State-of-the-Art Battery Charger

Team: May03-05 Client: Senior Design Faculty advisors: Patterson and Lamont Team members: Richard Musumhi, Pascal Openshaw, Bo Bo Oo, Chris Privitere 17 November 2002

Table of Contents
1. INTRODUCTORY MATERIAL ................................................................................................................ 1 1.1. 1.2. 2. ABSTRACT .......................................................................................................................................... 1 DEFINITION OF TERMS ......................................................................................................................... 1 PROJECT DESIGN ................................................................................................................................. 2 2.1. INTRODUCTION ................................................................................................................................... 2 2.1.1. General Background.................................................................................................................. 2 2.1.2. Technical Problem..................................................................................................................... 2 2.1.3. Operating Environment.............................................................................................................. 2 2.1.4. Intended Users and Uses .......................................................................................................... 2 2.1.5. Assumptions and Limitations ..................................................................................................... 3 2.2. DESIGN REQUIREMENTS ...................................................................................................................... 3 2.2.1. Design objectives ...................................................................................................................... 3 2.2.2. Functional requirements ............................................................................................................ 3 2.2.3. Design constraints ..................................................................................................................... 4 2.2.4. Measurable milestones.............................................................................................................. 5 2.3. END-PRODUCT DESCRIPTION .............................................................................................................. 5 2.4. APPROACH AND DESIGN ...................................................................................................................... 6 2.4.1. Technical approaches ............................................................................................................... 6 2.4.2. Technical design........................................................................................................................ 6 2.4.3. Testing description .................................................................................................................... 7 2.4.4. Risks and risk management ...................................................................................................... 8 2.5. FINANCIAL BUDGET FALL 2002 TO SPRING 2003 ................................................................................ 8 2.6. PERSONAL EFFORT BUDGET................................................................................................................ 9 2.7. PROJECT SCHEDULE ........................................................................................................................... 9 3. CLOSING MATERIAL............................................................................................................................. 9 3.1. PROJECT TEAM INFORMATION.............................................................................................................. 9 3.2. SUMMARY ........................................................................................................................................ 10 3.3. REFERENCES ................................................................................................................................... 10 3.3.1. Web......................................................................................................................................... 10 3.3.2. Books Insert battery book information here ............................................................................. 11 3.3.3. People ..................................................................................................................................... 11

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List of Tables and Figures

FIGURE 1: TWO SAMPLE BATTERY CHARGERS FROM RADIO SHACK AND ENERGIZER. ............................................. 4 FIGURE 2: SAMPLE POWER ADAPTER FOR 13.5 V CAMCORDER BATTERIES ............................................................ 4 FIGURE 3: SIMPLIFIED SCHEMATIC OF THE BATTERY CHARGER .............................................................................. 7 TABLE 1: FINANCIAL BUDGET ............................................................................................................................. 9

Appendices
Appendix A: Schematic and description of design Appendix B: Gantt chart for project schedule Appendix C: Battery specifications Appendix D: Data sheet summaries for components

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Introductory Material
1.1. Abstract
Many of today's new electronic devices require rechargeable batteries to function. To be practical, a battery charger should support 120V AC, 220V AC, 50-60 Hz or 12V DC car inputs and be portable. Companies have produced battery chargers that do one or two settings, but very few have all three voltages and current frequencies. Therefore, the team decided to research the current knowledge concerning rechargeable batteries and design a battery charger based on quality and usability principles that would be able to charge using any of the three voltages. The final product should be so efficient that the team could start a business and begin selling the battery chargers. When a large company offers enough money, the business would be sold and the team could start work on another project.

1.2. Definition of Terms

Battery charger Unless specified otherwise, refers to the battery charger being designed and developed by the May03-05 senior design team. Charge Reverse the reactions on a battery in order to replenish the power that was lost upon discharging the battery. NiCad and NiMH batteries can typically be slow charged within 9 hours. Conditioning Discharging a battery prior to charging. Commonly done in battery chargers to repair the effects of voltage depression or avoid overcharging in a time based charger. DAC Digital to analog converter. Fast charge Method of charging NiCad or NiMH batteries within 1-2 hours. LED Light-emitting diode. Memory Commonly refers to voltage depression, where a battery is slightly overcharged and crystals form inside the battery. These crystals result in a lower output voltage which may no longer be sufficient for proper operation in some devices. Voltage depression can be corrected by conditioning. PIC Peripheral interface controller from Microchip. Quick charge Method of charging NiCad or NiMH batteries within 4-5 hours. Smart A term generally referring to a device that is controlled by a microcontroller that makes decisions based on inputs or feedback from outputs. Commonly contains a state machine. P Microprocessor, a controller that is capable of receiving inputs and producing outputs based on its internal logic. Different from a generic processor in that it takes less space, power, and money to use.
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2. Project Design
2.1. Introduction
2.1.1. General Background The battery charger shall be small and portable, and be able to utilize American 120V/60Hz or European 220V/50Hz voltages as well as vehicle cigarette 12V/DC lighter plugs. It shall fast charge one to four AA/AAA NiCad or NiMH batteries in 1-2 hours. 2.1.2. Technical Problem The charger will have one 12V input plug in, with separate adapters for the cars cigarette lighter plug (12V) and the wall outlet plugs (120 or 220 V AC @ 50-60 Hz). The 12V input will then be converted to 12V and 5V for use in the charger. Voltage and temperature sensors on each battery will determine how close each of them is to being fully charged. This data will be fed back to the PIC uP, which will then send signals to regulate the voltage and current on each of the batteries. It will also control LED lights indicating charge, trickle charge, and finished charging on each battery independently. Single batteries could be plugged in at any time and in any state of charge and the battery charger would know when to stop charging them on independent circuits. Even if a battery is completely full before beginning the charge, the battery charger will be able to determine that and terminate the charge accordingly. The charge is terminated by setting a switch, and subsequently if a lower charge is detected the PIC does a trickle charge to fully charge the battery. A crystal will provide the clock for the PIC in order to provide safety timing. 2.1.3. Operating Environment The charger shall be used indoors or in a vehicle. Indoors the charger can plug into a wall outlet that is either 120 or 220 V AC at 50-60 Hz. In the vehicle, the charger requires a 12 V cigarette lighter plug. A plug adapter will be required to plug the charger into a foreign 220V AC source. Due to the temperature limits of the batteries and the environmental limits of the housing and electrical components, the charger is not meant for extreme heat, extreme cold, or wet conditions. 2.1.4. Intended Users and Uses The battery charger is designed for the frequent picture taker or other user of electronic equipment. Batteries frequently run out of power, and the person may be in a different country, driving, or just taking pictures at home. The charger will charge the batteries back as rapidly as possible without doing any damage to them.

2.1.5. Assumptions and Limitations Assumptions The power sources for 120V, 220V, and 12V are the most common voltages that the charger will need to run on. The user provides a separate adapter for other non-standard power sources. The charger will not charge more than four AA or AAA NiCad or NiMH batteries at a time. The limited number and type of battery was chosen in order to make the device less expensive and more portable. The charger is not meant for extreme cold or wet outdoor conditions. Limitations The budget for battery charger equipment is not to exceed $100. Inexpensive, off-the-shelf rechargeable batteries do not have smart capabilities to aid the charger, and the charger must be able to charge them regardless. The charger must work within the constraints of a cars DC power supply.

