PS5100 PS501 Nickel Chemistry Battery Manager Module with LED SOC Display • PS501 tested, fully populated modules for evaluation • Designed to work with 6 to 12 series cell NiMH and NiCD battery packs • Performs all major Nickel battery management functions including: - Accurate capacity monitoring - Optional external thermistor configuration for accurate temperature monitoring - Supports multiple full charge detection methods – dT/dt, -dV, programmable overcharge • SOC display with four LEDs and a switch • Fully compliant with industry standard Smart Battery Data Specification v1.1a • SMBus v1.1 communication with system host • High accuracy measurement of charge/discharge current, voltage and temperature with on-chip 16-bit integrating A/D • Precise capacity reporting using Microchip patented algorithms and 3D battery cell models • 3D models and “learned” parameters stored in integrated memory • Extremely low-power operation: - Run mode: < 170 µA typical - Low-Voltage Sleep mode: < 45 µA typical - Ultra Low-Power mode: < 1 µA typical • Complete hardware and software development tools available • Overall mechanical dimensions: - 0.339 W x 1.772 L (inches) - 8.6 W x 45.0 L (millimeters) 2004 Microchip Technology Inc. Part Number PS5100 Description Nickel Chemistry – 6 to 12 series cells DS21903A-page 1 PS5100 1.0 GENERAL DESCRIPTION The PS5100 module is a complete Smart Battery controller subsystem based on the Microchip PS501 battery manager with patented Accuron® technology. The module is designed to operate in a battery pack consisting of six (6) to twelve (12) series connected Ni-based cells. The module consists of the Microchip PS501 battery manager IC with a four LED SOC display and an optional connection for an external thermistor. 1.1 Quick Start – Pack Assembly Follow these directions to assemble a pack with the PS5100 module. • Use standard precautions when handling static sensitive devices. • Modules should be connected to battery cells in the order indicated below to insure proper start-up and operation. Wires should be attached to the modules first and then connected to the battery cells as instructed. • The connection sequence is critical to successful use of the PS501 family of CMOS ASICs. The pack positive should be securely connected to the module first, followed by pack negative. FIGURE 1-1: Step 1) Configure the module for optional external thermistor use. PS5100 modules are shipped configured to use the internal temperature sensor only. To add an external thermistor to the board, remove resistor R16 and connect the thermistor across via TN and TR. A parameter change is required to enable the external thermistor measurements. Bit 5 of Flags1 must be cleared. Step 2) Connect wires to module. Use large diameter wire (18 AWG-20 AWG) for current carrying lines from VR and V1. All others are signal only lines (24 to 22 AWG). Step 3) Connect V1 to the most positive point on the battery cell stack. Step 4) Connect VR to the most negative point on the battery cell stack. Step 5) Connect external connector to BN, T, C, D and BP. Step 6) Program the assembled pack using Microchip’s PowerTool™ 500 software and PowerCal™ 2 board or PowerInfo™ 2 board hardware. The module is shipped with default configuration values for a six series cell pack. The Configuration Wizard guides the user through basic configuration and initial download. All of the configuration parameters can be changed at will using the utilities on the Parameters page in the PowerTool 500 software. Step 7) Calibrate the