Hi All

I am looking for a PCB module solution where ideally with fuses and a protection circuit, that can produce about 5V 500-1A DC from a 240VAC source.

Can someone recommend any module device?

Till now, I have been using the following device on my various applications:
RS PRO DIN Rail Power Supply, 85 → 264 V ac, 120 → 370 V dc ac, dc Input, 5V dc Output, 2.4A Output, 12W | RS (rs-online.com)

 

digikey
This link should work. There are 60 items selected. Several are PCB modules.
I selected AC to DC 5 to 5.1V current 1 to 1.5A.
I did not select "PCB".

 

You might want to use a safety agency approved 5V cell phone charger. They are very inexpensive and take care of safety issues.

 

This would a lead on adaptor. I need a simple module on a custom PCB

 

 

A lot this device also need external capacitors and protection circuits, while the din rail version has it all included, so looking for something similar

 

need external capacitors and protection circuits

Add them to the PCB.

 

Add them to the PCB.

This something I want to avoid, I want make it simple integration, Is this even a possibility?

 

your topic title literally tells "PCB" but if you are doing industrial automation and need components to be DIN rail mounted, then use industrial automation parts. an example is MDS-20-5 or one you had before.
https://www.meanwell-web.com/en-gb/ac-dc-industrial-din-rail-power-supply-output-5vdc-mdr--20--5

Otherwise get DIN rail mounting kits and included PCB place your power module, fuses, terminals etc.
An example of this is shown below and it will not get smaller or cheaper than PSU but - you can make it anything you like and therefore better for your application (several USB ports with different form factor etc.):

 

An example is:
View attachment 278258

Wago and Phoenix-Contact also make these DIN mountings, use your own PCB.

 

yup, there are many products of this sorts, even on Amazon including both open frame and boxed versions. ones that include PCB can be handy even if one does not plan to use that board. It could make it easy to try if one wants to see sample board that fits in with all cutouts/terminal /mounting options without waiting for custom PCB. just place components, check the fit, rinse and repeat until it works out and then solder.