ACT2803 Demo Board Application Report 5V/2.4A Dual Cell Backup Battery Power Manager FEATURES Dedicated single-chip integrated dual cell battery management Meet EN55022 class B radiated EMI standard Auto detection support USB BC1.2, Chinese YD/T 1591-2009, Apple, and Samsung devices Output short circuit protection and nearly zero power >91% charge efficiency at 2.75A input current Thermal regulation for battery charge/discharge Weak input sources accommodation Battery over voltage protection 4.5V-5.5V input voltage and 2.75A input current limit 5.07V+/-1% output with prioritized power path from input to output 20V input voltage protection 2.4A output with CC regulation Pass MFi test Output over voltage protection Duel cell battery charger with cell balancing management Dual cell battery overcharge, over discharge, over charge current and over discharge current protections >92% discharge efficiency at 2.4A output Configurable charge, discharge and HZ modes Output plug-in detection to wakeup Light load detection <10uA low battery drainage current Battery operation voltage 6.0V-8.4V Battery termination voltage 8.4V for dual cell 4 LED battery level indication Preconditioning for deeply depleted battery Built-in charge and discharge safety timer 4.20V/4.35V +/- 0.5% battery charge voltage accuracy of each cell Optimized power path and battery charge control TQFN5x5-40 Active‐Semi, Inc. ‐ 1 ‐ www.active‐semi.com ACT2803: 5V/2.4A Output Power Bank Solution TABLE OF CONTENT 1 DEMO BOARD PHOTOS ........................................................................ 3 2 PCB LAYOUT ................................................................................. 3 3 SCHEMATICS ................................................................................. 4 4 BILL OF MATERIALS ........................................................................... 5 5 FUNCTIONAL TEST ............................................................................ 6 5.1 POWER PATH FUNCTION ....................................................................... 6 5.2 BATTERY CHARGE V/I PROFILE .................................................................. 7 5.3 CHARGE EFFICIENCY.......................................................................... 7 5.4 BUCK EFFICIENCY AND POWER LOSS (TA=25℃) ................................................... 8 5.5 BUCK CONSTANT CURRENT AND CONSTANT VOLTAGE REGULATION (TA=25℃) ........................... 9 5.6 BATTERY LEAKAGE CURRENT IN HZ MODE ....................................................... 10 5.7 RIPPLE AND NOISE .......................................................................... 10 5.8 LOAD DYNAMIC RESPONSE LOAD STEP .......................................................... 