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PS2070
PS200 Switch Mode Charger Evaluation Board
Features
* Complete PS200 Battery Charger application circuit * Direct connection to Microchip's PowerInfoTM 2 (PS051) interface board and PowerCalTM 2 (PS052) calibration board * Configure PS200 with PS020 PowerToolTM 200 PC software * Change or upgrade firmware with In-Circuit Serial ProgrammingTM (ICSPTM) * 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)
Ordering Information
Part Number PS2070 PS2070EV Description PS200 Charger Evaluation Board and PS020 PowerToolTM 200 Software PS2XX Charger Evaluation Board, PS051 Configuration Interface and PS020 PowerToolTM 200 Software
2005 Microchip Technology Inc.
DS21927A-page 1
PS2070
1.0 PRODUCT OVERVIEW
2.2 Jumpers
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. * 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 PS200 pin 2 to Red LED PS200 pin 2 to PHost CLK 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 ICSPTM) Enable VOVP input 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 ICSPTM) Enable TEMP input 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 OVP 8808 mV OVP 13200 mV OVP 17640 mV No OVP limit X O O O O O X O O O O O X O O O O O X O O X O X X O 2-3 O X
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 PowerToolTM 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.
Legend: O = open, X = connect
DS21927A-page 2
2005 Microchip Technology Inc.
PS2070
* VIN - Jumper to configure voltage sense scaling factors. The values indicate the maximum battery voltage. Jumper Position 1-8 2-7 3-6 4-5 (1 Cell) (2 Cells) (3 Cells) (4 Cells) 5V 10V 15V 16.8V X O O O O X O O O O X O O O O X
2.5
Configuration for Lead Acid Chemistries
Lead acid configuration will be updated when firmware is available.
3.0
3.1
FUNCTIONAL DESCRIPTION
PS2070 Switch Mode Charger Evaluation
Legend: O = open, X = connect
2.3
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.
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.
2.4
Configuration for Nickel Pack Chemistries
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
4.1
4.0
FIGURE 4-1:
1 2 3 4 5 6
1 2 3 4 5 6
ICSPTM INTERFACE CONNECTORS: OPEN JP2 AND JP5 WHEN USING ICSP/ICD. 1 2 POWER 1.5K R11 4.7 F C23 R1 620 R34 R33 R32 R31 R18 VI C3 100 nF GND R3 PSTP MBRS340 D2 C22 4.7 F 4 5 6 7 8 1 2 3 Q1 NDS9435A
BUCK CONVERTER POWER SECTION
18
17
3
VOVP
SHDN
10 LED1 INTP LED2 8 1 + VREF CP1 BATID HVOUT CHGOUT 1 PWM SNTP 68UH OUTP 3 2 R6 3.01K 16 10.0K 4 5 C16 1.0 nF CHGFBK PGND2 R40 0.100 PGND BATCTRLOUT CTRLIN IFBINB R13 1.00K 12 + OP1 IFBOUT IFBINA R14 19.6K IFBOUT C14 OPEN 13 + OP2 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. D1 MBRS340 C21 4.7 F GND GND D6 BAT54 R20 POWER MOSFET DRIVER L1
SHDN
VIN
PCB schematics and bill of materials are included here for completeness. Schematic and Bill of Materials are also available in the PowerToolTM 200 PC software.
WHEN BAND GAP IS PROPERLY TRIMMED, VDD IS SET AT 5.000 VDC. R4 4 MCLR R30 47 VDD CP2 + 6 IN LKDS OUT OUT 1 1.5K 2 3 7 6
PS200
PS2070 BOARD SCHEMATIC
VDD C1 100 nF 20 VSS CHGFBK CTRL R5 20.0K 5 9
VDD VDD
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. 20.0K FDBK 7 R8 20.0K 120 nF HARDWARE FEEDBACK TO PWM: OP1 IS ERROR AMP. R7/R8/C7/C8 ARE LOOP COMPENSATION COMPONENTS. 1.27K R7 10 nF C7 14 C8 OP2/R13/R14: CURRENT SCALING. SET FOR RANGE OF 0-2586 mA (2.53 mA/BIT). LOOPIN LOOPFBK C9 470 nF R12 8
DS21927A-page 4
PS2070
Schematic
J1 JP1 (SIP) CHARGER DC POWER SUPPLY INPUT (WITH POWER INDICATOR). RIGHT-ANGLE COMBICON CONNECTOR.
