DEMO MANUAL DC1830A-A/DC1830A-B LTC4000 Battery Charger Controller and PowerPath Manager DESCRIPTION Demonstration circuit 1830A is a battery charger controller and PowerPath™ manager featuring the LTC®4000. This board should be connected to a front-end DC/DC power supply for a complete charger solution. The DC1830A is customizable to handle a wide variety of applications with output voltages from 3V to 30V and output currents up to 6.5A with the PFETs supplied, and up to 60V and/or 13A with higher voltage rating and/or added PFETs. The reference design provided with DC1830A is targeted at 4-cell LiFePO4 (14.6V/5A) applications. The DC1830A loop compensation values were proven with the LTC3845A buck power converter shown and are typical for other applications. The output of this demo board was specifically tailored for a Tenergy 10A-hour battery, P/N 30207. Other voltages can be set by changing ROFB2 and RBFB2. The desired nominal voltage can be accurately trimmed by using trim resistors ROFBX and RBFBX. For example, for 14.4V battery float voltage, change ROFB2 and RBFB2 to 86.6k, and add 7.5M at ROFBX and RBFBX for greater setpoint accuracy. Other parameters can be adjusted to suit specific applications with guidance provided in the LTC4000 data sheet. Table 1 provides a summary of parameter adjustments. This circuit was designed to demonstrate the high levels of performance and small solution size attainable using PERFORMANCE SUMMARY SYMBOL VIN IIN VFLOAT VFLOAT IBAT tT VOUT-SYS IOUT-SYS PARAMETER Input Supply Range Input Current Limit Battery Float Voltage Output Regulation Battery Charge Current Battery Charge Current—Trickle Charge Termination Time System Output Voltage System Output Current Range this IC to control a switch mode power converter to form a battery charger, intelligent PowerPath manager, and power supply system. It produces a regulated 5.0A/14.6V battery charger output as well as a system output of up to 5.5A: suitable for a wide variety of portable applications including instruments, industrial equipment, power tools and computers. The DC1830A-A provides a solution complete with both battery charger control and PowerPath managment. It includes a second PFET (Q2) between VOUT-SYS and BAT to provide Instant-On functionality which keeps VOUT-SYS within a narrow range regardless of battery voltage, and disconnects the battery when it is fully charged and power is available from the front-end DC/DC converter. Thermal regulation circuitry is also provided to limit the temperature of both PFETs. The DC1830A-B provides a simple battery-charger-controller only solution without the PowerPath manager. It deletes the second PFET and thermal regulation circuitry. In this case, the battery is always “online” and VOUT-SYS tracks the BAT Voltage. Design files for this circuit board are available at http://www.linear.com/demo L, LT, LTC, LTM, Linear Technology and the Linear logo are registered trademarks and PowerPath is a trademark of Linear Technology Corporation. All other trademarks are the property of their respective owners. Specifications are at TA = 25°C CONDITIONS/COMMENTS This Is the Input Voltage of the Front-End DC/DC Supply This Is the Input Current Limit Set by the LTC4000 MIN 20 14.4 Line and Load (20V to 60V, 0A to 4.5A) VBAT = VFLOAT *Input Current Limited Below 35VIN 12.3 0 TYP 3.0 14.6 ±0.005 5.0 0.6 2.9 14.6 MAX 60 14.8 15.5 5.5* UNITS V A V % A A Hours V A dc1830af 1 DEMO MANUAL DC1830A-A/DC1830A-B QUICK START PROCEDURE Demonstration circuit 1830 is offered for use in combination with a front-end DC/DC converter, and will need to be customized to suit the intended application. It has been supplied with components for a design as outlined in the performance summary, and tested in conjunction with the LTC3845A buck converter that it was tailored to. A separate demonstration board is available for the LTC4000/LTC3789 buck-boost combination, the DC1721A. The LTC4000 data sheet should be used for guidance in determining circuit values for the application at hand. You may follow the design example on page 26 of the data sheet. Table 1 provides a summary of parameter adjustments. NOTE: The PFETs supplied on this board are rated at 30V. Once the circuit has been customized to suit the application at hand, it is easy to set up to evaluate the performance of the LTC4000 when combined with a suitable switching power converter, such as the LTC3845A. See page 9 for the modified DC1619A/LTC3845A schematic.Voltages and currents cited in this procedure are for the design as delivered; if the design has been customized, substitute the appropriate values. Refer to Figure 1 for proper measurement equipment setup and follow the procedure below: Warning: Batteries Are Potentially Dangerous High Energy Sources. Improper Connection, Overcharge, or Rapid Discharge Could Result in Explosion and/or Fire. 1. Set an input power supply that is capable of 60V and 3A, to 24V. Then turn off the supply. 2. With power off, connect the supply to the input terminals VIN and GND. NOTE: a. Input voltages lower than 20V can keep the converter from turning on due to the undervoltage lockout feature of the LTC4000. b. If efficiency measurements are desired, refer to Figure 1 for the test setup. 3. Set CHARGE jumper to ENABLE. 4. Turn on the power at the input. NOTE: Make sure that the input voltage never exceeds 60V. 5. Check for the proper BAT output voltage of 14.6V. Turn off the power at the input. 6. Now that the proper output voltage is established, connect a variable load capable of sinking 6A at 16V to the output terminals BAT and GND. Set the current for 0A. 7. Turn on the power at the input. NOTE: If there is no output, temporarily disconnect the load to make sure that the load is not set too high. 8. Once the proper BAT output voltage is again established, adjust the load and/or source within the operating range and observe the battery float voltage regulation, charge current, and other desired parameters. 9. Set the load to constant voltage mode to more easily observe charge current and trickle charge current. NOTE: The following applies to the DC1830A-A. NOTE: Operation in the Instant-On region (VOUT < 12.5V) may engage thermal limit circuit to protect Q2 in the linear region. NOTE: The optional thermal limit circuit for Q1 (Q5, RNTC3, R8-12 and U2) is included to protect Q1 in case of an extended short circuit on VOUT-SYS under adverse thermal conditions (TA > 40°C). It may not be needed in applications with less severe thermal conditions, lower current available to VOUT-SYS, or where continuous short-circuit protection on VOUTSYS is not required. 10. Turn off the power at the input. 11. Connect the output load and meters to the VOUT-SYS output. 12. Set CHARGE jumper to DISABLE. 13. Turn on the power at the input. 14. Once the proper VOUT-SYS is again established, adjust the load and/or source within the operating range and observe the output voltage regulation, ripple voltage, efficiency, input and output current limit, and other desired parameters. dc1830af 2 DEMO MANUAL DC1830A-A/DC1830A-B QUICK START PROCEDURE Table 1. LTC4000 Charger Setup Parameters and Reference Values REFERENCE DESCRIPTION NOMINAL VALUE (V)* MIN/MAX CONDITIONS IIL Input Current Regulation/Limit (50μA • RIL)/20 45μA/55μA 50mV Max ICL Charge Current Regulation/Limit (50μA • RCL)/20 45μA/55μA 50mV Max Trickle Charge Current Regulation/Limit (5μA • RCL)/20 4.5μA/5.5μA 50mV Max VBAT-FLOAT Battery Float Voltage 1.136V 1.125V/1.147V VOUT System Voltage 1.193V 1.181V/1.204V Charger Off (Follows VBAT) Charger Float (Follows VBAT) Charging at ICL, 0.86 • VBAT-FLOAT < VBAT < VBAT-FLOAT 0.86 • 1.136V 0.82/0.90 Instant-On, 0.68 • VBAT-FLOAT < VBAT < 0.86 • VBAT-FLOAT 0.86 • 1.136V 0.82/0.90 Instant-On, Trickle, VBAT < 0.68 • VBAT-FLOAT VM Input Voltage Monitor/UVLO 1.193V 1.181V/1.204V Falling, (40mV Hysteresis) CX C/X Monitor/Charge Termination (5μA • RCX – 10mV)/20 4.5μA/5.5μA Short TMR to BIAS for C/X Termination TMR Charge Termination Timer 104s/nF 83s/nF/126s/nF *Normalized to sense point OR – – DC SOURCE + + + + V A + V SCOPE – – A – + LOAD – Figure 1. Fixture Connections and Measurement Equipment Setup dc1830af 3 DEMO MANUAL DC1830A-A/DC1830A-B QUICK START PROCEDURE Figure 2. Block Diagram with Typical DC/DC Converter dc1830af 4 DEMO MANUAL DC1830A-A/DC1830A-B PARTS LIST ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER DC1380A-A Required Circuit Components 1 1 C1 CAP., X5R, 4.7μF, 10V, 20% 0603 AVX, 0603ZD475MAT2A 2 1 CBAT CAP., SMT ALUMINUM, 150μF, 35V SUNCON, 35HVH150M 3 1 CBIAS CAP., X7R, 1μF, 16V, 10% 0603 AVX, 0603YC105KAT2A 4 1 CBGATE CAP., X7R, 10nF, 25V, 5% 0603 AVX, 06033C103JAT2A 5 2 CC2, CTMR CAP., X7R, 0.1μF, 50V, 10% 0603 AVX, 06035C104KAT2A 6 2 CIIMON, CIBMON CAP., C0G, 1000pF, 25V, 5% 0603 AVX, 06033A102JAT2A 7 1 CIN CAP., X7R, 1μF, 50V, 10% 1210 AVX, 12105C105KAT2A 8 1 CL CAP., X7R, 2.2μF, 50V, 10% 1206 MURATA, GRM31CR71H225KA88L 9 1 D1 DIODE ZENER 3.0V 350MW SOT23-3 DIODE INC., BZX84C3V0-7-F 10 2 D3, D5 LED, RED HI BRT SS TYPE LO CUR SMT, 0603 PANASONIC, LNJ208R8ARA 11 1 D4 LED, GREEN, SMT, 0603 LITE-ON, LTST-C190KGKT 12 1 F2 FUSE 12A 32V T-LAG 1206 SMD COOPER BUSSMAN, 3216TD12-R 13 2 Q1, Q2 MOSFET P-CHAN., 30V, POWERPAK-8 VISHAY, SI7135DP-T1-GE3 14 2 Q5, Q6 SMALL-SIGNAL MOSFET ON SEMI., 2N7002LT1G 15 1 R5 RES., CHIP., 2.2k, 0.1W, 5% 0603 VISHAY, CRCW06032K2JKEA 16 2 R6, R18 RES., CHIP., 4.7k, 0.1W, 5% 0603 VISHAY, CRCW06034K7JKEA 17 4 R8, R13, RCX, RVM2 RES., CHIP., 10k, 0.1W, 1% 0603 YAGEO, RC0603FR-0710KL 18 1 R9 RES., CHIP., 46.4k, 0.1W, 1% 0603 VISHAY, CRCW060346K4FKEA 19 2 R10, R15 RES., CHIP., 20k, 0.1W, 1% 0603 VISHAY, CRCW060320K0FKEA 20 2 R11, R16 RES., CHIP., 38.3k, 0.1W, 1% 0603 VISHAY, CRCW060338K3FKEA 21 2 R12, R17 RES., CHIP., 1M, 0.1W, 1% 0603 VISHAY, CRCW06031M00FKEA 22 1 R14 RES., CHIP., 78.7k, 0.1W, 1% 0603 VISHAY, CRCW060378K7FKEA 23 2 RBFB1, ROFB1 RES., CHIP., 1M, 0.1W, 1% 0603 VISHAY, CRCW06031M00FKEA 24 2 RBFB2, ROFB2 RES., CHIP., 84.5k, 0.1W, 1% 0603 VISHAY, CRCW060384K5FKEA 25 1 RC1 RES., CHIP., 4.22k, 0.1W, 1% 0603 YAGEO, RC0603FR-07422KL 26 1 RCL RES., CHIP., 24.3k, 0.1W, 1% 0603 VISHAY, CRCW060324K3FKEA 27 1 RIL RES., CHIP., 18.2K, 0.1W, 1% 0603 VISHAY, CRCW060318K2FKEA 28 1 RCS SENSOR RES., 0.01Ω 1W 2% 1508 SMD SUSUMU, RL3720WT-R010-G 29 1 RIS1 SENSOR RES., 0.015Ω 1W 2% 1508 SMD SUSUMU, RL3720WT-R015-G 30 2 RNTC2, RNTC3 THERMISTOR NTC 10k 5% 0603 VISHAY, NTHS0603N02N1002J 31 1 RVM1 RES., CHIP., 143k, 0.1W, 1% 0603 VISHAY, CRCW0603143KFKEA 32 3 R4, R7, R19 RES., CHIP., 100k, 0.1W, 5% 0603 VISHAY, CRCW0603100KJKEA 33 1 U1 I.C., LTC4000EUFD, 28-PIN QFN LINEAR TECH., LTC4000EUFD#PBF 34 2 U2, U3 NANOPWR COMPARATOR, MSOP8 LINEAR TECH., LTC1540CMS8#PBF dc1830af 5 DEMO MANUAL DC1830A-A/DC1830A-B PARTS LIST ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER DC1380A-A Additional Demo Board Circuit Components 1 0 CC1, CIGATE, CNTC, CCX, CCL, CIL, CVM CAP.,0603 OPT 2 0 CL1, CL2, CL3, CL4, CL5 CAP.,1206 OPT 3 0 D2 DIODE ZENER, SOT23-3 OPT 4 0 F1, F3 FUSE 12A 32V T-LAG 1206 SMD OPT 5 0 JUMPER JUMPER WIRE (NO INSTALL) 6 0 Q3 MOSFET P-CHAN., 30V, POWERPAK-8 7 0 Q4 OPT 8 0 R1, R2, R3, R20, RCL, RIG, RBG, RBFBX, RES., 0603 ROFBX, ROFB2 OPT OPT DC1380A-A Hardware—For Demo Board Only 1 14 E1-E6, E9-E14, E18, E19 TESTPOINT, TURRET, 0.061" PBF MILL-MAX, 2308-2-00-80-00-00-07-0 2 5 E7, E8, E15, E16, E17 TESTPOINT, TURRET, 0.094" PBF MILL-MAX, 2501-2-00-80-00-00-07-0 3 4 JP1, JP2, JP3, JP4 HEADER, 3-PIN 0.079 SINGLE ROW SAMTEC, TMM-103-02-L-S 4 4 XJP1, XJP2, XJP3, XJP4 SHUNT, 0.079" CENTER SAMTEC, 2SN-BK-G 5 9 J1, J2, J3, J4, J5, J6, J7, J8, J9 CONNECTOR, BANANA JACK KEYSTONE, 575-4 6 4 MTG1, MTG2, MTG3, MTG4 STAND-OFF, NYLON (SNAP ON), 0.50" TALL KEYSTONE, 8833(SNAP ON) DC1380A-B Required Circuit Components 1 1 C1 CAP., X5R, 4.7μF, 10V, 20% 0603 AVX, 0603ZD475MAT2A 2 1 CBAT CAP., SMT ALUMINUM, 150μF, 35V SUNCON, 35HVH150M 3 1 CBIAS CAP., X7R, 1μF, 16V, 10% 0603 AVX, 0603YC105KAT2A 4 2 CC2, CTMR CAP., X7R, 0.1μF, 50V, 10% 0603 AVX, 06035C104KAT2A 5 2 CIIMON, CIBMON CAP., C0G, 1000pF, 25V, 5% 0603 AVX, 06033A102JAT2A 6 1 CIN CAP., X7R, 1μF, 50V, 10% 1210 AVX, 12105C105KAT2A 7 1 D1 DIODE ZENER 3.0V 350MW SOT23-3 DIODE INC., BZX84C3V0-7-F 8 2 D3, D5 LED, RED HI BRT SS TYPE LO CUR SMT, 0603 PANASONIC, LNJ208R8ARA 9 1 D4 LED, GREEN, SMT, 0603 LITE-ON, LTST-C190KGKT 10 1 F2 FUSE 12A 32V T-LAG 1206 SMD COOPER BUSSMAN, 3216TD12-R 11 1 JUMPER JUMPER WIRE (INSTALLED) 12 1 Q1 MOSFET P-CHAN., 30V, POWERPAK-8 VISHAY, SI7135DP-T1-GE3 13 1 Q2 ZERO OHM THICK FILM JUMPER CHIP, 2010 IRC., LRC-LRZ-2010LF-R000 14 1 R5 RES., CHIP., 2.2k, 0.1W, 5% 0603 VISHAY, CRCW06032K2JKEA 15 2 R6, R18 RES., CHIP., 4.7k, 0.1W, 5% 0603 VISHAY, CRCW06034K7JKEA 16 1 RVM2 RES., CHIP., 10k, 0.1W, 1% 0603 YAGEO, RC0603FR-0710KL 17 2 RBFB1, ROFB1 RES., CHIP., 1M, 0.1W, 1% 0603 VISHAY, CRCW06031M00FKEA 18 1 RBFB2 RES., CHIP., 84.5k, 0.1W, 1% 0603 VISHAY, CRCW060384K5FKEA 19 1 RC1 RES., CHIP., 4.22k, 0.1W, 1% 0603 YAGEO, RC0603FR-07422KL dc1830af 6 DEMO MANUAL DC1830A-A/DC1830A-B PARTS LIST ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER 20 1 RCL RES., CHIP., 24.3k, 0.1W, 1% 0603 VISHAY, CRCW060324K3FKEA 21 1 RIL RES., CHIP., 18.2k, 0.1W, 1% 0603 VISHAY, CRCW060318K2FKEA 22 1 RCS SENSOR RES., 0.01Ω 1W 2% 1508 SMD SUSUMU, RL3720WT-R010-G 22 1 RCX RES., CHIP., 0.0Ω, 0.1W, 0603 VISHAY, CRCW06030000Z0EA 23 1 RIS1 SENSOR RES., 0.015Ω 1W 2% 1508 SMD SUSUMU, RL3720WT-R015-G 24 1 RVM1 RES., CHIP., 143k, 0.1W, 1% 0603 VISHAY, CRCW0603143KFKEA 25 4 R4, R7, R14, R19 RES., CHIP., 100k, 0.1W, 5% 0603 VISHAY, CRCW0603100KJKEA 26 1 U1 I.C., LTC4000EUFD, 28-PIN QFN LINEAR TECH., LTC4000EUFD#PBF DC1380A-B Additional Demo Board Circuit Components 1 0 CC1, CIGATE, CNTC, CCX, CCL, CIL, CVM CAP., 0603 2 0 CBGATE NO INSTALL OPT 3 0 CL CAP., 1206, 50V OPT 4 0 CL1, CL2, CL3, CL4, CL5 CAP., 1206 OPT 5 0 D2 DIODE ZENER, SOT23-3 OPT 6 0 F1,F3 FUSE 12A 32V T-LAG 1206 SMD OPT 7 0 Q3, Q4 MOSFET P-CHAN., 30V, POWERPAK-8 OPT 8 0 Q5, Q6 SMALL-SIGNAL MOSFET OPT, ON SEMI., 2N7002LT1G 9 0 R1, R2, R3, R20, RCL, RIG, RBG, RBFBX, RES., 0603 ROFBX, ROFB2 10 0 R8, R13 RES., CHIP., 10k, 0.1W, 1% 0603 OPT, YAGEO, RC0603FR-0710KL 11 0 R9 RES., CHIP., 68.1k, 0.1W, 1% 0603 OPT, VISHAY, CRCW060368K1FKEA 12 0 R10, R15 RES., CHIP., 20k, 0.1W, 1% 0603 OPT, VISHAY, CRCW060320K0FKEA 13 0 R11, R16 RES., CHIP., 38.3k, 0.1W, 1% 0603 OPT, VISHAY, CRCW060338K3FKEA 14 0 R12, R17 RES., CHIP., 1M, 0.1W, 1% 0603 OPT, VISHAY, CRCW06031M00FKEA 15 0 R14 RES., CHIP., 78.7k, 0.1W, 1% 0603 OPT, VISHAY, CRCW060378K7FKEA 16 0 RNTC2, RNTC3 THERMISTOR NTC 10k 5% 0603 OPT, VISHAY, NTHS0603N02N1002J 17 0 U2,U3 NANOPWR COMPARATOR, MSOP8 OPT, LINEAR TECH., LTC1540CMS8#PBF OPT DC1380A-B Hardware—For Demo Board Only 1 14 E1-E6, E9-E14, E18, E19 TESTPOINT, TURRET, 0.061" PBF MILL-MAX, 2308-2-00-80-00-00-07-0 2 5 E7, E8, E15, E16, E17 TESTPOINT, TURRET, 0.094" PBF MILL-MAX, 2501-2-00-80-00-00-07-0 3 4 JP1, JP2, JP3, JP4 HEADER, 3-PIN 0.079 SINGLE ROW SAMTEC, TMM-103-02-L-S 4 4 XJP1, XJP2, XJP3, XJP4 SHUNT, 0.079" CENTER SAMTEC, 2SN-BK-G 5 9 J1, J2, J3, J4, J5, J6, J7, J8, J9 CONNECTOR, BANANA JACK KEYSTONE, 575-4 6 4 MTG1, MTG2, MTG3, MTG4 STAND-OFF, NYLON (SNAP ON), 0.50" TALL KEYSTONE, 8833 (SNAP ON) dc1830af 7 DEMO MANUAL DC1830A-A/DC1830A-B SCHEMATIC DIAGRAM–DC1830A dc1830af 8 DEMO MANUAL DC1830A-A/DC1830A-B SCHEMATIC DIAGRAM–MODIFIED DC1619A AS USED WITH DC1830A dc1830af 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. 9 DEMO MANUAL DC1830A-A/DC1830A-B 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 dc1830af 10 Linear Technology Corporation LT 0712 • PRINTED IN USA 1630 McCarthy Blvd., Milpitas, CA 95035-7417 (408) 432-1900 ● FAX: (408) 434-0507 ● www.linear.com © LINEAR TECHNOLOGY CORPORATION 2012