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qs40.241 q-series 24v, 40a, s ingle p hase i nput p ower s upply ? ac 100-240v wide-range input ? width only 125mm, weight only 1.9kg ? 94.6% full load and excellent partial load efficiencies ? 50% bonuspower ? , 1440w for up to 4s ? 110a high peak current for 10 ms for easy fuse tripping ? safe hiccup plus overload mode ? active pfc (power factor correction) ? negligible low input inrush current surge ? full power between -25c and +60c ? current sharing feature for parallel use ? internal data logging for troubleshooting included. ? remote control of output voltage ? dc-ok relay contact ? shut-down input ? atex and iecex approved ? 3 year warranty 1/28 g eneral d escription the most outstanding features of this dimension qs40.241 din-rail power supply are the extremely high efficiency and the small size , which are achieved by a synchronous rectification, a bridgeless pfc circuit and additional unique design details. large power reserves of 15 0% and built-in large sized output capacitors 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 a nd power surges as well as low electromagnetic emissions makes usage in nearly every environment possible. the integrated input fuse as well as the near zero input inrush current make insta llation 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. s hort - form d ata output voltage dc 24v nominal adjustment range 24 - 28vdc output current 40 C 34.3a continuous 60 C 51.5a short term (4s) output power 960w continuous 1440w short term (4s) output ripple < 100mvpp 20hz to 20mhz input voltage ac 100-240v -15%/+10% mains frequency 50-60hz 6% ac input current 8.6 / 4.5a at 120 / 230vac power factor 0.99 / 0.99 at 120 / 230vac ac inrush current 17 / 11a peak at 120 / 230vac efficiency 93.6 / 94.6% at 120 / 230vac losses 65.6 / 54.8w at 120 / 230vac temperature range -25c to +70c operational derating 24w/c +60 to +70c between 85-90vac see chapter 18 hold-up time 27 / 27ms at 120 / 230vac dimensions 125x124x127mm wxhxd weight 1900g / 4.2lb o rder n umbers power supply qs40.241 24-28v standard unit accessory zm2.wall wall mount bracket uf20.241 buffer unit yr80.242 redundancy module m arkings ind. cont. e q. ul 508 ul 60950-1 emc, lvd, rohs class i div 2 iecex atex ii 3g ex na nc ii t4 gc oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany
qs40.241 q-series 24v, 40a, s ingle p hase i nput i ndex page page 1. intended use .......................................................3 2. installation requirements ...................................3 3. ac-input ...............................................................4 4. input inrush current ...........................................5 5. dc-input ...............................................................5 6. output .................................................................6 7. hold-up time .......................................................8 8. dc-ok relay contact ..........................................9 9. shut-down input .................................................9 10. remote control of output voltage .................10 11. internal data logging .......................................10 12. efficiency and power losses ..............................11 13. lifetime expectancy and mtbf .........................12 14. functional diagram ...........................................12 15. terminals and wiring ........................................13 16. front side and user elements ...........................14 17. emc ....................................................................15 18. environment ......................................................16 19. protection features ...........................................17 20. safety features ..................................................17 21. dielectric strength ............................................18 22. approvals ...........................................................18 23. physical dimensions and weight ..................... 19 24. accessories ........................................................ 20 24.1. zm2.wall - wall mounting bracket .......20 24.2. uf20.241 - buffer module ........................20 24.3. yr80.242 - redundancy module ..............21 24.4. yr40.245 - redundancy module ..............21 25. application notes ............................................. 22 25.1. repetitive pulse loading ..........................22 25.2. peak current capability ...........................23 25.3. external input protection .........................23 25.4. charging of batteries ...............................24 25.5. output circuit breakers ............................24 25.6. parallel use to increase output power ....25 25.7. parallel use for redundancy ....................25 25.8. series operation .......................................26 25.9. inductive and capacitive loads ................26 25.10. back-feeding loads ..................................26 25.11. operation on two phases ........................27 25.12. use in a tightly sealed enclosure ............27 25.13. mounting orientations ............................28 the information presented in this docume nt is believed to be a ccurate and reliable and ma y change without notice. no part of this document may be reproduc ed or utilized in any form without pe rmission in writing from the publisher. 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 de scription 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 disregardi ng 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 im plied preference. shall a key word indicating a mandatory requirement. should a key word indicating flexibility of choi ce with a strongly pref erred implementation. oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 2/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 1. i ntended u se this device is designed for installation in an enclosure and is intended for th e general use such as in industrial control, office, communication, and instrumentation equipment. do not use this power supply in equipment, where malfuncti on may cause severe personal injury or threaten human life. this device is designed for use in hazardous, non-hazardous, ordinary or un classified locations. 