Industrial Automation Power Solutions

Industrial Automation Application

Description

High-reliability isolated DC-DC converters designed for industrial automation, PLCs, and distributed control systems

Core Advantages

Wide Input Voltage Range 2:1 and 4:1 input ranges accommodate 12V and 24V industrial systems with voltage variations
High Isolation Voltage 1500VDC isolation provides noise immunity and circuit protection in electrically noisy industrial environments
Extended Temperature Operation -40°C to +85°C operating range without derating supports outdoor and harsh environment installations
Exceptional Reliability Up to 2 million hour MTBF ensures continuous operation and minimizes maintenance requirements
Compact Industrial Packages SIP and DIP packages enable high-density designs while maintaining thermal performance

Recommended Bill of Materials (BOM)

Item Part Number Description Quantity Datasheet
1 EC4A21 4W DC-DC converter with 4:1 input range 1 📄 Download
2 Input-Cap-10uF 10µF ceramic input capacitor 1 📄 Download
3 Output-Cap-10uF 10µF ceramic output capacitor 1 📄 Download

Applications

Factory automation systems
Process control equipment
Industrial I/O modules
PLC and HMI systems
Motor drives and controls
Building automation
Test and measurement equipment
Robotics and motion control

Technical Specifications

Input Voltage
9-36VDC (4:1 range) or 18-36VDC (2:1)
Output Power
2W to 6W
Efficiency
Up to 89%
Isolation
1500VDC
Temperature
-40°C to +85°C

Customer Success Stories

Precision Manufacturing Corp

Factory Automation |

Challenge

Needed reliable isolated power for new PLC line with 24V industrial bus, operating in high-temperature factory environment up to 60°C ambient.

Solution

Implemented Cincon EC4A21 4W converters with 4:1 input range for PLC I/O modules. The 1500V isolation provided noise immunity in the electrically noisy factory environment.

Results

  • Achieved zero field failures over 3 years of operation
  • Successfully operated at 60°C ambient without derating
  • Reduced PLC power supply size by 40%
  • Passed all EMC compliance testing
"The Cincon EC4A21 converters have been rock-solid in our PLCs. The wide input range handles our 24V bus variations, and the compact size helped us reduce enclosure size."
— Engineering Manager, Precision Manufacturing Corp

Process Control Systems Inc

Process Automation |

Challenge

Required isolated power supplies for distributed I/O modules in chemical processing plant with severe electrical noise and temperature extremes.

Solution

Deployed Cincon EC6A21 6W converters with 1500V isolation for distributed I/O power. Implemented filtering for additional noise immunity.

Results

  • Successfully operated in 70°C ambient temperatures
  • Eliminated ground loop issues with 1500V isolation
  • Achieved 5+ years continuous operation without failures
  • Reduced maintenance costs by 60%
"The Cincon converters solved our noise problems and have been running flawlessly for years. The isolation is excellent and the temperature range handles our harsh environment."
— Plant Engineer, Process Control Systems Inc

FAE Expert Insights

S

Senior FAE

Industrial Applications Engineer

12+ years

Professional Insights

Cincon's industrial power solutions are my go-to recommendation for factory automation and process control applications. The combination of wide input ranges, extended temperature operation, and high reliability makes them ideal for demanding industrial environments. I've deployed these converters in hundreds of industrial applications with excellent results. The 4:1 input range is particularly valuable for 24V systems with voltage fluctuations - it eliminates the need for different converters for different voltage conditions. The -40°C to +85°C rating without derating is impressive and gives confidence for outdoor or high-temperature installations. For industrial designers, I recommend the EC4A series for battery or variable input applications, and the EC2A/EC6A series for stable 24V systems. Always add appropriate input and output capacitors per the datasheets for optimal performance. The 3-year warranty and Cincon's quality reputation provide peace of mind for production designs.

Key Takeaways

  • Wide input ranges handle industrial voltage variations
  • Extended temperature rating for harsh environments
  • High isolation provides noise immunity and safety
  • Excellent reliability with 2M hour MTBF
  • Compact packages fit space-constrained designs

Decision Framework

Industrial Power Solution Selection Framework
Steps:
  1. Determine input voltage range and nominal voltage
  2. Calculate required output power with margin
  3. Select appropriate converter series based on requirements
  4. Choose SIP or DIP package based on assembly method
  5. Design proper input/output filtering and thermal management

Ready to Implement This Solution?

Contact our FAE team for design support and quotes

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Frequently Asked Questions

What input voltage range do I need for 24V industrial systems?

