MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide © 2006 Microchip Technology Inc. DS51641A Note the following details of the code protection feature on Microchip devices: • Microchip products meet the specification contained in their particular Microchip Data Sheet. • Microchip believes that its family of products is one of the most secure families of its kind on the market today, when used in the intended manner and under normal conditions. • There are dishonest and possibly illegal methods used to breach the code protection feature. All of these methods, to our knowledge, require using the Microchip products in a manner outside the operating specifications contained in Microchip’s Data Sheets. Most likely, the person doing so is engaged in theft of intellectual property. • Microchip is willing to work with the customer who is concerned about the integrity of their code. • Neither Microchip nor any other semiconductor manufacturer can guarantee the security of their code. Code protection does not mean that we are guaranteeing the product as “unbreakable.” Code protection is constantly evolving. We at Microchip are committed to continuously improving the code protection features of our products. Attempts to break Microchip’s code protection feature may be a violation of the Digital Millennium Copyright Act. If such acts allow unauthorized access to your software or other copyrighted work, you may have a right to sue for relief under that Act. Information contained in this publication regarding device applications and the like is provided only for your convenience and may be superseded by updates. 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Trademarks The Microchip name and logo, the Microchip logo, Accuron, dsPIC, KEELOQ, microID, MPLAB, PIC, PICmicro, PICSTART, PRO MATE, PowerSmart, rfPIC and SmartShunt are registered trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. AmpLab, FilterLab, Migratable Memory, MXDEV, MXLAB, SEEVAL, SmartSensor and The Embedded Control Solutions Company are registered trademarks of Microchip Technology Incorporated in the U.S.A. Analog-for-the-Digital Age, Application Maestro, CodeGuard, dsPICDEM, dsPICDEM.net, dsPICworks, ECAN, ECONOMONITOR, FanSense, FlexROM, fuzzyLAB, In-Circuit Serial Programming, ICSP, ICEPIC, Linear Active Thermistor, Mindi, MiWi, MPASM, MPLIB, MPLINK, PICkit, PICDEM, PICDEM.net, PICLAB, PICtail, PowerCal, PowerInfo, PowerMate, PowerTool, REAL ICE, rfLAB, rfPICDEM, Select Mode, Smart Serial, SmartTel, Total Endurance, UNI/O, WiperLock and ZENA are trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. SQTP is a service mark of Microchip Technology Incorporated in the U.S.A. All other trademarks mentioned herein are property of their respective companies. © 2006, Microchip Technology Incorporated, Printed in the U.S.A., All Rights Reserved. Printed on recycled paper. Microchip received ISO/TS-16949:2002 certification for its worldwide headquarters, design and wafer fabrication facilities in Chandler and Tempe, Arizona, Gresham, Oregon and Mountain View, California. The Company’s quality system processes and procedures are for its PIC® 8-bit MCUs, KEELOQ® code hopping devices, Serial EEPROMs, microperipherals, nonvolatile memory and analog products. In addition, Microchip’s quality system for the design and manufacture of development systems is ISO 9001:2000 certified. DS51641A-page ii © 2006 Microchip Technology Inc. MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN USER’S GUIDE Table of Contents Preface ........................................................................................................................... 1 Introduction............................................................................................................ 1 Document Layout .................................................................................................. 1 Conventions Used in this Guide ............................................................................ 2 Recommended Reading........................................................................................ 2 The Microchip Web Site ........................................................................................ 3 Customer Support ................................................................................................. 3 Document Revision History ................................................................................... 3 Chapter 1. Product Overview ........................................................................................ 5 1.1 Introduction ..................................................................................................... 