Rockwell Automation Trusted T823, Trusted T8232, Trusted T8233, Trusted T8234, Trusted T8235 Series Manual

PD-T823X Trusted

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.

Rockwell Automation Publication PD-T823X Issue 11

Trusted PD-T823X

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Rockwell Automation Publication PD-T823X Issue 11

Trusted Power System PREFACE

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

Rockwell Automation Publication PD-T823X Issue 11 i

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

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

ii Issue 11 Rockwell Automation Publication PD-T823X

Trusted Power System PREFACE

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.

Rockwell Automation Publication PD-T823X Issue 11 iii

PREFACE Trusted Power System

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.

iv Issue 11 Rockwell Automation Publication PD-T823X

Trusted Power System PREFACE

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

Rockwell Automation Publication PD-T823X Issue 11 v

PREFACE Trusted Power System

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vi Issue 11 Rockwell Automation Publication PD-T823X

Trusted Power System Table of Contents

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

Rockwell Automation Publication PD-T823X Issue 11 1

Table of Contents Trusted Power System

7. Power Shields ....................................................................................................... 29

8. Power Shelf Interconnect ...................................................................................... 31

9. Power System Specification ................................................................................... 33

2 Issue 11 Rockwell Automation Publication PD-T823X

Trusted Power System 1. Product Range

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

Table 1 T823X Power System Product Range

For connection to a Power Controller or for current
sharing.

Rockwell Automation Publication PD-T823X Issue 11 3

1. Product Range Trusted Power System

Figure 1 Front View - Power Shelf with Power Packs

Figure 2 Rear View - Power Shelf, Power Port (uncovered) and 4U Mounting Brackets

4 Issue 11 Rockwell Automation Publication PD-T823X

Trusted Power System 2. Assembly

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

Rockwell Automation Publication PD-T823X Issue 11 5

2. Assembly Trusted Power System

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.

6 Issue 11 Rockwell Automation Publication PD-T823X

Trusted Power System 3. Power Shelf Specification

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.

Rockwell Automation Publication PD-T823X Issue 11 7

3. Power Shelf Specification Trusted Power System

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

8 Issue 11 Rockwell Automation Publication PD-T823X

Trusted Power System 3. Power Shelf Specification

Pin Number Signal Name Description

10 On/Off_2 Remote on off control for the second Power Pack - Not Used

11 V

Not Used

aux

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 V

return

aux

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.

Rockwell Automation Publication PD-T823X Issue 11 9

3. Power Shelf Specification Trusted Power System

Figure 5 Interface Connector

10 Issue 11 Rockwell Automation Publication PD-T823X

Trusted Power System 3. Power Shelf Specification

3.5. Stacked-up Assembly

Figure 6 4U Stacked-up Assembly

Rockwell Automation Publication PD-T823X Issue 11 11

3. Power Shelf Specification Trusted Power System

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12 Issue 11 Rockwell Automation Publication PD-T823X

Trusted Power System 4. Power Pack Specifications

4. Power Pack Specifications

The Power Pack is specifically designed to operate as an integral part of a complete
distributed Power System.

A full complement of protection, alarm and control features has been incorporated into the
Power Pack to provide versatility for use in many applications.

Power Packs can be inserted and removed when live, allowing ‘hot-swap’ of Power Packs
(see section 4.7). They are secured using a physical latch on the front of the Power Pack
which is pushed up to release or connect the Power Pack into the Power Shelf.

Figure 7 Power Pack Outline Drawing. Dimensions mm (inches)

4.1. Power Pack Features

4.1.1. Indicators

The Power Pack has two indicators on the front:

• AC OK: The LED is green if the input voltage is within limits.

• PWR OK: The LED is green if the Power Pack is healthy and within operating limits. If

a fault occurs with the power supply or a fan, the LED is amber.

Rockwell Automation Publication PD-T823X Issue 11 13

4. Power Pack Specifications Trusted Power System

Failure of an internal Power Pack fan results in shutdown of the output of the Power Pack.

