SHORT-FORM DATA MARKINGS. IECEx

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1 MOSFET REDUNDNCY MODULE For N1 and 11 Redundant Systems Dual Input with Single Only 6mV Voltage Drop at 1 Current Only.6W Loss at 1 16% (32.5) Peak Load Capability Reverse Input Polarity Protection Full Between 4 C and 7 C Width only 32mm Rugged Metal Housing Easy Wiring: Distribution Terminal for Negative Pole Included GENERL DESCRIPTION The YR2.242 is a redundancy module for building redundant power supply systems. It is equipped with two input channels and one output. The two inputs are decoupled by MOSFET technology. In addition to the YR2.242, the YR2.246 is available which is featured with an automated load sharing between the connected power supplies and functions which monitor defects in the redundancy circuit or too high output currents, which could prevent redundancy, if one power supply fails. The YR2.242 utilizes 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 32mm 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 1228V ±3% Input voltage range Vdc Input current 2x 24 ambient <45 C **) 2x 2 ambient <7 C ** current 24 ambient <45 C 2 ambient <7 C max. 26 in overload *) or short circuit mode Input to output voltage drop 6mV 11mV input: 2x5 input: 2x1 losses 21mW at no load.6w input: 2x5 2.W input: 2x1 Temperature range 4 C to 7 C operational Dimensions 32x124x117mm WxHxD Weight 25g,.56lb *) Currents at voltages below 6V **) Sum of input current of both input max. 2 rsp. 24 ORDER NUMBERS MRKINGS YR4.242 ccessory ZM11.SIDE Side mount bracket IND. CONT. EQ. UL 58 UL 6951 Class I Div 2 planned IECEx TEX II 3G Ex n IIC T4 Gc planned Marine planned 1/17

2 INDEX Page 1. Intended Use Installation Requirements Input and Characteristics Losses Lifetime Expectancy and MTBF Terminals and Wiring Functional Diagram Front Side and User Elements EMC Environment Protection Features Safety Features Dielectric Strength pprovals...11 Page 15. RoHS, RECH and Other Fulfilled Standards Physical Dimensions and Weight ccessories ZM11.SIDE Side Mounting Bracket pplication Notes Using Only One Input instead of Both Channels Recommendations for Inductive and Capacitive Loads Sidewards Installation Clearances up to N1, Example with Mounting Orientations...17 The information given in this document is correct to the best of our knowledge and experience at the time of publication. If not expressly agreed otherwise, this information does not represent a warranty in the legal sense of the word. s the state of our knowledge and experience is constantly changing, the information in this data sheet is subject to revision. We therefore kindly ask you to always use the latest issue of this document (available under No part of this document may be reproduced or utilized in any form without our prior permission in writing. TERMINOLOGY ND BREVITIONS DC 24V 24Vdc may shall should 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) figure with the unit (Vdc) at the end is a momentary figure without any additional tolerances included. key word indicating flexibility of choice with no implied preference key word indicating a mandatory requirement 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 DC 11 C C IN 1 IN 2 IN 1 IN 2 IN 1 IN 2 IN 1 IN 2 OUT Load OUT OUT DC 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 type of power supply as long as the maximum output current ratings are not exceeded. It is suitable for power supplies with constant current overload behavior as well as any kind of Hiccup overload behavior. Do not use this redundancy module in equipment, where malfunction may cause severe personal injury or threaten human life. 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 bottom and the output terminals on the top of the unit. For other mounting orientations see derating requirements of chapter 18.7 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 18.4 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. The input must be powered from a SELV source (according to IEC 6951), a PELV source (according to IEC ) or an Isolated Secondary Circuit (according to UL 58). Do not ground or earth the positive output pole which could prevent redundancy in case of a ground failure. Ground the negative output pole when needed. 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. 3/17

4 3. INPUT ND OUTPUT CHRCTERISTICS Number of inputs 2 Number of outputs 1 Input voltage nom. DC 1228V ±3% Input voltage range Vdc Voltage drop, input to output typ. 6mV at 2x5, 25 C, see Fig. 31 typ. 11mV at 2x1, 25 C, see Fig. 31 typ. 13mV at 2x12, 25 C, see Fig. 31 Input current nom. 2x 24 1) continuous, ambient temperature < 45 C nom. 2x 2 1) continuous, ambient temperature < 7 C nom. 2x ) for max. 5 seconds max. 2x 7 for max. 1ms current nom. 24 continuous, ambient temperature < 45 C nom. 2 continuous, ambient temperature < 7 C nom ) for max. 5 seconds max. 26 in overload /shortcircuit (voltage < 6V). Ensure that the sum of input currents does not exceed this value. Reverse current max. 1m at 24V, per input, 4 C to 7 C Reverse voltage max. 4Vdc voltage applied to the output, continuously allowed capacitance typ. 32μF 1) Ensure that the sum of both input currents stays below 24 rsp. 2. 2) Ensure that the sum of both input currents stays below ) The average value (R.M.S. value) of the output current must not exceed the values of the continuous output current. Fig. 31 Input to output voltage drop Fig. 32 Test setup for voltage drop measurements Voltage Drop, typ 15mV 125mV 1mV 75mV 5mV 25mV mv : Input: 5 2x x5 6 C 25 C Input / Current x7.5 2x1 2x V, 12 24V, 12 I1 V U1 I2 V U2 YR2.242 Input 1 Input 2 IOUT UOUT V Variable Load, 24 I1 = I2 U1 = U2 Voltage Drop = U1 UOUT 4/17