2. i nstallation r equirements this device may only be installed and put into opera tion 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 malfuncti on should occur during installation or operation, i mmediately turn power off and send unit to the factory for inspection. mount the unit on a din-rail so that the output and input terminals are located on the bo ttom of the unit. for other mounting orientations see de -rating requirements in this document. see chapter 25.13 . this device is designed for convection cooling and does not require an external fan. do not obstruct airflow and do not cover ventilation grid (e.g. cable conduits) by more than 15%! keep the following installation clearance s: 40mm on top, 20mm on the bottom, 5mm on the left and right sides are recommended when the device is loaded permanently with more than 50% of th e rated power. increase this clearance to 15mm in case the adjacent device is a heat source (e.g. another power supply). a disconnecting means shall be provided for the output of the power supplies when used in applications according to csa c22.2 no 107.1-01. warning risk of electrical shock, fi re, personal injury or death. - do not use the power supply without proper grounding (protective earth). us e the terminal on the input block for earth connection and not one of the screws on the housing. - turn power off before working on the devi ce. protect against inad vertent re-powering. - make sure that the wiring is correct by following all local and national codes. - do not modify or repair the unit. - do not open the unit as high voltages are present inside. - use caution to prevent any foreign objects from enteri ng the housing. - do not use in wet locations or in areas wh ere moisture or condens ation can be expected. - do not touch during power-on, and immediatel y after power-off. hot surfaces may cause burns. notes for use in hazardous location areas: the power supply is suitable for use in class i division 2 gr oups a, b, c, d locations and for use in group ii category 3 (zone 2) environments and are evaluated accord ing to en 60079-0:2012 and en 60079-15:2010. warning explosion hazards! substitution of components may impair su itability for this environment. do not disconnect the unit or operate the voltage adjustment or s/p jumper unless power has been switched off or the area is known to be non-hazardous. a suitable enclosure must be provided for the end product which has a mini mum protection of ip54 and fulfils the requirements of the en 60079-15:2010. oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 3/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 3. ac-i nput ac input nom. ac 100-240v suitable for tn, tt and it mains networks ac input range min. 90-264vac continuous operation min. 85-90vac < 55c ambient te mperature conti nuously allowed > 55c ambient temperature short term or with output derating according fig. 18-1 min. 60-85vac full power for up to 200ms min. 0-85vac no damage to the unit min. 264-300vac < 500ms allowed voltage l or n to earth max. 300vac continuous, iec 62103 input frequency nom. 50C60hz 6% turn-on voltage typ. 80vac steady-st ate value, load independent, see fig. 3-1 shut-down voltage typ. 74vac steady- state value, load independent, see fig. 3-1 external input protection see recommendations in chapter 25.3 . ac 100v ac 120v ac 230v input current typ. 10.5a 8. 6a 4.5a at 24v, 40a, see fig. 3-3 power factor *) typ. 0.99 0.99 0.99 at 24v, 40a, see fig. 3-4 crest factor **) typ. 1.47 1.53 1.56 at 24v, 40a start-up delay typ. 800ms 750ms 700ms see fig. 3-2 rise time typ. 15ms 15ms 15ms at 24v, 40a, resistive load, 0mf see fig. 3-2 typ. 18ms 18ms 18ms at 24v, 40a, resistive load, 40mf see fig. 3-2 turn-on overshoot max. 100mv 100mv 100mv see fig. 3-2 *) 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 fig. 3-2 turn-on behavior, definitions turn-on 85 rated input range v in p out 74 264vac shut-down 80 start-up delay rise time overshoot - 5% output voltage input voltage fig. 3-3 input current vs. output load at 24v fig. 3-4 power factor vs. output load at 24v 40a 4 8 12 16 20 24 28 32 36 0 2 4 6 8 10 12a output current input current, typ. a: 100vac b: 120vac c: 230vac a b c power factor, typ. 4 8 12 16 20 24 28 32 36 40a 0.75 0.8 0.85 0.9 0.95 1.0 output current a: 100vac b: 120vac c: 230vac a b c oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 4/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 4. i nput i nrush c urrent the power supply is equipped with an active inrush current limitation circuit, which li mits the input inrush current after turn-on to a negligible low valu e. the input current is usually smalle r than the steady sta te input current. ac 100v ac 120v ac 230v inrush current *) max. 25a peak 22a peak 16a peak over entire temperature range; mains interruptions > 1s typ. 20a peak 17a peak 11a peak over entire temperature range; mains interruptions > 1s inrush energy max. 5a 2 s 5a 2 s 5a 2 s over entire temperature range; mains interruptions > 1s *) 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 25c ambient temperature output 100ms/div input 230vac 24vdc input current 5a / div 5. dc-i nput do not operate this power supply with dc-input voltage. check the cps20. 241-d1 unit instead. two cps20.241-d1 units in parallel mi ght be necessary. oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 5/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 6. o utput output voltage nom. dc 24v adjustment range min. 24-28vdc guaranteed max. 29vdc ****) at clockwise end position of potentiometer factory setting typ. 24.1vdc 0.2%, at fu ll load, cold unit, in single use mode typ. 24.1vdc 0.5%, at full load, cold unit, in parallel use mode typ. 25.1vdc at no load, cold unit, in parallel use mode line regulation max. 10mv 85-300vac load regulation max. 50mv in s ingle use mode: static value, 0a ? 40a, see fig. 6-1 typ. 1000mv in parallel use mode: static value, 0a ? 40a, see fig. 6-2 ripple and noise voltage max. 100mvpp 20hz to 20mhz, 50ohm output current nom. 40a continuo usly available at 24v, see fig. 6-1 and fig. 6-2 nom. 34.3a continuously available at 28v, see fig. 6-1 and fig. 6-2 nom. 60a short term available bonuspower ?*) , at 24v for typical 4s, see fig. 6-1 and fig. 6-2 nom. 51.5a short term available bonuspower ?*) , at 28v for typical 4s, see fig. 6-1 and fig. 6-2 typ. 110a up to 10ms, output voltage stays above 20v, see fig. 6-4 , this peak current is available once every second. see chapter 25.2 for more peak current measurements. output power nom. 960w contin uously available at 24-28v nom. 1440w *) short term available bonuspower ?