Data Sheet

ManualsBrandsPULS ManualsRack & DIN Rail Mount PSUsDIMENSION DC/DC converter 24.5 V 16.3 A 400 W

CPS20.241-60

C-Series

24V, 400W, DC/DC CONVERTER

DC/DC CONVERTER

 EN 50155 Railway Compliant

 Conformal Coated PC-boards

 Built-in Redundancy (Decoupling Mosfet at the Output)

 Quick-connect Spring-clamp Terminals

 77-154Vdc Wide-range Input

 Width only 65mm

 Efficiency up to 93.7%

 Excellent Partial Load Efficiency

 Safe Hiccup

PLUS

Overload Mode

 Minimal Inrush Current Surge

 Full Power Between -40°C and +70°C

 DC-OK Relay Contact

 Reverse Input Polarity Protected

 3 Year Warranty

1/22

GENERAL DESCRIPTION

The CPS20.241-60 DC/DC converter is designed

specifically for railway & transportation applications. It

is approved according to the EN 50155 standard, which

is an international standard covering electronic

equipment used on rolling stock for railway

applications. The standard covers aspects such as

temperature, humidity, shock, vibration, EMI and other

parameters. Because of these requirements, the unit is

equipped with conformal coated pc-boards.

The unit features a DC-OK signal contact for remote

monitoring, a decoupling MOSFET for building

redundant power supply systems and quick-connect

spring-clamp terminals for a reliable connection even

when mechanical vibration and shock are involved. The

unit also covers an extreme wide temperature range

from -40°C up to +70°C with full output current.

This DC/DC converter comes in a very compact housing

and requires only 65mm space on the DIN-rail due to

the high efficiency and low power losses. The high

efficiency is achieved by utilizing cutting edge

technology and other unique design techniques.

SHORT-FORM DATA

Output voltage DC 24.5V

Adjustment range - not adjustable

Output current 16.3A

Output power 400W

Output ripple max. 70mVpp 20Hz to 20MHz

AC Input voltage - -

DC Input voltage DC 110V - 30%/ +40%

DC Input current 3.87A at 110Vdc

Inrush current typ. 6A peak at 110Vdc

Efficiency 93.7% at 110Vdc

Losses 26.9W at 110Vdc

Temperature range -40°C to +70°C operational

Derating - not required

Hold-up time typ. 35ms at 110Vdc

Dimensions 65x124x127mm WxHxD

Weight 980g / 2.2lb

ORDER NUMBERS

DC/DC converter CPS20.241-60

Accessory ZM2.WALL Wall mount bracket

ZM13.SIDE Side mount bracket

MARKINGS

EMC, LVD

Aug. 2016 / Rev. 1.0 DS-CPS20.241-60-EN

All parameters are specified at 24.5V, 16.3A, 110Vdc, 25°C ambient and after a 5 minutes run-in time unless otherwise noted.

www.pulspower.com Phone +49 89 9278 0 Germany

Summary of content (22 pages)

