PICREF-2 OVERVIEW Microchip Technology PICREF-2 Intelligent Batte
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PICREF-2
PICREF-2 OVERVIEW
Microchip Technology PICREF-2 Intelligent Battery Charger (IBC) Reference Design offers ready-made battery charger solution. This Reference Design targeted battery charger applications such camcorders, portable audio equipment, portable phones, portable power tools. With PICREF-2 Reference Design, user will able simply pick their complete battery charging system completing steps listed: Pick required battery management features from modular source code provided. Pick critical battery pack parameters modify global constants those specifications.
Intelligent Battery Charger Reference Design
Typically, simple battery chargers provide intelligence charge different battery technologies batteries with same technology different voltages capacities. best, this leave battery improperly charged. worst, pose serious safety hazard. microcontroller provide intelligence overcome these problems. addition intelligent control, microcontroller provide low-cost, flexible solution charging batteries. Complete battery charging applications developed quickly using microcontroller. this serial communication capability microcontroller, real-time data logging monitoring possible. Simple battery chargers analog components accomplish their function. However, using microcontroller, battery charger made intelligent.
Microcontroller Benefits
Flexibility handle different technologies, voltages capacities. Variable Voltage Generation Control Charge/Discharge Multiple Battery Packs "Windowed" High Resolution
hardware design contains necessary circuitry support charging discharging algorithms, charge termination methods, RS-232 communications. modular source code written consists charge termination algorithms, discharge algorithm, interdevice communications, RS-232 communications modules. based software provides means requesting displaying battery status information.
PICREF-2 Features
Compatibility Across Battery Technologies Cost Flexible Development Environment Fast Charge Rate High Charge Current Capability High Discharge Current Capability Conditioning Real-Time Debug Data Logging User Selectable Embedded Charge Termination Algorithms
Information contained this publication intended through suggestion only superseded updates. representation warranty given liability assumed Microchip Technology Inc. with respect accuracy such information, infringement patents arising from such otherwise. responsibility each user ensure that each Battery Charger adequately designed, safe, compatible with conditions encountered during use. "Typical" parameters vary different applications. operating parameters, including "Typicals", must validated each customer application customer's technical experts. Microchip's products critical components life support systems authorized except with express written approval Microchip. licenses conveyed, implicitly otherwise, under intellectual property rights.
1997 Microchip Technology Inc.
DS30451C-page
PICREF-2
TABLE CONTENTS
System Overview Hardware Overview Firmware Overview.10 Test Results NiCd.24 Test Results NiMH PICREF-2 Software Overview.26 Design Background.32 Design Modifications.35 Appendix System Specifications Appendix Minimum Charger Schematic Appendix Full Charger Schematic Appendix Firmware Listing.42 Appendix PICREF-2 Protocol Appendix Layout Drawing Appendix Bill Materials (BOM) Appendix Battery Charger Demo Unit
ACKNOWLEDGMENTS
Project Lead Engineer: Robert Schreiber, Microchip Technology, Inc. Reference Design Documentation: Beth McLoughlin, Microchip Technology, Inc. System Code Development: TriSys Inc.,Consultants
TRADEMARKS
Duracell registered trademark Duracell. Windows trademark Microsoft Corp. Microsoft registered trademark Microsoft Corp. Yuasa trademark Yuasa. trademark Philips Corporation.
DS30451C-page
1997 Microchip Technology Inc.
PICREF-2
System Overview
PICREF-2 system block diagram shown Figure This reference design charge discharge single dual batteries same type. PIC16C7XX microcontroller contains embedded charging algorithm controls external charging components buck, step-down, converter. develop charging algorithms, PICREF-2 development mode. Once algorithm been developed, PICREF-2 placed stand-alone mode. voltage battery charging generated through buck converter, which controlled PIC16C7XX's Hardware PWM. PIC16C7XX controls battery charging discharging through Battery Charge Select Battery Discharge Select lines. Battery Temperature Battery Voltage lines provide information charge termination algorithm calculation status. Current Sense line monitors current being delivered battery during charge status information. functions implemented using on-board converter PIC16C7XX. electrical specifications system listed Appendix
Development Mode
order develop firmware PICREF-2 system, development mode been included. This mode supports RS-232 serial link battery status communication. PIC16C73A also contains embedded charging algorithm controls external charging components buck converter. Development mode offers real-time debug charge termination algorithms. this mode, charging parameters changed microcontroller software battery data logged.
Stand-Alone Mode
Once correct charging algorithm been developed charge parameters have been determined, global constants stand-alone mode. There RS-232 communication discharge capacity this mode.
FIGURE
PICREF-2 INTELLIGENT BATTERY CHARGER (IBC) BLOCK DIAGRAVoltage Regulator Buck Converter Filter BATTERY CHARGE/ DISCHARGE Battery Charge Select
PIC16C7XX
RS-232
Battery Discharge
Battery
LEDs MCLR
Battery Temperature (A/D) Battery Charge Select
BATTERY CHARGE/ DISCHARGE
PushButtons
Battery Discharge Select
Battery
Battery Temperature (A/D) CURRENT/ VOLTAGE SENSE Voltage Reference
Jumper Selects
Current Sense (A/D) Battery Voltage (A/D) Battery Voltage (A/D)
Current Sense Resistor
1997 Microchip Technology Inc.
DS30451C-page
PICREF-2
Hardware Overview
This section describes PICREF-2 hardware functions Intelligent Battery Charger (IBC) system. Hardware detail (schematics) found Appendix
Voltage Regulator
input voltage (+V_FUSED) used voltage regulator generate needed board. voltage regulator LT1118CS8-5 (U10) replaced (NJM7805). Note: regulators. populated place designer's option.
Microcontroller
PIC16C7XX microcontroller gives PICREF-2 reference design flexibility. Changes made using software instead hardware, charging algorithms easily customized accommodate user's specific battery packs. ability charge discharge either single battery batteries same type means greater flexibility. control voltage generation (via buck converter) monitoring voltage means precise control over voltage used charging batteries. Development mode uses PIC16C73A microcontroller (Figure which provides more memory USART (RS-232) communications port development firmware. Stand-alone mode uses PIC16C72 (Figure PIC16C72 PIC16C73A inserted either 28-pin socket (U17 U19).
Buck (Step-Down) Converter
most critical parameter charging batteries control power source. Whether current voltage charging being used (PICREF-2 uses constant current method), control power source imperative proper battery charging. power source this design buck converter. buck converter chosen because simplicity, efficiency heat dissipation. simplified diagram converter circuit shown Figure
FIGURE
SIMPLIFIED BUCK CONVERTER
FIGURE
PIC16C73A PINOUT
SDIP, SOIC, Windowed Side Brazed Ceramic
MCLR/VPP RA0/AN0 RA1/AN1 RA2/AN2 RA3/AN3/VREF RA4/T0CKI RA5/AN4/SS OSC1/CLKIN OSC2/CLKOUT RC0/T1OSO/T1CKI RC1/T1OSI/CCP2 RC2/CCP1 RC3/SCK/SCL RB0/INT RC7/RX/DT RC6/TX/CK RC5/SDO RC4/SDI/SDA
Where:
Input from microcontroller Input voltage Output voltage Schottky Diode Output capacitor Inductor
PIC16C73A
Buck Converter Basics
PIC16C7XX microcontroller controls buck converter through hardware module external current sense resistor. hardware current sense resistor feedback significant providing accurate repeatable charge methodology. buck converter operates follows. When output high, current passes through transistor inductor battery. During this state, inductor energized capacitor charged. When output low, inductor voltage reverses, current provided through diode. inductor capacitor filter output voltage current.
FIGURE
PIC16C72 PINOUT
SDIP, SOIC, Windowed Side Brazed Ceramic
MCLR/VPP RA0/AN0 RA1/AN1 RA2/AN2 RA3/AN3/VREF RA4/T0CKI RA5/AN4/SS OSC1/CLKIN OSC2/CLKOUT RC0/T1OSO/T1CKI RC1/T1OSI RC2/CCP1 RC3/SCK/SCL RB0/INT RC5/SDO RC4/SDI/SDA
PIC16C72
DS30451C-page
1997 Microchip Technology Inc.
PICREF-2
There modes which buck converter operate: continuous, where current flowing continuously, discontinuous, where current drops zero period time. heavy current loads, converter would continuous mode. Under light load conditions, however, buck converter current fall zero period time. converter this reference design controlled such that always operates continuous mode. Thus, produces sawtooth waveform shown Figure Vsat, constant, increasing decreasing will increase decrease output voltage, Therefore, different battery technologies requiring different charging voltages, varied varying ton. fast recovery Schottky diode recommended diode Either diode provides necessary forward voltage switching speed required. fast recovery diode used PICREF-2. Schottky used lower forward voltage required. output capacitance chosen such that: IpkT 8Vripple where: IoMAX
FIGURE
BUCK CONVERTER OUTPUT CURRENT
Inductor Current Diode Current
IoMAX Maximum output current period Output voltage ripple
Ripple
Vripple
given input voltage output voltage, peak-to-peak amplitude this inductor current waveform remains constant. load current rises falls, entire sawtooth current waveform also rises falls. average value this waveform equal load current.
minimize ripple, choose large value, (equivalent series resistance) capacitor buck converter inductor value determined Vsat Vo)ton where: Vsat IoMAX Input voltage Output voltage Saturation voltage transistor IoMAX Maximum output current time"
Buck Converter Detail
microcontroller output will look like Figure
FIGURE
OUTPUT
relationship between output output voltage ton/T Vsat where: Vsat time" period Input voltage Output voltage Saturation voltage transistor Diode forward-bias voltage drop
From this equation, relationship between (ton) inductor value seen. minimum inductor value (LMIN) calculated from tonMAX. disadvantage this that resolution reduced frequency increased. However, reducing inductor size reduces overall buck converter size price.
This equation valid Since equation derived assuming current flow inductor, special cases (transistor switch (transistor switch valid this equation.
1997 Microchip Technology Inc.
DS30451C-page
PICREF-2
EXAMPLE CALCULATING INDUCTOR VALUE
Using Equation (3), calculate inductor value for: 13.6V Vsat 0.2V
PIC16C7XX powers idle state. battery discharge requested, discharge cycle started followed complete charging cycle. microcontroller also monitors current source (when charging through line) current sense resistor provide constant current battery. microcontroller displays status battery LEDs (see LEDs). LEDs display charging status (CHRG DISCHRG) faulty cell detection (ERROR). These LEDs driven directly from microcontroller lines. more information LEDs. Note: p-channel FETs used select battery charged. populated designer's option.