4.1.2. Overcurrent Protection

The over-current protection limits the output current in the event of an overload. There are
two overload circumstances:

• If the load is increased steadily a single Power Pack compensates by derating the

voltage, hence at 40 A (the specification limit) the voltage is derated to 18.75 V. This
derated voltage is on the limit of the Trusted System Modules’ specification.

• Note: This gradual increase is not typical of a system fault.

• If 24 V is maintained over a rapid current rise, the over-current protection will trip

the power supply when 35 A is reached. This rapid increase is more typical of a fault
situation in a system.

4.1.3. MCB Discrimination

Miniature circuit breaker (MCB) discrimination studies should be carried out when designing
the system power distribution.

Power Unit(s) Overload Current Vs Time

300

250

200

150

Time / ms

100

50

0

0 20 40 60 80 100 120 140

Current / Amps

1 Power
Unit
2 Power
Units

Figure 8 Power pack (s) Severe Overload Current v Time

14 Issue 11 Rockwell Automation Publication PD-T823X

Trusted Power System 4. Power Pack Specifications

The graph shows the response of a single Power Module to severe overloads. As the load is
increased the power supply protection mechanism operates and shuts down the output. It
can be seen that for a period of just in excess of 200 ms the Power Module can provide
currents up to 115 A or 380 % of its stated maximum(115/31 = 3.8). This 200 ms/380 % can
be extrapolated for additional power supplies in order to perform MCB discrimination
studies.

4.2. Input Specification

Parameter Min Type Max Unit Condition

Input Voltage 90 264 Vac

Input Frequency 47 63 Hz

Inrush Current (peak) per Pack 50

<25

Input current 0.2 A No load

Power Factor 0.95 0.99 > 50 % of full load

Input Leakage Current 1.7 mA 264 Vac, 50Hz

Lighting Surge and Transients
(damage free operation)

Hold Up Time 20 ms At 600 W

EMC (conducted) CISPR22 Class B,

IEC 61000-4-5 Level 3

Table 3 Input Specification

A A Full load

No load

IEC 61000-4-4 Level 3

EN 55022 Class B, with 3dB
margin

4.3. Line Harmonics

Active power factor correction circuitry ensures that this Power Pack meets the
requirements of IEC 61000-3-2.

Rockwell Automation Publication PD-T823X Issue 11 15

4. Power Pack Specifications Trusted Power System

4.4. Efficiency and Power Factor vs. Input Voltage at Full Load

Input voltage Efficiency (Typical) Power Factor (Typical)

90 Vac 78 % 0.99

100 Vac 79 % 0.99

110 Vac 80 % 0.99

120 Vac 81 % 0.98

180 Vac 82 % 0.98

220 Vac 83 % 0.98

240 Vac 83 % 0.98

264 Vac 84 % 0.98

Table 4 Efficiency and Power Factor vs. Input Voltage at Full Load

When using this table to calculate cable feed requirements, allow, at a minimum, an extra
3 % for variations between units. Actual measured results will depend upon the harmonic
content of the input voltage waveform.

4.5. Output Specification

Parameter Min Type Max Unit Note

V

Set Point:

OUT

T8231 24 Vdc

T8232 28 Vdc

Regulation (line, load,
temperature and set point)

-2 2 % Measured at remote sense

Remote-sense Drop 0.5 Vdc

I

(rated):

OUT

T8231 (24 V

T8232 (28 V

) 0 31.25 Adc 750 W maximum

OUT

) 0 26.78

OUT

Ripple (20 MHz bandwidth) 150 mVp-p

16 Issue 11 Rockwell Automation Publication PD-T823X

Trusted Power System 4. Power Pack Specifications

% step load transient with slew

Active Current Sharing Differential

Parameter Min Type Max Unit Note

Noise (20 MHz bandwidth) 300 mVp-p Under any load conditions

Transmission Noise (C message) 45 dBmc

Output Rise Time 10 100 ms Rise from 10 % to 90 % of final

output level (resistive load)

Over-voltage Protection 29 32 Vdc Reset by cycling AC input, on/off,

or reinsertion

Output Current Limit (steady

40A Adc

state)

