User's Guide SLUU419A - April 2010 - Revised April 2011 bq24180 Evaluation Module The bq24180 evaluation module allows for the complete evaluation of the bq24180, a switch-mode, charge-management device for single-cell Li-ion and Li-polymer batteries used in a wide range of portable applications. This document provides a test summary, equipment setup, and the procedures for using with a single-cell battery or a simulated battery load. 1 2 3 4 5 Contents Introduction .................................................................................................................. 2 1.1 EVM Features ...................................................................................................... 2 1.2 General Description ................................................................................................ 2 1.3 I/O Description ...................................................................................................... 2 1.4 Control and Key Parameters Setting ............................................................................ 3 1.5 Recommended Operating Conditions ........................................................................... 3 Test Summary ............................................................................................................... 3 2.1 Equipment ........................................................................................................... 3 2.2 DCOUT Load #2 ................................................................................................... 3 2.3 Multimeters and Oscilloscope .................................................................................... 3 2.4 Computer ............................................................................................................ 4 2.5 HPA172 Communication Kit ...................................................................................... 4 2.6 Software ............................................................................................................. 4 Equipment Setup ............................................................................................................ 4 Procedure for Use With Single-Cell Li-Ion Battery or Simulated Battery Load ..................................... 6 4.1 Charge Voltage and Current Regulation ........................................................................ 6 Schematic, Board Layouts, and Bill of Materials ........................................................................ 8 5.1 bq24180EVM Schematic .......................................................................................... 8 5.2 Board Layouts ...................................................................................................... 9 5.3 Bill of Materials .................................................................................................... 13 List of Figures 1 Connections of HPA172 Kit................................................................................................ 4 2 Evaluation Setup ............................................................................................................ 5 3 Main Window of bq24180 Evaluation Software ......................................................................... 5 4 TP9 - Switch Node at 5-Vdc Input and 1.15-A Charge With 3.3-Vdc Battery ...................................... 7 5 Top Assembly ............................................................................................................... 9 6 Top Copper Layer ......................................................................................................... 10 7 Bottom Copper Layer ..................................................................................................... 11 8 Silkscreen................................................................................................................... 