Slua556 Quick Start

Quick Start Guide
SLUA556 – April 2010
Quick-Start Guide for bq78PL114 With bq76PL102 Family

Gas Gauges
This application report gives an overview of the implementation and testing of Texas Instruments
bq78PL114 with companion bq76PL102 high-cell-count battery gas gauge and protector. It explores the
hardware and software graphical user interface (GUI) setup.
This document begins with the discussion of the communication setup between the chipset and the
personal computer. TI’s USB Interface Adapter communications box is used with the provided bqWizard™
software. The examples in this document show the S12 version of the firmware. The updated S12 version
has programming and hardware differences from the original S8 firmware. See the bq78PL114 and
bq78PL114S12 Technical Reference Manual (SLUU330) for those differences.
See the application report Chemistry Selection for bq78PL114 (SLUA505) for additional information on
configuring the gas gauge, as well as on the data collection process for defining a .AUX for your battery
pack. The .AUX file is provided by Texas Instruments.
Additionally, review the application report What is a .tmap File? (SLUA542) to understand the nuances of
the different programming files for the gas gauge. of this document includes questions on your pack
configuration required by TI to create a .tmap file. Automatic .AUX file generation is now available through
bqWizard™ software version 2.5.18.
The examples used in this quick-start guide are based on the hardware implementation shown in the
schematic and build of materials. Collateral on the bq78PL114 8S standard evaluation module (EVM)
offered by TI is available (SLUU335). Note that hardware changes are required moving from the S8
firmware to S12. Do not update the firmware on the bq78PL114 8S standard EVM unless you understand
the implications.
Contents
1 Getting Started With the bq78PL114 Graphical User Interface ....................................................... 3
2 Software Communication and Troubleshooting ......................................................................... 3
3 Updating the Firmware to S12 Configuration ............................................................................ 5
4 Exploring the GUI Software Screens ..................................................................................... 7
5 Updating the Chemistry File ............................................................................................... 9
6 Configuring the Gas Gauge .............................................................................................. 10
7 Final Setup Steps for Evaluation ........................................................................................ 15
7.1 To Initialize Gas Gauge and Turn On Charge and Discharge FETs ...................................... 15
7.2 To Enable PowerPump™ Cell Balancing Feature: .......................................................... 17
7.3 Initializing the Pack ............................................................................................... 19
8 Setting Up Logging Data ................................................................................................. 19
8.1 Setup of Dynamic Data Log Definition File .................................................................... 19
8.2 Data Logging Setup .............................................................................................. 21
9 Final Comments Concerning Evaluation ............................................................................... 23
Appendix A .PPCSV Data-Set File Export From S12 Firmware .......................................................... 24
Appendix B Default Data-Set Screen Captures From bqWizard™ GUI for S12 Firmware ............................ 28
Appendix C Reference Design and Reference Design Bill of Materials ................................................. 32
List of Figures
1 Unable to Connect to Chipset Warning. ................................................................................. 3
2 LAN is not built! Warning. .................................................................................................. 3
SLUA556 – April 2010 Quick-Start Guide for bq78PL114 With bq76PL102 Family Gas Gauges 1
Copyright © 2010, Texas Instruments Incorporated

www.ti.com
3 Proper "Loading" Percentage Start-up Screen .......................................................................... 4

4 Proper "8 cells found" Start-up Screen. .................................................................................. 4
5 Choose Appropriate Firmware Configuration if Communication is Lost ............................................. 4
6 bqWizard BootStrap Loader to Program S12 Firmware. .............................................................. 6
7 Progress Screen While Programming New Firmware S12 ............................................................ 6
8 Firmware Process Completed Successfully ............................................................................. 7
9 Click the Red X .............................................................................................................. 7
10 Successful Wired Bit Toggled Message ................................................................................. 8
11 Loading Proper TMAP File for Your Pack’s Configuration. ............................................................ 8
12 Home Screen After Loading 11s Configuration .TMAP File ........................................................... 8
13 Pack Parameter and Settings Tabs ...................................................................................... 9
14 Chemistry Selection Window .............................................................................................. 9
15 S12 Home Screen Showing Temperature Fault Condition .......................................................... 10
16 Calibration Screen, Used to Update Temperature Reading to Room Temperature .............................. 11
17 Home Screen Showing Correct Temperature Reading .............................................................. 11
18 Home Screen Showing Fuse Reset and no Safety Flags ............................................................ 12
19 Calibrating 0-mA Offset While Pack is at Rest (no Charging or Discharging) ..................................... 12
20 Read All Parameters to See All Data-Set Settings ................................................................... 13
21 Save Data-Set Menu ...................................................................................................... 13
22 GUI Indication That .PPCSV File Has Been Successfully Saved ................................................... 13
23 Select Read All Parameters Command After Importing a Data-Set .PPCSV File ................................ 15
24 Algorithm Enable Configuration.......................................................................................... 16
25 Enabling Charge and Discharge FETs ................................................................................. 16
26 S12 Home Screen ........................................................................................................ 17
27 Zoom-in on Status Field ................................................................................................. 17
28 Enabling PowerPump™ Cell Balancing ................................................................................ 18
29 Home Screen Showing PowerPump™ Cell Balancing Active ....................................................... 18
30 Default/Blank Log Definition Tool ....................................................................................... 19
31 Available Logging Parameters ........................................................................................... 20
32 Configured Dynamic Log Definition File ............................................................................... 20
33 Data Logging Configuration Window in bqWizard™ Software ...................................................... 21
34 Choosing Poll Data From Commands Menu to Begin Logging ..................................................... 22
35 Entering Comments via bqWizard™ Software ........................................................................ 22
36 Example of Dynamic Log File for an 11s Battery Pack............................................................... 23
37 Cell Balancing Data-Set Tab ............................................................................................. 28
38 Cell Chemistry Data-Set Tab ............................................................................................ 28
39 Pack Configuration Data-Set Tab ....................................................................................... 29
40 Safety Level 1 Data-Set Tab ............................................................................................. 29
41 Safety Level 2 Data-Set Tab ............................................................................................. 29
42 SBData Dynamic Data-Set Tab ......................................................................................... 30
43 SBData Static Data-Set Tab ............................................................................................. 30
44 Pack Dynamic Data-Set Tab ............................................................................................. 30
45 Charge Control Data-Set Tab ............................................................................................ 31
46 Pack History Data-Set Tab ............................................................................................... 31
List of Tables
1 Data-Set Parameters to Review in Your S12 Design ................................................................. 14
2 .PPCSV Data-Set File Export From S12 Firmware ................................................................... 24
3 Bill of Materials............................................................................................................. 33
2 Quick-Start Guide for bq78PL114 With bq76PL102 Family Gas Gauges SLUA556 – April 2010

www.ti.com Getting Started With the bq78PL114 Graphical User Interface
1 Getting Started With the bq78PL114 Graphical User Interface

