SIEB & MEYER Power Supply Unit W PS10 · 2016-05-02 · 6 Power supply unit PS10 ... Mechanical...

Power Supply UnitPS10Hardware DescriptionArticle number 02173XX

P-TD-0000410.22016-05-02

SIEB & MEYERW

CopyrightTranslation of the original instructions, Copyright © 2016 SIEB & MEYER AG

All rights reserved.

This manual or extracts thereof may only be copied with the explicit authorization ofSIEB & MEYER AG.

TrademarksAll product, font and company names mentioned in this manual may be trademarks or registeredtrademarks of their respective companies.

SIEB & MEYER worldwideFor questions regarding our products and technical problems please contact us.

SIEB & MEYER AGAuf dem Schmaarkamp 2121339 LüneburgGermany

Phone: +49 4131 203 0Fax: +49 4131 203 [email protected]://www.sieb-meyer.de

SIEB & MEYER Shenzhen Trading Co. Ltd.Room 306, 3rd Floor, Building A1,Dongjiaotou Industrial Area, Houhai Dadao,Shekou, Nanshan District,Shenzhen City, 518067China

Phone: +86 755 2681 1417 / +86 755 2681 2487Fax: +86 755 2681 [email protected]://www.sieb-meyer.cn

SIEB & MEYER Asia Co. Ltd.4 Fl, No. 532, Sec. 1Min-Sheng N. RoadKwei-Shan Hsiang333 Tao-Yuan HsienTaiwan

Phone: +886 3 311 5560Fax: +886 3 322 [email protected]://www.sieb-meyer.com

SIEB & MEYER USA3975 Port Union RoadFairfield, OH 45014USA

Phone: +1 513 563 0860Fax: +1 513 563 [email protected]://www.sieb-meyer.com

W

2 Power Supply Unit PS10 - Hardware Description

mailto:[email protected]

http://www.sieb-meyer.de


http://www.sieb-meyer.cn


http://www.sieb-meyer.com


http://www.sieb-meyer.com

About this Manual 1

General Information 2

Safety Instructions 3

Unit Assembly Complying EMC 4

Functional Description 5

Power supply unit PS10 6

Connector Pin Assignment 7

LED Status Display 8

Integration in Drive Systems 9

Initial Operation 10

Maintenance 11

Appendix 12

Index 13

W Chapter Overview

Power Supply Unit PS10 - Hardware Description 3

Chapter Overview W


1 About this Manual ............................................................. 71.1 Illustration of Warnings ............................................................................... 71.2 Illustration of General Notices ..................................................................... 81.3 Technical Symbols ...................................................................................... 8

2 General Information .......................................................... 9

3 Safety Instructions ........................................................... 113.1 General Information .................................................................................. 113.2 Appropriate Use ........................................................................................ 123.3 Transport and Storage .............................................................................. 123.4 Installation ................................................................................................. 133.5 Electrical Connection ................................................................................ 143.6 Operation .................................................................................................. 153.7 Maintenance ............................................................................................. 163.8 Disposal .................................................................................................... 163.9 Legal Warranty .......................................................................................... 16

4 Unit Assembly Complying EMC ...................................... 17

5 Functional Description ..................................................... 19

6 Power supply unit PS10 .................................................. 216.1 Dimensions ............................................................................................... 226.2 Technical Data .......................................................................................... 246.3 Ballast Resistor ......................................................................................... 256.3.1 Dimensioning of the Ballast Resistor .................................................................... 25

7 Connector Pin Assignment .............................................. 297.1 POWER OK / POWER ON ....................................................................... 297.1.1 Schematic Diagram for POWER ON ..................................................................... 307.2 24 V Input .................................................................................................. 307.3 Main Power Supply L1, L2, L3 .................................................................. 307.4 DC Link Connection +600, −600 ............................................................... 31

8 LED Status Display ......................................................... 33

9 Integration in Drive Systems ........................................... 359.1 Accessories ............................................................................................... 39

10 Initial Operation ............................................................... 4110.1 General Information Regarding the Wiring ............................................... 4110.1.1 Mains Connection ................................................................................................. 4110.1.2 Cable Requirements ............................................................................................. 4110.2 Tips for a Trouble-free Operation .............................................................. 4310.3 Connection ................................................................................................ 43

11 Maintenance .................................................................... 4511.1 Fuses ........................................................................................................ 45

W Content


12 Appendix ......................................................................... 4712.A Manufacturers ........................................................................................... 4712.A.1 Connectors of the Series PS10 ............................................................................. 4712.A.2 EPCOS Line Filters ............................................................................................... 4712.A.3 Phoenix Contact .................................................................................................... 47

13 Index ............................................................................... 49

Content W


1 About this ManualThis chapter explains symbols, signal words and abbreviations possibly used in thismanual.

1.1 Illustration of WarningsDepending on their degree of risk, warnings are classified into different levels. In themanual, the different levels and types of dangers are represented as follows:

[1] Risk level (signal word/warning color)Classification of the risk

[2] Safety symbolRisk of injury

[3] Risk symbolGraphic representation of the source of risk

Risk levels

Risk Level Description

Indicates an imminently hazardous situation which, if not avoided, willresult in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, couldresult in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may resultin minor or moderate injury or property damage.

Indicates a hazardous situation which, if not avoided, may result in propertydamage.

Risk symbols

Risk symbol Description

General hazardous situation

Risk of injury due to electric shock

Risk of injury due to hot surfaces

W About this Manual


1

Risk symbol Description

Potentially risk of injury when working on machines with open covers/doors

Risk of injury due to flying objects

Destruction risk of electrostatically sensitive components

Risk of property damage

1.2 Illustration of General NoticesSymbol Description

Hint with additional, further information

Tip with suggestions and useful information

Terms and Definitions

Terms that are specifically explained in the manual are highlighted as underlined andgreen words.

