Operating manual

Name:

Area

I IS MS EDM
Smart Power 1600

Introduction:

Smart Power 1600 unit is the power supply unit operating at 230 VAC (+/- 10%) 50/60 Hz and having
PROFIBUS functionality. The unit supplies stabile current at 0-100 V voltage, between 0 and 25 A as
output. Nominal output power is 1600 W. Output current in specified area can be adjusted on
PROFIBUS or analogue interface. Output current is adjusted based on load. Actual value of output
power is returned over relevant interface. This unit is calibrated as per environment temperature
between 0 and 40°C and has a air coolant.

Specifications:

• Output power is 1600 W / maximum 25 A / maximum 100 V

• Control and viewing is possible over PROFIBUS and analogue interface.
• Adjustable output current 0..25 A
• Configurable analogue interface is 0..10 V or 0(4)..20 mA
• Active power factor correction (PFC)
Operating manual Version 1.2 Smart Power 1600

0 Table of contents
0 Table of contents 2

1 Overview 4

2 General information 9

2.1 Installation and function of unit 9

2.1.1 Internal installation 9

2.1.2 Operation mode 9

2.1.3 Output indicator line 10

2.1.4 Profibus DP interface 11

3 Connections, sockets and interfaces 13

3.1.1 Out connections X1 13

3.1.2 Profibus connection X2 14

3.1.3 Analogue interface X3 14

3.1.4 Main station X4 15

3.1.5 DIP switch block S1 15

3.1.6 DIP switch block S2 16

3.1.7 Grounding connection unit on the back side 17

3.1.8 LED indicator 17

4 Technical data 18

5 Installation and operation 20

5.1 Installation 20

5.2 Connections 21

5.3 Operating 21

5.4 Limit data for output of Smart Power 1600 21

6 Miscellaneous 22

6.1 Terms/abbreviations 22

6.2 List of figures 23

6.3 Version summary 23

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1 Overview
This manual covers necessary information for operating the unit. This manual will be referred to as
measurement technique, control technique and calibration and automation technique and addresses to
the personnel having necessary knowledge and technical qualification. Please consider warnings and
safety instructions for the safety of installation, operating, commissioning and service. Only technical
personnel can interpret and implement safety instructions and warnings in this operating manual
properly. This operating manual is the integral part of the package delivered. For clarity, it does not
include details of all implementations of the product described and every kind of conditions about
installation, operating and service cannot be considered.

Meaning of signs:

! To be used only qualified personnel

.

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! Warning!
While operating electrical unit, certain parts of the unit carry dangerous current inevitably. Serious
injuries or material damages can occur if warnings are not considered. Only qualified personnel can
work on this unit. For safe and smooth operation of this unit, proper transportation, storing, installation
and assembly and careful operation and service are the essential aspects.

QUALIFIED PERSONNEL
Unqualified intervention to the unit/system or not following warnings in this manual can lead to severe
injuries and material damages. For this reason, only qualified personnel can intervene with this
unit/system. Qualified personnel are the person having following qualities within the scope of
instructions of safety described in this manual or unit;
• Being qualified in automation technique and safety technique concept as projecting personnel,
• Or trained as service personnel for installation of automation technique and being component
on information included in this operating manual;
• Or authorized trained person for repair of such automation technique as service or operating
personnel or authorized persons for operating such electricity circuits and units/systems,
grounding and identification within the scope of safety technique standards.

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Safety
technique
explanations This manual includes explanations you need to follow for your personal
safety and to prevent material damages. These explanations are highlighted
with warning triangles and explained as per degree of danger:

Danger
! Failure to take necessary safety measures may result in death, severe injury
or major damages.

Warning
! Failure to take necessary safety measures may result in death, severe
injuries or damages.

Caution

! Failure to take necessary measures may result in minor injuies or

damages.

Note

Includes important information about the product, information emphasized

for use of documentation or product.

Qualified
personnel
The unit can be operated and worked by only qualified personnel. Qualified
personnel within the scope of these safety instructions in this manual are the
persons authorized for operating, grounding and descriptions of any kinds of
electricity circuits, units and systems.

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Intended use Consider following points:

Warning

! This unit can be operated with units and components authorized to

be used by SIEMENS or stated in this manual.

To operate this unit smoothly and safely, it should be transported, stored,

installed, assembled and used properly.

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Waiver

Content of this manual, hardware and software described were checked by us for conformity. In spite of
this, differences cannot be excluded, and we are not responsible for the full compatibility. Information in
this manual is revised regularly. Corrections made are available in the later editions. We will appreciate
your correction recommendations.

