Puls CD10.482 Data Sheet

CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
DC/DC CONVERTER
48V DC-InputIsolated 48Vdc OutputEfficiency 95.1% Width only 42mm20% Output Power ReservesFull Power Between -25°C and +60°CSoft-start FunctionMinimal Inrush Current SurgeReverse Input Polarity Protection3 Year Warranty
PRODUCT DESCRIPTION
The CD10.482 is a DIN-rail mountable DC/DC converter of the
SHORT-FORM DATA
Output voltage
DC 48V
Nominal
Adjustment range
48 - 56V
Factory setting 48.0V
Output current
6 – 5.2A
Below +45°C ambient
5 – 4.3A
At +60°C ambient
3.8 – 3.2A
At +70°C ambient
Derate between +60°C and +70°C
Input voltage
DC 48V
±25%
Input current
5.3A
Input inrush current
7A peak
Efficiency
95.1%
Losses
12.4W
Hold-up time
7.7ms
Temperature range
-25°C to +70°C
Size (W x H x D)
42x124x117mm
Without DIN-rail
Weight
500g / 1.1lb
ORDER NUMBERS
MAIN APPROVALS
Ind. Cont. Eq.
planned
DIMENSION series which provides a floating, stabilized and galvanically separated SELV/PELV output voltage.
The CD-Series is part of the DIMENSION power supply family. The most outstanding features of CD10.482 are the high efficiency, the small size and the wide operational temperature range.
The CD-Series includes all the essential basic functions. The devices have a power reserve of 20% included, which may even be used continuously at temperatures up to +45°C.
High immunity to transients and power surges as well as low electromagnetic emission and a large international approval package for a variety of applications makes this unit suitable for nearly every situation.
DC/DC Converter
Mechanical Accessory
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
For details or a complete approval list see section 18.
CD10.482
ZM2.WALL Wall/panel mount bracket ZM12.SIDE Side mount bracket
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
INDEX
Page Page
TERMINOLOGY AND ABREVIATIONS
1. Intended Use ................................................................ 3
2. Installation Instructions ................................................ 3
3. DC-Input ....................................................................... 4
4. Input Inrush Current ..................................................... 6
5. Soft-start Feature ......................................................... 6
6. Output .......................................................................... 7
7. Hold-up Time ................................................................ 8
8. Efficiency and Power Losses ......................................... 9
9. Functional Diagram .................................................... 10
10. Front Side and User Elements .................................... 10
11. Connection Terminals ................................................ 11
12. Lifetime Expectancy ................................................... 12
13. MTBF .......................................................................... 12
14. EMC ............................................................................ 13
15. Environment ............................................................... 14
16. Safety and Protection Features .................................. 15
17. Dielectric Strength ...................................................... 15
18. Approvals ................................................................... 16
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.
19. Other Fulfilled Standards ........................................... 16
20. Physical Dimensions and Weight ............................... 17
21. Accessories................................................................. 18
21.1. ZM2.WALL – Wall/Panel Mount Bracket .......... 18
21.2. ZM12.SIDE - Side Mount Bracket ..................... 19
21.3. YRM2.DIODE - Redundancy Module ................ 20
21.4. UF20.481 - Buffer Module ................................ 20
22. Application Notes....................................................... 21
22.1. Peak Current Capability .................................... 21
22.2. Output Circuit Breakers .................................... 22
22.3. Charging of Batteries ........................................ 22
22.4. Series Operation ............................................... 23
22.5. Parallel Use to Increase Output Power ............ 23
22.6. Parallel Use for Redundancy ............................ 24
22.7. Use in a Tightly Sealed Enclosure ..................... 25
22.8. Mounting Orientations ..................................... 26
PE and symbol PE is the abbreviation for Protective Earth and has the same meaning as the symbol . Earth, Ground This document uses the term “earth” which is the same as the U.S. term “ground”. T.b.d. To be defined, value or description will follow later. DC 48V A figure displayed with the AC or DC before the value represents a nominal voltage with standard tolerances
included. E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (10V)
48Vdc A figure with the unit (Vac) at the end is a momentary figure without any additional tolerances included. may A key word indicating flexibility of choice with no implied preference. shall A key word indicating a mandatory requirement. should A key word indicating flexibility of choice with a strongly preferred implementation.
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
1. INTENDED USE
This device is designed for installation in an enclosure and is intended for commercial use, such as in industrial control, process control,
2. INSTALLATION INSTRUCTIONS
WARNING
monitoring and measurement equipment or the like. Do not use this device in equipment where malfunction may cause severe personal injury or threaten human life.
Risk of electrical shock, fire, personal injury or death.
- Turn power off before working on the device. Protect against inadvertent re-powering.
- Do not modify or repair the unit.
- Do not open the unit as high voltages may 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 surface may cause burns.
