Objective

To design and deliver a containerized, custom, high-current DC power system engineered for mission-critical clean-energy and industrial applications, with strict adherence to NEC and UL standards.

Challenges

• PSU, PLC, HMI, and Remote I/O panels within an E-House operating adjacent to Class I, Zone 2process areas.

• Full compliance with UL508A, NEC, and project-specific engineering requirements.

• Limited installation space, requiring a highly optimized panel layout.

• High-current busbar sizing and custom busbar fabrication for power infeed.

• Thermal management and enclosure climate-control under variable ambient conditions.

Trimasys Solution

This High-Power PSU project involved the development of a containerized 55 V DC, 2500 A high-current power supply panel, optimized for space-restricted and demanding operational environments. The system integrates:

• NEC-compliant busbar architecture

• Advanced enclosure climate-control with thermal calculations

• 3D AutoCAD modeling for layout, clearances, and heat-dissipation validation

• Robust construction ensuring safety, efficiency, and long-term reliability

Key Technical Highlights of the Containerized Panel

• Output: 55V DC, 2500A

• Instrumentation: Process IO, HMI Interface

• Signals: 24VDC Control, Communication, F&G System Integration

• Safety: Dedicated 24VDC for E-Stop and interlocks, and safety-critical circuits

• Custom Busbar Design per NEC

• Compact Footprint — 20–25% space optimization

• Forced Cooling Options for Thermal Control

• 3D AutoCAD Design Validation Completed

• Enclosure Climate Control Calculation

• Installation Environment:
  • Electrical room within process container — Unclassified (non-hazardous) area
  • Ambient Temperature Range: 5°C – 40°C
  • Adjacent Process Zone: Class I, Zone 2

Design Tools: AutoCAD 3D | NEC Standards | Thermal & Load Calculations

Overview of Containerized Panel Location E House 

 Domain based applications

• Battery Energy Storage Systems (BESS)

Charging/discharging control

DC distribution for power conversion equipment

• Industrial Automation & Process Control

Supplying stable DC power to PLCs, IO modules, drives, and field instruments

• Pharmaceutical & Biotech Manufacturing

High-reliability power for GMP-critical systems, analyzers, and cleanroom automation

• Data Centers & Server Infrastructure

High-current DC systems for server racks, UPS, and cooling systems

• EV Charging Infrastructure

High-power DC chargers

Power electronics and converter modules

• Renewable Energy Plants (Hydro/ Solar / Wind)

Auxiliary power for inverters, string monitoring units, trackers

• Testing & R&D Labs

High-power DC sources for endurance testing, load tests, and validation rigs

• Heavy Machinery & Manufacturing Plants

CNC machines, welding lines, robotics, furnaces, and motor drives

• Railways & Transportation Systems

Traction control, signaling systems, and auxiliary converters

• Oil & Gas / Energy Sector

Explosion-proof PSU boards for hazardous zones

Power supply for RTUs, field instruments, analyzers