CD5.242 Datasheet by PULS, LP

PULS DIMENSION @us “Still 0 17 s c us E“ US ECEx® CE DNV-GL dnvgl.com/af
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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1/22
DC/DC CONVERTER
48V 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
G
ENERAL
D
ESCRIPTION
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.
The CD5.242 converts a 48V voltage to a 24V voltage.
The CD5.242 includes all the essential basic functions
and has a power reserve of 20% included. This extra
power can be used continuously up to +45°C.
The output is electrically isolated from the input in a
safe way. The input is protected against reversed
voltages and contains a soft start function.
CD5.241
CD5.243
CD5.242
CD5.241-S1
CD-Series
Related products
24V->24V
48V->24V
12V->24V
CD5.241-L1 24V->24V, NEC Class 2,
Spring-clamp-terminals,
CD5.121 24V->12V
SLD2.100
24V->5V
CD5.051 24V->5V
24V->24V,
Spring-clamp-terminals,
Input-low, DC-OK signals
S
HORT
-
FORM
D
ATA
Output voltage
DC 24V
Adjustment range
24 - 28V
Output current
ambient <60°C
ambient <45°C
Output power
ambient <60°C
144W ambient <45°C
Output ripple
< 50mVpp 20Hz to 20MHz
Input voltage
Input voltage range
full specified
with derating
Input current
typ. 2.75A at 48Vdc input
Input inrush current
Efficiency
at 48Vdc input
Losses
12.9W at 48Vdc input
Temperature range
-25°C to +70°C operational
Derating
+60 to +70°C
Hold-up time
at 48Vdc input
Dimensions
WxHxD
Weight
*) extended guaranteed adjustment range down to 23V.
O
RDER
N
UMBERS
DC/DC Converter CD5.242 Standard unit
Accessory ZM1.WALL Wall mount bracket
ZM11.SIDE Side mount bracket
YRM2.DIODE Redundancy module
M
ARKINGS
Ind. Cont. Eq.
UL 508
UL 60950-1
EMC, ATEX
Class I Div 2 IECEx ATEX
II 3G Ex ec nC II T4 Gc Marine
PULS I DIMENSION
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc 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
I
NDEX
Page Page
1. Intended Use .......................................................3
2. Installation Requirements ...................................3
3. Input Voltage ......................................................4
4. Soft-start and Input Inrush Current Surge .........5
5. Output .................................................................6
6. Hold-up Time .......................................................7
7. Efficiency and Power Losses................................8
8. Functional Diagram .............................................9
9. Front Side and User Elements .............................9
10. Terminals and Wiring ........................................ 10
11. Reliability ........................................................... 10
12. EMC .................................................................... 11
13. Environment ...................................................... 12
14. Protection Features ........................................... 13
15. Safety Features .................................................. 13
16. Dielectric Strength ............................................ 14
17. Approvals ........................................................... 15
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.
PULS I DIMENSION 1.| U 2.| R AWARNING
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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3/22
1. I
NTENDED
U
SE
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. I
NSTALLATION
R
EQUIREMENTS
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 60079-7.
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 60079-7.
DIMENSION / PULS
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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4/22
3. I
NPUT
V
OLTAGE
I
nput voltage nom. DC 48V
I
nput voltage range 36.0-60.0Vdc full specified
30.5-36.0Vdc maximal 60 seconds or with de-rating see Fig. 3-2
max. 63.0Vdc absolute maximum continuous input voltage with no
damage to the DC/DC converter
Allowed voltage
between input
and
earth
max. 60Vdc or
42.2Vac
in case the output voltage is not grounded.
Allowed
input ripple voltage max. 5Vpp 47Hz-500Hz, the momentary input voltage must always
be within the specified limits.
Turn
-on voltage typ. 34.5Vdc steady-state value, see Fig. 3-1
Shut
-down voltage typ. 30.5Vdc steady-state value, see Fig. 3-1
typ. 63.5Vdc steady-state value, see Fig. 3-1
Input current
typ. 2.75A at 48Vdc input and output 24V, 5A, see Fig. 3-4
Start
-up delay typ. 670ms see Fig. 3-3
Rise time
typ. 80ms 0mF, 24V, constant current load 5A, see Fig. 3-3
typ. 150ms 5mF, 24V, constant current load 5A, see Fig. 3-3
Turn-on overshoot
max.
500mV
see Fig. 3-3
Input capacitance
typ. 800µF external capacitors on the input voltage bus are allowed
without any limitations.
