an1334

ISL9208EVAL1 (Rev C) User Guide
Application Note
August 31, 2007
Description
Initial Testing
This document is intended for use by individuals engaged in
the development of hardware for a 4- to 7-series connected
Li-ion battery pack using the ISL9208.
Setup
AN1334.0
• Make sure the following jumpers are on (See Figure 1): IC
GND JMPR, RGO LED JMPR, WKUP JMPR, I2C GND
JMPR, and the I2C Jumpers.
The evaluation kit consists of a main board and a USB to I2C
board. An optional link between the PC and the
microcontroller BKGD connector is available from NXP
(formerly Freescale) for monitoring and debugging the
microcontroller code.
• For initial testing, set the I2C jumpers (SCL and SDA) to
the PC position. This configures the board such that the
PC communicates directly with the ISL9208.
• Before connecting the PC to the ISL9208EVAL1 (Rev C)
board (through the USB to I2C interface) connect the
power supply to the ISL9208EVAL1 (Rev C) board.
Prior to powering the ISL9208 board, it is advised that the
USB to I2C board software be installed and the DeVaSys
board be connected to the PC (see “Appendix 1” on
page 13). Don’t connect the DeVaSys board to the
ISL9208EVAL1 (Rev C) board, yet. With these pieces in
place, the PC interface can quickly be used to monitor the
operation of the board once power is applied.
• The power supply should consist of a string of 4 to 7
batteries, or a string of 4 to 7 resistors and a power supply, or
4 to 7 individual power supplies (see Figure 2 or Figure 4).
• Once power is turned on (or Li-ion cells are connected to
the ISL9208 board,) the RGO LED should light. Use meter
1 to measure the RGO voltage. It should read about 3.3V.
TO BATTERY/POWER SUPPLY
VC7
IC GND JMPR
RGO LED JMPR
GND
WAKE UP JMPR
RGO (ISL9208)
METER 1
AO
RGO
3.3V
I2C
A2DIN
METER 2
TO PC:
(0-2.3V)
AO
E-LOAD
(60V/1A)
P-
SCL JUMPER
DeVaSys:
USB to I2C
I2C JUMPERS
SDA JUMPER
To PC:
I2C GND JMPR
USBLINK:
USB to BKGD
(OPTIONAL)
FIGURE 1. BOARD CONNECTION DIAGRAM
1
CAUTION: These devices are sensitive to electrostatic discharge; follow proper IC Handling Procedures.
1-888-INTERSIL or 1-888-468-3774 | Copyright Intersil Americas LLC 2007. All Rights Reserved
Intersil (and design) is a trademark owned by Intersil Corporation or one of its subsidiaries.
All other trademarks mentioned are the property of their respective owners.
Application Note 1334
It is recommended that the series resistors be 20 or less
and 2W minimum. Resistors with higher resistance can be
used, but when activating the ISL9208 cell balance outputs,
the 39 cell balance resistor will lower the voltage across
that series power supply resistor, while raising the voltage on
all of the other series resistors. Turning on multiple cell
balance outputs could then result in one or more of the
VCELLN input voltages exceeding their maximum specified
limit. If using series resistors greater than 20, the cell
balance resistors (R14 through R20) should be replaced with
higher values, with 1k resistors recommended.
Battery/Power Supply Connection
When connecting battery packs or power supplies, use the
connections of Figure 2 and Figure 3. If individual power
supplies are being used to replace battery cells, then
connect the power supplies identically to the battery
connections (see Figure 2). Also, make sure that the
individual power supply voltages do not exceed the ISL9208
maximum input voltage differential of 5V per cell.
If using a string of resistors to emulate the battery cells, then
use the connection in Figure 4 and Figure 5. In this case,
limit the power supply voltage so that the resistor divider
outputs do not exceed the ISL9208 input maximum ratings.
7 CELLS
19
20
17
18
15
16
13
14
11
12
9
10
7
8
5
6 CELLS
7 POWER SUPPLIES
19
VCELL7
CB7
VCELL6
V
CB6
VCELL5
V
CB5
VCELL4
V
CB4
VCELL3
V
CB3
VCELL2
V
CB2
VCELL1
V
CB1
VSS
V
20
17
18
15
16
13
14
11
12
9
10
7
8
5
6
VCELL7
CB7
VCELL6
CB6
VCELL5
CB5
VCELL4
CB4
VCELL3
CB3
VCELL2
CB2
VCELL1
19
20
17
18
15
16
13
14
11
12
9
10
7
8
CB1
VSS
5
6
6
VCELL7
CB7
VCELL6
CB6
VCELL5
CB5
VCELL4
CB4
VCELL3
CB3
VCELL2
CB2
VCELL1
CB1
VSS
5 CELLS
19
20
17
18
15
16
13
14
11
12
9
10
7
8
5
4 CELLS
19
VCELL7
20
CB7
VCELL6
17
18
CB6
VCELL5
15
16
CB5
VCELL4
13
14
CB4
VCELL3
11
12
9
CB3
VCELL2
10
CB2
VCELL1
7
8
CB1
VSS
5
6
VCELL7
CB7
VCELL6
CB6
VCELL5
CB5
VCELL4
CB4
VCELL3
CB3
VCELL2
CB2
VCELL1
CB1
VSS
6
NOTE: Multiple cells can be connected in parallel
FIGURE 2. BATTERY CONNECTION OPTIONS
OPTIONAL 6-CELL CONNECTION
7-CELL CONNECTION
TO
LOAD
TO
LOAD
B+/PACK+
B+/PACK+
3M CONNECTOR
MALE ON BOARD
(TOP VIEW)
3M CONNECTOR
MALE ON BOARD
(TOP VIEW)
Optional
Thermistor
(If used, remove
thermistor on
1 board)
1
Optional
Thermistor
or 50k Pot
(If used, remove
thermistor on
board)
BAT-
PACKTO
LOAD
Optional
Thermistor
or 50k Pot
(If used, remove
thermistor on
board)
BAT-
PACKTO
LOAD
FIGURE 3. BATTERY CELL CONNECTION TO ISL9208 PCB
2
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August 31, 2007
Application Note 1334
15V TO 30V
V
19
20
17
18
15
16
13
14
11
12
9
10
7
8
5
6
software is installed (See “Installing the DeVaSys USB to
I2C Board Software” on page 13).
