100W, 24V High Efficiency High PF Industrial Power Supply with Precision Current & Power Limit


Design files


TIDA-00701 is a 100W, 24V, Industrial AC-DC power supply designed for use in Industrial & Instrumentation systems such as process controls, factory automation and machinery control. This reference design has front end Power Factor Correction (PFC) circuit designed using UCC28051 PFC controller, followed by Quasi-Resonant flyback converter implemented using UCC28740 Primary Side regulated (PSR) CC-CV flyback controller, with all the necessary protections built-in. Hardware is designed and tested to pass conducted emissions, surge, and EFT requirements.

The key highlights of this reference design are:

  • Reduced component count design to achieve NEC Class-2 and Limited Power Source (LPS) norms
  • Meets Energy Star Rating and 2013 EU eco-design directive Energy-related Products (ErP) Lot 6
  • Meets stringent current THD norms
  • Robust output supply protected for output over-current, output short circuit, output over-voltage, and over temperature conditions

  • Wide operating input range 85-VAC to 265-VAC, with full power delivery over entire range.
  • Designed to drive wide range of downstream 24V Industrial systems and motor drives up to 100W.
  • High efficiency of 88% at 115VAC and >89% at 230VAC for wide load range from 40% to 100% load. No external cooling needed up to 60oC ambient operation
  • High power factor >0.97 at both 115VAC and 230VAC for 100% load. Meets Current THD regulations as per IEC 61000-3-2, Class-A.
  • Precision current limit within ±1% ensures maximum power delivery for entire AC input voltage range.
  • Very low standby power of < 200mW.
  • Start-up with high load capacitance up to 8500uF
  • Built-in loss-less ORing feature for paralleling multiple modules
  • Meets the requirements of Conducted Emissions Standard – EN55011 class B, EFT norm IEC6000-4-4 –Level-3, and Surge norm IEC61000-4-5 –Level-3.
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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.


Reference design overview and verified performance test data

TIDRH06.PDF (342 K)

Detailed schematic diagram for design layout and components

TIDRH07.PDF (115 K)

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

TIDRH08.PDF (258 K)

Detailed overview of design layout for component placement

TIDRH10.ZIP (2972 K)

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


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

TIDRH09.PDF (2121 K)

PCB layer plot file used for generating PCB design layout


Includes TI products in the design and potential alternatives.

Power factor correction (PFC) controllers

UCC28051Transition mode PFC controller with 12.5V/9.7V UVLO and IEC61000-3-2 compliance, -40°C to 105

Data sheet: PDF | HTML
Flyback controllers

UCC28740Constant-Voltage, Constant-Current (CVCC) Flyback controller with Secondary Side Regulation (SSR)

Data sheet: PDF | HTML
Ideal diode/ORing controllers

LM5050-26-V to 75-V 400-uA IQ ORing FET controller

Data sheet: PDF
N-channel MOSFETs

CSD18504Q5A40-V, N channel NexFET™ power MOSFET, single SON 5 mm x 6 mm, 6.6 mOhm

Data sheet: PDF | HTML
SR & load share controllers

UCC24630Synchronous rectifier controller With Ultra Low Standby current

Data sheet: PDF | HTML
Temperature switches

TMP302Pin-Selectable Trip Point 1.4V-Capable Family of Temperature Switches

Data sheet: PDF | HTML

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Technical documentation

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Type Title Date
* Design guide 100-W NEC Class 2, High-Efficiency DIN Rail Industrial Power Supply Design Guide (Rev. B) Apr. 25, 2017
Technical article How to design a limited power source industrial AC/DC power supply with minimal components – part 1 PDF | HTML Jan. 11, 2024
Technical article How to design a limited power source industrial AC/DC power supply - part 2 PDF | HTML Oct. 26, 2016
White paper Control Challenges for Low Power AC/DC Converters Oct. 02, 2015
Application note A High Efficiency Synchronous Rectifier Flyback for High Density AC/DC Adapter Jun. 03, 2011

Related design resources

Reference designs

TIDA-00702 60W, 24V High Efficiency Industrial Power Supply with Precision Voltage, Current and Power Limit

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