Beckhoff PS1021-2405-0000 Operator's manual

Documentation | EN
PS1021-2405-0000
Power supply 24 V DC, 5 A, 1-phase
2020-11-10 | Version: 1.0

Table of contents
PS1021-2405-0000 3Version: 1.0
Table of contents
1 Overview.....................................................................................................................................................5
2 Foreword ....................................................................................................................................................6
2.1 Notes on the documentation..............................................................................................................6
2.2 Safety instructions .............................................................................................................................7
2.3 Terminology and abbreviations .........................................................................................................9
3 Technical data, mounting, wiring...........................................................................................................10
3.1 AC input...........................................................................................................................................10
3.2 DC input...........................................................................................................................................12
3.3 Input inrush current..........................................................................................................................13
3.4 Output..............................................................................................................................................14
3.5 Hold-up time ....................................................................................................................................14
3.6 DC-OK relay contact........................................................................................................................16
3.7 Efficiency and losses .......................................................................................................................17
3.8 Lifetime expectancy and MTBF .......................................................................................................18
3.9 Functional wiring diagram................................................................................................................19
3.10 Terminals and wiring .......................................................................................................................20
3.11 Front side and operating elements ..................................................................................................21
3.12 EMC.................................................................................................................................................22
3.13 Environment ....................................................................................................................................23
3.14 Protective functions and safety features..........................................................................................24
3.15 Dielectric strength............................................................................................................................25
3.16 Declaration of conformity and approvals .........................................................................................26
3.17 Dimensions and weight ...................................................................................................................27
4 Application notes.....................................................................................................................................28
4.1 Peak current capability ....................................................................................................................28
4.2 Back-feeding loads ..........................................................................................................................29
4.3 External input protection..................................................................................................................29
4.4 Parallel use to increase power ........................................................................................................29
4.5 Series connection ............................................................................................................................29
4.6 Inductive and capacitive loads.........................................................................................................30
4.7 Charging batteries ...........................................................................................................................30
4.8 Operation on two phases.................................................................................................................30
4.9 Use in a tightly sealed enclosure.....................................................................................................30
5 Appendix ..................................................................................................................................................32
5.1 Documentation issue status ............................................................................................................32
5.2 Support and Service ........................................................................................................................33

Table of contents
PS1021-2405-00004 Version: 1.0

Overview
PS1021-2405-0000 5Version: 1.0
1 Overview
PS1021-2405-0000 | Power supply 24V, 5A, single phase
• AC 100-120V / 200-240V input with automatic selection
• Width only 39mm
• Efficiency of up to 92.3%
• Full power between -10°C and +55°C
• Including DC-OK relay contact
The PS1021-2405-0000 is a 1-phase 24V power supply with an output current of 5A and an output power
of 120W.
On the input side, the device has a wide-range input and an input inrush current limitation.
The output operates according to the UI characteristic curve and switches to the safe hiccup mode in case of
overload/short-circuit.
The power supply is part of the PS1000 family and has a width of 39 mm. A DC OK LED and a potential-free
relay contact monitor the status of the output voltage.
Overview of technical data *)
Overview of technical data PS1021-2405-0000
Output voltage DC 24V
Adjustment range 24 - 28V
Output current for AC 110-120 / 220-240V mains:
5.0 - 4.3A at 24-28V, <55°C
3.1 - 2.7A at 24-28V, <70°C
for AC 100 / 200V mains:
5.0 - 4.3A at 24-28V, <50°C
2.5 - 2.1A at 24-28V, <70°
Output ripple < 100mVpp, 20Hz to 20MHz
Input voltage AC AC 100-120 V / 220-240V (±10%, auto select)
Mains frequency 50-60Hz ±6%
Input current AC 1.72 / 1.05A at 120 / 230Vac
Power factor 0.64 / 0.54 at 120 / 230Vac
Efficiency 91.2% / 92.3% at 120 / 230Vac
Temperature range -10°C to +70°C (in operation)
Dimensions (W x H x D) 39x124x124mm
(without DIN rail)
Weight 370g
Approvals/markings CE
cULus
EAC
*) All values typical for 24V, 5A, 230Vac, 50Hz, +25°C ambient temperature and after a warm-up time of five
minutes, unless otherwise stated.

