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Embedded World 2023

Andreas Mühlbauer,

Power supply with EtherCAT interface

Beckhoff has expanded its PS power supply series within the PS2000 series to include devices with an EtherCAT interface. This provides additional measurement and device data for comprehensive monitoring, which can be used to increase system availability. The power supplies thus combine compactness and high performance with the option of predictive maintenance.

The PS device series of 24/48 V power supplies cover a wide range of applications, including demanding motion applications. © Beckhoff

The new PS2000 power supplies combine the powerful power supply units from Beckhoff with the fast EtherCAT communication standard. This means that extensive measurement and internal device data can be processed directly by the controller, remote access to the power supply can be realized and the DC output range for system monitoring and the AC input range for network monitoring can be monitored.

More transparency in system operation

For system monitoring, important operating parameters such as output current and voltage are transmitted in real time and continuously updated. This enables a transparent insight into the system and, based on this, automated detection of whether additional loads have been added subsequently. Voltage, current and temperature data can also be added to the monitoring, for example to monitor heat development in the device and to collect basic system data such as the number of switch-on processes or operating hours. With single-phase grid monitoring, fluctuations such as undervoltages and overvoltages are recorded using the input voltage values. A special feature here is the detection of input transients, i.e. high, energy-rich voltage peaks in the grid.

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Error messages, warnings and status information are also available directly in the control system via EtherCAT, so that the operating status of the system can be analyzed optimally and any errors can be detected at an early stage. Warning thresholds that can be set in the control system, for example for overcurrent, allow the signaling conditions to be defined specifically for the application and the power supplies to be adapted to the individual conditions. Remote access via EtherCAT also enables system components to be switched off in a targeted manner in the event of a machine standstill or fault.

Variety of power supplies

In the 24 V DC range, the new single-phase power supply units with EtherCAT interface are available in both 10 A and 20 A versions with an output power of 240 and 480 W respectively. A 10 A variant with 480 W is available for the 48 V range. The high efficiency of over 96% is achieved thanks to the optimized layout of the electronics. In addition to an inrush current limiter and active harmonic correction (PFC), the power supplies offer a wide-range input suitable for worldwide use. With the PS1000, PS2000 and PS3000 device series, Beckhoff offers high-quality power supplies for almost all areas of application in both the 24 and 48 V DC range, including motion applications with high regenerative power supply requirements. The good convection, the minimized power loss and the high efficiency of up to 96.3 % optimize the service life and reliability of the devices. The maximum peak power capability of 150 % makes it possible to provide up to 1.44 kW output power for short periods. Together with the space-saving design and high immunity to transients and overvoltages, this enables efficient and cost-effective use even in harsh industrial environments. Furthermore, the power supplies with the precise fuse tripping function can switch off circuit breakers quickly and accurately, so that longer machine downtimes can be avoided. The UL-approved power supply units can also be used in special industries, for example with SEMI F47 approval for the semiconductor industry and DNV GL approval for shipbuilding. Use in potentially explosive atmospheres (Class I Division 2, IECEx and ATEX) is also possible.

System consistency reduces effort and costs

Every machine or system requires a reliable power supply and appropriate protection. If these are also combined with a powerful energy data acquisition system, advantages can be gained as early as the machine design stage: Additional power measurement technology at the input of the power supplies provides an overview of the total power, including any losses.

With the PS2000 series, DIN rail power supplies with EtherCAT communication are available for the first time. © Beckhoff

With the power supplies from the PS series - in particular through the integration of EtherCAT technology - components are available for a complete, coordinated automation system in the spirit of PC-based control. The EL922x overcurrent protection terminals integrated directly into the EtherCAT I/O system are used to additionally protect and continuously record the power of the individual supply paths. If the machine manufacturer can use this holistic approach to avoid power peaks, for example, the connected load of the system is reduced and the installation costs for the end customer are also lower due to the smaller dimensions of the supply cables. Furthermore, consistent and system-integrated energy measurement technology is the prerequisite for comparing the target and actual status of the system directly within the machine control system. In this way, impending damage can be detected at an early stage and process optimization potential can be identified more easily.

Until now, continuous data monitoring was usually associated with considerable effort, as external sensors often had to be integrated subsequently at high cost and sometimes with the aid of special components. With the power supplies, energy measurement terminals, current transformers and overcurrent protection terminals from Beckhoff, however, this can be realized with standard components and correspondingly low effort as well as reduced logistics costs, for example for the storage of special parts - even in the context of retrofits of existing machines and systems.

Christian Jürgenhake, Product Manager I/O, Beckhoff Automation

embedded world, Hall 1, Stand 130

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