ACT2804 Demo Board Application Report 5V/3.4A Dual Cell Backup Battery Power Manager
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1 ACT2804 Demo Board Application Report 5V/3.4A Dual Cell Backup Battery Power Manager FEATURES Dedicated single-chip integrated dual cell battery management 4.5V-5.5V input voltage and 3.4A input current limit 5.07V+/-1% output with prioritized power path from input to output 20V input Voltage Protection 2.4A+1.0A dual outputs with CC regulation Pass MFi test Meet EN55022 class B radiated EMI standard Output short circuit protection and nearly zero power Output over voltage protection Duel cell battery charger with cell balancing management Dual cell battery overcharge, over discharge, over charge current and over discharge current protections >91% charge efficiency at 3.4A input >92% discharge efficiency at 3.4A output Configurable charge, discharge and HZ modes Output plug-in detection to wakeup Light load detection <10uA low battery drainage current Battery operation voltage 6.0V-8.4V Battery termination voltage 8.4V for dual cell 4 LED battery level indication Preconditioning for deeply depleted battery Built-in charge and discharge safety timer 4.20V/4.35V +/- 0.5% battery charge voltage accuracy of each cell Optimized power path and battery charge control Thermal regulation for battery charge/discharge Accommodation for >10mA input source Battery over voltage protection TQFN5x5-40 Active Semi, Inc. 1
2 TABLE OF CONTENT 1 DEMO BOARD PHOTOS PCB LAYOUT SCHEMATICS BILL OF MATERIALS FUNCTIONAL TEST BATTERY CHARGE V/I PROFILE POWER PATH FUNCTION CHARGE EFFICIENCY BUCK EFFICIENCY AND POWER LOSS (TA=25 ) BUCK CONSTANT CURRENT AND CONSTANT VOLTAGE REGULATION (TA=25 ) BATTERY LEAKAGE CURRENT IN HZ MODE RIPPLE AND NOISE LOAD DYNAMIC RESPONSE LOAD STEP LED INDICATION SYSTEM MANAGEMENT KEY COMPONENTS TEMPERATURE TEST (TA=25C, BURNING FOR 2 HOURS) EMI TEST Active Semi, Inc. 2
3 1 DEMO BOARD PHOTOS (DEMO BOARD SIZE: 48mm*31mm) LED Indication Push Button Input USB Output USB BATP BATC BATN 2 PCB LAYOUT TOP Layer Bottom Layer Active Semi, Inc. 3
4 3 SCHEMATICS SDA DP PGND DM HSB HYST SW RIMC SW PT BAT LEDLS4 BAT LEDLS3 BATS LEDLS2 BATP LEDLS1 BATC LED4 Application information Charge Current Setting: 8 Ic(A) Ricst K LED Indication: MODE TRIG LED1 LED2 LED3 LED4 CHARGE DISCHARGE HIGH V LED1 +V IMC +0.6*V HYST V LED2 +V IMC +0.6*V HYST V LED3 +V IMC +0.6*V HYST V LED4 +V IMC +0.6*V HYST LOW V LED1 +V IMC -100mV V LED2 +V IMC -100mV V LED3 +V IMC -100mV V LED4 +V IMC -100mV HIGH V LED1 -V IMC +100mV V LED2 -V IMC +100mV V LED3 -V IMC +100mV V LED4 -V IMC +100mV LOW V LED1 -V IMC -0.6*V HYST V LED2 -V IMC -0.6*V HYST V LED3 -V IMC -0.6*V HYST V LED4 -V IMC -0.6*V HYST V V V (A) 5. LED X 5 108K V RLS x K (V) 2106K * IBAT( A) IMC * HYST 4: 3 R 54K K HYST R R CS IMC K Active Semi, Inc. 4
