Puls CP Series - User Manual

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CP10.241-60

CP-Series

24V, 200W, DC/DC CONVERTER

P R E L I M I N A R Y

DC/DC CONVERTER

 EN 50155 Railway Compliant

 Conformal Coated PC-boards

 Quick-connect Spring-clamp Terminals

 67-154Vdc Wide-range Input

 Width only 39mm

 Efficiency up to 94.5%

 Excellent Partial Load Efficiency

 Minimal Inrush Current Surge

 Full Power Between -40°C and +70°C

 DC-OK Relay Contact

 Reverse Input Polarity Protected

 3 Year Warranty

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GENERAL DESCRIPTION

The DC/DC converter CP10.241-60 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, 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 39mm 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 24V

Adjustment range 24 - 28V

Output current 8.3 – 7.1A Continuous, < +70°C

8.3 – 7.1A For 10 minutes, < +85°C

Input voltage DC DC 96 - 110V - 30%/ +40%

Input voltage range

67.2 – 154V

Input current DC 2.25 / 1.95A At 96 / 110Vdc

Input inrush current 2.5A pk

Efficiency 94.3 / 94.5% At 96 / 110Vdc

Losses 12.1 / 11.6W At 96 / 110Vdc

Hold-up time 34ms

Temperature range -40 to +70°C

Size (wxhxd) 39x124x117mm Without DIN-rail

Weight 620g / 1.37lb

ORDER NUMBERS

DC/DC converter CP10.241-60

Accessory ZM4.WALL Wall/Panel mount bracket

ZM12.SIDE Side mount bracket

YR20.242 Redundancy module

YR20.246 Redundancy module

UF20.241 Buffer module

MARKINGS

IND. CONT. E

UL 508

planned

UL 60950-1

planned

EMC, LVD

planned

May 2017 / Rev. 0.1 DS-QS10.241-60-EN preliminary

All parameters are typical values specified at 24V, 8.3A output, 110Vdc input, 25°C ambient and after a 5 minutes run-in time

unless otherwise noted.

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

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The PULS CP10.241-60 is a 24V, 200W DC/DC converter designed for railway and transportation applications, as well as general professional use in industrial control, office, communication, and instrumentation equipment. It complies with the EN 50155 standard, which covers electronic equipment used in rolling stock, addressing aspects like temperature, humidity, shock, vibration, and EMI. The unit features conformal coated PC-boards for enhanced durability in demanding environments.

Function Description:

The CP10.241-60 converts a wide-range DC input voltage (67-154Vdc, nominal 96-110Vdc) into a regulated 24V DC output. It incorporates an active inrush limitation circuit to manage input current surges during turn-on. The converter is designed for convection cooling and does not require an external fan, making it suitable for enclosed installations. It features a DC-OK relay contact for remote monitoring of the output voltage, signaling when the output is above 90% of the adjusted level. The unit is protected against reverse input polarity, over-voltage, overload, and short-circuits.

Important Technical Specifications:

Output Voltage: 24V, adjustable from 24-28V (factory set to 24.1V).
Output Current: 8.3A (at 24V, <70°C ambient) or 7.1A (at 28V, <70°C ambient). Peak current capability up to 30A for up to 12ms.
Output Power: 200W continuously available.
Input Voltage Range: 67.2-154Vdc (nominal 96-110Vdc). Short term for 2s, no start at 57Vdc.
Efficiency: Up to 94.5% (at 110Vdc input, 8.3A output). Average efficiency is 93.5% (at 110Vdc input).
Power Losses: As low as 2.6W at no load (110Vdc input) and 11.6W at full load (110Vdc input).
Hold-up Time: 45ms (typical at 8.3A, 110Vdc input).
Temperature Range: -40°C to +70°C for continuous operation at full output current. Derating applies for temperatures up to +85°C.
Dimensions: 39mm (width) x 124mm (height) x 117mm (depth).
Weight: 620g (1.37lb).
EMC Immunity: Complies with EN 61000-6-1, EN 61000-6-2, and EN 50121-3-2 for electrostatic discharge, electromagnetic RF fields, fast transients, surge voltages, and conducted disturbances.
EMC Emission: Complies with CISPR 16-1-2, CISPR 16-2-1, EN 55011, EN 55022, and EN 50121-3-2 (Class B).
Safety Features: SELV/PELV output, double or reinforced isolation to input, Class I protection, isolation resistance >500MOhm.
Lifetime Expectancy: 336,000 hours (at 24V, 8.3A, 25°C ambient, 110Vdc input).
MTBF: T.B.D. (Mean Time Between Failure) according to SN 29500, IEC 61709, and MIL HDBK 217F.

Usage Features:

Installation: Designed for DIN-rail mounting with input terminals at the bottom. Clearances of 40mm top, 20mm bottom, and 5mm sides are recommended for permanent loads above 50% rated power.
Terminals: IP20 finger-safe, bi-stable quick-connect spring-clamp terminals for input and output, suitable for solid (max. 6mm²) and stranded (max. 4mm²) wires. Push-in terminals for the DC-OK signal (max. 1.5mm²).
Output Voltage Adjustment: A potentiometer on the front allows adjustment of the output voltage from 24V to 28V.
Overload Behavior: Provides continuous output current for 2s at heavy overloads (output voltage below 13V), then switches off for approximately 18s before attempting a restart (Hiccup PLUS mode).
Dynamic Current Capability: Can deliver up to 30.5A for 15ms or 28A for 12ms, aiding in starting current-demanding loads and tripping circuit breakers.
Parallel and Series Operation: Multiple units can be connected in parallel to increase output power or for redundancy (with appropriate modules like YR20.242 or YR20.246). Units can also be connected in series for higher output voltages (sum not exceeding 150Vdc).
Charging Batteries: Suitable for charging lead-acid or maintenance-free batteries (two 12V batteries in series) with precise output voltage adjustment and external protection.
Back-feeding Loads: Resistant to back-feeding voltages up to 35Vdc and peak currents up to 40A from loads like decelerating motors.

Maintenance Features:

No Serviceable Parts: The device does not contain serviceable parts. Internal fuse tripping indicates an internal defect requiring factory inspection.
Conformal Coating: All PC-boards are conformal coated, enhancing durability and protection against environmental factors like humidity and dust, reducing maintenance needs in harsh conditions.
Robust Design: Built with high-quality electrolytic capacitors for extended lifetime expectancy, minimizing the need for frequent replacement.
Diagnostic Feedback: The DC-OK relay contact and LED provide immediate visual and remote feedback on the output voltage status, aiding in quick troubleshooting.