MP2659 Reference Design

12V Lead Acid Battery Charge Solution

MP2659 Reference Design

12V Lead-Acid Battery Charging Solution

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 MP2659 Reference Design
12V Lead-Acid Battery Charging Solution

Contents
1 Overview ............................................................................................................................................ 2
1.1 Description ..................................................................................................................................... 2
1.2 Features ..................................................................................................................................... 2
1.3 Applications ................................................................................................................................ 2
2 Reference Design .............................................................................................................................. 3
2.1 Block Diagram ............................................................................................................................ 3
2.2 Related Solutions ....................................................................................................................... 3
2.3 System Specifications ................................................................................................................ 3
3 Design ............................................................................................................................................... 4
3.1 Design Method ........................................................................................................................... 4
3.2 Schematic ................................................................................................................................... 5
3.3 BOM ........................................................................................................................................... 8
3.4 PCB Layout .............................................................................................................................. 10
4 Test Results ..................................................................................................................................... 12
4.1 Efficiency .................................................................................................................................. 13
4.2 Time Domain Waveforms ......................................................................................................... 13
4.3 Thermal Measurements............................................................................................................ 15
5 Start-Up ........................................................................................................................................... 16
5.1 Connectors and Jumpers ......................................................................................................... 16
5.2 Quick Start Guide ..................................................................................................................... 16
6 Disclaimer ........................................................................................................................................ 18

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12V Lead-Acid Battery Charging Solution

1 Overview
1.1 Description
Lead-acid batteries are widely used in battery-powered devices due to their advantages, such as a stable
voltage, low price, simple maintenance, and high reliability. However, there are few chips on the market
that are designed specifically for applications that charge lead-acid batteries.
This reference design showcases a lead-acid battery charging solution. The solution uses the MP2659,
a highly integrated switching charger designed for portable devices with 3-cell to 6-cell series Li-ion or Li-
polymer battery packs.
1.2 Features
 Up to 36V Operating Input Voltage
 45V Maximum Sustainable Voltage When Not Switching
 Up to 3A Charge Current
 1-Cell, 12V Lead Acid Battery
 0.5% Reference Voltage Accuracy
 Input Current Limit Regulation
 Minimum Input Voltage Regulation
 Charge Operation Indicator
 Dead Battery Pack Recovery
 Battery Over-Voltage Protection (OVP)
 Configurable Safety Timer
 Battery NTC Thermal Monitor
1.3 Applications
 Industrial Medical Equipment
 Power Tools
 Robot and Portable Vacuum Cleaners
 Wireless Speakers
All MPS parts are lead-free and adhere to the RoHS directive. For MPS
green status, please visit the MPS website under Quality Assurance.
“MPS”, the MPS logo, and “Simple, Easy Solutions” are registered
trademarks of Monolithic Power Systems, Inc. or its subsidiaries.
Warning: Although this board is designed to satisfy safety
requirements, the engineering prototype has not been agency
approved. Therefore, all testing should be performed using an
isolation transformer to provide the AC input to the prototype
board.

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12V Lead-Acid Battery Charging Solution

2 Reference Design
2.1 Block Diagram
Figure 1 shows a block diagram for a highly integrated switching charger for lead-acid batteries. This
application has a 40W output capability and an input voltage up to 36V. To adjust the regulation voltage
of the lead-acid batteries, adjust the resistance of the voltage dividers.

IN BATT

Battery Voltage
Loop
BATT

EA
VBATT_REF

Integrated
Charger IC

Figure 1: Block Diagram

2.2 Related Solutions
This reference design is based on the following MPS solution:
Table 1: System Specifications
MPS Integrated Circuit Description
36V, standalone switching charger with
MP2659 integrated MOSFETs, 3-cell to 6-cell series
battery pack

2.3 System Specifications

Table 2: System Specifications
Parameter Specification
Input voltage range 4.5V to 36V
Output voltage Up to 14.4V
Maximum output current 3A
Switching frequency 680kHz or 350kHz (under nominal conditions)
Efficiency >92%

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12V Lead-Acid Battery Charging Solution

