User's Guide
SLUUAA8A – September 2013 – Revised August 2014
User's Guide for bq25505 Battery Charger Evaluation
Module for Energy Harvesting
This user’s guide describes the bq25505 evaluation module (EVM), how to perform a stand-alone
evaluation and how to allow the EVM to interface with the system and host. The boost charger output is
configured to deliver up to 4.2-V maximum voltage to its output, VSTOR, using external resistors. This
voltage is applied to the storage element as long as the storage element voltage at VBAT_SEC is above
the internally programmed undervoltage of 2 V. The VBAT_OK indicator toggles high when VSTOR ramps
up to 3 V and toggles low when VSTOR ramps down to 2.8 V.
5
Contents
Introduction ................................................................................................................... 2
1.1
EVM Features ....................................................................................................... 2
1.2
General Description ................................................................................................ 2
1.3
Design and Evaluation Considerations .......................................................................... 3
1.4
bq25505EVM Schematic........................................................................................... 4
1.5
EVM I/O Connections .............................................................................................. 5
EVM Performance Specification Summary ............................................................................... 7
Test and Measurement Summary ......................................................................................... 7
3.1
Test Setups and Results ........................................................................................... 8
Bill of Materials and Board Layout ....................................................................................... 15
4.1
Bill of Materials .................................................................................................... 15
4.2
EVM Board Layout ................................................................................................ 16
PCB Layout Guideline ..................................................................................................... 20
1
bq25505EVM Schematic.................................................................................................... 4
2
Test Setup for Measuring Boost Charger Efficiency .................................................................... 9
3
Charger Efficiency versus Input Voltage .................................................................................. 9
4
Charger Efficiency versus Input Current ................................................................................ 10
5
Test Setup for Measuring Charger Operation .......................................................................... 11
6
Charger Operational Waveforms During Battery Charging ........................................................... 11
7
Test Setup ................................................................................................................... 12
8
Switching from Primary to Secondary Battery .......................................................................... 13
9
Test Setup for Charging a Super Capacitor on VBAT_SEC.......................................................... 13
10
Charging a Super Cap on VBAT_SEC
11
EVM PCB Top Silk ......................................................................................................... 16
12
EVM PCB Top Assembly .................................................................................................. 17
13
EVM PCB Top Layer
1
2
3
4
List of Figures
14
.................................................................................
......................................................................................................
EVM PCB Bottom Layer ...................................................................................................
14
18
19
List of Tables
1
2
................................................. 5
Bill of Materials ............................................................................................................. 15
I/O Connections and Configuration for Evaluation of bq25505 EVM
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User's Guide for bq25505 Battery Charger Evaluation Module for Energy
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1
Introduction
1
Introduction
1.1
EVM Features
•
•
•
•
•
•
1.2
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Evaluation module for bq25505
Ultra-low power boost converter/charger with battery management for energy harvester applications
Resistor-programmable settings for overvoltage providing flexible battery management
Programmable push-pull output indicator for battery status (VBAT_OK)
Test points for key signals available for testing purpose – easy probe hook-up
Jumpers available – easy to change settings
General Description
The bq25505 is an integrated energy harvesting Nano-Power management solution that is well suited for
meeting the special needs of ultra-low power applications. The product is specifically designed to
efficiently acquire and manage the microwatts (µW) to milliwatts (mW) of power generated from a variety
of high output impedance (Hi-Z) DC sources like photovoltaic (solar) or thermal electric generators; or with
an AC/DC rectifier, a piezoelectric generator. The bq25505 implements a highly efficient, pulse-frequency
modulated (PFM) boost converter/charger targeted toward products and systems, such as wireless sensor
networks (WSN) which have stringent power and operational demands. Assuming a depleted storage
element has been attached, the bq25505 DC-DC boost converter/charger that requires only microwatts of
power to begin operating in cold-start mode. Once the boost converter output, VSTOR, reaches ~1.8 V
and can now power the converter, the main boost converter can now more efficiently extract power from
low voltage output harvesters such as thermoelectric generators (TEGs) or single- and dual-cell solar
panels. For example, assuming the Hi-Z input source can provide at least 5 µW typical and the load on
VSTOR (including the storage element leakage current) is less than 1 µA of leakage current, the boost
converter can be started with VIN_DC as low as 330 mV typical, and once VSTOR reaches 1.8 V, can
continue to harvest energy down to VIN_DC ≃ 120 mV.
