PS5163 PS501 Three-Cell Battery Manager Module with LED SOC Display for Lithium Chemistries Features • PS501 tested, fully populated modules for evaluation • Designed to work with 3 series cell Lithium chemistry configurations • Performs all major Lithium battery management functions, including: - Accurate capacity monitoring - Lithium cell protection • SOC display with four LEDs and a switch • Fully compliant with industry standard Smart Battery Data Specification v1.1a • SMBus v1.1 with PEC/CRC-8 communication with system host • High accuracy measurement of charge/discharge current, voltage and temperature with on-chip 16-bit integrating A/D • Precise capacity reporting using Microchip patented algorithms and 3D battery cell models • 3D models and “learned” parameters stored in integrated memory • Complete hardware and software development tools available: - PS050 PC software - ICD (In-Circuit Debugger) port to support development of custom code • Extremely low-power operation: - Run mode: 170 µA typical - Low-Voltage Sleep mode: 45 µA typical - Shelf-Sleep mode: 25 µA typical • Overall mechanical dimensions: - 0.525 W x 2.500 L (inches) - 13.3 W x 63.5 L (millimeters) 2004 Microchip Technology Inc. Ordering Information Part Number PS5163 Description Li Ion/Poly – 3 series cells DS21851B-page 1 PS5163 1.0 GENERAL DESCRIPTION The PS5163 module is a complete smart battery controller subsystem based on the Microchip PS501 field reprogrammable battery manager with patented Accuron® technology. The module is designed to operate in a battery pack consisting of three (3) series connected Li-based cells. The module consists of the Microchip PS501 battery manager IC with a four-LED SOC display and an optional connection for an external thermistor. Step 1) Step 2) Step 3) 1.1 Quick Start – Pack Assembly Follow these directions to assemble a pack with the PS5163 module. • Use standard precautions when handling static sensitive devices. • Modules should be connected to battery cells in the order indicated below to insure proper start-up and operation. Wires should be attached to the modules first and then connected to the battery cells as instructed. • The connection sequence is critical to successful use of the PS501 family of CMOS ASICs. The pack positive should be securely connected to the module first, followed by the intermediate cells from most positive to least positive and finally, pack negative. FIGURE 1-1: DS21851B-page 2 Step 4) Step 5) Step 6) Step 7) Configure the module for optional external thermistor use. PS5163 modules are shipped configured to use the internal temperature sensor only. To add an external thermistor to the board, remove resistor R16 (side 2) and connect the thermistor across via TN and TR. Connect wires to module. Use large diameter wire (18 AWG-20 AWG) for current carrying lines from VR, V1, B+ and BN. All others are signal only lines (24 to 22 AWG). Connect external connector to BN, T, C, D and B+. Connect V1 to the most positive point on the battery cell stack. Connect the negative end of the top-most cell to V2 and the negative end of the second cell to V3. Connect VR to the most negative point on the battery cell stack. Program the assembled pack using Microchip’s software and PowerCal™ board or PowerInfo™ board hardware. The memory parameters can be changed at will using the utilities on the memory page in the software. Step 8) Calibrate the pack using the software and PowerCal™ board hardware. The pack is now ready for use. CONNECTION POINTS (SIDE 1) 2004 Microchip Technology Inc. PS5163 FIGURE 1-2: BOARD ASSEMBLY (SIDE 1) FIGURE 1-3: BOARD ASSEMBLY (SIDE 2) 2004 Microchip Technology Inc. DS21851B-page 3 PS5163 2.0 FUNCTIONAL DESCRIPTION 2.1 PS501 Fuel Gauge The module fuel gauge provides State-Of-Charge (SOC) and battery status data in accordance with the SMBus standards version 1.1. The PS501 monitors the cell voltages, battery temperature and current to determine SOC and battery status. The State-Of-Charge calculations are compensated for cell self-discharge. The remaining time calculation is compensated for temperature and discharge rate. The parameters for determining battery status flags and alarm thresholds are all programmable, as is the battery design capacity and the battery performance model data. Please refer to the “PS501 Data Sheet” (DS21818) for details on configuring the PS501 device. 