BQ24091EVM

User's Guide SLUU392A – December 2009 – Revised June 2010 1.0-A Single-Input, Single-Cell Li-Ion Battery Charger This user’s guide describes the bq24090/1/2/3 evaluation module (EVM), how to perform a stand-alone evaluation or interface with a host or system. The charger is designed to deliver up to 1000mA of continuous current to the battery output when programmed with a resistor on the ISET pin and is programmed at the factory for ~540mA. The USB current limit modes are selected by the ISET2 pin and limits current to a maximum of 500mA (logic high) or 100mA (float or high impedance). A low on the ISET2 pin programs the charge current using the ISET resistor. 1 2 3 4 5 Contents Introduction .................................................................................................................. Considerations With Evaluating the bq24090/1/2/3 .................................................................... Performance Specification Summary ..................................................................................... Test Summary ............................................................................................................... 4.1 Equipment ........................................................................................................... 4.2 Equipment and EVM Setup ....................................................................................... 4.3 Test Procedure Using a Single Cell Li-Ion Battery ............................................................ 4.4 Alternate Test Methods ........................................................................................... Schematic, Physical Layouts and Bill of Materials ..................................................................... 5.1 Schematic ........................................................................................................... 5.2 Physical Layouts ................................................................................................... 5.3 Bill of Materials ..................................................................................................... 2 2 2 2 3 3 4 4 5 5 6 8 List of Figures 1 EVM Setup ................................................................................................................... 3 2 bq24090/1/2/3 EVM Board Schematic ................................................................................... 5 3 Assembly Layer ............................................................................................................. 6 4 Top Layer .................................................................................................................... 6 5 Bottom Layer ................................................................................................................ SLUU392A – December 2009 – Revised June 2010 1.0-A Single-Input, Single-Cell Li-Ion Battery Charger Copyright © 2009–2010, Texas Instruments Incorporated 7 1 Introduction 1 www.ti.com Introduction The bq24090/1/2/3 series of devices are highly integrated Li-ion linear charger devices targeted at space-limited portable applications. The devices operate from either a USB port or AC adapter. The bq24090/1/2/3 has a single power output that charges the battery. A system load can be placed in parallel with the battery as long as the average system load does not keep the battery from charging fully during the 10 hour safety timer. The battery is charged in three phases: conditioning, constant current, and constant voltage. In all charge phases, an internal control loop monitors the IC junction temperature and reduces the charge current if an internal temperature threshold is exceeded. The charger power stage and charge current sense functions are fully integrated. The charger function has high-accuracy current and voltage regulation loops, charge status display, and charge termination. The pre-charge current and termination current threshold are programmed via an external resistor on the bq24090/1/2/3. The fast charge current value is also programmable via an external resistor. 