MCP1630V Ref Design Guide Datasheet by Microchip Technology

View All Related Products | Download PDF Datasheet
MICROCHIP
© 2006 Microchip Technology Inc. DS51641A
MCP1630V
Bidirectional 4 Cell
Li-Ion Charger Reference Design
Users Guide
QUALITY MANAGEMENT SYSTEM CERTIFIED BY DNV = ISO/TS 1694922002 =
DS51641A-page ii © 2006 Microchip Technology Inc.
Information contained in this publication regarding device
applications and the like is provided only for your convenience
and may be superseded by updates. It is your responsibility to
ensure that your application meets with your specifications.
MICROCHIP MAKES NO REPRESENTATIONS OR
WARRANTIES OF ANY KIND WHETHER EXPRESS OR
IMPLIED, WRITTEN OR ORAL, STATUTORY OR
OTHERWISE, RELATED TO THE INFORMATION,
INCLUDING BUT NOT LIMITED TO ITS CONDITION,
QUALITY, PERFORMANCE, MERCHANTABILITY OR
FITNESS FOR PURPOSE. Microchip disclaims all liability
arising from this information and its use. Use of Microchip
devices in life support and/or safety applications is entirely at
the buyer’s risk, and the buyer agrees to defend, indemnify and
hold harmless Microchip from any and all damages, claims,
suits, or expenses resulting from such use. No licenses are
conveyed, implicitly or otherwise, under any Microchip
intellectual property rights.
Trademarks
The Microchip name and logo, the Microchip logo, Accuron,
dsPIC, KEELOQ, microID, MPLAB, PIC, PICmicro, PICSTART,
PRO MATE, PowerSmart, rfPIC and SmartShunt are
registered trademarks of Microchip Technology Incorporated
in the U.S.A. and other countries.
AmpLab, FilterLab, Migratable Memory, MXDEV, MXLAB,
SEEVAL, SmartSensor and The Embedded Control Solutions
Company are registered trademarks of Microchip Technology
Incorporated in the U.S.A.
Analog-for-the-Digital Age, Application Maestro, CodeGuard,
dsPICDEM, dsPICDEM.net, dsPICworks, ECAN,
ECONOMONITOR, FanSense, FlexROM, fuzzyLAB,
In-Circuit Serial Programming, ICSP, ICEPIC, Linear Active
Thermistor, Mindi, MiWi, MPASM, MPLIB, MPLINK, PICkit,
PICDEM, PICDEM.net, PICLAB, PICtail, PowerCal,
PowerInfo, PowerMate, PowerTool, REAL ICE, rfLAB,
rfPICDEM, Select Mode, Smart Serial, SmartTel, Total
Endurance, UNI/O, WiperLock and ZENA are trademarks of
Microchip Technology Incorporated in the U.S.A. and other
countries.
SQTP is a service mark of Microchip Technology Incorporated
in the U.S.A.
All other trademarks mentioned herein are property of their
respective companies.
© 2006, Microchip Technology Incorporated, Printed in the
U.S.A., All Rights Reserved.
Printed on recycled paper.
Note the following details of the code protection feature on Microchip devices:
Microchip products meet the specification contained in their particular Microchip Data Sheet.
Microchip believes that its family of products is one of the most secure families of its kind on the market today, when used in the
intended manner and under normal conditions.
There are dishonest and possibly illegal methods used to breach the code protection feature. All of these methods, to our
knowledge, require using the Microchip products in a manner outside the operating specifications contained in Microchip’s Data
Sheets. Most likely, the person doing so is engaged in theft of intellectual property.
Microchip is willing to work with the customer who is concerned about the integrity of their code.
Neither Microchip nor any other semiconductor manufacturer can guarantee the security of their code. Code protection does not
mean that we are guaranteeing the product as “unbreakable.”
Code protection is constantly evolving. We at Microchip are committed to continuously improving the code protection features of our
products. Attempts to break Microchip’s code protection feature may be a violation of the Digital Millennium Copyright Act. If such acts
allow unauthorized access to your software or other copyrighted work, you may have a right to sue for relief under that Act.
Microchip received ISO/TS-16949:2002 certification for its worldwide
headquarters, design and wafer fabrication facilities in Chandler and
Tempe, Arizona, Gresham, Oregon and Mountain View, California. The
Company’s quality system processes and procedures are for its PIC®
8-bit MCUs, KEELOQ® code hopping devices, Serial EEPROMs,
microperipherals, nonvolatile memory and analog products. In addition,
Microchip’s quality system for the design and manufacture of
development systems is ISO 9001:2000 certified.