All term definitions are to find in the glossary of the manual. In the PDF file a mouseclick on a highlighted term jumps directly to the according definition.

1.3 Technical SymbolsSymbol Description

LED indicator: LED on

LED indicator: LED off

LED indicator: LED flashes

About this Manual W


1

2 General InformationThis manual describes the power supply units of the series PS10. These devices areused to supply drive modules of the series FC71/FC72 and SD2 with voltage.

This manual provides information on:▶ Safety instructions and application advice▶ Category of electromagnetic compatibility▶ Functional Description▶ Views/dimensions▶ Technical data▶ Connector pin assignment▶ Initial operation▶ Status and error messages▶ Maintenance

This manual is available in German and English as PDF file, on CD ROM and asprinted version or it can be downloaded from the Internet. The PDF files can be printedon standard printers.

This manual has the following demands on the trained staff of machine manufacturers:

Transport: only by skilled employees familiar with handling electrostaticallysensitive components.

Installation: only by experts with electromechanical experience

Initial operation: only by experts with experience in the fields of electrical engi‐neering / drive technology

W General Information


2

General Information W


2

3 Safety InstructionsThese safety instructions contain important information for your safety. Readthem carefully and keep them for later use.

According to: ▶ Low-Voltage Directive 2014/35/EU▶ Machinery Directive 2006/42/EC▶ EMC Directive 2014/30/EU

3.1 General Information WARNING

Risk of serious injuries and material damage

Generally, the complete installation, the initial operation and the maintenance mustbe carried out by trained staff only.

Trained staff, according to this fundamental safety instruction, are persons familiarwith the installation, mounting, initial and permanent operation of the product andthey are qualified appropriately for the work. The standards DIN VDE 0100 andDIN VDE 0110 as well as the national accident prevention regulations shall beconsidered!

WARNINGRisk of burn due to hot surfaces

During operation the units can have hot surfaces according to their protectionsystem. When using ferrite rings temperatures may exceed 80°C in some cases.

Only use cables suitable for temperatures over 80 °C. This corresponds to theflammability rating UL 94V-0, RTI 105°C.

Consider the relevant notes in the manual.

DANGERMaterial may be damaged and persons be injured seriously:▶ when covers are removed illegally,▶ during any improper use,▶ when either the installation or the operation is incorrect

Consider the relevant notes in the manual.

WARNINGRisk of injuries and material damage due to illegal modifications

Only change the settings of the device after having contacted SIEB & MEYER.

W Safety Instructions


3

3.2 Appropriate UseTerms according to DIN EN 61800

Before initial operation, make sure that the machine will not expose danger (e.g.runaway moves). The conformity with the safety standards DIN EN 60204-1 and DINEN 61800-5-1 must be ensured.

The manufacturer of the system or the machine has to meet the requirements of thelegal values regarding the Electromagnetic Compatibility (EMC). SIEB & MEYER unitscan be operated in industrial areas, provided that the attached EMC information hasbeen taken into consideration.

SIEB & MEYER takes care in its own EMC laboratory over their products to meet therespective standards, when they are installed properly.

Deviations of the construction and the installation, described in the documentation andin the manual Unit Assembly Complying EMC require new measurements of thesystem or machine by the machine manufacturer to meet the statutory requirements.

The use in industrial areas under consideration of the EMC product standard (PDS)DIN EN 61800-3 is ensured by appropriate measures.

The use of line filters helps reaching the following:▶ Resistance to interference / immunity. The electronic system is protected against

high-frequency disturbances, possibly infiltrated via the mains cable.▶ Protection against radiation. High-frequency disturbances are reduced to legally

authorized measure. This prevents effects of the transients to adjacent compo‐nents or devices.

Products, not equipped with an integrated AC supply line filter must be operated with aseries connected external line filter. Detailed information can be found in the chapter"Unit Assembly Complying EMC".

If using the drive systems in residential areas, in business and commercial areas aswell as in small trade, the user has to take additional and larger filter measurements.

All SIEB & MEYER products meet the requirements of Low-Voltage Directive2014/35/EU. The harmonized standards of DIN EN 50178 and DIN EN 60204-1 incombination with the standards DIN EN 60947 and DIN EN 61800-5-1 are appliedconsequently.

Technical data and the connection specification can be found in the respective productdocuments.

3.3 Transport and StorageMake sure, that the unit is correctly used. The following points must especially betaken into consideration:▶ Protection against mechanical damage (transport, handling, etc.)!▶ Protection against dirt and humidity!▶ Protection against contact with electronic components (electrostatic discharge)!▶ No modification of insulating distances!

The following climatic conditions apply to the storage. If required, appropriate meas‐ures must be taken to ensure these climatic conditions (installation of heating/air condi‐tioning systems etc.):▶ The storage area must be clean (dust-free, if possible), dry and well-ventilated.▶ Storage in the open is not permitted.

Safety Instructions W


3

▶ The storage temperature must be in the range of -25 °C to +55 °C (-13 °F to+131 °F). Shortly it may be +70 °C (+158 °F).

▶ The relative humidity on the storage premises must be in the range of 5 % to 75 %(no bedewing).

▶ Sudden changes of the temperature or the humidity should be prevented.

The maximum storage period is 2 years. Electrolytic capacitors produce high leakagecurrents when a voltage is applied after a long storage period without applied voltageand must be reformed. For this, the operating voltage is applied via a 1 kΩ seriesresistor for one hour. Please contact the SIEB & MEYER service department fordetails.

3.4 Installation NOTICE

Damage of electrostatically sensitive components due to improper handling

Never touch electrostatically sensitive components!

