CD5.241 DC/DC Converter 24V, 5A CD-Series DC/DC CONVERTER 24V DC-Input Isolated 24Vdc Output Efficiency up to 90.3% Width only 32mm 20% Output Power Reserves Full Power Between -25°C and +60°C Soft-start Function Included 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 92-120W 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. The basic units include all the essential basic functions while the -S1 version is equipped with quickconnect spring clamp terminals, a DC-OK-contact which monitors the output and an input-low-relay-contact. The –L1 version additionally fulfills the NEC Class 2 requirements. All devices except the CD5.241-L1 have a PowerBoost of 20% incorporated. This extra power can even be used continuously up to +45°C. Output voltage Adjustment range Output current CD-Series CD5.121 24V->12V CD5.243 12V->24V CD5.242 48V->24V Related products 24V->24V CD5.241 SLD2.100 24V->5V 24V->24V, NEC Class 2, CD5.241-L1 Spring-clamp-terminals, 24V->24V, CD5.241-S1 Spring-clamp-terminals, Input-low, DC-OK signals ORDER NUMBERS DC 24V 24 - 28V 5 – 4.3A 6 – 5.2A Output power 120W 144W Output ripple < 50mVpp Input voltage DC 24V Input voltage range 18 to 32.4Vdc 14.4 to 18Vdc Input current typ. 5.5A Input inrush current typ. 1.2A peak Efficiency 90.3% Losses 12.9W Temperature range -25°C to +70°C Derating 3W/°C Hold-up time typ. 6ms Dimensions 32x124x102mm Weight 425g / 0.94lb *) ambient <60°C ambient <45°C ambient <60°C ambient <45°C 20Hz to 20MHz full specified with derating at 24Vdc input at 24Vdc input at 24Vdc input operational +60 to +70°C at 24Vdc input WxHxD *) extended guaranteed adjustment range down to 23V. MARKINGS DC/DC Converter CD5.241 Standard unit Accessory ZM1.WALL Wall mount bracket ZM11.SIDE Side mount bracket YRM2.DIODE Redundancy module UL 60950-1 UL 61010-1 Ind. Cont. Eq. UL 508 IECEx Class I Div 2 EMC, ATEX ATEX II 3G Ex nA nC II T4 Gc Marine Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 1/22 CD5.241 DC/DC Converter 24V, 5A CD-Series INDEX Page 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 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 ...........................................................10 EMC....................................................................11 Environment ......................................................12 Protection Features ...........................................13 Safety Features ..................................................13 Dielectric Strength ............................................14 Approvals...........................................................15 Page 18. RoHS, REACH and Other Fulfilled Standards .. 15 19. Physical Dimensions and Weight ..................... 16 20. Accessories ........................................................ 17 21. Application Notes............................................. 18 21.1. Peak Current Capability ...........................18 21.2. Back-feeding Loads ..................................18 21.3. Inductive and Capacitive Loads................18 21.4. Charging of Batteries ...............................19 21.5. External Input Protection.........................19 21.6. Requirements for the Supplying Source..19 21.7. Parallel Use to Increase Output Power....20 21.8. Parallel Use for Redundancy ....................20 21.9. Daisy Chaining of Outputs .......................21 21.10. Series Operation .......................................21 21.11. Use in a Tightly Sealed Enclosure ............21 21.12. Mounting Orientations ............................22 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. Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 2/22 CD5.241 DC/DC Converter 24V, 5A CD-Series 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 (if included) 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. - 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 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. Notes for use in hazardous location areas: The DC/DC Converter is suitable for use in Class I Division 2 Groups A, B, C, D locations and for use in Group II Category 3 (Zone 2) environments and are evaluated according to EN 60079-0 and EN 60079-15. WARNING EXPLOSION HAZARDS! Substitution of components may impair suitability for this environment. Do not disconnect the unit or operate the voltage adjustment unless power has been switched off or the area is known to be non-hazardous. A suitable enclosure must be provided for the end product which has a minimum protection of IP54 and fulfils the requirements of the EN 60079-15. Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 3/22 CD5.241 DC/DC Converter 24V, 5A CD-Series 3. INPUT VOLTAGE Input voltage Input voltage range nom. DC 24V 18.0-32.4Vdc 14.4-18.0Vdc 36.0Vdc max. Allowed voltage between input and earth Allowed input ripple voltage Turn-on voltage Shut-down voltage Input current Start-up delay Rise time Turn-on overshoot Input capacitance max. max. 60Vdc or 42.2Vac 5Vpp typ. typ. typ. typ. typ. typ. typ. max. typ. 17.5Vdc 14.0Vdc 35.0Vdc 5.5A 650ms 80ms 150ms 500mV 3 000μF Rated input range Output Current (a) 5 (b) Turn-on 6A 4 3 VIN 1 Input Voltage 0 14 Fig. 3-3 Turn-on behavior, definitions Input Voltage (a) Ambient < 45°C (b) Ambient < 60°C 2 32.4Vdc 35.0Vdc 17.5Vdc 18.0Vdc Shut-down 14.0Vdc 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 steady-state value, see Fig. 3-1 at 24Vdc input and output 24V, 5A, see Fig. 3-4 see Fig. 3-1 0mF, 24V, constant current load 5A, see Fig. 3-3 5mF, 24V, constant current load 5A, see Fig. 3-3 see Fig. 3-3 external capacitors on the input voltage bus are allowed without any limitations. Fig. 3-2 Allowable output current below 18V input voltage Fig. 3-1 Input voltage range POUT full specified maximal 60 seconds or with de-rating see Fig. 3-2 absolute maximum continuous input voltage with no damage to the DC/DC converter in case the output voltage is not grounded. 16 18 20 22 24Vdc Fig. 3-4 Input current vs. output load 8A Input Current, typ. dc 8V t: 1 u c Inp 4Vd t: 2 u p In 6 Output Voltage Start-up delay Rise Time Overshoot 4 - 5% 2 Output Current 0 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6A Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 4/22 CD5.241 DC/DC Converter 24V, 5A CD-Series 4. 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. typ. typ. Inrush energy 1.6Apeak 1.2Apeak negligible -25°C to +70°C, input: 24Vdc -25°C to +70°C, input: 24Vdc -25°C to +70°C, input: 24Vdc Fig. 4-1 Input inrush current, typical behavior Input Current Input Voltage Input: Output: Ambient: 24Vdc 24V, 5A, constant current load 25°C Upper curve: Middle curve: Lower curve: Time basis: Input current 2A / DIV Input voltage 20V / DIV Output voltage 20V / DIV 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. 4-2 Soft-start behavior Input Current Input: 24Vdc Output: 24V, 5A, constant current load Ambient: 25°C No additional external output capacitors Upper curve: Lower curve: Time basis: Input current 2A / DIV Output voltage 10V / DIV 20ms / DIV Output Voltage Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 5/22 CD5.241 DC/DC Converter 24V, 5A 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 max. max. max. typ. nom. nom. nom. nom. nom. nom. min. max. Output power Short-circuit current 24V 24-28V 30V 24.1V 25mV 100mV 50mVpp 2 200μF 6A 5A 5.2A 4.3A 144W 120W 7A 10A *) at clockwise end position of potentiometer ±0.2%, at full load, cold unit Input voltage variations between 18 to 32.4Vdc static value, 0A Æ 5A 20Hz to 20MHz, 50Ohm at 24V, ambient < 45°C, see Fig. 5-1 at 24V, ambient < 60°C, see Fig. 5-1 at 28V, ambient < 45°C, see Fig. 5-1 at 28V, ambient < 60°C, see Fig. 5-1 for ambient temperatures < 45°C for ambient temperatures < 60°C continuous current, short circuit impedance 200mOhm continuous current, short circuit impedance 200mOhm *) extended guaranteed adjustment range down to 23V. Fig. 5-1 Output voltage vs. output current at 24Vdc input voltage, typ. Output Voltage Output Current Adjustment Range 28V 6.6A 6.5 6.4 6.3 6.2 6.1 6.0 5.9 5.8 24 20 16 12 8 4 0 Output Current 0 2 Fig. 5-2 Current limitation vs. input voltage, (23V constant voltage load), typ. 4 6 8 10 12A Input Voltage 15 18 21 24 27 30 33Vdc Peak current capability (up to several milliseconds) 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 causes a voltage dip on the output. Detailed curves can be found in chapter 21.1. Peak current voltage dips typ. typ. typ. from 24V to 18V from 24V to 15V from 24V to 11.5V at 10A for 50ms, resistive load at 20A for 2ms, resistive load at 20A for 5ms, resistive load Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 6/22 CD5.241 DC/DC Converter 24V, 5A 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. 