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cd5.243 cd-series dc/dc converter 24v, 4a dc/dc c onverter ? 12v dc-input ? isolated 24vdc output ? efficiency up to 87.7% ? width only 32mm ? 20% output power reserves ? full power between -25c and +60c ? soft-start function included ? minimal inrush current surge ? reverse input polarity protection ? 3 year warranty 1/22 g eneral d escription the dimension cd-series offe r din-rail dc/dc converters in the 92-120w output power range in a very compact housing. these dc/dc conve rters are allowed to run with a battery or similar sources. the cd5.243 converts a 12v volt age to a 24v voltage. the cd5.243 includes all the essential basic functions and has a power reserve of 20% included. this extra power can be used conti nuously up to +45c. the output is electrically is olated from the input in a safe way. the input is protected against reversed voltages and contains a soft start function. cd5.241 cd5.242 cd5.243 cd5.241-s1 24v->24v, spring-clamp-terminals, in p ut-low, dc-ok si g nals cd-series related products 24v->24v 48v->24v 12v->24v cd5.241-l1 24v->24v, nec class 2, spring-clamp-terminals, cd5.121 24v->12v sld2.100 24v->5v s hort - form d ata output voltage dc 24v adjustment range 24 - 28v *) output current 4.0 C 3.4a ambient <60c 4.8 C 4.1a ambient <45c output power 96w ambient <60c 116w ambient <45c output ripple < 50mvpp 20hz to 20mhz input voltage dc 12v input voltage range 10.8 to 16.2vdc full specified 8.4 to 10.8vdc with derating input current typ. 9.2a at 12vdc input input inrush current typ. 1.0a peak efficiency 87.7% at 12vdc input losses 13.5w at 12vdc input temperature range -25c to +70c operational derating 2.5w/c +60 to +70c hold-up time typ. 3ms at 12vdc input dimensions 32x124x102mm wxhxd weight 435g / 0.96lb *) extended guaranteed adjustment range down to 23v. o rder n umbers dc/dc converter cd5.243 standard unit accessory zm1.wall wall mount bracket zm11.side side mount bracket yrm2.diode redundancy module m arkings ind. cont. eq. ul 508 ul 60950-1 emc, atex class i div 2 iecex atex ii 3g ex na nc ii t4 gc marine mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany
cd5.243 cd-series dc/dc converter 24v, 4a i ndex page page 1. intended use .......................................................3 2. installation requirements ...................................3 3. input voltage ......................................................4 4. soft-start and input inrush current surge .........5 5. output .................................................................6 6. hold-up time .......................................................7 7. efficiency and power losses ................................8 8. functional diagram .............................................9 9. front side and user elements .............................9 10. terminals and wiring ........................................10 11. reliability ...........................................................10 12. emc ....................................................................11 13. environment ......................................................12 14. protection features ...........................................13 15. safety features ..................................................13 16. dielectric strength ............................................14 17. approvals ...........................................................15 18. rohs, reach and othe r fulfilled standards .. 15 19. physical dimensions and weight ..................... 16 20. accessories ........................................................ 17 21. application notes ............................................. 18 21.1. peak current capability ...........................18 21.2. back-feeding loads ..................................18 21.3. inductive and capacitive loads ................18 21.4. charging of batteries ...............................19 21.5. external input protection .........................19 21.6. requirements for the supplying source ..19 21.7. parallel use to increase output power ....20 21.8. parallel use for redundancy ....................20 21.9. daisy chaining of outputs .......................21 21.10. series operation .......................................21 21.11. use in a tightly sealed enclosure ............21 21.12. mounting orientations ............................22 the information presented in this docume nt is believed to be a ccurate and reliable and ma y change without notice. some parts of this unit are patent by puls (us patent no 091662,063, des. 424,529, ). no part of this document may be repr oduced or utilized in any form without permission in writing from puls gmbh. 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. mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 2/22
