Texas Instruments Bq25505 User manual

User's Guide

SLUUAA8–September 2013

User's Guide for bq25505 Battery Charger Evaluation

Module for Energy Harvesting

This user’s guide describes the bq25505 evaluation module (EVM), how to perform a stand-alone

evaluation and how to allow the EVM to interface with the system and host. The boost charger output is

configured to deliver up to 4.2-V maximum voltage to its output, VSTOR, using external resistors. This

voltage is applied to the storage element as long as the storage element voltage at VBAT_SEC is above

the internally programmed undervoltage of 2 V. The VBAT_OK indicator toggles high when VSTOR ramps

up to 3 V and toggles low when VSTOR ramps down to 2.8 V.

Contents

1 Introduction ................................................................................................................... 2

1.1 EVM Features....................................................................................................... 2

1.2 General Description ................................................................................................ 2

1.3 Design and Evaluation Considerations .......................................................................... 3

1.4 bq25505EVM Schematic........................................................................................... 4

1.5 EVM I/O Connections .............................................................................................. 5

2 EVM Performance Specification Summary............................................................................... 7

3 Test and Measurement Summary......................................................................................... 7

3.1 Test Setups and Results........................................................................................... 8

4 Bill of Materials and Board Layout ....................................................................................... 14

4.1 Bill of Materials .................................................................................................... 14

4.2 EVM Board Layout................................................................................................ 15

5 PCB Layout Guideline ..................................................................................................... 19

List of Figures

1 bq25505EVM Schematic.................................................................................................... 4

2 Test Setup for Measuring Boost Charger Efficiency .................................................................... 8

3 Charger Efficiency versus Input Voltage.................................................................................. 9

4 Charger Efficiency versus Input Current.................................................................................. 9

5 Test Setup for Measuring Charger Operation .......................................................................... 10

6 Charger Operational Waveforms During Battery Charging........................................................... 10

7 Test Setup................................................................................................................... 11

8 Switching from Primary to Secondary Battery.......................................................................... 12

9 Test Setup for Charging a Super Capacitor on VBAT_SEC.......................................................... 12

10 Charging a Super Cap on VBAT_SEC ................................................................................. 13

11 EVM PCB Top Silk......................................................................................................... 15

12 EVM PCB Top Assembly.................................................................................................. 16

13 EVM PCB Top Layer ...................................................................................................... 17

14 EVM PCB Bottom Layer................................................................................................... 18

List of Tables

1 I/O Connections and Configuration for Evaluation of bq25505 EVM ................................................. 5

2 Bill of Materials ............................................................................................................. 14

SLUUAA8–September 2013 User's Guide for bq25505 Battery Charger Evaluation Module for Energy

Harvesting

Introduction

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1 Introduction

1.1 EVM Features

• Evaluation module for bq25505

• Ultra-low power boost converter/charger with battery management for energy harvester applications

• Resistor-programmable settings for overvoltage providing flexible battery management

• Programmable push-pull output indicator for battery status (VBAT_OK)

• Test points for key signals available for testing purpose – easy probe hook-up

• Jumpers available – easy to change settings

1.2 General Description

The bq25505 is an integrated energy harvesting Nano-Power management solution that is well suited for

meeting the special needs of ultra-low power applications. The product is specifically designed to

efficiently acquire and manage the microwatts (µW) to milliwatts (mW) of power generated from a variety

of high output impedance (Hi-Z) DC sources like photovoltaic (solar) or thermal electric generators; or with

an AC/DC rectifier, a piezoelectric generator. The bq25505 implements a highly efficient, pulse-frequency

modulated (PFM) boost converter/charger targeted toward products and systems, such as wireless sensor

networks (WSN) which have stringent power and operational demands. Assuming a depleted storage

element has been attached, the bq25505 DC-DC boost converter/charger that requires only microwatts of

power to begin operating in cold-start mode. Once the boost converter output, VSTOR, reaches ~1.8 V

and can now power the converter, the main boost converter can now more efficiently extract power from

low voltage output harvesters such as thermoelectric generators (TEGs) or single- and dual-cell solar

panels. For example, assuming the Hi-Z input source can provide at least 5 µW typical and the load on

VSTOR (including the storage element leakage current) is less than 1 µA of leakage current, the boost

converter can be started with VIN_DC as low as 330 mV typical, and once VSTOR reaches 1.8 V, can

continue to harvest energy down to VIN_DC ≃120 mV.

