Weidmüller IE-CL240W-PP-BASE User manual

FreeCon Contactless Power
Contactless power transmission
IE-CL240W-PP-BASE 1547440000
IE-CL240W-PP-REMOTE 1547450000
Operating instructions

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Technical service:
[e-mail]
Weidmüller Interface GmbH & Co. KG
Klingenbergstraße 16
32758 Detmold, Germany
T [phone]
F [phone]
[e-mail]
www.weidmueller.com Copyright © 2016 Weidmüller Interface GmbH & Co. KG

32002150000/03/06.2017
Contents
1 Safety........................................................................................................4
1.1 General safety notications .....................................................................4
1.2 Intended use............................................................................................4
1.3 Conformity with EU directives................................................................. 4
2 Product description ................................................................................5
2.1 Device description ...................................................................................5
2.2 Functional description .............................................................................5
2.3 Usage possibilities................................................................................... 6
2.4 Dimensions.............................................................................................. 7
2.5 Included in delivery.................................................................................. 7
2.6 Accessories .............................................................................................7
2.7 Type plate................................................................................................7
3 Installation and connections..................................................................8
3.1 Installation ...............................................................................................8
3.2 Power connection....................................................................................8
3.3 Earthing ...................................................................................................9
3.4 Pin assignment for power connector ..................................................... 10
3.5 Switching functions and status alerts...... ..............................................10
4 Status indicators and maintenance.....................................................13
4.1 LED indicators .......................................................................................13
4.2 Maintenance..........................................................................................14
5 Technical data........................................................................................15

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1 Safety
1.1 General safety notications
– Work on the FreeCon product may only
be performed by qualied electricians
with the support of trained persons. As
a result of their professional training
and experience, an electrician is qual-
ied to perform the necessary work
and identify any potential hazards. A
qualied electrician must dimension the
cables.
– Before any work is carried out on the
FreeCon product the power supply
must be switched off and secured
against being switched on again.
– The surface temperature of the
FreeCon products can exceed 70°C
depending on application. To avoid
unintentional touch, install a mechan-
ical barrier or a conspicuous security
advice.
– A power supply with secure isolation
must be used to power the base.
– If faults on a FreeCon product cannot
be rectied using the recommended
measures, the product concerned must
be sent to Weidmüller. Weidmüller
assumes no guarantee if the device is
tampered with!
– During operation, steps must be taken
to ensure that no metallic objects can
enter the air gap between the base and
remote.
1.2 Intended use
The FreeCon Contactless power system
is designed to provide a contactless elec-
tromagnetic connection in an industrial
environment. The housings comply with
IP65 protection. Any other usage is not
permitted and may lead to accidents or
destruction of the device. The observance
of the supplied documentation is part of
the intended use.
1.3 Conformity with EU directives
The product complies with the EMC direc-
tive 2004/108/EC. Weidmüller will provide
the CE Declaration of Conformity upon
request.

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2 Product description
2.1 Device description
The FreeCon Contactless power system
(FCP system) consists of a base and at
least one remote.
1 2
4 43 35 76 8 87 5 6
Device overview
1 Base (transmitter)
2 Remote (receiver)
3 Marker (stuck on)
4 PushPull powerport (for PROFINET-compli-
ant connectors)
5 Status LED
6 Earthing connection
7 Cooling ns
8 Type plate
FCP systems are used wherever conven-
tional plug-in connectors are subject to
substantial wear and tear (e.g. through
frequent plugging cycles, contact erosion,
bent contacts), as well as with applications
where the energy supply is to be automat-
ed.
2.2 Functional description
The base with a connected power source
transmits electric power to the remote to
which a load is connected. The transmis-
sion is contactless even over an air gap of
max. 5 mm. The two FCP elements can be
brought closer together axially, vertically
and horizontally. Power can be transmitted
even during rotation (rotational axis = cen-
tre-point axis).
During usage with a PLC, the voltage on
the remote can be switched on and off
from the base.

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2.3 Usage possibilities
Linear approximation, frontal
Linear approximation, side
Rotating approximation, frontal
The best efciency is achieved with as
small an air gap as possible and minimal
centre offset.
The sum of air gap and centre
offset must not exceed 5 mm!
∑max. 5 mm
max. 5°
Maximum permissible distance or offset

