PS3500-N+1 Redundant Power Supply Installation
Contents
1. Load Alarm share 2 NO 1 2 3 NOTE Alarm relay 3 shown in alarm position NOTE If serial alarm is used an alarm will occur when pulling out a module Figure 10 Serial alarm connection Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs PEPPERL FUCHS USA 1 330 486 0002 Germany 49 621 7762222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS 17 M PS3500 N 1 Redundant Power Supply 7 Output configurations Alarm configuration No module empty slot Parallel with Load Share Parallel without Load Share Serial with Load Share Serial without Load Share Note Diagnostic Module DIP Switches When the Diagnostic Module is not in use all Diagnostic Module port DIP switches must be set to the OFF position Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs PEPPERL FUCHS 18 USA 1 330 486 0002 Germany 49 621 776 2222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS M PS3500 N 1 Redundant Power Supply 8 Operations Warning Do not plug and power modules on the backplane before checking all the Warning Systems as recommended 1 Supply l2. 13 e Ea eE MOIS ee asc ns lue 14 GA DUMP COM GUIAU ON ed e aen so un mo d irm dE 16 0 17 rel iecit 18 ER CI EE mt 19 8 1 COUN ONY MINS CHECKS mU 19 8 2 Quiput ne CHECKS emina Ea 19 Alam MASS CHOCKS EET m T 19 A ees serene ae ee ds rie 19 9 Maintenance amp 20 10 cc 21 11 SPECIAL warnings m 22 UE o X 23 Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs PEPPERL FUCHS 4 USA 1 330 486 0002 Germany 49 621 7762222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS 2 M PS3500 N 1 Redundant Power Supply 1 Introduction This manual applies to the Pepperl Fuchs PS3500 system that consists of the products shown in Table 1 PS3500 PM 1 24 15 N 1 power supply module 24 V DC 15 PS3500 TB 3 Backplane for three power modules and one diagnostic module PS3500 TB 6 Backplane for six power modules and one dia
3. Input output 4 25 kV DC Input ground 2 12 KV DC 1 5 kV AC Output ground 2 12 kV DC E Ambient conditions Ambient temperature 25 45 derated 0 4 A C from 45 70 C Relative humidity lt 95 non condensing Protection degree IP20 Weight Approximately 1 8 kg 4 125 Ibs Electromagnetic compatibility Directive 2004 108 EC EN 61326 1 2006 EN 61000 sections 4 2 4 4 and 4 6 EN 55011 Conformity Electrical isolation IEC 61131 2 Electromagnetic compatibility Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs fa PEPPERL FUCHS 6 USA 1 330 486 0002 Germany 49 621 776 2222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS M PS3500 N 1 Redundant Power Supply 3 2 System specifications continued Data for application in conjunction with hazardous areas Type Examination Certificate 12ATEX1103387X Rev 1 Group category type of protection 13 G Ex nA nC IIC T4 PS3500 PM 13 Ex nA IIC T4 PS3500 TB Directive conformity Directive 94 9 EC EN 60079 0 EN 60079 15 EN 61010 1 IECEx approvals Ex nA nC T4 PS3500 PM Ex nA IIC T4 PS3500 TB IECEx UL 13 0082X UL Listed ANSI ISA 12 12 01 2011 UL 508 CSA C22 2 No 213 M1987 CSA C22 2 No 107 1 Approved for Class I Zone 2 Group T4 Class 1 Division 2 Groups A B C D T4 Supplementary information Statement of Conformity Declaration of Conformity and instructions have to be observed where applica
4. 1 330 486 0002 Germany 49 621 7762222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS M PS3500 N 1 Redundant Power Supply 6 3 2 Dual Line Input Wire per sketch in Figure 5 For redundant input line configuration load should not exceed 45 Amps per every 6 position backplane used Line 1 Note Line 2 Primary For this configuration the phases Backup of the two supplies should match o 2 em o Figure 5 Dual line input connection 6 3 3 Independent line connection Wire per sketch in Figure 6 For independent input line configuration load should remain separated Line 1 Line 2 Line 3 Primary Backup Optional Z J L 2 1 L 2 21 di Note For this configuration the phases of the three supplies should match Figure 6 Independent multi input line connections Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs rj SJPEPPERL FUCHS 4 USA 1 330 486 0002 Germany 49 621 776 2222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS 5 16 PS3500 N 1 Redundant Power Supply 6 4 Output configuration Each power module slot has a 6 position DIP switch that enables the various alarm configurations as well as the load sharing ability of each PS3500 power module See Table 4 for proper configuration These configurations are on a per slot b
