TIDA-01494

24-V, 480-W Nominal 720-W peak, >93.5% efficient, robust AC/DC industrial power supply reference

TIDA-01494

Design files

Overview

The TIDA-01494 reference design is a compact, high efficiency, 24-V DC, 480-W nominal, 720-W peak output reference design for industrial AC/DC power supplies. The circuit consists of a front-end continuous conduction mode (CCM) power factor correction (PFC) circuit followed by a robust LLC stage with synchronous rectification. The design enables efficiency greater than 93.5% over a wide load range, allowing the system to work without forced cooling. The LLC stage, based on the UCC256301, takes advantage of the ZCS avoidance feature in the UC256301 to enable peak output power, minimizing the PFC Bulk capacitor for meeting holdup requirements, while making the system robust to short circuit and over current conditions. The UCC24612-2 based synchronous rectifier helps in minimizing the losses in the output rectifier, while its advanced proportional gate drive and dead time optimization features helps to avoid shoot through and minimizes losses.

Features
  • Peak power conversion efficiency of 94% at 230V AC with average efficiency >93.5%
  • Delivers 20A continuous current and up to 30A peak current for 3 seconds
  • Power factor >0.99 and meets PF and current THD as per IEC 61000-3-2 Class A and EN55022 Class B Conducted Emission standard
  • ZCS avoidance in the LLC stage, enabling wider input voltage range operation and robustness
  • Over current, short circuit, over voltage and over temperature protection
  • Compact form-factor:  155mm x 125mm
Output voltage options TIDA-01494.1
Vin (Min) (V) 85
Vin (Max) (V) 265
Vout (Nom) (V) 24
Iout (Max) (A) 20
Output Power (W) 480
Isolated/Non-Isolated Isolated
Input Type AC
Topology Boost- PFC^Half Bridge- LLC

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.

TIDUDF3.PDF (5891 K)

Reference design overview and verified performance test data

TIDRT45A.PDF (354 K)

Detailed schematic diagram for design layout and components

TIDRT46A.PDF (117 K)

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

TIDRT47.PDF (351 K)

Detailed overview of design layout for component placement

TIDRT49A.ZIP (2004 K)

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

TIDCDX4.ZIP (877 K)

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

TIDRT48.PDF (1490 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

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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LLC controllers

UCC256304Wide vin LLC resonant controller with high-voltage start up enabling low standby power

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Linear & low-dropout (LDO) regulators

TLV704150-mA, 24-V, ultra-low-IQ, low-dropout voltage regulator

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N-channel MOSFETs

CSD19501KCS80-V, N channel NexFET™ power MOSFET, single TO-220, 6.6 mOhm

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Power factor correction (PFC) controllers

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

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SR & load share controllers

UCC24612High-frequency multi-mode synchronous rectifier controller

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Temperature switches

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

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Technical documentation

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Type Title Date
* Design guide 24V 480W Nom 720W Peak >93.5% Efficient AC/DC Industrial Power Supply Ref Design Oct. 10, 2017
Technical article How to boost efficiency in your industrial AC/DC power supply Nov. 09, 2017

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