an1444

ISL9208EVAL2Z (Rev. A) User Guide
Application Note
Description
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 ISL9208EVAL2Z board.
The evaluation kit consists of the ISL9208EVAL2Z board.
Operation of the ISL9208EVAL2Z board requires the use of
a USB to I2C kit, part number “ISLI2C-KIT”, which is ordered
separately. An optional link between the PC and the
microcontroller BKGD connector is available from
NXP (formerly Freescale) (used for monitoring and
debugging the microcontroller code).
First Steps
• If not already available, acquire the DeVaSys USB to I2C
interface cable and module. This is available from Intersil
in the ISLI2C-KIT.
• Download the software from the Intersil website on the
ISL9208 page: “ISL92xx Eval Kit Software Release
V1.41”.
• Unzip the software files to a directory of your choice.
• Prior to powering the ISL9208 board, install the USB to I2C
board software and connect the DeVaSys board to the PC
(see “Appendix 1” on page 13). However, don’t connect the
DeVaSys board to the ISL9208EVAL2Z board yet. This is
just preparation of the test set up. With these pieces in
place, the PC interface can then quickly be used to monitor
the operation of the board once power is applied.
• If changes to the microcontroller code are desired, then it
will be necessary to order a programming/debug module
from NXP (formerly Freescale), part number,
USBMULTILINKBDME. This kit also contains the Code
1
December 15, 2008
AN1444.0
Warrior development tools. To get the source code,
contact Intersil and sign the license agreement.
• Set up a power supply for the board. The power supply
should consist of a string of 4 to 7 batteries (see Figure 1),
or a string of 4 to 7 resistors and a power supply, or 4 to 7
individual power supplies (see Figures 1 or 2).
Battery/Power Supply Connection
When connecting battery packs or power supplies, use the
connections of Figures 1 and 2. If individual power supplies
are being used to replace battery cells, then connect the
power supplies identically to the battery connections (see
Figure 1.) 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 2. In this case, limit the power
supply voltage so that the resistor divider outputs do not
exceed the ISL9208 input maximum ratings.
It is recommended that, when using the circuit of Figure 2,
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 on the board 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 on the ISL9208EVAL2Z board (R14-R20)
should be replaced with higher values (1k recommended).
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 2008. 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 1444
7 CELLS
20
20
VCELL7
19
18
17
16
15
14
13
12
11
10
9
8
7
6
6 CELLS
7 POWER SUPPLIES
CB7
VCELL6
V
CB6
VCELL5
V
CB5
VCELL4
V
CB4
VCELL3
V
CB3
VCELL2
V
CB2
VCELL1
V
CB1
VSS
V
VCELL7
19
18
17
16
15
13
CB7
VCELL6
18
CB6
VCELL5
16
17
15
13
11
10
11
10
CB3
VCELL2
9
7
7
CB1
VSS
6
5
16
CB2
VCELL1
8
CB1
VSS
6
CB6
VCELL5
CB3
VCELL2
9
CB2
VCELL1
8
19
18
CB4
VCELL3
12
5 CELLS
20
CB7
VCELL6
CB5
VCELL4
14
CB4
VCELL3
12
VCELL7
19
CB5
VCELL4
14
5
20
5
17
15
14
13
12
11
10
9
8
7
6
4 CELLS
20
VCELL7
19
CB7
VCELL6
18
CB6
VCELL5
16
17
15
CB5
VCELL4
14
13
CB4
VCELL3
12
11
10
CB3
VCELL2
9
CB2
VCELL1
8
7
CB1
VSS
6
5
VCELL7
CB7
VCELL6
CB6
VCELL5
CB5
VCELL4
CB4
VCELL3
CB3
VCELL2
CB2
VCELL1
CB1
VSS
5
Note: Multiple cells can be connected in parallel
FIGURE 1. BATTERY CONNECTION OPTIONS
V
NOTES:
5
7
6
CB1
VSS
9
8
CB2
VCELL1
11
10
CB3
VCELL2
13
12
CB4
VCELL3
15
14
CB5
VCELL4
17
16
CB6
VCELL5
19
18
CB7
VCELL6
VCELL7
7 CELLS
20
15V TO 30V
1. For the battery simulation resistors, use 20/2W devices (minimum). 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. If the series resistors are larger than
20, we recommend replacing the cell balance resistors on the board
with 1k devices.
2. Before connecting the cable to the board, check the voltages at the
connector to verify that they are correct.
FIGURE 2. USING RESISTOR/POWER SUPPLY COMBINATION TO EMULATE A STRING OF BATTERIES
B+/PACK+
OPTIONAL 6 CELL CONNECTION
7 CELL CONNECTION
TO LOAD +
OR CHARGER +
TO LOAD +
OR CHARGER +
CONNECTOR
MALE ON BOARD
(TOP VIEW)
PACK-
Optional Thermistor or
50k Pot (If used, remove
thermistor on board)
BAT-
CH-
CONNECTOR
MALE ON BOARD
(TOP VIEW)
TO
LOAD -
TO
CHARGER -
PACK-
Optional Thermistor or
50k Pot (If used, remove
thermistor on board)
BAT-
CH-
TO
LOAD -
TO
CHARGER -
FIGURE 3. BATTERY CELL CONNECTION TO ISL9208 PCB
2
AN1444.0
December 15, 2008
Application Note 1444
supplies or battery cells. To obtain a blank interface board,
please contact your Intersil representative.