12 SLUU419A - April 2010 - Revised April 2011 Submit Documentation Feedback bq24180 Evaluation Module Copyright (c) 2010-2011, Texas Instruments Incorporated 1 Introduction 1 Introduction 1.1 EVM Features * * * * * * * * * 1.2 www.ti.com Evaluation module for bq24180 High-efficiency, fully integrated NMOS-NMOS synchronous buck charger with 3-MHz frequency Integrated power FETs for up to 1.5-A charge rate Programmable battery voltage, charge current, and input current via I2C interface Input operating range 4-V to 9.5-V normal operation and 9.5-V to 16-V limited operation Switched battery power, DCOUT LED indication for status signals Test points for key signals available for testing purposes. Easy probe hook-up Jumpers available. Easy-to-change connections. General Description The bq24180 evaluation module (EVM) is a complete charger module for evaluating a compact, flexible, high-efficiency, USB-friendly switch-mode charge-management solution for single-cell Li-ion and Li-polymer batteries used in a wide range of portable applications. The bq24180 integrates a synchronous PWM controller, power MOSFETs, input current sensing, high-accuracy current and voltage regulation, and charge termination, into a small WCSP package. The charge parameters can be programmed through an I2C interface. For details, see the bq24180 data sheet (SLUSA02). 1.3 2 I/O Description Jack Description J1-DC+ AC adapter or USB, positive output J1-GND AC adapter or USB, Ground J2-(CSOUT) Connect to battery positive terminal J2-BAT- (GND) Battery negative terminal, connect to Ground (DC-) J5-SCL I2C clock, connect to SCL pin J5-SDA I2C data, connect to SDA pin J5-DC- AC adapter or USB, Ground J4-Communication Connector Connect to 10-pin ribbon cable to USB interface adapter J3-DCOUT Switched battery connection J3-GND AC adapter or USB, Ground J6-TS Connect to external 4.7k NTC thermistor if JMP4 is removed. J6-STAT External status monitor connection; set JMP3 shunt to EXT J6-INT Status indication for host processor J6-GND Ground reference connection bq24180 Evaluation Module Copyright (c) 2010-2011, Texas Instruments Incorporated SLUU419A - April 2010 - Revised April 2011 Submit Documentation Feedback Test Summary www.ti.com 1.4 1.5 Control and Key Parameters Setting Jack Description Factory Setting JMP1 HI 1-2: CD high (disables charge) LO 2-3: CD low (enables charge) Jumper on LO (2-3) JMP2 HI 1-2: high (USB source connected) LO 1-2: low (adapter source connected) Jumper on (1-2) JMP3 LED 1-2: Connect STAT pin to LED on EVM EXT 2-3: Connect STAT pin to J6-3 Jumper on LED (1-2) JMP4 HI 1-2: High (charger disabled in default mode) LO 2-3: TS biased with fixed 4.7-k resistor Jumper on LED (2-3) Recommended Operating Conditions Min Typ Max Supply voltage, VIN Input voltage from ac adapter input 4 5 9 V Battery voltage, VBAT Voltage applied at VBAT terminal of J8 0 3-4.2 4.44 V Supply current, IAC Maximum input current from ac adapter input 0 0.1-0.5 1.5 A Charge current, Ichrg Battery charge current 0.55 0.7 1.5 A 125 C Operating junction temperature range, TJ 2 Test Summary 2.1 Equipment 2.1.1 0 Unit Power Supplies Power Supply 1 (PS#1) is a power supply capable of supplying 5 V at 2 A. Optional Power Supply 2 is for use with optional battery simulated load (PS#2), a power supply capable of supplying 5 V at 2 A. 2.1.2 Battery Pack or Simulated Load A Li-ion, single-cell pack with capacity of at least 1200 mAh can be used or a simulated load of 2.8 (two 5.6-, 10-W power resistors in parallel), with a 0.1- current sense in the return to the UUT and a power silicon diode (cathode) connected to the BAT+ side of the load. IN5821 Simulated Battery Load Circuit 2.2 DCOUT Load #2 A 25-, 3-W power resistor 2.3 Multimeters and Oscilloscope Three Fluke 75, (equivalent or better) multimeters Oscilloscope that can capture 10-MHz waveforms SLUU419A - April 2010 - Revised April 2011 Submit Documentation Feedback bq24180 Evaluation Module Copyright (c) 2010-2011, Texas Instruments Incorporated 3 Equipment Setup 2.4 www.ti.com Computer A computer with at least one USB port and a USB cable. The bq24180 evaluation software must be properly installed. 