Pepperl+Fuchs PS1000-D2-24.40.RM Manual

ISO9001
PS1000-D2-24.40.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

3
Power Supply PS1000-D2-24.40.RM
Contents
2021-11
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Terminology and Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Input and Output Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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 EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
12 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
13 Protection Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
14 Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
15 Dielectric Strength. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
16 Approvals And Fulfilled Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
17 Regulatory Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
18 Physical Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
19 Application Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Power Supply PS1000-D2-24.40.RM
Contents
4
2021-11

Power Supply PS1000-D2-24.40.RM
Introduction
2021-11
5
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.

2021-11
6
Power Supply PS1000-D2-24.40.RM
Terminology and Abbreviations
2 Terminology and Abbreviations
Figure 2.1 1+1 Redundancy
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
system.

AC
DC
AC
DC
Load
+ -
IN 1
OUT
IN 2

Power Supply PS1000-D2-24.40.RM
Terminology and Abbreviations
2021-11
7
Figure 2.2 N+1 Redundancy
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.
AC
DC
AC
DC
AC
DC
AC
DC
AC
DC
AC
DC
IN 1
OUT
IN 2 IN 1
OUT
IN 2 IN 1
OUT
IN 2
Load
+
-

2021-11
8
Power Supply PS1000-D2-24.40.RM
Intended Use
3 Intended Use
This device is designed for installation in an enclosure and is intended for commercial use,
such as in industrial control, office, communication and instrumentation equipment. Do not use
this device in equipment where malfunction may cause severe personal injury or threaten
human life.
The redundancy module is designed for use in hazardous, non-hazardous, ordinary or
unclassified locations
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 20 A and one output can be connected to the inputs. The power supplies can transmit a
rated current of up to 40 A and 40 A to 65 A for 5 s.
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 24 V, 40 A output current, 25 °C ambient
and after a 5 minutes run-in time unless otherwise noted.

Power Supply PS1000-D2-24.40.RM
Installation Instructions
2021-11
9
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 unit or operate the voltage adjustment or S/P jumper 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 60079-15:2010.
Note
If you use the device in hazardous areas, observe the safety information in the instruction
manual and in chapter 16.

2021-11
10
Power Supply PS1000-D2-24.40.RM
Installation Instructions
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.

Power Supply PS1000-D2-24.40.RM
Input and Output Characteristics
2021-11
11
5 Input and Output Characteristics
Figure 5.1 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)
Figure 5.2 Input to output voltage drop when only one input draws current
Number of inputs 2
Suitable power supplies Use only power supplies which are featured
with the Hiccup overload behaviour
Number of outputs 1
Input voltage nom. DC 12-28V ±30% The input circuitry must meet the SELV
requirements stipulated by IEC/EN/UL 60950-1.
Input voltage range 8.4-36.4Vdc
Voltage drop, input to output typ. 140mV at 2x20A, see Figure 5.1
typ. 72mV at 2x10A, see Figure 5.1
typ. 112mV at 1x20A, see Figure 5.2
Input current nom. 2x 0-20A continuous
nom. 2x 20-32.5A for 5 seconds
max. 2x 13A in overload (voltage < 6V) or short circuit mode
Peak input current max. 1000A for max. 1ms per input
Output current nom. 40A continuous
nom. 40-65A for 5 seconds
max. 26A in overload (voltage < 6V) or short circuit mode
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
Volt age Drop, typ
0mV
10A 30A
20mV
40mV
60mV
80mV
100mV
120mV
40A20A
Output:
A... 25°C
B... 60°C
2x10A2x5A
Input / Output Current
Input:
2x20A2x15A
0
0
140mV
160mV
AB
V
A
Power
supply
24V,20A
+
-
Power
supply
24V,20A
+
-
V
A
I 1
I 2
U 1
U 2
I 1 I 2 = U 2 U 1 = Volt age Drop U 1 = U OUT -
Out put
A
V
I OUT
U OUT
Variable
Loa d,
0-40A
PS1000-D2-
24.40.RM
Input 1
Input 2
Out put
Volt age Drop, typ.
0mV
5A 15A
20mV
40mV
60mV
80mV
100mV
120mV
20A10A
A... 25°C
B... 60°C
Output Current
0
140mV
160mV
AB
Vol t age Dro p U 1 = U OUT -
Not used or
power supply
with lower
vol t age
V
A
Power
supply
24V,20A
+
-
I
1
U 1
Out put
A
V
I OUT
U OUT
Variable
Loa d,
0-20A
PS1000-D2-
24.40.RM
Input 1
Input 2
Out put

