DC1830B-D - ANALOG DEVICES

dc1830b-c/b-df

DEMO MANUAL

DC1830B-C/DC1830B-D

DESCRIPTION

LTC4000-1

Battery Charger Controller and

PowerPath Manager with

Maximum Power Point Control

Demonstration circuit 1830B is a battery charger control-

ler and PowerPath™ manager with maximum power point

control (MPPC) featuring the LTC

4000-1. MPPC extracts

near maximum power from high impedance sources

such as solar panels, wind turbines or fuel cells. MPPC

is achieved by means of an input voltage regulation con-

trol loop. This board should be connected to a front-end

DC/DC power supply for a complete charger solution.

The DC1830B 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 DC1830B is

targeted at 4-cell LiFePO4 (14.6V/5A) applications.

The DC1830B loop compensation values were proven with

the LTC3845A buck power converter shown and are typi-

cal 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 ad-

justed to suit specific applications with guidance provided

in the LTC4000-1 data sheet. Table 1 provides a summary

of parameter adjustments. 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.

This circuit was designed to demonstrate the high levels

of performance and small solution size attainable using

this part 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 DC1830B-C provides a solution complete with both

battery charger control and PowerPath management. 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 DC1830B-D provides a simple battery-charger-con-

troller-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

dc1830b-c/b-df

DEMO MANUAL

DC1830B-C/DC1830B-D

PERMORMANCE SUMMARY

QUICK START PROCEDURE

SYMBOL PARAMETER CONDITIONS/COMMENTS MIN TYP MAX UNITS

VIN Input Supply Range This Is the Input Voltage of the Front-End DC/DC Supply 20 60 V

VIN-MP Input Regulation Voltage This Is the Input Voltage Lower Limit Set by the LTC4000-1 35.1 V

VFLOAT Battery Float Voltage 14.4 14.6 14.8 V

Output Regulation Line and Load (20V to 60V, 0A to 4.5A) 0 %

IBAT Battery Charge Current 5.0 A

Battery Charge Current – Trickle 0.6 A

tTCharge Termination Time VBAT = VFLOAT 2.9 Hours

VOUT-SYS System Output Voltage 12.3 14.6 15.5 V

IOUT-SYS System Output Current Range 0 5.5 A

Demonstration circuit 1830 is offered for use in com-

bination 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 LTC4000-1/LTC3789 buck-boost combination, the

DC1721B. The LTC4000-1 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 LTC4000-1 when combined with a suitable switching

power converter, such as the LTC3845A. Voltages and

currents cited in this procedure are for the design as de-

livered; if the design has been customized, substitute the

appropriate values. Refer to Figure 1 for proper measure-

ment 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 36V. 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 LTC4000-1.

b. Input voltages lower than the MPPC regulation point

(35.1V) will reduce the associated DC/DC converter’s

output to a minimum.

c. If efficiency measurements are desired, refer to Fig-

ure 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, con-

nect 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.

Specifications are at TA = 25°C

dc1830b-c/b-df

DEMO MANUAL

DC1830B-C/DC1830B-D

QUICK START PROCEDURE

8. Once the proper BAT output voltage is again es-

tablished, adjust the load and/or source within the

operating range and observe the battery float voltage

regulation, charge current, and other desired param-

eters.

9. Set the load to constant voltage mode to more easily

observe charge current and trickle charge current.

10. In order to observe MPPC operation, add a 4.7Ω or

5Ω, 10W resistor in series with the DC source and set

the source to 40V. Use a constant voltage or constant

resistance load characteristic. As the load is increased,

the input voltage will be regulated at the MPPC

regulation point (35.1V) by reducing the output of the

DC/DC converter.

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-R12, 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 condi-

tions, lower current available to VOUT-SYS, or where

continuous short circuit protection on VOUT-SYS is

not required.

NOTE: The following applies to the DC1830B-C.

11. Turn off the power at the input.

12. Connect the output load and meters to the VOUT-SYS

output.

13. Set CHARGE jumper to DISABLE.

14. Turn on the power at the input.

15. 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, output current limit and other desired

parameters.

