MEAN WELL DDR-480 Series 480W DIN Rail Type DC-DC Converter
User's Manual
Certifications: IEC62368-1, UL62368-1, AS/NZS62368-1, TPTC004
Features
- Compliance to BS EN/EN50155 and BS EN/EN45545-2 railway standard
- Width only 85.5mm
- 2:1 wide input range
- -40~+80℃ 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 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 system
- Industrial control system
- Semi-conductor fabrication equipment
- Factory automation
- Electro-mechanical
- Wireless network
- Telecom or datacom system
Description
The DDR-480 series is a 480W DIN Rail type DC-DC converter featuring DIN rail-type easy installation, an ultra-slim width of 85.5mm, 2:1 wide input voltage, fanless design, -40~+80℃ wide operating temperature, 4KVdc I/O isolation, 150% peak load, current sharing, DC OK, adjustable output voltage, and full protective functions. This series offers various input options: 16.8~33.6V, 33.6~67.2V, and 67.2~154V, and multiple output options: 12V, 24V, 48V. It is suitable for industrial & railway control, security control, communication systems, and other fields. Applications include DC buck/boost regulation, increasing system insulation levels, and voltage drop compensation along cables.
Model Encoding
The model encoding follows the pattern: DDR-480 [Input Voltage Code] - [Output Voltage]
- Output voltage: 12V, 24V, or 48Vdc
- Input voltage: B (16.8~33.6Vdc), C (33.6~67.2Vdc), D (67.2~154Vdc)
- Rated wattage: 480W
- Series name: DDR-480
Specifications
| MODEL | DDR-480B | DDR-480C | DDR-480D | ||||||
|---|---|---|---|---|---|---|---|---|---|
| 12V | 24V | 48V | 12V | 24V | 48V | 12V | 24V | 48V | |
| 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. (Note.5) | 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.) | Please refer to page 6 (Hold up time curve) | ||||||||
| VOLTAGE CONTINUOUS RANGE (Note.4) | 16.8~33.6Vdc | 33.6~67.2Vdc | 67.2~154Vdc | 16.8~33.6Vdc | 33.6~67.2Vdc | 67.2~154Vdc | 16.8~33.6Vdc | 33.6~67.2Vdc | 67.2~154Vdc |
| 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 | ||||||||
| 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 | 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 | ||||||
| DC OK RELAY CONTACT RATINGS (max.) | 30Vdc/1A resistive load | ||||||||
Functionality
Current Sharing
Parallel operation is available by connecting units as shown in the diagram (P+, P- connected mutually in parallel). The voltage difference among each output should be minimized to less than 0.2V. The total output current must not exceed the value determined by the equation: (Rated current per unit) x (Number of units) x 0.9. A maximum of 4 units can be paralleled; consult the manufacturer for other applications. When in parallel operation, the minimum output load should be greater than 3% of the total output load (Min. load > 3% rated current per unit x number of unit).
Diagram Description: Shows four PSUs (PSU1 to PSU4) connected in parallel. Each PSU has connections for +Vo, -Vo, P+, P-, DC OK, and Vo Adj. The P+ and P- terminals of all PSUs are connected together to form the main load connection.
Remote ON-OFF Control
The power supply can be turned ON/OFF using the "Remote ON-OFF" function. The control is typically connected to TB1 PIN 2 and 4.
| Remote ON-OFF (TB1 PIN 2,4) | Output Status |
|---|---|
| Open or 5.5 ~ 10VDC | Power supply ON |
| Short or 0 ~ 0.8VDC | Power supply OFF |
Environmental and Operating Conditions
- 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: 5000 meters / OVCII
Environmental & Safety Compliance
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 | BS EN/EN55032 (CISPR32) | Class A |
| Radiated | BS EN/EN55032 (CISPR32) | Class B |
| Voltage Flicker | BS EN/EN61000-3-3 | - |
| Harmonic Current | - | - |
EMC Immunity
| Parameter | Standard | Test Level / Note |
|---|---|---|
| ESD | BS EN/EN61000-4-2 | Level 3, 8KV air; Level 3, 6KV contact; criteria A |
| Radiated | BS EN/EN61000-4-3 | Level 3, 10V/m; criteria A |
| EFT/Burst | BS EN/EN61000-4-4 | Level 3, 2KV; criteria A |
| Surge | BS EN/EN61000-4-5 | Level 3, 1KV/Line-Line; Level 3, 2KV/Line-Line-FG; criteria A |
| Conducted | BS EN/EN61000-4-6 | Level 3, 10V; criteria A |
| Magnetic Field | BS EN/EN61000-4-8 | Level 4, 30A/m; criteria A |
Railway Standard
Compliance to BS EN/EN45545-2 for fire protection; Meets BS EN/EN50155 / IEC60571 including IEC61373 for shock & vibration, BS EN/EN50121-3-2 for EMC.
