ISL9216EVAL1 User Guide ® Application Note October 10, 2007 Description Initial Testing The ISL9216EVAL1 kit is intended for use by individuals engaged in the development of battery pack hardware using the ISL9216, ISL9217 chip set. Setup 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 Freescale for monitoring and debugging the microcontroller code. Prior to powering the ISL9216 board, it is advised that the DeVaSys USB to I2C board software be installed and the board connected to the PC. See “Appendix 1” on page 16. In this way, the PC interface can quickly be used to monitor the operation of the board. AN1335.0 • 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 ISL9216. • Before connecting the PC to the ISL9216EVAL1 board (through the USB to I2C interface), connect the power supply to the ISL9216EVAL1 board. • The power supply should consist of a string of 8 to 12 batteries, or a string of 8 to 12 resistors with three power supplies, or 12 individual power supplies (see Figure 2 or Figure 3). • Once power is turned on (or Li-ion cells are connected to the ISL9216EVAL1 cell inputs; (the RGO and RGO2 LEDs should light) use meter 1 and meter 2 to measure the RGO voltages. They should each read about 3.3V. TO BATTERY/POWER SUPPLY 7VS/6C5 7C7 IC GND JMPR RGO LED JMPR RGO2 LED JMPR GND WAKE UP JMPR UPRAO RGO (ISL9216) A2DIN (ISL9216) RGO2 RGO METER 3.3V A2DIN RGO (ISL9217) UPRAO (ISL9217) TO PC: I2C METER 3.3V DeVaSys: USB to I2C E-LOAD SCL JUMPER SDA JUMPER (60V/1A) I2C JUMPERS TO PC: I2C GND JMPR USBLINK: USB to BKGD (OPTIONAL) FIGURE 1. ISL9208EVAL1 BOARD CONNECTION 1 CAUTION: These devices are sensitive to electrostatic discharge; follow proper IC Handling Procedures. 1-888-INTERSIL or 1-888-468-3774 | Intersil (and design) is a registered trademark of Intersil Americas Inc. Copyright Intersil Americas Inc. 2007. All Rights Reserved All other trademarks mentioned are the property of their respective owners. Application Note 1335 Battery/Power Supply Connection When connecting battery packs or power supplies, use the connections shown in 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 ISL9216, ISL9217 maximum input voltage differential of 5V per cell. If using a string of resistors to emulate the battery cells, then use the connection shown in Figure 3 and Figure 6. In this case, limit the supply voltages so that the resistor divider 12 CELLS 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 12 POWER SUPPLIES VCELL7 CB7 VCELL6 V 30 29 CB6 VCELL5 V 28 27 CB5 VCELL4 V 26 25 CB4 VCELL3 V 24 23 V 22 21 CB2 VCELL1 V 20 19 CB1 VSS AO V 18 17 CB3 VCELL2 VCELL7 CB7 VCELL6 CB6 VCELL5 CB5 VCELL4 CB4 VCELL3 CB3 VCELL2 CB2 VCELL1 CB1 VSS outputs do not exceed the ISL9216, ISL9217 input maximum ratings. It is recommended that the series resistors be 20Ω and 2W minimum. Resistors with higher resistance can be used, but when activating the ISL9216, ISL9217 cell balance outputs, the 40Ω 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. 