Hybrid Battery Charger With Load Control for Telecom Equipment
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Application Report
SLPA013 – October 2014
Hybrid Battery Charger With Load Control for
Telecom Equipment
ABSTRACT
Commercial telecom equipment needs multiple power input systems to ensure continuous network
connectivity. The load must be backed up to different sources. This application note describes a
synchronous-buck-based reference design using MSP430 and CSD87350 power blocks, which use
multiple OR’ed inputs (solar and AC/DC adaptor) to charge a 12-V SLA battery. Priority charging is used
when solar energy is available. Seamless transfer between two sources ensures battery is always charged
when inputs are available. It runs MPPT algorithms to charge while on solar input and conventional
CC/CV charging when working from an adaptor input. Multiple protection schemes ensure it is a robust
design.
Topic ........................................................................................................................... Page
1 Design Specifications ........................................................................................... 2
2 Block Diagram ..................................................................................................... 2
3 System Explanation and Design ............................................................................ 3
4 Software Flow...................................................................................................... 4
5 Schematics ......................................................................................................... 9
6 Test Results ...................................................................................................... 11
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Design Specifications www.ti.com
1 Design Specifications
Table 1. Design Specifications
Parameter Description Value
Panel 16.5 to 21 V
VIN range
Adaptor 15.5 to 16 V
Battery specifications Capacity 12 V, 100 Ah
Charging current 7A
Charging specifications
Voltage during CV mode charging 14.2 V
FSW Switch frequency 100 kHz
Load current 4A
Output specifications
Output voltage 10.2 to 14.2 V
• Hot swappable load
• Output short circuit
• Reverse polarity protection
Protection features
• Two level overcurrent protection
• Battery UVLO
• Overtemperature protection
2 Block Diagram
Figure 1 shows the block level implementation of the system.
100-W
12-V Solar Panel
Temp Sensor
Input Current Sync Buck Output Current Load Current
Oring Control Load Switch
Sense Converter Sense Sense
Telecom
Microcontroller VBAT
ICS
Equipment
VPANEL
Universal OCS LCS
AC Adaptor
(15 V at 7-A Capacity)
LDO
Figure 1.
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Copyright © 2014, Texas Instruments Incorporatedwww.ti.com System Explanation and Design
3 System Explanation and Design
3.1 Power Source Control and Monitoring
The 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 drops
below adapter (15 V), the charge controller microcontroller turns off the panel switch and turns on the
AC/DC adapter switch, which also ensures no leakage of the stronger source into the weaker one. Two
30-V, ultra-low RDS(on) FETs from TI (CSD17527Q5A) are selected for this purpose. The simple transistor is
used for proving the drive from the microcontroller.
3.2 Synchronous Buck Power Stage
The synchronous buck convertor has better efficiency and lower loss compared to asynchronous topology
because a diode on the bottom side is replaced with a low RDS(on) value. A single 30-V, 25-A power block
from TI (CSD87350Q5D) is selected for this. The advantage of a power block is the smaller package and
ease of layout eliminating parasitics of board layout of high frequency hot nodes. The microcontroller
PWM module can generate multiple PWMs on the same timer base. Each output can be configured for
different output modes, for example, toggle, reset/on, reset/off, always on, and so forth. With this flexible
logic, the user can achieve complimentary logic with required dead band. However, a driver UCC27211 is
used to enable ease of driving. The other power stage components (inductor and capacitor) calculations
are 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 Inputs
To ensure continuity to ground loop, a high-side sense circuit was used. A zero-drift instrumentation
amplifier from TI, INA282, with a 50-V/V gain, wide common-mode input range is selected for this
application.
3.4 Load Management
A simple load switch with hotswap control from TI TPS25910 is used for monitoring the load behavior. If
there is any short or overload, it immediately trips sending it into a hiccup mode on the load. The fast-trip
comparator of the microcontroller also quickly disables the PWM. This is second-level protection for the
load. To prevent the load from discharging back into the source, a blocking FET (CSD17313Q2) from TI is
used. It is controlled by the load switch.
3.5 Microcontroller
A MSP430F5132 microcontroller is used in this application. See Section 4 for further details of the
software routines.
