Pepperl+Fuchs PS1550 User manual

INSTRUCTION MANUAL
MODEL PS1550
FAULT TOLERANT POWER SUPPLY
For Mission Critical Applications
Instruction Manual 114/GB - PN. 991204
DOC. TEC.
IIttaallyyHHeeaaddqquuaarrtteerrss
Pepperl+Fuchs Elcon
Via delle Industrie, 4 • 20050 Mezzago (MI) - Italy
Tel. [phone] • Fax [phone]
e-mail: [email protected]
WWoorrllddwwiiddeeHHeeaaddqquuaarrtteerrss
Pepperl+Fuchs GmbH • Königsberger Allee 87
68307 Mannheim - Germany
Tel. [phone] • Fax [phone]
http://www.pepperl-fuchs.com
e-mail: [email protected]
UUSSAAHHeeaaddqquuaarrtteerrss
Pepperl+Fuchs Inc. • 1600 Enterprise Parkway
Twinsburg, Ohio 44087 • Cleveland - USA
Tel. [phone] • Fax [phone]
AAssiiaaPPaacciiffiiccHHeeaaddqquuaarrtteerrss
Pepperl+Fuchs Pte Ltd • P+F Building
18 Ayer Rajah Crescent • Singapore 139942
Tel. [phone] • Fax [phone]
Subject to reasonable modifications due to technical advances • Copyright PEPPERL+FUCHS ELCON • Printed in Italy • IM-ENG-114/GB-AO-PN991204
www.elconinstruments.com

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IM-ENG-114/GB
INTRODUCTION page 2
UNPACKING “2
STORAGE “2
DESCRIPTION AND SPECIFICATIONS “3
4.1 GENERAL INFORMATION “ 3
4.2 OPERATIVE RANGE “ 3
4.3 SPECIFICATIONS “ 4
4.4 CONFIGURATIONS OF INPUT LINES “ 7
4.5 INPUT LINE REQUISITES “ 8
4.6 STRUCTURAL INFORMATION “ 9
FUNCTIONAL DESCRIPTION “10
5.1 GENERALITIES “ 10
5.2 INPUT MODULE 1550/TB-IN “ 11
5.3 OUTPUT MODULE 1550/TB-OUT “ 11
5.4 LINE MODULE 1550/LM “ 11
5.5 ALARMS “12
5.6 1550/PM POWER MODULE “ 13
5.7 CURRENT SHARING “ 14
5.8 FAN MONITORING CIRCUIT BOARD “ 15
5.9 MOTHER BOARD “ 15
5.10 1550/RFD CHASSIS “ 15
ELECTRICAL CONNECTIONS “17
6.1 POWER CONNECTIONS “ 17
6.2 INDICATION OF POWER FAILURE “ 18
6.3 ALARM CONNECTION “ 18
6.4 OUTPUT CONNECTIONS “ 18
OPERATING INSTRUCTIONS “19
7.1 PRELIMINARY CONTROLS AND CONNECTIONS “ 19
7.2 ISOLATION TESTING “ 19
7.3 STARTING UP “ 20
MAINTENANCE “20
8.1 SPARE PARTS “ 21
8.2 REPAIRS “ 21
8.3 TROUBLESHOOTING “ 22
WARRANTY “24
REV. A0 - 20 OCTOBER 99
I N D E X
1.
2.
3.
4.
5.
6.
7.
8.
9.
WARNING!
This manual is copyright by Elcon Instruments. All rights reserved. No part of manual may be reproduced in part or in
whole without express written consent from Elcon Instruments. Elcon Instruments reserves the right to modify manual
or any part thereof at its discretion without prior notice.

