XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
SEMI-REGULATED POWER SUPPLY
•
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•
•
•
•
•
•
•
•
•
•
GENERAL DESCRIPTION
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
SHORT-FORM DATA
Output voltage
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.
ORDER NUMBERS
Power Supply
Accessory
DC 24V
Adjustment range
Output current
none
40A
50A
Output power
960W
1200W
Output ripple
< 1500mVpp
< 200mVpp
Input voltage
3AC 400V
3AC 480V
Mains frequency
50-60Hz
AC Input current
1.65A / phase
1.4A / phase
Power factor
0.93
AC Inrush current
typ. 2A peak
Efficiency
95.5%
Losses
45.2W
Temperature range -25°C to +70°C
Derating
24W/°C
Dimensions
96x124x159mm
Factory setting to
24.1V
continuous
for typ. 15s
continuous
for typ. 15s
20Hz-2kHz
2kHz to 20MHz
XT40.241
XT40.242
±6%
XT40.241, 3x400V
XT40.242, 3x480V
24V, 40A
operational
+60 to +70°C
WxHxD
MARKINGS
XT40.241
400V Input
XT40.242
480V Input
UF20.241
24V Buffer Unit
SLR01
Redundancy Module
UL 508
UL 60950-1
Nov. 2020 / Rev. 1.1 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
IEC 60950-1
1/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
INDEX
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
PAGE
Intended Use .......................................................3
Installation Instruction ........................................3
AC-Input...............................................................4
Input Inrush Current ...........................................5
Output .................................................................6
Hold-up Time .......................................................7
Efficiency and Power Losses................................8
Functional Diagram.............................................9
Front Side and User Elements .............................9
Terminals and Wiring ........................................10
Reliability ...........................................................10
EMC ....................................................................11
Environment ......................................................12
Protection Features ...........................................13
Safety .................................................................13
Dielectric Strength ............................................13
Approvals and Fulfilled Standard .....................14
Regulatory Compliance .....................................14
Physical Dimensions and Weight ......................15
INDEX
PAGE
20. Installation and Operation Instructions .......... 15
21. Accessories ........................................................ 16
22. Comparison between the XT40, a Transformer
and a Traditional Switched-mode Power Supply .. 16
23. Application Notes ............................................. 17
23.1. Periodical Peak Power Capability .......... 17
23.2. Charging of Batteries ............................. 17
23.3. Output Circuit Breakers ......................... 18
23.4. External Input Protection....................... 19
23.5. Back-feeding Loads ................................ 19
23.6. Parallel Use to Increase Output Power . 19
23.7. Parallel Use for Redundancy .................. 19
23.8. Series Operation ..................................... 20
23.9. Inductive and Capacitive Loads ............. 20
23.10. Loss of One Input Phase ......................... 20
23.11. Use in a Tightly Sealed Enclosure .......... 20
23.12. Mounting Orientations .......................... 21
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.
Nov. 2020 / Rev. 1.1 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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Germany
2/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
1. INTENDED USE
This device is designed for installation in an enclosure and is intended for commercial use such as in industrial control,
process control, monitoring and measurement equipment or the like. The principal use are applications such as
motors, valves and other load circuits with high power consumption, where an accurate output voltage regulation
and low amount of ripple voltage (standard on switch mode power supplies) is not required.
Do not use this device in equipment, where malfunctioning may cause severe personal injury or threaten human life
without additional appropriate safety devices, that are suited for the end application.
If this device is used in a manner outside of its specification, the protection provided by the device may be impaired.
2. INSTALLATION INSTRUCTION
Install device in an enclosure providing protection against electrical, mechanical and fire hazards.
Install the device onto a DIN-rail according to EN 60715 with the input terminals on the bottom of the device. Other
mounting orientations require a reduction in output current.
Make sure that the wiring is correct by following all local and national codes. Use appropriate copper cables that are
designed for a minimum operating temperature of 60°C for ambient temperatures up to +45°C, 75°C for ambient
temperatures up to +60°C and 90°C for ambient temperatures up to +70°C.
Ensure that all strands of a stranded wire enter the terminal connection. Use ferrules for wires on the input terminals.
Unused screw terminals should be securely tightened.
The device is designed for pollution degree 2 areas in controlled environments. No condensation or frost is allowed.
The housing of the device provides a degree of protection of IP20. The housing does not provide protection against
spilled liquids.