Initial Testing
Setup (See Figure 4)
• Figure 4 shows a blue board that connects between a
power supply and the evaluation board. This board is not
provided in the kit, but is an example of an interface
connection that supports the connection of both a single
power supply (with resistor dividers) or separate power
• Before connecting the PC to the ISL9208EVAL2Z board
(through the USB to I2C interface) turn off the power
supply and then connect the power supply to the
ISL9208EVAL2Z board.
• Turn on the power to the board. Once power is turned on
(or Li-ion cells are connected to the ISL9208EVAL2Z
board,) the RGO LED should light. Use Meter 1 to
measure the RGO voltage. It should read about 3.3V.
Power Supply
Interconnect Board (blue
board, not provided in kit)
provides resistor divider
for generating cell
voltages).
If interested, please
contact Intersil for a blank
board.
TO PC:
DeVaSys:
USB to I2C
RGO (ISL9208)
AO (ISL9208)
METER 1
(3.3V)
GND
TO PC:
BKGD CONNECT
NXP (formerly
Freescale)
USB LINK
USB to BKGD
(Optional)
18V TO 29V BATTERY/POWER SUPPLY
I2C CONNECT
METER 2
(0V TO 2.3V)
USBLINK:
USB to BKGD
(Optional)
FIGURE 4. ISL9208EVAL2Z EVALUATION BOARD TEST CONNECTION
3
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December 15, 2008
Application Note 1444
USB to I2C interface
• Once the power supply connections are verified,
power-down the ISL9208EVAL2Z 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
software is installed (see software installation guide).
• Connect the I2C cable from the interface board to the
ISL9208EVAL2Z as in Figure 5. Use the 5-pin to 4-pin
cable provided in the ISLI2C-KIT.
.
ISL9208EVAL2Z
J8
SDA
NC
GND
SCL
FETs
DeVaSys BOARD
CABLE
J29 5-PIN TO 5-PIN
J2
1
1
USE 5-PIN TO
4-PIN CONNECTOR
SUPPLIED WITH ISLI2C-KIT
USB
FIGURE 5. I2C CONNECTION TO ISL9208 PCB
• CAUTION: The I2C interface ground pin connects with the
Battery negative terminal. If a load connected between the
Pack + and Pack - pins has the same ground reference as
the PC, then both sides of the power FETs will be
connected together through the PC and load ground
leads, so there will be no interruption in the power path.
Also, without proper care, there can be problems with
ground loops or excess voltage conditions as a result of
this connection. If this may be a concern, see “I2C
Isolation” on page 7.
Testing the Board
• Power-up the board and start 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 all be green. If the GUI is all gray, then there is a
communication problem. If there is a communication
problem, see the troubleshooting guide in the Appendix.
• If the FET indicators remain RED after power up, then it is
likely that at least one input voltage or the temperature is
out of range.
The microcontroller on 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 or undervoltage condition, the
microcontroller monitors the load and turns the FETs
back on when the load is released.
4
3. The microcontroller monitors the temperature and turns
off the cell balance and the power FETs 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.
Over/Undervoltage Testing
• 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
pack until the FETs turn on again and continue
charging until a cell overvoltage condition is reached.
– 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.
– 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).
Overcurrent Testing
Testing the overcurrent settings with the ISL9208EVAL2Z
Rev A is not easy without changing the values of the sense
resistors on the board, because it was designed as a
possible reference application.
As delivered, the ISL9208EVAL2Z provides a discharge
sense resistor of 2.5m and a charge sense resistor of
50m. To get a discharge short circuit condition requires
80A. To get a discharge overcurrent condition requires a
load of 40A. To get a charge overcurrent condition requires
2A. Changing both resistors to 0.5 provides a mechanism
for easily testing the current thresholds.
To test the board in an application most likely requires that
battery cells be used and that there is a large load available.
While the board was not extensively tested for these high
load currents, the traces are short and wide enough to
(theoretically) handle the currents up to the 40A threshold.
Cell Balance Testing
• Testing the cell balance operation requires the use of
Li-ion cells or a power supply, 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
AN1444.0
December 15, 2008
Application Note 1444
minimum voltage by more than 30mV. If so, note the cell
number of the maximum voltage cell.
CONNECT TO SIMULATE
CHARGER WAKE-UP
• Next, select “CB Max #” to be “1”. This limits the balancing
to only one cell - the one with the maximum voltage.
• Monitor the call balance LEDs on the board or the GUI to
track the cell balance operation. On the GUI, use the CB
refresh button (or start auto update) to update the
indicators to show 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.
Sleep/Wake Testing
The ISL9208 board can be put to sleep via commands from
the PC or by lowering the voltage on any cell below 2.5V
(default software setting). This sequence is described in the
following paragraphs.
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. Or, the
ISL9208 can be put to sleep by the microcontroller
automatically when it detects that the voltage on any cell is
less than 2.5V.
To wake-up the ISL9208 requires that the ISL9208 WKUP
pin go below its walk-up threshold.This can happen when a
charger connects to the pack charge terminals or when a
load is connected to the load terminals. This can be done
with real loads or chargers or by using a resistor, as shown
in Figure 6.
1.
If this is too long to wait, go to the “Pack Tab” in the GUI
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.
