Power Conversion Engineering
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Power Conversion Engineering
Rugged, high-efficiency DC/DC converters (6W to 1000W) engineered for rolling stock, traction control, signaling systems, and trackside equipment.
Wall Industries delivers field-proven, high-reliability railway DC/DC power converters designed to operate continuously under extreme ambient temperatures, severe vibration, electromagnetic interference, and dirty power supply lines. Our modules meet stringent European and international railway standards, providing trusted power conversion for global locomotive OEMs and transit operators.
Built for harsh traction battery environments, our converters feature wide 4:1 and ultra-wide 12:1 input voltage ranges (covering 24V, 48V, 72V, 96V, and 110V DC nominal inputs). High isolation voltages up to 3000VDC/2250VDC protect sensitive downstream microprocessors, communication radios, and diagnostic monitors from ground loops and high-voltage transients.
Available in industry-standard DIP, SMT, quarter-brick, half-brick, and full-brick footprints, as well as DIN-rail and chassis-mount enclosures. Optional thermal accessories—including integrated heatsinks, terminal blocks, and MIL-grade conformal coatings—ensure stable thermal performance across extended -40°C to +85°C operating envelopes.
Select from our high-performance modular converter series designed for onboard electronics, signaling, and controls.
| Series | Output Power | Input Voltage Window | Output Voltage Options | Package Format & Features |
|---|---|---|---|---|
| LANCUW8 | 8 Watts | 4:1 Ultra Wide (9–36, 18–75 VDC) | 3.3V, 5V, 12V, 15V, ±12V, ±15V | Compact DIP / SMT footprint (1.25" x 0.80" x 0.40"), low standby power, single & dual output. |
| DCREDUW20 | 20 Watts | 4:1 Ultra Wide (9–36, 18–75 VDC) | 3.3V, 5V, 12V, 15V, ±12V, ±15V | Industry standard 2" x 1" x 0.4" package, 1500VDC isolation, remote ON/OFF control. |
| RDW15 | 15 Watts | 4:1 Wide Range Input | 5V, 12V, 15V, 24V, ±12V, ±15V | Ultra-compact 1" x 1" x 0.39" package, optional heatsink, high efficiency up to 89%. |
| MRW20 | 20 Watts | 4:1 Wide Input Range | 3.3V, 5V, 12V, 15V, ±12V, ±15V | Compact 2" x 1" x 0.43" package, extended operating temp, short circuit & overvoltage protection. |
| DCQUW40 | 40 Watts | 4:1 Wide Input Range | 3.3V, 5V, 12V, 15V, 24V, 48V | Standard Quarter-Brick (1.45" x 2.28" x 0.50"), optional heatsink, high power density. |
| DCQUW60 | 60 Watts | 12:1 Ultra-Wide (16–160 VDC) | 5V, 12V, 15V, 24V, 48V, 54V | Quarter-Brick form factor, EN 50155 & EN 45545-2 design, 2250VDC basic isolation, no min load. |
| DCHBW75 | 75 Watts | 4:1 Wide Input Range | 3.3V, 5V, 12V, 15V, 24V, 48V | Standard Half-Brick package, high efficiency, convection or baseplate conduction cooling. |
| DCHBW100 | 100 Watts | 4:1 Wide (18–75, 43–160 VDC) | 5V, 12V, 15V, 24V, 48V | Half-Brick package, wall-mountable option, RoHS compliant, high shock/vibration tolerance. |
| DCHBW150 | 150–182 Watts | 4:1 Wide Input Range | 5V, 12V, 15V, 24V, 28V, 48V | High-power Half-Brick, broad thermal margin, optional heatsink and terminal block assembly. |
| FIL FLMCF | Transient / Filter | 4:1 Input Protection (9–36 VDC) | System Bus Protection | Non-isolated active EMI filter & transient surge suppressor module, low profile package. |
Rail rolling stock subjects electrical components to rigorous operational stress. Our power supplies are designed from the board level up to meet key international railway specifications.