Copyright

© Siemens AG, 2009. Alle

All rights reserved.

Restriction of use

This manual cannot be reproduced, copied, published and/or adopted by the third parties without
prior consent. Failure to obey this will constitute compensation right. All rights for patent registration,
utility or design registration are reserved.

Modifications

Technical modifications are protected.

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2 General information
2.1 Installation and function of unit
The unit consists of ventilator and plate covering air coolant and is placed in ½ 19” enclosure. All
connections and marking elements are on this main plate and their locations are present on the front
face.
2.1.1 I n t e r n a l i n s t a l l a t i o n
In figure 1 schematic internal installation of the unit consisting of power and control unit is shown.

Power level

X4 input 23C VAC +‐ X1 output 0.100 V

10% % 50 Hz 0.25 A/1600 W
External nominal value
Power
for configuration and
nominal value
communication
X3 Analogue interface

DIP 1 address profibus

Output power and
DIP 2 configuration voltage measurement

Status LED

X2 profibus

Additional grounding connection

at the back of unit

Figure 1: block diagram

The unit operates as controlled power supply. By means of external nominal value, output current can
be adjusted between 0..25 A and at the stags of 0,025 A (Attention: The definite accuracy of actual
output current is +/- 0,25 A). Output current ranges between 0 and 100 V and a peak value is
guaranteed above 100 V.
2.1.2 Operation mode
The unit has two different operation mode depending on which interface is used for nominal value. Both
operation modes are selected on DIP switch externally or can be configured. In both modes, actual
value of electricity is returned over both interfaces.

Operation of analogue interface (See 3.1.3 for description of this interface)

In this mode, nominal value and unit control are realized on analogue interface X3. The input channel
for nominal value in analogue mod may be of three different types and can be configured by DIP
switches on the unit:

1. At 0..10 V level, current input corresponding to 0..25 A

2. At 0..20 V level, current input corresponding to 0..25 A
3. At 4..20 V level, current input corresponding to 0..25 A

Operation on Profibus (See 2.1.4 for description of this interface)

In this mode, all nominal values and control directives are performed on Profibus. Only actual value of
electricity can be read on interface.

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2.1.3 O u t p u t i n d i c a t o r l i n e
Figure 2 shows the limitation of static overloading of output signal relating to UA and IA. In addition to
this, it is possible to see all working points within limitation curve. Maximum output current is limited to
100 V minimum value. Static power limitation is minimum 1600 W. Maximum output current value is 25
A.

Voltage limitation for U ≥100 V

Pmax power limitation ≥1600 W

Short‐circuit inspection

Power limitation = 15 A

Figure 2: Static load limitation

Short-circuit
protection
As short-circuit, output current is less than 15 V and output power is bigger than 15 A (corresponding to
“efficient” load resistance < 1 Ohm). In case of output current is 15 V, short-circuit is activated. In this
case, output power is limited to max. 15 A.

Values stated show static limitations. Dynamic, high

values in <1 second time frame can be seen.

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2.1.4 Profibus DP interface

PROFIBUS-Interface has 5 term inputs and outputs.

Term 1 Term 2 Term 3 Term 4 Term 5

5 terms input

State term Actual value I Actual value U Reserved Analogue

nominal value

5 terms output

Command Nominal value I Reserved Reserved Reserved

Nominal values and real values are formatted as 1/100 Ampere or 1/100 Volts.
E.g: Nominal value I: 1500 => 15 A; actual value I: 2000 => 20 A or actual value U: 7000 => 70 V

Description of State:

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Hardware Error
Power Ready
- (don’t care)
- (don’t care)
Power component error State
- (don’t care)
Power Error
- (don’t care)
- (don’t care)
- (don’t care)
- (don’t care)
- (don’t care) / reserved
- (don’t care) / reserved
Alive-Bit (Toggle bit appr. 1 Hz)
Hardware mode (Analogue = 0 / Profibus
= 1)
- (don’t care)

Figure 3: Description of State

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Bit identification of State

Hardware Error =1: hardware error

If this error occurs following start up, power component fails or does not connect to any load.
If it occurs during work, hardware is overheated, short-circuit or power component fails.
=0: Everything is o.k.

Power Ready =1: power is ready

=0: power is not ready. If this bit is not applicable in relative time, there is error of power
component.
Power component =1: collective failure of power component. As a result of improper operation of power component.
=0: Everything is o.k.
error
Power Error =1: load failure or short-circuit
=0: Everything is o.k.
Alive-Bit =0/1: This bit changes the State with 1 Hz frequency and indicates that connection is defective or
not ready for operation.
Hardware mode =1: Hardware is in PROFIBUS mode
=0: Hardware is in analogue mode. Only actual values can be followed over PROFIBUS.

