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cps20.481-d1 c-series 48v, 10a, dc/dc c onverter dc/dc c onverter ? 88-360vdc wide-range input ? width only 65mm ? efficiency up to 94.6% ? atex and iecex approved ? excellent partial load efficiency ? 20% output power reserves ? safe hiccup plus overload mode ? easy fuse tripping due to high overload current (typ. 45a for 15ms) ? minimal inrush current surge ? full power between -25c and +60c ? dc-ok relay contact ? reverse input polarity protected ? current sharing feature for parallel use ? 3 year warrant 1/26 g eneral d escription the dimension c-series are cost optimized power supplies and dc/dc converte rs without compromising quality, reliability and performa nce. the c-series is part of the dimension power supply family. the most outstanding features of cps20.481-d1 are the wide dc- input range, high efficiency, electronic inrush current limitation, wide operati onal temperature range. the c-series includes all th e essential basic functions. the devices have a power reserve of 20% included, which may even be used cont inuously at temperatures up to +45c. additionally, the cps20.481-d1 can deliver about 4 times the nominal output current for 15ms which helps to trip fuses on faulty output branches. high immunity to transients a nd power surges as well as low electromagnetic emission, a dc-ok relay contact and a large international appr oval package for a variety of applications makes this un it suitable for nearly every situation. s hort - form d ata output voltage dc 48v adjustment range 48 - 56v output current 10a at 48v, amb <60c 12a at 48v, amb <45c 8.6a at 56v, amb <60c 10.3a at 56v, amb <45c output power 480w ambient <60c 576w ambient <45c output ripple < 50mvpp 20hz to 20mhz ac input voltage - - dc input voltage dc 110-300v 20% dc input current 4.68 / 1.69a at 110 / 300vdc inrush current typ. 6 / 4a peak at 110 / 300vdc efficiency 93.1 / 94.6% at 110 / 300vdc losses 35.6 / 27.4w at 110 / 300vdc temperature range -25c to +70c operational derating 12w/c +60 to +70c hold-up time typ. 26 / 26ms at 110 / 300vdc dimensions 65x124x127mm wxhxd weight 940g 2.1lb o rder n umbers dc/dc converter cps20.481-d1 48-56v standard unit accessory zm2.wall wall mount bracket zm13.side side mount bracket yr40.482 redundancy module m arkings ind. cont. e q. ul 508 ul 60950-1 emc, lvd, rohs class i div 2 iecex atex ii 3g ex na nc ii t3 gc apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter i ndex page page 1. intended use .......................................................3 2. installation requirements ...................................3 3. ac-input ...............................................................4 4. dc-input ...............................................................4 5. input inrush current ...........................................5 6. output .................................................................6 7. hold-up time .......................................................8 8. dc-ok relay contact ..........................................8 9. efficiency and power losses ................................9 10. lifetime expectancy and mtbf .........................10 11. functional diagram ...........................................10 12. terminals and wiring ........................................11 13. front side and user elements ...........................12 14. emc ....................................................................13 15. environment ......................................................14 16. protection features ...........................................15 17. safety features ..................................................15 18. dielectric strength ............................................16 19. approvals ...........................................................17 20. physical dimensions and weight ..................... 18 21. accessories ........................................................ 19 21.1. zm2.wall - wall mounting bracket .......19 21.2. zm13.side - side mounting bracket ........19 21.3. redundancy modules ...............................20 22. application notes ............................................. 21 22.1. peak current capability ...........................21 22.2. back-feeding loads ..................................21 22.3. external input protection .........................22 22.4. output circuit breakers ............................22 22.5. parallel use to increase output power ....23 22.6. parallel use for redundancy ....................23 22.7. series operation .......................................24 22.8. inductive and capacitive loads ................24 22.9. charging of batteries ...............................25 22.10. use in a tightly sealed enclosure ............25 22.11. mounting orientations ............................26 the information presented in this docume nt is believed to be a ccurate and reliable and ma y change without notice. no part of this document may be reproduc ed or utilized in any form without pe rmission in writing from the publisher. 