Datalogic PWR-240 User manual

PWR-240 REDS
INSTALLATION MANUAL
Reading Station Redundant Power Supply

Datalogic S.r.l.
Via S. Vitalino, 13
40012 Calderara di Reno (BO)
Italy
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Datalogic has taken reasonable measures to provide information in this manual that is complete and accu-
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INSTALLATION MANUAL iii
TABLE OF CONTENTS
PREFACE ..................................................................................................................IV
About this Manual ........................................................................................................... iv
Manual Conventions ........................................................................................................................... iv
Technical Support ........................................................................................................... iv
Support Through the Website ............................................................................................................ iv
Reseller Technical Support ................................................................................................................ iv
Safety Regulations ........................................................................................................... v
Electrical Safety ................................................................................................................................... v
Product Data Label .............................................................................................................................. v
CE Compliance ..................................................................................................................................... v
General View .................................................................................................................. vi
CHAPTER 1. OPERATING FEATURES .........................................................................1
Description ...................................................................................................................... 1
Output Protection ............................................................................................................. 1
Short-Circuit Protection ......................................................................................................................2
Overload Protection ............................................................................................................................2
CHAPTER 2. PRE-INSTALLATION CHECKLIST ...........................................................4
System Wiring: DC Output ................................................................................................ 4
System Wiring: AC Input .................................................................................................. 5
System Wiring: Test ......................................................................................................... 5
CHAPTER 3. MECHANICAL INSTALLATION................................................................6
Cabinet Mounting ............................................................................................................. 6
CHAPTER 4. LOW VOLTAGE ELECTRICAL CONNECTIONS...........................................7
DC Low Voltage Cable Insertion ........................................................................................ 7
Cable Entry Plate .................................................................................................................................7
AS-I Cable Insertion ............................................................................................................................8
DC Voltage Terminal Block ............................................................................................... 8
DC OK Monitoring ................................................................................................................................9
DC Direct Output ..................................................................................................................................9
DC Low Voltage Example Wiring ........................................................................................................9
Laser Barcode Scanners ................................................................................................. 10
Supply Capacity When Wiring Directly to AS-I Compatible Scanners ............................................10
AS-I Wiring Topologies .....................................................................................................................11
Installing Accessory Industrial Ethernet Switch ............................................................... 12
CHAPTER 5. AC LINE VOLTAGE ELECTRICAL CONNECTIONS ................................... 13
AC Line Input Voltage ..................................................................................................... 13
12 Vdc Power Block Installation (Optional) ...................................................................... 14
CHAPTER 6. TECHNICAL FEATURES ....................................................................... 16
APPENDIX A. ELECTRICAL DIAGRAMS ................................................................... 17
PWR-240 REDs Electrical Diagram ................................................................................. 17

iv PWR-240 REDS
PREFACE
ABOUT THIS MANUAL
This Installation Manual is provided for users seeking advanced technical information,
including installation, connections, maintenance and specifications.
Manual Conventions
The following conventions are used in this document:
The symbols listed below are used in this manual to notify the reader of key issues or
procedures that must be observed:
TECHNICAL SUPPORT
Support Through the Website
Datalogic provides several services as well as technical support through its website. Log
on to (www.datalogic.com).
For quick access, from the home page click on the search icon , and type in the name of
the product you’re looking for. This allows you access to download Data Sheets, Manu-
als, Software & Utilities, and Drawings.
Hover over the Support & Service menu for access to Services and Technical Support.
Reseller Technical Support
An excellent source for technical assistance and information is an authorized Datalogic
reseller. A reseller is acquainted with specific types of businesses, application software,
and computer systems and can provide individualized assistance.
NOTE: Contains important information necessary for proper installation
and use of the device.
CAUTION; This symbol advises you of actions that could damage equipment
or property.
HIGH VOLTAGE: This symbol alerts the user they are about to perform an
action involving, either a dangerous level of voltage, or to warn against an
action that could result in damage to devices or electrical shock. Opera-
tions having this symbol must be performed by qualified personnel only.

