Some environments are relatively benign, while others can be more hostile and extreme (high operating temperatures, altitude, etc.). Both active and air cooling require a fan, which needs its own space in the system, increasing its weight and power consumption, generating noise, and providing an additional, and common, point of failure. In many cases, passive cooling in the form of conduction and convection is preferable, along with the addition of a heat sink.
In addition to the common demands placed on a power supply (efficiency, reliability, etc.), each market has specific requirements for these devices, such as:
• Communication applications like 5G base stations that require high efficiency and reliability to enable continuous operation
• Industrial applications like industrial printers that need a wide input and output voltage range
• Energy storage systems that require high efficiency for long-term operation as economically as possible
• Defense applications that require appropriate certifications to meet their stringent standards
• Robotics applications that require small, lightweight, passively cooled components with high stability and multiple output voltage options to meet the needs of actuators, motors, or control systems
• Automated applications that require a wide input voltage range to facilitate deployment in different countries, with a wide output voltage range to power a broad range of equipment.
In many cases, designers need to use multiple power supplies in parallel to increase the overall system capacity. However, not all power supplies support the same capacity, and using one that cannot handle the required load can lead to system failure and damage to all the equipment.
Non-technical managers and sales staff often think it's simply a matter of swapping one power supply for another from a different manufacturer with similar specifications, but this isn't always the case. Each power supply has unique characteristics, and there's a learning curve for system designers, who often prefer to use the same family of power supplies across all equipment. Meanwhile, manufacturers prefer to reduce inventory, which can be achieved by using a base power supply that can be configured to meet the requirements of different applications.
The P-DUKE TBF500 power supply
is a product of P-DUKE's commitment to the research, development, and production of high-performance power conversion products. Therefore, they offer a wide range of converters, power supplies, and energy conversion solutions for markets that demand the highest product quality and meet all requirements. OLFER Electronics includes and distributes all of their products in Spain and Portugal.
The P-DUKE TBF500 series of power supplies features a universal input voltage range (85-264V AC) and offers various output voltages: 12, 15, 24, 28, 48, and 54V DC. All products in this series offer low no-load power consumption (0.6W) and support loads up to 500W with 93% efficiency.
Featuring reinforced 3000V AC insulation, the TBF500 devices are packaged in a sealed brick containing active semiconductor components with an integrated thermally conductive aluminum base plate (Figure 1).
Figure 1: The TBF500 is packaged in a sealed brick.
In addition to a 3-year warranty, the TBF500 series complies with RoHS, REACH, and IEC/UL/EN 62368-1 standards. An implementation involves the use of additional components, including a metal oxide varistor (MOV) that acts as a fuse, resistors, capacitors, and inductors to meet electromagnetic compatibility (EMC) requirements, storage capacitors, and other components to provide output filtering (Figure 2).
Figure 2: Some of the additional components required in a typical TBF500 implementation.
When the TBF500 power supply is implemented as shown in the illustration, it offers overcurrent protection (OPC), overvoltage protection (OVP), overtemperature protection (OTP), and short-circuit protection (SCP).
For example, unless mitigated, overvoltage transients can damage the power supply and equipment, exposing users to potential hazards. The ISO/IEC 60664-1(2007) safety standard describes several overvoltage categories (OVCs) that address transient overvoltage levels from sources such as lightning or unstable power sources. OVC I is the lowest of these overvoltage categories. The TBF500 power supplies fully meet OVC III requirements.
The -Sense and +Sense inputs in Figure 2 allow the TBF500 power supply to detect the load voltage and automatically adjust its output to address any voltage drop caused by wiring resistance.
For systems requiring more than 500W, the TBF500 power supplies support a current distribution function (CSF), enabling multiple units to be connected in parallel.
Deployment Options (including XTBF500)
: To help electronics manufacturers minimize their inventory and meet the needs of the market and different applications, the TBF500 power supplies support a variety of deployment options, such as connecting directly to the system's main motherboard (PCB). In this case, the TBF500 could be cooled by convection and radiation via a heatsink mounted on its aluminum plate, possibly supplemented by forced air cooling. This option can be seen in Figure 3.
Figure 3: Mounting to the main PCB with convection cooling.
In this scenario, the external components mentioned in the previous section can be integrated into the main motherboard system.
An alternative scenario would involve mounting the TBF500 directly to the chassis. In this case, cooling would be achieved by convection through an aluminum plate integrated into the back of the power supply (Figure 4).
Figure 4: Mounting to the system chassis with conduction cooling.
Once again, the additional external components would be connected to the main system PCB.
Another alternative is the XTBF500 standalone power supply. In this case, the TBF500 power supply is attached by its aluminum plate to a larger aluminum base, as well as to a circuit board containing all the additional components mentioned in the previous section (Figure 5).
Figure 5: The XTBF500 combines the TBF500 with a circuit board.
The XTBF500 power supply has been designed in a closed-case format, and alternatively, an open-case option is also available, as shown in Figure 5. Furthermore, an open-case format offers the advantage of improved heat dissipation for easier repair or replacement. However, the closed-case format provides protection by not allowing access to the motherboard, thus preventing the possibility of electrical shocks.
As shown in Figure 6, the TBF500's aluminum PCB connects to the XTBF500's aluminum base, which, in turn, can be mounted in the system chassis, providing improved cooling capacity.
Figure 6: The XTBF500 provides improved cooling capacity
Examples of Markets and Applications for P-DUKE PSUs:
The TBF500 and XTBF500 power supply families are compatible with a wide range of markets and applications. Some examples are summarized below:
Communications (e.g., 5G base stations)
• 500W output power: Provides the stable, high power required for continuous operation.
• Up to 93% efficiency: Reduces power loss and operating costs.
• Wide input range (85-64VAC)
• Comprehensive protection features and designed for high-altitude operation. Ensures reliability in harsh environments.
• 3-year product warranty: Increases system reliability.
Industrial Applications (e.g., industrial printers)
• Multiple output voltages (12, 15, 24, 28, 48, 54VDC)
• High efficiency: Reduces operating costs and improves system stability.
• Current distribution function and stable voltage output: Provides stability and expandability.
• Filters that meet EMC standards: Provides robust EMI resistance.
• Comprehensive protection features: Includes overvoltage and short-circuit protection for system safety.
Energy Storage Systems (ESS)
• Up to 93% efficiency: Offers energy-saving advantages, making long-term operation more economical.
• Current distribution and parallel operation capabilities.
• Multiple output voltage options: Adapts to different ESS system requirements (e.g., 48V, 54V).
• High reliability and provides stable operation in harsh environments.
Defense
• IEC/UL/EN 62368-1 certified: Meets stringent defense safety standards.
• High efficiency and multiple protections: Increases system reliability.
• Designed for high-altitude operation. Ensures reliability in harsh environments.
• Excellent EMI compatibility: Offers superior EMI resistance performance.
Robotics
• High-stability output and multiple output voltage options: Meet the needs of robotic control systems.
• High-performance efficiency: Ensures fast response and reduced energy consumption.
• Sufficient protection mechanisms: Guarantee reliability for long-term operation.
• EMC compliance: EMI resistance ensures operational accuracy.
Factory automation
• 500W output power and multiple output voltages: Compatible with various automation equipment.
• High efficiency (93%): Reduces energy loss and supports long-term operation.
• Integrated peripheral circuits: Simplify design and implementation processes.
• Adaptability to harsh environments and multiple protections: Improve system stability and reliability.
