Linear DC101 Quick setup guide

1
DEMO MANUAL DC101
SMART BATTERY CHARGER
LT1511 Level 2, Smart
Battery Charger Demo Board
with SMBus Interface
BLOCK DIAGRA A D BOARD PHOTO
U
W
DESCRIPTIO
U
The DC101 board is a standalone Smart Battery charger
that receives Charging Voltage(), Charging Current() and
AlarmWarning() commands from the Smart Battery via
the System Management Bus (SMBus) and sets charging
current and voltage accordingly. The charger continu-
ously monitors the built-in thermistor in the battery. The
thermistor information is used by the software to inhibit
charging at temperature extremes and to set charging
strategy for different battery chemistries.
, LTC and LT are registered trademarks of Linear Technology Corporation.
PERFOR A CE SU ARY
UWWW
PARAMETER CONDITIONS MIN TYP MAX UNIT
Input Voltage 16 24 27 V
Input Current Hardware Limited 2 A
Output Current Software Limited 0 2.5 A
Output Voltage Software Limited 4 20 V
Thermistor Resistance Ni-MH Battery 3 30 kΩ
Li-Ion Battery 0.5 1 1.5 kΩ
VOLTAGE PWM
CURRENT PWM
SHUTDOWN
DC OUT
GND
C SMBus 
CLOCK (SCL)
D SMBus 
DATA (SDA)
T THERMISTOR
BATTERY
CONNECTOR
+
–
5V
SMB µP
Q1
Q2
Q3
DC101 BD
LT
®
1511
CHARGER
FROM
WALL
CUBE
R10 SYSTEM CURRENT
5V
LT1129
+
–
26 14
15
2
11
PIC16C73
13
12
DC101 Smart Battery Charger
Component Side

2
DEMO MANUAL DC101
SMART BATTERY CHARGER
SCHE ATIC DIAGRA
WW
1 2 3 4 5 6 7 8 9
10 11 12
24 23 22 21 20 19 18 17 16 15 14 13 
GND SW BOOST GND GND UV GND OVP CLP CLN COMP1 SENSE
GND GND
V
CC1
V
CC2
V
CC3
PROG
V
C

UV
OUT
GND
COMP2
BAT
SPIN
1 2 3 4 5 6 7 8 9
10 11 12 13 14
28 27 26 25 24 23 22 21 20 19 18 17 16 15 
MCLR
–

RA0/AN0 RA1/AN1 RA2/AN2 RA3/AN3 RA4 RA5/AN4 VSS OSC1 OSC2 RCO CCP2 CCP1 SCL
RB7 RB6 RB5 RB4 RB3 RB2 RB1
RB0/INT
V
DD

V
SS

RC7 RC6 RC5
SDA
U2
LT1511
C11 10µF 25V
Q4 MMBT3904LT1
C4 1µF 25V
C3 33µF 25V
Q1
2N7002LT1
Q3
2N7002LT1
C10 10µF 25V
C5
1µF
25V
C8 0.1µF
C2 10µF 10V
C9
0.47µF
25V
D5 MBRS340T3
D3
MBRS340T3
L1
20µH
E1 E2
D4
BAS16LT1
R10
0.05Ω
1/2W
C9 0.1µF
24V
2A
J2
CENTER POST
IS POSITIVE
C16 100pF 50V
R20
200Ω
1/10W
1%
R2
301Ω
1/10W
1%
R18
1k
1/10W
1%
5V
BOLD LINES INDICATE HIGH CURRENT PATHS
R3 1k 1/10W 1%
R24
10k
5%
R15
21.5k
1/10W
0.1%
R23
22Ω
R8 0.033Ω 1/2W
5V R19
200Ω
1/10W
1%
R14
330Ω
R13 143k 1/10W 0.1%
C7 0.015µF 25V 5% C6 0.047µF
D6 BAS16LT1
C12
10µF
25V
J1
AMP-787441-1
SMART BATTERY
CONNECTOR
C18 10µF 10V
TP1 TP2 TP3 TP4 TP5
C20 10µF 25V
+
R12 100k 1/10W 0.1%
(+) (+)
CLK CLK
DATA DATA
(T) (T) (–) (–)
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10
R11 510Ω
R16
3.32k
1/10W
1%
R17
1.05k
1/10W
1%
V
OUT
V
IN
2
DC IN
13
5V
4
GND
U3
LT1129IST-5
TAB
+
C17 0.1µF
Q2
2N7002LT1
UNLESS OTHERWISE SPECIFIED: 1. ALL RESISTANCES ARE IN OHMS, 1/10W, 5% 2. ALL CAPACITANCES ARE IN MICROFARADS, 50V, 10%
C14
33pF
SHUTDOWN
R4
3.32k
1%
U1
PIC16C73-20PS
CHARGER  ADJUSTMENT RANGE PWM1: 3FFh = 22.4V  000h = 6V PWM2:3FFh = 4.1A  000h = 0A  
C15
33pF
Y1 4MHz
R7
3.32k
1%
5V
JPR1
RESET
C1 0.1µF
R26
10k
R5 330Ω
D1 RED (SMB)
S1
5V
RESET
R6 330Ω
D2 GRN (µP)
E3
DC OUT
E4
R1 3.32k 1/10W 1%
R9 100k
R21 22k 5%
5V
R25 22k 5%
5V
E5
DC101 SD
E6 E7
SMBCLK
SMBDATA
INT
R22 22k 5%
5V
Smart Battery Charger with SMBus Interface

