, Dallas, Texas 75265 Copyright © 2007, Texas Instruments Incorporated SLUU270 – June 2007 Submit Documentation Feedback Using the bq2000EVM 11 IMPORTANT NOTICE Texas Instruments Incorporated and its subsidiaries (TI) reserve the right to make corrections, modifications, enhancements, improvements, and other changes to its products and services at any time and to discontinue any product or service without notice. Customers should obtain the latest relevant information before placing orders and should verify that such information is current and complete. All products are sold subject to TI’s terms and conditions of sale supplied at the time of order acknowledgment. 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