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 ORed 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

1
2
3
4
5
6

...........................................................................................................................

Page

Design Specifications ........................................................................................... 2

Block Diagram ..................................................................................................... 2
System Explanation and Design ............................................................................ 3
Software Flow...................................................................................................... 4
Schematics ......................................................................................................... 9
Test Results ...................................................................................................... 11

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Design Specifications

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Design Specifications
Table 1. Design Specifications
Parameter

Description

VIN range
Battery specifications
Charging specifications
FSW
Output specifications

16.5 to 21 V

Adaptor

15.5 to 16 V

Capacity

12 V, 100 Ah

Charging current

7A

Voltage during CV mode charging

14.2 V

Switch frequency

100 kHz

Load current

4A

Output voltage

10.2 to 14.2 V

Protection features

Value

Panel

Hot swappable load

Output short circuit
Reverse polarity protection
Two level overcurrent protection
Battery UVLO
Overtemperature protection

Block Diagram
Figure 1 shows the block level implementation of the system.

100-W
12-V Solar Panel

Temp Sensor

Oring Control

Input Current
Sense

Sync Buck
Converter

Microcontroller

Universal
AC Adaptor
(15 V at 7-A Capacity)

Output Current
Sense

VBAT

ICS

VPANEL

OCS

LCS

Load Current
Sense

Load Switch

Telecom
Equipment

LDO

Figure 1.
2

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System Explanation and Design

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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 H, selected LOUT = 10 H, from Wurth Electronics
Selected COUT = 47 F 1; 22 F 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 ORed 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 leadacid 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

3.8

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Should not be charged above 50C

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.

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 V applied to
the converter, increasing the V drives to MPP faster and at the MPP stage reduces the V and settles
smoothly at MPP.

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-A/MHz active current, lowest current at shut down is 0.25 A
Fast wake-up, less than 5 s from stand by
200 KSPS, 10-bit ADC, with just 110-A current consumption with built-in reference
Hi-resolution timer/PWM = 4-ns minimum pulse duration, 250-A 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

Hybrid Battery Charger With Load Control for Telecom Equipment

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Software Flow

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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 m. Hence, minimum current sensible
from panel/load/battery with a gain of 50 is about 13 mA.

Power on/
Reset

Source
S1
Panel V x I

Select S1,
Turn OFF S2

Source
S2
Adapter V x I

S1 S2

Select S2,
Turn OFF S1

Init ADC
Init PWM
Init Comparator for Tripping
Start Control Loop
Figure 2. Initialization Flow Chart

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Software Flow

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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)
Adaptor Voltage (A_V)
Load Current(A_I)

Wait for ADC

Interrupt

Yes

B_V > P_V

&&
B_V > A_V

Yes
P_V < A_V
&&
P_I ~= 0*

Yes

Adaptor Switch OFF, Panel switch ON

Turn OFF Adaptor LED and Turn ON Panel
Indicator LED

P_V > B_V

&&
P_I > Threshold

Yes
No

Disable Battery Charging Algorithm

Only Load Management Thread
Turn OFF Panel and Adaptor Indicator LEDs

Panel Switch OFF, Adaptor switch ON

Turn OFF Panel LED and Turn ON Adaptor
Indicator LED
Load Management and CC/CV Mode

P_V > A_V

&&
P_I > Lowest
Threshold*

Call Current Control (MPPT) and Load

Management
Load Management

Figure 3. Control Loop Flow Chart

Hybrid Battery Charger With Load Control for Telecom Equipment

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Software Flow

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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
Duty Cycle Count