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2.4 Dimensions
44 mm
M4
47 mm
100 mm
100 mm
19.5 mm
22 mm
Dimensions
2.5 Included in delivery
– IE-CL240W-PP-BASE (Order No.
1547440000)
Base with protective cap for transport-
ing on PushPull Powerport, operating
instructions
– IE-CL240W-PP-REMOTE (Order No.
1547450000)
Remote with snap ferrite and protective
cap for transporting on PushPull Pow-
erport
2.6 Accessories
– Plug-in connector IE-PS-VAPM-5P-2.5
(Order No. 2465440000)
– Marker ESG 6/17 K MC NE WS (Order
No. 1880120000)
2.7 Type plate
Type:
Name:
Art.No.:
HW-Rev.:
Output:
Temp.:
FreeCon Contactless Power
IE-CL240W-PP-REMOTE
1547450000
1.0
DC OK
DC NOK
LED:
GN
RD
Ser.no.: AQ3Q79PB4700000
19,2 - 28,8 V DC; max. 10 A @ 20°C
-20 °C … 45 °C
Remote OK
NO Remote
DC in NOK, Overld.
Overheating
LED:
GN
GN blk
RD
RD blk
Weidmüller Interface GmbH&Co. KG Klingenbergstr. 16 D-32758 Detmold
Made in Germany
Made in Germany
Weidmüller Interface GmbH&Co. KG Klingenbergstr. 16 D-32758 Detmold
Type:
Name:
Art.No.:
HW-Rev.:
Output:
Temp.:
FreeCon Contactless Power
IE-CL240W-PP-BASE
1547440000
1.1
Ser.no.: AQ3Q79PB4700000
21,6 - 26,4 V DC; max. 10 A
-20 °C … 45 °C
Type plates for base and remote

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3 Installation and connections
WARNING
Possible danger to life!
►Disconnect the power sup-
ply and secure it against
being switched on again.
ATTENTION
Material damage possible!
If metallic objects get into the air gap
between the base and remote during
operation, this may cause heating and
damage to the plastic cover.
►Select the installation site so that no
metallic objects can get into the air
gap.
3.1 Installation
Each FCP element can be secured using
one of the three long sides with no con-
nections.
►Secure each element using four M4
bolts (hole dimensions see below,
thread depth of the holes 8 mm).
44 mm
M4
22 mm
Hole dimensions
The best efciency is achieved with as
small an air gap as possible and low cen-
tre offset.
Depending on the application (power/air
gap/ambient temperature) the installa-
tion site must be designed in such a way
that the heat produced is dissipated (e.g.
installing on a metal sheet, heat sink or
similar).
3.2 Power connection
ATTENTION
Material damage possible!
If the power exceeds the maximum per-
missible value, this may cause the wiring
to overheat, which will cause serious da-
mage to your devices and equipment.
►Calculate the maximum current ge-
nerated in the individual cables. Note
all relevant regulations governing
the maximum permissible current for
each wire cross-section.
Take the following into account during in-
stallation:
– Use a power supply with secure isola-
tion to power the base!
– All cables must have a sufcient core
cross-section, which depends on the
current demand and the cable lengths.
We recommend using cables with a
cross-section of at least 1 mm².

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– The plug-in connector
IE-PS-VAPM-5P-2.5 (accessories) is
designed for the range 0.75 ... 2.5 mm².
IE-PS-VAPM-5P-2.5 connector
►Attach the included snap ferrite on the
remote cable at a distance of approxi-
mately 10 cm from the connecting plug.
10 cm
Assembled snap ferrite
3.3 Earthing
As an option, the FCP system can be
earthed via an M4 bolt with a toothed
washer using the particular blind hole on
the housing side with the power connec-
tion.

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3.4 Pin assignment for power
connector
Pin Base Remote
1 L1 24 V DC (US1+) L1 24 V DC (US1+)
2 N1 0 V DC (US1-) N1 0 V DC (US1-)
3 CMD; command from PLC (optional)
4 STAT; status to PLC (optional)
5 Functional earth (FE) Functional earth (FE)
1
2
3
4
5
1
2
3
4
5
INPUT DC OUTPUT DC
24 V DC
0 V DC
24 V DC
0 V DC
CMD
STAT
FE FE
Base Remote
PLC
optional
Block diagram for contactless power transmission
3.5 Switching functions and status
alerts
In order to disable the trans-
mission, Pin 3 must be set to
0 V. For this reason, either an
N-switching module or a relay
module must be used when op-
erating with a PLC. P-switching
modules must not be used!

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Pin 3: Switching function
Function Pin 3 (Base) Description Comment
CMD-1 24 V Power transmission enabled if a
valid remote is detected.
This state also applies if Pin 4 is
not connected.
CMD-2 0 V Power transmission disabled „Pin must be set from external
to “Low”.
(Open collector)“
Pin 4: Status alerts
Function Pin 4 (Base) Description Comment
STAT-1 24 V Valid remote detected, power
transmission is enabled
Open Collector
output
STAT-2 24 V
10/30 ms puls
Valid remote detected, power
transmission is disabled
STAT-3 0 V Invalid remote, power transmissi-
on is disabled
If Pin 3 and 4 of the base are not
assigned, the power is switched through
as soon as the remote is in the range
<5 mm to the base.