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 300v a figure displayed with the ac or dc before the value represents a nominal voltage with standard tolerances (usually 15%) included. e.g.: dc 12v describes a 12v battery disregardi ng whether it is full (13.7v) or flat (10v) 300vdc a figure with the unit (vdc) at the end is a momentary figure without any additional tolerances included. may a key word indicating flexibility of choice with no im plied preference. shall a key word indicating a mandatory requirement. should a key word indicating flexibility of choi ce with a strongly pref erred implementation. apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 2/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 1. i ntended u se this device is designed for installation in an enclosure a nd is intended for the general professional use such as in industrial control, office, communicati on, and instrumentation equipment. do not use this dc/dc converter in equipment, where ma lfunction may cause severe pe rsonal injury or threaten human life. this device is designed for use in hazardous, non-hazardous, ordinary or un classified locations. 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 terminals are located on the bo ttom of the unit. for other mounting orientations see de-rating requirements in this document. see chapter 24.13. this device is designed for convection cooling and does not require an external fan. do not obstruct airflow and do not cover ventilation grid (e.g. cable conduits) by more than 15%! keep the following installation 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 power supply). a disconnecting means shall be provided for the output of the power supplies when used in applications according to csa c22.2 no 107.1-01. warning risk of electrical shock, fi re, personal injury or death. - do not use the dc/dc converter wit hout proper grounding (protect ive earth). use the term inal on the input block for earth connection and not one of the screws on the housing. - 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 are 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 surfaces may cause burns. notes for use in hazardous location areas: the power supply is suitable for use in class i division 2 gr oups a, b, c, d locations and for use in group ii category 3 (zone 2) environments and are evaluated accord ing to en 60079-0:2012 and en 60079-15:2010. warning explosion hazards! substitution of components may impair su itability for this environment. do not disconnect the unit or operate the voltage adjustment or s/p jumper unless power has been switched off or the area is known to be non-hazardous. apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 3/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 3. ac-i nput do not operate this dc/dc converter with ac -input voltage. use the cps20.241 unit instead. 4. dc-i nput use a battery or a similar dc source. a supply from th e intermediate dc-bus of a frequency converter is not recommended and can cause a malf unction or damage the unit. dc input nom. dc 110-300v dc input range min. 88-360vdc min. 88-100vdc short term or with output derating (1%/v) or with reduced ambient temperature, see also fig. 15-1 , no damage between 0 and 88vdc min. 360-425vdc short term, < 500ms allowed voltage between input to earth (ground) max. 360vdc continuous, iec 62103 600v peak value, allowed for transients slew rate for voltage between input to earth (ground) max. 1000v/s allowed input ripple voltage max. 50vpp 15vpp 50hz C10khz 10khz C 50khz turn-on voltage typ. 85vdc steady-state value, see fig. 4-1 shut-down voltage typ. 37vdc stead y-state value at 2.5a load, see fig. 4-1 typ. 50vdc steady-state value at 5a load, see fig. 4-1 typ. 69vdc steady-state value at 10a load, see fig. 4-1 dc 110v dc 300v input current typ. 4.68a 1.69a at 48v, 10a, see fig. 4-3 start-up delay typ. 1100ms 830ms see fig. 4-2 rise time typ. 90ms 90ms at 48v , 10a const. current load, 0mf load capacitance, see fig. 4-2 typ. 230ms 230ms at 48v, 10a const. current load, 10mf load capacitance, see fig. 4-2 turn-on overshoot max. 200mv 200mv see fig. 4-2 fig. 4-1 input voltage range fig. 4-2 turn-on behavior, definitions turn-on 88v rated input range max. 500ms v in p out 425vdc 360v shut-down start-up delay rise time overshoot - 5% output voltage input voltage apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 4/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter fig. 4-3 input current vs. output load at 48v 12a 123456789 0 1 2 3 4 5 6a output current input current, typ. 3 0 0 v d c 1 1 0 v d c 10 11 5. i nput i nrush c urrent an active inrush limitation circuit limi ts the input inrush current after turn-on of the input voltage and after short input voltage interruptions. the charging current into emi suppression capacitors is disregarded in th e first microseconds after switch-on. dc 110v dc 300v inrush current *) max. 13a peak 10a peak temperature independent typ. 6a peak 4a peak temperature independent inrush energy *) max. 1a 2 s 1a 2 s temperature independent inrush delay typ. 1190ms 920ms start-up delay plus rise time *) mains interruptions > 500ms fig. 5-1 typical input inrush current behaviour at nominal load and 25c ambient output 200ms/div input 300vdc 48vdc input current 2a / div apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 5/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 6. o utput output voltage nom. 48v adjustment range min. 48-56v guaranteed max. 60v ****) at clockwise end position of potentiometer factory settings typ. 48.0v 0.2%, at fu ll load, cold unit, in single use mode typ. 46.0v 0.2%, at full load, cold unit, in parallel use mode typ. 48.0v at no load, cold unit, in parallel use mode line regulation max. 10mv 88-370vdc load regulation max. 150mv in s ingle use mode: static value, 0a ? 