5 4. POWER LOSSES DC 12V DC 24V losses typ..6w.6w input: 2x5, ambient temperature: 25 C typ. 2.W 2.W input: 2x1, ambient temperature: 25 C Standby power losses typ..11w.21w at no output current Fig. 41 losses Losses, typ. 3.5W 6 C C Current V, 12 Fig. 42 Test setup for power loss measurements 24V, 12 I1 V U1 I2 V U2 YR2.242 Input 1 Input 2 IOUT UOUT V Variable Load, 24 I1 = I2 U1 = U2 Losses = ( U1* I1 U2* I2 ) UOUT* IOUT 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: 2x5 : 1 Input: 2x1 : 2 Lifetime expectancy *) 553 h *) 355 h *) at 24V and 4 C h *) 1 3 h *) at 24V and 25 C MTBF **) SN 295, IEC h h at 24V and 4 C h h at 24V and 25 C MTBF **) MIL HDBK 217F 2 3 h 1 89 h Ground Fixed GF4 (24V and 4 C) 2 81 h h Ground Fixed GF25 (24V and 25 C) 441 h 44 h Ground Benign GB4 (24V and 4 C) 64 h 548 h Ground Benign GB25 (24V 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. 5/17

6 6. TERMINLS ND WIRING Input and Type Screw termination, IP2 Finger safe construction. Suitable for field installation. Solid wire max. 6mm 2 Stranded wire max. 4mm 2 merican Wire Gauge WG 21 Max. wire diameter 2.8mm (including ferrule) Wire stripping length 7mm /.275inch Screwdriver 3.5mm slotted or Pozidrive No 2 Recommended tightening torque.8nm, 7lb.in Instructions: a) 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. b) Follow national installation codes and installation regulations! c) Ensure that all strands of a stranded wire enter the terminal connection! d) Screws of unused terminal compartments should be securely tightened. e) Ferrules are allowed. 7. FUNCTIONL DIGRM Fig. 71 Functional diagram control Input 1 Input 2 control Chassis Ground 6/17

7 8. FRONT SIDE ND USER ELEMENTS Fig. 81 Front side B C Terminals (screw terminals) Chassis Ground Terminal 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) 7/17

8 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. EMC Immunity ccording to 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 frequency magnetic EN Hz 3/m Criterion field 1) Criterions: : module shows normal operation behavior within the defined limits. Notes: 1) 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 to generic standards: EN 6163 and EN 6164 Conducted emission input lines IEC/CISPR 1612, IEC/CISPR 1621 limits for DC power ports according 2) 3) EN 6163 fulfilled Conducted emission output lines IEC/CISPR 1612, IEC/CISPR 1621 limits for DC power ports according 2) 3) EN 6163 fulfilled Radiated emission EN 5511, EN 5522 Class B 3) 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. Notes: 2) 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 14kHz to 5kHz depending on the input voltage. 8/17

9 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 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 1.25/1m 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 EN , 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 32.5 short term (< 5s) mbient Temperature C normal mode Fig. 12 current vs. altitude llowed Current short term (< 5s) normal mode B Tamb < 45 C B... Tamb < 7 C ltitude 2 4 6m 9/17

10 11. PROTECTION FETURES overcurrent protection not included Reverse input polarity included unit does not start when input voltage is reversed protection Degree of protection IP 2 EN/IEC 6529 Penetration protection > 3.6mm e.g. screws, small parts Overtemperature protection not included Input transient protection included see EMC section 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 Safety level of output voltage The output voltage is regarded to be SELV (EN 6951) or PELV (EN 6241, EN , IEC ) if the input voltage fulfills the requirements for a SELV source or PELV source. 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 1/17

