QS40.244
24V, 40A, SINGLE PHASE INPUT
Q-Series
POWER SUPPLY
AC 200-240V Input
Width only 125mm, Weight only 1.8kg
94.6% Full Load and Excellent Partial Load Efficiencies
50% BonusPower®, 1440W for up to 4s
110A High Peak Current for 25ms for Easy Fuse Tripping
Safe HiccupPLUS Overload Mode
Active PFC (Power Factor Correction)
Negligible Low Input Inrush Current Surge
Full Power Between -25°C and +60°C
Current Sharing Feature for Parallel Use
Internal Data Logging for Troubleshooting Included.
DC-OK Relay Contact
Shut-down Input
3 Year Warranty
GENERAL DESCRIPTION
SHORT-FORM DATA
The most outstanding features of the DIMENSION QSeries DIN-rail power supplies are the extremely high
efficiencies and the small sizes, which are achieved by a
synchronous rectification and other technological
designs.
Output voltage
Adjustment range
Output current
The QS40.244 is a device for 200-240V mains voltages.
Large power reserves of 150% support the starting of
heavy loads such as DC-motors or capacitive loads. In
many cases this allows the use of a unit from a lower
wattage class which saves space and money.
High immunity to transients and power surges as well as
low electromagnetic emission makes usage in nearly
every environment possible.
The integrated output power manager and input fuses
as well as the near zero input inrush current make
installation and usage simple. Diagnostics are easy due
to the DC-OK relay, a green DC-OK LED and the red
overload LED.
A large international approval package for a variety of
applications makes this unit suitable for nearly every
application.
DC 24V
24 - 28Vdc
40 – 34.3A
60 – 51.5A
Output power
960W
1440W
Output ripple
< 100mVpp
Input voltage
AC 200-240V
Mains frequency
50-60Hz
AC Input current
4.6A
Power factor
0.96
AC Inrush current
14A peak
Efficiency
94.6%
Losses
54.8W
Temperature range -25°C to +70°C
Derating
24W/°C
Hold-up time
30ms
Dimensions
125x124x127mm
Weight
1800g / 3.97lb
nominal
continuous
short term (4s)
continuous
short term (4s)
20Hz to 20MHz
-15%/+10%
±6%
at 230Vac
at 230Vac
at 230Vac
at 230Vac
at 230Vac
operational
+60 to +70°C
at 230Vac
WxHxD
MARKINGS
ORDER NUMBERS
Power Supply
QS40.244
24-28V Standard unit
Accessory
ZM2.WALL
UF20.241
YR80.242
YR40.245
Wall mount bracket
Buffer unit
Redundancy module
Redundancy module
UL508
UL60950-1
IEC 60950-1
Marine
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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Germany
1/30
QS40.244
24V, 40A, SINGLE PHASE INPUT
Q-Series
INDEX
Page
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Intended Use .......................................................3
Installation Requirements ...................................3
AC-Input...............................................................4
Input Inrush Current ...........................................5
DC-Input...............................................................5
Output .................................................................6
Hold-up Time .......................................................8
DC-OK Relay Contact ..........................................9
Shut-down Input .................................................9
Remote Control of Output Voltage .................10
Internal Data Logging .......................................10
Efficiency and Power Losses..............................11
Lifetime Expectancy and MTBF.........................12
Functional Diagram...........................................12
Terminals and Wiring ........................................13
Front Side and User Elements ...........................14
EMC ....................................................................15
Environment ......................................................16
Protection Features ...........................................17
Safety Features ..................................................17
Dielectric Strength ............................................18
Approvals and Fulfilled Standard .....................19
Page
23. Regulatory Compliance .................................... 20
24. Physical Dimensions and Weight ..................... 21
25. Accessories ........................................................ 22
25.1. ZM2.WALL - Wall mounting bracket ....... 22
25.2. UF20.241 - Buffer module ........................ 22
25.3. YR80.242 - Redundancy Module .............. 23
25.4. YR40.245 - Redundancy Module .............. 23
26. Application Notes ............................................. 24
26.1. Repetitive Pulse Loading .......................... 24
26.2. Peak Current Capability ........................... 25
26.3. External Input Protection ......................... 25
26.4. Charging of Batteries ............................... 26
26.5. Output Circuit Breakers............................ 26
26.6. Parallel Use to Increase Output Power .... 27
26.7. Parallel Use for Redundancy .................... 27
26.8. Series Operation ....................................... 28
26.9. Inductive and Capacitive Loads................ 28
26.10. Back-feeding Loads .................................. 28
26.11. Operation on Two Phases ........................ 29
26.12. Use in a Tightly Sealed Enclosure ............ 29
26.13. Mounting Orientations ............................ 30
The information presented in this document is believed to be accurate and reliable and may change without notice.