Immunity to Environmental Conditions
| Test Method | Standard | Test Conditions | Status |
|---|---|---|---|
| Cooling Test | EN 50155 section 12.2.3 (Column 2, Class TX) EN 60068-2-1 |
Temperature: -40°C Dwell Time: 2 hrs/cycle |
No damage |
| Dry Heat Test | EN 50155 section 12.2.4 (Column 2, Class TX) EN 50155 section 12.2.4 (Column 3, Class TX & Column 4, Class TX) EN 60068-2-2 |
Temperature: 70°C / 85°C Duration: 6 hrs / 10min |
PASS |
| Damp Heat Test, Cyclic | EN 50155 section 12.2.5 EN 60068-2-30 |
Temperature: 25°C~55°C Humidity: 90%~100% RH Duration: 48 hrs |
PASS |
| Vibration Test | EN 50155 section 12.2.11 EN 61373 |
Temperature: 19°C Humidity: 65% Duration: 10 mins |
PASS |
| Increased Vibration Test | EN 50155 section 12.2.11 EN 61373 |
Temperature: 19°C Humidity: 65% Duration: 5 hrs |
PASS |
| Shock Test | EN 50155 section 12.2.11 EN 61373 |
Temperature: 21±3℃ Humidity: 65 ±5% Duration: 30ms*18 |
PASS |
| Low Temperature Storage Test | EN 50155 section 12.2.3 (Column 2, Class TX) EN 60068-2-1 |
Temperature: -40°C Dwell Time: 16 hrs |
PASS |
| Salt Mist Test | EN 50155 section 12.2.10 (Class ST4) | Temperature: 35℃ ±2℃ Duration: 48 hrs |
PASS |
EN45545-2 Fire Test Conditions
| Test Items | Items | Standard | Hazard Level | HL1 | HL2 | HL3 |
|---|---|---|---|---|---|---|
| Oxygen index test | R22 | EN 45545-2:2013 EN ISO 4589-2:1996 |
PASS | PASS | PASS | |
| R24 | EN 45545-2:2013 EN ISO 4589-2:1996 |
PASS | PASS | PASS | ||
| Smoke density test | R22 | EN 45545-2:2013 EN ISO 5659-2:2006 |
PASS | PASS | PASS | |
| Smoke toxicity test | EN 45545-2:2013 NF X70-100:2006 |
PASS | PASS | PASS | ||
| R24 | ||||||
| Glow-wire test | R25 | EN 45545-2:2013 EN 60695-2-11:2000 |
PASS | PASS | PASS | |
| Vertical flame test | R26 | EN 45545-2:2013 EN 60695-11:2003 |
PASS | PASS | PASS |
Performance Characteristics
Peak Loading
The 'Peak Loading' diagram illustrates the power handling capabilities over time. It shows that the converter can deliver 150% of its rated load for 5 seconds (e.g., 601.2W for 12V output, 720W for others), followed by a period where it can handle 100% of its rated load (e.g., 400.8W for 12V output, 480W for others) for a longer duration, indicated as 100 seconds in the diagram.
DC OK Relay Contact
| Contact State | Status |
|---|---|
| Contact Close | PSU turns on / DC OK |
| Contact Open | PSU turns off / DC Fail |
| Contact Ratings (max.) | 30V/1A resistive load |
Hold-up Time
EN50155:2017 version- B/C/D type comply with S2 level (10ms) @ full load. The table and curves below show the hold-up time specification.
| Model | Load | 100% load | 70% load | Other load |
|---|---|---|---|---|
| B type (24Vin) | 10ms min. | 16ms min. | figure 1,2,3 | |
| C type (48Vin) | 11ms min. | 17ms min. | figure 4,5,6 | |
| D type (110Vin) | 16ms min. | 24ms min. | figure 7,8,9 |
Hold-up Time Graphs Description: A series of graphs titled 'Hold-up Time' show Load (%) on the Y-axis against Time (ms) on the X-axis for various DDR-480 models (e.g., DDR-480B-12, DDR-480B-24, etc.). These graphs visually represent how long the output voltage is maintained after the input power is removed, under different load conditions (100% load, 70% load, other load).