Transient Response
Voltage Range

-2 2 % 25
rate 0.1 A/us within the range
from 25 % to 75 % of full load

±3.2 A Single wire current share at full

load

Efficiency

At full load, 120 Vac with

80 81 %

ORing diode

At full load, 264 Vac with

83.5 84 %

ORing diode

Reserve Output Current

ORing diode

Protection

Start-up Delay 1.3 2 S Measured from application of

valid AC voltage

Turn-on Delay 250 ms Measured from DC on/off

Rockwell Automation Publication PD-T823X Issue 11 17

Table 5 Output Specification

4. Power Pack Specifications Trusted Power System

4.6. Environmental Characteristics

Parameter Min Type Max Unit Note

Storage Temperature -40 -85 °C

Operating
Temperature

0 - 60 °C 1. Derate at 1.333 %/°C, 45 °C to 50 °C

2. Derate at 4.667 %/°C, 50 °C to 60 °C

(note 1)

Acoustics 47 52 dBa Sound Pressure Level at 1 m

Relative Humidity

10 95 %

(non-condensing)

Altitude -60 3962 m Derated at 2 °C/304 m above 2438 m

Electro Static

IEC 61000-4-2 Level 3 stand-alone

Discharge

Electromagnetic

IEC 61000-4-3 Level 2 stand-alone

Immunity (error free)

Isolation Voltage 3000

1500

1500

Vac

Vac

Vac

Primary to Secondary

Primary to chassis GND,

Secondary to chassis GND

MTBF 4 x 105 hours @110 Vinput 80 % load, TA = 30oC

Vibration Meet IEC 60068-2-6

Shock Meet IEC 60068-2-27

Weight 2.3 kg

Table 6 Environmental Characteristics

18 Issue 11 Rockwell Automation Publication PD-T823X

Trusted Power System 4. Power Pack Specifications

Figure 9 Operation Derating Curve

Rockwell Automation Publication PD-T823X Issue 11 19

4. Power Pack Specifications Trusted Power System

4.7. Power Pack Hot Replacement

1. Plug in slowly and smoothly.

2. Make sure the first set of pins are contacted – the AC OK LED will illuminate.

3. Push fully home - the PWR OK LED will illuminate.

Figure 10 Power Pack Hot Replacement

20 Issue 11 Rockwell Automation Publication PD-T823X

Trusted Power System 5. Power Port

Con 1

Con 2

Con 3

5. Power Port

5.1. General Description

The Power Port is a supplied accessory and is fitted onto the rear of the Power Shelf. It
converts alarm signals produced by the Power Packs and Power Shelf into volt-free alarm
contacts for use by the system and enables hot replacement of Power Packs. It consists of a
PCB fitted with connectors, relays and miscellaneous electronic components. The shape and
size of the Power Port is shown in Figure 11.

Figure 11 Power Port Outline Drawing

The alarm contacts are made available on a connector for ease of wiring into the system.
The system provides a supply for the Power Port, which is wired to the same connector. The
connector pin-outs are shown in section 5.3.

The Power Shelf is fitted with a 25 way D female connector to which the Power Port
connects. The Power Port is retained to the Power Shelf by means of the Dsub jack screws.
The Power Port is fitted with a 25 way D female connector to allow the Power Shelf

Rockwell Automation Publication PD-T823X Issue 11 21

5. Power Port Trusted Power System

connectivity to be extended to a Power Controller using a Power Shelf Interconnect ribbon
cable.

The Power Controller is powered from the Power Port 24 V supply via pin 7, when
connecting CON 2 on the Power Port to the Power Controller.

5.2. Circuit Description

The circuit is split into four functional sections: supply, DC alarms, AC alarms and jumpers.

5.2.1. Supply

The 24 V supply is connected to CON3 pins 1 and 6. The supply should be fused close to its
source, using a 500 mA F rated fuse. It is nevertheless protected by a non-replaceable fuse
on the Power Port. The 24 V is regulated down to 5 V with decoupling provided. The 5 V+ is
used to supply the low voltage electronics. The 24 V is used to supply the relays and is
connected through CON2 to power the optional Power Controller.

