PS042

PS042 Datasheet

PS042

Part	Datasheet
PS042	PS042 (pdf)

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PS042 PowerCal Calibration Platform • Hardware platform for configuration, verification, precision calibration and production test of Microchip smart battery systems • Operates under control of based PowerTool software through COM port Interface to PC • Directly connects to assembled smart battery pack or to stand-alone PowerSmart battery electronics • Supports loading and verification of battery configuration parameters and 3D cell models in PS40X EEPROM and OTP memory • Precision analog hardware calibrates PowerSmart battery pack for maximum possible accuracy in current, voltage and temperature measurements • Programmable load capable of drawing up to 36W continuous discharge power from battery pack during calibration using natural-convection cooling • Supports higher power ratings at reduced duty cycles, and/or with forced-air cooling • Powered by 24V DC external supply included • Extensive safety features including production proven EMI/ESD protection, fuses for device under test and optical isolation of serial port • Dimensions 8.66"W x 9.13"L x 2.06"H Board Photo Ordering Information Part No. PS042 Description PowerCal calibration board Development/Test Software Part No. PS040 Description PowerTool 2002 Microchip Technology Inc. DS40237A-page 1 PS042 PRODUCT OVERVIEW PowerCal is a comprehensive hardware platform that supports configuration, verification, calibration and production test of Microchip PowerSmart smart battery systems. It operates under the control of Microchip’s PowerTool Development/Test software interfaced to a Windows PC. The PowerCal board facilitates serial communication between the PC and the SMBus interface on smart batteries, providing a direct connection to both. Under control of PowerTool, PowerCal performs loading and verification of battery configuration parameters and 3D cell models in PS40X EEPROM and OTP memory. In addition, the PowerCal platform provides a complete precision system for calibrating current, voltage and temperature measurements in a smart battery, eliminating the need for expensive meters or power supplies. During calibration, the PowerCal board accurately measures current, voltage and temperature and compares these measured values to those reported by the smart battery. Calibration values are then loaded into the programmable storage and used by the chip to compensate raw measurements made during normal operation. Reported values from the PowerSmart IC are therefore corrected to eliminate known, measured errors. The PowerCal platform accomplishes calibration with programmable load and precision measurement hardware so that a known, constant discharge current is drawn from the battery pack. The programmable load circuit is capable of drawing up 36W continuous discharge power from the battery pack during calibration using natural-convection cooling. Higher discharge currents are supported at reduced duty cycles, and/or with forced-air cooling. In addition, there are provisions for the user to add their own external charger or load, at up to 10A. The PowerCal board is designed to support both development and test environments. Both RS-232 and RS-485 interfaces are present so that the board can operate with a stand-alone connection RS-232 or with a multidrop connection RS-485 to the host PC. The hardware supports up to 7 PowerCal boards interfaced on a multidrop link from a PC COM port. As a result, up to 28 boards can be interfaced on a single PC with 4 COM ports. PowerCal boards can fit in a DIN 6U rack board spacing they can also be panelmounted. Extensive safety features include production proven EMI/ESD protection, optical isolation of the serial ports and protective fuses. Fuses protect the device under test, the PowerCal hardware and any connected external charger or load. The board is implemented using 4 layers with a dedicated ground plane. All I/O’s are connected to bypass capacitors to earth ground. GENERAL SETUP The Microchip PowerCal platform is a very powerful, versatile calibration, test and evaluation system. It can be used in a variety of ways, as a single board in a development environment and as a multi-board system in a high volume production environment. The instructions that follow will guide you through setup for each of the features on the board. References to modules refer to PCB products not yet assembled into packs or connected to cells. Power is provided to the board to the JP connector with a 24V DC, 500 mA power supply wall adapter. Connections • JP 24V DC power supply. • TBP pluggable terminal block alternate 24V DC power supply parallel connections with JP . • TBS pluggable terminal block for board-level test I/Os to be developed later . • TBC Support for future capability. • TBB pluggable terminal block for device under test, module or pack includes connections for cell voltage measurement and programming voltage . • PC cell simulator port DS40237A-page 2 2002 Microchip Technology Inc. Jumpers • ADR jumper for board address identification Jumper Position Address O open, X connect • COM and RX jumpers to select RS-232 or RS-485 RS-232 COM RX 161 252 343 RS-485 COM RX 161 252 343 Jumper Symbol PS042 FUNCTIONAL DESCRIPTION With the current firmware, the PowerCal board can perform programming