Order this document by AN1593/D

 


  
 
 

Prepared by: Ondrej Pauk
Industrial System Application Laboratory
Roznov, CZ

Figure 1. Low Cost Current Source for Battery Chargers Demonstration Board

This paper describes two designs of low cost current General Description
sources for battery charger applications based on the
LM2575–ADJ switching step–down converter and the Today’s most popular rechargeable battery type is NiCd.
MC33341 regulator control circuit. When overcharged, this type of battery experiences
increasing pressure inside the cell. This can cause opening
INTRODUCTION of the cell’s vent and release of oxygen. This has a
detrimental affect on the battery, although it may still retain
This design is a highly cost effective 1.0 A current source
some useful capacity. When NiMH batteries are
for battery chargers with a rectangular constant–current,
overcharged, they also increase their internal pressure and
constant–voltage charging characteristic. This feature
release some hydrogen, an extremely explosive gas.
assures a basic protection against overcharge whose results
The schematic diagram is shown in Figure 2. It is a 1.0 A
can range from minor damage to catastrophic failure of the
(maximum) “dumb” battery charger that uses the
whole system.
LM2575–ADJ switching converter to step down the input dc
This circuit was designed to implement additional charge
voltage, together with the MC33341, which regulates the
control based either on the microcontroller or on any other
charging current flowing into the battery. The switching
charging control unit in the system that operates from NiCd or
regulator has high efficiency over a wide input voltage range,
NiMH batteries. The MC33341 and this board may be used in
which allows this design to be universal. Both 12 and 24 V car
a wide variety of applications. All functions needed are
batteries as well as cheap, poorly regulated, wall adaptors
performed by just two integrated circuits and a small number
can be used.
of external components. This allows a very compact printed
The term “dumb” battery charger means that it offers only
circuit board design and a very cost effective solution.
some basic protective features and the main protective and
The LM2575–ADJ Easy Switch step down converter
control functions are maintained by a µP based main control
allows the system to operate from 8.0 to 40 Vdc, thus
unit inside the PC or the control function of a cellular phone.
allowing direct operation from both 12 and 24 V board
This concept allows a very compact and cost effective
voltages used in the automotive industry. In comparison with
design.
linear topologies of battery chargers, this circuit provides
Various charge techniques have to be used to
much better efficiency, especially over a wide input voltage
accommodate both NiCd and NiMH type batteries. Both NiCd
range.
and NiMH batteries can be charged at a high current rate

 Motorola, Inc. 1997

AN1593
(‘c’ rate) up until the charge limit is reached. After that, the In the circuit shown in Figure 2, the MC33341 control
battery has to be charged by a much lower current at the so circuit is configured for high–side current sensing. The
called ‘trickle charge’ rate. Trickle charging is a continuous voltage drop across the sense resistor RS provides a voltage
low current charging rate that keeps the battery fully charged. that is proportional to the charging current. The current
While NiCd batteries have a recommended trickle charge regulation threshold Vsen can be adjusted externally (switch
rate of about c/10, for NiMH type it is not recommended to S1 in position “2”) in the range of 0 V to 200 mV with respect
exceed a charging rate of c/40. to Pin 4 of U2. When the switch S1 is in position “1”, the
Some battery manufacturers recommend, for their current regulation threshold level is set internally to 200 mV.
chemistry, pulse charging instead of continuous current Then the regulated current can be calculated as follows:
charging. This feature can be accomplished by use of the
ON/OFF pin of the LM2575. I reg + VRS
sen + 0.2
RS
Circuit Operation Resistor R3 is required in those applications where a high
peak level of reverse current is possible, if the source outputs
Circuit operation is as follows. When a discharged battery
are shorted and the diode D2 is not used. The resistor value
is connected to the charger, the circuit operates as a constant
should be chosen to limit the input current of the internal VCC
current source. The LM2575–ADJ buck regulator is used to
clamp diode to less than 20 mA. Excessively large values for
step down an unregulated dc input voltage. This regulator is
R3 will degrade the current sensing accuracy. Resistor R3
capable of providing up to 1.0 A of charging current.The
value can be calculated from the following expression:
amount of charging current flowing into the battery is
controlled by the MC33341 regulation control circuit. This IC I – 0.6
is used to control the feedback loop in either R3 + pkRS0.02
constant–current or constant–voltage mode with automatic
crossover. The MC33341 features the unique ability to where IpkRS is a peak current flowing through the sense
perform both high–side and low–side current sensing, each resistor RS.
with either internally fixed or externally adjustable threshold Once the battery voltage reaches a predetermined level,
level. This feature makes this circuit very universal and the MC33341 begins to regulate in the constant–voltage
ideally suited for use in connection with a microcontroller mode and the charger starts to regulate the voltage across
based intelligent control systems. the battery. This voltage is monitored by Pin 5 of U2, the

