Population of One Single Battery Charging Channel on PCBedge.rit.edu/edge/P12402/public/PCBpopulation.pdf · Population of One Single Battery Charging Channel on PCB ... Drawn By:

Population of One Single

Battery Charging

Channel on PCB

P12402: Charging Dock and Power Control

Document Name:

Component Population of Charging Dock and Power

Control PCB - Single Battery Channel

Drawn By: Pedro David Simon Herrera

Revised By: Matt Cappello

Approved By: Ryan Legault

PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

1 of 22

Rev

v1.7

Thursday, February 23, 2012

Hole Tolerances: +/- .004" (.1016 mm)

RIT_402_

E5

The figure to the left shows an empty channel on the PCB ready to

be populated. 10gm, 60/40, .032 Inch Dia. Solder was used to solder

all components onto the PCB. There are a total of eight (8) channels,

each charging one (1) LVE battery.

Components used for a single channel are listed in the following

table:

#

1

2

3

4

5

6

7

8

9

10

12

13

14

15

Qty.

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

Item Description

Micro Controller

Switches(Relays)

1W, 1% 0.75 Ω Resistor

½ w, 1% 750 Ω Resistor



½ W, 1% 20kΩ Resistor



0.1 µF Capacitor

10 µF Capacitor

100 µF Capacitor

1N4001 Diode

Battery Regulator

Manufacturer

Texas Instruments

Omron Electronics Inc.

Ohmite

Vishay/Dale

Vishay/Dale

Panasonic – ECG

Vishay/Dale

Vishay/Dale

Stackpole Electronics Inc

AVX Corporation

Panasonic – ECG

Panasonic – ECG

Comchip Technology

Linear Technology

Manufacturer Part #

MSP-ESP430G2

G6L-1P DC12

WHBR75FET

CMF55750R00FHEB

CMF55100R00FHEB

ERD-S2TJ101V

CMF5520K000FHEB

CMF5510K000FHEB

CF12JT30K0

SR215E104MAR

ECA-1CM100

ECA-1CM101

1N4001-G

LT1086CT

Vendor

Digi-Key

Digi-Key

Digi-Key

Digi-Key

Digi-Key

Digi-Key

Digi-Key

Digi-Key

Digi-Key

Digi-Key

Digi-Key

Digi-Key

Digi-Key

Linear Technology

Vendor Part #

296-25832-5-ND

Z1229-ND

WHBR75FECT-ND

CMF750HFCT-ND

CMF100HFCT-ND

P100BATB-ND

CMF20.0KHFCT-ND

CMF10.0KHFCT-ND

CF12JT30K0CT-ND

478-3193-ND

P5134-ND

P5138-ND

641-1310-1-ND

LT1086CT

Note: This is not a BOM. It is merely a list of components used in a single battery charging channel in the charging dock.

16

17

1

1

Test Point Socket

IC Socket 14 Pin

Aries

TE Connectivity

10-0513-10T

1-3990261-3

Mouser

Digi-Key

535-10-0513-10T

A100205-ND

Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

2 of 22

Rev

v1.7



RIT_402_

E5

The figure to the left shows the first component soldered onto the

single channel. This component was the 10kΩ precision resistor.

10gm, 60/40, .032 Inch Dia. solder was used to solder all

components onto the PCB.

There are a total of eight (8) channels, each charging one (1) LVE

battery.

Component(s) used in this step:

#

8

Qty.

1

Item Description


Manufacturer

Vishay/Dale

Manufacturer Part #

CMF5510K000FHEB

Vendor

Digi-Key

Vendor Part #

CMF10.0KHFCT-ND


Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

3 of 22

Rev

v1.7



RIT_402_

E5

The figure to the left shows the next component soldered onto the





battery.


#

7

Qty.

1

Item Description


Manufacturer

Vishay/Dale

Manufacturer Part #

CMF5520K000FHEB

Vendor

Digi-Key

Vendor Part #

CMF20.0KHFCT-ND


Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

4 of 22

Rev

v1.7



RIT_402_

E5


single channel. This component was the .75Ω precision resistor.




battery.


#

3

Qty.

