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cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w dc/dc c onverter ? 24v dc-input ? isolated 24vdc output ? efficiency 94.2% ? width only 42mm ? 20% output power reserves ? full power between -25c and +60c ? soft-start function ? minimal inrush current surge ? reverse input polarity protection ? 3 year warranty 1/25 g eneral d escription the cd10.241 is a din-rail mountable dc/dc converter of the dimension series wh ich provides a floating, stabilized and galvanically separated selv/pelv output voltage. the cd-series is part of the dimension power supply family. the most outstanding features of cd10.241 are the high efficiency, the small size and the wide operational temperature range. the cd-series includes all the essential basic functions. the devices have a power reserve of 20% included, which may even be used cont inuously at temperatures up to +45c. high immunity to transients a nd power surges as well as low electromagnetic emission and a large international approval package for a variety of applications makes this unit suitable for nearly every situation. s hort - form d ata output voltage dc 24v adjustment range 24 - 28v*) output current 12 C 10.3a below +45c amb. 10 C 8.6a at +60c ambient 7.5 C 6.5a at +70c ambient derate linearly between +45c and +70c input voltage dc 24v -25%/+46% input voltage range 18 to 35vdc input current typ. 10.5a at 24vdc input input inrush current typ. 6a peak at 25c efficiency 94.2% at 24vdc input losses 14.8w at 24vdc input temperature range -25c to +70c hold-up time 4ms at 24vdc input size (w x h x d) 42x124x117mm without din-rail weight 500g / 1.1lb *) extended guaranteed adjustment range down to 23v. o rder n umbers dc/dc converter cd10.241 accessory zm2.wall wall mount bracket zm12.side side mount bracket yr20.246 redundancy module m arkings ind. cont. eq. ul 508, planned ul 60950-1 planned class i div 2 planned iecex atex planned marine, planned jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w i ndex page page 1. intended use .......................................................3 2. installation requirements ...................................3 3. input voltage ......................................................4 4. input inrush current and soft-start behavior ....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. lifetime expectancy ..........................................11 12. mtbf ..................................................................11 13. emc ....................................................................12 14. environment ......................................................13 15. protection features ...........................................14 16. safety features ..................................................14 17. dielectric strength ............................................15 18. approvals ...........................................................16 19. rohs, reach and othe r fulfilled standards ...16 20. physical dimensions and weight ..................... 17 21. accessories ........................................................ 18 21.1. zm2.wall - wall mounting bracket .......18 21.2. zm12.side - side mounting bracket ........18 21.3. yr20.246 redundancy module ................19 22. application notes ............................................. 20 22.1. peak current capability ...........................20 22.2. back-feeding loads ..................................21 22.3. inductive and capacitive loads ................21 22.4. charging of batteries ...............................21 22.5. external input protection .........................21 22.6. requirements for the supplying source ..22 22.7. series operation .......................................22 22.8. parallel use to increase output power ....23 22.9. parallel use for redundancy ....................23 22.10. use in a tightly sealed enclosure ............24 22.11. mounting orientations ............................25 the information given in this document is correct to the best of our kn owledge and experience at the time of publication. if not expressly agreed othe rwise, this information does not represent a warranty in the legal sense of the word. as the state of our knowledge an d experience is constantly changing, the information in this data sheet is subject to revision. we therefore ki ndly ask you to always use the latest issue of this document (available under www.pulspower.com). no part of this document may be reproduced or utilized in any form without our prior permission in writing. t erminology and a breviations pe and symbol pe is the abbreviation for p rotective e arth 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 de scription 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 disregardi ng 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. jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 2/25
