ISL9208EVAL2Z (Rev. A) User Guide Application Note Description This document is intended for use by individuals engaged in the development of hardware for a 4 to 7 series connected Li-ion battery pack using the ISL9208EVAL2Z board. The evaluation kit consists of the ISL9208EVAL2Z board. Operation of the ISL9208EVAL2Z board requires the use of a USB to I2C kit, part number “ISLI2C-KIT”, which is ordered separately. An optional link between the PC and the microcontroller BKGD connector is available from NXP (formerly Freescale) (used for monitoring and debugging the microcontroller code). First Steps • If not already available, acquire the DeVaSys USB to I2C interface cable and module. This is available from Intersil in the ISLI2C-KIT. • Download the software from the Intersil website on the ISL9208 page: “ISL92xx Eval Kit Software Release V1.41”. • Unzip the software files to a directory of your choice. • Prior to powering the ISL9208 board, install the USB to I2C board software and connect the DeVaSys board to the PC (see “Appendix 1” on page 13). However, don’t connect the DeVaSys board to the ISL9208EVAL2Z board yet. This is just preparation of the test set up. With these pieces in place, the PC interface can then quickly be used to monitor the operation of the board once power is applied. • If changes to the microcontroller code are desired, then it will be necessary to order a programming/debug module from NXP (formerly Freescale), part number, USBMULTILINKBDME. This kit also contains the Code 1 December 15, 2008 AN1444.0 Warrior development tools. To get the source code, contact Intersil and sign the license agreement. • Set up a power supply for the board. The power supply should consist of a string of 4 to 7 batteries (see Figure 1), or a string of 4 to 7 resistors and a power supply, or 4 to 7 individual power supplies (see Figures 1 or 2). Battery/Power Supply Connection When connecting battery packs or power supplies, use the connections of Figures 1 and 2. If individual power supplies are being used to replace battery cells, then connect the power supplies identically to the battery connections (see Figure 1.) Also, make sure that the individual power supply voltages do not exceed the ISL9208 maximum input voltage differential of 5V per cell. If using a string of resistors to emulate the battery cells, then use the connection in Figure 2. In this case, limit the power supply voltage so that the resistor divider outputs do not exceed the ISL9208 input maximum ratings. It is recommended that, when using the circuit of Figure 2, the series resistors be 20 or less and 2W minimum. Resistors with higher resistance can be used, but when activating the ISL9208 cell balance outputs, the 39 cell balance resistor on the board will lower the voltage across that series power supply resistor, while raising the voltage on all of the other series resistors. Turning on multiple cell balance outputs could then result in one or more of the VCELLN input voltages exceeding their maximum specified limit. If using series resistors greater than 20, the cell balance resistors on the ISL9208EVAL2Z board (R14-R20) should be replaced with higher values (1k recommended). CAUTION: These devices are sensitive to electrostatic discharge; follow proper IC Handling Procedures. 1-888-INTERSIL or 1-888-468-3774 | Copyright Intersil Americas LLC 2008. All Rights Reserved Intersil (and design) is a trademark owned by Intersil Corporation or one of its subsidiaries. All other trademarks mentioned are the property of their respective owners. Application Note 1444 7 CELLS 20 20 VCELL7 19 18 17 16 15 14 13 12 11 10 9 8 7 6 6 CELLS 7 POWER SUPPLIES CB7 VCELL6 V CB6 VCELL5 V CB5 VCELL4 V CB4 VCELL3 V CB3 VCELL2 V CB2 VCELL1 V CB1 VSS V VCELL7 19 18 17 16 15 13 CB7 VCELL6 18 CB6 VCELL5 16 17 15 13 11 10 11 10 CB3 VCELL2 9 7 7 CB1 VSS 6 5 16 CB2 VCELL1 8 CB1 VSS 6 CB6 VCELL5 CB3 VCELL2 9 CB2 VCELL1 8 19 18 CB4 VCELL3 12 5 CELLS 20 CB7 VCELL6 CB5 VCELL4 14 CB4 VCELL3 12 VCELL7 19 CB5 VCELL4 14 5 20 5 17 15 14 13 12 11 10 9 8 7 6 4 CELLS 20 VCELL7 19 CB7 VCELL6 18 CB6 VCELL5 16 17 15 CB5 VCELL4 14 13 CB4 VCELL3 12 11 10 CB3 VCELL2 9 CB2 VCELL1 8 7 CB1 VSS 6 5 VCELL7 CB7 VCELL6 CB6 VCELL5 CB5 VCELL4 CB4 VCELL3 CB3 VCELL2 CB2 VCELL1 CB1 VSS 5 Note: Multiple cells can be connected in parallel FIGURE 1. BATTERY CONNECTION OPTIONS V NOTES: 5 7 6 CB1 VSS 9 8 CB2 VCELL1 11 10 CB3 VCELL2 13 12 CB4 VCELL3 15 14 CB5 VCELL4 17 16 CB6 VCELL5 19 18 CB7 VCELL6 VCELL7 7 CELLS 20 15V TO 30V 1. For the battery simulation resistors, use 20/2W devices (minimum). If the resistors are more than 100, then turning on the cell balance resistors cause fluctuations in the cell input voltages that can violate the ISL9208 max specifications. If the series resistors are larger than 20, we recommend replacing the cell balance resistors on the board with 1k devices. 