2.2. Design requirements

2.2.1. Design objectives External Transformer The transformer will convert the main wall or vehicle power to the 12V input that the charger needs. Internal transformer The internal transformer will change the input voltage from 12V to the smaller voltages that the digital logic will need. Battery Monitor There shall be logic to monitor the batteries' voltage and temperature. This information will go directly to the microprocessor. Current control The microprocessor will accurately set and adjust the current going into each battery based on the battery monitor information. Charging Characteristics The software controlling the microprocessor will have reliable information on the batteries and their charging characteristics.

2.2.2. Functional requirements Charging The charger shall be able to fast charge up to 4 batteries in 1 hour.

Maintaining Charge The charger shall keep the batteries in a state of full capacity for a long period of time without damaging the batteries. Multiple Voltage Sources The charger shall include adapters to power itself from 120V/60Hz, 220V/50Hz, or 12V DC sources.

Figure 1: Two sample battery chargers from Radio Shack and Energizer.

2.2.3. Design constraints Size The charger should not exceed 4x5x6 inches. Weight The charger shall not weigh more than half a pound. Power adapter The charger power adapters shall have at least 3 feet of cord and a transformer housing no bigger than 2x2x1 inches. See figure 2 below for acceptable adapter sizes.

Figure 2: Sample power adapter for 13.5 V 4

Heat The charger shall not consume so much power that it generates heat in excess of the temperature limits on the components.

2.2.4. Measurable milestones All components purchased Achieved when there is enough equipment to successfully build the charger. The criteria will be the amount of money spent and the ability to make the charger afterwards. 95% of the equipment must be functional to pass this milestone. Power transformation Using any components available, the power should be turned into something useful to the charging component and the microprocessor. Successful completion is measured through voltage and current reliability. +/- 5% accurate voltage output is required for the transformer to be considered usable. Charging implemented Measured by the ability of the initial prototype to charge NiCad and NiMH batteries successfully in less than 2 hours. Microprocessor coding Evaluated on correct operation, error-free code, and optimizations for battery characteristics. The microprocessor must make the correct decisions for charging 95% of the time for the initial prototype. Housing The basic housing should be able to hold all components other than the power adapters and still have everything function correctly. Testing Testing is successful when the final prototype works correctly in all appropriate situations. Final Report The final report at the end of the year is going to be evaluated by the impression of the course coordinator and the criteria that he/she will use. An A is considered the passing requirement; otherwise the report still needs work. Industrial Review Presentation The industrial review presentation is evaluated on many criteria and overall by the judges' total scores. A 70% satisfaction is the standard for having accomplished the milestone.

2.3. End-Product Description

The Super-State-of-the-Art battery charger shall be capable of charging up to four 1.2 V NiCad or NiMH batteries using either a car adapter or wall outlet. The
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batteries will not need to be fully discharged, and will be able to be inserted or removed in any order. For those who travel frequently, it will be able to handle 120 V/60 Hz, 220 V/50 Hz, and 12 V DC power inputs. The charger will be small enough to fit in a travel pouch.

2.4. Approach and Design

2.4.1. Technical approaches Plan A Use the MAX713 chipset to control the battery charging process. The batteries would be attached in series, with the voltage not to go below 2.4V to retain accuracy. A 5 Amp switching regulator, using the MAX724, would deliver the power to the batteries in an efficient manner. The 7555 generalpurpose timer would serve as a frequency generator to work out time delays on the charging and enable the LED lights to blink based on charging state. Since the MAX713 does not support less than two batteries at a time, an opamp would be needed in order to bring the voltage higher than the minimum of 2.4V for the Maxim IC chip. Plan B Use the DS2770 as a 3-cell NiMH charger that is temperature-controlled. When the change in temperature would be high enough, it would terminate the charge. Built-in safeguards would also terminate the charge after a certain amount of time or a maximum temperature. Status registers would be set in order to control the temperatures and time values to control the chip. Since the chip does not support doing only one battery at a time, an op-amp would have to be placed on each battery or pair of batteries to set the voltage within the limits of the DS2770. Plan C Use a PIC microprocessor along with voltage and temperature sensors in order to decide the current through the batteries. A DS2438 chip on each battery would detect the voltage and temperature and feed this information back to the microprocessor. Each DS2438 has its own ID number, so they could all use the same wire and be addressable by the PIC. The MAX500 quad DAC would take signals from the PIC and control the voltage on each battery through each of its four analog outputs. The voltage would drive a current through each battery, and the relay switch would cut off the current when the battery was done charging. The voltage sensor would remain in place to detect three events: Battery removal, voltage drop from selfdischarge, or battery insertion.

2.4.2. Technical design Plan C was chosen because it provides the most flexibility and options to the team for designing the battery charger. One of the problems with plan A is that the MAX713 has fewer options for setting the voltage drop that terminates the charging. It also does not have input control, for example settings based on whether the batteries are NiMH or NiCad. The same goes for the DS2770, which also has the disadvantage of being more expensive since it is meant to do Lith-Ion cells as well.
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The simplified circuit diagram for the finished charger is shown in figure 3.

Figure 3: Simplified schematic of the battery charger

A more complete diagram of the battery charger can be found in appendix A. 2.4.3. Testing description Power testing Once the power components are completed, the following must be tested: The 12, 120, and 220V adapters should be able to sustain the load of all four batteries being fast charged. The microprocessor should accurately detect the voltages within 10 mV and set the currents to within 5 mA. The microprocessor should detect four events on each battery line: i. Removal of the battery, which should cause the circuit to be reset. ii. Insertion of the battery, causing the charger to detect the battery characteristics and start charging the battery. iii. Full charge of the battery through temperature difference, when it cuts off the charging.
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iv.

Full charge of the battery through voltage difference, which should cut off the voltage as well.

Usability testing The charger should never overcharge the battery to within 95%, requiring at least 20 batteries to be charged during testing but no more than 100. The charger should be able to finish recharging 2 batteries with 1.5 hours and 4 batteries within 2 hours. Fully discharged 1850 mAh NiMH batteries will be used to verify how long the charger takes. The charger should be able to sustain 10-hour continuous usage on all four batteries without overheating. This will be tested through the use of temperature sensors and switching out discharged batteries as soon as each battery is done charging. End product testing The usability testing is the only part that needs to be repeated for the endproduct testing. 2.4.4. Risks and risk management There are very real risks to the project, but they can be managed. The loss of a critical person on the team is a substantial risk. By documenting research and design materials on paper and/or computer, it would be easier to continue the work of a team member who left. Two people will also be working on each task at a time in buddy pairs. The risk of none of the technical approaches being successful can also be mitigated. Other alternative approaches have been documented in the logbook of each team member, as well as commercial replacements for some of the parts. The team might determine late in the project that a given microprocessor is not useful for the project. This can be avoided by researching the microprocessor well in advance to make sure it does satisfy all the project requirements. Having a backup microprocessor available just in case could help, preferably one that uses similar assembly language. Delays in product shipments for items ordered could delay the delivery and testing of the battery charger. To mitigate this risk, materials and equipment will be ordered much in advance of when they are needed.

