PS4160 PS401 PS4160-3 PS4160-4 MM1414 18AWG-20 DS40238 MM1414DV 2N7002 100NF

PS401 Battery Manager Module with LED SOC Display Features · PS401 tested, fully populated modules for evaluation and

PS4160 PS4160 PS401 PS401 Battery Manager Module with LED SOC Display Features · PS401 PS401 tested, fully populated modules for evaluation and production · Designed to work with 3 cell and 4 cell series Li Ion configurations · Performs all major Li Ion battery management functions including - Accurate capacity monitoring - Direct control of external charge circuitry · Direct control of secondary safety functions · SOC display with four LEDs and a switch can be removed to use GPIOs for other operations · 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 15-bit integrating A/D · Precise capacity reporting using Microchip patented algorithms and 3D battery cell models · 3D models and "learned" parameters stored in integrated EPROM and EEPROM · Extremely low power operation: - SLEEP Mode: < 25 µA typical - Run Mode: < 500 µA typical - Sample Mode: < 250 µA typical · Complete hardware and software development tools available · Overall mechanical dimensions: - 0.525 W x 2.500 L (inches) - 13.34 W x 63.50 L (millimeters) 2003 Microchip Technology Inc. Board Photo Ordering Information Part No. Description Function PS4160-3 PS4160-3 Li Ion - 3 series cells PS4160-4 PS4160-4 Li Ion - 4 series cells DS40235B-page 1 PS4160 PS4160 1.0 GENERAL DESCRIPTION The PS4160 PS4160 module is a complete smart battery controller subsystem with safety based on the Microchip PS401 PS401 battery manager with patented AccuronTM technology. The module is designed to operate in a battery pack consisting of three (3) or four (4) series connected Lithium cells. The module consists of three circuit sections the Microchip PS401 PS401 battery manager IC, Mitsumi MM1414 MM1414 based primary safety circuit and a secondary safety circuit controlled by the PS401 PS401 to provide backup to the MM1414 MM1414. 1.1 Quick Start Pack Assembly Follow these directions to assemble a pack with the PS4160 PS4160 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 PS401 PS401 family of CMOS ASICs. Pack positive should always be connected first, followed by the intermediate cell voltages from highest to lowest, and finishing with the negative end of the pack. Step 1: Configure the module for the number of series cells according to the following chart: Li Ion 3-cell Li Ion 4-cell R27 Removed Installed R28 Installed Removed R30 Installed Removed Step 2: Configure the module for the following options. Use Optional External Thermistor The PS401 PS401 IC has an integrated temperature sensor. If you would like to add an optional external thermistor, remove R16. Charge FET Control The PS4160 PS4160 is shipped with the Mitsumi 1414 IC controlling both the charge and discharge FETs. If you would like to enable PS401 PS401 control of the charge FET, remove R25 and change the value of bit 2 of the FLAGS1 parameter to `0'. Setting bit 2 of FLAGS1 disables the GPIOs. DS40235B-page 2 GPIO Operation: The PS4160 PS4160 is shipped with four LEDs for a SOC display. These LEDs are connected to GPIO pins on the PS401 PS401 IC. The GPIO pins can be used for operation other than the LED SOC display by removing the LED and monitoring the adjacent test point. Step 3: Connect wires to module. Use large diameter wire (18AWG-20 18AWG-20 AWG) for current carrying lines from VR and V1. All others are signal only lines (24 to 22 AWG). Step 4: Connect V1 to the most positive point on the battery cell stack. Step 5: Connect cell voltage pickups: 4 series cells negative end of topmost cell in stack to V2, negative end of next cell to V3, and negative end of third cell to V4. 