11 14. PPROVLS EC Declaration of Conformity IEC 6951 UL 58 UL 6951 NSI / IS Class I Div 2, planned TEX EN 679, EN 67915, planned IECEx IEC 679, IEC 67915, planned Marine, planned EC TR Registration 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 and the TEX directive (planned). 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: T.B.D. 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 T.B.D. GL (Germanischer Lloyd) classified Environmental category: C, EMC1 Marine and offshore applications Registration for the Eurasian Customs Union market (Russia, Kazakhstan, Belarus) 15. ROHS, RECH ND OTHER FULFILLED STNDRDS RoHS Directive RECH Directive Directive 211/65/EU of the European Parliament and the Council of June 8 th, 211 on the restriction of the use of certain hazardous substances in electrical and electronic equipment. Directive 197/26/EU of the European Parliament and the Council of June 1 st, 27 regarding the Registration, Evaluation, uthorisation and Restriction of Chemicals (RECH) 11/17

12 16. PHYSICL DIMENSIONS ND WEIGHT Width 32mm 1.26 Height 124mm 4.88 Depth 117mm 4.61 The DINrail height must be added to the unit depth to calculate the total required installation depth. Weight 25g /.56lb DINRail Use 35mm DINrails according to EN 6715 or EN 522 with a height of 7.5 or 15mm. Housing material Body: luminium alloy Cover: zincplated steel Installation clearances See chapter 2 Fig. 161 Front view Fig. 162 Side view 12/17

13 17. CCESSORIES ZM11.SIDE SIDE MOUNTING BRCKET This bracket is used to mount the YR2.242 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. 171 Side mounting without DINrail brackets Fig. 172 Side mounting with DINrail brackets Fig. 173 Mounting Dimensions Side mounting bracket 13/17

14 18. PPLICTION NOTES USING ONLY ONE INPUT INSTED OF BOTH CHNNELS Using only one input instead of both is allowed up to a nominal input current of 24 (at max. 45 C ambient temperature) or 2 (at max. 7 C ambient temperature). However, it is always recommended to connect both input path in parallel for reduced power losses and voltage drop. In cases when this is not possible, the following values can be expected: Voltage drop, input to output typ. 8mV at 1x1, 25 C, see Fig. 181 typ. 15mV at 1x2, 25 C, see Fig. 181 losses typ..75w at 1x1, 25 C, see Fig. 183 typ. 3.W at 1x2, 25 C, see Fig. 183 Standby power losses typ..7w at 12V operation typ..14w at 24V operation Fig. 181 Input to output voltage drop when only one input is used Fig. 182 Test setup for voltage drop measurements Voltage Drop, typ. 2mV 15mV 6 C 25 C 24V, 24 I1 V U1 YR2.242 Input 1 IOUT UOUT V Variable Load, 24 1mV 5mV mv Current 2 25 Input 2 Voltage Drop = U1 UOUT Fig. 183 losses when only one input is used Fig. 184 Test setup for power loss measurements Losses, typ. 6W C 25 C 24V, 24 I1 V U1 YR2.242 Input 1 IOUT UOUT V Variable Load, Current Input 2 Losses = U1* I1 UOUT* IOUT 14/17

15 18.2. 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 additional 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). IN 1 IN 2 The clearance between the power supplies and the redundancy module can be reduced to zero under the following conditions: 11 redundancy application with maximum 12 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. Input YR2.242 Load Input mm mm 15/17

16 REDUNDNCY UP TO 1 11 up to 1 requires two 1 power supplies and one YR2.242 redundancy module. Fig. 185 Wiring diagram, 11, 1 output current Failure Monitor 24V,1 DC OK Input 1 Input 2 24V,1 DC OK YR2.242 L1 L2 L3 PE L1 L2 L3 PE L1 L2 L3 PE optional I I I I I I 1 Load Note: Use separate mains systems for each power supply whenever it is possible N1 REDUNDNCY, EXMPLE WITH 3 N1 up to 3 requires four 1 power supplies and two YR2.242 redundancy modules. Fig. 186 Wiring diagram, n1, 3 output current Failure Monitor 24V,1 DC OK Input 1 Input 2 24V,1 DC OK 24V,1 DC OK Input 1 Input 2 24V,1 DC OK YR2.242 YR2.242 L1 L2 L3 PE L1 L2 L3 PE L1 L2 L3 PE L1 L2 L3 PE L1 L2 L3 PE I I I optional I I I I I I I I I optional 3 Load Note: Use separate mains systems for each power supply whenever it is possible 16/17

17 18.7. 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 Curve 2 Recommended output current. Max allowed output current (results in approximately half the lifetime expectancy of 1). Fig. 187 Mounting Orientation (Standard orientation) INPUT OUTPUT Current mbient Temperature C Fig. 188 Mounting Orientation B (Upside down) OUTPUT Current INPUT 12 6 mbient Temperature C Fig. 189 Mounting Orientation C (Tabletop mounting) Current mbient Temperature C 2 1 Fig. 181 Mounting Orientation D (Horizontal cw) OUTPUT INPUT Current mbient Temperature C Fig Mounting Orientation E (Horizontal ccw) INPUT OUTPUT Current mbient Temperature C 17/17