3 Design
3.1 Design Method
Figure 2 shows an application circuit to charge lead-acid batteries with OR-selection power path
management. The circuit’s power stage uses one inductor (L1) and three capacitors (CIN, CPMID, and
CBATT). With the addition of external components, the complete charging function with power path
management can be implemented.
QIN
Power Input System

ZD 2
ZD 1
IN D1
Q BATT
50kΩ
1MΩ
CPMID

10kΩ 10kΩ

PMID_S PMID
BST
Q1 Q2
L1
SW

IN R1 CBATT
CIN
BATT
Q3
R2
ACOK ISET
ACOK
VDPM

ILIM CEL
Cell Count Setting
L
VCC
VCC

VCC
STAT
NTC
Full-Charge
Voltage Setting VB
PGND AGND

Figure 2: Application Circuit

OR-selection power path management can be realized with two P-channel MOSFETs and other
components (e.g. ZD1, ZD2, D1, and resistors). When there is no input source, QBATT turns on and
transfers energy from the battery to the system. When an input source is present, QBATT turns off, and the
system’s power is supplied by the input source from QIN.
The MP2659 is designed for 3-cell to 6-cell series Li-ion and Li-polymer batteries. Each cells has a
regulated battery voltage (3.6V, 4.15V, 4.2V, or 4.35V). To charge a lead-acid battery, there is a specific
regulated battery voltage that can be set using resistor dividers (R1 and R2). R1 and R2 can be calculated
with Equation (1):

R2 V
= BATT_REG (1)
R1 +R2 VBATT_TERM

Where VBATT_REG = the number of cells multiplied by VBATT_CELL (set by the CELL and VB pins), and
VBATT_TERM is the lead-acid battery’s termination voltage. R1 should range between 2kΩ and 5kΩ.

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12V Lead-Acid Battery Charging Solution

3.2 Schematic

Figure 3: MP2659 Solution Schematic

Figure 3 shows MP2659 solution schematic. To create this schematic, follow the guidelines below:
1. This circuit can work safely under applications where VIN < 20V.
2. For applications where VIN exceeds 20V, place a ≥47µF electrolytic capacitor between VIN and GND.
Add a Schottky diode with a higher current capacity (e.g. B240A) between VIN and PMID. Use a TVS
diode to clamp the VIN voltage if its voltage spike reaches 45V.
3. Consider the voltage spike on PMID during battery insertion. Add an extra TVS diode to clamp the
PMID voltage if its voltage spike reaches 45V.
4. The inductor on this evaluation board can only be used in applications where f SW = 680kHz or
ICC < 2.2A. For applications where fSW = 350kHz and ICC > 2.2A, select an inductor with a higher
inductance or higher saturation current.
5. For more component selection information, refer to the MP2659 datasheet.
Table 4 lists recommended components for applications where VIN exceeds 20V.

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12V Lead-Acid Battery Charging Solution

Table 4: Component Selections

Pin Condition Recommendations
Add a 1µF/50V ceramic capacitor to the IN pin for adaptor applications. Add a
≤20V input
≥47µF capacitor for solar applications.
IN Add a 47µF/50V electrolytic capacitor to the IN pin. A TVS diode is required if
>20V input the IN voltage exceeds the pin’s maximum voltage rating during the VIN hot-
insertion test.
3-cell or 4-cell Add a 10µF/50V ceramic capacitor to the BATT pin.
BATT
5-cell or 6-cell Add a TVS diode or ≥47µF electrolytic capacitor to the BATT pin.
Add a 2.2µF/50V ceramic capacitor (1206 size preferred) to the PMID pin. Add
a 2A/40V Schottky diode from IN to PMID. A TVS diode is required if the PMID
PMID -
voltage exceeds the pin’s maximum voltage rating during the VBATT hot-
insertion test.