5
CONNECT TO SIMULATE
LOAD WAKE-UP
1k
1k
FIGURE 6. ISL9208EVAL2Z CURRENT DETECTION
CONNECTIONS
• The charger connection works because it pulls the charger
negative terminal to about the ISL9208 VSS voltage, the
same as would an unloaded charger.
• The load connection works, because the load terminal is
pulled high (in sleep mode, the power FETs are off, so the
connection from the ISL9208 VSS pin to the Pack- pin is
open). Circuitry on the board inverts this signal to pull the
ISL9208 WKUP pin low to wake the device.
• When the WKUP pin is pulled low, the ISL9208 wakes up
and turns on the RGO output. This turns on the RGO LED.
Additional Testing
Further tests on the board will likely follow the lines of battery
pack testing, so it can become quite involved and be very
specific to the application. Therefore, 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
Current Direction Detection
The ISL9208EVAL2Z (Rev A) board has a circuit to detect a
charge or discharge condition (see Figure 7). It is designed
to detect a small current flowing into or out of the pack. The
software revision 1.5 does not yet support this hardware, but
the signals can be monitored with a meter or a scope to
determine their performance.
There are two main uses for the current direction detection
circuit. The first is in power control. If the microcontroller
does not see any current for a long period of time, it can put
the pack hardware to sleep to extend battery life. Second,
the cell balance routine is usually conducted only during a
charge condition. To do this requires information that charge
current is flowing.
The current direction detectors are comparators only, so
when the current is high enough, the indicators go high. For
AN1444.0
December 15, 2008
Application Note 1444
charge current, the threshold is about 60mA, for discharge
the threshold is about 800mA. These thresholds can be
changed by replacing a resistor, but making the thresholds
much lower may cause problems due to the LM358 input
offset. To change the discharge current detection threshold,
change the value of R46. A lower value lowers the current
threshold. To change the charge current detection threshold,
change the value of R40. A lower value lowers the current
threshold.
Pack Voltage Monitoring
The ISL9208EVAL2Z has a circuit that is activated by the
microcontroller to monitor the pack voltage directly. The input
to the microcontroller is the pack voltage divided by 16 (see
Figure 9).
PACK+
100k
RGO
1 OF 2
LM358
1M
1M
+
1k
1k R40
1.21M
1M
CHARGE
INDICATOR
368k
80.6k
PACKV
16
TO µC
A/D INPUT
GND
FMMT619
TO µC
OUTPUT
50k
GND
BSS84DW
CHARGE
0.05
FIGURE 9. DIRECT MONITOR OF THE PACK VOLTAGE
0.005
DISCHARGE
RGO
2 OF 2
1.8M
1k
GND
+
R46
DISCHARGE
INDICATOR
FIGURE 7. USING OP AMP AND FETS TO DETECT
CHARGE AND DISCHARGE CURRENT
Future code revisions will have support for this hardware,
but if custom code is desired, then the charge indicator
connects to the microcontroller pin PTB4 and the discharge
indicator connects to pin PTB5. See Figure 8.
CURRENT DIRECTION DETECT CIRCUITS
DISCHARGE DETECT
The software revision 1.5 does not support the pack voltage
monitor hardware, but if support is desired, then the
microcontroller needs to turn on the PTB6 output to enable
the circuit, then do an analog read of the ADP4 input.
PACK VOLTAGE MONITORING CIRCUIT
CHARGE DETECT
FIGURE 8. ISL9208EVAL2Z CURRENT DETECTION
CONNECTIONS
6
The purpose of this circuit is to get a more accurate reading
of the pack voltage. Without this circuit, the pack voltage is
determined by adding the individual cell voltages. However,
this results in adding the measurement errors of each cell,
so the accuracy of the pack voltage is not very useful. With
an accurate reading of the pack voltage, the microcontroller
can use the value to determine if there is any low level
discharge current or can use the value to compare to the
summation of the cell voltages to detect any gross cell
measurement errors.
PACK VOLTAGE ENABLE
PACK VOLTAGE µC INPUT
FIGURE 10. ISL9208EVAL2Z PACK VOLTAGE MONITORING
CONNECTIONS
AN1444.0
December 15, 2008
Application Note 1444
I2C Isolation
EEPROM
In some test conditions, ground connections can cause
problems. This is because the I2C ground, power supply,
load, and perhaps an oscilloscope, may all connect to
ground. This can cause problems ranging from grounding
both sides of the power FETs (taking them out of the circuit)
to creating ground loops or unexpected voltage potentials
that can damage components.
For applications that require non-volatile storage or require
calibration and the microcontroller flash is no longer
available, the ISL9208EVAL2Z (Rev A) board provides a
serial EEPROM connection to the microcontroller (see
Figure 11). An example EEPROM device is the AT24C16
from Atmel. This is not populated as shipped and there is no
code in the microcontroller in software release 1.5 to support
this device.
The ISL9208EVAL2Z provides an option for the addition of
an isolation device for the I2C interface; the Analog Device
ADuM1250. This allows the PC to monitor a battery pack
that is connected to a load without some of the grounding
problems that can arise. To use this option, the device and a
header needs to be installed on the board, then the
DeVaSys board needs to connect to the JP3 connector (see
Figure 11).
The DeVaSys board will need to connect with a 5-pin to 5-pin
point-to-point connector (pin 3 is not used, but the
ADuM1250 uses the 3.3V supply provided by the DeVaSys
board).