5 1.2 What is the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design? ................................................................................... 6 1.3 What the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design kit includes .................................................................. 6 Chapter 2. Installation and Operation .......................................................................... 7 2.4 Introduction ..................................................................................................... 7 2.5 Features ......................................................................................................... 7 2.6 Getting Started ............................................................................................... 8 Appendix A. Schematics and Board Layouts............................................................ 11 A.1 Introduction .................................................................................................. 11 A.2 Schematic - Sheet 1 ................................................................................... 12 A.3 Schematic - Sheet 2 ................................................................................... 13 A.4 Board – Top Silk Layer ............................................................................... 14 A.5 Board – Top Metal Layer ............................................................................ 15 A.6 Board – Mid Layer1 .................................................................................... 16 A.7 Board – Mid Layer2 .................................................................................... 17 A.8 Board – Metal Layer ................................................................................... 18 A.9 Board – Bottom Silk Layer ......................................................................... 19 Appendix B. Bill Of Materials (BOM) .......................................................................... 21 Appendix C. Firmware ................................................................................................. 23 C.1 Device Firmware - Flowchart ....................................................................... 23 C.2 Device Firmware - Flowchart (Continued) ................................................... 24 Worldwide Sales and Service .................................................................................... 26 © 2006 Microchip Technology Inc. DS51641A-page iii MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide NOTES: DS51641A-page iv © 2006 Microchip Technology Inc. MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN USER’S GUIDE Preface NOTICE TO CUSTOMERS All documentation becomes dated, and this manual is no exception. Microchip tools and documentation are constantly evolving to meet customer needs, so some actual dialogs and/or tool descriptions may differ from those in this document. Please refer to our web site (www.microchip.com) to obtain the latest documentation available. Documents are identified with a “DS” number. This number is located on the bottom of each page, in front of the page number. The numbering convention for the DS number is “DSXXXXXA”, where “XXXXX” is the document number and “A” is the revision level of the document. For the most up-to-date information on development tools, see the MPLAB® IDE on-line help. Select the Help menu, and then Topics to open a list of available on-line help files. INTRODUCTION This chapter contains general information that will be useful to know before using the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design. Items discussed in this chapter include: • • • • • • Document Layout Conventions Used in this Guide Recommended Reading The Microchip Web Site Customer Support Document Revision History DOCUMENT LAYOUT This document describes how to use the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design as a development tool to emulate and debug firmware on a target board. The manual layout is as follows: • Chapter 1. “Product Overview”– Important information about the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design. • Chapter 2. “Installation and Operation” – Includes instructions on how to get started with this user’s guide and a description of the user’s guide. • Appendix A. “Schematics and Board Layouts” – Shows the schematic and layout diagrams for the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design. • Appendix B. “Bill Of Materials (BOM)” – Lists the parts used to build the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design. • Appendix