Figure 2. Low Cost Switching Regulator Performs

Constant–Current/Constant–Voltage 3 Cell Charging Function
ON/OFF ON/OFF
Control
+ +Vin 5 (from Controller)
U1
LM2575–ADJ L1
1 Output
Unregulated 2 400 mH
DC – Input
C1 + 4 Feedback 3 Gnd + C2
100 mF/50 V 330 mF/16 V
Vin = 10 to 40 V
D1
R4
1.0 kW
1N5819

Gnd

RS
0.22 W A D2
+VO
1N4001
R3
27 W R2
8 7 6 39 W
C3 +
33 nF 3 Battery Cells
Under Charge
U2 –

1 MC33341 5

R1
2 3 4 10 kW

–VO

1 S1

2 Charge Current
Control
(from Controller)

2 MOTOROLA ANALOG IC APPLICATIONS INFORMATION

 AN1593
non–inverting input of the transconductance amplifier inside of a single 1.2 V cell may not be possible (depending on the
the MC33341. This voltage is divided by resistor divider R1, voltage drop on D2, if used). Also the current limit in the case
R2 to the 1.2 V internally fixed level Vth. By this arrangement of fully discharged cells or shorted output is given only by the
the battery charger output voltage threshold can be set. internal current limiting of the LM2575, as mentioned above.
Moreover, in the low–side current sensing configuration This drawback can be solved by using the circuit shown in
(refer to Figure 3) this threshold level can be externally Figure 3.
adjusted over a range of 0 to 1.2 V with respect to the U2
ground at Pin 4. The maximum battery charger output voltage Improved Battery Charger
Vreg (the voltage at the point A with respect to Pin 4 of U2) This circuit is very similar to the previous one. It uses the

ǒ ) Ǔ+ ǒ ) Ǔ
can be calculated as follows: same source IC, the LM2575 and also the same charger

V reg + Vth R2
R1
1 1.2 R2
R1
1
control IC, the MC33341 but now in the low–side current
sensing configuration.
The second difference is a different connection of the VCC
The current control loop is closed by connecting Pin 8 of pin of U2 which is the supply voltage pin of the MC33341.
U2 directly to the feedback input of the LM2575 (Pin 4 of U1). Now this VCC pin is connected directly to the unregulated dc
Under normal working conditions this pin is held at 1.23 V, input voltage through the supply current limiting resistor R5
resistor R4 is added to convert the MC33341 output current and resistor R6. The use of the coupling capacitor C4 is
to this voltage. The diode D2 protects the batteries against essential to assure a stable operation of the whole system.
discharge through U2 when the power source U1 is switched C4 transfers the ac part of the LM2575 output voltage (or the
off. For the 1N4001 diode, used in this design, the typical LM2575 output ripple voltage) through the MC33341 VCC
forward voltage drop is 0.9 V. This value must be added to the Pin 7 and output Pin 8 into the feedback Pin 4 of the LM2575.
voltage of three fully charged battery cells in series when the The way the LM2575 operates makes this connection
output voltage threshold level is chosen. Capacitor C3 is necessary. Since the maximum allowable supply voltage of
used for frequency compensation of an internal the MC33341 is 18 V, the Zener diode D3 has to be used to
transconductance amplifier. clamp the supply voltage of the MC33341to its operating limit
The circuit shown in Figure 2 provides high efficiency when the input voltage exceeds that value. Use of such an
battery charging with protection against short circuit arrangement assures that the charging control circuit U2 will
accomplished by the LM2575 internal current limiting. always have a supply voltage high enough, even under short
Because it is possible to set the output voltage threshold by a circuit conditions at the output of the battery charger. Switch
simple resistor divider, various types of battery cells, as well S1 can be used the same way as in the previous design.
as various number of cells, can be charged. Nonetheless, Switch S2 is used to alter the output voltage threshold. When
this circuit has some limitations. In the high–side current S2 is in position “1”, the voltage threshold on Pin 5 is set
sensing configuration, shown in Figure 2, the VCC Pin 7 of the internally to 1.2 V and consequently the output voltage
MC33341 is connected to the output of the power supply threshold can be set only by the resistor divider R1, R2.
circuit. Such a configuration offers the advantage of a Switching S2 to position “2” allows an external control of the
common return path for both ICs, the LM2575–ADJ and the Pin 5 voltage threshold Vth in the range of 0 V to 1.2 V. This
MC33341, but it has also a drawback. The low limit of the feature contributes to the universality of this battery charger.
MC33341 supply voltage is 1.9 V. That implies that charging

