PS2070 PS200 Switch Mode Charger Evaluation Board Features • Complete PS200 Battery Charger application circuit • Direct connection to Microchip’s PowerInfo™ 2 (PS051) interface board and PowerCal™ 2 (PS052) calibration board • Configure PS200 with PS020 PowerTool™ 200 PC software • Change or upgrade firmware with In-Circuit Serial Programming™ (ICSP™) • Evaluate charger circuits with: - Voltage max: 16.8V - Current max: 2.0A • Overall mechanical dimensions: - 2.5 W x 4.0 L (inches) - 63.5 W x 101.6 L (millimeters) 2005 Microchip Technology Inc. Ordering Information Part Number Description PS2070 PS200 Charger Evaluation Board and PS020 PowerTool™ 200 Software PS2070EV PS2XX Charger Evaluation Board, PS051 Configuration Interface and PS020 PowerTool™ 200 Software DS21927A-page 1 PS2070 1.0 PRODUCT OVERVIEW The PS2070 evaluation board is a complete charger evaluation circuit subsystem based on the Microchip PS200 charge controller. The board is designed to operate with a rechargeable battery pack consisting of lithium based, nickel based or lead acid cells. The board includes the Microchip PS200 battery monitor IC in a socket, a 100 mOhm sense resistor and power components to enable charging currents to a maximum of 2.0A. 2.0 GENERAL SETUP The Microchip PS2070 evaluation board plugs directly into a PowerInfo 2 interface board or PowerCal 2 calibration board. These development tools, connected to a PC running PowerTool™ 200 (PS020) development software, form a complete PS200 battery charger evaluation environment. The information that follows will guide you through the setup of the various features available. Please refer to the PowerInfo 2 or PowerCal 2 data sheet for information on setting up those products. 2.1 Connectors • JBat – Battery input connector. The battery pack to be charged is connected here. Looking into the connector on the board, the pins from left to right are: - BAT+: Battery pack positive - CLK: SMBus clock - DTA: SMBus data - TMP: Temperature - GND: Battery pack negative • PHost – Charger host interface. The PowerInfo 2 or PowerCal 2 is connected here. Looking into the connector on the board, the pins from left to right are: - GND: Battery pack negative - TMP: Temperature - DTA: SMBus data - CLK: SMBus clock - BAT+: Battery pack positive • J1 – In-Circuit Serial Programming (ICSP) interface. The PS200 Flash memory can be reprogrammed via this interface. This is only necessary to upgrade to a newer firmware revision or install firmware for a different rechargeable chemistry. • J3 – Charger DC power supply input. Input voltage range is 18 to 22 VDC. The supply must be current limited or fused to a maximum of 2.5A. DS21927A-page 2 2.2 Jumpers • JP2 – Jumper to configure board for standard operation with PS200 pin 2 (LED 2) connected to the red LED or connected to PHost CLK for communication with PowerTool 200 PC software. Jumper Position 1-2 2-3 PS200 pin 2 to Red LED X O PS200 pin 2 to PHost CLK O X Legend: O = open, X = connect • JP18 – Jumper to disconnect the overvoltage protection divider from PS200 pin 18 (VOVP). This allows pin 18 to be used for ICSP. Jumper Position 1-2 Disable VOVP (Enable ICSP™) O Enable VOVP input X Legend: O = open, X = connect • JP19 – Jumper to disconnect the temperature divider from PS200 pin 19 (TEMP). This allows pin 19 to be used for ICSP. Jumper Position 1-2 Disable TEMP (Enable ICSP™) O Enable TEMP input X Legend: O = open, X = connect • OPV – Jumper to configure overvoltage protection (OVP) limit. Jumper Position 1-8 2-7 3-6 4-5 (1 Cell) (2 Cells) (3 Cells) (4 Cells) OVP 4404 mV X O O O OVP 8808 mV O X O O OVP 13200 mV O O X O OVP 17640 mV O O O X No OVP limit O O O O Legend: O = open, X = connect 2005 Microchip Technology Inc. PS2070 • VIN – Jumper to configure voltage sense scaling factors. The values indicate the maximum battery voltage. 