Texas Instruments bq27530EVM User manual

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bq27530EVM with bq27530 Battery Management Unit Impedance Track™
Fuel Gauge and bq24161 2.5-A, Dual-Input, Switch-Mode Battery Charger for
Single-Cell Applications
Impedance Track is a trademark of Texas Instruments.
Microsoft, Windows are registered trademarks of Microsoft Corporation.
All other trademarks are the property of their respective owners.
User's Guide
SLUUA09B–December 2012–Revised July 2016
bq27530EVM with bq27530 Battery Management Unit
Impedance Track™ Fuel Gauge and bq24161 2.5-A, Dual-
Input, Switch-Mode Battery Charger for Single-Cell
Applications
This evaluation module (EVM) is a complete evaluation system for the Battery Management Unit (BMU)
chipset consisting of the bq27530-G1 fuel gauge and bq24161 battery charger. The EVM includes one
bq27530 circuit, including a current sense resistor and one thermistor. In addition, the fuel gauge controls
the bq24161 battery charger's settings and monitors its status via I2C communication lines. Together, the
chipset provides all necessary components to monitor and predict capacity for a system-side fuel gauge
solution as well as to charge the battery from either an adapter or USB input with up to 2.5-A of charge
current. The circuit module connects directly across the battery pack. With the EV2300 interface board
and software, the user can read the bq27530-G1 data registers, program the chipset for different pack
configurations, log cycling data for further evaluation, and evaluate the overall functionality of the battery
management unit solution under different charge and discharge conditions. The latest Microsoft®
Windows®based PC software can be downloaded from the product folder on the Texas Instruments Web
site.
Contents
1 Features....................................................................................................................... 2
2 bq27530-Based Circuit Module ............................................................................................ 2
3 Circuit Module Physical Layouts, Bill of Materials, and Schematic ................................................... 6
4 EVM Hardware and Software Setup..................................................................................... 13
5 Troubleshooting Unexpected Dialog Boxes ............................................................................ 16
6 Operation.................................................................................................................... 16
7 Calibration................................................................................................................... 18
8 Advanced Communication I2C ........................................................................................... 20
9 Related Documentation From Texas Instruments ..................................................................... 21
List of Figures
1 Schematic..................................................................................................................... 3
2 bq27530EVM-001 Layout – Layer 1 Silk Screen........................................................................ 6
3 Layer 2 ........................................................................................................................ 7
4 Layer 3 ........................................................................................................................ 8
5 Layer 4 ........................................................................................................................ 9
6 Layer 5....................................................................................................................... 10
7 BAT_Load (PR1010) Schematic ......................................................................................... 14
8 Original Test Setup for bq24160/161/163/168EVM (HPA721)....................................................... 15
9 Registers Screen........................................................................................................... 16
10 bqStudio Default Page..................................................................................................... 17
11 Data Memory Screen...................................................................................................... 18
12 Calibration Screen ......................................................................................................... 19
13 Advanced Communication I2C............................................................................................ 20

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Single-Cell Applications
14 Golden Image Output Screen ............................................................................................ 20
15 Perform Programming Screen............................................................................................ 20
List of Tables
1 Ordering Information ........................................................................................................ 2
2 Bill of Materials ............................................................................................................. 11
1 Features
• Complete evaluation system for the Battery Management Unit chipset consisting of the bq27530-G1
Impedance Track fuel gauge and bq24161 2.5-A Dual Input Battery Charger.
• Populated circuit module for quick setup
• Personal computer (PC) software and interface board for easy evaluation
• Software that allows data logging for system analysis
• Ability to upgrade to the latest firmware version by flash reprogramming
1.1 Kit Contents
• bq27530-G1 and bq24161 chipset circuit module (HPA763)
• NTC103AT thermistor
This EVM is used for the evaluation of the bq27530-G1 and bq24161 BMU chipset. Ensure that you visit
the product Web folder at www.ti.com to download the latest firmware version, evaluation software, and
documentation for the associated product to be evaluated.
1.2 Ordering Information
Table 1. Ordering Information
EVM PART NUMBER CHEMISTRY CONFIGURATION CAPACITY
bq27530EVM Li-ion 1 cell Any
2 bq27530-Based Circuit Module
The bq27530-based circuit module is a complete and compact example solution of a bq27530 circuit for
battery management. The circuit module incorporates a bq27530 battery gas gauge integrated circuit (IC)
and all other components necessary to accurately predict the capacity of 1-series Li-ion cell.

