Puls PIANO Series Manual

PIANO-Series

PIC480.241C

24V, 20A, S INGLE P HASE I NPUT

P

OWER

S

UPPLY

AC 200-240V Regional Input

Cost Optimized without Compromising Quality or

Reliability

Width only 49mm

Efficiency 95.7%

Full Power Between -25°C and +55°C

DC-OK Relay Contact Included

3 Year Warranty

G

ENERAL

D

ESCRIPTION

These PIANO series units are extraordinarily compact, industrial grade power supplies that focus on the essential features needed in today’s industrial applications. The excellent cost/performance ratio presents many new and exciting opportunities without compromising quality or reliability.

The mechanically robust housing is made of a highgrade, reinforced molded material, which permits the units to be used in surrounding temperatures up to

70°C.

Since typical industrial applications do not require multiple mains inputs, the reduction to a regional input voltage range (AC 200-240V) simplifies the circuitry and has significant advantages for reliability, efficiency and cost.

The addition of a DC-OK signal makes the unit suitable for many industry applications such as: process, automation and many other critical applications where preventive function monitoring can help to avoid long downtimes.

S

HORT

-

FORM

D

ATA

Output voltage DC 24V

Adjustment range 24 - 28V

Output current 20A

Output power

15A

17.1A

12.8A

480W at 24V, amb <55°C at 24V, amb <70°C at 28V, amb <55°C at 28V, amb <70°C ambient <55°C

Output ripple < 100mVpp 20Hz to 20MHz

AC Input voltage AC 200-240V ±10%

Mains frequency

AC Input current

50-60Hz

2.2A

±6% at 230Vac

Power factor 0.99

AC Inrush current 26A peak at 230Vac at 230Vac, 40°C

Temperature range -25°C to +70°C operational

Derating

Hold-up time

8W/°C

30ms

+55 to +70°C at 230Vac

O

RDER

N

UMBERS

Power Supply PIC480.241C

24-28V Standard unit

Weight

M

ARKINGS

IND. CONT. EQ.

UL 508 planned

620g / 1.37lb

UL 60950-1 planned

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN

All parameters are typical values specified at 24V, 20A output, 230Vac input , 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany

PIANO-Series

PIC480.241C


I

NDEX

Page

1.

Intended Use .......................................................3

2.

Installation Requirements...................................3

3.

AC-Input...............................................................4

4.

DC-Input...............................................................5

5.

Input Inrush Current ...........................................5

6.

Output .................................................................6

7.

Hold-up Time.......................................................7

8.

DC-OK Relay Contact ..........................................7

9.

Efficiency and Power Losses................................8

10.

Lifetime Expectancy and MTBF...........................8

11.

Functional Diagram.............................................9

12.

Terminals and Wiring..........................................9

13.

Front Side and User Elements...........................10

14.

EMC....................................................................11

15.

Environment ......................................................12

16.

Protection Features ...........................................13

17.

Safety Features ..................................................13

18.

Dielectric Strength ............................................14

19.

20.

21.

22.

23.

Page

Approvals .......................................................... 15

RoHS, REACH and Other Fulfilled Standards .. 15

Physical Dimensions and Weight ..................... 16

Accessory........................................................... 17

22.1.

22.2.

23.1.

23.2.

23.3.

23.4.

23.5.

23.6.

23.7.

23.8.

23.9.

Application Notes............................................. 18

23.10.

YR40.242 Redundancy Module ................17

PIRD20.241 Redundancy Module.............17

Peak Current Capability ...........................18

Back-feeding Loads ..................................18

External Input Protection.........................19

Parallel Use to Increase Output Power....19

Parallel Use for 1+1 Redundancy .............19

Series Operation .......................................20

Inductive and Capacitive Loads................20

Charging of Batteries ...............................20

Operation on Two Phases ........................21

Use in a Tightly Sealed Enclosure ............21

The information given in this document is correct to the best of our knowledge and experience at the time of publication. If not expressly agreed otherwise, this information does not represent a warranty in the legal sense of the word. As the state of our knowledge and experience is constantly changing, the information in this data sheet is subject to revision. We therefore kindly ask you to always use the latest issue of this document (available under www.pulspower.com). No part of this document may be reproduced or utilized in any form without our prior permission in writing.

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

T.b.d.

AC 230V

This document uses the term “earth” which is the same as the U.S. term “ground”.