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3.3 BOM
Table 3: Bill of Materials
Qty Ref Value Description Package Manufacturer Manufacturer P/N
1 C1 Electrolytic capacitor, DIP CD287-50V10
10µF Jianghai
50V
Ceramic capacitor ,
1 C2 1µF 1206 Wurth 885012208093
50V, X7R, 1206
Ceramic capacitor, GRM188R71H104
1 C4 100nF 0603 Murata
50V, X7R, 0603 KA93D
Ceramic capacitor, GRM31CR71H225
1 C6 2.2µF 1206 Murata
50V, X7R, 1206 KA88L
Ceramic capacitor,
1 C7 1µF 0805 Wurth 885012207078
25V, X7R, 0805
Ceramic capacitor. GRM31CR61H106
1 C8 10µF 1206 Murata
50V. X5R KA12L
Electrolytic capacitor,
1 C9 100µF DIP Rubycon 50YXF100MEFC
50V, 100μF
Inductor, 10μH, 35m,
1 L1 10µH SMD Wurth 744066100
4A
1 ACOK Red Red LED 0805 Bright LED F3D02R-4A
1 CHG Green Green LED 0805 Bright LED F3D02HG-1A
RC0603FR-
1 R1 3.57kΩ Film resistor, 1% 0603 Yageo
073K57L
RC0603FR-
2 R2, R18 51.1kΩ Film resistor, 1% 0603 Yageo
0751K1L
R15, R16, RC0603FR-
4 95.3kΩ Film resistor ,1% 0603 Yageo
R10, R12 0795K3L
1 R3 1kΩ Film resistor, 1% 0603 Yageo RC0603FR-071KL
RC0603FR-
1 R4 10.5kΩ Film resistor, 1% 0603 Yageo
0710K5L
RC0603FR-
1 R5 8.25kΩ Film resistor, 1% 0603 Yageo
078K25L
RC0603FR-
1 R6 3.48kΩ Film resistor, 1% 0603 Yageo
073K48L
RC0603JR-
2 R7, R8 100kΩ Film resistor, 5% 0603 Yageo
07100KL
RC0603FR-
2 R9, R11 196kΩ Film resistor, 1% 0603 Yageo
07196KL
1 R13 2kΩ Film resistor, 1% 0603 Yageo RC0603FR-072KL
1 R14 10kΩ Film resistor, 5% 0603 Yageo RC0603JR-0710K
RNTC1,
2 10kΩ Film resistor, 1% 0603 Yageo RC0603FR-0710KL
R17
1 RNTC2 15kΩ Film resistor, 1% 0603 Yageo RC0603FR-0715KL
1 R19 1MΩ Film resistor, 5% 0603 Yageo RC0603JR-071ML
QFN-19
3-cell to 6-cell battery
1 U1 MP2659 (3mmx MPS MP2659GQ-0000
charger
3mm)
1 D1 Diode Diode, 75V, 0.15A SOD-123 Diodes 1N4148W

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12V Lead-Acid Battery Charging Solution

Schottky diode. 40V.

1 D2 30V SMA Diodes B140
1A
2 ZD1, ZD2 12V Zener diode, 12V SOD-123 Diodes BZT52C12
QIN, P-channel MOSFET,
2 60V, 23mΩ SO-8 Analog Power AM4417P
QBATT 60V, 23mΩ
VIN, GND,
4 GND, 2mm 2.0mm male needle DIP Any
BATT
TP5, TP6,
4 Test point Test point DIP Any
TP7, TP8
TP9,
TP10, GND test
4 GND test point SMD Any
TP11, point
TP12
VDPM,
GND,
VCC,
NTC,
ACOK,
15 STAT 2.54mm 2.54mm connector DIP Any
JP1, JP2,
JP3, JP4,
JP5, JP6,
JP7, JP8,
JP9
JP1, JP3,
5 JP5, JP6, Sub-block Sub-block DIP Any
JP8

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3.4 PCB Layout

The PCB layout in Figure 4, Figure 5, Figure 6, and Figure 7 refers to the standard MP2659 evaluation
board.

Figure 4: Top Layer

Figure 5: Middle Layer 1

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Figure 6: Middle Layer 2

Figure 7: Bottom Layer

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12V Lead-Acid Battery Charging Solution

4 Test Results
The EV2659-Q-03A was used to test the12V lead-acid battery charging process.
To fine-tune the battery regulation voltage to charge lead-acid batteries, add an auxiliary circuit (see
Figure 8).

