Puls YR40.242 MOSFET redundancy module Owner's Manual

YR40.242

12-28V, 40A, D

UAL

R

EDUNDANCY

M

ODULE Y-Series

P

RODUCT

D

ESCRIPTION

The YR40.242 is a redundancy module, which can be used to build 1+1 and N+1 redundant system. It is equipped with two input channels, which can be connected to power supplies with up to 20A output current and one output, which can carry nominal currents up to 40A. In addition to the YR40.242, the YR40.241 is also available. This unit has an additional circuit included, which generates a supply voltage for the internal mosfets even when the output of the unit is in a short circuit condition. This makes the unit suitable for any power supplies.

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 36mm width on the DIN rail. Large connection terminals allow for a safe and fast installation.

The large international approval package makes this unit suitable for nearly every application.

O

RDER

Accessory

N

UMBERS

Redundancy YR40.242

Module

ZM2.WALL

ZM11.SIDE

12-28V Standard unit

Wall/ panel mount bracket

Side mount bracket

M

OSFET

R

EDUNDANCY

M

ODULE

 For N+1 and 1+1 redundant systems

 Dual input with single output

 Suitable for all DIMENSION power supplies

Except QT20 and QTD20 series

 Only 72mV voltage drop at 20A output current

 Only 1.7W loss at 20A and 5.9W at 40A output current

 160% (65A) peak load capability

 Reverse input polarity protection

 Full power between -40°C and +60°C

 Width only 36mm

 Rugged metal housing

 Easy wiring:

Distribution terminal for negative pole included

 3 year warranty

S

HORT

-

FORM

D

ATA

Input voltage DC 12-28V

Input voltage range 8.4-36.4Vdc

Input current 2x 0-20A

2x 20-32.5A

Output current

Input to output voltage drop

0-40A

40-65A max. 26A typ. 72mV typ. 112mV typ. 140mV typ. 230mW typ. 1.7W typ. 2.4W typ. 5.9W continuous for 5 seconds in overload

*)

or short circuit mode input: 2x10A input: 1x20A input: 2x20A at no load Power losses input: 2x10A input: 1x20A input: 2x20A

Temperature range -40°C to +70°C operational

Derating 1A/°C (output) +60 to +70°C

Dimensions **)

Weight

36x124x127mm WxHxD

280g, 0.62lb

*) Currents at voltages below 6V

**) Plus 4mm in depth for the screw terminal

±30% continuous for 5 seconds

M

AIN

A

PPROVALS

For details and the complete approval list, see chapter 14.

UL 508 UL 60950-1 Class I Div 2

ATEX IECEx Marine

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

1/19

Y-Series

YR40.242

12-28V, 40A, D

UAL

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M

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I

NDEX

Page

1.

Intended Use ....................................................... 3

2.

Installation Instructions ...................................... 3

3.

Input and Output Characteristics ....................... 5

4.

Power Losses ........................................................ 6

5.

Lifetime Expectancy and MTBF ........................... 7

6.

Terminals and Wiring .......................................... 8

7.

Functional Diagram ............................................. 9

8.

Front Side and User Elements ............................. 9

9.

EMC .................................................................... 10

10.

Environment ...................................................... 11

11.

Protection Features ........................................... 12

12.

Safety Features .................................................. 12

13.

Dielectric Strength ............................................ 12

14.

Approved, Fulfilled or Tested Standards.......... 13

Page

15.

Regulatory Product Compliance ...................... 14

16.

Physical Dimensions and Weight ..................... 15

17.

Accessories ........................................................ 16

17.1.

ZM2.WALL - Wall Mounting Bracket ....... 16

17.2.

ZM11.SIDE - Side Mounting Bracket ........ 16

18.

Application Notes ............................................. 17

18.1.

Recommendations for Redundancy ......... 17

18.2.

Inductive and Capacitive Loads................ 17

18.3.

Sideward Installation Clearances ............. 17

18.4.

1+1 Redundancy up to 20A ...................... 18

18.5.

N+1 Redundancy, Example with 60A ...... 18

18.6.

Mounting Orientations ............................ 19

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.

T

ERMINOLOGY AND

A

BREVIATIONS

PE and symbol PE is the abbreviation for P rotective E arth 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.

DC 24V

To be defined, value or description will follow later.