6‘ MICROCHIP
MCP1630V BIDIRECTIONAL 4 CELL
LI-ION CHARGER REFERENCE
DESIGN USERS GUIDE
© 2006 Microchip Technology Inc. DS51641A-page iii
Table of Contents
Preface ........................................................................................................................... 1
Introduction............................................................................................................ 1
Document Layout .................................................................................................. 1
Conventions Used in this Guide ............................................................................ 2
Recommended Reading........................................................................................ 2
The Microchip Web Site ........................................................................................ 3
Customer Support ................................................................................................. 3
Document Revision History ................................................................................... 3
Chapter 1. Product Overview ........................................................................................ 5
1.1 Introduction ..................................................................................................... 5
1.2 What is the MCP1630V Bidirectional 4 Cell Li-Ion Charger
Reference Design? ................................................................................... 6
1.3 What the MCP1630V Bidirectional 4 Cell Li-Ion Charger
Reference Design kit includes .................................................................. 6
Chapter 2. Installation and Operation .......................................................................... 7
2.4 Introduction ..................................................................................................... 7
2.5 Features ......................................................................................................... 7
2.6 Getting Started ............................................................................................... 8
Appendix A. Schematics and Board Layouts............................................................ 11
A.1 Introduction .................................................................................................. 11
A.2 Schematic - Sheet 1 ................................................................................... 12
A.3 Schematic - Sheet 2 ................................................................................... 13
A.4 Board – Top Silk Layer ............................................................................... 14
A.5 Board – Top Metal Layer ............................................................................ 15
A.6 Board – Mid Layer1 .................................................................................... 16
A.7 Board – Mid Layer2 .................................................................................... 17
A.8 Board – Metal Layer ................................................................................... 18
A.9 Board – Bottom Silk Layer ......................................................................... 19
Appendix B. Bill Of Materials (BOM) .......................................................................... 21
Appendix C. Firmware ................................................................................................. 23
C.1 Device Firmware - Flowchart ....................................................................... 23
C.2 Device Firmware - Flowchart (Continued) ................................................... 24
Worldwide Sales and Service .................................................................................... 26
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide
DS51641A-page iv © 2006 Microchip Technology Inc.
NOTES:
6‘ MICROCHIP
MCP1630V BIDIRECTIONAL 4 CELL
LI-ION CHARGER REFERENCE
DESIGN USERS GUIDE
© 2006 Microchip Technology Inc. DS51641A-page 1
Preface
INTRODUCTION
This chapter contains general information that will be useful to know before using the
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design. Items discussed in
this chapter include:
Document Layout
Conventions Used in this Guide
Recommended Reading
The Microchip Web Site
Customer Support
Document Revision History
DOCUMENT LAYOUT
This document describes how to use the MCP1630V Bidirectional 4 Cell Li-Ion Charger
Reference Design as a development tool to emulate and debug firmware on a target
board. The manual layout is as follows:
Chapter 1. “Product Overview”– Important information about the MCP1630V
Bidirectional 4 Cell Li-Ion Charger Reference Design.
Chapter 2. “Installation and Operation” – Includes instructions on how to get
started with this user’s guide and a description of the user’s guide.
Appendix A. “Schematics and Board Layouts” – Shows the schematic and
layout diagrams for the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference
Design.
Appendix B. “Bill Of Materials (BOM)” – Lists the parts used to build the
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design.
Appendix C. “Firmware” – Provides information about the application firmware
and where the source code can be found.
NOTICE TO CUSTOMERS
All documentation becomes dated, and this manual is no exception. Microchip tools and
documentation are constantly evolving to meet customer needs, so some actual dialogs
and/or tool descriptions may differ from those in this document. Please refer to our web site
(www.microchip.com) to obtain the latest documentation available.
Documents are identified with a “DS” number. This number is located on the bottom of each
page, in front of the page number. The numbering convention for the DS number is
“DSXXXXXA”, where “XXXXX” is the document number and “A” is the revision level of the
document.
For the most up-to-date information on development tools, see the MPLAB® IDE on-line help.
Select the Help menu, and then Topics to open a list of available on-line help files.
FIIe>Save
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide
DS51641A-page 2 © 2006 Microchip Technology Inc.
CONVENTIONS USED IN THIS GUIDE
This manual uses the following documentation conventions:
RECOMMENDED READING
This user's guide describes how to use MCP1630V Bidirectional 4 Cell Li-Ion Charger
Reference Design. The following Microchip documents are available and
recommended as supplemental reference resources.
MCP1630/MCP1630V Data Sheet, "High-Speed, Microcontroller-Adaptable, Pulse
Width Modulator" (DS21896)
This data sheet provides detailed information regarding the MCP1630/MCP1630V,
product family.
PIC16F88 Data Sheet, "20-Pin Flash-Based, 8-Bit CMOS Microcontrollers with
Nano Watt Technology” (DS30487)
This data sheet provides detailed information regarding the PIC16F88 product family.
APEC Conference Paper, "Bi-Directional Power System for Laptop Computers",
2005
This paper provides detailed information about powering laptop computers using 4
series cell Li-Ion batteries with a bidirectional laptop computer.
DOCUMENTATION CONVENTIONS
Description Represents Examples
Arial font:
Italic characters Referenced books MPLAB® IDE User’s Guide
Emphasized text ...is the only compiler...
Initial caps A window the Output window
A dialog the Settings dialog
A menu selection select Enable Programmer
Quotes A field name in a window or
dialog
“Save project before build”
Underlined, italic text with
right angle bracket
A menu path File>Save
Bold characters A dialog button Click OK
A tab Click the Power tab
N‘Rnnnn A number in verilog format,
where N is the total number of
digits, R is the radix and n is a
digit.
4‘b0010, 2‘hF1
Text in angle brackets < > A key on the keyboard Press <Enter>, <F1>
Courier New font:
Plain Courier New Sample source code #define START
Filenames autoexec.bat
File paths c:\mcc18\h
Keywords _asm, _endasm, static
Command-line options -Opa+, -Opa-
Bit values 0, 1
Constants 0xFF, ‘A’
Italic Courier New A variable argument file.o, where file can be
any valid filename
Square brackets [ ] Optional arguments mcc18 [options] file
[options]
Preface
© 2006 Microchip Technology Inc. DS51641A-page 3
THE MICROCHIP WEB SITE
Microchip provides online support via our web site at www.microchip.com. This web
site is used as a means to make files and information easily available to customers.
