Linear Analog Devices LTC4040 Quick setup guide

DEMO MANUAL DC2118B

Rev. 0

DESCRIPTION

LTC4040

Battery Charger and Backup

Power Manager

Demonstration circuit 2118B is a combination step-down

battery charger and step-up battery backup regulator

using the LT C

4040 monolithic system power manager.

The DC2118B 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, DC2118B 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

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PERFORMANCE SUMMARY

optional NTC input provides temperature fault detection

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 ini

tially 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.

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%

DEMO MANUAL DC2118B

Rev. 0

QUICK START PROCEDURE

Demonstration circuit 2118B is easy to set up to evalu-

ate 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 DC2118B 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 back-

up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

dc2118b 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

dc2118b F02

2:302:001:000:30

9600mAh Li-Ion

VSYS = 5V

ISYS = 2A

POWER

FAIL

BACKUP

STARTED

VSYS

IBAT VBAT

DEMO MANUAL DC2118B

Rev. 0

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 discharge curve with constant current

systemload.

12. WhenVSYS fallsbelow7.5%of the programmed value,

or 4.6V, then RST will toggle on.

Optional

1. Usean externalthermistorconnected betweenEXTNTC

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. MonitortheCLPROGpinvoltageforascaledrepresenta-

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

DEMO MANUAL DC2118B

Rev. 0

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 ANALOG DEVICES, 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)

DEMO MANUAL DC2118B

Rev. 0

Information furnished by Analog Devices is believed to be accurate and reliable. However, no responsibility is assumed by Analog

Devices for its use, nor for any infringements of patents or other rights of third parties that may result from its use. Specifications

subject to change without notice. No license is granted by implication or otherwise under any patent or patent rights of Analog Devices.

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)

REV

Z P

DESCRIPTION DATE

REVISION HISTORY

06/13/19

ECO

1PROD

APPROVED

VIN

VSYS

VDD

VDD VDD VDD VDD

VSYS

VDD

DATE:

IC NO.

SHEET OF

TITLE: DEMO CIRCUIT SCHEMATIC,

APPROVALS

PCB DES.

APP ENG. Phone: 1-408-432-1900

Milpitas, CA 95035

1630 McCarthy Blvd.

For ADI Customer Use Only

CUSTOMER NOTICE

ANALOG DEVICES INC. 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 ANALOG DEVICES

INC. APPLICATIONS ENGINEERING FOR ASSISTANCE.

THIS CIRCUIT IS PROPRIETARY TO ANALOG DEVICES INC. AND

SUPPLIED FOR USE WITH ANALOG DEVICES INC. PARTS.

SCALE = NONE

SIZE:

SKU NO. SCHEMATIC NO. AND REVISION:

PCA BOM:

PCA ASS'Y:

www.analog.com

Z P

LTC4040EUFD24

DC2118B

700-DC2118B_REV01

705-DC2118B_REV01

N/A

Thursday, June 13, 2019

710-DC2118B_REV01

BATTERY CHARGER BACKUP POWER MANAGER

M I

DATE:

IC NO.

SHEET OF

TITLE: DEMO CIRCUIT SCHEMATIC,

APPROVALS

PCB DES.

APP ENG. Phone: 1-408-432-1900

Milpitas, CA 95035

1630 McCarthy Blvd.

For ADI Customer Use Only

CUSTOMER NOTICE

ANALOG DEVICES INC. 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 ANALOG DEVICES

INC. APPLICATIONS ENGINEERING FOR ASSISTANCE.

THIS CIRCUIT IS PROPRIETARY TO ANALOG DEVICES INC. AND

SUPPLIED FOR USE WITH ANALOG DEVICES INC. PARTS.

SCALE = NONE

SIZE:

SKU NO. SCHEMATIC NO. AND REVISION:

PCA BOM:

PCA ASS'Y:

www.analog.com

Z P

LTC4040EUFD24

DC2118B

700-DC2118B_REV01

705-DC2118B_REV01

N/A

Thursday, June 13, 2019

710-DC2118B_REV01

BATTERY CHARGER BACKUP POWER MANAGER

M I

DATE:

IC NO.

SHEET OF

TITLE: DEMO CIRCUIT SCHEMATIC,

APPROVALS

PCB DES.

APP ENG. Phone: 1-408-432-1900

Milpitas, CA 95035

1630 McCarthy Blvd.

For ADI Customer Use Only

CUSTOMER NOTICE

ANALOG DEVICES INC. 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 ANALOG DEVICES

INC. APPLICATIONS ENGINEERING FOR ASSISTANCE.

THIS CIRCUIT IS PROPRIETARY TO ANALOG DEVICES INC. AND

SUPPLIED FOR USE WITH ANALOG DEVICES INC. PARTS.

SCALE = NONE

SIZE:

SKU NO. SCHEMATIC NO. AND REVISION:

PCA BOM:

PCA ASS'Y:

www.analog.com

Z P

LTC4040EUFD24

DC2118B

700-DC2118B_REV01

705-DC2118B_REV01

N/A

Thursday, June 13, 2019

710-DC2118B_REV01

BATTERY CHARGER BACKUP POWER MANAGER

M I

E14

0.1uF

0603

JP4

SiS424DN

JP2

OFF

ENCHG

R21

390

RED D5

ORG

R25

0805

ORG

6.2k

0805

R5 324k

R22

390

JP3

OFF

ENBST

COUT1

100uF

10V

1210

E12

RNTC

10k

JP6

OFF

LEDS

R23

390

5% R12

OPT

1.00k

0603

SiS488DN

E10

357k

LTC4040EUFD

FAULT

VIN 6

PFI

BSTFB 18

SW 22

SW 21

2PROG

CLPROG

VSYS 1

VSYS 24

BAT 23

CHGOFF

BSTOFF

RST

CLN 7

RSTFB 10

OVSNS 16

NTC 17

CHRG

IGATE 15

PFO

GND

R24

390

0.1uF

R16

OPT

GRN

10k

0.1uF

10V

R27

121k 1%

CIN1

0.1uF

50V

0805

OPT

2.2uH

COILCRAFT

XAL5030-222ME

0.01 1%

1206

BAT46WJ

E13

JP1

INT EXT

NTC

E15

R13

OPT

1.69M

E16

10uF, 10V

0603

JP5

2.2uF

6.3V

0805

JP7

E11

E18

R11

E19

SEE NOTE 3

COUT2

100uF

10V

1210

E17

OPT

DEMO MANUAL DC2118B

Rev. 0

 ANALOG DEVICES, INC. 2019

10/19

www.analog.com

ESD Caution

ESD (electrostatic discharge) sensitive device. Charged devices and circuit boards can discharge without detection. Although this product features patented or proprietary protection

circuitry, damage may occur on devices subjected to high energy ESD. Therefore, proper ESD precautions should be taken to avoid performance degradation or loss of functionality.

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