*) at 24-28v bonuspower ? time typ. 4s duration until the output voltage dips, see fig. 6-5 bonuspower ? recovery time typ. 7s overload fr ee time to reset power manager, see fig. 6-6 overload behavior cont. curre nt output voltage > 20vdc, see fig. 6-1 hiccup plus mode **) output voltage < 20vdc, see fig. 6-1 short-circuit cu rrent min. 60a ***) load impedance 25mohm, see fig. 6-3 max. 70a ***) load impedance 25mohm, see fig. 6-3 max. 23a average (r.m.s.) curre nt, load impedance 25mohm, see fig. 6-3 typ. 130a up to 10ms, load impedance <10mohm, see fig. 6-4 output capacitance typ. 10 200 f included in the power supply *) bonuspower ? , short term power capability (up to typ. 4s) the power supply is designed to support loads with a higher short-term power requirement without damage or shutdown. the short- term duration is hardware controlled by an output power manager. this bonuspower ? is repeatedly available. detailed information can be found in chapter 25.1 . if the power supply is loaded longer with the bonuspower ? than shown in the bonus-time diagram (see fig. 6-5 ), the max. output power is automatically reduced to 960w. if the power requirement is continuously above 960w and the voltage falls below approx. 20v (due to the current regulating mode at overload), the unit shuts-off and makes periodical resta rt attempts. this behavior is called hiccup mode which is described below. if the voltage is above 20v, the unit continuously deli vers current. **) hiccup plus mode up to 4s of overloading, the power supply delivers continuous output current. after this, the output power is reduced to nearly zero for approx. 17s before a new start attempt is automatically performed. if the overload has been cleared, the device will operat e normally. if the overload still exists, the output current will be delivered for 2 to 4s (depending on the overload) again foll owed by a 17s rest time. this cycle is repeated as long as the overload exists. see fig. 6-3 . during the off-period a small rest voltage and rest current is present on the output. ***) discharge current of output capacitors is not included. ****) this is the maximum output voltage which can occur at the clockwise end position of the potentiometer due to tolerances. it is not guaranteed value which can be achieved. the typical value is about 28.5v. oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 6/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput fig. 6-1 output voltage vs . output current in single use mode, typ. fig. 6-2 output voltage vs . output current in parallel use mode, typ. output voltage 0 010203040 4 8 12 28v 16 20 24 60 50 70a output current adjustment range hiccup mode a b a b short-term (4s) then switching to curve continuously available a output voltage (parallel use, typ.) 22v 02040 23v 24v 25v 29v 26v 27v 28v 60a 50 30 10 adjustment range factory setting output current continuously allowed bonus power fig. 6-3 short-circuit on output, hiccup plus mode, typ. fig. 6-4 dynamic overcurrent capability, typ. output current 0 65a 17s 17s 17s 2s 2s 2s t short -circuit normal operation normal operation output voltage (dynamic behavior, < 10ms) 0 0 4 8 12 28v 16 20 24 150 a 60 30 90 120 15 45 75 105 135 output current adjustment range fig. 6-5 bonus time vs. output power fig. 6-6 bonuspower ? recovery time ma x . bonus time 0 100 120 130 140 150 170% 1 2 3 4 5s 110 160 output power m i n . power demand 100% t t limitation by power manager output voltage bonus power disabled bonus time recovery time the bonuspower ? is available as soon as power comes on and after the end of an output short circuit or output overload. fig. 6-7 bonuspower ? after input turn-on fig. 6-8 bonuspower ? after output short 100% output voltage input voltage bonus power output power 150% short of output 100% output voltage bonus power output power 150% oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 7/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 7. h old - up t ime ac 100v ac 120v ac 230v hold-up time typ. 54ms 54 ms 54ms at 24v, 20a, see fig. 7-1 min. 45ms 45ms 45ms at 24v, 20a, see fig. 7-1 typ. 27ms 27ms 27ms at 24v, 40a, see fig. 7-1 min. 23ms 23ms 23ms at 24v, 40a, see fig. 7-1 fig. 7-1 hold-up time vs. input voltage fig. 7-2 shut-down behavior, definitions 0 10ms 20ms 30ms 40ms 60ms 90 120 155 190 230vac input voltage 50ms hold-up time 24v, 40a, typ. 24v, 20a, min. 24v, 20a, typ. 24v, 40a, min. - 5% hold-up time zero transition output voltage input voltage oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 8/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 8. dc-ok r elay c ontact this feature monitors the output voltage, which is produced by the power suppl y itself. it is indepe ndent of a back-fed voltage from a unit connected in parallel to the power supply output. contact closes as soon as the output voltage reaches 90% of the adjusted output voltage. contact opens as soon as the output voltage dips more than 10% belo w the adjusted output voltage. short dips will be extended to a signal length of 250ms. dips shorter th an 1ms will be ignored. contact re-closes as soon as the output volt age exceeds 90% of th e adjusted voltage. contact ratings max 60vdc 0.3a, 30vdc 1a, 30vac 0.5a resistive load min 1ma at 5vdc mi n. permissible load isolation voltage see dielec tric strength table in section 21. fig. 8-1 dc-ok relay contact behavior 250ms 0.9* v adj < 1ms 10% open v out = v adj open closed closed > 1ms 9. s hut - down i nput this feature allows a switch-off of the output of the power supply with a signal switch or an external voltage. the shut-down occurs immediately wh ile the turn-on is delayed up to 350ms. in a shut-down condition, the output voltage is <2v and the output power is <0.5w. the voltage between different minus pole output terminals must be below 1v when units are connected in parallel. in a series operation of multiple power supplies only wiring option a with individual signal switches is allowed. please note: - option c requires a current sink capability of the voltage source. do not use a blocking diode. - the shut-down function has no safety feature included. fig. 9-1 activation of the shut-down input 15 16 off: linked on : open shut- down input option a: 15 16 off: i > 0.3ma on : i < 0.1ma shut- down input option b: - (via open collector) i n.c. 15 16 off: u < 1v on : u = 4 -29v shut- down input option c: - (via external voltage + u n.c. oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 9/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 10. r emote c ontrol of o utput v oltage the shut-down input can also be used to remotely adjust the output voltage between typically 22vdc and 28vdc. all other functions of shut-dow n input remain the same. the control voltage is refe renced to the main ground (negative output voltage) fig. 10-1 remote control of the output voltage fig. 10-2 applying the control voltage output voltage 12v 0v 5v 14v 16v 18v 28v 20v 22v 26v control voltage 24v 10v potentiometer: 28v setting 24v setting 15 16 control voltage shut- down input - + n.c. instructions: 1. set the unit into single use mode 2. set the output voltage adjustment (24- 28v) to the maximum desired voltage. 