Beckhoff PS3031-2440-0000 Operator's manual

Documentation | EN
PS3031-2440-0000
Power supply 24 V DC, 40 A, 3-phase
2020-11-12 | Version: 1.0

Table of contents
PS3031-2440-0000 3Version: 1.0
Table of contents
1 Overview.....................................................................................................................................................5
2 Foreword ....................................................................................................................................................6
2.1 Notes on the documentation..............................................................................................................6
2.2 Safety instructions .............................................................................................................................7
2.3 Terminology and abbreviations .........................................................................................................9
3 Technical data, mounting, wiring...........................................................................................................10
3.1 AC input...........................................................................................................................................10
3.2 DC input...........................................................................................................................................11
3.3 Input inrush current..........................................................................................................................11
3.4 Output..............................................................................................................................................12
3.5 Hold-up time ....................................................................................................................................15
3.6 DC-OK relay contact........................................................................................................................16
3.7 Shutdown input................................................................................................................................17
3.8 Output voltage control .....................................................................................................................17
3.9 Efficiency and losses .......................................................................................................................18
3.10 Lifetime expectancy and MTBF .......................................................................................................20
3.11 Terminals and wiring .......................................................................................................................21
3.12 Functional wiring diagram................................................................................................................22
3.13 Front side and operating elements ..................................................................................................23
3.14 EMC.................................................................................................................................................25
3.15 Environment ....................................................................................................................................26
3.16 Protective functions .........................................................................................................................27
3.17 Safety features ................................................................................................................................27
3.18 Dielectric strength............................................................................................................................28
3.19 Declaration of conformity and approvals .........................................................................................29
3.20 Dimensions and weight ...................................................................................................................30
4 Application notes.....................................................................................................................................31
4.1 Repeated pulse load........................................................................................................................31
4.2 Peak current capability ....................................................................................................................33
4.3 External input protection..................................................................................................................34
4.4 Operation on two phases of a 3-phase system ...............................................................................35
4.5 Output circuit breakers ....................................................................................................................36
4.6 Charging batteries ...........................................................................................................................37
4.7 Series connection ............................................................................................................................37
4.8 Parallel use to increase power ........................................................................................................38
4.9 Inductive and capacitive loads.........................................................................................................38
4.10 Back-feeding loads ..........................................................................................................................39
4.11 Use in a tightly sealed enclosure.....................................................................................................39
4.12 Installation positions ........................................................................................................................39
5 Appendix ..................................................................................................................................................41
5.1 Accessories .....................................................................................................................................41
5.2 Documentation issue status ............................................................................................................41
5.3 Support and Service ........................................................................................................................42

Table of contents
PS3031-2440-00004 Version: 1.0

Overview
PS3031-2440-0000 5Version: 1.0
1 Overview
PS3031-2440-0000 | Power supply 24V, 40A, 3-phase
• 3AC 380-480V wide-range input
• Three built-in input fuses
• 95.3% full load and excellent part-load efficiencies
• Width only 110mm, weight only 1.5kg
• 150% peak power, 1440W for up to 4s
• 110A peak current over 25ms for triggering fuses
• Active power factor correction (PFC)
• Active filtering of input transients
• Negligible input inrush current surge
• Full power between -25°C and +60°C
• Option of current sharing for parallel connection
• Controllable output voltage level
• DC-OK relay contact
• Shutdown input
The PS3031-2440-0000 is a 3-phase 24V power supply with an output current of 40A and an output power
of 960W/1440W.
On the input side, the device features a wide-range input, active power factor correction (PFC) and inrush
current limiting.
The PS3031-2440-0000 features an Extra Power output with a maximum output power of 150% over
4seconds and is able to trigger fuses precisely with a short-term peak current. The output voltage can be
switched off by means of the shutdown contact. A DC-OK LED, an overload LED and a potential-free relay
contact monitor the status of the output voltage.
The power supply is part of the PS3000 family and has a width of 110mm.
Overview of technical data *)
Overview of technical data PS3031-2440-0000
Output voltage DC 24V (nominal)
Adjustment range 24 - 28V
Output current 40 - 34.3A (continuous); 60 - 51.5A (short-term for 4s)
Output power 960W (continuous); 1440W (short-term for 4s)
Output ripple < 100mVpp (20Hz to 20MHz)
Input voltage AC 3AC 380-480V -15%/+20%
Mains frequency 50-60Hz ±6%
Input current AC 1.65 / 1.35A at 3 x 400 / 480Vac
Power factor 0.88 / 0.90 at 3 x 400 / 480Vac
Inrush current surge AC typ. 4.5A peak
Efficiency 95.3 / 95.2% at 3 x 400 / 480Vac
Losses 47.3 / 48.4W at 3 x 400 / 480Vac
Operating temperature range -25°C to +70°C
Derating 24W / °C (+60°C to +70°C)
Hold-up time Typ. 25 / 25ms at 3 x400 / 480Vac
Dimensions (W x H x D) 110 x 124 x 127mm (without DIN rail)
Weight 1500g
Approvals/markings CE, cULus, EAC
*) All values typical for 24V, 40A, 3x 400Vac, 25°C ambient temperature and after a warm-up time of 5 minutes, unless otherwise
stated.

