TSM 500 Watt DC Converter User Manual

: June 1, 2024
: TSM

Table of Contents

TSM 500 Watt DC Converter
Product Information
Product Usage Instructions
FAQ
OVERVIEW
SPECIFICATIONS
Electrical and Safety
INSTALLATION AND WIRING
CONFIGURATION
OPERATION
APPLICATION OPTIONS
DIAGNOSTICS
HARDWARE VERSIONS
WARRANTY AND SUPPORT
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

TSM 500 Watt DC Converter

TSM-500-Watt-DC-Converter-Product

Product Information

Specifications

Operating Limits

Input Voltage Range:
- 48v: 36 – 75 Volts
- 72v: 40 – 90 Volts
- 96v: 72 – 135 Volts
- 144v: 110 – 180 Volts
Output Voltage: 13.8 Volts (no load)
Output Current: 50 Amps (maximum)
Maximum Efficiency: 88%
Moisture Resistance Rating: IP65
Operating Temperature: -20 to +60°C
Electrical Isolation: > 2 Meg Ohms

Electrical and Safety

The enclosure is sealed to protect it from moisture damage and is vibration-resistant.
Enable Switch Control: The converter can be controlled by a switch or relay on the enable (green) wire circuit. Connect to pack positive to enable.
Overheat Protection: Output shuts down in case of overheating and auto-resets after the issue is corrected.
Output Short Circuit Protection: Output shuts down in case of a short circuit and auto-resets after the issue is corrected.

Product Usage Instructions

Installation and Wiring
Before installing the DC-DC Converter, ensure the input and output cables are securely connected. Refer to the provided connectors and wire terminals for proper connections on the vehicle side.
Dimensions and Connectors
The DC-DC Converter comes with short input and output cables terminated with connectors. Make sure to match the connectors provided for vehicle side connections during installation.
Typical Circuit Design
For a typical circuit design, follow the wiring diagram provided in the manual. Ensure that all connections are made according to the specified guidelines to ensure the proper functioning of the DC-DC Converter.

FAQ

Q: Can I connect multiple DC-DC converters in parallel?

A: Multiple DC-DC converters can be connected in parallel to multiply the output current. Ensure proper connections and follow safety guidelines when doing so.

Q: How do I control the DC-DC Converter?

A: The converter can be controlled using a switch or relay on the enabled (green) wire circuit. Connect to pack positive the converter torter.

Q: What is the moisture resistance rating of the DC-DC Converter?

A: The DC-DC Converter has a moisture resistance rating of IP65, making it suitable for use in environments where exposure to moisture is a concern.

OVERVIEW

Thunderstruck Motors Isolated DC-DC Converters use high-voltage battery inputs to create a regulated 13.8V output for vehicle accessory systems including battery charging, lights, and electronics. See Figure 1 for the input voltage ranges supported by different models.
The DC-DC Converters are electrically isolated from input to output for operator and electronic safety. They are capable of 50 Amp output bursts at 12V. Multiple DC-DC converters can be connected in parallel to multiply the output current.

Included Components
The DC-DC Converter ships with short input and output cables terminated with connectors. Matching connectors and wire terminals are provided for vehicle- side connections. See the section Installation and Wiring for connection details.

SPECIFICATIONS

The ThunderStruck DC-DC Converters are designed for long life and high efficiency when operated within the limits and safety recommendations listed below. If additional information is needed, please contact ThunderStruck Motors.

Operating Limits
The following table lists operating information applicable for each of the DC- DC Converter models in this series.

PARAMETER	UNITS	DESCRIPTION
DC-DC Model	Volts	48v
Input Voltage Range	Volts	36 – 75
Output Voltage	Volts	13.8 (no load)
Output Current	Amps	50 (maximum)
Maximum Efficiency	%	≥88%
Moisture Resistance	Rating	IP65
Operating Temperature	Deg. C	-20 to +60
Output Voltage	Volts	13.8±0.2 @0A, >12 @50A
Electrical Isolation	Ohms (Ω)	> 2 Meg Ω
Water & Vibration Resistant		The enclosure is sealed to protect it from

moisture damage and is vibration-resistant.

