User's Guide SLUU397A – February 2011 – Revised May 2011 Advanced bqMTester EV2300 Texas Instruments SMB I2C ` HDQ FEATURES – Programs and Calibrates Smart Battery Modules Based on the Following Devices: bq306x and bq28xxx, and the Impedance Track™ devices bq20z4x, bq20z6x, bq20z7x, bq20z80, and bq20z9x – Calibrates Coulomb Counter Offset, Voltage, Temperature, and Current – Programs • Serial Number • Date • Pack Lot Code • Other Defaults Obtained from a Golden Image File – Provides Test Software Co
www.ti.com Appendix H Appendix I Programmers Manual: Flowcharts ............................................................................. 51 Creating the Golden Image File Without bqEASY ........................................................... 57 List of Figures 1 bqMTester Multi-Station Flow ............................................................................................. 6 2 One Testing Station: EV2x00/HPA495 Cal Board/Smart Battery Module Connections..........................
Description www.ti.com 1 Description 1.1 Introduction The Texas Instruments Advanced bqMTester Multi-Station Test and Program Board is designed to calibrate and program electronic smart battery modules based on the latest Texas Instruments advanced battery gas gauges (bq306x, and bq28xxx, and the Impedance Track™ devices bq20z4x, bq20z6x, bq20z7x, bq20z80, bq20z9x).
Advanced bqMTester Requirements • • 4 www.ti.com Traceable Digital Multi-Meter (DMM) capable of measuring 2.5 A and 20 V accurate to less than 1 mv and 1 mA Traceable Temperature probe accurate to 0.
Advanced bqMTester Environment www.ti.com 3 Advanced bqMTester Environment This is a brief explanation of the Advanced bqMTester software/hardware environment. 3.1 bqMTester: Hardware The Advanced bqMTester requires the following: • An HPA495 Advanced MTester Calibration Board • Two wall DC power supplies (5 V/2.5 A and 24 V/0.
Advanced bqMTester Instructions www.ti.com bqEASY Tester Preparation StationSetup Test Initialization / Test Flow Control Test Initialization / Test Flow Control MultiStationTester Statistical Data bqTester bqTester Statistical Data Test Software bqTester bqTester bqTester bqTester bqTester EV2v00 Controller HPAxxx Calibration Board Module Under Test Figure 1. bqMTester Multi-Station Flow 4 Advanced bqMTester Instructions 4.
Advanced bqMTester Instructions www.ti.com (a) Select the Update VTI screen to calibrate the HPA495 voltage, current, and temperature sources used to calibrate the modules. (b) Start testing. Log data is displayed on the log screens and stored to a file (as setup in Step 3 of this section). 4.2 Detailed Instructions This section describes the entire process of setting up the bqMTester software and hardware for a single station and a Texas Instruments bq20zxx EVM.
Advanced bqMTester Instructions www.ti.com 5. If you agree with the terms, click I Agree; otherwise, click Cancel and exit the installation software. 6. Click Next at the Choose Components screen (there is only one option for the bqMTester installation). 7. Choose the Start Menu Folder where you would like to install the bqMTester associated shortcuts. Texas Instruments shows as the default destination. Click Install.
Advanced bqMTester Instructions www.ti.com NOTE: If at any time you are asked to reboot, click No and continue. 8. When the software installs, click Finish to exit the software installation process. All bqMTester software is now installed on the PC. Now, the EV2x00 drivers need to be associated with the USB ports that will be used with bqMTester software, as described in the following section. 4.2.3 EV2x00 Driver to USB Port Association There are two drivers associated with the EV2x00.
Advanced bqMTester Instructions www.ti.com 2. On the next Found New Hardware screen, select Install the software automatically (Recommended) and click Next for the first of the two drivers (TI USB Firmware Updater) required for this instance of the EV2x00. 3. Click Continue Anyway on the Windows Logo Testing notification on the Hardware Installation screen. 4. It is common for the next screen to be the Confirm File Replace screen. Click No to continue.
Advanced bqMTester Instructions www.ti.com 5. The TI USB Firmware Update driver is now installed for this instance of the EV2x00. Click Finish to exit this Found New Hardware Wizard. 6. After a few seconds, another Found New Hardware Wizard screen appears to start the installation of the final driver for this instance of the EV2x00. Select No, not this time and click Next. If the screen that appears does not look like this screen, then proceed to the next step. 7.
