230-V: 400-W: 92% Efficiency Battery Charger w/PFC and LLC for 36-V Power Tools Reference Design
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 • 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
Applications
- Electric bike
- Cordless vacuum cleaner
- AC drive power stage module
- Spectrometer
- Semiconductor manufacturing
- Automotive test
- DIN rail power supply
- Servo drive power stage module
- DC-input BLDC motor drive
- Position sensor
- Appliances: battery charger
- Industrial AC-DC
- Merchant DIN rail power supply
- Source measurement unit (SMU)
- Battery test
- Mobile robot CPU board
- Drone accessories
- Circuit breakers
Product Categories
- Power management
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| Download the bill of materials for TIDA-00355 | Download |
Test Data
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Download the test file for TIDA-00355| Title | Updated | Type | Size (KB) | |
|---|---|---|---|---|
| TIDA-00355 Assembly Drawing (Rev. A) | 09 Jun 2015 | 103 | ||
| TIDA-00355 CAD Files (Rev. A) | 09 Jun 2015 | ZIP | 3404 | |
| TIDA-00355 PCB (Rev. A) | 09 Jun 2015 | 2705 | ||
| TIDA-00355 BOM (Rev. A) | 09 Jun 2015 | 105 | ||
| TIDA-00355 Schematic (Rev. A) | 09 Jun 2015 | 426 | ||
| TIDA-00355 Gerber (Rev. A) | 09 Jun 2015 | ZIP | 542 |