2.5 HPA172 Communication Kit A HPA172 USB to I2C communication kit. 2.6 Software 1.0 BQ24180A_Gui_Software.zip Double-click on the SETUP.EXE file. Follow the installation steps. 3 Equipment Setup 1. Set PS#1 for 5 V 100 mVdc, 1.7 0.1-A current limit and then turn off supply. Connect the output of PS#1 to J1 (DC+, DC-). 2. If simulated battery circuit is used in place of a battery, set the PS#2 for 3.5 V 100 mVdc, 1.8 0.1-A current limit and then turn off supply. 3. Connect the battery (discharged to ~3.1 V) or simulated battery load to J2 as shown in Figure 2. If simulated load is used, connect the output of PS#2 (+ lead) to the anode of the simulated load and return to ground (DC-). 4. Connect the system load to J3 (DCOUT, GND). 5. Connect digital multimeter 1 (DMM#1) across J2 (BAT+, GND), and set to measure DCV (5-V range). 6. Connect DMM#2 across BAT- Sense Resistor (0.1 , 2 W), and set to measure mVdc (< 300-mV range). 7. Connect DMM#3 across the J3 (DCOUT, GND), and set to measure DCV (5-V range). 8. Connect J4 to HPA172 kit by 10-pin ribbon cable. Connect the USB port of the HPA172 kit to the USB port of the computer. The connections are shown in Figure 1. I/O USB Interface Adapter Texas Instruments (c) 2006 USB To Computer USB port 10 - pin Ribbon Cable To EVM Figure 1. Connections of HPA172 Kit 9. Install jumpers JMP1-2/3 (CD, GND); JMP2-1/2 (PSEL, HI); JMP3-1/2 (LED); JMP4-2/3 (TS_4.7k, GND) 10. Connect scope to TP9 and set to 2 V/div and 200 ns/div (not shown in setup). 4 bq24180 Evaluation Module Copyright (c) 2010-2011, Texas Instruments Incorporated SLUU419A - April 2010 - Revised April 2011 Submit Documentation Feedback Equipment Setup www.ti.com Figure 2. Evaluation Setup 11. Ensure that EQUIPMENT SETUP steps are followed. Turn on the computer. Open the bq24180 evaluation software, by double-clicking on bq24180.exe (file found in the product folder, but needs uploaded to the computer running the test). The main window of the software is shown in Figure 3. Figure 3. Main Window of bq24180 Evaluation Software SLUU419A - April 2010 - Revised April 2011 Submit Documentation Feedback bq24180 Evaluation Module Copyright (c) 2010-2011, Texas Instruments Incorporated 5 Procedure for Use With Single-Cell Li-Ion Battery or Simulated Battery Load www.ti.com 4 Procedure for Use With Single-Cell Li-Ion Battery or Simulated Battery Load 4.1 Charge Voltage and Current Regulation * * * * * * * * * * * 6 Turn on PS#2 if simulated battery load is used and then PS#1. Software setup: (a) Under Settings: Set Maximum Battery Regulation Voltage to 4.3 V via the pulldown window. (b) Under Settings: Set Maximum Charge Current to 1.55 A via the pulldown window. (c) Under Registers R0-R7: Click the Write button (W) by the Safety Limit (R6) in the lower right corner. These values can only be changed on the first write command after having been powered by the battery. (d) Under Watchdog Timer: Check the Periodic Resets box, and set time to 20 Sec. (e) On the Top Tool Bar: Select the Write On Change button to turn to ON. (f) On the Top Tool Bar: Select the Auto Read button to turn to ON, and set the time to 10 Sec via the pulldown window. Measure and verify the following conditions: - Verify Meter #1 is between 3.0 and 3.4 V. (If battery is used and its voltage is over the default regulation voltage, then there is no charge current.) - Verify Meter #2 is between 9 mV and 15 mV (90 to 150 mA) - Verify Meter #3 is between 0.0 and 0.1 V. - Verify Input Current of PS#1 is between 80 mA and 100 mA. - Verify The STAT LED, on the UUT, is off (disabled). This is an example of default mode where the input current limit is 100 mA, maximum, with a maximum regulation of 3.5 V. If VBAT > 3.5 V, then the charge current goes to zero. Operation Changes Via Software: (a) Under Settings: Set Battery Regulation Voltage to 4.0 V via the pulldown window. (b) Under Settings: Set USB Host Current Limit to No Limit via the pulldown window. (c) Under Settings: Set Charge Current (ICHG) to 1.15 A via the pulldown window. (d) Under Controls: Check the Enable DCOUT box. (e) Under Controls: Check the Enable STAT