CD10.241 - PULS Power Supply

CD10.241 - PULS Power Supply
PRELIMINARY
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
DC/DC CONVERTER
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
ƒ
24V DC-Input
Isolated 24Vdc Output
Efficiency 94.2%
Width only 42mm
20% Output Power Reserves
Full Power Between -25°C and +60°C
Soft-start Function
Minimal Inrush Current Surge
Reverse Input Polarity Protection
3 Year Warranty
GENERAL DESCRIPTION
SHORT-FORM DATA
The Dimension CD-Series offer DIN-rail DC/DC converters
in the 92-240W output power range in a very compact
housing. These DC/DC converters are allowed to run
with a battery or similar sources or can also be used to
refresh and stabilize the 24Vdc on the end of long cable
runs.
Output voltage
Adjustment range
Output current
The CD10.241 has a from the input galvanically
separated output and can provide 20% extra power,
which can even be used continuously up to +45°C.
Thanks to the high efficiency and low power losses the
unit can be very slender and utilize only 42mm on the
DIN-rail.
DC 24V
24 - 28V
*)
12 – 10.3A
< +45°C ambient
10 – 8.6A
at +60°C ambient
7.5 – 6.5A
at +70°C ambient
Derate linearly between +45°C and +70°C
Output power
288/240/180W
<45°C/60°C/70°C
Output ripple
< 50mVpp
20Hz to 20MHz
Input voltage
DC 24V
Input voltage range 18 to 35Vdc
full specified
Input current
typ. 10.5A
at 24V input
Input inrush current typ. 6A peak
at 25°C
Efficiency
94.2%
at 24Vdc input
Losses
14.8W
at 24Vdc input
Temperature range -25°C to +70°C
operational
Hold-up time
typ. 4ms
at 24Vdc input
Dimensions
42x124x117mm
WxHxD
Weight
500g / 1.1lb
*) extended guaranteed adjustment range down to 23V.
ORDER NUMBERS
DC/DC Converter
CD10.241
Accessory
ZM2.WALL
ZM12.SIDE
YR20.246
MARKINGS
Wall mount bracket
Side mount bracket
Redundancy module
UL 60950-1
planned
Ind. Cont. Eq.
UL 508, planned
Class I Div 2
planned
IECEx
ATEX
planned
EMC, ATEX
planned
Marine,
planned
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
www.pulspower.com Phone +49 89 9278 0
Germany
1/25
PRELIMINARY
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
INDEX
Page
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Intended Use .......................................................3
Installation Requirements...................................3
Input Voltage ......................................................4
Soft-start and Input Inrush Current Surge .........5
Output .................................................................6
Hold-up Time.......................................................7
Efficiency and Power Losses................................8
Functional Diagram.............................................9
Front Side and User Elements.............................9
Terminals and Wiring........................................10
Reliability ...........................................................11
EMC....................................................................12
Environment ......................................................13
Protection Features ...........................................14
Safety Features ..................................................14
Dielectric Strength ............................................15
Approvals...........................................................16
RoHS, REACH and Other Fulfilled Standards ...16
Page
19. Physical Dimensions and Weight ..................... 17
20. Accessories ........................................................ 18
20.1. ZM2.WALL - Wall Mounting Bracket.......18
20.2. ZM12.SIDE - Side Mounting Bracket........18
20.3. YR20.246 Redundancy Module ................19
21. Application Notes............................................. 20
21.1. Peak Current Capability ...........................20
21.2. Back-feeding Loads ..................................21
21.3. Inductive and Capacitive Loads................21
21.4. Charging of Batteries ...............................21
21.5. External Input Protection.........................21
21.6. Requirements for the Supplying Source..22
21.7. Series Operation .......................................22
21.8. Parallel Use to Increase Output Power....23
21.9. Parallel Use for Redundancy ....................23
21.10. Use in a Tightly Sealed Enclosure ............24
21.11. Mounting Orientations ............................25
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.
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 disregarding whether it is full (13.7V) or flat (10V)
24Vdc
A figure with the unit (Vac) at the end is a momentary figure without any additional
tolerances included.
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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Germany
2/25
PRELIMINARY
CD-Series
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
1. INTENDED USE
This device 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 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 output terminals are located on top and input terminal on the bottom. For
other mounting orientations see de-rating requirements in this document.
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 30%!
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 DC/DC converter).
The input must be powered from a SELV source (according to IEC 60950-1), a PELV source (according to IEC 62477-1) or
an Isolated Secondary Circuit (according to UL 508).
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 may 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 surface may cause burns.
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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Germany
3/25
PRELIMINARY
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
3. INPUT VOLTAGE
nom.
max.