1-8 2-7 3-6 4-5 (1 Cell) (2 Cells) (3 Cells) (4 Cells) 5V X O O O 10V O X O O 15V O O X O 16.8V O O O X Legend: O = open, X = connect Configuration for Lithium Pack Chemistries Before attaching the lithium battery pack, please insure that jumpers OVP and VIN are properly configured for the maximum pack voltage. Attach the battery pack to the JBat connector by attaching the top of the pack (positive) to the left most pin (looking into the connector) and the bottom of the pack (negative) to the right most pin. 2.4 Configuration for Lead Acid Chemistries Lead acid configuration will be updated when firmware is available. Jumper Position 2.3 2.5 Configuration for Nickel Pack Chemistries 3.0 FUNCTIONAL DESCRIPTION 3.1 PS2070 Switch Mode Charger Evaluation The Switch Mode Charger Evaluation Board includes a simple buck topology charger using the PS200 IC. The PS200 monitors the battery to determine its status. The control is a dual loop design with hardware based current feedback control and firmware based voltage feedback control. The hardware is configured as a constant current loop, controlling the Pulse-Width Modulator (PWM). The firmware sets the current level by adjusting the PWM signal at PS200 pin 5 (CTRLOUT). The firmware also measures the voltage and dynamically adjusts the current to maintain the fully charged constant voltage value. Please refer to the “PS200 Data Sheet” for details on configuring the PS200. Overvoltage protection – the PS200 provides overcharge protection. This circuit can be disabled by leaving all OVP jumper positions open. JP18 should still be connected. Rechargeable nickel based battery packs can be attached to the PS2070. Before attaching battery cells, please insure that jumpers OVP and VIN are properly configured for the maximum pack voltage. Attach the battery pack to the JBat connector by attaching the top of the pack (positive) to the left most pin (looking into the connector) and the bottom of the pack (negative) to the right most pin. 2005 Microchip Technology Inc. DS21927A-page 3 1.5K 1.5K R2 R10 1 2 3 4 5 A1 B1 A2 B2 A3 B3 A4 B4 A5 B5 PHost INVERTED COMBICON CONNECTOR GND TMP DTA CLK BAT+ PowerInfo™/PowerCal™ HOST INTERFACE R5/R9/C9 FORM A LOW-PASS FILTER WITH A 4.7 MILLISECOND TIME CONSTANT. CTRLOUT IS COMPARE OUTPUT, WHICH IS A FIRMWARE CONTROLLED PWM THAT SETS CURRENT LEVEL. R5/R9/C9 SCALE AND FILTER THE VOLTAGE FROM CTRLOUT, FOR APPLICATION TO OP1. FIRMWARE CURRENT-CONTROL OUTPUT: WHEN BAND GAP IS PROPERLY TRIMMED, VDD IS SET AT 5.000 VDC. RED LED GRN LED VDD R9 20.0K JP2 1 2 3 C1 100 nF 18 (SIP) OP1 120 nF 10 nF C7 CP2 PS200 DUT CP1 17 HARDWARE FEEDBACK TO PWM: OP1 IS ERROR AMP. R7/R8/C7/C8 ARE LOOP COMPENSATION COMPONENTS. 1.27K C8 LOOPIN R7 1 2 JP18 VREF CTRLOUT CTRLIN VSS VDD MCLR 20.0K 8 5 9 20 1 4 LED2 R8 FDBK 20.0K R12 R5 20.0K C9 470 nF CTRL 1.5K R4 2 LED1 1 2 3 4 5 6 10 - RST JP1 C18 4.7 µF 3 13 12 IN LKDS J3 OUT OUT 7 6 POWER MOSFET DRIVER OP2/R13/R14: CURRENT SCALING. SET FOR RANGE OF 0-2586 mA (2.53 mA/BIT). 