24Vdc

A figure displayed with the AC 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 (10V)

A figure with the unit (Vdc) at the end is a momentary figure without any additional tolerances included. may shall should

A key word indicate flexibility of choice with no implied preference

A key word indicate a mandatory requirement

A key word indicate flexibility of choice with a strongly preferred implementation

1+1 Redundancy

N+1 Redundancy

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 10A power supplies are needed to achieve a 10A redundant system. N+1

Redundancy

1+1

Redundancy

Use of three or more identical power supplies in parallel to provide continued operation following most failures in a single power supply. All power supply outputs should be isolated from each other by utilizing diodes or other switching arrangements.

E.g.: To achieve a 40A redundant system, five 10A power supplies are needed in a N+1 redundant system.

AC

DC

IN 1

OUT

AC

IN 2

DC

Load

-

AC

DC

IN 1 IN 2

OUT

AC

DC

AC

DC

IN 1 IN 2

OUT

AC

DC

AC

DC

IN 1 IN 2

OUT

AC

-

Load

DC

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

2/19

YR40.242

12-28V, 40A, D

UAL

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ODULE Y-Series

1.

I

NTENDED

U

SE

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 except the QT20 series and the QTD20 series.

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, non-hazardous, ordinary or unclassified locations.

2.

I

NSTALLATION

I

NSTRUCTIONS

WARNING

Risk of electrical shock, fire, personal injury or death.

- Turn power off before working on the device and protect against inadvertent re-powering.

- Do not open, modify or repair the device.

- Use caution to prevent any foreign objects from entering into the housing.

- Do not use in wet locations or in areas where moisture or condensation can be expected.

- Do not touch during power-on, and immediately after power-off. Hot surface may cause burns.

Obey the following installation instructions:

This device may only be installed and put into operation by qualified personnel.

This device does not contain serviceable parts. The tripping of an internal fuse is caused by an internal defect.

If damage or malfunction should occur during installation or operation, immediately turn power off and send unit to the factory for inspection.

Install the device in an enclosure providing protection against electrical, mechanical and fire hazards.

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.

Use only power supplies with a negligible output ripple voltage in the low frequency range between 50Hz and 10kHz when used in marine applications according to the GL regulations.

Install the device onto a DIN rail according to EN 60715 with the input terminals on the top of the device. Other mounting orientations require a reduction in output current.

Make sure that the wiring is correct by following all local and national codes. Use appropriate copper cables that are designed for a minimum operating temperature of 60°C for ambient temperatures up to +45°C, 75°C for ambient temperatures up to +60°C and 90°C for ambient temperatures up to +70°C.

Ensure that all strands of a stranded wire enter the terminal connection.

Unused screw terminals should be securely tightened.

The device is designed for pollution degree 2 areas in controlled environments. No condensation or frost is allowed.

The enclosure of the device provides a degree of protection of IP20.

The input must be powered from a PELV or SELV source or an “Isolated Secondary Circuit” in order to maintain a SELV or PELV output.

Check correct input polarity. The device will not operate when input voltage is reversed.

The device is designed as “Class of Protection III” equipment according to IEC 61140.

A PE (ground) connection is not required. However, connecting the chassis ground terminal to ground can be beneficial to gain a high EMI immunity.

The device is designed for convection cooling and does not require an external fan. Do not obstruct airflow and do not cover ventilation grid!

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

3/19

YR40.242

12-28V, 40A, D

UAL

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The device is designed for altitudes up to 6000m (19685ft). See additional requirements in the product datasheet for use above 2000m (6560ft).

Keep the following minimum installation clearances: 40mm on top, 20mm on the bottom, 5mm left and right side.

Increase the 5mm to 15mm in case the adjacent device is a heat source. When the device is permanently loaded with less than 50%, the 5mm can be reduced to zero. Under special circumstances clearances can be reduced. See details in the product datasheet.

The maximum surrounding air temperature is +70°C (+158°F). The operational temperature is the same as the ambient or surrounding air temperature and is defined 2cm below the device.

The device is designed to operate in areas between 5% and 95% relative humidity.

Installation Instructions for Hazardous Location Areas

The device is suitable for use in Class I Division 2 Groups A, B, C, D locations and for use in Group II Category 3 (Zone 2) environments.

Hazardous Location classification: ATEX: EPS 11 ATEX 1 312 X, II 3G EX ec IIC T4 Gc

WARNING EXPLOSION HAZARDS!