No part of this document may be reproduced or utilized in any form without permission in writing from the publisher.
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.
AC 230V
A figure displayed with the AC or DC before the value represents a nominal voltage with
standard tolerances (usually ±15%) included.
E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (10V)
230Vac
A figure with the unit (Vac) at the end is a momentary figure without any additional
tolerances included.
50Hz vs. 60Hz
As long as not otherwise stated, AC 230V parameters are valid at 50Hz mains frequency.
may
A key word indicating flexibility of choice with no implied preference.
shall
A key word indicating a mandatory requirement.
should
A key word indicating flexibility of choice with a strongly preferred implementation.
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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2/30
QS40.244
24V, 40A, SINGLE PHASE INPUT
Q-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.
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 REQUIREMENTS
WARNING
-
Risk of electrical shock, fire, personal injury or death.
Turn power off before working on the device and protect against inadvertent re-powering.
Do not open, modify or repair the device.
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.
Do not touch during power-on, and immediately after power-off. Hot surface may cause burns.
Obey the following installation instructions:
This device may only be installed and put into operation by qualified personnel.
This device does not contain serviceable parts. The tripping of an internal fuse is caused by an internal defect.
If damage or malfunction should occur during installation or operation, immediately turn power off and send unit to the
factory for inspection.
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. Unused screw terminals should be securely
tightened. Use ferrules for wires on the input terminals.
The device is designed for pollution degree 2 areas in controlled environments. No condensation or frost is allowed.
The enclosure of the device provides a degree of protection of IP20. The enclosure does not provide protection against spilled
liquids.
The device is designed for overvoltage category II zones.
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 276Vac.
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 4000m (13125ft). Above 2000m (6560ft) a reduction in output current 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 30A (UL) and 32A (IEC) without additional protection
device. If an external fuse is utilized, do not use circuit breakers smaller than 10A B- or 8A 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.
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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3/30
QS40.244
24V, 40A, SINGLE PHASE INPUT
Q-Series
3. AC-INPUT
AC input
AC input range
nom.
Allowed voltage L or N to earth
Input frequency
Turn-on voltage
Shut-down voltage
Input current
Power factor*)
Crest factor**)
Start-up delay
Rise time
Turn-on overshoot
External input protection
AC 200-240V
suitable for TN, TT and IT mains networks
170-264Vac
continuous operation
110-170Vac
full power for up to 200ms
0-170Vac
no damage to the unit
264-300Vac
< 500ms
max.
300Vac
continuous, IEC 62103
nom.
50–60Hz
±6%
typ.
164Vac
steady-state value, load independent, see Fig. 3-1
typ.
151Vac
steady-state value, load independent, see Fig. 3-1
typ.
4.6A
at 24V, 40A, see Fig. 3-3
typ.
0.96
at 24V, 40A, see Fig. 3-4
typ.
1.65
at 24V, 40A
typ.
750ms
see Fig. 3-2
typ.
23ms
at 24V, 40A, resistive load, 0mF see Fig. 3-2
typ.
25ms
at 24V, 40A, resistive load, 40mF see Fig. 3-2
max.
200mV
see Fig. 3-2
See recommendations in chapter 26.3.
*) The power factor is the ratio of the true (or real) power to the apparent power in an AC circuit.
**) The crest factor is the mathematical ratio of the peak value to RMS value of the input current waveform.
Fig. 3-1 Input voltage range
VIN
151V 164V
170V
Output
Voltage
Start-up
delay
264Vac
Fig. 3-3 Input current vs. output load at 24V
Input Current, typ.
Rise
Time
Fig. 3-4 Power factor vs. output load at 24V
6A
1.00
5
0.95
4
0.90
3
- 5%
Overshoot
Input
Voltage
Rated input range
Turn-on
Shut-down
POUT
Fig. 3-2 Turn-on behavior, definitions
Power Factor, typ.
