COTS Journal

Digitally Controlled Power Factor Correction Solution Meets Radar Needs

By: Jeff Child, Editor-in-Chief

Gone are the days when military power supplies technology was exclusively dominated by costly custom-designed solutions. Today there's a rich variety of off-the-shelf solutions are available serving diverse needs. As military system developers demand more and more computing in ever smaller spaces, power has direct implications on the size, cooling and mobility of a system. Responding to those demands, military power conversion vendors are crafting more efficient products, new partitioning strategies and increased ruggedization in order to serve board- and box-level military electronic systems.

In the area of high-power-density DC/DC converters, the modular form factor, commonly referred to as a brick, continues to be the preferred building block component for any application, commercial and military. These are evolving to help systems designers deal with the challenges of multi-voltage electronics and the complexity of distributed system architecture. Meanwhile, uninterruptible power supplies (UPS) are now more critical than ever as computer and network gear pervade the battlefield. The direction for UPSes is toward high-quality, rugged products designed to pass strict military standards.

For this month's Editor's Pick section COTS Journal evaluated several rugged display systems based on three aspects: technology leadership, design innovation and market relevance. The winning product is SynQor's 3-Phase Power Factor Correction Module (standard product part number MPFC 115 3PH-270 FP) (Figure 1). The module provides an essential building block of an AC-DC power supply. It makes use of full digital control to enable control strategies not possible with conventional designs. For instance, the PFC output has a special constant-power output characteristic which helps pulsed-power systems-like radars for example-maintain good input harmonics. See datasheet section "Pulsed Loads" for more information along those lines. (Link to data sheet here). Digital control also allows for a data interface allowing the military system developers to view internal voltages, currents, and temperatures-information which would be difficult to obtain otherwise.

Advanced Construction Methods

Making use of SynQor's years of experience with high volume manufacturing for the telecommunications market, the MPFC 115 3PH-270 FP uses robust construction techniques including automated assembly, embedded planar magnetics, and compliant potting materials. The device boasts innovations including minimal inrush current, support for full load current during startup ramp and balanced phase currents with low THD (1.5 percent at full load). It delivers a wide input frequency range of 45- to 800-Hz.

In terms of market relevance SynQor's 3-Phase Power Factor Correction Module answers military customers' demands an integrated solution which was previously not available in the market. The full-brick sized converter delivers 1.5 kW at 270 VDC while switching at 200 kHz, which allows for a groundbreaking improvement in power density. System developers requiring 400 Hz 3-phase for airborne military platforms will find huge weight savings over existing custom solutions. EMI is fully characterized with the available 3-phase half-brick input line filter (SynQor product number MACF 115 3PH-UNV HT).

Boxborough, MA
(978) 849-0600


...And the Runners Up:

Scalable UPS System Features Auto-Sensing and Auto-Switching

The PowergridM intelligent backplane stacking system from AJ's Power Source features a stacking design, based on modular power service building blocks, allows multiple rugged UPS units to be intelligently stack connected and function as a single unit (Figure 2). This intelligent stacking design provides a highly resilient non-stop power support for operationally critical applications and with its Plug-&-Play Hot Swap Backplane capability and load-sharing design, allows for Repair/Replace maintenance activities with zero down time for attached systems.

To provide Global Power Of Choice capabilities, PowergridM UPS systems are the first to incorporate Auto-Sensing/Auto Switching technology allowing them to operate on either an AC or DC power sources. To provide deployable power resiliency, you can connect PowergridM to both services at the same time and the systems will automatically select the "best available" power source significantly improving mobile On-The-Move, On-The-Pause, and On-The-Stop applications. The PowergridM backplane design can accommodate the integration of AC, DC, and expanded battery support power services into a single Integrated Power Management System (IPMS) with backplanes available from 3U (800W-3600W) to 10U (1200W-12KW) fully ruggedized stack configurations for transit case, mobile shelter, or vehicle based mobile systems.

