High voltage charger solution

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High voltage charger solution

• Li, Wang wang-li_at_ti.com
• MGambrill, Michael mgambrill_at_ti.com
• Liang, Roger r-liang_at_ti.com

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Abstract

• A typical bq24610 Application
• A high voltage charger block diagram
• Test results
• More higher input voltage solution
• SMBus high voltage charger solution

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• A typical bq24610 Application

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A Typical standalone charger application circuit
SYSTEM LOAD
Q1
RAC 10m?
Q2
R16 2?
C3 10µF
C2 10µF
Adapter
10?
C11 0.1µF
C1 2.2µF
ACN ACP ACDRV VREF CE ISET1 ISET2 ACSET TS TTC
STAT1 STAT2 PG
VCC
BATDRV REGN BTST HIDRV PH LODRV GND SRP S
RN VFB
C7 0.1uF
bq24610
Q3
C12 1µF
C51µF
R7 100k?
R9 9.31k?
R5 100k?
R3 100k?
C4 10uF
Q4
Pack Thermistor
RSR 10m?
L 6.8µH
Battery Pack
R8 57.6k?
R10 430k?
R6 22.1k?
R4 95.3k?
C17 0.22µF
Q5
C8 10µF
C7 10µF
Adapter
C9 100pF
R1110k?
R1 953k?
C10 0.1µF
R1210k?
R2 105k?
R1310k?
bq24610 600kHz, Li-Ion 4x4mm QFN-24
Typical 1-6 Li-Ion Cells, VIN max 28V
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Optional section divider or presentation title
slide

• High voltage charger block diagram

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8-cell Li-ion battery charger

• Basic requirements Output if 4.2V/cell
  battery, the output voltage setting needs
  4.2Vx833.6V.Input Vin gt 33.6Vfew volt
  hysteresis

A typical bq24610/30 application circuit can not
accept the input voltage higher than 32V (Input
OVP setting).
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Modified Charger Block Diagram
The charger circuit have to do several
modifications. The block diagram of HPA603 EVM
814V Vcc
DC Input
Vcc Bias Supply TPS54060
3557V
ACN ACP
VCC
Pre-charge Deeply discharged Battery
BATDRV REGN BTST HIDRV PH LODRV GND
SRP SRN VFB
ACDRV
BTST setting
CE
CE
VREF ISET1 ISET2 ACSET TS TTC STAT1 STAT2 PG
Vcc
Q1
Half Bridge Gate Drive UCC27201
L
Battery Pack
Pack Thermistor
Rsns
Q2
Current Sense INA169
C
Vcc
Buffer LM358
VREF
Rs
23V Clamp
bq24610/30
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VCC bias supply solution

• Function block Vcc Bias supply
• It powers the charger IC-bq24610/30, external
  half bridge gate driver, current sense circuit
  and OMAMP buffer. And it is also used for
  charging up a deeply discharged battery. A
  switching Vcc bias power supply needs
• Operating from the maximum input voltage
• An 8-14 V output voltage It is set by the
  external half bridge gate driver requirement
• At least 200mA It is derived from the sum of the
  charging current for deeply discharged battery
  and the whole board current consumption.
• For 60V input, the TPS54060 is selected to meet
  these three requirements.

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Modified Charger Block Diagram
Half bridge gate drive solution
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Half bridge gate drive solution

• Function block Half Bridge Gate Drive
• It receives the charger IC HIDRV and LODRV signal
  and drive the buck FET Q5 and Q6. The half bridge
  gate drive needs
• 20 input voltage margin
• Have two Complementary inputs to match HIDRV and
  LODRV output of bq24610.
• Input logic high threshold need lower than 3V
  match the voltage level of bq24610/30s HIDRV and
  LODRV output.
• Reserve several resistors, caps and diode to
  adjust turn-onoff speed and dead time
• For 60V input, the UCC27201 is selected to meet
  these three requirements.