Table 1. LTC4000-1 Charger Setup Parameters and Reference Values

REFERENCE DESCRIPTION NOMINAL VALUE (V)* MIN/MAX CONDITIONS

VIN Input Voltage Regulation/Limit 1.000V 0.985/1.010

ICL Charge Current Regulation/Limit (50μA • RCL)/20 45/55 50mV Max

ICL Trickle Charge Current Regulation/Limit (50μA • RCL)/20 4.5/5.5

VBAT-FLOAT Battery Float Voltage 1.136V 1.125/1.147

VOUT

System Voltage

1.193V 1.181/1.204 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

VMInput Voltage Monitor/UVLO 1.193V 1.181/1.204 Falling, (40mV Hysteresis)

CX C/X Monitor/Charge Termination (5μA • RCX – 10mV)/20 4.5/5.5 Short TMR to BIAS for C/X Termination

TMR Charge Termination Timer 104s/nF 83/126

*Normalized to sense point.

dc1830b-c/b-df

DEMO MANUAL

DC1830B-C/DC1830B-D

QUICK START PROCEDURE

–

–+

SCOPE

–

LOAD

–+

–

SOURCE

Figure 1. Fixture Connections and Measurement Equipment Setup

Figure 2. Block Diagram with Typical DC/DC Converter

dc1830b-c/b-df

DEMO MANUAL

DC1830B-C/DC1830B-D

PAR

TS LIST—DC1

-C

ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER

Required Circuit Components

1 1 C1 CAP., X5R, 4.7μF, 10V, 20% 0603 AVX, 0603ZD475MAT2A

2 1 CBAT CAP., SMT ALUMINUM, 150μF, 35V SUNCON, 35HVP150M

3 1 CBIAS CAP., X7R, 1μF, 16V, 10% 0603 AVX, 0603YC105KAT2A

4 1 CBGATE CAP., X7R, 10nF, 50V, 5% 0603 MURATA, GRM188R71H103JA01D

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 2 COUT, CL CAP., X7R, 2.2μF, 50V, 10% 1206 MURATA, GRM31CR71H225KA88L

9 1 D1 DIODE ZENER 3.0V 200MW SOD-323 DIODE INC.,BZT52C3V0S-7-F

10 1 D2 LED, GREEN, SMT, 0603 LITE-ON, LTST-C190KGKT

11 2 D3, D4 LED 660NM SUPER RED DIFF 0603 SMD LUMEX, SML-LX0603SRW-TR

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 2 RBFB2, ROFB2 RES., CHIP, 84.5k, 0.1W, 1% 0603 VISHAY, CRCW060384K5FKEA