2. Before connecting the cable to the board, check the voltages at the connector to verify that they are correct. FIGURE 2. USING RESISTOR/POWER SUPPLY COMBINATION TO EMULATE A STRING OF BATTERIES B+/PACK+ OPTIONAL 6 CELL CONNECTION 7 CELL CONNECTION TO LOAD + OR CHARGER + TO LOAD + OR CHARGER + CONNECTOR MALE ON BOARD (TOP VIEW) PACK- Optional Thermistor or 50k Pot (If used, remove thermistor on board) BAT- CH- CONNECTOR MALE ON BOARD (TOP VIEW) TO LOAD - TO CHARGER - PACK- Optional Thermistor or 50k Pot (If used, remove thermistor on board) BAT- CH- TO LOAD - TO CHARGER - FIGURE 3. BATTERY CELL CONNECTION TO ISL9208 PCB 2 AN1444.0 December 15, 2008 Application Note 1444 supplies or battery cells. To obtain a blank interface board, please contact your Intersil representative. Initial Testing Setup (See Figure 4) • Figure 4 shows a blue board that connects between a power supply and the evaluation board. This board is not provided in the kit, but is an example of an interface connection that supports the connection of both a single power supply (with resistor dividers) or separate power • Before connecting the PC to the ISL9208EVAL2Z board (through the USB to I2C interface) turn off the power supply and then connect the power supply to the ISL9208EVAL2Z board. • Turn on the power to the board. Once power is turned on (or Li-ion cells are connected to the ISL9208EVAL2Z board,) the RGO LED should light. Use Meter 1 to measure the RGO voltage. It should read about 3.3V. Power Supply Interconnect Board (blue board, not provided in kit) provides resistor divider for generating cell voltages). If interested, please contact Intersil for a blank board. TO PC: DeVaSys: USB to I2C RGO (ISL9208) AO (ISL9208) METER 1 (3.3V) GND TO PC: BKGD CONNECT NXP (formerly Freescale) USB LINK USB to BKGD (Optional) 18V TO 29V BATTERY/POWER SUPPLY I2C CONNECT METER 2 (0V TO 2.3V) USBLINK: USB to BKGD (Optional) FIGURE 4. ISL9208EVAL2Z EVALUATION BOARD TEST CONNECTION 3 AN1444.0 December 15, 2008 Application Note 1444 USB to I2C interface • Once the power supply connections are verified, power-down the ISL9208EVAL2Z boards and make the PC connection to the board, via the USB port, the DeVaSys board, and the I2C cable. Before making this connection, make sure that the USB to I2C interface software is installed (see software installation guide). • Connect the I2C cable from the interface board to the ISL9208EVAL2Z as in Figure 5. Use the 5-pin to 4-pin cable provided in the ISLI2C-KIT. . ISL9208EVAL2Z J8 SDA NC GND SCL FETs DeVaSys BOARD CABLE J29 5-PIN TO 5-PIN J2 1 1 USE 5-PIN TO 4-PIN CONNECTOR SUPPLIED WITH ISLI2C-KIT USB FIGURE 5. I2C CONNECTION TO ISL9208 PCB • CAUTION: The I2C interface ground pin connects with the Battery negative terminal. If a load connected between the Pack + and Pack - pins has the same ground reference as the PC, then both sides of the power FETs will be connected together through the PC and load ground leads, so there will be no interruption in the power path. Also, without proper care, there can be problems with ground loops or excess voltage conditions as a result of this connection. If this may be a concern, see “I2C Isolation” on page 7. Testing the Board • Power-up the board and start the GUI. Now, the PC will be communicating with the microcontroller and the microcontroller will be communicating with the ISL9208. • The GUI should power up with some color. In this case, the FET controls should be GREEN and the indicators should be all be green. If the GUI is all gray, then there is a communication problem. If there is a communication problem, see the troubleshooting guide in the Appendix. • If the FET indicators remain RED after power up, then it is likely that at least one input voltage or the temperature is out of range. The microcontroller on the board performs a number of automatic functions. These are: 1. The cell inputs are monitored for too high or too low voltage. If any of the cell voltages go too high, the charge FET is turned off. If any of the cell voltages go too low, the discharge FET turns off. When the voltage recovers from these excursions, back into the normal range, the FETs automatically turn on. 2. After an overcurrent or undervoltage condition, the microcontroller monitors the load and turns the FETs back on when the load is released. 