Microchip Technology MCP1630 Input Boost Converter Demo Board User guide

MCP1630
Input Boost Converter
Demo Board
User’s Guide
© 2007 Microchip Technology Inc. DS51608B
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®
MCUs and dsPIC® DSCs, KEELOQ
®
code hopping
DS51608B-page ii © 2007 Microchip Technology Inc.
MCP1630 AUTOMOTIVE INPUT BOOST
CONVERTER DEMO BOARD USER’S GUIDE
Table of Contents
Preface ........................................................................................................................... 1
Introduction............................................................................................................ 1
Document Layout .................................................................................................. 1
Conventions Used in this Guide ............................................................................ 2
Recommended Reading........................................................................................ 2
The Microchip Web Site ........................................................................................ 3
Customer Support ................................................................................................. 3
Document Revision History................................................................................... 3
Chapter 1. Product Overview
1.1 Introduction...................................................................................................... 5
1.2 What is the MCP1630 Automotive Input Boost Converter Demo Board? ....... 6
1.3 What the MCP1630 Automotive Input Boost Converter Demo Board Kit
Includes ..................................................................................................... 6
Chapter 2. Installation and Operation
2.1 Introduction...................................................................................................... 7
2.2 Features .......................................................................................................... 7
2.3 Getting Started ................................................................................................ 8
Appendix A. Schematic and Layouts
A.1 Introduction ................................................................................................... 11
A.2 Board – Schematic........................................................................................ 12
A.3 Board – Top Silk Layer ................................................................................. 13
A.4 Board – Top Metal Layer .............................................................................. 14
A.5 Board – Bottom Metal Layer ......................................................................... 15
Appendix B. Bill Of Materials (BOM) Appendix C. Demo Board Firmware
C.1 Device Firmware........................................................................................... 19
Worldwide Sales and Service .................................................................................... 20
© 2007 Microchip Technology Inc. DS51608B-page iii
MCP1630 Automotive Input Boost Converter Demo Board User’s Guide
NOTES:
DS51608B-page iv © 2007 Microchip Technology Inc.
MCP1630 AUTOMOTIVE INPUT BOOST
CONVERTER DEMO BOARD USER’S GUIDE

Preface

NOTICE TO CUSTOMERS
All documentation becomes dated, and this manual is no exception. Microchip tools and documentation are constantly evolving to meet customer needs, so some actual dialogs and/or tool descriptions may differ from those in this document. Please refer to our web site (www.microchip.com) to obtain the latest documentation available.
Documents are identified with a “DS” number. This number is located on the bottom of each page, in front of the page number. The numbering convention for the DS number is “DSXXXXXA”, where “XXXXX” is the document number and “A” is the revision level of the document.
For the most up-to-date information on development tools, see the MPLAB Select the Help menu, and then Topics to open a list of available on-line help files.

INTRODUCTION

®
IDE on-line help.
This chapter contains general information that will be useful to know before using the MCP1630 Automotive Input Boost Converter Demo Board. Items discussed in this chapter include:
• Document Layout
• Conventions Used in this Guide
• Recommended Reading
• The Microchip Web Site
• Customer Support
• Document Revision History

DOCUMENT LAYOUT

This document describes how to use the MCP1630 Automotive Input Boost Converter Demo Board. The manual layout is as follows:
Chapter 1. “Product Overview” – Important information about the MCP1630
Automotive Input Boost Converter Demo Board.
Chapter 2. “Installation and Operation” – Includes instructions on how to get
started with this user’s guide and a description of the user’s guide.
Appendix A. “Schematic and Layouts” – Shows the schematic and layout
diagrams for the MCP1630 Automotive Input Boost Converter Demo Board.
Appendix B. “Bill Of Materials (BOM)” – Lists the parts used to build the
MCP1630 Automotive Input Boost Converter Demo Board.
Appendix C. “Demo Board Firmware” – Provides information about the
application firmware and where the source code can be found.
© 2007 Microchip Technology Inc. DS51608B-page 1
MCP1630 Automotive Input Boost Converter Demo Board User’s Guide

