120V AC 200W, 90% Efficiency, Interleaved Flyback for Battery Charging Applications Reference Design


Design files


TIDA-00200 proposes an interleaved flyback topology for battery charger applications that require an output power level of ~200 W with a minimized bill of material. Besides the actual electronic components, the efforts for cooling are a major contributor to the overall design cost. By taking advantage of the LM5032 high voltage dual interleaved current mode controller, the design accomplishes great efficiency of 90% at full load and spreads out the heat for reduced cooling efforts. A fan is typically not needed. The need for smaller form factor heat sinks provides additional design flexibility.

  • Input: 100 V to 120 V +/- 10% AC 50/60 Hz
  • Output voltage 21 V (5 Li-Ion battery cells), up-to 9.5-A charge current
  • 90% efficiency
  • Interleaved flyback topology based on LM5032 high voltage dual interleaved current mode controller
  • Programmable line under voltage lockout and cycle-by-cycle current limit
  • Feedback based on TLC272 dual single supply operational amplifier
??image.gallery.download_en_US?? View video with transcript Video

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.

TIDU413A.PDF (4176 K)

Reference design overview and verified performance test data

TIDRA05.PDF (233 K)

Detailed schematic diagram for design layout and components

TIDRA06.PDF (219 K)

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

TIDRA07.PDF (195 K)

Detailed overview of design layout for component placement

TIDRA09.ZIP (2242 K)

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

TIDC554.ZIP (203 K)

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

TIDRA08.PDF (1195 K)

PCB layer plot file used for generating PCB design layout


Includes TI products in the design and potential alternatives.

PWM controllers

LM5032High voltage dual Interleaved current mode controller

Data sheet: PDF | HTML
General-purpose op amps

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

Data sheet: PDF

Technical documentation

= Top documentation selected by TI
No results found. Please clear your search and try again.
View all 2
Type Title Date
* Design guide 120-V AC, 200-W, 90% Efficiency, Interleaved Flyback for Battery Charging (Rev. A) May 12, 2016
More literature Power Tips: How to control multiple loops in a power supply Sep. 01, 2015

Support & training

TI E2E™ forums with technical support from TI engineers

View all forum topics

Content is provided "as is" by TI and community contributors and does not constitute TI specifications. See terms of use.

If you have questions about quality, packaging or ordering TI products, see TI support. ​​​​​​​​