16 4 RBFB1, ROFB1, R12, R17 RES., CHIP, 1M, 0.1W, 1% 0603 VISHAY, CRCW06031M00FKEA

17 1 RC1 RES., CHIP, 4.22k, 1/10W 1% 0603 YAGEO, RT0603FRE074K22L

18 1 RCL RES., CHIP, 24.3k, 0.1W, 1% 0603 VISHAY, CRCW060324K3FKEA

19 1 RCS SENSOR RES., 0.01Ω 1W 2% 1508 SMD SUSUMU, RL3720WT-R010-G

20 3 RCX, R8, R13 RES., CHIP, 10k, 0.1W, 1% 0603 YAGEO, RC0603FR-0710KL

21 1 RIFB1 RES., CHIP, 68.1k, 0.1W, 1% 0603 VISHAY, CRCW060368K1FKEA

22 1 RIL RES., CHIP, 2.0k, 0.1W, 1% 0603 VISHAY, CRCW06032K00FKTA

23 2 RNTC2, RNTC3 THERMISTOR NTC 10kΩ 5% 0603 VISHAY, NTHS0603N02N1002J

24 1 RIS1 SENSOR RES 0.015Ω 1W 2% 1508 SMD SUSUMU, RL3720WT-R015-G

25 1 RVM1 RES., CHIP, 35.7k, 1/10W 1% 0603 VISHAY, CRCW060335K7FKEA

26 1 RVM2 RES., CHIP, 2.49k, 1/10W 1% 0603 YAGEO, RC0603FR-072K49L

27 1 R5 RES., CHIP, 2.2k, 0.1W, 5% 0603 VISHAY, CRCW06032K2JKEA

28 3 R4, R7, R19 RES., CHIP, 100k, 0.1W, 5% 0603 VISHAY, CRCW0603100KJKEA

29 2 R6, R18 RES., CHIP, 4.7k, 0.1W, 5% 0603 VISHAY, CRCW06034K7JKEA

30 1 R9 RES., CHIP, 46.4k, 0.1W, 1% 0603 VISHAY, CRCW060346K4FKEA

31 2 R10, R15 RES., CHIP, 20k, 0.1W, 1% 0603 VISHAY, CRCW060320K0FKEA

32 2 R11, R16 RES., CHIP, 38.3k, 0.1W, 1% 0603 VISHAY, CRCW060338K3FKEA

33 1 R14 RES., CHIP, 78.7k, 0.1W, 1% 0603 VISHAY, CRCW060378K7FKEA

34 1 U1 I.C. LTC4000EUFD-1, 28-PIN QFN LINEAR TECH., LTC4000EUFD-1#PBF

35 2 U2, U3 NANOPWR COMPARATOR, MSOP8 LINEAR TECH., LTC1540CMS8#PBF

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, 50V OPT

3 0 F1, F3 FUSE 12A 32V T-LAG 1206 SMD OPT

4 0 Q3, Q4 MOSFET P-CHAN., 30V, POWERPAK-8 OPT

5 0 R1, R2, R3, R20, R21, RIG, RBG, RBFBX,

RBFB3, ROFBX

RES., 0603 OPT

dc1830b-c/b-df

DEMO MANUAL

DC1830B-C/DC1830B-D

PARTS LIST—DC1830B-C

PARTS LIST—DC1830B-D

ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER

Hardware-For Demo Board Only

1 16 E1-E6, E9-E14, E18, E19, E20, E21 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)

ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER

Required Circuit Components

1 1 C1 CAP., X5R, 4.7μF, 10V, 20% 0603 AVX, 0603ZD475MAT2A

2 1 CBAT CAP., SMT ALUMINUM, 150μF, 35V SUNCON, 35HVP150M

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 COUT CAP., X7R, 2.2μF, 50V, 10% 1206 MURATA, GRM31CR71H225KA88L

