MCP1630 Li-Ion Multi-Bay
Battery Charger
User’s Guide
© 2005 Microchip Technology Inc.
DS51515A
Note the following details of the code protection feature on Microchip devices:
•
Microchip products meet the specification contained in their particular Microchip Data Sheet.
•
Microchip believes that its family of products is one of the most secure families of its kind on the market today, when used in the
intended manner and under normal conditions.
•
There are dishonest and possibly illegal methods used to breach the code protection feature. All of these methods, to our
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Sheets. Most likely, the person doing so is engaged in theft of intellectual property.
•
Microchip is willing to work with the customer who is concerned about the integrity of their code.
•
Neither Microchip nor any other semiconductor manufacturer can guarantee the security of their code. Code protection does not
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Code protection is constantly evolving. We at Microchip are committed to continuously improving the code protection features of our
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Information contained in this publication regarding device
applications and the like is provided only for your convenience
and may be superseded by updates. It is your responsibility to
ensure that your application meets with your specifications.
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RELATED TO THE INFORMATION, INCLUDING BUT NOT
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FanSense, FlexROM, fuzzyLAB, In-Circuit Serial
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© 2005, Microchip Technology Incorporated, Printed in the
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Printed on recycled paper.
Microchip received ISO/TS-16949:2002 quality system certification for
its worldwide headquarters, design and wafer fabrication facilities in
Chandler and Tempe, Arizona and Mountain View, California in
October 2003. The Company’s quality system processes and
procedures are for its PICmicro® 8-bit MCUs, KEELOQ® code hopping
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and manufacture of development systems is ISO 9001:2000 certified.
DS51515A-page ii
© 2005 Microchip Technology Inc.
MCP1630 LI-ION MULTI-BAY BATTERY
CHARGER USER’S GUIDE
Table of Contents
Preface ........................................................................................................................... 1
Chapter 1. Product Overview ........................................................................................ 5
1.1 Introduction ..................................................................................................... 5
1.2 What is the MCP1630 Li-Ion Multi-Bay Battery Charger? .............................. 6
1.3 What the MCP1630 Li-Ion Multi-Bay Battery Charger Kit Includes ................ 6
Chapter 2. Installation and Operation .......................................................................... 7
2.1 Introduction ..................................................................................................... 7
2.2 Features ......................................................................................................... 7
2.3 Getting Started ............................................................................................... 8
Appendix A. Schematic and Layouts ......................................................................... 11
A.1 Introduction .................................................................................................. 11
A.2 Board Schematic – Sheet 1 ....................................................................... 12
A.3 Board Schematic – Sheet 2 ....................................................................... 13
A.4 Board – Assembly Drawing ........................................................................ 14
A.5 Board – Top Layer ..................................................................................... 15
A.6 Board – Mid-Layer 1 ................................................................................... 16
A.7 Board – Mid-Layer 2 ................................................................................... 17
A.8 Board – Bottom Layer ................................................................................ 18
Appendix B. Bill-Of-Materials (BOM).......................................................................... 19
Appendix C. Evaluation Board Firmware
C.1 Device Firmware .......................................................................................... 21
© 2005 Microchip Technology Inc.
DS51515A-page iii
MCP1630 Li-Ion Multi-Bay Battery Charger User’s Guide
NOTES:
DS51515A-page iv
© 2005 Microchip Technology Inc.
MCP1630 LI-ION MULTI-BAY BATTERY
CHARGER USER’S GUIDE
Preface
NOTICE TO CUSTOMERS
All documentation becomes dated, and this manual is no exception. Microchip tools and
documentation are constantly evolving to meet customer needs, so some actual dialogs
and/or tool descriptions may differ from those in this document. Please refer to our web site
(www.microchip.com) to obtain the latest documentation available.
Documents are identified with a “DS” number. This number is located on the bottom of each
page, in front of the page number. The numbering convention for the DS number is
“DSXXXXXA”, where “XXXXX” is the document number and “A” is the revision level of the
document.
For the most up-to-date information on development tools, see the MPLAB® IDE on-line help.
Select the Help menu, and then Topics to open a list of available on-line help files.
INTRODUCTION
This chapter contains general information that will be useful to know before using the
MCP1630 Li-Ion Multi-Bay Battery Charger. Items discussed in this chapter include:
•
•
•
•
•
•
Document Layout
Conventions Used in this Guide
Recommended Reading
The Microchip Web Site
Customer Support
Document Revision History
DOCUMENT LAYOUT
This document describes how to use the MCP1630 Li-Ion Multi-Bay Battery Charger.
