Linear DC101 User's Manual
Contents
1. SMART BATTERY CHARGER PARTS LIST REFERENCE DESIGNATOR QUANTITY PART NUMBER DESCRIPTION VENDOR TELEPHONE R5 R6 R14 3 CR32 331J T 3300 1 8W 5 Resistor AVX 803 946 0524 R7 1 BCR1 8 3322F T 33 2k 1 8W 1 Resistor Beckman 714 447 2345 R8 1 LR2010 01 R033 J 0 0330 1 2W 5 Resistor IRC 512 992 7900 R9 1 CR32 104J T 100k 1 8W 5 Resistor AVX 803 946 0524 R10 1 LR2010 01 R050 J 0 050 1 2W 5 Resistor IRC 512 992 7900 R11 1 CR32 511J T 5100 1 8W 5 Resistor AVX 803 946 0524 R12 1 W1206R 03 1003 B 100k 1 8W 0 1 Resistor IRC 512 992 7900 R13 1 W1206R 03 1433 B 143k 1 10W 0 1 Resistor IRC 512 992 7900 R15 1 W1206R 03 2152 B 21 5k 1 10W 0 1 Resistor IRC 512 992 7900 R17 1 CR32 1051F T 1 05k 1 8W 1 Resistor AVX 803 946 0524 R19 R20 2 CR32 2000F T 2000 1 8W 1 Resistor AVX 803 946 0524 R21 R22 R25 3 CR32 223J T 22k 1 10W 5 Resistor AVX 803 946 0524 R23 1 CR32 220J T 22Q 1 10W 5 Resistor AVX 803 946 0524 R24 R26 2 CR1206 103J 10k 1 8W 5 Resistor Dale 605 665 9301 1 1 MJTP1230 PB Switch MORS ASC 617 246 1007 TP1 to TP5 E1 to E7 12 1502 2 Turret Testpoint Keystone 718 956 8900 U1 1 PIC16C73 20SP Microcontroller IC Microchip 602 786 7200 U2 1 LT1511 Battery Charger IC LTC 408 432 1900 U3 1 LT11291ST 5 Voltage Regulator IC LTC 408 432 1900 XU1 1 7167 14 G2 Sockets IC Comm Con 818 301 4200 Y1 1 MA 505 4 00M C2 4MHz Crystal Epson USA 310 787 6302. 0 OPERATION Input Voltage The nominal input voltage of the board is 24V DC The input voltage must be higher than the battery voltage by a minimum of 3V The minimum input voltage is 16V limited by the undervoltage lockout circuit in the LT1511 and set by resistors R16 R17 and R18 The highest input voltage is 27 4V limited by the maximum input voltage of the LT1511 The input is protected against reverse polarity up to 30V Input Current The sum of the system current and the charger input current is limited by the LT1511 to 2A When both the system current and the charger input current requirements are high the charger reduces the charging current to meet the 2A current limit Red LED A red LED indicates SMBus activity It lights up for about 1 second when the charger recognizes its own address 12 hex on the SMBus Green LED A flashing green LED indicates microproces sor activity and charger status Fast blinking approxi mately 8Hz indicates normal microprocessor activity and either trickle charge or shutdown charger status After valid voltage and current data have been received the blinking speed of the LED slows down to about 2Hz indicating normal charging 4 LI DEMO MANUAL DC101 SMART BATTERY CHARGER OPERATION Battery Removal Thermistor Measurements The charger periodically checks the thermistor in the battery through the T terminal When the thermistor is out of normal operating temperatur
3. 3 INI 8 f 1 93 WIOaWs N N x N A 0066 SY ans aay Yt 9601 A0S SAYYYAOYIIN NI SIINYLIIYdYI 11 G MOLE SINHO NI S39NVISIS3H T1V 041412445 ISIMYIH10 SSFINN L Lr 8 dNV LLT200 NZ n 20 30123NNO2 LUVINS B ri VO 4000 NSZ YE Use ZWMd mor 31101 AQ 000 029 219 NY GG U34 LAMd 39Nvu LNAWISnray m u39uvH2 1119158 fd O 00 Sd02 291ld 8u in LLTZOOZNZ 10 vas 105 ny LLTZO0LNe 999 422 0 198 028 9 SSA 2980 ge Ody 1250 Hi m 1NI 08H SSA 3 0 IgH vNv cVH 89 z984 ELOVESYaIN cay ENV EVH 111706518 eNV cvH di 9gH ONV OWY 299 N Ne 91 osgo 0 MOL L oly Azee LLT9LSVd 919 90 3AILISOd SI 1504 H31N39 or AS avi aNd 100 NIA SHIVd 1N3H8f0 H9IH 31V9IQNI SINIT 0108 AS S LSI6ZLLLI n SNGINS 13149 M peg yews AL DEMO MANUAL DC101 SMART BATTERY CHARGER PACKAGE DIAGRAM TOP VIEW GND GND SW GND BOOST GND GND PROS LT1511CSW GND Vc OVP UVoyr CLP GND CLN COMP2 COMP1 BAT SENSE SPIN SW PACKAGE 24 LEAD PLASTIC SO WIDE PRRTS LIST REFERENCE DESIGNATOR QUANTITY PART NUMBER DESCRIPTION VENDOR TELEPHONE C1 C8 C17 C19 4 12065C104KATMA 0 1uF 50V Chip