3 series cells negative end of topmost cell in stack to V2, negative end of next cell to V3, no connection at V4. Step 6: Connect VR to the most negative point on the battery cell stack. Step 7: Connect external connector to B-Neg, T, C, D and B+. Step 8: The PS4160 PS4160 is shipped with the secondary safety circuit disabled to avoid damage to the fuse during assembly. To enable the secondary safety circuit, remove R23 and change the value of bit 2 of the FLAGS1 parameter to `0'. Setting bit 2 of FLAGS1 disables the GPIOs configured for safety. Step 9: Program the assembled pack using Microchip's PowerToolTM software and PowerCalTM board or PowerInfoTM board hardware. The EEPROM parameters can be changed at will using the utilities on the P4 EE page in the PowerTool software. The OTP EPROM parameters can be changed a limited number of times using utilities on the P4 OTP page. To write to the OTP EPROM, an additional voltage (VPP) must be applied to the PS401 PS401. This programming voltage can be obtained from the PowerInfo board and applied to the PS4160 PS4160 at connection VP (small thru-hole) located on the small edge of the board opposite the connector edge. Step 10: Calibrate the pack using the PowerTool software and PowerCal board hardware. The pack is now ready for use. 2003 Microchip Technology Inc. PS4160 PS4160 FIGURE 1-1: BOARD ASSEMBLY (SIDE 1) · Connection points for cells and connector are located here. · To add an external thermistor, remove R16 (left side of drawing above). FIGURE 1-2: · To enable the secondary safety circuit, remove R23 (to the right of PS401 PS401, label at top). BOARD ASSEMBLY (SIDE 2) · Follow chart in step one to configure module for 3 or 4 series cells. The configuration resistors are located on side 2. Follow the label line to locate the resistors. Approximate label locations follow. - R27 - top of drawing, above protection IC, U2. - R28 - bottom of drawing, below protection IC, U2. - R30 - bottom of drawing, right of R28, left of R22. 2003 Microchip Technology Inc. · To enable PS401 PS401 control of the charge FET, remove R25 (right side of drawing, label at top). · LEDs and the test points for the GPIOs are located here. DS40235B-page 3 PS4160 PS4160 2.0 FUNCTIONAL DESCRIPTION 2.4 2.1 PS401 PS401 Fuel Gauge The third level of safety protection is activated by GPIO (pin 5) of the PS401 PS401 when R23 is removed and bit 2 of FLAGS1 = 0. This pin is activated whenever any individual cell voltage is measured above a programmable limit that is beyond both the primary and secondary safety limits. An N-channel MOSFET is turned on and allows current to pass through the resistive heater section of a fuse. This heating opens the fuse, permanently disabling the pack from further charge or discharge. The module fuel gauge provides State-of-Charge (SOC) and battery status data in accordance with the SMBus standards version 1.1. The PS401 PS401 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 PS401 PS401 Single Chip Battery Manager Data Sheet (DS40238 DS40238) for details on configuring the PS401 PS401. 2.2 Primary Safety The primary safety circuit provides cell protection from conditions of overcharge, overdischarge and overcurrent. Analog IC MM1414DV MM1414DV from Mitsumi measures individual cell voltages and voltage across the discharge FET. These values are compared against internal reference values and the gates of two P-channel power MOSFETs are controlled based on the comparison results. 