5. B 6 120 mm 100 m3 h brushless long life fans operated from the output bus at 24 V DC e g PAPST type installed immediately below the backplanes and blowing air up against the bottom of the power modules Make sure to allow relatively free airflow below the fans and above the supply rack 4 3 Clearances For clearances we would recommend 1 25 from the sides of the power supplies and 5 from the top and bottom when oriented in the standard horizontal position for convection cooling If using forced air convection cooling this may be reduced some This assumes that below the backplane is not another source of heat 5 inch clearance 1 25 inch clearance 1 25 inch clearance 5 inch clearance Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs 10 2982 Oe co OPEN FT PEPPERL FUCHS USA 1 330 486 0002 Germany 49 621 7762222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS M PS3500 N 1 Redundant Power Supply 5 Technical concept The power supply system consists of two different backplanes 3 and 6 slots and the power supply module The key features of the system are Nominal output 24 V 15 A per module Nominal input of 90 to 250 V AC 90 to 300 V DC per module e N 1 redundancy e Automatic load sharing e High efficiency up to 91 e Fanless e Module output voltage is adjustable at the backplane from 22 5 V to 30 V e Basic module failure
6. Industrial Control Equipment for use in Hazardous Locations WARNING DO NOT SEPARATE WHEN ENERGIZED UNLESS AREA IS KNOWN TO BE NONHAZARDOUS AVERTISSEMENT RISQUE D EXPLOSION NEPAS DEBRANCHER TANT QUE LE CIRCUIT EST SOUS TENSION MOINS QU IL NE S AGISSE D UN EMPLACEMENT NON DANGEREUX 25 C lt Tamp lt 45 C Type 1 70 C derated WARNING HOT SURFACE RISK OF BURN Avertissement surface chaude risk de br lures See Manual for operating instructions Figure 1 Power Supply Module EXPLOSION HAZARD DO SEPARATE WHEN ENERGIZED RISQUE D EXPLOSION NEPAS DEBRANCHER TANT QUE LE CIRCUIT EST SOUS 12ATEX1103387X UNLESS AREA IS KNOWN TO BE NONHAZARDOUS TENSION A MOINS QU IL NE S AGISSE D UN EMPLACEMENT NON DANGEREUX LISTED IECEx UL 13 0082X HOT SURFACE RISK OF BURN SURFACE C HAUDE RISK DE BRULURES 4KMO WARNING AVERTISSEMENT CE 25 C lt Tamb lt 70 C Type 1 RISK OF ELECTRIC SHOCK MORE THAN ONE amo yp CAUTI ON3S SCONNECT SWITCH M Y BE REQUIRED TO 44 66Hz Industrial Control Equipment THE EQUIPMENT BEFORE SERVICING 90 300VDC ere Lee Certified to ANSI ISA a Pun Groups A B C D T4 Certified to CSA STD C22 2 No 107 1 Classi Zone 2 RTISSE ME NT SOUS TENSION VOIR LE SCHEMA amp marper slot See Manual for operating instructions Cerifedis CSA STD 222 No 713 Groups lic T4 Certified to UL STD 508 Class Division 2 Figure 2 Backp
7. PROCESS AUTOMATION PS3500 N 1 REDUNDANT POWER SUPPLY INSTALLATION amp OPERATION MANUAL PEPPERL FUCHS M PS3500 N 1 Redundant Power Supply Contents 1 LION sem EREA 2 2 IN drei mt 3 SAIS ea a un 4 22 POUCES ae nn 4 29 API 5 3 SDC CHIC ANON mm 5 3 1 Power supply module specifications nenne 5 3 2 e SUSI SPECINIC ANIONS AMT m M 6 Oro DIMMS SIONS EE a a a 8 A Temperature considerations iare ooa d cao exu Cue aao e vaut exu OE cepa eR 9 Al Convecion CoO sm E E mm 9 A2 Forced ee ea de aU ie es 10 Ao Gearan ES NE m 10 57 RR TT G SSR EH 11 5 0 Uaec TE Tm 11 SN ME POr SW OO ING NN IEEE 11 53 Automatic 0 5 11 54 a sn en teen tt 11 Do Alann oumu ed ee due ee 11 5 6 Internal diagnostics recovery and 06 12 WINN sree sn dense ess dan sens ses attentes seems 13 6 1 Special conditons of USE ae 13 SMS seti Eee iP
8. YOUR PROCESS Subject to modifications 2013 PEPPERL FUCHS INC Printed in USA Part No 912759 Drawing No DOCT BOO1EENG 03 15