10 CELLS 11 CELLS 30 29 28 27 26 25 24 23 22 21 20 19 18 17 AO VCELL7 CB7 VCELL6 CB6 VCELL5 CB5 VCELL4 CB4 VCELL3 CB3 VCELL2 CB2 VCELL1 CB1 VSS AO 30 29 28 27 26 25 24 23 22 21 20 19 18 17 VCELL7 CB7 VCELL6 CB6 VCELL5 CB5 VCELL4 CB4 VCELL3 CB3 VCELL2 CB2 VCELL1 CB1 VSS AO 9 CELLS 30 29 28 27 26 25 24 23 22 21 20 19 18 17 8 CELLS VCELL7 CB7 VCELL6 CB6 VCELL5 CB5 VCELL4 CB4 VCELL3 CB3 VCELL2 CB2 VCELL1 CB1 VSS 30 29 28 27 26 25 24 23 22 21 20 19 18 17 AO VCELL7 CB7 VCELL6 CB6 VCELL5 CB5 VCELL4 CB4 VCELL3 CB3 VCELL2 CB2 VCELL1 CB1 VSS AO VCELL7 VCELL7 VCELL7 VCELL7 VCELL7 VCELL7 VCELL6 VCELL6 VCELL6 VCELL6 VCELL6 VCELL6 VCELL5 V 16 15 V 14 13 V 12 11 CB2 VCELL1 V 10 9 CB1 VSS V 8 7 CB5 VCELL4 CB4 VCELL3 CB3 VCELL2 6 5 VCELL5 CB5 VCELL4 CB4 VCELL3 CB3 VCELL2 CB2 VCELL1 CB1 VSS 16 15 14 13 12 11 10 9 8 7 6 5 VCELL5 CB5 VCELL4 CB4 VCELL3 CB3 VCELL2 CB2 VCELL1 CB1 VSS 16 15 14 13 12 11 10 9 8 7 6 5 VCELL5 CB5 VCELL4 CB4 VCELL3 CB3 VCELL2 CB2 VCELL1 CB1 VSS 16 15 14 13 12 11 10 9 8 7 6 5 VCELL5 CB5 VCELL4 CB4 VCELL3 CB3 VCELL2 CB2 VCELL1 CB1 VSS 16 15 14 13 12 11 10 9 8 7 6 5 VCELL5 CB5 VCELL4 CB4 VCELL3 CB3 VCELL2 CB2 VCELL1 CB1 VSS NOTE: Multiple cells can be connected in parallel FIGURE 2. BATTERY CONNECTION OPTIONS 2 AN1335.0 October 10, 2007 Application Note 1335 12 CELLS ALTERNATE CONNECTION WITH 11 CELLS TO LOAD+ TO LOAD+ 3M CONNECTOR (TOP VIEW) MALE CONNECTOR ON BOARD 1 PACK- 1 OPTIONAL THERMISTOR (IF USED, REMOVE THERMISTOR ON BOARD) BATTERY- 3M CONNECTOR (TOP VIEW) MALE CONNECTOR ON BOARD PACK- B+/PACK+ BATTERY- B+/PACK+ TO LOAD- TO LOAD- FIGURE 3. BATTERY CELL CONNECTION TO ISL9216 PCB 30 29 28 27 26 25 10V TO 21V V 24 23 22 21 20 19 18 17 VCELL7 RECOMMENDATION: CB7 VCELL6 1. For the battery simulation resistors, use 20Ω/5W units. If the resistors are more than 100Ω, then turning on the cell balance resistors cause fluctuations in the cell input voltages that can violate the ISL9216 max specifications. CB6 VCELL5 CB5 VCELL4 CB4 VCELL3 CB3 VCELL2 CB2 VCELL1 CB1 VSS AO V 4V TO 8.6V VCELL7 14 13 12 11 10V TO 21V V 2. Switch the power supplies on at the same time, or if this cannot be guaranteed, turn them on from bottom to top. VCELL6 16 15 10 9 8 7 6 5 20Ω/2W NOTES: VCELL5 CB5 VCELL4 CB4 VCELL3 3. This connection (using 3 power supplies) is required for proper inter-IC communication. CB3 VCELL2 CB2 VCELL1 ALL RESISTORS = 20Ω/2W 20V POWER SUPPLY 3M CONNECTOR (TOP VIEW) 8V POWER SUPPLY 20V POWER SUPPLY 1 OPTIONAL THERMISTOR (IF USED, REMOVE THERMISTOR ON BOARD) FIGURE 5. POWER SUPPLY/RESISTOR CONNECTION TO ISL9216 PCB USB to I2C Interface CB1 VSS FIGURE 4. USING RESISTOR/POWER SUPPLY COMBINATION TO EMULATE A STRING OF BATTERIES 3 • Once the power supply connections are verified, power down the ISL9216EVAL1 boards and make the PC connection. Before making this connection, make sure that the USB to I2C interface software is installed. See AN1335.0 October 10, 2007 Application Note 1335 “Installing the DeVaSys USB to I2C Board Software” on page 16. • Connect the I2C communication cable from the interface board to the ISL9216EVAL1 as shown in Figure 6. ISL9216EVAL1 DeVaSys BOARD USB 1 5-PIN RIBBON CABLE FETs 1 J2 J29 SDA GND NC SCL SCL J11 2 FIGURE 6. I C CONNECTION TO ISL9216 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 ISL9216 automatic response to overcurrent and over-temperature, all other actions of the board are manual and controlled through the GUI.. PC I2C INTERFACE ISL9216 PC SCL J43 SDA SCL µCONTROLLER J51 SDA SCL1 SDA1 µC SCL2 SDA2 FIGURE 7. PC OR µC CONNECTION