cd5.243 cd-series dc/dc converter 24v, 4a 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 dc/dc converter in e quipment where malfunction may cause seve re personal 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 pa rts. the tripping of an internal fuse (i f included) 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. - 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 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. notes for use in hazardous location areas: the dc/dc converter is suitable for use in class i division 2 groups a, b, c, d lo cations and for use in group ii category 3 (zone 2) environments and are evaluated according to en 60079-0 and en 60079-15. warning explosion hazards! substitution of components may impair su itability for this environment. do not disconnect the unit or operate the voltage adjustment unless power has been switched off or the area is known to be non-hazardous. a suitable enclosure must be provided for the end product which has a mini mum protection of ip54 and fulfils the requirements of the en 60079-15. mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 3/22
cd5.243 cd-series dc/dc converter 24v, 4a 3. i nput v oltage input voltage nom. dc 12v input voltage range 10.8-16 .2vdc full specified, see fig. 3-2 for derating below 10.8vdc 8.4-10.8vdc maximal 60 sec onds or with de-rating see fig. 3-2 . max. 24.0vdc absolute maximum continuous input voltage with no damage to the dc/dc converter allowed voltage between input and earth max. 60vdc or 42.2vac in case the output voltage is not grounded. allowed input ripple voltage max. 5vpp 47hz-500hz, the moment ary input voltage must always be within the specified limits. turn-on voltage typ. 8.7vdc steady-state value, see fig. 3-1 shut-down voltage typ. 7.2vdc steady-state value, see fig. 3-1 typ. 17.0vdc steady-state value, see fig. 3-1 input current typ. 9.2a at 12v dc input and output 24v, 4a, see fig. 3-4 start-up delay typ. 450ms see fig. 3-3 rise time typ. 80ms 0mf, 24v, constant current load 4a, see fig. 3-3 typ. 150ms 4mf, 24v, constant current load 4a, see fig. 3-3 turn-on overshoot max. 300mv see fig. 3-3 input capacitance typ. 3 600f external capa citors on the input voltage bus are allowed without any limitations. fig. 3-1 input voltage range fig. 3-2 allowable output current below 10.8v input voltage turn-on 8.7vdc v in p out shut-down 16.2vdc 7.2vdc 8.4vdc rated input range 17.0vdc 0 1 2 3 5a 8 9 10 11 12vdc output current ( a ) ( b ) 4 8.4 10.8 4.8a 4.0a ( c ) 3.0a (a) ambient < 45c (b) ambient < 60c (c) ambient < 70c input voltage fig. 3-3 turn-on behavior, definitions fig. 3-4 input current vs. output load start-up delay rise time overshoot - 5% output voltage input voltage 5a 11.52 3 0 2 8 14 16a output current 2.5 3.5 0.5 input current, typ 4 12 4.5 4 6 10 i npu t : 9 v dc i n p u t : 1 2 v d c mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 4/22
cd5.243 cd-series dc/dc converter 24v, 4a 4. s oft - start and i nput i nrush c urrent s urge inrush current limitation an active inrush limitation circuit (inr ush limiting resistor which is bypassed by a relay contact) limits the input inrush current after turn-on of the input voltage. the charging current into emi suppression capacitors is disregarded in th e first microseconds after switch-on. inrush current max. 1.3a peak -25c to +70c, input: 12vdc typ. 1.0a peak -25c to +70c, input: 12vdc inrush energy typ. negligible -25c to +70c, input: 12vdc fig. 4-1 input inrush current, typical behavior input current input voltage output voltage input: 12vdc output: 24v, 4a, constant current load ambient: 25c upper curve: input current 5a / div middle curve: input voltage 10v / div lower curve: output voltage 20v / div time basis: 100ms / div soft-start function: after the dc/dc converter is turned on, the internal output current rises 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. fig. 4-2 soft-start behavior output voltage input current input: 12vdc output: 24v, 4a, constant current load ambient: 25c no additional extern al output capacitors upper curve: input current 5a / div lower curve: output voltage 10v / div time basis: 20ms / div mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 5/22
cd5.243 cd-series dc/dc converter 24v, 4a 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 voltag e variations between 8.4 to 16.2vdc load regulation max. 100mv static value, 0a ? 