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PS5164
PS501 Four-Cell Battery Manager Module with LED SOC Display for Lithium Chemistries
Features
* PS501 tested, fully populated modules for evaluation * Designed to work with 4 series cell Lithium chemistry configurations * Performs all major Lithium battery management functions, including: - Accurate capacity monitoring - Lithium cell protection * SOC display with four LEDs and a switch * 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 16-bit integrating A/D * Precise capacity reporting using Microchip patented algorithms and 3D battery cell models * 3D models and "learned" parameters stored in integrated memory * Complete hardware and software development tools available: - PS050 PC software - ICD (In-Circuit Debugger) port to support development of custom code * Extremely low-power operation: - Run mode: 170 A typical - Low-Voltage Sleep mode: 45 A typical - Shelf-Sleep mode: 25 A typical * Overall mechanical dimensions: - 0.525 W x 2.500 L (inches) - 13.3 W x 63.5 L (millimeters)
Ordering Information
Part Number PS5164 Description Li Ion/Poly - 4 series cells
2004 Microchip Technology Inc.
DS21850B-page 1
PS5164
1.0 GENERAL DESCRIPTION
Step 1) The PS5164 module is a complete smart battery controller subsystem based on the Microchip PS501 field reprogrammable battery manager with patented Accuron(R) technology. The module is designed to operate in a battery pack consisting of four (4) series connected Li-based cells. The module consists of the Microchip PS501 battery manager IC with a four-LED SOC display and an optional connection for an external thermistor. Configure the module for optional external thermistor use. PS5164 modules are shipped configured to use the internal temperature sensor only. To add an external thermistor to the board, remove resistor R16 (side 2) and connect the thermistor across via TN and TR. Connect wires to module. Use large diameter wire (18 AWG-20 AWG) for current carrying lines from VR, V1, B+ and BN. All others are signal only lines (24 to 22 AWG). Connect external connector to BN, T, C, D and B+. Connect V1 to the most positive point on the battery cell stack. Connect the negative end of the top-most cell to V2, the negative end of the next cell to V3 and the negative end of the third cell to V4. Connect VR to the most negative point on the battery cell stack. Program the assembled pack using Microchip's software and PowerCalTM board or PowerInfoTM board hardware. The memory parameters can be changed at will using the utilities on the memory page in the software. Step 8) Calibrate the pack using the software and PowerCalTM board hardware. The pack is now ready for use.
Step 2)
Step 3) Step 4) Step 5)
1.1
Quick Start - Pack Assembly
Follow these directions to assemble a pack with the PS5164 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 PS501 family of CMOS ASICs. The pack positive should be securely connected to the module first, followed by the intermediate cells from most positive to least positive and finally, pack negative.
Step 6) Step 7)
FIGURE 1-1:
CONNECTION POINTS (SIDE 1)
DS21850B-page 2
2004 Microchip Technology Inc.
PS5164
FIGURE 1-2: BOARD ASSEMBLY (SIDE 1)
FIGURE 1-3:
BOARD ASSEMBLY (SIDE 2)
2004 Microchip Technology Inc.
DS21850B-page 3
PS5164
2.0
2.1
FUNCTIONAL DESCRIPTION
PS501 Fuel Gauge
2.2
Primary Safety
The module fuel gauge provides State-Of-Charge (SOC) and battery status data in accordance with the SMBus standards version 1.1. The PS501 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 "PS501 Data Sheet" (DS21818) for details on configuring the PS501.
The primary safety circuit provides cell protection from conditions of overcharge, overdischarge and overcurrent. The analog safety IC measures individual cell voltages, current and voltage across the safety FETs. These values are compared against internal reference values and the gates of two N-channel power MOSFETs are controlled based on the comparison results.
3.0
BOARD DESCRIPTION
PCB schematics and bill of materials are included here for completeness. To download the full size schematic and BOM, please visit the Microchip web site.
3.1
Mechanical Dimensions
Overall Dimensions: 2500 mils x 525 mils
DS21850B-page 4
2004 Microchip Technology Inc.
3.2
FIGURE 3-1:
1 TN EXTERNAL THERMISTOR CONNECTIONS (SEMITEC 103AT OR 103ETB -- 10K AT 25C) TR 3 2 1 TN TR LED0 4 CAUTION: LED1 18 LED2 R26 221K LED3 R5 3.65K IO4 IO5 11 VC(1) VC(2) VC(3) VC(4) VDDA
HV1 MCLR HV2
2 F1 SFD167A 1 3 Q1 IRF7424 8 7 6 5 8 7 6 5 4 4 Q2 IRF7424 3 2 1
Schematic
3
4
5
6
D U1 17 VREFT VNTC ROSC 16 REMOVE R16 IF AN EXTERNAL THERMISTOR IS USED PS501 R23 5.1K R21 1.0M R31 5.1K WHEN USING ICD PORT, A 10K RESISTOR MUST BE CONNECTED BETWEEN VDDD AND BNAUX.