9. alarming via relay contact normally open close configurable e Redundancy on supply line 5 1 1 redundancy N 1 redundancy is based on the fact that the maximum drawn current is lower than the maximum current provided by the overall number of modules minus one Based on the backplane size N can be any number between 1 and 5 5 2 Hot swapping Hot swapping allows replacement of a module under power without any visible functional impact on the output side Hot swapping is allowed only in an environment where no hazardous materials are present The hot swapping feature is not permitted in a Class 1 Div 2 area or Zone 2 area unless under a hot permit 5 3 Automatic load sharing The power supply modules implement a real load sharing function all modules supply the same amount of current The tolerance for the current difference between the modules should be within a range of 1 5 A 5 4 Variable output voltage The factory default output voltage is 24 V The output voltage is adjustable in a range from 22 5 V to 30 V for each module by using a potentiometer Inserted modules can be easily adjusted with a screwdriver during setup Potentiometers are accessible on the adjacent backplane slot making the voltage setting tamper proof during operation 5 5 Alarm output Each power module has its own alarm monitoring circuit that controls a relay for a common failure output signal It can be configured normally open or normally closed using t
10. asis of on ot Of x f o of x Load share OFF INN NN RE M slot not having a module should have DIP switch 4 turned Slot 1 S1 1 and S12 are in parallel therefore either one can be on Table 4 Alarm load sharing configuration 6 4 1 Independent outputs Use for separate output pM wire per 7 Out 1 Out 2 Out 3 Out 4 Out 5 Out 6 Figure 7 Independent output lines 6 4 2 Common outputs Use for bus connected output or redundant configurations wire per Figure 8 Refer to Table 4 for load share DIP switch configuration For multi backplane parallel operation extend load sharing connections at terminals 5 and 6 to the next backplane NOTE A separate bus is required for loads gt 45 A Figure 8 Bus connected output or redundant configurations Subject to m
11. ay Type of protection Sealed contacts Avertissement L exposition certains produits chimiques mai d grader la fermeture des propri t s des mat riaux utilis s dans les appareils suivants Panasonic DS series sealed relay The case is thermal setting PBT with an epoxy resin encapsulant Avertissement Risque d explosion la substitution se composants peut render ce mat riel inacceptable pour les emplacements de Classe 1 Division 2 Reference designation RL1 Description Relay Type of protection Sealed contacts 3 Warning Explosion hazard do not remove fuses or plug in modules as applicable unless power has been disconnected or the area is known to be free of ignitable concentrations of flammable gases or vapors Avertissement Risque d explosion Ne pas retirer les fusibles ou les plug in modules selon le cas que si le pouvoir a t d connect ou la r gion est connue pour tre exempts de inflammable concentrations de gaz inflammables ou vapeurs Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs A PEPPERL FUCHS 22 USA 1 330 486 0002 Germany 49 621 7762222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS PS3500 1 Redundant Power Supply 12 Notes Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs PEPPERL FUCHS 23 USA 1 330 486 0002 Germany 49 621 7762222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS PS3500 1 Redundant Power Su
12. ble For information see www pepperl fuchs com Table 3 System specifications Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs PEPPERL FUCHS USA 1 330 486 0002 Germany 49 621 776 2222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS 7 M PS3500 N 1 Redundant Power Supply 3 3 Dimensions mm in Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs PEPPERL FUCHS 8 USA 1 330 486 0002 Germany 49 621 776 2222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS M PS3500 N 1 Redundant Power Supply 4 Temperature considerations Temperature accelerates the failure mechanism of every electronic component Arrhenius criteria If the operating temperature is increased by 10 C from its normal operating range 25 45 C 11 113 F its expected life is almost cut in half Temperature rise depends on dissipated power density For the same enclosure volume more power dissipated produces higher temperature rise For example a cabinet 600 x 600 x 2000 mm dissipating 300 W with natural convection cooling produces an internal temperature rise of 10 C This should be regarded as an ideal case Identify the worst load temperature environment that the power supply will encounter and determine the recommended cooling method e Use convection cooling when the supply load operating temperature is typicall
