Linear Technology DC2118A Quick setup guide

dc2118af

DEMO MANUAL DC2118A

DESCRIPTION

LTC4040

Battery Charger and Backup

Power Manager

Demonstration circuit 2118A is a combination step-down

battery charger and step-up battery backup regulator us-

ing the LT C

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 LiFePO4chemistry 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

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.

PERFORMANCE SUMMARY

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

regulationcanbeenabled/disabledwiththeENBSTjumper.

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

Specifications are at TA= 25°C

PARAMETER CONDITIONS VALUE

Charge Mode

Input Voltage Range 4.8V to 5.5V

Overvoltage Protection Range Limited by Q1 BVDSS 5.5V to 40V

Input Current Limit R7 = 10mΩ 2.5A

Default Charging Voltage F2 = 1 (Li-Ion), F1 = 1, F0 = 1 4.10V

Charging Current RPROG = 1.00k 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%

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dc2118af

DEMO MANUAL DC2118A

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 charg-

ing application:

JP1 NTC INT

JP2 ENCHG ON

JP3 ENBST ON

JP4 F1 1

JP5 F0 1

JP6 LEDS ON

JP7 F2 1

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 condi-

tions 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.

Figure 1. Typical Battery Charge Cycle Figure 2. Typical Battery Discharge Cycle

PERFORMANCE SUMMARY

TIME (Hrs)

BAT

(A)

2.25

2.00

1.50

1.00

0.50

1.75

1.25

0.75

0.25

BAT

+ V

CHRG

(V)

4.2

4.0

3.6

3.2

2.8

3.8

3.4

3.0

2.6

2.4

5 93 7

dc2118 F01

104 82 61

9600mAh Li-Ion

VIN = 5V

RPROG = 1.00k

TIMER

RESTART

TIMER

START

CHRG

VBAT

IBAT

C/8

TERMINATION

TIME (Hrs)

0:00

BAT

(V)

BAT

(A)

1:30

dc2118a F02

2:302:001:000:30

9600mAh Li-Ion

VSYS = 5V

ISYS = 2A

POWER

FAIL

BACKUP

STARTED

VSYS

IBAT VBAT

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dc2118af

DEMO MANUAL DC2118A

QUICK START PROCEDURE

Figure 3. Proper Measurement Equipment Setup

11. Total backup runtime is based on battery capacity,

circuit efﬁciency, and system load. Figure 2 shows an

example dischargecurve with constant current system

load.

12. WhenVSYS falls below 7.5% of the programmed value,

or 4.6V, then RST will toggle on.

Optional

1. UseanexternalthermistorconnectedbetweenEXTNTC

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.

3. Monitor the PROG pin voltage for a scaled representa-

tion of the instantaneous charge current according to

the relationship:

IBAT =

2000 • V

PROG

RPROG

Where RPROG = R6 = 1kΩ.

4. MonitortheCLPROGpinvoltage forascaledrepresenta-

tion of the instantaneous total input current according

to the relationship:

IVIN =

CLPROG

32 •R

Where RS= R7 = 10mΩ.

5. All status LEDs can be disconnected to reduce the

quiescent current by setting the LEDS jumper, JP6 to

OFF.

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

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dc2118af

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)

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dc2118af

DEMO MANUAL DC2118A

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

D D

C C

B B

A A

VSYS

GND

VBAT

GND

DCIN

EXTNTC

4.8V - 5.5V

BSTOFF

CHGOFF

F2=1(LI-ION) F2=0(LIFEP04) F1 F0

3.95V 3.45V 0 0

4.00V 3.50V 0 1

4.05V 3.55V 1 0

4.10V 3.60V 1 1

FAULT

PFO

RST

CHRG

CLPROG

NOTES: UNLESS OTHERWISE SPECIFIED,

1. ALL RESISTORS ARE 0402, 1%.

EXTVDD

2. ALL CAPACITORS ARE 0603, X7R.

OV PROTECTION

GND

5V IN BACKUP

2A CHARGE

4. LIMITED BY Q1 VDS RATING.

SEE NOTE 4

PROG

(DEFAULT)

VIN

VSYS

VDD

VDD VDD VDD VDD

VSYS

VDD

SIZE

DATE:

IC NO. REV.

SHEET OF

TITLE:

APPROVALS

PCB DES.