Table 1: Bit identification of State

Identification of command :

15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Power Enable
Enable Interlock
- free
- free
- free
- free
- free
- free
- Hardware mode Bit 0
- Hardware mode Bit 1
- free
- free
- free
- free
- free
- free
Figure 4: Identification of command
Bit identification of
command

Hardware mode 00: Nominal value output power

01: not identified
Bit 0 and Bit 1
10: not identified
11: not identified
Power Enable =1: open power
=0: switch off power
Enable =1: Enable Interlock
=0: Disable Interlock
Interlock

Table 2: Bit identification of command

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3 Connections, sockets and interfaces

All connections are in front of the unit. Connections, signal LEDs and command hardware are shown in
the following figure. Functioning is described below.

Figure 5: front view of connections and control components.

3.1.1 Output connection X1

In X1 connection (type: Front 4-H-6,35 generator Phoenix Contact) output power or output current
controlled can be caught. Output is separated potentially for PE and power input (X4).

! Notice!
OUTPUT CURRENT LEVEL CONSTITUTES CONTACT DANGER!

Nominal data of output are as follows:

Nominal output current 100 V

Nominal output electricity 25 A
Nominal output power 1600 W

Nominal values of output current and output power are not present simultaneously; output power of unit
is limited to 1600 W nominal value in any case. Overloading shorter time as <1 seconds is an
exemption.

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Connection
designation:

Connection 1 (left): +0..100 V / 0..25 A

Connection 2 (right): 0V

Figure 6: connection allocation X1 (front view of the unit)

3.1.2 Profibus connection X2

Max. Baudrate: 12Mbaud
connection : UNC pin plug 9-pole Sub-D-plug for drawing relief

Number Meaning
1 N.C.
2 N.C.
3 PROFIBUS-DP - B
4 RTS
5 GND
6 +5 V
7 N.C.
8 PROFIBUS-DP - A
9 N.C.
Table 3: PROFIBUS – interface allocation Figure 7: Profibus connection X2

Switching between operating modes of analogue control over

PROFIBUS and triggering is realized by DIP switch block S1 (See
3.1.5)
3.1.3 Analogue interface X3
The unit can be controlled over analogue interface without PROFIBUS. This mode can be switched via
DIP switch block 1. Configuration of analogue interface is realized via DIP switch block S2.

Connection: UNC pin plug 9-pole Sub-D-plug for drawing relief

Galvanic division: 1 / 2 / 3 / 4 / 5 pins were applied as galvanized and they have
compound 0 V-potential pin 2.
6 / 7 / 8 / 9 pins are connected to Ground (Pin 7).

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Number Meaning
1 Interlock: If the signal is +24 V (Pin2), the unit is ready to function. Output
regulator switches off automatically in case of power failure and power of
component is interrupted (emergency power off) .
2 Interlock-/Enable-/Ready- Signal, 0V-potential
3 Enable (input): power output is activated via 24 V-Signal (release)

4 Reserved
5 Ready (output): p o t e n t i a l o f P i n 1 i s t r a n s f e r r e d t o p i n 5
over relay contact.
6 Actual value (output): the power is transferred between the values of 0..10
proportionally at the output (corresponds to 0..25 A). potential connection with
Ground (Pin7).
7 Analogue output current connection potential
8 Positive nominal value (input): In 0..10V or 0..20 mA or 4..20 mA area,
difference voltage (or input current) against negative value (pin 9) is adjusted
in 0..25 A proportionally to the output. Switching between current interface
or power interface and their configurations is performed via DIP switch
block 2.
9 Negative nominal value (input): low potential of nominal value voltage is
transferred to Pin8. This pin is grounded at the factory (Pin7)
.
Table 4: Connections of Analog interface / control interface X3

3.1.4 Main station X4

Current input is realized over main station X4 (L1 / N / PE) (Type.: Front 4-H-6,35 generator Phoenix
Contact). There is a fuse on the plate (T10AH,250V). The unit has no power switch, this is performed
by external fuse switch 816 A, Type B). Please see figure 8 for connections.

Figure 8: main station X4 distribution

3.1.5 DIP switch block S1

(DP) address of Block S1 is set via eight DIP switches by two encoding and Profibus address of unit is
set and operating mode is selected. Please see 9 for value and example setting of switches (operating
on PROFIBUS with Address 3).

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Figure 9: DIP switches in Block 1 for setting Profibus address and switching operating modes

If switch 8 is ON, the unit is in analogue mode (control is not active on PROFIBUS). In this case,
triggering is performed via interface X3. Configuration of analogue connection is realized via DIP
switch block 2.

