There are 2
different Dc to DC Converters supplied in your kit, one is 5v
the other is 12v. These are required to step down the voltage
from you Power Supply (24v, 36v, or 48v depending on the kit) to
a voltage usable by other devices in your kit. The 5v Converter
is intended for use with breakout boards requiring a 5V input
supply. The 12v Converter is primarily for the cooling fan but
can also be used for 12v gauges, pumps or other devices that you
may want to connect. Both coveters can supply up to 3 amps.
instructions will cover how to connect your DC to DC converter
to the Power supply.
AC Mains Power
can kill or seriously injure
DO NOT plug in
your equipment while you are working on it
changes to your board while it is powered up as it will
permanently damage it
1 x Mounted and
wired Power Supply
1 x Mounted 5v
DC to DC Converter
3 x Fork
1 x DC Wiring
Parts to be
- Terminal 1 - 24v DC + Out
- Terminal 2 - 24v DC + Out
- Terminal 3 - 24v DC + Out
- Terminal 4 - 24v DC - Out
- Terminal 5 - 24v DC - Out
- Terminal 6 - 24v DC - Out
- Terminal 7 - 240v AC Earth - In
- Terminal 8 - 240v AC Neutral - In
- Terminal 9 - 240v AC Live - In
- Power LED
- Minor voltage adjuster
- Power Supply input voltage selector 240v AC or 110v
- Cooling fan exhaust port
DC to DC
- Terminal 1 - DC+ 12V
to 48V Input
- Terminal 2 - DC- Common Ground to all circuits
(Terminals 2 & 3 on DC Converter Type 1)
- Terminal 3 - DC+ 5v Output (4th terminal on Type 1)
- 3mm Mounting points
- Heat sink
Required/Recommend Steps Before these instructions
Power supply via Power chassis with Auxiliary power panel.
Make sure your
kit is not powered on, unplug the lead from the wall socket.
Make sure power
supply is set to 240v and not 110v
will cover wiring the Power supply to the 5v DC converter or 12v
DC converter. Positions of parts and lengths of wires used
are for instruction only and may vary from your actual setup and
you will have to interpret/vary these instructions to meet your
the power supply to the 5v DC Converter
Roll out your
DC wire kit so it is flat. Make sure you have a Positive
and a Negative
It is highly recommended you use the correct
wire colours for
this will avoid confusion at a letter stage. Strip the
insulation off each of the wires
back 6mm (approx) and give each wire a twist to bind all the
loose fibers together.
terminals to the ends (these will connect to the
Power supply). These can be
crimped but soldering is preferred.
With a Philip's
head screwdriver loosen off the terminal screws 1 (labeled
and 4 (labeled -V).
Insert the "Positive" wire (Red) to terminal 1 and the
wire (Black) to terminal 4 on the power supply. Tighten screws
on terminals 1 and 4.
The next step
is slightly more complicated as we don't know the actual
wires needed to connect the DC Converter to the Power supply (as everyone's
we are going to have to measure them by running them from the
supply to the Converter. Leave the terminals connected at
the Power supply and run the
(Red) wire to Terminal 1 (DC in +) on the DC to DC
converter. Allow the
surplus wire to hang over
top or back or top of the converter. Now do the same thing with the "Negative"
wire, run it to Terminal 2 (DC - Common) on the DC Converter.
With the wires now
run to the Converter, allow another 6-10mm of wire as a
stripping allowance and cut off the remainder. Put the remainder
to one side as you'll need it for wiring other components. It's
important to have a small amount of additional wire length to
ensure the wires are not taught, taught wires can pull out of
their terminals as your enclosure goes through it's normal
heating and cooling cycles.
Strip each wire
back approx 6mm.
remaining fork terminal to the "Positive" (Red) wire. The
"Negative" (Black) wire will have a fork terminal attached in
latter instructions when connecting up to other devices and will
need to be combined with another wire.
With a Philip's head screwdriver loosen off the screws on
terminals 1 and 2 on the DC Converter. Connect the "Positive"
(Red) wire that leads from terminal 1 (DC+ Out) on the Power
supply to terminal 1 (DC+ In) on the DC Converter.
The last connection
is to connect the "Negative" (Black) wire that leads from
terminal 4 (DC- Out) on the Power supply to terminal 2 (DC-
Common) on the DC Converter. It will need to be inserted between
the two metal tabs of terminal 2. Tighten terminals 1 an 2 on
the DC Converter.
It's now time to
connect the power supply to power and test the DC to DC
under load. Make sure the Power switch on the
chassis is in the "Off" position.
Insert the power
into the chassis. Turn off your
wall socket and plug the
lead in. Turn on the wall socket and turn on your power
switch. The green LED on Power
supply should be on and (if fitted) the Active LED on the DC
to DC Converter should be
glowing. Some of the earlier converters may not have LEDs.
Observe the unit for a minute
or so to make
sure nothing is
wrong. If you have a multi-meter, you can test the output
voltage across terminals 2 (DC- Common) and 3 (DC+ Output). The
5v DC converter should read 5v and the 12, well - 12v. Remember
to turn it off when you are finished. Turn it off at
the switch then the power point and unplug it from
wall. Always unplug your
supply when not in use. After
turning off your power
supply, please wait at least
60 seconds before
turning it back on.
powered on and Power Supply active
Recommend Next Step
the JK02 Breakout board to the 5v DC to DC Converter