3. apply a control voltage to reduce the output voltage 11. i nternal d ata l ogging a protected microcontroller inside the power supply acquires and stores operating data during the life of the unit. the data can be downloaded with a small t ool and special software by the puls serv ice and repair personnel, even when the unit is defect. the data allows fo r better troubleshooting. analysis of what happened before a failure can be determined much more accurately. acquired data: - family name of unit (qs 40), revision of firmware - operational hours - expired portion of lifetime (combination of temperature and period of time) - maximum ambient temperatures with timestamp (max. 47 values) - maximal input voltages with timestamp (max. 47 values) and type of i nput voltage (ac or dc) - failure report (various internal errors) - number and timestamp of input overvoltage transients - number and timestamp of ov er-temperature shut-downs - number of turn-on sequences the data will be acquired with a fi xed sampling rate unless the peak de tectors do trigger due to an abnormal condition. in such cases, the abnormal condition will be captured . furthermore, data will be acquired every time shortly before the unit switches off. oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 10/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 12. e fficiency and p ower l osses ac 100v ac 120v ac 230v efficiency typ. 93.2% 93.6% 94.6% at 24v, 40a average efficiency *) typ. 92.7% 93.0% 93.9% 25% at 10a, 25% at 20a, 25% at 30a. 25% at 40a power losses typ. 3.6w 3.5w 3. 3w with activated shut-down typ. 13.9w 13.1w 13.2w at 24v, 0a (no load) typ. 36.1w 34.5w 30.6w at 24v, 20a (half load) typ. 70.0w 65.6w 54.8w at 24v, 40a (full load) *) the average efficiency is an assumption for a typical application where the power supply is loaded with 25% of the nominal load for 25% of the time, 50% of the nominal load for another 25% of the time, 75% of the nominal load for another 25% of the time and with 100% of the nominal load for the rest of the time. fig. 12-1 efficiency vs. output current at 24v, typ. fig. 12-2 losses vs. output current at 24v, typ. efficiency 8 1216202428323640a 88 89 90 91 92 93 output current 94 95 96% 1 2 0 v a c 1 0 0 v a c 230vac power losses 0 4 8 1216202428 40a 10 0 30 40 50 70 80w 120vac 100vac 230vac 32 36 60 20 output current fig. 12-3 efficiency vs. input voltage at 24v, 40a, typ. fig. 12-4 losses vs. input voltage at 24v, 40a, typ. efficiency 85 120 155 190 225 260vac 89 90 91 92 input voltage 93 94 95% power losses 20 30 40 50 60 70 80w 85 120 155 190 225 260vac input voltage oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 11/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 13. l ifetime e xpectancy and mtbf ac 100v ac 120v ac 230v calculated lifetime expectancy *) 288 000h *) 291 000h *) 317 000h *) at 24v, 20a and 25c 102 000h 103 000h 112 000h at 24v, 20a and 40c 163 000h *) 181 000h *) 238 000h *) at 24v, 40a and 25c 57 000h 64 000h 84 000h at 24v, 40a and 40c mtbf **) sn 29500, iec 61709 491 000h 481 000h 537 000h at 24v, 40a and 25c 274 000h 269 000h 300 000h at 24v, 40a and 40c mtbf **) mil hdbk 217f ground benign 170 000h 171 000h 183 000h at 24v, 40a and 25c; ground benign gb25 126 000h 127 000h 137 000h at 24v, 40a and 40c; ground benign gb40 mtbf **) mil hdbk 217f ground fixed 36 000h 36 000h 39 000h at 24v, 40a and 25c; ground fixed gf25 27 000h 27 000h 30 000h at 24v, 40a and 40c; ground fixed gf40 *) the calculated lifetime expectancy shown in the table indicates the minimum 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 calcu lated according to the capacitors manufacturer specification. the manufacturer of the electrolytic capacitors only guarantees a maximum life o f up to 15 years (131 400h). any number exceeding this value is a calculated theoretical lifetime which can be used to compare devices. **) mtbf stands for m ean t ime b etween f ailure, 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. the mtbf figure is a statistical representation of the likelihood of a device to fail. a mtbf figure of e.g. 1 000 000h means that statistically one unit will fail ev ery 100 hours if 10 000 units ar e installed in the field. how ever, it can not be determined if the failed unit has been running for 50 000h or only for 100h. 14. f unctional d iagram fig. 14-1 functional diagram + + - - v out dc-ok contact output over- voltage protection bridgeless pfc converter input fuse input filter inrush limiter output voltage regulator power converter output filter dc ok relay output voltage monitor output power manager temper- ature shut- down overload led dc-ok led n l single / parallel shut-down input & remote control shut- down 13 14 15 16 event datalogger oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 12/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 15. t erminals and w iring the terminals are ip20 finger sa fe constructed and suitable for field and factory wiring. input output dc-ok, shut-down type screw termination screw termin ation spring-clamp termination solid wire 0.5-6mm 2 0.5-16mm 2 0.15-1.5mm 2 stranded wire 0.5-4mm 2 0.5-10mm 2 0.15-1.5mm 2 american wire gauge awg 20-10 awg 22-8 awg 26-14 max. wire diameter 2.8mm (including ferrules) 5.2mm (including ferrules) 1.5mm (including ferrules) wire stripping length 7mm / 0.28inc h 12mm / 0. 5inch 7mm / 0.28inch screwdriver 3.5mm slotted or cross- head no 2 3.5mm or 5mm slotted or cross-head no 2 3mm slotted (to open the spring) recommended tightening torque 1nm, 9lb .in 2.3nm, 20.5lb.in not applicable instructions: a) use appropriate copper cables that are designed for minimum operating temperatures of: 60c for ambient up to 45c and 75c for ambient up to 60c minimum 90c for ambient up to 70c minimum. b) follow national installation c odes and installation regulations! c) ensure that all strands of a strande d wire enter the terminal connection! d) do not use the unit without pe connection. e) unused terminal compartments should be securely tightened. f) ferrules are allowed. daisy chaining: daisy chaining (jumping from one power s upply output to the next) is allowed as long as the average output current through one terminal pin does not exceed 54a. if the current is higher, use a separate distribution terminal block as shown in fig. 15-2 . fig. 15-1 daisy chaining of outputs fig. 15-2 using distribution terminals load + - power supply + + - - output power supply + + - - output max 54a! distribution terminals load + - power supply + + - - output power supply + + - - output oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 13/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 16. f ront