DEMO MANUAL DC2642A LTC4041 2.5A Supercapacitor Backup Power Manager DESCRIPTION Demonstration circuit 2642A shows the LTC4041 supercapacitor backup power manager operating with either a stack of two series supercapacitors (DC2642A-A) or a single supercapacitor (DC2642A-B). The board demonstrates the design of a 5V rail with a short-term power backup using 10F supercapacitors. through changing resistor values on the board. Test points for all monitoring pins and LED indicators on status pins are also available to assist in the evaluation. Design files for this circuit board are available at http://www.analog.com/DC2642A All registered trademarks and trademarks are the property of their respective owners. The input current limit, charge current limit, charge voltage, power fail threshold, and boost voltage are all configurable PERFORMANCE SUMMARY Specifications are at TA = 25C SYMBOL PARAMETER CONDITIONS MIN DCIN Input Voltage Range VPF = 4.7V 4.7 DCINOV DCIN Overvoltage Limit VBOOST Backup Boost Voltage R5 = 1.05M, R2 = 200k 5 VSYS System Voltage VIN > VPF (with Hysteresis) VIN < VPF (with Hysteresis) VIN VBOOST V VPF Power Fail Threshold Voltage R1 = 113k, R2 = 383k 4.7 V IIN Input Current Limit RS1 = 10m 2.5 A ISCAP Charge Current Limit RPROG = 1k 2 TYP MAX UNITS 5.5 V 42 V 5.5 V 2.5 A TYPICAL APPLICATION 4.7V TO 5.5V DCIN (PROTECTED TO 42V) MN1 10m 4.7V TO 5.5V 2.2F 6.2k 113k MN2 VIN OVSNS PFI 38.3k PFO SYSGD CAPGD IMON CAPFLT 1.05M CLN IGATE LTC4041 SW SCAP BAL 100F 200k 2.2H 10F 10F CHGEN BSTEN GND CAPSEL CPF L1: COILCRAFT XAL-5030-222 MN1: VISHAY/SILICONIX SiS488DN MN2: VISHAY/SILICONIX SiS488DN VSYS BSTFB RSTFB TO BACKED-UP SYSTEM OUTPUT VSYS CAPFB PROG 1nF 1.5M 342k 1k dc2642a F01 UG-1320 Rev 0 1 DEMO MANUAL DC2642A QUICK START PROCEDURE Refer to Figure 1 for the proper measurement equipment setup and jumper settings. Please follow the procedure below to familiarize yourself with the DC2642A. 4. Enable LD1, then disable PS1 and observe that the voltage on VM1 remains regulated at 5V. The voltage on VM2 will begin to fall. 1. Connect test equipment as shown in Figure 1. Ensure JP1 and JP2 are both in the ON position. 5. Observe that the PFO and CAPGD LEDs turn on to indicate that the DCIN voltage has fallen below the 4.7V power fail threshold and the supercapacitor voltage has fallen out of regulation. 2. Enable PS1 and observe as the voltage on VM2 begins to rise. The voltage on VM1 should be approximately 5V. The CAPGD LED will turn on to indicate that the supercapacitor voltage is not yet in regulation. 3. Observe that the voltage on VM2 regulates at a default 4.5V on DC2642A-A or 2.4V on DC2642A-B. At this point, the CAPGD LED will turn off. 6. Eventually, the supercapacitor voltage will fall enough that the VM1 voltage will fall out of regulation. As VM1 falls past ~4.625V, the SYSGD LED will turn on briefly before VM1 falls out of regulation. Figure 1. Quick Start Procedure Setup for DC2642A UG-1320 Rev 0 2 DEMO MANUAL DC2642A DEMO BOARD OPERATION DCIN Voltage Drops Because the LTC4041's power fail function monitors the input voltage to determine its operation mode, it is important to use low-impedance connections to the demo board. Poor