Accessible by using your favorite Internet browser, the web site contains the following
information:
Product Support – Data sheets and errata, application notes and sample
programs, design resources, user’s guides and hardware support documents,
latest software releases and archived software
General Technical Support – Frequently Asked Questions (FAQs), technical
support requests, online discussion groups, Microchip consultant program
member listing
Business of Microchip – Product selector and ordering guides, latest Microchip
press releases, listing of seminars and events, listings of Microchip sales offices,
distributors and factory representatives
CUSTOMER SUPPORT
Users of Microchip products can receive assistance through several channels:
Distributor or Representative
Local Sales Office
Field Application Engineer (FAE)
Technical Support
Customers should contact their distributor, representative or field application engineer
(FAE) for support. Local sales offices are also available to help customers. A listing of
sales offices and locations is included in the back of this document.
Technical support is available through the web site at: http://support.microchip.com
DOCUMENT REVISION HISTORY
Revision A (November 2006)
Initial Release of this Document.
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide
DS51641A-page 4 © 2006 Microchip Technology Inc.
NOTES:
IIIIIIII
MCP1630V BIDIRECTIONAL 4 CELL
LI-ION CHARGER REFERENCE
DESIGN USERS GUIDE
© 2006 Microchip Technology Inc. DS51641A-page 5
Chapter 1. Product Overview
1.1 INTRODUCTION
As high power portable applications continue to gain in popularity, more innovative
techniques are needed to charge the batteries while also providing a low regulated
voltage to the system’s high end digital electronics. For example, laptop computers,
portable test equipment, portable printers, etc., all require more power than a single or
two cell Li-Ion battery pack can efficiently store. As a result, three or four series Li-Ion
cell packs are used to store the necessary that power these high end applications. The
result is a high dc voltage used to store the energy requiring a difficult high voltage to
low voltage dc-dc conversion. The MCP1630V Bidirectional 4 Cell Li-Ion Charger Ref-
erence Design can be used to evaluate a design that boosts a low source voltage to
charge four Li-Ion series cells while providing energy to the system simultaneously.
When the source is removed, the same power train used to charge the battery pack
provides a low regulated voltage to operate the system.
This chapter covers the following topics.
What is the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design?
What the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design Kit
includes.
FIGURE 1-1: MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design
shown in Laptop Computer system level block diagram.
AC/DC
Converter
+
-
Wide Range
ac Input
(85 Vrms to 240 Vrms)
Low Voltage
dc Output (+7.0V)
+3.3V
DC/DC
Converter
+1.XV
DC/DC
Converter
Bidirectional
Charger and
DC/DC Converter
4 Cell Li-Ion
Battery Pack
dc-Bus
MCP1630V
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide
DS51641A-page 6 © 2006 Microchip Technology Inc.
1.2 WHAT IS THE MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER
REFERENCE DESIGN?
The MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design demonstrates
the use of a bidirectional buck-boost converter used to charge multiple series cell Li-Ion
batteries with the presence of an input source (boost) and provide a regulated output
voltage when the input source is removed (buck). The board also serves as a platform
to evaluate the MCP1630V device.
The MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design inputs were
developed to be easily attached to the I/O of a PIC® Microcontroller. The MCU supplies
the oscillator (OSC_IN) and reference voltage (VREF) to the MCP1630V creating a
flexible and adaptable power system. The power system switching frequency and
maximum duty cycle are set using the hardware PWM of the MCU. The reference input
to the high speed analog PWM can be external, a D/A Converter (DAC) output or as
simple as an I/O output from the MCU. This enables the power system to adapt to
external signals and variables in order to optimize performance and facilitate
calibration.
This board utilizes Microchip's MCP1630V (high-speed PIC MCU PWM MSOP8) with
the PIC16F88 (Flash MCU) in a four cell Li-Ion charger combined with a synchronous
buck regulator. Under normal operation, the input supply can range between 6.5V and
7.0V. The converter is capable of charging four Li-Ion cells connected in series when
the 6.5V input is present and regulating the bulk input voltage to 6.0V when the input
source voltage is removed by stepping, (bucking), down the battery pack voltage.
1.3 WHAT THE MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER
REFERENCE DESIGN KIT INCLUDES
This MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design kit includes:
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design
Analog and Interface Products Demonstration Boards CD-ROM (DS21912)
- MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s
Guide (DS51641)
6‘ MICROCHIP
MCP1630V BIDIRECTIONAL 4 CELL
LI-ION CHARGER REFERENCE
DESIGN USERS GUIDE
© 2006 Microchip Technology Inc. DS51641A-page 7
Chapter 2. Installation and Operation
2.4 INTRODUCTION
The MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design demonstrates
Microchip's high speed pulse width modulator (PWM) used in a four cell Li-Ion battery
charger combined power supply application. When used in conjunction with a micro-
controller, the MCP1630V will control the power system duty cycle to provide regulated
output voltage or current. The PIC16F88 microcontroller oscillator output is used to pro-
vide pulses at switching frequency of 500 kHz. The MCP1630V generates duty cycle
based on various external inputs. External signals include the input oscillator pulses
from PIC16F88, the reference voltage and the feed back voltage. The output signal is
a square wave pulse provided to the synchronous gate drive input. They synchronous
gate driver is used to turn on and off the upper buck MOSFET and lower synchronous
MOSFET.