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 1. i ntended u se this device is designed for installation in an enclosure and is intended for th e general use such as in industrial control, office, communication, and instrumentation equipment. do not use this device in equipment where malfunction may cause severe pers onal injury or threaten human life. 2. i nstallation r equirements this device may only be installed and put into opera tion 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 malfuncti on should occur during installation or operation, i mmediately 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 clearance s: 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 th e 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 pel v source (according to iec 62477-1) or an isolated secondary circuit (according to ul 508). warning risk of electrical shock, fi re, personal injury or death. - turn power off before working on the devi ce. protect against inad vertent 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 enteri ng the housing. - do not use in wet locations or in areas wh ere moisture or condens ation can be expected. - do not touch during power-on, and immediatel y after power-off. hot surface may cause burns. jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 3/25
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 3. i nput v oltage input voltage nom. dc 24v -25%/+46% input voltage range 18. 0-35.0vdc full specified max. 36.0vdc 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-500h z, the momentary inpu t voltage must always be within the specified limits. turn-on voltage typ. 17.5vdc steady-state value, see fig. 3-1 shut-down voltage typ. 15.5vdc steady-state value, see fig. 3-1 input current typ. 10.5a at 24vdc input and output 24v, 10a, see fig. 3-3 14,3a at 18vdc input and output 24v, 10a, see fig. 3-3 start-up delay typ. 200ms see fig. 3-1 rise time typ. 200ms 0mf, 24v, constant current load 10a, see fig. 3-2 typ. 200ms 10mf, 24v, constant current load 10a, see fig. 3-2 turn-on overshoot max. 250mv see fig. 3-2 input capacitance typ. 4 300f external capa citors on the input voltage bus are allowed without any limitations. fig. 3-1 input voltage range fig. 3-2 turn-on behavior, definitions turn-on 17.5vdc v in p out shut-down 32.4vdc 15.5vdc 18.0vdc rated input range 35.0vdc start-up rise delay time ov ershoot - 5% output voltage input voltage fig. 3-3 input current vs. output load 12a 2 34 6 8 0 4 8 12 16a 10 output current 5 7 9 11 i n p u t: 2 4 v d c input current, typ. i n p u t : 1 8 v d c jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 4/25
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 4. i nput i nrush c urrent and s oft - start b ehavior inrush current limitation an active inrush limitation circuit (inr ush limiting ntc resistor which is bypasse d 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 th e first microseconds after switch-on. inrush current typ. 6a peak +25c, cold start, input: 24vdc typ. 22a peak +60c, cold start, input: 24vdc inrush energy typ. negligible -25c to +70c, input: 24vdc fig. 4-1 input inrush current, typical behavior input current input voltage output voltage ipk 6a input: 24vdc output: 24v, 10a, constant current load ambient: 25c input current 2a / div input voltage 5v / div output voltage 5v / div time basis: 100ms / div soft-start function: after the dc/dc converter is turned on, the internal output current rises slow ly to its nominal value. this method charges the output capacitors (internal a nd external capacitors) slowly and avoi ds 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/d c 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. jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 5/25
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 5. o utput output voltage nom. 24v adjustment 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 volt age variations between 18 to 35vdc load regulation max. 100mv static value, 0a ? 10a ripple and noise voltage max. 50mvpp 20hz to 20mhz, 50ohm output capacitance typ. 4 500f output current nom. 12a at 24v, ambient < +45c, see fig. 5-1 nom. 10a at 24v, ambient < +60c, see fig. 5-1 nom. 7.5a at 24v, ambient at +70c, see fig. 5-1 nom. 10.3a at 28v, ambient < +45c, see fig. 5-1 nom. 8.6a at 28v, ambient < +60c, see fig. 5-1 nom. 6.5a at 28v, ambient at +70c, see fig. 5-1 output power nom. 288w for ambient temperatures < +45c nom. 240w for ambient temperatures < +60c nom. 180w at +70c ambient temperature short-circuit current min. 13a continuous current, short circui t impedance 100mohm max. 15a 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. fig. 5-2 current limitation vs. input voltage, (23v constant voltage load), typ. output voltage 6/25 0 048 4 8 12 28v 16 20 24 16 a 62 10 12 14 adjustment range output current output current 21 27 14a 13.0 13.5 30 24 18 10.0 10.5 11.0 11.5 12.5 12.0 33 input voltage 36vdc jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 6. h old - up t ime the input side of the dc/dc converter is equipped with a bulk capacitor which keeps the out put voltage alive for a certain period of time when the input vo ltage dips or is removed. the bulk capa citor can be discharged by loading the dc/dc converter on the output side or through a load which is parallel to the input. th ere 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. 