TO THE ISL9216 • 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 communication problem. If there is a communication 4 problem, see the troubleshooting guide in “Appendix 2” on page 17. • Use the GUI to read register 0 from both the ISL9216 and ISL9217. The ISL9216 should return the value 40H and the ISL9217 should return 80H. This verifies communication to both devices. • Next, move to the “MONITOR” tab of the GUI. • Set the ISL9216 to monitor the VCELL1 input by selecting the ISL9216 radio button and 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. • Using a meter, measure the CELL1 voltage (from test point 6C1 to GND) and measure the ISL9216 analog output voltage (test point AO to GND). The AO voltage x 2 should equal the VCELL1 voltage. Any errors in this measurement are due to the ISL9216. (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. Its output is determined by Equation 1: DigValue D ------------------------------- × 3.3 = A2DIN 32768 (EQ. 1) Since, the reference for the A/D converter is supplied by the ISL9216 RGO voltage, any difference in 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 ISL9216. • To monitor the voltages of the cells connected to the ISL9217, first set the ISL9216 to read VCELL6. Then, set the ISL9217 to read VCELL1. In this case, the ISL9216 AO voltage is a reflection of the ISL9217 VCELL1 voltage. The VCELL1 voltage is shifted within the ISL9217 divided by 2 and applied to the ISL9217 AO pin. The ISL9217 AO pin connects to the ISL9216 VCELL6 pin and the voltage is level shifted again to ground reference. It is not divided within the ISL9216. The voltage at AO times 2 should equal the ISL9217:CELL1 voltage. Any errors are due to the inaccuracies in the ISL9216 and ISL9217 devices. • Monitor the remaining cells connected to the ISL9217 by selecting (with the GUI) the individual ISL9217 cells. (Keep the ISL9216 set to monitor VCELL6). Discharge Overcurrent Testing • With the output off, connect an electronic load between Test Point 7C7 (Battery + terminal) and P- (Battery - AN1335.0 October 10, 2007 Application Note 1335 terminal). The E-load should be able to handle up to 60V and sink 1A minimum. • Use the GUI “CONFIGURATION” screen to set the desired discharge overcurrent and short circuit levels and time delays. • 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. • Set the e-load current such that it will exceed the expected overcurrent threshold. • Turn on both FETs by clicking on the FET buttons in the GUI. When they are on, they 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. (An automatic scan can also be started that updates all parameters every 1, 5, 10, or 30s, however, this might cause an update when not expected). • Turn on the load. This should cause the FETs to turn off (see Figure 8). ISL9216 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 ISL9216, the bit is 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 ISL9216 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. Charge Overcurrent Testing • Turn off the power to the board. • Remove any load on the board Pack+ and Pack- pins. • Turn on the ISL9216 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 they are on, they 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. DFET/ CFET VDSNS ILOAD • 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 1.5A limit, but will only need to provide 0.2V max). • Connect the charge emulation power supply positive terminal to the board GND pin and the charge emulation power supply negative terminal connected to the board Ppin. See Figure 9. A current probe can be used to monitor the overcurrent details. FIGURE 8. DISCHARGE OVERCURRENT TEST (0.1V THRESHOLD, 160ms TIME DELAY, 0.5Ω 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. In this case, 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 5 ISL9216 P- GND + V A FIGURE 9. CHARGE OVERCURRENT TEST CONNECTION • Turn the charge emulation power supply output on. This causes the ISL9216 to detect an overcurrent condition, which turns the FETs off. Figure 10 shows a charge AN1335.0 October 10, 2007 Application Note 1335 overcurrent condition where the charger turns on with current too high. WKUP pin. When using this technique, don’t leave the jumper in place. • When the WKUP pin is pulled low, the ISL9216 wakes up and turns on its RGO output. This turns on the RGO LED. Sleep/Wake Testing (WKPOL = 1) DFET/ CFET VCSNS ILOAD • This section only applies to the ISL9216. DON’T set the ISL9217 WKPOL bit to “1”, or the device will not wakeup once placed into the sleep mode. (Power cycling would be required to wake it up). • Set the WKUP jumper to the active high position (shunt on the side closest to the push-button switch). • Use the GUI to set the “WKUP Pin Active High” in the Configure Tab, feature set window. • Put the ISL9216 in sleep mode as before. • This time, the device can be waken by the press of the WKUP button on the board. FIGURE 10. CHARGE OVERCURRENT TEST (0.1V THRESHOLD, 160ms TIME DELAY, 0.5Ω SENSE RESISTOR) • The charge emulation power supply could have been connected across the Pack output pins (as in a “real world” operation). However, both the load and input power supplies need to sink current, the output supply would need to be floating when turned off (not shorted), and the load supply would need to handle a higher voltage than the input. Sleep/Wake Testing (Default Setting - WKPOL= 0) The ISL9216 board can be put to sleep via commands from the PC. This sequence is described in the following paragraphs. • Use the Register Access window of the GUI to write the value 80H to register 4 of the ISL9217. This sets the ISL9217 sleep bit. • Note that the RGO2 LED goes off. This indicates that ISL9217 has gone to sleep and turned off its output regulator. • Next, click on the ISL9208, ISL9216 Cell Balance CB6 box. This sets the ISL9216 WKUPR output low. This wakes up the ISL9217 causing the regulator to turn on, lighting the RGO2 LED. Click on the ISL9208, ISL9216 CB6 box again to turn off the WKUPR signal. • To put the ISL9216 into the sleep mode, write an 80H to the ISL9216 register 4. This turns off the ISL9216 RGO output and LED. • To wake up the ISL9216 requires that the ISL9216 WKUP pin go below its wakeup threshold. Normally, in a pack, a charger would be connected to the pack terminals. The higher voltage on the charger would pull the WKUP pin low, causing the part to wake up. However, in a test setup, it is not always advisable to connect the charger. Another way to do this is to connect a jumper from GND to the 6 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 ISL9216. • 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. 