The USB Interface Adapter box must be connected to your computer before the GUI can open. The
default firmware on the standard EVM and early production product supports up to 8 cells in series (called
8s). The latest release of the bq78PL114 firmware is called S12 and supports up to 12 cells in series. The
interface box used to communicate with the bq78PL114 is called USB-to-GPIO Adapter EVM. Note that it
is not included with the bq78PL114EVM-001 evaluation module and must be purchased separately.
2 Software Communication and Troubleshooting

When trying to connect to the gas gauge chipset, you may see the following screen message (Figure 1)
presented by the GUI software, "Unable to connect to device." Check the connections to the hardware,
and try to reconnect. Additionally, the "LAN is not built!" warning message (Figure 2) appears in the lower
right corner of your screen.
In some cases, everything is fine, and you need to close and open the software again. (LEDs blinking is a
good sign that the part is functional.) If not, check for voltage on VLDO1, V1, and V2 pins. Also, check for
shorts across the battery cell connections. A 10-second initialization period occurs after power up (POR)
during which communication with the device may fail.
Proper communication is indicated by the following screen captures (Figure 3 and Figure 4).
Note that the S8 firmware may be preprogrammed into your EVM or integrated circuit when you receive it.
The S8 firmware has been referred to as FW4452 throughout TI documentation. The S8 firmaware is
programmed at the factory as the default firmware. Follow the process in on updating the firmware to the
S12 version. Because hardware configurations are different for the different firmware versions, review the
bq78PL114 and bq78PL114S12 Technical Reference Manual (SLUU330) for those differences.
Figure 1. Unable to Connect to Chipset Warning.
Figure 2. LAN is not built! Warning.
bqWizard, PowerPump are trademarks of Texas Instruments.

Microsoft, Excel are trademarks of Microsoft Corporation.

Software Communication and Troubleshooting www.ti.com
Figure 3. Proper "Loading" Percentage Start-up Screen
Figure 4. Proper "8 cells found" Start-up Screen.
Figure 5. Choose Appropriate Firmware Configuration if Communication is Lost

www.ti.com Updating the Firmware to S12 Configuration
3 Updating the Firmware to S12 Configuration

To update the device firmware, open the Instruction README text file located at: C:\Program Files\Texas
Instruments\bqWizard 2.5\Documentation\Firmware Update Procedure.txt (This folder C:\Program
Files\Texas Instruments\bqWizard 2.5 folder is the default path created by the installation of the
bqWizard™ software.)
The following excerpts and screen captures are copied beginning with Step 5 to show the process
step-by-step. A detailed firmware update procedure is available on TI's E2E community Web site.
5) To load new firmware

– Go to Bootstrap Loader dialog box: Main menu → Utilities → Bootstrap Loader Main menu →
Commands → Read All Parameters - Turn on "Wired bit": Main Menu → Comma
– Click on Select File button.
– Browse to C:\Program Files\Texas Instruments\bqWizard 2.x\Configuration Files\Firmware.
– Select FW_0001_0000_5000_0012.enc, and click on Open.
– After returning to Bootstrap Loader dialog box, select Preserve Calibration box.
– Click on Download button.
– Save calibration data to a file.
– After download is complete, approximately 50 s, close the Bootstrap Loader dialog box. Control
returns to the bqWizard™ software.
– Read all parameters: Main menu → Commands → Read All Parameters.
– Turn on Wired bit: Main Menu → Commands → Toggle Wired Bit.
6) Configure Target Board
– Configure temperature sensors and cell count: Main Menu → File → Pack Configuration →
Load Configuration from File and Relearn.
– Browse to C:\Program Files\Texas Instruments\bqWizard 2.x\Configuration
Files\bq78PL114S12.
– Select file that corresponds to your specific board configuration.
– After download, the bqWizard™ software restarts and initializes
– Read all parameters: Main menu → Commands → Read All Parameters
– Go to Pack Configuration tab and verify that the parameters Actual Number of Cells and
Temperature Sensor Count match your expectations.
– Note that the temperature sensor count includes the sensor in the bq78PL114 package.

Updating the Firmware to S12 Configuration www.ti.com
Figure 6. bqWizard BootStrap Loader to Program S12 Firmware.
Concerning Figure 6, be sure to choose the Preserve Calibration box as individual IC voltage readings are
calibrated during assembly-test at TI.
Figure 7. Progress Screen While Programming New Firmware S12

www.ti.com Exploring the GUI Software Screens
Figure 8. Firmware Process Completed Successfully
Figure 9. Click the Red X
As Figure 9 shows, close the Bootstrap Loader Window by clicking the red X in the upper right corner of
the window.
Some issues may occur when trying to program the firmware. These errors can manifest themselves with
error messages described via the five onboard LED indicators. The bq78PL114 and bq78PL114S12
Technical Reference Manual (SLUU330) explains the LED indicator messages.
4 Exploring the GUI Software Screens

Once the firmware has been updated, the user can start setting up the gas gauge with the proper
configuration files.
The first step is to set the Wired Bit with the software.
Choose Commands from the File Menu, then choose Toggle Wired Bit or press the F7 key.
Next choose File → Pack Configuration → Load Configuration from File and Relearn…
In this example, a TMAP file is loaded for an 11s configuration. Figure 12 is the Home Screen after
completing this operation.
shows individual screen captures of the different tabs that are selectable in the lower right portion of the
screen (all tabs shown in Figure 13).

