IP67 2 In 1 Automotive PDU Power Distribution Unit Car DC DC Pre Charge Board

IP67 2-in-1 Automotive PDU with DC/DC Converter & Pre-Charge Board

Product Overview
The IP67 2-in-1 Automotive Power Distribution Unit (PDU) integrates a high-voltage DC/DC converter and a pre-charge circuit into a single compact module, designed specifically for electric vehicles (EVs) and hybrid electric vehicles (HEVs). This multi-functional device streamlines power management by combining critical functions—voltage conversion, distribution, and safe startup—into a ruggedized package rated for harsh environments.

Key Features

1. Dual-Function Integration
   • DC/DC Conversion: Steps down high-voltage battery output (300-800V DC) to 12V/24V DC for low-voltage systems (lighting, ECUs, infotainment).
   • Pre-Charge Circuit: Gradually charges capacitors during system startup to prevent inrush currents, protecting connectors and extending component lifespan.
2. IP67 Environmental Protection
   • Dust-tight and waterproof enclosure (immersion-resistant up to 1 meter for 30 minutes) ensures reliability in off-road, marine, or heavy-duty applications.
3. Safety & Compliance
   • Built-in overvoltage/undervoltage protection, thermal shutdown, and short-circuit safeguards.
   • Meets automotive standards (ISO 16750, LV123) and EMC requirements (CISPR 25).
4. Compact & Modular Design
   • Space-efficient layout reduces wiring complexity and installation time.
   • Compatible with central power distribution architectures in EVs, buses, and commercial vehicles.

Applications

• Battery Electric Vehicles (BEVs) and Plug-in Hybrids (PHEVs)
• Off-road EVs (construction machinery, mining trucks)
• Marine electric propulsion systems
• Autonomous vehicles requiring robust power management

Technical Specifications

DC/AC Basic Specification

Name	Specification	Remarks
Applicable motor	Three-phase AC synchronous and asynchronous motors
Rated power (KW)	15KW
Peak power (KW)	18.5KW
Rated DC input current	39A
Peak DC Input Current	58.8A	1 min.
Rated Output Current	32A
Peak Output Current	48A	1 min.
Overload capacity	150% 1min.；200% 0.5s(Inverse-time Characteristics)
Rated Condition Drive Efficiency (%)	≥95%
Input Voltage Range	DC250V(undervoltage point)~DC750V(overvoltage point)
Output frequency range	0.00~320Hz
Overall Dimension	349*340*158mm（W*D*H）	Unit：mm
Weight (kg)	Approx. 15 kg
Cooling method	Air-cooled
Speed control range	1：200	Vector control performance without speed sensor
Speed control accuracy	±0.2%
Starting torque	0．5Hz，180%
Torque response time	＜10ms
Torque control accuracy	±7.5%
Reliability	To ensure 3 years or 150,000 kilometers of normal use, if there is a problem, the manufacturer needs to provide the cause analysis and solution measures within 48h.
Noise	≤60dBA
Communication method	CAN
Other function	Speed control, torque control, speed/torque control switching, speed limitation, torque limitation, flexible function code visibility, three sets of fault records, over-excitation braking function, over-voltage stall, under-voltage stall, power-down restart function, frequency jumping function, frequency binding function, parameter identification of asynchronous machines, weak magnetism control function, high-precision torque limitation, fault reset.
Protection Function	Over-temperature and low-temperature protection; motor controller and motor overload protection, phase-to-phase short-circuit protection; over-current, over-voltage, under-voltage, phase-loss, out-of-phase, out-of-speed, temperature disconnection, encoder disconnection protection.
Storage Temperatur	-40℃~+85℃
Protection level	IP67
Operating Temperature	-25℃~+55℃, derating above 55℃, rated output current decreases by 3% for every degree of elevation.
Altitude	Below 2000 m, derated for use above 1000 m, rated output current reduced by 3% for every 100 m of elevation
Sweep vibration	3.5mm,2~9Hz;10m/s2,9~200Hz;1510m/s2,200~500Hz
Withstanding Voltage	AController power supply +, -, motor U, V, W to ground (shell) dielectric strength can withstand the duration of 1 minute 2500V AC voltage leakage current less than 10mA
Insulation resistance	Test insulation resistance steady state must be greater than 20MΩ
Humidity	5~95%, condensation not allowed
Safety grounding	The resistance between the conductive part accessible to the controller and the grounding point of the housing is less than 0.1Ω.

DC/DC/Basic Specification

Name	Specification	Remarks
Input Voltage Range	400-750Vdc
Rated Input Voltage	450-750Vdc	No reduction in this range
Maximum input current	9A
Rated Output Voltage	DC27.5±0.3V
Rated output current	110A
Rated output power	3000W
Output efficiency	Typical: 96% (540Vdc input, ≥50% LOAD)
Output Range	DC17–19V undervoltage protection (recoverable);DC32 – 33V overvoltage protection (recoverable)
Voltage Regulator Precision	±2%
Ripple Voltage	≤500mVp-p
Control Method	CAN communication
Input Rated Voltage	540Vdc
Input undervoltage	Undervoltage 390Vdc±5V, recovery point voltage 395Vdc±5V
Input overvoltage	Overvoltage 770Vdc±10V, recovery point voltage 750Vdc±10V
Output undervoltage protection	DC17–19V	self-recovery
Output overvoltage protection	DC32—33V	self-recovery
Output overcurrent protection	125±5A	self-recovery
Output short circuit protection	Can be short-circuit protection; continuous short-circuit 10 cycles of power supply lock protection, re-power can be recovered
Over Temperature Protection	Derating output when the aluminum substrate temperature is above 85°C;Output shutdown when the temperature is higher than 100°C;When the temperature is lower than 90 ℃ the output is automatically restored	Detects internal module temperature, self-recovering
DC/DC communication	CAN2.0