2.3 Secondary Safety A secondary level of safety protection is provided on the PS4160 PS4160. GPIO (pin 4) of the PS401 PS401, with R25 removed and bit 2 of FLAGS1 = 0, is programmed to provide backup overcharge protection and is activated in the case of pack over voltage, over temperature or charge over current. In the situation where the parameter being monitored is the same as that of the MM1414 MM1414 the limits are set beyond those of the MM1414 MM1414. This means that the secondary protection is triggered only in the event the primary protection fails to activate. DS40235B-page 4 2.5 Ultimate Safety OTP EPROM Programming To write to the OTP EPROM, an additional voltage (VPP) must be applied to the PS401 PS401. This programming voltage can be obtained from the PowerInfo board and applied to the PS4160 PS4160 at connection VP (small thruhole) located on the small edge of the board opposite the connector edge. Then use the utilities located on the PS OTP page of the PowerTool software to write new values to the PS401 PS401 OTP EPROM. 2.6 Programmable I/Os The PS4160 PS4160 features four additional pins, GPIO (pins 24-27), which are used to drive the LED SOC display. GPIO (pin 3), is connected to the switch which activates the LED display. Alternately, these GPIOs may be used for other purposes by removing the unused LEDs, programming the pins appropriately, and using the adjacent test points to monitor the pins. 3.0 BOARD DESCRIPTION PCB schematics and bill of materials are included here for completeness. To download full size schematic and BOM, please visit the Microchip web site (www.microchip.com). 2003 Microchip Technology Inc. A B C Q7 2N7002 2N7002 R2 R21 OPEN R11 R12 R13 R14 220 220 220 220 C11 100NF 100NF C12 100NF 100NF R30 0 1 2 R16 0 C14 100NF 100NF R32 15 C1 330NF 330NF C2 100NF 100NF C3 100NF 100NF C4 100NF 100NF R1 3.65K C13 100NF 100NF R21 AND R22 ARE USED TO ENABLE PACK-POWERED PROGRAMMING OF OTP, WHICH IS NORMALLY DISABLED. CONTACT AN APPLICATIONS ENGINEER FOR GUIDANCE BEFORE IMPLEMENTING THIS FEATURE. R27 - LEFT OPEN DURING MANUFACTURE; PLACE JUMPER FROM R28 HERE FOR 4-CELL OPERATION. R28 - REMOVE THIS JUMPER, AND MOVE IT TO THE R27 LOCATION FOR 4-CELL OPERATION. R30 - REMOVE FOR 4-CELL OPERATION. BOARD IS SHIPPED WITH R27/R28/R30 R27/R28/R30 CONFIGURED FOR 3-CELL OPERATION, AS SHOWN ON SCHEMATIC. MAKE THE FOLLOWING CHANGES FOR 4-CELL OPERATION. R16 - REMOVE ONLY WHEN EXTERNAL THERMISTOR IS USED. R23 - REMOVE TO ENABLE SECONDARY SAFETY. R25 - REMOVE TO ENABLE PS401 PS401 CONTROL OF CHARGE CONTROL SWITCH. CONFIGURATION DATA IN EEPROM MUST ALSO BE SET TO REFLECT THE FEATURES SELECTED BY THESE JUMPER SETTINGS. R15 330 220 V4 CAUTION! REMOVE R30 FOR 4-CELL APPLICATIONS! R4 220 V3 VR R3 220 R22 OPEN V2 V1 CONFIGURATION TABLE - ZERO-OHM JUMPERS VR V4 V3 V2 V1 CELL CONNECTION R24 200K TR TN TN TR R28 0 C15 100NF 100NF R27 OPEN 13 11 10 19 14 12 18 17 16 15 20 3 CDC COL COV NC NC NC DCHG CS OV 100NF 100NF C16 SCL SDA GPIO(0) GPIO(1) GPIO(2) GPIO(3) GPIO(4) GPIO(5) GPIO(6) GPIO(7) VPP TstClk NTEST XTAL2 7 8 9 2 4 6 5 3 VP R29 5.1K 150 150 TP1 C9 C10 C8 10NF 2.2NF 100NF 100NF PRIMARY SAFETY CIRCUIT 200K R37 CURRENT SENSE RESISTOR 6 7 24 25 26 27 2 3 4 5 22 21 23 20 19 R26 1 PS401 PS401 3 XTAL1 MM1414DV MM1414DV CON SEL GND NC NC NC V4 V3 V2 V1 VCC U2 VSSD VDDD VSSA VDDA VC(4) VC(3) VC(2) VC(1) VNTC VREFT 0.020 R36 C7 330NF 330NF 28 1 C5 330NF 330NF 13 12 8 9 10 11 16 17 U1 221K ROSC Q8 5HP01M 5HP01M 18 Rshp 14 Rshn 15 R25 0 R39 430K R5 R6 VP 1 3 Q4 MMBT3904 MMBT3904 TP6 TP5 TP4 TP3 4 R38 200K R40 20K C20 OPEN R41 2.0M Q6 MMBT3906 MMBT3906 R7 R8 SW1 SKQGADE010 SKQGADE010 D1 AZ23C5V6 