8ms at 24vdc input and 24vdc, 5a output, see fig. 6-1 typ. 4ms at 24vdc input and 24vdc, 10a output, see fig. 6-1 fig. 6-1 hold-up time vs. input voltage 0 2 4 6 8ms 18 20 22 24 28vdc input voltage hold-up time (a) 24v, 5a, typ. (b) 24v, 5a, min. (c) 24v, 10a, typ. (d) 24v, 10a, min. 26 ( a ) ( b ) ( c ) ( d ) fig. 6-2 shut-down test setup fig. 6-3 shut-down behavior, definitions 7/25 load + - dc/dc converter dc source + - input output + - cd10 s1 - 5% hold-up time output voltage intput voltage s1 opens note: at no load, the hold-up time can be up to several se conds. the green dc-ok lamp is also on during this time. jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 7. e fficiency and p ower l osses input 24vdc efficiency typ. 94.2% at 24v, 10a typ. 93.7% at 24v, 12a (power boost) average efficiency *) typ. 94.3% 25% at 2.5a, 25% at 5a, 25% at 7.5a. 25% at 10a power losses typ. 1.75w at no output load typ. 6.8w at 24v, 5a typ. 14.7w at 24v, 10a typ. 19.5w 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 8/25 2 90 92 94 89 95% 12a 481 0 output current 6 91 93 power losses 0 2 4 8 10 12a 0 3 9 15 18w 6 6 12 output current fig. 7-3 efficiency vs. input voltage at 24v, 10a, typ. fig. 7-4 losses vs. input voltage at 24v, 10a, typ. efficiency 18 20 22 26 28 32vdc 95% 92.5 93.5 94.5 94.0 93.0 92.0 24 30 input voltage power losses 13 14 15 16 17 18 19w 18 20 24 26 28 32vdc 30 input voltage 22 jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 8. f unctional d iagram fig. 8-1 functional diagram + + - - v out input fuse & input filter output voltage regulator power converter output filter dc ok output over- voltage protection reverse polarity protection & inrush limiter chassis ground + - 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 mini mize high-frequency emissions. b output terminals screw terminals, dual terminals per pole, both pins are equal + positive output - negative (return) output 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 jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 9/25
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 10. t erminals and w iring input output type screw terminals screw terminals solid wire max. 6mm 2 max. 6mm 2 stranded wire max. 4mm 2 max. 4mm 2 american wire gauge 20-10 awg 20-10 awg max. wire diameter 2.8mm (including ferrules) 2.8mm (including ferrules) 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 1n m, 9lb.in 1nm, 9lb.in instructions: a) use appropriate copper cables that are designed for an operating temperature of: 60c for ambient up to 45c and 75c for ambient up to 60c and 90c for ambient up to 70c minimum. b) follow national installation c odes and installation regulations! c) ensure that all strands of a strande d wire enter the terminal connection! d) screws of unused terminal compa rtments should be securely tightened. daisy chaining of outputs: daisy chaining (jumping from one dc/dc-c onverter output to the next) is allo wed as long as the average output current through one terminal pin does not exceed 25a. if the current is higher, use a se parate distribution terminal block. fig. 10-1 daisy chaining of outputs fig. 10-2 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 jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 10/25
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 11. l ifetime e xpectancy the lifetime expectancy shown in the table indicates the minimum operating hou rs (service life) a nd is determined by the lifetime expectancy of the built-in el ectrolytic capacitors. lifetime expectan cy is specified in operational hours and is calculated according to the capaci tors manufacturer sp ecification. the manufacturer of the electrolytic capacitors only guarantees a maximum life of up to 15 years (131 400h ). any number exceeding th is value is a calculated theoretical lifetime which can be used to compare devices. input 24vdc lifetime expectancy 299 000h at 24v, 5a and 40c 103 000h at 24v, 10a and 40c 56 000h at 24v, 12a and 40c 844 000h at 24v, 5a and 25c 292 000h at 24v, 10a and 25c 159 000h at 24v, 12a and 25c 12. mtbf mtbf stands for mean t ime between f ailure, which is calculated according to statistical device fa ilures, and indicates reliability of a device. it is the statisti cal representation of the li