230-V, 400-W High Efficiency Battery Charger w/PFC and LLC for 36-V Power Tools Reference Design (TIDA-00355)
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.
• 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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