Industrial Power Supply Solution

Application

Description

This industrial power supply solution provides a complete power system for industrial control equipment. It features a wide input range AC-DC converter with power factor correction, followed by multiple DC-DC converters generating isolated and non-isolated rails for controllers, sensors, and communication interfaces.

Core Advantages

Wide 85-265VAC input range for global operation
High efficiency up to 90% reduces heat generation
Multiple isolated and non-isolated output rails
Comprehensive protection for reliable operation
Meets industrial EMC and safety standards

Recommended Bill of Materials (BOM)

Item Part Number Description Quantity Datasheet
1 JW1550 Quasi-Resonant Flyback Controller 1 📄 Download
2 JW5359 Synchronous Buck Converter 1 📄 Download
3 JW5220 High PSRR LDO 1 📄 Download
4 JW7726B Synchronous Rectifier Controller 1 📄 Download
5 10A 650V Power MOSFET, 10A, 650V 1 📄 Download
6 EE25 Transformer, EE25 Core 1 📄 Download
7 100μF 450V Electrolytic Capacitor, 100μF, 450V 5 📄 Download
8 10μF 50V Ceramic Capacitor, 10μF, 50V, X7R 10 📄 Download

Applications

PLC systems
Industrial controllers
Sensor networks
Motor drives
Factory automation

Technical Specifications

Input Voltage
85VAC - 265VAC
Output Rails
24V, 12V, 5V, 3.3V
Total Power
Up to 100W
Efficiency
Up to 90%
Isolation
3kV primary to secondary
Operating Temperature
-40°C to +85°C
E M C Compliance
IEC 61000-4-x
Safety Standards
UL/EN/IEC 62368-1

Customer Success Stories

AutoControl Systems

Industrial Automation | PLC Power Supply

Challenge

Needed reliable multi-output power supply for industrial PLC system with wide input voltage range and high reliability requirements.

Solution

Implemented complete JoulWatt power solution with JW1550 AC-DC front end and JW5359 DC-DC converters for multiple output rails.

Results

Achieved 90% efficiency with stable operation across full input range. Passed all industrial EMC tests. Deployed in 1000+ systems without field failures.

SmartFactory Equipment

Factory Automation | Sensor Hub Power

Challenge

Required isolated power supply for distributed sensor hub with multiple voltage rails and strict EMI requirements.

Solution

Designed custom power supply using JoulWatt JW1550 controller with isolation transformer and multiple secondary rails.

Results

Successfully powered 32 sensors with excellent noise immunity. EMI performance exceeded requirements by 6dB margin.

FAE Expert Insights

D

Dr. Michael Chen

Senior FAE - Industrial Power

15 years

Professional Insights

Key considerations: Use quasi-resonant operation for reduced EMI in industrial applications; Implement proper transformer shielding for EMC compliance; Post-regulation provides clean power for sensitive circuits; Comprehensive protection is essential for industrial reliability. Common pitfalls to avoid: Inadequate input filtering causing conducted EMI failures; Insufficient creepage/clearance for safety isolation; Poor transformer design leading to saturation; Inadequate thermal management at high ambient temperatures.

Key Takeaways

  • Use quasi-resonant operation for reduced EMI in industrial applications
  • Implement proper transformer shielding for EMC compliance
  • Post-regulation provides clean power for sensitive circuits
  • Comprehensive protection is essential for industrial reliability

Decision Framework

Decision Framework
Steps:
  1. Evaluate requirements
  2. Compare solutions
  3. Consult FAE

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 does this solution support?

The solution supports universal AC input from 85VAC to 265VAC, covering all global mains voltage standards. This wide range allows the same design to be used worldwide without modifications. The JW1550 controller automatically adjusts operation for different input voltages.

Universal 85-265VAC input suitable for global deployment; no design changes needed for different regions.

What is the efficiency of this power supply?

The power supply achieves up to 90% efficiency at full load with 230VAC input. Efficiency at 115VAC input is typically 87-88%. The high efficiency is achieved through quasi-resonant operation, synchronous rectification, and optimized magnetic design. This reduces heat generation and cooling requirements.

90% efficiency at high line; 87-88% at low line; reduces cooling requirements.

Does this solution meet industrial EMC requirements?

Yes, the solution is designed to meet IEC 61000-4-x industrial EMC standards including conducted and radiated emissions, ESD immunity, and surge protection. Proper PCB layout, input filtering, and shielded transformer are essential for EMC compliance. Pre-compliance testing is recommended.

Designed for IEC 61000-4-x compliance; proper layout and filtering essential.

What safety standards does this solution meet?

The solution is designed to meet UL/EN/IEC 62368-1 safety standards for audio/video and IT equipment. Key safety considerations include 3kV isolation between primary and secondary, proper creepage and clearance distances, and comprehensive protection features. Third-party safety certification is recommended for end products.

Designed for UL/EN/IEC 62368-1; third-party certification recommended for end products.

Can this solution be scaled for different power levels?

Yes, the solution can be scaled by adjusting the transformer design, MOSFET selection, and output filter components. For lower power (50W), use smaller magnetic components and lower current MOSFETs. For higher power (150W), use larger transformer, higher current MOSFETs, and add synchronous rectification. Contact JoulWatt FAE for scaling guidance.

Scalable from 50W to 150W with component adjustments; contact FAE for specific designs.

What is the operating temperature range?

The solution is designed for industrial temperature range of -40°C to +85°C ambient. Proper thermal management including heatsinking for power devices and adequate airflow is required at high temperatures and maximum load. Component derating should be applied for high-temperature operation.

-40°C to +85°C ambient; proper thermal management required at high temperatures.