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TC3827 Lithium-Ion Battery Charger
FEATURES
s s s s s s s s s Low Power Dissipation Shutdown Current: 1A (Typical) Space-Saving 8-Pin MSOP Package No Inductor Required 1% Overall System Accuracy Charge Current Monitor Output Charge Status Indicator Output Foldback Current Limiting -20C to +85C Ambient Operating Temperature Range
GENERAL DESCRIPTION
The TC3827 is a battery charger controller for a single cell Li-Ion battery. Using an external PMOS transistor, safe and fast charging of a single Li-Ion cell is accomplished. Features include over-current foldback, charge current monitor, and charge status LED indicator output. An overall system accuracy of 1% ensures that the cell capacity is fully utilized without cycle life degradation. An external resistor sets charge current. The TC3827 operates with an input voltage range from 4.5V to 5.5V. It is specified over the ambient operating temperature range of -20C to +85C and is available in a space-saving 8-Pin MSOP.
TYPICAL APPLICATIONS
s s s s s s s s PDAs Cradle Chargers Li-Ion Battery Chargers Desktop Computers Hand-Held Instruments Cellular Telephones Battery Operated Devices Self-Charging Battery Packs
ORDERING INFORMATION
Part No. TC3827-4.1VUA TC3827-4.2VUA Package 8-Pin MSOP 8-Pin MSOP Temperature Range -20C to +85C -20C to +85C
PIN CONFIGURATION 8-Pin MSOP
SHDN 1 GND 2 MODE 3 IMON 4 8 VIN 7 VSNS
FUNCTIONAL BLOCK DIAGRAM
VIN VSNS GND
+
C/A K
IMON
TC3827
6 VDRV 5 VOUT
- +
E/A
-
TYPICAL APPLICATION CIRCUIT
+
RSENSE +5 VIN 10F LED VIN VSNS VDRV VOUT MODE IMON SHDN Controller MODE IMON SHDN NDP6020P PMOS
CONTROL BLOCK
VDRV
MODE
VOUT
E/A VREF
-
SHDN
TC3827
TC3827
GND
+
22F Li-Ion
-
Figure 1. TC3827 Typical Application Circuit
(c) 2001 Microchip Technology Inc. DS21558A
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Lithium-Ion Battery Charger
TC3827
ABSOLUTE MAXIMUM RATINGS*
Input Voltage (VIN), VOUT, VSNS, MODE, and IMON ........... .............................................................. -0.3V to 6.0V SHDN ...............................................-0.3V to (VIN + 0.3V) 8-Pin MSOP (derate 4.1mW/C above +70C) ..... 330mW Operating Ambient Temperature Range .. -20C to +85C Storage Temperature Range ................. -65C to +150C Lead Temperature (Soldering, 10 sec) ................. +300C Vapor Phase (60 sec) ........................................... +210C Infrared (15 sec) .................................................... +220C IIMON (source) ......................................................0.375mA IMODE (sink) .............................................................. 20mA IDRV ............................................................................1mA ESD Rating ................................................................. 2kV
*Static-sensitive device. Unused devices must be stored in conductive material. Protect devices from static discharge and static fields. Stresses above those listed under Absolute Maximum Ratings may cause permanent damage to the device. These are stress ratings only and functional operation of the device at these or any other conditions above those indicated in the operational sections of the specifications is not implied. Exposure to Absolute Maximum Rating Conditions for extended periods may affect device reliability.
