SHORT-FORM DATA MARKINGS. IECEx

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1 MOSFET REDUNDNCY MODULE For N1 and 11 Redundant Systems Dual Input with Single Suitable for all DIMENSION Power Supplies Only 6mV Voltage Drop at 2 Current Only 1.8W Loss at 2 and 5.4W at 4 Current 16% (65) Peak Load Capability Reverse Input Polarity Protection Full Power Between 4 C and 6 C Width only 46mm Rugged Metal Housing Easy Wiring: Distribution Terminal for Negative Pole Included 3 Year Warranty GENERL DESCRIPTION The is a redundancy module, which can be used to build 11 and N1 redundant systems. It is equipped with two input channels, which can be connected to power supplies with up to 2 output current and one output, which can carry nominal currents up to 4. The novelty of this redundancy module is the utilization of mosfets instead of diodes for the decoupling of the two input channels. This reduces the heat generation and the voltage drop between input and output. The redundancy module does not require an additional auxiliary voltage. Due to the low power losses, the unit is very slender and only requires 46mm width on the DINrail. Large connection terminals allow for a safe and fast installation. The large international approval package makes this unit suitable for nearly every application. SHORTFORM DT Input voltage DC 2456V ±15% Input voltage range Vdc Input current 2x 2 continuous 2x for 5 seconds current 4 continuous 465 for 5 seconds max. 45 in overload *) or short circuit mode Input to output voltage drop typ. 6mV typ. 95mV typ. 12mV input: 2x1 input: 1x2 input: 2x2 Power losses typ. 22mW 24V, at no load typ. 62mW 48V, at no load typ. 1.8W 48V,input: 2x1 typ. 2.3W 48V,input: 1x2 typ. 5.4W 48V,input: 2x2 Temperature range 4 C to 7 C operational Derating 1/ C (output) 6 to 7 C Dimensions 46x124x127mm WxHxD Weight 36g,.79lb *) Currents at voltages below 6V ORDER NUMBERS 2456V Standard unit ccessory ZM2.WLL Wall/ panel mount bracket ZM12.SIDE Side mount bracket MRKINGS IECEx IND. CONT. EQ. UL 58 UL 6951 Class I Div 2 TEX II 3G Ex n IIC T4 Gc Marine EMC, LVD 1/17

2 INDEX Page 1. Intended Use Installation Requirements Input and Characteristics Power Losses Lifetime Expectancy and MTBF Terminals and Wiring Functional Diagram Front Side and User Elements EMC Environment Protection Features Safety Features...11 Page 13. Dielectric Strength pprovals Physical Dimensions and Weight ccessories pplication Notes Recommendations for Inductive and Capacitive Loads Sidewards Installation Clearances up to N1, Example with Mounting Orientations...17 The information presented in this document is believed to be accurate and reliable and may change without notice. No part of this document may be reproduced or utilized in any form without permission in writing from the publisher. TERMINOLOGY ND BREVITIONS PE and symbol PE is the abbreviation for Protective Earth and has the same meaning as the symbol. Earth, Ground This document uses the term earth which is the same as the U.S. term ground. T.b.d. To be defined, value or description will follow later. DC 24V figure displayed with the C or DC before the value represents a nominal voltage with standard tolerances (usually ±15%) included. E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (1V) 24Vdc figure with the unit (Vdc) at the end is a momentary figure without any additional tolerances included. may key word indicating flexibility of choice with no implied preference shall key word indicating a mandatory requirement should key word indicating flexibility of choice with a strongly preferred implementation 11 Use of two identical power supplies in parallel to provide continued operation following most failures in a single power supply. The two power supply outputs should be isolated from each other by utilizing diodes or other switching arrangements. E.g. two 1 power supplies are needed to achieve a 1 redundant system. N1 Use of three or more identical power supplies in parallel to provide continued operation following most failures in a single power supply. ll power supply outputs should be isolated from each other by utilizing diodes or other switching arrangements. E.g.: To achieve a 4 redundant system, five 1 power supplies are needed in a N1 redundant system. C DC C DC N1 C C DC DC C DC C IN 1 IN 2 IN 1 IN 2 IN 1 IN 2 OUT Load OUT OUT DC 11 C C DC IN 1 IN 2 OUT Load DC 2/17