(MODULAR)
J3
FOR REVISION HISTORY, SEE 826196 CHANGE LOG
OVP TRIP POINT SELECTION: (OVP HEADER) JUMPER ONLY ONE PIN PAIR AT A TIME OVP 45 36 27 18 NO OVP -- LEAVE JUMPER OFF HEADER. VOLTAGE SENSE SCALING FACTORS: (VIN HEADER) JUMPER ONLY ONE PIN PAIR AT A TIME TEMP 1 CELL: 2 CELL: 3 CELL: 4 CELL: 4404 mV (JUMPER 1-8) 8808 mV (JUMPER 2-7) 13200 mV (JUMPER 3-6) 17640 mV (JUMPER 4-5)
RST 137K 100K 63.4K 26.7K 10.0K 30.9K 20.5K 10.5K 232 10.0K VIN 45 36 27 18
INPUT VOLTAGE RANGE: 18 TO 22 VDC SUPPLY MUST BE CURRENT LIMITED OR FUSED AT A MAXIMUM OF 2.5A.
12 JP18 C18 4.7 F R19 10.0K R24 R23 R22 R21
BOARD DESCRIPTION
GRN LED TEMP 15 BATID C6 100 nF U1 TC4431COA CHGOUT 11 19 JP19 21
R10
1.5K R2 2
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)
1.5K
RED LED
JP2 1 2 3
DUT
D2 PREVENTS REVERSE CURRENT WHEN CHARGER IS TURNED OFF.
BAT+ JBat
BAT+ CLK DTA TMP GND
FIRMWARE CURRENT-CONTROL OUTPUT:
R9 20.0K
1 2 3 4 5
5-PIN RIGHT-ANGLE COMBICON BATTERY INTERFACE CONNECTOR. (MATES WITH PSX070 PCBs)
R5/R9/C9 FORM A LOW-PASS FILTER WITH A 4.7 MILLISECOND TIME CONSTANT.
PowerInfoTM/PowerCalTM HOST INTERFACE
R40: CURRENT SENSE RESISTOR
INVERTED COMBICON CONNECTOR
PHost
BAT+
CLK
DTA
TMP
1 2 3 4 5
A1 B1 A2 B2 A3 B3 A4 B4 A5 B5
GND
2005 Microchip Technology Inc.
EVALUATION/TEST BOARD FOR PS200
PS2070
4.2 Bill of Materials
PS2070 BILL OF MATERIALS
Description Raw PCB, PS2070 C7 C9 C16 C1, C3, C6 C8 C18, C21-C23 GRNLED, POWER REDLED D1, D2 Capacitor, Ceramic, 120 nF, 25V, +/-10%, X7R dielectric, 1206 Capacitor, Ceramic, 470 nF, 25V, +/-10%, X7R dielectric, 1206 Capacitor, Ceramic, 1.0 nF, 50V, +/-10%, X7R dielectric, 1206 Capacitor, Ceramic, 100 nF, 50V, +/-10%, X7R dielectric, 1206 Capacitor, Ceramic, 10 nF, 50V, +/-10%, X7R dielectric, 1206 Capacitor, Ceramic, 4.7 F, 25V, +/-20%, X5R dielectric, 1206 LED, clear green, 1206 package LED, clear red, 1206 package Schottky Diode, 40V, 3A, SMC package Manufacturer Microchip Panasonic Murata Panasonic BC Components Panasonic Panasonic Lumex Lumex On Semiconductor International Rct. Central Semi. Central Semi. Zetex AMP Manufacturer PN 04-826196 Rev. 2.1 ECJ-3VB1E124K GRM319R71E474KA01D ECU-V1H102KBM 1206B104K500BT ECU-V1H103KBM ECJ-3YB1E475M SML-LX1206GC-TR SML-LX1206SIC-TR MBRS340T3 MBRS340TR CMSH3-40-PST CMSH3-40L-PST BAT54TA 382811-6 Qty. 1 1 1 1 3 1 4 2 1 2
TABLE 4-1:
Symbols
D6 JP2, JP18, JP19, OVP, VIN J3 JBat DUT J1 BAT-, GND, PGND, PGND2 BAT+ BATID, CHGFBK, CHGOUT, CTRL, FDBK, IFBOUT, TEMP, VI L1
