User Manual

DC-DC Converter Manual | 1
IDC-360
INSTRUCTIONAL MANUAL
Height: 83 mm
5
190.5
181
132.8
91
Note: All measurements are in millimetres.
FRONT
SIDE
BACK
SIDE
DESCRIPTION, FEATURES & APPLICATIONS
IDC-360 Series offer 360W capacity Isolated DC-DC Converter models covering wide
range of DC input voltages of 12V / 24V / 48V / 72V and outputs of
12V / 24V / 48V. Design features include:
- Advanced Switch Mode Technology with xed frequency PWM control for
optimum efciency and reliability and compact size
- Galvanic isolation between input and output sides with following benets:
- Noise on the input side is isolated from the output side for noise sensitive
loads like radios, instrumentation, data processing etc.
- Converts Positive voltage to Negative voltage with respect to common, non-
insulated ground. For example, IDC-360C-12 can convert - 48VDC of telecom
supply to +12VDC supply
- Can be used to create either Negative isolated or Positive isolated Rail using
single unit or dual Positive and Negative isolated Rails using 2 units in series.
− Protections against short circuit / overload, input over voltage / transients, output
over voltage, over heating and reverse polarity;
− Compliance with European EMI / EMC and Automotive Standards
Applications include noise sensitive loads like radios, instrumentation and data
processing for isolated input and output grounds and telecom, tractor trailers, buses,
forklifts, heavy machinery, locomotive / railroad, marine and aviation for non-isolated,
common input and output ground. For detailed information, please read
Application Note titled “Isolated DC-DC Converters” under online Support
Section at www.samlexamerica.com.
INSTALLATION & OPERATION
WARNING! This unit is NOT a Battery Charger. Please do not use it to charge a battery.
General Installation Requirements
- The unit is cooled by a temperature controlled fan. Install the unit in a cool,
dry & well ventilated space. Do not block fan vent openings on the sides.
- Do not install the unit inside engine compartment.
- Do not connect / disconnect input and output connections when live voltages
are present.
Fusing on the Input & Output Sides
The input side of the unit will be connected to the battery. A battery has the capacity to
supply very large currents. In case there is a short circuit between the input side wiring, very
heavy current will ow and will burn / melt the wiring and may be a re hazard. To prevent
this, use a suitable fast blow fuse (see Table 1) in line with the Positive input wire within 7"
from the battery Positive terminal. The output side should be connected through a suitable
fuse in line with the "Output +" terminal (see Table 2).
WARNING! The Warranty will be voided if proper fuse is not used as recommended.
Switching ON & Switching OFF Arrangement on the Input Side
There is no ON/OFF switch on the input side of the unit. An external ON/OFF switch may
be used in series with the Positive input wire, if required.
Sizing of Input and Output Wiring
In order to prevent excessive voltage drop and consequent loss of current capacity and
efciency, use proper size of input and output wires. Please note that as the current /
length of wiring are increased, the thickness of the wiring will also be required to be
increased. The thickness of wires and cables is normally expressed in AWG (American Wire
Gauge). Also, note that a lower AWG number denotes a thicker wire. Use multi-stranded
copper insulated wiring rated for at least 90C / 194F. Please refer to details of input/
output wire sizes (Tables 1 & 2).
Type of Input and Output Connections
The unit has a terminal block with 4 male, quick connect at blade type terminals
(6.3 mm / ¼ in.) for quick connection/disconnection (see Fig 2). Two blades are for input
(Marked “Input +” and “Input –”) and two are for output (Marked “Output -” and
“Output +”). The wiring for connection to the terminals should be terminated with the
corresponding female quick connect terminals meant for the above male 6.3 mm / ¼” at
blade type terminal.
Making Input & Output Connections & Operation
CAUTION! Please ensure that the polarity of the input connection is not reversed.
Connect the Positive of the battery to the Positive terminal and the Negative of the
battery to the Negative. In case the input polarity is reversed, the unit will be damaged
and will not be covered under Warranty.
- Input and output connections should not be made when live voltages are
present.
- Switch OFF the load that is required to be powered from the converter.
- Connect the output wires to the load and then to the output side of the unit
through the external fuse. OBSERVE CORRECT POLARITY.
- Switch OFF the external inline input side switch (if used) and also remove the
external inline fuse in the Positive input wire.
- Connect the input side wires to the converter’s input side rst. OBSERVE
CORRECT POLARITY.
- Connect the input wires to the battery.
- Insert the external inline input side fuse in the Positive input wire. NOTE: If an
ON/OFF switch is not used in series with the Positive input wire or if a switch
has been used and has not been switched OFF, a spark may be observed when
inserting the fuse due to the initial inrush current to charge the input side
capacitors inside the converter.
- Switch on the input power to the unit (if an external switch has been used).
Output voltage will now be available on the output side of the unit.
- Switch ON the load.
Protections
Overload/Short Circuit: Overloading beyond the maximum output current value
(30A for IDC-360x-12, 15A for IDC-360x-24 & 7.5A for IDC-360x-48) will produce
voltage drop on the output side. The output will recover automatically once the
overload condition is removed. Under short circuit conditions on the output side, the
voltage will drop to a very low value, output current will rise beyond the rated value
and external fuse will blow if short circuit condition persists for longer duration. There
is automatic reset if the short circuit condition is removed before the fuse blows.
Over Voltage On The Output Side: In case of over voltage, a zener diode across the
output will conduct and simulate short circuit protection (see above).
Over Voltage / Transients On The Input Side: A Metal Oxide Varistor (MOV) across the
input terminals provides protection against high voltage transients by blowing the internal
input side fuse(s) / external fuse(s).
Reversal Of Polarity On The Input Side Connection: In case of reversal on input side
polarity, a diode connected across the input terminals will conduct and will blow the
internal input side fuse(s) / external fuse(s).
Over Temperature: In case of over heating, the output voltage will drop. It will reset
automatically once the temperature drops to normal.
DIMENSIONS & LAYOUT
Head Ofce
103 - 4268 Lozells Avenue
Burnaby, BC, V5A 0C6, Canada
Toll Free Numbers
Ph: 1.800.561.5885
Fax: [phone]
Local Numbers
Ph: 604.525.3836
Fax: [phone]
Fig 1. Dimensions (Bottom View)