V4 12 20K V5 HV2 R6 HV1
VR
VR
C1 330 nF C2 100 nF C3 100 nF C4 100 nF 10 9 8 IO6-PGC IO7-PGD MCLR BNAUX VDDD ICD PORT
RSHP
PS5164 BOARD SCHEMATIC
D
VSSD 14 15 CURRENT SENSE RESISTOR
RSHN
4
C11 100 nF COP VMP CDT NC NC VSS CCT S8254A 7 C9 C8 10 nF 100 nF 6 5 2 15 14 13 12 10 11 VC1 VC2 VC3 VC4 SEL CTL 1 C15 2.2 F 8 9
1.0K 1.0K 1.0K 1.0K
R11 R12 R13 R14
C12 100 nF
C13 100 nF
C14 100 nF
VINI
2004 Microchip Technology Inc.
R16 0 20 240 240 240 R4 R3 R2 R1 SW1
LED0 LED1 LED2 LED3 IO4 IO5 IO6-PGC IO7-PGD SSAFE
CELL CONNECTION
V1
V1
V2
V2
V3
V3
V4
NDS355N Q3 B+ C17 100 nF R17 20K C18 1.0 nF C B+
C VSSA VDDD SMB-CLK SMB-DTA 6 7 20 20 R7 R8 V5 1
C5 330 nF 13
GPIO(0) GPIO(1) GPIO(2) GPIO(3) GPIO(4) GPIO(5) GPIO(6) GPIO(7) GPIO(8) GPIO(9) GPIOHV1 MCLR GPIOHV2
24 25 26 27 2 3 4 5 19 20 21 22 23
240 240 365 2 1 3 D1 AZ23C5V6
C7 330 nF 28
R9 R10 R35
C D T
C D T
R36 0.020 GROUND PLANE CONNECTION C16 100 nF R19 220
BPACK CONNECTIONS
BN
B U2 16 VDD DOP 3
B
PS501-BASED REFERENCE DESIGN FOR 4-CELL Li-ION APPLICATIONS.
FOR REVISION HISTORY, REFER TO 826170 CHANGE LOG. CONTRACT NO.
51
R15 APPROVALS
DRAWN
Microchip Technology, Inc.
DATE
R. CASEBOLT
CHECKED
PowerSmart Products Group 2745 Dallas Parkway, Suite 400 Plano, TX 75093
11/21/2003
http://www.microchip.com 469-241-0087 Voice/469-241-0106 Fax TITLE
A
PRIMARY SAFETY CIRCUIT
PS5164 SCHEMATIC
SIZE CODE IDENT NO. DRAWING NO. REV
A
WITH CAPACITOR VALUES SHOWN: OVERVOLTAGE TIME DELAY: 100 mSEC UNDERVOLTAGE TIME DELAY: 100mSEC OVERCURRENT TIME DELAY: 10 mSEC
B
SCALE FILE
03-826170
NONE
3 4 5
3.1
03-826170 REV 3-1.sch
6
*** CONFIDENTIAL *** THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION THAT IS THE INTELLECTUAL PROPERTY OF MICROCHIP TECHNOLOGY, INC.