Exploring the GUI Software Screens www.ti.com
Figure 10. Successful Wired Bit Toggled Message
Figure 11. Loading Proper TMAP File for Your Pack’s Configuration.
Figure 12. Home Screen After Loading 11s Configuration .TMAP File

www.ti.com Updating the Chemistry File
Figure 13. Pack Parameter and Settings Tabs
5 Updating the Chemistry File

To update the pack's chemistry identification file, choose File → Load Chemistry Data.
Figure 14. Chemistry Selection Window

Configuring the Gas Gauge www.ti.com
6 Configuring the Gas Gauge

Initial communication with the gas gauge shows the external temperature measurements as 90°C which
causes a safety fault condition. Several Safety flags are set in Figure 15. Note this home screen is for S12
version of Firmware.
Figure 15. S12 Home Screen Showing Temperature Fault Condition
To fix this issue, choose Utilities → Calibration. Type the appropriate ambient temperature under the
Calibrate Temperature section. In this example, 23°C ambient temperature has been entered. Voltage
reading for the IC are calibrated during production at TI; so, do not attempt to calibrate the voltage unless
necessary. The Calibrate Screen is shown in Figure 16. A relearn/initialize command overwrites any
manual calibration that a user may have entered in cells 5-12 with the values stored in the bq76PL102s.
Close the calibrate screen, and then choose Read All Parameters or Poll Data. Figure 17 shows the
updated home screen with proper temperature sensing.
Next, choose Commands → Reset Fuse. Figure 18 shows the updated home screen with the Fuse Status
flag set green and no Safety flags set.

www.ti.com Configuring the Gas Gauge
NOTE: Do NOT calibrate Voltage of IC unless necessary; voltage is calibrated during production.
Figure 16. Calibration Screen, Used to Update Temperature Reading to Room Temperature
Figure 17. Home Screen Showing Correct Temperature Reading


Figure 18. Home Screen Showing Fuse Reset and no Safety Flags
If the pack is at rest (not charging or discharging), the reported current is 0 mA. The Zero Offset current
now can be calibrated. [Ensure that the pack is not being charged or discharged while calibrating the Zero
Offset parameter.] Also, ensure that the sense resistor bits are programmed correctly for either (10 mΩ, 3
mΩ, or 1 mΩ) sense resistor. While using 1-mΩ sense resistor, all parameters are reported in tenths (i.e.,
a 1-A charge current is reported as 100 mA.
Click on the Calibrate button from Step 1 Zero Offset (Figure 19). Current Gain is also calibrated.
Next choose File → Read All Parameters from the Commands Menu (or Ctrl + R as the quick key.)
Figure 19. Calibrating 0-mA Offset While Pack is at Rest (no Charging or Discharging)

www.ti.com Configuring the Gas Gauge
Figure 20. Read All Parameters to See All Data-Set Settings
All the Data-Set parameter settings for the gas gauge can be accessed through the .PPCSV file. Save the
default .PPCSV by choosing File → Data-Set (.ppcsv) → Save Data-Set.
Figure 21. Save Data-Set Menu
Figure 22. GUI Indication That .PPCSV File Has Been Successfully Saved
Now, modify the data-set settings in the .PPCSV file as appropriate for your pack, and then choose File →
Load Data-Set (.ppcsv) → Load Data-Set To Device.
Pay special attention to the following Data-Set settings. The following example is configured for 12 series
cells of standard 4.2-V, Li-ion chemistry (using S12 firmware version).
An entry that is "-1" or "0 seconds" indicates that a feature is disabled. (See Table 1)
Pay special attention to the following Data-Set parameters in the .PPCSV file.

Table 1. Data-Set Parameters to Review in Your S12 Design

Design Voltage,mV,44000
Charge Completion Pack Voltage Qualifier,mV,49200
Discharge Completion Pack Voltage Qualifier,mV,39600
<Charge Control>,3,
...
...
...
FC Set SOC Threshold,%,98
FC Clear SOC Threshold,%,97
FD Set SOC Threshold,%,3
FD Clear SOC Threshold,%,4
FD Set Voltage,mV,40000
FD Clear Voltage,mV,40010
FD Set Voltage Time,Seconds,2
...
TDA Set SOC Threshold,%,4
TDA Set Voltage Threshold,mV,40000
TDA Set Voltage Time,Seconds,1
TDA Clear SOC Threshold,%,5
TDA Clear Voltage,mV,40020
TCA Set SOC Threshold,%,100
TCA Clear SOC Threshold,%,99
OCA Set Voltage,mV,51000
<Cell Chemistry>,6,
...
Default Charging Voltage,mV,50400
Default Charging Current,mA,2400
Capacity Algorithm,,0x0003
<Safety Level 1>,8,

...
POV Threshold,mV,51000
POV Recovery,mV,50400
POV Time,Seconds,6
PUV Threshold,mV,33600
PUV Recovery,mV,33700
PUV Time,Seconds,1

www.ti.com Final Setup Steps for Evaluation
After loading the new Data-Set file, be sure to select Read All Parameters from the Commands drop-down
menu.
Figure 23. Select Read All Parameters Command After Importing a Data-Set .PPCSV File
7 Final Setup Steps for Evaluation
7.1 To Initialize Gas Gauge and Turn On Charge and Discharge FETs
1. Choose the Pack Configuration tab in the Data-Set. (Figure 24)
Note: Ensure that the Wired bit is toggled on.
2. Double-click the Algorithm Enable line with the mouse. A secondary window opens. (Figure 25)
3. Uncheck the Inhibit Safety Rules box, and click OK. (Figure 25)
4. Next, from the Commands drop-down menu, choose Write Pending Changes to RAM CTRL+W
(Choosing the Ctrl + W keys is the quick-key sequence to write changes to RAM.)
5. Finally, select Read All Parameters to update the home screen. (Figure 26 and Figure 27)

Final Setup Steps for Evaluation www.ti.com
Figure 24. Algorithm Enable Configuration
Double-click Algorithm Enable parameter to open selection box.
Figure 25. Enabling Charge and Discharge FETs
Uncheck Inhibit Safety Rules to enable Charge and Discharge FETs.

www.ti.com Final Setup Steps for Evaluation
Figure 26. S12 Home Screen
Figure 26 shows the S12 home screen with the properly initialized gauge having the Charge and
Discharge FETs turned on.
Figure 27. Zoom-in on Status Field
Figure 27 is a zoom-in on the Status field. Discharge (D-FET), Charge (C-FET) and Pre-charge (P-FET)
MOSFETs are all on. Also, no FUSE error is indicated.
7.2 To Enable PowerPump™ Cell Balancing Feature:

1. Choose the Pack Configuration tab in the Data-Set. (Figure 24)
Note: Ensure that the Wired bit is toggled on.
2. Double-click the System Control line with the mouse. A secondary window opens. (Figure 28)
3. Un-check the "Pump Disable" box and click OK. (Figure 28)
4. Next choose Commands → Write Pending Changes to RAM Ctrl + W
5. Select Read All Parameters to update the home screen. (Figure 26 and Figure 27)
6. Figure 29 shows cells 3 and 4 actively being balanced because their resting voltage is greater than
Minimum Cell Differential For Balancing (default = 10 mV).