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 17. • If the FET indicators are RED, 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. They 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 AN1335.0 October 10, 2007 Application Note 1335 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 pack until the FETs turn on again and continue charging until a cell overvoltage condition is reached. 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. – If one the three power supplies with resistor string is being used, lower the voltage on one of the power supplies 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 twelve power supplies are used, then simply decrease or increase each 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. • Testing the cell balance operation requires the use of Li-ion cells or the replacement of the cell balance resistors with lower resistance devices. With the suggested resistor string, turning on one cell balance output will likely drop the voltage on that cell to less than the 2.5V sleep threshold and the microcontroller will put the ISL9216 and ISL9217 (and the board) to sleep. • Start the cell balance test by first observing if the cell with the maximum 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 2s, 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. 7 AN1335.0 October 10, 2007 AFE Schematic 1 2 3 4 6 5 J116 SCLHV 1 R34 1k uCSCL uCSDA J27 J28 SCL SDA 1 B1 J24 1 R3 510 J64 SDAIHV R8 39 R22 1 GND 4.7k GND GND 9 10 11 12 13 14 15 16 0 R19 39 9216 VCELL1 J16 SDAOHV SCLHV SCL SDA WKUP RGC RGO Temp3V J23 RGC 32 31 30 29 28 27 26 25 1 1 GND 17 18 19 20 21 22 23 24 1 C8 .01uF Therm O.T. = 55degC TH1=3.535k D10 4.7V J36 RGO LED Th1 10k Therm R10 1M CFET U3 100 3 2 1 R37 511 5 4 3 2 1 HEADER 5 D4 DIODE J37 AO 4 J70 JMP3 ADS1100 SCL SDA GNDVDD VIN+VIN- 4 5 6 B GND C10 1000pF 1 R35 DIODE D5 4.7V C9 4.7uF VMON J39 A2DIN A/D Converter R9 0 1 R13 D6 100k 18V C20 0.01uF 9216 VCELL5/9217 VSS Notes: 1) Keep wide traces as short as possible 2) Wide trace widths should be 0.4 inches wide or more 3) Use RoHS compliant materials 4) Use Immersion Gold for Plating 5) All components used are to be RoHS compliant J38 Pack- 249k AO B4 Q2 IRFS3207 Q3 IRFS3207 1 3 1 1 J30 R30 0.51Ohm or 0.005/3W 22 The A/D converter is optional and is used if there is no microcontroller GND D11 22V 3 J117 GND R39 1 R32 R33 0 0 1 100 BANANA 1 1M ~2.5mA D7 LED R40 511 1 R36 1 1 1 2 D3 B3 C22 4.7uF 1M R27 1 J32 J33 DSns 9217 VCELL1 C16 0.01uF GND R26 R25 4.7k J29 100 LED for test only. R38 46.4k J35 9216 VCELL1 R24 4.7k DFET J118 CON2 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 J26 WKUP 100 RGO J22 TMPI 1 1 J63 CB8 CB7 CB6 CB5 CB4 CB3 CB2 CB1 CSns J31 J25 RGO R28 R29 Q1 FMMT619 1 J19 J20 1 1 1 J4 J18 J5 1 GND 1 J49 J50 J6 1 1 GND J17 1 J15 1 J14 1 J12 J13 1 1 J1 R20 39 CB4 VCELL3 CB3 VCELL2 CB2 VCELL1 CB1 VSS PAD DSREF DSense CSense DFET CFET VMON AO TempI R18 39 TMP3V 1 VCELL4 CB5 VCELL5 WKUPR VCELL6 SDAIHV VC7/VCC HV12C R17 39 C PACKSCL PACKSDA BANANA J34 1 1 DGate CGate 3 22 A 3 Title ISL9216EVAL1Z AFE Q12 IRF2807 