The isolation of the device is designed to withstand impulse voltages of overvoltage category III according to IEC
60664-1.
The device is designed as “Class of Protection I” equipment according to IEC 61140.
Do not use without a proper PE (Protective Earth) connection.
The device is suitable to be supplied from TN, TT or IT mains networks. The continuous voltage between the input
terminal and the PE potential must not exceed 400Vac. The device is not designed to be used on corner grounded
delta systems.
A disconnecting means shall be provided for the input of the device.
The device is designed for convection cooling and does not require an external fan. Do not obstruct airflow and do
not cover ventilation grid!
The device is designed for altitudes up to 5000m (16400ft). Above 2000m (6560ft) a reduction in output current and
over voltage category is required.
Keep the following minimum installation clearances: 40mm on top, 20mm on the bottom, 5mm left and right side.
Increase the 5mm to 15mm in case the adjacent device is a heat source. When the device is permanently loaded with
less than 50%, the 5mm can be reduced to zero.
The device is designed, tested and approved for branch circuits up to 16A (IEC) and 15A (UL) without additional
protection device. If an external fuse is utilized, do not use circuit breakers smaller than 6A B- or 3A C-Characteristic
to avoid a nuisance tripping of the circuit breaker.
The maximum surrounding air temperature is +70°C (+158°F). The operational temperature is the same as the
ambient or surrounding air temperature and is defined 2cm below the device.
The device is designed to operate in areas between 5% and 95% relative humidity.
Nov. 2020 / Rev. 1.1 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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Germany
3/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
3. AC-INPUT
AC input
Mains arrangement
AC input range
Input frequency
Turn-on voltage
Shut-down voltage
Input current
Power factor **)
Turn-on overshoot
Start-up delay ***)
Rise time
*)
**)
***)
nom.
XT40.241
XT40.242
3AC 400V
3AC 480V
TN-, TT- or IT-Mains
3x 360-440Vac
3x 432-528Vac
*)
3x 300-460Vac
3x 360-552Vac *)
max.
3x 475Vac
3x 565Vac
nom.
typ.
typ.
nom.
typ.
typ.
typ.
typ.
typ.
50 – 60Hz
3x 325Vac
3x 295Vac
1.65A
0.93
480mV
400ms
40ms
70ms
50 – 60Hz
3x 390Vac
3x 355Vac
1.4A
0.93
480mV
350ms
40ms
70ms
consult factory if one phase is earthed
fully regulated output (±2%), Pout > 48W
permanently allowed,
see Fig. 5-1 for output voltage regulation
Absolute maximum input voltage with no
damage to the power supply. Output
might be off at this level.
±6%
see Fig. 5-2
see Fig. 5-2
at 40A, symmetrical input, see Fig. 5-4
at 40A, symmetrical input, see Fig. 5-5
see Fig. 5-3
over the entire load range, see Fig. 5-3
0mF, 40A, see Fig. 5-3
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 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).
Input Voltage Range
Fig. 5-1 Output voltage vs. input voltage and input current
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
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.
VOUT
POUT = 0W
28V
26V
POUT > 48W (5%)
24V
22V
VIN
20V
XT40.241: 300 320 340 360 380 400 420 440 460 480Vac
XT40.242: 360 384 408 432 456 480 504 528 552 576Vac
Nov. 2020 / Rev. 1.1 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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4/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
Fig. 5-2 Input voltage range
VIN
400V Version: 3x 360Vac
480V Version: 3x 432Vac
Start-up
delay
3x 440Vac
3x 528Vac
Fig. 5-4 Input current vs. output load
1.2
0.9
0.6
0.3
0
Power Factor, typ.
1.0
)
0V
40
x
3
1(
V)
80
.24
4
0
x
4
3
2(
XT
.24
40
T
X
1.5
Rise
Time
Fig. 5-5 Power factor vs. output load
Input Current per Phase, typ.
1.8A
- 5%
Output
Voltage
Overshoot
fully regulated
range
Turn-on
Shut-down
POUT
Fig. 5-3 Turn-on behavior definitions
Intput
Voltage
0.95
0.9
0.85
0.8
Output Current
0.75
Output Current
0.70
5 10 15 20 25 30 35 40 45 50A
5 10 15 20 25 30 35 40 45 50A
4. 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
Inrush energy
Inrush delay
max.
max.
typ.
