ELAU PacDrive Power Supply PS-5:

Comprehensive Technical Overview

Introduction to PacDrive PS-5 Power Supply

The ELAU PacDrive Power Supply PS-5 is a sophisticated component designed for integration within the PacDrive™ automation system, specifically developed for modern packaging and food processing machinery. As a critical element in ELAU's modular drive concept, the PS-5 provides reliable power distribution and management for intelligent servo modules (iSH) within industrial automation environments.

Manufactured by ELAU AG, a Schneider Electric company based in Marktheidenfeld, Germany, the PS-5 represents state-of-the-art power supply technology with a compact, closed construction optimized for switch cabinet installation. Its design emphasizes ease of installation, comprehensive diagnostics, and seamless integration with other PacDrive system components.

Key Features and Technical Specifications

The PacDrive PS-5 power supply unit boasts several notable features that make it suitable for demanding industrial applications:

• Integrated mains filter and bleeder for clean power distribution

• Intermediate circuit power capacity for up to 25 iSH modules (application-dependent)

• Integrated SERCOS interface for high-speed communication

• Comprehensive diagnostic capabilities through its integrated controller

• Simplified assembly with single connection line design

Technical Data Table

Safety Features and Compliance

The PacDrive PS-5 incorporates multiple safety features to protect both equipment and personnel:

1. Residual DC Bus Voltage Display: An LED indicator warns when dangerous voltages (>50V DC) are present in the DC bus.

2. Leakage Current Protection: With leakage current greater than 3.5 mA, the unit requires a fixed connection to the power supply network in accordance with DIN EN 50178 standards.

3. Comprehensive Safety Standards Compliance:

   • EN 60204-1 (2007): Safety of machinery - Electrical equipment

   • EN 50081-2 (3/1994): Electromagnetic compatibility

   • EN 61000-6-2 (3/2000): Electromagnetic immunity

The manufacturer's declaration confirms that the PS-5 is intended for installation in machines and complies with EC machine guidelines 98/37/EC. Commissioning is prohibited until it's confirmed that the host machine meets all EC Directive requirements.

Installation and Wiring Considerations

Proper installation of the PacDrive PS-5 requires attention to several critical factors:

Power Supply Grounding Requirements

• Grounded Operation: May be operated without potential separation on AC networks with a grounded star point

• Ungrounded Mains: Requires an isolating transformer when operating on IT networks or mains without grounded neutral points

UL Conformity Requirements

• Use of a fuse (Type: maximum 40 A, 600 VAC) in the feed line

• Operation only on circuits capable of delivering ≤5000 rms symmetrical amperes

• For 24V supply, use a fuse with max. 15 A

Connection Overview

The PS-5 features multiple connection points with specific requirements:

Indicators and Diagnostic Capabilities

The PS-5 features a comprehensive LED indicator system for status monitoring and diagnostics:

Power (POW) LED

• OFF: Control voltage missing or too low

• Slow Flash (0.5 Hz): Bootloader active, firmware defective

• Brief Flash (3 Hz): Device identification active

• ON: Device ready, error diagnosis possible

Error (ERR) LED

• OFF: No error

• Slow Flash (0.25 Hz): SERCOS error

• Quick Flash (2 Hz): General error or device not configured

• Long Flash: SERCOS ring interruption

• ON: Fatal system error

SERCOS Bus Indicators

• BUS ERR: Indicates fiber-optic cable connection problems

• SINK: Shows SERCOS bus state (copper cable)

• SERR: Displays errors for copper cable SERCOS connection

Operational Considerations

EMC Rules

The PS-5 requires careful attention to electromagnetic compatibility:

• Use shielded cables only with proper grounding

• Implement star configuration grounding from central point

• Avoid cable loops in switch cabinets

• Maintain short motor cable lengths

• Isolate controller from interference sources when necessary

Maintenance Requirements

While largely maintenance-free when correctly installed, the PS-5 requires:

• Periodic cleaning with dried compressed air (max 1 bar)

• Annual checks of brake functions (if present)

• Regular verification of safety functions (EMERGENCY OFF, etc.)

• Maintenance logbook entries for all component replacements

System Integration

The PacDrive PS-5 serves as a central component in the PacDrive system architecture, which includes:

1. PacDrive Controllers: Microprocessor-based control hardware with VxWorks RTOS

2. PacDrive Servo Amplifiers (MC-4)

3. PacDrive Motors

4. Distribution Box DB-5: Links between PS-5 and iSH modules

The system supports various HMIs and can coordinate multiple drives depending on controller model (C200: 8 drives, C400: 16 drives, C600: 99 drives).

Conclusion

The ELAU PacDrive Power Supply PS-5 represents a robust, feature-rich solution for industrial automation power distribution. Its combination of safety features, diagnostic capabilities, and flexible integration options make it particularly suitable for packaging and food processing machinery where reliability and precision are paramount.

With proper installation and maintenance in accordance with the manufacturer's guidelines, the PS-5 provides a stable power foundation for PacDrive automation systems, contributing to reduced downtime and enhanced system performance in demanding industrial environments.