4 3. The microcontroller monitors the temperature and turns off the cell balance and the power FETs if the temperature is too high or low. 4. The microcontroller performs cell balancing (once it is enabled through the GUI). 5. The microcontroller monitors the cell voltages and reports these voltages to the GUI. Over/Undervoltage Testing • Test the overvoltage and undervoltage conditions by: – If Li-ion cells are being used, discharge the pack until one or more of the cells reach the undervoltage limit and the discharge FET turns off. Then, charge the pack until the FETs turn on again and continue charging until a cell overvoltage condition is reached. – If one power supply is being used, lower the voltage on the power supply until one or more of the cells reach the undervoltage limit and the discharge FET turns off. Then, increase the voltage until the FETs turn on again and continue increasing the voltage until a cell overvoltage condition is reached. – If seven power supplies are used, then simply decrease or increase any individual supply until the thresholds are reached and the FET turns off (or on). Overcurrent Testing Testing the overcurrent settings with the ISL9208EVAL2Z Rev A is not easy without changing the values of the sense resistors on the board, because it was designed as a possible reference application. As delivered, the ISL9208EVAL2Z provides a discharge sense resistor of 2.5m and a charge sense resistor of 50m. To get a discharge short circuit condition requires 80A. To get a discharge overcurrent condition requires a load of 40A. To get a charge overcurrent condition requires 2A. Changing both resistors to 0.5 provides a mechanism for easily testing the current thresholds. To test the board in an application most likely requires that battery cells be used and that there is a large load available. While the board was not extensively tested for these high load currents, the traces are short and wide enough to (theoretically) handle the currents up to the 40A threshold. Cell Balance Testing • Testing the cell balance operation requires the use of Li-ion cells or a power supply, or requires modifying the board to use 1000 cell balancing resistors (with 7 cells, a string of 20 voltage divider resistors, and 39 cell balancing resistors, turning on one cell balance output drops the voltage on that cell to less than 2.5V. At this voltage, the microcontroller puts the ISL9208 to sleep). • Start the cell balance test by first observing if the cell with the maximum cell voltage exceeds the cell with the AN1444.0 December 15, 2008 Application Note 1444 minimum voltage by more than 30mV. If so, note the cell number of the maximum voltage cell. CONNECT TO SIMULATE CHARGER WAKE-UP • Next, select “CB Max #” to be “1”. This limits the balancing to only one cell - the one with the maximum voltage. • Monitor the call balance LEDs on the board or the GUI to track the cell balance operation. On the GUI, use the CB refresh button (or start auto update) to update the indicators to show which cell is being balanced, it should be the maximum voltage cell. Be patient, because the microcontroller will balance for 10s, then turn off balancing for 2s1, then balance again. Also, if the maximum voltage cell is very close to the next highest voltage cell, or if there are many cells within a narrow voltage range, then any of these cells could be balanced, due to the limited accuracy of the microcontroller A/D converter. • Next, select “CB Max #” to be “2”. This limits the balancing to two cells - the highest two voltage cells. Again refresh the CB screen periodically to see the operation of the cell balance code. • Open the pack tab in the GUI and change some of the settings for overvoltage, undervoltage, or cell balance and re-test. Remember to click on “Write” to send the new parameters to the microcontroller. Sleep/Wake Testing The ISL9208 board can be put to sleep via commands from the PC or by lowering the voltage on any cell below 2.5V (default software setting). This sequence is described in the following paragraphs. To put the ISL9208 into the sleep mode, use the Register Access window to write an 80H to the ISL9208 register 4. This turns off the ISL9208 RGO output and LED. Or, the ISL9208 can be put to sleep by the microcontroller automatically when it detects that the voltage on any cell is less than 2.5V. To wake-up the ISL9208 requires that the ISL9208 WKUP pin go below its walk-up threshold.This can happen when a charger connects to the pack charge terminals or when a load is connected to the load terminals. This can be done with real loads or chargers or by using a resistor, as shown in Figure 6. 