7.2V
time" (ton), calculated Processor clock (fosc) Duty Cycle Resolution full bits Tosc 63.75 And; 31.87 Finally; 98.8 resolution acceptable, then: Tosc 31.75 49.2 15.875
Voltage Sense
PIC16C7XX performs battery voltage readings during rest period charge cycle. This accomplished reading battery voltage when low. Reading battery voltage during active period charge cycle (PWM high) will result erroneous operation. converter uses "windowing" technique determine charge termination values. "windowing" feature gives higher resolution over standard 5.0V converter range. example, cell voltage NiCd battery typically ranges from 0.8V 1.6V cell. were monitoring four-cell pack, voltage range pack could 3.2V 6.4V. This would exceed limit converter. divide voltage before converter input, would actually lose resolution. "windowing" feature subtracts offset from battery voltage amplifies difference actually give higher resolution. difference voltage gained factor 3.33 that voltage range decreases this factor (and resolution increases this factor). standard range gives resolution (5.0V/ 256) 19.5 mV/bit. With gain factor 3.33, 5.0V range decreases (5.0/3.33) 1.50V (i.e., 1.5V difference will amplified 5.0V converter input). Therefore resolution becomes (1.50 256) 5.86 mV/bit.
Note:
p-channel FETs buck converter. populated place designer's option. populated place designer's option.
Filter Optional
filter circuit intended provide additional ripple suppression buck converter output stage (Figure filtering circuit bypassed connecting JMPR1-1 JMPR1-2 (see JUMPERS). enable filter circuit, connect JMPR2-1 JMPR2-2 JMPR3-1 JMPR3-2. Note: provide additional ripple filtering output buck converter. They populated designer's option.
FIGURE
FILTER
FIGURE Battery Battery Charge/Discharge
PIC16C7XX microcontroller Battery Select line uses transistor select battery charging. Discharge Battery Select line drives transistor ground fully discharge battery. This feature erase voltage depression "memory effect" (see Design Background).
4.8V 4.0V
WINDOWED
3.33R
8-bit with 5.86 mV/bit resolution
DS30451C-page
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PICREF-2
offset adjusted writing digital potentiometer microcontroller "seek out" battery voltage ranging from 15.0V. jumper settings operation "windowed" mode are: JMPR9-1 JMPR10-1 (Battery JMPR7-1 JMPR8-1 (Battery JMPR11-1 JMPR12-1 (Battery JMPR13-1 JMPR14-1 (Battery battery voltage known, digital potentiometer replaced fixed voltage reference still maintain 5.86 mV/bit resolution. jumper settings operation "fixed" mode are: JMPR8-1 JMPR8-2 (Battery JMPR9-1 JMPR10-1 (Battery JMPR12-1 JMPR12-2 (Battery JMPR13-1 JMPR14-1 (Battery addition, "windowing" "fixed" circuit bypassed direct battery voltage read lower resolution needed. jumper settings "direct" mode are: JMPR10-1 JMPR10-2 (Battery JMPR14-1 JMPR14-2 (Battery Note: R17, provide voltage reference "fixed" mode. this mode, removed. battery voltage divided resistors R10, R14. smaller dynamic range that required, these resistor values changed increase "direct" mode resolution.
FIGURE
TEMPERATURE SENSE CIRCUIT
(10k 25°C)
simple lookup table software provides corresponding temperature converted voltage. temperature sense resistors selectable. Note: temperature sense resistors replaced designer's option based designer's battery pack thermistor value.
temperature reading done during period buck converter.
Battery Pack
battery pack provided comprised KR-1100AEL NiCd Fast Charge Battery Cell. standard-charged rate fast-charged 1600 rate. temperature range charging (either standard fast) 45°C. discharge, temperature range -20°C 60°C. Note: Note: Refer manufacturer's specifications before charging battery pack. Improper disposal NiCd batteries poses environmental hazard. Contact local battery collection center recycling information.
Note:
Current Sense
PIC16C7XX performs battery current readings during rest period charge cycle. This accomplished reading battery current when low. Reading battery current during active period charge cycle (PWM high) will result erroneous operation. current sense circuitry works amplifying converting current through 0.05 resistor into voltage. maximum current reading with 0.05 resistor amplifier gain 2.5A (2.5A 0.05 ohms 5.00V). This translates into 9.77 mA/bit resolution (2.5A bits). current sense resistor user replaceable. Note: current sense resistor replaced designer's option give either more range more resolution.
LEDs
LEDs provided indicate status (Table locations PICREF-2 shown Figure through D10).
TABLE INDICATORS
BATTERY CHRG (D5) BATTERY DISCHRG (D6) BATTERY CHRG (D7) BATTERY DISCHRG (D8) ERROR (D9) POWER (D10) Steady Battery charging Battery discharging Battery charging Battery discharging Battery error detected Power Flashing trickle charge trickle charge
Temperature Sense
temperature sense accomplished through pull-up resistor voltage read corresponds thermistor's value relation 25°C value. This means that 25°C converted voltage would 2.5V. converted voltage decreases temperature increases thermistor value decreases.
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PICREF-2
Pushbuttons
Pushbutton switches used select different PICREF-2 modes (Table Pushbutton locations PICREF-2 shown Figure (SW1 through SW5).
Jumpers
Jumpers used select different options PICREF-2 operation (Table Jumper connection conditions shown Figure Jumper locations PICREF-2 shown Figure (JMPR1 through JMPR14).
TABLE PUSHBUTTON SELECTS
PushButton Reset Battery Charge Battery Discharge Battery Charge Battery Discharge Function
FIGURE
JUMPER CONNECTION CONDITIONS
JMPRX open JMPRX closed
JMPRX-1 JMPRY-1
TABLE JUMPER SELECTS
Function Bypass filter after buck converter (default) filter after buck converter Access Ground (GND) Stand-Alone Mode Development Mode (Handshake) Jumpers JMPR1 closed JMPR2 JUMPR3 open JMPR1 open JMPR2 JMPR3 closed JMPR4 JMPR5 closed JMPR6 open JMPR5 open JMPR6 open JMPR7-1 JMPR8-1 (Battery JMPR9-1 JMPR10-1 (Battery JMPR11-1 JMPR12-1 (Battery JMPR13-1 JMPR14-1 (Battery JMPR8-1 JMPR8-2 (Battery JMPR9-1 JMPR10-1 (Battery JMPR12-1 JMPR12-2 (Battery JMPR13-1 JMPR14-1 (Battery JMPR10-1 JMPR10-2 (Battery JMPR14-1 JMPR14-2 (Battery
Voltage Sense Windowed Mode
Voltage Sense Fixed Mode
Voltage Sense Direct Mode
DS30451C-page
1997 Microchip Technology Inc.
PICREF-2
FIGURE LED, PUSHBUTTON JUMPER LOCATIONS
Legend Pushbutton Jumper
1997 Microchip Technology Inc.
DS30451C-page
PICREF-2
Firmware Overview
source code PICREF-2 microcontroller designed modular. general, PICREF-2 software following features: Algorithms support NiCd battery technology Negative Delta (-V) Charge Termination Zero Delta (Zero Charge Termination Absolute Voltage Termination Delta Delta (T/t) Charge Termination PWM-Controlled Discharge Profile current charge termination flow diagram shown Figure discussion charge termination types battery technologies that them found section Design Background. Future revisions this reference design will include: Li-Ion Additional Charge Termination Algorithms
Algorithms
equations Table were used translate battery physical quantities into data.
TABLE EQUATIONS USED CHARGE TERMINATION CALCULATION
Fast Charge Term. Equations Battery Voltage volts Battery Voltage Scale Factor Battery Temperature Battery Temperature (signed, 1°C/bit) Battery Charge Current Battery Charge Current Battery Scale Factor Battery Scale Factor Battery Voltage volts Battery Voltage Scale Factor Battery Voltage volts Battery Voltage Scale Factor Measured minute Measured Scale Factor (signed) Measured rate minute Measured Scale Factor (unsigned) Measured Time second [MSB 256] Zero Fail-Safe Charge Term. timed temp trickle
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PICREF-2
FIGURE CHARGE TERMINATION FLOW DIAGRA
Start Fast Charge
Cell Voltage Within Charging Limits?
Cell Temperature Within Charging Limits? Settling Time Charge
Cell Voltage Within Charging Limits?
Cell Voltage Error?
Charge
Cell Temperature Error?
Time-Out Error?
Charge Complete?
Fast Charge Terminate Charge Error
1997 Microchip Technology Inc.
DS30451C-page
PICREF-2
Program Flow
flow MAIN.C shown Figure main program starts initializing hardware battery charger operation. program then performs endless loop checking communications, sensing battery parameters, performing control functions, checking counter. flow INIT.C shown Figure function initializes peripheral features variables. following peripherals initialized: Timer1, CCP1 (PWM), converter. Timer1 used counter. initialized that interrupt generated every seconds. This used frame clock battery charger algorithms. function initialized operation. peripheral enabled duty cycle. converter initialized conversion clock frequency enabled operation. addition peripherals, ports configured pushbutton, LED, serial communications. locations cleared initialized support charger operation. DEVELOPMENT mode selected, RS-232 communications initialized. flow COMMAND.C shown Figure STAND_ALONE mode switch inputs read debounced count (0.1 seconds). detected being pressed, battery charge state selected. detected being pressed, battery charge state selected. both switches were detected, battery will charge completely, then battery will charge. After charge completion both batteries, both batteries will simultaneously trickle charged. DEVELOPMENT mode, data received from interpreted converted battery control states. This enables selected feature executed. received character echoed back verification PC-based software. flow SENSE.C shown Figure counter counted seconds, then sense features executed. When goes disabled, current, voltage, temperature monitored (Figure 17). then re-enabled. counter control counter updated. initialization time completed, termination check done based selected charge termination algorithm. Also, initialization stage complete, fail safe limits checked (Figure 18). fail safe limit been exceeded, then charging terminated. control activated initialization done, then charge algorithm performed. charge algorithm either fast charge algorithm trickle charge algorithm. battery trickle charge state both batteries selected, then trickle charging swapped every loop execution. flow CONTROL.C shown Figure command been received, then appropriate states set. states executed following sequence: Discharge Battery (DEVELOPMENT mode only) Discharge Battery (DEVELOPMENT mode only) Fast Charge Battery Fast Charge Battery Trickle Charge Battery Trickle Charge Battery Repeat Selected States Idle
state selected then operation executed function advances next state. Each state must complete execution before next state commences.
DS30451C-page
1997 Microchip Technology Inc.
PICREF-2
FIGURE MAIN.C
Start
Initialize
Communicate
Sense
Control
Timer1 Overflow?
Reset Timer1
1997 Microchip Technology Inc.
DS30451C-page
PICREF-2
FIGURE INIT.C
Start
Init Timer1 (TIC Counter)
Init (Buck Converter)
Init Ports
Init Converter
Clear
Init Variables
Return
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1997 Microchip Technology Inc.
PICREF-2
FIGURE COMMAND.C
Start
Read Switch Input
Pressed Charge)
Enable Charge
Pressed Charge)
Enable Charge
Return
1997 Microchip Technology Inc.
DS30451C-page
PICREF-2
FIGURE SENSE.C
Start
Counter sec? Return
IVT_SENSE
Terminate Flag TRUE?
