High input voltage DC-DC converters with IP66-rated protection suit extreme environments

The HVI 500P-D3 series of ultra-rugged, high input voltage, IP66-rated DC-DC converters target extreme applications that require a waterproof, dust-proof, sand-proof, oil-proof solution. They are suitable for mining, marine, military, heavy industry, power generation and distribution, telecom and other severe environments.

The 500W converters accept a nominal input voltage of 600Vdc, with a 400V to 800V input range. To ensure high reliability and long operating life, all critical components on the primary side are designed and tested for corona inception levels that are significantly higher than the operating voltages. The design is verified for 5600Vdc input to output isolation, and production level testing is the 4300Vdc.

The converters offer output voltages of 24V, 36V, 48V or 110Vdc; custom output voltages available on request. An optional built-in redundancy diode allows for a number of units to be connected in parallel to achieve higher output power or N+1 redundancy. The output separation diode also makes the unit suitable for battery charging applications.

The HVI 500P-D3 conduction/convection cooled units are designed for operation over a -40°C to +70°C cold-plate temperature range at full specification. The internal converter module is entirely potted with a thermally conductive MIL-grade silicon rubber compound for immunity to high levels of shock and vibration, as well as cooling.

The converters are installed in IP66-rated waterproof, die cast aluminum packages with sealed connectors, which provide additional protection from the ingress of rain, humidity, sand, dust, oil and other contaminants. IP67-rated protection is available on request.

Depending on the target operating environment, ABSOPULSE IP66-rated converters employ application-specific vents which ensure that pressure inside the enclosures is equalized, strain on connectors is minimized and the environmental seal remains impermeable. These measures all contribute to the long-term reliability of the units.

The HVI 500P-D3G series utilizes ABSOPULSE′s new proprietary KHR 301 topology which enables a significantly more compact construction than earlier high input voltage designs at the same level of output power. The converters measure 360x160x90 mm.

If this design doesn’t meet your needs exactly, we will design and build one that does. Please contact us to discuss your application requirements.

Key Specifications

  • Ultra rugged, industrial quality converter;
  • Input: 600Vdc, 400V to 800V range (or custom);
  • Output: 24V, 36V, 48V or 110Vdc or custom;
  • -40°C to +70°C operating temp. range for full spec.;
  • IP66-rated diecast aluminum package;
  • Cable glands, sealed circular connectors, MIL connectors or cable glands;
  • Internal module fully encapsulated – MIL spec compound;
  • Application-specific vents for pressure equalization;
  • EMI: EN55022 Class A with margins;
  • Cooling: conduction and natural convection;
  • Ultra compact design: 406 x 320 x 94 mm (16 x 13.44 x 3.7″) – L x W x H.

Data sheet – HVI 500P-D3 (IP66) High input voltage DC-DC

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