To be defined, value or description will follow later.

230Vac

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)

A figure with the unit (Vac) at the end is a momentary figure without any additional tolerances included.

50Hz vs. 60Hz may shall should

As long as not otherwise stated, AC 230V parameters are valid at 50Hz mains frequency.

A key word indicating flexibility of choice with no implied preference.

A key word indicating a mandatory requirement.

A key word indicating flexibility of choice with a strongly preferred implementation.

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIC480.241C

PIANO-Series 24V, 20A, S INGLE P HASE I NPUT

1.

I

NTENDED

U

SE

This device is designed for installation in an enclosure and is intended for the general professional use such as in industrial control, office, communication, and instrumentation equipment.

Do not use this power supply in equipment, where malfunction may cause severe personal injury or threaten human life.

2.

I

NSTALLATION

R

EQUIREMENTS

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.

Mount the unit on a DIN-rail so that the input terminals are located on the bottom of the unit.

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 clearances: 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 the 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, fire, personal injury or death.

- Do not use the power supply without proper grounding (Protective Earth).

- Turn power off before working on the device. Protect against inadvertent 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 entering 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 surfaces may cause burns.

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIANO-Series

3.

AC-I

NPUT

AC input

AC input range

PIC480.241C

24V, 20A, S INGLE P HASE I NPUT nom. min.

AC 200-240V suitable for TN-, TT- and IT mains networks

Allowed voltage L or N to earth

Input frequency

Turn-on voltage

Shut-down voltage

External input protection max. nom. typ.

300Vac

50–60Hz

150Vac continuous, IEC 62103

±6%

steady-state value, see Fig. 3-1

typ. 130Vac

steady-state value, see Fig. 3-1

See recommendations in chapter 23.3.

Input current

Power factor

Crest factor

Start-up delay

Rise time

*)

**) typ. typ. typ. typ. typ. typ.

2.2A

0.99

1.6

400ms

60ms

240ms

at 24V, 20A, 230Vac, see Fig. 3-3 at 24V, 20A, 230Vac, see Fig. 3-4

at 24V, 20A, 230Vac

see Fig. 3-2

at 24V, 20A const. current load, 0mF load capacitance,

see Fig. 3-2

at 24V, 20A const. current load, 20mF load capacitance,

see Fig. 3-2

Turn-on overshoot max. 200mV resistive

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, typ. Fig. 3-2 Turn-on behavior, definitions

P

OUT

Rated input range max.

500ms

Input

Voltage

180V

V

IN

264V 300Vac

Fig. 3-3 Input current vs. output load at 24V

Input Current, typ.

3A

2.5

2.0

1.5

1.0

0.5

0

Output Current

0 2 4 6 8 10 12 14 16 18 20A

Output

Voltage

- 5%

Start-up delay

Rise

Time

Fig. 3-4 Power factor vs. output load

Power Factor, typ.

1.00

0.98

0.96

0.94

0.92

0.90

0.88

2 4 6 8

Output Current

10 12 14 16 18 20A

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIANO-Series

PIC480.241C


4.

DC-I

NPUT

Do not operate this power supply with DC-input voltage.

5.

I

NPUT

I

NRUSH

C

URRENT

A NTC inrush limiter, which is bypassed by a relay contact during normal operation, limits the input inrush current after turn-on of the input voltage.

Inrush current *) 40°C ambient, 230Vac, cold start

Inrush energy *) 40°C ambient, 230Vac, cold start

*) The charging current into EMI suppression capacitors is disregarded in the first microseconds after switch-on.

Fig. 5-1 Input inrush current, typical behavior

230Vac input, 24V, 20A output, 25°C ambient

Ipeak = 16A

Input current 5A/DIV

Input voltage 500V/DIV

Output voltage 20V/DIV

20ms/DIV

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIANO-Series

6.

O

UTPUT

Output voltage

Adjustment range

PIC480.241C

24V, 20A, S INGLE P HASE I NPUT nom. DC 24V min. 24-28V guaranteed

Factory settings

Line regulation

Load regulation

Ripple and noise voltage

Output current

Output power

Overload behaviour typ. 24.1V max. 50mV max. 150mV max. 100mVpp nom. 20A nom. 15A nom. 17.1A nom. 12.8A nom. 480W nom. 360W

±0.2%, at full load, cold unit

187-264Vac static value, 0A Æ

20A; see Fig. 6-1

20Hz to 20MHz, 50Ohm

at 24V, ambient temperature <55°C, see Fig. 6-1 at 24V, ambient temperature <70°C, see Fig. 6-1 at 28V, ambient temperature <55°C, see Fig. 6-1 at 28V, ambient temperature <70°C, see Fig. 6-1

ambient temperature <55°C ambient temperature <70°C cont. current

output voltage > 13.5Vdc, see Fig. 6-1

Hiccup PLUS mode **)

output voltage < 13.5Vdc, see Fig. 6-1

typ. 8.1A

load impedance 50mOhm, see Fig. 6-1 load impedance 50mOhm, see Fig. 6-1

average (R.M.S.) current, load impedance 50mOhm,

see Fig. 6-1

included inside the power supply Output capacitance typ. 4 300μF

*) Discharge current of output capacitors is not included.

**) Hiccup PLUS Mode

At heavy overloads (when output voltage falls below 13.5V), the power supply delivers continuous output current for 5s. After this, the output is switched off for approx. 8s before a new start attempts with duration of 1s are automatically performed. This cycle is repeated as long as the overload exists. If the overload has been cleared, the device will operate normally.

***) 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.

Fig. 6-1

Output voltage vs. output current, typ.

Fig. 6-2

Short-circuit (50mOhm) on output, Hiccup PLUS mode, typ.

Output Voltage

28V

24

20

16

12

8

4

0

0 5

Output Current

10 15 20

Adjustment

Range

2 5

Continuous current

Hiccup PLUS mode

30A

Output

Current

Normal operation

23A

0

5s

First pulse: 5s

8s

Short -circuit

1s 8s 1s 8s

Normal operation t

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIC480.241C


7.

H

OLD

-

UP

T

IME

Hold-up Time typ. min. typ. min.

Fig. 7-1 Hold-up time vs. input voltage

65ms

55ms

30ms

23ms

at 24V, 10A, 230Vac, see Fig. 7-1 at 24V, 10A, 230Vac, see Fig. 7-1 at 24V, 20A, 230Vac, see Fig. 7-1 at 24V, 20A, 230Vac, see Fig. 7-1

Fig. 7-2 Shut-down behavior, definitions

Hold-up Time

80ms

70

60

50

40

30

20

10

0

102 120 a) 24V 10A typ.

b) 24V 10A min.

c) 24V 20A typ.

d) 24V 20A min.

a b

Input Voltage c d

Input

Voltage

Output

Voltage

Zero Transition

Hold-up Time

- 5%

155 190 230Vac

8.

DC-OK R

ELAY

C

ONTACT

This feature monitors the output voltage, which is produced by the power supply itself. It is independent of a back-fed voltage from a unit connected in parallel to the power supply output (e.g. redundant application).

Threshold voltage

Contact closes

Contact opens

Contact ratings typ. 21.4V (fixed)

As soon as the output voltage reaches 21.4V.

As soon as the output voltage falls below 21.4V. max. 60Vdc 0.3A, 30Vdc 1A, 30Vac 0.5A resistive load

Isolation voltage

See dielectric strength table in section 18.

Fig. 8-1 DC-ok relay contact behavior

Output Voltage

21.4V

open closed

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIC480.241C


9.

E

FFICIENCY AND

P

OWER

L

OSSES

Efficiency

Average efficiency *) typ. typ.

95.7%

95.2% at 24V, 20A, 230Vac

25% at 5A, 25% at 10A, 25% at 15A. 25% at 20A

Power losses typ. typ.

1.35W

10.7W at 24V, 0A, 230Vac at 24V, 10A, 230Vac typ. 21.6W at 24V, 20A, 230Vac

*) 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. 9-1 Efficiency vs. output current at 24V, typ.

Fig. 9-2 Losses vs. output current at 24V, typ.

Efficiency

97%

96

95

94

93

92

91

4

Output Current

6 8 10 12 14 16 18 20A

10.