ISOLATED I2C INTERFACE CONNECTION
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.
Related Documentation
From Intersil
ISL9208, ISL9216, ISL9217 Microcode Reference Guide
ISL9208 (FN6446) Data Sheet
ISL9208 Application Note (AN1333)
ISL9208, ISL9216 GUI User Guide (AN1334)
DeVaSys USB-I2C Software Installation
From Texas Instruments
ADS1100 Data Sheet
From NXP (Formerly Freescale)
MC9S08QG8 Microcontroller Data Sheet
HCS08 Microcontrollers Family Reference Manual
EEPROM PAD
FIGURE 11. ISL9208EVAL2Z ISOLATED INTERFACE
CONNECTION AND EEPROM
7
AN1444.0
December 15, 2008
AFE Schematic
3
4
6
5
Notes:
Notes:
1)Keep
wide traces as
as short
as possibleas possible
1. Keep wide
traces
short
2) Wide trace widths should be 0.4 inches wide or
morewidths should be 0.4 inches
2. Wide trace
3) Use RoHS approved PCB materials
wide or more.
4) Use immersion gold plating
5) All components used must be RoHS approved
3. Use RoHs
approved PCB materials.
4. Use immersion gold plating.
D
5. All components used must be RoHs
approved.
1
1
J21 J27 J28
TEMP3V SCL SDA
1
1
J5 J6 J7
CB5 CB6 CB7
1
J4
CB4
1
2
1
1
TMP3V
uCSCL
uCSDA
D
J23
RGC
1
C7
1uF/50V
1
CB2
CB1
R68 1k
Q7
MMBT3906K
CELL5
C20
4.7uF
CB5
R69 1k
CELL3
C21
4.7uF
A
CB3
R70 1k
CELL1
CB1
C22
4.7uF
R12
100k
Q9
MMBT3906K
R16
100k
Q11
MMBT3906K
R20
100k
R71 1k
R55
750
CB6
C19
4.7uF
R10
100k
Q10
R17 SCHOTTKY R72 1k
MMBT3906K
39 D19
CELL2
LED
R18
C24
D8
R58
4.7uF
100k
CB2
750
SCHOTTKY
R19
39 D22
CELL1
LED
D11
R61 750
R21 SCHOTTKY R73 1k
39 D20
GND
LED
D9
R57
750
D15
J32
1
1
2
3
CHRG_I
Q13
FMMT619
RGO
2
1M
FYD0504SA
DIODE
6
5
4
R33
100
1
Q4
R65
1M
J42
Pack- CHG
1
J35
VMON
D4
DIODE
R49
1.2M R51
82k
R39
249k
3
RGO
R75
1.8M
GND
VCC
GND
LM358
U2
PACKV
C27
0.1uF
ENPV
2
Q2
IRF1404S
J30
R54
50k
GND
1
R43
1M
DGate
8
7
6
5
J38
Pack- DSC
A
3
1
2
3
4
B
GND
18V
100
R42
1M
R46
5.49k
J39
A2DIN
Q5
BSS8402DW
D23
CFET
R40
1k
DSCG_I
R64
1
1
J37
AO
R6
368k
C16
1000pF
6
5
4
J43
CSns
J31
DFET
BSS84DM
SCHOTTKY
R15
39 D21
CELL3
LED
D10
R60 750
D14
AO
R37 499
R66
100k
3
2
1
5m
SCHOTTKY
R11 39 D17
CELL5
LED
D6
R56 750
R74 1k
Q8
R13 SCHOTTKY
MMBT3906K
39 D18
CELL4
LED
R14
C23
D7
R59
4.7uF
100k
CB4
750
GND
10M
R50 50m
8
7
6
5
1
R48
DSns
R35
LED
D3
GND
1
R8
100k
Q6
MMBT3906K
J54
CON1
1
J25
RGO
1
C1
4.7uF
SCHOTTKY
D16
CELL6
D5
3.3V
1
R47
5k
5m
R53
BAT- DSC
RGO
R62 C8
1k
.01uF
D12
RGO
R26
1M R27
1M
Q14 IRF7469
1
Q15
MMBT3906K R9
39
JP2
TH1
J33
1
R52
J10
J22
TMPI
D13
DIODE
GND
C3
1000p
R67
49.9
4 HEADER
FMMT619
1
2
3
C18
0.1uF
Q1
R38
46.4k
O.T. = 55degC
17
18
19
20
21
22
23
24
CB3 CB2 CB1
R41
1k
C17
.47uF/50V
1
J19 J20
1
J18
1
4.7uF/50V
10uF/25V
4.7uF/50V
C6
10uF/16V
C5 C11 C2 C10 C9
10uF/16V
10uF/16V
C4
4.7uF/50V
GND
C
1
2
3
4
100
1
2
CB3
J29
100
2
1
100
R28
R29
150k
32
31
30
29
28
27
26
25
NC
NC
SCL
SDA
WKUP
RGC
RGO
Temp3V
2
1
100
R32
CB4
VCELL3
CB3
VCELL2
CB2
VCELL1
CB1
VSS
RGO
R31
CELL1
9
10
11
12
13
14
15
16
CB4
1
CELL2
CB5
2N7002
R5
ISL9208
4
CELL3
100
PACKSCL
PACKSDA
Q3
U1
CB6
1
100
R30
0
R25
R1
511
PAD
CELL4
8
7
6
5
4
3
2
1
49.9
D2
GND
CB7
VCELL4
CB5
VCELL5
CB6
VCELL6
CB7
V7/VCC
NC/VCC
49.9
R24
C12
0.47uF/50V
2
Title
Q12
IRF1404S
R76
R34 1k
3
1
ISL9208EVAL2Z Design
C28
Size
A
0.47uF/50V
Date:
File:
4
5
Number
ISL9208EVAL2Z
July10, 2008
