ACT2813 Demo Board Application Report Rev 0, 12-Mar-2015 Dedicated 5V/2.4A Power Bank Solution FEATURES 2.4A battery charge current 5V/2.4A boost output current 5.0V+/- 100mV output voltage Single chip integration solution with minimal component count Prioritized power path from input to output 91% charge efficiency and 94% discharge efficiency Accommodation for 10mA-3000mA input current Patent-pending constant output current control Battery disconnected at output short to ground <10uA battery drain current in HZ mode Automatic shut-down at no load and turns on by push button or device plug-in 4 LEDs indicating battery level and charge status with battery impedance compensation Preconditioning, fast charge, top off and end of charge in battery charge mode Battery OTP, OVP and OCP Charge current foldback at 110℃ die temperature IC over temperature protection FCQFN4x4-20 package SPECIFICATION Input voltage 4.7 - 5.5V Active-Semi, Inc. Boost output voltage Battery charge current Boost output current 5.0V 2.4A 2.4A -1- www.active-semi.com ACT2813: Dedicated 5V/2.4A Power Bank Solution TABLE OF CONTENT 1. DEMO BOARD PHOTOS................................................................................................................................................... 3 2. SCHEMATICS.......................................................................................................................................................................3 3. BILL OF MATERIALS........................................................................................................................................................ 4 4. PCB LAYOUT GUIDANCE................................................................................................................................................. 5 5. FUNCTIONAL TEST............................................................................................................................................................ 6 6. 5.1 BATTERY CHARGE V/I PROFILE.......................................................................................................................................6 5.2 CHARGE EFFICIENCY....................................................................................................................................................... 6 5.3 BOOST OUTPUT REGULATION......................................................................................................................................... 7 5.4 BOOST EFFICIENCY AND POWER LOSS (TA=25℃)..........................................................................................................7 5.5 BATTERY LEAKAGE CURRENT IN HZ MODE................................................................................................................... 8 5.6 BOOST STANDBY POWER (TA=25℃)...............................................................................................................................8 5.7 BOOST CONSTANT CURRENT AND CONSTANT VOLTAGE REGULATION (TA=27℃).........................................................9 5.8 RIPPLE AND NOISE........................................................................................................................................................ 10 5.9 LOAD DYNAMIC RESPONSE LOAD STEP (VBAT=3.7V).................................................................................................10 5.10 SYSTEM MANAGEMENT................................................................................................................................................. 