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DEMO MANUAL DC101
SMART BATTERY CHARGER
LT1511 Level 2, Smart
Battery Charger Demo Board
with SMBus Interface
DESCRIPTIO
U
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
Input Voltage
MIN
TYP
MAX
16
24
27
UNIT
V
Input Current
Hardware Limited
2
A
Output Current
Software Limited
0
2.5
A
Output Voltage
Software Limited
4
20
V
Thermistor Resistance
Ni-MH Battery
Li-Ion Battery
30
1.5
kΩ
kΩ
3
0.5
1
W U
BLOCK DIAGRA A D BOARD PHOTO
DC101 Smart Battery Charger
R10
+
FROM
WALL
CUBE
SYSTEM CURRENT
DC OUT
5V
LT1129
5V
µP
SMB
–
26
SHUTDOWN
14
PIC16C73
15
11
Q1
2
VOLTAGE PWM
CURRENT PWM
Q3
GND
+
LT ®1511
CHARGER
Q2
Component Side
13
C SMBus
CLOCK (SCL)
D SMBus
DATA (SDA)
T THERMISTOR
–
BATTERY
CONNECTOR
12
DC101 BD
1
2
24V
2A
L1
20µH
(+)
(+)
CLK
CLK
DATA
DATA
(T)
(T)
(–)
(–)
VOUT
4
5V
+
3
C2
10µF
10V
1
2
3
4
5
6
7
8
9
10
C20
10µF
25V
C18
10µF
10V
9
8
7
6
5
4
3
2
1
C16
100pF
50V
12
11
GND
CLP
13
14
R12
100k
1/10W
0.1%
R13
143k
1/10W
0.1%
SPIN
BAT
15
16
17
18
19
20
21
22
23
24
C11
10µF
25V
R2
301Ω
1/10W
1%
R15
21.5k
1/10W
0.1%
C4
1µF
25V
Q3
2N7002LT1
R1
3.32k
1/10W
1%
R9
100k
5V
Q2
2N7002LT1
C15
33pF
C14
33pF
R7
3.32k
1%
R18
1k
1/10W
1%
SHUTDOWN
Y1
4MHz
R4
3.32k
1%
BOLD LINES INDICATE HIGH CURRENT PATHS
Q1
2N7002LT1
R24
10k
5%
Q4
MMBT3904LT1
R3
1k
1/10W
1%
C3
33µF
25V
UNLESS OTHERWISE SPECIFIED:
1. ALL RESISTANCES ARE IN OHMS, 1/10W, 5%
2. ALL CAPACITANCES ARE IN MICROFARADS, 50V, 10%
C6
0.047µF
C7
0.015µF
25V
5%
R19
200Ω
1/10W
1%
SENSE
COMP1
COMP2
UVOUT
OVP
CLN
VC
PROG
UV
GND
VCC3
GND
VCC2
GND
GND
GND
VCC1
U2
LT1511
C10
10µF
25V
R17
1.05k
1/10W
1%
BOOST
SW
GND
C8
0.1µF
10
R14
330Ω
TP1 TP2 TP3 TP4 TP5
+
R23
22Ω
5V
R20
200Ω
1/10W
1%
R8
D4
0.033Ω BAS16LT1
1/2W
R11
510Ω
C5
1µF
25V
D5
MBRS340T3
D3
MBRS340T3
R16
D6
BAS16LT1 3.32k R10
1/10W 0.05Ω
1% 1/2W
2
GND TAB
VIN
C9
0.47µF
25V
C9
0.1µF
DC IN
SMART BATTERY
CONNECTOR
J1
AMP-787441-1
C12
10µF
25V
E2
E1
J2
CENTER POST
IS POSITIVE
C17
0.1µF
1
U3
LT1129IST-5
Smart Battery Charger with SMBus Interface
MCLR –
SDA
RC5
RC6
RC7
VSS
VDD
RB0/INT
RB1
RB2
RB3
RB4
RB5
RB6
RB7
U1
PIC16C73-20PS
SCL
CCP1
CCP2
RCO
OSC2
OSC1
VSS
RA5/AN4
RA4
RA3/AN3
RA2/AN2
RA1/AN1
RA0/AN0
S1
5V
R21
22k
5%
5V
R22
22k
5%
5V
15
16
17
18
19
20
21
22
23
24
25
26
27
28
R25
22k
5%
CHARGER
ADJUSTMENT RANGE
PWM1: 3FFh = 22.4V
000h = 6V
PWM2:3FFh = 4.1A
000h = 0A
14
13
12
11
10
9
8
7
6
5
4
3
2
1
R26
10k
RESET
5V
INT
SMBCLK
SMBDATA
R5
330Ω
E7
E5
E6
D1
RED
(SMB)
5V
RESET
DC101 SD
1
2
3
4
5
6
7
8
9
10
11
12
JPR1
C1
0.1µF
D2
GRN
(µP)
E3
E4
R6
330Ω
DC OUT
DEMO MANUAL DC101
SMART BATTERY CHARGER
W
W
SCHE ATIC DIAGRA
DEMO MANUAL DC101
SMART BATTERY CHARGER
W
PACKAGE DIAGRA
TOP VIEW
GND 1
24 GND
SW 2
23 GND
BOOST 3
22 VCC1
GND 4
21 VCC2
GND 5
20 VCC3
UV 6
19 PROG
GND 7
18 VC
OVP 8
17 UVOUT
CLP 9
16 GND
CLN 10
15 COMP2
COMP1 11
14 BAT
SENSE 12
13 SPIN
LT1511CSW
SW PACKAGE
