Puls Dimension CP, CP10.241-60 Series Manual

CP10.241-60

CP-Series

24V, 200W, DC/DC CONVERTER

DC/DC CONVERTER

 EN 50155 Railway Compliant
 Conformal Coated PC-boards
 Quick-connect Spring-clamp Terminals
 67-154Vdc Wide-range Input
 Width only 39mm
 Efficiency up to 94.5%
 Excellent Partial Load Efficiency
 Minimal Inrush Current Surge
 Full Power Between -40°C and +70°C
 DC-OK Relay Contact
 Reverse Input Polarity Protected
 3 Year Warranty

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GENERAL DESCRIPTION

The DC/DC converter CP10.241-60 is designed specifically
for railway & transportation applications. It is approved
according to the EN 50155 standard, which is an
international standard covering electronic equipment
used on rolling stock for railway applications. The
standard covers aspects such as temperature, humidity,
shock, vibration, EMI and other parameters. Because of
these requirements, the unit is equipped with
conformal coated pc-boards.

The unit features a DC-OK signal contact for remote
monitoring, and quick-connect spring-clamp terminals
for a reliable connection even when mechanical
vibration and shock are involved. The unit also covers an
extreme wide temperature range from -40°C up to
+70°C with full output current.

This DC/DC converter comes in a very compact housing
and requires only 39mm space on the DIN-rail due to
the high efficiency and low power losses. The high
efficiency is achieved by utilizing cutting edge
technology and other unique design techniques.

SHORT-FORM DATA

Output voltage DC 24V
Adjustment range 24 - 28V
Output current 8.3 – 7.1A Continuous, < +70°C

8.3 – 7.1A For 10 minutes, < +85°C
Input voltage DC DC 96 - 110V - 30%/ +40%
Input voltage range 67.2 – 154V
Input current DC 2.25 / 1.95A At 96 / 110Vdc
Input inrush current 2.5A pk
Efficiency 94.3 / 94.5% At 96 / 110Vdc
Losses 12.1 / 11.6W At 96 / 110Vdc
Hold-up time 34ms
Temperature range -40 to +70°C
Size (W x H x D) 39x124x117mm Without DIN-rail
Weight 620g / 1.37lb

ORDER NUMBERS

DC/DC converter

CP10.241-60

Mechanical Accessory

ZM4.WALL Wall/panel mount bracket
ZM12.SIDE Side mount bracket

MARKINGS

For details and a complete approval list see section 19.

Apr. 2018 / Rev. 1.0 DS-CP10.241-60-EN All parameters are typical values specified at 24V, 8.3A output, 110Vdc input,
25°C ambient and after a 5 minutes run-in time unless otherwise noted.

www.pulspower.com Phone [phone] Germany

CP10.241-60

CP-Series

24V, 200W, DC/DC CONVERTER

INDEX

Page Page

1.

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

2. Installation Requirements...................................4

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

4. AC-Input...............................................................6

5. Input Inrush Current ...........................................6

6. Output .................................................................7

7. Hold-up Time.......................................................8

8. DC-OK Relay Contact ..........................................9

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

10. Efficiency and Power Losses..............................10

11. Lifetime Expectancy ..........................................11

12. MTBF ..................................................................11

13. Terminals and Wiring........................................12

14. Front Side and User Elements...........................13

15. EMC....................................................................14

16. Environment......................................................15

17. Dielectric Strength ............................................16

18. Safety and Protection Features ........................17

19. Approvals and Declarations..............................18

20. RoHS, REACH and Other Fulfilled Standards .. 18

21. Physical Dimensions and Weight..................... 19

22. Accessories ........................................................ 20

22.1. ZM4.WALL – Wall/Panel Mount Bracket .20

22.2. ZM12.SIDE - Side Mounting Bracket........21

22.3. UF20.241 Buffer Module .......................... 22

22.4. YR20.242 - Redundancy Module.............. 22

22.5. YR20.246 - Redundancy Module with

Automated Load Sharing ....................................22

23. Application Notes............................................. 23

23.1. Peak Current Capability ...........................23

23.2. Charging of Batteries ...............................24

23.3. Series Operation .......................................24

23.4. Parallel Use to Increase Output Power....24

23.5. Parallel Use for Redundancy ....................25

23.6. Use in a Tightly Sealed Enclosure ............26

23.7. Mounting Orientations ............................27

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.