L

IFETIME

E

XPECTANCY AND

MTBF

Lifetime expectancy *) 93 000h

Power Losses

24W

20

16

12

8

4

0

0 2 4 6

Output Current

8 10 12 14 16 18 20A at 24V, 10A and 40°C, 230Vac

51 000h at 24V, 20A and 40°C, 230Vac

MTBF

MTBF

**)

**)

SN 29500, IEC 61709

MIL HDBK 217F

482 000h

894 000h

207 000h

279 000h at 24V, 20A and 40°C, 230Vac at 24V, 20A and 25°C, 230Vac at 24V, 20A and 40°C, 230Vac;

Ground Benign GB40 at 24V, 20A and 25°C, 230Vac;

Ground Benign GB25

45 000h

57 000h at 24V, 20A and 40°C, 230Vac;

Ground Fixed GF40 at 24V, 20A and 25°C, 230Vac;

Ground Fixed GF25

*) The 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 calculated according to the capacitor’s manufacturer specification. The manufacturer of the electrolytic capacitors only guarantees a maximum life of 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 every 100 hours if 10 000 units are installed in the field. However, it can not be determined if the failed unit has been running for 50 000h or only for 100h.

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIANO-Series

11.

F

UNCTIONAL

D

IAGRAM

Fig. 11-1 Functional diagram

PIC480.241C


L

N

Input Fuse

Input Filter

Input Rectifier

Inrush Current Limiter

PFC

Converter

Power

Converter

Output

Filter

DC-ok

Relay

-

-

+

+

DC-ok

Contact

Temperature

Shutdown

Output

Over-

Voltage

Protection

Output

Voltage

Regulator

DC-ok

LED

V

OUT

12.

T

ERMINALS AND

W

IRING

The terminals are IP20 finger safe constructed and suitable for field- and factory wiring.

Type

Solid wire

Stranded wire

American Wire Gauge

Maximal wire diameter

Input and output

Screw terminals

DC-OK-Signal

Push-in terminals max. 6mm 2 1.5mm

2 max. 4mm 2 1.5mm

2

AWG20-10

2.8mm (including ferrules)

AWG28-16

1.6mm (including ferrules)

Wire stripping length

Screwdriver

7mm / 0.28inch

3.5mm slotted or cross-head No 2

Recommended tightening torque 1Nm, 9lb.in

7mm / 0.28inch not required not applicable

Instructions: a) Use appropriate copper cables that are designed for minimum operating temperatures of:

75°C for ambient up to 55°C and

90°C for ambient up to 70°C minimum. b) Follow national installation codes and installation regulations! c) Ensure that all strands of a stranded wire enter the terminal connection! d) Unused terminal compartments should be securely tightened. e) Ferrules are allowed.

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIC480.241C


13.

F

RONT

S

IDE AND

U

SER

E

LEMENTS

Fig. 13-1 Front side

A Input (screw terminals)

N, Line input

PE (Protective Earth) input

B Output (screw terminals, two pins per pole)

+ Positive output

– Negative (return) output

C Output voltage potentiometer

Guaranteed adjustment range: 24-28V

Factory set: 24.1V

LED

On, when the output voltage is >18V

Description see chapter 8.

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIC480.241C


14.

EMC

The power supply is suitable for applications in industrial environment.

A detailed EMC report is available on request.

EMC Immunity According generic standards: EN 61000-6-1 and EN 61000-6-2

Electrostatic discharge

Electromagnetic RF field

EN 61000-4-2

EN 61000-4-3 contact discharge air discharge

80MHz-2.7GHz

8kV

8kV

10V/m

Surge voltage on input

Surge voltage on output

Surge voltage on DC-OK

Conducted disturbance

Mains voltage dips

Voltage interruptions

Voltage sags

Criterion A

Criterion A

Criterion A

EN 61000-4-5

EN 61000-4-5

EN 61000-4-5 output lines

DC-OK signal (coupling clamp)

L Æ N

L Æ PE, N Æ PE

+ Æ -

+ / - Æ PE

DC-OK signal Æ PE

EN 61000-4-6 0.15-80MHz

EN 61000-4-11 0% of 200Vac

40% of 200Vac

70% of 200Vac

EN 61000-4-11

SEMI F47 0706

0% of 200Vac (=0V)

4kV

2kV

2kV

2kV

4kV

500V

1kV

1kV

10V

0Vac, 20ms

80Vac, 200ms

140Vac, 500ms

Criterion A

Criterion A

Criterion A

Criterion A

Criterion A

Criterion A

Criterion A

Criterion A

Criterion A

Criterion C

Criterion C dips on the input voltage according to SEMI F47 standard

80% of 200Vac (160Vac)

70% of 200Vac (140Vac)

50% of 200Vac (100Vac)

5000ms

1000ms

500ms

200ms

Criterion C

Criterion A

Criterion C

Criterion C

Powerful transients VDE 0160 over entire load range 750V, 0.3ms Criterion A

Criterions:

A: Power supply shows normal operation behavior within the defined limits.

