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qs5.241-60 q-series 24v, 100w, dc/dc c onverter dc/dc c onverter ? en 50155 railway compliant ? conformal coated pc-boards ? quick-connect spring-clamp terminals ? 77-154vdc wide-range input ? width only 40mm ? efficiency up to 91.1% ? excellent partial load efficiency ? minimal inrush current surge ? full power between -25c and +70c ? dc-ok relay contact ? reverse input polarity protected ? 3 year warranty 1/27 g eneral d escription the qs5.241-60 dc/dc converte r is designed specifically for railway & transportation app lications. it is approved according to the en 501 55 standard, which is an international standard cove ring electronic equipment used on rolling stock for railway applications. the standard covers aspects such as temperature, humidity, shock, vibration, emi and ot her 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-conn ect spring-clamp terminals for a reliable connection even when mechanical vibration and shock are involv ed. the unit also covers an extreme wide temperature range from -25c up to +70c with full output current. this dc/dc converter comes in a very compact housing and requires only 40mm 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. s hort - form d ata output voltage dc 24v adjustment range 24 - 28v output current 4.2 C 3.6a continuous 6.3 C 5.4a for typ. 4s output power 100w continuous 150w for typ. 4s output ripple max. 50mvpp 20hz to 20mhz ac input voltage - - dc input voltage dc 110v - 30%/ +40% dc input current 1.0a at 110vdc inrush current typ. 10a peak at 110vdc efficiency 91.1% at 110vdc losses 9.8w at 110vdc temperature range -25c to +70c operational derating - not required hold-up time typ. 42ms at 110vdc dimensions 40x124x117mm wxhxd weight 640g / 1.41lb o rder n umbers dc/dc converter qs5.241-60 accessory zm12.side side mount bracket yr2.diode redundancy module uf20.241 buffer module m arkings emc, lvd aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany
qs5.241-60 q-series 24v, 100w, 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 ..........................................9 9. efficiency and power losses ..............................10 10. lifetime expectancy and mtbf .........................10 11. functional diagram ...........................................11 12. terminals and wiring ........................................12 13. front side and user elements ...........................13 14. emc ....................................................................14 15. environment ......................................................15 16. protection features ...........................................16 17. safety features ..................................................16 18. dielectric strength ............................................17 19. approvals and declarations ..............................18 20. rohs, reach and othe r fulfilled standards .. 18 21. physical dimensions and weight ..................... 19 22. accessories ........................................................ 20 22.1. zm12.side - side mounting bracket ........20 22.2. uf20.241 buffer module ..........................20 22.3. yr2.diode redundancy module .............21 23. application notes ............................................. 22 23.1. repetitive pulse loading ..........................22 23.2. peak current capability ...........................23 23.3. inductive and capacitive loads ................23 23.4. external input protection .........................24 23.5. charging of batteries ...............................24 23.6. parallel use to increase output power ....24 23.7. parallel use for redundancy ....................25 23.8. series operation .......................................25 23.9. back-feeding loads ..................................26 23.10. use in a tightly sealed enclosure ............26 23.11. mounting orientations ............................27 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 110v 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) 110vdc 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. aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 2/27