10 5.11 LED INDICATION........................................................................................................................................................... 11 5.12 KEY COMPONENTS TEMPERATURE TEST (TA=27℃, BURNING FOR 2 HOURS)...............................................................11 EMI TEST.............................................................................................................................................................................12 Active-Semi, Inc. www.active-semi.com -2- ACT2813: Dedicated 5V/2.4A Power Bank Solution 1. Demo Board Photos (DEMO BOARD SIZE: 46.4mm*21.2mm) Push button LED indication OUTPUT INPUT 2. Schematics R5 R6 LED2 LED3 LED4 RIMC BLVS LED1 TH ICST HZ R17 R4 R12 R15 R3 ACT2813 IOST R16 PB R13 CSP C6 nPG C7 VBAT/CSN PGND SW AGND SW VOUT R10 D2 VIN Input USB R8 R7 + D- C10 C2 R9 R2 D+ - C1 C5 D1 BAT C9 R1 L1 Q1 + R18 D- Q2 R19 C11 C3 C4 Output USB C8 R20 R21 Active-Semi, Inc. www.active-semi.com -3- D+ - R22 R23 ACT2813: Dedicated 5V/2.4A Power Bank Solution 3. Bill of Materials ITEM REFERENCE DESCRIPTION 1 L1 Core, 6.5*3*3 Dip, 2.2uH, 6A, Rdson=5mΩ 1 Sunlord 2 Q1 AO4453, Rdson=19mΩ at VGS = - 4.5 V 1 AOS 3 Q2 MMBT3906 1 Vishay 4 D1 SBR3U20SA, 20V/3A Schottky 1 Diodes 5 D2 1N4148, Vf=0.7V, 75V Schottky 1 Vishay 6 C1 Ceramic capacitor, 4.7uF/10V, X7R, 0805 1 Murata/TDK 7 C2,C3,C4,C9 Ceramic capacitor, 22uF/10V, X7R, 1206 4 Murata/TDK 8 C5,C6 Ceramic capacitor, 2.2uF/10V, X7R, 0603 2 Murata/TDK 9 C7 Ceramic capacitor, 10nF/10V, X7R, 0603 1 Murata/TDK 10 C8 Ceramic capacitor, 0.1uF/10V, X7R, 0603 1 Murata/TDK 11 C10 Ceramic capacitor, 10uF/10V, X7R, 0805 1 Murata/TDK 12 C11 Ceramic capacitor, 4.7nF/10V, X7R, 0603 1 Murata/TDK 13 R1,R2 Chip Resistor, 50mΩ, 1/4W, 1%, 1206 2 Murata/TDK 14 R3,R10 Chip Resistor, 100kΩ, 1/10W, 1%, 0603 2 Murata/TDK 15 R4 Chip Resistor, 48kΩ, 1/10W, 1%, 0603 1 Murata/TDK 16 R5 Chip Resistor, 68kΩ, 1/10W, 5%, 0603 1 Murata/TDK 17 R6 Chip Resistor, 60.4kΩ, 1/10W, 1%, 0603 1 Murata/TDK 18 R7,R8,R12 Chip Resistor, 0Ω, 1/10W, 1%, 0603 3 Murata/TDK 19 R9 Chip Resistor, 2.7Ω, 1/8W, 1%, 0805 1 Murata/TDK 20 R13 Chip Resistor, 100Ω, 1/10W, 1%, 0603 1 Murata/TDK 21 R15 Chip Resistor, 715kΩ, 1/10W, 5%, 0603 1 Murata/TDK 22 R16,R19 Chip Resistor, 200kΩ, 1/10W, 5%, 0603 2 Murata/TDK 23 R17 Chip Resistor, 10kΩ, 1/10W, 5%, 0603 1 Murata/TDK 24 R18 Chip Resistor, 0.47Ω, 1/4W, 1%, 1206 1 Murata/TDK 25 R20,R22 Chip Resistor, 43.2kΩ, 1/10W, 1%, 0603 2 Murata/TDK 26 R21,R23 Chip Resistor, 49.9kΩ, 1/10W, 1%, 0603 2 Murata/TDK 27 LED1,LED2 LED3,LED4 LED, 0603, Blue 4 LED Manu 28 PB Push Button 1 LED Manu 29 USB 10.2*14.6*7mm, 4P, DIP 1 30 Micro-USB MICRO USB 5P/F SMT B 1 31 U1 IC, ACT2813, FCQFN 4x4-20 1 Active-Semi, Inc. www.active-semi.com -4- QTY MANUFACTURER ACT ACT2813: Dedicated 5V/2.4A Power Bank Solution 4. PCb Layout Guidance When laying out the printed circuit board, the following checklist should be used to ensure proper operation of the IC. 1. Place input decoupling ceramic capacitor C1 and R9 as close to VIN pin as possible. Resistor R9 is added in series with capacitor C1 to damp the potential LC resonance. 2. Use copper plane for power GND for best heat dissipation and noise immunity. 3. Place CSP and CSN capacitor C7 (10nF) close to CSP and CSN pin as possible, use Kevin Sense from sense resistor R1 and R2 to CSP and CSN pins. 22uF decoupling capacitor is added close to VBAT pin. 4. Place the ceramic capacitor C2 and D1 as close to VOUT and PGND as possible, SW goes under the C2 (recommend C2 to use 1206 size). SW pad is a noisy node switching. It should be isolated away from the rest of circuit for good EMI and low noise operation. 