Cin
Vcc
R13 D3
bq24610
HIDRV PH LODRV PGND
R25
HB
VDD
HI
Q1
HO
UCC 27201
UCC 27201
C21
HS
C22
Q2
LI
LO
VSS
R26
R14 D4
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Modified Charger Block Diagram
Current sense solution
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Current sense solution

• Function block Current sense
• It is a high voltage bus current sensor or a
  current mirror circuit. It needs
• Set 11 ratio between Rsns Voltage and Rs
  voltage.
• For battery voltage is upto 60V, the INA169 is
  selected to meet that requirement.

Rsns

Current sense
1k
Rs (R6)
1k
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Modified Charger Block Diagram
buffer solution
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Current sense buffer solution

• Function block Buffer
• The SRP/SRN pin of charge IC has few milliampere
  sink current. The current sense output may not
  have enough current capability. The buffer
  circuit needs
• Keep the output voltage on SRP/SRN pin is same as
  Rs voltage
• Provides enough current (8mA) to drive SRP/SRN
  pin.
• The LM358 is selected to meet these two
  requirements.

Rsns
L
U1 bq24610
Buffer U5LM358
Current sense
Rs (R6)
SRP
R3
SRN
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Modified Charger Block Diagram
23V clamp circuit solution
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23V clamp circuit solution

• Function block 23v Clamp circuit
• If the SRP/SRN pin voltage is lower than 2V, the
  IC runs at a short protection mode. The low side
  MOSFET is held off at that mode. The clamp
  circuit needs
• Voltage is between 23V.
• Can absorb the Rs current
• Can support SRN pin sink current (8mA)
• A simple 23V clamp circuit can be created from
  the bq24610s 3.3V VREF.

Rsns
L
Current sense
Rs (R6)
bq24610
SRN
VREF
R27
C30
VREF
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Modified Charger Block Diagram
BTST setting
814V Vcc
DC Input
Vcc Bias Supply TPS54060
3557V
ACN ACP
VCC
Pre-charge Deeply discharged Battery
BATDRV REGN BTST HIDRV PH LODRV GND
SRP SRN VFB
ACDRV
BTST setting
CE
CE
VREF ISET1 ISET2 ACSET TS TTC STAT1 STAT2 PG
Vcc
Q1
Half Bridge Gate Drive UCC27201
L
Battery Pack
Pack Thermistor
Rsns
Q2
Current Sense INA169
C
Vcc
Buffer LM358
VREF
Rs
23V Clamp
bq24610/30
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BTST setting

• Function block BTST setting
• To isolate PH, HIDRV and BTST pin. The PH pin is
  connected to ground. BTST voltage needs
• Higher than 3V to keep correct gate logic.
• Lower than 4V to keep LODRV send refresh pulse
  every switching cycle. External half bridge gate
  will use that LODRV refresh pulse to charge its
  bootstrap cap.

A simply resistor divider from 6V REGN can set
the BTST voltage easily.
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Modified Charger Block Diagram
BTST setting
814V Vcc
DC Input
Vcc Bias Supply TPS54060
3557V
ACN ACP
VCC
Pre-charge Deeply discharged Battery
BATDRV REGN BTST HIDRV PH LODRV GND
SRP SRN VFB
ACDRV
BTST setting
CE
CE
VREF ISET1 ISET2 ACSET TS TTC STAT1 STAT2 PG
Vcc
Q1
Half Bridge Gate Drive UCC27201
L
Battery Pack
Pack Thermistor
Rsns
Q2
Current Sense INA169
C
Vcc
Buffer LM358
VREF
Rs
23V Clamp
bq24610/30
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Pre-condition deeply discharge battery solution

• Function block Pre-condition deeply discharge
  battery
• When battery voltage is deeply discharged lower
  than 3V, the current sense circuit can not work
  properly. The pre-condition circuit needs
• The pre-condition current can bring a deeply
  discharged battery voltage higher than 3V.
• The pre-condition current is lower than bias
  supply output capability.
• A simply resistor (R46 and R47) and diode (D8)
  pre-charge path can pre-charge the battery
  voltage up to the 3V that is a minimum operating
  voltage range of the current sense circuit. A
  comparator compares the battery voltage with
  3.3Vref. If the battery voltage is higher than
  3.3V, the CE is pulled to high and charger is
  enabled.

