MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide © 2006 Microchip Technology Inc.
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MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN USER’S GUIDE Table of Contents Preface ........................................................................................................................... 1 Introduction............................................................................................................ 1 Document Layout .................................................................................................. 1 Conventions Used in this Guide ..............
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide NOTES: DS51641A-page iv © 2006 Microchip Technology Inc.
MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN USER’S GUIDE Preface 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.
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide CONVENTIONS USED IN THIS GUIDE This manual uses the following documentation conventions: DOCUMENTATION CONVENTIONS Description Arial font: Italic characters Represents Examples Referenced books Emphasized text A window A dialog A menu selection A field name in a window or dialog A menu path MPLAB® IDE User’s Guide ...is the only compiler...
Preface 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.
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide NOTES: DS51641A-page 4 © 2006 Microchip Technology Inc.
MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN USER’S GUIDE 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.
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide 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).
MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN USER’S GUIDE 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 microcontroller, the MCP1630V will control the power system duty cycle to provide regulated output voltage or current.
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide 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.
Installation and Operation 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).
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide J1-1 +VBATT 3,300 µF 10Ω + VSIM - +12V to +17.5V J1-2 -VBATT 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™).
MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN USER’S GUIDE Appendix A. Schematics and Board Layouts A.
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide SCHEMATIC - SHEET 1 2 A.2 DS51641A-page 12 © 2006 Microchip Technology Inc.
Schematics and Board Layouts A.3 SCHEMATIC - SHEET 2 © 2006 Microchip Technology Inc.
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide A.4 BOARD – TOP SILK LAYER BOARD DS51641A-page 14 © 2006 Microchip Technology Inc.
Schematics and Board Layouts A.5 BOARD – TOP METAL LAYER © 2006 Microchip Technology Inc.
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide A.6 BOARD – MID LAYER1 DS51641A-page 16 © 2006 Microchip Technology Inc.
Schematics and Board Layouts A.7 BOARD – MID LAYER2 MIDLAYER2 © 2006 Microchip Technology Inc.
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide A.8 BOARD – METAL LAYER DS51641A-page 18 © 2006 Microchip Technology Inc.
Schematics and Board Layouts A.9 BOARD – BOTTOM SILK LAYER © 2006 Microchip Technology Inc.
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide NOTES: DS51641A-page 20 © 2006 Microchip Technology Inc.
MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN USER’S GUIDE Appendix B. Bill Of Materials (BOM) TABLE B-1: BILL OF MATERIALS (BOM) Reference Designator QTY 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.
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide TABLE B-1: Reference Designator QTY 1 BILL OF MATERIALS (BOM) (CONTINUED) Q4 Description MOSFET P-CH 30V 610MA SOT-23 Manufacturer Part Number 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 2 R3, R33 RES 9.
MCP1630V BIDIRECTIONAL 4 CELL LI-ION CHARGER REFERENCE DESIGN USER’S GUIDE 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. Charge States START Idle = 0 mA P.C. = Pre-Charge C.C. = Constant Current C.V. = Constant Voltage Initialize Ports, ADC, PWM, etc. A Read ADC Inputs VBATT and VBULK Yes Yes Is Charge State @ Idle? VBATT>12.
MCP1630V Bidirectional 4 Cell Li-Ion Charger Reference Design User’s Guide 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 C Yes Set Charge to Idle IBATT < 100 mA No B Yes Is SW1 Pressed? No Yes Is VBATT<12.8V VBULK<6.5V No Shutdown A End FIGURE C-2: DS51641A-page 24 Firmware Flowchart, page 2. © 2006 Microchip Technology Inc.
Firmware NOTES: © 2006 Microchip Technology Inc.
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