MEAN WELL DDR-480 Series 480W DIN Rail DC-DC Converter
Brand: MEAN WELL
Product Type: 480W DIN Rail DC-DC Converter
Overview
The MEAN WELL DDR-480 series is a robust 480W DC-DC converter designed for DIN rail mounting. It features an ultra-slim width of 85.5mm, a wide 2:1 input voltage range, and operates reliably in extreme temperatures from -40°C to +80°C. This fanless series offers high peak load capability (150%), current sharing up to 1920W (3+1 units), adjustable DC output, and comprehensive protection functions. With 4KVdc I/O isolation and DC OK relay contact, it is suitable for demanding industrial and railway applications.
⭐ Features
- ✅ Compliance to EN50155 and EN45545-2 railway standards
- ? Width only 85.5mm
- ↔️ 2:1 wide input range
- ?️ -40~+80°C wide operating temperature
- ? 150% peak load capability
- ? Current sharing up to 1920W (3+1 units)
- ?️ DC output adjustable
- ? Cooling by free air convection
- ?️ Can be installed on DIN rail TS-35/7.5 or TS-35/15
- ?️ Protections: ⚡ Short circuit / ⚖️ Overload / ⬆️ Over voltage / ?️ Over temperature / ↩️ Input reverse polarity / ⬇️ Input under voltage protection
- ? 4KVdc I/O isolation (Reinforced isolation)
- ? DC OK relay contact
- ?️ Remote ON-OFF control
- ⬆️ Operating altitude up to 5000 meters (Note.6)
- ⏳ 3 years warranty
? Applications
- Bus, tram, metro, or railway systems
- Industrial control systems
- Semi-conductor fabrication equipment
- Factory automation
- Electro-mechanical systems
- Wireless networks
- Telecom or datacom systems
? Description
The DDR-480 series is a 480W DIN Rail type DC-DC converter. Key features include easy DIN rail installation, an ultra-slim 85.5mm width, a 2:1 wide input voltage range, fanless design, a wide operating temperature range of -40°C to +80°C, 4KVdc I/O isolation, 150% peak load capability, current sharing, DC OK status indication, and adjustable output voltage. It offers comprehensive protective functions. This series supports various input voltage options: 16.8~33.6V, 33.6~67.2V, and 67.2~154V, with multiple output options: 12V, 24V, and 48V. It is ideal for industrial and railway control, security systems, communication systems, and other fields, serving as a DC buck/boost regulator, enhancing system insulation, and compensating for voltage drops along cables.
? Model Encoding
The model number follows the pattern: DDR - 480 B - 24
- DDR: Series name
- 480: Rated wattage
- Input voltage range (Type):
- B: 16.8~33.6Vdc
- C: 33.6~67.2Vdc
- D: 67.2~154Vdc
- Output voltage: 12V, 24V, or 48Vdc
? SPECIFICATION
| Parameter | MODEL | ||||||||
|---|---|---|---|---|---|---|---|---|---|
| DDR-480B-12 | DDR-480B-24 | DDR-480B-48 | DDR-480C-12 | DDR-480C-24 | DDR-480C-48 | DDR-480D-12 | DDR-480D-24 | DDR-480D-48 | |
| ⚡ OUTPUT | |||||||||
| DC VOLTAGE | 12V | 24V | 48V | 12V | 24V | 48V | 12V | 24V | 48V |
| RATED CURRENT | 33.4A | 20A | 10A | 33.4A | 20A | 10A | 33.4A | 20A | 10A |
| CURRENT RANGE | 0~33.4A | 0~20A | 0~10A | 0~33.4A | 0~20A | 0~10A | 0~33.4A | 0~20A | 0~10A |
| RATED POWER | 400.8W | 480W | 480W | 400.8W | 480W | 480W | 400.8W | 480W | 480W |
| PEAK CURRENT 5sec. (Note.5) | 50.1A | 30A | 15A | 50.1A | 30A | 15A | 50.1A | 30A | 15A |
| PEAK POWER 5sec. | 12Vo: 601.2W, 24Vo / 48Vo : 720W | ||||||||
| RIPPLE & NOISE (max.) (Note.2) | 100mVp-p | 120mVp-p | 150mVp-p | 100mVp-p | 120mVp-p | 150mVp-p | 100mVp-p | 120mVp-p | 150mVp-p |
| VOLTAGE ADJ. RANGE | 12~14V | 24~28V | 48~56V | 12~14V | 24~28V | 48~56V | 12~14V | 24~28V | 48~56V |
