ANALOG DEVICES LTC4020EUHF High Power Buck Boost Multi Chemistry Battery Charger Instructions

ANALOG DEVICES LTC4020EUHF High Power Buck-Boost Multi-Chemistry Battery

Charger

DESCRIPTION

Demonstration circuit 2134B is a high-power buck-boost multi-chemistry battery charger featuring the LTC®4020. The board will accept an input voltage between 15V and 55V. The float voltage of the battery output (BAT) is 25.2V, with a 6.3A maximum charge current. The converter out-put (VOUT) has a voltage range of 21V to 28V, with 8A maximum load current. The LTC4020 contains a high- efficiency synchronous buck-boost DC/DC controller and uses a proprietary average current mode architecture. The LTC4020 battery charger can provide a constant-current/constant-voltage charge algorithm (CC/CV); a four-step, three-stage lead-acid battery-charge profile or constant-current charging (CC). Battery-chemistry type is selected using onboard jumper JP1. The LTC4020 data sheet gives a complete description of the IC operation and application information. The data sheet must be read in conjunction with this quick-start guide.
Design files for this circuit board are available.

PERFORMANCE SUMMARY Specifications are at TA = 25°C

QUICK START PROCEDURE

Demonstration circuit 2134B is easy to set up to evaluate the performance of the LTC4020. Refer to Figure 1 for the proper measurement equipment setup and follow the procedure below.
NOTE: Make sure that the voltage applied to VIN does not exceed 55V. The combined converter output load current and battery charging current should not exceed 8A.

1. With power off, connect the input power supply (set for 0V) to VIN and GND (input return).
2. Connect the converter output load between VOUT and GND (Initial load: no load).
3. Connect the DVMs to the input and outputs.
4. Turn on the input power supply and slowly increase to 24V. Check for the proper output voltages, VOUT of 25.2V and BAT of 25.2V.
5. Once the proper output voltages are established, adjust the converter output load within the operating range (8A maximum) and/or adjust the input voltage (15V to 55V) and observe the output voltage regulation, ripple voltage, efficiency, and other parameters.

NOTE: When measuring the output or input voltage ripple, do not use the long ground lead on the oscilloscope probe. See Figure 2 for the proper scope probe technique. Short, stiff leads need to be soldered to the (+) and (–) terminals of an output capacitor. The probe’s ground ring needs to touch the (–) lead and the probe tip needs to touch the (+) lead.

WARNING:

BE CAREFUL WHEN TESTING WITH HIGH VOLTAGE. HIGH VOLTAGE CAN RESULT IN AN ELECTRIC SHOCK IF CARE IS NOT TAKEN.
BATTERIES ARE POTENTIALLY DANGEROUS HIGH-ENERGY SOURCES. IMPROPER CONNECTION, OVERCHARGE, OR RAPID DISCHARGE COULD RESULT IN EXPLOSION AND/OR FIRE. PLEASE READ THE SPECIFICATION/MANUAL OF THE BATTERY BEFORE TEST.

Additional Notes

1. Without a proper battery, BAT output can be opened or connected with other suitable loads for test purposes. It may be a good practice to add low ESR electrolytic capacitors to the BAT output (≥1000μF at ≥35V, for 25.2V float voltage). Note that these capacitors help simulate the low impedance of a battery and maintain the stability of the charge current loop. They are only needed for test purposes with electronic or resistive loads, and not needed in the actual battery application/test (where the BAT load is a battery).
2. The 0Ω, 2512 jumper (R41) in series with the inductor can be removed and a wire loop can be added in its place to facilitate the use of a current probe.
3. BAT float voltage can be easily adjusted with the resistor divider R44/R45. Converter output voltage VOUT can be adjusted with the resistor divider R9/R11. Adjust/optimize the loop compensations if necessary.

