Solectria Renewables DC-DC 750 User manual

Solectria
DC-DC 750
Converters
Owner’s Manual
First Edition
Solectria Corporation
33 Industrial Way
Wilmington, Massachusetts
01887

1
11
1
Foreword
Caution
The information provided in this manual is intended for use by persons with
appropriate technical skills. Any effort to perform repairs to, or service your
unit without the proper tools or knowledge required for the work can result
personal injury and product damage.
How To Report Errors
If, while reading through this manual, you discover an error in the technical
information provided, Solectria asks that you notify its Customer Service Department
at the phone number provided in your warranty. Please be prepared to provide the
following information:
• Your name
• Name and edition of your manual
• Page number(s) where the error(s) appear
• Serial number of your unit
Please feel free to call with any suggestions that you may have regarding the content of your
manual.
2000 Solectria Corporation All Rights Reserved
No part of this manual may be reproduced, stored in any retrieval system, or transmitted in any
form or by any means (including but not limited to electronic, mechanical, photocopying, and
recording) without the prior written permission of Solectria Corporation. This applies to all text,
illustrations, tables, and charts.

DCDC750: 150-250V, 13.2V
200V-400V, 12V
200-400V, 13.2V
200-400V, 24V
2
22
2
Table of Contents
Table of ContentsTable of Contents
Table of Contents
Foreword _______________________________________________________________________ 1
How To Report Errors ____________________________________________________________ 1
Safety___________________________________________________________________________ 1
Overview________________________________________________________________________ 1
Applications and Features _________________________________________________________ 1
Available and Custom Options______________________________________________________ 1
Specifications ____________________________________________________________________ 1
Dimensions ______________________________________________________________________ 6
Installation _________________________________________________________________ 7
Environment_____________________________________________________________________ 7
Connections _____________________________________________________________________ 9
Warranty __________________________________________________________________ 10

DCDC750: 150-250V, 13.2V
200V-400V, 12V
200-400V, 13.2V
200-400V, 24V
3
33
3
Safety
Warning Labels
Notices will be located on the right-hand side of the page to indicate areas in a procedure where
precautions should be taken. In areas of a procedure where safety equipment is needed or
hazardous conditions may exist, you will find the following symbols:
Hearing Protection Required Eye Protection Required
Risk of Electrical Shock Risk of Burns from Battery Acids
Always follow any safety instructions that are given at the beginning of a procedure. If you are
uncertain as to the safe and proper handling of your unit, contact the Solectria Customer Service
Department.
WARNING
(Indicates the serious risk
of personal injury or
damage to your unit)
CAUTION
(Indicates the possibility
of personal injury or
damage to your unit)
DANGER
(Indicates the risk of
being killed)

DCDC750: 150-250V, 13.2V
200V-400V, 12V
200-400V, 13.2V
200-400V, 24V
4
44
4
+
-
Anderson
(12V=gray
24V=blue)
Deutsch
DC-DC750 Converters
12V and 24V
Drawing is shown without the looms that protect the wires.
A
+
B
-
14awg white
14aw
g
g
reen/
y
ellow
INPUT
OUTPUT
Fuseholde
r
8awg white
8awg black

DCDC750: 150-250V, 13.2V
200V-400V, 12V
200-400V, 13.2V
200-400V, 24V
5
55
5
Overview
This sealed, solid-state DC-DC Converter takes a
range of input voltages and delivers a fixed 12, 13.2
or 24VDC output (depending on model) VDC at a
maximum of 63A to run your vehicle's accessories
such as fans, lights, horn, etc. The unit is very
efficient and has high power-to-weight and power-to-
volume ratios.
Applications and Features
These DC-DC Converters are fully automatic. The
input supply voltage can be turned on whether or not
the load is connected. The device will achieve 12,
13.2 or 24VDC output (depending on model) within a
fraction of a second after input is connected.
The unit also includes:
• Modular packaging
• High efficiency
• Factory-adjustable output voltage
• Heat sink thermal protection
• Automatic “shutdown” (over-current)
• Low “idle” power use
• Over output voltage shutdown
This unit is not to be used to charge batteries.
See the DCDC750BC data sheets for information on
units designed to operate with 12/24V batteries. Also,
this unit is not designed to be used in parallel with 2nd
or 3rd units on same circuit. If more than 750W is
needed, use separate circuits with one DCDC750 on
each circuit.
Interface package includes mating connectors and
mounting hardware.
Available and Custom Options
• 100-CFM cooling fan with mounting brackets
(helps maintain high output power)
• Custom output voltages available (factory-tuned)
An engineering fee applies to all customized orders.
Specifications
Output Voltages 12V, 13.2V or 24V
(depending on model)
Input Voltages
(Output Voltages)
150V-50V (13.2V)
200V-400V (12V)
200V-400V (24V)
200V-400V (13.2V)
Output Power 750W
Efficiency 85-90%
Current Peak @ 12V 63A
Current Peak @ 24V 32A
Weight 3.1kg
Operating Temperatures -40°C to +85°C
Fuses
150V-50V (13.2V)
8A midget
200V-400V (12V)
5A midget
200V-400V (24V)
5A midget
200V-400V (13.2V)
5A midget

DCDC750: 150-250V, 13.2V
200V-400V, 12V
200-400V, 13.2V
200-400V, 24V
Specifications
6
66
6
Dimensions