kelihood of a unit to fail and does not necessarily represent the life of a product. the mtbf figure is a statistica l representation of the likeli hood of a device to fail. a mt bf 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 fi eld. however, it can not be determined if the failed unit has b een running for 50 000h or only for 100h. for these types of units the mttf ( mean t ime t o f ailure) value is the same value as the mtbf value. input 24vdc mtbf sn 29500, iec 61709 731 000h at 24v, 10a and 40c 1 321 000h at 24v, 10a and 25c mtbf mil hdbk 217f 358 000h at 10a and 40c; ground benign gb40 556 000h at 10a and 25c; ground benign gb25 731 000h at 10a and 40c; ground fixed gf40 142 000h at 10a and 25c; ground fixed gf25 jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 11/25
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 13. emc the dc/dc converter is suitable for a pplications in industrial environment as well as in residential, commercial and light industry environments. emc immunity generic standards: en 61000-6-1 and en 61000-6-2 electrostatic disc harge 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 d c/dc converter will occur. emc emission generic standards: en 61000-6-3 and en 61000-6-4 conducted emission iec/cispr 16-1-2, ie c/cispr 16-2-1 class b, input lines (limits for dc power ports) radiated emission en 55011, en 55022 class b this device complies with fcc part 15 rules. operation is subjected to fo llowing two conditions: (1) this device may not cause ha rmful interference, and (2) this device must accept any interferenc e received, including interference that may cause undesired operation. switching frequency variable between 50khz and 300khz depe nding on load and input voltage jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 12/25
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 14. e nvironment operational temperature 1) -25c to +70c (-13f to 158f) reduce output power according fig. 14-1 storage temperature -40 to +85c (-40 f to 185f) for storage and transportation output de-rating 3.2w/c 45-60c (113f to 140f) 6w/c 60-70c (140f to 158f) humidity 2) 5 to 95% r.h. iec 60068-2-30 vibration sinusoidal 3) 2-17.8hz: 1.6mm; 17.8-500hz: 2g 2 hours / axis iec 60068-2-6 shock 3) 30g 6ms, 20g 11ms 3 bumps / direction, 18 bumps in total iec 60068-2-27 altitude 0 to 6000m (0 to 20 000ft) re duce output power or ambient temperature above 2000m sea level. altitude de-rating 15w/1000m or 5c/1000m above 2000m (6500ft), see fig. 14-2 over-voltage category not a pplicable the concept of the overvoltage category is used for equipment energized directly from the low voltage mains (i ec 60664-1 4.3.3.2.1). degree of pollution 2 iec 62477-1, not conductive labs compatibility the unit does not re lease any silicone or other labs-criti cal substances and is suitable for use in paint shops. corrosive gases isa-71.04-198 5, severity level g3, iec 60068-2-60 test ke method 4 audible noise some small audible noise wi ll be emitted from the power supply. 1) operational temperature is the same as the ambient temperature and is defined as the air temperature 2cm below the unit. 2) do not energize while condensation is present 3) tested in combination with din-rails according to en 60715 wi th a height of 15mm and a thickness of 1.3mm and standard mount ing orientation. higher levels allowed when using the wall mounting bracket zm2.wall. fig. 14-1 output current vs. ambient temp. fig. 14-2 output current vs. altitude at 24v 0 13/25 -25 0 20 40 70c 2 4 6 8 10 12a 60 ambient temperature c o n t i n u o u s s h o r t t e r m allowable output current at 24v 0 0 2000 4000 6000m 2 4 6 8 10 12a altitude a . . . t a m b < 6 0 c b . . . t a m b < 5 0 c c . . . t a m b < 4 0 c c b a s h o r t t e r m allowable output current at 24v jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 15. p rotection f eatures output protection electronically protected against overload, no-load and short-circuits. in case of a protection event, audible noise may occur. output over-voltage protection typ. 31vdc max. 32.5vdc in case of an internal pow er supply 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 protecti on electronically limited see fig. 5-1 degree of protection ip 20 according to en/iec 60529 penetration protection > 3.5 mm e.g. screws, small parts over-temperature protection no - input transient protection mov (metal oxide varistor) for protection values see chapter 13 (emc) internal input fuse included not user replaceable slo w-blow high-braking capacity fuse 16. s afety f eatures classification of output voltage selv 1) according to iec/en 60950-1 pelv 1) according to iec/en 60204-1, iec 62477-1, iec 60364-4- 41 class of protection iii pe (protectiv e earth) connection not required. a connection of the chassis ground pin to earth is recommended for best emi performance. isolation resistance > 500mohm 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 conv erter itself, depends on the input voltage ripple and need to be investigated in the final application. for a smooth dc input voltage, the pro duced leakage current is less than 100a. 1) provided, that the input voltage meets the requirements of chapter 2 . jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 14/25
