This thread has been locked.

If you have a related question, please click the "Ask a related question" button in the top right corner. The newly created question will be automatically linked to this question.

TPS54561-Q1: Unstable current control for battery charger application

Part Number: TPS54561-Q1
Other Parts Discussed in Thread: TPS54561

Hi all,

I have this design setup for a charger for dual seal lead acid batteries. The batteries charge to 14.2V x 2 (28.4V) and turn off with external control exactly as this design below which "works". I used a different design where this worked absolutely perfectly but had to swap it out for this as there were no stocks.

Design link:

webench.ti.com/.../SDP.cgi

The issue is that when you put "dead batteries" on this design the limit of 2Amps is ignored and it oscillates and goes switches current ultra high and low causing the power supply to go crazy and the current is definitely not limited in any way to 2Amps, it goes to 5 to 6Amps and switches on and off at 6amps by the looks of it.

The issue now is i have a design on my desk that I really need to get working. 

It looks like I have to do "something" to the COMP input to control the switching method this chip uses. Can anyone give some insites on how to get the chip to "stay" at 2Amps (its ok to go over for a second or so, but it just falls apart and switchs 5Amp on and off, looks like it shuts down, gets out of control. 

The input voltage is a toroidal transformer into a full bridge which is 24Vdc 10Amp, unreg output reads 36V to 40V on the 3 x 2200uF caps. This voltage goes crazy when the power supply is current limiting and the output of the regulator also goes crazy.

  • Hi,

    This is a 5A device and per the datasheet output inductor selection Section 8.2.1.2.3, the switch current limit of the TPS54561 is nominally 7.5A. As such it is generally recommended to pick an appropriate inductor with saturation current rating equal or greater than this amount.

    You may be experiencing the issue since during power up, faults, and transient loads the inductor current can increase above the peak inductor current level. 

    The inductor in your webench simulation doesn't appear to be properly rated.

    Regards,

    Jimmy