www.ti.com bq27530-Based Circuit Module
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Single-Cell Applications
Figure 1. Schematic

bq27530-Based Circuit Module www.ti.com
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Cell Applications
2.1 Circuit Module Connections
Contacts on the circuit module provide the following connections:
• Direct connection to the battery pack (J2 or J3): PACK+, PACK–, and TS
• To the serial communications port (J8): SDA, SCL, and VSS
• The system load and charger connect across charger and load (J6 and J7): CHARGER–/LOAD– and
CHARGER+/LOAD+.
• Access to signal outputs (J5): SOC_INT, BAT_GD, and BAT_LOW
2.2 I/O Description
Header/Terminal Block Description
J1–VIN Adapter positive terminal
J2–VIN Adapter positive terminal
J2–GND Adapter negative terminal
J3-GND Adapter negative header
J4-USB USB positive header
J5-USB USB positive terminal
J5-GND USB negative terminal
J6-GND USB negative header
J7 USB Miniconnector
J8-SYS System positive header
J9-SYS System positive terminal
J9-GND System negative terminal
J10-GND System ground header
J10-SYS System output positive header
J11 USBTOGPIO 10-pin connector (not installed)
J12-PACK+ Battery positive terminal
J12-T Pack thermistor input that leads to IC TS pin
J12-PACK- Battery negative terminal
J13 I2C SDA/SCL/VSS - I2C communication header
J14 EV2300 connector for using bq27530 software to communicate with bq27530 IC
2.3 Test Points
Test Point Description
TP1 bq24161 STAT pin
TP2 bq24161 TS pin
TP3 bq24161 DRV pin
TP4 bq24161 PMIDI pin
TP5 bq24161 PMIDU pin
TP6 bq24161 SW pin
TP7 bq24161 SDA = bq27530 BSDA - I2C communication data line
TP8 bq24161 SCL = bq27530 BSCL - I2C communication clock line
TP9 bq27530 VCC
TP10 bq27530 PACK-
TP11 bq27530 BI/TOUT
TP12 Battery pack NTC positive side
TP13 bq27530 TS pin
TP14 bq24161 INT pin

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Fuel Gauge and bq24161 2.5-A, Dual-Input, Switch-Mode Battery Charger for
Single-Cell Applications
Test Point Description
TP15 bq27530 SOC_INT pin - Access to open-drain output that signals interrupt for changes in SOC.
TP16 bq24161 IN voltage
TP17 bq24161 USB voltage
2.4 Control and Key Parameters Setting
Jumper Description Default Factory Setting
JP1
BGATE When installed, connects the bq24161's BGATE output to the gate of Q1, thereby enabling the external battery FET. INSTALLED
JP2
USB D+/D- Shorting jumper for USB data lines DM (D-) and DP (D+). When shorted,
USB input current limit defaults to 1.5 A. Otherwise, USB100 mode is
selected. NOT INSTALLED
JP3
PSEL
2-3 (PSEL = LO): Indicates that an ac adapter is connected to the USB input
and sets the USB input current limit to 1.5 A.
1-2 (PSEL = HI): Indicates that a USB source is connected to the USB input
and sets the input current limit to 500 mA. (DEFAULT) 1-2 (PSEL = HI)
JP4
CHARGE ENABLE 2-3 ON: Charge disable (CD) pin low for normal operation 1-2 OFF: Charge disable (CD) pin high to disable charge and enter Hi-Z
mode
1-2 OFF
JP5
FUEL GAUGE
ENABLE 1-2 ON: Charge enable (CE) pin high for normal operation
2-3 OFF: Charge enable (CE) pin low to disable charge and gauging 2-3 OFF

