Universal EV DC-DC converters
Updated Sep 08 2008


1200W converter

2500W converter

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       A DC-DC converter will provide power for all 12V  car's accessories - head and tail lights, wipers, radio, motorized windows, etc. Depending on the power output, a DC-DC can also run more demanding loads such as power steering pump. There are two standard ways to set the system up - with and without auxiliary 12V battery along with DC-DC converter. If it is desired not to have any auxiliary batteries and always have steady output, choose the power level you need. Normally it is average steady consumption current of all the loads you may run simultaneously. Instantaneous peak power demand can be handled by a large capacitor (supercapacitor) in parallel to the converter's output - peak load handling ability is required for fraction of a second and it is not worth having converter rated for continuous power equal to the peak power demand of your vehicle. Disadvantage of such a method is totally non-operable vehicle should DC-DC fail (unless you have small inexpensive extra converter just to run emergency lights/radio if needed). But consider that usually more stressed traction controller has greater chance to fail leaving the vehicle stranded; however normally no EV carries extra "emergency" controller and the risk of having that small chance is well accepted. Same applies to DC-DC converter.

Another way is to use lower power converter along with auxiliary 12V battery which will supply peak power and also work as emergency power source if main converter fails. This battery's charge will normally be maintained by the DC-DC converter. Apparent disadvantage is to have another battery to worry about. Overall weight and space taken by these components in this case will be more can a DC-DC alone - a factor user must consider optimizing setup. Traditionally this method has been used the most since standard DC-DC power supply grade converters, not meant to be used in vehicle, fail quite frequently, rendering use of auxiliary battery as necessary part. Unlike most generic DC-DC converters on the market, BRUSA DC-DC converters, designed ground up to work in an electric vehicle will provide long reliable and dependable operation, so its failure is no longer a concern.

Several models are offered with different power level and future set. Only 12V output models are presented here, but 24V and 48V models are available as well. One year warranty.

Main electrical characteristics:

Available Available Available Available Available Available Available
Model

DCDC250/xx/14*

DCDC600/xx/14*

MES 400-1000

BRUSA BNW41x

BRUSA BDC412

BRUSA BSC623-12V

BRUSA BSC624-12V

Output
voltage

13.8 VDC
nom

13.8 VDC nom

13.8 VDC nom
14.3 VDC max

11...14.5 VDC
(progr.)
13.8 VDC nom

100...400 VDC
(low side)
125...425 VDC
(high side)

8...16 VDC
(progr.)
(low side)
170...425 VDC
(high side)

8...16 VDC
(progr.)
(low side)
220...450 VDC
(high side)

Output
Current

16 A cont
20 A peak

35 A cont
42 A peak

70 A cont
80 A peak

80 A cont
125 A peak

100 A cont
150 A peak
low side

200 A cont
250 A peak
(low side),
3.6 A cont
4.5 A   peak
(high side)

200 A cont
250 A peak
(low side),
3.6 A cont
4.5 A   peak
(high side)

Output Power

250 W

600 W

1,000 W

1,200 W

1,200 W

2,800 W nom
3,500 W peak

  2,800 W nom
  3,500 W peak

Input voltage
range
(models)

-DCDC250/72/14:
51...94 VDC
-DCDC250/96/14:
56...145 VDC
-DCDC250/144/14:
100...200 VDC

-DCDC600/96/14:
67...125 VDC
-DCDC600/144/14:
100...200 VDC
-DCDC600/192/14:
135...250 VDC

100...400 VDC
(full power
at >190 VDC)

-BNW412:
125...370 VDC
450 V max)
-BNW415:
250...750 VDC
900V max)

125...425VDC
high side
100-400VDC
low side

170...425 VDC
(high side)
8...16VDC
(low side)

220...450 VDC
high side
8...16VDC
low side

Efficiency

85%

86%

 >90%

> 91%

> 97% (@>40A)

> 92%

> to 92%

Dimensions,
mm

150 x 125 x 90

230 x 125 x 90

254 x 155 x 137
(without
mounting feet)

209 x 152 x 183

333 x 196 x 110

300 x 150 x 70

300 x 150 x 70

Weight

1.7 kg

2,65 kg

2,65 kg

3.5 kg

10.25 kg

4.7 kg

4.7 kg

Env. Protection

 

 

IP-54 except for the fan

IP-54

IP-64

IP-65

IP-65

Special features

 

 

External enable

 

bi-directional
fully CAN controlled
liquid cooled

bi-directional
fully CAN controlled
liquid cooled

bi-directional
fully CAN controlled
liquid cooled

* DCDC250- and DCDC600- series converters are NOT developed or manufactured by BRUSA.


  Download DCDC250 and DCDC600 manual
  Download MES 400-1000 manual


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