YR40.242

YR40.242 12-28V, 40A, DUAL REDUNDANCY MODULE Y-Series MOSFET REDUNDANCY MODULE             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 PRODUCT DESCRIPTION SHORT-FORM DATA 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. Input voltage Input voltage range Input current 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. Output current Input to output voltage drop Power losses Temperature range Derating Dimensions **) Weight DC 12-28V 8.4-36.4Vdc 2x 0-20A 2x 20-32.5A 0-40A 40-65A max. 26A typ. 72mV typ. 112mV typ. 140mV typ. 230mW typ. 1.7W typ. 2.4W typ. 5.9W -40°C to +70°C 1A/°C (output) 36x124x127mm 280g, 0.62lb ±30% continuous for 5 seconds continuous for 5 seconds *) in overload or short circuit mode input: 2x10A input: 1x20A input: 2x20A at no load input: 2x10A input: 1x20A input: 2x20A operational +60 to +70°C WxHxD *) Currents at voltages below 6V **) Plus 4mm in depth for the screw terminal ORDER NUMBERS MAIN APPROVALS Redundancy Module YR40.242 12-28V Standard unit Accessory ZM2.WALL Wall/ panel mount bracket Side mount bracket ZM11.SIDE 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 YR40.242 12-28V, 40A, DUAL REDUNDANCY MODULE Y-Series INDEX Page 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Intended Use .......................................................3 Installation Instructions ......................................3 Input and Output Characteristics .......................5 Power Losses ........................................................6 Lifetime Expectancy and MTBF...........................7 Terminals and Wiring ..........................................8 Functional Diagram .............................................9 Front Side and User Elements .............................9 EMC ....................................................................10 Environment ......................................................11 Protection Features ...........................................12 Safety Features ..................................................12 Dielectric Strength ............................................12 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. TERMINOLOGY AND ABREVIATIONS PE and symbol PE is the abbreviation for Protective Earth and has the same meaning as the symbol . Earth, Ground This document uses the term “earth” which is the same as the U.S. term “ground”. t.b.d. To be defined, value or description will follow later. DC 24V 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) 24Vdc A figure with the unit (Vdc) at the end is a momentary figure without any additional tolerances included. may A key word indicate flexibility of choice with no implied preference shall A key word indicate a mandatory requirement should A key word indicate flexibility of choice with a strongly preferred implementation 1+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 N+1 1+1 system. N+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. Redundancy AC AC DC DC DC Redundancy AC AC AC AC DC DC AC AC DC DC DC IN 1 IN 2 IN 1 IN 2 OUT OUT OUT OUT - Load 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 + IN 1 IN 2 + IN 1 IN 2 - Load 2/19 YR40.242 12-28V, 40A, DUAL REDUNDANCY MODULE Y-Series 1. INTENDED USE This redundancy module is designed for installation in an enclosure and is intended for the general use such as in industrial control, office, communication, and instrumentation equipment. This redundancy module can be used with any DIMENSION power supplies 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. INSTALLATION INSTRUCTIONS 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, DUAL REDUNDANCY MODULE Y-Series 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, DUAL REDUNDANCY MODULE Y-Series 3. INPUT AND OUTPUT CHARACTERISTICS Number of inputs Suitable power supplies 2 QS20, CPS20, … Number of outputs Input voltage 1 DC 12-28V ±30% nom. Input voltage range Voltage drop, input to output Input current Peak input current Output current Reverse current Reverse voltage Output capacitance Use only power supplies which are featured with the HiccupPLUS overload behaviour The input circuitry must meet the SELV requirements stipulated by IEC/EN/UL 60950-1. 8.4-36.4Vdc 140mV 72mV 112mV 2x 0-20A 2x 20-32.5A 2x 13A typ. typ. typ. nom. nom. max max. nom. nom. max. max. max. typ. 