Energy efficiency not the only game for power supplies

Power supplies also pack more intelligence and location options

By Control Design Staff

With the power supply typically the largest processor of power in the cabinet, its efficiency is understandably an important factor.

"Low-efficiency power supplies translate to extra heat in a controls cabinet, which leads to larger cooling systems, which leads to more energy consumption," says Will Healy III, connectivity marketing manager at Balluff. "To fight this cyclic effect, engineers need to at least be aware of the efficiencies of the supplies they design into their control systems."

Efficiencies have improved. Most power supplies today have an efficiency rating above 90%, leaving little room for improvement, notes Ken Allwine, product marketing, Interface power solutions, Phoenix Contact. Some of the latest advances today are within the physical size and intelligence of the device.

"With America's aging infrastructure and the occasional blackouts/brownouts, the reliability of a location's power source can be questionable at times," Allwine says. "The more feedback the power supplies can provide, the more the user knows about the quality of their source." Advanced power supplies indicate overload conditions, battery backup status, and even when it's time to change the battery.

For an end user, knowing what is going on with his power supply can be critical to effective operation of the entire production line. Though often overlooked, workforce deployment is an important component of efficiency. "This is why we've integrated signal outputs and communication via serial interface — users get the efficiency of remote monitoring, ending routine in-the-field trips," says Michelle Goeman, product manager, terminal blocks and electronic interface for Wago. "It simplifies troubleshooting and can play a role in monitoring machine power consumption via I/O, which is helpful for asset management. This enhanced visibility ultimately prevents downtime, keeping overhead low."

Industrial manufacturing is also pushing to get devices out of the controls cabinet as much as possible, including power supplies, Healy says. "There is a developing need for rugged dc power supplies to be mounted on the machine outside the cabinet used to supply automation and controls equipment with power," he says. "This reduces the footprint of the controls cabinet and creates one less reason for maintenance to have to open the cabinet and be exposed to the dangers of arc-flash."

 Single-channel KCD2-STC-Ex.1ES and KFD2-STC4-Ex1.ES transmitter power supplies

Power for SIL 3
Single-channel KCD2-STC-Ex.1ES and KFD2-STC4-Ex1.ES transmitter power supplies are assembled to the 35 mm DIN mounting rail with power rail. HiC2025ES and HiD2025ES transmitter power supplies are mounted on pre-wired termination boards. These modules provide internal diagnostics information using a single failure signal, and are designed for intrinsically safe applications up to SIL 3 according to EN 61508. Only one transmitter is required to construct an intrinsically safe signal circuit for SIL 3.

 MiniLine 60 W power supply

Mini Power
MiniLine 60 W power supply offers an extended operating range down to -40 °C. It has universal wide-range input, efficiency up to 89.7%, low no-load losses less than 0.45 W, and large screw terminals that accept up to 10 AWG wire, and is NEC Class 2 approved. The extended low-range version and standard version have a 12–15 Vdc or 24–28 Vdc adjustable output voltage.
Puls Power Supplies
Balluff's IP67 intelligent power supplies with Heartbeat technology Status Feedback
IP67 intelligent power supplies with Heartbeat technology provide feedback on real-time and long-term status of the supply. They are rated >93% efficient, have a 150% power boost for 4 seconds, and claim a minimum service life of 15 years.
Murrelektronik's Picco switch-mode power supplies Power in Small Places
Picco switch-mode power supplies are 23–90 mm wide. Each of four models is available with 12 or 24 V output voltage and 10, 30, 60 or 100 W, with pluggable spring clamp terminals or soldered screw terminals. The outputs are short-circuit and overload protected and meet PFC standard 61000-3-2.

Rail-mounted uninterruptible power supply Quint UPS-IQ monitors

Knows Its Battery
Rail-mounted uninterruptible power supply Quint UPS-IQ monitors a scalable battery solution to indicate if the battery is fully charged, how long the battery backup will last, and if it needs to be replaced. For 24 V loads, it has output currents of 5, 10, 20 and 40 A. The ac version has an output power of 500 VA.
Phoenix Contact
Wago's Epsitron 787 Series Pro power supplies Need a Boost
Epsitron 787 Series Pro power supplies with two-stage PowerBoost handle high inrush loads to eliminate oversized switch-mode power supplies. Operating efficiency is up to 92%, and an energy-saving mode deactivates output when not required via remote control. TopBoost handles cost-effective circuit breakers for individual load circuit protection by providing 50 ms of additional output at 3–6 times the rated current.

