New Energy Power truck parts DC-DC High Voltage Converter Assembly 2123010-TV1A0

Adopting advanced full-bridge LLC resonant topology, this converter achieves industry-leading energy conversion efficiency of ≥96% (up to 97.5% at 70% load), outperforming traditional PWM converters by 5-8%. The 3kW rated output provides stable power for low-voltage loads (lights, air conditioning, ECU, etc.), supporting simultaneous operation of multiple components without voltage fluctuation. Its 0-3kW stepless power adjustment adapts to dynamic load demands—reducing high-voltage battery consumption by 12% compared to fixed-power converters. The built-in synchronous rectification technology minimizes conduction loss, while the soft-switching design lowers switching loss, ensuring efficient energy utilization and extending the truck’s driving range by 20-30km per full charge

Engineered with a comprehensive safety protection system, the converter effectively mitigates electrical risks in NEV operations. It integrates over-voltage (input ≥500V, output ≥28V), under-voltage (input ≤300V, output ≤20V), over-current (output ≥130A), and short-circuit protection (instantaneous current limiting ≤150A) to prevent component damage. The isolation voltage between high/low voltage circuits reaches 2500V AC, eliminating electric shock hazards for maintenance personnel. Additional protections include over-temperature (≥85℃ automatic derating, ≥100℃ shutdown), reverse polarity, and surge voltage resistance (6kV), complying with IEC 61000-4-5 standards. The fault self-diagnosis function sends real-time alerts to the VCU, enabling proactive maintenance

Designed for the harsh operating environments of commercial trucks, the converter maintains stable performance across diverse conditions. The aluminum alloy housing with heat pipe cooling system achieves a heat dissipation efficiency of 15W/(m·K), ensuring normal operation at ambient temperatures from -40℃ (northeast China winters) to 65℃ (desert regions). It passes 500,000 vibration cycles (5-2000Hz, ISO 16750-3) and IP67 waterproof/dustproof testing, withstanding rain, snow, and road dust intrusion. The high-voltage connectors use AMP Superseal 2.8 series with Viton seals, preventing water leakage and corrosion. In long-term reliability tests, it operates continuously for 2000 hours without failure, meeting the 8-year/400,000km service life requirement of commercial NEVs

Optimized for efficient NEV fleet maintenance, the converter features a user-friendly plug-and-play design. The high-voltage input (M12 connectors) and low-voltage output (DTM04-12P connectors) use tool-free locking mechanisms, simplifying wiring and reducing installation time by 50%. The 4-point mounting bracket matches standard chassis holes, requiring only M8×25 bolts (grade 8.8) and a torque wrench (25-30N·m) for fixation. The converter is maintenance-free—no capacitor replacement or cooling fluid refilling is needed—thanks to its solid-state design and long-life components. The built-in LED status indicators (power, fault) allow quick troubleshooting, while the modular structure enables easy replacement of individual modules if needed, minimizing truck downtime and maintenance costs