24V, 480W Nominal 720W Peak, >93.5% Efficient, Robust AC/DC Industrial Power Supply Reference Design

(ACTIVE) TIDA-01494

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Key Document

Description

The TIDA-01494 reference design is a compact, high efficiency, 24-V DC, 480-W nominal, 720-W peak output reference design for industrial AC/DC power supplies. The circuit consists of a front-end continuous conduction mode (CCM) power factor correction (PFC) circuit followed by a robust LLC stage with synchronous rectification. The design enables efficiency greater than 93.5% over a wide load range, allowing the system to work without forced cooling. The LLC stage, based on the UCC256301, takes advantage of the ZCS avoidance feature in the UC256301 to enable peak output power, minimizing the PFC Bulk capacitor for meeting holdup requirements, while making the system robust to short circuit and over current conditions. The UCC24612-2 based synchronous rectifier helps in minimizing the losses in the output rectifier, while its advanced proportional gate drive and dead time optimization features helps to avoid shoot through and minimizes losses.

Features
  • Peak power conversion efficiency of 94% at 230V AC with average efficiency >93.5%
  • Delivers 20A continuous current and up to 30A peak current for 3 seconds
  • Power factor >0.99 and meets PF and current THD as per IEC 61000-3-2 Class A and EN55022 Class B Conducted Emission standard
  • ZCS avoidance in the LLC stage, enabling wider input voltage range operation and robustness
  • Over current, short circuit, over voltage and over temperature protection
  • Compact form-factor:  155mm x 125mm

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Schematic/Block Diagram

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Design Guide

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Design Files

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Bill of Materials (BOM)

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Parametrics
 TIDA-01494.1
(Output Voltage 1)
Vin (Min) (V)85
Vin (Max) (V)265
Vout (Nom) (V)24
Iout (Max) (A)20
Output Power (W)480
Isolated/Non-IsolatedIsolated
Input TypeAC
TopologyBoost- PFC
Half Bridge- LLC

TI Devices (10)

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Part Number Name Product Family Sample & Buy Design Kits & Evaluation Modules
CSD19501KCS  80V, N-Channel NexFET™ Power MOSFET, CSD19501KCS  MOSFETs  Sample & Buy Not Available
INA181  26V, Bi-Directional, Low-/High-Side, Voltage Output Current Sense Amplifier  Current sense amplifiers  Sample & Buy View Design Kits & Evaluation Modules
TL103WA  Dual OpAmp With Internal Reference  Operational amplifiers (op amps)  Sample & Buy View Design Kits & Evaluation Modules
TLV3202  Dual, 40ns, microPower, Rail-to-Rail input Comparator with Push-pull outputs  Amplifiers  Sample & Buy Not Available
TLV704  24V Input Voltage, 150mA, Ultra-Low-Iq Low-Dropout (LDO) Regulators  Power management  Sample & Buy View Design Kits & Evaluation Modules
TMP302  Pin-Selectable Trip Point 1.4V-Capable Family of Temperature Switches  Temperature sensors  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
UCC256304  Wide Vin LLC Resonant Controller With High-Voltage Start Up Enabling Low Standby Power  Offline & isolated DC/DC controllers & converters  Sample & Buy View Design Kits & Evaluation Modules
UCC28180  8-Pin Continuous Conduction Mode (CCM) PFC Controller  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)
CSD19501KCS Download
INA181 Download
Download
TL103WA Download Download
TLV3202 Download
Download
TLV704 Download Download
TMP302 Download Download
UCC24612 Download Download
UCC256301 Download Download
UCC256304 Download Download
UCC28180 Download

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Technical Documents

View the Important Notice for TI Designs covering authorized use, intellectual property matters and disclaimers.

User guides (1)
Title Abstract Type Size (KB) Date Views TI Recommends
PDF 5891 10 Oct 2017 417
Design files (6)
Title Abstract Type Size (KB) Date Views
ZIP 2004 02 May 2018 92
PDF 117 02 May 2018 279
PDF 354 02 May 2018 528
ZIP 877 10 Oct 2017 58
PDF 1490 10 Oct 2017 80
PDF 351 10 Oct 2017 59

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