Author: Rolf Horn – Applications Engineer, DigiKey Electronics
Industrial operations of all kinds—including discrete and process manufacturing, renewable energy systems, telecommunications, and IT infrastructure—require a stable and reliable power supply. Power supply units (PSUs) provide this capability by taking an input voltage (AC or DC) and converting it into the required form and output voltage that systems need to operate.
Criteria for DIN rail power supplies and converters
Today's AC/DC converters must be safe, cost-effective, energy-efficient, reliable, and much smaller than their predecessors. In addition to working with highly inductive or capacitive loads, industrial AC/DC power converters must withstand severe AC input surges generated by the switching on and off of heavy machinery. They must also adapt to a wide range of temperatures and input voltages.
The DIN rail power supplies, which supply relays, actuators, valves, and monitoring and control systems, meet these criteria.
The power converter is mounted on a DIN rail, which is a standard metal channel that can be cut to convenient lengths and screwed into racks or walls (Figure 1).
Figure 1: Typical DIN rail installation (Image source: RECOM)
Although DIN rail power supplies offer several advantages, the conditions in which they operate require a set of additional special features. They require a long lifespan because they typically operate in continuous operation mode, even when a production line is stopped. They also require high performance—both under load and at idle—to save energy and minimize internal heat emissions. In addition, they require protection against undervoltage and overvoltage fluctuations, power surges, short circuits, overloads, and excessive temperatures.
La RACPRO1 series Chassis Mount LED AC/DC Power Supplies are industrial DIN Rail power supplies. RECOM Power that meet the above characteristics and much more. Their operating temperature ranges from -40°C to +70°C, with full power up to +60°C and a 150% power boost for 5 seconds. Their power consumption remains minimal during standby mode thanks to their low no-load power consumption, which ranges from 1 to 3 watts depending on the power supply's output.
Additional advantages of the DIN rail system
Standardized DIN rail mounting allows for quick and easy assembly, as a power supply can simply be snapped onto a rail without tools. The DIN rail saves space, allowing design engineers to tightly pack many standard-sized devices into a small footprint.
Furthermore, the DIN rail has evolved over the years to adapt to changes in the size of electrical components. Channel widths and sizes accommodate current power supplies, meaning design engineers can easily choose the power supplies needed to configure complex systems and fit them into standardized space. Furthermore, DIN rails can house different types of components together, so power supplies for many machines can be efficiently configured, often on the same metal strip.
Selecting the Right DIN Rail Power Supply
Complex industrial automation systems may require a variety of power supplies to meet their energy needs. The selection will depend on several factors, including electrical specifications, such as input and output voltage ranges and maximum current requirements.
The RECOM Power RACPRO1 series (Figure 2) is a set of DIN rail power supplies with AC and DC input voltage conversion. For example, the RACPRO1-T240, -T480, and -T960 series feature a universal AC and DC input voltage range of 3 x 320 V.CA at 3 x 575 VCA, and 430 VCC at 850 VCC. They are available in 240W, 480W, and 960W power ratings. The T480 and T960 models' load indicators allow you to quickly determine the percentage of rated output current being consumed. Both units offer a choice of constant current (CC) mode for tasks such as battery charging applications, and load-sharing mode for parallel operation.
Figure 2: The RACPRO1-T240, -T480 and -T960 models have a universal AC and DC input voltage range of 3 x 320 V.CA at 3 x 575 VCA and 430 VCC at 850 VCC, and are available in 240 W, 480 W and 960 W power classes. (Image source: RECOM)
The RACPRO1-T power supplies achieve efficiency of up to 97.1%, enabling high power density in a compact design. They are available in 43 mm, 52 mm, and 80 mm widths. They feature low power losses and offer a lifespan of over 80,000 hours.
They also have immunity to surges of up to 6 kV on the input and protection against reverse voltages of more than 35 V on the output. Their wide temperature range, from -40°C to +70°C, makes them ideal for harsh industrial environments and outdoor applications.
In addition, RECOM's RACPRO1 DIN-rail power supplies feature two independent flue channels that leverage the chimney effect to deliver 100% power operation at ambient temperatures up to +60°C. The chimney effect occurs when a vertical column of hot air rises, creating a natural draft that can significantly reduce the internal temperature of hot components.
e-Fuse RACPRO1-4SP Series
Also under the umbrella of RACPRO is the a series of RACPRO1-4SP, comprising 4-channel electronically fused (e-Fuse) load switches designed to provide independent overcurrent protection for each channel (Figure 3). They include real-time current monitoring and LED status indicators to simplify diagnostics. Each channel operates independently, ensuring system reliability even when faults occur. The design incorporates sequential switch-on to limit inrush current and reverse-sequence switch-off to prioritize essential loads. Adjustable overload modes allow flexible system configuration.
Figure 3: The RACPRO1-4SP series are 4-channel e-Fuse load switches with independent overcurrent limit control and real-time output current display. (Image source: RECOM)
RACPRO1 electronic fuses support 5 A or 10 A per channel, with a 150% power boost for up to five seconds to cope with temporary load peaks. For short-duration overcurrent events, they can sustain a 150% overload for up to 120 ms, reducing unnecessary tripping. The series guarantees high reliability with a life expectancy of >80,000 hours at +40°C, offers simplified installation with tool-less insertion terminals, and features paired input/output connectors that make wiring and daisy-chaining multiple modules faster and more efficient.
RACPRO1 Series Applications
The RACPRO1 series is used in a wide range of applications, including:
- Industrial automation and smart manufacturing
- Renewable energy and microgrids
- Infrastructure, traffic engineering and smart cities
- Power distribution and battery storage systems
- Test and measurement equipment
Conclusion
Today's industrial processes require a complex array of power supplies for equipment with widely varying current and voltage requirements. As industrial automation incorporates an increasing number of sensors, power supplies must be able to operate in confined spaces and harsh environments. RECOM's RACPRO1 series meets these demanding challenges, efficiently delivering reliable, consistent power to keep systems running.
Source: https://www.digikey.es/es/articles/reliable-din-rail-power-supplies
