! !"# $% User’s Guide June 2002 Advanced Analog Products SLUU110A IMPORTANT NOTICE Texas Instruments Incorporated and its subsidiaries (TI) reserve the right to make corrections, modifications, enhancements, improvements, and other changes to its products and services at any time and to discontinue any product or service without notice. Customers should obtain the latest relevant information before placing orders and should verify that such information is current and complete. All products are sold subject to TI’s terms and conditions of sale supplied at the time of order acknowledgment. TI warrants performance of its hardware products to the specifications applicable at the time of sale in accordance with TI’s standard warranty. Testing and other quality control techniques are used to the extent TI deems necessary to support this warranty. Except where mandated by government requirements, testing of all parameters of each product is not necessarily performed. TI assumes no liability for applications assistance or customer product design. Customers are responsible for their products and applications using TI components. To minimize the risks associated with customer products and applications, customers should provide adequate design and operating safeguards. TI does not warrant or represent that any license, either express or implied, is granted under any TI patent right, copyright, mask work right, or other TI intellectual property right relating to any combination, machine, or process in which TI products or services are used. Information published by TI regarding third–party products or services does not constitute a license from TI to use such products or services or a warranty or endorsement thereof. Use of such information may require a license from a third party under the patents or other intellectual property of the third party, or a license from TI under the patents or other intellectual property of TI. Reproduction of information in TI data books or data sheets is permissible only if reproduction is without alteration and is accompanied by all associated warranties, conditions, limitations, and notices. Reproduction of this information with alteration is an unfair and deceptive business practice. TI is not responsible or liable for such altered documentation. Resale of TI products or services with statements different from or beyond the parameters stated by TI for that product or service voids all express and any implied warranties for the associated TI product or service and is an unfair and deceptive business practice. TI is not responsible or liable for any such statements. Mailing Address: Texas Instruments Post Office Box 655303 Dallas, Texas 75265 Copyright 2002, Texas Instruments Incorporated Trademarks Preface Read This First About This Manual This user’s guide describes the bq24004/5/6 evaluation module (SLUP051). The SLUP051 conveniently evaluates a linear Li-ion charge-management solution that uses the bq24004/5/6. This guide describes a complete designed-and-tested charger, which delivers up to 1.0 A of continuous-charge current for two-cell applications. How to Use This Manual This document contains the following chapters: - Chapter 1—Introduction - Chapter 2—Test Summary - Chapter 3—Physical Layouts - Chapter 4—Bill of Materials - Appendix A—Schematic Related Documentation From Texas Instruments - bq24004, bq24005, bq24006 data sheet, literature number SLUS476 Trademarks PowerPAD is a trademark of Texas Instruments. Read This First iii iv Running Title—Attribute Reference Contents 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.2 Performance Specification Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 2 Test Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.1 I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.2 Jumper-Selectable Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 For Two-Cell Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Physical Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1 Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 