Power supplies are essential in converting readily available AC line voltage into regulated DC power suitable for powering a vast array of electronic devices. These devices must satisfy specific requirements in critical fields like medicine and industry.
Low noise operation is paramount to ensure the sensitive electronics within medical equipment function flawlessly, while excellent thermal management safeguards against overheating in industrial environments. Furthermore, a high power density allows for converting significant power within a compact footprint, a valuable attribute for space-constrained applications in medical and industrial settings.
XP Power, a company specializing in designing and developing power converter solutions, announced a new series of low-profile 550W AC-DC power supplies rated for convection, conduction, and forced-air cooling. Approved for use in both medical and industrial applications, the new PSUs are suited to a wide range of applications – including sealed enclosure environments. In an interview with Power Electronics News, Shravan Govindaraj, Product Marketing Manager at XP Power, provided insights on their newly introduced product, the CCP550 series, shown in Figure 1.
CPC550 technical details
The CCP550 series, a novel line of low-profile, high-power density (550W) AC-DC power supplies, cater to a broad spectrum of applications in both medical (body-floating compliant) and industrial settings. The CCP550 series distinguishes itself through its exceptional versatility in thermal management, offering convection, conduction, and forced-air cooling options.
“We have developed and brought to the market this new AC-DC power supply because we think there is a significant opportunity above the 300 Watts level, and there are a lot of applications across several industries that need a compact power supply to deliver these power levels”, said Shravan Govindaraj.
The series encompasses six variants (listed in Table 1), each providing a single, stable output voltage (12V, 15V, 18V, 24V, 36V, or 48V). Notably, all models except the 15V version incorporate a dedicated 12V, 0.5A fan output. An optional 5V/2A standby output and remote activation/deactivation functionality are also available.
The CCP550 series prioritizes efficiency and thermal performance. This is achieved through the combination of the following design solutions:
- Double-decker aluminum substrate baseplate
- Conduction-cooled power magnetics
- High-efficiency zero voltage switching (ZVS) topology.
This configuration enables silent operation at up to 300W using convection cooling and extends operation to 400W with conduction cooling, ideal for sealed enclosures and applications demanding quiet operation and high reliability.
“There was a need for a compact high power density product in the 500W range. The CCP550 can deliver up to 550 watts in a three by five inches footprint. It also features a very low profile, with a height of less than 1.5 inches (1.48”) and has an aluminium base plate which enables conduction cooled operation of up to 400 watts”, said Govindaraj.
For applications requiring the full 550W output, forced-air cooling with a 20 CFM airflow delivers exceptional power density within the series’ compact, low-profile footprint (37.5mm height, 127.0 x 76.2mm footprint).
In the medical domain, the CCP550 series adheres to IEC60601-1 Ed.3 standards, ensuring safety for body-floating patient contact applications. This is achieved through double Means of Patient Protection (MOPP) between primary and secondary circuits, and single MOPP from primary to earth and secondary to earth. Additionally, the units boast minimal earth and patient leakage currents.
The CCP550 series boasts a wide input voltage range (80-264VAC), facilitating global use including home healthcare environments. The units can function in extreme ambient temperatures, ranging from -30°C to +70°C. Furthermore, when the main output is disabled, the power consumption dips below 0.5W, satisfying rigorous energy efficiency standards.
The main technical features can be summarized as follows:
- Output power: 550W fan cooled, 400W conduction cooled
- Single phase input voltage: 80 to 264VAC
- Dimensions: 127.0 x 76.2mm footprint, 37.5mm profile
- Efficiency: up to 92%
- Low earth leakage <400μA
- Low patient leakage <90μA
- Medical (BF) & ITE safety approvals – 2 x MOPP isolation
- Standard fan supply on all models (excluding 15V)
- Optional 5VDC standby & remote on/off
- 3-year warranty
Typical applications of the CCP550 series include healthcare, robotics, process control, instrumentation, and technology.
A medical use case
As Govindaraj states, medical approvals require, among other features, low leakage currents and high isolation. Typical medical applications include patient treatment, dental care units, arthroscopy pumps, surgical robotics, medical imaging, and more.
As an example, let’s consider a state-of-the-art dental care unit as the one shown in Figure 2. Equipment like this requires a DC motor to adjust the height of the dental chair, depending on the patient’s physique and on the actions to be performed.
The typical power requirements to drive the DC motor are the following:
- Output voltage: 36V
- 2xMOPP isolation
- 550-600W peak power
- Baseplate-cooled
- 5V Standby
All these requirements can be satisfied by the CCP550 power supply, which also features low noise, compact size, and high efficiency.
Advantages over competitors’ models
As Govindaraj explains, “Within the 300 to 600 watts power range, there are many competitors’ models. However, what differentiates us is the availability of a fanless version with a 3 x 5 x 1.5 inches footprint capable of delivering an output power of 400W”.
Moreover, the new power supply series is highly versatile. “Flexibility is a big advantage. Depending on the specific customer requirements, you can need a convection operation, a conduction operation, or a forced cooled operation. Moreover, we can address both the medical and the industrial markets”, said Govindaraj.
Additionally, the forced-cooled operation allows this device to deliver higher output power for demanding industrial applications. The CCP550 is a versatile product that can be used in multiple markets and multiple applications due to its flexibility and different options.
Besides high power density and compact size, the CCP550 features very low noise. The fanless models (300W and 400W) are very silent and therefore particularly suitable for noise-sensitive medical applications.
“The fact that it’s fanless improves both reliability and thermal management. If you have high reliability, then your long-term costs are lower, too”, said Govindaraj.
The compliance with the EN55032/EN55011 standards for conducted emissions (test level class B) implies the power supply does not require a separate EMC filter. “All of these features make it easy to design into BF-rated patient contact applications. The CCP550 is a versatile product that can be used both in industrial and in medical applications”, said Govindaraj.
Conclusion
The CCP550 series by XP Power offers a compelling solution for a diverse range of applications requiring high power density and efficiency. The series’ versatility in thermal management, encompassing fan-cooled and fanless configurations, caters to medical device integration, industrial electronics, and test and measurement equipment. Notably, the ability to operate in sealed environments with conduction cooling broadens its applicability.