The manual layout is as follows:
• Chapter 1. “Product Overview” – Important information about the MCP1630
Li-Ion Multi-Bay Battery Charger.
• Chapter 2. “Installation and Operation” – Includes instructions on how to get
started with this user’s guide and a description of the user’s guide.
• Appendix A. “Schematic and Layouts” – Shows the schematic and layout
diagrams for the MCP1630 Li-Ion Multi-Bay Battery Charger.
• Appendix B. “Bill-Of-Materials (BOM)” – Lists the parts used to build the
MCP1630 Li-Ion Multi-Bay Battery Charger.
• Appendix C. “Evaluation Board Firmware” – Provides information about the
application firmware and where the source code can be found.
© 2005 Microchip Technology Inc.
DS51515A-page 1
MCP1630 Li-Ion Multi-Bay Battery Charger User’s Guide
CONVENTIONS USED IN THIS GUIDE
This manual uses the following documentation conventions:
DOCUMENTATION CONVENTIONS
Description
Arial font:
Italic characters
Initial caps
Quotes
Underlined, italic text with
right angle bracket
Bold characters
‘bnnnn
Text in angle brackets < >
Courier font:
Plain Courier
Italic Courier
0xnnnn
Square brackets [ ]
Curly brackets and pipe
character: { | }
Ellipses...
Represents
Examples
Referenced books
Emphasized text
A window
A dialog
A menu selection
A field name in a window or
dialog
A menu path
MPLAB® IDE User’s Guide
...is the only compiler...
the Output window
the Settings dialog
select Enable Programmer
“Save project before build”
A dialog button
A tab
A binary number where n is a
digit
A key on the keyboard
Click OK
Click the Power tab
‘b00100, ‘b10
File>Save
Press <Enter>, <F1>
Sample source code
Filenames
File paths
Keywords
Command-line options
Bit values
A variable argument
#define START
autoexec.bat
c:\mcc18\h
_asm, _endasm, static
-Opa+, -Opa0, 1
file.o, where file can be
any valid filename
A hexadecimal number where 0xFFFF, 0x007A
n is a hexadecimal digit
Optional arguments
mcc18 [options] file
[options]
Choice of mutually exclusive errorlevel {0|1}
arguments; an OR selection
Replaces repeated text
var_name [,
var_name...]
Represents code supplied by void main (void)
user
{ ...
}
RECOMMENDED READING
This user's guide describes how to use MCP1630 Li-Ion Multi-Bay Battery Charger.
Other useful documents are listed below. The following Microchip documents are available and recommended as supplemental reference resources.
MCP1630 Data Sheet, “High-Speed, Microcontroller-Adaptable, Pulse Width
Modulator”, (DS21896)
This data sheet provides detailed information regarding the MCP1630 product family.
DS51515A-page 2
© 2005 Microchip Technology Inc.
Preface
THE MICROCHIP WEB SITE
Microchip provides online support via our web site at www.microchip.com. This web
site is used as a means to make files and information easily available to customers.
Accessible by using your favorite Internet browser, the web site contains the following
information:
• Product Support – Data sheets and errata, application notes and sample
programs, design resources, user’s guides and hardware support documents,
latest software releases and archived software
• General Technical Support – Frequently Asked Questions (FAQs), technical
support requests, online discussion groups, Microchip consultant program
member listing
• Business of Microchip – Product selector and ordering guides, latest Microchip
press releases, listing of seminars and events, listings of Microchip sales offices,
distributors and factory representatives
CUSTOMER SUPPORT
Users of Microchip products can receive assistance through several channels:
•
•
•
•
•
Distributor or Representative
Local Sales Office
Field Application Engineer (FAE)
Technical Support
Development Systems Information Line
Customers should contact their distributor, representative or field application engineer
(FAE) for support. Local sales offices are also available to help customers. A listing of
sales offices and locations is included in the back of this document.
Technical support is available through the web site at: http://support.microchip.com
In addition, there is a Development Systems Information Line which lists the latest
versions of Microchip's development systems software products. This line also provides information on how customers can receive currently available upgrade kits.
The Development Systems Information Line numbers are:
1-800-755-2345 – United States and most of Canada
1-480-792-7302 – Other International Locations
DOCUMENT REVISION HISTORY
Revision A (March 2005)
• Initial Release of this Document.
© 2005 Microchip Technology Inc.