For 24V industrial systems, Cincon offers converters with appropriate input ranges: 4:1 range (9-36V): EC4A series handles full 24V variations including transients

2:1 range (18-36V): EC2A/EC6A series for stable 24V systems. Industrial 24V systems typically vary from 20V to 30V under normal operation, with transients up to 36V during load switching. The 4:1 range converters provide the most flexibility, handling both undervoltage and overvoltage conditions without additional protection. For systems with severe voltage transients, consider adding external TVS protection. Contact our FAE team for 24V system design assistance.

Use 4:1 range (9-36V) for variable 24V systems, 2:1 range (18-36V) for stable 24V. Contact us for design assistance.

How does the 1500V isolation help in industrial applications?

The 1500VDC isolation in Cincon industrial converters provides multiple benefits: Noise immunity isolates sensitive circuits from electrical noise on the 24V bus, which often carries switching transients from contactors, relays, and motor drives. Ground loop prevention allows different ground potentials between system sections without causing interference or damage. Safety protection provides isolation between input and output circuits for operator safety. EMI reduction minimizes conducted emissions and improves EMC compliance. In industrial environments, the 24V bus can have significant noise from switching loads. The 1500V isolation ensures clean, stable power to sensitive control circuits. This is particularly important for analog sensors, communication circuits, and microprocessor-based controls.

1500V isolation provides noise immunity and safety. Essential for industrial environments. Contact us for isolation requirements.

What is the MTBF and how does it relate to field reliability?

Cincon industrial converters have MTBF ratings of 1.8 to 2 million hours at 25°C per MIL-HDBK-217F. MTBF (Mean Time Between Failures) is a statistical measure of reliability: 2M hour MTBF = 0.5 failures per million hours = 0.044% annual failure rate. This translates to exceptional field reliability - in 1000 converters operating continuously, expect less than 0.5 failures per year. Factors affecting actual reliability include operating temperature (MTBF decreases at high temperature), electrical stress (derating improves reliability), environmental conditions (vibration, humidity), and application conditions (transients, overloads). For critical applications, consider redundancy or use converters at 50-70% of rated load to further improve reliability. Contact our FAE team for reliability analysis.

2M hour MTBF provides excellent reliability. Use derating for critical applications. Contact us for reliability analysis.

Can Cincon converters operate in outdoor industrial environments?

Yes, Cincon EC series converters are designed for harsh industrial environments including outdoor installations: Operating temperature range is -40°C to +85°C without derating, suitable for outdoor temperature extremes. The SIP/DIP packages are sealed and protected against moisture and contamination. High isolation (1500VDC) handles voltage transients common in outdoor installations. MTBF ratings account for industrial environmental stress. For outdoor applications, consider enclosure IP rating for moisture protection, conformal coating for additional PCB protection, thermal management for high-temperature operation, and surge protection for lightning/transient protection. Many Cincon converters are successfully deployed in outdoor industrial applications including traffic control, renewable energy, and remote monitoring systems.

Suitable for outdoor use with proper enclosure. Consider IP rating and surge protection. Contact us for outdoor design.

What protection features do Cincon industrial converters include?

Cincon industrial converters include comprehensive protection features: Short circuit protection provides continuous protection with automatic recovery - converter current-limits during short and resumes normal operation when removed. Overload protection activates at 150-200% of rated load with automatic recovery. Overvoltage protection on some models prevents output overvoltage conditions. Overtemperature protection shuts down converter if internal temperature exceeds safe limits, with automatic restart when cooled. Input undervoltage lockout prevents operation at insufficient input voltage. These protection features ensure reliable operation and prevent damage from fault conditions. The automatic recovery features minimize system downtime. For severe industrial environments, additional external protection may be recommended.

Comprehensive protection included. Automatic recovery minimizes downtime. Contact us for protection requirements.

How do I select between SIP and DIP packages?

Cincon offers SIP (Single In-line Package) and DIP (Dual In-line Package) options for many converters: SIP packages have pins in single row, more compact size, better for automated assembly, and smaller PCB footprint. DIP packages have pins in two rows, easier for manual soldering, more stable mechanical mounting, and wider body for better heat dissipation. Selection criteria include assembly method (SIP for automated, DIP for manual), PCB space (SIP more compact), thermal requirements (DIP slightly better), and mechanical stability (DIP more stable). Electrical performance is identical between packages. Thermal performance is similar - both operate at -40°C to +85°C. Cost difference is minimal. Many designers use DIP for prototypes and early production, then switch to SIP for high-volume automated assembly.

SIP for automated assembly and compact designs. DIP for manual assembly and prototypes. Contact us for recommendations.