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This manual serves to furnish adequate information for the installation, operation and maintenance of the PS-1550
Power System.
To avoid damage, breakdowns and improper utilization please read the manual carefully before attempting installa-
tion and utilization.
Furthermore, protect ouput and power lines from shortcircuiting considering that peak value and normal function of
power delivered by this power unit is notable and capable of causing considerable damage if improperly utilized.
Upon immediate reception of goods it is always advisable to check the integrity of the packaging and its contents.
In case of damage due to transport, the receiver must immediately communicate entity and nature of damage by
detailed report to carrier, furnishing all necessary information.
If the instrumentation is not destined for immediate utilization, it is always advisable to first control all characteristics
reported on instrument labels against specifications reported in order (model, voltage and frequency, input/ output
range, etc.) to assure that they are in conformance with real application requirements.
If not installed, the equipment should be stored according to the indications reported in the following paragraph:
storage.
IM-ENG-114/GB
1. INTRODUCTION
2. UNPACKING
If storaging instrumentation or accessories adequate precautions must be taken to protect them from damage.
Keep instrumentation in sealed original package until installed. See that adequate protection is taken to prevent da-
mage from exposure to:
• Rain, excessive humidity and/or thermal excursions (supply adequate shelter).
• Dust (formation of a corrosive layer that may cause oxidation and reduce insulation)
• Aggressive gases and pollutants (SO2, H2S, vapors, salts, flue gases, etc.) causing corrosion.
• Insects and rodents (damage to packaging and contents)
• Mechanical shock or non authorized opening of packaged product .
• Intense vibrations (loosening or detachment of fixed parts, breakage due to wear and tear, etc.)
• Any other possible risk.
Verify that warehouse or storage room temperature does not exceed limits -20°C and +60°C for middle to long term
storage (days/months) and -25°C and +75°C for short term shipment or transport.
Upon completion of inspection, repack instrumentation in its original package, seal in plastic envelope together with
Silica Gel, especially in damp environments. Itemize contents to avoid unnecessary further inspections.
3. STORAGE

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IM-ENG-114/GB
4.1 GENERAL INFORMATION
The PS1550 is a modular voltage power system devised to furnish 24V. Its characteristics make it particularly suita-
ble for applications requiring flexible compact systems.
The PS1550 permits:
• Having dual power supply with redundant function and automatic detection due to voltage loss.
Output is guaranteed without variation in the following circumstances:
a) loss of one of the two voltage sources (the second automatically provides necessary power).
b) loss of a Line Module (the fault is automatically indicated by alarm relay and the second Line Module immedia-
tely supplies necessary power).
c) loss of one or more of the Power Modules (the remaining Power Modules automatically share the load – sharing
current – and fault is indicated by alarm relay).
IMPORTANT: WHEN THE SYSTEM IS POWERED BY TWO LINES THEY MUST BE ISOLATED FROM EACH
OTHER (THERE MUST NOT BE ANY POINTS IN COMMON ) OTHERWISE AN ADEQUATE ISOLATION
POWER TRANSFORMER MUST BE INSERTED IN SERIES ON ONE OF THE TWO MODULES.
• Hot plug-in Module insertion, including the fan box.
• Having a compact (19’’ for 4 stacked units) and powerful system (1 KW maximum output).
• Being able to choose maximum power output and minimizing available space thanks to its modular
construction.
• Having an efficient system (typical yield 80%) with minimum heat dissipation.
Moreover the system:
• Limits the inrush current value during the first start up (by NTC at 15Ω2W).
• Is protected against power surges (by a varistor with energy absorption of 71 Joules in 2 ms).
• Is protected against shortcircuiting at output (pushbutton function).
• Is thermically protected (each Power Module has its own thermal protection of 85 °C).
The power supply system is mounted 4 units high on a 19’’modular rack (1550/RFD) and cooled by forced ventila-
tion (three 100 m3/h fans are incorporated).
The chassis accepts a 1550/TB-IN Input Module, a 1550/TB-OUT Output Module, two (to obtain redundancy)
1550/LM Line Modules and one or more (up to six with current sharing) Power Modules (max. 7A each).
4.2 OPERATIVE RANGE
The PS1550 power system is capable of generating elevated power (up to approximately 1KW) with high efficiency
(about 80%) in a reduced space.
Notwithstanding the efficiency of the system, a substantial quantity of power (approximately 210 W with a nominal
load of 36A) is dissipated in the form of heat which must be eliminated in order to maintain the temperature within
acceptable limits.
The device consents considerable cooling by natural convection thanks to the large finned dissipators mounted on
the Power Modules. This solution permits function without forced ventilation and the operative area (characteristic
Voltage output/ ambient Temperature) is displayed in figure 1.
4. DESCRIPTION AND SPECIFICATIONS

