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Design of 550W Battery charger

Rakesh P
Prodigy 20 points
Other Parts Discussed in Thread: PMP, PMP30521, UCC28180, UCC25600, UCC21220

Hi

We would like to design a battery charger with output power of 550W. Below given the specification, Please suggest a best solution for our application.

Input supply: Two Phases: 323V - 690VAC

Output: Dual output: 15V/20A - Constant current source for battery charging

                              :  15V/15A - Contant Voltage Source for Automotive Loads

Maximum Operating Temperature: 85 C

Cooling: Convection Cooling (No Forced Air)

Enclosure: Closed (IP66 rated)

Looking for a best solution with high efficiency.

With regards

Rakesh.P

Mb:9020849673

  • 0
    TI__Guru**** 166176 points

    Hi Rakesh,

    TI battery charge team does not have a solution for this.  I recommend searching through the multi-chip reference designs at TI Reference Designs Library.

    Regards,
    Jeff

  • 0 in reply to Jeff F
    Prodigy 20 points

    Hi Jeff

    Thanks for your reply.

    I am not looking for a single chip solution. I had gone through the Ti references and found PMP 30521 which is somewhat matching to our application. 

    Can you please confirm whether this reference design can work with our 600W output power and input voltage range?

    With regards

    Rakesh.P

  • 0 in reply to Rakesh P
    TI__Expert 6500 points

    Hi Rakesh,

    PMP30521 will not work as it is for your specifications. It would need to have the power stage redesigned to handle the wider input range and also the extended power that you need.

    This is not a trivial redesign, most all of the components would need to be redesigned.

    But, it is possible to do, and is a good starting point for a design.

    Thanks,

    Robert  

  • 0 in reply to Robert Taylor1
    TI__Expert 5875 points

    Hi Rakesh,

    I confirm the PMP30521 is a good starting point, since it uses for the PFC stage a UCC28180: this is a CCM PFC controller, suitable for power level up to few kW. Nevertheless, the maximum input AC voltage is 690VAC, which rectified makes 976V. Since the UCC28180 is driving typically a Boost topology, you will need to have at least 1 kV as Vout. That means, you can use the PMP30521 schematic for Boost topology, but need to replace the MOSFET with 1.2 or 1.5 kV SiC FET, as well as using 1.2 kV or 1.5 kV SiC diode. After that, the second stage has also to work wit this high voltage, therefore suggested are also SiC FETs with the same voltage rating.

    One question: the first output is a constant-current regulated 15V output; does it mean this output charges a 12V battery?

    If so, then Vout minimum would be 10V or 11V, while Vout max will be 14.4V or 15V. If this is the case, I believe a resonant LLC is also suitable for this DC/DC converter, but the UCC25640x cannot be used because it can not withstand so high voltage. Probably best is to use an LLC controller, like the UCC25600, which does not need the switch node voltage to calculate internal delay times. If you select then a UCC25600, you will have to add high voltage isolated drivers, like the UCC21220 which support up to 990 Vpeak.

    Please let me know if you have questions.

    Best regards,

    Roberto