Foreword
PS3031-2440-00006 Version: 1.0
2 Foreword
2.1 Notes on the documentation
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany.
The reproduction, distribution and utilization of this document as well as the communication of its contents to
others without express authorization are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.
Disclaimer
The documentation has been prepared with care. The products described are, however, constantly under
development.
We reserve the right to revise and change the documentation at any time and without prior announcement.
No claims for the modification of products that have already been supplied may be made on the basis of the
data, diagrams and descriptions in this documentation.
Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, EtherCATG®, EtherCATG10®, EtherCATP®, SafetyoverEtherCAT®,
TwinSAFE®, XFC®, XTS® and XPlanar® are registered trademarks of and licensed by Beckhoff Automation
GmbH. Other designations used in this publication may be trademarks whose use by third parties for their
own purposes could violate the rights of the owners.
Patent Pending
The EtherCAT Technology is covered, including but not limited to the following patent applications and
patents: EP1590927, EP1789857, EP1456722, EP2137893, DE102015105702 with corresponding
applications or registrations in various other countries.
Intended audience
This description is only intended for the use of trained specialists in control and automation engineering who
are familiar with the applicable national standards.
It is essential that the documentation and the following notes and explanations are followed when installing
and commissioning these components.
It is the duty of the technical personnel to use the documentation published at the respective time of each
installation and commissioning.
The responsible staff must ensure that the application or use of the products described satisfy all the
requirements for safety, including all the relevant laws, regulations, guidelines and standards.

Foreword
PS3031-2440-0000 7Version: 1.0
2.2 Safety instructions
Description of instructions
In this documentation the following instructions are used.
These instructions must be read carefully and followed without fail!
DANGER
Serious risk of injury!
Failure to follow this safety instruction directly endangers the life and health of persons.
WARNING
Risk of injury!
Failure to follow this safety instruction endangers the life and health of persons.
CAUTION
Personal injuries!
Failure to follow this safety instruction can lead to injuries to persons.
NOTE
Damage to environment/equipment or data loss
Failure to follow this instruction can lead to environmental damage, equipment damage or data loss.
Tip or pointer
This symbol indicates information that contributes to better understanding.
Intended use
This device is designed for installation in a housing and is intended for general professional use, for example
in industrial control systems or office, communication and measuring equipment.
Do not use this power supply in installations where a malfunction could cause serious injury or danger to
human life.
Exclusion of liability
All the components are supplied in particular hardware and software configurations appropriate for the
application. Modifications to hardware or software configurations other than those described in the
documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH & Co. KG.
Personnel qualification
This description is only intended for trained specialists in control, automation and drive engineering who are
familiar with the applicable national standards.
Safety regulations
Please note the following safety instructions and explanations!
Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,
commissioning etc.

