Home

User Manual SYS POWER SUPPLY UM E

1. 4 4 4 4 Installation in Distributed Control Cabinets ceceeeeeeeeeeteeeeeeeeeneeeneeeeeeeeeees 4 4 4 5 Applications in Building Services Automation Facility Management 4 5 4 6 Outlook ein Sia ei ee ee eee ES 4 6 PIGCUEKOVORVIGW en ne E anne een Eee een 5 1 Ar APBENIICES nee RR IRRE NR NG eh aia Nets ash Navan A 1 A1 List OF FIQUIOS 6525 a a a a A 1 A2 Explanation of Abbreviations nnerssnnernnnnenennnnennnnennnnnn nennen nennen ernennen rn A 5 A3 Nds enter Det re errmer a terete tron eres A 9 PHOENIX CONTACT 5598 _en_03 General 1 General Power supply units have a great influence on the availability and operational safety of elec trical systems Therefore the power supply unit should be chosen as carefully as all the other system components In the field of automation technology the innovation cycles are getting shorter and shorter For this reason the system planner must concentrate on the major tasks Universal power supply units must therefore meet all the demands required This reduces work for the plan ner and increases electrical system reliability at the same time This manual will help you choose the right power supply unit for your needs The Basics section provides information on the different types of power supply units The following sections are intended to answer frequently asked questions which arise when working with power supply units and he
2. 2 to 3x In approx 1 1 to 1 5 x In approx U I characteristic no switch off Field of application Electromechanical engineering Highly sensitive analog technology Universally applicable 4 2 PHOENIX CONTACT 5598 _en_03 Selecting a Power Supply Unit 4 1 Supplying Electromechanical Components Phoenix Contact generally recommends using enclosed devices for industrial applications because they ensure particularly high protection of persons and systems A regulated output voltage is not generally required for supplying electromechanical components such as valves relays or electromagnetic switches It is therefore sufficient to use an unregulated power supply unit for this If additionally reduced space requirement and high efficiency are demanded Phoenix Contact recommends using primary switched mode power supply units 4 2 Supplying Electronic Modules and Systems Open frame devices are often used for supplying devices inside an existing housing 19 slide in modules are most common for this For safety reasons the use of enclosed devices is recommended in control cabinets The use of regulated power supply units providing a stable 24 V DC output voltage independent of input voltage fluctuations and the connected load has proved to be effective for supplying electronic modules and systems In recent years the technical development of electronic components has lead to primary sw
3. 5A 25 A 5A 9 5A 9 5598D022 Figure 3 4 Example with 25 A load Solution A single 20 A device cannot supply this load with electrical energy on its own In order to avoid increased investment costs for a 40 A power supply unit a second 20 A power supply unit is connected in parallel to the existing 20 A power supply unit This makes 40 A output current available to supply the total load of 38 A 5 A 25 A 8 A Power supply units of the same type QUINT POWER MINI POWER and IEY STEP POWER can be connected in parallel for increasing power 3 4 PHOENIX CONTACT 5598_en_03 Useful Information from Everyday Practice Tips for Implementation Power supply unit 1 OO Oo 24V DC Power supply unit 2 O O Olavoe Load 5598D009 Figure 3 5 Correct parallel connection in the secondary circuit All cable connections must have the same length and the same cross section from the power supply unit to the busbar 5598_en_03 PHOENIX CONTACT 3 5 SYS POWER SUPPLY UM E Uniform current distribution The devices must never be connected as shown in Figure 3 6 Otherwise the connection terminals might be overloaded All devices with COMBICON connections must only carry a load of 20 A on each terminal point Power supply unit 1 Power supply unit 2 5598D010 Figure 3 6 In
4. 21 48 14 64 19 14 20 m 66 ft 22 83 27 33 21 66 26 16 19 32 23 82 14 64 19 14 9 96 14 46 5 29 9 79 30 m 98 ft 22 25 26 75 20 49 24 99 16 98 21 48 9 96 14 46 2 95 7 45 0 00 0 43 40 m 131 ft 21 66 26 16 19 32 23 82 14 64 19 14 5 29 9 79 0 00 0 43 0 00 0 00 50 m 164 ft 21 08 25 58 18 15 22 65 12 30 16 80 0 61 5 11 0 00 0 00 0 00 0 00 60 m 197 ft 20 49 24 99 16 98 21 48 9 96 1446 0 00 0 43 0 00 0 00 0 00 0 00 Table 3 6 On load voltage U as a function of the output current I and the cable length 1 for copper cables with a cross section of 2 5 mm 14 AWG il I 2 5A 5A 10A 20A 30 A 40A Om 24 0V 28 5 V 24 0V 28 5 V 24 0V 28 5 V 24 0V 28 5 V 24 0V 28 5 V 24 0V 28 5 V 10 m 33 ft 23 65 28 15 23 30 27 80 22 60 27 10 21 19 25 69 19 79 24 29 18 39 22 89 20 m 66 ft 23 30 27 80 22 60 27 10 21 19 25 69 18 39 22 89 15 58 20 08 12 77 17 27 30 m 98 ft 22 95 27 45 21 89 26 39 19 79 24 29 15 58 20 08 11 37 15 87 7 16 11 66 40 m 131 ft 22 60 27 10 21 19 25 69 18 39 22 89 12 77 17 27 7 16 11 66 1 54 6 04 50 m 164 ft 22 25 26 75 20 49 24 99 16 98 21 48 9 96 1446 2 95 745 0 00 0 43 60 m 197 ft 21 89 26 39 19 79 24 29 15 58 2
5. 5598 _en_03 PHOENIX CONTACT A 7 SYS POWER SUPPLY UM E Power boost 2uuuusssssssnnnnnennnenneeeeeen 3 16 3 39 3 42 Power distribution 244s4m44Bn nennen nenn nennen ernennen 3 1 Power factor correction usssssenersnnneennnnnennnnnn ernennen 3 52 Power e e VO erer annaa ra deurei iaa 3 39 3 42 Primary switched mode controller seeen 2 12 Protective earth ground uuesersnennsennnnnennennnnnnen nen 2 5 Push pull converter unessnersnnnersnnnernnnnn nennen ernennen 2 14 R Reactive power nnnnnnnensnnnnennnnennnnnnnnnnnennannen non 3 48 Reallpower u u u0sne leisen 3 48 ROCUACANCY iss ci sdesececia tadesenhasgeedeviaids AEE A aaa 3 1 Regulation types uuusnsnnnnesnnnnennnnnnennnnnn nennen nnnnn nn 2 10 S Ssafe lsolationi un rue see 2 6 Safety extra low voltage 2 20u00440ennnnnnnnnnennnnnn 2 6 Selective protection un22urnsennnnnnnnnnnennnnnnnnn nen 3 28 SELVA Rn 2 6 Shock ae eek 2 1 Shock protection ine naa a aE Aaina 2 1 Short circuit current unesenssensnennnnnnnneennnnnnnennnnnn nn 3 29 Single ended CONVETTEL eeeeseteeeeeeseeetteeeeeeetees 2 14 Starting behavior u euenseerssennnnnnsnnennnnnnnnnnnnn nen 3 38 T Transport conditions u 222sssrsnnne rennen nenne nennen nenn 2 1 V Vibration een 2 1 Voltage doubling uu 224srsnnen nenne rennen ernennen nenn 3 11 W Water protection usrresenen nennen nnnn
6. ED Kenne O CD OOE INSPIRING INNOVATIONS INTERFACE User Manual SYS POWER SUPPLY UM E Order No 27 45 855 Power Supply Units Z O A a wi r N gt Qa gt S lt INTERFACE User Manual Power Supply Units 07 2005 Designation SYS POWER SUPPLY UME Revision 03 Order No 27 45 855 This manual is valid for All power supply units of the types QUINT POWER MINI POWER and STEP POWER 5598_en_03 PHOENIX CONTACT SYS POWER SUPPLY UM E a D Please Observe the Following Notes In order to guarantee the safe use of the product described please read this manual care fully The following notes give you information on how to use this manual Qualifications of the User Group The product usage described in this manual is exclusively aimed at electricians or person nel trained by electricians who are familiar with the valid national standards and other reg ulations on electrotechnology in particular the pertinent safety concepts Phoenix Contact assumes no liability for damage to any products resulting from disregard of information contained in this manual Explanation of Symbols Used The attention symbol refers to an operating procedure which if not carefully followed could result in damage to equipment or personal injury The note symbol informs you of conditions that must strictly be observed to achieve error free operation It also gives
7. 1 0 0022 3 399 2 V 3 34 PHOENIX CONTACT 5598_en_03 Useful Information from Everyday Practice ElectroMagnetic Compatibility Table 3 12 Major standards 3 11 Questions on EMC The major EMC standards ElectroMagnetic Compatibility for EU conformity of compact power supply units are listed in the following table In general power supply units which are provided with the CE conformity mark must not interfere with other devices in an unauthorized manner and must not be interfered with in their function in an unauthorized manner by other devices Noise emission is described in the European standard EN 61000 6 3 noise immunity is defined in EN 61000 6 2 Noise emission is divided into two classes domestic sector Part 1 and industrial sector Part 2 The domestic sector comprises all loads which are connected to the public medium voltage transformer The industrial sector comprises all loads which are connected to the non public medium voltage transformer Part 1 Domestic Office and Part 2 Industrial Sector Commercial Sector Noise Emission According to EN 61000 6 3 fluctuations flicker Housing EN 60715 Class B EN 55011 Class A AC line supply current EN 60715 Class B EN 55011 Class A Limit values for harmonic currents EN 61000 3 2 Limit values for voltage EN 61000 3 3 Noise Immunity According to EN 61000 6 2 Electrostatic discharge ESD EN 61000 4 2 Electr
8. 5598 _en_03 Useful Information from Everyday Practice 3 15 Output Characteristic Curves of Power Supply Units A sound circuit concept is often revealed when it is first started The output characteristic curve used is typical of the power supply unit behavior The characteristic curve specifies the history of the output voltage as a function of the output current It must be noted that capacitive loads e g DC DC converter or PTC thermistor consume a much higher current during start up than during nominal operation Capacitive loads represent an overload or a short circuit for the power supply unit for a short time It is therefore of great importance to the design of an operational system that the power supply unit does not interpret this transient overload or short circuit as an error and does not shut down It greatly depends on the output characteristic curve to determine which loads can be safely started with which power supply unit For this reason the different characteristic curves are explained in more detail in the following When using the fold back characteristic power supply units switch off shortly in the event of a short circuit or an overload and restart the load after a short time Power supply units with U I characteristic continue to provide the complete output current while reducing the output voltage Power supply units with U I characteristic and power boost have the advantages of a U I characteris
9. Light and compact Example ton torr gt t 5598D007 Figure 2 10 Pulse duty factor diagram The efficiency of primary switched mode devices is 80 to 90 much better than the efficiency of linearly regulated devices Therefore in a primary switched mode device less heat loss is generated and the relatively small transformer needs to provide only a small amount of dissipated power Circuits based on the primary switched mode controller principle enable the design of extremely light and compact devices Primary switched mode devices are intended for general use in the field of automation technology Low heat loss compact design and a wide input voltage range make these devices ideally suitable for use in distributed junction boxes The following example will illustrate the advantages of primary switched mode power supply units in contrast to linearly regulated devices by comparing the power dissipation Modern primary switched mode power supply units have a typical efficiency greater than 90 This results in a total power dissipation of only about 75 W for an output voltage of 24 V DC and an output current of 40 A The typical efficiency of 50 of a linearly regulated device results in a power dissipation of about 500 W Dissipation occurs in the form of heat which causes the control cabinet temperature to rise unnecessarily 5598 _en_03 PHOENIX CONTACT 2 13
10. This standard contains limit values for harmonic currents which are determined with reference to the input network current It is valid for all electrical devices that are intended for use on the public low voltage network The standard is only valid for 75 W to 1000 W devices used within the European Union With regard to noise emission primary switched mode QUINT POWER MINIPOWER and STEP POWER devices may be used in domestic applications as well as in industrial applications Concerning noise emission this means that the limit values for harmonic currents must not be exceeded A decisive factor for noise immunity is that interferences of any kind do not affect the function of a power supply unit 3 12 Pollution Degree Depending on their load and use power supply units are exposed to certain environmental influences such as dust humidity and aggressive substances The resistance of an electrotechnical component to these influences is described by the pollution degree The pollution degree is divided into classes from 1 through 4 For industrial use power supply units with class 2 have proved to be effective Non conducting pollution may occur with class 2 devices In the event of condensation this pollution may temporarily become conductive Fields of application for class 2 devices are for example the domestic sales and office areas precision engineering workshops etc If class 2 power supply units are to be used in applications in
11. U Without inductance With inductance 5598D317 Figure 3 36 Harmonic filter 5598D318 Figure 3 37 Simple rectifier with inductance 5598_en_03 PHOENIX CONTACT 3 51 SYS POWER SUPPLY UM E In L1 3 18 2 PFC Ideally the generation of harmonics is already avoided when using primary switched mode power supply units With a sinusoidal current consumption the power supply unit responds like a linear load Harmonics and distortion power are not generated The power factor increases with reduced reactive power Ideally the apparent power is completely converted to real power In this case the power factor is exactly one In order to draw sinusoidal shaped current from the supply network an additional and complicated circuit is required This complicated circuit is correctly known as PFC Power Factor Correction PFC is often called active limitation of harmonics A PFC circuit usually exists in a step up transformer Figure 3 38 shows the simplified structure of a PFC circuit with a downstream flyback converter The step up transformer is also a power supply unit It basically consists of the coil L1 the diode D1 and the power switch S1 D2 0 JULst 2 Upro EI JU bus U l Step up transformer PFC Flyback converter 5598D320 Figure 3 38 PFC with downstream flyback converter Power switch S1 is controlled by controlling the step up transformer The clos
