CD5.121

CD5.121 DC/DC Converter 12V, 8A CD-Series DC/DC CONVERTER           24V DC-Input Isolated 12Vdc Output Efficiency up to 88.2% Width only 32mm 20% Output Power Reserves Full Power Between -25°C and +60°C Soft-start Function Included Minimal Inrush Current Surge Reverse Input Polarity Protection 3 Year Warranty PRODUCT DESCRIPTION SHORT-FORM DATA The Dimension CD-Series offer DIN rail DC/DC converters in the 92-120W output power range in a very compact housing. These DC/DC converters are allowed to run with a battery or similar sources. Output voltage Adjustment range Output current The CD5.121 converts a 24V voltage to a 12V voltage. The CD5.121 includes all the essential basic functions and has a power reserve of 20% included. This extra power can be used continuously up to +45°C. The output is electrically isolated from the input in a safe way. The input is protected against reversed voltages and contains a soft start function. CD-Series Related products 24V->24V CD5.051 24V->5V CD5.121 24V->12V CD5.243 12V->24V CD5.241 CD5.242 SLD2.100 24V->5V CD5.241-L1 CD5.241-S1 48V->24V 24V->24V, NEC Class 2, Spring-clamp-terminals, 24V->24V, Spring-clamp-terminals, Input-low, DC-OK signals ORDER NUMBERS DC 12V 12 - 15V 8 – 6.4A 9.6 – 7.7A Output power 96W 115W Output ripple < 75mVpp Input voltage DC 24V Input voltage range 18 to 32.4Vdc 14.4 to 18Vdc Input current typ. 4.6A Input inrush current typ. 1.2A peak Efficiency 88.2% Losses 12.8W Temperature range -25°C to +70°C Derating 2.5W/°C Hold-up time typ. 7ms Dimensions 32x124x102mm Weight 425g / 0.94lb ambient 5MOhm input to output, 500Vdc < 0.1Ohm between housing and Chassis Ground terminal The leakage current which is produced by the DC/DC converter itself depends on the input voltage ripple and need to be investigated in the final application. For a smooth DC input voltage, the produced leakage current is less than 100µA. provided, that the input voltage meets the requirements of chapter 2. Jul. 2021 / Rev. 1.8 DS-CD5.121-EN All parameters are specified at 12V, 8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 15/26 CD5.121 DC/DC Converter 12V, 8A CD-Series 17. 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. When testing, set the cut-off current settings to the value in the table below. Type test 60s A 1500Vac B 1500Vac C 500Vac Factory test 5s 1500Vac 1500Vac 500Vac Field test 5s 1000Vac 1000Vac 500Vac > 30mA > 30mA > 12mA Fig. 17-1 Dielectric strength Input + B - Output A Chassis ground + C - Cut-off current setting To fulfill the PELV requirements according to EN60204-1 § 6.4.1, we recommend that either the + pole, the – pole or any other part of the output circuit shall be connected to the protective earth system. This helps to avoid situations in which a load starts unexpectedly or can not be switched off when unnoticed earth faults occur. Jul. 2021 / Rev. 1.8 DS-CD5.121-EN All parameters are specified at 12V, 8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 16/26 CD5.121 DC/DC Converter 12V, 8A CD-Series 18. APPROVED, FULFILLED OR TESTED STANDARDS UL 508 IEC 60950-1 UL 60950-1 Class I Div 2 Class I Div 2 ATEX IECEx Marine (DNV) UL Certificate Listed equipment for category NMTR - Industrial Control Equipment Applicable for US and Canada E-File: E198865 CB Scheme Certificate General safety requirements for Information Technology Equipment (ITE) UL Certificate Recognized component for category QQGQ - Information Technology Equipment (ITE) Applicable for US and Canada E-File: E137006 CSA Certificate Power Supplies for Hazardous Location Applicable for Canada and US CSA Class: 5318-01 (Canada), 5318-81 (USA) Temperature Code: T4 Groups: A, B, C and D UL Certificate Listed equipment for category NRAD - Listed equipment Industrial Control Equipment for Use in Hazardous Locations Applicable for US and Canada E-File: E327416 Temperature Code: T4 Groups: A, B, C and D Agency Certificate (Bureau Veritas) EN 60079-0 Explosive atmospheres - General requirements EN 60079-7, EN 60079-15 Equipment protection by type of protection "e" and "n" Certificate: EPS 08 ATEX 1 142 X Temperature Code: T4 Type of Protection: ec nC IECEx Certificate IEC 60079-0 Explosive atmospheres - General requirements IEC 60079-15 Equipment protection by type of protection "n" Certificate: IECEx EPS 14.0001X Temperature Code: T4 Type of Protection: ec nC DNV