A New Solution for Voltage Drops

27 July 2008

One of the great difficulties we all face in automation design is the inherent voltage drop along long cables. How do we ensure that when the power gets to the other end its voltage level is enough to actually use?

PULS CD range of DIN rail DC-DC converters
PULS CD range of DIN rail DC-DC converters

The biggest problem with voltage drops is that they are current dependant, so calculating them can be tricky, especially when the load is variable as you would have in a motor or robotic system. The current solution is to adjust the voltage above what is required so when it does arrive it is correct. As with many theories, it doesn’t always work in practice—a lot of equipment has a maximum voltage level and if the power supply has been adjusted, this level may be breached during low current periods resulting in equipment damage.

The PULS CD range of DIN rail DC-DC converters were designed specifically for this application. In conjunction with the XT range of semi-regulated bulk power supplies PULS feel that not only does this solve the voltage drop problem but provides a low cost solution for large automation systems. This double unit solution will provide a large semi regulated AC-DC power supply for the total power and use the CD units as small modules closer to the individual motors, robotics or controls so that voltage drops are a thing of the past.

The CD units were designed for this purpose with their small size and integrated PULS filtering technology. There are 4 different models currently available with input voltages of 18Vdc to 34Vdc and 36Vdc to 60Vdc and output voltage options of 12-15Vdc or 23-28Vdc. The power available per individual unit is 96 watts for the 12-15Vdc version and 120 watts for the 23-28Vdc versions.

“We were first approached by a conveyer manufacturer who was having big issues with voltage drops causing motor stalls and operational failures, my mind instantly turned to our new DC-DC units as a solution. With their small size and robust design both physically and electrically they suited our customers’ needs down to the ground. Also in changing to use our high efficiency XT units they also created a more efficient and lower cost system” commented Harry Moore, managing director of PULS UK.

PULS, a market specialist in DIN Rail power supplies, is based in Munich, Germany.

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