EN
CPS20.481-D1 Installation Manual
Product Description
The CPS20.481-D1 is a DIN-rail mountable DC/DC converter, which provides a floating, stabilized and
galvanically separated SELV/PELV output voltage.
Intended Use
This device is designed for installation in an enclosure and is intended for commercial use, such as in
industrial control, process control, monitoring, measurement equipment or the like.
Do not use this device in equipment, where malfunctioning may cause severe personal injury or
threaten human life without additional appropriate safety devices, that are suited for the end-
application.
If this device is used in a manner outside of its specification, the protection provided by the device may
be impaired.
Installation Instructions
Install the device in an enclosure providing protection against electrical, mechanical and fire hazards.
Install the device onto a DIN-rail according to EN 60715 with the input terminals on the bottom of the
device. Other mounting orientations require a reduction in output current.
Make sure that the wiring is correct by following all local and national codes. Use appropriate copper
cables that are designed for a minimum operating temperature of 60°C for ambient temperatures up to
+45°C, 75°C for ambient temperatures up to +60°C and 90°C for ambient temperatures up to +70°C.
Ensure that all strands of a stranded wire enter the terminal connection. Use ferrules for wires on the
input terminals. Unused screw terminals should be securely tightened.
The device is designed for pollution degree 2 areas in controlled environments. No condensation or
frost is allowed.
The enclosure of the device provides a degree of protection of IP20. The enclosure does not provide
protection against spilled liquids.
The isolation of the devices is designed to withstand impulse voltages up to 2.5kV according to IEC
60664-1.
The device is designed as “Class of Protection I” equipment according to IEC 61140. Do not use
without a proper PE (Protective Earth) connection.
The input can be powered from batteries or similar DC sources. The continuous voltage between the
input terminals and PE potential must not exceed 360Vdc.
Check for correct input polarity. The device will not operate when the voltage is reversed.
A disconnecting means shall be provided for the input of the device.
The device is designed for convection cooling and does not require an external fan. Do not obstruct
airflow and do not cover ventilation grid!
The device is designed for altitudes up to 5000m (16400ft). Above 2000m (6560ft) a reduction in
output current is required.
Keep the following minimum installation clearances: 40mm on top, 20mm on the bottom, 5mm left and
right side. Increase the 5mm to 15mm in case the adjacent device is a heat source. When the device
is permanently loaded with less than 50%, the 5mm can be reduced to zero.
The device is designed, tested and approved for branch circuits up to 32A (IEC) and 30A (UL) without
additional protection device. If an external fuse is utilized, do not use circuit breakers smaller than 10A
B- or C-Characteristic to avoid a nuisance tripping of the circuit breaker.
The maximum surrounding air temperature is +70°C (+158°F). The operational temperature is the
same as the ambient or surrounding air temperature and is defined 2cm below the device.
The device is designed to operate in areas between 5% and 95% relative humidity.
Installation Instructions for Hazardous Location Areas
The device is suitable for use in Class I Division 2 Groups A, B, C, D locations and for use in Group II
Category 3 (Zone 2) environments.
Classification: ATEX: EPS 13 ATEX 1 555 X, II 3G EX nA nC IIC T3 Gc / IECEx EPS 13.0016X
WARNING EXPLOSION HAZARDS!
Substitution of components may impair suitability for this environment.
Do not disconnect the device 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 minimum protection of IP54
and fulfils the requirements of the EN 60079-0.
Functional Description
The output is electronically protected against no-load, overload and short circuit and can supply any
kind of loads, including unlimited inductive or capacitive loads. If capacitors with a capacitance >0.15F
are connected, the unit might charge the capacitor in an intermittent mode.
Do not apply return voltages from the load to the output higher than 63V.
The output voltage can be adjusted with a small flat-blade screwdriver on the front of the unit.
The green DC OK LED reports an output voltage above 90% of the adjusted voltage of a running
device.
The DC OK relay monitors the output voltage and the contact is closed when the DC OK LED is on.
