Smitec ICOS-PS 3160 Series Installation, Use And Maintenance Manual

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Power supply ICOS-PS 3160 series

Smitec S.p.A., viale Vittorio Veneto 4, 24016 San Pellegrino Terme (BG), Italy, www.smitec.it

Installation, use and maintenance manual

BEFORE PUTTING INTO SERVICE THE POWER SUPPLY UNITS OF THE ICOS-PS

3160 SERIES, CAREFULLY READ THIS MANUAL AND FOLLOW ALL INSTRUCTIONS,

IN ORDER TO ENSURE MAXIMUM SAFETY

The technical data and the drawings in this manual might have been modified later; always

refer to the latest version.

Ver. 1.05

POWER SUPPLY UNITS

ICOS-PS 3160 SERIES

Installation, use and maintenance manual - EN

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Page 1 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN Smitec S.p.A., viale Vittorio Veneto 4, 24016 San Pellegrino Terme (BG), Italy, www.smitec.it Installation, use and maintenance manual BEFORE PUTTING INTO SERVICE THE POWER SUPPLY UNITS OF THE ICOS-PS...
Page 2: Table Of Contents
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN Summary 1 Preface ............................... 4 2 General warnings ............................5 3 Safety instructions ............................ 7 3.1 General information ..........................7 3.2 Precautions during handling and assembly ..................7 3.3 Precautions against the risk of Electric Shock ..................
Page 3 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 9 Decommissioning and disposal ......................59 10 Analytical index ............................. 60 Ver. 1.05...
Page 4: Preface
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 1 Preface This manual provides all necessary information for the installation, use and maintenance of the power supply units ICOS-PS 3160. The instructions included in this manual are addressed to the following professionals:...
Page 5: General Warnings
MANUAL. THE EQUIPMENT MUST NOT BE USED FOR PURPOSES DIFFERENT THAN THE ONES DESCRIBED IN THIS MANUAL; SMITEC S.p.A. SHALL NOT BE HELD RESPONSIBLE FOR ANY DAMAGES, IN- CONVENIENCES OR ACCIDENTS DUE TO THE NON-COMPLIANCE WITH THESE PRESCRIPTIONS. In order to make the manual consultation easier, the following symbols have been adopted: Indication of “PROHIBITED ACTION”.
Page 6 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN The symbol “USE OF INDIVIDUAL PROTECTIONS” means that protective gloves must be worn. The symbol “USE OF INDIVIDUAL PROTECTIONS” means that protective glasses must be worn. Indication of “INFORMATION OF PARTICULAR RELEVANCE”.
Page 7: Safety Instructions
It is absolutely forbidden to use the equipment for different purposes than the ones de- scribed in this manual. The technical data and the drawings in this manual might have been modified later; always refer to the latest version. All upgrades can be requested to SMITEC S.p.A. directly.
Page 8: Precautions Against The Risk Of Electric Shock
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 3.3 Precautions against the risk of Electric Shock All connectors on the equipment except for the interface connector (CTR) are potentially connected to dangerous voltages. Pay attention, to avoid danger of Electric Shock.
Page 9: Residual Risks
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN By using the power supply in the construction of a machine, the manufacturer must take all precautions to avoid the operator's contact with the hot parts, to avoid the risk of burns.
Page 10: Technical Data
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 4 Technical data 4.1 Environmental specifications 0° ÷ +45°C with full-load operation Operating temperature (Maximum surrounding air temperature) 0° ÷ +55°C with current derating Environment of use Use in Pollution degree 2 Environment...
Page 11: Power Supply
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 4.2 Power supply Mains voltage 230V AC ±15% 50/60 Hz Type of power supply Single-phase or three-phase Maximum short-circuit current 5 kA at the installation point 28.2A RMS (single-phase power supply) Mains power supply absorption 26.5A RMS (three-phase power supply)
Page 12: Digital I/O
4.7 Accessories The power supply units of the ICOS-PS 3160 series are supplied with a complete series of detachable connec- tors for power supply and I/Os connection. The connectors can also be ordered separately, like other not in- cluded accessories.
Page 13: Mechanical Specifications
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 4.8 Mechanical specifications 4.8.1 Weight The following table indicates the weight of the different models, including all detachable connectors: Type Weight (kg) KZ010451 KZ010628 4.8.2 Overall dimensions External size of the device only, without detachable connectors.
Page 14: Installation And Putting Into Service
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 5 Installation and putting into service 5.1 Preliminary operations Before putting into service the device, make the following checks: • check the perfect integrity of the device and its components;...
Page 15: Installation Mode
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 5.2 Installation mode During the installation of the device, the upper and lower part must have a free space of at least 100 mm com- pared to other components or to the walls of the electrical panel, while other components can be placed along- side the ICOS-PS 3160 power supply without leaving any space.
Page 16: Positioning And Fastening
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 5.3 Positioning and fastening The device must be fastened to a vertical wall inside the electrical panel; the heat sink is provided with two slots for screws having metric ISO thread M5.
Page 17 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN The picture here below shows the position of the holes to be arranged in the holding panel. Ver. 1.05...
Page 18: Connections
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 5.4 Connections Electrical connections are ensured by detachable connectors, except for the connection PE (Ground), which must be connected by means of an eyelet crimp terminal and a suited fastening screw.
Page 19: Front View