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 17. d ielectric s trength the output voltage is floating and has no ohmic connection to the ground. type and factory tests are c onducted by the manufacturer. field tests ma y be conducted in the field using the appropriate test equipment wh ich applies the voltage with a slow ramp (2s up and 2s down). connect all input terminals together as we ll as all output poles before conducting the test. when testing, set the cut-o ff current settings to the value in the table below. fig. 17-1 dielectric strength a b c type test 60s 1500vac 1500vac 500vac factory test 5s 1500vac 1500vac 500vac field test 5s 1000vac 1000vac 500vac cut-off current setting 40ma 20ma 12ma a c b + input chassis ground output - + - to fulfill the pelv requirements a ccording to en60204- 1 6.4.1, we recommend that either the + pole, the C pole or any other part of the output circuit shall be conne cted to the protective earth system. this helps to avoid si tuations in which a load starts unexpectedly or can not be swit ched off when unnoticed earth faults occur. jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 15/25
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 18. a pprovals ec declaration of conformity the ce mark indicates conformance with the - emc directive and the - atex directive (planned). iec 60950-1 2 nd edition planned cb scheme, information technology equipment ul 508 planned ind. cont. eq . listed for use as industri al control equipment; u.s.a. (ul 508) and canada (c22.2 no. 107-1-01); e-file: e198865 ul 60950-1 planned 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 planned ii 3g ex ec ii t4 gc approval for use in hazardous locati ons zone 2 category 3g. the device must be built-i n in an ip54 enclosure. iec 60079-0, iec 60079-7 planned iecex suitable for use in class 1 zone 2 groups iia, iib and iic locations. number of ie cex certificate: t.b.d. ansi / isa 12.12.01-2007 class i div 2 planned 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 planned gl (germanischer lloyd) classified environmental category: c, emc2 marine and offshore applications eac tr registration registration for the eurasian customs union market (russia, kazakhstan, belarus) 19. 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 8 th , 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 1 st , 2007 regarding the registration, evaluation, authorisation a nd restriction of chemicals (reach) iec/en 61558-2-16 (annex bb) safety isolating transformer safety isolating transformers co rresponding to part 2-6 of the iec/en 61558 jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 16/25
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 20. p hysical d imensions and w eight width 42mm 1.65 height 124mm 4.88 depth 117mm 4.61 the din-rail height must be added to the unit depth to calculate the total required installation depth. weight 500g / 1.10lb din-rail use 35mm din-rails according to en 60715 or en 50022 with a height of 7.5 or 15mm. housing material body: aluminium alloy cover: zinc-plated steel installation clearances see chapter 2 fig. 20-1 front view fig. 20-2 side view jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 17/25
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 21. a ccessories 21.1. zm2.wall - w all m ounting b racket this bracket is used to mount the power supply onto a flat surface without utilizing a din-rail. 21.2. zm12.side - s ide m ounting b racket this bracket is used to mount dime nsion 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 th at the steel brackets can be mounted. for sideway din-rail mounting, the remo ved aluminum brackets and the black pl astic slider need to be mounted on the steel bracket. side mounting with din-rail brackets side mounting without din-rail brackets jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 18/25