and test of packs and modules and the calibration of pack and cell voltages on packs. Apply power 24V DC to the board at either the JP connector using an A/C wall adapter or at TBP connector. To use a single PowerCal board connected to the serial port of a PC, configure the COM and RX jumpers for RS-232 and connect the P1 connector to the PC serial port. To use multiple boards per COM port, configure the COM and RX jumpers for RS-485 and connect the P1 connector to the RS-485 connector on the PC card. Additional PowerCal boards my be added by connecting J1 on the first board to P1 on the next using a standard straight-through PC serial cable. Up to seven boards may be added in this manner. Use the ADR jumper to give each board a unique address. Install and run Microchip’s PowerTool software on the PC. The calibration platform is ready to use. Pack Programming, Calibration and Test Attach the external pack contacts of the Microchip SmartBattery pack V+, C, D, T, V- to the same terminals on the TBB connector. Using PowerTool software, the EEPROM can be programmed and the pack voltage can be calibrated. To program OTP memory, the VPP contact in the pack must be connected to VPP on the TBB connector. The additional connection is only necessary for OTP programming. Additional PowerTool features, such as final test, can also be performed on the pack. Microchip provides all the necessary hardware and software to enable easy tailoring of battery control algorithm parameters and cell performance models to meet specific application requirements and attain the highest accuracy available anywhere. Table 5-1 summarizes the development tool offering from Microchip to support the P3 and P4 families. Please refer to the Microchip web site for ordering information and design documentation including schematics at TABLE 5-1 MICROCHIP DEVELOPMENT TOOL SUMMARY Development Tool PowerInfo hardware with PowerTool software PS041 Read and write Smart Battery data values, EEPROM programming PowerCal hardware with PowerTool software PS042 Read and write Smart Battery data values, EEPROM programming, pack and individual calibration, pack test Reference Documents This data sheets provides an overview of the PowerCal Calibration Board. For further information on the PS401 and development tool operations, please refer to the following documents available for download at Document Number DS40239A DS40238A DS40234A Documents Available PS401 Smart Battery IC User’s Guide PS401 Single Chip Battery Manager Data Sheet IC Products PS041 PowerInfo Configuration Interface Product Brief 2002 Microchip Technology Inc. DS40237A-page 5 PS042 DS40237A-page 6 2002 Microchip Technology Inc. PS042 Information contained in this publication regarding device applications and the like is intended through suggestion only and may be superseded by updates. It is your responsibility to ensure that your application meets with your specifications. No representation or warranty is given and no liability is assumed by Microchip Technology Incorporated with respect to the accuracy or use of such information, or infringement of patents or other intellectual property rights arising from such use or otherwise. Use of Microchip’s products as critical components in life support systems is not authorized except with express written approval by Microchip. No licenses are conveyed, implicitly or otherwise, under any intellectual property rights. Trademarks The Microchip name and logo, the Microchip logo and PowerSmart are registered trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. Accuron, PowerTool, SmartSensor, SmartShunt, SmartTel, PowerCal and PowerInfo are trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. All other trademarks mentioned herein are property of their respective companies. 2002, Microchip Technology Incorporated. Printed in the U.S.A., All Rights Reserved. Printed on recycled paper. 2002 Microchip Technology Inc. DS40237A-page 7 WORLDWIDE SALES AND SERVICE AMERICAS Corporate Office 2355 West Chandler Blvd. Chandler, AZ 85224-6199 Tel 480-792-7200 Fax 480-792-7277 Technical Support 480-792-7627 Web Address: Rocky Mountain 2355 West Chandler Blvd. Chandler, AZ 85224-6199 Tel 480-792-7966 Fax 480-792-4338 Atlanta 500 Sugar Mill Road, Suite 200B Atlanta, GA 30350 Tel 770-640-0034 Fax 770-640-0307 Boston 2 Lan Drive, Suite 120 Westford, MA 01886 Tel 978-692-3848 Fax 978-692-3821 Chicago 333 Pierce Road, Suite 180 Itasca, IL 60143 Tel 630-285-0071 Fax 630-285-0075 Dallas 4570 Westgrove Drive, Suite 160 Addison, TX 75001 Tel 972-818-7423 Fax 972-818-2924 Detroit Tri-Atria Office Building 32255 Northwestern Highway, Suite 190 Farmington Hills, MI 48334 Tel 248-538-2250 Fax 248-538-2260 Kokomo 2767 S. Albright Road Kokomo, Indiana 46902 Tel 765-864-8360 Fax 765-864-8387 Los Angeles 18201 Von Karman, Suite 1090 Irvine, CA 92612 Tel 949-263-1888 Fax 949-263-1338 New York 150 Motor Parkway, Suite 202 Hauppauge, NY 11788 Tel 631-273-5305 Fax 631-273-5335 San Jose Microchip Technology Inc. 2107 North First Street, Suite 590 San Jose, CA 95131 Tel 408-436-7950 Fax 408-436-7955 Toronto 6285 Northam Drive, Suite 108 Mississauga, Ontario L4V 1X5, Canada Tel 905-673-0699 Fax 905-673-6509 ASIA/PACIFIC Australia Microchip Technology Australia Pty Ltd Suite 22, 41 Rawson Street Epping 2121, NSW Australia Tel 61-2-9868-6733 Fax 61-2-9868-6755

