DC-DC Converters | Echelon
1kW DC-DC Converter
Fanless 1kW DC-DC converter for 48V, 72V and 96V EV platforms: 1000W rated power, 9-16V/72A output, ≥94% efficiency, natural cooling, IP67, CAN Bus.
1kW DC/DC Converter for Electric Vehicles (Fanless)
Echelon Energy's 1kW DC/DC Converter (model PD-BI-1A-72Y) converts 64–128V DC from a 96V traction battery into a stable 9–16V DC output at up to 72A continuous for vehicle auxiliary systems. It delivers 1000W rated power (1200W peak for up to 6 minutes) at ≥94% efficiency, with fanless natural cooling, a 2.8kg sealed housing rated IP67, CAN Bus communication, and an enable signal. Three input-voltage versions are available — 48V, 72V, and 96V — all with the same 1000W 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 48V, 72V, and 96V versions
✓ 1kW rated output power
✓ 9-16V DC stable output
✓ 72A rated output current
✓ High efficiency ≥94%
✓ Fanless natural cooling design
✓ IP67 protection
✓ CAN Bus communication with enable control
✓ CC/CV output
✓ Built-in reverse polarity protection
✓ Multiple protection functions with self-recovery
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 1kW 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 1000W 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 1200W peak rating covers short bursts of up to 6 minutes, not continuous operation. If your continuous total is well below 1000W, a smaller unit may fit better: the 500W DC-DC Converter for light 12V systems. If it is close to or above 1000W, step up to the 1.5kW DC-DC Converter. 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
✓ Reverse polarity protection (built-in, high-voltage input)
Available Models
The 1kW DC/DC Converter is available in three input-voltage versions. All three share the same 14V nominal output, 72A output current, 1000W rated power, ≥94% efficiency, air cooling, and IP67 protection.
Parameter | PD-BI-1A-48 | PD-BI-1A-72 | PD-BI-1A-96 |
Input Voltage | 48Vdc | 72Vdc | 96Vdc |
Input Current | 30A | 30A | 30A |
Output Voltage | 14 ± 0.2Vdc | 14 ± 0.2Vdc | 14 ± 0.2Vdc |
Output Current | 72A | 72A | 72A |
Output Power | 1000W | 1000W | 1000W |
Efficiency | ≥94% | ≥94% | ≥94% |
Cooling Method | Air Cooling | Air Cooling | Air Cooling |
Protection Class | IP67 | IP67 | IP67 |
The detailed specifications below are for the 96V model (PD-BI-1A-72Y). For the 48V and 72V versions, contact Echelon for the full datasheet.
Technical Specifications
Electrical Parameters
Parameter | Specification |
|---|---|
Model | PD-BI-1A-72Y |
Voltage Platform | 96V DC |
Input Voltage | 64-128V DC |
Input Current | 0-24A |
Output Voltage | 9-16V DC |
Rated Output Current | 72A |
Peak Output Current | 86A |
Rated Power | 1000W |
Peak Power | 1200W (6 minutes) |
Efficiency | ≥94% |
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 | Natural Cooling (fanless) |
Dimensions | 278 × 166 × 74 mm (mounting 256 × 131 mm) |
Weight | 2.8kg |
Communication | CAN Bus |
Protection Class | IP67 |
Protection Parameters
Parameter | Specification |
Input Under-Voltage Protection | 59V ±5 |
Input Over-Voltage Protection | 131V ±5 |
Output Under-Voltage Protection | ≤7V, resumes when voltage reaches ≥8±0.2V |
Output Over-Voltage Protection | ≥16V, resumes when voltage falls to ≤15±0.2V |
Output Over-Current Protection | Output stops above 86A |
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 |
Reverse Polarity Protection | Built-in, high-voltage input |
Safety Parameters
Parameter | Specification |
Ground Resistance | ≤100mΩ @ 25A/AC |
Input Insulation | 20MΩ @ 500VDC |
Input Withstand Voltage | Leakage current ≤10mA @ 2000VDC, 3s |
Interface Definition
Interface | Connector | Terminals |
DC input | FUTRONICS socket FHV200236CX-04U01Y / plug FHV600236CX-04U01Y | Positive, Negative (4mm²) |
Signal control | ZJZ socket DJ7031-1.5-21 / plug DJ7031-1.5-11 | CANH, CANL, Enable (0.5mm²) |
DC output | M8 | DC+ |
Fanless or Fan-Cooled: Which 1kW Converter Fits?
Echelon offers two 1kW DC-DC converters with the same output current. The difference is cooling — and the installation it suits.
Parameter | 1kW Fanless DC-DC Converter (this page) | |
Rated power | 1000W | 1200W |
Peak power | 1200W (6 minutes) | 1200W (6 minutes) |
Rated current | 72A | 72A |
Output voltage | 9-16V DC | 9-16V DC |
Cooling | Natural cooling, no fan | Forced air cooling |
Weight | 2.8kg | 2.8kg |
Communication | CAN Bus + enable | CAN Bus |
Protection class | IP67 | — |
Choose the fanless version for dusty or wet installations where a fan would be a weak point; choose the fan-cooled version when the 12V system needs the full 1200W continuous rating.
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; 48V and 72V versions are also available)
- Required output voltage and continuous / peak current
- Total 12V load, including loads that run at the same time
- Installation space and airflow around the finned housing — fanless cooling relies on air movement around the unit — 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 the contact 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 1kW Fanless DC-DC Converter
What battery voltages does the fanless 1kW converter cover?
Three versions: 48V, 72V, and 96V (PD-BI-1A-48, PD-BI-1A-72, PD-BI-1A-96). The detailed specifications on this page are for the 96V model (PD-BI-1A-72Y), whose input range is 64-128V DC.
What output does it provide?
A stable 9-16V DC output at up to 72A continuous (86A peak), 1000W rated power and 1200W peak power for up to 6 minutes.
How is it cooled without a fan?
Natural cooling through the finned aluminium housing. The fins dissipate heat to the surrounding air, so mount the unit where air can move around the housing. With no fan, there is no fan to fail, clog, or maintain.
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 FUTRONICS high-voltage input connector, a ZJZ signal connector for CAN and enable, and an M8 stud for the DC output. See the Interface Definition table above.
What is the protection class?
IP67. The enclosure is dust-tight and protected against temporary immersion in water.
What protection functions are built in?
Input over-voltage and under-voltage, output over-voltage and over-current, short circuit, over-temperature, and built-in reverse polarity protection on the high-voltage input. Thresholds are listed in the Protection Parameters table.
How is it different from the fan-cooled 1kW converter?
Both deliver 72A at 9-16V DC. The fanless version is rated 1000W with natural cooling and IP67 protection; the fan-cooled 1kW converter is rated 1200W with forced air cooling. See the comparison table above.
What if my 12V loads add up to more than 1000W?
Choose the next size up — the 1.5kW DC-DC Converter — or contact Echelon to discuss a higher-power or customized configuration.
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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