Foreword
PS3031-2440-00008 Version: 1.0
Safety instructions and installation requirements for the PS3031-2440-0000 power supply
DANGER
Danger of electric shock, fire, injuries, injuries resulting in death!
• Do not use the power supply without proper grounding (protective conductor). Use the terminal at the in-
put terminal strip for the earth connection, not one of the screws on the housing.
• Switch off the power supply before working on the device. Provide protection against unintentional re-
connection.
• Ensure proper wiring by following all local and national regulations.
• Do not modify or attempt to repair the device.
• Do not open the device, as high voltages are present inside.
• Avoid foreign bodies entering the housing.
• Do not use the device in damp locations or in areas where moisture or condensation is likely to occur.
• Do not touch the device when it is switched on or immediately after it has been switched off. Hot sur-
faces can cause burns.
Further notes on installation requirements
• This device contains no serviceable parts.
• Triggering of an internal fuse indicates an internal defect.
• In the event of damage or malfunction during installation or operation, switch off the device im-
mediately and return it to the factory for inspection.
• Mount the device on a DIN rail so that the input and output terminals are at the bottom of the de-
vice. For other mounting orientations, please refer to the derating requirements in chapter
Mounting positions [}39].
• This device is designed for convection cooling and does not require an external fan. Do not ob-
struct the air flow and do not cover the ventilation grille (e.g., cable ducts) by more than 15%!
• Maintain the following installation distances: 40mm at the top, 20mm at the bottom and 5mm
on the left and right are recommended if the device continuously runs at more than 50% of the
rated output. Increase this distance to 15mm if the adjacent device is a heat source (e.g., an-
other power supply).

Foreword
PS3031-2440-0000 9Version: 1.0
2.3 Terminology and abbreviations
PE and the earthing
symbol
PE is the abbreviation for "protective earth" and has the same meaning as the
earthing symbol
Earth, ground The terms earth and ground are synonymous and are used interchangeably in this
document.
T.b.d. Still to be defined, value or description will follow in due course.
AC 400V A value preceded by "AC" or "DC" represents a nominal voltage or a nominal
voltage range. The nominal voltage or the nominal voltage range may be provided
with tolerances. (e.g., AC380 - 480V ±15%). The calculated total range then
indicates the working range of the device.
Example:
DC 12V refers to a 12V battery, regardless of whether it is fully charged
(13.7Vdc) or discharged (10Vdc).
400Vac A value followed by the unit Vac or Vdc is an instantaneous value that does not
contain any additional tolerances.
50Hz vs. 60Hz Unless otherwise specified, AC 230V parameters are valid at a mains frequency of
50Hz.
may A keyword indicating a choice without implied preference.
shall A keyword indicating a mandatory requirement.
should A keyword indicating a choice with a clearly preferred method of implementation.

Technical data, mounting, wiring
PS3031-2440-000010 Version: 1.0
3 Technical data, mounting, wiring
3.1 AC input
AC input
AC input Nom. 3AC 380 - 480V Wide-range input
AC input range Min. 3x 323 - 576Vac Continuous operation
Suitable mains systems TN, TT, IT Grounding of one phase is permitted, except for UL508 applica-
tions
Permissible voltage L to earth Max. 576Vac Continuous according to IEC 60664-1
Input frequency Nom. 50 - 60Hz ±6%
Turn-on voltage Typ. 3x 305Vac Static, load-independent, see Fig. Input voltage range; switch-on
behavior definitions
Shut-down voltage Typ. 3x 275Vac Static, load-independent, see Fig. Input voltage range; switch-on
behavior definitions
AC input 3AC 400V 3AC 480V
Input current Typ. 1.65A 1.35A At 24V, 40A per phase, see Fig. Input current over
output current; power factor over output current
Power factor*) Typ. 0.88 0.90 At 24V, 40A, see Fig. Input current over output cur-
rent; power factor over output current
Start-up delay Typ. 500ms 600ms See Fig. Input voltage range; switch-on behavior defini-
tions
Rise time Typ. 35ms 35ms At 24V, 40A, ohmic load only, 0mF see Fig. Input
voltage range; switch-on behavior definitions
Typ. 40ms 40ms At 24V, 40A ohmic load with an additional 40mF ca-
pacitor, see Fig. Input voltage range; switch-on behav-
ior definitions
Turn-on overshoot Max. 500mV 500mV See Fig. Input voltage range; switch-on behavior defini-
tions
*) The power factor is the ratio of real (or active) power to apparent power in an AC circuit.
Fig.1: Input voltage range; switch-on behavior definitions