Decrement PWM
Duty Cycle Count
Figure 4. MPPT Algorithm Flow Chart

Charge > 95%

Charge < 20%

State of Charge

Charge > 70%

Fast Charge
CC Mode

Topping Charge
CV Mode

Float Charge

Short

Safety Test
Temp

Open

Fault Wait

Figure 5. Battery Management Flow Chart

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Software Flow

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ADC Interrupt
Every 100 ms

Run CC/CV
Charging Loop
if Adapter
Powered

Run MPPT
Charging Loop
if Solar Panel
Powered

Run Battery
Management
Loop

Run Load
Management Loop

CPU Idle
State
Figure 6. Control Loop Logic

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Schematics

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Schematics
PANEL CONNECTOR

BATTERY CHARGER CIRCUIT

R12
10 m

P+

J2
CONN-RMC-2PIN

VP

2512 2

Q4
CSD87350Q5D

L2
10 H

QFN5X6MM_DUAL

DNP

1 VIN1

VSW3

VSW2

CONV_OUT

1
R30

CONN-RMC-2PIN

CONN-RMC-2PIN

R37
20 k

R13
10 m

R603

2512

C31
1000 F

C32
4.7 F

L1
10 H

6
TG

5
TGR

BG

D7
LED

2512

IND_74436xxxx

BAT+

PGND

2
10 m

VSW1
3.01

R14
1206

C11
47 F

BAT+
+ C12

CAP_EEUCF

47 F

C13
22 F

C15
22 F

C16
22 F

CAP_EEUCF

C603

C603

C603

R44

R31

2
10 m
2512

Q3
CSD17527Q5A

3
2
1

QFN5X6MM

P-

1 k

BAT+

C19
0.22 uF

C603

C603

C14
2.2 nF
D10
MMBZ5237

C603

R15
1206

R16
1206

R17
1 k

C17
1 F

U11
INA28xAID
VP

R603

PAN_SW

R603

Q5
MMBT2222ALT1

R32
1 k

1
2
3
4

C18

C
B

V3V3

SO8

U7
UCC27211_D_8

VDD
HB
HO
HS

LO
VSS
LI
HI

8
7
6
5

1
2
3
4

-IN
GND
REF2
NC

+IN
REF1
V+
OUT

8
7
6
5

P+

IP_SNS
C24
0.1 F

0.01 F
C603

C603

PANEL CURRENT SENSE

SOT23

R46 2 k

R38
10 k

R27
0
R603

BUCK_PWM

R603

SYNCB_PWM
R45 2 k
C33

R43
DNP

R42
DNP

100 p

U13
INA28xAID

C34

V3V3

SO8

100 p

BAT+

1
2
3
4

ADAPTOR CONNECTOR

-IN
GND
REF2
NC

+IN
REF1
V+
OUT

8
7
6
5

CONV_OUT

IBAT_SNS
P+

C26
0.1 F

VP
R52
70 k

VP

CONN-RMC-2PIN

QFN5X6MM

R53
74 k

R603

3
2
1

CONVERTER OUTPUT CURRENT SENSE

2N2907A
Q8

R603

2N2907A
Q9

VP_SNS

U15
INA28xAID
D11
BAT54S

R603

Q7
MMBT2222ALT1

VLOAD
D12
BAT54S

R603

SOT-23

SOT23

V3V3

SO8

R55
10 k

SOT-23

R603

R54
10 k

R48
10 k

R51
10 k

1
2
3
4

-IN
GND
REF2
NC

+IN
REF1
V+
OUT

8
7
6
5

BAT+

P-

C28
0.1 F

ADP-

R39
10 k

R29
0
R603

ILOAD_SNS

R34
1 k

VADP_SNS
R26
ADP1 k
R603

AC_SW

C603

R56
70 k

R47
74 k

Q6
CSD17527Q5A

CONN-RMC-2PIN

BAT+
CONN-RMC-2PIN
J3

R28
0
R603

LOAD CURRENT SENSE

C603

V3V3

V3V3

R603

PANEL AND ADAPTOR VOLTAGE SENSE

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Schematics

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LOAD CURRENT CONTROL

R6
1 k

R5
10 k

U1
TPS25910RSA

C1
0.1 F
C603

R1
40.2 k

R603

GATE

GND5

GND1

OUT2

GND2

OUT1