Terminate Charge
Sensor Initialization Complete?
FAIL_SAFE
Continued
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PICREF-2
FIGURE SENSE.C (CON'T)
Continued
Sensor Init Complete Control TRUE?
Charge State Active? Perform Charge
Trickle Charge State Selected?
Swap Batteries
Return
1997 Microchip Technology Inc.
DS30451C-page
PICREF-2
FIGURE INT_SENSE
Start
LOW?
Disable
Read Battery I,V,
Update Counter
Update Control Counter
Return
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PICREF-2
FIGURE FAIL_SAFE
Start
Fast Charge?
I,V,T Error?
Terminate Idle Reset Variables
Trickle Charge?
Error?
Disable Trickle Charge (Can Recover)
Return
1997 Microchip Technology Inc.
DS30451C-page
PICREF-2
FIGURE CONTROL.C
Command?
States
State Selected?
State Enabled?
Enable State
State Complete?
Advance State
Return
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PICREF-2
User Customization
order select between DEVELOPMENT mode STAND_ALONE mode, following modifications must made: Development Mode Stand-alone Mode user must update check_temp() lookup table match their thermistor's Resistance-Temperature (RT) tables. V_SENSE() algorithm performs differently from STAND_ALONE mode although resolution same. "windowing" feature used DEVELOPMENT mode which gives 5.85 mV/bit resolution. Therefore 16-bit variable used voltage readings DEVELOPMENT mode. This converted 58.5 mV/bit resolution variable used charge monitoring termination decisions. decision tree same both modes. system frequency changed, serial communications must updated appropriately.
Development Mode
DEVELOPMENT Mode uses PIC16C73A conjunction with PC-Based Development software selecting battery charge/discharge parameters. description below defines DEVELOPMENT mode enabled customized user. MAIN.C Comment "#define STAND_ALONE" line MAIN.C. This define used BATTERY.H include appropriate files, functions variables. Example:
//#define STAND_ALONE
Stand-Alone Mode
STAND_ALONE Mode uses PIC16C72 conjunction with defined battery parameters charge selected battery packs. description below defines STAND_ALONE mode enabled customized user. MAIN.C comment "#define STAND_ALONE" line MAIN.C. This define used BATTERY.H include appropriate files, functions, variables. Example:
#define STAND_ALONE
BATTERY.H
changes needed. Based DEVELOPMENT mode being defined, battery parameters placed that they modified PC-based software. Also, variables serial communications defined this mode. duty cycle limited constant FST_CHARGER_MAX 85%. higher duty cycle needed, this constant modified. INIT.C changes needed. COMMAND.C changes needed. Based DEVELOPMENT mode being defined, commands received RS-232 serial link, parsed, executed. SENSE.C changes needed. CONTROL.C changes needed. LIBRARY.C user must update TERMINATE() Delta match their Zero time-out voltage drop threshold. algorithm times voltage change detected within seconds when Zero selected. Also, voltage drop during Zero greater than then algorithm terminates. user must update FAST_CHARGE(). charge current limited 1100 DEVELOPMENT mode. higher charge rate desired, this limitation removed.
BATTERY.H
battery definition must modified user's battery pack. parameters that used DEVELOPMENT mode moved STAND_ALONE mode. algorithm performs charge termination based these definitions. code example (Example excerpt from BATTERY.H file includes battery definition Sanyo KR1100-AEL NiCd 4-cell battery. duty cycle limited constant FST_CHARGER_MAX 85%. higher duty cycle needed, this constant modified. INIT.C changes needed. COMMAND.C changes needed. Based STAND_ALONE mode being defined, switch inputs charge read executed. Only battery charge features supported. both switches pressed, then charging done both batteries defined state machine (CONTROL.C). switch inputs debounced clock (0.1 seconds). SENSE.C changes needed. CONTROL.C changes needed. Discharge features disabled STAND_ALONE mode.
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LIBRARY.C user must update TERMINATE() Delta match their Zero time-out voltage drop threshold. algorithm times voltage change detected within seconds when Zero selected. Also, voltage drop during Zero greater than then algorithm terminates. user must update check_temp() lookup table match their thermistor's Resistance-Temperature (RT) tables. V_SENSE() algorithm performs differently from DEVELOPMENT mode although resolution same. "direct sense" feature used STAND_ALONE mode which gives 58.5 mV/bit resolution. This resolution increased through hardware modifications. Therefore, 8-bit variable used voltage readings STAND_ALONE mode. However, decision tree same both modes.
EXAMPLE STAND-ALONE BATTERY DEFINITIONS
BATTERY DEFINITION STANDALONE MODE following definitions supplied NiCd battery pack. Battery Charge Temperature Battery Charge Voltage (1.63V cell) 6.52V Battery Charge Voltage (0.90V cell) 3.60V Battery Charge Time Limit minutes 3600 Battery Fast Charge Rate 1.10A Battery Trickle Charge Rate 0.01A Battery -dV/dt Threshold (0.03V cell) 0.12V Battery dT/dt Threshold minute) Battery Discharge Voltage (1.0V cell) 4.00V #define B1_SYSTEM_STATUS 0x60 Battery Setup: Charge Once, NiCD #define B2_SYSTEM_STATUS 0xA0 Battery Setup: Charge Once, NiCD //#define B1_CHARGE_STATUS 0x70 Battery Setup: Fast Charge, Voltage Termination //#define B1_CHARGE_STATUS 0x60 Battery Setup: Fast Charge, Delta T/Delta Termination #define B1_CHARGE_STATUS 0x50 Battery Setup: Fast Charge, Delta Termination //#define B2_CHARGE_STATUS 0x70 Battery Setup: Fast Charge, Voltage Termination //#define B2_CHARGE_STATUS 0x60 Battery Setup: Fast Charge, Delta T/Delta Termination #define B2_CHARGE_STATUS 0x50 Battery Setup: Fast Charge, Delta Termination #define FAIL_SAFE_FC_TEMP_LO 0x00 STAND_ALONE MODE: 8-bit signed, #define FAIL_SAFE_FC_TEMP_HI 0x5A STAND_ALONE MODE: 8-bit signed, #define FAIL_SAFE_FC_VOLT_HI 0x70 STAND_ALONE MODE: 8-bit unsigned, 58.5 mV/bit #define FAIL_SAFE_FC_VOLT_LO 0x3D
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STAND_ALONE MODE: 8-bit unsigned, 58.5 mV/bit #define FAIL_SAFE_TC_TEMP_LO 0x00 STAND_ALONE MODE: 8-bit signed, C/bit #define FAIL_SAFE_TC_TEMP_HI 0x5A STAND_ALONE MODE: 8-bit signed, C/bit #define TERMINATE_ABS_VOLT_HI 0x70 STAND_ALONE MODE: 8-bit unsigned, 58.5 mV/bit #define FAIL_SAFE_FC_TIME_OUT 0x0E10 STAND_ALONE MODE: 16-bit unsigned, second/bit #define FAIL_SAFE_FC_AMP_HI 0x6E STAND_ALONE MODE: 8-bit unsigned, mA/bit #define FAIL_SAFE_TC_AMP_HI 0x01 STAND_ALONE MODE: 8-bit unsigned, mA/bit #define FAIL_SAFE_DC_VOLT_LO 0x44 STAND_ALONE MODE: 8-bit unsigned, 58.5 mV/bit #define TERMINATE_DV_THRESHOLD 0x9C STAND_ALONE MODE: 8-bit unsigned, 5.85 mV/bit #define TERMINATE_DT_THRESHOLD 0x02 STAND_ALONE MODE: 8-bit unsigned, C/minute
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Test Results NiCd
battery packs four-cell Sanyo KR1100-AEL battery packs were tested changes battery pack capacity charge termination algorithms listed Table Table results show that there very high degree correlation based charge termination algorithm chosen (i.e., behavior battery packs Negative Delta Voltage terminations nearly identical). batteries were cycled through harsh usage conditions consecutive charge 0.8C discharge terminations (For definition Design Background Battery Packs Charge Rate). After this, battery fully recharged, battery capacity measured using constant 0.8C load. discharge terminated after reaching "knee" battery voltage curve (approximately volt cell). capacity measurement determined multiplying load current amount time before reaching battery voltage curve "knee" (Figure 20). seen tables, after cycles, tested battery packs maintained over capacity. manufacturer's test data under less strenuous conditions (0.1C charge 0.7C discharge) showed battery capacity through cycles testing. This data informational reference only. Differences battery pack construction, battery cells, thermistor characteristics, thermistor placement, battery usage, ambient conditions affect battery performance.
TABLE NEGATIVE DELTA VOLTAGE TERMINATION (100
Charge/Discharge Cycles Original Capacity 1100 Final Measured Capacity 1070 Percent Original Capacity
TABLE DELTA DELTA TERMINATION C/MIN)
Charge/Discharge Cycles Original Capacity 1100 Final Measured Capacity 1020 Percent Original Capacity
FIGURE
BATTERY CHARGING GRAPH
Temperature
Voltage
Current
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Test Results NiMH
Duracell battery packs (DR-15 DR-35) were tested changes battery pack capacity charge algorithm. results show that there very high degree correlation based this charge termination method. DR-15 cycled through consecutive 0.8C charge 0.6C discharge terminations. After which, battery fully recharged battery capacity measured using constant 0.5C load. discharge terminated after reaching "knee" battery voltage curve (approximately volt cell). capacity measurement determined multiplying load current amount time before reaching battery voltage curve "knee." seen Table Table after cycles, tested battery packs maintained over capacity. This data informational reference only. Differences battery pack construction, battery cells, thermistor characteristics, thermistor placement, battery usage, ambient conditions affect battery performance.
TABLE DR-15 NEGATIVE DELTA VOLTAGE TERMINATION (100
Charge/Discharge Cycles Original Capacity 1420 Final Measured Capacity 1340 Percent Original Capacity
TABLE DR-35 NEGATIVE DELTA VOLTAGE TERMINATION (100
Charge/Discharge Cycles Original Capacity 2200 Final Measured Capacity 2020 Percent Original Capacity
FIGURE
BATTERY CHARGING GRAPH
Temperature
Voltage
Current
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PICREF-2 Software Overview
Development mode provides means PICREF-2 talk RS-232 communications. This provides real-time battery monitoring battery data logging. PICREF-2 software WindowsTM-based application called Charger that allows easy programming PIC16C73A microcontroller monitoring operation.
