MCP1630 Low-Cost
Li-Ion Battery Charger
Reference Design
User’s Guide
© 2005 Microchip Technology Inc.
DS51555B
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•
Microchip believes that its family of products is one of the most secure families of its kind on the market today, when used in the
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•
There are dishonest and possibly illegal methods used to breach the code protection feature. All of these methods, to our
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•
Microchip is willing to work with the customer who is concerned about the integrity of their code.
•
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Printed on recycled paper.
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DS51555B-page ii
© 2005 Microchip Technology Inc.
MCP1630 LOW-COST BATTERY
CHARGER USER’S GUIDE
Table of Contents
Preface ........................................................................................................................... 1
Chapter 1. Product Overview
1.1 Introduction ..................................................................................................... 5
1.2 What is the MCP1630 Low-Cost Li-Ion Battery Charger? .............................. 6
1.3 What the MCP1630 Low-Cost Li-Ion Battery Charger Kit Includes ................ 6
Chapter 2. Installation and Operation
2.1 Introduction ..................................................................................................... 7
2.2 Features ......................................................................................................... 7
2.3 Getting Started ............................................................................................... 8
Appendix A. Schematic and Layouts
A.1 Introduction .................................................................................................. 11
A.2 Board Schematic ........................................................................................ 12
A.3 Board – Assembly Drawing ........................................................................ 13
A.4 Board – Top Overlay .................................................................................. 14
A.5 Board – Top Layer ..................................................................................... 15
A.6 Board – Bottom Layer
.............................................................................. 16
Appendix B. Bill Of Materials (BOM)
Appendix C. Evaluation Board Firmware
C.1 Device Firmware .......................................................................................... 19
Worldwide Sales and Service .................................................................................... 20
© 2005 Microchip Technology Inc.
DS51555B-page iii
MCP1630 Low-Cost Battery Charger User’s Guide
NOTES:
DS51555B-page iv
© 2005 Microchip Technology Inc.
MCP1630 LOW-COST BATTERY
CHARGER USER’S GUIDE
Preface
NOTICE TO CUSTOMERS
All documentation becomes dated, and this manual is no exception. Microchip tools and
documentation are constantly evolving to meet customer needs, so some actual dialogs
and/or tool descriptions may differ from those in this document. Please refer to our web site
(www.microchip.com) to obtain the latest documentation available.
Documents are identified with a “DS” number. This number is located on the bottom of each
page, in front of the page number. The numbering convention for the DS number is
“DSXXXXXA”, where “XXXXX” is the document number and “A” is the revision level of the
document.
INTRODUCTION
This chapter contains general information that will be useful to know before using the
MCP1630 Low-Cost Li-Ion Battery Charger. Items discussed in this chapter include:
•
•
•
•
•
•
Document Layout
Conventions Used in this Guide
Recommended Reading
The Microchip Web Site
Customer Support
Document Revision History
DOCUMENT LAYOUT
This document describes how to use the MCP1630 Low-Cost Li-Ion Battery Charger
as a development tool to emulate and debug firmware on a target board. The manual
layout is as follows:
• Chapter 1. “Product Overview” – Important information about the MCP1630
Low-Cost Li-Ion Battery Charger.
• Chapter 2. “Installation and Operation” – Includes instructions on how to get
started with this demo board and a description of the demo board.
• Appendix A. “Schematic and Layouts” – Shows the schematic and layout
diagrams for the MCP1630 Low-Cost Li-Ion Battery Charger.
• Appendix B. “Bill Of Materials (BOM)” – Lists the parts used to build the
MCP1630 Low-Cost Li-Ion Battery Charger.
• Appendix C. “Evaluation Board Firmware” – Provides information about the
application firmware and where the source code can be found.
© 2005 Microchip Technology Inc.
DS51555B-page 1
MCP1630 Low-Cost Battery Charger User’s Guide
CONVENTIONS USED IN THIS GUIDE
This manual uses the following documentation conventions:
DOCUMENTATION CONVENTIONS
Description
Arial font:
Italic characters
Initial caps
Quotes
Underlined, italic text with
right angle bracket
Bold characters
N‘Rnnnn
Text in angle brackets < >
Courier New font:
Plain Courier New
Represents
Referenced books
Emphasized text
A window
A dialog
A menu selection
A field name in a window or
dialog
A menu path
MPLAB® IDE User’s Guide
...is the only compiler...
the Output window
the Settings dialog
select Enable Programmer
“Save project before build”
A dialog button
A tab
A number in verilog format,
where N is the total number of
digits, R is the radix and n is a
digit.
