Puls Dimension CD, Dimension CD5.242, Dimension CD5.241, Dimension CD5.241-S1, CD5.242 Series 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
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
July 08 / Rev. 1.2 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
18WM
R
UL 60950-1
Marine
GL
Class I Div 2,
pending
EMC, LVD
1/21
CDSeries
DC/DC Converter; 24V, 5A
CD5.242
INDEX PAGE INDEX PAGE
1. 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.
July 08 / Rev. 1.2 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
2/21
CDSeries
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
P
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, constant current load, see Fig. 5-3
typ. 150ms 5mF, 24V, 5A, constant current load, see Fig. 5-3
60.0Vdc
500mV 800µF
V
IN
63.5Vdc
Overshoot
See Fig. 5-3
Fig. 5-2 Allowable output current below 36V
Output Current
6A
5
4
3
2
1
0
30 32 34 36 40Vdc
Input
4A
Current, typ.
3
2
1
0
1
1.5 2 3
input voltage
(a) Ambient < 45°C (b) Ambient < 60°C
Input Voltage
Output Current
3.5
2.5
u
p
n
I
n
I
4
t
p
4.5
)
a
(
)
b
(
38
c
d
V
6
3
:
V
8
4
:
t
u
5
d
5.5
c
6A
max.
July 08 / Rev. 1.2 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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3/21
CDSeries
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
July 08 / Rev. 1.2 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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4/21
A
c
CDSeries
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
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.
max.
24.1V 25mV
50mVpp 2200µF
±0.2%, at full load, cold unit
Input variations between 36 to 60Vdc
20Hz to 20MHz, 50Ohm
At 24V, ambient < 60°C, see
Fig. 7-1
nom. 5.1A At 28V, ambient < 45°C, see Fig. 7-1 nom. 4.3A
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
24
20
16
12
8
4 0
Adjustment
Range
Output Current
048
1062
12
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
July 08 / Rev. 1.2 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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5/21
CDSeries
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
10
8
6
4
2
0
Input Voltage
36 40 44 48 56Vdc
)
(
a
(
b
)
)
(
c
)
(
d
(a) 24V, 2.5A, typ. (b) 24V, 2.5A, min. (c) 24V, 5A, typ. (d) 24V, 5A, min.
52
Fig. 8-2 Shut-down test setup Fig. 8-3 Shut-down behavior, definitions
DC/DC
Converter
S1
Input
Output
CD5
+
+
Load
-
-
DC
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.
July 08 / Rev. 1.2 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
6/21
A
A
c
c
CDSeries
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%
90
89
88
87
86
85
1
Output Current
2453
6
Fig. 9-2 Losses vs. output current at 24V
output voltage and 48V input voltage
Power Losses
18W
15
12
9
6
3
0
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
48
Vd
Fig. 9-4 Losses vs. input voltage, 24V, 5A
Power Losses
18W
15
12
9
6
3
0
36 40 48 52 56 60
Output Current
3
output
Input Voltage
44
CD5.242
Vd
July 08 / Rev. 1.2 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
7/21
CDSeries
DC/DC Converter; 24V, 5A
CD5.242
10. FUNCTIONAL DIAGRAM
Fig. 10-1 Functional diagram
Output
Voltage
Regulator
+
Chassis
Ground
-
Input Fuse & Input Filter
Reverse Polarity Protection & Inrush Limiter
Over-
Temperature
Protection
Output
Over-
Voltage
Protection
Power
Converter
Output
Filter
V
OUT
+ +
-
-
DC ok
11. RELIABILITY
Input: 48Vdc
Lifetime expectancy min. 169 000h 40°C, 24V, 2.5A min. 64 000h 40°C, 24V, 5A min. 39 000h 40°C, 24V, 6A min. 181 000h 25°C, 24V, 5A MTBF SN 29500, IEC 61709 951 000h 40°C, 24V, 5A 1 560 000h 25°C, 24V, 5A MTBF MIL HDBK 217F 559 000h 40°C, 24V, 5A, Ground Benign GB40 749 000h 25°C, 24V, 5A, Ground Benign GB25
The Lifetime expectancy shown in the table indicates the operating hours (service life) and is determined by the lifetime expectancy of the built-in electrolytic capacitors. Lifetime expectancy is specified in operational hours. Lifetime expectancy is calculated according to the capacitor’s manufacturer specification. The prediction model allows a calculation of up to 15 years from date of shipment.