CONVENTIONS USED IN THIS GUIDE

This manual uses the following documentation conventions:
DOCUMENTATION CONVENTIONS
Description Represents Examples
Arial font:
Italic characters Referenced books MPLAB® IDE User’s Guide
Emphasized text ...is the only compiler...
Initial caps A window the Output window
A dialog the Settings dialog A menu selection select Enable Programmer
Quotes A field name in a window or
dialog
Underlined, italic text with right angle bracket
Bold characters A dialog button Click OK
N‘Rnnnn A number in verilog format,
Text in angle brackets < > A key on the keyboard Press <Enter>, <F1>
Courier New font:
Plain Courier New Sample source code #define START
Italic Courier New A variable argument file.o, where file can be
Square brackets [ ] Optional arguments mcc18 [options] file
Curly brackets and pipe character: { | }
A menu path File>Save
A tab Click the Power tab
where N is the total number of digits, R is the radix and n is a digit.
Filenames autoexec.bat File paths c:\mcc18\h Keywords _asm, _endasm, static Command-line options -Opa+, -Opa- Bit values 0, 1 Constants 0xFF, ‘A’
Choice of mutually exclusive arguments; an OR selection
“Save project before build”
4‘b0010, 2‘hF1
any valid filename
[options] errorlevel {0|1}

RECOMMENDED READING

This user's guide describes how to use MCP1630 Automotive Input Boost Converter Demo Board. The following Microchip documents are available and recommended as supplemental reference resources.
MCP1630/MCP1630V Data Sheet, "High-Speed, Microcontroller-Adaptable, Pulse Width Modulator" (DS21896)
This data sheet provides detailed information regarding the MCP1630/MCP1630V product family.
PIC12F683 Data Sheet, "8-Pin Flash-Based, 8-Bit CMOS Microcontrollers with Nano Watt Technology" (DS41211)
This data sheet provides detailed information regarding the PIC12F683 product family.
DS51608B-page 2 © 2007 Microchip Technology Inc.

THE MICROCHIP WEB SITE

Microchip provides online support via our web site at www.microchip.com. This web site is used as a means to make files and information easily available to customers. Accessible by using your favorite Internet browser, the web site contains the following information:
Product Support – Data sheets and errata, application notes and sample
programs, design resources, user’s guides and hardware support documents, latest software releases and archived software
General Technical Support – Frequently Asked Questions (FAQs), technical
support requests, online discussion groups, Microchip consultant program member listing
Business of Microchip – Product selector and ordering guides, latest Microchip
press releases, listing of seminars and events, listings of Microchip sales offices, distributors and factory representatives

CUSTOMER SUPPORT

Users of Microchip products can receive assistance through several channels:
• Distributor or Representative
• Local Sales Office
• Field Application Engineer (FAE)
• Technical Support Customers should contact their distributor, representative or field application engineer
(FAE) for support. Local sales offices are also available to help customers. A listing of sales offices and locations is included in the back of this document.
Technical support is available through the web site at: http://support.microchip.com
Preface

DOCUMENT REVISION HISTORY

Revision B (June 2007)
• Updated Bill of Materials (BOM) for C12, C13, and L1
• Add disclaimer to Bill of Materials regarding RoHS-Compliant part numbers.
Revision A (April 2006)
• Initial Release of this Document.
© 2007 Microchip Technology Inc. DS51608B-page 3
MCP1630 Automotive Input Boost Converter Demo Board User’s Guide
NOTES:
DS51608B-page 4 © 2007 Microchip Technology Inc.

Chapter 1. Product Overview

9V-18V
Battery Supply
MCP1630/V High-Speed,
Microcontroller-Adaptable,
Pulse Width Modulator
Boost
Converter
LOAD
36.5V / 400 mA
14.6W Max Power
PIC12F683 for Osc Input & V
REF
Voltage
Regulator
Feedback

1.1 INTRODUCTION

The proliferation of distributed power supplies is expected to accelerate their use in future generation cars. Distributed power supplies or "point-of-load" power supplies are being used increasingly throughout. These Power Supply Units (PSUs) are responsible for stepping up (or down) a 12V nominal bus, to power a multitude of subsystems. These include telematics/navigation systems, power seats and doors, interior and exterior lighting, electronic braking and engine management control.
Many automotive and industrial applications require higher voltages than are available on the input power supply rail. Supply voltages required for these systems can range from 36V (power seats and windows) to 1.8V (to drive low-voltage microprocessors). In addition, depending on where the PSU operates on the automotive power bus, it may be required to perform under very stringent power requirements.
Automotive subsystems with their inherent high voltage transients and high efficiency requirements place increasing demands on power supply designs. These supplies must provide high power, high efficiency and low noise from a very compact footprint and must maintain a high efficiency over a wide range of operational input voltages.
The MCP1630/V high-speed, microcontroller-adaptable Pulse Width Modulator (PWM) is capable of maintaining output regulation with no adverse effects on system performance or reliability. The MCP1630 Automotive Input Boost Converter Demo Board provides a better choice for automotive application design and high efficiency.
This chapter covers the following topics.
• What is the MCP1630 Automotive Input Boost Converter Demo Board?
• What the MCP1630 Automotive Input Boost Converter Demo Board Kit includes.
MCP1630 AUTOMOTIVE INPUT BOOST
CONVERTER DEMO BOARD USER’S GUIDE
© 2007 Microchip Technology Inc. DS51608B-page 5
FIGURE 1-1: MCP1630 Automotive Input Boost Converter Demo Board Block Diagram.
MCP1630 Automotive Input Boost Converter Demo Board User’s Guide

