230-V, 400-W, 92% Efficiency Battery Charger w/PFC and LLC for 36-V Power Tools Reference Design

(ACTIVE) TIDA-00355

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Key Document

Description

The design is a 400-W high efficiency battery charger power supply designed to charge wide range of batteries in the voltage range of 20V to 42V and ideal for 10-Cell Li-Ion battery pack used in cordless Power Tools and Garden Tools. The design has boost PFC pre-regulator stage opearting at an efficiency of 96%. It provides high Power Factor(PF) of >0.99 and meets PFC regulation as per IEC61000-3-2 class A. The main converter stage is realised using LLC configuration and operates at an efficiency of 96% at full load. The charger is designed for input voltage range of 175V – 265V AC. The design form factor (230mm x 80mm) is compact for the power level of 400W. The design has an operating overall system efficiency of 92% at full load, with voltage and current regulation within +/- 3%. The EMI filter at the front end of the circuit is designed to meet EN55011 class A conducted emission levels.

Features

• 400 W Battery Charger with front-end PFC and half bridge LLC resonant converter
• Designed to charge wide range of batteries - Li-ion, Li-poly, Ni-Cd and Lead-acid, in the voltage range of 20V to 42V
• Ideal charger for 10-cell Li-ion battery pack used in industrial power tools
• Delivers up to 9 A of continuous charging current for fast charging of batteries
• Overall efficiency of 92% at full charging current of 9A and 230V input, eliminating need for external cooling
• High power factor > 0.99 and meets PFC Regulations & Current THD as per IEC 61000-3-2 Class A
• Very low standby power of < 200mW when battery is not connected
• Small PCB form factor of 230 x 80 mm offers portability in usage
• Provides flexibility for charge profiling through an additional external microcontroller
• Charger is protected for Over current & Short-circuit at Output terminals ensuring safety needs
• Meets the requirements of Conducted Emissions standard – EN55011 class A


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TI Devices (6)

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Part Number Name Product Family Sample & Buy Design Kits & Evaluation Modules
TL103WA  Dual OpAmp With Internal Reference  Operational amplifiers (op amps)  Sample & Buy View Design Kits & Evaluation Modules
TLV704  24V Input Voltage, 150mA, Ultra-Low-Iq Low-Dropout (LDO) Regulators  Power management  Sample & Buy View Design Kits & Evaluation Modules
UCC25600  8-pin high-performance resonant mode LLC controller  Offline & isolated DC/DC controllers & converters  Sample & Buy View Design Kits & Evaluation Modules
UCC27714  High-Speed, 4-A, 600-V High-Side Low-Side Gate Driver  Gate drivers  Sample & Buy View Design Kits & Evaluation Modules
UCC28180  8-Pin Continuous Conduction Mode (CCM) PFC Controller  Offline & isolated DC/DC controllers & converters  Sample & Buy View Design Kits & Evaluation Modules
UCC28722  Low-Cost CVCC Flyback Controller With Primary-Side Regulation for Bipolar Power Device  Offline & isolated DC/DC controllers & converters  Sample & Buy View Design Kits & Evaluation Modules

CAD/CAE symbols

Part # Package | Pins CAD File (.bxl) STEP Model (.stp)
TL103WA Download Download
TLV704 Download Download
UCC25600 Download Download
UCC27714 Download -
UCC28180 Download
UCC28722 Download

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Technical Documents

View the Important Notice for TI Designs covering authorized use, intellectual property matters and disclaimers.

User guides (1)
Title Abstract Type Size (KB) Date
PDF 2408 11 Jan 2017
Design files (6)
Title Abstract Type Size (KB) Date
PDF 103 09 Jun 2015
ZIP 3404 09 Jun 2015
PDF 2705 09 Jun 2015
PDF 105 09 Jun 2015
PDF 426 09 Jun 2015
ZIP 542 09 Jun 2015
Related Tools & Software

Software (1)



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