7 1 CIN CAP., X7R, 1μF, 50V, 10% 1210 AVX, 12105C105KAT2A

8 1 D1 DIODE ZENER 3.0V 200MW SOD-323 DIODE INC.,BZT52C3V0S-7-F

9 2 D2,D3 LED 660NM SUPER RED DIFF 0603 SMD LUMEX, SML-LX0603SRW-TR

10 1 D4 LED, GREEN, SMT, 0603 LITE-ON, LTST-C190KGKT

11 1 F2 FUSE 12A 32V T-LAG 1206 SMD COOPER BUSSMAN, 3216TD12-R

12 1 Q1 MOSFET P-CHAN., 30V, POWERPAK-8 VISHAY, SI7135DP-T1-GE3

13 2 RBFB1, ROFB1 RES., CHIP, 1M, 0.1W, 1% 0603 VISHAY, CRCW06031M00FKEA

14 1 RBFB2 RES., CHIP, 84.5k, 0.1W, 1% 0603 VISHAY, CRCW060384K5FKEA

15 1 RC1 RES., CHIP, 4.22k, 1/10W 1% 0603 YAGEO, RT0603FRE074K22L

16 1 RCL RES., CHIP, 24.3k, 0.1W, 1% 0603 VISHAY, CRCW060324K3FKEA

17 1 RCS SENSOR RES., 0.01Ω, 1W 2% 1508 SMD SUSUMU, RL3720WT-R010-G

18 2 RCX, R21 RES., CHIP, 0.0Ω, 0.1W, 0603 VISHAY, CRCW06030000Z0EA

19 1 RIFB1 RES., CHIP, 68.1k, 0.1W, 1% 0603 VISHAY, CRCW060368K1FKEA

20 1 RIL RES., CHIP, 2.0k, 0.1W, 1% 0603 VISHAY, CRCW06032K00FKTA

21 1 RIS1 SENSOR RES 0.015Ω, 1W 2% 1508 SMD SUSUMU, RL3720WT-R015-G

22 1 RVM1 RES., CHIP, 35.7k, 1/10W 1% 0603 VISHAY, CRCW060335K7FKEA

23 1 RVM2 RES., CHIP, 2.49k 1/10W 1% 0603 YAGEO, RC0603FR-072K49L

24 3 R4, R7, R19 RES., CHIP, 100k, 0.1W, 5% 0603 VISHAY, CRCW0603100KJKEA

25 1 R5 RES., CHIP, 2.2k, 0.1W, 5%, 0603 VISHAY, CRCW06032K2JKEA

26 2 R6,R18 RES., CHIP, 4.7k, 0.1W, 5% 0603 VISHAY, CRCW06034K7JKEA

27 1 R22 ZERO OHM THICK FILM JUMPER CHIP, 2010 IRC., LRC-LRZ-2010LF-R000

28 1 U1 I.C., LTC4000EUFD-1, 28PIN QFN LINEAR TECH., LTC4000EUFD-1#PBF

dc1830b-c/b-df

DEMO MANUAL

DC1830B-C/DC1830B-D

PAR

TS LIST—DC1

-D

ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER

Additional Demo Board Circuit Components

1 0 CC1, CBGATE, CIGATE, CNTC, CCX, CCL,

CIL, CVM

CAP., 0603 OPT

2 0 CL, CL1, CL2, CL3, CL4, CL5 CAP.,1206, 50V OPT

3 0 F1, F3 FUSE 12A 32V T-LAG 1206 SMD OPT

4 0 RNTC2, RNTC3 THERMISTOR NTC 10kΩ 5% 0603 OPT VISHAY, NTHS0603N02N1002J

5 0 R1, R2, R3, R20, RIG, RBG, RBFBX,

ROFBX, RBFB3, ROFB2

RES., 0603 OPT

6 0 R8, R13 RES., CHIP, 10k, 0.1W, 1% 0603 OPT YAGEO, RC0603FR-0710KL

7 0 R9 RES., CHIP, 46.4k, 0.1W, 1% 0603 OPT VISHAY, CRCW060346K4FKEA

8 0 R10, R15 RES., CHIP, 20k, 0.1W, 1% 0603 OPT VISHAY, CRCW060320K0FKEA

9 0 R11, R16 RES., CHIP, 38.3k, 0.1W, 1% 0603 OPT VISHAY, CRCW060338K3FKEA

10 0 R12, R17 RES., CHIP, 1M, 0.1W, 1% 0603 OPT VISHAY, CRCW06031M00FKEA

11 0 R14 RES., CHIP, 78.7k, 0.1W, 1% 0603 OPT VISHAY, CRCW060378K7FKEA

12 0 Q3,Q4 MOSFET P-CHAN., 30V, POWERPAK-8 OPT

13 0 Q5,Q6 SMALL SIGNAL MOSFET OPT ON SEMI., 2N7002LT1G

14 0 U2,U3 NANOPWR COMPARATOR, MSOP8 OPT LINEAR TECH., LTC1540CMS8#PBF

Hardware-For Demo Board Only

1 16 E1-E6, E9-E14, E18, E19, E20, E21 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)

dc1830b-c/b-df

DEMO MANUAL

DC1830B-C/DC1830B-D

SCHEMATIC DIAGRAM

dc1830b-c/b-df

DEMO MANUAL

DC1830B-C/DC1830B-D

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 representa-

tion that the interconnection of its circuits as described herein will not infringe on existing patent rights.

SCHEMATIC DIAGRAM

Modifed DC1619A as used with DC1830B

dc1830b-c/b-df

DEMO MANUAL

DC1830B-C/DC1830B-D

Linear Technology Corporation

1630 McCarthy Blvd., Milpitas, CA 95035-7417

(408) 432-1900 ● FAX: (408) 434-0507 ● www.linear.com

LT 1012 • PRINTED IN USA

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

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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 applica-

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