pack using the PowerTool 500 software and PowerCal 2 board hardware. The pack is now ready for use. CONNECTION POINTS (SIDE 1) VR V1 VP TN TR DS21903A-page 2 BP C T D BN 2004 Microchip Technology Inc. PS5100 FIGURE 1-3: C5 R32 C7 LED3 SW1 LED2 C1 R36 C17 C18 R35 R16 R29 R26 LED1 R1 BOARD ASSEMBLY (SIDE 1) LED0 FIGURE 1-2: BOARD ASSEMBLY (SIDE 2) R10 D3 2004 Microchip Technology Inc. C16 R9 R8 R6 D2 R7 D1 R5 U1 DS21903A-page 3 PS5100 2.0 FUNCTIONAL DESCRIPTION 3.0 2.1 PS501-0901 Fuel Gauge PCB schematics and bill of materials are included here for completeness. To download full size schematic and BOM, please visit the Microchip web site (www.microchip.com). The module fuel gauge provides State-Of-Charge (SOC) and battery status data in accordance with the SMBus standards version 1.1. The PS501-0901 monitors the pack voltage, battery temperature and current to determine SOC and battery status. The State-Of-Charge calculations compensate for cell selfdischarge and charge acceptance. The remaining time calculation compensates for temperature and discharge rate. The parameters for determining battery status flags and alarm thresholds are all programmable as is the battery design capacity and the battery performance model data. Please refer to the data sheet “PS501-0901, Single Chip Field Reprogrammable Battery Manager – Nickel Chemistries” (DS21902) for details on configuring the PS501-0901. DS21903A-page 4 3.1 BOARD DESCRIPTION Mechanical Dimensions Overall Dimensions: 1772 mils (L) x 339 mils (W). 2004 Microchip Technology Inc. PS5100 Schematic PS5100 BOARD SCHEMATIC TN FIGURE 3-1: TR TH1 THERMISTOR CONNECTIONS (SEMITEC 103AT OR 103ETB -- 10K AT 25°C) PS501 U1 17 16 ROSC LED0 18 R16 221K VNTC LED1 R15 3.65K R11 VR 11 C11 330 nF 10 9 8 12 C10 330 nF 13 V5 1 GPIO(0) GPIO(1) GPIO(2) GPIO(3) GPIO(4) GPIO(5) GPIO(6) GPIO(7) GPIO(8) GPIO(9) GPIOHV1 MCLR GPIOHV2 VC(2) VC(3) VC(4) VDDA 24 25 26 27 2 3 4 5 19 20 21 22 23 LED3 SW1 20K R17 V5 VSSA BP VDDD SMB-CLK SMB-DTA VSSD 14 C15 330 nF 28 VC(1) RSHN 20 LED2 RSHP CELL STRING CONNECTION V1 VREFT 15 3.2 6 7 20 20 R42 R43 240 240 R40 R41 C D 2 1 3 D40 AZ23C5V6 C40 100 nF C41 1.0 nF R44 T 103KT16082P BN GROUND PLANE CONNECTION 2004 Microchip Technology Inc. R10 0.020 PACK CONNECTIONS DS21903A-page 5 PS5100 3.3 Bill of Materials TABLE 3-1: PS5100 BILL OF MATERIALS Symbols Description Manufacturer Raw PCB, PS5210 Microchip Manufacturer PN Qty. 04-826192 Rev. 1.1 1 C41 Capacitor, Ceramic, 1.0 nF, 50V, +/-10%, X7R Panasonic dielectric, 0603 ECJ-1VB1H102K 1 C40 Capacitor, Ceramic, 100 nF, 25V, +80%/-20%, Panasonic Y5V dielectric, 0603 ECJ-1VF1E104Z 1 C10, C11, C15 Capacitor, Ceramic, 330 nF, 25V, +80%/-20%, Panasonic Y5V dielectric, 0805 ECJ-2YF1E334Z 3 LED0-LED3 LED, clear green, 1206 package Lumex SML-LX1206GC-TR 4 D40 Dual Zener Diode, 5.6V, +/-5%, 300 mW, common-anode, SOT-23 Diodes Inc. General Semiconductor AZ23C5V6-7 AZ23-C5V6 1 R15 Resistor, film, 0603, 1%, 3.65 kOhms Panasonic ERJ-3EKF3651V 1 R16 Resistor, film, 0603, 1%, 221 kOhms, 25 ppm TC Susumu Co. Ltd. RR0816P-2213-D-34D 1 R42-R43 Resistor, film, 0603, 5%, 20 Ohms Panasonic ERJ-3GEYJ200V 2 R17 Resistor, film, 0603, 5%, 20 kOhms Panasonic ERJ-3GEYJ203V 1 R11 Resistor, film, 0805, 5%, 20 Ohms Panasonic ERJ-6GEYJ200V 1 R40-R41 Resistor, film, 0805, 5%, 240 Ohms Panasonic ERJ-6GEYJ241V 2 R10 Resistor, metal strip, 2512, 1%, 0.020 Ohms Vishay WSL2512-0.020-1%-R86 1 R44 Thermistor, 10 kOhms at 25°C, B value 3435, Semitec -40°C to +125°C operating temperature range, 0603 SMT package 103KT1608-2P 1 SW1 