Pepperl+Fuchs PS1000-A6-24.10.R Manual

ISO9001
PS1000-D2-24.20.RM
Redundancy Module
Technical Information

With regard to the supply of products, the current issue of the following document is applicable:
The General Terms of Delivery for Products and Services of the Electrical Industry, published by the Central
Association of the Electrical Industry (Zentralverband Elektrotechnik und Elektroindustrie (ZVEI) e.V.) in its most
recent version as well as the supplementary clause: "Expanded reservation of proprietorship"
Worldwide
Pepperl+Fuchs Group
Lilienthalstr. 200
68307 Mannheim
Germany
Phone: [phone] - 0
E-mail: [e-mail]
North American Headquarters
Pepperl+Fuchs Inc.
1600 Enterprise Parkway
Twinsburg, Ohio 44087
USA
Phone: [phone]
E-mail: [email protected].com
Asia Headquarters
Pepperl+Fuchs Pte. Ltd.
P+F Building
18 Ayer Rajah Crescent
Singapore 139942
Phone: [phone]
E-mail: [email protected]
https://www.pepperl-fuchs.com

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Power Supply PS1000-D2-24.20.RM
Contents
2021-11
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Terminology and Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Input and Output Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6 Power Losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7 Lifetime Expectancy and MTBF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8 Terminals and Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
9 Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10 Front Side and User Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
11 Redundancy Relay Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
12 Load Share Relay Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
13 Automated Load Sharing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
14 EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
15 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
16 Protection Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
17 Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
18 Dielectric Strength. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
19 Approvals And Fulfilled Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
20 Regulatory Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
21 Physical Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
22 Application Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Power Supply PS1000-D2-24.20.RM
Contents
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2021-11

Power Supply PS1000-D2-24.20.RM
Introduction
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1 Introduction
The information given in this document is correct to the best of our knowledge and experience
at the time of publication. If not expressly agreed otherwise, this information does not represent
a warranty in the legal sense of the word. As the state of our knowledge and experience is
constantly changing, the information in this data sheet is subject to revision. We therefore
kindly ask you to always use the latest issue of this document (available under
www.pepperl-fuchs.com).
No part of this document may be reproduced or utilized in any form without our prior
permission in writing.

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Power Supply PS1000-D2-24.20.RM
Terminology and Abbreviations
2 Terminology and Abbreviations
Figure 2.1 1+1 Redundancy
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
system.

AC
DC
AC
DC
Load
+ -
IN 1
OUT
IN 2

Power Supply PS1000-D2-24.20.RM
Intended Use
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3 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.
Function
The device is a redundancy module for building redundant power supply systems.
The device is equipped with 2 inputs and 1 output. Power supplies with an output current
of up to 24 A and one output can be connected to the inputs. The power supplies can transmit
a rated current of up to 20 A.
The both inputs are decoupled by MOSFETs. This reduces heat generation and voltage drop
between input and output.
The device is mounted on a 35 mm DIN mounting rail according to EN 60715.
Reference Conditions
All parameters are typical values specified at 24V, 20A output current, 25°C ambient
and after a 5 minutes run-in time unless otherwise noted.

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Power Supply PS1000-D2-24.20.RM
Installation Instructions
4 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 output 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.
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.
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 fulfills the requirements of the EN 60079-0.
Note
If you use the device in hazardous areas, observe the safety information in the instruction
manual and in chapter 19.

Power Supply PS1000-D2-24.20.RM
Installation Instructions
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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).
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.
To ensure a proper load share function, ensure that the wiring size and length between
the two power supplies and the redundancy module is identical.

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Power Supply PS1000-D2-24.20.RM
Input and Output Characteristics
5 Input and Output Characteristics
Figure 5.1 Input to output voltage drop
Number of inputs 2
Number of outputs 1
Input voltage nom. DC 24-28V ±25%
Input voltage range 18-35Vdc
Voltage drop, input to output typ. 0.1-0.5V at 2x5A, load share function dependent,
see Figure 5.1
typ. 0.2-0.5V at 2x10A, load share function dependent,
see Figure 5.1
typ. 0.24-0.5V at 2x12A, load share function dependent,
see Figure 5.1
Input current nom. 2x 0-12A continuous, ambient temperature < +45°C
nom. 2x 0-10A continuous, ambient temperature < +70°C
nom. 2x 17A 1for max. 5 seconds
max. 2x 700A for max. 1ms
Output current nom. 24A continuous, ambient temperature < +45°C
nom. 20A continuous, ambient temperature < +70°C
nom. 32.5A for max. 5 seconds
max. 26A in overload /short-circuit (voltage < 6V).
Ensure that the sum of input currents does
not exceed this value.
Reverse current max. 1mA at 24V, per input, -40°C to +70°C
Reverse voltage max. 40Vdc voltage applied to the output,
continuously allowed
Output capacitance typ. 320µF
1The average value (R.M.S. value) of the output current must not exceed the values of the continuous output current.

