User's Guide
SLUU235 – February 2006
bq2406x Evaluation Module
1
Introduction
This user’s guide describes the bq2406x evaluation module (EVM). The EVM provides a convenient
method for evaluating the performance of a charge management solution for portable applications using
the bq2406x product family. A complete designed and tested charger is presented. The charger is
designed to deliver up to 1 A of continuous charge current for single-cell Li-Ion or Li-polymer applications
using a DC power supply.
1.1
Background
The bq2406x series are highly integrated Li-Ion and Li-polymer linear chargers, targeted at space-limited
portable applications. The bq2406x series offers a variety of safety features and functional options, while
still implementing a complete charging system in a small package. The battery is charged in three phases:
conditioning, constant or thermally regulated current, and constant voltage. Charge is terminated based on
minimum current. An internal programmable charge timer provides a backup safety feature for charge
termination and is dynamically adjusted during the thermal regulation phase. The bq2406x automatically
re-starts the charge if the battery voltage falls below an internal threshold; sleep mode is set when the
external input supply is removed. Multiple versions of this device family enable easy design of the
bq2406x in cradle chargers or in the end equipment, while using low-cost or high-end AC adapters.
1.2
Performance Specification Summary
This section summarizes the performance specifications of the EVM. Table 1 gives the EVM performance
specifications.
Table 1. Performance Specification Summary
SPECIFICATION
TEST CONDITIONS
Input DC Voltage, VI(DC)
VREG +0.5
Battery Charge Current, IO(CHG)
Power Dissipation
(1)
MIN
(V(DC+)– V(BAT+)) × I(CHG)
TYP
MAX
5
12 (1)
UNITS
Volts
1 (1)
Amperes
1.5
Watts
This maximum recommended input of the IC is 16.5 V. The IC has an OVP (overvoltage protection) input circuit that disables
the charging circuit if the threshold is exceeded. Most IC selections are set for 6.5 V, but some are set as high as 12 V (see
data sheet specification). The EVM can handle an input voltage up to the recommended maximum of 16.5 V, but the IC will be
shut down due to the internal voltage protection. It is recommended that in normal operation the IC be designed and run below
the thermal regulation junction temperature of 125°C. The thermal loop can run continuously without any issues, but the
suggested thermal loop operational use is for more harsh environments where the ambient temperature is high (e.g., in an
automobile during the summer) or with an incorrect adaptor with a higher input voltage. For typical input and ambient conditions
with the PowerPAD™ tied to a copper plane, one can expect 1.5 W of heat dissipation prior to the thermal loop reducing the
current. PdissIC = ICHG x (VDC+ - VBAT+). For the worst-case, steady-state thermal condition, VBAT+ = 3.4 VDC (the battery when
transitioning from precharge to fast charge reaches a steady-state value after approximately 2 minutes). If the thermal
regulation limit of 125°C is reached, then the charging current is adjusted lower.
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Test Summary
2
Test Summary
This section shows the test setups used and the tests performed in evaluating the EVM.
Setup: The bq2406xEVM board requires a 5-VDC, 1-A power source to provide input power and a
single-cell Li-ion or Li-polymer battery pack. The test setup connections and jumper setting selections are
configured for a stand-alone evaluation but can be changed to interface with external hardware such as a
microcontroller.
Table 2. I/O and Jumper Connections
Jack
Connect To:
J1-DC+
Power supply positive, preset to 5 VDC, 1-A current limit.
J1-DC–
Power supply ground
J2-BAT+
Positive battery pack terminal
J2-BAT–
Negative battery pack terminal
J2-TS
NC
J2-BAT–
NC
J3-STAT1
External hardware if J4-EXT is jumpered (Not jumpered from factory)
J3-STAT2
External hardware if J5-EXT is jumpered (Not jumpered from factory)
J3-DC–
Return for J3 signals
J3-PG
External hardware if J6-EXT if jumpered (Not jumpered from factory)
J4 (Jumper)
STAT1 indication location –LED (1)(EVM) | EXT
J5 (Jumper)
STAT2 indication location –LED (1) (EVM) | EXT
J6 (Jumper)
PG indication location –LED (1)(EVM) | EXT
J7 (Jumper)
TMR enable - Installed (1)
(1)
2.1
Factory jumper selections are shown in BOLD.
