http://zeromanual.com/history/DC-DC_12V_Converter?feed=atom&DC-DC 12V Converter - Revision history2024-03-29T05:53:32ZRevision history for this page on the wikiMediaWiki 1.27.0http://zeromanual.com/index.php?title=DC-DC_12V_Converter&diff=6387&oldid=prevBrianTRice: multi-platform support2020-04-22T17:49:31Z<p>multi-platform support</p>
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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.<br />
: The converters mentioned here are used on [[Gen2]] and [[Gen3]] models.<br />
<br />
{| class="wikitable"<br />
|+ DC-DC Converters<br />
|-<br />
!Years<br />
!Platform<br />
!Manufacturer<br />
!Model<br />
!Replacement Options<br />
|-<br />
|2013-2014<br />
|rowspan="2"|S and X<br />
|rowspan="2"|Sevcon<br />
|[http://www.sevcon.com/products/dcdc-converters/dcdc-300w/ Sevcon DC-DC 300W converter]<br />
|OEM or [http://www.thunderstruck-ev.com/sevcon-72-80v-dc-dc-en.html via Thunderstruck Motors]<br />
* '''NOTE:''' Select the 300W model! connector hardware is an extra<br />
|-<br />
|2015+<br />
|[http://www.sevcon.com/products/dcdc-converters/dcdc-500w/ Sevcon DC-DC 500W converter]<br />
|OEM or [http://www.thunderstruck-ev.com/sevcon-72-80v-dc-dc-en.html via Thunderstruck Motors]<br />
* '''NOTE:''' Select the 500W model! connector hardware is an extra<br />
|}<br />
<br />
;Appearance<br />
: 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.<br />
{|<br />
|[[File:DC-DC Sevcon 500W Converter - 1.png|thumb|500W Sevcon DC-DC converter - top]]<br />
|[[File:DC-DC Sevcon 500W Converter - 2.png|thumb|500W Sevcon DC-DC converter - connector]]<br />
[[File:DC-DC Sevcon 500W Converter - 3.png|thumb|500W Sevcon DC-DC converter - connector side]]<br />
|[[File:DC-DC Sevcon 500W Converter - 4.png|thumb|500W Sevcon DC-DC converter - side]]<br />
[[File:DC-DC Sevcon 500W Converter - 5.png|thumb|500W Sevcon DC-DC converter - backplate (upside down)]]<br />
[[File:DC-DC Sevcon 500W Converter - 6.png|thumb|500W Sevcon DC-DC converter - backplate (as installed)]]<br />
|}<br />
<br />
;[[SDS Platform]] Location<br />
: Below the front of the seat under cable runs, between the [[MBB]] (separated by a bracket) and the back of the battery frame area.<br />
: [https://www.youtube.com/watch?v=yig2RtRuIoY Quick and dirty illustrative video of how to find and access the converter]<br />
;[[XMX Platform]] Location<br />
: Below the removable battery compartment. See [[XMX Platform/Electrical Routing|our FX teardown layout guide]].<br />
;[[FST Platform]] Location<br />
: Inside the tank, on the right of the bin, on the [[FST Platform/Board Mounting Plate|board mounting plate]].<br />
<br />
;Protections<br />
* Ingress: IP67<br />
* Short circuit overload<br />
* Reverse polarity<br />
* Fully isolated<br />
* Can parallel with diode safeguard<br />
<br />
;Mounting<br />
: 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.<br />
: 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.<br />
<br />
;Removal<br />
# [[Board Mounting Plate Removal|Remove]] the [[SDS Platform/Board Mounting Plate|board mounting plate]].<br />
# Remove the converter from the board using a 10mm hex socket wrench.<br />
# Disconnect the connector if appropriate.<br />
<br />
;Installation<br />
# Attach the converter to the [[SDS Platform/Board Mounting Plate|board mounting plate]] with a 10mm hex socket wrench.<br />
# Install the [[SDS Platform/Board Mounting Plate|board mounting plate]] with the converter back into the bike.<br />
<br />
;Connections<br />
: There is a 5-pin connector controlling the converter, facing the left as installed on the bike, connected as follows:<br />
