RACM1200-V: High Power Density AC/DC Power Supply
May 7, 2021
RECOM, a well-known manufacturer of AC/DC power supplies and DC/DC converters, has launched an AC/DC power supply with 1.2kW output, the RACM1200-V. The AC/DC converter is fully approved for medical applications. Developed in Austria and manufactured in Europe, this approach contributes to sustainability by shortening transport routes and supply chains.
Applications and Safety Features
An example of the need for a power supply exceeding 1kW is robotics. These robots are used in industrial environments and increasingly in medical applications. When a robot assists a surgeon, it must move precisely and without vibration. Rigid robot arms driven by high-torque stepper motors are employed to achieve this, resulting in high power consumption. For hygienic reasons, fans are prohibited in operating theaters. The power supply units must be base-plate cooled and meet higher insulation requirements such as IEC/EN or ANSI/AAMI 60601-1 (3rd edition), which exceed standard industrial specifications. A medical power supply can be used in industrial applications, but industrial units cannot replace medical ones.
When a power supply unit provides power to devices used directly on patients, it must have double insulation and double creepage distances, complying with 2xMOPP standards. "The safe option is the only option" is the principle RECOM has consistently applied to the RACM1200-V.
The high insulation strength of 4kV(AC) between mains and output voltages enables the RACM1200-V to be used in virtually any application requiring a power supply unit. These include chargers, LED lighting, laser devices, analysis instruments, high-frequency devices, robots, and medical beds and chairs, including devices used directly on patients. Device developers benefit from a power supply unit that already meets critical specifications. While the fully IEC 60601-1 certified power supply unit does not automatically guarantee IEC 60601-1 compliance for the entire device, it provides a key prerequisite, facilitating certification and reducing development costs.
The units are designed to maintain 2xMOPP (Means of Patient Protection) insulation. These patient protection measures, combined with low leakage currents, ensure medical safety standards are met. Signal outputs and the 5V output feature 1.5kV(AC) isolation from the mains voltage.
The series includes built-in EMC filtering with sufficient Class B clearance for radiated and conducted disturbances. It complies with international safety standards for industrial applications, IT products, and medical devices.
Fig. 2: The RACMxx series of medically certified power supplies, from left to right: 230W, 550W and 1200W
A single 1200W AC/DC converter is sufficient for many applications and can replace multiple smaller converters efficiently. Each power supply has internal consumption, which accumulates with multiple units. For instance, twelve 100W power supplies each consuming 2W internally result in 24W of losses. In contrast, a single large converter incurs only 2W of losses, potentially saving around 200kWh per year in continuous operation. The RACM1200-V features a no-load consumption of 0.75W (main output off, auxiliary output active) and meets "80 Plus Platinum" and "Ecodesign Lot 6" efficiency standards.
The input voltage range is 85VAC to 264VAC. The RACM1200-V delivers 1000W in a metal housing with contact cooling, measuring just 102mm x 229mm x 40mm. Short-term peaks of 1200W are supported for 10 seconds, while continuous 1200W output requires a user-controlled fan delivering 2.5m/s airflow. A controllable additional output allows precise temperature management.
Design and Efficiency
The RACM1200-V operates over a wide power range without a fan and features a remarkably compact design that sets new standards. A specialized base plate allows continuous heat dissipation up to 1000W. Two additional outputs eliminate the need for multiple power supplies in many applications. One output is adjustable from 5V to 12V and can, for example, power a fan. The second output provides 5V/1A and operates in the standby mode of the power supply unit.The high insulation strength of 4kV(AC) between mains and output voltages enables the RACM1200-V to be used in virtually any application requiring a power supply unit. These include chargers, LED lighting, laser devices, analysis instruments, high-frequency devices, robots, and medical beds and chairs, including devices used directly on patients. Device developers benefit from a power supply unit that already meets critical specifications. While the fully IEC 60601-1 certified power supply unit does not automatically guarantee IEC 60601-1 compliance for the entire device, it provides a key prerequisite, facilitating certification and reducing development costs.
The units are designed to maintain 2xMOPP (Means of Patient Protection) insulation. These patient protection measures, combined with low leakage currents, ensure medical safety standards are met. Signal outputs and the 5V output feature 1.5kV(AC) isolation from the mains voltage.
The series includes built-in EMC filtering with sufficient Class B clearance for radiated and conducted disturbances. It complies with international safety standards for industrial applications, IT products, and medical devices.
Fig. 2: The RACMxx series of medically certified power supplies, from left to right: 230W, 550W and 1200W
A single 1200W AC/DC converter is sufficient for many applications and can replace multiple smaller converters efficiently. Each power supply has internal consumption, which accumulates with multiple units. For instance, twelve 100W power supplies each consuming 2W internally result in 24W of losses. In contrast, a single large converter incurs only 2W of losses, potentially saving around 200kWh per year in continuous operation. The RACM1200-V features a no-load consumption of 0.75W (main output off, auxiliary output active) and meets "80 Plus Platinum" and "Ecodesign Lot 6" efficiency standards.
The input voltage range is 85VAC to 264VAC. The RACM1200-V delivers 1000W in a metal housing with contact cooling, measuring just 102mm x 229mm x 40mm. Short-term peaks of 1200W are supported for 10 seconds, while continuous 1200W output requires a user-controlled fan delivering 2.5m/s airflow. A controllable additional output allows precise temperature management.
Technical Specifications of the RACM1200-V
Output power: 1000W at 40°C ambient, 230V input; 1200W with fan or short-term peak
Dimensions (LxWxH): 228.0mm x 96.2mm x 40.0mm, with other manufacturers the connection area is mechanically exposed.
Power density:
Dimensions (LxWxH): 228.0mm x 96.2mm x 40.0mm, with other manufacturers the connection area is mechanically exposed.
Power density:
Efficiency: 95% see figure 2
Power factor: See figure 3
Power factor: See figure 3
Weight: 1kg typical
Input voltage: 85V to 264V
Output voltage:
Protection functions:
Lifetime at 40°C: 88,000 hours
Ripple: Maximum 1% of the output voltage
Output voltage tolerance: ±1% typ.@25°C, ±2% max above temperature
Certified: IEC/EN 62368, UL/IEC/EN 60601
Conformity: IEC/EN 61558-2-16, IEC61010-1, OVC III to IEC62477-1 up to 2000m
Cooling: Aluminum base plate or fan
Operation above sea level: Max 5000m (IEC/EN62368-1), 4000m (IEC/EN60601)
Additional output: 5V/1A isolated
Standby consumption: <1W (eco-design)
LED display: Indicates operating states for safety
Input voltage: 85V to 264V
Output voltage:
- 24V version adjustable to 28V in 100mV steps via dip switches
- 48V version adjustable to 56V in 200mV steps via dip switches
Protection functions:
- Overvoltage with auto-reset
- Overcurrent and short-circuit with auto-reset
- Overtemperature with auto-restart
Lifetime at 40°C: 88,000 hours
Ripple: Maximum 1% of the output voltage
Output voltage tolerance: ±1% typ.@25°C, ±2% max above temperature
Certified: IEC/EN 62368, UL/IEC/EN 60601
Conformity: IEC/EN 61558-2-16, IEC61010-1, OVC III to IEC62477-1 up to 2000m
Cooling: Aluminum base plate or fan
Operation above sea level: Max 5000m (IEC/EN62368-1), 4000m (IEC/EN60601)
Additional output: 5V/1A isolated
Standby consumption: <1W (eco-design)
LED display: Indicates operating states for safety
Remote on/off: TTL input
AC okay: Open collector output
PSU-good: Open collector output
PSU-good: Open collector output; indicates unit operation, correct voltage, acceptable temperature, no internal error
Maximum leakage current across patient: 100μA (normal), 500μA (one-fault)
Medical protection class: 2MOPP
Precisely adjusted output voltage: Remote main-output voltage sensing compensates for line drops under high currents (25A/50A), activated via two TTL inputs (5V)
Fig. 5: Remote sense for the main output voltage
AC okay: Open collector output
PSU-good: Open collector output
PSU-good: Open collector output; indicates unit operation, correct voltage, acceptable temperature, no internal error
Maximum leakage current across patient: 100μA (normal), 500μA (one-fault)
Medical protection class: 2MOPP
Precisely adjusted output voltage: Remote main-output voltage sensing compensates for line drops under high currents (25A/50A), activated via two TTL inputs (5V)
Fig. 5: Remote sense for the main output voltage
Applications
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