12. adequately supplied with power if the output voltage is more than 90 of the value set Monitoring of the output voltage is carried out by means of a signaling threshold value This value is set to 90 of the output voltage For an output voltage of 24 V for example this value is 21 6 V If a different output voltage value is set using the potentiometer the signaling value is automatically adjusted A signal is indicated if the output voltage falls below the signaling threshold value Table 3 1 shows which signal output is available for which power supply unit Remote monitoring of the power supply unit is possible using the active switching output and the electrically isolated contact Table 3 1 Signal outputs Power Supply LED Active DC OK Switching Electrically Isolated Unit Output Relay Contact Switching Voltage 24 V DC 30 V AC DC max 1A Short Circuit Proof QUINT POWER Yes Yes Yes MINI POWER Yes Yes STEP POWER Yes 3 12 PHOENIX CONTACT 5598 _en_03 Useful Information from Everyday Practice Figure 3 10 shows the curve of the voltage U over the time t The output voltage is above 90 of the value set This state is indicated by the LED which is permanently on by a 24 V DC voltage level of at the switching output and by the relay contact closed U Output voltage 10 Us gt 90 x U out Z O9xU F Signaling threshold value j 5598D301 Figure 3 10 Output vo
13. 1 Parallel Connection for Increasing Power Parallel connection for increasing power is used when expanding existing systems Parallel connection is only required if the most powerful load requires more current than the existing power supply unit can supply It is recommended in all other cases to distribute the loads on individual devices independent from each other 24 V DC devices with an output power of 15 W to 960 W are available as single units from the Phoenix Contact product range Example In an existing system three loads with a total current consumption of 18 A 5 A 5 A 8 A are being supplied from a single 20 A device With a system expansion an additional load of 16 A must be supplied ACTUAL REQUIRED 5A 20A gt gt 20A 20A F gt Expansion 16A lt q 5A 8A 5A 5A 8A 16A 5598D023 Figure 3 3 Example with additional load The best technical solution which also has the lowest wiring costs is to operate the existing loads on the 20 A power supply unit A further 20 A power supply unit is installed as a single device for the additional 16 A load 5598_en_03 PHOENIX CONTACT 3 3 SYS POWER SUPPLY UM E Problem 2 The existing 5 A load from the system described in problem 1 is to be replaced by a25 A load ACTUAL REQUIRED oO 20A 20A 20A oO O gt gt o 8A 9 8A o o 2A lt
14. 2 12 Flyback converter with switch S1 closed The rectified line voltage Uj is applied to the input of the flyback converter Capacitance C1 is used as temporary storage because the energy is stored there during the off state phase When power switch S1 is closed the primary voltage of the transformer U is equal to the input voltage U A constantly rising current l4 is flowing through the primary winding of transformer Tr During this time the transformer Tr consumes magnetic energy and stores it in the air gap Because of the differential winding sense voltages U and U on the primary and secondary winding are opposite to each other There is no current flow through the secondary winding because diode D1 is in the off state No energy is transferred into the output circuit Ua U Sp 5598D413 Figure 2 13 Flyback converter with switch S1 opened 2 16 PHOENIX CONTACT 5598_en_03 Basics If the power switch S1 is opened the polarity of the voltages U4 and U on the transformer Tr is reversed according to Faraday s law The transformer is now acting as a current source Diode D1 becomes conductive and forwards the stored energy to capacitance C2 In this type of converter energy is not transported continuously Energy is only transmitted to the output circuit if power switch S1 is opened Therefore this type of converter is known as flyback converter If power switch S1 is closed the flow
15. Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 2 8 Figure 2 9 Figure 2 10 Figure 2 11 Figure 2 12 Figure 2 13 Figure 2 14 Figure 2 15 Figure 2 16 Figure 2 17 Figure 2 18 Figure 2 19 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Open frame device srota n i a E 2 2 Enclosed device example QUINT POWER 20A 3 phase 2 3 Assignment of technical data eeeeeeesseeeeeeeereneeeeeeneeeenneeeennes 2 4 Without secondary grounding ceesceeeesneeeeeeeeeteneeeeeeneeeenneeeenaees 2 7 With secondary grounding ceesceeeseeeeesneeeeeeeeeteneeeeeeneeeeneeeesness 2 8 Secondary protection urs2unnnennnnnnnnnnnnnnnnnnnnnnnnnnnonannnnannannnnnnnann 2 9 Circuit diagram for unregulated devices ssnnnsen nennen 2 10 Circuit diagram for linearly regulated devices enn 2 11 Circuit diagram for primary switched mode devices 2 12 Pulse duty factor diagram unersnnnnrsnnnnesennnnnnnnnnn ernennen nnnnnenn nennen 2 13 Converter types ui ehe nehariegen AS 2 14 Flyback converter with switch S1 closed eee eeeceeeeeeeeeeeeeeeeneetees 2 16 Flyback converter with switch S1 opened 2 16 Characteristic curves of voltage and current for flyback Converters nersini mennina e a i 2 17 Flyback converter with two transistors eeens 2 18 Forward converter wit
16. Output circuit decoupling diodes required for 100 redundancy All power supply units from Phoenix Contact which can be connected in parallel are dimensioned in such a way that an internal short circuit in the secondary circuit is virtually impossible This means that for parallel connection of multiple power supply units no decoupling diodes are required in the output circuit External diodes are only needed for a 100 redundancy and when more than two units are required The following example shows unnecessary power dissipation when using decoupling diodes A 40 A QUINT POWER power supply unit has an efficiency of 92 and a maximum power dissipation of 75 W at nominal load There is a voltage drop across the decoupling diode of 1 V approximately The product of voltage and current results in a power dissipation of 40 W The total power dissipation for the power supply unit with decoupling diode thus increases to 115 W i e 53 At the same time the efficiency is reduced to 88 For redundant circuits monitoring of the individual power supply units is recommended in order to detect any failure 3 10 PHOENIX CONTACT 5598 _en_03 Useful Information from Everyday Practice Voltage doubling 48 V DC PS PS Il 3 2 Series Connection for Increasing Voltage 48 V DC Two devices designed for this purpose can be connected in series for voltage doubling 48 V DC All QUINT POWER power supply units from Phoenix Contact
17. Power Supply Unit Particular attention should be paid to the starting behavior of the power supply units in warm operating state The cost effective circuit version protects the power supply unit inputs from high input currents by means of an ohmic resistor and an NTC thermistor connected in series The disadvantages of these circuits for powerful devices are that electrical power is always converted to heat loss across the ohmic resistor and that the NTC has a very low resistance when switching warm devices on again With powerful devices P gt 250 W low resistance inputs allow inrush currents which may become so high that the primary fuses blow unintentionally When using active current limiting the power supply unit input is also protected against high inrush currents by means of an ohmic resistor However this resistor is bypassed in normal operating mode i e there are no losses When using active inrush current limiting starting up warm devices is no problem e R NTC gt R Passive current limiting t e t Active current limiting 5598D028 Figure 3 25 Current limiting All QUINT POWER power supply units from Phoenix Contact are provided with active inrush current limiting This ensures safe starting up of warm devices and provides high efficiency Due to their low output power MINI POWER and STEP POWER are provided with passive inrush current limiting 3 38 PHOENIX CONTACT
18. Protection Il For devices with class of protection II protection against electric shock is not only based on the basic insulation In addition a double or reinforced insulation is used There is no possibility for connecting a protective conductor for these devices With regard to safety the device is therefore independent of installation conditions Due to their good insulation concept and the non conductive housing MINI POWER and STEP POWER power supply units from Phoenix Contact do not require any protective conductor Class of protection II is obtained when the unit is installed in a closed control cabinet A further requirement for the professional use of a power supply unit is electrical isolation It is essentially determined by the insulation the transformer and a suitable closed loop control circuit For power supply units with electrical isolation there is no continuous conductive connection from the device input to the device output When designing the insulation it is the task of the manufacturer to select a suitable insulating material and to provide clearances that are large enough Besides other parameters the insulation voltage and the maximum installation altitude of the devices depend on the choice of insulation clearances Power supply units designed according to DIN VDE 0110 Part 1 are suitable for installation altitudes up to 2000 m 6562 ft above sea level minimum 5598 _en_03 PHOENIX CONTACT 2 5 SYS POWER
19. are designed for use in series connection Only devices of the same performance class should be connected in series STEP POWER and MINI POWER power supply units cannot be connected in series for increasing the voltage oO sO 24 V 48 V 48 V Oo 24V CH 4 odl O 5598D013 Figure 3 9 Series connection Fields of Application QUINT POWER power supply units are always used when an output voltage of more than 24 V DC is required An output voltage of 48 V can be provided if two 24 V power supply units are connected in series Depending on the specification of the PE connection output voltages of 48 V and 24 V DC can be provided Phoenix Contact offers QUINT POWER power supply units which can be connected as shown in Figure 3 9 No additional diodes are required for this circuit design 5598_en_03 PHOENIX CONTACT 3 11 SYS POWER SUPPLY UM E 3 3 Preventive Function Monitoring DC OK The combination of function monitoring and early error detection is called Preventive Function Monitoring at Phoenix Contact This technology allows reliable monitoring of the output voltage and early error detection on a load Function monitoring is designed as a separate electronic circuit in the power supply unit which continuously monitors the output voltage set Components of electrical systems are
20. capacitors 50 Hz Transformer Rectifying Smoothing LO O G Ca Input a Output NO O 5598D004 Figure 2 7 Circuit diagram for unregulated devices Because of its few components this relatively simple circuit has the advantage of a particularly long service life and a typical efficiency of 80 Due to the missing control level output voltage fluctuations will occur in the case of fluctuating input voltages and fluctuating current output Unregulated devices are used for supplying electromechanical loads such as contactors electromagnetic switches etc which do not require a regulated output voltage 2 10 PHOENIX CONTACT 5598 _en_03 Basics Series controller Primary switch controller Constant output voltage poor efficiency ed 2 3 2 Regulated Devices Two types of regulated power supply units have been successfully implemented On the one hand the widely distributed series controllers and on the other hand the primary switched mode controllers Success in the development of power electronics has contributed to primary switched mode power supply units gaining more and more importance Linearly Regulated Devices With linearly regulated devices the AC line voltage is transformed using a 50 Hz transformer and then rectified The pulsating DC voltage is smoothed and filtered using capacitors Up to there the technical configuration is very similar to the one of the unregulated
21. decisive importance to reliable blowing of the fuse gt EN lt lt I Current path 1 Current path 2 Current path n From the power supply unit 5598D029 Figure 3 21 Selective protection 3 28 PHOENIX CONTACT 5598 _en_03 Useful Information from Everyday Practice Unregulated Linearly regulated Primary switched mode Unregulated power supply units provide the highest short circuit current The maximum short circuit current of these devices is only limited by the fuse at the device output and can typically be ten times the nominal output current for a short period With linearly regulated devices the short circuit current is limited by the output fuse and the controller temperature and can be two to three times the nominal current for a short period Many of the primary switched mode power supply units available operate according to the fold back characteristic curve In order to avoid high component temperatures they switch off in the event of an overload or a load short circuit and attempt to start again after a short time The short circuit current is about 1 1 times the nominal current Inom The power supply unit continues to operate normally as soon as the overload or short circuit have been removed see section 3 15 Output Characteristic Curves of Power Supply Units In order to guarantee system selectivity at any time the blowing of the fuses used must occur earlier than the swit
22. length 1 for copper cables with a cross section of 10 mm 8 AWG 30 A 40 A Om 24 0V 28 5V 24 0V 28 5V 10 m 33 ft 22 95 27 45 22 60 27 10 20 m 66 ft 21 89 26 39 21 19 25 69 30 m 98 ft 20 84 25 34 19 79 24 29 40 m 131 ft 19 79 24 29 18 39 22 89 50 m 164 ft 18 74 23 24 16 98 21 48 60 m 197 ft 17 68 22 18 15 58 20 08 Example A power supply unit with a nominal output current of I 10 A supplies a load with an input voltage of U 23 0 V DC via a copper cable with a cross section of 4 mm 12 AWG 1 Table 3 7 shows the cable cross section of 4 mm 12 AWG 2 A power supply unit with a nominal current of 10 A is shown in the second and third columns If the power supply unit is set to 24 V the supply voltage across the load is above 23 V for a cable length of up to 10 m 33 ft If the output voltage of the power supply unit is set to 28 5 V the voltage across the load is above 23 V for a cable length of up to 60 m 197 ft Table 3 7 makes clear that central power supply over greater distances very quickly leads to large cable cross sections or high losses Both dramatically increases installation and operating costs The best technical and most cost effective solution is to use several distributed power supply units each positioned close to the load center Power supply units which have a low overall depth are particularly suitable for distribut