C. “Firmware” – Provides information about the application firmware and where the source code can be found. © 2006 Microchip Technology Inc. DS51641A-page 1 MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide CONVENTIONS USED IN THIS GUIDE This manual uses the following documentation conventions: DOCUMENTATION CONVENTIONS Description Arial font: Italic characters Represents Examples Referenced books Emphasized text A window A dialog A menu selection A field name in a window or dialog A menu path MPLAB® IDE User’s Guide ...is the only compiler... the Output window the Settings dialog select Enable Programmer “Save project before build” A dialog button A tab A number in verilog format, where N is the total number of digits, R is the radix and n is a digit. A key on the keyboard Click OK Click the Power tab 4‘b0010, 2‘hF1 Italic Courier New Sample source code Filenames File paths Keywords Command-line options Bit values Constants A variable argument Square brackets [ ] Optional arguments #define START autoexec.bat c:\mcc18\h _asm, _endasm, static -Opa+, -Opa0, 1 0xFF, ‘A’ file.o, where file can be any valid filename mcc18 [options] file [options] Initial caps Quotes Underlined, italic text with right angle bracket Bold characters N‘Rnnnn Text in angle brackets < > Courier New font: Plain Courier New File>Save Press <Enter>, <F1> RECOMMENDED READING This user's guide describes how to use MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design. The following Microchip documents are available and recommended as supplemental reference resources. MCP1630/MCP1630V Data Sheet, "High-Speed, Microcontroller-Adaptable, Pulse Width Modulator" (DS21896) This data sheet provides detailed information regarding the MCP1630/MCP1630V, product family. PIC16F88 Data Sheet, "20-Pin Flash-Based, 8-Bit CMOS Microcontrollers with Nano Watt Technology” (DS30487) This data sheet provides detailed information regarding the PIC16F88 product family. APEC Conference Paper, "Bi-Directional Power System for Laptop Computers", 2005 This paper provides detailed information about powering laptop computers using 4 series cell Li-Ion batteries with a bidirectional laptop computer. DS51641A-page 2 © 2006 Microchip Technology Inc. Preface THE MICROCHIP WEB SITE Microchip provides online support via our web site at www.microchip.com. This web site is used as a means to make files and information easily available to customers. Accessible by using your favorite Internet browser, the web site contains the following information: • Product Support – Data sheets and errata, application notes and sample programs, design resources, user’s guides and hardware support documents, latest software releases and archived software • General Technical Support – Frequently Asked Questions (FAQs), technical support requests, online discussion groups, Microchip consultant program member listing • Business of Microchip – Product selector and ordering guides, latest Microchip press releases, listing of seminars and events, listings of Microchip sales offices, distributors and factory representatives CUSTOMER SUPPORT Users of Microchip products can receive assistance through several channels: • • • • Distributor or Representative Local Sales Office Field Application Engineer (FAE) Technical Support Customers should contact their distributor, representative or field application engineer (FAE) for support. Local sales offices are also available to help customers. A listing of sales offices and locations is included in the back of this document. Technical support is available through the web site at: http://support.microchip.com DOCUMENT REVISION HISTORY Revision A (November 2006) • Initial Release of this Document. © 2006 Microchip Technology Inc. DS51641A-page 3 MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide NOTES: DS51641A-page 4 © 2006 Microchip Technology Inc. MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN USER’S GUIDE Chapter 1. Product Overview 1.1 INTRODUCTION As high power portable applications continue to gain in popularity, more innovative techniques are needed to charge the batteries while also providing a low regulated voltage to the system’s high end digital electronics. For example, laptop computers, portable test equipment, portable printers, etc., all require more power than a single or two cell Li-Ion battery pack can efficiently store. As a result, three or four series Li-Ion cell packs are used to store the necessary that power these high end applications. The result is a high dc voltage used to store the energy requiring a difficult high voltage to low voltage dc-dc conversion. The MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design can be used to evaluate a design that boosts a low source voltage to charge four Li-Ion series cells while providing energy to the system simultaneously. When the source is removed, the same power train used to charge the battery pack provides a low regulated voltage to operate the system. This chapter covers the following topics. • What is the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design? • What the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design Kit includes. Wide Range ac Input (85 Vrms to 240 Vrms) AC/DC Converter Low Voltage + dc Output (+7.0V) dc-Bus - +3.3V DC/DC Converter +1.XV DC/DC Converter MCP1630V Bidirectional Charger and DC/DC Converter 4 Cell Li-Ion Battery Pack FIGURE 1-1: MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design shown in Laptop Computer system level block diagram. © 2006 Microchip Technology Inc. DS51641A-page 5 MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide 1.2 WHAT IS THE MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN? The MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design demonstrates the use of a bidirectional buck-boost converter used to charge multiple series cell Li-Ion batteries with the presence of an input source (boost) and provide a regulated output voltage when the input source is removed (buck). The board also serves as a platform to evaluate the MCP1630V device. The MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design inputs were developed to be easily attached to the I/O of a PIC® Microcontroller. The MCU supplies the oscillator (OSC_IN) and reference voltage (VREF) to the MCP1630V creating a flexible and adaptable power system. The power system switching frequency and maximum duty cycle are set using the hardware PWM of the MCU. The reference input to the high speed analog PWM can be external, a D/A Converter (DAC) output or as simple as an I/O output from the MCU. This enables the power system to adapt to external signals and variables in order to optimize performance and facilitate calibration. This board utilizes Microchip's MCP1630V (high-speed PIC MCU PWM MSOP8) with the PIC16F88 (Flash MCU) in a four cell Li-Ion charger combined with a synchronous buck regulator. Under normal operation, the input supply can range between 6.5V and 7.0V. The converter is capable of charging four Li-Ion cells connected in series when the 6.5V input is present and regulating the bulk input voltage to 6.0V when the input source voltage is removed by stepping, (bucking), down the battery pack voltage. 1.3 WHAT THE MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN KIT INCLUDES This MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design kit includes: • MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design • Analog and Interface Products Demonstration Boards CD-ROM (DS21912) - MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide (DS51641) DS51641A-page 6 © 2006 Microchip Technology Inc. MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN USER’S GUIDE Chapter 2. Installation and Operation 2.4 INTRODUCTION The MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design demonstrates Microchip's high speed pulse width modulator (PWM) used in a four cell Li-Ion battery charger combined power supply application. When used in conjunction with a microcontroller, the MCP1630V will control the power system duty cycle to provide regulated output voltage or current. The PIC16F88 microcontroller oscillator output is used to provide pulses at switching frequency of 500 kHz. The MCP1630V generates duty cycle based on various external inputs. External signals include the input oscillator pulses from PIC16F88, the reference voltage and the feed back voltage. The output signal is a square wave pulse provided to the synchronous gate drive input. They synchronous gate driver is used to turn on and off the upper buck MOSFET and lower synchronous MOSFET. The PIC16F88 microcontroller is programmable, allowing the user to modify or develop their own firmware routines to further evaluate the MCP1630V in this application. 