DEMO MANUAL
DC1830B-C/DC1830B-D
LTC4000-1
Battery Charger Controller and
PowerPath Manager with
Maximum Power Point Control
DESCRIPTION
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 LiFePO
4
(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.
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
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.
dc1830b-c/b-df
1
DEMO MANUAL
DC1830B-C/DC1830B-D
PERMORMANCE SUMMARY
SYMBOL
V
IN
V
IN-MP
V
FLOAT
I
BAT
t
T
V
OUT-SYS
I
OUT-SYS
PARAMETER
Input Supply Range
Input Regulation Voltage
Battery Float Voltage
Output Regulation
Battery Charge Current
Battery Charge Current – Trickle
Charge Termination Time
System Output Voltage
System Output Current Range
V
BAT
= V
FLOAT
12.3
0
Line and Load (20V to 60V, 0A to 4.5A)
Specifications are at T
A
= 25°C
MIN
20
35.1
14.4
14.6
0
5.0
0.6
2.9
14.6
15.5
5.5
14.8
TYP
MAX
60
UNITS
V
V
V
%
A
A
Hours
V
A
CONDITIONS/COMMENTS
This Is the Input Voltage of the Front-End DC/DC Supply
This Is the Input Voltage Lower Limit Set by the LTC4000-1
QUICK START PROCEDURE
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.
dc1830b-c/b-df
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.
2
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 (V
OUT
<
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 (T
A
> 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
V
IN
I
CL
I
CL
V
BAT-FLOAT
V
OUT
Input Voltage Regulation/Limit
Charge Current Regulation/Limit
Trickle Charge Current Regulation/Limit
Battery Float Voltage
System Voltage
NOMINAL VALUE (V)*
1.000V
(50μA • R
CL
)/20
(50μA • R
CL
)/20
1.136V
1.193V
(Follows V
BAT
)
(Follows V
BAT
)
0.86 • 1.136V
0.86 • 1.136V
V
M
CX
TMR
Input Voltage Monitor/UVLO
C/X Monitor/Charge Termination
Charge Termination Timer
1.193V
(5μA • R
CX
– 10mV)/20
104s/nF
0.82/0.90
0.82/0.90
1.181/1.204
4.5/5.5
83/126
MIN/MAX
0.985/1.010
45/55
4.5/5.5
1.125/1.147
1.181/1.204
Charger Off
Charger Float
Charging at I
CL
, 0.86 • V
BAT-FLOAT
< V
BAT
< V
BAT-FLOAT
Instant-On, 0.68 • V
BAT-FLOAT
< V
BAT
< 0.86 • V
BAT-FLOAT
Instant-On, Trickle, V
BAT
< 0.68 • V
BAT-FLOAT
Falling, (40mV Hysteresis)
Short TMR to BIAS for C/X Termination
50mV Max
CONDITIONS
*Normalized to sense point.
dc1830b-c/b-df
3
DEMO MANUAL
DC1830B-C/DC1830B-D
QUICK START PROCEDURE
OR
DC
SOURCE
4
–
+
+
A
–
V
+
+
SCOPE
V
A
+
–
–
+
LOAD
–
–
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
PARTS LIST—DC1830B-C
ITEM
QTY REFERENCE
Required Circuit Components
1
1
C1
2
1
CBAT
3
1
CBIAS
4
1
CBGATE
5
2
CC2, CTMR
6
2
CIIMON, CIBMON
7
1
CIN
8
2
COUT, CL
9
1
D1
10
1
D2
11
2
D3, D4
12
1
F2
13
2
Q1, Q2
14
2