XT40.241
4Apeak
5A2s
400ms
XT40.242
4Apeak
5A2s
350ms
-25°C to +70°C, see Fig. 6-1
-25°C to +70°C, see Fig. 6-1
see Fig. 6-1
Fig. 6-1 Input inrush current, typical behavior
A:
Inrush delay
XT40.241:
Input:
Output:
Ambient:
3x400Vac, only one phase shown
24V, 40A
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
Nov. 2020 / Rev. 1.1 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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Germany
5/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
5. OUTPUT
Output voltage
Output voltage adjustment range
Output current
nom.
Short-circuit current
typ.
Output power
nom.
Line regulation
Load regulation
max.
max.
max.
max.
max.
typ.
Ripple and noise voltage *)
Output capacitance
24.1V
none
40A
50A
180A
nom.
960W
1200W
±2%
800mV
200mV
1500mVpp
50mVpp
20 000µF
The output voltage is fixed. No adjustment possible
continuous, see Fig. 7-1
up to 15s with full output voltage, see Fig. 7-1
load impedance 25mOhm, see Fig. 7-1
Note: The short-circuit current is available for 0.1s
continuous
up to 15s
see Fig. 5-1
static value, 0A 40A 0A
static value, 5A 40A 5A
20Hz-2kHz, 50Ohm
2kHz to 20MHz, 50Ohm
*) 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.
A
15s
VOUT
C
0.1s
B
5s
24V
XT40.241
3x 340V
3x 400V
3x 460V
12V
0
20A
40A 50A 60A
80A
100A
120A
140A
160A
XT40.242
3x 408V
3x 480V
3x 552V
180A
200A
IOUT
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
Nov. 2020 / Rev. 1.1 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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Germany
6/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
6. HOLD-UP TIME
Hold-up Time
Hold-up Time
typ.
typ.
typ.
typ.
min.
min.
min.
min.
XT40.241
2.0ms
1.8ms
4.0ms
3.6ms
1.6ms
1.45ms
3.2ms
2.9ms
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.
XT40.242
2.0ms
1.8ms
4.0ms
3.6ms
1.6ms
1.45ms
3.2ms
2.9ms
40A, resistive load, see Fig. 8-2
40A, constant power load, see Fig. 8-2
20A, resistive load
20A, constant power load
40A, resistive load, see Fig. 8-2
40A, constant power load, see Fig. 8-2
20A, resistive load
20A, constant power load
Fig. 8-1 Hold-up time, definitions
Zero Transition
Intput
Voltage
Output
Voltage
Holdup
Time
-15%
Fig. 8-2 Hold-up time vs. input voltage
VOUT
24V
40A, constant power load, min.
22V
40A, constant power load, typ.
20.4V
40A, resistive load, min.
40A, resistive load, typ.
18V
16V
14V
T
12V
0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 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.
Nov. 2020 / Rev. 1.1 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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Germany
7/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
7. EFFICIENCY AND POWER LOSSES
Efficiency
Power losses
XT40.241
95.5%
45.2W
18.2W
typ.
typ.
typ.
XT40.242
95.5%
45.2W
18.2W
Fig. 9-1 Efficiency vs. output current
40A
40A
0A
Fig. 9-2 Losses vs. output current
Power Losses
Efficiency
50W
96%
95
94
93
92
91
90
89
88
40
30
20
10
Output Current
5
10
15
20
25
30
35
40A
Fig. 9-3 Efficiency vs. input voltage, 24V, 40A
95.8%
Efficiency
95.6
XT40.241
XT40.242
Output Current
0
0
52W
95.2
46
95.0
44
94.8
42
350
400
450
Power Losses
50
48
Input Voltage
XT40.241
XT40.242
Input Voltage
40
500 3x550Vac
8 12 16 20 24 28 32 36 40A
Fig. 9-4 Losses vs. input voltage, 24V, 40A
95.4
94.6
4
350
400
450
500 3x550Vac
Nov. 2020 / Rev. 1.1 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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Germany
8/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
8. FUNCTIONAL DIAGRAM
Fig. 10-1 Functional diagram
L1
L2
L3
Input
Filter
Input
Rectifier
Input
Voltage
Monitor
Active
Transient
Blocker
Semiregulated
Power
Converter
Output
Filter
Temp.
