Samlexpower IDC-360 Series User Manual

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IDC-360

USER MANUAL

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 T

Galvanic isolation between input and output sides with following benets:

Noise on the input side is isolated fr

Converts Positive voltage to Negative voltage with r

of telecom supply to +12VDC supply

Can be used to cr

units in series.

- Protections against short circuit/overload, input over voltage/transients, output over voltage, over heating and reverse polarity;

Compliance with Eur

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.

echnology with xed frequency PWM control for optimum efciency and reliability and compact size

om the output side for noise sensitive loads like radios, instrumentation, data processing etc.

espect to common, non-insulated ground. For example, IDC-360C-12 can convert - 48VDC

eate either Negative isolated or Positive isolated Rail using single unit or dual Positive and Negative isolated Rails using 2

opean EMI/EMC and Automotive Standards

INSTALLATION & OPERATION

WARNING! This unit is NOT a Battery Charger. Please do not use to charge a battery.

General Installation Requirements

- The unit is cooled by a temperature controlled fan. Install the unit in a cool, dry and 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.

For more information on input / output grounding e.g. installation on Positive Grounding System, refer to www.samlexamerica.com under: Support Ò Application Notes Ò DC-DC Converters − Input and Output Grounding.

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 and 2).

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IDC-360 | USER MANUAL

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 in 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 ar

- Switch OFF the load that is required to be powered from the converter.

Connect the output wir

- 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 charge the input side capacitors inside the converter.

- Switch on the input power to the unit (if an exter

Switch ON

the load.

es to the load and then to the output side of the unit through the external fuse. OBSERVE CORRECT POLARITY.

OFF, a spark may be observed when inserting the fuse due to the initial inrush current to

nal switch has been used). Output voltage will now be available on the output side of the unit.

e present.

Protections

Overload/Short Circuit: Overloading beyond the maximum output current value (30A for IDC-360x-12, 15A for IDC-360x-24 and 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. 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.

Reverse

reverse polarity on the output side, internal Zener Diode across the output terminals will conduct and blow the external fuse on the output side.

transients by blowing the internal input side fuse(s)/external fuse(s).

Polarity / Over Voltage on the Output Side: In case of (i) overvoltage on the outside (18V for 12V ; 30V for 24V ; 60V for 48V) or (ii)

ver Voltage/T

ransients on the Input Side:

A Metal Oxide Varistor (MOV) across the input terminals provides protection against high voltage

(Except IDC-360D-XX Series)

Under short

Reversal

will conduct and will blow the internal input side fuse(s)/external fuse(s).

an Cooling: The unit is cooled by 1 temperature controlled fan (7, Fig 2). Temperature of internal hot spot is sensed and at 45°C, the fan is

switched ON. The fan is switched OFF automatically when the internal hot spot temperature cools down to 40°C

ver T

the internal hot spot may rise beyond permissible limits. At >70°C, the output voltage will start dropping to reduce the output current. If the temperature still continues to rise, the output will be shut down at 80C. The unit will reset automatically when the unit cools down to 70°C.

utput Current De-rating at Ambient T

temperature of +30°C. The output current will be required to be reduced (de-rated) linearly from the full rated Amps at +30°C to 0 Amps at +70°C.

For example, IDC-360A-12 will provide full rated current of 30A till +30°C. The load current should be linearly reduced to 0A at +70°C (At +70°C, over temperature protection will be initiated and the output voltage will drop). This means that the output current capacity should be reduced linearly at the rate of 0.75A/°C for every 1°C rise higher than +30°C. At say +50°C, the maximum permissible output current should be reduced to 15A [30A – {(50C – 30C) x 0.75A /°C}].

Of Polarity on the Input Side Connection: In case of reversal on input side polarity, internal diode connected across the input terminals

emperatur

e: In case of higher ambient temperature or fan failure or blockage of fan suction / exhaust openings, the temperature of

emperatur

e > +30°C: The unit is designed to provide the full rated output current up to ambient

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IDC-360 | USER MANUAL

190.5

FRONT

DIMENSIONS & LAYOUT

BACK SIDE

Height: 83 mm

Note: All measurements are in mm.

181

Fig 1. Dimensions (Bottom View)

SPECIFICATIONS

MODEL

IDC-360A-12 9 - 18 <40 12.5 30

IDC-360B-12 20 - 35 <30 12.5 30

IDC-360C-12 30 - 60 <20 12.5 30

IDC-360D-12 60 - 120 <10 12.5 30

IDC-360A-24 9 - 18 <40 24.5 15

IDC-360B-24 20 - 35 <30 24.5 15

IDC-360C-24 30 - 60 <20 24.5 15

IDC-360D-24 60 - 120 <10 24.5 15

IDC-360B-48 20 - 35 <30 48.0 7.5

IDC-360C-48 30 - 60 <20 48.0 7.5

NO LOAD CURRENT DRAW < 25 mA

INPUT TO OUTPUT ISOLATIONYes. > 400V RMS

OPERATING TEMPERATURE

HUMIDITY, NON-CONDENSING Max 95%

SAFETY AND EMC STANDARDS

INPUT / OUTPUT CONNECTIONS Quick Connect ; Male, 6.3 mm /

NOTE: Specications are subject to change without notice

INPUT VOLTAGE

ANGE (VDC)

OUTPUT RIPPLE & NOISE < 50 mV RMS

PEAK EFFICIENCY 85%

COOLING

D DE-RATING

PROTECTIONS

AUTOMOTIVE DIRECTIVE UN Regulation ECE R10-4

DIMENSIONS (W x D x H) 132.8 x 190.5 x 83 mm / 5.23 x 7.5 x 3.27 in

IMMUNITY EN55014-2

WEIGHT 1.4 Kg / 3.1 lb

MAX INPUT

CURRENT (A)