0.85
2
0.80
1
Output Current
0
4
8 12 16 20 24 28 32 36 40A
Output Current
0.75
4
8 12 16 20 24 28 32 36 40A
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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QS40.244
24V, 40A, SINGLE PHASE INPUT
Q-Series
4. INPUT INRUSH CURRENT
The power supply is equipped with an active inrush current limitation circuit, which limits the input inrush current
after turn-on to a negligible low value. The input current is usually smaller than the steady state input current.
Inrush current*)
Inrush energy
Inrush delay
*)
max.
typ.
max.
typ.
18Apeak
14Apeak
4A2s
750ms
over entire temperature range
over entire temperature range
over entire temperature range
The charging current into EMI suppression capacitors is disregarded in the first microseconds after switch-on.
Fig. 4-1 Typical turn-on behaviour at nominal
load and 25°C ambient temperature
5. DC-INPUT
Do not operate this power supply with DC-input voltage. Check the CPS20.241-D1 unit instead. Two CPS20.241-D1
units in parallel might be necessary.
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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5/30
QS40.244
24V, 40A, SINGLE PHASE INPUT
Q-Series
6. OUTPUT
Output voltage
Adjustment range
Factory setting
Line regulation
Load regulation
Ripple and noise voltage
Output current
Output power
BonusPower® time
BonusPower® recovery time
Overload behavior
Short-circuit current
Output capacitance
*)
**)
***)
****)
nom.
max.
typ.
typ.
typ.
max.
max.
typ.
DC 24V
24-28Vdc
30Vdc****)
24.1Vdc
24.1Vdc
25.1Vdc
10mV
50mV
1000mV
max.
nom.
nom.
nom.
100mVpp
40A
34.3A
60A
nom.
51.5A
typ.
110A
nom.
nom.
typ.
typ.
min.
max.
max.
960W
1440W*)
4s
7s
cont. current
HiccupPLUS mode**)
60A***)
70A***)
23A
min.
typ.
typ.
110A
125A
10 200µF
guaranteed
at clockwise end position of potentiometer
±0.2%, at full load, cold unit, in “single use” mode
±0.5%, at full load, cold unit, in “parallel use” mode
at no load, cold unit, in “parallel use” mode
170-264Vac
in “single use” mode: static value, 0A40A, see Fig. 6-1
in “parallel use” mode: static value, 0A40A,
see Fig. 6-2
20Hz to 20MHz, 50Ohm
continuously available at 24V, see Fig. 6-1 and Fig. 6-2
continuously available at 28V, see Fig. 6-1 and Fig. 6-2
short term available BonusPower®*), at 24V
for typical 4s, see Fig. 6-1 and Fig. 6-2
short term available BonusPower®*), at 28V
for typical 4s, see Fig. 6-1 and Fig. 6-2
up to 25ms, output voltage stays above 20V, see Fig.
6-4, This peak current is available once every second.
See chapter 26.2 for more peak current measurements.
continuously available at 24-28V
short term available BonusPower®*) at 24-28V
duration until the output voltage dips, see Fig. 6-5
overload free time to reset power manager, see Fig. 6-6
output voltage > 20Vdc, see Fig. 6-1
output voltage < 20Vdc, see Fig. 6-1
load impedance 25mOhm, see Fig. 6-3
load impedance 25mOhm, see Fig. 6-3
average (R.M.S.) current, load impedance 25mOhm, see
Fig. 6-3
up to 25ms, load impedance 5mm
e.g. screws, small parts
yes
Output shut-down with automatic restart
MOV (Metal Oxide Varistor)
included
not user replaceable
In case of a protection event, audible noise may occur.
20. SAFETY FEATURES
Input / output separation*)
Class of protection
Isolation resistance
PE resistance
Touch current (leakage current)
*)
SELV
IEC/EN 60950-1
PELV
IEC/EN 60204-1, EN 50178, IEC 62103, IEC 60364-4-41
double or reinforced insulation
I
PE (Protective Earth) connection required
> 100MOhm
input to output, 500Vdc
< 0.1Ohm
typ. 0.59mA / 1.38mA
230Vac, 50Hz, TN-,TT-mains / IT-mains
max. 0.75mA / 1.74mA
264Vac, 50Hz, TN-,TT-mains / IT-mains
double or reinforced insulation
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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17/30
QS40.244
24V, 40A, SINGLE PHASE INPUT
Q-Series
21. DIELECTRIC STRENGTH
The output voltage is floating and has no ohmic connection to the ground. Type and factory tests are conducted by
the manufacturer. Field tests may be conducted in the field using the appropriate test equipment which applies the
voltage with a slow ramp (2s up and 2s down). Connect all input-terminals together as well as all output poles before
conducting the test. When testing, set the cut-off current settings to the value in the table below.