23. load According to formula 2 there is with P U I 200 24V 5A u 24 V 57 5m 1 5 om ann The output voltage U 24 V falls by 1 5 to U 23 64 V 5598_en_03 PHOENIX CONTACT 3 33 SYS POWER SUPPLY UM E 3 10 Rating of the AC Low Voltage Supply Line For one phase systems with p U I cos according to formula 2 there is 200 p 200 I cos ul l Dj 3 1 FRA L meer 3 For three phase systems with p V3 U I cos according to formula 2 there is 100 p 100 V3 I cos 4 3 u U K A U K A 4 All formulaic symbols are defined in section 3 9 Layout of 24 V DC Supply Cables Cable Cross Section cos power factor of the power supply unit Example A three phase QUINT POWER 20 A 3 400V power supply unit is connected to a free output of a distribution box via a 75 m 246 ft copper cable with A 2 5 mm 14 AWG A voltage of U 3 400 V AC is measured at the distribution box How high is the AC voltage at the input of the power supply unit L1 2 L2 U 400 V AC o L3 N PE 75m a 0000 L1 L2 L3 PE OO Figure 3 24 TN S network U 5598D027 According to formula 4 there is is ules 100 V3 1 4A 0 7 e a Aa m 2 400 V 2 5 mm 57 Omm The AC input voltage across the power supply unit is UL 3 400 V
24. more than 60 s The base load is 0 5 times Iy and the ambient temperature is 20 C to 25 C 68 F to 77 F according to Section 8 2 The cable length terminal to terminal in the secondary circuit is 1 m 3 ft according to Section 8 2 the cable cross section is 1 5 mm 16 AWG 3 30 PHOENIX CONTACT 5598 _en_03 Useful Information from Everyday Practice 3 8 Layout of External Primary Circuit Fusing All one phase power supply units from Phoenix Contact are provided with internal fuses in the primary circuit If the fuse blows there probably is a device fault In this case the device must be sent back to and checked by Phoenix Contact The primary circuits of three phase QUINT POWER power supply units are protected externally using three phase thermomagnetic circuit breakers For protection either 6 A 10 A or 16 A circuit breakers characteristic B can be used The three phase circuit breakers must not be coupled mechanically Two phase operation is permanently possible without restrictions It must be noted that the devices have reduced mains buffering and the amount of harmonics is increased It is recommended to provide circuit breakers in the primary circuit for each power supply unit Device installation must be carried out according to the regulations in EN 60950 It must be possible to switch the device when the power is switched off using an appropriate external disconnecting device For this prim
25. of energy into the output circuit through diode D1 is interrupted Capacitance C2 then again generates a continuous energy flow from the transmitted energy in the output circuit For the flyback converter the transformer Tr is acting as a temporary storage The load connected to the output does not directly affect the input voltage source Only the energy stored in the transformer Tr is available in the output circuit Due to this power limitation flyback converter outputs are short circuit proof Ura A S1 closed S1 open t U U X tr out 5598D414 Figure 2 14 Characteristic curves of voltage and current for flyback converters 5598_en_03 PHOENIX CONTACT 2 17 SYS POWER SUPPLY UM E Flyback Converters With Two Power Transistors For the performance range from 200 W to 1000 W flyback converters with two power transistors are used These power transistors are controlled in parallel The principle of function of this flyback converter is very similar to the basic principle mentioned above The two power switches in the primary circuit now require two diodes The secondary circuit remains unchanged with regard to the basic principle of the flyback converter Using two power switches and diodes divides the reverse voltage Urey in two for every power switch Smaller power switches with reduced dissipation can be used out oO g O 5598D415 Figure 2 15 Flyback converter
26. you tips and advice on hardware and software optimization to save you extra work The text symbol refers you to detailed sources of information manuals data sheets liter ature etc on the subject matter product etc This text also provides helpful information for the orientation in the manual We Are Interested in Your Opinion We are constantly striving to improve the quality of our documents Should you have any suggestions or recommendations for improving the contents and lay out of our documents please send us your comments PHOENIX CONTACT GmbH amp Co KG Documentation Services 32823 Blomberg GERMANY Phone 49 0 52 35 3 00 Telefax 49 0 52 35 3 4 20 21 E Mail tecdoc phoenixcontact com PHOENIX CONTACT 5598 _en_03 SYS POWER SUPPLY UM E General Terms and Conditions of Use for Technical Documentation Phoenix Contact GmbH amp Co KG reserves the right to alter correct and or improve the technical documentation and the products described in the technical documentation at its own discretion and without giving any notice The receipt of technical documentation in particular data sheets installation instructions manuals etc does not constitute any further duty on the part of Phoenix Contact GmbH amp Co KG to furnish information on alterations to products and or technical documentation Any other agreement shall only apply if expressly confirmed in writing by Phoenix Contact GmbH amp C
27. 0 08 7 16 11 66 0 00 3 24 0 00 0 00 Table 3 7 On load voltage U as a function of the output current I and the cable length 1 for copper cables with a cross section of 4 mm 12 AWG N 10A 20 A 30 A 40 A Om 24 0V 28 5 V 24 0V 28 5 V 24 0V 28 5 V 24 0V 28 5 V 10 m 33 ft 23 12 27 62 22 25 26 75 21 37 25 87 20 49 24 99 20 m 66 ft 22 25 26 75 20 49 24 99 18 74 23 24 16 98 21 48 30 m 98 ft 21 37 25 87 18 74 23 24 16 11 20 61 13 47 17 97 40 m 131 ft 20 49 24 99 16 98 21 48 13 47 17 97 9 96 14 46 50 m 164 ft 19 61 24 11 15 23 19 73 10 84 15 34 6 46 10 96 60 m 197 ft 18 74 23 24 13 74 17 97 8 21 12 71 2 95 7 45 5598_en_03 PHOENIX CONTACT 3 21 SYS POWER SUPPLY UM E Solution Positioning power supply units close to the load center Table 3 8 On load voltage U as a function of the output current I and the cable length 1 for copper cables with a cross section of 6 mm 10 AWG gt W 30 A 40 A Om 24 0V 28 5V 24 0V 28 5V 10 m 33 ft 22 25 26 75 21 66 26 16 20 m 66 ft 20 49 24 99 19 32 23 82 30 m 98 ft 18 74 23 24 16 98 21 48 40 m 131 ft 16 98 21 48 14 64 19 14 50 m 164 ft 15 23 19 73 12 30 16 80 60 m 197 ft 13 47 17 97 9 96 14 46 Table 3 9 On load voltage U as a function of the output current I and the cable
28. 0 V isolated one phase 3 wire I Phase 1 o 240 VAC PEN conductor y Phase 2 Ground QUINT PS 5598D321 Figure 3 19 US network configurations one phase 3 26 PHOENIX CONTACT 5598_en_03 Useful Information from Everyday Practice 480 277 V three phase 4 wire T Phase 1 m Phase 2 480 V AC PEN conductor PE 480 V AC y y Phase 3 480 VAC 24 V DC QUINT PS Figure 3 20 US network configurations three phase 5598D322 Phoenix Contact power supply units are suitable for connection to all network configurations shown above 5598_en_03 PHOENIX CONTACT 3 27 SYS POWER SUPPLY UM E 3 7 Selective Protection by Means of Fusing in the Sec ondary Circuit High quality power supply units are electronically protected against short circuit and overload For device protection external fuses in the secondary circuit are thus not required for these power supply units Protecting current paths If the output current of a central 24 V power supply is distributed onto several loads it is individually recommended to protect each current path individually In this way only the assigned fuse blows in the event of a load failure All remaining loads are still supplied with electrical energy In practice the output current of a power supply unit is mainly distributed for powerful power supply units Maximum short circuit current is of
29. 1 U o O 5598D311 Figure 3 33 Rectifier with diode and capacitance 5598D312 Figure 3 34 Time history of voltage and current 5598_en_03 PHOENIX CONTACT 3 47 SYS POWER SUPPLY UM E Reactive power Apparent power Power factor All periodic functions can be evolved into a Fourier series i e they can be divided into sinusoidal portions The pulse shaped current lin can therefore be considered as a superimposition of a sinusoidal current with the network frequency as the basic frequency and several sinusoidal currents with integer multiples of this basic frequency These currents are called harmonics harmonic currents The sum of all harmonic currents represents a reactive power In addition to the real power P the reactive power Q must be provided from the supply network and paid by the system operator The relationship between consumed power apparent power S actually provided power real power P and reactive power Q is S2 P24 Q2 5 The apparent power S is the product of the effective current and voltage values The unit of the apparent power S is VA Volt Ampere S U I 6 S VA The power factor X indicates the ratio between the real power P and the apparent power S P Ne 7 S According to formula 5 the power factor is reduced with increasing reactive power Q via the apparent power S Basically there are two different types of reactive power displacement powe
30. Capacitance unuuessunnnnennnnnnnnnnnnnennnnnnn 3 47 Figure 3 34 Time history of voltage and current uuersnenersnnnnennnnnnnnnnnen nennen 3 47 Figure 3 35 Phase displacement Po eeceeseessesetseseseseeeeeeeseseseecseaeeeeseseeeeeeesaeaeeeees 3 49 Figure 3 36 Harmonie filter 2 2 2 0222 arena 3 51 Figure 3 37 Simple rectifier with inductance 2 20440444044nnnnnnnnnnnnnnnnnnnnnnn 3 51 Figure 3 38 PFC with downstream flyback converter eee ees 3 52 Figure 3 39 Limitation of harmonics by means of PFC 0 eee 3 53 Section 5 Figure 5 1 QUINT POWER MINI POWER and STEP POWER eeee 5 1 A 2 PHOENIX CONTACT 5598 _en_03 Explanation of Abbreviations A2 Explanation of Abbreviations General Abbreviations CE Communaut Europ enne conformity mark CSA Canadian Standards Association COMBICON Combined Connection DIN Deutsche Industrie Norm German Standards Assiciations ELV Extra Low Voltage EMV ElectroMagnetic Compatibility EN European Standard EVU Elektrizitats Versorgungs Unternehmen power supply company GS Gepr fte Sicherheit approved safety IEC International Electrotechnical Commission ISO International Organization for Standardization LS switch Leitungsschutzschalter circuit breaker NTC Negative Temperature Coefficient PELV Protective Extra Low Voltage RC Recognized Component SELV Safety Extra Low Voltage UPS Uninterruptible Powe
31. SUPPLY UM E Safe isolation SELV Safety Extra Low Voltage According to DIN VDE 0106 Part 101 two circuits are safely isolated if there is an adequate degree of certainty that the voltage of one circuit cannot affect the other circuit This includes a careful choice of the insulation the use of safety transformers and complete electrical isolation including the isolation of the closed loop control circuit by optocouplers Primary switched mode QUINT POWER MINI POWER and STEP POWER power supply units have been tested with regard to safe isolation according to DIN VDE 0100 410 DIN VDE 0106 1010 and EN 61558 2 17 DIN VDE 0555 EN 60742 deals with electrical safety of isolation transformers and safety transformers with a rated frequency of more than 500 Hz Due to the system primary switched mode power supply units are not provided with a transformer according to DIN VDE 0551 but with a transformer operating at a frequency of 40 kHz to 180 kHz Because of these high frequencies transformers of primary switched mode power supply units cannot be tested according to DIN VDE 0551 DIN VDE 0570 2 17 EN 61558 2 17 is a subsequent standard to DIN VDE 0551 It deals with the safe isolation of transformers with an increased rated frequency and is used as a basis for testing transformers of primary switched mode power supply units Because the power supply units are safely isolated there is no need for expensive isolating transformers in order
32. SYS POWER SUPPLY UM E 2 4 Converter Types For use in primary switched mode power supply units different types of converters have proved to be effective Generally a distinction must be made between single ended converters and push pull converters Single ended converters are the simplest primary switched mode power supply units The most important converter types are described in Figure 2 11 Primary switched power supply unit Y Single ended converter Flyback converter erin Y i Push pull converter Forward converter 2 transistors Beanies tarsi Figure 2 11 Converter types 5598D411 2 14 PHOENIX CONTACT 5598 _en_03 Basics 2 4 1 Flyback Converter Flyback converters enable wide distribution of low power Up to now flyback converters have only been used in power supply units with up to 200 W approximately Thanks to more powerful components with reduced power dissipation flyback converters can now be used for power supply units with an output power of up to 1000 W approximately Flyback converters are categorized according to the number of power switches used Up to 200 W flyback converters require one power switch Up to 1000 W each flyback converter uses two power switches Flyback converters consist of a smaller number of components than forward converters For this reason dev
33. W Watt P U i coso 8 P W Because of the phase displacement the consumed apparent power S is not completely converted to real power P in the load As a result reactive power Q is generated If the reactive power Q is only generated by the phase displacement the power factor A corresponds to the cosine of the displacement angle according to formulas 7 and 8 L P_ U l coso S Ui Therefore the terms power factor and cos are often used as synonyms COs 5598 _en_03 PHOENIX CONTACT 3 49 SYS POWER SUPPLY UM E Distortion power EN 61000 3 2 Non linear loads e g rectifiers with smoothing capacitors or primary switched mode power supply units often do not have a sinusoidal shaped current consumption Reactive power Q is generated with these loads due to a distorted current consumption and harmonic currents This reactive power is called distortion power For calculating the apparent power S for non linear loads the sum of all harmonic currents is being considered S U di 9 n number of harmonics The power factor X is calculated according to the above formula P A 7 S For non linear loads the power factor does therefore not correspond to cos Phase displacement and cos cannot be specified because there is no sinusoidal current consumption For primary switched mode power supply units the terms power factor and cos must not be used as synonyms The European S
34. ally between the different input voltage ranges Operation between these defined input ranges e g in the even of voltage fluctuations is not reliable 5598 _en_03 PHOENIX CONTACT 3 23 SYS POWER SUPPLY UM E 3 6 Connection to Different Network Configurations Figure 3 17 shows the connection of a one phase power supply unit to different network configurations Network configurations TN S network TN C network TT network iT network LE See L N PEN N i L N FEO O 5598D015 Figure 3 17 Connection of a one phase power supply unit 3 24 PHOENIX CONTACT 5598 _en_03 Useful Information from Everyday Practice The following graphics show the connection of a three phase power supply unit to different network configurations Network configurations TN S network 41 OOOO _ 0009 OO TT network p GOW re L1 L2 L3 PE OO Figure 3 18 L1 L2 L3 N PE L1 L2 L3 TN C network L1 L2 L3 PEN JOO 2 x L1L2 L3 PE OO iT network L1 L2 L3 OOOO L1L2 L3 PE a O 5598D016 Connection of a three phase power supply unit 5598_en_03 PHOENIX CONTACT 3 25 SYS POWER SUPPLY UM E 120 V one phase 2 wire 120 VAC Phase 1 PEN conductor Ground PE 120 VAC 24V DC i QUINT PS 120 24