10 5.9 LED INDICATION ............................................................................ 11 5.10 SYSTEM MANAGEMENT ....................................................................... 12 5.11 6 KEY COMPONENTS TEMPERATURE TEST (TA=25C, BURNING FOR 2 HOURS) ............................ 12 EMI TEST .................................................................................... 13 Active‐Semi, Inc. ‐ 2 ‐ www.active‐semi.com ACT2803: 5V/2.4A Output Power Bank Solution 1 DEMO BOARD PHOTOS (DEMO BOARD SIZE: 46mm*31mm) LED Indication Push Button Input USB BATP BATC BATN 2 PCB LAYOUT TOP Layer Bottom Layer Active‐Semi, Inc. ‐ 3 ‐ www.active‐semi.com Output USB ACT2803: 5V/2.4A Output Power Bank Solution 3 SCHEMATICS Application information Charge Current Setting: Ic(A) 8 Ricst K LED Indication: MODE CHARGE DISCHARGE TRIG LED1 LED2 LED3 LED4 HIGH VLED1+VIMC+0.6*VHYST VLED2+VIMC+0.6*VHYST VLED3+VIMC+0.6*VHYST VLED4+VIMC+0.6*VHYST LOW VLED1+VIMC-100mV VLED2+VIMC-100mV VLED3+VIMC-100mV VLED4+VIMC-100mV HIGH VLED1-VIMC+100mV VLED2-VIMC+100mV VLED3-VIMC+100mV VLED4-VIMC+100mV LOW VLED1-VIMC-0.6*VHYST VLED2-VIMC-0.6*VHYST VLED3-VIMC-0.6*VHYST VLED4-VIMC-0.6*VHYST VLED X (A) 5.5V 108K RLS x K VIMC(V) 2106 K * IBAT ( A) * VHYST 4:3 RCS RIMC K 54K RHYST K Active‐Semi, Inc. ‐ 4 ‐ www.active‐semi.com ACT2803: 5V/2.4A Output Power Bank Solution 4 BILL OF MATERIALS Item Reference Description QTY Manufacturer 1 L1 SWPA8040S4R7NT 4.7uH 5.9A(8*8*4mm) 1 Sunlord 2 D1 MBR1020VL, 20V/1A Schottky, SMA, Optional 1 Panjit 3 D2 MBR1020VL, 20V/1A Schottky, SMA 1 Panjit 4 C1 Ceramic capacitor, 10uF/16V, X7R, 1206 1 Murata/TDK 4 C2 Ceramic capacitor, 4.7uF/10V, X7R, 0805 1 Murata/TDK 5 C3,C10,C11,C12 Ceramic capacitor, 22uF/10V, X7R, 1206 4 Murata/TDK 6 C5,C7,C8 Ceramic capacitor, 22uF/16V, X7R, 1206 3 Murata/TDK 7 C4,C9 Ceramic capacitor, 47nF/16V, X7R, 0603 2 Murata/TDK 8 C6,C13 Ceramic capacitor, 0.1uF/16V, X7R, 0603 2 Murata/TDK 9 C14 Ceramic capacitor, 2.2nF/10V, X7R, 0603 1 Murata/TDK 10 C15 Ceramic capacitor, 1uF/10V, X7R, 0603 1 Murata/TDK 11 C16 Ceramic capacitor, 2.2uF/10V, X7R, 0603 1 Murata/TDK 12 C17,C18 Ceramic capacitor, 0.22uF/10V, X7R, 0603 1 Murata/TDK 11 C19 Ceramic capacitor, 3.3uF/10V, X7R, 0603 1 Murata/TDK 13 C20 Ceramic capacitor, 100nF/10V, X7R, 0603 1 Murata/TDK 16 R1 Chip Resistor, 2.7Ω, 1/8W, 5%, 0805 1 Murata/TDK 17 R2,R2A,R3,R3A Chip Resistor, 50mΩ, 1/4W, 1%, 1206 4 Sart 18 R5 Chip Resistor, 8kΩ, 1/10W, 1%, 0603 1 Murata/TDK 19 R6 Chip Resistor, 83kΩ, 1/10W, 1%, 0603 1 Murata/TDK 20 R7 Chip Resistor, 63.5kΩ, 1/10W, 1%, 0603 1 Murata/TDK 21 R8 Chip Resistor, 51.4kΩ, 1/10W, 1%, 0603 1 Murata/TDK 22 R9 Chip Resistor, 41.5kΩ, 1/10W, 1%, 0603 1 Murata/TDK 23 R10,R11 