With the rapid development of industrial automation, advanced manufacturing, and new energy systems, the requirements for power supply stability and reliability in control systems have significantly increased. As a critical component of control systems, DIN rail-mounted power supplies not only affect the operation of individual devices but also directly impact the stability of the entire system.
In real-world applications, DIN rail power supplies must ensure continuous operation under demanding conditions:
· operation across a wide temperature range (cold start at low temperatures and full-load operation at high temperatures);
· high humidity and contaminated environments (e.g., condensation or dust);
· high inrush currents caused by inductive loads;
· increased enclosure temperature due to reduced convection at higher altitudes;
· long-term continuous operation (24/7 reliability requirements).
In addition, due to the digitalization and increasing intelligence of industrial systems, power supplies are evolving from “passive power components” into “monitored and controllable system elements”, requiring communication capabilities for remote monitoring, enabling predictive maintenance, and supporting system integration.
Modern DIN rail power supplies must meet the following technical requirements:
· adaptability to environmental conditions;
· ability to withstand short-term overloads;
· system-level protection and redundancy capabilities;
· communication and monitoring functionality.
To meet these industrial demands, MEAN WELL has introduced the high-end XDR series DIN rail power supplies, optimized for environmental adaptability, dynamic load handling, overload capability, and system integration.
Key Features:
1. Wide Temperature Range and Environmental Adaptability
XDR series units operate in a temperature range from -40 °C to +85 °C, making them suitable for both high-temperature enclosed control cabinets and low-temperature outdoor environments.
The PCBs are coated with a moisture-resistant layer, ensuring stable operation in high-humidity environments or applications such as semiconductor processing equipment.
The design complies with OVC III overvoltage category and ensures stable operation at altitudes up to 5,000 meters.
2. Peak Power and Inrush Current Handling
To handle high short-term loads commonly found in industrial equipment, the XDR series supports:
· up to 200% peak power (short-term overload);
· up to 600% peak current (short-term).
Thanks to optimized control architecture and power component design, the power supply can quickly respond to load changes, reducing the risk of startup failures or controller resets.
3. Advanced Communication and Remote Monitoring
As industrial systems become increasingly digitalized, power supplies are now an integral part of system monitoring.
XDR models rated at 240 W and above feature built-in Modbus communication, enabling real-time monitoring of voltage, current, temperature, and other parameters, as well as remote data collection and fault alerts.
Additionally, the entire series supports remote ON/OFF control, simplifying automated system management.
4. Built-in “Oring-FET” Protection
The XDR series includes an integrated Oring-FET circuit, which allows automatic isolation of power supplies.
If one unit fails, reverse current is blocked, preventing negative impact on other system modules.
5. Long-Term Reliability
The XDR series comes with a 5-year warranty, which is longer compared to many similar DIN rail power supplies. This helps reduce maintenance costs and overall cost of ownership.
6. Notes on Peak Power and Peak Current Usage
In industrial systems, motors and inductive loads often generate high inrush currents during startup. If the power supply cannot handle these surges, system startup may fail.
The XDR series supports 200% peak power and 600% peak current, enabling millisecond-level response to load changes, improving startup success rates and overall system stability.
When designing systems, consider the following factors:
· duration of peak currents;
· frequency of peak events;
· staged startup design for multiple parallel loads;
· proper selection of circuit breakers before loads.
Proper system design ensures optimal use of peak capabilities while avoiding unintended protection triggering.
7. Application Notes
All XDR series units support peak power and inrush current functions by default, without additional configuration.
When operating in parallel mode or constant current mode (for example, in battery charging applications), ensure that the TC and GND terminals are disconnected to disable the peak function.
Otherwise, OLP (overload protection) may be triggered, which can cause the power supply output to shut down.
8. Optional Connection Methods
XDR series power supplies are available with three types of connection terminals, allowing you to determine the most suitable connection method already at the design stage.