DS51515A-page 3
MCP1630 Li-Ion Multi-Bay Battery Charger User’s Guide
NOTES:
DS51515A-page 4
© 2005 Microchip Technology Inc.
MCP1630 LI-ION MULTI-BAY BATTERY
CHARGER USER’S GUIDE
Chapter 1. Product Overview
1.1
INTRODUCTION
The MCP1630 Li-Ion Multi-Bay Battery Charger is used to evaluate Microchip’s
MCP1630, when used in a Single-Ended Primary Inductive Converter (SEPIC) power
converter application. The MCP1630 Li-Ion Multi-Bay Battery Charger is capable of
charging two single-cell, Li-Ion battery packs in parallel utilizing an input voltage of 10V
to 28V. Multiple boards can be daisy-chained for a maximum of sixteen charger bays.
The MCP1630 Li-Ion Multi-Bay Battery Charger is intended for use in pseudo-smart
battery charger applications in conjunction with battery packs containing Microchip’s
PS700 Battery Monitor. Standard battery packs can be utilized as well. The MCP1630
Li-Ion Multi-Bay Battery Charger provides a constant-current, constant-voltage charge
with preconditioning, cell temperature monitoring and battery pack fault monitoring.
Each charger bay provides status and fault indications. The MCP1630 Li-Ion Multi-Bay
Battery Charger automatically detects the insertion or removal of a battery pack.
This chapter covers the following topics:
• What is the MCP1630 Li-Ion Multi-Bay Battery Charger?
• What the MCP1630 Li-Ion Multi-Bay Battery Charger kit includes
10V - 28V
Power
Supply
Charger
1
B+
SDA
SCL
TEMP
B-
Battery
Pack 1
Maximum Charge Current = 2A
SMBus
Charge
Manager
FIGURE 1-1:
© 2005 Microchip Technology Inc.
Charger
n
B+
SDA
SCL
TEMP
B-
Battery
Pack n
MCP1630 Li-Ion Multi-Bay Battery Charger Block Diagram.
DS51515A-page 5
MCP1630 Li-Ion Multi-Bay Battery Charger User’s Guide
1.2
WHAT THE MCP1630 LI-ION MULTI-BAY BATTERY CHARGER IS
The MCP1630 Li-Ion Multi-Bay Battery Charger is a complete, stand-alone,
constant-current, constant-voltage battery charger for single-cell Li-Ion battery packs.
Different battery chemistries (i.e. three NiMH or NiCd batteries connected in series) can
be charged with minor modifications to the firmware. This board utilizes Microchip’s
MCP1630 (High-speed PWM MSOP8), MCP6292 (Dual Op Amp MSOP8) and
PIC18F2410 (Flash MCU SOIC28). The input voltage range for the MCP1630 Li-Ion
Multi-Bay Battery Charger is 10V to 28V. The output is capable of charging at a
fast-charge rate of 2A constant current.
An input terminal block is provided to apply an input voltage to the charger and as a
convenient means to daisy-chain boards together. Output headers are also provided
as a means to connect the external battery packs or simulated battery loads. A
programming header is available for updating the firmware contained in the
PIC18F2410.
1.3
WHAT THE MCP1630 LI-ION MULTI-BAY BATTERY CHARGER KIT
INCLUDES
This MCP1630 Li-Ion Multi-Bay Battery Charger kit includes:
• MCP1630 Li-Ion Multi-Bay Battery Charger (102-00038)
• MCP1630 Li-Ion Multi-Bay Battery Charger User’s Guide (DS51515)
• MCP1630, High-Speed, Microcontroller-Adaptable, Pulse Width Modulator
Data Sheet (DS21896)
DS51515A-page 6
© 2005 Microchip Technology Inc.
MCP1630 LI-ION MULTI-BAY BATTERY
CHARGER USER’S GUIDE
Chapter 2. Installation and Operation
2.1
INTRODUCTION
The MCP1630 Li-Ion Multi-Bay Battery Charger demonstrates Microchip’s MCP1630
High-Speed PWM when used in a pseudo-smart battery charger application. The
MCP1630 is a High Speed, microcontroller adaptable, pulse width modulator. When
used in conjunction with a microcontroller, the MCP1630 will control the power system
duty cycle to provide output voltage or current regulation. The microcontroller
(PIC18F2410) can be used to regulate output voltage or current, switching frequency
and maximum duty cycle. The MCP1630 generates duty cycle while providing fast
overcurrent protection based off various external inputs. External signals include the
input oscillator, the reference voltage, the feedback voltage and the current sense. The
output signal is a square-wave pulse. The power train used for the MCP1630 is a
SEPIC.
