AC-DC Single Output Power Module: PFE Series
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An Overview study on PFE Series AC-DC Power Module
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AC-DC Single Output Power Module: PFE Series
- 16. PFE model number listing
Editor's Notes
- Welcome to the Training module on the PFE Series AC-DC Single Output Power Module from TDK-Lambda.
- This training module introduces the PFE-F and PFE-S series of power modules. The module’s features and block diagram are also discussed.
- The market for mid-power and fan-less AC-DC power solutions is expanding. Everyday, new applications arise for outdoor mounted electronics including: pole mounted wireless cell repeaters, LED signs, traffic signals and warning signs, toll equipment and automated service kiosks. Some of the key requirements for these types of outdoor applications include: no fan, wide temperature ranges of -40 º C up to +85 º C, conduction cooling and where a custom configuration is required.
- Many customers are using regular AC-DC power supplies for these outdoor mounted and robust applications. However, they often run into problems in cooling the supplies especially in hot desert areas, such as Phoenix, Arizona. Often they have to modify their design to provide extra cooling for the power semiconductors, and the capacitors, and these supplies are usually not rated for operation above +70 degrees C. Most AC-DC power supplies that provide 300 watts and above must have an internal fan. Since fans are electromechanical devices they are the least reliable component in these power supplies. We are now seeing a migration of many customers from conventional AC-DC power “boxes” to the use of these new brick PFE brick power modules, because the new brick design places all the power components on the same PCB thus reducing the size of the end product and eliminating the power interconnect wires. In addition, this design allows the power supplies to be cooled by means of heat sinks or cold plates.
- The PFE Series combines what previously required two bricks into a single brick. In the past, a separate AC front-end module that included the rectification and power factor correction functions would be required in addition to a second module that comprised a DC to DC converter that would provide the regulated lower voltage DC output. This diagram shows the mechanical layout for a typical two-brick solution along with some of the necessary external components. This once popular solution has been made obsolete by the introduction of the PFE series, a single-brick solution. The space and cost savings of the PFE series are significant.
- The TDK-Lambda PFE Series is a unique family of PCB-mountable, “Brick” based AC-DC power modules. This single-brick solution provides a lower cost and smaller footprint AC-DC solution. Some external components are required, as is the case with other power modules, but the net result is a pc-board saving of up to 50% compared to a two-brick solution. And, because the module and it’s external components can be fitted to the customer’s available shape and space, the PFE’s work well in custom applications. These power modules operate with a universal AC input of 85 to 265VAC and include Power Factor Correction. Modules are available with output voltages ranging from 12 volts up to 48 volts DC and power ratings from 300 watts to 1000 watts. All the models are fully isolated and are ideal for conduction cooled and custom applications.
- One module of PFE series now contains the functions previously only obtainable by combining a front-end module with a high voltage input DC-DC converter. The product is made using a wide range input AC-DC front end function based on harmonic current control and power factor correction and DC-DC back-end. PFHC (or Power Factor Harmonic Current, AC-DC conversion) is also provided. Primary and Secondary isolation exists for better safety and wider input range. High efficiencies with up to 100deg C max base plate temperatures are possible.
- The PFE Series includes six standard PFE300S (rated at 300 watts) & PFE500S (rated at 500 watts) models, where the “S” stands for “Simple Function Modules”. These models are fully regulated and are available with output voltages of either 12V, 28V and 48VDC. The modules have a large adjustment range as can be seen in the slide. For example, the 28V unit can easily be adjusted to 24 volts and the 48V unit can provide 56 volts if desired. The maximum operating base plate temperature for these PFE modules ranges from +85 degrees C to +100 degrees C and the modules can be mounted to cold-plates or metal structures for conduction cooling. These modules have standard full brick dimensions: 2.4” Wide by 0.5” High by 4.6” Long.
- This is the external circuitry for the PFE500S module. It’s input voltage range can be single phase from 85 to 265VAC, and the line frequency ranges from 47 to 63Hz. Care should be taken while applying the input voltage range otherwise it may be damaged. This power module has no internal fuse. An external fuse must be used to acquire each safety standard. In addition, a fast-blow type of fuse must be used per one module. In-rush surge-current, flows during line throw. I2t rating of the external switch and external fuse must be checked.
- There are a number of “ safety critical ” external components that are recommended for use with the PFE Series. The EMI filter of C1-14, L1-2 which is X2 and Y2 approved should be used and the inrush resistor must be sand filled and of the fusible type, it’s value can be found using the formula given here. A bulk capacitor value of 780uF will give a typical 25ms hold up at 500W load.
- Except for the PFE700S, all the other models in the PFE series are fully regulated. The PFE700S (rates at up to 714 watts) is semi-regulated and has a nominal output of 50 to 57VDC depending upon the load. This model is fully isolated and ideal as a source for an Intermediated Bus Architecture where a tightly regulated DC to DC converter is not required. These modules can be parallel connected using the droop-mode method and have no output voltage adjustment. The PFE700S is a standard full brick size module (2.4 x 0.5 x 4.6”).
- The PFE Series consists of six “F” or “Full Function Versions” which have added features including: active current sharing (up to six modules) and remote On/Off control. The PFE500F is rated at 500 watts and the PFE1000F is rated from 720 watts up to 1000 watts, depending upon the output voltage. Like the other PFE modules, these too are available with fully regulated DC outputs of either 12V, 28V, or 48V and have wide adjustment ranges for specific applications. The maximum base plate temperature range is from +85 degrees C up to +100 degrees C. The PFE500 F is only slightly larger than the PFE500 S . The PFE1000F, (since it can provide up to 1000 watts) is the largest of the series, 3.94” wide by 0.53” high by 6.3” long, but is still a very compact package for the amount of output power it can provide.
- Here is a block diagram of the PFE1000F showing from input to output the basic functional components. Included in the PFE module are the AC rectifiers, the PFC circuits, filters, controls, DC to DC converters, output rectifiers, and signal circuits to name a few. The PFE series are fully isolated from input to output. In addition to Active Current Sharing for paralleling up to 6 PFE modules, the PFE500F & PFE1000F models have a Remote On/Off control which is an Opto-isolated input plus an auxiliary output from 10 to 14VDC at up to 20mA is included. In addition, a “DC Good” open collector output that can sink up to 10mA when the output is good, is also included with these models.
- Here the PCB Board design will be discussed. As with all power modules, the calculations for cooling and heat management need to be taken care of since it improves the efficiency of power supply. Some of the guidelines for PCB spacing have been shown here.
- Lets now discuss the PFE evaluation board. The PFE1000F evaluation board has all PFE features and as such is the quickest way to evaluate the entire series. Alternatively, TDK Lambda can provide bare pcb’s, Bills of Materials, Gerber files, outline drawings and PCB-layouts to customers who want to build up their own eval boards.
- This slide was taken from a section in the PFE datasheet. It shows the standard model numbers and their ratings.
- A selection of heat sinks and suggested Inrush Resistor and EMI Inductor for the PFE Series are shown on this slide. The part numbering scheme is also shown.
- Thank you for taking the time to view this presentation on the “ PFE Series AC-DC Single Output Power Module ” . If you would like to learn more or go on to purchase some of these devices, you may either click on the part list link, or simply call our sales hotline. For more technical information you may either visit the TDK-Lambda site, or if you would prefer to speak to someone live, please call our hotline number, or use our ‘live chat’ online facility. You may visit Element 14 e-community to post your questions.