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XT40.481
Data Sheet
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Puls XT40.481, XT40.482 Data Sheet

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– 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.
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
SEMI-REGULATED POWER SUPPLY
• Alternative or Replacement for AC Transformer
• Three Phase Input – DC Output
• DIN-Rail Mountable
• Width only 96mm
• 96% 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 48V Adjustment range none Output current 20A continuous 25A for typ. 15s Output power 960W continuous 1200W for typ. 15s Output ripple < 2500mVpp 20Hz-2kHz < 300mVpp 2kHz to 20MHz Input voltage 3AC 400V XT40.481 3AC 480V XT40.482 Mains frequency 50-60Hz ±6% AC Input current 1.65A / phase XT40.481, 3x400V
1.4A / phase XT40.482, 3x480V Power factor 0.93 48V, 20A AC Inrush current typ. 2A peak Efficiency 96.0% Losses 40.0W Temperature range -25°C to +70°C operational Derating 24W/°C +60 to +70°C Dimensions 96x124x159mm WxHxD
3. ORDER NUMBERS
Power Supply
Accessory UF20.481 48V Buffer Unit
Jan. 2007 / Rev. 1.0 DS-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
XT40.481 XT40.482
400V Input 480V Input
4. MARKINGS
LISTED
IND. CONT. EQ.
UL 508
18WM
UL 60950-1
EMC, LVD
1/20
– X-Series
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
INDEX PAGE INDEX PAGE
1.
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-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
2/20
– X-Series
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
5. AC-INPUT
XT40.481 XT40.482
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 20A, symmetrical input, see Fig. 5-4 Power factor **) typ. 0.93 0.93 at 20A, symmetrical input, see Fig. 5-5 Turn-on overshoot typ. 1000mV 1000mV 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, 20A, see Fig. 5-3
*) A minimum voltage of 3x340Vac (XT40.481) or 3x408Vac (XT40.482) 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 UF20.481 as an accessory when longer mains interruptions need to be bridged (see chapter 24).
typ. 70ms 70ms 20mF, 20A, 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
V
OUT
56V
52V
P
OUT
> 48W (>5%)
P
OUT
= 0W
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 57.2V 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.
48V
44V
40V
XT40.481: XT40.482:
420340 480Vac320
400360 380 440 480
528 552432408360
504456 576Vac384
460300
Jan. 2007 / Rev. 1.0 DS-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
V
IN
3/20
– X-Series
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
Fig. 5-2 Input voltage range Fig. 5-3 Turn-on behavior definitions
P
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
0
2.5 5 15
fully regulated
range
3x 432Vac480V Version:
x
3
(
1
8
4
.
0
4
XT
Output Current
10 20
8
4
.
0
4
T
X
3x 440Vac3x 360Vac400V Version: 3x 528Vac
)
V
0
0
4
8
4
x
3
(
2
V
IN
)
V
0
25A
Intput Voltage
Output Voltage
Start-up
delay
Power Factor, typ.
