Puls PIC480.241C DIN rail power supply Owner's Manual

PIC480.241C, PIC480.241C-C1

24V, 20A, 480W, S

INGLE

P

HASE

I

NPUT PIANO-Series

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.

P

OWER

S

UPPLY

 AC 200-240V Regional Input

 Cost Optimized without Compromising Quality or

Reliability

 Optional with Conformal Coated PC-Boards

 Active PFC

 Width only 49mm

 Efficiency 95.7%

 Full Power Between -25°C and +55°C

 DC-OK Relay Contact Included

 3 Year Warranty

S

HORT

-

FORM

D

ATA

Output voltage DC 24V

Adjustment range 24 - 28V

Output current 20A

15A

17.1A

12.8A at 24V, amb <55°C at 24V, amb <70°C at 28V, amb <55°C at 28V, amb <70°C

Output power

Output ripple

AC Input voltage

480W

360W

Mains frequency

AC Input current

50-60Hz

2.2A

Power factor 0.99

AC Inrush current 26A peak ambient <55°C ambient <70°C

< 100mVpp 20Hz to 20MHz

AC 200-240V ±10%

±6% at 230Vac at 230Vac at 230Vac, 40°C

Efficiency

Losses

95.7%

21.6W at 230Vac at 230Vac

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

Derating 8W/°C +55 to +70°C

Hold-up time

Dimensions

Weight

30ms at 230Vac

49x124x124mm WxHxD

620g / 1.37lb The PIC480.241C-C1 device is the same as the

PIC480.241C but with conformal coated pc-boards.

O

RDER

N

UMBERS

Power Supply PIC480.241C

PIC480.241C-C1 With conformal

Accessory YR40.242

PIRD20.241 coated pc-boards

Redundancy module

Redundancy module

M

ARKINGS

IEC 61010-2-201 UL 61010-2-201 IEC 62368

Mar. 2021 / Rev. 1.2 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

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PIANO-Series

PIC480.241C, PIC480.241C-C1

24V, 20A, 480W, S

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I

NDEX

Page

1.

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

2.

Installation Instructions ...................................... 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.

Safety and Protection Features ........................ 13

17.

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

Page

18.

Approvals and Fulfilled Standards ................... 15

19.

Regulatory Compliance .................................... 15

20.

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

21.

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

21.1.

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

21.2.

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

22.

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

22.1.

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

22.2.

External Input Protection ......................... 18

22.3.

Parallel Use to Increase Output Power .... 18

22.4.

Parallel Use for 1+1 Redundancy ............. 18

22.5.

Series Operation ....................................... 19

22.6.

Inductive and Capacitive Loads................ 19

22.7.

Charging of Batteries ............................... 19

22.8.

Operation on Two Phases ........................ 19

22.9.

Use in a Tightly Sealed Enclosure ............ 19

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.

A figure displayed with the AC or DC before the value represents a nominal voltage with standard tolerances (usually ±15%) included.

E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (10V)

230Vac A figure with the unit (Vac) at the end is a momentary figure without any additional tolerances included.

As long as not otherwise stated, AC 230V parameters are valid at 50Hz mains frequency. 50Hz vs. 60Hz may shall should

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.

Mar. 2021 / Rev. 1.2 DS-PIC480.241C-EN


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PIC480.241C, PIC480.241C-C1

24V, 20A, 480W, S

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1.

I

NTENDED

U

SE

This device is designed for installation in an enclosure and is intended for commercial use, such as in industrial control, process control, monitoring, measurement, Audio/Video, information or communication equipment or the like. Do not use this device in equipment where malfunction may cause severe personal injury or threaten human life.

If this device is used in a manner outside of its specification, the protection provided by the device may be impaired.

Without additional measures to reduce the conducted emissions on the output (e.g. by using a filter), the device is not suited to supply a local DC power network in industrial, residential, commercial and light-industrial environments

2.