Foreword
PS1021-2405-00006 Version: 1.0
2 Foreword
2.1 Notes on the documentation
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany.
The reproduction, distribution and utilization of this document as well as the communication of its contents to
others without express authorization are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.
Disclaimer
The documentation has been prepared with care. The products described are, however, constantly under
development.
We reserve the right to revise and change the documentation at any time and without prior announcement.
No claims for the modification of products that have already been supplied may be made on the basis of the
data, diagrams and descriptions in this documentation.
Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, EtherCATG®, EtherCATG10®, EtherCATP®, SafetyoverEtherCAT®,
TwinSAFE®, XFC®, XTS® and XPlanar® are registered trademarks of and licensed by Beckhoff Automation
GmbH. Other designations used in this publication may be trademarks whose use by third parties for their
own purposes could violate the rights of the owners.
Patent Pending
The EtherCAT Technology is covered, including but not limited to the following patent applications and
patents: EP1590927, EP1789857, EP1456722, EP2137893, DE102015105702 with corresponding
applications or registrations in various other countries.
Intended audience
This description is only intended for the use of trained specialists in control and automation engineering who
are familiar with the applicable national standards.
It is essential that the documentation and the following notes and explanations are followed when installing
and commissioning these components.
It is the duty of the technical personnel to use the documentation published at the respective time of each
installation and commissioning.
The responsible staff must ensure that the application or use of the products described satisfy all the
requirements for safety, including all the relevant laws, regulations, guidelines and standards.

Foreword
PS1021-2405-0000 7Version: 1.0
2.2 Safety instructions
Description of instructions
In this documentation the following instructions are used.
These instructions must be read carefully and followed without fail!
DANGER
Serious risk of injury!
Failure to follow this safety instruction directly endangers the life and health of persons.
WARNING
Risk of injury!
Failure to follow this safety instruction endangers the life and health of persons.
CAUTION
Personal injuries!
Failure to follow this safety instruction can lead to injuries to persons.
NOTE
Damage to environment/equipment or data loss
Failure to follow this instruction can lead to environmental damage, equipment damage or data loss.
Tip or pointer
This symbol indicates information that contributes to better understanding.
Intended use
This device is designed for installation in a housing and is intended for general professional use, for example
in industrial control systems or office, communication and measuring equipment.
Do not use this power supply in installations where a malfunction could cause serious injury or danger to
human life.
Exclusion of liability
All the components are supplied in particular hardware and software configurations appropriate for the
application. Modifications to hardware or software configurations other than those described in the
documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH & Co. KG.
Personnel qualification
This description is only intended for trained specialists in control, automation and drive engineering who are
familiar with the applicable national standards.
Safety regulations
Please note the following safety instructions and explanations!
Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,
commissioning etc.

Foreword
PS1021-2405-00008 Version: 1.0
Safety instructions and installation requirements for the PS1021-2405-0000 power supply
DANGER
Danger of electric shock, fire, injuries, injuries resulting in death!
• Do not use the power supply without proper grounding (protective conductor). Use the terminal at the in-
put terminal strip for the earth connection, not one of the screws on the housing.
• Switch off the power supply before working on the device. Provide protection against unintentional re-
connection.
• Ensure proper wiring by following all local and national regulations.
• Do not modify or attempt to repair the device.
• Do not open the device, as high voltages are present inside.
• Avoid foreign bodies entering the housing.
• Do not use the device in damp locations or in areas where moisture or condensation is likely to occur.
• Do not touch the device when it is switched on or immediately after it has been switched off. Hot sur-
faces can cause burns.
Further notes on installation requirements
• This device contains no parts that require maintenance. If an internal fuse trips, this is due to an
internal defect.
• If any damage or malfunction occurs during installation or operation, turn off the power supply
immediately and return the device to the factory for inspection.
• Mount the device on a DIN rail so that the input terminals are at the bottom of the device. For
other mounting positions, please refer to the load reduction requirements in this document. See
chapter Installation positions.
• This device is designed for convection cooling and does not require an external fan. Do not ob-
struct the air circulation. No more than 15% of the ventilation grille may be covered (e.g. by cable
ducts)!
• Maintain the following installation distances: 40mm at the top, 20mm at the bottom and 5mm
on the left and right are recommended if the device continuously runs at more than 50% of the
rated output. Increase this distance to 15mm if the adjacent device is a heat source (e.g. an-
other power supply unit).