T
I
EXAS
NSTRUMENTS
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Single-Cell Applications
3 Circuit Module Physical Layouts, Bill of Materials, and Schematic
This section contains the board layout, bill of materials, assembly drawings, and schematic for the
bq27530 circuit module.
3.1 Board Layout
This section shows the printed-circuit board (PCB) layers (Figure 2 through Figure 5), assembly drawing,
and schematic for the bq27530 module.
Figure 2. bq27530EVM-001 Layout – Layer 1 Silk Screen

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Single-Cell Applications
Figure 3. Layer 2

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Figure 4. Layer 3

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Figure 5. Layer 4

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Figure 6. Layer 5

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Cell Applications
3.2 Bill of Materials and Schematic
Table 2. Bill of Materials
Count Reference
Designator Value Description Size Part Number MFR
2 C1, C3 1.0uF Capacitor, Ceramic, 25V, X5R, 10% 0603 Std Std
3 C2, C5, C12 1.0uF Capacitor, Ceramic, 6.3V, X5R, 10% 0402 Std Std
2 C4, C6 4.7uF Capacitor, Ceramic, 25V, X5R, 10% 0805 Std Std
1 C7 0.01uF Capacitor, Ceramic, 16V, X7R, 10% 0402 Std Std
1 C8 10uF Capacitor, Ceramic, 10V, X5R, 10% 0603 Std Std
1 C9 47uF Capacitor, Ceramic, 10V, X5R, 20% 1206 Std Std
4 C10, C11, C13,
C15 0.1uF Capacitor, Ceramic, 6.3V, X5R, 10% 0402 Std Std
1 C14 0.033uF Capacitor, Ceramic, 16V, X7R, 10% 0402 Std Std
1 D1 Green Diode, LED, Green, 2.1-V, 20-mA, 6-mcd 0603 LTST-C190GKT Liteon
6 J1, J3, J4, J6,
J8, J10 PEC02SAAN Header, Male 2-pin, 100mil spacing, 0.100 inch x 2 PEC02SAAN Sullins
0 J11 Open Connector, Male Straight 2x5 pin, 100mil spacing, 4
Wall 0.338 x 0.788 inch N2510-6002-RB 3M
1 J12 ED555/3DS Terminal Block, 3-pin, 6-A, 3.5mm 0.41 x 0.25 inch ED555/3DS OST
1 J13 ED555/4DS Terminal Block, 4-pin, 6-A, 3.5mm 0.55 x 0.25 inch ED555/4DS OST
1 J14 22-05-3041 Header, Friction Lock Ass'y, 4-pin Right Angle 0.400 x 0.500 22-05-3041 Molex
3 J2, J5, J9 ED555/2DS Terminal Block, 2-pin, 6-A, 3.5mm 0.27 x 0.25 ED555/2DS OST
1 J7 UX60-MB-5ST Connector, Recpt, USB-B, Mini, 5-pins, SMT 0.354 X 0.303 Inches UX60-MB-5ST Hiroise
2 JP1, JP2 PEC02SAAN Header, Male 2-pin, 100mil spacing, 0.100 inch x 2 PEC02SAAN Sullins
2 JP4, JP5 PEC03SAAN Header, Male 3-pin, 100mil spacing, 0.100 inch x 3 PEC03SAAN Sullins
1 JP3 PEC03SAAN Header, Male 3-pin, 100mil spacing, 0.100 inch x 3 PEC03SAAN Sullins
1 L1 1.5uH Inductor, SMT, 3.5A, 70 milliohm 4.1x4.4 mm SPM4012T-1R5M
Alternate: FDSD0415-H-
1R5M
TDK Alternate: Toko
1 Q1 CSD25401Q3 MOSFET, PChan, -20V, 60A, 8.7 milliOhm QFN3.3X3.3mm CSD25401Q3 TI
1 R1 0 Resistor, Chip, 1/16W, 1% 0603 Std Std
0 R3 0 Resistor, Chip, 1/16W, 1% 0603 Std Std
4 R10, R11, R12,
R13 10.0k Resistor, Chip, 1/16W, 1% 0402 Std Std
1 R2 510k Resistor, Chip, 1/16W, 1% 0402 Std Std
0 R4, R5 Open Resistor, Chip, 1/16W, 1% 0603 Std Std
1 R6 1.80M Resistor, Chip, 1/16W, 1% 0402 Std Std