qs5.241-60 q-series 24v, 100w, 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 rolling stock for railway applications or in industrial control, office, communi cation, and instrument ation equipment. do not use this dc/dc converter in equipment, where ma lfunction may cause severe pe rsonal 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 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 input terminals are located on the bottom of the unit. for other mounting orientations see de-rating requirements in this document. see chapter 23.11. 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). 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. aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 3/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 3. ac-i nput do not operate this dc/dc converter with an ac-input voltage. use th e qs10.241 or qs10.241-c1 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. input voltage nom. dc 110v -30%/+40% input voltage range 77-154vdc 66-77vdc short term for 100ms input current typ. 1.0a at 8.3a and 110vdc input voltage, see fig. 4-3 allowed voltage between input to earth (ground) max. 375vdc 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. 15vpp 3vpp 50hz C10khz 10khz C 50khz turn-on voltage typ. 73vdc steady-state va lue, at ambient temperatures between -20c and +70c, see fig. 4-1 shut-down voltage typ. 63vdc steady-state value, see fig. 4-1 start-up delay typ. 120ms see fig. 4-2 rise time typ. 18ms at 4.2a constant current load, 0mf load capacitance, see fig. 4-2 typ. 38ms at 4.2a constant current load, 5mf load capacitance, see fig. 4-2 turn-on overshoot max. 100mv see fig. 4-2 external input protection see recommendations in chapter 23.4 . fig. 4-1 input voltage range fig. 4-2 turn-on behavior, definitions turn-on 77v rated input range max. 500ms v in p out 375vdc 154v shut-down start-up delay rise time overshoot - 5% output voltage input voltage aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 4/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter fig. 4-3 input current vs. output load at 24v output voltage 4.0 0 0.5 1.0 1.5 2.0 0 0.25 0.5 0.75 1a output current input current at 110vdc input, typ. 2.5 3.0 3.5 4.5a 5. i nput i nrush c urrent an active inrush limitation circui t limits the input inrush current af ter 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. 20a peak at 110vdc, temperature independent typ. 10a peak at 110vdc, temperature independent inrush energy max. 1a 2 s at 110vdc, temperature independent fig. 5-1 typical input inrush curren t behaviour at nominal load and 25c ambient aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 5/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 6. o utput output voltage nom. 24v adjustment range min. 24-28v guaranteed max. 30v ***) at clockwise end position of potentiometer factory setting typ. 24.1v 0.2%, at full load, cold unit line regulation max. 20mv 77-154vdc load regulation max. 100mv static value, 0a ? 4.2a ripple and noise voltage max. 50mvpp 20hz to 20mhz, 50ohm output current nom. 4.2a contin uously available at 24v, see fig. 6-1 nom. 3.6a continuously available at 28v, see fig. 6-1 nom. 6.3a *) short term available bonuspower ? *) , at 24v, for typical 4s, see fig. 6-1 nom. 5.4a *) short term available bonuspower ? *) , at 28v, for typical 4s, see fig. 6-1 output power nom. 100w c ontinuously available nom. 150w *) short term available bonuspower ? *) bonuspower ? time typ. 4s duration until the output voltage dips, see fig. 6-2 min. 3s max. 5s bonuspower ? recovery time typ. 7s overload fr ee time to reset power manager, see fig. 6-3 overload behaviour cont. current short-circuit current min. 4a **) continuous, load im pedance 100mohm, see fig. 6-1 max. 7a **) continuous, load im pedance 100mohm, see fig. 6-1 min. 8a **) during bonuspower ? *) , load impedance 100mohm max. 13a **) during bonuspower ? *) , load impedance 100mohm max. 7a **) continuous, load impedance <10mohm, see fig. 6-1 output capacitance typ. 3 500f included inside the power supply *) bonuspower?, short term power capability (up to typ. 4s) the power supply is designed to support loads with a higher short-term power requirement without damage or shutdown. the short- term duration is hardware controlled by an output power manager. this bonuspower ? is repeatedly available. detailed information can be found in chapter 23.1 . if the power supply is loaded longer with the bonuspower ? than shown in the bonus-time diagram (see fig. 6-2 ), the max. output power is automatically reduced to 100w. **) 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. i t is not a guaranteed value, which can be achieved. the typical value is about 28.6v. fig. 6-1 output voltage vs. output current, typ. fig. 6-2 bonus time vs. output power output voltage 0 02 6810a 4 8 12 28v 16 20 24 4 output current s h o r t - t e r m adjustment range c on t i n uo u s bonus time 0 110 120 130 140 150 160% 1 2 3 7 4 5 6 8 9 10s m i n m a x typ output power aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 6/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter fig. 6-3 bonuspower ? recovery time power demand 100% t t limitation by power manager output voltage bonus power disabled bonus time recovery time the bonuspower ? is available as soon as power co mes on and immediately after the end of an output short circuit or output overload. fig. 6-4 bonuspower ? after input turn-on fig. 6-5 bonuspower ? after output short 100% output voltage input voltage bonus power output power 150% short of output 100% output voltage bonus power output power 150% aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 7/27