1.0
0.95
0.9
0.85
0.8
0.75
0.70
2.5 5 15
- 5%
Rise
Time
Output Current
10 20
Overshoot
25A
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
A
typ. 400ms 350ms see Fig. 6-1
Input Current
Input Voltage
Output Voltage
XT40.481 XT40.482
4A
peak
-25°C to +70°C, see Fig. 6-1
peak
A: Inrush delay
XT40.481: Input: 3x400Vac, only one phase shown Output: 48V, 20A Ambient: 25°C
Upper curve: Input current 2A / DIV Medium curve: Input voltage 500V / DIV (measured between L and N) Lower curve: Output voltage 40V / DIV Time basis: 100ms / DIV
Jan. 2007 / Rev. 1.0 DS-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
4/20
– X-Series
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
7. OUTPUT
Output voltage Output voltage adjustment range Output current 25A 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. 1600mV static value, 0A Æ 20A Æ 0A
Ripple and noise voltage *) max. 300mVpp 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. 48V none The output voltage is fixed. No adjustment possible nom. 20A continuous, see Fig. 7-1
typ. 90A load impedance 50mOhm, see Fig. 7-1
Note: The short-circuit current is available for 0.1s
nom. 960W continuous
max. ±2% see Fig. 5-1
max. 100mV static value, 2.5A Æ 20A Æ 2.5A max. 2500mVpp 20Hz-2kHz, 50Ohm
typ. 7 600µF
V
OUT
48V
24V
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-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
A
15s
20A 25A 70A40A0
B
5s
30A10A 50A 60A 80A 90A
C
0.1s
XT40.481 XT40.482 3x 340V 3x 408V 3x 400V 3x 480V 3x 460V 3x 552V
100A
I
OUT
5/20
– X-Series
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
8. HOLD-UP TIME
XT40.481 XT40.482
Hold-up Time typ. 3.1ms 3.1ms 20A, resistive load, see typ. 2.7ms 2.7ms 20A, constant power load, see Fig. 8-2 typ. 6.2ms 6.2ms 10A, resistive load typ. 5.4ms 5.4ms 10A, constant power load Hold-up Time min. 2.5ms 2.5ms 20A, resistive load, see min. 2.2ms 2.2ms 20A, constant power load, see Fig. 8-2 min. 5.0ms 5.0ms 10A, resistive load min. 4.4ms 4.4ms 10A, 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 48V
(40.8V). 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. 8-2
Fig. 8-1 Hold-up time, definitions
Zero Transition
Hold-
up
Time
-15%
V
OUT
48V
44V
40.8V
36V
32V
28V
24V
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 9.0
20A, constant power load, min.
20A, constant power load, typ.
20A, resistive load, min.
20A, resistive load, typ.
11ms9.5 10 10.5
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-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
T
6/20
A
A
c
c
– X-Series
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
9. EFFICIENCY AND POWER LOSSES
XT40.481 XT40.482
Efficiency typ. 96.0% 96.0% 20A Power losses typ. 40.0W 40.0W 20A typ. 18.2W 18.2W 0A
Fig. 9-1 Efficiency vs. output current Fig. 9-2 Losses vs. output current
Efficiency
96%
95 94 93 92 91 90 89 88
2.5 5 20
7.5 10 12.5 15 17.5
Output Current
Power Losses
50W
40
30
20
10
0
02468101214 20
Fig. 9-3 Efficiency vs. input voltage, 48V, 20A Fig. 9-4 Losses vs. input voltage, 48V, 20A
96.2%
96.0
95.8
95.6
95.4
95.2
95.0
Efficiency
XT40.481
350 400
XT40.482
Input Voltage
450
500 3x550
Va
47W
45
43
41
39
37
35
Output Current
16 18
Power Losses
XT40.481
350 400 450 500 3x550
XT40.482
Input Voltage
Va
Jan. 2007 / Rev. 1.0 DS-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
7/20
– X-Series
10. FUNCTIONAL DIAGRAM
Fig. 10-1 Functional diagram
L1 L2
L3
Input Filter
Input
Rectifier
Input Voltage Monitor
Active
Transient
Blocker
Temp.
Shut­down
Semi-
regulated
Power
Converter
Over-
Voltage
Protection
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
Output
Filter
Output Voltage Monitor
Output
Power
Manager
+
-
DC-ok LED
Warning LED
Shut-down LED
Reset
11. FRONT SIDE AND USER ELEMENTS
Fig. 11-1 Front side of XT40.481
Output Terminals
Large screw terminal
+ Positive output
- Negative (return)
output
See chapter 12 “Terminals and Wiring” to choose appropriate wire size.
Input Terminals
Screw terminals L1, L2, L3: Line inputs
PE (Protective
Earth) input
DC-ok LED (green) Indicates a normal operation. The LED is on
if the output voltage is higher than 43.2V.
Warning LED (yellow)
- A steady-state light indicates an output
current higher than the nominal current and that the internal shutdown timer is running.