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The calculation tool of L, C value and other
parameters
The calculation tool of L, C value and other
parameters can be found in http//www.ti.com/litv/
zip/sluc175c
Battery charge voltage setting
Battery pre-charge/termination current setting
Battery fast-charge current setting
Iripple_Lout_Vripple
LC output filter resonant frequency
Fast charge timer
TS resistor network
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EVM and Application note information
The high voltage charge EVM (HPA603) and users
guide (SLUU447) are available.
Application notes (SLUA580) is released A
practical high voltage charger solution with
existing bq24610 charger IC.
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• Test Results on HPA603 EVM

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Test result on HPA603 EVM

• 1 ISET1 control IBAT
• 1.1 ISET1 vs IBAT waveform
• 1.2 ISET1 transient
• 1.3 ISET1 accuracy
• 2 Switching waveforms
• 3 Charger start-up or shut-down with CE control
• 4 Battery insertion and removal
• 5 soft start
• 6 efficiency

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Modified Charger Block Diagram
The charger circuit have to do several
modifications. The block diagram of HPA603 EVM
814V Vcc
DC Input
Vcc Bias Supply TPS54060
3557V
ACN ACP
VCC
Pre-charge Deeply discharged Battery
BATDRV REGN BTST HIDRV PH LODRV GND
SRP SRN VFB
ACDRV
BTST setting
CE
CE
VREF ISET1 ISET2 ACSET TS TTC STAT1 STAT2 PG
Vcc
Q1
Half Bridge Gate Drive UCC27201
L
Battery Pack
Pack Thermistor
Rsns
Q2
Current Sense INA169
C
Vcc
Buffer LM358
VREF
Rs
23V Clamp
bq24610/30
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1.1 ISET1 vs IBAT waveform
IBAT
ISET1

• IBAT are proportional to ISET1. The ratio follows
  the datasheet equation.

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1.2 ISET1 transient 2

• ISET1 from 1V to 2V (CCM)

IBAT
ISET1
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1.3 ISET1 accuracy
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2 Switching waveforms
High side gate
High side gate
Switching node
Inductor current
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3. Charger start-up or shut-down with CE control
VBAT
CE
Switching node
Inductor current
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4 Battery removal and insertion
VBAT
VIN
Switching node
Inductor current
Ch1 (yellow) Vin Ch2 (blue) Vbat Ch3 (pink)
PH 4 (green) IL
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5 soft start
VBAT
VIN
Switching node
Inductor current
Ch1 (yellow) Vin Ch2 (blue) Vbat Ch3 (pink)
PH ch4 (green) IL
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6 efficiency
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• More Higher input voltage charger
• 100Vin_max and 16-cell

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Higher input range solution
If need a even high voltage, for example 16 cell
battery charger with 80V input. Please update
those components and circuits
Changer requirement Output Input
bq24610EVM (HPA603EVM) 8-cell Li-ion battery 8x4.233.6V Maximum 60V input
80Vin/16cell Li-ion battery Charger 16-cell Li-ion battery 16x4.267.2V Maximum 100V input
Change list VCC bias supply Current sense circuit R23 (Vbat setting) L1 value (Keep ?I constant) Power FET
bq24610EVM (HPA603EVM) TPS54060 INA169 R23 464k 22uH 80V FET Si7852
80Vin/16cell Li-ion battery Charger Any 100V input 10Vout_at_150mA bias supply Current mirror ZDS1009 R23 953k 47uH 100V FET SiR846
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• SMBus High voltage charger solution

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SMBus High Voltage Charger Solution
814V Vcc
DC Input
Vcc Bias Supply TPS54060
CSSN CSSP
DCIN
Pre-charge Deeply discharged Battery
ACIN VDDSMB
BTST setting
PVCC BOOT UGATE PHASE LGATE
VREF CE ACOK
Vcc
SMBUS
Q4
SCL SDA
Half Bridge Gate Drive UCC27201
L
Battery Pack
Rsns
VICM
Q5
Current Sense INA169
C
ICOUT ICREF
R9 7.5k
GND CSOP CSON
Buffer LM358
EAO EAI FBO
C21 2000p
VREF
C23 51p
Rs
23V Clamp
R10 20k
VFB
C22 130p
R11 200k
bq24747
1MO
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• Thank you
• Questions