B: Temporary voltage dips possible. No change in operation mode.

C: Temporary loss of function is possible. Power supply may shut-down and restarts by itself. No damage or hazards for the power supply will occur.

EMC Emission According generic standards: EN 61000-6-3, EN 61000-6-4

Conducted emission input lines

Conducted emission output lines **)

EN 55011, EN 55022, FCC Part 15,

CISPR 11, CISPR 22

IEC/CISPR 16-1-2, IEC/CISPR 16-2-1

Class B fulfilled limits for DC power port according EN

61000-6-3 not fulfilled

Class B fulfilled Radiated emission

Harmonic input current

EN 55011, EN 55022

EN 61000-3-2 Class A fulfilled between 0A and 20A load

Class C fulfilled between 7A and 20A load fulfilled *) Voltage fluctuations, flicker

EN 61000-3-3

This device complies with FCC Part 15 rules.

Operation is subjected to following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

*) tested with constant current loads, non pulsing

**) for information only, not mandatory for EN 61000-6-3

Switching Frequencies

Switching frequency 1

Switching frequency 2

The power supply has two converters with two different switching frequencies included.

40-120kHz

80-140kHz

PFC converter, input voltage and output power dependent

Main converter, output voltage and output power dependent

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIANO-Series

PIC480.241C


15.

E

NVIRONMENT

Operational temperature *) -25°C to +70°C (-13°F to 158°F)

Storage temperature

Output de-rating

Humidity **)

-40°C to +85°C (-40°F to 185°F)

8W/°C

5 to 95% r.h.

Vibration sinusoidal

Shock

2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g ***)

2 hours / axis ***)

30g 6ms, 20g 11ms ***)

3 bumps / direction, 18 bumps in total

Altitude 0 to 2000m (0 to 6 560ft)

2000 to 6000m (6 560 to 20 000ft)

reduce output power according Fig. 15-1

for storage and transportation

55°C to 70°C (131°F to 158°F)

IEC 60068-2-30

IEC 60068-2-6

IEC 60068-2-27

Altitude de-rating

Over-voltage category

Degree of pollution

30W/1000m or 5°C/1000m

III

II

2 without any restrictions reduce output power or ambient temperature,

see Fig. 15-2

IEC 62103, EN 50178, overvoltage category II

> 2000m (6500ft), see Fig. 15-2

IEC 62477-1, altitudes up to 2000m altitudes from 2000m to 6000m

IEC 62477-1, not conductive

LABS compatibility The unit does not release any silicone or other LABS-critical 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 below the unit.

**) Do not energize while condensation is present

***) Tested on a DIN-Rail with a thickness of 1.3mm.

Fig. 15-1 Output current vs. ambient temp.

Allowable Output Current at 24V

20A

15A

10A

5A

0

-25 -10 0

Ambient Temperature

+20 +40 +55 +70°C

Fig. 15-2 Output current vs. altitude

Allowed Output

Current at 24V

24A

20A

16A

12A

8A

4A

0

0

A... Tamb < 55°C

B... Tamb < 45°C

C... Tamb < 35°C

2000 4000

C

B

A

Altitude

6000m

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIC480.241C


16.

P

ROTECTION

F

EATURES

Output protection Electronically protected against overload, no-load and short-circuits *) max. 32.0Vdc

In case of an internal power supply defect, a redundant circuit limits the maximum output voltage. The output shuts down and automatically attempts to restart.

Degree of protection

Over-temperature protection

Input transient protection

IP 20 yes

MOV (Metal Oxide Varistor)

Internal input fuse included

*) In case of a protection event, audible noise may occur.

EN/IEC 60529

Caution: For use in a controlled environment according to CSA 22.2 No 107.1-01.

Output shut-down with automatic restart

Not user replaceable

17.

