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[原创] TI TIDA-01494 480W工业电源参考设计

关键词:电源管理 AC/DC转换器 开关电源

时间:2017-12-26 09:23:04       作者:TI       来源:中电网

TI公司的TIDA-01494是480W工业电源AC/DC转换器参考设计,具有PFC前端和半桥LLC谐振转换器,输入电压85V到 265VAC,提供20A连续电流,可调输出电压从22V到28V,满负载时的效率93.5%,峰值效率大于94%,能够实现自然冷却,功率因素大于0.99,满足Per IEC 61000-3-2 Class A的PFC稳压和电流THD,主要用在工业AC/DC,DIN轨电源,医疗电源,能量存储系统和电池充电器.本文介绍了参考设计TIDA-01494主要特性和指标,框图,电路图,材料清单和PCB设计图.

Industrial AC/DC power supplies are used in various applications such as process control, data logging,machinery control, instrumentation, factory automation, and security systems. These AC/DC suppliesprovide a convenient means for powering DC operated devices including programmable logic controllers(PLCs), sensors, transmitters and receivers, analyzers, motors, actuators, solenoids, relays, and so on.

These supplies are convection cooled and need to support features like power boost where it supplies aincreased output load for a short duration. The supplies operate over a wide input range from 85- to 265-VAC, delivering full load for entire input voltage range. The output voltages from these supplies range from5 to 56 V with power ratings from 7.5 to 480 W. Many of these supplies can be connected in parallel forhigher power applications.

This reference design is a 480-W high efficiency industrial AC/DC power supply. The design consists of aCCM boost PFC converter, which operates from an input voltage range of 85- to 265-V AC RMS andgenerates a 390-V DC bus. The second stage is made up of an isolated half-bridge LLC stage, whichgenerates a 24-V, 20-A nominal output. The output voltage range is settable from 22 to 28 V usingpotentiometer present on the board. Industrial power supplies have requirements of high efficiency overtheir entire operating voltage range and wide load variations from a 50% to 100% load. This designdemonstrates high efficiency operation in a small form factor (155 × 125 mm) and delivers continuous480 W of power over the entire input operating voltage range from 85- to 265-V AC. It gives an efficiencyof > 93.5% for 230-V AC nominal operation and 91% for 115-V AC nominal operation. The CCM PFCstage is controlled by the UCC28180 fixed frequency PFC device. CCM PFC offers a cost-optimizedsolution at this power level and wide input range. The HB-LLC power stage is controlled through the stageof the art UCC256301 resonant controller, which implements current mode control for increased controlbandwidth. This increased control bandwidth reduces the output capacitors required to suppress the ACripple on the output. To achieve high efficiency, the output of the LLC stage uses synchronous rectificationbased on the UCC24612 device and the CSD19501KCS MOSFET.

The design has low standby power of < 400 mW and meets ENERGY STAR® rating requirements as wellas 2013 EU eco-design directive ErP Lot 6. The EMI filter is designed to meet EN55011 class-Bconducted emission levels. The design is fully tested and validated for various parameters such asregulation, efficiency, EMI signature, output ripple, startup, and switching stresses. Overall, the designmeets the key challenges of industrial power supplies to provide safe and reliable power with allprotections built in, while delivering high performance with low power consumption and low bill of material(BOM) cost.This reference design is a compact, high efficiency,24-V DC, 480-W nominal, 720-W peak outputreference design for industrial AC/DC power supplies.

The circuit consists of a front-end continuousconduction mode (CCM) power factor correction (PFC)circuit followed by a robust LLC stage withsynchronous rectification. The design enablesefficiency greater than 93.5% over a wide load range,allowing the system to work without forced cooling.

The LLC stage, based on the UCC256301, takesadvantage of the ZCS avoidance feature in theUC256301 to enable peak output power, minimizingthe PFC bulk capacitor for meeting holduprequirements, while making the system robust to shortcircuitand overcurrent conditions. The UCC24612-2-based synchronous rectifier helps in minimizing thelosses in the output rectifier.

参考设计TIDA-01494主要特性:

• 480-W Industrial AC/DC With PFC Front End andHalf-Bridge LLC Resonant Converter
• Delivers up to 20-A Continuous Current and up to30-A Peak Current for 3 Seconds
• Adjustable Output Voltage From 22 to 28 V
• Overall Efficiency of 93.5% at Full Load With PeakEfficiency > 94%, Enables Natural ConvectionCooling
• High Power Factor > 0.99 and Meets PFCRegulations and Current THD as Per IEC 61000-3-2 Class A
• Meets Requirements of Conducted EmissionsStandard (EN55011 Class B)
• Very Low No Load Power Consumption of 400 mW
• Small PCB Form Factor of 155 × 125 mm
• System Protected for Overcurrent, Short-Circuit,Overvoltage, Output Terminals Ensuring SafetyNeeds Along With Overtemperature Protection forPower Stage

参考设计TIDA-01494应用:

• Industrial AC/DC
• DIN Rail Power Supply
• Medical Power Supply
• Energy Storage Systems
• Battery Chargers

图1.参考设计TIDA-01494外形图
参考设计TIDA-01494主要系统指标:


图2.参考设计TIDA-01494框图

图3.参考设计TIDA-01494电路图(1)

图4.参考设计TIDA-01494电路图(2)

图5.参考设计TIDA-01494电路图(3)
参考设计TIDA-01494材料清单:





图6.参考设计TIDA-01494 PCB设计图(1)

图7.参考设计TIDA-01494 PCB设计图(2)

图8.参考设计TIDA-01494 PCB设计图(3)

图9.参考设计TIDA-01494 PCB设计图(4)

图10.参考设计TIDA-01494 PCB设计图(5)

图11.参考设计TIDA-01494 PCB设计图(6)

图12.参考设计TIDA-01494 PCB设计图(7)

图13.参考设计TIDA-01494 PCB设计图(8)
详情请见:
http://www.ti.com/lit/ug/tidudf3/tidudf3.pdf
http://www.ti.com/lit/df/tidrt45/tidrt45.pdf
以及http://www.ti.com/lit/df/tidrt46/tidrt46.pdf
http://www.ti.com/lit/df/tidrt48/tidrt48.pdf
tidudf3.pdf
tidrt45.pdf
tidrt46.pdf
tidrt48.pdf

 

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