DEMO MANUAL DC2043A LTC3305EFE Lead Acid Battery Balancer Description Demonstration circuit 2043A is a lead Acid Battery Balancer featuring the LTC®3305. The LTC3305 balances up to 4 lead acid batteries connected in series and incorporates all voltage monitoring, gate drive and fault detection circuitry. The LTC3305 employs an auxiliary battery or an alternative storage cell to transfer charge to or from each individual battery within the stack. There are two operating modes, TIMER mode and CONTINUOUS mode, selected by the MODE pin. In TIMER mode, once the balancing operation is complete, the LTC3305 goes to a low power state for a programmed time and then periodically rebalances the batteries. In CONTINUOUS mode, the balancing operation continues even after the batteries are balanced to their programmed termination voltage. The LTC3305EFE is available in a 7mm × 7mm 38-lead TSSOP surface mount package with exposed pad. Design files for this circuit board are available at http://www.linear.com/demo/DC2043A 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. Board Photo Figure 1. DC2043A Demo Board Figure 2. Thermal Image of DC2043A dc2043af 1 DEMO MANUAL DC2043A Performance Summary Specifications are at TA = 25°C SYMBOL PARAMETER CONDITIONS MIN MAX UNITS VBAT Battery Voltage Range 16.0 V VTERMINATE Termination Voltage Range TERM2 = 0, TERM1 = 0 ±5 VTERMINATE Termination Voltage Range TERM2 = 0, TERM1 = 1 ±17.5 to ±20 mV to ±32.5 mV VTERMINATE Termination Voltage Range TERM2 = 1, TERM1 = 0 ±42.5 to ±57.5 mV VTERMINATE Termination Voltage Range TERM2 = 1, TERM1 = 1 VREG Regulator Output Voltage Range IVREG = 200µA ±90 to ±110 mV 2.4 to 2.6 4.0 to V OPERATING PRINCIPLE Refer to the block diagram within the LTC3305 data sheet for its operating principle. The LTC3305 balances batteries using an auxiliary cell or an alternate storage cell as a charge reservoir. The LTC3305 controls external N Channel MOSFET switches in a preprogrammed sequence to connect a battery in the stack to an auxiliary cell. Charge is transferred to or from the auxiliary cell when it is connected to a battery. The LTC3305 can operate in one of two modes, TIMER mode or CONTINUOUS mode, programmable via the MODE pin. Balancing operation begins once the CBOOST capacitor is charged to at least 6.95V. The EN1 and EN2 pins select the number of batteries in the stack. EN1 EN2 Application 0 0 SHUTDOWN 0 1 2 Battery Stack 1 0 3 Battery Stack 1 1 4 Battery Stack With the MODE pin set to 0 the LTC3305 will operate in the TIMER Mode. The BAL pin will be pulled low, indicating that the part is enabled and balancing the battery stack. The balancing operation begins with the terminal of the auxiliary cell connected to the negative terminal of BAT1, the lowest battery in the stack. The bottom switches that connect the negative terminals of BAT1 to the Auxiliary cell’s negative terminal are turned on. After a 50ms delay, 2 the voltages across the auxiliary cell and BAT1 are compared by the termination sense comparator. If the voltage difference between the auxiliary cell and BAT1 is less than the selected termination voltage, the battery is deemed to be in a balance state with respect to the auxiliary cell. The bottom switches will be turned off and the next battery within the stack will be connected. If the