Test Procedure
Set up the evaluation board as previously described by making the necessary I/O connections and jumper
selections. Prior to test and evaluation, it is important to verify that the maximum power dissipation on the
IC is not exceeded, P(MAX) = 1.5 W.
1. Turn on the power supply, which was preset to 5 VDC, and 1 A for the current-limit setting.
2. The bq2406x enters preconditioning mode if the battery is below the V(LOWV) threshold. In this mode,
the bq2406x precharges the battery with a low current (typically IO(CHG) /10 = 0.7A/10 = 70 mA) until
the battery voltage reaches the V(LOWV) threshold or until the precharge timer expires. If the timer
expires, then the charge current is terminated and the bq2406x enters fault mode. Both LEDs turn off
when in fault mode. Toggling input power or battery replacement resets fault mode.
3. Once the battery voltage is above the V(LOWV) threshold, the battery enters fast-charge mode. This
EVM is programmed for 0.7 A of fast-charging current.
4. Once the battery reaches voltage regulation (4.2 V), the current tapers down as the battery reaches its
full capacity.
5. The battery remains at the fast charge mode until either the charge timer expires or the charge
termination current threshold is reached.
6. Once the charge terminates, J7 (TMR jumper) can be removed, putting the IC in LDO mode, and the
charger should turn on the supply 4.2 V or the programmed fast-charge current. Replacing the jumper
allows the IC to terminate properly. Note that loads across the battery can affect termination.
7. If the battery discharges to the recharge threshold, the charger starts fast charging.
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Test Summary
Note:
Because of the battery detection circuit, it is difficult to test the different charge phases
without a battery (using just resistors); the algorithm sinks and sources current and
applies precharge and fast-charge current depending on the mode it is in. Applying a load
that would keep the voltage at 3.5 V (3.5 V/0.7 A) would pull the output into precharge
mode and keep it there during the battery detection algorithm, which always occurs when
the output is discharged to the refresh threshold. Once in precharge mode, a load
sufficient to allow the capacitor to charge to V(lowV) would allow the output to jump to
voltage regulation once the 0.7-A fast charge function activated.
In place of a battery, a source meter that can sink current can easily be adjusted to test
each mode.
To briefly see each mode on a scope, connect a 1-mF capacitor in parallel with a 20-kΩ
resistor on the output in place of a battery to observe the power up and cycling between
voltage regulation and fast charge via the refresh threshold.
This is an alternative way of testing the EVM using a dynamic load board in place of a battery. The circuit
is adjusted to work with the displayed parts and their inherent thresholds. The sequence of the test
procedure is important due to the active battery detection circuit, refresh feature, precharge, and
fast-charge current levels (switching the load in and out in different modes has different results). No
damage should occur, but one might get different results than anticipated if the procedure is altered.
2.1.1
1.
2.
3.
4.
EQUIPMENT
Power Source: Current-limited 5-V laboratory power supply with its current limit set to 1 A ±0.1 A
Two Fluke 75 digital multimeters, equivalent or better
Oscilloscope – TDS220 or better
Load test board:
+
2.1.2
EQUIPMENT SETUP
1. Connect the load board to the BAT+ and BAT–. Set SW1 through SW4 in the closed position.
2. Connect a voltage meter to the BAT+/BAT– output to monitor the output voltage. (The range is 0 V to
5 V.)
3. Set the laboratory power supply for 5.1 V ± 0.1 VDC, 1-A ± 0.1-A current limit and then turn off this
supply. Connect the source supply to a current meter and to J1, noting polarity (an internal source
current meter can be used if it has 5% or better accuracy).