4a ripple and noise voltage max. 50mvpp 20hz to 20mhz, 50ohm output capacitance typ. 2 200f output current nom. 4.8a at 24v, below 45c ambient temperat ure, input voltage between 10.8v and 16.2v nom. 4.0a at 24v, at 60c ambi ent temperature, input voltage between 10.8v and 16.2v nom. 3.0a at 24v, at 70c ambi ent temperature, input voltage between 10.8v and 16.2v nom. 4.1a at 28v, below 45c ambi ent temperature, input voltage between 10.8v and 16.2v nom. 3.4a at 28v, at 60c ambi ent temperature, input voltage between 10.8v and 16.2v nom. 2.6a at 28v, at 70c ambi ent temperature, input voltage between 10.8v and 16.2v derate output current at input voltag es below 10.8v acco rding to chapter 3 . derate linearely between +45c and +70c and between 10.8v and 8.4v input voltage. output power nom. 116w for ambient temperatures < 45c nom. 96w for ambient temperatures < 60c short-circuit current min. 6a continuous current, short circui t impedance 200mohm max. 9a continuous current, short circuit impedance 200mohm *) extended guaranteed adjustment range down to 23v. fig. 5-1 output voltage vs . output current at 12vdc input voltage, typ. fig. 5-2 current limitation vs. input voltage, (23v constant voltage load), typ. output voltage 0 048 4 8 12 28v 16 20 24 12 a 10 6 2 adjustment range output current output current 4.8 81113 4.9 5.0 5.1 5.6a 5.3 5.4 5.5 16vd c 15 12 9 5.2 10 14 input voltage mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 6/22
cd5.243 cd-series dc/dc converter 24v, 4a peak current capability (up to several milliseconds) the dc/dc converter can deliver a peak current, which is high er than the specified short term current. this helps to start current demanding loads or to safely operate subsequent circuit breakers. the extra current is supplied by the out put capacitors inside the dc/dc converter. during this event, the capacitors will be discharged and causes a voltage dip on the output. detailed curves ca n be found in chapter 21.1 . peak current voltage dips typ. from 24v to 18v at 8a for 50ms, resistive load typ. from 24v to 12.5v at 16a for 2ms, resistive load typ. from 24v to 10v at 16a for 5ms, resistive load 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. 5.8ms input 12vdc, output: 24vdc, 2a, see fig. 6-1 typ. 3.0ms input 12vdc, output: 24vdc, 4a, see fig. 6-1 fig. 6-1 hold-up time vs. input voltage 0 1 2 3 4 6ms 9101112 14vd c input voltage hold-up time (a) 24v, 2a, typ. (b) 24v, 2a, min. (c) 24v, 4a, typ. (d) 24v, 4a, min. 5 13 ( a ) ( b ) ( c ) ( d ) fig. 6-2 shut-down test setup fig. 6-3 shut-down behavior, definitions load + - dc/dc converter dc source + - input output + - cd5 s1 - 10% 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. mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 7/22
cd5.243 cd-series dc/dc converter 24v, 4a 7. e fficiency and p ower l osses input 12vdc efficiency typ. 87.7% at 24v, 4a power losses typ. 0.7w at no output load typ. 6.2w at 24v, 2a typ. 13.5w at 24v, 4a typ. 17.8w at 24v, 4.8a fig. 7-1 efficiency vs. output current at 24v output and 12vdc input voltage, typ. fig. 7-2 losses vs. output current at 24v output and 12vdc input voltage, typ. efficiency 1 84 86 88 83 89% 4.8 a 23 . 5 2.5 85 87 1.5 0.5 3 4 output current power losses 012 4. 8 a 0 3 9 15 18w 6 3 12 output current 4 fig. 7-3 efficiency vs. input voltage at 24v, 4a, typ. fig. 7-4 losses vs. input voltage at 24v, 4a, typ. efficiency 910 11 13 14 16vd c 90% 85 87 89 88 86 84 12 15 input voltage power losses 0 3 6 9 12 15 18w 9 10 121314 16vd c 11 15 input voltage mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 8/22
cd5.243 cd-series dc/dc converter 24v, 4a 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 + - over- temperature protection 9. f ront s ide and u ser e lements fig. 9-1 front side a input terminals screw terminals + positive input - negative (return) input chassis ground: can be used to bond the housing to pe ground this terminal to mini mize high-frequency emissions. b output terminals screw terminals, dual terminals per pole, both pins are equal + positive output - negative (return) output screw terminals c output voltage potentiometer open the flap to set the output voltage. factory set: 24.1v d dc-ok led (green) on when the voltage on the output terminals is > 21v mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 9/22
cd5.243 cd-series dc/dc converter 24v, 4a 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 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) the external circuitry of all termi nals must meet the safety requirements stipulated by iec/en/ul 60950-1: selv. b) use appropriate copper cabl es that are designed for an operating temperature of: 60c for ambient up to 45c and 75c for ambient up to 60c minimum. c) follow national installation c odes and installation regulations! d) ensure that all strands of a strande d wire enter the terminal connection! e) do not load the terminals with more than 25a! see section 21.9 f) screws of unused terminal compa rtments should be securely tightened. g) ferrules are allowed. h) do not connect or disconnect the wi res from the terminals below -25c (-13f). 11. r eliability input 12vdc lifetime expectancy *) 199 000h at 24v, 2a and 40c 73 000h at 24v, 4a and 40c 33 000h at 24v, 4.8a and 40c 206 000h at 24v, 4a and 25c mtbf **) sn 29500, iec 61709 1 056 000h at 24v, 4a and 40c 1 934 000h at 24v, 4a and 25c mtbf **) mil hdbk 217f 552 000h at 24v, 4a and 40c; ground benign gb40 770 000h at 24v, 4a and 25c; ground benign gb25 *) the lifetime expectancy shown in the table indicates the minimum operating hours (service life) and is determined by the lifetime expectancy of the built-in electrolytic capacitors. lifetime expectancy is specified in operational hours and is calculated acc ording to the capacitors manufacturer specification. the prediction model allows only a calculation of up to 15 years from date of shipment. **) 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. mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 10/22