The PIC16F88 microcontroller is programmable, allowing the user to modify or develop
their own firmware routines to further evaluate the MCP1630V in this application.
2.5 FEATURES
The MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design has the following
features:
Four Cell Li-Ion Battery Charger, operates stand alone. (Additional firmware
added allows the charger to communicate with smart battery packs)
Charges four cell Li-Ion battery pack from 6.5V to 7.0V Input (complete
precondition, constant current and constant voltage charge algorithm in firmware)
Regulates input dc bus voltage, (steps battery pack voltage down), to 6.0V when
input source is removed (providing uninterrupted power source for system)
ON/OFF button used to enable and disable system, low IQ drain on the battery
when disabled (< 10 µA)
Output over-voltage protection in the event of open battery connections
High efficiency over entire operating input voltage range (94% typical)
PIC16F88 is used to generate ref Voltage and Oscillator signal at 500 kHz
frequency at maximum duty cycle
Proprietary features can be added by modifying the firmware contained in the
PIC16F88
Factory programmed source code is available
ms nu m m ¢ 0 m- In Elk© Ifill . c, “5 MICROCHIP BliD‘RECTIONAL POWER SUPPLY IOZ—DOGSZ
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide
DS51641A-page 8 © 2006 Microchip Technology Inc.
2.6 GETTING STARTED
The MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design is fully
assembled and tested for charging a four series cell Li-Ion battery pack (Battery Pack
should have internal overvoltage, overcurrent and overtemperature protection). The
board requires the use of an external input voltage source (+7.0V) for charging.
2.6.1 Power Input and Output Connection
2.6.1.1 POWERING THE MCP1630V BIDIRECTIONAL 4 CELL LI-ION
CHARGER REFERENCE DESIGN
1. Connect the positive side of the +6.5V to +7.0V input to J2 Pin 2, connect the
negative side (or ground) to Pin 1 of J2. This source voltage should not exceed
7.0 and be rated for 8A minimum supply current.
2. Connect the positive side of the Four cell Li-Ion battery pack voltage to J1 Pin 1,
connect the battery pack return to the negative side of J1 Pin 2.
3. Once the SW1 push button is pressed, the MCP1630V Bidirectional 4 Cell Li-Ion
Charger Reference Design is powered. When powered, a charge cycle will start
automatically if the 7.0V is connected and all preconditions are meet, (see
Appendix C. “Firmware”).
4. LED D3 will be illuminated when the board is running, (charging or bucking).
5. LED D5 will flash only when a charge cycle is in progress.
6. Again, a subsequent pressing of the SW1 push button during normal operation
of the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design will
power-off the converter.
FIGURE 2-2: Board Top Assembly and Connections
Note: Both supplies should have a separate isolated return (ground), there is a
current sense resistor between the +7.0V (VBULK) and +14V(VBATT) supply
returns. If the returns are connected, the charge current can not be
controlled.
LOCATIONS
FOR
D3 D5
CONN
ICD 2
SW1
SWITCH
+14 VBAT
+7V
I
Installation and Operation
© 2006 Microchip Technology Inc. DS51641A-page 9
2.6.1.2 APPLYING BATTERY TO MCP1630V BIDIRECTIONAL 4 CELL LI-ION
CHARGER REFERENCE DESIGN
A four cell battery pack (with internal protection) is connected to the J1 connector
before applying input power and pressing SW1 to start the charge cycle. Once the
battery pack is connected, SW1 can be pressed to start the synchronous buck
converter (assuming there is no 7.0V input applied to J2). With the battery pack
connected, the source for J2 can be “hot” plugged in and out, a voltage will always be
present on J2 until SW1 is pressed shutting off the converter.
2.6.1.3 ALTERNATIVE BATTERY PACK SIMULATOR
As an alternative to the four cell Li-Ion battery pack, a battery pack simulation circuit
can be used, (Figure 2-3). This simulation circuit consists of an adjustable metal wound
power load resistor (10Ω, 100W), Aluminum Electrolytic Capacitor (3,300 µF 25V) and
Schottky Diode (10V, 30V). For evaluating the bidirectional converter design, the bat-
tery simulator circuit is recommended. When using the battery pack simulator, the
operating point for charging and discharging can be easily be adjusted using the VBATT
power supply and load resistor value.
2.6.1.4 LED STATUS INDICATION
Two LED’s are connected to the I/O of the PIC16F88 to provide status of the charger.
LED D3 provides indication that the converter is running while LED D5 flashing
provides indication that the converter is charging. With a 6.5V to 7.0V source applied
to J2 while the converter is running, a charge cycle is initiated. Once the charge cycle
is complete, the charger will continue to operate providing 0 mA of current to the
battery. If the source is removed from J2, the converter will regulate the VBULK voltage
to 6.0V with a load up to 6A.
Evaluating the Application
The best way to evaluate the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference
Design is to operate the bidirectional power system over a wide range using the battery
pack simulator. The simulator consists of a 10Ω power resistor, diode and variable
voltage source. When configured as shown in Figure 2-3, the circuit will simulate a
battery. The load resistor is used to sink current from the charger while a large capacitor
is used to simulate the battery voltage (VSIM). By adjusting the VSIM voltage, different
operating points in the charge cycle can be evaluated.