2.5. Financial budget Fall 2002 to Spring 2003

The total budget for the project is $100, not including expenses related to the project poster, printing, and other internal development costs. Table 1 shows a breakdown of the budget by item. Revised estimates inlcude some more digital components that were added to the design, and the final housing was removed due to that not being a required part of the project.

Table 1: Financial budget

Item Student labor Microprocessors 12 V car adapter 120/220V adapter to 12V Wires, resistors, capacitors 4 NiCd batteries 4 NiMH batteries Final housing Digital ICs Total Cost

Estimated cost $0.00 $5.00 $8.00 $15.00 $15.00 $12.00 $12.00 $30.00 N/A $97.00

Revised Estimates Actual Cost $0.00 $6.00 $8.00 $15.00 $15.00 $12.00 $12.00 N/A $21.00 $89.00

2.6.

Personal Effort Budget

It is anticipated that the computer engineering students will spend more time working with the battery charger due to the requirements of programming the microprocessor. Appendix B shows a work breakdown by task and individual with the timeline going across the top.

2.7. Project Schedule

The two longest tasks are writing the microprocessor control code and testing the charger before the PCB is built. The breakdown by task is shown in figure 4.

3. Closing Material 3.1. Project Team Information

Team Members Musumhi, Richard 49 Schilletter Vlg Apt A Ames, IA 50010 (515) 572-4127 rmusumhi@iastate.edu EE Openshaw, Pascal 5529 Friley Nilesfoster Ames, IA 50012 (515) 572-5501 pascalo@iastate.edu Cpr E Oo, Bo Bo 301 South 5th Street #310 Ames, IA 50010 (515) 233 1715 bobooo@iastate.edu EE
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Privitere, Chris 3311 Birch Stevenson Ames, IA 50013 (515) 572-3591 sabin100@iastate.edu Cpr E Faculty advisors Patterson, Ralph 326 Town Engr Ames, IA 50011-3230 (515) 294 2428 repiii@iastate.edu ECpE Lamont, John 324 Town Engr Ames, IA 50011-3230 (515) 294 3600 jwlamont@iastate.edu ECpE Client E E Senior Design 2215 Coover Hall Iowa State University Ames, IA 50010 (515) 294 2663 ece@ee.iastate.edu Electrical and Computer Engineering Department

3.2. Summary
Battery chargers are an important tool for high-end electronic equipment. There are many chargers on the market, however each of them lacks some features that are useful. By utilizing all the research available on rechargeable batteries and chargers, the group can produce a battery charger that is more convenient, efficient, and long lasting than the ones currently on the market.

3.3. References
3.3.1. Web 3.3.1.1. Charging NiCad and NiMH batteries http://www.rcbatteryclinic.com/seminar.htm http://www.repairfaq.org/ELE/F_NiCd_Battery.html 3.3.1.2. Maxim Part Descriptions and Data Sheets http://www.maxim-ic.com

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3.3.2. Books 3.3.2.1. Handbook of Batteries, third edition. David Linden and Thomas B. Reddy, McGraw-Hill, New York 2002. 3.3.3. People 3.3.3.1. John Oeler, john.oeler@dalsemi.com, (888) 629-4642 followed by asking for Dallas technical support or directly with (972) 371-4448.

3.4. Appendices
Appendix A: Schematic and description of design Appendix B: Gantt chart for project schedule Appendix C: Battery specifications Appendix D: Data sheet summaries for components

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Appendix A
The overall design of the battery charger involves the Microchip PIC controller sending signals to the various chips and receiving inputs from the sensors. Based on this input, the software decided what it should do and sends the binary information out to the DAC or relay switches. See appendix A for details on the components being used.

U1 2 3 4 5 6 7 21 22 23 24 25 26 27 28 9 1 20
C

RC0/T1OSO/T1CKI RA0/AN0 RC1/T1OSI/CCP2 RA1/AN1 RC2/CCP1 RA2/AN2/VREFRC3/SCK/SCL RA3/AN3/VREF+ RC4/SDI/SDA RA4/T0CKI RC5/SDO RA5/SS/AN4 RC6/TX/CK RB0/INT RC7/RX/DT RB1 RB2 OSC2/CLKOUT RB3/PGM RB4 RB5 RB6/PGC RB7/PGD PIC16F872 OSC1/CLKIN MCLR/VPP/THV VDD