2021-11
12
Power Supply PS1000-D2-24.40.RM
Power Losses
6 Power Losses
Figure 6.1 Power losses when both inputs draw equal current
Figure 6.2 Power losses when only one input is used
DC 12V DC 24V
Power losses typ. 1.6W 1.7W input: 2x10A
typ. 5.8W 5.9W input: 2x20A
typ. 2.3W 2.4W input: 1x20A,
(only one input is connected to input voltage)
Standby power losses typ. 0.07W 0.15W at no output current,
(only one input is connected to input voltage)
typ. 0.12W 0.23W at no output current,
(both inputs are connected to input voltages)
Pow er Lo sse s, t y p.
0
0 5 10 30
1.0
2.0
4.0
5.0
7W
40A2515 20 35
Output Current
A
3.0
A... 25°C
B... 60°C
6.0
B
Out put
V
A
Power
supply
24V,20A
+
-
set to
24.5V
V
A
I
1
I 2
U
1
U
2
A
V
I OUT
U OUT
I
1
I
2
= U
2
U
1
= Lo sses U
1
= U
OUT
-
*
I
1
+)(* U
2
*
I
2
I
OUT
Power
supply
24V,20A
+
-
set to
24.5V
Variable
Loa d,
0-40A
PS1000-D2-
24.40.RM
Input 1
Input 2
Out put
Pow e r Lo sses, t yp.
0
02.55 15
0.5
1.0
2.0
2.5
4W
20A12.57.5 10 17.5
Out p ut Cur r en t
1.5
3.0
3.5
A... 25°C
B... 60°C
A
B
Losses U
1
= U
OUT
-
*
I
1
*
I
OUT
Out put
V
A
Power
supply
24V,20A
+
-
I
1
U
1
A
V
I OUT
U OUT
PS1000-D2-
24.40.RM
Input 1
Input 2
Out put
Variable
Loa d,
0-20A

Power Supply PS1000-D2-24.40.RM
Lifetime Expectancy and MTBF
2021-11
13
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: 2x10A
Output: 20A
Input: 2x20A
Output: 40A
Lifetime expectancy 1672 000h 1 255 000h 1 at 24V and 40°C
1 900 000h 1 720 000h 1 at 24V and 25°C
MTBF 2 SN 29500, IEC 61709 7 234 000h 4 533 000h at 24V and 40°C
12 445 000h 8 218 000h at 24V and 25°C
MTBF 2 MIL HDBK 217F 325 000h 294 000h Ground Fixed GF40 (24V and 40°C)
438 000h 392 000h Ground Fixed GF25 (24V and 25°C)
1 588 000h 1 457 000h Ground Benign GB40 (24V and 40°C)
2 159 000h 1 964 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.

2021-11
14
Power Supply PS1000-D2-24.40.RM
Terminals and Wiring
8 Terminals and Wiring
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.
Connecting Terminals
1. The external circuitry of all terminals must meet the safety requirements stipulated by
IEC/EN/UL 60950-1: SELV.
2. 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.
3. Follow national installation codes and installation regulations!
4. Ensure that all strands of a stranded wire enter the terminal connection!
5. Screws of unused terminal compartments should be securely tightened.
6. Ferrules are allowed.
7. Do not connect or disconnect the wires from the terminals below -25°C (-13°F).
Input Output
Type Screw termination
IP20 Finger safe construction.
Suitable for field installation.
Screw termination
IP20 Finger safe construction.
Suitable for field installation.
Solid wire 0.5-6mm20.5-16mm2
Stranded wire 0.5-4mm20.5-10mm2
American Wire Gauge 20-10 AWG 22-8 AWG
Max. wire diameter 2.8mm (including ferrule) 5.2mm (including ferrules)
Wire stripping length 7mm / 0.275inch 12mm / 0.5inch
Screwdriver 3.5mm slotted or Pozidrive No 2 3.5mm slotted or Pozidrive No 2
Recommended tightening torque 0.8Nm, 7lb.in 1.2Nm, 10.6lb.in

