Suitable solutions for AC/DC power supply 115/230V - 24Vdc/25A (600W)

Hello!

Thank you for your answer!

I have briefly looked into three of the designs that you proposed; the two 480W (TIDA-01494 and TIDA-01495) and the 500W (TIDA-010015).
At this stage all three seems to be possible in my view, except for to low power capacity.

One circuit which is used in TIDA-01495 and TIDA-010015, seems to be non existing: UCC25630DDB.
- Is this part name correct?

- Can you say anything about the predicted life-span of the included key circuits from TI?
(The desired life-span of the product is 30 year)

The new supply unit shall replace an old existing supply rated 600W 50/60Hz transformer based un-regulated 24V supply (transformer, rectifier and filter cap).
There are two versions of this supply with different input voltage; 115Vac to "24Vac" and 115Vac to "24Vac".
The new supply could preferably have 85-265V input voltage range, but if it would be a benefit for the effiency, two versions of the new supply, "115" and "230V" (with acceptable tolerance ranges) could be a solution..

The new supply shall be built inside the existing mechanical enclosure; a 19" 4U rack mount enclosure with depth of approx 200mm (8 inch).
Through the available space in the existing enclosure, maybe the need for a "low profile" design is not necesarry.
The old supply is passive cooled through perforated steel plate in the enclosure top and bottom and therefore the new supply should preferably also be fanless type.

The old transformer supply is rated 600W, therefore I think the rated continues power of the new supply also shall be at least 600W.
- Is any of the three ref-designs easier than the other to modify for 600-700W?
- Can TI help with a change in power capacity?

As we now today, the predicted volumes are 100 units per month for up to 30 years.

Thanks!

L-O

Hi L-O,

Thanks for looking at those reference designs and providing the detail of your design. 

First, the UCC256301 is here http://www.ti.com/product/UCC256301 .

Next, I've asked the power supply experts to review this, a reply will be forthcoming. 

Regards,

~Leonard  

Hi L-O,

As Leonard said, the correct part number is UCC256301. We will correct it in the documentation.

Since you require a long life time for the power supply, my recommendation is the interleaved PFC and LLC topologies followed in TIDA-01495 & TIDA-010015. Please see further discussion on this here: e2e.ti.com/.../how-topology-selection-can-help-improve-reliability-in-industrial-ac-dc-power-supplies

The design can be easily modified to 600W. Please follow the design procedure explained in the TI Design guides and the respective part datasheets. And yes, designing separate power supplies for 115V input and 230V input will be beneficial in improving efficiency as well as reliability.

We haven't done any lifetime prediction analysis on these designs.

Regards,

Salil

Hi Salil!

Thank you for the answer.

Just to be sure that there are no missunderstandings due to bad english from my side:

What I meant with life-span, is the time period where it´s possible to build the design we finally will select, that means time before EOL.
Our customer want the new design will have as long life-span as the old design that was designed in the 80's and has been able to be produced until now.
When I read predicted lifetime, I think of MTBF, maybe I'm wrong?
Of course it's an advantage if also the MTBF is as high as possible, but if it's not 30+ years, it's not a major problem, our customer has also for the previous design been forced to replace many of the supplies, mostly due to bad filter caps. And since there are many more components in modern switch mode supplies, it would not be any surprise if these also have to be replaced, but in such case, it should preferrably be possible to produce new ones without a new re-design and certification cost run.

Do you have any information about the life-span (YTEOL) of the key circuits from TI that are included in the actual ref-designs?

Have I understood it right; TI does not help with any tweaking of any ref design for a customer, the customer have to do it himself?

Thanks!

L-O