User's Guide
SLUU358 – April 2009
1.1-A, Single-Input, Single-Cell, Li-Ion Battery Charger
With 50-mA LDO and 2.3-A Production Test Support
This user's guide describes the bq25040 evaluation module (EVM), how to setup the EVM to perform a
stand-alone evaluation or interface with a system or host. The charger is designed to deliver up to 1.1 A of
continuous current to the battery output in the adapter mode, ISET, or current limits the input to either 100
mA or 500 mA when in USB100/500 modes. The charge is programmed from the factory for 0.51 A in
ISET mode. In the Protection Test Support (PTS) mode, the battery output is capable of delivering > 2.3 A
of current for short pulses. The LDO regulator output can deliver up to 50 mA of current.
1
2
3
4
5
6
7
Contents
Introduction ...................................................................................................................
Considerations When Testing the bq25040 IC ..........................................................................
Performance Specification Summary .....................................................................................
Test Summary ................................................................................................................
4.1
Equipment ...........................................................................................................
4.2
Equipment and EVM Setup........................................................................................
4.3
Test Procedure ......................................................................................................
Schematics ...................................................................................................................
Layout .........................................................................................................................
Bill of Materials ...............................................................................................................
2
2
2
3
3
3
3
6
7
8
List of Figures
1
2
3
4
5
6
7
8
9
Evaluation Setup Charging Circuit Shown; Pulse Programming Circuit not Shown ................................
One-Pulse Programming Shows Change From USB500 to ISET Mode .............................................
Two-Pulse Programming Shows Timing of Program Change From 0.4 A to 0.1 A .................................
Power-Up Sequence Shows Timing Between Vin, Viset, Vpg, and Vchg. C1: Chg @ JMP1; C4: PG @
JMP8; LEDs Pulled Up to 4.15-V Battery ................................................................................
Basic EVM Charger Circuit .................................................................................................
Circuit for Programming Pulse (Typically Done by Host) ...............................................................
Assembly Layer ..............................................................................................................
Top Copper Layer ...........................................................................................................
Bottom Copper Layer Bottom View .......................................................................................
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4
5
5
6
6
7
7
8
List of Tables
1
HPA437A Bill of Materials - bq25040 ..................................................................................... 8
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1
Introduction
1
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Introduction
The bq25040 is an integrated Li-ion linear battery charger targeted at space-limited portable applications.
It operates from either a USB port or ac adapter and charges a single-cell, Li-Ion battery with up to 1.1 A
of charge current. The bq25040 has a single-power output that charges the battery. A system load can be
placed in parallel with the battery. The charge current is programmed using the ISET and EN/SET inputs.
The charge current is programmable to USB100, USB500, or a user-programmed charge current up to 1.1
A. Additionally, a 4.9-V, 3%, 50-mA LDO is integrated into the integrated circuit (IC) for supplying
low-power external circuitry. The single-input interface (EN/SET) is used to select the charge current and
to place the bq25040 into Production Test Mode (PTM). In PTM, the bq25040 operates as a linear
regulator without a battery connected, where the output is regulated at 4.2 V and supplies up to 2.3 A to
calibrate GSM transceivers.
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 accuracy current and voltage regulation loops, charge status display, and charge termination.
2
Considerations When Testing the bq25040 IC
The input current is regulated by the ISET loop or may be restricted by the USB current-limit circuitry
when in either USB100 or USB500 mode.
The input connection to the LDO is connected upstream of the charge-sense circuit and is not part of the
current-regulation or current-limit circuit. It is the designer's responsibility to ensure that excessive loading
on the LDO output does not exceed USB specifications. The USB500 mode is set for a 400-mA current
limit so that the LDO load does not cause the USB500 limit to be exceeded.
The LEDs can be run from any power source and are connected to the LDO from the factory. Moving the
resistor from R20 to R21 connects the LEDs to the battery. Note that as the battery voltage decreases, the
illuminated LED dims.
JMP6 is a connection to an onboard pulse generator circuit that can program the desired mode via pulses.
Use only one shunt on JMP1 through JMP5 to program one through five pulses, respectively. The pulse
generator always starts or stops in the low state, which leaves the IC in its active state. The part can only
be programmed once unless it is reset by cycling power or removing JMP6. Removing JMP6 allows
EN/SET to be pulled high and disables the IC. Reapplying the shunt to JMP6 pulls EN/SET low and
enables the IC to the USB500 mode. Toggling switch S1 from the UP position to the DOWN position and
back UP delivers the program pulse(s) to the IC.
3
Performance Specification Summary
SPECIFICATION
TEST CONDITIONS
MIN
TYP
MAX
Input dc voltage, VIN
In recommended voltage range
4.75
5
6.5
Reduced performance range, Vin
Voltage outside recommended range
Power dissipation
Pdiss = (VIN Vout) (1) Iout (2)
IOUT
R1 = 1k
(1)
(2)
2
(1)
3.5
0.5
UNITS
V
30
V
1.5
W
0.8
A
Input voltage range is specified for normal operation. Input voltage between UVLO and 4.75 V has limitations and may have
some 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 charge current when not in PTS mode.