Certificate DNV Type approved product Certificate: TAA00001ST Temperature: Class D Humidity: Class B Vibration: Class C EMC: Class A Enclosure: Class A Jul. 2021 / Rev. 1.8 DS-CD5.121-EN All parameters are specified at 12V, 8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 17/26 CD5.121 DC/DC Converter 12V, 8A CD-Series Marine (ABS) IEC 60068-2-60 ISA-71.04 G3 VDMA 24364 ABS Design Assessment Certificate ABS (American Bureau of Shipment) assessed product Certificate: 17-HG1599236-PD Manufacturer's Declaration (Online Document) Environmental Tests, Flowing Mixed Gas Corrosion Test Test Ke - Method 4 H2S: 10ppb NO2: 200ppb Cl2: 10ppb SO2: 200ppb Test Duration: 3 weeks, which simulates a service life of at least 10 years. Manufacturer's Declaration (Online Document) Airborne Contaminants Corrosion Test Severity Level: G3 Harsh H2S: 100ppb NOx: 1250ppb Cl2: 20ppb SO2: 300ppb Test Duration: 3 weeks, which simulates a service life of at least 10 years Paint Wetting Impairment Substances Test (or LABS-Test) Tested for Zone 2 and test class C1 according to VDMA 24364C1-L/W for solvents and water-based paints 19. REGULATORY PRODUCT COMPLIANCE EU Declaration of Conformity KC REACH Directive WEEE Directive EAC TR Registration The CE mark indicates conformance with the - EMC directive - ATEX directive - RoHS directive KC Registration Korean registration of Broadcasting and Communication Equipment Registered under Clause 3, Article 58-2 of Radio Waves Act. Manufacturer's Statement EU-Directive regarding the Registration, Evaluation, Authorization and Restriction of Chemicals Manufacturer's Statement EU-Regulation on Waste Electrical and Electronic Equipment Registered in Germany as business to business (B2B) products. EAC Certificate EAC EurAsian Conformity - Registration Russia, Kazakhstan and Belarus 8504408200, 8504409000 Jul. 2021 / Rev. 1.8 DS-CD5.121-EN All parameters are specified at 12V, 8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 18/26 CD5.121 CD-Series DC/DC Converter 12V, 8A 20. PHYSICAL DIMENSIONS AND WEIGHT Weight DIN rail Installation Clearances 425g / 0.94lb Use 35mm DIN rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm. The DIN rail depth must be added to the unit depth (102mm) to calculate the total required installation depth. See chapter 2 Fig. 20-1 Front view Fig. 20-2 Side view Jul. 2021 / Rev. 1.8 DS-CD5.121-EN All parameters are specified at 12V, 8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 19/26 CD5.121 DC/DC Converter 12V, 8A CD-Series 21. ACCESSORIES 21.1. 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 slider of the unit have to be removed, so that the two steel brackets can be mounted. Fig. 21-1 ZM1.Wall Wall mounting bracket*) *) Fig. 21-2 Side mounting with DIN rail brackets*) PSU for illustration purpose only. 21.2. ZM10.WALL - WALL/PANEL MOUNT BRACKET This bracket is used to mount the devices on a wall/panel without utilizing the DIN rail. The bracket can be mounted without detaching the DIN rail brackets from the power supply. Fig. 21-2 ZM10.Wall Wall mounting bracket*) *) Fig. 21-4 Side mounting with DIN rail brackets *) PSU for illustration purpose only. Jul. 2021 / Rev. 1.8 DS-CD5.121-EN All parameters are specified at 12V, 8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 20/26 CD5.121 DC/DC Converter 12V, 8A CD-Series 21.3. 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 that the steel brackets can be mounted. For sideway DIN rail mounting, the removed aluminum brackets and the black plastic slider need to be mounted on the steel bracket. Fig. 21-5 ZM11.SIDE Side mounting bracket*) *) Fig. 21-6 Side mounting with DIN rail brackets*) PSU for illustration purpose only. Jul. 2021 / Rev. 1.8 DS-CD5.121-EN All parameters are specified at 12V, 8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 21/26 CD5.121 DC/DC Converter 12V, 8A CD-Series 22. APPLICATION NOTES 22.1. PEAK CURRENT CAPABILITY 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 PowerBoost) The same situation applies, when starting a capacitive load. Branch circuits are often protected with circuit 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 peak current capability ensures the safe operation of subsequent 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. 