PD_T8200 Trusted Trusted High Integrity Power Supply System (110-240 Vac and 24 Vdc) Product Overview The Trusted power supply assembly converts redundant main line voltages of either 110 Vac / 240 Vac or 24 Vdc, to +15 Vdc or +24 Vdc output power for system and field power requirements. Features: Redundant power inputs. 250 W. Hot replaceable. Current sharing. Power factor correction. Front panel indicators for input, output voltage status and output current level on each module. External status signals. TϋV Certified IEC 61508 SIL 3. Rockwell Automation Publication PD_T8200 Issue 11
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Trusted High Integrity Power Supply System PREFACE PREFACE In no event will Rockwell Automation be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples given in this manual are included solely for illustrative purposes. Because of the many variables and requirements related to any particular installation, Rockwell Automation does not assume responsibility or reliability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, with respect to use of information, circuits, equipment, or software described in this manual. All trademarks are acknowledged. DISCLAIMER It is not intended that the information in this publication covers every possible detail about the construction, operation, or maintenance of a control system installation. You should also refer to your own local (or supplied) system safety manual, installation and operator/maintenance manuals. REVISION AND UPDATING POLICY This document is based on information available at the time of its publication. The document contents are subject to change from time to time. The latest versions of the manuals are available at the Rockwell Automation Literature Library under "Product Information" information "Critical Process Control & Safety Systems". TRUSTED RELEASE This technical manual applies to Trusted Release: 3.6.1. LATEST PRODUCT INFORMATION For the latest information about this product review the Product Notifications and Technical Notes issued by technical support. Product Notifications and product support are available at the Rockwell Automation Support Centre at http://rockwellautomation.custhelp.com At the Search Knowledgebase tab select the option "By Product" then scroll down and select the Trusted product. Some of the Answer ID s in the Knowledge Base require a TechConnect Support Contract. For more information about TechConnect Support Contract Access Level and Features please click on the following link: https://rockwellautomation.custhelp.com/app/answers/detail/a_id/50871 This will get you to the login page where you must enter your login details. IMPORTANT A login is required to access the link. If you do not have an account then you can create one using the "Sign Up" link at the top right of the web page. Rockwell Automation Publication PD_T8200 Issue 11 i
PREFACE Trusted High Integrity Power Supply System DOCUMENTATION FEEDBACK Your comments help us to write better user documentation. If you discover an error, or have a suggestion on how to make this publication better, send your comment to our technical support group at http://rockwellautomation.custhelp.com ii Issue 11 Rockwell Automation Publication PD_T8200
Trusted High Integrity Power Supply System PREFACE SCOPE This manual specifies the maintenance requirements and describes the procedures to assist troubleshooting and maintenance of a Trusted system. WHO SHOULD USE THIS MANUAL This manual is for plant maintenance personnel who are experienced in the operation and maintenance of electronic equipment and are trained to work with safety systems. SYMBOLS In this manual we will use these notices to tell you about safety considerations. SHOCK HAZARD: Identifies an electrical shock hazard. If a warning label is fitted, it can be on or inside the equipment. WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which can cause injury or death, property damage or economic loss. ATTENTION: Identifies information about practices or circumstances that can cause injury or death. CAUTION: Identifies information about practices or circumstances that can cause property damage or economic loss. BURN HAZARD: Identifies where a surface can reach dangerous temperatures. If a warning label is fitted, it can be on or inside the equipment. This symbol identifies items which must be thought about and put in place when designing and assembling a Trusted controller for use in a Safety Instrumented Function (SIF). It appears extensively in the Trusted Safety Manual. IMPORTANT NOTE TIP Identifies information that is critical for successful application and understanding of the product. Provides key information about the product or service. Tips give helpful information about using or setting up the equipment. Rockwell Automation Publication PD_T8200 Issue 11 iii