2.2 Primary Safety The primary safety circuit provides cell protection from conditions of overcharge, overdischarge and overcurrent. The analog safety IC measures individual cell voltages, current and voltage across the safety FETs. These values are compared against internal reference values and the gates of two N-channel power MOSFETs are controlled based on the comparison results. 3.0 BOARD DESCRIPTION PCB schematics and bill of materials are included here for completeness. To download the full size schematic and BOM, please visit the Microchip web site. 3.1 Mechanical Dimensions Overall Dimensions: 2500 mils x 525 mils DS21851B-page 4 2004 Microchip Technology Inc. A B C VR V3 V2 V1 1 R11 R12 R13 2 C11 100 nF 240 V3 1.0K 1.0K 1.0K 240 V2 VR 20 V1 CELL CONNECTION C12 100 nF R3 R2 R1 REMOVE R16 IF AN EXTERNAL THERMISTOR IS USED TN 12 51 C13 100 nF 8 9 10 11 16 17 TR R15 VC1 VC2 VC3 VC4 SEL CTL VDD C16 100 nF 0.020 R36 20 20 HV1 MCLR HV2 6 5 2 1 PRIMARY SAFETY CIRCUIT S8254A CCT CDT VMP COP 3 R7 R8 C9 C8 10 nF 100 nF LED0 LED1 LED2 LED3 IO4 IO5 IO6-PGC IO7-PGD SSAFE CURRENT SENSE RESISTOR 6 7 24 25 26 27 2 3 4 5 19 20 21 22 23 R26 221K 18 DOP U2 R19 220 SMB-CLK SMB-DTA GPIO(0) GPIO(1) GPIO(2) GPIO(3) GPIO(4) GPIO(5) GPIO(6) GPIO(7) GPIO(8) GPIO(9) GPIOHV1 MCLR GPIOHV2 ROSC PS501 3 WITH CAPACITOR VALUES SHOWN: OVERVOLTAGE TIME DELAY: 100 mSEC UNDERVOLTAGE TIME DELAY: 100mSEC OVERCURRENT TIME DELAY: 10 mSEC 15 14 13 12 10 11 16 VSSD VDDD VSSA VDDA VC(4) VC(3) VC(2) VC(1) VNTC VREFT U1 C15 2.2 µF C7 330 nF 28 1 C5 330 nF 13 TN TR GROUND PLANE CONNECTION V5 C1 330 nF C2 100 nF C3 100 nF R5 3.65K R16 0 RSHN 15 RSHP 14 3 20K SW1 R6 LED3 LED2 LED1 LED0 4 4 V5 CAUTION: R23 5.1K Q1 IRF7424 8 7 6 5 5 8 7 6 5 Q2 IRF7424 3 2 1 R21 1.0M C17 1 100 nF R31 5.1K 240 240 365 R17 20K D1 AZ23C5V6 3 2 6 11/21/2003 DATE *** CONFIDENTIAL *** THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION THAT IS THE INTELLECTUAL PROPERTY OF MICROCHIP TECHNOLOGY, INC. CHECKED R. CASEBOLT DRAWN APPROVALS PowerSmart Products Group 2745 Dallas Parkway, Suite 400 Plano, TX 75093 03-826171 REV 3-1.sch 6 FILE B+ B- C D T 1.0 nF C18 BN C D T B+ 15-Mar-2004 15:24:41 3.1 REV http://www.microchip.com 469-241-0087 Voice/469-241-0106 Fax Sheet 1 of 1 03-826171 DRAWING NO. NONE 5 CODE IDENT NO. SCALE B SIZE PS5163 SCHEMATIC TITLE Microchip Technology, Inc. FOR REVISION HISTORY, REFER TO 826171 CHANGE LOG. CONTRACT NO. R9 R10 R35 3 PACK CONNECTIONS F1 SFD167A NDS355N Q3 1 PS501-BASED REFERENCE DESIGN FOR 3-CELL Li-ION APPLICATIONS. HV2 HV1 IO6-PGC IO7-PGD MCLR BNAUX VDDD IO4 IO5 WHEN USING ICD PORT, A 10K RESISTOR MUST BE CONNECTED BETWEEN VDDD AND BNAUX. 3 2 1 4 2 4 EXTERNAL THERMISTOR CONNECTIONS (SEMITEC 103AT OR 103ETB -- 10K AT 25°C) 4 VINI VSS 2004 Microchip Technology Inc. NC NC ICD PORT A B C D FIGURE 3-1: 8 9 4 3.2 7 D 1 PS5163 Schematic PS5163 BOARD SCHEMATIC DS21851B-page 5 PS5163 3.3 Bill of Materials TABLE 3-1: PS5163 BILL OF MATERIALS Symbols Description Manufacturer Manufacturer PN Qty. Raw PCB, PS5163 Microchip 04-826171 REV. 3.1 1 C9 Capacitor, Ceramic, 10 nF, 25V, +/-10%, X7R dielectric, 0603 Panasonic ECJ-1VB1E103K 1 C18 Capacitor, Ceramic, 1.0 nF, 50V, +/-10%, X7R dielectric, 0603 Panasonic ECJ-1VB1H102K 1 C2-C3, C11-C13, Capacitor, Ceramic, 100 nF, 25V, +80%/-20%, C16-C17 Y5V dielectric, 0603 Panasonic ECJ-1VF1E104Z 7 C8 Capacitor, Ceramic, 100 nF, 25V, +/-10%, X7R dielectric, 0805 Panasonic ECJ-2VB1E104K 1 C1, C5, C7 Capacitor, Ceramic, 330 nF, 25V, +80%/-20%, Y5V dielectric, 1206 Panasonic ECJ-2YF1E334Z 3 C15 Capacitor, Ceramic, 2.2 µF, 25V, +/-10%, X7R dielectric, 1206 Panasonic ECJ-3YF1E225Z 1 LED0-LED3 LED, clear green, 1206 package Lumex SML-LX1206GC-TR 4 D1 Dual Zener Diode, 5.6V, +/-5%, 300 mW, common anode, SOT-23 Diodes Inc. General Semi. AZ23C5V6-7 AZ23-C5V6 1 F1 Fuse, battery pack protector, 7A, 36 VDC, 50A breaking capacity, 5 +/- 1.5 