Substitution of components may impair suitability for this environment.

Do not disconnect the device unless power has been switched off or the area is known to be non-hazardous.

A suitable enclosure must be provided for the end product which has a minimum protection of IP54 and fulfils the requirements of the EN 60079-0

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

4/19

YR40.242

12-28V, 40A, D

UAL

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3.

I

NPUT AND

O

UTPUT

C

HARACTERISTICS

Number of inputs

Suitable power supplies

Number of outputs

Input voltage

Input voltage range

Voltage drop, input to output

Input current

Peak input current

Output current

Reverse current

Reverse voltage

Output capacitance

2

QS20, CPS20, … Use only power supplies which are featured with the

Hiccup PLUS overload behaviour

1 nom. DC 12-28V ±30% The input circuitry must meet the SELV requirements stipulated by IEC/EN/UL 60950-1.

8.4-36.4Vdc typ. typ. typ.

140mV

72mV

112mV nom. 2x 0-20A nom. 2x 20-32.5A max 2x 13A

at 2x20A, see Fig. 3-1 at 2x10A, see Fig. 3-1 at 1x20A, see Fig. 3-2

continuous for 5 seconds in overload (voltage < 6V) or short circuit mode max. 1000A nom. 40A nom. 40-65A max. 26A max. 1mA max. 40Vdc typ. 320µF for max. 1ms per input continuous for 5 seconds in overload (voltage < 6V) or short circuit mode at 24V, per input, -40°C to +70°C voltage applied to the output, continuously allowed

Fig. 3-1 Input to output voltage drop when both inputs draw current

(typical 1+1 redundant case, when the output voltages of the two units are equal)

160mV

140mV

120mV

100mV

80mV

60mV

40mV

20mV

0mV

Output:

Input:

Voltage Drop, typ

0

0

A... 25°C

B... 60°C

Input / Output Current

10A

2x5A

20A

2x10A

B

30A

2x15A

A

40A

2x20A

QS20/

CPS20

24V,20A +

I

1

= I

2

-

QS20/

CPS20

24V,20A +

-

V

I

1

A

U

1

V

I

2

A

U

2

U

1

= U

2

YR40.242

Input 1

Input 2

Output

Output

I

OUT

A

U

OUT

V

Load,

0-40A

Voltage Drop = U

1

U

OUT

Fig. 3-2 Input to output voltage drop when only one input draws current

160mV

140mV

120mV

100mV

80mV

60mV

40mV

20mV

0mV

Voltage Drop, typ.

A... 25°C

B... 60°C

B A

Output Current

0 5A 10A 15A 20A

QS20/

CPS20

24V,20A +

-

Not used or power supply with lower voltage

V

I

1

A

U

1

YR40.242

Input 1

Input 2

Output

Output

I

OUT

A

U

OUT

V

Load,

0-20A

Voltage Drop = U

1

U

OUT

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

5/19

Y-Series

4.

P

OWER

L

OSSES

Power losses typ. typ. typ.

Standby power losses typ. typ.

DC 12V

1.6W

5.8W

2.3W

0.07W

0.12W

DC 24V

1.7W

5.9W

2.4W

0.15W

0.23W

YR40.242

12-28V, 40A, D

UAL

R

EDUNDANCY

M

ODULE input: 2x10A input: 2x20A input: 1x20A,

(only one input is connected to input voltage) at no output current,

(only one input is connected to input voltage) at no output current,

(both inputs are connected to input voltages)

Fig. 4-1 Power losses when both inputs draw equal current

Power Losses, typ.

7W

6.0

5.0

4.0

3.0

2.0

1.0

0

A... 25°C

B... 60°C

0 5 10 15 20

B A

Output Current

25 30 35 40A

QS20/

CPS20

24V,20A + set to

24.5V

-

V

I

1

A

U

1

YR40.242

Input 1

QS20/

CPS20

24V,20A + set to

24.5V

-

I

1

= I

2

V

U

1

= U

2

I

2

A

U

2

Input 2

Output

Output

I

OUT

A

U

OUT

V

Variable

Load,

0-40A

Losses = ( U

1 * I

1

+ U

2 * I

2

) U

OUT * I

OUT

Fig. 4-2 Power losses when only one input is used

Power Losses, typ.

