Converter DC-DC 10A 8.5-48V to 10-50V 250W

DSC_7007

DSC_6994

The module arrived in a antistatic bag in a envelope

DSC_6995



Measurements

All the test is published here


Load%20sweep%209V%2012V

This is about the minimum output voltage, it maintain voltage nicely up to 7A, then drops to below input voltage and continues to supply current, this is standard boost regulator behaviour. I do not expect the over current protection to help with this.

Load%20sweep%209V%2018V

The boost regulator destroyed itself when I tested with 18V output and a power source limit of 15A. I changed to 8A limit and used a second module. Boosting from 9V to 18V means a bit below half current in output.

Load%20sweep%2015V%2024V

Boosting 15V to 24V, here the efficiency is good

Load%20sweep%2024V%2048V

Boosting 24V to 48V also looks good, generally the module works fine as long as the current is limited.

Voltage%20sweep%200.1A%2036V%20input%20current

Voltage%20sweep%200.1A%2036V

A low load and and a voltage sweep from 36V down to 0V, the module mains output to about 7.5V where it do some strange stuff including higher output voltage!

Voltage%20sweep%201A%2036V%20input%20current

Voltage%20sweep%201A%2036V

With 1A load it again maintains voltage down to 7.5V, where the current increases slightly above 8A, this kills this module!

Voltage%20sweep%201A%2048V%20input%20current

Voltage%20sweep%201A%2048V

I did get a curve with 48V output and 1A load, here it worked fine.

No%20load%20voltage%20sweep%2048V

Without load the module must still keep the boost converter running, how much power it uses depends on input and output voltage. Worst case looks to be about 60mA.



With two dead modules I stopped testing this converter



A closer look

DSC_6995

The diode at the input is mounted in reverse polarity and will short the input if polarity is swapped, both input and output capacitors are in parallel, i.e. the maximum voltage is 50V.

DSC_7008

With the module dead I had no problem with removing the inductor, the mains switcher controller is a TL494C and the switching transistor is NCE6075K. The zener diode (ZD1: 15V) and nearby transistor (Q1) is the voltage regulator for the switcher IC, it is only rated for 41V.
In both modules it is the switching transistor that died.

DSC_6997

DSC_6998 DSC_7000


DSC_6999

DSC_6996

This aluminium bottom makes it easy to mount the converter on a heatsink and with up to 10W loss in the module it may be necessary.

DSC_7001




Conclusion

The module works fine to boost voltage, but the over current protection and maximum current is not something to depend on.
But without noise and on/off test I will not conclude anything about the modules, except they are not that robust.