qs5.241-60 q-series 24v, 100w, 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. hold-up time typ. 83ms at 2.1a, see fig. 7-1 min. 59ms at 2.1a, see fig. 7-1 typ. 42ms at 4.2a, see fig. 7-1 min. 30ms at 4.2a, see fig. 7-1 fig. 7-1 hold-up time vs. input voltage fig. 7-2 shut-down behavior, definitions 0 25 50 100ms 90 120 155 190 230vac input voltage 75 hold-up time 24v, 4.2a, typ. 24v, 2.1a, min. 24v, 2.1a, typ. 24v, 4.2a, min. - 5% hold-up time output voltage input voltage aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 8/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 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 voltag e reaches the adjusted 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 250ms. dips shorter th an 1ms will be ignored. contact re-closes as soon as the output volt age exceeds 90% of th e adjusted voltage. contact ratings max 60vdc 0.3a, 30vdc 1a, 30vac 0.5a resistive load min 1ma at 5vdc mi n. permissible load isolation voltage see dielec tric strength table in section 18. fig. 8-1 dc-ok relay contact behavior 250ms 0.9* v adj < 1ms 10% open v out = v adj open closed closed > 1ms note: the dc-ok feature requires that the output voltage reaches the nominal (=adjusted) level after turn-on in order to function according to specification. if this level cannot be achieved, the overload lamp will be on and the dc-ok contact will be open. the overload signal will only shut off as soon as the adjusted voltage is reached. this is an important condition to consider particularly, if the load is a battery, the power supply is used in parallel or the pow er supply is used for n+1 redundant systems. aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 9/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 9. e fficiency and p ower l osses efficiency typ. 91.1% at 110vdc input and 24v, 4.2a average efficiency *) typ. 88.9% 25% at 1.05a, 25% at 2.1a, 25% at 3.15a. 25% at 4.2a power losses typ. 4.0w at 110vdc input and 24v, 0a typ. 6.5w at 110vdc input and 24v, 2.1a (= 50% load) typ. 9.8w at 110vdc input and 24v, 4.2a *) 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 24v, typ. fig. 9-2 losses vs. output current, at 24v, typ. efficiency 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5a 84 85 86 87 88 89 output current 90 91 92% power losses 0 0.5 1 1.5 2 2.5 3 3.5 0 2 4 6 8 10 12w 4 4.5a output current 10. l ifetime e xpectancy and mtbf lifetime expectancy *) 196 000h *) at 24v, 2.1a and 40c 535 000h *) at 24v, 2.1a and 25c 127 000h *) at 24v, 4.2a and 40c 360 000h *) at 24v, 4.2a and 25c mtbf **) sn 29500, iec 61709 956 000h at 24v, 4.2a and 40c 1 619 000h at 24v, 4.2a and 25c mtbf **) mil hdbk 217f 382 000h at 24v, 4.2a and 40c, ground benign gb40 515 000h at 24v, 4.2a and 25c, ground benign gb25 87 000h at 24v, 4.2a and 40c, ground fixed gf40 115 000h at 24v, 4.2a 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. aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 10/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 11. f unctional d iagram fig. 11-1 functional diagram + + - - dc-ok contact output over- voltage protection boost converter (pre conditioning) output voltage regulator output filter dc-ok relay output voltage monitor output power manager temper- ature shut- down overload led dc-ok led input fuse input filter active inrush limiter v out power converter + - reverse polarity and back-feeding protection aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 11/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 12. t erminals and w iring the terminals are ip20 finger safe con structed and suitable for field- and fa ctory wiring. shipped in open position. input output dc-ok-signal type bi-stable, spring-clamp terminals bi-stable, spring-clamp terminals bi-stable, spring-clamp terminals solid wire max. 6mm 2 max. 4mm 2 max. 4mm 2 stranded wire max. 4mm 2 max. 2.5mm 2 max. 2.5mm 2 american wire gauge 20-10 awg 26-12 awg 26-12 awg wire stripping length 10mm / 0.4inch 6mm / 0.25inch 6mm / 0.25inch screwdriver not applicable not applicable not applicable recommended tightening torque not applicable not appl icable not applicable fig. 12-1 connecting a wire 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 stranded wire enter the terminal connection! d) do not use the unit without pe connection. d) ferrules are allowed. 