3 1. INTENDED USE This redundancy module is designed for installation in an enclosure and is intended for the general use such as in industrial control, office, communication, and instrumentation equipment. This redundancy module can be used with any DIMENSION power supplies Do not use this redundancy module in equipment, where malfunction may cause severe personal injury or threaten human life. This device is designed for use in hazardous, nonhazardous, ordinary or unclassified locations. 2. INSTLLTION REQUIREMENTS This device may only be installed and put into operation by qualified personnel. This device does not contain serviceable parts. If damage or malfunction should occur during installation or operation, immediately turn power off and send unit to the factory for inspection. Mount the unit on a DINrail so that the input terminals are located on the bootom and the output terminals on the top of the unit. For other mounting orientations see derating requirements of chapter 17.6 in this document. This device is designed for convection cooling and does not require an external fan. Do not obstruct airflow and do not cover the ventilation grid (e.g. cable conduits) by more than 3%! Keep the following installation clearances: 4mm on top, 2mm on the bottom, 5mm on the left and right sides are recommended when the device is loaded permanently with more than 5% of the rated output current. Increase the side clearance to 15mm in case the adjacent device is a heat source (e.g. another power supply). See chapter 17.3 for other allowed clearances when used with the PULS DIMENSION series in a 11 redundant configuration. Use only power supplies with a negligible output ripple voltage in the low frequency range between 5Hz and 1kHz when used in marine applications according to the GL regulations. WRNING Risk of electrical shock, fire, personal injury or death. Turn power off before working on the device. Protect against inadvertent repowering. Make sure that the wiring is correct by following all local and national codes. Do not open, modify or repair the unit. Use caution to prevent any foreign objects from entering the housing. Do not use in wet locations or in areas where moisture or condensation can be expected. Do not touch during poweron, and immediately after poweroff. Hot surfaces may cause burns. Notes for use in hazardous location areas: The redundancy module is suitable for use in Class I Division 2 Groups, B, C, D locations and for use in Group II Category 3 (Zone 2) environments and is evaluated according to EN 679:29 and EN 67915:21. WRNING EXPLOSION HZRDS! Substitution of components may impair suitability for this environment. Do not disconnect the unit unless power has been switched off or the area is known to be nonhazardous. suitable enclosure must be provided for the end product which has a minimum protection of IP54 and fulfils the requirements of the EN 67915:21. 3/17

4 3. INPUT ND OUTPUT CHRCTERISTICS Number of inputs 2 Number of outputs 1 Input voltage nom. DC 2456V ±15% The input circuitry must meet the SELV requirements stipulated by IEC/EN/UL Input voltage range Vdc Voltage drop, input to output typ. 12mV at 2x2, see Fig. 31 typ. 6mV at 2x1, see Fig. 31 typ. 95mV at 1x2, see Fig. 32 Input current nom. 2x 2 continuous nom. 2x for 5 seconds max 2x 22.5 in overload (voltage < 6V) or short circuit mode Peak input current max. 1 for max. 1ms per input current nom. 4 continuous nom. 465 for 5 seconds max. 45 in overload (voltage < 6V) or short circuit mode Reverse current max. 1m at 48V, per input, 4 C to 7 C Reverse voltage max. 65Vdc voltage applied to the output, continuously allowed capacitance typ. 31μF Fig. 31 Input to output voltage drop when both inputs draw current (typical 11 redundant case, when the output voltages of the two units are equal) 16mV 14mV 12mV 1mV 8mV 6mV 4mV 2mV mv : Input: Voltage Drop, typ C B... 6 C 1 2x5 Input / Current 2 2x1 B 3 2x15 4 2x2 QS2/ QS4/ CPS2 48V, max.2 QS2/ QS4/ CPS2 48V, max.2 I1 V U1 I2 V U2 Input 1 Input 2 IOUT UOUT V Variable Load, 4 I1 = I2 U1 = U2 Voltage Drop = U1 UOUT Fig. 32 Input to output voltage drop when only one input draws current Voltage Drop, typ. 12mV 15mV 9mV 75mV B 6mV 45mV 3mV 15mV mv Current C B... 6 C QS2/ QS4/ CPS2 48V, max.2 V U1 Not used or power supply with lower voltage I1 Input 1 Input 2 IOUT UOUT V Voltage Drop Variable Load, 2 = U1 UOUT 4/17