A key on the keyboard
Click OK
Click the Power tab
4‘b0010, 2‘hF1
Italic Courier New
Sample source code
Filenames
File paths
Keywords
Command-line options
Bit values
Constants
A variable argument
Square brackets [ ]
Optional arguments
Curly brackets and pipe
character: { | }
Ellipses...
Choice of mutually exclusive
arguments; an OR selection
Replaces repeated text
Represents code supplied by
user
DS51555B-page 2
Examples
File>Save
Press <Enter>, <F1>
#define START
autoexec.bat
c:\mcc18\h
_asm, _endasm, static
-Opa+, -Opa0, 1
0xFF, ‘A’
file.o, where file can be
any valid filename
mcc18 [options] file
[options]
errorlevel {0|1}
var_name [,
var_name...]
void main (void)
{ ...
}
© 2005 Microchip Technology Inc.
Preface
RECOMMENDED READING
This user's guide describes how to use the MCP1630 Low-Cost Li-Ion Battery Charger.
The following Microchip documents are available and recommended as supplemental
reference resources.
MCP1630 Data Sheet, “High-Speed, Microcontroller-Adaptable, Pulse Width
Modulator”, DS21896
This data sheet provides detailed information regarding the MCP1630 product family.
MCP6291/2/3/4/5 Data Sheet, “1.0 mA, 10 MHz, Rail-to-Rail Op Amp”, DS21812
This data sheet provides detailed information regarding the MCP6291/2/3/4/5 product
family.
PIC12F683 Data Sheet, “8-Pin Flash-Based, 8-Bit CMOS Microcontrollers with
nanoWatt Technology”, DS41211
This data sheet provides detailed information regarding the PIC12F683 product family.
THE MICROCHIP WEB SITE
Microchip provides online support via our web site at www.microchip.com. This web
site is used as a means to make files and information easily available to customers.
Accessible by using your favorite Internet browser, the web site contains the following
information:
• Product Support – Data sheets and errata, application notes and sample
programs, design resources, user’s guides and hardware support documents,
latest software releases and archived software
• General Technical Support – Frequently Asked Questions (FAQs), technical
support requests, online discussion groups, Microchip consultant program
member listing
• Business of Microchip – Product selector and ordering guides, latest Microchip
press releases, listing of seminars and events, listings of Microchip sales offices,
distributors and factory representatives
CUSTOMER SUPPORT
Users of Microchip products can receive assistance through several channels:
•
•
•
•
•
Distributor or Representative
Local Sales Office
Field Application Engineer (FAE)
Technical Support
Development Systems Information Line
Customers should contact their distributor, representative or field application engineer
(FAE) for support. Local sales offices are also available to help customers. A listing of
sales offices and locations is included in the back of this document.
Technical support is available through the web site at: http://support.microchip.com
© 2005 Microchip Technology Inc.
DS51555B-page 3
MCP1630 Low-Cost Battery Charger User’s Guide
DOCUMENT REVISION HISTORY
Revision B (November 2005)
• Updated Fast Charge Current to 1.5A.
• Added Constant Voltage Charge Calibration.
Revision A (June 2005)
• Initial Release of this Document.
DS51555B-page 4
© 2005 Microchip Technology Inc.
MCP1630 LOW-COST BATTERY
CHARGER USER’S GUIDE
Chapter 1. Product Overview
1.1
INTRODUCTION
The MCP1630 Low-Cost Li-Ion Battery Charger is used to evaluate Microchip’s
MCP1630 in a SEPIC power converter application. As provided, the MCP1630
Low-Cost Li-Ion Battery Charger is capable of charging a single-cell, Li-Ion battery pack
from an input voltage of 6V to 18V. The MCP1630 Low-Cost Li-Ion Battery Charger
provides a constant current, constant voltage charge with preconditioning, cell
temperature monitoring and battery pack fault monitoring. Also, the charger provides a
status or fault indication. The MCP1630 Low-Cost Li-Ion Battery Charger automatically
detects the insertion or removal of a battery pack.