The choice depends on the application, how often wiring will be connected or disconnected, and the type of wiring used.
|
Criteria |
Push-in |
Lever |
Screw |
|
Clamping principle |
Spring |
Spring + lever |
Screw |
|
Vibration resistance |
✅ Very good |
✅ Very good |
❌ Moderate–poor |
|
Thermal cycles |
✅ Stable |
✅ Stable |
❌ Loosens |
|
Installation speed |
⭐⭐⭐⭐⭐ |
⭐⭐⭐⭐ |
⭐⭐ |
|
Tool required |
Sometimes |
❌ No |
✅ Yes |
|
Suitable for flexible wires |
⚠️ With ferrule |
✅ Yes |
✅ Yes |
|
Suitable for solid wires |
✅ Ideal |
✅ |
✅ |
|
Frequent disconnection |
⚠️ Limited |
✅ Ideal |
❌ Poor |
|
Certification (CE/UL) |
✅ Excellent |
✅ Excellent |
✅ Excellent |
Instalācijas vadu izvēle, sagatavošana un nostiprināšana
Wire Selection, Preparation, and Installation
|
Parameter |
AC input T.B |
DC output T.B |
|
|
Solid wire |
Max. 6 mm². |
Max. 6 mm² |
|
|
A.W.G |
18–10 AWG |
16–10 AWG |
|
|
Wire stripping length |
Screw terminal |
10–11 mm |
10–11 mm |
|
LA |
11–12 mm |
11–12 mm |
|
|
PI |
14–15 mm |
14–15 mm |
|
|
Terminal tightening torque |
Screw terminal |
0,6 N·m |
0,6 N·m |
|
LA/PI |
Not applicable |
||
9. Parallel Operation – Maximum Power up to 3840W
If the required system power exceeds the capacity of a single power supply, XDR-960, 480, and 240 series units feature built-in active current sharing and can be connected in parallel (up to 4 units) to achieve higher output power, as shown below.
· The peak current function must be disabled – the TC terminal must not be connected to GND.
· Parallel operation is achieved by connecting units as shown (CS and GND connected in parallel).
· The output voltage difference between parallel units should be less than 0.2 V.
· The total output current must not exceed:
· (Parallel output current) = (Rated current per unit) × (Number of units) × 0.9
· A maximum of 4 units can be connected in parallel. For other configurations, consult the manufacturer.
· Use short, thick wires for parallel connections, then connect to the load.
· Minimum load in parallel operation must be greater than 5% of total output load:
· (Min. load > 5% of rated current per unit × number of units)
· If total load is below 5%, only one unit (master) will operate. Other units (slaves) may enter standby mode, and their output LEDs and relays will not activate.
Parallel connection diagram: CS and GND connected using twisted pair wiring
10. Modbus Communication Support
XDR-240, 480, and 960 series power supplies are equipped with a Modbus RTU communication interface, enabling control, configuration, and monitoring.
Available parameters include output voltage, output power, input voltage, and more.
· A computer can be connected directly using an isolated RS-485 to USB converter.
· Drivers must be installed to create a COM port (usually installed automatically).
· Monitoring software such as QModMaster, Modbus Poll, Simply Modbus RTU, or similar is required.
· For remote monitoring via Ethernet, a gateway is needed. Common devices include:
· Moxa MGate MB3170 / MB3270, Advantech EKI / ADAM, USR-TCP232-410S, or similar.
Detailed connection instructions, settings, and register information are available here: https://www.meanwell.com/webapp/product/search.aspx?prod=XDR-960&pdf=WERSLTc1fjk2MC1FLlBERg==&a=4
In industrial automation systems, DIN rail-mounted power supplies not only deliver energy but also play a critical role in ensuring system stability and reliability.
In demanding environments with high transient loads, power supplies designed for wide temperature ranges, redundancy architectures, and advanced communication capabilities can significantly improve system performance.
The MEAN WELL XDR series is specifically optimized for industrial environments, providing reliable power solutions for:
· industrial automation systems,
· IT and telecommunications infrastructure,
· semiconductor manufacturing equipment,
· port and marine applications.
The products are certified according to CB / TUV / UL / RCM / BSMI / CCC / EAC / BIS / KC / CE / UKCA, meeting requirements across global markets. This is especially beneficial for manufacturers supplying equipment internationally.
The power supplies also comply with safety standards:
EN/IEC 62368-1, EN/IEC 61010-1, EN/IEC 61558-1, C1D2 HazLoc, Marine DNV, SEMI F47.
For product selection or application support, contact your LEMONA electronics manager.
More information about DIN rail power supplies can be found here:
https://expo.meanwell.com/aboutRange.aspx?i=33#D
https://www.youtube.com/watch?v=kfNX4dfhPFY&t=8s
https://www.meanwell.com/webapp/product/search.aspx?prod=XDR-75
https://www.meanwell.com/webapp/product/search.aspx?prod=XDR-120
https://www.meanwell.com/webapp/product/search.aspx?prod=XDR-240
https://www.meanwell.com/webapp/product/search.aspx?prod=XDR-480
https://www.meanwell.com/webapp/product/search.aspx?prod=XDR-960