5 4 BILL OF MATERIALS Item Reference Description QTY Manufacturer 1 L1 SWPA8040S4R7NT, 4.7uH 5.9A(8*8*4mm) 1 Sunlord 2 D1 MBR1020VL, 20V/1A Schottky, SMA, Optional 1 Panjit 3 D2 MBR1020VL, 20V/1A Schottky, SMA 1 Panjit 4 C2 Ceramic capacitor, 4.7uF/10V, X7R, Murata/TDK 5 C3, C10,C11,C12 Ceramic capacitor, 10uF/10V, X7R, Murata/TDK 6 C7,C8, C21, C22 Ceramic capacitor, 22uF/16V, X7R, Murata/TDK 7 C5,C9 Ceramic capacitor, 47nF/16V, X7R, Murata/TDK 8 C6,C13 Ceramic capacitor, 0.1uF/16V, X7R, Murata/TDK 9 C14 Ceramic capacitor, 2.2nF/16V, X7R, Murata/TDK 10 C15 Ceramic capacitor, 1uF/10V, X7R, Murata/TDK 11 C16 Ceramic capacitor, 2.2uF/10V, X7R, Murata/TDK 12 C17,C18 Ceramic capacitor, 0.22uF/10V, X7R, Murata/TDK 11 C19, C26 Ceramic capacitor, 3.3uF/10V, X7R, Murata/TDK 13 C20 Ceramic capacitor, 100nF/10V, X7R, Murata/TDK 16 R1 Chip Resistor, 2.7Ω, 1/8W, 5%, Murata/TDK 17 R2,R2A,R3,R3A,R4, R4A Chip Resistor, 50mΩ, 1/2W, 1%, Sart 18 R5 Chip Resistor, 8kΩ, 1/10W, 1%, Murata/TDK 19 R6 Chip Resistor, 83kΩ, 1/10W, 1%, Murata/TDK 20 R7 Chip Resistor, 63.5kΩ, 1/10W, 1%, Murata/TDK 21 R8 Chip Resistor, 51.4kΩ, 1/10W, 1%, Murata/TDK 22 R9 Chip Resistor, 41.5kΩ, 1/10W, 1%, Murata/TDK 23 R10,R11 Chip Resistor, 540kΩ, 1/10W, 1%, Murata/TDK 24 R12 Chip Resistor, 0.47Ω, 1/8W, 1%, Murata/TDK 25 R13 Chip Resistor, 200Ω, 1/10W, 1%, Murata/TDK 26 R14,R26 Chip Resistor, 715K, 1/10W, 5%, Murata/TDK 27 R15 Chip Resistor, 12K, 1/10W, 1%, Murata/TDK 28 R16 Chip Resistor, 4.7Ω, 1/8W, 1%, Murata/TDK 29 R17 Chip Resistor, 10Ω, 1/10W, 5%, Murata/TDK 30 R18 Chip Resistor, 47Ω, 1/8W, 5%, Murata/TDK 31 R19 Chip Resistor, 0.01Ω, 1/10W, 1%, Murata/TDK 32 R20,R21,R30,R31 Chip Resistor, 510Ω, 1/10W, 5%, Murata/TDK Active Semi, Inc. 5
6 33 R22 Chip Resistor, 1K, 1/10W, 5%, Murata/TDK 34 R24 Chip Resistor, 47Ω, 1/4W, 1%, Murata/TDK 35 R27 Chip Resistor, 100Ω, 1/10W, 1%, Murata/TDK 36 R32 Chip Resistor, 10K, 1/10W, 5%, Murata/TDK 37 LED1,LED2,LED3,LED4 LED, 0603, Blue 4 LED Manu 38 Q1 SSF2318, 20V/6.5A N MOSFET, Optional 1 Silikron 39 Q2 2S Battery protection IC, S Seiko 40 Q3 20V Dual N-Channel Power MOSFET, 8205A 1 Fortune 41 PB Push button 1 42 Output USB1, Output USB2 10.2*14.6*7mm,4P 2 43 Micro-USB MICRO USB 5P/F SMT B 1 44 U1 IC, ACT2804 T-QFN 5X ACT 5 FUNCTIONAL TEST 5.1 Battery Charge V/I profile Active Semi, Inc. 6
7 5.2 Power Path Function (Test condition: Vin=5.05V, Vbat=7V, input current limit=3.4a, fast charge current=1.0a) Input current(ma) Output current(ma) Charge current(ma) Charge Efficiency (Vin=5V and charge current set at 1000mA) Battery voltage (V) Efficiency (%) Active Semi, Inc. 7