1. If this is too long to wait, go to the “Pack Tab” in the GUI and change the cell balance on/off times. Setting 1s on and 1s off is the minimum setting for cell balancing, but 2s on, 2s off is the recommended minimum, only because an autoscan of 1s can cause confusion due to the asynchronous nature of cell balance and autoscan. 5 CONNECT TO SIMULATE LOAD WAKE-UP 1k 1k FIGURE 6. ISL9208EVAL2Z CURRENT DETECTION CONNECTIONS • The charger connection works because it pulls the charger negative terminal to about the ISL9208 VSS voltage, the same as would an unloaded charger. • The load connection works, because the load terminal is pulled high (in sleep mode, the power FETs are off, so the connection from the ISL9208 VSS pin to the Pack- pin is open). Circuitry on the board inverts this signal to pull the ISL9208 WKUP pin low to wake the device. • When the WKUP pin is pulled low, the ISL9208 wakes up and turns on the RGO output. This turns on the RGO LED. Additional Testing Further tests on the board will likely follow the lines of battery pack testing, so it can become quite involved and be very specific to the application. Therefore, before setting up the tests, see the “GUI user Manual” for information on using the interface and see the “Microcode Reference Guide” for information about how the software works. Other Board Features/Options Current Direction Detection The ISL9208EVAL2Z (Rev A) board has a circuit to detect a charge or discharge condition (see Figure 7). It is designed to detect a small current flowing into or out of the pack. The software revision 1.5 does not yet support this hardware, but the signals can be monitored with a meter or a scope to determine their performance. There are two main uses for the current direction detection circuit. The first is in power control. If the microcontroller does not see any current for a long period of time, it can put the pack hardware to sleep to extend battery life. Second, the cell balance routine is usually conducted only during a charge condition. To do this requires information that charge current is flowing. The current direction detectors are comparators only, so when the current is high enough, the indicators go high. For AN1444.0 December 15, 2008 Application Note 1444 charge current, the threshold is about 60mA, for discharge the threshold is about 800mA. These thresholds can be changed by replacing a resistor, but making the thresholds much lower may cause problems due to the LM358 input offset. To change the discharge current detection threshold, change the value of R46. A lower value lowers the current threshold. To change the charge current detection threshold, change the value of R40. A lower value lowers the current threshold. Pack Voltage Monitoring The ISL9208EVAL2Z has a circuit that is activated by the microcontroller to monitor the pack voltage directly. The input to the microcontroller is the pack voltage divided by 16 (see Figure 9). PACK+ 100k RGO 1 OF 2 LM358 1M 1M + 1k 1k R40 1.21M 1M CHARGE INDICATOR 368k 80.6k PACKV 16 TO µC A/D INPUT GND FMMT619 TO µC OUTPUT 50k GND BSS84DW CHARGE 0.05 FIGURE 9. DIRECT MONITOR OF THE PACK VOLTAGE 0.005 DISCHARGE RGO 2 OF 2 1.8M 1k GND + R46 DISCHARGE INDICATOR FIGURE 7. USING OP AMP AND FETS TO DETECT CHARGE AND DISCHARGE CURRENT Future code revisions will have support for this hardware, but if custom code is desired, then the charge indicator connects to the microcontroller pin PTB4 and the discharge indicator connects to pin PTB5. See Figure 8. CURRENT DIRECTION DETECT CIRCUITS DISCHARGE DETECT The software revision 1.5 does not support the pack voltage monitor hardware, but if support is desired, then the microcontroller needs to turn on the PTB6 output to enable the circuit, then do an analog read of the ADP4 input. PACK VOLTAGE MONITORING CIRCUIT CHARGE DETECT FIGURE 8. ISL9208EVAL2Z CURRENT DETECTION CONNECTIONS 6 The purpose of this circuit is to get a more accurate reading of the pack voltage. Without this circuit, the pack voltage is determined by adding the individual cell voltages. However, this results in adding the measurement errors of each cell, so the accuracy of the pack voltage is not very useful. With an accurate reading of the pack voltage, the microcontroller can use the value to determine if there is any low level discharge