Hi-Z DC sources have a maximum output power point (MPP) that varies with ambient conditions. For
example, a solar panel's MPP varies with the amount of light on the panel and with temperature. The MPP
is listed by the harvesting source manufacturer as a percentage of its open circuit (OC) voltage. Therefore,
the bq25505 implements a programmable maximum power point tracking (MPPT) sampling network to
optimize the transfer of power into the device. The bq25505 periodically samples the open circuit input
voltage every 16 seconds by disabling the boost converter for 256 ms and stores the programmed MPP
ratio of the OC voltage on the external reference capacitor (C2) at VREF_SAMP. Typically, solar cells are
at their MPP when loaded to ~70–80% of their OC voltage and TEGs at ~50%. While the storage element
is less than the user programmed maximum voltage (VBAT_OV), the boost converter loads the harvesting
source until VIN_DC reaches the MPP (voltage at VREF_SAMP). This results in the boost charger
regulating the input voltage of the converter until the output reaches VBAT_SEC_OV, thus transferring the
maximum amount of power currently available per ambient conditions to the output.
The battery undervoltage, VBAT_UV, threshold is checked continuously to ensure that the internal battery
FET, connecting VSTOR to VBAT_SEC, does not turn on until VSTOR is above the VBAT_UV threshold
(2 V).The overvoltage (VBAT_OV) setting initially is lower than the programmed value at startup (varies on
conditions) and is updated after the first ~32 ms. Subsequent updates are every ~64 ms. The VBAT_OV
threshold sets maximum voltage on VSTOR and the boost converter stops switching when the voltage on
VSTOR reaches the VBAT_OV threshold. The open circuit input voltage (VIN_OC) is measured every ~16
seconds in order for the Maximum Power Point Tracking (MPPT) circuit to sample and hold the input
regulation voltage. This periodic update continually optimizes maximum power delivery based on the
harvesting conditions.
PowerPAD is a trademark of Texas Instruments.
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Introduction
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The bq25505 was designed with the flexibility to support a variety of energy storage elements. The
availability of the sources from which harvesters extract their energy can often be sporadic or timevarying. Systems will typically need some type of energy storage element, such as a re-chargeable
battery, super capacitor, or conventional capacitor. The storage element will make certain constant power
is available when needed for the systems. In general, the storage element also allows the system to
handle any peak currents that can not directly come from the input source. It is important to remember
that batteries and super capacitors can have significant leakage currents that need to be included with
determining the loading on VSTOR.
To prevent damage to a customer’s storage element, both maximum and minimum voltages are monitored
against the internally programmed undervoltage (VBAT_UV) and user programmed overvoltage
(VBAT_OV) levels.
To further assist users in the strict management of their energy budgets, the bq25505 toggles a user
programmable battery good flag (VBAT_OK), checked every 64 ms, to signal the microprocessor when
the voltage on an energy storage element or capacitor has risen above (OK_HYST threshold) or dropped
below (OK_PROG threshold) a pre-set critical level. To prevent the system from entering an undervoltage
condition or if starting up into a depleted storage element, it is recommended to isolate the system load
from VSTOR by using an NFET to invert the BAT_OK signal so that it drives the gate of PFET, which
isolates the system load from VSTOR.
For details, see bq25505 data sheet (SLUSBJ3).
1.3
Design and Evaluation Considerations
This user's guide is not a replacement for the data sheet. Reading the data sheet first will help in
understanding the operations and features of this IC. In this document, “secondary rechargeable battery”
or "VBAT_SEC" will be used but one could substitute any appropriate storage element.
System Design Tips
Compared to designing systems powered from an AC/DC converter or large battery (for example, low
impedance sources), designing systems powered by Hi-Z sources requires that the system load-per-unit
time (for example, per day for solar panel) be compared to the expected loading per the same time unit.
Often there is not enough real time input harvested power (for example, at night for a solar panel) to run
the system in full operation. Therefore, the energy harvesting circuit collects more energy than being
drawn by the system when ambient conditions allow and stores that energy in a storage element for later
use to power the system. See SLUC461 for an example spreadsheet on how to design a real solar-panelpowered system in three easy steps:
1. Referring the system rail power back to VSTOR
2. Referring the required VSTOR power back to bq255xx input power
3. Computing the minimum solar panel area from the input power requirement
As demonstrated in the spreadsheet, for any boost converter, you must perform a power balance:
POUT / PIN = (VSTOR × ISTOR) / (VIN × IIN) = η
(1)
where η is the estimated efficiency for the same or similar configuration in order to determine the minimum
input power needed to supply the desired output power.