Hi-Z DC sources have a maximum output power point (MPP) that varies with ambient conditions. For

example, a solar panel's MPP varies with the amount of light on the panel and with temperature. The MPP

is listed by the harvesting source manufacturer as a percentage of its open circuit (OC) voltage. Therefore,

the bq25505 implements a programmable maximum power point tracking (MPPT) sampling network to

optimize the transfer of power into the device. The bq25505 periodically samples the open circuit input

voltage every 16 seconds by disabling the boost converter for 256 ms and stores the programmed MPP

ratio of the OC voltage on the external reference capacitor (C2) at VREF_SAMP. Typically, solar cells are

at their MPP when loaded to ~70–80% of their OC voltage and TEGs at ~50%. While the storage element

is less than the user programmed maximum voltage (VBAT_OV), the boost converter loads the harvesting

source until VIN_DC reaches the MPP (voltage at VREF_SAMP). This results in the boost charger

regulating the input voltage of the converter until the output reaches VBAT_SEC_OV, thus transferring the

maximum amount of power currently available per ambient conditions to the output.

The battery undervoltage, VBAT_UV, threshold is checked continuously to ensure that the internal battery

FET, connecting VSTOR to VBAT_SEC, does not turn on until VSTOR is above the VBAT_UV threshold

(2 V).The overvoltage (VBAT_OV) setting initially is lower than the programmed value at startup (varies on

conditions) and is updated after the first ~32 ms. Subsequent updates are every ~64 ms. The VBAT_OV

threshold sets maximum voltage on VSTOR and the boost converter stops switching when the voltage on

VSTOR reaches the VBAT_OV threshold. The open circuit input voltage (VIN_OC) is measured every ~16

seconds in order for the Maximum Power Point Tracking (MPPT) circuit to sample and hold the input

regulation voltage. This periodic update continually optimizes maximum power delivery based on the

harvesting conditions.

PowerPAD is a trademark of Texas Instruments.

2User's Guide for bq25505 Battery Charger Evaluation Module for Energy SLUUAA8–September 2013

Harvesting Submit Documentation Feedback

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Introduction

The bq25505 was designed with the flexibility to support a variety of energy storage elements. The

availability of the sources from which harvesters extract their energy can often be sporadic or time-

varying. Systems will typically need some type of energy storage element, such as a re-chargeable

battery, super capacitor, or conventional capacitor. The storage element will make certain constant power

is available when needed for the systems. In general, the storage element also allows the system to

handle any peak currents that can not directly come from the input source. It is important to remember

that batteries and super capacitors can have significant leakage currents that need to be included with

determining the loading on VSTOR.

To prevent damage to a customer’s storage element, both maximum and minimum voltages are monitored

against the internally programmed undervoltage (VBAT_UV) and user programmed overvoltage

(VBAT_OV) levels.

To further assist users in the strict management of their energy budgets, the bq25505 toggles a user

programmable battery good flag (VBAT_OK), checked every 64 ms, to signal the microprocessor when

the voltage on an energy storage element or capacitor has risen above (OK_HYST threshold) or dropped

below (OK_PROG threshold) a pre-set critical level. To prevent the system from entering an undervoltage

condition or if starting up into a depleted storage element, it is recommended to isolate the system load

from VSTOR by using an NFET to invert the BAT_OK signal so that it drives the gate of PFET, which

isolates the system load from VSTOR.

For details, see bq25505 data sheet (SLUSBJ3).

1.3 Design and Evaluation Considerations

This user's guide is not a replacement for the data sheet. Reading the data sheet first will help in

understanding the operations and features of this IC. In this document, “secondary rechargeable battery”

or "VBAT_SEC" will be used but one could substitute any appropriate storage element.

System Design Tips

Compared to designing systems powered from an AC/DC converter or large battery (for example, low

impedance sources), designing systems powered by Hi-Z sources requires that the system load-per-unit

time (for example, per day for solar panel) be compared to the expected loading per the same time unit.

Often there is not enough real time input harvested power (for example, at night for a solar panel) to run

the system in full operation. Therefore, the energy harvesting circuit collects more energy than being

drawn by the system when ambient conditions allow and stores that energy in a storage element for later

use to power the system. See SLUC461 for an example spreadsheet on how to design a real solar-panel-

powered system in three easy steps:

1. Referring the system rail power back to VSTOR

2. Referring the required VSTOR power back to bq255xx input power

3. Computing the minimum solar panel area from the input power requirement

As demonstrated in the spreadsheet, for any boost converter, you must perform a power balance:

POUT / PIN = (VSTOR × ISTOR) / (VIN × IIN) = η(1)

where ηis the estimated efficiency for the same or similar configuration in order to determine the minimum

input power needed to supply the desired output power.