2.2
FEATURES
The MCP1630 has the following features:
• Programmed Parameters – Modified in firmware
• Factory Settings:
- Preconditioning charge current = 200 mA
- Preconditioning threshold = 2.8V
- Constant-current fast charge = 2A
- Constant-voltage charge = 4.2V
- Charge termination threshold = 100 mA
• Overvoltage protection (battery removed)
• Overcharge protection to prevent damaging the battery
• Overcurrent protection in the event of a shorted battery
• Battery-reversal protection
• Input short circuit protection
• Overtemperature protection to prevent the battery from reaching too high a
temperature during charge
• Fast charge termination in the event the battery temperature is to high
• Soft-start capability by holding the reference voltage low during power-up
• The MCP1630 terminates charge by detecting a predefined charge current
threshold during constant-voltage charge, or a specified elapsed time
• The MCP1630 has the flexibility to optimize the charging algorithm for new battery
technology and add proprietary features by modifying the firmware contained in
the PIC18F2410. The factory-programmed source code is available
• Ability to adapt to environmental effects, such as ambient temperature
© 2005 Microchip Technology Inc.
DS51515A-page 7
MCP1630 Li-Ion Multi-Bay Battery Charger User’s Guide
2.3
GETTING STARTED
The MCP1630 Li-Ion Multi-Bay Battery Charger is fully assembled and tested for
charging single-cell, Li-Ion battery packs with the recommended charge profile for
Li-Ion batteries. This board requires the use of an external input voltage source (+10V
to +28V) and external load (battery or simulated battery load). It is recommended that
a battery pack containing Microchip’s PS700 battery monitor be used to maximize the
full benefits of the pseudo-smart battery system with the shortest charge cycle times.
Alternatively, standard battery packs or the recommended simulated load can be
utilized to evaluate the system performance.
2.3.1
Power Input and Output Connections
Powering the MCP1630 Li-Ion Multi-Bay Battery Charger
1. Apply the input voltage to the input terminal block (JP2). The input voltage source
should be limited to the 0V to +28V range. For normal operation, the input voltage
should be between +10V and +28V. The input voltage must not exceed an
absolute maximum of +35V.
2. Connect the positive side (+) of the input source to pin 1 of JP2. Connect the
negative or return side (-) of the input source to pin 2 of JP2. Refer to Figure 2-1.
B+
S DA
SCL
T E MP
B-
Bay 2
Battery
Header
+
Input
Voltage –
B+
S DA
SCL
T E MP
B-
Bay 1
Battery
Header
PGC
PGD
VS S
V DD
Programming
Header
VPP
FIGURE 2-1:
DS51515A-page 8
Setup Configuration Diagram.
© 2005 Microchip Technology Inc.
Installation and Operation
Apply the load to a battery header.
1. To apply a load to the MCP1630 Li-Ion Multi-Bay Battery Charger, the positive
side of the load (B+) should be connected to pin 1 of JP1 or JP3. The negative
side of the load (B-) should be connected to pin 5 of JP1 or JP3. Care should be
taken when using either electronic loads or ground-referenced loads.
2. A thermistor referenced to B- in the battery pack should be utilized. If a thermistor
is not available or desired, a 10 kΩ resistor should be placed between pin 4 and
pin 5 of the battery header. Alternatively, the firmware can be modified to ignore
the thermistor input.
3. SMBus interface connections are provided at the battery headers for communication with battery packs containing Microchip’s PS700. Utilizing a pseudo-smart
battery system will provide reduced charge cycle times by compensating for IR
voltage drops in the high-current charge path.
4. The code will prevent the board from entering the 2A Fast Charge mode if the
battery terminal voltage is less than 2.8V. During power-up, the board will always
trickle charge first, so using a purely resistive load will not work for trickle and fast
charge current. The best way to evaluate the charger is to use a single-cell, Li-Ion
battery pack or the reccomended simulated battery load. Refer to Figure 2-2.
B+
+
–
1,000 µF
10V Al
1Ω
1W
2Ω
5W
+
Variable
Power Supply
– 0V - 6V
B–
FIGURE 2-2:
Simulated Battery Load.
Status LEDs
1. Each charger bay has a LED to indicate charge status (D8 for charge bay 1 and
D6 for charge bay 2), as well as a LED to indicate a fault (D4 for charge bay 1
and D5 for charge bay 2).
