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reference designLM5023 | Demoboard PMP8740

Texas Instruments LM5023 | Demoboard PMP8740

2-kW industrial AC/DC battery charger reference design with 92% full-load efficiency

Overview

TopologyFlyback Converter
Input voltage195-265 V
Output 112 V / 4.2 A
IC revisionA

Description

This reference design is a module that can be set as standard power supply or a battery charger. The output voltage ranges from 0 V to 32 V at a maximum current of 62.5 A. It consists of four boards, a boost PFC, a phase shift full bridge, a small daughter board (hosting the microcontroller), and a display board with three LEDs and four push-buttons. The input voltage range is universal: 90 VAC to 264 VAC and the input current is limited to 10 Arms, which limits the input power below 200 VAC. The microcontroller interfaces the power supply to an operator and controls all functions, including enabling and shutting down the PFC and DC/DC stage, setting different output voltage levels and charging current limits.

Features

  • 93.5% peak efficiency optimizes thermal management of the module
  • Serial interface gives users the ability to easily parallel up to 10 hardware modules
  • Primary/Secondary or stand-alone configuration for battery charging or standard power supply unit
  • Two raw displays and four pushbuttons simplify configuration
  • Pre-defined levels for li-ion, lead-acid and gel batteries

Typical applications

  • Digital controlled industrial AC/DC

More information

Parts approved by Texas Instruments

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Order Code
Data­sheet
Simu­lation
Downloads
Status
Product series
IRP,40K(A)
ISAT,10%(A)
ISAT,30%(A)
RDC(mΩ)
Qty.
IR(A)
L(µH)
RDC max.(mΩ)
VR(V (AC))
VT(V (AC))
Material
L(mm)
W(mm)
H(mm)
Mount
L1(µH)
L2(µH)
IR(A)
IR 2(A)
ISAT(A)
RDC1 typ(Ω)
RDC2 typ(Ω)
RDC1 max(Ω)
RDC2 max(Ω)
fres(MHz)
Type
SamplesAvailability & Sample
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7443550230
SPECWE-HCI SMT Flat Wire High Current Inductor, 23.8 A, 7 A
Simu­lation
Availability
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Downloads8 files

Status
ActiveProduction is active. Expected lifetime: >10 years.
iProduction is active. Expected lifetime: >10 years.
Product seriesWE-HCI SMT Flat Wire High Current Inductor
Performance Rated Current23.8 A
Saturation Current @ 10%7 A
Saturation Current @ 30%17 A
DC Resistance3.7 mΩ
Packaging Unit400 
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Inductance2.3 µH
DC Resistance3.96 mΩ
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MaterialWE-PERM 
Length13 mm
Width12.8 mm
Height4.7 mm
MountSMT 
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Self Resonant Frequency40 MHz
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744822110
SPECWE-CMB Common Mode Power Line Choke, –, –
Simu­lation
Availability
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Downloads10 files

Status
ActiveProduction is active. Expected lifetime: >10 years.
iProduction is active. Expected lifetime: >10 years.
Product seriesWE-CMB Common Mode Power Line Choke
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Packaging Unit140 
Rated Current1 A
Inductance10000 µH
DC Resistance360 mΩ
Rated Voltage250 V (AC)
Insulation Test Voltage1500 V (AC)
MaterialMnZn 
Length17.5 mm
Width13 mm
Height22 mm
MountTHT 
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7448251201
SPECWE-CMB Common Mode Power Line Choke, –, –
Simu­lation
Availability
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Downloads10 files

Status
ActiveProduction is active. Expected lifetime: >10 years.
iProduction is active. Expected lifetime: >10 years.
Product seriesWE-CMB Common Mode Power Line Choke
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Packaging Unit20 
Rated Current12 A
Inductance1000 µH
DC Resistance9 mΩ
Rated Voltage250 V (AC)
Insulation Test Voltage1500 V (AC)
MaterialMnZn 
Length31 mm
Width22 mm
Height35 mm
MountTHT 
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744878100
SPECWE-DD SMT Shielded Coupled Inductor, –, –
Simu­lation
Availability
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Downloads8 files

Status
ActiveProduction is active. Expected lifetime: >10 years.
iProduction is active. Expected lifetime: >10 years.
Product seriesWE-DD SMT Shielded Coupled Inductor
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Packaging Unit1000 
Rated Current1 A
Inductance10 µH
DC Resistance150 mΩ
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Length7.3 mm
Width7.3 mm
Height4 mm
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Inductance 110 µH
Inductance 210 µH
Rated Current1 A
Rated Current 21 A
Saturation Current2 A
DC Resistance 10.125 Ω
DC Resistance 20.125 Ω
DC Resistance 10.15 Ω
DC Resistance 20.15 Ω
Self Resonant Frequency30 MHz
TypeStraight 
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750815330
SPECOffline Transformer, –, –
Simu­lation
Availability
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Downloads5 files

Status
ActiveProduction is active. Expected lifetime: >10 years.
iProduction is active. Expected lifetime: >10 years.
Product series Offline Transformer
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Inductance800 µH
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Insulation Test Voltage3750 V (AC)
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Length27.05 mm
Width32.25 mm
Height22.86 mm
MountTHT 
Inductance 1800 µH
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Saturation Current2.6 A
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