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 5.4.2 Front view The following picture shows the connections available on the front face of the device: Connections Marker Description Auxiliary power and I/Os Ver. 1.05...
Page 20: Bottom View
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 5.4.3 Bottom view The following picture shows the connections available on the bottom face of the device: Connections Marker Description Reactor (if not used, connect a jumper using 6 mm / 8 AWG wire.)
Page 21: Mains Power Supply - J1
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 5.5 Mains power supply - J1 These are the connections to 230VAC mains power and line filter. CAUTION Large capacitors inside the device. Risk of Electric Shock; wait at least No. 600 seconds (10 minutes) after disconnecting power.
Page 22 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN Connector type: Phoenix Contact SPC 5/3-ST-7,62 (1996029) Order code: KF101042 Features Conductors cross section * ** Connection in accordance with EN-VDE Solid min. 0,2 mm² Rated voltage 1000 V Solid max.
Page 23 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN CAUTION For safety reasons, the device must always operate with the PE (Ground) terminal connect- ed, to avoid electrical shock. The PE (Ground) connection must be carried out by means of the specific terminal;...
Page 24: Connection Schematic
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 5.5.1 Connection schematic The recommended connection schematic is shown on the following page; these devices are designed to operate with TT or TN distribution networks. For use in accordance with UL certification, only TN distribution is permitted.
Page 25 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN NETWORK FILTER PROTECTION DEVICES POWER SUPPLY Ver. 1.05...
Page 26: Conductors And Protective Devices
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 5.5.2 Conductors and protective devices 5.5.2.1 Protection for UL applications This device is Suitable For Use On A Circuit Capable Of Delivering Not More Than 5000 Arms Symmetrical Amperes, 230Vac Maximum when protected by semiconductor fuse model FR14GR69V40T by Mersen.
Page 27: Emi Filtering
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN In case of protection by means of automatic circuit breakers, it is recommended to use C-curve devices con- form to IEC 60947-2 standard. The following table shows the recommended solutions:...
Page 28 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN CAUTION The EMI filter gives rise to a considerable leakage current directed versus PE (Ground); don't energize the device without the PE (Ground) connection, in order to avoid the risk of Electric Shock when touching the exposed metal parts (such as the heatsink).
Page 29: Braking/Discharge Resistor Output - J2
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 5.6 Braking/discharge resistor output - J2 This connector allows the wiring of a power resistor for the dynamic braking and automatic discharge (ICOS- PS 3162 only); the following illustration shows the pinout of the connector (because it's a resistor, it is not nec-...
Page 30 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN This function is sometimes necessary when you supply power to servodrives, which may create a flow of elec- tric power directed versus the power supply unit during the motor braking phase. This often happens during cycles (cams) or during an emergency stop.
Page 31: Dc Bus Output - J3
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN The braking resistor can also be used to automatically discharge the internal capacities of the ICOS-PS 3162 power supplies; if in the application it is not necessary to perform dynamic braking but want to use the automatic...
Page 32 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN Stranded min. 0,2 mm² Rated current 41 A Stranded max. 6 mm² Stranded, with ferrule without plastic Insulating material 0,25 mm² sleeve min. Inflammability class according to Stranded, with ferrule without plastic 6 mm²...
Page 33 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN Wait until POWER GOOD output is active (logic level “1”) before starting to drain current from the output. Otherwise, the unit and the devices connected to it could be damaged.
Page 34: Auxiliary Power And I/Os - Ctr
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 5.8 Auxiliary power and I/Os - CTR This connector is used for the connection of digital I/Os, allowing the device to interface with an external system (eg. a PLC).
Page 35: Power Supply Setting
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN Connector type: Phoenix Contact FMC 1,5/7-ST-3,5 (1952319) Order code: KF101050 Features Conductors cross section * ** Connection in accordance with EN-VDE Solid min. 0,2 mm² Rated voltage 160 V Solid max.
Page 36: Interface I/Os
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 5.8.2 Interface I/Os The power supply unit features a digital input (RESET) and two outputs (POWER GOOD and ALARM). They allow to interface the unit with external devices (such as a PLC). In this way, it is possible to know if the power supply unit is ready to operate and the user can reset some error conditions.
Page 37 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN The I/O functions are described in the following table: Denomination Types Notes Input used for resetting possible error conditions. It includes the debouncing function to interface with electro-mechanical switch-...
Page 38: Reactor - J4
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 5.9 Reactor - J4 This connector serves to connect a reactor (optional) in series at the output of the rectifier bridge. Because the input current is highly distorted due to the non-linearity of the rectifiers, a large generation of current harmonics arise related to the current drawn from the mains.
Page 39 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN Connector type: Phoenix Contact SPC 5/2-ST-7,62 (1996016) Order code: KF101078 Features Conductors cross section * ** Connection in accordance with EN-VDE Solid min. 0,2 mm² Rated voltage 1000 V Solid max.
Page 40 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN CAUTION Large capacitors inside the device. Risk of Electric Shock; wait at least No. 600 seconds (10 minutes) after disconnecting power. Do not connect or disconnect cable and connectors be- fore that time.
