150~600W AC-DC Power Supply Design

1Key input/output specifications of the 150~600W AC-DC design

Input voltage: AC100V~AC240V

Output power

150-600W,

Output voltage

DC 10V~100V (specific voltage to be specified), regulation accuracy ±1%

Output current

3A-30A, current accuracy ±5%

Standby power

below 1W (AC100V)

Power efficiency

92% @AC100V, 95% @AC220V

2Overall circuit scheme of the 150~600W AC-DC design

This design uses the integrated "PFC + LLC resonant" controller TEA2017 together with a synchronous rectification scheme. The TEA2017 combined controller integrates front-end PFC control and half-bridge LLC control, with built-in drivers that directly drive GaN FETs and MOSFETs. The PFC stage can be configured as BCM boundary mode (below 300W) or CCM continuous mode (300W~600W). LLC resonant half-bridge control and drive are also integrated in the TEA2017; resonance achieves ZVS for the primary switches and ZCS for the secondary rectifiers. On the output side, the MP6924A high-performance synchronous rectifier (SR) controller replaces traditional Schottky rectifier diodes, minimizing secondary rectification loss and raising overall efficiency. The TEA2017 can directly drive GaN FET switches; using GaN significantly reduces high-frequency losses, allowing a smaller, more compact converter with less heat and higher efficiency.

3Circuit schematic of the 150~600W AC-DC design

4Key components BOM calculation of the 150~600W AC-DC design

(This example is designed for 48V 4A; for other powers, currents and voltages, adjust the component parameter values)

Key power-device loss & thermal evaluation of the 150~600W AC-DC design

The main heat-generating components are the input rectifier bridge, the magnetic components of the PFC and LLC stages, power switches and power rectifiers. Heat dissipation differs with output power, voltage and current, but for well-designed products the thermal performance is roughly similar. The table below gives several concrete examples.