Tailored Power Solutions Engineered for Absolute Reliability
Over 50% of systems shipped by Helios Power Solutions are customized to meet specific operational requirements. Standard off-the-shelf equipment often fails to satisfy complex industrial constraints, harsh operating environments, or strict SCADA communication requirements.
Our experienced power electronics design engineers collaborate directly with global consultants, OEM integrators, and procurement teams. Leveraging our ISO 9001:2015 certified engineering and assembly facilities in Australia and New Zealand, we transform complex specifications into fully documented, factory-tested power architecture.
ISO 9001:2015 Accredited Engineering & Assembly Facilities End-to-End Design & Manufacturing Services
From component-level modifications to turnkey 47U cabinet integration, our engineering workflow ensures high reliability, extended product lifecycles, and seamless field integration.
Qualified Engineering Consultation
Direct technical dialogue with senior power electronics engineers to analyze your electrical load profile, autonomy requirements, ambient temperature derating, and mechanical installation limits.
Schematic Drafting & Prototyping
Comprehensive electrical schematics, 3D CAD mechanical modeling, single-line diagrams (SLDs), and protocol point mapping tailored for SCADA integration prior to manufacturing release.
Factory Acceptance Testing (FAT)
Rigorous bench testing, full-load burn-in, thermal profiling, and client-witnessed FAT verification ensure compliance before systems leave our production hubs in Sydney and Auckland.
Engineering Levels Tailored to Your Project Requirements
PCB-Level Customization
Modifying core switch-mode power circuits, board dimensions, output voltage trim ranges, thermal heat sinking, and auxiliary signal outputs for OEM embedded applications.
- Custom output voltages & current limits
- Conformal coating for harsh/coastal environments
- Military & railway standard compliance
- Wide operating temperature re-rating
Sub-Rack & 19" Rackmount Systems
Enclosing power conversion components into 1U to 6U rackmount chassis equipped with custom distribution circuit breakers, status alarms, and digital comms cards.
- N+1 / N+X redundant module configurations
- DNP3, Modbus RTU/TCP & SNMP monitoring
- Specialized output connectors & busbars
- Hot-swappable module shelves
Industrial Floor-Standing Cabinets
Turnkey floor-standing system enclosures (up to 47U) integrating high-capacity chargers, battery autonomy banks, AC/DC distribution, and environmental control units.
- IP31 to IP66 & NEMA-rated outdoor enclosures
- Seismic-certified mechanical designs
- Integrated HVAC or convection cooling
- Full battery capacity monitoring systems
Technical Options & Architectural Flexibility
Specify exact engineering requirements across electrical, mechanical, and communications domains.
| Domain | Engineering Options & Features | Industry Applications |
|---|---|---|
| Electrical Architecture | Multi-voltage output combinations (12V, 24V, 48V, 110V, 220VDC / 110V, 230VAC), active load sharing, low voltage disconnect (LVD), surge protection, dual mains input redundancy. | Substations, Process Automation, Telecommunications |
| Monitoring & Control | Volt-free alarm contacts, local LCD touch interfaces, battery temperature compensation, remote reboot per output channel, DNP3 Outstation server compliance. | Power Utilities, Critical Infrastructure, Water Treatment |
| Environmental Hardening | Conformal coating, IP54/IP65/IP66 weatherproof cabinets, shock/vibration isolation, extended operating temperatures (-40°C to +70°C). | Defence Platforms, Mining, Marine, Railway Infrastructure |
| Documentation & Testing | Complete schematic sets, Operation & Maintenance (O&M) manuals, Factory Acceptance Test (FAT) reports, compliance certificates (CE, UL, IEC, EN). | Global EPC Projects, Government Contracting |
Real-World Engineered Solutions
Custom Monitored Battery Charger — Fire Service & Rescue
Engineered dual 500W redundant battery charger systems (AMP-K5913) featuring individual output channel current monitoring, mains voltage remote monitoring, circuit breaker protection per channel, and automatic remote channel reboot functionality upon loss of network connectivity.
Modular Redundant Substation DC Systems — Electrical Utilities
Designed and manufactured N+1 modular DC power systems delivering 110VDC tripping power across multiple high-voltage substations. Systems featured DNP3 SCADA integration, seismic-rated 19-inch cabinets, temperature-compensated battery charging, and automated insulation testing.
Need a Custom Power System Sized & Engineered for Your Project?
Submit your system requirements—including input/output voltages, load profile, required battery autonomy, ambient temperature, and protocol requirements—to consult with our senior power engineers.
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