PREFACE Trusted High Integrity Power Supply System WARNINGS AND CAUTIONS WARNING: EXPLOSION RISK Do not connect or disconnect equipment while the circuit is live or unless the area is known to be free of ignitable concentrations or equivalent AVERTISSEMENT - RISQUE D EXPLOSION Ne pas connecter ou déconnecter l équipement alors qu il est sous tension, sauf si l environnement est exempt de concentrations inflammables ou équivalente MAINTENANCE Maintenance must be carried out only by qualified personnel. Failure to follow these instructions may result in personal injury. CAUTION: RADIO FREQUENCY INTERFERENCE Most electronic equipment is influenced by Radio Frequency Interference. Caution should be exercised with regard to the use of portable communications equipment around such equipment. Signs should be posted in the vicinity of the equipment cautioning against the use of portable communications equipment. CAUTION: The module PCBs contains static sensitive components. Static handling precautions must be observed. DO NOT touch exposed connector pins or attempt to dismantle a module. iv Issue 11 Rockwell Automation Publication PD_T8200
Trusted High Integrity Power Supply System PREFACE ISSUE RECORD Issue Date Comments 8 Sep 05 Format 9 Mar 06 Removed hidden characters 10 Sep 15 Rebranded and reformatted 11 Apr 16 Standardisation of Operating Temperature and Relative Humidity Range Statements in the Specification section Rockwell Automation Publication PD_T8200 Issue 11 v
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Trusted High Integrity Power Supply System Table of Contents Table of Contents 1. Description... 3 1.1. Power Supply Chassis... 3 1.2. Power Supply Modules... 4 1.3. Input Power Regulation... 4 1.4. Front Panel Indicators... 7 1.4.1. Input Power Voltage Indicator... 7 1.4.2. Output Power Display... 7 1.4.3. Output Power Indicator... 7 2. Installation... 9 2.1. Chassis Mounting... 9 2.2. Backplane Versions and Module Keying... 10 2.2.1. Input Power Terminals: TB1, TB2 (#8 Screw Terminals)... 10 2.2.2. Output Power Terminals: TB3, TB4 (#6 Screw Terminals)... 11 2.2.3. Status Connectors: J14, J15... 11 2.2.4. Monitor Connector: J13... 12 3. Configuration... 13 3.1. Current Sharing... 13 3.2. REGENT Power Supply Load Units... 13 3.3. Regent I/O Triplicated Power Distribution... 13 4. Maintenance... 15 5. Specifications... 17 Rockwell Automation Publication PD_T8200 Issue 11 1
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Trusted High Integrity Power Supply System 1. Description 1. Description The Power Supply Assembly consists of a Power Supply Chassis containing up to six Power Supply Modules. The Chassis may be configured to distribute power in various combinations. For example, a Chassis containing six Power Supply Modules may be set up with three Modules providing triplicated power for Regent+Plus Input/Output (I/O) assemblies and three Modules providing field power in a N+1 configuration. Alternatively, the Chassis may be set up to provide separate dual 24 Vdc supplies for both a Trusted System and associated field devices. 1.1. Power Supply Chassis Figure 1 Power Supply Assembly The Power Supply Chassis houses a maximum of six Power Supply Modules. It may be mounted in a 19-inch rack or flush mounted on a panel. Table 1 identifies the available types of Chassis. Catalogue No. Chassis Unit Input Power Voltage Configuration T8200 I/O Power Supply Chassis 110-240 Vac, 50/60 Hz Straight Bussed T8201 I/O Power Supply Chassis 110-240 Vac, 50/60 Hz Cross Bussed T8202 I/O Power Supply Chassis 24 Vdc Table 1 Chassis Types Rockwell Automation Publication PD_T8200 Issue 11 3
