DV2031S2 Lead-Acid Charger Development System Control of On-Board P-FET Switch-Mode Regulator The DV2031S2 can be configured for three different charge algorithms with jumpers JP1 and JP3. The charge algorithms available are Features a bq2031 fast-charge control evaluation and development Two-step voltage a Onboard configuration for fast charge of 2, 3, 4 or 6 lead-acid cells; user-defined option allows other configurations Two-step current Pulsed current a Selectable charge algorithms: Two-Step Voltage, Two-Step Current, or Pulsed Current Each algorithm consists of pre-charge qualification, fast charge, and maintenance charge periods. a Constant current (up to 2.5A) and constant voltage (up to 15V) provided by on-board switch-mode regulator Fast charge termination occurs on Maximum voltage The second difference of cell voltage ( 2V) a Charge termination by maximum voltage, second difference of cell voltage, minimum current, or maximum time-out Minimum current Maximum time-out a Direct connections for battery, thermistor, and power supply The maintenance charge may be configured for either a regulated float voltage or a pulsed current. a MTO is set for 3.1 hours The user provides a DC power supply and batteries and configures the board for the number of cells, the minimum current threshold, and the LED display mode. The board has direct connections for the battery and the provided thermistor. a Jumper-configurable 3-LED display General Description Before using the DV2031S2 board, please review the bq2031 data sheet (SLUS156) and the application note entitled "Using the bq2031 to Charge Lead-Acid Batteries" (SLUA017). The DV2031S2 Development System provides a development environment for the bq2031 Lead-Acid FastCharge IC. The DV2031S2 incorporates a bq2031 in a buck-type switch-mode regulation mode to provide fast-charge control for 2, 3, 4, or 6 lead-acid cells. Please be aware that three important notices concerning operating limitations, standard warranty, and liability limitations appear at the end of this data sheet. SLUU023B DECEMBER 1998 REVISED MARCH 2007 Rev. B Board 1 DV2031S2 Connection Descriptions ICHG = TB1 DC+ Charger supply (DC) 30V MAX DC- Ground from charger supply and low side of system load The value of RSNS (R20 in the schematic) at shipment is 0.10. This resistor can be changed depending on the application. The suggested maximum charging current I MAX for the bq2031S1 board is 2.5A with an accuracy of 10%. TB2 BAT+ Positive battery terminal BAT- Negative battery terminal TEM- Thermistor connection (negative) TEM+ Thermistor connection (positive) JP1 QSEL Charge algorithm select JP2 DSEL Display mode select JP3 TSEL Charge algorithm select JP4 IGSEL Minimum current select JP5 Number of cells T h e t h er m is t or p r ov id ed is t h e P h ili p s 2322-640-63103. With this thermistor connected between TEM+ and TEM-, the temperature fault limits are VLTF (low temperature fault) = 0C, VHTF (high temperature fault) = 45C, and VTCO (charge cutoff) = 47C. Jumper-Selectable Configuration The DV2031S2 must be configured as follows: DSEL (JP2) selects the LED display options as described in Table 1 on the following page. TSEL (JP3) and QSEL (JP1) select the charge algorithm as shown in Table 2 on the following page. Fixed Configuration IGSEL (JP4) sets IMIN and the Two-Step Current maintenance charge as a ratio of IMAX. ICOND = IMAX/5, as shown below: The DV2031S2 board has the following fixed characteristics: VCC for the fast charge IC is regulated on-board from the supply at connector TB1. TB1 can accept a maximum of 30VDC. The minimum charging voltage for two cells is 10VDC, and the minimum charging voltage for six cells is 22VDC. JP4 L H None LED1 and LED2 indicate charge status. Charge begins on the later application of The battery 2. Supply voltage IMIN IMAX IMAX IMAX 10 20 30 Fixed-Pulse Average Current ICOND ICOND ICOND 2 4 8 = = = IMAX IMAX IMAX 10 20 30 As indicated in the Jumper Configuration Diagram, JP5 configures the board for the number of lead-acid cells. LED3 indicates a charge-pending or fault condition. 1. 