Installing Charger
install application: Start Windows Insert Charger disk 1/2" disk drive (ex: Windows Program Manager, choose from File menu. Windows click Start Button select from drop-down menu. Type a:\setup Command Line (Where disk drive letter). Choose Follow setup instructions. When setup complete, should have Charger program group shown Figure
System Requirements
Charger application, will need: with processor higher) running enhanced mode hard disk with Mbyte free space mouse other pointing device EGA, other compatible display Mbyte free serial (COM) port Microsoft® Windows higher)
FIGURE
CHARGER ICONS
System Setup
Connect power PICREF-2. Then, connect PICREF-2 free port with serial cable. firmware PIC16C73 microcontroller will automatically establish communications with
Starting Charger
start Charger application Windows 3.1, simply double click application icon Charger program group. Windows click Start button, select Programs, then Charger program group, finally Charger application (charger.exe). Charger window shown Figure
FIGURE
CHARGER WINDOW
print open configure stop charging (red icon) start charging (green icon)
single line help
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Setting Charger
Charger application, select Options command under File menu open Battery Charger Setup Options window, Figure changed deleting default value entering value from second 60,000 seconds (1000 minutes almost hrs). When charger accept input clicking Accept button.
FIGURE
BATTERY CHARGER SETUP OPTIONS
Charger Configuration
When charger setup first time, will automatically start Battery Configuration window (Figure after setup. open this window another time, select Charger Configure. command from Charger menu click configure button. Battery configuration parameters their value ranges follows.
Fail Safe Limits
communications port chosen displayed (ex: COM2). want different port, select from pull-down menu. connected properly PICREF-2, error message will appear. Exit from Charger application check PICREF-2 connections power PICREF-2. Then restart Charger attempt Communications Port again. Display Update Time seconds) rate which battery charging data will displayed when graphed screen. default time will entered. This time Charge Voltage Limit (V): Maximum values: 15V, Minimum values: 15V. Fast Charge Temp Limit (C): Maximum values: 60°C, Minimum values: -20°C 0°C. Trickle Charge Temp Limit (C): Maximum values: 60°C, Minimum values: -20°C 0°C. Charge Time-out (Min): Values: minutes minutes (over hrs).
FIGURE
BATTERY CONFIGURATION
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Primary Charge Termination Limits
Absolute Voltage (V): Values: 15V. (Negative Zero) Threshold (mV): Values: 1500 Threshold (Deg C/Min): Values: 0°C/Min 5°C/Min. Charging button. Also, charging halted selecting Stop Charging from Charger menu clicking Stop Charging button.
Charger Menus
charger application menus: File, Charger, Charting, Window, Help.
File Menu
File Menu contains following list commands: Open Print. Print Setup. Window Color Window Font Exit (Alt-F4) Opens existing data file graph Print this document Setup this document's print characteristics Change background color edit window Change font edit window Quit Charger application
Discharge Termination Limits
Discharge Voltage (V): Values: 15V.
Battery Type
Pb-Acid with Temp Pb-Acid without Temp NiCd NiMH Li-Ion (not available)
Charge Algorithm
Fast Charge Trickle Charge
Charger Menu
Charger Menu contains following list commands: Stop Charging Start Charging Charger Configure. Options. Stop charging batteries Start charging batteries Configure battery charger parameters communications graphing options
Termination Algorithm
(Negative Zero) Absolute Voltage
Discharge/Charge Sequence
Battery Discharge/Charge Once Battery Discharge/Charge Repeatedly Battery Discharge, Battery Charge Battery Charge, Battery Discharge Battery Discharge Battery Charge Battery Discharge/Charge Once Battery Discharge/Charge Repeatedly Battery Discharge Battery Charge Battery Discharge/Charge Once
Charting Menu
Charting Menu contains following list commands: Center Marker Zoom Zoom Zoom Zoom Display Configuration Zoom full centered marker position Display data point graph point available data points graph Increase data point resolution Decrease data point resolution Display configuration graphing parameters data file chart
Fast Charge Rate (Amperes)
Fast Charge Rate (Amperes): Values: 2.55A.
Trickle Charge Rate (Amperes)
Trickle Charge Rate (Amperes): Values: 0.3A. familiar with different battery technologies charge algorithms used with them, please refer section Design Background.
Windows Menu
Windows Menu contains following list commands: Cascade Tile Arrange Icons Close Cascade open windows Tile open windows vertically Arrange icons desktop Close open windows
Running Charger
Once Charger application configured, battery charging started selecting Start Charging from Charger menu, clicking Start
Help Menu
this time, there on-line help.
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Charger Example NiCd using Delta
PICREF-2 charge Sanyo NiCd battery pack using Delta termination algorithm, configure charger shown Figure Charging commence once PICREF-2 configured. Clicking Start Charging button will bring Select Battery Save File window. Determine name (ex: battery1.dat) directory charging information stored then click Charging will commence with display charging graph (Figure 27). charging clicking Stop Charging Button. Clicking completed graph point will place marker there. Current, voltage temperature information will displayed right-hand data box) time offset left-hand data box) represented marker.
FIGURE
NICD BATTERY CONFIGURATION DELTA (NEGATIVE ZERO)
FIGURE
NICD CHARGING GRAPH DELTA (NEGATIVE ZERO)
MARKER
Voltage Temp
Current
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Charger Example NiCd using DeltaT/Deltat
PICREF-2 charge Sanyo NiCd battery pack using DeltaT Deltat termination algorithm, configure charger shown Figure Charging commence once PICREF-2 configured. Clicking Start Charging button will bring Select Battery Save File window. Determine name (ex: battery2.dat) directory charging information stored then click Charging will commence with display charging graph (Figure 29). charging clicking Stop Charging Button. Clicking completed graph point will place marker there. Current, voltage, temperature information will displayed right-hand data box) time offset left-hand data box) represented marker.
FIGURE
NICD BATTERY CONFIGURATION DELTAT DELTAt
FIGURE
NICD CHARGING GRAPH DELTAT DELTAt
MARKER
Voltage
Temp
Current
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Charger Example NiMH using Delta
PICREF-2 charge NiMH battery pack using Delta termination algorithm, configure charger shown Figure Charging commence once PICREF-2 configured. Clicking Start Charging button will bring Select Battery Save File window. Determine name (ex: battery3.dat) directory charging information stored then click Charging will commence with display charging graph (Figure 31). charging clicking Stop Charging Button. Clicking completed graph point will place marker there. Current, voltage, temperature information will displayed right-hand data box) time offset left-hand data box) represented marker.
FIGURE
NIMH BATTERY CONFIGURATION DELTA (NEGATIVE ZERO)
FIGURE
NIMH CHARGING GRAPH DELTA (NEGATIVE ZERO)
Voltage MARKER Temp
Current
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Design Background
example implement battery charger using microcontrollers been described previous sections. However, customer wishes change part this design, then understanding design developed was, i.e., understanding batteries, battery technology, charging methods, essential.
Charge Rate
charge rate battery defined terms capacity battery capacity 3000 mAh, charge rate would correspond charge current amps.
Maximum Discharge Rate
Floating loads used applications such emergency devices, alarm systems, memory back-up. These applications continually charge battery that battery provides power when primary power removed. Battery life typically measured years. Cyclic loads applications such camcorders, portable audio equipment, portable phones, portable power tools. These applications battery primary power source. battery depleted recharged repeatedly. Battery life typically measured terms cycles.
Battery Technologies
list available battery technologies, along with manufacturers battery specifications, shown Table
TABLE BATTERY SPECIFICATIONS
Battery Technology NiCd NiMH Manufacturer Sanyo Duracell® Specifications 4.8V 12.0V 1.1Ah 1.7Ah Capacity DR-XX: 4.8V 12.0V 1.2Ah 2.8Ah Capacity NPX: 4.0V 12.0V 2.0Ah 7.0Ah Capacity LP9: 3.6V 0.8Ah Capacity (Gaphite Electrode)
Charging Considerations Excess Thermal Runaway
Recharging must controlled that gasses produced built dangerous levels. Manufacturers typically compensate this oversizing negative plate. Also, heat cause deterioration separator plate which will weaken battery cell charges, bubbles released accumulate plates. This reduces effective area plate increases cell impedance. When cell approaches full charge, rate generation thermal energy increase. This causes cell impedance increase, which turn produces more gas. This condition called thermal runaway. charge lead acid, provide charge current that below gassing voltage.
Lead Acid Li-Ion
YuasaGS Batteries
Battery Packs
battery pack will consist following connections: Battery Battery Thermistor Interface
Battery Pack Capacity
capacity battery pack function individual cells used. cells standard, rapid-charge, high-temperature, high-capacity, super high-capacity. Rapid charge cells have increased negative plate absorption characteristics which allow charging hour. High-temperature cells contain separator (typically polypropylene), which allow operating temperatures exceed 65°C. High-capacity cells have both high-capacity density positive plate high-density paste negative plate which provides 30%+ additional capacity over standard cell. Super high-capacity cells contain enhanced positive negative plate densities which provides 80%+ additional capacity over standard cell. capacity battery pack application requirements 1200 range, while high capacity battery pack application requirements 3000 range. PICREF-2 will support both battery pack application requirements, though hardware must changed support 3000 mAh.
Memory Effect
Memory effect formation crystals. Periodic full (deep) discharge sufficient reduce memory effect. Therefore, necessary fully discharge NiCd battery each time.
Voltage Depression
reversible drop voltage capacity occur when sealed NiMH battery partially discharged then recharged. This results voltage depression "memory effect." loss voltage capacity occurs because only portion active materials discharged recharged during shallow partial charging. active materials that have been cycled change physical characteristics increase resistance. active materials restored their original state subsequent full discharging-charging cycles.
Overdischarge
When multi-cell series-connected battery discharged, lowest capacity cell will reach point full discharge before other cells. discharge con-
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tinued, lower capacity cell driven into overdischarge condition through 0.0V. This will cause polarity reverse. This caused positive electrode being discharged producing hydrogen gas. absorbed negative electrode with remainder building cell. discharge continues, active material been depleted oxygen produced negative electrode. minimize possibility polarity reversal, cells should "matched" within capacities.
TABLE 12:FAST CHARGE TERMINATION ALGORITHMS.
Fast Charge Termination Method Zero Absolute Voltage Li-Ion NiMH NiCd Lead Acid
Self Discharge
Self discharge caused reaction residual hydrogen cell with positive electrode along with slow decomposition both electrodes (the decomposition reversed subsequent charging). self discharge rate increases with temperature (Table 10).
TABLE 13:FAIL-SAFE CHARGE TERMINATION ALGORITHMS
"Fail-Safe" Termination Method Timed Charge Over/Under Temperature Over/Under Voltage Li-Ion NiMH NiCd Lead Acid
TABLE 10:SELF DISCHARGE OVER 30-DAY PERIOD
Battery Technology NiCd Temperature (degrees NiMH Residual Capacity
basic flow diagram charge termination algorithms shown Figure cell voltage temperature monitored until within safe charging limits. battery then charged initial settling period that proper cell operation ensured false termination signals filtered out. Fast charge continues until primary charge termination method been satisfied fail-safe termination condition met.
Charge Termination Types
controller specifies primary "fail-safe" charge termination algorithms NiMH, NiCd, Li-Ion, Lead Acid. modes charging implemented: high current fast charge mode current trickle charge mode. Several "fail-safe" backup mechanisms provided ensure that fast charge mode allowed continue indefinitely. Fail-safe mechanisms trickle charge mode also included allow termination charging battery voltage temperature range. Fast charging will continue until programmed limit selected principal fast charge method reached exceeded. Fast charging also terminate fast charge "fail-safe" limits exceeded. Trickle charge mode will always entered after fast charge mode terminates, normal termination occurs. (Fail safe termination stops charging.)
