230-V, 400-W high efficiency battery charger w/PFC and LLC for 36-V power tools reference design

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

Parts Include:
TL103WA Dual OpAmp With Internal Reference 
TLV704 24-V Input Voltage, 150-mA, Ultralow IQ Low-Dropout Regulators 
UCC25600 8-Pin High-Performance Resonant Mode Controller 

Learn more by downloading the reference design below