3
DEMO MANUAL DC101
SMART BATTERY CHARGER
REFERENCE
DESIGNATOR QUANTITY PART NUMBER DESCRIPTION VENDOR TELEPHONE
C1, C8, C17, C19 4 12065C104KATMA 0.1µF 50V Chip Capacitor AVX [phone]
C2, C18 2 TAJB106M010 10µF 10V Tantalum Capacitor AVX [phone]
C3 1 12063G334ZAT2 0.33µF 25V Chip Capacitor AVX [phone]
C4, C5 2 12063G105ZATMA 1µF 25V Chip Capacitor AVX [phone]
C6 1 12065C473KAT 0.047µF 50V 10% Chip Capacitor AVX [phone]
C7 1 12063C153KAT2 0.015µF 25V 5% Chip Capacitor AVX [phone]
C9 1 12063G474ZAT2 0.47µF 25V Chip Capacitor AVX [phone]
C10, C11, C12, C20 4 THCS50E1E106Z 10µF 25V Ceramic Capacitor Marcon [phone] x374
C14, C15 2 1206A330KAT2 33pF 50V Chip Capacitor AVX [phone]
C16 1 VJ1206A101KXA 100pF 50V Chip Capacitor Vitramon [phone]
D1 1 SF1-BR Red LED Data Display Product [phone]
D2 1 SF1-G Green LED Data Display Product [phone]
D3, D5 2 MBRS340T3 Diode Motorola [phone]
D4, D6 2 BAS16LT1 Diode Motorola [phone]
J1 1 AMP-787441-1 Connector AMP [phone]
J2 1 CUI-PJ-002A Connector Cui-Stack [phone]
JPR1 1 3801S-12-G1 12-Pin Header Jumper Comm Con Conn. [phone]
L1 1 CTX20-4 20µH Inductor Coiltronics [phone]
Q1,Q2, Q3 3 2N7002LT N-Channel MOSFET Motorola [phone]
Q4 1 MMBT3904LT1 NPN Transistor Motorola [phone]
R1, R4, R16 3 CR32-3321F-T 3.32k 1/8W 1% Resistor AVX [phone]
R2 1 CR32-3010F-T 301Ω1/8W 1% Resistor AVX [phone]
R3, R18 2 CR32-1001F-T 1k 1/8W 1% Resistor AVX [phone]
PACKAGE DIAGRA
W
1
2
3
4
5
6
7
8
9
10
11
12
TOP VIEW
SW PACKAGE
24-LEAD PLASTIC SO WIDE
24
23
22
21
20
19
18
17
16
15
14
13

GND
SW
BOOST
GND
GND
UV
GND
OVP
CLP
CLN
COMP1
SENSE
GND
GND
V
CC1
V
CC2
V
CC3
PROG
V
C

UV
OUT
GND
COMP2
BAT
SPIN
LT1511CSW
PARTS LIST

4
DEMO MANUAL DC101
SMART BATTERY CHARGER
REFERENCE
DESIGNATOR QUANTITY PART NUMBER DESCRIPTION VENDOR TELEPHONE
R5, R6, R14 3 CR32-331J-T 330Ω1/8W 5% Resistor AVX [phone]
R7 1 BCR1/8-3322F-T 33.2k 1/8W 1% Resistor Beckman [phone]
R8 1 LR2010-01-R033-J 0.033Ω1/2W 5% Resistor IRC [phone]
R9 1 CR32-104J-T 100k 1/8W 5% Resistor AVX [phone]
R10 1 LR2010-01-R050-J 0.05Ω1/2W 5% Resistor IRC [phone]
R11 1 CR32-511J-T 510Ω1/8W 5% Resistor AVX [phone]
R12 1 W1206R-03-1003-B 100k 1/8W 0.1% Resistor IRC [phone]
R13 1 W1206R-03-1433-B 143k 1/10W 0.1% Resistor IRC [phone]
R15 1 W1206R-03-2152-B 21.5k 1/10W 0.1% Resistor IRC [phone]
R17 1 CR32-1051F-T 1.05k 1/8W 1% Resistor AVX [phone]
R19, R20 2 CR32-2000F-T 200Ω1/8W 1% Resistor AVX [phone]
R21, R22, R25 3 CR32-223J-T 22k 1/10W 5% Resistor AVX [phone]
R23 1 CR32-220J-T 22Ω1/10W 5% Resistor AVX [phone]
R24, R26 2 CR1206-103J 10k 1/8W 5% Resistor Dale [phone]
S1 1 MJTP1230 PB Switch MORS-ASC [phone]
TP1 to TP5, E1 to E7 12 1502-2 Turret Testpoint Keystone [phone]
U1 1 PIC16C73-20SP Microcontroller IC Microchip [phone]
U2 1 LT1511 Battery Charger IC LTC [phone]
U3 1 LT1129IST-5 Voltage Regulator IC LTC [phone]
XU1 1 7167-14-G2 Sockets IC Comm Con [phone]
Y1 1 MA-505-4.00M-C2 4MHz Crystal Epson (USA) [phone]
OPERATIO
U
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
chargerinputcurrentislimitedbytheLT1511 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.
PARTS LIST