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 110V A figure displayed with the AC or DC before the value represents a nominal voltage with

standard tolerances (usually ±15%) included.
E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (10V)

110Vdc A figure with the unit (Vdc) 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.

Apr. 2018 / Rev. 1.0 DS-CP10.241-60-EN All parameters are typical values specified at 24V, 8.3A output, 110Vdc input,
25°C ambient and after a 5 minutes run-in time unless otherwise noted.

www.pulspower.com Phone [phone] Germany

2/27

CP10.241-60

CP-Series

24V, 200W, DC/DC CONVERTER

1. INTENDED USE

This device is designed for installation in an enclosure and is intended for general use such as in rolling stock for
railway applications (according to EN 50155) or in industrial control, office, communication, and instrumentation
equipment.

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

Apr. 2018 / Rev. 1.0 DS-CP10.241-60-EN All parameters are typical values specified at 24V, 8.3A output, 110Vdc input,
25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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3/27

CP10.241-60

CP-Series

24V, 200W, DC/DC CONVERTER

2. INSTALLATION REQUIREMENTS

This device may only be installed and put into operation by qualified personnel.
This device does not contain serviceable parts. The tripping of an internal fuse is caused by an internal defect.
If damage or malfunction should occur during installation or operation, immediately turn power off and send unit to

the factory for inspection.
Install device in an enclosure providing protection against electrical, mechanical and fire hazards.
Install the device onto a DIN-rail according to EN 60715 with the input terminals on the bottom of the device. 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.

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 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 can be powered from a regulated power supply or a similar DC source. The voltage between the supply

voltage terminals and ground must not exceed 300Vdc continuously.
A disconnecting means shall be provided for the input of the device.
The output is electronically protected against no-load, overload and short circuit and can supply any kind of loads,

including unlimited inductive loads and capacitive loads. If capacitors with a capacitance >1.5F are connected, the unit
might charge the capacitor in an intermittent mode.

Do not apply return voltages from the load to the output terminals higher than 35V.
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 6000m (19685ft). 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 20A without additional protection device. If an
external fuse is utilized, do not use circuit breakers smaller than 6A B- or 4A C-Characteristic to avoid a nuisance
tripping of the circuit breaker.

The maximum surrounding air temperature is +85°C (+185°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.
Check for correct input polarity. The device will not operate when the voltage is reversed.

WARNING

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

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

- Make sure that the wiring is correct by following all local and national codes.

- Do not modify or repair the unit.

- Do not open the unit as high voltages are present inside.

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

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

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

Apr. 2018 / Rev. 1.0 DS-CP10.241-60-EN All parameters are typical values specified at 24V, 8.3A output, 110Vdc input,
25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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4/27

CP10.241-60

CP-Series

24V, 200W, DC/DC CONVERTER

3. DC-INPUT

Use a battery or a similar DC source. A supply from the intermediate DC-bus of a frequency converter is not
recommended and can cause a malfunction or damage the unit.

Input voltage Nom. DC 96-110V -30%/+40%
Input voltage range 67-154Vdc
57-67Vdc Short term for 2s, no start at 57Vdc
Input current Typ. 2.25A At 8.3A and 96Vdc input voltage, see Fig. 3-3
Typ. 1.95A At 8.3A and 110Vdc input voltage, see Fig. 3-3
Allowed voltage between input

to earth (ground)

Max. 300Vdc Continuous, IEC 62477-1

Allowed input ripple voltage Max. 15Vpp

3Vpp

50Hz –10kHz
10kHz – 50kHz

Turn-on voltage Typ. 64.5Vdc Steady-state value, temperature independent, see Fig.

3-1

Shut-down voltage Typ. 62.5Vdc Steady-state value, temperature independent, see Fig.

3-1
Start-up delay Typ. 700ms At 96Vdc input, see Fig. 3-2
Typ. 600ms At 110Vdc input, see Fig. 3-2
Rise time Typ. 45ms At 8.3A constant current load, 0mF load capacitance
Typ. 90ms At 8.3A constant current load, 8mF load capacitance,

see Fig. 3-2

Reverse input polarity protection Included The device will not operate when the voltage is

reversed.
Turn-on overshoot Max. 200mV See Fig. 3-2
External input protection See recommendations in chapter .