1. insert the wire 2. close the lever to disconnect wire: reverse the procedure 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 13a. if the current is higher, use a se parate distribution terminal block as shown in fig. 12-3 . fig. 12-2 daisy chaining of outputs fig. 12-3 using distribution terminals dc/dc converter + + - - input output load + - max 13a! dc/dc converter + + - - input output load + - distribution terminals dc/dc converter + + - - input output dc/dc converter + + - - input output aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 12/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 13. f ront s ide and u ser e lements fig. 13-1 front side a input terminals (quick-connect spri ng-clamp terminals) + positive input C negative (return) input pe (protective earth) input b output terminals (quick-connect spring-clamp terminals, two pins per pole) + positive output C ne gative (return) output c 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. d output voltage potentiometer open the flap to adjust the output voltage. factory set: 24.1v e dc-ok led (green) on, when the output voltage is >90% of the adjusted output voltage f overload led (red) on, when the voltage on the output terminals is <90% of the adjusted output voltage, or in case of a short circuit in the output. input voltage is required flashing, when the unit has switched off due to over-temperature. indicators, leds overload led dc-ok led dc-ok contact normal mode off on closed during bonuspower ? off on closed overload (v out < 90%) on off open output short circuit on off open temperature shut-down intermitted off open no input power off off open aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 13/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 14. emc the dc/dc converter is suitable for rollin g stock railway applications, for applicat ions in industrial environment as well as in residential commercia l and light industry environment without any restrictions. emc immunity 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 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 0.5kv 1kv 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 10v criterion a power C frequency magnetic field en 61000-4-8 16.7hz, 50hz 100a/m criterion a power C frequency magnetic field en 61000-4-8 0hz 300a/m criterion a pulsed magnetic field en 61000-4-9 300a/m criterion a criterions: a: dc/dc converter shows normal operation behavior within the defined limits. emc emission according generic standards: en 61000-6-3 and en 61000-6-4 and according to en 50121-3-2 conducted emission input lines cispr 16-1-2, cispr 16-2-1 limi ts for en 50121-3-2 fulfilled, limits for dc power port according en 61000-6-3 fulfilled conducted emission output lines cispr 16-1-2, cispr 16-2-1 limi ts for en 50121-3-2 fulfilled, limits for dc power port according en 61000-6-3 fulfilled radiated emission en 55011, en 55022, en 50121-3-2 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 frequencies the power supply has three converters with three different switching frequencies included. two are nearly constant. the other one is input voltage and load dependent. switching frequency 1 110khz nearly constant switching frequency 2 400khz nearly constant switching frequency 3 55khz to 500khz input voltage and load dependent aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 14/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 15. e nvironment conformal coating yes all pc- boards are conformal coated operational temperature *) -25c to +70c (-13f to 158f) continuous op eration, see fig. 15-1 -40c start-up tested +70c to +85c (185f to 185f) for maximal 10 minutes every hour storage temperature -40 to +85c (-40f to 185f) for storage and transportation output de-rating not required see fig. 15-1 . 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; dc/dc converter in operation vibration broadband 1.01grms for 10 minutes; 5-150hz ***) iec 60068-2-64, dc/dc c onverter in operation; tests limits according to en 61373 vibration broadband 5.72grms for 300 minutes; 5-150hz ***) iec 60068-2-64, dc/dc converter not in operation; tests limits according to en 61373 shock 30g 6ms, 20g 11ms, 50g 30ms ***) 3 bumps / direction, 18 bumps in total iec 60068-2-27; dc/dc c onverter in operation shock 50g 30ms ***) 3 bumps / direction, 18 bumps in total iec 60068-2-27, dc/dc converter not in operation; tests limits according to en 61373 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 6w/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. *) 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. fig. 15-1 output current vs. ambient temp. at 24v output voltage fig. 15-2 output current vs. altitude at 24v output voltage allowed output current 0 -25 0 25 50 85c 1 2 3 4 6a 60 70 5 c o n t i n u o u s f o r t y p . 