YR80.241

YR80.241 12-28V, 80A, DUAL REDUNDANCY MODULE Y-Series MOSFET REDUNDANCY MODULE             For N+1 and 1+1 Redundant Systems Dual Input with Single Output Suitable for all Power Supplies Only 50mV Voltage Drop at 40A Output Current Only 2.7W Loss at 40A and 8.3W at 80A Output Current 160% (130A) Peak Load Capability Reverse Input Polarity Protection Full Power Between -40°C and +70°C Width only 46mm Rugged Metal Housing Easy Wiring: Distribution Terminal for Negative Pole Included 3 Year Warranty PRODUCT DESCRIPTION SHORT-FORM DATA The YR80.241 is a redundancy module, which can be used to build 1+1 and N+1 redundant systems. It is equipped with two input channels, which can be connected to power supplies with up to 40A output current and one output, which can carry nominal currents up to 80A. The module is suitable for power supplies with constant current overload behavior as well as any kind of “Hiccup” overload behavior. In addition to the YR80.241, the YR80.242 is also available which is cost-optimized and suitable for all DIMENSION power supplies except the QT40 series. 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 and is self-sufficient even in case of a short circuit across the output. Due to the low power losses, the unit is very slender and only requires 46mm width on the DIN rail. Large connection terminals allow for a safe and fast installation with a large international approval package. This unit is suitable for nearly every application. ORDER NUMBERS Output current Input to output voltage drop DC 12-28V 8.4-36.4Vdc 2x 0-40A 2x 40-65A 0-80A 80-130A 130A ±30% Temperature range typ. 49mV typ. 85mV typ. 95mV typ. 700mW typ. 2.7W typ. 3.6W typ. 8.3W -40°C to +70°C Dimensions 46x124x127mm Weight 440g / 0.97lb Power losses *) continuous for 5 seconds continuous for 5 seconds at cont. overload or short circuit input: 2x20A input: 1x40A input: 2x40A at no load input: 2x20A input: 1x40A input: 2x40A operational, no derating req. WxHxD *) plus 6mm in depth for the screw terminal MAIN APPROVALS For details and the complete approval list, see chapter 14. Redundancy Module YR80.241 Accessory ZM2.WALL Wall/panel mount bracket ZM12.SIDE Side mount bracket UL 508 UL 60950-1 Class I Div 2 ATEX IECEx Marine Jul. 2021 / Rev. 1.5 DS-YR80.241-EN All parameters are specified at 24V, 80A 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 YR80.241 12-28V, 80A, 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. ZM12.SIDE - Side mounting bracket ........ 16 18. Application Notes ............................................. 17 18.1. Recommendations for Redundancy......... 17 18.2. Inductive and Capacitive Loads................ 17 18.3. Sidewards Installation Clearances............ 17 18.4. 1+1 Redundancy up to 40A ...................... 18 18.5. N+1 Redundancy, Example with 120A .... 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 indicating flexibility of choice with no implied preference shall A key word indicating a mandatory requirement should A key word indicating 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 AC DC DC DC Redundancy AC AC AC DC DC AC DC AC DC DC IN 1 IN 2 IN 1 IN 2 OUT OUT OUT OUT - Load Jul. 2021 / Rev. 1.5 DS-YR80.241-EN All parameters are specified at 24V, 80A 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 YR80.241 12-28V, 80A, DUAL REDUNDANCY MODULE Y-Series 1. INTENDED USE This device is designed for installation in an enclosure and is intended for commercial use, such as in industrial control, process control, monitoring and measurement equipment or the like. Do not use this device in equipment where malfunction may cause severe personal injury or threaten human life. The redundancy module can be used with any type of power supply as long as the maximum output current ratings are not exceeded. It is suitable for power supplies with continuous overload current as well as any kind of intermittent (Hiccup) overload behavior. 