1

Item Description

1W, 1% 0.75 Ω Resistor

Manufacturer

Ohmite

Manufacturer Part #

WHBR75FET

Vendor

Digi-Key

Vendor Part #

WHBR75FECT-ND


Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

5 of 22

Rev

v1.7



RIT_402_

E5


single channel. This component was the 100Ω precision resistor.




battery.


#

5

Qty.

1

Item Description


Manufacturer

Vishay/Dale

Manufacturer Part #

CMF55100R00FHEB

Vendor

Digi-Key

Vendor Part #

CMF100HFCT-ND


Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

6 of 22

Rev

v1.7



RIT_402_

E5


single channel. This component was the 750Ω precision resistor.




battery.


#

4

Qty.

1

Item Description


Manufacturer

Vishay/Dale

Manufacturer Part #

CMF55750R00FHEB

Vendor

Digi-Key

Vendor Part #

CMF750HFCT-ND


Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

7 of 22

Rev

v1.7



RIT_402_

E5






battery.


#

9

Qty.

1

Item Description


Manufacturer

Stackpole Electronics Inc

Manufacturer Part #

CF12JT30K0

Vendor

Digi-Key

Vendor Part #

CF12JT30K0CT-ND


Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

8 of 22

Rev

v1.7



RIT_402_

E5






battery.


#

8

Qty.

1

Item Description


Manufacturer

Vishay/Dale

Manufacturer Part #

CMF5510K000FHEB

Vendor

Digi-Key

Vendor Part #

CMF10.0KHFCT-ND


Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

9 of 22

Rev

v1.7



RIT_402_

E5


single channel. This component was the 100Ω resistor used for the

Red LED. Although the silkscreen of the PCB states that it should be

a 910Ω resistor, it was found during testing that the LED was not

bright enough. The 100Ω resistor was used instead to allow the LED

to be brighter.




battery.


#

6

Qty.

1

Item Description


Manufacturer

Panasonic – ECG

Manufacturer Part #

ERD-S2TJ101V

Vendor

Digi-Key

Vendor Part #

P100BATB-ND


Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

10 of 22

Rev

v1.7



RIT_402_

E5


single channel. This component was the 100Ω resistor used for the

Green LED. Although the silkscreen of the PCB states that it should

be a 820Ω resistor, it was found during testing that the LED was not

bright enough. The 100Ω resistor was used instead to allow the LED

to be brighter.




battery.


#

6

Qty.

1

Item Description


Manufacturer

Panasonic – ECG

Manufacturer Part #

ERD-S2TJ101V

Vendor

Digi-Key

Vendor Part #

P100BATB-ND


Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

11 of 22

Rev

v1.7



RIT_402_

E5


single channel. This component was the diode.




battery.


#

14

Qty.

1

Item Description

1N4001 Diode

Manufacturer

Comchip Technology

Manufacturer Part #

1N4001-G

Vendor

Digi-Key

Vendor Part #

641-1310-1-ND


Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

12 of 22

Rev

v1.7



RIT_402_

E5


single channel. This component was the 100µF Capacitor.




battery.


#

13

Qty.

1

Item Description

100 µF Capacitor

Manufacturer

Panasonic – ECG

Manufacturer Part #

ECA-1CM101

Vendor

Digi-Key

Vendor Part #

P5138-ND


Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

13 of 22

Rev

v1.7



RIT_402_

E5


single channel. This component was the 10µF Capacitor.




battery.


#

12

Qty.

1

Item Description

10 µF Capacitor

Manufacturer

Panasonic – ECG

Manufacturer Part #

ECA-1CM100

Vendor

Digi-Key

Vendor Part #

P5134-ND


Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

14 of 22

Rev

v1.7



RIT_402_

E5


single channel. This component was the test pin sockets. An item

that was overlooked that became critical as testing was done was the

labeling of the test pins. Beginning from the pin closest to the edge

of the board, the pins are:

1. TP1 - Voltage to Battery

2. TP2 - Input Voltage to LT1086

3. TP3 - Output Voltage from LT1086

4. TP4 - Output Voltage from voltage divider to Microcontroller

5. TP5 - Voltage to Relay

TP(1-5) are also referenced on document RIT_402_E10.




battery.


# Qty. Item Description Manufacturer Manufacturer Part # Vendor Vendor Part #


16 1 Test Point Socket Aries 10-0513-10T Mouser 535-10-0513-10T

Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

15 of 22

Rev

v1.7



RIT_402_

E5


single channel. This component was the Relay.




battery.