Fast Charge Terminations
fast charge mode designed allow rapid, high-current charging battery pack. Although there many techniques available, techniques used this reference design are: Negative Delta (-V) Charge Termination Zero Delta (Zero Charge Termination Delta Delta (T/t) Charge Termination Absolute Voltage Charge Termination
Zero Charge Termination
When NiCd battery reaches full charge, voltage decreases. method makes this property terminating fast charge mode when voltage slope becomes negative. This method widely used NiCd. However, voltage drop NiMH great; therefore Zero method used NiMH. When NiMH battery reaches full charge, voltage plateaus. Zero method makes this property terminating fast charge mode when voltage slope reaches this plateau. Figure shows these characteristics.
TABLE 11:FAST CHARGE NOMENCLATURE
Text Negative Delta Zero Delta Delta Delta Symbolic Zero Formula -dV/dt dV/dt dT/dt
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FIGURE BATTERY VOLTAGE TIME (NICD/NIMH) FIGURE BATTERY VOLTAGE TIME (LI-ION/LEAD ACID)
Absolute Voltage NiCd Battery Voltage NiMH Zero Battery Voltage Lead Acid 2.0V 4.1V
Time
Charge Termination
Time
Charge Termination
Fail-Safe Charge Terminations Charge Termination
When NiCd NiMH battery reaches full charge, battery pack will experience rapid rise temperature. This increase conversion charging energy into thermal energy. method makes this property using internal thermistor detect rise temperature. controller measures battery temperature calculates temperature rise rate with respect time. then compares this value stored threshold. controller will terminate fast-charge mode, measured rate meets exceeds stored rate threshold. Figure shows this characteristic. fail-safe charge termination methods are: Timed Charge Termination Over/Under Temperature Charge Termination Over/Under Voltage Charge Termination Trickle Charge Mode
Timed Charge Termination
timed charge termination fail-safe method terminating charging algorithm. charging algorithm does complete within predefined amount time, charge will terminate.
Over/Under Temperature Charge Termination
over/under temperature charge termination fail-safe method terminating charging algorithm. Temperature limits both over-temperature under-temperature monitored. Fast charging will allowed battery temperature exceeds over-temperature limit less than under-temperature limit. Fast charging will begin resume when temperature falls within these limits.
FIGURE
BATTERY TEMPERATURE TIME (NICD/NIMH)
NiCd/ NiMH
Battery Temp
Over/Under Voltage Charge Termination
over/under voltage charge termination fail-safe method terminating charging algorithm. Voltage limits both over-voltage under-voltage monitored. Fast charging will allowed battery voltage exceeds over-voltage limit less than under-voltage limit. Fast charging will begin resume when voltage falls within these limits.
Time
Charge Termination
Absolute Voltage Charge Termination
When Li-Ion Lead Acid battery approaches full charge, battery pack voltage reaches predefined limit based technology cell. absolute voltage method makes this property terminating charging when battery voltage meets exceeds limit. This should confused with fail-safe over-voltage mechanism that will terminate charging, maximum voltage limit exceeded. over-voltage limit backup mechanism fast-charge termination always enabled. predefined voltage limit primary charge termination limit only active when absolute voltage charge termination enabled. Figure shows this characteristic.
Trickle Charge Mode
trickle charge mode allows battery continue charging remain near 100% state charge during periods charge/discharge inactivity. amount current provided battery determined duty cycle PWM-driven current source. Fail-safe limits battery over-temperature, under-temperature, over-voltage, under-voltage suspend trickle mode charging.
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Reference Material
additional battery information, please refer following books: "Handbook Batteries" Edition, McGraw-Hill, David Linden, 1995 "Rechargeable Batteries Applications Handbook," Butterworth-Heinemann, 1992
Design Modifications
This reference design guidance only, anticipated that customers will make modifications. With this mind, this section suggests modifications that customer wish make design. This design modified create single battery charger using PIC16C711 microcontroller (Figure Figure 36). hardware this modification supported, firmware been developed. Several circuits optional used used user's discretion. trade-offs reduced cost using fewer circuits/components) necessary performance.
FIGURE
PIC16C711 PINOUT
PDIP, SOIC, Windowed CERDIP
RA2/AN2 RA3/AN3/VREF RA4/T0CKI MCLR/VPP RB0/INT RA1/AN1 RA0/AN0 OSC1/CLKIN OSC2/CLKOUT
PIC16C711
FIGURE
PICREF-2 INTELLIGENT BATTERY CHARGER SINGLE BATTERY SYSTEVoltage Regulator Buck Converter Filter BATTERY CHARGE/ DISCHARGE Battery Charge Select
PIC16C711
LEDs MCLR
Battery Discharge Select
Battery
PushButtons
Battery Temperature (A/D) CURRENT/VOLTAGE SENSE
Jumper Selects
Current Sense (A/D) Battery Voltage (A/D)
Current Sense Resistor
Voltage Reference
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NOTES:
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APPENDIX SYSTEM SPECIFICATIONS
Voltage Range: based battery pack Maximum Battery Pack Capacity: 3000 25°C Maximum Charge Current: 2.0A 1.3A with Operating Temperature: -20°C 60°C
Minimum Charger System
schematic minimum charger system shown Appendix This system will only charge batteries discharge). PIC16C72 microcontroller used this system, which means functions stand-alone mode only. Also, voltage regulator used, there input filter.
Full Charger System
schematics full charger system shown Appendix This system includes circuits that replaced others designer's option. PIC16C73A microcontroller shown main schematic. However, PIC16C72 used (for STAND-ALONE mode only) PIC16C711 (for STAND-ALONE mode, single battery). crystal oscillator shown with PIC16C73A main schematic. This replaced with (CTX163). PIC16C72 microcontroller used, crystal oscillator (CTX163) used.
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BATT-
4.7K ORANGE GREEN GREEN
CHG_BAT2
0.05 SW1:A
MCLR
U12C LM6134AIM BAT_I
SW4:A
ERROR_IND B2_CHG_IND B1_CHG_IND
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MCLR BAT_I BAT_T1 BAT_V1 BAT_T2
APPENDIX
976K
PICREF-2
24.9K
0.1µF
SW2:A
BAT_V2
BAT_T1
BAT_T2
CHY1 CHY2 SPARE CHG_BAT1
10.0MHZ
15PF
15PF
0.1µF PIC16C72P MCLR RA0/AN0 RA1/AN1 RA2/AN2 RA3/AN3/VREF RA4/T0CKI RA5/AN4/SS RB0/INT OSC1/CLKIN OSC2/CLKOUT RC0/T1OSO/T1CKI RC1/T1OSI RC2/CCP1 RC5/SDO RC3/SCK/SCL RC4/SDI/SDA
BAT_V2
BAT_V1
BAT_T1 BATT-
NDT454P 2N2222A
BAT_T2 BATT-
PICREF-2 Minimum Charger Schematic
644894-5
NDT454P 644894-5
MINIMUM CHARGER SCHEMATIC
2N2222A
LT1118CS8-5
V_OUT +V_FUSED
10µF
0.01µF 100UH 30BF20 30BF20 470µF 0.01µF
3AG-5 DJ005B
NDT454P
This schematic obtained electronically Microchip sites (OrCAD, v4.40).
1.5K
1997 Microchip Technology Inc.
2N2222A
PICREF-2
APPENDIX
FULL CHARGER SCHEMATIC
This schematic obtained electronically Microchip site (OrCAD, v4.40).
PICREF-2 Full Charger Schematic
0.05
BATTpp U12C BAT_I LM6134AIM 976K 24.9K 0.1µF
HANDSHAKE
STANDALONE JMPR5
JMPR6
4.7K SW1:A MCLR 0.1µF PIC16C73P MCLR/VPP RA0/AN0 RA1/AN1 RA2/AN2 RA3/AN3/VREF RA4/T0CKI RA5/SS/AN4 RB0/INT OSC1/CLKIN OSC2/CLKOUT RC0/T1OSO/T1CKI RC7/RX/DT RC1/T1OSI/CCP2 RC6/TX/CK RC2/CCP1 RC5/SDO RC3/SCK/SCL RC4/SDI/SDA JMPR4
BAT_T1 BAT_T2 10.0MHZ 15pF
MCLR BAT_I BAT_T1 BAT_V1 BAT_T2 HANDSHAKE BAT_V2 CHY1_73 CHY2_73 SPARE CHG_BAT1
15pF CTX163
STANDALONE DIS_BAT2 ERROR_IND B2_DIS_IND B2_CHG_IND B1_DIS_IND B1_CHG_IND DIS_BAT1 RECV XMIT CHG_BAT2
CHY1_73
DOUT VDRV RXIN TXOUT DS1275S
Optional Oscillator Circuit RECV XMIT Optional Voltage Regulator VOUT NJM7805
LT1118CS8-5 DB9F 10µF +V_FUSED IRF7406 100uH 30BF20 0.01µF
JMPR1 470µF 0.01µF JMPR2 27uH 0.47µF IRF9540
V_OUT
3AG-5
DJ005B
30BF20
JMPR3 0.47µF
1.5K
2N2222A
NDT454P
Optional Input Filter
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PICREF-2 Full Charger Schematic
V_OUT IRF7406 BAT_V1 644894-5 IRF7403 TBLOCK
BAT_T1 BATTpp
NDT454P
VSENSE_BAT1
CHG_BAT1
2N2222A
DIS_BAT1
V_OUT DIS_BAT2 IRF7406
BAT_V2
BAT_T2 BATT-
CHG_BAT2
2N2222A
NDT454P
644894-5 TBLOCK
VSENSE_BAT2
IRF7403
VSENSE_BAT1
U11D LM6134AIM
0.01µF U12A JMPR9 BAT_V1 JMPR10 VSENSE_BAT1
JMPR8 JMPR7
0.01µF
U11A LM6134AIM
LM6134AIM
DS1803Z
VSENSE_BAT2
U11C LM6134AI
0.47µF
JMPR12 JMPR11
U11B LM6134AIM
U12B LM6134AIM JMPR13 BAT_V2 JMPR14 VSENSE_BAT2
24LC01B
0.47µF U12D LM6134AI
0.01µF
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PICREF-2 Full Charger Schematic
SPARE
SW2:A B1_CHG_IND SW3:A B1_DIS_IND SW4:A B2_CHG_IND SW5:A B2_DIS_IND
GREEN YELLOW GREEN YELLOW ORANGE
ERROR_IND
PIC16C72 Oscillator Options 10.0MHZ 15pF
Microcontroller Option: PIC16C72
CHY1
CHY2 15pF MCLR BAT_I BAT_T1 BAT_V1 BAT_T2 HANDSHAKE BAT_V2 CHY1 CHY2 SPARE CHG_BAT1
CTX163
CHY1
0.1µF MCLR RA0/AN0 RA1/AN1 RA2/AN2 RA3/AN3/VREF RA4/T0CKI RA5/AN4/SS RB0/INT OSC1/CLKIN OSC2/CLKOUT RC0/T1OSO/T1CKI RC1/T1OSI RC2/CCP1 RC5/SDO RC3/SCK/SCL RC4/SDI/SDA PIC16C72P
STANDALONE DIS_BAT2 ERROR_IND B2_DIS_IND B2_CHG_IND B1_DIS_IND B1_CHG_IND DIS_BAT1 RECV XMIT CHG_BAT2
Microcontroller Option: PIC16C711 0.1µF RA2/AN2 RA1/AN1 RA3/AN3/VREF RA0/AN0 RA4/T0CKI OSC1/CLKIN MCLR OSC2/CLKOUT RB0/INT PIC16C711P
BAT_V1 SPARE HANDSHAKE MCLR B1_CHG_IND B1_DIS_IND CHG_BAT1
BAT_T1 BAT_I CHY1 CHY2 ERROR_IND DIS_BAT1
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APPENDIX FIRMWARE LISTING
PIC16C7X firmware source code listings obtained electronically Microchip site. Source code written compiled using MPLAB-C. Source code files: battery.h control.c command.c init.c library.c sense.c main.c
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APPENDIX PICREF-2 PROTOCOL
This section describes communications protocol used between PICREF-2 Intelligent Battery Charger (IBC) Host physical data link layers this interface provided RS-232 serial link. This protocol forms transport layer; i.e., provides mechanism transporting control data between PICREF-2 Host protocol consists message format, commands, data field definitions each command. master-slave protocol, meaning that Host controls flow information between units (i.e., PICREF-2 only sends data response request from Host PC). Host send commands configuration data PICREF-2 status sent back Host PICREF-2. communications over RS-232 link done 9600 baud rate, eight bits, stop bit, parity, using binary data (vs. ASCII-based text data).