Shutdown
OverVoltage
Protection
Output
Voltage
Monitor
+
-
DC-ok
LED
Warning
LED
Output
Power
Manager
Shut-down
LED
Reset
9. FRONT SIDE AND USER ELEMENTS
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.
Nov. 2020 / Rev. 1.1 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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Germany
9/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
10. 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.
Input
Screw terminal
0.5-6mm2
0.5-4mm2
20-10 AWG
7mm / 0.26inch
0.8Nm / 7lb.inch
Type
Solid wire
Stranded wire
American wire gauge
Wire stripping length
Recommended tightening torque
Output
Screw terminal
0.5-16mm2
0.5-10mm2
22-8 AWG
12mm / 0.5inch
1.2Nm / 10.6lb.inch
11. RELIABILITY
Lifetime expectancy
MTBF SN 29500, IEC 61709
MTBF MIL HDBK 217F
min.
min.
min.
51 000h
t.b.d.
142 000h
529 000h
959 000h
206 000h
276 000h
40°C, 24.1V, 40A
40°C, 24.1V, 20A
25°C, 24.1V, 40A
40°C, 24.1V, 40A
25°C, 24.1V, 40A
40°C, 24.1V, 40A, Ground Benign GB40
25°C, 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 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.
Nov. 2020 / Rev. 1.1 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
10/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
12. 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
Electromagnetic RF field
Fast transients (Burst)
Surge voltage on input
Surge voltage on output
Conducted disturbance
Mains voltage dips
Powerful transients
EN 61000-6-1 and EN 61000-6-2
Contact discharge
EN 61000-4-2
Air discharge
EN 61000-4-3
80MHz-1GHz
Input lines
EN 61000-4-4
Output lines
L1 L2, L2 L3, L1 L3
EN 61000-4-5
L1 / L2 / L3 PE
+EN 61000-4-5
+ / - PE
EN 61000-4-6
0.15-80MHz
0% of 400Vac
EN 61000-4-11
40% of 400Vac
70% of 100Vac
0% of 480Vac
40% of 480Vac
70% of 480Vac
VDE 0160
over entire load range
Generic standards
8kV
15kV
10V/m
4kV
2kV
2kV
4kV
500V
500V
10V
20ms
200ms
500ms
20ms
200ms
500ms
1300V, 1.3ms
Criterion A
Criterion A
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
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 works 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 supply.
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
described in the hold-up time section during such an event.
EMC Emission
Conducted emission
EN 61000-6-3 and EN 61000-6-4
Generic standards
EN 55011, EN 55032, FCC Part 15, CISPR 11, CISPR 32 Class B, input lines
EN 55032
Class B, output lines
Radiated emission
EN 55011, EN 55032
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
Nov. 2020 / Rev. 1.1 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
11/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
13. ENVIRONMENT
Operational temperature
Output de-rating
Storage temperature
Humidity
-25°C to +70°C (-13°F to 158°F)
24W/°C
-40 to +85°C (-40°F to 185°F)
5 to 95% r.H.
2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g
2 hours / axis
0.5m2(s3)
2 hours / axis
15g 6ms, 10g 11ms
3 bumps / direction, 18 bumps in total
0 to 6000m (0 to 20 000ft)
Vibration sinusoidal
Vibration random
Shock
Altitude
Output de-rating (for altitude)
Over-voltage category
60W/1000m or 5°C/1000m
III
II
2
Degree of pollution
Fig. 15-1 Output current vs. ambient temp.,
Allowed
Output Current
IEC 60068-2-6
IEC 60068-2-64
IEC 60068-2-27
Reduce output power or ambient
temperature above 2000m sea level.
above 2000m, see Fig. 15-2
EN 50178, altitudes up to 2000m
Altitudes from 2000m to 6000m
EN 50178, non conductive
Fig. 15-2 Output current vs. altitude
Allowed Output
Current
40A
40A
30
30
20
20
10
10
0
-25
reduce output power above +60°C
60-70°C (140°F to 158°F), see Fig. 15-1
storage and transportation
no condensation allowed
Ambient Temperature
0
20
40
60 70°C
B
C
A
A... Tamb < 60°C
B... Tamb < 50°C
C... Tamb < 40°C
Altitude
0
0
2000
4000
6000m
The ambient temperature is defined 2cm below the unit.
