24V, 480W (nominal), 720W (peak), reliable AC/DC industrial power supply reference design with energy efficiency higher than 93.5%

The TIDA-01494 reference design is a compact, high-efficiency, 24V DC, 480W nominal, 720W peak output reference design for industrial AC/DC power supplies. The circuit includes a front-end continuous conduction mode (CCM) power factor correction (PFC) circuit, followed by a powerful LLC stage with synchronous rectification. The design ensures an efficiency greater than 93.5% over a wide load range, allowing the system to operate without forced cooling. The UCC256301-based LLC stage utilizes the ZCS avoidance feature in the UC256301 to achieve peak output power, minimizing the PFC bulk capacitor to meet holdup requirements while enabling the system to handle short circuit and overcurrent conditions. The UCC24612-2-based synchronous rectifier helps minimize losses in the output rectifier, while its advanced proportional gate driver and dead-time optimization help avoid breakdown and minimize losses.

characteristic

• ● It has a peak power conversion efficiency of 94% under 230V AC, and the average efficiency is greater than 93.5%
• ● Provides 20A continuous current and up to 30A peak current (for 3 seconds)
• ● Power factor is greater than 0.99 and meets PF and current THD regulations (according to IEC 61000-3-2 Class A and EN55022 Class B conducted emission standards)
• ● ZCS bypass in LLC stage, enabling wider input voltage range operation and robustness
• ● Overcurrent, short circuit, overvoltage and overheating protection
• ● Compact size: 155mm x 125mm