13. down the system See Section 5 2 Hot swapping Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs S PEPPERL FUCHS 4 USA 1 330 486 0002 Germany 49 621 776 2222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS M PS3500 1 Redundant Power Supply 3 Specifications PS3500 has a wall mount multi slot backplane accepting hot swappable plug in power converter modules that provides an isolated output at 24 V DC nominal Each power module has an individually isolated input port accepting either AC or DC that provides inrush current limiting and power factor control The output port is completely isolated from the input and provides up to 15 A per module at a nominal 24 V DC adjustable 22 5 to 30 V from chassis mounted trimmer with a load sharing configuration for paralleled output operation Input and output lines can be wired independently or in parallel providing N 1 redundant structures System configuration is obtained by wiring and configuration DIP switches on the various backplane slots leaving power modules interchangeable and easily swappable under load All relevant failures in the modules are detected and signaled by individual LEDs and alarm relays providing a flexible combination of redundancy fault tolerance and automatic fault detection ideally suited to critical applications Full compliance to the EU directives for EMC and low voltage equipment ensure minimum emissions and high immunity in harsh envi
14. gnostic module Table 1 PS3500 series product range The manual assumes that the user has technical knowledge of and experience with power supply systems explosion protection as well as planning and installing power systems It does not provide an introduction to power systems or explosion protection for inexperienced users The content of this manual applies in conjunction with the respective data sheets Declaration of Conformity and Certificate of Compliance For further information please refer to the Pepperl Fuchs Wiring and Installation Guide Substantial amounts of voltage current and power are provided by the supply Read this manual carefully before installation and operation to avoid risk of damage failures or personal injury Take great care on input and output supply lines to protect from the effects of short circuits and provide the required ground connections Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs PEPPERL FUCHS USA 1 330 486 0002 Germany 49 621 7762222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS M PS3500 N 1 Redundant Power Supply 2 Instructions 2 1 Intended use The PS3500 product range may be installed in Zone 2 or Class l Division 2 hazardous areas Type of protection is Ex nA nC non arcing sealed device for Zone 2 Gas Groups and non incendive for use in Class Division 2 Warming Gas Groups A B C and D Please consult local electrical codes for hazardous locati
15. he terminal blocks on the backplane Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs FA PEPPERL FUCHS 11 USA 1 330 486 0002 Germany 49 621 776 2222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS PS3500 1 Redundant Power Supply 5 6 Internal diagnostics recovery and LEDs Overvoltage OV overcurrent OC and overheat OHT conditions lead to an output shutdown of the unit Also they create an alarm signal at the internal relay Undervoltage UV creates an alarm but does not shutdown the unit During shutdown mode the unit continuously checks for the actual failure condition to go away If that is the case the unit would go back to normal operation However this behavior must not impact the remaining running units in an N 1 redundant system There are three LEDs Power good green e Fault red e Alarm red Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs S PEPPERL FUCHS 12 USA 1 330 486 0002 Germany 49 621 776 2222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS M PS3500 N 1 Redundant Power Supply 6 Wiring The PS3500 system has separate input output terminal blocks for simple configuration Connect ground terminals to the mains ground otherwise lethal voltages STOP may occur Permanent power module damage will result in case of input voltage overload Warning 6 1 Special conditions of use 1 To be installed in an end use ATEX approved sys