This IC is a highly efficient charger for a storage element such as a battery or super capacitor. The main
difference between a battery and a super capacitor is the capacity curve. The battery typically has little or
no capacity below a certain voltage, whereas the capacitor does have capacity at lower voltages. Both can
have significant leakage currents that will appear as a DC load on VSTOR/VBAT_SEC.
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Introduction
1.4
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bq25505EVM Schematic
Figure 1 is the schematic for this EVM.
VSTOR
VSTOR
TP4
VIN1
J4
VSTOR
VSTOR
C4
C5
R4
+
GND
C8
0.1uF
4.7uF
10M
J5
DNP
VOC_SAMP
JP1
GND
BAT_SEC
4.99M
J6
80%
50%
VIN
2.0V-5.5V
JP4
JP1 to R3-R5
R5
L1
C3
J11
3
4
18
16
17
NC
NC
VBAT_SEC
15
14
VOC_SAMP
VBAT_OK
13
VREF_SAMP
OK_PROG
12
OK_HYST
11
6
VRDIV
VB_SEC_ON
VB_PRI_ON
EN
8
5
VSS
9
TP3
4.7uF
1
2.1V - 5.5V
J9
VBAT_PRI
GND
C9
GND
DNP
GND
J12
BAT_OK
GND
VSTOR
Q1-A
Q1-B
J13
VSTOR
U1
C11
10
C6
0.1uF
19
21
PWPD
4.7uF
+
C10
VBAT_PRI
BQ25505RGR
NC
C1
DNP
VIN_DC
VBAT_OV
C7
VSS
2
7
VOC_SAMP
+
1
VSTOR
TP1
LBOOST
GND
20
22uH
J3
1
GND
TP8
J10
LBOOST
VIN1
4.2V (Adj up to 5.5V)
BAT_SEC
VBAT_PRI
100uF
VBAT_PRI
GND
J7
J8
TP6
TP2
J2
VIN
BAT_SEC
TP5
VOC_SAMP
J1
4.2V (Adj up to 5.5V)
1
R3
4.99M
VRDIV
1
VB_PRI_ON
VB_SEC_ON
VB_SEC_ON
TP7
VRDIV
R6
887K
VREF_SAMP
GND
VRDIV
JP3
C2
R7
6.98M
R1
7.5M
2
VBAT_PRI
0.01uF
Q2-A
Q2-B
C13
1uF
R2
5.76M
R8
5.36M
BAT_SEC
C12
VB_PRI_ON
1
BAT_SEC
JP2
/EN
1
Not Installed
J16
J15
J14
GND
VOR GND
GND
VOR
Figure 1. bq25505EVM Schematic
white
white
4
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1.5
EVM I/O Connections
Table 1. I/O Connections and Configuration for Evaluation of bq25505 EVM
REFERENCE
DESIGNATOR
DESCRIPTION
COMMENTS / DEFAULT SETTINGS
HEADERS AND TERMINALS
J1 – VIN
Input source (+)
If VIN_DC is higher than VSTOR and VSTOR is equal to VBAT_OV, the input VIN_DC is pulled to ground
through a small resistance to stop further charging of the attached battery or capacitor. It is critical that if
this case is expected, the impedance of the source attached to VIN_DC be higher than 20 Ω and not a low
impedance source.
J2 – VIN/GND
Input source terminal block
J3 – GND
Input source return (–)
J4 – VSTOR
Boost charger output (+)
J5 – VSTOR/GND
Boost charger output terminal block
J6 – GND
Boost charger return (–)
J7– BAT_SEC
Rechargeable storage element connection (+)
J8 – BAT_SEC/GND
Rechargeable storage element terminal block
J9 – GND
Rechargeable storage element connection return (–)
J10 – VBAT_PRI
Non-rechargeable storage element connection (+)
J11 –
VBAT_PRI/GND
Non-rechargeable storage element connection terminal
block
J12 – GND
Non-rechargeable storage element connection return (–)
J13 – BAT_OK/GND
Battery Status Indicator (+/–)
J14 – VOR
Output of multiplexing switches, either VSTOR or
VBAT_PRI (+)
J15 – VOR/GND
Output of multiplexing switches terminal block
J16 – GND
Return for output of multiplexing switches (–)
VBAT_PRI is an optional non-rechargeable battery that switches in to the power the system when
BAT_SEC drops below the VBAT_OK threshold.