Fig. 3-1 Input voltage range Fig. 3-2 Turn-on behavior, definitions

Turn-on

67V

Rated

input range

max.

500ms

V

IN

P

OUT

5/27

375Vdc154V

Shut-down

Start-up Rise

delay Time

Overshoot

- 5%

Output
Voltage

Input
Voltage

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

8

01234

0

0.5

1.0

1.5

2.5

Output Current

Input Current, typ.

567

9A

2.0

3A

(a) 96Vdc,
(b) 110Vdc

(a)
(b)

Apr. 2018 / Rev. 1.0 DS-CP10.241-60-EN All parameters are typical values specified at 24V, 8.3A output, 110Vdc input,
25°C ambient and after a 5 minutes run-in time unless otherwise noted.

www.pulspower.com Phone [phone] Germany

CP10.241-60

CP-Series

24V, 200W, DC/DC CONVERTER

4. AC-INPUT

Do not operate this DC/DC converter with an AC-input voltage. Use the CP10.241 or CP10.241-C1 (when conformal
coating is needed) unit instead.

5. INPUT INRUSH CURRENT

An active inrush limitation circuit (inrush limiting fixed resistor which is bypassed by a relay) 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.

DC 96V DC 110V

Inrush current Max. 8A

peak

8A

peak

Temperature independent

Typ. 2.5A

peak

2.5A

peak

Temperature independent

Inrush energy Max. 0.1A²s 0.1A²s Temperature independent

Fig. 5-1 Typical input inrush current behaviour at

nominal load and 25°C ambient

50ms/DIV

Input
current

0.5A/DIV

Input
voltage
20V/DIV

Output voltage 5V/DIV

Apr. 2018 / Rev. 1.0 DS-CP10.241-60-EN All parameters are typical values specified at 24V, 8.3A output, 110Vdc input,
25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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6/27

CP10.241-60

CP-Series

24V, 200W, DC/DC CONVERTER

6. OUTPUT

The output provides a SELV/PELV/ES1 rated voltage, which is galvanically isolated from the input voltage.
The device is designed to supply any kind of loads, including capacitive and inductive loads. If extreme large

capacitors, such as EDLCs (electric double layer capacitors or “UltraCaps”) with a capacitance >1.5F are connected, the
unit might charge the capacitor in an intermittent mode.

Output voltage Nom. 24V
Adjustment range Min. 24-28V Guaranteed

Max. 30V 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 Typ. 24.1V ±0.2% At full load, cold unit
Line regulation Max. 10mV Between 67 and 154Vdc
Load regulation Max. 100mV Between 0A and 8.3A, static value
Ripple and noise voltage Max. 50mVpp Bandwidth 20Hz to 20MHz, 50Ohm

Output current

Nom. 8.3A At 24V and an ambient temperature below 70°C or at

+85°C for maximum 10 minutes.

Nom. 7.1A At 28V and an ambient temperature below 70°C or at

+85°C for maximum 10 minutes.
Fuse breaking current

1)

Typ. 30A Up to 12ms once every five seconds, see Fig. 6-2.

Overload protection Included Electronically protected against overload, no-load and

short-circuits. In case of a protection event, audible

noise may occur.

Overload behaviour Continuous current Output voltage above 13Vdc, see Fig. 6-1
Intermitted current2) Output voltage below 13Vdc, see Fig. 6-1

Overload/ short-circuit current Max. 10.6A Continuous current, see Fig. 6-1

Typ. 11.5A Intermitted current peak value for typ. 2s

Load impedance 50mOhm, see Fig. 6-3

Discharge current of output capacitors is not included.

Max. 4.3A Intermitted current average value (R.M.S.)

Load impedance 50mOhm, see Fig. 6-3
Output capacitance Typ. 4 400μF Included inside the power supply
Back-feeding loads

Max. 35V 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.

1) The fuse braking current is an enhanced transient current which helps to start heavy loads or to trip fuses on faulty output branches. The

output voltage stays above 20V. See chapter 23.1 for additional measurements.