Fig. 21-1 Dielectric strength
Type test
L
N
B
A
B*)
Earth, PE
C
B
3000Vac
C
500Vac
D
500Vac
Factory test
5s
2500Vac
2500Vac
500Vac
500Vac
Field test
5s
2000Vac
2000Vac
500Vac
500Vac
14
Cut-off current setting
> 20mA
> 20mA
> 40mA
> 1mA
D
Output
A
2500Vac
13
DC-ok
Input
60s
+/-
Shut-down
15/16
To fulfil the PELV requirements according to EN60204-1 § 6.4.1, we
recommend that either the + pole, the – pole or any other part of
the output circuit shall be connected to the protective earth
system. This helps to avoid situations in which a load starts
unexpectedly or can not be switched off when unnoticed earth
faults occur.
B*) When testing input to DC-OK ensure that the max. voltage between DC-OK and the output is not exceeded (column D). We recommend
connecting DC-OK pins and the output pins together when performing the test
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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18/30
QS40.244
24V, 40A, SINGLE PHASE INPUT
Q-Series
22. APPROVALS AND FULFILLED STANDARD
UL 508
IEC 60950-1
UL 60950-1
Marine (DNV GL)
Marine (ABS)
SEMI F47
IEC 60068-2-60
ISA-71.04-1985
VDMA 24364
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 Certificate
Recognized component for category QQGQ - Information
Technology Equipment (ITE)
Applicable for US and Canada
E-File: E137006
DNV-GL Certificate
DNV-GL Type approved product
Certificate: TAA00002JT
Temperature: Class D
Humidity: Class B
Vibration: Class C
EMC: Class A
Enclosure: Class A
ABS Design Assessment Certificate
ABS (American Bureau of Shipment) assessed product
Certificate: 17-HG1599236-PDA
Test Report
Voltage Sag Immunity for Semiconductor Processing Equipment
Tested for AC 208V L-L or L-N mains voltages, nominal output
voltage and nominal output load
Manufacturer's Declaration (Online Document)
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 24364C1-L/W for solvents and water-based paints
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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19/30
QS40.244
24V, 40A, SINGLE PHASE INPUT
Q-Series
23. REGULATORY COMPLIANCE
EU Declaration of
Conformity
REACH Directive
EAC TR Registration
The CE mark indicates conformance with the
- EMC directive
- Low-voltage directive
- RoHS directive
Manufacturer's Statement
EU-Directive regarding the Registration, Evaluation,
Authorisation and Restriction of Chemicals
Registration for the Eurasian Customs Union market
(Russia, Kazakhstan, Belarus)
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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QS40.244
24V, 40A, SINGLE PHASE INPUT
Q-Series
24. PHYSICAL DIMENSIONS AND WEIGHT
Width
Height
Depth
Weight
DIN-Rail
Housing material
Installation clearances
125mm 4.92’’
124mm 4.88’’
127mm 5.0’’
The DIN-rail height must be added to the unit depth to calculate the total required
installation depth.
1800g / 3.97lb
Use 35mm DIN-rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm.
Aluminium body, steel cover
See chapter 2
Fig. 24-1 Front view
Fig. 24-2 Side view
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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QS40.244
24V, 40A, SINGLE PHASE INPUT
Q-Series
25. ACCESSORIES
25.1. ZM2.WALL - WALL MOUNTING BRACKET
This bracket is used to mount specific DIMENSION units onto a flat surface without
utilizing a DIN-Rail.
25.2. UF20.241 - BUFFER MODULE
This buffer unit is a supplementary device for DC 24V power supplies. It delivers power to bridge typical mains failures
or extends the hold-up time after turn-off
Power
Buffer
of the AC power. In times when the power
Load
AC
Supply
Unit(s)
supply provides sufficient voltages, the
buffer unit stores energy in integrated
+
DC
electrolytic capacitors. In case of mains
voltage fault, this energy is released again
in a regulated process. One buffer module can deliver 20A. To buffer the full output
current of 40A, two buffer modules are needed in parallel.