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.
July 08 / Rev. 1.2 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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8/21
CDSeries
12. FRONT SIDE AND USER ELEMENTS
Fig. 12-1
Front side
A Output Terminals Screw terminals
Dual terminals per pole + Positive output
- Negative (return) output
Input Terminals
B Screw terminals + Positive input
- Negative (return) input Chassis ground can be used to bond the housing to PE Ground this terminal to minimize high-frequency emissions.
Output voltage potentiometer
C Open the flap to set the output voltage. Factory set: 24.1V
D DC-OK LED (green)
On when the voltage on the output terminals is > 21V
CD5.242
DC/DC Converter; 24V, 5A
13. TERMINALS AND WIRING
Type Screw terminals Solid wire 0.5-6mm Stranded wire 0.5-4mm2 American wire gauge 20-10 AWG Recommended tightening torque 1Nm, 9lb.in Screwdriver 3.5mm slotted or Pozidrive No 2 Wire stripping length 7mm / 0.275inch
Instructions:
a) Use appropriate copper cables that are designed for an operating temperature of:
60°C for ambient up to 45°C and
75°C for ambient up to 60°C minimum. b) Follow local and national installation codes and regulations! c) Ensure that all strands of a stranded wire enter the terminal connection! d) Up to two stranded wires with the same cross section are permitted in one connection point. e) Ferrules are allowed but not required f) In order to fulfill GL requirements, unused terminal spaces must be closed.
2
July 08 / Rev. 1.2 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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9/21
CDSeries
DC/DC Converter; 24V, 5A
CD5.242
14. EMC
The CE mark indicates conformance with EMC directive 89/336/EC, 93/68/EC and 2004/108/EC and the low-voltage directive (LVD) 73/23/EC, 93/68/EC, 2006/95/EC. A detailed EMC Report is available on request.
EMC Immunity
Electrostatic discharge EN 61000-4-2 Contact discharge
Electromagnetic RF field EN 61000-4-3 80MHz-2.7GHz 10V/m Criterion A
Fast transients (Burst) EN 61000-4-4 Input lines
Surge voltage on input EN 61000-4-5 + Æ -
Surge voltage on output EN 61000-4-5 + Æ -
Conducted disturbance EN 61000-4-6 0,15-80MHz 10V Criterion A
Criterions:
A: DC/DC converter shows normal operation behavior within the defined limits. C: Temporary loss of function is possible. DC/DC converter might shut-down and restarts by itself. No damage or hazards will occur
to the DC/DC converter.
EMC Emission
Conducted emission IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 Class B, Input lines (Limits for DC power ports) Radiated emission EN 55011, EN 55022 Class B
This device complies with FCC Part 15 rules. Operation is subjected to the 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
EN 61000-6-2, EN 61000-6-1
Air discharge
Output lines Signal lines
+ / - Æ chassis ground
+ / - Æ chassis ground
EN 61000-6-3, EN 61000-6-4 Generic standards
90kHz to 140kHz (Output current > 0.5A) Input voltage and output current
Generic standards 8kV
15kV
4kV 2kV 2kV
1kV 2kV
500V 500V
dependent
Criterion A Criterion A
Criterion A Criterion A Criterion A
Criterion A Criterion A
Criterion A Criterion A
July 08 / Rev. 1.2 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
10/21
C
CDSeries
DC/DC Converter; 24V, 5A
CD5.242
15. ENVIRONMENT
Operational temperature -25°C to +70°C (-13°F to 158°F) Reduce output power according to Fig. 15-1 Output de-rating 1.6W/°C 45-60°C (113°F to 140°F), see Fig. 15-1 3W/°C 60-70°C (140°F to 158°F), see Fig. 15-1 Storage temperature -40 to +85°C (-40°F to 185°F) During storage and transportation
Humidity 5 to 95% r.H. IEC 60068-2-30
Vibration sinusoidal 2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g
Shock 30g 6ms, 20g 11ms
2 hours / axis
3 bumps / direction, 18 bumps in total
Altitude 0 to 6000m (0 to 20000ft) Reduce output power or ambient
Output de-rating (for altitude) 7.5W/1000m or 5°C/1000m Above 2000m (6500ft), see Fig. 15-2 Over-voltage category III EN 50178, altitudes up to 2000m II Altitudes from 2000m to 6000m Degree of pollution 2 EN 50178, non conductive
Fig. 15-1 Output current vs. ambient temp. Fig. 15-2 Output current vs. altitude, 24V
Allowable Output Current at 24V
6A
5
4
3
2
1
0
-25 0 20 40
c
n
o
n
i
t
u
o
u
s
Ambient Temperature
60
s
h
r
o
t
t
e
r
m
70°
Allowable Output Current at 24V
6A
5
4
3
2
1
0
The ambient temperature is defined 2cm below the unit.
