GODIYMODULES DC-DC High Voltage Boost Converter Module User Manual

1. Product Overview

The GODIYMODULES DC-DC High Voltage Boost Converter Module is designed to convert a lower DC input voltage (9-24V) into a higher, adjustable DC output voltage ranging from 220V to 450V. This non-isolated converter provides a stable output voltage even when the input voltage fluctuates. It is suitable for applications requiring high voltage DC power, such as magnetizing load capacitors, test fixtures, product pressure testing, and luminous tube power supplies.

Figure 1: Top view of the Boost Converter Module, highlighting input/output terminals and key components.

2. Safety Information and Warnings

WARNING: This board produces high voltage output. High voltage poses a significant hazard. Exercise extreme caution during installation and operation to prevent electric shock. Direct short-circuiting of the output is strictly prohibited.

• Ensure all connections are secure and correct before applying power.
• Do not touch the module or connected components when power is applied.
• Always disconnect the power source before making any adjustments or disconnections.
• If the power is large, the internal warranty component may burn out. This component needs to be replaced for the module to function again.
• When using lithium batteries or similar power supplies, ensure the protection board can withstand sufficient current. Insufficient current capacity can damage the protection board or lead to input undervoltage protection, preventing proper operation.
• Avoid using low-current, low-capacity batteries (e.g., 9V laminated multimeter batteries) as the primary power source for charging large capacitors, as this will result in very slow charging and rapid battery depletion.

3. Product Features

• Input Voltage: DC 9-24V (Lowest starting voltage: 8.4V)
• Output Voltage: DC adjustable 220V-450V (Maximum 450V output voltage remains stable even with varying input voltage)
• Power Output: 40W continuous working, up to 70W for intermittent operation. Output power is dependent on input voltage (higher input voltage yields higher output power, but output voltage remains regulated).
• Dimensions: 85 x 50 x 28 mm
• Undervoltage Protection: Yes (Voltage will not increase if input is less than 7.6V)
• Reverse Connection Protection: Yes
• Charging Indicator: LED illuminates when charging is complete.
• Charging Speed: Approximately 5 seconds to charge a 1000µF capacitor to 450V.

4. Specifications

5. Setup and Installation

This section outlines the general steps for connecting and setting up your boost converter module. Always ensure power is disconnected before making any connections.

1. Power Supply Selection:

   A stable DC power source is required. Recommended power supplies include a DC 12V lead-acid battery or a 3/4 series of 18650 batteries, capable of providing more than 7A of current. Ensure your power supply can meet the current demands, especially when charging large capacitors.

2. Input Connections:

   Connect your DC input power supply to the module's input terminals. Observe polarity: connect the positive (+) terminal of your power supply to the module's input positive, and the negative (-) terminal to the module's input negative. The module features reverse connection protection.

   

   Figure 2: Angled view of the module, showing connection points.
3. Output Connections:

   Connect your load (e.g., capacitor, test equipment) to the module's output terminals. Pay close attention to polarity. The output voltage is high, so ensure all connections are properly insulated and secure.

   For charging capacitors: The module uses a current-limiting mode on the low voltage side, which is suitable for charging capacitors. For capacitors up to 1000µF, direct connection is possible. For capacitors larger than 1000µF, it is recommended to add a 5W, 10-ohm cement resistor in series with the capacitor to manage initial charging current.

4. Initial Power-Up:

   After all connections are verified, apply power to the input. The module will begin operation. The output voltage can be adjusted using the onboard potentiometer (if present and accessible, typically a blue square component with a screw for adjustment).

6. Operating Instructions

The module is designed for straightforward operation once properly set up.

• Voltage Adjustment: The output voltage is adjustable from 220V to 450V. Use a suitable insulated tool to carefully turn the potentiometer on the module to set the desired output voltage. Monitor the output with a high-voltage-rated multimeter.
• Output Current: The output current is dynamic and depends on the output voltage and load. The maximum continuous power is 40W, with occupational peaks up to 70W. The approximate output current can be calculated as Power (W) / Output Voltage (V). For example, at 450V and 40W, the current is approximately 0.089A.
• Charging Status: An LED indicator will light up when the charging process (e.g., of a capacitor) is complete.

Figure 3: Close-up of the module, showing the voltage adjustment potentiometer.

7. Maintenance

The GODIYMODULES Boost Converter Module is designed for reliable operation with minimal maintenance. However, observing the following guidelines can prolong its lifespan:

• Keep Clean: Ensure the module is free from dust, dirt, and moisture. Use a soft, dry brush or compressed air for cleaning.
• Ventilation: Ensure adequate airflow around the module, especially if it is enclosed, to prevent overheating. The module features a heatsink for thermal management.
• Inspect Connections: Periodically check all input and output connections for tightness and signs of corrosion or damage.
• Component Integrity: Visually inspect the module for any signs of physical damage, burnt components, or bulging capacitors. If any damage is observed, discontinue use and replace the module.

Figure 4: Side view of the module, showing the heatsink.

8. Troubleshooting

This section addresses common issues you might encounter with the boost converter module.

• No Output Voltage / Module Not Boosting:
  • Check input voltage: Ensure the input voltage is within the 9-24V range and above the lowest starting voltage of 8.4V. If the input is below 7.6V, undervoltage protection will prevent boosting.
  • Check input current: Verify that your power supply can provide sufficient current (recommended >7A). If the input power supply is weak (e.g., low-capacity battery), the input voltage may drop significantly under load, triggering undervoltage protection or reducing charging speed.
  • Check reverse connection: The module has reverse connection protection, but always ensure correct polarity.
  • Inspect for damage: Look for any visible signs of burnt components, especially if the module was subjected to high power loads. A burnt component may need replacement.
• Unstable Output Voltage (under load):
  • Overload condition: If the output is overloaded beyond its continuous (40W) or occupational (70W) power limits, the output voltage may drop. Reduce the load.
  • Insufficient input power: A weak input power supply can cause the input voltage to sag, leading to unstable output. Ensure the input power supply is robust enough for the intended load.
  • Capacitor issues: If charging multiple capacitors in parallel, ensure each capacitor is tested individually first. Faulty capacitors or those with high leakage can prevent the output voltage from reaching the set value.
• Slow Charging Speed for Capacitors:
  • Input power supply: A low-current input power supply will significantly slow down charging. Use a power source capable of delivering sufficient current.
  • Capacitor size: Very large capacitors naturally take longer to charge.

9. Warranty and Support

This product is manufactured by GODIYMODULES. Specific warranty details may vary depending on the retailer and region of purchase. Please refer to your purchase documentation or contact your seller for warranty information.

For technical support or inquiries, please contact the manufacturer or your point of purchase. When contacting support, please provide your product model number (5fe83ce9-8401-4278-940f-4b2d6b538de7) and a detailed description of the issue.