Puls CD–Series User Manual

CD–Series

1. GENERAL DESCRIPTION

The Dimension CD5-Series offers a range of DIN-rail mountable DC/DC-converters in a very compact housing.

The CD5.242 converts a 48V voltage to a 24V voltage. The input source can be a battery, a solar panel or any other 48V sources.

The CD5.242 includes all the essential basic functions and has a power reserve of 20% included. This extra power can be used continuously up to +45°C.

The output is electrically isolated from the input in a safe way. The input is protected against reversed voltages and contains a soft start funtion.

CD-Series

Related products

24V->24V

CD5.241-S1

24V->24V

CD5.241 CD5.121

24V->12V

48V->24V

CD5.242

Spring-clamp terminals, Input-low, DC-OK contacts

CD5.242

DC/DC Converter; 24V, 5A

DC/DC CONVERTER

■ Wide Range DC Input (36-60Vdc)

■ Isolated 24Vdc Output

■ Efficiency up to 90.3%

■ Width only 32mm

■ 20% Output Power Reserves

■ Full Output Power Between -25°C and +60°C

■ Soft-start Function Included

■ Minimal Inrush Current Surge

■ Reverse Input Polarity Protection

■ 3 Year Warranty

2. SHORT-FORM DATA

Output voltage DC 24V Adjustment range 23 - 28V Output current

Output power 120W Ambient <60°C 144W Ambient <45°C Output ripple < 50mVpp 20Hz to 20MHz Input voltage DC 48V 36 to 60Vdc

Input current typ. 2.75A At 48Vdc input Input inrush current typ. 0.6A peak Efficiency typ. 90.3% At 48Vdc input Losses typ. 12.9W At 48Vdc input Hold-up time typ. 5.6ms At 48Vdc input Temperature range -25°C to +70°C Operational Derating 3W/°C +60 to +70°C Dimensions 32x124x102mm WxHxD

5 – 4.3A 6 – 5.1A

Ambient <60°C Ambient <45°C

(30.5 to 36Vdc with derating)

3. ORDER NUMBERS

DC/DC Converter

Accessories ZM1.WALL Wall mount bracket ZM11.SIDE Side mount bracket

YR2.DIODE Decoupling module

Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.

CD5.242

YRM2.DIODE Redundancy module

Standard unit

www.pulspower.com Phone +49 89 9278 0 Germany

4. MARKINGS

LISTED

IND. CONT. EQ.

UL 508

CUS

182790

pending

18WM

UL 60950-1

Marine, pending

Class I Div 2,

pending

EMC, LVD

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CD–Series

DC/DC Converter; 24V, 5A

CD5.242

INDEX PAGE INDEX PAGE

General Description ............................................1

2. Short-form Data ..................................................1

3. Order Numbers....................................................1

4. Markings..............................................................1

5. Input Voltage ......................................................3

6. Soft-start and Input Inrush Current Surge .........4

7. Output .................................................................5

8. Hold-up Time.......................................................6

9. Efficiency and Power Losses................................7

10. Functional Diagram.............................................8

11. Reliability.............................................................8

12. Front Side and User Elements.............................9

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

14. EMC....................................................................10

15. Environment......................................................11

16. Protection Features...........................................12

17. Safety .................................................................12

18. Dielectric Strength ............................................12

19. Approvals...........................................................13

20. Fulfilled Standards ............................................13

21. Used Substances ............................................... 13

22. Physical Dimensions and Weight..................... 14

23. Installation and Operation Instructions .......... 14

24. Accessory........................................................... 15

25. Application Notes............................................. 16

25.1. Peak Current Capability......................... 16

25.2. Back-feeding Loads................................ 16

25.3. Inductive and Capacitive Loads ............. 16

25.4. Output Circuit Breakers ......................... 17

25.5. Series Operation..................................... 18

25.6. Parallel Use to Increase Output Power . 18

25.7. Daisy Chaining of Outputs..................... 18

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

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

25.10. Requirements for the Supplying Source 20

25.11. External Input Protection....................... 20

25.12. Use in a Tightly Sealed Enclosure .......... 20

25.13. Mounting Orientations.......................... 21

INTENDED USE

The DC/DC converter shall only be installed and put into operation by qualified personnel. This DC/DC converter is designed for installation in an enclosure and is intended for the general use, such as in

industrial control, office, communication, and instrumentation equipment. Do not use this device in aircraft, trains and nuclear equipment, where malfunctioning of the DC/DC converter may cause severe personal injury or threaten human life.