22-1 Peak loading with 2x the nominal current for 50ms, typ. Fig. 22-2 Peak loading with 5x the nominal current for 5ms, typ. Peak load 16A (resistive load) for 50ms Output voltage dips from 12V to 8.3V. Peak load 40A (resistive load) for 5ms Output voltage dips from 12V to 4.3V. 22.2. BACK-FEEDING LOADS Loads such as decelerating motors and inductors can feed voltage back to the DC/DC converter. This feature is also called return voltage immunity or resistance against Back- E.M.F. (Electro Magnetic Force). This DC/DC converter is resistant and does not show malfunctioning when a load 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 16Vdc. The absorbing energy can be calculated according to the built-in large sized output capacitance which is specified in chapter 5. 22.3. INDUCTIVE AND CAPACITIVE LOADS The unit is designed to supply any kind of loads, including unlimited capacitive and inductive loads. Jul. 2021 / Rev. 1.8 DS-CD5.121-EN All parameters are specified at 12V, 8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 22/26 CD5.121 DC/DC Converter 12V, 8A CD-Series 22.4. CHARGING OF BATTERIES The DC/DC converter can be used to charge lead-acid or maintenance free 12V VRLA batteries. Instructions for charging batteries: a) Ensure that the ambient temperature of the DC/DC converter is below 45°C b) Do not use DC/DC converters in mounting 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 13.9V 13.75V 13.6V 13.4V Battery temperature 10°C 20°C 30°C 40°C d) Use a 10A circuit breaker (or blocking diode) between the DC/DC converter and the battery. e) Ensure that the output current of the DC/DC converter is below the allowed charging current of the battery. f) The return current to the DC/DC converter (battery discharge current) is typ. 15mA when the DC/DC converter is switched off (except in case a blocking diode is utilized). 22.5. EXTERNAL INPUT PROTECTION The unit is tested and approved for branch circuits up to 50A. An external protection is only required, if the supplying branch has an ampacity greater than this. 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 minimum value of 10A B- or 8A C-Characteristic breaker should be used. 22.6. REQUIREMENTS FOR THE SUPPLYING SOURCE In certain circumstances, the input filter of the DC/DC converter can show a resonant effect which is caused by the supplying network. Especially when additional external input filters are utilized, a superimposed AC voltage can be generated on the input terminals of the DC/DC converter which might cause a malfunction of the unit. Therefore, additional input filters are not recommended. To avoid the resonant effects, the minimal resistance of the supplying network which depends on the inductance of the input network, shall be above the boundary curve in Fig. 22-3. Fig. 22-3 External input filter requirements to avoid filter instabilities Resistance of the supplying network 1 Ohm 100 mOhm (a) (b) 10 mOhm (a) max. (b) typ. 1 mOhm 0.1mH 1mH 10mH Inductance of the supplying network Jul. 2021 / Rev. 1.8 DS-CD5.121-EN All parameters are specified at 12V, 8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 23/26 CD5.121 DC/DC Converter 12V, 8A CD-Series 22.7. PARALLEL USE TO INCREASE OUTPUT POWER Unit A The DC/DC-converter can be paralleled to increase the output power. There are no feature included which balances the load current between the DC/DCconverters. Therefore some restrictions and limitations apply. The DC/DCconverter 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 temperature stays below 45°C. The CD5.121 can also be paralleled with power supplies from the QS10.121 from the DIMENSION QSseries. For other power supplies consult PULS. Input Output Unit B Input + - Load + + - Output The output voltages of all DC/DC-converters shall be adjusted to the same value (±100mV) at full load. A fuse or diode on the output of each unit is only required if more than three units are connected in parallel. This avoid that more than 2 times of the nominal output current can flow backwards into the DC/DC converter in case the output stage of one DC/DC converter 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) between two DC/DC-converters and avoid installing the DC/DCconverters on top of each other. Do not use DC/DC-converters in parallel in mounting orientations other than the standard mounting orientation (input terminals on the bottom and output terminals on top of the unit). 