Description

GE IC695PSA040

GE IC695PSA040 is a redundant power supply module whose core function is to provide stable and redundant DC power for RX3i series PLC/DCS systems. Through a dual-module hot-standby redundant design, it ensures the uninterrupted operation of industrial automation systems when a single power module fails. Adopting a wide-voltage input, high-efficiency power conversion, and multi-protection design, this product features redundancy fault tolerance, strong anti-interference capability, and easy integration. It is specifically compatible with IC695 series backplanes (such as IC695CHS007) and widely used in medium and large-scale industrial control systems with high requirements for power supply reliability, including manufacturing automation, energy monitoring, and rail transit control. It serves as a core power supply component to guarantee the continuous operation of critical industrial processes. Its core value lies in eliminating single points of failure in power supply through a redundant architecture, improving the system's Mean Time Between Failures (MTBF), and providing stable and pure DC power for industrial control modules.

I. Technical Parameters

Input Power Parameters:

Input Voltage Range: 85-264V AC (wide voltage adaptation), compatible with 100-300V DC backup input;
Input Frequency: 47-63Hz (for AC input), supporting adaptive grid frequency fluctuations;
Input Current: 0.8A (rated) at 230V AC, 1.6A (rated) at 115V AC;
Power Factor: ≥0.9 (full load, AC input), reducing grid harmonic pollution.

Output Power Parameters:

Output Voltage: Dual DC output channels: +5V DC (main power supply) and +3.3V DC (auxiliary power supply);
Output Current: 8A (rated) at +5V DC, 3A (rated) at +3.3V DC, with a total output power of 40W;
Voltage Accuracy: ±1% (under full load conditions), ensuring stable module power supply;
Ripple and Noise: ≤50mVpp (for +5V output), ≤30mVpp (for +3.3V output), providing pure power;
Redundancy Features: Supports parallel redundant operation of 2 modules with automatic load balancing, and redundant switching time ≤1ms (seamless switching).

Mechanical Structure Parameters:

Dimensions: 141.4mm × 88.3mm × 147.3mm (Height × Width × Depth), weight approximately 0.6kg;
Installation Method: Only compatible with Slot 0 of IC695 series backplanes (dedicated power supply installation position), no independent DIN rail mounting design;
Protection Level: IP20 (NEMA Type 1), suitable for installation in control cabinets.

Environmental and Reliability Parameters:

Operating Temperature: 0℃~60℃; Storage Temperature: -40℃~85℃;
Relative Humidity: 5%~95% (non-condensing), adapting to high-humidity industrial environments;
Heat Dissipation Method: Natural convection cooling without fans, reducing the risk of mechanical failures;
Mean Time Between Failures (MTBF): ≥200,000 hours (at 25℃);
Electromagnetic Interference (EMI) Resistance: Complies with standards such as IEC 61000-4-2 (ESD) and IEC 61000-4-3 (RS), compatible with high-EMI industrial environments.

Protection Function Parameters:

Overvoltage Protection: Upper limit of 5.6V for +5V output and 3.7V for +3.3V output, with automatic recovery after current limiting;
Overcurrent Protection: Current limiting of 10A for +5V output and 4A for +3.3V output, avoiding damage caused by short circuits;
Overheating Protection: Automatic derated output when internal temperature ≥85℃, shutdown when ≥95℃, and automatic recovery after cooling;
Short Circuit Protection: Supports self-recovery of output short circuits without damage risk.

II. Key Features

Redundant Parallel Design to Eliminate Single Points of Failure in Power Supply:Supports parallel connection of 2 IC695PSA040 modules to form a redundant power supply system. During normal operation, the two modules share the load equally; when one module fails, the other immediately takes over the full load seamlessly (switching time ≤1ms), ensuring uninterrupted system power supply. In automotive welding production lines, the redundant power supply guarantees continuous power for PLCs and I/O modules, avoiding production line downtime caused by power failures (a single downtime can result in losses exceeding 100,000 RMB).
Wide Voltage Input + Dual-Mode Compatibility for Multi-Scenario Power Supply:The 85-264V AC wide voltage input adapts to power grids in different regions worldwide, while supporting 100-300V DC backup input for direct connection to industrial DC buses. With a power factor ≥0.9, it reduces harmonic interference to the power grid and meets industrial power grid specifications. In overseas factory projects, the module can directly adapt to local 110V AC or 230V AC power grids without additional voltage converters.
Dual Precise Output + Low Ripple to Ensure Stable Module Operation:The dual output channels (+5V DC/8A and +3.3V DC/3A) precisely match the power supply requirements of RX3i series controllers and I/O modules. With a voltage accuracy of ±1% and ripple noise ≤50mVpp, it avoids module data loss or logic errors caused by power fluctuations. In high-precision sensor data acquisition systems, the low-ripple power supply reduces the acquisition error rate to below 0.01%.
Multi-Protection + Natural Convection Cooling for High Reliability:Integrates four protection functions (overvoltage, overcurrent, overheating, and short circuit) to fully resist power supply abnormalities and load failures. The fanless natural convection cooling design reduces mechanical wear, achieving an MTBF of ≥200,000 hours—80% lower failure rate than fan-equipped power modules. In unattended substations, the module can operate continuously for 5 years without maintenance.
Plug-and-Play + Status Visualization for Convenient Operation and Maintenance:Can work immediately after being inserted into Slot 0 of IC695 series backplanes without complex configuration. The front panel is equipped with power indicators (green: normal), fault indicators (red: fault), and redundancy indicators (yellow: redundancy mode) to intuitively reflect operating status. It supports reading power supply status information through the controller to achieve remote fault early warning, improving operation and maintenance efficiency by 50%.

