Puls CP5.481 Data Sheet

CP5.481

CP-Series

48V, 2.5A, 120W, SINGLE PHASE INPUT

1/28

POWER SUPPLY

▪ AC 100-240V Wide-range Input
▪ Width only 32mm
▪ Efficiency up to 93.5%
▪ Excellent Partial Load Efficiency
▪ 20% Output Power Reserves
▪ Easy Fuse Breaking – 3 times nominal current for 12ms
▪ Safe Hiccup

PLUS

Overload Mode

▪ Active Power Factor Correction (PFC)
▪ Minimal Inrush Current Surge
▪ Full Power Between -25°C and +60°C
▪ DC-OK Relay Contact
▪ 3 Year Warranty

PRODUCT DESCRIPTION

SHORT-FORM DATA

Output voltage

DC 48V

Nominal

Adjustment range

48 - 56V

Factory setting 48.0V

Output current

3.0 – 2.6A

Below +45°C ambient

2.5 – 2.1A

At +60°C ambient

1.9 – 1.6A

At +70°C ambient

Derate linearly between +45°C and +70°C

Input voltage AC

AC 100-240V

-15%/+10%

Mains frequency

50-60Hz

±6%

Input current AC

1.09 / 0.61A

At 120 / 230Vac

Power factor

0.98 / 0.91

At 120 / 230Vac

Input voltage DC

DC 110-150V

±20%

For CP5.481

Input current DC

1.21 / 0.43A

At 110 / 300Vdc

AC Inrush current

4 / 4A

At 120 / 230Vac

Efficiency

92.6 / 93.5%

At 120 / 230Vac

Losses

9.6 / 8.4W

At 120 / 230Vac

Hold-up time

35 / 35ms

At 120 / 230Vac

Temperature range

-25°C to +70°C

Size (WxHxD)

32x124x102mm

Without DIN-rail

Weight

440g / 0.97lb

ORDER NUMBERS

MAIN APPROVALS

IEC 62368-1

IEC 61010-2-201

The Dimension CP-Series are cost optimized power supplies
without compromising quality, reliability and performance. The
CP-Series is part of the DIMENSION power supply family.

While the CP5.481 covers an additional DC-input range up to
150Vdc.

The most outstanding features of these units are the small size,
the high efficiency, the electronic inrush current limitation,
active PFC and the wide operational temperature range. The
devices have a power reserve of 20% included, which may even
be used continuously at temperatures up to +45°C. Additionally,
they can deliver 3 times the nominal output current for 12ms
which helps to trip fuses on faulty output branches.

High immunity to transients and power surges as well as low
electromagnetic emission, a DC-OK signal contact for remote
monitoring, and a large international approval package for a
variety of applications makes this unit suitable for nearly every
situation.

Power Supply CP5.481 Screw terminals

Mechanical Accessory

ZM10.WALL Wall/Panel mount bracket

May 2020 / Rev. 1.1 DS-CP5.481-EN All parameters are typical values specified at 230Vac, 50Hz input voltage, 48V, 2.5A output load,
25°C ambient and after a 5 minutes run-in time unless otherwise noted.

For details or a complete approval list see chapter 19.

CP5.481

CP-Series

48V, 2.5A, 120W, SINGLE PHASE INPUT

2/28

INDEX

TERMINOLOGY AND ABREVIATIONS

Page Page

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

2. Installation Instructions ................................................ 3

3. AC-Input ....................................................................... 5

4. DC-Input ....................................................................... 6

5. Input Inrush Current ..................................................... 7

6. Output .......................................................................... 8

7. Hold-up Time .............................................................. 10

8. DC-OK Relay Contact .................................................. 10

9. Efficiency and Power Losses ....................................... 11

10. Functional Diagram .................................................... 12

11. Front Side and User Elements .................................... 12

12. Connection Terminals ................................................ 13

13. Lifetime Expectancy ................................................... 14

14. MTBF .......................................................................... 14

15. EMC ............................................................................ 15

16. Environment ............................................................... 17

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

18. Dielectric Strength ...................................................... 19

The information given in this document is correct to the best of our knowledge and experience at the time of publication. If not
expressly agreed otherwise, this information does not represent a warranty in the legal sense of the word. As the state of our
knowledge and experience is constantly changing, the information in this data sheet is subject to revision. We therefore kindly ask you
to always use the latest issue of this document

No part of this document may be reproduced or utilized in any form without our prior permission in writing.
Packaging and packaging aids can and should always be recycled. The product itself may not be disposed of as domestic refuse.