S

AFETY

F

EATURES

Input / output separation

Class of protection

Isolation resistance

SELV

PELV double or reinforced insulation

I PE (Protective Earth) connection required

> 500MOhm

IEC/EN 60950-1

IEC/EN 60204-1, IEC 62477-1, IEC 60364-4-41

> 500MOhm

At delivered condition between input and output, measured with 500Vdc

At delivered condition between input and PE, measured with 500Vdc

> 500MOhm

> 500MOhm

At delivered condition between output and PE, measured with 500Vdc

At delivered condition between output and DC-OK contacts, measured with 500Vdc

Touch current (leakage current) 0.33mA / 0.69mA

0.43mA / 0.89mA

230Vac, 50Hz, TN-,TT-mains / IT-mains

264Vac, 50Hz, TN-,TT-mains / IT-mains

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIC480.241C


18.

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 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. 18-1 Dielectric strength A B C D

Type test 60s 2500Vac 3000Vac 500Vac 500Vac

Input

L

N

B *)

DC-ok

Factory test

Field test

5s

5s

2500Vac

2000Vac

2500Vac

2000Vac

500Vac

500Vac

500Vac

500Vac

+

-

Cut-off current setting 10mA 10mA 10mA 1mA

A

Earth, PE

C

B

D

Output

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.

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIC480.241C


19.

A

PPROVALS

EC Declaration of Conformity

IEC 60950-1

2 nd Edition, planned

UL 60950-1

2 nd Edition, planned

UL 508, planned

RoHS Directive

REACH Directive

IND. CONT. EQ.

The CE mark indicates conformance with the

EMC directive and the Low-voltage directive (LVD).

CB Scheme,

Information Technology Equipment

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.

Listed for use as Industrial Control Equipment;

U.S.A. (UL 508) and Canada (C22.2 No. 107-1-01);

E-File: E198865

20.

R

O

HS, REACH

AND

O

THER

F

ULFILLED

S

TANDARDS

Directive 2011/65/EU of the European Parliament and the

Council of June 8 th , 2011 on the restriction of the use of certain hazardous substances in electrical and electronic equipment.

Directive 1907/2006/EU of the European Parliament and the

Council of June 1 st , 2007 regarding the Registration,

Evaluation, Authorisation and Restriction of Chemicals

(REACH)

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIANO-Series

21.

P

HYSICAL

D

IMENSIONS AND

W

EIGHT

PIC480.241C


Weight

DIN-Rail

Plastic Material of Housing

Installation Clearances

Fig. 21-1 Front view

The DIN-rail height must be added to the unit depth to calculate the total required installation depth.

620g / 1.37lb

Use 35mm DIN-rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm.

Flame retardant Polycarbonate (PC) - UL94-V0

Vicat softening temperature specified with 149°C according to ASTM D1525

See chapter 2

Fig. 21-2 Side view

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIANO-Series

22.

A

CCESSORY

PIC480.241C


22.1.

YR40.242

R

EDUNDANCY

M

ODULE

The YR40.242 is the preferred redundancy module for PIC480.241C power supplies. It is equipped with two input channels (20A each), which are individually decoupled by utilizing MOSFET technology.

The output current can go as high as 40A.

Failure

Monitor

Using MOSFETs instead of diodes reduces the heat generation and the voltage drop between input and output.

The YR40.242 does not require an additional auxiliary voltage.

+ + - -

24-28V

DC-OK

DC-

OK

+ -

Input

+ -

Input

1 2

YR40.242

Redundancy

Module

+ + - -

24-28V

DC-OK

DC-

OK

Due to the low power losses, the unit is very slender and only requires 36mm width on the DIN-rail.

See chapter 23.5 for instructions how to

build a redundant system.

PIC480.241C

Power Supply

L N PE

I

Output

+ -

PIC480.241C

Power Supply

L N PE

I

24V,20A

Load

L

N

PE

22.2.

PIRD20.241

R

EDUNDANCY

M

ODULE

The PIRD20.241 is a very cost effective diode redundancy module, which can be used to build 1+1 and N+1 redundant systems. It is equipped with two input channels, which can be connected to power supplies with up to 10A output current and one output, which can carry nominal currents up to 20A.

If 20A power supplies are utilized, it is recommended to connect the power supply output to both inputs of the redundancy module. Therefore, two redundancy modules are required to build a 20A redundant power system. Failure

Monitor

The PIRD20.241 is the perfect solution to use in a redundant system, if the power supply itself is equipped with a DC-

OK signal.

