500-W, >94.5% efficiency analog control AC/DC reference design for 5G telecom rectifier


Design files


This compact, high efficiency reference design with a 48-V DC, 500-W output targets 5G telecom power and industrial AC/DC power supplies. The circuit consists of a front-end continuous conduction mode (CCM) power factor correction (PFC) circuit based on the UCC28180, followed by a robust LLC stage for an isolated DC/DC converter based on the UCC256403. For high efficiency needs, the UCC24624 handles synchronous rectification. This design uses an auxiliary power supply flyback with the UCC28911, which has an internal high-voltage MOSFET. This design enables 94.5% peak efficiency and allows the system to work without forced cooling. The whole system has low iTHD, with 30% load at <12%, 50% load at <8%, 100% load at <5.5% and good load transient performance. 

  • Peak efficiency of 94.5% at 230-V AC and 94% across 30%~100% load
  • CCM PFC and half-bridge LLC based (UCC28180 and UCC256403)
  • Low iTHD: 30% load at <12%, 50% load at <8%, 100% load at <5.5%
  • Good load transient performance at less than 1% regulation
  • Meets ±1% accuracy for input power meter across whole load range
  • Passive cooling with sealed metal case
Output voltage options TIDA-010080.1
Vin (Min) (V) 90
Vin (Max) (V) 265
Vout (Nom) (V) 48
Iout (Max) (A) 10.5
Output Power (W) 504
Isolated/Non-Isolated Isolated
Input Type AC
Topology Boost- PFC^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.

TIDUET3.PDF (2902 K)

Reference design overview and verified performance test data

TIDM802A.ZIP (887 K)

Detailed schematic diagram for design layout and components

TIDM803.ZIP (200 K)

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

TIDM804.ZIP (424 K)

Detailed overview of design layout for component placement

TIDM806A.ZIP (11796 K)

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

TIDCFZ5.ZIP (1121 K)

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

TIDM805.ZIP (805 K)

PCB layer plot file used for generating PCB design layout


Includes TI products in the design and potential alternatives.

AC/DC & DC/DC controllers (external FET)

UCC24624High-frequency, dual synchronous rectifier controller for LLC converters

Data sheet: PDF | HTML
AC/DC & DC/DC controllers (external FET)

UCC256403LLC resonant controller with ultra-low power and ultra-quiet standby operation

Data sheet: PDF | HTML
AC/DC & DC/DC controllers (external FET)

UCC2818018-kHz-250-kHz CCM PFC controller with enhanced startup & transient response

Data sheet: PDF | HTML
AC/DC & DC/DC converters (integrated FET)

UCC28911700V Flyback switcher with constant-voltage constant-current and primary-side regulation

Data sheet: PDF | HTML
Analog current-sense amplifiers

INA18026V, 350kHz current sense amplifier

Data sheet: PDF | HTML
General-purpose op amps

TLV9001One-channel, 1-MHz rail-to-rail input and output 1.8-V to 5.5-V operational amplifier

Data sheet: PDF | HTML
General-purpose op amps

TLV9101Single, 16-V, 1.1-MHz, low-power operational amplifier

Data sheet: PDF | HTML
Linear & low-dropout (LDO) regulators

TLV760100-mA, 30-V, low-dropout voltage regulator

Data sheet: PDF | HTML
Shunt voltage references

ATL4312.5-V low-IQ adjustable precision shunt regulator

Data sheet: PDF | HTML

Technical documentation

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Type Title Date
* Design guide 500-W, > 94.5% Efficiency, Analog Control AC/DC Reference Design for 5G Telecom PDF | HTML Feb. 15, 2019

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