47 INTP R3 4 D1 MBRS340 SNTP C22 4.7 µF MBRS340 D2 R30 PSTP 10.0K 30.9K 20.5K 10.5K 232 10.0K R18 R24 R23 R22 R21 137K 100K 63.4K 26.7K R34 R33 R32 R31 VIN 4 5 3 6 2 7 1 8 OVP 4 5 3 6 2 7 1 8 PGND2 R40: CURRENT SENSE RESISTOR PGND 0.100 R40 BAT- OUTP BUCK CONVERTER POWER SECTION TEMP 4404 mV (JUMPER 1-8) 8808 mV (JUMPER 2-7) 13200 mV (JUMPER 3-6) 17640 mV (JUMPER 4-5) BAT+ BAT+ CLK DTA TMP GND 1 2 3 4 5 JBat 5-PIN RIGHT-ANGLE COMBICON BATTERY INTERFACE CONNECTOR. (MATES WITH PSX070 PCBs) 1 CELL: 4.969 mV/BIT (JUMPER 1-8) 2 CELL: 9.971 mV/BIT (JUMPER 2-7) 3 CELL: 15.01 mV/BIT (JUMPER 3-6) 4 CELL: 20.18 mV/BIT (JUMPER 4-5) VOLTAGE SENSE SCALING FACTORS: (VIN HEADER) JUMPER ONLY ONE PIN PAIR AT A TIME NO OVP -- LEAVE JUMPER OFF HEADER. 1 CELL: 2 CELL: 3 CELL: 4 CELL: OVP TRIP POINT SELECTION: (OVP HEADER) JUMPER ONLY ONE PIN PAIR AT A TIME FOR REVISION HISTORY, SEE 826196 CHANGE LOG EVALUATION/TEST BOARD FOR PS200 C21 4.7 µF 68UH L1 Q1 NDS9435A D2 PREVENTS REVERSE CURRENT WHEN CHARGER IS TURNED OFF. INPUT VOLTAGE RANGE: 18 TO 22 VDC SUPPLY MUST BE CURRENT LIMITED OR FUSED AT A MAXIMUM OF 2.5A. U1 TC4431COA C23 4.7 µF CHARGER DC POWER SUPPLY INPUT (WITH POWER INDICATOR). RIGHT-ANGLE COMBICON CONNECTOR. R6/C16/D6 CONVERT 400 kHz PWM OUTPUT TO RAMP WAVEFORM, WHICH IS FED BACK TO CP2 AND COMPARED TO ERROR AMP SIGNAL TO DETERMINE PWM DUTY CYCLE. CHGFBK 1.00K R13 D6 BAT54 C6 100 nF BATID 2 3 620 R1 R19 10.0K R11 POWER 1.5K JP19 2 1 CHGOUT R6 3.01K 16 6 11 15 19 C16 1.0 nF C14 OPEN 19.6K R14 IFBINA IFBINB CHGFBK PWM SHDN CHGOUT + OP2 - IFBOUT BATID TEMP GND C3 100 nF VI HVOUT VIN 1 2 (MODULAR) 3 VOVP + J1 1 2 1 2 3 4 5 6 IFBOUT 14 R20 10.0K 8 1 VDD VDD GND GND SHDN LOOPFBK 7 + - DS21927A-page 4 4 5 FIGURE 4-1: 1 2 3 4.1 5 6 7 8 4.0 + ICSP™ INTERFACE CONNECTORS: OPEN JP2 AND JP5 WHEN USING ICSP/ICD. PS2070 BOARD DESCRIPTION PCB schematics and bill of materials are included here for completeness. Schematic and Bill of Materials are also available in the PowerTool™ 200 PC software. Schematic PS2070 BOARD SCHEMATIC 2005 Microchip Technology Inc. PS2070 4.2 Bill of Materials TABLE 4-1: PS2070 BILL OF MATERIALS Symbols Description Manufacturer Manufacturer PN Qty. Raw PCB, PS2070 Microchip 04-826196 Rev. 2.1 1 C7 Capacitor, Ceramic, 120 nF, 25V, +/-10%, X7R dielectric, 1206 Panasonic ECJ-3VB1E124K 1 C9 Capacitor, Ceramic, 470 nF, 25V, +/-10%, X7R dielectric, 1206 Murata GRM319R71E474KA01D 1 C16 Capacitor, Ceramic, 1.0 nF, 50V, +/-10%, X7R dielectric, 1206 Panasonic ECU-V1H102KBM 1 C1, C3, C6 Capacitor, Ceramic, 100 nF, 50V, +/-10%, X7R dielectric, 1206 BC Components 1206B104K500BT 3 C8 Capacitor, Ceramic, 10 nF, 50V, +/-10%, X7R dielectric, 1206 Panasonic ECU-V1H103KBM 1 C18, C21-C23 Capacitor, Ceramic, 4.7 µF, 25V, +/-20%, X5R dielectric, 1206 Panasonic ECJ-3YB1E475M 4 GRNLED, POWER LED, clear green, 1206 package Lumex SML-LX1206GC-TR 2 REDLED LED, clear red, 1206 package Lumex SML-LX1206SIC-TR 1 D1, D2 Schottky Diode, 40V, 3A, SMC package On Semiconductor International Rct. Central Semi. Central Semi. MBRS340T3 MBRS340TR CMSH3-40-PST CMSH3-40L-PST 2 D6 Diode, Schottky, 200 mA/30V, SOT-23 Zetex BAT54TA 1 JP2, JP18, JP19, OVP, VIN Connnector, shorting jumper, female, 2-position, 100 mil spacing, mates with 25 mil square pins, 15-microinch gold over nickel. AMP 382811-6 5 J3 Header, pluggable terminal block, 5.08 mm pitch x 2 positions, 12A/250V, right-angle, closed end Phoenix 1757242 1 JBat