Chip Resistor, 540kΩ, 1/10W, 1%, 0603 2 Murata/TDK 24 R12 Chip Resistor, 0.47Ω, 1/8W, 1%, 0805 1 Murata/TDK 26 R14,R26 Chip Resistor, 715K, 1/10W, 5%, 0603 2 Murata/TDK 27 R15 Chip Resistor, 12K, 1/10W, 1%, 0603 1 Murata/TDK 28 R16 Chip Resistor, 4.7Ω, 1/8W, 1%, 0805 1 Murata/TDK 29 R17 Chip Resistor, 10Ω, 1/10W, 5%, 0603 1 Murata/TDK 30 R18 Chip Resistor, 47Ω, 1/8W, 5%, 0805 1 Murata/TDK 31 R20,R21,R30,R31 Chip Resistor, 510Ω, 1/10W, 5%, 0603 4 Murata/TDK 32 R22 Chip Resistor, 1K, 1/10W, 5%, 0603 1 Murata/TDK 33 R24 Chip Resistor, 47Ω, 1/4W, 1%, 1206 1 Murata/TDK 34 R27 Chip Resistor, 100Ω, 1/10W, 1%, 0603 1 Murata/TDK 35 R32 Chip Resistor, 10K, 1/10W, 5%, 0603 1 Murata/TDK Active‐Semi, Inc. ‐ 5 ‐ www.active‐semi.com ACT2803: 5V/2.4A Output Power Bank Solution 36 LED1,LED2,LED3,LED4 LED, 0603, Blue 4 LED Manu 37 Q1 SSF2318, 20V/6.5A N MOSFET, Optional 1 Silikron 38 Q2 2S Battery protection IC, S8252 1 Seiko 39 Q3 20V Dual N-Channel Power MOSFET, 8205A 1 Fortune 40 PB Push Button Switch 1 41 Output USB 10.2*14.6*7mm,4P 1 42 Micro-USB MICRO USB 5P/F SMT B 1 43 U1 IC, ACT2803 T-QFN 5X5-40 1 ACT 5 FUNCTIONAL TEST 5.1 Power Path Function Input current(mA) Output current(mA) Charge current(mA) 1499 1717 1931 2139 2227 2275 2329 2349 2412 2424 2421 2417 2408 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2300 2380 1019 1020 1018 1016 942 845 743 642 532 399 260 61 0 (Test condition: Vin=5.05V, Vbat=7.0V, input current limit=2.75A, fast charge current=1.0A) Active‐Semi, Inc. ‐ 6 ‐ www.active‐semi.com ACT2803: 5V/2.4A Output Power Bank Solution 5.2 Battery Charge V/I profile 5.3 Charge Efficiency (Vin=5V and charge current set at 1000mA) Battery voltage (V) 6.0 6.5 7.0 7.5 8.0 8.2 Efficiency (%) 95.9 95.3 94.1 93.1 92.1 91.7 Active‐Semi, Inc. ‐ 7 ‐ www.active‐semi.com ACT2803: 5V/2.4A Output Power Bank Solution 5.4 Buck Efficiency and Power Loss (Ta=25℃) Vbat Efficiency (%) Io=500mA Io=1000mA Io=1500mA Io=2000mA Io=2400mA 6.0V 95.8 95.6 94.7 93.9 92.9 7.0V 93.0 94.6 94.1 93.2 92.5 8.4V 90.4 91.7 92.0 91.7 91.2 Vbat Power Loss (W) Io=500mA Io=1000mA Io=1500mA Io=2000mA Io=2400mA 6.0V o.11 0.23 0.42 0.65 0.91 7.0V 0.19 0.29 0.47 0.73 0.98 8.4V 0.27 0.46 0.65 0.91 1.16 Active‐Semi, Inc. ‐ 8 ‐ www.active‐semi.com ACT2803: 5V/2.4A Output Power Bank Solution 5.5 Buck Constant Current and Constant Voltage Regulation (Ta=25℃) Vbat=6.0V CC Load CV Load Vbat=7.0V Vbat=8.0V Vout(V) Iout(mA) Vout (V) Iout(mA) Vout(V) Iout(mA) 5.23 0 5.23 0 5.23 0 5.08 12 5.08 10 5.08 10 5.02 1000 5.02 1000 5.01 1000 4.99 1500 4.99 1500 4.98 1500 4.96 2000 4.97 2000 4.96 2000 4.94 2400 4.95 2400 4.94 22400 4.92 2682 4.92 2692 4.92 2630 4.9 2681 4.9 2687 4.9 2675 4.8 2677 4.8 2685 4.8 2680 4.6 2676 4.6 2683 4.6 2678 