2 Q13 IRF2807 3 If using parallel FETs, use (4) IRF 2807 If using standalone FETs, use (2) IRFS3207 4 5 Size A Number ISL9216EVAL1Z Date: File: Oct 16, 2006 ISL9216EVAL1Z_REVB Revision B Sheet 2 of Drawn by: CEM 6 4 Application Note 1335 R16 39 D2 J41 J40 PSDAPSCL J21 TEMP3V 1 1 ISL9216Z SDAOHV U1 DIODE U2 ISL88694 (Optional) WKUP invert J51 JMP3 1 R15 39 9216 VCELL5/9217 VSS R23 59k WKUPR 1 8 7 6 5 4 3 2 1 9217 VCELL1 B A R? 1M J69 7VS/6C5 6C4 6C3 6C2 6C1 C21 4.7uF J43 JMP3 D8 LED J65 R14 39 5 DIODE WKUP Non-invert R21 511 1 39 R31 100k C1 1uF R2 1.8M D1 1 39 R7 J42 Board Modification J8 JMP3 D9 15V VDD SB1 GND NC SB2 R6 C7 .01uF The ISL88694 is optional and is only used if there is a long cable connected to the pack causing communication errors. 1 2 3 39 J68 39 R5 UPRAO 1 C R4 0 13 14 15 16 17 18 CB9 9217 VC7/VCC 9217 CB7 9217 VCELL6 9217 CB6 9217 VCELL5 9217 CB5 9217 VCELL4 9217 CB4 9217 VCELL3 9217 CB3 9217 VCELL2/9216 VCC 9217 CB2 9217 VCELL1 9217 CB1 9216 VCELL5/9217 VSS 9216 CB5 9216 VCELL4 9216 CB4 9216 VCELL3 9216 CB3 9216 VCELL2 9216 CB2 9216 VCELL1 9216 CB1 GND 1 FMMT619 C17 1 1 SW-PB R1 412k Q4 J67 RGO2 PAD CB1 VSS NC AO SDAI RGO 8 CB10 J48 BANANA PACK+ SCL SDA S1 24 23 22 21 20 19 V7/VCC VC5R SCL SDAO WKUP RGC .01uF 1 CB4 VCELL3 CB3 VCELL2 CB2 VCELL1 D BAT+ J66 RGC2 R12 4.7k VCELL4 CB5 VCELL5 CB6 VCELL6 CB7 7C6 7C7 1 7C5 7C4 7C3 7C2/6VC 7 8 9 10 11 12 1 CB11 J47 J44 1 J11 1 J10 1 J9 1 J7 7C1 1 CB12 J46 1 J3 J2 ISL9217Z RGO2LED U4 1 RGO2 J45 D 1 6 5 4 3 2 1 1 AN1335.0 October 10, 2007 Microcontroller Schematic D D Extra "Breadboard" components J60 C2 .01 C3 .01 C4 .01 C5 .01 C6 .01 1 2 3 4 9 5 J52 6 1 7 uCp2 8 5 3 1 JP1 9 10 6 4 2 BKGD C 11 J53 R11 1 2 3 4 5 R43 100k 6 R44 100k 7 R45 100k 8 R46 100k 9 R47 100k R48 100k HEADER 11 1 10k J61 10 C 11 HEADER 11 uCp1 C14 U6 J54 0.01uF 0.1uF RGO GND 1 uCp5 J55 1 R41 RESIST R42 RESIST 1 2 3 4 5 6 7 8 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 0.1uF 16 15 14 13 12 11 10 9 AO TMP3V PACKSDA PACKSCL J58 RxDp12 1 uCSCL uCSDA J59 TxDp11 1 MC9S08QC8 Y1 J56 uCp8 1 CRYSTAL C11 CAPNP B T1 T7 TPAD Q14 MOSFET P TPAD 0 uCp6 J57 uCp7 C12 CAPNP T4 1 B TPAD T2 T8 TPAD TPAD Q5 MOSFET P T5 TPAD T3 T9 TPAD Q6 MOSFET P TPAD T6 TPAD T19 T21 TPAD Q7 MOSFET P TPAD T20 TPAD A A Microcontroller Schematic 1 2 3 Title ISL9216EVAL1Z Micro 4 5 Size A Number ISL9216EVAL1Z Date: File: Oct 16, 2006 ISL9216EVAL1Z_REVB Revision B Sheet 3 of Drawn by: CEM 6 4 Application Note 1335 C13 C15 AN1335.0 October 10, 2007 Battery Connection Schematic D D 10 Board Modification C D? D? D? D? D? D? D? D? D? D? D? D? 4.7V 4.7V 4.7V 4.7V 4.7V 4.7V 4.7V 4.7V 4.7V 4.7V 4.7V 4.7V C 9217 CB7 9217 CB6 9217 CB5 9217 CB4 9217 CB3 9217 CB2 9217 CB1 9216 CB5 9216 CB4 9216 CB3 9216 CB2 9216 CB1 29 27 25 23 21 19 17 15 13 11 9 7 5 3 1 Therm 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 B 9217 VC7/VCC 9217 VCELL6 9217 VCELL5 9217 VCELL4 9217 VCELL3 9217 VCELL2/9216 VCC 9217 VCELL1 9216 VCELL5/9217 VSS 9216 VCELL4 9216 VCELL3 9216 VCELL2 9216 VCELL1 GND GND Battery Conn A A Title ISL9216EVAL1Z BattConnector Size A Number ISL9216EVAL1Z Date: File: Oct 16, 2006 ISL9216EVAL1Z_REVB Revision B Sheet 4 of Drawn by: CEM 4 Application Note 1335 J62 B AN1335.0 October 10, 2007 Application Note 1335 Bill of