Configurable Power Supplies by Sager Electronics and Advanced Energy: A Modular Approach to Power System Design

EXECUTIVE SUMMARY

Modern industries demand power supply solutions that are flexible, scalable, and compliant with stringent standards. Traditional approaches, such as standard fixed-function power supplies or fully custom designs, often struggle to balance performance, cost, and time-to-market. Configurable power supplies address these challenges, offering tailored solutions for diverse applications across sectors like industrial automation, medical technology, aerospace, and renewable energy.

Sager Electronics collaborates with Advanced Energy to deliver innovative configurable power supply solutions. These modular power supplies provide high power density, scalability, and regulatory compliance, meeting the demands of critical applications while reducing development costs and accelerating deployment.

Through Sager’s Custom Solutions Center and the 3x5 Quick-turn Program, OEMs benefit from rapid delivery of tailored power systems. By combining precision, efficiency, and adaptability, configurable power supplies redefine power system design, ensuring reliable performance in even the most demanding environments.

Introduction

As industries evolve and technology advances, the need for efficient, adaptable, and compliant power supply solutions continues to grow. Sectors like industrial automation and medical technology require power systems capable of addressing unique and changing demands. This shift has revealed the limitations of standard and fully custom solutions while highlighting the increasing demand for flexible and cost-effective alternatives.

In collaboration with Advanced Energy, Sager Electronics offers configurable power solutions designed to meet these challenges. Solutions like the NeoPower AC-DC configurable power supplies combine adaptability and efficiency to address the diverse needs of modern applications.

This white paper examines the evolution of power supply technologies, the benefits of configurability, and how Sager and Advanced Energy empower engineers to meet application-specific requirements. It also features real-world applications and case studies, illustrating the practical impact of configurable power solutions across various industries.

The Evolution of Power Supplies: Meeting the Demands of Modern Applications

Whether for industrial automation systems or life-critical medical equipment, power supply solutions must strike a balance between efficiency, adaptability, and adherence to stringent safety regulations. Traditional power supply solutions have served well but are often limited in their ability to meet the evolving needs of today's industries. Standard fixed-function power supplies are cost-effective but inflexible, while fully custom designs can address specific requirements but come with long lead times and high costs. These limitations have created a gap that configurable power supplies are uniquely positioned to fill.

Standard power supplies offer simplicity and affordability, while fully custom designs provide specificity but require more time and cost. Configurable power supplies combine the advantages of both.

Challenges in Modern Power Supplies

Modern industries face several challenges that traditional power supply solutions struggle to address:

1. Variability in Power Demands: Different industries and applications require diverse voltage, current, and power configurations. Standard solutions often fall short of meeting these varied needs.
2. Cost and Time of Custom Solutions: While custom designs can meet specific requirements, they are resource-intensive, with development cycles extending to months, delaying time-to-market.
3. Compliance with Safety and Environmental Standards: Medical and industrial sectors require adherence to standards like IEC 60601 for medical devices and IEC 62368 and SEMI F47 for industrial equipment, making compliance a critical factor.
4. Harsh Operating Conditions: Many applications, such as those in aerospace and industrial automation, demand power supplies that can withstand extreme temperatures, vibrations, and other challenging environments.

The increasing complexity of these requirements has driven innovation in configurable power solutions, offering a modular approach that bridges the gap between standard and custom designs.

The Power of Configurability

Configurable power supplies present a modular approach to power system design that allows engineers to build solutions to specific application requirements. Unlike standard fixed-function power supplies or costly custom designs, configurable power supplies leverage a plug-and-play architecture. These systems consist of a base unit and interchangeable modules that can be combined to achieve the desired voltage, current, and power specifications.

This modularity enables rapid prototyping and faster time-to-market while maintaining cost efficiency. Advanced Energy’s NeoPower AC-DC configurable power supplies, for instance, provide thousands of output combinations, achieved by connecting modules in series or parallel using their innovative configurable bus bar system. This allows design engineers to achieve precision without the need for extensive redesigns or over-specification.

