94.5% Efficiency, 500W industrial AC-DC reference design


Design files


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.

  • 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
Output voltage options TIDA-010015.1
Vin (Min) (V) 85
Vin (Max) (V) 265
Vout (Nom) (V) 24
Iout (Max) (A) 21
Output Power (W) 504
Isolated/Non-Isolated Isolated
Input Type AC
Topology Boost- Transition Mode^Half Bridge- LLC
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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


Detailed schematic diagram for design layout and components


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


Detailed overview of design layout for component placement

TIDRXC8.ZIP (3060 K)

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

TIDCEY1.ZIP (1752 K)

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

TIDRXC7.PDF (1379 K)

PCB layer plot file used for generating PCB design layout


Includes TI products in the design and potential alternatives.

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Technical documentation

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Type Title Date
* Design guide 94.5% Efficiency, 500-W Industrial AC/DC Reference Design (Rev. B) PDF | HTML May 06, 2020
Technical article How topology selection can help improve reliability in industrial AC/DC power supp PDF | HTML Feb. 14, 2019

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