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xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 1/20 s emi -r egulated p ower s upply ? 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 -25c and +60c ? easy failure diagnostics ? no electrolytic capaci tors on input side ? cost effective and robust ? 3 year warranty 1. g eneral d escription 2. s hort - form d ata 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 -25c to +70c operational derating 24w/c +60 to +70c 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 e fficiency and extremely competitive pricing with onl y 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 applicatio ns involving supplies to motors, valves and other lo ad 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. dimensions 96x124x159mm wxhxd 3. o rder n umbers 4. m arkings power supply xt40.241 400v input xt40.242 480v input ind. cont. eq. 18wm listed ul 508 ul 60950-1 emc, lvd accessory uf20.241 slr01 24v buffer unit redundancy module
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 2/20 i ndex p age i ndex p age 1. general desc ription ............................................1 2. short-form data ..................................................1 3. order numb ers....................................................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 lo sses................................7 10. functional di agram.............................................8 11. front side and us er elements.............................8 12. terminals a nd wiring..........................................9 13. reliability .............................................................9 14. emc....................................................................10 15. environm ent ......................................................11 16. protection fe atures ...........................................12 17. safety .................................................................12 18. dielectric s trength ............................................12 19. approval s...........................................................13 20. fulfilled stan dards ............................................13 21. used sub stances ............................................... 13 22. physical dimensi ons and weight ..................... 14 23. installation and operat ion instructions .......... 14 24. accessori es ........................................................ 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 ba tterie s ............................. 16 26.3. output circui t breake rs ......................... 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 oper ation..................................... 19 26.9. inductive and capacitive loads ............. 19 26.10. loss of one in put phase......................... 19 26.11. use in a tightly sealed enclosure .......... 19 26.12. mounting orientations .......................... 20 i ntended u se 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 instrume ntation equipment. do not use this de vice in aircraft, trains and nuclear equipment, where malfunctioning of the power supply may ca use severe personal injury or threaten human life. t erminology and a breviations pe and symbol pe is the abbreviation for p rotective e arth 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 pa rameters 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. d isclaimer the information presented in this document is believed to be accurate and reliable and may change without notice.
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 3/20 5. ac-i nput xt40.241 xt40.242 ac input nom. 3ac 400v 3ac 480v mains arrangement tn-, tt- or it-mains consult fa ctory 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 *) permanently allowed, see fig. 5-1 for output voltage regulation max. 3x 475vac 3x 565vac absolute ma ximum input voltage with no damage to the power supply. output might be off at this level. 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 typ. 70ms 70ms 40mf, 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 350 ms 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). input voltage range fig. 5-1 output voltage vs. inpu t voltage and input current changes of the input voltage will be fully regulated within ce rtain limits. the output voltage will only start to change proportionally to the input voltage with extreme under or over-voltages. the 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 re ports ?shut-down? by the red led. 24v 20v 26v 22v 420 340 480vac 320 504 456 576vac 384 xt40.241: v out v in xt40.242: 400 360 380 440 480 460 300 28v 528 552 432 408 360 p out > 48w (5%) p out = 0w