ISL9208EVAL2Z
Revsion
A
Sheet
2 of
Drawn by: CEM
6
3
Application Note 1444
R22
CELL5
Connect GND and
BAT- DSC at battery
string negative
terminal. Use small
gauge wire. The
resistance of this
wire needs to be
kept to a minimum
(preferrably
DIODE
GND
10
R7
CELL6
CON8
CB7
R23
330k
1
R36
1.2M
1
8
7
6
5
4
3
2
1
CELL7
J40 J41
PSCL PSDA
DIODE
1
1
1
J8
B
R2
1.8M
D1
WKUP
CELL7
C
J26
WKUP
1
R63
511
1
R3 R4
4.7k 4.7k
1
1
DSREF/ISREF
DSense
CSense
DFET
CFET
VMON
AO
TempI
8
J3
VC7
J2
VC6
J1
VC5
J12
VC4
J13
VC3
J14
VC2
J15
VC1
AN1444.0
December 15, 2008
Microcrontroller Schematic
D
D
9
J45
U4
1
1
2
3
4
uCp2
C
C25
0.1uF
5
3
1
JP1
VDD1 VDD2
SDA1 SDA2
SCL1 SCL2
GND1 GND2
8
7
6
5
JP3
HEADER 5
C26
0.1uF
BKGD
6
4
2
ADUM1250
1
10k
uCp1
U3
1
J48 ENPV
ENPV
1
DSCG_I
CHRG_I
B
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
PAD
1
2
3
4
5
6
7
8
16
15
14
13
12
11
10
9
AO
TMP3V
PACKSDA
PACKSCL
J51 PV
1
uCSCL
uCSDA
J52 WP
1
MC9S08QG8
0
C13
C15
C14
.1uF
.01uF
RGO
GND
PACKV
J49 CHI
B
1
U5
J50 DCI
1
2
3
4
1
A0 Vcc
A1
WP
A3 SCL
Vss SDA
8
7
6
5
EEPROM 8L
A
A
Title
ISL9208EVAL2Z Reference Design - Microcontroller
Size
A
Date:
File:
1
2
3
4
5
Number
ISL9208EVAL2Z
July 10, 2008
ISL9208EVAL2Z
Revsion
A
Sheet
3 of
Drawn by: CEM
6
3
Application Note 1444
J47 ENI
C
J46
R45
.1uF
1
2
3
4
5
AN1444.0
December 15, 2008
Application Note 1444
ISL9208EVAL2Z Bill of Materials
PART NUMBER
QTY UNITS
REFERENCE
DESIGNATOR
ISL9208EVAL2ZREVAPCB
1
ea
GMK212BJ474KG-T
3
ea
C12, C17, C28
GRM31CF51H475ZA01L-T
3
ea
C6, C9, C10
H1044-00102-25V10-T
1
ea
H1044-00104-16V10-T
1
H1045-00102-25V10-T
DESCRIPTION
PWB-PCB, ISL9208EVAL2Z,
REVA, QFN, ROHS
MANUFACT.
TBD
MANUFACTURER PART
ISL9208EVAL2ZREVAPCB
CAP, SMD, 0805, 0.47µF, 35V, TAIYO YUDEN
10%, X5R, ROHS
GMK212BJ474KG-T
CAP, SMD, 1206, 4.7µF, 50V, MURATA
-20 + 80%, Y5V, ROHS
GRM31CF51H475ZA01L
C3
CAP, SMD, 0402, 1000pF,
25V, 10%, X7R, ROHS
GRP155R71E102K
ea
C18
CAP, SMD, 0402, 0.1µF, 16V, MURATA
10%, X7R, ROHS
GRM36X7R104K016AD
1
ea
C16
CAP, SMD, 0603, 1000PF,
25V, 10%, X7R, ROHS
08053C102KAT2A
H1045-00103-16V10-T
2
ea
C8, C15
CAP, SMD, 0603, 0.01µF, 16V, VENKEL
10%, X7R, ROHS
C0603X7R160-103KNE
H1045-00104-16V10-T
3
ea
C13, C14, C27
CAP, SMD, 0603, 0.1µF, 16V, MURATA
10%, X7R, ROHS
GRM39X7R104K016AD
H1045-00104-16V10-T
0
ea
DNP (C25, C26)
CAP, SMD, 0603, 0.1µF, 16V, MURATA
10%, X7R, ROHS
GRM39X7R104K016AD
H1045-00475-6R3V10-T
7
ea
C1, C19-C24
CAP, SMD, 0603, 4.7µF, 6.3V, VENKEL
10%, X5R, ROHS
C0603X5R6R3-475KNE
H1065-00106-25V10-T
4
ea
C2, C4, C5, C11
CAP, SMD, 1206, 10µF, 25V,
10%, X5R, ROHS
VENKEL
C1206X5R250-106KNE
H1082-00105-50V10-T
1
ea
C7
CAP, SMD, 1210, 1µF, 50V,
10%, X7R, ROHS
VENKEL
C1210X7R500-105KNE
1266
1
ea
B- (Located right
of J10)
CONN-TERMINAL, TH,
QUICK-FIT MALE TAB,
20.1x8.9, ROHS
KEYSTONE
1266
22-23-2041
1
ea
J29
CONN-HEADER, 1x4, SOLID, MOLEX
2.54mm, FRICTION LOCK,
ROHS
22-23-2041
22-23-2051
0
ea
DNP (JP3)
CONN-HEADER, 1x5, SOLID, MOLEX
2.54mm, VERTICAL,
FRICTION LOCK, TIN,
PbFREE
22-23-2051
22-28-8361
1
ea
J8 (Break off in
8-pin segments)
MOLEX
CONN-HEADER, 1x36,
BREAK-AWAY, 2.54mm, R/A,
ROHS
22-28-8361
67996-272HLF-2x3
1
ea
JP1
CONN-HEADER, 2x3,
BRKAWY 2X36, 2.54mm,
VERTICAL, ROHS
AZ23C3V3-7-F-T
1
ea
D5
DIODE-ZENER, DUAL, SMD, DIODES INC.