#

14

Qty.

1

Item Description

Relay Switches

Manufacturer

Omron Electronics Inc

Manufacturer Part #

G6L-1P DC12

Vendor

Digi-Key

Vendor Part #

Z1229-ND


Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

16 of 22

Rev

v1.7



RIT_402_

E5


single channel. This component was the Op-Amp.




battery.


#

14

Qty.

1

Item Description

Op-Amp

Manufacturer

STMicroelectronics

Manufacturer Part #

TS912AIN

Vendor

Digi-Key

Vendor Part #

497-7682-5-ND


Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

17 of 22

Rev

v1.7



RIT_402_

E5


single channel. These components were the 14 Pin DIP sockets and

the msp430 Microcontroller. Although it is not shown in the figure,

the 14 DIP sockets were soldered onto the board and the

Microcontroller was placed on top of it. This was done for easy

removal of the Microcontroller in case it needed to be reprogramed

or if it was broken.




battery.

Component(s) used in this step: #

1

17

Qty.

1

1

Item Description

Micro Controller

IC Socket 14 Pin (THT)

Manufacturer

Texas Instruments

TE Connectivity

Manufacturer Part #

MSP430G2231IN14

1-390261-3

Vendor

Digi-Key

Digi-Key

Vendor Part #

296-25832-5-ND

A100205-ND


Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

18 of 22

Rev

v1.7



RIT_402_

E5


single channel. This component was the LT1086 Regulator




battery.


#

15

Qty.

1

Item Description

Relay Switches

Manufacturer

Linear Technology

Manufacturer Part #

LT1086CT

Vendor

Linear Technology

Vendor Part #

LT1086CT


Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

19 of 22

Rev

v1.7



RIT_402_

E5


single channel. This component was the 0.1 µF Capacitor




battery.


#

10

Qty.

1

Item Description

0.1 µF Capacitor

Manufacturer

AVX Corporation

Manufacturer Part #

SR215E104MAR

Vendor

Linear Technology

Vendor Part #

478-3193-ND


Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

20 of 22

Rev

v1.7



RIT_402_

E5

The figure to the left shows the next component added onto the

single channel. This component was the regulator heat sink. It did

not require solder to be applied to it, just needed to be screwed on.




battery.


#

10

Qty.

1

Item Description

Capacitor (0.1µF)

Manufacturer

AVX Corporation

Manufacturer Part #

SR215E104MAR

Vendor

Digi-Key

Vendor Part #

478-3193-ND


Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

21 of 22

Rev

v1.7



RIT_402_

E5

The figure to the left shows a 3D rendering of one completely

populated battery charging channel of the charging dock. This

process was done seven (7) times for a total of eight (8) channels.

The connections to the batteries and LEDs are explained further in

document RIT_402_E12




battery.

Document Name:






PCB Thickness

.062"(1.57 mm)

PCB Material

FR-4 Epoxy Glass

Number of Layers

2

Size

5" x 7"

Copper Thickness

1 oz/ft^2

Drawing Name

22 of 22

Rev

v1.7



RIT_402_

E5

The figure to the left shows the rest of the circuit which consists of

the power barrel conector for external power, the fuse, and the

regulator used to power the microcontroller. Note that this regulator

is not the same as the regulator(s) used in the battery charging

channels.




battery.


#

18

19

20

21

22

Qty.

1

1

1

2

1

Item Description

Power Barrel Connector

Fuse Holder

Fuse

10µF Capacitor

Regulator

Manufacturer

CUI Inc.

Littelfuse/Wickmann

Littelfuse Inc

Panasonic – ECG

Linear Technology

Manufacturer Part #

PJ-063BH

65600001009

021706.3HXP

ECA-1CM100

LT1086CT-3.6

Vendor

Digi-Key

Digi-Key

Digi-Key

Digi-Key

Linear Technology

Vendor Part #

CP-063BH-ND

WK6245-ND

F2401-ND

P5134-ND

LT1086CT-3.6


22

21

21

19

20

18

Documents

Population of One Single Battery Charging Channel on PCBedge.rit.edu/edge/P12402/public/PCBpopulation.pdf · Population of One Single Battery Charging Channel on PCB ... Drawn By: