Linear Dc101 User Manual

DEMO MANUAL DC101  
SMART BATTERY CHARGER  
LT1511 Level 2, Smart  
Battery Charger Demo Board  
with SMBus Interface  
U
DESCRIPTIO  
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.  
W U  
WW  
PERFOR A CE SU ARY  
PARAMETER  
CONDITIONS  
MIN  
TYP  
MAX  
27  
UNIT  
Input Voltage  
16  
24  
V
A
A
V
Input Current  
Hardware Limited  
Software Limited  
Software Limited  
2
Output Current  
Output Voltage  
Thermistor Resistance  
0
4
2.5  
20  
Ni-MH Battery  
Li-Ion Battery  
3
0.5  
30  
1.5  
kΩ  
kΩ  
1
W U  
BLOCK DIAGRA A D BOARD PHOTO  
DC101 Smart Battery Charger  
R10  
SYSTEM CURRENT  
+
DC OUT  
GND  
Component Side  
5V  
FROM  
WALL  
CUBE  
5V  
LT1129  
SMB  
µP  
+
LT®1511  
CHARGER  
26  
14  
15  
2
C SMBus  
CLOCK (SCL)  
PIC16C73  
SHUTDOWN  
D SMBus  
DATA (SDA)  
11  
Q1  
T THERMISTOR  
VOLTAGE PWM  
CURRENT PWM  
13  
12  
Q2  
BATTERY  
CONNECTOR  
Q3  
DC101 BD  
1
DEMO MANUAL DC101  
SMART BATTERY CHARGER  
W
PACKAGE DIAGRA  
TOP VIEW  
GND  
SW  
1
2
3
4
5
6
7
8
9
24 GND  
23 GND  
BOOST  
GND  
GND  
UV  
22  
21  
20  
V
CC1  
V
CC2  
V
CC3  
19 PROG  
18  
17 UV  
LT1511CSW  
GND  
OVP  
V
C
OUT  
CLP  
16 GND  
CLN 10  
COMP1 11  
SENSE 12  
15 COMP2  
14 BAT  
13 SPIN  
SW PACKAGE  
24-LEAD PLASTIC SO WIDE  
PARTS LIST  
REFERENCE  
DESIGNATOR  
QUANTITY PART NUMBER  
DESCRIPTION  
VENDOR  
AVX  
TELEPHONE  
(803) 946-0362  
(207) 282-5111  
(803) 946-0362  
(803) 946-0362  
(803) 946-0362  
(803) 946-0362  
(803) 946-0362  
(847) 696-2000 x374  
(803) 946-0362  
(203) 268-6261  
(800) 421-6815  
(800) 421-6815  
(602) 244-3576  
(602) 244-3576  
(717) 780-4409  
(503) 643-4899  
(818) 301-4200  
(407) 241-7876  
(602) 244-3576  
(602) 244-4342  
(803) 946-0524  
(803) 946-0524  
(803) 946-0524  
C1, C8, C17, C19  
4
2
1
2
1
1
1
4
2
1
1
1
2
2
1
1
1
1
3
1
3
1
2
12065C104KATMA  
TAJB106M010  
12063G334ZAT2  
12063G105ZATMA  
12065C473KAT  
12063C153KAT2  
12063G474ZAT2  
THCS50E1E106Z  
1206A330KAT2  
VJ1206A101KXA  
SF1-BR  
0.1µF 50V Chip Capacitor  
10µF 10V Tantalum Capacitor  
0.33µF 25V Chip Capacitor  
1µF 25V Chip Capacitor  
0.047µF 50V 10% Chip Capacitor  
0.015µF 25V 5% Chip Capacitor  
0.47µF 25V Chip Capacitor  
10µF 25V Ceramic Capacitor  
33pF 50V Chip Capacitor  
100pF 50V Chip Capacitor  
Red LED  
C2, C18  
AVX  
C3  
AVX  
C4, C5  
AVX  
C6  
AVX  
C7  
AVX  
C9  
AVX  
C10, C11, C12, C20  
Marcon  
AVX  
C14, C15  
C16  
Vitramon  
Data Display Product  
Data Display Product  
Motorola  
Motorola  
AMP  
D1  
D2  
SF1-G  
Green LED  
D3, D5  
D4, D6  
J1  
MBRS340T3  
Diode  
BAS16LT1  
Diode  
AMP-787441-1  
CUI-PJ-002A  
3801S-12-G1  
CTX20-4  
Connector  
J2  
Connector  
Cui-Stack  
Comm Con Conn.  
Coiltronics  
Motorola  
Motorola  
AVX  
JPR1  
L1  
12-Pin Header Jumper  
20µH Inductor  
Q1,Q2, Q3  
Q4  
2N7002LT  
N-Channel MOSFET  
NPN Transistor  
MMBT3904LT1  
CR32-3321F-T  
CR32-3010F-T  
CR32-1001F-T  
R1, R4, R16  
R2  
3.32k 1/8W 1% Resistor  
3011/8W 1% Resistor  
1k 1/8W 1% Resistor  
AVX  
R3, R18  
AVX  
3
DEMO MANUAL DC101  
SMART BATTERY CHARGER  
PARTS LIST  
REFERENCE  
DESIGNATOR  
QUANTITY PART NUMBER  
DESCRIPTION  
VENDOR  
AVX  
TELEPHONE  
(803) 946-0524  
(714) 447-2345  
(512) 992-7900  
(803) 946-0524  
(512) 992-7900  
(803) 946-0524  
(512) 992-7900  
(512) 992-7900  
(512) 992-7900  
(803) 946-0524  
(803) 946-0524  
(803) 946-0524  
(803) 946-0524  
(605) 665-9301  
(617) 246-1007  
(718) 956-8900  
(602) 786-7200  
(408) 432-1900  
(408) 432-1900  
(818) 301-4200  
(310) 787-6300  
R5, R6, R14  
3
1
1
1
1
1
1
1
1
1
2
3
1
2
1
12  
1
1
1
1
1
CR32-331J-T  
3301/8W 5% Resistor  
33.2k 1/8W 1% Resistor  
0.0331/2W 5% Resistor  
100k 1/8W 5% Resistor  
0.051/2W 5% Resistor  
5101/8W 5% Resistor  
100k 1/8W 0.1% Resistor  
143k 1/10W 0.1% Resistor  
21.5k 1/10W 0.1% Resistor  
1.05k 1/8W 1% Resistor  
2001/8W 1% Resistor  
22k 1/10W 5% Resistor  
221/10W 5% Resistor  
10k 1/8W 5% Resistor  
PB Switch  
R7  
BCR1/8-3322F-T  
LR2010-01-R033-J  
CR32-104J-T  
Beckman  
IRC  
R8  
R9  
AVX  
R10  
LR2010-01-R050-J  
CR32-511J-T  
IRC  
R11  
AVX  
R12  
W1206R-03-1003-B  
W1206R-03-1433-B  
W1206R-03-2152-B  
CR32-1051F-T  
CR32-2000F-T  
CR32-223J-T  
IRC  
R13  
IRC  
R15  
IRC  
R17  
AVX  
R19, R20  
AVX  
R21, R22, R25  
AVX  
R23  
CR32-220J-T  
AVX  
R24, R26  
CR1206-103J  
MJTP1230  
Dale  
S1  
MORS-ASC  
Keystone  
Microchip  
LTC  
TP1 to TP5, E1 to E7  
1502-2  
Turret Testpoint  
U1  
U2  
U3  
XU1  
Y1  
PIC16C73-20SP  
LT1511  
Microcontroller IC  
Battery Charger IC  
LT1129IST-5  
Voltage Regulator IC  
Sockets IC  
LTC  
7167-14-G2  
Comm Con  
Epson (USA)  
MA-505-4.00M-C2  
4MHz Crystal  
U
OPERATIO  
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.  
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.  
Input Current: The sum of the system current and the  
chargerinputcurrentislimitedbytheLT1511to2A. 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.  
4
DEMO MANUAL DC101  
SMART BATTERY CHARGER  
U
OPERATIO  
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 500< RTH < 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.  
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).  
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:  
“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.  
SDA  
SCLK  
0
0
0
1
0
0
2
1
R/W  
ACK  
DC101 F01  
START  
1
0 = WRITE  
1 = 1ST NIBBLE  
2 = 2ND NIBBLE (TRUNCATED)  
THIS EXAMPLE = 12(H)  
Figure 1. SMBus Waveforms Indicating Battery Address  
5
DEMO MANUAL DC101  
SMART BATTERY CHARGER  
U
OPERATIO  
INIT VARIABLES  
START  
INTERRUPT  
Y
Y
Y
Y
Y
THERMISTOR OPEN  
TURN RED LED ON  
FOR 2 SEC  
Y
Y
Y
Y
Y
Y
DISABLE INTERRUPTS  
12C DATA RECEIVED  
RESET 12C POINTER  
PUT 12C DATA ON THE  
12C STACK INCREMENT  
POINTER  
THERMISTOR TOO HOT  
A/D COUNTER = 0  
MEASURE THERMISTOR  
ENABLE INTERRUPTS  
THERMISTOR  
IN RANGE  
SET ERROR FLAG  
SHUT DOWN CHARGER  
ERASE COMMAND  
ALARM WARNING  
ON STACK  
RETURN FROM  
INTERRUPT  
THERMISTOR  
TOO COLD  
LOAD IPWM  
ERASE COMMAND  
ENABLE CHARGER  
ERASE ERROR FLAG  
CHARGING CURRENT  
ON STACK  
Li-Ion  
LOAD VPWM  
ERASE COMMAND  
ENABLE CHARGER  
ERASE ERROR FLAG  
CHARGING VOLTAGE  
ON STACK  
THERMISTOR  
SHORTED  
ERROR FLAG  
SET FAST BLINKING  
SET TRICKLE CHARGE  
SET ERROR FLAG  
SET SLOW BLINKING  
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  
Figure 2. Software Flowchart  
6
DEMO MANUAL DC101  
SMART BATTERY CHARGER  
U
W
PCB LAYOUT A D FIL  
Component Side Silkscreen  
Component Side Solder Mask  
Component Side  
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.  
7
DEMO MANUAL DC101  
SMART BATTERY CHARGER  
U
W
PCB LAYOUT A D FIL  
Solder Side Solder Mask  
Solder Side  
U
PC FAB DRAWI G  
NUMBER  
OF HOLES  
H
A
H
SYMBOL DIAMETER  
H
A
B
C
D
E
125  
120  
100  
94  
4
2
1
12  
14  
4
40  
55  
132  
G
G
A
H
E
D
0.150"  
H
G
40  
H
E
F
39  
B
B
H
G
H
37  
18  
H
3.019"  
H
TOTAL HOLES  
H
H
C
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  
H
D
D
0.150"  
0.219"  
F
E
A
A
5. FINISH: SMOBC  
6. SOLDER MASK: USE FILM PROVIDED, GREEN  
DC101 FD  
0.150"  
0.150"  
2.744"  
3.900"  
LT/GP 0796 500 • PRINTED IN USA  
Linear Technology Corporation  
1630 McCarthy Blvd., Milpitas, CA 95035-7417  
8
(408) 432-1900 FAX: (408) 434-0507 TELEX: 499-3977  
LINEAR TECHNOLOGY CORPORATION 1996  

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