| VOLTAGE TOLERANCE (Note.3) | ±1.0% | ±1.0% | ±1.0% | ±1.0% | ±1.0% | ±1.0% | ±1.0% | ±1.0% | ±1.0% |
| LINE REGULATION | ±0.5% | ±0.5% | ±0.5% | ±0.5% | ±0.5% | ±0.5% | ±0.5% | ±0.5% | ±0.5% |
| LOAD REGULATION | ±1.0% | ±1.0% | ±1.0% | ±1.0% | ±1.0% | ±1.0% | ±1.0% | ±1.0% | ±1.0% |
| SETUP, RISE TIME | 500ms, 60ms | ||||||||
| HOLD UP TIME (Typ.) (Note.4) | Please refer to page 6 for hold up time (Load de-rating curve) | ||||||||
| VOLTAGE CONTINUOUS RANGE | 16.8~33.6Vdc (14.4~16.8Vdc) | 33.6~67.2Vdc (28.8~33.6Vdc) | 67.2~154Vdc (66~67.2Vdc) | ||||||
| EFFICIENCY (Typ.) | 90% | 91% | 90.5% | 91% | 92% | 92% | 91% | 92% | 93% |
| DC CURRENT (Typ.) | 23A @24Vdc | 11.2A @48Vdc | 5A @110Vdc | ||||||
| INRUSH CURRENT (Typ.) | 30A | ||||||||
| INTERRUPTION OF VOLTAGE SUPPLY | EN50155: 2017-B/C/D type comply with S2 level (10ms) @ full load | ||||||||
| ?️ PROTECTION | |||||||||
| OVERLOAD (Note.5) | Normally works within 150% rated output power for more than 5 seconds and then constant current protection 105~135% rated output power with auto-recovery | ||||||||
| OVER VOLTAGE | Protection type: Shut down o/p voltage, re-power on to recover | ||||||||
| OVER TEMPERATURE | Shut down o/p voltage, re-power on to recover | ||||||||
| REVERSE POLARITY | By internal, MOSFET, no damage, recovers automatically after fault condition is removed | ||||||||
| UNDER VOLTAGE LOCKOUT | 24Vin (B-type): Power ON 16.8V, OFF 16.5V | 48Vin (C-type): Power ON 33.6V, OFF 33V | 110Vin (D-type): Power ON 67.2V, OFF 65V | ||||||
| ⚙️ FUNCTION | |||||||||
| DC OK RELAY CONTACT RATINGS (max.) | 30Vdc/1A resistive load | ||||||||
| CURRENT SHARING | Up to 1920W (3+1 units). Please refer to the Function Manual | ||||||||
| REMOTE ON-OFF CONTROL | Please refer to the Function Manual | ||||||||
| ? ENVIRONMENT | |||||||||
| WORKING TEMP. | -40~+80°C (Refer to "Derating Curve") | ||||||||
| WORKING HUMIDITY | 5~95% RH non-condensing | ||||||||
| STORAGE TEMP., HUMIDITY | -40~+85°C, 5~95% RH non-condensing | ||||||||
| TEMP. COEFFICIENT | ±0.03%/°C (0~55°C) | ||||||||
| VIBRATION | Component: 10~500Hz, 5G 10min./1cycle, 60min. each along X, Y, Z axes; Mounting: Compliance to IEC61373 | ||||||||
| OPERATING ALTITUDE (Note.6) | 5000 meters / OVCII | ||||||||
| ?️ SAFETY & EMC (Note 7) | |||||||||
| SAFETY STANDARDS | UL 62368-1, IEC 62368-1, AS/NZS 62368-1, EAC TP TC 004 approved | ||||||||
| WITHSTAND VOLTAGE | I/P-O/P:4KVdc, I/P-FG:2.5KVdc, O/P-FG:0.71KVdc | ||||||||
| ISOLATION RESISTANCE | I/P-O/P, I/P-FG, O/P-FG: >100M Ohms / 500Vdc / 25°C / 70% RH | ||||||||
| EMC EMISSION | Parameter | Standard | Test Level / Note | ||||||
| Conducted | EN55032 (CISPR32) | Class A | |||||||
| Radiated | EN55032 (CISPR32) | Class B | |||||||
| Voltage Flicker | EN61000-3-3 | ||||||||
| Harmonic Current | EN55035 | ||||||||
| EMC IMMUNITY | Parameter | Standard | Test Level / Note | ||||||
| ESD | EN61000-4-2 | Level 3, 8KV air; Level 3, 6KV contact; criteria A | |||||||
| Radiated | EN61000-4-3 | Level 3, 10V/m; criteria A | |||||||
| EFT/Burst | EN61000-4-4 | Level 3, 2KV; criteria A | |||||||
| Surge | EN61000-4-5 | Level 3, 1KV/Line-Line ; Level 3, 2KV/Line-Line-FG; criteria A | |||||||
| Conducted | EN61000-4-6 | Level 3, 10V; criteria A | |||||||
| Magnetic Field | EN61000-4-8 | Level 4, 30A/m; criteria A | |||||||
| ? RAILWAY STANDARD | |||||||||
