View source for DC-DC 12V Converter

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The DC-DC 12V converter is a solid state switching power DC step-down converter designed to produce low voltage DC power from the pack voltage.
: The converters mentioned here are used on [[Gen2]] and [[Gen3]] models.

{| class="wikitable"
|+ DC-DC Converters
|-
!Years
!Platform
!Manufacturer
!Model
!Replacement Options
|-
|2013-2014
|rowspan="2"|S and X
|rowspan="2"|Sevcon
|[http://www.sevcon.com/products/dcdc-converters/dcdc-300w/ Sevcon DC-DC 300W converter]
|OEM or [http://www.thunderstruck-ev.com/sevcon-72-80v-dc-dc-en.html via Thunderstruck Motors]
* '''NOTE:''' Select the 300W model! connector hardware is an extra
|-
|2015+
|[http://www.sevcon.com/products/dcdc-converters/dcdc-500w/ Sevcon DC-DC 500W converter]
|OEM or [http://www.thunderstruck-ev.com/sevcon-72-80v-dc-dc-en.html via Thunderstruck Motors]
* '''NOTE:''' Select the 500W model! connector hardware is an extra
|}

;Appearance
: It's about the size of a long box of soap with a black surface, but for 2013-2014 models will be covered entirely with Nashua aluminum ducting tape, so will appear silver.
{|
|[[File:DC-DC Sevcon 500W Converter - 1.png|thumb|500W Sevcon DC-DC converter - top]]
|[[File:DC-DC Sevcon 500W Converter - 2.png|thumb|500W Sevcon DC-DC converter - connector]]
[[File:DC-DC Sevcon 500W Converter - 3.png|thumb|500W Sevcon DC-DC converter - connector side]]
|[[File:DC-DC Sevcon 500W Converter - 4.png|thumb|500W Sevcon DC-DC converter - side]]
[[File:DC-DC Sevcon 500W Converter - 5.png|thumb|500W Sevcon DC-DC converter - backplate (upside down)]]
[[File:DC-DC Sevcon 500W Converter - 6.png|thumb|500W Sevcon DC-DC converter - backplate (as installed)]]
|}

;[[SDS Platform]] Location
: Below the front of the seat under cable runs, between the [[MBB]] (separated by a bracket) and the back of the battery frame area.
: [https://www.youtube.com/watch?v=yig2RtRuIoY Quick and dirty illustrative video of how to find and access the converter]
;[[XMX Platform]] Location
: Below the removable battery compartment. See [[XMX Platform/Electrical Routing|our FX teardown layout guide]].
;[[FST Platform]] Location
: Inside the tank, on the right of the bin, on the [[FST Platform/Board Mounting Plate|board mounting plate]].

;Protections
* Ingress: IP67
* Short circuit overload
* Reverse polarity
* Fully isolated
* Can parallel with diode safeguard

;Mounting
: The Sevcon 500W DC-DC converter is mounted to its own baseplate via 4 Torx T10 cap head screws and there are 3 additional Torx T15 cap head screws in the middle.
: The Sevcon baseplate is then bolted to Zero's [[SDS Platform/Board Mounting Plate|board mounting plate]] with 4 10mm hex head bolts which have 6mm outer diameter, 16mm length, and 1mm pitch.

;Removal
# [[Board Mounting Plate Removal|Remove]] the [[SDS Platform/Board Mounting Plate|board mounting plate]].
# Remove the converter from the board using a 10mm hex socket wrench.
# Disconnect the connector if appropriate.

;Installation
# Attach the converter to the [[SDS Platform/Board Mounting Plate|board mounting plate]] with a 10mm hex socket wrench.
# Install the [[SDS Platform/Board Mounting Plate|board mounting plate]] with the converter back into the bike.

;Connections
: There is a 5-pin connector controlling the converter, facing the left as installed on the bike, connected as follows:
{| class="wikitable"
!Pin
!Function
!Measurement
!Component
!Years
!Wire
!MBB Pin
!Illustration
|-
|rowspan="2"|1
|rowspan="2"|Enable signal
|rowspan="2"|Battery voltage when key is on
|rowspan="2"|[[MBB]]
|2013
|rowspan="2"|Orange (Red) 18AWG
|21
|rowspan="6"|[[File:dc-dc-connector.png|400px]]
|-
|2015
|20
|-
|2
|Input (Positive)
|rowspan="2"|116V
|rowspan="2"|[[#Battery|Battery]]
|2013
|Orange (Blue) 16AWG
|7
|-
|3
|Input (Negative)
|2013
|Orange (Black) 20AWG
|5
|-
|4
|Output (Positive)
|rowspan="2"|13.5V
|[[#Fuse_Block|Fuse Block]]
|2013
|Blue (16AWG, 14AWG) wires
|-
|5
|Output (Negative/Ground)
|[[#Routing|12V return conduits]]
|2013
|Black 10AWG
|}

;Output
: It is configured to output 13.5V DC; usually produces ~13.8V DC.
: There is very little ripple that is typical of a gas-power motorcycle's alternator-driven DC supply.
: Capacity is 300W (20-25A) for pre-2015 bikes and 500W (35-40A) for 2015+ models, with most of that excess needed to run ABS pumps, etc.

;Operation
: The input side is always-on DC from the battery, upstream of the contactor.
:: This is the best place to tap for an always-on power supply.
: The converter is enabled by a 12V signal from the [[MBB]].

;Environmental Vulnerability
* The Sevcon DC-DC converter is rated to IP67 for intrusion protection and seems very robust as such.
* However, the connector is not sealed, faces the left side of the inside of the frame arms with not much splash protection from beneath; on 2015+ models, it is also vulnerable to debris and splash impact from the rear near the motor and belt.
* No sealed connector option is currently available for Sevcon's DC-DC converter models that Zero uses.
* Connector looseness could age and wear the converter prematurely due to sporadic voltage input or output changes.
* Leakage across pins could cause the enable signal to activate inadvertently.

;Connector Inspection
: Try to inspect the pins' tabs to ensure they are in the right shape to clamp that enable pin securely.
: The connector is not well-sealed, and the pins are too easy to bend into not-connecting if there's any tension/tugging on the wires.
: If the connector seems grimy, remove and clean it while de-energized; then apply grease once dry before re-seating it.
: Test the connector before fully re-assembling the bike.

;Failure to De-energize Condition
: The converter can fail in a way where it shorts its enable line and will not turn off even if the bike is keyed off.
:* If this condition happens in rain:
:*# Let the bike dry out until it clears.
:*# Attempt a dielectric grease application to the inputs while de-energized.
: If the DC system output disappears:
:* Check DC voltage upstream of the fuse block in case the fuse block is faulty.
:* Check the continuity and snugness of the connectors and pins.
:* Check for the enable signal from the MBB
:*: Continuity: < 1Ω between pins.
:*: Not shorted to B+?: > 151kΩ from pin 20 to pin 7.
:*: Not shorted to ground?: > 1MΩ from pin 20 to 18.

;Protection Recommendations
* Splash protection around the left-side's connector from all sides is worth considering.

;References
: [http://electricmotorcycleforum.com/boards/index.php?topic=6904.msg57973#msg57973 Re: My DC-DC converter has died again, local dealer has gone bust]
: [http://electricmotorcycleforum.com/boards/index.php?topic=7041 Re: A puddle, some rain and some problems]

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[[Category:HV Component]]