RECOM: Mastering Peak Loads with Reliable Power Supply for Dynamic Loads
Power Supplies I 28.08.2025
Industrial applications are increasingly characterized by dynamic load profiles consisting of typical loads, maximum loads, and short peak loads. Traditional power supplies quickly reach their limits in such scenarios. With its peak-load capable power supplies, RECOM provides a well-designed answer to these challenges.
Figure 1: The RACPRO1 series has been awarded the Red Dot Award for Product Design 2025 for its combination of technical innovation and appealing design. (Source: RECOM)
Where are the pitfalls in industrial applications?
Power supplies – whether AC/DC or DC/DC – must withstand a wide range of influences such as temperature, humidity, and input/output transients. Efficient energy management is crucial: the power supply must be able to deliver its full rated power instantly under maximum operating conditions and maintain it according to the load. In the electromechanical sector in particular, industrial applications often feature dynamic load profiles. Motors, pumps, drives, or capacitive loads frequently require significantly higher power during startup than in continuous operation. Since conventional power supplies are generally designed for continuous operation, they can only handle such short-term peak loads to a limited extent. This can lead to thermal overload of the components, resulting in temperature-related failures. As a consequence, solutions are often oversized, which increases space requirements and costs. In addition, insufficiently dimensioned systems face a higher risk of failure and premature component aging.
On top of this, certain applications generate multiple peak loads. When selecting a power supply for such use cases, the load cycle – i.e., the time between peaks – is just as important as the peak load value itself. This is why carefully balanced energy management is essential. Power supply monitoring also plays a key role: only through continuous monitoring, especially during and after peak load phases, can long-term stability, safety, and reliability be ensured.
Which components can be used to achieve efficient energy management?
RECOM offers a range of power supplies with peak-load capability, specifically designed for applications with high and short-term peak load demands. These units are engineered to exceed their rated power for a defined period without compromising reliability or efficiency.
One example is the RACPRO1-T480, a highly reliable DIN-rail power supply with a three-phase AC input and 24V or 48V output versions. Thanks to intelligent real-time monitoring, energy output can be continuously tracked via the LED load indicator. In addition, the device supports both battery charging functions and parallel operation, for example in industrial applications requiring redundancy. It is suitable for both inductive and capacitive loads. Another advantage lies in its power reserves: alongside the rated output of 480 watts at ambient temperatures up to 60°C, the units provide a “thermal bonus” at reduced ambient temperatures down to 45°C, allowing loads up to 120% of rated power.
Depending on the load profile, the power supplies can deliver up to 2.5 times their rated power for short periods – for example, 250% for up to 20 milliseconds to trigger connected fuses in the event of a fault, or 150% for up to 7.5 seconds. This makes it possible to deliberately choose smaller power supplies while still safely handling short-term load peaks, saving space, cost, and energy (see Figure 2). The underlying load management is clearly defined: after a 150% peak load for 7.5 seconds, the load must remain at or below the rated power for at least 52.5 seconds. Only then can a new peak occur – resulting in a total cycle of 60 seconds. This precise definition of the permissible duty cycle ensures reliable dimensioning without the risk of overload.
Figure 2: Diagram showing the peak-load capability of RECOM’s RACPRO-T480 series AC/DC DIN-rail power supply. The unit can deliver up to 250% of its rated power for up to 20 ms. A peak load of up to 150% of the maximum rated power is permissible for up to 7.5 s. (Source: RECOM)
What key features do the RACPRO1-T series offer:
- High efficiency: Up to 97.1%, depending on the model. This reduces power loss and heat generation, lowers operating costs, and extends service life.
- Passive cooling: Thanks to the special housing design, the power supplies deliver full power at ambient temperatures up to 60°C – without an additional fan. This makes them ideal for dusty, humid, or low-maintenance environments.
- Remote monitoring: DC-OK signals enable status detection and early warning.
- Slim design: Only 43 mm wide at 240 W, 52 mm at 480 W, and 80 mm at 960 W. This allows for more compact control cabinets or frees up space for additional functions.
- 25° push-in connectors: Enable fast, tool-free installation, maintenance, and retrofitting, even in confined spaces.
- Award-winning product design: Winner of the Red Dot Award 2025 – combining functionality with ergonomics.
These features ensure efficient and reliable operation, even with complex load profiles.
Which application areas are these power supplies targeted at?
The peak-load capable power supplies are certified according to EN/IEC/UL 62368-1, 61010-1, and 61010-2-201, and are used in industries such as automation, robotics, smart cities, battery systems, as well as energy distribution and measurement technology. Examples include:
- Motor controls: for starting electric motors, which often require multiple times their rated power.
- Pumps and drives: to handle high inrush currents and dynamic load changes.
- Automation systems: where components or subsystems need to be switched on briefly.
- Capacitive and inductive loads: which initially demand high energy.
Dimensioning power supplies requires system designers to carefully consider continuous load, peak load values, their duration, and the intervals between individual peaks. This analysis is usually based on the datasheets of the components involved and is essential to ensure the overall system’s lifetime and reliability.
With the RACPRO1-4SP, RECOM also offers system designers an optional 4-channel load switch with electronic fuse (e-fuse). Each channel provides independent overcurrent protection. All channels operate autonomously to ensure system reliability even in the event of a fault.
With us
We supply our customers with power supplies from RECOM and other renowned manufacturers. At our automated central warehouse in Monheim am Rhein, we stock around 6,000 different types of AC/DC power supplies and DC/DC converters in production-ready quantities.
In addition, we offer fast and expert support — including dedicated contacts and a field service team for on-site problem solving.
Our customers benefit from the quick processing of their inquiries, the provision of datasheets and samples, as well as flexible delivery quantities ranging from prototypes to full-scale production.