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Table 2. Bill of Materials (continued)
Count Reference
Designator Value Description Size Part Number MFR
1 R7 18.2k Resistor, Chip, 1/16W, 1% 0402 Std Std
1 R8 0.01 Resistor, Chip, 1/4W, 1% 0805 WSL0805R0100FEA18 Vishay
2 R9, R14 1.00k Resistor, Chip, 1/16W, 1% 0402 Std Std
20 TP1, TP2, TP3,
TP4, TP5, TP6,
TP7, TP8, TP9,
TP10, TP11,
TP12, TP13,
TP14, TP15,
TP16, TP17,
TP18, TP19,
TP20
5002 Test Point, White, Thru Hole Color Keyed 0.100 x 0.100 inch 5002 Keystone
1 U1 BQ24161YFF IC, 2.5A, Dual-Input, Single Cell SwitchmodeLi-Ion
BATTERY CHARGER with Power Path Management BGA BQ24161YFF TI
1 U2 BQ27530-
G1YZF IC, Battery Monitor and Data Logger DSBGA BQ27530-G1YZF TI
4 -- Shunt, 100-mil, Black 0.100 929950-00 3M
1 -- PCB HPA763 Any
1 -- Label (See note 5) 1.25 x 0.25 inch THT-13-457-10 Brady
2 J5 mate Connector, Female, 0.100 Centers 22-01-3047 Molex
8 N/A Terminals, Crimp, Tin 08-50-0114 Molex
N/A Wire, Insulated 24 Awg, Red, 18 Inches (+/- 3
inches)(USB_5V) 1854-3 Alpha
N/A Wire, Insulated 24 Awg, White, 18 Inches (+/- 3
inches)(SCL) 1854-1 Alpha
N/A Wire, Insulated 24 Awg, Black, 18 Inches (+/- 3
inches)(GND) 1854-2 Alpha
N/A Wire, Insulated 24 Awg, Brown, 18 Inches (+/- 3
inches) (SDA) 1854-7 Alpha
1 N/A Heatshrink 1" placed at middle of wire set Any Any

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3.3 bq27530 Circuit Module Performance Specification Summary
This section summarizes the performance specifications of the bq circuit module.
3.4 Recommended Operating Conditions
Min Typ Max Unit
Supply voltage, VIN Input voltage from ac adapter 4.2 10 V
USB voltage, VUSB Input voltage from USB or equivalent supply 4.2 6 V
System voltage, VSYS Voltage output at SYS terminal (depends on VBAT voltage
and status of VINDPM and input current limit circuits) 3.3 VBATR EG+4.17
%
V
Battery voltage, VBAT Voltage output at VBAT terminal (registers set via bq27530
software) 3 4.2 4.44 V
Supply current, IIN(MAX) Maximum input current from ac adapter input (registers set
via bq27530 software) 1.5 2.5 A
Supply current, IUSB(MAX) Maximum input current from USB input (registers set via
bq27530 software) 0.1 0.5 1.5 A
Fast charge current,
ICHRG(MAX)
Battery charge current (registers set via bq27530 software) 0.550 2.5 A
Operating junction temperature range, TJ-40 125 °C
4 EVM Hardware and Software Setup
This section describes how to connect the different components of the EVM how to install the
bq27530EVM PC software and.
4.1 Recommended Test Equipment
4.1.1 Power Supplies
1. Power Supply #1 (PS #1) capable of supplying 6 V at 3 A is required.
2. If not using a battery as the load, then power supply #2 (PS #2) capable of supplying up to 5 V at 5 A
is required to power the circuit shown in Figure 7.
4.1.2 Load #1 Between BAT and GND
Testing with an actual battery is the best way to verify operation in the system. If a battery is not available,
then a circuit similar to the one shown inFigure 7 can simulate a battery when connected to a power
supply.