SAFETY REGULATIONS
INSTALLATION MANUAL v
SAFETY REGULATIONS
Electrical Safety
This product conforms to the applicable requirements contained in the following Euro-
pean Standards:
• EN 61439-1
• EN 60204-1
• EN 60950-1 +A11 +A1 +A12 +A2
Product Data Label
The Product data label is located on the outside door panel.
Figure 1 – Product Data Label
CE Compliance
CE marking states the compliance of the product with essential requirements listed in
the applicable European directive. Since the directives and applicable standards are
subject to continuous updates, and since Datalogic promptly adopts these updates,
therefore the EU declaration of conformity is a living document. The EU declaration of
conformity is available for competent authorities and customers through Datalogic
commercial reference contacts. Since April 20th, 2016 the main European directives
applicable to Datalogic products require inclusion of an adequate analysis and assess-
ment of the risk(s). This evaluation was carried out in relation to the applicable points of
the standards listed in the Declaration of Conformity. Datalogic products are mainly
designed for integration purposes into more complex systems. For this reason, it is
under the responsibility of the system integrator to do a new risk assessment regarding
the final installation.
Warning
This is a Class A product. In a domestic environment this product may cause radio inter-
ference in which case the user may be required to take adequate measures.

PREFACE
vi PWR-240 REDS
GENERAL VIEW
Figure 2 - PRW-240 REDs General View












1 Key Lock 8 Thermal-magnetic Circuit Breakers
2 Product Data Label 9 Cooling Fan
3 AC Input Cable Compression Connector 10 Protection Earth Block
4 Cable Entry Plate with Grommets 11 “DC OK” Terminal Block
5 Monophase Switching Power Supplies 12 Low Voltage Current Limiting Fuse
6 Decoupling Module 13 24 Vdc Terminal Block
7 AC Line Input Terminal Block

INSTALLATION MANUAL 1
CHAPTER 1
OPERATING FEATURES
DESCRIPTION
The PWR-240 REDs is an electrical cabinet housing two 24 Vdc power supplies which
operate in parallel to provide Redundant power to a varying number of reading devices
(depending on the product), along with their relative accessory devices. It is specifically
designed for use in Baggage Handling Reading Stations. See chapter 4 for details.
As shown in the Electrical Diagram in Appendix A, the AC Input Line passes through two
sets of protective thermo-magnetic circuit breakers and connects to the two mono-
phase switching power supplies.
The 24 Vdc outputs are connected through a Decoupling Module and then routed
through a protective current limiting Miniature circuit breaker (MCB), 10 A, 1p, C-Char
before arriving at the output terminal blocks.
Two output power supply status monitoring signals (DC-OK) for each power supply are
provided to connect to an optional digital alarm. If for some reason the output voltage is
reduced by less than 90% of nominal) these lines open.
The major advantage to the PWR-240 REDs redundant power supply is that if a single
power supply fails, it can be replaced by qualified personnel without shutting down the
system, (hot-swap).
OUTPUT PROTECTION
The two 24 Vdc 10 A nominal supplies operate in parallel. Output short-circuit and over-
load protection is mainly provided through the current limiting MCB.

OPERATING FEATURES
2 PWR-240 REDS
Short-Circuit Protection
If a short-circuit occurs on the output lines (electrical event), the MCB opens within less
than 1 second (t) interrupting supplied power. Refer to the diagram below.
Figure 3 – Short-Circuit Protection
The short-circuit must be resolved and the MCB must be manually re-armed to restore
normal operation.
Overload Protection
Overload is a condition in which, due to a malfunction, current above the nominal max
value is required to maintain output device functioning. This condition can be sustained
for short periods but causes a thermal event which over time could ultimately damage
wiring and/or devices.
Since the PWR-240 REDs utilizes two 24 Vdc 10 A power supplies in parallel, they divide
the required current evenly and so can provide up to a combined 20 A without going
into an overload condition.
Overload protection is instead provided by the 10 A MCB as described in the figure
below.
Figure 4 – Overload Protection