4. Capacitor AVX 803 946 0362 C2 C18 2 TAJB106M010 10uF 10V Tantalum Capacitor AVX 207 282 5111 C3 1 12063G334ZAT2 0 33uF 25V Chip Capacitor AVX 803 946 0362 C4 C5 2 12063G105ZATMA 1pF 25V Chip Capacitor AVX 803 946 0362 C6 1 12065C473KAT 0 047yF 50V 10 Chip Capacitor AVX 803 946 0362 C7 1 12063C153KAT2 0 015uF 25V 5 Chip Capacitor AVX 803 946 0362 C9 1 12063G474ZAT2 0 47yF 25V Chip Capacitor AVX 803 946 0362 C10 C11 C12 C20 4 THCS50E1E106Z 10uF 25V Ceramic Capacitor Marcon 847 696 2000 x374 C14 C15 2 1206A330KAT2 33pF 50V Chip Capacitor AVX 803 946 0362 C16 1 VJ1206A101KXA 100pF 50V Chip Capacitor Vitramon 203 268 6261 D1 1 SF1 BR Red LED Data Display Product 800 421 6815 D2 1 SF1 G Green LED Data Display Product 800 421 6815 D3 D5 2 MBRS340T3 Diode Motorola 602 244 3576 D4 D6 2 BAS16LT1 Diode Motorola 602 244 3576 J1 1 AMP 787441 1 Connector AMP 717 780 4409 J2 1 CUI PJ 002A Connector Cui Stack 503 643 4899 JPR1 1 38015 12 01 12 Pin Header Jumper Comm Con Conn 818 301 4200 L1 1 CTX20 4 20uH Inductor Coiltronics 407 241 7876 Q1 02 03 3 2N7002LT N Channel MOSFET Motorola 602 244 3576 04 1 MMBT3904LT1 NPN Transistor Motorola 602 244 4342 R1 R4 R16 3 CR32 3321F T 3 32k 1 8W 1 Resistor AVX 803 946 0524 R2 1 CR32 3010F T 3010 1 8W 1 Resistor AVX 803 946 0524 R3 R18 2 CR32 1001F T 1k 1 8W 196 Resistor AVX 803 946 0524 LI Ue 3 DEMO MANUAL DC101
5. DC101 SMART BATTERY CHARGER PCB LAYOUT AND FILM Solder Side 000 ee e Solder Side Solder Mask PC FAB DRAWING MES A 0 150 Qe c OOm 00000000 OOm 3 019 S50 i se 2 oot g XDOOOO gt O c 00000000000000 o o 00000000000000 e C ooooooooooo0 e gt C 0 150 2 744 3 900 0 150 7 NUMBER DIAMETER OF HOLES 125 4 120 2 100 1 94 12 40 14 39 4 37 40 18 55 TOTAL HOLES 132 SYMBOL gt NOTES 1 MATERIAL 2 LAYERS 0 062 THICK FR 4 GLASS EPOXY 2 07 COPPER CLAD 2 ALL HOLES SHALL BE PLATED THROUGH 3 PLATE THROUGH HOLES WITH COPPER 0 0014 MIN THICKNESS ALL HOLE SIZES IN HOLE TABLE ARE AFTER PLATING 4 SILKSCREEN WITH WHITE EPOXY NONCONDUCTIVE INK 5 FINISH SMOBC 6 SOLDER MASK USE FILM PROVIDED GREEN DC101 FD Linear Technology Corporation 1630 McCarthy Blvd Milpitas CA 95035 7417 408 432 1900 FAX 408 434 0507 TELEX 499 3977 LT GP 0796 500 PRINTED IN USA TECHNOLOGY LINEAR TECHNOLOGY CORPORATION 1996
6. DEMO MANUAL DC101 SMART BATTERY CHARGER TECHNOLOGY LT1511 Level 2 Smart Battery Charger Demo Board with SMBus Interface DESCRIPTION The DC101 board is a standalone Smart Battery charger ously monitors the built in thermistor in the battery The that receives Charging Voltage Charging Current and thermistor information is used by the software to inhibit AlarmWarning commands from the Smart Battery via charging at temperature extremes and to set charging the System Management Bus SMBus and sets charging strategy for different battery chemistries current and voltage accordingly The charger continu 1 LTC and LT are registered trademarks of Linear Technology Corporation PERFORMANCE SUMMARY PARAMETER CONDITIONS MIN TYP MAX UNIT Input Voltage 16 24 27 Input Current Hardware Limited 2 A Output Current Software Limited 0 2 5 A Output Voltage Software Limited 4 20 Thermistor Resistance Ni MH Battery 3 30 Li lon Battery 0 5 1 1 5 kQ BLOCK DIAGRAM AND BOARD PHOTO DC101 Smart Battery Charger Component Side O FROM WALL 071129 CUBE m m an ae C SMBus CLOCK SCL D SMBus DATA SDA 4 i i 4 i E Q4 1 1 1 1 1 1 1 1 1 1 T THERMISTOR 1 1 4 B C LT YR 1 DEMO MANUAL DC101 SMART BATTERY CHARGER SCHEMATIC DIAGRAM as 10190 Lud Mro 2 19539 AS 4