2 Considerations With Evaluating the bq24090/1/2/3 Refer to the data sheet for specific details on the charger ICs. The main differences between the bq24090, at 25° and bq24091 is that NTC thermistor valve is 10k for bq24090 and 100k for bq24091. The ISET current control loop sets the maximum charge current. This maximum programmed current level can be further reduced by entering a USB mode, selected by the ISET2 pin. A system load may be connected to the OUT pin, which takes away some of the charge current. Normally it is not recommended to operate the device in pre-charge since the system load keeps the battery from recovering; but, since the PRE_TERM pin can program a higher pre-charge current this restriction is not necessary. 3 Performance Specification Summary Specification Test Conditions MIN MAX UNIT Input DC voltage, Vin Recommended input voltage range 4.45 6.45 V 3.5 28 V 1.5 W 0.8 A Reduced Performance, Vin Will not charge with Over Voltage input condition. Limited charging with under voltage input. Power Dissipation (2) PDISS = (VIN – VOUT) × IOUT IOUT RISET = 1k (1) (2) 4 (1) TYP 0.54 Input voltage range is specified for normal operation. Input voltage between UVLO and 4.75 V has limited functionality, but does not damage the IC nor present any safety issue with the battery. Input voltage above OVP and less than 30 Vdc has no operation and will not damage the IC. Lower input voltage (closer to dropout operation) produces less heat dissipation and potentially better performance. The junction temperature rise above ambient is proportional to the power dissipation. Once the junction temperature reaches ~125°C, thermal regulations reduces the programmed charge current. Test Summary The bq24090/1/2/3 EVM 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. 2 1.0-A Single-Input, Single-Cell Li-Ion Battery Charger SLUU392A – December 2009 – Revised June 2010 Copyright © 2009–2010, Texas Instruments Incorporated Test Summary www.ti.com 4.1 Equipment • • • • 4.2 Power supply +5.1 ±0.1 V, current limit set to 1.5 ±0.1 A Battery: 4.2 V LiCoO2 or equivalent Three Fluke 75 DMMs (equivalent or better) Oscilloscope, Model TDS220 (equivalent or better) Equipment and EVM Setup Jack/Component Connect or Adjustment 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 JMP1 Apply shunt for Pre-TERM connection. JMP2 Apply shunt for PG LED connection. JMP3 Apply shunt for ISET2: ISET2-LO (pins 2-3) connection. JMP4 Apply shunt for CHG LED connection. JMP5 Apply shunt for TS connection. R2 (RISET) Adjust R2 for 1k between TP2 and GND R3 (RPRE-TERM) Adjust R4 for 2k between TP4 and GND R11 ( RTS) Adjust R11 for 10k between TP9 and GND PS # 1 + 5 V bq24090/1 + ++ Figure 1. EVM Setup SLUU392A – December 2009 – Revised June 2010 1.0-A Single-Input, Single-Cell Li-Ion Battery Charger Copyright © 2009–2010, Texas Instruments Incorporated 3 Test Summary 4.3 www.ti.com Test Procedure Using a Single Cell Li-Ion Battery 1. Verify that the setup is correct and turn on the power supply, which was preset to 5 VDC, and 1 A for the current-limit setting. 2. The bq24090/1/2/3 enters preconditioning mode if the battery is below the V(LOWV) threshold. In this mode, the bq24090/1/2/3 pre-charges the battery with a low current programmed by the PRE-TERM resistor (typically set to 10% of fast charge) until the battery voltage reaches the V(LOWV) threshold or until the pre-charge timer expires. If the timer expires, then the charge current is terminated and the bq24090/1/2/3 enters fault mode. The CHG LED turns off when in timer fault mode. Toggling input power, toggling TS (BAT_EN) or battery replacement resets fault mode. 3. When the battery voltage rises above the V(LOWV) threshold, the battery enters fast-charge constant current mode. This EVM is programmed for 0.54 A of fast-charging current. 