1.2 WHAT IS THE MCP1630 AUTOMOTIVE INPUT BOOST CONVERTER DEMO BOARD?

The MCP1630 Automotive Input Boost Converter Demo Board demonstrates the use of a conventional boost topology with automotive input. The board also serves as a platform to evaluate the MCP1630/V devices.
The MCP1630/V inputs were developed to be easily attached to the I/O of a microcontroller. The Microcontroller Unit (MCU) supplies the oscillator pulses and reference voltage (V adaptable power system. The power system switching frequency and maximum duty cycle are set using the I/O of the MCU. The reference input to the high-speed PWM can be external, a D/A Converter (DAC) output or as simple as an I/O output from the MCU. This enables the power system to adapt to many external signals and variables in order to optimize performance and facilitate calibration.
This board utilizes Microchip's MCP1630/V (high-speed PICmicro integrated with PIC12F683 (Flash MCU SOIC8) in automotive input application. Under normal operation, the vehicle voltage at the supply lines ranges between 9V-18V (12V system). The converter is capable of delivering an output voltage of 36.5V at 400 mA load current with maximum power of 14.6W. The line and load regulation is within the regulation band of 3%.
) to the MCP1630/V devices to provide the most flexible and
REF
®
MCU PWM)

1.3 WHAT THE MCP1630 AUTOMOTIVE INPUT BOOST CONVERTER DEMO BOARD KIT INCLUDES

This MCP1630 Automotive Input Boost Converter Demo Board kit includes:
• MCP1630 Automotive Input Boost Converter Demo Board (102-00095)
• Analog and Interface Products Demonstration Boards CD-ROM (DS21912)
- MCP1630 Automotive Input Boost Converter Demo Board User’s Guide (DS51608)
DS51608B-page 6 © 2007 Microchip Technology Inc.

Chapter 2. Installation and Operation

2.1 INTRODUCTION

The MCP1630 Automotive Input Boost Converter Demo Board demonstrates Microchip's high-speed pulse width modulator used for automotive applications. When used in conjunction with a microcontroller, the MCP1630/V devices will control the power system duty cycle to provide regulated output voltage. The PIC12F683 microcontroller is used to provide oscillator pulses at switching frequency of 500 kHz and set maximum duty cycle. The MCP1630/V devices generate duty cycles based on various external inputs. External signals include the input oscillator pulses from PIC12F683, the reference voltage and the feedback voltage. The output signal is a square wave pulse given to drive the MOSFET.
The PIC12F683 microcontroller is programmable, allowing the user to modify or develop their own firmware routines to further evaluate the MCP1630/V devices in this application.

2.2 FEATURES

MCP1630 AUTOMOTIVE INPUT BOOST
CONVERTER DEMO BOARD USER’S GUIDE
The MCP1630 Automotive Input Boost Converter Demo Board has the following features:
• Compact size for an output power of 14.6W
• Tight line and load regulation and high efficiency over entire operating input
voltage range
• PIC12F683 is used to generate reference voltage and oscillator signal at 500 kHz
frequency at maximum duty cycle
• Proprietary features can be added by modifying the firmware contained in the
PIC12F683
• Factory programmed source code is available
© 2007 Microchip Technology Inc. DS51608B-page 7
MCP1630 Automotive Input Boost Converter Demo Board User’s Guide
Programming
Header
Output -
Output +
Input +
Input -

