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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 | ISAT,10%(A) | ISAT,30%(A) | IR,40K(A) | IRP,40K(A) | 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 | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
 | WE-PD SMT Power Inductor, 3.1 A, 3.8 A | Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWE-PD SMT Power Inductor | Saturation Current @ 10%3.1 A | Saturation Current @ 30%3.8 A | Rated Current2.5 A | Performance Rated Current3.2 A | Self Resonant Frequency4.3 MHz | Size1210 | VersionStandard | Rated Current2.5 A | Inductance100 µH | DC Resistance110 mΩ | – | – | – | Length12 mm | Width12 mm | Height10 mm | MountSMT | ||||
 | WE-CMBNC Common Mode Power Line Choke Nanocrystalline, –, – | Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWE-CMBNC Common Mode Power Line Choke Nanocrystalline | – | – | – | – | – | SizeM | VersionTHT | Rated Current4 A | Inductance17000 µH | DC Resistance52 mΩ | Rated Voltage300 V (AC) | Insulation Test Voltage2100 V (AC) | MaterialNanocrystalline | Length23 mm | Width13.5 mm | Height26 mm | MountTHT | ||||
750342670 | Power Transformer, –, – | Simulation– | Downloads– | Status Activei| Production is active. Expected lifetime: >10 years. | Product series Power Transformer | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | ||
750342669 | Power Transformer, –, – | Simulation– | Downloads– | Status Activei| Production is active. Expected lifetime: >10 years. | Product series Power Transformer | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | – | ||
 | 750342671 | Transformer, –, – | Status Activei| Production is active. Expected lifetime: >10 years. | Product series Transformer | – | – | – | – | – | SizeEE13/7/4 | – | – | Inductance4000 µH | – | – | Insulation Test Voltage3000 V (AC) | – | Length13.72 mm | Width20.45 mm | Height10.16 mm | MountTHT |