DC2134A - Demo Manual

DEMO MANUAL DC2134A
LTC4020EUHF
High Power Buck-Boost
Multi-Chemistry Battery Charger
Description
Demonstration circuit 2134A is a high power buck-boost
multichemistry battery charger featuring the LTC®4020.
The board will accept an input voltage between 15V and
55V. The float voltage of the battery output (BAT) is 25.2V,
with 6.3A maximum charge current. The converter output
(VOUT) has a voltage range of 21V to 28V, with 8A maximum load current. The LTC4020 contains a high efficiency
synchronous buck-boost DC/DC controller, and uses a
proprietary average current mode architecture.
The LTC4020 battery charger can provide a constantcurrent/constant-voltage charge algorithm (JP1: CC/CV,
Performance Summary
PARAMETER
with mode pin grounded), constant-current charging (JP1:
CC, with mode pin floated), or charging with an optimized
4-step, 3-stage lead-acid battery charge profile (JP1: leadacid, with mode pin connected to INTVCC).
The LTC4020 data sheet gives a complete description of the
IC operation and application information. The data sheet
must be read in conjunction with this quick start guide.
Design files for this circuit board are available at
http://www.linear.com/demo/DC2134A
L, LT, LTC, LTM, Linear Technology and the Linear logo are registered trademarks of Linear
Technology Corporation. All other trademarks are the property of their respective owners.
Specifications are at TA = 25°C
CONDITION
Input Voltage Range
VALUE
15V to 55V
Battery Float Voltage (BAT) (Nominal)
IBAT = 0A
Converter Output Voltage (VOUT)
IOUT = 0A to 8A
Maximum Battery Charge Current, IBAT
IOUT = 0A
6.3A
Maximum Converter Output Current, IOUT
IBAT= 0A
8A
Typical Efficiency
VIN = 24V, VOUT = 25.2V, IOUT = 8A
Typical Converter Output Ripple
VIN = 55V, VOUT = 25.2V, IOUT = 8A (20MHz Bandwidth)
25.2V
21V to 28V
98.1%
109mVP–P
dc2134af
1
DEMO MANUAL DC2134A
Quick Start Procedure
Demonstration circuit 2134A is easy to set up to evaluate
the performance of the LTC4020. Refer to Figure 1 for
the proper measurement equipment setup and follow the
procedure below:
1.With power off, connect the input power supply (set
for 0V) to VIN and GND (input return).
2.Connect the converter output load between Vout and
GND (Initial load: no load).
3.Connect the DVMs to the input and outputs.
4.Turn on the input power supply and slowly increase
to 24V. Check for the proper output voltages, VOUT of
25.2V and BAT of 25.2V.
5.Once the proper output voltages are established, adjust
the converter output load within the operating range (8A
maximum) and/or adjust input voltage (15V to 55V), and
observe the output voltage regulation, ripple voltage,
efficiency and other parameters.
Note: When measuring the output or input voltage ripple, do not use the long ground lead on the oscilloscope
probe. See Figure 2 for the proper scope probe technique.
Short, stiff leads need to be soldered to the (+) and (–)
terminals of an output capacitor. The probe’s ground ring
needs to touch the (–) lead and the probe tip needs to
touch the (+) lead.
2
Additional Notes:
1.CAUTION: Be careful when testing with high voltage.
High voltage can result in an electric shock if care is
not taken.
2.CAUTION: Batteries are potentially dangerous high
energy sources. Improper connection, overcharge, or
rapid discharge could result in explosion and/or file.
Please read the specification/manual of the battery
before test.
3.The combined converter output load current and battery charging current should not exceed 8A.
4.Without a proper battery, BAT output can be open or
connected with other suitable loads for test purposes.
It may be a good practice to add low ESR electrolytic
capacitors to the BAT output (≥1000µF at ≥35V, for
25.2V float voltage).
Note: These capacitors help simulate the low impedance
of a battery and maintain stability of the charge current
loop. It’s only needed for test purposes with electronic
or resistive loads, and not needed in the actual battery
application/test (where the BAT load is a battery).
5.BAT float voltage can be easily adjusted with the resistor divider R8/R10. Converter output voltage VOUT can
be adjusted with the resistor divider R9/R11. Adjust/
optimize the loop compensations if necessary.
dc2134af
DEMO MANUAL DC2134A
Quick Start Procedure
Figure 1. Proper Measurement Equipment Setup
+
VOUT
–
COUT
GND
Figure 2. Measuring Output Voltage Ripple
dc2134af
3
DEMO MANUAL DC2134A
Quick Start Procedure
100
95
90
85
EFFICIENCY (%)
80
75
70
65
60