Demands full functionality across extended operating ambient temperatures (-40°C to +85°C including Class OT4 startup over-temperature requirements) with integrated thermal shutdown and heatsink options.
Shielded designs engineered to withstand strong magnetic fields from traction motors, pantograph arcing, ESD, and radio interference without degrading system performance or emitting unwanted EMI.
Encapsulated bodies, ruggedized mounting pins, and potted enclosures tested against severe body-mount and axle-mount random vibrations, continuous shocks, and mechanical impacts encountered on tracks.
Materials selected to meet stringent European fire protection standards for railway vehicles, using UL 94V-0 flame-retardant plastics and low-smoke zero-halogen (LSZH) potting compounds.
Designed to handle power supply interruptions, battery voltage sags, voltage surges, and line switching transients up to 1.4 × nominal input without loss of regulated DC output.
Protects inner circuitry from high humidity (75% average, 90% cyclic relative humidity), conductive brake dust, salt spray, oil mist, and atmospheric pollutants in harsh operating environments.
Engineering Experience
For specialized railway applications where off-the-shelf power supplies do not fit mechanical enclosures or unique pinout requirements, Wall Industries provides custom engineering services. With over 60 years of power design experience in New Hampshire, USA, our engineering team works directly with your technical staff to modify standard catalog platforms or build fully custom converters from the ground up.
Common modifications include customizing input/output voltage ratios, adding specialized connector harnesses, applying conformal coatings, configuring custom heat-sinks, and providing custom mechanical chassis brackets for easy retrofit into existing rolling stock control racks.
Every custom railway power supply project follows a controlled qualification process, including thermal stress screening, high isolation testing, and full EMC pre-compliance evaluation. Whether you require low-volume prototype builds for passenger rail trials or full-scale multi-year production orders for metro fleet overhauls, Wall Industries ensures supply continuity and long product lifecycle support.
Our long-term commitment guarantees form-fit-function replacement availability, eliminating risk of premature component obsolescence in railway capital equipment designed for 20- to 30-year operational lifespans.
Six decades of specialized US power conversion design, serving mission-critical transit, defense, medical, and industrial OEMs globally.
Strict counterfeit parts mitigation policy, ISO-compliant quality practices, and 100% full-load production burn-in testing.
Direct access to our senior power design engineers in Exeter, NH to solve complex thermal, isolation, and EMI challenges.
A railway DC to DC power converter is a ruggedized power module engineered specifically for applications within the railway industry. It converts direct current (DC) from traction batteries or third-rail buses into clean, regulated DC voltage to power onboard control logic, door actuators, HVAC controls, passenger information displays, radio communications, and trackside signaling systems.
Our railway converters are engineered to meet or exceed EN 50155 (electronic equipment used on rolling stock), EN 50121-3-2 (electromagnetic compatibility EMC), EN 61373 (shock and vibration resistance), and EN 45545-2 (fire safety protection for rail vehicles).
Railway electrical systems experience heavy voltage fluctuations due to motor starting, regenerative braking, pantograph bounce, and battery state-of-charge variations. Standard nominal rail voltages (24V, 48V, 72V, 96V, 110V DC) can surge or sag significantly. Our 4:1 and 12:1 wide-input converters guarantee stable output voltage despite extreme line voltage swings.
Yes. Galvanic isolation is essential to break ground loops, protect low-voltage microprocessors from high-voltage traction transients, and isolate primary battery circuits from chassis ground. Wall Industries railway converters offer basic and reinforced isolation options rated up to 3000VDC / 2250VDC.
Absolutely. We specialize in custom and modified-standard designs. If your project requires non-standard input ranges, custom pinouts, specialized cooling baseplates, high surge protection, or custom enclosures, our engineering team will design a solution to meet your exact specification.
Consult with our engineering team in Exeter, New Hampshire for standard catalog quotes, sample requests, or custom modified-standard power designs for your transit project.