MEAN WELL 480W DIN Rail Type DC-DC Converter

Key Features

• Compliance to BS EN/EN50155 and BS EN/EN45545-2 railway standard
• Ultra-slim width: 85.5mm
• 2:1 wide input range
• Wide operating temperature: -40~+80℃
• 150% peak load capability
• Current sharing up to 1920W (3+1 units)
• Adjustable DC output voltage
• Cooling by free air convection (fanless design)
• Installable on DIN rail TS-35/7.5 or TS-35/15
• Comprehensive Protections: Short circuit / Overload / Over voltage / Over temperature / Input reverse polarity / Input under voltage
• 4KVdc I/O isolation (Reinforced isolation)
• DC OK relay contact
• Remote ON-OFF control
• Operating altitude up to 5000 meters
• 3 years warranty

Applications

• ? Bus, tram, metro or railway systems
• ? Industrial control systems
• Semi-conductor fabrication equipment
• Factory automation
• Electro-mechanical equipment
• ? Wireless networks
• ? Telecom or datacom systems

Product Description

The DDR-480 series is a 480W DIN Rail type DC-DC converter designed for demanding industrial and railway applications. It features an easy DIN rail installation, an ultra-slim width of 85.5mm, a wide 2:1 input voltage range, and a fanless design for reliable operation in temperatures from -40℃ to +80℃. Key functionalities include 4KVdc I/O isolation, 150% peak load capability, current sharing, DC OK status, adjustable output voltage, and a full suite of protective functions. The series offers various input voltage options (16.8~33.6V, 33.6~67.2V, 67.2~154V) and multiple output voltage options (12V, 24V, 48V). It is suitable for applications such as DC buck/boost regulators, increasing system insulation levels, and voltage drop compensation along cables.

Model Encoding

The model number follows the format: DDR - 480 B - 24

• DDR-480: Series name and rated wattage (480W)
• Input voltage type: B (16.8~33.6Vdc), C (33.6~67.2Vdc), D (67.2~154Vdc)
• Output voltage: 12 (12Vdc), 24 (24Vdc), 48 (48Vdc)

Specifications

Notes:

• 1. Parameters measured at normal input (B:24Vdc, C:48Vdc, D:110Vdc), rated load, and 25℃ ambient temperature unless otherwise specified.
• 2. Ripple & noise measured with a 20MHz bandwidth using a 12" twisted pair-wire terminated with a 0.1µF & 47µF parallel capacitor.
• 3. Tolerance includes set up, line, and load regulation.
• 4. Derating may be needed under low input voltage. Refer to derating curves.
• 5. 150% peak load for 5 seconds. Refer to peak loading curves.
• 6. Ambient temperature derating: 3.5℃/1000m for fanless models, 5℃/1000m for fan models, for altitudes above 2000m (6500ft).
• 7. The power supply is considered an independent unit; the final equipment must comply with EMC directives. Refer to "EMI testing of component power supplies" for guidance.

Block Diagram

The block diagram illustrates the internal components and signal flow of the DC-DC converter. It includes an input fuse, EMI filter, power switching stage, PWM control, over-voltage protection (OVP), over-load protection (OLP), detection circuit, rectifiers and filter, DC OK signal output, and current sharing terminals (P+, P-). The unit also features remote ON/OFF control.

Derating Curves

Ambient Temperature Derating Curve: This graph shows the load capacity relative to ambient temperature. It indicates a continuous load rating up to 40℃ and a reduced load capacity at higher temperatures, with a peak load capability for short durations (e.g., 5 seconds) up to 150% of rated power. The curve is specific for DDR-480B/C/D-12 and DDR-480D-24/48 models.

Output Derating vs. Input Voltage Curve: This graph illustrates how the output load capacity is affected by the input voltage. It shows different derating curves for 'B Type' (16.8-33.6Vdc input) and 'C/D Type' (33.6-67.2Vdc and 67.2-154Vdc input) models, indicating that optimal performance is achieved within specific input voltage ranges.