Foreword
PS1021-2405-0000 9Version: 1.0
2.3 Terminology and abbreviations
PE and the earthing
symbol
PE is the abbreviation for "protective earth" and has the same meaning as the
earthing symbol
Earth, ground This document uses the term “earth” which is the same as the U.S. term “ground”.
T.b.d. Still to be defined, value or description will follow in due course.
AC 230V A value preceded by "AC" or "DC" represents a nominal voltage or a nominal
voltage range. The nominal voltage or the nominal voltage range may be provided
with tolerances. (e.g. AC 230V ±10%). The calculated total range then indicates
the working range of the device.
Example:
DC 12V refers to a 12V battery, regardless of whether it is fully charged
(13.7Vdc) or discharged (10Vdc).
230Vac A value followed by the unit Vac or Vdc is an instantaneous value that does not
contain any additional tolerances.
50Hz vs. 60Hz Unless otherwise specified, AC 100V and AC 230V parameters are valid at a
mains frequency of 50Hz. AC 120V parameters are valid for a mains frequency of
60Hz.
may A keyword indicating a choice without implied preference.
shall A keyword indicating a mandatory requirement.
should A keyword indicating a choice with a clearly preferred method of implementation.

Technical data, mounting, wiring
PS1021-2405-000010 Version: 1.0
3 Technical data, mounting, wiring
3.1 AC input
AC input
AC input Nom. AC 100-120V / 220-240V Auto select,
suitable for TN, TT, and IT networks
AC input range Min. 90-132Vac / 180-264Vac Continuous operation
Min. 264-300Vac For up to 500ms max.
Permissible voltage L or N to earth Max. 300Vac Continuous, IEC 62103
Input frequency Nom. 50-60Hz ±6%
External input protection See recommendations in chapter External input protection [}29]
AC input AC 100V AC120V AC230V
Input current Typ. 2.0A 1.72A 1.05A At 24V, 5A, see Fig. Input current over output
current
Power factor*) Typ. 0.66 0.64 0.54 At 24V, 5A, see Fig. Input current over output
current;
Peak factor**) Typ. 2.7 2.8 3.4 At 24V, 5A
Turn-on voltage Typ. 78Vac 78Vac 157Vac Static, at 24V, 0A, see Fig. Input voltage range
Shut-down voltage Typ. 68Vac 68Vac 68Vac Static, at 24V, 5A, see Fig. Input voltage range
Start-up delay Typ. 400ms 400ms 100ms See Fig. Switch-on behavior definitions
Rise time Typ. 30ms 30ms 30ms At 24V, 5A constant current load, 0mF load ca-
pacitance, see Fig. Switch-on behavior defini-
tions
Typ. 90ms 90ms 90ms At 24V, 5A constant current load, 5mF load ca-
pacitance, see Fig. Switch-on behavior defini-
tions
Turn-on overshoot Max. 200mV 200mV 200mV See Fig. Switch-on behavior definitions
*) The power factor is the ratio of real (or active) power to apparent power in an AC circuit.
**) The peak factor is the mathematical ratio of the peak value to the RMS value of the input current
waveform.
Fig.1: Input voltage range; switch-on behavior definitions

Technical data, mounting, wiring
PS1021-2405-0000 11Version: 1.0
Fig.2: Input current over output current; power factor over output current

Technical data, mounting, wiring
PS1021-2405-000012 Version: 1.0
3.2 DC input
Do not operate this power supply with DC input voltage!

