PSS SIL3 Power Supply System PSS1250, 24Vdc, A, Zone 2/Div Rack for up to 6 modules PSM1250

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1 Characteristics: Features: PSS 1250 General Description: The Power Supply System type PSS1250 is an anodized aluminum 19 Rack unit (4U high) suitable to accept up to 6 plugin Power Supply Modules type and 1 Overview module for diagnostic functions. Each module provides 24Vdc, 50 A output. Modules can be paralleled with load sharing circuits which distribute current load equally to each power supply module to increase reliability and reduce internal power dissipation. The system accepts up to two independent AC power sources from 100 to 264 Vac. Twelve configurations of 19 Rack Units are available with or without Hot Swapping and with or without diagnostic. Four configurations of 9 Rack Units are available with or without Hot Swapping and with or without diagnostic. For more information about different configurations see pages Hot Swap Plugins: When using rack PSR12506, each power supply module can be replaced in Zone 2/Div. 2 Hazardous ocations without having to monitor the hazardous gas presence and without disturbing Power Supply operations. Diagnostic: Racks PSR12506, accept a plugin module () dedicated to monitoring all diagnostic functions of each power supply, via a front panel touch screen CD color display which indicates Input/Output Voltage, Current and Power; ine Frequency; Output sharing Current; alarm status; Internal Temperature. RS485 Modbus output provides full diagnostic and status conditions. presence or fault does not affect PSS1250 operation and safety function. Overvoltage protection: 3 independent overvoltage protections: 1 voltage limiting loop at 30 Vdc and 11 crowbars at 31 Vdc. EMC: Fully compliant with CE marking applicable requirements. High load fuses breaking capability: In case of short circuit on the load, the Power supply system delivers a very high peak current (about 800 Amp) for a duration of 0.5 ms. This characteristic ensures the instant breakage of the protective fuse or circuit breaker. Because of the very short peak current duration, other equipment connected to the load are not affected by the failure event and continue to operate without interruption. SI 3 for E oad according IEC 61508:2010. SI 2 (on redundant configuration) for D oad according to IEC 61508: universal AC Input ines, 100 to 264 Vac (48 to 62 Hz). Installation in Zone 2 / Div.2 hazardous locations. Reduces Power dissipation (in paralleled/redundant configuration) by replacing a Schottky diode with Mosfet Active Ideal Diode. TÜV, ATEX, IECEx Certifications. Hot swappable modules. Power factor correction. High load fuse breaking capability without interrupting operations. 3 over voltage redundant protections. Redundant parallel connections with load sharing. Highly regulated output of 24 Vdc, 50 A, per module. Under and over voltage alarm monitoring. 