Peak Loading

The DDR-480 series converters can handle peak loads for short durations. For 12V output models, peak power is 601.2W (150% load) for 5 seconds, and normal load is 400.8W. For other output voltages (24V, 48V), peak power is 720W (150% load) for 5 seconds, and normal load is 480W.

DC OK Relay Contact

The unit provides a DC OK relay contact. When the PSU is on and the DC output is within normal operating parameters, the contact is closed. If the PSU fails or the DC output is out of range, the contact opens. The contact ratings are a maximum of 30Vdc/1A resistive load.

Function Manual Details

Current Sharing

Parallel operation is supported by connecting units with their P+ and P- terminals mutually in parallel. The voltage difference between any two outputs must be minimized to less than 0.2V. The total output current must not exceed 90% of the sum of the rated currents of the connected units (Total Current ≤ (Rated Current per unit) x (Number of units) x 0.9). A maximum of 4 units can be paralleled. The minimum output load should be greater than 3% of the total rated output load.

Remote ON-OFF Control

The power supply can be turned ON or OFF remotely using the 'Remote ON-OFF' function (TB1 PIN 2,4). Applying a voltage between 5.5Vdc and 10Vdc, or leaving the pins open, turns the power supply ON. Applying a voltage between 0Vdc and 0.8Vdc turns the power supply OFF.

Input Fuse

An internal time-lag fuse is connected in series to the positive input line to protect against abnormal surges. Fuse specifications vary by model type:

Input Protection

Input Under-Voltage Protection

If the input voltage drops below a specified minimum (Vimin), the internal control IC shuts down, resulting in no output voltage. The unit automatically recovers once the input voltage reaches above Vimin. Specific turn-on and turn-off voltages are detailed for DDR-480B-24, DDR-480C-24, and DDR-480D-24 models.

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 output and protecting the unit.

Inrush Current

Inrush current is suppressed by a resistor during initial start-up. This resistor is then bypassed by MOSFETs to reduce power consumption after the start-up sequence is complete.

Hold-up Time

The DDR-480 series (B/C/D types) complies with EN50155:2017 S2 level (10ms) at full load. Hold-up times vary based on model type and load conditions:

• B type (24Vin): 10ms min. (100% load), 16ms min. (70% load), refer to figures 1, 2, 3 for other loads.
• C type (48Vin): 11ms min. (100% load), 17ms min. (70% load), refer to figures 4, 5, 6 for other loads.
• D type (110Vin): 16ms min. (100% load), 24ms min. (70% load), refer to figures 7, 8, 9 for other loads.

Efficiency vs Load & Vin Curves

Graphs are provided showing the efficiency of each model across various load percentages and input voltage levels. These curves help in selecting the optimal operating point for maximum efficiency.

Environmental Testing & Compliance

Immunity to Environmental Conditions

EN45545-2 Fire Test Conditions

Mechanical Specifications

Dimensions: 85.5mm (Width) x 125.2mm (Height) x 129.2mm (Depth) (tolerance ± 1mm).

Mounting: Designed for DIN rail TS-35/7.5 or TS-35/15.

Terminal Pin Assignments

Terminal TB1 (Input & Control)

• Pin 1: FG [Frame Ground]
• Pin 2: DC input -Vin
• Pin 3: DC input +Vin
• Pin 4: Remote ON/OFF control

Terminal TB2 (Output & Status)

• Pins 1, 2: DC output +Vo
• Pins 3, 4: DC output -Vo
• Pins 5, 6: DC OK Relay Contact
• Pins 7, 8: P+, P- (Current sharing)

Installation Instruction

This series fits standard DIN rails TS35/7.5 or TS35/15. For detailed installation instructions, please refer to the official Instruction Manual.

Installation Manual Link: http://www.meanwell.com/manual.html