Function box. Measure and verify the following conditions: - Verify Meter #1 is between 3.2 V and 3.6 V. - Verify Meter #2 is between 80 mV and 120 mV (800 mA to 1200 mA). - Verify Meter #3 is between 3.2 V and 3.6 V. - Verify Input Current of PS#1 is between 75 mV and 100 mV (750 mA and 1000 mA). - Verify The STAT LED, on the UUT, is on (enabled). This shows operation in fast charge constant current. Measure TP9 with ground sleeve of oscilloscope probe touching TP8 (GND). Set the oscilloscope to 200 ns/div and 2 V/div. The waveform must look like Figure 4 with the following boundaries: frequency must be 3 MHz 20%, the amplitude is +5 V 0.5 V and 0 V to -0.5 V and the duty cycle is 30 10% duty cycle. Uncheck the Watchdog Timer box and wait until the charge goes into default mode (less than 35 seconds), and observe that the charge current has dropped to ~125 mA (USB 100-mA input current limit). Ground the TS pin by placing a short between J6-TS and J6-GND. This simulates a high-temperature fault in default mode and shuts down the charge current in less than 35 seconds. To return to default mode, remove the short. A temperature fault in default mode shuts off the charge, whereas a temperature fault in normal communication mode only notifies the host of a change in its register and does not disable the charge. See the data sheet for complete information on all specifications and functions. The software menu is intuitive and can be used to change many parameters. After evaluation, turn off PS#1 and then PS#2, if used. bq24180 Evaluation Module Copyright (c) 2010-2011, Texas Instruments Incorporated SLUU419A - April 2010 - Revised April 2011 Submit Documentation Feedback Procedure for Use With Single-Cell Li-Ion Battery or Simulated Battery Load www.ti.com TP9_Switch node Figure 4. TP9 - Switch Node at 5-Vdc Input and 1.15-A Charge With 3.3-Vdc Battery SLUU419A - April 2010 - Revised April 2011 Submit Documentation Feedback bq24180 Evaluation Module Copyright (c) 2010-2011, Texas Instruments Incorporated 7 Schematic, Board Layouts, and Bill of Materials 5 Schematic, Board Layouts, and Bill of Materials 5.1 bq24180EVM Schematic 8 bq24180 Evaluation Module Copyright (c) 2010-2011, Texas Instruments Incorporated www.ti.com SLUU419A - April 2010 - Revised April 2011 Submit Documentation Feedback Schematic, Board Layouts, and Bill of Materials www.ti.com 5.2 Board Layouts Figure 5. Top Assembly SLUU419A - April 2010 - Revised April 2011 Submit Documentation Feedback bq24180 Evaluation Module Copyright (c) 2010-2011, Texas Instruments Incorporated 9 Schematic, Board Layouts, and Bill of Materials www.ti.com Figure 6. Top Copper Layer 10 bq24180 Evaluation Module Copyright (c) 2010-2011, Texas Instruments Incorporated SLUU419A - April 2010 - Revised April 2011 Submit Documentation Feedback www.ti.com Schematic, Board Layouts, and Bill of Materials Figure 7. Bottom Copper Layer SLUU419A - April 2010 - Revised April 2011 Submit Documentation Feedback bq24180 Evaluation Module Copyright (c) 2010-2011, Texas Instruments Incorporated 11 Schematic, Board Layouts, and Bill of Materials www.ti.com Figure 8. Silkscreen 12 bq24180 Evaluation Module Copyright (c) 2010-2011, Texas Instruments Incorporated SLUU419A - April 2010 - Revised April 2011 Submit Documentation Feedback Schematic, Board Layouts, and Bill of Materials www.ti.com 5.3 Bill of Materials Table 1. Bill of Materials for bq24180EVM Count RefDes Value Description Size Part Number MFR 3 C1, C2, C7 1 F Capacitor, Ceramic, Low Inductance, 10V, X5R, 10% 0603 ECJ-1VB1A105K Panasonic 2 C9, C10 10 F Capacitor, Ceramic, 10V, X5R, 10% 0805 ECJ-2FB1A106K Panasonic 1 C3 1 F Capacitor, Ceramic, X5R, 16V, 10% 0603 ECJ-1VB1C105K Panasonic 2 C4, C6 0.1 F Capacitor, Ceramic, Low Inductance, 16V, X7R, 10% 0603 ECJ-1VB1C104K Panasonic 1 C5 0.01 F Capacitor, Ceramic, Low Inductance, 25V, X7R, 10% 0603 ECJ-1VB1E103K Panasonic 1 C8 4.7 F Capacitor, Ceramic, 16V, X5R, 10% 0805 ECJ-2FB1C475K Panasonic 1 D1 BZX84C6V2W Diode, Zener, 6.2-V, 200-mW SOT-323 BZX84C6V2W Diodes 1 D2 Green Diode, LED, Green, 