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IM-ENG-114/GB
Fig. 1. Operative area of PS1550 system.
The Power Modules are thermally protected. If temperature exceeds 85 °C at ‘baseplate’, the Modules deactivate
until correct operative conditions are restored. Such conditions set off alarm relay.
The chassis is fitted with 3 fans, 100 m3/h each for a total air flow of 300 m3/h. These values permit the system to
function at maximum power up to an ambient temperature of 50 °C while with nominal load the curve is that repor-
ted in figure 1. The fans are housed in the lower part of the chassis and are all mounted on a sliding box; they can
be removed easily by extraction via the hinged panel situated at lower front side. When the panel is opened, a mi-
croswitch interrupts power supply to fans permitting easy access without risk.
If one of the fans breaks down, the corresponding green LED function indicator is set OFF and the alarm relay is
activated.
4.3 SPECIFICATIONS
I N P U T
- Input voltage (Line 1 and/or Line 2)
- AC: 230 Vac nominal ±15% (195 ÷ 264 Vac) at 47 ÷ 63 Hz.
- AC: 115 Vac nominal ±15% (97.5 ÷ 132 Vac) at 47 ÷ 63 Hz.
- DC: 130 Vdc nominal (100 ÷ 180 Vdc).
- PS1550 Versions
Two versions of the system have been foreseen:
- Type-230: version with alternating input voltage both at 230 Vac.
- Type-115: version with input voltage at 115 Vac and/or 130 Vdc.
- Input current in stationary conditions and nominal (rated) load (36 A)
- AC 230 Vac: 6.6 A rms (17.0 A peak).
- AC 115 Vac: 12.1 A rms (25.5 A peak).
- DC 130 Vdc: 9.0 A.
25°C45°C
0°C
36A
Natural
convection
Forced
ventilation
TAMB
65°C
18A
ILOAD
0A

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IM-ENG-114/GB
- Input current in stationary conditions and maximum load (1 KW)
- AC 230 Vac: 7.4 A rms (19.3 A peak).
- AC 115 Vac: 13.3 A rms (28.0 A peak).
- DC 130 Vdc: 10.1 A.
- Inrush current
- AC 230 Vac: the inrush current value for the first start up is 35 A for each Line Module.
- AC 115 Vac: the inrush current value for the first start up is 18 A for each Line Module.
- DC 130 Vdc: the peak current for the first start up is 13 A.
- Crest factor
- AC 230 Vac: the ratio between peak value and effective voltage input is 2.6.
- AC 115 Vac: the ratio between peak value and effective voltage input is 2.1.
- Switching from Line 1 to Line 2 and vice versa (with two line Modules inserted)
If one of the two power sources fails, switch over from one Line to the other is automatic and instantaneous.
- Under voltage Signal
The alarm relay commutes if line voltage is less than 75% of nominal value.
- Turn-on Time
The time lapse between the application of line voltage and the instant in which output is stabilized is at maximum
300 ms.
O U T P U T
- Voltage
Each Power Module provides a voltage of 24.7 V ±10%, adjustable by rotating trimmer accessible on front panel
of 1550-PM Modules. Voltage can be read via test points situated on panel front (refers to the readout upstream
from the decoupling diode present at outlet of each Module).
- Ripple
Output ripple is 100 mVpp at nominal load (36 A).
- Current
- Nominal Current: each Power Module delivers 6 A nominal (the current can be read via test points situated on
panel front: 100 mV correspond to 1 A output).
- Current alarm: each Power Module delivers up to 7 A before signalling alarm via relay.
- Current overload: each Power Module can deliver up to 7.5 A before limiting voltage. At 20.5 V output, the cur-
rent is about 8 A.
- Shortcircuiting: in overload conditions the output voltage starts pulsing when below 9 V; if after such conditions a
nominal load is applied (36 A), output reaches 24 V with maximum delay of 1.3 seconds.
- Output terminals
- Output Module type 1550/TB-OUT: out with 16+16 2.5 mm2terminal blocks, up to 4 Amperes each.
- Output Module type 1550/TB-OUT 4/20: out with 4+4 6 mm2terminal blocks, up to 16 Amperes each.
- Output Module type 1550/TB-OUT 60:out with 1+1 terminal blocks, up to 60 Amperes each.

