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If the programmable logic controller PLC
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is the brain of an industrial automation
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system, the power supply is undoubtedly
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its heart. Without a clean, reliable
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flow of energy, the smartest control
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systems in the world are just expensive
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paper weights. In the complex ecosystem
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of an industrial control cabinet,
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managing power isn't just about turning
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things on. It's about safety,
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reliability, and longevity. Today we're
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looking at a workhorse component
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designed exactly for this environment,
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the PSRS 24 to 60 power supply and
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exploring why dedicated industrial power
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and proper installation practices are
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Detailed information contained in this
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video can be found at acccca.ca.
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A link has been put in the description
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below. The website offers extensive
0:48
links, references, and coding samples,
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making it a one-stop shop for all your
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automation queries. accutomation.ca.
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Why do industrial cabinets need
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specialized power supplies? Walk up to
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any industrial control panel. The power
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coming into that cabinet is usually raw
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high voltage AC, perhaps 120V, 240V, or
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even 480V 3-phase. It's powerful, but
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it's also noisy, fluctuating, and
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inherently dangerous. Conversely, the
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sensitive components inside the cabinet,
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the PLC's, sensors, HMIs, and safety
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relays operate in a different world.
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They require stable, clean, low- voltage
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DC power, almost universally 24VDC. In
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modern automation, you cannot simply
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plug a sensitive DC sensor into a 480V
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AC line. You need a bridge that does
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more than just convert AC to DC. You
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need a device built to withstand the
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heat, vibration, and electrical noise
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typical of a factory floor, all while
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providing unwavering voltage regulation.
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The critical role of isolation beyond
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just converting voltage. The most vital
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function of an industrial power supply
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like the PSRS 2460 is providing galvanic
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isolation. Imagine a massive voltage
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spike occurring on the incoming AC mains
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line due to a nearby motor starting or a
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lightning strike. Without isolation,
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that spike could travel directly through
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to the DC side, instantly destroying
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sensitive and expensive control
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components. Galvanic isolation
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physically separates the input AC high
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voltage circuit from the output DC low
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voltage circuit using a transformer.
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There is no direct metallic conductive
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path between the high side and the low
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side. Energy is transferred via magnetic
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fields. Why this matters for your low
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voltage circuits? Component protection.
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It acts as a firewall. Faults on the
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main side do not propagate to the DC
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side. Ground loop prevention. It helps
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prevent noise issues caused by
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differences in ground potential across
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the facility. Personnel safety seal. By
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isolating the output from dangerous line
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voltages, the 24V DC side becomes a
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safety extra low voltage SEV circuit
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which is significantly safer for
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technicians to work around for
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maintenance and troubleshooting.
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Spotlight on the PSRS 2460. The PSRS
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2460 is designed specifically to sit in
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that critical gap between line power and
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control power. As a 24VDC 60W supply, it
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occupies a sweet spot for many
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industrial applications. It provides
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enough power to run a standard PLC CPU,
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several input output cards, and a
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handful of field sensors without being
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overly bulky or expensive. Designed for
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DNR rail mounting, it integrates
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seamlessly into standard cabinet
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layouts, providing the necessary
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isolation and regulated DC power that
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keeps processes running smoothly without
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interruption. Installation corner. The
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importance of fererals with stranded
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wire. We can't talk about reliable power
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without talking about reliable
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connections. In industrial cabinets, we
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almost exclusively use stranded wire
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rather than solid core wire. Stranded
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wire is flexible, making it easier to
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route through tight wire ducts and able
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to withstand the constant vibration of
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machinery without work hardening and
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snapping. However, stranded wire has a
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weakness. Screw terminals. When you
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insert bare stranded wire into a
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terminal block or the input terminals of
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the PSRS 2460 and tighten the screw,
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several things go wrong. Spllaying. The
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twisting action of the screw pushes the
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strands apart. Broken strands. The sharp
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edge of the screw cuts some of the fine
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copper strands, reducing the current
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carrying capacity. Loose connections,
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hot spots. Over time, thermal cycling
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causes the splade strands to settle,
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leading to a loose connection, increased
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resistance, heat buildup, and eventual
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failure. The solution? Use a fereral. A
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fereral is a thin tincoated copper tube
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crimped over the end of stranded wire.
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By using a feral, you consolidate the
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strands into a solid gas-tight mass.
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When you insert a fereral wire into the
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PSRS 2460 terminal block, the screw
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makes solid contact with the metal tube.
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This ensures maximum surface area
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contact, prevents oxidation between
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strands, and guarantees a vibration
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proof connection that won't loosen over
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time. Using fererals isn't just extra
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credit work. It's an industry best
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practice that ensures the reliable power
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delivered by your supply actually makes
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it to the device that needs it. If you
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are enjoying this video, please hit the
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Selecting the correct wire size is
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crucial for safety and performance.
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Using a wire that is too small for the
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current load can lead to overheating,
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voltage drops, and potential fire
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hazards. Below is a general guide for
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typical copper wire impacity used in
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control panels. Note, this chart is for
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general guidance only. Always consult
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local electrical codes such as the NEC
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in the US or CEC in Canada, wire
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manufacturer specifications, and
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consider factors like ambient
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temperature, wire insulation type, and
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number of conductors in a raceway when
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making a final selection. Note, this
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chart is for general guidance only.
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Always consult local electrical codes
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such as the NEC in the US or CEC in
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Canada, wire manufacturer
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specifications, and consider factors
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like ambient temperature and insulation
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type. A reliable control panel starts
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with a stable foundation. By choosing a
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rugged isolated power supply like the
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PSRS 2460 and adhering to best
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installation practices like using fuels
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and selecting the correct wire size, you
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ensure the long-term health and safety
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of your automation investments.
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