4 Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1 Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 A Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 2-1 2-2 2-2 2-2 2-2 2-2 Figures 3–1 3–2 3–3 SLUP051 Board Layout Top Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 SLUP051 Board Layout Bottom Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 SLUP051 Top Assembly View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Tables 1–1 4–2 Performance Specification Summary (Two Cell) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 SLUP051 Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Contents v vi Chapter 1 Introduction This user’s guide describes the bq24004/5/6 evaluation module (SLUP051). The SLUP051 conveniently evaluates a linear Li-ion charge-management solution for battery-pack applications that uses the bq24004/5/6. This guide describes a complete designed-and-tested charger, which delivers up to 1.0 A of continuous-charge current. Topic Page 1.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.2 Performance Specification Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-1 Background 1.1 Background The bq24004/5/6 series ICs are advanced Li-Ion linear charge management devices for highly integrated and space-limited applications. They combine high-accuracy current and voltage regulation; FET pass-transistor and reverse-blocking Schottky; battery conditioning, temperature, or input-power monitoring; charge termination; charge-status indication; and charge timer in a small, 20-lead TSSOP PowerPAD package. The bq24004/5/6 continuously measures battery temperature using an external thermistor. For safety reasons, the bq24004/5/6 inhibits charge until the battery temperature is within the user-defined thresholds. Alternatively, the user can monitor the input voltage to qualify charge. The bq24004/5/6 series then charge the battery in three phases: preconditioning, constant current and constant voltage. If the battery voltage is below the internal low-voltage threshold, the bq24004/5/6 uses trickle-charge to condition the battery. A preconditioning timer is provided for additional safety. Following pre-conditioning, the bq24004/5/6 applies a constant-charge current to the battery. An external sense-resistor sets the magnitude of the current. The constant-current phase is maintained until the battery reaches the charge-regulation voltage. The bq24004/5/6 then transitions to the constant voltage phase. The user can configure the device for cells with either coke or graphite anodes. Charge is terminated by either of the following methods: - Maximum time - Minimum current detection plus 23-minute timeout 1.2 Performance Specification Summary This section summarizes the performance specifications of the bq24004/5/6 EVM. Table 1–1 gives the performance specifications of the hubs. The bq24004/5/6 automatically restarts the charge if the battery voltage falls below an internal recharge threshold. Table 1–1. Performance Specification Summary (Two Cell) Specification Test Conditions Min Typ Max Units Input dc voltage, VDC 9.1 9.5 † V Battery charge current, ICHG 0.9 1 1.1 A J6 set to VCC 8.35 8.40 8.45 J6 set to GND 8.15 8.20 8.25 Battery voltage regulation, regulation VREG Therm fault High, TBATMAX J2 set to Therm 43 48 53 Low, TBATMIN J2 set to Therm 0 5 10 APG (user defined, see data sheet) J2 set to APG Power dissipation, PD (VI-VO) × Iload V °C ‡ 2.3 W † VI, for a 2-cell, should not exceed 9.1 VDC for the 1-A charge rate and 10.6 V for the 0.5-A charge rate. (VI is the input voltage to the bq2400x IC, pins 2 and 3. The power supply source voltage, at J1, is 0.1 V larger than VI because of the regulated voltage drop across the current sense resistor, during constant current regulation.) ‡ If J2 is set to APG, then the chip is disabled when the input is outside of this range: 4.02 V±0.07 V and 10.76 V ±0.09 V. 1-2 Chapter 2 Test Summary This chapter shows the test setups used, and the tests performed, in designing the bq24004/5/6 