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Texas Instruments UCC25600 | Demoboard TIDA-00355
230-V, 400-W, 92% High Efficiency Battery Charger With PFC and LLC for 36-V Power Tools Reference Design
Overview
| Topology | LLC Resonant Converter |
| Input voltage | 350-400 V |
| Output 1 | 42 V / 9 A |
| IC revision | C |
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 AREMARK:Schematic ,BOM AND pdf is added.
Typical applications
- Battery Chargers for – Vacuum Cleaner– Robotic Mower– E-Bike, E-Cycle
- Cordless Power Tools,Cordless Garden Tools
More information
Products
| Order Code | Datasheet | Simulation | Downloads | Status | Product series | IRP,40K (A) | ISAT (mA) | fres (MHz) | Size | Version | IR (A) | L (µH) | RDC max. (mΩ) | VR (V (AC)) | VT (V (AC)) | Material | L (mm) | W (mm) | H (mm) | Mount | Samples | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
 | 7447709101 | SPEC | 9 files | Active i| Production is active. Expected lifetime: >10 years. | WE-PD SMT Power Inductor | 3.2 | – | 4.3 | 1210 | Standard | 2.5 | 100 | 110 | – | – | – | 12 | 12 | 10 | SMT | ||
 | 7448030417 | SPEC PCN pendingDue to a pending PCN, a modification of the component will be implemented soon. Please find the PCN below. If you have further questions please get in contact with our sales staff. | 11 files | Active i| Production is active. Expected lifetime: >10 years. | WE-CMBNC Common Mode Power Line Choke Nanocrystalline | – | – | – | M | THT | 4 | 17000 | 52 | 300 | 2100 | Nanocrystalline | 23 | 13.5 | 26 | THT | ||
| 750342670 | SPEC | – | – | Active i| Production is active. Expected lifetime: >10 years. | Power Transformer | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | ||
| 750342669 | SPEC | – | – | Active i| Production is active. Expected lifetime: >10 years. | Power Transformer | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | ||
 | 750342671 | SPEC | 4 files | Active i| Production is active. Expected lifetime: >10 years. | Transformer | – | 100 | – | EE13/7/4 | – | – | 4000 | – | – | 3000 | – | 13.72 | 20.45 | 10.16 | THT |
| Order Code | Datasheet | Simulation | |
|---|---|---|---|
| 7447709101 | SPEC | |
| 7448030417 | SPEC PCN pendingDue to a pending PCN, a modification of the component will be implemented soon. Please find the PCN below. If you have further questions please get in contact with our sales staff. | |
| 750342670 | SPEC | – | |
| 750342669 | SPEC | – | |
| 750342671 | SPEC |
| Samples |
|---|
| Order Code | Datasheet | Simulation | Downloads | Status | Product series | IRP,40K (A) | ISAT (mA) | fres (MHz) | Size | Version | IR (A) | L (µH) | RDC max. (mΩ) | VR (V (AC)) | VT (V (AC)) | Material | L (mm) | W (mm) | H (mm) | Mount | Samples |
|---|