APP ENG.

TECHNOLOGY Fax: (408)434-0507

Milpitas, CA 95035

Phone: (408)432-1900

1630 McCarthy Blvd.

LTC Confidential-For Customer Use Only

CUSTOMER NOTICE

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.

THIS CIRCUIT IS PROPRIETARY TO LINEAR TECHNOLOGY AND

SCHEMATIC

SUPPLIED FOR USE WITH LINEAR TECHNOLOGY PARTS.

SCALE = NONE

www.linear.com

Thursday, April 30, 2015

BATTERY CHARGER

N/A

LTC4040EUFD24

DEMO CIRCUIT 2118A

BACKUP POWER MANAGER

SIZE

DATE:

IC NO. REV.

SHEET OF

TITLE:

APPROVALS

PCB DES.

APP ENG.

TECHNOLOGY Fax: (408)434-0507

Milpitas, CA 95035

Phone: (408)432-1900

1630 McCarthy Blvd.

LTC Confidential-For Customer Use Only

CUSTOMER NOTICE

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.

THIS CIRCUIT IS PROPRIETARY TO LINEAR TECHNOLOGY AND

SCHEMATIC

SUPPLIED FOR USE WITH LINEAR TECHNOLOGY PARTS.

SCALE = NONE

www.linear.com

Thursday, April 30, 2015

BATTERY CHARGER

N/A

LTC4040EUFD24

DEMO CIRCUIT 2118A

BACKUP POWER MANAGER

SIZE

DATE:

IC NO. REV.

SHEET OF

TITLE:

APPROVALS

PCB DES.

APP ENG.

TECHNOLOGY Fax: (408)434-0507

Milpitas, CA 95035

Phone: (408)432-1900

1630 McCarthy Blvd.

LTC Confidential-For Customer Use Only

CUSTOMER NOTICE

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.

THIS CIRCUIT IS PROPRIETARY TO LINEAR TECHNOLOGY AND

SCHEMATIC

SUPPLIED FOR USE WITH LINEAR TECHNOLOGY PARTS.

SCALE = NONE

www.linear.com

Thursday, April 30, 2015

BATTERY CHARGER

N/A

LTC4040EUFD24

DEMO CIRCUIT 2118A

BACKUP POWER MANAGER

0.1uF

0603

SiS424DN

R22

390

0.1uF

10V

ORG

JP6

OFF

LEDS

1.00k

0603

2.2uH

COILCRAFT

XAL5030-222ME

COUT1

100uF

10V

1210

R13

OPT

1.69M

SEE NOTE 3

E17

6.2k

0805

R24

390

2.2uF

6.3V

0805

JP4

R27

121k 1%

10uF, 10V

0603

E11

E18

LTC4040EUFD

FAULT

VIN 6

PFI

BSTFB 18

SW 22

SW 21

PROG

CLPROG

VSYS 1

VSYS 24

BAT 23

CHGOFF

BSTOFF

RST

CLN 7

RSTFB 10

OVSNS 16

NTC 17

CHRG

IGATE 15

PFO

GND

OPT

E12

357k

R16

OPT

JP1

INT EXT

NTC

COUT2

100uF

10V

1210

JP2

OFF

ENCHG

JP3

OFF

ENBST

RNTC

10k

E13

E15

R21

390

5% R12

OPT

R5 324k

R23

390

E14

RED

0.1uF

10k

CIN1

0.1uF

50V

0805

OPT

BAT46WJ

E16

ORG

0.01 1%

1206

GRN

JP7

E19

R25

0805

E10

JP5

SiS488DN

R11

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dc2118af

DEMO MANUAL DC2118A

Linear Technology Corporation

1630 McCarthy Blvd., Milpitas, CA 95035-7417

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

 LINEAR TECHNOLOGY CORPORATION 2015

LT 0615 • PRINTED IN USA

DEMONSTRATION BOARD IMPORTANT NOTICE

Linear Technology Corporation (LT C ) 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 LT C 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 LT C 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. LT C assumes no liability for applications assistance,

customer product design, software performance, or infringement of patents or any other intellectual property rights of any kind.

LT C 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 LT C applica-

tion engineer.

Mailing Address:

Linear Technology

1630 McCarthy Blvd.

Milpitas, CA 95035

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