10a; see fig. 6-1 typ. 2000mv in parallel use mode: static value, 0a ? 10a, see fig. 6-2 ripple and noise voltage max. 50mvpp 20hz to 20mhz, 50ohm output current nom. 10a at 48v, ambient temperature <60c, see fig. 6-1 nom. 12a *) at 48v, ambient temperature <45c, see fig. 6-1 nom. 8.6a at 56v, ambient temperature <60c, see fig. 6-1 nom. 10.3a *) at 56v, ambient temperature <45c, see fig. 6-1 typ. 40a up to 15ms,output voltage stays above 40v, see fig. 6-4 . this peak current is available once every five seconds. see chapter 22.1 for more peak current measurements. output power nom. 480w c ontinuously available nom. 576w *) power boost ?*) overload behaviour cont. curre nt output voltage >25vdc, see fig. 6-1 hiccup plus mode **) output voltage <25vdc, see fig. 6-1 short-circuit cu rrent min. 18a ***) load impedance <10mohm, see fig. 6-3 max. 22a ***) load impedance <10mohm, see fig. 6-3 max. 7a ***) average (r.m.s.) current, load impedance 100mohm, see fig. 6-3 min. 40a up to 15ms, load impedance <10mohm, see fig. 6-4 typ. 50a up to 15ms, load impedance <10mohm, see fig. 6-4 output capacitance typ. 2 450f in cluded inside the dc/dc converter *) power boost this power/ current is continuously allowed up to an ambient temperature of 45c. above 45c, do not use this power/ current lo nger than a duty cycle of 10% and/ or not longer than 1 minute every 10 minutes. **) hiccup plus mode at heavy overloads (when output voltage falls below 13v), the dc/dc converter delivers continuous output current for 2s. after this, the output is switched off for approx. 18s before a new start attempt is automatically performed. this cycle is repeated as lon g as the overload exists. if the overload has been cleared, the device will operate normally. see fig. 6-3 . ***) discharge current of output capacitors is not included. ****) this is the maximum output voltage which can occur at the clockwise end position of the potentiometer due to tolerances. it is not guaranteed value which can be achieved. the typical value is about 57.0v (in single use mode). apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 6/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter fig. 6-1 output voltage vs. output current, typ. fig. 6-2 output voltage in parallel use mode, typ. output voltage (single use, typ.) 0 0 12.5 8 16 24 56v 32 40 48 20a 7.5 2.5 5 10 15 17.5 adjustment range output current continuous current factory setting hiccup mode output voltage (parallel use, typ.) 42v 048 44v 46v 48v 56v 50v 52v 54v 12a 10 6 2 adjustment range factory setting output current fig. 6-3 short-circuit on output, hiccup plus mode, typ. fig. 6-4 dynamic overcurrent capability, typ. output current 0 20a 18s 18s 18s 2s 2s 2s t short -circuit normal operation normal operation output voltage (dynamic behavior, < 15ms) 0 0 8 16 24 56v 32 40 48 50a 20 10 30 40 515253545 adjustment range output current apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 7/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 7. h old - up t ime the internal capacitor, which supplies th e energy for the hold-up time is isolat ed by a diode to the input voltage. a short on the input line does not discha rge the internal hold-up capacitor. dc 110v dc 300v hold-up time typ. 65ms 65ms at 48v, 5a, see fig. 7-1 min. 54ms 54ms at 48v, 5a, see fig. 7-1 typ. 26ms 26ms at 48v, 10a, see fig. 7-1 min. 21ms 21ms at 48v, 10a, see fig. 7-1 fig. 7-1 hold-up time vs. input voltage fig. 7-2 shut-down behavior, definitions 0 10 20 30 40 80ms 120 180 240 300 360vdc input voltage 50 60 hold-up time 48v, 10a, typ. 48v, 5a, min. 48v, 5a, typ. 70 48v, 10a, min. - 5% hold-up time output voltage input voltage 8. dc-ok r elay c ontact this feature monitors the output voltage, which is produced by the dc/dc converte r itself. it is inde pendent of a back- fed voltage from a unit connected in parallel to the dc/dc converter output. contact closes as soon as the output voltage r eaches 90% of the adjuste d output voltage level. contact opens as soon as the output voltage dips more than 10% belo w the adjusted output voltage. short dips will be extended to a signal length of 100ms. dips shorter th an 1ms will be ignored. contact ratings max. 60vdc 0.3a, 30vdc 1a, 30vac 0.5a resistive load min. 1ma at 5vdc min. permissible load isolation voltage see dielec tric