Microchip Technology MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User guide

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MCP1630V

Bidirectional 4 Cell

Li-Ion Charger Reference Design

User’s Guide

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code hopping devices, Serial EEPROMs,

MCP1630V BIDIRECTIONAL 4 CELL

LI-ION CHARGER REFERENCE

DESIGN USER’S GUIDE

Table of Contents

Preface ........................................................................................................................... 1

Introduction............................................................................................................ 1

Document Layout .................................................................................................. 1

Conventions Used in this Guide ............................................................................ 2

Recommended Reading........................................................................................ 2

The Microchip Web Site ........................................................................................ 3

Customer Support ................................................................................................. 3

Document Revision History ................................................................................... 3

Chapter 1. Product Overview ........................................................................................ 5

1.1 Introduction ..................................................................................................... 5

1.2 What is the MCP1630V Bidirectional 4 Cell Li-Ion Charger

Reference Design? ................................................................................... 6

1.3 What the MCP1630V Bidirectional 4 Cell Li-Ion Charger

Reference Design kit includes .................................................................. 6

Chapter 2. Installation and Operation .......................................................................... 7

2.4 Introduction ..................................................................................................... 7

2.5 Features ......................................................................................................... 7

2.6 Getting Started ............................................................................................... 8

Appendix A. Schematics and Board Layouts............................................................ 11

A.1 Introduction .................................................................................................. 11

A.2 Schematic - Sheet 1 ................................................................................... 12

A.3 Schematic - Sheet 2 ................................................................................... 13

A.4 Board – Top Silk Layer ............................................................................... 14

A.5 Board – Top Metal Layer ............................................................................ 15

A.6 Board – Mid Layer1 .................................................................................... 16

A.7 Board – Mid Layer2 .................................................................................... 17

A.8 Board – Metal Layer ................................................................................... 18

A.9 Board – Bottom Silk Layer ......................................................................... 19

Appendix B. Bill Of Materials (BOM) .......................................................................... 21

Appendix C. Firmware ................................................................................................. 23

C.1 Device Firmware - Flowchart ....................................................................... 23

C.2 Device Firmware - Flowchart (Continued) ................................................... 24

Worldwide Sales and Service .................................................................................... 26

MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide

NOTES:

MCP1630V BIDIRECTIONAL 4 CELL

LI-ION CHARGER REFERENCE

DESIGN USER’S GUIDE

Preface

NOTICE TO CUSTOMERS

All documentation becomes dated, and this manual is no exception. Microchip tools and documentation are constantly evolving to meet customer needs, so some actual dialogs and/or tool descriptions may differ from those in this document. Please refer to our web site (www.microchip.com) to obtain the latest documentation available.

Documents are identified with a “DS” number. This number is located on the bottom of each page, in front of the page number. The numbering convention for the DS number is “DSXXXXXA”, where “XXXXX” is the document number and “A” is the revision level of the document.

For the most up-to-date information on development tools, see the MPLAB Select the Help menu, and then Topics to open a list of available on-line help files.

IDE on-line help.

INTRODUCTION

This chapter contains general information that will be useful to know before using the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design. Items discussed in this chapter include:

• Document Layout

• Conventions Used in this Guide

• Recommended Reading

• The Microchip Web Site

• Customer Support

• Document Revision History

DOCUMENT LAYOUT

This document describes how to use the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design as a development tool to emulate and debug firmware on a target board. The manual layout is as follows:

• Chapter 1. “Product Overview”– Important information about the MCP1630V

Bidirectional 4 Cell Li-Ion Charger Reference Design.

• Chapter 2. “Installation and Operation” – Includes instructions on how to get

started with this user’s guide and a description of the user’s guide.

• Appendix A. “Schematics and Board Layouts” – Shows the schematic and

layout diagrams for the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design.

• Appendix B. “Bill Of Materials (BOM)” – Lists the parts used to build the

MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design.

• Appendix C. “Firmware” – Provides information about the application firmware

and where the source code can be found.

MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide

CONVENTIONS USED IN THIS GUIDE

This manual uses the following documentation conventions:

DOCUMENTATION CONVENTIONS

Description Represents Examples

Arial font:

Italic characters Referenced books MPLAB® IDE User’s Guide

Emphasized text ...is the only compiler...

Initial caps A window the Output window

A dialog the Settings dialog A menu selection select Enable Programmer

Quotes A field name in a window or

dialog

Underlined, italic text with right angle bracket

Bold characters A dialog button Click OK

N‘Rnnnn A number in verilog format,

Text in angle brackets < > A key on the keyboard Press <Enter>, <F1>

Courier New font:

Plain Courier New Sample source code #define START

Italic Courier New A variable argument file.o, where file can be

Square brackets [ ] Optional arguments mcc18 [options] file

A menu path File>Save

A tab Click the Power tab

where N is the total number of digits, R is the radix and n is a digit.

Filenames autoexec.bat File paths c:\mcc18\h Keywords _asm, _endasm, static Command-line options -Opa+, -Opa- Bit values 0, 1 Constants 0xFF, ‘A’

“Save project before build”

4‘b0010, 2‘hF1

any valid filename

[options]

THE MICROCHIP WEB SITE

Microchip provides online support via our web site at www.microchip.com. This web site is used as a means to make files and information easily available to customers. Accessible by using your favorite Internet browser, the web site contains the following information:

• Product Support – Data sheets and errata, application notes and sample

programs, design resources, user’s guides and hardware support documents, latest software releases and archived software

• General Technical Support – Frequently Asked Questions (FAQs), technical

support requests, online discussion groups, Microchip consultant program member listing

• Business of Microchip – Product selector and ordering guides, latest Microchip

press releases, listing of seminars and events, listings of Microchip sales offices, distributors and factory representatives

CUSTOMER SUPPORT

Users of Microchip products can receive assistance through several channels:

• Distributor or Representative

• Local Sales Office

• Field Application Engineer (FAE)

• Technical Support

Customers should contact their distributor, representative or field application engineer (FAE) for support. Local sales offices are also available to help customers. A listing of sales offices and locations is included in the back of this document.

Technical support is available through the web site at: http://support.microchip.com

Preface

DOCUMENT REVISION HISTORY

Revision A (November 2006)

• Initial Release of this Document.

MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide

NOTES:

Chapter 1. Product Overview

1.1 INTRODUCTION

As high power portable applications continue to gain in popularity, more innovative techniques are needed to charge the batteries while also providing a low regulated voltage to the system’s high end digital electronics. For example, laptop computers, portable test equipment, portable printers, etc., all require more power than a single or two cell Li-Ion battery pack can efficiently store. As a result, three or four series Li-Ion cell packs are used to store the necessary that power these high end applications. The result is a high dc voltage used to store the energy requiring a difficult high voltage to low voltage dc-dc conversion. The MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design can be used to evaluate a design that boosts a low source voltage to charge four Li-Ion series cells while providing energy to the system simultaneously. When the source is removed, the same power train used to charge the battery pack provides a low regulated voltage to operate the system.

This chapter covers the following topics.

• What is the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design?

• What the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design Kit includes.

MCP1630V BIDIRECTIONAL 4 CELL

LI-ION CHARGER REFERENCE

DESIGN USER’S GUIDE

Wide Range ac Input (85 Vrms to 240 Vrms)

Low Voltage

dc Output (+7.0V)

AC/DC

Converter

FIGURE 1-1: MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design shown in Laptop Computer system level block diagram.

DC/DC

Converter

+3.3V

+1.XV

DC/DC

Converter

4 Cell Li-Ion

Battery Pack

dc-Bus

MCP1630V

Bidirectional

Charger and

DC/DC Converter

MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide

1.2 WHAT IS THE MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN?

The MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design demonstrates the use of a bidirectional buck-boost converter used to charge multiple series cell Li-Ion batteries with the presence of an input source (boost) and provide a regulated output voltage when the input source is removed (buck). The board also serves as a platform to evaluate the MCP1630V device.

The MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design inputs were developed to be easily attached to the I/O of a PIC the oscillator (OSC_IN) and reference voltage (V flexible and adaptable power system. The power system switching frequency and maximum duty cycle are set using the hardware PWM of the MCU. The reference input to the high speed analog PWM can be external, a D/A Converter (DAC) output or as simple as an I/O output from the MCU. This enables the power system to adapt to external signals and variables in order to optimize performance and facilitate calibration.

This board utilizes Microchip's MCP1630V (high-speed PIC MCU PWM MSOP8) with the PIC16F88 (Flash MCU) in a four cell Li-Ion charger combined with a synchronous buck regulator. Under normal operation, the input supply can range between 6.5V and

7.0V. The converter is capable of charging four Li-Ion cells connected in series when the 6.5V input is present and regulating the bulk input voltage to 6.0V when the input source voltage is removed by stepping, (bucking), down the battery pack voltage.

Microcontroller. The MCU supplies

) to the MCP1630V creating a

REF

1.3 WHAT THE MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN KIT INCLUDES

This MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design kit includes:

• MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design

• Analog and Interface Products Demonstration Boards CD-ROM (DS21912)

- MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide (DS51641)

Chapter 2. Installation and Operation

2.4 INTRODUCTION

The MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design demonstrates Microchip's high speed pulse width modulator (PWM) used in a four cell Li-Ion battery charger combined power supply application. When used in conjunction with a microcontroller, the MCP1630V will control the power system duty cycle to provide regulated output voltage or current. The PIC16F88 microcontroller oscillator output is used to provide pulses at switching frequency of 500 kHz. The MCP1630V generates duty cycle based on various external inputs. External signals include the input oscillator pulses from PIC16F88, the reference voltage and the feed back voltage. The output signal is a square wave pulse provided to the synchronous gate drive input. They synchronous gate driver is used to turn on and off the upper buck MOSFET and lower synchronous MOSFET.

The PIC16F88 microcontroller is programmable, allowing the user to modify or develop their own firmware routines to further evaluate the MCP1630V in this application.

MCP1630V BIDIRECTIONAL 4 CELL

LI-ION CHARGER REFERENCE

DESIGN USER’S GUIDE

2.5 FEATURES

The MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design has the following features:

• Four Cell Li-Ion Battery Charger, operates stand alone. (Additional firmware

• Charges four cell Li-Ion battery pack from 6.5V to 7.0V Input (complete

• Regulates input dc bus voltage, (steps battery pack voltage down), to 6.0V when

• ON/OFF button used to enable and disable system, low I

• Output over-voltage protection in the event of open battery connections

• High efficiency over entire operating input voltage range (94% typical)

• PIC16F88 is used to generate ref Voltage and Oscillator signal at 500 kHz

• Proprietary features can be added by modifying the firmware contained in the

• Factory programmed source code is available

added allows the charger to communicate with smart battery packs)

precondition, constant current and constant voltage charge algorithm in firmware)

input source is removed (providing uninterrupted power source for system)

drain on the battery

when disabled (< 10 µA)

frequency at maximum duty cycle

PIC16F88

MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide

2.6 GETTING STARTED

The MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design is fully assembled and tested for charging a four series cell Li-Ion battery pack (Battery Pack should have internal overvoltage, overcurrent and overtemperature protection). The board requires the use of an external input voltage source (+7.0V) for charging.

2.6.1 Power Input and Output Connection

2.6.1.1 POWERING THE MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN

1. Connect the positive side of the +6.5V to +7.0V input to J2 Pin 2, connect the

negative side (or ground) to Pin 1 of J2. This source voltage should not exceed

7.0 and be rated for 8A minimum supply current.

2. Connect the positive side of the Four cell Li-Ion battery pack voltage to J1 Pin 1,

connect the battery pack return to the negative side of J1 Pin 2.