Switch, SPST-momentary, push button, surface mount SKQGADE010 11871501 1 U1 IC, single chip Battery Manager, programmable, Microchip -20°C to +85°C, SSOP-28 PS501-I/ST 1 43.6 mm 45.0 mm 41.5 mm 38.5 mm 31.0 mm 32.4 mm 28.0 mm 25.0 mm 22.0 mm 16.0 mm PS5100 DIMENSION DETAILS 0 1.1 mm FIGURE 3-2: ALPS Fuk Hing Ind. 0 1.6 mm 3.4 mm 4.3 mm 1.4 mm 3.4 mm 4.3 mm 5.2 mm 7.2 mm 5.2 mm DS21903A-page 6 L-SHAPED BOX INDICATES AREA CLEAR OF COMPONENTS ON THE BOTTOM SIDE, BEHIND THE LEDs AND SWITCH. EDGE OF BOX UNDER LEDs IS LOCATED 3.3 mm FROM UPPER EDGE OF PCB. 42.0 mm 14.6 mm 12.4 mm 8.6 mm 2004 Microchip Technology Inc. PS5100 4.0 DEVELOPMENT TOOL SUMMARY Microchip provides all the necessary hardware and software to enable easy tailoring of battery control algorithm parameters and cell performance models to meet specific application requirements and attain the highest accuracy available anywhere. Table 4-1 summarizes the development tool offering from Microchip to support the PS5100. Please refer to the Microchip web site for ordering information and design documentation (including schematics) at www.microchip.com. TABLE 4-1: 4.1 Reference Documents This data sheet provides an overview of the PS5100 Battery Manager module. For further information on the PS501-0901 and development tool operations, please refer to the following documents available for download at www.microchip.com. MICROCHIP DEVELOPMENT TOOL SUMMARY Development Tool Use PowerInfo™ 2 hardware with PowerTool™ 500 Read and write Smart Battery data values, memory programming software (PS051) PowerCal™ 2 hardware with PowerTool™ 500 Read and write Smart Battery data values, memory programming, software (PS052) pack calibration, pack test TABLE 4-2: MICROCHIP REFERENCE DOCUMENTS Document Number DS21902 Documents Available PS501-0901 Single Chip Field Reprogrammable Battery Manager – Nickel Chemistries Data Sheet (IC Products) DS21815 PS051 PowerInfo™ 2 Configuration Interface Data Sheet DS21817 PS052 PowerCal™ 2 Calibration Platform Data Sheet 2004 Microchip Technology Inc. DS21903A-page 7 PS5100 NOTES: DS21903A-page 8 2004 Microchip Technology Inc. PS5100 Information contained in this publication regarding device applications and the like is intended through suggestion only and may be superseded by updates. It is your responsibility to ensure that your application meets with your specifications. No representation or warranty is given and no liability is assumed by Microchip Technology Incorporated with respect to the accuracy or use of such information, or infringement of patents or other intellectual property rights arising from such use or otherwise. Use of Microchip’s products as critical components in life support systems is not authorized except with express written approval by Microchip. No licenses are conveyed, implicitly or otherwise, under any intellectual property rights. Trademarks The Microchip name and logo, the Microchip logo, Accuron, PIC, PICmicro, PowerSmart and SmartShunt are registered trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. SmartSensor is a registered trademark of Microchip Technology Incorporated in the U.S.A. PowerCal, PowerInfo, PowerMate, PowerTool and SmartTel are trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. All other trademarks mentioned herein are property of their respective companies. © 2004, Microchip Technology Incorporated. Printed in the U.S.A., All Rights Reserved. Printed on recycled paper. 2004 Microchip Technology Inc. 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