ACT2801 Demo Board Application Report Rev 2.0, 05-Aug-2014 Dedicated Power Bank Solution FEATURES 5V/1.5A input current limit 1.0A battery charge current 5V/1.2A boost output current 1.4A boost output constant current limit 5.0V+/- 100mV output voltage Programmable 4.1V to 4.35V battery voltage Single chip integration solution with minimal component count Prioritized power path from input to output 92% charge efficiency and 94.5% efficiency for boost Accommodation for 10mA-2100mA input source Battery disconnected at output short to ground 1.1MHz switching frequencies allowing 2.2µH inductor <10uA battery drain current in HZ mode Boost shuts down at no load and turns on by push button 4 LEDs indicating battery level and charge status with impedance compensation Preconditioning, fast charge, top off and end of charge in battery charge mode Battery temperature monitoring and thermal protection Low battery level alarm 4.6V battery over voltage protection Charge current foldback at 110℃ die temperature IC over temperature protection TQFN4x4-24 package SPECIFICATION Input voltage 4.7 - 5.5V Active-Semi, Inc. Boost output voltage Input current limit Battery charge current Boost output current limit 5.0V 1.5A 1A 1.4A -1- www.active-semi.com ACT2801: Dedicated Power Bank Solution TABLE OF CONTENT 1 DEMO BOARD PHOTOS .................................................................................................................................................. 3 2 SCHEMATIC ....................................................................................................................................................................... 3 3 BILL OF MATERIALS ....................................................................................................................................................... 4 4 PCB LAYOUT ...................................................................................................................................................................... 5 5 FUNCTIONAL TEST .......................................................................................................................................................... 5 5.1 BATTERY CHARGE V/I PROFILE ...................................................................................................................................... 5 5.2 POWER PATH FUNCTION ................................................................................................................................................. 5 5.3 CHARGE EFFICIENCY ...................................................................................................................................................... 6 5.4 BOOST OUTPUT REGULATION (MEASURED AT USB PORT).............................................................................................. 6 5.5 BOOST EFFICIENCY AND POWER LOSS (TA=25℃) .......................................................................................................... 7 5.6 BOOST STANDBY POWER (TA=25℃) .............................................................................................................................. 8 5.7 BOOST CONSTANT CURRENT AND CONSTANT VOLTAGE REGULATION (TA=25℃) ......................................................... 8 5.8 BATTERY LEAKAGE CURRENT IN HZ MODE ................................................................................................................... 9 5.9 RIPPLE AND NOISE .......................................................................................................................................................... 9 5.10 LOAD DYNAMIC RESPONSE LOAD STEP ........................................................................................................................ 10 5.11 LED INDICATION .......................................................................................................................................................... 10 5.12 SYSTEM MANAGEMENT................................................................................................................................................ 11 5.13 KEY COMPONENTS TEMPERATURE TEST (TA=40℃, BURNING FOR 2 HOURS) ............................................................... 