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INTRODUCTION
This chapter contains general information that will be useful to know before using the
MCP1640 12V/50 mA Two Cells Input Boost Converter Reference Design. 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 MCP1640 12V/50 mA Two Cells Input Boost
Converter Refere nce Des ign as a develop ment t ool to ev aluate the MC P1640 de vice’ s
capability to boost low voltages to a high output value, using a single inductor. The
manual layout is as follows:
• Chapter 1. “Product Overview” – Important information about the MCP1640
Input Boost Converter.
• Chapter 2. “Installation and Operation” – Includes instructions on how to get
started with the MCP1640 Input Boost Converter and a description of the User’s
Guide.
• Appendix A. “Schematic and Layouts” – Shows the schematic and layout
diagrams for the MCP1640 Input Boost Converter.
• Appendix B. “Bill of Materials” – Lists the parts used to build the MCP1640
Input Boost Converter.
This user’s guide describes how to use the MCP1640 12V/50 mA Two Cells Input
Boost Converter Reference Design. Other useful documents are listed below. The
following Microchip document is available and recommended as a supplemental
reference resource.
• MCP1640/B/C/D Data Sheet – “0.65V Start-up Synchronous Boos t Regula tor
with True Output Disconnect or Input/Output Bypass Option” (DS22234)
THE MICROCHIP WEB SITE
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Preface
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:
This chapter provides an overview of the MCP1640 12V/50 mA Two Cells Input Boost
Converter Reference Design and covers the following topics:
• MCP1640 Short Overview
• What is the MCP1640 12V/50 mA Two Cells Input Boost Converter Reference
Design?
• What Does the MCP1640 12V/50 mA Two Cells Input Boost Converter Reference
Design Kit Include?
1.2MCP1640 SHORT OVERVIEW
The MCP1640 device is a compact, high-efficiency, fixed frequency, step-up DC-DC
converter. It provides an easy-to-use power supply solution, with a minimum number of
external components, for applications powered by one-cell, two-cell, or three-cell
alkaline, NiCd, NiMH, one-cell Li-Ion or Li-Polymer batteries.
The MCP1640/C device automatically selects the best operating mode for efficiency,
PWM (Pulse-Width Modulation) or PFM (Pulse Frequency Modulation). The
MCP1640B/D device is running in PWM mode only and is ideal for noise sensitive
applications. It has a low quiescent current (19 µA, PFM mode typical), a wide input
voltage range (0.35 to 5.5V) and a low start-up voltage (0.65V at 1 mA load current).
The MCP1640 device consumes less than 1 µA in Shutdown mode.
Microchip Technology Inc. provides the MCP1640 device in four variants, which help
engineers to meet different system requirements. The devices and their available
options are presented in Table 1-1.
The MCP1640 is available in SOT23-6 and 8-LD DFN (2x3 mm) packages. For
additional information on the MCP1640 device, refer to the “MCP1640/B/C/D Data Sheet” (DS22234).
1.3WHAT IS THE MCP1640 12V/50 mA TWO CELLS INPUT BOOST
CONVERTER REFERENCE DESIGN?
The MCP1640 12V/50 mA Two Cells Input Boost Converter Reference Design is
designed to demonstrate the MCP1640 device’s high-voltage boost capability above its
typical output range of 5.5V. This board boosts the low-voltage input to 12V and up to
70 mA load. By changing the sense resistors (R
output than 12V will be obtained. The MCP1640 Input Boost Converter was developed
to help engineers reduce product design cycle time.
At 2.0V input and 12V o utp ut, th e bo ard is ca p able of a maxi m um of 50mA load current.
The N-MOS switch is connected between the inductor and the main switch, allowing
the application to output higher voltage (see Figure 1-2).
The converter is configured as nonsynchronous; a Schottky diode is connected
between the inductor and the High-Voltage Output (V
starts as the current generator for the Output Capacitor (C
the internal N-MOS switch is OFF, a St art-up Resistor (R
the N-MOS switch, should be used.