Final Setup Steps for Evaluation www.ti.com
Figure 28. Enabling PowerPump™ Cell Balancing
Uncheck Pump Disable to enable PowerPump™ cell balancing.
Figure 29. Home Screen Showing PowerPump™ Cell Balancing Active
Figure 29 shows that the PowerPump™ Cell Balancing is active. Cells 3 and 4 are actively balanced
because their resting voltage is greater than Minimum Cell Differential For Balancing (default = 10 V).

www.ti.com Setting Up Logging Data
7.3 Initializing the Pack

After completing configuration settings, choose Commands → Relearn / Initialize.
8 Setting Up Logging Data

Now that the pack is properly configured, it is time to set up the log files prior to exercising the pack.
8.1 Setup of Dynamic Data Log Definition File

This is done by choosing Logging → Generate Log Definition File. Scroll between available Logging
Parameters by clicking the left or right arrow next to Available Parameters" heading.
Figure 30 shows the default/blank Log Definition Tool. After you create this file once, it can be reused.
Figure 31 highlights the scroll-through arrows in the Log File Definition Tool.
Click on Generate File after choosing the Data-Set logging parameters. Only 30 parameters can be
continuously monitored during logging. The 31st parameter indicated by the tool is a tick parameter that is
automatically added to each file.
Figure 30. Default/Blank Log Definition Tool

Setting Up Logging Data www.ti.com
Figure 31. Available Logging Parameters
In Figure 31, scroll between available Logging Parameters by clicking the arrows highlighted by the red
box.
Figure 32. Configured Dynamic Log Definition File

www.ti.com Setting Up Logging Data
Click Generate File when complete. Choose up to 31 parameters to log (Figure 32).
8.2 Data Logging Setup

This is done by choosing Logging → Configure…
Under the Dynamic Data Log Definition File section, click on the Select button and choose the .DLOG file
you created in the preceding steps.
Under the Data Logging File section, click on the Select button and choose a filename with which to save
your Data-Set log file.
Finally, choose Commands → Poll Data to begin the data logging process (Figure 34). The bqWizard™
software allows you to add comments to the log file during testing. This can be done by choosing Logging
→ Add Comment.
Figure 33. Data Logging Configuration Window in bqWizard™ Software

Setting Up Logging Data www.ti.com
Figure 34. Choosing Poll Data From Commands Menu to Begin Logging
Figure 35. Entering Comments via bqWizard™ Software
The bqWizard™ software allows the designer to enter comments throughout the log process. To add more
comments, the designer chooses the Logging → Add Comment menu during testing (Figure 35).

www.ti.com Final Comments Concerning Evaluation
Figure 36. Example of Dynamic Log File for an 11s Battery Pack
9 Final Comments Concerning Evaluation

Always be sure to log data during testing. Confirm that the log file content is correct by copying and
pasting the .CSV file, and opening with Microsoft™ Excel™.
Use a standard bench power supply for charging your battery and testing functionality with the simulation
resistor string on PMP5118-RevB. First, set the voltage of the bench supply using a precise digital
multimeter to precisely 4.2 V/cell multiplied by the number of cells (or whatever the appropriate charge
voltage is for your specific cell, 4.1 V, etc.). After you have set the appropriate charge voltage, next
short-circuit the positive and negative leads from the bench power supply and limit the current to an
appropriate level (usually not greater than a 1C rate determined by the packs battery cells). If the current
limit is set high, you may see a spark. After this procedure, you can connect to PACK+ and GND
connections (shown in PMP5118-RevB) and properly charge a Li-ion battery with constant current,
followed by constant voltage profile.
See the application report Chemistry Selection for bq78PL114 (SLUA505) for additional information on
configuring the gas gauge, as well as the data collection process for defining a .AUX for your battery pack.

www.ti.com
Appendix A .PPCSV Data-Set File Export From S12 Firmware
Table 2. .PPCSV Data-Set File Export From S12 Firmware
<SBData Static>,1,
Manufacturer Name,,TEXAS INSTRUMENTS
Device Name,,bq78PL114
Device Chemistry,,LION
Manufacturer Data,,0E4D616E20446174612020202020200000000000000000000000000000000000
Serial Number,,1
Manufacture Date,,14964
Design Voltage,mV,33600
At Rate,mAh/10mWh,0
Battery Mode,,0x6001
Remaining Time Alarm,Minutes,10
Remaining Capacity Alarm,mAh/10mWh,560
<Charge Control>,3,
Pre-Charge Temperature,Kelvin,273
Pre-Charge Voltage,mV,3000
Pre-Charge Recovery,mV,3100
Pre-Charge Current,mA,240
Charge Inhibit Temperature Low,Kelvin,273
Charge Inhibit Temperature High,Kelvin,318
Charge Inhibit Recovery Temperature Low,Kelvin,278
Charge Inhibit Recovery Temperature High,Kelvin,313
Charge Suspend Temperature Low,Kelvin,278
Charge Suspend Recovery Temperature Low,Kelvin,283
Charge Suspend Temperature High,Kelvin,333
Charge Suspend Recovery Temperature High,Kelvin,328
Charge Completion Taper Current Qualifier,mA,240
Charge Completion Time,Seconds RDTE,10
Charge Completion FET Activation Time,Seconds RDTE,10
Discharge Completion Time,Seconds RDTE,4
Discharge Completion FET Activation Time,Seconds RDTE,6
Discharge Under Temperature,Kelvin,263
Discharge Under Temperature Recovery,Kelvin,273
Discharge Under Temperature Time,Seconds RDTE,2
FC Set SOC Threshold,%,-1
FC Clear SOC Threshold,%,-1
FD Set SOC Threshold,%,-1
FD Clear SOC Threshold,%,-1
FD Set Voltage,mV,24800
FD Clear Voltage,mV,25600
FD Set Voltage Time,Seconds,0
Transition to Idle Current,mA,50
Transition to Idle Time,Seconds,30
Transition to Discharge Current,mA,-75
Transition to Charge Current,mA,75
Cell Shutdown Voltage,mV,2500
Design Capacity mAh,mAHrs,2400
Design Capacity 10mWh,10mWh,6912
24 .PPCSV Data-Set File Export From S12 Firmware SLUA556 – April 2010

www.ti.com Appendix A
Table 2. .PPCSV Data-Set File Export From S12 Firmware (continued)