NOTES:
7 CELLS
1. For the battery
simulation resistors,
use 20/5W units. If
the resistors are more
than 100, then turning
on the cell balance
resistors cause
fluctuations in the cell
input voltages that can
violate the ISL9208
max specifications.
VCELL7
CB7
VCELL6
CB6
VCELL5
CB5
VCELL4
CB4
VCELL3
CB3
VCELL2
• Connect the I2C cable from the interface board to the
ISL9208EVAL1 (Rev C) as in Figure 6. The kit may come
with a 5-pin to 5-pin cable or a 5-pin to 4-pin cable.
J11
FETs
2. Switch the power
supplies on at the same
time, or if this cannot be
guaranteed, turn them
on from bottom to top.
CB2
VCELL1
CB1
VSS
FIGURE 4. USING RESISTOR/POWER SUPPLY
COMBINATION TO EMULATE A STRING OF
BATTERIES
SCL
NC
NC
GND
SDA
NEEDED
J29 ONLY 3 WIRES
1
CABLE
5-PIN TO 5-PIN
J2
1
USB
DeVaSys BOARD
ISL9208EVAL1 (REV C)
FIGURE 6. I2C CONNECTION TO ISL9208 PCB
Testing without the Microcontroller
Cell Voltage Monitor Accuracy Check
• For this test, make sure the SCL and SDA jumpers are set
to the PC position. In this case, the PC has full control of
the board and the microcontroller function is disabled (see
Figure 7). Except for the ISL9208 automatic response to
overcurrent and over temperature, all other actions of the
board are manual and controlled through the GUI.
RECOMMENDATION:
ALL RESISTORS = 20/2W
3M CONNECTOR
(TOP VIEW)
.
PC I2C
INTERFACE
ISL9208
PC
30V
POWER
SUPPLY
SCL
J43
SDA
1
Optional
Thermistor or
50k trim pot
(If used, remove
thermistor on
board)
FIGURE 5. POWER SUPPLY/RESISTOR CONNECTION TO
ISL9208 PCB
SCL
µCONTROLLER
J51
SDA
SCL1
SDA1
SCL2
µC
SDA2
USB to I2C Interface
• Once the power supply connections are verified, power
down the ISL9208EVAL1 (Rev C) boards and make the
PC connection to the board, via the USB port, the
DeVaSys board, and the I2C cable. Before making this
connection, make sure that the USB to I2C interface
FIGURE 7. I2C JUMPERS: PC or µC CONNECTION TO THE
ISL9208
• Make the I2C port connection to the PC.
• Power up the board and re-check the RGO voltages.
Since RGO is the voltage reference for the on-board A/D
converter, this voltage may be needed in the accuracy
calculations.
• Start the GUI. Execute the program BATTERYPACK.EXE
from the “Software” directory.
• The GUI should power up with some color. That is, the
FET controls should be RED and the indicators should be
green or red. If the GUI is all gray, then there is a
3
AN1334.0
August 31, 2007
Application Note 1334
10, or 30s, however, this might cause an update when not
expected).
communication problem. If there is a communication
problem, see the troubleshooting guide in the Appendix.
• Use the GUI to read register 0 from the ISL9208. The
ISL9208 should return the value 20H. This verifies
communication to the device.
• Turn on the e-load output. This should cause the FETs to
turn off (see Figure 8).
• Next, move to the “MONITOR” tab of the GUI.
• Set the ISL9208 to monitor the VCELL1 input by choosing
VCELL1 in the Monitor drop down box. Execute this
command by clicking “refresh.” This operation connects
the VCELL1 input to the AO output (through a level shifter
and divider). Any changes on VCELL1 appear on AO.
DFET/
CFET
VDSNS
• Using a meter, measure the CELL1 voltage (from test
point VC1 to GND) and measure the voltage on the
ISL9208 analog output (from AO to GND). The AO
voltage, times 2, should equal the CELL1 voltage. Any
errors in this measurement are due to the ISL9208. (Note:
make sure that all of the cell balance outputs are off,
because cell balance current will cause inaccurate
measurements).