Mechanical installation conditions for the system according to DIN EN 61800-2:

Vibrations must remain within the limit values of the IEC 60721-3-3, class 3M1,standard for fixed equipment.

Frequency [Hz] Amplitude [mm] Acceleration [m/s²]

2 ≤ f < 9 0,3 Not applicable

9 ≤ f < 200 Not applicable 1

Tab. 1: Vibration limits of the system

Vibrations which exceed these limits, or the use on mobile equipment, are consideredas abnormal mechanical conditions.

Operating conditions:

The following requirements are to be considered for the installation and the operationof the device. Noncompliance with theses requirements is regarded as abnormal oper‐ating condition:▶ The device is conceived according to DIN EN 61800-1 / DIN EN 50178 for the dirt

level 2.▶ The units can be loaded to their maximum up to a height of 1000 m above MSL

(3281 ft above MSL).For an operation in areas higher than 1000 m (3281 ft) above MSL the capacitymust be reduced by 15 % per 1000 m (3281 ft).

▶ The device must be protected against harmful gas, oil vapor and salty air at theplace of installation.

▶ The ambient air must not contain aggressive, grinding, electrically conductive orflammable substances as well as any amount of dust.

▶ The admissible relative humidity is between 5 % and 85 % (no bedewing).▶ The admissible ambient temperature during operation is +5 °C to +40 °C (+41 °F

to +104 °F). Extreme and sudden changes of the temperature should beprevented.



3

─ For devices that can be operated at ambient temperatures up to +60 °C(+140 °F) – see technical data – the output power must be reduced at temper‐atures above +40 °C. The following applies: -1.5 % per 1 °C. Note:F=C×9/5+32; C=(F-32)×5/9In addition, the service life of the device is probably reduced due to increasedwear of the components.

─ Devices with polyester film at the front panel: The polyester films must not beexposed to direct sunlight for extended periods of time. In conditions of highhumidity (>80 %) the ambient temperature must not exceed +40 °C (+104 °F).The polyester films must not come in contact with benzyl alcohol or methylenechloride.

▶ Make sure that the fans installed in the units have sufficient space to take in andexhaust the cooling air. In addition pay attention to the direction of air flow throughinternally installed fans.

3.5 Electrical Connection DANGER

Risk of serious injuries when working on energized devices

Consider the applicable accident prevention regulations.

DANGERRisk of serious injuries due to high currents

Incorrect or insufficient connection of the system to ground may cause dangerouscurrents.

Carry out all earthing measures as described in the manual.

The electrical installation must be carried out according to the relevant electrical codes(e.g. appropriate wire gauges, fuse protection and connections of ground conductorsmust be considered).

Connecting the device to an IT mains is only possible with isolating transformer.

Recommendations for the installation according to the EMC (e.g. shields, connection toearth and line installations) can be found in the technical documents of the unit (onlyfor machine manufacturers). The manufacturer of the system or machine has to meetthe requirements of the legislation regarding the EMC.

➮ All work at and within the units must only be carried out, when the units are turnedoff, the mains supply is cut and the DC bus is completely discharged.

➮ Consider that the mains supply must be protected via an overload release withrestricted guidance for each mains phase. The mains line should only beconnected, when the work is completed.

➮ Before turning on the unit the first time, make sure that the connected machine willnot have runaway axes!

➮ After turning off the unit hazardous voltages may still exist for up to 3 minutes inthe power supply (due to capacitors).

➮ Never connect capacitive loads to the output phases of the servo amplifiers andfrequency converters.



3

➮ Prevent cable loops. Therefore, the units must only be connected to earth at theprovided PE connection for the mains supply line and the racks only at theprovided earth screw.

DANGERConnection of the power supply unit

This product may cause touch current in the protective earthing conductor. Thecurrent in the protective earthing conductor can exceed 3.5 mA AC or 10 mA DC.

Pay attention to the local safety regulations for electric equipment with highleakage currents, in particular the minimum cross-section of the protective earthingconductor.

Generally, the product can be operated with a residual current device. Nevertheless,like all clocked units of the power electronics, also SIEB & MEYER products can leadleakage currents via the earth system. Due to the DC component in the leakagecurrent the protection of the residual current device could be reduced. Consequently,there might be no protection against direct touching or for technical equipment of theinstallation.

DANGERUsed residual current device/monitor

This product may cause direct current in the protective earthing conductor. If aresidual current device (RCD) or a residual current monitor (RCM) is used forprotection in the event of direct or indirect contact, only a type B (all current sensi‐tive) RCD/RCM is permitted on the current supply side of this product.

If a type B RCD/RCM is used at the product, all upstream connected RCDs/RCMsup to the supply transformer must be of type B as well.

Depending on the sensitivity of the residual current device and the installation type,consider the following points for the operation with residual current device:➮ Use the shortest connection and motor cables possible.➮ Do not connect additional consumers to the same residual current device.➮ Use residual current devices with high response threshold and time-lag response

time. Depending on the required protection class we recommend using short-timedelay or selective residual current device.

3.6 Operation WARNING

Risk of serious injuries due to moving machine parts

During the operation of an installation with open doors or removed covers, personsmay seriously be injured by moving machine parts.

Keep the doors closed during the operation and do not remove covers.



3

WARNINGRisk of injuries and material damage due to flying parts

Persons may be injured or material be damaged, if screws of the front panels andhousing parts are not fastened.

Before the initial operation of the installation ensure that all screws are tightened.

Systems, into which servo amplifiers and frequency converters are mounted, possiblymust be equipped with additional protective devices according to the valid safetyinstructions (e.g. law about technical material, rules for prevention of accidents, etc.).

3.7 MaintenanceThe unit must be checked regularly for cleanness and functionality depending on theambient pollution. This applies in particular for installed fans.