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 4/20 fig. 5-2 input voltage range fig. 5-3 turn-on behavior definitions turn-on fully regulated range v in p out 3x 528vac shut-down 3x 432vac 480v version: 3x 440vac 3x 360vac 400v version: start-up delay rise time overshoot - 5% output voltage intput voltage fig. 5-4 input current vs. output load fig. 5-5 power factor vs. output load 50a 510 30 45 0 0.3 0.6 0.9 1.2 1.5 1.8a input current per phase, typ. output current 15 20 25 35 40 xt 4 0 . 2 4 1 ( 3 x 4 0 0 v ) x t 4 0 . 2 4 2 ( 3 x 4 8 0 v ) 50a 510 30 45 0.70 0.75 0.8 0.85 0.9 0.95 1.0 power factor, typ. output current 15 20 25 35 40 6. i nput i nrush c urrent there is virtually no input inrush current surge as there ar e no electrolytic bulk-capacitors utilized on the input side of the power supply. the charging current into the emi su ppression capacitors is disregarded for the first millisecond after switch-on. xt40.241 xt40.242 inrush current max. 4a peak 4a peak -25c to +70c, see fig. 6-1 inrush energy max. 5a 2 s 5a 2 s -25c to +70c, see fig. 6-1 inrush delay typ. 400ms 350ms see fig. 6-1 fig. 6-1 input inrush current, typical behavior input current input voltage output voltage a a: inrush delay xt40.241: input: 3x400vac, only one phase shown output: 24v, 40a ambient: 25c 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
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 5/20 7. o utput output voltage nom. 24.1v output voltage adjustment range none the output voltage is fi xed. no adjustment possible output current nom. 40a continuous, see fig. 7-1 50a up to 15s with full output voltage, see fig. 7-1 short-circuit current typ. 180a load impedance 25mohm, see fig. 7-1 note: the short-circuit curre nt is available for 0.1s output power nom. 960w continuous 1200w up to 15s line regulation max. 2% see fig. 5-1 load regulation max. 800mv static value, 0a ? 40a ? 0a max. 200mv static value, 5a ? 40a ? 5a ripple and noise voltage *) max. 1500mvpp 20hz-2khz, 50ohm max. 50mvpp 2khz to 20mhz, 50ohm output capacitance typ. 20 000f *) 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 controlle d by an output power manager. if th e 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 shut- down. pressing the reset button or cycling the input power (10s off time is require d) 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. v out 40a 50a 140a 80a 0 a 15s 24v 200a 60a 20a 100a 120a 160a 180a 12v i out b 5s c 0.1s 3x 340v 3x 408v 3x 400v 3x 480v 3x 460v 3x 552v xt40.241 xt40.242 zone a : 25% extra output power for typ. 15s zone b : 100% higher output current for typ. 5s zone c : quick-acting shut-down after typ. 0.1s
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 6/20 8. h old - up t ime xt40.241 xt40.242 hold-up time typ. 2.0ms 2. 0ms 40a, resistive load, see fig. 8-2 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 fig. 8-2 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 fig. 8-1 hold-up time, definitions 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 fig. 8-2 . the 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 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 when the input is turned off and until the output voltage falls below 24v ?15% (20.4v). this value is defined in the iec61131-2 as the lower limit for the supplying voltage. -15% hold- up time zero transition output voltage intput voltage fig. 8-2 hold-up time vs. input voltage 24v 12v 18v 14v v out 22v 16v 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 8.0 5.0 8.5 9.0ms 40a, constant power load, typ. 40a, resistive load, typ. t 40a, constant power load, min. 40a, resistive load, min. 20.4v note: at no load, the hold-up time can be up to one minute. the green dc-ok led is on during this time.
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 7/20 9. e fficiency and p ower l osses xt40.241 xt40.242 efficiency typ. 95.5% 95.5% 40a power losses typ. 45.2w 45.2w 40a typ. 18.2w 18.2w 0a fig. 9-1 efficiency vs. output current fig. 9-2 losses vs. output current efficiency 510 40 a 88 89 90 91 92 93 output current 94 95 96% 15 20 25 30 35 power losses 0481216202428 40 a 0 10 20 30 40 50w 32 36 output current fig. 9-3 efficiency vs. input voltage, 24v, 40a fig. 9-4 losses vs. input voltage, 24v, 40a efficiency 350 400 450 500 3x550 va c 94.6 94.8 95.0 95.2 input voltage 95.4 95.6 95.8% xt40.241 xt40.242 power losses 350 400 450 500 3x550 va c 40 42 44 46 input voltage 48 50 52w xt40.241 xt40.242
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 8/20 10. f unctional d iagram fig. 10-1 functional diagram + - active transient blocker input filter input rectifier reset output voltage monitor over- voltage protection output power manager temp. shut- down input voltage monitor l3 l2 l1 semi- regulated power converter output filter dc-ok led warning led shut-down led 11. f ront s ide and u ser e lements fig. 11-1 front side of xt40.241 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 21.6v. 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. (xt40.241: < 3x333vac or > 3x467vac xt40.242: < 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.