16. ine checks Grounding conductor to be connected and firmly secured to the GND terminals 2 Input lines to be protected by appropriately sized fuses or sectioning circuit breakers turning them off 3 Line conductors to be of adequate size and firmly secured with no exposed conductors risking contacts with the backplane or short circuits 4 Supply line voltage to meet power module rating Check side label 8 2 Output line checks 1 Output polarity to be correct Severe damage to the powered equipment might result in case of reverse polarity powering 2 Output voltage value 24 V Check on side label of power modules 3 Output conductors to be of adequate size and firmly secured with no exposed risking contacts with the backplane or short circuits 4 Load sharing DIP switches configuration are set See section 6 4 8 3 Alarm lines checks 1 Alarm circuit to be correctly wired and conductors firmly secured with no exposed conductors risking contacts with the backplane or short circuits 2 Alarm DIP switches configuration set See section 6 4 8 4 Commissioning 1 Pull out all modules from the backplane 2 Disconnect load on the 24 V output bus and switch the input mains ON 3 Plug one of the PS3500 modules in slot 1 of the backplane and validate the output to be within the limits for a 24 V nominal output 23 6 V to 24 24 V Factory default for the modules is 24 V 1 If a different output voltage is required
17. lane Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs rd PEPPERL FUCHS USA 1 330 486 0002 Germany 49 621 7762222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS 3 PS3500 1 Redundant Power Supply 2 3 Mounting 2 3 1 Mounting PS3500 backplanes termination boards PS3500 TB The PS3500 backplanes are designed for protection class IP20 in accordance with EN 60529 and must be protected against adverse ambient conditions such as water or dirt ingress The backplane chassis is mounted on a flat metal sheet plate or on two properly spaced rails four 5 mm 0 2 DIA holes and tap them 6 MA or 1 4 NC Insert the top and bottom screws but leave a gap of approximately 5 mm 0 2 between the screw heads and mounting surface Slide the chassis through the keyed holes and hang it firmly on the screw heads Proceed to tighten all the screws 2 3 2 Mounting PS3500 PM 1 24 15 power modules The housing of PS3500 PM 1 24 15 meets the degree of protection class IP 20 It is intended for mounting on the PS3500 backplane PS3500 TB To install a new module on the backplane proceed as follows 1 Carefully center and mate the plug and connector on the back of the power module to the backplane then press firmly on the module 2 With a screwdriver screw in the top and bottom mounting screw on the power module to secure the module in the slot 3 The modules are hot swappable they can be replaced without shutting
18. necting capability and over current protection by adequately sized fuses or circuit breakers on the lines Circuit breakers or fusing shold be 20A or less connections to 6 poition backplane will require 2 breakers or fused sources feeding the backplane Group of 3 slots needs 20A breaker or less A single 40A breaker is not allowed Ground connection should be made first Input Terminals Strip length 8mm wire guage max 4mm sq 10AWG tightening torque 0 6 0 8Nm Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs PEPPERL FUCHS 1 USA 1 330 486 0002 Germany 49 621 776 2222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS 3 PS3500 1 Redundant Power Supply Output Terminals Strip length 12mm wire guage max 10mm sq GAWG tightening torque 1 2 1 5N Other Terminals strip length 7mm wire guage max 2 5mm sq 12AWG tightening torque 0 5 0 6Nm 6 3 Input configurations 6 3 1 Single line input Use with uninterruptible power systems UPS supply or when input line integrity is not critical wire per sketch in Figure 4 For DC input polarity does not matter Note Zi Each spur to the individual group of 3 power supplies needs its own 20 A breaker Figure 4 Single line input connection Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs 14 PEPPERL FUCHS USA