L
Two Cell s I npu t
Boost
and RB on Figure 1-2), a lower/higher
T
High). At start-up, MCP1640
OUT
Start
). Because at this time,
OUT
), connected in parallel with
V
OUT
High > 6V
C
IN
N-MOS
Switch
V
IN
SW
EN
FB
V
OUT
GND
R
Start
C
OUT
R
T
R
B
FIGURE 1-2:MCP1640 12V/50 mA Two Cells Input Boost Converter
Reference Design Block Diagram.
1.4WHAT DOES THE MCP1640 12V/50 mA TWO CELLS INPUT BOOST
CONVERTER REFERENCE DESIGN KIT INCLUD E?
The MCP1640 Input Boost Converter kit includes:
• MCP1640 12V/50 mA Two Cells Input Boost Converter Reference Design, 102-00386
The MCP1640 12V/50 mA Two Cells Input Boost Converter Reference Design is
developed to demonstrate how the MCP1640 device can operate as a high output
voltage DC-DC converter when powered from two batteries. This reference design
allows boosting from the input range of 2.0V-5V to an output higher than 5.5V of the
typical MCP1640 application. High-voltage outputs, such as 9V, 12V or 24V, can be
generated from just two alkaline cells.
For this reference design, the output voltage is set at 12V. Typically, a minimum of a
50 mA load can be supported from a 2.0V input. The board can deliver more output current (up to 70 mA) if it is powered with 3.0V. A small 3x3x1 mm inductor offers a good
efficiency of up to 75%. Good converter stability is obtained with the B option of
MCP1640 (PWM Mode Only and True Output Disconnect options).
2.1.1Board Features
MCP1640 12V/50 mA TWO CELLS
INPUT BOOST CONVERTER
REFERENCE DESIGN
The MCP1640 Input Boost Converter has the following features:
• Input Voltage: Two Alkaline or Lithium Cells, 2.0-3.0V Typical
The MCP1640 12V/50 mA Two Cells Input Boost Converter Reference Design is fully
assembled and tested to evaluate and demonstrate the MCP1640 family of products.
2.2.1Powering the MCP1640 12V/50 mA Two Cells Input Boost
Converter Reference Design
The extended input range of the MCP1640 Input Boost Converter is 2.0 to 5.0V input.
Good efficiency is obtained by supplying from two cells (primary and secondary batteries).
Input power connectors are placed on the left side of the board:
•V
for positive power
IN
• GND for negative power
The maximum input voltage should not exceed 5.0V. The output voltage will be out of
regulation for input voltages lower than 2.0V.
The output connector is called V
current is 50 mA when the board is powered by two alkaline batteries that are close to
the end of their run time, at approximately 1V each.
2.2.2Board Testing
Installation and Operation
and is referenced to GND. The minimum output
OUT
Set 3.0V
PWR Supply
Because this board is boosting the input voltage, the input current is greater than the
output current. The variable power supply for testing requires output capability of at
least 1A and a voltage range of 2.0V to 5V.
To test the board, follow these steps:
1. Connect the power at V
and GND terminals of the board.
IN
2. Set the power supply to 3.0V.
3. Connect a voltmeter and a 240Ω/0.5W resisto r betw een V
and GND
OUT
connectors, as shown in Figure 2-3.
4. Check to be sure the voltmeter indicates 12V.
5. Set the power supply to 2.0V and verify if the output of the converter stays
regulated (V
OUT
=12V).
V-meter
R
240R/0.5W
FIGURE 2-3:MCP1640 12V/50 mA Two Cells Input Boost Converte r Reference Design
Setup Circuit.
MCP1640 12V/50 mA Two Cells Input Boost Converter Reference Design
The board has several test points that help engineers analyze the switch node’s
waveforms or MCP1640’s output:
• The high-voltage switch node test point (SWH).
• The test point of the MCP1640 device’s switch node (SWL).
• VO test point shows the MCP1640 device’s V
The difference between SWH and SWL signals is their amplitude. For 12V output, the
amplitude of SWL is approximately 5V, while SWH shows the sum of MCP1640's SW
node (SWL signal) and external n-channel MOS voltage.
Figures 2-4 and 2-5 show the Discontinuous (25 mA load for 2.4V V
mode waveforms (60 mA load at 2.4V V
, where the inductor peak current is close to
IN
the maximum input peak current limit of the MCP1640 device, 800 mA). Once the
800 mA limit is reached, V
value of the inductor current (I
value is decreasing (goes out of regulation).The mean
OUT
) is equal for a boost converter with the input current
L
(except the current consumption of MCP1640).
pin (this output is unregulated).
