DEMO MANUAL DC2134A LTC4020EUHF High Power Buck-Boost Multi-Chemistry Battery Charger Description Demonstration circuit 2134A is a high power buck-boost multichemistry battery charger featuring the LTC®4020. The board will accept an input voltage between 15V and 55V. The float voltage of the battery output (BAT) is 25.2V, with 6.3A maximum charge current. The converter output (VOUT) has a voltage range of 21V to 28V, with 8A 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 (JP1: CC/CV, Performance Summary PARAMETER with mode pin grounded), constant-current charging (JP1: CC, with mode pin floated), or charging with an optimized 4-step, 3-stage lead-acid battery charge profile (JP1: leadacid, with mode pin connected to INTVCC). 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/DC2134A 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 CONDITION Input Voltage Range VALUE 15V to 55V Battery Float Voltage (BAT) (Nominal) IBAT = 0A Converter Output Voltage (VOUT) IOUT = 0A to 8A Maximum Battery Charge Current, IBAT IOUT = 0A 6.3A Maximum Converter Output Current, IOUT IBAT= 0A 8A Typical Efficiency VIN = 24V, VOUT = 25.2V, IOUT = 8A Typical Converter Output Ripple VIN = 55V, VOUT = 25.2V, IOUT = 8A (20MHz Bandwidth) 25.2V 21V to 28V 98.1% 109mVP–P dc2134af 1 DEMO MANUAL DC2134A Quick Start Procedure Demonstration circuit 2134A 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: 1. With power off, connect the input power supply (set for 0V) to VIN and GND (input return). 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 (8A 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. 2 Additional Notes: 1. CAUTION: Be careful when testing with high voltage. High voltage can result in an electric shock if care is not taken. 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. 3. The combined converter output load current and battery charging current should not exceed 8A. 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. dc2134af DEMO MANUAL DC2134A Quick Start Procedure Figure 1. Proper Measurement Equipment Setup + VOUT – COUT GND Figure 2. Measuring Output Voltage Ripple dc2134af 3 DEMO MANUAL DC2134A Quick Start Procedure 100 95 90 85 EFFICIENCY (%) 80 75 70 65 60 55 50 45 15VIN, 25.2VOUT 24VIN, 25.2VOUT 55VIN, 25.2VOUT 40 35 30 0.1 1 LOAD CURRENT (A) 10 DC2134A F03 Figure 3. Efficiency vs Load Current (VOUT = 25.2V) 99.0 98.5 98.0 97.5 EFFICIENCY (%) 97.0 96.5 96.0 95.5 95.0 94.5 94.0 93.5 93.0 92.5 92.0 25.2VOUT, 8A 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 VIN (V) DC2134A F04 Figure 4. Efficiency vs Input Voltage (VOUT = 25.2V, IOUT = 8A) 4 dc2134af DEMO MANUAL DC2134A Parts List ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER Required Circuit Components 1 1 C1 CAP, CHIP, X7S, 0.1µF, 10%, 100V, 0603 TDK, C1608X7S2A104K 2 2 C2,C3 