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 for max. 1ms per input continuous for 5 seconds in overload (voltage < 6V) or short circuit mode 1000A 40A 40-65A 26A 1mA 40Vdc 320µF 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 Voltage Drop, typ QS20/ CPS20 B A... 25°C B... 60°C I1 A 24V,20A + A - V U1 QS20/ CPS20 Output: 0 Input: 0 - 10A 30A 40A 20A 2x5A 2x10A 2x15A 2x20A IOUT A Input 1 Output V U2 UOUT V Input 2 Voltage Drop = U1 - UOUT U1 = U2 I1 = I2 Variable Load, 0-40A I2 A 24V,20A + Input / Output Current Output YR40.242 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. QS20/ CPS20 I1 A 24V,20A + A... 25°C B... 60°C B A Output Current 0 5A 10A 15A - V U1 Not used or power supply with lower voltage Output YR40.242 IOUT A Input 1 Output Variable Load, 0-20A UOUT V Input 2 20A Voltage Drop = U1 - UOUT 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 YR40.242 12-28V, 40A, DUAL REDUNDANCY MODULE Y-Series 4. POWER LOSSES Power losses typ. typ. typ. DC 12V 1.6W 5.8W 2.3W DC 24V 1.7W 5.9W 2.4W Standby power losses typ. 0.07W 0.15W typ. 0.12W 0.23W 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 QS20/ CPS20 24V,20A + set to 24.5V A... 25°C B... 60°C - 24V,20A + set to 24.5V Output Current 5 V U1 Output YR40.242 IOUT A Input 1 Output Variable Load, 0-40A UOUT V B A QS20/ CPS20 0 I1 A 10 15 20 25 30 - 35 40A I2 A V U2 Input 2 Losses = ( U1 * I1 + U2 * I2 ) - UOUT * IOUT U1 = U2 I1 = I2 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 QS20/ CPS20 24V,20A + A... 25°C B... 60°C - B I1 A V U1 Output YR40.242 IOUT A Input 1 Output Variable Load, 0-20A UOUT V A Input 2 Output Current 0 2.5 5 7.5 10 12.5 15 17.5 20A Losses = U1 * I1 - UOUT * IOUT 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, DUAL REDUNDANCY MODULE Y-Series 5. LIFETIME EXPECTANCY 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**) SN 29500, IEC 61709 MTBF**) 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 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. 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, DUAL REDUNDANCY MODULE Y-Series 6. TERMINALS AND WIRING 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. 0.5-6mm2 0.5-4mm2 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. 0.5-16mm2 0.5-10mm2 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 YR40.242 12-28V, 40A, DUAL REDUNDANCY MODULE Y-Series 7. FUNCTIONAL DIAGRAM Fig. 7-1 Functional diagram control + + - - Input 1 Chassis Ground + Input 2 - Output control 8. FRONT SIDE AND USER ELEMENTS 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, DUAL REDUNDANCY MODULE Y-Series 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 According generic standards: EN 61000-6-1 and EN 61000-6-2 Contact discharge 8kV EN 61000-4-2 Air discharge 15kV EN 61000-4-3 80MHz-2.7GHz 20V/m Input lines 2kV EN 61000-4-4 Output lines 2kV 500V EN 61000-4-5 +1kV +/-  Chassis ground Surge voltage on output lines EN 61000-4-5 Conducted disturbance Power-frequency magnetic field *) EN 61000-4-6 EN 61000-4-8 ++/-  Chassis ground 0.15-80MHz 50Hz Criterion A Criterion A Criterion A Criterion A Criterion A Criterion A Criterion A 500V 1kV Criterion A Criterion A 20V 30A/m Criterion A 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. According generic standards: EN 61000-6-3 and EN 61000-6-4 limits for DC power ports according IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 EN 61000-6-3 fulfilled *) Radiated emission EN 55011, EN 55032 Class B This device complies with FCC Part 15 rules. Operation is subjected to following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. EMC Emission Conducted emission *) 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, DUAL REDUNDANCY MODULE Y-Series 10. ENVIRONMENT Operational temperature *) Storage temperature Output derating Humidity **) Vibration sinusoidal***) Shock***) Altitude -40°C to +70°C (-40°F to 158°F) -40 to +85°C (-40°F to 185°F) 1A / °C 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 0 to 2000m (0 to 6 560ft) 2000 to 6000m (6 560 to 20 000ft) Altitude derating Over-voltage category 2.5A/1000m or 5°C/1000m not applicable Degree of pollution 2 for storage and transportation 60-70°C (140°F to 158°F) IEC 60068-2-30 IEC 60068-2-6 IEC 60068-2-27 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). 