Materials ITEM QTY PART TYPE 1 3 0 2 4 3 DESIGNATOR FOOTPRINT DESCRIPTION PART FIELD 1 R9, R32, R33 603 * 100 R28, R29, R35, R36 603 * 4 511 R3, R21, R40, R37 603 * 4 2 0.01µF C7, C17 603 * 5 3 0.01µF C15, C16, C20 603 * 6 2 0.1µF C13, C14 603 * 7 1 100k R31 603 * 8 1 10k R11 603 * 9 1 10k Therm Th1 603 * 10 1 1k R34 603 * 11 4 1M R10, R26, R27, + added 603 * 12 1 1µF C1 603 * 13 1 1000pF C10 603 * 14 4 4.7k R12, R22, R24, R25 603 * 15 2 4.7µF C21, C22 603 * 16 1 0.01µF C8 805 * 17 1 412k R1 805 * 18 1 1.8M R2 805 * 19 1 100k R13 805 * 20 1 59k R23 805 * 21 1 249k R39 805 * 22 1 4.7µF C9 805 * 23 1 46.4k R38 805 * 24 12 39 R4, R5, R6, R7, R8, R14, R15, R16, R17, R18, R19, R20 2512 Digikey: 25 1 SW-PB 26 2 IRFS3207 27 1 Battery Conn (Female) J62 HEADER 15X2 3M Digikey MSD30K-ND 28 1 Battery Conn (Male) J62 HEADER 15X2 3M Digikey MHC30K-ND 29 1 BKGD JP1 HEADER 3X2 * 30 1 HEADER 5 J29 HEADER 5X1 * 31 1 RGO LED J36 JP_2 Digikey WM6436-ND 32 1 RGO2LED J68 JP_2 Digikey WM6436-ND 33 4 JMP3 J8, J43, J51, J70 JP_3 Digikey WM6436-ND 34 2 LED 11 S1 Q2, Q3 D7, D8 B3WN-6002 D2PAK LED_GW PT39AFCT-ND Digikey: SW425CT-ND * Digikey: P490CT-ND AN1335.0 October 10, 2007 Application Note 1335 Bill of Materials (Continued) ITEM QTY PART TYPE DESIGNATOR 35 1 0.51Ω or 0.005/3W R30 MISC_SENSE - ALT 36 1 MC9S08QC8 U6 QFN16 Digikey: MC9S08QG8FFE-ND 37 1 ISL9217Z U4 QFN24 Intersil Provided 38 1 ISL9216Z U1 QFN32 Intersil Provided 39 1 15V D9 SOD-123 * 40 1 18V D6 SOD-123 Digikey: BZT52C18-FDICT-ND 41 1 22V D11 SOD-123 Digikey: BZT52C22-FDICT-ND 42 13 4.7V D10, + 12 on input SOD-123 Digikey: BZT52C4V7-FDICT-ND 43 4 DIODE D1, D2, D3, D4 SOD-123 Digikey: B0540W-FDICT-ND 44 1 4.7V 45 2 FMMT619 Q1, Q4 46 1 ADS1100 47 34 D5 FOOTPRINT DESCRIPTION PART FIELD 1 Digikey: SOT23 Digikey: PT.51YCT-ND (0.51Ω) AZ23C3V6-FDICT-ND SOT23 - NPN Digikey: FMMT619CT-ND U3 SOT23-6 Digikey: 296-14299-1-ND 6C1 J15 TP 6C2 J14 6C3 J13 6C4 J12 7C1 J2 7C2/6VC J3 7C3 J7 7C4 J9 7C5 J10 7C6 J11 7C7 J44 7VS/6C5 J1 A2DIN J39 AO J37 CFET J32 CSns J63 DFET J31 DSns J33 Pack- J38 RGC J23 RGC2 J66 RGO J25 RGO2 J67 SCL J27 12 Connector DigikeyL 5000K-ND AN1335.0 October 10, 2007 Application Note 1335 Bill of Materials (Continued) ITEM QTY PART TYPE DESIGNATOR SCLHV J116 SDA J28 SDAIHV J64 SDAOHV J65 TEMP3V J21 TMPI J22 UPRAO J42 VMON J35 WKUP J26 WKUPR J69 48 1 CON2 J118 49 3 GND J16, J17, J117 FOOTPRINT DESCRIPTION PART FIELD 1 JP_2 Connector * TP SM Connector * DEVICES NOT POPULATED BANANA B1 BANANA Not Populated BANANA B3 BANANA Not Populated BANANA B4 BANANA 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 0.01 C5 603 Not Populated 0.01 C6 603 Not Populated CB3 J18 TP Connector Not Populated CB2 J19 TP Connector Not Populated CB1 J20 TP Connector Not Populated BAT+ J24 TP Connector Not Populated DGate J30 TP Connector Not Populated CGate J34 TP Connector Not Populated CB4 J4 TP Connector Not Populated PSCL J40 TP Connector Not Populated PSDA J41 TP Connector Not Populated CB12 J45 TP Connector Not Populated CB11 J46 TP Connector Not Populated CB10 J47 TP Connector Not Populated CB9 J48 TP Connector Not Populated 13 AN1335.0 October 10, 2007 Application Note 1335 Bill of Materials (Continued) ITEM QTY PART TYPE DESIGNATOR FOOTPRINT DESCRIPTION PART FIELD 1 CB8 J49 TP