s ide and u ser e lements fig. 16-1 front side a input terminals (screw terminals) n, l line input ...pe (protective earth) input b output terminals (screw terminals, two pins per pole) + positive output C ne gative (return) output c parallel use single use selector set jumper to parallel use when power supplies are connected in parallel to incr ease the output power. in order to achieve a sharing of th e load current between the individual power supplies, the parallel use 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 25.6 . a missing jumper is equal to a single use mode. d output voltage potentiometer multi turn potentiometer; open the flap to se t the output voltage. factory set: 24.1v at full out put current, single use mode. e dc-ok led (green) on, when the voltage on the output terminals is >90% of the adjusted output voltage f overload led (red) - on, when the voltage on the output terminals is <90% of the adjusted output voltage, or in case of a short circuit in the output. - flashing, when the shut-down has been activated or the unit has switched off due to over-temperature. - input voltage is required g dc-ok relay contact the dc-ok relay contact is sync hronized with the dc-ok led. see chapter 8 for details. h shut-down and remote control input allows the power supply to be shut down. can be activated with a switch contact or an external voltage. the remote control input allows adjusting the output voltage between 22v and 28v. see chapter 9 and 10 for details. indicators, leds overload led dc-ok led dc-ok contact normal mode off on closed during bonuspower ? off on closed overload (hiccup mode) flashing off open output short circuit flashing off open temperature shut-down flashing off open active shut-down input flashing off open no input power off off open oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 14/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 17. emc the power supply is suitable for applicat ions in industrial environm ent as well as in reside ntial, commercia l and light industry environment without any restrictions. a detailed emc re port is available on request. emc immunity according generic standards: en 61000-6-1 and en 61000-6-2 electrostatic discharge en 61000-4-2 contact discharge air discharge 8kv 15kv criterion a criterion a electromagnetic rf field en 61000-4-3 80mhz-2.7ghz 20v/m criterion a fast transients (burst) en 61000-4-4 input lines output lines signal lines (coupling clamp) 4kv 2kv 2kv criterion a criterion a criterion a surge voltage on input en 61000-4-5 l ? n l ? pe, n ? pe 2kv 4kv criterion a criterion a surge voltage on output en 61000-4-5 + ? - + / - ? pe 1kv 1kv criterion a criterion a surge voltage on signal line s en 61000-4-5 dc-ok signal ? pe 1kv criterion a en 61000-4-5 shut-down input ? pe not relevant due to wire length **) conducted disturbance en 61000-4- 6 0.15-80mhz 20v criterion a mains voltage dips en 61000-4-11 0% of 100vac 40% of 100vac 70% of 100vac 0% of 200vac 40% of 200vac 70% of 200vac 0vac, 20ms 40vac, 200ms 70vac, 500ms 0vac, 20ms 80vac, 200ms 140vac, 500ms criterion a criterion c criterion a criterion a criterion a criterion a voltage interruptions en 61000-4-11 0% of 200vac (=0v) 5000ms criterion c voltage sags semi f47 0706 dips on the in put voltage according to semi f47 standard 80% of 120vac (96vac) 70% of 120vac (84vac) 50% of 120vac (60vac) 1000ms 500ms 200ms criterion a criterion a criterion a powerful transients vde 0160 over entire load range 750v, 1.3ms criterion b *) *) criterion a is fulfilled fo r output current up to 30a. **) do not use longer wires than 30m for the shut-down input or use an additional protection. criterions: a: power supply shows normal operation behavior within the defined limits. b: output voltage will dip from 24v to 21v for 5ms c: temporary loss of function is possible. power supply may shut-down and restarts by itself. no damage or hazards for the powe r supply will occur. emc emission according generic standards: en 61000-6-3 and en 61000-6-4 conducted emission input lines en 55011, en 55022, fcc part 15, cispr 11, cispr 22 class b conducted emission output lines iec/cispr 16-1-2, iec/cispr 16-2-1 10db higher than aver age limits for dc power port according en 61000-6-3 ***) radiated emission en 55011, en 55022 class b harmonic input current en 61000-3- 2 fulfilled for class a equipment voltage fluctuations, flic ker en 61000-3-3 fulfilled **) this device complies with fcc part 15 rules. operation is subjected to fo llowing two conditions: (1) this device may not cause ha rmful interference, and (2) this device must accept any interferenc e received, including interference that may cause undesired operation. **) tested with constant current loads, non pulsing ***) restrictions apply for applications in residential, commercial and light-industrial environments, where local dc power net works according to en 61000-6-3 are involved. no restricti ons for all kinds of industrial applications. oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 15/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput switching frequencies the power supply has four converters with f our different switchin g frequencies included. one is nearly constant. the others ar e input voltage and load dependent. switching frequency 1 105khz resonant converter, nearly constant switching frequency 2 1khz to 150khz boost conv erter, input voltage and load dependent switching frequency 3 1khz to 100khz pfc conv erter, input voltage and load dependent switching frequency 4 25khz to 45khz aux. conv erter, input voltage and load dependent 18. e nvironment operational temperature *) -25c to +70c (-13f to 158f) reduce output power according fig. 18-1 storage temperature -40 to +85c (-40 f to 185f) for storage and transportation output de-rating 24w/c 60-70c (140f to 158f) humidity **) 5 to 95% r.h. iec 60068-2-30 vibration sinusoidal 2-17.8hz: 1.6mm; 17.8-500hz: 1g ***) 2 hours / axis iec 60068-2-6 shock 15g 6ms, 10g 11ms ***) 3 bumps / direction, 18 bumps in total iec 60068-2-27 altitude 0 to 2000m (0 to 6 560ft) without any restrictions 2000 to 6000m (6 560 to 20 000ft) reduce output power or ambient temperature, see fig. 18-2 iec 62103, en 50178, overvoltage category ii altitude de-rating 60w/1000m or 5c/1000m > 2000m (6500ft), see fig. 18-2 over-voltage category iii iec 62103, en 50178, altitudes up to 2000m ii altitudes from 2000m to 6000m degree of pollution 2 iec 62103, en 50178, not conductive labs compatibility the unit does not re lease any silicone or other labs-criti cal substances and is suitable for use in paint shops. *) operational temperature is the same as the ambient or surrounding temperature and is defined as the air temperature 2cm bel ow the unit. **) do not energize while condensation is present. ***) higher levels allowed when using the wall mounting bracket zm2.wall fig. 18-1 output current vs. ambient temp. fig. 18-2 output current vs. altitude allowed output current at 24v 0 -25 0 20 40 70c 10 20 30 40 50 60a 60 ambient temperature a b a . . . 