current or can use the value to compare to the summation of the cell voltages to detect any gross cell measurement errors. PACK VOLTAGE ENABLE PACK VOLTAGE µC INPUT FIGURE 10. ISL9208EVAL2Z PACK VOLTAGE MONITORING CONNECTIONS AN1444.0 December 15, 2008 Application Note 1444 I2C Isolation EEPROM In some test conditions, ground connections can cause problems. This is because the I2C ground, power supply, load, and perhaps an oscilloscope, may all connect to ground. This can cause problems ranging from grounding both sides of the power FETs (taking them out of the circuit) to creating ground loops or unexpected voltage potentials that can damage components. For applications that require non-volatile storage or require calibration and the microcontroller flash is no longer available, the ISL9208EVAL2Z (Rev A) board provides a serial EEPROM connection to the microcontroller (see Figure 11). An example EEPROM device is the AT24C16 from Atmel. This is not populated as shipped and there is no code in the microcontroller in software release 1.5 to support this device. The ISL9208EVAL2Z provides an option for the addition of an isolation device for the I2C interface; the Analog Device ADuM1250. This allows the PC to monitor a battery pack that is connected to a load without some of the grounding problems that can arise. To use this option, the device and a header needs to be installed on the board, then the DeVaSys board needs to connect to the JP3 connector (see Figure 11). The DeVaSys board will need to connect with a 5-pin to 5-pin point-to-point connector (pin 3 is not used, but the ADuM1250 uses the 3.3V supply provided by the DeVaSys board). ISOLATED I2C INTERFACE CONNECTION Microcontroller Options The BKGD connection on the ISL9208 board allows development of new or modified code for the NXP (formerly Freescale) MC9S08QG8 microcontroller, which is supplied on the board. Related Documentation From Intersil ISL9208, ISL9216, ISL9217 Microcode Reference Guide ISL9208 (FN6446) Data Sheet ISL9208 Application Note (AN1333) ISL9208, ISL9216 GUI User Guide (AN1334) DeVaSys USB-I2C Software Installation From Texas Instruments ADS1100 Data Sheet From NXP (Formerly Freescale) MC9S08QG8 Microcontroller Data Sheet HCS08 Microcontrollers Family Reference Manual EEPROM PAD FIGURE 11. ISL9208EVAL2Z ISOLATED INTERFACE CONNECTION AND EEPROM 7 AN1444.0 December 15, 2008 AFE Schematic 3 4 6 5 Notes: Notes: 1)Keep wide traces as as short as possibleas possible 1. Keep wide traces short 2) Wide trace widths should be 0.4 inches wide or morewidths should be 0.4 inches 2. Wide trace 3) Use RoHS approved PCB materials wide or more. 4) Use immersion gold plating 5) All components used must be RoHS approved 3. Use RoHs approved PCB materials. 4. Use immersion gold plating. D 5. All components used must be RoHs approved. 1 1 J21 J27 J28 TEMP3V SCL SDA 1 1 J5 J6 J7 CB5 CB6 CB7 1 J4 CB4 1 2 1 1 TMP3V uCSCL uCSDA D J23 RGC 1 C7 1uF/50V 1 CB2 CB1 R68 1k Q7 MMBT3906K CELL5 C20 4.7uF CB5 R69 1k CELL3 C21 4.7uF A CB3 R70 1k CELL1 CB1 C22 4.7uF R12 100k Q9 MMBT3906K R16 100k Q11 MMBT3906K R20 100k R71 1k R55 750 CB6 C19 4.7uF R10 100k Q10 R17 SCHOTTKY R72 1k MMBT3906K 39 D19 CELL2 LED R18 C24 D8 R58 4.7uF 100k CB2 750 SCHOTTKY R19 39 D22 CELL1 LED D11 R61 750 R21 SCHOTTKY R73 1k 39 D20 GND LED D9 R57 750 D15 J32 1 1 2 3 CHRG_I Q13 FMMT619 RGO 2 1M FYD0504SA DIODE 6 5 4 R33 100 1 Q4 R65 1M J42 Pack- CHG 1 J35 VMON D4 DIODE R49 1.2M R51 82k R39 249k 3 RGO R75 1.8M GND VCC GND LM358 U2 PACKV C27 0.1uF ENPV 2 Q2 IRF1404S J30 R54 50k GND 1 R43 1M DGate 8 7 6 5 J38 Pack- DSC A 3 1 2 3 4 B GND 18V 100 R42 1M R46 5.49k J39 A2DIN Q5 BSS8402DW D23 CFET R40 1k DSCG_I R64 1 1 J37 AO R6 368k C16 1000pF 6 5 4 J43 CSns J31 DFET BSS84DM SCHOTTKY R15 39 D21 CELL3 LED D10 R60 750 D14 AO R37 499 R66 100k 3 2 1 5m SCHOTTKY R11 39 D17 CELL5 LED D6 R56 750 R74 1k Q8 R13 SCHOTTKY MMBT3906K 39 D18 CELL4 LED R14 C23 D7 R59 4.7uF 100k CB4 750 GND 10M R50 50m 8 7 6 5 1 R48 DSns R35 LED D3 GND 1 R8 100k Q6 MMBT3906K J54 CON1 1 J25 RGO 1 C1 4.7uF SCHOTTKY D16 CELL6 D5 3.3V 1 R47 5k 5m R53 BAT- DSC RGO R62 C8 1k .01uF D12 RGO R26 1M R27 1M Q14 IRF7469 1 Q15 MMBT3906K R9 39 JP2 TH1 J33 1 R52 J10 J22 TMPI D13 DIODE GND C3 1000p R67 49.9 4 HEADER FMMT619 1 2 3 C18 0.1uF Q1 R38 46.4k O.T. = 55degC 17 18 19 20 21 22 23 24 CB3 CB2 CB1 R41 1k C17 .47uF/50V 1 J19 J20 1 J18 1 4.7uF/50V 10uF/25V 4.7uF/50V C6 10uF/16V C5 C11 C2 C10 C9 10uF/16V 10uF/16V C4 4.7uF/50V GND C 1 2 3 4 100 1 2 CB3 J29 100 2 1 100 R28 R29 150k 32 31 30 29 28 27 26 25 NC NC SCL SDA WKUP