Fig. 3-1 Input voltage range Fig. 3-2 Allowable output current below 36V
input voltage
Turn-on
34.5Vdc
V
IN
P
OUT
Shut-down
60.0Vdc
30.5Vdc
36.0Vdc
Rated input range
63.5Vdc
0
1
2
3
4
6A
30 32 34 36 40Vdc
Input Voltage
Output Current
5
38
(a)
(b)
(a) Ambient < 45°C
(b) Ambient < 60°C
Fig. 3-3 Turn-on behavior, definitions Fig. 3-4 Input current vs. output load
Start-up
delay Rise
Time
Overshoot
- 5%
Output
Voltage
Input
Voltage
6A
11.5 2 3 4
0
1
2
3
4A
5
Output Current
2.5 3.5 4.5 5.5
Input: 48Vdc
Input
Current,
typ.
Input: 36Vdc
PULS DIMENSION 4.5 T- | | r. F \anIt Current / t Input Voltage Output Voltage Input Current , ‘ Output Voltage '
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc 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
4. S
OFT
-
START AND
I
NPUT
I
NRUSH
C
URRENT
S
URGE
Inrush current limitation
An active inrush limitation circuit (inrush limiting resistor which is bypassed by a relay contact) limits the input inrush
current after turn-on of the input voltage.
The charging current into EMI suppression capacitors is disregarded in the first microseconds after switch-on.
Inrush current
max. 0.8Apeak -25°C to +70°C, input: 48Vdc
typ. 0.6Apeak -25°C to +70°C, input: 48Vdc
Inrush energy
typ.
negligible
-25°C to +70°C, input: 48Vdc
Fig. 4-1 Input inrush current, typical behavior
Input: 48Vdc
Output: 24V, 5A, constant current load
Ambient: 25°C
Upper curve: Input current 1A / DIV
Middle curve: Input voltage 50V / DIV
Lower curve: Output voltage 20V / DIV
Time basis: 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 soft-
start 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: 48Vdc
Output: 24V, 5A, constant current load
Ambient: 25°C
No additional external output capacitors
Upper curve: Input current 2A / DIV
Lower curve: Output voltage 10V / DIV
Time basis: 20ms / DIV
PULS DIMENSION 5.0 12A
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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6/22
5. O
UTPUT
Output voltage
nom. 24V
Adjust
ment range min. 24-28V *)
max. 30V at clockwise end position of potentiometer
Factory setting
24.1V ±0.2%, at full load, cold unit
Line regulation
max.
25mV
Input voltage variations between 36 to 60Vdc
Load regulation
max. 100mV static value, 0A 5A
Ripple and noise voltage
max. 50mVpp 20Hz to 20MHz, 50Ohm
Output capacitance
typ. 2 200µF
Output current
nom. 6A at 24V, ambient < 45°C, see Fig. 5-1
nom. 5A at 24V, ambient < 60°C, see Fig. 5-1
nom. 5.2A at 28V, ambient < 45°C, see Fig. 5-1
nom. 4.3A at 28V, ambient < 60°C, see Fig. 5-1
Output power
nom.
144W
for ambient temperatures < 45°C
nom. 120W for ambient temperatures < 60°C
Short
-circuit current min. 7A continuous current, short circuit impedance 200mOhm
max. 10A continuous current, short circuit impedance 200mOhm
*) extended guaranteed adjustment range down to 23V.
Fig. 5-1 Output voltage vs. output current, at
48Vdc input voltage, typ.
Fig. 5-2 Current limitation vs. input voltage,
(23V constant voltage load), typ.
Output Voltage
0
048
4
8
12
28V
16
20
24
12A
1062
Adjustment
Range
Output Current
Output Current
6.2
30 42 54
6.3
6.4
6.5
7.0A
6.7
6.8
6.9
60Vdc
4836
6.6
Input Voltage
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. from 24V to 17.1V at 10A for 50ms, resistive load
typ. from 24V to 15V at 20A for 2ms, resistive load
typ. from 24V to 11V at 20A for 5ms, resistive load
DIMENSION PULS
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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7/22
6. H
OLD
-
UP
T
IME
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. 10.5ms input 48Vdc, output: 24Vdc, 2.5A, see Fig. 6-1
typ. 5.6ms input 48Vdc, output: 24Vdc, 5A, see Fig. 6-1
Fig. 6-1 Hold-up time vs. input voltage
0
2
4
6
8
12ms
36 40 44 48 56Vdc
Input Voltage
Hold-up Time
(a) 24V, 2.5A, typ.
(b) 24V, 2.5A, min.
(c) 24V, 5A, typ.
(d) 24V, 5A, min.