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The following diagram shows the signals
of Pins 3 and 4 if these are interconnect-
ed and triggered, as well as the output
voltage of the remote.
Output
Remote
Pin 4
„STAT“
Base
Pin 3
„CMD“
Base
Pin 2
24 V DC
Remote
0 V
0 V
0 V
24 V
24 V
24 V
STAT-3 STAT-2 STAT-1 STAT-2 STAT-3
CMD -2 CMD -2CMD -1
PLC
Signal path and output characteristics

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4.1 LED indicators
There is a status LED on each FCP ele-
ment next to the PushPull Powerport.
Status LED
Status LED on the base
Status LED Meaning Recommended action
Flashes green Input voltage OK, no remote coupled (STAT-3)
Flashes green
intermittently
Remote is repeatedly coupled and decoupled
(pulses)
Reduce centre offset between base and
remote to <5 mm
Lights up green Input voltage OK, remote coupled (STAT-1)
Lights up red Input voltage not OK or overload Check input voltage
Check load for short-circuit
Flashes red Over-temperature (>85 °C) Improve heat dissipation or incorporate
ventilation
Reduce connected load
Status LED on the remote
Status LED Meaning Recommended action
Lights up green Output voltage OK
Lights up red Output voltage not OK, current limiting enabled Reduce connected load
4 Status indicators and maintenance

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4.2 Maintenance
Clean the surfaces of the FCP elements
with a dry or moist cloth. Do not use clean-
ing agents that contain acetone.

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5 Technical data
Electrical data
Input voltage 21.6…26.4 V DC (24 V DC ±10 %)
Output voltage 19.2…28.8 V DC (24 V DC ±20 %)
No-load current, base Approx. 40 mA (without remote)
Approx. 260 mA (remote without load)
Power connection PushPull Power plug-in connector (as per
PROFINET specication)
Reverse polarity protection Yes
Overload protection Yes (>12 A)
Max. load current, remote 10 A (12 A for 50 ms); consider derating, see Annex
Max. power 240 W; consider derating, see Annex
Turn-om time, base 1 s
Coupling time, remote < 500 ms
Efciency Max. 91 %
Operating frequency Approx. 55 kHz
Mechanical specications
Housing main material Diecast zinc, painted, PBT plastic
Protection degree IP65 as per DIN EN
Dimensions 100 mm x 100 (108) mm x 47 mm
Weight 1,020 g (per FCP element)
Type of mounting Four M4 bolts (blind hole depth 8 mm)
Air gap 0…5 mm; consider derating, see Annex
Centre offset ± 5 mm
Angle offset max. 5°
Coupling range 5...7 mm
Decoupling range 10...18 mm
Environmental conditions
Ambient temperature (operational) -20…+45 °C; consider derating, see Annex
Storage temperature -40…+85 °C
Relative humidity 5...95 %, no condensation

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Standards / approvals
UL In preparation
EMC / Emissions EN 61000-6-4, Class A (09/2011)
EMC / Electrostatic discharge immunity EN 61000-4-2, Criteria B (12/2009)
EMC / Radiated, radio-frequency, electromagnetic eld
immunity
EN 61000-4-3, Criteria A (04/2011)
EMC / Electrical fast transient/burst immunity EN 61000-4-4, Criteria A (04/2013)
EMC / Surge immunity EN 61000-4-5, Criteria B (06/2007)
EMC / Immunity to conducted disturbances EN 61000-4-6, Criteria A (08/2014)
EMC / Immunity to magnetic elds EN 61000-4-8, Criteria A (11/2010)
Vibrations DIN EN 60068-2-6 (10/2008)
Shock DIN EN 60068-2-27 (02/2010)
CCC Products with an operating voltage <24 V are exempt
from approval.

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Annex
Derating
The derating curve shows the depend-
ence of the current strength on the air
gap and ambient temperature if the centre
offset is 0 mm. With a centre offset >0 mm
the permissible air gap or the transmissi-
ble power is reduced.
The derating gures only apply if a heat
sink with 1.5 K/W or better is used during
operation or comparable heat dissipation
is ensured.
20100-10 50 30 40
0
1
2
3
4
5
-20
2 A
4 A
6 A
8 A
10 A
Air gap [mm]
Ambient temperature [°C]
Current strength depends on air gap and ambient
temperature

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Dependence of efciency on air gap or load current
0
10
20
30
40
50
60
70
80
90
100
0,5
2,0
3,5
5,0
Air gap [mm]
Efficiency [%]
6 A load current
2 A 6 load current
Efciency dependent on air gap (24 V DC, 15 °C)
0
10
20
30
40
50
60
70
80
90
100
2
4
6
8
10
Load current [A]
Efficiency [%]
Air gap 0.5 mm
Air gap 3.5 mm
Efciency dependent on load current (24 V DC, 15 °C)

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2002150000/03/06.2017
Weidmüller Interface GmbH & Co. KG
Klingenbergstraße 16
32758 Detmold, Germany
T [phone]
F [phone]
[e-mail]
www.weidmueller.com