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Application ReportSLPA013–October 2014
Hybrid Battery Charger With Load Control forTelecom Equipment
ABSTRACTCommercial telecom equipment needs multiple power input systems to ensure continuous networkconnectivity. The load must be backed up to different sources. This application note describes asynchronous-buck-based reference design using MSP430 and CSD87350 power blocks, which usemultiple OR’ed inputs (solar and AC/DC adaptor) to charge a 12-V SLA battery. Priority charging is usedwhen solar energy is available. Seamless transfer between two sources ensures battery is always chargedwhen inputs are available. It runs MPPT algorithms to charge while on solar input and conventionalCC/CV charging when working from an adaptor input. Multiple protection schemes ensure it is a robustdesign.
Topic ........................................................................................................................... Page
1 Design Specifications........................................................................................... 22 Block Diagram ..................................................................................................... 23 System Explanation and Design ............................................................................ 34 Software Flow...................................................................................................... 45 Schematics ......................................................................................................... 96 Test Results ...................................................................................................... 11
1SLPA013–October 2014 Hybrid Battery Charger With Load Control for Telecom EquipmentSubmit Documentation Feedback
Copyright © 2014, Texas Instruments Incorporated
100-W
12-V Solar Panel
Universal
AC Adaptor
(15 V at 7-A Capacity)
Telecom
EquipmentMicrocontroller
Oring ControlInput Current
Sense
Sync Buck
ConverterOutput Current
SenseLoad Switch
Load Current
Sense
Temp Sensor
LDO
ICS
OCS
VPANEL
LCS
VBAT
Design Specifications www.ti.com
1 Design Specifications
Table 1. Design Specifications
Parameter Description ValuePanel 16.5 to 21 V
VIN rangeAdaptor 15.5 to 16 V
Battery specifications Capacity 12 V, 100 AhCharging current 7 A
Charging specificationsVoltage during CV mode charging 14.2 V
FSW Switch frequency 100 kHzLoad current 4 A
Output specificationsOutput voltage 10.2 to 14.2 V
• Hot swappable load• Output short circuit• Reverse polarity protectionProtection features• Two level overcurrent protection• Battery UVLO• Overtemperature protection
2 Block DiagramFigure 1 shows the block level implementation of the system.
Figure 1.
2 Hybrid Battery Charger With Load Control for Telecom Equipment SLPA013–October 2014Submit Documentation Feedback
Copyright © 2014, Texas Instruments Incorporated
www.ti.com System Explanation and Design
3 System Explanation and Design
3.1 Power Source Control and MonitoringThe telecom equipment (load) is always powered either from a solar panel, AC/DC adaptor, or the battery.As long as solar energy from the panel is available, priority charging is used to deliver the required power(average 17 V and current sufficient enough to manage load or to charge battery). If panel voltage dropsbelow adapter (15 V), the charge controller microcontroller turns off the panel switch and turns on theAC/DC adapter switch, which also ensures no leakage of the stronger source into the weaker one. Two30-V, ultra-low RDS(on) FETs from TI (CSD17527Q5A) are selected for this purpose. The simple transistor isused for proving the drive from the microcontroller.
3.2 Synchronous Buck Power StageThe synchronous buck convertor has better efficiency and lower loss compared to asynchronous topologybecause a diode on the bottom side is replaced with a low RDS(on) value. A single 30-V, 25-A power blockfrom TI (CSD87350Q5D) is selected for this. The advantage of a power block is the smaller package andease of layout eliminating parasitics of board layout of high frequency hot nodes. The microcontrollerPWM module can generate multiple PWMs on the same timer base. Each output can be configured fordifferent output modes, for example, toggle, reset/on, reset/off, always on, and so forth. With this flexiblelogic, the user can achieve complimentary logic with required dead band. However, a driver UCC27211 isused to enable ease of driving. The other power stage components (inductor and capacitor) calculationsare designed using standard equations of the buck converter based on the prior specifications.• LOUT (cal) = 12.67 μH, selected LOUT = 10 μH, from Wurth Electronics• Selected COUT = 47 µF × 1; 22 µF × 2
3.3 Current Sense InputsTo ensure continuity to ground loop, a high-side sense circuit was used. A zero-drift instrumentationamplifier from TI, INA282, with a 50-V/V gain, wide common-mode input range is selected for thisapplication.