11 6 PCB LAYOUT GUIDANCE ............................................................................................................................................. 12 7 EMI TEST .......................................................................................................................................................................... 13 Active-Semi, Inc. www.active-semi.com - - Active-Semi. Confidential-Do Not Copy or Distribute 2 ACT2801: Dedicated Power Bank Solution 1 DEMO BOARD PHOTOS (DEMO BOARD SIZE: 38mm*16.5mm) LED indication Push button Input USB Output USB 2 SCHEMATIC Active-Semi, Inc. www.active-semi.com - - Active-Semi. Confidential-Do Not Copy or Distribute 3 ACT2801: Dedicated Power Bank Solution 3 BILL OF MATERIALS QTY Manufacturer SWPA4020S1R0NT 2.2uH 3.4A (4*4*2mm) 1 Sunlord Q1 SI2333DDS, Rdson=28mÙ at VGS = - 4.5 V 1 Vishay 3 D1 SR22, Vf=0.5V, 20V Schottky 1 Panjit 4 D2 1N4148, Vf=0.7V, 75V Schottky 1 Vishay 5 C2,C5 Ceramic Capacitor, 22uF/10V, X7R, 1206 2 Murata/TDK 6 C3 Ceramic Capacitor, 4.7uF/10V, X7R, 1206 1 Murata/TDK 7 C4 Ceramic Capacitor, 0.1uF/10V, X7R, 0603 1 Murata/TDK 8 C6 Ceramic Capacitor, 10nF/10V, X7R, 0402 1 Murata/TDK 9 C7 Ceramic Capacitor, 4.7nF/10V, X7R, 0603 1 Murata/TDK 10 C8 Ceramic Capacitor, 1uF/10V, X7R, 0603 1 Murata/TDK 11 C9,C10 Ceramic Capacitor, 39pF/10V, X7R, 0603, 2 Murata/TDK 12 C11,C12 Ceramic Capacitor, 2.2uF/10V, X7R, 0603 2 Murata/TDK 13 C13 Ceramic Capacitor, 4.7uF/10V, X7R, 0603 1 Murata/TDK 14 R1 Chip Resistor, 1.2kÙ, 1/16W, 1%, 0402 1 Murata/TDK 15 R2 Chip Resistor, 50mÙ, 1/4W, 1%, 1206 1 Murata/TDK 16 R3 Chip Resistor, 97.6kÙ, 1/16W, 1%, 0402 1 Murata/TDK 17 R4 Chip Resistor, 60.4kÙ, 1/16W, 1%, 0402 1 Murata/TDK 18 R5 Chip Resistor, 25kÙ, 1/16W, 1%, 0402 1 Murata/TDK 19 R6 Chip Resistor, 10kÙ, 1/16W, 1%, 0402 1 Murata/TDK 20 R7 Chip Resistor, 60kÙ, 1/16W, 1%, 0402 1 Murata/TDK 21 R8 Chip Resistor, 100kÙ, 1/16W, 1%, 0402 1 Murata/TDK 22 R9 Chip Resistor, 0.47Ù, 1/8W, 5%, 0805 1 Murata/TDK 23 R10 Chip Resistor, 2.7Ù, 1/4W, 5%, 1206 1 Murata/TDK 24 R11 Chip Resistor, 200kÙ, 1/10W, 5%, 0603 1 Murata/TDK 25 R12,R13 Chip Resistor, 715kÙ, 1/10W, 5%, 0603 2 Murata/TDK 26 R14 Chip Resistor, 100kÙ, 1/10W, 5%, 0603 1 Murata/TDK 27 R15 Chip Resistor, 2.2Ù, 1/10W, 5%, 0603 1 Murata/TDK 28 R16 Chip Resistor, 100Ù, 1/10W, 5%, 0603 1 Murata/TDK 29 R18,R19 Chip Resistor, 22Ù, 1/10W, 5%, 0603, Optional 2 Murata/TDK 30 LED1,LED2, LED3,LED4 LED, 0603, Blue 4 LED Manu 31 PB Push Button Switch 1 Nikkai Omron 32 USB 10.2*14.6*7mm, 4P 1 33 Micro-USB MICRO USB 5P/F SMT B 1 34 U1 IC, ACT2801, T-QFN 44-24 1 Item Reference 1 L1 2 Active-Semi, Inc. www.active-semi.com Description - - Active-Semi. Confidential-Do Not Copy or Distribute ACT 4 ACT2801: Dedicated Power Bank Solution 4 PCB LAYOUT *C3 should be placed close to VIN and PGND; C2 must be placed across VOUT and PGND pins 5 FUNCTIONAL TEST 5.1 Battery Charge V/I profile 5.2 Power Path Function Input current(mA) Output current(mA) Charge current(mA) 792 895 993 1092 1287 1312 1325 1330 1334 1343 1347 1355 1359 0 100 200 300 500 600 800 900 1000 1100 1200 1300 1360 1021 1020 1021 1020 1017 923 680 551 430 312 194 78 0 (Test condition: Vin=5V, Vbat=3.5V, input current limit=1.5A, fast charge current=1.0A) Active-Semi, Inc. www.active-semi.com - - Active-Semi. Confidential-Do Not Copy or Distribute 5 ACT2801: Dedicated Power Bank Solution 5.3 Charge Efficiency (Vin=5V and charge current set at 1000mA) Battery voltage (V) 3.0 3.5 3.8 4.1 Efficiency (%) 89.6 91.3 92.0 92.2 5.4 Boost Output Regulation (Measured at USB port) Active-Semi, Inc. www.active-semi.com Battery Output Voltage Output Voltage at Load Voltage at 1A Output No Load Regulation (V) (V) (V) (%) 3.2 4.955 5.008 1.06 3.7 4.95 5.016 1.31 4.2 4.946 5.028 1.63 - - Active-Semi. Confidential-Do Not Copy or Distribute 6 ACT2801: Dedicated Power Bank Solution 5.5 Boost Efficiency and Power Loss (Ta=25℃) Vbat Efficiency (%) Io=100mA Io=200mA Io=500mA Io=800mA Io=1000mA 3.2V 94.1 93.7 94.2 92.5 90.5 3.7V 95.3 94.8 95.5 94.0 92.7 4.2V 96.5 95.8 96.6 95.4 94.3 (Note: bigger inductor size can improve efficiency further) Active-Semi, Inc. www.active-semi.com - - Active-Semi. Confidential-Do