cd5.243 cd-series dc/dc converter 24v, 4a 12. 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. 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, iec/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 75khz and 140khz depending on load and input voltage (output current > 0.5a) mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 11/22
cd5.243 cd-series dc/dc converter 24v, 4a 13. e nvironment operational temperature *) -25c to +70c (-13f to 158f) reduce output power according fig. 13-1 storage temperature -40 to +85c (-40 f to 185f) for storage and transportation output de-rating 1.28w/c 45-60c (113f to 140f) 2.5w/c 60-70c (140f to 158f) additional derating is required for inpu t voltages below 10.8vdc, see chapter 3 for further details and values. humidity **) 5 to 95% r.h. iec 60068-2-30 vibration sinusoidal ***) 2-17.8hz: 1.6mm; 17.8-500hz: 2g 2 hours / axis iec 60068-2-6 shock ***) 30g 6ms, 20g 11ms 3 bumps / direction, 18 bumps in total iec 60068-2-27 altitude 0 to 6000m (0 to 20 000ft) re duce output power or ambient temperature above 2000m sea level. altitude de-rating 6w/1000m or 5c/1000m above 2000m (6500ft), see fig. 13-2 over-voltage category iii iec 62477-1, en 50178, altitudes up to 2000m ii altitudes from 2000m to 6000m degree of pollution 2 iec 62477-1, en 50178, not conductive labs compatibility the unit does not re lease any silicone or other labs-criti cal substances and is suitable for use in paint shops. *) operational temperature is the same as the ambient temperature and is defined as the air temperature 2cm below the unit. **) do not energize while condensation is present ***) tested in combination with din-rails according to en 60715 with a height of 15mm and a thickness of 1.3mm and standard mou nting orientation. fig. 13-1 output current vs. ambient temp. fig. 13-2 output current vs. altitude at 24v 0 -25 0 20 45 70 c 1 2 3 4 5a 60 ambient temperature allowable output current at 24v s h o r t t e r m 0 0 2000 4000 6000m 1 2 3 4 5a 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 mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 12/22
cd5.243 cd-series dc/dc converter 24v, 4a 14. p rotection f eatures output protection electronically protected against overload , no-load and short-circuits *) output over-voltage protection typ. 31vdc max. 32vdc in case of an internal 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 protec tion electronically limited *) see fig. 5-1 degree of protection ip 20 en/iec 60529 penetration protection > 3.5 mm e.g. screws, small parts over-temperature protection yes output shut-down with automatic restart input transient protection mov metal oxide varistor internal input fuse included not user replaceable *) in case of a protection event, audible noise may occur. 15. s afety f eatures classification of output voltage selv iec/en 60950-1 pelv iec/en 60204-1, en 50178, iec 62477-1, iec 60364-4-41 class of protection iii pe (protectiv e earth) connection not required. a connection of the chassis ground pin to earth is recommended for best emi performance isolation resistance > 5mohm input to output, 500vdc pe resistance < 0.1ohm between housing and chassis ground terminal touch current (leakage current) the leakage current which is produced by 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. *) provided, that the input voltage meets the requirements of chapter 2 . mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 13/22
cd5.243 cd-series dc/dc converter 24v, 4a 16. 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 phase- terminals together as well as all output poles before conducting the test. when testing, set the cu t-off current settings to the value in the table below. fig. 16-1 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 > 30ma > 30ma > 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. mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 14/22
