DC-DC Converter Manual | 1
IDC-100
USER MANUAL
Head Ofce
103 - 4268 Lozells Avenue
Burnaby, BC V5A 0C6 Canada
Toll Free Numbers
Ph: 1-800-561-5885
Fax: 1-888-814-5210
Local Numbers
Ph: 604-525-3836
Fax: 604-525-5221
DESCRIPTION, FEATURES & APPLICATIONS
IDC-100 is an Isolated DC-DC Converter series covering wide range of DC input voltages of 12V/24V/48V and outputs of 12V/24V. 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-100C-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.
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 convection. 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).
DC-DC Converter Manual | 2
IDC-100 | 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 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 (8A for IDC-100x-12 and 4A for IDC-100x-24) 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.
Reverse Polarity / Over Voltage on the Output Side: In case of (i) overvoltage on the outside (18V for 12V and 30V for 24V) or (ii) reverse
polarity on the output side, internal Zener Diode across the output terminals will conduct and blow the external fuse on the output side.
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 input side fuse. NOTE: This protection is not available in IDC-100C / IDC-100D.
Reversal Of Polarity on the Input Side Connection: IDC-100A / IDC-100B: In case of reversal on input side polarity, internal diode connected
across the input terminals will conduct and will blow the input side fuse. IDC-100C / IDC-100D: Internal diode in series with the Positive input line
will block Negative input voltage.
Cooling: The unit is cooled by convection (there is no internal cooling fan). Ensure that the unit is located in an open area with availability of cool
air changes for adequate cooling by convection.
Over Temperature: In case of higher ambient temperature or blockage of fan suction / exhaust openings, the temperature of 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.
Output Current De-rating at Ambient Temperature > +30°C: The unit is designed to provide the full rated output current up to ambient
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-100A-12 will provide full rated current of 8A 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 0.2A/°C for every 1°C rise higher than +30°C. At say +50°C, the maximum permissible output current should be reduced to
4A [8A – {(50C – 30C) x 0.2A /°C}].