MCP1630 Low-Cost NiMH Battery Charger Reference Design © 2007 Microchip Technology Inc.
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MCP1630 LOW-COST NIMH BATTERY CHARGER REFERENCE DESIGN Table of Contents Preface ........................................................................................................................... 1 Introduction............................................................................................................ 1 Document Layout .................................................................................................. 1 Conventions Used in this Guide .................................
MCP1630 Low-Cost NiMH Battery Charger Reference Design NOTES: DS51648A-page iv © 2007 Microchip Technology Inc.
MCP1630 LOW-COST NIMH BATTERY CHARGER REFERENCE DESIGN 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.
MCP1630 Low-Cost NiMH Battery Charger Reference Design CONVENTIONS USED IN THIS GUIDE This manual uses the following documentation conventions: DOCUMENTATION CONVENTIONS Description Arial font: Italic characters Represents 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 RECOMMENDED READING This user's guide describes how to use MCP1630 Low-Cost NiMH Battery Charger Reference Design. Other useful documents are listed below. 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.
MCP1630 Low-Cost NiMH Battery Charger Reference Design DOCUMENT REVISION HISTORY Revision A (February 2007) • Initial Release of this Document. DS51648A-page 4 © 2007 Microchip Technology Inc.
MCP1630 LOW-COST NIMH BATTERY CHARGER REFERENCE DESIGN Chapter 1. Product Overview 1.1 INTRODUCTION The MCP1630 Low-Cost NiMH Battery Charger Reference Design is used to charge three series cell NiMH or NiCd batteries. The board uses the MCP1630 high-speed analog PWM and PIC12F683 to generate the charge algorithm for NiMH or NiCd batteries. The MCP1630 Low-Cost NiMH Battery Charger Reference Design is used to evaluate Microchip’s MCP1630 in a SEPIC power converter application.
MCP1630 Low-Cost NiMH Battery Charger Reference Design 1.2 WHAT IS THE MCP1630 LOW COST NIMH BATTERY CHARGER REFERENCE DESIGN? The MCP1630 Low-Cost NiMH Battery Charger Reference Design is a complete stand-alone constant current battery charger for a three series cell NiMH or NiCd battery pack. Different battery chemistries (i.e. Li-Ion batteries connected in series) can be charged with minor modifications to the firmware or with the MCP1630 Low-Cost NiMH Battery Charger Reference Design.
MCP1630 LOW-COST NIMH BATTERY CHARGER REFERENCE DESIGN Chapter 2. Installation and Operation 2.1 INTRODUCTION The MCP1630 Low-Cost NiMH Battery Charger Reference Design demonstrates Microchip’s high-speed Pulse Width Modulator (PWM) (the MCP1630) used in a battery charger application. When used in conjunction with a microcontroller, the MCP1630 will control the power system duty cycle to provide output voltage or current regulation.
MCP1630 Low-Cost NiMH Battery Charger Reference Design 2.3 GETTING STARTED 60 5.0 50 4.0 40 3.0 30 2.0 20 1.0 10 0.0 0 Temperature (C) 6.0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 Battery Voltage (V) Charge Current (A) The MCP1630 Low-Cost NiMH Battery Charger is fully assembled and tested for charging three series cell NiMH batteries.
Installation and Operation J1 C1 C2 L1 C3 D1 Input + Input - C4 J2 Battery Header Q1 R3 R1 C5 R5 C9 R1 1 R1 2 R1 3 C1 0 R1 6 R2 R7 R6 C6 J3 C8 R1 5 U2 U4 R4 R8 C7 R9 R1 0 R1 4 U3 Programming Header R1 7 D2 R2 1 FIGURE 2-2: 2.3.1.2 R1 8 R1 9 C1 2 C1 3 C1 4 Setup Configuration Diagram. APPLYING A LOAD TO THE MCP1630 LOW-COST NIMH BATTERY CHARGER REFERENCE DESIGN 1.