4.4 2675 4.4 2681 4.4 2677 4.2 2674 4.2 2679 4.2 2676 4 2673 4 2677 4 2675 3.9 2672 3.9 2676 3.9 2674 3.8 2672 3.8 2675 3.8 2672 3.7 2671 3.7 2674 3.7 2671 3.6 2671 3.6 2674 3.6 2670 3.5 2671 3.5 2673 3.5 2668 3.4 0 3.4 0 3.4 0 Active‐Semi, Inc. ‐ 9 ‐ www.active‐semi.com ACT2803: 5V/2.4A Output Power Bank Solution 5.6 Battery Leakage Current in HZ Mode Battery Input Current Power Loss （µA） (µW) Vbat=6V 2.5 15 Vbat=7V 2.6 18.2 Vbat=8V 2.8 22.4 Vbat=8.4V 3.1 26 Test Conditions 5.7 Ripple and Noise Ripple & noise are measured by using 20MHz bandwidth limited oscilloscope. Output Ripple at 2.4A Load Vbat=6.0V Vbat=7.0V Vbat=8.4V Ripple(mV) 45 40 40 5.8 Load Dynamic Response Load Step (Output=80mA-1A-80mA load step) Vbat=8V (Output=1A-2.4A-1A load step) Vbat=8V Vbat=6.6V Vbat=6.6V Active‐Semi, Inc. ‐ 10 ‐ www.active‐semi.com ACT2803: 5V/2.4A Output Power Bank Solution 5.9 LED Indication Conventional LED indication PB time>40ms (HZ Mode) LED1 LED2 LED3 LED4 VBAT<Vcut-off Off Off Off Off Vcut-off ≤VBAT<VLED1 Flash Off Off Off VLED1≤VBAT< VLED2 On Off Off Off VLED2≤VBAT< VLED3 On On Off Off VLED3≤VBAT< VLED4 On On On Off VBAT≥VLED4 On On On On Charge Mode LED1 LED2 LED3 LED4 VBAT<VLED2 Flash Off Off Off VLED2≤VBAT< VLED3 On Flash Off Off VLED3≤VBAT< VLED4 On On Flash Off VLED4≤VBAT Charge Mode On On On Flash VLED4≤VBAT EOC Mode On On On On ACT2804 is designed with a simple ADC to convert 5 levels of PT pin voltage into 5 application patterns. INDICATION PATTERN Conventional Always On In Discharge Conventional 5s Indication in Discharge Breathing 5s Indication in Discharge Bottom Charging 5s Indication in Discharge Circulating 5s Indication in Discharge PT Resistor R15=3.3K R15=12K R15=24K R15=42K R15=68K Active‐Semi, Inc. ‐ 11 ‐ www.active‐semi.com ACT2803: 5V/2.4A Output Power Bank Solution 5.10 System Management PB is pressed for >5s or Discharge load is <10mA for 12.5s, Discharge mode is go into HZ mode PB is pressed for 40ms, Discharge mode is turned on PB is pressed for 40ms, LED indication is on for 5.0 seconds 2 seconds transition time between Charge Mode and Boost Mode 5.11 Key Components Temperature Test (Ta=25C, burning for 2 hours) Charge mode, 1.0A charge current Vin(V) IC(℃) Inductor(℃) Vbat(V) 5.0 36.5 34.3 6 5.0 45.4 41.8 7.5 5.0 51.6 46.6 8.2 Discharge mode, 2.4A output current Vbat(V) IC(℃) Inductor(℃) Vout(V) 6.0 49.0 43.2 5.0 7.0 50.3 44.2 5.0 8.0 52.5 46.2 5.0 8.4 53.1 46.9 5.0 Active‐Semi, Inc. ‐ 12 ‐ www.active‐semi.com ACT2803: 5V/2.4A Output Power Bank Solution 6 EMI TEST Vbat=7.8V, Output: 5V/2.4A Horizontal Active‐Semi, Inc. ‐ 13 ‐ www.active‐semi.com ACT2803: 5V/2.4A Output Power Bank Solution Vbat=7.8V, Output: 5V/2.4A Vertical Active‐Semi, Inc. ‐ 14 ‐ www.active‐semi.com