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4.24 High Voltage DC-DC Converter
There are two (2) variants of the DC-DC Converter mentioned in this manual. There is an epoxy, potted style which
was in production since compressor inception and there is the open frame DC-DC converter that was released to
production as replacement of the potted style in April 2019. The removal and installation of the two (2) variants are
very similar. The open frame style utilizes six (6) mounting fasteners while the potted style uses eight (8). The open-
frame style utilizes three (3) connectors whereas the potted style uses four (4). The open frame design no longer
uses the 15VAC trigger signal from the Soft Start, thus eliminating the need for 15VAC on the DC-DC.
The open frame DC-DC Converter is fully backwards compatible, and it works with all of the voltage applications.
The potted DC-DC Converter is specific to a given voltage.
4.24.1 DC-DC Converter Function
The DC-DC Converter provides the Backplane with +24VDC (with respect to 0V) and HV+ (+250VDC with respect to
HV-) for the Bearing PWM Amplifier.
DC bus voltage (460-900VDC) is supplied to the Potted DC-DC converter through the Closed-Top Soft Start Board F1
fuse. DC bus voltage (460-900VDC) is supplied to the Open Frame DC-DC converter directly through the AC/DC
harness.
The Closed-Top Soft Start Board also powers the potted-style DC-DC Converter with 15VAC when the DC bus has
reached minimum level.
Refer to Figure 4-229 Potted DC-DC on page 206 andFigure 4-230 Open Frame DC-DC on page 206 for the DC-DC
Converter input-output (I/O) connections:
Inputs:
l
J1 Bus Input
l
J4 15VAC (potted version only)
Outputs:
l
J2 250VDC
l
J3 24VDC (potted) J4 24VDC (open frame)
4.24.2 DC-DC Converter Verification
4.24.2.1 Input Voltage Verification
1. Isolate the compressor power as described in Section 1.8 Electrical Isolation on page 22.
2. Install the DC bus test harness. Refer to Section 1.10.1 General Verification and Installation of the DC
3. Turn on the mains power to the compressor.
4. Using the DC bus test harness, verify the expected voltages are present. Refer to Table 4-18 Expected
4.24.2.2 Output Voltage Verification
1. Remove the Service Side Cover. Refer to Section 4.1.3.1 Service Side Cover Removal and Installation on
2. Provided the Input Voltage is correct, with mains power on, using a multimeter set for DC voltage
measurements, place the multimeter leads in the HV+ and HV- test points on the Backplane. Refer to
Figure 4-239 Backplane Test Points on page 213 for this and the following step. The result should be
220 – 280 VDC.
3. Place the multimeter leads in the +24 and 0V test points on the Backplane. The result should be 22 – 26
VDC.
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