11 12 13 14 15 16 17 18 10

OSCILLATOR CRYSTAL CURRENT SENSOR

DAC

CURRENT SENSOR

BATTERY CELL PIC16F873 10uF CAPACITOR U11 240 6 RESISTOR LM741 7 1 U13 240 6 RESISTOR LM741 10k VOLTAGE SENSOR

BATTERY CELL U17 240 6 RESISTOR LM741 10uF CAPACITOR

C

7 1

U14 240 6 RESISTOR

3 + 2 4 5 13.2k

3 + 2 13.2k 4 5

3 + 2 13.2k 4 5

3 + 2 13.2k 4 5

LM741

7 1

10k RESISTOR
B

VOLTAGE SENSOR

10k RESISTOR

10k RESISTOR VOLTAGE SENSOR U12 240 6 RESISTOR 13.8k 7 1 3 + 2 4 5

RESISTOR

RESISTOR VOLTAGE SENSOR

B

7 1

3 + 2 4 5 13.8k

240 6 RESISTOR

3 + 2 4 5

240 6 RESISTOR 13.8k

7 1

U15

7 1

U16

7 1

U20 240 6 RESISTOR

3 + 2 4 5

LM741

LM741

13.8k

LM741

LM741

10k RESISTOR
A

R17 CURRENT SENSOR

RESISTOR 10k CURRENT SENSOR

10k RESISTOR

10k

RESISTOR
A

Title

PIC BATTERY CHARGER -APPEN

BATTERY CELL
5 4

10uF CAPACITOR
3

BATTERY CELL

Size Document Number A 10uF CAPACITOR Date: Sunday, November 17, 2002
2

Rev <RevCode Sheet 1

1

of

Appendix B Gantt chart and work breakdown

ProjectPlan ID 1 Details -4 8 Resource Name Work Pascal Openshaw 128 hrs Work 7h Write Project Plan 8 hrs Work 7h Revise Plan 7 hrs Work Research Needed Components 5 hrs Work Write Purchasing Proposals 1 hr Work Layout Poster 4 hrs Work Error Check Poster 2 hrs Work Have Poster Printed 1 hr Work Write Design Report 3 hrs Work Review/Make Suggestions 3 hrs Work Revise Design Report 3 hrs Work Put together presentation2 hrs Work Practice/Rehearse Presentation 2 hrs Work Work Demonstrate power supply1 to hr rest of group Get Microprocessor and transformers 7 hrs Work to work together Test 2 hrs Work Learn how to code/use processor 4 hrs Work Work Learn how to interact with8 other hrs components Learn development tools 3 hrs Work Write code 10 hrs Work Debug Code 6 hrs Work Demonstrate Code with components 1 hr Work Research Housings 2 hrs Work Order Housing 1 hr Work Put Charger into Housing5 hrs Work Test Charger in Housing 2 hrs Work Safety Testing 5 hrs Work Usuability Testing 5 hrs Work Write Final Report 7 hrs Work Review/Make Suggestions 2 hrs Work Revise Final Report 5 hrs Work Learn how to make PCB 4 hrs Work Test PCB 2 hrs Work Put together Presentation3 hrs Work Practice/Rehearse Presentation 2 hrs Work Chris Privitere 121 hrs Work Review/Make Suggestions 3 hrs Work Revise Plan 7 hrs Work Research Needed Components 5 hrs Work Write Purchasing Proposals 1 hr Work Layout Poster 4 hrs Work Error Check Poster 2 hrs Work Write Design Report 3 hrs Work Review/Make Suggestions 3 hrs Work Revise Design Report 3 hrs Work Put together presentation2 hrs Work 19 1h 1h 13h 7h 3h 30 22h 41 11h 52 12h 63 17h 74 4h 85 9h 96 19h 107 10h 118

2h 1h 4h 2h 1h 3h 1h 2h 2h 2h 7h 2h 4h 4h 4h 3h 4h

3h

1h

6h 5h

1h 1h 2h 1h 4h

1h 2h 5h 3h 7h 1h

2h 1h 5h

4h 2h 2h 10h

2h 2h

14h 1h 7h 3h

21h

11h

12h

17h

4h

8h

19h

2h 1h 4h 2h 3h 1h 2h 2h

3h

Page 1

ProjectPlan ID Details -4 8 Resource Name Work Practice/Rehearse Presentation 2 hrs Work Work Demonstrate power supply1 to hr rest of group Get Microprocessor and transformers 7 hrs Work to work together Test 2 hrs Work Learn how to code/use processor 4 hrs Work Work Learn how to interact with8 other hrs components Learn development tools 3 hrs Work Write code 10 hrs Work Debug Code 6 hrs Work Demonstrate Code with components 1 hr Work Research Housings 2 hrs Work Put Charger into Housing5 hrs Work Test Charger in Housing 2 hrs Work Safety Testing 5 hrs Work Usuability Testing 5 hrs Work Write Final Report 7 hrs Work Review/Make Suggestions 2 hrs Work Revise Final Report 5 hrs Work Learn how to make PCB 4 hrs Work Test PCB 2 hrs Work Put together Presentation3 hrs Work Practice/Rehearse Presentation 2 hrs Work Richard Musumhi 100 hrs Work Review/Make Suggestions 3 hrs Work Research Needed Components 5 hrs Work Write Purchasing Proposals 1 hr Work Layout Poster 4 hrs Work Error Check Poster 2 hrs Work Write Design Report 3 hrs Work Review/Make Suggestions 3 hrs Work Revise Design Report 3 hrs Work Put together presentation2 hrs Work Practice/Rehearse Presentation 2 hrs Work Learn how to use power supply 7 hrs Work Work Demonstrate power supply1 to hr rest of group Get Microprocessor and transformers 7 hrs Work to work together Test 2 hrs Work Demonstrate Code with components 1 hr Work Research Housings 2 hrs Work Order Housing 1 hr Work Put Charger into Housing5 hrs Work Test Charger in Housing 2 hrs Work Safety Testing 5 hrs Work Usuability Testing 5 hrs Work Write Final Report 7 hrs Work Review/Make Suggestions 2 hrs Work 19 30 1h 7h 2h 4h 4h 4h 3h 4h 41 52 63 2h 74 85 96 107 118

6h 5h

1h 1h 2h 4h 1h 2h 5h 3h 7h 1h

2h 1h 5h

4h 2h 2h 10h

2h 2h

7h 1h 3h

20h 2h 1h 4h 2h 3h

1h

16h

11h

11h

19h

3h 1h 2h 2h 2h

7h 1h 7h 2h 1h 2h 1h 4h

1h 2h 5h 3h 7h 1h

2h 1h

Page 2

ProjectPlan ID Details -4 8 Resource Name Work Revise Final Report 5 hrs Work Learn how to make PCB 4 hrs Work Diagram PCB 4 hrs Work Make PCB 5 hrs Work Test PCB 2 hrs Work Put together Presentation3 hrs Work Practice/Rehearse Presentation 2 hrs Work Bo Bo Oo 99 hrs Work Review/Make Suggestions 3 hrs Work Research Needed Components 5 hrs Work Write Purchasing Proposals 1 hr Work Layout Poster 4 hrs Work Error Check Poster 2 hrs Work Write Design Report 3 hrs Work Review/Make Suggestions 3 hrs Work Revise Design Report 3 hrs Work Put together presentation2 hrs Work Practice/Rehearse Presentation 2 hrs Work Learn how to use power supply 7 hrs Work Work Demonstrate power supply1 to hr rest of group Get Microprocessor and transformers 7 hrs Work to work together Test 2 hrs Work Demonstrate Code with components 1 hr Work Research Housings 2 hrs Work Put Charger into Housing5 hrs Work Test Charger in Housing 2 hrs Work Safety Testing 5 hrs Work Usuability Testing 5 hrs Work Write Final Report 7 hrs Work Review/Make Suggestions 2 hrs Work Revise Final Report 5 hrs Work Learn how to make PCB 4 hrs Work Diagram PCB 4 hrs Work Make PCB 5 hrs Work Test PCB 2 hrs Work Put together Presentation3 hrs Work Practice/Rehearse Presentation 2 hrs Work 19 30 41 52 63 74 4h 4h 3h 85 96 107 5h 118

2h 2h 2h 10h

2h 2h

7h 1h 3h

20h 2h 1h 4h 2h 3h

1h

16h

11h

10h

19h

3h 1h 2h 2h 2h

7h 1h 7h 2h 1h 2h 4h 1h 2h 5h 3h 7h 1h

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Page 3

ID 1 2 3 4 5 6 7 12 13 14 15 8 9 10 11 19 20 21 25 26 27 28 29 30 31 16 17 18 22 23 24 44 45 46 47 48 32 33 34 35 36 37 38 39 40 41 42 43 49 51 50

Task Name Project Plan Write Project Plan Review/Make Suggestions Revise Plan Components Purchased Research Needed Components Write Purchasing Proposals Design Report Write Design Report Review/Make Suggestions Revise Design Report Poster Layout Poster Error Check Poster Have Poster Printed Power Transformation Learn how to use power supply

12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM 12:00 AM 12:00 PM Pascal Openshaw Chris Privitere,Richard Musumhi,Bo Bo Oo Pascal Openshaw,Chris Privitere

Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo Pascal Openshaw,Richard Musumhi,Chris Privitere,Bo Bo Oo

Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo Pascal Openshaw,Richard Musumhi,Chris Privitere,Bo Bo Oo Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo

Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo Pascal Openshaw

Richard Musumhi,Bo Bo Oo Richard Musumhi,Pascal Openshaw,Chris Privitere,Bo Bo Oo

Demonstrate power supply to rest of group Microprocessor Coding Learn how to code/use processor Learn how to interact with other components Learn development tools Write code Debug Code Demonstrate Code with components Oral Presentation of Design Report Put together presentation Practice/Rehearse Presentation Charging Implemented Get Microprocessor and transformers to work together Test Board Layout Learn how to make PCB Diagram PCB Make PCB Test PCB Housing Research Housings Order Housing Put Charger into Housing Test Charger in Housing Final Testing Safety Testing Usuability Testing Final Report Write Final Report Review/Make Suggestions Revise Final Report Industrial Review Presentation Practice/Rehearse Presentation Put together Presentation

Pascal Openshaw,Chris Privitere Pascal Openshaw,Chris Privitere Pascal Openshaw,Chris Privitere Pascal Openshaw,Chris Privitere Pascal Openshaw,Chris Privitere Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo

Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo

Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo

Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo Richard Musumhi,Bo Bo Oo Richard Musumhi,Bo Bo Oo Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo

Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo Pascal Openshaw,Richard Musumhi Richard Musumhi,Pascal Openshaw,Chris Privitere,Bo Bo Oo Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo

Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo

Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo Chris Privitere,Pascal Openshaw,Richard Musumhi,Bo Bo Oo Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo

Pascal Openshaw,Chris Privitere,Richard Musumhi,Bo Bo Oo Pascal Openshaw,Chris Privitere,Richard

Page 1

Appendix C NiCad and NiMH battery specifications

Abstract Nickel Cadmium and Nickel-Metal Hydride Batteries Information from Handbook of Batteries by David Linden and Thomas Reddy, McGraw-Hill, 3rd ed. 2001. The goal of the battery charger being developed by the senior design May03-05 team (http://www.public.iastate.edu/~pascalo/ee491.html) at Iowa State (http://www.iastate.edu) is to charge NiCad and NiMH batteries. After a conversation with an engineer at Dallas Semiconductor (http://www.dalsemi.com), a handbook on different batteries was checked out from the ISU library (http://www.lib.iastate.edu). This document is a summary and description of the important characteristics of NiCad and NiMH batteries as it concerns a battery charging application. Much more information was given in the book about discharge characteristics and cycle life, however those details were not relevant to the team's goals. The Handbook of Batteries has 36 chapters, and the ones covering NiCad and NiMH portable sealed batteries are chapters 28 and 29. Of potential benefit to the electrical car team at ISU are the chapters covering large-scale NiMH batteries or the other battery technologies listed, such as Zinc-based batteries for electric cars. Since the library has the 2nd edition from 1995 as well, that book could be used as a reference. Otherwise our team may decide to help work with them also to develop their battery design. This would only involve purchasing a commercial battery and battery charger since theirs does not need as much custom design work. Their project concerns mainly the eletric car part of it, which is the design aspect for their team. 1. Main characteristics The battery charger will do sealed, portable, cylindrical AA and AAA batteries. Other battery types are button, rectangular, and prismatic NiCad or NiMH. The advantage with the rectangular or prismatic versions are the greater power density by volume that can be obtained by not having to spiral the materials within a cylindrical casing. However, almost all portable electronics can use the AA or AAA sizes, so the decision was made to charge only those. As part of the design report, a sampling of different elecctronic devices from various companies might be taken in order to calculate an exact percentage of devices that use each kind of battery. Within the laptop market, it seems that most batteries are of the lithium or lithium ion kind, although some of them are moving to the high capacity NiMH batteries. (a) Housing The positive electrode, negative electrode, and separator wafers are spiraled within a nickel-plated steel can. The electrodes and separator have pores that are filled with the electrolyte afterwards. The top assembly has a lid, resealable safety vent, a terminal cap,

and a plastic gasket. The steel can itself is the negative terminal, which is separated from the positive one by the gasket. (b)Reactions i. For NiCad batteries, the reaction is Cd + 2NiOOH + 2H2 O ? Cd(OH) 2 ? 2Ni(OH) 2 with a discharge going to the right and a charge moving to the left. During the charging process, the positive wafer reaches full charge before the negative and produces oxygen, which then makes its way to the negative wafer and combines with the Cd as follows: 1 Cd + O 2 + H2 O ? Cd(OH)2 . The separator is permeable to the oxygen so that 2 it can pass through to the negative electrode. Charging must be done carefully to avoid the pressure buildup from too much oxygen. The resealable safety valve is there to regulate pressure in case of an otherwise disastrous case of malfunction, high charge rate, or abuse. ii. For NiMH batteries, the charge reaction is MH + NiOOH ? M + Ni ?OH?2 . As with the NiCad batteries, the positive electrode reaches full charge before the negative and produces oxygen. This oxygen then goes to the negative electrode and transforms the MH into M + H2 O . Care must simply be taken to not let the overcharge carry on for longer than the oxygen recombination can handle. (c) Discharge characteristics NiCad and NiMH batteries are typically discharged only to 1.0 V. When multiple battery cells are connected together, it is possible for the one with the lowest initial capacity to be discharged completely and then suffer a polarity reversal. The positive electrode starts to generate hydrogen gas until the positive electrode is saturated, followed by the negative electrode starting to produce oxygen. Overdischarging leads to deterioration of the cell and the opening of the safety valve to reduce the pressure within the battery. However, since only one battery will be discharged at a time in the team's design, overdischarge to negative polarity should not be an issue. The book examines discharge curves for currents up to 8C for the NiCad batteries and 3C for NiMH batteries. On both of these, the only limiting factor should be the amount of heat generated by the reactions. Since both batteries are rated for operation up to 50 deg C, the discharge speed should not be a major problem or could simply be monitored by the temperature sensor. (d)Battery failure causes Reversible failures can be fixed through reconditioning. Irreversible failures cannot be changed back and will eventually cause the battery to cease functioning. i. Reversible failures: The voltage depression or memory effect happens when batteries are continually discharged only partially followed by recharging. Overcharging occurs when a battery is charged at low current for too long. Both are reversible problems that are easily fixed by a few normal charge and discharge cycles. The second problem is not an issue for NiMH batteries because they should not be overcharged to begin with unless the current is at the top-off rate of 0.02C to 0.05C. NiMH batteries have a greater tendency to overheat because the entire charging reaction is

exothermic. For NiCad batteries, only the fully-charged reactions are exothermic. ii. Irreversible failures: These are caused by essentially two causes: Electrolyte loss and short-circuiting. The electrolyte can be lost through the pressure safety valve when the battery is overcharged, or through the normal seals for example at high temperatures. Short-circuits can form because of high temperatures that damage the internal components of the battery. 2. Charging techniques Both batteries are typically charged through the use of the constant-current method. (a) Overview NiCads can use a 0.1C rate for 12 to 16 hours (140%). Most NiCad batteries can be safely charged then overcharged with the C/100 to C/3 rate. NiMH batteries are more sensitive to overcharge, and therefore should be more carefully monitored and rarely use a fixded-time, higher constant current charge to avoid overdoing an only half-discharged battery. (b)Charging rates and their effects on the battery There are typically three charging settings: slow charge, quick charge, and fast charge, corresponding to 12, 5, and 1 hour(s) respectively. i. Temperature curves ii. Voltage curves iii. Cycle life iv.Charge rates (c) Charge termination There are several ways to terminate the charging process, and some are more accurate than others. The main ways of terminating the charging process are through measurements of time, voltage, or temperature. i. NiCad batteries The preferred method of charge termination for NiCad batteries is negative voltage slope with reference to time. ii. NiMH batteries Charge termination through temperature measurement is actually more accurate than with voltage slope, because the downward slope with NiMH batteries is less noticeable than with NiCads.