cd5.243 cd-series dc/dc converter 24v, 4a 17. a pprovals ec declaration of conformity the ce mark indicates conformance with the - emc directive and the - atex directive. iec 60950-1 2 nd edition cb scheme, information technology equipment ul 508 ind. cont. eq. listed for use as industri al control equipment; u.s.a. (ul 508) and canada (c22.2 no. 107-1-01); e-file: e198865 ul 60950-1 recognized for the use as information technology equipment, level 3; u.s.a. (ul 60950-1) and canada (c22.2 no. 60950-1); e-file: e137006 en 60079-0, en 60079-15 atex ii 3g ex na nc ii t4 gc approval for use in hazardous locati ons zone 2 category 3g. number of atex certificate: eps 08 atex 1 142 x the device must be built-i n 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 14.0001x ansi / isa 12.12.01-2007 class i div 2 recognized for use in hazardous location class i div 2 t4 groups a,b,c,d systems; u.s.a. (ansi / isa 12.12.01) and canada (c22.2 no. 213-m1987) marine gl (germanischer lloyd) classified and abs (american bureau for shipping) pda environmental category: c, emc2 marine and offshore applications eac tr registration registration for the eurasian customs union market (russia, kazakhstan, belarus) 18. r o hs, reach and o ther f ulfilled s tandards rohs directive directive 2011/65/eu of the european parliament and the council of june 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) mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 15/22
cd5.243 cd-series dc/dc converter 24v, 4a 19. p hysical d imensions and w eight weight 435g / 0.96lb din-rail use 35mm din-rails according to en 60715 or en 50022 with a height of 7.5 or 15mm. the din-rail height must be added to the unit depth (102mm) to calculate the total required installation depth. installation clearances see chapter 2 fig. 19-1 front view fig. 19-2 side view mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 16/22
cd5.243 cd-series dc/dc converter 24v, 4a 20. a ccessories zm1.wall wall mounting bracket this bracket is used to mount specific dimension units onto a flat surface without utilizing a din-rail. the two aluminum brackets and the black plastic sl ider of the unit have to be removed, so that the two steel brackets can be mounted. fig. 20-1 zm1.wall wall mounting bracket fig. 20-2 assembled wall mounting bracket *) *) picture of the dc/dc converter is for representation only zm11.side side mounting bracket this bracket is used to mount dimension units sideways with or without utilizing a din-rail. the two aluminum brackets and the black plastic slider of the unit have to be detached, so 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. fig. 20-3 zm11.side side mounting bracket *) fig. 20-4 side mounting with din-rail brackets *) *) picture of the dc/dc converter is for representation only mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 17/22
cd5.243 cd-series dc/dc converter 24v, 4a 21. a pplication n otes 21.1. p eak c urrent c apability solenoids, contactors and pneumatic modu les often have a steady state coil an d a pick-up coil. the inrush current demand of the pick-up coil is several times higher than the st eady-state current and usually exceeds the nominal output current (including the powerboost) the same si tuation applies, when sta rting a capacitive load. branch circuits are often protected with ci rcuit breakers or fuses. in case of a short or an overload in the branch circuit, the fuse needs a certain amount of over -current to trip or to blow. the p eak current capability ensures the safe operation of subseque nt circuit breakers. assuming the input voltage is turned on before such an event, the built-in large sized output capacitors inside the dc/dc converter can deliver extra current. discharging this capacitor causes a voltage dip on the output. the following two examples show typical voltage dips: fig. 21-1 peak loading with 2x the nominal current for 50ms, typ. fig. 21-2 peak loading with 5x the nominal current for 5ms, typ. 10ms/div output voltage output current 24v 0a 8a 18v 1ms/div output voltage output current 24v 0a 20a 10v peak load 8a (resi stive load) for 50ms output voltage dips from 24v to 18v. peak load 20a (resi stive load) for 5ms output voltage dips from 24v to 10v. 21.2. 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, whethe r the dc/dc converter is on or off. the maximum allowed feed-back- voltage is 30vdc. the absorbin g energy can be calculated according to the built-in large sized output capacitance which is specified in chapter 5 . 21.3. 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. mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 18/22
cd5.243 cd-series dc/dc converter 24v, 4a 21.4. 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 6a or 10a circuit breaker (or blocking di ode) between the dc/dc c onverter 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. 18ma when the dc/dc converter is switched off (except in case a blocking diode is utilized). 21.5. 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 16a b- or c-char acteristic breaker should be used. 21.6. 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. 21-3 . fig. 21-3 external input filter requirements to avoid filter instabilities 1 mohm 10 mohm 100 mohm 1 ohm 0.1mh 1mh 10mh inductance of the supplying network resistance of the supplying network (a) max. (b) typ. ( b ) ( a ) mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 19/22