- A double flash indicates a phase-loss or
too low / too high input voltage. (XT40.481: < 3x333Vac or > 3x467Vac XT40.482: < 3x400Vac or > 3x560Vac)
- A fast flash warns of an impending
temperature shut-down. A shut-down can be expected within 10 minutes, if the ambient temperature or the load current stays constant.
Shut-down LED (red) and reset button
The red LED flashes when the device has shut down. Pressing the reset button or cycling the input power (10s required) initiates a restart. If the fault has been cleared the device will operate normally.
Jan. 2007 / Rev. 1.0 DS-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
8/20
– X-Series
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
12. TERMINALS AND WIRING
Use appropriate copper cables that are designed for a minimum operating temperatures of 60°C (for ambient up to 45°C) and 75°C (for ambient up to 60°C). Follow national installation codes and regulations! Ensure that all strands of a stranded wire enter the terminal connection! Do not use the power supply without PE (Ground) connection! Up to two stranded wires with the same cross section are permitted in one connection point (except PE wire). Ferrules are allowed, but not required.
Type Screw terminal Screw terminal Solid wire 0.5-6mm2 0.5-16mm2 Stranded wire 0.5-4mm2 0.5-10mm2 American wire gauge 20-10 AWG 22-8 AWG Wire stripping length 7mm / 0.26inch 12mm / 0.5inch Recommended tightening torque 0.8Nm / 7lb.inch 1.2Nm / 10.6lb.inch
Input Output
13. RELIABILITY
Lifetime expectancy min. 77 000h 40°C, 20A min. > 15 years 40°C, 10A min. > 15 years 25°C, 20A MTBF SN 29500, IEC 61709 541 000h 40°C, 20A 978 000h 25°C, 20A MTBF MIL HDBK 217F 199 000h 40°C, 20A, Ground Benign GB40 267 000h 25°C, 20A, Ground Benign GB25
The Lifetime expectancy shown in the table above indicates the operating hours (service life) and is determined by the lifetime expectancy of the built-in electrolytic capacitors.
Lifetime expectancy is specified in operational hours and is calculated according to the capacitor’s manufacturer specification. The prediction model allows a calculation of up to 15 years from date of shipment.
MTBF stands for Mean Time Between Failure, which is calculated according to statistical device failures, and indicates reliability of a device. It is the statistical representation of the likelihood of a unit to fail and does not necessarily represent the life of a product.
Jan. 2007 / Rev. 1.0 DS-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
9/20
– X-Series
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
14. EMC
The power supply is suitable for applications in industrial environments as well as in residential, commercial and light industry environments without any restrictions. The CE mark is in conformance with EMC guideline 89/336/EEC and 93/68/EEC and the low-voltage directive (LVD) 73/23/EWG. A detailed EMC report is available on request.
EMC Immunity
Electrostatic discharge EN 61000-4-2 Contact discharge
Electromagnetic RF field EN 61000-4-3 80MHz-1GHz 10V/m Criterion A
Fast transients (Burst) EN 61000-4-4 Input lines
Surge voltage on input EN 61000-4-5 L1 Æ L2, L2 Æ L3, L1 Æ L3
Surge voltage on output EN 61000-4-5 + Æ -
Conducted disturbance EN 61000-4-6 0.15-80MHz 10V Criterion A
Mains voltage dips EN 61000-4-11 0% of 400Vac
Powerful transients VDE 0160 over entire load range 1300V, 1.3ms Criterion D
Criteria: A: Power
B: During the mains voltage dip, the output voltage will decrease according to curves in the section “Hold-up Time”. The unit works in normal mode
C: Temporary loss of function is possible. Power supply might shut-down and restarts by itself. No damages or hazards for the power supply will occur. D: The input transient blocker opens and the main converter is without input power during such transients. The output voltage decreases similar as
supply shows normal operation behavior within the defined limits.
once the voltage dip is over. If criteria A is required, use the buffer module UF20.481 in addition to the XT40 power supply.
described in the hold-up time section during such an event.