Contact ratings: 60Vdc 0.3A, 30Vdc 1A, 30Vac 0.5A for resistive loads.
The device is equipped with an over-temperature protection. In case of a high temperature, the output
shuts down and starts automatically again after cooling off.
At heavy overloads (when output voltage falls below 25V), the device delivers continuous output
current for 2s. After this, the output is switched off for 18s before a new start attempt is automatically
performed. This cycle is repeated as long as the overload exists.
Devices can be paralleled to increase the output power. The ambient temperature is not allowed to
60°C. The output voltage of all devices shall be adjusted to the same value (±100mV) in
“Single Use” mode with the same load conditions on all units, or the units can be left with the factory
settings. After the adjustments, set the unit to “Parallel Use” mode, in order to achieve load sharing.
The “Parallel Use” mode regulates the output voltage in such a manner that the voltage at no load is
approx. 4% higher than at nominal load. Energize all units at the same time. It also might be
necessary to cycle the input power (turn-off for at least five seconds), if the output was in overload or
short circuit. If more than three devices are connected in parallel, a diode, fuse or circuit breaker with a
rating of 15A or 16A is required on each output.
Same devices can be connected in series for higher output voltages. It is allowed to connect as many
devices in series as needed, providing the sum of the output voltage does not exceed 150Vdc.
In case of an internal defect, a redundant circuit limits the maximum output voltage to 60V. The output
shuts down and automatically attempts to restart.
Technical data
All values are typical figures specified at 300Vdc input voltage, 48V 10A
output load
, 25°C ambient temperature and after a 5 minutes run-in time
unless otherwise noted.
Output voltage
DC 48V
Nominal
Adjustment range
48
– 56Vdc
Factory setting 48.0V
Output current
12.0
– 10.3A
Below +45°C ambient
10.0
– 8.6A
At +60°C ambient
7.5
– 6.5A
At +70°C ambient
Derate linearly
b45°C and +70°C
Input voltage DC
DC 110 - 300V
±20%
Input current DC
4.68 / 1.69A
At 110 / 300Vdc
Input inrush current
6 / 4A pk
At 110 / 300Vdc
Efficiency
93.1 / 94.6%
At 110 / 300Vdc
Power losses
35.6 / 27.4W
At 110 / 300Vdc
Hold-up time
26 / 26ms
At 110 / 300Vdc
Temperature range
-25 t
o +70°C
Max. wire size (litz wire)
4mm²
Power terminals
Wire size AWG
AWG 20-10
Power terminals
Max. wire diameter
2.8mm
Power terminals
Wire stripping length
7mm / 0.28inch
Power terminals
Tightening torque
1Nm / 9lb.inch
Power terminals
Max. wire size (litz wire)
1.5mm²
Signal terminals
Wire size AWG
AWG 26-14
Signal terminals
Max. wire diameter
1.5 mm
Signal terminals
Wire stripping length
7mm / 0.28inch
Signal terminals
Size
(wxhxd)
65x124x127mm
Without DIN-rail
Weight
940g / 2.1lb
Functional diagram
Single /
Parallel
Use
+
+
-
-
Output
Over-
Voltage
Protection
Boost
Converter
Power
Converter
Output
Filter
Output
Power
Manager
Temper-
ature
Shut-
down
Input Fuse
Input Filter
Reverse
Polarity Prot.
Inrush Current
Limiter
13
14
Output
Voltage
Regulator
Output
Voltage
Monitor
V
OUT
DC-ok
Contact
DC-ok
LED
DC-ok
Relay
+
-
Output characteristic
Output voltage (single use)
48V
Output current
24V
0V
5A
15A
20A
0A
Adjustment range
56V
10A
A: continuous current
B: intermitted current
A
B
Temperature range
Allowed output current at 48V
Ambient temperature
0A
-25
A: 88Vdc, continuous
B: 100-360Vdc, continuous
C: short term (max. 5s)
12A
+25
0
+45
+70°C
7.5A
B
C
10A
+60
A