Puls QS10.241-60, Dimension Q-Series User Manual

QS10.241-60

Q-Series

24V, 200W, DC/DC CONVERTER

DC/DC CONVERTER

 EN 50155 Railway Compliant
 Conformal Coated PC-boards
 Quick-connect Spring-clamp Terminals
 77-154Vdc Wide-range Input
 Width only 60mm
 Efficiency up to 93.0%
 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

1/27

GENERAL DESCRIPTION

The QS10.241-60 DC/DC converter 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 60mm 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

12.5 – 10.7A for typ. 4s
Output power 200W continuous
300W for typ. 4s
Output ripple max. 50mVpp 20Hz to 20MHz
AC Input voltage - ­DC Input voltage DC 110V - 30%/ +40%
DC Input current 1.96A at 110Vdc
Inrush current typ. 4A peak at 110Vdc
Efficiency 93.0% at 110Vdc
Losses 15.0W at 110Vdc
Temperature range -40°C to +70°C operational
Derating - not required
Hold-up time typ. 23ms at 110Vdc
Dimensions 60x124x117mm WxHxD
Weight 920g / 2.03lb

ORDER NUMBERS

DC/DC converter QS10.241-60

Accessory ZM13.SIDE Side mount bracket
YR2.DIODE Redundancy module
UF20.241 Buffer module

MARKINGS

EMC, LVD

Aug. 2016 / Rev. 1.0 DS-QS10.241-60-EN
All parameters are specified at 24V, 8.3A, 110Vdc, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

www.pulspower.com Phone [phone] Germany

QS10.241-60

Q-Series

24V, 200W, DC/DC CONVERTER

INDEX

Page Page

1.

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

2. Installation Requirements...................................3

3. AC-Input...............................................................4

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

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

6. Output .................................................................6

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

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

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

10. Lifetime Expectancy and MTBF.........................10

11. Functional Diagram...........................................11

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

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

14. EMC....................................................................14

15. Environment......................................................15

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

17. Safety Features ..................................................16

18. Dielectric Strength ............................................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. ZM13.SIDE - Side Mounting Bracket........20

22.2. UF20.241 Buffer Module .......................... 20

22.3. YR2.DIODE Redundancy Module.............21

23. Application Notes............................................. 22

23.1. Repetitive Pulse Loading..........................22

23.2. Peak Current Capability ...........................23

23.3. Inductive and Capacitive Loads................23

23.4. External Input Protection.........................24

23.5. Charging of Batteries ...............................24

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

23.7. Parallel Use for Redundancy .................... 25

23.8. Series Operation .......................................25

23.9. Back-feeding Loads ..................................26

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

23.11. Mounting Orientations ............................27

The information presented in this document is believed to be accurate and reliable and may change without notice.
No part of this document may be reproduced or utilized in any form without permission in writing from the publisher.

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.

Aug. 2016 / Rev. 1.0 DS-QS10.241-60-EN
All parameters are specified at 24V, 8.3A, 110Vdc, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

www.pulspower.com Phone [phone] Germany

2/27

QS10.241-60

Q-Series

24V, 200W, DC/DC CONVERTER

1. INTENDED USE

This device is designed for installation in an enclosure and is intended for the general professional use such as in
rolling stock for railway applications or in industrial control, office, communication, and instrumentation equipment.

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

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.
Mount the unit on a DIN-rail so that the input terminals are located on the bottom of the unit. For other mounting

orientations see de-rating requirements in this document. See chapter 23.11.
This device is designed for convection cooling and does not require an external fan. Do not obstruct airflow and do

not cover ventilation grid (e.g. cable conduits) by more than 15%!
Keep the following installation clearances: 40mm on top, 20mm on the bottom, 5mm on the left and right sides are

recommended when the device is loaded permanently with more than 50% of the rated power. Increase this clearance
to 15mm in case the adjacent device is a heat source (e.g. another power supply).

WARNING

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

- Do not use the DC/DC converter without proper grounding (Protective Earth). Use the terminal on the input block
for earth connection and not one of the screws on the housing.

- 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.

Aug. 2016 / Rev. 1.0 DS-QS10.241-60-EN
All parameters are specified at 24V, 8.3A, 110Vdc, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

www.pulspower.com Phone [phone] Germany

3/27

QS10.241-60

Q-Series

24V, 200W, DC/DC CONVERTER

3. AC-INPUT

Do not operate this DC/DC converter with an AC-input voltage. Use the QS10.241 or QS10.241-C1 unit instead.