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IM-ENG-114/GB
- Line regulation
Varying line voltage from minimum to maximum value and working at nominal load, output varies less than 50
mV.
- Load regulation
Varying current output from 0 to 36 A, output varies less than 500 mV.
- Undervoltage alarm
The alarm relay is activated when voltage output is less than 20.5 V ±0.5 V.
- Short Power Mains Interruption
- AC 230 Vac: with mains voltage at minimum (195 Vac) and nominal load of 36 A, the time interval between
power loss and the instant the output voltage starts to drop, is greater than 15 ms.
- AC 115 Vac: with mains voltage at minimum (97 Vac) and nominal load of 36 A, the time interval between
power loss and the instant the output voltage starts to drop, is greater than 15 ms.
- AC 130 Vdc: with mains voltage at minimum (100 Vdc) and nominal load of 36 A, the time interval between
power loss and the instant the output voltage starts to drop, is greater than 10 ms.
A L A R M R E L A Y C H A R A C T E R I S T I C S
250 Vac / 2 Amp / 100 VA
125 Vdc / 2 Amp / 50 W
I N T E R N A L F U S E S
- Line Module
- F1: resistance 2.2 Ω1/2 W.
- F2, F3: T 10A 250/500V 6.3x32 for type-230 or T 20A 250/500V 6.3x32 for type-115.
- Power Module
F1: T 3.15A 500V 6.3x32 for type-230 or T 5A 250/500V 6.3x32 for type-115.
- Fan power supply
F1, F2, F3: T 0.5 A 250V 5x20.
I N S U L A T I O N
- Inputs/Ground: 2500 Vac per 1 minute.
- Inputs/Output: 2500 Vac per 1 minute.
- Output/Ground: 500 Vdc per 1 minute.
R E F E R E N C E N O R M S
The PS1550 power system conforms to the following norms:
- EN 50081-2
- EN 50082-2
- EN 60950

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IM-ENG-114/GB
4.4 CONFIGURATION OF INPUT LINES
The PS1550 system equipped with two Line Modules can be powered by two separate voltages (Line1 and Line 2)
and its particular type of redundancy permits dealing with the loss of one of the lines without affecting output..
The possibility of having an alternating or continuous current , makes the system highly flexible leaving the user the
possibility of selecting the best strategy to employ.
Various cases are possible:
A) ONE ALTERNATING CURRENT INPUT
In order to have a reliable system the power line must be furnished with a UPS unit to guarantee redundancy of
line Modules, Line1 and Line 2 must be connected in parallel to mains.
B) TWO STANDARD ALTERNATING CURRENT INPUTS
This is a low cost solution and is very easy to carry out: it simply requires connecting two power lines; so that if
one line fails, the second automatically fulfills all power requirements.
The two power lines must originate from two separate power sources so that if one fails it does not provoke the
additional consequent loss of the other.
If the probability and duration of one line loss is low for both inputs, it is easy to assume that the contempora-
neous loss of both inputs would be an improbable event and therefore system reliability is at any rate guaran-
teed.
C) STANDARD ALTERNATING CURRENT AND EMERGENCY ALTERNATING CURRENT
(OR UPS) INPUT
This solution utilizes standard alternating current as well as an emergency power source (it must be activated
within 10ms from the loss of the power line or must be an uninterruptible type –UPS-). In order to avoid having
the UPS line under permanent charge, its voltage output must always remain slightly below (a few volts) that of
the main line so that it does not supply current under normal conditions.
This set up is more costly than A) due to the fact that it has a truly independent source, but is certainly more
practical and safe.
If the line is not a UPS type, make sure that maximum intervention time does not exceed 10 ms in order to avoid
‘glitches’ or transitory output losses.
D) STANDARD ALTERNATING CURRENT (115 Vac) AND DIRECT CURRENT BUFFER
(BATTERY at 110 Vdc)
This solution utilizes standard alternating current at 115 Vac which normally powers the system, and an emer-
gency direct current system (system with buffer battery at 110 Vdc) which intervenes in case of loss of main li-
ne.
This set up is cheaper than B) and offers equal or even more reliability.
The battery system must be such as to permit 24 V output for at least 20 minutes for maximum power (20 minu-
tes is generally an acceptable time to carry out emergency procedures).
In all cases analyzed the loss of one line is signaled via alarm relay mounted on respective line Module.