quality or lengthy wiring to DCIN can result in a substantial voltage drop across the wires as the DC2642A passes power to the load or charges the supercapacitor(s), leading to undesired triggering of the power fail threshold, 4.7V default. Short, high-conductivity wires with a good connection are desirable and will mitigate this issue. As a workaround, the power fail threshold can be lowered or a higher voltage can be output from the power source to account for these drops, but this should not exceed the 5.5V rating of the DC2642A. Number of Supercapacitors Table 1. Configuring Supercapacitor Count Supercapacitor Configuration Dual (Series) Single Populated Footprint(s) Populated CAPSEL Resistor SCAP1 & SCAP2 R19 SCAP3 R20 Evaluating Power Consumption When evaluating the power consumption of the LTC4041 using the demo board, it is recommended that SW1 is placed in the EXTVDD position to disable the LEDs or power them externally. Discharging Supercapacitors Throughout the course of evaluation, it may become necessary to discharge the supercapacitors. If possible, it is recommended that an electronic load is used to discharge slowly and safely. The LTC4041 can support either one or two supercapacitors. For safety reasons, DC2642A is broken into two variants: DC2642A-A has two supercapacitors and balancing enabled, while DC2642A-B has one supercapacitor and has no need for balancing. Directly shorting the supercapacitors will not damage them, but can result in sparks and damage to the conductor causing the short. The LTC4041 uses the CAPSEL pin to determine whether one or two supercapacitors are present and whether balancing should be enabled. The charger also features supercapacitor over-voltage protection, and the voltage limits are based on the number of supercapacitors present as indicated by CAPSEL. The onboard supercapacitors can be moved into singlesupercapacitor or dual-supercapacitor (series) configuration, or can be replaced with a user's own supercapacitor models. It is recommended that supercapacitors are discharged sufficiently before being removed. As a result, it is imperative that CAPSEL is configured to correctly reflect the number of series supercapacitors in the system. Resistor jumpers (R19 & R20) on the back of the DC2642A allow the CAPSEL state to be configured according to Table 1. Removing Supercapacitors CHGEN and BSTEN Diodes: D4 D4 is used to diode-OR the voltages on VSYS and SCAP to create a logic-high voltage for the CHGEN and BSTEN pins that will be available in situations where VSYS is not present. This is necessary to disable the boost function (BSTEN tied high), and it is also necessary to enter shutdown mode (CHGEN and BSTEN tied high). In applications where CHGEN and BSTEN are always tied to ground, the diode-OR is not needed. UG-1320 Rev 0 3 DEMO MANUAL DC2642A DEMO BOARD OPERATION Optional Components: R7 & R8 By default, the RSTFB input is fed the same voltage as the BSTFB input. The 0.74V threshold of the RSTFB pin is 92.5% of the 0.8V BSTFB servo voltage. As a result, tying both pins to the same voltage divider causes the SYSGD pin to pull low when the VSYS voltage drops below 92.5% of the programmed backup boost