4. Remove the shunt from JMP3 and see the IC go into USB100 mode (charge current drops); place shunt between ISET2 and HI and see the USB500 mode; return shunt to ISET2-GND for programmed current. 5. (a) For bq24090/1: Adjust R11 (TS potentiometer) clockwise until the cold fault threshold is reached (VTS = ~1.4V); note that the charging stops, and the CHG LED STAYS on (for 1st charge only). Adjust R11 until VTS ≈ 0.5; note that the charging has continued. Continue adjusting R11 until VTS ≈ 150 mV; note that charging has stopped due to a high temperature fault and the CHG LED remains on during the first charge. Adjust R11 until VTS ≈ 0.5V. (b) For bq24092/3: Adjust R11 (TS potentiometer) clockwise until the cold operation threshold is reached (VTS = ~790mV); note that the fast charge current drops to have the amplitude, Continue to adjust R11 until the cold fault threshold is reached (VTS = ~1.4V); note that the charging stops, and the CHG LED STAYS on (for 1st charge only). Adjust R11 until VTS ≈ 0.5; note that the charging has continued. Continue adjusting R11 until VTS ≈ 278 mV; note that in voltage regulation mode the regulation voltage will be ~4.06V. Continue adjusting R11 until VTS ≈ 150 mV; note that charging has stopped due to a high temperature fault and the CHG LED remains on during the first charge. Adjust R11 until VTS ≈ 0.5V and verify that charging continues. 6. Once the battery reaches the voltage regulation threshold (4.2 V), the voltage control loop takes over and the current tapers down as the battery reaches its full capacity. 7. The battery remains at the fast-charge mode until either the charge timer expires or the charge termination current threshold is reached. 8. When the charge terminates, the CHG LED turns off. 9. Remove JMP5 (TS) and the charger turns on. This mode is Termination and Timer Disable Mode (TTDM). This allows continuous power applied from the input to the output, regulated to 4.2V with a maximum current programmed by the ISET resistor (can be restricted further if in USB mode). The system can operate without a battery in this mode as long as the system does not exceed the supplied input current. 10. If the battery discharges to the recharge threshold, the charger starts fast charging, but the CHG LED will not come on for the subsequent charges. Cycling the input power, replacing the battery, or toggling the TS pin low starts a new charge with the CHG LED on. NOTE: Loads across the battery can affect termination. The pre-term pin can be adjusted to offset the system current. See data sheet for more details. 4.4 Alternate Test Methods A 4-quadrant power supply that can source and sink current can be used in place of the battery pack to evaluate the charger. It allows each transfer between pre-charge, constant-current and constant voltage fast charge. Keep leads short to avoid adding too much inductance which may cause an interaction between the power supply and charger. A large capacitor across the output helps cancel the inductance if long leads are necessary. 