ELECTRICAL CHARACTERISTICS: VIN = [VREG + 1V] , TA = -20C to +85C, unless otherwise noted. Typical values
at TA = +25C, RSENSE = 500m, Test Circuit Figure 3. Symbol
IVIN
Parameter
Power Supply Current
Test Conditions
Shutdown Mode, VSHDN = 0V Constant Voltage Mode
Min
-- -- 4.5 -- -- -1 -10 -1 -- -- 0.08 -- -- 40 -- -- -- -- --
Typ
1 350 -- 4.2 4.1 -- -- 0.2 1 -- -- 1.0 100 53 46 0.46 VREG -- --
Max
15 560 5.5 -- -- +1 +10 +1 5 1 -- -- -- 75 -- -- -- 400 +1
Units
A V V % mV mV A mA V dB mV mA A/A V mV A
VIN Power Supply Voltage In Voltage Regulation (Constant Voltage Mode) VREG Battery Regulation Volts 3827- 4.2VUA 3827- 4.1VUA VOUT Output Voltage Accuracy VIN = VREG + 1V to 5.5V, LIREG Line Regulation VIN = 4.5V to 5.5V, IOUT = 75mA LDREG Load Regulation IOUT =10mA to 75mA IDISCH Output Reverse Leakage VIN = Floating, VOUT = VREG MOSFET Gate Drive IDRV Gate Drive Current Sink, Constant Voltage Mode (Note 1) Source, Constant Voltage Mode (Note 1) VDRV Gate Drive Min Voltage Current Sense Amp VGAIN GAIN (VGS/VOUT) VCS Current Limit Threshold (VIN - VSNS) @ IMAX ISC Short Circuit Current K KFactor MODE VTH Mode Threshold VOL Mode Low Voltage ISINK = 10mA, VOUT = 3.5V ILK Mode Leakage Current VMODE = 5.5V, IO = 0mA, MODE = Constant Voltage SHDN VIH SHDN High Threshold VIL SHDN Low Threshold ILK SHDN Leakage Current VSHDN = 0V to 5V IMON VIMON Current Sense Gain VO = 0V to 3.5V,RL > 20k (VIN - VSNS)
Notes: 1. Where VOUT = 1% from Nominal, continuous current.
40 - -- --
-- -- -- 26
-- 25 +1 --
%VDD %VDD A V/V
TC3827-2 12/12/00
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(c) 2001 Microchip Technology Inc.
DS21558A
Lithium-Ion Battery Charger
TC3827
PIN DESCRIPTION
Pin No. 8-Pin MSOP 1 2 3 4 5 6 7 8 Symbol SHDN GND MODE IMON VOUT VDRV VSNS VIN Type Signal Input Power Signal Output Voltage Output Voltage Input Signal Output Signal Input Power Description Shutdown Input System Ground Charge Mode Indicator Buffered Copy of Current Sense Resistor Drop Charger DC Output Voltage Sense Gate Drive to External MOSFET Current Sense Voltage Input Charger DC Input Voltage
I/O DESCRIPTION
SHDN: When SHDN is low, VDRV is pulled high to VIN and the charge is interrupted. GND: Connect to the battery's negative terminal. See Layout Guidelines for information on system grounding. VOUT: Battery positive terminal and charger regulated output voltage.This pin is connected to the external PMOS drain and directly to the load for optimal regulation. VOUT pin draws typically 1A from the battery when VIN power is removed. Requires a Bypass capacitor. MODE: Charge Status Indicator. Mode is an open-drain, N-channel MOSFET capable of sinking 20mA for an LED status indication of charger in current limited mode. LED is off in current-voltage mode. VDRV: Gate drive output for the external PMOS pass device. IMON : Battery Charge current profile. This output is an amplified copy of the voltage drop across the current sense resistor. It can be used as input to an A/D converter to provide the controller with information about the charge current profile. VIN: Charger power supply input (+6V absolute max.). Bypass to GND with a capacitor. VSNS: Battery charge current sense voltage feedback. This voltage is developed across a small value precision resistor that is in series with the battery.