| Compliance to EN45545-2 for fire protection; Meet EN50155 / IEC60571 including IEC61373 for shock & vibration, EN50121-3-2 for EMC | |||||||||
| ➕ OTHERS | |||||||||
| MTBF | 280.0K hrs min. Telcordia SR-332 (Bellcore); 101.7K hrs min. MIL-HDBK-217F (25°C) | ||||||||
| DIMENSION | 85.5*125.2*128.5mm (W*H*D) | ||||||||
| PACKING | 1.375Kg; 8pcs/12Kg/0.95CUFT | ||||||||
| ℹ️ NOTE |
|
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?️ Block Diagram
The block diagram illustrates the internal architecture of the DDR-480 series converter. It shows the signal path starting from the DC Input (I/P), passing through an EMI Filter for noise suppression, then to the Power Switching stage controlled by PWM CONTROL. Overload Protection (O.L.P.) and Over Voltage Protection (O.V.P.) circuits monitor and regulate the power. The Rectifiers & Filter stage processes the switched power, and a Detection Circuit monitors output parameters. Current Sharing capability is indicated, and a DC OK signal is generated. Inputs include FG (Frame Ground) and a Remote ON/OFF control. The output provides regulated DC voltage (+Vo, -Vo) and terminals for current sharing (P+, P-).
? Derating Curve
The Derating Curve graph displays the relationship between Load (%) on the Y-axis and Ambient Temperature (°C) on the X-axis. It indicates that continuous operation is supported up to 100% load within a specific temperature range (approximately 0°C to 55°C). A peak load of 150% is available for a duration of 5 seconds. Beyond the continuous operating temperature limit, load derating is necessary to prevent overheating and ensure reliable operation. For DDR-480B/C/D-12 and DDR-480D-24/48 models, specific derating considerations apply.
? Output derating VS Input Voltage
This graph illustrates the output derating based on input voltage. The Y-axis represents Load (%) and the X-axis represents Input Voltage (V). Separate curves are shown for 'B Type' (16.8-33.6Vdc input), 'C/D Type' (33.6-67.2Vdc and 67.2-154Vdc input). It shows that the maximum allowable output load percentage varies depending on the input voltage, with optimal performance typically achieved within the nominal input range for each type.
? Peak Loading
The DDR-480 series is capable of handling peak loads. It can deliver 150% of its rated power for a duration of 5 seconds. Specifically, this translates to 601.2W for 12V output models and 720W for 24V and 48V output models. For continuous operation (100% load), the ratings are 400.8W for 12V output models and 480W for 24V and 48V output models.
? DC OK Relay Contact
The DC OK relay contact provides a status indication of the power supply's output. When the 'Contact Close' state is active, the PSU is turned on and the DC OK signal is valid. Conversely, when the 'Contact Open' state occurs, the PSU is turned off or experiencing a DC Fail condition. The maximum rating for this contact is 30Vdc at 1A resistive load.
? Function Manual
? Current Sharing
Parallel operation is supported to increase output capacity. Units are connected in parallel by linking their P+ and P- terminals. To ensure stable operation, the voltage difference among outputs should be minimized to less than 0.2V. The total output current must not exceed the rated current per unit multiplied by the number of units and a factor of 0.9. A maximum of 4 units can be paralleled; for more, consult the manufacturer. A minimum output load of 3% of the total rated output load is required when operating in parallel.