ILIM

GND3

15

R7
100 k

R8
200 k

R603

R603

R603

3
14

LOAD_ENABLE

12
8
6
5
2
1

Q1
CSD17313Q2

11

SON_2X2MM

4
7

10

OUT

J5
CONN-RMC-2PIN

12 V at 4.5 A

GND4

SET

C4
0.1 F

47 F

C603

VCC

OT

HYST

C2
100 nF

DBV_5

C603

B
Q2
MMBT2222ALT1
SOT23

VOUT

CONN-RMC-2PIN

D2
MBR130

+ C3

R603

GND

13

17

CAP_EEUCF

SMA

GND6

C6
DNP

D1
SMAJ20A

FLT

VIN3

VIN2

U2
TMP709

R603

PWPD

VLOAD

16

EN

D_SOD123

CAP_EEUCF

CONN-RMC-2PIN

VIN1

R4
26 k

R2
20 k

R603

RSA-16

V3V3

TEMPERATURE SENSOR

LOAD_ENABLE

AGND
R33
10 m

LOAD CONNECTOR

2010

C5
DNP

CONN-RMC-2PIN

C603

A2

A1

5
3

D6
BAT54C
SOT-23

C10
10 F

C7
0.1 F

C603

R3
0
R603

IN

OUT

EN
GND

GND1

2
R9
6.8k

FB

R603

C8
10uF

C9
0.1uF

C603

C603

BATTERY CONNECTOR

C603

R10
4k

IBAT_SNS

V3V3

BAT+

R603

J4
CONN-4P-TOPENTRY

R40
0
U5
MSP430F5132IDAR

C603

C23
2.2nF

VBAT_SNS

C603

VP_SNS

ILOAD_SNS

R603

BUCK_PWM
SYNCB_PWM

3
4

C22
2.2 nF
C603

V3V3
C20
C603

R35
47k

470 nF
AC_SW
PAN_SW

R603

R24
1 k

R23
1 k

V3V3
LOAD_ENABLE

R603

CONTROLLER SECTION

LOW_BAT

AC_CHRG

D5
LED

C30
2.2 nF
C603
DNP

R19
10 k

C25
10 nF

R603

C603
DNP

D9
BAT54S

SOT-23

R603

R25
1 k

VBAT_SNS

ILOAD_SNS
VADP_SNS

R41
0
R603

AVCC
P3.6
PJ.4/XOUT
P3.5
PJ.5/XIN NMI/SBWTDIO_RST
AVSS
SBWTCK/TEST
P1.0
P3.3
P1.2
P3.2
P1.1
PJ.6
P1.3
DVCC
P1.4
DVSS2
P1.5
VCORE
PJ.0
P3.1
PJ.1
P3.0
PJ.2
P2.7
PJ.3
P2.6
P1.6
P2.5
P1.7
P2.4
P2.0
DVSS1
P2.1
DVIO
P2.2
P2.3

38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20

V3V3

C29
2.2 nF

R603

DA_38P

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

C603

C21
0.1 F

R603

R603

R36
0

R18
46.8 k

BATTERY VOLTAGE SENSE

V3V3

D3
LED

Hybrid Battery Charger With Load Control for Telecom Equipment

D4
LED

R603

R22
47 k

BAT_CHRG

IP_SNS

10

2010

J1
CONN-RMC-2PIN

V3V3

BAT+

VLOAD
R11
10 m

CONN-RMC-2PIN

DCQ

BAT+

U3
TPS738xxDCQR

VP

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Test Results

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Test Results

Figure 7. Variation of the Duty Cycle from the Controller

Figure 8. Seamless Transfer from Panel to Adaptor

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11

Test Results

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Figure 9. Output PWM Pulses from UCC27211

Figure 10. Load Switch Response to Short Circuit

12

Hybrid Battery Charger With Load Control for Telecom Equipment

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Test Results

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Figure 11. MSP430 Fast Trip Comparator Response to Load Short Circuit (EN)

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13

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