IN SW BATT

R1

MP2659 BATT

R2

ACOK

Figure 8: Auxiliary Circuit to Fine-Tune Battery Voltage Regulation

For OR-selection power path management, add an auxiliary circuit (see Figure 9).
QIN
Power Input System

ZD2
ZD1
IN D1
QBATT
50kΩ
1MΩ

10kΩ 10kΩ

Q1 Q2
SW BATT

CIN IN

Q3
ACOK

MP2659

Figure 9: Auxiliary Circuit for OR-Selection Power Path Management

For OR-selection power path management (and to ensure that VBATT_TERM = 13.96V) with the auxiliary
circuit, set the following parameters on the evaluation board:
 Cell numbers = 3
 VB = 4.35V/cell
Set the following parameters for the auxiliary circuit:
 R1 = 3.57kΩ
 R2 = 51.1kΩ
 QIN = QBATT = AM4417P
 ZD1 = ZD2 = BZT52C12
 D1 = 1N4148W

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4.1 Efficiency
L = 10µH/35mΩ, fSW = 680kHz, and TA = 25°C.
Figure 10: Efficiency vs. Charge Current
Constant voltage mode
Efficiency vs. IBATT
0.98
0.97
0.96
Efficiency

0.95
0.94
0.93
0.92 VIN=16V
0.91 VIN=20V
VIN=24V
0.9
0 1 2 3
IBATT (A)

4.2 Time Domain Waveforms

L = 10µH/35mΩ, fSW = 680kHz, and TA = 25°C.
Figure 11: Battery Charge Curve
Figure 12: Auto-Recharge
VIN = 20V, VBATT_TERM = 14V, ICC = 2A,
VIN = 20V, VBATT_TERM = 14V, ICC = 2A, IIN_LIM = 2A
IIN_LIM = 2A

C1: VIN C1: VIN

10V/div. 10V/div.
C2: VBATT C2: VBATT
5V/div. 5V/div.
C4: IBATT C4: IBATT
1A/div. 1A/div.
C3: VSW C3: VSW
10V/div. 10V/div.

Figure 13: Steady State Figure 14: Steady State

VIN = 20V, VBATT = 4V, ICC = 2A, IIN_LIM = 2A, VIN = 20V, VBATT = 8V, ICC = 2A, IIN_LIM = 2A, pre-
trickle charge mode charge mode

C2: VBATT C2: VBATT

5V/div. 5V/div.
C4: IL C1: VIN
1A/div. 5V/div.
C1: VIN C3: VSW
5V/div. 10V/div.
C3: VSW C4: IL
10V/div. 1A/div.

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Figure 15: Steady State Figure 16: Steady State

VIN = 20V, VBATT = 12V, ICC = 2A, IIN_LIM = 2A, VIN = 20V, VBATT = 14V, ICC = 2A, IIN_LIM = 2A,
constant current charge mode constant voltage charge mode

C2: VBATT C4: IL

5V/div. 1A/div.
C1: VIN C2: VBATT
5V/div. 5V/div.
C4: IL C1: VIN
1A/div. 5V/div.
C3: VSW C3: VSW
10V/div. 10V/div.

Figure 17: Start-Up Figure 18: Shutdown

VIN = 20V, VBATT = 13V, ICC = 2A, IIN_LIM = 2A, VIN = 20V, VBATT = 13V, ICC = 2A, IIN_LIM = 2A,
ISYS = 1A, power path operation ISYS = 1A, power path operation

C1: VIN C1: VIN

10V/div. 10V/div.
C2: VBATT C2: VBATT
5V/div. 5V/div.
C4: IBATT C4: IBATT
1A/div. 1A/div.
C3: VSYS C3: VSYS
5V/div. 5V/div.

Figure 19: VIN_LIM Loop Control

Figure 20: IIN_LIM Loop Control
VIN = 20V/1A, VBATT = 12V, ICC = 3A,
VIN = 20V, VBATT = 12V, ICC = 3A, IIN_LIM = 1A
IIN_LIM = 2A, VIN_LIM = 15V

C2: VBATT C2: VBATT

5V/div. 5V/div.
C1: VIN C1: VIN
5V/div. 5V/div.
C4: IL C4: IL
0.5A/div. 0.5A/div.
C3: VSW C3: VSW
10V/div. 10V/div.

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12V Lead-Acid Battery Charging Solution

4.3 Thermal Measurements

L = 10µH/35mΩ, fSW = 680kHz, TA = 25°C, and burns in 30 minutes. Board information:
63.5mmx63.5mm, 4-layer, 1oz/layer.

