Linear Technology DC1830A-A Quick setup guide

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DEMO MANUAL
DC1830A-A/DC1830A-B
DESCRIPTION
LTC4000
Battery Charger Controller
and PowerPath Manager
Demonstrationcircuit1830Aisabatterychargercontroller
and PowerPath™ manager featuring the LTC
®
4000. This
board should be connected to a front-end DC/DC power
supply for a complete charger solution.
The DC1830A 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 DC1830A is
targeted at 4-cell LiFePO4(14.6V/5A) applications.
The DC1830A 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 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
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.
PERFORMANCE SUMMARY
this IC 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 DC1830A-A provides a solution complete with both
battery charger control and PowerPath managment. 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 isfullycharged
andpowerisavailablefromthefront-end DC/DC converter.
Thermal regulation circuitry is also provided to limit the
temperature of both PFETs. The DC1830A-B provides a
simple battery-charger-controller 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
Specifications are at TA= 25°C
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
IIN Input Current Limit This Is the Input Current Limit Set by the LTC4000 3.0 A
VFLOAT Battery Float Voltage 14.4 14.6 14.8 V
VFLOAT Output Regulation Line and Load (20V to 60V, 0A to 4.5A) ±0.005 %
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 *Input Current Limited Below 35VIN 0 5.5* A

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DEMO MANUAL
DC1830A-A/DC1830A-B
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/LTC3789 buck-boostcombination, theDC1721A.
The LTC4000 data sheet should be used for guidance in
determining circuit values for the application at hand. You
may follow the designexample on page26 of the datasheet.
Table 1 provides a summary of parameter adjustments.
NOTE: The PFETs supplied on this board are rated at 30V.
Oncethecircuithas been customized to suit the application
at hand, it is easy to set up to evaluate the performance
of the LTC4000 when combined with a suitable switching
power converter, such as the LTC3845A. See page 9 for
the modified DC1619A/LTC3845A schematic.Voltages
and currents cited in this procedure are for the design as
delivered;ifthedesignhas 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 24V. Then turn off the supply.
2. With power off, connect the supply to the input ter-
minals VIN and GND.
NOTE:
a. Input voltages lowerthan 20Vcan keep theconverter
from turning on due to the undervoltage lockout
feature of the LTC4000.
b. If efficiency measurements are desired, refer to
Figure 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,
connect 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.
8. Once the proper BAT output voltage is again estab-
lished, adjust the load and/or source within the operat-
ing range and observe the battery float voltage regula-
tion, charge current, and other desired parameters.
9. Set the load to constant voltage mode to more easily
observe charge current and trickle charge current.
NOTE: The following applies to the DC1830A-A.
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, R8-12 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
conditions, lower current available to VOUT-SYS, or
where continuous short-circuit protection on VOUT-
SYS is not required.
10. Turn off the power at the input.
11. Connect the output load and meters to the VOUT-SYS
output.
12. Set CHARGE jumper to DISABLE.
13. Turn on the power at the input.
14. Oncethe proper VOUT-SYS is againestablished,adjust
the load and/or source within the operating range and
observe the output voltage regulation, ripple voltage,
efficiency, input and output current limit, and other
desired parameters.

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DEMO MANUAL
DC1830A-A/DC1830A-B
QUICK START PROCEDURE
Table 1. LTC4000 Charger Setup Parameters and Reference Values
REFERENCE DESCRIPTION NOMINAL VALUE (V)* MIN/MAX CONDITIONS
IIL Input Current Regulation/Limit (50μA • RIL)/20 45μA/55μA 50mV Max
ICL Charge Current Regulation/Limit (50μA • RCL)/20 45μA/55μA 50mV Max
Trickle Charge Current Regulation/Limit (5μA • RCL)/20 4.5μA/5.5μA 50mV Max
VBAT-FLOAT Battery Float Voltage 1.136V 1.125V/1.147V
VOUT System Voltage 1.193V 1.181V/1.204V 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
VM Input Voltage Monitor/UVLO 1.193V 1.181V/1.204V Falling, (40mV Hysteresis)
CX C/X Monitor/Charge Termination (5μA • RCX – 10mV)/20 4.5μA/5.5μA Short TMR to BIAS for C/X
Termination
TMR Charge Termination Timer 104s/nF 83s/nF/126s/nF
*Normalized to sense point
+
–
+
–
V
+
–
SCOPE
A
–+
V
+
–
LOAD
OR
A
–+
DC
SOURCE
Figure 1. Fixture Connections and Measurement Equipment Setup

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DEMO MANUAL
DC1830A-A/DC1830A-B
QUICK START PROCEDURE
Figure 2. Block Diagram with Typical DC/DC Converter