10
52
(a) (b)
(c) (d)
Fig. 6-2 Shut-down test setup Fig. 6-3 Shut-down behavior, definitions
Load
+
-
DC/DC
Converter
DC
Source
+
-
Input
Output
+
-
CD5
S1
- 5%
Hold-up Time
Output
Voltage
Intput
Voltage
S1 opens
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.
PULS DIMENSION "rfirfiTfiTfifififi
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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8/22
7. E
FFICIENCY AND
P
OWER
L
OSSES
Input 48Vdc
Efficiency
typ. 90.3% at 24V, 5A
Power losses
typ. 0.9W at no output load
typ. 6.9W at 24V, 2.5A
typ. 12.9W at 24V, 5A
typ. 16.4W at 24V, 6A
Fig. 7-1 Efficiency vs. output current at 24V
output and 48Vdc input voltage, typ.
Fig. 7-2 Losses vs. output current at 24V
output and 48Vdc input voltage, typ.
Efficiency
1
86
88
90
85
91%
6A2 4 53
87
89
Output Current
Power Losses
012 456A
0
3
9
15
18W
6
3
12
Output Current
Fig. 7-3 Efficiency vs. input voltage at 24V,
5A, typ.
Fig. 7-4 Losses vs. input voltage at 24V, 5A,
typ.
Efficiency
36 40 44 52 56 60Vdc
91%
88.5
89.5
90.5
90.0
89.0
88.0
48
Input Voltage
Power Losses
0
3
6
9
12
15
18W
36 40 48 52 56 60Vdc44
Input Voltage
DIMENSION PULS I
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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9/22
8. F
UNCTIONAL
D
IAGRAM
Fig. 8-1 Functional diagram
+
+
-
-
VOUT
Input Fuse
&
Input Filter
Output
Voltage
Regulator
Power
Converter Output
Filter
DC
ok
Output
Over-
Voltage
Protection
Reverse
Polarity
Protection
&
Inrush
Limiter
Chassis
Ground
+
-
Over-
Temperature
Protection
9. F
RONT
S
IDE AND
U
SER
E
LEMENTS
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
PULS I DIMENSION 10.T W 11.R
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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10/22
10. T
ERMINALS AND
W
IRING
Input Output
Type
screw terminals screw terminals
S
olid wire max. 6mm2 max. 6mm2
Stranded wire
max. 4mm2 max. 4mm2
American Wire Gauge
20-10 AWG 20-10 AWG
Wire stripping length
7mm / 0.275inch 7mm / 0.275inch
Screwdriver
3.5mm slotted or
Pozidrive No 2
3.5mm slotted or
Pozidrive No 2
Recommended
tightening torque 1Nm, 9lb.in 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. R
ELIABILITY
Input 48Vdc
Lifetime expectancy
*) 169 000h at 24V, 2.5A and 40°C
64 000h at 24V, 5A and 40°C
39 000h
at 24V, 6A and 40°C
181 000h at 24V, 5A and 25°C
MTBF
**) SN 29500, IEC 61709 951 000h at 24V, 5A and 40°C
1 560 000h at 24V, 5A and 25°C
MTBF
**) MIL HDBK 217F 559 000h at 24V, 5A and 40°C; Ground Benign GB40
749 000h 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.
PULS I DIMENSION 12. EMC
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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11/22
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
Generic standards: EN 61000-6-1 and EN 61000-6-2
Electrostatic discharge
EN 61000-4-2 Contact discharge
Air discharge
8kV
15kV
Criterion A
Criterion A
Electromagnetic RF field
EN 61000-4-3 80MHz-2.7GHz 10V/m Criterion A
Fast transients (Burst)
EN 61000-4-4 Input lines
Output lines
4kV
2kV
Criterion A
Criterion A
Surge voltage on input
EN 61000-4-5
+
-
1kV
Criterion A
+/- chassis ground 2kV Criterion A
Surge voltage on output
EN 61000-4-5 + -
+ / - chassis ground
500V
1kV
Criterion A
Criterion A
Conducted disturbance
EN 61000-4-6 0.15-80MHz 10V Criterion A
Criterions:
A: DC/DC converter shows normal operation behavior within the defined limits.
C: Temporary loss of function is possible. DC/DC converter may shut-down and restarts by itself. No damage or hazards for the DC/DC
converter will occur.
EMC Emission
Generic standards: EN 61000-6-3 and EN 61000-6-4
Conducted emission on
input
IEC/CISPR 16-1-2, IEC/CISPR 16-2-1
Limits for DC power ports
acc. EN 61000-6-3 fulfilled
Radiated emission
EN 55011, EN 55022 Class B
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
d
evice must accept any interference received, including interference that may cause undesired operation.
