DC2118A - Demo Manual

DEMO MANUAL DC2118A
LTC4040
Battery Charger and Backup
Power Manager
DESCRIPTION
Demonstration circuit 2118A is a combination step-down
battery charger and step-up battery backup regulator using the LTC®4040 monolithic system power manager. The
DC2118A has an input voltage range from 4.8V to 5.5V
with overvoltage protection (OVP) to 40V, as limited by
the external MOSFET. The input current is monitored to
prioritize the load up to the 2.5A threshold before charge
current is reduced.
Battery Charging
As initially configured, DC2118A is programmed for 2A
charge current limit when in charge mode. The charge
voltage is jumper-selectable in 8 discrete steps from
3.45V to 3.6V for LiFePO4 chemistry or 3.95V to 4.1V for
Li-ion chemistry, according to the F2/F1/F0 programming
input settings.
The charge current limit is adjustable via the PROG pin
resistor. End-of-charge status is triggered by current
falling below C/8 and indicated by the CHRG LED. The
optional NTC input provides temperature fault detection
PERFORMANCE SUMMARY
PARAMETER
and status indicated by the FAULT LED. Charging can be
enabled/disabled with the ENCHG jumper.
Battery Backup
Following an input power failure, the circuit automatically
shifts to battery backup boost mode to regulate the VSYS
output rail. The backup mode system output voltage is
initially programmed for 5V. The input power failure status
is indicated by the PFO LED.
If VSYS ever falls below the programmed reset threshold
voltage, the RST LED will change states to indicate the
need to reset the system and recharge the battery. Backup
regulation can be enabled/disabled with the ENBST jumper.
For convenience, all LEDs can be disabled with the LED
jumper to reduce the quiescent current of the system.
Design files for this circuit board are available at
http://www.linear.com/demo/DC2118A
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
CONDITIONS
VALUE
Charge Mode
Input Voltage Range
4.8V to 5.5V
Overvoltage Protection Range
Limited by Q1 BVDSS
Input Current Limit
R7 = 10mΩ
5.5V to 40V
2.5A
Default Charging Voltage
F2 = 1 (Li-Ion), F1 = 1, F0 = 1
Charging Current
RPROG = 1.00k
4.10V
2.0A
Safety Timer Period
F2 = 1 (Li-Ion)
4Hr
F2 = 0 (LiFePO4)
2Hr
Backup Mode
DCIN Input Power Fail Threshold
R2 = 357k, R27 = 121k, DCIN Falling
4.8V
System Output Voltage
R4 = 1.69M, R5 = 324k
5.0V
Backup Battery Voltage Range
2.7V to 5.0V
System Reset Threshold
R4 = 1.69M, R5 = 324k, VSYS Falling
4.6V
Backup Boost Efficiency
VBAT = 3.6V, ISYS = 2A, VOUT = 5V
89%
dc2118af
1
DEMO MANUAL DC2118A
PERFORMANCE SUMMARY
4.2
2.00
TIMER
START
1.75
VBAT
IBAT (A)
IBAT
1.00
3.4
TERMINATION
3.2
CHRG
0.75
3.0
TIMER
RESTART
0.50
0.25
0
2.8
1
2
3
4 5 6
TIME (Hrs)
7
8
9
10
5
POWER
FAIL
4
VBAT
3
2
2
1
0
0:00
2.4
VSYS
IBAT
dc2118 F01
1
9600mAh Li-Ion
VSYS = 5V
ISYS = 2A
2.6
C/8
0
3
BACKUP
STARTED
0:30
1:00
1:30
TIME (Hrs)
IBAT (A)
1.25
4
VBAT + VCHRG (V)
1.50
4.0
9600mAh Li-Ion
3.8
VIN = 5V
RPROG = 1.00k
3.6
5
VBAT (V)
2.25
0
2:30
2:00
dc2118a F02
Figure 1. Typical Battery Charge Cycle
Figure 2. Typical Battery Discharge Cycle
QUICK START PROCEDURE
Demonstration circuit 2118A is easy to set up to evaluate
the performance of LTC4040. Refer to Figure 2 for proper
measurement equipment setup and follow the procedure
below.