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Figure 7. BAT_Load (PR1010) Schematic
4.1.3 Load #2 Between SYS and GND
Although not required, a resistive load capable of sinking up to 3 A can be used.
4.1.4 Meters
Four equivalent voltage meters (VM #) and two equivalent current meters (CM #) are required. The current
meters must be able to measure 3-A current.
4.1.5 Test Equipment Setup
1. For all power connections, use short, twisted-pair wires of appropriate gauge wire for the amount of the
current.
2. Set Power Supply #1 (PS #1) for 6-V, 3-A current limit and then turn off supply.
3. If BAT_Load as shown in Figure 8 is used, connect Power Supply #2 (PS #2) set to approximately 3.6
V to the input side (PS #2+/-) of BAT_Load, then turn off PS #2.
4. Connect the output side of the battery or BAT_Load in series with current meter (multimeter) #2 (CM
#2) to J2 and J6 or J3 (BAT, GND). Ensure that a voltage meter is connected across J2 or TP3 and J6
or TP9 (BAT, GND).
5. Connect VM #3 across J10 or TP7 and J14 or TP9 (SYS, GND).
6. Connect VM #4 across J15 or TP5 and J14 or TP9 (DRV, GND).
7. Ensure jumpers are at the default factory settings per Section 2.4
8. Connect I2C port of EV2300 with J14 board using the assembled 4 colored-wire connector included
with EV2300 kit (GND / BLACK at the bottom).
9. After the preceding steps have been performed, the test setup for HPA721 is configured as is shown in
Figure 8

Battery or
Simulated
Battery
Elec Load/
Resistor box
VM#2
CM#1
PS#1
VM#1
EV2300
GND
SCL
SDA
www.ti.com EVM Hardware and Software Setup
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Single-Cell Applications
Figure 8. Original Test Setup for bq24160/161/163/168EVM (HPA721)
10. Turn on the computer. Open the bq27530 evaluation software. The main window of the software is
shown in Figure 9 (DataRAM Screen)
4.2 Software Installation
Find the latest software version at http://www.ti.com/tool/bqStudio. Use the following steps to install
Battery Management Studio:
4.2.1 Using EV2300
1. Ensure that the EV2300 is not connected to the PC through a USB cable before starting this
procedure.
2. Select the Tool and Software tab in the product folder.
3. Under the Software section, click on Battery Management Studio (bqStudio) Software Suite.
4. Click the Download button to download the software.
5. Download software to hard drive.
6. Double-click the software executable and follow all instructions and prompts.
4.2.2 Using EV2400:
1. Ensure that the EV2400 is not connected to the PC through a USB cable before starting this
procedure.
2. Browse for the supported software link within the bq27530 TI web site product folder to find the
downloadable EVSW installation files.
3. Open the software file that was downloaded from the TI web site.
4. Follow the instructions on screen until the software installation is completed.

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5 Troubleshooting Unexpected Dialog Boxes
The user that is downloading the files must be logged in as the administrator.
The driver is not signed, so the administrator must allow installation of unsigned drivers in the operating
system policy.
6 Operation
This section details the operation of the bqStudio software.
6.1 Starting the Program
Run bqStudio from the Start | All Programs | Texas Instruments | Battery Management Studio. The main
screen (Figure 9) appears. If instead of Figure 9 appearing, Figure 10 appears, it may mean that the EVM
is not connected to the computer correctly. Make sure that the USB interface (EV2300 or EV2400 or GDK)
and the bq27530 are connected and restart bqStudio. If this still does not resolve the issue, check if the
I2C pullup resistors are connected. Data begins to appear once the <Refresh> (single-time scan) button is
clicked, or when the Scan button is clicked. To disable the scan feature, simply click the Scan button
again.
The continuous scanning period can be set by opening Window | Preferences →Registers section. The
range for this interval is 0 ms to 65,535 ms. Only items that are selected for scanning are scanned within
this period.
Battery Management Studio provides a logging function which logs the values that were last scanned. To
enable this function, select the Start Log button; this causes the Scan button to be pressed. When logging
is Stopped, the Scan button will still be selected and has to be manually clicked again.
Figure 9. Registers Screen
This screen (Figure 9) shows the RAM data in the bq27530 device. Additional Flags and Status data can
be viewed at the bottom of the Registers screen.