3.4 Load ManagementA simple load switch with hotswap control from TI TPS25910 is used for monitoring the load behavior. Ifthere is any short or overload, it immediately trips sending it into a hiccup mode on the load. The fast-tripcomparator of the microcontroller also quickly disables the PWM. This is second-level protection for theload. To prevent the load from discharging back into the source, a blocking FET (CSD17313Q2) from TI isused. It is controlled by the load switch.
3.5 MicrocontrollerA MSP430F5132 microcontroller is used in this application. See Section 4 for further details of thesoftware routines.
3.6 LDO and Temperature SensorA simple OR’ed supply is used as the input of the LDO to ensure that power to the controller is alwaysavailable to sense any inappropriate condition. The 3.3 V generated by the LDO (TPS73801) is used topower the MCU, LEDs, instrumentation amplifiers, and a simple thermostat TMP709, which is used fortripping the load in case there is any abnormal increase in the temperature.
3.7 Battery ManagementThe section explains the battery management software portion in the microcontroller. It checks for thestate-of-charge of the battery and applies the charging profile appropriately. This application uses a lead-acid battery. The following list shows the battery properties that are considered while charging.• Minimum 2.10 V per cell is considered as a good battery• Cells in a string are not the same strength, some are weak and some are strong.
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System Explanation and Design www.ti.com
• Should not be charged above 50°C• Overcharging increases the risk of hydrogen gassing on the positive plate.• Undercharging increases sulfation on the negative plate.• Battery charge profile is in constant current mode until battery attains, for example, 70%, constant
voltage mode from 70% to 90% and float charge after that.
3.8 Maximum Power Point Tracking AlgorithmA simple MPPT algorithm known as perturb and observe is used for controlling this system. As explainedin the PWM Resolution section, every one count of PWM timer yields 0.04% of duty cycle variation, whichis “fine” enough to achieve smoother and slower tracking. With this at MPP stage, there will be 0.04%oscillation which may be negligible in a low-power application. If duty cycle variation is increased morethan 1 count, tracking is faster and reduces the variation to minimize the MPP stage oscillations. This alsoresembles incremental conductance method. It monitors battery/load current with respect to ΔV applied tothe converter, increasing the ΔV drives to MPP faster and at the MPP stage reduces the ΔV and settlessmoothly at MPP.
4 Software FlowThis application uses the MSP430F5132 microcontroller. The following are key features, which enableefficient usage of resources to achieve an efficient solar power convertor.
MSP430F5132 key features supporting efficiency expectation:• Fully operates from 3.6 to 1.8 V• Only 180-µA/MHz active current, lowest current at shut down is 0.25 µA• Fast wake-up, less than 5 µs from stand by• 200 KSPS, 10-bit ADC, with just 110-µA current consumption with built-in reference• Hi-resolution timer/PWM = 4-ns minimum pulse duration, 250-µA current consumption
4.1 PWM ResolutionThe MSP430F5132 has a special hi-resolution timer, timer-D. This timer can be programmed to generatehigh switching frequency to accommodate a smaller inductor's size. This timer is clocked from thefollowing sources:• MCLK/SMCLK – Maximum range is 16 MHz• ACLK – Maximum 32 kHz• Special timer-D clock generator of the following values:
– 64 MHz– 128 MHz– 200 MHz– 256 MHZ
Effective number of bits (ENOB) is an important parameter in achieving smoother control, therebyreducing switching noise and protecting the battery from stress caused by larger voltage variations causedin a low-resolution system.
