Save Energy in Your System with R3 DC/DC Converter
1 Introduction of R3 DC/DC Converter
Energy conservation is becoming increasingly critical as well as the ability to meet new energy efficiency standards; therefore, decreasing the standby power consumption of electronic devices is becoming more and more important. Being the “heart” of the electronic system, power supplies need to be more efficient, This is what the Mornsun R3 wide-input DC/DC converter is made for.
2 Application Problems in the Industry
【Question 1: High standby power consumption shortens the endurance of the energy storage power system】
There are two modes of energy consumption in energy storage systems: operating mode and standby mode. In operating mode, it can realize energy saving with the same performance by decreasing power consumption of the devices; while in standby mode, some units need a permanent power supply in case of system restarting and operating. For example, the most common power supply of DC/DC converter is a battery, such as BMS and supercapacitor power system, etc. In these systems, the devices usually work in no-load condition, thus, the over input current directly consumes the energy in the energy storage systems.
In the industry, most 6W power modules’ no-load current is 12~15mA with 24V input, in comparison, the no-load the current of Mornsun R3 DC/DC converter is typically only 4~5mA. Tested under the same condition, the no-load loss of the R3 converter is as low as 0.12W. Taking a 20AH battery for example, when the battery is powering a DC/DC converter, the no-load input current is 15mA, and battery life is 1333.3H. To extend battery life, we need to decrease the no-load current. The no-load current of Mornsun R3 DC/DC converter is only one-third of other products’ in the industry, which is up to 4000H. Therefore, the R3 DC/DC converter significantly improves the life of the accumulator and decreases the energy consumption of energy storage systems at the same time.
In addition, many power supply systems need to be compatible with the wide input voltage, thus we need to pay attention to power balance within all voltage range, that is, to keep the low no-load power consumption at any input voltage. Mornsun R3 DC/DC converter keeps balanced no-load power consumption in all input voltage range. For example, in the wide input voltage of 18~36V and the no-load current is: 5~6mA (low voltage input); 4~5mA (nominal voltage input); 2~3mA (high voltage input), no-load power consumption stays at about 0.1W. Therefore, R3 products avoid the waste of standby energy in the whole system.
Mornsun R3 DC/DC converter features the ultra-low no-load power consumption and power balance within all input voltage range, which reduces the high power consumption in long no-load operation and achieve high efficiency and energy savings.
【Question 2: How much does derating affect the temperature rise of the converter enclosure?】
In most cases, the customers tend to use the converters with 10%~30% loads. It is considered that derating can improve product’s long-term reliability. However, in practical application, the low efficiency in long light-load operation causes serious self-heating, the temperature rise of the enclosure, and ultimately results in failures in multiple converter applications or in closed environments.
There is a case of a customer in the military industry. The load power of the application is 1W, and the engineers think that derating can improve a product’s long-term reliability, thus they selected a 6W converter of another company. Tested in the nominal voltage input, the output load power is 1W; while tested at 25℃, the shell temperature reached 44℃; tested in 85℃, it reached 103℃. Thus the reliability of the power converter will be reduced in continuous high-temperature operation.
The efficiency is only about 40% in the 1W load. We can see from the formula, the power consumption of the module itself is higher then the load power, which causes the temperature rise of the enclosure and reduces the product’s reliability. In contrast, the efficiency of the Mornsun R3 6W converter is up to 75% in light load, which is 35% higher than the common standard in the industry. From the formula, we know that the consumption is only 0.3W, and the enclosure temperature of R3 DC/DC converter is 10℃ lower than common converters’, which lowers the self-heating of the converter and improves the reliability.
Meanwhile, as the no-load consumption has been reduced, the consumption of all load points is also reduced, which significantly improves product efficiency in all ranges of the load.
Mornsun R3 wide-input DC/DC converter adopts patented design, solves the problems of low efficiency in the light-load operation, high-temperature rise, etc., and achieves energy saving of the application.
【Question 3: High-temperature rise of the shell cause product failure in many temperature-sensitive conditions】
As many applications are sensitive with temperature rise, there are strict requirements for temperature in the industries such as the underground mining and oil exploration field which have inflammable gas. For these applications, the lower temperature rise ensures the reliability and safety of the system.
Mornsun R3 DC/DC products reduce temperature to rise significantly by improving circuit design as well as offering innovations in the mechanical structure. Apart from standard packages, R3 DC/DC products feature integrated heat sinks. Compared with common glued heat sinks and installed heat sinks, it completely avoids the temperature difference caused by the connecting gaps of the heat sink and the surface of the enclosure. The integrated heat sink reduces heat resistance, optimizes thermal conduction, lowers the temperature rise, and enhances product reliability.
3 Conclusions of R3 DC/DC Converter
Mornsun meets IPD Product Development Specification, ISO9001 Product Development Requirement, Reliability Platform Requirement and Overall Process Target Cost Management Requirement, and created an R&D Management System with Mornsun features which provides a full system assurance for creating competitive power supply products. Since 2012, Mornsun R2 products earn the highest reputation from customers in short-circuit protection and ripple & noise, EMC, etc. After continuous research and innovation, Mornsun R3 DC/DC converter makes a significant breakthrough on reducing the no-load consumption and improving light-load efficiency.
Mornsun R3 DC/DC converters feature ultra-low no-load power consumption, high efficiency in all load range, operating temperature of -40℃~+85℃, multiple protections (short-circuit protection, over-current protection, under-voltage protection, output over-voltage protection), high capacitive load, quick start and etc. Save energy in your power system design with Mornsun R3 DC/DC converters.