TEST RESULTS

PARTS LIST

ITEM| QTY| REFERENCE| PART DESCRIPTION| MANUFACTURER/PART NUMBER
---|---|---|---|---
1| 2| C1, C5| CAP., 0.22μF, X7R, 16V, 10%, 0402, AEC-Q200| MURATA, GCM155R71C224KE02D
---|---|---|---|---
2| 1| C11| CAP., 4.7μF, X7R, 10V, 10%, 0603| MURATA, GRM188Z71A475KE15D
3| 1| C12| CAP., 0.1μF, X7R, 10V, 10%, 0402| MURATA, GRM155R71A104KA01D
4| 1| C13| CAP., 0.022μF, X7R, 25V, 10%, 0603, AEC-Q200| KEMET, C0603C223K3RACAUTO
5| 4| C14, C18, C27, C28| CAP., 10μF, X7R, 35V, 10%, 1210| AVX, 1210DD106KAT2A
6| 2| C15, C17| CAP., 220μF, ALUM POLY HYB, 35V, 20%, 10mm × 12.5mm, SMD, AEC-Q200| SUN ELECTRONIC INDUSTRIES CORP, 35HVH220M
7| 2| C16, C23| CAP., 4.7μF, X7S, 100V, 10%, 1210, AEC-Q200| MURATA, GCM32DC72A475KE02L
8| 2| C19, C20| CAP., 1μF, X7R, 16V, 10%, 0603| KEMET, C0603C105K4RAC7867
9| 2| C2, C3| CAP., 56μF, ALUM POLY HYB, 63V, 20%, 10mm × 112.5mm SMD, AEC-Q200| SUN ELECTRONIC INDUSTRIES CORP, 63HVH56M
10| 2| C21, C42| CAP., 10μF, X7R, 16V, 10%, 0805| TAIYO YUDEN, EMK212BB7106MG-T
11| 2| C39, C40| CAP., 0.22μF, X7R, 10V, 10%, 0402| MURATA, GRM155R71A224KE01D
12| 1| C4| CAP., 100pF, C0G, 50V, 5%, 0402| AVX, 04025A101JAT2A
13| 2| C41, C43| CAP., 0.01μF, X7R, 100V, 10%, 0603, AEC-Q200| MURATA, GCJ188R72A103KA01D
14| 1| C44| CAP., 0.01μF, X7R, 50V, 10%, 1206| KEMET, C1206C103K5RAC7025
15| 1| C45| CAP., 1μF, X7R, 50V, 10%, 0603| AVX, 06035C105KAT2A
16| 1| C8| CAP., 270pF, C0G, 50V, 5%, 0603| AVX, 06035A271JAT2A
17| 3| D1, D2, D7| DIODE, SBR, 60V, 500mA, SOD123| DIODES INC., SBR0560S1Q-7
18| 1| D3| LED, RED, WATER-CLEAR, 0603| LITE-ON, LTST-C193KRKT-5A
19| 1| D4| LED, GREEN, WATER-CLEAR, 0603| LITE-ON, LTST-C190KGKT
20| 2| D5, D6| DIODE, SCHOTTKY RECTIFIER, 60V, 3A,