4 s 6.3a f o r m a x . 1 0 m i n u t e s 4.2a ambient temperature 0 0 2000m 4000m 6000m 1 2 3 4 5 6a 4.2a continuous operation 6.3a for typ. 4s allowable output current altitude b c a . . . t a m b < 7 0 c b . . . t a m b < 6 0 c c . . . t a m b < 5 0 c a aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 15/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 16. p rotection f eatures output protection electronically protected against overload , no-load and short-circuits *) output over-voltage protection typ. 32vdc max. 36vdc 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 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 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 classification of output voltage selv iec/en 60950-1 pelv iec/en 60204-1, en 50178, iec 62103, iec 60364-4-41 double or reinforced isolation to the input 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. aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 16/27
qs5.241-60 q-series 24v, 100w, 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 500vac 500vac factory test 5s 2500vac 2500vac 500vac 500vac field test 5s 2000vac 2000vac 500vac 500vac cut-off current setting > 10ma > 10ma > 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. aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 17/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 19. a pprovals and d eclarations ec declaration of conformity the ce mark indicates conformance with the - emc directive and the - low-voltage directive railway applications - electronic equipment used on rolling stock. en 50155:2007 the manufacturers declaration indicate conformance with the following characteristics: - altitude category: ax (en 50125-1 4.2.1) - environmental category: t3 (en 50155 4.1.2) - interruption of voltage supply: s2 (en 50155 5.1.1.2) - supply change over: c2 (en 50155 5.1.3) - shock and vibration: category 1, class a and b (en 61373) - emi: en 50121-3-2 - fire classification: hl3 (en 45545-2) 20. 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) aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 18/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 21. p hysical d imensions and w eight width 40mm 1.57 height 124mm 4.88 depth 117mm 4.61 the din-rail height must be added to the unit depth to calculate the total required installation depth. weight 640g / 1.41lb din-rail use 35mm din-rails according to en 60715 or en 50022 with a height of 7.5 or 15mm. housing material body: aluminium alloy cover: zinc-plated steel installation clearances see chapter 2 fig. 21-1 front view fig. 21-2 side view aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 19/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 22. a ccessories 22.1. zm12.side - s ide m ounting b racket this bracket is used to mount the dc /dc converter 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 22.2. uf20.241 b uffer m odule this buffer unit is a supplementary device for dc 24v power supplies. it delivers power to bridge typi cal mains failures or extends the hold-up time after turn-off of the input power. in times when the power supply provides sufficient voltage the buffer unit stores energy in integrat electrolytic capacitors. in case of input voltage fault, this ener gy is released again in a regulated process. one buffer m odule can deliver 20a additional curren 20/27 s, ed t. dc buffer unit(s) power supply load ac + - the buffer unit does not require any control wiring. it can be a dded in parallel to the load circuit at any given point. buffer units can be added in parallel to increase the output ampacity or the hold-up time. aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 22.3. yr2.diode r edundancy m odule 21/27 ures. + - pe + + - - qs5.241-60 dc/dc-conv. adj overload dcok output input failure monitor 24v load optional i i l n pe yr2.diode redundancy module + - out + - in 1 + - in 2 + - pe + + - - qs5.241-60 dc/dc-conv. adj overload dcok output input the yr2.diode is a dual redundanc y module, which has two diodes as decoupling devices included. it can be used for various purposes. the most popular application is to configure highly reliable and true redundant power supply systems. another interesting application is the separation of sensitive loads from non-sensitive loads. this avoids the distortion of the power quality for the sensitive loads which can cause controller fail aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 23. a pplication n otes 23.1. r epetitive p ulse l oading typically, a load current is not constant and varies over time. this power