1. Description Trusted High Integrity Power Supply System 1.2. Power Supply Modules The Power Supply Assembly Modules are single (if redundant inputs are not required) and dual input, hot swap, user-replaceable ac and dc units. Table 2 identifies the available types of Modules. Catalogue No. Input Type Input Power Voltage Output Power Voltage T8220 Dual 110-240 Vac 15 Vdc T8222 Dual 24 Vdc 15 Vdc T8223 Single 110-240 Vac 24 Vdc T8224 Single 110-240 Vac 15 Vdc T8225 Dual 110-240 Vac 24 Vdc T8226 Dual 24 Vdc 24 Vdc Table 2 Module Types The dual inputs on the ac Modules are galvanically isolated from each other. The inputs on the dc Modules are diode isolated and share a common return. 1.3. Input Power Regulation A block diagram of a typical dual ac input I/O Power Supply Module is shown in Figure 2. A block diagram of a typical dual dc input I/O Power Supply Module is shown in Figure 3. I/P A Fail PFC A Fail PFC A Off High Tempterature Fail Reset Status & Control PWM Source A I/P Filter & Protection Rectifier PFC T1:b T1:a DC Output T1:c Source B I/P Filter & Protection Rectifier PFC PFC B Off PFC B Fail I/P B Fail Switching Regulator O/P Current Remote Off Power Supply Module Status & Control Figure 2 Block Diagram of a Dual ac I/O Power Supply Module 4 Issue 11 Rockwell Automation Publication PD_T8200
Trusted High Integrity Power Supply System 1. Description I/P A Fail High Tempterature Fail Reset Status & Control Source A I/P Filter & Protection DC Output T1:b T1:a PWM Source B I/P Filter & Protection Switching Regulator O/P Current I/P B Fail Remote Off Status & Control Power Supply Module Figure 3 Block Diagram of a Dual dc I/O Power Supply Module Each primary power input is individually fused and filtered with both standard line filters and metal oxide varistors (MOVs). The filters attenuate any high frequency common mode and normal mode noise present in the power distribution system. The MOVs clamp high voltage transients. Filter, rectifier, and power factor correction circuits convert primary ac input power to bulk dc voltage. The switching regulator converts bulk dc power to regulated dc output voltage. Sensing, status, control and timing circuits provide for the following: Input power failure - Active low status output. Indicates when the input voltage is below 85 Vac or 18 Vdc. There is a separate signal for each input. Bulk power failure - Active high status output on ac input modules only. Indicates the dc bulk voltage (power factor correction (PFC output)) is outside the specified range. There is a separate signal for each input. High temperature warning alarm - Both an active high and active low status output are provided. Indicates when the module temperature exceeds 75 C. The temperature is sensed near the air inlet (bottom) of the module. High temperature shutdown - Internal signal that will shut down the switching regulator if module temperature is above 85 C. The temperature is sensed near the air inlet (bottom) of the module. Output over-voltage - Internal signal that will shut down the switching regulator if the output voltage exceeds +18 Vdc for the 15 volt module and +28 Vdc for the 24 volt module. Over-voltage protection circuitry activation is a permanent error condition, requiring manual intervention to return module to normal operation. Rockwell Automation Publication PD_T8200 Issue 11 5
1. Description Trusted High Integrity Power Supply System dc output fail - Active high status output indicates the dc output voltage has gone out of regulation. The dc output fail threshold is 13.75 Vdc (±0.25 Vdc) for the 15 volt module, and 21.75 Vdc (±0.25 Vdc) for the 24 volt module. Output current limiting - Internal signal limits output current in excessive current demand situations. POWER FAIL - Active high status signal that indicates impending loss of output power due to one of the following: o Both inputs have indicated power failure. o Remote off control signal activated. o Thermal shutdown. o Output over-voltage. RESET - Active high status signal that is generated a minimum of 10 ms (ac input module) or 0.5 ms (dc input module) after a POWER FAIL signal. RESET remains asserted for 200 ms (minimum) after module power-up. PFC off - Active low input that turns off the power factor correction of an individual input. This signal provides the capability to test the input circuitry of a module by turning off each input independently while monitoring the module fail signal. Remote off - Active low input that turns off the output power of a module. Note: Bulk Power Fail, PFC Off and Remote Off are accessed through the Monitor Module Connector on the chassis backplane. The Monitor Module Connector allows for a future development of a