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 bottom 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! The device is designed for altitudes up to 6000m (19685ft). See additional requirements in the product datasheet for use above 2000m (6560ft). Jul. 2021 / Rev. 1.5 DS-YR80.241-EN All parameters are specified at 24V, 80A 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 YR80.241 12-28V, 80A, DUAL REDUNDANCY MODULE Y-Series 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-YR80.241-EN All parameters are specified at 24V, 80A 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 YR80.241 12-28V, 80A, DUAL REDUNDANCY MODULE Y-Series 3. INPUT AND OUTPUT CHARACTERISTICS Number of inputs Number of outputs Input voltage nom. Input voltage range Voltage drop, input to output Input current Peak input current Output current Reverse current Reverse voltage Output capacitance Note: 2 1 DC 12-28V ±30% The input circuitry must meet the SELV requirements stipulated by IEC/EN/UL 60950-1. 8.4-36.4Vdc 95mV 49mV 81mV 2x 0-40A 2x 40-65A 2x 65A 1500A 80A 80-130A 130A typ. typ. typ. nom. nom. max max. nom. nom. max. max. max. typ. at 2x40A, see Fig. 3-1 at 2x20A, see Fig. 3-1 at 1x40A, see Fig. 3-2 continuous for 5 seconds at continuous overload or short circuit for max. 1ms per input continuous for 5 seconds at continuous overload or short circuit 1mA 40Vdc 320µF at 24V, per input, -40°C to +70°C voltage applied to the output, continuously allowed Ensure that the continuous output current does not exceed 130A. Check the short-circuit current of the power sources and if the power source can deliver more than 130A together, use an appropriate fuse on the output. 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 or set into “parallel use” mode) Voltage Drop, typ QT40 I1 A 24V,40A 120mV 100mV 80mV 60mV 40mV 20mV 0mV A... 25°C B... 60°C B A "Parallel Use" + - V U1 QT40 Output: 0 Input: 0 20A 40A 60A 80A 2x10A 2x20A 2x30A 2x40A "Parallel Use" + - I1 = I2 IOUT A Input 1 Output Variable Load, 0-80A UOUT V I2 A 24V,40A Input / Output Current Output YR80 V U2 Input 2 U1 = U2 Voltage Drop = U1 - UOUT Fig. 3-2 Input to output voltage drop when only one input draws current QT40 Voltage Drop, typ. I1 A 24V,40A + 120mV 100mV 80mV 60mV 40mV 20mV 0mV A... 25°C B... 60°C - B 10A 20A 30A IOUT A Input 1 Output Variable Load, 0-40A UOUT V A Output Current 0 V U1 Output YR80 40A Not used or power supply with lower voltage Input 2 Voltage Drop = U1 - UOUT Jul. 2021 / Rev. 1.5 DS-YR80.241-EN All parameters are specified at 24V, 80A 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 YR80.241 12-28V, 80A, DUAL REDUNDANCY MODULE Y-Series 4. POWER LOSSES Power losses typ. typ. typ. DC 24V 2.7W 8.3W 3.6W Standby power losses typ. 0.35W typ. 0.7W input: 2x20A input: 2x40A input: 1x40A, (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 (typical n+1 or 1+1 redundant case, when the power supplies are set into “parallel use” mode) Power Losses, typ. QT40 10W 24V,40A 8 A... 25°C B... 60°C 6 B A "Parallel Use" 4 QT40 2 "Parallel Use" + - 24V,40A Output Current 0 0 10 20 30 40 50 60 70 80A + - I1 = I2 I1 A V U1 Output YR80 IOUT A Input 1 Output Variable Load, 0-80A UOUT V I2 A V U2 Input 2 Losses = ( U1 * I1 + U2 * I2 ) - UOUT * IOUT U1 = U2 Fig. 4-2 Power losses when only one input is used Power Losses, typ. QT40 5W 24V,40A + 4 A... 25°C B... 60°C 3 B A - I1 A V U1 Output YR80 IOUT A Input 1 Output Variable Load, 0-40A UOUT V 2 1 Input 2 Output Current 0 0 5 10 15 20 25 30 35 40A Losses = U1 * I1 - UOUT * IOUT Note: As soon as voltage is applied on input 2, an additional 0.35W will be consumed. It is not relevant, whether this channel contributes to the output current or not. Jul. 2021 / Rev. 1.5 DS-YR80.241-EN All parameters are specified at 24V, 80A 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 YR80.241 12-28V, 80A, 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: 2x20A Output: 40A 513 000h *) 1 450 000h *) 2 673 000h 4 544 000h 100 000h 133 000h 536 000h 707 000h Input: 2x40A Output: 80A 143 000h *) 405 000h *) 2 088 000h 3 669 000h 89 000h 117 000h 478 000h 628 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-YR80.241-EN All parameters are specified at 24V, 80A 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 YR80.241 12-28V, 80A, 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. 