B&R Industrial Automation's DIN-rail-mountable power supplies

Compact Power
Compact, DIN-rail-mountable power supplies range from 2.1 A/100–240 Vac single-phase input to 40 A/400–500 Vac three-phase input. They have a power backup buffer module that supplies standby voltage during brownouts or load peaks for a defined period of time, tolerate ambient temperatures -25 to 70 °C, and have short-circuit, overload and continuous open-circuit protection. Approvals include UL 508, CSA, IEC and EN.
B&R Industrial Automation

Automationdirects' Rhino PSE switch-mode power supplies

Power Is Universal
Rhino PSE switch-mode power supplies have universal input of 85–264 Vac in single- or dual-output models. Output voltages include 5, 12, 15 and 24 Vdc; and ±12 and ±15 Vdc. Single-output models provide a maximum output range 15–60 W; dual-output models provide 15 and 30 W. Screw terminal blocks provide easy connection, and the series is short-circuit and overload protected.
  Have Power at Hand
Compact PS3X switching power supplies are available in 15, 25, 50, 75 and 100 W versions with 5, 12 and 24 Vdc outputs and direct or DIN-rail mounting. They are UL/c-UL recognized and CE marked, and EMC and EN55022 Class B compliant.
 Power Sources Unlimited's XL375 single-output, 260 W, low-profile, convection-cooled ac-dc power supply

Power Power
Pro-H power supplies offer Zone 2 ATEX hazardous area approvals and have two redundancy power modules for up to 15 and 25 A loads. The redundancy status of the system is continuously monitored, and has an alarm output if a power unit fails.

