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User’s Guide
January 2003
PMP Portable Power
SLUU125A
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EVM IMPORTANT NOTICE
Texas Instruments (TI) provides the enclosed product(s) under the following conditions:
This evaluation kit being sold by TI is intended for use for ENGINEERING DEVELOPMENT OR EVALUATION
PURPOSES ONLY and is not considered by TI to be fit for commercial use. As such, the goods being provided
may not be complete in terms of required design-, marketing-, and/or manufacturing-related protective
considerations, including product safety measures typically found in the end product incorporating the goods.
As a prototype, this product does not fall within the scope of the European Union directive on electromagnetic
compatibility and therefore may not meet the technical requirements of the directive.
Should this evaluation kit not meet the specifications indicated in the EVM User’s Guide, the kit may be returned
within 30 days from the date of delivery for a full refund. THE FOREGOING WARRANTY IS THE EXCLUSIVE
WARRANTY MADE BY SELLER TO BUYER AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED,
IMPLIED, OR STATUTORY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY
PARTICULAR PURPOSE.
The user assumes all responsibility and liability for proper and safe handling of the goods. Further, the user
indemnifies TI from all claims arising from the handling or use of the goods. Please be aware that the products
received may not be regulatory compliant or agency certified (FCC, UL, CE, etc.). Due to the open construction
oftheproduct, itistheuser’sresponsibilitytotakeanyandallappropriateprecautionswithregardtoelectrostatic
discharge.
EXCEPT TO THE EXTENT OF THE INDEMNITY SET FORTH ABOVE, NEITHER PARTY SHALL BE LIABLE
TO THE OTHER FOR ANY INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES.
TI currently deals with a variety of customers for products, and therefore our arrangement with the user is not
exclusive.
TI assumes no liability for applications assistance, customer product design, software performance, or
infringement of patents or services described herein.
Please read the EVM User’s Guide and, specifically, the EVM Warnings and Restrictions notice in the EVM
User’sGuidepriortohandlingtheproduct. Thisnoticecontainsimportantsafetyinformationabouttemperatures
and voltages. For further safety concerns, please contact the TI application engineer.
Persons handling the product must have electronics training and observe good laboratory practice standards.
No license is granted under any patent right or other intellectual property right of TI covering or relating to any
machine, process, or combination in which such TI products or services might be or are used.
Mailing Address:
Texas Instruments
Post Office Box 655303
Dallas, Texas 75265
Copyright 2003, Texas Instruments Incorporated
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EVM WARNINGS AND RESTRICTIONS
ItisimportanttooperatethisEVMwithintheinputvoltagerangeof5.6Vandtheoutputvoltage
range of 0 V and 4.25 V.
Exceeding the specified input range may cause unexpected operation and/or irreversible
damage to the EVM. If there are questions concerning the input range, please contact a TI
field representative prior to connecting the input power.
Applyingloadsoutsideofthespecifiedoutputrangemayresultinunintendedoperationand/or
possible permanent damage to the EVM. Please consult the EVM User’s Guide prior to
connecting any load to the EVM output. If there is uncertainty as to the load specification,
please contact a TI field representative.
During normal operation, some circuit components may have case temperatures greater than
60°C. The EVM is designed to operate properly with certain components above 60°C as long
as the input and output ranges are maintained. These components include but are not limited
tolinearregulators, switchingtransistors, passtransistors, andcurrentsenseresistors. These
types of devices can be identified using the EVM schematic located in the EVM User’s Guide.
When placing measurement probes near these devices during operation, please be aware
that these devices may be very warm to the touch.
Mailing Address:
Texas Instruments
Post Office Box 655303
Dallas, Texas 75265
Copyright 2003, Texas Instruments Incorporated
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Contents
1
2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1
1.2
Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Performance Specification Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Test Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1
2.2
I/O and Jumper Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.2 Equipment Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
3
Schematic, Physical Layouts, and Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1
3.2
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Physical Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.1 Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3
3.4
Figures
2–1
3–1
3–2
3–3
3–4
Load Test Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
EVM Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Assembly View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Top Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Bottom Layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Tables
1–1
3–1
Performance Specification Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
v
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vi
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Chapter 1
Introduction
This user’s guide describes the bq24010/2 (bqTINY ) evaluation module.
The EVM provides a convenient method for evaluating the performance of a
charge-management solution for portable applications using the bq24010/2
product family. A complete designed and tested charger is presented. The
charger is designed to deliver up to 1.0 A of continuous charge current, but is
programmed for 0.7 A, for single-cell Li-Ion or Li-Pol applications using a dc
power supply.