This chapter covers the following topics:
• What is the MCP1630 Low-Cost Li-Ion Battery Charger?
• What the MCP1630 Low-Cost Li-Ion Battery Charger Kit Includes
6V – 18V
Power
Supply
B+
Charger
THERM
Battery
Pack
BMaximum Charge Current = 2A
FIGURE 1-1:
Diagram.
© 2005 Microchip Technology Inc.
MCP1630 Low-Cost Li-Ion Battery Charger System Block
DS51555B-page 5
MCP1630 Low-Cost Battery Charger User’s Guide
1.2
WHAT IS THE MCP1630 LOW-COST LI-ION BATTERY CHARGER?
The MCP1630 Low-Cost Li-Ion Battery Charger is a complete stand-alone constant
current, constant voltage battery charger for single-cell Li-Ion battery packs. Different
battery chemistries (i.e. three NiMh or NiCd batteries connected in series) can be
charged with minor modifications to the firmware. Multiple series cell Li-Ion battery
packs can be charged with minor modifications to the hardware.
This board utilizes Microchip’s MCP1630 (high-speed PIC® MCU PWM MSOP8),
MCP6292 (dUAL op-amp MSOP8), and PIC12F683 (Flash MCU SOIC8). The input
voltage range for the demo board is 6V to 18V. The output is capable of charging at a
fast charge rate of 2A constant current.
An input terminal block is provided to apply the input voltage to the charger. An output
header is also provided as a means to connect the external battery pack or simulated
battery load. A programming header is available for updating the firmware contained in
the PIC12F683.
1.3
WHAT THE MCP1630 LOW-COST LI-ION BATTERY CHARGER KIT
INCLUDES
This MCP1630 Low-Cost Li-Ion Battery Charger Kit includes:
• The MCP1630 Low-Cost Li-Ion Battery Charger Board,102-00069
• MCP1630 Low-Cost Li-Ion Battery Charger User’s Guide, (DS51555).
• MCP1630 Data Sheet, “High-Speed, Microcontroller-Adaptable, Pulse Width
Modulator”, (DS21896).
• MCP6291/2/3/4/5 Data Sheet, “1.0 mA, 10 MHz, Rail-to-Rail Op Amp”,
(DS21812).
• PIC12F683 Data Sheet, “8-Pin Flash-Based, 8-Bit CMOS Microcontrollers with
nanoWatt Technology”, (DS41211).
DS51555B-page 6
© 2005 Microchip Technology Inc.
MCP1630 LOW-COST BATTERY
CHARGER USER’S GUIDE
Chapter 2. Installation and Operation
2.1
INTRODUCTION
The MCP1630 Low-Cost Li-Ion Battery Charger demonstrates Microchip’s high-speed
Pulse Width Modulator (PWM) (the MCP1630) used in a battery charger application.
When used in conjunction with a microcontroller, the MCP1630 will control the power
system duty cycle to provide output voltage or current regulation. The PIC12F683
microcontroller can be used to regulate output voltage or current, switching frequency
and maximum duty cycle. The MCP1630 generates duty cycle and provides fast
overcurrent protection based off various external inputs. External signals include the
input oscillator, the reference voltage, the feedback voltage and the current sense. The
output signal is a square-wave pulse. The power train used for the MCP1630 Low-Cost
Li-Ion Battery Charger is a Single-Ended Primary Inductive Converter (SEPIC).