5.2.2. DC Alarms

CON1 is the 25 way D male interface to the Power Shelf. The Power Pack and Power Shelf
alarm outputs are derived from here. There are two DC alarms per Power Pack: DCFAIL (dc
output fail) and OTP (over-temperature protection). The Power Port ORs together DCFAIL
and OTP to give one DC fail alarm, via CON 3. If either alarm triggers, the corresponding
relay de-energises.

Each relay operates a volt-free contact. These are closed when healthy (relay energised) and
open in alarm. The contacts share a common return line.

5.2.3. AC Alarms

In a similar manner, each Power Pack generates an AC alarm. When an alarm is triggered,
the corresponding relay de-energises. Each relay operates a volt-free contact. These are
closed when healthy (relay energised) and open in alarm. The contacts share a common
return line.

22 Issue 11 Rockwell Automation Publication PD-T823X

Trusted Power System 5. Power Port

Fault Condition Output OK LED OTP Alarm AC Fail Alarm DC Fail Alarm DC Output

No fault Green Low Closed Closed ON

Fan locked rotor Amber Low Closed Closed OFF

Secondary over

Amber High Closed Open OFF

temperature

Primary over

Off High Closed Open OFF

temperature

AC Feeder fail Off Low Open Open OFF

Table 7 Alarm Conditions

5.2.4. Jumpers

There are three jumpers, J1, J2 and J3.

J1 and J2 set the Power Shelf address lines for the I2C control bus. With J1 and J2 fitted the
Pack addresses are 1, 2 and 3, which is the default. Other addresses may be set by removing
one or both of J1 and J2, up to 4 Shelves worth (or 12 Power Packs).

Power Shelf J1 J2

1 fitted fitted

2 fitted removed

3 removed fitted

4 removed removed

Table 8 Power Shelf Addressing

J3 connects together the common return lines of the DC alarms and AC alarms. J3 is fitted by
default.

Rockwell Automation Publication PD-T823X Issue 11 23

5. Power Port Trusted Power System

5.3. Mechanical

5.3.1. Pin-out CON 1, CON 2

CON 1 on the Power Port connects to the Power Shelf. The pin-out details are shown in
Table 2.

CON 2 is used to connect to other Power Shelves to current share or to connect to a Power
Controller.

Pin Number Signal Name Description

1

2

3

4 ON SYNC Not Used

5 SDA I2C Serial data bus

6 SCL I2C Clock

7 24v Supply from Power port

8

9

10

11

12

13

14

15

16 INT BUS Not Used

17

18

19 SRTN Signal return and V

24 Issue 11 Rockwell Automation Publication PD-T823X

return

aux

Trusted Power System 5. Power Port

Pin Number Signal Name Description

20 RS- Remote sense for V-

21

22 RS+ Remote sense for V+

23

24 CS Current Sharing

25 V- V-

Table 9 Connected Pins on CON 2

5.3.2. Pin-out CON 3

Pin Description

1 +24 V system supply

2 DCFAIL common

3 DCFAIL_3

4 DCFAIL_2

5 DCFAIL_1

6 0 V system supply return

7 ACFAIL_1

8 ACFAIL_2

9 ACFAIL_3

10 AC Fail common

Table 10 Connector 3 Pin-out

CON 3 provides volt-free alarm contacts as detailed in section 5.2.2 and 0 for use by the
system and these are made available on a connector for ease of wiring into the system.

Rockwell Automation Publication PD-T823X Issue 11 25

5. Power Port Trusted Power System

5.3.3. Fault Relay Technical Specifications

Contact Form SPDT

Resistive Load

at 125 Vac 0.5 A

at 24 Vdc 1 A

Max Switching Power 62.5 VA, 30 W

Rated Voltage 3 Vdc to 24 Vdc

Power Consumption 150 mW

Mechanical Endurance 5,000,000 operations minimum

Electrical Endurance 100,000 operations minimum

Operating Temperature -40 °C to +70 °C (-40 °F to +158 °F)

26 Issue 11 Rockwell Automation Publication PD-T823X

Trusted Power System 6. Power Controller

6. Power Controller

The Power Controller is designed to control and monitor the 19 inch rack mount 1U high
Power Shelf Units. It is used to address each Power Pack in turn and adjust the respective
Power Pack voltage.