Obey the following installation requirements:
Install device in an enclosure providing protection against electrical, mechanical and fire hazards. Install the device onto a DIN-rail according to EN 60715 with the input terminals on the bottom of the device. Other mounting orientations require a reduction in output current. Make sure that the wiring is correct by following all local and national codes. Use appropriate copper cables that are designed for a minimum operating temperature of 60°C for ambient temperatures up to +45°C, 75°C for ambient temperatures up to +60°C and 90°C for ambient temperatures up to +70°C. Ensure that all strands of a stranded wire enter the terminal connection. Unused screw terminals should be securely tightened. 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 input can be powered from batteries or similar DC sources. The voltage between the input terminals and ground must not exceed 60Vdc continuously. The input must be powered from a PELV or SELV source or an "Isolated Secondary Circuit" in order to maintain a SELV or PELV output. Check for correct input polarity. The device will not operate when the voltage is reversed. A disconnecting means shall be provided for the input of the device. 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 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). See additional requirements in the product datasheet for use above 2000m (6560ft). 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 50A without additional protection device. If an external fuse is utilized, do not use circuit breakers smaller than 10A B- or 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.
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
3. DC-INPUT
The input can be powered from batteries or similar DC sources and must be a PELV or SELV source or an "Isolated Secondary Circuit" in
DC input
Nom.
DC 48V
±25%
DC input range
Min.
36-60Vdc
Continuous operation
Allowed voltage between input and earth/ground
Max.
60Vdc or
42.2Vac
Continuous operation, according to IEC 62477-1
Allowed input ripple voltage
Max.
10Vpp
In the frequency range from 47 to 500Hz, the momentary input voltage must always be within the specified limits.
Turn-on voltage
Typ.
35Vdc
Steady-state value, see Fig. 3-1
Shut-down voltage
Typ.
31Vdc
Steady-state value, see Fig. 3-1
Input current
Typ.
5.3A
At 48Vdc input and 48V, 5A output load, see Fig. 3-3
Typ.
7.0A
At 36Vdc input and 48V, 5A output load, see Fig. 3-3
Start-up delay
Typ.
530ms
See Fig. 3-1
Rise time
Typ.
80ms
At 48V, 5A constant current load, 0mF load capacitance, see Fig. 3-2
Typ.
380ms
At 48V, 5A constant current load, 5mF load capacitance, see Fig. 3-2
Turn-on overshoot
Max.
500mV
See Fig. 3-2
Input capacitance
Typ.
1 650µF
Installed inside the device, external capacitors on the input are allowed without any limitations.
External input protection
See recommendations in chapter 2.
Fig. 3-1 Input voltage range
Fig. 3-2 Turn-on behavior, definitions
Turn-on
17.5Vdc
V
IN
P
OUT
Shut-down
32.4Vdc
15.5Vdc
18.0Vdc
Rated input range
35.0Vdc
Start-up
delay
Rise
Time
Overshoot
-5%
Output Voltage
Input Voltage
Fig. 3-3 Input current vs. output load
6A
1
2 3
4
0
2
4
6
8A
5
Output Current
Input: 48Vdc
Input Current, typ.
Input: 36Vdc
order to maintain a SELV or PELV output. Check for correct input polarity. The device will not operate when the voltage is reversed.
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
Requirements for the Supplying Source
Fig. 3-4 External input filter requirements to avoid filter
instabilities
1 mOhm
10 mOhm
100 mOhm
1 Ohm
0.1mH 1mH 10mH
Inductance of the supplying network
Resistance of the supplying network
(a) max. (b) typ.
(a)
(b)
In certain circumstances, the input filter of the DC/DC converter can show a resonant effect which is caused by the supplying network. Especially when additional external input filters are utilized, a superimposed AC voltage can be generated on the input terminals of the DC/DC converter which might cause a malfunction of the unit. Therefore, additional input filters are not recommended. To avoid the resonant effects, the minimal resistance of the supplying network which depends on the inductance of the input network, shall be above the boundary curve in Fig. 3-4.
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
4. INPUT INRUSH CURRENT
An active inrush limitation circuit (inrush limiting NTC resistor which is bypassed by a MOSFET) limits the input inrush current after turn-
Inrush current
Max.
10A
peak
Temperature independent
Typ.
7A
peak
Temperature independent
Inrush energy
Max.
1A2s
Temperature independent
Fig. 4-1 Typical input inrush current behavior at nominal load and
25°C ambient
Input Current
Input Voltage
Output Voltage
Ipk 7A
Input: 48Vdc Output: 48V, 5A, constant current load Ambient: 25°C
Input current 2A / DIV Input voltage 10V / DIV Output voltage 10V / DIV Time basis: 100ms / DIV
5. SOFT-START FEATURE
on of the input voltage. The charging current into EMI suppression capacitors is disregarded in the first microseconds after switch-on.