TEST POINTS
TP1
Input source, VIN_DC (+)
TP2
Boost charger switching node
TP3
Buck converter switching node
TP4
Boost charger output, VSTOR (+)
TP5
Rechargeable storage element, VBAT_SEC (+)
TP6
Non-rechargeable storage element, VBAT_PRI(+)
TP7
VRDIV node
TP8
Output return (–)
TP9
Input return (–)
CAUTION: Providing an additional low impedance current path in parallel with the feedback resistors , for
example, with a 10-MΩ scope probe attached, will degrade regulation accuracy.
WHITE
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Table 1. I/O Connections and Configuration for Evaluation of bq25505 EVM (continued)
REFERENCE
DESIGNATOR
DESCRIPTION
COMMENTS / DEFAULT SETTINGS
JP1 – VOC_SAMP
VOC_SAMP = external resistors sized to configure the IC
to regulate VIN to 75% of VINOC.
Uninstalled (NOTE: Do not install if JP4 shunt is installed)
JP2 - EN
EN = GND enables the IC. EN = BAT_SEC disables the
IC.
EN = GND
JP3 - VREF_SAMP
to GND
VREF_SAMP = GND
Uninstalled (NOTE: Providing an additional leakage path for the VREF_SAMP capacitor for example,
through a 10-MΩ scope probe attached to VREF_SAMP, will degrade input voltage regulation
performance).
JP4 - VOC_SAMP
VOC_SAMP = 80% configures the IC to regulate VIN to
80% of VIN_OC. VOC_SAMP = 50% configures the IC to
regulate VIN to 50% of VIN_OC.
JP4 = 80% (NOTE: Do not install if JP1 shunt is installed)
JUMPERS
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EVM Performance Specification Summary
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2
EVM Performance Specification Summary
See Data Sheet “Recommended Operating Conditions” for component adjustments. For details about the
resistor programmable settings, see bq25505 data sheet (SLUSBJ3).
MIN
VIN(DC)
DC input voltage into VIN_DC
0.13
VIN_STARTUP(D DC minimum start-up voltage into depleted storage element, no load attached
C)
to VSTOR or VOUT and IBAT(LEAK) ≤ 1 µA
VBAT_OV
VBAT_OK
NOM
MAX
4.0
330
UNIT
V
mV
Battery overvoltage Threshold –min and max values include ±2% set point
accuracy and ±1% resistor tolerance but excludes effects of output ripple
4.04
4.18
4.32
V
OK_HYST indication toggles high when VSTOR ramps up - min and max
values include ±2% set point accuracy and ±1% resistor tolerance
2.70
2.79
2.88
V
OK_PROG indication toggles low when VSTOR ramps down - min and max
values include ±2% set point accuracy and ±1% resistor tolerance
2.89
2.99
3.09
V
MPPT
Maximum Power Point Tracking, Resistor Programmed % of Open Circuit
Voltage
CBAT
A 100-µF low leakage ceramic capacitor is installed on the EVM as the
minimum recommended equivalent battery capacitance.
80%
100
µF
See SLUC484 spreadsheet tool to assist with modifying the MPPT, VBAT_OV and VBAT_OK resistors for
your application.
CAUTION
If changing the board resistors or the capacitor on VREF_SAMP (C2), it is
important to remember that residual solder flux on a board has a resistivity in
the 1–20 MΩ range. Therefore, flux remaining in parallel with changed 1–20
MΩ resistors can result in a lower effective resistances, which will produce
different operating thresholds than expected. Similarly, flux remaining in parallel
with the VREF_SAMP capacitor provides an additional leakage path, which
results in the input voltage regulation set point drooping during the 16-s MPPT
cycle. Therefore, it is highly recommended that boards be thoroughly cleaned
twice, once after removing the old components and again after installing the
new components. If possible, the boards should be cleaned until the wash
solution measures ionic contamination greater than 50 MΩ.