Topic
Page
1.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Performance Specification Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
bqTINY is a trademark of Texas Instruments.
1-1
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Background
1.1 Background
The bqTINY series are highly integrated Li-Ion and Li-Pol linear charge
management devices targeted at space limited portable applications. In a
small package, the bqTINY series offer integrated PowerFET and current
sensor, reverse blocking diode, high accuracy current and voltage regulation,
charge status, and charge termination.
The bqTINY charges the battery in three phases: conditioning, constant
current, and constant voltage. Charge is terminated on the basis of minimum
current. An internal charge timer provides backup safety for charge
termination. The bqTINY automatically restarts the charge if the battery
voltage falls below an internal threshold. The bqTINY automatically enters
sleep mode when V supply is removed.
CC
In addition to the standard features, different versions of the bqTINY offer a
multitude of additional features. These include temperature-sensing input for
detecting hot or cold battery packs, power good (PG) output indicating the
presence of the ac adapter, a TTL-level charge enable input (CE) to disable
or enable the charge process, and a TTL-level timer and termination-enable
(TTE) input to disable or enable the fast-charge timer and charge termination.
1.2 Performance Specification Summary
This section summarizes the performance specifications of the EVM.
Table 1–1 gives the performance specifications of the EVM.
Table 1–1.Performance Specification Summary
Specification
Test Conditions
Min
Typ
Max Units
†
Input dc voltage, V
V
+0.5 5.0
REG
5.2
V
A
I(DC)
†
Battery charge current, I
Power dissipation
See note
0.7
O(CHG)
(V
–V
)*I
1.5
W
(DC+)
(BAT+) (CHG)
†
This input voltage maximum is a function of the maximum allowable power dissipation on the IC. The current level is pro-
grammed for 0.7 amps. If the programmed charge is changed, then the maximum input voltage needs to be adjusted.
P
= 1.5 Watt = I
(V
– V
).
BAT+
maxIC
CHG DC+
1-2
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Chapter 2
Test Summary
This chapter shows the test setups used and the tests performed in evaluating
the EVM.
Setup: The bq24010/2 EVM board requires a 5-VDC, 1-A power source to
provide input power and a single-cell Li-Ion or Li-Pol battery pack. The test set-
up connections and jumper setting selections are configured for a stand-alone
evaluation but can be changed to interface with external hardware, such as a
microcontroller.
Topic
Page
2.1 I/O and Jumper Connecations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-1
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I/O and Jumper Connections
2.1 I/O and Jumper Connections
Jack
Connect To:
J1–DC+
J1–DC–
J2–BAT+
J2–BAT–
J2–TS
Power supply positive, preset to 5.0VDC, 1-A current limit.
Power supply ground
Positive battery pack terminal
Negative battery pack terminal
NC
J2–BAT–
J3–STAT1
J3–STAT2
J3–DC–
J3–PG
NC
External hardware if J4-EXT is jumpered (Not jumpered from factory)
External hardware if J5-EXT is jumpered (Not jumpered from factory)
Return for J3 signals
External hardware if J6–EXT if jumpered (Not jumpered from factory)
J4 (Jumper) STAT1 indication location – LED (EVM) | EXT
J5 (Jumper) STAT2 indication location – LED (EVM) | EXT
J6 (Jumper) PG indication location – LED (EVM) | EXT
Note: Factory jumper selections shown in bold.
2.2 Test Procedure
Set up the evaluation board as described above, by making the necessary I/O
connections and jumper selections. Before test and evaluation, it is
important to verify that the maximum power dissipation on the IC is not
exceeded: P
= 1.5 watts.
(MAX)
1) Turn on the power supply, which was preset to 5.0 VDC and 1 A for the
current limit setting.
2) The bq24010/2 enters preconditioning mode if the battery is below the
V
threshold. In this mode, the bq24010/2 precharges the battery
(LOWV)
withalowcurrent(typicallyI
/10=0.7A/10=70mA)untilthebattery
O(CHG)
voltage reaches the V
threshold or until the precharge timer
(LOWV)
expires. If the timer expires, then the charge current is terminated, the
bq24010/2entersfaultmode, andbothLEDsturnoff. Togglinginputpower
or battery replacement resets fault mode.
3) Once the battery voltage is above the V
threshold, the battery
(LOWV)
enters fast-charge mode. This EVM is programmed for 0.7 amps of fast
charging current.
4) Once the battery reaches voltage regulation (4.2 V), the current tapers
down as the battery reaches its full capacity.
5) The battery remains at the fast-charge mode until the fast-charge timer
expires, the charge taper time expires, or the charge termination threshold
is reached.