?️ Remote ON-OFF Control
The power supply can be remotely turned ON or OFF using the 'Remote ON-OFF' function via TB1 PIN 2 and 4. With the control pins open or at 5.5~10VDC, the power supply is ON. When the pins are shorted or at 0~0.8VDC, the power supply is OFF.
? Input Fuse
A fuse is connected in series with the positive input line to protect against abnormal surges. The fuse type and rating vary by model type:
| Type | Fuse Type | Reference and Rating |
|---|---|---|
| B | Time-Lag | Conquer MST, 10A, 250V *5 |
| C | Time-Lag | Conquer MST, 8A, 250V *3 |
| D | Time-Lag | Conquer MST, 6.3A, 250V *2 |
⬇️ Input Under-Voltage Protection
If the input voltage drops below a specified minimum (Vimin), the internal control IC shuts down the output. The output voltage automatically recovers when the input voltage rises above Vimin. Graphs are provided for DDR-480B-24, DDR-480C-24, and DDR-480D-24 models, showing the turn-on and turn-off thresholds for input voltage (Vin) versus output voltage (Vo).
↩️ Input Reverse Polarity Protection
Two MOSFETs are connected in series to the negative input line. If the input polarity is reversed, these MOSFETs open, preventing current flow and protecting the unit from damage.
⚡ Inrush Current
Inrush current is suppressed during initial start-up by a resistor. After the start-up sequence is complete, this resistor is bypassed by MOSFETs to reduce power consumption.
⏳ Hold-up Time
The DDR-480 series, specifically B/C/D types, complies with EN50155 S2 level (10ms) at full load. The hold-up time specification is detailed in the table and illustrated by curves. The table shows minimum hold-up times for different load conditions (100%, 70%, other) and input voltage types (B, C, D). The accompanying graphs plot the remaining load percentage over time after input power is removed, demonstrating the hold-up duration for various scenarios.
? Efficiency vs Load & Vin Curve
These graphs show the efficiency of the DDR-480 series converters under varying load conditions and input voltages. The Y-axis represents Efficiency (%), and the X-axis represents Load (%). Multiple curves on each graph correspond to different input voltage (Vin) levels for a specific model, illustrating how efficiency is affected by both load percentage and input voltage.
?️ Immunity to Environmental Conditions
The DDR-480 series has undergone rigorous environmental testing to ensure reliability. Key tests include:
- Cooling Test: -40°C, 2 hrs/cycle (No damage)
- Dry Heat Test: Up to 85°C, 6 hrs/10min (PASS)
- Damp Heat Test, Cyclic: 25°C~55°C, 90%~100% RH, 48 hrs (PASS)
- Vibration Test: 19°C, 65% RH, 10 mins (PASS)
- Increased Vibration Test: 19°C, 65% RH, 5 hrs (PASS)
- Shock Test: 21±3°C, 65±5% RH, 30ms*18 (PASS)
- Low Temperature Storage Test: -40°C, 16 hrs (PASS)
- Salt Mist Test: 35°C ±2°C, 48 hrs (PASS)
? EN45545-2 Fire Test Conditions
The DDR-480 series meets EN45545-2 fire safety standards for railway applications. Tests for Oxygen Index, Smoke Density, Smoke Toxicity, Glow-wire, and Vertical Flame all passed across Hazard Levels HL1, HL2, and HL3.
? Mechanical Specification
Dimensions: 85.5mm (Width) x 125.2mm (Height) x 128.5mm (Depth)
Terminal Pin Assignments
TB2 (Output & Current Sharing)
| Pin No. | Assignment |
|---|---|
| 1,2 | DC output +Vo |
| 3,4 | DC output -Vo |
| 5,6 | DC OK Relay Contact |
| 7,8 | P+, P- (Current sharing) |
TB1 (Input & Control)
| Pin No. | Assignment |
|---|---|
| 1 | FG (Frame Ground) |
| 2 | DC input -Vin |
| 3 | DC input +Vin |
| 4 | Remote ON/OFF |
? Installation Instruction
This series is designed to fit standard DIN rails: TS35/7.5 or TS35/15. For detailed installation procedures, please refer to the official Instruction Manual.
Admissible DIN-RAIL: TS35/7.5 OR TS35/15 (For reference only. Not included with unit.)
? Installation Manual
For comprehensive installation details, please refer to the Installation Manual available at: http://www.meanwell.com/manual.html
