PS4160

DS40235B-page 2

 2003 Microchip Technology Inc.

1.0

GENERAL DESCRIPTION

The PS4160 module is a complete smart battery

controller subsystem with safety based on the

Microchip PS401 battery manager with patented

Accuron™ technology. The module is designed to

operate in a battery pack consisting of three (3) or four

(4) series connected Lithium cells. The module

consists of three circuit sections – the Microchip PS401

battery manager IC, Mitsumi MM1414 based primary

safety circuit and a secondary safety circuit controlled

by the PS401 to provide backup to the MM1414.

1.1

Quick Start – Pack Assembly

Follow these directions to assemble a pack with the

PS4160 module.

• Use standard precautions when handling static

sensitive devices.

• Modules should be connected to battery cells in

the order indicated below to insure proper start-up

and operation. Wires should be attached to the

modules first and then connected to the battery

cells as instructed.

• The connection sequence is critical to successful

use of the PS401 family of CMOS ASICs. Pack

positive should always be connected first,

followed by the intermediate cell voltages from

highest to lowest, and finishing with the negative

end of the pack.

Step 1: Configure the module for the number of series

cells according to the following chart:

Step 2: Configure the module for the following options.

Use Optional External Thermistor

The PS401 IC has an integrated temperature sensor. If

you would like to add an optional external thermistor,

remove R16.

Charge FET Control

The PS4160 is shipped with the Mitsumi 1414 IC

controlling both the charge and discharge FETs. If you

would like to enable PS401 control of the charge FET,

remove R25 and change the value of bit 2 of the

FLAGS1 parameter to ‘0’. Setting bit 2 of FLAGS1

disables the GPIOs.

GPIO<3:0> Operation:

The PS4160 is shipped with four LEDs for a SOC

display. These LEDs are connected to GPIO<3:0> pins

on the PS401 IC. The GPIO<3:0> pins can be used for

operation other than the LED SOC display by removing

the LED and monitoring the adjacent test point.

Step 3: Connect wires to module. Use large diameter

wire (18AWG-20 AWG) for current carrying lines from

VR and V1. All others are signal only lines (24 to 22

AWG).

Step 4: Connect V1 to the most positive point on the

battery cell stack.

Step 5: Connect cell voltage pickups:

4 series cells – negative end of topmost cell in stack to

V2, negative end of next cell to V3, and negative end of

third cell to V4.

3 series cells – negative end of topmost cell in stack to

V2, negative end of next cell to V3, no connection at

V4.

Step 6: Connect VR to the most negative point on the

battery cell stack.

Step 7: Connect external connector to B-Neg, T, C, D

and B+.

Step 8: The PS4160 is shipped with the secondary

safety circuit disabled to avoid damage to the fuse

during assembly. To enable the secondary safety

circuit, remove R23 and change the value of bit 2 of the

FLAGS1 parameter to ‘0’. Setting bit 2 of FLAGS1

disables the GPIOs configured for safety.

Step 9:

Program

the assembled pack

using

Microchip's PowerTool™ software and PowerCal™

board or PowerInfo™ board hardware.

The EEPROM parameters can be changed at will using

the utilities on the P4 EE page in the PowerTool

software. The OTP EPROM parameters can be

changed a limited number of times using utilities on the

P4 OTP page. To write to the OTP EPROM, an

This programming voltage can be obtained from the

PowerInfo board and applied to the PS4160 at

connection VP (small thru-hole) located on the small

edge of the board opposite the connector edge.

Step 10:

Calibrate the pack using the PowerTool

software and PowerCal board hardware. The pack is

now ready for use.

Li Ion 3-cell

Li Ion 4-cell

R27

Removed

Installed

R28

Installed

Removed

R30

Installed

Removed