19. odifications www pepperl fuchs com Copyright Pepperl Fuchs fa PEPPERL FUCHS USA 1 330 486 0002 Germany 49 621 776 2222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS PS3500 1 Redundant Power Supply 6 5 Alarm configuration 6 5 1 Parallel alarm Connect in parallel as per Figure 9 the normally closed N C alarm contacts on all power modules and refer to Table 4 for parallel alarm DIP switch configuration When any specific relay on a module deenergizes under alarm condition including power off the circuit will close and actuate an alarm at terminals 1 2 of the alarm terminal block Pulling a power module out of the backplane will not actuate an alarm Power Module Alarm 1 2 3 4 5 6 86806060 share NC 1 2 3 NOTE Alarm relay 3 shown in alarm position Figure 9 Parallel alarm 6 5 2 Serial alarm Connect in series as per Figure 10 the normally open alarm contacts on all power modules and refer to Table 4 for serial alarm DIP switch configuration When any specific relay on a module de energizes under alarm condition the circuit will open and cause an alarm Removing a module will set off the alarm Any slot without a module will need to have DIP switch Sx 4 turned on Power Module Alarm 12 3 4 5 6
20. on installation guidelines NOTE This equipment is suitable for use in Class Division 2 Groups A B C D and Class Zone 2 Group or nonhazardous locations only The Declaration of Conformity Certificate of Compliance and data sheets are considered as an integral part of this user manual The data sheets contain the electrical data of the Declaration of Conformity and the Certificate of Compliance Laws and or regulations governing the use or intended use must be observed The PS3500 products are only approved for proper professional use in accordance with the intended purposes Improper handling will void any claim made under the warranty as well as any manufacturer s liability The PS3500 system can only be operated by trained professionals in accordance with this manual 2 2 Product label For proper identification and operation examine the system model number nameplate to identify the appropriate approvals area classification and type as noted in Figure 1 fal PEPPERL FUCHS Twinsburg OH 44087 USA www pepperl fuchs com PS 3500 PM 1 24 15 Part No 913919 Input 90 250VAC Output 22 5 30VDC 44 66Hz 15A 90 300VDC 6 5A max I13 G Ex nA nC IIC T4 Gc 12ATEX1103387X LISTED IECEx UL 13 0082X Class 1 Division 2 Certified to UL STD 508 Certified to ANSVISA STD 12 12 01 Groups A B C D T4 Certified to CSA STD C22 2 No 107 1 Class Zone 2 Certified to CSA STD C22 2 No 213 Groups T4
21. pply 12 Notes Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs PEPPERL ee FUCHS 24 USA 1 330 486 0002 Germany 49 621 776 2222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS PROCESS AUTOMATION PROTECTING YOUR PROCESS Worldwide German Headquarters Pepperl Fuchs GmbH Mannheim Germany Tel 49 621 776 2222 E Mail pa info de pepperl fuchs com Asia Pacific Headquarters Pepperl Fuchs PTE Ltd Singapore Company Registration No 199003130E Tel 65 6779 9091 E Mail pa info sg pepperl fuchs com www pepperl fuchs com Central Western Europe amp Africa Headquarters Pepperl Fuchs N V Schoten Antwerp Belgium Tel 32 3 6442500 E Mail pa info be pepperl fuchs com Middle East Headquarters Pepperl Fuchs M E FZE Dubai UAE Tel 971 4 883 8378 E Mail pa info ae pepperl fuchs com North Central America Headquarters Pepperl Fuchs Inc Twinsburg Ohio USA Tel 1 330 486 0002 E Mail pa info us pepperl fuchs com Northern Europe Headquarters Pepperl Fuchs GB Ldt Oldham England Tel 44 161 6336431 E Mail pa info gb pepperl fuchs com Southern Eastern Europe Headquarters Pepperl Fuchs Elcon srl Sulbiate Italy Tel 39 039 62921 E Mail pa info it pepperl fuchs com South America Headquarters Pepperl Fuchs Ltda Sao Bernado do Campo SP Brazil Tel 55 11 4341 8448 E Mail pa infoGbr pepperl fuchs com JPEPPERL4 FUCHS PROTECTING