1. The jumpers are set as below for a typical 4.1V charging application:
JP1
NTC
INT
JP2
ENCHG
ON
JP3
ENBST
ON
JP4
F11
JP5
F01
JP6
LEDS
JP7
F21
ON
2. With all power off, connect the input supply, system
load, and meters as shown in Figure 3.
Charge Mode
3. Connect the battery as shown in Figure 3 to charge at
4.1V, 2A. For alternate charge voltage settings, refer
to Table 1.
4. Turn on the input power supply to evaluate charge
mode. Adjust the input voltage and current limit to
the desired value.
NOTE: While DC2118A is robust to overvoltage conditions up to 40V on DCIN, DO NOT exceed this limit or
damage may occur to MOSFET Q1 and IC U1.
5. Turn on and adjust the system load as necessary.
Charging current will be limited when input current
exceeds 2.5A.
6. The CHRG LED will toggle off when the charge current
has dropped below 250mA. The timer will continue to
run and charging will continue until the timer period
ends. Multiple timer periods may be necessary to fully
charge a large capacity battery, such as the one used
to obtain Figure 1.
7. If the battery voltage does not increase above the low
battery threshold during the precondition time or the
thermistor value exceeds the normal range, CHRG will
toggle off and FAULT will toggle on indicating a bad
battery.
Backup Mode
8. Turn off the input power supply to evaluate backup
mode.
9. The PFO LED will toggle on indicating input power
failure.
10.Adjust the system load as necessary.
dc2118af
2
DEMO MANUAL DC2118A
QUICK START PROCEDURE
11.Total backup runtime is based on battery capacity,
circuit efficiency, and system load. Figure 2 shows an
example discharge curve with constant current system
load.
12.When VSYS falls below 7.5% of the programmed value,
or 4.6V, then RST will toggle on.
Optional
IBAT =
2000 • VPROG
RPROG
Where RPROG = R6 = 1kΩ.
4. Monitor the CLPROG pin voltage for a scaled representation of the instantaneous total input current according
to the relationship:
IVIN =
VCLPROG
32 •RS
1. Use an external thermistor connected between EXTNTC
and GND as shown in Figure 3, with the NTC jumper,
JP1, set to EXT.
2. Change the setting of the ENCHG, JP2, or ENBST, JP3,
jumpers to enable/disable charging and backup boost
respectively.
5. All status LEDs can be disconnected to reduce the
quiescent current by setting the LEDS jumper, JP6 to
OFF.
3. Monitor the PROG pin voltage for a scaled representation of the instantaneous charge current according to
the relationship:
Where RS = R7 = 10mΩ.
6. External VDD can be used by connecting to EXTVDD
and installing 0Ω for R16.