This IC is a highly efficient charger for a storage element such as a battery or super capacitor. The main

difference between a battery and a super capacitor is the capacity curve. The battery typically has little or

no capacity below a certain voltage, whereas the capacitor does have capacity at lower voltages. Both can

have significant leakage currents that will appear as a DC load on VSTOR/VBAT_SEC.

SLUUAA8–September 2013 User's Guide for bq25505 Battery Charger Evaluation Module for Energy

Harvesting

1Not Installed

VIN

GND

VREF_SAMP

VSTOR

GND

VSTOR

BAT_SEC

GND

BAT_SEC

GND

BAT_OK

GND

VBAT_PRI

GND

BAT_SEC

/EN

JP1 to R3-R5

VOC_SAMP

50%

80%

VRDIV

VSTOR

GND

VBAT_PRI

GND

VOR

LBOOST

VOR

2.0V-5.5V

4.2V (Adj up to 5.5V)

2.1V - 5.5V

4.7uF

TP1

0.1uF

JP3

0.01uF

7.5M

5.76M

TP2

4.7uF J5

0.1uF

100uF

TP4

TP5

4.99M

10M

JP4

JP1

J13

5.36M

6.98M

TP7

Q2-A

Q1-A

J11

C13

1uF

JP2

Q2-B

Q1-B

887K

22uH

C11

C12

J6 J7

J10

J12

4.99M

J3 +C9

DNP

+C7

DNP

J15

J14

J16

+C8

DNP

1VSS

2VIN_DC

3VOC_SAMP

4VREF_SAMP

5EN

6NC

7VBAT_OV

8VRDIV

9VB_SEC_ON

10 VB_PRI_ON

OK_HYST

OK_PROG

VBAT_OK

VBAT_PRI

VSS

VBAT_SEC

VSTOR

LBOOST

PWPD

BQ25505RGR

TP6

TP8

TP3

C10

4.7uF

VIN1

VB_PRI_ON

VBAT_PRI

VSTOR

VOC_SAMP

BAT_SEC

VB_SEC_ON

VSTOR

VB_PRI_ON

VOC_SAMP

BAT_SEC

VBAT_PRI

VRDIV

VB_SEC_ON

Introduction

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1.4 bq25505EVM Schematic

Figure 1 is the schematic for this EVM.

Figure 1. bq25505EVM Schematic

white

4User's Guide for bq25505 Battery Charger Evaluation Module for Energy SLUUAA8–September 2013

Harvesting Submit Documentation Feedback

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Introduction

1.5 EVM I/O Connections

Table 1. I/O Connections and Configuration for Evaluation of bq25505 EVM

REFERENCE DESCRIPTION COMMENTS / DEFAULT SETTINGS

DESIGNATOR

HEADERS AND TERMINALS

J1 – VIN Input source (+) If VIN_DC is higher than VSTOR and VSTOR is equal to VBAT_OV, the input VIN_DC is pulled to ground

through a small resistance to stop further charging of the attached battery or capacitor. It is critical that if

J2 – VIN/GND Input source terminal block this case is expected, the impedance of the source attached to VIN_DC be higher than 20 Ωand not a low

J3 – GND Input source return (–) impedance source.

J4 – VSTOR Boost charger output (+)

J5 – VSTOR/GND Boost charger output terminal block

J6 – GND Boost charger return (–)

J7– BAT_SEC Rechargeable storage element connection (+)

J8 – BAT_SEC/GND Rechargeable storage element terminal block

J9 – GND Rechargeable storage element connection return (–)

J10 – VBAT_PRI Non-rechargeable storage element connection (+) VBAT_PRI is an optional non-rechargeable battery that switches in to the power the system when

BAT_SEC drops below the VBAT_OK threshold.

J11 – Non-rechargeable storage element connection terminal

VBAT_PRI/GND block

J12 – GND Non-rechargeable storage element connection return (–)

J13 – BAT_OK/GND Battery Status Indicator (+/–)

J14 – VOR Output of multiplexing switches, either VSTOR or

VBAT_PRI (+)

J15 – VOR/GND Output of multiplexing switches terminal block

J16 – GND Return for output of multiplexing switches (–)

TEST POINTS

TP1 Input source, VIN_DC (+)

TP2 Boost charger switching node

TP3 Buck converter switching node

TP4 Boost charger output, VSTOR (+)

TP5 Rechargeable storage element, VBAT_SEC (+)

TP6 Non-rechargeable storage element, VBAT_PRI(+)

TP7 VRDIV node CAUTION: Providing an additional low impedance current path in parallel with the feedback resistors , for

example, with a 10-MΩscope probe attached, will degrade regulation accuracy.

