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AC to DC Power Supply Low Cost

Navi Singh
Prodigy 230 points
Other Parts Discussed in Thread: UCC28740, UCC28742, PMP40487

Hi,

I have Design AC to DC Power Supply. Please share me solution as per given below requirement-

1. Input Voltage - (85 to 264)VAC 

2. Output Voltage- 5VDC/1A or 5VDC/2A (Both are given)

3.Voltage Accuracy- 1% to 2%

4.Power -5W/10W

5.Line Regulation- 0.5%

6.Load Regulation- 1%

7.Ripple- 50 to 150mV

8.Efficiency-80 to 90%

9. Isolation- 4000VAC (Input to Output)

10.Protection- Over Current, Short Circuit, Over voltage and Temperature Protection

  • 0
    Prodigy 230 points

    Hi,

    I have Design AC to DC Power Supply in automation Field. Please share me solution as per given below requirement-

    1. Input Voltage - (85 to 264)VAC 

    2. Output Voltage- 5VDC/1A or 5VDC/2A (Both are given)

    3.Voltage Accuracy- 1% to 2%

    4.Power -5W/10W

    5.Line Regulation- 0.5%

    6.Load Regulation- 1%

    7.Ripple- 50 to 150mV

    8.Efficiency-80 to 90%

    9. Isolation- 4000VAC (Input to Output)

    10.Protection- Over Current, Short Circuit, Over voltage and Temperature Protection

  • 0 in reply to Navi Singh
    TI__Mastermind 40550 points

    Hello Navi, 

    Thank you for your interest in TI controllers. 
    An expert can address your request early next week.

    Thank you for your patience.
    Ulrich

  • 0 in reply to Navi Singh
    TI__Genius 17875 points

    Hi Navi,

    Thank you for your patience and interest in TI controllers. From the requirements you have given above, I would recommend looking at the UCC28740 datasheet's design example that's included (UCC28740 Constant-Voltage Constant-Current Flyback Controller Using Optocoupled Feedback datasheet (Rev. D) (ti.com)). 

    The TI Reference Design page can also be of use to you when searching for UCC28740 or UCC28742 if you do not want a HV start-up(TI Reference Designs Library).

    Best Regards,

    Alexis

  • 0 in reply to Alexis_H
    Prodigy 230 points

    Ok 

    Thanks for suggestion. I will see datasheet.

    Please share me if any reference design with UCC28740.

    Please suggest me transformer part number  with UCC28740.

    I am study PMP40487 reference design but I am facing problem selection of transformer.

    I am seeing BOM Part number of transformer RM6-T-750UH-W4/3LCoils. But I have not found datasheet / availability

  • 0 in reply to Navi Singh
    TI__Genius 17875 points

    Hi Navi,

    As for the transformer, I would recommend following the data sheet/reference design in calculating the transformer values needed and then going to a third party vendor that designs transformers to make the part for you. You will not find a datasheet/availability for the transformer part as it is specifically designed to that reference design. 

    Best Regards,

    Alexis

  • 0 in reply to Alexis_H
    Prodigy 230 points

    Hi Alexis,

    As per suggestion I have found two solution-

    S.No Reference Design Switching Part Number Transformer PartNumber Turn Ratio  Line Regulation Load Regulation Efficiency

    BOM Cost

    (Approx)

    		 Alternate Transformer Part Number Any Make PCB Size
    1 PMP9204 UCC28740 RLTI-1067 0.41:0.07 1% 1% 81% ? ? ?
    2 PMP40487 UCC28742 RM6-T-750UH-W4 ? 1% 1% 80% ? ? ? Not found datasheet 

    Please see solution -1 transformer turn ratio is OK and solution -2 not found any details/datasheet in website.

    Please suggest question mark details also.

  • 0 in reply to Navi Singh
    TI__Genius 17875 points

    Hi Navi,

    The design tool calculator for the UCC28740 (https://www.ti.com/lit/zip/sluc487) should help you double check your turn ratios for your transformer. Here is the design tool calculator for UCC28742(https://www.ti.com/lit/zip/sluc652) as well. The BOM cost and alternate transformer part number, you will need to reach out to a third-party vendor who makes transformers to acquire the information. 

    Best Regards,

    Alexis

  • 0 in reply to Alexis_H
    Prodigy 230 points

    Please share me Layout File and Gerber File

  • 0 in reply to Navi Singh
    TI__Genius 17875 points

    Hello,

    Due to the Fourth of July holiday, the forum response may be delayed from July 3 through July 4. Thank you for your patience.

  • 0 in reply to Alexis_H
    Prodigy 230 points

    Hi

    Please share me GerberFile PMP9204

  • 0 in reply to Navi Singh
    TI__Genius 17875 points

    Hello Navi,

    Thank you for your patience. Unfortunately, PMP9204 does not have a Gerber File that can be shared. However, the schematic and test results are available for use. (PMP9204 reference design | TI.com)

    Best Regards,

    Alexis

  • 0 in reply to Alexis_H
    Prodigy 230 points

    OK Thanks for feedback.