2.5 FEATURES The MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design has the following features: • Four Cell Li-Ion Battery Charger, operates stand alone. (Additional firmware added allows the charger to communicate with smart battery packs) • Charges four cell Li-Ion battery pack from 6.5V to 7.0V Input (complete precondition, constant current and constant voltage charge algorithm in firmware) • Regulates input dc bus voltage, (steps battery pack voltage down), to 6.0V when input source is removed (providing uninterrupted power source for system) • ON/OFF button used to enable and disable system, low IQ drain on the battery when disabled (< 10 µA) • Output over-voltage protection in the event of open battery connections • High efficiency over entire operating input voltage range (94% typical) • PIC16F88 is used to generate ref Voltage and Oscillator signal at 500 kHz frequency at maximum duty cycle • Proprietary features can be added by modifying the firmware contained in the PIC16F88 • Factory programmed source code is available © 2006 Microchip Technology Inc. DS51641A-page 7 MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide 2.6 GETTING STARTED The MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design is fully assembled and tested for charging a four series cell Li-Ion battery pack (Battery Pack should have internal overvoltage, overcurrent and overtemperature protection). The board requires the use of an external input voltage source (+7.0V) for charging. 2.6.1 Power Input and Output Connection 2.6.1.1 POWERING THE MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN 1. Connect the positive side of the +6.5V to +7.0V input to J2 Pin 2, connect the negative side (or ground) to Pin 1 of J2. This source voltage should not exceed 7.0 and be rated for 8A minimum supply current. 2. Connect the positive side of the Four cell Li-Ion battery pack voltage to J1 Pin 1, connect the battery pack return to the negative side of J1 Pin 2. Note: Both supplies should have a separate isolated return (ground), there is a current sense resistor between the +7.0V (VBULK) and +14V(VBATT) supply returns. If the returns are connected, the charge current can not be controlled. 3. Once the SW1 push button is pressed, the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design is powered. When powered, a charge cycle will start automatically if the 7.0V is connected and all preconditions are meet, (see Appendix C. “Firmware”). 4. LED D3 will be illuminated when the board is running, (charging or bucking). 5. LED D5 will flash only when a charge cycle is in progress. 6. Again, a subsequent pressing of the SW1 push button during normal operation of the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design will power-off the converter. LOCATIONS FOR D3 D5 CONN ICD 2 +14 VBAT SW1 SWITCH I +7V FIGURE 2-2: DS51641A-page 8 Board Top Assembly and Connections © 2006 Microchip Technology Inc. Installation and Operation 2.6.1.2 APPLYING BATTERY TO MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN A four cell battery pack (with internal protection) is connected to the J1 connector before applying input power and pressing SW1 to start the charge cycle. Once the battery pack is connected, SW1 can be pressed to start the synchronous buck converter (assuming there is no 7.0V input applied to J2). With the battery pack connected, the source for J2 can be “hot” plugged in and out, a voltage will always be present on J2 until SW1 is pressed shutting off the converter. 2.6.1.3 ALTERNATIVE BATTERY PACK SIMULATOR As an alternative to the four cell Li-Ion battery pack, a battery pack simulation circuit can be used, (Figure 2-3). This simulation circuit consists of an adjustable metal wound power load resistor (10Ω, 100W), Aluminum Electrolytic Capacitor (3,300 µF 25V) and Schottky Diode (10V, 30V). For evaluating the bidirectional converter design, the battery simulator circuit is recommended. When using the battery pack simulator, the operating point for charging and discharging can be easily be adjusted using the VBATT power supply and load resistor value. 2.6.1.4 LED STATUS INDICATION Two LED’s are connected to the I/O of the PIC16F88 to provide status of the charger. LED D3 provides indication that the converter is running while LED D5 flashing provides indication that the converter is charging. With a 6.5V to 7.0V source applied to J2 while the converter is running, a charge cycle is initiated. Once the charge cycle is complete, the charger will continue to operate providing 0 mA of current to the battery. If the source is removed from J2, the converter will regulate the VBULK voltage to 6.0V with a load up to 6A. Evaluating the Application The best way to evaluate the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design is to operate the bidirectional power system over a wide range using the battery pack simulator. The simulator consists of a 10Ω power resistor, diode and variable voltage source. When configured as shown in Figure 2-3, the circuit will simulate a battery. The load resistor is used to sink current from the charger while a large capacitor is used to simulate the battery