SOT23, 3.3V, 300mW, ROHS
AZ23C3V3-7-F
BAT6203WE6327
1
ea
D15
DIODE-SCHOTTKY, SMD, 2P, INFINEON
SOD323, 40V, 20mA, ROHS TECHNOLOGY
BAT6203WE6327
FYD0504SATM
1
ea
D14
DIODE-SCHOTTKY
RECTIFIER, SMD, D-PAK,
40V, 5A, ROHS
FAIRCHILD
MBR0540T1G-T
11
ea
D1, D2, D4, D13,
D16-D22
DIODE-RECTIFIER, SMD,
SOD-123, 2P, 40V, 0.5A,
ROHS
ON
MBR0540T1G
SEMICONDUCTOR
10
MURATA
AVX
BERG/FCI
67996-272HLF
FYD0504SATM
AN1444.0
December 15, 2008
Application Note 1444
ISL9208EVAL2Z Bill of Materials (Continued)
PART NUMBER
QTY UNITS
REFERENCE
DESIGNATOR
DESCRIPTION
MANUFACT.
MANUFACTURER PART
DIODE-ZENER, SMD, 2P,
SOD-123, 18V, 500mW,
ROHS
ON
MMSZ4705T1G
SEMICONDUCTOR
LED, SMD, 0603, ORANGE,
19mcd, 5mA, 1.9V, 620nm,
ROHS
PANASONIC
DNP (U4)
IC-HOT SWAP DUAL I2C
ISOLATOR, 8P, NSOIC,
ROHS
ANALOG DEVICES ADUM1250ARZ
ea
DNP (U5)
CAT24C01WI-GT3
IC-CMOS SERIAL EEPROM, CATALYST
SEMICONDUCTOR
8P, SOIC, 1.7V to 5.5V,
INC
16BYTE, ROHS
1
ea
U1
IC-MULTI-CELL BATTERY
INTERSIL
PACK, 32P, QFN, 5x5, ROHS
ISL9208IRZ
LM358AM
1
ea
U2
IC-DUAL OP AMP, 8P, SOIC, FAIRCHILD
ROHS
LM358AM
MC9S08QG8CFFE
1
ea
U3
IC-MCU, FLASH, 8kx8,
10MHz, 16P, QFN, ROHS
2N7002-7-F-T
1
ea
Q3
TRANSISTOR, N-CHANNEL, DIODES, INC.
3 Ld, SOT-23, 60V, 115mA,
ROHS
2N7002-7-F
BSS8402DW-7-F-T
1
ea
Q5
DIODES INC.
TRANSIST-MOS,
P-CHANNEL/N-CHANNEL,
6P, SOT-363, 200mW, ROHS
BSS8402DW-7-F
BSS84DW-7-F-T
1
ea
Q4
TRANSIST, DUAL
P-CHANNEL, 6P, SOT-363,
-50V, -130mA, ROHS
FMMT619TA-T
2
ea
Q1, Q13
TRANSISTOR, NPN, SOT23, ZETEX, INC.