8 5.4 Buck Efficiency and Power Loss (Ta=25 ) Vbat Efficiency (%) Io=1000mA Io=1500mA Io=2000mA Io=2400mA Io=3400mA 6.0V V V Vbat Power Loss (W) Io=1000mA Io=1500mA Io=2000mA Io=2400mA Io=3400mA 6.0V V V Active Semi, Inc. 8
9 5.5 Buck Constant Current and Constant Voltage Regulation (Ta=25 ) CC Load CV Load Buck V/I Profile (Output1) Vbat=6.0V Vbat=7.0V Vbat=8.0V Vout(V) Iout(mA) Vout (V) Iout(mA) Vout(V) Iout(mA) Active Semi, Inc. 9
10 CC Load CV Load Buck V/I Profile (Output2) Vbat=6.0V Vbat=7.0V Vbat=8.0V Vout(V) Iout(mA) Vout (V) Iout(mA) Vout(V) Iout(mA) Active Semi, Inc. 10
11 5.6 Battery Leakage Current in HZ Mode Test Conditions Battery Input Current Power Loss (µa) (µw) Vbat=6V Vbat=7V Vbat=8V Vbat=8.4V Ripple and Noise Ripple & noise are measured by using 20MHz bandwidth limited oscilloscope. Test Conditions Output Ripple at 2.4A Load (mv) Output Ripple at 3.4A Load (mv) Vbat=6.0V Vbat=7.0V Vbat=8.4V Load Dynamic Response Load Step (Output2=80mA-1A-80mA load step Ouput1=0A) Vbat=8V Vbat=6.6V (Output2=1A-2.4A-1A load step Ouput1=0A) Vbat=8V Vbat=6.6V Active Semi, Inc. 11
12 (Output2=80mA-1A-80mA load step Ouput1=1A) Vbat=8V Vbat=6.6V (Output2=1A-2.4A-1A load step Ouput1=1A Vbat=8V Vbat=6.6V 5.9 LED Indication Conventional LED indication PB time>40ms (HZ Mode) LED1 LED2 LED3 LED4 VBAT<Vcut-off Off Off Off Off Vcut-off VBAT<VLED1 Flash Off Off Off VLED1 VBAT< VLED2 On Off Off Off VLED2 VBAT< VLED3 On On Off Off VLED3 VBAT< VLED4 On On On Off VBAT VLED4 On On On On Charge Mode LED1 LED2 LED3 LED4 VBAT<VLED2 Flash Off Off Off VLED2 VBAT< VLED3 On Flash Off Off VLED3 VBAT< VLED4 On On Flash Off VLED4 VBAT Charge Mode On On On Flash VLED4 VBAT EOC Mode On On On On Active Semi, Inc. 12
13 ACT2804 is designed with a simple ADC to convert 5 levels of PT pin voltage into 5 application patterns. INDICATION PATTERN Conventional Always On In Discharge Conventional 5s Indication in Discharge Breathing 5s Indication in Discharge Bottom Charging 5s Indication in Discharge Circulating 5s Indication in Discharge PT Resistor R15=3.3K R15=12K R15=24K R15=42K R15=68K 5.10 System Management PB is pressed for >5s or Discharge load is <10mA for 12.5s, Discharge mode is go into HZ mode PB is pressed for 40ms, Discharge mode is turned on PB is pressed for 40ms, LED indication is on for 5.0 seconds 2 seconds transition time between Charge Mode and Boost Mode Active Semi, Inc. 13
14 5.11 Key Components Temperature Test (Ta=25C, burning for 2 hours) Charge mode, 1.0A charge current Vin(V) IC( ) Inductor( ) Vbat(V) Discharge mode, 3.4A output current Vbat(V) IC( ) Inductor( ) Vout(V) Active Semi, Inc. 14
15 6 EMI TEST Vbat=7.8V, Output: 5.07V/3.4A Horizontal Active Semi, Inc. 15
16 Vbat=7.8V, Output: 5.07V/3.4A Vertical Active Semi, Inc. 16
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