Once evaluated using the battery pack simulator, the bi-directional reference design
can be used to run charge and discharge cycles using a four cell Li-ion battery pack. If
using an actual Li-ion battery pack, it must have the proper protection features
including, (overvoltage, overcurrent, overtemperature, etc.).
/\
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide
DS51641A-page 10 © 2006 Microchip Technology Inc.
FIGURE 2-3: Battery Simulator Circuit.
Firmware
The PIC16F88 comes pre programmed with firmware to operate the system as
described above. The file listing and firmware flow diagram are shown in Appendix
C. “Firmware”.
Programming
Header J4 is provided for In-Circuit Serial Programming™ (ICSP™). This is an optional
feature since the demo board comes preprogrammed with firmware to operate the
system. The PIC16F88 can be reprogrammed with the Baseline Flash Microcontroller
Programmer (BFMP).
+
-
10Ω
3,300 µF VSIM
+VBATT
J1-1
-VBATT
J1-2
+12V to +17.5V
6‘ MICROCHIP
MCP1630V BIDIRECTIONAL 4 CELL
LI-ION CHARGER REFERENCE
DESIGN USERS GUIDE
© 2006 Microchip Technology Inc. DS51641A-page 11
Appendix A. Schematics and Board Layouts
A.1 INTRODUCTION
This appendix contains the following schematics and layouts for the MCP1630V Bidi-
rectional 4 Cell Li-Ion Charger Reference Design:
Board – Schematic Sheet 1
Board – Schematic Sheet 2
Board – Top Silk Layer
Board – Top Metal Layer
Board – Internal MidLayer 1
Board – Internal MidLayer 2
Board – Metal Layer
Board – Bottom Silk Layer
N a . 2% ”SE“ 3:22.. Zia a: A k s. r m K ‘ 2 : ix N ass vs 352 we azo< 33$="" egon="" 2295mm="" dim.="" 32="" 4="" x5="" h="" ,="" [a];="" ¢="" 3="" ‘="" e="" n23“="" hfiéivnu;="" u:="" s="" ‘="" h5="" swai,="" .fl="" if="" n="" e="" \="" dz”:="" w="" es="" 5="" v="" x"="" 2="" .n«="" mwx="" news="" xe="" ea.="" a="" 31="" e="" «23w="" m="" nazca="" to:="" in="" 32h="" e="" n="" s5="" m5="" km="" 12="" 3="" 4="" 5="" mm="" 9="" j="" ‘="" de="" 3%="" a="" &="" f3?="" 8="" e="" d="" .="" is="" as="" ,="" azuu="" 2="" «vs="" 3="" 1="" n="" xe="" i.="" mi="" m2="">< m“="" 1;="" w="" em="" eu="" 3:,="" fl="" g="" _="" a="" v="" ka="" x="" 5m)="" 1="" nz‘un="" 9e="" ,3="" 9e="" 5%;="" m="" as="" w="" ‘="" a="" ‘="" ‘="" \-="" u="" 508="" i="" s="" .="" 422="" h="" .mflv="" e="" a="" ‘="" 2="" n="" 5="" ,="" 212mm="" em?="" e="" h="" “r:="" x="" 2,.="" x34="" 33="" _!|\_="" .="" 8="" i="" 8="" e="" n="" e="" ed="" 25:="" u="" ms:="" 5="" as,="" .s="" z="" z="" a?="" x”:="" :="" wet="" .="" 56.="" so:="" an)="" »="" aw.="" 593323="" e="" v="" a="" s="" k="" :3="" m:="" $34.15="" e="" 8="" e="">
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide
DS51641A-page 12 © 2006 Microchip Technology Inc.
A.2 SCHEMATIC - SHEET 1
2
:23“ 952% 533m 538 #20555 a, m “w“. s. , m u 7 a E m3 a fl we. I H5 32 x3. w a. :3 \ ‘ ma 5 E a ‘ .3 N i L, .‘ XS 4 ‘ 5; 5% Lo \ 76 ms 2 i E 9“ ‘ ‘ E osmnfiw‘: m o a i é D 3 a mslz, msm m % “““““““““““‘ \ Xn ht xm 3 n; W «2% E E E m
Schematics and Board Layouts
© 2006 Microchip Technology Inc. DS51641A-page 13
A.3 SCHEMATIC - SHEET 2
R18 R36 R31 R28 3 c12|:| El El El El m R45|:|I]:| R16I:I D623 :IRSS , D5 R21 |_| E021 J3 |:|c24 R40 C15 |:| . C16 |:| v E] El R24 |:| l_|cza czs TP6 03 I]: III U‘ C17|:||:|R30 D3 U5 €19 1: EIR7 a, El cw |:| R3 "2% $55st ’5 [V] E '3’“ 1:1 :1 Elm Elcg M 1—1 “LEI C” ‘ v |:| 07 cu El R14 R20|:| 03 oz |:| |:|R9 E R'3EI ”1 |:| R15 l_|ca '- ' 08 I IR39 J1 U1 TP1 m SW1 0 :IR33 0‘— —_ L1 6 R25|:I :le: ° 04 8 [RIM c1 02 613': R37 TR: 0. m E E Us; _ zkzs TP2 ‘2 ' = A _ 4 _cs III II I] cs R8 R6 c22 DZ R1. F1 QMUEELEJ©£§D=UHIE J2 BI—DIRECTIONAL POWER SUPPLY 102—00052 REV—1
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide
DS51641A-page 14 © 2006 Microchip Technology Inc.