3
Test and Measurement Summary
Test Setup Tips
Energy harvesting power sources are high impedance sources. A source-meter configured as a current
source with voltage compliance set to the harvester's open circuit voltage is the best way to simulate the
harvester. When simulating a Hi-Z energy harvester with low output impedance lab power supply, it is
necessary to simulate the harvester's impedance with a physical resistor between the supply, VPS, and
VIN_DC of the EVM. When the MPPT sampling circuit is active, VIN_DC = VPS = the harvester open
circuit voltage (VIN_OC) because there is no input current to create a drop across the simulated
impedance (that is, open circuit); therefore, VPS should be set to the intended harvester's open circuit
voltage. When the boost converter is running, it draws only enough current until the voltage at VIN_DC
droops to the MPPT's sampled voltage that is stored at VREF_SAMP.
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Test and Measurement Summary
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The battery (storage element) can be replaced with a simulated battery. Often electronic 4 quadrant loads
give erratic results with a “battery charger” due to the charger changing states (fast-charge to termination
and refresh) while the electronic load is changing loads to maintain the “battery” voltage. The charging and
loading get out of phase and create a large signal oscillation which is due to the 4 quadrant meter. A
simple circuit can be used to simulate a battery and can be adjusted for voltage. It consists of load resistor
(~10 Ω, 2 W) to pull the output down to some minimum storage voltage (sinking current part of battery)
and a lab supply connected to the BAT pin via a diode. The lab supply biases up the battery voltage to the
desired level. It may be necessary to add more capacitance across R1.
D1
C
A
BAT+
R1
GND
3.1
3.1.1
Test Setups and Results
Boost Charger Efficiency
The test setup is shown in Figure 2. The specific equipment used for the test results in Figure 3 and
Figure 4 is listed below:
1. VIN_DC was connected to a Keithley 2420 source-meter configured as a current source with voltage
compliance (clamp) set to the open circuit voltage.
2. VSTOR was connected a Keithley 2420 source-meter configured as a voltage source set to the
VSTOR voltage. The current sunk by the source-meter was the output current of the charger.
3. VREF_SAMP was connected to a power supply configured to output the desired input voltage
regulation point (that is, the MPPT% times the HiZ source's VOC). No jumper is required on JP4.
8
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SM2
SM2
+
+
Source (Sink)
meter
configured
as voltage
source
-
SM1
SM1
Source
meter
configured
as current
source
+
-
- +
Power Supply set to
desired input voltage
regulation point
(that is, MPPT% × VOC)
Figure 2. Test Setup for Measuring Boost Charger Efficiency
100
90
80
Efficiency (%)
70
IIN = 100 PA
60
50
40
30
VSTOR = 2.0 V
VSTOR = 3.0 V
VSTOR = 5.5 V
20
10
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3
Input Voltage (V)
Figure 3. Charger Efficiency versus Input Voltage
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100
90
VIN = 0.5 V
Efficiency (%)
80
70
60
50
40
VSTOR = 1.8 V
VSTOR = 3.0 V
VSTOR = 5.5 V
30
20
0.01
0.1
1
10
100
Input Current (mA)
Figure 4. Charger Efficiency versus Input Current
Because the boost converter regulates input voltage instead of output voltage, uses PFM switching,
operates at very low currents, and has MPPT, efficiency cannot be measured using the same test setup
as for an output regulating, higher power, fixed-frequency PWM switching boost converter. The VSTOR
output must be held at a fixed voltage (below VBAT_OV threshold) by an external source that is capable
of sinking current, with that sunk current being the measured output current. In addition to filtering bursts
of current due to PFM switching and the ripple voltage on VIN_DC due to input voltage regulation, the
series input current meter and input voltage meter must be set to filtering/averaging which will result in
longer than usual measurement times, but not longer than the 16-s MPPT sample time. Measurements for
both VIN and IN will be most accurate when taken at the midpoint of the 16-s MPPT period. Remote
sensing by the source-meters is possible but, on the input side, the source-meter output regulation loop
and the charger MPPT input regulation loop may interfere with each other and cause the input voltage to
oscillate. Adding a large capacitor across VIN_DC and GND will eliminate this oscillation but the
capacitor's leakage current will inflate the input current measurement and result in lower efficiency.
See SLUA691 for a detailed explanation on how to take these and other measurements with sourcemeters.