Key Features of Configurable Power Supplies

Configurable power supplies like the NeoPower series offer several adjustable parameters and features that set them apart from traditional solutions:

1. Programmable Voltage and Current Outputs: Configurable as voltage or current sources with adjustable ratings, these outputs allow engineers to precisely match specific load requirements. This reduces over-specification, optimizes energy efficiency, and ensures accurate power delivery for various applications.
2. Advanced Load Regulation and Stability: Sophisticated load regulation maintains stable output under fluctuating load conditions, preventing performance disruptions and ensuring consistent operation in sensitive systems.
3. Flexibility and Scalability: Modular designs allow for easy scaling and adaptation to changing requirements without overhauling the entire system. Modules can be swapped or added quickly, saving time and resources while enhancing system versatility.
4. Accelerated Time-to-Market: By eliminating lengthy custom design cycles, configurable power supplies reduce lead times significantly. Programs like Sager’s 3x5 Quick-turn ensure fast delivery of configured power supplies, accelerating project completion.
5. Compliance and Reliability: Certified to meet key industry standards, these power supplies simplify regulatory approvals and provide consistent, dependable performance across applications.
6. Comprehensive Protection Settings: Configurable over-voltage, over-current, and over-temperature protection safeguard critical systems by minimizing damage risks, reducing downtime, and extending system lifespan.
7. High Efficiency and Thermal Management: Configurable power supplies like NeoPower achieve industry-leading efficiency ratings, minimizing energy losses and heat generation. Optimized thermal management enhances reliability and lowers operational costs, even under high loads or extreme conditions.
8. Customizable Cooling Mechanisms: Adaptive fan speed and cooling configurations ensure efficient heat dissipation, preventing overheating and maintaining performance across varying operational environments.
9. Diagnostics and Digital Control Interfaces: Integrated communication protocols (e.g., Modbus RTU, I²C, IoT) enable real-time monitoring, diagnostics, and adjustments. These features support seamless system management and proactive maintenance through remote control and smarter connectivity.Modular power supplies such as the Advanced Energy’s NeoPower comes with Modbus RTU as the default communication bus
10. Environmental Resilience: Designed for harsh conditions, including extreme temperatures, dust, vibrations, and humidity, these power supplies deliver reliable performance in industrial, medical, and outdoor applications with ruggedized and conformal-coated designs.

To illustrate the distinct advantages of configurable power supplies, a table summarising the differences between standard, fully custom, and configurable solutions is presented below.

Applications of Configurable Power Supplies

Configurable power supplies, like the ones used by Sager Electronics to build power solutions, have become a key-enabler in industries where precision, reliability, and adaptability are critical. They address diverse and evolving demands across several key applications:

• Industrial Automation: Powering robotics, assembly lines, and process control systems, these solutions adapt to dynamic voltage and current requirements. Their scalability helps optimize efficiency and reduce downtime, even under fluctuating load conditions.
• Medical Equipment: Certified to IEC 60601 standards, configurable power supplies provide precise, low-noise power delivery for critical devices like imaging systems and diagnostic tools. Their modularity ensures compliance with stringent safety regulations while maintaining operational excellence.
• Aerospace: With rugged designs, these power supplies withstand extreme conditions, including high altitudes, temperature fluctuations, and vibrations. They offer redundancy and fault tolerance for mission-critical operations.
• Automotive: Electric vehicles (EVs) and smart vehicle systems benefit from compact, scalable power supplies that manage varying loads and isolated outputs. These solutions support innovation in EV systems and advanced automotive technologies.
• Renewable Energy Systems: Modular configurations and digital monitoring capabilities enable seamless integration into solar inverters, wind turbines, and energy storage systems, supporting sustainability initiatives.
• Data Centers and IT Infrastructure: High-efficiency power supplies minimize energy costs and meet growing power demands. Their compact designs ensure scalability while optimizing energy consumption and space utilization.

Compliance and Reliability for Critical Applications

In industries that demand safety and consistent performance, power supply systems must not only deliver precise performance but also adhere to strict regulatory standards.

Safety Certifications for Industry Confidence

Compliance with global safety and performance standards is essential for power supplies used in critical sectors. Configurable power supplies meet these stringent requirements, helping OEMs streamline regulatory approvals and reduce time-to-market challenges. Key certifications include:

• IEC/EN 60601-1 and IEC 60601-1-2: Essential for ensuring safety and electromagnetic compatibility (EMC) in medical devices, these standards safeguard patients and operators by addressing risks such as electrical shocks, fire hazards, and electromagnetic interference. They are mandatory for gaining regulatory approval for life-critical medical equipment like imaging systems, patient monitors, and surgical tools.