TP8 Output return (–)

TP9 Input return (–)

WHITE

SLUUAA8–September 2013 User's Guide for bq25505 Battery Charger Evaluation Module for Energy

Harvesting

Introduction

www.ti.com

Table 1. I/O Connections and Configuration for Evaluation of bq25505 EVM (continued)

REFERENCE DESCRIPTION COMMENTS / DEFAULT SETTINGS

DESIGNATOR

JUMPERS

JP1 – VOC_SAMP VOC_SAMP = external resistors sized to configure the IC Uninstalled (NOTE: Do not install if JP4 shunt is installed)

to regulate VIN to 75% of VINOC.

JP2 - EN EN = GND enables the IC. EN = BAT_SEC disables the EN = GND

IC.

JP3 - VREF_SAMP VREF_SAMP = GND Uninstalled (NOTE: Providing an additional leakage path for the VREF_SAMP capacitor for example,

to GND through a 10-MΩscope probe attached to VREF_SAMP, will degrade input voltage regulation

performance).

JP4 - VOC_SAMP VOC_SAMP = 80% configures the IC to regulate VIN to JP4 = 80% (NOTE: Do not install if JP1 shunt is installed)

80% of VIN_OC. VOC_SAMP = 50% configures the IC to

regulate VIN to 50% of VIN_OC.

6User's Guide for bq25505 Battery Charger Evaluation Module for Energy SLUUAA8–September 2013

Harvesting Submit Documentation Feedback

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EVM Performance Specification Summary

2 EVM Performance Specification Summary

See Data Sheet “Recommended Operating Conditions” for component adjustments. For details about the

resistor programmable settings, see bq25505 data sheet (SLUSBJ3).

MIN NOM MAX UNIT

VIN(DC) DC input voltage into VIN_DC 0.13 4.0 V

VIN_STARTUP(D DC minimum start-up voltage into depleted storage element, no load attached 330 mV

C) to VSTOR or VOUT and IBAT(LEAK) ≤1 µA

VBAT_OV Battery overvoltage Threshold –min and max values include ±2% set point 4.04 4.18 4.32 V

accuracy and ±1% resistor tolerance but excludes effects of output ripple

OK_HYST indication toggles high when VSTOR ramps up - min and max 2.70 2.79 2.88 V

values include ±2% set point accuracy and ±1% resistor tolerance

VBAT_OK OK_PROG indication toggles low when VSTOR ramps down - min and max 2.89 2.99 3.09 V

values include ±2% set point accuracy and ±1% resistor tolerance

MPPT Maximum Power Point Tracking, Resistor Programmed % of Open Circuit 80%

Voltage

CBAT A 100-µF low leakage ceramic capacitor is installed on the EVM as the 100 µF

minimum recommended equivalent battery capacitance.

See SLUC484 spreadsheet tool to assist with modifying the MPPT, VBAT_OV and VBAT_OK resistors for

your application.

CAUTION

If changing the board resistors or the capacitor on VREF_SAMP (C2), it is

important to remember that residual solder flux on a board has a resistivity in

the 1–20 MΩrange. Therefore, flux remaining in parallel with changed 1–20

MΩresistors can result in a lower effective resistances, which will produce

different operating thresholds than expected. Similarly, flux remaining in parallel

with the VREF_SAMP capacitor provides an additional leakage path, which

results in the input voltage regulation set point drooping during the 16-s MPPT

cycle. Therefore, it is highly recommended that boards be thoroughly cleaned

twice, once after removing the old components and again after installing the

new components. If possible, the boards should be cleaned until the wash

solution measures ionic contamination greater than 50 MΩ.

3 Test and Measurement Summary

Test Setup Tips

Energy harvesting power sources are high impedance sources. A source-meter configured as a current

source with voltage compliance set to the harvester's open circuit voltage is the best way to simulate the

harvester. When simulating a Hi-Z energy harvester with low output impedance lab power supply, it is

necessary to simulate the harvester's impedance with a physical resistor between the supply, VPS, and

VIN_DC of the EVM. When the MPPT sampling circuit is active, VIN_DC = VPS = the harvester open

circuit voltage (VIN_OC) because there is no input current to create a drop across the simulated

impedance (that is, open circuit); therefore, VPS should be set to the intended harvester's open circuit

voltage. When the boost converter is running, it draws only enough current until the voltage at VIN_DC

droops to the MPPT's sampled voltage that is stored at VREF_SAMP.