Diode, Schottky, 200 mA/30V, SOT-23 Connnector, shorting jumper, female, 2-position, 100 mil spacing, mates with 25 mil square pins, 15-microinch gold over nickel. Header, pluggable terminal block, 5.08 mm pitch x 2 positions, 12A/250V, right-angle, closed end Header, pluggable terminal block, 5.08 mm pitch x 5 positions, 12A/250V, right-angle, closed end Socket, 20-pin DIP, 0.300" spacing, machine pin Connector, modular, 6-position/6-contact, right-angle mount Test point, 0.125" OD, for 0.062" hole, black Test point, 0.125" OD, for 0.062" hole, red Test point, 0.125" OD, for 0.062" hole, white
1 5
Phoenix Phoenix Mill-Max AMP Keystone Keystone Keystone
1757242 1757271 110-93-320-41-001000 520470-3 5011 5010 5012
1 1 1 1 4 1 8
Inductor, 68 H, 1.8A, 130 mOhms DCR, 730 x 600 mil SMT package, -40C to +85C Bumper, hemispherical, 0.44" D x 0.20" H, transparent plastic
Coilcraft 3M
DO5022P-683 SJ-5303 (CLEAR) 929665-09-36-I
1 4 1
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 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 3M
JP2, JP18, JP19
929647-09-36-I
1
J3 JBat
Pluggable terminal block, 5.08 mm pitch x 2 positions, Phoenix 12A/250V Pluggable terminal block, 5.08 mm pitch x 5 positions, Phoenix 12A/250V
1757019 1757048
1 1
2005 Microchip Technology Inc.
DS21927A-page 5
PS2070
TABLE 4-1:
Symbols PHost Q1 R13 R7 R3, R18-R20 R22 R33 R34 R14 R5, R8-R9, R12 R23 R21 R31 R6 R24 R32 R2, R4, R10, R11 R30 R40 R1 RST DUT U1
PS2070 BILL OF MATERIALS (CONTINUED)
Description Manufacturer Manufacturer PN 1786433 NDS9435A ERJ-8ENF1001V ERJ-8ENF1271V ERJ-8ENF1002V ERJ-8ENF1052V ERJ-8ENF1003V ERJ-8ENF1373V ERJ-8ENF1962V ERJ-8ENF2002V ERJ-8ENF2052V ERJ-8ENF2320V ERJ-8ENF2672V ERJ-8ENF3011V ERJ-8ENF3092V ERJ-8ENF6342V ERJ-8GEYJ152V ERJ-8GEYJ470V WSL2512-0.100-1%-R86 ERJ-1TYJ621U TL3301NF260QG PS200 TC4431COA Qty. 1 1 1 1 4 1 1 1 1 4 1 1 1 1 1 1 4 1 1 1 1 1 1 Plug, inverted Combicon, 5.08 mm pitch x 5 positions, Phoenix 12A/250V MOSFET, P-channel Enhancement mode, -30V, -5.3A, Fairchild Semi. 50 mOhms, 2.5W, SO-8, -55C to +125C Resistor, film, 1206, 1%, 1.00 kOhms Resistor, film, 1206, 1%, 1.27 kOhms Resistor, film, 1206, 1%, 10.0 kOhms Resistor, film, 1206, 1%, 10.5 kOhms Resistor, film, 1206, 1%, 100 kOhms Resistor, film, 1206, 1%, 137 kOhms Resistor, film, 1206, 1%, 19.6 kOhms Resistor, film, 1206, 1%, 20.0 kOhms Resistor, film, 1206, 1%, 20.5 kOhms Resistor, film, 1206, 1%, 232 ohms Resistor, film, 1206, 1%, 26.7 kOhms Resistor, film, 1206, 1%, 3.01 kOhms Resistor, film, 1206, 1%, 30.9 kOhms Resistor, film, 1206, 1%, 63.4 kOhms Resistor, film, 1206, 5%, 1.5 kOhms Resistor, film, 1206, 5%, 47 ohms Resistor, metal strip, 2512, 1%, 0.100 ohms Resistor, film, 2512, 5%, 620 ohms Switch, SPST momentary tact, surface mount, 6 mm square, 4.3 mm high, 260 G-force IC, Battery Charger Microcontroller, 20-pin DIP, -40C to +85C Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Vishay Panasonic E-Switch Microchip
IC, Power MOSFET Driver circuit, 30V, 1.5A, inverting, Microchip with UV lockout, SO-8, 0C to +70C