22.8. PARALLEL USE FOR REDUNDANCY The DC/DC converters can be paralleled 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 converter fails, the other one is automatically able to support the load current without any interruption. Redundant systems for a higher power demand are usually built in an N+1 method. E.g. six DC/DC converters, each rated for 8A are paralleled to build a 40A 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/DCconverters and the output voltage can not be maintained any more. This can only be avoided by utilizing decoupling diodes which are included in the decoupling module YR2.DIODE. Recommendations for building redundant power systems: a) Use separate input fuses for each DC/DC-converter. b) Monitor the individual DC/DC-converter units. c) 1+1 Redundancy is allowed up to an ambient temperature of 60°C N+1 Redundancy is allowed up to an ambient temperature of 45°C d) It is desirable to set the output voltages of all units to the same value (± 100mV) or leave it at the factory setting. Jul. 2021 / Rev. 1.8 DS-CD5.121-EN All parameters are specified at 12V, 8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 24/26 CD5.121 DC/DC Converter 12V, 8A CD-Series 22.9. DAISY CHAINING OF OUTPUTS 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. Fig. 22-4 Daisy chaining of outputs Fig. 22-5 Using distribution terminals max 25A! Output + + - - Output + + - - DC/DC Converter Input + - Output + + - - Output + + - - DC/DC Converter DC/DC Converter DC/DC Converter Input Input Input Load 22.10. SERIES OPERATION + - Load Distribution Terminals Unit A + Input DC/DC converters of the exact 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 Output a potential above 60Vdc are not SELV any more and can be dangerous. Such voltages must be installed with a protection against touching. Earthing of the Unit B + output is required when the sum of the output voltage is above 60Vdc. Avoid Input 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-converters on top of each Output other. Do not use DC/DC-converters in series in mounting orientations other than the standard mounting orientation (input terminals on the bottom and output terminals on top of the unit). Load + - 22.11. USE IN A TIGHTLY SEALED ENCLOSURE When the DC/DC-converter is installed in a tightly sealed enclosure, the temperature inside the enclosure will be higher than outside. In such situations, the inside temperature defines the ambient temperature for the DC/DCconverter. 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 the middle of the box, no other heat producing items are inside the box Enclosure: Load: Input: Temperature inside enclosure: Temperature outside enclosure: Temperature rise: Rittal Typ IP66 Box PK 9516 100, plastic, 110x180x165mm 12V, 6.4A; (=80%) load is placed outside the box 24Vdc 48.0°C (in the middle of the right side of the DC/DC converter with a distance of 2cm) 22.6°C 25.4K Jul. 2021 / Rev. 1.8 DS-CD5.121-EN All parameters are specified at 12V, 8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 25/26 CD5.121 DC/DC Converter 12V, 8A CD-Series 22.12. MOUNTING ORIENTATIONS Mounting orientations other than input terminals on the bottom and output on the top require a reduction in continuous output power or a limitation in the max. 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. Max allowed output current (results in approximately half the lifetime expectancy of A1). Fig. 22-6 Mounting Orientation A (Standard orientation) Output Current OUTPUT 10A 8 6 4 2 0 DC/DC Converter INPUT A1 Ambient Temperature 10 Fig. 22-7 Mounting Orientation B (Upside down) INPUT 10A 8 6 4 2 0 DC/DC Converter OUTPUT Fig. 22-8 Mounting Orientation C (Table-top mounting) 40 60°C 50 A2 A1 Ambient Temperature 20 30 40 50 60°C Output Current 10A 8 6 4 2 0 A2 A1 Ambient Temperature 10 20 30 40 50 60°C Output Current OUTPUT DC/DC Converter INPUT 10A 8 6 4 2 0 A2 A1 Ambient Temperature 10 20 30 40 50 60°C INPUT DC/DC Converter Output Current OUTPUT Fig. 22-10 Mounting Orientation E (Horizontal ccw) 30 Output Current 10 Fig. 22-9 Mounting Orientation D (Horizontal cw) 20 10A 8 6 4 2 0 A2 A1 Ambient Temperature 10 20 30 40 50 60°C Jul. 2021 / Rev. 1.8 DS-CD5.121-EN All parameters are specified at 12V, 8A, 24Vdc input voltage, 25°C ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com Phone +49 89 9278 0 Germany 26/26