11.8ms 6ms input 24Vdc, output: 24Vdc, 2.5A, see Fig. 6-1 input 24Vdc, output: 24Vdc, 5A, see Fig. 6-1 Fig. 6-1 Hold-up time vs. input voltage Hold-up Time 12ms 10 (a) 8 (b) (c) 6 4 (a) 24V, 2.5A, typ. (b) 24V, 2.5A, min. (c) 24V, 5A, typ. (d) 24V, 5A, min. 2 Input Voltage 0 18 20 22 (d) 24 28Vdc 26 Fig. 6-2 Shut-down test setup S1 + DC Source - DC/DC Converter Input + Intput Voltage S1 opens + CD5 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. Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 7/22 CD5.241 DC/DC Converter 24V, 5A CD-Series 7. EFFICIENCY AND POWER LOSSES Efficiency Power losses Fig. 7-1 Input 24Vdc 90.3% 0.7W 6.2W 12.9W 16.3W typ. typ. typ. typ. typ. Efficiency vs. output current at 24V output and 24Vdc input voltage, typ. at 24V, 5A at no output load at 24V, 2.5A at 24V, 5A at 24V, 6A Fig. 7-2 Losses vs. output current at 24V output and 24Vdc input voltage, typ. Efficiency Power Losses 91% 18W 90 15 89 12 88 9 87 6 86 3 Output Current 85 1 Fig. 7-3 2 3 4 Output Current 0 5 6A Efficiency vs. input voltage at 24V, 5A, typ. 0 Fig. 7-4 1 3 4 5 6A Losses vs. input voltage at 24V, 5A, typ. Efficiency Power Losses 91% 18W 90.5 15 90.0 12 89.5 9 89.0 6 3 88.5 88.0 18 2 Input Voltage 20 22 24 26 Input Voltage 0 28 30 32Vdc 18 20 22 24 26 28 30 32Vdc Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 8/22 CD5.241 DC/DC Converter 24V, 5A CD-Series 8. FUNCTIONAL DIAGRAM Fig. 8-1 Functional diagram Output Voltage Regulator + - Input Fuse & Input Filter Chassis Ground Reverse Polarity Protection & Inrush Limiter OverTemperature Protection 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 Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 9/22 CD5.241 DC/DC Converter 24V, 5A CD-Series 10. TERMINALS AND WIRING Type Solid wire Stranded wire American Wire Gauge Wire stripping length Screwdriver Recommended tightening torque Input screw terminals max. 6mm2 max. 4mm2 20-10 AWG 7mm / 0.275inch 3.5mm slotted or Pozidrive No 2 1Nm, 9lb.in Output screw terminals max. 6mm2 max. 4mm2 20-10 AWG 7mm / 0.275inch 3.5mm slotted or Pozidrive No 2 1Nm, 9lb.in Instructions: a) The external circuitry of all terminals must meet the safety requirements stipulated by IEC/EN/UL 60950-1: SELV. b) 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. c) Follow national installation codes and installation regulations! d) Ensure that all strands of a stranded wire enter the terminal connection! e) Do not load the terminals with more than 25A! See section 21.9 f) Screws of unused terminal compartments should be securely tightened. g) Ferrules are allowed. h) Do not connect or disconnect the wires from the terminals below -25°C (-13°F). 11. RELIABILITY Lifetime expectancy *) MTBF **) SN 29500, IEC 61709 MTBF **) MIL HDBK 217F Input 24Vdc 183 000h 65 000h 37 000h 185 000h 1 178 000h 1 932 000h 625 000h 838 000h at 24V, 2.5A and 40°C at 24V, 5A and 40°C at 24V, 6A and 40°C at 24V, 5A and 25°C at 24V, 5A and 40°C at 24V, 5A and 25°C at 24V, 5A and 40°C; Ground Benign GB40 at 24V, 5A 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. Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 10/22 CD5.241 DC/DC Converter 24V, 5A CD-Series 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 Class B, input lines (Limits for DC power ports) Class B IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 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) Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 11/22 CD5.241 DC/DC Converter 24V, 5A 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) 1.6W/°C 3W/°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. 