After the DC/DC converter is turned on, the internal output current rises slowly to its nominal value. This method charges the output capacitors (internal and external capacitors) slowly and avoids high input currents during turn-on. High input currents can produce a high voltage drop on the input wiring (especially with long and thin cables) which reduces the terminal voltage on the DC/DC converter. If the terminal voltage is below the shut-down voltage, the DC/DC converter will turn-off and will make a new start-up attempt. This effect is avoided with the integrated soft-start function. Please note that this function increases the rise time of the output voltage by a small amount.
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
6. OUTPUT
The output provides a SELV/PELV rated voltage, which is galvanically isolated from the input voltage and is designed to supply any kind
Output voltage
Nom.
48V
Adjustment range
Min.
48-56V
Guaranteed value
Max.
58.0V
This is the maximum output voltage which can occur at the clockwise end position of the potentiometer due to tolerances. It is not a guaranteed value which can be achieved.
Factory setting
48.0V
±0.2%, at full load, cold unit
Line regulation
Max.
50mV
Between 36 and 60Vdc input voltage variation
Load regulation
Max.
200mV
Between 0 and 5A load variation, static value
Ripple and noise voltage
Max.
100mVpp
Bandwidth 20Hz to 20MHz, 50Ohm
Output current
Nom.
6A
At 48V and an ambient temperature below +45°C
Nom.
5A
At 48V and +60° ambient temperature
Nom.
3.8A
At 48V and +70° ambient temperature
Nom.
5.2A
At 56V and an ambient temperature below +45°
Nom.
4.3A
At 56V and +60° ambient temperature
Nom.
3.2A
At 56V and +70° ambient temperature
Overload behavior
Continuous current
Overload/ short-circuit current
Max.
9A
RMS current, short circuit impedance <90mOhm
Output capacitance
Typ.
1 750µF
Included inside the power supply
Back-feeding loads
Max.
63V
The unit 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 absorbing energy can be calculated according to the built-in large sized output capacitor.
Fig. 6-1 Output voltage vs. output current at 48Vdc input
voltage, typ.
Fig. 6-2 Current limitation vs. input voltage, (46V
constant voltage load), typ.
Output Voltage
0
0 2 4
8
16
24
56V
32
40
48
8A31 5 6 7
Adjustment
Range
Output Current
5.0
6.0
7.0A
30 35 45 50 60Vdc
Input Voltage
Output Current
6.5
55
5.5
40
of loads, including unlimited capacitive and inductive loads. The output is electronically protected against overload, no-load and short-circuits. In case of a protection event, audible noise may
occur. The input voltage must also fulfill the SELV/PELV requirements.
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
7. HOLD-UP TIME
The input side of the DC/DC converter is equipped with a bulk capacitor which keeps the output voltage alive for a certain period of time
Hold-up Time
Typ.
14ms
At 48Vdc input voltage, 48V, 2.5A output, see Fig. 7-1
Min.
11ms
At 48Vdc input voltage, 48V, 2.5A output, see Fig. 7-1
Typ.
7.7ms
At 48Vdc input voltage, 48V,.5A output, see Fig. 7-1
Min.
6.2ms
At 48Vdc input voltage, 48V, 5A output, see Fig. 7-1
Fig. 7-1 Hold-up time vs. input voltage
0
3
9
12
18ms
36 40 44 48 56Vdc
Input Voltage
Hold-up Time
52
(a)
(b)
(c) (d)
6
15
(a) 48V, 2.5A, typ. (b) 48V, 2.5A, min. (c) 48V, 5A, typ. (d) 48V, 5A, min.
Fig. 7-2 Shut-down test setup
Fig. 7-3 Shut-down behavior, definitions
Load
+
-
DC/DC
Converter
DC
Source
+
-
Input
Output
+
-
CD10
S1
-5%
Hold-up Time
Output Voltage
Intput Voltage
S1 opens
when the input voltage dips or is removed. The bulk capacitor can be discharged by loading the DC/DC converter on the output side or through a load which is parallel to the input. There is no protection in the DC/DC converter which prevents current from flowing back to the input terminals. If prevention is needed, an external diode should be used.
At no load, the hold-up time can be up to several seconds. The green DC-ok lamp is also on during this time.
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
8. EFFICIENCY AND POWER LOSSES
Input 48Vdc
Efficiency
Typ.
95.1%
At 48V, 5A
Typ.
94.9%
At 48V, 6A (Power Boost)
Average efficiency*)
Typ.
94.6%
At 25% at 1.25A, 25% at 2.5A, 25% at 3.75A. 25% at 5A
Power losses
Typ.
2.1W
At no output load
Typ.
6.7W
At 48V, 2.5A
Typ.
12.4W
At 48V, 5A
Typ.
15.5W
At 48V, 6A
*) 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
Fig. 8-1 Efficiency vs. output current at 48V output and
48Vdc input voltage, typ.
Fig. 8-2 Losses vs. output current at 48V output and
48Vdc input voltage, typ.