19 Rack unit, 4 U high,anodized aluminium, durable metal enclosure. Tropicalization for electronic components. 87% Vac input and 24 Vdc output and full load. RS485 Modbus RTU diagnostic output. Images: Example configuration of PSS1250HS3D PSR1250HS3D 2 x 1 x 1 x WMP1250HS3 SI3 Power Supply System PSS1250, 24Vdc, A, Zone 2/Div Rack for up to 6 modules Single module Technical Data: Supply: Input voltage: 100 to 264 Vac (48 to 62 Hz). imit input voltage to 250 Vrms for Intrinsically Safe applications. Power Factor Correction (AC input): 0.98 typ.@230vac, typ.@115vac, full load. out (full load): better than Vac and 115 Vac. Max. internal power out (full load): Vac; Vac. AC input current (sinusoidal at full out: Vac input voltage, Vac input voltage, Vac input voltage. Inrush current: 35 A 264 Vac; 30 A 230 Vac; 15 A 115 Vac. AC input connection: screw terminal blocks suitable for 4mm 2 wires. Isolation: Input to output isolation: 2500 Vrms (routine test). Input to Ground isolation: 1500 Vrms (routine test). Ground to output isolation: 2500 Vrms (routine test). Output: Output voltage: 24 Vdc (adjustable from 21 to 28 Vdc). Regulation: 0.2 % for a 100 % load change. Stability: 0.1 % for a 20 % line voltage change. Ripple: 250 mvpp. Output Rise Time: 2.5 s. Dynamic Response: 3 % in 200 µs for a 1090% load change. Output current: 50 A nominal (@24Vdc out). Parallel connection for redundancy with load sharing ± 5%. Connection: screw terminals on copper bars suitable for 300A available on rear panel of 9 or 19 rack unit. Holdup time at full load: 20 ms (AC input). Over voltage protection: output limited to 30 Vdc plus two redundant crowbars for over voltage protection at 31 Vdc. Power good signaling: Output good: 19.5 V Vout 29.5 V. Indication: via CD screen on and Modbus protocol. Signaling: voltage free SPST normally energized relay, deenergize in overvoltage/undervoltage/overload conditions. Contact Rating: 3 A 100 Vac 300 VA, 3 A 100 Vdc 90 W (resistive load). Connection: screw terminal blocks suitable for 2.5 mm 2 wires. Compatibility: CE mark compliant, conforms to directive 2004/108/CE EMC, conforms to E , E and E60950 for electrical safety. Environmental conditions: Operating temperature limits: 40 to 70 C derated linearly 6570% load above 50 C. Relative humidity limits (up to 40 C): 10 to 90 %, non condensing. Transport, storage temperature limits: 45 to 85 C. Safety Description: Approvals ATEX Category 3 for Zone 2. II 3 G Ex na nc IIC T3 Gc. IECEx Ex na nc IIC T3 Gc. SI 3 / SI 2 according to IEC 61508:2010 Ed. 2. Mechanical: Mounting: 9 or 19 Rack unit, 4 units high. Weight: 9 fully equipped about 10 Kg. 19 fully equipped about 24 Kg. ocation: Safe Area/on Hazardous ocations or Zone 2, Group IIC T3, Class I, Zone 2, Group IIC, IIB, IIA T3 installation. Protection class: IP 20. Dimensions: see drawings pages 35. Example configuration of PSS1250HS7D: PSR1250HS7D 6 x 1 x 1 x WMP1250HS7 G.M. International DTS04129 PREIMIARY IFORMATIO Page 1/16