4W

3.5

3.0

2.5

2.0

1.5

1.0

0.5

0

A... 25°C

B... 60°C

0 2.5

5 7.5 10

B

Output Current

12.5

15 17.5

A

20A

QS20/

CPS20

24V,20A +

-

V

I

1

A

U

1

YR40.242

Input 1

Input 2

Output

Losses = U

1 * I

1

U

OUT * I

OUT

Output

I

OUT

A

U

OUT

V

Variable

0-20A

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

6/19

YR40.242

12-28V, 40A, D

UAL

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ODULE Y-Series

5.

L

IFETIME

E

XPECTANCY AND

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

Lifetime expectancy

MTBF

MTBF

**)

**)

*)

SN 29500, IEC 61709

MIL HDBK 217F

Input: 2x10A

Output: 20A

672 000h *)

1 900 000h *)

7 234 000h

12 445 000h

325 000h

438 000h

1 588 000h

2 159 000h

Input: 2x20A

Output: 40A

255 000h

720 000h

*)

*)

4 533 000h

8 218 000h

294 000h

392 000h

1 457 000h

1 964 000h at 24V and 40°C at 24V and 25°C at 24V 40°C at 24V 25°C

Ground Fixed GF40 (24V and 40°C)

Ground Fixed GF25 (24V and 25°C)

Ground Benign GB40 (24V and 40°C)

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 built-in 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 400h). Any number exceeding this value is a calculated theoretical lifetime which can be used to compare devices.

**) MTBF stands for M ean T ime B etween F ailure, 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. A MTBF figure of e.g. 1 000 000h means that statistically one unit will fail every 100 hours if 10 000 units are installed in the field. However, it can not be determined if the failed unit has been running for 50 000h or only for 100h.

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

7/19

YR40.242

12-28V, 40A, D

UAL

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ODULE Y-Series

6.

T

ERMINALS AND

W

IRING

Type

Solid wire

Stranded wire

American Wire Gauge

Max. wire diameter

Wire stripping length

Screwdriver

Recommended tightening torque

Input

Screw termination

IP20 Finger safe construction.

Suitable for field installation.

0.5-6mm 2

0.5-4mm 2

20-10 AWG

2.8mm (including ferrule)

7mm / 0.275inch

3.5mm slotted or Pozidrive No 2

0.8Nm, 7lb.in

Output

Screw termination

IP20 Finger safe construction.

Suitable for field installation.

0.5-16mm 2

0.5-10mm 2

22-8 AWG

5.2mm (including ferrule)

12mm / 0.5inch

3.5mm slotted or Pozidrive No 2

1.2Nm, 10.6lb.in

To connect the chassis to ground, use a ring-type 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 60950-1: SELV. b) Use appropriate copper cables that are designed for minimum operating temperatures of:

60°C for ambient up to 45°C and

75°C for ambient up to 60°C and

90°C for ambient up to 70°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).

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

8/19

Y-Series

7.

F

UNCTIONAL

D

IAGRAM

Fig. 7-1 Functional diagram

YR40.242

12-28V, 40A, D

UAL

R

EDUNDANCY

M

ODULE control

Input 1

+

-

+

-

Output

Input 2

+

-

Chassis

Ground control

8.

F

RONT

S

IDE AND

U

SER

E

LEMENTS

Fig. 8-1 Front side

A Output Terminals (screw terminals)

B Chassis Ground Terminals

To be connected on the top side of the housing with a ring-type 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.

C Input Terminals for Input 1 (screw terminals)

D Input Terminals for Input 2 (screw terminals)

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

9/19

YR40.242

12-28V, 40A, D

UAL

R

EDUNDANCY

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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. A detailed EMC report is available on request.

EMC Immunity

Electrostatic discharge

Electromagnetic RF field

Fast transients (Burst)

Surge voltage on input lines

Surge voltage on output lines

According generic standards: EN 61000-6-1 and EN 61000-6-2

EN 61000-4-2 Contact discharge

Air discharge

8kV

15kV

EN 61000-4-3

EN 61000-4-4

EN 61000-4-5

EN 61000-4-5

EN 61000-4-6

80MHz-2.7GHz

Input lines

Output lines

+  -

+/  Chassis ground

+  -

+/  Chassis ground

0.15-80MHz

20V/m

2kV

2kV

500V

1kV

500V

1kV

20V

Criterion A

Criterion A

Criterion A

Criterion A

Criterion A

Criterion A

Criterion A

Criterion A

Criterion A

Conducted disturbance Criterion A

Power-frequency magnetic field *)

EN 61000-4-8 50Hz 30A/m Criterion A

Criterions:

A: Redundancy module shows normal operation behavior within the defined limits.

