Rockwell Automation Trusted T823 Series User manual

PD-T823X Trusted
Rockwell Automation Publication PD-T823X Issue 11
Trusted Power System
Product Overview
The Trusted® Power System is a high density flexible power supply designed to convert main line
voltages of either 110 Vac or 240 Vac. Outputs are either 24 Vdc for Trusted product or 28 Vdc
adjustable field power.
The Trusted Power System consists of a 1U Power Shelf with mechanical support, containing up to
three 750 W Power Packs. The Power Packs load share in configurations using one or more Power
Shelves. Each Power Pack has an individual supply connection via a mechanically retained IEC 60320
type connector. Each Power Shelf can supply 2250 W of power or 1500 W with n+1 redundancy
from a single source. Multiple units can be connected for further capacity or redundancy
requirements.
Diagnostic information of Power Pack status is provided via the Power Port, which connects to the
rear of the Power Shelf. This device monitors input and output conditions and reports out of range
faults and over-temperature/fan failure using relay contacts. The Power Port also allows connection
of the optional rack mounted Power Controller for live configuration, of output voltage and current,
monitoring up to 12 Power Packs in 4 Power Shelves.
Features:
•Redundant and N+1 configurations.
•Hot replaceable Power Packs.
•Current sharing.
•Current limiting.
•Power factor correction.
•Diagnostic contacts.
•Configurable output voltage.
•Input/output fail diagnostics per power pack.

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Trusted Power System PREFACE
Rockwell Automation Publication PD-T823X Issue 11 i
PREFACE
In no event will Rockwell Automation be responsible or liable for indirect or consequential damages
resulting from the use or application of this equipment. The examples given in this manual are
included solely for illustrative purposes. Because of the many variables and requirements related to
any particular installation, Rockwell Automation does not assume responsibility or reliability for
actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, with respect to use of information, circuits,
equipment, or software described in this manual.
All trademarks are acknowledged.
DISCLAIMER
It is not intended that the information in this publication covers every possible detail about the
construction, operation, or maintenance of a control system installation. You should also refer to
your own local (or supplied) system safety manual, installation and operator/maintenance manuals.
REVISION AND UPDATING POLICY
This document is based on information available at the time of its publication. The document
contents are subject to change from time to time. The latest versions of the manuals are available at
the Rockwell Automation Literature Library under "Product Information" information "Critical
Process Control & Safety Systems".
TRUSTED RELEASE
This technical manual applies to Trusted Release: 3.6.1.
LATEST PRODUCT INFORMATION
For the latest information about this product review the Product Notifications and Technical Notes
issued by technical support. Product Notifications and product support are available at the Rockwell
Automation Support Centre at
http://rockwellautomation.custhelp.com
At the Search Knowledgebase tab select the option "By Product" then scroll down and select the
Trusted product.
Some of the Answer ID’s in the Knowledge Base require a TechConnect Support Contract. For more
information about TechConnect Support Contract Access Level and Features please click on the
following link:
https://rockwellautomation.custhelp.com/app/answers/detail/a_id/50871
This will get you to the login page where you must enter your login details.
IMPORTANT A login is required to access the link. If you do not have an account then you can create one
using the "Sign Up" link at the top right of the web page.

PREFACE Trusted Power System
ii Issue 11 Rockwell Automation Publication PD-T823X
DOCUMENTATION FEEDBACK
Your comments help us to write better user documentation. If you discover an error, or have a
suggestion on how to make this publication better, send your comment to our technical support
group at http://rockwellautomation.custhelp.com