4 1.0-A Single-Input, Single-Cell Li-Ion Battery Charger SLUU392A – December 2009 – Revised June 2010 Copyright © 2009–2010, Texas Instruments Incorporated Schematic, Physical Layouts and Bill of Materials www.ti.com 5 Schematic, Physical Layouts and Bill of Materials 5.1 Schematic Figure 2. bq24090/1/2/3 EVM Board Schematic SLUU392A – December 2009 – Revised June 2010 1.0-A Single-Input, Single-Cell Li-Ion Battery Charger Copyright © 2009–2010, Texas Instruments Incorporated 5 Schematic, Physical Layouts and Bill of Materials 5.2 www.ti.com Physical Layouts Figure 3. Assembly Layer Figure 4. Top Layer 6 1.0-A Single-Input, Single-Cell Li-Ion Battery Charger SLUU392A – December 2009 – Revised June 2010 Copyright © 2009–2010, Texas Instruments Incorporated Schematic, Physical Layouts and Bill of Materials www.ti.com Figure 5. Bottom Layer SLUU392A – December 2009 – Revised June 2010 1.0-A Single-Input, Single-Cell Li-Ion Battery Charger Copyright © 2009–2010, Texas Instruments Incorporated 7 Schematic, Physical Layouts and Bill of Materials 5.3 www.ti.com Bill of Materials Table 1. HPA506B Bill of Materials -001 -002 -003 -004 RefDes Value Description Size Part Number MFR 1 1 1 1 C1 1 µF Capacitor, Ceramic, 25V, X5R, 10% 0603 ECJ-1VB1E105K Panasonic 0 0 0 0 C2 Capacitor, Ceramic, 25V, X5R, 10% 0805 ECJ-2FB1E225K Panasonic 1 1 1 1 C3 Capacitor, Ceramic, 10V, X5R, 10% 0603 ECJ-1VB1A225K Panasonic 0 0 0 0 C4 Capacitor, Ceramic, 10V, X5R, 10% 0805 ECJ-2FB1A106K Std 0 0 0 0 C5 Capacitor, Ceramic, 10V, X5R, 10% 0603 ECJ-1VB1A225K Panasonic 2 2 2 2 D1, D2 LTST-C190GKT Diode, LED, Green, 2.1-V, 20-mA, 6-mcd 0603 LTST-C190GKT Lite On 0 0 0 0 D3 BZX84C5V6-7-F Diode, Zener, 5.6-V, 350-mW SOT-23 BZX84C5V6-7-F Diodes 1 1 1 1 J1 ED555/2DS Terminal Block, 2-pin, 6-A, 3.5mm 0.27 x 0.25 inch ED555/2DS OST 1 1 1 1 J2 ED555/4DS Terminal Block, 4-pin, 6-A, 3.5mm 0.55 x 0.25 inch ED555/4DS OST 4 4 4 4 JMP1, JMP2, JMP4, JMP5 PEC02SAAN Header, Male 2-pin, 100mil spacing, 0.100 inch x 2 PEC02SAAN Sullins 1 1 1 1 JMP3 PEC03SAAN Header, Male 3-pin, 100mil spacing, 0.100 inch x 3 PEC03SAAN Sullins 1 1 1 1 R1 665 Resistor, Chip, 1/16W, 1% 0603 Std Std 1 0 1 0 R11 50k Potentiometer, 3/8 Cermet, Single-Turn 0.25x0.17 inch 3266W-503-LF Bourns 0 1 0 1 R11 500k Potentiometer, 3/8 Cermet, Single-Turn 0.25x0.17 inch 3266W-504-LF Bourns 2 2 2 2 R2, R4 10k Potentiometer, 3/8 Cermet, Single-Turn 0.25x0.17 inch 3266W-103-LF Bourns 2 2 2 2 R3, R12 1.0k Resistor, Chip, 1/16W, 1% 0603 Std Std 2 2 2 2 R5, R9 1.5k Resistor, Chip, 1/16W, 1% 0603 Std Std 0 0 0 0 R6, R13, R14 Resistor, Chip, 1/16W, 1% 0603 Std Std 1 1 1 1 R7 10k Resistor, Chip, 1/16W, 1% 0603 Std Std 2 2 2 2 R8, R10 0 Resistor, Chip, 1/16W, 1% 0603 Std Std 1 0 0 0 U1 BQ24090DGQ IC, 800mA, Single-Input, Single Cell Li-Ion BATTERY CHARGER HTSSOP BQ24090DGQ TI 0 1 0 0 U1 BQ24091DGQ IC, 800mA, Single-Input, Single Cell Li-Ion BATTERY CHARGER HTSSOP BQ24091DGQ TI 0 0 1 0 U1 BQ24092DGQ IC, 800mA, Single-Input, Single Cell Li-Ion BATTERY CHARGER HTSSOP BQ24092DGQ TI 0 0 0 1 U1 BQ24093DGQ IC, 800mA, Single-Input, Single Cell Li-Ion BATTERY CHARGER HTSSOP BQ24093DGQ TI 5 5 5 5 Shunt (Note 5) Shunt, 100-mil, Black 0.1 929950-00 3M 1 1 1 1 – PCB, 3 In x 1.85 In x 0.0031 In HPA506 Any 2.2 µF 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. Apply shunt to JMP1/2/4/5 and JMP3:2/3. 8 1.0-A Single-Input, Single-Cell Li-Ion Battery Charger SLUU392A – December 2009 – Revised June 2010 Copyright © 2009–2010, Texas Instruments Incorporated 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. 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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. EVM WARNINGS AND RESTRICTIONS It is important to operate this EVM within the power supply voltage range of 4.45 V and 6.45 V. Input voltage range is specified for normal operation. Input voltage between UVLO and 4.75 V has limited functionality, but does not damage the IC nor present any safety issue with the battery. Input voltage above OVP and less than 30 Vdc has no operation and will not damage the IC. Lower input voltage (closer to dropout operation) produces less heat dissipation and potentially better performance. 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 60°C. The EVM is designed to operate properly with certain components above 60°C as long as the input and output ranges are maintained. 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