voltage. If a different threshold is desired, R4 can be removed to detach the dividers from each other, and R7 & R8 can be installed with values to set a custom SYSGD indication threshold. Backup Time The amount of time that the supercapacitor can back up the system is influenced by many factors. The most prevalent are the supercapacitor voltage, the system boost voltage, and the system load current. However, other factors such as supercapacitor leakage and ESR can also play a significant role under some circumstances. An equation for estimating backup time is given in the LTC4041 data sheet, but it is still necessary to test operation with given values and components. The backup time decreases as the load current increases, as expected. However, the decline in backup time is accelerated due to several of the aforementioned factors. When using a single supercapacitor, the lower voltage limit of the supercapacitor and the fixed boost converter switch current of the LTC4041 will result in a shorter backup time when compared to two supercapacitors stacked in series. Switch Current Limit At higher load currents with lower supercapacitor voltages, the LTC4041 will need to limit the supercapacitor's discharge current as to not exceed the current limit of its internal boost switch. This protects the IC, but VSYS will begin to collapse when the switch current limit is reached due to power-limiting. Equivalent Series Resistance (ESR) All supercapacitors have ESR which dissipates power and causes a voltage drop when they are being discharged. At lower supercapacitor voltages, the switch limit will be reached sooner, causing a faster collapse of VSYS. For this reason, it is beneficial to select supercapacitors with low ESR. The 10F supercapacitors used on the DC2642A have a typical ESR of 20m. Figure 2. Measured Backup Time for Single/Dual 10F Supercapacitors (Boost to 5V) UG-1320 Rev 0 4 DEMO MANUAL DC2642A DEMO BOARD OPERATION In Figure 3, it can be observed that the dropout voltage for dual supercapacitors (in series) is greater than the dropout voltage for a single supercapacitor. This is because the ESR is greater for series-connected capacitors. Figure 3 shows the voltage of the supercapacitor(s) at different VSYS loads after VSYS has dropped out, charging has terminated, and the supercapacitor voltage has relaxed. Charging terminates at the same voltage for both supercapacitors as seen by the LTC4041; however, the voltage drop across the ESR causes the supercapacitor voltages to appear lower when being discharged. As the current draw from the supercapacitors stops, the voltage across the ESR approaches 0V, and the supercapacitors relax to a voltage unaffected by ESR. A higher voltage after the supercapacitor relaxes indicates that more energy was unused when discharging. Figure 4 shows the measured losses due to ESR for a single 10F supercapacitor configuration. The total ESR losses are a combination of the resistive loss from the ESR and the energy unused as a result of early termination due to the ESR. The amount of energy loss is particularly high for the single-supercapacitor case at higher load currents. This is due to the low starting voltage which gives