Advanced bqMTester Instructions www.ti.com 8. Click Continue Anyway on the Windows Logo Testing notification on the Hardware Installation screen. 9. It is common for the next screen to be the Confirm File Replace screen. Click No to continue. If this screen does not appear, then go to the next step. 10. The TI bq80xx Driver is now installed for this instance of the EV2x00. Click Finish to exit this Found New Hardware Wizard.
Advanced bqMTester Instructions www.ti.com The driver installation process of each instance of the EV2x00 boards should only be done one time. After the initial installation, the only reason it would be required to repeat the process is if the orientation between the USB ports and EV2x00 boards changes. This could happen if a USB hub position is changed, a USB hub is installed, or if an additional EV2x00 is installed. USB hubs can be used to accommodate stations for the bqMTester.
Advanced bqMTester Instructions www.ti.com EV2300 USB Texas Instruments SMB I2C ` HDQ While the HPA495 Calibration Board includes an on-board temperature sensor, it is recommended that you use external temperature sensors for the most accurate temperature calibration. For an external temperature sensor, use the TI TMP100 (not supplied) and connect as shown in Figure 3. The software distinguishes between the on-board temperature sensor and any external temperature sensor.
Advanced bqMTester Instructions www.ti.com 4.4 Station Setup (StationSetup.exe) NOTE: For the first run through the installation procedures, use only one station. You can install up to 12 stations, but ensure the first station is running properly and then repeat the procedures for each subsequent station. When setting up for the first time or adding testing stations to the PC, run the StationSetup.exe program to identify and setup the configurations for all the test stations connected to the PC.
Advanced bqMTester Instructions www.ti.com 6. Select which stations will have their internal or external temperature probes available for use for calibration by clicking the On Board Temp Probe or Ext Temp Probe checkbox. If neither internal nor external temperatures are selected, then that station will be required to either use a temperature probe from another station or manual input of the temperature.
Advanced bqMTester Instructions www.ti.com If only one temperature probe is required for all channels, and it is to be an external temperature sensor and not the one installed on the calibration board for a station named Station1, you would do the following: 1. Start the StationSetup.exe program. 2. Unlock and click Search for boards. 3. Name all of the stations using a unique Station ID but name one station Station1 so that it can be referenced in the next couple of steps. 4. Select the Ext.
Advanced bqMTester Instructions www.ti.com Figure 6. Global Configuration Screen 4.6.1 Board Offset Calibration Board Offset Calibration is activated depending on which device is selected. Some devices do not support Board Offset Calibration for each module tested. If activated, this option is used to check for board offset values within user configurable limits. The software automatically computes the board offset in microvolts for the cases where it is activated and enabled.
Advanced bqMTester Instructions www.ti.com NOTE: If this test is disabled, the values from the Golden Image File will be used and not the values currently in the part. 4.6.4 Temperature Calibration Temperature Calibration can be selected by placing a check in its selection box, or deselected by removing the check. The default is checked. The temperature calibration area also offers three different temperature probe selections or five different temperature probe selections for some devices.
Advanced bqMTester Instructions 4.6.8 www.ti.com Voltage Frame This frame will be grayed out if not selected in the Type of calibration to perform frame. This frame contains two values: 1. Reference/FSV: The tester calibrates the voltage gain by manipulating the Full Scale Voltage Reference. Do not change the values in this field. The Voltage frame looks the same for most of the parts, except for the bq306x. For bq306x device-based parts, extra K-factor fields appear.
Advanced bqMTester Instructions www.ti.com 4.6.14 Save Clicking Save Configuration and Proceed will cause the current configuration settings to be saved. 4.6.15 Data Flash Image File Input the location of the Golden Image File that will be stored in all parts to be tested when running the bqMTester.exe program. Clicking the browse ( ) button gives the option to browse for the Golden Image File.
Advanced bqMTester Instructions www.ti.com Figure 9. Multi-Station Tester Window 4.7.1 Verifying the V, T, I Configuration First, click on Configure VTI. The Update VTI window will pop up as shown in Figure 10. If “Allow V, T, I while locked” is not selected then the Unlock Configuration button must be pressed to allow voltage, temperature, and current reference adjustment. If no calibration is selected in the StationSetup.
Advanced bqMTester Instructions www.ti.com Figure 10. Update VTI Window As you can see above, this is the calibration screen for a regular device. Selecting the appropriate control flashes the board in calibration. In this case, Board 0 is calibrating (and should be flashing). The new board HPA495 supports multiple devices, some of them K-factor–based, as described in previous chapters.