FUNCTIONAL DESCRIPTION
The TC3827 controller only requires a P-channel power MOSFET and two small capacitors to perform as an inexpensive Li-Ion battery charger. The TC3827 controller drives an external PMOS to provide a regulated output current to charge the battery. Initially, current limited charging occurs until a pre-specified battery voltage is measured at the VOUT pin. It then switches to constant-voltage mode. During constant-voltage mode the TC3827 works like a linear regulator, holding the output voltage within the specified accuracy. The charger output is sensed at the VOUT pin. The charging current follows the foldback characteristic as shown in Figure 2. The sense resistor sets the maximum charging current, IMAX. The voltage drop across the current sense resistor is sensed at the VSNS input. An amplified copy of this sense voltage is provided as output on the current monitor pin (IMON). When the battery is deeply discharged to a minimum voltage level, or if the battery is shorted, the current sense circuit folds back the charge current to limit the power dissipation of the PMOS. Both the VIN and VOUT pins
(c) 2001 Microchip Technology Inc. DS21558A
of the IC need a suitable bypass capacitor. The TC3827 also has a logic-level shutdown input, SHDN, which may be connected to the input voltage to enable the IC. Pulling it "low" or to ground will disable the PMOS drive (VDRV pulled up to VIN voltage). Also, a charger mode pin (MODE) is provided to drive an optional LED for a visual indication of current limited mode operation. LED will be turned off in constant voltage mode operation.
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TC3827
APPLICATIONS INFORMATION
A typical Li-Ion cell should be charged at a controlled current until it reaches 4.1V or 4.2V (depending on the type of cell), then charged at this voltage. The TC3827 is designed to offer the maximum integration and function with a small application circuit. The only necessary external components are a PMOS , two small capacitors, and an RSENSE. The charge current profile can be monitored using the voltage signal at IMON. The use of an LED as a status indicator is optional. The application circuit is shown in Figure 1.
VOUT
R SENSE=500m
NDP6020P PMOS S D G
VREG
IREG Constant Voltage Mode Foldback Current Limited Mode
VIN
IMAX
10F
VIN
VSNS
VDRV VOUT VOUT 22F GND
IFOLDBACK
MODE
TC3827
IMON
SHDN
ISC
IOUT
Figure 2. TC3827 Charging Characteristic
Figure 3. TC3827 Test Circuit
SELECTING EXTERNAL COMPONENTS Power Supply Input
In most applications, this will be a small "wall cube" switching converter with an output voltage limit range of 5V to 6V.
CHARGER MODES DESCRIPTION Initiating a Charge Cycle
The TC3827 initiates a charge upon toggling the shutdown pin high, insertion of the battery or application of an external power source. The TC3827 provides a foldback current limited charge where an external current sense resistor sets IMAX. The voltage drop across the current sense resistor is applied to the VIN -VSNS pins and presented to the current limited control-loop.The current loop will protect a deeply discharged (or shorted) battery by folding back the current limited charge, and reduces the power dissipation in PMOS.
P-Channel Pass Device
The PMOS is used to regulate current from the source into the Li-Ion cell. Specifications to consider when choosing an appropriate PMOS are the minimum drain-source breakdown voltage, the minimum turn-on threshold voltage (VGSTH), drain current and power-dissipation capabilities.
Bypass Capacitors
Bypass VIN with a capacitor value of at least 10F. Bypass VOUT with a capacitor value of at least 1F.
Current Limited, Constant-voltage Charge Cycle
The TC3827 begins to charge the Li-Ion cell by turning on the external PMOS. The charge continues until the battery voltage rises to the lithium-ion cell voltage of 4.2V or 4.1V (depending on type of cell). As the battery voltage reaches the regulated output voltage, the internal feedback
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(c) 2001 Microchip Technology Inc. DS21558A
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Lithium-Ion Battery Charger
TC3827
control loop changes from current limiting to voltage regulation. If an external micro-controller determines battery conditions are unsafe for charge it can toggle the shutdown pin low and interrupt the charge cycle. Otherwise, once the predetermined cell voltage is reached the TC3827 shifts into a constant-voltage mode (linear regulation) and a variable charge current is applied as required to maintain the battery cell voltage to within 1% accuracy of the cell voltage setpoint.