MCP1630 Low-Cost NiMH Battery Charger Reference Design VBAT+ + 1,000 µF 10V AL Variable Power Supply - 0V - 6V 2Ω 10W VBAT- FIGURE 2-3: 2.3.1.3 Simulated Battery Load. STATUS LED 1. The MCP1630 Low-Cost NiMH Battery Charger has an LED to indicate charge status or fault status. Table 2-1 represents the state of the LED during various states of the charge cycle.
MCP1630 LOW-COST NIMH BATTERY CHARGER REFERENCE DESIGN Appendix A. Schematic and Layouts A.1 INTRODUCTION This appendix contains the following schematics and layouts for the MCP1630 Low-Cost NiMH Battery Charger Reference Design: • • • • • Board Schematic Board – Top Silk Layer Board – Top Metal Layer Board – Bottom Silk Layer Board – Bottom Metal Layer © 2007 Microchip Technology Inc.
MCP1630 Low-Cost NiMH Battery Charger Reference Design A 3 2 6 A K 5 A 1 BOARD – SCHEMATIC 7 A.2 1 2 3 4 5 6 7 8 K A DS51648A-page 12 © 2007 Microchip Technology Inc.
Schematic and Layouts A.3 BOARD – TOP SILK LAYER J1 C1 C2 L1 C3 D1 C4 J2 Q1 R3 R1 C5 R5 C9 R11 R12 R13 C10 R16 R2 R7 R6 C6 R15 U2 U4 R4 R8 C7 R9 R10 C8 J3 R14 U3 R17 D2 R21 © 2007 Microchip Technology Inc.
MCP1630 Low-Cost NiMH Battery Charger Reference Design A.4 BOARD – TOP METAL LAYER DS51648A-page 14 © 2007 Microchip Technology Inc.
Schematic and Layouts A.5 BOARD – BOTTOM METAL LAYER © 2007 Microchip Technology Inc.
MCP1630 Low-Cost NiMH Battery Charger Reference Design NOTES: DS51648A-page 16 © 2007 Microchip Technology Inc.
MCP1630 LOW-COST NIMH BATTERY CHARGER REFERENCE DESIGN Appendix B. Bill Of Materials (BOM) TABLE B-1: Qty BILL OF MATERIALS (BOM) Reference Description Manufacturer Panasonic® Part Number 3 C1, C2, C4 10uF, X5R Ceramic, 25V, 1206 1 C3 1uF, X7R Ceramic, 25V, 1206 Panasonic-ECG ECJ-3YB1E105K 5 C5, C10, C12, C13 0.
MCP1630 Low-Cost NiMH Battery Charger Reference Design NOTES: DS51648A-page 18 © 2007 Microchip Technology Inc.
MCP1630 LOW-COST NIMH BATTERY CHARGER REFERENCE DESIGN Appendix C. Demo Board Firmware C.1 DEVICE FIRMWARE FLOWCHART - PAGE 1 For the latest copy of the MCP1630 Low-Cost NiMH Battery Charger Reference Design firmware, visit our website at www.microchip.com. START Initialize Ports, ADC, PWM, etc. No Is BATT present? Yes Pre-Charge Turn On LED ICHARGE = 170 ma No No No Is BATT present? Yes Timer Expired Yes Charge Fault Terminate Charge Flash LED Is BATT present? Yes No No Is BATT > 3V Temp.
Demo Board Firmware C.2 DEVICE FIRMWARE FLOWCHART - PAGE 2 For the latest copy of the MCP1630 Low-Cost NiMH Battery Charger Reference Design firmware, visit our website at www.microchip.com. A Top Off Charge ICHARGE = 130 mA B No No Is BATT present? Yes Timer Expired? No Temp. out of Range? Yes Temp. Fault Suspend Charge Flash LED Yes Charge Complete Turn LED OFF FIGURE C-2: © 2007 Microchip Technology Inc. No Temp. out of Range? Yes Firmware Flowchart, page 2.
Demo Board Firmware NOTES: © 2007 Microchip Technology Inc.
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