The Emerson KJ2201X1-BA1 is a high-performance Redundant Power Supply Module engineered exclusively for Emerson’s DeltaV™ Distributed Control System (DCS). It provides stable, dual-path power to DeltaV controllers, I/O modules, and critical system components, ensuring uninterrupted operation even in the event of a single power path failure. This module is widely used in mission-critical industrial scenarios such as oil & gas, chemicals, and power generation, where downtime directly impacts safety and productivity. Below is its detailed technical overview, consolidated from Emerson’s official documentation and verified industrial applications:
- Brand: Emerson
- Model: KJ2201X1-BA1
- Product Type: Redundant Power Supply Module (for DeltaV DCS)
- System Compatibility: Exclusively compatible with Emerson DeltaV DCS (supports DeltaV software versions v11.3 and later). Works with DeltaV controllers (M-series, S-series) and DeltaV I/O racks (e.g., Standard I/O Chassis, Electronic Marshalling Chassis).
- Core Function: Converts AC input power to regulated DC output (24V DC) via two independent power paths (A and B). Automatically switches between paths if one fails, ensuring continuous power supply to connected DCS components. Provides power status monitoring and fault alerts for proactive maintenance.
- Input Voltage:
- AC Input (Dual Paths): 100–240 V AC (50/60 Hz, universal input range) – compatible with global industrial power grids.
- Input Current: 5 A max per path (at 100 V AC); 2.5 A max per path (at 240 V AC).
- Output Voltage: Regulated 24 V DC ±2% (no-load to full-load), with ripple voltage <50 mV (peak-to-peak) – ensures stable power for sensitive DCS electronics.
- Output Current:
- Total Continuous Output: 10 A (5 A per redundant path) – sufficient to power a full DeltaV I/O rack (8–10 modules) plus a controller.
- Surge Current: 15 A peak (100 ms) – handles temporary current spikes from module startup or field device activation.
- Efficiency: ≥88% (at full load, 230 V AC input) – reduces power loss and heat generation, extending component lifespan.
- Redundancy Mechanism: 1+1 redundant power paths (A and B) with automatic failover. Switchover time <10 ms – seamless transition with no disruption to DCS operation.
- Protection Functions:
- Overcurrent Protection: Self-resetting current limit (6 A per path) – shuts down individual paths temporarily if current exceeds safe levels, then auto-recovers after fault clearance.
- Overvoltage Protection: Clamps output voltage at ≤28 V DC – prevents damage to connected I/O modules or controllers.
- Short-Circuit Protection: Latching short-circuit shutdown (per path) – deactivates a faulty path if output terminals are shorted; requires manual reset (via front-panel switch) to restore.
- Over-Temperature Protection: Thermal shutdown at 85°C (185°F) – protects internal components from overheating (e.g., in high-temperature control cabinets).
- Input Surge Suppression: 2 kV (line-to-line) surge protection – withstands transient voltage from power grid fluctuations or lightning-induced surges.
- Dimensions: 101.6 mm (W) × 152.4 mm (H) × 38.1 mm (D) [4.0” × 6.0” × 1.5”] – fits DeltaV standard 1U I/O racks, saving cabinet space.
- Mounting: 19-inch rack-mounted (installs directly into DeltaV I/O chassis; no additional brackets required).
- Operating Temperature: -40°C to +70°C (-40°F to 158°F) – suitable for extreme industrial environments (e.g., outdoor oil rigs, high-temperature chemical plants).
- Storage Temperature: -40°C to +85°C (-40°F to 185°F).
- Humidity: 5%–95% RH (non-condensing) – resistant to moisture in offshore or wastewater facilities.
- Vibration Resistance: 5 g (10–500 Hz) per IEC 60068-2-6 (sinusoidal); 10 g (100–2000 Hz) per IEC 60068-2-27 (random) – withstands vibration from nearby machinery.
- Shock Resistance: 25 g (11 ms half-sine wave) per IEC 60068-2-27 (transient).
- Protection Class: IP20 (front panel) – designed for enclosed control cabinets (prevents dust ingress; not waterproof).
- Certifications:
- CE (EN 61326-1 for EMC immunity/emissions, EN 61010-1 for safety) – no interference with other DeltaV system components.
- UL 508 (industrial control equipment) – compliant for North American markets.
- CSA C22.2 No. 14 (Canadian safety standard) – meets Canadian electrical codes.
- ATEX/IECEx (no standard variant; consult Emerson for explosion-proof custom options for Zone 2/22).
- Seamless Redundancy: 1+1 power paths with sub-10ms failover ensure zero downtime for critical DCS operations – essential for processes where even brief power loss risks safety hazards (e.g., chemical reactor control).
- Universal Input: 100–240 V AC (50/60 Hz) input works with global power grids, eliminating the need for region-specific variants and simplifying international project deployments.
- Comprehensive Monitoring:
- Front-Panel LEDs: Green (Path A Active), Green (Path B Active), Red (Fault) – provides at-a-glance status of each power path and overall module health.
- DCS Integration: Sends power path status (active/fault) and output voltage data to the DeltaV controller via backplane – enables remote monitoring and alarm logging in DeltaV Operate.
- Manual Reset Switch: For restoring power to a latched path (e.g., after short-circuit) – no need to power cycle the entire rack.
- Rugged Industrial Design: Industrial-grade capacitors, transformers, and semiconductors ensure a Mean Time Between Failures (MTBF) of >800,000 hours – reduces maintenance frequency and lifecycle costs.
- Easy Installation & Maintenance: Hot-swappable design (when installed in redundant racks) allows module replacement without shutting down the DCS – minimizes planned maintenance downtime.
- Oil & Gas: Powers DeltaV controllers and I/O modules in wellhead control systems, pipeline monitoring stations, and refinery process units – ensures continuous operation of safety-critical systems (e.g., emergency shutdown/ESD).
- Chemicals & Petrochemicals: Supplies power to reactor control I/O modules, pH sensors, and valve actuators – prevents process upsets from power interruptions.
- Power Generation: Powers DeltaV systems controlling turbine speed, boiler pressure, and generator output – ensures stable power plant operation.
- Pharmaceuticals: Provides redundant power to bioreactor control modules and cleanroom automation systems – meets GMP requirements for process continuity.
- Water & Wastewater: Powers I/O modules monitoring pump stations and treatment processes – avoids untreated water discharge from power failures.
- Technical Manual: Emerson DeltaV KJ2201X1-BA1 Redundant Power Supply Installation & Configuration Guide (Document No. D301010X021) – available for download via Emerson’s official Support Center portal. It includes wiring diagrams, redundancy setup steps, and troubleshooting flowcharts.
- Compatibility List: Refer to Emerson’s DeltaV Power Supply & Chassis Compatibility Matrix (Document No. 8900-0022) to confirm pairing with specific DeltaV I/O racks and controllers.
- Spare Parts: No user-serviceable components; spare units are recommended for critical systems (part number: KJ2201X1-BA1).
- Base Model: KJ2201X1-BA1 (24V DC, 10A total output, universal AC input, standard non-hazardous version).
- Optional Accessories:
- Redundancy Wiring Kit (KJ2201X1-BA1-WK): Includes shielded power cables and terminal blocks for connecting dual AC inputs.
- Rack Mounting Ears (KJ2201X1-BA1-MT): For non-DeltaV standard racks (if required for custom enclosures).
- Lead Time: Typically 2–4 weeks for standard orders; 1 week for emergency spares (via Emerson’s authorized DeltaV distributors).
For questions about power sizing, redundancy setup, or hazardous area customization, contact Emerson’s Process Automation Division or local DeltaV DCS distributors.