EMC Emission
Conducted emission EN 55011, EN 55022, FCC Part 15, CISPR 11, CISPR 22 Class B, input lines EN 55022 Class B, output lines Radiated emission EN 55011, EN 55022 Class B Harmonic input current EN 61000-3-2 Fulfilled, active PFC Voltage fluctuations, flicker EN 61000-3-3 Fulfilled
This device complies with FCC Part 15 rules. Operation is subjected to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.
Switching Frequency
Switching frequency 36kHz nearly constant
EN 61000-6-1 and EN 61000-6-2
Generic standards 8kV
Air discharge
15kV
4kV
Output lines
2kV 2kV
L1 / L2 / L3 Æ PE
4kV 500V
+ / - Æ PE
40% of 400Vac 70% of 100Vac 0% of 480Vac 40% of 480Vac 70% of 480Vac
500V
20ms 200ms 500ms 20ms 200ms 500ms
EN 61000-6-3 and EN 61000-6-4 Generic standards
Criterion A Criterion A
Criterion A Criterion A
Criterion A Criterion A
Criterion A Criterion A
Criterion B Criterion C Criterion C Criterion B Criterion C Criterion C
Jan. 2007 / Rev. 1.0 DS-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
10/20
C
– X-Series
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
15. ENVIRONMENT
Operational temperature -25°C to +70°C (-13°F to 158°F) reduce output power above +60°C Output de-rating 24W/°C 60-70°C (140°F to 158°F), see Fig. 15-1 Storage temperature -40 to +85°C (-40°F to 185°F) storage and transportation Humidity 5 to 95% r.H. no condensation allowed
Vibration sinusoidal
Vibration random
Shock
Altitude 0 to 6000m (0 to 20 000ft) Reduce output power or ambient
Output de-rating (for altitude) 60W/1000m or 5°C/1000m above 2000m, see Fig. 15-2 Over-voltage category III EN 50178, altitudes up to 2000m II Altitudes from 2000m to 6000m Degree of pollution 2 EN 50178, non conductive
Fig. 15-1 Output current vs. ambient temp., Fig. 15-2 Output current vs. altitude
Allowed Output Current
20A
15
2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g 2 hours / axis
2(s3
0.5m
)
2 hours / axis 15g 6ms, 10g 11ms
3 bumps / direction, 18 bumps in total
Allowed Output Current
20A
15
IEC 60068-2-6
IEC 60068-2-64
IEC 60068-2-27
temperature above 2000m sea level.
C
B
A
10
5
0
-25 0 20 40
Ambient Temperature
60
70°
10
.
A
.
.
a
T
m
b
5
B C
<
.
.
.
a
T
m
b
<
.
.
.
a
T
m
b
<
0
0 2000 4000
6
C
°
0
5
C
°
0
4
C
°
0
Altitude
6000m
The ambient temperature is defined 2cm below the unit.
Jan. 2007 / Rev. 1.0 DS-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
11/20
– X-Series
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
16. PROTECTION FEATURES
Output protection Electronically protected against overload, no load and short circuits *) Output over-voltage protection max. 57.2Vdc In case of an internal power supply failure, a redundant
circuit limits the maximum output voltage. The output
shuts-down and automatically attempts to restart. Input overvoltage shut-down typ. 3x 470Vac XT40.481 typ. 3x 560Vac XT40.482 Degree of protection IP 20 EN/IEC 60529 Penetration protection > 3.5mm e.g. screws, small parts Over-temperature protection yes output shut-down, reset required Input transient protection MOV (Metal Oxide Varistor) and active transient blocker Internal input fuse not included See section 26.4
*) An audible noise may be heard during a no load, overload or short circuit event.