Input of S1 is realized via operating supply power to the unit for one time. For input of this
change, supply current of the unit should be disconnected or restarted. Change made during
operation has no affect.

3.1.6 DIP switch block S2

Block 2 (Mode) can be configured as analogue interface via DIP switch 1 and 2. Switch 3 and 4 has no
function.

Figure 10: DIP switch block 2

Designation and functions of switches are listed in the following table.
Switch No. Designation Function
1 ve 2 Switch combinations Current input / electricity input analogue channel
Nr. 1 / Nr. 2 switching
OFF / don’t care
ON / OFF Current control (0..10 V) analogue interface
ON / ON 0..20 mA electricity interface
3 ve 4 Without function

Table 5: DIP switch combinations

Input of S2 position is realized via supply current for one time. For input of this change, supply
current of the unit should be disconnected or restarted. Change made during operation has no
affect.
DIP switch no.2 cannot be changed during operation.

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3.1.7 Back side of grounding connection

There is an additional grounding connection under type plate (See figure 11) main protection line
connection this X4 .

Figure 11: Additional grounding connection under type plate at the back of the unit (PE)

3.1.8 LED indicators

Four LED’s in front of the unit (See figure 12) and provides information operating State, output electricity
and possible failures.

Figure 12: LED indicators in front of the unit

Various meanings of LEDs are listed in table 6.
LED Color Definition Meaning
State Green Operating State If unit is off, LED is off.
If the unit is on, LED flashes slowly, however Profibus has no
connection.
If LED flashes fast, the unit is on and data exchange is performed.

Error Red Error / failure This LED is on when maximum temperature exceeds internally.

Current Green Output active This LED is on when there is current more than 0,2 A at the output.

Limit Red Short-circuit, This LED is active when one of limitations activates. In other
over current, words, existing working point is on limitation curve. (See figure 2)
Relay,
overloading
Table 6: Meaning of LED indicators

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4 Technical data

Construction data
Case Stainless steel 1.4016 1.5 mm wall thickness
Width: ½-19“ (210 mm) (except installation
connections)
Length: 3 HE (112 mm)
Installation to switch cabinet
Depth: 295 mm, including ventilator (except installation
Fixing connections)
Weight
Cooling With 4 ∅ 6mm screw, at the back of unit about 7 kg
Electricity data
Power supply 230 VAC +/-10% 50/60 Hz / 8,5 A
Maximum 1900 VA / 1900 W
Power input
type.> 80%
Affect grade
pole connection X4 (L1 / N / PE) (Type.: Front 4-H-6,35
Electricity supply connection X4
producer Phoenix Contact)

External protection Extra grounding over metal case.

Protection class Fuse switch 16A, triggering characteristic B1
Over voltage category II

Electricity circuit isolation Isolation as per EN60950-1:2006

IP protection class IP20

Electricity output X1 Screw connection (Type.: Front 4-H-6,35 producer Phoenix

Connection Contact)
Nominal output current + 100 V
+ 0...25 A
Nominal output electricity
Maximum electricity and current is not possible
simultaneously.
Nominal
power Power is limited to 1600 W -0/+10%.
Calibration: 1600 W
Accuracy: Calibration of output electricity
From < 1% maximum value
Act in case of short-circuit:
(25 A) continuous short-circuit
test

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PROFIBUS X2
Connection For 9-pole UNC threaded Sub-D-PROFIBUS-
Baud rate 9,6kBd...12MBd
Functions supported - Standard DP-Slave
- Auto Baud detection

Functions not supported - Sync / Unsync

- Freeze / Unfreeze
- expanded diagnosis
Protocol: - Profibus DP – Functions
Inputs: 5 terms
outputs: 5 terms
PROFIBUS-ID number available upon request
Control - / Analogue- interface X3
Connection For 9-pole UNC-screw and grease Sub-D-pin
socket
Digital control current for Interlock 24 V +/-10%, from external control
and Enable galvanized separated inputs.

Switched between interface electricity and current

Current control:

Analogue nominal value –control 0...10 V (0...25 A corresponding to output electricity)

current 0...10 V (0...25 A corresponding to output electricity)
Analogue actual value –output current
0..20 mA (4..20 mA) 0..25 A corresponds to output electricity
Proper ambient conditions
Temperature during operating 0°C bis +40°C
Temperature during storing -20°C bis +60°C
Temperature during -25°C bis +70°C
transportation 10% - 93% (humidity is not proper)
Air humidity Up to 2000 m ü. NN.
Instructions
Safety EN60950-1:2006
Electromagnetic EN 61000-6-4
interference
Interference EN 61000-6-2
Immunity

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5 Installation and operating

! Warning!
During operation of electricity units, certain parts of these units are under dangerous current inevitably.
Failure to obey operating instructions may result in severe injuries or material damages. For this
reason, the unit should be installed and fixed by only qualified personnel. All warnings must be
considered.