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.
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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22/30
QS40.244
24V, 40A, SINGLE PHASE INPUT
Q-Series
25.3. YR80.242 - REDUNDANCY MODULE
The YR80.242 is equipped with two input channels (40A each), which are individually
decoupled by utilizing mosfet technology. The output current can go as high as 80A. Using
mosfets instead of diodes reduces the heat generation and the voltage drop between input
and output. The YR80.242 does not require an additional auxiliary voltage and is selfpowered even in case of a short circuit across the output.
Due to the low power losses, the unit is very slender and only requires 46mm width on the
DIN-rail.
25.4. YR40.245 - REDUNDANCY MODULE
The YR40.245 is a 40A single channel redundancy module, which is equipped with a plug
connector on the output. The plug connector allows replacing the power supply or the
redundancy module while the system is running. The plug connector avoids that the output
wires can touch and short the load circuit.
The YR40.245 is very slender and only requires 46mm width on the DIN-rail. It also utilizes
mosfet technology instead of diodes for low heat generation and a minimal voltage drop
between input and output. It does not require an additional auxiliary voltage and is selfpowered even in case of a short circuit across the output.
Fig. 25-1 Typical 1+1 Redundant configuration for
40A with a dual redundancy module
24V
40A
Load
QS40.244
24-28V 960W
Power Supply
DCOK
Single Use
AC Input
L N PE
I
L
N
PE
24V, 40A
+ +
- -
Input
1
+
Parallel Use
DCOK
Input
2
AC Input
- + -
L N PE
DCOK
Single Use
24V, 40A
+ +
AC Input
- -
L N PE
I
*) YR80.241
also possible
YR40.245
Redundancy
Module
24V, 40A
+ +
- -
I
Output
DCOK
Parallel Use
Single Use
Input
+
AC Input
-
L N PE
-
+
QS40.244
24-28V 960W
Power Supply
Output
Parallel Use
Single Use
-
+
QS40.244
24-28V 960W
Power Supply
QS40.244
24-28V 960W
Power Supply
YR80.242*)
Redundancy
Module
24V
40A
Load
Failure
Monitor
Failure
Monitor
Output
Parallel Use
Fig. 25-2 Typical N+1 or 1+1 Redundant configuration for 40A with
multiple YR40.245 redundancy modules
YR40.245
Redundancy
Module
24V, 40A
+ +
- -
Input
+
-
I
L
N
PE
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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24V, 40A, SINGLE PHASE INPUT
Q-Series
26. APPLICATION NOTES
26.1. REPETITIVE PULSE LOADING
Typically, a load current is not constant and varies over time. This power supply is designed to support loads with a
higher short-term power demand (=BonusPower®). The short-term duration is hardware controlled by an output
power manager and is available on a repeated basis. If the BonusPower® load lasts longer than the hardware
controller allows it, the output voltage will dip and the next BonusPower® is available after the BonusPower® recovery
time (see chapter 6) has elapsed.
To avoid this, the following rules must be met:
a) The power demand of the pulse must be below 150% of the nominal output power.
b) The duration of the pulse power must be shorter than the allowed BonusPower® time. (see output section)
c)
The average (R.M.S.) output current must be below the specified continuous output current.
If the R.M.S. current is higher, the unit will respond with a thermal shut-down after a period of time. Use the
maximum duty cycle curve (Fig. 26-2) to check if the average output current is below the nominal current.
d) The duty cycle must be below 0.75.
Fig. 26-1 Repetitive pulse loads, definitions
Fig. 26-2 Max. duty cycle curve
P0 = 10%
P0 = 50%
P0 = 75%
Duty Cycle
PPEAK TPEAK
T0
0.75
max.
150%
0.6
100%
0.4
P0 = 100%
0.2
P0
0
100
P0
PPEAK
T0
TPEAK
Example:
Base load (W)
Pulse load (above 100%)
Duration between pulses (s)
Pulse duration (s)
110
DutyCycle =
T0 =
120
130
PPEAK
140
150%
Tpeak
Tpeak + T0
Tpeak - (DutyCycle x Tpeak)
DutyCycle
A load is powered continuously with 480W (= 50% of the rated output load). From time to time a peak
power of 1440W (= 150% of the rated output load) is needed for 1 second.