• Also, read the GUI value for CELL1. In this configuration
(without the µC) the cell voltage is converted to digital
using a 15-bit A/D converter. This A/D converter is an
ADS1100 from Texas Instruments. Its output is determined
by Equation 1:.
DigValue D
(EQ. 1)
-------------------------------  3.3 = A2DIN
32768
Since, the reference for the A/D converter is supplied by the
ISL9208 RGO voltage, any difference between the RGO
voltage and 3.3V turns up as an accuracy error.
• Proceed, in sequence, to read the AO voltage for each cell
connected to the ISL9208.
Discharge Overcurrent Testing
• Select an E-load that is able to handle up to 30V and sink
1A minimum.
• With the e-load output off, connect the positive terminal to
Test Point VC7 (Battery + terminal) and the negative
terminal to test point P- (Battery - terminal).
• Use the GUI “CONFIGURATION” screen to set the
desired discharge overcurrent and short circuit levels and
time delays in the ISL9208.
• To test overcurrent, a pulse load or a continuous load can
be used. A continuous load has the advantage of showing
the load monitor operation (see below).
• Set the e-load current such that it will exceed the expected
overcurrent threshold for more than the selected time
delay interval.
ILOAD
FIGURE 8. DISCHARGE OVERCURRENT TEST
(0.1V THRESHOLD, 160ms TIME DELAY, 0.5
SENSE RESISTOR)
• Do a refresh of the GUI and the FET buttons should have
gone to RED. Also, the “Discharge Overcurrent” indicator
should now be red.
.
• Leave the load on and click on the “Enable Load Monitor”
button in the lower right corner of the screen. This turns on
the load monitor output.
• Click on the “Status Refresh” button and the “Load Fail”
indicator should now also be red.
• Turn off or remove the load and again click on “Status
Refresh”. The “Load Fail” indicator should go to green.
Click on the “Reset Overcurrent” button to reset the
“Discharge Overcurrent” indicator. It should also go to
green. If the indicators are still red, it is because the
remaining resistance on the load keeps the voltage on the
ISL9208 load monitor (VMON) pin above its input
threshold. Try disconnecting the load.
• Note: In the GUI, the discharge overcurrent, discharge
short circuit, and charge overcurrent indicators are latched
by the GUI. Internal to the ISL9208, the bits are reset by a
read (if the condition has been resolved). The GUI latch is
provided, because the overcurrent condition goes away as
soon as the FETs turn off and the bits in the ISL9208 are
reset by reading the registers. So, without the latch, the
indicator would not stay on long enough for the user to
monitor. Reset the latch by clicking on the “Clear
Overcurrent” button.
• Turn on both FETs by clicking on the FET buttons in the
GUI. When the FETs are on, the GUI indicators will turn
GREEN. Periodically click on the “Status Refresh” button
on the lower right of the screen to make sure that the GUI
reflects the latest status of the device. (An automatic scan
can also be started that updates all parameters every 1, 5,
4
AN1334.0
August 31, 2007
Application Note 1334
overcurrent condition where the charger turns on with
current too high.
Charge Overcurrent Testing
• Turn off the power to the board.
• Remove any load on the board Pack+ and Pack- pins.
• Turn on the ISL9208 board power supply (or connect the
Li-ion cells to the pack).
• Use the GUI “CONFIGURATION” screen to set the
desired charge overcurrent level and time delay.
• Turn on both FETs by clicking on the FET buttons in the
GUI. When the FETs are on, the GUI indicators will
indicate GREEN. Periodically click on the “Status Refresh”
button on the lower right of the screen to make sure that
the GUI reflects the latest status of the device.
• Use another power supply for charge emulation. With the
output off and not connected to the board, set the output to
just over the chosen overcurrent detect voltage threshold.
(This supply should have a 2.5A limit, but will only need to
provide 1.5V max).
• Connect the charge emulation power supply positive
terminal to the board GND pin and connect the charge
emulation power supply negative terminal to the board Ppin (see Figure 9). A current probe can be used to monitor
the overcurrent details.
.
ISL9208
P-
GND
+
VCSNS
ILOAD
FIGURE 10. CHARGE OVERCURRENT TEST (0.1V
THRESHOLD, 160ms TIME DELAY, 0.5 SENSE
RESISTOR)
• The charge emulation power supply could have been
connected across the Pack output pins - as in a “real
world” operation. However, doing this requires that both
the “charger” and “battery” power supplies sink current,
that the “charger” supply needs to be floating when turned
off (not shorted), and that the “charger” supply needs to
handle a higher voltage than the input.
Sleep/Wake Testing (Default Setting - WKPOL = 0)
The ISL9208 board can be put to sleep via commands from
the PC. This sequence is described in the following
paragraphs.
V
DFET/
CFET
A
FIGURE 9. CHARGE OVERCURRENT TEST CONNECTION
• Turn the charge emulation power supply output on. This
causes the ISL9208 to detect an overcurrent condition,
which turns the FETs off. Figure 10 shows a charge
• To put the ISL9208 into the sleep mode, use the Register
Access window to write an 80H to the ISL9208 register 4.