2 Reasons for using an Ideal DiodeOR Controller circuit, in 1 redundant power supply applications with high availability systems High availability systems often employ power supply modules connected in parallel to achieve redundancy and enhance system reliability. ORing diodes have been a popular means of connecting these supplies at a point of load. The disadvantage of this approach is the forward voltage drop and resulting efficiency loss. This drop reduces the available supply voltage and dissipates significant power. Replacing channel MOSFETs with Schottky diodes reduces power dissipation and eliminates the need for expensive heat sinks or large thermal layouts in high power applications. In the Ideal DiodeOR Controller circuit (active ideal diode), the voltage across source and drain is monitored by I and OUT pins, and GATE pin drives the MOSFETs to control their operation. In effect the MOSFET source and drain serve as the anode and cathode of an ideal diode. In the event of a power supply failure, for example if the output of a fully loaded supply is suddenly shorted to ground, reverse current temporarily flows through the MOSFETs that are O. This current is sourced from any load capacitance and from the other supplies. The active ideal diode quickly responds to this condition turning off the MOSFETs in about 0.5µs, thus minimizing disturbance and oscillations to the output bus. In standard configuration, to parallel two, or more, 24 VDC power supply modules for redundancy, one Schottky diode is used for each module. The voltage drop across the diode can reach about 0.8 V at 50 A, this means about 40 W dissipation for each module. Then, if six 50 A paralleled modules are used for full A redundancy, a total power of about 240 W is dissipated for this purpose. This reduces efficiency, reliability and increases space for heat sinks. Moreover, in case of module failure, diodes take time to recover and consequently they do not preserve the load from transients during the backup operation. To avoid all these problems G.M. International has introduced, in the new PSS1250 Power Supply System, the use of active ideal diodes. The MOSFETs resistance for active ideal diodes is about 1.2 mω resulting in 3.6 W dissipation for each power module. Then, if six 50 A paralleled modules are used for full A redundancy, a total power of about 22 W is dissipated for the purpose resulting in about ten times less dissipation compared to Schottky diodes solution. This increases efficiency, reliability, availability and reduces space for heat sinks. This circuit provides also very smooth voltage switchovers without oscillations with fast turnoff, minimizing reverse current transients. Hot swapping capability PSS1250 Power Supply System is able to provide power to devices in Zone 2 / Div. 2 Hazardous ocations, without the need to monitor hazardous gas presence and without disturbing power supply operations, because it is fully protected for the Hot Swapping of any power, or diagnostic, module. This protection system operates for both the insertion and disconnection of the modules. When inserting the module, the mains voltage is applied when mechanical and electrical connections of the modules are completely and correctly positioned, while before disconnecting the module the external electrical connections have to be at zero voltage level. To achieve this result, a sophisticated 1oo2 mechanical and electrical protection circuit, using micro switches, relays and special hot swapping circuits, has been designed. All modules have a mains terminal block for ineeutralearth, placed in the wall mounting panel that can be used for two independent mains lines. The ine and eutral are connected to the power supply module via 1oo2 mechanical switches and two 1oo2 relay contacts. Two micro switches for each Power Module are placed in the front part of the 9 or 19 Rack unit and are activated by front panel screws used to fix the module at Rack. 24 relays (4 for each power module) are installed on the wall mounting rear panel close to the mains terminal blocks in 1oo2 architecture for safety purposes. For further safety, close to the relays, for each position, there is a red ED (total 6 EDs). When the ED is lit it means that there is a failure in one relay and consequently the relays architecture, in that specific position, is 1oo1 instead of 1oo2. Therefore, before inserting a power module, the operator must verify that the red ED is in OFF state. The opening of the micro switches, operated by unscrewing the front panel screws, initiates the following two actions: 1. Mains line is disconnected from the module; 2. Voltage on the module connectors is brought to 0 volts, to avoid any sparking possibility. This is done by a MOSFET solid state switch connected in series with the active ideal diodes, which disconnects the output from the bus. The internal voltage in the disconnected power module remains completely isolated from the output connections and therefore, even if an operator shorts the connections with a screw driver or any other tool, this will not generate a spark. When the module is inserted, this switch remains open until the power supply starts to operate correctly, then it closes applying voltage to the load. Output voltage setting Fault indications Diagnostic information For each module, the output voltage can be set to 24 Vdc 17%; 15% via a front panel trimmer. Under voltage threshold at 19.5 V, Over voltage threshold at 29.5 V. A front panel power O green ED signals that mains voltage is applied to the module. Fault conditions are signaled by a normally closed contact with E relay on the wall mounting terminal block, which opens in the following conditions: Under voltage Vout < 19.5 V. Over voltage Vout > 29.5 V. Blowers failure. If output voltage goes below 19.5 V, the green Power O ED blinks and remains steady for values lower than 20 V. If output voltage goes over 29.5 V, the green Power O ED is OFF and remains steady for values higher than 29 V. If output voltage is within 20 V 29 V range, the green Power O ED is O. Communication with the six Power modules is achieved via the diagnostic module, which incorporates a front panel color touch screen. The diagnostic module is able to query power modules (using an internal proprietary bus) and read data such as, Input/Output Voltage, Current and Power; ine Frequency; Output sharing Current; alarm status; Internal Temperature. This information is available via front panel CD and externally via Modbus RTU on a terminal block in the wall mounting rear panel. The diagnostic module does not interfere with the Power system functional safety. The power system can perfectly work without the diagnostic module and any failure of the diagnostic module does not affect system performance and reliability. Functional block diagram: AC 1 AC 2 RE RE HSC HSC MS MS PFC Module 1 PFC Module 2 PWM PWM AID AID SSS SSS oad 24 Vdc egend: AC 1: Mains line AC 2: Mains backup line PFC: Power Factor Controller PWM: Power Module HSC: Hot Swappable Circuit AID: Active Ideal Diode SSS: Solid State Switch MS: Micro switches on 19 rack unit RE: Relays on Backplane : ine : eutral G.M. International DTS04129 PREIMIARY IFORMATIO Page 2/16

