High Voltage DC to DC Power Supply Module

High Voltage Power Supply 

1.      Product Description

API is seeking a vendor to design a power supply for applications in a mining environment.  The open frame conduction cooled power supply operates in mines and tunnel that see harsh environments.  The power supply outputs 4 constant current sources that are used to power sensitive mine safety equipment.  The input power can be either AC or DC voltage and the unit is not polarity sensitive.  The power supply is isolated and does not provide any feedback onto the input line.  The unit has a MTBF of 50,000 hours. 

2.      Input Characteristics

2.1.       DC Voltage Characteristics

2.1.1.      450VDC to 1,000VDC(must perform continuously between these voltages)

2.1.2.      Transients

2.1.2.1.            50 microseconds at 3000V

2.1.2.2.            1 second at 2500V

2.1.2.3.            10 seconds at 1500V

2.1.3.      Polarity insensitive (i.e. unit will operate if accidently positive input is connected to negative rail and negative input connected to positive rail)

2.2.       AC Voltage Characteristic

2.2.1.      600VAC  � 15%

2.2.2.      Transient of 3000VAC for 1 second

2.3.       Two wire connection with no chassis ground (Wire is 14awg 41 strand with a Hypalon over EPR coating with a OD of .32

2.4.       Either wire may be hot

2.5.       Input current <.2A

3.      Output Characteristics

3.1.       4 channel output each meeting below characteristic

3.1.1.      24VDC �2V

3.1.2.      .75A constant current (�1%)

3.2.       Maximum loss for all 4 channels of 18W(ie > 80% efficiency)

3.3.       Response time < 2 sec

3.4.       Over Current Protection.  When the current to any one of the four outputs exceeds the current limit, the output will shut down, but the other outputs will continue to operate.  Power supply will have to be cycled for the output to recover

4.      Isolation

4.1.       Assembled power supply in mining equipment enclosure will pass a hi-pot test applied from case to input ground at 3000VDC for 1 minute with a leakage current of d3 micro amps

5.      Mechanical

5.1.       Size and Weight

5.1.1.       must adhere to constraints of attached PDF (roughly 9X2X2)

5.1.2.      Weight: < 1 lb

5.2.       Cooling

5.2.1.      Conduction cooled via metal plate in current mechanical design

5.2.2.      Heat dissipation is up to 18W

5.2.3.      On over temperature the unit will shutdown and will automatically restart when it cools.

5.3.       Conformal coated to protect against moisture

6.      Lifetime

6.1.       50,000 hour MTBF per MIL-HDBK-217F

6.2.       3 year manufacturer warranty

7.      Environmental Characteristics

7.1.       Shock

7.1.1.      8 drop test

7.1.2.      Mechanical shock (11ms) during shipping and operation: 10g peak

7.2.       -40� to 50癈 ambient air temperature with metal plate surface at 70癈 or below

7.3.       Storage:  -50� to 85癈

7.4.       Vibration Sinusoidal Resonance Sweep:

7.4.1.      5 to 10 Hz  .05 p-p

7.4.2.      10 to 200 Hz .5 g peak

7.4.3.      5-20 Hz .1 p-p

7.4.4.      20 to 200Hz 2.0 g peak

7.5.       Humidity

7.5.1.      While power supply will be in a watertight compartment, the assembly will be conformal coated to protect against condensation and general corrosion

7.5.2.      Relative Humidity (%) Non-condensing 

7.5.2.1.            Operating

7.5.2.1.1.              Minimum 0

7.5.2.1.2.              Maximum 95

7.5.2.2.            Storage

7.5.2.2.1.              Minimum 0

7.5.2.2.2.              Maximum 95

7.6.       Impervious to steel dust, salt, fog, rain, sand, hail metallic dust, contaminants, etc

8.      Design Specifications

8.1.       RoHS compliant

8.2.       Designed to be UL 609050 compatible

8.3.       CISPR/FCC Class A

8.4.       EMI/Safety

8.4.1.      Designed with an EMI filter to limit back feed into input supply as well as EMI and EMC

8.4.2.      Designed to meet Mil-STD-461E