PSD1220 and PSD1220-098
INSTRUCTION MANUAL
SIL 3 Power Supply PSD1220 and PSD1220-098
24Vdc, 20 A, Zone 2
DIN Rail Mounting
G.M. International s.r.l.
20852 Villasanta MB Italy
PSD1220 & PSD1220-098 - SIL 3 Power Supply, 24Vdc, 20 A, Zone 2, DIN Rail Mounting G.M. International ISM0370-3
Index
SIL 3 Power Supply PSD1220 and PSD1220-098 24Vdc, 20 A, Zone 2, DIN Rail Mounting
General Characteristics ................................................................................................................................................................. 2
Ordering Information ..................................................................................................................................................................... 2
Features ........................................................................................................................................................................................ 2
Technical Data .............................................................................................................................................................................. 3
Active Ideal Diode-OR circuit - Output voltage setting, Fault indications ..................................................................................... 4
Warning ......................................................................................................................................................................................... 4
Storage .......................................................................................................................................................................................... 4
Disposal......................................................................................................................................................................................... 4
Functional Diagram for PSD1220 .................................................................................................................................................. 5
Functional Diagram for PSD1220-098 .......................................................................................................................................... 6
Installation Procedure - 1st step ................................................................................................................................................... 7
Installation Procedure - 2nd step (only for single PSD1220 or PSD1220-098 unit) ...................................................................... 9
Installation Procedure - 2nd step (only for PSD1220 or PSD1220-098 units in parallel/redundant configuration) - Section A ... 10
- Section B ... 11
General characteristics
General Description:
The Power Supply types PSD1220 and PSD1220-098 are anodized aluminum unit.
The Power Supply provides 24Vdc, 20 A output. PSD1220 or PSD1220-098 unit can be paralleled, with load sharing circuits, which distribute current load equally to each power supply
to increase reliability and reduce internal power dissipation.
The Power Supply accepts AC power input sources with nominal voltage range 110 to 240 Vrms (± 10%). Therefore lower limit is 100 Vrms and upper limit is 264 Vrms.
The PSD1220-098 unit has got the same AC, DC, Fault and Current Sharing connectors used in the PSD1210 power supply module, for easy model to model replacement.
Overvoltage protection:
3 independent overvoltage protections:
1 voltage limiting loop at 28.5 Vdc and 1+1 crowbars at 29 Vdc.
High load fuses breaking capability:
In case of short circuit on the load, the Power supply system delivers a very high peak current (about 500 Amp) for a duration of 0.5 ms.
This characteristic ensures the instant breakage of the protective fuse or circuit breaker. Because of the very short peak current duration, other equipment connected to the load are not
affected by the failure event and continue to operate without interruption.
Functional Safety Management Certification:
G.M. International is certified by TUV to conform to IEC61508:2010
part 1 clauses 5-6 for safety related systems up to and included SIL3.
FSM
SIL 3
Ordering Information
Model: PSD1220
Model: PSD1220-098
Features
SIL 3 for NE Load according IEC 61508:2010, with one PSD1220 / PSD1220-098 module or more PSD1220 / PSD1220-098 modules in redundant configuration
(see ISM0371 for more information).
SIL 2 / SIL3 for ND Load according IEC 61508:2010, with two or more PSD1220 / PSD1220-098 modules in redundant configuration (see ISM0371 for more
information).
Systematic capability SIL 3.
Power factor correction.
PSD1220-098 has the same AC, DC, Fault and Current Sharing connectors used in PSD1210 power supply module, for easy model to model replacement.
Installation in Zone 2.
EMC Compatibility to EN61000-6-2, EN61000-6-4.
ATEX, IECEx, TÜV Certifications.
TÜV Functional Safety Certification.
Type Approval Certificate DNV for maritime applications (pending).
Highly regulated output of 24 Vdc, 20 A.
Under and over voltage alarm monitoring.
3 over voltage redundant protections.
Redundant parallel connections with load sharing.
Reduces Power dissipation (in parallel/redundant configuration) by replacing a Schottky diode with Mosfet Active Ideal Diode.
Better than 93% efficiency @230 Vac input, full load and full output voltage range.
High load fuse breaking capability without interrupting operations.
Conformal coated on all boards for durability and protection.
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PSD1220 & PSD1220-098 - SIL 3 Power Supply, 24Vdc, 20 A, Zone 2, DIN Rail Mounting G.M. International ISM0370-3
Technical Data
Supply:
AC Input voltage: nominal 110 to 240 Vrms (±10 %), with frequency range 48 to 62 Hz.
Power Factor Correction (AC input, full load): 0.97 typ.@230Vac, 0.995 typ.@115Vac
Efficiency (full load, full Vout range): better than 93% @230Vac and 91% @115Vac.
Efficiency (50% full load, full Vout range): better than 91% @230Vac, 90% @115Vac.
Max. internal power dissipation (full load, 24 Vout): 35W @230Vac, 43W @115Vac.
Max. internal power dissipation (50% full load): 24W @230Vac, 28W @115Vac.