24-LEAD PLASTIC SO WIDE
PARTS LIST
REFERENCE
DESIGNATOR
QUANTITY
PART NUMBER
DESCRIPTION
VENDOR
TELEPHONE
C1, C8, C17, C19
4
12065C104KATMA
0.1µF 50V Chip Capacitor
AVX
(803) 946-0362
C2, C18
2
TAJB106M010
10µF 10V Tantalum Capacitor
AVX
(207) 282-5111
C3
1
12063G334ZAT2
0.33µF 25V Chip Capacitor
AVX
(803) 946-0362
C4, C5
2
12063G105ZATMA
1µF 25V Chip Capacitor
AVX
(803) 946-0362
C6
1
12065C473KAT
0.047µF 50V 10% Chip Capacitor
AVX
(803) 946-0362
C7
1
12063C153KAT2
0.015µF 25V 5% Chip Capacitor
AVX
(803) 946-0362
C9
1
12063G474ZAT2
0.47µF 25V Chip Capacitor
AVX
C10, C11, C12, C20
4
THCS50E1E106Z
10µF 25V Ceramic Capacitor
Marcon
C14, C15
2
1206A330KAT2
33pF 50V Chip Capacitor
AVX
(803) 946-0362
C16
1
VJ1206A101KXA
100pF 50V Chip Capacitor
Vitramon
(203) 268-6261
D1
1
SF1-BR
Red LED
Data Display Product
(800) 421-6815
D2
1
SF1-G
Green LED
Data Display Product
(800) 421-6815
D3, D5
2
MBRS340T3
Diode
Motorola
(602) 244-3576
D4, D6
2
BAS16LT1
Diode
Motorola
(602) 244-3576
J1
1
AMP-787441-1
Connector
AMP
(717) 780-4409
(803) 946-0362
(847) 696-2000 x374
J2
1
CUI-PJ-002A
Connector
Cui-Stack
(503) 643-4899
JPR1
1
3801S-12-G1
12-Pin Header Jumper
Comm Con Conn.
(818) 301-4200
L1
1
CTX20-4
20µH Inductor
Coiltronics
(407) 241-7876
Q1,Q2, Q3
3
2N7002LT
N-Channel MOSFET
Motorola
(602) 244-3576
Q4
1
MMBT3904LT1
NPN Transistor
Motorola
(602) 244-4342
R1, R4, R16
3
CR32-3321F-T
3.32k 1/8W 1% Resistor
AVX
(803) 946-0524
R2
1
CR32-3010F-T
301Ω 1/8W 1% Resistor
AVX
(803) 946-0524
R3, R18
2
CR32-1001F-T
1k 1/8W 1% Resistor
AVX
(803) 946-0524
3
DEMO MANUAL DC101
SMART BATTERY CHARGER
PARTS LIST
REFERENCE
DESIGNATOR
QUANTITY
PART NUMBER
DESCRIPTION
VENDOR
330Ω 1/8W 5% Resistor
AVX
TELEPHONE
R5, R6, R14
3
CR32-331J-T
(803) 946-0524
R7
1
BCR1/8-3322F-T
33.2k 1/8W 1% Resistor
Beckman
(714) 447-2345
R8
1
LR2010-01-R033-J
0.033Ω 1/2W 5% Resistor
IRC
(512) 992-7900
R9
1
CR32-104J-T
100k 1/8W 5% Resistor
AVX
(803) 946-0524
R10
1
LR2010-01-R050-J
0.05Ω 1/2W 5% Resistor
IRC
(512) 992-7900
R11
1
CR32-511J-T
510Ω 1/8W 5% Resistor
AVX
(803) 946-0524
R12
1
W1206R-03-1003-B
100k 1/8W 0.1% Resistor
IRC
(512) 992-7900
R13
1
W1206R-03-1433-B
143k 1/10W 0.1% Resistor
IRC
(512) 992-7900
R15
1
W1206R-03-2152-B
21.5k 1/10W 0.1% Resistor
IRC
(512) 992-7900
R17
1
CR32-1051F-T
1.05k 1/8W 1% Resistor
AVX
(803) 946-0524
R19, R20
2
CR32-2000F-T
200Ω 1/8W 1% Resistor
AVX
(803) 946-0524
R21, R22, R25
3
CR32-223J-T
22k 1/10W 5% Resistor
AVX
(803) 946-0524
R23
1
CR32-220J-T
22Ω 1/10W 5% Resistor
AVX
(803) 946-0524
R24, R26
2
CR1206-103J
10k 1/8W 5% Resistor
Dale
(605) 665-9301
S1
1
MJTP1230
PB Switch
MORS-ASC
(617) 246-1007
TP1 to TP5, E1 to E7
12
1502-2
Turret Testpoint
Keystone
(718) 956-8900
U1
1
PIC16C73-20SP
Microcontroller IC
Microchip
(602) 786-7200
U2
1
LT1511
Battery Charger IC
LTC
(408) 432-1900
U3
1
LT1129IST-5
Voltage Regulator IC
LTC
(408) 432-1900
XU1
1
7167-14-G2