Efficiency
1
91
93
95
90
96%
6A2 4 5
Output Current
3
92
94
Power Losses
0 1 2 4 5 6A
0
3
9
15
18W
6
3
12
Output Current
Fig. 8-3 Efficiency vs. input voltage at 48V, 10A, typ.
Fig. 8-4 Losses vs. input voltage at 48V, 10A, typ.
Efficiency
36 40
44
52 56 60Vdc
96%
93.5
94.5
95.5
95.0
94.0
93.0 48
Input Voltage
Power Losses
10
11
12
13
14
15
16W
36 40
48
52 56 60Vdc44
Input Voltage
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.
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
10/26
9. FUNCTIONAL DIAGRAM
Fig. 9-1 Functional diagram
+
+
-
-
V
OUT
Input Fuse & Input Filter
Output
Voltage
Regulator
Power
Converter
Output
Filter
DC ok
Output
Over-
Voltage
Protection
Reverse Polarity Protection & Inrush Limiter
Chassis
Ground
+
-
10. FRONT SIDE AND USER ELEMENTS
Fig. 10-1 Front side
A Input terminals
+ Positive input
- Negative / return input
Chassis ground: to bond the housing to ground, PE or Functional Earth
B Output terminals
+ Positive output (two identical + poles)
- Negative / return output (two identical - poles)
C Output voltage potentiometer
Open the flap to set the output voltage. Factory set: 48.0V
D DC-OK LED (green)
On when the voltage on the output terminals is > 40V
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
11/26
11. CONNECTION TERMINALS
The terminals are IP20 Finger safe constructed and suitable for field- and factory wiring.
Input
Output
Type
Screw terminals
Screw terminals
Solid wire
Max. 6mm2
Max. 6mm2
Stranded wire
Max. 4mm2
Max. 4mm2
American Wire Gauge
20-10 AWG
20-10 AWG
Max. wire diameter (including ferrules)
2.8mm
2.8mm
Recommended tightening torque
1Nm, 9lb.in
1Nm, 9lb.in
Wire stripping length
7mm / 0.28inch
7mm / 0.28inch
Screwdriver
3.5mm slotted or Phillips No 1
3.5mm slotted or Phillips No 1
Fig. 11-1 Daisy chaining of outputs
Fig. 11-2 Using distribution terminals
DC/DC
Converter
+ +
- -
Input
Output
Load
+
-
max 25A!
DC/DC
Converter
+ +
- -
Input
Output
Load
+
-
Distribution Terminals
DC/DC
Converter
+ +
- -
Input
Output
DC/DC
Converter
+ +
- -
Input
Output
Daisy chaining of outputs:
Daisy chaining (jumping from one DC/DC-converter output to the next) is allowed as long as the average output current through one terminal pin does not exceed 25A. If the current is higher, use a separate distribution terminal block.
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
12/26
12. LIFETIME EXPECTANCY
The Lifetime expectancy shown in the table indicates the minimum operating hours (service life) and is determined by the lifetime
Input 48Vdc
Lifetime expectancy
160 000h
At 48V, 5A and 40°C
307 000h
At 48V, 2.5A and 40°C
112 000h
At 48V, 6A and 40°C
453 000h
At 48V, 5A and 25°C
868 000h
At 48V, 2.5A and 25°C
318 000h
At 48V, 6A and 25°C
13. MTBF
Input 48Vdc
MTBF SN 29500, IEC 61709
853 000h
At 48V, 5A and 40°C
1 512 000h
At 48V, 5A and 25°C
MTBF MIL HDBK 217F
285 000h
At 48V, 5A and 40°C; Ground Benign GB40
421 000h
At 48V, 5A and 25°C; Ground Benign GB25
71 000h
At 48V, 5A and 40°C; Ground Fixed GF40
97 000h
At 48V, 5A and 25°C; Ground Fixed GF25
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 Mean Time Between Failure, 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.
For these types of units the MTTF (Mean Time To Failure) value is the same value as the MTBF value.
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
13/26
14. EMC
The EMC behavior of the device is designed for applications in industrial environment as well as in residential, commercial and light
EMC Immunity
Electrostatic discharge
EN 61000-4-2
Contact discharge Air discharge
8kV 15kV
Criterion A Criterion A
Electromagnetic RF field
EN 61000-4-3
80MHz-2.7GHz
20V/m
Criterion A
Fast transients (Burst)
EN 61000-4-4
Input lines Output lines
4kV 2kV
Criterion A Criterion A
Surge voltage on input
EN 61000-4-5
+ -
1kV
Criterion A
+/- chassis ground
2kV
Criterion A
Surge voltage on output
EN 61000-4-5
+ → - + / - chassis ground
500V 1kV
Criterion A Criterion A
Conducted disturbance
EN 61000-4-6
0.15-80MHz
20V
Criterion A
EMC Emission
Conducted emission on input lines
IEC/CISPR 16-1-2, IEC/CISPR 16-2-1
Limits for DC power networks according to EN 61000-6-3 fulfilled
Radiated emission
EN 55011, EN 55032
Class B
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.