Note: Both supplies should have a separate isolated return (ground), there is a

current sense resistor between the +7.0V (V returns. If the returns are connected, the charge current can not be controlled.

) and +14V(V

BULK

BATT

) supply

3. Once the SW1 push button is pressed, the MCP1630V Bidirectional 4 Cell Li-Ion

Charger Reference Design is powered. When powered, a charge cycle will start automatically if the 7.0V is connected and all preconditions are meet, (see Appendix C. “Firmware”).

4. LED D3 will be illuminated when the board is running, (charging or bucking).

5. LED D5 will flash only when a charge cycle is in progress.

6. Again, a subsequent pressing of the SW1 push button during normal operation

of the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design will power-off the converter.

LOCATIONS

FOR

D3 D5

CONN ICD 2

+14 V

BAT

SW1

SWITCH

+7V

FIGURE 2-2: Board Top Assembly and Connections

Installation and Operation

2.6.1.2 APPLYING BATTERY TO MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN

A four cell battery pack (with internal protection) is connected to the J1 connector before applying input power and pressing SW1 to start the charge cycle. Once the battery pack is connected, SW1 can be pressed to start the synchronous buck converter (assuming there is no 7.0V input applied to J2). With the battery pack connected, the source for J2 can be “hot” plugged in and out, a voltage will always be present on J2 until SW1 is pressed shutting off the converter.

2.6.1.3 ALTERNATIVE BATTERY PACK SIMULATOR

As an alternative to the four cell Li-Ion battery pack, a battery pack simulation circuit can be used, (Figure 2-3). This simulation circuit consists of an adjustable metal wound power load resistor (10Ω, 100W), Aluminum Electrolytic Capacitor (3,300 µF 25V) and Schottky Diode (10V, 30V). For evaluating the bidirectional converter design, the battery simulator circuit is recommended. When using the battery pack simulator, the operating point for charging and discharging can be easily be adjusted using the V power supply and load resistor value.

2.6.1.4 LED STATUS INDICATION

Two LED’s are connected to the I/O of the PIC16F88 to provide status of the charger. LED D3 provides indication that the converter is running while LED D5 flashing provides indication that the converter is charging. With a 6.5V to 7.0V source applied to J2 while the converter is running, a charge cycle is initiated. Once the charge cycle is complete, the charger will continue to operate providing 0 mA of current to the battery. If the source is removed from J2, the converter will regulate the V

BULK

to 6.0V with a load up to 6A.

BATT

voltage

Evaluating the Application

The best way to evaluate the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design is to operate the bidirectional power system over a wide range using the battery pack simulator. The simulator consists of a 10 voltage source. When configured as shown in Figure 2-3, the circuit will simulate a battery. The load

resistor is used to sink current from the charger while a large capacitor

is used to simulate the battery voltage (V operating points in the charge cycle can be evaluated.

Once evaluated using the battery pack simulator, the bi-directional reference design can be used to run charge and discharge cycles using a four cell Li-ion battery pack. If using an actual Li-ion battery pack, it must have the proper protection features including, (overvoltage, overcurrent, overtemperature, etc.).

Ω power resistor, diode and variable

). By adjusting the V

SIM

voltage, different

SIM

MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide

J1-1

BATT

SIM

+12V to +17.5V

-V

3,300 µF

J1-2

BATT

10Ω

FIGURE 2-3: Battery Simulator Circuit.

Firmware

The PIC16F88 comes pre programmed with firmware to operate the system as described above. The file listing and firmware flow diagram are shown in Appendix

C. “Firmware”.

Programming

Header J4 is provided for In-Circuit Serial Programming™ (ICSP™). This is an optional feature since the demo board comes preprogrammed with firmware to operate the system. The PIC16F88 can be reprogrammed with the Baseline Flash Microcontroller Programmer (BFMP).