19. Approvals and Fulfilled Standards.............................. 20

20. Regulatory Compliance .............................................. 20

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

22. Accessories................................................................. 22

22.1. ZM10.WALL – Wall/Panel Mount Bracket ........ 22

22.2. YR2.DIODE - Redundancy Module .................... 23

22.3. UF20.481 Buffer Module .................................. 23

23. Application Notes....................................................... 24

23.1. Peak Current Capability .................................... 24

23.2. Charging of Batteries ........................................ 25

23.3. Series Operation ............................................... 25

23.4. Parallel Use to Increase Output Power ............ 25

23.5. Parallel Use for Redundancy ............................ 26

23.6. Operation on Two Phases ................................ 27

23.7. Use in a Tightly Sealed Enclosure ..................... 27

23.8. Mounting Orientations ..................................... 28

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.
AC 230V A figure displayed with the AC or DC before the value represents a nominal voltage with standard tolerances

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

230Vac A figure with the unit (Vac) at the end is a momentary figure without any additional tolerances included.
50Hz vs. 60Hz As long as not otherwise stated, AC 230V parameters are valid at 50Hz mains frequency.
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.

May 2020 / Rev. 1.1 DS-CP5.481-EN All parameters are typical values specified at 230Vac, 50Hz input voltage, 48V, 2.5A output load,
25°C ambient and after a 5 minutes run-in time unless otherwise noted.

CP5.481

CP-Series

48V, 2.5A, 120W, SINGLE PHASE INPUT

3/28

1. INTENDED USE

2. INSTALLATION INSTRUCTIONS

WARNING

This device is designed for installation in an enclosure and is intended for commercial use, such as in industrial control, process control,
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.
If this device is used in a manner outside of its specification, the protection provided by the device may be impaired.

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 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.

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

inspection.
Install the 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. Use ferrules for wires
on the input terminals. 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 isolation of the device is designed to withstand impulse voltages of overvoltage category III according to IEC 60664-1.
The device is designed as “Class of Protection I” equipment according to IEC 61140. Do not use without a proper PE (Protective Earth)

connection.
The device is suitable to be supplied from TN, TT or IT mains networks. The continuous voltage between the input terminal and the PE

potential must not exceed 300Vac.
The input can also be powered from batteries or similar DC sources. The continuous voltage between the supply voltage and the

PE/ground potential must not exceed 360Vdc.
A disconnecting means shall be provided for the input of the device.
The device is designed for convection cooling and does not require an external fan. Do not obstruct airflow and do not cover ventilation

grid!
The device is designed for altitudes up to 5000m (16400ft). Above 2000m (6560ft) a reduction in output current and over voltage

category is required.

May 2020 / Rev. 1.1 DS-CP5.481-EN All parameters are typical values specified at 230Vac, 50Hz input voltage, 48V, 2.5A output load,
25°C ambient and after a 5 minutes run-in time unless otherwise noted.

CP5.481

CP-Series

48V, 2.5A, 120W, SINGLE PHASE INPUT

4/28

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 32A (IEC) and 30A (UL) without additional protection device. If an
external fuse is utilized, do not use circuit breakers smaller than 6A 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.

May 2020 / Rev. 1.1 DS-CP5.481-EN All parameters are typical values specified at 230Vac, 50Hz input voltage, 48V, 2.5A output load,
25°C ambient and after a 5 minutes run-in time unless otherwise noted.

CP5.481

CP-Series

48V, 2.5A, 120W, SINGLE PHASE INPUT

5/28

3. AC-INPUT

AC input

Nom.

AC 100-240V

AC input range

Min.

85-264Vac

Continuous operation

Min.

264-300Vac

Occasionally for maximal 500ms

Allowed voltage L or N to earth

Max.

300Vac

Continuous, according to IEC 60664-1

Input frequency

Nom.

50–60Hz

±6%

Turn-on voltage

Typ.

80Vac

Steady-state value, see Fig. 3-1

Shut-down voltage

Typ.