Allowed voltage between input
and earth
Allowed input ripple voltage
max.
60Vdc or
42.2Vac
5Vpp
Turn-on voltage
Shut-down voltage
Input current
typ.
typ.
typ.
17.5Vdc
15.5Vdc
10.5A
Start-up delay
Rise time
typ.
typ.
typ.
max.
typ.
200ms
350ms
T.B.D.
250mV
4 300μF
Turn-on overshoot
Input capacitance
max.
DC 24V
18.0-35.0Vdc
36.0Vdc
Fig. 3-1 Input voltage range
Turn-on
Input
Voltage
32.4Vdc
35.0Vdc
17.5Vdc
18.0Vdc
VIN
15.5Vdc
Shut-down
47Hz-500Hz, the momentary input voltage must always
be within the specified limits.
steady-state value, see Fig. 3-1
steady-state value, see Fig. 3-1
at 24Vdc input and output 24V, 10A, see Fig. 3-3
at 24Vdc input and output 24V, 10A, see Fig. 3-3
see Fig. 3-1
0mF, 24V, resistive current load 10A, see Fig. 3-2
10mF, 24V, constant current load 10A, see Fig. 3-2
see Fig. 3-2
external capacitors on the input voltage bus are allowed
without any limitations.
Fig. 3-2 Turn-on behavior, definitions
Rated input range
POUT
-25%/+46%
full specified
absolute maximum continuous input voltage with no
damage to the DC/DC converter
in case the output voltage is not grounded.
Output
Voltage
- 5%
Start-up
delay
Rise
Time
Overshoot
Input voltage
Input voltage range
Fig. 3-3 Input current vs. output load
Input
Current,
typ.
16A
c
Vd
18
:
t
u
Inp
Vdc
: 24
t
u
Inp
12
8
4
Output Current
0
2
3
4
5
6
7
8
9 10 11 12A
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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Germany
4/25
PRELIMINARY
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
4. SOFT-START AND INPUT INRUSH CURRENT SURGE
Inrush current limitation
An active inrush limitation circuit (inrush limiting NTC resistor which is bypassed by a MOSFET) 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
Inrush energy
typ.
typ.
typ.
6Apeak
22Apeak
negligible
+25°C, cold start, input: 24Vdc
+60°C, cold start, input: 24Vdc
-25°C to +70°C, input: 24Vdc
Fig. 4-1 Input inrush current, typical behavior
Input Voltage
Ipk 6A
Output Voltage
Input Current
Input:
Output:
Ambient:
24Vdc
24V, 10A, constant current load
25°C
Input current
Input voltage
Output voltage
Time basis:
2A / DIV
5V / DIV
5V / DIV
100ms / DIV
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.
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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Germany
5/25
PRELIMINARY
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
5. OUTPUT
Output voltage
Adjustment range
nom.
min.
max.
Factory setting
Line regulation
Load regulation
Ripple and noise voltage
Output capacitance
Output current
24V
24-28V
30V
24.1V
25mV
100mV
50mVpp
4 500μF
12A
10A
7.5A
10.3A
8.6A
6.5A
288W
240W
180W
13A
15A
max.
max.
max.
typ.
nom.
nom.
nom.
nom.
nom.
nom.
nom.
nom.
nom.
min.
max.
Output power
Short-circuit current
*)
at clockwise end position of potentiometer
±0.2%, at full load, cold unit
Input voltage variations between 18 to 35Vdc
static value, 0A Æ 10A
20Hz to 20MHz, 50Ohm
at 24V, ambient < +45°C, see Fig. 5-1
at 24V, ambient < +60°C, see Fig. 5-1
at 24V, ambient at +70°C, see Fig. 5-1
at 28V, ambient < +45°C, see Fig. 5-1
at 28V, ambient < +60°C, see Fig. 5-1
at 28V, ambient at +70°C, see Fig. 5-1
for ambient temperatures < +45°C
for ambient temperatures < +60°C
at +70°C ambient temperature
continuous current, short circuit impedance 100mOhm
continuous current, short circuit impedance 100mOhm
*) extended guaranteed adjustment range from 23V to 28V.
Fig. 5-1 Output voltage vs. output current at
24Vdc input voltage, typ.
Output Voltage
Adjustment
Range
28V
24
20
16
12
8
4
0
Output Current
0
2
4
6
8
10
12
14 16A
Fig. 5-2 Current limitation vs. input voltage,
(23V constant voltage load), typ.
Output Current
14A
13.5
13.0
12.5
12.0
11.5
11.0
10.5
10.0
Input Voltage
18
21
24
27
30
33
36Vdc
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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Germany
6/25
PRELIMINARY
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
6. 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.