I

NSTALLATION

I

NSTRUCTIONS

WARNING

Risk of electrical shock, fire, personal injury or death .

- Turn power off before working on the device and protect against inadvertent re-powering.

- Do not open, modify or repair the device.

- Use caution to prevent any foreign objects from entering into the housing.

- Do not use in wet locations or in areas where moisture or condensation can be expected.

- Do not touch during power-on, and immediately after power-off. Hot surface may cause burns.

Obey the following installation instructions:

This device may only be installed and put into operation by qualified personnel.

This device does not contain serviceable parts. The tripping of an internal fuse is caused by an internal defect.

If damage or malfunction should occur during installation or operation, immediately turn power off and send unit to the factory for inspection.

Install device in an enclosure providing protection against electrical, mechanical and fire hazards.

Install the device onto a DIN-rail according to EN 60715 with the input terminals on the bottom of the device.

Make sure that the wiring is correct by following all local and national codes. Use appropriate copper cables that are designed for a minimum operating temperature of 60°C for ambient temperatures up to +45°C, 75°C for ambient temperatures up to +55°C and 90°C for ambient temperatures up to +70°C. Ensure that all strands of a stranded wire enter the terminal connection. Unused screw terminals should be securely tightened.

The device is designed for pollution degree 2 areas in controlled environments. No condensation or frost is allowed.

The enclosure of the device provides a degree of protection of IP20. The enclosure does not provide protection against spilled liquids.

The isolation of the device is designed to withstand impulse voltages of overvoltage category III according to IEC 60664-1.

The device is designed as “Class of Protection” I equipment according to IEC 61140. Do not use without a proper PE

(Protective Earth) connection.

The device is suitable to be supplied from TN, TT or IT mains networks. The continuous voltage between the input terminals and the PE potential must not exceed 300Vac.

A disconnecting means shall be provided for the input of the device.

The device is designed for convection cooling and does not require an external fan. Do not obstruct airflow and do not cover ventilation grid!

The device is designed for altitudes up to 5000m (16400ft). Above 2000m (6560ft) the overvoltage category is reduced to level

II and a reduction in output current is required.

Keep the following minimum installation clearances: 40mm on top, 20mm on the bottom, 5mm left and right side. Increase the 5mm to 15mm in case the adjacent device is a heat source. When the device is permanently loaded with less than 50%, the 5mm can be reduced to zero.

The device is designed, tested and approved for branch circuits up to 20A without additional protection device. For higher branch circuits use an additional protection device. If an external input protection device is utilized, do not use one smaller than a 10A B- or 6A C-characteristic to avoid a nuisance tripping of the circuit breaker.

The maximum surrounding air temperature is +70°C (+158°F). The operational temperature is the same as the ambient or surrounding air temperature and is defined 2cm below the device.

The device is designed to operate in areas between 5% and 95% relative humidity.

Mar. 2021 / Rev. 1.2 DS-PIC480.241C-EN


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PIC480.241C, PIC480.241C-C1

24V, 20A, 480W, S

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3.

AC-I

NPUT

AC input

AC input range nom.

Allowed voltage L or N to earth max.

Input frequency

Turn-on voltage

Shut-down voltage

External input protection nom. typ. typ.

AC 200-240V

180-264Vac

264-300Vac

300Vac

50–60Hz

150Vac

130Vac suitable for TN-, TT- and IT mains networks continuous operation

< 500ms continuous, IEC 62103

±6%

steady-state value, see Fig. 3-1 steady-state value, see Fig. 3-1

See recommendations in chapter 23.3.

Input current

Power factor

Crest factor **)

Rise time

*)

Start-up delay 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 load, 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, typ. Fig. 3-2 Turn-on behavior, definitions

P

OUT

Rated input range max.

500ms

Input

Voltage

180V

V

IN

264V 300Vac

2.0

1.5

1.0

0.5

0

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

Input Current, typ.

3A

2.5

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 10

Output Current

12 14 16 18 20A

Mar. 2021 / Rev. 1.2 DS-PIC480.241C-EN


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PIC480.241C, PIC480.241C-C1

24V, 20A, 480W, S

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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 *)

Inrush energy *) max. typ. typ. max.

32A

26A

16A peak peak peak

2.1A

2 s

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

Mar. 2021 / Rev. 1.2 DS-PIC480.241C-EN


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PIC480.241C, PIC480.241C-C1

24V, 20A, 480W, S

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6.

O

UTPUT

Output voltage

Adjustment range

Factory settings

Line regulation

Load regulation

Ripple and noise voltage

Output current

Output power

Overload behaviour

Short-circuit current nom. DC 24V

24-28V max. 30V ***) typ. 24.1V max. 50mV max. 150mV max. 100mVpp guaranteed at clockwise end position of potentiometer

±0.2%, at full load, cold unit

187-264Vac static value, 0A 

20A; see Fig. 6-1

20Hz to 20MHz, 50Ohm nom. 20A nom. 15A nom. 17.1A nom. 12.8A nom. 480W nom. 360W

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

Hiccup PLUS mode **)

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

min. 21A *) max. 25A *) typ. cont. current

8.1A

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

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

*) 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

25

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

Mar. 2021 / Rev. 1.2 DS-PIC480.241C-EN


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PIC480.241C, PIC480.241C-C1

24V, 20A, 480W, S

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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.

Input Voltage a b c d

Input

Voltage

Output

Voltage

Zero Transition

Hold-up Time

- 5%

Threshold voltage

Contact closes

Contact opens

Contact ratings

Isolation voltage

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). 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 min. 1mA at 5Vdc

See dielectric strength table in section 18.

min. permissible load

Fig. 8-1 DC-ok relay contact behavior

Output Voltage

21.4V

open closed

Mar. 2021 / Rev. 1.2 DS-PIC480.241C-EN


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PIC480.241C, PIC480.241C-C1

24V, 20A, 480W, S

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9.

E

FFICIENCY AND

P

OWER

L

OSSES

Efficiency

Average efficiency *)

Power losses typ. typ. typ. typ. typ.

95.7%

95.2%

1.35W

10.7W

21.6W at 24V, 20A, 230Vac

25% at 5A, 25% at 10A, 25% at 15A. 25% at 20A at 24V, 0A, 230Vac at 24V, 10A, 230Vac 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%

Power Losses

24W

96

95

94

93

20

16

12

8

92 4

Output Current Output Current

91 0

4 6 8 10 12 14 16 18 20A

10.

L

IFETIME

E

XPECTANCY AND

MTBF

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

Lifetime expectancy *)

MTBF **) SN 29500, IEC 61709

93 000h

264 000h

51 000h

144 000h

*)

*)

482 000h

894 000h at 24V, 10A and 40°C, 230Vac at 24V, 10A and 25°C, 230Vac at 24V, 20A and 40°C, 230Vac at 24V, 20A and 25°C, 230Vac at 24V, 20A and 40°C, 230Vac at 24V, 20A and 25°C, 230Vac

MTBF **) MIL HDBK 217F 207 000h

279 000h

45 000h

57 000h at 24V, 20A and 40°C, 230Vac;

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

Ground Benign GB25 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.

Mar. 2021 / Rev. 1.2 DS-PIC480.241C-EN


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PIC480.241C, PIC480.241C-C1

24V, 20A, 480W, S

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11.

F

UNCTIONAL

D

IAGRAM

Fig. 11-1 Functional diagram

L

N

Input Fuse

Input Filter

Input Rectifier

Inrush Current Limiter

PFC

Converter

Power

Converter

Output

Filter

-

-

+

+

DC-ok

Contact

DC-ok

Relay

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

Input and output

Screw terminals

Solid wire

Stranded wire

American Wire Gauge

Maximal wire diameter

Wire stripping length max. 6mm max. 4mm

2

2

AWG20-10

2.8mm (including ferrules)

7mm / 0.28inch

Screwdriver 3.5mm slotted or cross-head No 2

Recommended tightening torque 1Nm, 9lb.in

DC-OK-Signal

Push-in terminals max. 1.5mm

2 max. 1.5mm

2

AWG28-16

1.6mm (including ferrules)

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.