2.3 GETTING STARTED

The MCP1630 Automotive Input Boost Converter Demo Board is fully assembled and tested for automotive input. The board requires the use of an external input voltage source (+9V to 18V) and external load.
2.3.1 Power Input and Output Connection
2.3.1.1 POWERING THE MCP1630 AUTOMOTIVE INPUT BOOST CONVERTER DEMO BOARD
1. Connect the positive side of the input source (+) to TP1.
2. Connect the negative or return side (-) of the input source to TP2. Refer to
Figure 2-1. The input voltage source should be limited to the 0V to +18V range. For normal operation, the input voltage should be between +9V to +18V. The input voltage must not exceed an absolute maximum of +20V.
FIGURE 2-1: Set-up Configuration Diagram.
DS51608B-page 8 © 2007 Microchip Technology Inc.
Installation and Operation
2.3.1.2 APPLY LOAD TO MCP1630 AUTOMOTIVE INPUT BOOST CONVERTER DEMO BOARD
A variable resistive load can be used to verify the line and load regulation. The load resistance is connected between the points TP3 and TP4. To measure the output voltage, connect the common point of a multimeter to TP4 and the positive terminal to TP3. By varying the load, the load regulation can be verified by measuring the output voltage over the entire load range of 0 mA to 400 mA. Similarly, the line regulation can be calculated by varying the line voltage from 9V to 18V and checking the output voltage.
Evaluating the Application
The best way to evaluate the MCP1630 is to dig into the circuit and measure voltages and currents with a Digital Voltage Meter (DVM) and probe the board with an oscilloscope.
The firmware program in the PIC12F683 can also be edited to modify the operation of the application.
Firmware
The PIC12F683 comes pre-programmed with firmware to operate the system as described above. The file listing and firmware flow diagram are shown in Appendix C. “Demo Board Firmware”.
The program is fairly simple and straight forward. There is an initialization routine at the beginning of the program.
The TRISIO register controls the direction of GPIO pins, and is configured to set GP2 (oscillator pulses to the MCP1630/V) and GP5 (V output port.
The Capture/Compare/PWM (CCP) module contains a 16-bit register which can operate in PWM mode. The PWM period can be calculated by writing to the PR2 register. The PWM duty cycle is specified by writing to the CCPR1L register and to the CCP1CON <5:4> bits. Up to 10-bit resolution is available. The CCPR1L contains the eight MSbs and the CCP1CON <5:4> contains the two LSbs. This 10-bit value is represented by CCPR1L:CCP1CON<5:4>. The switching frequency is set to 500 kHz.
The user can obtain different output voltages by programming the MCU to obtain different V
voltages.
REF
voltage to MCP1630/V) as an
REF
Programming
Header J1 is provided for in-circuit programming. This is an optional feature since the MCP1630 Automotive Input Boost Converter Demo Board comes pre-programmed with firmware to operate the system. The PIC12F683 can be reprogrammed with the Baseline Flash Microcontroller Programmer (BFMP).
© 2007 Microchip Technology Inc. DS51608B-page 9
MCP1630 Automotive Input Boost Converter Demo Board User’s Guide
NOTES:
DS51608B-page 10 © 2007 Microchip Technology Inc.

Appendix A. Schematic and Layouts

A.1 INTRODUCTION

This appendix contains the following schematics and layouts for the MCP1630 Auto­motive Input Boost Converter Demo Board:
• Board – Schematic
• Board – Top Silk Layer
• Board – Top Metal Layer
• Board – Bottom Metal Layer
MCP1630 AUTOMOTIVE INPUT BOOST
CONVERTER DEMO BOARD USER’S GUIDE
© 2007 Microchip Technology Inc. DS51608B-page 11
MCP1630 Automotive Input Boost Converter Demo Board User’s Guide
M
3
1
2

A.2 BOARD – SCHEMATIC

DS51608B-page 12 © 2007 Microchip Technology Inc.

A.3 BOARD – TOP SILK LAYER

Schematic and Layouts
© 2007 Microchip Technology Inc. DS51608B-page 13
MCP1630 Automotive Input Boost Converter Demo Board User’s Guide

A.4 BOARD – TOP METAL LAYER

DS51608B-page 14 © 2007 Microchip Technology Inc.

A.5 BOARD – BOTTOM METAL LAYER

Schematic and Layouts
© 2007 Microchip Technology Inc. DS51608B-page 15
MCP1630 Automotive Input Boost Converter Demo Board User’s Guide
NOTES:
DS51608B-page 16 © 2007 Microchip Technology Inc.
MCP1630 AUTOMOTIVE INPUT BOOST
CONVERTER DEMO BOARD USER’S GUIDE

Appendix B. Bill Of Materials (BOM)