17. SAFETY
Input / output separation SELV IEC/EN 60950-1 PELV EN 60204-1, EN 50178, IEC 60364-4-41 double or reinforced insulation Class of protection I PE (Protective Earth) connection required Isolation resistance > 5MOhm input to output, 500Vdc PE resistance < 0.1Ohm between housing and PE terminal Touch current (leakage current) typ. 0.30mA XT40.481: 3x400V, 50Hz, TN mains < 0.35mA XT40.481: 3x440V, 50Hz, TN mains typ. 0.40mA XT40.482: 3x480V, 60Hz, TN mains < 0.45mA XT40.482: 3x524V, 60Hz, TN mains
18. DIELECTRIC STRENGTH
The output voltage is floating and has no ohmic connection to ground. Grounding of output allowed. To fulfill the PELV requirements according to EN60204-1 paragraph 6.4.1, PULS recommend that either the + pole or
the – pole shall be connected to the protective earth system. This helps to avoid situations in which a load starts unexpectedly or cannot be switched off when an unnoticed ground fault occurs.
Jan. 2007 / Rev. 1.0 DS-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
Fig. 18-1 Dielectric strength
Input
L1 L2 L3
A
Earth
B
C
Output
+
-
Type test 60s 2500Vac 3000Vac 500Vac
Factory test 5s 2500Vac 2500Vac 500Vac
Field test 5s 2000Vac 2000Vac 500Vac
Type tests and factory tests: Conducted by the manufacturer. Do not repeat these test in the field! Rules for field test: Use appropriate test equipment which applies the voltage with a slow ramp! Connect L1, L2 and L3 together as well as all output poles.
A B C
12/20
– X-Series
19. APPROVALS
IEC 60950-1
UL 508
UL 60950-1
IECEE
CB SCHEME
18WM
LISTED
IND. CONT. EQ.
CB Scheme, Information Technology Equipment
LISTED for Industrial Control Equipment, E198865
RECOGNIZED E137006 recognized for the use in U.S.A. (UL 60950-
1) and Canada (C22.2 No. 60950) Information Technology Equipment, Level 5
20. FULFILLED STANDARDS
EN 61558-2-17 Safety of Power Transformers
EN/IEC 60204-1 Safety of Electrical Equipment of Machines
EN/IEC 61131-2 Programmable Controllers
EN 50178, IEC 62103 Electronic Equipment for Use in Power Installations
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
21. USED SUBSTANCES
The unit does not release any silicone and is suitable for the use in paint shops.
Electrolytic capacitors included in this unit do not use electrolytes such as Quaternary Ammonium Salt Systems.
Plastic housings and other molded plastic materials are free of halogens.
The materials used in our production process do not include the following toxic chemicals: Polychlorinated Biphenyl (PCB), Pentachlorophenol (PCP), Polychlorinated naphthalene (PCN), Polybrominated Biphenyl (PBB), Polybrominated Biphenyl Oxide (PBO), Polybrominated Diphenyl Ether (PBDE), Polychlorinated Diphenyl Ether (PCDE), Polybrominated Diphenyl Oxide (PBDO), Cadmium, Asbestos, Mercury, Silica
Jan. 2007 / Rev. 1.0 DS-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
13/20
– X-Series
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
22. PHYSICAL DIMENSIONS AND WEIGHT
Weight 1400g / 3.09lb DIN-Rail Use 35mm DIN-rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm.
The DIN-rail height must be added to the depth (157mm) to calculate the total required installation depth.
CAD files with mechanical data can be downloaded at www.pulspower.com
Fig. 22-1 Front view Fig. 22-2 Side view
23. INSTALLATION AND OPERATION INSTRUCTIONS
Mounting and installation:
Output terminal must be located on top and input terminal on the bottom. For other orientations see section 26.12. An appropriate electrical and fire end-product enclosure needs to be considered in the end use application.
Cooling:
Convection cooled, no forced air cooling required. Do not block ventilation grill by more than 30%!
Installation clearances:
40mm on top, 20mm on the bottom, 5mm on the left and right side are recommended when loaded permanently with full power. If the adjacent device is a heat source, 15mm clearance are recommended.
Risk of electrical shock, fire, personal injury or death!