Notes:

*) A test is not applicable according to EN 61000-6-2, since the device does not contain components susceptible to magnetic fields, e.g. hall elements, electrodynamic microphones, etc.

EMC Emission

Conducted emission

According generic standards: EN 61000-6-3 and EN 61000-6-4

IEC/CISPR 16-1-2, IEC/CISPR 16-2-1

EN 55011, EN 55032 limits for DC power ports according

EN 61000-6-3 fulfilled

Class B

*)

Radiated emission

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 61000-6-3. 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 140kHz to 500kHz depending on the input voltage.

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

10/19

YR40.242

12-28V, 40A, D

UAL

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ODULE Y-Series

10.

E

NVIRONMENT

Operational temperature *) -40°C to +70°C (-40°F to 158°F)

Storage temperature

Output derating

-40 to +85°C (-40°F to 185°F)

1A / °C

Humidity **)

Vibration sinusoidal ***)

Shock ***)

5 to 95% r.H.

2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g

2 hours / axis

30g 6ms, 20g 11ms

3 bumps / direction, 18 bumps in total for storage and transportation

60-70°C (140°F to 158°F)

IEC 60068-2-30

IEC 60068-2-6

IEC 60068-2-27

Altitude

Altitude derating

Over-voltage category

0 to 2000m (0 to 6 560ft)

2000 to 6000m (6 560 to 20 000ft)

2.5A/1000m or 5°C/1000m not applicable without any restrictions reduce output power or ambient temperature,

see Fig. 10-2

> 2000m (6500ft), see Fig. 10-2

The concept of the overvoltage category is used for equipment energized directly from the low voltage mains (IEC 60664-1 §4.3.3.2.1).

Degree of pollution 2 IEC 62103, EN 50178, not conductive

*) 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 DIN rails according to EN 60715 with a height of 15mm and a thickness of 1.3mm and standard mounting orientation.

Fig. 10-1 Output current vs. ambient temp. Fig. 10-2 Output current vs. altitude

Allowed Output Current

65A short term (< 5s)

50 normal mode

40

30

20

10

Ambient Temperature

0

-40 -25 0 20 40 60 70°C

Allowed Output Current

65A short term (< 5s)

50 normal mode

40

30

20

10

A... Tamb < 70°C

B... Tamb < 60°C

C... Tamb < 50°C

A

B

C

Altitude

0

0 2000 4000 6000m

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

11/19

YR40.242

12-28V, 40A, D

UAL

R

EDUNDANCY

M

ODULE Y-Series

11.

P

ROTECTION

F

EATURES

Output over-current protection not included

Reverse input polarity protection included

Degree of protection

Penetration protection

IP 20

> 3.6mm

Over-temperature protection

Input transient protection

Output transient protection

Internal input fuse not included not included included not included unit does not start when input voltage is reversed

EN/IEC 60529 e.g. screws, small parts see EMC chapter

12.

S

AFETY

F

EATURES

Input / output separation

Class of protection

PE resistance

13.

D

IELECTRIC

S

TRENGTH

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 cut-off current settings to the value in the table below.

In- / Output

+

-

A no galvanic separation

III

< 0.1Ohm

Fig. 13-1 Dielectric strength

Chassis

Mosfet between input and output

PE (Protective Earth) or chassis connection not required between housing and chassis-ground terminal

Type test

Factory test

Field test

Cut-off current setting

60s

5s

5s

A

500Vac

500Vac

500Vac

> 2mA

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

12/19

YR40.242

12-28V, 40A, D

UAL

R

EDUNDANCY

M

ODULE Y-Series

14.

