• Production-intent power supply design for a 400 Hz AC source.
• Likely aerospace/defense/industrial 400 Hz environment; exact compliance target remains to be confirmed.
• User is experienced with production PCB design, so architecture should be suitable for manufacturable hardware rather than a hobby-grade supply.

• Accept 120–230 VAC input at 400 Hz.
• Provide reinforced or safety-rated isolation between AC input and all DC outputs.
• Deliver 12 VDC at 10 A continuous.
• Deliver 5 VDC at 5 A continuous.
• Maintain a shared secondary ground between the 12 V and 5 V outputs.
• Use power-factor-correction front end unless later requirements show passive/no-PFC is acceptable.

• AC input protection and EMI filtering.
• Rectified high-voltage DC bus.
• Active boost PFC stage targeting approximately 380–400 VDC bus.
• Isolated primary-to-secondary DC/DC stage.
• Main regulated 12 V rail.
• Non-isolated secondary-side synchronous buck from 12 V to 5 V.
• Overcurrent, overvoltage, thermal, inrush, and fault protection.

Diagram

• Fuse or circuit protection sized from final input current and fault analysis.
• Surge protection appropriate to the source environment.
• Inrush limiting for high-voltage bulk capacitor charging.
• Common-mode and differential-mode EMI filter.
• Safety-rated spacing and components on the primary side.

• Full bridge rectifier feeding an active boost PFC stage.
• Target HV bus: nominally 380–400 VDC.
• PFC controller and boost components must be selected against 400 Hz input operation, low-line input current, thermal limits, and EMI.

• Converts HV bus to isolated 12 V secondary rail.
• Candidate topologies: LLC resonant, two-switch forward, active clamp forward, or phase-shift/full-bridge depending on final controller/reference design availability.
• Flyback is likely marginal for 145 W continuous output and should not be the default unless a proven design/controller supports the required power and thermal margin.

• Derive 5 V / 5 A from the isolated 12 V rail using a synchronous buck converter on the secondary side.
• 5 V output shares ground with 12 V output.

• AC input connector: 120–230 VAC, 400 Hz.
• DC output connector: 12 V, 5 V, shared secondary return.
• Optional signals to consider: PWR_GOOD, inhibit/enable, remote sense, chassis/earth connection, fault output.

• 12 V rail: 12 V × 10 A = 120 W.
• 5 V rail: 5 V × 5 A = 25 W.
• Total DC output: 145 W.
• Estimated total input power: ~160–175 W depending on efficiency.
• Design target recommendation: size magnetic, semiconductor, thermal, and protection parts for at least 175–200 W electrical stress margin.

• Production-oriented PCB with primary/secondary isolation barrier.
• Creepage and clearance must be designed to applicable safety standard and pollution/altitude category.
• Use safety-certified parts for fuse, X/Y capacitors, optocouplers/digital isolators, transformer insulation system, and input protection.
• Layout must be reviewed for primary high-current loops, PFC switching loop, transformer isolation, EMI, thermal paths, and secondary high-current copper.

• None required unless a digital PFC/controller or telemetry/control interface is selected.

• Board size, height, mounting, airflow, chassis/earth bonding, and thermal limits are TBD.
• High-voltage primary and isolated secondary should be clearly partitioned.
• Keepout/slot strategy may be needed along the isolation barrier.

• Confirmed: AC input isolated from DC outputs.
• Confirmed: 12 V and 5 V outputs do not need isolation from each other.
• Confirmed: PFC controller is TI UCC28064A / UCC28064ADT.
• Confirmed: isolated DC/DC topology is active-clamp forward for lower-risk bring-up.
• Recommended: 12 V is the main isolated regulated output; 5 V is derived from the 12 V secondary rail by synchronous buck.
• Recommended: use an active boost PFC front end followed by an isolated DC/DC converter rather than a single-stage flyback.

• Output rails are continuous rated, not peak-only.
• PFC is desired/required because the user requested a PFC switching supply.
• 400 Hz source may imply aerospace/defense requirements, but DO-160, MIL-STD-704, and EMI limits are not yet confirmed.
• Reinforced vs basic isolation requirement is not yet confirmed.
• Input transient/surge profile, hold-up time, output ripple, remote sense, and operating temperature are TBD.

• Initial requirements captured: 120–230 VAC 400 Hz input; 12 VDC 10 A and 5 VDC 5 A outputs; AC-to-output isolation required; 12 V/5 V mutual isolation not required.
• User confirmed TI UCC28064A as the PFC controller and active-clamp forward as the isolated DC/DC topology.