mOhm resistance, 31.6 +/- 3.2 ohms heater resistance, 11.1-25.0V heater operating voltage range, UL248-14, 3-terminal surface mount package Sony Chemicals SFD-167A 1 Q1-Q2 MOSFET, P-channel Enhancement mode, -30V, 11A, 13.5 mOhms, 1.9W, SO-8 Int. Rectifier Toshiba IRF7424 TPC8108 2 Q3 MOSFET, N-channel Enhancement mode, 30V, 1.6A, 0.125 ohms, 500 mW, SOT-23 Fairchild Semi. Fairchild Semi. NDS355N NDS355AN 1 R5 Resistor, film, 0603, 1%, 3.65 KOhms Panasonic ERJ-3EKF3651V 1 R35 Resistor, film, 0603, 1%, 365 ohms Panasonic ERJ-3EKF3650V 1 R26 Resistor, film, 0603, 1%, 221 KOhms, 25 ppm, TC Susumu Co. Ltd. RR0816P-2213-D-34D 1 R16 Resistor, zero ohm, 0603 Panasonic ERJ-3GEY0R00V 1 R11-R13 Resistor, film, 0603, 5%, 1.0 KOhms Panasonic ERJ-3GEYJ102V 3 R21 Resistor, film, 0603, 5%, 1.0 Megohms Panasonic ERJ-3GEYJ105V 1 R7-R8 Resistor, film, 0603, 5%, 20 ohms Panasonic ERJ-3GEYJ200V 2 R6, R17 Resistor, film, 0603, 5%, 20 KOhms Panasonic ERJ-3GEYJ203V (Note 2) 2 R19 Resistor, film, 0603, 5%, 220 ohms Panasonic ERJ-3GEYJ221V 1 R23, R31 Resistor, film, 0603, 5%, 5.1 KOhms Panasonic ERJ-3GEYJ512V 2 R15 Resistor, film, 0603, 5%, 51 ohms Panasonic ERJ-3GEYJ510V 1 R1 Resistor, film, 0805, 5%, 20 ohms Panasonic ERJ-6GEYJ200V 1 R2-R3 Resistor, film, 0805, 5%, 240 ohms Panasonic ERJ-6GEYJ241V 2 R9-R10 Resistor, film, 1206, 5%, 240 ohms Panasonic ERJ-8GEYJ241V 2 R36 Resistor, metal strip, 2512, 1%, 0.020 ohms Vishay WSL2512-0.020-1%-R86 1 SW1 Switch, SPST-momentary, push button, surface mount ALPS SKQGADE010 1 U1 IC, Single chip Battery Manager, programmable, 25°C to 85°C, SSOP-28 Microchip PS501-I/ST 1 U2 IC, Battery Protection Circuit, Li Ion, 3 or 4-cell, 40°C to 85°C, 4.4 mm body width TSSOP-16 package Seiko Instruments S-8254AAJFT-TB (Note 1) Note 1: 2: 1 Other variants of the S-8254A series, with different trip points, are also available. Consult the S-8254A series data sheet. R6 is left open (not placed). DS21851B-page 6 2004 Microchip Technology Inc. PS5163 FIGURE 3-2: PS5163 DIMENSION DETAILS 2004 Microchip Technology Inc. DS21851B-page 7 PS5163 4.0 DEVELOPMENT TOOL SUMMARY 4.1 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 4-1 summarizes the development tool offering from Microchip to support the PS5163. Please refer to the Microchip web site for ordering information and design documentation (including schematics) at www.microchip.com. TABLE 4-1: Reference Documents This data sheet provides an overview of the PS5163 Battery Manager module. For further information on the PS501 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™ hardware with PC software (PS041) Read and write Smart Battery data values, memory programming PowerCal™ hardware with PC software (PS042) Read and write Smart Battery data values, memory programming, pack calibration, pack test TABLE 4-2: MICROCHIP REFERENCE DOCUMENTS Document Number Documents Available DS21818 PS501 Single Chip Field Reprogrammable Battery Manager Data Sheet (IC Products) DS40234 PS041 PowerInfo™ Configuration Interface Product Brief DS40237 PS042 PowerCal™ Calibration Platform Data Sheet DS21851B-page 8 2004 Microchip Technology Inc. PS5163 Information contained in this publication regarding device applications and the like is intended through suggestion only and may be superseded by updates. It is your responsibility to ensure that your application meets with your specifications. No representation or warranty is given and no liability is assumed by Microchip Technology Incorporated with respect to the accuracy or use of such information, or infringement of patents or other intellectual property rights arising from such use or otherwise. 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 intellectual property rights. Trademarks The Microchip name and logo, the Microchip logo, Accuron and PowerSmart are registered trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. SmartShunt is a registered trademark Technology Incorporated in the U.S.A. of Microchip PowerCal, PowerInfo, PowerMate, PowerTool, SmartSensor and SmartTel are trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. 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