3.6 LDO and Temperature Sensor
A simple OR’ed supply is used as the input of the LDO to ensure that power to the controller is always
available to sense any inappropriate condition. The 3.3 V generated by the LDO (TPS73801) is used to
power the MCU, LEDs, instrumentation amplifiers, and a simple thermostat TMP709, which is used for
tripping the load in case there is any abnormal increase in the temperature.
3.7 Battery Management
The section explains the battery management software portion in the microcontroller. It checks for the
state-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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• 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 Algorithm
A simple MPPT algorithm known as perturb and observe is used for controlling this system. As explained
in the PWM Resolution section, every one count of PWM timer yields 0.04% of duty cycle variation, which
is “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 more
than 1 count, tracking is faster and reduces the variation to minimize the MPP stage oscillations. This also
resembles incremental conductance method. It monitors battery/load current with respect to ΔV applied to
the converter, increasing the ΔV drives to MPP faster and at the MPP stage reduces the ΔV and settles
smoothly at MPP.
4 Software Flow
This application uses the MSP430F5132 microcontroller. The following are key features, which enable
efficient 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 Resolution
The MSP430F5132 has a special hi-resolution timer, timer-D. This timer can be programmed to generate
high switching frequency to accommodate a smaller inductor's size. This timer is clocked from the
following 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, thereby
reducing switching noise and protecting the battery from stress caused by larger voltage variations caused
in 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 bits
VOUT = D × VIN
where
• D = Duty cycle or on-time of the switch
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• 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 this
calculation. For a single bit change in D varies by approximately 4 ns in a 100-kHz period wave, which is
0.038% of VIN; if a VIN of 17, VOUT varies by 0.00646 V.
4.2 ADC Module
This device has 10-bit SAR ADC, speed can be configured for 50ksps for low power or 200ksps for faster
processing. This application can go slow, which helps to conserve additional power loss caused by the
ADC module itself (refer to the data sheet for power consumption data). This module can be operated
independently 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 available
at 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 is
required every loop, until then the CPU can be put in IDLE to conserve power.
4.3 ADC Measurement Range
This MCU has a 10-bit SAR ADC, input voltage range is 0 V to AVCC, which can be up to 3.6 V (refer to
data sheet for more electrical data). Hence, input signal strength can be from 3.3 mV per count of ADC
