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100W Isolated DC-DC Converter for PLC & Factory Automation Control Systems

2026-06-05 14:55

Product Introduction: MDA100-48S24

In modern factory automation, a stable and reliable power supply is fundamental to ensuring the continuous operation of PLCs (Programmable Logic Controllers), industrial sensors, and communication modules. The MDA100-48S24 is an industrial-grade 100W isolated DC-DC converter designed to convert 48VDC industrial bus voltage to clean, regulated 24VDC output, providing pure, isolated power for factory control systems.

表格

Parameter	Specification
Model	MDA100-48S24
Nominal Input Voltage	48 VDC
Input Voltage Range	36–72 VDC (2:1 wide input range)
Output Voltage	24 VDC
Output Current	4.16 A
Output Power	100 W
Ripple & Noise (PK-PK)	200 mV
Efficiency (Typ)	86%
Isolation (Input–Output)	>1500 VDC
Isolation (Input–Case)	>1050 VDC
Isolation (Output–Case)	>500 VDC
Operating Temperature	-25°C ~ +85°C (Industrial) / -40°C ~ +85°C (Military I) / -55°C ~ +85°C (Military II)
Dimensions	116.4 × 65 × 22 mm
Protections	Input under/over voltage, over temperature, output over current, output short circuit
Switching Frequency	100–200 KHz

I. Why Factory Automation Systems Need 48V to 24V Isolated DC-DC Power?

Industrial facilities widely adopt 48V DC bus as the standard power distribution architecture, commonly found in:

Factory 48V DC distribution panels
Solar/storage 48V battery bank systems
Industrial 48V UPS (Uninterruptible Power Supply)
Forklift and industrial vehicle 48V battery systems

However, core automation components such as PLC control systems, industrial sensors, HMI panels, and industrial communication modules typically require 24VDC to operate.

Directly using non-isolated buck converters presents serious risks: inrush currents and common-mode interference generated by motor starting, variable frequency drives, and welding equipment can conduct along power lines into the control host, causing PLC crashes, malfunctions, communication packet loss, or even module damage.

Solution: Insert an isolated DC-DC converter between the 48V bus and 24V loads to fundamentally cut off interference conduction paths while reliably converting voltage levels.

II. Typical Applications of MDA100-48S24 in Factory Automation

1. PLC (Programmable Logic Controller) Power Supply

PLC is the "brain" of factory automation. CPU modules, I/O modules, and communication gateways typically require stable 24VDC power. The MDA100-48S24 converts power from the workshop 48V DC panel to clean 24V, providing reliable power input for mainstream PLC brands such as Siemens S7 series, Mitsubishi FX series, and Omron CP1 series—effectively preventing PLC resets or program loss caused by voltage fluctuations.

Key advantages: Wide input range (36–72V) tolerates 48V bus voltage sags and transient surges; >1500V isolation blocks interference conduction from motor circuits.

2. Industrial Sensor & Actuator Power Supply

Pressure sensors, level sensors, temperature sensors, photoelectric sensors, solenoid valves, and hydraulic proportional valves widely operate on 24VDC. These field instruments are extremely sensitive to power noise—excessive ripple directly impacts measurement accuracy and valve response speed.

The MDA100-48S24's 200mV low-ripple output and fast dynamic response ensure stable excitation voltage for sensors, improving measurement accuracy and system control precision.

3. Industrial Communication Equipment (RS485/CAN/Ethernet) Power Supply

The Industrial Internet of Things (IIoT) relies on industrial switches, serial servers, fiber transceivers, and wireless gateways—devices highly sensitive to power noise. When communication chips suffer power interference, data packet loss, communication timeouts, or even complete network failures can occur.

The isolated DC-DC converter provides electrically isolated power domains for communication equipment, effectively filtering interference from the bus side and ensuring stable industrial network communication.

4. HMI & Industrial Display Terminal Power Supply

HMI touchscreens, industrial displays, and LED indicator panels are also common 24VDC applications. The MDA100-48S24's 100W output margin is sufficient to power multiple HMIs and display modules centrally, simplifying power distribution design.

5. AGV & Warehouse Logistics Equipment

In smart warehouse scenarios, AGVs (Automated Guided Vehicles), shuttle cars, and sorting machines typically use 48V main batteries, while onboard controllers, scanners, and RFID readers require 24V. The MDA100-48S24's high efficiency (86%) helps extend equipment endurance, and its compact dimensions (116.4×65×22mm) facilitate installation in space-constrained control enclosures.

III. Key Technical Advantages

表格

Technical Feature	Value for Factory Automation
36–72V Wide Input Range	Accommodates 48V nominal ±25% voltage fluctuation; adapts to complex industrial power environments
1500V+ Input-Output Isolation	Completely blocks surge and common-mode interference from entering PLC control systems
200mV Low-Ripple Output	Provides "clean" power for sensors and communication devices; avoids measurement errors and packet loss
Dual Input UV/OV Protection	Prevents battery over-discharge/over-charge and grid anomalies from damaging downstream equipment
Auto-Recovery Short-Circuit Protection	Auto-protects on field wiring short circuits; auto-recovers after fault clearance—reducing maintenance downtime
-40°C~+85°C Military Grade Available	Meets temperature requirements for metallurgy, cold chain, and outdoor industrial sites
100–200KHz Switching Frequency	Optimized EMC performance; minimizes interference with nearby sensitive equipment
Dual-Side Pin Out Design	Flexible installation; adapts to various control cabinet layouts

IV. Why Choose MDA100-48S24 Over Standard Power Modules?

表格

Comparison	Standard Non-Isolated Buck	MDA100-48S24 Isolated Module
Electrical Isolation	❌ No isolation, interference conducts directly	✅ Input-output >1500V isolation
Surge Resistance	Weak; motor interference easily causes crashes	Strong; isolation layer blocks interference
Industrial Certification	Consumer-grade; narrow temp range	Industrial / Military I / Military II multiple grades
Input Voltage Range	Typically 36–60V; narrow range	36–72V; wide-range adaptability
Protection Features	Basic short-circuit only	Five-in-one: UV/OV/OT/OC/SC protection
EMC Performance	Standard	Input π-type filter + low-ripple design
Suitable Scenarios	Consumer electronics	PLC control, industrial comms, sensor networks

V. Typical Wiring Diagram

plaintext

[48V DC Bus / Battery] → [MDA100-48S24] → [24V PLC / I/O Modules / Sensors / Comms Equipment]
                           ↑
                      Galvanic Isolation
                      Surge Blocking

The module features a dual-side pin-out layout: input side (-VIN/+VIN) and output side (-Vo/+Vo) are separated, avoiding electromagnetic coupling from crossed input/output wiring and simplifying control cabinet routing.

VI. Selection Guide & Complementary Solutions

Selection Criteria: MDA100-48S24 is the ideal choice if your system meets any of the following:

✅ Industrial site has 48V DC bus or battery system
✅ PLC, sensors, HMI and other equipment require 24VDC power
✅ Variable frequency drives, motors, or welding equipment nearby generate interference
✅ Strict requirements for power reliability and EMC performance
✅ Need wide temperature range for outdoor/harsh indoor environments

Complementary Options: For higher power requirements (200W/300W) or dual-output needs, explore other MDA series models or custom solutions. Our complete 10-model product line covers 30W–100W single and dual output scenarios.

MDA100-48S24_IndustrialAutomation - 副本(1).jpg