Power Supply PS1000-D2-24.20.RM
Input and Output Characteristics
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Figure 5.2 Test setup for voltage drop measurements
PS1000-D2-
24.20.RM

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Power Supply PS1000-D2-24.20.RM
Power Losses
6 Power Losses
Figure 6.1 Power losses
Figure 6.2 Test setup for power loss measurements
Power losses typ. 2.6-4.7W at 2x5A, 25°C ambient temperature
typ. 5.6-8.7W at 2x10A, 25°C ambient temperature
Standby power losses typ. 1.7W at no output current
PS1000-D2-
24.20.RM

Power Supply PS1000-D2-24.20.RM
Lifetime Expectancy and MTBF
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7 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 Input: 2x5A
Output: 10A
Input: 2x10A
Output: 20A
Lifetime expectancy 1372 000h 1 182 000h 1 at 24V and 40°C
1 053 000h 1 516 000h 1 at 24V and 25°C
MTBF 2 SN 29500, IEC 61709 2 306 000h 1 954 000h at 24V and 40°C
3 913 000h 3 359 000h at 24V and 25°C
MTBF 2 MIL HDBK 217F 964 000h 858 000h Ground Fixed GF40 (24V and 40°C)
1 379 000h 1 226 000h Ground Fixed GF25 (24V and 25°C)
278 000h 243 000h Ground Benign GB40 (24V and 40°C)
381 000h 330 000h Ground Benign GB25 (24V and 25°C)
1The 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.
2MTBF 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.

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Power Supply PS1000-D2-24.20.RM
Terminals and Wiring
8 Terminals and Wiring
Connecting Terminals
1. 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 minimum
•90°C for ambient up to 70°C minimum.
2. Follow national installation codes and installation regulations!
3. Ensure that all strands of a stranded wire enter the terminal connection!
4. Screws of unused terminal compartments should be securely tightened.
5. Ferrules are allowed.
Input and Output Signals
Type Screw termination
IP20 Finger safe construction.
Suitable for field installation.
Push-in terminals
Solid wire max. 6mm2max. 1.5mm2
Stranded wire max. 4mm2max. 1.5mm2
American Wire Gauge 20-10 AWG AWG 24-16
Max. wire diameter 2.8mm (including ferrule) max. 1.6mm (including ferrules)
Wire stripping length 7mm / 0.28inch 7mm / 0.28inch
Screwdriver 3.5mm slotted or Pozidrive No 2 not required
Recommended tightening torque 0.8Nm, 7lb.in not applicable

Power Supply PS1000-D2-24.20.RM
Functional Diagram
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9 Functional Diagram
Figure 9.1 Functional diagram

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Power Supply PS1000-D2-24.20.RM
Front Side and User Elements
10 Front Side and User Elements
Figure 10.1 Front side
1 Input terminals for input 1 (screw terminals)
2 Input terminals for input 2 (screw terminals)
3 Green LED Output
The LED is on solid when the output current is smaller
than the adjusted value of the output current alarm
selector (6).
4 Green LED Redundancy
The LED is on solid when no errors are detected.
Errors:
•One or both input voltages are out of range
(below 22V or above 30V).
•Output current is higher than the adjusted value
of the output current threshold setting.
•Internal defect is detected
5 Load share LEDs
The three LEDs indicate the status of the load sharing
between the two power supplies.
See chapter 13 for detailed description.
6 Selector for output current warning threshold
If the output current increases, e. g. due to additionally loads,
and exceeds the nominal current of one power supply unit,
redundancy is no longer guaranteed. To avoid the loss
in redundancy, the output current is monitored and is reported
through LEDs and relay contacts when exceeding
the predefined value.
•Set the selector to 5A in combination with two 5A
power supplies (1+1 red.)
•Set the selector to 10A in combination with two 10A
power supplies (1+1 red.)
•Set the selector to 20A for n+1 redundant system.
With this setting, redundancy cannot be checked
by the redundancy module anymore.
Exceeding the current by less than 2 seconds will be ignored.
7 Load share relay contact (push-in terminals)
The relay contact is closed when the output voltage
of the two power supplies are sufficiently adjusted.
Deviations less than 2s will be ignored.
See chapter 13 for detailed description.
See chapter 12 for contact ratings.
8 Redundancy relay contact (push-in terminals)
The relay contact is closed when no redundancy errors
are detected. The relay contact is also synchronized
with the Redundancy LED.
See chapter 11 for contact ratings.
9 Output terminals (screw terminals)
10 Chassis-ground terminal (screw terminal)
Connection of the chassis is optional and not required since
the unit fulfills the requirements according to protection
class III.
PS1000-D2-24.20.RM
Part No. 70103527
Redundancy Module
INPUT2
DC 24-28V
INPUT1
DC 24-28V
OUTPUT
REDUNDANCY
INPUT 1
LOAD SHARE
INPUT 2
20 A
10 A
5 A
OUTPUT 24-28V DC 20 A
13
14
23
24
8
910
7
6
5
4
23
21