Hold-up Time
typ.
typ.
8ms
4ms
input 24Vdc, output: 24Vdc, 5A, see Fig. 6-1
input 24Vdc, output: 24Vdc, 10A, see Fig. 6-1
Fig. 6-1 Hold-up time vs. input voltage
Hold-up Time
8ms
(a) (b)
6
(c)
4
2
Input Voltage
0
18
20
22
(d)
(a) 24V, 5A, typ.
(b) 24V, 5A, min.
(c) 24V, 10A, typ.
(d) 24V, 10A, min.
24
28Vdc
26
Fig. 6-2 Shut-down test setup
S1
+
DC
Source
-
DC/DC
Converter
Input
+
Intput
Voltage
S1 opens
+
CD10
Output -
Fig. 6-3 Shut-down behavior, definitions
Load
-
- 5%
Output
Voltage
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.
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
www.pulspower.com Phone +49 89 9278 0
Germany
7/25
PRELIMINARY
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
7. EFFICIENCY AND POWER LOSSES
Efficiency
Average efficiency*)
Power losses
*)
typ.
typ.
typ.
Input 24Vdc
94.2%
93.7%
94.3%
typ.
typ.
typ.
typ.
1.75W
6.8W
14.7W
19.5W
at 24V, 10A
at 24V, 12A (Power Boost)
25% at 2.5A, 25% at 5A,
25% at 7.5A. 25% at 10A
at no output load
at 24V, 5A
at 24V, 10A
at 24V, 12A
The average efficiency is an assumption for a typical application where the power supply is loaded with 25% of the nominal load for 25%
of the time, 50% of the nominal load for another 25% of the time, 75% of the nominal load for another 25% of the time and with 100%
of the nominal load for the rest of the time.
Fig. 7-1
Efficiency vs. output current at 24V
output and 24Vdc input voltage, typ.
Fig. 7-2
Losses vs. output current at 24V
output and 24Vdc input voltage, typ.
Efficiency
Power Losses
95%
18W
94
15
93
12
92
9
91
6
3
90
Output Current
89
2
Fig. 7-3
4
6
8
Output Current
0
10
12A
Efficiency vs. input voltage at 24V,
10A, typ.
0
Fig. 7-4
2
6
8
10
12A
Losses vs. input voltage at 24V, 10A,
typ.
Efficiency
Power Losses
95%
19W
94.5
18
94.0
17
93.5
16
93.0
15
14
92.5
92.0
18
4
Input Voltage
20
22
24
26
Input Voltage
13
28
30 32Vdc
18
20
22
24
26
28
30 32Vdc
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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Germany
8/25
PRELIMINARY
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
8. FUNCTIONAL DIAGRAM
Fig. 8-1 Functional diagram
Output
Voltage
Regulator
+
-
Input Fuse
&
Input Filter
Chassis
Ground
Reverse
Polarity
Protection
&
Inrush
Limiter
Power
Converter
Output
Filter
Output
OverVoltage
Protection
VOUT
+
+
DC
ok
9. FRONT SIDE AND USER ELEMENTS
Fig. 9-1 Front side
A
Input terminals
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.
B
Output terminals
Screw terminals, dual terminals per pole, both pins are equal
+ Positive output
- Negative (return) output Screw terminals
C
Output voltage potentiometer
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
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
www.pulspower.com Phone +49 89 9278 0
Germany
9/25
PRELIMINARY
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
10. TERMINALS AND WIRING
Input
screw terminals
max. 6mm2
max. 4mm2
20-10 AWG
2.8mm (including ferrules)
7mm / 0.275inch
3.5mm slotted or
Pozidrive No 2
1Nm, 9lb.in
Type
Solid wire
Stranded wire
American Wire Gauge
Max. wire diameter
Wire stripping length
Screwdriver
Recommended tightening torque
Output
screw terminals
max. 6mm2
max. 4mm2
20-10 AWG
2.8mm (including ferrules)
7mm / 0.275inch
3.5mm slotted or
Pozidrive No 2
1Nm, 9lb.in
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 and
90°C for ambient up to 70°C minimum.
b) Follow national installation codes and installation regulations!
c) Ensure that all strands of a stranded wire enter the terminal connection!
d) Screws of unused terminal compartments should be securely tightened.
Daisy chaining of outputs:
Daisy chaining (jumping from one DC/DC-converter output to the next) is allowed as long as the average output
current through one terminal pin does not exceed 25A. If the current is higher, use a separate distribution terminal
block.
