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Texas Instruments LM5023 | Demoboard PMP8740
2-kW industrial AC/DC battery charger reference design with 92% full-load efficiency
Overview
| Topology | Flyback Converter |
| Input voltage | 195-265 V |
| Output 1 | 12 V / 4.2 A |
| IC revision | A |
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
Products
Order Code | Datasheet | Simulation | Downloads | Status | Product series | IRP,40K(A) | ISAT,10%(A) | ISAT,30%(A) | RDC(mΩ) | 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 | Samples | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
 | WE-HCI SMT Flat Wire High Current Inductor, 23.8 A, 7 A | Status Activei| Production 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 | – | Inductance2.3 µH | DC Resistance3.96 mΩ | – | – | MaterialWE-PERM | Length13 mm | Width12.8 mm | Height4.7 mm | MountSMT | – | – | – | – | – | – | – | – | – | Self Resonant Frequency40 MHz | – | ||||
 | WE-CMB Common Mode Power Line Choke, –, – | Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWE-CMB Common Mode Power Line Choke | – | – | – | – | 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 | – | – | – | – | – | – | – | – | – | – | – | ||||
| WE-CMB Common Mode Power Line Choke, –, – | Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWE-CMB Common Mode Power Line Choke | – | – | – | – | 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 | – | – | – | – | – | – | – | – | – | – | – | ||||
 | WE-DD SMT Shielded Coupled Inductor, –, – | Status Activei| Production is active. Expected lifetime: >10 years. | Product seriesWE-DD SMT Shielded Coupled Inductor | – | – | – | – | Rated Current1 A | Inductance10 µH | DC Resistance150 mΩ | – | – | – | Length7.3 mm | Width7.3 mm | Height4 mm | – | 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 | ||||
 | 750815330 | Offline Transformer, –, – | Status Activei| Production is active. Expected lifetime: >10 years. | Product series Offline Transformer | – | – | – | – | – | Inductance800 µH | – | – | Insulation Test Voltage3750 V (AC) | – | Length27.05 mm | Width32.25 mm | Height22.86 mm | MountTHT | Inductance 1800 µH | – | – | – | Saturation Current2.6 A | – | – | – | – | – | – |