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DC-DC Converter


The first thing for all EV owners or controllers to know about DC-DC converters is that they’re the element in the EV that converts your car’s high voltage drive system (around MH – 48 V or EV/HEV – 100s of V) to the traditional 12 V power bus or 12 volts. What happens during this conversion is the battery and basic electrics running in your car battery are sort of harmonized or just generally working. Without such a component, the 12 volt parts of your EV, which includes your turn signals, radio etc and headlights, would simply go flat or dysfunctional. The conversion process would let them continue running, which is especially useful during emergency cases where there’s a need for hazard lights.

It’s not an understatement to state that a DC-DC converter would be a key component in hybrid and EV architectures. In fact, they’re so important that there’s a lot of innovation now to boost the performance of these converters in rendering the EV fully functional at its full strength. One of these technologies is the bidirectional DC-DC converter that would enable the recycling of the battery test charge energy by making sure that the energy is returned to the system. This returned energy would then be a subsequent fuel for the EVs battery cells, which yields a higher level of system efficiency during charge/discharge-conversion losses. This new technology would mean that there’ s no loss of energy on the EV that commonly results from a dissipating load.

A new development today in DC-DC converters is in how a high-efficiency DC-DC converter becomes a frontend control for a Battery Backup System (BBU). In a resource paper from Vicor Power, this DC-DC converter mechanism will sustain continued operation of an equipment usually following from a power failure. These information systems found in today’s modern EV need a reliable power source when emergency situations happen, and this battery bank through the converter becomes that needed back-up, acting as a secondary form of generator for the vehicle. Without such DC-DC converter as a battery back-up, there’s no mechanism to maintain the correct bus voltage for some of the areas of the EV. All these sequences in the conversion are accomplished with the help of the innovation in a single bidirectional DC-DC converter.

Other than being used as an interface for a battery bank and a DC-bus conversion, the bidirectional system will also allow a back-up power after a charge of about 2.3 hours and will now be able to support the bus (1500W load) for about 28 minutes. That’s more than enough time to make sure that the rest of the components in the EV are working properly during emergency events.

Another vital information to learn about the electronic conversion in a DC-DC converter relates to the switched-mode to DC-to-DC conversion. In this process, the input energy is still temporarily stored and then released to an energy output at a different voltage. However, the storage process here can happen either in magnetic field storage components or in electric field storage components, such as in capacitors.

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GE 72/80V DC/DC Converter CNV4HF GE 24/48V DC/DC Converter CNV4LF Sevcon 72/80V In 12V  Out DC/DC Converter 62211112
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DC/DC Converter 400W 30 Amp Isolated 108-216 Volts DC/DC Converter 400W 30 Amp Isolated 55-100 Volts DC/DC Converter 400W 30 Amp Isolated 72-144 Volts
When you want the best, you can consider these Isolated DC-DC Converters to be your top choice, especially because they are 400W in capacity and are 13.5V in Output at 30 Amps. While that is something to brag about, it still boosts its reputation as a TDC High Efficiency Series DC/DC Converter by having a reduced voltage supply design that fits perfectly for all the major auxiliary electrical systems available for electric vehicles. Add to that fact is the extra powerful boost feature of being an internationally advanced digital analogy technology that’s enabled with high transition efficiency and easy-to-install option for a mini-type design. Other features of this component include its high-stability and long lifespan, as well as its well-founded protecting function that employs soft key technology that allows it to have the functions of fail-safe during low-voltage scenario. Overheat and over current issues are also non-existent with this component because of the redundancy protection installed that matches very well with its high-transition efficiency and sustained short-circuit design. There’s a reset button, too, after shorting and that gives this converter an even added powerful advantage over others.
SPECS:
Input Current Range:0-3 Amps at 120 volts
Output Current Range: 0-30 Amps at 12 volts
Height: 3 Inches
Width: 7 Inches
Length: 6.25 Inches
Weight: 5 lbs
Max Input Voltage Range:108 - 216 volts DC
Input Voltage Nominal:132-168 volts DC
Isolated: Selectable
Efficiency: 0.92
Short Circuit Protection:Internally protected
Overheat Protection:Yes at 90C
Shock and Vibration: SAE J1738 Standard
Warranty Period: One year
Wiring:
Red and Yellow:Load side of the contactor that gets fed from the positive terminal of the high voltage battery.
Black: Negative side of the high voltage battery or commonly to the load side of the shunt which is usually found on the negative loop.
Blue: 12V Battery negative terminal.
Green: 12V Battery positive terminal.