4. 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 110V -30%/+40%
Input voltage range 77-154Vdc
66-77Vdc short term for 100ms
Input current typ. 1.96A at 8.3A and 110Vdc input voltage, see Fig. 4-3
Allowed voltage between input

to earth (ground)

max. 375Vdc continuous, IEC 62103

± 600V peak value, allowed for transients
Slew rate for voltage between

input to earth (ground)

max. 1000V/μs

Allowed input ripple voltage max. 15Vpp

3Vpp

50Hz –10kHz
10kHz – 50kHz

Turn-on voltage typ. 71Vdc steady-state value, at ambient temperatures between

-40°C and +70°C, see Fig. 4-1
Shut-down voltage typ. 61Vdc steady-state value, see Fig. 4-1
Start-up delay typ. 500ms see Fig. 4-2
Rise time typ. 20ms at 8.3A constant current load, 0mF load capacitance,

see Fig. 4-2

typ. 45ms at 8.3A constant current load, 8mF load capacitance,

see Fig. 4-2
Turn-on overshoot max. 200mV see Fig. 4-2
External input protection See recommendations in chapter 23.4.

Fig. 4-1 Input voltage range Fig. 4-2 Turn-on behavior, definitions

Turn-on

77V

Rated

input range

max.

500ms

V

IN

P

OUT

375Vdc154V

Shut-down

Start-up

delay

Rise

Time

Overshoot

- 5%

Output
Voltage

Input
Voltage

Aug. 2016 / Rev. 1.0 DS-QS10.241-60-EN
All parameters are specified at 24V, 8.3A, 110Vdc, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

www.pulspower.com Phone [phone] Germany

4/27

QS10.241-60

Q-Series

24V, 200W, DC/DC CONVERTER

Fig. 4-3 Input current vs. output load at 24V

output voltage

8

01234

0

0.5

1.0

1.5

2A

Output Current

Input Current at 110Vdc input, typ.

567

9A

5. INPUT INRUSH CURRENT

An active inrush limitation circuit 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. 13A

peak

at 110Vdc, temperature independent

typ. 4A

peak

at 110Vdc, temperature independent

Inrush energy max. 1A

2

s at 110Vdc, temperature independent

Inrush delay typ. 500ms start-up delay plus rise time at 110Vdc

Fig. 5-1 Typical input inrush current behaviour at nominal load

and 25°C ambient

Aug. 2016 / Rev. 1.0 DS-QS10.241-60-EN
All parameters are specified at 24V, 8.3A, 110Vdc, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

www.pulspower.com Phone [phone] Germany

5/27

QS10.241-60

Q-Series

24V, 200W, DC/DC CONVERTER

6. OUTPUT

Output voltage nom. 24V
Adjustment range min. 24-28V guaranteed
max. 30V

***)

at clockwise end position of potentiometer
Factory setting typ. 24.1V ±0.2%, at full load, cold unit
Line regulation max. 10mV 77-154Vdc
Load regulation max. 100mV static value, 0A Æ 8.3A
Ripple and noise voltage max. 50mVpp 20Hz to 20MHz, 50Ohm
Output current nom. 8.3A continuously available at 24V, see Fig. 6-1
nom. 7.1A continuously available at 28V, see Fig. 6-1

nom. 12.5A

*)

short term available BonusPower

® *)

,

at 24V, for typical 4s, see Fig. 6-1

nom. 10.7A

*)

short term available BonusPower

® *)

,

at 28V, for typical 4s, see Fig. 6-1
Output power nom. 200W continuously available
nom. 300W

*)

short term available BonusPower

® *)

BonusPower® time typ. 4s duration until the output voltage dips, see Fig. 6-2
min. 3s
max. 5s
BonusPower

®

recovery time typ. 7s overload free time to reset power manager, see Fig. 6-3
Overload behaviour cont. current
Short-circuit current min. 6.7A

**)

continuous, load impedance 100mOhm, see Fig. 6-1

max. 10.5A

**)

continuous, load impedance 100mOhm, see Fig. 6-1

min. 17.5A

**)

during BonusPower

® *)

, load impedance 100mOhm

max. 22.5A

**)

during BonusPower

® *)

, load impedance 100mOhm

max. 12.5A

**)

continuous, load impedance <10mOhm, see Fig. 6-1

Output capacitance typ. 7 000μF included inside the power supply

*) BonusPower®, short term power capability (up to typ. 4s)

The power supply is designed to support loads with a higher short-term power requirement without damage or shutdown. The short­term duration is hardware controlled by an output power manager. This BonusPower® is repeatedly available. Detailed information
can be found in chapter 23.1. If the power supply is loaded longer with the BonusPower

®

than shown in the Bonus-time diagram (see

Fig. 6-2), the max. output power is automatically reduced to 200W.