Nov. 2020 / Rev. 1.1 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
12/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
14. PROTECTION FEATURES
Output protection
Output over-voltage protection
Electronically protected against overload, no load and short circuits *)
In case of an internal power supply failure, a redundant
max. 29.9Vdc
circuit limits the maximum output voltage. The output
shuts-down and automatically attempts to restart.
typ. 3x 470Vac
XT40.241
typ. 3x 560Vac
XT40.242
IP 20
EN/IEC 60529
> 3.5mm
e.g. screws, small parts
yes
output shut-down, reset required
MOV (Metal Oxide Varistor) and active transient blocker
not included
See section 26.4
Input overvoltage shut-down
Degree of protection
Penetration protection
Over-temperature protection
Input transient protection
Internal input fuse
*) An audible noise may be heard during a no load, overload or short circuit event.
15. SAFETY
Input / output separation
SELV
IEC/EN 60950-1
PELV
EN 60204-1, EN 50178, IEC 60364-4-41
double or reinforced insulation
I
PE (Protective Earth) connection required
> 5MOhm
input to output, 500Vdc
< 0.1Ohm
between housing and PE terminal
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
Class of protection
Isolation resistance
PE resistance
Touch current (leakage current)
16. DIELECTRIC STRENGTH
Type test
60s
A
2500Vac
B
3000Vac
C
500Vac
Factory test
5s
2500Vac
2500Vac
500Vac
Field test
5s
2000Vac
2000Vac
500Vac
Fig. 18-1 Dielectric strength
Input
L1
L2
L3
B
A
Earth
Output
+
C
-
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 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.
Nov. 2020 / Rev. 1.1 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
13/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
17. APPROVALS AND FULFILLED STANDARD
UL Certificate
Listed equipment for category NMTR - Industrial Control Equipment
Applicable for US and Canada
E-File: E198865
CB Scheme Certificate
General safety requirements for Information Technology Equipment
(ITE)
UL 508
IEC 60950-1
UL Certificate
Recognized component for category QQGQ - Information Technology
Equipment (ITE)
Applicable for US and Canada
E-File: E137006
Manufacturer's Declaration (Online Document)
IEC 60068-2-60 - Environmental Tests, Flowing Mixed Gas Corrosion
Test
Test Ke - Method 4
H2S: 10ppb
NO2: 200ppb
Cl2: 10ppb
SO2: 200ppb
Test Duration: 3 weeks, which simulates a service life of at least 10
years
Manufacturer's Declaration (Online Document)
Airborne Contaminants Corrosion Test
Severity Level: G3 Harsh
H2S: 100ppb
NOx: 1250ppb
Cl2: 20ppb
SO2: 300ppb
Test Duration: 3 weeks, which simulates a service life of at least 10
years.
Paint Wetting Impairment Substances Test (or LABS-Test)
Tested for Zone 2 and test class C1 according to VDMA 24364-C1-L/W
for solvents and water-based paints
UL 60950-1
Corrosion
IEC 60068-2-60
Method 4
Corrosion
G3-ISA-71.04
VDMA 24364
18. REGULATORY COMPLIANCE
EU Declaration of
Conformity
REACH Directive
EAC TR Registration
The CE mark indicates conformance with the
- EMC directive
- Low-voltage directive (LVD)
- RoHS directive
Manufacturer's Statement
EU-Directive regarding the Registration, Evaluation,
Authorisation and Restriction of Chemicals
EAC Certificate
EAC EurAsian Conformity - Registration Russia, Kazakhstan and
Belarus
8504408200, 8504409000
Nov. 2020 / Rev. 1.1 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
14/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
19. PHYSICAL DIMENSIONS AND WEIGHT
Weight
DIN-Rail
1400g / 3.09lb
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
20. 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!
Nov. 2020 / Rev. 1.1 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
15/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
21. ACCESSORIES
Buffer module UF20.241
This buffer unit is a supplementary device for DC24V 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 20.241
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 holdup time.
Power
Supply
AC
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.
22. COMPARISON BETWEEN THE XT40, A TRANSFORMER AND A TRADITIONAL
SWITCHED-MODE POWER SUPPLY
XT40 Semiregulated 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
Traditional
switched-mode
power supply
Transformer
power supply
++
+
+
+
++
++
++
++
++
+
++
++
++
+
+
-
++…very good
+…good
-…poor
Nov. 2020 / Rev. 1.1 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
16/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
23. APPLICATION NOTES
23.1. PERIODICAL PEAK POWER CAPABILITY
Fig. 26-Periodical peak power compatibility.