35. ary circuit line protection for example is suitable 5598 _en_03 PHOENIX CONTACT 3 31 SYS POWER SUPPLY UM E 3 9 Layout of 24 V DC Supply Cables Cable Cross Section Cables are designed according to VDE 0100 Part 523 current carrying capacity of conductors and cables The following current carrying capacities for isolated multi wire cables are permitted Table 3 11 Cable cross sections Nominal cross section Cu in mm 1 5 2 5 4 6 10 16 Current carrying capacity in A 18 26 34 44 61 82 The following formula is used for rating the 24 V DC cable 200 P se 1 A u U2 i M 5 200 P j 21 gt u _ U2 K A Where A Cross section in mm 1 single cable length in m Power supply unit L 5598D024 Figure 3 22 Cable length U voltage in Volts P load power in Watts u voltage drop in x conductivity in m Q mm Copper 57 m Q mm Aluminum 36 m Q mm 2 3 32 PHOENIX CONTACT 5598 _en_03 Useful Information from Everyday Practice Example A power supply unit with the output values I 5 A and U 24 V supplies a load which is connected to it via a 5 m 16 ft copper cable with a cross section of A 2 5 mm 14 AWG How high is the voltage U across the load A 2 5 mm Cu 1 5A P ee ee j Load m 5m 5598D026 Figure 3 23 Voltage across the
36. bility and minimum downtimes are important Load errors which may lead to power supply unit overload can often only hardly be localized In the worst case they cannot be localized at all On a long term view this can lead to expensive system downtimes which are difficult to maintain The solution is an early error detection called preventive function monitoring U z Early error detection DCOK gt 24V 21 6V 10 i Signaling threshold value Typichal switch off value of electronic control systems Power Nominal range Boost Overload Boost 5598D305 Figure 3 14 Early error detection with power boost and DC OK Figure 3 14 shows the U I characteristic curve of a power supply unit with power boost and preventive function monitoring If the power boost is fully consumed the overload of the power supply unit caused by the load results in the output voltage falling down Overload may occur slowly or sporadically if for example the power consumption of solenoid valves increases due to more and more dirt on the valves Incorrect system expansion leads to permanent overload of the power supply unit A signal is indicated if the output voltage falls below the signaling threshold value The lower voltage value for typical loads e g PLC is between 18 V and 20 V When the signaling threshold value is reached e g 21 6 V for an output voltage of 24 V the PLC is still supplied with ad
37. ces in parallel without additional power share cable No additional measures are required in redundancy operation as all one phase power supply units of Phoenix Contact are internally protected in the primary circuit 5598 _en_03 PHOENIX CONTACT 3 7 SYS POWER SUPPLY UM E In order to operate the devices independently from a phase failure each single unit should be connected to a different phase if possible see Figure 3 7 400 V AC Connection to L1 Connection to L2 2 i L2 a 13 N u i ONE OWE POOO e o oon an a Load 24 V DC 5598D011 Figure 3 7 One phase redundancy operation For three phase devices with external protection individual protection must be provided for each device To increase operational reliability all three phase QUINT POWER power supply units IEY also operate when a phase permanently fails It must be noted that the devices have reduced mains buffering and the amount of harmonics in the primary circuit increases 3 8 PHOENIX CONTACT 5598_en_03 Useful Information from Everyday Practice 400 V AC NN W L1 L2 t i N T a EH DOr CH OO SH SH Load Load Besen Figure 3 8 Three phase redundancy operation 5598_en_03 PHOENIX CONTACT 3 9 SYS POWER SUPPLY UM E
38. ching off of the power supply unit If not the erroneous path is not enabled and the short circuit will remain The power supply unit permanently tries to carry out an unsuccessful warm start and changes to clock operation As a result the supply of all the loads connected in the system will be interrupted The faulty load can only hardly be localized because no fuse has blown This leads to long downtimes and unnecessary costs Fuse blowing depends on the I t value pre arcing of the fuse The higher the short circuit current the more reliable the fuse blowing Reliable solutions can thus be implemented using power supply units which do not switch off in the event of an overload or a load short circuit but permanently supply output current These power supply units operate according to the U I characteristic When selecting miniature circuit breakers modules with low internal resistance must be used Using thermomagnetic circuit breakers TMC which have a low internal resistance is recommended Cable cross sections should also be chosen large enough It must be noted that cable resistance increases with reduced cable cross section Too high cable resistance causes too high cable losses According to Ohm s law the maximum current is therefore not able to flow However the maximum current is required for reliable fuse blowing All QUINT POWER and MINI POWER power supply units from Phoenix Contact are being provided with a U I controlled cha
39. correct parallel connection in the secondary circuit For a uniform current distribution to the power supply units connected in parallel it is useful to clamp a and a busbar from the 24 V DC outputs All cables of the power supply units to this busbar should have the same length and the same cross section The cable cross sections in the secondary circuit should be large enough to keep the voltage drops on the cables as low as possible For cable connections in the primary circuit please refer to section 3 1 2 Parallel Connection for Designing Redundant Circuits 3 6 PHOENIX CONTACT 5598 _en_03 Useful Information from Everyday Practice Increasing system availability 3 1 2 Parallel Connection for Designing Redundant Circuits Fields of Application Redundant circuits are intended to supply systems which have a high demand concerning operational reliability If a fault occurs in the primary circuit of the first power supply unit the second device automatically takes over the complete power supply without interruption and vice versa For this purpose the power supply units to be connected in parallel are designed large enough to enable the power supply of all loads using only one power supply unit Method of Operation Two suitably designed power supply units from Phoenix Contact with identical functions are connected in parallel for simple redundancy N fold redundancy can be achieved by connecting n 1 devi
40. d sold according to the applicable directives of the European Union Particularly for power supply units compliance with the low voltage directive and the EMC directive is required Further approvals not being required by law underline additional safety In Germany the approval Gepr fte Sicherheit GS approved safety provides an additional safety certification for devices The approval Germanischer Lloyd GL German Lloyd certifies maximum reliability under extreme climatic conditions and maximum vibration resistance in continuous operation The following table lists the major approvals Table 3 13 Approvals Standard Meaning EN 60950 Electrical safety for information technology equipment UL 60950 US version of EN 60950 EN 50178 Electronic equipment for use in power installations UL 508 US safety standard for industrial control systems similar to EN 50178 EN 61000 3 2 Limits for harmonic currents in the public network EN 60204 Electrical equipment of machines EN 61558 2 17 Safety transformers for power supply units EN 61000 6 3 Basic standard on electromagnetic compatibility EMC EN 50082 GS Gepr fte Sicherheit approved safety see below CE EU declaration of conformance GL Germanischer Lloyd German Lloyd see below CB Scheme Basic safety certification see below 3 54 PHOENIX CONTACT 5598_en_03 Useful Information from Everyday Practice G
41. device After rectification linearly regulated power supply units either have a DC series controller or a DC quadrature controller in the form of a power transistor which functions as a variable resistor Depending on the forward DC resistance of the transistor the current flowing through the load is regulated in such a way that the voltage across the load remains constant 50 Hz Transformer Rectifying Smoothing Regulation Smoothing T L Tr O i c1 i c I 1 Controller 3 G EE gt Input i Output N O 5598D005 Figure 2 8 Circuit diagram for linearly regulated devices The efficiency of these circuits is approximately 40 to 60 depending on the circuit structure The power dissipation consists of the losses in the 50 Hz transformer the rectifier the transistor and the closed loop control circuit The transformer must be designed large enough to provide useful power and power dissipation This means an increased size of the transformer of at least 50 The field of electronics is the optimum application for these devices Here a precisely regulated 24 V DC voltage which is as free as possible from harmonics is required 5598_en_03 PHOENIX CONTACT 2 11 SYS POWER SUPPLY UM E Constant output voltage good efficiency Regulated Primary Switched Mode Devices In primary switched mode power supply units the AC line voltage is first rectified The DC voltage generated in this way i
42. e the time required for energy storage and energy discharge is the same Power switch S1 must be opened for the same time as it was closed before The reverse voltage U is the sum of the inverse transformation voltage U4 and the input voltage Uin It is present at the opened power switch S1 The reverse voltage of conventional forward converters is lower than the reverse voltage of flyback converters with one power switch For a long time this was the reason for only designing forward converters for this performance range 5598 _en_03 PHOENIX CONTACT 2 21 SYS POWER SUPPLY UM E Use A Si closed Si open 5598D418 Figure 2 18 Characteristic curves of current and voltage for forward converters 2 22 PHOENIX CONTACT 5598_en_03 Basics 2 4 3 Push Pull Converter Push pull converters are used for very high performance ranges beginning at 1000 W Basically a push pull converter consists of two forward converters and therefore always has two power switches Using push pull converters every clock is used for power transmission As a result the output power is much higher compared to forward converters As with flyback and forward converters the rectified line voltage U is used as the input voltage The power switches S1 and S2 in the primary circuit are switched alternately by means of the control voltage Uestr Both switches are never closed at the same time Otherwise there would be no in
43. ed control boxes QUINT POWER power supply units from Phoenix Contact fulfill these requirements 3 22 PHOENIX CONTACT 5598 _en_03 Useful Information from Everyday Practice 3 5 Wide Range Input All QUINT POWER MINI POWER and STEP POWER power supply units are equipped with a wide range input Therefore all one phase power supply units can be operated on line voltages from 85 to 264 V AC and all three phase power supply units on line voltages from 320 to 575 V AC These voltage ranges cover the most important supply networks worldwide Compared to devices with a fixed voltage input devices with wide range input have the following advantages Systems may be tested at any production location and may be operated anywhere in the world without erroneous switching over of the input voltage Wide range inputs ensure reliable functioning of the power supply units even in the event of high voltage fluctuations caused by instable supply networks Using power supply units with wide range inputs reduces storage and logistics because for one performance class only one devices is required independent of the input voltage When selecting a power supply unit it must be considered that the term wide range input is not always used clearly Automatic switching over of the input voltage ranges Auto Range for example is incorrectly used for wide range Auto range devices detect the applied input voltage and switch over intern
44. ed loop control circuit controls the input current lin The sinusoidal voltage Uin serves as the setpoint definition This makes the current consumption lin follow the sinusoidal voltage as shown in Figure 3 38 At the output the step up transformer generates the constant voltage Upfc which is independent from the line frequency This voltage is always higher than the maximum supply voltage of Uin Capacitor C1 is therefore permanently being charged and thus buffers the pulse shaped current consumption of the flyback converter 3 52 PHOENIX CONTACT 5598_en_03 Useful Information from Everyday Practice UIA lt Uin I with PFC 5598D319 Figure 3 39 Limitation of harmonics by means of PFC All QUINT POWER MINI POWER and STEP POWER power supply units from Phoenix Contact are below the limit values for harmonics and comply with EN 61000 3 2 5598 _en_03 PHOENIX CONTACT 3 53 SYS POWER SUPPLY UM E 3 19 Approvals Each device must comply with the safety directives of the country in which the device is intended to be used For power supply units this for example applies to the device safety which is defined by EN 60950 in Europe by UL 60950 in the USA and by CSA C22 2 in Canada For industrial applications compliance with EN 50178 is often required in Europe and with UL 508 in the USA With the CE certification the manufacturer guarantees that the device is being developed produced an
45. en nennen nenne nennen 2 1 Wide range input uessssnensnennenennen nennen nnnnenennnnn ern 3 23 A 8 PHOENIX CONTACT 5598_en_03
46. ened Opened contact Meaning Output voltage above 90 of the voltage set Output voltage below 90 of the voltage set No voltage at the output State description QUINT POWER operational Output voltage and output current OK QUINT POWER operational Load error Current consumption is higher than IBOOST Output short circuited QUINT POWER out of service No line voltage present Fuse blown in primary circuit QUINT POWER faulty Remedy Remove load error Use more powerful QUINT POWER Connect QUINT POWER of the same type in parallel to the existing device Remove short circuit Apply line voltage Reactivate fuse Replace QUINT POWER if required Table 3 3 MINI POWER Green DC OK LED LED ON LED OFF Transistor switching output only for MINI 24 V DC U 24V U 0V Meaning Output voltage greater than 21 6 V Output voltage lower than 21 6 V State description MINI POWER operational Output voltage and output current OK Load error MINI POWER out of service Output current is higher than IgoosT Output short circuited No line voltage present Fuse blown in primary circuit MINI POWER faulty Remedy Remove load error Connect MINI POWER of the same type in parallel to the existing device Apply line voltage reactivate fuse or r