OUTPUT PROTECTION
INSTALLATION MANUAL 3
After time (t) in seconds, the MCB opens, interrupting supplied power according to the
following table:
The overload condition must be resolved and the MCB must be manually re-armed to
restore normal operation.
CURRENT (A) MCB TIME TO TRIP (S)
14.5 120
16.8 34
19.2 22
21.4 16

4 PWR-240 REDS
CHAPTER 2
PRE-INSTALLATION CHECKLIST
This chapter can be used as a checklist to verify all the steps necessary to complete
installation of the PWR power supply.
1. Read all information in this manual before installation, paying particular attention
to all Caution and Warning notes.
2. Mount the PWR to the Station frame using the brackets and bolts provided in the
package. See "Cabinet Mounting" on page 6.
SYSTEM WIRING: DC OUTPUT
3. Connect your devices to the PWR according to your application.
Barcode Scanners
Correctly connect the AS-I cabling to the PWR using the AS-I cable wiring instruc-
tions for backbone and branch wiring. See "Laser Barcode Scanners" on page 10
and your scanner manual for details.
All cables must pass through the cable entry plate using the correct AS-I cable
grommets as described in "Cable Entry Plate" on page 7 and "AS-I Cable Insertion"
on page 8.
24 Vdc Industrial Ethernet Switch
Mount the Industrial Ethernet Switch inside the cabinet and connect the 24 Vdc
wires to power it as described in "Installing Accessory Industrial Ethernet Switch" on
page 12. All Ethernet Cables must pass through the grommets of the Cable Entry
plate.
Optional 12 Vdc Power Block for RFID Applications
Mount the 12 Vdc Power Block inside the cabinet, prepare the AC cord and con-
nect it to the AC input terminals as described in "12 Vdc Power Block Installation
(Optional)" on page 14.
HIGH VOLTAGE: Opening the cabinet requires a key that should be used by a
person adequately advised or supervised by an electrically skilled person
to enable him or her to perceive risks and avoid hazards which electricity
can create. Internal components guarantee an IP20 degree of protection
against direct contact.

SYSTEM WIRING: AC INPUT
INSTALLATION MANUAL 5
SYSTEM WIRING: AC INPUT
4. To comply with EN 60950-1:2007 par.1.7.2.2, par. 2.7.1, par 2.7.4, par. 3.4.6, and to
protect the AC input connection to the device; a disconnecting device with built in
overcurrent and earth protection shall be installed external to the equipment
according to local regulations.
According to EN 60950-1:2007 par. 3.2.3; the AC input cable must have a maxi-
mum diameter of 14mm and the conduit a max diameter of 16mm.
5. With AC line voltage OFF, wire the AC Line to the AC Line Input Terminal Block see
"AC Line Input Voltage" on page 13.
SYSTEM WIRING: TEST
6. Apply the AC line voltage from the building installation or the DWS-SWITCH and
check that the PWR powers up correctly. On each supply the green DC-OK light
should be on steady and the overload light (red) should off.
7. Close and lock the PWR enclosure and check that it does not open (lock functions
correctly).
The PWR-240 REDs installation is now complete.

6 PWR-240 REDS
CHAPTER 3
MECHANICAL INSTALLATION
CABINET MOUNTING
The cabinet must be mounted to the reading station frame using the brackets and bolts
provided in the package.
1. Mount the bracket to the
cabinet.
2. Mount the cabinet to the
frame.
Figure 5 – Mounting Brackets
Figure 6 – PWR-240 REDs cabinet max. height
Please note that the cabinet door can be unlocked and opened by using the key pro-
vided along with the product.
IMPORTANT: The cabinet must be installed vertically in such a way that the
key lock is no higher than 1.90 m from the ground (see Figure 6).
max. 190 cm

