Connecting the DC to DC Converter to the Power supply
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. These 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
Never make 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 terminals
1 x DC Wiring set
Parts to be sourced
No additional parts required.
Philips head screwdriver
Flat head screwdriver (small)
Soldering iron (optional)
- 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 AC
- Cooling fan exhaust port
DC to DC Converter
- 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
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
These instructions 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 own needs.
Wiring the power supply to the 5v DC Converter
Roll out your DC wire kit so it is flat. Make sure you have a Positive (Red) and a Negative (black) wire. It is highly recommended you use the correct wire colours for each step, 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.
Attach fork 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 +V) and 4 (labeled -V). Insert the “Positive” wire (Red) to terminal 1 and the “Negative 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 length of wires needed to connect the DC Converter to the Power supply (as everyone’s enclosure will be different). So we are going to have to measure them by running them from the Power supply to the Converter. Leave the terminals connected at the Power supply and run the “Positive” (Red) wire to Terminal 1 (DC in +) on the DC to DC converter. Allow the surplus wire to hang over the top or back or top of the converter. Now do the same thing with the “Negative” (Black) 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.
Attach the 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 Converter while not under load. Make sure the Power switch on the Power chassis is in the “Off” position. Insert the power lead into the chassis. Turn off your wall socket and plug the power 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 the wall. Always unplug your power supply when not in use. After turning off your power supply, please wait at least 60 seconds before turning it back on.
DC Converter powered on and Power Supply active
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