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Test Summary
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4
Test Summary
This section covers the setup and tests performed in evaluating the EVM.
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
LDO Load: from 100-Ω to 10k-Ω resistor
Three Fluke 75 DMMs (equivalent or better)
Oscilloscope, Model TDS220 (equivalent or better)
Equipment and EVM Setup
•
•
•
•
•
•
•
Preset P/S#1 to 5.1 ±0.1 V, 1.5 ±0.1-A current limit, turn off and connect to J1 (+ to IN and - to GND).
Connect a fully discharged battery to J2 (+ to BAT+ and - to BAT-).
Apply a 1-kΩ load resistor to J3-1/2.
Apply shunt jumpers to JMP1, JMP6, JMP7, and JMP8.
Set switch, SW1, in the UP position.
Adjust R7 fully CW, and then back off four turns CCW.
Connect the DMMs and oscilloscope as shown in Figure 1, if desired.
Figure 1. Evaluation Setup Charging Circuit Shown; Pulse Programming Circuit not Shown
4.3
Test Procedure
1. Make sure setup procedure was followed.
2. Turn on P/S#1; preset to 5.1 Vdc.
3. Verify that the PG (D1) and CHG (D2) LEDs turned on. Verify that the input/output current is around
~0.4 A (DMM3 is ~40 mV). This is the power-up USB500 default mode (no programming pulses have
been delivered yet) and typically delivers up to ~400 mA. The charge current limit is set lower than 500
mA to ensure that the total charge and LDO (maximum of 50 mA) current do not exceed 500 mA on
the input.
4. Set the scope to trigger off of CH2 (positive trigger, 1 ms/div), to capture the program pulse going to
(EN/SET TP6). Note that only one shunt at a time should be placed on JMP1 through JMP5 to select
the desired number of programmed pulses.
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3
Test Summary
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5. Switch, S1, DOWN, then back UP. The scope captures one pulse on CH2 (Figure 2). The pulse must
be less than 1.5-ms wide. If too wide, the potentiometer, R7, can adjust the pulse width.
6. Verify that the input current changes from 0.4 A to 0.51 A (one pulse programmed the IC for ISET
mode). The ISET resistor, 1 kΩ, programs the ISET mode to ~0.51 A. Note that the IC can only be
programmed once. If a different program level is desired, the part must be reset by cycling power or
pulling EN/SET high to disable the IC.
7. Remove shunt JMP6, and verify that the input current goes to zero. Removing the shunt, JMP6, allows
EN/SET to be pulled up. This disables the charge and allows programming to be done once EN/SET is
pulled back low by replacing the shunt JMP6.
8. Replace shunt on JMP6, and move shunt on JMP1 to JMP2 (two-pulse programming). The charger
returns to the USB500 mode, delivering ~400 mA. If the IC comes up in a different mode, then while
placing the shunt on JMP6, a contact bounce occurred and the IC was programmed. Remove and
replace the shunt if this happens.
9. Switch, S1, DOWN, then UP to program charger to USB100 mode (Figure 3).
10. This procedure can be repeated (steps 7 to 9) for the shunt on any jumper JMP1 through JMP5 to
program one to five pulses, respectively. Note that programming three pulses puts the IC in PTS mode
and delivers > 2.3 A if the source current is available and the load is great enough. This mode is
intended for production testing without a battery. If a less-than-full battery is connected, the current
may exceed the recommended charge current of the battery or the charger circuit. For maximum
current, the duty cycle must be less than 20% and for no longer than 10 ms. See the data sheet for
programming information (SLUS910).
11. Verify that the LDO output voltage on DMM#2 measures ~4.9 Vdc, 0.1 V.
12. Allow battery to charge to full and verify that D2 LED turns off.
13. Discharge battery below 4.1 V, and verify that the charging is enabled and the D2 CHG LED is off for
the second and subsequent charges.