7. ISTOR TOO COLD LOAD IPWM Y ERASE COMMAND ENABLE CHARGER ERASE ERROR FLAG CHARGING CURRENT ON STACK LOAD VPWM CHARGING VOLTAGE ERASE COMMAND ON STACK ENABLE CHARGER ERASE ERROR FLAG THERMISTOR SHORTED ERROR FLAG SET FAST BLINKING SET TRICKLE CHARGE SET ERROR FLAG SET SLOW BLINKING IF NO Li lon FLAG INIT Li lon MODE ERASE ERROR FLAG IF Li lon FLAG SET ERASE Li lon FLAG ERASE ERROR FLAG INIT Ni MH MODE Figure 2 Software Flowchart 6 LI DEMO MANUAL DC101 SMART BATTERY CHARGER PCB LAYOUT AND FILM Dt 02 SMB uC ACTIVITY ACTIVITY a4 05 RS R6 DC U OUT C 2 F1 GND R25 INT EH 9 LY UE ee ne TECHNOLOGY 408 432 1900 Smart Battery Charger LT1511 Demo Ckt 101C CAUTION OBSERVE BATTERY POLARITY Component Side Silkscreen e Q m nium B a Component Side Component Side Solder Mask Information furnished by Linear Technology Corporation is believed to be accurate and reliable y However no responsibility is assumed for its use Linear Technology Corporation makes no represen TECHNOLOGY tation that the interconnection of circuits as described herein will not infringe on existing patent rights DEMO MANUAL
8. OP The idealized SMBus waveforms shown in Figure 1 illus trate SMBus communication between the battery and the charger The first seven bits afterthe START sequence are the battery address The R W bit tells the charger that the battery is attempting to write to the charger During the acknowledge period ACK the charger becomes active and pulls the data line SDA low indicating reception of a data word When reception of the data word is not acknowledged by the charger the battery terminates the communication by sending a STOP sequence to the bus The clock pulses for the communication are always gen erated by the battery BUS MASTER C Source Code The latest version of C language source code header file code file and hex dump file is provided on a 3 5 disk 2 25 l R W ACK DC101 F01 bs 0 WRITE 1 15 NIBBLE 2 2ND NIBBLE TRUNCATED THIS EXAMPLE 12 H Figure 1 SMBus Waveforms Indicating Battery Address LT Ue DEMO MANUAL DC101 SMART BATTERY CHARGER OPERATION THERMISTOR OPEN TURN RED LED ON FOR 2 SEC DISABLE INTERRUPTS 126 DATA RECEIVED RESET 12C POINTER Y PUT 12C DATA ON THE 12C STACK INCREMENT POINTER THERMISTOR TOO HOT A D COUNTER 0 MEASURE THERMISTOR ENABLE INTERRUPTS THERMISTOR IN RANGE SET ERROR FLAG SHUT DOWN CHARGER ERASE COMMAND ALARM WARNING ON STACK RETURN FROM INTERRUPT THERM
9. e range the charger switches to trickle charge mode and increases the flashing fre quency of the green LED to indicate an abnormal charg ing condition When the resistance of the thermistor is in the 500Q lt Rty lt 1 5k range the charger assumes a Li lon battery is at the output Instead of trickle charging the battery it shuts down the charger until a valid voltage and current request arrives from the battery An open ther mistor forces the charger into trickle charge mode and the charger disregards data on the SMBus System Management Bus SMBus When charge in the Smart Battery SB drops below 85 of the nominal capacity it initiates communication over the SMBus every 64 seconds After sending a START sequence the battery addresses the Smart Battery charger and waits for an acknowledgment ACK from it If the charger fails to acknowledge the word the battery termi nates further communication by placing aSTOP sequence onto the SMBus If the charger acknowledges ACK the reception of the first word the battery continues the communication sequence and sends six more words to the charger The complete current and voltage request communication sequence is as follows SDA SCLK zl gt m E er START address 12 hex Charging Current command code 14 hex current LSB current MSB address 12 hex Charging Voltage command code 15 hex voltage LSB voltage MSB ST
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