TIDA-010038

94% Peak efficiency, 150W norm, 240W peak industrial AC/DC power supply with CC/CV reference design

TIDA-010038

Design files

Overview

This compact, high efficiency, 24V DC, 150W nominal, 240W peak output at 230VAC reference design is targeted for industrial AC/DC power supplies. The circuit consists of a frontend transition mode (TrM) power factor correction(PFC) circuit based on the UCC28056, followed by a robust LLC stage for an isolated DC/DC converter based on the UCC256301. For high efficiency needs, synchronous rectification is done with the UCC24624. This design does not need an additional auxiliary power supply to meet no-load consumption. The design enables 94% peak efficiency and allows the system to work without forced cooling. This design has both constant current(CC) and constant voltage(CV) feedback loop which is suitable for battery charger application.

Features
  • Wide operation input range of 90 to 265V AC with full power delivery over entire range
  • Peak overall efficiency of 94.4% at 230V AC and 93% at 115V AC, enables natrual convection cooling
  • Delivers up to 6.25A continuous current and up to 10A peak current for 3 seconds
  • Adjustable output voltage from 22 to 28V
  • Very low no load power consumption of <400mW
  • System protected for overcurrent, short-circuit, and overvoltage ensuring safety needs

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.

TIDUEJ1A.PDF (3686 K)

Reference design overview and verified performance test data

TIDRXU2A.PDF (356 K)

Detailed schematic diagram for design layout and components

TIDRXU3B.PDF (344 K)

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

TIDRXU4.PDF (466 K)

Detailed overview of design layout for component placement

TIDRXU6.ZIP (70237 K)

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

TIDCF19.ZIP (281 K)

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

TIDRXU5.PDF (1610 K)

PCB layer plot file used for generating PCB design layout

Products

Includes TI products in the design and potential alternatives.

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General-purpose op amps

LM258Dual, 30-V, 700-kHz operational amplifier with -25°C to 85°C operation

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General-purpose op amps

TL103WADual, 32-V, 900-kHz, 3-mV offset voltage operational amplifier with internal reference

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LLC controllers

UCC256301Wide vin LLC resonant controller with high-voltage start up enabling ultra-low standby power

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Linear & low-dropout (LDO) regulators

LM317L100-mA, 35-V, adjustable linear voltage regulator

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N-channel MOSFETs

CSD19533Q5A100-V, N channel NexFET™ power MOSFET, single SON 5 mm x 6 mm, 9.5 mOhm

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Power factor correction (PFC) controllers

UCC280566-pin high-performance CrM & DCM PFC controller

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SR & load share controllers

UCC24624High-frequency, dual synchronous rectifier controller for LLC converters

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

Technical documentation

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Type Title Date
* Design guide 94% peak efficiency, 150-W norm, 240-W peak, industrial AC/DC power supply (Rev. A) Feb. 12, 2019
Technical article Three considerations for achieving high efficiency and reliability in industrial AC/DC power supplies Apr. 04, 2019

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