2.2
FEATURES
The MCP1630 Low-Cost Li-Ion Battery Charger has the following features:
• Programmed parameters - modified in firmware
• Factory Settings:
- Preconditioning Charge Current = 200 mA
- Preconditioning Threshold = 3 V
- Constant Current Fast Charge = 1.5 A
- Constant Voltage Charge = 4.2 V
- Charge Termination Threshold = 100 mA
• Overvoltage protection (battery removed)
• Overcharge protection to prevent damaging the battery
• Overcurrent protection in the event of a shorted battery
• Battery reversal protection
• Input short circuit protection
• Overtemperature protection to prevent the battery from reaching too high a
temperature during charge
• Soft-start capability by holding the reference voltage low during power-up
• The MCP1630 Low-Cost Li-Ion Battery Charger terminates charge by detecting a
predefined charge current threshold during constant voltage charge, or a specified
elapsed time
• The MCP1630 Low-Cost Li-Ion Battery Charger has the flexibility to optimize the
charging algorithm for new battery technology, different battery chemistries or
different battery pack configurations
• Proprietary features can be added by modifying the firmware contained in the
PIC12F683
• The factory-programmed source code is available
• Ability to adapt to environmental effects, such as ambient temperature
© 2005 Microchip Technology Inc.
DS51555B-page 7
MCP1630 Low-Cost Battery Charger User’s Guide
2.3
GETTING STARTED
The MCP1630 Low-Cost Li-Ion Battery Charger is fully assembled and tested for
charging single-cell, Li-Ion battery packs with the recommended charge profile for
Li-Ion batteries. This board requires the use of an external input voltage source (+6V
to +18V) and external load (battery or simulated battery load).
2.3.1
Power Input and Output Connections
2.3.1.1
POWERING THE MCP1630 LOW-COST LI-ION BATTERY CHARGER
1. Apply the input voltage to the input terminal block, J1. The input voltage source
should be limited to the 0V to +18V range. For normal operation, the input voltage
should be between +6V and +18V. The input voltage must not exceed an
absolute maximum of +20V.
2. Connect the positive side of the input source (+) to pin 1 of J1. Connect the
negative or return side (–) of the input source to pin 2 of J1. Refer to Figure 2-1.
J1
C1
C2
L1
C3
D1
Input +
Input –
C4
J2
Battery
Header
Q1
U1
R3
R1
C5
R5
C9
R11
R12
R13
R16
C10
R17
R2
R6
R7 C6
R4
R8 C7 R9 R10 C8
J3
R14
Q2
U3
R15
U4
U2
Programming
Header
D2
R21
FIGURE 2-1:
2.3.1.2
R18 R19 C11 R20C12
C13 C14
Setup Configuration Diagram.
APPLY THE LOAD TO A BATTERY HEADER
1. To apply a load to the MCP1630 Low-Cost Li-Ion Battery Charger, the positive
side of the load (B+) should be connected to pin 1 of J2. The negative side of the
load (B-) should be connected to pin 5 of J2. Care should be taken when using
electronic loads or ground referenced loads.
2. A thermistor referenced to (B-) in the battery pack should be utilized. If a
thermistor is not available or not desired, a 10 kΩ resistor should be placed
between pins 4 and 5 of the battery header (J2).
3. The installed firmware will prevent the board from entering the Fast Charge mode
if the battery terminal voltage is less than 3V. During power-up, the board will
always trickle charge first, so using a purely resistive load will not work for trickle
and fast-charge current. The best way to evaluate the charger is to use a single-cell Li-Ion battery pack, or the recommended simulated battery load. Refer to
Figure 2-2.
DS51555B-page 8
© 2005 Microchip Technology Inc.
Installation and Operation
VBAT+
+
+
1,000 µF
10V Al
Variable
Power Supply
– 0V – 6V
2Ω
10W
VBAT–
FIGURE 2-2:
2.3.1.3
Simulated Battery Load.
STATUS LED
1. The MCP1630 Low-Cost Li-Ion Battery Charger has an LED to indicate charge
status or fault status. Table 2-1 represents the state of the LED during various
states of the charge cycle.
TABLE 2-1:
STATUS OUTPUT
CHARGE CYCLE STATE
LED
Qualification
OFF
Preconditioning
ON
Constant Current Fast Charge
ON
Constant Voltage
ON
Charge Complete
OFF
Safety Timer Fault
Flashing (2 Hz, 50% duty cycle)
Cell Temperature Invalid
Flashing (1 Hz, 50% duty cycle)
Battery Disconnected
OFF
Input Power Removed
OFF
2.3.1.4
PROGRAMMING
Header J3 is provided for In-Circuit System Programming™.
If the factory installed firmware is modified or if the PIC12F683 is reprogrammed, the
board needs to be calibrated. To perform calibration, a 4.2V source should be applied
to the battery header. Then, when input power is applied for the first time, the board will
perform a self calibration. The LED will flash when the calibration has been completed.
The 4.2V source should be removed and input power cycled for normal operation.
© 2005 Microchip Technology Inc.
DS51555B-page 9
MCP1630 Low-Cost Battery Charger User’s Guide
NOTES:
DS51555B-page 10
© 2005 Microchip Technology Inc.
MCP1630 LOW-COST BATTERY
CHARGER USER’S GUIDE
Appendix A. Schematic and Layouts
A.1
INTRODUCTION
This appendix contains the following schematics and layouts for the MCP1630
Low-Cost Li-Ion Battery Charger.
Diagrams included in this appendix:
•
•
•
•
•
Board Schematic
Board – Assembly Drawing
Board – Top Overlay
Board – Top Layer
Board – Bottom Layer
© 2005 Microchip Technology Inc.
DS51555B-page 11
MCP1630 Low-Cost Battery Charger User’s Guide
A
3
2
6
A
K
5
A
1
BOARD SCHEMATIC
7
A.2
1
2
3
1 OUT
3
GND
IN 2
4
5
6
7
8
2
1
3
K
A
DS51555B-page 12
© 2005 Microchip Technology Inc.
© 2005 Microchip Technology Inc.
R11
R13
C10
C9
R12
R16
D2
R17
R5
C5
R1
C1
U4
R2
C2
R21
U2
R6
Q2
R14
R3
C3
R15
C13 C14
U3
Q1
D1
R8 C7 R9 R10 C8
R18 R19 C11 R20 C12
R7 C6
L1
R4
C4
J3
J2
A.3
U1
J1
Schematic and Layouts
BOARD – ASSEMBLY DRAWING
DS51555B-page 13
MCP1630 Low-Cost Battery Charger User’s Guide
A.4
BOARD – TOP OVERLAY
J1
C1
C2
L1
C3
D1
C4
J2
Q1
U1
R3
R1
C5
R5
C9
R11
R12
R13
R16
C10
R17
R2
R6
R7 C6
R4
R8 C7 R9 R10 C8
J3
R14
Q2
U4
U3
R15
U2
D2
R21
R18 R19 C11 R20C12
C13 C14
Scale = 2:1
DS51555B-page 14
© 2005 Microchip Technology Inc.
Schematic and Layouts
A.5
BOARD – TOP LAYER
Scale = 2:1
© 2005 Microchip Technology Inc.
DS51555B-page 15
MCP1630 Low-Cost Battery Charger User’s Guide
A.6
BOARD – BOTTOM LAYER
Scale = 2:1
DS51555B-page 16
© 2005 Microchip Technology Inc.
MCP1630 LOW-COST BATTERY
CHARGER USER’S GUIDE
Appendix B. Bill Of Materials (BOM)
TABLE B-1:
Qty.
BILL OF MATERIALS (BOM)
Reference
Description
5
2
1
1
1
3
1
1
1
C5,C10,C11,C12,C13
C9,C14
C8
C7
C3
C1,C2,C4
L1
J3
J2
1
D2
0.1 µF, X7R Ceramic, 16V, 0805
1 µF, X5R Ceramic, 16V, 0805
22 pF, NPO Ceramic, 50V, 0805
1500 pF, X7R Ceramic, 100V, 0805
1 µF, X7R Ceramic, 25V, 1206
10 µF, X5R Ceramic, 25V, 1206
10 µH, Coupled Inductor, DRQ127
Header, 5 Pos., 2.54 mm, HDR1X5
Header, 5 Pos., 2.54 mm, Friction
Lock, HDR1X5-FL
Green LED, 0805
1
U1
5.0V, Voltage Regulator, SOT23
1
U3
PWM Building Block, MSOP8
1
U2
1
Q1
Dual Operational Amplifier 10 MHz,
MSOP8
N-Channel MOSFET, SOIC8
1
1
Q2
U4
N-Channel MOSFET, SOT23
8-Bit FLASH MCU, SOIC8
5
4
1
1
1
1
1
2
4
1
1
R7,R9,R10,R17,R21
R5,R11,R14,R16
R18
R8
R20
R6
R19
R12,R13
R1,R2,R3,R4
D1
J1
1.00 kΩ, 1/10W, Chip Resistor, 0805
10.0 kΩ, 1/10W, Chip Resistor, 0805
15.0 kΩ, 1/10W, Chip Resistor, 0805
47.5 kΩ, 1/10W, Chip Resistor, 0805
49.9 kΩ, 1/10W, Chip Resistor, 0805
100 kΩ, 1/10W, Chip Resistor, 0805
110k, 1/10W, Chip Resistor, 0805
422 kΩ, 1/10W, Chip Resistor, 0805
0.22Ω, 1/4W, Chip Resistor, 1206
3.0A, 30V Schottky Diode, SMA
Terminal Block, 2 Pos., 2.54 mm,
TB254-2
© 2005 Microchip Technology Inc.
Mfgr.
®
Part Number
Panasonic -ECG
Panasonic-ECG
Panasonic-ECG
Panasonic-ECG
Panasonic-ECG
Panasonic-ECG
Coiltronics®
Molex®
Molex®
ECJ-2VB1C104K
ECJ-2FB1C105K
ECJ-2VC1H220J
ECJ-2VB2A152K
ECJ-3YB1E105K
ECJ-3YB1E106M
DRQ127-100
22-03-2051
22-23-2051
Lumex®
Opto/Components
National
Semicondutor
Microchip
Technology Inc.
Microchip
Technology Inc.
International
Rectifier
Fairchild®
Microchip
Technology Inc.
Panasonic-ECG
Panasonic-ECG
Panasonic-ECG
Panasonic-ECG
Panasonic-ECG
Panasonic-ECG
Panasonic-ECG
Panasonic-ECG
Panasonic-ECG
Toshiba®
Phoenix Contact
SML-LXT0805GW-TR
LM3480IM3-5.0
MCP1630-E/MS
MCP6292-E/MS
IRF7807V
NDS7002A
PIC12F683-I/SN
ERJ-6ENF1001V
ERJ-6ENF1002V
ERJ-6ENF1502V
ERJ-6ENF4752V
ERJ-6ENF4992V
ERJ-6ENF1003V
ERJ-6ENF1103V
ERJ-6ENF4223V
ERJ-8RQFR22V
CMS01 (TE12L)
1725656
DS51555B-page 17
MCP1630 Low-Cost Battery Charger User’s Guide
NOTES:
DS51555B-page 18
© 2005 Microchip Technology Inc.
MCP1630 LOW-COST BATTERY
CHARGER USER’S GUIDE
Appendix C. Evaluation Board Firmware
C.1
DEVICE FIRMWARE
For the latest copy of the MCP1630 Low-Cost Battery Charger User’s Guide firmware,
visit our web site at www.microchip.com.
Power-Up
Initialize:
Ports, Clocks, ADC,
PWM, and Interrupts
No
Is Battery
Present?
Yes
Trickle Charge:
Turn on LED,
Start PWM,
Current = 200 mA
No
No
Is Battery
Present?
No
Yes
Is Battery
> 3V?
Timer
Expired?
Yes
Charge Fault:
,
Terminate Charge
Flash LED
Yes
Temperature Fault:
Suspend Charge,
Flash LED
Is Battery
Present?
Yes
No
No
Temp. Out
of Range?
Yes
Fast Charge:
Reset Timers
Control Current to
Maintain 4.2V,
Max. Current = 2A
No
Temp. Out
of Range?
Yes
No
Is Battery
Present?
No
Yes
Is Current
< 100 mA?
Temp. Out
of Range?
Yes
Temperature Fault:
Suspend Charge,
Flash LED
No
No
Timer
Expired?
No
Temp. Out
of Range?
Yes
Yes
Yes
Charge Complete:
,
Terminate Charge
Turn off LED
No
Is Battery
Present?
Yes
No
FIGURE C-1:
© 2005 Microchip Technology Inc.
Is Battery
> 4.0V?
Yes
Firmware Flowchart.
DS51555B-page 19
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10/31/05
DS51555B-page 20
© 2005 Microchip Technology Inc.