3.1.2
Boost Charger Operation during Battery Charging
The test setup is shown in Figure 5. The specific equipment used for the test results in Figure 6 is listed
below:
1. VIN_DC and VBAT_SEC are configured as shown in Section 3.1.2.
2. The boost charger inductor current (IL) was measured by using an oscilloscope current probe across a
current loop that was inserted in series with inductor L1.
3. VSTOR's ripple voltage was measured using an oscilloscope voltage probe placed directly across the
VSTOR capacitor (C5). The scope probe's standard ground lead was replaced with short lead.
4. VIN_DC and the LBOOST pin (switching node of the boost charger) were measured by oscilloscope
voltage probes connected to TP1 and TP2.
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0.5 F
75
75 :
:
+
1.5
-
Figure 5. Test Setup for Measuring Charger Operation
Figure 6. Charger Operational Waveforms During Battery Charging
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Test and Measurement Summary
3.1.3
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Switching Between Primary and Secondary Batteries
The test setup is shown in Figure 5. The specific equipment used for the test results in Figure 8 is listed
below:
1. VIN_DC, VBAT_SEC and VBAT_PRI are configured as shown in Section 3.1.2.
2. The function generator and power amplifier simulated VSTOR charging up and discharging.
3. VBAT_SEC, VBAT_PRI, VBAT_OK and VOR were measured with oscilloscope voltage probes at TP5,
TP6, J13 and J14, respectively.
Function
Generator
Power
Amplifier
-
PS
+
1 k:
Figure 7. Test Setup
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Figure 8. Switching from Primary to Secondary Battery
Charging a Super Capacitor on VBAT_SEC
The test setup is shown in Figure 9. The specific equipment used for the test results in Figure 10 is listed
below:
1. VIN_DC was connected to a Keithley 2420 configured as a 1.0-mA current source with 1.2-V voltage
compliance.
2. VBAT_SEC was connected to a 120-mF super capacitor. There were no other loads on VSTOR or
VBAT_SEC.
3. VIN_DC, VSTOR and VBAT_SEC were measured with oscilloscope voltage probes connected at TP1,
TP4 and TP5 respectively.
Keithley 2420
120mF
IOUT =1.0 mA
COMP=1.2 V
Figure 9. Test Setup for Charging a Super Capacitor on VBAT_SEC
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Figure 10. Charging a Super Cap on VBAT_SEC
Tips for other Tests and Measurements
The quiescent current during main boost operation, which is basically the current from the battery to the
IC, is measured at the VSTOR pin. If a source-meter is not available to make the measurement, connect a
100-kΩ resistor to VSTOR and connect a 3-V supply from the other end of this resistor to the ground of
the EVM. A 10-MΩ meter can be used to measure the voltage drop across the resistor and calculate the
current. No other connections should be made to the EVM and the measurement should be taken after
steady state conditions are reached (may take a few minutes). The reading should be much less than 100
nA.
14
User's Guide for bq25505 Battery Charger Evaluation Module for Energy
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Bill of Materials and Board Layout
www.ti.com
4
Bill of Materials and Board Layout
This section contains the bq25505 bill of materials (BOM) and PCB board layout.
4.1
Bill of Materials
Table 2 lists the BOM for the bq25505EVM.