voltage (VSIM). By adjusting the VSIM voltage, different operating points in the charge cycle can be evaluated. Once evaluated using the battery pack simulator, the bi-directional reference design can be used to run charge and discharge cycles using a four cell Li-ion battery pack. If using an actual Li-ion battery pack, it must have the proper protection features including, (overvoltage, overcurrent, overtemperature, etc.). © 2006 Microchip Technology Inc. DS51641A-page 9 MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide J1-1 +VBATT 3,300 µF 10Ω + VSIM - +12V to +17.5V J1-2 -VBATT FIGURE 2-3: Battery Simulator Circuit. Firmware The PIC16F88 comes pre programmed with firmware to operate the system as described above. The file listing and firmware flow diagram are shown in Appendix C. “Firmware”. Programming Header J4 is provided for In-Circuit Serial Programming™ (ICSP™). This is an optional feature since the demo board comes preprogrammed with firmware to operate the system. The PIC16F88 can be reprogrammed with the Baseline Flash Microcontroller Programmer (BFMP). DS51641A-page 10 © 2006 Microchip Technology Inc. MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN USER’S GUIDE Appendix A. Schematics and Board Layouts A.1 INTRODUCTION This appendix contains the following schematics and layouts for the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design: • • • • • • • • Board – Schematic Sheet 1 Board – Schematic Sheet 2 Board – Top Silk Layer Board – Top Metal Layer Board – Internal MidLayer 1 Board – Internal MidLayer 2 Board – Metal Layer Board – Bottom Silk Layer © 2006 Microchip Technology Inc. DS51641A-page 11 MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide SCHEMATIC - SHEET 1 2 A.2 DS51641A-page 12 © 2006 Microchip Technology Inc. Schematics and Board Layouts A.3 SCHEMATIC - SHEET 2 © 2006 Microchip Technology Inc. DS51641A-page 13 MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide A.4 BOARD – TOP SILK LAYER BOARD DS51641A-page 14 © 2006 Microchip Technology Inc. Schematics and Board Layouts A.5 BOARD – TOP METAL LAYER © 2006 Microchip Technology Inc. DS51641A-page 15 MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide A.6 BOARD – MID LAYER1 DS51641A-page 16 © 2006 Microchip Technology Inc. Schematics and Board Layouts A.7 BOARD – MID LAYER2 MIDLAYER2 © 2006 Microchip Technology Inc. DS51641A-page 17 MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide A.8 BOARD – METAL LAYER DS51641A-page 18 © 2006 Microchip Technology Inc. Schematics and Board Layouts A.9 BOARD – BOTTOM SILK LAYER © 2006 Microchip Technology Inc. DS51641A-page 19 MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide NOTES: DS51641A-page 20 © 2006 Microchip Technology Inc. MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN USER’S GUIDE Appendix B. Bill Of Materials (BOM) TABLE B-1: BILL OF MATERIALS (BOM) Reference Designator QTY Description Manufacturer Part Number 2 C1, C2 CAP CER 10UF 25V X5R 1210 Taiyo Yuden® TMK325BJ106MN-T 2 C3, C17 CAP CERM.22UF 10% 10V X7R 0603 AVX Corporation 0603ZC224KAT2A 2 C4, C29 CAP CERAMIC 1.0UF 10V X5R 0603 Kemet® Electronics Corp C0603C105K8PACTU 2 C5, C6 CAP TANT 100UF 10V 20% POLY SMD EPCOS Inc. 12 C7, C11, C13, CAP .10UF 10V CERAMIC X7R 0603 C16, C18, C19, C20, C21, C22, C26, C28 Kemet Electronics Corp C0603C104K8RACTU 1 C8 CAP CERM 8200PF 10% 50V X7R 0603 AVX Corporation 06035C822KAT2A 1 C9 CAP CER 2200PF 50V C0G 5% 0603 TDK Corporation C1608C0G1H222J 1 C10 CAP CERAMIC 330PF 50V NP0 0603 Kemet Electronics Corp C0603C331J5GACT 1 C12 CAP 3300PF 50V CERAMIC X7R 0603 Kemet Electronics Corp C0603C332K5RACTU 2 C14 CAP CERAMIC 120PF 50V NP0 0603 Kemet Electronics Corp C0603C121J5GACTU 1 C15 CAP CERAMIC 100PF 50V NP0 0603 Kemet Electronics Corp C0603C101J5GACTU 1 C23 CAP CERAMIC 180PF 50V NP0 0603 Kemet Electronics Corp C0603C181J5GACTU 1 C24 CAP CERAMIC 10PF 50V NP0 0603 Kemet Electronics Corp C0603C100J5GACTU 1 C30 CAP 10000PF 50V CERAMIC X7R 0603 Kemet Electronics Corp C0603C103K5RACTU 1 C31 CAP 1500PF 50V CERAMIC X7R 0603 Kemet Electronics Corp C0603C152K5RACTU 2 D1 DIODE SCHOTTKY 30V 200MW SOD123 Diodes Inc. BAT42W-7-F 1 D2 IC ADJ SHUNT REGULATOR SOT-23-5 Texas Instruments TL431IDBVR 2 D3, D5 LED 660NM SUPER RED DIFF 0603SMD Lumex® Opto/ Components Inc SML-LX0603SRW-TR 1 F1 FUSE 5.0A 32V FAST SMD 0603 Tyco® Electronics/ Raychem Circuit Protection 0603SFF500F/32-2 2 J1, J2 CONN TERM BLOCK 2POS 5MM PCB Phoenix Contact 1715022 1 J3 CONN MOD JACK 6-6 RT/A PCB 50AU Tyco Electronics/Amp 5555165-1 1 J4 CONN HEADER VERT 3POS.100 TIN Tyco Electronics/Amp 640454-3 1 L1 INDUCTOR POWER HI CURR 10UH SMD Coiltronics/Div of Cooper/Bussmann