TERMINOLOGY AND ABREVIATIONS

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 24V 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 regardless whether it is full (13.7V) or flat (10V)

24Vac A figure with the unit (Vdc) at the end is a momentary figure without any additional

tolerances included.

DISCLAIMER

The information presented in this document is believed to be accurate and reliable and may change without notice. Some parts of this unit are patent by PULS (US patent No 091662,063, Des. 424,529, …). No part of this document may be reproduced or utilized in any form without permission in writing from PULS GmbH.

Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.

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CD–Series

DC/DC Converter; 24V, 5A

CD5.242

5. INPUT VOLTAGE

Input Input voltage range typ. 30.5-36.0Vdc Max. 60 seconds or with de-rating, see Fig. 5-2

Allowed voltage between input and earth (ground)

Allowed input ripple voltage

Turn-on voltage typ. 34.5Vdc Steady-state value, see Fig. 5-1 Shut-down voltage typ. 30.5Vdc Steady-state value, see Fig. 5-1

Input current Start-up delay typ. Rise time typ. 80ms 0mF, 24V, 5A, constant current load, see Fig. 5-3

Turn-on overshoot Input capacitance typ.

External capacitors on the input voltage bus are allowed without any limitations.

Fig. 5-1 Input voltage range

OUT

Shut-down

30.5Vdc

Rated input range

Turn-on

35.0Vdc

36.0Vdc

Fig. 5-3 Turn-on behavior, definitions Fig. 5-4 Input current vs. output load

Intput Voltage

Output Voltage

- 5%

Start-up

delay

Rise

Time

nom. DC 48V nom. 36.0-60.0Vdc Continuous operation

max. 63.0Vdc Absolute maximum continuous input voltage with no

damage to the DC/DC converter. Please note that the unit can switch off above 60Vdc

max. 60Vdc or

42.4Vac

max. 5Vpp 47Hz-40kHz, the momentary input voltage must always be

within the specified limits.

typ. 63.5Vdc Steady-state value, see Fig. 5-1 typ. 2.75A At 48Vdc input and output 24V, 5A, see Fig. 5-4

670ms

0mF, 24V, 5A, see Fig. 5-3

typ. 150ms 5mF, 24V, 5A, constant current load, see Fig. 5-3

60.0Vdc

500mV 800µF

63.5Vdc

Overshoot

See Fig. 5-3

Fig. 5-2 Allowable output current below 36V

Output Current

30 32 34 36 40Vdc

Input

Current, typ.

1.5 2 3

input voltage

(a) Ambient < 45°C (b) Ambient < 60°C

Input Voltage

Output Current

3.5

2.5

4.5

)

(

)

(

5.5

max.

Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.

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CD–Series

DC/DC Converter; 24V, 5A

CD5.242

6. SOFT-START AND INPUT INRUSH CURRENT SURGE

Inrush current limitation

An active inrush limitation circuit (inrush limiting resistor which is bypassed by a relay contact) limits the input inrush current after turn-on of the input voltage.

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

Inrush current

max. 0.8A typ. 0.6A Inrush energy

typ. negligible -25°C to +70°C

Fig. 6-1 Input inrush current, typical behavior

Input Current

Input Voltage

Input 48Vdc

-25°C to +70°C

peak

-25°C to +70°C

peak

Input: 48Vdc Output: 24Vdc, 5A, constant current load Ambient: 25°C

Upper curve: Input current 1A / DIV Middle curve: Input voltage 50V / DIV Lower curve: Output voltage 20V / DIV Time scale: 100ms / DIV

Output Voltage

Soft-start function:

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 softstart function. Please note, that this function increases the rise time of the output voltage by a small amount.

Fig. 6-2 Soft-start behavior

Input: 48Vdc Output: 24Vdc, 5A, constant current load Ambient: 25°C No additional external capacitors

Input Current

Upper curve: Input current 2A / DIV Lower curve: Output voltage 10V / DIV Time scale: 20ms / DIV

Output Voltage

Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.