PDF Datasheet Preview

PS042

PowerCal Calibration Platform
• Hardware platform for configuration, verification, precision calibration and production test of Microchip smart battery systems
• Operates under control of based PowerTool software through COM port Interface to PC
• Directly connects to assembled smart battery pack or to stand-alone PowerSmart battery electronics
• Supports loading and verification of battery configuration parameters and 3D cell models in PS40X EEPROM and OTP memory
• Precision analog hardware calibrates PowerSmart battery pack for maximum possible accuracy in current, voltage and temperature measurements
• Programmable load capable of drawing up to 36W continuous discharge power from battery pack during calibration using natural-convection cooling
• Supports higher power ratings at reduced duty cycles, and/or with forced-air cooling
• Powered by 24V DC external supply included
• Extensive safety features including production proven EMI/ESD protection, fuses for device under test and optical isolation of serial port
• Dimensions 8.66"W x 9.13"L x 2.06"H

Board Photo
Ordering Information

Part No. PS042

Description PowerCal calibration board

Development/Test Software

Part No. PS040

Description PowerTool
2002 Microchip Technology Inc.

DS40237A-page 1

PS042

PRODUCT OVERVIEW

PowerCal is a comprehensive hardware platform that supports configuration, verification, calibration and production test of Microchip PowerSmart smart battery systems. It operates under the control of Microchip’s PowerTool Development/Test software interfaced to a Windows PC.

The PowerCal board facilitates serial communication between the PC and the SMBus interface on smart batteries, providing a direct connection to both. Under control of PowerTool, PowerCal performs loading and verification of battery configuration parameters and 3D cell models in PS40X EEPROM and OTP memory.

In addition, the PowerCal platform provides a complete precision system for calibrating current, voltage and temperature measurements in a smart battery, eliminating the need for expensive meters or power supplies.

During calibration, the PowerCal board accurately measures current, voltage and temperature and compares these measured values to those reported by the smart battery. Calibration values are then loaded into the programmable storage and used by the chip to compensate raw measurements made during normal operation. Reported values from the PowerSmart IC are therefore corrected to eliminate known, measured errors.