3 Wall Mounting Panels type WMP12507 and WMP12503 overall dimensions: TYPES: WMP1250HS7D WMP1250HS7 WMP12507D WMP12507 TYPES: WMP1250HS3D WMP1250HS3 WMP12503D WMP12503 G.M. International DTS04129 PREIMIARY IFORMATIO Page 3/16

4 Wall mounting panel type WMP1250HS7 with PSR1250HS7 Rack unit overall dimensions: 19 Rack Unit type PSR1250HS7 Top view without cover 19 Rack Unit type PSR1250HS7 Top view G.M. International DTS04129 PREIMIARY IFORMATIO Page 4/16

5 Wall mounting panel type WMP1250HS3 with PSR1250HS3 Rack unit overall dimensions: 9 Rack Unit type PSR1250HS3 Top view without cover 9 Rack Unit type PSR1250HS3 Top view G.M. International DTS04129 PREIMIARY IFORMATIO Page 5/16

6 Power Supply Module : PSW1250 Maximum Output Power vs. Ambient Operating Temperature Output Power vs. Ambient Operating Temperature Pout (W) Tamb ( C) Side view Output voltage: 28 Vdc 24 Vdc 21 Vdc Valid for Input Voltage range 100 to 264 Vac With 50% redundant configuration (two with paralleled outputs), each module can give 600 W power output up to 70 C operating ambient temperature, with output voltage range 2128 Vdc and input voltage range Vac. Top view Front view Side view without cover G.M. International DTS04129 PREIMIARY IFORMATIO Page 6/16

7 Power Supply Diagnostic Module : Side view Side view Top view Front view G.M. International DTS04129 PREIMIARY IFORMATIO Page 7/16

8 Function Diagram Dual AC Supply wiring architecture for PSS1250HS73: SAFE AREA or ZOE 2 GROUP IIC T4, O HAZARDOUS OCATIOS or CASS I, DIVISIO 2, GROUPS A, B, C, D TCode T3, CASS I, ZOE 2, GROUP IIC T3 PSS1250HS7, dual AC supply, 3 redundant 50 A Outputs, overview module six modules connected in parallel in groups of two to provide full redundancy on AC lines (AC1 and AC2) and three independent 24 Vdc, 50 A redundant outputs. AC 1 AC 2 FT AC FT AC FT AC FT AC FT AC FT AC COM. Modbus AC1 AC2 FT CD touch screen color display DC 1 DC 2 DC 3 24 Vdc, 50A 50 A 24 Vdc, 50A 50 A 24 Vdc, 50A 50 A Wall Mounting Panel type WMP1250HS73: Wall Mounting Panel type WMP125073: G.M. International DTS04129 PREIMIARY IFORMATIO Page 8/16

9 Function Diagram Dual AC Supply wiring architecture for PSS1250HS72: SAFE AREA or ZOE 2 GROUP IIC T4, O HAZARDOUS OCATIOS or CASS I, DIVISIO 2, GROUPS A, B, C, D TCode T3, CASS I, ZOE 2, GROUP IIC T3 PSS1250HS7, dual AC supply, 1 redundant 100 A Output 1 redundant 50 A Output, overview module four modules connected in parallel to provide full redundancy on AC lines (AC1 and AC2) and one 100 A redundant output. two modules connected in parallel to provide full redundancy on AC lines (AC1 and AC2) and one 50 A redundant output. AC 1 AC 2 FT AC FT AC FT AC FT AC FT AC FT AC COM. Modbus AC1 AC2 FT CD touch screen color display DC 1 DC 2 24 Vdc, 100A 100 A 24 Vdc, 50A 50 A Wall Mounting Panel type WMP1250HS72: Wall Mounting Panel type WMP125072: G.M. International DTS04129 PREIMIARY IFORMATIO Page 9/16

10 Function Diagram Dual AC Supply wiring architecture for PSS1250HS71: SAFE AREA or ZOE 2 GROUP IIC T4, O HAZARDOUS OCATIOS or CASS I, DIVISIO 2, GROUPS A, B, C, D TCode T3, CASS I, ZOE 2, GROUP IIC T3 PSS1250HS7, dual AC supply, 1 redundant 150 A Output, overview module six modules connected in parallel to provide full redundancy on AC lines (AC1 and AC2) and one 150 A redundant output. AC 1 AC 2 FT AC FT AC FT AC FT AC FT AC FT AC COM. Modbus AC1 AC2 FT CD touch screen color display DC 1 24 Vdc, 150A 150 A Wall Mounting Panel type WMP1250HS71: Wall Mounting Panel type WMP125071: G.M. International DTS04129 PREIMIARY IFORMATIO Page 10/16

11 Function Diagram Dual AC Supply wiring architecture for PSS1250HS3: SAFE AREA or ZOE 2 GROUP IIC T4, O HAZARDOUS OCATIOS or CASS I, DIVISIO 2, GROUPS A, B, C, D TCode T3, CASS I, ZOE 2, GROUP IIC T3 PSS1250HS3, dual AC supply, 1 redundant 50 A Output 1 redundant 50 A Output, overview module two modules connected in parallel to provide full redundancy on AC lines (AC1 and AC2) and one 50 A redundant output. AC 1 AC 2 FT AC FT AC COM. Modbus AC1 AC2 FT CD touch screen color display DC 1 24 Vdc, 50A 50 A Wall Mounting Panel type WMP1250HS3: Wall Mounting Panel type WMP12503: G.M. International DTS04129 PREIMIARY IFORMATIO Page 11/16