EVM. Topic Page 2.1 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.2 Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Test Summary 2-1 Setup 2.1 Setup The bq24004/5/6 EVM board requires a dc power source 9–10VDC, ≥ 1.1 A or equivalent to provide input power and a dual-cell lithium-ion or lithium-polymer battery to charge. Adjust the power supply for 9.1 ±0.1 VDC and set the current limit to 1.3 A ±0.2 A. Power down the supply. Note: bq24005/6 ICs can be evaluated by replacing reference designator U1 with the desired version. Refer to the IC data sheet for the correct status display and the BOM for the correct status components (D1, D2, U2, J6). The test setup connections and jumper setting selections are listed below. 2.1.1 2.1.2 I/O Connections Jack Connect to: J1 – VCC Power source positive output J1 – DC– Power source negative output J7 – BAT+ Positive lead of dual lithium-ion cell J7 – BAT– Negative lead of dual lithium-ion cell J7 – VSENSE Tie to battery’s positive terminal J8 – THERM Tie to thermistor lead in battery pack J8 – DC– Tie to other thermistor lead (may be same wire as BAT–) Jumper-Selectable Configuration (Factory Set to Bold Selections) Jumper Selection J2 Adapter power good (APG) or battery thermistor, APG/THRM J3 Enable, on or off J4 Regulation voltage per cell, 4.2 V or 4.1 V J5 Timer, 3-hour (float, no jumper), 4.5-hour, or 6-hour J6 Stat2 green diode, jumper for bq24005/6 2.2 Test Procedures 2.2.1 For Two-Cell Applications Set up the evaluation board as described above, by making the necessary I/O connections and jumper selections. Note: Before test and evaluation, it is important to verify that the maximum power dissipation on the IC is not exceeded. Pmax = 2.3 W. Pdiss, 2 cell = (VI – 6.8 V) × ICHG 2-2 where VI = VCC –0.1 V Test Procedures Note: For the two-cell case, at 1-A charge rate, where the battery pack is at 6 V, the power dissipation is temporarily as high as 3.1 W until the pack charges to 6.8 V. This condition is fine for the short time (~1 min.) before the pack reaches 6.8 V. Adjust the input power supply for 9.1 V. The red LED illuminates to indicate charging, unless there is a fault or the battery is fully charged. The bq24004/5/6 enters preconditioning mode if the battery is below the LowV threshold. In this mode, the bq24004/5/6 trickle-charges with approximately 65 mA for approximately 23 minutes. If the battery does not reach the LowV threshold during this period, then the charge current is terminated and the bq24004/5/6 enters fault mode. The red LED flashes in fault mode. This feature may be tested by removing input power, replacing the battery with a 30–40-Ω resistor from BAT+ to DC–, and applying power (Vin) for more than 23 minutes. Fault mode is reset by toggling input power or enable pin. Once the battery charges to the LowV-stop threshold, the battery enters fastcharge mode and charges at the programmed 1-A level. Program charge level may be changed by adjusting R3 ǒ Ǔ R3 + 0.10 V . I chg The battery remains at the fast-charge mode until either the selected time expires or the battery charges to the selected regulation voltage. The time-out feature is tested by using a 25–28-Ω, 5-W resistor in place of the battery. Apply the resistor after the unit is powered. If the battery discharges down to the HighV threshold, the charger starts fast charging. The refresh feature may be tested by charging a battery to completion (Iterm + 23 minutes) and, without disconnecting the battery, installing a 8–10-Ω, 10-W resistor in parallel with the battery. The regulator should start charging once the HIGHV threshold is reached. Note: The battery is still charging for another 23 minutes after the LED turns off. If a load (>Iterm) is applied before the 23 minutes has timed out then the load resets the 23 minute timer. The circuit has an overvoltage comparator for added protection. If the battery voltage exceeds this threshold for 330 ms, then the charger goes into fault mode. This may be tested by connecting an external power supply