TABLE B-1: BILL OF MATERIALS (BOM)
Qty Reference Description Manufacturer Part Number
2 C1, C2 Cap 4.7uF 25V Ceramic X5R 1206 Panasonic 5 C3, C4, C5,
C10, C11 2 C6, C7 Cap 1uF 16V Ceramic X7R 0805 Panasonic - ECG ECJ-2FB1C105K 1 C8 Cap 1500pF 100V Ceramic X7R 0805 Panasonic - ECG ECJ-2VB2A152K 1 C9 Cap 1000pF 50V Cerm Chip 0805 Panasonic - ECG ECJ-2VC1H102J 2 C12, C13 Cap Cer 4.7uF 50V 10% X7R 1210 Murata GRM32ER71H475KA88L 1 C14 Cap 470pF 50V Cerm Chip 0805 SMD Panasonic - ECG ECJ-2VC1H471J 1 C15 Cap 22pF 50V Cerm Chip 0805 SMD Panasonic - ECG ECJ-2VC1H220J 1 D1 Diode Schottky 60V 1A SMB International Rectifier 10BQ060 1 J1 Conn Header 5 Pos.100 Vert Tin Molex 22-03-2051 1 L1 Inductor Shielded Drum Power 15uH
1 Q1 MOSFET N-CH 55V 3.1A SOT-23 International Rectifier IRLL024N 1 Q2 MOSFET N-CH 60V 280mA SOT-33 Fairchild Semiconductor 1 R1 Res 2.00K Ohm 1/8W 1% 0805 SMD Panasonic - ECG ERJ-6ENF2001V 1 R2 Res 10.0K Ohm 1/8W 1% 0805 SMD Panasonic - ECG ERJ-6ENF10R0V 1 R3 Not Used — 1 R4 Res 80.6K Ohm 1/8W 1% 0805 SMD Panasonic - ECG ERJ-6ENF8062V 2 R5, R6 Res 100K Ohm 1/8W 1% 0805 SMD Panasonic - ECG ERJ-6ENF1003V 1 R7 Res 49.9K Ohm 1/8W 1% 0805 SMD Panasonic - ECG ERJ-6ENF4992V 1 R8 Res 47.5K Ohm 1/8W 1% 0805 SMD Panasonic - ECG ERJ-6ENF4752V 1 R9 Res 34.0K Ohm 1/8W 1% 0805 SMD Panasonic - ECG ERJ-6ENF3402V 1 R10 Res 2.49K Ohm 1/8W 1% 0805 SMD Panasonic - ECG ERJ-6ENF2491V 1 R11 Res 3.40K Ohm 1/8W 1% 0805 SMD Panasonic - ECG ERJ-6ENF3401V 1 R12 Res 165K Ohm 1/8W 1% 0805 SMD Panasonic - ECG ERJ-6ENF1653V 5 TP1,TP2,
TP3,TP4,
TP5 1 U1 IC 5.0 100 mA LDO Vreg SOT23 National Semiconductor®LM3480IM3-5.0 1 U2 IC MCU Flash 2KX14 8SOIC Microchip Technology Inc PIC12F683-I/SN 1 U3 IC PWM HS MCU-Adaptable 8MSOP Microchip Technology Inc MCP1630V-E/MS Note 1: The components listed in this Bill of Materials are representative of the PCB assembly. The released BOM
used in manufacturing uses all RoHS-compliant components.
Cap 0.1uF 16V Ceramic X7R 0805 Panasonic - ECG ECJ-2VB1C104K
Coiltronics DR125-150-R
SMD
PC Test point compact SMT Keystone Electronics
®
- ECG ECJ-3YB1E475M
®
NDS7002A
®
5016
© 2007 Microchip Technology Inc. DS51608B-page 17
MCP1630 Automotive Input Boost Converter Demo Board User’s Guide
NOTES:
DS51608B-page 18 © 2007 Microchip Technology Inc.

Appendix C. Demo Board Firmware

Set PR2 for 500 kHz Freq
Configure Ansel & CMCON0 as Digital I/O
Internal Osc clock to 8 MHz, TMR0 = 0
and GP5 (for Output V
REF
)
Initialize:GP2 (for Output PWM)
Output V
REF
Signal thro’ GP5
Duty Cycle Set by CCPR1L:CCP1CON<5:4>
Start

C.1 DEVICE FIRMWARE

For the latest copy of the MCP1630 Automotive Input Boost Converter Demo Board User’s Guide firmware, visit our web site at www.microchip.com
MCP1630 AUTOMOTIVE INPUT BOOST
CONVERTER DEMO BOARD USER’S GUIDE
FIGURE C-1: Firmware Flowchart.
© 2007 Microchip Technology Inc. DS51608B-page 19

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Tel: 33-1-69-53-63-20 Fax: 33-1-69-30-90-79
Germany - Munich
Tel: 49-89-627-144-0 Fax: 49-89-627-144-44
Italy - Milan
Tel: 39-0331-742611 Fax: 39-0331-466781
Netherlands - Drunen
Tel: 31-416-690399 Fax: 31-416-690340
Spain - Madrid
Tel: 34-91-708-08-90 Fax: 34-91-708-08-91
UK - Wokingham
Tel: 44-118-921-5869 Fax: 44-118-921-5820
12/08/06
DS51608B-page 20 © 2007 Microchip Technology Inc.
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