A

PPROVED

, F

ULFILLED OR

T

ESTED

S

TANDARDS

UL 508

IEC 60950-1

UL 60950-1

Class I Div 2

ATEX

IECEx

Marine (DNV)

Marine (ABS)

IEC 60068-2-60

UL Certificate

Listed equipment for category NMTR - Industrial Control Equipment

Applicable for US and Canada

E-File: E198865

CB Scheme Certificate

General safety requirements for Information Technology Equipment

(ITE)

UL Certificate

Recognized component for category QQGQ - Information

Technology Equipment (ITE)

Applicable for US and Canada

E-File: E137006

CSA Certificate

Power Supplies for Hazardous Location

Applicable for Canada and US

CSA Class: 5318-01 (Canada), 5318-81 (USA)

Temperature Code: T4

Groups: A, B, C and D

Agency Certificate (Bureau Veritas)

EN 60079-0 Explosive atmospheres - General requirements

EN 60079-7, EN 60079-15 Equipment protection by type of protection "e" and "n"

Certificate: EPS 11 ATEX 1 312 X

Temperature Code: T4

Type of Protection: ec

IECEx Certificate

IEC 60079-0 Explosive atmospheres - General requirements

IEC 60079-7, IEC 60079-15 Equipment protection by type of protection "e" and "n"

Certificate: IECEx EPS 12.0032 X

Temperature Code: T4

Type of Protection: ec

DNV Certificate

DNV Type approved product

Certificate: TAA00002A7

Temperature: Class D

Humidity: Class B

Vibration: Class C

EMC: Class B

Enclosure: Class A

ABS Design Assessment Certificate

ABS (American Bureau of Shipment) assessed product

Certificate: 17-HG1599236-PD

Manufacturer's Declaration (Online Document)

Environmental Tests, Flowing Mixed Gas Corrosion Test

Test Ke - Method 4

H2S: 10ppb

NO2: 200ppb

Cl2: 10ppb

SO2: 200ppb

Test Duration: 3 weeks, which simulates a service life of 10 years.

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

13/19

YR40.242

12-28V, 40A, D

UAL

R

EDUNDANCY

M

ODULE Y-Series

ISA-71.04-1985

VDMA 24364

15.

R

EGULATORY

P

RODUCT

C

OMPLIANCE

EU Declaration of

Conformity

REACH Directive

WEEE Directive

Manufacturer's Declaration (Online Document)

Airborne Contaminants Corrosion Test

Severity Level: G3 Harsh

H2S: 100ppb

NOx: 1250ppb

Cl2: 20ppb

SO2: 300ppb

Test Duration: 3 weeks, which simulates a service life of 10 years

Paint Wetting Impairment Substances Test (or LABS-Test)

Tested for Zone 2 and test class C1 according to VDMA 24364-C1-L/W for solvents and water-based paints

The CE mark indicates conformance with the

- EMC directive

- ATEX directive

- RoHS directive

Manufacturer's Statement

EU-Directive regarding the Registration, Evaluation,

Authorization and Restriction of Chemicals

Manufacturer's Statement

EU-Regulation on Waste Electrical and Electronic Equipment

Registered in Germany as business to business (B2B) products.

KC Korean Certificate

EAC TR Registration

KC Registration

Korean registration of Broadcasting and Communication

Equipment

Registered under Clause 3, Article 58-2 of Radio Waves Act.

EAC Certificate

EAC EurAsian Conformity - Registration Russia, Kazakhstan and Belarus

8504408200, 8504409000

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

14/19

YR40.242

12-28V, 40A, D

UAL

R

EDUNDANCY

M

ODULE Y-Series

16.

P

HYSICAL

D

IMENSIONS AND

W

EIGHT

Weight

DIN rail

280g / 0.62lb

Use 35mm DIN rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm.

The DIN rail depth must be added to the unit depth (127mm) to calculate the total required installation depth.

Installation clearances

See chapter 2

Fig. 16-1 Front view Fig. 16-2 Side view

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

15/19

Y-Series

17.

A

CCESSORIES

YR40.242

12-28V, 40A, D

UAL

R

EDUNDANCY

M

ODULE

17.1.

ZM2.WALL

W

ALL

M

OUNTING

B

RACKET

This standard bracket is used to mount the YR40.242 redundancy module onto a flat surface without utilizing a DIN rail.

Fig. 17-1 ZM2.WALL Wall mounting bracket Fig. 17-2 Assembled wall mounting bracket

17.2.

ZM11.SIDE

S

IDE

M

OUNTING

B

RACKET

This bracket is used to mount the YR40.242 redundancy module sideways with or without utilizing a DIN rail.

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 DIN rail mounting, the removed aluminum brackets and the black plastic slider need to be mounted on the steel bracket.

Fig. 17-3

ZM11.SIDE Side mounting bracket

Fig. 17-4

Side mounting with DIN-rail brackets

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

16/19

Y-Series

18.