9 0 - 2 6 4 v a c b . . . 8 5 - 9 0 v a c c o n t i n u o u s f o r t y p . 4 s allowed output current at 24v 0 0 2000 4000 6000m 10 20 30 40 50 60a c o n t i n u o u s altitude f o r t y p . 4 s 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 oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 16/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 19. p rotection f eatures output protection electronically protected against overload , no-load and short-circuits *) output over-voltage protection typ. 30vdc max. 32vdc in case of an internal pow er supply defect, a redundant circuit limits the maximum output voltage. the output shuts down and automatically attempts to restart. degree of protecti on ip 20 en/iec 60529 caution: for use in a contro lled environment according to csa 22.2 no 107.1-01. penetration protection > 5mm e.g. screws, small parts over-temperature protection yes output shut-down with automatic restart input transient protection mo v (metal oxide varistor) internal input fuse included not user replaceable *) in case of a protection event, audible noise may occur. 20. s afety f eatures input / output separation *) selv iec/en 60950-1 pelv iec/en 60204-1, en 50178, iec 62103, iec 60364-4-41 double or reinforced insulation class of protection i pe (protect ive earth) connection required isolation resistance > 5mohm input to output, 500vdc pe resistance < 0.1ohm touch current (leakage current) typ. 0.39ma / 1.0ma 100vac, 50hz, tn-,tt-mains / it-mains typ. 0.56ma / 1.43ma 120vac, 60h z, tn-,tt-mains / it-mains typ. 0.90ma / 2.25ma 230vac, 50h z, tn-,tt-mains / it-mains max. 0.50ma / 1.21ma 110vac, 50h z, tn-,tt-mains / it-mains max. 0.71ma / 1.73ma 132vac, 60h z, tn-,tt-mains / it-mains max. 1.18ma / 2.82ma 264vac, 50h z, tn-,tt-mains / it-mains *) double or reinforced insulation oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 17/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 21. d ielectric s trength 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 c onducted in the field using the appropr iate test equipment which applies the voltage with a slow ramp (2s up and 2s down). connect all input-terminals togeth er as well as all ou tput 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 a b c d type test 60s 2500vac 3000vac 500vac 500vac factory test 5s 2500vac 2500vac 500vac 500vac field test 5s 2000vac 2000vac 500vac 500vac cut-off current setting > 20ma > 20ma > 40ma > 1ma a d c b b *) l input dc-ok 13 14 earth, pe output 15/16 +/- shut-down n to fulfil the pelv requirements a ccording to en60204- 1 6.4.1, we recommend that either the + pole, the C pole or any other part of the output circuit shall be conne cted to the protective earth system. this helps to avoid si tuations in which a load starts unexpectedly or can not be swit ched 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 recomm end connecting dc-ok pins and the output pins together when performing the test. 22. a pprovals ec declaration of conformity the ce mark indicates conformance with the - emc directive 2004/108/ec, - low-voltage directive (lvd) 2006/95/ec and - rohs directive 2011/65/eu. iec 60950-1 2 nd edition cb scheme, information technology equipment applicable for altitudes up to 2000m. ul 508 ind. cont. eq. listed for use as industri al control equipment; u.s.a. (ul 508) and canada (c22.2 no. 107-1-01); e-file: e198865 ul 60950-1, 2 nd edition recognized for use as information technology equipment, level 5; u.s.a. (ul 60950-1) and canada (c22.2 no. 60950-1); e-file: e137006 applicable for altitudes up to 2000m. ansi / isa 12.12.01-2013 class i div 2 recognized for use in hazardous location class i div 2 t4 groups a,b,c,d systems; u.s.a. (ansi / isa 12.12.01-2013) and canada (c22.2 no. 213-m1987) en 60079-0, en 60079-15 atex ii 3g ex na nc ii t4 gc approval for use in hazardous locati ons zone 2 category 3g. number of atex certificate: eps 14 atex 1 638 x the power supply must be built -in in an ip54 enclosure. iec 60079-0, iec 60079-15 iecex suitable for use in class 1 zone 2 groups iia, iib and iic locations. number of iecex ce rtificate: iecex eps 14.0007x oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 18/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 23. p hysical d imensions and w eight weight 1900g / 4.2lb 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 unit depth (127mm) to calculate the total required installation depth. installation clearances see chapter 2 fig. 23-1 front view fig. 23-2 side view oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 19/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 24. a ccessories 24.1. zm2.wall - w all mounting bracket this bracket is used to mount specific dimension units onto a flat surface without utilizing a din-rail. 24.2. uf20.241 - b uffer module this buffer unit is a supplementary device for dc 24v power supplies. it delivers power to bridge typi cal mains failures or extends the hold-up time after turn-off of the ac power. in times when the pow supply provides sufficient voltages, the buffer unit stores energy in integrated electrolytic capacitors. in case of mains voltage fault, this ener gy is released again in a regulated process. one buffer module can deliver 20a. to buffer the full outpu current of 40a, two buffer modul es are needed in parallel. 20/28 er t dc buffer unit(s) power supply load ac + - the buffer unit does not require any control wiring. it can be a dded 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. oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany
qs40.241 q-series 24v, 40a, s ingle p hase i nput 24.3. yr80.242 - r edundancy m odule the yr80.242 is equipped with two input ch annels (40a each), wh ich 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 vo ltage and is self- powered 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. 24.4. yr40.245 - r edundancy m odule the yr40.245 is a 40a single channel redundanc y module, which is eq uipped with a plug connector on the output. the pl ug connector allows replac ing the power supply or the redundancy module while the system is running. the plug connector avoids that the output wires can touch and sho rt 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 generati on and a minimal voltage drop between input and output. it does not require an additional auxiliary voltage and is self- powered even in case of a short circuit across the output. fig. 24-1 typical 1+1 redundant configuration for 40a with a dual redundancy module fig. 24-2 typical n+1 or 1+1 redundant configuration for 40a with multiple yr40.245 redundancy modules yr80.242 *) redundancy module + - + - input 1 input 2 output l n pe + + - - 24v, 40a parallel use single use dc- ok qs40.241 24-28v 960w power supply ac input l n pe + + - - 24v, 40a parallel use single use dc- ok qs40.241 24-28v 960w power supply ac input 24v 40a load failure monitor *) yr80.241 also possible l n pe i i l n pe + + - - 24v, 40a parallel use single use dc- ok qs40.241 24-28v 960w power supply ac input l n pe + + - - 24v, 40a parallel use single use dc- ok qs40.241 24-28v 960w power supply ac input yr40.245 redundancy module + - input output + - yr40.245 redundancy module + - input output + - l n pe i i 24v 40a load failure monitor oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 21/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 25. a pplication n otes 25.1. r epetitive p ulse l oading typically, a load current is not constant and varies over time. this power suppl y is designed to support loads with a higher short-term power demand (=bonuspower ? ). the short-term duration is ha rdware 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 volt age 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 be low 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 cont inuous output current. if the r.m.s. current is higher, the unit will respond wi th a thermal shut-down afte r a period of time. use the maximum duty cycle curve ( fig. 25-2 ) to check if the average output cu rrent is below the nominal current. d) the duty cycle must be below 0.75. fig. 25-1 repetitive pulse loads, definitions fig. 25-2 max. duty cycle curve 100% p peak t peak p 0 t 0 max. 150% 150% 100 0 0.2 0.4 0.6 0.75 duty cycle 110 120 130 140 p peak p 0 = 1 0 % p 0 = 5 0 % p 0 = 7 5 % p 0 = 1 0 0 % p 0 base load (w) p peak pulse load (above 100%) t 0 duration between pulses (s) t peak pulse duration (s) d uty c ycle t 0 = t peak - (d uty c ycle x t peak ) t peak + t 0 t peak d uty c ycle = example: a load is powered continuously with 480w (= 50% of the rated output load). fr om time to time a peak power of 1440w (= 150% of the rated out put 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 p peak = 150% and a horizontal line where the vertical line crosses the p 0 = 50% curve. read the max. duty cycle fro m the duty cycle-axis (= 0.37) - c alculate the required pause (base load) length t 0 : 22/28 - r esult: the required pause length = 1.7s - max. repetition rate = pulse +pause length = 2.7s more examples for pulse load compatibility: p peak p 0 t peak t 0 p peak p 0 t peak t 0 1440w 960w 1s >25s 1440w 480w 0.1s >0.16s 1440w 0w 1s >1.3s 1440w 480w 1s >1.6s 1200w 480w 1s > 0.75s 1440w 480w 3s >4.9s d uty c ycle t 0 = t peak - (d uty c ycle x t peak ) 0.37 1s - (0.37 x 1s) == 1 . 7 s oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany
qs40.241 q-series 24v, 40a, s ingle p hase i nput 25.2. p eak c urrent c apability the power supply can deliver peak currents (up to several m illiseconds) 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 ou tput current (including the bonuspower ? ). the same situation applies when starting a capacitive load. the peak current capability also ensures the safe operati on of subsequent circuit breakers of load circ uits. the load branches are often individually protected with circuit breakers or fuses. in ca se 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 supplie d by the power converter and the built -in large sized output capacitors of the power supply. the capacito rs get discharged during such an event, which causes a vo ltage dip on the output. the following two examples show typical voltage dips: fig. 25-3 peak load with 2x the nominal current for 50ms, typ. fig. 25-4 peak load with 5x the nominal current for 5ms, typ. 10ms/div output voltage output current 24v 0a 80a 18.9v 1ms/div output voltage output current 24v 0a 200a 13.8v 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. from 24v to 18.9v at 80a for 50ms, resistive load typ. from 24v to 15.9v at 20 0a for 2ms, resistive load typ. from 24v to 13.8v at 20 0a for 5ms, resistive load 25.3. e xternal i nput p rotection 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 re gulations 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 mini mum value of 16a b- or c-charac teristic breaker should be chosen , when the unit is used at ac100 and ac120v mains voltages (including ac 230v). if the unit is used only at ac 230v mains, a 10a b- or c- characteristic breaker is sufficient. oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 23/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 25.4. c harging of b atteries the power supply can be used to char ge lead-acid or maintenance free batte ries. (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 10c 20c 30c 40c b) use a 50a or 63a circuit breaker (or blocking diode) between th e power supply and the battery. c) ensure that the output current of the power supply is below the allowe d charging current of the battery. d) use only matched batteries when putting 12v types in series. e) the return current to the power s upply (battery discharge current) is typ. 35ma when the power supply is switched off (except in case a blocking diode is utilized). 25.5. o utput c ircuit b reakers standard miniature circuit breakers (mcbs or ul 1077 circuit breakers) are commonl y used for ac-supply systems and may also be used on dc branches. mcbs are designed to protect wires and ci rcuits. if the ampere value and the char acteristics of the mcb are adapted to the wire size that is used, the wiring is considered as thermally safe rega rdless of whether the mcb opens or not. to avoid voltage dips and under-voltage situations in adjacent 24v branches wh ich 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 re quires power supplies with high current reserves and large output capacitors. furthermore, the impedance of the faulty branch must be sufficiently small in or der for the current to actually flow. the best current reserve in the power su pply does not help if ohms law does not permit current flow. the following table has typical test results showing which b- and c-characteristic mcbs magneti cally trip depending on the wire cross section and wire length. fig. 25-5 test circuit maximal wire length *) for a fast (magnetic) tripping: 0.75mm2 1.0mm2 1.5mm2 2.5mm2 c-2a 29m 38m 54m 86m c-3a 27m 34m 48m 78m c-4a 19m 26m 38m 58m c-6a 10m 15m 21m 34m c-8a 8m 12m 18m 28m c-10a 7m 11m 16m 26m