5
DEMO MANUAL DC101
SMART BATTERY CHARGER
OPERATIO
U
Battery Removal, Thermistor Measurements: The
charger periodically checks the thermistor in the battery
through the T-terminal. When the thermistor is out of
normaloperatingtemperaturerange,thechargerswitches
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 500Ω< R
TH
< 1.5k range, the charger assumes a Li-
Ion 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,thebatteryaddressestheSmartBatterycharger
and waits for an acknowledgment (ACK) from it. If the
charger fails to acknowledge the word, the battery termi-
nates further communication by placing a STOP 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:
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
STOP
The idealized SMBus waveforms shown in Figure 1 illus-
trate SMBus communication between the battery and the
charger. The first seven bits after the 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.
SCLK
SDA
START 1 2 0 = WRITE
1 = 1ST NIBBLE
2 = 2ND NIBBLE (TRUNCATED)
THIS EXAMPLE = 12(H)
DC101 F01
0001001R/WACK
Figure 1. SMBus Waveforms Indicating Battery Address

6
DEMO MANUAL DC101
SMART BATTERY CHARGER
OPERATIO
U
12C DATA RECEIVED
THERMISTOR OPEN
A/D COUNTER = 0
ALARM WARNING
ON STACK
CHARGING CURRENT
ON STACK
CHARGING VOLTAGE
ON STACK
ERROR FLAG
SET SLOW BLINKING
INIT VARIABLES START
Y
THERMISTOR TOO HOT
THERMISTOR
IN RANGE
THERMISTOR 
TOO COLD
Li-Ion
Y
INTERRUPT
RETURN FROM
INTERRUPT
TURN RED LED ON 
FOR 2 SEC
RESET 12C POINTER
DISABLE INTERRUPTS
PUT 12C DATA ON THE 
12C STACK INCREMENT 
POINTER
ENABLE INTERRUPTS
YSET ERROR FLAG
SHUT DOWN CHARGER
ERASE COMMAND
Y
Y
Y
Y
Y
Y
LOAD IPWM
ERASE COMMAND
ENABLE CHARGER
ERASE ERROR FLAG
YLOAD VPWM
ERASE COMMAND
ENABLE CHARGER
ERASE ERROR FLAG
SET TRICKLE CHARGE
SET ERROR FLAG
IF NO Li-Ion FLAG:
INIT Li-Ion MODE
ERASE ERROR FLAG
IF Li-Ion FLAG SET:
ERASE Li-Ion FLAG
ERASE ERROR FLAG
INIT Ni-MH MODE
YSET FAST BLINKING
MEASURE THERMISTOR
THERMISTOR
SHORTED
Figure 2. Software Flowchart

7
DEMO MANUAL DC101
SMART BATTERY CHARGER
PCB LAYOUT A D FIL
UW
Component Side Silkscreen
Component Side Component Side Solder Mask
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 represen-
tation that the interconnection of circuits as described herein will not infringe on existing patent rights.

8
DEMO MANUAL DC101
SMART BATTERY CHARGER
Linear Technology Corporation
1630 McCarthy Blvd., Milpitas, CA 95035-7417
[phone]
●
FAX : [phone]
●
TELEX : 499-3977
 LINEAR TECHNOLOGY CORPORATION 1996
LT/GP 0796 500 • PRINTED IN USA
PCB LAYOUT A D FIL
UW
Solder Side Solder Side Solder Mask
PC FAB DRAWI G
U
A
A
0.150"
0.150"
0.150"
A
DC101 FD
F
A
B
D
D
NOTES
1.MATERIAL: 2 LAYERS, 0.062" THICK. 
 FR-4 GLASS EPOXY 2 OZ 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 
D
GG
G
B
E
E
E
H
H
HH
H
H
H
H
H
H
H
H
C
SYMBOL
A
B
C
D
E
F
G
H
DIAMETER
125
120
100
94
40
39
37
18
TOTAL HOLES
NUMBER
OF HOLES
4
2
1
12
14
4
40
55
132
0.219"
0.150"
2.744"
3.900"
3.019"