Your SMPS needs sub-2V output, cool. That means it only needs to accept small portions of the incoming.
But, if the incoming is 48V, it needs 48V tolerant parts. All your caps, inductor (optional typically), diodes, the SMPS itself.
Maybe there isn’t a sides difference in a 0603 50V capacitor and 10V 0603 capacitor, but there is a cost difference. And it definitely doesn’t get smaller just because.
Your traces at 48V likely need more space/separation or routing considerations that they would at 24V, but this should be a quickly resolved problem at your SMPS is likely right next to your connector.
Yes. And it also doesn’t need to handle 40+ AMPs on input, with associated large bus bars, large input wires, etc.
Extra insulation is likely only a mm or two, those other components are big and heavy, and have to be.
It’s the same reason inverters have been moving away from 12v to 48v. Larger currents require physically larger and heavier parts in a difficult to manage way. Larger voltages don’t start being problematic until either > 48v or >1000v (depending on the power band).
Your SMPS needs sub-2V output, cool. That means it only needs to accept small portions of the incoming.
But, if the incoming is 48V, it needs 48V tolerant parts. All your caps, inductor (optional typically), diodes, the SMPS itself.
Maybe there isn’t a sides difference in a 0603 50V capacitor and 10V 0603 capacitor, but there is a cost difference. And it definitely doesn’t get smaller just because.
Your traces at 48V likely need more space/separation or routing considerations that they would at 24V, but this should be a quickly resolved problem at your SMPS is likely right next to your connector.