50V, 2A, ROHS
FMMT619TA
IRF1404SPBF
2
ea
Q2, Q12
INTERNATIONAL
TRANSIST-MOS, NCHANNEL, TH, D2-PAK, 40V, RECTIFIER
162A, ROHS
IRF1404SPBF
IRF7469PBF
1
ea
Q14
TRANSISTOR-MOS, SMPS,
8P, SOIC, 40V, 9A, ROHS
IRF7469PBF
MMBT3906K-T
7
ea
Q6-Q11, Q15
CSNL20.0051%R-T
2
ea
R52, R53
RES-CURR SENSE, SMD,
2512, 0.005, 2W, 1%, MF,
ROHS
STACKPOLE
CSNL 2 0.005 1% R
CSRN20.051%I-T
1
ea
R50
RES-CURR SENSE, SMD,
2512, 0.05, 2W, 1%, TF,
ROHS
STACKPOLE
CSRN 2 0.05 1% I
H2510-00100-1/16W1-T
1
ea
R7
RES, SMD, 0402, 10, 1/16W, PANASONIC
1%, TF, ROHS
H2510-01000-1/16W1-T
4
ea
R25, R30, R31,R32 RES, SMD, 0402, 100,
1/16W, 1%, TF, ROHS
PANASONIC
ERJ-2RKF1000
H2510-01001-1/16W1-T
9
ea
R34, R40, R68-R74 RES, SMD, 0402, 1k, 1/16W,
1%, TF, ROHS
VENKEL
CR0402-16W-102JT
H2510-01003-1/16W1-T
8
ea
R8, R10, R12, R14, RES, SMD, 0402, 100k,
R16, R18, R20, R66 1/16W, 1%, TF, ROHS
PANASONIC
ERJ2RKF1003
MMSZ4705T1G-T
1
ea
D23
LNJ826W83RA
8
ea
D3, D6-D12
ADUM1250ARZ
0
ea
CAT24C01WI-GT3
0
ISL9208IRZ
11
LNJ826W83RA
MC9S08QG8CFFE
NXP (formerly
Freescale)
SEMICONDUCTOR
DIODES INC.
INTERNATIONAL
RECTIFIER
TRANSISTOR, PNP, 3P,
FAIRCHILD
SOT-23, -40V, -200mA, ROHS
BSS84DW-7-F
MMBT3906K
ERJ-2RKF10R0
AN1444.0
December 15, 2008
Application Note 1444
ISL9208EVAL2Z Bill of Materials (Continued)
PART NUMBER
QTY UNITS
REFERENCE
DESIGNATOR
H2510-01004-1/16W1-T
3
ea
R42, R43, R64
H2510-01005-1/16W1-T
1
ea
H2510-01204-1/16W1-T
2
H2510-01804-1/16W1-T
DESCRIPTION
MANUFACT.
MANUFACTURER PART
RES, SMD, 0402, 1M, 1/16W, PANSONIC
1%, TF, ROHS
ERJ-2RKF1004X
R48
RES, SMD, 0402, 10M,
1/16W, 1%, TF, ROHS
VISHAY/DALE
CRCW040210M0FKED
ea
R36, R49
RES, SMD, 0402, 1.2M,
1/16W, 1%, TF, ROHS
VENKEL
CR0603-16W-1204FT
1
ea
R75
RES, SMD, 0402, 1.8M,
1/16W, 1%, TF, ROHS
VENKEL
CR0402-16W-1804FT
H2510-03653-1/16W1-T
1
ea
R6
RES, SMD, 0402, 365k,
1/16W, 1%, TF, ROHS
VENKEL
CR0402-16W-3653FT
H2510-04642-1/16W1-T
1
ea
R38
RES, SMD, 0402, 46.4k,
1/16W, 1%, TF, ROHS
PANASONIC
ERJ2RKF4642
H2510-04701-1/16W1-T
2
ea
R3,R4
RES, SMD, 0402, 4.7k,
1/16W, 1%, TF, ROHS
VENKEL
CR0402-16W-4701FT
H2510-04991-1/16W1-T
1
ea
R47
RES, SMD, 0402, 4.99k,
1/16W, 1%, TF, ROHS
KDA
RK73H1E4991F
H2510-04992-1/16W1-T
1
ea
R54
RES, SMD, 0402, 49.9k,
1/16W, 1%, TF, ROHS
PANASONIC
ERJ-2RKF4992
H2510-049R9-1/16W1-T
3
ea
R22, R24, R67
RES, SMD, 0402, 49.9,
1/16W, 1%, TF, ROHS
PANASONIC
ERJ-2RKF49R9
H2510-05491-1/16W1-T
1
ea
R46
RES, SMD, 0402, 5.49k,
1/16W,1%, TF, ROHS
H2510-07500-1/16W1-T
7
ea
R55-R61
RES, SMD, 0402, 750,
1/16W, 1%, TF, ROHS
PANASONIC
ERJ-2RKF7500X
H2510-08202-1/16W1-T
1
ea
R51
RES, SMD, 0402, 82k, 1/16W, PANASONIC
1%, TF, ROHS
ERJ-2RKF8202X
H2511-01000-1/10W1-T
4
ea
H2511-01001-1/10W1-T
2
ea
R41, R62
H2511-01002-1/10W1-T
1
ea
R45
H2511-01004-1/10W1-T
3
ea
R26, R27, R65
H2511-01503-1/10W1-T
1
ea
H2511-01804-1/10W1-T
1
H2511-02493-1/10W1-T
R28, R29, R33, R35 RES, SMD, 0603, 100,
1/10W, 1%, TF, ROHS
RES, SMD, 0603, 1k, 1/10W,
1%, TF, ROHS
KOA
RK73H1JT1000F
KOA
RK73H1JTTD1001F
RES, SMD, 0603, 10k, 1/10W, KOA
1%, TF, ROHS
RK73H1JT1002F
RES, SMD, 0603, 1M, 1/10W, PANASONIC
1%, TF, ROHS
ERJ-3EKF1004V
R5
RES, SMD, 0603, 150k,
1/10W, 1%, TF, ROHS
YAGEO
RC0603FR-07150KL
ea
R2
RES, SMD, 0603, 1.8M,
1/10W, 1%, TF, ROHS
VENKEL
CR0603-10W-1804FT
1
ea
R39
RES, SMD, 0603, 249k,
1/10W, 1%, TF, ROHS
YAGEO
9C06031A2493FKHFT
H2511-03303-1/10W1-T
1
ea
R23
RES, SMD, 0603, 330k,
1/10W, 1%, TF, ROHS
YAGEO
RC0603FR-07330KL
H2511-04990-1/10W1-T
1
ea
R37
RES, SMD, 0603, 499,
1/10W, 1%, TF, ROHS
KOA
RK73H1JTTD4990F
H2511-05110-1/10W1-T
2
ea
R1,R63
RES, SMD, 0603, 511,
1/10W, 1%, TF, ROHS
VENKEL
CR0603-10W-5110FT
H2512-00010-1/8W1-T
1
ea
R76
RES, SMD, 0805, 1, 1/8W,
1%, TF, ROHS
VENKEL
CR0805-8W-1R00FT
12
AN1444.0
December 15, 2008
Application Note 1444
ISL9208EVAL2Z Bill of Materials (Continued)
PART NUMBER
QTY UNITS
REFERENCE
DESIGNATOR
DESCRIPTION
MANUFACT.
H2515-00390-1W1-T
7
ea
R9, R11, R13, R15, RES, SMD, 2512, 39, 1W,
R17, R19, R21
1%, TF, ROHS
SJ-5003-BLACK
4
ea
3M
Bottom four corners BUMPONS,
0.44inWx0.20inH, DOMETOP,
BLACK
5X8-STATIC-BAG
1
ea
Place assy in bag
DNP
0
ea
B1-B7
DO NOT POPULATE OR
PURCHASE
DNP
0
ea
J10
DO NOT POPULATE OR
PURCHASE
DNP
0
ea
J42, P-
DO NOT POPULATE OR
PURCHASE
DNP
0
ea
VC1-VC7
DO NOT POPULATE OR
PURCHASE
DNP
0
ea
a) CSns, DSns,
CFET, DFET, TI,
RGO, AO, SCL,
DO NOT POPULATE OR
PURCHASE
DNP
0
ea
LABEL-SERIAL NUMBER
1
ea
NTSD1XH103FPB50
1
ea
BAG, STATIC, 5x8, ZIP LOC
VENKEL
INTERSIL
MANUFACTURER PART
CR2512-1W-39R0FT
SJ-5003SPBL
212403-013
DO NOT POPULATE OR
b) SDA, PSCL,
PSDA, VMon, WKU, PURCHASE
WP
LABEL, FOR SERIAL
NUMBER AND BOM REV #
JP2
THERMISTOR-NTC, TH, 10k, MURATA
15mW, 1%, 50mm,
B VALUE = 3380k, ROHS
NTSD1XH103FPB50
The following screen should pop up.
Appendix 1
Installing the DeVaSys USB to I2C Board Software
Obtain the DeVaSys software along with the GUI code from
the Intersil website on the ISL9208 page. Copy and extract
the files from the “ISL92xx Eval Kit Software Release V1.41”
zip file to the PC at whichever location is desired.
Disconnect the DeVaSys board from the ISL9208, ISL9216
board.
Plug in the DeVaSys board into the USB port.
Select “Yes, this time only” and click “Next”.
13
AN1444.0
December 15, 2008
Application Note 1444
Then, this screen will come up:
This should install the software, eventually bringing up the
following screen:
Select “Install from a list or specific location” and click “Next”
A screen like the next one will come up:
Click “Finish” and you’re done.
Appendix 2
Communication Troubleshooting
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 lit.
Browse for the Software in directory “ISL9208_16 Eval Kit
SW and docs” folder then click “Next”.
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.
Power Supply Troubleshooting
IF RGO DOES NOT HAVE THE CORRECT VOLTAGE
1. Check that the voltage on each of the input terminals are
between 2.6V and 4.5V.
2. Check that there is no unexpected load on the RGO
output.
ISL9208 Troubleshooting
IF THE AO VOLTAGES ARE READING INCORRECTLY
AT THE AO PIN
1. Check that all cell balance outputs are off.
2. Make sure that there is no series resistance between the
battery and the input pins of the ISL9208EVAL2Z board
and that the input voltage is between 2.6V and 4.3V.
14
AN1444.0
December 15, 2008
Application Note 1444
IF THE AO VOLTAGES ARE READING INCORRECTLY
ON THE GU
1. 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.
2. Power-down the board and stop the GUI. Power-up the
board and restart the GUI. This should clear any
communication problems.
3. Turn off the cell balancing. On the ISL9208EVAL2Z
board, external PNP transistors are used to provide
external balancing elements. When the PNP transistor
turns on, current flows into the CBN pin and out the
VCELL(N-1) pin. The current flowing out the VCELL(N-1)
pin causes the VCELL voltage on one side of the
balanced input to go up and the other side to go down.
This difference can be up to 200mV to 300mV. This is an
inherent design deficiency. An alternative is to replace the
PNP transistors with P-Channel FETs or reduce the value
of the series resistors on the inputs. However, these
changes introduce some reliability concerns during a
pack “dead short circuit”. A future revision of the board is
planned that will address these issues.
Other Questions
Forward any ISL9208EVAL2Z questions to the Intersil
Application Engineer at [email protected]
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
15
AN1444.0
December 15, 2008
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