DC-DC Converters | Echelon
1.5kW DC-DC Converter
Available in 72V, 96V, and 320V versions, this DC/DC converter delivers stable 9-16V DC output at up to 110A, with 1500W rated power and ≥94% maximum efficiency.
1.5kW DC/DC Converter for Electric Vehicles
Echelon Energy's 1.5kW DC/DC Converter (model PD-BC-1F-96Y) converts 64–128V DC from a 96V traction battery into a stable 9–16V DC output at up to 110A continuous for vehicle auxiliary systems. It delivers 1500W rated power (1800W peak for up to 6 minutes) at ≥94% efficiency, with forced air cooling, a 2.8kg housing, CAN Bus communication, and an enable signal. Three input-voltage versions are available — 72V, 96V, and 320V — all with the same 9–16V output; see Available Models below.
What Does a DC-DC Converter Do in an EV?
An electric vehicle's traction battery runs at high voltage — 96V in this converter's case — but the lights, controllers, instruments and other auxiliary equipment run on 12V-class power. A DC-DC converter sits between the two: it steps the high-voltage DC down to a stable low-voltage output, so every 12V load gets clean power even as the battery voltage rises and falls with charge and load.
Because the converter separates the high-voltage side from the low-voltage circuits, it also keeps the vehicle's 12V system safe to work with and protects sensitive electronics from voltage swings on the traction battery.
Key Features
✓ Available in 72V, 96V, and 320V versions
✓ 1.5kW rated output power
✓ 9-16V DC stable output
✓ 110A rated output current
✓ High efficiency ≥94%
✓ CAN Bus communication with enable control
✓ Forced air cooling design
✓ Multiple protection functions with self-recovery ✓ IP67 protection
Applications
Designed for:
- Electric commercial vehicles
- Electric utility vehicles
- Electric trucks
- Electric agricultural vehicles
- Special-purpose EVs
- Other electric vehicle auxiliary power systems
Typical Applications
Stable Power Supply for EV Auxiliary Systems
Electric vehicles require a reliable low-voltage power source to support different electrical components.
This DC/DC converter converts high-voltage battery power into stable 12V-class output, providing power for:
- Vehicle controllers
- Lighting systems
- Instrument panels
- Auxiliary electrical equipment
Is 1.5kW the Right Size?
Add up the continuous draw of everything on the 12V side — controllers, lighting, dashboard, pumps, fans and any auxiliary equipment — and compare the total with the converter's 1500W continuous rating. Loads that switch on together (for example lights plus a cooling fan) should be counted at the same time, not one at a time.
The 1800W peak rating covers short bursts of up to 6 minutes, not continuous operation. If your continuous total is well below 1500W, a smaller unit may fit better: the 500W DC-DC Converter for light 12V systems, or the 1kW DC-DC Converter (1200W rated) in between. If you also need onboard AC charging in the same housing, read OBC vs DC-DC Converter vs 2-in-1 Integrated Power Unit to compare a standalone converter with an integrated unit.
Reliable Performance & Protection
Designed for demanding EV operating environments, the converter integrates multiple protection functions to improve system safety and reliability.
Protection functions include:
✓ Input over-voltage protection
✓ Input under-voltage protection
✓ Output over-voltage protection
✓ Output over-current protection
✓ Short circuit protection
✓ Over-temperature protection
Available Models
The 1.5kW DC/DC Converter is available in three input-voltage versions. All three share the same 9-16V DC output, 110A output current, 1500W rated power, ≥94% efficiency, air cooling, and IP67 protection.
Parameter | PD-BC-1F-72 | PD-BC-1F-96 | PD-BC-1F-320 |
Input Voltage | 72Vdc | 96Vdc | 320Vdc |
Input Current | 32Amax | 25Amax | 6.7Amax |
Output Voltage | 9-16 Vdc | 9-16 Vdc | 9-16 Vdc |
Output Current | 110A | 110A | 110A |
Output Power | 1500W | 1500W | 1500W |
Efficiency | ≥94% | ≥94% | ≥94% |
Cooling Method | Air Cooling | Air Cooling | Air Cooling |
Protection Class | IP67 | IP67 | IP67 |
The Electrical Parameters table below covers all three versions. Cells marked — are not published for the 72V and 320V versions — s, contact Echelon for the full datasheet. The Protection Parameters, Safety Parameters, and Interface Definition tables further down show the 96V version (PD-BC-1F-96Y).
