Puls XT40.241, XT40.242 Data Sheet

– X-Series

1. GENERAL DESCRIPTION

The power supplies in the Dimension X-Series include a new and innovative concept for generating an isolated DC voltage from a three-phase mains system.

A semi-regulated resonant converter enables a very compact design, maximum efficiency and extremely competitive pricing with only a small compromise in the output voltage regulation, output ripple and hold-up time.

Weighing just 1.4 kg, the device provides 960 watts of continuous output power and an additional 25% power reserve for dynamic loads. The light-weight design along with compact dimensions facilitate straightforward mounting on DIN-rail.

Primary use are applications involving supplies to motors, valves and other load circuits with a high power consumption, where an accurate output voltage regulation which is standard on traditional switched-mode power supplies is not required. Furthermore, these switched-mode power supplies can often replace mains transformers with rectifiers.

XT40.241, XT40.242

24V, 40A, THREE-PHASE INPUT

SEMI-REGULATED POWER SUPPLY

• Alternative or Replacement for AC Transformer

• Three Phase Input – DC Output

• DIN-Rail Mountable

• Width only 96mm

• 95.5% Efficiency

• 125% Peak Power Capability

• No Input Inrush Current

• Active Input Transient Blocker

• Full Power Between -25°C and +60°C

• Easy Failure Diagnostics

• No Electrolytic Capacitors on Input Side

• Cost Effective and Robust

• 3 Year Warranty

2. SHORT-FORM DATA

Output voltage DC 24V Factory setting to

24.1V Adjustment range none Output current 40A continuous 50A for typ. 15s Output power 960W continuous 1200W for typ. 15s Output ripple < 1500mVpp 20Hz-2kHz < 200mVpp 2kHz to 20MHz Input voltage 3AC 400V XT40.241 3AC 480V XT40.242 Mains frequency 50-60Hz ±6% AC Input current 1.65A / phase XT40.241, 3x400V

1.4A / phase XT40.242, 3x480V Power factor 0.93 24V, 40A AC Inrush current typ. 2A peak Efficiency 95.5% Losses 45.2W Temperature range -25°C to +70°C operational Derating 24W/°C +60 to +70°C Dimensions 96x124x159mm WxHxD

3. ORDER NUMBERS

Power Supply

Accessory UF20.241

Jan. 2007 / Rev. 1.0 DS-XT40.24x-EN All parameters are specified at 24V 40A, 3x400Vac (XT40.241) or 3x480Vac (XT40.242), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

XT40.241 XT40.242

SLR01

400V Input 480V Input

24V Buffer Unit Redundancy Module

www.pulspower.com Phone +49 89 9278 0 Germany

4. MARKINGS

LISTED

IND. CONT. EQ.

UL 508

18WM

UL 60950-1

EMC, LVD

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– X-Series

XT40.241, XT40.242

24V, 40A, THREE-PHASE INPUT

INDEX PAGE INDEX PAGE

General Description ............................................1

2. Short-form Data ..................................................1

3. Order Numbers....................................................1

4. Markings..............................................................1

5. AC-Input...............................................................3

6. Input Inrush Current ...........................................4

7. Output .................................................................5

8. Hold-up Time.......................................................6

9. Efficiency and Power Losses................................7

10. Functional Diagram.............................................8

11. Front Side and User Elements.............................8

12. Terminals and Wiring..........................................9

13. Reliability.............................................................9

14. EMC....................................................................10

15. Environment......................................................11

16. Protection Features ...........................................12

17. Safety .................................................................12

18. Dielectric Strength ............................................12

19. Approvals...........................................................13

20. Fulfilled Standards ............................................13

21. Used Substances ............................................... 13

22. Physical Dimensions and Weight..................... 14

23. Installation and Operation Instructions .......... 14

24. Accessories ........................................................ 15

25. Comparison between the XT40, a Transformer and a Traditional Switched-mode Power Supply .. 15

26. Application Notes............................................. 16

26.1. Periodical Peak Power Capability.......... 16

26.2. Charging of Batteries............................. 16

26.3. Output Circuit Breakers ......................... 17

26.4. External Input Protection....................... 18

26.5. Back-feeding Loads................................ 18

26.6. Parallel Use to Increase Output Power . 18

26.7. Parallel Use for Redundancy.................. 18

26.8. Series Operation..................................... 19

26.9. Inductive and Capacitive Loads ............. 19

26.10. Loss of One Input Phase......................... 19

26.11. Use in a Tightly Sealed Enclosure .......... 19

26.12. Mounting Orientations .......................... 20

INTENDED USE

The power supply shall only be installed and put into operation by qualified personnel. This power supply is designed for installation in an enclosure and is intended for the general use, such as in industrial

control, office, communication, and instrumentation equipment. Do not use this device in aircraft, trains and nuclear equipment, where malfunctioning of the power supply may cause severe personal injury or threaten human life.

TERMINOLOGY AND ABREVIATIONS

PE and symbol PE is the abbreviation for Protective Earth and has the same meaning as the symbol .

Earth, Ground This document uses the term “earth” which is the same as the U.S. term “ground”.