Appendix D Summary of data sheets for components used

PIC16F87X
28/40-Pin 8-Bit CMOS FLASH Microcontrollers
Devices Included in this Data Sheet:
PIC16F874 PIC16F877

Pin Diagram
PDIP
MCLR/VPP RA0/AN0 RA1/AN1 RA2/AN2/VREFRA3/AN3/VREF+ RA4/T0CKI RA5/AN4/SS RE0/RD/AN5 RE1/WR/AN6 RE2/CS/AN7 VDD VSS OSC1/CLKIN OSC2/CLKOUT RC0/T1OSO/T1CKI RC1/T1OSI/CCP2 RC2/CCP1 RC3/SCK/SCL RD0/PSP0 RD1/PSP1 1 2 3 4 5 6 40 39 38 37 36 35 RB7/PGD RB6/PGC RB5 RB4 RB3/PGM RB2 RB1 RB0/INT VDD VSS RD7/PSP7 RD6/PSP6 RD5/PSP5 RD4/PSP4 RC7/RX/DT RC6/TX/CK RC5/SDO RC4/SDI/SDA RD3/PSP3 RD2/PSP2

Microcontroller Core Features:

High performance RISC CPU Only 35 single word instructions to learn All single cycle instructions except for program branches which are two cycle Operating speed: DC - 20 MHz clock input DC - 200 ns instruction cycle Up to 8K x 14 words of FLASH Program Memory, Up to 368 x 8 bytes of Data Memory (RAM) Up to 256 x 8 bytes of EEPROM Data Memory Pinout compatible to the PIC16C73B/74B/76/77 Interrupt capability (up to 14 sources) Eight level deep hardware stack Direct, indirect and relative addressing modes Power-on Reset (POR) Power-up Timer (PWRT) and Oscillator Start-up Timer (OST) Watchdog Timer (WDT) with its own on-chip RC oscillator for reliable operation Programmable code protection Power saving SLEEP mode Selectable oscillator options Low power, high speed CMOS FLASH/EEPROM technology Fully static design In-Circuit Serial Programming (ICSP) via two pins Single 5V In-Circuit Serial Programming capability In-Circuit Debugging via two pins Processor read/write access to program memory Wide operating voltage range: 2.0V to 5.5V High Sink/Source Current: 25 mA Commercial, Industrial and Extended temperature ranges Low-power consumption: - < 0.6 mA typical @ 3V, 4 MHz - 20 A typical @ 3V, 32 kHz - < 1 A typical standby current

PIC16F877/874

7 8 9 10 11 12 13 14 15 16 17 18 19 20

34 33 32 31 30 29 28 27 26 25 24 23 22 21

Peripheral Features:
Timer0: 8-bit timer/counter with 8-bit prescaler Timer1: 16-bit timer/counter with prescaler, can be incremented during SLEEP via external crystal/clock Timer2: 8-bit timer/counter with 8-bit period register, prescaler and postscaler Two Capture, Compare, PWM modules - Capture is 16-bit, max. resolution is 12.5 ns - Compare is 16-bit, max. resolution is 200 ns - PWM max. resolution is 10-bit 10-bit multi-channel Analog-to-Digital converter Synchronous Serial Port (SSP) with SPI (Master mode) and I2C (Master/Slave) Universal Synchronous Asynchronous Receiver Transmitter (USART/SCI) with 9-bit address detection Parallel Slave Port (PSP) 8-bits wide, with external RD, WR and CS controls (40/44-pin only) Brown-out detection circuitry for Brown-out Reset (BOR)

PDIP, SOIC
MCLR/VPP RA0/AN0 RA1/AN1 RA2/AN2/VREFRA3/AN3/VREF+ RA4/T0CKI RA5/AN4/SS VSS OSC1/CLKIN OSC2/CLKOUT RC0/T1OSO/T1CKI RC1/T1OSI/CCP2 RC2/CCP1 RC3/SCK/SCL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 28 27 26 25 24 23 22 21 20 19 18 17 16 15 RB7/PGD RB6/PGC RB5 RB4 RB3/PGM RB2 RB1 RB0/INT VDD VSS RC7/RX/DT RC6/TX/CK RC5/SDO RC4/SDI/SDA RA3/AN3/VREF+ RA2/AN2/VREFRA1/AN1 RA0/AN0 MCLR/VPP NC RB7/PGD RB6/PGC RB5 RB4 NC 6 5 4 3 2 1 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 9

PIC16F876/873

PLCC

RC6/TX/CK RC5/SDO RC4/SDI/SDA RD3/PSP3 RD2/PSP2 RD1/PSP1 RD0/PSP0 RC3/SCK/SCL RC2/CCP1 RC1/T1OSI/CCP2 NC

QFP

44 43 42 41 40 39 38 37 36 35 34

NC NC RB4 RB5 RB6/PGC RB7/PGD MCLR/VPP RA0/AN0 RA1/AN1 RA2/AN2/VREFRA3/AN3/VREF+

12 13 14 15 16 17 18 19 20 21 22

RC7/RX/DT RD4/PSP4 RD5/PSP5 RD6/PSP6 RD7/PSP7 VSS VDD RB0/INT RB1 RB2 RB3/PGM

1 2 3 4 5 6 7 8 9 10 11

PIC16F877 PIC16F874

33 32 31 30 29 28 27 26 25 24 23

NC RC0/T1OSO/T1CKI OSC2/CLKOUT OSC1/CLKIN VSS VDD RE2/AN7/CS RE1/AN6/WR RE0/AN5/RD RA5/AN4/SS RA4/T0CKI

RC1/T1OSI/CCP2 RC2/CCP1 RC3/SCK/SCL RD0/PSP0 RD1/PSP1 RD2/PSP2 RD3/PSP3 RC4/SDI/SDA RC5/SDO RC6/TX/CK NC

18 19 20 21 22 23 24 25 26 27 282

RA4/T0CKI RA5/AN4/SS RE0/RD/AN5 RE1/WR/AN6 RE2/CS/AN7 VDD VSS OSC1/CLKIN OSC2/CLKOUT RC0/T1OSO/T1CK1 NC

7 8 9 10 11 12 13 14 15 16 17

PIC16F877 PIC16F874

RB3/PGM RB2 RB1 RB0/INT VDD VSS RD7/PSP7 RD6/PSP6 RD5/PSP5 RD4/PSP4 RC7/RX/DT

Key Features PICmicro Mid-Range Reference Manual (DS33023) Operating Frequency RESETS (and Delays) FLASH Program Memory (14-bit words) Data Memory (bytes) EEPROM Data Memory Interrupts I/O Ports Timers Capture/Compare/PWM Modules Serial Communications Parallel Communications 10-bit Analog-to-Digital Module Instruction Set