Q5, Q6
15
2
RBFB2, ROFB2
16
4
RBFB1, ROFB1, R12, R17
17
1
RC1
18
1
RCL
19
1
RCS
20
3
RCX, R8, R13
21
1
RIFB1
22
1
RIL
23
2
RNTC2, RNTC3
24
1
RIS1
25
1
RVM1
26
1
RVM2
27
1
R5
28
3
R4, R7, R19
29
2
R6, R18
30
1
R9
31
2
R10, R15
32
2
R11, R16
33
1
R14
34
1
U1
35
2
U2, U3
Additional Demo Board Circuit Components
1
0
CC1, CIGATE, CNTC, CCX, CCL, CIL, CVM
2
0
CL1, CL2, CL3, CL4, CL5
3
0
F1, F3
4
0
Q3, Q4
5
0
R1, R2, R3, R20, R21, RIG, RBG, RBFBX,
RBFB3, ROFBX
PART DESCRIPTION
CAP., X5R, 4.7μF, 10V, 20% 0603
CAP., SMT ALUMINUM, 150μF, 35V
CAP., X7R, 1μF, 16V, 10% 0603
CAP., X7R, 10nF, 50V, 5% 0603
CAP., X7R, 0.1μF, 50V, 10% 0603
CAP., C0G, 1000pF, 25V, 5% 0603
CAP., X7R, 1μF, 50V, 10% 1210
CAP., X7R, 2.2μF, 50V, 10% 1206
DIODE ZENER 3.0V 200MW SOD-323
LED, GREEN, SMT, 0603
LED 660NM SUPER RED DIFF 0603 SMD
FUSE 12A 32V T-LAG 1206 SMD
MOSFET P-CHAN., 30V, POWERPAK-8
SMALL SIGNAL MOSFET
RES., CHIP, 84.5k, 0.1W, 1% 0603
RES., CHIP, 1M, 0.1W, 1% 0603
RES., CHIP, 4.22k, 1/10W 1% 0603
RES., CHIP, 24.3k, 0.1W, 1% 0603
SENSOR RES., 0.01Ω 1W 2% 1508 SMD
RES., CHIP, 10k, 0.1W, 1% 0603
RES., CHIP, 68.1k, 0.1W, 1% 0603
RES., CHIP, 2.0k, 0.1W, 1% 0603
THERMISTOR NTC 10kΩ 5% 0603
SENSOR RES 0.015Ω 1W 2% 1508 SMD
RES., CHIP, 35.7k, 1/10W 1% 0603
RES., CHIP, 2.49k, 1/10W 1% 0603
RES., CHIP, 2.2k, 0.1W, 5% 0603
RES., CHIP, 100k, 0.1W, 5% 0603
RES., CHIP, 4.7k, 0.1W, 5% 0603
RES., CHIP, 46.4k, 0.1W, 1% 0603
RES., CHIP, 20k, 0.1W, 1% 0603
RES., CHIP, 38.3k, 0.1W, 1% 0603
RES., CHIP, 78.7k, 0.1W, 1% 0603
I.C. LTC4000EUFD-1, 28-PIN QFN
NANOPWR COMPARATOR, MSOP8
CAP., 0603 OPT
CAP., 1206, 50V OPT
FUSE 12A 32V T-LAG 1206 SMD OPT
MOSFET P-CHAN., 30V, POWERPAK-8 OPT
RES., 0603 OPT
MANUFACTURER/PART NUMBER
AVX, 0603ZD475MAT2A
SUNCON, 35HVP150M
AVX, 0603YC105KAT2A
MURATA, GRM188R71H103JA01D
AVX, 06035C104KAT2A
AVX, 06033A102JAT2A
AVX, 12105C105KAT2A
MURATA, GRM31CR71H225KA88L
DIODE INC.,BZT52C3V0S-7-F
LITE-ON, LTST-C190KGKT
LUMEX, SML-LX0603SRW-TR
COOPER BUSSMAN, 3216TD12-R
VISHAY, SI7135DP-T1-GE3
ON SEMI., 2N7002LT1G
VISHAY, CRCW060384K5FKEA
VISHAY, CRCW06031M00FKEA
YAGEO, RT0603FRE074K22L
VISHAY, CRCW060324K3FKEA
SUSUMU, RL3720WT-R010-G
YAGEO, RC0603FR-0710KL
VISHAY, CRCW060368K1FKEA
VISHAY, CRCW06032K00FKTA
VISHAY, NTHS0603N02N1002J
SUSUMU, RL3720WT-R015-G
VISHAY, CRCW060335K7FKEA
YAGEO, RC0603FR-072K49L
VISHAY, CRCW06032K2JKEA
VISHAY, CRCW0603100KJKEA
VISHAY, CRCW06034K7JKEA
VISHAY, CRCW060346K4FKEA
VISHAY, CRCW060320K0FKEA
VISHAY, CRCW060338K3FKEA
VISHAY, CRCW060378K7FKEA
LINEAR TECH., LTC4000EUFD-1#PBF
LINEAR TECH., LTC1540CMS8#PBF
dc1830b-c/b-df
5
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