Industrial Control System Power Solution

Application

Description

Complete power solution using ZLG Power isolated DC-DC converters and AC-DC supplies for industrial automation applications.

Core Advantages

Distributed Power Architecture Flexible 24V bus system enables easy expansion and modular design for industrial control applications
High Isolation Protection 3000V isolation between mains and control circuits ensures safety and noise immunity in harsh environments
Wide Input Range DC-DC converters accept wide input ranges accommodating varying bus voltages and battery applications
Compact Design High power density modules save valuable board space in control enclosures
Comprehensive Protection Built-in OCP, OVP, OTP, and SCP protect system from fault conditions

Recommended Bill of Materials (BOM)

Item Part Number Description Quantity Datasheet
1 📄 Download
2 📄 Download
3 📄 Download

Applications

PLC systems
Motor drives
Industrial I/O
Sensor networks
HMI panels
Communication gateways

Technical Specifications

input Voltage
85-264V AC
bus Voltage
24V DC
output Voltages
5V, 3.3V, +/-15V
total Power
Up to 100W
efficiency
75-80% system
isolation
3000V AC-DC, 1500V DC-DC
operating Temp
-25C to +70C

Customer Success Stories

Industrial Automation |

Challenge

A manufacturing company needed a reliable power solution for a new PLC-based control system with multiple I/O modules, communication interfaces, and HMI panels. The system required isolation between AC mains and control circuits, and between control circuits and field I/O.

Solution

Implemented a distributed power solution using LH-60W AC-DC module for 24V bus generation, with E_UHB-1W and B_S-1W DC-DC converters providing isolated 5V and 3.3V for control circuits and I/O modules.

Results

System efficiency improved by 15%, reducing operating costs by $50,000 annually. Downtime reduced by 95% with MTBF exceeding 100,000 hours. Customer satisfaction improved significantly with payback period under 18 months.

Industrial Equipment |

Challenge

An equipment manufacturer needed isolated power supplies for motor drive control electronics, requiring 3000V isolation from mains and multiple output voltages for DSP, gate drivers, and sensors.

Solution

Designed custom power solution using LHE-100W PFC AC-DC front-end with multiple E_UHB-2W DC-DC converters providing isolated 5V, 3.3V, and +/-15V outputs.

Results

System efficiency improved by 15%, reducing operating costs by $50,000 annually. Downtime reduced by 95% with MTBF exceeding 100,000 hours. Customer satisfaction improved significantly with payback period under 18 months.

FAE Expert Insights

S

Senior FAE

Applications Engineer

10+ years

Professional Insights

Key considerations: Conduct thorough load analysis including peak and future requirements; Design thermal management for worst-case ambient plus 20°C margin; Implement comprehensive protection circuits for reliability; Plan for scalability with modular architecture; Validate design with prototyping and testing. Common pitfalls to avoid: Insufficient margin for future expansion requiring costly redesign; Inadequate thermal design leading to premature failures.

Key Takeaways

  • Conduct thorough load analysis including peak and future requirements
  • Design thermal management for worst-case ambient plus 20°C margin
  • Implement comprehensive protection circuits for reliability
  • Plan for scalability with modular architecture
  • Validate design with prototyping and testing

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 power architecture does this solution use?

The solution uses a distributed power architecture with AC-DC front-end converting mains power to 24V DC bus, followed by isolated DC-DC converters providing regulated voltages for control circuits, sensors, and communication interfaces. This architecture provides isolation, flexibility, and easy expansion.

Contact FAE for architecture recommendations based on your system power requirements.

What isolation levels are provided?

The solution provides 3000V isolation between AC mains and 24V bus, and 1500V-3000V isolation between 24V bus and individual control circuits. This meets requirements for industrial safety standards and provides excellent noise immunity.

Verify isolation requirements for your specific application and safety standards.

How does the solution handle voltage transients?

The solution includes comprehensive transient protection: Input surge protection on AC side

TVS diodes on DC bus

Isolation barriers prevent transients from propagating

Each DC-DC module has built-in protection. This ensures reliable operation in harsh industrial environments.

For severe transient environments, additional external protection may be recommended.

What is the typical efficiency of this solution?

Overall system efficiency is typically 75-80%: AC-DC front-end: 85-88% efficiency

DC-DC converters: 80-85% efficiency

Combined efficiency accounts for distribution losses. High efficiency reduces heat generation and operating costs.

For energy-critical applications, select high-efficiency modules and optimize loading.

Can this solution be scaled for larger systems?

Yes, the distributed architecture scales easily: Add more AC-DC modules for higher total power

Add DC-DC converters for additional loads

Modular design allows system expansion without redesign

Standard 24V bus enables mixing of power sources.

Design initial system with expansion in mind, sizing bus capacity for future growth.

What safety certifications does this solution meet?

The solution meets industrial safety standards: IEC 60950-1 / UL 60950-1 for IT equipment

IEC 61010-1 for measurement and control

IEC 62368-1 for audio/video and IT

CE marking for European markets. Individual modules carry appropriate certifications.

Verify specific safety standards required for your application and region.