As specialists in dc/dc converters and their applications we are often asked this question by our customers and as is typical there is rarely a simply straightforward answer but recently our manufacturing Company, Powergood has designed a product range that simply blows the competition away. Based on the Industrial standard footprint and pin out and fully replaceable with 2” x 1” (ESB) and 2”x 2” (ESC) products the 28ES series offers 28 standard full power models but saving 25-40% board space, a boon when space on a pcb is at a premium. With an Extra Wide (4:1) Input voltage range the 28ES series operate from 9-36V or 18-75V DC. Output voltages cover 3.3, 5, 12, 15 and 24V DC with dual outputs of ±12, ±15V and ±24V DC at powers of: ESB:20W output power, or up to 6A of output current at lower output voltage and the ESC-30W output power, or up to 9A of output current at lower output voltage. Positive enable gives the user start-up control and the output has a +/-10% trim facility. Protection features include input and output over-voltage protection, over-temperature protection, current limit and short circuit protection, and under voltage lockout. Not content with reducing the size they also have built in an EMC filter to EN55022 Curve B.
These converters combine a creative design concept and conservative component selection to achieve very high reliability and high performance but at an affordable price. Quality is designed-in right from the start with topology choice, utilising high efficiency fixed frequency synchronous rectification control circuitry and innovative thermal management and to this end has a number of current patents for thermal conductive compound, a ‘silicone’ type product used to encapsulate the pcb and components within the six sided metal enclosure. All materials specified and choice of component and suppliers must meet RoHS-6 and Reach 73. This careful approach to the design and manufacture of the converters pays dividends when reliability and MTBF results are considered. This works so well that no actual hot spots develop within the converter and temperature measurements on the outer enclosure surface never differ by more than 15°C. This leads to high efficiencies in excess of 90%, output currents of up to 15 Amps and allows the product to easily meet ambient temperatures of 85°C at 50% load free air. With field failure rates below 0.001% and MTBF in the region of 2M hours (Bellcore TR-332 @ 50C) the efforts made in the areas of design, component choice and sourcing, manufacturing, testing and burn-in become very apparent.
In 2011 an Ideal Power customer requested assistance regarding a new product they were designing and their specification described a DC power source that needed to be compact, robust, efficient, reliable and be able to withstand ambient temperatures of +85C. It goes without saying they also had to be commercially viable. Looking at the actual specification and required power profile in detail lead us to offer four different models, three with a single output and one with a dual output. All four had to meet an Ultra wide input voltage range of 10V-42V DC, stringent EMC levels and survive standard shock and vibration testing. Initially we offered standard off the shelf converters and these were used successfully for evaluation and design proving purposes but it soon became apparent that the actual equipment being powered also needed some non-standard output voltages of 8V, 15.6V and 27V DC, whilst all these voltages were available by trimming the standard models we agreed to supply models that were modified during manufacture so as to give exactly the voltage required. This was carried out and new samples were received 2 weeks later from the factory in plenty of time to be evaluated as part of the next equipment revision. Temperature testing lead to prolonged periods with the complete assembly including the four converters and associated heatsink being heated up to an ambient of 85°C then allowed to cycle from 50% to full load and back again continuously for 7 days. The surface temperature of the converters rose to a maximum of 100°C with a load of 45% of maximum. No further de-rating was measured and all models survived the ordeal unscathed. Whereas this might not seem unduly difficult for military grade products costing hundreds of pounds each this was achieved using products costing much less The customer was duly impressed!
Apart from this satisfied customer we have successfully helped a number of other customers meet what on the surface has appeared to be a tough specification but with help from Ideal Power and Powergood designers and engineers a suitable solution has been developed and supplied within budget. These successful projects include, Telecom, Satellite, Bank ATM’s, Railway signalling and commercial aircraft communication systems and between them the 28ES series had all its parameters tested to the full.
Product designers continually require more and more power, but insist it is from smaller and cheaper products, so to meet these needs Powergood has a continual programme of product development and enhancement. Recent additions to the Powergood 28ES series are the ‘PV’ versions. Simply adding PV to the part number identifies a model which will give at least 33% increased overall power; ESB-30Watts, ESC-50Watts and up to 60Watts from particular models and providing up to 15A of output current at lower output voltages. There is no change in the footprint or Pin-out and the overall height increases by less than 3mm.
Powergood are emerging as one of the best DC/DC Converter designers and manufacturers and enjoy the kudos of supplying a number of well known major Blue-Chip electronic Companies throughout the World. Consistency, reliability and competitiveness are all easily measureable and those Customers who have taken advantage of the Powergood success story are realising the many benefits gained through careful supplier choice.
Powergood DC/DC Converters: Consistency, reliability and competitive.
Samples and Volume quotations available from Ideal Power Ltd
Email: info@idealpower.co.uk
Tel: 0845 260 3400