INSTALLATION MANUAL 7
CHAPTER 4
LOW VOLTAGE ELECTRICAL
CONNECTIONS
DC LOW VOLTAGE CABLE INSERTION
The Cable Entry Plate has several forms of sealing grommets that must be inserted to
provide IP65 protection capability. This includes AS-I cable sealing grommets.
Cable Entry Plate
Follow these instructions to correctly insert the cables:
1. Determine the number and size of the cables coming into and leaving the PWR-
240 REDs.
2. Unmount the Cable Entry Plate frame and select all the necessary grommets for
your application.
3. Insert the correct size sealing grommets and positions relative to the cables.
Unused positions must mount the closed grommets with their flat closed surface
facing the outside of the PWR.
4. Remount the Cable Entry Plate.
5. Press the cable end through the proper grommet so that it seals around the cable.
The Cable Entry Plate has 10 cable entry positions with the following grommet kit sup-
plied:
GROMMETS CABLE DIAMETER
QTY TYPE MM INCH
2single 3 0.118
1 double 4 0.157
1single 6 0.236
4 double 6 0.236
2 AS-I Cable form --
7closed --

LOW VOLTAGE ELECTRICAL CONNECTIONS
8 PWR-240 REDS
AS-I Cable Insertion
Prepare the AS-I cable by stripping the outer protection sheath leaving about 5 cm of
blue and brown wires free for positioning. Strip the individual wires for insertion into
the Terminal Block.
Figure 7 - AS-I Cable Prep
Pass the AS-I cable through the AS-I cable sealing grommet and make sure there is
enough length to easily reach the 24 Vdc Terminal Block.
Figure 8 – Cable Insertion
DC VOLTAGE TERMINAL BLOCK
Figure 9 – PWR-240 REDs DC Output Power Connections
The terminal block marked with the ground symbol is a special block which allows direct
connection of the Protection Earth with the enclosure of the PWR-240 REDs.
AS-I cable sealing
grommets
Protection
Earth Ground
DC OK Signals
10 A MCB
protected
DC Outputs

DC VOLTAGE TERMINAL BLOCK
INSTALLATION MANUAL 9
DC OK Monitoring
The DC voltage terminal block provides two sets of wiring terminals which monitor the
status of the two switching power supplies (DC OK feature). When the power supply
modules run correctly, lines 13 and 14 form a normally closed contact. If a power mod-
ule experiences problems (i.e. voltage drop below 90% of nominal or other failure) its
DC OK lines open. Lines 13 and 14 are decoupled from the power output lines and can
be connected to a free digital input to signal this alarm condition.
• T1013, T1014 monitor the T10 Power Supply
• T2013, T2014 monitor the T20 Power Supply
DC Direct Output
The 24 volt DC Output terminals connect to the output devices according to your appli-
cation requirements.
All DC outputs are protected by a miniature circuit breaker (MCB), 10A, 1p, C-Char
device.
DC Low Voltage Example Wiring
Figure 10 - Low Voltage Example Wiring
NOTE: The PWR-240 REDs allows the station to continue functioning even
in the event of a single internal power supply failure. Therefore it is
strongly recommended to connect the DC OK signals to digital alarms in
order to be warned about the loss of the redundant power supply.