Higher Current Option
The current sense resistor for the circuit shown in Figure 1 is calculated by: RSENSE = VCS /IMAX . Where VCS is the current limit threshold voltage of 40mV to 75mV, 50mV typical. If IMAX = 1A is desired, RSENSE = 50m. Pre-regulated Input Voltage (5V 0%) For this application, the required JA thermal impedance is calculated as follows:
IMON - Charge Current Status
The IMON pin provides an output voltage that is proportional to the battery charging current . It is an amplified version of the sense resistor voltage drop that the current loop uses to control the PMOS device. This voltage signal can be applied to the input of an A/D Converter and used by a controller to display information about the state of the battery or charge current profile.
if: then:
the PMOS data sheet allows a max junction temperature of TJMAX = 150C, at 50C ambient with convection cooling, the maximum allowed junction temperature rise is:
MODE - Charge Mode Status LED
The MODE pin indicates the battery charging mode. An LED can be connected to the MODE for a visible indicator. Alternatively, a pull-up resistor (typically 100k) from the interfacing logic supply to MODE provides a logic-level output. The MODE pin will toggle LOW and the LED will illuminate when the charger is in the current limited mode. The MODE pin toggles to a high impedance state and the LED will be off during constant-voltage mode charging or if the battery is not connected. The MODE pin toggles at a VOUT of VREG, typically.
TJMAX - TAMAX = 150C - 50C = 100C.
JA = T/(IOx k x VIN) = 100/(1 x 0.46 x 5.5) = 39.5 C/W This k factor is: k = ISC/IMAX 0.46. This thermal impedance can be realized using the transistor shown in Figure 1 when mouted to a heat sink. The SA or thermal impedance of a suitable heatsink is calculated below: SA (JA - JC - CS) = 39.5 - 2.5 - 0.3 = 36.7C/W Where the JC, or junction-to-case thermal impedance is for the PMOS from the PMOS data sheet. A low cost heatsink is Thermalloy type PF430, with a SA = +25.3C/W.
APPLICATION CIRCUIT DESIGN
Due to the low efficiency of Linear Regulator Charging, the most important factors are thermal design and cost, which is a direct function of the input voltage, output current and thermal impedance between the PMOS and the ambient cooling air. The worst-case situation is when the battery is shorted since the PMOS has to dissipate the maximum power. A tradeoff must be made between the charge current, cost and thermal requirements of the charger. Higher current requires a larger PMOS with more effective heat dissipation leading to a more expensive design. Lowering the charge current reduces cost by lowering the size of the PMOS, possibly allowing a smaller package such as 6-Pin SOT. The following designs consider both options.
(c) 2001 Microchip Technology Inc.
DS21558A
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TC3827
Lower Current Option
Preregulated Input Voltage (5V +/- 10%) The selected PMOS must satisfy these criteria. If lower charging current is allowed, the JA value can be increased, and the system cost decreased. This is accomplished by using a FDC638P PMOS, for example, in a 6-Pin SOT package mounted on a small 1in x 1in area of 2oz Cu on FR-4 board. This provides a convection cooled thermal impedance of JA = +78C/W. Allowing a maximum FET junction temperature of +150C, at +50C ambient, with convection cooling the maximum allowed heat rise is: 150C-50C = 100C. The maximum short circuit current, ISC, is found as: ISC = T/(JA x VIN) = 100/(78 x 5.5) = 0.23A Thus the maximum charging current, IMAX, is: IMAX = ISC/k = 0.51A The current sense resistor for this application is then: RSENSE = VCS/IMAX = 0.05/0.51 = 98m 100m RDS(ON) = VDS/IMAX 0.725V/1A = 725m
External Capacitors
The TC3827 is stable with or without a battery load, and virtually any good quality output filter capacitors can be used, independent of the capacitor's minimum ESR (Effective Series Resistance) value. The actual value of the capacitor and its associated ESR depends on the gm and capacitance of the external PMOS device. A 22F tantalum or aluminum electrolytic capacitor at the output is sufficient to ensure stability for up to a 10A output current.