2.1-V, 20-mA, 6-mcd 0603 LTST-C190GKT-7-F Lite On 3 J1, J2, J3 ED555/2DS Terminal Block, 2-pin, 6-A, 3.5mm 0.27 x 0.25 inch ED555/2DS OST 1 J4 Connector, Male Straight 2x5 pin, 100mil spacing, 4 Wall 0.338 x 0.788 inch N2510-6002-RB 3M 1 J5 ED555/3DS Terminal Block, 3-pin, 6-A, 3.5mm 0.41 x 0.25 inch ED555/3DS OST 1 J6 ED555/4DS Terminal Block, 4-pin, 6-A, 3.5mm 0.55 x 0.25 inch ED555/4DS OST 4 JMP1, JMP2, JMP3, JMP4 PEC03SAAN Header, Male 3-pin, 100mil spacing, 0.100 inch x 3 PEC03SAAN Sullins 1 L1 1.0 H Inductor, SMT, 1.5A, 80milliohm, 30% 2.5 x 2.0 mm LQM2HPN1R0MJ0 or MIPS2520D1R0 or MDT2520-CN1R0M or CP1008 Murata or FDK or TOKO or Inter-Technical 1 R1 4.99k Resistor, Chip, 1/16W, 1% 0603 Std Std 1 R2 4.7k Resistor, Chip, 1/16W, 1% 0603 Std Std 1 R3 100k Resistor, Chip, 1/16W, 1% 0603 Std Std 1 R4 0.068 Resistor, Chip, 1/10W, 1% 0805 Std Std 1 R5 1.5k Resistor, Chip, 1/16-W, 5% 0603 Std Std 2 R6, R7 200 Resistor, Chip, 1/16W, 1% 0603 Std Std 0 TP1 thru TP7 STD Test Point, 0.020 Hole" 1 TP8 5001 Test Point, Black, Thru Hole Color Keyed 0.100 x 0.100 inch 5001 Keystone 1 TP9 5000 Test Point, Red, Thru Hole Color Keyed 0.100 x 0.100 inch 5000 Keystone 1 U1 BQ24180YFF IC, Fully Integrated Switch-Mode One-Cell Li-Ion Charger with Full USB Compliance WCSP BQ24180YFF TI 1 -- HPA478 Any 929950-00 3M 4 PCB, 2 In x 2 In x 0.031 In 929950-00 Notes: 1. Shunts 100 mill These assemblies are ESD sensitive, ESD precautions shall 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. Ref designators marked with an asterisk ('**') cannot be substituted. All other components can be substituted with equivalent MFG's components. 5. Installed jumpers JMP1-2/3 (CD, GND); JMP2-1/2 (PSEL, HI); JMP3-1/2 (LED); JMP4-2/3 (TS_4.7k, GND) SLUU419A - April 2010 - Revised April 2011 Submit Documentation Feedback bq24180 Evaluation Module Copyright (c) 2010-2011, Texas Instruments Incorporated 13 Evaluation Board/Kit Important Notice Texas Instruments (TI) provides the enclosed product(s) under the following conditions: This evaluation board/kit is intended for use for ENGINEERING DEVELOPMENT, DEMONSTRATION, OR EVALUATION PURPOSES ONLY and is not considered by TI to be a finished end-product fit for general consumer use. Persons handling the product(s) must have electronics training and observe good engineering practice standards. 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TI assumes no liability for applications assistance, customer product design, software performance, or infringement of patents or services described herein. Please read the User's Guide and, specifically, the Warnings and Restrictions notice in the User's Guide prior to handling the product. This notice contains important safety information about temperatures and voltages. For additional information on TI's environmental and/or safety programs, please contact the TI application engineer or visit www.ti.com/esh. 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. FCC Warning This evaluation board/kit is intended for use for ENGINEERING DEVELOPMENT, DEMONSTRATION, OR EVALUATION PURPOSES ONLY and is not considered by TI to be a finished end-product fit for general consumer use. It generates, uses, and can radiate radio frequency energy and has not been tested for compliance with the limits of computing devices pursuant to part 15 of FCC rules, which are designed to provide reasonable protection against radio frequency interference. Operation of this equipment in other environments may cause interference with radio communications, in which case the user at his own expense will be required to take whatever measures may be required to correct this interference. EVM Warnings and Restrictions It is important to operate this EVM within the input voltage range of 0 V to 16 V and the output voltage range of 0 V to 4.5 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 75 C. The EVM is designed to operate properly with certain components above 75 C 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. 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