Switching frequency
Variable between 90kHz and 140kHz depending on load and input voltage
(output current > 0.5A)
E PULS DIMENSION 13.
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.
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12/22
13. E
NVIRONMENT
Operational t
emperature *) -25°C to +70°C (-13°F to 158°F) reduce output power according Fig. 13-1
Storage temperature
-40 to +85°C (-40°F to 185°F) for storage and transportation
Output de
-rating 1.6W/°C 45-60°C (113°F to 140°F)
3W/°C 60-70°C (140°F to 158°F)
Humidity
**) 5 to 95% r.H. IEC 60068-2-30
Vibration sinusoidal
***) 2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g
2 hours / axis
IEC 60068-2-6
Shock
***) 30g 6ms, 20g 11ms
3 bumps / direction, 18 bumps in total
IEC 60068-2-27
Altitude
0 to 6000m (0 to 20 000ft) reduce output power or ambient temperature
above 2000m sea level.
Altitude de
-rating 7.5W/1000m or 5°C/1000m above 2000m (6500ft), see Fig. 13-2
Over
-voltage category III IEC 62477-1, EN 50178, altitudes up to 2000m
II
altitudes from 2000m to 6000m
Degree of pollution
2 IEC 62477-1, EN 50178, not conductive
LABS compatibility
The unit does not release any silicone or other LABS-critical substances and is suitable for
use in paint shops.
*) 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. Fig. 13-2 Output current vs. altitude at 24V
0
-25 020 40 70°C
1
2
3
4
5
6A
60
Ambient Temperature
continuous
short
term
Allowable Output
Current at 24V
0
02000 4000 6000m
1
2
3
4
5
6A
Altitude
A... Tamb < 60°C
B... Tamb < 50°C
C... Tamb < 40°C
C
B
A
short term
Allowable Output
Current at 24V
PULS I DIMENSION 14. P F 15.5 F
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc 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
14. P
ROTECTION
F
EATURES
Output protection
Electronically protected against overload, no-load and short-circuits *)
Output over
-voltage protection typ. 31Vdc
max. 32Vdc
in case of an internal DC/DC converter defect, a redundant
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. S
AFETY
F
EATURES
Classification of output voltage
SELV IEC/EN 60950-1
PELV IEC/EN 60204-1, EN 50178, IEC 62477-1, IEC 60364-4-41
Class of protection
III PE (Protective Earth) connection not required. A
connection of the “Chassis Ground” pin to earth is
recommended for best EMI performance
Isolation resistance
> 5MOhm input to output, 500Vdc
PE resistance
< 0.1Ohm between housing and Chassis Ground terminal
Touch current (leakage current)
The leakage current which is produced by the DC/DC converter itself depends on 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.
PULS DIMENSION I 16. D S ll k/
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc 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
16. D
IELECTRIC
S
TRENGTH
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.
Fig. 16-1 Dielectric strength A B C
A
C
B
+
Input
Chassis
ground
Output
-
+
-
Type test 60s 1500Vac 1500Vac 500Vac
Factory test 5s 1500Vac 1500Vac 500Vac
Field test 5s 1000Vac 1000Vac 500Vac
Cut-off current setting > 30mA > 30mA > 12mA
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.
PULS DIMENSION 17. A IE CE E CB SCHEME ".N'éscw‘g'é [In US (E2) 18. ROHS, REACH £5: DNV-GL dnvg|.com/af ABS [HI DO F RoHS\/ REACH \/
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc 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
17. A
PPROVALS
EC Declaration
of Conformity
The CE mark indicates conformance with the
- EMC directive and the
- ATEX directive.
IEC 60950
-1
2
nd Edition
CB Scheme,
Information Technology Equipment
UL 508
IND. CONT. EQ.
LISTED for use as Industrial Control Equipment;
U.S.A. (UL 508) and Canada (C22.2 No. 107-1-01);
E-File: E198865
UL 60950-1
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
EN 60079
-0, EN 60079-7
ATEX
II 3G Ex ec nC II T4 Gc
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.
IEC 60079
-0, IEC 60079-7
IECEx
Suitable for use in Class 1 Zone 2 Groups IIa, IIb and IIc
locations. Number of IECEx certificate: IECEx EPS 14.0001X
ANSI / IS
A 12.12.01-2007
Class I Div 2
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)
Marine
GL (Germanischer Lloyd) classified and
ABS (American Bureau for Shipping) PDA
Environmental category: C, EMC2
Marine and offshore applications
EAC TR Registration
Registration for the Eurasian Customs Union market
(Russia, Kazakhstan, Belarus)
18. R
O
HS,
REACH
AND
O
THER
F
ULFILLED
S
TANDARDS
RoHS 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.