A

PPLICATION

N

OTES

YR40.242

12-28V, 40A, D

UAL

R

EDUNDANCY

M

ODULE

18.1.

R

ECOMMENDATIONS FOR

R

EDUNDANCY

Recommendations for the configuration of redundant power systems:

Use separate input fuses for each power supply.

Use three-phase power supplies to gain functional safety if one phase fails.

When single-phase power supplies are utilized connect them to different phases or mains circuits if possible.

Set the power supply in “Parallel-Use” mode if this feature is available

It is desirable to set the output voltages of all power supplies to the same value.

18.2.

I

NDUCTIVE AND

C

APACITIVE

L

OADS

The unit is designed to supply any kind of loads, including unlimited capacitive and inductive loads.

18.3.

S

IDEWARD

I

NSTALLATION

C

LEARANCES

The minimum clearance recommendations are defined in chapter 2.

Normally, the following installation clearance are recommended: 40mm on top, 20mm on the bottom, 5mm on the left and right sides when the device is loaded permanently with more than 50% 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:

0mm 0mm 1+1 redundancy application with maximum 20A output current.

The power supplies are from the PULS DIMENSION series.

20A

Load

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

YR40.242

Redundancy

Module

Power

Supply

L N PE + + -

Input

1

+

Input

2

+ L N PE + + -

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

17/19

Y-Series

YR40.242

12-28V, 40A, D

UAL

R

EDUNDANCY

M

ODULE

18.4.

1+1 R

EDUNDANCY UP TO

20A

1+1 Redundancy up to 20A requires two 20A power supplies and one YR40.242 redundancy module.

Fig. 18-1 Wiring diagram, 1+1 Redundancy, 20A output current

20A

Load

Failure

Monitor

Power

Supply

DC-OK

L N PE + + -

+ -

Output

YR40.242

Redundancy

Module

Input

1

+

Input

2

+ -

Power

Supply

DC-OK

L N PE + + -

I I

L

N

PE

Note: Use separate mains systems for each power supply whenever it is possible

18.5.

N+1 R

EDUNDANCY

, E

XAMPLE WITH

60A

N+1 Redundancy up to 60A requires four 20A power supplies and two YR40.242 redundancy modules.

Fig. 18-2 Wiring diagram, n+1 Redundancy, 60A output current

60A

Load

Failure

Monitor

Power

Supply

DC-OK

L N PE + + -

+ -

Output

YR40.242

Redundancy

Module

Input

1

+

Input

2

+ -

Power

Supply

DC-OK

L N PE + + -

Power

Supply

DC-OK

L N PE + + -

+ -

Output

YR40.242

Redundancy

Module

Input

1

+

Input

2

+ -

Power

Supply

DC-OK

L N PE + + -

I I I

L

N

PE

Note: Use separate mains systems for each power supply whenever it is possible

I

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

18/19

Y-Series

YR40.242

12-28V, 40A, D

UAL

R

EDUNDANCY

M

ODULE

18.6.

M

OUNTING

O

RIENTATIONS

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 A1

Curve A2

Fig. 18-3

Mounting

Orientation A

(Standard orientation)

Recommended output current.

Max allowed output current (results in approximately half the lifetime expectancy of A1).

OUTPUT

YR40.242

Module

INPUTS

Output Current

40A

30

20

10

0

10 20

A1

Ambient Temperature

30 40 50 60°C

Fig. 18-4

Mounting

Orientation B

(Upside down)

.242

UTS

YR40

Redundancy

INP

Module

Output Current

40A

30

20

A1

10

UT OUTP Ambient Temperature

0

10 20 30 40 50 60°C

Fig. 18-5

Mounting

Orientation C

(Table-top mounting)

Output Current

40A

30

20

A2

A1

Fig. 18-6

Mounting

Orientation D

(Horizontal cw)

Fig. 18-7

Mounting

Orientation E

(Horizontal ccw)

10

0

10 20

Ambient Temperature

30 40 50

Output Current

40A

Output Current

40A

30

20

10

A2

Ambient Temperature

0

10 20 30 40 50

A2

30

20

10

0

10 20

Ambient Temperature

30 40 50

60°C

A1

60°C

A1

60°C

Jul. 2021 / Rev. 1.5 DS-YR40.242-EN

All parameters are specified at 24V, 40A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany

19/19