+ +

24-28V

DC-OK

DC-

OK

- - + +

IN

1

IN

2

+ +

DC-

OK

- -

24-28V

DC-OK

- + +

IN

1

IN

2

The PIRD20.241 does not require an additional auxiliary voltage and is

PIC480.241C

Power Supply

PIRD20.241

Redundancy

Module

- OUT +

PIC480.241C

Power Supply self- powered even in case of a short circuit across the out put.

L N PE L N PE

PIRD20.241

Redundancy

Module

- OUT +

See chapter 23.5 for instructions

how to build a redundant system.

I I

24V, 20A

Load

L

N

PE

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIANO-Series

23.

A

PPLICATION

N

OTES

PIC480.241C


23.1.

P

EAK

C

URRENT

C

APABILITY

The unit 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. 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. 23-1 Peak load with 2x the nominal current for 50ms, typ.

Fig. 23-2 Peak load with 5x the nominal current for 5ms, typ.

24V

Output Voltage 24V

Output

Voltage

100A

40A

13.5V

5.5V

0A

Output

Current

10ms/DIV

40A Peak load (resistive) for 50ms

Output voltage dips from 24V to 14V.

Peak current voltage dips typ. typ. typ. from 24V to 13.5V from 24V to 7.5V from 24V to 5.5V

0A

1ms/DIV

Output

Current

100A Peak load (resistive) for 5ms

Output voltage dips from 24V to 4V. at 40A for 50ms, resistive load at 100A for 2ms, resistive load at 100A for 5ms, resistive load

23.2.

B

ACK

-

FEEDING

L

OADS

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.

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIANO-Series

PIC480.241C


23.3.

E

XTERNAL

I

NPUT

P

ROTECTION

The unit is tested and approved for branch circuits up to 30A (UL) 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 6A C-Characteristic breaker should be used.

23.4.

P

ARALLEL

U

SE TO

I

NCREASE

O

UTPUT

P

OWER

Do not use the power supply in parallel to increase the output power.

23.5.

P

ARALLEL

U

SE FOR

1+1 R

EDUNDANCY

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.

Failure

Monitor

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 defect unit becomes a load for the other power supplies and the output voltage can not be maintained any more. This can only be avoided by utilizing decoupling diodes which are included in the redundancy module

YR40.241.

Recommendations for building redundant power systems:

+ + - -

24-28V

DC-OK

DC-

OK

PIC480.241C

Power Supply

L N PE

+

Input

1

+ -

Input

2

YR40.242

Redundancy

Module

Output

+ -

+ + - -

24-28V

DC-OK

DC-

OK

PIC480.241C

Power Supply

L N PE a) Monitor the individual power supply units. Therefore, use the

DC-OK relay contact of the PIC480.241C power supply.

I I

24V,20A

Load b) Use separate input fuses for each power supply. c) Use separate mains systems for each power supply whenever it is possible.

L

N

PE d) It is desirable to set the output voltages of all units to the same value (± 100mV) or leave it at the factory setting.

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIANO-Series

PIC480.241C


23.6.

S

ERIES

O

PERATION

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 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.

Unit A

AC

DC

Unit B

AC

DC

+

-

+

-

+

-

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.

Pay attention that leakage current, EMI, inrush current, harmonics will increase when using multiple power supplies.

23.7.

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 capacitors or “UltraCaps”) with a capacitance larger than 1.5F are connected to the output, the unit might charge the capacitor in the Hiccup PLUS

mode (see chapter 6).

23.8.

C

HARGING OF

B

ATTERIES

Do not use the power supply to charge batteries.

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


PIANO-Series

PIC480.241C


23.9.

O

PERATION ON

T

WO

P

HASES

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% .

L3

L1

L2

Fuse

Power Supply

L

AC internal fuse

N

PE

DC

23.10.

U

SE IN A

T

IGHTLY

S

EALED

E

NCLOSURE

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: Rittal Type IP66 Box PK 9519 100, plastic, 180x180x165mm

Load:

Temperature inside the box:

24V, 16A; (=80%) load is placed outside the box

51.5°C (in the middle of the right side of the power supply with a distance of 1cm)

Temperature outside the box: 25.5°C

Temperature rise: 26.0K

Jul. 2017 / Rev. 1.1 DS-PIC480.241C-EN


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