Switching Frequency
Main converter
75kHz to 500kHz
Output load and input voltage dependent
industry environments. The device is investigated according to the generic standards EN 61000-6-1, EN 61000-6-2, EN 61000-6-3 and EN 61000- 6-4.
Criterions: A: The device shows normal operation behavior within the defined limits. C: Temporary loss of function is possible. The device may shut down and restarts by itself. No damage or hazards for the device will occur.
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
14/26
15. ENVIRONMENT
Operational temperature
-25°C to +70°C (-13°F to 158°F)
The operational temperature is the ambient or surrounding temperature and is defined as the air temperature 2cm below the device.
Storage temperature
-40°C to +85°C (-40°F to 185°F)
For storage and transportation
Output de-rating
3.2W/°C
6W/°C 15W/1000m or 5°C/1000m 9W/-5kPa or 3°C/-5kPa
Between +45°C and +60°C (113°F to 140°F) Between +60°C and +70°C (140°F to 158°F) For altitudes >2000m (6560ft), see Fig. 15-2 For atmospheric pressures <80kPa, see Fig. 15-2
The de-rating is not hardware controlled. The customer has to take care by himself to stay below the de-rated current limits in order not to overload the unit.
Humidity
5 to 95% r.h.
According to IEC 60068-2-30
Atmospheric pressure
110-47kPa
See Fig. 15-2 for details
Altitude
Up to 5000m (16 400ft)
See Fig. 15-2 for details
Degree of pollution
2
According to IEC 62477-1, not conductive
Vibration sinusoidal
2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g 2 hours / axis
According to IEC 60068-2-6
Shock
30g 6ms, 20g 11ms 3 bumps / direction, 18 bumps in total
According to IEC 60068-2-27
Shock and vibration is tested in combination with DIN-Rails according to EN 60715 with a height of 15mm and a thickness of 1.3mm and standard orientation.
LABS compatibility
As a rule, only non-silicon precipitating materials are used. The unit conforms to the LABS criteria and is suitable for use in paint shops.
Corrosive gases
Tested according to ISA-71.04-1985, Severity Level G3 and IEC 60068-2-60 Test Ke Method 4 for a service life of minimum 10years in these environments.
Audible noise
Some audible noise may be emitted from the power supply during no load, overload or short circuit.
Fig. 15-1 Output current vs. ambient temp.
Fig. 15-2 Output current vs. altitude at 48V
0
-25 0 20 40
70°C
1A
2A
3A
4A
5A
6A
60
Ambient Temperature
A... Continuous B... Short term
A
B
Allowed Output Current at 48V
2000m 4000m 6000m
1A
2A
3A
4A
5A
6A
Altitude
Allowed Output Current at 48V
AP
*)
80kPa 62kPa 47kPa110kPa
0m
*) Atmospheric pressure
A... Ambient < 60°C B... Ambient < 45°C C... Short term
A
B
C
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
15/26
16. SAFETY AND PROTECTION FEATURES
Isolation resistance
Min.
500MOhm
At delivered condition between input and output, measured with 500Vdc
Min.
500MOhm
At delivered condition between input and Chassis Ground, measured with 500Vdc
Min.
500MOhm
At delivered condition between output and Chassis Ground, measured with 500Vdc
PE resistance
Max.
0.1Ohm
Resistance between PE terminal and the housing in the area of the DIN-rail mounting bracket.
Output over-voltage protection
Typ.
58Vdc
Max.
60Vdc
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
According to IEC 61140
Degree of protection
IP 20
According to EN/IEC 60529
Over-temperature protection
Not included
Input transient protection
MOV (Metal Oxide Varistor)
For protection values see chapter 14 (EMC).
Internal input fuse
Included
Not user replaceable slow-blow high-braking capacity fuse
Touch current (leakage current)
The leakage current, which is produced by the DC/DC converter itself, depends on the input voltage ripple and need to be investigated in the final application. For a smooth DC input voltage, the produced leakage current is less than 100µA.
17. DIELECTRIC STRENGTH
The output voltage is floating and has no ohmic connection to the ground.
Fig. 17-1 Dielectric strength
A B C
A
C
B
+
Input
Chassis ground
Output
-
+
-
Type test
60s
1500Vac
1500Vac
500Vac
Routine test
5s
1500Vac
1500Vac
500Vac
Field test
5s
1000Vac
1000Vac
500Vac
Cut-off current setting
20mA
15mA
12mA
It is recommend that either the + pole, the – pole or any other part of the output circuit shall be connected to the earth/ground system. This helps to avoid situations in which a load starts unexpectedly or cannot be switched off when unnoticed earth faults occur.