The question is: How often can this pulse be supplied without overloading the power supply?
- Make a vertical line at PPEAK = 150% and a horizontal line where the vertical line crosses the P0 = 50%
curve. Read the max. duty cycle from the duty cycle-axis (= 0.37)
- Calculate the required pause (base load) length T0:
- Result: The required pause length = 1.7s
T0=
- Max. repetition rate = pulse +pause length = 2.7s
Tpeak - (DutyCycle x Tpeak)
DutyCycle
=
1s - (0.37 x 1s)
0.37
= 1.7s
More examples for pulse load compatibility:
PPEAK
1440W
1440W
1200W
P0
960W
0W
480W
TPEAK
1s
1s
1s
T0
>25s
>1.3s
> 0.75s
PPEAK
1440W
1440W
1440W
P0
480W
480W
480W
TPEAK
0.1s
1s
3s
T0
>0.16s
>1.6s
>4.9s
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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24V, 40A, SINGLE PHASE INPUT
Q-Series
26.2. PEAK CURRENT CAPABILITY
The power supply can deliver peak currents (up to several milliseconds) which are higher than the specified short term
currents.
This helps to start current demanding loads. Solenoids, contactors and pneumatic modules often have a steady state
coil and a pick-up coil. The inrush current demand of the pick-up coil is several times higher than the steady-state
current and usually exceeds the nominal output current (including the BonusPower®). The same situation applies when
starting a capacitive load.
The peak current capability also ensures the safe operation of subsequent circuit breakers of load circuits. The load
branches are often individually protected with circuit breakers or fuses. In case of a short or an overload in one branch
circuit, the fuse or circuit breaker need a certain amount of over-current to open in a timely manner. This avoids
voltage loss in adjacent circuits.
The extra current (peak current) is supplied by the power converter and the built-in large sized output capacitors of
the power supply. The capacitors get discharged during such an event, which causes a voltage dip on the output. The
following two examples show typical voltage dips:
Fig. 26-3 Peak load with 2x the nominal
current for 50ms, typ.
Fig. 26-4 Peak load with 5x the nominal
current for 5ms, typ.
80A Peak load (resistive) for 50ms
Output voltage dips from 24V to 18.9V.
200A Peak load (resistive) for 5ms
Output voltage dips from 24V to 13.8V.
Please note: The DC-OK relay triggers when the voltage dips more than 10% for longer than 1ms.
Peak current voltage dips
typ.
typ.
typ.
from 24V to 18.9V
from 24V to 15.9V
from 24V to 13.8V
at 80A for 50ms, resistive load
at 200A for 2ms, resistive load
at 200A for 5ms, resistive load
26.3. EXTERNAL INPUT PROTECTION
The unit is tested and approved for branch circuits up to 30A (U.S.A.) and 32A (IEC). An external protection is only
required if the supplying branch has an ampacity greater than this. Check also local codes and local requirements. In
some countries local regulations might apply.
If an external fuse is necessary or utilized, minimum requirements need to be considered to avoid nuisance tripping of
the circuit breaker. A minimum value of 10A B- or 8A C-Characteristic breaker should be used.
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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24V, 40A, SINGLE PHASE INPUT
Q-Series
26.4. CHARGING OF BATTERIES
The power supply can be used to charge lead-acid or maintenance free batteries. (Two 12V batteries in series)
Instructions for charging batteries:
a)
Set output voltage (measured at no load and at the battery end of the cable) very precisely to the end-of-charge
voltage.
End-of-charge voltage
27.8V
27.5V
27.15V
26.8V
Battery temperature
10°C
20°C
30°C
40°C
b)
Use a 50A or 63A circuit breaker (or blocking diode) between the power supply and the battery.
c)
Ensure that the output current of the power supply is below the allowed charging current of the battery.
d)
Use only matched batteries when putting 12V types in series.
e)
The return current to the power supply (battery discharge current) is typ. 35mA when the power supply is
switched off (except in case a blocking diode is utilized).
26.5. OUTPUT CIRCUIT BREAKERS
Standard miniature circuit breakers (MCB’s or UL1077 circuit breakers) are commonly used for AC-supply systems and
may also be used on DC branches.