Technical data, mounting, wiring
PS1021-2405-0000 13Version: 1.0
3.3 Input inrush current
Active inrush current limitation (NTCs) limits inrush current surge after the input voltage is switched on.
The charge current of the interference suppression capacitors during the first few microseconds after
switching on is not taken into account.
AC 100V AC 120V AC 230V
Input inrush
current
Max. 23Apeak 27Apeak 40Apeak At +40°C, cold start
Typ. 18Apeak 22Apeak 33Apeak At +40°C, cold start
Typ. 13Apeak 16Apeak 30Apeak At +25°C, cold start
Inrush energy Max. 0.4A2s 0.5A2s 1.5A2s At +40°C, cold start
Fig.3: Input inrush current, typical behavior, 230Vac input, 24V/5A output, 40°C ambient temperature;
Input inrush current, zoomed to the first peak, 230Vac input, 24V 5A output, 40°C ambient temperature

Technical data, mounting, wiring
PS1021-2405-000014 Version: 1.0
3.4 Output
Output voltage Nom. DC 24V
Adjustment range Min. 24-28V Guaranteed value
Max. 30V 2) In end position of the potentiometer, clockwise.
Factory settings Typ. 24.1V ±0.2%, at full load (cold device)
Line regulation Max. 10mV 90-132 / 180-264Vac
Load regulation Max. 150mV 0A → 5A → 0A, static value
Residual ripple and
ripple voltage
Max. 100mVpp 20Hz to 20MHz, 50Ohm
Output current 3) for mains voltages AC 110-120 / 220-240V (including mains AC 208V):
Nom. 5A At 24V and ambient temperature below 55°C
Nom. 4.3A At 28V and ambient temperature below 55°C,
Nom. 3.1A At 24V and an ambient temperature of 70°C
Nom. 2.7A At 28V and an ambient temperature of 70°C
Output current 3) for mains voltages AC 100 / 200V:
Nom. 5A At 24V and ambient temperature below 55°C
Nom. 4.3A At 28V and ambient temperature below 55°C,
Nom. 2.5A At 24V and an ambient temperature of 70°C
Nom. 2.1A At 28V and an ambient temperature of 70°C
Overload characteris-
tics
Continuous current Output voltage > 10Vdc, see Fig. Output voltage over output current, typ.
Hiccup mode Output voltage < 10Vdc, see Fig. Output voltage over output current, typ.
Short circuit current Min. 3.5A1) Load impedance 50mOhm, see Fig. Output voltage over output current, typ.
The discharge current of the output capacitors is not included.
Output capacity Typ. 2,050µF Included in the power supply
1) The discharge current of the output capacitors is not included.
2) This is the maximum output voltage that can occur in the end position of the potentiometer in clockwise direction due to tolerances. It
is not a guaranteed value that can be achieved. A typical value is 28.5V.
3) Linear derating between +55°C and +70°C
Fig.4: Output voltage over output current, typ.; intermittent operation, short circuit at output
3.5 Hold-up time
AC 100V AC 120V AC 230V
Hold-up
time
Typ. 64ms 108ms 105ms At 24V, 2.5A, see Fig. Hold-
up time over input voltage
Min. 54ms 91ms 88ms At 24V, 2.5A, see Fig. Hold-
up time over input voltage
Typ. 26ms 51ms 50ms At 24V, 5A, see Fig. Hold-
up time over input voltage
Min. 22ms 43ms 42ms At 24V, 5A, see Fig. Hold-
up time over input voltage

Technical data, mounting, wiring
PS1021-2405-0000 15Version: 1.0
Fig.5: Hold-up time over input voltage; switch-off behavior, definitions

Technical data, mounting, wiring
PS1021-2405-000016 Version: 1.0
3.6 DC-OK relay contact
This function monitors the output voltage generated by the power supply itself.
The contact closes when the output voltage reaches 21.4V.
The contact opens when the output voltage drops below 21.4V.
Contact load capacity Maximum 60Vdc 0.3A, 30Vdc 1A, 30Vac 0.5A, ohmic load
Minimum permissible load: 1mA at 5Vdc
Insulation voltage See the dielectric strength table in the chapter on Dielectric strength
Fig.6: Behavior of the DC-OK relay contact

Technical data, mounting, wiring
PS1021-2405-0000 17Version: 1.0
3.7 Efficiency and losses
AC 100V AC 120V AC 230V
Efficiency Typ. 90.7% 91.2% 92.3% At 24V, 5A
Average efficiency*) Typ. 89.2% 89.4% 90.6% 25% at 1.25A, 25% at 2.5A,
25% at 3.75A. 25% at 5A
Losses Typ. 1.4W 1.5W 0.7W At 24V, 0A
Typ. 7.0W 7.4W 6.0W At 24V, 2.5A
Typ. 12.3W 11.6W 10.0W At 24V, 5A
*) The average efficiency is based on assumptions for a typical application with the power supply unit
operating at 25% of the nominal load during 25% of the time, 50% of the nominal load during 25% of the
time, 75% of the nominal load during 25% of the time and 100% of the nominal load during the remaining
time.
Fig.7: Efficiency over output current; losses over output current
Fig.8: Efficiency over input voltage; losses over input voltage