strength table in section 18. fig. 8-1 dc-ok relay contact behavior 100ms 0.9* v adj < 1ms 10% open v out = v adj open closed closed > 1ms apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 8/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 9. e fficiency and p ower l osses dc 110v dc 300v efficiency typ. 93.1% 94.6% at 48v, 10a typ. 93.1% 94.5% at 48v, 12a (power boost) average efficiency *) typ. 92.1% 93.3% 25% at 2.5a, 25% at 5a, 25% at 7.5a. 25% at 10a power losses typ. 7.4w 2.5w at 48v, 0a typ. 20.0w 15.9w at 48v, 5a typ. 35.6w 27.4w at 48v, 10a typ. 42.7w 33.5w at 48v, 12a (power boost) *) the average efficiency is an assumption for a typical application where the dc/dc converter is loaded with 25% of the nomin al 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 w ith 100% of the nominal load for the rest of the time. fig. 9-1 efficiency vs. output current at 48v, typ fig. 9-2 losses vs. output current at 48v, typ. efficiency 234567 910 12a 88 89 90 91 92 93 94 95 96% output current 811 a) 110vdc b) 300vdc b a power losses 01 34 67 12a 10 0 15 20 25 40w 910 30 2 5 8 output current 11 b a 35 5 a) 110vdc b) 300vdc fig. 9-3 efficiency vs. input voltage at 48v, 10a, typ. fig. 9-4 losses vs. input voltage at 48v, 10a, typ. efficiency 80 140 200 260 320 380vdc 90 91 92 93 94 95 96% input voltage power losses 10 15 20 25 30 35 40w 80 140 200 260 320 380vdc input voltage apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 9/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 10. l ifetime e xpectancy and mtbf dc 110v dc 300v lifetime expectancy *) 156 000h *) 179 000h *) at 48v, 5a and 40c 440 000h *) 506 000h *) at 48v, 5a and 25c 85 000h 110 000h at 48v, 10a and 40c 241 000h *) 313 000h *) at 48v, 10a and 25c 58 000h 76 000h at 48v, 12a and 40c 164 000h *) 214 000h *) at 48v, 12a and 25c mtbf **) sn 29500, iec 61709 468 000h 537 000h at 48v, 10a and 40c 770 000h 882 000h at 48v, 10a and 25c mtbf **) mil hdbk 217f 254 000h 290 000h at 48v, 10a and 40c; ground benign gb40 355 000h 395 000h at 48v, 10a and 25c; ground benign gb25 56 000h 64 000h at 48v, 10a and 40c; ground fixed gf40 75 000h 86 000h at 48v, 10a and 25c; ground fixed gf25 *) 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 acc ording to the capacitors manufacturer specification. the manufacturer of the electrolytic capacitors only guarantees a maximum life of up to 15 years (131 400h). any number exceeding this value is a calculated theoretical lifetime which can be used to compare devices. **) mtbf stands for m ean t ime b etween f ailure, 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 ev ery 100 hours if 10 000 units ar e installed in the field. how ever, it can not be determined if the failed unit has been running for 50 000h or only for 100h. 11. f unctional d iagram fig. 11-1 functional diagram + + - - output over- voltage protection boost converter output voltage regulator power converter output filter output voltage monitor output power manager temper- ature shut- down input fuse input filter active inrush limiter reverse polarity protection v out + - dc-ok contact dc-ok led single / parallel dc-ok relay apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 10/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 12. t erminals and w iring the terminals are ip20 finger sa fe constructed and suitable fo r field- and factory wiring. input and output dc-ok-signal type screw terminals spring-clamp terminals solid wire 0.5-6mm 2 0.15-1.5mm 2 stranded wire 0.5-4mm 2 0.15-1.5mm 2 american wire gauge awg20-10 awg26-14 max. wire diameter 2.8mm (including ferrules) 1.5mm (including ferrules) wire stripping length 7mm / 0.28inch 7mm / 0.28inch screwdriver 3.5mm slotted or cross-head no 2 3.5mm sl otted (to open the spring) recommended tightening torque 1n m, 9lb.in not applicable instructions: a) use appropriate copper cables that are designed for minimum operating temperatures of: 60c for ambient up to 45c and 75c for ambient up to 60c minimum 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) do not use the unit without pe connection. e) unused terminal compartments should be securely tightened. f) ferrules are allowed. daisy chaining: 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 as shown in fig. 12-2 . fig. 12-1 daisy chaining of outputs fig. 12-2 using distribution terminals load + - power supply + + - - output power supply + + - - output max 25a! continuous distribution terminals load + - power supply + + - - output power supply + + - - output apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 11/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 13. f ront s ide and u ser e lements fig. 13-1 front side a input terminals (screw terminals) + positive input C negative (return) input pe (protective earth) input b output terminals (screw terminals, two pins per pole) + positive output C ne gative (return) output c output voltage potentiometer open the flap to adjust the output voltage. factory set: 48.0v d dc-ok led (green) on, when the output voltage is >90% of the adjusted output voltage e dc-ok relay contact (quick-connect sp ring-clamp terminals) the dc-ok relay contact is sync hronized with the dc-ok led. see chapter 8 for details. f parallel use single use selector set jumper to parallel use when dc/dc converter are connected in parallel to increase the output power. in orde r to achieve a sharing of the load current between the individual dc /dc converter, the parallel use regulates the output voltage in such a manner that the voltage at no load is approx. 