55
50
45
15VIN, 25.2VOUT
24VIN, 25.2VOUT
55VIN, 25.2VOUT
40
35
30
0.1
1
LOAD CURRENT (A)
10
DC2134A F03
Figure 3. Efficiency vs Load Current (VOUT = 25.2V)
99.0
98.5
98.0
97.5
EFFICIENCY (%)
97.0
96.5
96.0
95.5
95.0
94.5
94.0
93.5
93.0
92.5
92.0
25.2VOUT, 8A
14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56
VIN (V)
DC2134A F04
Figure 4. Efficiency vs Input Voltage (VOUT = 25.2V, IOUT = 8A)
4
dc2134af
DEMO MANUAL DC2134A
Parts List
ITEM
QTY
REFERENCE
PART DESCRIPTION
MANUFACTURER/PART NUMBER
Required Circuit Components
1
1
C1
CAP, CHIP, X7S, 0.1µF, 10%, 100V, 0603
TDK, C1608X7S2A104K
2
2
C2,C3
CAP, ELEC., 56µF, 20%, 63V, 10X12.5
SUNCON, 63HVH56M
3
1
C4
CAP, CHIP, C0G, 100pF, 10%, 16V, 0402
AVX, 0402YA101KAT9A
4
1
C6
CAP., MLCC, 6800pF, 50V,10%, 0603
AVX,ESD35C682K4T2A-18
5
1
C8
CAP, CHIP, C0G, 47pF, 10%, 50V, 0603
AVX., 06035A470KAT2A
6
1
C11
CAP, CHIP, X5R, 4.7µF, 10%, 6.3V, 0603
AVX, 06036D475KAT2A
7
1
C12
CAP, CHIP, X7R, 0.033µF, 10%, 25V, 0402
TDK, C1005X7R1E333K
8
4
C14, C18, C27, C28
CAP, CHIP, X5R, 10µF, 20%, 35V, 1210
AVX, 1210DD106MAT2A
9
2
C15, C17
CAP, ELEC., 220µF, 20%, 35V 10X12.5
SUNCON, 35HVH220M
10
2
C16, C23
CAP, CHIP, X7S, 4.7µF, 20%, 100V, 1210
TDK,C3225X7S2A475M
11
3
C5, C19, C20
CAP, CHIP, X5R,0.22µF, 10%, 25V, 0603
AVX, 06033D224KAT2A
12
1
C21
CAP, CHIP, X5R, 10µF, 20%, 6.3V, 0805
AVX., 08056D106KAT2A
13
2
C39, C40
CAP, CHIP, X7R,0.22µF, 20%, 10V, 0603
AVX, 0603ZC224MAT2A
14
2
D1, D2
DIODE, SMT, SUPERBARRIER, 60V, 0.5A, SOD123
DIODES INC., SBR0560S1-7
15
1
D3
DIODE, LED, RED, SMT, 0603
WÜRTH, 150060SS75000
16
1
D4
DIODE, LED, GREEN, 0603
WÜRTH, 150060VS75000
17
1
D6
DIODE., SMT SCHOTTKY BARRIER RECTIFIER, SMA
VISHAY, B360A-E3
18
1
L1
IND, SMT, 5.6µH
WÜRTH, 7443556560
19
1
M1
P-CHANNEL MOSFET, –30V PowerPAKS08
VISHAY, Si7145DP-T1-GE3
20
2
M2, M4
N-CHANNEL MOSFET, 60V, PowerPAKS08
VISHAY, SiR664DP-T1-GE3
21
2
M3, M7
N-CHANNEL MOSFET, 40V, PowerPAKS08
VISHAY, SiR422DP-T1-E3
22
1
RCBAT1
RES, CHIP, 0.008Ω, 1%, 1W, 2512
VISHAY, WSL25128L000FEA
23
2
RCBRB1, RCBRT1
RES, CHIP, 0.002Ω, 1%, 1W, 2512
VISHAY, WSL25122L000FEA
24
2
R1, R13
RES, CHIP, 100kΩ, 5%, 0402
VISHAY, CRCW0402100KJNED
25
1
R2
RES, CHIP, 510kΩ, 5%, 0402
VISHAY, CRCW0402510KJNED
26
1
R4
RES, CHIP, 51kΩ, 1%, 0402
VISHAY, CRCW040251K0FKED
27
3
R6, R7, R19
RES, CHIP, 20Ω, 5%, 0402
VISHAY, CRCW040220R0JNED
28
1
R8
RES, CHIP, 226kΩ, 0.1%, 0603
VISHAY, TNPW06030F226BEEA
29
1
R9
RES, CHIP, 226kΩ, 1%, 0603
VISHAY, CRCW0603226KFKEA
30
1
R10
RES, CHIP, 24.9kΩ, 0.1%, 0402
VISHAY, TNPW04020F24K9BEED
31
1
R11
RES, CHIP, 24.9kΩ, 1%, 0402
VISHAY, CRCW040224K9FKED
32
1
R14
RES, CHIP, 10kΩ, 1%, 0402
VISHAY, CRCW040210K0FKED
33
1
R15
RES, CHIP, 36kΩ, 1%, 0603
VISHAY, CRCW060336K0FKEA
34
1
R16
RES, CHIP, 47kΩ, 1%, 0603
VISHAY, CRCW060347K0FKEA
35
2
R18, R20
RES, CHIP, 100Ω, 5%, 0402
VISHAY, CRCW0402100RJNED
36
2
R26, R27
RES, CHIP, 3kΩ, 5%, 0402
VISHAY, CRCW04023K00JNED
37
1
U1
IC, LTC4020EUHF, 5mm × 7mm QFN-38
LINEAR TECH., LTC4020EUHF
dc2134af
5
DEMO MANUAL DC2134A
Parts List
ITEM
QTY
REFERENCE
PART DESCRIPTION
MANUFACTURER/PART NUMBER
Additional Demo Board Circuit Components
1
0
C13, C7, C9, C10,
C30, C31 (OPT)
CAP, CHIP, OPT 0603
OPT
2
0
C22, C24, C25 (OPT)
CAP, CHIP, OPT 0402
OPT
3
0
C26, C29, C32-C38
(OPT)
CAP, CHIP, OPT 1210
OPT
4
0
D5 (OPT)
DIODE, OPT SMA
OPT
5
0
D7 (OPT)
DIODE, OPT SOD123
OPT
6
0
M5, M6, M8, M9
(OPT)
N-CHANNEL MOSFET, OPT PowerPAKS08
OPT
7
0
R3 (OPT)
RES, OPT 0402
OPT
8
8
R21-25, R34, R35,
R37
RES, CHIP, 0Ω JUMPER, 0402
VISHAY, CRCW04020000Z0ED
9
0
R17, R31, R32 (OPT)
RES, OPT 0603
OPT
10
1
R36
RES, CHIP, 0Ω JUMPER, 0603
VISHAY, CRCW06030000Z0EA
11
1
R38
RES, CHIP, 5.1, 5%, 0805
VISHAY,CRCW08055R10JNEA
TURRET, 0.09" DIA
MILL-MAX, 2501-2-00-80-00-00-07-0
Hardware: For Demo Board Only
6
1
8
E1, E2, E5, E9, E10,
E13, E14, E17
2
6
E3, E4, E11, E12, E15, VERTICAL BANANA JACK, 575-4
E16
KEYSTONE, 575-4
3
1
JP1
HEADER, HD2X3-079
WÜRTH, 62000311121
4
1
XJP1
SHUNT, .079" CENTER
WÜRTH, 60800213421
5
4
STAND-OFF, NYLON (SNAP ON), 0.375" TALL
KEYSTONE, 8832 (SNAP ON)
dc2134af
Information furnished by Linear Technology Corporation is believed to be accurate and reliable.
However, no responsibility is assumed for its use. Linear Technology Corporation makes no representation that the interconnection of its circuits as described herein will not infringe on existing patent rights.
A
B
C
D
VIN
VIN
E17
E9
E5
E2
E4
E3
E1
1
3
5
JP1
MODE
C3
56uF
63V
63HVH56M
2 CC/CV
4 CC
6 LEAD-ACID
+
C4
100pF
16V
C24
OPT
C2
56uF
63V
63HVH56M
R14
10k
+
5