MCB’s are designed to protect wires and circuits. If the ampere value and the characteristics of the MCB are adapted to
the wire size that is used, the wiring is considered as thermally safe regardless of whether the MCB opens or not.
To avoid voltage dips and under-voltage situations in adjacent 24V branches which are supplied by the same source, a
fast (magnetic) tripping of the MCB is desired. A quick shutdown within 10ms is necessary corresponding roughly to
the ride-through time of PLC's. This requires power supplies with high current reserves and large output capacitors.
Furthermore, the impedance of the faulty branch must be sufficiently small in order for the current to actually flow.
The best current reserve in the power supply does not help if Ohm’s law does not permit current flow. The following
table has typical test results showing which B- and C-Characteristic MCBs magnetically trip depending on the wire cross
section and wire length.
Fig. 26-5 Test circuit
Power Supply
AC
MCB
+
+
Wire length
DC S1... Fault simulation switch
*)
Load
S1
-
Maximal wire length*) for a fast (magnetic) tripping:
0.75mm²
1.0mm²
1.5mm²
2.5mm²
29m
38m
54m
86m
C-2A
27m
34m
48m
78m
C-3A
19m
26m
38m
58m
C-4A
10m
15m
21m
34m
C-6A
8m
12m
18m
28m
C-8A
7m
11m
16m
26m
C-10A
4m
6m
8m
13m
C-13A
19m
25m
35m
55m
B-6A
11m
17m
24m
40m
B-10A
10m
13m
21m
29m
B-13A
7m
11m
15m
24m
B-16A
5m
7m
9m
16m
B-20A
Don’t forget to consider twice the distance to the load (or cable length) when calculating the total wire length (+ and – wire).
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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24V, 40A, SINGLE PHASE INPUT
Q-Series
26.6. PARALLEL USE TO INCREASE OUTPUT POWER
Unit A
Power supplies from the same series (Q-Series) can be paralleled to increase
the output power. The output voltage shall be adjusted to the same value
(±100mV) in “Single use” mode with the same load conditions on all units, or
the units can be left with the factory settings. After the adjustments, the
jumper on the front of the unit shall be moved from “Single use” to “Parallel
use”, in order to achieve load sharing. The “Parallel use” mode regulates the
output voltage in such a manner that the voltage at no load is approx. 4%
higher than at nominal load. See also chapter 6. If no jumper is plugged in, the
unit is in “Single use” mode. Factory setting is also “Single use” mode.
AC
DC
+
+
Unit B
AC
DC
Load
+
-
-
If more than three units are connected in parallel, a fuse or circuit breaker with a rating of 50A or 63A is required on
each output. Alternatively, a diode or redundancy module can also be utilized.
Energize all units at the same time to avoid the overload HiccupPLUS mode. It also might be necessary to cycle the input
power (turn-off for at least five seconds), if the output was in HiccupPLUS mode due to overload or short circuits and the
required output current is higher than the current of one unit.
Keep an installation clearance of 15mm (left / right) between two power supplies and avoid installing the power
supplies on top of each other. Do not use power supplies in parallel in mounting orientations other than the standard
mounting orientation (terminals on the bottom of the unit) or in any other condition where a derating of the output
current is required (e.g. altitude, above 60°C, …).
Pay attention that leakage current, EMI, inrush current, harmonics will increase when using multiple power supplies.
26.7. PARALLEL USE FOR REDUNDANCY
Power supplies can be paralleled for redundancy to gain higher system availability. 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
power supplies in parallel. This 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. Redundant systems for a higher power
demand are usually built in a N+1 method. E.g. five power supplies, each rated for 40A are paralleled to build a 160A
redundant system. For N+1 redundancy the same restrictions apply as for increasing the output power, see also
chapter 26.6.
Please note: This simple way to build a redundant system does not cover failures such as an internal short circuit in
the secondary side of the power supply. In such a case, the defective unit becomes a load for the other power supplies
and the output voltage can not be maintained any more. This can be avoided by utilizing redundancy modules, which
have decoupling devices (diodes or mosfets) included. Further information and wiring configurations can be found in
chapter 25.3 and 25.4.
Recommendations for building redundant power systems:
a)
b)
c)
d)
Use separate input fuses for each power supply. A separate source for each supply when possible increases the
reliability of the redundant system.
Set the power supply into “Parallel Use” mode.
