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