Design Help

Milind Ranjan

Other Parts Discussed in Thread: UCC28180, UCC28951, UCC28950, UCC28070

Hello All,

I need help in designing a 84V 10A actual output supply(only one output) , a charger that operates on CV/CC mode and i dont know how and where to start from. My input is 90-270VAC@50Hz.

over 6 years ago

0 Peter Meaney over 6 years ago

TI__Mastermind 31580 points

Hi Milind

I recommend you use a two stage approach, PFC + DC/DC isolation stage. For the PFC I suggest the UCC28180 and if you follow this link you can find a list of reference designs that use this device, www.ti.com/.../index.html

For the DC/DC stage I suggest you use the UCC28951 (new version of the UCC28950) this link will has a 2kW design using the UCC28180 with the UCC28950, www.ti.com/.../slup349.pdf

Another option for the PFC is the UCC28070 and this link will bring you to a 1.2kW design, http://www.ti.com/tool/pr779.

I hope these links help.

Please also take a look through the TI power supply design seminars at www.ti.com/.../login.shtml, which have a lot of good information in them.

Regards

Peter

0 Milind Ranjan over 6 years ago in reply to Peter Meaney

Prodigy 120 points

Thanks a lot sir i will dive deeper into what you recommended and if i have some problems will tell you here. Still thank you very much for providing me guidance!!.

0 Milind Ranjan over 6 years ago in reply to Milind Ranjan

Prodigy 120 points

sir for pfc stage the link isnt working

0 Peter Meaney over 6 years ago in reply to Milind Ranjan

TI__Mastermind 31580 points

Hi Milind,

Sorry, try this link.

Regards

Peter

0 Milind Ranjan over 6 years ago in reply to Peter Meaney

Prodigy 120 points

https://webench.ti.com/appinfo/webench/scripts/SDP.cgi?ID=B3EC777B19113CC1

i tried this on webench , can i go in this way?

0 Peter Meaney over 6 years ago in reply to Milind Ranjan

TI__Mastermind 31580 points

Hi Milind

This is an LLC design which really needs a PFC stage in front of it to converter the AC line to a stable DC input voltage first. The LLC is generally not able to vary its output voltage over a wide range for battery charging applications, that is why I suggested the phase shifted full bridge option using the UCC28951 controller.

Regards

Peter

0 Milind Ranjan over 6 years ago in reply to Peter Meaney

Prodigy 120 points

Oh yeah i almost forgot , yes now i got it phase shifted full bridge is really best one! . Thanks a lot sir.

0 Milind Ranjan over 6 years ago in reply to Peter Meaney

Prodigy 120 points

sir i generated two different designs according to my calculations using UCC28180 & UCC25630 , can i merge both of them to form a final design?? I have attached both the webench links?

https://webench.ti.com/appinfo/webench/scripts/SDP.cgi?ID=00B812B5C290B669

https://webench.ti.com/appinfo/webench/scripts/SDP.cgi?ID=C7C07D823D155DEB

0 Peter Meaney over 6 years ago in reply to Milind Ranjan

TI__Mastermind 31580 points

Hi Milind

The PMP20946 shows how the UCC28180 and UCC25630 can combined together

www.ti.com/.../PMP20946

I also noticed that they are powering the UCC28180 from the RVCC pin of the UCC25630 which does not work all the time as the min voltage from the UCC25630 is lower than the max turn-on voltage of the UCC28180. I advise you to use a simple regulator from the Vcc pin of the UCC25630 to power the UCC28180 instead.

Regards

Peter

0 Milind Ranjan over 6 years ago in reply to Peter Meaney

Prodigy 120 points

yes i got it. I took 390VDC@2.2A VDC output from PFC using UCC28180 and then i will interface this output to HB-LLC stage of UCC25630 as input to obtain final output of 84V@10A. But now only doubt i feel that do i have to get the output current of 10A from PFC stage at 390VDC and put same into LLC stage in order to obtain final output of 84V and 10A output? Then wouldnt it be too much to pressure on the IC for handling atleast 4000W power output to produce 840W? I am so far only using the datasheets for calculation purposes so i feel a bit stuck here also.

0 Peter Meaney over 6 years ago in reply to Milind Ranjan

TI__Mastermind 31580 points

Hi Milind,

The transformer stage in the LLC will converter the 390V at 2A from the PFC down to 84V and it will scale the scale the current from 2A to 10A so the PFC stage will only be delivering slightly more power than the output. There will be some power lost in the LLC stage but generally this is about 5% of the output power.

I am concerned that you might find the development of the power stage very challenging as there are many aspects to consider beyond the electrical requirements such as EMI and safety. Many experience power supply designers would find this project a challenge.

Regards

Peter

0 Milind Ranjan over 6 years ago in reply to Peter Meaney

Prodigy 120 points

Yes i had a notion that LLc would scale. I m like just a noob in power management area being a college student i m still learning , the problem is i dont have any SMPS experienced people around me but this forum has helped me a lot. So now i gotta go understand and finish my calculations. Thanks a lot sir!

Simulation, hardware & system design tools

Simulation, hardware & system design tools forum

Design Help