TDA Set SOC Threshold,%,-1
TDA Set Voltage Threshold,mV,25600
TDA Set Voltage Time,Seconds,0
TDA Clear SOC Threshold,%,-1
TDA Clear Voltage,mV,29600
TCA Set SOC Threshold,%,-1
TCA Clear SOC Threshold,%,-1
OCA Set Voltage,mV,34400
OCA Activation Time,Seconds RDTE,2
<Cell Balancing>,5,
Minimum Cell Differential For Balancing,mV,10
<Cell Chemistry>,6,
Chemistry ID,,105
FCC Learn Qualifier,%,30
Cycle Fade,%,0.05
Min OCV Slope,mV/% RSOC,2
OCV Idle Qualifier,Minutes,30
Stale FCC Timeout,Minutes,2880
Default Charging Voltage,mV,33600
Default Charging Current,mA,1680
Capacity Algorithm,,0x0003
User Rate,mA,1000
<Pack Configuration>,7,
Hardware Configuration,,0x0731
Algorithm Enable,,0x800E
System Control,,0x8000
Current Delta,mA,100
EPD Pump Time,Cycle Counts,120
EPD Write Time,Cycle Counts,70
Display Driver Frequency,Hz,30
Product Sub ID,,0
<Safety Level 1>,8,
COV Threshold,mV,4250
COV Recovery,mV,4100
COV High Temperature Threshold,mV,4250
COV High Temperature Adjust,Kelvin,323
COV Time,Seconds,2
CUV Threshold,mV,2700
CUV Recovery,mV,3000
CUV Time,Seconds,1
POV Threshold,mV,34000
POV Recovery,mV,32800
POV Time,Seconds,6
PUV Threshold,mV,22400
PUV Recovery,mV,24000
PUV Time,Seconds,1
OC Charge Tier 1 Threshold,mA,4800
OC Charge Tier 1 Recovery,Seconds,2
OC Charge Tier 1 Time,Seconds,6
OC Discharge Tier 1 Threshold,mA,-7200
OC Discharge Tier 1 Recovery,Seconds,2
OC Discharge Tier 1 Time,Seconds,8
SLUA556 – April 2010 .PPCSV Data-Set File Export From S12 Firmware 25

Appendix A www.ti.com

OC Charge Tier 2 Threshold,mA,5200
OC Charge Tier 2 Recovery,Seconds,8
OC Charge Tier 2 Time,Seconds,2
OC Discharge Tier 2 Threshold,mA,-9600
OC Discharge Tier 2 Recovery,Seconds,8
OC Discharge Tier 2 Time,Seconds,1
OC Max Attempts,,3
Hardware OC Charge Threshold,,211
Hardware OC Charge Recovery,Seconds,1
Hardware OC Charge Time,,60
Hardware OC Discharge Threshold,,98
Hardware OC Discharge Recovery,Seconds,1
Hardware OC Discharge Time,,37
HOC Max Attempts,,3
Hardware Short Circuit Threshold,,47
Hardware Short Circuit Recovery,Seconds,8
Hardware Short Circuit Time,,3
HSC Max Attempts,,3
EUV Threshold,mV,2500
EUV Time,Seconds,2
EUV Recovery,mV,2900
OT Charge Threshold,Kelvin,323
OT Charge Recovery,Kelvin,318
OT Charge Time,Seconds RDTE,2
OT Discharge Threshold,Kelvin,333
OT Discharge Recovery,Kelvin,323
OT Discharge Time,Seconds RDTE,2
Host Watchdog Timeout,Seconds RDTE,0
Board Over Temperature,Kelvin,358
Board Over Temperature Recovery,Kelvin,338
Board Over Temperature Time,Seconds RDTE,2
Hardware LP Discharge Threshold,,32
Hardware LP Discharge Duration,,127
Hardware LP Charge Threshold,,224
Hardware LP Charge Duration,,127
<Safety Level 2>,9,
SOV Threshold,mV,4350
SOV Time,Seconds RDTE,8
Cell Imbalance Current,mA,50
Cell Imbalance Fail Voltage,mV,500
Cell Imbalance Time,Seconds,180
Cell Imbalance SOC Inhibit Threshold,%,30
SOC Charge Threshold,mA,6000
SOC Charge Time,Seconds RDTE,2
SOC Discharge Threshold,mA,-12000
SOC Discharge Time,Seconds RDTE,2
SOT Charge Threshold,Kelvin,343
SOT Charge Time,Seconds RDTE,2
SOT Discharge Threshold,Kelvin,343
SOT Discharge Time,Seconds RDTE,2
Open Temperature Sensor Threshold,Kelvin,233
Open Temperature Sensor Time,Seconds RDTE,2
FET Fail Time,Seconds RDTE,2
26 .PPCSV Data-Set File Export From S12 Firmware SLUA556 – April 2010

www.ti.com Appendix A

Fuse Fail Limit,mA,40
Fuse Fail Time,Seconds RDTE,2
VLAN Fail Time,Seconds RDTE,2
Current Measurement Fail Time,Seconds RDTE,10
Pre-Charge Voltage Timeout,Seconds RDTE,900
Charge Duration Timeout,Seconds RDTE,14400
IGR Limit,,200
IGR Fail Count,,255
IGR Ratio Limit,,120
IGR Ratio Fail Count,,255
Rate Limit Threshold,,200
Rate Limit Activation Count,,100
SLUA556 – April 2010 .PPCSV Data-Set File Export From S12 Firmware 27

www.ti.com
Appendix B Default Data-Set Screen Captures From bqWizard™ GUI for S12 Firmware
Figure 37. Cell Balancing Data-Set Tab
Figure 38. Cell Chemistry Data-Set Tab
28 Default Data-Set Screen Captures From bqWizard™ GUI for S12 Firmware SLUA556 – April 2010

www.ti.com Appendix B
Figure 39. Pack Configuration Data-Set Tab
Figure 40. Safety Level 1 Data-Set Tab
Figure 41. Safety Level 2 Data-Set Tab
SLUA556 – April 2010 Default Data-Set Screen Captures From bqWizard™ GUI for S12 Firmware 29