AZ23C5V6 150 150 TP2 4 3 R23 0 R9 APPROVALS 9/13/2002 DATE * CONFIDENTIAL * THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION THAT IS THE INTELLECTUAL PROPERTY OF MICROCHIP TECHNOLOGY, INC. CHECKED R. CASEBOLT DRAWN Q3 5 Q1 TPC8108 TPC8108 3 2 1 PowerSmart Products Group 2745 Dallas Parkway, Suite 400 Plano, TX 75093 DRAWING NO. 826127-01-03B 826127-01-03B.sch SCALE 5 Q2 TPC8108 TPC8108 3 2 1 R35 365 B+ C17 B+ B- D C T D3 SMBJ20A SMBJ20A PACK CONNECTIONS B- D C 47PF C19 T 1.0NF 100NF 100NF C18 6 6 Sheet 1 of 1 13-Sep-2002 17:53:52 B REV http://www.microchip.com 469-241-0087 Voice/469-241-0106 Fax 826127-01-03 FILE CODE IDENT NO. NONE B SIZE R31 100 8 7 6 5 4 Microchip Technology, Inc. Q5 5HP01M 5HP01M 8 7 6 5 PS4160 PS4160 SCHEMATIC C6 100NF 100NF 3 SEC. SAFETY OUTPUT F1 SFD167A SFD167A NDS355N NDS355N TITLE R10 360 R33 5.1K R34 1.5K 360 CONTRACT NO. D2 AZ23C5V6 AZ23C5V6 LED3 LED2 LED1 LED0 Q2 IS CHARGE CONTROL SWITCH Q1 IS DISCHARGE CONTROL SWITCH 1 4 2 4 EXTERNAL THERMISTOR CONNECTIONS (SEMITEC 103AT 103AT OR 103ETB 103ETB - 10K AT 25C) 2 2003 Microchip Technology Inc. 2 A B C D FIGURE 3-1: 1 D 1 PS4160 PS4160 BOARD SCHEMATIC DS40235B-page 5 PS4160 PS4160 TABLE 3-1: Manufacturer Manufacturer Part Number Qty Capacitor, Ceramic, 10 nF, 25V, +/- 10%, X7R dielectric, 0603 Capacitor, Ceramic, 1.0 nF, 50V, +/-10%, X7R dielectric, 0603 Capacitor, Ceramic, 2.2 nF, 50V, +/-10%, X7R dielectric, 0603 Capacitor, Ceramic, 47 pF, 50V, +/-5%, C0G dielectric, 0603 Capacitor, Ceramic, 100 nF, 25V, +80%/-20%, Y5V dielectric, 0603 Panasonic Panasonic Panasonic Panasonic Panasonic ECJ-1VB1E103K ECJ-1VB1E103K ECJ-1VB1H102K ECJ-1VB1H102K ECJ-1VB1H222K ECJ-1VB1H222K ECJ-1VC1H470J ECJ-1VC1H470J ECJ-1VF1E104Z ECJ-1VF1E104Z 1 2 1 1 11 Capacitor, Ceramic, 100 nF, 25V, +/-10%, X7R dielectric, 0805 Capacitor, Ceramic, 330 nF, 25V, +80%/-20%, Y5V dielectric, 0805 Capacitor, Ceramic, 330 nF, 25V, +/-10%, X7R dielectric, 1206 LED, clear green, 1206 package Panasonic Panasonic Panasonic Lumex ECJ-2VB1E104K ECJ-2VB1E104K ECJ-2YF1E334Z ECJ-2YF1E334Z ECJ-3VB1E334K ECJ-3VB1E334K SML-LX1206GC-TR SML-LX1206GC-TR 1 2 1 4 Diodes, Inc. Crydom Diodes Inc. General Semiconductor Sony Chemicals SMBJ20A-13 SMBJ20A-13 SMBJ20A SMBJ20A AZ23C5V6-7 AZ23C5V6-7 AZ23-C5V6 AZ23-C5V6 1 SFD-167A SFD-167A 1 Microchip Technology Inc. Diodes Inc. Diodes Inc. Sanyo PCB-826127-01-03 PCB-826127-01-03 1 MMBT3904-7 MMBT3904-7 MMBT3906-7 MMBT3906-7 5HP01M 5HP01M 1 1 2 Toshiba TPC8108 TPC8108 2 Fairchild Semiconductor Fairchild Semiconductor Panasonic Panasonic Panasonic Panasonic 2N7002 2N7002 1 NDS355N NDS355N 1 ERJ-3EKF2213V ERJ-3EKF2213V ERJ-3EKF3651V ERJ-3EKF3651V ERJ-3EKF3650V ERJ-3EKF3650V ERJ-3GEY0R00V ERJ-3GEY0R00V 1 1 1 6 Resistor, film, 0603, 5%, 1.5 kOhms Resistor, film, 0603, 5%, 100 ohms Resistor, film, 0603, 5%, 150 ohms Resistor, film, 0603, 5%, 15 ohms Resistor, film, 0603, 5%, 2.0 Megohms Resistor, film, 0603, 5%, 200 kOhms Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic ERJ-3GEYJ152V ERJ-3GEYJ152V ERJ-3GEYJ101V ERJ-3GEYJ101V ERJ-3GEYJ151V ERJ-3GEYJ151V ERJ-3GEYJ150V ERJ-3GEYJ150V ERJ-3GEYJ205V ERJ-3GEYJ205V ERJ-3GEYJ204V ERJ-3GEYJ204V 1 1 4 1 1 3 Resistor, film, 0603, 5%, 20 kOhms Resistor, film, 0603, 5%, 220 ohms Panasonic Panasonic ERJ-3GEYJ203V ERJ-3GEYJ203V ERJ-3GEYJ221V ERJ-3GEYJ221V 1 7 Resistor, film, 0603, 5%, 330 ohms Resistor, film, 0603, 5%, 430 kOhms Resistor, film, 0603, 5%, 5.1 kOhms Resistor, film, 0805, 5%, 360 ohms Resistor, metal strip, 2512, 1%, 0.020 ohms Panasonic Panasonic Panasonic Panasonic Vishay ERJ-3GEYJ331V ERJ-3GEYJ331V ERJ-3GEYJ434V ERJ-3GEYJ434V ERJ-3GEYJ512V ERJ-3GEYJ512V