TIDA-00702

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

TIDA-00702

Design files

Overview

The TIDA-00702 is a 60-W, industrial AC-DC power supply designed for use in industrial and instrumentation systems such as process controls, factory automation, and machinery control. This reference design is a Quasi-resonant (QR) flyback converter implemented using the UCC28740 CC-CV flyback controller with optocoupled feedback for voltage and primary-side regulation (PSR) for constant current regulation, with all the necessary protections built-in. Hardware is designed and tested to pass conducted emissions, surge, and EFT requirements.

The key highlights of reference design:

  • 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
  • Robust output supply protected for output over-current, output short circuit, output over-voltage, and over temperature conditions

Features
  • Wide Operating Input Range of 85-V to 265-V AC With Full Power Delivery Over Entire Range
  • Designed to Drive Wide Range of Downstream 24-V Industrial Systems and Motor Drives up to 60 W
  • High Efficiency of > 89% at 115-V AC and > 91% at 230-V AC for Wide Load Range From 30% to 100% Load; No External Cooling Needed up to 60°C Ambient Operation
  • Meets Current THD Regulations as per IEC 61000-3-2, Class-A
  • Precision Current Limit Within ±1% Ensures Maximum Power Delivery for Entire AC Voltage Range
  • Very Low Standby Power of < 200 mW
  • Start-up With High Load Capacitance up to 8500 μF
  • Built-in Lossless 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
  • Power Supply With Small PCB Form Factor (96 × 82 mm)

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.

TIDUB51.PDF (3439 K)

Reference design overview and verified performance test data

TIDRIU5.PDF (543 K)

Detailed schematic diagram for design layout and components

TIDRIU6A.PDF (65 K)

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

TIDCBF7.ZIP (315 K)

Tool for calculating critical component values required in the reference design

TIDRIU7.PDF (259 K)

Detailed overview of design layout for component placement

TIDRIU9.ZIP (3344 K)

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

TIDCBF6.ZIP (610 K)

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

TIDRIU8.PDF (2627 K)

PCB layer plot file used for generating PCB design layout

Products

Includes TI products in the design and potential alternatives.

Flyback controllers

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

Data sheet document-pdfAcrobat PDF open-in-new HTML
Ideal diode/ORing controllers

LM5050-26-V to 75-V, 400-uA IQ ideal diode controller

Data sheet document-pdfAcrobat PDF
N-channel MOSFETs

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

Data sheet document-pdfAcrobat PDF open-in-new HTML
SR & load share controllers

UCC24630Synchronous rectifier controller With Ultra Low Standby current

Data sheet document-pdfAcrobat PDF open-in-new HTML
Temperature switches

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

Data sheet document-pdfAcrobat PDF open-in-new HTML

Technical documentation

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Type Title Date
* Design guide 60W, High Efficiency Industrial Power Supply with Precision Voltage Design Guide Jan. 22, 2016
Technical article How to design a limited power source industrial AC/DC power supply with minimal components – part 2 Oct. 26, 2016
Technical article How to design a limited power source industrial AC/DC power supply with minimal components – part 1 Oct. 10, 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

REFERENCE DESIGN
TIDA-00701 100W, 24V High Efficiency High PF Industrial Power Supply with Precision Current & Power Limit

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