Prototype v1.0 Testing Protocol

[Informaticore]

General

• USB-C Delivers 5V when connected
• USB-UART connection established
• auto Flashing ESP32
• enable 3.3V via GPIO
• enable 5V via GPIO
• i2C detect LTC
• i2C detect RTC
• Load test 3.3V
• Load test 5V
• RGB LED test
• Reset button test
• Wake button test (RTC)
• Timed sleep and wakeup (RTC)
• Wake on power on test (RTC)
• [ ]
• ... TBD

LTC4162-L
CAUTION : There is a SOT23-3 pin configuration issue with the 2 Power Path MOSFETs DMN3023L (Q3 & Q15)
1st apply the workaround by replacing the SOT23-3 chip 120° Left.

1. Power Check

• Internal +5V Regulator (INTVcc) Pin 2 -> measured 4.8V
• Internal +2.5V Regulator (VCC2P5) Pin 8 -> measured 2.5V
• +3.3V for I2C IO (DVCC) Pin 15

2. Power Path Check

• IN_FET (pin 6) signal when the board is powered from an external power source with or without a battery. (Expected value : about Vin + 5V)
• BAT_FET (pin 22) signal when the board is powered from a battery ONLY. (Expected value : about Vbat+ + 5V)
• Vout (pin 27 & 28) is about equal to Vin when the board is powered from an external source and about equal to Vbat+ when the board is ONLY powered from the battery.

3. Battery Charging Check
   @ VBat=3.20V or less and @ Iload=0mA.

• When starting the charging process, the charging current is near 500mA or less.
• First, there is a Constant Current charging process (CC mode) and then a Constant Voltage charging process (CV mode) up to about 4.20V or a bit less.
• The battery protection chip doesn't disconnect the battery while the battery charging process.

4. Using more than 1 battery cell

Buck-Boost 3.3V (TPS63060)
3v3_enable pin = 3.3V

1. Buck-Boost transitions

• While battery charging process, there is no load interruption from boost to buck mode (with Lipo 1 cell only)
• While battery discharging process, there is no load interruption from buck to boost mode (with Lipo 1 cell only)

2. Buck Mode : 3.3V<Vbat<12.0V

• @ Iout=0mA (no load) :
• 3.3V Vout = 3.3V : 3.41V mesured on DUPONT connector with a ohmtec 254087 multimeter (TPS63060 Vout=3.41V)
• @ Iout=500mA :
• 3.3V Vout = 3.3V : 3.24V mesured on DUPONT connector with a ohmtec 254087 multimeter (TPS63060 Vout=3.30V)
• @ Iout=1000mA :
• 3.3V Vout = 3.3V : 3.18V mesured on DUPONT connector with a ohmtec 254087 multimeter (TPS63060 Vout=3.30V)
• @ Iout=1500mA :
• 3.3V Vout = 3.3V : 2.65V mesured on DUPONT connector with a ohmtec 254087 multimeter (TPS63060 Vout=2.82V and the board is hot)

3. Boost Mode : 2.8V<Vbat<3.3V

• @ Iout=0mA (no load) :
• 3.3V Vout = 3.3V
• @ Iout=500mA :
• 3.3V Vout = 3.3V

Buck-Boost 5.0V (TPS63060)
5v0_enable pin = 3.3V

1. Buck-Boost transitions

• While battery charging process, there is no load interruption from boost to buck mode (with Lipo 2 cell only)
• While battery discharging process, there is no load interruption from buck to boost mode (with Lipo 2 cell only)

2. Buck Mode : 5.0V<Vbat<12.0V

• @ Iout=0mA (no load) :
• 5.0V Vout = 5.0V
• @ Iout=500mA :
• 5.0V Vout = 5.0V
• @ Iout=1000mA :
• 5.0V Vout = 5.0V

3. Boost Mode : 2.8V<Vbat<5.0V

• @Iout=0mA (no load) :
• 5.0V Vout = 5.0V
• @Iout=500mA :
• 5.0V Vout = 5.0V

Battery Protection IC (AP9101Cxxx-AYTRG1)

• While battery discharging process, the battery is disconnected when the battery voltage reaches 2.800V (Over-Discharge cut-off)
• While battery charging process, the battery is disconnected when the battery voltage reaches 4.275V (Over-Charge cut-off)

[dr-stefan-krank]

• Noticeable coil whining on different loads for 3v3 MCU regulator.
• LED2 for SMBALERT lights up when RTC cuts of power to the ESP. Most likely GPIO32 goes into pulldown at power loss.

[MantaRayDeeJay]

SOT23-3 DMN3023L MOSFETs correction :

[MantaRayDeeJay]

* Noticeable coil whining on different loads for 3v3 MCU regulator.

Ceramic capacitor whinings come from a "not good working" of the LTC4162-L chip due to the SOT23-3 DMN3023L MOSFETs issue

[MantaRayDeeJay]

Ibat Rsense (R20) :
Currently, the resistor used is a 0805 68mohm 0,25W
Buck-Boost chips can sink more than 2A from the battery.
In this case, vsns = 32mV x4 (128mV) @ I=2A -> 0,256W.
There are 2 chips on board, so Power can raise about 0,5W.
I recommand to replace the 0805 0,25W by a 1206 1W resistor as ERJ8BWFR068V.