PIC16F873 DC - 20 MHz POR, BOR (PWRT, OST) 4K 192 128 13 Ports A,B,C 3 2 MSSP, USART 5 input channels 35 instructions

PIC16F874 DC - 20 MHz POR, BOR (PWRT, OST) 4K 192 128 14 Ports A,B,C,D,E 3 2 MSSP, USART PSP 8 input channels 35 instructions

PIC16F876 DC - 20 MHz POR, BOR (PWRT, OST) 8K 368 256 13 Ports A,B,C 3 2 MSSP, USART 5 input channels 35 instructions

PIC16F877 DC - 20 MHz POR, BOR (PWRT, OST) 8K 368 256 14 Ports A,B,C,D,E 3 2 MSSP, USART PSP 8 input channels 35 instructions

DS2438 Smart Battery Monitor

www.maxim-ic.com

FEATURES

Unique 1-Wire interface requires only one port pin for communication Provides unique 64-bit serial number to battery packs Eliminates thermistors by sensing battery temperature on-chip On-board A/D converter allows monitoring of battery voltage for end-of-charge and endof-discharge determination On-board integrated current accumulator facilitates fuel gauging Elapsed time meter in binary format 40-byte nonvolatile user memory available for storage of battery-specific data Operating range -40C to +85C Applications include portable computers, portable/cellular phones, consumer electronics, and handheld instrumentation

PIN ASSIGNMENT
GND VSENS+ VSENSVAD 1 2 3 4 8 7 6 5 DQ NC NC VDD

DS2438Z, DS2438AZ 8-Pin SOIC (150-mil)

PIN DESCRIPTION
DQ VAD VSENS+ VSENSVDD GND NC Data In/Out General A/D input Battery current monitor input (+) Battery current monitor input (-) Power Supply (2.4V to 10.0V) Ground No connect

DESCRIPTION
The DS2438 Smart Battery Monitor provides several functions that are desirable to carry in a battery pack: a means of tagging a battery pack with a unique serial number, a direct-to-digital temperature sensor which eliminates the need for thermistors in the battery pack, an A/D converter which measures the battery voltage and current, an integrated current accumulator which keeps a running total of all current going into and out of the battery, an elapsed time meter, and 40 bytes of nonvolatile EEPROM memory for storage of important parameters such as battery chemistry, battery capacity, charging methodology and assembly date. Information is sent to/from the DS2438 over a 1-Wire interface, so that only one wire (and ground) needs to be connected from a central microprocessor to a DS2438. This means that battery packs need only have three output connectors: battery power, ground, and the 1-Wire interface. Because each DS2438 contains a unique silicon serial number, multiple DS2438s can exist on the same 1-Wire bus. This allows multiple battery packs to be charged or used in the system simultaneously. Applications for the smart battery monitor include portable computers, portable/cellular telephones, and handheld instrumentation battery packs in which it is critical to monitor real-time battery performance. Used in conjunction with a microcontroller in the host system, the DS2438 provides a complete smart battery pack solution that is fully chemistry-independent. The customization for a particular battery chemistry and capacity is realized in the code programmed into the microcontroller and DS2438 EEPROM, and only a software revision is necessary should a designer wish to change battery pack chemistry.

DETAILED PIN DESCRIPTION

PIN 1 2 3 4 5 6, 7 8 SYMBOL GND VSENS+ VSENSVAD VDD NC DQ DESCRIPTION Ground Battery Input: connection for battery current to be monitored (see text) Battery Input: connection for battery current to be monitored (see text) ADC Input: input for general purpose A/D VDD Pin: input supply voltage No Connect Data Input/Out: for 1-Wire operation: Open drain

OVERVIEW
The block diagram of Figure 1 shows the seven major components of the DS2438: 1. 2. 3. 4. 5. 6. 7. 64-bit lasered ROM temperature sensor battery voltage A/D battery current A/D current accumulators elapsed time meter 40-byte nonvolatile user-memory

Each DS2438 contains a unique 64-bit lasered ROM serial number so that several battery packs can be charged/monitored by the same host system. Furthermore, other Dallas products featuring the same 1-Wire bus architecture with a 64-bit ROM can reside on the same bus; refer to the Dallas Automatic Identification Data book for the specifications of these products. Communication to the DS2438 is via a 1-Wire port. With the 1-Wire port, the memory and control functions will not be available until the ROM function protocol has been established. The master must first provide one of four ROM function commands: 1) Read ROM, 2) Match ROM, 3) Search ROM, or 4) Skip ROM. These commands operate on the 64-bit lasered ROM portion of each device and can singulate a specific device if many are present on the 1-Wire line as well as to indicate to the bus master how many and what types of devices are present. After a ROM function sequence has been successfully executed, the memory and control functions are accessible and the master may then provide any one of the six memory and control function commands. Control function commands may be issued which instruct the DS2438 to perform a temperature measurement or battery voltage A/D conversion. The result of these measurements will be placed in the DS2438s memory map, and may be read by issuing a memory function command which reads the contents of the temperature and voltage registers. Additionally, the charging/discharging battery current is measured without user intervention, and again, the last completed result is stored in DS2438 memory space. The DS2438 uses these current measurements to update three current accumulators; the first stores net charge for fuel gauge calculations, the second accumulates the total charging current over the life of the battery, and the remaining accumulator tallies battery discharge current. The elapsed time meter data, which can be used in calculating battery self-discharge or time-related charge termination limits, also resides in the DS2438 memory map and can be extracted with a memory function command. The nonvolatile user memory of the DS2438 consists of 40 bytes of EEPROM. These locations may be used to store any data the user wishes and are written to using a memory function command. All data and commands are read and written least significant bit first.

19-1016; Rev 2; 2/96

CMOS, Quad, Serial-Interface 8-Bit DAC

_______________General Description
The MAX500 is a quad, 8-bit, voltage-output digital-toanalog converter (DAC) with a cascadable serial interface. The IC includes four output buffer amplifiers and input logic for an easy-to-use, two- or three-wire serial interface. In a system with several MAX500s, only one serial data line is required to load all the DACs by cascading them. The MAX500 contains double-buffered logic and a 10-bit shift register that allows all four DACs to be updated simultaneously using one control signal. There are three reference inputs so the range of two of the DACs can be independently set while the other two DACs track each other. The MAX500 achieves 8-bit performance over the full operating temperature range without external trimming.

____________________________Features
o Buffered Voltage Outputs o Double-Buffered Digital Inputs o Microprocessor and TTL/CMOS Compatible o Requires No External Adjustments o Two- or Three-Wire Cascadable Serial Interface o 16-Pin DIP/SO Package and 20-Pin LCC o Operates from Single or Dual Supplies

MAX500

______________Ordering Information
TEMP. RANGE PIN-PACKAGE ERROR (LSB) PART MAX500ACPE 0C to +70C 16 Plastic DIP 1 MAX500BCPE MAX500ACWE MAX500BCWE MAX500BC/D MAX500AEPE MAX500BEPE MAX500AEWE MAX500BEWE MAX500AEJE MAX500BEJE MAX500AMJE MAX500BMJE MAX500AMLP MAX500BMLP 0C to +70C 0C to +70C 0C to +70C 0C to +70C -40C to +85C -40C to +85C -40C to +85C -40C to +85C -40C to +85C -40C to +85C -55C to +125C -55C to +125C -55C to +125C -55C to +125C 16 Plastic DIP 16 Wide SO 16 Wide SO Dice* 16 Plastic DIP 16 Plastic DIP 16 Wide SO 16 Wide SO 16 CERDIP 16 CERDIP 16 CERDIP 16 CERDIP 20 LCC 20 LCC 2 1 2 2 1 2 1 2 1 2 1 2 1 2

________________________Applications
Minimum Component Count Analog Systems Digital Offset/Gain Adjustment Industrial Process Control Arbitrary Function Generators Automatic Test Equipment

________________Functional Diagram
SRO VREFC AGND DGND VSS VDD LDAC VREFA/B VREFD

VOUTA INPUT REG A DAC REG A DAC A

*Contact factory for dice specifications.

_________________Pin Configurations
VOUTB

TOP VIEW
V OUT B 1 16 V OUT C 15 V OUT D 14 V DD

DATA BUS

10/11BIT SHIFT REGISTER

INPUT REG B

DAC REG B

DAC B

VOUTC INPUT REG C DAC REG C DAC C

V OUT A 2 V SS 3 V REF A/B 4

MAX500

13 V REF C 12 V REF D 11 SRO 10 SCL 9 LOAD

VOUTD INPUT REG D CONTROL LOGIC DAC REG D DAC D

AGND 5 DGND 6 LDAC 7

MAX500

SDA 8

LOAD SDA SCL

DIP/SO

Pin Configurations continued on last page.

________________________________________________________________ Maxim Integrated Products 1

For free samples & the latest literature: http://www.maxim-ic.com, or phone 1-800-998-8800

CMOS, Quad, Serial-Interface, 8-Bit DAC MAX500

A15 A8

ADDRESS BUS A0 82C55 PA0 A1 PA1 CS PA2 WR D7 D0 PA3 . . SCL SDA LDAC LOAD*
MAX500

A15 A0

ADDRESS BUS

8085/ 8088
WR ALE AD7 AD0 EN LATCH

ADDRESS DECODE

6809/ 6502
R/W OR E

ADDRESS DECODE

6821 6521 PA0 C32 PA1 R/W PA2 E DB7 PA3 . . DB0

SCL SDA LDAC LOAD*

MAX500

ADDRESS AND DATA BUS

7 D0

DATA BUS

* CONNECT LOAD TO P1.3 FOR 3-WIRE MODE OR CONNECT LOAD TO VDD FOR 2-WIRE MODE

* CONNECT LOAD TO P1.3 FOR 3-WIRE MODE OR CONNECT LOAD TO VDD FOR 2-WIRE MODE

Figure 15. 8085/8088 with Programmable Peripheral Interface

Figure 16. 6809/6502 Interface

____Pin Configurations (continued)

TOP VIEW
20 V OUT C 19 V OUT D 2 V OUT B 3 V OUT A 1 N.C.

___________________Chip Topography
V OUT B V ss V OUT A V OUT D V DD V OUT C

V SS 4 V REF A/B 5 AGND 6 N.C. 7 N.C. 8

18 V DD 17 V REF C

V REF B V REF A AGND

V REF C V REF D 0.159" (4.039mm) SRO

MAX500

16 V REF D 15 SRO 14 N.C.

LDAC 10

SDA 11

LOAD 12

SCL 13

DGND

DGND

SDA SCL LOAD LDAC 0.150" (3.810mm)

LCC

Maxim cannot assume responsibility for use of any circuitry other than circuitry entirely embodied in a Maxim product. No circuit patent licenses are implied. Maxim reserves the right to change the circuitry and specifications without notice at any time.

12 __________________Maxim Integrated Products, 120 San Gabriel Drive, Sunnyvale, CA 94086 (408) 737-7600 1996 Maxim Integrated Products Printed USA is a registered trademark of Maxim Integrated Products.

LM741 Operational Amplifier

General Description
The LM741 series are general purpose operational amplifiers which feature improved performance over industry standards like the LM709. They are direct, plug-in replacements for the 709C, LM201, MC1439 and 748 in most applications. The amplifiers offer many features which make their application nearly foolproof: overload protection on the input and output, no latch-up when the common mode range is exceeded, as well as freedom from oscillations. The LM741C/LM741E are identical to the LM741/LM741A except that the LM741C/LM741E have their performance guaranteed over a 0C to +70C temperature range, instead of 55C to +125C.

Schematic Diagram

DS009341-1

Offset Nulling Circuit

DS009341-7

Electrical Characteristics (Note 4)

(Continued)

Note 2: For operation at elevated temperatures, these devices must be derated based on thermal resistance, and Tj max. (listed under Absolute Maximum Ratings). Tj = TA + (jA PD).

Thermal Resistance jA (Junction to Ambient) jC (Junction to Case)

Cerdip (J) 100C/W N/A

DIP (N) 100C/W N/A

HO8 (H) 170C/W 25C/W

SO-8 (M) 195C/W N/A

Note 3: For supply voltages less than 15V, the absolute maximum input voltage is equal to the supply voltage. Note 4: Unless otherwise specified, these specifications apply for VS = 15V, 55C TA +125C (LM741/LM741A). For the LM741C/LM741E, these specifications are limited to 0C TA +70C. Note 5: Calculated value from: BW (MHz) = 0.35/Rise Time(s). Note 6: For military specifications see RETS741X for LM741 and RETS741AX for LM741A. Note 7: Human body model, 1.5 k in series with 100 pF.

Connection Diagram
Metal Can Package Ceramic Dual-In-Line Package

DS009341-2

Note 8: LM741H is available per JM38510/10101

DS009341-5

Order Number LM741H, LM741H/883 (Note 8), LM741AH/883 or LM741CH See NS Package Number H08C Dual-In-Line or S.O. Package

Note 9: also available per JM38510/10101 Note 10: also available per JM38510/10102

Order Number LM741J-14/883 (Note 9), LM741AJ-14/883 (Note 10) See NS Package Number J14A Ceramic Flatpak

DS009341-6 DS009341-3

Order Number LM741J, LM741J/883, LM741CM, LM741CN or LM741EN See NS Package Number J08A, M08A or N08E

Order Number LM741W/883 See NS Package Number W10A