Technical data, mounting, wiring
PS3031-2440-0000 11Version: 1.0
Fig.2: Input current over output current; power factor over output current
3.2 DC input
Do not use the power supply unit with DC input voltages!
3.3 Input inrush current
The power supply is equipped with an active inrush current limiting circuit that limits the input inrush current
to a very low value after power-up and after short interruptions of the input voltage.
3AC 400V 3AC 480V
Input inrush current* Max. 6A peak 6A peak temperature-independent
Typ. 4.5A peak 4.5A peak
Inrush energy Max. 1.5A²s 1.5A²s
Start-up delay Typ. 500ms 600ms
*The charge current of the interference suppression capacitors during the first few microseconds after
switching on is not taken into account.
Fig.3: Typical switch-on behavior at nominal load, 25°C ambient temperature

Technical data, mounting, wiring
PS3031-2440-000012 Version: 1.0
3.4 Output
Output
Output voltage Nom. DC 24V
Adjustment range Min. 24 - 28Vdc Guaranteed value
Max. 30Vdc This is the maximum output voltage that can occur in the end position of the poten-
tiometer in clockwise direction due to tolerances. It is not a guaranteed value that can
be achieved. A typical value is 28.5V.
Factory settings Typ. 24.1Vdc ±0.2%, at full load (cold device), in "Single Use" mode
Typ. 24.1Vdc ±0.2%, at full load (cold device), in "Parallel Use" mode
Typ. 25.1Vdc At idle, cold device, in "Parallel Use" mode
Line regulation Max. 10mV 3 x 323 - 576Vac
Load regulation Max. 50mV In "Single Use" mode: between 0 and 40A, static value, see Fig. Output voltage over
output current typ. in "Single Use" mode
Typ. 1000mV In "Parallel Use" mode: between 0 and 40A, static value, see Fig. Output voltage
over output current typ. in "Parallel Use" mode
Residual ripple and rip-
ple voltage
Max. 100mVPP Bandwidth 20Hz to 20MHz, 50ohm
Output current -
continuous
Nom. 40A At 24V, see Fig. Output voltage over output current typ. in "Single Use" mode; output
voltage over output current typ. in "Parallel Use" mode
Nom. 34.3A At 28V, see Fig. Output voltage over output current typ. in "Single Use" mode; output
voltage over output current typ. in "Parallel Use" mode
Output current -
Extra power up to 4 s1)
Nom. 60A At 24V, see Fig. Output voltage over output current typ. in "Single Use" mode; output
voltage over output current typ. in "Parallel Use" mode and Fig. Dynamic overcurrent
capability, typ. < 10ms; Dynamic overcurrent capability, typ. < 25 ms
Nom. 51.5A At 28V, see Fig. Output voltage over output current typ. in "Single Use" mode; output
voltage over output current typ. in "Parallel Use" mode and Fig. Dynamic overcurrent
capability, typ. < 10ms; Dynamic overcurrent capability, typ. < 25 ms
Output current Typ. 110A up to 25ms, output voltage remains above 20V, see Fig. Dynamic overcurrent ca-
pacity, typ. < 10ms; Dynamic overcurrent capability, typ. < 25 ms
This peak current is available once per second.
for further peak current measurements see chapter Peak current capability [}33]
Output power -
continuous
Nom. 960W At 24 - 28V
Output power -
Extra Power 4 s1)
Nom. 1440W At 24 - 28V
Extra power time
(bonus time)
Typ. 4s Time until the output voltage drops, see Fig. Bonus time over output power
Recovery time Typ. 7s Overload-free time until the power manager is reset, see Fig. Extra power recovery
time
Overload behavior Continuous cur-
rent
see Fig. Output voltage over output current, typ. in "Single Use" mode
Short-circuit current2) Min. 40A Continuous, load impedance 25mOhm, see Fig. Output voltage over output current,
typ. in "Single Use" mode
Max. 44A Continuous, load impedance 25mOhm, see Fig. Output voltage over output current,
typ. in "Single Use" mode
Min. 60A Short term for 4s, load impedance 25mOhm, see Fig. Output voltage over output
current, typ. in "Single Use" mode
Max. 68A Short term for 4s, load impedance 25mOhm, see Fig. Output voltage over output
current, typ. in "Single Use" mode
Typ. 46A Continuous, load impedance <10mOhm
max 51A Continuous, load impedance <10mOhm
Output capacity Typ. 10,200μF Included in the power supply
1) Extra power
The power supply is designed to support loads with higher short-term power requirements without damage
or shutdown.
The short-time duration/bonus time is controlled in hardware by an output power manager.
Extra power is available repeatedly. Detailed information can be found in the chapter on Repeated pulse load
[}31].
If the power supply is subjected to extra power for longer than shown in the bonus time diagram (see Fig.
Bonus time over output power [}13]), the maximum output power is automatically reduced to 960W.