DCDC750: 150-250V, 13.2V
200V-400V, 12V
200-400V, 13.2V
200-400V, 24V
Installation
7
77
7
WARNING
Cooling air of 100CFM on
the heat-sink fins must be
maintained at all times, or
your unit will shut down.
Installation
Environment
Moisture
Your converter should be kept dry at all times. The unit is factory sealed to withstand moisture, but is
not waterproof. Use the following guidelines regarding placement of your unit:
• Avoid locations were your unit will be routinely exposed to water.
• Do not wash your unit with a pressure sprayer. Large amounts of water will cause a
malfunction.
• If you have reason to believe water has entered the unit, Do Not open the case. Disconnect
your unit and return it for service as soon as possible. Units with extensive water damage
may not be repairable. Units returned to Solectria with the factory seal broken will be
ineligible for warranty service.
Cooling Air Requirements
Ample airflow must be available to cool your converter. Your unit is forced-air cooled because this
gives greater overall electrical efficiency.
Your units’ performance and lifetime will both be reduced if cooling air is not
available. If your unit is running at a temperature of 75°C or greater, the output
current will be limited to 50% of the rated maximum.

DCDC750: 150-250V, 13.2V
200V-400V, 12V
200-400V, 13.2V
200-400V, 24V
Installation
8
88
8
To check for proper airflow, operate the unit under the most demanding conditions for 15 minutes.
Exhaust air temperature measured at the cooling fins should not exceed 65°C during this period. The
unit should not be routinely exposed to ambient temperatures above 65°C unless equipped with high-
power cooling fans designed for warmer climates.
Once you have decided upon a location for your unit, you can now mount it into position using the
unit’s flanges, industrial tape or Velcro.

DCDC750: 150-250V, 13.2V
200V-400V, 12V
200-400V, 13.2V
200-400V, 24V
Installation
9
99
9
Connections
There are two connections that must be made to operate your converter. Be certain that your low-
voltage input harness is connected to your 12V system. Make the 2-pin Anderson SB-50 low voltage
output system connection to your low-voltage input harness, as shown in
photos one and two.
Low Voltage Output: Anderson Connector
Photo One Photo Two
To bring high voltage input power to your unit you must connect the three-pin, two-wire high-
voltage input Deutsch connector to your high-voltage output harness, as shown in photos three and
four.
Photo Three Photo Four
High-Voltage Input: Deutsch Connector
Operation of your converter begins as soon as the unit is connected to a power source.
If your unit is not operating after having been linked to a power source, carefully check for possible
loose connections. If you are still experiencing difficulties in getting your unit to begin operation, call
the Solectria Customer Service Department at the number provided in your warranty.
Reminder
A
lways use connector
grease for all Anderson
SB-50.

DCDC750: 150-250V, 13.2V
200V-400V, 12V
200-400V, 13.2V
200-400V, 24V
Warranty
10
1010
10
Warranty
In an effort to keep our customers completely satisfied with the quality and performance of items purchased from
Solectria, the following warranty policy applies.
Solectria Corporation shall pay for the repair or replacement (at our option) of any component found to be defective
due to flaws in materials and/or workmanship within the first 12 months following the date of sale with no (US$0.00)
deductible, with the exceptions noted below. The customer shall pay for the shipping cost (UPS ground) to return the
unit(s) to Solectria. For warranty repairs and replacements, Solectria will pay the shipping costs (UPS ground) of
returning the unit to the customer. Solectria will not pay for the cost of rush delivery.
For the purpose of this warranty, components include but are not limited to motors, motor controllers, DC-DC
converters, battery chargers, amp-hour counters, etc.
This warranty does not cover:
• Products that have been opened, tampered with, or modified in any way.
• Items defined as routine maintenance.
• Damage caused by misuse, accident, alteration, lack of maintenance, inadequate packaging or use of
incorrect lubricants.
• Damage or corrosion caused by exposure to after-market products, the environment, or chemical treatments,
and;
• Wear items including but not limited to extension cords, plugs, connectors, cables, and enclosures.
In the event that it becomes necessary to return a product to us for service, call ahead for a Return of Merchandise
Authorization Number to help expedite the repair. Any item being returned should be wrapped securely in the original
or similar packaging to prevent damage in transit. Use the following guidelines for packing your unit for return shipment.
Keep your shipping carton!
Your carton is specially designed to prevent shipping damage to the metal case and cable connectors of your unit. If
the carton is lost, Solectria will supply a replacement carton for a fee.
If the unit must be shipped immediately, you must triple-wrap it with large cell bubble-pack and place it securely in a
double-walled, corrugated carton for shipment back to Solectria. Any repair costs for the unit that are associated with
case damage due to improper shipment will be borne by the carrier or the customer and will affect your warranty.
Customer will be charged an evaluation fee for Non-Warranty items returned to Solectria Warranty items returned to
Solectria that are found operable will also incur an evaluation fee. Call Solectria’s Customer Service Department for
details.

DCDC750: 150-250V, 13.2V
200V-400V, 12V
200-400V, 13.2V
200-400V, 24V
Warranty
11
1111
11
Returned items should be sent to:
Solectria Corporation
Component Repair Department
33 Industrial Way
Wilmington, MA 01887
USA
All items returned for repair must include a letter indicating, return address and contact, model number, serial number,
date of purchase (or receipt of purchase), and reason for return. If this information is not provided the repair will be
delayed.
Customer will be charged an evaluation fee for Non-Warranty items returned to Solectria. Warranty items returned to
Solectria that are operable will incur an evaluation fee.
Please call Solectria’s Customer Service Department at 978-658-2231, fax us at 978-658-3224, or email us at
[e-mail] if you have any questions.