ENOB = Log2(Module clock / Output frequency) (1)
This application requires 100-kHz switching frequency. Therefore, the following settings provide,
Module clock = 256 MHz
Output frequency = 100 kHz
ENOB = 11.36 bitsVOUT = D × VIN
where• D = Duty cycle or on-time of the switch
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Source
S1
Panel V x I
Source
S2
Adapter V x I
S1 S2≥Select S2,
Turn OFF S1
Select S1,
Turn OFF S2
Power on/
Reset
Init ADC
Init PWM
Init Comparator for Tripping
Start Control Loop
www.ti.com Software Flow
• VIN = Input voltage (from battery, solar panel, or ACDC adapter)• VOUT = Output voltage (2)
Consider the converter to be 100% efficient. Therefore, no loss factor is taken into account in thiscalculation. For a single bit change in D varies by approximately 4 ns in a 100-kHz period wave, which is0.038% of VIN; if a VIN of 17, VOUT varies by 0.00646 V.
4.2 ADC ModuleThis device has 10-bit SAR ADC, speed can be configured for 50ksps for low power or 200ksps for fasterprocessing. This application can go slow, which helps to conserve additional power loss caused by theADC module itself (refer to the data sheet for power consumption data). This module can be operatedindependently without sharing the CPU clock. Hence, the CPU can be placed in low-power mode,enabling only the ADC to function.
A special ADC DMA can be configured to scan all channels and interrupt the CPU when data is availableat the RAM for further processing. This application requires 6 channels: battery current, panel current,battery voltage, panel voltage, load current, and temperature sensor. Therefore, a 6-channel conversion isrequired every loop, until then the CPU can be put in IDLE to conserve power.
4.3 ADC Measurement RangeThis MCU has a 10-bit SAR ADC, input voltage range is 0 V to AVCC, which can be up to 3.6 V (refer todata sheet for more electrical data). Hence, input signal strength can be from 3.3 mV per count of ADCuntil 3.3 V (1023 counts) can be sensed. Sense resistors are 5 mΩ. Hence, minimum current sensiblefrom panel/load/battery with a gain of 50 is about 13 mA.
Figure 2. Initialization Flow Chart
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Copyright © 2014, Texas Instruments Incorporated
ADC Interrupt every
100 ms
SAMPLE
• Panel Voltage (P_V)
• Panel Current (P_I)
• Battery Voltage(B_V)
• Battery Current(B_I)
• Adaptor Voltage (A_V)
• Load Current(A_I)
B_V > P_V
&&
B_V > A_V
P_V < A_V
&&
P_I ~= 0*
P_V > A_V
&&
P_I > Lowest
Threshold*
P_V > B_V
&&
P_I > Threshold
• Disable Battery Charging Algorithm
• Only Load Management Thread
• Turn OFF Panel and Adaptor Indicator LEDs
Wait for ADC
Interrupt