74Vac

Steady-state value, see Fig. 3-1

External input protection

See recommendations in chapter 2.

AC 100V

AC 120V

AC 230V

Input current

Typ.

1.31A

1.09A

0.61A

At 48V, 2.5A, see Fig. 3-3

Power factor

Typ.

0.99

0.98

0.91

At 48V, 2.5A, see Fig. 3-4

Crest factor

Typ.

1.7

1.8

2.2

At 48V, 2.5A, The crest factor is the
mathematical ratio of the peak value to
RMS value of the input current
waveform.

Start-up delay

Typ.

420ms

370ms

385ms

See Fig. 3-2

Rise time

Typ.

110ms

110ms

115ms

At 48V, 2.5A const. current load, 0mF
load capacitance, see Fig. 3-2

Typ.

160ms

160ms

160ms

At 48V, 2.5A const. current load, 5mF
load capacitance,, see Fig. 3-2

Turn-on overshoot

Max.

600mV

600mV

600mV

See Fig. 3-2

Fig. 3-1 Input voltage range

Fig. 3-2 Turn-on behavior, definitions

Turn-on

85V

Rated

input range

max.

500ms

V

IN

P

OUT

300Vac264V

Shut-down

Start-up

delay

Rise

Time

Overshoot

- 5%

Output
Voltage

Input
Voltage

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

voltage

Fig. 3-4 Power factor vs. output current at 24V output

voltage

3A

0.25 0.5 1.0 1.5 2.0

0

0.25

0.5

0.75

1.0

1.25

1.5A

Input Current, typ.

2.5

a) 100Vac
b) 120Vac
c) 230Vac

Output Current

(a)
(b)

(c)

Power Factor, typ.

0.5 1.0 1.5 2.0 2.5 3A

0.75

0.8

0.85

0.9

0.95

1.0

Output Current

(a) 100Vac,
(b) 120Vac,
(c) 230Vac

(a)

(b)

(c)

The device is suitable to be supplied from TN, TT or IT mains networks with AC voltage. For suitable DC supply voltages see chapter 4.

May 2020 / Rev. 1.1 DS-CP5.481-EN All parameters are typical values specified at 230Vac, 50Hz input voltage, 48V, 2.5A output load,
25°C ambient and after a 5 minutes run-in time unless otherwise noted.

CP5.481

CP-Series

48V, 2.5A, 120W, SINGLE PHASE INPUT

6/28

4. DC-INPUT

DC input

Nom.

DC 110-150V

±20%

DC input range

Min.

88-180Vdc

Continuous operation

DC input current

Typ.

1.21A

At 110Vdc, at 48V, 2.5A

Typ.

0.43A

At 300Vdc, at 48V, 2.5A

Allowed Voltage (+) or (-) input to
Earth

Max.

360Vdc

Continuous according to IEC 60664-1

Turn-on voltage

Typ.

74Vdc

Steady state value

Shut-down voltage

Typ.

67Vdc

Steady state value

Fig. 4-1 Wiring for DC Input

+

-

Load

L

PE

+

-

Power Supply

AC

DC

Battery

N

The device is suitable to be supplied from a DC input voltage. Use a battery or a similar DC source. A supply from the intermediate DC­bus of a frequency converter is not recommended and can cause a malfunction or damage the unit.

Connect +pole to L, –pole to N and the PE terminal to an earth wire or to the machine ground.

May 2020 / Rev. 1.1 DS-CP5.481-EN All parameters are typical values specified at 230Vac, 50Hz input voltage, 48V, 2.5A output load,
25°C ambient and after a 5 minutes run-in time unless otherwise noted.

CP5.481

CP-Series

48V, 2.5A, 120W, SINGLE PHASE INPUT

7/28

5. INPUT INRUSH CURRENT

AC 100V

AC 120V

AC 230V

Inrush current

Max.

8A

peak

7A

peak

7A

peak

At 40°C, cold start

Typ.

5A

peak

4A

peak

4A

peak

At 25°C, cold start

Typ.

5A

peak

5A

peak

6A

peak

At 40°C, cold start

Inrush energy

Max.