Do not energize while condensation is present
IEC 60068-2-6
IEC 60068-2-27
temperature above 2000m sea level.
h
s
r
o
t
t
e
m
r
C
B
A
.
A
.
a
.
T
b
m
<
6
C
°
.
B
.
.
T
C
.
.
.
T
0 2000 4000
0
a
b
m
5
<
C
°
0
a
b
m
4
<
C
°
0
Altitude
6000m
July 08 / Rev. 1.2 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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11/21
CDSeries
DC/DC Converter; 24V, 5A
CD5.242
16. PROTECTION FEATURES
Output protection Electronically protected against overload, no-load and short-circuits Output over-voltage protection typ. 31Vdc
max. 32Vdc
Reverse input polarity protection included Unit does not start when input voltage is reversed Output over-current protection electronically limited See Fig. 7-1 Degree of protection IP 20 EN/IEC 60529 Penetration protection > 3.5mm E.g. screws, small parts Over-temperature protection yes Output shut-down with automatic restart Input transient protection MOV Metal Oxide Varistor Internal input fuse T5A H.B.C. Not user replaceable
An audible noise may be heard during a no load, overload or short circuit event.
In case of an internal DC/DC converter fault, a redundant circuit limits the maximum output voltage. The output shuts down and automatically attempts to restart.
17. SAFETY
Input / output separation SELV IEC/EN 60950-1 PELV EN 60204-1, EN 50178, IEC 60364-4-41
Class of protection II PE (Protective Earth) connection not required Isolation resistance > 5MOhm Input to output, 500Vdc Chassis Ground resistance < 0.1Ohm Between housing and Chassis Ground terminal
Touch current (leakage current) The leakage current which is produced by the DC/DC converter itself depends on
Double or reinforced insulation, Max. allowed voltage between any input pin and ground: 60Vdc or 42.4Vac
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.
18. DIELECTRIC STRENGTH
The output voltage is floating and has no ohmic connection to ground. To fulfill the PELV requirements according to EN60204-1 § 6.4.1, it is recommend that either the + pole, the – pole or
any other part of the output circuit shall be connected to the protective earth system. This helps to avoid situations in which a load starts unexpectedly or can not be switched off any more when an unnoticed earth faults occur.
Fig. 18-1 Dielectric strength
Input
+
-
A
Chassis ground
B
C
Output
+
-
Type test 60s 1500Vac 1500Vac 500Vac
Factory test 5s 1500Vac 1500Vac 500Vac
Field test 5s 1000Vac 1000Vac 500Vac Type tests and factory tests:
Conducted by the manufacturer. Do not repeat test in field! Rules for field test: Use appropriate test equipment which applies the voltage with a slow ramp! Connect all input poles together as well as all output poles.
A B C
July 08 / Rev. 1.2 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
12/21
CDSeries
DC/DC Converter; 24V, 5A
CD5.242
19. APPROVALS
IEC 60950-1
IECEE
CB SCHEME
UL 508
UL 60950-1
UL 1604
pending
The unit is suitable for use in Class I Division 2 Groups A, B, C, D locations as well as for Class I
CSA pending
Marine
pending
Zone 2 Groups IIA, IIB and IIC locations. Substitution of components may impair suitability for Class I Division 2 environment. Do not disconnect equipment unless power has been switched off. Wiring must be in accordance with Class I, Division 2 wiring methods of the National Electrical Code, NFPA 70, and in accordance with other local or national codes.
18WM
LISTED
IND. CONT. EQ.