voltage difference between the auxiliary cell and BAT1 is greater than the selected termination voltage, the top switches that connect the positive terminal of BAT1 to the auxiliary cell’s positive terminals through the PTC thermistor are turned on. Current is limited by the PTC thermistor. Figure 3 shows the startup battery current where the PTC is limiting as it heats up. Figure 4 is the steady state battery current after the PTC has reached its thermal equilibrium. After a 50ms delay, the termination sense comparator starts to monitor the voltage across the auxiliary cell and the battery. The battery will remain connected to the auxiliary cell until the voltage difference decreases to the selected termination voltage or a tBAT timeout occurs. At this point all switches are turned off and the second battery in the stack will be connected to the auxiliary cell after a 50ms delay. This 50ms delay provides a break before make function before the next battery is connect-ed. The cycle will be repeated for each battery in the stack. dc2043af DEMO MANUAL DC2043A OPERATING PRINCIPLE In TIMER mode, the balancing operation continues for a maximum of the programmed tON time. After the tON time, LTC3305 is put into a low power off state for a programmed tOFF time, even though the batteries may not be balanced. Once the tOFF time expires, the LTC3305 is put into the ON state and normal operation resumes. The BAL pin is in its high impedance state if the part is in the OFF state or when the part is in shutdown. BAT CURRENT BATTERY BALANCING CURRENT 0.25V DIFFERENTIAL BETWEEN BATTERY AND AUX BATTERY dc2043a F03 100mA/DIV Figure 3. Start-Up Battery Balancing Current 1.There are no ON or OFF states. The balancing operation continues even if the stack is in balance. The balancing operation is terminated only if the part is put into shutdown. The BAL pin is always pulled low. 2.In CONTINUOUS mode, the top switches are turned on and balancing operation on a battery is terminated by the tBAT time out. Since the auxiliary cell remains connected to the battery until a tBAT time out, its voltage can change before it connects to the next battery in the stack. As a result, when the stack is balanced and the DONE pin is pulled low, the voltages across individual batteries in the stack may differ by more than the programmed VTERMINATE. In the worst case, when the capacity of the auxiliary cell is much smaller than the battery, the individual battery voltages will differ by twice the programmed VTERMINATE when balanced. BAT CURRENT BATTERY BALANCING CURRENT 0.25V DIFFERENTIAL BETWEEN BATTERY AND AUX BATTERY 100mA/DIV With the MODE pin set to 1, the LTC3305 will operate in the CONTINUOUS Mode. The part functions in much the same way as in the TIMER mode with the following differences. dc2043a F04 Figure 4. Steady State Battery Balancing Current Once all batteries in the stack are balanced the DONE pin is pulled low, the BAL pin is in its high state and the LTC3305 is put into a low power off state. The stack is deemed balanced when for a four battery stack, the termination sense comparator detects VTERMINATE on five consecutive cycles that connects each of the batteries to the auxiliary cell using the bottom switches only. The LTC3305 provides undervoltage and overvoltage threshold detection