Linear Technology DC1830B-C Quick setup guide

1
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 thebattery when it is fully charged
andpower isavailable fromthe front-endDC/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

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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.
Oncethe circuithas beencustomized tosuit theapplication
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. Withpower off,connect thesupply tothe inputterminals
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

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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. Oncethe properVOUT-SYS isagainestablished, 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.

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dc1830b-c/b-df
DEMO MANUAL
DC1830B-C/DC1830B-D
QUICK START PROCEDURE
V
+
–
A
–+
SCOPE
V
+
–
+
–
LOAD
OR
A
–+
+
–
DC
SOURCE
Figure 1. Fixture Connections and Measurement Equipment Setup
Figure 2. Block Diagram with Typical DC/DC Converter

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dc1830b-c/b-df
DEMO MANUAL
DC1830B-C/DC1830B-D
PAR
TS LIST—DC1
8
3
0B
-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

6
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

7
dc1830b-c/b-df
DEMO MANUAL
DC1830B-C/DC1830B-D
PAR
TS LIST—DC1
8
3
0B
-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)

8
dc1830b-c/b-df
DEMO MANUAL
DC1830B-C/DC1830B-D
SCHEMATIC DIAGRAM

9
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

10
dc1830b-c/b-df
DEMO MANUAL
DC1830B-C/DC1830B-D
Linear Technology Corporation
1630 McCarthy Blvd., Milpitas, CA 95035-7417
[phone] ●FAX: [phone] ●www.linear.com
© LINEAR TECHNOLOGY CORPORATION 2012
LT 1012 • PRINTED IN USA
DEMONSTRATION BOARD IMPORTANT NOTICE
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