Page 41 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN The following graphs indicate the current magnitude as a function of the reactor inductance (the first chart re- fers to single-phase power supply, the second one to three-phase). The maximum inductance value must be equal to 500uH.
Page 42 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN The insertion of a reactor causes a reduction of the output voltage as indicated in the two following graphs, showing the output voltage magnitude as a function of the reactor inductance, with the maximum permissible load pertinent to the type of power supply (the first graph refers to single-phase, the second one to three- phase).
Page 43 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN Ver. 1.05...
Page 44: Status Leds
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 5.10 Status LEDs The power supply unit features some LEDs on the front panel, indicating the status of the device and operation errors, if any. There are six LEDs; the following image shows their position:...
Page 45 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN CPU FAULT: it switches ON in case of CPU fault (device failure). Ver. 1.05...
Page 46: Operation And Diagnostics
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 6 Operation and diagnostics The power supply units are designed to rectify and stabilize the mains voltage (single-phase or three-phase), in order to deliver power to servodrives or other devices requiring a DC voltage.
Page 47: Capacitors Charging
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 6.2 Capacitors charging For the stabilization of the rectified line voltage, the power supply unit contains high-capacitance electrolytic capacitors, initially discharged. The initial charging must be adequately controlled, in order to prevent the...
Page 48: Anomalies During The Charging Phase
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 6.3 Anomalies during the charging phase In some cases, the charging phase may not be completed and the power supply unit enters the alarm status, waiting for the RESET signal in order to be restored and start a new charging phase.
Page 49: Working Operation And Possible Anomalies
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN One of the three phases power Voltage supply is missing or Power >250VDC the power supply unit supply Lamp within has not been set to missing from single-phase...
Page 50 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN In these cases, the diagnosis of the problem causing the alarm must also take into consideration the informa- tion coming from the servodrives connected to the power supply unit, according to the following table.
Page 51 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN Short-circuit dynamic braking resistor output. The power supply unit continues working, but can not dissipate the excess energy. Wait reset signal. Dynamic NOTE: resetting the braking Voltage power...
Page 52 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN The maximum currents that are continuously available at the output are indicated in the following table: Power supply Current Single-phase 9.0A Three-phase 16.0A The following chart indicates the maximum time during which a certain current limit can be exceeded, without overload error message.
Page 53: Dynamic Braking
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN The following chart refers to single-phase power supply: The curves refer to gPV 10x38 fuse-links. More precisely, the overload diagnostic intervenes earlier than the fuse, provided the rated current of the fuses in use is equal to 12A (single-phase) and 20A (three-phase). The fuse blows only in case of short-circuit or heavy overload, thus avoiding its interruption during normal operation.
Page 54: Missing Phase
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN In order to avoid this problem, the dynamic braking stage dissipates this energy in a power resistor (external to the power supply unit and properly sized). It is connected to the bus voltage using an IGBT transistor, which is activated only when the bus exceeds a preset threshold.
Page 55: Digital Input: Reset
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN For reference, keep in mind that the DC Bus voltage to reduce from 450VDC to 60VDC overall takes approxi- mately: • 400ms with 20ohm resistor • 550ms with 30ohm resistor •...
Page 56: Storage
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 7 Storage The power supply unit and its components can be stored in their original packaging and always in a covered place, even if they are packed. Protect the device against dust and atmospheric agents.
Page 57: Maintenance
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 8 Maintenance WARNING Large capacitors inside the device. Risk of Electric Shock; wait at least No. 600 seconds (10 minutes) after disconnecting power. Do not connect or disconnect cable and connectors be- fore that time.
Page 58: Replacement Of The Charging Resistor
Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 8.1 Replacement of the charging resistor In case of failure of the charging resistor, replace it as indicated in the following image (the component KG020098 must be ordered as a spare part).
Page 59 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 9 Decommissioning and disposal The disposal of this device must be carried out according to the laws in force in the country where it was in- stalled. Should the disposal be partial (frame, heat sink, electronic boards), separate the components made of plastic from the components made of aluminium, etc.
Page 60 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN 10 Analytical index Numerics 1PH/3PH ..........12, 34, 37 Handling ............7 24V..............34 Heatsink ............8 Alarm........12, 34, 36, 37, 48, 50 I/O ............12, 34, 36 Altitude .............
Page 61 Power supply ICOS-PS 3160 series Installation, use and maintenance manual - EN Temperature ............ 27 Three-phase..........35, 52 TN distribution..........24 Working operation ..........49 Ver. 1.05...

This manual is also suitable for:

Icos-ps 3161 Icos-ps 3162