Technical data, mounting, wiring
PS1021-2405-000018 Version: 1.0
3.8 Lifetime expectancy and MTBF
The lifetime expectancy shown in the table indicates the minimum number of operating hours (service life)
and is determined by the lifetime expectancy of the built-in electrolytic capacitors. The lifetime expectancy is
stated in operating hours and is calculated according to the specifications of the capacitor manufacturer. The
manufacturer of the electrolytic capacitors only guarantees a maximum life of up to 15 years (131,400h). Any
number exceeding this value represents a calculated theoretical lifetime which can be used to compare
devices.
AC 100V AC 120V AC 230V
Lifetime
expectancy
181,000h 194,000h 219,000h At 24V, 2.5A and +40°C
511,000h 548,000h 621,000h At 24V, 2.5A and +25°C
66,000h 68,000h 83,000h At 24V, 5A and +40°C
188,000h 193,000h 234,000h At 24V, 5A and +25°C
MTBF stands for Mean Time Between Failure, which is calculated from the statistical failure rate of the
components and indicates the reliability of a device. It is a statistical representation of the probability of
equipment failure and does not necessarily represent the service life of a product.
The MTBF number is a statistical representation of the probability of equipment failure. An MTBF number of
1,000,000h, for example, means that statistically, if there are 10,000 devices in use, one device will fail every
100 hours. However, it is not possible to say whether the failed device has been in operation for 50,000
hours or only 100 hours.
AC 100V AC 120V AC 230V
MTBF SN 29500,
IEC 61709
1,065,000h 1,147,000h 1,379,000h At 24V, 5A and +40°C
2,038,000h 2,166,000h 2,519,000h At 24V, 5A and +25°C
MTBF MIL HDBK
217F
681,000h 651,000h 645,000h At 24V, 5A and 40°C; Ground Benign GB40
872,000h 842,000h 839,000h At 24V, 5A and 25°C; Ground Benign GB25
165,000h 164,000h 168,000h At 24V, 5A and 40°C; Ground Fixed GF40
206,000h 205,000h 211,000h At 24V, 5A and 25°C; Ground Fixed GF25

Technical data, mounting, wiring
PS1021-2405-0000 19Version: 1.0
3.9 Functional wiring diagram
Fig.9: Functional wiring diagram

Technical data, mounting, wiring
PS1021-2405-000020 Version: 1.0
3.10 Terminals and wiring
The terminals are designed to be finger-safe according to IP20 and are suitable for field or factory wiring.
Technical data Input Output DC-OK signal
Connection cross-section e*: max. 6mm²
f*: max. 4mm²
a*: max. 4mm² (d<2.8mm)
e*: max. 6mm²
f*: max. 4mm²
a*: max 4mm² (d<2.8mm)
e*: max. 1.5mm²
f*: max. 1.5mm²
a*: max. 1.5mm²
(d<1.6mm)
Connection cross section
(AWG)
e*: AWG 20-10
f*: AWG 20-10
a* AWG 20-10 (d<2.8mm)
e*: AWG 20-10
f*: AWG 20-10
a* AWG 20-10
(d<2.8mm)
e*: AWG 28-16
f*: AWG 28-16
a*: AWG 28-16
(d<1.6mm)
Strip length 7mm / 0.28inch 7mm / 0.28inch 7mm / 0.28inch
e* = solid wire
f* = stranded wire
a* = with ferrule
Wiring instructions:
• Use suitable copper cables that are designed for at least the following operating temperatures:
+75°C, for ambient temperatures up to +55°C (minimum) and
+90°C, for ambient temperatures up to +70°C (minimum)
• Observe the national installation rules and regulations!
• Do not use the device without PE connection.
• Make sure that all single wires of a strand are connected to the terminal!
• Unused terminals should be tightened firmly.
• Ferrules are permitted.