Enable Switch Control

| | The converter can be controlled by a switch or relay on the enable (green) wire circuit.

Connect to pack positive to enable.

Overheat Protection

| | Automatically reduces output current when internal temperature reaches 60°C.
Output Short Circuit Protection| | Output shuts down, then auto-resets after the short circuit is corrected.
Weight| Kg| 1.25

Figure 1 – DC-DC Operating Limits

Electrical and Safety

The ThunderStruck DC-DC converter is isolated between input and output terminals, and between terminals and case. This prevents the DC-DC unit from producing a ground fault from the high-voltage pack and is necessary for vehicle equipment and personnel safety. It is sealed from external moisture, but cannot withstand submersion. Do not operate the unit if it has been submerged.

See Figure 1 for additional information.

Improper installation can damage the DC-DC converter and void the device warranty. Take the following steps to protect the device and promote safety:

Observe correct polarity when connecting to input and output terminals.
Never connect the high voltage pack negative terminal to the vehicle ground. High-voltage wiring must be isolated from structures.
Use the proper crimping devices for terminals.
Select a wire gauge to meet or exceed the current requirements for each circuit.
Place fuses in circuits near the largest current source, rated to protect wires from overheating. All branch circuits should be fused where they connect to the battery, heavier gauge wire, or busbars.
Do not open the component case – there is a risk of electric shock, and the device warranty may be voided.

A circuit that may exceed 50V is considered high voltage. When working with high voltage systems, please follow electrical safety guidelines and regulations, including training, Personal Protective Equipment (PPE), and short circuit prevention practices. Components connected to a lithium battery must not be allowed to charge or discharge the battery beyond the manufacturer’s voltage specifications. A Battery Management System (BMS) can be configured to disable the component before battery specifications are compromised. Without protection, leaving the DC-DC converter enabled for long periods may discharge and damage the high-voltage pack. An external battery maintainer is recommended for the 12v system if the DC-DC converter is not enabled for over a month, or if the 12v system tends to self-discharge over time.

INSTALLATION AND WIRING

The DC-DC converter is installed in a location close to the 12V system battery, with easy access to the high voltage pack, and in a ventilated space with protection from the elements. All circuits should be protected by fuses located near the batteries (both high voltage and 12v). If junction busses are used, branch fuses may be located there assuming the buss circuit is fused at the pack. Fuse Amp rating should be selected based on the branch circuit wire gauge, to prevent currents capable of causing wire overheating or fire.

Output connections may carry high currents, so care must be taken when selecting wire gauges and crimping terminal connections. Crimping tools designed for the wire size and terminal style must be used. Poor connections are a common cause of failures and can lead to overheated connectors, degraded performance, and fire hazards.

Dimensions and Connectors
The information shown in Figure 1 is intended to assist in the installation process. Units shown are metric (mm). Cooling fins should be kept at least 50 mm from any surface, and the space should be ventilated, unless large enough for unventilated cooling, e.g. a vehicle trunk space. Avoid mounting the DC-DC converter with its long axis aligned vertically, which could restrict airflow around cooling fins.

$TSM-500-Watt-DC-Converter-Fig- $1$$

Typical Circuit Design

The following circuit diagram shows how the DC-DC may be used in an electric vehicle system along with a device like the MCU. To keep the diagram simple, only DC-DC circuit fuses are shown.
MCU configuration is required for the circuit shown. In the MCU user interface, enter:

set out5 -lv
(this enables the DC-DC Converter only if low voltage cells are NOT found)

DCDC Enable Circuit with MCU
An MCU or key switch-activated relay completes the enable circuit for the DCDC converter. The DCDC is enabled during charge and operation with the MCU, and only during operation with the keyswitch.

Note:
Fuses are recommended at ALL positive branch circuits, rated for the branch wire gauge and voltage. The high voltage battery negative does NOT connect to 12v (chassis) ground for safety reasons.