suppl y is designed to support loads with a higher short-term power demand (=bonuspower ? ). the short-term duration is ha rdware controlled by an output power manager and is available on a repeated basis. if the bonuspower ? load lasts longer than the hardware controller allows it, the output volt age will dip and the next bonuspower ? is available after the bonuspower ? recovery time (see chapter 6 ) has elapsed. to avoid this, the following rules must be met: a) the power demand of the pulse must be be low 150% of the nominal output power. b) the duration of the pulse power must be shorter than the allowed bonuspower ? time. (see output section) c) the average (r.m.s.) output current must be below the specified cont inuous output current. if the r.m.s. current is higher, the unit will respond wi th a thermal shut-down afte r a period of time. use the maximum duty cycle curve ( fig. 23-2 ) to check if the average output cu rrent is below the nominal current. fig. 23-1 repetitive pulse loads, definitions fig. 23-2 max. duty cycle curve 100% p peak t peak p 0 t 0 max. 150% 150% 100 0 0.2 0.4 0.6 0.8 1.0 dutycycle 110 120 130 140 p peak p 0 = 1 0 % p 0 = 5 0 % p 0 = 7 5 % p 0 = 1 0 0 % p 0 base load (w) p peak pulse load (above 100%) t 0 duration between pulses (s) t peak pulse duration (s) d uty c ycle t 0 = t peak - (d uty c ycle x t peak ) t peak + t 0 t peak d uty c ycle = example: a load is powered continuously with 100w (= 50% of the rated output load). fr om time to time a peak power of 300w (= 150% of the rated out put load) is needed for 1 second. the question is: how often can this pulse be supplied without overloading the power supply? - make a vertical line at p peak = 150% and a horizontal line where the vertical line crosses the p 0 = 50% curve. read the max. duty cycle fro m the duty cycle-axis (= 0.37) - c alculate the required pause (base load) length t 0 : 22/27 - result: the required pause length = 1.7s - max. repetition rate = pulse +pause length = 2.7s more examples for pulse load compatibility: p peak p 0 t peak t 0 p peak p 0 t peak t 0 150w 100w 1s >25s 150w 50w 0.1s >0.16s 150w 0w 1s >1.3s 150w 50w 1s >1.6s 120w 50w 1s > 0.75s 150w 50w 3s >4.9s d uty c ycle t 0 = t peak - (d uty c ycle x t peak ) 0.37 1s - (0.37 x 1s) == 1 . 7 s aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 23.2. 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. 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 built-in large sized output ca pacitors of the dc/d c converter. the capacitors get discharged duri ng such an event, which causes a voltage di p on the output. the following two examples show typical voltage dips: fig. 23-3 peak load with 2x the nominal current for 50ms, typ. fig. 23-4 peak load with 5x the nominal current for 5ms, typ. output voltage output current 24v 0a 8.4a 20.5v 10ms/div output voltage output current 24v 0a 21a 14.5v 1ms/div 8.4a peak load (resistive) for 50ms output voltage dips from 24v to 20.5v. 21a peak load (resistive) for 5ms output voltage dips from 24v to 14.5v. peak current voltage dips typ. from 24v to 20.5v at 8.4a for 50ms, resistive load typ. from 24v to 19.5v at 21a for 2ms, resistive load typ. from 24.5v to 14.5v at 21a for 5ms, resistive load 23.3. 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. aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 23/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 23.4. 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 ampacity greater than this. check also local codes and local requirements. in some countries local re gulations 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 6a b- or 3a c-characteristic breaker should be used. 23.5. 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) 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 b) use a 10a circuit breaker (or blocking diode) between the dc/dc converter 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 power supply (battery discharge current) is ty p. 2.5ma when the power supply is switched off (except in case a blocking diode is utilized). 