Trusted Power System PREFACE
Rockwell Automation Publication PD-T823X Issue 11 iii
SCOPE
This manual specifies the maintenance requirements and describes the procedures to assist
troubleshooting and maintenance of a Trusted system.
WHO SHOULD USE THIS MANUAL
This manual is for plant maintenance personnel who are experienced in the operation and
maintenance of electronic equipment and are trained to work with safety systems.
SYMBOLS
In this manual we will use these notices to tell you about safety considerations.
SHOCK HAZARD: Identifies an electrical shock hazard. If a warning label is fitted, it
can be on or inside the equipment.
WARNING: Identifies information about practices or circumstances that can cause
an explosion in a hazardous environment, which can cause injury or death,
property damage or economic loss.
ATTENTION: Identifies information about practices or circumstances that can cause
injury or death.
CAUTION: Identifies information about practices or circumstances that can cause
property damage or economic loss.
BURN HAZARD: Identifies where a surface can reach dangerous temperatures. If a
warning label is fitted, it can be on or inside the equipment.
This symbol identifies items which must be thought about and put in place when
designing and assembling a Trusted controller for use in a Safety Instrumented
Function (SIF). It appears extensively in the Trusted Safety Manual.
IMPORTANT Identifies information that is critical for successful application and understanding of
the product.
NOTE Provides key information about the product or service.
TIP Tips give helpful information about using or setting up the equipment.

PREFACE Trusted Power System
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WARNINGS AND CAUTIONS
WARNING: EXPLOSION RISK
Do not connect or disconnect equipment while the circuit is live or unless the area is
known to be free of ignitable concentrations or equivalent
AVERTISSEMENT - RISQUE D’EXPLOSION
Ne pas connecter ou déconnecter l’équipement alors qu’il est sous tension, sauf si
l’environnement est exempt de concentrations inflammables ou équivalente
MAINTENANCE
Maintenance must be carried out only by qualified personnel. Failure to follow these
instructions may result in personal injury.
CAUTION: RADIO FREQUENCY INTERFERENCE
Most electronic equipment is influenced by Radio Frequency Interference. Caution
should be exercised with regard to the use of portable communications equipment
around such equipment. Signs should be posted in the vicinity of the equipment
cautioning against the use of portable communications equipment.
CAUTION:
The module PCBs contains static sensitive components. Static handling precautions
must be observed. DO NOT touch exposed connector pins or attempt to dismantle a
module.

Trusted Power System PREFACE
Rockwell Automation Publication PD-T823X Issue 11 v
ISSUE RECORD
Issue Date Comments
1 July 04
2 Nov 04
3 Apr 05 Removed CS from Con 3, added section 6.1
4 Sep 05 Format
5 Feb 06 Fault relay details added.
6 Apr 07 Inrush current details added
7 Nov 07 Current sharing
8 Sep 08 TC-323 clarification
9 Sep 08 Current sharing with low loads
10 Sep 15 Rebranded and reformatted with Corrections to the Operating
Temperature and Relative Humidity Range statements in the
Specifications Section
11 APR 16 Document Updated to incorporate IEEE standards and to correct
typographical errors

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Trusted Power System Table of Contents
Rockwell Automation Publication PD-T823X Issue 11 1
Table of Contents
1. Product Range ........................................................................................................3
2. Assembly ................................................................................................................5
3. Power Shelf Specification ........................................................................................7
3.1. Input Connector .......................................................................................................................... 7
3.2. Output Connector ....................................................................................................................... 8
3.3. Current Sharing ...........................................................................................................................8
3.4. Interface Connector ....................................................................................................................8
3.5. Stacked-up Assembly ................................................................................................................11
4. Power Pack Specifications......................................................................................13
4.1. Power Pack Features.................................................................................................................13
4.1.1. Indicators...........................................................................................................................13
4.1.2. Overcurrent Protection .....................................................................................................14
4.1.3. MCB Discrimination...........................................................................................................14
4.2. Input Specification ....................................................................................................................15
4.3. Line Harmonics..........................................................................................................................15
4.4. Efficiency and Power Factor vs. Input Voltage at Full Load ......................................................16
4.5. Output Specification .................................................................................................................16
4.6. Environmental Characteristics ..................................................................................................18
4.7. Power Pack Hot Replacement...................................................................................................20
5. Power Port............................................................................................................21
5.1. General Description .................................................................................................................. 21
5.2. Circuit Description.....................................................................................................................22
5.2.1. Supply ................................................................................................................................22
5.2.2. DC Alarms .......................................................................................................................... 22
5.2.3. AC Alarms .......................................................................................................................... 22
5.2.4. Jumpers .............................................................................................................................23
5.3. Mechanical................................................................................................................................24
5.3.1. Pin-out CON 1, CON 2........................................................................................................24
5.3.2. Pin-out CON 3....................................................................................................................25
5.3.3. Fault Relay Technical Specifications..................................................................................26
6. Power Controller ...................................................................................................27
6.1. Power Up Sequence ..................................................................................................................28