R
CUS
182790
GL
ABS
CB Scheme, Information Technology Equipment
LISTED E198865 Industrial Control Equipment
RECOGNIZED E137006 recognized for the use in U.S.A. (UL 60950-1) and Canada (C22.2 No. 60950) Information Technology Equipment, Level 3
RECOGNIZED E246877 recognized for use in U.S.A. (UL 1604) and Canada (C22.2 No. 213-M1987) Hazardous Location Class I Div 2 T4 Groups A,B,C,D and Class I Zone 2 Groups IIA, IIB and IIC
CSA approval for Canada CAN/CSA C22.2 No 107-1; CAN/ CSA 60950-1-03; UL60950-1
GL (Germanischer Lloyd) classified and ABS (American Bureau for Shipping) PDA for marine and offshore applications.
Environmental category: C, EMC2
20. FULFILLED STANDARDS
EN 61558-2-17 Safety of Power Transformers
EN/IEC 60204-1 Safety of Electrical Equipment of Machines
EN/IEC 61131-2 Programmable Controllers
EN 50178, IEC 62103 Electronic Equipment in Power Installations
21. USED SUBSTANCES
The unit does not release any silicone and is suitable for the use in paint shops.
The unit conforms to the RoHS directive 2002/96/EC
Electrolytic capacitors included in this unit do not use electrolytes such as Quaternary Ammonium Salt Systems.
Plastic housings and other molded plastic materials are free of halogens, wires and cables are not PVC insulated.
The materials used in our production process do not include the following toxic chemicals: Polychlorinated Biphenyl (PCB), Pentachlorophenol (PCP), Polychlorinated naphthalene (PCN), Polybrominated Biphenyl (PBB), Polybrominated Biphenyl Oxide (PBO), Polybrominated Diphenyl Ether (PBDE), Polychlorinated Diphenyl Ether (PCDE), Polybrominated Diphenyl Oxide (PBDO), Cadmium, Asbestos, Mercury, Silica
July 08 / Rev. 1.2 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
13/21
CDSeries
DC/DC Converter; 24V, 5A
CD5.242
22. PHYSICAL DIMENSIONS AND WEIGHT
Weight 425g / 0.94lb DIN-Rail Use 35mm DIN-rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm.
The DIN-rail height must be added to the depth (102mm) to calculate the total required installation depth.
Electronic files with mechanical data can be downloaded at www.pulspower.com
Fig. 22-1
Front view
Fig. 22-2
Side view
23. INSTALLATION AND OPERATION INSTRUCTIONS
Mounting:
Output terminal must be located on top and input terminal on the bottom. For other orientations see chapter 25.13. An appropriate electrical and fire end-product enclosure should be considered in the end use application.
Cooling:
Convection cooled, no forced cooling required. Do not cover ventilation grill (e.g. cable conduits) by more than 30%!
Installation clearances:
40mm on top, 20mm on the bottom, 5mm on the left and right side are recommended when loaded permanently with full power. In case the adjacent device is a heat source, 15mm clearance are recommended.
Risk of electrical shock, fire, personal injury or death!
Turn power off before working on the DC/DC converter. Protect against inadvertent re-powering. Make sure the wiring is correct by following all local and national codes. Do not open, modify or repair the unit. Use caution to prevent any foreign objects from entering into the housing. Do not use in wet locations or in areas where moisture or condensation can be expected.
Supplying source:
The inductance and resistance of the supplying network shall be below in Fig. 25-9 in chapter 25.10 to avoid resonant effects on the input terminals. Please also check chapter 25.10.
Service parts: The unit does not contain any service parts. The tripping of an internal fuse is caused by an internal fault. If damage or malfunctioning should occur during operation, immediately turn power off and send unit to the factory for inspection!
July 08 / Rev. 1.2 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
14/21
CDSeries
DC/DC Converter; 24V, 5A
CD5.242
24. ACCESSORY
ZM1.WALL Wall mounting bracket This bracket is used to mount specific Dimension units onto a flat surface without utilizing a DIN-Rail. The two
aluminum brackets and the black plastic slide of the unit have to be removed, so that the two steel brackets can be mounted.
(Please note: Picture shows a different unit)
Fig. 24-1 ZM1.WALL Wall Mounting Bracket Fig. 24-2 Assembled Wall Mounting Bracket
ZM11.SIDE Side mounting bracket This bracket is used to mount specific Dimension units sideways with or without utilizing a DIN-Rail. The two
aluminum brackets and the black plastic slide of the unit have to be removed, so that the steel bracket can be mounted.