A.4 BOARD – TOP SILK LAYER
BOARD
O H“; to 43% 0 ° °° 62%. H
Schematics and Board Layouts
© 2006 Microchip Technology Inc. DS51641A-page 15
A.5 BOARD – TOP METAL LAYER
O O FFIEIYAJCIIM O
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide
DS51641A-page 16 © 2006 Microchip Technology Inc.
A.6 BOARD – MID LAYER1
Schematics and Board Layouts
© 2006 Microchip Technology Inc. DS51641A-page 17
A.7 BOARD – MID LAYER2
MIDLAYER2
O F—VEIFI SBOOO—bOl‘ O
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide
DS51641A-page 18 © 2006 Microchip Technology Inc.
A.8 BOARD – METAL LAYER
SM! [MI 3in I] can I] csa Aw K) 271 [II] 5“ .YU 8S0
Schematics and Board Layouts
© 2006 Microchip Technology Inc. DS51641A-page 19
A.9 BOARD – BOTTOM SILK LAYER
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide
DS51641A-page 20 © 2006 Microchip Technology Inc.
NOTES:
MICROCHIP Tyco®
MCP1630V BIDIRECTIONAL 4 CELL
LI-ION CHARGER REFERENCE
DESIGN USERS GUIDE
© 2006 Microchip Technology Inc. DS51641A-page 21
Appendix B. Bill Of Materials (BOM)
TABLE B-1: BILL OF MATERIALS (BOM)
QTY Reference
Designator Description Manufacturer Part Number
2 C1, C2 CAP CER 10UF 25V X5R 1210 Taiyo Yuden®TMK325BJ106MN-T
2 C3, C17 CAP CERM.22UF 10% 10V X7R 0603 AVX Corporation 0603ZC224KAT2A
2 C4, C29 CAP CERAMIC 1.0UF 10V X5R 0603 Kemet® Electronics Corp C0603C105K8PACTU
2 C5, C6 CAP TANT 100UF 10V 20% POLY SMD EPCOS Inc. B76010V1079M055
12 C7, C11, C13,
C16, C18, C19,
C20, C21, C22,
C26, C28
CAP .10UF 10V CERAMIC X7R 0603 Kemet Electronics Corp C0603C104K8RACTU
1 C8 CAP CERM 8200PF 10% 50V X7R
0603
AVX Corporation 06035C822KAT2A
1 C9 CAP CER 2200PF 50V C0G 5% 0603 TDK Corporation C1608C0G1H222J
1 C10 CAP CERAMIC 330PF 50V NP0 0603 Kemet Electronics Corp C0603C331J5GACT
1 C12 CAP 3300PF 50V CERAMIC X7R 0603 Kemet Electronics Corp C0603C332K5RACTU
2 C14 CAP CERAMIC 120PF 50V NP0 0603 Kemet Electronics Corp C0603C121J5GACTU
1 C15 CAP CERAMIC 100PF 50V NP0 0603 Kemet Electronics Corp C0603C101J5GACTU
1 C23 CAP CERAMIC 180PF 50V NP0 0603 Kemet Electronics Corp C0603C181J5GACTU
1 C24 CAP CERAMIC 10PF 50V NP0 0603 Kemet Electronics Corp C0603C100J5GACTU
1 C30 CAP 10000PF 50V CERAMIC X7R
0603
Kemet Electronics Corp C0603C103K5RACTU
1 C31 CAP 1500PF 50V CERAMIC X7R 0603 Kemet Electronics Corp C0603C152K5RACTU
2 D1 DIODE SCHOTTKY 30V 200MW
SOD123
Diodes Inc. BAT42W-7-F
1 D2 IC ADJ SHUNT REGULATOR
SOT-23-5
Texas Instruments TL431IDBVR
2 D3, D5 LED 660NM SUPER RED DIFF
0603SMD
Lumex® Opto/
Components Inc
SML-LX0603SRW-TR
1 F1 FUSE 5.0A 32V FAST SMD 0603 Tyco® Electronics/
Raychem Circuit
Protection
0603SFF500F/32-2
2 J1, J2 CONN TERM BLOCK 2POS 5MM PCB Phoenix Contact 1715022
1 J3 CONN MOD JACK 6-6 RT/A PCB 50AU Tyco Electronics/Amp 5555165-1
1 J4 CONN HEADER VERT 3POS.100 TIN Tyco Electronics/Amp 640454-3
1 L1 INDUCTOR POWER HI CURR 10UH
SMD
Coiltronics/Div of
Cooper/Bussmann
HC1-100-R
1 Q1 MOSFET N-CH 30V 35A DPAK International Rectifier IRLR3303PBF
1 Q2 MOSFET N-CH 30V 91A DPAK International Rectifier IRLR8103VPBF
4 Q3, Q6, Q7,
Q8
MOSFET N-CH 30V 1.2A SSOT3 Fairchild Semiconductor NDS351AN
Note 1: The components listed in this Bill of Materials are representative of the PCB assembly. The released BOM
used in manufacturing uses all RoHS-compliant components.
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide
DS51641A-page 22 © 2006 Microchip Technology Inc.