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Figure 10. bqStudio Default Page
6.2 Setting Programmable bq27530 Options
The bq27530 data memory comes configured per the default settings detailed in the bq27530 technical
reference manual. Ensure that the settings are correctly changed to match the pack and application for the
bq27530 solution being evaluated.
IMPORTANT: The correct setting of these options is essential to get the best performance.
The settings can be configured using the Data Memory screen (Figure 11).

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Figure 11. Data Memory Screen
To read all the data from the bq27530 non-volatile flash memory, click on the Read All button on the Data
Memory window. Make sure the device is not sealed and in full access to read or write to the data
memory. To update a parameter, click on the desired parameter and a window pops-up that provides
details on the selected parameter. Next, enter the value in the value textbox and press Enter. After
pressing Enter, bqStudio updates the selected parameter. The Import button in the Data Memory window
can be clicked in order to import an entire configuration from a specified *.gg.csv file.
Save the configuration to a file by clicking the Export button in the Data Memory window and entering a
file name. The configuration is saved to a *.gg.csv file. The module calibration data is also held in the
bq27530 data memory. If the Gauge Dashboard is not displaying any information, then the bq27530 may
not be supported by the bqStudio version being used, a bqStudio upgrade may be required.
7 Calibration
The bq27530EVM must be calibrated to ensure accurate value reporting. This can be done by going to the
Calibration window in bqStudio (Figure 12).
7.1 Calibrating the bq27530
Calibrate each item one at a time in the order presented in this document. Select the types of calibration
to be performed by selecting the corresponding checkbox (see Figure 12).
Enter the measured values for the types selected, if necessary.
Then press the Calibrate Part as indicated below button. After all calibration is complete, close the
Calibrate subwindow. While the Calibrate subwindow is open, even in the background, the calibration
routines are running in firmware. Close the subwindow to ensure that they are stopped before proceeding
with configuration or testing.
7.2 CC Offset Calibration
This performs the internal calibration of the coulomb counter input offset. Press the Calibrate Coulomb
Counter button.

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7.3 Voltage Calibration
• Measure the voltage across Pack+ and Pack- with a calibrated meter.
• Type the voltage value in mV into Enter Actual Voltage .
• Measure the temperature for PACK.
• Type the temperature value into Enter Actual Temperature.
• Press the Calibrate Voltage and Temperature as indicated below button.
7.4 Board Offset Calibration
This performs the offset calibration for the current offset of the board. It takes approximately 35 seconds to
complete.
It is expected that no current is flowing through the sense resistor while performing this calibration step.
Remove load and short PACK– to GND.
Press the Calibration Board Offset button.
7.5 Pack Current Calibration
• Connect a load to GND and SYS that draws approximately 1 A, or connect a current source to GND
and Pack–. Ensure that the Measured Current reported is negative, or else reverse the connections.
• Measure the current with a calibrated meter, and type the value into Enter Actual Current using (-) for
current in discharge direction.
• Press the Calibrate Gas Gauge button.
Figure 12. Calibration Screen

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20 SLUUA09B–December 2012–Revised July 2016
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8 Advanced Communication I2C
8.1 I 2C Communication
I2C read/write operations are not specific to any gas gauge. These operations serve as general-purpose
communication tools (Figure 13).
Figure 13. Advanced Communication I2C
Figure 14. Golden Image Output Screen
Figure 15. Perform Programming Screen