 Staco Energy's FirstLine P parallelable, three-phase, 480 Vac, 65 kVA UPS Strong Parallelism
FirstLine P parallelable, three-phase, 480 Vac, 65kVA UPS is up to 98% efficient, has upstream filtering of harmonics, and reactive load emanating from the powered load. Up to eight units can be run in parallel.
Staco Energy
Lutze's Compact 722811 power supply Compact Power
Compact 722811 power supply is 960 W, three-phase, 40 A, 24 Vdc with 340–550 V input range, maximum output overload current at 60 A for 5 s, and 94% efficiency. DIN-rail-mountable units have power factor correction and an output alarm relay. Versions for 48 and 72 Vdc have the same footprint.
 Carlo Gavazzi's EM11 Series 120/230 Vac single-phase energy meter A Display of Power
EM11 Series 120/230 Vac single-phase energy meter displays and controls a main energy supply. It prevents line overload conditions by switching off selected non-priority loads through an alarm output. It can control and limit power before a shutdown of the entire electrical system occurs. It is also suitable for metering most industrial applications.
Carlo Gavazzi
 TDK Lambda Americas' 65-W MWS65 open-frame, information technology equipment (ITE)-certified ac-dc power supplies Use a 2x4
65-W MWS65 open-frame, information technology equipment (ITE)-certified ac-dc power supplies have 4 kVac reinforced input to output isolation and output to ground isolation of 1500 Vac, and an industry-standard 2x4 in. footprint, and operate on a universal 90–265 Vac input, with nominal outputs of 5, 12, 15, 24 or 48 Vdc. All outputs are user-adjustable by ±10%.
TDK Lambda Americas
 Power Sources Unlimited's XL375 single-output, 260 W, low-profile, convection-cooled ac-dc power supply Keep a Low Profile
XL375 single-output, 260 W, low-profile, convection-cooled ac-dc power supply has a universal active PFC 90–264 Vac input and 12, 24, 28, 36, 40, 48, 54 and 56 Vdc outputs. Units provide up to 93% efficiency, active current sharing for N, N+1 with OR-ing board option, remote on-off and active in-rush current protection.
Power Sources Unlimited
 Omron Industrial Automation's S8VS-BE power supply Be the Power
S8VS-BE power supply with built-in run time, voltage and current status monitoring displays output voltage, output current and peak hold current, and detects undervoltage to visualize machine faults and simplify setup. It is available in 90, 120, 180 and 240 Vac input with 24 Vdc output. Models that meet UL Class 2 output standards are also available.
Omron Industrial Automation
Kepco's  HSF 3U 300, 600 and 1,200/1,500 W hot-swap power supplies  Single or Redundant
HSF 3U 300, 600 and 1,200/1,500 W hot-swap power supplies are for high-power-density applications capable of wide-range voltage programmability. Four single outputs or two redundant pairs fit in a 19 in. rack. They are designed to be combined in an N+1 fault-tolerant power system. Built-in active current sharing and OR-ing diodes are provided.
Green Watt Power's GLC-50 constant-current ac/dc LED power supplies Constant Current
GLC-50 constant-current ac/dc LED power supplies have universal/full-range 100–277 Vac input, 50 W output power, constant current outputs at 1.05, 1.40, 1.75, 2.1 or 2.8 A, and self-adjusting 12–48 Vdc output ranges. All models are enclosed to IP67 standards in extruded aluminum metal case design, and have efficiencies to 90% with active power-factor correction greater than 0.90.
Green Watt Power
SolaHD's SDN 5-24-480C (5 A) and SDN 10-24-480C (10 A) DIN-rail power supplies  5 & 10
SDN 5-24-480C (5 A) and SDN 10-24-480C (10 A) DIN-rail power supplies feature visual diagnostic LEDs to show input and output status at a glance, and have standard screw terminal connections. The metal outer case dissipates heat, and delivers full power in a wide temperature range from -25 to 60 °C.
Moore Industries' Trunkguard TPS400 Fieldbus power supplies  FIELDBUs POWER
Trunkguard TPS400 Fieldbus power supplies have 350 mA for non-isolated, energy-limited applications or 500 mA for high-current-demand applications of isolated, conditioned simplex, non-redundant, or duplex, redundant power to up to four segments. It has a high-availability, modular design that is hot-swappable with load sharing in redundant pairs, a metal housing, optional pluggable surge protection, and multi-segment H1 connectors.
Moore Industries
Acopian's Infinity power supplies  To the Power and Beyond
Infinity power supplies provide the tighter output voltage regulation, and lower output ripple advantages of linear regulation technology. Line and load regulation for many models is 2 mV, and ripple less than 0.25 mVrms, 0.75 mVp-p with virtually no common mode noise. Standard models are available with outputs to 150 V and 150 W, with both slot output voltage ranges and wide-adjust models.
Siemens Industry's Sitop PSU100C controlled power supply  Power for the Modest Consumer
Sitop PSU100C controlled power supply for the low-end performance range has 12 Vdc at 22.5 mm wide, and 24 Vdc at 30 mm models. Input voltage ranges 85–264 Vac for 120 V and 230 Vac single-phase networks without changeover, and operates on 110–300 Vdc networks at an operating temperature range of -20 to 70 °C.
Siemens Industry
Turck's PSU67 network power supply  Network Power
PSU67 network power supply provides 24 V outputs of 50, 100 and 200 W from inputs of 90–264 Vac and 110–375 Vdc with efficiencies above 90%. Encapsulated case and potting materials meet UL94-VO. Connection is a 7/8-16 UN minifast.
ASI's DIN-rail-mounted 100 A, 2,400 W power supply  More Power to you
DIN-rail-mounted 100 A, 2,400 W power supply eliminates the need to connect power supplies together to attain higher power levels. It has three-phase input, high outrush current and high efficiency levels greater than 92%, and short circuit, overload, over temperature, input and output overvoltage protection.
  Dense Power
FH3000U1 front-end power supply in 1U form factor with DSP technology provides 48 V/3,000 W from 180–264 Vac, is 95% efficient at 50% load, and has a power density of 33 W/in.3 at 3,000 W. It has ac input over-voltage and under-voltage protection, variable fans, dc output over-voltage, over-current and short-circuit protection, remote sense, remote on/off and over-temperature protection.
Fuji Electric
Phihong's Passive PoE power injectors  Passive Power
Passive PoE power injectors have two- and three-wire input versions, output 56 Vdc and meet Energy Star EPS Version 2.0 and Ecodesign (ErP) Directive 2009/125/EC Level 2 Annex 1b. The 60 W midspans are available with optional Gigabit BaseT data rates and have over-voltage, over-current and short-circuit protection, and UL and CE safety approval markings.
PSG series is a general-purpose family of power supplies for the majority of 24 Vdc control applications. With an operating temperature range of -20 to 75 °C, PSG series includes eight DIN-rail-mounted power supplies with input and output ratings ranging 2.5–20 A. Class I, Div. 2 protection guards the device from sparking. It includes surge protection against transient and internal surges.
  PoE Power
POE-Inj-S PoE Injectors inject dc power to a Cat. 5 cable to power remote equipment using Power over Ethernet. There is an LED version with one LED that indicates power is being supplied to the inserter. The other LED indicates when a device is plugged in at the far end of the Cat. 5 cable and that device is drawing current.
Tycon Power
Rockwell Automation's Bulletin 1609-U uninterruptible power supplies (UPS)  Ups Protection
Bulletin 1609-U uninterruptible power supplies (UPS) in 750, 1000 and 1500 VA models are designed for protecting PCs, PLCs, servers and data networks with improved surge protection to reduce downtime of critical process applications.
Rockwell Automation
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