• IEC/EN 62368-1: Applicable to IT and industrial systems, this modern standard addresses the latest technological requirements, replacing older certifications like EN60950. It combines aspects of safety for IT and audio-visual equipment, focusing on hazard-based design principles to ensure robust performance in complex systems like industrial controllers and telecommunications equipment.

• SEMI F47: Ensures voltage sag immunity for industrial equipment, guaranteeing operational stability in fluctuating power environments. This certification is particularly important in manufacturing facilities and automation systems, where power disturbances can lead to costly downtimes, equipment failures, or product defects.

By meeting these certifications, configurable power supplies provide manufacturers with pre-tested solutions, reducing the challenges associated with regulatory compliances.

Configurable Power Solutions by Sager and Advanced Energy

As power demands become increasingly varied and time-to-market pressures escalate, configurable power supplies provide an effective means to address ever-evolving requirements of the electrical engineering industry. With the Advanced Energy NeoPower series, Sager redefines the delivery of tailored, efficient, and compliant power systems. By blending cutting-edge technology with the collaborative expertise of the Sager Custom Solutions Center, the company has established itself as a reliable partner for OEMs and design engineers.

Transforming Power Design with Configurability

The traditional approach to power supply design—relying on either fixed-function standard parts or fully custom solutions—often fails to balance speed, cost, and adaptability. Fully custom solutions, while precise, demand significant time and expense, with development cycles spanning 8–9 months, along with additional costs for NRE and safety testing. Fixed-function standard power supplies, on the other hand, lack the flexibility needed to meet evolving application demands.

The Advanced Energy NeoPower NP08 Series AC-DC power supply offers 18 W/in³ power density, up to 4000 W output, eight configurable slots, and exceptional flexibility for embedded or multi-output power applications.

Sager addresses this gap by offering configurable power supplies that blend the precision of custom solutions with the efficiency and speed of modular design. With Advanced Energy’s NeoPower series, engineers can leverage configurable modules to build tailored power solutions without the delays or high costs of custom builds. This approach ensures that the solutions are efficient, adaptable, and fully compliant with industry regulatory standards.

Sager Electronics’ Custom Solutions Center: Engineering Excellence

At the core of Sager's success lies its Custom Solutions Center in Lewisville, Texas. This state-of-the-art facility specializes in designing and delivering power supply solutions that meet the specific requirements of customers. The process is built on close collaboration between Sager’s engineering team, sales engineers, and the customer, ensuring that every solution aligns with the unique demands of the application.

The collaborative process includes:

1. Requirements Gathering: Sager’s sales engineers engage with OEMs and design engineers to capture detailed application requirements, including voltage, current, environmental factors, and compliance needs.
2. Engineering Analysis and Recommendations: The gathered data is evaluated by the Custom Solutions Center's engineering team to design a solution that optimally balances performance, cost, and efficiency.
3. Custom Assembly and Testing: The recommended solution is assembled and rigorously tested in-house to ensure it meets all operational and compliance standards.
4. Deployment: Once validated, the solution is delivered to the customer, ready for seamless integration into their application.

This systematic process enables Sager to deliver high-quality power solutions quickly and efficiently, setting it apart as a leader in configurable power supplies.

Quick-Turn Capabilities: The 3x5 Program

Recognizing the critical importance of speed in today’s market, Sager offers its 3x5 Quick-turn Program, a game-changing initiative that provides up to three configured power supplies in five days or less. This program is built on Advanced Energy’s modular power technology and Sager’s vast inventory, enabling engineers to prototype, test, and deploy solutions faster than ever before. It empowers customers to meet tight project deadlines without compromising quality or functionality.

The 3x5 Quick-turn Program by Sager Electronics enables rapid delivery of up to three fully configured power supplies in just five days, allowing OEMs to prototype, test, and deploy solutions quickly.

NeoPower Series: Modular Innovation

The NeoPower Series by Advanced Energy is a great example of the advantages brought in by configurable power solutions. Designed for industrial and medical applications, the NeoPower series offers:

• Unparalleled Power Density: Compact, high-performance modules with up to 18 W/in³ power density.
• Modular Design: Configurable bus bars support thousands of output combinations, providing flexibility to meet varied application demands.
• Programmable Versatility: Functions as both a voltage and current source, enabling dynamic adjustments based on load requirements. The NeoPower NP08 stands out as one of the few power supplies in the industry designed to function as a constant current source, offering exceptional versatility and a wide range of applications.
• Digital Communication: Modbus RTU compatibility allows real-time monitoring, diagnostics, and adjustments.
• Certifications and Reliability: Compliance with certain industry certifications ensures safety and performance across a large set of applications.

