FOXBORO P0916KN power module

FOXBORO P0916KN power module

Product Overview

The FOXBORO P0916KN module is a core power supply component developed by FOXBORO for the I/A Series distributed control system in the United States. As the "energy center" for stable system operation, it undertakes the key task of converting industrial grade AC input into high-precision DC output, providing continuous and reliable power support for core equipment such as I/O modules, controllers, and communication modules in the system. This module deeply meets the demanding requirements of industrial automation scenarios, with core advantages such as dual redundancy, wide input, and intelligent monitoring. It can maintain stable output under complex working conditions such as voltage fluctuations and electromagnetic interference, and provide strong power supply guarantee for the continuous production of key industries such as petrochemicals and power energy.

As a dedicated power module for the I/A Series system, P0916KN continues the brand's design genes of high reliability and stability. Compared with other power modules in the same series (such as P0916HN and P0916MN), it is more competitive in output accuracy, redundant switching speed, and load adaptation range. It can flexibly match the power supply needs of control systems of different scales and is the core component for achieving centralized power management and security in distributed control systems.

Specification parameters

Module Type

Industrial grade DC switching power module, supporting dual redundant parallel connection

Input specifications

Communication 100-240V (wide input), frequency 50/60Hz ± 5%, input current ≤ 8A

Output specifications

DC 24V precise output, output current 0-20A, output power 480W; output voltage adjustment range 23.5-24.5V

output accuracy

Load adjustment rate ≤ ± 0.1%, voltage ripple ≤ 50mVp-p, linear adjustment rate ≤ ± 0.05%

Redundancy feature

Support N+1 redundant configuration, automatic current sharing when dual modules are connected in parallel, with a current sharing error of ≤± 2%; Fault switching time ≤ 10ms

working environment

Temperature: -20 ℃~+75 ℃; Relative humidity: 10%~90% (no condensation); Protection level: IP20 (module body)

protection function

Overcurrent protection (action current 22-25A, automatic recovery), overvoltage protection (26-27V), short circuit protection, over temperature protection (85 ℃± 5 ℃)

communication interface

FOXBORO proprietary bus+RS485 interface, supporting communication with system controller and upper computer, transmitting power supply status data

Overall dimensions

170mm (length) x 105mm (width) x 32mm (height), compatible with standard 35mm DIN rail installation

certification standard

Complies with IEC 61010-1 and UL 60950-1 standards, and has passed CE and ATEX explosion-proof certifications (Ex II 2G Ex d IIB T6)

Performance characteristics

-High stability output characteristics: Adopting a full bridge LLC resonant topology structure and high-precision feedback regulation chip, combined with digital PID control algorithm, the output voltage fluctuation is ≤ ± 0.1% when the load changes. The low ripple characteristic of 50mVp-p can effectively avoid interference with sensitive electronic components and ensure the signal processing accuracy of the I/O module.

-Dual redundancy guarantee: Supports dual module hot swappable redundant parallel connection, with built-in intelligent current sharing circuit to ensure load current sharing. When the main power module fails, the backup module seamlessly switches within 10ms without voltage fluctuations, meeting the "zero interruption" power supply requirements of critical industrial systems.

-Wide range adaptation and strong protection: 100-240V wide AC input range can adapt to different regional power grid standards, and the input side integrates surge suppression circuit (can withstand 2kV differential/4kV common mode surges); Equipped with quadruple protection against overcurrent, overvoltage, short circuit, and overheating, it automatically limits current or shuts off output in case of faults, and can automatically resume operation after the fault is resolved.

-Intelligent monitoring and diagnosis: Built in voltage, current, and temperature sensors, real-time collection of operating parameters and uploading them to the system controller through the bus; It has self diagnostic functions for module faults, input abnormalities, output overcurrent, etc. It supports remote fault location through dual prompts of panel LED indicator lights and upper computer alarms.

-Efficient energy saving and long-lasting durability: conversion efficiency ≥ 92%, using synchronous rectification technology to reduce power consumption and minimize heat dissipation requirements; Electrolytic capacitors are selected from long-life industrial grade products, with a lifespan of ≥ 50000 hours at a working temperature of 85 ℃; The module housing is made of aluminum alloy material to enhance heat dissipation performance and mechanical strength.

-Convenient installation and maintenance: adopting a front plug design and spring type wiring terminals, there is no need to disconnect external wiring during installation and replacement; The panel is equipped with power, operation, and fault status indicator lights, which provide intuitive feedback on the working status of the module and increase maintenance efficiency by 70% compared to traditional power sources.