Technical data, mounting, wiring
PS3031-2440-0000 13Version: 1.0
2) The discharge current of the output capacitors is not included.
Fig.4: Output voltage over output current typ. in "Single Use" mode; output voltage over output current typ.
in "Parallel Use" mode,
Fig.5: Dynamic overcurrent capability, typ. < 10ms; Dynamic overcurrent capability, typ. < 25ms
Fig.6: Bonus time over output power; Extra power recovery time
Extra power is available as soon as the power is turned on and after an output short-circuit or output
overload.

Technical data, mounting, wiring
PS3031-2440-000014 Version: 1.0
Fig.7: Extra power after switching on; extra power after short circuit or overload

Technical data, mounting, wiring
PS3031-2440-0000 15Version: 1.0
3.5 Hold-up time
3AC 400V1) 3AC 480V1)
Hold-up
time
Typ. 50ms 50ms At 24V, 20A, see Fig. Hold-up time over
input voltage
Min. 40ms 40ms At 24V, 20A, see Fig. Hold-up time over
input voltage
Typ. 25ms 25ms At 24V, 40A, see Fig. Hold-up time over
input voltage
Min. 20ms 20ms At 24V, 40A, see Fig. Hold-up time over
input voltage
1) Characteristic curves and figures for operation on only two external conductors of a 3-phase system can
be found in chapter Operation on two phases of a 3-phase system [}35].
Fig.8: Hold-up time over input voltage; switch-off behavior, definitions

Technical data, mounting, wiring
PS3031-2440-000016 Version: 1.0
3.6 DC-OK relay contact
This function monitors the output voltage generated by the power supply itself. It is independent of a voltage
fed back from a unit connected in parallel to the power supply output.
The contact closes when the output voltage reaches 90% of the set output voltage.
The contact opens when the output voltage drops more than 10% below the set output voltage.
Short bursts are extended to a signal length of 250ms. Drops that are shorter
than 1ms are ignored.
The contact closes again when the output voltage exceeds 90% of the set voltage.
Contact load capacity Maximum 60Vdc 0.3A, 30Vdc 1A, 30Vac 0.5A, ohmic load
Minimum permissible load: 1mA at 5Vdc
Insulation voltage See the table in chapter Dielectric strength [}28]
Fig.9: Behavior of the DC-OK relay contact
Nature and source of the danger
The DC-OK function requires the output voltage to reach the rated (=set) level after power-up in or-
der to function as specified.
• If this level is not reached, the overload LED lights up and the DC-OK contact opens. The over-
load LED goes out when the set voltage is reached.
ðThis is an important condition to be considered especially if the load is a battery, the power sup-
ply is used in parallel or the power supply is used for N+1 redundant systems.

