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