AND9031 Constant Current Regulator Charging Circuit Prepared by: Steven Shackell ON Semiconductor http://onsemi.com APPLICATION NOTE ABSTRACT Nickel Cadmium batteries can be charged using this circuit. They perform very similar to NiMH batteries so this method will work well for them. This application note describes how a Constant Current Regulator, CCR, can be used in a low cost charging circuit for rechargeable batteries, providing a simple controller to terminate charging. Lithium Ion The usual method of charging a Li−Ion battery is to charge the battery to 4.2 V/cell at 0.5C to 1C followed by a trickle charge. The temperature rise of Li−Ion batteries should be kept below 5°C while charging, a higher temperature rise indicates a potential to combust. The trickle charge portion of the charge cycle is when the battery temperature rises the most and it has the greatest chance to combust. High end charges use smart IC’s, such as the NCP1835B, to monitor and control the charge of Lithium ion batteries because of this issue. The CCR controller discussed here eliminates this by not including a trickle charge, keeping the battery in a safe operating area and helping to increase the life of the battery. However, by eliminating the trickle charge the battery will only receive ≈ 85% charge. Current + − Voltage Reference Controller Charge Indicator Battery Source Control Figure 1. Block Diagram of Charging Circuit Types of Rechargeable Batteries The three most common rechargeable batteries are Nickel Metal Hydride (NiMH), Nickel Cadmium (NiCad), and Lithium Ion (Li−Ion). When referring to the rate at which a battery is charged the letter “C” is used. The “C” defines the capacity of the battery over 1.0 hour. For example, a battery rated at 800 mAh could be charged at 0.5C resulting in a charge current of 400 mA over two hours to fully charge the battery. Setting the Reference Voltage The TL431, a three−terminal programmable shunt regulator, is used to set the reference voltage. It is designed to give a constant 2.5 V output at its reference pin. When two external resistors are connected as shown in Figure 2, the reference voltage can be selected from 2.5 V to 36 V. For our purposes we will set R2 to 1.0 kW, and will adjust Rref to match the reference voltage we want. The equation used to find the ratio of R2/Rref is given by: Nickel Metal Hydride and Nickel Cadmium The nominal voltage of a NiMH battery is 1.2 V/cell and should be charged up to 1.5−1.6 V/cell. There are several different techniques for determining when to shutoff the charge. They include: peak voltage detection, negative delta voltage, delta temperature (dT/dt), temperature threshold, and timers. For high end chargers these may be all combined into one charger. The CCR charger is a peak voltage detect circuit and terminates charging at a predetermined peak. The predetermined peak voltage is 1.5 V/cell, and will charge the battery to ≈ 97%. © Semiconductor Components Industries, LLC, 2012 January, 2012 − Rev. 2 ǒ V ref + 1 ) R2 Ǔ R ref 2.5 The resistor that is connected to the cathode of the TL431 is used to limit the current, and to separate the input voltage from the reference voltage. 1 Publication Order Number: AND9031/D AND9031 than 200 mV because when charging is terminated the voltage of the battery will drop slightly. The equations to calculate the high and low voltages of the inverting input are: V inL + V inH + R3 R3 ) Rh R3 R3 ) Rh ǒVOL * VrefǓ ) Vref ǒVOH * VrefǓ ) Vref A 1.0k resistor (R4) is connected to the output of the comparator to act as a pull−up resistor. Figure 2. Setup of Reference Voltage Comparator with Hysteresis Loop The LM311, a Single comparator, is used to compare the voltage of the battery to the reference voltage. Connected to the inverting input is the battery voltage. Hysteresis is provided by a feedback resistor (Rh) between the output and the non−inverting input. R3, a 1.0 kW resistor is used to make the ratio of R3/Rh simple. By adjusting Rh you can change the bandwidth of the hysteresis loop. By increasing Rh you decrease the bandwidth and vice versa. It is recommended the bandwidth of the hysteresis be greater Figure 3. Hysteresis Setup Figure 4. Schematic of Charging Circuit Current Switch resistor (R6). The collector of Q6 is connected to the base of Q3 through a 1.0 kW resistor (R5). When the output of the comparator goes Low, Q6 is turned off, causing Q3 to turn off which terminates the charge current. The two BJTs (Q3 and Q6) in the circuit are acting as the switch to control the charging current. The base of Q6 is controlled by the output of the comparator through a 5.6 kW http://onsemi.com 2 