Delphi

Delphi DC-DC Converter

Delphi Universal 2.2kW DC/DC Converter creates DC voltages in hybrid and electric vehicles necessary to power accessories and the HVAC system. Liquid-cooled, the DC-DC converter operates at input voltages from 216 to 422VDC with a power range to 2.2kW.

Benefits

• In production
• Proven automotive design, reliable even in the harsh environment of the engine compartment
• Highly efficient conversion using synchronous rectification
• Applicable to multiple vehicle platforms without re-engineering

Features

• Analog output voltage is adjustable through CAN serial communication; 11V – 15.5V
• Bi-directional capability supports charging of high-voltage battery
• Over-voltage, over-current, and over-temperature protection with fault reporting
• CAN serial interface

Mounting Information (Vibration Dampening)

There are no "dampening feet" used with our DC/DC Converter. In most cases where a vehicle manufacturer has used this, it has been mounted underhood, out of the splash zone, and typically on a frame or bracket.

This bracket utilizes the mounting bosses per the description in the U2C Customer Manual (i.e., bolt size and thread type, grounding cable location, etc.). In many cases the bracket itself is attached to the engine, but the U2C is never directly attached to the engine.

The U2C has been validated to operate at underhood temperatures and with a vibration profile commensurate with being on a frame attached to the powerplant. Using it in that manner should preclude the need for any type of additional "dampening".

Cooling Notes

The U2C is robustly protected from "over temp" conditions. There are two thermistors on our product. One measures inlet coolant temperature ("heat plate temperature"), the other measures the temperature of the electronics ("14V temperature"). When the heat plate temperature reaches 85°C we set a fault. To protect the converter we begin to "de-rate" its output (reduce available power) when the temperature reaches 87°C. If the heat plate temperature should reach 105°C we will shut down the converter. It will start up again in a "de-rated" mode when the temperature falls below 100°C and the "14V Enable" (a requirement for initially going into conversion - see the 1D7 message, "Enable/Set point request") is toggled.

If the electronics temperature reaches 95°C we also set a fault. "De-rating" due to the electronics temperature begins at 95°C, and shut down occurs at 125°C. It will start up again in a "de-rated" mode when the temperature falls below 105°C. Both of these temperatures are monitored continuously (every 250msec) by the 48A status message. They both set DTC 14 when a fault occurs. DTC 14 cannot differentiate between the two, but of course you can look at the 48A message to see the actual temperatures.

One important note is this - When the Converter is operating in a “de-rated” condition, the heat plate temperature has highest priority on setting the de-rated output.

Wiring Reference Sheet

Wiring the U2C DC/DC Converter

Datasheets

Download Data Sheet

Document explaining how CAN works in the DC-DC converter

Webstore

Webstore: DC-DC Converter

Connectors and Plug Description

CAN Bus Connector

High Voltage Connector

==>>

HV Connector Change

As shown in the above figure, the circular HV connector has been changed to a square connector recently. The following are notes about the changes:

• Delphi's current HV connecter from Amphenol was selected by previous customers due to its use in other areas of their vehicle.
• Delphi-Packard (PED) has an existing HV header and mating connection system that has been applied by modifying the plastic body of the header. (ONLY)
• A small modification is required to the converter housing to accommodate the PED header connecter.
• The mating connecters are currently available from Packard
• Part Number for the Converter assembly with PED is: 28304007-01

General Specs

• Rated current - 12.7 A/15 A
• Voltage Level - 450 V (DC)
• Temperature Range - -40 deg C to +110 deg C

Contents of ASM-UNIV-HV-001

The connector kit provided by New Eagle would contain the LV connector, latest HV connector, ground lugs and ring terminal. Cable assembly is not a part of connector kit.