22. ronments High conversion efficiency normally permits natural convection cooling operation eliminating cooling fans for most application requirements 3 1 Power supply module specifications Mechanical specifications Dimensions 134 mm x 62 mm x 268 mm 5 3 x 2 5 x 10 6 Voltage 90 250 V AC 10 90 300 V DC overvoltage category II Max 6 5A Up to 91 lt 50 A peak for 50 us gt 0 97 50 100 load Input current Efficiency Inrush current Power factor Voltage 24 V DC 1 adjustable between 22 5 30 V 15A Relay 50 V 0 6 A or 30 V 1 A DC 20A Temperature coefficient 0 01 per C max lt 100 mV 90 250 90 300 V DC 100 mV 0 15 A output load 200 ms to final value no over under shoot 35 MV ims lt 100 mV pp Min hold up time gt 25 ms at nominal input voltage amp output load Current Fault signal Short circuit current Input regulation Load regulation Turn on turn off voltage transient Ripple time Indicators settings Display elements LED Power green power on LED Fault red fault indication LED Alarm red module shut down Table 2 Power supply module specifications Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs rj PEPPERL FUCHS USA 1 330 486 0002 Germany 49 621 7762222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS 9 M PS3500 N 1 Redundant Power Supply 3 2 System specifications Electrical isolation
23. s be replaced Defective housing parts must be replaced by original parts only For detailed information please refer to the respective data sheet Tasks for eliminating malfunctions must be performed only by specialists who are specially trained and authorized for the task Contact customer service for an RMA return merchandise authorization Returns for repair should be sent to Pepperl Fuchs Inc 1600 Enterprise Pkwy Twinsburg OH 44087 2245 Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs 20 TT PIN PPS PE PPERL FUCHS USA 1 330 486 0002 Germany 49 621 7762222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS M PS3500 N 1 Redundant Power Supply 10 Troubleshooting Error condition Corrective action Low high output voltage Using a voltage meter Measure the output voltage to identify error type Measure input voltage to ensure the voltage range is within proper limits If output voltage is low measure output current to ensure that it does not exceed 15 A per module If modules are load sharing make sure DIP switches are configured properly and that each of the modules is supplying the same voltage If error persists module needs to be replaced Over voltage shutdown Identify faulty module using a voltage meter e Measure input voltage to ensure the voltage range is within the proper limit e Unplug the module and then plug back in e f error persi
24. sts module needs replaced Unequal load sharing Using a voltage meter Measure input voltage to ensure proper range Measure the output voltage of each module and if needed adjust voltage potentiometer on backplane so that each module supplies the same voltage If problem persists replace module Alarm LED illuminated Check module alarm configuration Ensure DIP switches are set properly for serial or parallel alarm Repeat first three steps above for previously mentioned error conditions If alarm persists replace module Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs FA PEPPERL FUCHS 24 USA 1 330 486 0002 Germany 49 621 7762222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS M PS3500 N 1 Redundant Power Supply 11 Special warnings 1 Warning Explosion hazard do not disconnect equipment unless power has been switched off or the area is known to be non hazardous STOP Avertissement Risque d explosion avant de d connecter Warning l equipement couper le courant ou s assurer que l emplacement est d sign non dangereux 2 Exposure to some chemicals may degrade the sealing properties of materials used in the following devices Panasonic DS series sealed relay The case is thermal setting PBT with an epoxy resin encapsulant Warning Substitution of the following components may impair suitability for Division 2 Reference designation RL1 Description Rel