1 Q4 MOSFET P-CH 30V 610MA SOT-23 International Rectifier IRLML5103TRPBF
1 Q5 TRANSISTOR GP NPN AMP SOT-23 Fairchild Semiconductor®MMBT3904
0 R1, R21 SMT0603 RESISTOR
DO NOT POPULATE
——
1 R2 RES 499K OHM 1/10W 1% 0603 SMD Panasonic® - ECG ERJ-3EKF4993V
2 R3, R33 RES 9.53K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF9531V
2 R4, R5 RESISTOR .100 OHM 1W 1% 2512 Panasonic - ECG ERJ-L1WKF10CU
5 R6, R7, R13,
R29, R39
RES 10.0K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1002V
1 R8 RES 1.50K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1501V
6 R9, R15, R19,
R22, R38
RES 10.0K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1002V
1 R10 RES 1.00K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1001V
3 R11, R42, R43 RES 47.5K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF4752V
1 R12, R17 RES 15.0K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1502V
1 R14 RES 6.98K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF6981V
2 R16, R32 RES 49.9K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF4992V
3 R18, R40, R45 RES 2.00K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF2001V
1 R20 RES 150 OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1500V
3 R23, R34, R37 RES 7.87K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF7871V
1 R24 RESISTOR 1.20M OHM 1/10W 1%
0603
Panasonic - ECG ERJ-3EKF1204V
1 R25 RES 30.1K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF3012V
3 R26, R27 RES 4.99K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF4991V
1 R28 RES 43.2K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF4322V
1 R30 RES 14.7K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1472V
1 R31 RES 24.9K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF2492V
1 R35 RES 1.62K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF1621V
1 R36 RES 221K OHM 1/10W 1% 0603 SMD Panasonic - ECG ERJ-3EKF2213V
1 R44 RES 3.3 OHM 1W 1% 2512 SMD Panasonic - ECG ERJ-1TRQF3R3U
1 SW1 SWITCH TACT 6MM 260GF SMT E-Switch TL3301NF260QG
6 TP1, TP2, TP3,
TP4, TP5, TP6
PC TEST POINT COMPACT SMT Keystone Electronics®5016
1 U1 IC DRIVER MOSFET DUAL SYNC
8SOIC
Intersil ISL6207CBZ
1 U2 MCP1630V HIGH SPEED ANALOG
PWM
Microchip Technology Inc. MCP1630V-E/MS
2 U3, U4 DUAL10MHz AMPLIFIER 8 PIN
TSSOP PACKAGE
Microchip Technology Inc. MCP6022-I/ST
1 U5 IC MCU FLASH 4KX14 EEPROM
20SSOP
Microchip Technology Inc. PIC16F88T-I/SS
1 U7 IC DGTL THERM SENSOR 5V
SOT23A-5
Microchip Technology Inc. TC74A5-5.0VCTTR
TABLE B-1: BILL OF MATERIALS (BOM) (CONTINUED)
QTY Reference
Designator Description Manufacturer Part Number
Note 1: The components listed in this Bill of Materials are representative of the PCB assembly. The released BOM
used in manufacturing uses all RoHS-compliant components.
MICRDCHIP VBAW>16.8V ‘5 Charge S‘ale @ C C. ‘5 Charge Slam @ C.V.
MCP1630V BIDIRECTIONAL 4 CELL
LI-ION CHARGER REFERENCE
DESIGN USERS GUIDE
© 2006 Microchip Technology Inc. DS51641A-page 23
Appendix C. Firmware
C.1 DEVICE FIRMWARE - FLOWCHART
For the latest copy of the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference
Design User’s Guide firmware, visit our web site at www.microchip.com.
FIGURE C-1: Firmware Flowchart, page 1.
START
Initialize Ports, ADC, PWM, etc.
Read ADC Inputs
VBATT and VBULK
Is Charge
State @ Idle?
Yes
No
No
VBATT>12.8V
Yes
Set State to
P. C .
B
No
Is Charge
State @ C.C.
VBATT > 12.8V
Set State to
C.C
No
Yes
B
Inc. IBATT
VBATT>16.8V
Yes
Set State to
C.V.
B
No
A
Is Charge
State @ C.V.
VBATT > 16.8V
B
No
Dec. IBATT
C
VBATT<16.3V
Yes
Yes
Yes
Yes
No
No
to IMAX
Charge States
Idle = 0 mA
P.C. = Pre-Charge
C.C. = Constant Current
C.V. = Constant Voltage
Is Charge
State @ P.C.?
\Bm< 100="" ma="" ls="" sw1="" pressed="" 7="" vamdzav=""><6.5v>
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide
DS51641A-page 24 © 2006 Microchip Technology Inc.
C.2 DEVICE FIRMWARE - FLOWCHART (CONTINUED)
For the latest copy of the MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference
Design User’s Guide firmware, visit our web site atwww.microchip.com
FIGURE C-2: Firmware Flowchart, page 2.
IBATT < 100 mA
No
Is SW1
Pressed?
No
Yes
C
Shutdown
Is
A
No
Set Charge
to Idle
B
Yes
End
VBATT<12.8V
VBULK<6.5V
Yes
Firmware
© 2006 Microchip Technology Inc. DS51641A-page 25
NOTES:
MICFIDCHIP AMERICAS ASIA/PACIFIC ASIA/PACIFIC EUROPE
DS51641A-page 26 © 2006 Microchip Technology Inc.