Sockets IC
Comm Con
(818) 301-4200
Y1
1
MA-505-4.00M-C2
4MHz Crystal
Epson (USA)
(310) 787-6300
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.
Input Current: The sum of the system current and the
charger input current is limited by the LT1511 to 2A. 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
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 microprocessor activity and charger status. Fast blinking (approximately 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.
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
normal operating temperature range, the charger switches
to trickle charge mode and increases the flashing frequency of the green LED to indicate an abnormal charging condition. When the resistance of the thermistor is in
the 500Ω < RTH < 1.5k range, the charger assumes a LiIon 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 thermistor forces the charger into trickle charge mode and
the charger disregards data on the SMBus.
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, the battery addresses the Smart Battery charger
and waits for an acknowledgment (ACK) from it. If the
charger fails to acknowledge the word, the battery terminates 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:
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 illustrate 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 generated by the battery (BUS MASTER).
“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
START
1
2
1
R/W
ACK
DC101 F01
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
THERMISTOR OPEN
12C DATA RECEIVED
Y
DISABLE INTERRUPTS
THERMISTOR TOO HOT
A/D COUNTER = 0
Y
Y
TURN RED LED ON
FOR 2 SEC
RESET 12C POINTER
Y
PUT 12C DATA ON THE
12C STACK INCREMENT
POINTER
MEASURE THERMISTOR
ENABLE INTERRUPTS
ALARM WARNING
ON STACK
CHARGING CURRENT
ON STACK
Y
Y
SET ERROR FLAG
SHUT DOWN CHARGER
ERASE COMMAND
LOAD IPWM
ERASE COMMAND
ENABLE CHARGER
ERASE ERROR FLAG
THERMISTOR
IN RANGE
Y
RETURN FROM
INTERRUPT
THERMISTOR
TOO COLD
Y
Y
Li-Ion
CHARGING VOLTAGE
ON STACK
Y
LOAD VPWM
ERASE COMMAND
ENABLE CHARGER
ERASE ERROR FLAG
THERMISTOR
SHORTED
ERROR FLAG
Y
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
Component Side Solder Mask
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 representation 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
H
A
H
0.150"
H
D
G
E
H
G
A
H
B
G
H
E
B
H
H
3.019"
H
H
C
H
H
D
D
0.150"
0.219"
A
F
E
A
0.150"
0.150"
SYMBOL
A
B
C
D
E
F
G
H
NUMBER
DIAMETER
OF HOLES
125
4
120
2
100
1
94
12
40
14
39
4
37
40
18
55
TOTAL HOLES
132
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
5. FINISH: SMOBC
6. SOLDER MASK: USE FILM PROVIDED, GREEN
DC101 FD
2.744"
3.900"
8
Linear Technology Corporation
LT/GP 0796 500 • PRINTED IN USA
1630 McCarthy Blvd., Milpitas, CA 95035-7417
(408) 432-1900 ● FAX: (408) 434-0507 ● TELEX: 499-3977
 LINEAR TECHNOLOGY CORPORATION 1996