The Power Controller is a digital system and communicates with the Power Packs by means
of a TC-323 Power Shelf Interconnect ribbon cable, via the Power Port. The shelf addresses
are set using jumpers on the Power Port, as described in paragraph 5.2.4.

The Power Controller offers adjustment of the system voltage in 100 mV steps over the
range 24-28 V for the Power Packs. Power supplies share through their analogue control
circuitry. A Power Controller will ensure that a power supply, regardless of its voltage setting
when plugged in, is adjusted (via the I2C serial data bus) to be within the current/voltage
sharing window of the power supply’s analogue control circuitry.

The front panel contains two switches. The Address switch is used to select a Power Pack.
The Voltage switch is used to raise or lower the voltage of that Power Pack. The two displays
show the current and voltage of that Power Pack.

Up to 12 hot swap Power Packs can be used in parallel. The Power Controller can be used to
select a particular Power Pack’s position and read the current being drawn from that unit
with a resolution of 100 mA.

Note that the Power Controller should not be connected to power supplies on different
busbars with the TC-323 cable, because it will attempt to perform load sharing between
unconnected power supplies. It may also be presented with power supplies having duplicate
addresses on its I2C bus.

Unused connectors on the TC-323 cable should be tied back and left unused.

Rockwell Automation Publication PD-T823X Issue 11 27

6. Power Controller Trusted Power System

Figure 12 Power Controller Outline Drawing

6.1. Power Up Sequence

When a Power Controller is connected to more than one Power Shelf, Power Shelves should
have their supplies applied in turn, e.g. power up first Shelf (idents 1-3), followed by Shelf
two (idents 4-6) etc. This ensures that the Power Pack addresses are not duplicated.

28 Issue 11 Rockwell Automation Publication PD-T823X

Trusted Power System 7. Power Shields

7. Power Shields

If a Power Shelf is not fully populated, Power Shields are used to cover unused spare slots.

Rockwell Automation Publication PD-T823X Issue 11 29

7. Power Shields Trusted Power System

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30 Issue 11 Rockwell Automation Publication PD-T823X

Trusted Power System 8. Power Shelf Interconnect

8. Power Shelf Interconnect

A ribbon cable is required to connect Power Shelves together in order to current share, or to
connect shelves to a Power Controller.

The supplied ribbon cable has 5 connectors, to allow the maximum of 4 Shelves and a Power
Controller to be connected.

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.

Rockwell Automation Publication PD-T823X Issue 11 31

8. Power Shelf Interconnect Trusted Power System

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32 Issue 11 Rockwell Automation Publication PD-T823X

Trusted Power System 9. Power System Specification

9. Power System Specification

Voltage Range

Input 90 Vac to 264 Vac

Output 24 Vdc to 28 Vdc

Frequency Range 47 Hz to 63 Hz

Inrush Current 50 A Max per Pack

Power Factor 0.95 min, 0.99 typical

Efficiency 78 % – 84 %

Output Power 750 W per Power Pack

Power Hold-up Time 20 ms

Operating Temperature 0 °C to +60 °C (+32 °F to +140 °F)

Relative Humidity range
(operating, storage & transport)

10 % – 95 %, non-condensing

Environmental Specifications Refer to Document 552517

Power Shelf Dimensions

Height: 43 mm (1.71 in)

Width: 483 mm (19 in)

Depth: 340 mm (13.36 in)

Weight Data

T8231,T8232 Power Pack 2.7 kg

T8230 Shelf (without supports) 4.4 kg

UL Approvals

Power Supplies, Information Technology

E223750
Equipment Including Electrical Business
Equipment - Component

Power Supplies, Medical and Dental -

E223749
Component

Rockwell Automation Publication PD-T823X Issue 11 33