Thursday, April 16, 2020

DC-DC converter bought

Several test drives have been done, and a couple have been longer than expected.  The issue seems to be that as the 12V car battery system voltage droops the DMOC adapter shuts off power to the DMOC.  So the last two weeks have been used to research DC-DC needs and options.  The 403Vdc max of the Nissan Leaf system seems to limit the option significantly, and looking at many EV websites no standard option was found.  From previous blog notes, we note that the original alternator in the car was capable of 90 amps.  An ammeter was placed on the main battery positive terminal and readings were taken:
Car OFF:  no resolution
Ignition ON: Spike, 10A : Steady state, 4.5A
+DRL's ON: Steady State 20A
All things on that can be controlled: Spike, 80A : Steady State, 50A

Therefore minimum 450W, Steady max: 600W, Spikes: 1000W

Vicor provides two current options, the 3623 and 4623 chips.  The chips can be had on evaluation boards.



















Two of either board would be needed.  Available from Vicor for $1610.  Or Digikey for $1323.

eBay was scanned for alternate options.  It was found that old Vicor PFC Mini, Maxi, and Mega power converters could be applicable but less efficient.  On the Mini versions the outputs are usually printed directly on the main sticker, but on the Mega units the main sticker does not tell about the outputs and unfortunately most retailers do not seem to recognize that the numbers are on the individual modules and require closer pictures to identify the many different outputs.  Eight outfits were contacted to collect the output information.  Five of the stores responded with the identical ?stock? answer "Thank you for your inquiry. A picture of the sticker with all of the information is in the listing. If you are interested, please make an offer via eBay and we will review it. If you have any other questions or concerns, please advise. Thank you and have a nice day."

Thanks to:
An eBay Store





Alternately a used Vicor PFC Mini PM1-03-576 was found on eBay. 



It is rated at: Input, 115-230Vac 10A: Output, 12V/99.9A
Despite these being listed as A/C input, the user guide specifically says they are rated up to 380Vdc input. Their output capability is 600W/module but derated in the pack to 500W/module allowing 1500W max output as the -03- designates this unit has 3 modules in parallel.  You can see the bus bars connecting the three modules in the above image.  The Output voltage can also be adjusted between 8 and 15V.

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