Appendix B www.ti.com
Figure 42. SBData Dynamic Data-Set Tab
Figure 43. SBData Static Data-Set Tab
Figure 44. Pack Dynamic Data-Set Tab
30 Default Data-Set Screen Captures From bqWizard™ GUI for S12 Firmware SLUA556 – April 2010

www.ti.com Appendix B
Figure 45. Charge Control Data-Set Tab
Figure 46. Pack History Data-Set Tab
SLUA556 – April 2010 Default Data-Set Screen Captures From bqWizard™ GUI for S12 Firmware 31

www.ti.com
Appendix C Reference Design and Reference Design Bill of Materials
C.1 PMP5118-RevB Reference Design Schematic in S12 Hardware Configuration

The reference design schematic is appended to the following pages.
32 Reference Design and Reference Design Bill of Materials SLUA556 – April 2010

+
www.ti.com PMP5118-Rev B Bill of Materials
C.2 PMP5118-Rev B Bill of Materials
Table 3. Bill of Materials

Count RefDes Part Number Value Description Mfr Size
4 U2 BQ76PL102RGTR BQ76PL102RGTR IC, Power-LAN Dual-Cell Li-Ion Batterry Monitor W/ Powerpump TI VQFN
U3 BQ76PL102RGTR BQ76PL102RGTR IC, Power-LAN Dual-Cell Li-Ion Batterry Monitor W/ Powerpump TI VQFN
2 U10 BQ77PL157PW BQ77PL157PW IC, Secondary Voltage Protection for 3-6 Series Li-Ion Cells TI TSSOP-16
U11 BQ77PL157PW BQ77PL157PW IC, Secondary Voltage Protection for 3-6 Series Li-Ion Cells TI TSSOP-16
1 U1 BQ78PL114RGZR BQ78PL114 IC, PowerLAN Master Gateway Battery Management Controller TI VQFN
With PowerPump Cell Balancing Technology
12 C46 Std 0.01 µF Capacitor, Ceramic, 10V, X7R, 10% Std 603
C48 Std 0.01 µF Capacitor, Ceramic, 10V, X7R, 10% Std 603
1 C58 STD 0.1 µF Capacitor, Ceramic, Low Inductance, 6.3V, X7R, 20% STD 603
12 C49 STD 1.0 µF Capacitor, Ceramic, Low Inductance, 10V, X5R, 10% STD 603
C50 STD 1.0 µF Capacitor, Ceramic, Low Inductance, 10V, X5R, 10% STD 603
SLUA556 – April 2010 Reference Design and Reference Design Bill of Materials 33

PMP5118-Rev B Bill of Materials www.ti.com
Table 3. Bill of Materials (continued)

2 C53 STD 1000 pF Capacitor, Ceramic, Low Inductance, 10V, X5R, 10% STD 603
C56 STD 1000 pF Capacitor, Ceramic, Low Inductance, 10V, X5R, 10% STD 603


1 C105 ECJ-ZVF1C104Z 0.047 µF Capacitor, Ceramic, 0 .047-uF, 16-V, Y5V, +80/-20% Panasonic 805
1 C35 100V 0.1 µF Capacitor, Ceramic, 100V, X7R, 10% STD 805
2 C37 C0805C104K1RACTU 0.1 µF Capacitor, Ceramic, 100V, X7R, 10% KEMET 805
C38 C0805C104K1RACTU 0.1 µF Capacitor, Ceramic, 100V, X7R, 10% KEMET 805
1 C43 STD 0.1 µF Capacitor, Ceramic, 6.3V, X5R, 10% STD 805
1 C45 STD 1 µF Capacitor, Ceramic, 6.3V, X5R, 10% STD 805
5 C42 STD 10 µF Capacitor, Ceramic, 10V, X5R, 10% STD 805
C61 STD 10 µF Capacitor, Ceramic, 10V, X5R, 10% STD 805
C2 STD 22 µF Capacitor, Ceramic, 6.3V, X5R, 10% STD 805


1 C47 STD 10000 pF Capacitor, Ceramic, 6.3V, X5R, 10% STD 805
1 C106 ECJ-3YBZA104K 0.1 µF Capacitor, Ceramic, 0.1-uF, 100-V, X7R, +-10% Panasonic 1206
1 C40 B32529C1104J 0.1 µF Capacitor, Leaded, 100V, [temp], [tol] Epcos 0.177 x 0.287 in.
1 C107 ECA-ZAM101 100 µF Capacitor, Panasonic, 100-uF, 100-V, , 20% Panasonic 0.315
1 J14 3267 BATT+ Connector, Banana Jack, Uninsulated Pomona 0.500 dia
1 J15 3267 BATT– Connector, Banana Jack, Uninsulated Pomona 0.500 dia
1 J16 3267 GND Connector, Banana Jack, Uninsulated Pomona 0.500 dia
1 J20 3267 PACK+ Connector, Banana Jack, Uninsulated Pomona 0.500 dia
1 J43 3267 PACK+PROT Connector, Banana Jack, Uninsulated Pomona 0.500 dia
1 J44 3267 PACK-PROT Connector, Banana Jack, Uninsulated Pomona 0.500 dia
2 J54 3267 unconnected Connector, Banana Jack, Uninsulated Pomona 0.500 dia
J55 3267 unconnected Connector, Banana Jack, Uninsulated Pomona 0.500 dia
12 D38 MMBD4148SE MMBD4148SE Diode, Dual Ultra Fast, Series, 200-mA, 100-V Fairchild SOT23
D39 MMBD4148SE MMBD4148SE Diode, Dual Ultra Fast, Series, 200-mA, 100-V Fairchild SOT23
22 D6 MA21D3800L MA21D3800L Diode, Switching, 1A, 30-V Panasonic 0.067 x 0.049 in.
D7 MA21D3800L MA21D3800L Diode, Switching, 1A, 30-V Panasonic 0.067 x 0.049 in.


5 D59 160-1183-1-ND Green Diode, LED, Green, 2.1-V, 20-mA, 6-mcd Liteon 603
D60 160-1183-1-ND Green Diode, LED, Green, 2.1-V, 20-mA, 6-mcd Liteon 603
4 D35 BZT52C12 BZT52C12-7-F Diode, Zener, 12V Diodes Inc. SOD-123
D37 BZT52C12 BZT52C12-7-F Diode, Zener, 12V Diodes Inc. SOD-123
1 D16 5.1V SMAZ5V1 Diode, Zener 100-mA, 5.1-V Diodes Inc SMA
11 D1 5.1V SMAZ5V1 Diode, Zener, 100-mA, 5.1-V Diodes Inc SMA
D2 5.1V SMAZ5V1 Diode, Zener, 100-mA, 5.1-V Diodes Inc SMA


1 D36 IRF 10BQ0100 Diode, Schottky, 1-A, 100-V STD SMB
1 D41 AZ23C5V6 AZ23C5V6 Diode, Dual, Zener, 5.6 V, 300mW Diodes SOT23
1 D57 SMAT70A SMAT70A Diode, 100V transient voltage supressor Diodes Inc. SMA
1 J42 PTC36SAAN Enable Header, 2-pin, 100mil spacing, (36-pin strip) Sullins 0.100 x 2
1 J24 PTC36SAAN Reset (active low) Header, 2-pin, 100mil spacing, (36-pin strip) Sullins 0.100 x 2
12 J2 PTC36SAAN Simulate Header, 2-pin, 100mil spacing, (36-pin strip) Sullins 0.100 x 2
J3 PTC36SAAN Simulate Header, 2-pin, 100mil spacing, (36-pin strip) Sullins 0.100 x 2
2 J18 PTC36SAAN XT2 Header, 2-pin, 100mil spacing, (36-pin strip) Sullins 0.100 x 2
J22 PTC36SAAN XT2 Header, 2-pin, 100mil spacing, (36-pin strip) Sullins 0.100 x 2
2 J52 PTC36SAAN Header, 2-pin, 100mil spacing, (36-pin strip) Sullins 0.100 x 2
J53 PTC36SAAN Header, 2-pin, 100mil spacing, (36-pin strip) Sullins 0.100 x 2
1 J461 PEC03SAAN PEC03SAAN Header, Male 3-pin, 100mil spacing, Sullins 0.100 in. x 3
1 J1 PEC36SAAN PEC36SAAN Header, Male 20-pin, 100mil spacing, (36-pin strip) STD 0.100 in. x 20
6 J45 640454-4 640454-4 Header, Polarized Notched, 4 Pin 100 mil Pitch Tyco 0.400 x 0.225 in.
J47 640454-4 640454-4 Header, Polarized Notched, 4 Pin 100 mil Pitch Tyco 0.400 x 0.225 in.


1 J46 C-5103309-1 C-5103309-1 Connector, 10 pin Shrouded Vertical Tyco 0.388 x 0.400 in.
11 L1 LPS4012-472ML 4.7 µH Inductor, SMT, 1.8A, 175 mΩ Coilcraft 0.153 x 0.153 in.
L2 LPS4012-472ML 4.7 µH Inductor, SMT, 1.8A, 175 mΩ Coilcraft 0.153 x 0.153 in.
L9 LPS4012-472ML 4.7 µH Inductor, SMT, 1.8A, 175 m Coilcraft 0.153 x 0.153 in.
10 R71 Std 1M Resistor, Chip, 1/16W, 5% Std 603
R80 Std 1M Resistor, Chip, 1/16W, 5% Std 603
11 R16 Std 2K Resistor, Chip, 1/16W, 5% Std 603
R17 Std 2K Resistor, Chip, 1/16W, 5% Std 603


2 R96 Std 4.7K Resistor, Chip, 1/16W, 5% Std 603
R98 Std 4.7K Resistor, Chip, 1/16W, 5% Std 603
9 R95 Std 100 Resistor, Chip, 1/16W, 5% Std 603
R97 Std 100 Resistor, Chip, 1/16W, 5% Std 603


1 R152 Std 0Ω Resistor, Chip, 1/16W, 5% Any 603
2 R149 Std 0Ω Resistor, Chip, 1/16W, 5% Any 603
R166 Std 0Ω Resistor, Chip, 1/16W, 5% Any 603
15 R140 Std 1K Resistor, Chip, 1/16W, 5% Any 603
R147 Std 1K Resistor, Chip, 1/16W, 5% Any 603
1 R153 STD 5.1M Resistor, Chip, 1/16W, 5% Std 603
1 R74 Std 100 Resistor, Chip, 1/16W, 5% Any 603
1 R139 Std 6K Resistor, Chip, 6 kΩ, 1/10-W, 1% Std 805
1 R137 Std 10K Resistor, Chip, 10 kΩ, 1/10-W,1% Std 805


1 R142 Std 10 Ω Resistor, Chip, 10-Ω, 1/8-W, 5% Std 1206
1 R141 Std 100K Resistor, Chip, 100 kΩ, 1/8-W, 5% Std 1206
9 R1 STD 2.7 Ω Resistor, 2.7 mΩ, 1W, 5% STD 2512
R2 STD 2.7 Ω Resistor, 2.7 mΩ, 1W, 5% STD 2512
27 R6 STD 2.7 Ω Resistor, 2.7 mΩ, 2W, 5% STD 2512


3 R89 STD 100 Resistor, 100 Ω, 1W, 5% STD 2512
R90 STD 100 Resistor, 100 Ω, 1W, 5% STD 2512
R91 STD 100 Resistor, 100 Ω, 1W, 5% STD 2512
1 R100 ERJ-M1WSF3M0U 0.003R Resistor, Chip, 1W, 1%, 350ppm Panasonic 2512
3 R77 PR2512FKF070R003L (Digikey 0.003R Resistor, Chip, 0.003 Ω, 1W, 1%, 100ppm Yageo 2512
311-0.003AGCT-ND)
R78 PR2512FKF070R003L (Digikey 0.003R Resistor, Chip, 0.003 Ω, 1W, 1%, 100ppm Yageo 2512
311-0.003AGCT-ND)
R79 PR2512FKF070R003L (Digikey 0.003R Resistor, Chip, 0.003 Ω, 1W, 1%, 100ppm Yageo 2512
311-0.003AGCT-ND)
1 R101 ERJ-M1WSF3M0U DNP Resistor, Chip, 1W, 1%, 350ppm Panasonic 2512
6 J17 8196 8196 Terminal, PC Screw #10-32, 30A Keystone 0.470 x 0.470 in.
J19 8196 8196 Terminal, PC Screw #10-32, 30A Keystone 0.470 x 0.470 in.
2 SPK1 Spark Gap {Value} Spark Gap, 0.010 inch space mfg 0.050 x 0.070 in.
SPK2 Spark Gap {Value} Spark Gap, 0.010 inch space mfg 0.050 x 0.070 in.
1 S2 FSM4JSMA FSM4JSMA Switch, Micro Push Button xxV, xxA ITT 0.394 x 0.200 in.
3 TP8 STD STD Test Point, O.032 Hole STD
TP17 STD STD Test Point, O.032 Hole STD
TP22 STD STD Test Point, O.032 Hole STD
2 TP11 5000 5000 Test Point, Red, Thru Hole Color Keyed Keystone 0.100 x 0.100 in.
TP12 5000 5000 Test Point, Red, Thru Hole Color Keyed Keystone 0.100 x 0.100 in.
6 TP1 5001 5001 Test Point, Black, Thru Hole Color Keyed Keystone 0.100 x 0.100 in.
TP2 5001 5001 Test Point, Black, Thru Hole Color Keyed Keystone 0.100 x 0.100 in.