Fig. 10-1 Daisy chaining of outputs
Fig. 10-2 Using distribution terminals
max 25A!
Output
+ + - -
Output
+ + - -
+
-
Load
Output
+ + - -
Output
+ + - -
DC/DC
Converter
DC/DC
Converter
DC/DC
Converter
DC/DC
Converter
Input
Input
Input
Input
+
-
Load
Distribution
Terminals
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
www.pulspower.com Phone +49 89 9278 0
Germany
10/25
PRELIMINARY
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
11. RELIABILITY
Lifetime expectancy *)
MTBF **) SN 29500, IEC 61709
MTBF **) MIL HDBK 217F
Input 24Vdc
T.B.D.
ca. 80 000h
T.B.D.
T.B.D.
T.B.D.
T.B.D.
T.B.D.
T.B.D.
at 24V, 5A and 40°C
at 24V, 10A and 40°C
at 24V, 12A and 40°C
at 24V, 10A and 25°C
at 24V, 10A and 40°C
at 24V, 10A and 25°C
at 24V, 10A and 40°C; Ground Benign GB40
at 24V, 10A and 25°C; Ground Benign GB25
*)
The Lifetime expectancy shown in the table indicates the minimum operating hours (service life) and is determined by the lifetime
expectancy of the built-in electrolytic capacitors. Lifetime expectancy is specified in operational hours and is calculated according to the
capacitor’s manufacturer specification. The prediction model allows only 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.
The MTBF figure is a statistical representation of the likelihood of a device to fail. A MTBF figure of e.g. 1 000 000h means that
statistically one unit will fail every 100 hours if 10 000 units are installed in the field. However, it can not be determined if the failed unit
has been running for 50 000h or only for 100h.
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
www.pulspower.com Phone +49 89 9278 0
Germany
11/25
PRELIMINARY
CD-Series
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
12. EMC
The DC/DC converter is suitable for applications in industrial environment as well as in residential, commercial and
light industry environment without any restrictions.
EMC Immunity
Electrostatic discharge
Electromagnetic RF field
Fast transients (Burst)
Surge voltage on input
Surge voltage on output
Conducted disturbance
Generic standards: EN 61000-6-1 and EN 61000-6-2
EN 61000-4-2
Contact discharge
Air discharge
EN 61000-4-3
80MHz-2.7GHz
EN 61000-4-4
Input lines
Output lines
EN 61000-4-5
+Æ+/- Æ chassis ground
EN 61000-4-5
+Æ+ / - Æ chassis ground
EN 61000-4-6
0.15-80MHz
8kV
15kV
10V/m
4kV
2kV
1kV
2kV
500V
1kV
10V
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
Criterion A
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 may shut-down and restarts by itself. No damage or hazards for the DC/DC
converter will occur.
EMC Emission
Conducted emission
Generic standards: EN 61000-6-3 and EN 61000-6-4
IEC/CISPR 16-1-2, IEC/CISPR 16-2-1
Class B, input lines
(Limits for DC power ports)
Class B
Radiated emission
EN 55011, EN 55022
This device complies with FCC Part 15 rules.
Operation is subjected to 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
Variable between 90kHz and 135kHz depending on load and input voltage
(output current > 0.5A)
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
www.pulspower.com Phone +49 89 9278 0
Germany
12/25
PRELIMINARY
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
13. ENVIRONMENT
Operational temperature *)
Storage temperature
Output de-rating
Humidity **)
Vibration sinusoidal ***)
Shock ***)
Altitude
-25°C to +70°C (-13°F to 158°F)
-40 to +85°C (-40°F to 185°F)
3.2W/°C
6W/°C
5 to 95% r.H.
2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g
2 hours / axis
30g 6ms, 20g 11ms
3 bumps / direction, 18 bumps in total
0 to 6000m (0 to 20 000ft)
reduce output power according Fig. 13-1
for storage and transportation
45-60°C (113°F to 140°F)
60-70°C (140°F to 158°F)
IEC 60068-2-30
IEC 60068-2-6
IEC 60068-2-27
reduce output power or ambient temperature
above 2000m sea level.
15W/1000m or 5°C/1000m
above 2000m (6500ft), see Fig. 13-2
III
IEC 62477-1 altitudes up to 2000m
II
altitudes from 2000m to 6000m
2
IEC 62477-1, not conductive
The unit does not release any silicone or other LABS-critical substances and is suitable for
use in paint shops.
Altitude de-rating
Over-voltage category
Degree of pollution
LABS compatibility
*) Operational temperature is the same as the ambient temperature and is defined as the air temperature 2cm below the unit.