Advanced bqMTester Instructions www.ti.com Also, depending on items selected in the StationSetup Program, the Update VTI screen is populated accordingly. As seen in Figure 12, there is only one difference between the previous and following setups. The following setup does not have Voltage selected in the StationSetup Program; thus, the voltage controls are not populated during calibration. Figure 12. Update VTI: No Voltage Selected 4.7.
Advanced bqMTester Instructions www.ti.com 4.7.4 Locking and Unlocking the Configuration Once all information is updated as required then click Update V, T, and I and Close. This locks the software and enables the Start button. To unlock the software at any time, click Configure VTI on the main screen and then click Unlock Configuration. A password dialog window displays. Supply the required password and click OK. The default password is bq20z80. This password should be changed after the first use.
Advanced bqMTester Instructions 4.8.5 www.ti.com Date/Time Date and Time shows the date and time the tests were performed. 4.8.6 Serial# Serial Number is the serial number given to the device. The serial number increments depending on the progress of the tests for each station. No two stations can have the same serial number even if they start at the same time because the software assigns serial numbers in such a way to prevent this.
Source Code www.ti.com 4.8.11 Real Time Statistics The Statistics data displayed on the lower right corner of the main window displays real time test statistics for all stations combined. 4.8.12 Number Tested This textbox displays the total number of devices that have been tested on all test stations. 4.8.13 Number Passed This textbox displays the total number of devices that have passed the test on all test stations. 4.8.
Source Code www.ti.com So u Av rce ai C la od bl e e recommended to keep a copy of the original bqTester.exe file.) TesterDFReader StationSetup Test Initialization / Test Flow Control Test Initialization / Test Flow Control MultiStationTester bqTester So u Av rce ai C la od bl e e Statistical Data bqTester Statistical Data bqTester bqTester bqTester bqTester bqTester Figure 14. Source Code is Available for bqTester.exe and TesterDFReader.
www.ti.com Appendix A Theory of Operation for HPA495 Calibration Board The HPA495 multi-station tester board consists of three sections: a communication, control, and temperature section, a voltage supply section, and a current supply section. The board is designed to be temperature-independent. The board can be controlled through an SMBus via an EV2x00 interface, or through a user-designed custom interface supporting I2C. For the schematic, see Appendix B. For cell voltage references, see TBD.
Theory of Operation for HPA495 Calibration Board Copyright © 2011, Texas Instruments Incorporated SLUU397A – February 2011 – Revised May 2011 Submit Documentation Feedback
Appendix B www.ti.
Appendix B 32 www.ti.
www.ti.com Appendix C HPA495 Calibration Board Bill of Materials Table 1. HPA495 Calibration Board Bill of Materials Coun RefDes t Value Description Size Device Number MFR 2 C1, C6 1 µF 50V Capacitor, Ceramic, 50 V, X7R, 10% 1206 STD Any 4 C13, C16, C18, C21 4.7 µF Capacitor, Ceramic, 25 V, X7R, 10% 1206 STD Any 1 C2 100 µF Capacitor, Aluminum, 10 V, 20% 0.177 x 0.177 EEE-1AA101WR Panasonic 8 C3, C4, C5, 0.
Appendix C www.ti.com Table 1. HPA495 Calibration Board Bill of Materials (continued) Coun RefDes t Value Description Size Device Number MFR 1 R47 1.00M Resistor, Chip, 1/8W, 0.1%, 25 ppm 0805 ERA-6AEB105V Panasonic - ECG 2 R5, R6 390 Resistor, Chip, 1/16W, 5% 0603 STD Any 2 R7, R12 10K Resistor, Chip, 1/16W, 5% 0603 STD Any 10 R8, R10, R14, 10K R19, R30, R31, R33, R34, R41, R48 Resistor, Chip, 1/8W, 0.
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Appendix D 36 www.ti.
www.ti.com Appendix E Error Code Definitions Table 2. Error Code Definitions Error Code Error # Description Most Probable Cause Possible Action EV2x00 lost synchronization EV2x00 has outdated firmware or drivers are outdated. Contact TI to get EV2x00 with latest firmware. Ensure latest drivers for EV2x00 installed. 2 USB Connection Missing. No EV2x00 is connected. Close program, reboot, and connect EV2x00 first. BAD_PEC 3 Bad PEC on SMBus Possible Bad hardware.
Appendix E www.ti.com Table 2. Error Code Definitions (continued) Error Code Most Probable Cause Possible Action BUS_BUSY 94 SMBus communication terminated unexpectedly / timed out or the bus was busy. Wrong kind of target connected or target timing is off Trim oscillator make sure that the target mode accepts the SMB command being sent T2H_ERR_BAD_SIZE 95 SMBus communication terminated unexpectedly / timed out or the bus was busy.