T.b.d. To be defined, value or description will follow later.

3AC 400V A figure displayed with the AC or DC before the value represents a nominal voltage with

standard tolerances (usually ±15%) included. 3AC means three phase input. E.g.: DC 12V describes a 12V battery disregarding whether it is charged (13.7V) or discharged (10V) As long as otherwise stated, 3AC 400V parameters are valid at 50Hz and 3AC 480V parameters are valid at 60Hz mains frequency.

3x 400Vac A figure with the unit (Vac) at the end is a value which is used during testing without any

additional tolerances included. 3x 400Vac means a three phase input.

DISCLAIMER

The information presented in this document is believed to be accurate and reliable and may change without notice.

Jan. 2007 / Rev. 1.0 DS-XT40.24x-EN All parameters are specified at 24V 40A, 3x400Vac (XT40.241) or 3x480Vac (XT40.242), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

www.pulspower.com Phone +49 89 9278 0 Germany

2/20

– X-Series

XT40.241, XT40.242

24V, 40A, THREE-PHASE INPUT

5. AC-INPUT

XT40.241 XT40.242

AC input nom. 3AC 400V 3AC 480V Mains arrangement TN-, TT- or IT-Mains consult factory if one phase is earthed AC input range

min. 3x 360-440Vac 3x 432-528Vac fully regulated output (±2%), Pout > 48W min. 3x 300-460Vac

3x 360-552Vac

max. 3x 475Vac 3x 565Vac Absolute maximum input voltage with no

Input frequency nom. 50 – 60Hz 50 – 60Hz ±6% Turn-on voltage typ. 3x 325Vac 3x 390Vac see Fig. 5-2 Shut-down voltage typ. 3x 295Vac 3x 355Vac see Fig. 5-2 Input current

nom. 1.65A 1.4A at 40A, symmetrical input, see Fig. 5-4 Power factor **) typ. 0.93 0.93 at 40A, symmetrical input, see Fig. 5-5 Turn-on overshoot typ. 480mV 480mV see Fig. 5-3 Start-up delay ***) typ. 400ms 350ms over the entire load range, see Fig. 5-3 Rise time typ. 40ms 40ms 0mF, 40A, see Fig. 5-3

*) A minimum voltage of 3x340Vac (XT40.241) or 3x408Vac (XT40.242) is required to turn the power supply on. **) The power factor is the ratio of the true (or real) power to the apparent power in an AC circuit. ***) The start-up delay for mains voltage interruptions up to 350ms is close to zero. In such cases, the power supply will

immediately generate the output voltage once the mains voltage interruption is over. Do not use the buffer module UF20.241 as an accessory when longer mains interruptions need to be bridged (see chapter 24).

typ. 70ms 70ms 40mF, 40A, see Fig. 5-3

Input Voltage Range

Fig. 5-1 Output voltage vs. input voltage and input current

permanently allowed, see Fig. 5-1 for output voltage regulation

damage to the power supply. Output might be off at this level.

Changes of the input voltage will be fully regulated within certain limits. The output voltage will only start to change proportionally to the input voltage with extreme under or over-voltages. The

OUT

28V

26V

OUT

= 0W

> 48W (5%)

yellow LED reports an input voltage problem if exceeded by a window of ±15%. The maximum increase of the output voltage is limited to the 29.9V OVP level. This level will be kept regulated for 2s before the power supply will shut down and reports “Shut-down” by the red LED.

24V

22V

20V

XT40.241: XT40.242:

420340 480Vac320

400360 380 440

504456 576Vac384

480

528 552432408360

460300

Jan. 2007 / Rev. 1.0 DS-XT40.24x-EN All parameters are specified at 24V 40A, 3x400Vac (XT40.241) or 3x480Vac (XT40.242), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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3/20

– X-Series

XT40.241, XT40.242

24V, 40A, THREE-PHASE INPUT

Fig. 5-2 Input voltage range Fig. 5-3 Turn-on behavior definitions

OUT

Turn-on

Shut-down

Fig. 5-4 Input current vs. output load Fig. 5-5 Power factor vs. output load

Input Current per Phase, typ.

1.8A

1.5

1.2

0.9

0.6

0.3

510 30 45

15 20 25 35 40

3x 432Vac480V Version:

fully regulated

range

(

Output Current

3x 440Vac3x 360Vac400V Version: 3x 528Vac

)

(

)

50A

Intput Voltage

Output Voltage

Power Factor, typ.

1.0

0.95

0.9

0.85

0.8

0.75

0.70 510 30 45

- 5%

Start-up

delay

15 20 25 35 40

Rise

Time

Output Current

Overshoot

50A

6. INPUT INRUSH CURRENT

There is virtually no input inrush current surge as there are no electrolytic bulk-capacitors utilized on the input side of the power supply.

The charging current into the EMI suppression capacitors is disregarded for the first millisecond after switch-on.

Inrush current max. 4A Inrush energy max. 5A2s 5A2s -25°C to +70°C, see Fig. 6-1 Inrush delay

Fig. 6-1 Input inrush current, typical behavior

typ. 400ms 350ms see Fig. 6-1

Input Current

Input Voltage

Output Voltage

XT40.241 XT40.242

peak

-25°C to +70°C, see Fig. 6-1

peak

A: Inrush delay

XT40.241: Input: 3x400Vac, only one phase shown Output: 24V, 40A Ambient: 25°C

Upper curve: Input current 2A / DIV Medium curve: Input voltage 500V / DIV (measured between L and N) Lower curve: Output voltage 20V / DIV Time basis: 100ms / DIV

Jan. 2007 / Rev. 1.0 DS-XT40.24x-EN All parameters are specified at 24V 40A, 3x400Vac (XT40.241) or 3x480Vac (XT40.242), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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4/20

– X-Series

XT40.241, XT40.242

24V, 40A, THREE-PHASE INPUT

7. OUTPUT

Output voltage Output voltage adjustment range Output current 50A up to 15s with full output voltage, see Fig. 7-1

Short-circuit current

Output power 1200W up to 15s Line regulation Load regulation max. 800mV static value, 0A Æ 40A Æ 0A

Ripple and noise voltage *) max. 50mVpp 2kHz to 20MHz, 50Ohm Output capacitance

*) The ripple and noise voltage mostly consist of a mains ripple with 300Hz (50Hz mains) or 360Hz (60Hz mains). The ripple and noise voltage can be reduced by the utilization of external capacitors.

The power supply is also designed to support loads with a higher short-term current and power requirement. The short-term duration is firmware controlled by an output power manager. If the nominal output power is exceeded for a certain period of time which is defined in the zone A, B and C, the power supply responds with an automatic shutdown. Pressing the reset button or cycling the input power (10s off time is required) initiates an attempt to restart. If the fault has been cleared the device will operate normally.

The short term power can be used periodically. See chapter 26.1 for further information.

Fig. 7-1 Output voltage vs. output current, typ.

nom. 24.1V none The output voltage is fixed. No adjustment possible nom. 40A continuous, see Fig. 7-1

typ. 180A load impedance 25mOhm, see Fig. 7-1

Note: The short-circuit current is available for 0.1s

nom. 960W continuous

max. ±2% see Fig. 5-1

max. 200mV static value, 5A Æ 40A Æ 5A max. 1500mVpp 20Hz-2kHz, 50Ohm

typ. 20 000µF

OUT

24V

12V

Zone A: 25% extra output power for typ. 15s

Zone B:

Zone C:

100% higher output current for typ. 5s

Quick-acting shut-down after typ. 0.1s

Jan. 2007 / Rev. 1.0 DS-XT40.24x-EN All parameters are specified at 24V 40A, 3x400Vac (XT40.241) or 3x480Vac (XT40.242), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

15s

40A 50A 140A80A0

60A20A 100A 120A 160A 180A

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0.1s

XT40.241 XT40.242 3x 340V 3x 408V

3x 400V 3x 480V 3x 460V 3x 552V

200A

OUT

5/20

– X-Series

XT40.241, XT40.242

24V, 40A, THREE-PHASE INPUT

8. HOLD-UP TIME

XT40.241 XT40.242

Hold-up Time typ. 2.0ms 2.0ms 40A, resistive load, see typ. 1.8ms 1.8ms 40A, constant power load, see Fig. 8-2 typ. 4.0ms 4.0ms 20A, resistive load typ. 3.6ms 3.6ms 20A, constant power load Hold-up Time min. 1.6ms 1.6ms 40A, resistive load, see min. 1.45ms 1.45ms 40A, constant power load, see Fig. 8-2 min. 3.2ms 3.2ms 20A, resistive load min. 2.9ms 2.9ms 20A, constant power load

The energy is stored in the output capacitor. As soon as the input is turned off, the output capacitor will be discharged and the voltage will dissipate according to the curves in lighter the load, the longer the hold-up time. Half the load means twice the hold-up time.

The hold-up time depends on the load

Fig. 8-2. The

Intput Voltage

characteristic. The curves below show the hold-up time for a load with a resistive and a constant power characteristic.

The hold-up time is defined as the period of time

Output Voltage

when the input is turned off and until the output

–15%

voltage falls below 24V

(20.4V). This value is defined in the IEC61131-2 as the lower limit for the supplying voltage.

Fig. 8-2 Hold-up time vs. input voltage

Fig. 8-2

Fig. 8-1 Hold-up time, definitions

Zero Transition

Hold-

Time

-15%

OUT

24V

22V

20.4V

18V

16V

14V

40A, constant power load, min.

40A, constant power load, typ.

40A, resistive load, min.

40A, resistive load, typ.

12V

0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5

5.5 6.0 6.5 7.0 7.5 8.05.0 8.5 9.0ms

Note: At no load, the hold-up time can be up to one minute. The green DC-ok LED is on during this time.

Jan. 2007 / Rev. 1.0 DS-XT40.24x-EN All parameters are specified at 24V 40A, 3x400Vac (XT40.241) or 3x480Vac (XT40.242), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

www.pulspower.com Phone +49 89 9278 0 Germany

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