Message Format
message format communications from PICREF-2 defined follows: <command> <data1> <data2> <dataN> <checksum> where <command> represents command byte, <data#> represents more data bytes associated with command byte, <checksum> represents 8-bit checksum. checksum determined summing bytes message (command data bytes), truncating lower eight bits summation, then inverting (one's complement) byte. Data sent from PICREF-2 follows same format shown above, with exception that there command byte start message. There only data definition PICREF-2, header byte needed distinguish between data sets.
Handshaking
prevent from having interrupts PICREF-2, handshake built into protocol having each byte received PICREF-2 from Host being echoed back Host after reception. Host eventual (one second) time-out, after which time assumes last character sent received. this case, character will resent. character will also resent echoed character does match character sent Host Note that Host does echo received characters back PICREF-2; i.e., handshake only one-way.
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Command Data Field Definitions
E.3.1 SYSTEM ENABLE COMMAND (04h) commands defined communication from Host PICREF-2 follows: System enable Configure Send data Send configuration This command sends System (byte Charge Enable (byte bytes, respectively, which override current settings initiate action (e.g., charge discharge). This command also effect resetting battery error byte battery charging algorithm. Data field definitions shown follows:
Message Format Host: System Enable Byte Charge Enable Byte Checksum
Byte System Enable Byte (charge/discharge sequence) Battery Charge/Discharge Mode bit7 7-4: Battery Charge/Discharge Mode 0000 Idle Mode 0001 Special Mode Discharge B1/Charge (not supported prototype) 0010 Special Mode Charge B1/Discharge (not supported prototype) 0011 Battery Discharge/Charge ONCE Mode 0100 Reserved 0101 Battery Discharge Mode 0110 Battery Charge Mode 0111 Battery Discharge/Charge Mode 1000 Reserved 1001 Battery Discharge Mode 1010 Battery Charge Mode 1011 Battery Discharge/Charge Mode 1100 Reserved 1101 Battery Discharge Mode 1110 Battery Charge Mode 1111 Battery Discharge/Charge REPEAT Mode Reserved 2-1: Battery Chemistry (assumes battery same type) NiCd enabled NiMH enabled Lead Acid enabled Li-Ion enabled (Provisional) Reserved Battery Chemistry bit0
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Byte Charge Enable Byte Charge Algorithm bit7 7-6: Charge Algorithm Reserved Fast Charge Algorithm Trickle Charge Algorithm 5-4: Charge Termination Algorithm None Enabled (except Fail Safe always enabled) Delta-V (Zero Delta-V Negative Delta-V) Delta-T/Delta-t Absolute Voltage 3-0: Reserved Charge Term. Algorithm bit0
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PICREF-2
E.3.2 CONFIGURE COMMAND (2Ah) This command sends configuration data PICREF-2. This command used pass device-specific parameterization input from PICREF-2. This information will overwrite previous settings, this command does initiate activity. charge discharge progress when Message Format Host: Temp_Lo Temp_Hi Max_Voltage Max_Voltage Checksum Configure command received, current activity will stopped (i.e., device parameters should changed mid-way through charge discharge). Data field definitions defined follows: (Note: batteries present, assumed that both started same time same parameters).
Byte TEMP_LO Minimum temperature degrees Fast Charge/discharge mode, represented 8-bit signed binary value with degrees C/bit (range: -64°C [80h] +63.5°C [7Fh]). Byte TEMP_HI Maximum high temperature degrees Fast Charge/discharge mode, represented 8-bit signed binary value with degrees C/bit (range: -64°C [80h] +63.5°C [7Fh]). Byte MAX_VOLTAGE Overall maximum voltage charge mode (for Fail-Safe termination) battery cells, represented 8-bit unsigned binary value with each representing 58.5mV (range: 14.91V). Byte MIN_VOLTAGE Overall minimum voltage discharge mode (for Fail Safe termination) battery cells, represented 8-bit unsigned binary value with each representing 58.5mV (range: 14.91V). Byte TRICKLE_TEMP_LO Minimum temperature degrees maintenance charge mode, represented 8-bit signed binary value with degrees C/bit (range: -64°C [80h] +63.5°C [7Fh]). Byte TRICKLE_TEMP_HI Maximum high temperature degrees maintenance charge mode, represented 8-bit signed binary value with degrees C/bit (range: -64°C [80h] +63.5°C [7Fh]). Byte ABS_VOLT_HIGH Lead acid maximum voltage charge mode, represented 8-bit unsigned binary value with each representing 58.5mV (range: 14.91V). Byte MAX_TIME_LIMIT_LB byte maximum allowable time, seconds, during charge mode Fail-Safe charge termination, represented 16-bit unsigned binary value (range: 65,536 seconds, about 18.2 hours). Byte MAX_TIME_LIMIT_HB High byte maximum allowable time, seconds, during charge mode Fail-Safe charge termination, represented 16-bit unsigned binary value (range: 65,536 seconds, about 18.2 hours). Byte FAST_CHARGE_RATE current, which battery charged Fast Charge mode. Expressed 8-bit unsigned binary value with each representing (range: 2.55A). Byte TRICKLE_CHARGE_RATE current, which battery charged Trickle Charge mode. Expressed 8-bit unsigned binary value with each representing (range: 2.55A). Byte SPARE Reserved.
DS30451C-page
1997 Microchip Technology Inc.
PICREF-2
Byte DISCHARGE_VOLTAGE voltage, which discharge battery will stop, represented 8-bit unsigned binary value with each representing 58.5mV (range: 14.91V). Byte DELTAV_THRESH_SIGNED charge termination threshold, Volts, used battery charged. Expressed 8-bit signed binary value, with each representing 5.85mV (range: -750 +744 mV). Byte DELTAT_DELTAt_THRESH charge termination threshold, degrees minute. Expressed 8-bit signed binary value, with each representing degrees C/min (range: 127.5 °C/min).
1997 Microchip Technology Inc.
DS30451C-page
PICREF-2
E.3.3 SEND DATA COMMAND (15h) This command requests PICREF-2 send real-time data set, which typically requested periodic rate second update Host PC's screen. This command consists only command byte checksum (EAh). data which returned from PICREF-2 response Send Data command defined follows:
Message Format Host: PICREF-2 Response: B1_Volts B1_Temp B1_Current B2_Volts Checksum
Byte B1_Volts Battery Voltage, represented 8-bit unsigned binary value with each representing 58.5 range: 14.91V). Byte B1_Temp Battery Temperature degrees 8-bit signed binary value with degrees C/bit (range: -64°C [80h] +63.5°C [7Fh]). Byte B1_Current Measured Battery Charge Current, 8-bit unsigned binary value with each representing (range: 2.55A). Byte B2_Volts Battery Voltage, represented 8-bit unsigned binary value with each representing 58.5 (range: 14.91V). Byte B2_Temp Battery Temperature degrees 8-bit signed binary value with degrees (range: -64°C [80h] +63.5°C [7Fh]). Byte B2_Current Measured Battery Charge Current, 8-bit unsigned binary value with each representing (range: 2.55A).
DS30451C-page
1997 Microchip Technology Inc.
PICREF-2
Byte System Status
Battery Charge/Discharge Mode bit7 7-4: Battery Charge/Discharge Mode 0000 Idle Mode 0001 Reserved 0010 Reserved 0011 Battery Discharge/Charge ONCE Mode 0100 Reserved 0101 Battery Discharge Mode 0110 Battery Charge Mode 0111 Battery Discharge/Charge Mode 1000 Battery Discharge/Charge REPEAT Mode 1001 Battery Discharge Mode 1010 Battery Charge Mode 1011 Battery Discharge/Charge Mode 1100 Battery Discharge/Charge REPEAT Mode 1101 Battery Discharge Mode 1110 Battery Charge Mode 1111 Battery Discharge/Charge REPEAT Mode Reserved
Battery Chemistry bit0
2-1: Battery Chemistry (assumes battery same type) NiCd enabled NiMH enabled Lead Acid enabled Li-Ion enabled (Provisional) Reserved
Byte Charge Status
Charge Algorithm bit7
Charge Term. Algorithm
Battery Charge Status
Battery Charge Status bit0
7-6: Charge Algorithm Reserved Fast Charge Algorithm Trickle Charge 5-4: Charge Termination Algorithm None Enabled (except Fail Safe always enabled) Delta (Zero Delta Negative Delta Delta T/Delta Absolute Voltage 3-2: Battery Present Charge Status Idle Fast Charging Trickle Charging Discharging 1-0: Battery Present Charge Status Idle Fast Charging Trickle Charging Discharging
1997 Microchip Technology Inc.
DS30451C-page
PICREF-2
Byte Battery Error Status
bit7
Overvoltage Error Error error Undervoltage Error Error error
bit0
Note: This field cleared either CONFIGURE SYSTEM ENABLE command.
