Key Takeaways
- AC/DC Print Modules such as the TPS-AWS10/1523S series are compact AC/DC converters designed for direct PCB mounting in space-constrained industrial systems
- Wide input range (85–305 VAC or 100–430 VDC) supports operation across global mains conditions
- Reinforced isolation, extended temperature range, and integrated protections support use in demanding environments
- Compact design enables decentralized power architectures for smart industrial devices
- Compliance with IEC/UL 62368-1 and EMC standards can be supported with appropriate external circuitry
1. What Are AC/DC Print Modules?
Despite the name, AC/DC print modules are not related to printing devices. The term “print” refers to printed circuit board (PCB) mounting. These modules are encapsulated AC/DC converters designed for direct integration into electronic assemblies.
They convert AC mains or high-voltage DC into regulated low-voltage DC outputs (e.g., 3.3 V, 5 V, 12 V, 24 V), supplying power to:
- Electronic shelf labels (ESLs)
- RFID systems
- Sensors and controllers
- Industrial display units
This makes them suitable for distributed industrial electronics where space and reliability are critical.
2. Distributed Power in Industry 4.0
Modern Industry 4.0 environments rely on a growing number of decentralized devices. Traditional centralized power architectures with long cable runs can introduce:
- Voltage drops
- Electromagnetic interference (EMI)
- Installation complexity
Placing compact AC/DC converters close to the load can help reduce these effects. AC/DC print modules enable this decentralized approach by converting local AC input directly into the required DC voltage.
3. Key Technical Characteristics
3.1 Wide Input Voltage Range
The TPS-AWS10/1523S series supports:
- 85–305 VAC (47–63 Hz)
- 100–430 VDC
This range allows operation across different regional power systems and helps maintain functionality under varying input conditions.
3.2 Isolation Voltage
The modules provide reinforced isolation (4000 VAC) between input and output. This contributes to:
- Protection of low-voltage circuits
- Reduction of common-mode noise
- Support for compliance with relevant safety standards
3.3 Operating Temperature Range
Typical operating range:
- -40°C to +85°C (with derating above specified thresholds)
This enables use in environments with significant temperature variation, such as warehouses or production lines.
3.4 Protection Functions
Integrated protections include:
- Short-circuit protection (SCP) with self-recovery
- Overcurrent protection (OCP)
- Overvoltage protection (OVP) supported via external components (e.g., TVS diode)
These mechanisms help reduce the risk of damage under fault conditions.
3.5 Ripple and Noise Performance
Typical ripple and noise values:
- ~80 mV typical
- Up to 150 mV (20 MHz bandwidth)
This level is generally suitable for applications involving communication modules or sensitive electronics.
3.6 Efficiency and Thermal Behavior
Efficiency up to approximately 84% (depending on model and load conditions) supports:
- Reduced heat generation
- Operation with natural convection cooling
No forced cooling is required under typical conditions.
3.7 Mechanical Design
Typical dimensions:
- 32.0 × 14.5 × 20.0 mm
- Lightweight construction (~10 g)
This allows direct PCB integration and supports compact system design.
3.8 Compliance and Standards
The modules are designed to align with:
- IEC/UL 62368-1
- IEC/EN 60335-1
- IEC/EN 61558-1
EMC compliance (e.g., EN55032 Class B) can be achieved with recommended external circuitry.
4. Typical Industrial Applications
4.1 Electronic Shelf Labels (ESL)
Modules can supply low-voltage power to ESL systems, reducing reliance on batteries and enabling continuous operation.
4.2 RFID Systems
Decentralized AC/DC conversion can simplify wiring in conveyor-based RFID tracking systems.
4.3 Industrial Displays (HMI)
Modules can power display logic and backlighting from local AC sources, supporting compact integration.
4.4 Smart Indicators and IO-Link Devices
Embedding AC/DC modules allows devices to operate directly from AC mains while maintaining separate communication interfaces.
5. Selection Considerations
When selecting an AC/DC print module, consider:
- Output voltage and power requirements
- Input voltage range compatibility
- Isolation requirements
- Thermal conditions and derating behavior
- EMC design requirements
6. Comparison with Conventional Power Solutions
Compared to centralized or enclosed power supplies:
- Space: PCB-mounted modules reduce enclosure requirements
- Cabling: Shorter low-voltage paths can simplify installation
- System design: Modular approach supports distributed architectures
- Integration: Easier incorporation into compact devices
7. Installation Considerations
- Through-hole mounting compatible with wave soldering
- Follow recommended PCB layout from datasheet
- Ensure sufficient copper area for thermal dissipation
- Observe derating curves at elevated temperatures
8. Example Application Scenario
In a production line using distributed display units, AC/DC print modules can be integrated directly behind each display. This approach reduces the need for centralized DC distribution and simplifies installation.
Performance benefits depend on system design and operating conditions.
9. Future Development Trends
Ongoing developments in AC/DC modules may include:
- Further size reduction
- Improved efficiency
- Integration with monitoring or control functions
- Compatibility with DC-based industrial power architectures
10. FAQ
Q: Do these modules support 50 Hz and 60 Hz operation?
A: Yes, typical input range is 47–63 Hz.
Q: Is an external fuse required?
A: Yes, datasheets typically recommend a fuse for protection.
Q: Is a minimum load required?
A: Operation at very low load may increase ripple but generally does not affect functionality.
Q: Can they be used outdoors?
A: Only when integrated into a suitable enclosure with appropriate protection (e.g., IP-rated housing).
11. Conclusion
AC/DC print modules provide a compact solution for converting mains power directly on the PCB. Their combination of small form factor, wide input range, and integrated protection features supports their use in distributed industrial systems.
They can contribute to simplified system design and flexible power architectures, particularly in Industry 4.0 environments where many devices operate in parallel.
