ACT2804 Demo Board Application Report 5V/3.4A Dual Cell Backup Battery Power Manager FEATURES Dedicated single-chip integrated dual cell battery management Meet EN55022 class B radiated EMI standard Output short circuit protection and nearly zero power >91% charge efficiency at 3.4A input Thermal regulation for battery charge/discharge Accommodation for >10mA input source Battery over voltage protection 4.5V-5.5V input voltage and 3.4A input current limit 5.07V+/-1% output with prioritized power path from input to output 20V input Voltage Protection 2.4A+1.0A dual outputs 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 3.4A 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 ACT2804: Dual 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 BATTERY CHARGE V/I PROFILE .................................................................. 6 5.2 POWER PATH FUNCTION ....................................................................... 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 ....................................................... 11 5.7 RIPPLE AND NOISE .......................................................................... 11 5.8 LOAD DYNAMIC RESPONSE LOAD STEP .......................................................... 11 5.9 LED INDICATION ............................................................................ 12 5.10 SYSTEM MANAGEMENT ....................................................................... 13 5.11 6 KEY COMPONENTS TEMPERATURE TEST (TA=25C, BURNING FOR 2 HOURS) ............................ 14 EMI TEST .................................................................................... 15 Active‐Semi, Inc. ‐ 2 ‐ www.active‐semi.com ACT2804: Dual Output Power Bank Solution 1 DEMO BOARD PHOTOS (DEMO BOARD SIZE: 48mm*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 ACT2804: Dual Output Power Bank Solution PT LEDLS4 LEDLS3 LEDLS2 LEDLS1 LED4 BAT BAT BATS BATP BATC RIMC SW HYST SW PGND HSB DP DM SDA 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 ACT2804: Dual Output Power Bank Solution 4 BILL OF MATERIALS Item Reference 1 L1 2 Description QTY Manufacturer SWPA8040S4R7NT, 4.7uH 5.9A(8*8*4mm) 1 Sunlord D1 MBR1020VL, 20V/1A Schottky, SMA, Optional 1 Panjit 3 D2 MBR1020VL, 20V/1A Schottky, SMA 1 Panjit 4 C2 Ceramic capacitor, 4.7uF/10V, X7R, 0805 1 Murata/TDK 5 C3, C10,C11,C12 Ceramic capacitor, 10uF/10V, X7R, 1206 4 Murata/TDK 6 C7,C8, C21, C22 Ceramic capacitor, 22uF/16V, X7R, 1206 4 Murata/TDK 7 C5,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/16V, 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, C26 Ceramic capacitor, 3.3uF/10V, X7R, 0603 2 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,R4, R4A Chip Resistor, 50mΩ, 1/2W, 1%, 1206 6 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 25 R13 Chip Resistor, 200Ω, 1/10W, 1%, 0603 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 R19 Chip Resistor, 0.01Ω, 1/10W, 1%, 0603 1 Murata/TDK 32 R20,R21,R30,R31 Chip Resistor, 510Ω, 1/10W, 5%, 0603 4 Murata/TDK Active‐Semi, Inc. ‐ 5 ‐ www.active‐semi.com ACT2804: Dual Output Power Bank Solution 33 R22 Chip Resistor, 1K, 1/10W, 5%, 0603 1 Murata/TDK 34 R24 Chip Resistor, 47Ω, 1/4W, 1%, 1206 1 Murata/TDK 35 R27 Chip Resistor, 100Ω, 1/10W, 1%, 0603 1 Murata/TDK 36 R32 Chip Resistor, 10K, 1/10W, 5%, 0603 1 Murata/TDK 37 LED1,LED2,LED3,LED4 LED, 0603, Blue 4 LED Manu 38 Q1 SSF2318, 20V/6.5A N MOSFET, Optional 