For sideways DIN-rail mounting, the removed aluminum brackets and the black plastic slide need to be reinstalled on the steel bracket.
(Please note: Pictures show a different unit)
Fig. 24-3 ZM11.SIDE Side Mounting Bracket Fig. 24-4 Side Mounting with DIN-rail brackets
July 08 / Rev. 1.2 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
15/21
CDSeries
DC/DC Converter; 24V, 5A
CD5.242
25. APPLICATION NOTES
25.1. PEAK CURRENT CAPABILITY
Solenoids, contactors and pneumatic modules often have a steady state (sealed) 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 (including the PowerBoost) The same situation applies, when starting a capacitive load.
Branch circuits are often protected with circuit breakers or fuses. In case of a short or an overload in the branch circuit, the fuse needs a certain amount of over-current to trip or to blow. The peak current capability ensures the safe operation of subsequent circuit breakers.
Assuming the input voltage is turned on before such an event, the built-in large sized output capacitors inside the DC/DC converter can deliver extra current. Discharging this capacitor causes a voltage dip on the output. The following two examples show typical voltage dips:
Fig. 25-1 Peak load 10A for 50ms, typ. Fig. 25-2 Peak load 20A for 5ms, typ.
24V
Output Voltage
24V
10A
0.7A
10ms/DIV
Peak load 10A (resistive) for 50ms
Output voltage dips from 24V to 17.1V.
17.1V
Output Current
20A
0.7A 1ms/DIV
Peak load 20A (resistive) for 5ms
Output voltage dips from 24V to 11V.
Output Voltage
11V
Output Current
25.2. BACK-FEEDING LOADS
Loads such as decelerating motors and inductors can feed voltage back to the DC/DC converter. This feature is also called return voltage immunity or resistance against Back- E.M.F. (E
This DC/DC converter is resistant and does not show malfunctioning when a load feeds back voltage to the DC/DC converter. It does not matter, whether the DC/DC converter is on or off.
The maximum allowed feed back voltage is 30Vdc. The absorbing energy can be calculated according to the built-in large sized output capacitor which is specified in chapter 7.
lectro Magnetic Force).
25.3. INDUCTIVE AND CAPACITIVE LOADS
The unit is designed to supply any kind of load, including unlimited capacitive and inductive loads.
July 08 / Rev. 1.2 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
16/21
CDSeries
DC/DC Converter; 24V, 5A
CD5.242
25.4. OUTPUT CIRCUIT BREAKERS
Standard miniature circuit breakers (MCBs or UL1077 circuit breakers) can be used for branch circuit protection. Ensure that the MCB is also rated for DC voltage. The following tests show which circuit breakers the DC/DC converter typically trips.
Circuit breakers have huge tolerances in their tripping behavior, therefore, these typical tests can only be used as a recommendation or for comparing two different DC/DC converters. Furthermore, the loop impedance has a major influence on whether a breaker trips or not. Two tests were performed, representing typical situations:
Test 1: Short circuit with S1 on the DC/DC converter end of the cable (loop impedance approx. 20mOhm)
Fig. 25-3 Branch protectors, test circuit 1
Circuit
Breaker
I
+
S1
-
+
Load
-
DC/DC
Converter
Input
DC
Test 2: Short circuit with S1 on the load end (additional impedance included; represents longer load wire length).
Fig. 25-4 Branch protectors, test circuit 2
Circuit
DC/DC
Converter
AC
DC
Breaker
I
+
-
R
+
S1 Load
-
*) A list of the circuit breakers under test is available on request.
Example: Which wire gauge must be used to trip a C-Characteristic circuit breaker with a rating of 3A? The load wire length is 21m.
Answer: A 3A C-Characteristic circuit breaker requires a loop impedance of less than 270mOhm (test results). The wire length table shows that up to 23m wire with a cross section of 1.5mm
2
1.5mm
shall be used.