2 TP13 STD STD Test Point, 0.020 Hole STD
TP27 STD STD Test Point, 0.020 Hole STD
1 U9 TPS2490DGS TPS2490DGSR IC, TI DGS10
11 Q1 FDC6327C FDC6327C Transistor, Dual N&P-Channel 2.5V Specified PowerTrench Fairchild SuperSOT-6
Q2 FDC6327C FDC6327C Transistor, Dual N&P-Channel 2.5V Specified PowerTrench Fairchild SuperSOT-6
1 Q30 SUM90N10-8m2P SUM90N10-8m2P Transistor, NFET, 100V, 97A, 8 mΩ Vishay D2PAK
2 Q12 MMBFJ201 MMBFJ201 JFET, NChan -40V, 50mA Fairchild SOT-23
Q21 MMBFJ201 MMBFJ201 JFET, NChan -40V, 50mA Fairchild SOT-23
1 Q20 FDS3682 FDS3682 MOSFET, N-ch, 100-V, 6-A, 35-mΩ Fairchild SO8
3 Q13 BC846ALT1G BC846ALT1G Bipolar, NPN, -65-V, 100-mA, 100-mW Vishay SOT23
Q17 BC846ALT1G BC846ALT1G Bipolar, NPN, -65-V, 100-mA, 100-mW Vishay SOT23
Q19 BC846ALT1G BC846ALT1G Bipolar, NPN, -65-V, 100-mA, 100-mW Vishay SOT23
4 Q14 SUM110P08-11L SUM110P08-11L MOSFET, Pch, -80V, 109 A, 11mΩ (Vgs=-10V), 14.5mΩ Vishay D2PAK
(Vgs=-4.5V)
Q15 SUM110P08-11L SUM110P08-11L MOSFET, Pch, -80V, 109 A, 11mΩ (Vgs=-10V), 14.5mΩ Vishay D2PAK
(Vgs=-4.5V)
(Vgs=-4.5V)
(Vgs=-4.5V)

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Quick Start Guide

SLUA556 – April 2010

Quick-Start Guide for bq78PL114 With bq76PL102 Family

Copyright © 2010, Texas Instruments Incorporated

3 Proper "Loading" Percentage Start-up Screen .......................................................................... 4

Copyright © 2010, Texas Instruments Incorporated

1 Getting Started With the bq78PL114 Graphical User Interface

2 Software Communication and Troubleshooting

Figure 1. Unable to Connect to Chipset Warning.

Figure 2. LAN is not built! Warning.

bqWizard, PowerPump are trademarks of Texas Instruments.

Copyright © 2010, Texas Instruments Incorporated

Figure 3. Proper "Loading" Percentage Start-up Screen

Figure 4. Proper "8 cells found" Start-up Screen.

Figure 5. Choose Appropriate Firmware Configuration if Communication is Lost

Copyright © 2010, Texas Instruments Incorporated

3 Updating the Firmware to S12 Configuration

5) To load new firmware

Copyright © 2010, Texas Instruments Incorporated

Figure 6. bqWizard BootStrap Loader to Program S12 Firmware.

Figure 7. Progress Screen While Programming New Firmware S12

Copyright © 2010, Texas Instruments Incorporated

Figure 8. Firmware Process Completed Successfully

Figure 9. Click the Red X

4 Exploring the GUI Software Screens

Copyright © 2010, Texas Instruments Incorporated

Figure 10. Successful Wired Bit Toggled Message

Copyright © 2010, Texas Instruments Incorporated

Figure 13. Pack Parameter and Settings Tabs

5 Updating the Chemistry File

Figure 14. Chemistry Selection Window

Copyright © 2010, Texas Instruments Incorporated

6 Configuring the Gas Gauge

Figure 15. S12 Home Screen Showing Temperature Fault Condition

Copyright © 2010, Texas Instruments Incorporated

Figure 17. Home Screen Showing Correct Temperature Reading

Copyright © 2010, Texas Instruments Incorporated

Copyright © 2010, Texas Instruments Incorporated

Figure 20. Read All Parameters to See All Data-Set Settings

Figure 21. Save Data-Set Menu

Copyright © 2010, Texas Instruments Incorporated

Table 1. Data-Set Parameters to Review in Your S12 Design

<Safety Level 1>,8,

Copyright © 2010, Texas Instruments Incorporated

7 Final Setup Steps for Evaluation

Copyright © 2010, Texas Instruments Incorporated

Figure 24. Algorithm Enable Configuration

Double-click Algorithm Enable parameter to open selection box.

Figure 25. Enabling Charge and Discharge FETs

Uncheck Inhibit Safety Rules to enable Charge and Discharge FETs.

Copyright © 2010, Texas Instruments Incorporated

Figure 26. S12 Home Screen

Figure 27. Zoom-in on Status Field

7.2 To Enable PowerPump™ Cell Balancing Feature:

Copyright © 2010, Texas Instruments Incorporated

Figure 28. Enabling PowerPump™ Cell Balancing

Uncheck Pump Disable to enable PowerPump™ cell balancing.

Figure 29. Home Screen Showing PowerPump™ Cell Balancing Active

Copyright © 2010, Texas Instruments Incorporated

7.3 Initializing the Pack