Universal input, 500-W CC/CV e-Bike charger reference design


Design files


This reference design is a universal input, 71.4-V, 7-A constant current, constant voltage (CC/CV) charger for e-bike applications. The UCC28180 device is used for CCM PFC stage for 0.99 power factor and low-current total harmonic distortion. The UCC256403 is used for a half-bridge resonant converter, achieving 95.8% efficiency and fast load transient at constant voltage mode. A flyback using the UCC28910 provides auxiliary power for PFC, LLC, control circuits and cooling fans. The adjustable CC/CV option is reserved for the MCU board to make it feasible for multiple-cell battery charging applications.

  • 0.99 power factor at full load output
  • 95.8% peak efficiency
  • Charging status indication
  • Reserved digital option for adjustable CC/CV
Output voltage options PMP40766.1 PMP40766.2 PMP40766.3
Vin (Min) (V) 90 350 120
Vin (Max) (V) 264 410 410
Vout (Nom) (V) 390 71.4 12
Iout (Max) (A) 1.33 7 .25
Output Power (W) 518.7 499.8 3
Isolated/Non-Isolated Non-Isolated Isolated Isolated
Input Type AC DC DC
Topology Boost- PFC Full Bridge- LLC Flyback- DCM
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A fully assembled board has been developed for testing and performance validation only, and is not available for sale.

Design files & products

Design files

Download ready-to-use system files to speed your design process.

TIDT215.PDF (6469 K)

Test results for the reference design, including efficiency graphs, test prerequisites and more

TIDM793.PDF (429 K)

Detailed schematic diagram for design layout and components

TIDM794.PDF (186 K)

Complete listing of design components, reference designators, and manufacturers/part numbers

TIDM795.PDF (383 K)

Detailed overview of design layout for component placement

TIDM797.ZIP (2231 K)

Files used for 3D models or 2D drawings of IC components

TIDCFZ3.ZIP (2271 K)

Design file that contains information on physical board layer of design PCB

TIDM796.PDF (1569 K)

PCB layer plot file used for generating PCB design layout


Includes TI products in the design and potential alternatives.

AC/DC & DC/DC controllers (external FET)

UCC256403LLC resonant controller with ultra-low power and ultra-quiet standby operation

Data sheet: PDF | HTML
AC/DC & DC/DC controllers (external FET)

UCC2818018-kHz-250-kHz CCM PFC controller with enhanced startup & transient response

Data sheet: PDF | HTML
AC/DC & DC/DC converters (integrated FET)

UCC28910700V Flyback switcher with constant-voltage constant-current and primary-side control

Data sheet: PDF | HTML
Analog current-sense amplifiers

INA18026V, 350kHz current sense amplifier

Data sheet: PDF | HTML

LMV393Dual General Purpose Low-Voltage Comparator

Data sheet: PDF | HTML
General-purpose op amps

TL103WDual, 32-V, 900-kHz operational amplifier with internal reference

Data sheet: PDF | HTML
Shunt voltage references

TL431LIAdjustable precision shunt regulator with optimized reference current (pin layout: KRA)

Data sheet: PDF | HTML

Technical documentation

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Type Title Date
* Test report Universal Input, 500-W CC/CV e-Bike Charger Reference Design Jan. 11, 2021

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