4% higher than at nom inal load. see also chapter 22.5 . a missing jumper is equal to a single use mode. apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 12/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 14. emc the dc/dc converter is suitable for a pplications in industrial environment as well as in residential, commercial and light industry environment without any restrictions. a detailed emc report is available on request. emc immunity according 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 20v/m criterion a fast transients (burst) en 61000-4-4 input lines output lines dc-ok signal (coupling clamp) 4kv 2kv 2kv criterion a criterion a criterion a surge voltage on input en 61000-4-5 + ? - + ? pe, - ? pe 2kv 4kv criterion a criterion a surge voltage on output en 61000-4-5 + ? - + / - ? pe 1kv 2kv criterion a criterion a surge voltage on dc-ok en 61000-4-5 dc-ok signal ? pe 1kv criterion a conducted disturbance en 61000-4- 6 0.15-80mhz 20v 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 according generic standards: en 61000-6-3 and en 61000-6-4 conducted emission input lines cispr 16-1-2, cispr 16-2-1 limits for dc power port according en 61000-6-3 fulfilled conducted emission output lines *) cispr 16-1-2, cispr 16-2-1 limits for dc power port according 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 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. *) for information only, not mandatory for en 61000-6-3 switching frequencies the dc/dc converter has two converters wi th two different switching frequencies included. switching frequency 1 70khz to 130khz pfc converte r, input voltage and ou tput power dependent switching frequency 2 80khz to 140khz main converter, output power dependent apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 13/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 15. e nvironment operational temperature *) -25c to +70c (-13f to 158f) reduce output power according fig. 15-1 storage temperature -40 to +85c (-40 f to 185f) for storage and transportation output de-rating 6.4w/c 12w/c 45c to 60c (113f to 140f) 60c to 70c (140f to 158f) humidity **) 5 to 95% r.h. iec 60068-2-30 vibration sinusoidal 2-17.8h z: 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 2000m (0 to 6 560ft) without any restrictions 2000 to 6000m (6 560 to 20 000ft) reduce output power or ambient temperature, see fig. 15-2 iec 62103, en 50178, overvoltage category ii altitude de-rating 30w/1000m or 5c/1000m > 2000m (6500ft), see fig. 15-2 over-voltage category iii iec 62103, en 50178, altitudes up to 2000m ii altitudes from 2000m to 6000m degree of pollution 2 iec 62103, en 50178, 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. audible noise at load currents below 1a some audi ble noise will be emitted from the dc/dc converter *) 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 orientation. higher levels allowed when using the wall mounting bracket zm2.wall fig. 15-1 output current vs. ambient temp. fig. 15-2 output current vs. altitude allowed output current at 48v 0 -25 0 20 40 70c 2a 4a 6a 8a 10a 12a 60 a...100 to 360vdc, continuous b... 88vdc, continuous c... short term b a ambient temperature c 0 0 2000m 4000m 6000m 2a 4a 6a 8a 10a 12a b a c a . . . t a m b < 6 0 c b . . . t a m b < 5 0 c c . . . t a m b < 4 0 c d . . . s h o r t t e r m d allowable output current at 48v altitude apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 14/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 16. p rotection f eatures output protection electronically protected against overload , no-load and short-circuits *) output over-voltage pr otection typ. 58.5vdc max. 60vdc 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. degree of protecti on ip 20 en/iec 60529 caution: for use in a contro lled environment according to csa 22.2 no 107.1-01. penetration protection > 5mm e.g. screws, small parts over-temperature protection yes output shut-down with automatic restart input transient protection mo v (metal oxide varistor) internal input fuse dc suitable fuse included not user replaceable reverse input polarity protection yes unit does not start, no signalling *) in case of a protection event, audible noise may occur. 17. s afety f eatures input / output separation *) selv iec/en 60950-1 pelv iec/en 60204-1, en 50178, iec 62103, iec 60364-4-41 double or reinforced insulation class of protection i pe (protect ive earth) connection required isolation resistance > 5mohm input to output, 500vdc pe resistance < 0.1ohm touch current (leakage current) the leakage current which is produced by th e dc/dc converter itself depends on the input voltage ripple and need to be in vestigated in the final application. for a smooth dc input voltage, the pro duced leakage current is less than 100a. *) double or reinforced insulation apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 15/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 18. 