Appendix E www.ti.com Table 2.
Appendix E www.ti.com Table 2. Error Code Definitions (continued) Error Code Error # Description Possible Action 5043 NVALID_FILENAME 65537 DEVICE_VERSION_MISMATCH 65538 Incompatible device/version RETURN_TO_ROM_FAILED 65539 Gas gauge could not be put in Rom mode Hardware incompatibility Check Connections. Verify version compatibility between bqMTester software and Module under Test. RUNGG_FAILED 65541 Gas gauge could not exit ROM mode Hardware incompatibility Check Connections.
Appendix E www.ti.com Table 2. Error Code Definitions (continued) Error Code Error # Description Most Probable Cause Possible Action SENSE_RES_CAL_LOW 65571 Sense resistor value too low in post cal checks Sensor Resistor Hardware Failure, Connection Problem, Setting Problem, or HPA169 Power Supply Problem Verify Sense Resistor Value, check current supply connections, and verify VTI and Configuration Settings.
Error Code Definitions Copyright © 2011, Texas Instruments Incorporated SLUU397A – February 2011 – Revised May 2011 Submit Documentation Feedback
Appendix F www.ti.com Appendix F Using TesterDFReader to Create an Image of the Data Flash 1. To run the data flash that reads the software in the bqMTester suite, double-click the TesterDFReader.exe file in the directory where the software was installed. Figure 15. TesterDFReader.exe Software 2. Select the device type from the Device pulldown menu. 3. Type in a complete path and file name with a .rom extension in the dialog box or click Browse ( ). 4. Click the Read Data Flash Image button.
Using TesterDFReader to Create an Image of the Data Flash Copyright © 2011, Texas Instruments Incorporated SLUU397A – February 2011 – Revised May 2011 Submit Documentation Feedback
Appendix G www.ti.com Appendix G Programming Guide 1. The programming language for bqMTester is Visual Basic v6.0 with Service Pack 6. 2. The bqMTester project file is bqTester.vbp. The project contains the following objects: (a) Forms (i) frmMainS—This form is the main form for the single station tester that is invoked by the Multi-Station Tester. (ii) frmSplash—The splash screen is the first screen that you see when the program executes.
Appendix G 3. 4. 5. 6. 7. 46 www.ti.com (i) bqTester.RES Tool Box Objects—In addition to the standard Visual Basic GUI objects, the tool box also contains the following objects: (a) Bq80xRW1 (b) clsPassword (c) clsReminder (d) EV2x00ID (e) TesterLog (f) GlobalConfig frmMainS—Important functions (a) Sub SetState(nState As StatusType, Optional sStatusText As String = "")—Sets the status of the program.
Appendix G www.ti.com 8. ModCalBoard (a) Initialization() (i) If Cal Board in use then exit (ii) Use modComm.I2CReadWrite() to turn on power (iii) Use modComm.CheckForError to check for Bq80xRW1 errors (iv) Turn off voltage and current if ON Turn off current (v) Setup the temperature sensor resolution (vi) Loop until no Bq80xRW1 errors (b) InitialTurnOnPower() (i) Set voltage setting time. (ii) If current is enabled, set current setting time. (iii) If DF writing not enabled then increase settling time.
Appendix G www.ti.com (ii) Check voltage limits 1. Errors: a. VBUSER_VOLT_CAL_LOW b. VBUSER_VOLT_CAL_HIGH (iii) Check sense resistor limits 1. Errors: a. VBUSER_SENSE_RES_CAL_HIGH b. VBUSER_SENSE_RES_CAL_LOW (iv) Check temperature limits 1. Error code returned from TempOffsetChecking() (b) TempOffsetChecking() (i) Reports the % error of Temperature offsets 1. Errors: a. VBUSER_TEMP_CAL_LOW b. VBUSER_TEMP_CAL_HIGH 11.
Appendix G www.ti.com (b) New error codes returned to VB (c) Added codes for Programming/Compare Srec errors (d) Config errors (e) The VER byte in the devices instruction flash does not match errors (f) New Error codes corresponding to PKTSpec Error codes (g) New Generic error codes (h) EVSW error codes reserved 5000–6000 (i) VB_ERR_CALIBRATION_IN_FIRMWARE errors (j) All error codes below 65536 are reserved for use by TI Austin (k) User defined error codes must be above 65536 15.