**) Do not energize while condensation is present
***) Tested in combination with DIN-Rails according to EN 60715 with a height of 15mm and a thickness of 1.3mm and standard mounting
orientation. Higher levels allowed when using the wall mounting bracket ZM2.WALL.
Fig. 13-1 Output current vs. ambient temp.
Allowable Output
Current at 24V
12A
short
term
continuous
Fig. 13-2 Output current vs. altitude at 24V
Allowable Output
Current at 24V
10
10
8
8
6
6
4
4
2
2
Ambient Temperature
0
-25
0
20
40
short term
12A
B
C
A
A... Tamb < 60°C
B... Tamb < 50°C
C... Tamb < 40°C
Altitude
0
60 70°C
0
2000
4000
6000m
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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13/25
PRELIMINARY
CD-Series
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
14. PROTECTION FEATURES
Output protection
Output over-voltage protection
Electronically protected against overload, no-load and short-circuits *)
typ. 31Vdc
in case of an internal power supply defect, a redundant
max. 32.5Vdc
circuit limits the maximum output voltage. The output
shuts down and automatically attempts to restart.
Reverse input polarity protection Included
unit does not start when input voltage is reversed
Output over-current protection
electronically limited *)
see Fig. 5-1
Degree of protection
IP 20
EN/IEC 60529
Penetration protection
> 3.5mm
e.g. screws, small parts
Over-temperature protection
no
Input transient protection
MOV
Metal Oxide Varistor
Internal input fuse
included
not user replaceable
*)
In case of a protection event, audible noise may occur.
15. SAFETY FEATURES
Classification of output voltage
Class of protection
Isolation resistance
PE resistance
Touch current (leakage current)
*)
SELV *)
PELV *)
III
T.B.D.
IEC/EN 60950-1
IEC/EN 60204-1, IEC 62477-1, IEC 60364-4-41
PE (Protective Earth) connection not required.
A connection of the “Chassis Ground” pin to earth is
recommended for best EMI performance.
> 5MOhm
input to output, 500Vdc
< 0.1Ohm
between housing and Chassis Ground terminal
The leakage current, which is produced by the DC/DC converter itself, depends on
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.
provided, that the input voltage meets the requirements of chapter 2.
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
16. DIELECTRIC STRENGTH
The output voltage is floating and has no ohmic connection to the ground.
Type and factory tests are conducted by the manufacturer. Field tests may be conducted in the field using the
appropriate test equipment which applies the voltage with a slow ramp (2s up and 2s down). Connect all input
terminals together as well as all output poles before conducting the test.
When testing, set the cut-off current settings to the value in the table below.
Type test
60s
A
1500Vac
B
1500Vac
C
500Vac
Factory test
5s
1500Vac
1500Vac
500Vac
Field test
5s
1000Vac
1000Vac
500Vac
T.B.D.
T.B.D.
T.B.D.
Fig. 16-1 Dielectric strength
Input
+
B
-
Cut-off current setting
Output
A
Chassis
ground
+
C
-
To fulfill the PELV requirements according to EN60204-1 § 6.4.1, we
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 when unnoticed earth
faults occur.
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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PRELIMINARY
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
17. APPROVALS
EC Declaration of Conformity
planned
The CE mark indicates conformance with the
- EMC directive and the
- ATEX directive.
CB Scheme,
Information Technology Equipment
IEC 60950-1
2nd Edition
planned
UL 508
planned
IND. CONT. EQ.
UL 60950-1
planned
EN 60079-0, EN 60079-15
ATEX
planned
IEC 60079-0, IEC 60079-15
planned
ANSI / ISA 12.12.01-2007
Class I Div 2
planned
Marine
planned
EAC TR Registration
planned
II 3G Ex nA II T4 Gc
IECEx
LISTED for use as Industrial Control Equipment;
U.S.A. (UL 508) and Canada (C22.2 No. 107-1-01);
E-File: E198865
RECOGNIZED for the use as Information Technology
Equipment, Level 3; U.S.A. (UL 60950-1) and Canada (C22.2
No. 60950-1); E-File: E137006
Approval for use in hazardous locations Zone 2 Category 3G.
Number of ATEX certificate: T.B.D.
The device must be built-in in an IP54 enclosure.