until 3.3 V (1023 counts) can be sensed. Sense resistors are 5 mΩ. Hence, minimum current sensible
from panel/load/battery with a gain of 50 is about 13 mA.
Power on/
Reset
Source Source
S1 S2
Panel V x I Adapter V x I
Select S1, Select S2,
Turn OFF S2
S1 ≥ S2 Turn OFF S1
Init ADC
Init PWM
Init Comparator for Tripping
Start Control Loop
Figure 2. Initialization Flow Chart
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ADC Interrupt every
100 ms
SAMPLE
• Panel Voltage (P_V)
• Panel Current (P_I)
• Battery Voltage(B_V)
• Battery Current(B_I) Wait for ADC
• Adaptor Voltage (A_V) Interrupt
• Load Current(A_I)
Yes • Disable Battery Charging Algorithm
B_V > P_V
&& • Only Load Management Thread
B_V > A_V • Turn OFF Panel and Adaptor Indicator LEDs
Yes • Panel Switch OFF, Adaptor switch ON
P_V < A_V
&& • Turn OFF Panel LED and Turn ON Adaptor
P_I ~= 0* Indicator LED
• Load Management and CC/CV Mode
• Adaptor Switch OFF, Panel switch ON Yes P_V > A_V
• Turn OFF Adaptor LED and Turn ON Panel &&
P_I > Lowest
Indicator LED
Threshold*
P_V > B_V
Yes
• Call Current Control (MPPT) and Load
&&
P_I > Threshold Management
No
• Load Management
Figure 3. Control Loop Flow Chart
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Current Control
Loop Start
(MPPT)
Sample Battery Current
I_B(n)
Yes No
I_B(n) >
I_B(n-1)
Increment PWM Decrement PWM
Duty Cycle Count Duty Cycle Count
Figure 4. MPPT Algorithm Flow Chart
Charge < 20% Charge > 95%
State of Charge
Charge > 70%
Fast Charge Topping Charge Float Charge
CC Mode CV Mode
Short
Safety Test
Temp Open Fault Wait
Figure 5. Battery Management Flow Chart
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ADC Interrupt
Every 100 ms
Run MPPT Run CC/CV
Charging Loop Charging Loop
if Solar Panel if Adapter
Powered Powered
Run Battery
Run Load
Management
Management Loop
Loop
CPU Idle
State
Figure 6. Control Loop Logic
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Copyright © 2014, Texas Instruments Incorporatedwww.ti.com Schematics
5 Schematics
PANEL CONNECTOR
BATTERY CHARGER CIRCUIT
R12 Q4 L2
P+ VP CONV_OUT
J2 10 mΩ CSD87350Q5D 10 µH
CONN-RMC-2PIN 1 2512 2 QFN5X6MM_DUAL DNP
1 1 VIN1 VSW3 8 2 1
CONN-RMC-2PIN R30
1 2 VSW2 7 L1 1 2
2 C31 + 10 µH
CONN-RMC-2PIN R37 R13 1000 µF C32 3 6 10 mΩ
20 kΩ 10 mΩ 4.7 µF TG VSW1 2 1 2512
R603 2512 4 5 IND_74436xxxx
BAT+
TGR BG
PGND BAT+ R14 C11 + C12 C13 C15 C16 R31
3.01
+
K 1206 47 µF 47 µF 22 µF 22 µF 22 µF 1 2
9
D7 CAP_EEUCF CAP_EEUCF C603 C603 C603
LED R44 10 mΩ
2512
Q3 1 kΩ
CSD17527Q5A C14
A
QFN5X6MM 3 2.2 nF
2 D10 C603
5 1 C17 C19 MMBZ5237
P-
1 µF 0.22 uF
C603 C603 R15 U11
BAT+ V3V3
R16 1206 INA28xAID
1206 SO8
R17 4 U7 1 8 R27
VP -IN +IN P+
1 kΩ UCC27211_D_8 2 7 0Ω
R603 3 GND REF1 6 R603
1 8 4 REF2 V+ 5
2 VDD LO 7 NC OUT
3 HB VSS 6
HO LI IP_SNS
C18 4 5
C
HS HI C24
B Q5 0.01 µF 0.1 µF
PAN_SW
MMBT2222ALT1 C603 C603
R32 SOT23 PANEL CURRENT SENSE
E
1 kΩ R46 2 kΩ
R603 R38
BUCK_PWM
10 kΩ
R603
SYNCB_PWM
R45 2 kΩ
U13
V3V3
C33 R43 R42 C34 INA28xAID
DNP DNP SO8
CONV_OUT
100 p 100 p 1 8 R28
BAT+ -IN +IN
2 7 0Ω
3 GND REF1 6 R603
4 REF2 V+ 5
NC OUT