Table of Contents Trusted Power System
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7. Power Shields ....................................................................................................... 29
8. Power Shelf Interconnect ...................................................................................... 31
9. Power System Specification ...................................................................................33

Trusted Power System 1. Product Range
Rockwell Automation Publication PD-T823X Issue 11 3
1. Product Range
Catalogue No. Product name Description
T8230 Power Shelf 19 inch x 1U chassis for up to 3 Power Packs.
Includes 4U fixing kit, Power Port (with push fit BLZF
3.5/10 connector), mains plugs and retaining clips.
T8231 Power Pack 24 Vdc 750 W, universal input, 24 Vdc out.
T8232 Power Pack 28 Vdc 750 W, universal input, 28 Vdc out.
T8233 Power Port Plug in diagnostic interface.
T8234 Power Controller For live adjustment of output voltage. 19 inch x 1U.
T8235 Power Shield Covers unused Power Pack positions.
TC-323 Power Shelf
Interconnect
For connection to a Power Controller or for current
sharing.
Table 1 T823X Power System Product Range

1. Product Range Trusted Power System
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Figure 1 Front View - Power Shelf with Power Packs
Figure 2 Rear View - Power Shelf, Power Port (uncovered) and 4U Mounting Brackets

Trusted Power System 2. Assembly
Rockwell Automation Publication PD-T823X Issue 11 5
2. Assembly
A pair of brackets mounted in to a 19 inch frame supports up to 4 Power Shelves and are
required to provide support at the rear of the Power Shelf.
The brackets supplied mount the equipment by its 19 inch rack ears and provide a box
structure to brace the power supplies. The back of the power supplies are fixed using M3.5
screws that are fixed via tapped holes in the Power Shelf. The front of the Power Shelf is
located and supported via screws through the lugs of the Power Shelf.
The mounting bracket occupies 4U and can accommodate up to 4 Power Shelves. The
design is such that no space outside the 4U aperture is required. When installed it is
possible to remove individual Power Shelves should this be required. The design of the
mounting bracket does not obstruct access to the front or back of the Power Tray.
Power Packs are slotted into the 1U Power Shelf with the first Power Pack in the right hand
slot, as shown in Figure 4. Each Power Pack provides 750 W (31.25 A at 24 Vdc) to the DC
output on the Power Shelf.
The standard AC input connection to the Power Shelf is through IEC 60320 type connectors
rated at 10 A/250 Vac in Europe/Asia and 15A/120 Vac in North America.
Figure 3 AC Power Connectors and Retaining Clips

2. Assembly Trusted Power System
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Output terminal blocks on each Power Shelf have three M4 screw connections. Ring type
connectors should be used when connecting from the Power Shelf to system power
distribution busbars.
The Power Port plugs into the back of the Power Shelf and requires a 24 V supply. The
Power Port can provide monitoring and control via a 25 way D connector when connected
to a Power Controller. A separate connector (CON3) via a push fit connector (supplied),
provides DC and AC fail contacts. When more than one Power Shelf is used, Power Ports are
linked via the CS terminal, using a Power Shelf Interconnect cable to enable current sharing.
Spare slots in the Power Shelf are covered by Power Shields.
The 1U Power Controller is connected via the Power Port, using a TC-323 Power Shelf
Interconnect ribbon cable, and allows live configuration of output voltage. The Power
Controller can monitor up to 12 Power Packs in 4 Power Shelves. Each Power Shelf is
identified by the Power Controller by selecting addresses on the Power Port as described in
paragraph 5.2.4.
Unused slots in the 4U brackets may be used for other equipment or fitted with blanking
plates.
Unused connectors on the TC-323 ribbon cable should be tied back and left unused.