The output is insulated to the input by a double or reinforced insulation. Type and routine 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.
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
16/26
18. APPROVALS
IEC 60950-1 2nd Edition
CB Scheme, Information Technology Equipment
IEC 61010-2-201 2nd Edition
CB Scheme for electrical equipment for measurement, control, and laboratory use - Part 2-201: Particular requirements for control equipment
ANSI/UL 61010-2-201 (former UL 508)
Ind. Cont. Eq.
Listed as Open Type Device for use in Control Equipment UL Category NMTR, NMTR7 E-File: E198865
EN 60079-0, EN 60079-7 ATEX planned
II 3G Ex ec II TX Gc
Approval for use in hazardous locations Zone 2 Category 3G. Number of ATEX certificate: T.B.D.
IEC 60079-0, IEC 60079-7 planned
IECEx
Suitable for use in Class 1 Zone 2 Groups IIa, IIb and IIc locations. Number of IECEx certificate: T.B.D.
19. OTHER FULFILLED STANDARDS
EC Declaration of Conformity
EU Declaration of Conformity Trade conformity assessment for Europe The CE mark indicates conformance with the European
- RoHS directive,
- EMC directive,
- Low-voltage directive (LVD)
REACH Directive
Directive 1907/2006/EU of the European Parliament and the Council of June 1st, 2007 regarding the Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH)
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load,
17/26
20. PHYSICAL DIMENSIONS AND WEIGHT
Width
42mm 1.65’’
Height
124mm 4.88’’
Depth
117mm 4.61’’ The DIN-rail height must be added to the unit depth to calculate the total required installation depth.
Weight
500g / 1.10lb
DIN-Rail
Use 35mm DIN-rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm.
Housing material
Body: Aluminium alloy Cover: zinc-plated steel
Installation clearances
See chapter 2
Penetration protection
Small parts like screws, nuts, etc. with a diameter larger than 3.5mm
Fig. 20-1 Front view
Fig. 20-2 Side view
All dimensions in mm
All dimensions in mm
25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
18/26
21. ACCESSORIES
21.1. ZM2.WALL WALL/PANEL MOUNT BRACKET
Fig. 21-1 ZM2.Wall
Fig. 21-2 Hole pattern
Fig. 21-3 Side view
All dimensions in mm
All dimensions in mm
Fig. 21-4 Isometric view
Fig. 21-5 Isometric view
Fig. 21-6 Isometric view
These brackets are used to mount the device on a flat surface or panel without utilizing a DIN-rail. The brackets can be mounted without detaching the DIN-rail brackets.
The order number ZM2.WALL contains two brackets needed for one device.
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
19/26
21.2. ZM12.SIDE - SIDE MOUNT BRACKET
Fig. 21-7
Side mounting
without DIN-rail brackets
Fig. 21-8
Side mounting
with DIN-rail brackets
Fig. 21-9
Hole pattern
All dimensions in mm
This ZM12.SIDE bracket is used to mount the device sideways with or without utilizing a DIN-rail to save installation depth.
The two aluminum brackets and the black plastic slider of the unit have to be detached, so that the ZM12.SIDE steel bracket can be mounted.
For sideway DIN-rail mounting, the removed aluminum brackets and the black plastic slider need to be mounted on the ZM12.SIDE steel bracket.
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
20/26
21.3. YRM2.DIODE - REDUNDANCY MODULE
The YRM2.DIODE is a dual redundancy module, which can be used to build 1+1 or N+1 redundant system. The device is equipped with two input channels each 10A nominal, which are individually decoupled by
utilizing diode technology. The output can be loaded with nominal 20A. The device does not require an additional auxiliary voltage and is self-powered even in case of a short circuit
across the output. The device has a monitoring circuit included and is the perfect choice when the power supply has no DC-OK
function. Two LEDs and two relay contacts signal when one of the two input voltages are not in range due to a non-functioning or disconnected power supply.
The unit is very slender and only requires 32mm width on the DIN-rail.
See chapter 22.6 for wiring information.
21.4. UF20.481 - BUFFER MODULE
The UF20.481 buffer module is a supplementary device for 48V DC/DC converters. It delivers power to bridge typical supply voltage faults or extends the hold-up time after turn-off of the input power.
In times when the DC/DC converter provides sufficient voltages, the buffer module stores energy in integrated electrolytic capacitors. In case of a supply voltage fault, this energy is released again in a regulated process.
The buffer module does not require any control wiring. It can be added in parallel to the load circuit at any given point.
One buffer module can deliver 20A additional current. Buffer modules can be added in parallel to increase the output ampacity or the hold-up time.
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
21/26
22. APPLICATION NOTES
22.1. PEAK CURRENT CAPABILITY
Fig. 22-1 10A Resistive peak load (2x the nominal current) for
50ms, typ.
Fig. 22-2 25A Resistive peak load (5x the nominal current) for 5ms,
typ.