c-13a 4m 6m 8m 13m b-6a 19m 25m 35m 55m b-10a 11m 17m 24m 40m b-13a 10m 13m 21m 29m b-16a 7m 11m 15m 24m mcb power supply ac dc + - + - load wire length s1... fault simulation switch s1 b-20a 5m 7m 9m 16m *) dont forget to consider twice the distance to the load (or cable length) when calculating the total wire length (+ and C wi re). oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 24/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 25.6. p arallel u se to i ncrease o utput p ower unit a ac dc unit b ac dc - + - + load + - power supplies from the same series (q-s eries) can be para lleled to increase the output power. the output voltage sh all 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 factor y 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 th e 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. if more than three units are connected in parallel, a fuse or circui t 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 ti me to avoid the overload hiccup plus mode. it also might be necessary to cycle the input power (turn-off for at least five se conds), if the output was in hiccup plus 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) be tween two power supplies and avoid installing the power supplies on top of each other. do not use power supplies in paralle l in mounting orientations other than the standard mounting orientation (te rminals on the bottom of the unit) or in any ot her condition where a derating of the output current is required (e.g. altitude, above 60c, ). pay attention that leakage current, emi, inrush current, ha rmonics will increase when usin g multiple power supplies. 25.7. p arallel u se for r edundancy power supplies can be paralleled fo r redundancy to gain higher system ava ilability. redundant systems require a certain amount of extra power to support th e load in case one power supply unit fa ils. 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 lo ad 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 in creasing the output power, see also chapter 25.6 . 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 beco mes a load for the other power supplies and the output voltage can not be mainta ined any more. this can be avoided by utilizing redundancy modules, which have decoupling devices (diode s or mosfets) included. further information and wiring configurati ons can be found in chapter 24.3 and 24.4 . recommendations for building redundant power systems: a) use separate input fuses for each power supply. a separate s ource for each supply when possible increases the reliability of the redundant system. b) set the power supply in to parallel use mode. c) monitor the individual power supply units. therefore, use the dc-ok relay contact of the qs40 power supply. d) it is desirable to set the output voltages of all units to the same value ( 100m v) or leave it at the factory setting. oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 25/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 25.8. s eries o peration unit a ac dc unit b ac dc - + - + load + - earth (see notes) power supplies of the same type can be connected in series for higher output voltages. it is possible to connec t as many units in series as needed, providing the sum of the output volt age does not exceed 150vdc. voltages with a potential above 60vdc are not selv any more and can be dangerous. such voltages must be installed with a protection against touching. earthing of the output is required when the sum of the output voltage is above 60vdc. avoid return voltage (e.g. from a decelerating motor or battery) which is applied to the output terminals. keep an installation clearance of 15mm (left / right) be tween 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, ha rmonics will increase when usin g multiple power supplies. 25.9. i nductive and c apacitive l oads 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 capa citors or ultracaps) with a capacita nce > 2.5f are connected to the output, the unit might charge the capacitor in the hiccup plus mode (see chapter 6 ). 25.10. b ack - feeding l oads loads such as decelerating motors and induc tors can feed voltage 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 malfunctioning when a load f eeds 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 absorbin g energy can be calculated according to the built-in large sized output capacitor wh ich is specified in chapter 6 . oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 26/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput 25.11. o peration on t wo p hases 240v +10% max. l2 l1 l3 l n pe power supply ac dc internal fuse the power supply can also be used on two-phases of a three-phase-system. such a phase to phase connection is a llowed as long as the supplying voltage is below 240v +10% . 25.12. 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. in such situations, th e inside temperature defi nes the ambient temperatur e 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: rittal typ ip66 box pk 9522 100, plastic, 254x180x165mm load: 24v, 32a; (=80%) lo ad is placed outside the box input: 230vac temperature inside enclosure: 68.6c (i n the middle of the right side of the pow er supply with a distance of 2cm) temperature outside enclosure: 24.3c temperature rise: 44.3k oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 27/28
qs40.241 q-series 24v, 40a, s ingle p hase i nput oct. 2014 / rev. 1.2 ds-qs40.241-en all parameters are specified at 24v, 40a, 230vac, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 25.13. m ounting o rientations mounting orientations ot her than all terminals on the bottom require a reduction in continuous output power or a limitation in the maximum allowed ambien t temperature. the amount of reduction influences the lifetime expectancy of the power supply. therefore, tw o different derating curves for cont inuous operation can be found below: curve a1 recommended output current. curve a2 max allowed output current (res ults in approximately half the lifetime expectancy of a1). fig. 25-6 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. 25-7 mounting orientation b (upside down) power supply output input output current 0 10 20 30 40 60c 10 20 30 40a 50 a 2 ambient temperature a 1 fig. 25-8 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. 25-9 mounting orientation d (horizontal cw) power supply output input output current 0 10 20 30 40 60c 10 20 30 40a 50 ambient temperature a 1 a 2 fig. 25-10 mounting orientation e (horizontal ccw) power supply output input output current 0 10 20 30 40 60c 10 20 30 40a 50 ambient temperature a 1 a 2 28/28

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