Sheet 1 of 1
15-Mar-2004 13:25:09
PS5164
DS21850B-page 5
2
1
PS5164
3.3 Bill of Materials
PS5164 BILL OF MATERIALS
Description Raw PCB, PS5164 C9 C18 Capacitor, Ceramic, 10 nF, 25V, +/-10%, X7R dielectric, 0603 Capacitor, Ceramic, 1.0 nF, 50V, +/-10%, X7R dielectric, 0603 Manufacturer Microchip Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Lumex Diodes Inc. General Semi. Sony Chemicals Manufacturer PN 04-826170 REV. 3.1 ECJ-1VB1E103K ECJ-1VB1H102K ECJ-1VF1E104Z ECJ-2VB1E104K ECJ-2YF1E334Z ECJ-3YF1E225Z SML-LX1206GC-TR AZ23C5V6-7 AZ23-C5V6 SFD-167A Qty. 1 1 1 9 1 3 1 4 1 1
TABLE 3-1:
Symbols
C2-C4, C11-C14, Capacitor, Ceramic, 100 nF, 25V, +80%/-20%, C16-C17 Y5V dielectric, 0603 C8 C1, C5, C7 C15 LED0-LED3 D1 F1 Capacitor, Ceramic, 100 nF, 25V, +/-10%, X7R dielectric, 0805 Capacitor, Ceramic, 330 nF, 25V, +80%/-20%, Y5V dielectric, 0805 Capacitor, Ceramic, 2.2 F, 25V, +80%/-20%, Y5V dielectric, 1206 LED, clear green, 1206 package Dual Zener Diode, 5.6V, +/-5%, 300 mW, common anode, SOT-23 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, 3-terminal surface mount package MOSFET, P-channel Enhancement mode, -30V, 11A, 13.5 mOhms, 1.9W, SO-8 MOSFET, N-channel Enhancement mode, 30V, 1.6A, 0.125 ohms, 500 mW, SOT-23 Resistor, film, 0603, 1%, 3.65 KOhms Resistor, film, 0603, 1%, 365 ohms Resistor, film, 0603, 1%, 221 KOhms, 25 ppm, TC Resistor, zero ohm, 0603 Resistor, film, 0603, 5%, 1.0 KOhms Resistor, film, 0603, 5%, 1.0 Megohms Resistor, film, 0603, 5%, 20 ohms Resistor, film, 0603, 5%, 20 KOhms Resistor, film, 0603, 5%, 220 ohms Resistor, film, 0603, 5%, 5.1 KOhms Resistor, film, 0603, 5%, 51 ohms Resistor, film, 0805, 5%, 20 ohms Resistor, film, 0805, 5%, 240 ohms Resistor, film, 1206, 5%, 240 ohms Resistor, metal strip, 2512, 1%, 0.020 ohms Switch, SPST-momentary, push button, surface mount IC, Single chip Battery Manager, programmable, 25C to 85C, SSOP-28 IC, Battery Protection Circuit, Li Ion, 3 or 4-cell, 40C to 85C, 4.4 mm body width TSSOP-16 package
Q1-Q2 Q3 R5 R35 R26 R16 R11-R14 R21 R7-R8 R6, R17 R19 R23, R31 R15 R1 R2-R4 R9-R10 R36 SW1 U1 U2 Note 1:
Int. Rectifier Toshiba Fairchild Semi. Fairchild Semi. Panasonic Panasonic Susumu Co. Ltd. Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Vishay ALPS Microchip
IRF7424 TPC8108 NDS355N NDS355AN ERJ-3EKF3651V ERJ-3EKF3650V RR0816P-2213-D-34D ERJ-3GEY0R00V ERJ-3GEYJ102V ERJ-3GEYJ105V ERJ-3GEYJ200V ERJ-3GEYJ203V ERJ-3GEYJ221V ERJ-3GEYJ512V ERJ-3GEYJ510V ERJ-6GEYJ200V ERJ-6GEYJ241V ERJ-8GEYJ241V WSL2512-0.020-1%-R86 SKQGADE010 PS501-I/ST
2 1 1 1 1 1 4 1 2 2 1 2 1 1 3 2 1 1 1 1
Seiko Instruments S-8254AAJFT-TB (Note 1)
Other variants of the S-8254A series, with different trip points, are also available. Consult the S-8254A series data sheet.
DS21850B-page 6
2004 Microchip Technology Inc.
PS5164
FIGURE 3-2: PS5164 DIMENSION DETAILS
2004 Microchip Technology Inc.
DS21850B-page 7
PS5164
4.0 DEVELOPMENT TOOL SUMMARY
4.1 Reference Documents
This data sheet provides an overview of the PS5164 Battery Manager module. For further information on the PS501 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 4-1 summarizes the development tool offering from Microchip to support the PS5164. Please refer to the Microchip web site for ordering information and design documentation (including schematics) at www.microchip.com.
TABLE 4-1:
MICROCHIP DEVELOPMENT TOOL SUMMARY
Use Read and write Smart Battery data values, memory programming Read and write Smart Battery data values, memory programming, pack calibration, pack test
Development Tool PowerInfoTM hardware with PC software (PS041) PowerCalTM hardware with PC software (PS042)
TABLE 4-2:
DS21818 DS40234 DS40237
MICROCHIP REFERENCE DOCUMENTS
Documents Available PS501 Single Chip Field Reprogrammable Battery Manager Data Sheet (IC Products) PS041 PowerInfoTM Configuration Interface Product Brief PS042 PowerCalTM Calibration Platform Data Sheet
Document Number
DS21850B-page 8
2004 Microchip Technology Inc.
PS5164
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, Accuron and PowerSmart are registered trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. SmartShunt is a registered trademark Technology Incorporated in the U.S.A. of Microchip
PowerCal, PowerInfo, PowerMate, PowerTool, SmartSensor 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) 2004, Microchip Technology Incorporated. Printed in the U.S.A., All Rights Reserved.
Printed on recycled paper.
2004 Microchip Technology Inc.
DS21850B-page 9
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DS21850B-page 10
2004 Microchip Technology Inc.

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