Shutdown Mode
Applying a logic high signal to the SHDN pin or tying it to the input pin will enable the output. Pulling this pin low or tying it to ground will disable the output. In shutdown mode, the controller's quiescent current is reduced to typically 1A.
Short Circuit Protection
The PMOS is protected during short circuit conditions with a foldback type of current limiting that reduces the power dissipation.
FET Selection
The type and size of the pass transistor is determined by the threshold voltage, input-output voltage differential and load current. The selected PMOS must satisfy the physical and thermal design requirements. To ensure that the maximum VGS provided by the controller will turn on the FET at worst case conditions, (i.e., temperature and manufacturing tolerances) the maximum available VGS must be determined. Maximum VGS is calculated as follows: VGSMAX = VIN - (IMAX x RSENSE) - VDRVMAX For example: VIN = 5V, and IMAX = 1A, VGSMAX = 5V - (1A x 50m) - 1V= 3.95V
Current Sense Resistor
The current limit sense resistor, RSENSE, is calculated previously. Proper de-rating is advised to select the power dissipation rating of the resistor. The simplest and cheapest sense resistor for high current applications, is a PCB trace. However, the temperature dependence of the copper trace and the thickness tolerances of the trace must be considered in the design. Copper's Tempco, in conjunction with the proportionalto-absolute temperature (0.3%) current limit voltage, can provide an accurate current limit. Alternately, an appropriate sense resistor, such as surface mount sense resistors, available from KRL, can be used.
PCB Layout Issues
For optimum voltage regulation, place the load as close as possible to the device's VOUT and GND pins. It is recommended to use dedicated PCB traces to connect the PMOS drain to the positive terminal and VSS to the negative terminal of the load to avoid voltage drops along the high current carrying PCB traces. If the PCB layout is used as a heatsink, adding many vias around the power FET helps conduct more heat from the FET to the back-plane of the PCB, thus reducing the maximum FET junction temperature.
The difference between VIN and VO (VDS) must exceed the voltage drop due to the sense resistor plus the ONresistance of the PMOS at the maximum charge current. VDS VIN - VO - VCS = 5V - 4.2V - 0.075V = 0.725V The maximum RDS(ON) required at the available gate drive (VDR) and Drain-to-Source voltage (VDS) is:
TC3827-2 12/12/00
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(c) 2001 Microchip Technology Inc.
DS21558A
Lithium-Ion Battery Charger
TC3827
TYPICAL CURVES
VOUT vs ILOAD (VIN=5.1V)
4.110
4.110
VOUT vs VIN (ILOAD=1A)
4.105
4.105
VOUT - V
VOUT - V
0 200 400 600 800 1000
4.100
4.100
4.095
4.095
4.090
4.090 4.5 4.6 4.7 4.8 4.9
ILOAD - mA
5.0 VIN - V
5.1
5.2
5.3
5.4
5.5
Figure. 4
VOUT vs VIN (ILOAD=10mA)
0.300
Figure. 5
IGND vs VIN (ILOAD=10mA)
4.110
4.105
0.290 0.280
IGND - mA
VOUT - V
0.270 0.260 0.250 0.240 0.230 0.220 0.210
4.100
4.095
4.090 4.5
0.200
4.6
4.7
4.8
4.9
5.0 VIN - V
5.1
5.2
5.3
5.4
5.5
4.5
4.6
4.7
4.8
4.9
5.0 VIN - V
5.1
5.2
5.3
5.4
5.5
Figure. 6
IGND vs VIN (ILOAD=1A)
0.500 0.450 0.400
Figure. 7
IGND vs ILOAD (VIN = 5.1V)
0.500
0.400
IGND - mA
0.350 0.300 0.250 0.200 4.5 4.6 4.7 4.8 4.9 5.0 5.1 5.2 5.3 5.4 5.5
IGND - mA
0.300
0.200
0.100
0.000 0.001
0.01
0.1
1 ILOAD - mA
10
100
1000
VIN - V
Figure. 8
Figure. 9
(c) 2001 Microchip Technology Inc.