3.8 DisposalSIEB & MEYER products fulfill the requirements covered in the Directive 2002/95/ECon the restriction of the use of hazardous substances in electrical and electronic equip‐ment (RoHS Directive).

Make sure that the country-specific waste and disposal laws and statutes are consid‐ered for the disposal of packing material, used batteries and irreparable devices.

3.9 Legal WarrantySIEB & MEYER products are liable to a legal warranty of at least one year. Any claimsfor the products beyond this warranty shall be declared in an additional contractualagreement between SIEB & MEYER and the customer.

NOTICEDue diligence of the machine manufacturer

A first programming carried out by SIEB & MEYER does not release the machinemanufacturer from his duty to check the programmed values for correctness.



3

4 Unit Assembly Complying EMCThe EC guidelines must be considered for the initial operation of allSIEB & MEYER devices!

The manual "Unit Assembly Complying EMC" is available in German and English andincludes:▶ EMC rules▶ information regarding the professional grounding and wiring▶ safety-relevant aspects▶ extracts from the EMC product standard▶ possibilities for the connection to different supply system types

Availability:▶ hard copy version directly from SIEB & MEYER▶ PDF file on CD-ROM directly from SIEB & MEYER▶ PDF file in the internet under www.sieb-meyer.com

W Unit Assembly Complying EMC


4

http://www.sieb-meyer.de

Unit Assembly Complying EMC W


4

5 Functional DescriptionThe power supply units of series PS10 were developed especially for theSIEB & MEYER frequency converters of the series FC71/FC72. Design and powergrading are perfectly coordinated. In addition, the PS10 power supply units are usedwith the drive amplifiers of the series SD2.

All power supply units of this series are 3-phase full bridge rectifiers. The AC mainsvoltage (terminals L1, L2, L3) is rectified and supplied as DC voltage to the terminals+600, −600. This DC voltage directly depends on the amplitude of the connected ACvoltage (mains voltage).

If energy is returned to the power supply unit, it results in an increased DC voltage inthe so called DC link. If a default maximum value is exceeded, the returned energy canbe converted into heat with the help of power resistors (ballast resistors) in order tolimit the maximum value of the DC voltage. These ballast resistors are integrated intothe power supply unit by standard.

In order to reduce peak loads in the mains voltage supply, preloaded circuits (alsocalled "soft start") are integrated. If preloading was successful, the preloading circuitsare bridged by a main contactor.

The command POWER ON (terminal connection on the front panel) initiates thepreloading process. The mains voltage must be activated before the commandPOWER ON is triggered. If not, the power supply unit signals the error U.V. and thesoft start is cancelled. If the preloading process was finished successfully, themessage POWER OK is signaled via the same terminal connection. The signal for themessage POWER OK is connected with the drive module (FC71/FC72 or SD2). If anerror occurs and/or the command POWER ON is not set, the message POWER OK isdeleted. In this case, the main contactor disconnects the electronic device from themains. An error message (see chapter 8 "LED Status Display", page 33) can bereset with the positive edge of the command POWER ON.

If the preloading process is repeated in regular time intervals, a waiting timeof 12 s between two preloading processes is required. Up to 5 preloadingprocesses can be executed within 15 s, if a waiting time of 60 s follows.

The LEDs integrated in the front panel indicate the current status and errors (ifpresent). When the module is ready for operation, only the LEDs 24V and EN are on.

The logic and the internal fans of the power supply unit are supplied with 24 V DC byan external voltage source. This voltage is connected to the terminals 24V-INPUT (+)and 24V-GND (−).

Every power supply unit of series PS10 is internally protected by fuses (quick-acting,for semiconductor protection).

W Functional Description


5

Functional Description W


5

6 Power supply unit PS10

Fig. 1: Device view PS10

W Power supply unit PS10


6

6.1 Dimensions

Fig. 2: Module dimensions

Devicevariant

Width [mm] Height [mm] Depth [mm]

A B C C1(1) D D1(1)

PS10/13 100

440 480 about 550 260 about 330

PS10/30150

PS10/55

PS10/100300

PS10/150(1) Module dimensions including connectors, terminals and cables

NOTICERestriction of cooling air flow

The device is convection ventilated. If the circulation of air is restricted, the devicecould overheat and possibly become damaged.

When you install the device, make sure that the air inlets and outlets are kept freeand the air circulation is not obstructed by other devices.

Power supply unit PS10 W


6

Fig. 3: Dimensions of the mounting holes

The mounting holes are suitable for M5 and M6 bolts.

Device variantModule width [mm] Width [mm]

A B C D

PS10/13 100

466 25

75

PS10/30150 125

PS10/55

PS10/100300 275

PS10/150



6

6.2 Technical Data

Device variant PS10/13 PS10/30 PS10/55 PS10/100 PS10/150

Article number 0217311 0217321 0217331 0217341 0217351

Mains voltage 400 VAC −10 % to 480 VAC +10 %

50/60 Hz

Power(1) [kW] S1(2) 11.4 26.4 48 86.4 120

S6(3) 14.4 32.4 60 100.5 130.2

Peak(4) 16.8 42 69 100.5 130.2

Output Current(1) [ADC] S1(2) 20.4 47.1 85.7 154.3 214

S6(3) 25.7 57.9 107.1 179.5 232.5

Peak(4) 30 75 123.2 179.5 232.5

Capacity of DC link(1) [µF] Internal 330 660 990 1980 2970

Ext. min 330 495 990 1485 2475

Ext. max 660 1320 1485 3630 3630

Logic supply(external)

Voltage [V] 24

Current [A] 0.3 0.5 0.5 1 1

Rated power ballast resistor [W] 250 500 500 1000 1000

Pulse power ballast resistor(5) [kW] 17 34 34 68 68

Efficiency(6) ca. 0.99

Ambient temperature range 5 °C to 40 °C at a maximum relative humidity (without moisture condensation) of85 %

