Introduction

Industrial power supplies serve dual roles: voltage conversion and system protection. These functions ensure that equipment receives a stable, interference-free current supply, critical for uninterrupted operation of automation equipment like robotics, high-speed actuators, and embedded controllers. With systems becoming more compact and interconnected, engineers must now evaluate a supply’s behaviour under transient loads, its ability to withstand environmental factors, and its conformity to global standards.

Power supply types, SMPS specifics

The two most common types of power supplies in industrial systems are linear regulators and switched-mode power supplies (SMPS). Linear regulators provide clean output with low ripple but suffer from low efficiency (30–40%) due to continuous energy dissipation across the regulating element. SMPS systems, by contrast, use high-frequency switching circuits, resulting in compact designs and conversion efficiencies exceeding 90% ^[1][2].

In SMPS, energy is rapidly stored and released through inductors and capacitors, enabling dynamic load handling and voltage regulation over wide input ranges. Schneider Electric’s ABL Series incorporates this architecture to support decentralised control panels, PLCs, and distributed I/O systems, while ensuring long-term energy efficiency.

Basic requirements of all supplies 

Industrial-grade power supplies must meet essential design and safety criteria:

• Support for 100–240 V single-phase and 100–500 V three-phase input voltages
   
• Consistent regulation of 24–48 VDC outputs within ±1% tolerance
   
• High current headroom (up to 40 A) for inrush compensation
   
• Fault protection for overvoltage, short-circuit, and thermal overload
   
• Electromagnetic compatibility per IEC 61000‑3‑2 and relevant UL/CE safety certifications
   

The ABL series not only meets these criteria but adds diagnostic outputs, energy reserves, and flexible mounting options for real-world industrial environments ^[3].

As smart manufacturing evolves, power supplies are expected to deliver energy while also monitoring, protecting, and communicating. The ABL Series addresses this need for intelligent power infrastructure across sectors ranging from industrial automation to embedded robotics.

Industrial Automation supply selection 

Selecting the right power supply for automation involves evaluating more than just nominal specifications. In practice, systems must handle varying loads, operate under harsh conditions, and integrate with complex safety and control architectures.

Requirements for large motors, actuators 

Many automation systems involve solenoid valves, conveyors, and motors, each generating high inrush currents during activation. For instance, a 24 VDC actuator may draw up to 150% of its nominal current for several seconds. The ABL series includes integrated capacitor banks that act as short-term energy buffers, ma

intaining voltage stability during transients and reducing nuisance tripping ^[3][5]. This ensures devices like emergency shutdown systems or servo drives operate without interruption.

Requirements for industrial automation environment 

Environmental factors such as heat, vibration, and EMI pose additional challenges:

• Metal enclosures protect against electromagnetic fields emitted by nearby inverters.
   
• DIN rail and screw mounting options provide flexibility for mobile equipment or panel constraints.
   
• Low ripple voltage (< 100 mVpp) ensures stable operation of sensitive analog sensors and PLC inputs.
   

The ABL series is particularly well suited for deployment in AGVs and robotic arms, where compact size and mechanical shock tolerance are critical, As such there are integrated anti-harmonics filters reduce total harmonic distortion (THD) and support compliance with IEC 61000‑3‑2 standards ^[3][6].

Special certifications 

Industrial environments often demand UL 508 compliance for North America and CE/CB marking for global markets. The ABL range satisfies:

• IEC/EN 61010-2-201 for control panel safety
   
• EN 55011 Class B for conducted and radiated EMI
   
• Diagnostic relay outputs for direct connection to safety relays or SCADA

These standards enable rapid deployment into validated systems without redesigning protection or isolation schemes ^[4][5].

Schneider ABL supplies 

Schneider Electric’s ABL series includes compact, high-efficiency SMPS power supplies designed for industrial environments. This section details the ABL family’s performance envelope, flexibility, and integration features.

Series overview 

Current models span:

• Output voltages: 24 VDC and 48 VDC,
   
• Output power: 120 W to 960 W,
   
• Current capacity: 5 A to 40 A,
   
• Input: 100–240 V AC (1-ph) and 100–500 V AC (3-ph) [3][4][6].

These specifications support both legacy control cabinet upgrades and modern decentralized automation topologies.

Flexibility of ABL Series 4

The latest evolution of the ABL Series – specifically the ABLS1A and ABLU3A product lines – demonstrates Schneider Electric’s commitment to high-performance, compact SMPS solutions for demanding industrial environments.

The ABLS1A models, such as the ABLS1A48050 and ABLS1A48100, are single-phase power supplies offering 48 VDC outputs at 5 A and 10 A respectively. Designed for panel-mounted control and safety systems, they operate over a wide input range of 100–240 VAC or 140–375 VDC, offering flexibility in both AC mains and battery-backed applications.