The PowerCal platform accomplishes calibration with programmable load and precision measurement hardware so that a known, constant discharge current is drawn from the battery pack. The programmable load circuit is capable of drawing up 36W continuous discharge power from the battery pack during calibration using natural-convection cooling. Higher discharge currents are supported at reduced duty cycles, and/or with forced-air cooling. In addition, there are provisions for the user to add their own external charger or load, at up to 10A.

The PowerCal board is designed to support both development and test environments. Both RS-232 and RS-485 interfaces are present so that the board can operate with a stand-alone connection RS-232 or with a multidrop connection RS-485 to the host PC. The hardware supports up to 7 PowerCal boards interfaced on a multidrop link from a PC COM port. As a result, up to 28 boards can be interfaced on a single PC with 4 COM ports. PowerCal boards can fit in a DIN 6U rack board spacing they can also be panelmounted.

Extensive safety features include production proven EMI/ESD protection, optical isolation of the serial ports and protective fuses. Fuses protect the device under test, the PowerCal hardware and any connected external charger or load. The board is implemented using 4 layers with a dedicated ground plane. All I/O’s are connected to bypass capacitors to earth ground.

GENERAL SETUP

The Microchip PowerCal platform is a very powerful, versatile calibration, test and evaluation system. It can be used in a variety of ways, as a single board in a development environment and as a multi-board system in a high volume production environment. The instructions that follow will guide you through setup for each of the features on the board. References to modules refer to PCB products not yet assembled into packs or connected to cells.

Power is provided to the board to the JP connector with a 24V DC, 500 mA power supply wall adapter.

Connections
• JP 24V DC power supply.
• TBP pluggable terminal block alternate 24V DC
power supply parallel connections with JP .
• TBS pluggable terminal block for board-level
test I/Os to be developed later .
• TBC Support for future capability.
• TBB pluggable terminal block for device under
test, module or pack includes connections for cell voltage measurement and programming voltage .
• PC cell simulator port

DS40237A-page 2
2002 Microchip Technology Inc.

Jumpers
• ADR jumper for board address identification

Jumper Position

Address

O open, X connect
• COM and RX jumpers to select RS-232 or RS-485

RS-232 COM RX 161 252 343

RS-485 COM RX 161 252 343

Jumper Symbol

PS042

FUNCTIONAL DESCRIPTION

With the current firmware, the PowerCal board can perform programming and test of packs and modules and the calibration of pack and cell voltages on packs. Apply power 24V DC to the board at either the JP connector using an A/C wall adapter or at TBP connector. To use a single PowerCal board connected to the serial port of a PC, configure the COM and RX jumpers for RS-232 and connect the P1 connector to the PC serial port. To use multiple boards per COM port, configure the COM and RX jumpers for RS-485 and connect the P1 connector to the RS-485 connector on the PC card. Additional PowerCal boards my be added by connecting J1 on the first board to P1 on the next using a standard straight-through PC serial cable. Up to seven boards may be added in this manner. Use the ADR jumper to give each board a unique address. Install and run Microchip’s PowerTool software on the PC. The calibration platform is ready to use.

Pack Programming, Calibration and Test

Attach the external pack contacts of the Microchip SmartBattery pack V+, C, D, T, V- to the same terminals on the TBB connector. Using PowerTool software, the EEPROM can be programmed and the pack voltage can be calibrated. To program OTP memory, the VPP contact in the pack must be connected to VPP on the TBB connector. The additional connection is only necessary for OTP programming. Additional PowerTool features, such as final test, can also be performed on the pack.
Microchip provides all the necessary hardware and software to enable easy tailoring of battery control algorithm parameters and cell performance models to meet specific application requirements and attain the highest accuracy available anywhere. Table 5-1 summarizes the development tool offering from Microchip to support the P3 and P4 families. Please refer to the Microchip web site for ordering information and design documentation including schematics at

TABLE 5-1 MICROCHIP DEVELOPMENT TOOL SUMMARY

Development Tool

PowerInfo hardware with PowerTool software PS041

Read and write Smart Battery data values, EEPROM programming

PowerCal hardware with PowerTool software PS042

Read and write Smart Battery data values, EEPROM programming, pack and individual calibration, pack test

Reference Documents

This data sheets provides an overview of the PowerCal Calibration Board. For further information on the PS401 and development tool operations, please refer to the following documents available for download at

Document Number DS40239A DS40238A DS40234A

Documents Available PS401 Smart Battery IC User’s Guide PS401 Single Chip Battery Manager Data Sheet IC Products PS041 PowerInfo Configuration Interface Product Brief
2002 Microchip Technology Inc.