INT_VCC
NTC
SGND
SHDN
GND
GND
15V - 55V
5
C23
C16
4.7uF
100V
1210
R13
100k
0
R37
C25
OPT
R3
OPT
R1
100k
C13
OPT
0603
R17
OPT
0603
R11
24.9k
1%
R10
24.9k
0.1%
C5
0.22uF
0603
R9
226k
0603
1%
R7
20
R6
20
C39
0.22uF
0603
R8
226k
0603
0.1%
VOUT
R4
51k
VBAT
C40
0.22uF
0603
C34
C33
C32
C29
OPT
1210
R2
510k
4
4
8
14
11
24
16
18
17
26
19
25
15
10
9
RT
TIMER
MODE
CSOUT
NTC
FBG
VFB
VFBMAX
VFBMIN
ILIMIT
RNG/SS
36
PVIN
C1
3
29
SGND
35
PGND
39
SGND
Vc
ITH
BAT
BGATE
CSN
CSP
BG2
TG2
SENSBOT
SENSGND
BG1
TG1
SW1
SW2
STAT1
BST1
BST2
STAT2
INT_Vcc
SENSVIN
SENSTOP
0.1uF
100V 0603
U1
LTC4020EUHF
SGND
VIN_REG
SHDN
R38
5.1
0805
28
27
20
21
22
23
33
31
5
4
37
1
38
32
12
2
30
13
34
7
6
0
R22
0
R24
1 2 3
1 2 3
3
C7
OPT
0603
RCBRB1
0.002
1W
2512
C6
6.8nF
0603
R15
36k
0603
R34
0
R21
0
C12
0.033uF
4
C8
47pF
0603
R16
47k
0603
0
R35
4
1 2 3
0603
D6
B360A
C20
0.22uF
25V
0603
100
R18
100
R20
C31
OPT
0603
R32
OPT
0603
4
3 2 1
4
M8
OPT
C10
OPT
0603


