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PMP41106

Universal input, 500W constant current and constant voltage E-bike charger reference design

PMP41106

Design files

Overview

This reference design is a universal input, 48V, 10.4A constant current (CC), constant voltage (CV) charger for e-bike applications. The reference design achieves 91.5% end-to-end peak efficiency with a 110Vac input, and 93.50% end-to-end peak efficiency with a 230Vac input. This design includes fan control and charging status indication based on output current. This reference design uses the UCC28180, UCC256603, UCC28910, and TL103W devices.

Features
  • 93.5% peak efficiency
  • Power factor of greater than 0.9 for output power larger than 100W
  • Charging status indication
Output voltage options PMP41106.1
Vin (Min) (V) 90
Vin (Max) (V) 264
Vout (Nom) (V) 48
Iout (Max) (A) 10.4
Output Power (W) 499.2
Isolated/Non-Isolated Isolated
Input Type AC
Topology Boost- PFC^Half Bridge- LLC
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A fully assembled board has been developed for testing and performance validation only, and is not available for sale.

Design files & products

Design files

Download ready-to-use system files to speed your design process.

PDF | HTML
TIDT411.PDF (1449 K)

Test results for the reference design, including efficiency graphs, test prerequisites and more

TIDMD82.PDF (464 K)

Detailed schematic diagram for design layout and components

TIDMD86.PDF (171 K)

Detailed schematic diagram for design layout and components

TIDMD84.PDF (415 K)

Detailed overview of design layout for component placement

TIDMD85.ZIP (16403 K)

Files used for 3D models or 2D drawings of IC components

TIDCGR1.ZIP (72 K)

Design file that contains information on physical board layer of design PCB

Products

Includes TI products in the design and potential alternatives.

AC/DC & DC/DC controllers (external FET)

UCC25660Wide VIN and VOUT 750kHz LLC controller

Data sheet: PDF | HTML
AC/DC & DC/DC controllers (external FET)

UCC2818018-kHz-250-kHz CCM PFC controller with enhanced startup & transient response

Data sheet: PDF | HTML
AC/DC & DC/DC converters (integrated FET)

UCC28910700V Flyback switcher with constant-voltage constant-current and primary-side control

Data sheet: PDF | HTML
General-purpose op amps

TL103WDual, 32-V, 900-kHz operational amplifier with internal reference

Data sheet: PDF | HTML

Technical documentation

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Type Title Date
* Test report Universal Input, 500W Constant Current and Constant Voltage E-Bike Charger Reference Design PDF | HTML Sep. 05, 2024

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