Table 1. Battery Charge Voltage Jumper Settings
+
+
JP7
JP5
JP4
F2 = 1 (Li-Ion) F2 = 0 (LiFePO4)
F1
F0
3.95
3.45
0
0
4.00
3.50
0
1
4.05
3.55
1
0
4.10
3.60
1
1
+
–
Figure 3. Proper Measurement Equipment Setup
dc2118af
3
DEMO MANUAL DC2118A
PARTS LIST
ITEM
QTY
REFERENCE
PART DESCRIPTION
MANUFACTURER/PART NUMBER
Required Circuit Components
1
1
CIN1
CAP., X7R, 0.1µF, 10%, 50V, 0805
AVX, 08055C104KAT4A
2
2
COUT1, COUT2
CAP., X5R, 100µF, 20%, 10V, 1210
MURATA, GRM32ER61A107ME20L
3
1
C2
CAP., X7R, 2.2µF, 10%, 6.3V, 0805
MURATA, GRM21BR70J225MA01L
4
1
C3
CAP., X5R, 10µF, 20%, 10V, 0603
AVX, 0603ZD106MAT2A
5
2
C7, C9
CAP., X7R, 0.1µF, 10%, 10V, 0603
AVX, 0603ZC104KA72
6
1
L1
INDUCTOR, 2.2µH
COILCRAFT, XAL5030-222ME
7
1
Q2
XSTR, MOSFET N-CHANNEL, 20-V
VISHAY, SiS424DN-T1-GE3
8
1
R2
RES., 357k, 1/16W, 1%, 0402
VISHAY, CRCW0402357KFKED
9
1
R4
RES., 1.69MΩ, 1/16W, 1%, 0402
VISHAY, CRCW04021M69FKED
10
1
R5
RES., 324k, 1/16W, 1%, 0402
VISHAY, CRCW0402324KFKED
11
1
R6
RES., 1.00k, 1/10W, 1%, 0603
VISHAY, CRCW06031K00FKED
12
1
R7
RES., 0.01Ω, 1/4W, 1%, 1206
VISHAY, WSL1206R0100FEB
13
1
R8
RES., 10k, 1/16W, 1%, 0402
VISHAY, CRCW040210K0FKED
14
1
R11
RES., 0Ω JUMPER, 0402
VISHAY, CRCW04020000Z0ED
15
1
R25
RES., 1Ω, 1/8W, 5%, 0805
VISHAY, CRCW0805100RJNEA
16
1
R27
RES., 121k, 1/16W, 1%, 0402
VISHAY, CRCW040260K4FKED
17
1
U1
I.C., LTC4040EUFD
LINEAR TECH, LTC4040EUFD#PBF
Additional Demo Board Circuit Components
1
0
C4, C6
CAP., 0402
OPT
2
1
C5
CAP., X5R, 0.1µF, 10%, 10V, 0402
MURATA, GRM155R71A104KA01J
3
1
D1
DIODE, SCHOTTKY
NXP, BAT46WJ
4
1
D3
DIODE, LED, SMT, RED, 0603
LITE-ON, LTST-C193KRKT-5A
5
2
D4, D5
DIODE, LED, SMT, ORANGE, 0603
LTIE-ON, LTST-C193KFKT-5A
6
1
D6
DIODE, LED, SMT, GREEN, 0603
LITE-ON, LTST-C193KGKT-5A
7
1
Q1
XSTR, MOSFET N-CHANNEL, 40-V
VISHAY, SiS488DN-T1-GE3
8
1
RNTC
RES., 10k, 1/16W, 1%, 0402
VISHAY, CRCW040210K0FKED
9
1
R1
RES., 6.2k, 1/8W, 5%, 0805
VISHAY, CRCW08056K20JNEA
10
0
R12, R13, R16
RES., 0402
OPT
11
4
R21-R24
RES., 390Ω, 1/16W, 5%, 0402
VISHAY, CRCW0402390RJNED
Hardware: For Demo Board Only
1
18
E1, E2, E4-E19
TEST POINT, TURRET, 0.094"
MILL-MAX, 2501-2-00-80-00-00-07-0
2
7
JP1-JP7
3 PIN JUMPER, 2mm
SAMTEC TMM-103-02-L-S
3
7
XJP1-XJP7
SHUNT, 2mm
SAMTEC 2SN-BK-G
4
4
STAND-OFF
STAND-OFF, NYLON
KEYSTONE, 8834(SNAP ON)
dc2118af
4
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
E15
E14
E11
E12
E13
E17
E2
E18
E9
D6
GRN
R21
390
5%
CIN1
0.1uF
50V
0805
R25
1
5%
0805
D3
RED
R24
390
5%
F2=0(LIFEP04)
3.45V
3.50V
3.55V
3.60V
F2=1(LI-ION)
3.95V
4.00V
4.05V
4.10V
5
4. LIMITED BY Q1 VDS RATING.
3.