AND9031 Current Regulation Table 1. RESISTANCE VALUES FOR TESTS The charging current for the batteries is controlled by using a CCR. The current can be adjusted by using an adjustable CCR and/or putting CCR’s in parallel. This demo board is designed for two CCRs in parallel, Q4 and Q5. (It is possible to connect more than two CCR’s in parallel so any current that you desire can be reached). For the experiments discussed in this application note the CCR (NSI45090JDT4G) could be adjusted from 90 mA − 160 mA. The three currents used for data analysis were, 90, 180, and 300 mA. Battery Type /Charge Current Rref Rh Radj1 Radj2 Li−Ion/90 mA 1.8 kW 18 kW ∞ * Li−Ion/180 mA 1.8 kW 18 kW ∞ ∞ Li−Ion/300 mA 1.8 kW 18 kW 5.0 W 5.0 W NiMH/90 mA 1.4 kW 18 kW ∞ * NiMH/180 mA 1.4 kW 18 kW ∞ ∞ NiMH/300 mA 1.4 kW 18 kW 5.0 W 5.0 W *Q5 is not used, no need for Radj2 Indicator LED To indicate that the battery is being charged a LED with a CCR, Q7, is used. A CCR supplies the LED with a constant current. The LED will also be “On” when there is no battery connected to the charger. When the LED turns “Off” this indicates that the battery has been fully charged. Results The CCR charging circuit was tested by charging both Li−ion and NiMH batteries at 90 mA, 180 mA, and 300 mA. Table 2 shows key voltages that were monitored while a battery was being charged. While Table 3 shows the same key voltages just after the circuit terminates the charging of the battery. In Table 3 the data for the NiMH being charged at 90 mA is excluded. During this test the temperature of the battery started to climb rapidly (see Table 4), the test was ended before the battery voltage reached the reference voltage. This high temperature rise of the NiMH batteries when being charged at low currents is discussed on the TECHNIK website www.technik.net. Setup for the Different test Currents Table 1 shows the values to the variable components that determine the charge current and at what voltage the charge is terminated. While testing at 180 mA two NSI45090JDT4G CCRs were used to give an output current of 90 mA with Radj = 10 W. Table 2. VOLTAGES WHILE CHARGING Battery Type /Charge Current Comparator Output Voltage (V) PNP Collector Voltage (V) PNP Emitter Voltage (V) PNP Collector − Emitter Voltage (V) PNP Base Voltage (V) Diode Forward Voltage (V) Li−Ion/90 mA 10.13 12.123 12.141 0.018 8.776 0.2914 Li−Ion/180 mA 10.124 12.102 12.134 0.032 8.785 0.3109 Li−Ion/300 mA 10.08 12.029 12.08 0.051 8.745 0.3247 NiMH/90 mA 10.155 12.132 12.151 0.019 8.782 0.2918 NiMH/180 mA 10.142 12.103 12.135 0.032 8.787 0.3107 NiMH/300 mA 10.109 12.045 120.94 0.049 8.746 0.3263 Table 3. VOLTAGES JUST AFTER CHARGING WAS TERMINATED Battery Type /Charge Current Comparator Output Voltage (V) PNP Collector Voltage (V) PNP Emitter Voltage (V) PNP Collector − Emitter Voltage (V) Diode Forward Voltage (V) Li−Ion/90 mA 0.223 1.381 12.167 10.786 −2.764 Li−Ion/180 mA 0.223 1.3 12.165 10.865 −2.378 Li−Ion/300 mA 0.223 1.383 12.16 10.777 −2.679 NiMH/180 mA 0.223 1.37 12.165 10.795 −3.025 NiMH/300 mA 0.223 1.35 12.16 10.81 −2.936 http://onsemi.com 3 AND9031 rise. The same can be said for NiMH batteries when charging above 0.1C. It is important to keep this in mind when selecting what charge rate will be used. Table 4 contains temperature data for the batteries. In all cases the ambient temperature was approximately 25°C. For Li−ion batteries it can be concluded that the higher the charge current the more the temperature of the battery will Table 4. TEMPERATURES OF THE BATTERIES Battery Type /Charge Current Start Battery Temperature (5C) Maximum Battery Temperature (5C) Change in Battery Temperature (5C) Li−Ion/90 mA 25.0 26.0 1.0 Li−Ion/180 mA 25.0 27.7 2.7 Li−Ion/300 mA 25.0 28.4 3.4 NiMH/90 mA 25.0 30.0 5.0 NiMH/180 mA 25.0 27.9 2.9 NiMH/300 mA 25.0 28.1 3.1 Charge Current Over Time current of approximately 300 mA the power dissipated over the transistor is less than 15 mW. In addition to using a low VCE(sat) BJT a DSN2 low VF Schottky barrier diode was used to minimize the power dissipated. The diode is used for reverse current protection. The NSR10F40NXT5G was used because it has one of the lowest VF’s the market has to offer. At the highest charging current tested the power dissipated by the diode is around 95 mW. Figure 7 shows the power dissipation of the DSN2 Low VF Schottky barrier diode as the battery is being charged. With using both a Low VCE(sat) BJT and Low VF Schottky diode the input voltage is the lowest possible. With the use of the Constant Current Regulator the charge current is held constant until the charging is terminated as seen in Figure 5. Figure 5. Charge Current