2-kW industrial AC/DC battery charger reference design with 92% full-load efficiency
PMP8740
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Description & Features

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Key Document

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
  • Master/slave 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

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Schematic/Block Diagram

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Design Guide

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Design Files

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Parametrics
 PMP8740.1
(Output Voltage 1)
PMP8740.2
(Output Voltage 2)
PMP8740.3
(Output Voltage 3)
PMP8740.4
(Output Voltage 4)
PMP8740.5
(Output Voltage 5)
Vin (Min) (V)90909035010
Vin (Max) (V)26526526542014
Vout (Nom) (V)3901232325
Iout (Max) (A)3.9.0562.562.5.3
Output Power (W)1521.6200020001.5
Isolated/Non-IsolatedNon-IsolatedIsolatedIsolatedIsolatedNon-Isolated
Input TypeACACACDCDC
TopologyPFC- BoostFlyback- Quasi ResonantFlyback- Quasi ResonantFull Bridge- Phase ShiftedBuck- Synchronous

TI Devices (16)

Order samples, get tools and find more information on the TI products in this reference design.

Part Number Name Product Family Sample & Buy Design Kits & Evaluation Modules
CSD18532Q5B  60V, N ch NexFET MOSFET™, single SON5x6, 3.2mOhm  MOSFETs  Sample & Buy View Design Kits & Evaluation Modules
LM5023  AC-DC quasi-Resonant current mode PWM controller  Offline & isolated DC/DC controllers & converters  Sample & Buy View Design Kits & Evaluation Modules
LMT87  ±2°C 2.7V to 5.5V analog output temperature sensor with -13.6 mV/°C gain  Temperature sensors  Sample & Buy View Design Kits & Evaluation Modules
LMV431A  1%, low-voltage (1.24-V) adjustable precision shunt regulator  Voltage references  Sample & Buy Not Available
MSP430F2252  16 MHz MCU with 16KB FLASH, 512B SRAM, 10-bit ADC, I2C/SPI/UART  Microcontrollers (MCU)  Sample & Buy View Design Kits & Evaluation Modules
MSP430G2544  16 MHz MCU with 16KB FLASH, 512B SRAM, 10-bit ADC, UART/SPI/I2C, Timer  Microcontrollers (MCU)  Sample & Buy View Design Kits & Evaluation Modules
OPA378  Low-Noise, 900kHz, RRIO, Precision Operational Amplifier, Zerø-Drift Series   Operational amplifiers (op amps)  Sample & Buy View Design Kits & Evaluation Modules
SN65HVD256  CAN Transceiver With Fast Loop Times for Highly Loaded Networks  Interface  Sample & Buy Not Available
TL431  Adjustable precision shunt regulator  Voltage references  Sample & Buy View Design Kits & Evaluation Modules
TLC272  Dual Single Supply Operational Amplifier  Operational amplifiers (op amps)  Sample & Buy View Design Kits & Evaluation Modules
TPS560200  17V Input, 500mA Synchronous Step-Down Regulator in SOT-23 with Advanced Eco-Mode™  Step-down (buck) regulators  Sample & Buy View Design Kits & Evaluation Modules
TPS715  50-mA, 24-V, ultra-low-IQ, low-dropout voltage regulator  Power management  Sample & Buy View Design Kits & Evaluation Modules
UCC27517  4-A/4-A single-channel gate driver with 5-V UVLO and 13-ns prop delay in SOT-23 package  Gate drivers  Sample & Buy View Design Kits & Evaluation Modules
UCC27524  5-A/5-A dual-channel gate driver with 5-V UVLO, enable, and 1-ns delay Matching  Gate drivers  Sample & Buy View Design Kits & Evaluation Modules
UCC28180  18kHz-250kHz CCM PFC controller with Enhanced Start-up and Transient Response  Offline & isolated DC/DC controllers & converters  Sample & Buy View Design Kits & Evaluation Modules
UCC28951  Green phase-shifted full-bridge controller with SR control for Wide input voltage Range  Offline & isolated DC/DC controllers & converters  Sample & Buy View Design Kits & Evaluation Modules

CAD/CAE symbols

Part # Package | Pins CAD File (.bxl) STEP Model (.stp)
CSD18532Q5B VSON-CLIP (DNK)| 8 Download Download
LM5023 Download Download
LMT87 Download Download
Download
Download
LMV431A Download Download
Download Download
Download
MSP430F2252 Download -
Download Download
Download -
MSP430G2544 Download -
Download Download
Download -
OPA378 Download Download
Download Download
SN65HVD256 Download Download
TL431 Download Download
Download Download
Download -
Download Download
Download Download
Download Download
Download Download
Download -
Download Download
TLC272 Download Download
Download -
Download Download
Download -
Download Download
Download -
TPS560200 Download Download
TPS715 Download Download
UCC27517 Download
UCC27524 Download Download
Download Download
Download -
Download Download
UCC28180 Download
UCC28951 Download -

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Technical documentation

See the Important Notice and Disclaimer covering reference designs and other TI resources.

User guide (1)
Title Type Size (KB) Date
PDF 3434 03 Oct 2019
Design files (6)
Title Type Size (KB) Date
ZIP 393 03 Oct 2019
ZIP 4420 03 Oct 2019
ZIP 2195 03 Oct 2019
ZIP 538 03 Oct 2019
ZIP 416 03 Oct 2019
ZIP 983 03 Oct 2019

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