**) Discharge current of output capacitors is not included.

***) 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. The typical value is about 28.6V.

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

typ.

Fig. 6-2 Bonus time vs. output power

c
on

t
i

n

uo

u
s

Output Voltage

0

04 81216

4

8

12

28V

16

20

24

20

A

Output Current

s

h

or

t

-

t

e

r

m

Adjustment

Range

Bonus Time

0

110 120 130 140 150

160%

1

2

3

7

4

5

6

8

9

10s

m

i

n

m

a

x

typ

Output Power

Aug. 2016 / Rev. 1.0 DS-QS10.241-60-EN
All parameters are specified at 24V, 8.3A, 110Vdc, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

www.pulspower.com Phone [phone] Germany

6/27

QS10.241-60

Q-Series

24V, 200W, DC/DC CONVERTER

Fig. 6-3 BonusPower® recovery time

Power
Demand

100%

t

t

Limitation by
Power Manager

Output
Voltage

Bonus Power disabled

Bonus

Time

Recovery Time

The BonusPower

®

is available as soon as power comes on and immediately after the end of an output short circuit or

output overload.

Fig. 6-4 BonusPower® after input turn-on Fig. 6-5 BonusPower® after output short

100%

Output
Voltage

Input
Voltage

Bonus
Power

Output
Power

150%

Short of

Output

100%

Output
Voltage

Bonus
Power

Output
Power

150%

Aug. 2016 / Rev. 1.0 DS-QS10.241-60-EN
All parameters are specified at 24V, 8.3A, 110Vdc, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

www.pulspower.com Phone [phone] Germany

7/27

QS10.241-60

Q-Series

24V, 200W, DC/DC CONVERTER

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.

Hold-up Time typ. 47ms at 4.15A, see Fig. 7-1
min. 36ms at 4.15A, see Fig. 7-1
typ. 23ms at 8.3A, see Fig. 7-1
min. 18ms at 8.3A, see Fig. 7-1

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

0

10

20

30

40

50ms

70 90 110 130 150Vdc

Input Voltage

Hold-up Time

at 8.3A, typ.

at 4.14A, min.

at 4.15A, typ.

at 8.3A, min.

- 5%

Hold-up Time

Output
Voltage

Input
Voltage

Aug. 2016 / Rev. 1.0 DS-QS10.241-60-EN
All parameters are specified at 24V, 8.3A, 110Vdc, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

www.pulspower.com Phone [phone] Germany

8/27

QS10.241-60

Q-Series

24V, 200W, DC/DC CONVERTER

8. DC-OK RELAY CONTACT

This feature monitors the output voltage, which is produced by the DC/DC converter itself. It is independent of a back­fed voltage from a unit connected in parallel to the DC/DC converter output.

Contact closes As soon as the output voltage reaches 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 250ms. Dips shorter than 1ms will be ignored.

Contact re-closes As soon as the output voltage exceeds 90% of the adjusted voltage.

Contact ratings max 60Vdc 0.3A, 30Vdc 1A, 30Vac 0.5A resistive load
min 1mA at 5Vdc min. permissible load

Isolation voltage See dielectric strength table in section 18.

Fig. 8-1 DC-ok relay contact behavior

250ms

0.9* V

ADJ

<

1ms

10%

open

V

OUT

= V

ADJ

openclosed closed

>

1ms

Note:

The DC-ok feature requires that the output voltage reaches the nominal
(=adjusted) level after turn-on in order to function according to
specification. If this level cannot be achieved, the overload lamp will be
on and the DC-ok contact will be open. The overload signal will only shut
off as soon as the adjusted voltage is reached. This is an important
condition to consider particularly, if the load is a battery, the power
supply is used in parallel or the power supply is used for N+1 redundant
systems.

Aug. 2016 / Rev. 1.0 DS-QS10.241-60-EN
All parameters are specified at 24V, 8.3A, 110Vdc, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

www.pulspower.com Phone [phone] Germany

9/27