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Cypress Semiconductor CY8C24794 Application Note

Power management - low-cost, two-cell li-ion/li-pol battery charger with cell-balancing support
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Application Note Abstract
This application note describes a low cost, two-cell Li-Ion/Li-Pol battery charger. An effective cell-balancing algorithm during
both charge and discharge phases is presented. This charger can be used either as a standalone application to charge a
battery pack with two serial connected Li-Ion/Li-Pol batteries or embedded in residential, office, and industrial applications.
Introduction
A modern portable system requires more operating voltage
than a single-cell Lithium-ion (Li-Ion) or Lithium-polymer (Li-
Pol) battery can provide. A serial connection results in a
pack voltage equal to the sum of the cell voltages. To
increase the battery pack capacity, the cells are connected
in parallel. For many applications, two cells in series are
sufficient, with one or more cells in parallel. This
combination gives nominal voltage and the necessary power
for
laptop
computers
and
applications. Problems can occur when the cells have
different capacities or charge levels. During charging or
discharging, the cells in the battery pack do not have
matched voltage every cell. Therefore, the battery pack is
not balanced. The unbalanced charge between cells causes
the following problems:
Reduced overall battery pack capacity to the value of
the cell with the least capacity. During the charge
process, this cell reaches the maximum charge level
before the other cells, and during the discharge process
this cell is depleted before the other cells in the pack.
Reduced overall battery pack life. The charge or
discharge of cells at different values increases pack
imbalance.
Cell damage, which occurs if the charger monitors only
the summary voltage. For example, if the lower cell has
a capacity deficiency of at least 10 percent, its cell
voltage begins to rise into the dangerous area above
4.3 volts. This can result in additional degradation of the
cell or a safety system response that greatly reduces
pack capacity.
November 25, 2007
Power Management - Low-Cost, Two-Cell
Associated Part Family: CY8C24x23A, CY8C24794, CY8C27x43, CY8C29x66
Associated Application Notes: AN2107, AN2258, AN2267,
medical
and
industrial
Document No. 001-17394 Rev. *B
Li-Ion/Li-Pol Battery Charger with
Cell-Balancing Support
G ET FREE SAMPLES HERE
T
Software Version: PSoC Designer™ 5.0 SP1
PSoC Application Notes Index
This application note describes a two-cell Li-Ion/Li-Pol
battery charger. An effective cell-balancing algorithm is
designed. It avoids the issues that appear in battery packs
with two cells in series. Through modification of the
configuration parameters, the cell-balancing algorithm can
easily be adapted for various applications and selected
batteries. The unique architecture of the PSoC
provides an integrated hardware solution for a two-cell
battery charger and a flexible μC-based, cell-balancing
algorithm with minimal external components at a very
affordable price. The CY8C24x23A PSoC device family
used in this implementation reduces the total device cost
even further.
When you want to use algorithms for the latest charging or
cell-balancing technologies, only the firmware needs to be
modified. PSoC Designer's in-circuit and self-programming
capabilities make these operations simple.
Specifications for a two-cell Li-Ion/Li-Pol battery charger with
cell-balancing support are listed in
AN2309
Author: Oleksandr Karpin
Associated Project: Yes
H
T
AN2294
®
device
Table 1
on page 2.
- 1 -
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Summary of Contents for Cypress Semiconductor CY8C24794

  • Page 1 Associated Part Family: CY8C24x23A, CY8C24794, CY8C27x43, CY8C29x66 Application Note Abstract This application note describes a low cost, two-cell Li-Ion/Li-Pol battery charger. An effective cell-balancing algorithm during both charge and discharge phases is presented. This charger can be used either as a standalone application to charge a battery pack with two serial connected Li-Ion/Li-Pol batteries or embedded in residential, office, and industrial applications.
  • Page 2 Table 1. Specifications for Two-Cell Li-Ion/Li-Pol Battery Charger with Cell-Balancing Support Item Battery Charger Parameters Built-In Battery Charger Type Power Supply Voltage Power Consumption Battery Current Measurement Error (Not Calibrated) Battery Voltage Measurement Error (After Calibration) Battery Thermistor Resistance Measurement Error...
  • Page 3  Temperature gradient across the battery pack. Temperature mismatches of 15 degrees Celsius can cause up to 5- percent capacity differential among cells. Such a temperature gradient is relatively common in densely packed products, where multiple heat sources are located close to the battery pack. An example of this is a laptop computer.
  • Page 4 If you choose another PSoC device family for the same project, the overnight conditioning cell- balancing algorithm can easily be added (see AN2258, “Cell Balancing in a Multi-Cell Li-Ion/Li-Pol Battery Charger”). But November 25, 2007 for most applications it is not necessary to use this algorithm.
  • Page 5 AN2258, AN2294, and AN2267. Note that the fuel gauge function can easily be added to this project without changing any hardware: It is only necessary to switch from the CY8C24423A to a PSoC device with more program memory. The main fuel gauge calculation parameters are described in AN2294, “The Li-Ion/Li-Pol Battery Charger with Fuel Gauge Function.
  • Page 6: Device Schematic