5 4. POWER LOSSES DC 24V DC 48V Power losses typ. 1.4W 1.8W input: 2x1 typ. 5.W 5.4W input: 2x2 typ. 2.W 2.3W input: 1x2, (only one input is connected to input voltage) Standby power losses typ..14w.42w at no output current, (only one input is connected to input voltage) typ..22w.62w at no output current, (both inputs are connected to input voltages) Fig. 41 Power losses when both inputs draw equal current Power Losses, typ. 6W V, 25 C B... 24V, 6 C 4. C... 48V, 25 C D... 48V, 6 C Current D B C 4 QS2/ QS4/ CPS2 set to 48V QS2/ QS4/ CPS2 set to 48V I1 V U1 I2 V U2 Input 1 Input 2 IOUT UOUT V Variable Load, 4 I1 = I2 U1 = U2 Losses = ( U1* I1 U2* I2 ) UOUT* IOUT Fig. 42 Power losses when only one input is used Power Losses, typ. 3W V, 25 C B... 24V, 6 C C... 48V, 25 C D... 48V, 6 C D B C QS2/ QS4/ CPS2 set to 48V I1 V U1 Input 1 IOUT UOUT V Variable Load, Current Input 2 Losses = U1* I1 UOUT* IOUT 5/17

6 5. LIFETIME EXPECTNCY ND MTBF The redundancy module has two input channels which are completely independent from each other. Each control circuit, auxiliary voltage source, or other circuitry in the module are designed separately for each input. The dual input redundancy module can be considered as two single redundancy modules combined together in one housing. The only common point is the circuit trace that ties the two separate circuits together at the output. The MTBF figures below are for the entire dual input module. If the MTBF number of only one path is needed, simply double the value from the table. Input / output current conditions Input: 2x1 : 2 Input: 2x2 : 4 Lifetime expectancy *) 448 h *) 222 h *) at 48V and 4 C h *) 629 h *) at 48V and 25 C MTBF **) SN 295, IEC h 4 98 h at 48V 4 C h 7 88 h at 48V 25 C MTBF **) MIL HDBK 217F 211 h 178 h Ground Fixed GF4 (48V and 4 C) 288 h 238 h Ground Fixed GF25 (48V and 25 C) 959 h 839 h Ground Benign GB4 (48V and 4 C) h h Ground Benign GB25 (48V and 25 C) *) The Lifetime expectancy shown in the table indicates the minimum operating hours (service life) and is determined by the lifetime expectancy of the builtin electrolytic capacitors. Lifetime expectancy is specified in operational hours and is calculated according to the capacitor s manufacturer specification. The manufacturer of the electrolytic capacitors only guarantees a maximum life of up to 15 years (131 4h). ny number exceeding this value is a calculated theoretical lifetime which can be used to compare devices. **) MTBF stands for Mean Time Between Failure, which is calculated according to statistical device failures, and indicates reliability of a device. It is the statistical representation of the likelihood of a unit to fail and does not necessarily represent the life of a product. The MTBF figure is a statistical representation of the likelihood of a device to fail. MTBF figure of e.g. 1 h means that statistically one unit will fail every 1 hours if 1 units are installed in the field. However, it can not be determined if the failed unit has been running for 5 h or only for 1h. 6/17