Header, pluggable terminal block, 5.08 mm pitch x 5 positions, 12A/250V, right-angle, closed end Phoenix 1757271 1 DUT Socket, 20-pin DIP, 0.300" spacing, machine pin Mill-Max 110-93-320-41-001000 1 J1 Connector, modular, 6-position/6-contact, right-angle mount AMP 520470-3 1 BAT-, GND, PGND, PGND2 Test point, 0.125" OD, for 0.062" hole, black Keystone 5011 4 BAT+ Test point, 0.125" OD, for 0.062" hole, red Keystone 5010 1 BATID, CHGFBK, CHGOUT, CTRL, FDBK, IFBOUT, TEMP, VI Test point, 0.125" OD, for 0.062" hole, white Keystone 5012 8 L1 Inductor, 68 µH, 1.8A, 130 mOhms DCR, 730 x 600 mil SMT package, -40°C to +85°C Coilcraft DO5022P-683 1 Bumper, hemispherical, 0.44" D x 0.20" H, transparent plastic 3M SJ-5303 (CLEAR) 4 OVP, VIN Connector, break apart PCB header, straight, 3M 2-row x 36-pin, 100 x 100 mil spacing, 235 mil/100 mil/ 145 mil length, 25 mil square pins, 10-microinch gold 929665-09-36-I 1 JP2, JP18, JP19 Connector, break apart PCB header, straight, 36-pin, 100 mil spacing, 235 mil/100 mil/145 mil length, 25 mil square pins, 10-microinch gold 929647-09-36-I 1 J3 Pluggable terminal block, 5.08 mm pitch x 2 positions, Phoenix 12A/250V 1757019 1 JBat Pluggable terminal block, 5.08 mm pitch x 5 positions, Phoenix 12A/250V 1757048 1 2005 Microchip Technology Inc. 3M DS21927A-page 5 PS2070 TABLE 4-1: Symbols PS2070 BILL OF MATERIALS (CONTINUED) Description Manufacturer Manufacturer PN Qty. PHost Plug, inverted Combicon, 5.08 mm pitch x 5 positions, Phoenix 12A/250V 1786433 1 Q1 MOSFET, P-channel Enhancement mode, -30V, -5.3A, Fairchild Semi. 50 mOhms, 2.5W, SO-8, -55°C to +125°C NDS9435A 1 R13 Resistor, film, 1206, 1%, 1.00 kOhms Panasonic ERJ-8ENF1001V 1 R7 Resistor, film, 1206, 1%, 1.27 kOhms Panasonic ERJ-8ENF1271V 1 R3, R18-R20 Resistor, film, 1206, 1%, 10.0 kOhms Panasonic ERJ-8ENF1002V 4 R22 Resistor, film, 1206, 1%, 10.5 kOhms Panasonic ERJ-8ENF1052V 1 R33 Resistor, film, 1206, 1%, 100 kOhms Panasonic ERJ-8ENF1003V 1 R34 Resistor, film, 1206, 1%, 137 kOhms Panasonic ERJ-8ENF1373V 1 R14 Resistor, film, 1206, 1%, 19.6 kOhms Panasonic ERJ-8ENF1962V 1 R5, R8-R9, R12 Resistor, film, 1206, 1%, 20.0 kOhms Panasonic ERJ-8ENF2002V 4 R23 Resistor, film, 1206, 1%, 20.5 kOhms Panasonic ERJ-8ENF2052V 1 1 R21 Resistor, film, 1206, 1%, 232 ohms Panasonic ERJ-8ENF2320V R31 Resistor, film, 1206, 1%, 26.7 kOhms Panasonic ERJ-8ENF2672V 1 R6 Resistor, film, 1206, 1%, 3.01 kOhms Panasonic ERJ-8ENF3011V 1 R24 Resistor, film, 1206, 1%, 30.9 kOhms Panasonic ERJ-8ENF3092V 1 1 R32 Resistor, film, 1206, 1%, 63.4 kOhms Panasonic ERJ-8ENF6342V R2, R4, R10, R11 Resistor, film, 1206, 5%, 1.5 kOhms Panasonic ERJ-8GEYJ152V 4 R30 Resistor, film, 1206, 5%, 47 ohms Panasonic ERJ-8GEYJ470V 1 R40 Resistor, metal strip, 2512, 1%, 0.100 ohms Vishay WSL2512-0.100-1%-R86 1 R1 Resistor, film, 2512, 5%, 620 ohms Panasonic ERJ-1TYJ621U 1 RST Switch, SPST momentary tact, surface mount, 6 mm square, 4.3 mm high, 260 G-force E-Switch TL3301NF260QG 1 DUT IC, Battery Charger Microcontroller, 20-pin DIP, -40°C to +85°C Microchip PS200 1 U1 IC, Power MOSFET Driver circuit, 30V, 1.5A, inverting, Microchip with UV lockout, SO-8, 0°C to +70°C TC4431COA 1 DS21927A-page 6 2005 Microchip Technology Inc. PS2070 4.3 Mechanical Dimensions Overall Dimensions: 2.5" W x 4.0" L PS2070 DIMENSION DETAILS 2063 (mil) C6 500 (mil) D1 R30 R20 L1 C18 JP18 R19 R31 R32 R33 R34 R18 TEMP PGND U1 D6 C16 CHGFBK C23 175 (mil) R40 C21 D2 Q1 340 (mil) C22 