Technical data, mounting, wiring
PS3031-2440-0000 17Version: 1.0
3.7 Shutdown input
The shutdown input allows the output of the power supply to be switched off by means of a signal switch or
external voltage.
• The shutdown takes place without delay, while switching on is delayed by up to 350ms.
• When switched off, the output voltage is less than 2V and the output power is less than 0.5W.
• When units are connected in parallel, the voltage difference between the various negative output
terminals must be less than 1V.
• When operating several power supplies in series, only wiring option "A" with single signal switches is
permitted.
Information regarding the use of the shutdown input
Please note the following:
• Option C (see diagram below) requires current reduction capability of the voltage source. Do not
use a blocking diode!
• The shutdown function does not include any safety functionality.
Fig.10: Activation of the shutdown input
3.8 Output voltage control
The shutdown input can also be used to remotely adjust the output voltage between typically 22Vdc and
28Vdc. All other functions of the shutdown input remain the same.
The control voltage is relative to the ground (negative output voltage).
Fig.11: Remote control of the output voltage; applying the control voltage
Instructions:
1. Set the device to "Single Use" mode.
2. Set the output voltage (24-28V) to the maximum required voltage.
3. Apply a control voltage to reduce the output voltage.

Technical data, mounting, wiring
PS3031-2440-000018 Version: 1.0
3.9 Efficiency and losses
Efficiency for 3-phase operation:
3AC 400V 3AC 480V
Efficiency Typ. 95.3% 95.2% At 24V, 40A
Average
efficiency1)
Typ. 94.7% 94.6% 25% at 10A, 25% at 20A,
25% at 30A. 25% at 40A
Losses Typ. 1.5W 1.5W If switch-off is activated
Typ. 9.5W 9.8W At 24V, 0A, (no load)
Typ. 24.1W 25.0W At 24V, 20A, (half load)
Typ. 47.3W 48.4W At 24V, 40A, (full load)
1) The average efficiency is based on assumptions for a typical application with a power supply load of
25% of the nominal load for 25% of the time,
50% of the nominal load for 25% of the time,
75% of the nominal load for 25% of the time and
100% of the nominal load during the remaining time.
Fig.12: Efficiency over output current; losses over output current
Fig.13: Efficiency over input voltage; losses over input voltage

Technical data, mounting, wiring
PS3031-2440-0000 19Version: 1.0
Efficiency when using only two phases of a 3-phase system:
NOTE
Operation on two phases of a 3-phase system
Please note the information in chapter Operation on two phases of a 3-phase system
[}35]!
2AC 400V 2AC 480V
Efficiency Typ. 94.4% 94.7% At 24V, 40A
Losses Typ. 56.9% 53.7% At 24V, 40A (full load)
Fig.14: Efficiency over output current at 24V; losses over output current at 24V

Technical data, mounting, wiring
PS3031-2440-000020 Version: 1.0
3.10 Lifetime expectancy and MTBF
3AC 400V 3AC 480V
Calculated lifetime
expectancy1)
69,000h 66,000h At 24V, 40A and +40°C
86,000h 81,000h At 24V, 32A and +40°C
114,000h 112,000h At 24V, 20A and +40°C
196,000h 1) 186,000h 1) At 24V, 40A and +25°C
244,000h 1) 230,000h 1) At 24V, 32A and +25°C
322,000h 1) 316,000h 1) At 24V, 20A and +25°C
MTBF2) SN 29500, IEC 61709 375,000h 369,000h At 24V, 40A and +40°C
685,000h 678,000h At 24V, 40A and +25°C
MTBF2) MIL HDBK 217F 158,000h 157,000h At 24V, 40A and +40°C, Ground Benign
GB40
211,000h 210,000h At 24V, 40A and +25°C, Ground Benign
GB25
1) The calculated lifetime expectancy shown in the table indicates the minimum number of operating hours
(service life) and is determined by the lifetime expectancy of the built-in electrolytic capacitors. The lifetime
expectancy is stated in operating hours and is calculated according to the specifications of the capacitor
manufacturer. The manufacturer of the electrolytic capacitors only guarantees a maximum service life of up
to 15years (131,400h). Any number exceeding this value represents a calculated theoretical service life
which can be used to compare devices.
2) MTBF stands for Mean Time Between Failure, which is calculated on the basis of statistical equipment
failures and indicates the reliability of a device. It is the statistical representation of the probability of failure of
a device and does not necessarily represent the service life of a product.
The MTBF number is a statistical representation of the failure probability of a device. For example, an MTBF
number of 1,000,000h means that statistically, if 10,000 devices are installed in the field, one device will fail
every 100hours. However, it is not possible to determine whether the failed device has run for 50,000hours
or only 100hours.