RGC RGO Temp3V 2 1 100 R32 CB4 VCELL3 CB3 VCELL2 CB2 VCELL1 CB1 VSS RGO R31 CELL1 9 10 11 12 13 14 15 16 CB4 1 CELL2 CB5 2N7002 R5 ISL9208 4 CELL3 100 PACKSCL PACKSDA Q3 U1 CB6 1 100 R30 0 R25 R1 511 PAD CELL4 8 7 6 5 4 3 2 1 49.9 D2 GND CB7 VCELL4 CB5 VCELL5 CB6 VCELL6 CB7 V7/VCC NC/VCC 49.9 R24 C12 0.47uF/50V 2 Title Q12 IRF1404S R76 R34 1k 3 1 ISL9208EVAL2Z Design C28 Size A 0.47uF/50V Date: File: 4 5 Number ISL9208EVAL2Z July10, 2008 ISL9208EVAL2Z Revsion A Sheet 2 of Drawn by: CEM 6 3 Application Note 1444 R22 CELL5 Connect GND and BAT- DSC at battery string negative terminal. Use small gauge wire. The resistance of this wire needs to be kept to a minimum (preferrably DIODE GND 10 R7 CELL6 CON8 CB7 R23 330k 1 R36 1.2M 1 8 7 6 5 4 3 2 1 CELL7 J40 J41 PSCL PSDA DIODE 1 1 1 J8 B R2 1.8M D1 WKUP CELL7 C J26 WKUP 1 R63 511 1 R3 R4 4.7k 4.7k 1 1 DSREF/ISREF DSense CSense DFET CFET VMON AO TempI 8 J3 VC7 J2 VC6 J1 VC5 J12 VC4 J13 VC3 J14 VC2 J15 VC1 AN1444.0 December 15, 2008 Microcrontroller Schematic D D 9 J45 U4 1 1 2 3 4 uCp2 C C25 0.1uF 5 3 1 JP1 VDD1 VDD2 SDA1 SDA2 SCL1 SCL2 GND1 GND2 8 7 6 5 JP3 HEADER 5 C26 0.1uF BKGD 6 4 2 ADUM1250 1 10k uCp1 U3 1 J48 ENPV ENPV 1 DSCG_I CHRG_I B PTA5/IRQ/TCLK/RESET PTA0/KBIP0/TPMCH0/ADP0/ACMP+ PTA4/ACMPO/BKGD/MS PTA1/KBIP1/ADP1/ACMPVDD PTA2/KBIP2/SDA/ADP2 VSS PTA3/KBIP3/SCL/ADP3 PTB7/SCL/EXTAL PTB0/KBIP4/RxD/ADP4 PTB6/SDA/XTAL PTB1/KBIP5/TxD/ADP5 PTB5/PMCH1/SS PTB2/KBIP6/MSCK/ADP6 PTB4/MISO PTB3/KBIP7/MOSI/ADP7 PAD 1 2 3 4 5 6 7 8 16 15 14 13 12 11 10 9 AO TMP3V PACKSDA PACKSCL J51 PV 1 uCSCL uCSDA J52 WP 1 MC9S08QG8 0 C13 C15 C14 .1uF .01uF RGO GND PACKV J49 CHI B 1 U5 J50 DCI 1 2 3 4 1 A0 Vcc A1 WP A3 SCL Vss SDA 8 7 6 5 EEPROM 8L A A Title ISL9208EVAL2Z Reference Design - Microcontroller Size A Date: File: 1 2 3 4 5 Number ISL9208EVAL2Z July 10, 2008 ISL9208EVAL2Z Revsion A Sheet 3 of Drawn by: CEM 6 3 Application Note 1444 J47 ENI C J46 R45 .1uF 1 2 3 4 5 AN1444.0 December 15, 2008 Application Note 1444 ISL9208EVAL2Z Bill of Materials PART NUMBER QTY UNITS REFERENCE DESIGNATOR ISL9208EVAL2ZREVAPCB 1 ea GMK212BJ474KG-T 3 ea C12, C17, C28 GRM31CF51H475ZA01L-T 3 ea C6, C9, C10 H1044-00102-25V10-T 1 ea H1044-00104-16V10-T 1 H1045-00102-25V10-T DESCRIPTION PWB-PCB, ISL9208EVAL2Z, REVA, QFN, ROHS MANUFACT. TBD MANUFACTURER PART ISL9208EVAL2ZREVAPCB CAP, SMD, 0805, 0.47µF, 35V, TAIYO YUDEN 10%, X5R, ROHS GMK212BJ474KG-T CAP, SMD, 1206, 4.7µF, 50V, MURATA -20 + 80%, Y5V, ROHS GRM31CF51H475ZA01L C3 CAP, SMD, 0402, 1000pF, 25V, 10%, X7R, ROHS GRP155R71E102K ea C18 CAP, SMD, 0402, 0.1µF, 16V, MURATA 10%, X7R, ROHS GRM36X7R104K016AD 1 ea C16 CAP, SMD, 0603, 1000PF, 25V, 10%, X7R, ROHS 08053C102KAT2A H1045-00103-16V10-T 2 ea C8, C15 CAP, SMD, 0603, 0.01µF, 16V, VENKEL 10%, X7R, ROHS C0603X7R160-103KNE H1045-00104-16V10-T 3 ea C13, C14, C27 CAP, SMD, 0603, 0.1µF, 16V, MURATA 10%, X7R, ROHS GRM39X7R104K016AD H1045-00104-16V10-T 0 ea DNP (C25, C26) CAP, SMD, 0603, 0.1µF, 16V, MURATA 10%, X7R, ROHS GRM39X7R104K016AD H1045-00475-6R3V10-T 7 ea C1, C19-C24 CAP, SMD, 0603, 4.7µF, 6.3V, VENKEL 10%, X5R, ROHS C0603X5R6R3-475KNE H1065-00106-25V10-T 4 ea C2, C4, C5, C11 CAP, SMD, 1206, 10µF, 25V, 10%, X5R, ROHS VENKEL C1206X5R250-106KNE H1082-00105-50V10-T 1 ea C7 CAP, SMD, 1210, 1µF, 50V, 10%, X7R, ROHS VENKEL C1210X7R500-105KNE 1266 1 ea B- (Located right of J10) CONN-TERMINAL, TH, QUICK-FIT MALE TAB, 20.1x8.9, ROHS KEYSTONE 1266 22-23-2041 1 ea J29 CONN-HEADER, 1x4, SOLID, MOLEX 2.54mm, FRICTION LOCK, ROHS 22-23-2041 22-23-2051 0 ea DNP (JP3) CONN-HEADER, 1x5, SOLID, MOLEX 2.54mm, VERTICAL, FRICTION LOCK, TIN, PbFREE 22-23-2051 22-28-8361 1 ea J8 (Break off in 8-pin segments) MOLEX CONN-HEADER, 1x36, BREAK-AWAY, 2.54mm, R/A, ROHS 22-28-8361 67996-272HLF-2x3 1 ea JP1 CONN-HEADER, 2x3, BRKAWY 2X36, 2.54mm, VERTICAL, ROHS AZ23C3V3-7-F-T 1 ea D5 DIODE-ZENER, DUAL, SMD, DIODES INC. SOT23, 3.3V, 300mW, ROHS AZ23C3V3-7-F BAT6203WE6327 1 ea D15 DIODE-SCHOTTKY, SMD, 2P, INFINEON SOD323, 40V, 20mA, ROHS TECHNOLOGY BAT6203WE6327 FYD0504SATM 1 ea D14 DIODE-SCHOTTKY RECTIFIER, SMD, D-PAK, 40V, 5A, ROHS FAIRCHILD MBR0540T1G-T 11 ea D1, D2, D4, D13, D16-D22 DIODE-RECTIFIER, SMD, SOD-123, 2P, 40V, 0.5A, ROHS ON MBR0540T1G SEMICONDUCTOR 10 MURATA AVX BERG/FCI 67996-272HLF FYD0504SATM AN1444.0 December 15, 2008 Application Note 1444 ISL9208EVAL2Z Bill of Materials (Continued) PART NUMBER QTY UNITS REFERENCE DESIGNATOR DESCRIPTION MANUFACT. MANUFACTURER PART DIODE-ZENER, SMD, 2P, SOD-123, 18V, 500mW, ROHS ON MMSZ4705T1G SEMICONDUCTOR LED, SMD, 0603, ORANGE, 19mcd, 5mA, 1.9V, 