Power Supply PS1000-D2-24.20.RM
Redundancy Relay Contact
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11 Redundancy Relay Contact
This feature reports the loss of redundancy by opening the relay contact (pin 23 and 24).
Contact is closed When no errors are detected
Contact is open When:
•one or both input voltages are below 22Vdc or above 30Vdc.
•the output current is higher than the adjusted value of the output current threshold
setting.
•an internal defect of the redundancy module is detected (decoupling measures and
several internal test routines).
Input voltage errors less than 2s will be ignored.
Overcurrent errors (less than 150% of the adjusted value) less than 4s will be ignored.
Overcurrent errors (above 150% of the adjusted value) less than 30ms will be ignored.
Internal errors less than 10s will be ignored
Contact ratings max. 60Vdc 0.3A, 30Vdc 1A, 30Vac 0.5A resistive load
min. 1mA at 5Vdc minimum permissible load
Isolation voltage See dielectric strength table in chapter 18.

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Power Supply PS1000-D2-24.20.RM
Load Share Relay Contact
12 Load Share Relay Contact
This feature monitors if the output voltages of the two power supplies connected to the input
are sufficiently adjusted for an even current distribution. The relay contact (pin 13 and 14)
is closed, when load sharing occurs.
Contact is closed When the adjustment of the output voltages are sufficient
Contact is open When an even load share does not occur, and readjustment of the output voltages
is recommended. Details see chapter 13.
Contact ratings max. 60Vdc 0.3A, 30Vdc 1A, 30Vac 0.5A resistive load
min. 1mA at 5Vdc minimum permissible load
Isolation voltage See dielectric strength table in chapter 18.

Power Supply PS1000-D2-24.20.RM
Automated Load Sharing
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13 Automated Load Sharing
Drawing even current from both power supplies in a redundancy application can provide
a longer service life of the redundant power supply system. An evenly shared current can avoid
that one of the two units is getting much hotter than the other, which reduces the lifetime
of the power supply system. The redundancy module is equipped with an automated load
share feature, which can compensate a certain voltage unbalance between the two power
supplies connected to the inputs.
However, to reduce the losses of the active circuit in the redundancy module, the individual
output voltages shall be set as close as possible. The three LEDs on the front of the unit help
to indicate if adjustment is necessary.
Figure 13.1 Functional diagram
The active load share feature of the device has a similar effect and benefit as the feature
Parallel Mode (soft output characteristic), which is available on larger power supplies.

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Power Supply PS1000-D2-24.20.RM
EMC
14 EMC
The redundancy module is suitable for applications in industrial environment as well
as in residential, commercial and light industry environment without any restrictions.
EMC Immunity According to generic standards: EN 61000-6-1 and EN 61000-6-2
Electrostatic discharge EN 61000-4-2 Contact discharge
Air discharge
8kV
15kV
Criterion A
Criterion A
Electromagnetic RF field EN 61000-4-3 80MHz-2.7GHz 10V/m Criterion A
Fast transients (Burst) EN 61000-4-4 Input lines
Output lines
Redundancy OK signal 1
Load share OK signal 1
2kV
2kV
2kV
2kV
Criterion A
Criterion A
Criterion A
Criterion A
Surge voltage on input lines EN 61000-4-5 + → –
+ / – → Chassis ground
500V
1kV
Criterion A
Criterion A
Surge voltage on output lines EN 61000-4-5 + → –
+ / – → Chassis ground
500V
1kV
Criterion A
Criterion A
Surge voltage on signal lines EN 61000-4-5 Load Share OK signal →
PE
Redundancy OK signal
1kV
1kV
Criterion A
Criterion A
Conducted disturbance EN 61000-4-6 0.15-80MHz 20V Criterion A
Power-frequency magnetic field 2EN 61000-4-8 50Hz 30A/m Criterion A
1Tested with capacitive coupling clamp.
2A 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.
Criterion A Redundancy module shows normal operation behavior within the defined limits.
EMC Emission According to generic standards: EN 61000-6-3 and EN 61000-6-4
Conducted emission input lines IEC/CISPR 16-1-2,
IEC/CISPR 16-2-1
Limits for DC power port according
EN 61000-6-3 fulfilled 1 2
Conducted emission output lines IEC/CISPR 16-1-2,
IEC/CISPR 16-2-1
Limits for DC power port according
EN 61000-6-3 fulfilled 1 2
Radiated emission EN 55011, EN 55022 Class B 2
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.
1For information only, not mandatory for EN 61000-6-3.
2Provided, 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.