• Panel Switch OFF, Adaptor switch ON
• Turn OFF Panel LED and Turn ON Adaptor
Indicator LED
• Load Management and CC/CV Mode
• Adaptor Switch OFF, Panel switch ON
• Turn OFF Adaptor LED and Turn ON Panel
Indicator LED
• Call Current Control (MPPT) and Load
Management
• Load Management
Yes
Yes
Yes
No
Yes
Software Flow www.ti.com
Figure 3. Control Loop Flow Chart
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State of Charge
Fast Charge
CC Mode
Topping Charge
CV ModeFloat Charge
Safety Test
Temp
Short
Open
Charge < 20%
Charge > 70%
Charge > 95%
Fault Wait
Current Control
Loop Start
(MPPT)
Sample Battery Current
I_B(n)
I_B(n) >
I_B(n-1)
Increment PWM
Duty Cycle Count
Decrement PWM
Duty Cycle Count
Yes No
www.ti.com Software Flow
Figure 4. MPPT Algorithm Flow Chart
Figure 5. Battery Management Flow Chart
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ADC InterruptEvery 100 ms
Run MPPT
Charging Loop
if Solar Panel
Powered
Run CC/CV
Charging Loop
if Adapter
Powered
Run Load
Management Loop
Run Battery
Management
Loop
CPU Idle
State
Software Flow www.ti.com
Figure 6. Control Loop Logic
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Copyright © 2014, Texas Instruments Incorporated
PANEL CURRENT SENSE
CONVERTER OUTPUT CURRENT SENSE
LOAD CURRENT SENSE
BATTERY CHARGER CIRCUITPANEL CONNECTOR
ADAPTOR CONNECTOR
IND_74436xxxx
3.01
CONN-RMC-2PIN
CONN-RMC-2PIN
R603
2512
2512
QFN5X6MM
R603
R603
SOT23
CONN-RMC-2PIN
CONN-RMC-2PIN
R603
R603
R603
SOT23
QFN5X6MM
QFN5X6MM_DUAL
C603 C603
C603
C603
CAP_EEUCF CAP_EEUCF C603 C603 C603
2512
2512
SO8
SO8
SO8
R603
R603
R603
C603
C603
C603
R603
DNP
R603
R603
SOT-23
R603
R603
SOT-23
PANEL AND ADAPTOR VOLTAGE SENSE
VP P+
V3V3
IP_SNS
BAT+
CONV_OUT
V3V3
IBAT_SNS
VLOAD BAT+
V3V3
ILOAD_SNS
BAT+
CONV_OUT
BUCK_PWM
SYNCB_PWM
P+
BAT+
PAN_SW
BAT+
AC_SW
VP
BAT+
VP
P+
VP_SNSV
3V
3
P-
ADP-
P-
VP
VADP_SNS
V3V
3
ADP-
L110 Hµ
12
U13INA28xAID
REF23
NC4
-IN1
GND2
OUT5V+6REF17+IN8
R4810 kΩ
R5510 kΩ
Q3CSD17527Q5A
5
4
123
C324.7 µF
R141206
R4774 kΩ
Q82N2907A
Q92N2907A
J2CONN-RMC-2PIN
1
2
R39
10 kΩ
C18
0.01 µF
U11INA28xAID
REF23
NC4
-IN1
GND2
OUT5V+6REF17+IN8
R42DNP
D10
MMBZ5237
R5670 kΩ
D12
BAT54S
S
A C
C190.22 uF
Q5MMBT2222ALT1
B
CE
C33
100 p
C171 µF
D7
LED
AK
R321 kΩ
U15INA28xAID
REF23
NC4
-IN1
GND2
OUT5V+6REF17+IN8
R45 2 kΩ
R171 kΩ
Q6CSD17527Q5A
5
4
123
R1310 mΩ
1 2
L210 µH
12
R1210 mΩ
1 2
R46 2 kΩ
R44
1 kΩ
R151206
C142.2 nF
R270 Ω
R341 kΩ
R43DNP
C1622 Fµ
R261 kΩ
+ C1247 µF
C1522 Fµ
J3CONN-RMC-2PIN
1
2
R5110 kΩ
C34
100 p
R3810 kΩ
C1322 Fµ
R280 Ω
U7UCC27211_D_8
HO3
HS4
VDD1
HB2
HI5LI6VSS7LO8
R30
10 mΩ
1 2
C260.1 Fµ
+C1147 µF
R5410 kΩ
R3720 kΩ
C240.1 Fµ
R5374 kΩ
D11
BAT54S
S
A C
Q7MMBT2222ALT1
B
CE
R31
10 mΩ