4. Install shunt jumpers on the LED pins 1 and 2 of each header J4, J5, and J6 and also on J7-1/2 TMR.
2.1.3
PROCEDURE
1. Ensure that the preceding Equipment Setup steps are followed (switches should be in the closed
position, shunts installed, and the power source set to 5.1 V ± 0.1 VDC). Turn on the power source.
2. Verify that the output voltage, BAT+, charges to between 2.5 V to 2.9 V and the red LED (D1) is lit (all
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Test Summary
dash numbers).
3. Verify that the green LED (D3) is lit for -001/2/5/6/7.
4. Verify that the voltage on J2-2 (TS, CE, TE) to J2-1 (BAT-) is between 2 VDC to 3 VDC for -001/3/5/6,
between 0 VDC to 0.4 VDC for -002/7, and between 4.6 VDC to 5.6 VDC for -004.
5. Verify the voltage between J6-2 (CE)and J1-2 (DC-) for -003/4. Jumper should not be shorting J6 pins.
6. Open switch SW2, and then close it.
7. Verify that the output voltage, BAT+, settles between 3.2 V to 3.95 V.
8. Verify that the input current is between 0.69 A to 0.75 A.
9. Open switch SW3.
10. Verify that the input current is between 100 mA and 150 mA.
11. Verify that the output voltage, BAT+, is between 4.150 VDC and 4.250 VDC.
12. Open switch SW2.
13. With a scope (250 ms/div, 1 V/div), verify that output, BAT+, charges and discharges between the
maximum limits of 3 V and 4.7 V, with a period of between 600 ms to 850 ms.
14. Verify that the LEDs flash between red (D1) and green (D2, mostly on green).
15. Remove J7 and verify that voltage on BAT+ is between 4.150 VDC and 4.250 VDC, and the red LED
(D1) turns on.
16. Install J7.
17. Open SW4, and verify that D1 and D2 are off and D3 is on (D3 does not apply to -003/4).
18. With a scope on BAT+, verify that a square wave is seen between the maximum limits of 1.3 VDC
and 4.35 VDC and between 3.5 Hz and 4.5 Hz.
19. Close switches SW2, SW3, and SW4 (all switches should be closed now), and power down the
supply.
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Schematic
3
Schematic
This section contains the schematic diagram for the EVM.
NOTE: C3 is optional and not installed.
Figure 1. EVM Schematic Diagram
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Physical Layouts
4
Physical Layouts
This section contains the board layout and assembly drawings for the EVM. Figure 2, Figure 3, and
Figure 4 show the top layer, the bottom layer, and the top assembly view of the EVM, respectively.
Figure 2. Board Layout Top Layer
Figure 3. Board Layout Bottom Layer
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Bill of Materials
Figure 4. Top Assembly View
5
Bill of Materials
This section contains the bill of materials required for the EVM.