180mOhm
270mOhm
Parameters: Input voltage: 24Vdc, load current: 0A
The following circuit breaker tripped during the test:
A- or Z- Characteristic:: equal or smaller 8A *) B- Characteristic: no tripping 6A *)
no breaker available < 6A C- Characteristic: equal or smaller 3A *)
Parameters: Input voltage: 24Vdc, load current: 0A
The following circuit breaker tripped during the test:
A- or Z- Characteristic:: 6A and R= 180mOhm *) B- Characteristic: no tripping 6A *)
no breaker available < 6A C- Characteristic: ≤ 3A and R= 270mOhm *)
What does this resistance mean in wire length?
2
0.5mm
0.7mm2 1.0mm2 1.5mm2 2.5mm2 4.0mm2
5.0m 7.0m 10m 15m 25m 40m
7.5m 10.5m 15m 23m 38m 60m
2
are below 270mOhm. A wire not smaller than
July 08 / Rev. 1.2 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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CDSeries
25.5. SERIES OPERATION
DC/DC converters can be connected in series to increase the output voltage.
Fig. 25-5 Schematic for series operation
Unit A
Input
Unit B
Input
Output
+
-
+
Output
-
+
Load
-
Earth (see notes)
Instructions for use in series:
a) It is possible to connect as many units in series as needed,
providing the sum of the output does not exceed 150Vdc.
b) Voltages with a potential above 60Vdc are not SELV any more
and can be dangerous. Such voltages must be installed with a
protection against touching. c) For serial operation use DC/DC converters of the same type. d) Earthing of the output is required when the sum of the output
voltage is above 60Vdc. e) Keep an installation clearance of 15mm (left/right) between
two DC/DC converters and avoid installing the DC/DC
converters on top of each other. Note:
Avoid return voltage (e.g. from a decelerating motor or
battery) which is applied to the output terminals.
CD5.242
DC/DC Converter; 24V, 5A
25.6. PARALLEL USE TO INCREASE OUTPUT POWER
Several DC/DC converter can be paralleled to increase the output power.
Fig. 25-6 Schematic for parallel operation
Unit A
Input
Output
Unit B
Input
Output
Fuse
+
-
Fuse
+
-
*)
+
*)
Load
-
Instructions for parallel use:
a) Use only DC/DC converters from the same series (C-Series) or
consult PULS. b) Adjust the output voltages of all power supplies to
approximately the same value (±200mV). c) A fuse (or diode) on the output is only required if more than
three units are connected in parallel. d) Do not load terminals with more than 25A. Follow wiring
instructions according to chapter 25.7 e) Ensure that the ambient temperature of the power supply does
not exceed 45°C.
25.7. DAISY CHAINING OF OUTPUTS
Daisy chaining (jumping from one power supply output to the next) is allowed as long as the maximum current through one terminal pin does not exceed 25A. If the current is higher, use a separate distribution terminal block.
Fig. 25-7 Daisy chaining of outputs
max 25A!
Output
+ +
- -
DC/DC
Converter
Output
+ +
- -
DC/DC
Converter
+
Load
-
Fig. 25-8 Using distribution terminals
Output
+ +
- -
DC/DC
Converter
Output
+ +
- -
DC/DC
Converter
+
Load
-
Input
July 08 / Rev. 1.2 DS-CD5.242-EN / All parameters are specified at 24V, 5A and 48Vdc input at 25°C ambient unless otherwise noted.
Input
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Input
Input
Distribution Terminals
18/21
CDSeries
DC/DC Converter; 24V, 5A
CD5.242
25.8. PARALLEL USE FOR 1+1 REDUNDANCY
DC/DC converters can be paralleled for 1+1 redundancy to gain a higher system availability. Redundant systems require a certain amount of extra power to support the load in case one DC/DC converter unit fails. The simplest way is to put two DC/DC converters in parallel. In case one converter fails, the other one is automatically able to support the load current without any interruption.
Furthermore, redundant systems can be built by using a DC/DC converter powered from a battery and a power supply with AC input.
- Use the decoupling module YR2.DIODE in combination with two CD5.241-S1 and use the DC-OK signals of the DC/DC converter to monitor a faulty unit or input voltage.
- Use the redundancy module YRM2.DIODE in combination with two CD5.241 and use the DC-OK signals of the redundancy module to monitor a faulty unit or input voltage.
Recommendations for building redundant power systems: a) Use separate input fuses for each DC/DC converter. b) Monitor the individual voltage sources of a redundant system. A DC-ok lamp and a DC-ok contact is included in
the redundancy module YRM2.DIODE and the DC/DC converter CD5.241-S1. This feature reports a faulty unit.
c) When possible, connect each DC/DC converter to different power sources.