Appendix A. Schematics and Board Layouts

A.1 INTRODUCTION

This appendix contains the following schematics and layouts for the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design:

• Board – Schematic Sheet 1

• Board – Schematic Sheet 2

• Board – Top Silk Layer

• Board – Top Metal Layer

• Board – Internal MidLayer 1

• Board – Internal MidLayer 2

• Board – Metal Layer

• Board – Bottom Silk Layer

MCP1630V BIDIRECTIONAL 4 CELL

LI-ION CHARGER REFERENCE

DESIGN USER’S GUIDE

MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide

A.2 SCHEMATIC - SHEET 1

A.3 SCHEMATIC - SHEET 2

Schematics and Board Layouts

MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide

A.4 BOARD – TOP SILK LAYER

BOARD

A.5 BOARD – TOP METAL LAYER

Schematics and Board Layouts

MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide

A.6 BOARD – MID LAYER1

A.7 BOARD – MID LAYER2

Schematics and Board Layouts

MIDLAYER2

MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide

A.8 BOARD – METAL LAYER

Schematics and Board Layouts

A.9 BOARD – BOTTOM SILK LAYER

MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide

NOTES:

MCP1630V BIDIRECTIONAL 4 CELL

LI-ION CHARGER REFERENCE

DESIGN USER’S GUIDE

Appendix B. Bill Of Materials (BOM)

TABLE B-1: BILL OF MATERIALS (BOM)