Cooling(7) Air

Weight [kg] 6.7 10 11 23 23.8

Module width [mm] 100 150 150 300 300

(1) Calculated for a mains voltage of 400 VAC and a resultant DC voltage of 560 VDC.(2) S1 = continuous load with S1 values(3) S6 = load alternates between 72 s of S6 values (load) and 48 s of 40 % of S6 values (open-circuit opera‐tion):

(4) The peak values are admissible for a maximum time period of 10 s.(5) If the pulse power is required in regular time intervals for a maximum time period of 1 s, a break of 180 smust be ensured. If the pulse power is required in shorter time intervals (e.g. 3 × in 20 s), you must extendthe break accordingly.(6) At rated power (S1)(7) To ensure sufficient air supply, a free space of at least 150 mm must be provided below the module (inletof the air) and above the module (outlet of the air).



6

6.3 Ballast ResistorAll power supply units of the series PS10 come with internal ballast resistors. Theseresistors are required when energy is fed back into the drive (and then into the powersupply unit) during deceleration.

The returned energy is greater,▶ the faster the motor is decelerated.▶ the greater the moment of inertia of the rotating parts (shaft, rotor and tool) is.▶ the greater the speed is at which the deceleration is started.

Besides, the frequency of motor deceleration processes during a certain time period(cycle time or chip-to-chip time) must be considered. Without any measures to limit thereturned energy, the voltage in the DC link increases rapidly. Inevitably, the highvoltage causes damage to the components (transistors, diodes, capacitors, etc.).

WARNINGHot surfaces

The ballast resistors are located on the rear side of the module and can reachtemperatures of more than approx. 150 °C during operation.

The modules are only to be mounted on mounting walls appropriate for suchtemperatures.

Ensure protection against contact for the ballast resistors.If you use PS10 power supply units with the frequency converter modules FC71/FC72, touching the ballast resistors is not possible under the following conditions:▶ The power supply units are mounted directly on the left side of the frequency

converters FC71/FC72.▶ The mounting wall is closed in the part the module is to be mounted.

The following table indicates the braking power (Pr) of the respective power module:Device variant Rated power Pulse power(1)

PS10/13 250 W 17 kW

PS10/30 500 W 34 kW

PS10/55 500 W 34 kW

PS10/100 1000 W 68 kW

PS10/150 1000 W 68 kW(1) If the pulse power is required in regular time intervals for a maximum time period of 1 s, a break of 180 smust be ensured. If the pulse power is required in shorter time intervals (e.g. 3 × in 20 s), you must extendthe break accordingly.

In high dynamical applications with high energy flow, the capacity of the integratedballast resistors might not be sufficient. This problem could be solved by using a powersupply unit capable of feeding energy back into the mains.

SIEB & MEYER can provide a suitable solution.

6.3.1 Dimensioning of the Ballast ResistorThis chapter describes how to check, whether the existing ballast resistor is sufficientfor the drive.



6

Many data for the ballast resistor mentioned above may vary or may not have beenspecified when dimensioning the drive. Nevertheless, the following two examples,which frequently occur in practice, will make a pre-calculation possible for the user.

The following data are specified in most cases:▶ characteristic curve for power as a function of the speed▶ specification of the rated current▶ specifications or experimental values of possible deceleration time intervals at

rated current

Assumption:

The motor is decelerated at rated current. For this reason, a speed-dependent power isreturned to the drive. This power must be diminished by the efficiency (η) of the motor.

Example 1: linear performance curve

Fig. 4: linear characteristic curve

Pn Rated power of the motorPmax Maximum returned power diminished by the efficiency of the motorPr Rated power of the ballast resistorPb Real braking powern Speedtb Deceleration timetp Interruption timeη Efficiency of the motor

Pmax = Pn × η Pr > Pb Pb = Pmax / 2 × tb / (tb + tp)

Example: Pn =10 kW, Pr = 250 W, tb = 4 s (at rated current), tp = 90 s, η = 0.9

Pmax = 10 kW × 0.9 = 9 kW

Pb = 9 kW / 2 × 4 s / (4 s + 90 s) = 191.5 W

Condition Pr > Pb fulfilled.



6

Example 2: performance curve with field weakening

Fig. 5: Characteristic curve with field weakening

Pn Rated power of the motorPmax Maximum returned power diminished by the efficiency of the motorPr Rated power of the ballast resistorPb Real braking powern Speedtb Deceleration timetp Interruption timettotal Cycle timeη Efficiency of the motor

Pmax = Pn × η Pr > Pb Pb = Pmax / 2 x tb2 / (ttotal) + Pmax × tb1 / (ttotal)

Example: Pn =10 kW, Pr = 250 W, tb1 = 2 s, tb2 = 2 s, tp = 90 s, η = 0.9

Pmax = 10 kW × 0.9 = 9 kW

ttotal = tb1 + tb2 + tp = 94 s

Pb = 9 kW / 2 × 2 s / 94 s + 9 kW × 2 s / 94 s = 287 W

Condition Pr > Pb is not fulfilled.

Possible Solution: Extended interruption time (tp) and/or deceleration time.



6



6

7 Connector Pin Assignment

7.1 POWER OK / POWER ON This terminal bar allows connecting the status message (POWER OK) and the startsignal (POWER ON). The message (POWER OK) is designed as a relay contact. Thestart signal (POWER ON) is electrically isolated by means of an optocoupler input.Error messages (if present) can be reset with the positive edge of the commandPOWER ON. The preloading process is not initiated or is interrupted, if the cause ofthe error has not been eliminated. In addition, the respective LED for indicating theerror is on.