Table 3. HPA149A Bill of Materials, bq2406xEVM (1) (2) (3)
bq24060
-001
bq24061
-002
bq24064
-005
Ref Des
Value
Description
Size
Part Number
MFR
Count
(1)
(2)
(3)
1
1
1
C1
0.1 µF
Capacitor, ceramic, 25V, X7R, 10%
0603
ECJ.-1VB1E104K
Panasonic
2
2
2
C2, C3
1 µF
Capacitor, ceramic, 25V, X5R, 10%
0805
ECJ-2FB1E105K
Panasonic
1
1
1
D1
Diode, LED, red, 1.8-V, 20-mA, 20-mcd
0603
1600-1181-1-ND
Liteon
1
1
1
D2
Diode, LED, green, 2.1-V, 20-mA, 6-mcd
0603
1600-1181-1-ND
Liteon
0
0
0
D3
Resistor, Chip, 0-Ω, 1/16-W, 1%
0603
Std
Std
1
1
1
J1
Terminal block, 2-pin, 6-A, 3,5 mm
0.27 × 0.25
ED1514
OST
2
2
2
J2, J3
Terminal block, 4-pin, 6-A, 3,5 mm
0.55 × 0.25
ED1516
OST
2
2
2
J4, J5
Header, 3-pin, 100-mil spacing, (36-pin strip)
0.100 × 3
PTC36SAAN
Sullins
1
1
1
J6
Header, 3-pin, 100-mil spacing, (36-pin strip)
0.100 × 3
PTC36SAAN
Sullins
0
0
0
J6 (3)
Header, 2-pin, 100-mil spacing, (36-pin strip)
0.100 × 2
PTC36SAAN
Sullins
1
1
1
J7
Header, 2-pin, 100-mil spacing, (36-pin strip)
0.100 in × 2
PTC36SAAN
Sullins
1
1
1
R8
0
Resistor, chip, 0-Ω, 1/16-W 1%
0603
Std
Std
3
3
3
R1, R2, R5
1.5k
Resistor, chip, 1.5-kΩ, 1/16-W 1%
0603
Std
Std
1
0
1
R3
1M
Resistor, chip, 1-MΩ, 1/16-W 1%
0603
Std
Std
1
1
1
R6
1M
Resistor, chip, 1-MΩ, 1/16-W 1%
0603
Std
Std
0
0
0
R9
1M
Resistor, chip, 1-MΩ, 1/16-W 1%
0603
Std
Std
1
1
1
R4
1.13K
Resistor, chip, 1.13 kΩ, 1/16-W 1%
0603
Std
Std
1
1
1
R7
49.9k
Resistor, chip, 49.9 kΩ, 1/16-W 1%
0603
Std
Std
0
0
0
TP1, TP2,
TP3
Std
Std
0
Test Point, 0.032 hole
When J6 is a 2 pin header, Install in J6-1/2
Install Jumper Shunts, for -001/2/5/6/7, on: J4-1/2 (LED), J5-1/2 (LED), J6-1/2 (LED), and J7-1/2.
Install Jumper Shunts, for -003/4, on: J4-1/2 (LED), J5-1/2 (LED), J6-1 (just pin 1), and J7-1/2
bq24062/3/5/6 are not released at this time. Check WEB for availability.
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References
Table 3. HPA149A Bill of Materials, bq2406xEVM (continued)
bq24060
-001
bq24061
-002
bq24064
-005
Ref Des
Value
Description
Size
Part Number
MFR
Count
6
1
0
0
U1
IC, TPOD, PG, TS
3×3 mm
bq24060DRC
TI
0
1
0
U1
IC, TPOD, PG, CE
3×3 mm
bq24061DRC
TI
0
0
0
U1
IC, TPOD, PG, CE
3×3 mm
bq24062DRC
TI
0
0
0
U1
IC, TPOD, PG, CE
3×3 mm
bq24063DRC
TI
0
0
1
U1
IC, TPOD, PG, CE
3×3 mm
bq24064DRC
TI
0
0
0
U1
IC, TPOD, PG, CE
3×3 mm
bq24065DRC
TI
0
0
0
U1
IC, TPOD, PG, CE
3×3 mm
bq24066DRC
TI
1
1
1
—
PCB, 1.3 in × 1 in × 0.031 in
HPA149, PCB EVM
Any
4
4
4
Shunt (2)
Shunt
Guess
Shunt
References
1. bq24060 data sheet (SLUS689)
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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
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electromagnetic compatibility, restricted substances (RoHS), recycling (WEEE), FCC, CE or UL, and therefore may not meet the
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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
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This evaluation board/kit is intended for use for ENGINEERING DEVELOPMENT, DEMONSTRATION, OR EVALUATION
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EVM WARNINGS AND RESTRICTIONS
It is important to operate this EVM within the input voltage range of 4.4 V to 16 V and the output voltage range of 2.3 V to 4.4 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 75°C. The EVM is designed to
operate properly with certain components above 100°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.
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