Suitable for use in Class 1 Zone 2 Groups IIa, IIb and IIc
locations. Number of IECEx certificate: IECEx EPS 14.0001X
Recognized for use in Hazardous Location Class I Div 2 T4
Groups A,B,C,D systems; U.S.A. (ANSI / ISA 12.12.01) and
Canada (C22.2 No. 213-M1987)
GL (Germanischer Lloyd) classified and
ABS (American Bureau for Shipping) PDA
Environmental category: C, EMC2
Marine and offshore applications
Registration for the Eurasian Customs Union market
(Russia, Kazakhstan, Belarus)
18. ROHS, REACH AND OTHER FULFILLED STANDARDS
RoHS Directive
REACH Directive
Directive 2011/65/EU of the European Parliament and the
Council of June 8th, 2011 on the restriction of the use of
certain hazardous substances in electrical and electronic
equipment.
Directive 1907/2006/EU of the European Parliament and the
Council of June 1st, 2007 regarding the Registration,
Evaluation, Authorisation and Restriction of Chemicals
(REACH)
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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PRELIMINARY
CD-Series
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
19. PHYSICAL DIMENSIONS AND WEIGHT
Width
Height
Depth
Weight
DIN-Rail
Housing material
Installation clearances
42mm 1.65’’
124mm 4.88’’
117mm 4.61’’
The DIN-rail height must be added to the unit depth to calculate the total required
installation depth.
500g / 1.10lb
Use 35mm DIN-rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm.
Body: Aluminium alloy
Cover: zinc-plated steel
See chapter 2
Fig. 19-1 Front view
Fig. 19-2 Side view
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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PRELIMINARY
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
20. ACCESSORIES
20.1. ZM2.WALL - WALL MOUNTING BRACKET
This bracket is used to mount the power
supply onto a flat surface without utilizing a DIN-Rail.
20.2. ZM12.SIDE - SIDE MOUNTING BRACKET
This bracket is used to mount DIMENSION units sideways with or without utilizing a DIN-Rail. The two aluminum
brackets and the black plastic slider of the unit have to be detached, so that the steel brackets can be mounted.
For sideway DIN-rail mounting, the removed aluminum brackets and the black plastic slider need to be mounted on
the steel bracket.
Side mounting with DIN-rail brackets
Side mounting without DIN-rail brackets
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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Germany
18/25
PRELIMINARY
CD-Series
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
20.3. YR20.246 REDUNDANCY MODULE
The YR20.246 redundancy module is equipped with two input channels each 10A nominal, which
are individually decoupled by utilizing MOSFET technology. The output can be loaded with
nominal 20A. Using MOSFETs instead of diodes reduces the heat generation and the voltage
drop between input and output.
The YR20.246 does not require an additional auxiliary voltage and is self-powered even in case of
a short circuit across the output.
Due to the low power losses, the unit is very slender and only requires 32mm width on the DINrail.
The YR20.246 is equipped with a load share feature, which balance the load current between the
two inputs of the redundancy module.
The “Load Share OK” and the “Redundancy OK” relay contacts enable a remotely alarming of critical situations.
See chapter 21.9 for further wiring information.
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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PRELIMINARY
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
21. APPLICATION NOTES
21.1. PEAK CURRENT CAPABILITY
The unit can deliver peak currents (up to several milliseconds) which are higher than the specified short term currents.
This helps to start current demanding loads. Solenoids, contactors and pneumatic modules often have a steady state
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.
The peak current capability also ensures the safe operation of subsequent circuit breakers of load circuits. The load
branches are often individually protected with circuit breakers or fuses. In case of a short or an overload in one branch
circuit, the fuse or circuit breaker need a certain amount of over-current to open in a timely manner. This avoids
voltage loss in adjacent circuits.
The extra current (peak current) is supplied by the power converter and the built-in large sized output capacitors of
the power supply. The capacitors get discharged during such an event, which causes a voltage dip on the output. The
following two examples show typical voltage dips:
Fig. 21-1 Peak loading with 2x the nominal current
for 50ms, typ.
Output
Voltage
24V
20A
Fig. 21-2 Peak loading with 4x the nominal current
for 5ms, typ.
40A
Output
Voltage
24V
16V
0A
10ms/DIV
Output
Current
Peak load 20A (resistive load) for 50ms
Output voltage dips from 24V to 16V.
Peak current voltage dips
typ.
typ.
typ.
6V
0A
2ms/DIV
Output
Current
Peak load 40A (resistive load) for 5ms
Output voltage dips from 24V to 6V.
from 24V to 16V
from 24V to 12V
from 24V to 6V
at 10A for 50ms, resistive load
at 40A for 2ms, resistive load
at 40A for 5ms, resistive load
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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Germany
20/25
PRELIMINARY
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
21.2. BACK-FEEDING LOADS
Loads such as decelerating motors and inductors can feed voltage back to the power supply. This feature is also called
return voltage immunity or resistance against Back- E.M.F. (Electro Magnetic Force).
