Our modular and scalable design approach uses multiple standard ALE 303 series 50 kW power modules to deliver raw high voltage DC power for the system. The outputs of each 303 power module are combined using a simple Junction box which can also accommodate any necessary output filtering and voltage/current feedback required. The complete system and individual power module outputs are centrally controlled by a Master Controller which offers both local and remote user interfaces.

The Master Controller generates all control signals required by each of the 303S power modules, and enables both local or remote user control of the system output voltage and current. The use of a multi-phase variable frequency control technique, results in low output voltage ripple without the need for large output energy storage filter capacitors. The controller interfaces to each 303 power module (or bank of 303 power modules), and to the Junction Box to provide system output voltage and current feedback, and operating status.

Each Power Module comprises a single model 303S water-cooled power supply. The 303S is a proven 50 kW rated DC power supply which can be offered with any output voltage between 1 kV and 50 kV. The total number of 303S modules required in the system is determined by the overall power requirements, with one module for every 50 kW of power (one per 40 kW with 400 VAC input). Since the overall design is 100% scalable, there is no theoretical limit to the number of 303 supplies that can be connected in parallel, and hence very high power ultra compact systems can be built using standard modules.

A Junction Box is used to combine the high voltage outputs from the individual power modules, and also serves to provide precision voltage and current feedback signals to the Master Controller. The Junction Box can also be used to house any filter or output protection components required. Filters can be as simple as a ripple reduction capacitor, or more complex multi-stage LC filter when ultra-low stored energy and ripple are required.

The modular design approach enables TDK-Lambda to offer Compact Turnkey power systems with average output powers from as little as 60 kW, to over 1 MW using the same basic proven building blocks. This enables rapid delivery at a cost effective price.

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