2) At heavy overloads (when output voltage falls below 13V), the power supply delivers continuous output current for 2s. After this, the

output is switched off for approx. 18s before a new start attempt is automatically performed. This cycle is repeated as long as the overload
exists. If the overload has been cleared, the device will operate normally. see Fig. 6-2.

Apr. 2018 / Rev. 1.0 DS-CP10.241-60-EN All parameters are typical values specified at 24V, 8.3A output, 110Vdc input,
25°C ambient and after a 5 minutes run-in time unless otherwise noted.

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7/27

CP10.241-60

CP-Series

24V, 200W, DC/DC CONVERTER

Fig. 6-1 Output voltage vs. output current,

typ.

Fig. 6-2 Dynamic output current capability,

typ.

Output Voltage

0

01

4

8

12

28V

16

20

24

0

12A62 4 8

Adjustment Range

Output Current

A

B

A: continuous current
B: intermitted current

Output Voltage

(dynamic behavior, < 12ms)

0

0

4

8

12

28V

16

20

24

50A2010 30 40515253545

Adjustment

Range

Output Current

Fig. 6-3 Short-circuit on output, Hiccup

PLUS

mode, typ.

Output
Current

0

11.5A

18s

18s

18s

2s

2s

2s

t

Short -circuit

Normal

operation

Normal

operation

7. HOLD-UP TIME

The internal capacitor, which supplies the energy for the hold-up time is isolated by a diode to the input voltage. A
short on the input line does not discharge the internal hold-up capacitor.

DC 96V DC 110V

Hold-up Time Typ. 72ms 72ms At 4.15A, see Fig. 7-1
Min. 54ms 54ms At 4.15A, see Fig. 7-1
Typ. 34ms 34ms At 8.3A, see Fig. 7-1
Min. 26ms 26ms At 8.3A, see Fig. 7-1

Fig. 7-1 Hold-up time vs. input voltage Fig. 7-2 Shut-down behavior, definitions

8/27

0

15

30

45

60

75ms

70 90 110 130 150Vdc

Hold-up Time

Input Voltage

at 8.3A, typ.

at 4.15A, min.

at 4.15A, typ.

at 8.3A, min.

- 5%

Output
Voltage

Input
Voltage

Hold-up Time

Apr. 2018 / Rev. 1.0 DS-CP10.241-60-EN All parameters are typical values specified at 24V, 8.3A output, 110Vdc input,
25°C ambient and after a 5 minutes run-in time unless otherwise noted.

www.pulspower.com Phone [phone] Germany

CP10.241-60

CP-Series

24V, 200W, DC/DC CONVERTER

8. DC-OK RELAY CONTACT

This feature monitors the output voltage on the output terminals of a running power supply.

Contact closes As soon as the output voltage reaches typ. 90% of the adjusted output voltage level.
Contact opens As soon as the output voltage dips more than 10% below the adjusted output voltage.

Short dips will be extended to a signal length of 100ms. Dips shorter than 1ms will be ignored.
Switching hysteresis 1V
Contact ratings Maximal 60Vdc 0.3A, 30Vdc 1A, 30Vac 0.5A, resistive load
Minimal permissible load: 1mA at 5Vdc
Isolation voltage See dielectric strength table in section 18.

Fig. 8-1 DC-ok relay contact behavior

100ms

0.9* V

ADJ

<

1ms

10%

open

V

OUT

= V

ADJ

openclosed closed

>

1ms

9. FUNCTIONAL DIAGRAM

Fig. 9-1 Functional diagram

+

+

-

-

DC-ok
contact

Output

Over-

Boost

Converter

(pre

conditioning)

Voltage

Protection

Output

Voltage

Regulator

Output

Filter

9/27

DC-ok
Relay

Output

Voltage

Monitor

Output

Power

Manager

Temper-

ature
Shut­down

DC-ok
LED

Input Fuse
Input Filter
Active Inrush
Limiter

V

OUT

Power

Converter

+

-

Reverse Polarity
and Back-feeding
Protection

-

Apr. 2018 / Rev. 1.0 DS-CP10.241-60-EN All parameters are typical values specified at 24V, 8.3A output, 110Vdc input,
25°C ambient and after a 5 minutes run-in time unless otherwise noted.

www.pulspower.com Phone [phone] Germany