23.6. p arallel u se to i ncrease o utput p ower qs5.241-60 dc/dc converters can be para lleled to increase the output power. the output voltage shall be adjusted to the same value (100mv) with the same lo ad conditions on all units, or the uni ts can be left with the factory settings. the ambient temperature is not allowed to exceed +60c. if more than three units are connected in parallel, a fuse or circui t breaker with a rating of 8a or 10a is required on each output. alternatively, a diode or redundancy module can also be utilized. fig. 23-5 parallel use to increase the output power instructions for parallel use: unit a unit b - + - + load + - input output input output - 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 parallel dc/dc conve rters in orient ations other than the standard mounting orientation (terminals on bottom of the unit) or in any other condition where a derating of the output current is required (e.g. altitude, temperature, input voltages). - pay attention that emi and inrush current will increase when using multiple dc/dc converters. aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 24/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 23.7. p arallel u se for r edundancy qs5.241-60 dc/dc converters ca n be paralleled 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 co nverter unit fails. the simplest way is to put two dc/dc converters in paralle l. this is called a 1+1 redundancy. in ca se one dc/dc converter unit fails, the other one is automatically able to su pport the load current without any inte rruption. redundant systems for a higher power demand are usually built in a n+1 method. e.g. five power supplies, each rated for 4.2a are paralleled to build a 16.8a redundant system. for n+1 redundancy the same restrict ions apply as for increasing the output power, see also section 23.6 . 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 power supply. in such a case, the defective unit beco mes a load for the other power supplies and the output voltage can not be mainta ined any more. this can be avoided by utilizing decoupling diodes which are included in the redundancy module yr2.diode. fig. 23-6 redundant power design + - pe + + - - qs5.241-60 dc/dc-conv. adj overload dcok output input failure monitor 24v load optional i i l n pe yr2.diode redundancy module + - out + - in 1 + - in 2 + - pe + + - - qs5.241-60 dc/dc-conv. adj overload dcok output input recommendations for buil ding redundant power systems: - use separate input fuses for each dc/dc converter. - monitor the individual dc/dc converter units. use the dc-ok relay contact of the qs5 dc/dc converter. - it is desirable to set the output voltages of all units to the same value ( 100mv) or leave it at the factory setting. 23.8. s eries o peration dc/dc converters of the same type can be connected in series for higher output vo ltages. it is possible to connect as many units in series as needed, providing the sum of th e output voltage does not exceed 150vdc. voltages with a potential above 60vdc are not selv any more and can be da ngerous. such voltages must be installed with a protection against touching. avoid return voltage (e.g. from a de celerating motor or battery) which is applied to the output terminals. fig. 23-7 parallel use to increase the output power instructions for series use: unit a input output unit b - + - + load + - input output - 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 converte rs in series in mounting orientations other than the standard mounti ng orientation (terminals on bottom of the unit). - pay attention that emi and inrush current will increase when using multiple dc/dc converters. aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 25/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter 23.9. 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 35vdc. 23.10. 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 9516 100, plastic, 110x180x165mm load: 24v, 3.2a; (=80%) load is placed outside the box input: 110vdc temperature inside enclosure: 32.8c (i n the middle of the right side of the dc /dc converter with a distance of 2cm) temperature outside enclosure: 22.4c temperature rise: 14.4k aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 26/27
qs5.241-60 q-series 24v, 100w, dc/dc c onverter aug. 2016 / rev. 1.0 ds-qs5.241-60-en all parameters are specified at 24v, 4.2a, 110vdc, 25c ambient and after a 5 minutes run-in time unless otherwise noted. www.pulspower.com phone +49 89 9278 0 germany 23.11. 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. 23-8 mounting orientation a (standard orientation) power supply output input output current 0 20 30 40 50 70c 1 2 3 4a 60 a 1 ambient temperature 4.2a fig. 23-9 mounting orientation b (upside down) power supply output input output current 0 20 30 40 50 70c 1 2 3 4a 60 ambient temperature a 1 a 2 4.2a fig. 23-10 mounting orientation c (table-top mounting) output current 0 20 30 40 50 70c 1 2 3 4a 60 a 2 ambient temperature a 1 4.2a fig. 23-11 mounting orientation d (horizontal cw) power supply output input output current 0 20 30 40 50 70c 1 2 3 4a 60 a 2 ambient temperature a 1 4.2a fig. 23-12 mounting orientation e (horizontal ccw) power supply output input output current 0 20 30 40 50 70c 1 2 3 4a 60 a 2 ambient temperature a 1 4.2a 27/27

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