620nm, ROHS PANASONIC DNP (U4) IC-HOT SWAP DUAL I2C ISOLATOR, 8P, NSOIC, ROHS ANALOG DEVICES ADUM1250ARZ ea DNP (U5) CAT24C01WI-GT3 IC-CMOS SERIAL EEPROM, CATALYST SEMICONDUCTOR 8P, SOIC, 1.7V to 5.5V, INC 16BYTE, ROHS 1 ea U1 IC-MULTI-CELL BATTERY INTERSIL PACK, 32P, QFN, 5x5, ROHS ISL9208IRZ LM358AM 1 ea U2 IC-DUAL OP AMP, 8P, SOIC, FAIRCHILD ROHS LM358AM MC9S08QG8CFFE 1 ea U3 IC-MCU, FLASH, 8kx8, 10MHz, 16P, QFN, ROHS 2N7002-7-F-T 1 ea Q3 TRANSISTOR, N-CHANNEL, DIODES, INC. 3 Ld, SOT-23, 60V, 115mA, ROHS 2N7002-7-F BSS8402DW-7-F-T 1 ea Q5 DIODES INC. TRANSIST-MOS, P-CHANNEL/N-CHANNEL, 6P, SOT-363, 200mW, ROHS BSS8402DW-7-F BSS84DW-7-F-T 1 ea Q4 TRANSIST, DUAL P-CHANNEL, 6P, SOT-363, -50V, -130mA, ROHS FMMT619TA-T 2 ea Q1, Q13 TRANSISTOR, NPN, SOT23, ZETEX, INC. 50V, 2A, ROHS FMMT619TA IRF1404SPBF 2 ea Q2, Q12 INTERNATIONAL TRANSIST-MOS, NCHANNEL, TH, D2-PAK, 40V, RECTIFIER 162A, ROHS IRF1404SPBF IRF7469PBF 1 ea Q14 TRANSISTOR-MOS, SMPS, 8P, SOIC, 40V, 9A, ROHS IRF7469PBF MMBT3906K-T 7 ea Q6-Q11, Q15 CSNL20.0051%R-T 2 ea R52, R53 RES-CURR SENSE, SMD, 2512, 0.005, 2W, 1%, MF, ROHS STACKPOLE CSNL 2 0.005 1% R CSRN20.051%I-T 1 ea R50 RES-CURR SENSE, SMD, 2512, 0.05, 2W, 1%, TF, ROHS STACKPOLE CSRN 2 0.05 1% I H2510-00100-1/16W1-T 1 ea R7 RES, SMD, 0402, 10, 1/16W, PANASONIC 1%, TF, ROHS H2510-01000-1/16W1-T 4 ea R25, R30, R31,R32 RES, SMD, 0402, 100, 1/16W, 1%, TF, ROHS PANASONIC ERJ-2RKF1000 H2510-01001-1/16W1-T 9 ea R34, R40, R68-R74 RES, SMD, 0402, 1k, 1/16W, 1%, TF, ROHS VENKEL CR0402-16W-102JT H2510-01003-1/16W1-T 8 ea R8, R10, R12, R14, RES, SMD, 0402, 100k, R16, R18, R20, R66 1/16W, 1%, TF, ROHS PANASONIC ERJ2RKF1003 MMSZ4705T1G-T 1 ea D23 LNJ826W83RA 8 ea D3, D6-D12 ADUM1250ARZ 0 ea CAT24C01WI-GT3 0 ISL9208IRZ 11 LNJ826W83RA MC9S08QG8CFFE NXP (formerly Freescale) SEMICONDUCTOR DIODES INC. INTERNATIONAL RECTIFIER TRANSISTOR, PNP, 3P, FAIRCHILD SOT-23, -40V, -200mA, ROHS BSS84DW-7-F MMBT3906K ERJ-2RKF10R0 AN1444.0 December 15, 2008 Application Note 1444 ISL9208EVAL2Z Bill of Materials (Continued) PART NUMBER QTY UNITS REFERENCE DESIGNATOR H2510-01004-1/16W1-T 3 ea R42, R43, R64 H2510-01005-1/16W1-T 1 ea H2510-01204-1/16W1-T 2 H2510-01804-1/16W1-T DESCRIPTION MANUFACT. MANUFACTURER PART RES, SMD, 0402, 1M, 1/16W, PANSONIC 1%, TF, ROHS ERJ-2RKF1004X R48 RES, SMD, 0402, 10M, 1/16W, 1%, TF, ROHS VISHAY/DALE CRCW040210M0FKED ea R36, R49 RES, SMD, 0402, 1.2M, 1/16W, 1%, TF, ROHS VENKEL CR0603-16W-1204FT 1 ea R75 RES, SMD, 0402, 1.8M, 1/16W, 1%, TF, ROHS VENKEL CR0402-16W-1804FT H2510-03653-1/16W1-T 1 ea R6 RES, SMD, 0402, 365k, 1/16W, 1%, TF, ROHS VENKEL CR0402-16W-3653FT H2510-04642-1/16W1-T 1 ea R38 RES, SMD, 0402, 46.4k, 1/16W, 1%, TF, ROHS PANASONIC ERJ2RKF4642 H2510-04701-1/16W1-T 2 ea R3,R4 RES, SMD, 0402, 4.7k, 1/16W, 1%, TF, ROHS VENKEL CR0402-16W-4701FT H2510-04991-1/16W1-T 1 ea R47 RES, SMD, 0402, 4.99k, 1/16W, 1%, TF, ROHS KDA RK73H1E4991F H2510-04992-1/16W1-T 1 ea R54 RES, SMD, 0402, 49.9k, 1/16W, 1%, TF, ROHS PANASONIC ERJ-2RKF4992 H2510-049R9-1/16W1-T 3 ea R22, R24, R67 RES, SMD, 0402, 49.9, 1/16W, 1%, TF, ROHS PANASONIC ERJ-2RKF49R9 H2510-05491-1/16W1-T 1 ea R46 RES, SMD, 0402, 5.49k, 1/16W,1%, TF, ROHS H2510-07500-1/16W1-T 7 ea R55-R61 RES, SMD, 0402, 750, 1/16W, 1%, TF, ROHS PANASONIC ERJ-2RKF7500X H2510-08202-1/16W1-T 1 ea R51 RES, SMD, 0402, 82k, 1/16W, PANASONIC 1%, TF, ROHS ERJ-2RKF8202X H2511-01000-1/10W1-T 4 ea H2511-01001-1/10W1-T 2 ea R41, R62 H2511-01002-1/10W1-T 1 ea R45 H2511-01004-1/10W1-T 3 ea R26, R27, R65 H2511-01503-1/10W1-T 1 ea H2511-01804-1/10W1-T 1 H2511-02493-1/10W1-T R28, R29, R33, R35 RES, SMD, 0603, 100, 1/10W, 1%, TF, ROHS RES, SMD, 0603, 1k, 1/10W, 1%, TF, ROHS KOA RK73H1JT1000F KOA RK73H1JTTD1001F RES, SMD, 0603, 10k, 1/10W, KOA 1%, TF, ROHS RK73H1JT1002F RES, SMD, 0603, 1M, 1/10W, PANASONIC 1%, TF, ROHS ERJ-3EKF1004V R5 RES, SMD, 0603, 150k, 1/10W, 1%, TF, ROHS YAGEO RC0603FR-07150KL ea R2 RES, SMD, 0603, 1.8M, 1/10W, 1%, TF, ROHS VENKEL CR0603-10W-1804FT 1 ea R39 RES, SMD, 0603, 249k, 1/10W, 1%, TF, ROHS YAGEO 9C06031A2493FKHFT H2511-03303-1/10W1-T 1 ea R23 RES, SMD, 0603, 330k, 1/10W, 1%, TF, ROHS YAGEO RC0603FR-07330KL H2511-04990-1/10W1-T 1 ea R37 RES, SMD, 0603, 499, 1/10W, 1%, TF, ROHS KOA RK73H1JTTD4990F H2511-05110-1/10W1-T 2 ea R1,R63 RES, SMD, 0603, 511, 1/10W, 1%, TF, ROHS VENKEL CR0603-10W-5110FT H2512-00010-1/8W1-T 1 ea R76 RES, SMD, 0805, 1, 1/8W, 1%, TF, ROHS VENKEL CR0805-8W-1R00FT 12 AN1444.0 December 15, 2008 Application Note 1444 ISL9208EVAL2Z Bill of Materials (Continued) PART NUMBER QTY UNITS REFERENCE DESIGNATOR