Do not use the unit without proper earth connection (Protective Earth). Use the pin on the terminal block for earth connection and not one of the screws on the housing. Turn power off before working on the power supply. Protect against inadvertent re-powering. Make sure the wiring is correct by following all local and national codes. Do not open, modify or repair the unit. Use caution to prevent any foreign objects from entering into the housing. Do not use in wet locations or in areas where moisture or condensation can be expected
Service parts: The unit does not contain any field replaceable parts. If damage or malfunctioning should occur, immediately turn power off and send the unit back to the factory for inspection!
Jan. 2007 / Rev. 1.0 DS-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
14/20
– X-Series
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
24. ACCESSORIES
Buffer module UF20.481 This buffer unit is a supplementary device for DC48V power supplies. It delivers power to bridge typical mains failures
or extends the hold-up time after turn-off of the AC power. In times when the power supply provides sufficient voltages, the buffer unit stores energy in integrated electrolytic capacitors. In case of mains voltage fault, this energy is released again in a regulated process.
Fig. 24-1 Buffer module UF 20.481 Fig. 24-2 Wiring diagram XT40 and UF20.481
The buffer unit does not require any
control wiring. It can be added in parallel
to the load circuit at any given point.
Buffer units can be added in parallel to
increase the output ampacity or the hold-
up time.
AC
Power
Supply
Buffer
Unit(s)
Load
DC
Do not use the buffer module to bridge mains interruptions which are longer than typ. 350ms. Once the mains is off for longer than typ. 350ms, the XT power supply needs an additional 1s to restart again.
+
-
25. COMPARISON BETWEEN THE XT40, A TRANSFORMER AND A TRADITIONAL SWITCHED-MODE POWER SUPPLY
Input voltage range Inrush current surge Hold-up time Phase-loss operation Efficiency Output voltage regulation Output adjustment range Ripple & noise voltage Error diagnostics Harmonic distortion (PFC) EMC Ease of installation Size Weight
+++…very, very good ++…very good +…good -…poor
XT40 Semi-
regulated power
supply
+ ++ -
++ + -
- + -
- + -
+++ ++ -
+ ++ -
- ++ -
- ++ -
++ ++ -
+ + ­++ ++ + ++ ++ -
+++ ++ ­+++ + -
Traditional
switched-mode
power supply
Transformer
power supply
Jan. 2007 / Rev. 1.0 DS-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
15/20
– X-Series
26. APPLICATION NOTES
26.1. PERIODICAL PEAK POWER CAPABILITY
The short term power can be used periodically.
The duration of the peak power (T must be shorter than 15s.
The time between two peak power pulses must be three times longer than the duration of the preceding pulse length.
Fig. 26-Periodical peak power compatibility.
)
P
P
OUT
P
NOM
125% 100%
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
T
TP> 3x T
P
t
26.2. CHARGING OF BATTERIES
The power supply shall not be used to charge batteries.
Jan. 2007 / Rev. 1.0 DS-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
16/20
– X-Series
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
26.3. OUTPUT CIRCUIT BREAKERS
Standard miniature circuit breakers (MCB`s or UL 1077 supplementary breakers) can be used for branch protection but ensure, that the MCB is rated for DC voltage too. The following tests show which circuit breakers the power supply typically will trip.
Circuit breakers have huge tolerances in their tripping behavior. Therefore, these typical tests can only be used as a recommendation or for comparing two different power supplies. Furthermore, the loop impedance has a major influence on whether a breaker trips or not. Two tests were performed, representing typical situations:
Test 1: Short circuit with S1 on the power supply end of the cable (loop impedance approx. 20mOhm)
Fig. 26-1 Branch protectors, test circuit 1
Circuit Power Supply
AC
DC
Breaker
I
+
S1
-
+
Load
-
Test 2: Short circuit with S1 on the load end (additional impedance included; represents longer load wire length).
Fig. 26-2 Branch protectors, test circuit 2
Circuit Power Supply
AC
DC
Breaker
I
+
-
R
+
S1 Load
-
*) A list of the circuit breakers under test is available on request.
Example: Which wire gauge must be used at a length of 8.5m before a B-Characteristic circuit breaker with 32A will trip?
Answer: A 32A B-Characteristic circuit breaker requires a loop impedance of less than 29mOhm based on the test results. The wire length table shows that a length of 9.7m with a cross section of 6.0mm2 has an impedance of 29mOhm. A wire not smaller than 6.0mm
29mOhm 50mOhm 82mOhm
2
shall be used.
Parameters: Input voltage: 3x400Vac, load current: 0A
The following circuit breaker tripped during the test:
A- or Z- Characteristic:: equal or smaller 25A *) B- Characteristic: equal or smaller 32A *) C- Characteristic: equal or smaller 20A *)
Parameters: Input voltage: 3x400Vac, load current: 0A
The following circuit breaker tripped during the test:
A- or Z- Characteristic:: ≤ 25A and R= 50mOhm *) B- Characteristic: ≤ 32A and R= 29mOhm *) C- Characteristic: ≤ 20A and R= 82mOhm *)
What does this resistance mean in wire length?
2
1.0mm
1.5mm2 2.5mm2 4.0mm2 6mm2 10mm2
1.6m 2.4m 4.0m 6.5m 9.7m 16.2m
2.8m 4.2m 7.0m 11.1m 16.7m 27.9m
4.6m 6.9m 11.4m 18.3m 27.4m 45.7m
Jan. 2007 / Rev. 1.0 DS-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
17/20
– X-Series
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
26.4. EXTERNAL INPUT PROTECTION
The power supply has no internal input fuses included. The unit is tested and approved for branch circuits up to 16A (U.S.A 15A). External protection is only required if the supplying branch has an ampacity greater than this. In some countries local regulations might apply so check all local codes and requirements. If an external fuse is necessary or utilized, minimum requirements need to be considered to avoid nuisance tripping of the fuse.
B-Characteristic C-Characteristic
Ampacity max.
min.
20A 20A
6A 3A
26.5. BACK-FEEDING LOADS
Loads such as decelerating motors and inductors can feed voltage back to the power supply. This feature is also called return voltage immunity or resistance against Back- E.M.F. (E
This power supply is resistant and does not show adverse effects when a load feeds back voltage to the power supply. It does not matter, whether the power supply is on or off.
If the power supply is fully loaded after a return-feeding event, the output voltage can dip to 21V for approx 20ms. The maximum allowed feed back voltage is 55.1Vdc. The absorbing energy can be calculated according to the built-in
large sized output capacitor which is specified in chapter 7.
lectro Magnetic Force).
26.6. PARALLEL USE TO INCREASE OUTPUT POWER
The XT40 Series of power supplies shall not be paralleled to increase the output power.
26.7. PARALLEL USE FOR REDUNDANCY
Power supplies can be paralleled for a 1+1 redundancy to gain a higher system availability and reliability. Redundant systems require a certain amount of extra power to support the load in case one power supply unit fails. The simplest way is to put two X-Series power supplies in parallel which is called a 1+1 redundancy. In case one power supply unit fails, the other one is automatically able to support the load current without any interruption.
Please note: This simple way to build a redundant system does not cover failures such as an internal short circuit on the secondary side of the power supply. In such a condition, the shorted unit becomes a load for the other power supplies and the output voltage can not be maintained. This can be avoided by utilizing decoupling diodes which are included in the Dimension redundancy module YRM2.DIODE or YR2.DIODE. One module is needed per XT-power supply.
Recommendations for building redundant power systems: a) Use separate input fuses for each power supply. b) Monitor the individual power supply units. A DC-ok LED and a DC-ok contact is included in the redundancy
module YRM2.DIODE and can report a faulty unit.
Jan. 2007 / Rev. 1.0 DS-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
18/20
– X-Series
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
26.8. SERIES OPERATION
The power supplies of the X-Series can be put in series to increase the output voltage.
