What to Consider for Selecting Reliable AC/DC Switching Power Supplies for Systems in Harsh Environments?

With the shift to an electrified society, the use of AC/DC switching power supply converters is becoming more and more widespread. They are essentially incorporated in automation, AC servos, manufacturing, robotics, and other fields. 

Almost all electrical devices come with AC/DC switching power supply converters. As power supply voltage conversion devices, they convert AC voltage to DC voltage for the normal operation of electrical equipment. They are widely used in areas of medical equipment, industrial automation, lighting, smart building, telecommunication, electric power, security, instrumentation and IoT, etc. Moreover, the AC/DC switching power supply converters are a main component of heaters, motors, PLCs, controller systems, and sensors. These uses of converters are varied and wide, but similarly, their operating environments are also diverse and even harsh. Customers indicated that they encounter some problems such as moisture, high noise levels, and input overvoltage when using mainstream switching power supplies, which invariably raises the maintenance costs of the equipment.

Read below to discover the benefits of choosing an AC/DC switching power supply during harsh environmental conditions.

Challenges For Today’s AC/DC Switching Power Supply Systems

Usually, the most common AC/DC switch mode power supplies consist of a fan, bare board patch, and housing with holes for heat dissipation. With a flat profile, these designs have added a few challenges to AC/DC switching power supply systems: dust, noise, and moisture. For conventional SMPS power supplies with an input voltage range of 85 to 264 VAC, power grid fluctuations can be equally damaging.

• Dust

Dust is the most obvious threat in a harsh working environment. It will damage the fan or other PCB components if the dust accumulates, affecting the lifespan of the device. This is especially a tricky issue for SMPS with a fan, holes in the housing, and a hollow enclosure – the fan sucks wind with dust into the device when dissipating heat.

• Moisture

Another factor that may shorten the lifespan of the SMPS is moisture. An enclosure with holes cannot prevent the penetration of humid air, and the air inlet leaves the door open for damp air. A wet environment is destructive for both indoor and outdoor devices with AC/DC switching power supply systems.

• Noise

The noise of equipment should meet the design requirements. A major source of noise when the equipment is running is the noise of the fan in an SMPS. In the applications of facial instruments or for the devices in the classroom and office, the huge noise of an SMPS fan may interrupt the peaceful environment and cause an awful user experience.

• Power Grid Fluctuation

The common input voltage range is 85-264VAC, but actually, there is an instantaneous input voltage at the device when start-up and shutdown and larger power grid fluctuation that may go beyond 264VAC, resulting in a risk of damaging SMPS electronics.

How Does MORNSUN Solve These Problems?

MORNSUN’s fanless semi-potted AC/DC enclosed power supply is born to solve all the above questions. They are high-frequency devices for power conversion. They function to convert the given voltage into the required current through varied topology. See how they achieve the goals below:

1. Removing Fan

MORNSUN removes the fan on the AC/DC enclosed switching power supply to shut the door for dust, moisture, and noise. What’s more, removing fans brings the SMPS a more compact size and shape. The volume is reduced by about 50% and is able to save more space, allowing flexible side installation.

• Potting

MORNSUN adopts semi-potting technology for sealing, refusing moisture and dust to prevent short circuits while not affecting heat dissipation. The semi-potted process design also improves the insulation strength of the power supply, which is better than the one with conformal coating on each side. Reliability and lifespan are all improved now!

• Increase input voltage range

To react to the grid fluctuation, MORNSUN has given some workable answers. Increasing the input voltage range to a maximized 305VAC is one solution.

MORNSUN’s Semi-Potted, Fanless AC/DC Enclosed Power Supply

The MORNSUN’s semi-potted, fanless, ultra-slim dustproof and low-noise enclosed power supply LMFxxx-23BxxUH series comes with excellent efficiency up to 95% and a wide input voltage range of 85-305VAC / 120-430VDC that supports both AC and DC input. It also offers excellent EMC performance and meets EN/UL62368, EN61558, EN60335, and GB4943 standards. Except for the feature of 150% peak load output for 1 second, it supports a wide operating temperature range of -40℃ to +85℃, operating altitude up to 5000m, high isolation voltage up to 4000VAC, enables PF as high as 0.95 (Full load at 230VAC), and completed protections such as output short circuit, over-current, over-voltage, and over-temperature protection. These products are imperative for applications in building automation, industrial controls, energy systems, factory automation, security, telecommunication, smart home, etc.

But why are these enclosed, semi-potted, fanless power SMPS distinctive? Here’s why:

1. Multiple options:

MORNSUN’s LMFxxx-23BxxUH series of high-power fanless semi-potted switching power supplies are not only capable of proofing dust and reducing noise, but they are also an independent branch of MORNSUN’s enclosed switching power supplies. This new branch, which complements the family of enclosed switching power supplies, provides our customers with a new, reliable, and efficient power supply solution for applications under harsh operating environments or requiring fanless power supplies.

•  Electromagnetic immunity:

MORNSUN’s SMPS has excellent EMC performance, mainly reflected in the following:

• CE & RE meet the requirement of CISPR32/EN55032 CLASS B;
• Harmonic current meets IEC/EN61000-3-2 CLASS A;
• ESD meets IEC/EN61000-4-2 Contact±6KV/Air±8KV.

This ensures the safe and stable usage of our power supply products.

• Simple and reliable:

Regarding the manufacturing, MORNSUN’s up-to-70% automatic production not only ensures consistent product quality but also increases reliability for all products. Simultaneously, the utilization of potting technology also allows more sturdy protection for power supplies against a variety of complex operating conditions. All of these advantages help to ensure the reliability of your power supply systems, cutting maintenance costs while enhancing the competitiveness and cost-effectiveness of your equipment. In terms of the reliability and superior performance of MORNSUN’s AC/DC enclosed SMPS, it is undoubtedly very suitable for various complex working conditions, making it ideal for industrial and harsh outdoor environments.

Conclusion

The demand for AC/DC converters is growing daily, with added requirements and challenges to be met. The MORNSUN’s converters and power supplies cater to the design needs of different applications in terms of sizes, functions, and reliability. The AC/DC switching power supply converter is the core component of electronic devices. Choosing the right power supply not only saves maintenance costs but also helps to enhance competitiveness, thus building a reliable brand image. The key is choosing suitable and reliable power supply products for different scenarios. From AC/DC power supply and DC/DC converter to transceiver and LED/IGBT driver, MORNSUN has you covered. 

For more information, please visit www.mornsun-power.com