AMERICAS
Corporate Office
2355 West Chandler Blvd.
Chandler, AZ 85224-6199
Tel: 480-792-7200
Fax: 480-792-7277
Technical Support:
http://support.microchip.com
Web Address:
www.microchip.com
Atlanta
Alpharetta, GA
Tel: 770-640-0034
Fax: 770-640-0307
Boston
Westborough, MA
Tel: 774-760-0087
Fax: 774-760-0088
Chicago
Itasca, IL
Tel: 630-285-0071
Fax: 630-285-0075
Dallas
Addison, TX
Tel: 972-818-7423
Fax: 972-818-2924
Detroit
Farmington Hills, MI
Tel: 248-538-2250
Fax: 248-538-2260
Kokomo
Kokomo, IN
Tel: 765-864-8360
Fax: 765-864-8387
Los Angeles
Mission Viejo, CA
Tel: 949-462-9523
Fax: 949-462-9608
Santa Clara
Santa Clara, CA
Tel: 408-961-6444
Fax: 408-961-6445
Toronto
Mississauga, Ontario,
Canada
Tel: 905-673-0699
Fax: 905-673-6509
ASIA/PACIFIC
Asia Pacific Office
Suites 3707-14, 37th Floor
Tower 6, The Gateway
Habour City, Kowloon
Hong Kong
Tel: 852-2401-1200
Fax: 852-2401-3431
Australia - Sydney
Tel: 61-2-9868-6733
Fax: 61-2-9868-6755
China - Beijing
Tel: 86-10-8528-2100
Fax: 86-10-8528-2104
China - Chengdu
Tel: 86-28-8665-5511
Fax: 86-28-8665-7889
China - Fuzhou
Tel: 86-591-8750-3506
Fax: 86-591-8750-3521
China - Hong Kong SAR
Tel: 852-2401-1200
Fax: 852-2401-3431
China - Qingdao
Tel: 86-532-8502-7355
Fax: 86-532-8502-7205
China - Shanghai
Tel: 86-21-5407-5533
Fax: 86-21-5407-5066
China - Shenyang
Tel: 86-24-2334-2829
Fax: 86-24-2334-2393
China - Shenzhen
Tel: 86-755-8203-2660
Fax: 86-755-8203-1760
China - Shunde
Tel: 86-757-2839-5507
Fax: 86-757-2839-5571
China - Wuhan
Tel: 86-27-5980-5300
Fax: 86-27-5980-5118
China - Xian
Tel: 86-29-8833-7250
Fax: 86-29-8833-7256
ASIA/PACIFIC
India - Bangalore
Tel: 91-80-4182-8400
Fax: 91-80-4182-8422
India - New Delhi
Tel: 91-11-4160-8631
Fax: 91-11-4160-8632
India - Pune
Tel: 91-20-2566-1512
Fax: 91-20-2566-1513
Japan - Yokohama
Tel: 81-45-471- 6166
Fax: 81-45-471-6122
Korea - Gumi
Tel: 82-54-473-4301
Fax: 82-54-473-4302
Korea - Seoul
Tel: 82-2-554-7200
Fax: 82-2-558-5932 or
82-2-558-5934
Malaysia - Penang
Tel: 60-4-646-8870
Fax: 60-4-646-5086
Philippines - Manila
Tel: 63-2-634-9065
Fax: 63-2-634-9069
Singapore
Tel: 65-6334-8870
Fax: 65-6334-8850
Taiwan - Hsin Chu
Tel: 886-3-572-9526
Fax: 886-3-572-6459
Taiwan - Kaohsiung
Tel: 886-7-536-4818
Fax: 886-7-536-4803
Taiwan - Taipei
Tel: 886-2-2500-6610
Fax: 886-2-2508-0102
Thailand - Bangkok
Tel: 66-2-694-1351
Fax: 66-2-694-1350
EUROPE
Austria - Wels
Tel: 43-7242-2244-39
Fax: 43-7242-2244-393
Denmark - Copenhagen
Tel: 45-4450-2828
Fax: 45-4485-2829
France - Paris
Tel: 33-1-69-53-63-20
Fax: 33-1-69-30-90-79
Germany - Munich
Tel: 49-89-627-144-0
Fax: 49-89-627-144-44
Italy - Milan
Tel: 39-0331-742611
Fax: 39-0331-466781
Netherlands - Drunen
Tel: 31-416-690399
Fax: 31-416-690340
Spain - Madrid
Tel: 34-91-708-08-90
Fax: 34-91-708-08-91
UK - Wokingham
Tel: 44-118-921-5869
Fax: 44-118-921-5820
WORLDWIDE SALES AND SERVICE
10/19/06

Products related to this Datasheet

IC REG CTRLR MULT TOPOLOGY 8MSOP
IC REG CTRLR MULT TOPOLOGY 8MSOP
IC REG CTRLR MULT TOPOLOGY 8MSOP
IC REG CTRLR MULT TOPOLOGY 8DFN
IC REG CTRLR MULT TOPOLOGY 8MSOP
BOARD DEMO MCP1630 BIAS SUPPLY
BOARD DEM MCP1630 BOOST MODE LED
IC REG CTRLR MULT TOPOLOGY 8MSOP
REFERENCE DESIGN FOR MCP1630
IC REG CTRLR MULT TOPOLOGY 8MSOP
IC REG CTRLR MULT TOPOLOGY 8DFN
IC REG CTRLR MULT TOPOLOGY 8DFN
EVAL BOARD FOR MCP1630
BOARD CONV DEMO MCP1630 TRPL-OUT
REF DESIGN MCP1630V BI-DIR 4CELL
IC REG CTRLR MULT TOPOLOGY 8DFN
IC REG CTRLR MULT TOPOLOGY 8MSOP
IC REG CTRLR MULT TOPOLOGY 8MSOP