Table 2. Bill of Materials
COUNT
RefDes
Value
Description
Size
Part Number
MFR
1
C1
4.7uF
Capacitor, Ceramic Chip, 6.3V, X7R, ±10%
805
C0805C475K9RACTU
Kemet
1
C10
4.7uF
Capacitor, Ceramic Chip, 6.3V, X5R, ±20%
603
GRM188R60J475ME19D
Murata
0
C11-12
DNP
Capacitor, Ceramic Chip, 6.3V, X5R, ±20%
603
Engineering Only
n/a
1
C2
0.01u
Capacitor, Ceramic, 50V, X7R, 10%
0603
GRM188R71H103KA01D
Murata
1
C3
100u
Capacitor, Ceramic Chip, 6.3V, X5R, 20%
1812
GRM43SR60J107ME20L
Murata
2
C4 C6
0.1u
Capacitor, Ceramic Chip, 6.3V, X5R, 10%
603
06036D104KAT2A
AVX
1
C5
4.7uF
Capacitor, Ceramic Chip, 10V, X7R, ±10%
805
LMK212B7475KG-T
Taiyo Yuden
0
C7-9
DNP
Capacitor, Electrolytic, Snap Mt., vvV
7343 (D)
Engineering Only
n/a
1
C13
1.0uF
Capacitor, Ceramic Chip, 10V, X5R, ±20%
603
GRM188R61A105MA61D
Murata
11
J1 J3-4 J6-7 J910 J12-14 J16
PEC02SAAN
Header, Male 2-pin, 100mil spacing,
0.100 inch x 2
PEC02SAAN
Sullins
5
J2 J5 J8 J11 J15
ED555/2DS
Terminal Block, 2-pin, 6-A, 3.5mm
0.27 x 0.25 inch
ED555/2DS
OST
2
JP1 JP3
PEC02SAAN
Header, Male 2-pin, 100mil spacing,
0.100 inch x 2
PEC02SAAN
Sullins
2
JP2 JP4
PEC03SAAN
Header, Male 3-pin, 100mil spacing,
0.100 inch x 3
PEC03SAAN
Sullins
1
L1
22uH
Inductor, SMT, 0.65A, 360mΩ
Inductor SMT, 0.36A, 410mΩ
4.0mm x4.0mm x1.80mm
3.8mm x3.8mm x1.65mm
LPS4018-223M
744031220
Coilcraft
Wurth Elektronik
2
Q1-2
CSD75205W1015
MOSFET, Dual PChan, -20V, 1.2A, 190 milliOhm
CSP 1x1.5mm
CSD75205W1015
TI
1
R1
7.5M
Resistor, Chip, 1/16W, 1%
603
CRCW06037M50FKEA
Vishay Dale
1
R2
5.76M
Resistor, Chip, 1/16W, 1%
603
CRCW06035M76FKEA
Vishay Dale
2
R3 R5
4.99M
Resistor, Chip, 1/16W, 1%
603
CRCW06034M99FKEA
Vishay Dale
1
R4
10M
Resistor, Chip, 1/16W, 1%
603
CRCW060310M0FKEA
Vishay Dale
1
R6
887K
Resistor, Chip, 1/16W, 1%
603
CRCW0603887KFKEA
Vishay Dale
1
R7
6.98M
Resistor, Chip, 1/16W, 1%
603
CRCW06036M98FKEA
Vishay Dale
1
R8
5.36M
Resistor, Chip, 1/16W, 1%
603
CRCW06035M36FKEA
Vishay Dale
4
TP1 TP4-6
5002
Test Point, White, Thru Hole Color Keyed
0.100 x 0.100 inch
5002
Keystone
0
TP2 TP7
DNP
Test Point, 0.020 Hole
0.100 x 0.100 inch
n/a
n/a
2
TP3 TP8
5001
Test Point, Black, Thru Hole Color Keyed
0.100 x 0.100 inch
5001
Keystone
1
U1
BQ25505RGR
IC, Ultra-Low Power Harvester Charger
VQFN
BQ25505RGR
TI
Shunt, 100-mil, Black
0.1
929950-00
3M
PWR218
Any
2
1
--
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PCB, 2.5212 in x 2.6039 in
User's Guide for bq25505 Battery Charger Evaluation Module for Energy
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Copyright © 2013–2014, Texas Instruments Incorporated
15
Bill of Materials and Board Layout
4.2
www.ti.com
EVM Board Layout
Figure 12 through Figure 14 are the board layouts for this EVM.