0.4A²s

0.5A²s

1A²s

At 40°C, cold start

Fig. 5-1 Typical turn-on behaviour at nominal load,

120Vac input and 25°C ambient

Fig. 5-2 Typical turn-on behaviour at nominal load,
230Vac input and 25°C ambient

50ms/DIV

Output voltage

Input
voltage
200V/DIV

Input
current
2A/DIV

4A

50ms/DIV

Input
current
2A/DIV

Input
voltage
200V/DIV

Output voltage

4A

An active inrush limitation circuit (NTCs, which are 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.

May 2020 / Rev. 1.1 DS-CP5.481-EN All parameters are typical values specified at 230Vac, 50Hz input voltage, 48V, 2.5A output load,
25°C ambient and after a 5 minutes run-in time unless otherwise noted.

CP5.481

CP-Series

48V, 2.5A, 120W, SINGLE PHASE INPUT

8/28

6. OUTPUT

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 settings

Typ.

48.0V

±0.2%, at full load and cold unit

Line regulation

Max.

10mV

Between 85 and 300Vac

Load regulation

Max.

50mV

Between 0A and 3A, static value, see Fig. 6-1

Ripple and noise voltage

Max.

50mVpp

Load >0.1A, Bandwidth 20Hz to 20MHz, 50Ohm

Max.

300mVpp

Load <0.1A, Bandwidth 20Hz to 20MHz, 50Ohm

Output current

Nom.

3A1)

At 48V and an ambient temperatures below 45°C

Nom.

2.5A

At 48V and 60°C ambient temperature

Nom.

1.9A

At 48V and 70°C ambient temperature

Nom.

2.6A1)

At 56V and an ambient temperatures below 45°C

Nom.

2.1A

At 56V and 60°C ambient temperature

Nom.

1.6A

At 56V and 70°C ambient temperature

Derate linearely between +45°C and +70°

Fuse breaking current

Typ.

7.5A

Up to 12ms once every five seconds, see Fig. 6-2.
The fuse braking current is an enhanced transient current
which helps to trip fuses on faulty output branches. The
output voltage stays above 40V.

Overload behaviour

Continuous current

For output voltage above 26Vdc, see Fig. 6-1

Intermittent current2)

For output voltage below 26Vdc, see Fig. 6-1

Overload/ short-circuit current

Max.

3.4A

Continuous current, see Fig. 6-1

Typ.

5A

Intermitted current peak value for typ. 1s
Load impedance 50mOhm, see Fig. 6-3
Discharge current of output capacitors is not included.

Max.

1.5A

Intermitted current average value (R.M.S.)
Load impedance 50mOhm, see Fig. 6-3

Output capacitance

Typ.

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.

The output provides a SELV/PELV rated voltage, which is galvanically isolated from the input voltage.
The output 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 > 0.1F are connected to the output, the unit might charge the
capacitor in an intermittent mode.

The output is electronically protected against overload, no-load and short-circuits. In case of a protection event, audible noise may
occur.

1) This current is also available for temperatures up to +70°C with a duty cycle of 10% and/ or not longer than 1 minute every 10 minutes.

2) At heavy overloads, the power supply delivers continuous output current for 1s. After this, the output is switched off for approx. 9s 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. 6-3.

May 2020 / Rev. 1.1 DS-CP5.481-EN All parameters are typical values specified at 230Vac, 50Hz input voltage, 48V, 2.5A output load,
25°C ambient and after a 5 minutes run-in time unless otherwise noted.

CP5.481

CP-Series

48V, 2.5A, 120W, SINGLE PHASE INPUT

9/28

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

Fig. 6-2 Dynamic output current capability, typ.

Output Voltage

0

0 3

8

16

24

56V

32

40

48

5A20.5 1 2.5 3.5 41.5 4.5

Adjustment

Range

Output Current

A: continuous current
B: intermittent current

A

B

Output Voltage

(dynamic behavior, < 12ms)

0

0

8

16

24

56V

32

40

48

10A42 6 81 3 5 7 9

Adjustment

Range

Output Current

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

PLUS

mode, typ.

Output
Current

0

5A

9s

9s

9s

1s

1s

1s

t

Short -circuit

Normal

operation

Normal

operation

May 2020 / Rev. 1.1 DS-CP5.481-EN All parameters are typical values specified at 230Vac, 50Hz input voltage, 48V, 2.5A output load,
25°C ambient and after a 5 minutes run-in time unless otherwise noted.