10ms/DIV
Output Voltage
Output Current
0A
10A
32V
48V
2ms/DIV
Output Voltage
Output Current
0A
25A
13V
48V
Peak current voltage dips
typ.
from 48V to 32V
At 10A for 50ms, resistive load
typ.
from 48V to 28V
At 25A for 2ms, resistive load
typ.
from 48V to 13V
At 25A for 5ms, resistive load
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:
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
22/26
22.2. OUTPUT CIRCUIT BREAKERS
Fig. 22-3 Test circuit for maximum wire length
Test results for maximum wire length:
MCB
DC/DC
Converter
DC
DC
+
-
+
-
Load
Wire length
S1... Fault simulation switch
S1
0.75mm²
1.0mm²
1.5mm²
2.5mm²
C-2A
43m
54m
82m
117m
C-3A
21m
28m
41m
66m
C-4A
9m
11m
15m
23m
C-6A
3m
3m
4m
6m
B-6A
11m
13m
20m
30m
B-10A
2m
2m
3m
4m
End-of-charge voltage
55.6V
55.0V
54.3V
53.6V
Battery temperature
10°C
20°C
30°C
40°C
Standard miniature circuit breakers (MCB’s or UL 1077 circuit breakers) are commonly used for AC-supply systems and may also be used on 48V branches.
MCB’s are designed to protect wires and circuits. If the ampere value and the characteristics of the MCB are adapted to the wire size that is used, the wiring is considered as thermally safe regardless of whether the MCB opens or not.
To avoid voltage dips and under-voltage situations in adjacent 24V branches which are supplied by the same source, a fast (magnetic) tripping of the MCB is desired. A quick shutdown within 10ms is necessary corresponding roughly to the ride-through time of PLC's. This requires power supplies with high current reserves and large output capacitors. Furthermore, the impedance of the faulty branch must be sufficiently small in order for the current to actually flow. The best current reserve in the power supply does not help if Ohm’s law does not permit current flow. The following table has typical test results showing which B- and C-Characteristic MCBs magnetically trip depending on the wire cross section and wire length.
The following test results indicate the maximal wire length for a magnetic (fast) tripping. The wire length is always two times the distance to the load (+ and – wire).
22.3. CHARGING OF BATTERIES
The device can be used to charge lead-acid or maintenance free batteries. Four 12V SLA or VLRA batteries are needed in series connection.
Instructions for charging batteries:
a) Ensure that the ambient temperature of the Device is below 45°C. b) Set output voltage, measured at no load and at the battery end of the cable, very precisely to the end-of-charge voltage.
c) Use a 10A circuit breaker or blocking diode between the Device and the battery. d) Ensure that the output current of the Device is below the allowed charging current of the battery. e) Use only matched batteries when putting 12V types in series. f) The return current to the Device (battery discharge current) is typ. 6mA when the Device is switched off (except in case a blocking
diode is utilized).
g) Do not use the devices for battery charging in mounting orientations other than the standard mounting orientation or in any other
condition where a reduction of the output current is required (e.g. altitude).
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
23/26
22.4. SERIES OPERATION
Unit A
Input
Output
Unit B
-
+
-
+
+
-
Input
Output
Load
Unit A
Input
Output
Unit B
-
+
-
+
+
-
Input
Output
Load
Devices 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 must be installed with a protection against touching.
Avoid return voltage (e.g. from a decelerating motor or battery) which is applied to the output terminals.
Keep an installation clearance of 15mm (left / right) between two power supplies and avoid installing the power supplies on top of each other. Do not use power supplies in series in mounting orientations other than the standard mounting orientation.
Pay attention that EMI and inrush current will increase when using multiple devices.
22.5. PARALLEL USE TO INCREASE OUTPUT POWER
Devises can be paralleled to increase the output power. The output voltage shall be adjusted to the same value (±100mV) with the same load conditions on all devices, or the devices can be left with the factory settings.
The ambient temperature is not allowed to exceed +45°C. If more than three devices are connected in parallel, a fuse or circuit breaker with a rating of
10A is required on each output. Alternatively, a diode or redundancy module can also be utilized.
Keep an installation clearance of 15mm (left / right) between two devices and avoid installing devices on top of each other. Do not use devices in parallel in mounting orientations other than the standard mounting orientation or in any other condition where a reduction of the output current is required (e.g. altitude).
Pay attention that EMI and inrush current will increase when using multiple devices.