Working principle

The FOXBORO P0916KN power module serves as the "energy conversion core" of the I/A Series system. Its working principle revolves around the complete chain of "input rectification power conversion voltage regulation output state monitoring", which is divided into five key links:

1. Input filtering and rectification: The AC input power supply is filtered by an EMC filter circuit to remove electromagnetic interference from the power grid, and then enters a bridge rectifier circuit to convert it into pulsating DC; The power factor correction (PFC) circuit on the input side increases the power factor to ≥ 0.95, reducing harmonic pollution to the power grid.

2. Power Conversion: Pulsating DC is filtered by a high-voltage capacitor and sent to a full bridge LLC resonant converter. The DC voltage is converted into a high-frequency AC signal through a high-frequency switching transistor (IGBT), and the high-frequency transformer achieves voltage level conversion and electrical isolation to ensure the safety of the output side.

3. Output rectification and filtering: High frequency AC signals are converted into DC through synchronous rectification circuits, and then ripple is filtered out through LC filtering circuits to obtain stable 24V DC output; The output side voltage sampling circuit real-time collects the output voltage and feeds back the signal to the control chip.

4. Closed loop voltage regulation: The control chip compares the sampled voltage with the reference voltage, adjusts the conduction time of the high-frequency switch tube through PID algorithm, dynamically adjusts the output voltage, and ensures that the output voltage remains stable within the range of 24V ± 0.1% when the load changes or the input voltage fluctuates.

5. Redundancy control and status feedback: In redundancy mode, the main and backup modules achieve current sharing control through the current sharing bus; The status monitoring circuit collects input and output parameters and module temperature. When the parameters exceed the threshold, the protection mechanism is triggered, and the fault information is uploaded to the system through the communication interface, and the corresponding status indicator light is lit.

In the I/A Series distributed system, multiple P0916KN modules can form a redundant power supply system. Centralized management of power supply resources is realized through the system controller. When a module fails, the system will automatically alarm and record fault information to ensure the continuity and reliability of power supply for the entire control system.

Precautions

This module is the core power supply component of the system, which directly affects the safe operation of the entire control system. All installation, debugging, and maintenance work must be completed by professionals with industrial power operation qualifications and FOXBORO I/A Series system experience.

-Preparation before installation: Before installation, check the appearance of the module for any damage to the housing or deformed wiring terminals. Use a multimeter to measure the resistance between the input/output terminals and confirm that there is no short circuit; Confirm that the installation environment meets the requirements, avoid installing in environments with high temperature, high humidity, high dust or corrosive gases, reserve ≥ 10mm heat dissipation space around the module, and stay away from high-power heating equipment.

-Wiring specifications: Wiring must be carried out in a completely power-off state, and the input side must distinguish between the live wire (L), neutral wire (N), and ground wire (PE). It is strictly prohibited to connect or miss the ground wire; The output side must distinguish between positive and negative poles (+24V/-24V), and the polarity of the wiring must be consistent with that of the load module. Reverse connection is strictly prohibited; When redundant parallel connection is required, a dedicated current sharing cable should be used to connect the module's current sharing terminals to ensure normal current sharing function.

-Redundancy configuration requirements: All modules in the redundant system must be of the same model P0916KN and have the same firmware version; It is recommended to take the input power of the module from different circuits to achieve input power redundancy; The capacity configuration of the redundant system must meet the requirement of "total load current ≤ rated current of a single module x (number of redundant modules -1)" to ensure that the backup module can fully support the load in case of a fault.

-Operation and maintenance: Regularly (recommended every 3 months) check the operation status of the module, including indicator light display, output voltage stability, wiring tightness, and shell temperature (≤ 60 ℃ during normal operation); To avoid the module running at full load for a long time, it is recommended to control the load rate within 80% to extend its lifespan; When replacing a module, it is necessary to first disconnect the corresponding input power supply and use hot swapping to replace it. It is forbidden to plug in or unplug the module without power off.

-Safety protection: When used in explosion-proof areas, it is necessary to confirm that the explosion-proof level of the module meets the on-site requirements (Ex II 2G Ex d IIB T6), and it is strictly prohibited to disassemble the explosion-proof shell of the module; The grounding resistance of the module should be ≤ 4 Ω, and a circuit breaker (recommended 10A) that meets the specifications should be installed on the input side as a supplement to short-circuit protection; When conducting live detection, insulated tools should be used to avoid direct contact with the output terminals.

-Storage and transportation: Unused modules should be stored in a dry and ventilated environment, with a storage temperature of -40 ℃~+85 ℃ and a relative humidity of ≤ 80%, avoiding direct sunlight and severe vibration; During transportation, it is necessary to use original packaging and add cushioning materials to prevent collision and damage to internal components.