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


Design files


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.

  • 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
Output voltage options PMP8740.1 PMP8740.2 PMP8740.3 PMP8740.4 PMP8740.5
Vin (Min) (V) 90 90 90 350 10
Vin (Max) (V) 265 265 265 420 14
Vout (Nom) (V) 390 12 32 32 5
Iout (Max) (A) 3.9 .05 62.5 62.5 .3
Output Power (W) 1521 .6 2000 2000 1.5
Isolated/Non-Isolated Non-Isolated Isolated Isolated Isolated Non-Isolated
Input Type AC AC AC DC DC
Topology PFC- Boost Flyback- Quasi Resonant Flyback- Quasi Resonant Full Bridge- Phase Shifted Buck- Synchronous
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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.

TIDT140.PDF (3505 K)

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

TIDM224.ZIP (983 K)

Detailed schematic diagram for design layout and components

TIDM225.ZIP (416 K)

Complete listing of design components, reference designators, and manufacturers/part numbers

TIDM226.ZIP (538 K)

Detailed overview of design layout for component placement

TIDM228.ZIP (4420 K)

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


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

TIDM227.ZIP (2195 K)

PCB layer plot file used for generating PCB design layout


Includes TI products in the design and potential alternatives.

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

LM5023AC-DC quasi-Resonant current mode PWM 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 controllers (external FET)

UCC28951Green phase-shifted full-bridge controller with SR control for Wide input voltage Range

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

TPS56020017V Input, 500mA Synchronous Step-Down Regulator in SOT-23 with Advanced Eco-Mode™

Data sheet: PDF | HTML
Analog temperature sensors

LMT87±2°C 2.7V to 5.5V analog output temperature sensor with -13.6 mV/°C gain

Data sheet: PDF | HTML
CAN transceivers

SN65HVD256CAN Transceiver With Fast Loop Times for Highly Loaded Networks

Data sheet: PDF | HTML
General-purpose op amps

TLC272Dual, 16-V, 2-MHz, In to V- operational amplifier

Data sheet: PDF
Linear & low-dropout (LDO) regulators

TPS71550mA 24V ultra-low-IQ low-dropout (LDO) voltage regulator

Data sheet: PDF | HTML
Low-side drivers

UCC275174-A/4-A single-channel gate driver with 5-V UVLO and 13-ns prop delay in SOT-23 package

Data sheet: PDF | HTML

CSD18532Q5B60-V, N channel NexFET™ power MOSFET, single SON 5 mm x 6 mm, 3.2 mOhm

Data sheet: PDF | HTML
MSP430 microcontrollers

MSP430F225216 MHz MCU with 16KB Flash, 512B SRAM, 10-bit ADC, 1 OpAmp, UART/SPI/I2C

Data sheet: PDF
MSP430 microcontrollers

MSP430G254416 MHz MCU with 16KB Flash, 512B SRAM, 10-bit ADC, UART/SPI/I2C, timer

Data sheet: PDF | HTML
Precision op amps (Vos<1mV)

OPA378Low-noise, 900-kHz, RRIO, precision operational amplifier, zero-drift series

Data sheet: PDF
Shunt voltage references

LMV431A1%, low-voltage (1.24-V) adjustable precision shunt regulator

Data sheet: PDF
Shunt voltage references

TL431Adjustable precision shunt regulator

Data sheet: PDF | HTML

Technical documentation

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Type Title Date
* Test report 2-kW Industrial AC/DC Battery Charger Reference Design Oct. 03, 2019

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