5. RC snubber is recommended to add across SW to PGND to reduce EMI noise. *C2 must be placed close to VOUT and PGND pins Active-Semi, Inc. www.active-semi.com -5- ACT2813: Dedicated 5V/2.4A Power Bank Solution 5. Functional Test 5.1 Battery Charge V/I Profile 5.2 Charge Efficiency (Vin=5V and charge current set at 2400mA) Battery voltage (V) 3.0 3.2 3.7 4.1 Efficiency (%) 89.8 90.1 91.1 91.3 Active-Semi, Inc. www.active-semi.com -6- ACT2813: Dedicated 5V/2.4A Power Bank Solution 5.3 Boost Output Regulation Output Voltage Output Voltage at Load at 2.4A Output No Load Regulation (V) (V) (%) 3.2 5.01 5.05 0.79 3.7 5.01 5.05 0.79 4.1 5.01 5.05 0.79 Battery Voltage (V) 5.4 Boost Efficiency and Power Loss (Ta=25℃) Vbat Efficiency (%) Io=500mA Io=1000mA Io=1500mA Io=2000mA Io=2400mA 3.2V 92.5 92.7 90.9 88.7 86.2 3.7V 93.2 94.0 92.8 91.0 89.5 4.1V 94.0 95.1 94.4 93.0 91.8 (Note: bigger inductor size can improve efficiency further) Active-Semi, Inc. www.active-semi.com -7- ACT2813: Dedicated 5V/2.4A Power Bank Solution 5.5 Battery Leakage Current in HZ Mode Battery Leakage Power Loss (µA) (µW) Vbat=2.8V 5.3 14.8 Vbat=3.2V 5.8 18.6 Vbat=3.7V 6.6 24.4 Vbat=4.1V 7.4 30.3 Test Conditions 5.6 Boost Standby Power (Ta=25℃) Active-Semi, Inc. www.active-semi.com Battery Voltage(V) 3.2 3.7 4.1 Boost Standby Current(mA) 0.86 0.76 0.72 Boost Standby Power(mW) 2.75 2.81 2.95 -8- ACT2813: Dedicated 5V/2.4A Power Bank Solution 5.7 Boost Constant Current and Constant Voltage Regulation (Ta=27℃) Vbat=3.2V CC Load CV Load Active-Semi, Inc. www.active-semi.com Vbat=3.7V Vbat=4.1V Vout(V) Iout(mA) Vout (V) Iout(mA) Vout(V) Iout(mA) 5.05 0 5.05 0 5.05 0 5.03 1000 5.03 1000 5.03 1000 5.02 2000 5.01 2000 5.01 2000 5.01 2400 5.01 2400 5 2400 5.01 2600 5.01 2600 5 2600 5 2636 5 2670 5 2696 4.85 2643 4.85 2681 4.85 2696 4.65 2653 4.6 2694 4.6 2707 4.5 2658 4.5 2698 4.5 2714 4.3 2668 4.3 2705 4.3 2720 4.27 2673 4.27 2708 4.27 2726 4.25 0 4.25 0 4.25 0 -9- ACT2813: Dedicated 5V/2.4A Power Bank Solution 5.8 Ripple and Noise (Ripple & noise are measured by using 20MHz bandwidth limited oscilloscope) Test Output Ripple at 1A Load Output Ripple at 2.4A Load Conditions (mV) (mV) Vbat=3.2V 32 76 Vbat=3.7V 31 59 Vbat=4.1V 27 54 5.9 Load Dynamic Response Load Step (Vbat=3.7V) 80mA-1000mA-80mA load step 5.10 1000mA-2400mA-1000mA load step System Management ACT2813 System Operation Flow Chart Active-Semi, Inc. www.active-semi.com - 10 - ACT2813: Dedicated 5V/2.4A Power Bank Solution 5.11 LED Indication PB time>30ms LED1 LED2 LED3 LED4 VBAT<2.9V Off Off Off Off 2.9V≤VBAT<LED1 Flash Off Off Off LED1≤VBAT<LED2 On Off Off Off LED2≤VBAT<LED3 On On Off Off LED3≤VBAT<LED4 On On On Off VBAT≥LED4 On On On On Charge Mode LED1 LED2 LED3 LED4 VBAT<LED1V Flash Off Off Off LED1≤VBAT<LED2 On Flash Off Off LED2≤VBAT<LED3 On On Flash Off LED3≤VBAT<LED4 On On On Flash VBAT>LED4 (End of Charge ) On On On On (Boost mode or HZ Mode) 5.12 Key Components Temperature Test (Ta=27℃, burning for 2 hours) Charge mode, 2.4A charge current Vbat(V) IC(℃) Diode(℃) Inductor(℃) PCB(V) 3.2V 56.8 48.6 52.6 49.7 3.7V 59.0 50.1 52.3 51.5 4.1V 63.1 53.2 54.0 54.9 Boost mode, 2.4A output current Active-Semi, Inc. www.active-semi.com Vbat (V) IC(℃) Diode(℃) Inductor(℃) PCB(℃) 3.2 94.4 80.6 82.0 77.4 3.7 76.6 65.7 67.2 64.2 4.1 68.3 59.9 60.0 58.7 - 11 - ACT2813: Dedicated 5V/2.4A Power Bank Solution 6. EMI TEST Output: 5V/2.4A Horizontal Active-Semi, Inc. www.active-semi.com - 12 - ACT2813: Dedicated 5V/2.4A Power Bank Solution Output: 5V/2.4A Vertical Active-Semi, Inc. www.active-semi.com - 13 -