Overtemperature Error Error error Undertemperature Error Error error Time-out Error Error error Checksum Error Error error Selftest Error Error error Battery Detected battery detected Battery detected
DS30451C-page
1997 Microchip Technology Inc.
PICREF-2
Byte Battery Error Status
bit7
Overvoltage Error Error error Undervoltage Error Error error
bit0
Note: This field cleared either CONFIGURE SYSTEM ENABLE command.
Overtemperature Error Error error Undertemperature Error Error error Time-out Error Error error Checksum Error Error error Selftest Error Error error Battery Detected battery detected Battery detected
Byte Battery Measured Signed Battery measured Volts, running average voltage difference between present last sample. Expressed 8-bit signed binary value, with each representing 5.85 (range: -750 +744 mV). Byte Battery Measured Rate Battery measured Delta T/Delta rate, degrees minute, running average change temperature over time, with each representing 0.5° C/min (range: C/min 127.5° C/min). Byte Battery Measured Signed Battery measured Volts, running average voltage difference between present last sample. Expressed 8-bit signed binary value, with each representing 5.85 (range: -750 +744 mV). Byte Battery Measured Rate Battery measured rate, degrees minute, running average change temperature over time, with each representing 0.5° C/min (range: C/min 127.5° C/min).
1997 Microchip Technology Inc.
DS30451C-page
PICREF-2
E.3.4 SEND CONFIGURATION COMMAND (3Ch) This command requests PICREF-2 send configuration data Host These same configuration fields sent Configure Command. Data field definitions defined same Configure Command. Message Format Host: PICREF-2 Response: Temp_Lo Temp_Hi Max_Voltage Max_Voltage Checksum
E.3.5
RESET COMMAND (55h)
This command causes software reset processor controlling charging discharging battery, known Battery Controller. This command will stop ongoing activity terms charge/discharge. Message Format Host:
DATA FILE FORMAT
order information follows: sizeof(int) Battery number that charged sizeof(gOptionSettings) option settings session. sizeof(gConfigSettings) configuration settings session. sizeof(TBatFileDataStruct) Each sample taken.
structures Example define battery charger data organized. data resolution called preceding documentation well firmware. data file saved during charge session binary file which dump charge information data received charge session single battery.
Once configuration read determine attributes apply TBatFileDataStruct, (i.e., need know sample frequency form gOptionSeettings). Each data point successively read from file (TBatFileDataStruct).
DS30451C-page
1997 Microchip Technology Inc.
PICREF-2
EXAMPLE E-1: CODE STRUCTURE
This structure contains data interval saved disk. struct TBatFileDataStruct uint8 ui8Voltage; int8 i8Temperature; uint8 ui8MeasuredChargeCurrent; uint8 ui8SystemStatus; uint8 ui8ChargeStatus; uint8 ui8ErrorStatus; int8 i8DeltaV; int8 i8DeltaT; This class contains option settings chosen charge session. These determine graphing characteristics graphing support routines. class TOptionSettings public: char szComPort[10]; iDisplayUpdateFrequency; iMaxGraphCurrentRange; iMaxGraphVoltageRange; iMaxGraphTempRange; iMinGraphCurrentRange; iMinGraphVoltageRange; iMinGraphTempRange; iTimeDisplayed; iMaxY; iMinY; inline inline inline inline inline inline This stucture contains configuration settings chosen charge session. struct TConfigSettings iChargeAlgorithm; iChargeDischargeSequence; iTerminationAlgorithm; iChemistry; float float uint16 float float float float float float float fChargeVoltageMax; fChargeVoltageMin; iFastChargeTempMax; iFastChargeTempMin; iTrickleTempMax; iTrickleTempMin; ui16MaxChargeTime; fMaxVoltage; fDischargeRate; fDischargeVoltage; fDTDtThreshold; iDvThreshold; fFastChargeAmps; iSpare; fTrickleChargeAmps; fReserved; float float float float float float NormalizeCurrent(float fCurrent); NormalizeVoltage(float fVoltage); NormalizeTemp(float fTemp); UnNormalizeCurrent(float fCurrent); UnNormalizeVoltage(float fVoltage); UnNormalizeTemp(float fTemp);
1997 Microchip Technology Inc.
DS30451C-page
PICREF-2
NOTES:
DS30451C-page
1997 Microchip Technology Inc.
PICREF-2
APPENDIX LAYOUT DRAWING
silk screen drawing battery charger shown below. board dimensions listed are, with respect orientation this page, horizontal dimension vertical dimension.
FIGURE F-1:
INTELLIGENT BATTERY CHARGER LAYOUT
4.25")
1997 Microchip Technology Inc.
DS30451C-page
PICREF-2
APPENDIX BILL MATERIALS (BOM)
TABLE G-1:
Line
PICREF-2
Part
03-01422 04-01422
Part Description
SCHEMATIC, CARD FABRICATION, CARD
Manufacturer
Vendor
Vendor Part
DM003002
Reference Designator
DJ005B 644894-5
CONN, POWER CONNECTOR, 5PIN, BATTERY
(301) 921-4600 (717) 564-0100 (800) 522-6752* TECH (773) 907-5193 OMRON (847) 843-7900 (800) 55OMRON* JAMECO (415) 592-8097 (800) 831-4242* JAMECO (415) 592-8097 (800) 831-4242* SULLINS (619) 744-0125 SULLINS (619) 744-0125 PANASONIC (714) 373-7366 PANASONIC (714) 373-7366 SPRAGUE (516) 334-8700 JAMECO (415) 592-8097 (800) 831-4242* PANASONIC (714) 373-7366 PANASONIC (714) 373-7366 PANASONIC (714) 373-7366 WICKMAN (404) 699-7820 (800) 553-7894* MAGNETEK (219) 297-3111 INTL RECT (310) 322-3331 LITE-ON (408) 946-4873 LITE-ON (408) 946-4873 LITE-ON (408) 946-4873 LITE-ON (408) 946-4873
NEWARK
RL30B 644894-5
J2,J3
DE9S-FRS
CONN, PCB, ANGL, CONTACT SOCKET
NEWARK
89N1583
B3S-1002
SWITCH, MOMENT,
DIGIKEY
SW416-ND
SW1,SW2,SW3, SW4,SW5 TB1,TB2
99426
TBLOCK
NEWARK
99426
37330
HEADER,
NEWARK
37330
H1,H2
PZC36SAFN SULLINS ECA-1HFQ471
HEADER, 0.025 JUMPER CAP, 470UF, ALUM ELEC, RADIAL
DIGIKEY DIGIKEY DIGIKEY
S1061-36-ND S9002-ND P5772-ND
JMPR HEADERS JMPR1-14
ECU-V1H103KB
CAP, 0.01UF, SMT, 1206
DIGIKEY NEWARK NEWARK
PCC103BCT-ND 95F9802 87222
C2,C6,C8,C9,C12 C7,C10
195D106X9035D2T CAP, TANT CHIP, 10UF, 87222 CAP, 0.47UF, SMT, 1206
ECU-V1H102JCH ECU-V1H150JCM ECU-V1H104KBW WK0003-ND
CAP, 1000PF, SMT, 1206 CAP, 15PF, SMT, 1206 CAP, 0.1UF, SMT, 1206 FUSE, 3AG-5
DIGIKEY DIGIKEY DIGIKEY DIGIKEY
PCC102CCT-ND PCC150CCT-ND PCC104BCT-ND WK0003-ND
C15,C16,C18,C19 C11,C13,C17,C20
RC-10
CORE, CUR,
DIGIKEY
10606-ND
30BF20
DIODE, FAST RECOVERY 200V
30BF20
D1,D2
LT1120CT-ND LT1122CT-ND LT1123CT-ND LT1119CT-ND
LED, SMT, GREEN LED, SMT, YELLOW LED, SMT, LED, SMT, ORANGE
DIGIKEY DIGIKEY DIGIKEY DIGIKEY
LT1120CT-ND LT1122CT-ND LT1123CT-ND LT1119CT-ND
D5,D7 D6,D8
numbers valid only.
DS30451C-page
1997 Microchip Technology Inc.
PICREF-2
TABLE G-1:
Line
PICREF-2 (CONTINUED)
Part
ERJ-1WYI201 ERJ-8ENF1.00K ERJ-8ENF1.50K ERJ-8ENF10.0K
Part Description
RES, 200, SMT, 2512 RES, SMT, 1206 RES, 1.5K, SMT, 1206 RES, 10K, SMT, 1206
Manufacturer
PANASONIC (714) 373-7366 PANASONIC (714) 373-7366 PANASONIC (714) 373-7366 PANASONIC (714) 373-7366
Vendor
DIGIKEY DIGIKEY DIGIKEY DIGIKEY
Vendor Part
P200XCT-ND P1.00KFCT-ND P1.50KFCT-ND P10.0KFCT-ND
Reference Designator
R19,R20,R23 R4,R6,R7,R8,R9,R11, R12,R13,R14,R15, R16,R1,R21,R22, R26,R29,R30 R5,R10 R33,R34,R35,R36, R37,R38 (PROVISIONAL)
ERJ-8ENF20.0K ERJ-8ENF976K ERJ-8ENF24.9K ERJ-8ENF4.75K ERJ-8ENF332 SFB270
RES, 20K, SMT, 1206 RES, 976K, SMT, 1206 RES, 24.9K, SMT, 1206 RES, 4.75K, SMT, 1206 RES, 332, SMT, 1206 INDUCTOR, 27UH
PANASONIC (714) 373-7366 PANASONIC (714) 373-7366 PANASONIC (714) 373-7366 PANASONIC (714) 373-7366 PANASONIC (714) 373-7366 WILCO (317) 293-9300 (800) 611-2343* INTL RECT (310) 322-3331 SEMI (408) 712-5800 (800) 272-9959* INTL RECT (301) 322-3331 INTL RECT (301) 322-3331 LINEAR TECH (408) 432-1900 SEMI (408) 712-5800 (800) 272-9959* DALLAS (214) 450-0400 CORP. (415) 961-3901 MICROCHIP (602) 786-7200 MICROCHIP (602) 786-7200 MILL-MAX (516) 922-6000 (888) 922-6544 MICROCHIP (602) 786-7200 MILL-MAX (516) 922-6000 (888) 922-6544
DIGIKEY DIGIKEY DIGIKEY DIGIKEY DIGIKEY WILCO
P20.0KFCT-ND P976KFCT-ND P24.9KFCT-ND P4.75KFCT-ND P332FCT-ND SFB270
IRF7406
SO-8
NEWARK
IRF7406
U1,U4,U8 (PROVISIONAL)
NDT456P
MOSFET, CHAN, SOT-223
DIGIKEY
NDT456PCT-ND
U2,U6,U7
IRF9540 IRF7403 LT1118CST-5
HEXFET, P-CH, TO-220AB SO-8 REG, 800MA, SOT223
NEWARK DIGIKEY
IRF9540 IRF7403 LT1118CST-5-ND
(PROVISIONAL) U5,U9
LM6134AI
QUAD AMP, SO-14
DIGIKEY
LM6134AIM-ND
U11,U12
DS1803Z-100K
DUAL EEPROM POT, SO-16
NEWARK
DS1803Z-100K/10K
NJM7805 24LC65 PIC16C711
SERIAL EEPROM, SO-8 MICROCONTROLLER,
DIGIKEY MICROCHIP MICROCHIP
NJM78MOSFA-MD 24LC65/SO PIC16C711-20
(PROVISIONAL)
110-99-318-41-001
SOCKET,
DIGIKEY
ED3118-ND
U16a
PIC16C72
MICROCONTROLLER,
MICROCHIP
PIC16C72-20
110-99-328-41-001
SOCKET,
DIGIKEY
ED3128-ND
U17a, U19a
numbers valid only.