TABLE 2-1:
STATUS OUTPUT
CHARGE CYCLE STATE
STATUS (GREEN)
FAULT (RED)
Qualification
OFF
ON
Preconditioning
ON
OFF
Constant Current Fast Charge
ON
OFF
Constant Voltage
ON
OFF
Charge Complete
Flashing
(0.5 Hz, 50% duty cycle)
OFF
Safety Timer Fault
Flashing
(0.5 Hz, 50% duty cycle)
ON
Cell Temperature Invalid
ON
ON
Battery Disconnected
OFF
ON
Input Power Removed
OFF
OFF
Programming
1. Header JP4 is provided for in-system circuit programming.
© 2005 Microchip Technology Inc.
DS51515A-page 9
MCP1630 Li-Ion Multi-Bay Battery Charger User’s Guide
NOTES:
DS51515A-page 10
© 2005 Microchip Technology Inc.
MCP1630 LI-ION MULTI-BAY BATTERY
CHARGER USER’S GUIDE
Appendix A. Schematic and Layouts
A.1
INTRODUCTION
This appendix contains the following schematics and layouts for the MCP1630 Li-Ion
Multi-Bay Battery Charger:
•
•
•
•
•
•
Board Schematic (Sheets 1 and 2)
Board – Assembly Drawing
Board – Top Layer
Board – Mid-Layer 1
Board – Mid-Layer 2
Board – Bottom Layer
© 2005 Microchip Technology Inc.
DS51515A-page 11
DS51515A-page 12
A
B
1
2
1
HE A DE R 2
JP5
CL K _IN
I SE T 1
I SE T 2
V SNS2
V SNS1
OSC2
I SE T 2
SDA2
SCL
OSC1
I SE T 1
SDA1
SCL
R7
7.87k
47.5k
R 48
R 36
7.87k
OSC2
I SE T 2
SDA2
SCL 2
OSC1
I SE T 1
SDA1
SCL 1
PowerT rain1
PowerT rain1
10.0k
R 20
D6
LED
R 56
1.00k
47.5k
R 51
V SNS2
T SNS2
V BAT2
V SNS1
T SNS1
V BAT1
V SNS2
T SNS2
V BAT2
V SNS1
T SNS1
V BAT1
2
R 59
1.00k
D8
LED
10.0k
R 35
R 45
47.5k
2
R 47
47.5k
R 53
1.00k
R 58
47.5k
V DD
U9A
U9B
14
13
12
11
10
9
8
7
6
5
4
3
2
1
C26
4.7uF
C31
4.7uF
3
V DD
PIC18F2220/SO(28)
R C3/SCK /SCL
R C2/CCP1/P1A
R C1/T 1OSI /CCP2
R C0/T 1OSO/T 1CK I
OSC2/CL K O/R A 6
OSC1/CL K I/R A 7
V SS
R A 5/A N4/SS/C2OUT
R A 4/T -CK I/C1OUT
R A3/AN3/V R E F+
6
1
2
7
CL K _OUT
NC7SZ74
CL R (R )
CK
D
PR (S)
U7
R C4/SDI/SDA
R C5/SDO
R C6/T X /CK
R C7/R X /DT
V SS
V DD
R B 0/A N12/INT 0
R B 1/A N10/INT 1
R B 2/A N8/INT 2
R B 3/A N9/CCP2
R B 4/A N11/K B I0
R B 5/K B I1/PGM
R B 6/K B I2/PGC
R B 7/K B I3/PGD
C32
0.1uF
R A2/AN2/V R E F-/CV R E F
R A1/AN1
R A0/AN0
MCL R /V PP/R E 3
U8
V DD
3
HE A DE R 2
1
2
JP6
Q
Q
15
16
17
18
19
20
21
22
23
24
25
26
27
28
3
5
V DD
1.00k
R 50
C27
0.01uF
4
1.00k
R 54
D4
LED
1
4
A B
C
1
4
D5
LED
74L V C1G66
2
10.0k
R 55
C30
0.01uF
U6
10.0k
R 52
R 49
10.0k
V DD
C29
0.01uF
R 46
10.0k
V DD
C28
0.01uF
4
2
74L V C1G66
A B
C
U3
1.00k
R 60
1.00k
R 57
R 62
10.0k
V DD
1.00k
R 61
1.00k
R 27
1.00k
R5
D7B
D7A
V DD
5
FCSM No.
6
DW G No.
