DEMO MANUAL DC2044A LTC4020EUHF High Voltage Buck-Boost Multi-Chemistry Battery Charger Description Demonstration circuit 2044A is a 55V buck-boost multichemistry battery charger featuring the LTC4020. The board will accept an input voltage between 15V and 55V. The float voltage of the battery output (BAT) is 25.2V, with 3.3A maximum charge current. The converter output (VOUT) has a voltage range of 21V to 28V, with 3A 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 (CC/CV, with MODE pin grounded), constant-current charging (CC, with Performance Summary SYMBOL MODE pin floated), or charging with an optimized 4-step, 3-stage lead-acid battery charge profile (connect MODE pin to INTVCC, with a 0Ω jumper at the optional R29 position). 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/DC2044A 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 Battery Float Voltage (BAT) (Nominal) IBAT = 0A to 3.3A 25.2V Converter Output Voltage (VOUT) IOUT = 0A to 3A 21V to 28V Maximum Battery Charge Current, IBAT IOUT = 0A 3.3A Maximum Converter Output Current, IOUT IBAT = 0A 3A Typical Efficiency VIN = 24V, VOUT = 25.2V, IOUT = 3A 97% Typical Converter Output Ripple VIN = 55V, VOUT = 25.2V, IOUT = 3A (20MHz BW) 56mVP-P Input Voltage Range 15V to 55V dc2044af 1 DEMO MANUAL DC2044A Quick Start Procedure Demonstration circuit 2044A 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: Additional Notes: 1.With power off, connect the input power supply (set for 0V) to VIN and GND (input return). 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. 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 (3A 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. 1. CAUTION: Be careful when testing with high voltage. High voltage can result in an electric shock if care is not taken. 3. The combined converter output load current and battery charging current should not exceed 3.3A. 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. dc2044af 2 DEMO MANUAL DC2044A Quick Start Procedure dc2044a F01 Figure 1. Proper Measurement Equipment Setup + VOUT – COUT GND dc2044a F02 Figure 2. Measuring Output Voltage Ripple dc2044af 3 DEMO MANUAL DC2044A Quick Start Procedure 100 90 EFFICIENCY (%) 80 70 60 50 40 30 20 16VIN 55VIN 24VIN 10 0 0.01 0.1 1 LOAD CURRENT (A) 10 dc2044a F03 Figure 3. Efficiency vs Load Current (VOUT = 25.2V) 98 97 EFFICIENCY (%) 96 95 94 93 92 91 90 14 18 22 26 30 34 38 42 46 50 56 VIN (V) dc2044a F04 Figure 4. Efficiency vs Input Voltage (VOUT = 25.2V, IOUT = 3A) dc2044af 4 DEMO MANUAL DC2044A Parts List ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER TDK, C1608X7S2A104K Required Circuit Components 1 1 C1 CAP, CHIP, X7S, 0.1µF, 10%, 100V, 0603 2 4 C2, C3, C15, C17 CAP, ELEC, 56µF, 20%, 63V, 10.3mm × 10.3mm SUNCON, 63HVH56M 3 1 C4 CAP, CHIP, C0G, 100pF, 10%, 16V, 0402 AVX, 0402YA101KAT9A 4 1 C5 CAP, CHIP, C0G, 0.1µF, 10%, 16V, 1206 KEMET, C1206H104J3GACTU 5 1 C6 CAP, CHIP, X7R 10nF, 10%, 50V, 0603 AVX, 06035C103KAT 6 1 C8 CAP, CHIP, C0G, 680pF, 10%, 50V, 0603 AVX, 06035A681KAT2A 7 1 C9 CAP, CHIP, C0G, 68pF, 5%, 16V, 0402 AVX, 0402YA680JAT4A 8 2 C19, C20 CAP, CHIP, X5R, 0.22µF, 10%, 25V, 0603 AVX, 06033D224KAT2A 9 1 C10 CAP, CHIP, X7R, 0.001µF, 10%, 25V, 0603 AVZ, 06033C102KAT2A 10 1 C11 CAP, CHIP, X5R, 2.2µF, 10%, 16V, 0603 TDK, C1608X5R1C225K 11 1 C12 CAP, CHIP, X7R, 0.033µF, 10%, 25V, 0402 TDK, C1005X7R1E333K 12 6 C14, C16, C18, C23, C27, C28 CAP, CHIP, X7S, 4.7µF,20%, 100V, 1210 TDK, C3225X7S2A475M 13 1 C21 CAP, CHIP, X5R, 10µF, 20%, 6.3V, 0805 AVX, 08056D106KAT2A 14 2 D1, D2 DIODE, SMT, SUPERBARRIER, 60V, 0.5A, SOD123 DIODES INC, SBR0560S1 15 1 D3 DIODE, LED, RED, SMT, 0603 PANASONIC, LNJ208R8ARA 16 1 D4 DIODE, LED, GREEN, 0603 LITE-ON, LTST-C190KGKT 17 1 D6 DIODE, SMT SCHOTTKY BARRIER RECTIFIER, SMA VISHAY, B360A-E3 18 1 L1 IND, SMT, 15µH, 10A, 20%, 10mm × 11.3mm COILCRAFT, XAL1010-153MEB 19 1 M1 P-CHANNEL MOSFET, –60V, –14.4A, PowerPAKSO8 VISHAY, Si7461DP-T1-E3 20 2 M2, M3 DUAL N-CHANNEL MOSFET, 60V, 9.7A, PowerPAKSO8 VISHAY, Si7960DP-T1-E3 21 1 R2 RES, CHIP, 510kΩ, 5%, 0402 VISHAY, CRCW0402510KFKED 22 5 R1, R4, R5, R12, R13 RES, CHIP, 100kΩ, 5%, 0402 VISHAY, CRCW0402100KJNED 23 2 R6, R7 RES, CHIP, 20Ω, 5%, 0402 VISHAY, CRCW040220R0JNED 24 1 R8 RES, CHIP, 226kΩ, 0.1%, 0603 VISHAY, TNPW06030F226BEEA 25 1 R9 RES, CHIP, 226kΩ, 1%, 0402 VISHAY, CRCW0402226KFKED 26 1 R10 RES, CHIP, 24.9kΩ, 0.1%, 0402 VISHAY, TNPW04020F24K9BEED 27 1 R11 RES, CHIP, 24.9kΩ, 1%, 0402 VISHAY, CRCW040224K9FKED 28 1 R14 RES, CHIP, 10kΩ, 1%, 0402 VISHAY, CRCW040210K0FKED 29 1 R15 RES, CHIP, 56kΩ, 1%, 0402 VISHAY, CRCW040256K0FKED 30 1 R16 RES, CHIP, 47kΩ, 1%, 0402 VISHAY, CRCW040247K0FKED 31 8 R21 TO 25, R34, R35, R37 RES, CHIP, 0Ω JUMPER, 0402 VISHAY, CRCW04020000Z0ED 32 1 R36 RES, CHIP, 0Ω JUMPER, 0603 VISHAY, CRCW06030000Z0EA 33 2 R18, R20 RES, CHIP, 100Ω, 5%, 0402 VISHAY, CRCW0402100RJNED 34 1 R19 RES, CHIP, 4.7Ω, 5%, 0402 VISHAY, CRCW04024R70JNED 35 2 R26, R27 RES, CHIP, 3kΩ, 5%, 0402 VISHAY, CRCW04023K00JNED dc2044af 5 DEMO MANUAL DC2044A Parts List ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER 36 1 R28 RES, CHIP, 51kΩ, 5%, 0402 VISHAY, CRCW040251K00JNED 37 1 R38 RES, CHIP, 5.1, 5%, 0805 VISHAY, CRCW08055R10JNEA 38 2 RCBRB1, RCBRT1 RES, CHIP, 0.008Ω, 1%, 0.5W, 1206 VISHAY, WSL12068L000FEA18 39 1 RCBAT1 RES, CHIP, 0.015Ω, 1%, 0.5W, 1206 TT ELEC LRC-LRF1206F-01-F 40 1 U1 IC, LTC4020EUHF, 5mm × 7mm QFN38 LINEAR TECHNOLOGY, LTC4020EUHF Additional Demo Board Circuit Components 1 0 C7, C13, C22, C24 ,C25 , C26, C30, C31 (OPT) CAP, CHIP, OPTIONAL 2 0 D7 (OPT) DIODE, SMT SOD123 3 0 D5(OPT) DIODE, SMT SCHOTTKY BARRIER RECTIFIER, SMA 4 0 R3, R17, R29, R31, R32 OPT RES, OPTIONAL Hardware: For Demo Board Only 1 11 E1, E2, E5 TO E10, E13, E14, E17 TURRET, 0.09" DIA MILL-MAX, 2501-2-00-80-00-00-07-0 2 6 E3, E4, E11, E12, E15, E16 VERTICAL BANANA JACK, 575-4 KEYSTONE, 575-4 3 4 STAND-OFF, NYLON (SNAP ON), 0.375" TALL KEYSTONE, 8832 (SNAP ON) 4 1 FAB, PRINTED CIRCUIT BOARD DEMO CIRCUIT 2044A dc2044af 6 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 MODE NTC SGND ILIMIT RNG / SS SHDN GND VIN 15V - 55V E8 E17 E9 E7 E6 E5 E2 E4 E3 E1 R4 100k 5 R29 OPT R14 10k + C4 100pF 16V C3 56uF 63V 63HVH56M INT_VCC R5 100k + C5 0.1uF 1206 R10 24.9k 0.1% R8 226k 0.1% 0603 R11 24.9k R9 226k R7 20 R6 20 R28 51k VOUT R13 100k C23 4.7uF 100V 1210 VBAT C16 4.7uF 100V 1210 R37 C25 OPT R3 OPT R1 100k 0 8 14 11 24 16 18 17 26 19 25 15 10 9 0603 R17 R2 510k OPT RT TIMER MODE CSOUT NTC FBG VFB 4 1. ALL RESISTORS ARE IN OHMS, 0402. ALL CAPACITORS ARE IN MICROFARADS, 0402. 3 36 U1 PVIN C1 0603 OPT 29 SGND 35 PGND BG1 TG1 SW1 SW2 STAT1 BST1 BST2 STAT2 INT_Vcc SENSVIN SENSTOP 39 SGND Vc ITH BAT BGATE CSN CSP BG2 TG2 SENSBOT SENSGND 0603 100V 0.1uF LTC4020EUHF 5.1 SGND 0805 C13 VFBMAX VFBMIN ILIMIT RNG/SS VIN_REG SHDN NOTE: UNLESS OTHERWISE SPECIFIED R12 100k C24 OPT C2 56uF 63V 63HVH56M R38 28 27 20 21 22 23 33 31 5 4 37 1 38 32 12 2 30 13 34 7 6 0 R21 4 R34 3 C6 10nF 0603 R15 56k 0 0 M2B Si7960DP 0 2 C12 0.033uF R22 R24 M2A Si7960DP C21 10uF 6.3V 0805 C22 0.033uF OPT 3 7 8 1 C7 OPT 0 C8 680pF 0603 R16 47k R35 D5 B360A OPT OPT 0603 C30 OPT 0603 0603 R31 R36 0 RCBRT1 0.008 0.5W 1206 RCBRB1 0.008 0.5W 1206 5 6 3 R20 D6 B360A D7 OPT 100 100 D3 RED 4 2 C10 1nF 0603 25V R23 0 Si7960DP THIS CIRCUIT IS PROPRIETARY TO LINEAR TECHNOLOGY AND SUPPLIED FOR USE WITH LINEAR TECHNOLOGY PARTS. 2 4 SCALE = NONE HZ Charlie Z. PCB DES. APPROVALS 5 6 7 8 M1 Si7461DP 1 2 3 RCBAT1 0.015 0.5W 1206 VOUT APP ENG. 0 R25 D4 GREEN M3B M3A Si7960DP CUSTOMER NOTICE R18 C31 OPT 0603 R32 OPT 0603 C11 2.2uF 0603 R19 4.7 3K R26 C20 0.22uF 25V 0603 3K R27 D2 SBR0560S1 2 LINEAR TECHNOLOGY HAS MADE A BEST EFFORT TO DESIGN A CIRCUIT THAT MEETS CUSTOMER-SUPPLIED SPECIFICATIONS; HOWEVER, IT REMAINS THE CUSTOMER'S RESPONSIBILITY TO VERIFY PROPER AND RELIABLE OPERATION IN THE ACTUAL APPLICATION. COMPONENT SUBSTITUTION AND PRINTED CIRCUIT BOARD LAYOUT MAY SIGNIFICANTLY AFFECT CIRCUIT PERFORMANCE OR RELIABILITY. CONTACT LINEAR TECHNOLOGY APPLICATIONS ENGINEERING FOR ASSISTANCE. C9 68pF 15uH XAL1010-153ME L1 C19 0.22uF 25V 0603 D1 SBR0560S1 INT_VCC 6 5 3 4 8 7 1 5 C18 4.7uF 1210 100V 2 1 DATE: N/A SIZE 1 C28 4.7uF 1210 100V VBAT + E11 E12 E10 C17 56uF 63V 63HVH56M 1 DEMO CIRCUIT 2044A Thursday, September 19, 2013 LTC4020EUHF GND VOUT 21V - 28V 3A MAX GND SHEET 1 HIGH VOLTAGE BUCK / BOOST MULTI-CHEMISTRY BATTERY CHARGER IC NO. DATE 5-29-13 8-13-12 BAT 25.2V VFLOAT 3.3A MAX E13 E15 E16 E14 Charlie Z. GB APPROVED OF 1 2 REV. 1630 McCarthy Blvd. Milpitas, CA 95035 Phone: (408)432-1900 www.linear.com Fax: (408)434-0507 LTC Confidential-For Customer Use Only C26 OPT 1210 + C15 56uF 63V 63HVH56M PRODUCTION 1st PROTOTYPE DESCRIPTION REVISION HISTORY TECHNOLOGY C27 4.7uF 1210 100V REV TITLE: SCHEMATIC C14 4.7uF 1210 100V __ ECO A B C D DEMO MANUAL DC2044A Schematic Diagram dc2044af 7 DEMO MANUAL DC2044A 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 dc2044af 8 Linear Technology Corporation LT 1113 • PRINTED IN USA 1630 McCarthy Blvd., Milpitas, CA 95035-7417 (408) 432-1900 ● FAX: (408) 434-0507 ● www.linear.com LINEAR TECHNOLOGY CORPORATION 2013