vs. Time Power Dissipation of BJT and Diode In today’s circuits people are very concerned about power dissipation. Lowering the input voltage is one way to increase the performance of the circuit. This is one reason why a low VCE(sat) transistor was used. As shown in Table 1 the VCE of the transistor is very low. This is also reinforced with Figure 6 which depicts the power dissipated by the PNP transistor over time. As one would expect as the charge current is increased the PD increases. However at a charge Figure 6. PD of PNP Transistor vs. Time http://onsemi.com 4 AND9031 Rechargeable Batteries section this circuit is designed to stop charging at predefined voltage, in this case 4.15 V. Figure 7. PD of Diode vs. Time Power Dissipation of CCR Figure 9. Battery Voltage vs. Time Power dissipation is a very important parameter when using a CCR. This is the device where all the voltage will be dropped to ensure that the battery is charged at a constant current. As the device begins to heat up the current begins to drop. To minimize the temperature rise of the CCR copper is placed on most of the empty space of the board. The cathode of the CCR is then connected to this area of copper to act as a heat sink. When using multiple CCR’s in parallel keep in mind that the power dissipated by the individual CCR is only the voltage multiplied by the individual current that is going through the CCR. Not the total charge current. Figure 8 shows the power dissipated by the CCRs over time. Only one of the CCRs data is shown when multiple CCRs are used to obtain higher charge currents. Conclusion In conclusion, a Constant Current Regulator, CCR, can be used to provide a constant current to a battery while charging. Furthermore, when the controller discussed here is implemented with a CCR it is possible to charge different battery chemistries at different currents with the same circuit. References 1. NSR10F20/D, “Schottky Barrier Diode”, Data Sheet, ON Semiconductor. 2. NSS40200L/D, “40 V, 4.0 A, Low VCE(sat) PNP Transistor”, Data Sheet, ON Semiconductor. 3. NSI45090DD/D, “Adjustable Constant Current Regulator & LED Driver”, Data Sheet, ON Semiconductor. 4. LM211/D, “Single Comparators”, Data Sheet, ON Semiconductor. 5. TL431/D, “Programmable Precision References”, Data Sheet, ON Semiconductor. 6. MMBT3904LT1/D, “General Purpose Transistor”, Data Sheet, ON Semiconductor. 7. Battery University. “Charging Lithium−ion”. http://batteryuniversity.com/learn/article/charging_ lithium_ion_batteries 8. Battery University. “Charging Nickel−metal−hydride”. http://batteryuniversity.com/learn/article/charging_ nickel_metal_hydride 9. Battery University. “Charging Nickel−cadmium”. http://batteryuniversity.com/learn/article/charging_ nickel_based_batteries 10. TECHNIK. “Charging the Nickel−Metal Hydride Battery”. http://www.technick.net/public/code/cp_dpage.php ?aiocp_dp=guide_bpw2_c04_05 Figure 8. PD of CCR vs. Time Battery Voltage over Time Figure 9 depicts the voltage of the battery for all six test cases. For the Li−Ion battery voltages one would expect to see them start to flatten off as the voltage reaches 4.2 V. In more advanced circuits this would be when a trickle charge would be applied. However, as discussed in the Types of http://onsemi.com 5 AND9031 APPENDIX I − BILL OF MATERIALS FOR CCR CHARGING CIRCUIT DEMO BOARD Qty Location on PCB Part No. Description Manufacturer 1 D1 NSR10F20NXT5G DSN2 Low VF Schottky Diode ON Semiconductor 1 Q3 NSS40200LT1G Low VCE(sat) PNP Transistor ON Semiconductor 1 Q6 MMBT3904LT1G NPN Transistor ON Semiconductor 1 Q2 LM311DG Single Comparator ON Semiconductor 1 Q1 TL431BCDG Programmable Precision Reference ON Semiconductor 1 Q4, Q5 NSI45090JDT4G 90−160 mA CCR ON Semiconductor 1 Q7 NSI45025AZT1G 25 mA CCR ON Semiconductor 2 R4, R5 1206 SMD Resistor, 1 kW 1/4 W 1% 3 R1, R2, R3 0805 SMD Resistor, 1 kW 1/8 W 1% 1 R6 0805 SMD Resistor, 5.6 kW 1/8 W 1% 2 Radj1, Radj2 1210 SMD Resistor, 1/2 W 1%, value depends on design 1 Rref 0805 SMD Resistor, 1/8 W 1%, value depends on design 1 Rh 0805 SMD Resistor, 1/8 W 1%, value depends on design 1 LED SMD 50 mA LED 15 All TP’s Conn. Header 1 Vdc PJ−102A Conn Jack Power 2.1 mm PCB CUI Inc. 2 Vin−, Vbatt− 571−0100 Banana Conn Deltron 2 Vin+, Vbatt+ 571−0500 Banana Conn Deltron http://onsemi.com 6 AND9031 APPENDIX II − PCB LAYOUT OF CCR CHARGING CIRCUIT DEMO BOARD Figure 10. Top Layer Copper and Silkscreen Figure 11. Bottom Layer Copper ON Semiconductor and are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). SCILLC reserves the right to make changes without further notice to any products herein. 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