Fig. 26-3 Schematic for series operation
Unit A
AC
Unit B
AC
DC
DC
+
-
+
-
+
Load
-
Earth (see notes)
Installation notes for use in series:
a) It is possible to connect as many units in series as needed,
providing the sum of the output voltage does not exceed 150Vdc.
b) Voltages with a potential above 60Vdc are no longer rated SELV
and can be hazardous in some situations. Such voltages must be
installed with a protection to make the unit touch-safe. c) For serial operation use power supplies of the same type. d) Earthing of the output is required when the sum of the output
voltage is above 60Vdc. e) Keep an installation clearance of 15mm (left/right) between two
power supplies and avoid installing the power supplies on top of
each other.
Avoid return voltage (e.g. from a decelerating motor or
Note: battery) which is applied to the output terminals.
26.9. INDUCTIVE AND CAPACITIVE LOADS
The unit is designed to supply any kind of loads, including inductive loads or capacitive loads with a capacity of up to120mF.
26.10. LOSS OF ONE INPUT PHASE
The unit protects itself against a loss of one input phase and does not require an external protection device. A phase-loss operation is possible for output currents below 4A. Above this level, the yellow LED indicates an
impending shut-down. If the missing phase does not recover, the unit switches off after 3.5s. Pressing the reset button or cycling the input power (10s required) initiates a restart.
Please note that the input current and the output ripple are higher during the time when one phase is missing.
26.11. USE IN A TIGHTLY SEALED ENCLOSURE
When the power supply is installed in a tightly sealed enclosure, the temperature inside the enclosure will be higher than outside. The inside temperature defines the ambient temperature for the power supply.
Results from such an installation: Power supply is placed in the middle of the box, no other heat producing equipment inside the box Enclosure: Rittal Typ IP66 Box PK 9519 100, plastic, 180x180x165mm
Load: 48V, 16A (=80% of the rated current); load is placed outside the box Input: 3x400Vac Temperature inside the box: 52.9°C (in the middle of the right side of the power supply with a distance of 2cm) Temperature outside the box: 25.1°C Temperature rise: 27.8K
Jan. 2007 / Rev. 1.0 DS-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
19/20
C
C
C
C
C
– X-Series
XT40.481, XT40.482
48V, 20A, THREE-PHASE INPUT
26.12. MOUNTING ORIENTATIONS
Mounting orientations other than input terminals on the bottom and output on the top require a reduction in continuous output power or a limitation in the max. allowed ambient temperature. The amount of reduction defines the lifetime expectancy of the power supply. Therefore, two different derating curves for continuous operation can be found below:
Curve A1 Recommended output current to achieve a minimum lifetime expectancy of 50 000h at 40°C ambient. Curve A2 Max allowed output current for a safe operation (results approx. in half the lifetime expectancy of A1).
Fig. 26-4
Mounting Orientation A
Standard Orientation
Fig. 26-5
Mounting Orientation B (Upside down)
OUTPUT
Power
Supply
INPUT
INPUT
Supply
Power
OUTPUT
Fig. 26-6
Mounting Orientation C
(Table-top mounting)
Fig. 26-7
Mounting Orientation D
(Horizontal cw)
Supply
INPUT
OUTPUT
Power
Fig. 26-8
Mounting Orientation E
(Horizontal ccw)
OUTPUT
Power
INPUT
Supply
Output Current
20A
15
10
5
0
Ambient Temperature
10 20 30 40
Output Current
20A
15
10
5
0
Ambient Temperature
10 20 30 40
Output Current
20A
15
10
5
0
Ambient Temperature
10 20 30 40
Output Current
20A
15
10
5
0
Ambient Temperature
10 20 30 40
Output Current
20A
15
10
5
0
Ambient Temperature
10 20 30 40
A
1
60°
50
A
2
A
1
50
A
2
A
1
50
50
A
2
A
1
50
60°
60°
A
2
A
1
60°
60°
Jan. 2007 / Rev. 1.0 DS-XT40.48x-EN All parameters are specified at 48V 20A, 3x400Vac (XT40.481) or 3x480Vac (XT40.482), 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
20/20
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