Connector Not Populated CB5 J5 TP Connector Not Populated CB7 J50 TP Connector Not Populated µCp2 J52 TP Connector Not Populated µCp1 J53 TP Connector Not Populated µCp5 J54 TP Connector Not Populated µCp6 J55 TP Connector Not Populated µCp8 J56 TP Connector Not Populated µCp7 J57 TP Connector Not Populated RxDp12 J58 TP Connector Not Populated TxDp11 J59 TP Connector Not Populated CB6 J6 TP Connector Not Populated HEADER 11 J60 HEADER11 Not Populated HEADER 11 J61 HEADER11 Not Populated IRF2807 Q12 D2PAK Not Populated IRF2807 Q13 D2PAK Not Populated MOSFET P Q14 SOT23 Not Populated MOSFET P Q5 SOT23 Not Populated MOSFET P Q6 SOT23 Not Populated MOSFET P Q7 SOT23 Not Populated RESIST R41 603 Not Populated RESIST R42 603 Not Populated 100k R43 603 Not Populated 100k R44 603 Not Populated 100k R45 603 Not Populated 100k R46 603 Not Populated 100k R47 603 Not Populated 100k R48 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 14 AN1335.0 October 10, 2007 Application Note 1335 Bill of Materials (Continued) ITEM QTY PART TYPE DESIGNATOR FOOTPRINT DESCRIPTION PART FIELD 1 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 15 Crystal Not Populated AN1335.0 October 10, 2007 Application Note 1335 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 next one 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. 16 AN1335.0 October 10, 2007 Application Note 1335 Appendix 2 ISL9216, ISL9217 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 voltages are 3.3V (relative to their device VSS pins). 3. If the RGO voltages are not powered to the right voltage, move to the power supply troubleshooting section. 4. Make sure that the board drivers are installed correctly. When using the DeVaSys USB to I2C interface board, there should be one red LED and one green LED on 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 ISL9216 status register. Set the scope to single trigger on the falling edge of SCL. 6. If the I2C communication is correct at the SCL and SDA pins, check that the communication is correct at the ISL9217. Connect the scope to the SCL terminal and the SCLHV terminal. The SCLHV terminal should follow the SCL voltage, but be shifted to ~3.3V above the ISL9217 VSS terminal (and be slightly delayed). Also check the SDA and SDAOHV test points. SDAOHV should follow SDA, but be shifted in voltage and slightly delayed. 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 ISL9216 and ISL9217 and that the input voltage on each cell is between 2.3V and 4.3V. IF THE AO VOLTAGES ARE READING INCORRECTLY ON THE GUI 4. Check that the RGO output is 3.33V. GUI and microcontroller calculations assume the RGO voltage is 3.33V. 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. 7. Check that the SDA and SCL jumpers (J51 and J43) have shunts on the “PC” side. 8. Check to see that the “I2C GND” jumper is in place in the “GND” position. 9. Check that the “IC GND” jumper (J118) is in place. Power Supply Troubleshooting IF RGO OR RGO2 DO NOT HAVE THE CORRECT VOLTAGE 1. Check that the voltage on each of the input terminals are correct. 2. Check that all cell balance outputs are off. 3. Check that there is no unexpected load on the RGO outputs. 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 17 AN1335.0 October 10, 2007