DS40237A-page 5

PS042

DS40237A-page 6
2002 Microchip Technology Inc.

PS042

Information contained in this publication regarding device applications and the like is intended through suggestion only and may be superseded by updates. It is your responsibility to ensure that your application meets with your specifications. No representation or warranty is given and no liability is assumed by Microchip Technology Incorporated with respect to the accuracy or use of such information, or infringement of patents or other intellectual property rights arising from such use or otherwise. Use of Microchip’s products as critical components in life support systems is not authorized except with express written approval by Microchip. No licenses are conveyed, implicitly or otherwise, under any intellectual property rights.

Trademarks The Microchip name and logo, the Microchip logo and PowerSmart are registered trademarks of Microchip Technology Incorporated in the U.S.A. and other countries.

Accuron, PowerTool, SmartSensor, SmartShunt, SmartTel, PowerCal and PowerInfo are trademarks of Microchip Technology Incorporated in the U.S.A. and other countries.

All other trademarks mentioned herein are property of their respective companies.
2002, Microchip Technology Incorporated. Printed in the U.S.A., All Rights Reserved.

Printed on recycled paper.
2002 Microchip Technology Inc.

DS40237A-page 7

WORLDWIDE SALES AND SERVICE

AMERICAS

Corporate Office 2355 West Chandler Blvd. Chandler, AZ 85224-6199 Tel 480-792-7200 Fax 480-792-7277 Technical Support 480-792-7627 Web Address:

Rocky Mountain 2355 West Chandler Blvd. Chandler, AZ 85224-6199 Tel 480-792-7966 Fax 480-792-4338

Atlanta 500 Sugar Mill Road, Suite 200B Atlanta, GA 30350 Tel 770-640-0034 Fax 770-640-0307

Boston 2 Lan Drive, Suite 120 Westford, MA 01886 Tel 978-692-3848 Fax 978-692-3821

Chicago 333 Pierce Road, Suite 180 Itasca, IL 60143 Tel 630-285-0071 Fax 630-285-0075

Dallas 4570 Westgrove Drive, Suite 160 Addison, TX 75001 Tel 972-818-7423 Fax 972-818-2924

Detroit Tri-Atria Office Building 32255 Northwestern Highway, Suite 190 Farmington Hills, MI 48334 Tel 248-538-2250 Fax 248-538-2260

Kokomo 2767 S. Albright Road Kokomo, Indiana 46902 Tel 765-864-8360 Fax 765-864-8387 Los Angeles
18201 Von Karman, Suite 1090 Irvine, CA 92612 Tel 949-263-1888 Fax 949-263-1338

New York 150 Motor Parkway, Suite 202 Hauppauge, NY 11788 Tel 631-273-5305 Fax 631-273-5335

San Jose Microchip Technology Inc. 2107 North First Street, Suite 590 San Jose, CA 95131 Tel 408-436-7950 Fax 408-436-7955

Toronto 6285 Northam Drive, Suite 108 Mississauga, Ontario L4V 1X5, Canada Tel 905-673-0699 Fax 905-673-6509

ASIA/PACIFIC

Australia Microchip Technology Australia Pty Ltd Suite 22, 41 Rawson Street Epping 2121, NSW Australia Tel 61-2-9868-6733 Fax 61-2-9868-6755

Notice: we do not provide any warranties that information, datasheets, application notes, circuit diagrams, or software stored on this website are up-to-date or error free. The archived PS042 Datasheet file may be downloaded here without warranties.

Datasheet ID: PS042 648189