{| class="wikitable"<br />
!Pin<br />
!Function<br />
!Measurement<br />
!Component<br />
!Years<br />
!Wire<br />
!MBB Pin<br />
!Illustration<br />
|-<br />
|rowspan="2"|1<br />
|rowspan="2"|Enable signal<br />
|rowspan="2"|Battery voltage when key is on<br />
|rowspan="2"|[[MBB]]<br />
|2013<br />
|rowspan="2"|Orange (Red) 18AWG<br />
|21<br />
|rowspan="6"|[[File:dc-dc-connector.png|400px]]<br />
|-<br />
|2015<br />
|20<br />
|-<br />
|2<br />
|Input (Positive)<br />
|rowspan="2"|116V<br />
|rowspan="2"|[[#Battery|Battery]]<br />
|2013<br />
|Orange (Blue) 16AWG<br />
|7<br />
|-<br />
|3<br />
|Input (Negative)<br />
|2013<br />
|Orange (Black) 20AWG<br />
|5<br />
|-<br />
|4<br />
|Output (Positive)<br />
|rowspan="2"|13.5V<br />
|[[#Fuse_Block|Fuse Block]]<br />
|2013<br />
|Blue (16AWG, 14AWG) wires<br />
|-<br />
|5<br />
|Output (Negative/Ground)<br />
|[[#Routing|12V return conduits]]<br />
|2013<br />
|Black 10AWG<br />
|}<br />
<br />
;Output<br />
: It is configured to output 13.5V DC; usually produces ~13.8V DC.<br />
: There is very little ripple that is typical of a gas-power motorcycle's alternator-driven DC supply.<br />
: 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.<br />
<br />
;Operation<br />
: The input side is always-on DC from the battery, upstream of the contactor.<br />
:: This is the best place to tap for an always-on power supply.<br />
: The converter is enabled by a 12V signal from the [[MBB]].<br />
<br />
;Environmental Vulnerability<br />
* The Sevcon DC-DC converter is rated to IP67 for intrusion protection and seems very robust as such.<br />
* 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.<br />
* No sealed connector option is currently available for Sevcon's DC-DC converter models that Zero uses.<br />
* Connector looseness could age and wear the converter prematurely due to sporadic voltage input or output changes.<br />
* Leakage across pins could cause the enable signal to activate inadvertently.<br />
<br />
;Connector Inspection<br />
: Try to inspect the pins' tabs to ensure they are in the right shape to clamp that enable pin securely.<br />
: 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.<br />
: If the connector seems grimy, remove and clean it while de-energized; then apply grease once dry before re-seating it.<br />
: Test the connector before fully re-assembling the bike.<br />
<br />
;Failure to De-energize Condition<br />
: 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.<br />
:* If this condition happens in rain:<br />
:*# Let the bike dry out until it clears.<br />
:*# Attempt a dielectric grease application to the inputs while de-energized.<br />
: If the DC system output disappears:<br />
:* Check DC voltage upstream of the fuse block in case the fuse block is faulty.<br />
:* Check the continuity and snugness of the connectors and pins.<br />
:* Check for the enable signal from the MBB<br />
:*: Continuity: < 1Ω between pins.<br />
:*: Not shorted to B+?: > 151kΩ from pin 20 to pin 7.<br />
:*: Not shorted to ground?: > 1MΩ from pin 20 to 18.<br />
<br />
;Protection Recommendations<br />
* Splash protection around the left-side's connector from all sides is worth considering.<br />
<br />
;References<br />
: [http://electricmotorcycleforum.com/boards/index.php?topic=6904.msg57973#msg57973 Re: My DC-DC converter has died again, local dealer has gone bust]<br />
: [http://electricmotorcycleforum.com/boards/index.php?topic=7041 Re: A puddle, some rain and some problems]<br />
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[[Category:HV Component]]</div>BrianTRice