little headroom to avoid the switch current limit. DUAL SERIES: 5F, 40m SINGLE: 10F, 20m Figure 4. Energy Loss Due to ESR at Various VSYS Loads (Single 10F, Boost to 5V) Supercapacitor Leakage Figure 3. SCAP Voltage at VSYS Dropout for Single/Dual 10F Supercapacitors (Boost to 5V) Internal leakage in a supercapacitor is comprised of diffusion current and steady-state leakage current. Diffusion current decreases as the supercapacitor is held at a voltage. Manufacturers typically spec leakage at a certain time after the supercapacitor has been charged. UG-1320 Rev 0 5 DEMO MANUAL DC2642A DEMO BOARD OPERATION The 10F supercapacitors on the DC2642A have a specified leakage current of 0.023mA after 72 hours of being held at the rated charge voltage. Near the start of charging, though, the leakage current is significantly higher. Supercapacitor leakage is primarily a concern for backing up loads for a longer time. To test operation with worstcase leakage current, charge a supercapacitor and trigger a power-fail immediately after the supercapacitor reaches its full charge voltage. Figure 5 shows the self-discharge of the supercapacitor triggering a recharge cycle. Note that the recharge cycles become less frequent as the supercapacitor remains near full charge. Keeping these factors in mind, the LTC4041 can be used to design a robust 5V backup system using either a single supercapacitor or two supercapacitors in series. Given the effects of the switch current limit and the ESR of the supercapacitor model, using two supercapacitors in series is generally preferable when operating at higher load currents. However, designs with lower load currents can save space and lower costs by using a single supercapacitor. Figure 5. Supercapacitor Recharge Rate Due to Self-Discharge (Dual 10F, Unloaded) UG-1320 Rev 0 6 DEMO MANUAL DC2642A PARTS LIST ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER Required Circuit Components 1 1 C1 CAP., 0.1F, X7R, 50V, 10%, 0805 AVX 08055C104KAT2A 2 1 C2 CAP., 10F, X5R, 50V, 10%, 1206 MURATA GRM31CR61H106KA12L 3 1 C3 68F 20% 50V Aluminum Polymer Capacitor Radial, Can - SMD 20m Panasonic Electronic Components 50SVPF68M 4 1 C5 CAP., 2.2F, X5R, 10V, 10%, 0603, NO SUBS. ALLOWED MURATA GRM188R61A225KE34D 5 3 C6, C11, C14 CAP., 0.1F, X7R, 10V, 10%, 0402 MURATA GRM155R71A104KA01D 6 2 C8, C9 CAP., 100pF, C0G, 100V, 5%, 0805 AVX 08051A101JAT2A 7 1 C12 CAP., 10F, X5R, 10V, 20%, 0603 AVX 0603ZD106MAT2A 8 1 C13 CAP., 1000pF, X7R, 16V, 10%, 0402 AVX 0402YC102KAT2A 9 1 D4 DIODE ARRAY SCHOTTKY 40V SOT23 Diodes Incorporated BAS40-05-7-F 10 1 L1 IND., 2.2H, PWR, 20%, 9.2A, 14.5m, 5.48mm x 5.28mm, XAL5030,AEC-Q200 COILCRAFT XAL5030-222MEB 11 2 M1, M2 MOSFET N-CH 40V 40A 1212-8 Vishay Siliconix SIS488DN-T1-GE3 12 1 R1 RES., 113k, 1%, 1/10W, 0402 PANASONIC ERJ2RKF1133X 13 1 R2 RES SMD, 38.3K, 1%, 1/16W, 0402 Vishay Dale CRCW040238K3FKED 14 1 R3 RES SMD, 6.2K, 5%, 1/4W, 0603 Rohm Semiconductor ESR03EZPJ622 15 1 R4 RES., 0, 1/16W, 0402 ROHM MCR01MZPJ000 16 1 R5 RES., AEC-Q200, 1.05M, 1%, 1/16W, 0402 VISHAY CRCW04021M05FKED 17 1 R6 RES., 200k, 1%, 1/16W, 0402 PANASONIC ERJ2RKF2003X 18 1 R11 RES., 1k, 1%, 1/10W, 0603 NIC NRC06F1001TRF 19 3 R14, R18, R21 