12 Ordering Information: Power Supply System Component Type Component View Description WMP1250HS71D 150 Amp 150 Amp Redundant Hot Swappable Capability. PSS1250HS71D PSR1250HS7 6 Power Supply Modules and 1 Diagnostic Module. Power Supply Module Diagnostic Module WMP1250HS72D 100 Amp 100 Amp Redundant and one Power Supply 50 Amp 50 Amp Redundant Hot Swappable Capability PSS1250HS72D PSR1250HS7 6 Power Supply Modules and 1 Diagnostic Module. Power Supply Module Diagnostic Module WMP1250HS73D Wall mounting panel, fully wired for 3 Power Supply 24VDC, each 50 Amp 50 Amp Redundant. Hot Swappable Capability PSS1250HS73D PSR1250HS7 6 Power Supply Modules and 1 Diagnostic Module. Power Supply Module Diagnostic Module G.M. International DTS04129 PREIMIARY IFORMATIO Page 12/16

13 Ordering Information: Power Supply System Component Type Component View Description WMP1250HS71D 150 Amp 150 Amp Redundant. Hot Swappable Capability PSS1250HS71 PSR1250HS7 6 Power Supply Modules. Power Supply Module MCHP228 Blank panel WMP1250HS72D 100 Amp 100 Amp Redundant and one Power Supply 50 Amp 50 Amp Redundant. Hot Swappable Capability PSS1250HS72 PSR1250HS7 6 Power Supply Modules. Power Supply Module MCHP228 Blank panel WMP1250HS73D Wall mounting panel, fully wired for 3 Power Supply 24VDC, each 50 Amp 50 Amp Redundant. Hot Swappable Capability PSS1250HS73 PSR1250HS7 6 Power Supply Modules. Power Supply Module MCHP228 Blank panel G.M. International DTS04129 PREIMIARY IFORMATIO Page 13/16

14 Ordering Information: Power Supply System Component Type Component View Description WMP125071D 150 Amp 150 Amp Redundant. PSS125071D PSR Power Supply Modules and 1 Diagnostic Module. Power Supply Module Diagnostic Module WMP125072D 100 Amp 100 Amp Redundant and one Power Supply 50 Amp 50 Amp Redundant PSS125072D PSR12507D 6 Power Supply Modules and 1 Diagnostic Module. Power Supply Module Diagnostic Module WMP125073D 50 Amp 50 Amp Redundant. PSS125073D PSR12507D 6 Power Supply Modules and 1 Diagnostic Module. Power Supply Module Diagnostic Module G.M. International DTS04129 PREIMIARY IFORMATIO Page 14/16

15 Ordering Information: Power Supply System Component Type Component View Description WMP125071D 150 Amp 150 Amp Redundant. PSS PSR Power Supply Modules. Power Supply Module MCHP228 Blank panel WMP125072D 100 Amp 100 Amp Redundant and one Power Supply 50 Amp 50 Amp Redundant PSS PSR Power Supply Modules. Power Supply Module MCHP228 Blank panel WMP125073D Wall mounting panel, fully wired for 3 Power Supply 24VDC, each 50 Amp 50 Amp Redundant. PSS PSR Power Supply Modules. Power Supply Module MCHP228 Blank panel G.M. International DTS04129 PREIMIARY IFORMATIO Page 15/16

16 Ordering Information: Power Supply System Component Type Component View Description PSS1250HS3D WMP1250HS3D 50 Amp50 Amp Redundant. Hot Swappable Capability PSR1250HS3 9 Rack unit sutable to accept up to 2 Power Supply Modules and 1 Diagnostic Module. Two Power Supply module Diagnostic Module PSS1250HS3 WMP1250HS3D 50 Amp50 Amp Redundant. Hot Swappable Capability PSR1250HS3 9 Rack unit sutable to accept up to 2 Power Supply Modules Two Power Supply module MCHP228 Blank panel PSS12503D WMP12503D 50 Amp50 Amp Redundant. PSR12503D 9 Rack unit sutable to accept up to 2 Power Supply Modules and 1 Diagnostic Module. Two Power Supply module Diagnostic Module PSS12503 WMP12503D 50 Amp50 Amp Redundant. PSR Rack unit sutable to accept up to 2 Power Supply Modules Two Power Supply module MCHP228 Blank panel G.M. International DTS04129 PREIMIARY IFORMATIO Page 16/16