Trusted Power System 3. Power Shelf Specification
Rockwell Automation Publication PD-T823X Issue 11 7
3. Power Shelf Specification
The Power Shelf is designed to operate as a key element in a complete distributed Power
System.
This Power Shelf can house up to three Power Packs, provides physical protection and a
number of alarm and control features.
The Power Shelf can supply up to 1500 W of n+1 redundant power or up to 2250 W of total
power depending on configuration of Power Packs. Four stacked Power Shelves can provide
up to 9000 W total power.
Figure 4 1U Power Shelf Mechanical Outline
3.1. Input Connector
The Power Shelf can be used with any standard global line voltages. The standard AC input
connection to the Power Shelf is through three clip retained IEC 60320 type connectors
rated at 10 A / 250 Vac in Europe/Asia and 15 A /120 Vac in North America.

3. Power Shelf Specification Trusted Power System
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3.2. Output Connector
The Power Shelf has two terminal blocks for DC output (each with three M4 screws). The V+
and V- are floating with respect to frame GND, either of which can be connected to GND as
required.
3.3. Current Sharing
Note: If there is a low load on a Power Shelf (less than 2 A per Power Pack) then the current sharing circuit may
not work correctly and the ‘PWR OK’ LED may not illuminate on the Power Packs.
In systems where more than one Power Shelf is being used, Shelves should connect their CS
terminals by using a Power Shelf Interconnect cable TC-323. This ensures that the Power
Shelves current share.
Do not connect the TC-323 cable between ‘A’ and ‘B’ supplies or between two sets of
Shelves which connect to separate busbars. The supplies will attempt to share current
between the two busbars, which may damage the power packs and shelves’ sensing circuits.
Unused connectors on the TC-323 cable should be tied back and left unused.
3.4. Interface Connector
The Power Shelf has an optional DSB, 25-pin, female interface connector on the back. The
Power System can be monitored and controlled through this interface, by a Power
Controller, using a Power Shelf Interconnect. AC and DC fail alarms are available from a
separate connector on the Power Port.
Pin Number Signal Name Description
1 DC Fail_2 DC Fail signal of the second Power Pack
2 A2 I2C address bit 2
3 A3 I2C address bit 3
4 ON SYNC Not Used
5 SDA I2C Serial data bus
6 SCL I2C Clock
7 NC No connection
8 On/Off_1 Remote on off control for the first Power Pack - Not Used
9 OTP_1 Fan Fail or Over-temperature signal for the first Power Pack

Trusted Power System 3. Power Shelf Specification
Rockwell Automation Publication PD-T823X Issue 11 9
Pin Number Signal Name Description
10 On/Off_2 Remote on off control for the second Power Pack - Not Used
11 Vaux Not Used
12 DC Fail_1 DC Fail signal of the first Power Pack
13 AC Fail_3 AC Fail signal of the third Power Pack
14 OTP_3 Fan Fail or Over-temperature signal of the third Power Pack
15 DC Fail_3 DC Fail signal of the third Power Pack
16 INT BUS Not used
17 AC Fail_1 AC Fail signal of the first Power Pack
18 On/Off_3 Remote on off control for third Power Pack - Not Used
19 SRTN Signal return and Vaux return
20 RS- Remote sense for V-
21 OTP_2 Fan Fail or Over-temperature signal of the second Power Pack
22 RS+ Remote sense for V+
23 AC Fail_2 AC Fail signal of the second Power Pack
24 CS A single wire interface for current sharing
25 V- V-
Table 2 Pin Assignment of the Interface Connector
Refer to Figure 4 - 1U Power Shelf Mechanical Outline for the locations of Power Pack 1, 2
and 3.

3. Power Shelf Specification Trusted Power System
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Figure 5 Interface Connector

Trusted Power System 3. Power Shelf Specification
Rockwell Automation Publication PD-T823X Issue 11 11
3.5. Stacked-up Assembly
Figure 6 4U Stacked-up Assembly

3. Power Shelf Specification Trusted Power System
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