103-00038
Sheet
1 of 2
OSC2
OSC1
SCL
SDA1
SDA2
V BAT2
V SNS1
V SNS2
T SNS2
T SNS1
V BAT1
I CD Port
1
2
3
4
5
JP4
MCP1630 L i-Ion Multi B ay B attery Charger R eference Design
Scale
Size
B
R 28
10.0k
V DD
Microchip T echnology, Inc.
2355 West Chandler B oulevard
Chandler, A Z 85224
R6
10.0k
V DD
5
6
R ev
1
A
B
C
D
A.2
C
D
1
MCP1630 Li-Ion Multi-Bay Battery Charger User’s Guide
BOARD SCHEMATIC – SHEET 1
© 2005 Microchip Technology Inc.
© 2005 Microchip Technology Inc.
A
B
C
D
I SE T 2
OSC2
I SE T 1
OSC1
1
V DD
R 39
100k
1
2
F1
100k
C7
0.01uF
R 17
147k
47.5k
10.0
R 16
R 12
R 11
DNP
R 18
C20
0.01uF
147k
47.5k
10.0
R 38
R 42
DNP
R 40
R 31
HE A DE R 2
JP2
ISNS2
ISNS1
V DD
V PWR
COMP
COMP
2
R 25
7.87k
MCP1630
V REF
CS
OSC V E X T
FB
U1
CS
1500pF
C8
MCP1630
V REF
OSC V E X T
FB
U4
C18
10uF
C9
0.022uF
8
4
2
C25
0.022uF
8
4
2
1500pF
C22
2
R 26
7.87k
3
6
1
3
6
1
V DD
V DD
C10
4.7uF
C21
4.7uF
V DD
C11
0.1uF
1.00k
4
7.87k
R 33
T L 431A I
D3
R 34
7.87k
C6
DNP
R8
1.00k
C2
10uF
15uH
R9
C3
10uF
V PWR
Q3
NPN
V DD
1.00k
L1
R 37
C19
DNP
1.00k
C14
10uF
15uH
L3
R 29
C13
10uF
V PWR
C23
0.1uF
R 10
100k
V DD
V DD
R 30
100k
V DD
3
3
3
R1
0.22
R 23
0.22
R2
0.22
Q1
IR F7478
1uF
C1
R 21
0.22
Q2
IR F7478
1uF
C15
R3
0.22
L2
15uH
R 22
0.22
L4
15uH
D1
D2
R4
0.22
R 24
0.22
C4
10uF
V BAT2
C17
10uF
V BAT1
4
C5
10uF
C16
10uF
4
10.0k
R 14
10.0k
R 13
100k
R 15
10.0k
R 44
10.0k
R 32
100k
R 43
3
2
6
5
3
2
6
5
MCP6292
+
-
U2A
100k
R 19
MCP6292
-
+
U2B
MCP6292
+
-
U5A
100k
R 41
MCP6292
-
+
U5B
1
7
1
7
C12
0.1uF
V BAT2
SDA2
SCL 2
T SNS2
V BAT1
SDA1
SCL 1
T SNS1
V BAT2
V BAT1
5
FCSM No.
6
DW G No.
103-00038
MCP1630 L i-Ion Multi B ay B attery Charger R eference Design
Scale
Size
B
V DD
V SNS2
C24
0.1uF
Microchip T echnology, Inc.
2355 West Chandler B oulevard
Chandler, A Z 85224
ISNS2
ISNS1
V DD
V SNS1
5
Sheet
2 of 2
HE A DE R 5
1
2
3
4
5
JP1
HE A DE R 5
1
2
3
4
5
JP3
6
R ev
1
A
B
C
D
A.3
5
1
Schematic and Layouts
BOARD SCHEMATIC – SHEET 2
DS51515A-page 13
MCP1630 Li-Ion Multi-Bay Battery Charger User’s Guide
A.4
BOARD – ASSEMBLY DRAWING
DS51515A-page 14
© 2005 Microchip Technology Inc.
Schematic and Layouts
A.5
BOARD – TOP LAYER
© 2005 Microchip Technology Inc.
DS51515A-page 15
MCP1630 Li-Ion Multi-Bay Battery Charger User’s Guide
A.6
BOARD – MID-LAYER 1
DS51515A-page 16
© 2005 Microchip Technology Inc.
Schematic and Layouts
A.7
BOARD – MID-LAYER 2
© 2005 Microchip Technology Inc.
DS51515A-page 17
MCP1630 Li-Ion Multi-Bay Battery Charger User’s Guide
A.8
BOARD – BOTTOM LAYER
DS51515A-page 18
© 2005 Microchip Technology Inc.