25.9. CHARGING OF BATTERIES
The power supply can be used for float-charging of lead-acid or maintenance free 24V VRLA batteries.
Instructions for charging batteries:
a) Ensure that the ambient temperature of the power supply does not exceed 50°C. b) Set the output voltage on a disconnected load, very precisely to the end-of-charge voltage according to the
expected battery temperature.
End-of-charge voltage 27.8V 27.5V 27.15V 26.8V Battery temperature 10°C 20°C 30°C 40°C
c) Use a 6A or 10A circuit breaker (or blocking diode ) between the power supply and the battery. d) Ensure that the output current of the power supply 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 power supply is typ. 26.4mA at 25Vdc when the power supply is switched off (except in
case a blocking diode is utilized).
July 08 / Rev. 1.2 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
19/21
CDSeries
DC/DC Converter; 24V, 5A
CD5.242
25.10. REQUIREMENTS FOR THE SUPPLYING SOURCE
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. 25-9.
Fig. 25-9 Requirements for an input filter
Resistance of the supplying network
1 Ohm
100 mOhm
stability
10 mOhm
1 mOhm
0.1mH 1mH 10mH
Inductance of the supplying network
)
(
a
)
(
b
(a) max. (b) typ.
25.11. EXTERNAL INPUT PROTECTION
The unit is tested and approved for branch circuits up to 50A. External protection is only required if the supplying branch has an ampacity greater than this. In some countries local regulations might apply so check local codes and local requirements. If an external fuse is necessary or utilized, a minimum value is required to avoid undesired tripping of the fuse.
B-Characteristic C-Characteristic
Ampacity max.
min.
50A 50A
6A 6A
25.12. USE IN A TIGHTLY SEALED ENCLOSURE
When the DC/DC converter is installed in a tightly sealed enclosure, the temperature inside the enclosure will be higher than the outside. The inside temperature defines the ambient temperature for the DC/DC converter.
Results from such an installation: DC/DC converter is placed in the middle of the box, no other heat producing equipment inside the box Enclosure: Rittal Type IP66 Box PK 9516 100, plastic, 110x180x165mm
Load: 24V, 4A; (=80%) load is placed outside the box Input: 48Vdc Temperature inside the box: 42.8°C (in the middle of the right side of the DC/DC converter with a distance of 2cm) Temperature outside the box: 24.0°C Temperature rise: 28.8K
July 08 / Rev. 1.2 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
20/21
CDSeries
DC/DC Converter; 24V, 5A
CD5.242
25.13. MOUNTING ORIENTATIONS
Mounting orientations other than input terminals on the bottom and output on the top requires a reduction in continuous output power or a limitation in the maximum allowed ambient temperature. The amount of reduction influences the lifetime expectancy of the DC/DC converter. Therefore, two different derating curves for continuous operation can be found below:
Curve A1 Recommended output current. Curve A2 Max allowed output current (results approx. in half the lifetime expectancy of A1).
Fig. 25-10
Mounting Orientation A
Standard Orientation
Fig. 25-11
Mounting Orientation B (Upside down)
OUTPUT
DC/DC
Converter
INPUT
INPUT
Converter
DC/DC
OUTPUT
Fig. 25-12
Mounting Orientation C
(Table-top mounting)
Fig. 25-13
Mounting Orientation D
(Horizontal cw)
Converter
INPUT
OUTPUT
DC/DC
Fig. 25-14
Mounting Orientation E
(Horizontal ccw)
OUTPUT
DC/DC
INPUT
Converter
Output Current
6A
5 4 3 2 1
0
10 20 30
Output Current
6A
5 4 3 2 1
0
10 20 30
Output Current
6A
5 4 3 2 1
0
10 20 30
Output Current
6A
5 4 3 2 1
0
10 20 30
Output Current
6A
5 4 3 2 1
0
10 20 30
Ambient Temperature
40
50
Ambient Temperature
40
A
2
A
1
Ambient Temperature
40
A
2
A
1
Ambient Temperature
40
Ambient Temperature
40
50
50
50
50
A
1
60°C
A
2
A
1
60°C
60°C
60°C
A
2
A
1
60°C
July 08 / Rev. 1.2 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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21/21
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