Max. AC input current (sinusoidal at full load): 4.8A @ 100Vac & full Vout range; 4.4A @ 110Vac & full Vout range; 2.2A (24Vout), 2.3A (25Vout), 2.4A (26Vout) @ 240Vac.
Inrush current: 15.7 Apeak @ 264Vac, 13 Apeak @ 230Vac, 5.2 Apeak @ 115Vac.
AC connection (for PSD1220): push-in spring connection terminal block suitable for 6mm
AC connection (for PSD1220-098): plug-in screw connection terminal block suitable for 4mm
Isolation:
Input to Output isolation: 2500 Vrms (routine test).
Input to Ground isolation: 1500 Vrms (routine test).
Ground to Output isolation: 500 Vrms (routine test).
Output or Ground to Fault contact isolation: 500 Vrms (routine test).
Output:
Voltage: 24 Vdc factory setting (adjustable range 23.6÷26.1 Vdc by front panel trimmer).
Regulation: 0.4% for a 100 % load change.
Stability: 0.03 % for a 20 % input line voltage change.
Max. Ripple: ≤ 300 mVpp.
Output current: 20 A (on full output voltage range and 230 Vac input). Parallel connection for redundancy with load sharing capability within ±2.5 % of output voltage setting.
Output current limitation: 22A @ 24Vout, 21A @ 25 & 26 Vout. Protected to short circuit.
Output power: up to 520 W @ 26 Vdc output and 230 Vac input.
Max. Output Rise Time (after AC Input supplying): ≤ 2.4 sec.
Dynamic Response: 1.5 ms for 10-90% load change (overshoot ±2% of Vout setting).
DC connection (for PSD1220): push-in spring connection terminal block suitable for 6mm
DC connection (for PSD1220-098): plug-in screw connection terminal block suitable for 4mm
Hold-up time at full load: 20 msec (AC input).
Overheat protection: double overheat protection on the 1st and 2nd internal stages.
Over voltage protection: output limited to 28.5 Vdc plus two redundant crowbars for over voltage protection at 29 Vdc.
Power good signaling:
Output good: 22 V ≤ Vout ≤ 28 V (see page 4 for more information).
Signaling: voltage free SPST normally energized relay (contact closed), de-energize in over/under voltage conditions (contact open).
Contact Rating: 2 A 50 Vac 100 VA, 2 A 24 Vdc 48 W (resistive load).
Connection (for PSD1220): push-in spring connection terminal block suitable for 1.5mm
Connection (for PSD1220-098): plug-in screw connection terminal block suitable for 2.5mm
Compatibility:
CE mark compliant, conforms to Directive:
2014/34/EU ATEX, 2014/30/EU EMC, 2014/35/EU LVD, 2011/65/EU RoHS.
Environmental conditions:
Operating temperature limits: -40 to +60°C de-rated linearly 75-80% load above 50°C; see Output Current & Power vs. Ambient Operating Temperature diagrams on this page.
Relative humidity limits: 95 %, up to 55°C.
Transport, storage temperature limits: - 45 to + 85 °C. Max altitude: 2000 m a.s.l.
Safety Description:
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ATEX: II 3G Ex ec nC ic IIC T4 Gc.
IECEx: Ex ec nC ic IIC T4 Gc.
Approvals
BVS 18 ATEX E 004 X conforms to EN60079-0, EN60079-7, EN60079-11, EN60079-15.
IECEx BVS 18.0004X conforms to IEC60079-0, IEC60079-7, IEC60079-11, IEC60079-15.
TUV Certificate No. C-IS-272994-01 SIL 3 / SIL 2 conforms to IEC61508:2010 Ed. 2.
TÜV Certificate No. C-IS-236198-09, SIL 3 Functional Safety Certificate conforms to IEC61508:2010 Ed.2, for Management of Functional Safety.
Mechanical:
Mounting: EN/IEC60715 TH 35 DIN-Rail, into a cabinet.
Weight: 1.8 Kg (2 Kg with packaging).
Location: Safe Area or Zone 2, Group IIC T4 installation.
Protection class: IP 20, Open Type.
Dimensions: see drawings page 7.
Maximum Output Current & Power vs. Ambient Operating Temperature
PSD1220 & PSD1220-098 - SIL 3 Power Supply, 24Vdc, 20 A, Zone 2, DIN Rail Mounting G.M. International ISM0370-3
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Reasons for using an Ideal Diode-OR Controller circuit, in N+1 redundant power supply applications with high availability systems
High availability systems often employ power supply modules connected in parallel to achieve redundancy and enhance system reliability.
ORing diodes have been a popular means of connecting these supplies at a point of load. The disadvantage of this approach is the forward voltage drop and resulting efficiency loss.
This drop reduces the available supply voltage and dissipates significant power.
Replacing Schottky diodes with N-channel MOSFETs reduces power dissipation and eliminates the need for expensive heat sinks or large thermal layouts in high power applications.
In the Ideal Diode-OR Controller circuit (active ideal diode), the voltage across source and drain is monitored by the IN and OUT pins, and GATE pin drives the MOSFETs to control
their operation. In effect the MOSFET source and drain serve as the anode and cathode of an ideal diode.