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 c onducted in the field using the appropr iate test equipment which applies the voltage with a slow ramp (2s up and 2s down). connect all input-terminals togeth er as well as all ou tput poles before conducting the test. when testing, set the cut-off current settings to the value in the table below. fig. 18-1 dielectric strength a b c d type test 60s 2500vac 3000vac 1000vac 500vac factory test 5s 2500vac 2500vac 500vac 500vac field test 5s 2000vac 2000vac 500vac 500vac cut-off current setting > 15ma > 15ma > 20ma > 1ma ad c b b *) - + input dc-ok earth, pe output - + to fulfil 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. b*) when testing input to dc-ok ensure that the max. voltage between dc-ok and the output is not exceeded (column d). we recomm end connecting dc-ok pins and the output pins together when performing the test. apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 16/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 19. a pprovals ec declaration of conformity the ce mark indicates conformance with the - emc directive 2004/108/ec, - low-voltage directive (lvd) 2006/95/ec, - rohs directive 2011/65/eu and the - atex directive 94/9/ec (for use in explosive atmospheres) iec 60950-1 2 nd edition cb scheme, information technology equipment ul 508 ind. cont. e q. 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 2 nd edition recognized for use as information technology equipment, level 5; u.s.a. (ul 60950-1) and canada (c22.2 no. 60950-1); e-file: e137006 applicable for altitudes up to 2000m. ansi / isa 12.12.01-2007 class i div 2 recognized for use in hazardous location class i div 2 t3 groups a,b,c,d systems; u.s.a. (ansi / isa 12.12.01-2007) and canada (c22.2 no. 213-m1987) en 60079-0, en 60079-15 atex ii 3g ex na nc ii t3 gc approval for use in hazardous locati ons zone 2 category 3g. number of atex certificate: eps 13 atex 1 555 x the dc/dc converter must be bui lt-in in an ip54 enclosure. iec 60079-0, iec 60079-15 iecex suitable for use in class 1 zone 2 groups iia, iib and iic locations. number of iecex ce rtificate: iecex eps 13.0016x gost r certificate of conformity for russia and other gus countries apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 17/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 20. p hysical d imensions and w eight weight 940g / 2.1lb 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 (127mm) to calculate the total required installation depth. installation clearances see chapter 2 fig. 20-1 front view fig. 20-2 side view apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 18/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 21. a ccessories 21.1. zm2.wall - w all m ounting b racket this bracket is used to mount the dc/dc converter onto a flat surface wit hout utilizing a din-rail. 21.2. zm13.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 apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 19/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 21.3. r edundancy m odules yr40.482 C (2x 20a inputs, 1x 40a output) the yr40.482 is equipped with two input channels, which are individua lly decoupled by utilizing mosfet technology. using mosfets instead of diodes reduces the heat generation and the voltage drop between input and output. the yr40.482 does not require an additional auxiliary voltage and is self-powered even in case of a short circuit across the output. due to the low power losses, the unit is very slender and only requires 46mm width on the din-rail. fig. 21-1 typical 1+1 redundant configuration for 48v, 10a with a dual redundancy module 48v 10a load l n pe failure monitor cps20.481-d1 48-56v 480w dc/dc converter + + - - 48v 10a dc- ok dc input output pe + - yr40.482 *) redundancy module input 1 input 2 output + - + - + - + + - - 48v 10a dc- ok dc input output cps20.481-d1 48-56v 480w dc/dc converter pe + - *) yrm2.diode or yr2.diode also possible (2 x required) fuse fuse apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 20/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 22. a pplication n otes 22.1. p eak c urrent c apability the dc/dc converter can deliver peak cu rrents (up to several millis econds) which are higher th an the specified short term currents. this helps to start current demanding loads. solenoids, contactors and pneumatic modules often have a steady state coil and a pick-up coil. the inrush current demand of the pick-up coil is several times higher than the steady-state current and usually exceeds the nominal output current (including the 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 dc/dc converter. the capa citors get discharged during su ch an event, which causes a voltage dip on the output. the following two examples