Power Supply PS1000-D2-24.40.RM
Functional Diagram
2021-11
15
9 Functional Diagram
Figure 9.1 Functional diagram
+
-
+
-
+
-
Input 1
control
control
Input 2
Chassi s
Gr oun d
Out put

2021-11
16
Power Supply PS1000-D2-24.40.RM
Front Side and User Elements
10 Front Side and User Elements
Figure 10.1 Front side
1 Output terminals (screw terminals)
2 Chassis-ground terminal
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 fulfills the
requirements according to protection class III.
3 Input terminals for input 1 (screw terminals)
4 Input terminals for input 2 (screw terminals)
PS1000-D2-24.40.RM
Part No. 70103528
DC 12-28V 40A
OUTPUT
Redundancy Module
Input 1
DC 12-28V
20A
Input 2
DC 12-28V
20A
Chassis
Ground
3
4
22
1

Power Supply PS1000-D2-24.40.RM
EMC
2021-11
17
11 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 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 20V/m Criterion A
Fast transients (Burst) EN 61000-4-4 Input lines
Output lines
2kV
2kV
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
Conducted disturbance EN 61000-4-6 0.15-80MHz 20V Criterion A
Power-frequency magnetic field 1EN 61000-4-8 50Hz 30A/m Criterion A
1A 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 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 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.
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.

2021-11
18
Power Supply PS1000-D2-24.40.RM
Environment
12 Environment
Figure 12.1 Output current vs. ambient temp.
Figure 12.2 Output current vs. altitude
Operational temperature 1-40°C to +70°C (-40°F to 158°F)
Storage temperature -40 to +85°C (-40°F to 185°F) for storage and transportation
Output de-rating 1A/°C 60-70°C (140°F to 158°F)
Humidity 25 to 95% r.H. IEC 60068-2-30
Vibration sinusoidal 32-17.8Hz: ±1.6mm; 17.8-500Hz:
2g
2 hours / axis
IEC 60068-2-6
Shock 330g 6ms, 20g 11ms
3 bumps / direction, 18 bumps
in total
IEC 60068-2-27
Altitude 0 to 2000m (0 to 6 560ft) without any restrictions
2000 to 6000m (6 560 to 20 000ft) reduce output power or ambient temperature,
see Figure 12.2
Altitude de-rating 2.5A/1000m or 5°C/1000m > 2000m (6500ft), see Figure 12.2
Over-voltage category not applicable The concept of the overvoltage category
is used for equipment energized directly
from the low voltage mains
(IEC 60664-1 §4.3.3.2.1).
Degree of pollution 2 IEC 62103, EN 50178, not conductive
1Operational temperature is the same as the ambient or surrounding temperature and is defined as the air temperature 2cm
below the unit.
2Do not energize while condensation is present.
3Tested in combination with DIN mounting rails according to EN 60715 with a height of 15mm and a thickness of 1.3mm
and standard mounting orientation.
Allowed Out put Current
0
-40 0 20 40 70°C
10
20
30
40
50
65A
60-25
normal mode
sh o r t t er m (< 5s)
Ambient Temperature
Allowed Out put Current
0
0 2000 4000 6000m
10
20
30
40
50
65A
normal mode
Altit ude
sh o r t t er m ( < 5 s)
A... Tamb < 70°C
B... Tamb < 60°C
C... Tamb < 50°C
ABC

Power Supply PS1000-D2-24.40.RM
Protection Features
2021-11
19
13 Protection Features
Output over-current protection not included
Reverse input polarity protection included unit does not start when input voltage is reversed
Degree of protection IP 20 EN/IEC 60529
Penetration protection > 3.6mm e.g. screws, small parts
Over-temperature protection not included
Input transient protection not included
Output transient protection included see EMC section
Internal input fuse not included

2021-11
20
Power Supply PS1000-D2-24.40.RM
Safety Features
14 Safety Features
Input / output separation no galvanic separation Mosfet between input and output
Class of protection III PE (Protective Earth) or chassis connection
not required
PE resistance < 0.1Ohm between housing and chassis-ground terminal