MOTOROLA ANALOG IC APPLICATIONS INFORMATION 3

AN1593

Figure 3. Low Cost Switching Regulator Performs Constant–Current/Constant–Voltage 3 Cell Charging Function.
Version with Full Short–Circuit Regulation Control Capability.
ON/OFF ON/OFF
Control
+ +Vin U1 5 (from Controller)
LM2575–ADJ L1
1 Output
Unregulated 2 400 mH
DC – Input C1 + 4 Feedback 3 Gnd + C2
Vin = 10 to 40 V 100 mF/50 V D1 330 mF/16 V
R4
1.0 kW
1N5819

Gnd C4
R5
560 W
D3 680 nF
Threshold Voltage
1N4745A R6 Control
100 W D2 (from Controller)
A +VO
1N4001
1 2
S2 R2
8 7 6 39 W
C3 +
33 nF 3 Battery Cells
R3
27 W U2 –
Under Charge

1 MC33341 5

R1
2 3 4 10 kW

–VO
RS
1 S1 0.22 W

2 Charge Current
Control
(from Controller)

Figure 4. Constant–Voltage/Constant–Current Charging Characteristic

of the Improved Current Source for Battery Chargers
6

5
VO, OUTPUT VOLTAGE (V)

0
0 0.4 0.2 0.6 0.8 1.0
IO, OUTPUT CURRENT (A)

Figure 4 shows the V/I charging characteristic of the or this diode might be replaced by shorting wire. Both actions
improved circuit (see schematic in Figure 3). The small would cause also another effect on the V/I characteristic of
voltage drop in the beginning of the V/I characteristic is this circuit. When the output voltage drops below
caused by dynamic resistance of the diode D2. This approximately 1.2 V, the output current will fall down
phenomenon can be eliminated either by reconnection of the accordingly, thus creating a typical “foldback” V/I
resistor R2 from the point “A” to the cathode of the diode D2, characteristic.

4 MOTOROLA ANALOG IC APPLICATIONS INFORMATION

 AN1593

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Table 1. Parts List (Refer to the Circuit Shown in Figure 2)

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Component Quantity Value/Rating Description

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R1 1 10 kΩ, 1/4 W Resistor

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ÁÁÁÁÁÁÁÁ
R2

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R3
1

1
39 kΩ, 1/4 W

27 Ω, 1/4 W
Resistor

Resistor

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R4

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1 1.0 kΩ, 1/4 W

0.22 Ω, 1/2 W
Resistor

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RS 1 Resistor

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C1 1 100 µF, 50 V Capacitor Electrolytic

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C2 1 330 µF, 16 V Capacitor Electrolytic

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ÁÁÁÁÁÁÁÁ
C3

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D1
1

1
33 nF

1.0 A, 40 V
Capacitor Ceramic

Schottky Diode, 1N5819

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ÁÁÁÁÁÁÁÁ
D2

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1 1.0 A, 100 V Diode, 1N4001

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ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
S1 1 – Switch

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L1 1 400 µH, 1.6 A Inductor, 77 458 BV

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U1

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U2
1

1
–

–
IC, LM2575–ADJ

IC, MC33341

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
NOTES: 1. Inductor L1: Inductance Pins 4, 6. Manufacturer: TECH 39 Power Electronic,

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Tel. +33/1–4115–1681, Fax +33/1–4409–5051.
2. All tolerances ±10%, unless otherwise specified.

Figure 5. PCB Layout Component Side Figure 6. PCB Layout Copper Side
U1 ON/OFF
Gnd –VO
D1

+Vin + C1 C2 +VO
R1

R4 +
RS
C3

L1 U2
R2
R3
D2

SW1
Current Control

Performance of the Sample Design (Refer to the Circuit Shown in Figure 2)

Input voltage range . . . . . . . . . . . 8.0 to 40 Vdc
Battery charging current . . . . . . . 0.88 A
Open output voltage . . . . . . . . . . 5.45 V
Power converter efficiency . . . . . 77%, Vin = 24 V

MOTOROLA ANALOG IC APPLICATIONS INFORMATION 5

AN1593

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Table 2. Parts List (Refer to the Circuit Shown in Figure 3)

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Component

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R1
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Quantity

1
Value/Rating

10 kΩ, 1/4 W
Description

Resistor

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R2
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1 39 kΩ, 1/4 W

27 Ω, 1/4 W
Resistor

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R3 1 Resistor

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R4 1 1.0 kΩ, 1/4 W Resistor

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R5
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R6
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1

1
560 Ω, 1.0 W

100 Ω, 1/4 W
Resistor

Resistor

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RS
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1 0.22 Ω, 1/2 W

100 µF, 50 V
Resistor

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C1 1 Capacitor Electrolytic

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C2 1 330 µF, 16 V Capacitor Electrolytic

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C3 1 33 nF Capacitor Ceramic

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C4
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D1
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1

1
680 nF

1.0 A, 40 V
Capacitor Ceramic

Schottky Diode, 1N5819

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D2 1 1.0 A, 100 V Diode, 1N4001

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D3 1 16 V, 1.0 W Zener Diode, 1N4745A

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S1 1 – Switch

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S2
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L1
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1

1
–

400 µH, 1.6 A

Switch

Inductor, 77 458 BV

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U1
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ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
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1 – IC, LM2575–ADJ

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U2 1 – IC, MC33341

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NOTES: 1. Inductor L1: Inductance Pins 4, 6. Manufacturer: TECH 39 Power Electronic,
Tel. +33/1–4115–1681, Fax +33/1–4409–5051

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2. All tolerances ±10%, unless otherwise specified.