show typical voltage dips: fig. 22-1 peak load with 2x the nominal current for 50ms, typ. fig. 22-2 peak load with 5x the nominal current for 5ms, typ. 10ms/div output voltage output current 48v 0a 20a 32v 1ms/div output voltage output current 48v 0a 50a 37v peak load 20a (resistive) for 50ms output voltage dips from 48v to 32v. peak load 50a (resistive) for 5ms output voltage dips from 48v to 37v. please note: the dc-ok relay triggers when the voltage dips more than 10% for longer than 1ms. peak current voltage dips typ. from 48v to 32v at 20a for 50ms, resistive load typ. from 48v to 39v at 50a for 2ms, resistive load typ. from 48v to 37v at 50a for 5ms, resistive load 22.2. b ack - feeding l oads loads such as decelerating motors and in ductors can feed voltage back to the dc /dc converter. this feature is also called return voltage immunity or resistance against back- e.m.f. ( e lectro m agnetic f orce). this dc/dc converter is resistant and does not show malfunctioning when a lo ad 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 63vdc. the absorbin g energy can be calculated according to the built-in large sized output capacitor wh ich is specified in chapter 6 . apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 21/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 22.3. e xternal i nput p rotection the unit is tested and approved for bran ch circuits up to 30a (ul) and 32a (i ec). an external protection is only required if the supplying branch has an am pacity greater than this. provided, that the negative pole is grounded. if the positive pole is grounded, an a dditional external fast-acting input fuse in th e negative input is re quired (e.g. 8a klkd fuse from littelfuse or a comp arable ul-listed fuse with the same ratings and characteristics). ot herwise the status of the ul approvals becomes void. 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 mi nimum value of 10a b- or c-char acteristic breaker should be used. 22.4. o utput c ircuit b reakers standard miniature circuit breakers (mcbs or ul 1077 circuit breakers) are commonl y used for ac-supply systems and may also be used on 48v branches. mcbs are designed to protect wires and ci rcuits. if the ampere value and the char acteristics of the mcb are adapted to the wire size that is used, the wiring is considered as thermally safe rega rdless of whether the mcb opens or not. to avoid voltage dips and under-voltage situations in adjacent 48v branches wh ich are supplied by the same source, a fast (magnetic) tripping of the mcb is desired. a quick shutdown within 10ms is necessary corresponding roughly to the ride-through time of plc's. this re quires dc/dc converters with high current reserves and large output capacitors. furthermore, the impedance of the faulty branch must be sufficiently small in or der for the current to actually flow. the best current reserve in the dc/dc converter does not help if ohms law does not permit current flow. the following table has typical test results showing which b- and c-cha racteristic mcbs magnetica lly trip depending on the wire cross section and wire length. fig. 22-3 test circuit maximal wire length *) for a fast (magnetic) tripping: 0.75mm2 1.0mm2 1.5mm2 2.5mm2 c-2a 74m 98m 134m 198m c-3a 57m 74m 106m 168m c-4a 43m 56m 73m 114m c-6a 11m 16m 23m 33m c-8a 1m 1m 2m 3m b-6a 19m 36m 51m 82m b-10a 9m 12m 18m 27m mcb power supply ac dc + - + - load wire length s1... fault simulation switch s1 b-13a 7m 10m 16m 24m *) dont forget to consider twice the distance to the load (or cable length) when calculating the total wire length (+ and C wi re). apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 22/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 22.5. p arallel u se to i ncrease o utput p ower unit a unit b - + - + load + - input output input output cps20.481-d1 dc/dc converter can be paralleled to increase the output power. the output voltage of all dc/dc converters shall be adjusted to the same value (100mv) in single use mode with the same lo ad conditions on all units, or the units can be left with the factory settings. after the adjustments, the jumper on the front of the unit shall be moved from single use to parallel use, in order to achieve load sharing. the parallel use mode regulates the output voltage in such a manner that the voltage at no load is approx. 4% higher than at nominal load. see also chapter 6 . if no jumper is plugged in, the unit is in single use mode. factory setting is single use mode. if more than three units are connected in parallel, a fuse or circui t breaker with a rating of 15a or 16a is required on each output. alternatively, a diode or redundancy module can also be utilized. energize all units at the same ti me to avoid the overload hiccup plus mode. it also might be necessary to cycle the input power (turn-off for at least five se conds), if the output was in hiccup plus mode due to overload or short circuits and the required output current is higher than the current of one unit. 