7.5W/1000m or 5°C/1000m above 2000m (6500ft), see Fig. 13-2 III IEC 62477-1, EN 50178, altitudes up to 2000m II altitudes from 2000m to 6000m 2 IEC 62477-1, EN 50178, 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. Fig. 13-1 Output current vs. ambient temp. Allowable Output Current at 24V 6A short term continuous Fig. 13-2 Output current vs. altitude at 24V Allowable Output Current at 24V 5 5 4 4 3 3 2 2 1 1 Ambient Temperature 0 -25 0 20 40 short term 6A B C A A... Tamb < 60°C B... Tamb < 50°C C... Tamb < 40°C Altitude 0 60 70°C 0 2000 4000 6000m Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 12/22 CD5.241 CD-Series DC/DC Converter 24V, 5A 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. 32Vdc 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 yes output shut-down with automatic restart 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 IEC/EN 60950-1 IEC/EN 60204-1, EN 50178, 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. Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 13/22 CD5.241 DC/DC Converter 24V, 5A 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 phaseterminals 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. Fig. 16-1 Dielectric strength Type test Input + B - 60s A 1500Vac B 1500Vac C 500Vac Factory test 5s 1500Vac 1500Vac 500Vac Field test 5s 1000Vac 1000Vac 500Vac > 30mA > 30mA > 12mA 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. Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 14/22 CD5.241 DC/DC Converter 24V, 5A CD-Series 17. APPROVALS EC Declaration of Conformity The CE mark indicates conformance with the - EMC directive and the - ATEX directive. CB Scheme, Information Technology Equipment IEC 60950-1 2nd Edition IEC 61010-1 UL 508 IND. CONT. EQ. UL 60950-1 UL 61010-1 EN 60079-0, EN 60079-15 ATEX II 3G Ex nA nC II T4 Gc IEC 60079-0, IEC 60079-15 ANSI / ISA 12.12.01-2007 Class I Div 2 Marine EAC TR Registration IECEx CB Scheme, Electrical Equipment for Measurement, Control and Laboratory Use 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 RECOGNIZED for use in Electrical Equipment for Measurement, Control and Laboratory Use; E-File: E326782 Approval for use in hazardous locations Zone 2 Category 3G. Number of ATEX certificate: EPS 08 ATEX 1 142 X 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) Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 15/22 CD5.241 CD-Series DC/DC Converter 24V, 5A 19. PHYSICAL DIMENSIONS AND WEIGHT Weight DIN-Rail Installation Clearances 425g / 0.94lb 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 unit depth (102mm) to calculate the total required installation depth. See chapter 2 Fig. 19-1 Front view Fig. 19-2 Side view Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 16/22 CD5.241 DC/DC Converter 24V, 5A CD-Series 20. ACCESSORIES 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 slider of the unit have to be removed, so that the two steel brackets can be mounted. Fig. 20-1 ZM1.WALL Wall mounting bracket *) Fig. 20-2 Assembled wall mounting bracket *) Picture of the DC/DC converter is for representation only ZM11.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. Fig. 20-3 ZM11.SIDE Side mounting bracket *) *) Fig. 20-4 Side mounting with DIN-rail brackets *) Picture of the DC/DC converter is for representation only Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 17/22 CD5.241 DC/DC Converter 24V, 5A CD-Series 21. APPLICATION NOTES 21.1. PEAK CURRENT CAPABILITY 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. 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. 21-1 Peak loading with 2x the nominal current for 50ms, typ. Output Voltage 24V 10A Fig. 21-2 Peak loading with 4x the nominal current for 5ms, typ. 24V Output Voltage 18V 20A 11.5V Output Current 0A 10ms/DIV Output Current 0A 1ms/DIV Peak load 10A (resistive load) for 50ms Output voltage dips from 24V to 18V. Peak load 20A (resistive load) for 5ms Output voltage dips from 24V to 11.5V. 21.2. 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. (Electro Magnetic Force). 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 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. Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 18/22 CD5.241 DC/DC Converter 24V, 5A CD-Series 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. 26.4mA 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 10A B- or 8A C-Characteristic breaker should be used. 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 Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 19/22 CD5.241 DC/DC Converter 24V, 5A CD-Series 21.7. PARALLEL USE TO INCREASE OUTPUT POWER Unit A 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. The CD5.241 can also be paralleled with power supplies from the DIMENSION CT, QS or QT-series. For other power supplies consult PULS. Set the “single use / parallel use” jumper to “parallel use” if such an option is available. Input Output Unit B Input + - Load + + - Output - 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 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/DC-converters 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). 21.8. 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 put 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 5A are paralleled to build a 20A 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. 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/DCconverters and the output voltage can not be maintained any more. This can only be avoided by utilizing decoupling diodes which are included in the decoupling module YRM2.DIODE. Recommendations for building redundant power systems: a) Use separate input fuses for each DC/DC-converter. b) Monitor the individual DC/DC-converter units. A DC-ok lamp and a DC-ok contact is included in the redundancy module YRM2.DIODE. This feature reports a faulty unit. 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. Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 20/22 CD5.241 DC/DC Converter 24V, 5A CD-Series 21.9. 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. 21-4 Daisy chaining of outputs Fig. 21-5 Using distribution terminals max 25A! + - Output + + - - Output + + - - DC/DC Converter DC/DC Converter DC/DC Converter DC/DC Converter Input Input Input Input Load Output + + - - Output + + - - 21.10. SERIES OPERATION + - Load Distribution Terminals Unit A + Input 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 Output 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 Unit B + output is required when the sum of the output voltage is above 60Vdc. Avoid Input return voltage (e.g. from a decelerating motor or battery) which is applied to the output terminals. Keep an installation clearance of 15mm (left / right) between two DC/DC-converters and avoid installing the DC/DC-converters on top of each Output 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). Load + - 21.11. 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 Enclosure: Load: Input: Temperature inside enclosure: Temperature outside enclosure: Temperature rise: Rittal Typ IP66 Box PK 9516 100, plastic, 110x180x165mm 24V, 4A; (=80%) load is placed outside the box 24Vdc 42.8°C (in the middle of the right side of the DC/DC converter with a distance of 2cm) 24.0°C 18.8K Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 21/22 CD5.241 DC/DC Converter 24V, 5A CD-Series 21.12. 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. 21-6 Mounting Orientation A (Standard orientation) Output Current 6A 5 4 3 2 1 0 10 OUTPUT DC/DC Converter INPUT Fig. 21-7 Mounting Orientation B (Upside down) 30 40 60°C 50 6A 5 4 3 2 1 0 10 A2 A1 Ambient Temperature 20 30 40 60°C 50 INPUT DC/DC Converter OUTPUT Output Current 6A 5 4 3 2 1 0 10 A2 A1 Ambient Temperature 20 30 40 60°C 50 Output Current OUTPUT DC/DC Converter INPUT 6A 5 4 3 2 1 0 10 A2 A1 Ambient Temperature 20 30 40 60°C 50 INPUT DC/DC Converter Output Current OUTPUT Fig. 21-10 Mounting Orientation E (Horizontal ccw) Ambient Temperature 20 Output Current Fig. 21-8 Mounting Orientation C (Table-top mounting) Fig. 21-9 Mounting Orientation D (Horizontal cw) A1 6A 5 4 3 2 1 0 10 A2 A1 Ambient Temperature 20 30 40 50 60°C Mar. 2016 / Rev. 1.5 DS-CD5.241-EN All parameters are specified at 24V, 5A, 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 22/22