  • 0 in reply to Alexis_H
    Prodigy 230 points

    Reference Design Number- PMP9204 (85-265) VAC

    1. Can This Power Supply working input  Voltage (75 to 275)VAC

    Lower Voltage -75VAC and Upper Voltage-275 with 5V/1A and 5V/2A

    1. I want to set output Voltage 5.1 or 5.2VDC. Which resistance value is change in Circuit?
    2. I want to set input under voltage and input over voltage limit. How will be set in circuit.
    3. If Load variation(200mA,500mA,1A,2A) output voltage is constant
    4. Line variation-? Load variation-?
    5. I seen part number of transformer RLTI-1067 in BOM but there is no stock. Please suggest me any alternate part number of transformer.
    6. Why use SBR10U45SP5 (Schottky Diodes) in output ground terminal. If Schottky Diodes is used Output positive terminal. What is effect?
    7. What is size of PCB and BOM Cost.
  • 0 in reply to Navi Singh
    TI__Genius 17875 points

    Hi Navi,

    Please wait a bit as I look into your questions. 

    Best Regards,

    Alexis

  • 0 in reply to Alexis_H
    Prodigy 230 points

    Ok

    Please as soon as reply my question

  • 0 in reply to Navi Singh
    Prodigy 230 points

    Please as soon as reply my question

  • 0 in reply to Navi Singh
    TI__Genius 17875 points
    Hi Navi,

    Thank you for your patience.

    Question 1:
    Can This Power Supply working input Voltage (75 to 275)VAC
    Lower Voltage -75VAC and Upper Voltage-275 with 5V/1A and 5V/2A
    Answer 1:
        The design parameters for PMP9204 are from 85VAC - 265VAC. You can change the components on the design to work with 75-275 VAC, however, you would need to calculate and change the entire design to fit with those requirements so I do not recommend doing this.

    Question 2:
    I want to set output Voltage 5.1 or 5.2VDC. Which resistance value is change in Circuit?

    Answer 2:
        Please look at UCC28740's Datasheet Section 8 Application and Implementation on how to calculate for these values. (www.ti.com/.../ucc28740.pdf
       

    Question 3:
    I want to set input under voltage and input over voltage limit. How will be set in circuit.

    Answer 3:
        Please look at UCC28740's Datasheet Section 8 Application and Implementation on how to calculate for these values. (www.ti.com/.../ucc28740.pdf

    Question 4:
    If Load variation(200mA,500mA,1A,2A) output voltage is constant
    Line variation-? Load variation-?

    Answer 4:
        Please look at UCC28740's Datasheet Section 8 Application and Implementation on how these values would change. (www.ti.com/.../ucc28740.pdf

    Question 5:
    I seen part number of transformer RLTI-1067 in BOM but there is no stock. Please suggest me any alternate part number of transformer.

    Answer 5:
        Flyback transformers are almost always custom to fit the specific application.  Both Renco and Wurth are very responsive when it comes to providing transformer samples to fit specific applications. The power stage is designed based upon the minimum bulk voltage so if you are not targeting the 115V range, the transformer design would be different than this reference design.

    Question 6:
    Why use SBR10U45SP5 (Schottky Diodes) in output ground terminal. If Schottky Diodes is used Output positive terminal. What is effect?

    Answer 6:
        A Schottky diode has a low forward drop and low reverse recovery time which helps in overall less power loss and higher efficiency. If the Schottky Diode is used on the positive output terminal, you would need to flip the polarity of the dots of the transformer/design a new transformer to have an effective working flyback design.



    Question 7:
    What is size of PCB and BOM Cost.

    Answer 7:
        Please reference the image provided (www.ti.com/.../PMP9204 at the link for an idea of the size of the PCB or the PMP9204 Test Results document (www.ti.com/.../sluuax2.pdf
    Regards,
    Alexis
  • 0 in reply to Alexis_H
    Prodigy 230 points

    1.You have Board File of PMP9204.

    2.You have layout of PMP9204 in any format so I design the PCB.

  • 0 in reply to Alexis_H
    TI__Genius 17875 points
    Hi Navi,
    I realized there were some errors in some of the previous answers I replied too. I have addressed them below. Thank you for your understanding.

    Question 3:

    I want to set input under voltage and input over voltage limit. How will be set in circuit.

    Answer 3:
       This part has no input OV detection. This part instead has an input brown-out threshold based on VS(stop) as a consequence of setting the input brown-in threshold at VS(run).  (www.ti.com/.../ucc28740.pdf)

    Question 6:
    Why use SBR10U45SP5 (Schottky Diodes) in output ground terminal. If Schottky Diodes is used Output positive terminal. What is effect?

    Answer 6:
        A Schottky diode has a low forward drop and low reverse recovery time which helps in overall less power loss and higher efficiency. If the Schottky Diode is used on the positive output terminal, as long as it is pointing towards the output, the polarity will NOT change. 
    Regards,
    Alexis
  • 0 in reply to Navi Singh
    TI__Genius 17875 points

    Hi Navi,

    The board file and layout file for PMP9204 are, unfortunately, not available.

    Best Regards,

    Alexis