PSTP SNTP INTP OUTP 1100 (mil) 2013 (mil) 188 (mil) 415 (mil) 250 (mil) 1 JBat J3 R1 PGND2 R4 R14 R11 JP19 BATID R6 CHGOUT POWER C14 R13 1548 (mil) REDLED R2 IFBOUT 2500 (mil) 6 J1 GRNLED R10 2000 (mil) C1 R12 1 BAT+ C3 R8 C8 (J1 CENTER) R21 R22 R23 R24 R3 VIN R5 VI JP2 DUT 1 C9 PHost GND FDBK CTRL JP1 1 RST R12 C7 R7 R9 1000 (mil) BAT- OVP FIGURE 4-2: 3625 (mil) 4000 (mil) FOR REVISION HISTORY, REFER TO 826196 CHANGE LOG. BODY OF J4 IS 1080 MILS WIDE, AND OVERHANGS BOARD EDGE BY 23 MILS. 2005 Microchip Technology Inc. DS21927A-page 7 PS2070 5.0 DEVELOPMENT TOOL SUMMARY 5.1 Microchip provides all the necessary hardware and software to enable easy tailoring of battery control algorithm parameters and cell performance models to meet specific application requirements and attain the highest accuracy available anywhere. Table 5-1 summarizes the development tool offering from Microchip to support the PS2070. Please refer to the Microchip web site for ordering information and design documentation (including schematics) at www.microchip.com. TABLE 5-1: Reference Documents This data sheet provides an overview of the PS2070 Switch Mode Charger Evaluation Board. For further information on the PS200 and development tool operations, please refer to the following documents available for download at www.microchip.com. MICROCHIP DEVELOPMENT TOOL SUMMARY Development Tool Use PowerInfo™ 2 hardware with PowerTool™ 200 software (PS051) Read and write register values, EEPROM programming and test PowerCal™ 2 hardware with PowerTool™ 200 software (PS052) Read and write register values, EEPROM programming, test and calibration TABLE 5-2: Document Number MICROCHIP REFERENCE DOCUMENTS Documents Available DS21891 PS200 PowerSmart® Configurable Lithium Ion/Lithium Polymer Battery Charger Data Sheet DS21815 PS051 PowerInfo™ 2 Configuration Interface Data Sheet DS21817 PS052 PowerCal™ 2 Calibration Platform Data Sheet DS21925 PS020 PowerTool™ 200 Development Software User’s Guide DS21927A-page 8 2005 Microchip Technology Inc. PS2070 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. MICROCHIP MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND WHETHER EXPRESS OR IMPLIED, WRITTEN OR ORAL, STATUTORY OR OTHERWISE, RELATED TO THE INFORMATION, INCLUDING BUT NOT LIMITED TO ITS CONDITION, QUALITY, PERFORMANCE, MERCHANTABILITY OR FITNESS FOR PURPOSE. Microchip disclaims all liability arising from this information and its use. Use of Microchip’s products as critical components in life support systems is not authorized except with express written approval by Microchip. No licenses are conveyed, implicitly or otherwise, under any Microchip intellectual property rights. Trademarks The Microchip name and logo, the Microchip logo, Accuron, KEELOQ, MPLAB, PIC, PICmicro, PowerSmart and SmartShunt are registered trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. SmartSensor and The Embedded Control Solutions Company are registered trademarks of Microchip Technology Incorporated in the U.S.A. PowerCal, PowerInfo, PowerMate, PowerTool, Select Mode, Smart Serial and SmartTel are trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. All other trademarks mentioned herein are property of their respective companies. © 2005, Microchip Technology Incorporated. Printed in the U.S.A., All Rights Reserved. Printed on recycled paper. 2005 Microchip Technology Inc. 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