7 6. TERMINLS ND WIRING Input and output Type Screw termination IP2 Finger safe construction. Suitable for field installation. Solid wire.516mm 2 Stranded wire.51mm 2 merican Wire Gauge 228 WG Max. wire diameter 5.2mm (including ferrule) Wire stripping length 12mm /.5inch Screwdriver 3.5mm slotted or Pozidrive No 2 Recommended tightening torque 1.2Nm, 1.6lb.in To connect the chassis to ground, use a ringtype terminal (ring cable lug) which is suitable for a M4 screw and connect it to the chassis ground terminal on top of the unit. Instructions: a) The external circuitry of all terminals must meet the safety requirements stipulated by IEC/EN/UL 6951: SELV. b) Use appropriate copper cables that are designed for minimum operating temperatures of: 6 C for ambient up to 45 C and 75 C for ambient up to 6 C and 9 C for ambient up to 7 C minimum. c) Follow national installation codes and installation regulations! d) Ensure that all strands of a stranded wire enter the terminal connection! e) Screws of unused terminal compartments should be securely tightened. f) Ferrules are allowed. g) Do not connect or disconnect the wires from the terminals below 25 C (13 F). 7/17

8 7. FUNCTIONL DIGRM Fig. 71 Functional diagram control Input 1 Input 2 control Chassis Ground 8. FRONT SIDE ND USER ELEMENTS Fig. 81 Front side B C Terminals (screw terminals) Chassis Ground Terminals To be connected on the top side of the housing with a ringtype terminal (ring cable lug) which is suitable for a M4 screw. Connection of the chassis is optional and not required since the unit fulfils the requirements according to protection class III. Input Terminals for Input 1 (screw terminals) D Input Terminals for Input 2 (screw terminals) 8/17

9 9. EMC The redundancy module is suitable for applications in industrial environment as well as in residential, commercial and light industry environment without any restrictions. detailed EMC report is available on request. EMC Immunity ccording generic standards: EN 6161 and EN 6162 Electrostatic discharge EN 6142 Contact discharge ir discharge 8kV 15kV Criterion Criterion Electromagnetic RF field EN MHz2.7GHz 2V/m Criterion Fast transients (Burst) EN 6144 Input lines lines Surge voltage on input lines Surge voltage on output lines EN 6145 / Chassis ground EN 6145 / Chassis ground 2kV 2kV 5V 1kV 5V 1kV Criterion Criterion Criterion Criterion Criterion Criterion Conducted disturbance EN MHz 2V Criterion Powerfrequency magnetic EN Hz 3/m Criterion field *) Criterions: : module shows normal operation behavior within the defined limits. Notes: *) test is not applicable according to EN 6162, since the device does not contain components susceptible to magnetic fields, e.g. hall elements, electrodynamic microphones, etc. EMC Emission ccording generic standards: EN 6163 and EN 6164 Conducted emission IEC/CISPR 1612, IEC/CISPR 1621 limits for DC power ports according EN 6163 fulfilled *) Radiated emission EN 5511, EN 5522 Class B This device complies with FCC Part 15 rules. Operation is subjected to following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. *) For information only, not mandatory for EN Provided, that power sources connected on the inputs fulfill the requirements too. Switching frequency The internal auxiliary supply is generated with a boost converter. The switching frequency varies from 55kHz to 18kHz depending on the input voltage. 9/17

10 1. ENVIRONMENT Operational temperature *) 4 C to 7 C (4 F to 158 F) Storage temperature 4 to 85 C (4 F to 185 F) for storage and transportation derating 1 / C 67 C (14 F to 158 F) Humidity **) 5 to 95% r.h. IEC Vibration sinusoidal ***) 217.8Hz: ±1.6mm; 17.85Hz: 2g IEC hours / axis Shock ***) 3g 6ms, 2g 11ms IEC bumps / direction, 18 bumps in total ltitude to 2m ( to 6 56ft) without any restrictions 2 to 6m (6 56 to 2 ft) reduce output power or ambient temperature, see Fig. 12 ltitude derating 2.5/1m or 5 C/1m > 2m (65ft), see Fig. 12 Overvoltage category not applicable The concept of the overvoltage category is used for equipment energized directly from the low voltage mains (IEC ). Degree of pollution 2 IEC 6213, EN 5178, not conductive LBS compatibility The unit does not release any silicone or other LBScritical substances and is suitable for use in paint shops. *) Operational temperature is the same as the ambient temperature and is defined as the air temperature 2cm below the unit. **) Do not energize while condensation is present ***) Tested in combination with DINRails according to EN 6715 with a height of 15mm and a thickness of 1.3mm and standard mounting orientation. Fig. 11 current vs. ambient temp. llowed Current short term (< 5s) normal mode mbient Temperature C Fig. 12 current vs. altitude llowed Current 65 short term (< 5s) ltitude 2 4 6m normal mode... Tamb < 7 C B... Tamb < 6 C C... Tamb < 5 C B C 1/17