DESCRIPTION MANUFACT. H2515-00390-1W1-T 7 ea R9, R11, R13, R15, RES, SMD, 2512, 39, 1W, R17, R19, R21 1%, TF, ROHS SJ-5003-BLACK 4 ea 3M Bottom four corners BUMPONS, 0.44inWx0.20inH, DOMETOP, BLACK 5X8-STATIC-BAG 1 ea Place assy in bag DNP 0 ea B1-B7 DO NOT POPULATE OR PURCHASE DNP 0 ea J10 DO NOT POPULATE OR PURCHASE DNP 0 ea J42, P- DO NOT POPULATE OR PURCHASE DNP 0 ea VC1-VC7 DO NOT POPULATE OR PURCHASE DNP 0 ea a) CSns, DSns, CFET, DFET, TI, RGO, AO, SCL, DO NOT POPULATE OR PURCHASE DNP 0 ea LABEL-SERIAL NUMBER 1 ea NTSD1XH103FPB50 1 ea BAG, STATIC, 5x8, ZIP LOC VENKEL INTERSIL MANUFACTURER PART CR2512-1W-39R0FT SJ-5003SPBL 212403-013 DO NOT POPULATE OR b) SDA, PSCL, PSDA, VMon, WKU, PURCHASE WP LABEL, FOR SERIAL NUMBER AND BOM REV # JP2 THERMISTOR-NTC, TH, 10k, MURATA 15mW, 1%, 50mm, B VALUE = 3380k, ROHS NTSD1XH103FPB50 The following screen should pop up. Appendix 1 Installing the DeVaSys USB to I2C Board Software Obtain the DeVaSys software along with the GUI code from the Intersil website on the ISL9208 page. Copy and extract the files from the “ISL92xx Eval Kit Software Release V1.41” zip file to the PC at whichever location is desired. Disconnect the DeVaSys board from the ISL9208, ISL9216 board. Plug in the DeVaSys board into the USB port. Select “Yes, this time only” and click “Next”. 13 AN1444.0 December 15, 2008 Application Note 1444 Then, this screen will come up: This should install the software, eventually bringing up the following screen: Select “Install from a list or specific location” and click “Next” A screen like the next one will come up: Click “Finish” and you’re done. Appendix 2 Communication Troubleshooting IF THE GUI STARTS UP WITH ALL ITEMS “GRAYED OUT” 1. Check that the I2C cable is connected properly. 2. Check that the board is powered and that the RGO voltage is ~3.3V. 3. If the RGO voltage is not powered to the right voltage, move to the power supply troubleshooting section. 4. Make sure that the board drivers are installed correctly. On the DeVaSys USB to I2C interface board, there should be one red LED and one green LED lit. Browse for the Software in directory “ISL9208_16 Eval Kit SW and docs” folder then click “Next”. 5. Use a scope to see that the I2C communication is correct at the board. Monitor the SCL and the SDA lines while initiating a read of the ISL9208 status register. Set the scope to single trigger on the falling edge of SCL. Power Supply Troubleshooting IF RGO DOES NOT HAVE THE CORRECT VOLTAGE 1. Check that the voltage on each of the input terminals are between 2.6V and 4.5V. 2. Check that there is no unexpected load on the RGO output. ISL9208 Troubleshooting IF THE AO VOLTAGES ARE READING INCORRECTLY AT THE AO PIN 1. Check that all cell balance outputs are off. 2. Make sure that there is no series resistance between the battery and the input pins of the ISL9208EVAL2Z board and that the input voltage is between 2.6V and 4.3V. 14 AN1444.0 December 15, 2008 Application Note 1444 IF THE AO VOLTAGES ARE READING INCORRECTLY ON THE GU 1. Check that the RGO output is 3.3V. GUI and microcontroller calculations assume the RGO voltage is 3.3V. Any variation translates directly into errors in the GUI screen value. 2. Power-down the board and stop the GUI. Power-up the board and restart the GUI. This should clear any communication problems. 3. Turn off the cell balancing. On the ISL9208EVAL2Z board, external PNP transistors are used to provide external balancing elements. When the PNP transistor turns on, current flows into the CBN pin and out the VCELL(N-1) pin. The current flowing out the VCELL(N-1) pin causes the VCELL voltage on one side of the balanced input to go up and the other side to go down. This difference can be up to 200mV to 300mV. This is an inherent design deficiency. An alternative is to replace the PNP transistors with P-Channel FETs or reduce the value of the series resistors on the inputs. However, these changes introduce some reliability concerns during a pack “dead short circuit”. A future revision of the board is planned that will address these issues. Other Questions Forward any ISL9208EVAL2Z questions to the Intersil Application Engineer at [email protected] Intersil Corporation reserves the right to make changes in circuit design, software and/or specifications at any time without notice. Accordingly, the reader is cautioned to verify that the Application Note or Technical Brief is current before proceeding. For information regarding Intersil Corporation and its products, see www.intersil.com 15 AN1444.0 December 15, 2008