This turns off the ISL9208 RGO output and LED.
• To wake up the ISL9208 requires that the ISL9208 WKUP
pin go below its wakeup threshold. Normally, a charger
would connect to the pack terminals to generate a
wake-up signal. This works because the unloaded charger
voltage is equal to, or greater than, the voltage on a fully
charged pack. This makes the charger voltage higher than
the voltage on the cells in any charge state. So,
connecting the charger forces the WKUP pin low, causing
the part to wake up. However, in a test setup, it is not
always desirable to connect the charger. In the test setup,
it is possible to force a wake-up by connecting a jumper
from GND to the P- pin. Alternatively, a jumper can be
connected between GND and the WKUP pin to wake the
ISL9208. When using these techniques, don’t leave the
jumper in place.
• When the WKUP pin is pulled low, the ISL9208 wakes up
and turns on the RGO output. This turns on the RGO LED.
5
AN1334.0
August 31, 2007
Application Note 1334
pack until the FETs turn on again and continue
charging until a cell overvoltage condition is reached.
Sleep/Wake Testing (WKPOL = 1)
• Set the WKUP jumper to the active high position (shunt on
the side closest to the push-button switch).
– If one power supply is being used, lower the voltage
on the power supply until one or more of the cells
reach the undervoltage limit and the discharge FET
turns off. Then, increase the voltage until the FETs turn
on again and continue increasing the voltage until a
cell overvoltage condition is reached.
• Use the GUI to set the “WKUP Pin Active High” in the
Configure Tab, feature set window.
• Put the ISL9208 in sleep mode as before.
• This time, the device can be waken by the press of the
WKUP button on the board.
Testing with the Microcontroller
• To operate the board using the microcontroller, power
down the board
• Set the I2C jumpers to the µC position.
• Power up the board and restart the GUI. Now, the PC will
be communicating with the microcontroller and the
microcontroller will be communicating with the ISL9208.
• The GUI should power up with some color. In this case,
the FET controls should be GREEN and the indicators
should be green or red. (Note: there is a 5s delay after
power-up before the microcontroller turns on the FETS, so
the indicators may be RED when initially powered up.
Clicking on the “refresh button” after 5s should change the
FET indicators to GREEN). If the GUI is all gray, then
there is a communication problem. If there is a
communication problem, see the troubleshooting guide in
“Appendix 2” on page 14.
• If the FET indicators are remain RED after 5s, then it is
likely that at least one input voltage is out of range.
With the microcontroller in place, the board performs a
number of automatic functions. These are:
1. The cell inputs are monitored for too high or too low
voltage. If any of the cell voltages go too high, the charge
FET is turned off. If any of the cell voltages go too low, the
discharge FET turns off. When the voltage recovers from
these excursions, back into the normal range, the FETs
automatically turn on.
2. After an overcurrent condition, the microcontroller
monitors the load and turns the FETs back on when the
load is released.
3. The microcontroller monitors the temperature and turns
off the cell balance if the temperature is too high or low.
4. The microcontroller performs cell balancing (once it is
enabled through the GUI).
5. The microcontroller monitors the cell voltages and reports
these voltages to the GUI. The microcontroller A/D
converter accuracy is only 10-bits, so the voltage reading
are not as accurate as when using only the PC interface.
• Test the overvoltage and undervoltage conditions by:
– If Li-ion cells are being used, discharge the pack until
one or more of the cells reach the undervoltage limit
and the discharge FET turns off. Then, charge the
6
– If seven power supplies are used, then simply
decrease or increase any individual supply until the
thresholds are reached and the FET turns off (or on).
• Test the overcurrent in the same way as before, but this
time, when the load is removed the FETs should
automatically turn back on. In this case, with the
microcontroller operating, the status indicators in the GUI
may not prove to be very useful, because the
microcontroller is often doing things too quickly to display
on the screen. To get an indication of the operation,
monitor the voltage at the VMON test point with a scope.
• Testing the cell balance operation requires the use of
Li-ion cells or requires modifying the board to use 1000
cell balancing resistors. (With 7-cells, a string of 20
voltage divider resistors, and 39 cell balancing resistors,
turning on one cell balance output drops the voltage on
that cell to less than 2.5V. At this voltage, the
microcontroller puts the ISL9208 to sleep).
• Start the cell balance test by first observing if the cell with
the maximum cell voltage exceeds the cell with the
minimum voltage by more than 30mV. If so, note the cell
number of the maximum voltage cell.
• Next, select “CB Max #” to be “1”. This limits the balancing
to only one cell (the one with the maximum voltage).
• Use the CB refresh button (or start auto update) to update
the indicators to see which cell is being balanced, it should
be the maximum voltage cell. Be patient, because the
microcontroller will balance for 10s, then turn off balancing
for 2s1, then balance again. Also, if the maximum voltage
cell is very close to the next highest voltage cell, or if there
are many cells within a narrow voltage range, then any of
these cells could be balanced, due to the limited accuracy
of the microcontroller A/D converter.
• Next, select “CB Max #” to be “2”. This limits the balancing
to two cells (the highest two voltage cells). Again refresh
the CB screen periodically to see the operation of the cell
balance code.