0.5-16mm2 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 Output Screw termination IP20 Finger safe construction. Suitable for field installation. 0.5-35mm2 0.5-35mm2 20-2 AWG 18mm / 0.7inch 5mm slotted or Pozidrive No 2 2.5Nm, 22lb.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-YR80.241-EN All parameters are specified at 24V, 80A 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 YR80.241 12-28V, 80A, DUAL REDUNDANCY MODULE Y-Series 7. FUNCTIONAL DIAGRAM Fig. 7-1 Functional diagram control + + - - Input 1 Output Chassis Ground + Input 2 - 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-YR80.241-EN All parameters are specified at 24V, 80A 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 YR80.241 12-28V, 80A, 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 is typ. 16kHz. Jul. 2021 / Rev. 1.5 DS-YR80.241-EN All parameters are specified at 24V, 80A 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 YR80.241 12-28V, 80A, DUAL REDUNDANCY MODULE Y-Series 10. ENVIRONMENT Operational temperature *) Storage temperature Humidity **) Vibration sinusoidal ***) Shock ***) Altitude -40°C to +70°C (-40°F to 158°F) -40 to +85°C (-40°F to 185°F) 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 5A/1000m or 5°C/1000m not applicable Degree of pollution 2 for storage and transportation 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. Fig. 10-2 Output current vs. altitude Allowed Output Current Allowed Output Current 130A 130A at overload / short circuit 100 80 100 normal mode 60 40 40 20 20 Ambient Temperature 0 20 normal mode 80 60 0 -40 -25 overload / short circuit 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-YR80.241-EN All parameters are specified at 24V, 80A 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 YR80.241 12-28V, 80A, 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 section 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-YR80.241-EN All parameters are specified at 24V, 80A 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 YR80.241 Y-Series 12-28V, 80A, DUAL REDUNDANCY MODULE 14. APPROVED, FULFILLED OR TESTED STANDARDS UL 508 IEC 60950-1 UL 60950-1 ATEX IECEx Class I Div 2 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 Agency Certificate (Bureau Veritas) EN 60079-0 Explosive atmospheres - General requirements EN 60079-7 Equipment protection by type of protection "e" 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 Equipment protection by type of protection "e" Certificate: IECEx EPS 12.0032 X Temperature Code: T4 Type of Protection: ec 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 DNV Certificate DNV Type approved product Certificate: TAA00002YX 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-YR80.241-EN All parameters are specified at 24V, 80A 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 YR80.241 12-28V, 80A, DUAL REDUNDANCY MODULE Y-Series ISA-71.04 G3 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-C1L/W for solvents and water-based paints 15. REGULATORY PRODUCT COMPLIANCE EU Declaration of Conformity REACH Directive WEEE Directive 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. EAC Certificate EAC EurAsian Conformity - Registration Russia, Kazakhstan and Belarus 8504408200, 8504409000 Jul. 2021 / Rev. 1.5 DS-YR80.241-EN All parameters are specified at 24V, 80A 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 YR80.241 12-28V, 80A, DUAL