MCP1630 LI-ION MULTI-BAY BATTERY
CHARGER USER’S GUIDE
Appendix B. Bill-Of-Materials (BOM)
TABLE B-1:
Qty
BILL-OF-MATERIALS
Reference
(BOM)
Description
2
C1, C15
1 µF, X7R Ceramic, 50V, 1206
5
10 µF, Y5U Ceramic, 50V, 1210
2
1
C2, C3, C13,
C14, C18
C4, C5, C16, C17
C6, C19, R18,
R40
C7, C20, C27,
C28, C29, C30
C8, C22
C9, C25
C10, C21, C26,
C31
C11, C12, C23,
C24, C32
D1, D2
D3
2
D4, D5
Red LED, 0805
2
D6, D8
Green LED, 0805
1
1
2
D7
F1
JP1, JP3
1
JP2
1
JP4
2
JP5, JP6
2
L1, L3
Dual Schottky, 45V, 75 mA, S-MINI 4P
Polyswitch, 2.0A, Resettable, MINISMDC
Connector Header, 5 Pos., 2.54mm,
Friction Lock, HDR1X5-FL
Connector Terminal Block, 2-Pos., 5.08mm,
TB508-2
Connector Header, 5 Pos., 2.54mm,
HDR1X5
Connector Terminal Block, 2-Pos., 2.54mm,
TB254-2
Power Inductor, 15 µH, 1.47A, CDRH74
2
L2, L4
Power Inductor, 15 µH, 3.6A, CDRH104R
2
Q1, Q2
N-channel MOSFET, SOIC8
1
8
Q3
R1, R2, R3, R4,
R21, R22, R23,
R24
NPN Transistor, SOT23-6
0.22Ω, 1/4W, Chip Resistor, 1206
4
4
6
2
2
4
5
Mfgr.
Part Number
TDK Electronic Co.,
LTD
Panasonic®
ECJ-4YF1H106Z
10 µF, X5R Ceramic, 10V, 1206
DNP
Panasonic
ECJ-3YB1A106M
0.01 µF, X7R Ceramic, 50V, 0805
Panasonic
ECJ-2VB1H103K
1500 pF, X7R Ceramic, 100V, 0805
0.022 µF, X7R Ceramic, 50V, 0805
4.7 µF, X5R Ceramic, 6.3V, 0805
Panasonic
Panasonic
Panasonic
ECJ-2VB2A152K
ECJ-2VB1H223K
ECJ-2FB0J475M
0.1 µF, X7R Ceramic, 16V, 0805
Panasonic
ECJ-2VB1C104K
Schottky Diode, 40V, 3A, SMA
Shunt Regulator, SOT23-5
Diodes Inc.
Texas Instruments
Inc.
Lumex®
Opto/Components
Lumex
Opto/Components
Panasonic
Raychem®
Molex®/Waldon®
B340A-13
TL431IDBVR
MA4ZD0300L
MINISMDC200-2
22-23-2051
Phoenix Contact
1729128
Molex
22-03-2051
Phoenix Contact
1725656
Sumida
Corporation®
Sumida
Corporation
International
Rectifier
Zetex® Inc.
Panasonic
CDRH74-150MC
© 2005 Microchip Technology Inc.
C3216X7R1H105K
SML-LXT0805IW-TR
SML-LXT0805GW-TR
CDRH104R-150NC
IRF7478
ZXT10N50DE6TA
ERJ-8RQFR22V
DS51515A-page 19
MCP1630 Li-Ion Multi-Bay Battery Charger User’s Guide
TABLE B-1:
Qty
14
BILL-OF-MATERIALS
Reference
(BOM) (CONTINUED)
Description
2
2
R5, R8, R9, R27,
R29, R37, R50,
R53, R54, R56,
R57, R59, R60,
R61
R6, R13, R14,
R20, R28,
R32, R35, R44,
R46, R49, R52,
R55, R62
R7, R25, R26,
R33, R34, R36
R10, R15, R17,
R19, R30, R39,
R41, R43
R11, R31
R12, R42, R45,
R47, R48, R51,
R58
R16, R38
U1, U4
2
U2, U5
Dual Op Amp 10 MHz, MSOP8
2
U3, U6
Bilateral Switch, SOT23-5
1
1
U7
U8
D-Type Flip-Flop, US8
Enhanced Flash, SOIC28
1
U9
Dual Inverter, SOT23-6
13
6
8
2
7
DS51515A-page 20
Mfgr.