4-pole Combicon connector, suitable for mating connector MSTB 2,5/ 4-ST-5,08(Phoenix)

Mating connector Pin I/O Name Meaning

4 O POWER OK (+) Relay contact: NO contact(1)

If the power unit is ready for operation,this pin is internally connected to pin 3.Connect this output to the input of theFC71/FC72 modules with the same nameor to connector X1 of the SD2 module.

3 O POWER OK (−) Relay contact: NO contact(1)

When the power supply unit is ready foroperation, this pin is internally connectedto pin 4.Connect this output to the input of theFC71/FC72 modules with the same nameor to connector X1 of the SD2 module.

2 I POWER ON (+) Anode connector of the optocoupler diodeImax = 11 mA at 24 V

1 I POWER ON (−) Cathode connector of the optocouplerdiodeImax = 11 mA at 24 V

(1) The following applies to the relay contacts: 1 ADC / 24 VDC

Specification of terminal connections▶ Conductor cross-section solid/stranded: 0.2 – 2.5 mm²▶ Tightening torque: 0.5 – 0.6 Nm

W Connector Pin Assignment


7

7.1.1 Schematic Diagram for POWER ON

If the preloading process is repeated in regular time intervals, a waiting timeof 12 s between two preloading processes is required. Up to 5 preloadingprocesses can also be executed within 15 s, if a waiting time of 60 s isaccepted afterwards.

7.2 24 V Input The logic and the internal fans of the power supply unit are supplied by an external24 V DC voltage source. This voltage is to be connected to the terminals 24V-INPUT(+) and 24V-GND (−).

2-pole Combicon connector, suitable for mating connector MSTB 2,5/ 4-ST-5,08(Phoenix)

Mating connector Pin I/O Name Meaning

2 I 24V‑INPUT (+) External voltage supply: +24 V (currentconsumption → see Technical Data,page 24)

1 I 24V-GND (−) External voltage supply: ground (currentconsumption → see Technical Data,page 24)

NOTICEWrong polarity

Ensure correct polarity of the cables. Interchanging the phases causes a shortcircuit and corresponding damage to the device.

Specification of terminal connections▶ Conductor cross-section solid/stranded: 0.2 – 2.5 mm²▶ Tightening torque: 0.5 – 0.6 Nm

7.3 Main Power Supply L1, L2, L3 These power terminals serve for connecting the mains phases.

Connector Pin Assignment W


7

3 lead-through terminals (Phoenix)Name Meaning

L1 Main supply

L2 Main supply

L3 Main supply

The following table lists the conductor cross sections suited to the terminals:Device variant Terminal type Conductor cross-section [mm²] Tightening torque

[Nm]Solid Stranded

PS10/13 UW 16/S 6 – 25 6 – 16 2 – 2.3

PS10/30 UW 25/S 16 – 35 16 – 25 4 – 4.5

PS10/55 UW 25/S 25 – 35 25 4 – 4.5

PS10/100 HDFK 95-F-VP 50 – 95 50 – 95 15 – 20

PS10/150 HDFK 95-F-VP 70 – 95 70 – 95 15 – 20

7.4 DC Link Connection +600, −600 These power terminals are provided for connecting the DC link voltage (600 VDC).Connect these terminals to the terminals of the FC71/FC72 modules with the samename or to connector X20 of the SD2 module.

2 lead-through terminals (Phoenix)Name Meaning

+600 DC link voltage +600 VDC

−600 DC link voltage −600 VDC

NOTICEWrong polarity

Ensure correct polarity of the cables. Interchanging the phases causes a shortcircuit and corresponding damage to the device.

The following table lists the conductor cross sections suited to the terminals:Device variant Terminal type Conductor cross-section [mm²] Tightening torque

[Nm]Solid Stranded

PS10/13 UW 16/S 6 – 25 6 – 16 2 – 2.3

PS10/30 UW 25/S 16 – 35 16 – 25 4 – 4.5

PS10/55 UW 25/S 25 – 35 25 4 – 4.5

PS10/100 HDFK 95-F-VP 50 – 95 50 – 95 15 – 20

PS10/150 HDFK 95-F-VP 70 – 95 70 – 95 15 – 20

W Connector Pin Assignment


7

Connector Pin Assignment W


7

8 LED Status Display The 6 LEDs integrated in the front panel indicate the current device status and errors(if present).

When the module is ready for operation, only the LEDs 24V and EN are on.

The following table describes the different LED states:

LED Status Meaning Possible error cause

TEMP. Red The power electronics and/orballast circuit became too hot.

▶ The power electronics and/or ballast circuitis/are overloaded (possible remedy byreducing the load and/or extending the decel‐eration time of the motor connected to thedrive module).

▶ The ambient temperature is too high.▶ The ventilation is not sufficient.

ERR. DC. Red The preloading process was notsuccessful.

▶ The capacitive load at the terminals +/−600 istoo high.

▶ A short circuit occurred at the terminals +/−600.

▶ A load was connected to the DC link during thepreloading process (LED EN was not on yet),e.g. because the motor or the drive modulewas activated too early.

O.V. Red An overvoltage has been detected. ▶ At least for a short time the mains voltage wastoo high.

▶ The ballast circuit cannot consume thereturned energy completely (possible remedyby extending the deceleration time of the motorconnected to the drive module).

U.V. Red An undervoltage has beendetected.

▶ At least for a short time the mains voltage wastoo low.

24V Green The 24 V operating voltage issupplied.

–

EN Yellow The preloading process wassuccessful and the power supplyunit signals POWER OK.

–

W LED Status Display


8

LED Status Display W


8

9 Integration in Drive SystemsA working drive combination consists of the following components:▶ Power supply unit PS10/XXX

(XXX indicates the performance range.)▶ Drive module of series FC71/FC72 or SD2▶ External 24 VDC voltage supply to supply the electronics with the required auxiliary

voltages, current consumption of the power supply units max. 2 AUsually, each switch cabinet provides a sufficient voltage supply of 24 VDC.