This power supply 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 maximum allowed feed-back-voltage is 35Vdc. The maximum allowed feed-back peak current is 40A. Higher
currents can temporarily shut-down the output voltage. The absorbing energy can be calculated according to the
built-in large sized output capacitance which is specified in chapter 5.
21.3. INDUCTIVE AND CAPACITIVE LOADS
The unit is designed to supply any kind of loads, including unlimited capacitive and inductive loads.
21.4. CHARGING OF BATTERIES
The DC/DC converter can be used to charge lead-acid or maintenance free batteries. (Two 12V batteries in series)
Instructions for charging batteries:
a)
Ensure that the ambient temperature of the DC/DC converter is below 45°C
b)
Do not use DC/DC converters in mounting orientations other than the standard mounting orientation (input
terminals on the bottom and output terminals on top of the unit).
c)
Set output voltage (measured at no load and at the battery end of the cable) very precisely to the end-of-charge
voltage.
End-of-charge voltage
27.8V
27.5V
27.15V
26.8V
Battery temperature
10°C
20°C
30°C
40°C
d)
Use a 6A or 10A circuit breaker (or blocking diode) between the DC/DC converter and the battery.
e)
Ensure that the output current of the DC/DC converter is below the allowed charging current of the battery.
f)
Use only matched batteries when putting 12V types in series.
g)
The return current to the DC/DC converter (battery discharge current) is typ. 10mA when the DC/DC converter is
switched off (except in case a blocking diode is utilized).
21.5. EXTERNAL INPUT PROTECTION
The unit is tested and approved for branch circuits up to 50A. An external protection is only required, if the supplying
branch has an ampacity greater than this. Check also local codes and local requirements. In some countries local
regulations might apply.
If an external fuse is necessary or utilized, minimum requirements need to be considered to avoid nuisance tripping of
the circuit breaker. A minimum value of 20A B- or C-Characteristic breaker should be used.
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
www.pulspower.com Phone +49 89 9278 0
Germany
21/25
PRELIMINARY
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
21.6. 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. 21-3.
Fig. 21-3 External input filter requirements to
avoid filter instabilities
Resistance of the
supplying network
1 Ohm
(a)
(b)
100 mOhm
10 mOhm
(a) max.
(b) typ.
1 mOhm
0.1mH
1mH
10mH
Inductance of the supplying network
21.7. SERIES OPERATION
Unit A
DC/DC converters of the exact same type can be connected in series for higher
output voltages. It is possible to connect as many units in series as needed,
providing the sum of the output voltage does not exceed 150Vdc. 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. Earthing of the
output is required when the sum of the output voltage is above 60Vdc.
Avoid return voltage (e.g. from a decelerating motor or battery) which is applied
to the output terminals.
Input
Output
Unit B
Input
+
+
Load
+
-
-
Output
Keep an installation clearance of 15mm (left / right) between two DC/DCconverters and avoid installing the DC/DC-converters on top of each other. Do not use DC/DC-converters in series in
mounting orientations other than the standard mounting orientation (input terminals on the bottom and output
terminals on top of the unit).
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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PRELIMINARY
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
21.8. PARALLEL USE TO INCREASE OUTPUT POWER
Unit A
Input
The DC/DC-converter can be paralleled to increase the output power. There are
no feature included which balances the load current between the DC/DCconverters. Therefore some restrictions and limitations apply. The DC/DCconverter with the higher adjusted output voltage draws current until it goes
into current limitation. This means no harm or switch-off to this DC/DC-converter
as long as the ambient temperature stays below 45°C.
Output
Unit B
Input
+
-
Load
+
+
The output voltages of all DC/DC-converters shall be adjusted to the same value
(±100mV) at full load. A fuse or diode on the output of each unit is only required
Output
if more than three units are connected in parallel. This avoid that more than 2
times of the nominal output current can flow backwards into the DC/DC
converter in case the output stage of the DC/DC converter has a defect. If a fuse (or circuit breaker) is used, choose one
with approximately 150% of the rated output current of one DC/DC-converter.
Keep an installation clearance of 15mm (left / right) between two DC/DC-converters and avoid installing the DC/DCconverters on top of each other. Do not use DC/DC-converters in parallel in mounting orientations other than the
standard mounting orientation (input terminals on the bottom and output terminals on top of the unit).
21.9. PARALLEL USE FOR REDUNDANCY
The DC/DC converters can be paralleled for 1+1 redundancy
to gain higher system availability. Redundant systems require
a certain amount of extra power to support the load in case
one DC/DC converter fails. The simplest way is to connect two
DC/DC converters in parallel. This is called a 1+1 redundancy.