CAP, ELEC., 56µF, 20%, 63V, 10X12.5 SUNCON, 63HVH56M 3 1 C4 CAP, CHIP, C0G, 100pF, 10%, 16V, 0402 AVX, 0402YA101KAT9A 4 1 C6 CAP., MLCC, 6800pF, 50V,10%, 0603 AVX,ESD35C682K4T2A-18 5 1 C8 CAP, CHIP, C0G, 47pF, 10%, 50V, 0603 AVX., 06035A470KAT2A 6 1 C11 CAP, CHIP, X5R, 4.7µF, 10%, 6.3V, 0603 AVX, 06036D475KAT2A 7 1 C12 CAP, CHIP, X7R, 0.033µF, 10%, 25V, 0402 TDK, C1005X7R1E333K 8 4 C14, C18, C27, C28 CAP, CHIP, X5R, 10µF, 20%, 35V, 1210 AVX, 1210DD106MAT2A 9 2 C15, C17 CAP, ELEC., 220µF, 20%, 35V 10X12.5 SUNCON, 35HVH220M 10 2 C16, C23 CAP, CHIP, X7S, 4.7µF, 20%, 100V, 1210 TDK,C3225X7S2A475M 11 3 C5, C19, C20 CAP, CHIP, X5R,0.22µF, 10%, 25V, 0603 AVX, 06033D224KAT2A 12 1 C21 CAP, CHIP, X5R, 10µF, 20%, 6.3V, 0805 AVX., 08056D106KAT2A 13 2 C39, C40 CAP, CHIP, X7R,0.22µF, 20%, 10V, 0603 AVX, 0603ZC224MAT2A 14 2 D1, D2 DIODE, SMT, SUPERBARRIER, 60V, 0.5A, SOD123 DIODES INC., SBR0560S1-7 15 1 D3 DIODE, LED, RED, SMT, 0603 WÜRTH, 150060SS75000 16 1 D4 DIODE, LED, GREEN, 0603 WÜRTH, 150060VS75000 17 1 D6 DIODE., SMT SCHOTTKY BARRIER RECTIFIER, SMA VISHAY, B360A-E3 18 1 L1 IND, SMT, 5.6µH WÜRTH, 7443556560 19 1 M1 P-CHANNEL MOSFET, –30V PowerPAKS08 VISHAY, Si7145DP-T1-GE3 20 2 M2, M4 N-CHANNEL MOSFET, 60V, PowerPAKS08 VISHAY, SiR664DP-T1-GE3 21 2 M3, M7 N-CHANNEL MOSFET, 40V, PowerPAKS08 VISHAY, SiR422DP-T1-E3 22 1 RCBAT1 RES, CHIP, 0.008Ω, 1%, 1W, 2512 VISHAY, WSL25128L000FEA 23 2 RCBRB1, RCBRT1 RES, CHIP, 0.002Ω, 1%, 1W, 2512 VISHAY, WSL25122L000FEA 24 2 R1, R13 RES, CHIP, 100kΩ, 5%, 0402 VISHAY, CRCW0402100KJNED 25 1 R2 RES, CHIP, 510kΩ, 5%, 0402 VISHAY, CRCW0402510KJNED 26 1 R4 RES, CHIP, 51kΩ, 1%, 0402 VISHAY, CRCW040251K0FKED 27 3 R6, R7, R19 RES, CHIP, 20Ω, 5%, 0402 VISHAY, CRCW040220R0JNED 28 1 R8 RES, CHIP, 226kΩ, 0.1%, 0603 VISHAY, TNPW06030F226BEEA 29 1 R9 RES, CHIP, 226kΩ, 1%, 0603 VISHAY, CRCW0603226KFKEA 30 1 R10 RES, CHIP, 24.9kΩ, 0.1%, 0402 VISHAY, TNPW04020F24K9BEED 31 1 R11 RES, CHIP, 24.9kΩ, 1%, 0402 VISHAY, CRCW040224K9FKED 32 1 R14 RES, CHIP, 10kΩ, 1%, 0402 VISHAY, CRCW040210K0FKED 33 1 R15 RES, CHIP, 36kΩ, 1%, 0603 VISHAY, CRCW060336K0FKEA 34 1 R16 RES, CHIP, 47kΩ, 1%, 0603 VISHAY, CRCW060347K0FKEA 35 2 R18, R20 RES, CHIP, 100Ω, 5%, 0402 VISHAY, CRCW0402100RJNED 36 2 R26, R27 RES, CHIP, 3kΩ, 5%, 0402 VISHAY, CRCW04023K00JNED 37 1 U1 IC, LTC4020EUHF, 5mm × 7mm QFN-38 LINEAR TECH., LTC4020EUHF dc2134af 5 DEMO MANUAL DC2134A Parts List ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER Additional Demo Board Circuit Components 1 0 C13, C7, C9, C10, C30, C31 (OPT) CAP, CHIP, OPT 0603 OPT 2 0 C22, C24, C25 (OPT) CAP, CHIP, OPT 0402 OPT 3 0 C26, C29, C32-C38 (OPT) CAP, CHIP, OPT 1210 OPT 4 0 D5 (OPT) DIODE, OPT SMA OPT 5 0 D7 (OPT) DIODE, OPT SOD123 OPT 6 0 M5, M6, M8, M9 (OPT) N-CHANNEL MOSFET, OPT PowerPAKS08 OPT 7 0 R3 (OPT) RES, OPT 0402 OPT 8 8 