monitor card that would provide remote control and enhanced monitoring of the Power Supply Chassis. Active low signals are not maintained while RESET is active. All status signals are open collector and require external pull-up resistors. RESET is used in the Regent I/O Transceivers for power system interlocking within the I/O system. A power failure (either input power or module fault) activates RESET and turns off the dc output Front Panel Indicator. The POWER FAIL and RESET signals are required for proper operation of Regent I/O Transceivers and I/O modules during power-up, power down, and loss of power. Refer to Assembly Installation in the associated Regent Product Description for details of connecting these signals to a Regent I/O Chassis. 6 Issue 11 Rockwell Automation Publication PD_T8200
Trusted High Integrity Power Supply System 1. Description 1.4. Front Panel Indicators The Front Panel of each I/O Power Supply Module supports three Light Emitting Diode (LED) indicators detailed in the following sub-paragraphs 1.4.1. Input Power Voltage Indicator Each green INPUT POWER indicator is lit when the associated input (Input A, Input B) is above the lower input voltage threshold. 1.4.2. Output Power Display The 10-segment LED indicator bar displays the approximate output current level percentage (0 % - 100 %) 1.4.3. Output Power Indicator The DC Output indicator is lit when the I/O Power Supply Module's dc output is within tolerance. Out-of-tolerance conditions, loss of input power or brown-out, and module failures turn off this indicator. Rockwell Automation Publication PD_T8200 Issue 11 7
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Trusted High Integrity Power Supply System 2. Installation 2. Installation 2.1. Chassis Mounting Figure 4 and Figure 5 show the front and rear views of the Power Supply Chassis. 19" TB3 J1 J2 J3 J4 J5 J6 J14 Input Crossover Patch 10.5" J15 J13 J7 J8 J9 J10 J11 J12 TB1 Figure 4 Power Supply Chassis Front View TB4 TB2 Figure 5 Power Supply Chassis Rear View Rockwell Automation Publication PD_T8200 Issue 11 9
2. Installation Trusted High Integrity Power Supply System Mounting flanges can be attached to either the rear or the front of the Chassis. This allows flush mounting the Chassis to a panel or mounting in a 19-inch rack. The Input Crossover Patch is on the T8200 chassis only. Input Crossover Patch configured for no crossover, source 1 and source 2 are connected to input A and input B respectively for all modules slots. Input Crossover Patch configured to swap source 1 and source 2 for modules slots 4 through 6. Source 1 and source 2 are connected to input A and input B respectively for slots 1-3. Source 1 and source 2 are connected to input B and input A respectively for slots 4-6. 6E5 6E7 6E3 6E1 6E5 6E7 6E3 6E1 6E6 6E8 6E4 6E2 6E6 6E8 6E4 6E2 2.2. Backplane Versions and Module Keying Connector placement on ac Input Modules and backplanes differ from dc modules and backplanes. This prohibits insertion of the wrong Input Module type into a backplane. Module slots in a chassis can be individually keyed to only accept a Module of a particular output voltage. 2.2.1. Input Power Terminals: TB1, TB2 (#8 Screw Terminals) Terminal No. T8200 T8202 Source 1 N DC- B 2 L DC+ 3 N DC- A 4 L DC+ Table 3 Input Power Terminals 10 Issue 11 Rockwell Automation Publication PD_T8200
Trusted High Integrity Power Supply System 2. Installation 2.2.2. Output Power Terminals: TB3, TB4 (#6 Screw Terminals) Terminal No. Module Slot T8200, T8202 12 6 11 5 10 4 9 3 8 2 + DC Output 7 1 6 5 4 1-6 3 2 DC Return (terminals 1-6 are connected together on Backplane) 1 2.2.3. Status Connectors: J14, J15 Table 4 Output Power Terminals Type: 10 pin shrouded header, double row, 0.100 x 0.100 Centres Manufacturer: AMP Manufacturer Part No: 102618-3 Mating Connector: AMP 87631-5 Pin Out: Pin J14 J15 Slot Signal Slot Signal 1 2 All Input A Fail 3 All Input B Fail Rockwell Automation Publication PD_T8200 Issue 11 11
2. Installation Trusted High Integrity Power Supply System Pin J14 J15 Slot Signal Slot Signal 4 All Hi Temperature 5 1 Reset 4 Reset 6 1 Power Fail 6 Reset 7 2 Reset 4 Power Fail 8 3 Power Fail 6 Power Fail 9 2 Power Fail 5 Power Fail 10 3 Reset 5 Reset Table 5 Status Connectors 2.2.4. Monitor Connector: J13 Type: 72 pin Edge Connector, 0.125 in centreline Manufacture: AMP Manufacturer Part No: 1-530844-9 Pin-out: Not Configured 12 Issue 11 Rockwell Automation Publication PD_T8200