OUT
) and Continuous
IN
FIGURE 2-4:MCP1640 12V/50 mA Two Cells Input Boost Converter
Reference Design Test Points (SWH, SWL), Inductor (I_L) and Load Current (I_OUT)
Waveforms for 25 mA Load and 2.4V Input in Discontinuous Mode.
FIGURE 2-5:MCP1640 12V/50 mA Two Cells Input Boost Converter
Reference Design Test Points (SWH, SWL), Inductor (I
Waveforms for 60 mA Load and 2.4V Input in Continuous mode.
) and Load Current (I
L
OUT
)
2.2.3How Does the MCP1640 12V/50 mA Two Cells Input Boost
Converter Reference Design Works?
The board was designed to boost low voltage from two alkaline cells or NiCd/NiMH
cells to high voltage. The topology used in this reference design is adapting a
low-voltage boost converter into a high-voltage boost converter using a single inductor,
instead of using a flyback topology that requires a more expensive flyback transformer.
Another advantage is that the switching voltage spikes are kept below the safe value,
6V, for MCP1640 device’s SW pin.
The converter is configured as nonsynchronous; an external diode, D, is connected
between the inductor and the high-voltage output (V
The two sense resistors, R
and RB, set the output (V
T
following equation:
EQUATION 2-1:
V
OUT
R
=
T
⎛⎞
R
------------ -1–
×
B
⎝⎠
V
FB
Where:
VFB=1.21V
=Reference voltage of the FB pin
V
FB
V
=12.0V
OUT
R
=Resisto r’s value is selected by the designer
B
).
OUT
) at 12.0V according to the
OUT
Note:The reference board is tested up to 24V output with a maximum load of
20 mA. The internal error amplifier is a transconductance type; its gain is
not related to the feedback resistors’ values.
MCP1640 12V/50 mA Two Cells Input Boost Converter Reference Design
Attention should be paid to the values of the sense resistors. When testing the board
for other output voltage, a potential issue with higher value resistors is environmental
contamination, which can create a leakage current path on the PCB. This will affect the
feedback voltage and the output voltage regulation. Engineers should use resistors that
are larger than 1 MΩ with precaution. In normal humidity conditions, the V
leakage is very low and the resistors’ values will not affect the stability of the system.
When the board is powered up, the internal MCP1640 device’s start-up logic circuitry
turns the internal rectifying switch on until the output capacitor, connected at the V
pin (C
switch limits the maximum current. Because at start-up, the external n-channel MOS
(Q) transi stor i s OFF, a start-up res istor (R
MCP1640 starts switching, and the external N-MOS is turned on, cascading the
internal N-MOS switch of the MCP1640 to work with high voltage, more than 6V.
Notice that the MCP1640 is working internally as a synchronous rectifier and delivers
on its output (Pin 5) a part of the total output power. This output is unregulated because
the sense resistors, R
MCP1640 gets its start-up bias from V
comes from the output. The C
of MCP1640. This voltage is used to supply the internal blocks after start-up (including
the compensation circuitry). In case of instability, a few mA loads may be required (R
is not populated on the board; for 12V output, use a 2k or 3k resistor). On the output of
MCP1640 (VO test point), a maximum 5 mA load can be connected. Exceeding the
load produces unregulated board V
The board works well in Discontinuous mode. However, once entered into Continuous
mode, V
There is no undervoltage lockout feature for the MCP1640 family of devices. The
device will start up at the lowest voltage possible and run down to the lowest voltage
possible.
), is charged to a value close to the input voltage. During start-up, the rectifying
L
) is bypassing it and the CL cap is supplied.
S
and RB, are connected to the high output voltage. The
T
goes out of regulation.
OUT
capacitor is mandatory, because it smooths the output
L
. Once the ou tput exceeds the input, bias
IN
.
OUT
FB
input
OUT
L
Note:Because this configuration is an nonsynchronous converter, the MCP1640
device’s features, true disconnect output and short-circuit protection, will be
lost for this reference board. In case of a short circuit, inductor L, and diode
D, can be broken. Notice that the MCP1640 will not be affected.