Figure 21: Thermal Image

VIN = 20V, VBATT = 12V, ICC = 3A,
TRISE = 62.1°C to 25°C = 37.1°C

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5 Start-Up
5.1 Connectors and Jumpers
Table 5: Connectors
Connectors Description
TP1/VIN Connect to the input source’s positive terminal.
TP2/GND Connect to the input source’s negative terminal.
TP3/BATT Connect to the battery pack’s positive terminal.
TP4/GND Connect to the battery pack’s negative terminal.
TP5/VIN Test point of VIN.
TP6/SW Test point of the switching node.
TP7/BATT Test point of BATT.
TP8/PMID Test point of PMID.
TP9, TP10, TP11, TP12 Test point of ground.
VDPM, VCC, NTC, ACOK, STAT Test connection for related signals.

Table 6: Jumpers and Shunts

Jumpers Description Default All Open
JP1, JP2 Selects the battery regulation voltage for each cell. 4.35V 4.2V
JP3, JP4 Selects the battery cell numbers. 3 cells 4 cells
JP5 Selects the input current limit. 2A 1A
JP6 Selects the constant current charge current. 2A 1A
JP7,JP8,JP9 Selects the input voltage minimum limit. 14V 28V
5.2 Quick Start Guide
The EV2659-Q-03A is designed for the MP2659, a highly integrated switching charger that charges
batteries across a wide full-battery voltage range. It layout accommodates most commonly used
capacitors. A solution for a 1-cell, 12V lead-acid battery charging application with OR-selection power
path management can be implemented with the addition of auxiliary circuits.
1. Connect the battery pack to the BATT and GND connectors. Ensure that the battery’s positive and
negative terminals are correctly connected.
2. If using a battery emulator, preset the battery emulator to a proper voltage, then turn the emulator off.
Connect the battery emulator to BATT and GND, then turn the emulator’s output on.
3. Preset the input power source to its proper voltage then turn the power source off. Connect the power
source to VIN and GND, then turn the power source on. The board should start charging the battery.
4. To modify the charging parameters, configure the evaluation board using the jumpers (see Table 6).
Table 7 lists the adjustable parameters.
Table 7: Adjustable Parameters
Parameter Value Units
Charge current 1, 1.5, or 2 A
Input current limit 1, 1.5, or 2 A
Cells 3 or 4 N/A
Battery regulation voltage (each cell) 3.6, 4.2, 4.35, or 4.15 V
Minimum input voltage limit 14, 18, 24, or 28 V
Battery termination voltage According to R1, R2 value kΩ

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5. Note that the MP2659 utilizes dead battery pack recovery if the battery voltage drops below 1.5V/cell.
During recovery the devices charges for a 20ms pulse, with a 1.4s suspension time.

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6 Disclaimer
Monolithic Power Systems (MPS) reserves the right to make changes to its products and to discontinue
products without notice. The applications information, schematic diagrams, and other reference
information included herein is provided as a design aid only and are therefore provided as-is. MPS makes
no warranties with respect to this information and disclaims any implied warranties of merchantability or
non-infringement of third-party intellectual property rights.
MPS cannot assume responsibility for use of any circuitry other than circuitry entirely embodied in an
MPS product. No circuit patent licenses are implied.
Certain applications using semiconductor products may involve potential risks of death, personal injury,
or severe property or environmental damage (“Critical Applications”).
MPS PRODUCTS ARE NOT DESIGNED, INTENDED, AUTHORIZED, OR WARRANTED TO BE
SUITABLE FOR USE IN LIFE SUPPORT APPLICATIONS, DEVICES OR SYSTEMS, OR OTHER
CRITICAL APPLICATIONS.
Inclusion of MPS products in critical applications is understood to be fully at the risk of the customer.
Questions concerning potential risk applications should be directed to MPS.
MPS semiconductors are typically used in power supplies in which high voltages are present during
operation. High-voltage safety precautions should be observed in design and operation to minimize the
chance of injury.

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REVISION HISTORY
Revision # Revision Date Description Pages Updated
1.0 4/14/2021 Initial Release -

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