Mar. 2021 / Rev. 1.2 DS-PIC480.241C-EN


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24V, 20A, 480W, S

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13.

F

RONT

S

IDE AND

U

SER

E

LEMENTS

Fig. 13-1 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

– Negative (return) output

C Output voltage potentiometer

Guaranteed adjustment range: 24-28V

Factory set: 24.1V

D DC-OK LED (green)

On, when the output voltage is >18V

E DC-OK Relay Contact (push-in terminals)

Description see chapter 8.

Mar. 2021 / Rev. 1.2 DS-PIC480.241C-EN


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PIC480.241C, PIC480.241C-C1

24V, 20A, 480W, S

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14.

EMC

The power supply is suitable for applications in industrial environment.

A detailed EMC report is available on request.

EMC Immunity

Electrostatic discharge

Electromagnetic RF field

Fast transients (Burst)

Surge voltage on input

Surge voltage on output

Surge voltage on DC-OK

Conducted disturbance

Mains voltage dips

Voltage interruptions

Voltage sags

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

EN 61000-4-2

EN 61000-4-3 contact discharge air discharge

80MHz-2.7GHz

8kV

8kV

10V/m

EN 61000-4-4

EN 61000-4-5

EN 61000-4-5

EN 61000-4-5

EN 61000-4-6

EN 61000-4-11

EN 61000-4-11

SEMI F47 0706 input lines output lines

DC-OK signal (coupling clamp)

L  N

L  PE, N  PE

+  -

+ / -  PE

4kV

2kV

2kV

2kV

4kV

500V

1kV

Criterion A

Criterion A

Criterion A

Criterion A

Criterion A

Criterion A

Criterion A

Criterion A

Criterion A

Criterion A

DC-OK signal  PE

0.15-80MHz

0% of 200Vac

40% of 200Vac

70% of 200Vac

1kV

10V

0Vac, 20ms

80Vac, 200ms

140Vac, 500ms

Criterion A

Criterion A

Criterion A

Criterion C

Criterion C

0% of 200Vac (=0V) 5000ms Criterion C dips on the input voltage according to SEMI F47 standard

80% of 200Vac (160Vac)

70% of 200Vac (140Vac)

50% of 200Vac (100Vac)

1000ms

500ms

200ms

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

Conducted emission input lines

Conducted emission output lines **)

Radiated emission

Harmonic input current

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

EN 55011, EN 55032, FCC Part 15,

CISPR 11, CISPR 32

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

Class B fulfilled

EN 55011, EN 55032

EN 61000-3-2 limits for DC power port according EN

61000-6-3 not fulfilled

Class B fulfilled

Class A fulfilled between 0A and 20A load

Class C fulfilled between 7A and 20A load

Voltage fluctuations, flicker

EN 61000-3-3 fulfilled *)

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

Mar. 2021 / Rev. 1.2 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. 11/19 www.pulspower.com Phone +49 89 9278 0 Germany

PIC480.241C, PIC480.241C-C1

24V, 20A, 480W, S

INGLE

P

HASE

I

NPUT PIANO-Series

15.

E

NVIRONMENT

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

Storage temperature -40°C to +85°C (-40°F to 185°F)

Output de-rating 8W/°C

Humidity **)

Vibration sinusoidal

Shock

Altitude

5 to 95% r.h.

