High efficiency 12-V, 5-A active clamp forward with 9-V to 60-V wide input range reference design


Design files


This forward-converter reference design is designed for an isolated 60-W, 12-V intermediate bus voltage rail. It operates in a wide-input range of 9 V to 60 V. The design features LM5026, a 100-V active clamp current mode PWM controller. A self-driven secondary rectifier with UCC27511 4-A and 8-A driver is used for high efficiency. It can be used in isolated-supply applications where high efficiency and hiccup protection are needed.

  • High efficiency of 92.2% at 12 VIN
  • Wide-input range of 9 V to 60 V
  • Self-driven secondary rectifier improves efficiency
  • Hiccup protection enhances reliability
Output voltage options PMP22075.1
Vin (Min) (V) 9
Vin (Max) (V) 60
Vout (Nom) (V) 12
Iout (Max) (A) 5
Output Power (W) 60
Isolated/Non-Isolated Isolated
Input Type DC
Topology Forward- Active Clamp
Communications equipment

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.

TIDT159.PDF (6525 K)

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

TIDM450.PDF (65 K)

Detailed schematic diagram for design layout and components

TIDM451.PDF (116 K)

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

TIDM452.PDF (637 K)

Detailed overview of design layout for component placement


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

TIDM453.PDF (226 K)

PCB layer plot file used for generating PCB design layout


Includes TI products in the design and potential alternatives.

PWM controllers

LM5026100-V active clamp current mode PWM controller with P or N-channel clamp FET and CS restart timer

Data sheet document-pdfAcrobat PDF open-in-new HTML
Low-side drivers

UCC275114-A/8-A single-channel gate driver with 5-V UVLO, split outputs, and 13-ns Prop delay

Data sheet document-pdfAcrobat PDF open-in-new HTML
Shunt voltage references

LMV4311.5%, low-voltage (1.24-V) adjustable precision shunt regulator

Data sheet document-pdfAcrobat PDF
Shunt voltage references

TL431Adjustable precision shunt regulator

Data sheet document-pdfAcrobat PDF open-in-new HTML

Technical documentation

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Type Title Date
Test report High Efficiency 12-V/5-A Active-Clamp Forward Reference Design Feb. 06, 2020

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