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CD–Series

DC/DC Converter; 24V, 5A

CD5.242

7. OUTPUT

Output voltage Adjustment range max. 30V At clockwise end position of potentiometer Factory setting Line regulation Load regulation max. 100mV Static value, 0A Æ 5A Æ 0A Ripple and noise voltage Output capacitance typ. Output current nom. 6A At 24V, ambient < 45°C, see Fig. 7-1 nom. 5A nom. 5.1A At 28V, ambient < 45°C, see Fig. 7-1

Output power nom. 144W Ambient < 45°C nom. 120W Short-circuit current max. 10A Load impedance 200mOhm, see Fig. 7-1

Fig. 7-1 Output voltage vs. output current,

typ. (48Vdc input voltage)

nom. 24V min. 23-28V Guaranteed

max.

24.1V 25mV

50mVpp 2200µF

nom. 4.3A

±0.2%, at full load, cold unit

Input variations between 36 to 60Vdc

20Hz to 20MHz, 50Ohm

At 24V, ambient < 60°C, see

At 28V, ambient < 60°C, see

Fig. 7-1

Ambient < 60°C

min. 7A Load impedance 200mOhm, see Fig. 7-1

Fig. 7-2 Current limitation vs. input voltage,

typ. (23V constant voltage load)

Output Voltage

28V

4 0

Adjustment

Range

Output Current

048

1062

Output Current

7.0A

6.9

6.8

6.7

6.6

6.5

6.4

6.3

6.2 30 42 54

Input Voltage

4836

60Vd

Peak current capability (up to several ms)

The DC/DC converter can deliver a peak current which is higher than the specified short term current. This helps to start current demanding loads or to safely operate subsequent circuit breakers.

The extra current is supplied by the output capacitors inside the DC/DC converter. During this event, the capacitors will be discharged and cause a voltage dip on the output. Detailed curves can be found in chapter 25.1.

Peak current voltage dips typ. from 24V to 17.1V At 10A for 50ms, resistive load typ. from 24V to 15V

typ. from 24V to 11V

At 20A for 2ms, resistive load At 20A for 5ms, resistive load

Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.

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CD–Series

DC/DC Converter; 24V, 5A

CD5.242

8. 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 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.

Input 48Vdc

Hold-up Time typ. 10.5ms Input 48Vdc, Output: 24Vdc, 2.5A, see typ. 5.6ms Input 48Vdc, Output: 24Vdc, 5A, see Fig. 8-1

Fig. 8-1 Hold-up time vs. input voltage

Hold-up Time

12ms

Input Voltage

36 40 44 48 56Vdc

)

(

)

(

)

(

(a) 24V, 2.5A, typ. (b) 24V, 2.5A, min. (c) 24V, 5A, typ. (d) 24V, 5A, min.

Fig. 8-2 Shut-down test setup Fig. 8-3 Shut-down behavior, definitions

DC/DC

Converter

Input

Output

CD5

Load

Source

Intput Voltage

Output Voltage

Fig. 8-1

S1 opens

- 5%

Hold-up Time

Note: At no load, the hold-up time can be up to several seconds. The green DC-ok lamp is also on during this time.

Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.

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CD–Series

DC/DC Converter; 24V, 5A

9. EFFICIENCY AND POWER LOSSES

Input 48Vdc

Efficiency typ. 90.3% 5A, 24V Power losses typ. 0.9W At no output load typ. 6.9W 2.5A, 24V typ. 12.9W 5A, 24V typ. 16.4W 6A, 24V

Fig. 9-1 Efficiency vs. output current at 24V

output voltage and 48V input voltage

Efficiency

91%

Output Current

2453

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

output voltage and 48V input voltage

Power Losses

18W

012 456

Fig. 9-3 Efficiency vs. input voltage, 24V, 5A

Efficiency

91%

90.5

90.0

89.5

89.0

88.5

88.0 36 40 44 52 56 60

output

Input Voltage

Fig. 9-4 Losses vs. input voltage, 24V, 5A

Power Losses

18W

36 40 48 52 56 60

Output Current

output

Input Voltage

CD5.242

Jan. 08 / Rev. 1.1 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.

www.pulspower.com Phone +49 89 9278 0 Germany

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