The battery (storage element) can be replaced with a simulated battery. Often electronic 4 quadrant loads

give erratic results with a “battery charger” due to the charger changing states (fast-charge to termination

and refresh) while the electronic load is changing loads to maintain the “battery” voltage. The charging and

loading get out of phase and create a large signal oscillation which is due to the 4 quadrant meter. A

simple circuit can be used to simulate a battery and can be adjusted for voltage. It consists of load resistor

(~10 Ω, 2 W) to pull the output down to some minimum storage voltage (sinking current part of battery)

and a lab supply connected to the BAT pin via a diode. The lab supply biases up the battery voltage to the

desired level. It may be necessary to add more capacitance across R1.

SLUUAA8–September 2013 User's Guide for bq25505 Battery Charger Evaluation Module for Energy

Harvesting

Source

meter

configured

as current

source

SM1

Source (Sink)

meter

configured

as voltage

source

SM2

- +

Power Supply set to

desired input voltage

regulation point

(that is, MPPT% × VOC)

C A

BAT+

GND

Test and Measurement Summary

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3.1 Test Setups and Results

3.1.1 Boost Charger Efficiency

The test setup is shown in Figure 2. The specific equipment used for the test results in Figure 3 and

Figure 4 is listed below:

1. VIN_DC was connected to a Keithley 2420 source-meter configured as a current source with voltage

compliance (clamp) set to the open circuit voltage.

2. VSTOR was connected a Keithley 2420 source-meter configured as a voltage source set to the

VSTOR voltage. The current sunk by the source-meter was the output current of the charger.

3. VREF_SAMP was connected to a power supply configured to output the desired input voltage

regulation point (that is, the MPPT% times the HiZ source's VOC). No jumper is required on JP4.

Figure 2. Test Setup for Measuring Boost Charger Efficiency

8User's Guide for bq25505 Battery Charger Evaluation Module for Energy SLUUAA8–September 2013

Harvesting Submit Documentation Feedback

100

0.01 0.1 1 10 100

Efficiency (%)

Input Current (mA)

VSTOR = 1.8 V

VSTOR = 3.0 V

VSTOR = 5.5 V

VIN = 0.5 V

100

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3

Efficiency (%)

Input Voltage (V)

VSTOR = 2.0 V

VSTOR = 3.0 V

VSTOR = 5.5 V

IIN = 100 PA

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Test and Measurement Summary

Figure 3. Charger Efficiency versus Input Voltage

Figure 4. Charger Efficiency versus Input Current

Because the boost converter regulates input voltage instead of output voltage, uses PFM switching,

operates at very low currents, and has MPPT, efficiency cannot be measured using the same test setup

as for an output regulating, higher power, fixed-frequency PWM switching boost converter. The VSTOR

output must be held at a fixed voltage (below VBAT_OV threshold) by an external source that is capable

of sinking current, with that sunk current being the measured output current. In addition to filtering bursts

of current due to PFM switching and the ripple voltage on VIN_DC due to input voltage regulation, the

series input current meter and input voltage meter must be set to filtering/averaging which will result in

longer than usual measurement times, but not longer than the 16-s MPPT sample time. Measurements for

both VIN and IN will be most accurate when taken at the midpoint of the 16-s MPPT period. Remote

sensing by the source-meters is possible but, on the input side, the source-meter output regulation loop

and the charger MPPT input regulation loop may interfere with each other and cause the input voltage to

oscillate. Adding a large capacitor across VIN_DC and GND will eliminate this oscillation but the

capacitor's leakage current will inflate the input current measurement and result in lower efficiency.

See SLUA691 for a detailed explanation on how to take these and other measurements with source-

meters.

3.1.2 Boost Charger Operation during Battery Charging

The test setup is shown in Figure 5. The specific equipment used for the test results in Figure 6 is listed

below:

1. VIN_DC and VBAT_SEC are configured as shown in Section 3.1.2.

2. The boost charger inductor current (IL) was measured by using an oscilloscope current probe across a

current loop that was inserted in series with inductor L1.

SLUUAA8–September 2013 User's Guide for bq25505 Battery Charger Evaluation Module for Energy

Harvesting

1.5

75 :

0.5 F

Test and Measurement Summary

www.ti.com

3. VSTOR's ripple voltage was measured using an oscilloscope voltage probe placed directly across the

VSTOR capacitor (C5). The scope probe's standard ground lead was replaced with short lead.

4. VIN_DC and the LBOOST pin (switching node of the boost charger) were measured by oscilloscope

voltage probes connected to TP1 and TP2.

Figure 5. Test Setup for Measuring Charger Operation

Figure 6. Charger Operational Waveforms During Battery Charging

10 User's Guide for bq25505 Battery Charger Evaluation Module for Energy SLUUAA8–September 2013

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