in place of the battery and adjusting the voltage above the threshold. Test Summary 2-3 2-4 Chapter 3 Physical Layouts This chapter contains the board layout and assembly drawings for the SLUP051 board used for the bq24004/5/6 EVM. Topic 3.1 Page Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Physical Layouts 3-1 Board Layout 3.1 Board Layout Figure 3-1 shows the top layer of the SLUP051. Figure 3-2 shows the bottom layer. Figure 3-3 shows the SLUP051 top assembly view. Figure 3–1. SLUP051 Board Layout Top Layer 3-2 Board Layout Figure 3–2. SLUP051 Board Layout Bottom Layer Figure 3–3. SLUP051 Top Assembly View Physical Layouts 3-3 Chapter 4 Bill of Materials This chapter contains the bill of materials required for the bq24004/5/6 EVM. It also specifies the charge status configurations for the bq24004/5/6 ICs. Topic 4.1 Page Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Bill of Materials 4-1 Bill of Materials 4-2 4.1 Bill of Materials Table 4-1 lists materials required for the bq24004/5/6 EVM using the SLUP051 (PWB) baord.. Bill of Materials Table 4–1. bq24004/5/6 EVM (SLUP051) Bill of Materials Item # –001 bq24004 –002 bq24005 –003 bq24006 RefDes Description Size MFR Part Number 1 2 2 2 C1, C4 Capacitor, tantalum, 10-µF, 16 V 1210 Panasonic ECS–T1CX106R 2 1 1 1 C2 Capacitor, ceramic, 0.1-µF, 16 V X7R 805 Panasonic ECJ–2VB1C104K 3 1 1 1 C3 Capacitor, ceramic, 0.22-µF, 16 V X7R 805 Panasonic ECJ–2VB1C224K 4 1 1 1 C5 Capacitor, ceramic, 10-pF, 50 V, NPO, 1% 603 Panasonic ECJ–1VC1H100D 5 1 1 0 D1 LED, red, 20 mA maximum Panasonic LN1271R–(TR) 6 0 1 0 D2 LED, green, 20 mA maximum Panasonic D–LN1371G–(TR) 7 0 0 1 U2 LED, BiColor, red/green, 20 mA maximum Chicago Miniature Lamp CMD67–22SRUGC/TR8 8 2 2 2 J1, J10 Terminal block, 2 pin, 6 A, 3,5 mm 75525 OST ED1514 9 4 4 4 J2, J3, J4, J5 Header, 3 pin, 100 mil spacing, (36-pin strip) 34100 Sullins PTC36SAAN 10 0 1 1 J6 Header, 2 pin, 100 mil spacing, (36-pin strip) 23100 Sullins PTC36SAAN 11 1 1 1 J7 Terminal block, 3 pin, 6 A, 3,5 mm 112625 OST ED1515 12 1 1 1 R1 Resistor, chip, 51.1 kΩ, 1/16 W, 1% 603 Std Std 13 1 1 1 R10 Resistor, chip, 10 MΩ, 1/16 W, 1% 603 Std Std 14 1 1 1 R2 Resistor, chip, 316 kΩ, 1/16 W, 1% 603 Std Std 15 1 1 1 R3 Resistor, chip, 0.1 Ω, 1/8 W 1206 Panasonic ERJ–8RSJR10 16 1 1 1 R5 Resistor, chip, 18.7 kΩ, 1/16 W, 1% 603 Std Std 17 2 2 2 R6, R8 Resistor, chip, 1 kΩ, 1/16 W, 1% 603 Std Std 18 1 1 1 R7 Resistor, chip, 95.3 kΩ, 1/16 W, 1% 603 Std Std 19 1 1 1 R9 Resistor, chip, 2 kΩ, 1/16 W, 1% 603 Std Std 20 1 0 0 U1 IC, dual Li-ION, charger, 1 LED 20 pin TSSOP TI bq24004PWP 21 0 1 0 U1 IC, dual Li-ION, charger, 2 LED 20 pin TSSOP TI bq24005PWP 22 0 0 1 U1 IC, dual Li-ION, charger, bicolor LED 20 pin TSSOP TI bq24006PWP Table 4–1. bq24004/5/6 EVM (SLUP051) Bill of Materials (Continued) Item # –001 bq24004 –002 bq24005 –003 bq24006 23 1 1 1 PWB 24 4 5 5 Shunts RefDes Description Size PWB, bq24004/5/6PWP (SLUP051)–EVM Shunts for header – J2–J6, 4 to 5 shunts 0.1” MFR Part Number TI SLUP051 Rev. A Sullins Electronics Corp. SPC02SYAN Assembly Note: 1) Shunts to be applied to J2–APG, J3–ON, J4–4.2V, J5–4.5Hr, and J6 if required 4-3 Bill of Materials Bill of Materials Bill of Materials 4-4 Bill of Materials Appendix A Schematic This chapter contains the schematic diagram for the EVM. Topic A.1 Page Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Schematic A-1 J5 R8 1 kΩ 1 R6 1 kΩ U2 TMR JUMPER U1 bq2400x J1 DC+ DC– R3 0.1 Ω 1 2 C2 0.1 µF C1 10 µF 1 2 3 4 5 6 7 8 9 10 N/C NC OUT IN OUT IN VSNS VCC AGND SNS STAT2 NC STAT1 APG/THM TMR_SEL EN CR VSEL NC PBKG R2 316 kΩ R R9 2 kΩ D1 C4 10 µF 3 2 1 J7 BAT+ BAT– SENSE+ R10 10 MΩ 2 1 C5 10 pF J6 STAT2 JUMPER 1 2 3 J3 R5 18.7 kΩ J4 EN JUMPER VSEL JUMPER C3 0.22 µF 2 1 1 2 3 R1 51.1 kΩ G 20 19 18 17 16 15 14 13 12 11 THERMAL_PAD 1 2 3 D2 J2 R7 95.3 kΩ APG/THM JUMPER “BAT–” is “DC–” J8 THERMISTOR BAT– Figure A–1 shows the SLUP051 EVM schematic diagram. 2 3 Schematic A.1 Schematic A-2 Check BOM for correct component selection on D1, D2, R6, R8, and U2 for IC selected.