47. eplace MINI POWER if required 3 18 PHOENIX CONTACT 5598_en_03 Useful Information from Everyday Practice Table 3 4 STEP POWER Green POWER LED LED ON LED ON LED OFF Red OVERLOAD LED LED OFF LED ON LED OFF Meaning STEP POWER Load error STEP POWER out of operational STEP POWER service Output voltage OK operational No line voltage present Thermally or electrically overloaded Fuse blown in primary circuit STEP POWER faulty Remedy Remove load error Connect STEP POWER of the same type in parallel to the existing device Reset STEP POWER by shortly disconnecting the line voltage or the load Apply line voltage Reactivate fuse Replace STEP POWER if required 5598_en_03 PHOENIX CONTACT 3 19 SYS POWER SUPPLY UM E 3 4 Adjustability of the Output Voltage Adjustment range Phoenix Contact offers power supply units with either fixed voltage output or adjustable 22 5 V DC to 28 5 V DC voltage output QUINT POWER power supply units have a nominal output voltage of 24 V This voltage can be freely adjusted in the range from 22 5 V to 28 5 V By default these devices are set to a voltage of exactly 24 V DC Fields of Application The adjustable outputs allow for compensation of voltage drops in connected cables for spatially distributed systems Adjusting the charging voltage also enables charging lead gel accumulators Compensating
48. epr fte Sicherheit GS Approved Safety GS stands for Gepr fte Sicherheit approved safety It is a European certification for devices according to the German Equipment Safety Law GS It is provided for products which are included in the application area of the equipment safety law This application area includes power supply units because the minimum distance for example between line voltage and output voltage is important for safety related considerations The Gepr fte Sicherheit approved safety mark is issued by an approved body e g T V Technischer Uberwachungsverein technical supervision body when carrying out a type approval test For testing the safety features of the power supply units the insurance conditions against occupational accidents German Berufsgenossenschaft are applied These conditions are much more difficult to fulfill than the demands of the European Machinery Directive CE mark Germanischer Lloyd GL German Lloyd The German Lloyd approval is a type approval test required in naval and offshore engineering Power supply units with this approval fulfill maximum demands with regard to the climatic and mechanical environment CB Scheme CB Scheme is operated by numerous international safety related committees of different countries and testing organizations CB Scheme developed a system for approvals dealing with the safety of electrical and electronic products A power supply unit tested acco
49. equate voltage Evaluation of the signal outputs helps to respond to load errors early and prevent a total system failure 3 16 PHOENIX CONTACT 5598_en_03 Useful Information from Everyday Practice Signaling in parallel operation System availability is additionally increased if two power supply units are connected in parallel for redundancy reasons Remote monitoring is recommended for each power supply unit in order to immediately detect a device failure and to keep the redundancy at any point of time Multiple power supply units can either be monitored individually or using a common signal As shown in Figure 3 15 a loop connects the active switching output of the first device and the electrically isolated contacts of further devices For function monitoring the signal output is isolated from the power output Reverse supply by a power supply unit to the DC OK output of the power supply units connected in parallel is not possible A clear function signal is generated at any point of time Output 24 V DC Output 24V DC 13 NT ReH 13 Na REH 5598D306 Figure 3 15 Monitoring multiple power supply units using only one signal 5598_en_03 PHOENIX CONTACT 3 17 SYS POWER SUPPLY UM E The following tables give you an overview of the signal meanings Table 3 2 QUINT POWER Green DC OK LED LED ON LED Flashing LED OFF Transistor switching U 24V U 0V U 0V output Electrically isolated Closed Op
50. ge even in the event of a strongly fluctuating input voltage 4 4 Installation in Distributed Control Cabinets In the field of automation technology a growing trend away from central control cabinets and towards distributed control cabinets can be observed Power supply units for use in distributed control cabinets must above all meet two important requirements flat design and very high efficiency to keep the power dissipation to a minimum The primary switched mode QUINT POWER MINI POWER and STEP POWER power supply units from Phoenix Contact meet both requirements flat design and high efficiencies of approx 90 4 4 PHOENIX CONTACT 5598 _en_03 Selecting a Power Supply Unit 4 5 Applications in Building Services Automation Facility Management Electrical power is mainly supplied to buildings via the public low voltage network Compliance with EN 55022 Class B is essential for equipment in the commercial business and domestic sector In addition all power supply units connected to the public network must comply with the European standard EN 61000 3 2 on limitation of harmonic currents EN 61000 3 2 is valid since January 1st 2001 All power supply units above 75 W connected to the puplic supply network must comply with this standard Irrespective of compliance with the standard it is useful from en electrical point of view to equip power supply units with a filter for suppressing network harmonics in o
51. gulated Devices eececceeessceeseeeeeeeeeeeseeeeseeeseeseaeeneneeeeteeeees 2 10 2 3 2 Regulated Devices icc tne aa a ENN 2 11 2 4 Converter TYP amp s 22 22a len 2 14 2 4 1 Flyback Converter Heilen 2 15 2 4 2 Forward Converter ioeina aa a ei Eai aia 2 19 2 4 3 Push Pull Converter tsune ians ae eiaa 2 23 3 Useful Information from Everyday Practice uusmsssssssnnannnnnnnnnnnnnnnnnnnnnnnnnnnnannnnnnnnn nn 3 1 3 1 Parallel Connection seeren a es ease 3 1 3 1 1 Parallel Connection for Increasing Power unnnesssensneensnennnnnnnnnen 3 3 3 1 2 Parallel Connection for Designing Redundant Circuits 3 7 3 2 Series Connection for Increasing Voltage 48 V DO 3 11 3 3 Preventive Function Monitoring DC OK 22 24424 nnnnnnnnnnnennennnnnnnnnn 3 12 3 4 Adjustability of the Output Voltage u 20u4200nrnennnnnnnnensnnnnnnnnnnnnnnnnnnnnn nn 3 20 3 5 Wide Range Input eeraa chuscesta ers denne 3 23 3 6 Connection to Different Network Configurations ecceceeeteeeeeeseeeeneereeees 3 24 3 7 Selective Protection by Means of Fusing in the Secondary Circuit 3 28 3 8 Layout of External Primary Circuit FUSING ceccececeeeeeeseeeeeeeeeeeeeeeteeeeeetes 3 31 3 9 Layout of 24 V DC Supply Cables Cable Cross Section neen 3 32 3 10 Rating of the AC Low Voltage Supply Line 0 0 0 0 eee eeeeeeeeteeeeeeeeetnee
52. h power switch S1 closed 2 20 Forward converter with power switch S1 opened l 2 20 Characteristic curves of current and voltage for forward converters unnnuenessnnnnnsnnnnennnnnnnnnnnernnnnn nennen nen ernennen 2 22 Half bridge push pull converter uuursnnnersennnenennnnnnnnnen nennen nn 2 23 Voltage balancing 1st step 20nnsernnnnnnennnnnnnennnnnnnnnnnnnn nn 3 1 Voltage balancing 2nd step 4sn4snsnnnnennnnnnnennnnnnnnnnnnn nn 3 2 Example with additional load uussrs2nserennnnn nennen nennen ernennen nen 3 3 Example with 25 A load piisi e a aai 3 4 Correct parallel connection in the secondary circuit 3 5 Incorrect parallel connection in the secondary circuit 3 6 One phase redundancy operation ecceeseeeeeeseeeeeeeeeeeeteeeeeneeeaaes 3 8 Three phase redundancy operation unnesnssssnnnnnsnnnnnnnnnnn nennen nn 3 9 5598_en_03 PHOENIX CONTACT A 1 SYS POWER SUPPLY UM E Figure 3 9 Series CONNECHION siret noe iit wien 3 11 Figure 3 10 Output voltage OK 2 eel ook thee ela 3 13 Figure 3 11 Output voltage not OK neiseis piniienn a a 3 14 Figure 3 12 DC OK switching output uurseersensnennnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnn nn 3 15 Figure 3 13 Electrically isolated contact 00 0 0 cece eee rete e eee enee tenes 3 15 Figure 3 14 Early error detection with power boost and DC OK 3 16 Figure 3 15 Monitoring multiple power supply units
53. ices automation eee 4 5 C Class of protection oo eccceeseeeeeeeseeeseeseeetieeeeeeeeneees 2 5 Class of protection I oo ceeceeeeeseseeeeeeseeeteeeeeeeeeneees 2 5 COMBICON mirc eaa a E nn 3 43 CONTACTO Siasi a a ie 2 10 Control cabinet distributed ur nn 4 4 Current patikrinau a 3 28 D Degree of protection ccescceeseceeeseeeeeeeeereseeeees 2 1 Device structure MeCchanical ccccccceccsssseseeees 2 1 DIN VDE 0106 Part 1 0 0 cece ceeeeeeeeeeeeeeeeeeeeneeeees 2 5 DIN VDE 0106 Part 101 0000 eee eecceeeeeeeeeteeeeeeeeeeeeees 2 6 Displacement power nuessneenssenenesennnen nennen 3 48 3 49 Distortion power uuensneessssnnnnsennnnn nennen nn 3 48 3 50 Domestic sector uzsumnsnsnnennannennnnnnnnnnnnnnnnnnnn ran 3 35 E Early error detection 0 eee 3 12 3 16 Electrical isolation 0 0 0 0 cece iiia 2 5 Electromagnetic switch u 22uer nen rennen nennen nn 2 10 EMC stand rds 0 0 40 ee 3 35 Emergency Stop iiini aae e eiaa 3 46 INRE Ooae EET T A 2 1 EN 61000 62 naana a ne 3 35 EN61000 6 9 22 2 R iS 3 35 Enclosed AeViCOS ee cccesenceesecceseseeeeeeeeeeeseneeeenees 2 3 EU Conformity aiiis Espe pasane a E 3 35 F Facility management uuessnseersnnnrsennnnnennnnnnnnnnn nen 4 5 Flyback Converter a ee 2 15 Fold back characteristic 3 40 Foreign body protection 2244440 nennen 2 1 Function monitor
54. ices with flyback converters have a light and small design and operate particularly reliable Therefore all QUINT POWER MINI POWER and STEP POWER power supply units from Phoenix Contact are designed as flyback converters They cover a performance range from 15 W to 960 W Method of Operation Figure 2 12 shows the simplified structure of a flyback converter with one power switch The power switch S1 is switched on and off by means of a controller with the control voltage U tr The value of the output voltage Usut depends on the winding factor of the transformer Tr and the pulse duty factor of switch S1 The value of the output voltage Uout is continuously measured and transmitted to the controller In this way a stabilized output voltage Uout is generated Because of the switching process the energy transport in the flyback converter is carried out in two steps For easier understanding the procedures are illustrated in two different graphics Figure 2 12 shows the circuit with switch S1 closed During this operating cycle an amount of energy is taken from the supplying network and stored in the transformer Tr Figure 2 13 shows the circuit with switch S1 opened The energy stored in the transformer is passed on to the secondary circuit The corresponding characteristic curves of the voltage and current are shown in Figure 2 14 5598 _en_03 PHOENIX CONTACT 2 15 SYS POWER SUPPLY UM E 5598D412 Figure
55. iched mode devices being used more and more instead of linearly regulated devices The major reasons for using primary switched mode devices are high efficiency and the associated low heat dissipation low weight and compact design Phoenix Contact recommends primary switched mode devices for universal use Phoenix Contact offers regulated primary switched mode power supply units with output currents of 1 a to 40 A covering the complete voltage range of 5 10 12 15 24 and 48 V DC QUINT POWER MINI POWER and STEP POWER devices For supplying highly sensitive analog technology linearly regulated devices still maintain their position Compared to earlier primary switched mode controllers linearly regulated power supply units generate a smoother output voltage which is almost free from residual ripple and switching peaks 5598 _en_03 PHOENIX CONTACT 4 3 SYS POWER SUPPLY UM E 4 3 Using Power Supply Units on Strongly Fluctuating Networks Strongly fluctuating input networks are on the one hand present in countries which do not have a stable interconnected network and on the other hand when starting and braking large electric motors In these cases it is unsuitable to use unregulated devices because the input voltage fluctuations are directely transferred to the output voltage Phoenix Contact recommends using primary switched mode power supply units for unstable networks These devices provide a fixed output volta
56. ilized output voltage U is generated Energy transport in the forward converter is carried out in two steps For easier understanding the procedures are illustrated in two different graphics Figure 2 16 shows the circuit with switch S1 closed During this operating cycle energy is taken from the supplying network and transformed into the output circuit Figure 2 17 shows the circuit with the switch opened In this operating cycle no energy is transformed into the secondary circuit Storage inductance L1 avoids interruptions of the energy flow in the secondary circuit The corresponding characteristic curves of the voltage and current are shown in Figure 2 18 5598 _en_03 PHOENIX CONTACT 2 19 SYS POWER SUPPLY UM E If switch S1 is closed the current I flows through the primary winding N1 of the transformer Tr As with the flyback converter one part of the current I is stored in the transformer Tr in the form of magnetic energy Unlike the flyback converter the windings N1 and N2 have the same winding sense As a result the current I induces the square wave voltage Us of the same polarity in the secondary winding N2 The voltage U causes the current l to flow across diode D1 and the current l4 to flow across the inductance L1 It also loads the capacitance C2 Inductance L1 stores one part of the current l3 in the form magnetic energy Ni Nt N24 DI L1 gt gt o 5598D416 Figure 2 16 Forward con
57. ing preventive 3 12 Index N ETE es eet Ae oe ee a eer ir 3 28 Fuse secondary CirCuit ccccccsseeeeeeeseeeeeeeeees 3 30 FUSES u ae aaa 3 31 G Ground fault serepan aR 2 7 2 8 H Harmonic filter pennn 3 51 HarMON CS 2 05 serge een aa 3 47 HOUSING niii ioe 22 a ee 2 1 2 3 IEG 60068 2 27 22 0 2 ee and 2 1 IEC 60068 2 6 uceeenennasnenunnsnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 2 1 Increasing Power ueeenssennssnnnnnsnnnnen nennen nn 3 1 3 3 Industrial sector uuuuuseuuu22nnnnnnnennnnnennnnnen nennen 3 35 Input vari bles 2 2 H ern 2 4 Inrush currentSs ueeeseeneneenennnnennnnnnnnnnnenennnnnnen ne nnnnnnnnn 3 38 Installation altitudes 2222222222220BBRnneenennnnnennn 2 5 IP International Protection code 2 1 L Limitation of harmonics active ccccceeeeeeeeeee 3 52 Limitation of harmonics passive en 3 51 M Mains buffering ccc ce eeeseeeeseeereeeeeeeneeeerseeeneneeees 3 37 N Network Configurations s e 3 24 NOISE EMISSION 4 2 ieee i 2 ce E 3 35 NT Chr een 3 38 O Output variables 0u4444 nen nnennnennnnnnnnennnnennnnn 2 4 P P c b terminal blocks 2222204002nn nennen ennnenenn 3 45 Parallel connection 222222222222222nBne nen enennnnennnn 3 1 PFEi as ie ie ies tee eed 3 52 Pollution degree 2sumnn4nnnennennnnnnnnnnnnnnnenn 3 36