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. Allowed Output Current 65A 50 40 Fig. 10-2 Output current vs. altitude Allowed Output Current 65A short term (< 5s) 50 normal mode 30 20 20 10 10 Ambient Temperature 0 20 normal mode 40 30 0 -40 -25 short term (< 5s) 40 A A... Tamb < 70°C B... Tamb < 60°C C... Tamb < 50°C 0 60 70°C 0 2000 B C Altitude 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, DUAL REDUNDANCY MODULE Y-Series 11. PROTECTION FEATURES Output over-current protection Reverse input polarity protection Degree of protection Penetration protection Over-temperature protection Input transient protection Output transient protection Internal input fuse not included included unit does not start when input voltage is reversed IP 20 > 3.6mm not included not included included not included EN/IEC 60529 e.g. screws, small parts see EMC chapter 12. SAFETY FEATURES Input / output separation Class of protection PE resistance no galvanic separation III < 0.1Ohm Mosfet between input and output PE (Protective Earth) or chassis connection not required between housing and chassis-ground 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 cut-off current settings to the value in the table below. Type test 60s A 500Vac Factory test 5s 500Vac Field test 5s 500Vac Fig. 13-1 Dielectric strength In- / Output + - A Chassis Cut-off current setting > 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 Y-Series 12-28V, 40A, DUAL REDUNDANCY MODULE 14. APPROVED, FULFILLED OR TESTED STANDARDS 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, DUAL REDUNDANCY MODULE Y-Series ISA-71.04-1985 VDMA 24364 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 15. REGULATORY PRODUCT COMPLIANCE EU Declaration of Conformity REACH Directive WEEE Directive KC Korean Certificate EAC TR Registration 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 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, DUAL REDUNDANCY MODULE Y-Series 16. PHYSICAL DIMENSIONS AND WEIGHT Weight DIN rail Installation clearances 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. 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 YR40.242 12-28V, 40A, DUAL REDUNDANCY MODULE Y-Series 17. ACCESSORIES 17.1. ZM2.WALL - WALL MOUNTING BRACKET 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 - SIDE MOUNTING BRACKET 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 YR40.242 12-28V, 40A, DUAL REDUNDANCY MODULE Y-Series 18. APPLICATION NOTES 18.1. RECOMMENDATIONS FOR REDUNDANCY 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. INDUCTIVE AND CAPACITIVE LOADS The unit is designed to supply any kind of loads, including unlimited capacitive and inductive loads. 18.3. SIDEWARD INSTALLATION CLEARANCES 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 1+1 redundancy application with maximum 20A 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. 0mm 20A Load + - Output YR40.242 Redundancy Module Power Supply L N PE + + -- Input Input 2 1 + - + - Power Supply 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 YR40.242 12-28V, 40A, DUAL REDUNDANCY MODULE Y-Series 18.4. 1+1 REDUNDANCY 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 + - Output DC-OK DC-OK YR40.242 Redundancy Module Power Supply + + L N PE Power Supply Input Input 2 1 -- + - + - I L N PE + + -- I L N PE Note: Use separate mains systems for each power supply whenever it is possible 18.5. N+1 REDUNDANCY, EXAMPLE 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 DC-OK I - DC-OK YR40.242 Redundancy Module Power Supply L N PE + Output + + -- DC-OK Power Supply Input Input 2 1 + - + - L N PE I -- L N PE - DC-OK YR40.242 Redundancy Module Power Supply ++ + Output ++ -- Power Supply Input Input 2 1 + - + - I L N PE ++ -- I L N PE Note: Use separate mains systems for each power supply whenever it is possible 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 YR40.242 12-28V, 40A, DUAL REDUNDANCY MODULE Y-Series 18.6. MOUNTING ORIENTATIONS 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 Recommended output current. Max allowed output current (results in approximately half the lifetime expectancy of A1). Fig. 18-3 Mounting Orientation A (Standard orientation) Output Current 40A OUTPUT 30 YR40.242 Redundancy Module 20 10 Ambient Temperature 0 INPUTS 10 Fig. 18-4 Mounting Orientation B (Upside down) A1 20 30 50 40 60°C Output Current 40A A1 INPUTS 30 Redundancy Module 20 YR40.242 10 Ambient Temperature 0 OUTPUT 10 Fig. 18-5 Mounting Orientation C (Table-top mounting) 20 30 50 40 60°C Output Current 40A 30 A2 20 A1 10 Ambient Temperature 0 10 40 40A 50 60°C A2 OUTPUT YR40.242 Redundancy Module 30 20 A1 10 Ambient Temperature 0 10 20 30 40 50 60°C Output Current INPUTS YR40.242 Redundancy Module 40A OUTPUT Fig. 18-7 Mounting Orientation E (Horizontal ccw) 30 Output Current INPUTS Fig. 18-6 Mounting Orientation D (Horizontal cw) 20 A2 30 20 A1 10 Ambient Temperature 0 10 20 30 40 50 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