J5
TP4
J8
GND
VSTOR
TP1
J9
J6
J4
J7
GND
BAT_SEC
TP8
+
C3
C8
J1
VIN
TP2
LBOOST
+
C7
J12
C5
C4
C9
L1
GND
C10
C1
C6
J2
TP5
J11
TP3
VREF_SAMP
GND
JP2
GND
JP3
/EN
J10
BAT_PRI
R5
R6
R7
R8
50%
U1
JP1
R2
R1
GND
VOC_SAMP
R3
R4
C2
J3
JP4
80%
+
1
TP7
VRDIV
C11
1
Q1
BAT_SEC
C12
Q2
C13
2013
PWR218 REV A
J14
1
GND
J13
BAT_OK
GND
VOR
bq25505EVM-218
TP6
J16
J15
Figure 11. EVM PCB Top Silk
16
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J5
J4
TP1
J6
J8
J9
J7
+
TP5
C8
TP8
J12
J1
C3
TP4
+
TP2
L1
C9
J11
C1
C6
C2
1
U1
R2
R1
R6
R7
R8
J10
+
R3
R4
R5
C7
JP4
JP1
C4
C10
J3
J2
C5
TP6
TP7
JP2
C11
C12
JP3
TP3
1Q1
J13
1Q2
J16
J14
C13
J15
Figure 12. EVM PCB Top Assembly
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17
Bill of Materials and Board Layout
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Figure 13. EVM PCB Top Layer
18
User's Guide for bq25505 Battery Charger Evaluation Module for Energy
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Bill of Materials and Board Layout
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Figure 14. EVM PCB Bottom Layer
SLUUAA8A – September 2013 – Revised August 2014
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User's Guide for bq25505 Battery Charger Evaluation Module for Energy
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19
PCB Layout Guideline
5
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PCB Layout Guideline
As for all switching power supplies, the PCB layout is an important step in the design, especially at high
peak currents and high switching frequencies. If the layout is not carefully done, the boost
converter/charger and buck converter could show stability problems as well as EMI problems. Therefore,
use wide and short traces for the main current path and for the power ground paths. The input and output
capacitors as well as the inductors should be placed as close as possible to the IC. For the boost charger,
the first priority are the output capacitors, including the 0.1-µF bypass capacitor (CBYP), followed by
CSTOR, which should be placed as close as possible between VSTOR, pin 19, and VSS, pin 1. Next, the
input capacitor, CIN, should be placed as close as possible between VIN_DC, pin 2, and VSS, pin 1. Last
in priority is the boost converter inductor, L1, which should be placed close to LBOOST, pin 20, and
VIN_DC, pin 2. It is best to use vias and bottom traces for connecting the inductors to their respective pins
instead of the capacitors.
To minimize noise pickup by the high impedance voltage setting nodes (VBAT_OV, OK_PROG, and
OK_HYST), the external resistors should be placed so that the traces connecting the midpoints of each
divider to their respective pins are as short as possible. When laying out the non-power ground return
paths (for example from resistors and CREF), it is recommended to use short traces as well, separated
from the power ground traces and connected to VSS pin 15. This avoids ground shift problems, which can
occur due to superimposition of power ground current and control ground current. The PowerPAD™
should not be used as a power ground return path.
The remaining pins are either NC pins, that should be connected to the PowerPad as shown below, or
digital signals with minimal layout restrictions.
In order to maximize efficiency at light load, the use of voltage level setting resistors > 1 MΩ is
recommended. However, during board assembly, contaminants such as solder flux and even some board
cleaning agents can leave residue that may form parasitic resistors across the physical resistors or from
one end of a resistor to ground, especially in humid, fast airflow environments. This can result in the
voltage regulation and threshold levels changing significantly from those expected per the installed resistor
values. Therefore, it is recommended that no ground planes be poured near the voltage setting resistors.
In addition, the boards must be carefully cleaned, possibly rotated at least once during cleaning, and then
rinsed with de-ionized water until the ionic contamination of that water is well above 50 Ω. If this is not
feasible, then it is recommended that the sum of the voltage setting resistors be reduced to at least 5X
below the measured ionic contamination.
Revision History
Changes from Original (September 2013) to A Revision ............................................................................................... Page
•
Changed contents in the bill of materials ............................................................................................. 15
NOTE: Page numbers for previous revisions may differ from page numbers in the current version.
20
Revision History
SLUUAA8A – September 2013 – Revised August 2014
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Products
Applications
Audio
www.ti.com/audio
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www.ti.com/automotive
Amplifiers
amplifier.ti.com
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www.ti.com/communications
Data Converters
dataconverter.ti.com
Computers and Peripherals
www.ti.com/computers
DLP® Products
www.dlp.com
Consumer Electronics
www.ti.com/consumer-apps
DSP
dsp.ti.com
Energy and Lighting
www.ti.com/energy
Clocks and Timers
www.ti.com/clocks
Industrial
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Interface
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Medical
www.ti.com/medical
Logic
logic.ti.com
Security
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Power Mgmt
power.ti.com
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www.ti.com/space-avionics-defense
Microcontrollers
microcontroller.ti.com
Video and Imaging
www.ti.com/video
RFID
www.ti-rfid.com
OMAP Applications Processors
www.ti.com/omap
TI E2E Community
e2e.ti.com
Wireless Connectivity
www.ti.com/wirelessconnectivity
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