11 11. PROTECTION FETURES overcurrent protection not included Reverse input polarity protection included unit does not start when input voltage is reversed Degree of protection IP 2 EN/IEC 6529 Penetration protection > 3.6mm e.g. screws, small parts Overtemperature protection not included Input transient protection not included transient protection included see EMC section Internal input fuse not included 12. SFETY FETURES Input / output separation no galvanic separation Mosfet between input and output Class of protection III PE (Protective Earth) or chassis connection not required PE resistance <.1Ohm between housing and chassisground terminal 13. DIELECTRIC STRENGTH The input and output voltages have the same reference, are floating and have no ohmic connection to ground. Type and factory tests are conducted by the manufacturer. Field tests may be conducted in the field using the appropriate test equipment which applies the voltage with a slow ramp (2s up and 2s down). Connect input/output terminals together before conducting the test. When testing, set the cutoff current settings to the value in the table below. Fig. 131 Dielectric strength In / Chassis Type test 6s 5Vac Factory test 5s 5Vac Field test 5s 5Vac Cutoff current setting > 2m 11/17

12 14. PPROVLS EC Declaration of Conformity EC Declaration of Conformity TEX IEC 6951 UL 58 UL 6951 HazLoc (Class 1 Div 2) NSI / IS TEX EN 679, EN IECEx IEC 679, IEC Marine GOST R IND. CONT. EQ. II 3G Ex n IIC T4 Gc IECEx Ex n IIC T4 Gc The CE mark indicates conformance with the EMC directive 24/18/EC, Lowvoltage directive (LVD) 26/95/EC and RoHS directive 211/65/EU. The CE mark indicates conformance with the TEX directive 94/9/EC (Equipment and protection systems intended for use in potentially explosive atmospheres) CB Scheme, Information Technology Equipment Listed for use as Industrial Control Equipment; U.S.. (UL 58) and Canada (C22.2 No. 1711); EFile: E Recognized for use as Information Technology Equipment, Level 5; U.S.. (UL 6951) and Canada (C22.2 No. 695); EFile: E1376 LISTED for use in Hazardous Location Class I Div 2 T4 Groups,B,C,D systems; U.S.. (NSI / IS ) and Canada (C22.2 No. 213M1987) Suitable for use in Category 3 Zone 2 locations. Number of TEX certificate: EPS 11 TEX X The redundancy module must be builtin in an IP54 enclosure. Suitable for use in Category 3 Zone 2 locations. Number of IECEx certificate: IECEx EPS 12.32X GL (Germanischer Lloyd) classified Environmental category: C, EMC1 Marine and offshore applications Certificate of Conformity for Russia and other GUS countries 12/17

13 15. PHYSICL DIMENSIONS ND WEIGHT Weight 36g /.79lb DINRail Use 35mm DINrails according to EN 6715 or EN 522 with a height of 7.5 or 15mm. The DINrail height must be added to the unit depth (127mm) to calculate the total required installation depth. Installation clearances See chapter 2 Fig. 151 Front view Fig. 152 Side view 13/17