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IM-ENG-114/GB
4.5 INPUT LINE REQUISITES
Line1 and Line 2 must respect the following requisites:
LINE INSULATION
WHEN THE PS1550 SYSTEM IS POWERED BY TWO LINES, THE LINES MUST BE ISOLATED FROM EACH
OTHER IN ORDER TO AVOID POTENTIALLY HAZARDOUS CONNECTIONS BETWEEN THE TWO DUE TO A
COMMON CONNECTION TO NEUTRAL. THIS AVOIDS THE APPARANCE IN THE RECTIFICATION SYSTEM
OF A COMBINATION OF INPUT VOLTAGES SUPERIOR TO BOTH VALUES: THE CAUSE IS A PHASE DISPLA-
CEMENT BETWEEN THE TWO (FOR A PHASE DISPLACEMENT OF 180° THE SUM OF THE TWO LINES AP-
PEARS!). NOTE THAT UPS SYSTEMS VARY THEIR PHASES IN ORDER TO LINK ON TO MAIN LINE FRE-
QUENCY.
VOLTAGE
- Type-230: 230 Vac nominal ± 15% (195 ÷ 264 Vac), 47 ÷ 63 Hz, 10% T.H.D. maximum.
- Type-115: 115 Vac nominal ± 15% (97.5 ÷ 132 Vac), 47 ÷ 63 Hz, 10% T.H.D. maximum 130 Vdc nominal (100 ÷
180 Vdc).
SHORT POWER MAINS INTERRUPTION
Power input must not lack for more than 10 mseconds to avoid the appearance of ‘glitches’ or transitory output
loss.
INRUSH CURRENT
- AC 230 Vac: to be able to guarantee each line Module an inrush current value of 40 A during first start up.
- AC 115 Vac: to be able to guarantee each line Module an inrush current value of 20 A during first start up.
- AC 130 Vdc: to be able to guarantee each line Module a 16 A voltage peak during first start up.
CREST FACTOR
- AC 230 Vac: the ratio between peak value and effective value of voltage must be 3.
- AC 115 Vac: the ratio between peak value and effective value of voltage must be 2.5.
VOLTAGE IN STATIONARY CONDITIONS AND MAXIMUM LOAD (1 KW)
- AC 230 Vac: 8 A rms (21 A peak)
- AC 115 Vac: 14 A rms (30 A peak)
- DC 130 Vdc: 12 A
PROTECTION AGAINST SURGES
The power lines must have some form of protection against transitory phenomena that may result hazardous. Pro-
tection against surges permits limiting voltage spikes which may be generated in the following cases:
- A short circuit along the power line generates the sudden passage of very high voltage. Repeated interruption of
this nature on the part of the fuses creates a high energy voltage spike throughout the entire system with conse-
quent risks to the whole system.
- Opening an inductive load generates a high energy voltage spike thus submitting the entire system to notable
stress.
- A very short power interruption may create mains voltage spikes due to coupling with consequent system stress.
The PS1550 is protected against interference and transitory phenomena by the implementation of a suitable filter at
input and varistor with energy absorption of 71 Joules in 2 ms.

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IM-ENG-114/GB
4.6 STRUCTURAL INFORMATION
The PS1550 power system consists of:
A) a chassis:
1550/RFD A 19’’rack predisposed to accept 4 stacked units including extractable fan box.
B) an Input Module:
1550/TB-IN is the terminal module for power inputs (230 Vac, 115 Vac, 130 Vdc) also including the terminal
board for alarm relay contacts.
C) an Output Module; three different versions exist (figure 2):
1550/TB-OUT is the standard output module with 16+16 terminals suitable for connections up to 4 Amperes ea-
ch.
1550/TB-OUT 4/20 is an optional output module wih 4+4 terminals suitable for connections up to 16 Amperes
each.
1550/TB-OUT 60 is an optional output module with 1+1 terminals suitable for per a single maximum power con-
nection, (~60 A).
D) two redundancy line Modules which must of the same version; based on the type of system (type-230 or type-
115) there are two possibilities:
1550/LM-230 is the module that permits working with 230 Vac input voltage.
1550/LM-115 is the module that permits working with 115 Vac or 130 Vdc input voltage.
Fig. 2. Input module and three versions for Output Modules
Circuit board 1550/TB-OUT 4/20
is equipped with 4÷4
terminals 24Vcc up to 16A each
OUTPUT
Terminals
24 VDC
+
+
+
+
c
c
c
c
POSITIVE COMMON
OUTPUT
24 VDC
COMMON
+
Alarm
contacts
1
Line
2
Note:
Contacts are indicated
in de-energized state
12
~
ON 16
10
11
12
13
14
15
1
2
3
4
5
6
7
8
9
~
~
~
16
10
11
12
13
14
15
1
2
3
4
5
6
7
8
9
0 Volt +24V
Input
Module
and Alarms
Standard
Output Module
Different output circuit
boards available
Circuit board 1550/TB-OUT 60
is equipped with 2 bolts
24Vcc up to 60A each
Alarm
contacts
2
Line
1
Circuit board 1550/TB-OUT
is equipped with 16÷16
terminals 24Vcc up to 4A each
1550/TB-IN 1550/TB-OUT 1550/TB-OUT 4/20 1550/TB-OUT 60