Bosch e-GoKart PowerTrain Young Star Manual page 35

5.3.3 DC/DC Converter
5.3.4 Power Unit PU 5-10
Bosch Motorsport
Overall Integration Requirements of e-GoKart System Components into the Superior Vehicle Context | 5
# In general, the DC/DC converter shall be installed so that sufficient air intake to cool the
components is guaranteed. Therefore at least 10 mm distance between the DC/DC con-
verter and chassis parts is needed.
Insufficient airflow will lead to derating behavior and decreasing of lifetime.
# If the DC/DC converter is installed in chambers, sufficient air exchange between DC/DC
charger chamber and environment outside shall be considered.
# Appropriate protection should be taken to prevent each wire isolation from being dam-
aged.
# The DC/DC shall be located in the vehicle such that electrical connections are not per-
manently exposed to water.
# Wiring harnesses of input and output leads must be routed with a certain distance to re-
duce a short circuit risk in case of mechanical damage of the wiring harness.
The Power Unit PU 5-10 shall be installed under consideration of:
– Sufficient air intake to cool the components of the Power Unit PU 5-10 shall be en-
sured,
– splash water protected installation position,
– dust-protected installation position,
– no critical radiant heat by other components,
– The Power Unit PU 5-10 needs to be protected against stone-chipping, mud and any
parts that could enter the Power Unit PU 5-10 which could cause a blocking (e.g. by
undercoating)
The power connection is realized via B+ and B- bolts designed as threaded pins.
# The connection of B+ conductor needs to be realized by a cable shoe.
– Thread of B+ bolt M8 x 12,
– min. required contact face (cable lug to B+ contact face) 125 mm²
– min. required conductor cross section 35 mm²
– tightening torque: 18 to 25 Nm
– max. allowed fixation torque: 25 Nm
– max. allowed loosening torque: 32 Nm
– max. allowed cable length up to next fixation: each max. 300 mm
# The connection of B- conductor needs to be realized by a cable lug.
– Thread of B- bolt M8 x 12,
– min. required contact face (cable lug to B- contact face) 125 mm²
– min. required conductor cross section 35 mm²
– tightening torque: 18 to 25 Nm
– max. allowed fixation torque: 25 Nm
– max. allowed loosening torque: 32 Nm
– max. allowed cable length up to next fixation: each max 300 mm
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