6) If the battery discharges to the recharge threshold, the charger starts fast
charging.
2-2
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Test Procedure
In place of a battery, a source meter that can sink current can easily be
adjusted to test each mode.
Another way to briefly see each mode on a scope is to connect a 1-mF
capacitor and a 10-kΩ resistor on the output in place of a battery to observe
the power-up and cycling between voltage regulation and fast charge via the
refresh threshold.
The difference between the bq2401x parts, where x is a 0 or 2, is as follows:
The functions on the 0 part are power good output (PG) for pin 7 and
temperature sense Input (TS) for pin 8. On part 2, pin 8 is charge enable (CE).
From the factory, the CE pin has a pulldown resistor and the TS pin is set at
50%ofV , whereapplicable. Thesesignals, ifapplicable, areavailableatthe
CC
connectors for external control.
Note:
Because of the battery-detection circuit, it is not possible to switch-in static
load resistors to jump between regulation and constant-current modes. An
alternate procedure described below uses a dynamic load to replace the
battery circuit. That procedure allows testing of each mode.
This is an alternative way of testing the EVM using a dynamic load board in
place of a battery. The circuit is adjusted to work with the displayed parts and
their inherent thresholds. The sequence of the test procedure is important
because of the active battery-detection circuit, refresh feature, and precharge
and fast-charge current levels. (Switching load in or out has different results
in different modes.) No damage should occur, but results might be different
than anticipated if procedure is altered.
Test Summary
2-3
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Test Procedure
2.2.1 Equipment
1) Power source: current-limited 5-V lab supply with its current limit set to
1.0 A ±0.1 A
2) Two Fluke 75, equivalent or better
3) Oscilloscope – TDS220 or better
4) Load test board (See Figure 2–1.)
Figure 2–1. Load Test Board
Power Supply
DMM
Volts
S4
S1
S2
S3
UUT
5.1 V ± 0.1 V
R1
bq24010/2 EVM
Current Limit
5 Ω
5 W
1 A ± 0.1 A
BAT+
BAT+
R4
66.5 Ω
0.25 W
D1
1N4148
DMM
+
DC+
C1
2000 µF
25 V
R5
66.5 Ω
0.25 W
–
DC–
BAT–
BAT–
R3
3 kΩ
0.25 W
8
7
6
5
8
7
6
2
5
1
Q1
Si4410DY
Q2
Si4410DY
4
4
R6
10 kΩ
R7
10 kΩ
3
2
1
3
0.25 W
0.25 W
2.2.2 Equipment Setup
1) Connect the load board to the BAT+ and BAT–. Set SW1 through SW4 in
the closed position.
2) Connect a voltage meter to the BAT+/BAT– output to monitor the output
voltage (Range is 0 to 5 V).
3) Set the lab supply for 5.1 V ±0.1VDC, 1.0 ±0.1 A current limit and then turn
off supply. Connect the source supply to a current meter and to J1, noting
polarity. (You may use an internal source current meter if it has 5% or
better accuracy.)
4) Install shunt jumpers on the LED pins 1 and 2 of each header J4, J5, and
J6.
5) Connect the scope to the output, BAT+.
2.2.3 Procedure
1) Ensure that equipment setup steps are followed. (Switches should be in
the closed position, shunts installed, and power source set to 5.1V/-0.1V.
Turn on the power source.
2) Verify that output voltage BAT+ charges up to between 2.5 V and 2.9 V,
and the red LED (D1) and green LED (D3) are lit.
3) Open switch SW2, and then close switch SW2.
2-4
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Test Procedure
4) Verify that output voltage BAT+ settles between 3.2 V and 3.95 V.
5) Verify that the input current is between 0.69 A and 0.75 A.
6) Open switch SW3.
7) Verify that the input current is between 100 mA and 150 mA.
8) Verify the output voltage BAT+ is between 4.150 VDC and 4.250 VDC.
9) Open switch SW2.
10) Verify with a scope (250 ms/div, 1 V/div) that output BAT+ charges and
discharges are between the maximum limits of 3 V and 4.35 V, with a
period between 600 ms and 850 ms.
11) Verify that the LEDs flash between RED (D1) and GREEN (D2, mostly on
green).
12) Open switch SW4 and verify that D1 and D2 are off and D3 is on.
13) Verify, with a scope on BAT+, a square wave between the maximum limits
of 1.3 and 4.35 VDC and a frequency between 3.5 and 4.5 Hz.
14) Close switches SW2, SW3, and SW4 (all switches should be closed now)
and power down the supply.