III. Working Principle and Applications

3.1 Working Principle

GE IC695PSA040 achieves stable power supply through a core process of "power conversion - redundancy control - protection feedback", as detailed below:① Power Conversion Stage: Converts the input AC/DC power into pure +5V DC and +3.3V DC power through rectification, filtering, and voltage stabilization circuits, with voltage accuracy controlled within ±1%;② Redundancy Control Stage: When operating as a single module, it directly supplies power to the backplane; when operating in dual-module redundancy, it achieves load balancing (each bearing 50% of the load) through internal redundancy control circuits and monitors each other's status in real time. If one module fails, the other immediately increases the output current to the rated value and takes over the full load seamlessly;③ Protection Feedback Stage: Real-time monitors output voltage, current, and module temperature. When overvoltage, overcurrent, overheating, or short circuit occurs, it immediately activates protection mechanisms (current limiting, derating, or shutdown), lights up the fault indicator, and feeds back the fault status to the controller through the backplane bus;④ Status Monitoring Stage: Real-time feeds back power supply operating status (normal/fault/redundancy) through panel indicators and controller communication, supporting remote fault diagnosis and early warning.

3.2 Application Scenarios

Critical Manufacturing Production Lines:Provides redundant power for RX3i PLCs, I/O modules, and communication modules in critical processes such as automotive assembly lines and electronic chip production lines, avoiding production line downtime caused by power failures. A welding production line in an automotive factory adopts a redundant configuration of 2 IC695PSA040 modules and has operated continuously for 3 years without power-related failures.
Energy Monitoring Systems:Provides stable power for RTU controllers, data acquisition modules, and protection relays in DCS systems of power plants and substations, ensuring the continuity of energy equipment status monitoring and control command execution. In photovoltaic power plant monitoring systems, the module adapts to photovoltaic DC bus power supply, and the redundant design avoids the loss of power generation data due to power failures.
Rail Transit Control:Provides redundant power for RX3i controllers and signal transmission modules in subway signal systems and high-speed rail dispatching systems, meeting the "zero downtime" requirement of rail transit. The signal system of a subway line adopts this module to ensure continuous transmission of train dispatching signals with no power-related fault records.
Unattended Equipment:Provides long-term stable power for PLCs and sensor modules in unattended equipment such as hydrological monitoring stations in remote areas and oil pipeline monitoring terminals. The natural convection cooling and multi-protection design adapt to harsh environments and reduce on-site maintenance frequency.
Old System Upgrades:When upgrading 90-30 series systems to the RX3i platform, it is used as a supporting power supply module to connect to IC695 series backplanes, compatible with the power supply requirements of both old and new modules, ensuring stable system power supply during the upgrade process.

IV. Common Faults and Solutions

Fault Phenomenon	Possible Causes	Solutions
Power indicator not lit; no module output	Abnormal input voltage, incorrect power cable wiring, poor backplane contact, module failure	1. Use a multimeter to measure the input voltage and ensure it is within the range of 85-264V AC or 100-300V DC; 2. Check the power cable wiring (L/N/PE or positive/negative poles) to ensure it is secure and not loose; 3. Power off, reinsert the module to ensure good contact between the gold fingers and backplane Slot 0; 4. Test with a spare module; if normal operation is restored, the original module is faulty and should be repaired
Fault indicator lit; output interrupted	Overload, short circuit, overheating, excessive input voltage	1. Check the total power consumption of modules inserted into the backplane to avoid exceeding the 40W rated power (+5V×8A +3.3V×3A=49.9W with redundancy reserved); 2. Use a multimeter to detect if the output terminal is short-circuited (focus on checking +5V & GND and +3.3V & GND) and troubleshoot short circuit faults; 3. Check the module's heat dissipation space to ensure ≥10cm ventilation around it and an ambient temperature ≤60℃; 4. Measure the input voltage to avoid exceeding the rated range
Redundancy mode invalid; redundancy indicator not lit	Unconnected redundancy cable, mismatched module models, failure of one module	1. Confirm that both modules are IC695PSA040 and connected via a dedicated redundancy cable; 2. Check if the power indicators of both modules are green; eliminate faults in one module first if present; 3. Reinsert the redundancy cable to ensure a secure connection; 4. Access the controller configuration interface and confirm that the power redundancy function is enabled
Large output voltage deviation; unstable module operation	Fluctuating input voltage, unbalanced load, module aging	1. Check if the input voltage is stable; install a voltage stabilizer if fluctuations exceed ±10%; 2. Ensure balanced load distribution between the two modules in redundancy mode (view the output current of each module through the controller); 3. If the module has been used for more than 5 years, voltage deviation may be caused by capacitor aging—replace the module if necessary
Module overheating; automatic derated output	Excessive ambient temperature, insufficient heat dissipation space, overload	1. Reduce the installation ambient temperature to ≤60℃ and keep the module away from heat sources such as frequency converters and heaters; 2. Increase heat dissipation space, remove obstacles around the module to ensure air circulation; 3. Check the total load power consumption; if exceeding 40W, remove unnecessary modules or add redundant modules to share the load

IC695PSA040 - Power Supply