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Author Topic: SMPS 2.5kW/ Battery Charger  (Read 4067 times)
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Orcino Borges
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« on: November 05, 2009, 08:04:56 20:04 »

Hi, I'm designing a power suplly ( 60V, 42A)  for a battery charger and want to exchange information with people who also have the same interest.

                 Orcino
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DarkClover
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« Reply #1 on: November 05, 2009, 08:24:25 20:24 »

Why such a big amount of power? For which kind of battery is it ?
Is it digital controlled or analog ?

I'm very interested in such projects but I had no time before to do one.
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Orcino Borges
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« Reply #2 on: November 05, 2009, 10:36:53 22:36 »

Hi, this charger is for 48 volts batteries, controlled by a DSPic 30F2020 and de power is a Full bridge with ZVS and synchronous retification.

               Orcino
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cerebronico
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« Reply #3 on: November 06, 2009, 02:21:15 02:21 »

Hi Orcino,

What are the characteristics of your design, have you considered designing it foolproof?, (0 VDC at open terminals), do you make your own ferrite core transformer? which is the operating Frecuency?

regards,

c
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janakfun
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« Reply #4 on: November 06, 2009, 04:57:43 04:57 »

Are you sure you want to design it for 42A...
your supply will be very bulky... I'm seeing this kind of requirement first time... an unusual.
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Janak
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« Reply #5 on: November 06, 2009, 08:03:20 20:03 »

Are you sure you want to design it for 42A...
your supply will be very bulky... I'm seeing this kind of requirement first time... an unusual.
This is not unusaul at all, I've seen battery chargers upto 150amps and upto 80volts,

I take it that the battery charger is charging 600AH batteries and they are lead acid ?

will you be using thyristor controlled to limt the current or just a standard taper transformer where the current is limted by the transfomer and the current tapers to a smaller current at the end of charge, Will you kepp it floating or teminate it at the end of charge ?

Sounds a god project.
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cerebronico
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« Reply #6 on: November 06, 2009, 08:43:24 20:43 »

Indeed this isn't unusual, rather is is normal to find this chargers in comunications equipment which mostly works on -48VDC, I have build several of this system in the past but using analog parts, i was planning switch to digital a long ago but because lack of time, I have delayed the project.

I would like to share any info about this project

c
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veli
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« Reply #7 on: November 17, 2009, 12:54:28 12:54 »

I know a charger of that type that uses a bulky transformer(coil)4 such current
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Diramo
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« Reply #8 on: November 26, 2009, 02:23:18 02:23 »

Well, I have finished design of medium power re-configurable battery charger, max. output power 1.6KW, output voltage 24/36/48 V. There is two stages in my design - PFC (controller - Marvell 88EM8011) and ZVS (controller from Linear Technology LTC3722-2), MOSFETs for PFC - Infineon IPW60R099CP, for PWM - IPW60R199CP, also from Infineon. This product already commercialized and manufactured by my former company.
Nowadays I have getting started a new design, charger for 360V and 720V battery pack, output power 3200W and 6500W. Unfortunately until now I have no good idea how to design high efficiency PFC. Temporary I use well-known solution from TI based on UCC28070, 4ch interleaved PFC, but I do not like it because it has high efficiency at maximum power - up to 97%, but very poor at low power. It is dropped down to 83...87%. So I would like to listen somebody's opinion.
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Orcino Borges
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« Reply #9 on: November 26, 2009, 11:25:09 11:25 »

Hi Diramo,

    In my design I'm using a DSPic 30F2020  for the control and generation of the PWM, and I use a MOSFET 35N60C3 Infineon. I looked on the Marvell site and saw that the 88EM8011 is up to 250W, as you did to use it up to 1.6KW ?

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Diramo
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« Reply #10 on: November 26, 2009, 12:14:22 12:14 »

Hi, Orcino Borges!
Marvell 88EM8011 is CCM PFC controller and the output power limited only by the current of the output gate driver - Adaptive gate driver for applications between 10W–250W - taken from the chip manual.
If you use external high speed and high capacity gate driver, the maximum reachable power can be as high as 2 kW and even higher. Also I do not use current sensing resistor. Instead of this I applied two high speed current sensors Si8506 placed in series with boost inductor and in MOSFET drain network.

Infineon IPW60R099CP MOSFET has very good dynamic switching properties and intended for hard switching, so I do not need to include passive or active additional components for to provide soft switching.
I did not use any DSP because of customer wishes. But for a prototype design I used Freescale 56F8006.
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