Finding the best converters would lead you to consider these Isolated DC-DC Converters to be your top choice, especially because they are 400W in capacity and are 13.5V in Output at 30 Amps. While we can say that's a lot to boast about it boosts its reputation as a TDC High Efficiency Series DC/DC Converter by also having a reduced voltage supply design that fits perfectly for all the major auxiliary electrical systems available for electric vehicles. Another boost to this component's rating is its powerful boost feature of being an internationally advanced digital analogy technology that’s enabled with high transition efficiency and easy-to-install option for a mini-type design. Other features of this component include its high-stability and long lifespan, as well as its well-founded protecting function that employs soft key technology that allows it to have the functions of fail-safe during low-voltage scenario. Overheat and over current issues are also non-existent with this component because of the redundancy protection installed that matches very well with its high-transition efficiency and sustained short-circuit design. There’s a reset button, too, after shorting and that gives this converter an even added powerful advantage over others.
SPECS:
Input Current Range:0-5 Amps @ 76 volts
Output Current Range: 0-30 Amps @ 12 volts
Height: 3 Inches
Width: 7 Inches
Length: 6.25 Inches
Weight: 5 lbs
Max Input Voltage Range:55-100 volts DC
Input Voltage Nominal:60-84 volts DC
Isolated: Selectable
Efficiency: 0.92
Short Circuit Protection:Internally protected
Overheat Protection:Yes at 90C
Shock and Vibration: SAE J1738 Standard
Warranty Period: One year
Wiring:
Red and Yellow:Load side of the contactor that gets fed from the positive terminal of the high voltage battery.
Black: Negative side of the high voltage battery or commonly to the load side of the shunt which is usually found on the negative loop.
Blue: 12V Battery negative terminal.
Green: 12V Battery positive terminal.

What you should consider about these Isolated DC-DC Converters is the fact that they are 400W in capacity and are 13.5V in Output at 30 Amps. Basically, it retains its names as a leading TDC High Efficiency Series DC/DC Converter with a reduced voltage supply design that fits perfectly for all the major auxiliary electrical systems available for electric vehicles. It also helps that this converter has an internationally advanced digital analogy technology that’s enabled with high transition efficiency and easy-to-install option for a mini-type design. Other features of this component include its high-stability and long lifespan, as well as its well-founded protecting function that employs soft key technology that allows it to have the functions of fail-safe during low-voltage scenario. Overheat and over current issues are not a big deal because of the redundancy protection installed in this converter that matches very well with its high-transition efficiency and sustained short-circuit design. There’s a reset button, too, after shorting and that gives this converter even a stronger edge than the rest.
SPECS:
Input Current Range:0-3 Amps at 120 volts
Output Current Range: 0-30 Amps at 12 volts
Height: 3 Inches
Width: 7 Inches
Length: 6.25 Inches
Weight: 5 lbs
Max Input Voltage Range:72-144 volts DC
Input Voltage Nominal:84-120 volts DC
Isolated: Selectable
Efficiency: 0.92
Short Circuit Protection:Internally protected
Overheat Protection:Yes at 90C
Shock and Vibration: SAE J1738 Standard
Warranty Period: One year
Wiring:
Red and Yellow:Load side of the contactor that gets fed from the positive terminal of the high voltage battery.
Black: Negative side of the high voltage battery or commonly to the load side of the shunt which is usually found on the negative loop.
Blue: 12V Battery negative terminal.
Green: 12V Battery positive terminal.

GE 36/80V 12A DC/DC Converter 6CNV1A1 GE 36/80V 12A DC/DC Converter 6CNV1B1 GE 36/80V 12A DC/DC Converter 6CNV2B1
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Toyota 5FBE DC Converter & SDD/SDP 24230-12240 Toyota 5FBC DC Converter & SDD/SDP 2423012242 Toyota 5FBC DC Converter & SDD/SDP 2423012241
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Toyota 5FBE DC Converter & SDD/SDP 2423013300
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