Monitor the individual power supply units. Therefore, use the DC-OK relay contact of the QS40 power supply.
It is desirable to set the output voltages of all units to the same value (± 100mV) or leave it at the factory setting.
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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24V, 40A, SINGLE PHASE INPUT
Q-Series
26.8. SERIES OPERATION
Unit A
AC
Power supplies of the same type can be connected in series for higher
output voltages. It is possible to connect as many units in series as needed,
providing the sum of the output voltage does not exceed 150Vdc. Voltages
with a potential above 60Vdc are not SELV anymore and can be dangerous.
Such voltages must be installed with a protection against touching.
DC
+
+
Unit B
AC
Earthing of the output is required when the sum of the output voltage is
above 60Vdc.
DC
Avoid return voltage (e.g. from a decelerating motor or battery) which is
applied to the output terminals.
Load
+
-
Earth
(see notes)
Keep an installation clearance of 15mm (left / right) between two power supplies and avoid installing the power
supplies on top of each other. Do not use power supplies in series in mounting orientations other than the standard
mounting orientation (terminals on the bottom of the unit).
Pay attention that leakage current, EMI, inrush current, harmonics will increase when using multiple power supplies.
26.9. INDUCTIVE AND CAPACITIVE LOADS
The unit is designed to supply any kind of loads, including capacitive and inductive loads. If extreme large capacitors,
such as EDLCs (electric double layer capacitors or “UltraCaps”) with a capacitance > 2.5F are connected to the output,
the unit might charge the capacitor in the HiccupPLUS mode (see chapter 6).
26.10. 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 malfunctioning when a load feeds back voltage to the power supply.
It does not matter whether the power supply is on or off.
The maximum allowed feed-back-voltage is 35Vdc. The absorbing energy can be calculated according to the built-in
large sized output capacitor which is specified in chapter 6.
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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26.11. OPERATION ON TWO PHASES
The power supply can also be used on two-phases of a three-phase-system.
Such a phase to phase connection is allowed as long as the supplying voltage
is below 240V+10%.
Power Supply
L1
240V +10% max.
Q-Series
L3
L2
AC
L
internal
fuse
N
PE
DC
26.12. 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. In such situations, the inside temperature defines the ambient temperature for the power supply.
The following measurement results can be used as a reference to estimate the temperature rise inside the enclosure.
The power supply is placed in the middle of the box, no other heat producing items are inside the box
Enclosure:
Load:
Input:
Temperature inside enclosure:
Temperature outside enclosure:
Temperature rise:
Rittal Typ IP66 Box PK 9522 100, plastic, 254x180x165mm
24V, 32A; (=80%) load is placed outside the box
230Vac
61.6°C (in the middle of the right side of the power supply with a distance of 2cm)
23.3°C
38.3K
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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Q-Series
26.13. MOUNTING ORIENTATIONS
Mounting orientations other than all terminals on the bottom require a reduction in continuous output power or a
limitation in the maximum allowed ambient temperature. The amount of reduction influences 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.
Max allowed output current (results in approximately half the lifetime expectancy of A1).
Fig. 26-6
Mounting
Orientation A
(Standard
orientation)
Output Current
40A
A1
30
Power
Supply
20
10
Ambient Temperature
0
INPUT OUTPUT
10
Fig. 26-7
Mounting
Orientation B
(Upside down)
20
30
40
60°C
50
Output Current
40A
30
A2
20
A1
INPUT OUTPUT
Power
Supply
10
Ambient Temperature
0
10
Fig. 26-8
Mounting
Orientation C
(Table-top
mounting)
20
30
40
60°C
50
Output Current
40A
30
A2
A1
20
10
Ambient Temperature
0
10
40
60°C
50
40A
Power
Supply
30
A2
A1
20
10
Ambient Temperature
0
10
20
30
40
50
60°C
Output Current
INPUT OUTPUT
40A
Power
Supply
Fig. 26-10
Mounting
Orientation E
(Horizontal ccw)
30
Output Current
INPUT OUTPUT
Fig. 26-9
Mounting
Orientation D
(Horizontal cw)
20
30
A2
A1
20
10
Ambient Temperature
0
10
20
30
40
50
60°C
Dez. 2020 / Rev. 3.2 DS-QS40.244-EN
All parameters are specified at 24V, 40A, 230Vac, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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