Technical Specifications
Electrical Parameters
Parameter | PD-BC-1F-72 | PD-BC-1F-96 | PD-BC-1F-320 |
Voltage Platform | 72V DC | 96V DC | 320V DC |
Input Voltage | 72Vdc (nominal) | 64-128V DC | 320Vdc (nominal) |
Input Current | 32Amax | 0-30A | 6.7Amax |
Output Voltage | 9-16Vdc | 9-16V DC | 9-16Vdc |
Rated Output Current | 110A | 110A | 110A |
Peak Output Current | — | 132A | — |
Rated Power | 1500W | 1500W | 1500W |
Peak Power | — | 1800W (6 minutes) | — |
Efficiency | ≥94% | ≥94% | ≥94% |
Parameter | PD-BC-1F-72 | PD-BC-1F-96 | PD-BC-1F-320 |
Voltage Adjustment Rate | — | ≤1% | — |
Load Adjustment Rate | — | ≤1% | — |
Voltage Control Accuracy | — | ≤1% | — |
Current Control Accuracy | — | ≤2% | — |
Ripple Voltage Coefficient | — | ≤2% @ rated working status | — |
Cooling Method | Air Cooling | Forced Air Cooling | Air Cooling |
Dimensions | — | 275 × 184 × 82 mm | — |
Weight | — | 2.8kg | — |
Communication | — | CAN Bus | — |
Protection Class | IP67 | IP67 | IP67 |
Protection Parameters
Parameter | Specification |
Input Under-Voltage Protection | ≤59V DC |
Input Over-Voltage Protection | ≥133V DC |
Output Under-Voltage Protection | 7±1V, resumes when voltage reaches ≥9±0.2V |
Output Over-Voltage Protection | 16±0.5V, resumes when voltage falls to ≤14±0.2V |
Output Over-Current Protection | Output stops above 132A |
Output Short-Circuit Protection | Self-recovery after troubleshooting |
Overheat Protection | Power derating from 100°C internal temperature, shutdown at 110°C, automatic recovery as temperature drops |
Safety Parameters
Parameter | Specification |
Ground Resistance | ≤100mΩ @ 25A/AC |
Input Insulation | 20MΩ @ 1000VDC |
Input Withstand Voltage | Leakage current ≤10mA @ 1500VDC, 3s |
Interface Definition
Interface | Connector | Terminals |
DC input | TE socket 2310540-4 / plug 2310537-4 | Positive (4mm²), Negative (4mm²), high-voltage interlock (0.35-0.5mm²) |
Signal control | ZJZ socket DJ7041-1.5-21 / plug DJ7041-1.5-11 | CANH, CANL, Enable (0.5mm²) |
DC output | M8 studs | DC+ / DC- |
Compare Echelon DC-DC Converters
Parameter | 1.5kW DC-DC Converter (PD-BC-1F-96Y) | ||
Rated power | 500W | 1200W | 1500W |
Peak power | 600W (6 minutes) | 1200W (6 minutes) | 1800W (6 minutes) |
Rated current | 36A | 72A | 110A |
Cooling | Natural cooling | Forced air cooling | Forced air cooling |
Weight | 1.35kg | 2.8kg | 2.8kg |
Communication | +12V enable line | CAN Bus | CAN Bus + enable |
All three models cover 96V battery systems with a 9-16V DC output range.
Communication & Integration
The DC/DC converter supports CAN Bus communication, allowing integration with EV control systems. The signal connector carries CANH, CANL and an enable signal, so the vehicle controller can monitor the converter and switch it on and off.
Designed with compact structure and vehicle mounting capability, it helps OEM manufacturers simplify low-voltage power system design.
What to Confirm Before Ordering
Every vehicle platform is different. Before ordering, it helps to confirm:
- Battery voltage platform and full input range (this model covers 64-128V DC)
- Required output voltage and continuous / peak current
- Total 12V load, including loads that run at the same time
- Installation space, airflow and ambient temperature around the mounting position
- Whether CAN Bus integration with the vehicle control system is needed
- Quantity, target market and any certification requirements
Send these details through thecontact page, or talk to our engineers about a customized configuration on the OEM/ODM page.
Customization: From Requirement to Production
Need a different voltage, current, cooling method or connector? Custom programmes follow three steps:
- Requirement review — send the vehicle platform, battery voltage and power the 12V system needs.
- Technical proposal and sample — our engineers confirm the configuration and build a sample for your platform.
- Testing, validation and production — the configuration is validated against the agreed specification, then released to series production.
Common Questions About the 1.5kW DC-DC Converter
What battery voltage is the 1.5kW converter designed for?
Three versions: 72V, 96V, and 320V. The detailed specifications on this page are for the 96V version, whose input range is 64-128V DC — it keeps working as the battery voltage moves across its full charge and discharge window.
What output does it provide?
A stable 9-16V DC output at up to 110A continuous (132A peak), 1500W rated power and 1800W peak power for up to 6 minutes.
How long can it run at 1800W?
Up to 6 minutes. The continuous rating is 1500W — size the converter on the continuous total of the 12V loads, not the peak.
How is it cooled?
Forced air cooling, with a fan built into the finned housing. Mount it where air can move around the unit.
What is the protection class?
IP67. The enclosure is dust-tight and protected against temporary immersion in water.
Does it support CAN communication?
Yes. The signal connector carries CANH, CANL and an enable signal for integration with the vehicle control system.
What connectors does it use?
A TE high-voltage input connector with interlock, a ZJZ signal connector for CAN and enable, and M8 studs for the DC output. See the Interface Definition table above.
What protection functions are built in?
Input over-voltage and under-voltage, output over-voltage and over-current, short circuit, and over-temperature protection with automatic recovery. Thresholds are listed in the Protection Parameters table.
What if my 12V loads add up to more than 1500W?
Contact Echelon to discuss a higher-power or customized configuration — or, if the vehicle also needs onboard AC charging, compare a standalone converter with an integrated unit in OBC vs DC-DC Converter vs 2-in-1 Integrated Power Unit.
Designed for OEM EV Platforms
From prototype development to mass production, Echelon Energy provides reliable DC/DC converter solutions for different electric vehicle applications.
Get in TouchEchelon Energy Technology specializes in onboard chargers, DC/DC converters, and integrated EV power solutions for commercial and specialty electric vehicles. Need help choosing the right DC-DC converter, or a customized configuration for your platform? Send us your requirements and our engineers will reply with a technical proposal. What to include in your message:
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