1 Silikron 39 Q2 2S Battery protection IC, S8252 1 Seiko 40 Q3 20V Dual N-Channel Power MOSFET, 8205A 1 Fortune 41 PB Push button 1 10.2*14.6*7mm,4P 2 MICRO USB 5P/F SMT B 1 IC, ACT2804 T-QFN 5X5-40 1 42 Output USB1, Output USB2 43 Micro-USB 44 U1 ACT 5 FUNCTIONAL TEST 5.1 Battery Charge V/I profile Active‐Semi, Inc. ‐ 6 ‐ www.active‐semi.com ACT2804: Dual Output Power Bank Solution 5.2 Power Path Function (Test condition: Vin=5.05V, Vbat=7V, input current limit=3.4A, fast charge current=1.0A) Input current(mA) Output current(mA) Charge current(mA) 1540 1759 1965 2161 2369 2563 2752 2774 2772 2771 2769 2766 2743 0 200 400 600 800 1000 1200 1300 1500 1700 2000 2400 2728 976 973 970 970 968 967 963 913 792 666 473 209 0 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 ACT2804: Dual Output Power Bank Solution 5.4 Buck Efficiency and Power Loss (Ta=25℃) Vbat Efficiency (%) Io=1000mA Io=1500mA Io=2000mA Io=2400mA Io=3400mA 6.0V 95.6 94.7 93.9 92.9 91.1 7.0V 94.6 94.1 93.2 92.5 90.8 8.4V 91.7 92.0 91.7 91.2 90.1 Vbat Power Loss (W) Io=1000mA Io=1500mA Io=2000mA Io=2400mA Io=3400mA 6.0V 0.23 0.42 0.65 0.91 1.67 7.0V 0.29 0.47 0.73 0.98 1.73 8.4V 0.46 0.65 0.91 1.16 1.88 Active‐Semi, Inc. ‐ 8 ‐ www.active‐semi.com ACT2804: Dual Output Power Bank Solution 5.5 Buck Constant Current and Constant Voltage Regulation (Ta=25℃) Buck V/I Profile (Output1) 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 5.24 12 5.08 12 5.08 12 5.07 200 5.07 200 5.07 200 5.06 500 5.06 500 5.06 500 5.04 800 5.04 800 5.04 800 5.04 1000 5.04 1000 5.04 1000 5.00 1281 5.00 1281 5.00 1278 4.9 1281 4.9 1280 4.9 1277 4.8 1280 4.8 1280 4.8 1277 4.6 1280 4.6 1280 4.6 1277 4.4 1280 4.4 1280 4.4 1276 4.2 1280 4.2 1280 4.2 1276 4 1280 4 1280 4 1276 3.9 1280 3.9 1280 3.9 1276 3.8 1280 3.8 1280 3.8 1276 3.7 1280 3.7 1280 3.7 1276 3.6 1280 3.6 1280 3.6 1276 3.5 0 3.5 0 3.5 0 Active‐Semi, Inc. ‐ 9 ‐ www.active‐semi.com ACT2804: Dual Output Power Bank Solution Buck V/I Profile (Output2) 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. ‐ 10 ‐ www.active‐semi.com ACT2804: Dual 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. 5.8 Test Output Ripple at 2.4A Load Output Ripple at 3.4A Load Conditions (mV) (mV) Vbat=6.0V 45 50 Vbat=7.0V 40 50 Vbat=8.4V 40 45 Load Dynamic Response Load Step (Output2=80mA-1A-80mA load step Ouput1=0A) Vbat=8V (Output2=1A-2.4A-1A load step Ouput1=0A) Vbat=8V Vbat=6.6V Vbat=6.6V Active‐Semi, Inc. ‐ 11 ‐ www.active‐semi.com ACT2804: Dual Output Power Bank Solution (Output2=80mA-1A-80mA load step Ouput1=1A) Vbat=8V Vbat=6.6V (Output2=1A-2.4A-1A load step Ouput1=1A Vbat=8V Vbat=6.6V 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 Active‐Semi, Inc. ‐ 12 ‐ www.active‐semi.com ACT2804: Dual Output Power Bank Solution 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 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 Active‐Semi, Inc. ‐ 13 ‐ www.active‐semi.com ACT2804: Dual Output Power Bank Solution 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, 3.4A output current Vbat(V) IC(℃) Inductor(℃) Vout(V) 6 69.3 62 5.0 7.5 76.6 65.8 5.0 8.2 78.5 67.1 5.0 Active‐Semi, Inc. ‐ 14 ‐ www.active‐semi.com ACT2804: Dual Output Power Bank Solution 6 EMI TEST Vbat=7.8V, Output: 5.07V/3.4A Horizontal Active‐Semi, Inc. ‐ 15 ‐ www.active‐semi.com ACT2804: Dual Output Power Bank Solution Vbat=7.8V, Output: 5.07V/3.4A Vertical Active‐Semi, Inc. ‐ 16 ‐ www.active‐semi.com