Meanwhile, the ABLU3A modelsm, including ABLU3A24100 (10 A), ABLU3A24200 (20 A), and ABLU3A24400 (40 A), support three-phase 380–500 VAC input and deliver 24 VDC output with robust current capabilities.

Common advantages across the ABL Series 4 include:

• Voltage trimmer adjustment to fine-tune output by ±10%
   
• Detachable terminal blocks for faster servicing and clean wiring
   
• Relay contact diagnostics that trigger error or voltage drop alerts
   
• Parallel operation support for load sharing across multiple units

All units operate at full rated load in ambient temperatures up to 60 °C without derating, and they are certified to RoHS, IEC/EN 61010-2-201, and UL 508.

These new ABL Series 4 supplies extend the usability of the ABL platform into higher-power, higher-resilience segments of industrial automation. Their compact form factor and harmonised mounting standards make them easy to retrofit into legacy panels or standardise across global manufacturing lines.

c. Integration Advantages in Modular Control Systems

The ABL units are designed for plug-and-play integration:

• Compact footprints for dense DIN rail layouts
   
• LED status indicators and fault contacts for real-time visibility
   
• SCADA and EcoStruxure compatibility for remote diagnostics

These features simplify commissioning and support predictive maintenance.

Additional Technical Considerations

Galvanic Isolation

SMPS designs like those in the ABL Series incorporate galvanic isolation via transformers between input and output stages. This prevents ground loops and protects downstream devices from high-voltage spikes. Galvanic isolation is essential in mission-critical systems such as CNC controllers and process instrumentation, where signal integrity and electrical separation are mandatory ^[7].

Integration with UPS and Redundant Systems

The wide input range (140–375 VDC) allows Series 4 supplies to interface directly with uninterruptible power supplies (UPS) or battery arrays, extending runtime during brownouts. In high-availability systems, engineers can run ABLU3A units in parallel, ensuring uninterrupted supply even if one module fails.

Application Case Studies

Automated Packaging Facilities

ABL units have been deployed in bottling lines to support PLCs, pneumatic valves, and quality inspection systems. The voltage trimmer compensates for long wire runs, while diagnostic outputs alert operators of any under-voltage events before they cause process halts.

AGVs and Mobile Robotics

In intralogistics, mobile platforms equipped with ABL Series 4 units benefit from shock-resistant design and consistent voltage during high-current surges, such as during acceleration or lift operations. Passive cooling and high ambient tolerance extend operational uptime in 24/7 logistics hubs.

Modular Machine Panels

OEMs standardise on ABL8WPS and ABLU3A units for modular machine panels shipped globally. The wide input tolerance eliminates external transformers, and screw/rail compatibility ensures installation consistency. This reduces time-to-commission across geographies and simplifies post-sale servicing.

Smart HVAC and Building Automation

In intelligent building systems, the ABL Series powers BACnet/Modbus gateways, actuators, and environmental sensors. These components demand ultra-low ripple to prevent signal noise and accurate fault reporting to building management systems (BMS). Schneider’s integrated diagnostics and filtering ensure seamless operation within building automation networks.

Conclusion 

Today’s industrial systems require more than simple voltage regulation. Engineers need power supplies that stabilise dynamic loads, report health conditions, and meet compliance across multiple jurisdictions. The ABL Series 4 from Schneider Electric delivers these capabilities within a compact, rugged package. With wide input support, energy buffering, smart fault signalling, and robust thermal tolerance, the ABL line meets the evolving needs of automation, robotics, and advanced manufacturing.

With its ability to adapt to dynamic demands while maintaining global compliance, the ABL Series is not just a power supply, it is an enabling layer for next-generation control systems and industrial intelligence.

References

1. Wikipedia. Switched‑mode power supply. https://en.wikipedia.org/wiki/Switched-mode_power_supply

2. ON Semiconductor. Switch‑Mode Power Supply Reference Manual, July 2002. https://www.onsemi.com/pub/collateral/smpsrm-d.pdf

3. Schneider Electric. ABL8RPS24100 Data Sheet. https://media.distributordatasolutions.com/schneider_synd_rework/2024q1/documents/99b35dd47a81dae5a911f5d19e359f2fadbda50d.pdf

4. MRO Electric. ABL8REM24050 Product Guide. https://www.mroelectric.com/static/app/product/pdfs/ABL8REM24050.pdf

5. Schneider Electric. Modicon Power Supply ABL8WPS24200 Overview. https://www.se.com/us/en/product/ABL8WPS24200/regulated-switch-power-supply-modicon-power-supply-3-phases-380-to-500v-ac-24v-20a

6. Mouser Electronics. Schneider Electric ABL Series Overview. https://www.mouser.com/new/schneider-electric/schneider-abl-power-supplies/

7. Ott, H. W. (2011). Electromagnetic Compatibility Engineering. Wiley.