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
24/26
22.6. PARALLEL USE FOR REDUNDANCY
Fig. 22-4 1+1 Redundant configuration for 5A load current
with a dual redundancy module
Fig. 22-5 N+1 Redundant configuration for 15A load current
with multiple DC/DC converters and redundancy modules
Load
Failure
Monitor
YRM2.DIODE
Redundancy Module
Output
Input
1
Input
2
+-+
-
+
-
o o o o
2
1
Input ok
DC/DC
Converter
+ +
- -
+
-
Output
Input
I I
optional
DC/DC
Converter
+ +
- -
+
-
Output
Input
Functional Earth
+
-
Load
I I
optional
YRM2.DIODE
Redundancy Module
Output
Input
1
Input
2
+-+
-
+
-
o o o o
2
1
Input ok
YRM2.DIODE
Redundancy Module
Output
Input
1
Input
2
+-+
-
+
-
o o o o
2
1
Input ok
Failure
Monitor
I I
optional
DC/DC
Converter
+ +
- -
+
-
Output
Input
DC/DC
Converter
+ +
- -
+
-
Output
Input
DC/DC
Converter
+ +
- -
+
-
Output
Input
DC/DC
Converter
+ +
- -
+
-
Output
Input
+
-
Functional Earth
1+1 Redundancy:
Devices 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 device fails. The simplest way is to put two devices in parallel. This is called a 1+1 redundancy. In case one device fails, the other one is automatically able to support the load current without any interruption. It is essential to use a redundancy module to decouple devices from each other. This prevents that the defective unit becomes a load for the other device and the output voltage cannot be maintained any more.
1+1 redundancy allows ambient temperatures up to +70°C. Pay attention that EMI and inrush current will increase when using multiple devices. Recommendations for building redundant power systems:
- Use separate input fuses for each device.
- Use separate supply systems for each device whenever it is possible.
- Monitor the outputs of the individual devices. Use the DC-ok lamp or the DC-ok contact, which are included in the redundancy module YRM2.DIODE.
- It is desirable to set the output voltages of all devices to the same value (± 100mV) or leave it at the factory setting.
N+1 Redundancy:
Redundant systems for a higher power demand are usually built in a N+1 method. E.g. four devices, each rated for 10A are paralleled to build a 30A redundant system.
Pay attention that EMI and inrush current will increase when using multiple devices. Keep an installation clearance of 15mm (left / right) between two devices and avoid installing the devices on top of each other. Do not use devices in parallel in mounting orientations other than the standard mounting orientation or in any other condition, where a
reduction of the output current is required. For N+1 redundancy the ambient temperature is not allowed to exceed +45°C.
Wiring examples for 1+1 and n+1 redundancy:
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
25/26
22.7. USE IN A TIGHTLY SEALED ENCLOSURE
Case A
Case B
Enclosure size
110x180x165mm Rittal Typ IP66 Box PK 9516 100, plastic
110x180x165mm Rittal Typ IP66 Box PK 9516 100, plastic
Input voltage
48Vdc
48Vdc
Load
48V, 4A; (=80%)
48V, 5A; (=100%)
Temperature inside the box
43.5°C
48.1°C
Temperature outside the box
26.2°C
26.6°C
Temperature rise
17.3K
21.5K
When the device 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 device.
In the following test setup, the device is placed in the middle of the enclosure; no other heat producing items are inside the enclosure. The load is placed outside the enclosure.
The temperature sensor inside the enclosure is placed in the middle of the right side of the device with a distance of 1cm. The following measurement results can be used as a reference to estimate the temperature rise inside the enclosure.
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
CD10.482
CD-Series
DC/DC Converter 48V/48V, 5A, 240W
26/26
22.8. MOUNTING ORIENTATIONS
Fig. 22-6
Mounting Orientation A
(Standard orientation)
DC/DC
Converter
OUTPUT
INPUT
Allowed Output Current at 48V
0
+45 +70°C
3.8A
5A
6A
Ambient Temperature
+60
Fig. 22-7 Mounting Orientation B (Upside down)
DC/DC
Converter
OUTPUT
INPUT
Allowed Output Current at 48V
0
+30 +70°C
4A
6A
Ambient Temperature
+60
Fig. 22-8 Mounting Orientation C
(Table-top mounting)
Allowed Output Current at 48V
0
+25 +70°C
3.5A
6A
Ambient Temperature
+60
Fig. 22-9 Mounting Orientation D (Horizontal cw)
DC/DC
Converter
OUTPUT
INPUT
Allowed Output Current at 48V
0
+25 +70°C
3.5A
6A
Ambient Temperature
+60
Fig. 22-10 Mounting Orientation E (Horizontal ccw)
DC/DC
Converter
OUTPUT
INPUT
Allowed Output Current at 48V
0
+25 +70°C
3.5A
6A
Ambient Temperature
+60
Mounting orientations other than input terminals on the bottom and output on the top require a reduction in continuous output power or a limitation in the maximum allowed ambient temperature.
The listed lifetime and MTBF values from this datasheet apply only for the standard mounting orientation. The following curves give an indication for allowed output currents for altitudes up to 2000m (6560ft).
Jun 2020 / Rev. 1.0 DS-CD10.482-EN All values are typical figures specified at 48Vdc input voltage 48V, 5A output load, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
Loading...