Figure 7. PCB Layout Component Side Figure 8. PCB Layout Copper Side
U1 ON/OFF
Gnd D2 +VO
C1 C2
D1
D3

+ +
+Vin R4 R2 –VO
R3

RS

C4 U2
R1

L1
R5

C3
R6

S1 S2
MOTOROLA ISAL Roznov Current Control Voltage Control

Performance of the Sample Design (Refer to the Circuit Shown in Figure 3)

Input voltage range . . . . . . . . . . . 8.0 to 40 Vdc
Battery charging current . . . . . . . 0.88 A
Open output voltage . . . . . . . . . . 5.45 V
Power converter efficiency . . . . . 77%, Vin = 24 V

6 MOTOROLA ANALOG IC APPLICATIONS INFORMATION

 AN1593
Post–Design Recommendation Conclusion
In some cases, there is a need to compensate for a small The LM2575–ADJ step–down converter and the
voltage drop on the constant–voltage part of the V/I MC33341 regulator control circuit used in the battery charger
characteristic of this current source or to compensate a applications offer a solution which is simple, highly efficient
voltage drop across wires leading from the output of the and cost effective. The two current sources for battery
current source to the charged battery. In that case, it is chargers described in this paper can operate directly from
possible to add a resistor between Pin 5 of the MC33341 and both 12 and 24 V board voltages with no change of the
the ground of the circuit shown in Figure 3. electrical connection. This fact makes these applications
especially suitable for the automotive industry.

REFERENCES
1. LM2575 Data Sheet and Application Note; order from Motorola by LM2575/D.
2. MC33341 Data Sheet and Application Note; order from Motorola by MC33341/D.

MOTOROLA ANALOG IC APPLICATIONS INFORMATION 7

AN1593

Motorola reserves the right to make changes without further notice to any products herein. Motorola makes no warranty, representation or guarantee regarding
the suitability of its products for any particular purpose, nor does Motorola assume any liability arising out of the application or use of any product or circuit, and
specifically disclaims any and all liability, including without limitation consequential or incidental damages. “Typical” parameters which may be provided in Motorola
data sheets and/or specifications can and do vary in different applications and actual performance may vary over time. All operating parameters, including “Typicals”
must be validated for each customer application by customer’s technical experts. Motorola does not convey any license under its patent rights nor the rights of
others. Motorola products are not designed, intended, or authorized for use as components in systems intended for surgical implant into the body, or other
applications intended to support or sustain life, or for any other application in which the failure of the Motorola product could create a situation where personal injury
or death may occur. Should Buyer purchase or use Motorola products for any such unintended or unauthorized application, Buyer shall indemnify and hold Motorola
and its officers, employees, subsidiaries, affiliates, and distributors harmless against all claims, costs, damages, and expenses, and reasonable attorney fees
arising out of, directly or indirectly, any claim of personal injury or death associated with such unintended or unauthorized use, even if such claim alleges that
Motorola was negligent regarding the design or manufacture of the part. Motorola and are registered trademarks of Motorola, Inc. Motorola, Inc. is an Equal
Opportunity/Affirmative Action Employer.

Mfax is a trademark of Motorola, Inc.

How to reach us:
USA / EUROPE / Locations Not Listed: Motorola Literature Distribution; JAPAN: Nippon Motorola Ltd.: SPD, Strategic Planning Office, 4–32–1,
P.O. Box 5405, Denver, Colorado 80217. 1–303–675–2140 or 1–800–441–2447 Nishi–Gotanda, Shinagawa–ku, Tokyo 141, Japan. 81–3–5487–8488

Customer Focus Center: 1–800–521–6274

Mfax: [email protected] – TOUCHTONE 1–602–244–6609 ASIA/PACIFIC: Motorola Semiconductors H.K. Ltd.; 8B Tai Ping Industrial Park,
Motorola Fax Back System – US & Canada ONLY 1–800–774–1848 51 Ting Kok Road, Tai Po, N.T., Hong Kong. 852–26629298
– http://sps.motorola.com/mfax/
HOME PAGE: http://motorola.com/sps/

8 ◊ MOTOROLA ANALOG IC APPLICATIONS INFORMATION

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