QTY

2 C1, C2 CAP CER 10UF 25V X5R 1210 Taiyo Yuden

2 C3, C17 CAP CERM.22UF 10% 10V X7R 0603 AVX Corporation 0603ZC224KAT2A

2 C4, C29 CAP CERAMIC 1.0UF 10V X5R 0603 Kemet

2 C5, C6 CAP TANT 100UF 10V 20% POLY SMD EPCOS Inc. B76010V1079M055

12 C7, C11, C13,

1 C8 CAP CERM 8200PF 10% 50V X7R

1 C9 CAP CER 2200PF 50V C0G 5% 0603 TDK Corporation C1608C0G1H222J

1 C10 CAP CERAMIC 330PF 50V NP0 0603 Kemet Electronics Corp C0603C331J5GACT

1 C12 CAP 3300PF 50V CERAMIC X7R 0603 Kemet Electronics Corp C0603C332K5RACTU

2 C14 CAP CERAMIC 120PF 50V NP0 0603 Kemet Electronics Corp C0603C121J5GACTU

1 C15 CAP CERAMIC 100PF 50V NP0 0603 Kemet Electronics Corp C0603C101J5GACTU

1 C23 CAP CERAMIC 180PF 50V NP0 0603 Kemet Electronics Corp C0603C181J5GACTU

1 C24 CAP CERAMIC 10PF 50V NP0 0603 Kemet Electronics Corp C0603C100J5GACTU

1 C30 CAP 10000PF 50V CERAMIC X7R

1 C31 CAP 1500PF 50V CERAMIC X7R 0603 Kemet Electronics Corp C0603C152K5RACTU

2 D1 DIODE SCHOTTKY 30V 200MW

1 D2 IC ADJ SHUNT REGULATOR

2 D3, D5 LED 660NM SUPER RED DIFF

1 F1 FUSE 5.0A 32V FAST SMD 0603 Tyco

2 J1, J2 CONN TERM BLOCK 2POS 5MM PCB Phoenix Contact 1715022

1 J3 CONN MOD JACK 6-6 RT/A PCB 50AU Tyco Electronics/Amp 5555165-1

1 J4 CONN HEADER VERT 3POS.100 TIN Tyco Electronics/Amp 640454-3

1 L1 INDUCTOR POWER HI CURR 10UH

1 Q1 MOSFET N-CH 30V 35A DPAK International Rectifier IRLR3303PBF

1 Q2 MOSFET N-CH 30V 91A DPAK International Rectifier IRLR8103VPBF

4 Q3, Q6, Q7, Q8MOSFET N-CH 30V 1.2A SSOT3 Fairchild Semiconductor NDS351AN

Reference

Designator

C16, C18, C19, C20, C21, C22, C26, C28

Description Manufacturer Part Number

Electronics Corp C0603C105K8PACTU

CAP .10UF 10V CERAMIC X7R 0603 Kemet Electronics Corp C0603C104K8RACTU

AVX Corporation 06035C822KAT2A

0603

Kemet Electronics Corp C0603C103K5RACTU

0603

Diodes Inc. BAT42W-7-F

SOD123

Texas Instruments TL431IDBVR

SOT-23-5

0603SMD

SMD

Lumex Components Inc

Raychem Circuit Protection

Coiltronics/Div of Cooper/Bussmann

Opto/

Electronics/

TMK325BJ106MN-T

SML-LX0603SRW-TR

0603SFF500F/32-2

HC1-100-R

Note 1: The components listed in this Bill of Materials are representative of the PCB assembly. The released BOM

used in manufacturing uses all RoHS-compliant components.

MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide

TABLE B-1: BILL OF MATERIALS (BOM) (CONTINUED)

QTY

1 Q4 MOSFET P-CH 30V 610MA SOT-23 International Rectifier IRLML5103TRPBF

1 Q5 TRANSISTOR GP NPN AMP SOT-23 Fairchild Semiconductor®MMBT3904

0 R1, R21 SMT0603 RESISTOR

1 R2 RES 499K OHM 1/10W 1% 0603 SMD Panasonic

2 R3, R33 RES 9.53K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF9531V

2 R4, R5 RESISTOR .100 OHM 1W 1% 2512 Panasonic - ECG ERJ-L1WKF10CU

5 R6, R7, R13,

1 R8 RES 1.50K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1501V

6 R9, R15, R19,

1 R10 RES 1.00K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1001V

3 R11, R42, R43 RES 47.5K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF4752V

1 R12, R17 RES 15.0K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1502V

1 R14 RES 6.98K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF6981V

2 R16, R32 RES 49.9K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF4992V

3 R18, R40, R45 RES 2.00K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF2001V

1 R20 RES 150 OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1500V

3 R23, R34, R37 RES 7.87K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF7871V

1 R24 RESISTOR 1.20M OHM 1/10W 1%

1 R25 RES 30.1K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF3012V

3 R26, R27 RES 4.99K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF4991V

1 R28 RES 43.2K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF4322V

1 R30 RES 14.7K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1472V

1 R31 RES 24.9K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF2492V

1 R35 RES 1.62K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1621V

1 R36 RES 221K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF2213V

1 R44 RES 3.3 OHM 1W 1% 2512 SMD Panasonic - ECG ERJ-1TRQF3R3U

1 SW1 SWITCH TACT 6MM 260GF SMT E-Switch TL3301NF260QG

6 TP1, TP2, TP3,

1 U1 IC DRIVER MOSFET DUAL SYNC

1 U2 MCP1630V HIGH SPEED ANALOG

2 U3, U4 DUAL10MHz AMPLIFIER 8 PIN

1 U5 IC MCU FLASH 4KX14 EEPROM

1 U7 IC DGTL THERM SENSOR 5V

Note 1: The components listed in this Bill of Materials are representative of the PCB assembly. The released BOM

Reference

Designator

Description Manufacturer Part Number

DO NOT POPULATE

RES 10.0K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1002V

R29, R39

RES 10.0K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1002V

R22, R38

0603

PC TEST POINT COMPACT SMT Keystone Electronics

TP4, TP5, TP6

8SOIC

PWM

TSSOP PACKAGE

20SSOP

SOT23A-5

used in manufacturing uses all RoHS-compliant components.

——

- ECG ERJ-3EKF4993V

Panasonic - ECG ERJ-3EKF1204V

5016

Intersil ISL6207CBZ

Microchip Technology Inc. MCP1630V-E/MS

Microchip Technology Inc. MCP6022-I/ST

Microchip Technology Inc. PIC16F88T-I/SS

Microchip Technology Inc. TC74A5-5.0VCTTR

MCP1630V BIDIRECTIONAL 4 CELL

LI-ION CHARGER REFERENCE

Appendix C. Firmware

C.1 DEVICE FIRMWARE - FLOWCHART

For the latest copy of the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide firmware, visit our web site at www.microchip.com.