HC1-100-R 1 Q1 MOSFET N-CH 30V 35A DPAK International Rectifier IRLR3303PBF 1 Q2 MOSFET N-CH 30V 91A DPAK International Rectifier IRLR8103VPBF 4 Q3, Q6, Q7, Q8 MOSFET N-CH 30V 1.2A SSOT3 Fairchild Semiconductor NDS351AN Note 1: B76010V1079M055 The components listed in this Bill of Materials are representative of the PCB assembly. The released BOM used in manufacturing uses all RoHS-compliant components. © 2006 Microchip Technology Inc. DS51641A-page 21 MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide TABLE B-1: Reference Designator QTY 1 BILL OF MATERIALS (BOM) (CONTINUED) Q4 Description MOSFET P-CH 30V 610MA SOT-23 Manufacturer Part Number International Rectifier IRLML5103TRPBF ® 1 Q5 TRANSISTOR GP NPN AMP SOT-23 Fairchild Semiconductor MMBT3904 0 R1, R21 SMT0603 RESISTOR DO NOT POPULATE — — 1 R2 RES 499K OHM 1/10W 1% 0603 SMD Panasonic® - ECG 2 R3, R33 RES 9.53K OHM 1/10W 1% 0603 SMD Panasonic - ECG 2 R4, R5 RESISTOR .100 OHM 1W 1% 2512 5 R6, R7, R13, R29, R39 RES 10.0K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1002V 1 R8 RES 1.50K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1501V 6 R9, R15, R19, R22, R38 RES 10.0K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1002V 1 R10 RES 1.00K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1001V 3 R11, R42, R43 RES 47.5K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF4752V 1 R12, R17 RES 15.0K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1502V 1 R14 RES 6.98K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF6981V 2 R16, R32 RES 49.9K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF4992V 3 R18, R40, R45 RES 2.00K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF2001V 1 R20 Panasonic - ECG ERJ-3EKF1500V 3 R23, R34, R37 RES 7.87K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF7871V 1 R24 RESISTOR 1.20M OHM 1/10W 1% 0603 Panasonic - ECG ERJ-3EKF1204V 1 R25 RES 30.1K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF3012V 3 R26, R27 RES 4.99K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF4991V 1 R28 RES 43.2K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF4322V 1 R30 RES 14.7K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1472V 1 R31 RES 24.9K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF2492V 1 R35 RES 1.62K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1621V 1 R36 RES 221K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF2213V 1 R44 RES 3.3 OHM 1W 1% 2512 SMD Panasonic - ECG ERJ-1TRQF3R3U 1 SW1 SWITCH TACT 6MM 260GF SMT E-Switch TL3301NF260QG 6 TP1, TP2, TP3, PC TEST POINT COMPACT SMT TP4, TP5, TP6 Keystone Electronics® 5016 1 U1 IC DRIVER MOSFET DUAL SYNC 8SOIC Intersil ISL6207CBZ 1 U2 MCP1630V HIGH SPEED ANALOG PWM Microchip Technology Inc. MCP1630V-E/MS 2 U3, U4 DUAL10MHz AMPLIFIER 8 PIN TSSOP PACKAGE Microchip Technology Inc. MCP6022-I/ST 1 U5 IC MCU FLASH 4KX14 EEPROM 20SSOP Microchip Technology Inc. PIC16F88T-I/SS 1 U7 IC DGTL THERM SENSOR 5V SOT23A-5 Microchip Technology Inc. TC74A5-5.0VCTTR Note 1: RES 150 OHM 1/10W 1% 0603 SMD ERJ-3EKF4993V ERJ-3EKF9531V Panasonic - ECG ERJ-L1WKF10CU The components listed in this Bill of Materials are representative of the PCB assembly. The released BOM used in manufacturing uses all RoHS-compliant components. DS51641A-page 22 © 2006 Microchip Technology Inc. MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN USER’S GUIDE Appendix C. Firmware C.1 DEVICE FIRMWARE - FLOWCHART For the latest copy of the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide firmware, visit our web site at www.microchip.com. Charge States START Idle = 0 mA P.C. = Pre-Charge C.C. = Constant Current C.V. = Constant Voltage Initialize Ports, ADC, PWM, etc. A Read ADC Inputs VBATT and VBULK Yes Yes Is Charge State @ Idle? VBATT>12.8V No VBATT<16.3V Set State to P.C. Is Charge State @ P.C.? No B No Yes Set State to C.V. VBATT>16.8V Yes Set State to C.C No B No Is Charge State @ C.V. No No VBATT > 12.8V Is Charge State @ C.C. Inc. IBATT to IMAX Yes Yes Yes VBATT > 16.8V Yes B Dec. IBATT No B C FIGURE C-1: © 2006 Microchip Technology Inc. Firmware Flowchart, page 1. DS51641A-page 23 MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide C.2 DEVICE FIRMWARE - FLOWCHART (CONTINUED) For the latest copy of the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide firmware, visit our web site atwww.microchip.com C Yes Set Charge to Idle IBATT < 100 mA No B Yes Is SW1 Pressed? No Yes Is VBATT<12.8V VBULK<6.5V No Shutdown A End FIGURE C-2: DS51641A-page 24 Firmware Flowchart, page 2. © 2006 Microchip Technology Inc. Firmware NOTES: © 2006 Microchip Technology Inc. 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