15) The EVM is good if all tests are passed.
Test Summary
2-5
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Chapter 3
Schematic, Physical Layouts, and
Bill of Materials
This chapter contains the schematic diagram, the board layouts and assembly
drawings, and the bill of materials required for the EVM.
Topic
Page
3.1 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Physical Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4 Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-1
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U1
bq24010
J1
4
3
2
1
1
2
1
2
3
4
5
10
9
BAT+
DC+
IN
OUT
BAT
TS
BAT–
DC–
VCC
8
TS(/CE)
BAT–
2
STAT1
STAT2
VSS
7
C2
1 µF
10 V
C1
1 µF
10 V
PG
6
R1
1.5 kΩ
R2
1.5 kΩ
ISET
J2
J3
11
R3
1
TP1
1 MΩ
D1
Red
D2
Green
2
R5
1.5 kΩ
D3
Green
C3
0.47 µF
R6
1 MΩ
R4
1.13 kΩ
TP2
1
2
3
4
STAT1
STAT2
DC–
PG
LED EXT
STAT1 JUMPER
LED EXT
STAT2 JUMPER
LED EXT
PG JUMPER
1
2
Not installed
bq24012 EVM (IC)– TS pin becomes /CE. R6 becomes 10 kΩ and R3 is removed
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Physical Layouts
3.2 Physical Layouts
3.2.1 Board Layout
Figure 3–2 shows the assembly view of the EVM. Figure 3–3 shows the top
layer. Figure 3–4 shows the bottom layer.
Figure 3–2. Assembly View
Schematic, Physical Layouts, and Bill of Materials
3-3
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Physical Layouts
Figure 3–3. Top Layer
Figure 3–4. Bottom Layer
3-4
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Bill of Materials
3.3 Bill of Materials
Table 3–1 lists materials required for the EVM.
Table 3–1.Bill of Materials
bq24010 bq24012
Ref
Item#
Description
Size
MFR
Part Number
–1
–2
Des
1
0
0
C1
Capacitor, ceramic, X5R,
1 µF, 10 V
805
Panasonic ECJ-2YB1A105K
Panasonic ECJ-2YB1A105K
Panasonic ECJ-2YB1C474K
2
3
1
1
1
2
1
2
3
3
2
0
1
1
0
1
1
1
2
1
2
3
3
0
1
1
0
1
C2
C3
D1
Capacitor, ceramic, X5R,
1 µF, 10 V
805
805
Capacitor, ceramic, X7R,
0.47 µF, 16 V
4
Diode, LED, red, 1.8 V,
20 mA, 20 mcd
603
Lite-On
Lite-On
OST
OST
Sullins
Std
160-1181-1-ND
160-1183-1-ND
ED1514
5
D2, D3 Diode, LED, green, 2.1 V,
20 mA, 6 mcd
603
6
J1
Terminal block, 2 pin, 6 A,
3,5 mm
0.27 × 0.25
0.55 × 0.25
0.100 × 3
603
7
J2, J3
Terminal block, 4 pin, 6 A,
3,5 mm
ED1516
8
J4, J5, Header, 3 pin, 100 mil
J6 spacing, (36-pin strip)
PTC36SAAN
Std
9
R1, R2, Resistor, chip, 1.5 kΩ,
R5 1/16 W, 1%
10
11
12
13
14
R3, R6 Resistor, chip, 1 MΩ,
602
Std
Std
1/16 W, 1%
R6
R4
U1
U1
Resistor, chip, 10 kΩ,
1/16 W, 1%
603
Std
Std
Resistor, chip, 1.3 kΩ,
1/16 W, 1%
603
Std
Std
IC, single Li-Ion/Li-Poly,
charge manager
MLP10
MLP10
0.100
TI
bq24010DRC
bq24012DRC
IC, single Li-Ion/Li-Poly,
charge manager
TI
15
16
3
1
3
1
—
—
Shunt, 100-mil, black
3M
929950-00
SLUP162
PCB, bq24010/2,
Any
1.6 in × 1.3 in × 0.031 in
Notes: 1) These assemblies are ESD sensitive; ESD precautions must be observed.
2) These assemblies must be clean and free from flux and all contaminants. Use of no-clean flux is not acceptable.
3) These assemblies must comply with workmanship standards IPC-A-610 Class 2.
4) Reference designators marked with an asterisk (**) cannot be replaced by substitutes. All other components can
be replaced with equivalent manufacturer components.
3.4 Reference
1) bq2401x data sheet (SLUS530)
Schematic, Physical Layouts, and Bill of Materials
3-5
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