2
R23
0
4
RCBAT1
0.008
1W
2512


1210
35V
C18
10uF


1210
35V
C27
10uF



C28
10uF
VBAT
+
E11
E12
E10
GND
GND
VOUT
21V - 28V
8A MAX
VOUT
GND
BAT
25.2V FLOAT
6.3A MAX
BAT
E13
E15
C17
220uF
35V
35HVH220M
1






 

 



 


C26
OPT
1210
+ C15
220uF
35V
35HVH220M
E16
E14




TECHNOLOGY
1210
35V
C38
C37
C36
C35
OPT
1210


1



  


1210
35V
C14
10uF
M1
Si7145DP
1 2 3
5 6 7 8
R25
0
4
VOUT

3 2 1
8 7 6 5
4
8 7 6 5
M3
SiR422DP
M9
OPT
D4
GRN
M7
3 2 1 SiR422DP
8 7 6 5
3 2 1
8 7 6 5
D7
OPT
D3
RED

C11
4.7uF
6.3V
0603
R19
20
D5
OPT
3K
R26
R27
3K
D2
SBR0560S1
WURTH 7443556560
L1
5.6uH
C19
0.22uF
25V
0603
D1
SBR0560S1
INT_VCC
2








C9
OPT
0603
1 2 3
M5
OPT
5 6 7 8
C30
OPT
0603
R31
OPT 0603
R36
0
M6
OPT
5 6 7 8
5 6 7 8
4
RCBRT1
0.002
1W
2512
5 6 7 8
M4
SiR664DP
M2
SiR664DP
4
C21
10uF
6.3V
0805
C22
OPT
3
A
B
C
D
DEMO MANUAL DC2134A
Schematic Diagram
dc2134af
7
DEMO MANUAL DC2134A
DEMONSTRATION BOARD IMPORTANT NOTICE
Linear Technology Corporation (LTC) provides the enclosed product(s) under the following AS IS conditions:
This demonstration board (DEMO BOARD) kit being sold or provided by Linear Technology is intended for use for ENGINEERING DEVELOPMENT
OR EVALUATION PURPOSES ONLY and is not provided by LTC for commercial use. As such, the DEMO BOARD herein may not be complete
in terms of required design-, marketing-, and/or manufacturing-related protective considerations, including but not limited to product safety
measures typically found in finished commercial goods. As a prototype, this product does not fall within the scope of the European Union
directive on electromagnetic compatibility and therefore may or may not meet the technical requirements of the directive, or other regulations.
If this evaluation kit does not meet the specifications recited in the DEMO BOARD manual the kit may be returned within 30 days from the date
of delivery for a full refund. THE FOREGOING WARRANTY IS THE EXCLUSIVE WARRANTY MADE BY THE SELLER TO BUYER AND IS IN LIEU
OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED, OR STATUTORY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS
FOR ANY PARTICULAR PURPOSE. EXCEPT TO THE EXTENT OF THIS INDEMNITY, NEITHER PARTY SHALL BE LIABLE TO THE OTHER FOR
ANY INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES.
The user assumes all responsibility and liability for proper and safe handling of the goods. Further, the user releases LTC from all claims
arising from the handling or use of the goods. Due to the open construction of the product, it is the user’s responsibility to take any and all
appropriate precautions with regard to electrostatic discharge. Also be aware that the products herein may not be regulatory compliant or
agency certified (FCC, UL, CE, etc.).
No License is granted under any patent right or other intellectual property whatsoever. LTC assumes no liability for applications assistance,
customer product design, software performance, or infringement of patents or any other intellectual property rights of any kind.
LTC currently services a variety of customers for products around the world, and therefore this transaction is not exclusive.
Please read the DEMO BOARD manual prior to handling the product. Persons handling this product must have electronics training and
observe good laboratory practice standards. Common sense is encouraged.
This notice contains important safety information about temperatures and voltages. For further safety concerns, please contact a LTC application engineer.
Mailing Address:
Linear Technology
1630 McCarthy Blvd.
Milpitas, CA 95035
Copyright © 2004, Linear Technology Corporation
8
dc2134af
Linear Technology Corporation
LT 0414 • PRINTED IN USA
1630 McCarthy Blvd., Milpitas, CA 95035-7417
(408) 432-1900
●
FAX: (408) 434-0507 ● www.linear.com
 LINEAR TECHNOLOGY CORPORATION 2014
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