By temperature controlled fan

-20 to +30C / -4F to 86F (De-rate linearly to zero at 70C / 158F)

Overload / short circuit on the output side; Over voltage on the output side; Over voltage / transients on the input side; Reverse polarity on the input side; Over heating

ISSIONS EN55014-1

1/4" at blade

OUTPUT

VOLTAGE (VDC)

CURRENT (A)

132.8

SIDE

OUTPUT

1 2 3 4

91mm

LEGEND

1. Input +

2. Input -

3. Output -

4. Output +

5. Chassis Ground

6. Fan suction openings

7. Fan

8. Fan exhaust openings NOTE: Terminals 1 to 4: Quick Connect - Male,

6.3 mm / 1/4” at blade

At the back

}

(not shown)

Fig. 2 Layout (Front View)

TABLE 1.

EXTERNAL INPUT SIDE FUSE & WIRING

MODEL

AME

IDC-360A-12, 24 32V, 40A AWG#10

IDC-360B-12, 24, 48 32V, 30A AWG#14

IDC-360C-12, 24, 48 80V, 20A AWG#16

IDC-360D-12, 24 125V, 10A AWG#22

FUSE SPECS

WIRE SIZE (3

ft from Battery)

(SEE NOTE 1 BELOW)

TABLE 2.

EXTERNAL OUTPUT SIDE FUSE & WIRING

MODEL N

AME

IDC-360A-12 32V, 30A AWG#10

IDC-360B-12 32V, 30A AWG#10

IDC-360C-12 32V, 30A AWG#10

IDC-360D-12 32V, 30A AWG#10

IDC-360A-24 32V, 15A AWG#16

IDC-360B-24 32V, 15A AWG#16

IDC-360C-24 32V, 15A AWG#16

IDC-360D-24 32V, 15A AWG#16

IDC-360B-48 58V, 7.5A AWG#22

IDC-360C-48 58V, 7.5A AWG#22

FUSE SPECS

NOTES FOR TABLE 1 AND 2:

a) Wire sizes shown are based on 90C / 194F wire temperature rating and

2% voltage drop over distance of 3' from battery or load for current = Amp rating of the fuse.

b) For distances > 3', use thicker wires to limit voltage drop to <2% for

current = Amp rating of the fuse.

TERMINATION OF CONNECTING WIRES:

c) Use 6.3mm / 1/4" "Quick Connect", Female mating terminal on the

connecting wiring. This type of terminal is available for maximum wire size of AWG #10. When using wires thicker than AWG #10, you may terminate the wire as follows:

 • Use6.3mm/1/4""QuickConnect"Femalemattingconnector

(AWG #10 size)

 • Usearound2"pieceofAWG#10wireandcrimptheconnectortoone

end Solder / splice the other end of AWG #10 wire to wire the thicker wire

Use of short length of 2" of smaller AWG #10 wire will not increase voltage drop appreciably.

WIRE SIZE (3

ft from Battery)

(SEE NOTE 1 BELOW)

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IDC-360 | USER MANUAL

2 YEAR LIMITED WARRANTY

IDC-360 manufactured by Samlex America, Inc. (the “Warrantor“) is warranted to be free from defects in workmanship and materials under normal use and service. The warranty period is 2 years for the United States and Canada, and is in effect from the date of purchase by the user (the “Purchaser“).

Warranty outside of the United States and Canada is limited to 6 months. For a warranty claim, the Purchaser should contact the place of purchase to obtain a Return Authorization Number.

The defective part or unit should be returned at the Purchaser’s expense to the authorized location. A written statement describing the nature of the defect, the date of purchase, the place of purchase, and the Purchaser’s name, address and telephone number should also be included.

If upon the Warrantor’s examination, the defect proves to be the result of defective material or workmanship, the equipment will be repaired or replaced at the Warrantor’s option without charge, and returned to the Purchaser at the Warrantor’s expense. (Contiguous US and Canada only)

No refund of the purchase price will be granted to the Purchaser, unless the Warrantor is unable to remedy the defect after having a reasonable number of opportunities to do so. Warranty service shall be performed only by the Warrantor. Any attempt to remedy the defect by anyone other than the Warrantor shall render this warranty void. There shall be no warranty for defects or damages caused by faulty installation or hook-up, abuse or misuse of the equipment including exposure to excessive heat, salt or fresh water spray, or water immersion.

No other express warranty is hereby given and there are no warranties which extend beyond those described herein. This warranty is expressly in lieu of any other expressed or implied warranties, including any implied warranty of merchantability, tness for the ordinary purposes for which such goods are used, or tness for a particular purpose, or any other obligations on the part of the Warrantor or its employees and representatives.

There shall be no responsibility or liability whatsoever on the part of the Warrantor or its employees and representatives for injury to any persons, or damage to person or persons, or damage to property, or loss of income or prot, or any other consequential or resulting damage which may be claimed to have been incurred through the use or sale of the equipment, including any possible failure of malfunction of the equipment, or part thereof. The Warrantor assumes no liability for incidental or consequential damages of any kind.

Samlex America Inc. (the “Warrantor”) www.samlexamerica.com

Disclaimer of Liability

UNLESS SPECIFICALLY AGREED TO IN WRITING, SAMLEX AMERICA, INC.:

MAKES NO W DOCUMENTATION. ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER SPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL,

WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USERS RISK.

Samlex America reserves the right to revise this document and to periodically make changes to the content hereof without obligation or organization of such revisions or changes.

ARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER

11004-IDC-360-0417

DC-DC Converter Manual | 4

Samlexpower IDC-360 Series User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual