PS5162 PS501 Two-Cell Battery Manager Module with LED SOC Display for Lithium Chemistries Features • PS501 tested, fully populated modules for evaluation • Designed to work with 2 series cell Lithium chemistry configurations • Performs all major Lithium battery management functions, including: - Accurate capacity monitoring - Lithium cell protection • SOC display with four LEDs and a switch • Fully compliant with industry standard Smart Battery Data Specification v1.1a • SMBus v1.1 with PEC/CRC-8 communication with system host • High accuracy measurement of charge/discharge current, voltage and temperature with on-chip 16-bit integrating A/D • Precise capacity reporting using Microchip patented algorithms and 3D battery cell models • 3D models and “learned” parameters stored in integrated memory • Complete hardware and software development tools available: - ICD (In-Circuit Debugger) port to support development of custom code • Extremely low-power operation: - Run mode: 140 µA typical - Low-Voltage Sleep mode: 30 µA typical - Shelf-Sleep mode: 5 µA typical • Overall mechanical dimensions: - 0.339 W x 2.165 L (inches) - 8.6 W x 55.0 L (millimeters) 2004 Microchip Technology Inc. Ordering Information Part Number PS5162 Description Li Ion/Poly – 2 series cells DS21842B-page 1 PS5162 1.0 GENERAL DESCRIPTION The PS5162 module is a complete smart battery controller subsystem based on the Microchip PS501 field reprogrammable battery manager with patented Accuron® technology. The module is designed to operate in a battery pack consisting of two (2) series connected Li-based cells. The module consists of the Microchip PS501 battery manager IC with a four-LED SOC display and an optional connection for an external thermistor. 1.1 Quick Start – Pack Assembly Follow these directions to assemble a pack with the PS5162 module. • Use standard precautions when handling static sensitive devices. • Modules should be connected to battery cells in the order indicated below to insure proper start-up and operation. Wires should be attached to the modules first and then connected to the battery cells as instructed. • The connection sequence is critical to successful use of the PS501 family of CMOS ASICs. The pack positive should be securely connected to the module first, followed by the intermediate cell connection and then pack negative. FIGURE 1-1: DS21842B-page 2 Step 1) Configure the module for optional external thermistor use. PS5162 modules are shipped configured to use the internal temperature sensor only. To add an external thermistor to the board, remove resistor R16 (side 2) and connect the thermistor across via TN and TR. Step 2) Connect wires to module. Use large diameter wire (18 AWG-20 AWG) for current carrying lines from VR, V1, BP and BN. All others are signal only lines (24 to 22 AWG). Step 3) Connect external connector to BN, T, C, D and BP. Step 4) Connect V1 to the most positive point on the battery cell stack. Step 5) Connect V2 to the middle of the cell stack. Step 6) Connect VR to the most negative point on the battery cell stack. Step 7) Program the assembled pack using Microchip’s software and PowerCal™ board or PowerInfo™ board hardware. The memory parameters can be changed at will using the utilities on the memory page in the software. Step 8) Calibrate the pack using the software and PowerCal™ board hardware. The pack is now ready for use. CONNECTION POINTS (SIDE 1) 2004 Microchip Technology Inc. PS5162 FIGURE 1-2: BOARD ASSEMBLY (SIDE 1) FIGURE 1-3: BOARD ASSEMBLY (SIDE 2) 2004 Microchip Technology Inc. DS21842B-page 3 PS5162 2.0 FUNCTIONAL DESCRIPTION 2.1 PS501 Fuel Gauge The module fuel gauge provides State-Of-Charge (SOC) and battery status data in accordance with the SMBus standards version 1.1. The PS501 monitors the cell voltages, battery temperature and current to determine SOC and battery status. The State-Of-Charge calculations are compensated for cell self-discharge. The remaining time calculation is compensated for temperature and discharge rate. The parameters for determining battery status flags and alarm thresholds are all programmable, as is the battery design capacity and the battery performance model data. Please refer to the “PS501 Data Sheet” (DS21818) for details on configuring the PS501 device. 2.2 Primary Safety The primary safety circuit provides cell protection from conditions of overcharge, overdischarge and overcurrent. The analog safety IC measures individual cell voltages, current and voltage across the safety FETs. These values are compared against internal reference values and the gates of two N-channel power MOSFETs are controlled based on the comparison results. 3.0 BOARD DESCRIPTION PCB schematics and bill of materials are included here for completeness. To download the full size schematic and BOM, please visit the Microchip web site. 3.1 Mechanical Dimensions Overall Dimensions: 2165 mils x 339 mils DS21842B-page 4 2004 Microchip Technology Inc. A B C 1 VR V2 V1 CELL CONNECTION 2 240 V2 VR 20 V1 100 R11 100 R12 R2 R1 TN TN 12 8 9 10 11 16 17 TR R16 0 C11 1.0 µF C12 1.0 µF 6 4 5 C7 330 nF 28 1 C5 330 nF 13 TR GROUND PLANE CONNECTION V5 C1 330 nF C2 100 nF R5 3.65K REMOVE R16 IF EXTERNAL THERMISTOR IS INSTALLED VSS VC VDD U2 VSSD VDDD VSSA VDDA VC(4) VC(3) VC(2) VC(1) VNTC VREFT U1 ROSC PS501 3 SMB-CLK SMB-DTA GPIO(0) GPIO(1) GPIO(2) GPIO(3) GPIO(4) GPIO(5) GPIO(6) GPIO(7) GPIO(8) GPIO(9) GPIO(10) GPIO(11) GPIO(12) R36 VM S8242A C16 100 nF 0.020 RSHP 14 RSHN 15 2 DO 1 CO 3 2 EXTERNAL THERMISTOR CONNECTIONS (SEMITEC 103AT OR 103ETB -- 10K AT 25°C) 3 R6 V5 PRIMARY SAFETY CIRCUIT 20K SW PGC PGD MCLR LED0 LED1 LED2 LED3 CURRENT SENSE RESISTOR VSHN 6 7 24 25 26 27 2 3 4 5 19 20 21 22 23 R26 221K 18 SW1 LED3 LED2 LED1 LED0 4 4 DATE *** CONFIDENTIAL *** THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION THAT IS THE INTELLECTUAL PROPERTY OF MICROCHIP TECHNOLOGY, INC. CHECKED 7 6 1 20 20 5 R15 2.0K D1 AZ23C5V6 3 2 R7 R8 240 240 365 C17 B- 1.0 nF C18 C D T BP BN C D T PACK CONNECTIONS 100 nF R9 R10 R35 V1 PGC PGD MCLR VDDD EGND WHEN USING ICD PORT, A 10K RESISTOR MUST BE CONNECTED BETWEEN VDDD AND EGND CAUTION: 6 PowerSmart Products Group 2745 Dallas Parkway, Suite 400 Plano, TX 75093 6 03-826172 REV 3-1.sch NONE Sheet 1 of 1 03-826172 DRAWING NO. FILE 5 CODE IDENT NO. SCALE B SIZE 3-Mar-2004 18:50:09 3.1 REV http://www.microchip.com 469-241-0087 Voice/469-241-0106 Fax Microchip Technology, Inc. PS5162 SCHEMATIC TITLE 12 FOR REVISION HISTORY, REFER TO 826172 CHANGE LOG. REFERENCE PS500-BASED DESIGN FOR 2-Cell LiIon APPLICATIONS Q1 TPCS8209 10 nF R. CASEBOLT 27 Oct 2003 DRAWN APPROVALS CONTRACT NO. 3 2 C3 1 8 2004 Microchip Technology Inc. 4 A B C D FIGURE 3-1: 5 3.2 ICD PORT D 1 PS5162 Schematic PS5162 BOARD SCHEMATIC DS21842B-page 5 PS5162 3.3 Bill of Materials TABLE 3-1: PS5162 BILL OF MATERIALS Symbols Description Manufacturer Manuafacturer PN Qty. Raw PCB, PS5162 Microchip 04-826172 Rev. 3.1 1 C11, C12 Capacitor, Ceramic, 1.0 µF, 16V, +/-10%, X5R dielectric, 0603 Panasonic Murata ECJ-1VB1C105K GRM188R61C105KA93D 2 C18 Capacitor, Ceramic, 1.0 nF, 50V, +/-10%, X7R dielectric, 0603 Panasonic ECJ-1VB1H102K 1 C3 Capacitor, Ceramic, 10 nF, 50V, +/-10%, X7R dielectric, 0603 Panasonic ECJ-1VB1H103K 1 C2, C16-C17 Capacitor, Ceramic, 100 nF, 25V, +80%/-20%, Y5V dielectric, 0603 Panasonic ECJ-1VF1E104Z 3 C1, C5, C7 Capacitor, Ceramic, 330 nF, 25V, +80%/-20%, Y5V dielectric, 0805 Panasonic ECJ-2YF1E334Z 3 SML-LX1206GC-TR LED0-LED3 LED, clear green, 1206 package Lumex D1 Dual Zener Diode, 5.6V, +/-5%, 300 mW, common anode, SOT-23 AZ23C5V6-7 Diodes Inc. General Semiconductor AZ23-C5V6 1 Q1 MOSFET, dual N-channel Enhancement mode, -20V, -5A, TSSOP (8/4.4 mm body width) package Toshiba 1 R16 Resistor, zero ohm, 0402 Panasonic ERJ-2GE0R00X 1 R5 Resistor, film, 0603, 1%, 3.65 KOhms Panasonic ERJ-3EKF3651V 1 R35 Resistor, film, 0603, 1%, 365 ohms Panasonic ERJ-3EKF3650V 1 R26 Resistor, film, 0603, 1%, 221 KOhms, 25 ppm TC Susumu Co. Ltd. RR0816P-2213-D-34D 1 R7-R8 Resistor, film, 0603, 5%, 20 ohms Panasonic ERJ-3GEYJ200V 2 R6 Resistor, film, 0603, 5%, 20 KOhms Panasonic ERJ-3GEYJ203V 1 R11-R12 Resistor, film, 0805, 5%, 100 ohms Panasonic ERJ-6GEYJ101V 2 R15 Resistor, film, 0805, 5%, 2.0 KOhms Panasonic ERJ-6GEYJ202V 1 R1 Resistor, film, 0805, 5%, 20 ohms Panasonic ERJ-6GEYJ200V 1 R2, R9-R10 Resistor, film, 0805, 5%, 240 ohms Panasonic ERJ-6GEYJ241V 3 R36 Resistor, metal strip, 2512, 1%, 0.020 ohms Vishay WSL2512-0.020-1%-R86 1 SW1 Switch, SPST-momentary, push button, surface mount ALPS Fuk Hing Ind. SKQGADE010 11871501 1 U2 IC, Battery Protection Circuit, Li Ion, 2-cell, -40°C to +85°C, SOT-23-6 package Seiko Instruments S-8242AAG-M6T2G (Note 1) 1 U1 IC, Single Chip Battery Manager, programmable, -20°C to +85°C, SSOP-28 Microchip PS501-I/ST 1 Note 1: TPCS8209(TE12L) 4 Other variants of the S-8242A series, with different trip points, are also available. Consult the S-8242A series data sheet. FIGURE 3-2: DS21842B-page 6 PS5162 DIMENSION DETAILS 2004 Microchip Technology Inc. PS5162 4.0 DEVELOPMENT TOOL SUMMARY 4.1 Microchip provides all the necessary hardware and software to enable easy tailoring of battery control algorithm parameters and cell performance models to meet specific application requirements and attain the highest accuracy available anywhere. Table 4-1 summarizes the development tool offering from Microchip to support the PS5162. Please refer to the Microchip web site for ordering information and design documentation (including schematics) at www.microchip.com. TABLE 4-1: Reference Documents This data sheet provides an overview of the PS5162 Battery Manager module. For further information on the PS501 and development tool operations, please refer to the following documents available for download at www.microchip.com. MICROCHIP DEVELOPMENT TOOL SUMMARY Development Tool Use PowerInfo™ hardware with PC software (PS041) Read and write Smart Battery data values, memory programming PowerCal™ hardware with PC software (PS042) Read and write Smart Battery data values, memory programming, pack calibration, pack test TABLE 4-2: MICROCHIP REFERENCE DOCUMENTS Document Number Documents Available DS21818 PS501 Single Chip Field Reprogrammable Battery Manager Data Sheet (IC Products) DS40234 PS041 PowerInfo™ Configuration Interface Product Brief DS40237 PS042 PowerCal™ Calibration Platform Data Sheet 2004 Microchip Technology Inc. DS21842B-page 7 PS5162 NOTES: DS21842B-page 8 2004 Microchip Technology Inc. PS5162 Information contained in this publication regarding device applications and the like is intended through suggestion only and may be superseded by updates. It is your responsibility to ensure that your application meets with your specifications. No representation or warranty is given and no liability is assumed by Microchip Technology Incorporated with respect to the accuracy or use of such information, or infringement of patents or other intellectual property rights arising from such use or otherwise. Use of Microchip’s products as critical components in life support systems is not authorized except with express written approval by Microchip. No licenses are conveyed, implicitly or otherwise, under any intellectual property rights. Trademarks The Microchip name and logo, the Microchip logo, Accuron and PowerSmart are registered trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. SmartShunt is a registered trademark Technology Incorporated in the U.S.A. of Microchip PowerCal, PowerInfo, PowerMate, PowerTool, SmartSensor and SmartTel are trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. All other trademarks mentioned herein are property of their respective companies. © 2004, Microchip Technology Incorporated. Printed in the U.S.A., All Rights Reserved. Printed on recycled paper. 2004 Microchip Technology Inc. DS21842B-page 9 WORLDWIDE SALES AND SERVICE AMERICAS China - Beijing Korea Corporate Office Unit 706B Wan Tai Bei Hai Bldg. No. 6 Chaoyangmen Bei Str. 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