In the event of a power supply failure, for example if the output of a fully loaded supply is suddenly shorted to ground, reverse current temporarily flows through the MOSFETs that are
ON. This current is sourced from any load capacitance and from the other supplies. The active ideal diode quickly responds to this condition turning off the MOSFETs in about 0.5µs,
thus minimizing disturbance and oscillations to the output bus.
Using ORing diodes, to parallel two, or more, 24VDC power supply modules for redundancy, one Schottky diode is used for each module. The voltage drop across the diode can reach
about 0.8 V at 20 A, this means about 16 W dissipation for each module. Then, if two 20 A paralleled modules are used for full 20 + 20 A redundancy, a total power of about 32 W is
dissipated for this purpose. This reduces efficiency, reliability and increases space for heat sinks. Moreover, in case of module failure, diodes take time to recover and consequently
they do not preserve the load from transients during the backup operation.
To avoid all these problems G.M. International has introduced, in the new PSD1220 or PSD1220-098 Power Supply System, the use of active ideal diodes.
The MOSFETs resistance for active ideal diodes is about 1 mΩ resulting in 0.4 W dissipation for each power module. Then, if two 20 A paralleled modules are used for full
20 + 20 Amp redundancy, a total power of about 0.8 W is dissipated for the purpose resulting in about forty times less dissipation compared to Schottky diodes solution.
This increases efficiency, reliability, availability and reduces space for heat sinks.
This circuit provides also very smooth voltage switchovers without oscillations with fast turnoff, minimizing reverse current transients.
Output voltage setting - Fault indications
The output voltage can be set from 23.6 to 26.1 Vdc by a front panel trimmer.
Under voltage threshold is set to 22 V, while Over voltage threshold is set to 28 V.
A front panel power ON green LED signals that mains voltage is applied to the power module and normal DC output voltage is present on DC output terminal block.
Power module Fault conditions are signaled by opening contact of NE relay (in normal condition contact is closed) on the “Fault” terminal block. Faults can be:
Under voltage Vout < 22 V.
Over voltage Vout > 28 V.
In absence of under / over voltage fault, the green Power ON LED is ON if output voltage is within 22 V - 28 V range
If output voltage goes below 22 V, the green Power ON LED blinks and remains steady for values lower than 22.5 V.
If output voltage goes over 28 V, the green Power ON LED is OFF and remains steady for values higher than 27.5 V.
After under / over voltage fault, coming back to normal condition, the green Power ON LED is ON if output voltage is within 22.5 V - 27.5 V range.
Warning
PSD1220 and PSD1220-098 are isolated Switching Power Supply units located in Safe Area or Zone 2, Gas Group IIC, Temperature T4 Hazardous Area within the specified
operating temperature limits -40°C ≤ Tamb ≤ +60°C and mounting conditions.
Read installation manual before operating the unit. Failure of proper installation or use of the equipment may damage the unit or cause severe personal injury.
PSD1220 and PSD1220-098 must be installed, wired, operated and maintained only by qualified personnel, in accordance to the relevant national/international installation
standards (e.g. IEC/EN60079-14 Explosive atmospheres - Part 14: Electrical installations design, selection and erection), following established installation guide lines.
PSD1220 and PSD1220-098 must be placed in an enclosure with IP4X protection degree when used in locations providing adequate protection against the entry of solid foreign
objects or water, capable of impairing safety, or be placed in an enclosure with IP54 protection degree for other locations. Substitution of components may impair suitability for
Zone 2.
Explosion Hazard: to prevent ignition of flammable or combustible atmospheres, disconnect power and wait that green power-on LED is OFF before servicing or unless area is
known to be nonhazardous. Remove power before opening the case.
Clean only with dry cloth.
Green Power ON LED of power supply unit: check that green LED is OFF before disconnecting power supply.
Failure to properly installation or use of the equipment may risk to damage the unit or severe personal injury. The unit cannot be repaired by the end user and must be returned
to the manufacturer or his authorized representative. Any unauthorized modification must be avoided.
Storage
If after an incoming inspection the unit is not installed directly on a system (parts for spare or expansion with long storage periods) it must be conveniently stocked.
Stocking area characteristics must comply with the following parameters:
Temperature -40 to +70 °C, the -45 to +80 °C is meant for limited periods, -10 to +30 °C is preferred.
Humidity 0 to 95 %, 0 to 60 % humidity is preferred.
Vibration: no prolonged vibration should be perceivable in the stocking area to avoid loosening of parts or fatigue ruptures of components terminals.
Pollution: presence of pollutant or corrosive gases or vapors must be avoided to prevent corrosion of conductors and degradation of insulating surfaces.
Disposal
The product should not be disposed with other wastes at the end of its working life. It may content hazardous substances for the health and the environment, to prevent possible harm
from uncontrolled waste disposal, please separate this equipment from other types of wastes and recycle it responsibly to promote the sustainable reuse of material resources.
This product should not be mixed with other commercial wastes for disposal.
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PSD1220 & PSD1220-098 - SIL 3 Power Supply, 24Vdc, 20 A, Zone 2, DIN Rail Mounting G.M. International ISM0370-3
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