Messung Systems NEXGEN PLC PSU Modules

NEXGEN Series of PLCs

Universal

100-220 VAC Power Supply Module (4113)

Document No. ED-2002-066

Version: 1.0

Published Nov 2003

MESSUNG SYSTEMS
EL-2, J- Block MIDC Bhosari,
Pune – 411026.(INDIA)

Tel: (+91)-020-(2)7120807, (2)7122807.

Email : marketing@ms.messung.com
WEB: www.messung.com

Power Supply Module (4113) User Manual Published Nov 2003

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NEXGEN PLC PSU Modules Messung Systems

Revision:

Version Date Description

1.0 Nov 2003 Power Supply Module (4113) NEXGEN Series of PLCs.

Published Nov 2003 Power Supply Module (4113) User Manual

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Messung Systems NEXGEN PLC PSU Modules

INDEX

1. Power Supply Module (4113).......................................................................................5

2. Module Specifications..................................................................................................6
3. Module Wiring ...............................................................................................................7
3.1 LINE, NEUTRAL and EARTH connections.................................................................8
3.2 24 VDC Connection ....................................................................................................8
3.3 FG Connection............................................................................................................8
3.4 Red LED 'POWER' .....................................................................................................8
3.5 Red LED '24V'.............................................................................................................8
3.6 Fuse Protection...........................................................................................................9
4. Auxiliary Power Supply Requirement.........................................................................9
5. Troubleshooting .........................................................................................................10

INDEX OF FIGURES
Figure 1: Front View of Power Supply Module (4113)...............................................................6
Figure 2: Connection Diagram of Power Supply Module (4113) ...............................................7

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Guidelines for the Safety of the user and protection of Power Supply Module

a) DESIGN ENGINEER Any engineer who is responsible for the planning, design,
and construction of automatic equipment using the product associated with this
manual should be of a competent nature, trained and qualified to the local and
national standards required to fulfill the role.. These engineers should be fully
aware of all the aspects of safety with regards to automated equipment.
b) COMMISSIONING/SERVICE ENGINEER. Any engineer who is responsible for
the commissioning, use and maintenance of automatic equipment using the
product associated with this manual should be of a competent nature, trained
and qualified to the local and national standards required to fulfill the role. This
includes being completely familiar with all the associated documentation for the
said system. Maintenance to be carried out in accordance to the established
safety practices.
c) OPERATORS. The personnel using the completed equipment should be trained
to use the product in a safe and coordinated manner in compliance to
established safety practices. They should be also familiar with documentation,
which is relevant to the actual operation of the equipment.
Note: The term-completed equipment refers to a third party constructed device,
which contains or uses the product associated with this manual.

Notes on Symbols used in this Manual

The following symbols will be used throughout this manual to highlight points of information
regarding the users personal SAFETY and protection of the unit's integrity. The meaning of the
symbols must be clearly understood and due cognizance be taken of the associated note
where these symbols appear. The symbols and their descriptions are given ahead for ready
reference

HARDWARE RELATED
1
Indicates that the identified danger WILL cause physical and property damage.

2
Indicates that the identified danger could POSSIBLY cause physical and property
damage.

3
Indicates a point of further interest or explanation.

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1. Power Supply Module (4113)

This is a switched mode type of power supply module with 100-240 VAC
input. The power supply serves following purposes.

Output Use External Access

5 VDC For Processor and I/O modules No
12 VDC For serial communication No
24 VDC Supply for user input devices Yes
PFNMI signal Aid for CPU housekeeping function No

This module is not recommened to use for any other application other than
powering up a Nexgen series PLC.

The power supply module is fixed at the left most position in the basic rack.
’POWER’ is marked on mother board at this position. In expansion rack, if
required module can be fixed to share I/O module load. It should be fixed in
the slot position marked as ‘POWER’. For the same, expansion plate with
auxilary power supply module mounting facility is required.

The subsequent sections explain technical specifications and recommended

wiring of the module

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2. Module Specifications
The technical specifications of the Power Supply Module are as given below.