DS21558A
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TC3827-2 12/12/00
Lithium-Ion Battery Charger
TYPICAL CURVES (CONT.)
TC3827
IGND vs Temperature (VIN = 5.1V, ILOAD = 10mA)
0.500 0.450 0.400 0.350
4.5 4.0 3.5 3.0
Power-Up/Power-Down (ILOAD=10mA)
IGND - mA
0.250 0.200 0.150 0.100 0.050 0.000 -20.0 0.0 20.0 40.0 60.0 80.0
VOUT - V
0.300
2.5 2.0 1.5 1.0 0.5 0.0 0.0 1.0 2.0 3.0 4.0 5.0 VIN - V 4.0 3.0 2.0 1.0 0.0
TEMPERATURE - C
Figure. 10
Current Limit Foldback (VIN = 5.1V, RSENSE=0.5Ohms) 5.000
4.220
Figure. 11
VOUT vs Temperature (VIN = 5.1V, ILOAD = 10mA)
4.000 3.000
VOUT - V
4.200 4.180
VOUT=
2.000 1.000 0.000 0 20 40 60
ILOAD -mA
VOUT - V
4.160 4.140 4.120 4.100 VOUT
80
100
120
4.080 -20.0
0.0
20.0
40.0
60.0
80.0
TEMPERATURE - C
Figure. 12
Line Transient Response (10F Output Cap)
Figure. 13
VOUT - V
5.5 4.5
VOUT - V
4.2 4.1 4.0
Figure. 14
TC3827-2 12/12/00
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(c) 2001 Microchip Technology Inc.
DS21558A
Lithium-Ion Battery Charger
TC3827
TAPING FORM
Component Taping Orientation for 8-Pin MSOP Devices
User Direction of Feed
PIN 1
User Direction of Feed
W
PIN 1 Standard Reel Component Orientation for TR Suffix Device
P
Reverse Reel Component Orientation for RT Suffix Device
Carrier Tape, Number of Components Per Reel and Reel Size
Package Carrier Width (W) Pitch (P) Part Per Full Reel Reel Size
8-Pin MSOP
12 mm
8 mm
2500
13 in
PACKAGE DIMENSIONS
8-Pin MSOP
PIN 1
.122 (3.10) .114 (2.90)
.197 (5.00) .187 (4.80)
.026 (0.65) TYP.
.122 (3.10) .114 (2.90) .043 (1.10) MAX. .016 (0.40) .010 (0.25) .006 (0.15) .002 (0.05)
6 MAX. .028 (0.70) .016 (0.40)
.008 (0.20) .005 (0.13)
Dimensions: inches (mm)
(c) 2001 Microchip Technology Inc.
DS21558A
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Printed in the U.S.A. TC3827-2 12/12/00
Lithium-Ion Battery Charger
TC3827
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All rights reserved. (c) 2001 Microchip Technology Incorporated. Printed in the USA. 1/01
Information contained in this publication regarding device applications and the like is intended through suggestion only and may be superseded by updates. It is your responsibility to ensure that your application meets with your specifications. No representation or warranty is given and no liability is assumed by Microchip Technology Incorporated with respect to the accuracy or use of such information, or infringement of patents or other intellectual property rights arising from such use or otherwise. Use of Microchipis products as critical components in life support systems is not authorized except with express written approval by Microchip. No licenses are conveyed, implicitly or otherwise, except as maybe explicitly expressed herein, under any intellectual property rights. The Microchip logo and name are registered trademarks of Microchip Technology Inc. in the U.S.A. and other countries. All rights reserved. All other trademarks mentioned herein are the property of their respective companies.
TC3827-2 12/12/00
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