Bridging the Gap Between Standard and Custom

Sager’s approach transforms power system design by offering a middle ground that blends the best of both worlds: the adaptability of configurable solutions and the efficiency of modular technology. By working closely with customers to understand their requirements, Sager ensures that its solutions not only meet but often exceed expectations in terms of performance, compliance, and cost savings.

This ability to bridge the gap between standard and custom power supplies makes Sager a trusted partner for OEMs and design engineers, providing solutions that are as innovative as the applications they power.

Case Study: Modular Power Solutions for an Industrial Inkjet Printer

To illustrate the impact of configurable power supplies and Sager’s custom solutions, let us explore a real-world example where tailored solutions transformed a critical application for an OEM in the industrial printing industry.

The Challenge: Ensuring Reliable Power for a New Industrial Printing System

A manufacturer developing a new industrial inkjet printer required a modular power supply capable of efficiently distributing power to multiple system components, including UV lamps, optics, drive electronics, motors, pumps, fans, and heaters. Initially, the customer had planned to use two iHP power supplies for their system.

However, there was confusion regarding the specific power requirements and correct part numbers needed for the build. With production expected to scale to 20+ units over the next few years, the customer needed expert guidance to ensure they selected the most suitable power configuration.

The Solution: Sager’s Expertise in Power Supply Selection

At the recommendation of a manufacturing representative, Sager Electronics was brought in to assist with the project. One of Sager’s Power Systems Sales Engineers (PSE) reached out to the customer’s operations manager, who introduced them to their electrical and mechanical engineering teams.

During a detailed review session, the PSE:

• Clarified power requirements by analyzing the customer's schematic.

• Resolved confusion over the correct part numbers needed for each subsystem.

• Recommended an optimized modular power configuration to meet performance and reliability demands.

The final power solution included:

• Two IHP24SH-TW(2)-4P units dedicated to UV lamps, optics, and drive electronics, ensuring stable and precise power delivery to critical subsystems.

• One IHP24SH3A-SQ(8)-GP-9S unit used to power motors, pumps, fans, and heaters, handling high-power loads efficiently.

By leveraging Advanced Energy’s iHP modular platform, the customer could allocate power efficiently while maintaining system reliability and scalability.

The Outcome: Fast Deployment and Scalable Power for Future Growth

The benefits of Sager’s involvement were immediate. Within just two days of the meeting, the customer placed an order for the recommended power supplies, allowing them to proceed with building their first unit. The manufacturer expected to build another seven systems within a year and more than 20 units in the following years.

A modular power supply approach enables scalable, high-power configurable solutions, ensuring efficient and reliable performance for industrial inkjet printers.

By ensuring the correct selection and configuration of power supplies, Sager helped streamline the design, ordering, and integration process, reducing delays and eliminating uncertainty.

This case highlights the advantages of modular power solutions for industrial applications. This project utilized Advanced Energy’s iHP series, and a similar approach can be applied using the NeoPower series, offering a high-power, configurable solution with the added benefit of compact design and scalability for future applications.

Conclusion

Sager, in partnership with Advanced Energy, redefines power supply innovation with configurable solutions like the NeoPower series. These modular power supplies combine adaptability, efficiency, and regulatory compliance to meet the demands of critical industries such as medical, industrial, and aerospace. Through Sager’s Custom Solutions Center and the 3x5 Quick-turn Program, OEMs benefit from rapid, cost-effective, and reliable solutions tailored to their needs.

For power solutions that drive excellence, contact the expert team of engineers and design-in specialists at Sager’s Custom Solutions Center today: www.sager.com/custom-solutions

References

[1] Jones C. Understanding the real benefits of flexibility and configurability in power systems design [Internet]. Advanced Energy Industries, Inc. . Available from: https://www.advancedenergy.com/en-us/benefits-of-flexibility-and-configurability-in-power-systems-design/

[2] Advanced Energy Industries, Inc. NeoPower NP08 Series [Internet]. Advanced Energy. Available from: https://www.advancedenergy.com/en-us/products/ac-dc-power-supply-units/configurable-modular-psus/neopower-configurable-series/neopower/