• Open the pack tab in the GUI and change some of the
settings for overvoltage, undervoltage, or cell balance and
re-test. Remember to click on “Write” to send the new
parameters to the microcontroller.
1.
If this is too long to wait, go to the “Pack Tab” and
change the cell balance on/off times. Setting 1s on and
1s off is the minimum setting for cell balancing, but 2s
on, 2s off is the recommended minimum, only because
an autoscan of 1s can cause confusion due to the asynchronous nature of cell balance and autoscan.
AN1334.0
August 31, 2007
Application Note 1334
Further tests on the board will likely follow the lines of battery
pack testing, so can become quite involved and be very
specific to the application. So, before setting up the tests,
see the “GUI user Manual” for information on using the
interface and see the “Microcode Reference Guide” for
information about how the software works.
Other Board Features/Options
Sense Resistor
The ISL9208EVAL1 (Rev C) board has three basic sense
resistor “footprints” for different types of sense resistors. The
basic footprint is a standard 2512 surface mount. The board
uses a 0.5 resistor in this form factor as the default.
A second footprint is for an axial lead sense resistor. In this
case, remove the resistor that was shipped with the board.
The third footprint is for a 4 terminal sense resistor with
Kelvin connections. These are higher precision sense
resistor devices, but are more costly.
In summary, in addition to a standard 2512 footprint, the
board is laid out to handle the following resistors:
Microcontroller Options
The BKGD connection on the ISL9208 board allows
development of new or modified code for the NXP (formerly
Freescale) MC9S08QG8 microcontroller, which is supplied
on the board.
The PCB provides optional connections for an external
crystal for the microcontroller and brings all microcontroller
terminals out for use in other application modes.
The external, 15-bit, A/D converter is not used by the
microcontroller, but it could be, if changes are made to the
microcontroller code. To use this, refer to the Texas
Instruments ADS1100 data sheet. The version of the A/D
converter used on the ISL9208 board is the ADS1100A2,
which has an I2C address of “1001 010x.”
Use with an External Microcontroller
The ISL9208 board can be used as a platform for developing
code for a microcontroller other than the NXP (formerly
Freescale) microcontroller on the board. To do this, set the
I2C jumpers in the PC mode and use the I2C interface for
communication with the external microcontroller.
To get good communication between the external
microcontroller and the ISL9208, connect the “I2C GND
jumper” to the GND position. However, in this case, make
sure that the external microcontroller is isolated from earth
ground before connecting a load or charger to the pack. This
is because the board GND terminal and the P- terminal are
not the same when the FETs are off.
Isotek:
– SMV-R005-1.0
– SMR-R005-1.0
– LMSR005-5.0
– BVS-A-R004-1.0
TT electronics (IRC):
– OAR-5 0.005 5% LF (Mouser 66-OAR5R005JLF)
Related Documentation
Additional FETs
From Intersil
The board has pads on the bottom of the board to handle
additional power FETs. As shown in the schematic, these
parallel the ones on the top of the board. While this can be
used to test very high discharge current applications, the
primary purpose of adding these optional FETs to the PCB
was to test the performance of the FET drive circuitry in
applications where higher capacitance FETs or multiple
FETs were used.
ISL9208, ISL9216, ISL9217 Microcode Reference Guide
If the FETs are added to the bottom of the board, monitor the
FET gate drive voltage during FET turn on and turn off to
determine if the response times are suitable for the
application.
No tests have been made to determine if the board traces
can handle the amount of current supported by the FETs on
the board.
7
ISL9208 FN6446 Data Sheet
ISL9208 Application Note
ISL9208, ISL9216 GUI User Guide
DeVaSys USB-I2C Software Installation
From Texas Instruments
ADS1100 Data Sheet
From NXP (Formerly Freescale)
MC9S08QG8 Microcontroller Data Sheet
HCS08 Microcontrollers Family Reference Manual
AN1334.0
August 31, 2007
AFE Schematic
1
2
3
4
5
6
1
TMP3V
uCSCL
uCSDA
1
1
1
J5 J6 J7
CB5 CB6 CB7
1
J4
CB4
1
1
J21 J27 J28
TEMP3V SCL SDA
D
D
S1
J23
RGC
1
SW-PB
R1
187k
Not Populated
R44 0
1
CB3 CB2 CB1
C5
R40 511
J35
1
D3
R35
CFET
1M
~2.5mA
D7
LED
R36
100
R43
0
D4
DIODE
C9
U3
3
2
4.7uF
3
2
1
R37 500
1
C10
J37
AO
1000pF
J39
A2DIN
B
A/D Converter
R13
D6
100k
18V
J38
Pack-
R39
0
GND
AO
B4
Q3
IRF2804S
22
BANANA BLACK
3
Q13
IRF4104S
1
Q12
IRF4104S
J58
GND
4
5
6
3
1
3
SCL SDA
GNDVDD
VIN+VIN-
1
Q2
IRF2804S
R30
0.005/3W
Connect Rs for desired sense R
0.005Ohm application/0.5Ohm test
Sized for 1/100 scale S.C. current
S.C. current = .7A @0.35V setting
O.C. = .2A @0.1V setting
R rated at 5x power for 5sec.