LOW VOLTAGE ELECTRICAL CONNECTIONS
10 PWR-240 REDS
LASER BARCODE SCANNERS
Supply Capacity When Wiring Directly to AS-I Compatible Scanners
For direct wiring, power distribution is performed simultaneously for all the scanners.
However all the scanner motors start up slowly so that there is no significant peak cur-
rent draw. See the specific scanner manual for consumption data.
The maximum number of same type scanners to be supplied for direct wiring by a single
PWR-240 REDs is shown in the table below and depends on the wiring topology:
The following products are also AS-I compatible: DS5100, DM3610, SC5000. In case of
networks using a mix of products, you must calculate the total power consumption so as
not to exceed the limits for the specific topology used. See the specific product refer-
ence manual in the Technical Features chapter for consumption data.
The power supply unit is connected directly to the scanners via AS-I cabling.
Figure 11 - Connecting PWR-240 REDs Directly to Scanners
Refer to the specific scanner manual for I/O interface wiring connections.
SCANNER TYPE MAXIMUM NUMBER OF SCANNERS BY
TOPOLOGY
DOUBLE BRANCH SINGLE BRANCH
DS8110 11 (balanced 6+5) 9
DX8210 11 (balanced 6+5) 9
AS-I Single Branch 200 W max
AS-I Double Branch 240 W max total (200 W max for a single branch)
24 Vdc to scanners using AS-I cabling
DC OK (for REDs applications)
AC in

LASER BARCODE SCANNERS
INSTALLATION MANUAL 11
AS-I Wiring Topologies
Figure 12 – Single Branch Topology
Figure 13 – Double Branch Topology
The load for Double Branches should be kept as balanced as possible. For example 6+5
or 5+4 scanners instead of 9+2.
device
nodes
24 Vdc AS-I single branch with end cap
200 W max
device
nodes
24 Vdc AS-I double branch with end caps
240 W max total of all devices
200 W max for a single branch

LOW VOLTAGE ELECTRICAL CONNECTIONS
12 PWR-240 REDS
INSTALLING ACCESSORY INDUSTRIAL ETHERNET SWITCH
An accessory 24 Vdc Industrial Ethernet Switch can be installed and powered from
inside the PWR-240 REDs power supply.
Figure 14 - 24 Volt Industrial Ethernet Switch
Fix the Industrial Ethernet Switch to the DIN rail using the clips provided inside the PWR
and connect the power cables (marked F1020+ and R1020 -) to the DC low voltage ter-
minal block and to the Ethernet Switch terminals as shown in the figure below.
Figure 15 - Industrial Ethernet Switch Mounted Inside PWR-240 REDs
Route the Ethernet Cables through the Cable Entry Plate grommets to the devices.
24 Vdc Accessory Ethernet Switch
(purchased separately)
Ethernet Switch power cables
(included in PWR-240 REDs package)

INSTALLATION MANUAL 13
CHAPTER 5
AC LINE VOLTAGE ELECTRICAL
CONNECTIONS
AC LINE INPUT VOLTAGE
Wire according to the following points:
• Primary wiring: Overcurrent protection should be provided by a 16 A building
installation circuit breaker. PWR-240 REDs input components are rated for an Icp
of 10 kA max.
• Wiring methods from the branch circuit breaker to the PWR-240 REDs power sup-
ply shall comply with the National Electric Code ANSI\NFPA. The Datalogic DWS-
SWITCH is an AC Power Disconnector and Distributor cabinet which provides this
protection.
• For primary wiring use a 3-conductor cable (between 2.5 mm2 - 4 mm2 (13 AWG –
11 AWG), for every conductor. Choose the overall cable diameter and UL Listed
conduits accordingly. The AC input cable must be inserted through the AC Input
Cable Compression Connector.
• The individual conductors must be inserted into the dedicated terminal blocks on
the DIN rail (see figure below) which are marked Line (L) neutral (N) and Protec-
tion Earth (PE).
• Replace the protection cover over the spring clamp connector after correctly
installing the wires.
HIGH VOLTAGE: This operation must be performed by a certified electrician.

AC LINE VOLTAGE ELECTRICAL CONNECTIONS
14 PWR-240 REDS
Figure 16 – PWR-240 REDs AC Line Terminal Block with Protection Covers
12 VDC POWER BLOCK INSTALLATION (OPTIONAL)
A DC Power Block can be installed inside the PWR-240 REDs to supply RFID devices with
12 Vdc.
Figure 17 - 12 Vdc Power Block
The DC Power Block connects to the AC input line and Its AC cord must be adapted to
connect to the PWR AC input terminal block.
AC Line
terminal block
protection covers