4.6mm × 2.92mm

| DIODES INC., B360A-13-F
21| 1| D8| DIODE, ZENER, 12V, 500mW, SOD123, AEC-Q101| DIODES INC., BZT52C12-13-F
22| 1| L1| IND., 5.6μH, SHIELDED WIREWOUND, 20%, 19A, 18.30mm × 18.20mm SMT| WURTH ELEKTRONIK, 7443556560
23| 1| Q1| XSTR., MOSFET, P-CH, 60V, 8.6A, PowerPAK SO-8| VISHAY, Si7461DP-T1-GE3
24| 4| Q2, Q3, Q4, Q7| XSTR., MOSFET, N-CH, 60V, 93A, DFN5 (SO-8FL), AEC-Q101| ONSEMI, NTMFS5C646NLT1G
25| 2| R1, R17| RES., 0Ω, JUMPER, 0603, AEC-Q200| KOA SPEER, RK73Z1JTTDD
26| 1| R11| RES., 24.9k, 1%, 1/10W, 0603, AEC-Q200| NIC, NRC06F2492TRF
27| 1| R12| RES., 226k, 1%, 1/16W, 0402, AEC-Q200| NIC, NRC04F2263TRF
28| 1| R14| RES., 10k, 1%, 1/10W, 0402, AEC-Q200| KOA SPEER, RK73H1ETTP1002F
29| 1| R16| RES., 82.5k, 1%, 1/10W, 0603, AEC-Q200| PANASONIC, ERJ3EKF8252V
30| 2| R18, R20| RES., 100Ω, 1%, 1/16W, 0402, AEC-Q200| KOA SPEER, RK73H1ETTP1000F
31| 1| R19| RES., 20Ω, 1%, 1/16W, 0402, AEC-Q200| NIC, NRC04F20R0TRF
32| 1| R2| RES., 511k, 1%, 1/16W, 0402, AEC-Q200| NIC, NRC04F5113TRF
33| 4| R22-R25| RES., 10Ω, 1%, 1/16W, 0402| YAGEO, RC0402FR-0710RL
34| 2| R26, R27| RES., 2k, 1%, 1/16W, 0402, AEC-Q200| VISHAY, CRCW04022K00FKED
35| 2| R28, R42| RES., 0.002Ω, 2%, 3W, 2512, LONG-SIDE TERM., METAL, AEC-Q200| SUSUMU, KRL6432E-M-R002-G-T1
36| 2| R3, R13| RES., 100k, 1%, 1/16W, 0402, AEC-Q200| NIC, NRC04F1003TRF
ITEM| QTY| REFERENCE| PART DESCRIPTION| MANUFACTURER/PART NUMBER
---|---|---|---|---
37| 2| R35, R37| RES., 0Ω, 5%, 1/16W, 0402| ROHM, MCR01MZPJ000
38| 1| R4| RES., 51.1k, 1%, 1/16W, 0402, AEC-Q200| STACKPOLE ELECTRONICS, INC., RMCF0402FT51K1
39| 1| R40| RES., 0.008Ω, 1%, 1W, 2512| VISHAY, WSL25128L000FEA
40| 1| R41| RES., 0Ω, 200A, 2512, COPPER, SENSE| VISHAY, WSL251200000ZEA9
41| 1| R43| RES., 1Ω, 1%, 1/10W, 0603| YAGEO, RC0603FR-071RL
42| 1| R44| RES., 226k, 0.1%, 1/10W, 0603, HIGH STABILITY| VISHAY, TNPW0603226KBEEA
43| 1| R45| RES., 24.9k, 0.1%, 1/8W, 0603, AEC-Q00| VISHAY, TNPW060324K9BEEA
44| 1| R5| RES., 825k, 1%, 1/16W, 0402, AEC-Q200| VISHAY, CRCW0402825KFKED
45| 2| R6, R7| RES., 20Ω, 1%, 1/10W, 0603| YAGEO, RC0603FR-0720RL
46| 1| R9| RES., 226k, 1%, 1/10W, 0603| NIC, NRC06F2263TRF
47| 1| U1| IC, 55V BUCK-BOOST BATTERY CHARGER, 38-PIN QFN| ANALOG DEVICES, LTC4020EUHF#PBF
48| 1| U2| IC, 250mA, 4V TO 80V LDO LINEAR REG, DFN-12| ANALOG DEVICES, LT3012EDE#PBF

Optional Electrical Components

1| 0| C6, C7, C9, C24, C25, C30, C31| CAP., OPTION, 0603|
---|---|---|---|---
2| 0| C10, C22| CAP., OPTION, 0402|
3| 0| C26, C44| CAP., OPTION, 1206|
4| 0| C29, C32-C38| CAP., OPTION, 1210|
5| 0| Q5, Q6, Q8, Q9| XSTR., OPTION, MOSFET, N-CH, DFN5 (SO-8FL)|
6| 0| R15| RES., OPTION, 0603|
7| 0| R29, R30, R33, R39| RES., OPTION, 0402|
8| 0| R31, R32| RES., OPTION, 0805|

Hardware: For Demo Board Only

1| 7| E1, E2, E10, E11, E13, E14, E18| TEST POINT, TURRET, 0.094″ MTG. HOLE, PCB 0.062 THK| MILL-MAX, 2501-2-00-80-00-00-07-0
---|---|---|---|---
2| 4| E5, E6, E9, E17| TEST POINT, TURRET, 0.064″ MTG. HOLE, PCB 0.062″ THK| MILL-MAX, 2308-2-00-80-00-00-07-0
3| 6| J3, J4, J11, J12, J15, J16| CONN., BANANA JACK, FEMALE, THT, NON- INSULATED, SWAGE, 0.218″| KEYSTONE, 575-4
4| 1| JP1| CONN., HDR, MALE, 1×4, 2mm, VERT, ST, THT| SULLINS CONNECTOR SOLUTIONS, NRPN041PAEN-RC
5| 4| MP1-MP4| STANDOFF, NYLON, SNAP-ON, 0.50″| WURTH ELEKTRONIK, 702935000
6| 1| XJP1| CONN., SHUNT, FEMALE, 2-POS, 2mm| SAMTEC, 2SN-BK-G

SCHEMATIC DIAGRAM

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