DESIGN USER’S GUIDE

Charge States

Idle = 0 mA P.C. = Pre-Charge C.C. = Constant Current C.V. = Constant Voltage

Yes

Set State to

P. C .

BATT

START

Initialize Ports, ADC, PWM, etc.

Read ADC Inputs V

and V

BATT

Yes

>12.8V

<16.3V

Yes

Is Charge

State @ Idle?

Is Charge

State @ P.C.?

Is Charge

State @ C.C.

BULK

Yes

BATT

> 12.8V

Yes

Set State to

C.C

Set State to

C.V.

Yes

Inc. I

to I

BATT

MAX

>16.8V

Is Charge

State @ C.V.

Yes

BATT

> 16.8V

Yes

Dec. I

BATT

FIGURE C-1: Firmware Flowchart, page 1.

MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide

C.2 DEVICE FIRMWARE - FLOWCHART (CONTINUED)

For the latest copy of the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide firmware, visit our web site atwww.microchip.com

Shutdown

End

Yes

Set Charge

to Idle

Is SW1

Pressed?

<12.8V

BATT

<6.5V

BULK

Yes

BATT

< 100 mA

FIGURE C-2: Firmware Flowchart, page 2.

NOTES:

Firmware

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Tel: 86-10-8528-2100 Fax: 86-10-8528-2104

China - Chengdu

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Tel: 86-591-8750-3506 Fax: 86-591-8750-3521

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Tel: 86-29-8833-7250 Fax: 86-29-8833-7256

ASIA/PACIFIC

India - Bangalore

Tel: 91-80-4182-8400 Fax: 91-80-4182-8422

India - New Delhi

Tel: 91-11-4160-8631 Fax: 91-11-4160-8632

India - Pune

Tel: 91-20-2566-1512 Fax: 91-20-2566-1513

Japan - Yokohama

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Korea - Gumi

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Korea - Seoul

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Philippines - Manila

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Singapore

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Taiwan - Hsin Chu

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Taiwan - Kaohsiung

Tel: 886-7-536-4818 Fax: 886-7-536-4803

Taiwan - Taipei

Tel: 886-2-2500-6610 Fax: 886-2-2508-0102

Thailand - Bangkok

Tel: 66-2-694-1351 Fax: 66-2-694-1350

EUROPE

Austria - Wels

Tel: 43-7242-2244-39 Fax: 43-7242-2244-393

Denmark - Copenhagen

Tel: 45-4450-2828 Fax: 45-4485-2829

France - Paris

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Germany - Munich

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Netherlands - Drunen

Tel: 31-416-690399 Fax: 31-416-690340

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Tel: 34-91-708-08-90 Fax: 34-91-708-08-91

UK - Wokingham

Tel: 44-118-921-5869 Fax: 44-118-921-5820

10/19/06

Microchip Technology MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

INTRODUCTION

DOCUMENT LAYOUT

CONVENTIONS USED IN THIS GUIDE

RECOMMENDED READING

THE MICROCHIP WEB SITE

CUSTOMER SUPPORT

DOCUMENT REVISION HISTORY

Chapter 1. Product Overview

1.1 INTRODUCTION

1.2 WHAT IS THE MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN?

1.3 WHAT THE MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN KIT INCLUDES

Chapter 2. Installation and Operation

2.4 INTRODUCTION

2.5 FEATURES

2.6 GETTING STARTED

Appendix A. Schematics and Board Layouts

A.1 INTRODUCTION

Appendix B. Bill Of Materials (BOM)

Appendix C. Firmware

C.1 DEVICE FIRMWARE - FLOWCHART

C.2 DEVICE FIRMWARE - FLOWCHART (CONTINUED)

WORLDWIDE SALES AND SERVICE