2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g ***)

2 hours / axis ***)

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

3 bumps / direction, 18 bumps in total

0 to 2000m (0 to 6 560ft)

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

Altitude de-rating

Over-voltage category

Degree of pollution

LABS compatibility

30W/1000m or 5°C/1000m

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 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

III

II

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

2 IEC 62477-1, not conductive

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

Mar. 2021 / Rev. 1.2 DS-PIC480.241C-EN


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PIC480.241C, PIC480.241C-C1

24V, 20A, 480W, S

INGLE

P

HASE

I

NPUT PIANO-Series

16.

S

AFETY AND

P

ROTECTION

F

EATURES

Isolation resistance Min.

Min.

Min.

Min.

500MOhm

500MOhm

500MOhm

500MOhm

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

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

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

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

Output over-voltage protection Typ. 30.5Vdc

Max. 32.0Vdc

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

Class of protection I

Ingress protection

Over-temperature protection

IP 20

Included

According to IEC 61140

A PE (Protective Earth) connection is required

According to EN/IEC 60529

Output shut-down with automatic restart.

Temperature sensors are installed on critical components inside the unit and turn the unit off in safety critical situations, which can happen e.g. when ambient temperature is too high, ventilation is obstructed or the de-rating requirements are not followed. There is no correlation between the operating temperature and turn-off temperature since this is dependent on input voltage, load and installation methods.

Input transient protection

Internal input fuse

Touch current (leakage current) Typ.

MOV (Metal Oxide

Varistor)

Included

0.33mA / 0.69mA

Max. 0.43mA / 0.89mA

For protection values see chapter Fehler!

Verweisquelle konnte nicht gefunden werden.

(EMC).

Not user replaceable slow-blow high-braking capacity fuse

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

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

Mar. 2021 / Rev. 1.2 DS-PIC480.241C-EN


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PIC480.241C, PIC480.241C-C1

24V, 20A, 480W, S

INGLE

P

HASE

I

NPUT PIANO-Series

17.

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. 17-1 Dielectric strength

Type test

A B C D

60s 2500Vac 3000Vac 500Vac 500Vac

Input

L

N

B *)

DC-ok Factory test

Field test

5s

5s

2500Vac 2500Vac

2000Vac 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.

Mar. 2021 / Rev. 1.2 DS-PIC480.241C-EN


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PIC480.241C, PIC480.241C-C1

24V, 20A, 480W, S

INGLE

P

HASE

I

NPUT PIANO-Series

18.

A

PPROVALS AND

F

ULFILLED

S

TANDARDS

UL 61010

IEC 61010

IEC 62368

ISA-71.04-1985

VDMA 24364

UL Certificate

Listed equipment for category NMTR - UL 61010-2-201 Electrical

Equipment for Measurement, Control and Laboratory Use -

Particular requirements for control equipment

Applicable for US and Canada

E-File: E198865

CB Scheme Certificate

IEC 61010-2-201 Electrical Equipment for Measurement, Control and Laboratory Use - Particular requirements for control equipment

CB Scheme Certificate

IEC 62368-1 Audio/video, information and communication technology equipment - Safety requirements

Output safety level: ES1

Manufacturer's Declaration (Online Document)

Airborne Contaminants Corrosion Test

Severity Level: G3 Harsh

H2S: 100ppb

NOx: 1250ppb

Cl2: 20ppb

SO2: 300ppb

Test Duration: 3 weeks, which simulates a service life of at least 10 years

Paint Wetting Impairment Substances Test (or LABS-Test)

Tested for Zone 2 and test class C1 according to VDMA 24364-C1-L/W for solvents and water-based paints

19.

R

EGULATORY

C

OMPLIANCE

EU Declaration of

Conformity

REACH Directive

WEEE Directive

The CE mark indicates conformance with the

- EMC directive

- Low-voltage directive

- RoHS directive

Manufacturer's Statement

EU-Directive regarding the Registration, Evaluation,

Authorization and Restriction of Chemicals


EU-Regulation on Waste Electrical and Electronic Equipment

Registered in Germany as business to business (B2B) products.