ADAPTOR CONNECTOR IBAT_SNS
P+
VP C26
0.1 µF
R52 C603
70 kΩ R56
1 R47 70 kΩ
CONN-RMC-2PIN VP
Q6 74 kΩ R53 CONVERTER OUTPUT CURRENT SENSE
CSD17527Q5A R603 74 kΩ
2 QFN5X6MM 3 2N2907A R603
CONN-RMC-2PIN 2 Q8 2N2907A
5 1 VP_SNS Q9
BAT+
CONN-RMC-2PIN VADP_SNS
J3 R26 U15
ADP- V3V3
1 kΩ R51 INA28xAID
4
S
R603 R48 10 kΩ R55 SO8
S
10 kΩ R54 10 kΩ 1 8 BAT+ R29
VLOAD -IN +IN
R34 R603 D11 10 kΩ 2 7 0Ω
1 kΩ R603 D12 3 GND REF1 6 R603
BAT54S
C
AC_SW REF2 V+
R603 SOT-23 BAT54S 4 5
B Q7 SOT-23 NC OUT
A
C
MMBT2222ALT1
ILOAD_SNS
A
C
SOT23
P-
E
ADP- C28
R39 0.1 µF
C603
10 kΩ
R603 LOAD CURRENT SENSE
V3V3
V3V3
PANEL AND ADAPTOR VOLTAGE SENSE
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LOAD CURRENT CONTROL
V3V3
LOAD_ENABLE TEMPERATURE SENSOR
R6
R5 1 kΩ
U1 10 kΩ R4 U2 R603
TPS25910RSA R603 R2 26 kΩ TMP709
RSA-16 20 kΩ 1 5
1 16 R603 R7 R8 SET VCC
VIN1 EN 100 kΩ 200 kΩ R603 2
2 15 R603 R603 GND
VLOAD VIN2 FLT 3 4 C2
3 14 OT HYST 100 nF
VIN3 GND6 LOAD_ENABLE
DBV_5 C603
C
4 13
GATE GND5 B
5 12 Q2
C6 R1 GND1 OUT2 Q1 8 MMBT2222ALT1
C1
K
E
DNP 0.1 µF 40.2 kΩ 6 11 CSD17313Q2 6 J5 SOT23
D1 + C603 R603 GND2 OUT1 SON_2X2MM 5 CONN-RMC-2PIN
SMAJ20A 7
ILIM OUT
10 4 2 12 V at 4.5 A VOUT
PWPD
SMA 7 1
CAP_EEUCF
K
8 9 1 CONN-RMC-2PIN
A
GND3 GND4 D2
C4 + C3 MBR130
17
0.1 µF 47 µF D_SOD123 2
3
C603 CAP_EEUCF
CONN-RMC-2PIN
A
AGND
R33
LOAD CONNECTOR 10 mΩ
2010
C5
DNP CONN-RMC-2PIN 1 BAT+
C603 VLOAD
R11
U3 2 10 mΩ
VP A2 TPS738xxDCQR CONN-RMC-2PIN 2010
DCQ
C 1 2 V3V3 J1
IN OUT CONN-RMC-2PIN
BAT+ A1 5 R9
EN
GND1
6.8k
D6 3 4 R603 C8 C9
BAT54C R3 GND FB 10uF 0.1uF BATTERY CONNECTOR
SOT-23 C10 C7 0Ω C603 C603
6
10 µF 0.1 µF R603
C603 C603
R10 V3V3 BAT+
IBAT_SNS 4k
R603
IP_SNS J4
R40 CONN-4P-TOPENTRY R18
0Ω R22 46.8 kΩ
R603 47 kΩ 1 R603
V3V3
R36 U5 R603
0Ω C21 MSP430F5132IDAR
R603 0.1 µF DA_38P 2 VBAT_SNS
C603 1 38 ILOAD_SNS
C29 2 AVCC P3.6 37
PJ.4/XOUT P3.5 VADP_SNS
2.2 nF 3 36 3
C603 4 PJ.5/XIN NMI/SBWTDIO_RST 35
S
C23 5 AVSS SBWTCK/TEST 34 R19 C25
VBAT_SNS P1.0 P3.3
2.2nF 6 33 C22 4 10 kΩ 10 nF
C603 7 P1.2 P3.2 32 2.2 nF R603 C603 D9
VP_SNS P1.1 PJ.6
8 31 V3V3
C603 DNP BAT54S
9 P1.3 DVCC 30 R35 SOT-23
10 P1.4 DVSS2 29 C20 470 nF 47k
A
C
11 P1.5 VCORE 28 C603 R603
PJ.0 P3.1 AC_SW
12 27
PJ.1 P3.0 PAN_SW
ILOAD_SNS 13 26
14 PJ.2 P2.7 25
15 PJ.3 P2.6 24
P1.6 P2.5
V3V3
BUCK_PWM 16 23 R24
R41 R25 17 P1.7 P2.4 22 R23 1 kΩ
SYNCB_PWM P2.0 DVSS1
0Ω 1 kΩ 18 21 V3V3 1 kΩ
R603 R603 19 P2.1 DVIO 20 R603 R603
P2.2 P2.3 LOAD_ENABLE BATTERY VOLTAGE SENSE
A
A
A
AC_CHRG
LOW_BAT
BAT_CHRG
D5 D3 D4
C30 LED
CONTROLLER SECTION LED LED
2.2 nF
C603
DNP
K
K
K
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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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Figure 9. Output PWM Pulses from UCC27211
Figure 10. Load Switch Response to Short Circuit
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Figure 11. MSP430 Fast Trip Comparator Response to Load Short Circuit (EN)
SLPA013 – October 2014 Hybrid Battery Charger With Load Control for Telecom Equipment 13
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