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TEA19161+19162 & MCU Based CC-CV 2.5kW Charger Concept

Hi team,

I’m evaluating a 2.5 kW 48 V CC–CV charger concept similar to ST’s reference design (LLC with MCU control):
https://www.st.com/en/evaluation-tools/stdes-2kw5ch48v.html

Goal
Develop the power stage using NXP’s TEA19161 (LLC resonant controller) together with an MCU for telemetry, protection, and CC–CV management.

Preliminary targets

Input: 390–400 VDC from PFC (or 325–420 VDC if a wider range is preferred)
Output: 48 V nominal, up to ≈50 A (≈2.4–2.5 kW)
Regulation: CC–CV with smooth transition and fast OCP response
Efficiency: ≥92 % peak, ≥93 % at 50–100 % load
Topology: Full-bridge LLC with synchronous rectification on the secondary, using the two gate-drive outputs of the TEA19161 to generate the complementary signals required for full-bridge operation, and external stronger drivers to handle the higher gate charge and power level.

Key questions

1. CC–CV control concept
I plan to implement two op-amp loops on the secondary side: one for voltage sensing and one for current sensing (via a shunt).
The MCU will adjust both reference levels dynamically to realize the CC↔CV transition. The combined feedback from these two loops will then drive a single optocoupler back to the TEA19161 for primary-side control.

Could you confirm whether this approach is compatible with TEA19161?

2. Power scalability

Once reconfigured for full-bridge operation with stronger gate drivers,
is it realistic to reach ≈2.5 kW output power using TEA19161

Thanks in advance for your support and any design recommendations for using TEA19161 + MCU in this 2.5 kW CC–CV charger project.

Re: TEA19161+19162 & MCU Based CC-CV 2.5kW Charger Concept

HI

We only have LLC controller and newest part is TEA2226AT | Digital Configurable LLC Controller | NXP Semiconductors

But this part can drive maximum up to 1KW,so in your design should have two in parallel to get 2KW. You should add some circuits to achieve average/equal current in both controllers.