Layout allows 2512, SMR, SMV, axial R
22
1
BAT-
GND
A2D
100
1
1
R32 R33
0
0
BANANA BLACK
4
J55
CON3
GND
VMON
DIODE
C
HEADER 5
D5
4.7V
R47
4.7K
1
J32 DFET
R8
J16
BAT-
5
0
J36
RGO LED
Th1
10k Therm
B3
1
D9
4.7V
C8
.01uF
1
2
1
Notes:
1)Keep wide traces as short as possible
2) Wide trace widths should be 0.4 inches wide or
more
3) Use RoHS approved PCB materials
4) Use immersion gold plating
5) All components used must be RoHS approved
GND
5
4
3
2
1
100
1
CELL1
0.1uF
CON2
A
R46
4.7K
RGO
TH1
1
J33
DSns
1
J24
WKUP
J22
TMPI
J29
100
R26 1M
R27 1M
J31
1
4.7uF
C6
J25
RGO
Q1
FMMT619
R38
46.4k
O.T. = 55degC
17
18
19
20
21
22
23
24
J57 J17
GND GND
J44
CSns
1
1
VC7 VC6 VC5 VC4 VC3 VC2 VC1
J19 J20
1
J18
1
J14
J13
J12
J1
J2
J15
1
1
1
1
1
1
1
J3
GND
R28
R29
J43
JMP3
3
2
1
39
R20
R?
510
32
31
30
29
28
27
26
25
J30
DGate
J34
CGate
3
A
Title
ISL9208EVAL1Z REVC AFE
4
5
Size
A
Number
ISL9208EVAL1Z
Date:
File:
Nov 13, 2006
ISL9208 EVAL1Z_REVC
Revsion
C
Sheet
2 of
Drawn by: CEM
6
3
Application Note 1334
39
CB1
VC5R
NC
SCL
SDA
WKUP
RGC
RGO
Temp3V
1
R18 39
CB2 R19
CB4
VCELL3
CB3
VCELL2
CB2
VCELL1
CB1
VSS
ISL9208
1
CB3
9
10
11
12
13
14
15
16
PAD
R17 39
PACKSCL
PACKSDA
Add-on component
VCELL4
CB5
VCELL5
CB6
VCELL6
CB7
V7/VCC
NC
R16 39
CB4
U1
DSREF
DSense
CSense
DFET
CFET
VMON
AO
TempI
CB5
U2
ISL88694
(Optional)
1
2
3
R15 39
J26
R14 39
CB6
D2
J42
JMP3
J40 J41
PSCLPSDA
1
CB7
CELL1
Battery Connect
B
DIODE
WKUP invert
GND
19
17
15
13
11
9
7
5
3
1
TH1
GND
WKUP Non-invert
GND
.01uF/50V
1
C
20
18
16
14
12
10
8
6
4
2
R23
68.1k
1
C7
J11
CB7
CB6
CB5
CB4
CB3
CB2
CB1
DIODE
D8
15V
4.7V
4.7V
4.7V
4.7V
4.7V
4.7V
4.7V
1
D?
D?
D?
BANANA RED D?
D?
D?
D?
8
7
6
5
4
3
2
1
8
CON1
R2
1.2M
D1
VDD SB1
GND
NC SB2
J56
1
J8
JMP3
Add-on components
1
B1
AN1334.0
August 31, 2007
Microcontroller Schematic
Extra "Breadboard" components
D
J9
.01
C2
.01
C3
.01
C4
.01
R3
100k
R4
100k
R5
100k
R6
100k
R7
100k
2
3
4
5
6
9
7
8
9
J45
HEADER 9
1
D
J10
C1
1
1
2
3
4
5
6
7
8
9
HEADER 9
JP1
5
3
1
BKGD
6
4
2
uCp2
J46
R45
1
J47 uCp5
uCp1
C13
C15
C14
.1uF
.01uF
U4
RGO
GND
1
J48 uCp6
R41 RESIST
PTA5/IRQ/TCLK/RESET PTA0/KBIP0/TPMCH0/ADP0/ACMP+
PTA4/ACMPO/BKGD/MS
PTA1/KBIP1/ADP1/ACMPVDD
PTA2/KBIP2/SDA/ADP2
VSS
PTA3/KBIP3/SCL/ADP3
PTB7/SCL/EXTAL
PTB0/KBIP4/RxD/ADP4
PTB6/SDA/XTAL
PTB1/KBIP5/TxD/ADP5
PTB5/PMCH1/SS
PTB2/KBIP6/MSCK/ADP6
PTB4/MISO
PTB3/KBIP7/MOSI/ADP7
16
15
14
13
12
11
10
9
AO
TMP3V
PACKSDA
PACKSCL
J51 RxDp12
1
uCSCL
uCSDA
J52 TxDp11
T1
T7
TPAD
Q4
MOSFET P
TPAD
T4
1
TPAD
MC9S08QG8
T2
T8
0
1
R42
RESIST
1
2
3
4
5
6
7
8
Y1
J49 uCp8
B
TPAD
Q5
MOSFET P
1
CRYSTAL
C11
CAPNP
J50 uCp7
C12
CAPNP
TPAD
B
T5
1
TPAD
T3
T9
TPAD Q6
MOSFET P
TPAD
T6
TPAD
T19
T21
TPAD Q7
MOSFET P
TPAD
T20
TPAD
A
A
Title
ISL9208EVAL1Z REVC Micro
Size
A
Date:
File:
1
2
3
4
5
Number
ISL9208EV1Z
June 27, 2006
ISL9208EVAL1Z_REVC
Revsion
C
Sheet
3 of
Drawn by: CEM
6
3
Application Note 1334
10k
.1uF
C
PAD
C
AN1334.0
August 31, 2007
Application Note 1334
Bill of Materials
ITEM
QTY
PART TYPE
DESIGNATOR
1
3
0
R32, R33, R43
2
1
0.51
R30
3
7
39
4
4
5
FOOTPRINT DESCRIPTION
PART FIELD 1
603
*
R4, R15, R16, R17, R18, R19, R20
2512
Digikey: PT39AFCT-ND
100
R28, R29, R35, R36
603
*
3
511
R40, R37, + add-on (Q1 collector)
603
*
6
2
0.01µF
C15, C16
603
*
7
1
0.01µF
C8
805
*
8
1
0.01µF/50V
C7
603
*
9
3
0.1µF
C6, C13, C14