25. tem providing fire impact grounding and accessibility protection The power supply must be installed in an ATEX Certified IP54 enclosure Alternatively the power can be installed in an IP4X enclosure having adequate protection against the entry of solid foreign objects or water capable of impairing safety 2 GND connection on backplane at Mains supply connections is a protective ground connection The wire guage should be at least the same as what is used for the mains power feed For any hazardous locations Class 2 Zone 2 the PS3500 system must be installed in a locked enclosure 4 Power supply must be secured to system using screws requiring tools for removal 5 For indoor use only not to be subjected to UV exposure from luminaires 6 Ambient ratings for operation are 25 45 C derated 0 4 A C from 45 70 C See Figure 3 temperature curve 7 The PS3500 system is designed for use in pollution degree 2 environments For use with Class 1 conductors or equivalent 9 For use with CU conductors or equivalent 10 Use 14 AWG conductors or equivalent 11 Use conductors rated 75 C minimum or equivalent 12 Alarm relay contacts are rated for 50 VDC or less and are intended to be powered by DC sources with proper isolation from MAINS 6 2 Input supply line Power line voltage is 90 250 V AC 10 90 300 V DC Check supply line voltage to meet power module supply requirements Plan for discon
26. within the 22 5 V to 28 V range adjust the potentiometer on the backplane to obtain the desired output 4 Repeat step 3 using the same module plugged in the backplane slot 2 3 etc and check the output voltage to be within the limits 5 Turn power off reconnect the load plug in and tighten all modules on the backplane with the fixing screws 6 Turn power ON Only the green LED should appear no alarms If any alarm is displayed check mains voltage module configuration and adjustment If problem remains refer to the troubleshooting section Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs rj SJPPEPPERL FUCHS 4 USA 1 330 486 0002 Germany 49 621 776 2222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS 9 PS3500 N 1 Redundant Power Supply 9 Maintenance amp Repair 1 Supply systems do not require special maintenance except normal periodic functional checks and cleaning 2 Keep power modules air inlets and outlets free from dust or particles that may prevent free air circulation through the cabinet and in the enclosure Accumulation of dust on heat dissipating surface limits heat exchange with the surrounding air reducing heat sinking capabilities 3 Periodically every year check and record the output voltage value to capture any long term deviation 4 PS3500 power supply products operated in conjunction with hazardous areas must not be modified If there is a defect the product must alway
27. y in the lower part of the diagram and free air circulation is ensured e Use forced cooling when the supply load operating temperature is in the upper part of the diagram for extended periods of time or when a very high system reliability is required PS3500 Temperature Derating Load Current A 0 5 15 25 35 45 55 65 70 Ambient Temperature C Figure 3 Recommended load current per module vs operating temperature 4 1 Convection cooling Hot components exchange heat with the surrounding air producing a vertically rising hot air flow This determines new cool air intake to cool the component in a natural convection cooling mode which is controlled by the intake air temperature and flow For good convection cooling install the equipment with an unobstructed vertical flow of relatively cool ambient temperature air entering from the bottom and flow out at a higher temperature from the top To avoid excessive temperature build up do not stack power dissipating devices vertically in close proximity Subject to modifications www pepperl fuchs com Copyright Pepperl Fuchs PEPPERL FUCHS USA 1 330 486 0002 Germany 49 621 7762222 Singapore 65 6779 9091 PROTECTING YOUR PROCESS 9 PS3500 1 Redundant Power Supply 4 2 Forced cooling Forced cooling is obtained by using suitable fans Fans generate a strong air flow that removes heat from the power generating equipment Use two PS3500 TB 3 or four PS3500 T
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