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DEMO MANUAL
DC1830A-A/DC1830A-B
PARTS LIST
ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER
DC1380A-A Required Circuit Components
1 1 C1 CAP., X5R, 4.7μF, 10V, 20% 0603 AVX, 0603ZD475MAT2A
2 1 CBAT CAP., SMT ALUMINUM, 150μF, 35V SUNCON, 35HVH150M
3 1 CBIAS CAP., X7R, 1μF, 16V, 10% 0603 AVX, 0603YC105KAT2A
4 1 CBGATE CAP., X7R, 10nF, 25V, 5% 0603 AVX, 06033C103JAT2A
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 1 CL CAP., X7R, 2.2μF, 50V, 10% 1206 MURATA, GRM31CR71H225KA88L
9 1 D1 DIODE ZENER 3.0V 350MW SOT23-3 DIODE INC., BZX84C3V0-7-F
10 2 D3, D5 LED, RED HI BRT SS TYPE LO CUR SMT, 0603 PANASONIC, LNJ208R8ARA
11 1 D4 LED, GREEN, SMT, 0603 LITE-ON, LTST-C190KGKT
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 1 R5 RES., CHIP., 2.2k, 0.1W, 5% 0603 VISHAY, CRCW06032K2JKEA
16 2 R6, R18 RES., CHIP., 4.7k, 0.1W, 5% 0603 VISHAY, CRCW06034K7JKEA
17 4 R8, R13, RCX, RVM2 RES., CHIP., 10k, 0.1W, 1% 0603 YAGEO, RC0603FR-0710KL
18 1 R9 RES., CHIP., 46.4k, 0.1W, 1% 0603 VISHAY, CRCW060346K4FKEA
19 2 R10, R15 RES., CHIP., 20k, 0.1W, 1% 0603 VISHAY, CRCW060320K0FKEA
20 2 R11, R16 RES., CHIP., 38.3k, 0.1W, 1% 0603 VISHAY, CRCW060338K3FKEA
21 2 R12, R17 RES., CHIP., 1M, 0.1W, 1% 0603 VISHAY, CRCW06031M00FKEA
22 1 R14 RES., CHIP., 78.7k, 0.1W, 1% 0603 VISHAY, CRCW060378K7FKEA
23 2 RBFB1, ROFB1 RES., CHIP., 1M, 0.1W, 1% 0603 VISHAY, CRCW06031M00FKEA
24 2 RBFB2, ROFB2 RES., CHIP., 84.5k, 0.1W, 1% 0603 VISHAY, CRCW060384K5FKEA
25 1 RC1 RES., CHIP., 4.22k, 0.1W, 1% 0603 YAGEO, RC0603FR-07422KL
26 1 RCL RES., CHIP., 24.3k, 0.1W, 1% 0603 VISHAY, CRCW060324K3FKEA
27 1 RIL RES., CHIP., 18.2K, 0.1W, 1% 0603 VISHAY, CRCW060318K2FKEA
28 1 RCS SENSOR RES., 0.01Ω 1W 2% 1508 SMD SUSUMU, RL3720WT-R010-G
29 1 RIS1 SENSOR RES., 0.015Ω 1W 2% 1508 SMD SUSUMU, RL3720WT-R015-G
30 2 RNTC2, RNTC3 THERMISTOR NTC 10k 5% 0603 VISHAY, NTHS0603N02N1002J
31 1 RVM1 RES., CHIP., 143k, 0.1W, 1% 0603 VISHAY, CRCW0603143KFKEA
32 3 R4, R7, R19 RES., CHIP., 100k, 0.1W, 5% 0603 VISHAY, CRCW0603100KJKEA
33 1 U1 I.C., LTC4000EUFD, 28-PIN QFN LINEAR TECH., LTC4000EUFD#PBF
34 2 U2, U3 NANOPWR COMPARATOR, MSOP8 LINEAR TECH., LTC1540CMS8#PBF

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DEMO MANUAL
DC1830A-A/DC1830A-B
PARTS LIST
ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER
DC1380A-A 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 OPT
3 0 D2 DIODE ZENER, SOT23-3 OPT
4 0 F1, F3 FUSE 12A 32V T-LAG 1206 SMD OPT
5 0 JUMPER JUMPER WIRE (NO INSTALL)
6 0 Q3 MOSFET P-CHAN., 30V, POWERPAK-8 OPT
70Q4 OPT
8 0 R1, R2, R3, R20, RCL, RIG, RBG, RBFBX,
ROFBX, ROFB2
RES., 0603 OPT
DC1380A-A Hardware—For Demo Board Only
1 14 E1-E6, E9-E14, E18, E19 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)
DC1380A-B Required Circuit Components
1 1 C1 CAP., X5R, 4.7μF, 10V, 20% 0603 AVX, 0603ZD475MAT2A
2 1 CBAT CAP., SMT ALUMINUM, 150μF, 35V SUNCON, 35HVH150M
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 CIN CAP., X7R, 1μF, 50V, 10% 1210 AVX, 12105C105KAT2A
7 1 D1 DIODE ZENER 3.0V 350MW SOT23-3 DIODE INC., BZX84C3V0-7-F
8 2 D3, D5 LED, RED HI BRT SS TYPE LO CUR SMT, 0603 PANASONIC, LNJ208R8ARA
9 1 D4 LED, GREEN, SMT, 0603 LITE-ON, LTST-C190KGKT
10 1 F2 FUSE 12A 32V T-LAG 1206 SMD COOPER BUSSMAN, 3216TD12-R
11 1 JUMPER JUMPER WIRE (INSTALLED)
12 1 Q1 MOSFET P-CHAN., 30V, POWERPAK-8 VISHAY, SI7135DP-T1-GE3
13 1 Q2 ZERO OHM THICK FILM JUMPER CHIP, 2010 IRC., LRC-LRZ-2010LF-R000
14 1 R5 RES., CHIP., 2.2k, 0.1W, 5% 0603 VISHAY, CRCW06032K2JKEA
15 2 R6, R18 RES., CHIP., 4.7k, 0.1W, 5% 0603 VISHAY, CRCW06034K7JKEA
16 1 RVM2 RES., CHIP., 10k, 0.1W, 1% 0603 YAGEO, RC0603FR-0710KL
17 2 RBFB1, ROFB1 RES., CHIP., 1M, 0.1W, 1% 0603 VISHAY, CRCW06031M00FKEA
18 1 RBFB2 RES., CHIP., 84.5k, 0.1W, 1% 0603 VISHAY, CRCW060384K5FKEA
19 1 RC1 RES., CHIP., 4.22k, 0.1W, 1% 0603 YAGEO, RC0603FR-07422KL