RoHS (China RoHS 2)

EAC TR Registration


Administrative Measures for the Restriction of the Use of

Hazardous Substances in Electrical and Electronic Products

25 years

EAC Certificate

EAC EurAsian Conformity - Registration Russia, Kazakhstan and Belarus

8504408200, 8504409000

Mar. 2021 / Rev. 1.2 DS-PIC480.241C-EN


15/19

PIC480.241C, PIC480.241C-C1

24V, 20A, 480W, S

INGLE

P

HASE

I

NPUT PIANO-Series

20.

P

HYSICAL

D

IMENSIONS AND

W

EIGHT

Width

Height

Depth

Weight

DIN-Rail

Plastic Material of Housing

Installation Clearances

49mm 1.93’’

124mm 4.88’’

124mm 4.88’’

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. 20-1 Front view Fig. 20-2 Side view

Mar. 2021 / Rev. 1.2 DS-PIC480.241C-EN


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PIANO-Series

21.

A

CCESSORY

PIC480.241C, PIC480.241C-C1

24V, 20A, 480W, S

INGLE

P

HASE

I

NPUT

21.1.

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.

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.

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

See chapter 22.5 for instructions how to

build a redundant system.

+ + - -

24-28V

DC-OK

DC-

OK

PIC480.241C

Power Supply

I

L N PE

+

Input

1

+ -

Input

2

YR40.242

Redundancy

Module

Output

+ -

PIC480.241C

Power Supply

I

+ + - -

24-28V

DC-OK

DC-

OK

L N PE

Failure

Monitor

24V,20A

Load

L

N

PE

21.2.

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.

+ +

DC-

OK

- -

24-28V

DC-OK

- + +

IN

1

IN

2

+ +

24-28V

DC-OK

DC-

OK

- - + +

IN

1

IN

2

The PIRD20.241 does not require an additional auxiliary voltage and is self- powered even in case of a short circuit across the output.

PIC480.241C

Power Supply

L N PE

PIRD20.241

Redundancy

Module

- +

PIC480.241C

Power Supply

L N PE

PIRD20.241

Redundancy

Module

- +

See chapter 22.5 for instructions

how to build a redundant system.

L

N

PE

I I

24V, 20A

Load

Mar. 2021 / Rev. 1.2 DS-PIC480.241C-EN


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PIANO-Series

22.

A

PPLICATION

N

OTES

PIC480.241C, PIC480.241C-C1

24V, 20A, 480W, S

INGLE

P

HASE

I

NPUT

22.1.

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.

22.2.

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.

22.3.

P

ARALLEL

U

SE TO

I

NCREASE

O

UTPUT

P

OWER

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

22.4.

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.

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.

+ + - -

24-28V

DC-OK

DC-

OK

+

Input

1

+

Input

2

-

YR40.242

Module

+ + - -

24-28V

DC-OK

DC-

OK

Failure

Monitor

PIC480.241C

Power Supply

L N PE

Output

+ -

PIC480.241C

Power Supply

L N PE

Recommendations for building redundant power systems: a) Monitor the individual power supply units. Therefore, use the

DC-OK relay contact of the PIC480.241C power supply. b) Use separate input fuses for each power supply.

I I

24V,20A

Load 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.

Mar. 2021 / Rev. 1.2 DS-PIC480.241C-EN


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PIC480.241C, PIC480.241C-C1

24V, 20A, 480W, S

INGLE

P

HASE

I

NPUT PIANO-Series

22.5.

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.

22.6.

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).

22.7.

C

HARGING OF

B

ATTERIES

Do not use the power supply to charge batteries.

22.8.

O

PERATION ON

T

WO

P

HASES

The power supply can also be used on two-phases of a three-phasesystem. Such a phase-to-phase connection is allowed as long as the supplying voltage is below 240V +10% .

L3

L1

Fuse

Power Supply

L

AC internal fuse

N

PE

DC

L2

22.9.

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:

Input:

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

230Vac

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

Mar. 2021 / Rev. 1.2 DS-PIC480.241C-EN


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