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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
14.2 V
Switch frequency
100 kHz
Load current
4A
Output voltage
10.2 to 14.2 V
Protection features
Value
Panel
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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3.1
3.2
3.3
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
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.
3.8
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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
Software Flow
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(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
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
Software Flow
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Yes
Yes
P_V < A_V
&&
P_I ~= 0*
Yes
Yes
No
Software Flow
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Current Control
Loop Start
(MPPT)
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
Topping Charge
CV Mode
Float Charge
Short
Safety Test
Temp
Open
Fault Wait
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
Schematics
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Schematics
PANEL CONNECTOR
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
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
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
C603
V3V3
V3V3
R603
Schematics
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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
V3V3
D3
LED
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
Test Results
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Test Results
11
Test Results
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12
Test Results
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Figure 11. MSP430 Fast Trip Comparator Response to Load Short Circuit (EN)
13
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