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 mounti ng orientations other than the standard mounting orientat ion (terminals on bottom of the unit) or in any other condition where a derating of the output current is re quired (e.g. altitude, above 60c, ). pay attention that emi and inrush current will increase when using mult iple dc/dc converters. 22.6. p arallel u se for r edundancy dc/dc converters can be para lleled for 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 unit fails. the simplest way is to put two dc/dc converters in para llel. this is called a 1+1 redunda ncy. in case one dc/dc conv erter unit fails, the other one is automatically able to su pport the load current withou t any interruption. redundant systems for a higher power demand are usually built in a n+1 method. e.g. five dc/dc converter, each rated for 10a are paralleled to build a 40a redundant system. for n+1 redundancy the same restrictions apply as for in creasing the output power, see also chapter 22.5 . 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 ca se, the defective unit becomes a load for the other dc/dc converters and the output voltage can no t be maintained any more. this can be avoided by utilizing redundancy modules, which have decoupling devices (diodes or mosfets) included. fu rther information and wiring configurations can be found in chapter 21.3 . recommendations for building redundant power systems: a) use separate input fuses for each dc/dc converter. b) set the dc/dc converter into parallel use mode. c) monitor the individual dc/dc converter units. therefor e, use the dc-ok relay contact of the cps20 dc/dc converter. d) it is desirable to set the output voltages of all units to the same value ( 100m v) or leave it at the factory setting. apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 23/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 22.7. s eries o peration dc/dc converters of the same type ca n 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 volt age 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. 24/26 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 c onverters on top of each other. do not use dc/dc converters in series in mounting orientations other than the standard m ounting orientation (termina ls on bottom of the unit). unit a input output unit b - + - + load + - earth (see notes) input output pay attention that emi and inrush current will increase when using mult iple dc/dc converters. 22.8. i nductive and c apacitive l oads the unit is designed to supply any kind of loads, including capacitive and inductive loads. if extreme large capacitors, such as edlcs (electric double layer capa citors or ultracaps) with a capacitanc e > 0.15f are connected to the output, the unit might charge the capacitor in the hiccup plus mode (see chapter 6 ). apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter 22.9. c harging of b atteries the dc/dc converter can be used to ch arge lead-acid or maintena nce free batteries. (four 12v batteries in series) instructions for charging batteries: a) 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 55. 6v 55.0v 54.3v 53.6v battery temperature 10c 20c 30c 40c b) use a 15a or 16a circuit breaker (or blocking di ode) between the dc/dc c onverter and the battery. c) ensure that the output current of th e dc/dc converter is below the allowed charging current of the battery. d) use only matched batteries when putting 12v types in series. e) the return current to the dc/dc conve rter (battery discharge current) is ty p. 7ma when the dc/dc converter is switched off (except in case a blocking diode is utilized). 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 enclosure: rittal typ ip66 box pk 9522 100, plastic, 254x180x165mm load: 48v, 8a; (=80%) load is placed outside the box input: 300vdc temperature inside enclosure: 50.3c (i n the middle of the right side of the dc /dc converter with a distance of 2cm) temperature outside enclosure: 24.2 temperature rise: 25.8k apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 25/26
cps20.481-d1 c-series 48v, 10a, dc/dc c onverter apr. 2014 / rev. 1.3 ds-cps20.481-d1-en all parameters are specified at 48v, 10a, 300vdc, 25c ambi ent 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 ot her than all terminals on the bottom require a reduction in continuous output power or a limitation in the maximum allowed ambien t temperature. the amount of reduction influences the lifetime expectancy of the dc/dc converter. therefore, tw o different derating curves for cont inuous 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 3 6 9 12a 50 a 1 ambient temperature fig. 22-5 mounting orientation b (upside down) dc/dc converter output input output current 0 10 20 30 40 60c 3 6 9 12a 50 ambient temperature a 2 a 1 fig. 22-6 mounting orientation c (table-top mounting) output current 0 10 20 30 40 60c 3 6 9 12a 50 ambient temperature 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 3 6 9 12a 50 ambient temperature 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 3 6 9 12a 50 ambient temperature a 1 a 2 26/26

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