RES., 1M, 1%, 1/16W, 0402 Vishay Dale CRCW04021M00FKED 20 3 R15-R17 RES., 1.5k, 1%, 1/16W, 0402 NIC NRC04F1501TRF 21 1 RS1 RES., SENSE, 0.01, 1%, 1/3W, 0603 SUSUMU PRL0816-R010-F-T1 22 1 U1 IC,2.5A Supercap Backup Power Manager LINEAR TECHNOLOGY LTC4041EUFD#TRPBF Additional Demo Board Circuit Components 23 0 C4, C7, C10 CAP., OPTION, 0402 24 0 R7,R8 RES., OPTION, 0402 25 0 R12, R13 RES., OPTION, 0603 Hardware: For Demo Board Only 26 2 D1, D2 LED,SUPER YELLOW, MILKY WHITE DIFF., 0603 SMD LUMEX SML-LX0603SYW-TR 27 1 D3 LED, RED, WATER CLEAR, 0603 LITE-ON TECHNOLOGY CORP LTST-C193KRKT-5A 28 19 E1-E19 TEST POINT, TURRET, 0.094", MTG. HOLE MILL-MAX 2501-2-00-80-00-00-07-0 29 4 E20-E23 CONN., BANANA JACK, FEMALE, THT, NON-INSULATED, SWAGE KEYSTONE 575-4 30 2 JP1, JP2 CONN., HDR, MALE, 1 x 3, 2mm, THT, STR, NO SUBS. ALLOWED Wurth Elektronik 62000311121 31 1 LB1 LABEL SPEC, DEMO BOARD SERIAL NUMBER BRADY THT-96-717-10 32 4 MP1-MP4 STANDOFF, NYLON, SNAP-ON, 0.625" KEYSTONE 8834 33 1 SW1 SWITCH SLIDE DPDT 300MA 6V C&K JS202011CQN 34 2 XJP1, XJP2 CONN., SHUNT, FEMALE, 2 POS, 2mm Wurth Elektronik 60800213421 UG-1320 Rev 0 7 DEMO MANUAL DC2642A PARTS LIST ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER DC2642A-A Required Circuit Components 35 1 R9 RES., AEC-Q200, 1.5M, 1%, 1/16W, 0402 Vishay Dale CRCW04021M50FKED 36 1 R10 RES., 324k, 1%, 1/16W, 0402 NIC NRC04F3243TRF 37 1 R19 RES., 0, 1/10W, 0603 YAGEO RC0603FR-070RL 38 0 R20 RES., OPTION, 0603 - 39 2 SCAP1, SCAP2 CAP., 10F, ULTRA, 2.7V, -10/+20%, THT, RADIAL NESSCAP CO. LTD. ESHSR-0010C0-002R7 40 0 SCAP3 CAP., 10F, ULTRA, 2.7V, -10/+20%, THT, RADIAL NESSCAP CO. LTD. ESHSR-0010C0-002R7 DC2642A-B Required Circuit Components 41 1 R9 RES., 698k, 1%, 1/16W, 0402 Vishay Dale CRCW0402698KFKED 42 1 R10 RES., 348k, 1%, 1/16W, 0402 KOA SPEER RK73H1ETTP3483F 43 0 R19 RES., OPTION, 0603 44 1 R20 RES., 0, 1/10W, 0603 YAGEO RC0603FR-070RL 45 0 SCAP1, SCAP2 CAP., 10F, ULTRA, 2.7V, -10/+20%,T HT, RADIAL NESSCAP CO. LTD. ESHSR-0010C0-002R7 46 1 SCAP3 CAP., 10F, ULTRA, 2.7V, -10/+20%, THT, RADIAL NESSCAP CO. LTD. ESHSR-0010C0-002R7 UG-1320 Rev 0 8 A B C D E15 E14 E13 E12 E11 E10 E9 C14 0.1uF 0402 E19 VSYS SW1 R14 1M R21 1M DPDT 1 0 1 0 Information furnished by Analog Devices is believed to be accurate and reliable. However, no responsibility is assumed by Analog Devices for its use, nor for any infringements of patents or other rights of third parties that may result from its use. Specifications subject to change without notice. No license is granted by implication or otherwise under any patent or patent rights of Analog Devices. PCB, DC2642A 5 STNCL1 TOOL, STENCIL, 700-DC2642A REV04 REV04 MP4 STANDOFF,NYLON,SNAP-ON,0.625" 2 JP1 ON 2 JP2 4 R13 OPT R2 38.3k PF THRESH = 4.7V R3 6.2k 0603 5 4 3 8 13 14 11 19 C5 2.2uF 10V 0603 BSTEN CHGEN IMON CAPFLT CAPGD PFO SYSGD PFI U1 M1 SIS488DN-T1-GE3 NOTES: UNLESS OTHERWISE SPECIFIED 1. RESISTORS: OHMS, 0402, 1%, 1/16W 2. CAPACITORS: 0402, 10%, 50V TO CONTROL CHGEN OR BSTEN FROM AN EXTERNAL MICROCONROLLER, REMOVE THE JUMPER FROM JP1 OR JP2, RESPECTIVELY. DO NOT CHANGE JP1 OR JP2 POSITIONS DURING OPERATION UNLESS R12 OR R13 ARE INSTALLED, RESPECTIVELY. OFF ON ENBST OFF ENCHG C4 OPT D4 