Input supply 100 to 240 VAC ± 15%, (85 -265 V)

4113 Inrush current

50 /60 Hz, ± 6%
50 VA nominal
8 Amp for 10 ms typical at 220V
POWER SUPPLY
100 - 240 V Output voltages 5.00 V, 3 Amp
t POWER 12.00 V, 0.3 Amp
24V 24 V, 0.4 Amp
Hold ON time > 15 ms at 85 V AC input supply
Fuse protection for 3 Amp / 20 mm glass fuse.
incoming mains
Protections provided MOV protection for input over voltage.
Output short circuit protection for 5VDC and 12
VDC.
Miniature glass fuse (500 mA) protection for 24
VDC.
Noise Immunity Conforms to EMC requirements of EN 61131-2
(1995) and IEC50081-1
Connector 8 pin (removable) connector with 5.08 mm pitch

Figure 1: Front View of Power Supply Module (4113)

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3. Module Wiring
The figure shows the connection diagram of the power supply module.

1 24V
2 24V GND
24 VDC, 0.4 Amp 3 R1
supply for external use.
4 R2
5 LINE
2
1.5 to 2.5 mm (16-12 AWG) stranded copper wire 6 NEUTRAL
is recommend. No lugs to be used.
7 EARTH
8 FG

Isolation transformer
FUSE 250V 3A
with shield
Replace with
Same rating only
100/220
440/220 VAC
VAC
50 VA
0

Earth

Earth

Figure 2: Connection Diagram of Power Supply Module (4113)

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3.1 LINE, NEUTRAL and EARTH connections

A Healthy AC supply with proper earth should be connected to power ON

the PLC. The Line and Neutral to the Power Supply Module should be
preferably isolated from those of load supply by shielded isolation
transformer of minimum 50 VA rating. Earth should be connected to a good
quality factory ground. For this matter the complete PLC installation should
have a single electrical grounding point, which can be called a reference
ground. This can be either grounding point of an electrical cabinet or the
main earth busbar. The Earth line on module should be connected to this
2
ground by copper wire with a size not less than 2.5 mm (AWG12). This
connection should be direct, continuous and permanent.

It is recommended to use such an isolated supply exclusively for PLC power

supply only. It is suggested that isolation transformers with interwinding
shield be used.Keeping provision of different voltage taps on the transformer
would prove helpful in case site power conditions are adverse.

3.2 24 VDC Connection

24 VDC, 0.4 Amp supply is available for external use. This supply is
protected by miniature glass fuse (500 mA) on the PCB itself.

3.3 FG Connection

In the Nexgen PLC module,the Printed Circuit Board with metallic front is
fixed inside plastic molded box. Each plastic box is covered by a metallic
plate from the right side. These are zinc plated mild steel plates serving as
EMI shield. When the Processor and I/O modules are mounted on base
plate, every module gets covered by shield plates from right as well as left
side. All these shield plates are connected electrically to each other through
the copper tracks on the mother board. This common point is then brought
out as FG at Power Supply Module. This is termed as Frame Ground. It
should be connected to main earth bus bar only if earth is clean. If earth is
noisy, it should not be connected to Frame Ground.

3.4 Red LED 'POWER'

The top LED glows after applying AC, if power supply is healthy i.e. 5V is
healthy.

3.5 Red LED '24V'

The second LED glows if 24 VDC supply is available for external use. If 24
VDC supply is not healthy or on-board miniature fuse (500 mA) is blown, this
LED indication is not avaialble.

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3.6 Fuse Protection

This is a bayonet type fuse holder with 3 A / 20 mm glass fuse provided for
incoming mains protection. It is recommended to connect a Miniature Circuit
Breaker (MCB) of proper rating in series with mains as additional protection
and to serve as a manual isolater.

All these recommendations should be observed when this power supply

module is fixed in the expansion rack as auxiliary power supply also.

4. Auxiliary Power Supply Requirement

The power supply module in basic rack provides 5 VDC to the Processor
and I/O modules fixed in basic rack as well as in expansion rack. The
current rating of 5 V supply is 3 Amp maximum. Each module draws current
as per the 5 V consumption mentioned in the technical specifications of each
module. Around 5-10% capacity may be kept as spare.