ERJ-6GEYJ361V ERJ-6GEYJ361V WSL2512-0 WSL2512-0.0201%-R86 SKQGADE010 SKQGADE010 PS401 PS401 1 1 2 2 1 1 1 MM1414DV MM1414DV 1 Symbols C9 C18, C20 C10 C19 C2-C4, C6 C11-C17 C11-C17 C8 C5, C7 C1 LED0LED3 D3 BILL OF MATERIALS Description TVS, 20V, 600W, unipolar, SMB package D1, D2 Dual Zener Diode, 5.6V +/- 5%, 300 mW, common-anode, SOT-23 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 UL248-14, 3-terminal surface-mount package Raw PCB, PS4160 PS4160 Q4 Q6 Q5, Q8 Q1, Q2 Q7 Q3 R26 R1 R35 R16, R21, R23, R25, R28, R30 R34 R31 R5-R8 R32 R41 R24, R37-R38 R37-R38 R40 R2-R4, R11-R14 R11-R14 R15 R39 R29, R33 R9-R10 R9-R10 R36 SW1 U1 U2 Transistor, NPN, 40V, 350 mW SOT-23 Transistor, PNP, -40V, 350 mW SOT-23 MOSFET, P-channel enhancement-mode, -50V, 250 mW, surfacemount package MOSFET, P-channel enhancement-mode, -30V, -11A, 9.5 mOhm, 1.9W, SO-8 MOSFET, N-channel enhancement-mode, 60V, 115 mA, 7.5 Ohm, 200 mW, SOT-23 MOSFET, N-channel enhancement-mode, 30V, 1.6A, 0.125 Ohm, 500 mW, SOT-23 Resistor, film, 0603, 1%, 221 kOhms Resistor, film, 0603, 1%, 3.65 kOhms Resistor, film, 0603, 1%, 365 ohms Resistor, zero-ohm, 0603 Switch, SPST-momentary, push button, surface-mount IC, Single-chip Battery Manager, programmable, -25°C to 85°C, SSOP-28 SSOP-28 IC, Battery Protection Circuit, Li-Ion, 3- or 4-cell, -20°C to 70°C, TSOP-20 TSOP-20 DS40235B-page 6 ALPS Microchip Technology Inc. Mitsumi 2 2003 Microchip Technology Inc. PS4160 PS4160 3.1 Mechanical Dimensions Overall Dimensions: 2500 mils x 525 mils FIGURE 3-2: PS401 PS401 BATTERY MANAGER MODULE WITH LED SOC DISPLAY 2003 Microchip Technology Inc. DS40235B-page 7 PS4160 PS4160 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 PS4160 PS4160. 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 PS4160 PS4160 Battery Manager Module. For further information on the PS401 PS401 and development tool operations, please refer to the documents listed in Table 4-2 available for download at www.microchip.com. MICROCHIP DEVELOPMENT TOOL SUMMARY Development Tool Use PowerInfoTM hardware with PowerToolTM software (PS041 PS041) Read and write Smart Battery data values, EEPROM programming, OTP EPROM programming PowerCalTM hardware with PowerTool software (PS042 PS042) Read and write Smart Battery data values, EEPROM programming, OTP EPROM programming, pack calibration, pack test TABLE 4-2: MICROCHIP REFERENCE DOCUMENTS Document Number Documents Available DS40238A DS40238A PS401 PS401 Single Chip Battery Manager Data Sheet (IC Products) DS40234A DS40234A PS041 PS041 PowerInfo Configuration Interface Product Brief DS40237A DS40237A PS042 PS042 PowerCal Calibration Platform Data Sheet DS40235B-page 8 2003 Microchip Technology Inc. PS4160 PS4160 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 and PowerSmart are registered trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. Accuron, PowerCal, PowerInfo, PowerMate, PowerTool, SmartSensor, SmartShunt 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. © 2003, Microchip Technology Incorporated. Printed in the U.S.A., All Rights Reserved. Printed on recycled paper. 2003 Microchip Technology Inc. DS40235B-page 9 WORLDWIDE SALES AND SERVICE AMERICAS ASIA/PACIFIC Japan Corporate Office Australia 2355 West Chandler Blvd. Chandler, AZ 85224-6199 Tel: 480-792-7200 Fax: 480-792-7277 Technical Support: 480-792-7627 Web Address: http://www.microchip.com Microchip Technology Australia Pty Ltd Marketing Support Division Suite 22, 41 Rawson Street Epping 2121, NSW Australia Tel: 61-2-9868-6733 Fax: 61-2-9868-6755 Microchip Technology Japan K.K. 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