2. ALL CAPACITORS ARE 0603, X7R.
1. ALL RESISTORS ARE 0402, 1%.
1
1
0
0
F1
NOTES: UNLESS OTHERWISE SPECIFIED,
GND
BSTOFF
E10
CHGOFF
CLPROG
CHRG
FAULT
PFO
RST
GND
GND
4.8V - 5.5V
1
0
1
0
F0
JP6
D5
ORG
R22
390
5%
3
2
1
LEDS
(DEFAULT)
D4
ORG
R23
390
5%
VDD
R2
357k
1%
4
ON
OFF
JP2
ENCHG
OPT
C6
121k 1%
R27
OFF
ON
3
2
1
VDD
ON
OFF
JP3
3
2
1
0.01 1%
1206
R7
JP4
F0
3
2
1
VDD
3
2
1
3
2
1
VDD
JP5
F1
0
1
17
23
21
22
10
18
1
3
2
SCALE = NONE
3
2
1
VDD
2
0
1
10k
C7
0.1uF
0603
INT
DATE:
N/A
SIZE
C5
0.1uF
VDD
E4
VSYS
GND
EXTVDD
E19
PROG
E7
E16
EXTNTC
1
SHEET 1
LTC4040EUFD24
DEMO CIRCUIT 2118A
4
OF 1
REV.
1630 McCarthy Blvd.
Milpitas, CA 95035
Phone: (408)432-1900 www.linear.com
Fax: (408)434-0507
LTC Confidential-For Customer Use Only
OPT
R16
E8
SEE NOTE 3
2A CHARGE
VBAT
GND
E6
E5
5V IN BACKUP
D1
BAT46WJ
VSYS
VIN
COUT2
100uF
10V
1210
VSYS
1
BATTERY CHARGER
BACKUP POWER MANAGER
TECHNOLOGY
EXT
NTC
JP1
10k
R8
C3
10uF, 10V
0603
OPT
R13
R12
OPT
COUT1
100uF
10V
1210
Thursday, April 30, 2015
IC NO.
TITLE: SCHEMATIC
JP7
F2
0
R11
R5 324k
R4
1.69M
RNTC
L1
2.2uH
COILCRAFT
XAL5030-222ME
C4
OPT
APPROVALS
NTC
BAT
SW
SW
RSTFB
BSTFB
VSYS
C9
0.1uF
10V
7
6
5
Q2
SiS424DN 8
THIS CIRCUIT IS PROPRIETARY TO LINEAR TECHNOLOGY AND
SUPPLIED FOR USE WITH LINEAR TECHNOLOGY PARTS.
CUSTOMER NOTICE
0
1
R6
1.00k
1%
0603
BSTOFF
CHGOFF
CLPROG
CHRG
FAULT
PFO
RST
PFI
VIN
LINEAR TECHNOLOGY HAS MADE A BEST EFFORT TO DESIGN A
CIRCUIT THAT MEETS CUSTOMER-SUPPLIED SPECIFICATIONS;
HOWEVER, IT REMAINS THE CUSTOMER'S RESPONSIBILITY TO PCB DES.
VERIFY PROPER AND RELIABLE OPERATION IN THE ACTUAL
APPLICATION. COMPONENT SUBSTITUTION AND PRINTED
APP ENG.
CIRCUIT BOARD LAYOUT MAY SIGNIFICANTLY AFFECT CIRCUIT
PERFORMANCE OR RELIABILITY. CONTACT LINEAR
TECHNOLOGY APPLICATIONS ENGINEERING FOR ASSISTANCE.
VDD
5
4
3
8
9
20
11
19
U1
C2
2.2uF
6.3V
0805
3
2
1
LTC4040EUFD
ENBST
R1
6.2k
0805
Q1
8 SiS488DN
7
6
5
OV PROTECTION
4
E1
16
OVSNS
6
VIN
7
CLN
25
PROG
2
IGATE
15
14
F1
13
GND
F0
24
VSYS
4
F2
12
3
1
SEE NOTE 4
2
4
3
DCIN
5
A
B
C
D
DEMO MANUAL DC2118A
SCHEMATIC DIAGRAM
dc2118af
5
DEMO MANUAL DC2118A
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
dc2118af
6
Linear Technology Corporation
LT 0615 • PRINTED IN USA
1630 McCarthy Blvd., Milpitas, CA 95035-7417
(408) 432-1900
●
FAX: (408) 434-0507 ● www.linear.com
 LINEAR TECHNOLOGY CORPORATION 2015
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