1997 Microchip Technology Inc.
DS30451C-page
PICREF-2
TABLE G-1:
Line
PICREF-2 (CONTINUED)
Part
PIC16C73
Part Description
MICROCONTROLLER,
Manufacturer
MICROCHIP (602) 786-7200 DALLAS (214) 450-0400 (913) 782-7787 (800) 237-1041* SEMI (408) 712-5800 (800) 272-9959*
Vendor
MICROCHIP
Vendor Part
PIC16C73-20
Reference Designator
DS275S ECS-100-S-4
RS232 TRANS, SO-8 10.0MHz QUARTZ CRYSTAL
NEWARK DIGIKEY
DS275S X422-ND
X1,X2
2N2222A
TRANS, NPN, T0-18
DIGIKEY
2N2222A-ND
Q1,Q2,Q3
numbers valid only.
DS30451C-page
1997 Microchip Technology Inc.
PICREF-2
APPENDIX BATTERY CHARGER DEMONSTRATION UNIT
limited number battery charger demonstration units available customer evaluation. obtain demonstration unit, contact Microchip sales office. more detailed description demonstration circuits, Hardware Overview. Microcontrollers PIC16C72 PIC16C73A inserted either 28-pin socket (U17 U19). Voltage Regulator voltage regulator LT1118CS8-5 (U10) replaced (NJM7805). Note: regulators. populated place designer's option. Note: discharge mode, drives N-channel FET, connecting load TB1/TB2 ground. This line software either OFF, user pulse line simulate various discharge modes. Voltage Sense Voltage Sense modes: windowed, fixed, direct, which selected jumpers (see Hardware Overview Jumpers). Note: R17, provide voltage reference "fixed" mode. this mode, removed. battery voltage divided resistors R14. smaller dynamic range than required, these resistor values changed increase "direct" mode resolution.
Current Sense current sense circuitry works amplifying converting current through 0.05 resistor into voltage. Note: current sense resistor replaced designer's option give either more range more resolution.
Buck Converter output from microcontroller drives transistor (Q1) which biases P-channel (U2). when output high, conducts, providing gate-source voltage turn P-channel FET. This allows current flow through inductor Diode used isolate buck converter output from battery voltage. Capacitor used conjunction with filter output buck converter capacitor used filter high frequency. Note: p-channel FETs buck converter. populated place designer's option. populated place designer's option.
Temperature Sense temperature sense accomplished through simple pull-up resistor. Note: temperature sense resistors replaced designer's option based designer's battery pack thermistor value.
Battery Pack KR-1100AEL Fast Charge Battery Cell that charged 1600 rate less than hour. discharged rate minutes discharge takes minutes). Note: Note: Refer manufacturer's specifications before charging battery pack. Improper disposal NiCd batteries poses environmental hazard. Contact local battery collection center recycling information.
Filter filter circuit intended provide additional ripple suppression buck converter output stage. Note: provide additional ripple filtering output buck converter. They populated designer's option.
Battery Battery Charge/Discharge PIC16C7X controls charge discharge both battery battery through lines. charge mode, line drives transistor bias P-Channel same fashion that drives buck converter. Note: p-channel FETs used select battery charged. populated designer's option.
LED's, Pushbuttons, Jumpers LED's (D5-D10) provided indicator lights. Pushbuttons (SW1-SW5) Jumpers (JMPR1-JMPR14) provided charger control. more detailed functional descriptions, respective sections under Hardware Overview.
1997 Microchip Technology Inc.
DS30451C-page
PICREF-2
Demonstration Specifications Demonstration Unit Assembly
Maximum Charge Current: maximum charging current limited following components: D1,D2 1.3A (Provisional) 2.0A 3.0A PICREF-2 Intelligent Battery Charger demonstration board photo shown Figure H-1. demonstration board comes part that includes disks (PIC16C7X source code development software), power supply sample battery pack (Figure H-2).
bypassed increase charging current 2.0A. Also, replaced higher current inductor increase charging current 3.0A. Maximum Input Voltage: Volts Supported Battery Technologies: NiCd, NiMH, Lead Acid Li-Ion
FIGURE H-1:
PICREF-2 DEMONSTRATION BOARD
JMPR1-3 Input Power Buck Converter
Filter JMPR7-14 JMPR4(GND) Current/Volt Sense Temp Sense Resistors
Batt Charge/ Discharge
PIC16C711 RS-232 PIC16C73A PIC16C72 Batt Charge/ Discharge
Current Sense Resistor
Stand-alone JMPR5-6
Reset
LEDs Pushbuttons
DS30451C-page
1997 Microchip Technology Inc.
PICREF-2
FIGURE H-2: PICREF-2 DEMONSTRATION
Disks Battery Pack
Power Supply
Demonstration Board
Demonstrate PICREF-2 Development Mode
demonstration board should hooked shown Figure H-3.
Plug power supply (13.6V, 1.9A) Plug battery pack Connect demonstration board (RS-232) Software (See PICREF-2 Software Overview) simple charge/discharge cycle
FIGURE H-3:
PICREF-2 SETUP DEVELOPMENT MODE
Power Supply
Demonstration Board RS-232 PIC16C73A Battery Pack
1997 Microchip Technology Inc.
DS30451C-page
PICREF-2
Demonstrate PICREF-2 Stand-Alone Mode
demonstration board should hooked shown Figure H-4. Plug power supply (13.6V, 1.9A) Plug battery pack pushbuttons charge/discharge (See Hardware Overview Pushbuttons)
FIGURE H-4:
PICREF-2 SETUP STAND-ALONE MODE
Power Supply
Demonstration Board
PIC16C72
Battery Pack
DS30451C-page
1997 Microchip Technology Inc.
PICREF-2
NOTES:
1997 Microchip Technology Inc.
DS30451C-page
WORLDWIDE SALES SERVICE
AMERICAS
Corporate Office
Microchip Technology Inc. 2355 West Chandler Blvd. Chandler, 85224-6199 Tel: 602-786-7200 Fax: 602-786-7277 Technical Support: 786-7627 Web: www.microchip.com
ASIA/PACIFIC
Hong Kong
Microchip Asia Pacific 3801B, Tower Metroplaza Hing Fong Road Kwai Fong, N.T., Hong Kong Tel: 852-2-401-1200 Fax: 852-2-401-3431
EUROPE
United Kingdom
Arizona Microchip Technology Ltd. Unit Courtyard Meadow Bank, Furlong Road Bourne End, Buckinghamshire Tel: 44-1628-851077 Fax: 44-1628-850259
France
Arizona Microchip Technology SARL Zone Industrielle Bonde Buisson Fraises 91300 Massy, France Tel: 33-1-69-53-63-20 Fax: 33-1-69-30-90-79
Atlanta
Microchip Technology Inc. Sugar Mill Road, Suite 200B Atlanta, 30350 Tel: 770-640-0034 Fax: 770-640-0307
India
Microchip Technology India Legacy, Convent Road Bangalore 025, India Tel: 91-80-229-0061 Fax: 91-80-229-0062
Boston
Microchip Technology Inc. Mount Royal Avenue Marlborough, 01752 Tel: 508-480-9990 Fax: 508-480-8575
Korea
Microchip Technology Korea 168-1, Youngbo Bldg. Floor Samsung-Dong, Kangnam-Ku Seoul, Korea Tel: 82-2-554-7200 Fax: 82-2-558-5934
Germany
Arizona Microchip Technology GmbH Gustav-Heinemann-Ring D-81739 Germany Tel: 49-89-627-144 Fax: 49-89-627-144-44
Chicago
Microchip Technology Inc. Pierce Road, Suite Itasca, 60143 Tel: 630-285-0071 Fax: 630-285-0075
Italy
Arizona Microchip Technology Centro Direzionale Colleone Palazzo Taurus Colleoni 20041 Agrate Brianza Milan, Italy Tel: 39-39-6899939 Fax: 39-39-6899883
Shanghai
Microchip Technology Shanghai Golden Bridge Bldg. 2077 Yan'an Road West, Hongiao District Shanghai, 200335 Tel: 86-21-6275-5700 Fax: 21-6275-5060
Dallas
Microchip Technology Inc. 14651 Dallas Parkway, Suite Dallas, 75240-8809 Tel: 972-991-7177 Fax: 972-991-8588
Singapore
Microchip Technology Taiwan Singapore Branch Middle Road #10-03 Prime Centre Singapore 188980 Tel: 65-334-8870 Fax: 65-334-8850
JAPAN
Microchip Technology Intl. Inc. Benex 3-18-20, Shin Yokohama Kohoku-Ku, Yokohama Kanagawa Japan Tel: 81-4-5471- 6166 Fax: 81-4-5471-6122 06/16/97
Dayton
Microchip Technology Inc. Prestige Place, Suite Miamisburg, 45342 Tel: 937-291-1654 Fax: 937-291-9175
Angeles
Microchip Technology Inc. 18201 Karman, Suite 1090 Irvine, 92612 Tel: 714-263-1888 Fax: 714-263-1338
Taiwan, R.O.C
Microchip Technology Taiwan 10F-1C Tung North Road Taipei, Taiwan, Tel: 2-717-7175 Fax: 886-2-545-0139
York
Microchip Technology Inc. Motor Parkway, Suite Hauppauge, 11788 Tel: 516-273-5305 Fax: 516-273-5335
Jose
Microchip Technology Inc. 2107 North First Street, Suite Jose, 95131 Tel: 408-436-7950 Fax: 408-436-7955
Toronto
Microchip Technology Inc. 5925 Airport Road, Suite Mississauga, Ontario 1W1, Canada Tel: 905-405-6279 Fax: 905-405-6253
rights reserved. ©1997, Microchip Technology Incorporated, USA. 6/97
Printed recycled paper.
Information contained this publication regarding device applications like intended suggestion only superseded updates. representation warranty given liability assumed Microchip Technology Incorporated with respect accuracy such information, infringement patents other intellectual property rights arising from such otherwise. Microchip's products critical components life support systems authorized except with express written approval Microchip. licenses conveyed, implicitly otherwise, under intellectual property rights. Microchip logo name registered trademarks Microchip Technology Inc. U.S.A. other countries. rights reserved. other trademarks mentioned herein property their respective companies.
DS30451C-page
1997 Microchip Technology Inc.
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