Efficiency Curves
These graphs, titled 'Efficiency vs Load & Vin Curve', plot Efficiency (%) on the Y-axis against Load (%) on the X-axis for different input voltages (Vin) for each specific model (e.g., DDR-480B-12, DDR-480B-24, etc.). They show how the conversion efficiency varies with the load percentage and input voltage.
Input Characteristics
Input Fuse
| 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 input voltage drops below Vmin, the internal control IC shuts down and there is no output voltage. It recovers automatically when input voltage reaches above Vmin. Please refer to the curves below.
Diagram Description: For each model type (DDR-480B-24, DDR-480C-24, DDR-480D-24), the Y-axis shows Output Voltage (Vo) and the X-axis shows Input Voltage (Vin). Two lines are shown: 'Turn On' and 'Turn Off'. The graphs indicate the specific input voltage thresholds below which the converter shuts down and above which it restarts.
Input Reverse Polarity Protection
There are two MOSFETs connected in series to the negative input line. If the input polarity is connected reversely, the MOSFETs open, and there will be no output to protect the unit.
Inrush Current
Inrush current is suppressed by a resistor during the initial start-up, and then the resistor is bypassed by MOSFETs to reduce power consumption after accomplishing the start-up.
Diagram Description: The 'Inrush Current' graph displays the current profile during startup. The Y-axis shows current (Amps) and the X-axis shows time (ms). It depicts a high initial 'Inrush current limit' which quickly drops to a 'Power start' level, and then settles to the 'Normal current' consumption after the startup phase, suppressed by a resistor and then bypassed by MOSFETs.
Block Diagram
Diagram Description: The block diagram illustrates the internal architecture of the DDR-480 series converter. It shows the signal flow from the DC input (I/P) through an EMI filter, then to a power switching stage controlled by PWM control. This is followed by rectifiers and a filter. Protection circuits include Overload Protection (O.L.P.), Over Voltage Protection (O.V.P.), and a Detection Circuit. A Current Share output is also present. The unit provides a DC OK signal, and features Remote Control for ON/OFF functionality. The Ground (FG) connection is also indicated.
Mechanical Specifications
Dimensions: 85.5mm (Width) * 125.2mm (Height) * 128.5mm (Depth)
Case No.: 984F
Terminal Pin Assignments
TB2 (Output & Relay)
| 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 |
| 2 | DC input -Vin |
| 3 | DC input +Vin |
| 4 | Remote ON/OFF |
Installation
Installation Instruction
This series fits DIN rail TS35/7.5 or TS35/15. For installation details, please refer to the Instruction manual.
Admissible DIN-RAIL: TS35/7.5 OR TS35/15 (For reference only. Not included with unit.)
Installation Manual
Please refer to: http://www.meanwell.com/manual.html
Notes
- All parameters NOT specially mentioned are measured at normal input (B:24Vdc, C:48Vdc, D:110Vdc), rated load and 25°C of ambient temperature.
- Ripple & noise are measured at 20MHz of bandwidth by using a 12" twisted pair-wire terminated with a 0.1μf & 47μf parallel capacitor.
- Tolerance: includes set up tolerance, line regulation and load regulation.
- Derating may be needed under low input voltage. Please check the derating curve for more details.
- 150% peak load is for 5 seconds. Please refer to peak loading curves.
- The ambient temperature derating of 3.5°C/1000m with fanless models and of 5°C/1000m with fan models for operating altitude higher than 2000m (6500ft).
- The power supply is considered as an independent unit, but the final equipment still needs to re-confirm that the whole system complies with the EMC directives. For guidance on how to perform these EMC tests, please refer to "EMI testing of component power supplies." (as available on http://www.meanwell.com)
Product Liability Disclaimer: For detailed information, please refer to https://www.meanwell.com/serviceDisclaimer.aspx
