UCC28632: AC to DC Power Supply 220VAC to 150VDC

Hello Farhan,

You listed the UCC28632, which is a flyback controller. However, since flyback AC/DC is typically not suitable for designs >100W, the UCC28632 would not be a good choice for your 900W application.

At >100W AC/DC applications, you will need two stages: A PFC stage and a DC/DC stage. Please see this E2E post for a more detailed explanation on why this is required: https://e2e.ti.com/support/power-management-group/power-management/f/power-management-forum/1268017/2kw-pfc-smps-controller/4804234?tisearch=e2e-sitesearch&keymatch=%25252525252520user%2525252525253A525510#4804234.

At 900W, you can use either an interleaved TM PFC, such as the UCC28065, or a single-phase CCM PFC, such as the UCC28180. See the PFC Controller Step-by-Step Selection Guide for pros and cons between each PFC controller. For your DC/DC stage, you can use the UCC25660 LLC controller. 

You can use TI's Webench to generate general schematics based on your requirements or Power Stage Designer to make component calculations. 

Regards,

Jonathan Wong

Hello Farhan,

You can search our TI reference design library here: https://www.ti.com/reference-designs/index.html. I have highlighted a few key reference designs that are relevant to your design below. Many of the reference designs use the UCC25640x LLC controller, which is the previous gen LLC controller. These designs can be replaced with the UCC25660 LLC controller that I mentioned above. We also do not have any reference designs that have a 150VDC output, but our UCC25660 LLC controller has a design calculator that will help you make adjustments on your board to meet your design. You can also use Power Stage Designer to select your LLC components (Ex. the inductor, turns ratio, etc.).

TIDA-00443: https://www.ti.com/tool/TIDA-00443 

• Vin = 195VAC - 270VAC
• Vout = 390VDC
• Pout = 900W
• PFC stage only. Uses the UCC28180 single-phase CCM PFC controller. Consider a separate HB-LLC stage afterwards.

PMP31179: https://www.ti.com/tool/PMP31179

• Vin = 95VAC - 135VAC
• Vout = 30VDC
• Pout = 400W
• PFC stage controlled by UCC28064A interleaved TM PFC controller and LLC stage controlled by UCC256404 HB-LLC controller. Designed for avionics applications w/ Vin AC frequency = 400Hz - 800Hz (helps show design when NOT universal AC input)

TIDA-010080: https://www.ti.com/tool/TIDA-010080

• Vin = 90VAC - 265VAC (universal AC input)
• Vout = 48VDC
• Pout = 500W
• PFC stage controlled by UCC28180 single-phase CCM PFC controller and LLC stage controlled by UCC256403 HB-LLC controller. For telecom applications

PMP40766: https://www.ti.com/tool/PMP40766 

• Vin = 90VAC - 265VAC (universal AC input) 
• Vout = 71VDC
• Pout = 500W
• PFC stage controlled by UCC28180 single-phase CCM PFC controller and LLC stage controlled by UCC256403 HB-LLC controller. Uses UCC28910 flyback controller for aux power to PFC and LLC control circuits. For E-bike applications.

TIDA-010081: https://www.ti.com/tool/TIDA-010081

• Vin = 85VAC - 265VAC (universal AC input) 
• Vout = 54VDC
• Pout = 1kW
• PFC stage controlled by UCC28180 single-phase CCM PFC controller and LLC stage controlled by UCC256403 HB-LLC controller. For telecom applications.

Other parameters to consider are cost, space, efficiency, etc. Table 2 in the PFC Controller Selection Guide mentioned above can help you choose between an interleaved TM and a single-phase CCM.

Our PFC controllers also have design calculators listed below. See this app note for the differences between the UCC28065 and UCC28064A: https://www.ti.com/lit/an/sluaa28/sluaa28.pdf. Additionally, each of the PFC controllers and LLC controllers have EVMs that you can order to test out yourself. Please see each controller's respective product page to see the available resources.

• UCC28180 Design Calculator: https://www.ti.com/tool/download/SLUC506
• UCC28065 Design Calculator: https://www.ti.com/tool/download/SLUC697 
• UCC28064A Design Calculator: https://www.ti.com/tool/download/SLUC645 

Regards,

Jonathan Wong