REDUNDANCY MODULE Y-Series 16. PHYSICAL DIMENSIONS AND WEIGHT Weight DIN rail Installation clearances 440g / 0.97lb 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-YR80.241-EN All parameters are specified at 24V, 80A 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 YR80.241 12-28V, 80A, DUAL REDUNDANCY MODULE Y-Series 17. ACCESSORIES 17.1. ZM2.WALL - WALL MOUNTING BRACKET This bracket is used to mount the YR80.241 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. ZM12.SIDE - SIDE MOUNTING BRACKET This bracket is used to mount the YR80.241 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 ZM12.SIDE Side mounting bracket Fig. 17-4 Side mounting with DIN rail brackets Jul. 2021 / Rev. 1.5 DS-YR80.241-EN All parameters are specified at 24V, 80A 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 YR80.241 12-28V, 80A, 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. SIDEWARDS 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: - 1+1 redundancy application with maximum 40A output current. - The power supplies are from the PULS DIMENSION series. - The redundancy module is placed between the two power supplies. - The power supplies are set into “Parallel Use” mode max. 40A Load Power Supply Power Supply Output Parallel Use Single Use YR80.241 Redundancy Module DCOK 24V, 40A L1 L2 L3 PE + + - - 0mm Input 1 + Parallel Use Single Use Input 2 - + - 24V, 40A L1 L2 L3 PE Germany + + - - 0mm Jul. 2021 / Rev. 1.5 DS-YR80.241-EN All parameters are specified at 24V, 80A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 DCOK 17/19 YR80.241 12-28V, 80A, DUAL REDUNDANCY MODULE Y-Series 18.4. 1+1 REDUNDANCY UP TO 40A 1+1 Redundancy up to 40A requires two 40A power supplies and one YR80.241 redundancy modules. Fig. 18-1 Wiring diagram, 1+1 Redundancy, 40A output current 40A Load Failure Monitor Power Supply Power Supply Output Parallel Use Single Use YR80.241 Redundancy Module DCOK Input 1 24V, 40A + + L1 L2 L3 PE I I - - + DCOK Parallel Use Single Use Input 2 24V, 40A - + - L1 L2 L3 PE I I I + + - - I L1 L2 L3 PE Note: Use separate mains systems for each power supply whenever it is possible 18.5. N+1 REDUNDANCY, EXAMPLE WITH 120A n+1 Redundancy up to 120A requires four 40A power supplies and two YR80.241 redundancy module. Fig. 18-2 Wiring diagram, n+1 Redundancy, 120A output current 120A Load Power Supply Power Supply Power Supply Power Supply Output Parallel Use Single Use 24V, 40A L1 L2 L3 PE I I I + + Output YR80.241 Redundancy Module DCOK - - Input 1 + Failure Monitor Parallel Use Single Use Input 2 DCOK Parallel Use Single Use 24V, 40A - + - L1 L2 L3 PE I I I + + YR80.241 Redundancy Module DCOK 24V, 40A - - L1 L2 L3 PE I I + + - - Input 1 + I Parallel Use Single Use Input 2 DCOK 24V, 40A - + - L1 L2 L3 PE I I + + - - I L1 L2 L3 PE Note: Use separate mains systems for each power supply whenever it is possible Jul. 2021 / Rev. 1.5 DS-YR80.241-EN All parameters are specified at 24V, 80A 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 YR80.241 12-28V, 80A, 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 80A OUTPUT 60 YR80 Redundancy Module 40 20 Ambient Temperature 0 INPUTS 20 Fig. 18-4 Mounting Orientation B (Upside down) A1 30 40 50 60 70°C Output Current 80A A1 INPUTS 60 YR80 Redundancy Module 40 20 Ambient Temperature 0 OUTPUT 20 Fig. 18-5 Mounting Orientation C (Table-top mounting) 30 40 50 70°C 60 Output Current 80A 60 A2 A1 40 20 Ambient Temperature 0 20 50 60 70°C 80A OUTPUT YR80 Redundancy Module 60 A2 40 A1 20 Ambient Temperature 0 20 30 40 50 60 70°C Output Current INPUTS YR80 Redundancy Module 80A OUTPUT Fig. 18-7 Mounting Orientation E (Horizontal ccw) 40 Output Current INPUTS Fig. 18-6 Mounting Orientation D (Horizontal cw) 30 60 A2 40 A1 20 Ambient Temperature 0 20 30 40 50 60 70°C Jul. 2021 / Rev. 1.5 DS-YR80.241-EN All parameters are specified at 24V, 80A 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