! Warning!
It is not allowed to operate the unit as it is open.

! Warning!
The unit should be connected to feed network with fixed connection.

5.1 Installation
• The place of installation must be free of vibrations as much as possible. Proper ambient conditions
(operating temperature or storing temperature and transportation temperature conditions) must be
followed (See Technical data)
• Operating except the temperature range may result in dangers, wrong operation and non-operation.
• Protection class of metal case is I as per EN60950-1:2006
• The unit can be operated in only closed cases or switch cabinet. These should meet requirements of
fire resistance and durability of EN60950-1.2006. The unit should be installed in a place to be
accessed by only qualified personnel.
• To protect construction groups, before discharging static electricity, the personnel must discharge
himself electro statically before opening switch cabinet.
• To ensure adequate ventilation for the unit, minimum 3,5 cm space should be left in front of the air
gaps of the unit. The space at the back of unit should be the same. Many units can be installed side
by side, otherwise but minimum 1,5 cm space should be left between unit and unit.
• The temperature of air absorbed should not exceed 4 0 C .
o

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5.2 Connection
• During power installation, installation instructions for strong current centres should be considered.
• Connection of supply voltage should be performed (230 VAC +/- 10%) as per VDE0100 and
VE0160.
• Supply voltage of the unit should be equipped with protection fitting (fuse switch) (16 A /
triggering characteristic B).
• Main protection line connection is placed in X4 plug. In addition to this, a grounding connection is
available at the back of unit.
• The section of supply connection line should be minimum 1,5 mm2.
• The output lines should be of 4 mm2 section minimum.
• External connections of the unit should be performed by double isolation lines.
• While connecting the unit to the supply network, overvoltage category of this network should meet
category II. (See EN60950-1:2006). If necessary, overvoltage protection is connected to this unit as
serial connection and overvoltage category II is met (See EN 60950-1:2006).

5.3 Operating

! Note!
Following steps should be performed. Most importantly, supply lines should be installed last!

1. Check whether operating data comply to data on the type plate.

2. Do not change the unit, configure the unit as described in section 3 if necessary (in other words,
set operating mode and PROFIBUS address via both DIP switch blocks).
3. Fix the unit to the switch cabinet via connection part at the back of unit and (∅ 6mm) screws and
nut stamp.
4. Ensure grounding of additional units at the back of unit (See Figure 11)
5. Fixing different plugs (analogue interface, PROFIBUS plug)
6. Connecting the load to the output plug should be performed considering polarity marked on the
unit.
7. Connecting supply line should be performed considering plug designation marked on the unit.
8. The unit will be ready for operation after operating the supply line. Green LED “State” flashes.

5.4 Limit data for output of Smart Power 1600

Maximum values:

Output electricity: maximum 25 A continuous.

Output voltage: maximum 100 V continuous.
Output power: maximum 1.6 kW continuous.

Values stated are the values that the unit limits. These values can be exceeded for shorter time (<0,1
s).

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Minimum values:
Power fluctuations rise in small output electricity, for this reason, it is not a recommended operating
area.

For unloaded output, approximately 150 V maximum voltage can be acquired by output plugs.

6 Miscellaneous
6.1 Terms/abbreviations
AUSG output
EING Input
EN European Norm
DP Off center perimeter (Profibus)
LED Light diode
SUB-D Sub miniature plug, D form

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6.2 Figure index

Figure 1: block diagram of the unit 9
Figure 2: Static load limitation 10
Figure 3: Definition of state 11
Figure 4: Definition of command 12
Figure 5: Front view of connections and control components 13
Figure 6: Connection designation X1 (front of unit) 14
Figure 7: Profibus connection X2 14
Figure 8: Main station X4 distribution 15
Figure 9: DIP switches in Block 1 to set Profibus address and to change operating modes

16
Figure 10: DIP switch block 2 16
Figure 11: Additional grounding connections under the type plate of the unit (PE) 17
Figure 12: LED indicators in front of the unit 17

6.3 Version summary

Version Date Note
V 1.0 13.01.09 Document preparation
V 1.1 23.02.09 Processing amendments following safety pre-review
V 1.2 24.02.09 Adapting safety requirements to SN 11108:2007

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