that can be programmed using resistors that are connected between the ISET, VL and VH pins and ground. The voltages set on VL and VH are scaled by a factor of 10, setting the battery undervoltage and overvoltage thresholds, respectively. When an undervoltage or overvoltage fault condition is detected, the corresponding UVFLT or OVFLT pin is pulled low. The balancing operation is not interrupted during this time. If the fault condition goes away during balancing, the corresponding fault pin is put into its high impedance state. dc2043af 3 DEMO MANUAL DC2043A QUICK START PROCEDURE Using short twisted pair leads for any power connections, with all loads and power supplies off, refer to Figure 5 for the proper measurement and equipment setup. 5. Set JP2 to EN. Measure the voltage from the BOOST Test Point to V4. The voltage should read approximately 8.5V. Follow the procedure below: 6. Measure the voltage from the ISET Test Point to ground. The voltage should read approximately 1.2V. 1. Before connecting PS1-PS5 to the DC2043A, the power supplies must have its current limit set to 5A . For most power supplies with a current limit adjustment feature the procedure to set the current limit is as follows. Turn the voltage and current adjustment to minimum. Short the outputs terminals and turn the voltage adjustment to maximum. Adjust the current limit to 5A for PS1. Turn the voltage adjustment to minimum and remove the short between the output terminals. Repeat for PS2-PS5 The power supplies are now current limited to 5A . a. Initial Jumper and PS settings: JP1(MODE) = CONT JP2 (EN) = SD JP3(TERM1) = 1 JP4 (TERM2) = 1 PS1 = Off PS2 = Off PS3 = OFF PS4 = OFF PS5 = Off PS6 = Off 2. Connect power supplies, load resistors and meters as shown in Figure 5. Turn on PS1 and slowly increase voltage to 2.0V while monitoring the input current. If the current remains less than 200mA, increase PS1 to 12.0V. Repeat for PS2-PS4. 3. Turn on PS5 and slowly increase voltage to 2.0V while monitoring the input current. If the current remains less than 200mA, increase PS5 to 11.8V. Turn on PS6 and slowly increase voltage to 2.0V while monitoring the input current. If the current remains less than 20mA, increase PS6 to 5.0V. 4. Measure the voltage from the VREG Turret to ground. The voltage should read approximately 2.6V. Measure the voltage from the BOOST Test Point to V4. The voltage should read approximately 0V. No LED should be on. 4 7. Measure the voltage from the VH Test Point to ground. The voltage should read approximately 1.52V. 8. Measure the voltage from the VL Test Point to ground. The voltage should read approximately 0.95V. 9. With JP1 set to CONT, JP2 set to EN, JP3 set to 1 and JP4 set to 1, observe that the BATX and BATY LEDs are cycling through their four states. BATX LED OFF OFF ON ON BATY LED OFF ON ON OFF Active Battery BAT1 BAT2 BAT3 BAT4 10.Decrease PS1 and PS5 to 9.4V and observe that while the BATX and BATY are off, the UVFLT LED is on. 11.Increase PS1 and PS5 to 15.9V and observe that while the BATX and BATY are off, the OVFLT LED is on. Decrease PS1and PS2 to 12.0V. 12.Decrease PS2 to 11.5V. Set JP1 to TIMER. Observe that the BATX LED is off and BATY LED is on the majority of the time .Increase PS2 to 12V and observe that the balancing action stops. The BAL LED will be off and the DONE LED will be on. 13.Set JP1 to CONT and JP2 to SD. Set PS5 to 11.8V. Observe that balancing action has stopped and no LEDs are on. Set JP2 to EN and observe that balancing action starts. 