14. Figure 4 shows the power up and timing of the Stat pins and charge current.
Vin
V_EN/SET
Vout
V_0.1 ohm_BAT
Figure 2. One-Pulse Programming Shows Change From USB500 to ISET Mode
4
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SLUU358 – April 2009
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Test Summary
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Vbat
Viset
V_0.1 ohm_BAT
Ven/set
Figure 3. Two-Pulse Programming Shows Timing of Program Change From 0.4 A to 0.1 A
Vin
Viset
C1
C2
C3
Vchg
Vpg
C4
Figure 4. Power-Up Sequence Shows Timing Between Vin, Viset, Vpg, and Vchg. C1: Chg @ JMP1; C4:
PG @ JMP8; LEDs Pulled Up to 4.15-V Battery
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5
Schematics
5
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Schematics
Figure 5. Basic EVM Charger Circuit
Figure 6. Circuit for Programming Pulse (Typically Done by Host)
6
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Layout
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6
Layout
Figure 7. Assembly Layer
Figure 8. Top Copper Layer
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Bill of Materials
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Figure 9. Bottom Copper Layer Bottom View
7
Bill of Materials
Table 1. HPA437A Bill of Materials - bq25040
Count
8
RefDes
Value
Description
Size
Part Number
MFR
1
C1
1F
Capacitor, Ceramic, 25V, X5R, 10%
0805
ECJ-2FB1E105K
Panasonic
9
C2, C3,
C6C12
1F
Capacitor, Ceramic, 10V, X5R, 10%
0603
ECJ-1VB1A105K
Panasonic
1
C4
10 F
Capacitor, Ceramic, 25V, X5R, 10%
1210
ECJ-3YB1E106K
Panasonic
1
C5
47 F
Capacitor, Ceramic, 10V, XR5, 20%
1210
ECJ-4YB1A476M
Panasonic
2
D1, D2
LTST-C190GKT
Diode, LED, Green, 2.1-V, 20-mA,
6-mcd
0603
LTST-C190GKT
Lite On
1
D3
BZX84C10LT1G
Diode, Zener, 10-V, 350-mW
SOT-23
BZX84C10LT1G
On Semi
4
GND1 GND4
BLK
Test Point, 0.032 Hole
5011
Keystone
3
J1J3
ED555/2DS
Terminal Block, 2-pin, 6-A, 3,5mm
0.27 0.25 inch
ED555/2DS
OST
8
JMP1JMP8
PTC36SAAN
Header, Male 2-pin, 100mil spacing,
(36-pin strip)
0.100 inch 2
PTC36SAAN
Sullins
1
Q1
MMBT3904LT1G
Bipolar, NPN, 40-V, 200-mA,225-mW
SOT23
MMBT3904LT1G
On Semi
1
R1
1k
Resistor, Chip, 1/16W, 1%
0603
Std
Std
2
R11, R12
1.0k
Resistor, Chip, 1/16W, 1%
0603
Std
Std
0
R21
DNI
Resistor, Chip, 1/16W, 1%
0603
Std
Std
2
R3, R4
1.5k
Resistor, Chip, 1/16W, 1%
0603
Std
Std
3
R5, R17, R18
100k
Resistor, Chip, 1/16W, 1%
0603
Std
Std
1
R6
100
Resistor, Chip, 1/16W, 1%
0603
Std
Std
1
R2
2k
Resistor, Chip, 1/16W, 1%
0603
Std
Std
1
R7
2k
Potentiometer, 1/4 in. Cermet, 12-Turn,
Top-Adjust
0.25 0.17
3266W-202
Bourns
6
R8, R13R16,
R20
0k
Resistor, Chip, 1/16W, 1%
0603
Std
Std
3
R9, R10, R19
10k
Resistor, Chip, 1/16W, 1%
0603
Std
Std
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Bill of Materials
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Table 1. HPA437A Bill of Materials - bq25040 (continued)
Count
RefDes
Value
Description
Size
Part Number
MFR
1
S1
G12AP
Switch, ON-ON Mini Toggle
0.28 0.18 inch
G12AP
NKK
4
TP1, TP2,
TP6, TP10
WHT
Test Point, O.032 Hole
5012
Keystone
1
U1
BQ25040DQC
IC, 1.2A, Single-Input, 1 Cell Li-Ion
CHARGER
TDFN-10
BQ25040DQC
TI
1
U2
TPS76133DBV
IC, Low-Power 100 mA LDO Regulator
SOT23-5
TPS76133DBV
TI
1
U3
SN74LV175APW
IC, Quad D-Flip Flop with Clear
TSSOP
SN74LV175APW
TI
1
U4
MC74HC74ADTR2G
IC, Dual D Flip Flop with Set and Reset
TSSOP
MC74HC74ADTR2G
On Semi
1
U5
SN74LVC2G132DCT
R
IC, Dual 2-Input NAND Gate With
Schmitt-Trigger Inputs
SSOP-8
SN74LVC2G132DCTR
TI
1
U6
SN74HC10QPWREP
IC, Triple 3-Input Positive NAND Gate
TSSOP
SN74HC10QPWREP
TI
929950-00
Shunts
100 mill
Black
3M
HPA437
Any
4
1
PCB, 1.9 In 2 In 0.031 In
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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
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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 SELLER TO BUYER
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This evaluation board/kit is intended for use for ENGINEERING DEVELOPMENT, DEMONSTRATION, OR EVALUATION PURPOSES
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EVM WARNINGS AND RESTRICTIONS
It is important to operate this EVM within the input voltage range of 0 V to 30 V and the output voltage range of 0 V to 4.25 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 85°C. The EVM is designed to operate
properly with certain components above 85°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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