R21-25, R34, R35, R37 RES, CHIP, 0Ω JUMPER, 0402 VISHAY, CRCW04020000Z0ED 9 0 R17, R31, R32 (OPT) RES, OPT 0603 OPT 10 1 R36 RES, CHIP, 0Ω JUMPER, 0603 VISHAY, CRCW06030000Z0EA 11 1 R38 RES, CHIP, 5.1, 5%, 0805 VISHAY,CRCW08055R10JNEA TURRET, 0.09" DIA MILL-MAX, 2501-2-00-80-00-00-07-0 Hardware: For Demo Board Only 6 1 8 E1, E2, E5, E9, E10, E13, E14, E17 2 6 E3, E4, E11, E12, E15, VERTICAL BANANA JACK, 575-4 E16 KEYSTONE, 575-4 3 1 JP1 HEADER, HD2X3-079 WÜRTH, 62000311121 4 1 XJP1 SHUNT, .079" CENTER WÜRTH, 60800213421 5 4 STAND-OFF, NYLON (SNAP ON), 0.375" TALL KEYSTONE, 8832 (SNAP ON) dc2134af 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 VIN VIN E17 E9 E5 E2 E4 E3 E1 1 3 5 JP1 MODE C3 56uF 63V 63HVH56M 2 CC/CV 4 CC 6 LEAD-ACID + C4 100pF 16V C24 OPT C2 56uF 63V 63HVH56M R14 10k + 5 INT_VCC NTC SGND SHDN GND GND 15V - 55V 5 C23 C16 4.7uF 100V 1210 R13 100k 0 R37 C25 OPT R3 OPT R1 100k C13 OPT 0603 R17 OPT 0603 R11 24.9k 1% R10 24.9k 0.1% C5 0.22uF 0603 R9 226k 0603 1% R7 20 R6 20 C39 0.22uF 0603 R8 226k 0603 0.1% VOUT R4 51k VBAT C40 0.22uF 0603 C34 C33 C32 C29 OPT 1210 R2 510k 4 4 8 14 11 24 16 18 17 26 19 25 15 10 9 RT TIMER MODE CSOUT NTC FBG VFB VFBMAX VFBMIN ILIMIT RNG/SS 36 PVIN C1 3 29 SGND 35 PGND 39 SGND Vc ITH BAT BGATE CSN CSP BG2 TG2 SENSBOT SENSGND BG1 TG1 SW1 SW2 STAT1 BST1 BST2 STAT2 INT_Vcc SENSVIN SENSTOP 0.1uF 100V 0603 U1 LTC4020EUHF SGND VIN_REG SHDN R38 5.1 0805 28 27 20 21 22 23 33 31 5 4 37 1 38 32 12 2 30 13 34 7 6 0 R22 0 R24 1 2 3 1 2 3 3 C7 OPT 0603 RCBRB1 0.002 1W 2512 C6 6.8nF 0603 R15 36k 0603 R34 0 R21 0 C12 0.033uF 4 C8 47pF 0603 R16 47k 0603 0 R35 4 1 2 3 0603 D6 B360A C20 0.22uF 25V 0603 100 R18 100 R20 C31 OPT 0603 R32 OPT 0603 4 3 2 1 4 M8 OPT C10 OPT 0603 2 R23 0 4 RCBAT1 0.008 1W 2512 1210 35V C18 10uF 1210 35V C27 10uF C28 10uF VBAT + E11 E12 E10 GND GND VOUT 21V - 28V 8A MAX VOUT GND BAT 25.2V FLOAT 6.3A MAX BAT E13 E15 C17 220uF 35V 35HVH220M 1 C26 OPT 1210 + C15 220uF 35V 35HVH220M E16 E14 TECHNOLOGY 1210 35V C38 C37 C36 C35 OPT 1210 1 1210 35V C14 10uF M1 Si7145DP 1 2 3 5 6 7 8 R25 0 4 VOUT 3 2 1 8 7 6 5 4 8 7 6 5 M3 SiR422DP M9 OPT D4 GRN M7 3 2 1 SiR422DP 8 7 6 5 3 2 1 8 7 6 5 D7 OPT D3 RED C11 4.7uF 6.3V 0603 R19 20 D5 OPT 3K R26 R27 3K D2 SBR0560S1 WURTH 7443556560 L1 5.6uH C19 0.22uF 25V 0603 D1 SBR0560S1 INT_VCC 2 C9 OPT 0603 1 2 3 M5 OPT 5 6 7 8 C30 OPT 0603 R31 OPT 0603 R36 0 M6 OPT 5 6 7 8 5 6 7 8 4 RCBRT1 0.002 1W 2512 5 6 7 8 M4 SiR664DP M2 SiR664DP 4 C21 10uF 6.3V 0805 C22 OPT 3 A B C D DEMO MANUAL DC2134A Schematic Diagram dc2134af 7 DEMO MANUAL DC2134A 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 dc2134af Linear Technology Corporation LT 0414 • PRINTED IN USA 1630 McCarthy Blvd., Milpitas, CA 95035-7417 (408) 432-1900 ● FAX: (408) 434-0507 ● www.linear.com LINEAR TECHNOLOGY CORPORATION 2014