DS21927A-page 6
2005 Microchip Technology Inc.
PS2070
4.3 Mechanical Dimensions
Overall Dimensions: 2.5" W x 4.0" L
FIGURE 4-2:
PS2070 DIMENSION DETAILS
CTRL
FDBK
GND
1
R7 C9 R9
R12 C7 R5 R8 C8 C3
JP1
JP2 R21 R22 R23 R24 R3
DUT
1
VI
R12
(J1 CENTER) 6
C1
2500 (mil)
GRNLED R10 REDLED R2 POWER R11 R4
R13
R14
C14
1548 (mil)
500 (mil)
D1 R30 C23
L1
R40
175 (mil)
D2 C22
Q1 INTP
250 (mil)
PSTP
SNTP
OUTP
188 (mil)
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.
415 (mil)
2013 (mil)
1100 (mil)
JBat
C21
BAT+
U1
C6
PGND2
CHGFBK
J3
R1
IFBOUT
JP18 R20
TEMP PGND
CHGOUT
D6 C16
BAT- OVP
BATID R6
JP19
R19 R31 R32 R33 R34 R18
1
DS21927A-page 7
2000 (mil)
J1
C18
VIN
PHost
RST
340 (mil)
2063 (mil)
1000 (mil)
1
PS2070
5.0 DEVELOPMENT TOOL SUMMARY
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 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:
MICROCHIP DEVELOPMENT TOOL SUMMARY
Development Tool Use Read and write register values, EEPROM programming and test Read and write register values, EEPROM programming, test and calibration
PowerInfoTM 2 hardware with PowerToolTM 200 software (PS051) PowerCalTM 2 hardware with PowerToolTM 200 software (PS052)
TABLE 5-2:
Document Number DS21891 DS21815 DS21817 DS21925
MICROCHIP REFERENCE DOCUMENTS
Documents Available PS200 PowerSmart(R) Configurable Lithium Ion/Lithium Polymer Battery Charger Data Sheet PS051 PowerInfoTM 2 Configuration Interface Data Sheet PS052 PowerCalTM 2 Calibration Platform Data Sheet PS020 PowerToolTM 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. (c) 2005, Microchip Technology Incorporated. Printed in the U.S.A., All Rights Reserved.
Printed on recycled paper.
2005 Microchip Technology Inc.
DS21927A-page 9
WORLDWIDE SALES AND SERVICE
AMERICAS
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ASIA/PACIFIC
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ASIA/PACIFIC
India - Bangalore Tel: 91-80-2229-0061 Fax: 91-80-2229-0062 India - New Delhi Tel: 91-11-5160-8631 Fax: 91-11-5160-8632 Japan - Kanagawa Tel: 81-45-471- 6166 Fax: 81-45-471-6122 Korea - Seoul Tel: 82-2-554-7200 Fax: 82-2-558-5932 or 82-2-558-5934 Singapore Tel: 65-6334-8870 Fax: 65-6334-8850 Taiwan - Kaohsiung Tel: 886-7-536-4818 Fax: 886-7-536-4803 Taiwan - Taipei Tel: 886-2-2500-6610 Fax: 886-2-2508-0102 Taiwan - Hsinchu Tel: 886-3-572-9526 Fax: 886-3-572-6459
EUROPE
Austria - Weis Tel: 43-7242-2244-399 Fax: 43-7242-2244-393 Denmark - Ballerup Tel: 45-4450-2828 Fax: 45-4485-2829 France - Massy Tel: 33-1-69-53-63-20 Fax: 33-1-69-30-90-79 Germany - Ismaning Tel: 49-89-627-144-0 Fax: 49-89-627-144-44 Italy - Milan Tel: 39-0331-742611 Fax: 39-0331-466781 Netherlands - Drunen Tel: 31-416-690399 Fax: 31-416-690340 England - Berkshire Tel: 44-118-921-5869 Fax: 44-118-921-5820
10/20/04
DS21927A-page 10
2005 Microchip Technology Inc.

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