0.25V RSNS The onboard regulator supplies a fast charge current IMAX of 2.5A. The fast (bulk) charge voltage VBLK is set at 2.45V per cell (1%) and the float voltage VFLT is set at 2.25V per cell (1%) The number of cells can be changed within board-defined parameters, as described below in "Jumper-Selectable Configuration." The switching frequency of the PWM control is 100kHz. The regulated current is controlled by the value of the sense resistor RSNS according to the equation Rev. B Board 2 DV2031S2 Table 1. bq2031 LED Display Output Summary Mode Charge Action State L LED2 LED3 Battery absent or over-voltage fault Low Low High Pre-charge qualification Flash Low Low Fast charging High Low Low Maintenance charging Low High Low Charge pending (temperature out of range) X X Flash Charging fault X X High H Battery absent or over-voltage fault Low Low High Pre-charge qualification High High Low Fast charge Low High Low Maintenance charging High Low Low Charge pending (temperature out of range) X X Flash Charging fault X X High Battery absent or over-voltage fault Low Low High None Notes: LED1 Pre-charge qualification Flash Flash Low Fast charge: current regulation Low High Low Fast charge: voltage regulation High High Low Maintenance charging High Low Low Charge pending (temperature out of range) X X Flash Charging fault X X High 1 = VCC; 0 = VSS; X = LED state when fault occurred; Flash = 16 s low, 16 s high. In the Pulsed Current algorithm, the bq2031 annunciates maintenance when charging current is off and fast charge whenever charging current is on. Table 2. Charge Algorithms JP1 JP3 Fast Charge Termination Maintenance L H or L Two-Step Voltage IMIN or MTO Constant voltage at VFLT H L Two-Step Current VBLK or 2V or MTO Fixed-pulse current at ICOND H H Pulsed Current VBLK (see Note) Fast-charge rate when VBLK VFLT Note: Fast-charge termination by MTO is a fault. Rev. B Board 3 DV2031S2 Jumper Configuration Diagram JP5 TB2 BAT+ TB1 QSEL DSEL TSEL BAT- 2 TEM- 3 4 6 Cells # L L DC- L DC+ TEM+ L JP4 IGSEL H JP1 H JP2 H JP3 H JC2031.eps Setup Procedure 1. Configure DSEL, TSEL, QSEL, maximum time-out, and the number of cells. 2. Connect the thermistor to TEM+ and TEM-. 3. Attach the battery pack to BAT+ and BAT-. 4. Connect the charging supply to TB1 (DC+, DC-). The combined charging and system load should not exceed the IMAX limit of 2.5A. Rev. B Board 4 DV2031S2 DV2031S2 Board Schematic D6A VDC 1 2 VDC+ 1N5821 TB1 R21 D6B Q3 ZTX790A SBL845DI 20K Q1 MTP23P06V R6 L1 10K 200H 1 D1 1N4148 C6 R4 1000F 35V 10K D2 1N4744 U2 102K 1% 2 Cell 3 Cell 261K 1% C14 470F 35v TB2 BAT BAT+ BAT- 6 Cell 1 2 3 4 TEM 0.1F R20 2 4 6 8 0.10 2W JP5 Q4 ZTX790A C9 10F 4 Cell R14 C15 100K 1000pF C3 154K 1% TEMTEM+ R7 +5V 78L05 52.3K 1% 1 C4 IN OUT GND D7A SBL845DI R17 R15 R16 D7B 1N5821 Q2 2N3904 10F 1 3 5 7 1 C7 10F 35V R22 43_OHMS JP3 JP2 JP1 TSEL DSEL QSEL Q5 3 2 1 3 2 1 R12 R8 2N3904 3 2 1 220 49.9K 1% +5V +5V JP4 IGSEL R10 10K R11 R9 10K 10K C2 R5 C5 0.1F 62K 0.1F R19 464K 1% 0.01F 3 2 1 R18 1K C13 U1 LED3 C11 2 2 LED2 LED1 C8 16 15 14 13 12 11 10 9 LED2/DSEL LED1/TSEL MOD VCC VSS COM LED3/QSEL TPWM TMTO FLOAT BAT VCOMP ICOMP IGSEL SNS TS +5V R2 6.81K 1% R3 3.74K 1% 1 2 3 4 5 6 7 8 0.1F bq2031 D4 LED1 D3 LED2 D5 LED3 R1 1K C12 1000pF C1 R13 0.1F 0_OHMS C10 2031s2-b.eps 1 See application note for additional details. 2 Not used 0.1F Rev. B Board 5 EVM WARNINGS AND RESTRICTIONS It is important to operate this EVM within the input voltage range of 30 V and the output voltage range of 21 V and 4.6 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. Applying loads outside of the specified output range may result in unintended operation and/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 60C. The EVM is designed to operate properly with certain components above 60C as long as the input and output ranges are maintained. These components include but are not limited to linear regulators, switching transistors, pass transistors, and current sense resistors. 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 2007, Texas Instruments Incorporated 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 of the product, it is the user's responsibility to take any and all appropriate precautions with regard to electrostatic 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's Guide prior to handling the product. This notice contains important safety information about temperatures 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 2007, Texas Instruments Incorporated 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 2007, Texas Instruments Incorporated Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: Texas Instruments: DV2031S2