BAS40-05-7-F VSYS SCAP SUPER YELLOW D3 RED R17 1.5k R1 113k DCIN PROTECTED UP TO 42V D2 SUPER YELLOW D1 STANDOFF,NYLON,SNAP-ON,0.625" LABEL C3 68uF 50V 50SVPF68M R16 1.5k MP2 STANDOFF,NYLON,SNAP-ON,0.625" LB1 PCB1 + R15 1.5k MP1 STANDOFF,NYLON,SNAP-ON,0.625" MP3 C2 10uF 50V 1206 SW1 POSITIONS 0: VSYS - LEDS POWERED BY VSYS 1: EXTVDD - LEDS POWERED BY EXTVDD IF PRESENT R12 OPT C1 0.1uF 50V 0805 LED PWR E21 E2 PCA ADDITIONAL PARTS BSTEN CHGEN IMON CAPFLT CAPGD PFO SYSGD 4V-5.5V EXTVDD GND E20 4 0.01 RS1 * R6 200k R5 1.05M C10 OPT * R9 2.2uH L1 2 SCAP1 & SCAP2 SCAP3 TWO ONE DNP DC2642A- B DNP SCAP2 LOADED SCAP1 THIS CIRCUIT IS PROPRIETARY TO LINEAR TECHNOLOGY AND SUPPLIED FOR USE WITH LINEAR TECHNOLOGY PARTS. R19 DNP SKU NO. SIZE: N/A 2 SCALE = NONE SEE ASSY TABLE R10 E23 E22 R18 1M + + * * SCAP2 10F SCAP1 10F 2A ZP www.analog.com PROG GND BAL SCAP ** GND GND GND GND VSYS DATE 01-18-18 DATE: 01-18-18 1 SHEET 1 OF 710-DC2642A_REV04 SCHEMATIC NO. AND REVISION: 2.5A SUPERCAPACITOR BACKUP POWER MANAGER 1 1630 McCarthy Blvd. Milpitas, CA 95035 Phone: (408)432-1900 Fax: (408)434-0507 E8 E7 E6 E5 E18 E17 E16 E4 E3 TITLE: DEMO CIRCUIT SCHEMATIC, TM 348k 324k * SCAP3 10F AHEAD OF WHAT'S POSSIBLE 698k LOADED + ANALOG DEVICES R9 1.5M R20 DNP C12 10uF 0603 SCAP DEFAULT 4.5V 2.4V PCA BOM: 700-DC2642A_REV04 PCA ASS'Y: 705-DC2642A_REV04 LOADED APPROVALS LOADED DNP SCAP3 ASSEMBLY VERSION TABLE LINEAR TECHNOLOGY HAS MADE A BEST EFFORT TO DESIGN A PCB DES. NC CIRCUIT THAT MEETS CUSTOMER-SUPPLIED SPECIFICATIONS; HOWEVER, IT REMAINS THE CUSTOMER'S RESPONSIBILITY TO APP ENG. ZP VERIFY PROPER AND RELIABLE OPERATION IN THE ACTUAL APPLICATION. COMPONENT SUBSTITUTION AND PRINTED IC NO. CIRCUIT BOARD LAYOUT MAY SIGNIFICANTLY AFFECT CIRCUIT PERFORMANCE OR RELIABILITY. CONTACT LINEAR LTC4041 TECHNOLOGY APPLICATIONS ENGINEERING FOR ASSISTANCE. 3 R19 R20 INSTALLED RESISTOR CAUTION: IF SCAP3 IS INSTALLED WHILE R19 IS INSTALLED, THE SUPERCAPACITOR IS NOT PROTECTED FROM OVERVOLTAGE AND CAN BE DANGEROUS INSTALLED SUPERCAPS NUMBER OF SUPERCAPS VSYS C9 100uF 10V 1210 2.5A PRODUCTION 1 REVISION HISTORY DESCRIPTION APPROVED RSTFB FALLING THRESH = 4.625V RSTFB RISING THRESH = 4.75V C8 100uF 10V 1210 4.7V-5.5V 4 REV DEMO CIRCUIT DC2642A-A DC2642A-B ** R8 OPT C11 0.1uF 0402 SCAP 0 R4 R7 OPT - ECO ONLY ONE OF R19 & R20 SHOULD BE INSTALLED AT ANY TIME. * R10 LOADED CUSTOMER NOTICE C7 OPT BSTFB SETTING = 5V SKU NO. R20 0 * R19 0 VSYS 12 23 21 22 10 18 1 DC2642A- A * C13 1000pF CAPFB SCAP SW SW RSTFB BSTFB VSYS C6 0.1uF 0402 M2 SIS488DN-T1-GE3 LTC4041-UFD CHARGE CURRENT SETTING = 2A R11 1k 0603 3 6 VIN E1 2 2 24 DCIN 1 3 16 OVSNS PROG 7 CLN CAPSEL 20 GND 25 15 IGATE CPF 17 VSYS BAL 9 4.7V-5.5V 3 1 3 1 5 A B C D DEMO MANUAL DC2642A SCHEMATIC DIAGRAM UG-1320 Rev 0 9 DEMO MANUAL DC2642A ESD Caution ESD (electrostatic discharge) sensitive device. Charged devices and circuit boards can discharge without detection. Although this product features patented or proprietary protection circuitry, damage may occur on devices subjected to high energy ESD. Therefore, proper ESD precautions should be taken to avoid performance degradation or loss of functionality. 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