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 21.3. yr20.246 r edundancy m odule 19/25 put. the yr20.246 redundancy module is e quipped with two input cha nnels 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 out the yr20.246 does not require an addi tional auxiliary voltage and is self-powered even in case of a short circuit across the output. due to the low power losses, th e unit is very slender and only requires 32mm width on the din- rail. the yr20.246 is equipped with a lo ad share feature, which balanc e 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 22.9 for further wiri ng information. jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 22. a pplication n otes 22.1. p eak c urrent c apability the unit can deliver peak currents (up to several milliseconds) which are higher than the sp ecified 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 powerboo st). the same situation applies when starting a capacitive load. the peak current capability also ensures the safe operati on of subsequent circuit breakers of load circ uits. the load branches are often individually protected with circuit breakers or fuses. in ca se 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 supplie d by the power converter and the built -in large sized output capacitors of the power supply. the capacito rs get discharged during such an event, which causes a vo ltage dip on the output. the following two examples show typical voltage dips: fig. 22-1 peak loading with 2x the nominal current for 50ms, typ. fig. 22-2 peak loading with 4x the nominal current for 5ms, typ. output voltage 40a output voltage 24v 24v 20a 16v 6v output current 0a output current 0a 20/25 10ms/div 2ms/div peak load 20a (resi stive load) for 50ms output voltage dips from 24v to 16v. peak load 40a (resi stive load) for 5ms output voltage dips from 24v to 6v. peak current voltage dips typ. from 24v to 16v at 20a for 50ms, resistive load typ. from 24v to 12v at 40a for 2ms, resistive load typ. from 24v to 6v at 40a for 5ms, resistive load jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 22.2. b ack - feeding l oads loads such as decelerating motors and induc tors can feed voltage back to the power supply. this feature is also called return voltage immunity or resi stance against back- e.m.f. ( e lectro m agnetic f orce). this power supply is resistant and does not show malfunctioning when a load f eeds back voltage to the power supply. it does not matter whether the power supply is on or off. the maximum allowed feed-b ack-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 capacitanc e which is specified in chapter 5 . 22.3. i nductive and c apacitive l oads the unit is designed to supply any kind of loads, in cluding unlimited capaciti ve and inductive loads. 22.4. c harging of b atteries the dc/dc converter can be used to ch arge lead-acid or maintena nce free batteries. (two 12v batteries in series) instructions for charging batteries: a) ensure that the ambient temperature of the dc/dc converter is below 45c b) do not use dc/dc converters in mo unting 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 10c 20c 30c 40c d) use a 16a circuit breaker (or blocking diode) between the dc/dc converter and the battery. e) ensure that the output current of th e 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 conve rter (battery discharge current) is ty p. 10ma when the dc/dc converter is switched off (except in case a blocking diode is utilized). 22.5. e xternal i nput p rotection the unit is tested and approved for branch circuits up to 50a. an external prot ection is only required, if the supplying branch has an ampacity greater than this. check also local codes and local requirements. in so me 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 mi nimum value of 20a b- or c-char acteristic breaker should be used. jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 21/25
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 22.6. r equirements for the s upplying s ource in certain circumstances, the input filter of the dc/dc converter can show a res onant effect which is caused by the supplying network. especially when addi tional external input filters are utilized, a superimposed ac voltage can be generated on the input terminals of the dc/dc converter which might caus e a malfunction of th e unit. therefore, additional input filters are not recommende d. to avoid the resonant effects, th e minimal resistance of the supplying network which depends on the induct ance of the input network, shall be above the boundary curve in fig. 22-3 . fig. 22-3 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 ) 22.7. s eries o peration 22/25 dc/dc converters of the exact same type can be connected in series for higher output voltages. it is possible to connec t 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 protec tion against touchi ng. earthing of the output is required when the sum of the output voltage is above 60vdc. avoid return voltage (e.g. from a decelera ting 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 th e standard mounting orient ation (input terminals on the bottom and output terminals on top of the unit). unit a input output unit b - + - + + - input output load jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 22.8. p arallel u se to i ncrease o utput p ower 23/25 e tput current of one dc/dc-converter. the dc/dc-converter can be paralleled to increase the output