The short term power can be used
periodically.
The duration of the peak power (TP)
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.
POUT
PNOM
T
TP
> 3x TP
125%
100%
t
23.2. CHARGING OF BATTERIES
The power supply shall not be used to charge batteries.
Nov. 2020 / Rev. 1.1 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
17/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
23.3. 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
Power
Supply
AC
Parameters:
Circuit
Breaker
I
Input voltage:
+
+
The following circuit breaker tripped during the test:
Load
S1
DC -
3x400Vac, load current: 0A
A- or Z- Characteristic::
B- Characteristic:
C- Characteristic:
-
equal or smaller 25A *)
equal or smaller 32A *)
equal or smaller 20A *)
Test 2: Short circuit with S1 on the load end (additional impedance included; represents longer load wire length).
Parameters:
Fig. 26-2 Branch protectors, test circuit 2
Circuit
Breaker
I
Power
Supply
AC
+
Input voltage:
The following circuit breaker tripped during the test:
R
A- or Z- Characteristic::
B- Characteristic:
C- Characteristic:
+
Load
S1
DC -
3x400Vac, load current: 0A
-
≤ 25A and R= 50mOhm *)
≤ 25A and R= 50mOhm *)
≤ 20A and R= 82mOhm *)
What does this resistance mean in wire length?
50mOhm
1.0mm2
2.8m
1.5mm2
4.2m
2.5mm2
7.0m
4.0mm2
11.1m
6.0mm2
16.7m
10mm2
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 breaker 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 length of 11.1m with a cross section of 4.0mm2 has an impedance of
50mOhm. A wire not smaller than 4.0mm2 shall be used.
Nov. 2020 / Rev. 1.1 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
18/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
23.4. 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.
Ampacity
max.
min.
B-Characteristic
20A
6A
C-Characteristic
20A
3A
23.5. 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. (Electro Magnetic Force).
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 28.9Vdc. The absorbing energy can be calculated according to the built-in
large sized output capacitor which is specified in chapter 7.
23.6. PARALLEL USE TO INCREASE OUTPUT POWER
The XT40 Series of power supplies shall not be paralleled to increase the output power.
23.7. 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 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.
Nov. 2020 / Rev. 1.1 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
19/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
23.8. 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
DC
+
+
Unit B
AC
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.
Note: Avoid return voltage (e.g. from a decelerating motor or
battery) which is applied to the output terminals.
23.9. 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
to160mF.
23.10. 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 8A. 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.
23.11. 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:
Load:
Input:
Temperature inside the box:
Temperature outside the box:
Temperature rise:
Rittal Typ IP66 Box PK 9519 100, plastic, 180x180x165mm
24V, 32A (=80% of the rated current); load is placed outside the box
3x400Vac
54.9°C (in the middle of the right side of the power supply with a distance of 2cm)
25.7°C
29.7K
Nov. 2020 / Rev. 1.1 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
20/21
XT40.241, XT40.242
24V, 40A, THREE-PHASE INPUT
– X-Series
23.12. 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
Curve A2
Recommended output current to achieve a minimum lifetime expectancy of 50 000h at 40°C ambient.
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
Output Current
40A
OUTPUT
A1
30
Power
Supply
20
10
Ambient Temperature
0
INPUT
10
Fig. 26-5
Mounting
Orientation B
(Upside down)
20
30
40
60°C
50
Output Current
40A
INPUT
30
A2
Power
Supply
20
A1
OUTPUT
0
10
Ambient Temperature
10
Fig. 26-6
Mounting
Orientation C
(Table-top
mounting)
20
30
50
40
60°C
Output Current
40A
30
A2
A1
20
10
Ambient Temperature
0
10
50
40
60°C
40A
OUTPUT
Power
Supply
30
A2
20
A1
10
Ambient Temperature
0
10
20
30
40
50
60°C
Output Current
30
INPUT
Power
Supply
40A
OUTPUT
Fig. 26-8
Mounting
Orientation E
(Horizontal ccw)
30
Output Current
INPUT
Fig. 26-7
Mounting
Orientation D
(Horizontal cw)
20
A2
A1
20
10
Ambient Temperature
0
10
20
30
40
50
60°C
Nov. 2020 / Rev. 1.1 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
21/21
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