Not Copy or Distribute 7 ACT2801: Dedicated Power Bank Solution 5.6 Boost Standby Power (Ta=25℃) Battery Voltage(V) 3.2 3.7 4.2 Boost Standby Current(mA) 0.54 0.52 0.52 Boost Standby Power(mW) 1.73 1.92 2.18 5.7 Boost Constant Current and Constant Voltage Regulation (Ta=25℃) Vbat=3.2V CC Load CV Load Active-Semi, Inc. www.active-semi.com Vbat=3.7V Vbat=4.2V Vout(V) Iout(mA) Vout (V) Iout(mA) Vout(V) Iout(mA) 5.008 0 5.017 0 5.024 0 5.004 100 4.944 100 4.999 100 4.988 200 4.987 200 4.997 200 4.975 500 4.972 500 4.96 500 4.95 1000 4.95 1000 4.946 1000 4.944 1200 4.936 1200 4.932 1200 4.937 1300 4.929 1300 4.924 1300 4.9 1363 4.9 1381 4.9 1376 4.85 1357 4.85 1376 4.85 1375 4.8 1358 4.8 1373 4.8 1375 4.75 1357 4.75 1372 4.75 1375 4.7 1357 4.7 1370 4.7 1375 4.65 1356 4.65 1368 4.65 1376 4.6 1356 4.6 1369 4.6 1376 4.55 1355 4.55 1368 4.55 1376 4.5 1356 4.5 1368 4.5 1376 4.35 1357 4.35 1368 4.35 1378 4.3 1357 4.3 1369 4.3 1378 4..25 1358 4..25 1369 4..25 1379 4.2 1358 4.2 1369 4.2 1380 4.15 1359 4.15 370 4.15 1380 4.1 0 4.1 0 4.1 0 - - Active-Semi. Confidential-Do Not Copy or Distribute 8 ACT2801: Dedicated Power Bank Solution 5.8 Battery Leakage Current in HZ Mode Power Loss Test Conditions Battery Input Current（µA） Vbat=2.8V 5.1 14.3 Vbat=3.2V 5.8 18.6 Vbat=3.7V 6.4 23.7 Vbat=4.2V 7.2 30.2 (µW) 5.9 Ripple and Noise Ripple & noise are measured by using 20MHz bandwidth limited oscilloscope. Test Output Ripple at 0.5A Load Output Ripple at 1A Load Conditions (mV) (mV) Vbat=3.2V 18.0 25.2 Vbat=3.7V 18.4 25.2 Vbat=4.2V 18.5 24.9 Active-Semi, Inc. www.active-semi.com - - Active-Semi. Confidential-Do Not Copy or Distribute 9 ACT2801: Dedicated Power Bank Solution 5.10 Load Dynamic Response Load Step (80mA-1000mA-80mA load step) Vbat=3.7V Vbat=4.2V 5.11 LED Indication PB time>100ms (HZ Mode) LED1 LED2 LED3 LED4 2.9V<VBAT<3.32V Off Off Off Off 3.32V≤VBAT<3.66V On Off Off Off 3.66V≤VBAT<3.81V On On Off Off 3.81V≤VBAT<4.06V On On On Off VBAT≥4.06V On On On On Charge Mode LED1 LED2 LED3 LED4 VBAT<3.58V Flash Off Off Off 3.58V≤VBAT<3.82V On Flash Off Off 3.82V≤VBAT<3.96V On On Flash Off 3.96V≤VBAT<4.06V On On On Flash VBAT≥4.06V On On On Flash VBAT=4.15V (End of Charge ) On On On On Active-Semi, Inc. www.active-semi.com - - Active-Semi. Confidential-Do Not Copy or Distribute 10 ACT2801: Dedicated Power Bank Solution 5.12 System Management ACT2801 System Operation Flow Chart 5.13 Key Components Temperature Test (Ta=40℃, burning for 2 hours) Charge mode, 1.0A charge current Vin(V) IC(℃) Inductor(℃) PCB(℃) Vbat(V) 5.0 67.4 62.3 58.8 3.2 5.0 65.6 60.6 57.3 3.7 5.0 63.7 59.3 56.0 4.2 Boost mode, 1.2A output current Active-Semi, Inc. www.active-semi.com Vbat(V) IC(℃) Inductor(℃) PCB(℃) Vout(V) 3.2 80.4 84.2 72.9 5.0 3.7 70.0 72.4 65.2 5.0 4.2 63.3 64.9 60.1 5.0 - - Active-Semi. Confidential-Do Not Copy or Distribute 11 ACT2801: Dedicated Power Bank Solution 6 PCB LAYOUT GUIDANCE The following guideline is base on the schematic in Section 2. 1) Arrange the power components to reduce the AC loop size that consists of C2, VOUT, SW and PGND. C2 (1206 size) must be placed close to the IC and across the VOUT and PGND traces and SW trace goes under the C2 as shown in the following layout figure. 2) Use copper plane for PGND for best heat dissipation and noise immunity. AGND and PGND are connected under the IC thermal pad with 4x4 vias matrix. 3) SW copper area should be limited due to EMI consideration. 4) Use Kevin sense from sense resistor R2 to CSP and CSN pins as shown in the layout figure. 5) A separate trace is from VBAT input to BAT pin for battery voltage sense accuracy. 6) RC snubber is recommended to add across SW to PGND to reduce EMI noise. 7) A 10V/1A schottky is added from inductor terminal to VOUT to reduce EMI noise. Top Layer Bottom Layer Active-Semi, Inc. www.active-semi.com - - Active-Semi. Confidential-Do Not Copy or Distribute 12 ACT2801: Dedicated Power Bank Solution 7 EMI TEST Vbat=4.1V, Output : 5V/1A Horizontal Active-Semi, Inc. www.active-semi.com - - Active-Semi. Confidential-Do Not Copy or Distribute 13 ACT2801: Dedicated Power Bank Solution Vbat=4.1V, Output : 5V/1A Vertical Active-Semi, Inc. www.active-semi.com - - Active-Semi. Confidential-Do Not Copy or Distribute 14