14.Turn off all power supplies dc2043af DEMO MANUAL DC2043A QUICK START PROCEDURE 10Ω 25W + PS5 + PS6 5V + 10Ω 25W PS4 10Ω 25W PS3 10Ω 25W PS2 5Ω 50W PS1 + + + Figure 5. Proper Measurement Equipment Set-Up dc2043af 5 DEMO MANUAL DC2043A Parts List ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER CAP.,X7R, 4.7µF, 25V, 20%, 0805 TDK, C2012X7R1E475M Required Circuit Components 1 4 C1-C4 2 7 C5, C6, C12-C16 CAP.,X7R, 10µF, 25V, 20%, 1206 MURATA, GRM31CR71E106KA12 3 1 C7 CAP.,C0G, 0.033µF, 50V, 5%, 0805 TDK, CGA4J2C0G1H333J125AA 4 2 C8, C9 CAP.,C0G, 0.01µF, 50V, 5%, 0805 TDK, CGA4C2C0G1H103J060AA 5 1 C10 CAP., X7R, 1.0µF, 16V, 10%, 0603 MURATA, GRM188R71C105KA12D 6 2 D1-D2 SMD, SCHOTTKY DIODE, 1A, 100V, SOD123 CENTRAL SEMI, CMMSH1-100G 7 10 Q1-Q3_1, Q3_2, Q4-Q9 MOSFET, 100V, 0.009Ω, 60A,POWERPAK-SO-8 VISHAY, SiR882DP 8 8 R1, R2, R4-R9 RES, CHIP, 6.04k, 1/16W, 1%, 0402 VISHAY, CRCW04026K04FKED 9 1 R3 RES, CHIP, 3.01k, 1/16W, 1%, 0402 VISHAY, CRCW04023K01FKED 10 2 R10, R11 RES, CHIP,12.1k, 1/8W, 1%, 0805 VISHAY, CRCW080512K1FKED 11 7 R12-R18 RES, CHIP, 10.0, 1/16W, 1%, 0402 VISHAY, CRCW040210R0FKED 12 2 R19, R34 RES, CHIP, 665, 1/2W, 1%, 1210 VISHAY, CRCW1210665RFKED 13 1 R20 RES, CHIP, 12.1k, 1/16W, 1%, 0402 VISHAY, CRCW040212K1FKED 14 1 R21 RES, CHIP, 46.4k, 1/16W, 1%, 0402 VISHAY, CRCW040246K4FKED 15 1 R22 RES, CHIP, 28.7k, 1/16W, 1%, 0402 VISHAY, CRCW040228K7FKED 16 4 R30-R33 RES, CHIP, 1.82M, 1/16W, 1%, 0402 VISHAY, CRCW04021M82FKED 17 1 R35 RES, CHIP, 249, 1/4W, 1%, 1206 VISHAY, CRCW1206249RFKED 18 1 RT1 DISC, TH, PTC, 0.15Ω, 16V, 10.1mm DIA, MURATA, PTGLESARR15M1B51B0 19 1 U1 IC,SMT, LEAD ACID BATTERY BALANCER/EFE LINEAR, LTC3305EFE#PBF Additional Demo Board Circuit Components 1 1 C11 CAP., X7R, 4.7µF, 25V, 20%, 0805 TDK, C2012X7R1E475M 2 3 D3, D6, D7 SMD, RED LED, 0603 LITE ON, LTST-C193KRKT-5A 3 4 D4, D5, D8, D9 SMD, GREEN LED, 0603 LITE ON, LTST-C193KGKT-5A 4 4 F1-F4 SMD, FUSE, 7A, FAST ACTING, 1206 32VDC BUSSMANN, 3216FF7-R 5 6 F5-F10 SMD, FUSE, 1/4A, FAST ACTING, 1206 32VDC BUSSMANN, 3216FF250-R 6 1 Q10 MOSFET, P-CHANNEL, 20V, 0.085Ω, 0.95ASOT-23 CENTRAL SEMI, CMPDM8120 7 7 R23-R29 RES, CHIP, 1.00k, 1/16W, 1%, 0402 VISHAY, CRCW04021K00FKED 8 1 R36 RES, CHIP, 100k, 1/16W, 1%, 0402 VISHAY, CRCW0402100KFKED 9 7 R37-R43 RES, CHIP, 2.00k, 1/16W, 1%, 0402 VISHAY, CRCW04022K00FKED Hardware: For Demo Board Only 1 7 E1-E7 Turret, 0.061" MILL-MAX, 2308-2-00-80-00-00-07-0 2 17 E8-E24 Turret, 0.09" MILL-MAX, 2501-2-00-80-00-00-07-0 3 4 JP1-JP4 HEADER, 3PINS, 2mm SAMTEC, TMM-103-02-L-S 4 4 JP1-JP4 SHUNT 2mm SAMTEC, 2SN-BK-G 5 6 STAND-OFF, NYLON 0.375" tall KEYSTONE, 8832 (SNAP ON) 6 dc2043af 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. GND_K E16 VEXT_RTN E15 3.3V - 5.5V VEXT BATX E7 BATY E6 OVFLT E5 UVFLT E4 BAL E3 DONE E2 PTCFLT E1 C11 4.7uF PTCFLT D3 LED-LN RED R28 1k R26 1k R24 1k PTCFLTB R29 1k R27 1k R25 1k R23 1k TP3 U1 CTBAT TP2 C8 10nF 50V 5% 15 DONEB DONE GRN D4 LED-LN NG8 16 17 BATX NG9 18 BATY 20 UVFLTB 19 21 BALB OVFLTB 22 DONEB 23 LTC3305EFE CTON PTCFLTB TP4 R37 2k CTOFF C7 33nF 50V 5% GND_K 3. INSTALL SHUNTS ON JUMPERS AS SHOWN. VL TP14 C9 