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DEMO MANUAL
DC1830A-A/DC1830A-B
PARTS LIST
ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER
20 1 RCL RES., CHIP., 24.3k, 0.1W, 1% 0603 VISHAY, CRCW060324K3FKEA
21 1 RIL RES., CHIP., 18.2k, 0.1W, 1% 0603 VISHAY, CRCW060318K2FKEA
22 1 RCS SENSOR RES., 0.01Ω 1W 2% 1508 SMD SUSUMU, RL3720WT-R010-G
22 1 RCX RES., CHIP., 0.0Ω, 0.1W, 0603 VISHAY, CRCW06030000Z0EA
23 1 RIS1 SENSOR RES., 0.015Ω 1W 2% 1508 SMD SUSUMU, RL3720WT-R015-G
24 1 RVM1 RES., CHIP., 143k, 0.1W, 1% 0603 VISHAY, CRCW0603143KFKEA
25 4 R4, R7, R14, R19 RES., CHIP., 100k, 0.1W, 5% 0603 VISHAY, CRCW0603100KJKEA
26 1 U1 I.C., LTC4000EUFD, 28-PIN QFN LINEAR TECH., LTC4000EUFD#PBF
DC1380A-B Additional Demo Board Circuit Components
1 0 CC1, CIGATE, CNTC, CCX, CCL, CIL, CVM CAP., 0603 OPT
2 0 CBGATE NO INSTALL
3 0 CL CAP., 1206, 50V OPT
4 0 CL1, CL2, CL3, CL4, CL5 CAP., 1206 OPT
5 0 D2 DIODE ZENER, SOT23-3 OPT
6 0 F1,F3 FUSE 12A 32V T-LAG 1206 SMD OPT
7 0 Q3, Q4 MOSFET P-CHAN., 30V, POWERPAK-8 OPT
8 0 Q5, Q6 SMALL-SIGNAL MOSFET OPT, ON SEMI., 2N7002LT1G
9 0 R1, R2, R3, R20, RCL, RIG, RBG, RBFBX,
ROFBX, ROFB2
RES., 0603 OPT
10 0 R8, R13 RES., CHIP., 10k, 0.1W, 1% 0603 OPT, YAGEO, RC0603FR-0710KL
11 0 R9 RES., CHIP., 68.1k, 0.1W, 1% 0603 OPT, VISHAY, CRCW060368K1FKEA
12 0 R10, R15 RES., CHIP., 20k, 0.1W, 1% 0603 OPT, VISHAY, CRCW060320K0FKEA
13 0 R11, R16 RES., CHIP., 38.3k, 0.1W, 1% 0603 OPT, VISHAY, CRCW060338K3FKEA
14 0 R12, R17 RES., CHIP., 1M, 0.1W, 1% 0603 OPT, VISHAY, CRCW06031M00FKEA
15 0 R14 RES., CHIP., 78.7k, 0.1W, 1% 0603 OPT, VISHAY, CRCW060378K7FKEA
16 0 RNTC2, RNTC3 THERMISTOR NTC 10k 5% 0603 OPT, VISHAY, NTHS0603N02N1002J
17 0 U2,U3 NANOPWR COMPARATOR, MSOP8 OPT, LINEAR TECH.,
LTC1540CMS8#PBF
DC1380A-B Hardware—For Demo Board Only
1 14 E1-E6, E9-E14, E18, E19 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)

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DEMO MANUAL
DC1830A-A/DC1830A-B
SCHEMATIC DIAGRAM–DC1830A

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DEMO MANUAL
DC1830A-A/DC1830A-B
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–MODIFIED DC1619A AS USED WITH DC1830A

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DEMO MANUAL
DC1830A-A/DC1830A-B
Linear Technology Corporation
1630 McCarthy Blvd., Milpitas, CA 95035-7417
[phone] ●FAX: [phone] ●www.linear.com
© LINEAR TECHNOLOGY CORPORATION 2012
LT 0712 • PRINTED IN USA
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