AJ's Power Source
Land O Lakes, FL
(813) 996-2583


Rugged 3V 350W Power Supplies Provide Four Configurable Outputs

The 3V Series of COTS MOTS power supplies from XCEL Power Systems, a subsidiary of Data Device Corporation, provide a configurable 250W solution designed to meet the demands of military vehicle and aerospace applications (Figure 3). The 3V series offers the flexibility of up to four configurable outputs, within a proven ruggedized mechanical design, and fitting standard 3U enclosures According to the company, the product benefits from the investment in digital power conversion technology, the use of SIC and GAN switching devices, higher switching frequencies and associated topologies to achieve market leading efficiency, minimizing the requirement for customer's thermal management.

The mechanical and thermal designs of these power products are tailored to specific applications and in many cases are a stressed part of the structure of the overall package, minimizing duplicate hardware. Use of remote control and monitoring is a fundamental part of the product, incorporating RS485, CANBUS, 2 wire unscreened Ethernet and so on. While providing high conversion efficiency, the device also enables the extraction of the remaining heat from the unit through mechanical design and thermal modeling. Other key factors in the performance criteria of the unit are its EMI performance along with minimum output noise and harmonic distortion. It is capable of operating in arduous environmental conditions over wide temperature ranges and at any attitude.

Data Device Corp.
Bohemia, NY
(631) 567-5600


Check Out These Rugged Display Products Too...

Behlman Electronics' DCR2U Critical Mission COTS Power Supply Series accepts inputs of either 80-265 VAC at 47 to 440 HZ, power factor corrected; 240 to 400 VDC; or 115/200 VAC, 3-phase at 360 to 440 Hz . Output power of 2,000 to 4,000 Watts is available.

Behlman Electronics, Hauppauge, NY. (631) 435-0410. 4

The 360 Watt TCM Series of chassis mount DC/DC converters from Calex offers wide 4:1 input range of 9 to 36 VDC. This makes the TCM ideal for 28V military COTS applications. The chassis mount case is designed for backplane or enclosure mounting with or without DIN rails.

Calex, Concord, CA. (925) 687-4411. 5

Extreme Engineering's XPm2222 is a VITA 62.0 form factor 3U VPX power supply. The unit takes in a MIL-STD-704A/E/F or MIL-STD-1275D 28 VDC input voltage and provides up to 260 W on 3.3 V, 5 V, and ±12 V at up to 87 percent efficiency.

Extreme Engineering Solutions, Middleton, WI. (608) 833-1155. 6

The expanded SSG Series Industrial UPS product line Falcon Electric now spans power levels from 1kVA to 6kVA that address a broad range of demanding applications. Like Falcon's other SSG models, the 4 to 6kVA units are rugged, rackmount on-line UPSs.

Falcon Electric, Irwindale, CA. (626) 962-7770. 7

North Atlantic Industries' 56TS1 is a rugged, 500W AC/DC power supply that provides full-power at a baseplate temperature of +85 degrees C. It provides current share and MIL-STD-461F filtering. Output voltages supported range from +12 VDC to +48 VDC.

North Atlantic Industries, Bohemia, NY. (631) 567-1100. 8

The AVP/AVN series from Pico Electronics are unregulated high voltage DC-DC converters with output voltages to 10,000 VDC and are produced in an ultra-miniature encapsulated package. For military applications an operating temperature range -55 to +85 degrees C is available.

Pico Electronics, Pelham, NY. (914) 738-1400. 9

The CPW-5700 Series (AC-DC) and BPW-5700 Series (Battery Charger) are part of Schaefer's Heavy Industrial/Military COTS/MOTS (20KW to 30KW) Power Series. The units offer three phase, wide input ranges for 200/400/440 and 480VAC and selectable output voltages and currents.

Schaefer, Hopkinton, MA, (508) 436-6400. A

Vicor 's ChiP DCM series are isolated, regulated DC-DC converter modules based on the company's Converter housed in Package (ChiP) power component platform. The series spans DC-DC conversion requirements from 12 V to 420 V input and 12 V to 55 V output.

Vicor, Andover, MA. (978) 749-8359. B

The HTD Series from VPT are DC-DC converters specifically designed for harsh and extreme temperature environments. The HTD isolated 1.5 W DC-DC converters operate from -55 to 155 degrees C and the HTD non-isolated DC-DC converters operate from -55 to 185 degrees C.

VPT, Blacksburg, VA. (425) 353-3010. C



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