In case one DC/DC converter fails, the other one is
automatically able to support the load current without any
interruption. Redundant systems for a higher power demand
are usually built in an N+1 method. E.g. five DC/DC
converters, each rated for 10A are paralleled to build a 40A
redundant system.
Furthermore, 1+1 redundant systems can be built by using a
DC/DC converter powered from a battery and a power supply
with AC input.
Failure
Monitor
- -
+ +
Output
- -
+ +
Output
24-28V
DC-OK
24-28V
DC-OK
CD10.241
DC/DC
Converter
CD10.241
DC/DC
Converter
Input
+
Input
-
I
+
-
- - + +
In1 In2
YR20.246
Redundancy Module
Load Share
OK
Redundancy
OK
Output
- +
I
24V,10A
Load
+
Functional Earth
Please note: This simple way to build a redundant system
does not cover failures such as an internal short circuit in the secondary side of the DC/DC-converter. In such a case, the
defect unit becomes a load for the other DC/DC-converters and the output voltage can not be maintained any more.
This can only be avoided by utilizing the redundancy module YR20.246, which utilized MOSFETs as decoupling devices.
Recommendations for building redundant power systems:
a)
Use separate input fuses for each DC/DC-converter.
b)
Monitor the “Redundancy OK” relay contact of the YR20.246. This feature reports a faulty DC/DC converter or
problems with the redundancy modules.
c)
1+1 Redundancy is allowed up to an ambient temperature of 60°C
N+1 Redundancy is allowed up to an ambient temperature of 45°C
d)
It is desirable to set the output voltages of all units to the same value (± 100mV) or leave it at the factory setting.
Use the load share feature LEDs of the redundancy module to adjust the output voltages of the DC/DC coverters if
necessary.
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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PRELIMINARY
CD-Series
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
21.10. 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 outside. In such situations, the inside temperature defines the ambient temperature for the DC/DC
converter.
The following measurement results can be used as a reference to estimate the temperature rise inside the enclosure.
The DC/DC-converter is placed in the middle of the box, no other heat producing items are inside the box
Condition 1: 80% load
Enclosure:
Load:
Input:
Temperature inside enclosure:
Temperature outside enclosure:
Temperature rise:
Rittal Typ IP66 Box PK 9516 100, plastic, 110x180x165mm
24V, 8A; (=80%) load is placed outside the box
24Vdc
52.2°C (in the middle of the right side of the DC/DC converter with a distance of 2cm)
31.0°C
21.2K
Condition 2: 100% load
Enclosure:
Load:
Input:
Temperature inside enclosure:
Temperature outside enclosure:
Temperature rise:
Rittal Typ IP66 Box PK 9516 100, plastic, 110x180x165mm
24V, 10A; (=100%) load is placed outside the box
24Vdc
59.3°C (in the middle of the right side of the DC/DC converter with a distance of 2cm)
31.4°C
27.9K
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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PRELIMINARY
CD10.241
DC/DC Converter 24V/24V, 10A, 240W
CD-Series
21.11. MOUNTING ORIENTATIONS
Mounting orientations other than input terminals on the bottom and output on the top require a reduction in
continuous output power or a limitation in the max. 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
Curve A2
Recommended output current.
Max allowed output current (results in approximately half the lifetime expectancy of A1).
Fig. 21-4
Mounting
Orientation A
(Standard
orientation)
Output Current
12A
10
8
6
4
2
0
10
OUTPUT
DC/DC
Converter
INPUT
Fig. 21-5
Mounting
Orientation B
(Upside down)
Ambient Temperature
20
30
40
60°C
50
Output Current
12A
10
8
6
4
2
0
10
INPUT
DC/DC
Converter
OUTPUT
Fig. 21-6
Mounting
Orientation C
(Table-top
mounting)
A2
A1
Ambient Temperature
20
30
40
60°C
50
Output Current
12A
10
8
6
4
2
0
10
Fig. 21-7
Mounting
Orientation D
(Horizontal cw)
A2
A1
Ambient Temperature
20
30
40
60°C
50
Output Current
OUTPUT
DC/DC
Converter
INPUT
12A
10
8
6
4
2
0
10
A2
A1
Ambient Temperature
20
30
40
60°C
50
INPUT
DC/DC
Converter
Output Current
OUTPUT
Fig. 21-8
Mounting
Orientation E
(Horizontal ccw)
A1
12A
10
8
6
4
2
0
10
A2
A1
Ambient Temperature
20
30
40
50
60°C
Jun. 2016 / Rev. 0.1 DS-CD10.241-EN
All parameters are specified at 24V, 10A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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