603
*
10
1
1.2M
R2
805
*
11
1
100k
R13
805
*
12
1
10k
R45
603
*
13
1
10k Therm
Th1
603
*
14
1
15V
D8
SOD-123
15
1
187k
R1
805
16
1
18V
D6
SOD-123
17
2
1M
R26, R27
603
*
18
1
249k
R39
805
*
19
1
1000pF
C10
603
*
20
2
4.7k
R46, R47
603
*
21
1
4.7µF
C5
603
*
22
1
4.7µF
C9
805
*
23
1
4.7V
D5
SOT23
Digikey: AZ23C3V6-FDICT-NDD
24
8
4.7V
D9 + 7 add-on (VCn inputs)
SOD-123
Digikey: BZT52C4V7-FDICT-ND
25
1
46.4k
R38
805
*
26
1
68.1k
R23
805
*
27
1
A2D
U3
SOT23-6
28
41
29
1
A2DIN, AO, CB1, CB2, J39, J37, J20, J19, J18, J4, J5, J6,
J7, J32, J34, J44, J31, J30, J33,
CB3, CB4, CB5, CB6,
J1, J12, J13, J14, J15, J2, J21,
CB7, CFET, CGATE,
J22, J23, J25, J26, J27, J28, J3,
CSns, DFET, Dgate,
DSns, VC5, VC4, VC3, J35, J38, J40, J41, J45, J46, J47,
J48, J49, J50, J51, J52
VC2, VC1, VC6,
TEMP3V, TMPI, RGC,
RGO, WKUP, SCL, SDA,
VC7, VMON, Pack-,
PSCL, PSDA, µCp2,
µCp1, µCp5, µCp6,
µCp8, µCp7, RxDp12,
TxDp11
Battery Connect
(Female)
10
TP
HEADER
10X2 3M
Digikey: MMSZ4702T10SCT-ND
*
Digikey: MMSZ4705T10SCT-ND
Digikey: 296-14299-1-ND
Connector
Digikey: 5000K-ND
Digikey: MSD20K-ND
AN1334.0
August 31, 2007
Application Note 1334
Bill of Materials (Continued)
ITEM
QTY
PART TYPE
DESIGNATOR
FOOTPRINT DESCRIPTION
PART FIELD 1
30
1
Battery Connect (Male)
J11
HEADER
10X2 3M
31
1
BKGD
JP1
HEADER
3X2
32
2
CON2, RGO_LED
J24, J36
JP_2
33
1
CON3, JMP3
J55, J42, J8, J43
JP_3
34
4
DIODE
D1, D2, D3, D4
SOD-123
Digikey: B0540WDICT-ND
35
1
FMMT619
Q1
SOT23 NPN
Digikey: FMMT619CT-ND
36
4
GND, BAT-
J58, J57, J17, J16
TP SM
37
1
HEADER 5
J29
HEADER
5X1
38
2
IRF4104S
Q2, Q3
D2PAK
Digikey: IRF2804S-ND
39
1
ISL9208
U1
QFN32
Intersil Provided
40
1
LED
D7
LED_GW
41
1
MC9S08QG8
U4
QFN16
42
1
SW-PB
S1
B3WN-6002
BANANA RED
B1
BANANA
(Not Populated)
BANANA BLACK
B3
BANANA
(Not Populated)
BANANA BLACK
B4
BANANA
(Not Populated)
0.01
C1
603
(Not Populated)
CAPNP
C11
603
(Not populated)
CAPNP
C12
603
(Not Populated)
0.01
C2
603
(Not Populated)
0.01
C3
603
(Not Populated)
0.01
C4
603
(Not Populated)
HEADER 9
J10
HEADER9
(Not Populated)
CON1
J56
TPAD
(Not Populated)
HEADER 9
J9
HEADER9
(Not Populated)
IRF4104S
Q12
D2PAK
(Not Populated) Digikey: IRF4104S-ND
IRF4104S
Q13
D2PAK
(Not Populated) Digikey: IRF4104S-ND
MOSFET P
Q4
SOT23
(Not Populated)
MOSFET P
Q5
SOT23
(Not Populated)
MOSFET P
Q6
SOT23
(Not Populated)
MOSFET P
Q7
SOT23
(Not Populated)
Digikey: MHC20K-ND
*
Connector
Connector
*
Digikey: 5011K-ND
*
Digikey: 490CT-ND
Digikey: MC9S08QG8FFE-ND
Digikey: SW425TB-ND
4
COMPONENTS NOT POPULATED
11
AN1334.0
August 31, 2007
Application Note 1334
Bill of Materials (Continued)
ITEM
QTY
PART TYPE
DESIGNATOR
100k
R3
603
(Not Populated)
100k
R4
603
(Not Populated)
RESIST
R41
603
(Not Populated)
RESIST
R42
603
(Not Populated)
0
R44
603
(Not Populated)
100k
R5
603
(Not Populated)
100k
R6
603
(Not Populated)
100k
R7
603
(Not Populated)
1M
R8
603
(Not Populated)
TPAD
T1
TPAD
(Not Populated)
TPAD
T19
TPAD
(Not Populated)
TPAD
T2
TPAD
(Not Populated)
TPAD
T20
TPAD
(Not Populated)
TPAD
T21
TPAD
(Not Populated)
TPAD
T3
TPAD
(Not Populated)
TPAD
T4
TPAD
(Not Populated)
TPAD
T5
TPAD
(Not Populated)
TPAD
T6
TPAD
(Not Populated)
TPAD
T7
TPAD
(Not Populated)
TPAD
T8
TPAD
(Not Populated)
TPAD
T9
TPAD
(Not Populated)
ISL88694
U2
SOT23-5
(Not Populated) *
CRYSTAL
Y1
32k XTAL