Appendix G www.ti.com (p) ProgramFlashPostCondition()—Restore the first 64 instructions that were corrupted in ProgramFlashPreCondition (q) VerifyProgramFlashFirstRow() (r) Delay() (s) WaitForRomCommandComplete()—returns with VBUSER_WRITEFLASH_ROM_FAILED if error. Make sure to change this in calling function if needed 19. modSerial (a) WriteSerialNumber()—The serial number assigned must be sent back to the caller in "sSerial" 20.
www.ti.com Appendix H Programmers Manual: Flowcharts Start Start modShared.main() frmMainS Instantiate Class SingleSite Attach to EV2300 Display frmMainS Disable Start button Check UseCalBoard checkbox Form_Initialize() Form_Load() Respond to Button Events Form_Unload() Exit Global Configuration Button cmdConfigGlobal_Click() WriteSerialForSingleStation() frmTesterCfg.Configure() lError = SingleSite.InitCacheFromSetup() clsSerial.
Appendix H www.ti.com VTI Configuration Button frmTesterCfg.Configure() clsCfg.m_sInitFile = GetInitFilename() clsCfg.LoadVTIConfiguration() ExposedClass.SetInitFile() sErrStr = ExposedClass.
Appendix H www.ti.com PostCalibrationChecks() "Initialize to success" PostCalibrationChecks = 0 K Factor Enabled? Yes No Checking Voltage Limits? No Yes lError = ReadRefVoltage(nVolt) <>0 lError "Set Post Calibration Checks to Fail" PostCalibrationChecks = lError Exit nCfgVolt = clsCfgRW.m_nVoltageRef nCfgVolt = nCfgVolt * 20 Abs((nCfgVolt - nVolt) / nCfgVolt * 100) > Abs(clsCfgRW.
Appendix H www.ti.com A No Check sense resistor limits Yes lError = ReadSenseResistor(nResist) lError <>0 "Set Post Calibration Checks to Fail" PostCalibrationChecks = lError Exit nCfgResist = clsCfgRW.m_nSenseResistor 'Convert from milliOhms to uOhm nCfgResist = nCfgResist * 1000 Yes Abs((CLng(nCfgResist) - nResist) / nCfgResist * 100) > Abs(clsCfgRW.
Appendix H www.ti.com B No Check temperature limits Yes lError = ReadTempOffsets(nIntTempOffset, nExt1TempOffset, nExt2TempOffset) <>0 "Set Post Calibration Checks to Fail" PostCalibrationChecks = lError lError Exit Yes Internal Temp. Sensor lError = TempOffsetChecking(nIntTempOffset, clsCfgRW.m_nTempOffset) Yes External Temp. Sensor 1 lError = TempOffsetChecking(nExt1TempOffset, clsCfgRW.m_nTempOffset) Yes External Temp. Sensor 2 lError = TempOffsetChecking(nExt2TempOffset, clsCfgRW.
Programmers Manual: Flowcharts Copyright © 2011, Texas Instruments Incorporated SLUU397A – February 2011 – Revised May 2011 Submit Documentation Feedback
Appendix I www.ti.com Appendix I Creating the Golden Image File Without bqEASY NOTE: bqEASY only supports catalog, not custom, parts. After engineering development is completed, a Golden Image File must be made from an Engineering Perfect module. Flash constants in smart battery modules that use this Golden Image File are used as a default to program the Static Data Flash constants in all the smart battery modules that use the bqMTester during production.
Creating Golden GG File from the Engineering Perfect Battery Pack www.ti.com 7. Connect the pack to the EV software, go to the data flash screen, and ensure that Update Status is 0x06. 8. The battery pack is now Engineering Perfect. I.2 Creating Golden GG File from the Engineering Perfect Battery Pack Create a GG file with all of the data from the Engineering Perfect battery pack to create the Golden Image File.
Creating the Golden Image File: www.ti.com software for the applicable device is open. 5. Go to the Pro screen in the EV software. Used Command 0 x 08 to put bq 20 zXX back into Gas Gauge Mode from ROM mode Write 0 x 0 F 00 to SMBus command 0 x 00 to put bq 20 zXX into ROM mode for SENC file creation Load the SENC file Figure 17. EV Software Pro Screen 6. Ensure that Write SMB Word frame has the SMBus Command set to 0x00, and the SMBus Word set to 0x0F00.If they are not, then change them. 7.
Creating the Golden Image File: www.ti.com data into a Golden Image File. 4. Go to Appendix F to read the DFI file from a golden pack.
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