Trusted High Integrity Power Supply System 3. Configuration 3. Configuration 3.1. Current Sharing The Modules are capable of current sharing by connecting their outputs together in parallel. This can be done external to the Chassis or by using a shorting bar that mounts directly to the output terminals on the Chassis backplane. This allows separate groups of Modules from within a single Chassis to have their outputs configured as Single, Dual or N+1. The Module uses a passive droop method of current sharing and will share to within 25 % of the rated load. 3.2. REGENT Power Supply Load Units When using the Power Supply System with Regent and Regent+Plus, power supply loading is based on the number of I/O Modules in the I/O Chassis and the load imposed by each I/O Module. Load units for each I/O Module are shown in that Module s product description and specification sheet under the Safetybus Power heading. A set of three Power Supply Modules will provide the following load units: Number of I/O Units (Chassis): 1 2 3 4 Load Unit Capacity: 82 78 74 70 Table 6 Available Load Units (for a set of three power supplies) Calculating the number of load units in the system helps determine the number of I/O Power Supplies required by the system. For economic power distribution, and to avoid overloading individual Power Supply Units, calculate power supply loading when configuring systems. 3.3. Regent I/O Triplicated Power Distribution A Chassis can contain two sets of triple-redundant Power supplies for Regent I/O. Each of the triple-redundant I/O Power Supply Modules within the I/O Power Supply Chassis provides power for one leg of the three redundant legs of the I/O Safetybus Transceivers, and provides power to all the I/O Modules within its associated I/O Chassis. Each I/O Module contains a diode OR power-sharing circuit that receives power from all three I/O Power Supply Modules. Should any I/O Power Supply Module fail, only one leg of the transceiver modules loses power: the two remaining legs maintain proper Regent operation. In addition, all the I/O Modules continue to operate properly by drawing their current from the two remaining Power Supplies within the I/O Power supply assembly. Rockwell Automation Publication PD_T8200 Issue 11 13
3. Configuration Trusted High Integrity Power Supply System I/O Transceivers and I/O Modules require power fail and reset status signals for proper operation. 14 Issue 11 Rockwell Automation Publication PD_T8200
Trusted High Integrity Power Supply System 4. Maintenance 4. Maintenance No periodic maintenance or calibration is required for I/O Power Supply Modules. There are no user-replaceable parts. A failed I/O Power Supply Module can be hot-replaced without disrupting system operations. Main power wiring and I/O power cables (connected to the Chassis) are not disturbed during Module replacement. Rockwell Automation Publication PD_T8200 Issue 11 15
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Trusted High Integrity Power Supply System 5. Specifications 5. Specifications Voltage Range T8220, T8223, T8224, T8225 85 Vac to 264 Vac T8222, T8226 20 Vdc to 32 Vdc Frequency Range T8220, T8223, T8224, T8225 47 Hz to 63 Hz Inrush Current (120/260 Vac) T8220, T8223, T8224, T8225 20/4 0A (peak) Cold, 35/65 A (peak) Hot Power Factor 0.95 min. Efficiency 70 % Use with Chassis T8220, T8223, T8224, T8225 T8200 T8222, T8226 T8202 Fusing (Internal to module) T8220, T8223, T8224, T8225 6 A, 250 V, 3AG Slow Blow T8222, T8226 20 A, 250 V, 3AB Slow Blow Output Voltage T8220, T8222, T8224 +15 Vdc T8223, T8225, T8226 +24 Vdc Output Power 250 W, per module Power Hold-up Time T8220, T8223, T8224, T8225 20 ms, minimum T8222, T8226 1 ms, minimum Operating Temperature 0 C to +60 C (+32 F to +140 F) Rockwell Automation Publication PD_T8200 Issue 11 17
5. Specifications Trusted High Integrity Power Supply System Non-operating Temperature -25 C to +70 C (-25 F to +158 F) Relative Humidity range (operating, storage & transport) 10 % 95 %, non-condensing Environmental Specifications Refer to document 552517 Module Dimensions Height Width Depth 266 mm (10.47 in) 61 mm (2.38 in) 318 mm (2.5 in) Chassis Dimensions Height Width Depth Module Weight Chassis Weight 266 mm (10.47 in) 483 mm (19 in) 343 mm (13.5 in) 3.25 kg (7.2 lb) 7 kg (15.4 lb) 18 Issue 11 Rockwell Automation Publication PD_T8200