PAGE 1
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series DC/DC CONVERTER EN 50155 Railway Compliant Conformal Coated PC-boards Built-in Redundancy (Decoupling Mosfet at the Output) Quick-connect Spring-clamp Terminals 77-154Vdc Wide-range Input Width only 65mm Efficiency up to 93.
PAGE 2
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series INDEX Page 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Intended Use .......................................................3 Installation Requirements...................................3 AC-Input...............................................................4 DC-Input...............................................................4 Input Inrush Current ...........................................5 Output ...............................
PAGE 3
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series 1. INTENDED USE This device is designed for installation in an enclosure and is intended for the general professional use such as in rolling stock for railway applications or in industrial control, office, communication, and instrumentation equipment. Do not use this DC/DC converter in equipment, where malfunction may cause severe personal injury or threaten human life. 2.
PAGE 4
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series 3. AC-INPUT Do not operate this DC/DC converter with an AC-input voltage. Use the CPS20.241 or CPS20.241-C1 unit instead. 4. DC-INPUT Use a battery or a similar DC source. A supply from the intermediate DC-bus of a frequency converter is not recommended and can cause a malfunction or damage the unit. Input voltage Input voltage range nom. Input current Allowed voltage between input to earth (ground) typ. max. DC 110V 77-154Vdc 66-77Vdc 3.
PAGE 5
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series Fig. 4-3 Input current vs. output load Input Current at 110Vdc input, typ. 5A 4 3 2 1 0 0 2 4 6 8 10 12 14 16 18A Output Current 5. INPUT INRUSH CURRENT An active inrush limitation circuit limits the input inrush current after turn-on of the input voltage. The charging current into EMI suppression capacitors is disregarded in the first microseconds after switch-on. Inrush current Inrush energy max. typ. max.
PAGE 6
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series 6. OUTPUT Output voltage nom. Adjustment range Line regulation Load regulation Ripple and noise voltage Output current Output power Overload behaviour min. max. typ. max. nom. nom. Short-circuit current min. max. max. 24.5V ***) 25.0V ***) 10mV 500mV ***) 70mVpp 16.3A 400W cont. current HiccupPLUS mode*) 25A**) 32A**) 11A**) Output capacitance typ. 7 000μF *) **) ***) ±2%, at 16.
PAGE 7
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series 7. HOLD-UP TIME The internal capacitor, which supplies the energy for the hold-up time is isolated by a diode to the input voltage. A short on the input line does not discharge the internal hold-up capacitor. Hold-up Time typ. min. typ. min. 80ms 64ms 35ms 28ms Fig. 7-1 Hold-up time vs. input voltage at 8.2A, see Fig. 7-1 at 8.2A, see Fig. 7-1 at 16.3A, see Fig. 7-1 at 16.3A, see Fig. 7-1 Fig.
PAGE 8
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series 9. EFFICIENCY AND POWER LOSSES Efficiency Average efficiency*) typ. typ. 93.7% 92.3% Power losses typ. typ. typ. 4.7W 17.4W 26.9W *) at 110Vdc input and 16.3A output current 25% at 4.1A, 25% at 8.2A, 25% at 12.2A. 25% at 16.3A at 110Vdc input and 0A output current at 110Vdc input and 8.2A output current at 110Vdc input and 16.
PAGE 9
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series 11. FUNCTIONAL DIAGRAM Fig.
PAGE 10
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series Daisy chaining: Daisy chaining (jumping from one DC/DC converter output to the next) is allowed as long as the average output current through one terminal pin does not exceed 25A. If the current is higher, use a separate distribution terminal block as shown in Fig. 12-2. Fig. 12-1 Daisy chaining of outputs DC/DC Converter + + - - Output Fig.
PAGE 11
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series 14. EMC The DC/DC converter is suitable for rolling stock railway applications, for applications in industrial environment as well as in residential commercial and light industry environment without any restrictions. According generic standards: EN 61000-6-1 and EN 61000-6-2 and according to EN 50121-3-2 Electrostatic discharge EN 61000-4-2 contact discharge 8kV air discharge 15kV Electromagnetic RF field EN 61000-4-3 80MHz-2.
PAGE 12
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series 15. ENVIRONMENT Conformal coating Operational temperature*) yes -40°C to +70°C (-40°F to 158°F) Storage temperature Output de-rating +70°C to +85°C (185°F to 185°F) -40 to +85°C (-40°F to 185°F) 0.08A/V at +70°C or 0.16A/°C at 77Vdc Humidity **) Vibration sinusoidal all pc-boards are conformal coated continuous operation, reduce output power according Fig.
PAGE 13
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series 16. PROTECTION FEATURES Output protection Output over-voltage protection Electronically protected against overload, no-load and short-circuits*) typ. 30.5Vdc In case of an internal DC/DC converter defect, a max. 32Vdc redundant circuit limits the maximum output voltage. The output shuts down and automatically attempts to restart. Degree of protection IP 20 EN/IEC 60529 Penetration protection > 5mm e.g.
PAGE 14
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series 18. DIELECTRIC STRENGTH The output voltage is floating and has no ohmic connection to the ground. Type and factory tests are conducted by the manufacturer. Field tests may be conducted in the field using the appropriate test equipment which applies the voltage with a slow ramp (2s up and 2s down). Connect all input-terminals together as well as all output poles before conducting the test.
PAGE 15
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series 19. APPROVALS AND DECLARATIONS EC Declaration of Conformity Railway applications - Electronic equipment used on rolling stock. EN 50155:2007 The CE mark indicates conformance with the - EMC directive and the - Low-voltage directive The manufacturer’s declaration indicate conformance with the following characteristics: - Altitude category: AX (EN 50125-1 § 4.2.1) - Environmental category: TX (EN 50155 § 4.1.
PAGE 16
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series 21. PHYSICAL DIMENSIONS AND WEIGHT Width Height Depth Weight DIN-Rail Housing material Installation clearances 65mm 2.56’’ 124mm 4.88’’ 127mm 5.0’’ The DIN-rail height must be added to the unit depth to calculate the total required installation depth. 980g / 2.2lb Use 35mm DIN-rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm. Body: Aluminium alloy Cover: zinc-plated steel See chapter 2 Fig. 21-1 Front view Fig. 21-2 Side view Aug.
PAGE 17
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series 22. ACCESSORIES 22.1. ZM2.WALL - WALL MOUNTING BRACKET This bracket is used to mount the DC/DC converter onto a flat surface without utilizing a DIN-Rail. Due to the small size of the unit, it is required that the black-DIN-rail slide on the back of the unit must be removed. Instructions how to do this can be found in the manual of the ZM2.WALL. 22.2. ZM13.
PAGE 18
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series 23. APPLICATION NOTES 23.1. PEAK CURRENT CAPABILITY The DC/DC converter can deliver peak currents (up to several milliseconds) which are higher than 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.
PAGE 19
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series 23.3. EXTERNAL INPUT PROTECTION The unit is tested and approved for branch circuits up to 30A (UL) and 32A (IEC). An external protection is only required if the supplying branch has an ampacity greater than this. Provided, that the negative pole is grounded. If the positive pole is grounded, an additional external fast-acting input fuse in the negative input is required. Check also local codes and local requirements.
PAGE 20
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series 23.6. PARALLEL USE TO INCREASE OUTPUT POWER CPS20.241-60 DC/DC converters can be paralleled to increase the output power as long as the ambient temperature stays below 60°C. Energize all units at the same time to avoid the overload HiccupPLUS mode.
PAGE 21
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series 23.8. SERIES OPERATION DC/DC converters of the same type can be connected in series for higher output voltages. It is possible to connect as many units in series as needed, providing the sum of the output voltage does not exceed 150Vdc. Voltages with a potential above 60Vdc are not SELV any more and can be dangerous. Such voltages must be installed with a protection against touching. Avoid return voltage (e.g.
PAGE 22
CPS20.241-60 24V, 400W, DC/DC CONVERTER C-Series 23.11. MOUNTING ORIENTATIONS Mounting orientations other than all terminals on the bottom require a reduction in continuous output power or a limitation in the maximum allowed ambient temperature. The amount of reduction influences the lifetime expectancy of the DC/DC converter. Therefore, two different derating curves for continuous operation can be found below: Curve A1 Curve A2 Recommended output current.