10nF 50V 5% NG8 NG9 BATX BATY OVFLT UVFLT BAL DONE PTCFLT R38 2k VH TP15 28.7k R22 BALB BAL D5 LED-LN GRN R20 TERM2 TP16 ISET 46.4k 12.1k R21 E17 VREG 2.5V R39 2k UVFLTB UVFLT D6 LED-LN RED JP3 TERM1 R30 1.82M 0 JP4 1 R40 2k R31 1.82M 0 1 BATTERY 4 BATTERY 3 BATTERY 2 BATTERY 1 BATTERY BEING BALANCED V2 AUXN AUXP V3 V4 BOOST CM CP GND OVFLTB OVFLT D7 LED-LN RED SD 4 R41 2k GND_K 6 BAT2_K C13 10uF 1206 BATY BATY D8 LED-LN GRN BALB C12 10uF 1206 BAT1_K C14 10uF 1206 C15 10uF 1206 BOOST 3 BAT3_K 5 1210 1210 R19 665 R34 665 R33 1.82M JP1 MODE BAT4 R42 2k R36 100k AUXN_K E24 AUXP_K E23 BATX BATX R43 2k Q10 CMPDM8120 1206 D9 LED-LN GRN AUXN_K C16 1206 10uF 1206 F10 1/4A C6 1206 10uF 1206 AUXP_K F9 1/4A C10 1uF 16V 0603 10% CMMSH1-100G D1 GND_K TIMER CONT. VREG ± 100mV ±50mV ± 25mV ± 12.5mV TERMINATION VOLTAGE C5 10uF D2 CMMSH1-100G 1206 TP18 CM R35 249 CP TP17 2 BAT4_K 1 EN R32 1.82M 38 TP1 37 39 JP2 EN 1 OFF ON 1 ON ON 0 0 1 1 OFF TERM2 0 0 OFF ON OFF TERM1 BATY LED BATX LED E9 E8 NG7 TP10 NG7 5 6 7 8 10 R16 10 R15 5 6 7 8 Q6 SiR882DP Q7 SiR882DP 3 2 1 R6 6.04k R7 6.04k THIS CIRCUIT IS PROPRIETARY TO LINEAR TECHNOLOGY AND SUPPLIED FOR USE WITH LINEAR TECHNOLOGY PARTS. CUSTOMER NOTICE 10 R18 Q9 SiR882DP 3 5 2 6 1 7 8 R9 6.04k 5 6 7 8 3 2 1 NG5 SCALE = NONE JD NC 3 - 8 7 6 5 0805 1 2 3 SiR882DP Q2 N/A DATE: SIZE 9 - 23 - 14 IC NO. Q5 R1 1 2 3 6.04K 1 2 3 6.04K R2 Q3_2 SiR882DP 8 7 6 5 SiR882DP 8 7 6 5 Q4 C4 4.7uF F1 7A E20 E12 BAT2_K BAT2 GND E22 GND_K E14 9.5V-15.5V E21 E13 BAT1_K BAT1 9.5V-15.5V GND_K 1206 E19 BAT3_K E11 BAT3 9.5V-15.5V 1206 F2 7A E18 9.5V-15.5V 1206 F3 7A E10 1206 BAT4_K BAT4 F4 7A F8 1206 1/4A 1206 F7 1/4A 1206 F6 1/4A 1206 F5 1/4A DATE 9- 23 - 14 LTC3305EFE DEMO CIRCUIT 2043A SHEET 1 3 REV. OF 1 LEAD ACID BATTERY BALANCER 1630 McCarthy Blvd. Milpitas, CA 95035 Phone: (408)432-1900 www.linear.com Fax: (408)434-0507 LTC Confidential-For Customer Use Only GND BAT1_K C1 4.7uF BAT1 BAT2_K C2 4.7uF BAT2 BAT3_K C3 4.7uF BAT3 BAT4_K BAT4 JD SiR882DP 8 7 6 5 APPROVED DESCRIPTION REVISION HISTORY PRODUCTION FAB TECHNOLOGY SiR882DP Q1 8 7 6 5 R10 12.1k 0805 R11 12.1k 1 2 3 R3 3.01K R12 10 1 2 3 R4 6.04K R13 10 1 2 3 R5 6.04k R14 10 REV ECO TITLE: SCHEMATIC NG1 NG2 APPROVALS TP5 NG1 8 7 6 5 Q3_1 SiR882DP TP13 NG3 NG3 TP7 NG4 NG4 TP8 NG5 TP6 NG2 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 APP ENG. APPLICATION. COMPONENT SUBSTITUTION AND PRINTED CIRCUIT BOARD LAYOUT MAY SIGNIFICANTLY AFFECT CIRCUIT PERFORMANCE OR RELIABILITY. CONTACT LINEAR TECHNOLOGY APPLICATIONS ENGINEERING FOR ASSISTANCE. NG9 Q8 SiR882DP R8 6.04K 3 2 1 TP11 R17 NG8 NG8 10 AUXN 9.5V-15.5V AUXP PTGLESARR15M1B51B0 RT1 NG6 TP9 NG6 TP12 NG9 t 1 2 2. ALL CAPACITORS ARE IN MICROFARADS, 0805, 20%, 25V. 24 NG7 14 4 1. ALL RESISTORS ARE IN OHMS, 0402, 1%, 1/16W. 25 CTOFF NG7 26 NG6 13 CTON 27 CTBAT NG6 28 VL 29 VH NG5 NG5 12 30 NG4 11 ISET 31 VREG NG4 32 NG3 10 TERM2 33 TERM1 NG3 34 EN2 35 EN1 9 NG2 NG2 NC 36 MODE NG1 8 NG1 V1 7 4 4 4 4 4 4 4 4 4 NOTES: UNLESS OTHERWISE SPECIFIED DEMO MANUAL DC2043A Schematic Diagram dc2043af 7 DEMO MANUAL DC2043A 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 8 dc2043af Linear Technology Corporation LT 1214 • PRINTED IN USA 1630 McCarthy Blvd., Milpitas, CA 95035-7417 (408) 432-1900 ● FAX: (408) 434-0507 ● www.linear.com LINEAR TECHNOLOGY CORPORATION 2014