94.5% Efficiency, 500W industrial AC-DC reference design
TIDA-010015
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Key Document

Description

This reference design is a compact, high efficiency, 24-V DC, 500-W reference design for industrial AC/DC power supplies. This design consists of a front-end, two-phase interleaved transition mode (TM) power factor correction (PFC) based on the UCC28064A. This minimizes the PFC inductor size and reduces EMI filter requirements. The DC-DC is implemented using the HB-LLC stage implemented using TI's UCC256301 device. For efficiency improvement, synchronous rectification is used at secondary which uses the UCC24612.

Features
  • Overall efficiency of 94.5% at full load with peak efficiency > 95%
  • Up to 330-W operation without forced cooling
  • High power factor > 0.99 and meets PFC regulations and current THD as per IEC 61000-3- 2 Class A
  • Meets requirements of conducted emissions standard (EN55011 Class B)
  • ZCS avoidance feature and OVP sensing feature in LLC controller improves robustness and protects systems from overcurrent, short circuit, and overvoltage to ensure safety
  • Small 160 mm × 80 mm × 35 mm PCB form factor

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Schematic/Block Diagram

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Design Guide

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Design Files

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Parametrics
 TIDA-010015.1
(Output Voltage 1)
Vin (Min) (V)85
Vin (Max) (V)265
Vout (Nom) (V)24
Iout (Max) (A)21
Output Power (W)504
Isolated/Non-IsolatedIsolated
Input TypeAC
TopologyBoost- Transition Mode
Half Bridge- LLC

TI Devices (10)

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Part Number Name Product Family Sample & Buy Design Kits & Evaluation Modules
CSD19505KCS  80V, N ch NexFET MOSFET™, single TO-220, 3.1mOhm  MOSFETs  Sample & Buy Not Available
INA181  26V bi-directional current sense amplifier for cost-sensitive systems  Current sense amplifiers  Sample & Buy View Design Kits & Evaluation Modules
LP2951-N  Series of Adjustable Micropower Voltage Regulators  Power management  Sample & Buy View Design Kits & Evaluation Modules
LP2981  100-mA ultra-low dropout regulator with shutdown & 1.25% tolerance  Power management  Sample & Buy View Design Kits & Evaluation Modules
TL331  High Voltage Single Differential Comparator  Amplifiers  Sample & Buy Not Available
TLV171  36V Low-Power RRO General-Purpose Operational Amplifier  Operational amplifiers (op amps)  Sample & Buy View Design Kits & Evaluation Modules
UCC24612  High-frequency multi-mode synchronous rectifier controller  Offline & isolated DC/DC controllers & converters  Sample & Buy View Design Kits & Evaluation Modules
UCC256301  Wide vin LLC resonant controller with high-voltage start up enabling ultra-low standby power  Offline & isolated DC/DC controllers & converters  Sample & Buy View Design Kits & Evaluation Modules
UCC27517  4A/4A Single Channel High-speed Low-side Gate Driver  Gate drivers  Sample & Buy View Design Kits & Evaluation Modules
UCC28064A  Natural Interleaving™ transition-mode PFC controller with high light-load efficiency  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)
CSD19505KCS Download
INA181 Download Download
Download
LP2951-N Download Download
Download Download
Download
Download
LP2981 Download Download
TL331 Download Download
TLV171 Download Download
Download
UCC24612 Download Download
UCC256301 Download Download
UCC27517 Download
UCC28064A Download Download

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Technical Documents

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User guides (1)
Title Type Size (KB) Date
PDF 2057 14 May 2019
Design files (6)
Title Type Size (KB) Date
ZIP 1752 26 Oct 2018
ZIP 3060 26 Oct 2018
PDF 1379 26 Oct 2018
PDF 348 26 Oct 2018
PDF 116 26 Oct 2018
PDF 618 26 Oct 2018

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