58. lp you to choose the right device At the end of this manual the complete product range of Phoenix Contact power supply units is listed 5598 _en_03 PHOENIX CONTACT 1 1 SYS POWER SUPPLY UM E 1 2 PHOENIX CONTACT 5598 _en_03 Basics 2 Basics Shock protection Foreign body protection Water protection IP20 Shock resistance Vibration resistance This section introduces the most important basic terms with regard to power supply units This information will enable you to choose the power supply unit that best meets your requirements 2 1 Mechanical Structure The mechanical structure and the housing of the device largely determine its compliance with safety regulations and thus the possible installation location of the power supply unit According to EN 60529 particular attention must be paid to shock protection foreign body protection and water protection These degrees of protection are listed in the IP International Protection code Generally IP20 protection is adequate for dry rooms and control cabinets This degree of protection ensures reliable protection from touching live components and prevents penetration of foreign particles with a diameter of more than 12 5 mm 0 5 in Protection against water is not provided If required the devices are installed in a control cabinet which itself ensures the desired degree of protection Further important parameters are the resistance of the power supply unit to
59. ltage OK Relay contact closed 24 V switching output LEDON 5598_en_03 PHOENIX CONTACT 3 13 SYS POWER SUPPLY UM E Figure 3 11 shows the curve of the voltage U over the time t Point t4 indicates the falling of the output voltage below the signaling threshold value This state is indicated by a flashing LED a 0 V voltage level at the switching output and the relay contact opened A load error often causes the output voltage to fall down Short circuit and overload are typical errors Function monitoring not only monitors the output voltage but also the connected loads U out Signaling threshold value ist Us lt 90 x U Output voltage t 5598D304 Figure 3 11 Output voltage not OK Relay contact opened 0 V switching output LED flashing 3 14 PHOENIX CONTACT 5598 _en_03 Useful Information from Everyday Practice Figure 3 12 and Figure 3 13 show the possible signal output circuits for evaluation using signal indicators Both signal outputs can also be directly read by a higher level control system e g PLC Output 24 V DC 13 14 5598D302 Figure 3 12 DC OK switching output Output 24V DC ow et max 30 V AC DC 1A 5598D303 Figure 3 13 Electrically isolated contact 5598 _en_03 PHOENIX CONTACT 3 15 SYS POWER SUPPLY UM E Early error detection Power supply units with function monitoring are always used if maximum system availa
60. manual including all illustrations contained herein is copyright protected This man ual is to be used for its intended purpose only all other usage is prohibited Reproduction translation and public disclosure as well as electronic and photographic archiving and modification require written consent by Phoenix Contact Violators are liable for damages Phoenix Contact reserves the right to make any technical changes that serve the purpose of technical progress Phoenix Contact reserves all rights in the case of patent award or listing of a registered design External products are always named without reference to patent rights The exist ence of such rights shall not be excluded Internet You will find current information on products from Phoenix Contact on the Internet at www phoenixcontact com All the latest Phoenix Contact documentation can be found on the Internet at www download phoenixcontact com PHOENIX CONTACT 5598_en_03 Table of Contents 1 General ne ee 1 1 Qe BASICS Ase E ces oak EE ATE ecu stack ates sastceei ad dens E E A cs 2 1 2 1 Mechanical Structure ccc en al ie 2 1 2 1 1 Open Frame Devices 2444440nnennnnnennnensnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 2 2 2 1 2 Encl sed Devices 3 ch nn RR 2 3 2 2 Electrical Structures 2 2 anita alien 2 4 2 3 Regulation Types icccvsectiseccccccheehecteashaascecscehah ida ov acdaadie teuatsstesdesshiatetasteRbiadasessh 2 10 2 3 1 Unre
61. ned position Ideally the secondary grounding is established directly on the output terminal of the power supply unit as shown in Figure 2 5 If in this way the first ground fault is generated intentionally and at a defined position every other unintentional ground fault will cause an output voltage short circuit in the critical area between the fuse and the load This will cause the fuse to blow and the faulty area of the electrical system to shut down In this way persons and machines are being protected Ground fault Critical area 230 V AC 5598D409 Figure 2 5 With secondary grounding 2 8 PHOENIX CONTACT 5598_en_03 Basics Figure 2 6 shows how the secondary grounding of the safety extra low voltage to PE according to VDE 0100 410 can be created OL N l PE no a U lt 50V 5598D410 Figure 2 6 Secondary protection 5598_en_03 PHOENIX CONTACT 2 9 SYS POWER SUPPLY UM E Voltage fluctuations at the output good efficiency 2 3 Regulation Types Apart from the mechanical and electrical structure the type of regulation is of major importance for the choice of a power supply unit A distinction must generally be made between regulated and unregulated devices 2 3 1 Unregulated Devices With unregulated devices the AC line voltage is transformed using a 50 Hz transformer and then rectified The pulsating DC voltage resulting from this process is smoothed and filtered using
62. o KG Please note that the supplied documentation is a product specific documentation only Although Phoenix Contact GmbH amp Co KG makes every effort to ensure that the informa tion content is accurate up to date and state of the art technical inaccuracies and or printing errors in the information cannot be ruled out Phoenix Contact GmbH amp Co KG does not offer any guarantees as to the reliability accuracy or completeness of the infor mation appearing on the Website Phoenix Contact GmbH amp Co KG accepts no liability or responsibility for errors or omissions in the content of the technical documentation in par ticular data sheets installation instructions manuals etc As far as is permissible by applicable jurisdiction no guarantee or claim for liability for de fects whatsoever shall be granted in conjunction with the information available in the tech nical documentation whether expressly mentioned or implied This information does not include any guarantees on quality does not describe any fair marketable quality and does not make any claims as to quality guarantees or guarantees on the suitability for a special purpose Phoenix Contact GmbH amp Co KG reserves the right to alter correct and or im prove the information and the products described in the information at its own discretion and without giving any notice 5598 _en_03 PHOENIX CONTACT SYS POWER SUPPLY UM E Statement of Legal Authority This
63. omagnetic HF field EN 61000 4 3 Fast transients burst EN 61000 4 4 Surge current load EN 61000 4 5 Conducted interference EN 61000 4 6 Voltage fluctuations EN 61000 4 11 EN 61000 6 2 Burst Surge For complying with the basic EMC standard EN 6100 6 2 a power supply unit must for example have effective protective equipment against noise e g lightning burst surge or electrostatic discharge in the range of more than one kV Low energy but quickly recurring transient interferences are known as burst These interferences occur in welding systems but they are also caused by lightning strikes close to electrical lines The lightning bolt must not even directly strike the line Inducing electromagnetic fields in the lines will already lead to a voltage discharge High energy and transient interferences are known as surge They occur in the form of surge current loads e g in the event of high load changes in the primary network A short circuit in the supply lines through the following fuse blowing causes a short and high current load 5598 _en_03 PHOENIX CONTACT 3 35 SYS POWER SUPPLY UM E Harmonics Suppressing high frequently reverse currents is explained in the EN 61000 3 2 standard This standard is valid since January 1st 2001 and is based on the predecessor standard EN 60555 2 EN 61000 3 2 is part of the basic EMC standard EN 61000 6 3 noise emission see also section 3 18 Harmonics
64. own in Figure 3 28 In the event of a short circuit the output current of up to two times the nominal current is still available while the output voltage is reduced The power reserve ensures that highly capacitive loads and loads with DC DC converters in the input circuit are supplied at any time without problems In the event of a load short circuit the high short circuit current ensures reliable fuse blowing in the secondary circuit in order to keep the selectivity These properties make power supply units with U I characteristic and power boost optimally suitable for use in universal industrial applications Vou V 24 mI Al R Boost 5598D307 Figure 3 28 U I characteristic with power boost QUINT POWER MINI POWER and STEP POWER power supply units from IEY Phoenix Contact operate according to the U I characteristic and are provided with the power boost power reserve 3 42 PHOENIX CONTACT 5598_en_03 Useful Information from Everyday Practice 3 16 Installation and Connection It is of decisive importance for quick and safe installation of industrial power supply units that the power supply unit can be mounted on DIN rails and is provided with a reliable connection method All Phoenix Contact power supply units can be mounted on DIN rails This also applies IE to powerful devices with output currents of up to 40 A For quick device connection and visible isolation of the elec
65. power Power dissipation in the supply cable for the secondary circuit increases linearly with dissipation increasing current and cable length Table 3 5 shows the voltage losses in function of the cable cross section and the output current For the calculation of the voltage losses also see section 3 9 Layout of 24 V DC Supply Cables Cable Cross Section If the default 24 V DC setting has been adjusted for devices which are to be connected in parallel it is strictly necessary to carry out a balancing procedure as described in section 3 1 Parallel Connection Power supply unit 5598D024 Figure 3 16 Cable length Explanation of the Tables Table 3 5 shows the on load voltages U for an output voltage of 24 V and 28 5 V The first line indicates the nominal output voltage of the power supply unit Lines 3 to 8 indicate the cable lengths in meters The cable path from the power supply unit to the load has been taken into account 3 20 PHOENIX CONTACT 5598 _en_03 Useful Information from Everyday Practice Table 3 5 On load voltage U as a function of the output current I and the cable length 1 for copper cables with a cross section of 1 5 mm 16 AWG N I 2 5 A 5A 10A 20 A 30 A 40 A Om 24 0 V 28 5 V 24 0V 28 5 V 24 0 V 28 5 V 24 0 V 28 5 V 24 0V 28 5 V 24 0 V 28 5 V 10 m 33 ft 23 42 27 92 22 83 27 33 21 66 26 16 19 32 23 82 16 98
66. pts the secondary DC circuit 3 46 PHOENIX CONTACT 5598 _en_03 Useful Information from Everyday Practice 3 18 Harmonics Each power supply unit transforming an AC line voltage in a DC voltage in order to supply electrical loads generates unwanted harmonics The functioning mode of the power supply unit used has no influence on the generation of harmonics Harmonics which are generated by rectifiers with downstream smoothing capacitors or primary switched mode power supply units will be fed back into the electrical supply network if no appropriate limiting measures are taken This affects sensitive electronic loads Harmonics cause the power consumption of the loads to increase Cable cross sections would unnecessarily need to be designed larger Harmonics are caused by a pulse shaped current which is generated by the current consumption of rectifiers with a downstream capacitance or primary switched mode power supply units A simple rectifier with diode D1 and capacitance C1 is shown in Figure 3 33 The time history of voltage and current is shown in Figure 3 34 The U AC voltage is rectified by diode D1 and smoothed by capacitance C1 The pulse shaped current lin is generated when capacitance C1 is recharged with a positive half wave of the input voltage Uin The capacitance is always recharged when the supply voltage U is higher than the voltage Uc across capacitance C1 D1 lin e gt gt e O Un J C
67. put short circuit Each switching process of S1 and S2 causes the polarity of the primary winding N1 to change The transformer is thus operated with an AC voltage In every switching phase of S1 ad S2 the transformer Tr transmits power into the output circuit This power is then rectified by the alternately conductive and reversing diodes D1 to D4 hd s Ni N2 L1 c3 i D1 N D3 ie N tr C1 C2 e er Tr y c4 D2 D4 5598D419 Figure 2 19 Half bridge push pull converter 5598_en_03 PHOENIX CONTACT 2 23 SYS POWER SUPPLY UM E 2 24 PHOENIX CONTACT 5598 _en_03 Useful Information from Everyday Practice 3 Useful Information from Everyday Practice Increasing power Redundancy Questions arising from practical work are being answered in this section The questions have been sorted by subjects and serve as a reference work for the user both in the planning stage and when maintaining and expanding existing systems 3 1 Parallel Connection Only specifically designed power supply units can be connected in parallel The systems engineer can pursue two different objectives using parallel connection Increasing power The existing power supply unit is no longer adequate for the supplying the expanded system Redundancy Operation can be maintained in the event of a power supply failure For both objectives the total power should be distributed as
68. r Supply UL Underwriters Laboratories VDE Verband Deutscher Elektrotechniker e V German Association of Electrical Engineers 5598_en_03 PHOENIX CONTACT A 3 SYS POWER SUPPLY UM E AC DC I IP Code 1 LED L1 L2 L3 N N N P PE PFC Technical Abbreviations Alternating Current Direct Current Frequency Electrical current International Protection Code Two digit number indicating the degree of protection The first number indicates the shock protection in ascending order and the second number indicates the foreign body protedc tion is ascending order Length Light Emitting Diode External AC conductors Neutral conductor Normal Null above sea level Power Protective Earth Power Factor Correction Electrical voltage A 4 PHOENIX CONTACT 5598_en_03 Explanation of Abbreviations Units A Ampere unit of the electrical current Ah Ampere hours unit of electricity C Degrees Celsius unit of temperature g Gravitational acceleration Hz Hertz unit of frequency m Meter unit of length ms Millisecond 1 1000 second Q Ohm unit of electrical resistance s Second unit of time V Volt unit of electrical voltage Vpp Volt peak to peak peak voltage 5598_en_03 PHOENIX CONTACT A 5 SYS POWER SUPPLY UM E A 6 PHOENIX CONTACT 5598_en_03 A3 Index A Apparent power witcher dla 3 48 Automation technology ccessceesssetesseeeeeneeeeeees 4 4 B Building serv