$TSM-500-Watt-DC-Converter-Fig- $2$$

CONFIGURATION

The DC-DC Converter is factory configured to maintain output voltage while the high voltage pack is within the range stated in the Speciﬁcations section. Operation is automatic once the enabled connection is made to the high-voltage pack positive. No other controls or settings are possible with this device. Opening the case is hazardous because of capacitive discharge, and may void the product warranty. Product and software upgrades are not provided.

OPERATION

The DC-DC enable circuit is used to activate and deactivate the device. When deactivated, the output circuit is disabled. See Figure 3 for a wiring example using the Thunderstruck MCU Out5 output.
To activate the enable circuit, connect the enable (green) wire circuit to the high-voltage battery positive. This is typically handled by either a relay operated by a 12v circuit or by a manual switch.
With the DC-DC Converter installed in the vehicle system, test by observing the output voltage rise after the enable circuit has been activated. Output voltage should match the specifications listed in Figure 1. Note that the regulated voltage is reduced as the output current approaches maximum.

APPLICATION OPTIONS

The DC-DC with MCU solution shown in Figure 3 is an automated solution activating the DC-DC Converter during both charge and vehicle operation conditions.
In addition to this application, it is possible to control the DC-DC Converter using a manually operated switch or relay. This can be accomplished by replacing the MCU Out5 circuit with a manual switch rated at 12v, or by replacing the entire enable relay circuit with a switch rated for pack voltage.
All switches and relays controlling the high voltage enable circuit must have contacts rated at or above the system voltage. This is essential to prevent premature wear on contacts, which can lead to the relay welding shut. This kind of failure leaves your DC-DC system enabled even when the enable control circuit is turned off.

DIAGNOSTICS

If the DC-DC converter does not operate after installation, please check Figure 4 below for suggested remedies. No fault codes are displayed by the DC- DC converter. If the DC-DC converter does not operate after accidental miswiring, then the suggested remedies may not help. Please contact ThunderStruck Motors if you are unable to resolve the issue.

Problem	Cause	Remedy	Recommendation
No output from DC- DC	Enable circuit disconnected	Use a switch, relay, or

other device to

enable.

Bad connection, Faulty 12v battery

| Test and repair connections, and replace fuse or battery.|
Pack discharging when the vehicle OFF| Enable always connected| Add a switch or relay. Check for faulty relays or switches.| Use an automatic control like the MCU
Low voltage DC-DC output| Wire gauge too small, Poor connections,

current draw too high

| Correct wire gauge for output current. Rework connections.| Limit accessory loads to less than DC-DC

maximum output

Hot or burned connections.| Dirty or loose connector terminals| Replace damaged wire and terminals| Use the correct crimp tool. Solder terminals for best results.

Figure 4 – DC-DC Troubleshooting

HARDWARE VERSIONS

ThunderStruck DC-DC Converters sold before the year 2022 used a single rectangular connector including both input and output circuits. Figure 5 below shows a connection diagram along with pinouts for the earlier model connector.
The 2022 and later DC-DC Converters are designed with the input and output connectors separated as shown above in Figure 2.

$TSM-500-Watt-DC-Converter-Fig- $3$$

WARRANTY AND SUPPORT

ThunderStruck Motors offers a high level of support and warranty consideration for anyone purchasing our products. The DIY industry invites participants of all skill levels, and our goal is to meet their needs with tolerance, understanding and flexibility as our way of contributing to the success of the electric transportation movement.

Warranty
The Thunderstruck DC-DC Converter is guaranteed against operational and material defects for one year after the device purchase date. The recommended first point of contact for warranty consideration is the company that sold the product. If purchased directly from ThunderStruck Motors, please use the contact information below. Because the customer is responsible for the device installation and wiring, the product warranty does not cover errors such as incorrect wiring connections or device placement, exceeding voltage limits, physical damage to any part of the unit, or any device failure caused by misuse or modification by the customer.

Support
Customers purchasing products directly from ThunderStruck Motors have access to support for instruction and troubleshooting needed during product installation and operation. Customers purchasing from vendors selling our products receive support first from the vendor and then from ThunderStruck Motors if the vendor is unsuccessful or unresponsive.

Contact Us