Universal AC Input to 30Vmax@6A Lead-acid Battery Charger Reference Design with PFC


Design files


The PMP10110 design converts the universal input AC voltage to isolated 17V...30V@6A and is suitable to charge lead-acid or Li-Ion batteries. The converter is a constant-V and constant-I genarator and the set points for output voltage (charge level) and current are settable by means of two PWM signals. The first stage is a PFC boost while the isolation ad current stabilization is performed by DC-DC half bridge stage. An isolated quasi-resonant flyback converter supplies all internal voltages and provide some extra current for external loads (fan or analog section), in details 12V@400mA and 5V@300mA.

  • The first stage is a CCM PFC boost driven with UCC28180, showing high efficiency and low EMI signature
  • The second stage is a DC/DC half bridge, wich includes both current and voltage loops; a PWM signal is used as reference for voltage and current
  • An auxiliary power supply generates all needed voltages; a network is disconnecting all resistors tied to high voltage to reduce stand-by losses
  • Plug-to-plug efficiency at full load:  86%...92% in the whole input voltage range
  • This design is tested and includes test results and CAD files
Output voltage options PMP10110.1 PMP10110.2 PMP10110.3 PMP10110.4
Vin (Min) (V) 85 120 360 6
Vin (Max) (V) 264 440 440 15
Vout (Nom) (V) 390 12 30 5
Iout (Max) (A) .51 .4 6 .3
Output Power (W) 198.9 4.8 180 1.5
Isolated/Non-Isolated Non-Isolated Isolated Isolated Non-Isolated
Input Type AC DC DC DC
Topology PFC- Boost Flyback- Quasi Resonant Half Bridge- Hard Switched 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.

TIDUAQ9.PDF (1497 K)

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


Detailed schematic diagram for design layout and components


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


Detailed overview of design layout for component placement

TIDCB06.ZIP (130 K)

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


Includes TI products in the design and potential alternatives.

Power factor correction (PFC) controllers

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

Data sheet: PDF | HTML
Analog current-sense amplifiers

INA194-16 to 80V, 500kHz current sense amplifier

Data sheet: PDF | HTML
Buck converters (integrated switch)

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

Data sheet: PDF | HTML
Flyback controllers

UCC28710Constant-voltage, constant-current PWM with PSR, valley switching & Programmable cable compensation

Data sheet: PDF | HTML
General-purpose op amps

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

Data sheet: PDF
Half-bridge drivers

UCC277144-A, 600-V half bridge gate driver

Data sheet: PDF | HTML
PWM controllers

LM5039Half-bridge PWM controller with advanced current limit

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 PMP10110 Test Results Sep. 24, 2015

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