69. r and distortion power A distinction is made because both reactive powers are generated in different ways 3 48 PHOENIX CONTACT 5598_en_03 Useful Information from Everyday Practice Displacement power The reactive power that is occurring most often in the field of electrical power engineering is called displacement power It is generated in AC circuits with linear capacitive and inductive loads With ohmic loads the current consumption is in phase with the sinusoidal voltage In the load the consumed apparent power S is completely converted to real power P Reactive power Q is not generated and the value of the power factor X is 1 With capacitive or inductive loads the current consumption also has a sinusoidal shape but is not in phase with the voltage see Figure 3 35 In this example the current lags behind the voltage In general the voltage lags behind the current when using capacitive loads and vice versa when using inductive loads The time shift between current and voltage is called phase displacement The size of this displacement is measured by means of the phase displacement angle 9 Ay t Aj t aa 5598D314 Figure 3 35 Phase displacement o The real power P actually transformed in the load in the event of a phase displacement between current and voltage is the product of the effective values of current voltage and cosine of the displacement angle The unit of the real power P is
70. racteristic 5598 _en_03 PHOENIX CONTACT 3 29 SYS POWER SUPPLY UM E Secondary circuit fusing When using secondary miniature circuit breakers fuses the question arises what type to use Table 3 10 shows which circuit breaker fuse is activated by which power supply unit In the shown combinations the miniature circuit breaker fuse is activated by means of the magnetic portion of the protection characteristic Table 3 10 Secondary circuit breakers fuses Circuit Breaker TMC NEOZED c F1 Fast Blow M Medium Blow Type lt SII lt lt lt il lt lt lt i J lt lt lt S I lt lt lt 3 N tT A N tT oO a N qT N r m QUINT 2 5 A one phase QUINT 5 A one x phase QUINT5A x three phase QUINT 10 A x x one phase QUINT 10 A P three phase REA QUINT 20 A x xix one phase QUINT 40 A xi xix one phase QUINT 20 A xi xix three phase QUINT 30 A xi xixi x three phase QUINT40A Ty x ix ix ix ie ix ix I xix xixi xx xixi three phase In this combination the power supply unit activates the circuit breaker fuse by means of the thermal portion of the protection characteristic For measuring the blowing times a test set up according to the standard has been used The testing and ambient conditions are based on DIN VDE 0641 Part 11 The warm up phase of the power supply unit is more than 60 s the cooling phase of the TMC
71. rder to avoid undesirable interference with other electronic components All QUINT POWER MINI POWER and STEP POWER power supply units from Phoenix Contact comply with both standards Power supply units with a flat design are suitable for installation in junction and sub distribution boxes as well as in operating panels STEP POWER power supply units have a flat double step housing with standardized dimensions 5598 _en_03 PHOENIX CONTACT 4 5 SYS POWER SUPPLY UM E 4 6 Outlook In the field of electrical engineering the level of innovation i e continual innovation increases at an enormous rate To the same extent the life cycle of the products becomes shorter The technical development of electrotechnical systems and components follows two directions Expensive mechanical and electromechanical components are more and more being replaced by electronic solutions Centrally structured electrical installations and systems are continuously being supplemented or even replaced by distributed electronics Power supply units are taking on the central task of supplying electrical modules and systems with the established 24 V control voltage The use of regulated power supply units is recommended for electronic components In the past the devices were large and heavy Together with their high heat loss this contributed to the undesireable control cabinet heating The trend towards distributed electronics pro
72. rding to CB Scheme safety directives can obtain national certification in all other member countries of the CB Scheme 5598 _en_03 PHOENIX CONTACT 3 55 SYS POWER SUPPLY UM E 3 56 PHOENIX CONTACT 5598 _en_03 Selecting a Power Supply Unit 4 Selecting a Power Supply Unit Selecting a power supply unit for a specific application is the subject of this section The power supply unit is selected successively on the basis of the following two lists of questions mechanical structure and electrical structure All terms used are explained in section 2 Basics The following must be considered for devices which are mainly used in the control cabinet for industrial applications What kind of shock protection is required Protection against finger contact of dangerous parts is ensured as from IP20 class of protection What kind of water protection is required As from IP23 devices are protected against spraying water For higher demands installation in a control cabinet with appropriate class of protection is necessary Phoenix Contact recommends IP20 class of protection for devices installed in a control cabinet What kind of shock vibration resistance is required The vibration resistance for industrial applications should be 2 3g g gravitational acceleration Shock resistance of 30g ensures safety transportation of preassembled control cabinets Which device is required for which supply voltage Thanks
73. s is of decisive importance 2 4 PHOENIX CONTACT 5598_en_03 Basics Class of protection Protective earth ground PE Electrical isolation Installation altitude According to DIN VDE 0106 Part 1 electrical equipment including power supply units is divided into the classes of protection 0 I Il and Ill Devices with class of protection 0 are not permitted in Germany Compact power supply units are usually designed to meet class of protection or Il The classes of protection each relate to the single device To guarantee the safety of the entire system all the wiring required must be implemented by trained personnel as defined in the current VDE guidelines and DIN standards Devices with Class of Protection For devices with class of protection protection against electric shock is not only based on the basic insulation In addition parts are connected to the protective conductor of the permanent installation in such a way that no voltage can remain even if the basic insulation fails These devices are always provided with a protective earth ground connection PE QUINT POWER power supply units correspond to class of protection I These units are usually grounded using the PE connection on the input terminal The power supply unit is electrically connected to the mounting rail via the mounting rail adapter PE connection via the terminal point is not required if the mounting rail is grounded Devices with Class of
74. s then smoothed and chopped or switched This is carried out periodically by a power transistor at frequencies from 40 kHz to 180 kHz The square wave voltage resulting from this process is transformed by means of a high frequency transformer The main difference between primary switched mode devices and linearly regulated devices is that primary switched mode controllers first rectify and then transform whereas linear controllers first transform and then rectify Rectifyer Smoothing Switching Transformer Filter Controller Electr Isolation D L O Tr D gt O G cal c2 i vP Le B a Input 1 Output I N Oo O 5598D006 Figure 2 9 Circuit diagram for primary switched mode devices Because the frequency at which the voltage is transformed is very much higher than the line frequency the volume and thus the weight of the magnetic transformer can be reduced considerably If the transistor is used as a variable resistor in linearly regulated devices it operates as a switch in primary switched mode controllers This reduces the power dissipation considerably In the secondary circuit the pulsating DC voltage is again smoothed The output voltage is regulated depending on the load using the amount of energy transferred in one period The amount of energy transferred can be varied by the pulse duty factor P P ton ton torr 2 12 PHOENIX CONTACT 5598 _en_03 Basics Ie
75. shock and vibration The parameters shock resistance and vibration resistance provide information on what mechanical pressures the device structure will withstand The shock resistance of devices is specified in IEC 60068 2 27 The vibration resistance is tested according to IEC 60068 2 6 Solidly constructed devices should be able to withstand vibration of 2 3g in the frequency range from 10 Hz to 150 Hz g gravitational acceleration Examples are devices for general industrial applications power stations and devices used in the operating area of heavy rotating machine parts Shock resistance provides information on the operating and transport conditions of the devices For industrial requirements acceleration peaks of 30g over a shock period of 18 ms is considered sufficient Power supply units tested according to these conditions can in the completely installed control cabinet be transported to the installation location without slipping from the mounting rail 5598 _en_03 PHOENIX CONTACT 2 1 SYS POWER SUPPLY UM E 2 1 1 Open Frame Devices a 5598A406 A Figure 2 1 Open frame device Power supply units constructed for 19 racks or as open frame modules are mainly used to supply single components within an existing housing e g internal power supply of an oscilloscope Devices with an open frame structure correspond to IPOO protection These devices are not protected agains
76. stic are electronically protected against overload and short circuit For a 24 V DC voltage the maximum output current is typically 1 1 times the nominal current In the event of an overload or a short circuit the output current of 1 1 times In is still available while the output voltage is reduced Vout V 24 la A In l Tixi 5598D020 Figure 3 27 U I characteristic There are two significant advantages of using devices with U I characteristic compared to using devices with fold back characteristic Capacitive loads of any size and loads with DC DC converter can be started When dividing the output into individual selectively fused current paths reliable fuse blowing is ensured thanks to the continuous current see also section 3 7 Selective Protection by Means of Fusing in the Secondary Circuit This makes power supply units with this characteristic more suitable for use in the industrial area 5598 _en_03 PHOENIX CONTACT 3 41 SYS POWER SUPPLY UM E 3 15 3 U I Characteristic With Power Boost Power supply units with U I characteristic and power boost are electronically protected against overload and short circuit At nominal voltage the maximum output current of these devices is up to two times the nominal current depending on the type and ambient temperature Overloading individual power supply units is thus permitted up to 100 In the event of heavier loads the working point uses the U I curve sh
77. t the penetration by foreign bodies or water 2 2 PHOENIX CONTACT 5598_en_03 Basics 2 1 2 Enclosed Devices 5598C407 Figure 2 2 Enclosed device example QUINT POWER 20A 3 phase Power supply units accommodated in a housing are known as enclosed devices These can be simple plug in supply units for supplying portable domestic appliances or high grade industrial power supply units for installation on standardized mounting rails These devices types are mainly designed with IP20 protection 5598_en_03 PHOENIX CONTACT 2 3 SYS POWER SUPPLY UM E 2 2 Electrical Structure For power supply units a distinction is made between input and output variables For a better understanding the variables are illustrated in Figure 2 3 Input gt Output Input voltage Output voltage Frequency Output current Inrush current Output fuse Current consumption 3 Start up relay Input fuse Control deviation Power factor u Rise time Mains buffering gt Residual ripple Harmonic filter E Reverse voltage PFC 3 Primary grounding 2 Secondary grounding e o I u AC D Jv e o 06 o Climate Ambient temperature Humidity Altitude Vibration Shock 5598D003 Figure 2 3 Assignment of technical data The electrical configuration of a power supply unit determines its operational safety availability and the guaranteed protection of persons Compliance with all safety parameter
78. tandard EN 61000 3 2 for the limitation of harmonics is valid since January 1st 2001 This standard is valid for loads connected to the public network with a real power consumption of between 75 W and 1000 W Loads with lower real power consumption or loads which are supplied using a medium voltage transformer must not comply with these standardized limit values EN 61000 3 2 is valid for the European market There are attempts to introduce similar standards to the US market Feedback of harmonics into the supply network may technically be prevented by means of two methods PFC or harmonic filters Both methods will be explained in the following 3 50 PHOENIX CONTACT 5598 _en_03 Useful Information from Everyday Practice 3 18 1 Harmonic Filter Inductance Harmonic filters prevent harmonics from feeding back into the electrical supply network Using inductance L1 in the primary circuit of the power supply unit the harmonic content is filtered Figure 3 37 shows a simple rectifier with inductance L1 as an example Because of using a filter this limiting method is often called passive limitation of harmonics Figure 3 36 shows the pulse shaped current curve of a power supply unit with and without harmonic inductance The inductance causes the narrow and high energy current pulse to be attenuated and enlarged in time This reduces the amount of harmonics The shorter and higher a current pulse the more harmonics are generated UTA
79. teeeeeneeeee 3 34 3 41 Questions oM EMG re O aaa e aA N aa 3 35 3 12 Poll ton Degrande aii Reena 3 36 3 13 Short Term Mains Buffering ccceeeceeeeeeeeeeeeeeeeeeaeeeeeeeeneeseaeeeeeeeseeseeeeeneeeee 3 37 3 14 Starting Behavior of the Power Supply Unit ee eee eeeeeeneeeeeeeeeeeseeeeeneeeee 3 38 3 15 Output Characteristic Curves of Power Supply Units ueseesseenseneennnnn 3 39 3 15 1 Fold Back Characteristic 0 eceeceeeeeesceeeneeeeeeeeeeeeeeeeeeeeeeaeeeeeeneees 3 40 3 15 2 U l Characteristic 2 en Ri 3 41 3 15 3 U I Characteristic With Power Boost nneesseenssensnennnnnnnnnennnnnnnennn 3 42 3 16 Installation and Connection usssrsnsernensnnnnnnnnnennnnnnnnennnnnnnnnnnnnnnnnnnn nennen 3 43 3 17 Emergency Stop Circuit urssersennnnnnnnnsnnnnnnonnnnnnnnennnnnnnnnnnnnnnnenn nennen 3 46 5598_en_03 PHOENIX CONTACT i SYS POWER SUPPLY UM E 4 5 9 18 Harmonies 22222 Bun 3 47 3 18 1 Harmonic Filter Inductance cee eeceeceeeeeeeeeeteeeeeeeeeeeeeeaeeseeeeeeees 3 51 93 18 2 PRC Auen ans tissue Picts Ae ea 3 52 93 19 Approval 2 sic 2 eines 3 54 Selecting a Power Supply Unit u a ae lb 4 1 4 1 Supplying Electromechanical Components us44rnsnnnennnnnsnnensnennnnnnnnnn 4 3 4 2 Supplying Electronic Modules and Systems u 24s240nnnsnnnnnnnnnensnennnnnnnnnn 4 3 4 3 Using Power Supply Units on Strongly Fluctuating Networks