power. there are no feature included which balances th e load current between the dc/dc- converters. therefore some restricti ons 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 temp erature stays below 45c. the output voltages of all dc/dc-converte rs 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 backward s into the dc/dc converter in case the output stage of th e dc/dc converter has a defect. if a fuse (or circuit breaker) is used, choose on with approximately 150% of the rated ou unit a input output unit b - + - + + - input output load keep an installation clearance of 15mm (left / right) betw een 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 orie ntation (input terminals on the bottom a nd output terminals on top of the unit). 22.9. p arallel u se for r edundancy the dc/dc converters can be paralleled for 1+1 redundancy to gain higher system availab ility. redundant systems require a certain amount of extra power to support the load in case one dc/dc converter fails. the si mplest way is to connect two dc/dc converters in parallel. this is called a 1+1 redundancy. in case one dc/dc converte r fails, the other one is automatically able to support the load current without any interruption. redundant syste ms 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 syste ms 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 ot her dc/dc-converters and the output volt age can not be maintained any more. this can only be avoided by utilizing the redundancy module yr20.246, which uti lized mosfets as decoupling devices. failure monitor 24v,10a load i i + + - - cd10.241 dc/dc converter 24-28v dc-ok output input + - + + - - cd10.241 dc/dc converter 24-28v dc-ok output input + - yr20.246 redundancy module output in1 + - + - + - in2 load share ok redundancy ok + - functional earth 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 60c n+1 redundancy is allowed up to an ambient temperature of 45c d) it is desirable to set the output volt ages of all units to the same value ( 100mv) or leave it at the factory setting. use the load share feature leds of th e redundancy module to adjust the output voltages of the dc/dc coverters if necessary. jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w 22.10. u se in a t ightly s ealed e nclosure when the dc/dc-converter is installed in a tightly sealed enclosure, the temp erature inside the enclosure will be higher than outside. in such situati ons, the inside temperature defines th e 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 th e middle of the box, no other heat producing items are inside the box condition 1: 80% load enclosure: rittal typ ip66 box pk 9516 100, plastic, 110x180x165mm load: 24v, 8a; (=80%) load is placed outside the box input: 24vdc temperature inside enclosure: 52.2c (i n the middle of the right side of the dc /dc converter with a distance of 2cm) temperature outside enclosure: 31.0c temperature rise: 21.2k condition 2: 100% load enclosure: rittal typ ip66 box pk 9516 100, plastic, 110x180x165mm load: 24v, 10a; (=100%) load is placed outside the box input: 24vdc temperature inside enclosure: 59.3c (i n the middle of the right side of the dc /dc converter with a distance of 2cm) temperature outside enclosure: 31.4c temperature rise: 27.9k jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 24/25
cd10.241 cd-series dc/dc converter 24v/24v, 10a, 240w jul. 2017 / rev. 1.1 ds-cd10.241-en all parameters are typical values at 24v, 10a, 24vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 22.11. m ounting o rientations mounting orientations other than input terminals on the bottom and output on the top require a reduction in continuous output power or a limit ation in the max. allowed ambient temperature. the amount of reduction influences the lifetime expectancy of the dc/dc converter. therefore, two different de rating curves for continuous operation can be found below: curve a1 recommended output current. curve a2 max allowed output current (res ults in approximately half the lifetime expectancy of a1). fig. 22-4 mounting orientation a (standard orientation) dc/dc converter output input output current 0 10 20 30 40 60c 4 6 10 12a 50 a 1 ambient temperature 8 2 fig. 22-5 mounting orientation b (upside down) dc/dc converter output input output current 0 10 20 30 40 60c 4 6 10 12a 50 ambient temperature 8 2 a 2 a 1 fig. 22-6 mounting orientation c (table-top mounting) output current 0 10 20 30 40 60c 4 6 10 12a 50 ambient temperature 8 2 a 1 a 2 fig. 22-7 mounting orientation d (horizontal cw) dc/dc converter output input output current 0 10 20 30 40 60c 4 6 10 12a 50 ambient temperature 8 2 a 1 a 2 fig. 22-8 mounting orientation e (horizontal ccw) dc/dc converter output input output current 0 10 20 30 40 60c 4 6 10 12a 50 ambient temperature 8 2 a 1 a 2 25/25

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