1 2
Q4CSD87350Q5D
3TG
1 VIN1
4
TGR
5
BG
6VSW1
7VSW2
8VSW3
9
PGND
R5270 kΩ
+C311000 µF
C280.1 Fµ
R161206
R290 Ω
www.ti.com Schematics
5 Schematics
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Copyright © 2014, Texas Instruments Incorporated
LOAD CURRENT CONTROL
TEMPERATURE SENSOR
LOAD CONNECTOR
BATTERY CONNECTOR
CONTROLLER SECTION
12 V at 4.5 A
CONN-RMC-2PIN
CONN-RMC-2PIN
CONN-RMC-2PIN
CONN-RMC-2PIN
SMA
CAP_EEUCF
C603 R603
RSA-16
R603
R603
SON_2X2MM
C603
C603 CAP_EEUCF
SOT23
R603 R603
R603
DBV_5 C603
R603
2010
2010
D_SOD123
R603
R603 C603
DNP
SOT-23
R603
R603
C603
C603
R603 R603
BAT_CHRG
LOW_BAT
DA_38P
AC_CHRG
R603
C603
DNP
R603
C603
R603
C603
R603
C603
SOT-23
C603 C603
R603
DCQ
R603
R603
C603 C603
BATTERY VOLTAGE SENSE
BAT+
LOAD_ENABLE
VLOAD
VOUT
AGND
V3V3
LOAD_ENABLE
VLOAD
V3V3
V3V3
V3V3
V3V3
BAT+
VBAT_SNS
BAT+
VP
AC_SWPAN_SW
V3V3
LOAD_ENABLE
VBAT_SNS
IBAT_SNS
VP_SNS
IP_SNS
ILOAD_SNS
SYNCB_PWMBUCK_PWM
V3V
3
ILOAD_SNSVADP_SNS
D1SMAJ20A
AK
R96.8k
R400 Ω
+ C347 µF
R251 kΩ
C2100 nF
U3TPS738xxDCQR
IN1
EN5
OUT2
FB4
GND3
GN
D1
6
D6BAT54C
C
A2
A1
R8200 kΩ
R3310 mΩ
R7100 kΩ
U2TMP709
VCC5
GND2
OT3
HYST4
SET1
J1CONN-RMC-2PIN
1
2
C10.1 µF
R410 Ω
R61 kΩ
C5DNP
C90.1uF
C1010 µF
R241 kΩ
R1846.8 kΩ
J5CONN-RMC-2PIN
1
2
D4
LED
AK
R231 kΩ
D3
LED
AK
C222.2 nF
C302.2 nF
R360 Ω
R510 kΩ
C292.2 nF
C40.1 µF
R3547k
R30 Ω
C2510 nF
D9
BAT54S
S
A C
D2MBR130
AK
R104k
R426 kΩ
C21
0.1 µF
C232.2nF
R140.2 kΩ
U5MSP430F5132IDAR
AVCC1
PJ.4/XOUT2
PJ.5/XIN3
AVSS4
P1.05
P1.26
P1.17
P1.38
P1.49
P1.510
PJ.011
PJ.112
PJ.213
PJ.314
P1.615
P1.716
P2.017
P2.118
P2.219
P2.320DVIO21DVSS122P2.423P2.524P2.625P2.726P3.027P3.128VCORE29DVSS230DVCC31PJ.632P3.233P3.334SBWTCK/TEST35NMI/SBWTDIO_RST36P3.537P3.638
+
C6DNP
C20 470 nF
R2247 kΩ
R220 kΩ
C810uF
C7
0.1 µF
Q2MMBT2222ALT1
B
CE
R1910 kΩ
J4CONN-4P-TOPENTRY
4
3
2
1
R1110 mΩ
Q1CSD17313Q2
1
3
74 2
568
D5
LED
AK
U1TPS25910RSA
VIN11
VIN22
VIN33
GATE4
GND15
GND26
ILIM7
GND38
GND49
OUT10
OUT111
OUT212
GND513
GND614
FLT15
EN16
PW
PD
17
Schematics www.ti.com
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www.ti.com Test Results
6 Test Results
Figure 7. Variation of the Duty Cycle from the Controller
Figure 8. Seamless Transfer from Panel to Adaptor
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Test Results www.ti.com
Figure 9. Output PWM Pulses from UCC27211
Figure 10. Load Switch Response to Short Circuit
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www.ti.com Test Results
Figure 11. MSP430 Fast Trip Comparator Response to Load Short Circuit (EN)
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Copyright © 2014, Texas Instruments Incorporated
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