If the total 5 V consumption of all the modules exceeds 3 Amp, auxiliary

supply is required in the expansion rack. The Power Supply Module (4113)
can be used for this purpose. To use this module, specific expansion plate is
required. The table below gives the expansion plates available with this
facility

I/Os Ordering Code

8 I/O 4907
5 I/O 4933
3 I/O 4931

One should calculate the total 5 V consumption and accordingly the power
supply module and expansion plate must be selected and ordered.

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5. Troubleshooting
The Power supply module (4113) has two red LED indications named as
‘POWER’ and ‘24V’. If these LEDs are ON, the module is healthy. If these
LEDs are OFF, the probable causes are explained in table below and proper
corrective action should be taken.

LED Indication Probable Cause Remedial Action

‘POWER’ is OFF 1. Input supply is absent Check for external problem if any. Input supply
should be as per specifications.
MCB tripped/Switch off.
2. Input supply not within Check for proper input supply as per
specified range specifications.
3. Module fuse blown. Replace the glass fuse 3 Amp / 20 mm by
same type*
4. Overloading of output 5 VDC due to
a. Faulty Processor module Remove the Processor module from rack and
check if ‘POWER’ LED is glowing. If it is
glowing, problem is due to eth Processor
module. Replace it.
b. Faulty I/O module Remove I/O modules one by one and find out
which module is creating a problem. If faulty
module is observed, replace it.
c. Faulty expansion cable, if Remove expansion cable and find out if it is
any. creating a problem. If found faulty, replace it.
d. 5 V current capacity Ensure that 5 V consumption of modules do
exceeded. not exceed than specified.
In multiple rack system, if necessary, use
auxiliary power supply module with proper
expansion plate.
5. Overloading of output 12 Check communication cable and external
VDC due to external device, which is interfaced on serial port.
device like MMI Jr
connected to any serial
port on the Processor
module.
6. Module defective Replace the module.
‘24V’ is OFF 1. On-board miniature glass Replace the fuse by same type.
fuse (500 mA) is blown.
2. 24 VDC supply circuit is Replace the module.
defective

Be sure that power is removed while replacing the 3 A/20mm fuse. To

remove the fuse, press fuse holder cap and rotate in anti-clockwise direction
slightly. Fuse cap along with glass fuse link will come out of holder. For
fixing fuse, insert glass fuse in cap. Push cap inside fuse holder. Press and
rotate the cap in clockwise direction. Always replacethe fuse with the same
type, same rating fuse to maintain user safety. If the fuse repeatedly blows
module may be faulty.

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The miniature glass fuse (500mA) protection is provided on the PCB for 24
VDC supply. To replace this fuse, it is necessary to remove PCB by
removing the screw provided on the middle end of the right side of the
module. The recommended fuse type is Wickmann make TR5 373 F 0500.

Troubleshooting points explained in the table are also applicable for the
power supply module fixed in expansion rack as auxiliary power supply. In
addition, if power supply module fixed in expansion plate has failed, The
Processor module is put in STOP mode indication ‘APSF’ on its 4-character
alphanumeric display.

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Warning !
The specifications of product and contents of manual are subject to change without notice. This
manual has been prepared taking utmost care; the performance of the final equipment depends
on many other parameters beyond any control of Messung Systems. Messung systems does not
assume any responsibility/liability of any damage to life or property that might result due to any
malfunction due to design, use, of the equipment using this component.

MESSUNG SYSTEMS
EL – 2, J - Block, MIDC, Bhosari,
PUNE – 411 026. INDIA
Tel. – (+91)–020–712 0807, 712 2807
Fax. –(+91)–020–712 0391

NEXGEN PLC PSU Modules

100-240 V Power Supply Module (4113)

Document No.: ED-2002-066 Version 1.0

Published Nov 2003 Power Supply Module (4113) User Manual

Page 12 of 12 Document No.: ED-2002-066/V1.0