▶ Cooling system for water-cooling of the output stage heat sink (if available)▶ Control system (CNC, PC or remote control) to control the required functions▶ Line filter (if required)

There are no additional filters integrated into the power supply units of seriesPS10. In most of the industrial installations, either no additional filtering is neces‐sary or filters are already integrated (e.g. a common main filter for all componentsof the switch cabinet). Nevertheless, if an additional filter is necessary, a three-phase line filter (without neutral connection) should be used. Filter effect, mainsvoltage and current load must be calculated according to the conditions of theplace of installation.

▶ Accessories, for example motor chokes, motor filters, line filters or peripheraldevices for water-cooling

The following figures show the connection between the power supply unit PS10 andthe different drive modules.

Read the manual of the used drive module as well.

W Integration in Drive Systems


Connection example PS10 and FC71


Connection example PS10 and FC72


Connection example PS10 and SD2


Wiring PS10 and SD2: 24 V logic voltage and power supply status

PS10Connector POWER OK / POWER ON Meaning

SD2Connector X1

Terminal Pin I/O I/O Pin Terminal

4 O 24 V supply I 4

3 O Power supply status I 1

I 2

2 I POWER ON of e.g. PLC —

1 I/O GND I/O 3

Consider that an SD2 in connection with a PS10 does not receive the sameerror evaluation of the power supply unit as with a PS2.

9.1 AccessoriesSIEB & MEYER can help you to find suppliers for the required peripheral devices aswell as deliver appropriate products on demand. These are:▶ Line filters▶ 24 V supply units▶ Cooling systems▶ Mobile mounting walls (e.g. for test installations)▶ Jointing elements (for electronic and mechanical components)

Possibly required motor chokes and motor filters can be exactly calculated bySIEB & MEYER. Thus, power losses due to mismatching can be prevented or mini‐mized. We offer this service from the tender phase and we are able to give you infor‐mation on the efficiency of every combination by means of a special calculation soft‐ware.

W


8

W


8

10 Initial OperationThe following sections provide information on the connection and the operation of thedevice.

When connecting and setting up the installation consider the safety instruc‐tions and the manual "Unit Assembly Complying EMC".

10.1 General Information Regarding the Wiring

10.1.1 Mains Connection

NOTICEProperty damage due to incorrect mains connection

Direct connection to ungrounded / asymmetrically grounded mains (IT mains withstart point / IT delta mains) can destroy the devices.

Connecting the device to this mains type is only possible with isolating transformer.

Also consider the manual "Unit Assembly Complying to EMC", chapter "Connec‐tion to Different Supply System Types".

10.1.2 Cable RequirementsThe cables described in this chapter meet the SIEB & MEYER requirements to cablesand connectors in order to ensure their proper function.

NOTICERisk of cable damage due to mechanical loads

Cables that are exposed to mechanical loads, e.g. trailing chains or similar, mustbe suited for this purpose. Otherwise, damage may occur. SIEB & MEYER cablesare not suitable for trailing chains!

The machine manufacturer must ensure that only cables are used that are suitablefor this purpose.

In general, the following principles apply for the cables (see also documentation "UnitAssembly Complying EMC")▶ Motor and signal cables must not be wired in the same cable protection hose!▶ Motor cables must have a wire-meshed shield. They must be wired separately

from signal cables.▶ Signal lines must have a wire-meshed shield. Differential signals should only be

transmitted with twisted-pair lines. They must be wired separately from motorcables.

▶ The cable shields must be connected to the connector shell inside of the connec‐tors. In the switch cabinet they should be connected to a ground bus.

W Initial Operation


10

▶ Cable shields not ending in a connector inside of the switch cabinet such as motorcables must be connected to the ground bus.

▶ Both ends of the shield of shielded cables must generally be connected to theshell.

The line cross-sections should be selected carefully: The maximum admissible currentshould not be exceeded at the maximum ambient temperature (see technical data).DIN EN 60204-1 defines the admissible values for the individual line cross-sectionswhich must absolutely be taken into account.

The current carrying capacity in connection with the line cross-section of copperconductors isolated with PVC or cables according to DIN EN 60204-1 for wiring typeB2 and an ambient temperature of +40°C are indicated in the following table:

Conductor cross-section A [mm²] Admissible current I [A]

0.75 7.60

1.00 9.60

1.50 12.20

2.50 16.50

4.00 23.00

6.00 29.00

10.00 40.00

16.00 53.00

25.00 67.00

35.00 83.00

The following correction factors are provided for deviating ambient temperatures:Ambient temperature T [°C] Correction factor

30 1.15

35 1.08

40 1.00

45 0.91

50 0.82

55 0.71

60 0.58

Cross-sections of round conductors

The standard values of the cross-section of round copper conductors as well as theapproximate ratio of metric ISO and AWG/MCM values are shown in the followingtable.

Standardized cross-sections of round conductors:ISO cross-section [mm²] AWG/MCM

Value Equivalent cross-section [mm²]

0.2 24 0.205

– 22 0.324

0.5 20 0.519

0.75 18 0.82

1.0 – –

1.5 16 1.3

2.5 14 2.1

4.0 12 3.3

Initial Operation W


10

ISO cross-section [mm²] AWG/MCM

Value Equivalent cross-section [mm²]

6.0 10 5.3

10 8 8.4

16 6 13.3

25 4 21.2

35 2 33.6

50 0 53.5

70 00 67.4

95 000 85.0

– 0000 107.2

120 250 MCM 127

150 300 MCM 152

185 350 MCM 177

240 500 MCM 253

300 600 MCM 304

The line corresponds to a value when the connection possibilities are takeninto account.