(Not Populated)
12
FOOTPRINT DESCRIPTION
PART FIELD 1
AN1334.0
August 31, 2007
Application Note 1334
Appendix 1
Select “Install from a list or specific location” and click “Next”
Installing the DeVaSys USB to I2C Board Software
A screen like the following will come up:
Copy and extract the files from the “PC_software.zip” to the
PC at whatever location is desired.
Disconnect the DeVaSys board from the ISL9208/ISL9216
board.
Then, plug in the DeVaSys board into the USB port.
The following screen should pop up.
Browse for the “Software” directory in the “ISL9208, ISL9216
Eval Kit SW and docs” folder then click “Next”.
This should install the software, eventually bringing up the
following screen:
Select “Yes, this time only” and click “Next”.
Then, this screen will come up:
Click “Finish” and you’re done.
13
AN1334.0
August 31, 2007
Application Note 1334
Appendix 2
ISL9208 Troubleshooting
Communication Troubleshooting
IF THE AO VOLTAGES ARE READING INCORRECTLY
AT THE AO PIN
IF THE GUI STARTS UP WITH ALL ITEMS “GRAYED
OUT”
1. Check that the I2C cable is connected properly.
2. Check that the board is powered and that the RGO
voltage is ~3.3V.
3. If the RGO voltage is not powered to the right voltage,
move to the power supply troubleshooting section.
4. Make sure that the board drivers are installed correctly.
On the DeVaSys USB to I2C interface board, there
should be one red LED and one green LED lighted.
5. Use a scope to see that the I2C communication is correct
at the board. Monitor the SCL and the SDA lines while
initiating a read of the ISL9208 status register. Set the
scope to single trigger on the falling edge of SCL.
6. Check that the SCL and SDA jumpers (J42 and J43) have
shunts on the “PC” side.
7. Check to see that the “I2C GND” jumper is in place in the
“GND” position.
1. Make sure that the I2C jumpers are in the “PC” position.
2. Check that all cell balance outputs are off.
3. Make sure that there is no series resistance between the
battery and the input of the ISL9208 and that the input
voltage is between 2.3V and 4.3V.
IF THE AO VOLTAGES ARE READING INCORRECTLY
ON THE GUI
4. Check that the RGO output is 3.3V. GUI and
microcontroller calculations assume the RGO voltage is
3.3V. Any variation translates directly into errors in the
GUI screen value.
5. Power down the board and stop the GUI. Power up the
board and restart the GUI. This should clear any
communication problems.
6. If operating with the I2C Jumpers in the µC position, make
sure that the “Partition” setting in the Pack Tab matches
the battery connection on the board.
8. Check that the “IC GND” jumper (J24) is in place.
Power Supply Troubleshooting
IF RGO DOES NOT HAVE THE CORRECT VOLTAGE
1. Check that the voltage on each of the input terminals are
correct.
2. Check that there is no unexpected load on the RGO
output.
Intersil Corporation reserves the right to make changes in circuit design, software and/or specifications at any time without notice. Accordingly, the reader is cautioned to
verify that the Application Note or Technical Brief is current before proceeding.
For information regarding Intersil Corporation and its products, see www.intersil.com
14
AN1334.0
August 31, 2007
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