80. th the UL approval use copper cables designed for operating temperatures of 75 C 167 F 5598_en_03 PHOENIX CONTACT 3 45 SYS POWER SUPPLY UM E Installation turned by 90 The DIN rail adapter already mounted upon delivery enables easy snapping on of the power supply unit onto the DIN rail It is therefore ideal for the installation on NS 35 DIN rails QUINT POWER can be adapted to the geometric demands of the most different applications By adjusting the universal DIN rail adapter the devices may be installed if space requirements are either particularly narrow or flat see Figure 3 32 55980323 Figure 3 32 Installation turned by 90 example adjustment from narrow to flat 3 17 Emergency Stop Circuit In many applications with an integrated emergency stop circuit switching off is carried out centrally inthe AC circuit When using power supply units with energy storing intermediate circuits this includes all primary switched mode power supply units it must be noted that there may be a DC current in the secondary circuit for a certain period of time when the primary circuit is switched off e g in the event of an emergency stop This effect has been deliberately implemented in the devices to buffer a possible power failure To clearly isolate the loads connected to the primary switched mode power supply units from the supply line it is therefore recommended to use a relay circuit which interru
81. tic combined with an additional power reserve The power reserve ensures a constant output voltage even in the event of an overload 5598 _en_03 PHOENIX CONTACT 3 39 SYS POWER SUPPLY UM E 3 15 1 Fold Back Characteristic Power supply units with fold back characteristic are electronically protected against overload and short circuit The maximum output current is typically 1 1 times the nominal current In the event of an overload the working point passes along the curve shown in Figure 3 26 Depending on the controller temperature and in the event of a short circuit the device output is switched off to be protected against high currents Overcurrent U a V A 24 li A 5598D017 Figure 3 26 Fold back characteristic After approximately one second the device tries again to start the connected load This procedure is repeated until the overload or short circuit has been removed The power supply unit will not start the load in the event of an overload which is caused by the high inrush current during starting up when using heavier loads If these devices switch off too quickly in the event of a short circuit secondary fuses will not blow The faulty current path cannot be isolated from the remaining system parts This results in a failure of the entire system 3 40 PHOENIX CONTACT 5598_en_03 Useful Information from Everyday Practice 3 15 2 U l Characteristic Power supply units with U I characteri
82. to comply with DIN VDE 0551 The Safety Extra Low Voltage SELV is always kept if on the one hand overspill of a voltage from one circuit into another is prevented and on the other hand safety extra low voltages with a nominal voltage of Un lt 50 V AC or 120 V DC are not exceeded For keeping the SELV secondary grounding is permissible but not required PELV For keeping the PELV secondary grounding is absolutely necessary Otherwise the same Protective Extra Low regulations apply as for keeping the SELV Voltage 2 6 _ PHOENIX CONTACT 5598_en_03 Basics Secondary grounding The secondary grounding ensures reliable protection in case of ground faults in DC circuits of electrical systems Ground faults may lead to dangerous situations for persons and machines A ground fault is an impermissible conductive connection to PE e g if the bare wire touches a grounded housing as a result of a damaged insulation Figure 2 4 shows that ground faults are extremely critical when occurring in the current path between the secondary fuse and load A double ground fault in this area leads to a short circuit across the switch in the worst case and thus to an unintentional machine start 230 V Sar AC 5598D408 Figure 2 4 Without secondary grounding 5598_en_03 PHOENIX CONTACT 2 7 SYS POWER SUPPLY UM E Reliable protection can be obtained by grounding the safety extra low voltage after PE on the secondary side at a defi
83. to the wide range input the power supply unit can be used all over the world This simplifies the choice of a suitable device At the same time logistics is reduced because only one device type is required for one performance class What installation options are required For devices installed in a control cabinet mounting on NS 35 DIN rails according to EN 50022 has proved to be most suitable A universal mounting rail adapter ensures easy mounting on and removal from the DIN rail With QUINT POWER devices the mounting rail adapter can be replaced by a special S7 adapter to enable mounting on different mounting rail systems e g S7 300 rail 5598_en_03 PHOENIX CONTACT 4 1 SYS POWER SUPPLY UM E Table 4 1 Device comparison Unregulated Filtered Linearly Regulated Primary Switched Mode mance range standardized Weights for the same perfor 5 7 1 mance range standardized Volume for the same perfor 2 1 2 2 1 Efficiency 80 approx 40 to 60 approx gt 90 Power dissipation at 200 W approx 600 W approx lt 75W Pout 1000 W Input range 10 lt Un lt 6 10 lt Un lt 6 20 lt Un lt 15 approx Output voltage Depending on input volt Precisely adjusted Precisely adjusted adjust age and load able versions available 22 5 V DC to 28 5 V DC Residual ripple 2000 MVpp approx 50 MV pp approx lt 100 MV pp Short circuit current 10 x In approx
84. trical connection if required all MINI POWER and QUINT POWER power supply units with an output current of up to 10 A are equipped with COMBICON connectors 55980404 Figure 3 29 Primary connection using COMBICON 5598_en_03 PHOENIX CONTACT 3 43 SYS POWER SUPPLY UM E 55980402 Figure 3 30 Secondary connection using COMBICON In these connector systems the supply lines are fastened to the connector using screws at initial installation If required the connector can be removed from the power supply unit without any tools The connector must not be removed while power is connected COMBICON connectors are being labeled by default It is therefore impossible to mix up the input and output connectors when using COMBICON devices With MINI POWER the COMBICON connector encoding prevents secondary connectors of power supply units with different output voltages from being mixed up QUINT POWER power supply units with output currents of 20 A and higher and STEP POWER power supply units are equipped with p c b terminal blocks 3 44 PHOENIX CONTACT 5598 _en_03 Useful Information from Everyday Practice 55980401 Figure 3 31 Connection using p c b terminal block In order to handle high output currents safely and to enable the connection of cable cross sections of up to 10 mm 8 AWG p c b terminal blocks are used for QUINT POWER with output currents of 20 A an higher To comply wi
85. uniformly as possible onto the single units Voltage balancing is required for all power supply units with adjustable output voltage if the default 24 V output voltage has been set to a different value Voltage balancing is shown in Figure 3 1 and Figure 3 2 Output 24 V DC Output 24V DC 5598D021 Figure 3 1 Voltage balancing 1st step 5598 _en_03 PHOENIX CONTACT 3 1 SYS POWER SUPPLY UM E Device balancing 1 Power supply unit 1 is in operation and at no load mode The desired output voltage is set via the potentiometer using a voltmeter see Figure 3 1 Output 24V DC Output 24V DC 5598D008 Figure 3 2 Voltage balancing 2nd step 2 Both power supply units and the voltmeter are connected as shown in Figure 3 2 Both power supply units are in operation and at no load mode Balancing of the power supply units is carried out by means of differential voltage measurement For this the output voltage of power supply unit 2 is adjusted using the potentiometer until the voltmeter no longer measures any voltage Both output voltages are exactly set if the differential voltage between both power supply units is O V The lower the differential voltage of the power supply units 1 and 2 the more symmetrical the distribution of the total current for the two single units 3 2 PHOENIX CONTACT 5598 _en_03 Useful Information from Everyday Practice Field of application System expansion Problem 1 Solution 3 1
86. using only one signal 3 17 Figure 3 16 Cable length ans Reiki iii 3 20 Figure 3 17 Connection of a one phase power supply unit uerseensssensnensnnnnnnn 3 24 Figure 3 18 Connection of a three phase power supply unit 00 0 0 eee 3 25 Figure 3 19 US network configurations one phase 2ersnenn nennen 3 26 Figure 3 20 US network configurations three phase eeeeeeesteeeteeeereeeaes 3 27 Figure 3 21 Selective Protection eeeeecceeseeeececeeeetseeeeeeeeeeteaeeteeeeeaeeseeeeeeeees 3 28 Figure 3 22 Cable length 4 2 ee ght ALO rend Mati 3 32 Figure 3 23 Voltage across the load o oo ee cence renee eee e tees tae enaee tate 3 33 Figure 3 24 TN S network usa an eh eerie ak 3 34 Figure 3 25 Currentilimiting 2 22 44 ee ea 3 38 Figure 3 26 Fold back characteristic siirsin tieien 3 40 Figure 3 27 Ulicharacteristich u une2ssengna ie abend 3 41 Figure 3 28 U I characteristic with power boost uuerssnsneennnennnnnnnnnnnenn nn 3 42 Figure 3 29 Primary connection using COMBICON ursunnseensssesnnnenneennnennnnnn 3 43 Figure 3 30 Secondary connection using COMBICON sccssseeeereeeeees 3 44 Figure 3 31 Connection using p c b terminal block 2 4224 nennen nenn 3 45 Figure 3 32 Installation turned by 90 example adjustment from Marrow to flat 20ur20u4snennnnnnnnennnnnnnnnnensnnnnnnnnnnnnnnnnnnnnnn nn 3 46 Figure 3 33 Rectifier with diode and
87. verter with power switch S1 closed If the power switch S1 is opened the polarities on the windings N1 and N2 are reversed Diode D1 in the output circuit is now in reverse direction Windings N1 and N2 are at zero current As a result the energy flow from the primary to the secondary circuit is interrupted The energy stored in inductance L1 avoids interruptions of the energy flow in the secondary circuit The storage inductance L1 avoids interruptions of the current Iz using the free wheeling diode D3 N1 S L1 I U 03 Vou C1 oa Um UL s o 5598D417 Figure 2 17 Forward converter with power switch S1 opened 2 20 PHOENIX CONTACT 5598_en_03 Basics In order for the transformer Tr to be available for the maximum energy flow after re closing the power switch S1 the remaining magnetic energy in the transformer Tr must be dis charged when the power switch S1 is open Because of the reversing diode D1 the secondary circuit is not available This requires an additional winding N1 in the primary circuit The winding discharges the magnetic energy The winding N1 consumes the magnetic energy and leads it back to capacitance C1 across diode D2 in the form of electrical energy This energy is then again available for transmission into the output circuit when closing switch S1 Both primary windings N1 and N1 often have the same number of turns but an opposite winding sense Therefor
88. vide a new role for power supply units Today the reliability of power supply units is not only responsible for the availability of individual components but also for safe and reliable operation of complex systems Thanks to developments in the field of power electronics it is possible to introduce primary switched mode devices which have four important advantages over conventional linearly regulated power supply units Weight reduced by a factor of 3 to 5 Increased efficiency from approx 50 to 90 and consequently Heat loss reduced by a factor of 5 Volume reduced by a factor of 1 5 The future definitely lies with regulated primary switched mode power supply units Phoenix Contact has recognized this development at an early stage and now offers the complete performance range from 15 W to 960 W in a uniform design with its QUINT POWER MINI POWER and STEP POWER primary switched mode controllers 4 6 PHOENIX CONTACT 5598 _en_03 Product Overview 5 Product Overview For ordering data on the Phoenix Contact power supply units please refer to the Phoenix Contact INTERFACE catalog and to the internet at www interface phoenixcontact com 55980420 Figure 5 1 QUINT POWER MINI POWER and STEP POWER 5598_en_03 PHOENIX CONTACT 5 1 SYS POWER SUPPLY UM E 5 2 PHOENIX CONTACT 5598_en_03 A Appendices Section 2 Section 3 Appendices A1 List of Figures Figure 2 1
89. which a higher degree of pollution must be expected the power supply units are installed in a distribution cabinet with an appropriate degree of protection see section 2 1 Mechanical Structure 3 36 PHOENIX CONTACT 5598 _en_03 Useful Information from Everyday Practice Emergency stop I 3 13 Short Term Mains Buffering In many applications the power supply unit must also buffer the DC voltage during short term interruptions of the supplying AC voltage For primary switched mode power supply units this can be achieved with a minimum effort by buffering the 600 V DC voltage in the intermediate circuit using capacitors The aim should be mains buffering of at least 20 ms in order to be able to buffer the voltage dip of a complete line supply cycle For three phase power supply units the mains buffering time is reduced in the event of a phase failure because the capacitors in the intermediate circuit have not been completely charged To implement emergency stop circuits in conjunction with energy storing power supply units please refer to section 3 16 Installation and Connection All QUINT POWER MINI POWER and STEP POWER power supply units from Phoenix Contact are able to buffer the output voltage for more than 20 ms in the event of a power failure 5598 _en_03 PHOENIX CONTACT 3 37 SYS POWER SUPPLY UM E Active inrush current limiting instead of NTC Is 3 14 Starting Behavior of the
90. with two transistors 2 18 PHOENIX CONTACT 5598_en_03 Basics 2 4 2 Forward Converter Primary switched mode power supply units with an output power of greater than 200 W used to be designed with forward converters Today flyback converters may be used for an output power of up to 1000 W Therefore forward converters are more and more being replaced by space saving and reliable flyback converters also for higher performance ranges The following section explains the circuit principle of forward converters The major difference between a flyback converter and a forward converter is that in the forward converter the energy transport from the primary to the secondary circuit is carried out with the switch closed The forward converter owes its name to this principle The design of the forward converter is more complicated than the design of the flyback converter The transformer requires an additional primary winding and the output circuit additional diodes and an inductance This makes forward converters larger in size and heavier than flyback converters Method of Operation Figure 2 16 shows the simplified structure of a forward converter The power switch S1 is switched on and off by means of a controller with the control voltage U tr The value of the output voltage Usut depends on the pulse duty factor of switch S1 The value of the output voltage Ugut is continuously measured and transmitted to the controller In this way a stab

User Manual SYS POWER SUPPLY UM E

Contents

Download Pdf Manuals

Related Search

Related Contents