REACH Directive
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)
PULS DIMENSION 19. P D g. 254 _ Ou'pul = a: 247 § I 25v , ncoxo E E
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc 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
19. P
HYSICAL
D
IMENSIONS AND
W
EIGHT
Weight
425g / 0.94lb
DIN
-Rail Use 35mm DIN-rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm.
The DIN-rail height must be added to the unit depth (102mm) to calculate the total required
installation depth.
Installation Clearances
See chapter 2
Fig. 19-1 Front view Fig. 19-2 Side view
PULS I DIMENSION 20. A
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc 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
20. A
CCESSORIES
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
PULS DIMENSION 21. A N S “V u 33%;: 24v " ‘-"“‘\ Out ut Voltage / 10A Hg“ Output Out ut (WA Current ‘Currpem ' WA 10ms/DIV lms/DIV
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc 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
21. A
PPLICATION
N
OTES
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.
Fig. 21-2 Peak loading with 4x the nominal
current for 5ms, typ.
Peak load 10A (resistive load) for 50ms
Output voltage dips from 24V to 17.1V. Peak load 20A (resistive load) for 5ms
Output voltage dips from 24V to 11V.
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.
PULS DIMENSION
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc 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
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 6A B- or 6A 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
1 mOhm
10 mOhm
100 mOhm
1 Ohm
0.1mH 1mH 10mH
Inductance of the supplying network
Resistance of the
supplying network
(a) max.
(b) typ.
(a)
(b)
PULS DIMENSION
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc 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
21.7. PARALLEL USE TO INCREASE OUTPUT POWER
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/DC
converters. Therefore some restrictions and limitations apply. The DC/DC
converter 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 CD5.242 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.
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/DC
converters 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.
Unit A
Input
Output
Unit B
-
+
-
+
+
-
Input
Output
Load
PULS DIMENSION maxZSA!\ |—l \T‘ x e e e e f l—\ |—‘ UmIA uma
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc 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
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
DC/DC
Converter
+ +
- -
Input
Output
Load
+
-
max 25A!
DC/DC
Converter
+ +
- -
Input
Output
Load
+
-
Distribution
Terminals
DC/DC
Converter
+ +
- -
Input
Output
DC/DC
Converter
+ +
- -
Input
Output
21.10. SERIES OPERATION
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. 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 series in mounting orientations other than
the standard mounting orientation (input terminals on the bottom and output terminals on top of the unit).
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: Rittal Typ IP66 Box PK 9516 100, plastic, 110x180x165mm
Load: 24V, 4A; (=80%) load is placed outside the box
Input: 48Vdc
Temperature inside enclosure: 42.8°C (in the middle of the right side of the DC/DC converter with a distance of 2cm)
Temperature outside enclosure: 24.0°C
Temperature rise: 18.8K
Unit A
Input
Output
Unit B
-
+
-
+
+
-
Input
Output
Load
PULS DIMENSION Muunli g 7 31:22?" A 7 ’%"’*"’::’ J E j !—| Orienta on a |—‘ E 3 l—I (Ya blarlop ng,2|40 Orientation E
CD5.242
CD-Series DC/DC Converter 24V, 5A
Nov. 2019 / Rev. 1.6 DS-CD5.242-EN
All parameters are specified at 24V, 5A, 48Vdc 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
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 Recommended output current.
Curve A2 Max allowed output current (results in approximately half the lifetime expectancy of A1).
Fig. 21-6
Mounting
Orientation A
(Standard
orientation) DC/DC
Converter
OUTPUT
INPUT
Output Current
0
10 20 30 40 60°C
2
3
5
6A
50
A1
Ambient Temperature
4
1
Fig. 21-7
Mounting
Orientation B
(Upside down)
DC/DC
Converter
OUTPUT
INPUT
Output Current
0
10 20 30 40 60°C
2
3
5
6A
50
Ambient Temperature
4
1
A2
A1
Fig. 21-8
Mounting
Orientation C
(Table-top
mounting)
Output Current
0
10 20 30 40 60°C
2
3
5
6A
50
Ambient Temperature
4
1
A1
A2
Fig. 21-9
Mounting
Orientation D
(Horizontal cw)
DC/DC
Converter
OUTPUT
INPUT
Output Current
0
10 20 30 40 60°C
2
3
5
6A
50
Ambient Temperature
4
1
A1
A2
Fig. 21-10
Mounting
Orientation E
(Horizontal ccw)
DC/DC
Converter
OUTPUT
INPUT
Output Current
0
10 20 30 40 60°C
2
3
5
6A
50
Ambient Temperature
4
1
A1
A2