This document describes the Sure Electronics 500W Boost Converter for Car Audio, model TL494. It is a self-made DC/DC boost converter specifically designed for car audio applications, capable of converting a DC12V input into various higher DC voltages for powering amplifiers.
Function Description:
The primary function of the TL494 is to provide a stable and adjustable boosted DC voltage for car audio amplifiers. It takes a nominal 12V DC input and can output voltages of 18V, 24V, 30V, 36V, or 48V, with a maximum power output of 500W. The output voltage is selected using DIP switches, and fine-tuning is possible via an adjustable resistance (R27). The converter incorporates an Enable (EN) pin for external control, allowing the boost converter to be turned on or off. When the EN pin is suspended or grounded, the converter operates. When connected to DC12V, it will not work. An LED indicator provides visual feedback on the operational status, illuminating green when the converter is working normally.
Important Technical Specifications:
- Product Name: 500W Boost Converter for CAR Audio - TL494
- Input Voltage (Supply Voltage):
- Minimum: 11V
- Typical: 12V
- Maximum: 27V
- Low-voltage protection: 10V
- Over-voltage protection: 28V
- Output Power: Up to 500W
- Output Voltage Options (selectable via DIP switches): 24V, 30V, 36V, 40V, 48V
- 24V: K1 ON, K2 OFF, K3 OFF, K4 OFF
- 30V: K1 OFF, K2 ON, K3 OFF, K4 OFF
- 36V: K1 OFF, K2 OFF, K3 ON, K4 OFF
- 40V: K1 OFF, K2 OFF, K3 OFF, K4 ON
- 48V: K1 OFF, K2 OFF, K3 OFF, K4 OFF
- Output Voltage Fine-tuning: Adjustable via resistance R27
- Oscillation Frequency: 55KHz
- Quiescent Current (VIN=12V): 20mA
- Operating Temperature:
- Minimum: 0°C
- Typical: 20°C
- Maximum: 80°C
- Storage Temperature:
- Minimum: -20°C
- Typical: 20°C
- Maximum: 105°C
- Thermal Shutdown: 150°C
- EN Enabled Voltage: 12V
- Dimensions:
- Length: 4.80 inches (121.90 mm)
- Width: 3.60 inches (91.40 mm)
- Mounting Hole Spacing (Length): 4.40 inches (111.80 mm)
- Mounting Hole Diameter: 0.07 inches (1.90 mm) (4-R)
- Fuses: Input lines are protected by fuses.
- Cooling: Equipped with a smart cooling fan.
Usage Features:
- Ease of Use: The product is designed for straightforward integration into car audio systems. Output voltage selection is simplified through DIP switches.
- Adjustable Output: Users can select from several preset output voltages (24V, 30V, 36V, 40V, 48V) using DIP switches. For more precise voltage requirements, an adjustable resistance (R27) allows for fine-tuning. It is crucial to turn off the power before adjusting the DIP switches.
- External Control: The Enable (EN) pin offers flexibility for external control of the converter's operation. It works when suspended or grounded and turns off when connected to DC12V.
- Status Indication: A green LED indicator provides immediate visual confirmation of the converter's operational status.
- Wide Compatibility: Designed to be used with amplifiers from Sure Electronics and other car audio systems requiring boosted DC voltage.
- Robust Design: Features rigorous component selection, optimized layout, and testing to ensure performance stability.
- Quick Start Procedure:
- Unpack the product and inspect for any missing, damaged, or deformed components.
- Connect the converter according to the provided connection schematic (Figure 1-2). Use a DC12V power source and a multimeter for initial testing.
- The converter is deemed qualified if the indicator LED remains on and the output voltage matches or is similar to the selected value.
Maintenance Features:
- Durability: Built with high-quality components and robust design principles to ensure a long service life.
- Protection Mechanisms:
- Fuses: Input lines are protected by fuses to prevent damage from overcurrent.
- Low-voltage protection (10V): Safeguards the device from operating under insufficient input voltage.
- Over-voltage protection (28V): Protects against excessive input voltage that could damage components.
- Thermal Shutdown (150°C): Automatically shuts down the converter if it reaches an unsafe operating temperature, preventing heat-related damage.
- Cooling System: A smart cooling fan is integrated to ensure excellent heat dissipation, eliminating the need for an additional heat sink in most applications.
- Safety Precautions:
- Operate the product according to the relevant steps outlined in the manual to maintain optimal working condition and extend its service life.
- The warranty is void if damage results from incorrect use or negligence.
- Never immerse the product in rain or any humid environment to prevent fire or electric shock.
- Ensure the product is properly fixed and keep metal objects away from it to prevent short circuits or damage.
- Avoid using the product in extreme conditions.
- It is recommended to power the product with DC12V for one hour during initial setup or testing.
This 500W Boost Converter is a reliable and versatile solution for powering car audio amplifiers, offering adjustable output, robust protection features, and ease of integration.
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