10.2 Tips for a Trouble-free Operation➮ Take care that the cables to be connected are as short as possible.➮ Adapt the line cross-section to the rated current and the wiring.➮ Connect the different components of the switch cabinet by star connection to one

common ground point (ground bar).➮ Wire power lines and sensor or logic lines in separately arranged cable channels.➮ If a line filter is added, it should be mounted as close as possible to the power

supply unit. The line filter and the power supply unit should be connected to earthwith the largest surface via a conductive material (e.g. mounting wall). Not conduc‐tive material as lacquer or anodic coating must be removed completely at themounting points.

➮ Ensure sufficient air supply. A free space of at least 150 mm must be providedbelow the module (inlet of the air) and above the module (outlet of the air).

10.3 ConnectionBefore starting the connection works, ensure that the power supply unit is mountedfirmly and securely.

In particular, consider the following points during wiring the device according to thedifferent connection possibilities:

W Initial Operation


10

WARNINGElectric shock due to energized supply lines

Make sure that the supply lines are de-energized during connection of the device.

➮ Switch a possibly existing main switch into the 0 position.➮ Ground the module using the common ground point of the installation or of the

switch cabinet.➮ Connect the terminal/screw connections POWER OK and POWER ON with the

corresponding terminals of the drive module and the control system.➮ Connect the external 24 V logic supply to the terminal/screw connections

24V‑INPUT and 24V‑GND.➮ Establish the DC link connections +600 VDC and −600 VDC between the drive

module and the power supply unit.➮ Establish the connection with the mains supply L1, L2, L3.➮ After a careful installation you can activate the 24 V logic supply. If successful, the

green LED 24V is on.➮ Activate the main supply.

Setting the input POWER ON starts the preloading process. After successfulpreloading the main contactor is activated and the yellow LED EN is on. If preloading isnot finished successfully, one of the red LEDs TEMP., ERR. DC., O.V. or U.V. is onsignaling an error message. If an error is indicated, please recheck all connections.Also refer to chapter 8 "LED Status Display", page 33.

Initial Operation W


10

11 Maintenance

11.1 FusesAll power supply units of the series PS10 are equipped with meltable fuses. In order tocheck or replace these fuses, the front panel must be removed.

DANGERHigh voltages in the DC link

Before working at the device you must disconnect all dangerous voltages from thedevice.

Wait until the discharge time of the of the DC link capacities has expired. It islonger than 3 minutes.

3 fuses are mounted in the lower part of the module to protect the power supply unit onthe mains side. These components are very quick-acting fuses for semiconductorprotection.

Depending on the device variant the following fuses are used:Devicevariant

Fuses Type Supplier

PS10/13 3 × 32 A FWP-32A22F, clip mounting Gemballa Electronics (or others)

PS10/30 3 × 63 A FWP-63A22F, clip mounting Gemballa Electronics (or others)

PS10/55 3 × 100 A FWP‑100A22F, clip mounting Gemballa Electronics (or others)

PS10/100 3 × 200 A 3NE8 725, screw mounting Siemens, Sitor (or others)

PS10/150 3 × 250 A 3NE8 727, screw mounting Siemens, Sitor (or others)

In addition, a small, standard fine fuse (IEC 127) with 1 A / semi time-lag is mountedon the PCB. It is located in the upper part on the right.

W Maintenance


11

Maintenance W


11

12 Appendix

12.A Manufacturers

12.A.1 Connectors of the Series PS10SIEB & MEYER article number Description

322 99 558 Connector kit with mating connectors for the terminals POWER OK /POWER ON and 24V-INPUT / 24V-GND by Phoenix

12.A.2 EPCOS Line Filters▶ 1- and 3-phase line filters▶ high attenuation▶ partial RCD compatibility

The maximum current (Imax) must be adapted to the back-up fuses of thedevice.

When such a line filter is used, very high leakage currents arise, becauseCy > 1.5 μF. For this reason it is only partially compatible with an RCD(residual current protective device).

You can order the suitable EPCOS line filter for your device at SIEB & MEYER by itsindividual article number:SIEB & MEYER articlenumber

EPCOS article number Rated voltage (Urated) Rated current(Irated)

Leakagecurrent (Ileak)

35063105 B84143A0016R105 520 / 300 V 16 A 15 mA

35063103 B84143A0050R105 520 / 300 V 50 A 15 mA

35063106 B84143A0090R105 520 / 300 V 90 A 18 mA

12.A.3 Phoenix Contacthttp://www.phoenixcontact.com

W Appendix


12.A

http://www.phoenixcontact.com

Order key for Phoenix connectors

Labeled connectors can be ordered at SIEB & MEYER.

Appendix W


12.A

13 Index0-924V-GND (−) 3024V-INPUT (+) 30600 VDC 31

AAccessories 39 , 47

BBallast resistor 25

dimensioning 25

CCable requirements 41Connection exampleFC71 36Connection exampleFC72 37Connection exampleSD2 38Connector kit 47

DDC link 31Device view 21Dimensions 22Drive combinations 35

EError messages 33

FFC71 connection example 36FC72 connection example 37Fuses 45

IInitial operation 41

LL1, L2, L3 30LED status display 33Line cross-sections 42Logic supply 30

MMains phases 30Maintenance 45Manufacturers 47Mounting 22

PPOWER OK 29POWER ON 29 , 30Power supply 30

SSD2 connection example 38

TTechnical data 24

WWiring instructions 41

W Index


13

Date post:	18-Jun-2018
Category:	Documents
Upload:	duongque
View:	223 times
Download:	0 times

SIEB & MEYER Power Supply Unit W PS10 · 2016-05-02 · 6 Power supply unit PS10 ... Mechanical...

Documents