cd5.243 cd-series dc/dc converter 24v, 4a 21.7. p arallel u se to i ncrease o utput p ower unit a input output unit b - + - + + - input output load 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 te mperature stays below 45c. the cd5.243 can also be paralleled with power supplies from the dimension ct, qs or qt-series. for other power supplies consult puls. set th e single use / parallel use jumper to parallel use if such an option is available. 20/22 the bottom and output terminals on top of the unit). the output voltages of all dc/dc converte r 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 av oid that more than 2 times of the nominal output current can flow backwards into the dc/dc converter in case the out put stage of the dc/dc conve rter has a defect. if a fuse (or circuit breaker) is used, choose one with approximately 150% of the rated output current of one dc/dc converter. keep an installation clearance of 15mm (left / right) betw een two dc/dc converters and avoid in stalling the dc/dc converters on top of each other. do not use dc/dc converte rs in parallel in mountin g orientations other th an the standard mounting orientation (input terminals on 21.8. p arallel u se for r edundancy the dc/dc converters can be paralle led for 1+1 redundancy to gain higher system availability. redundant systems require a certain amount of extra power to support the load in case one dc/dc converter fails. the simplest way is to put two dc/dc converters in parallel. this is called a 1+1 redundancy. in case one dc/dc conv erter 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 an n+1 method. e.g. four dc/dc converters, each rated for 4a are paralleled to build a 12a redundant system. furthermore, 1+1 redundant systems can be built by using a dc/dc converter powered from a battery and a power supply with ac input. please note: this simple way to build a redundant system does not cover failures such as an internal short circuit in the secondary side of the dc/dc converter. in such a case, the defect unit becomes a load for the other dc/dc converters and the output voltage can not be maintained an y more. this can only be av oided by utilizing decoupling diodes which are included in the decoupling module yrm2.diode. recommendations for building redundant power systems: a) use separate input fuses for each dc/dc converter. b) monitor the individual dc/dc conve rter units. a dc-ok lamp and a dc-ok contact is included in the redundancy module yrm2.diode. this feat ure reports a faulty unit. 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. mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany
cd5.243 cd-series dc/dc converter 24v, 4a 21.9. d aisy c haining of o utputs 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. 21-4 daisy chaining of outputs fig. 21-5 using distribution terminals dc/dc converter + + - - input output load + - max 25a! dc/dc converter + + - - input output load + - distribution terminals dc/dc converter + + - - input output dc/dc converter + + - - input output 21.10. s eries o peration 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 th e output voltage is above 60vdc. avoid return voltage (e.g. from a decelerating mo tor 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 seri es in mounting orientations other than the standard mounting orientation (in put terminals on the bottom and outpu t terminals on top of the unit). unit a input output unit b - + - + + - input output load 21.11. 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 9516 100, plastic, 110x180x165mm load: 24v, 3.2a; (=80%) load is placed outside the box input: 12vdc temperature inside enclosure: 44.8c (i n the middle of the right side of the dc /dc converter with a distance of 2cm) temperature outside enclosure: 23.2c temperature rise: 21.6k mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 21/22
cd5.243 cd-series dc/dc converter 24v, 4a mar. 2016 / rev. 1.3 ds-cd5.243-en all parameters are specified at 24v, 4a, 12vdc input voltage, 25c ambient and after a 5 minutes run-in time unless otherwise n oted. www.pulspower.com phone +49 89 9278 0 germany 21.12. 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. 21-6 mounting orientation a (standard orientation) dc/dc converter output input output current 0 10 20 30 40 60c 2 3 5a 50 a 1 ambient temperature 4 1 fig. 21-7 mounting orientation b (upside down) dc/dc converter output input output current 0 10 20 30 40 60c 2 3 5a 50 ambient temperature 4 1 a 1 a 2 fig. 21-8 mounting orientation c (table-top mounting) output current 0 10 20 30 40 60c 2 3 5a 50 ambient temperature 4 1 a 1 a 2 fig. 21-9 mounting orientation d (horizontal cw) dc/dc converter output input output current 0 10 20 30 40 60c 2 3 5a 50 ambient temperature 4 1 a 1 a 2 fig. 21-10 mounting orientation e (horizontal ccw) dc/dc converter output input output current 0 10 20 30 40 60c 2 3 5a 50 ambient temperature 4 1 a 1 a 2 22/22

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