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 9/20 12. t erminals and w iring use appropriate copper cables that are designed for a minimum operating temperatures of 60c (for ambient up to 45c) and 75c (for ambient up to 60c). follow national installation codes and regulations! ensure that all strands of a stranded wire enter the terminal connection! do not us e 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. input output type screw terminal screw terminal solid wire 0.5-6mm 2 0.5-16mm 2 stranded wire 0.5-4mm 2 0.5-10mm 2 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 13. r eliability lifetime expectancy min. 51 000h 40c, 24.1v, 40a min. t.b.d. 40c, 24.1v, 20a min. 142 000h 25c, 24.1v, 40a mtbf sn 29500, iec 61709 529 000h 40c, 24.1v, 40a 959 000h 25c, 24.1v, 40a mtbf mil hdbk 217f 206 000h 40 c, 24.1v, 40a, ground benign gb40 276 000h 25c, 24.1v, 40a, 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 calc ulation of up to 15 years from date of shipment. mtbf stands for m ean t ime b etween f ailure, which is calculated according to statistical device fa ilures, and indicates reliability of a device. it is the statistical representati on of the likelihood of a unit to fail and does not necessarily represent the life of a product.
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 10/20 14. emc the power supply is suitable for applicat ions in industrial environm ents as well as in reside ntial, commercial and light industry environments without any restrict ions. the ce mark is in conforma nce with emc guide line 89/336/eec and 93/68/eec and the low-voltage directive (lvd) 73/23/ew g. a detailed emc report is available on request. emc immunity en 61000-6-1 and en 61000-6-2 generic standards electrostatic discharge en 61000-4-2 contact discharge air discharge 8kv 15kv criterion a criterion a electromagnetic rf field en 6100 0-4-3 80mhz-1ghz 10v/m criterion a fast transients (burst) en 61000-4-4 input lines output lines 4kv 2kv criterion a criterion a surge voltage on input en 61000-4-5 l1 ? l2, l2 ? l3, l1 ? l3 l1 / l2 / l3 ? pe 2kv 4kv criterion a criterion a surge voltage on output en 61000-4-5 + ? - + / - ? pe 500v 500v criterion a criterion a conducted disturbance en 61000-4-6 0.15-80mhz 10v criterion a mains voltage dips en 61000-4-11 0% of 400vac 40% of 400vac 70% of 100vac 0% of 480vac 40% of 480vac 70% of 480vac 20ms 200ms 500ms 20ms 200ms 500ms criterion b criterion c criterion c criterion b criterion c criterion c powerful transients vde 0160 over entire load range 1300v, 1.3ms criterion d criteria: a: power supply shows normal operation behavior within the defined limits. b: during the mains voltage dip, the output voltage will decrease according to curves in the section ?hold-up time?. the unit wo rks in normal mode once the voltage dip is over. if criteria a is required, use one or two buffer modules uf20.241 in addition to the xt40 power s upply. c: temporary loss of function is possible. power supply might shut -down and restarts by itself. no damages or hazards for the po wer supply will occur. d: the input transient blocker opens and the main converter is without input power during such transients. the output voltage de creases similar as described in the hold-up time section during such an event. emc emission en 61000-6-3 and en 61000-6-4 generic standards 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 61 000-3-2 fulfilled, active pfc voltage fluctuations, flic ker en 61000-3-3 fulfilled this device complies with fcc part 15 rules. operation is subjected to the following two conditions: (1) th is 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
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 11/20 15. e nvironment operational temperature -25c to +70c (-13f to 158f) reduce output power above +60c output de-rating 24w/c 60-70c (140f to 158f), see fig. 15-1 storage temperature -40 to +85c (-40f to 185f) storage and transportation humidity 5 to 95% r.h. no condensation allowed vibration sinusoidal 2-17.8hz: 1.6mm; 17.8-500hz: 2g 2 hours / axis iec 60068-2-6 vibration random 0.5m 2 (s 3 ) 2 hours / axis iec 60068-2-64 shock 15g 6ms, 10g 11ms 3 bumps / direction, 18 bumps in total iec 60068-2-27 altitude 0 to 6000m (0 to 20 000ft) reduce output power or ambient temperature above 2000m sea level. output de-rating (for altitude) 60w/1000m or 5c/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 0 -25 0 20 40 70 c 10 20 30 40a 60 ambient temperature allowed output current 0 0 2000 4000 6000m 10 20 30 40a altitude a . . . t a m b < 6 0 c b . . . t a m b < 5 0 c c . . . t a m b < 4 0 c a b c the ambient temperature is defined 2cm below the unit.
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 12/20 16. p rotection f eatures output protection electronically protected against overload, no load and short circuits *) output over-voltage protection max. 29.9vdc in ca se 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 xt40.241 typ. 3x 560vac xt40.242 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 oxid e 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. s afety input / output separation selv iec/en 60950-1 pelv en 60204-1, en 50178, iec 60364-4-41 double or rein forced insulation class of protection i pe (protective earth) connection required isolation resistance > 5moh m input to output, 500vdc pe resistance < 0.1ohm between housing and pe terminal touch current (leakage current) typ. 0. 30ma xt40.241: 3x400v, 50hz, tn mains < 0.35ma xt40.241: 3x440v, 50hz, tn mains typ. 0.40ma xt40.242: 3x480v, 60hz, tn mains < 0.45ma xt40.242: 3x524v, 60hz, tn mains 18. d ielectric s trength fig. 18-1 dielectric strength a b c type test 60s 2500vac 3000vac 500vac factory test 5s 2500vac 2500vac 500vac field test 5s 2000vac 2000vac 500vac a c b l1 input earth output - + l3 l2 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. the output voltage is floating and has no ohmic co nnection to ground. grounding of output allowed. to fulfill the pelv requirements accord ing to en60204-1 paragraph 6.4.1, puls recommend that eith er 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.
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 13/20 19. a pprovals iec 60950-1 iecee cb scheme cb scheme, information technology equipment ul 508 ind. cont. eq. 18wm listed listed for industrial con trol equipment, e198865 ul 60950-1 recognized e137006 recognize d for the use in u.s.a. (ul 60950- 1) and canada (c22.2 no. 60950) information technology equipment, level 5 20. f ulfilled s tandards 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 21. u sed s ubstances 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 oxid e (pbdo), cadmium, asbestos, mercury, silica
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 14/20 22. p hysical d imensions and w eight 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 ca n be downloaded at www.pulspower.com fig. 22-1 front view fig. 22-2 side view 23. i nstallation and o peration i nstructions 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 ri ght 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 ea rth). 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 s upply. 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 obje cts from entering in to the housing. do not use in wet locations or in areas wher e moisture or condensation can be expected service parts: the unit does not contain any field repl aceable parts. if damage or malfunctioning should o ccur, immediately turn power off and send the unit back to the factory for inspection!
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 15/20 24. a ccessories buffer module uf20.241 this buffer unit is a supplementary device for dc24v power s upplies. it delivers power to bridge typical mains failures or extends the hold-up time after turn-off of the ac pow er. in times when the power supply provides sufficient voltages, the buffer unit stores energy in in tegrated electrolytic capaci tors. in case of mains vo ltage fault, this energy is released again in a regulated process. fig. 24-1 buffer module uf 20.241 fig. 24-2 wiring diagram xt40 and uf20.241 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. 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 additi onal 1s to restart again. 25. c omparison between the xt40, a t ransformer and a t raditional s witched - mode p ower s upply xt40 semi- regulated power supply traditional switched-mode power supply transformer 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 dc buffer unit(s) power supply load ac + -
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 16/20 26. a pplication n otes 26.1. p eriodical p eak p ower c apability fig. 26-periodical p eak power compatibility . the short term power can be used periodically. the duration of the peak power (t p ) 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. t t 100% 125% p out p nom t p > 3x t p 26.2. c harging of b atteries the power supply shall not be used to charge batteries.
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 17/20 26.3. o utput c ircuit b reakers standard miniature circuit breakers (mcb`s or ul 1077 suppl ementary breakers) can be used for branch protection but ensure, that the mcb is rated for dc voltage too. the follo wing tests show which circuit breakers the power supply typically will trip. circuit breakers have huge tolera nces in their tripping behavi or. therefore, these typical tests can only be used as a recommendation or for comparing two different power s upplies. furthermore, the loop impedance has a major influence on whether a breaker trips or not. two tests were performed, represen ting 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 breaker power supply ac dc + - i load + - s1 parameters: input voltage: 3x400vac, load current: 0a the following circuit breaker tripped during the test: a - or z - characteristic:: equa l or smaller 25a *) b - characteristic: e qual or smaller 32a *) c - characteristic: e qual or smaller 20a *) 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 r circuit breaker power supply ac dc + - i s1 load + - 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: 25a and r= 50mohm *) c - characteristic: 20a and r= 82mohm *) what does this resistance mean in wire length? 1.0mm 2 1.5mm 2 2.5mm 2 4.0mm 2 6.0mm 2 10mm 2 50mohm 2.8m 4.2m 7.0m 11.1m 16.7m 27.9m 82mohm 4.6m 6.9m 11.4m 18.3m 27.4m 45.7m *) a list of the circuit breakers under test is available on request. example: which wire gauge must be used at a length of 10m before a b- characteristic circuit brea ker with 25a will trip? answer: a 25a b-characteristic circuit breaker requires a loop impedance of less than 50mohm based on the test results. the wire length table shows that a le ngth of 11.1m with a cross section of 4.0mm 2 has an impedance of 50mohm. a wire not smaller than 4.0mm 2 shall be used.
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 18/20 26.4. e xternal i nput p rotection 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 s upplying branch has an ampacity greater than this. in some countries local regulations might apply so check all local code s and requirements. if an external fuse is necessary or utilized, minimum requirements need to be consid ered to avoid nuisance tripping of the fuse. b-characteristic c-characteristic ampacity max. 20a 20a min. 6a 3a 26.5. b ack - feeding l oads loads such as decelerating motors and inductors can feed voltag e back to the power supply. this feature is also called return voltage immunity or resi stance against back- e.m.f. (e lectro m agnetic f orce). 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 ev ent, the output voltage can dip to 21v for approx 20ms. the maximum allowed feed back voltage is 28.9vdc. the absorbing energy can be calculated according to the built-in large sized output capacitor which is specified in chapter 7. 26.6. p arallel u se to i ncrease o utput p ower the xt40 series of power supplies shall not be paralleled to increase the output power. 26.7. p arallel u se for r edundancy 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 wh ich is called a 1+1 redundancy. in case one power supply unit fails, the other one is automatically able to supp ort the load current without any interruption. please note: this simple way to build a redundant system does not co ver failures such as an in ternal short circuit on the secondary side of the power supply. in such a condi tion, 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 silverline redundancy module slr01. 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 slr01and can report a faulty unit.
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 19/20 26.8. s eries o peration the power supplies of the x-series can be put in series to increase the output voltage. fig. 26-3 schematic for series operation installation notes for use in series: unit b - + load + - ac dc ac dc - + unit a earth (see notes) a) it is possible to connect as many units in series as needed, providing the sum of the out put 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 requi red 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. note: avoid return voltage (e.g. from a decelerating motor or battery) which is applied to the output terminals. 26.9. i nductive and c apacitive l oads the unit is designed to supply any kind of loads, including inductive loads or capacitive loads with a capacity of up to160mf. 26.10. l oss of o ne i nput p hase 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 8a. above this level, the yellow led indicates an impending shut-down. if the missing phase does not recove r, the unit switches off af ter 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. u se in a t ightly s ealed e nclosure when the power supply is installed in a tightly sealed encl osure, 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: 24v, 32a (=80% of the rated current); load is placed outside the box input: 3x400vac temperature inside the box: 54.9c (in the middle of the ri ght side of the power supply with a distance of 2cm) temperature outside the box: 25.7c temperature rise: 29.7k
xt40.241, xt40.242 ? x-series 24v, 40a, t hree -p hase i nput jan. 2007 / rev. 1.0 ds-xt40.24x-en all parameters are specified at 24v 40a, 3x400vac (xt40.241) or 3x480vac (xt40.242), 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone + 49 89 9278 0 germany 20/20 26.12. m ounting o rientations mounting orientations other than input terminals on th e 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 s upply. 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 40c ambient. curve a2 max allowed output current for a safe operation (resul ts approx. in half the lifet ime expectancy of a1). fig. 26-4 mounting orientation a standard orientation power supply output input output current 0 10 20 30 40 60 c 10 20 30 40a 50 a 1 ambient temperature fig. 26-5 mounting orientation b (upside down) power supply output input output current 0 10 20 30 40 60 c 10 20 30 40a 50 a 2 ambient temperature a 1 fig. 26-6 mounting orientation c (table-top mounting) output current 0 10 20 30 40 60 c 10 20 30 40a 50 ambient temperature a 1 a 2 fig. 26-7 mounting orientation d (horizontal cw) power supply output input output current 0 10 20 30 40 60 c 10 20 30 40a 50 ambient temperature a 1 a 2 fig. 26-8 mounting orientation e (horizontal ccw) power supply output input output current 0 10 20 30 40 60 c 10 20 30 40a 50 ambient temperature a 1 a 2

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