    The schematics shown in Figure 4 on page 7 and on page 8 constitute a complete two-cell battery charger. A signal from the PWM goes to the RC-filter, which consists of resistor R4 and capacitor C4. A constant voltage signal proportional to the PWM duty cycle value forms at the Q2 gate.
  • Page 7 Figure 4. Two-Cell Battery Charger Schematic – CPU, Cell Balancing, and Measuring Equipment POWER+ 0.01uF R4 1K DRIVE BC817 0.1uF P0[7] P0[6] Tbat P0[5] P0[4] Vref P0[3] P0[2] BAT_GND P0[1] P0[0] P2[7] P2[6] P2[5] P2[4] LED_Y ELLOW P2[3] P2[2] LED_GREEN...
  • Page 8 Note that if you require more program memory and analog pins, or require USB support, in your user-defined projects, you can import this charger to the CY8C24794 or the CY8C27x43 PSoC device family. The CY8C24794 device includes a full-featured, full-speed (12 Mbps) USB port and...
  • Page 9: Battery Measurement

    PSoC signals, precise resistive dividers are used. To limit the current flow from the battery to the powered-down battery charger, divider resistors of large nominal resistance are employed. To provide higher current measurement accuracy, a current- sense resistor was put in the pack current path close to the negative battery voltage.
  • Page 10 The voltage measurement also is performed by the INA on the corresponding resistor. The resistive dividers (R7, R6), (R13, R12), and (R18, R19) transform cell voltage into signals suitable for the PSoC device. It is very important to use the high precision resistors in the resistive divider to obtain a high value common mode signal rejection.
  • Page 11  Full Discharge: Indicates that the battery pack is discharged completely and is not suitable for further use. The two-cell battery charger state diagram is shown in Figure 8 on page 12. Document No. 001-17394 Rev. *B AN2309...
  • Page 12 Figure 8. Two-Cell Battery Charger State Diagram Initialization Activation Rapid Charge Complete Initially the charger is in the Initialization state. After some device preparation, the charger goes to the Activation state (1). When the battery voltage reaches the rapid start voltage, the charger leaves the Activation state and switches to the Rapid state (2).
  • Page 13 Figure 9. Two-Cell Battery Charger Firmware Flowchart Part 1 Start Init Device Set Initialization State Send Debug Data Measure V Calc V bmin bmax State is not Check For Error or Wait For Negative Ich Temperature Check for charge stop...
  • Page 14 Figure 10. Two-Cell Battery Charger Firmware Flowchart Part 2 State Charge Off Charge Timers Off Complete State Charge Off Wait For Timers Off Temperature State Charge Off Error Timers Off State Charge Off Discharge Open LOAD Out State Charge Off...
  • Page 15 The minimum cell-balance parameter consists of the voltage measure error value plus the internal impedance error value. The cell-balancing algorithm that is implemented here does not significantly lengthen the charge time. The charger monitors all of the cell voltages. Cell balancing is performed during both phases and it is realized in one common module. The cell- balancing algorithm is represented in Figure page 19 and...
  • Page 16 Two-Cell Battery Charger Parameters All two-cell battery charger parameters are located in the header file globdefs.h in the project folder. The header file globdefs.h contains the following parameters: Table 2. Two-Cell Battery Charger Parameters Parameter Unit Charging Parameters Rapid-Charge Stage Start Condition...
  • Page 17 Ibal_min T_BAL_INTERVAL second Conclusion A two-cell battery charger with cell-balancing technology has been described. Recommendations for cell-balancing circuit components are given. An effective cell-balancing algorithm for both charge and discharge phases is developed. The algorithm avoids problems that can arise in a battery pack with two cells in series.
  • Page 18 Appendix Charge/Discharge and Cell-Balancing Profile Examples Cell Voltages Without Charger State Charge Interrupt Charge /Discharge Current Constant Current Charge Battery Discharge November 25, 2007 Figure 13. Charge/Discharge Manager Profile Cell-Balancing State Thermistor Resistance Constant Voltage Charge Document No. 001-17394 Rev. *B AN2309 COM # Start Button...
  • Page 19 Cell Voltages With Charge Interrupt November 25, 2007 Figure 14. Cell-Balancing Activity Profile Document No. 001-17394 Rev. *B AN2309 Voltage Imbalance Value - 19 - [+] Feedback...
  • Page 20: About The Author

    Figure 15. Cell-Balancing Parameter Profile Screen About the Author Name: Oleksandr Karpin Title: Application Engineer Oleksandr received a PhD’s degree in computer science in 2008 from Background: Lviv Polytechnic National University (Ukraine). His interests include embedded systems design and new technologies. Contact: oleksandr.karpin@cypressua.com November 25, 2007...
  • Page 21: Document History

    Document History Document Title: Power Management - Low-Cost, Two-Cell Li-Ion/Li-Pol Battery Charger with Cell-Balancing Support Document Number: 001-17394 Orig. of Rev. Change 1352043 1736124 VICK 2612415 AESA PSoC is a registered trademark of Cypress Semiconductor Corp. "Programmable System-on-Chip," PSoC Designer, and PSoC Express are trademarks of Cypress Semiconductor Corp.

This manual is also suitable for:

An2309Cy8c29x66Cy8c24x23aCy8c27x43