Part Number
1.00 kΩ, 1/10W, Chip Resistor, 0805
Panasonic
ERJ-6ENF1001V
10.0 kΩ, 1/10W, Chip Resistor, 0805
Panasonic
ERJ-6ENF1002V
7.87 kΩ, 1/10W, Chip Resistor, 0805
Panasonic
ERJ-6ENF7871V
100 kΩ, 1/10W, Chip Resistor, 0805
Panasonic
ERJ-6ENF1003V
10.0Ω, 1/10W, Chip Resistor, 0805
47.5 kΩ, 1/10W, Chip Resistor, 0805
Panasonic
Panasonic
ERJ-6ENF10R0V
ERJ-6ENF4752V
147 kΩ, 1/10W, Chip Resistor, 0805
PWM Building Block, MSOP8
Panasonic
Microchip
Technology Inc.
Microchip
Technology Inc.
Texas
Instruments Inc.
Fairchild®
Microchip
Technology Inc.
Texas
Instruments Inc.
ERJ-6ENF1473V
MCP1630-I/MS
MCP6292-E/MS
SN74LVC1G66DBVR
NC7SZ74K8X
PIC18F2410-I/SO
SN74LVC2G14DBVR
© 2005 Microchip Technology Inc.
MCP1630 LI-ION MULTI-BAY BATTERY
CHARGER USER’S GUIDE
Appendix C. Evaluation Board Firmware
C.1
DEVICE FIRMWARE
For the latest version of the MCP1630 Li-Ion Multi-Bay Battery Charger firmware, visit our web site at
www.microchip.com.
Power-Up
Initialize:
Ports, Clocks, ADC
PWM, IIC, and
Interrupts
No
Is battery
present?
Yes
Trickle Charge:
Turn-off RED LED,
Turn-on GREEN
LED, Start PWM,
Current = 200 mA
No
No
Is battery
present?
No
Yes
Is battery
> 2.8V?
Timer
expired?
Yes
Charge Fault:
Terminate Charge
Turn-on RED LED,
Flash GREEN LED
Yes
Temperature Fault:
Suspend Charge,
Turn-on RED LED
Is battery
present?
Yes
No
No
Temp. Out
of Range?
Yes
Fast Charge:
Reset Timers
Control Current to
Maintain 4.2V,
Max. Current = 2A
No
Is Battery
present?
No
No
Yes
Is Current
< 100 mA?
Temp. Out
of Range?
Temp. Out
of Range?
Yes
Yes Temperature Fault:
Suspend Charge,
Turn-on RED LED
No
No
Yes
Timer
expired?
No
Temp. Out
of Range?
Yes
Yes
Charge Complete:
,
Terminate Charge
Flash GREEN LED
No
No
FIGURE C-1:
Is Battery
present?
Is Battery
> 4.0V?
Yes
Firmware Flowchart - Page 1
© 2005 Microchip Technology Inc.
DS51515A-page 21
WORLDWIDE SALES AND SERVICE
AMERICAS
ASIA/PACIFIC
ASIA/PACIFIC
EUROPE
Corporate Office
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Chandler, AZ 85224-6199
Tel: 480-792-7200
Fax: 480-792-7277
Technical Support:
http://support.microchip.com
Web Address:
www.microchip.com
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Tel: 61-2-9868-6733
Fax: 61-2-9868-6755
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Tel: 91-80-2229-0061
Fax: 91-80-2229-0062
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Tel: 86-10-8528-2100
Fax: 86-10-8528-2104
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Tel: 91-11-5160-8631
Fax: 91-11-5160-8632
Austria - Weis
Tel: 43-7242-2244-399
Fax: 43-7242-2244-393
Denmark - Ballerup
Tel: 45-4450-2828
Fax: 45-4485-2829
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Tel: 86-28-8676-6200
Fax: 86-28-8676-6599
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Tel: 81-45-471- 6166
Fax: 81-45-471-6122
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Tel: 33-1-69-53-63-20
Fax: 33-1-69-30-90-79
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Tel: 86-591-8750-3506
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Fax: 86-532-502-7205
Los Angeles
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Fax: 949-462-9608
San Jose
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Tel: 650-215-1444
Fax: 650-961-0286
Toronto
Mississauga, Ontario,
Canada
Tel: 905-673-0699
Fax: 905-673-6509
10/20/04
DS51515A-page 22
© 2005 Microchip Technology Inc.