14 16. CCESSORIES ZM2.WLL Wall mounting bracket This standard bracket is used to mount the redundancy module onto a flat surface without utilizing a DIN Rail. Fig. 161 ZM2.WLL Wall mounting bracket Fig. 162 ssembled wall mounting bracket ZM12.SIDE Side mounting bracket This bracket is used to mount the redundancy module sideways with or without utilizing a DINRail. The two aluminum brackets and the black plastic slider of the unit have to be detached, so that the steel brackets can be mounted. For sideway DINrail mounting, the removed aluminum brackets and the black plastic slider need to be mounted on the steel bracket. Fig. 163 ZM12.SIDE Side mounting bracket Fig. 164 Side mounting with DINrail brackets 14/17

15 17. PPLICTION NOTES RECOMMENDTIONS FOR REDUNDNCY Recommendations for the configuration of redundant power systems: Use separate input fuses for each power supply. Use threephase power supplies to gain functional safety if one phase fails. When singlephase power supplies are utilized connect them to different phases or mains circuits if possible. Set the power supply in ParallelUse mode if this feature is available It is desirable to set the output voltages of all power supplies to the same value INDUCTIVE ND CPCITIVE LODS The unit is designed to supply any kind of loads, including unlimited capacitive and inductive loads SIDEWRDS INSTLLTION CLERNCES The minimum clearance recommendations are defined in chapter 2. Normally, the following installation clearance are recommended: 4mm on top, 2mm on the bottom, 5mm on the left and right sides when the device is loaded permanently with more than 5% of the rated power. Increase this clearance to 15mm in case the adjacent device is a heat source (e.g. another power supply). The clearance between the power supplies and the redundancy module can be reduced to zero under the following conditions: 11 redundancy application with maximum 2 output current. The power supplies are from the PULS DIMENSION series. The redundancy module is placed between the two power supplies. The output voltage is set to the same level on both power supplies. Power Supply L N PE 48V, 2 2 Load Input Input 1 2 Power Supply Parallel Use Single Use L N PE 48V, 2 mm mm 15/17

16 REDUNDNCY UP TO 2 11 up to 2 requires two 48V, 2 power supplies and one redundancy module. Fig. 171 Wiring diagram, 11, 2 output current 2 Load Failure Monitor Power Supply Power Supply Parallel Use Single Use DC OK Parallel Use Single Use DC OK L N PE 48V, 2 Input Input 1 2 L N PE 48V, 2 L N PE I I Note: Use separate mains systems for each power supply whenever it is possible N1 REDUNDNCY, EXMPLE WITH 6 N1 up to 6 requires four 48V, 2 power supplies and two redundancy modules. Fig. 172 Wiring diagram, n1, 6 output current 6 Load Failure Monitor Power Supply Power Supply Power Supply Power Supply Parallel Use Single Use DC OK Parallel Use Single Use DC OK Parallel Use Single Use DC OK Parallel Use Single Use DC OK L N PE 48V, 2 Input Input 1 2 L N PE 48V, 2 L N PE 48V, 2 Input Input 1 2 L N PE 48V, 2 L N PE I I I I Note: Use separate mains systems for each power supply whenever it is possible 16/17

17 17.6. MOUNTING ORIENTTIONS Mounting orientations other than input terminals on the bottom and output on the top require a reduction in continuous output power or a limitation in the maximum allowed ambient temperature. The amount of reduction influences the lifetime expectancy of the power supply. Therefore, two different derating curves for continuous operation can be found below: Curve 1 Recommended output current. Curve 2 Max allowed output current (results in approximately half the lifetime expectancy of 1). Fig. 173 Mounting Orientation (Standard orientation) OUTPUT INPUTS Current mbient Temperature C Fig. 174 Mounting Orientation B (Upside down) INPUTS OUTPUT Current mbient Temperature C Fig. 175 Mounting Orientation C (Tabletop mounting) Current mbient Temperature C 2 1 Fig. 176 Mounting Orientation D (Horizontal cw) INPUTS OUTPUT Current mbient Temperature C 2 1 Fig. 177 Mounting Orientation E (Horizontal ccw) OUTPUT INPUTS Current mbient Temperature C /17