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1000W DC-DC converter tweaked for fuel cell powered vehicles

24 Oct 2013  | Paul Buckley

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Powerstax has recently included its Flexistax D1001 DC-DC converter module to its collection of power solutions aimed at next generation vehicles. The DC-DC converter module is rated at 1000W and is capable of supporting typical system efficiency levels of 86 per cent.

Based on the company's F501 brick technology, the module exhibits a high degree of operational flexibility, with an input voltage range covering 10VDC to 36VDC and a choice of 12VDC, 13.8VDC, 15VDC, 24VDC, 28VDC, 32VDC and 48VDC standard outputs. The attributes mean that the modules are highly optimised for the electric or fuel cell powered vehicle market.

A 4-channel boost converter enables DC voltages to be stepped up or down as required. This boost converter delivers a non-isolated bus voltage that drives the two parallel configured brick converters—so that the regulation, isolation (2200VDC) and stability (<2 per cent peak-to-peak ripple) needed by modern, sophisticated electronics can be fully realised. Conduction cooled using a baseplate, the D1001 has an operational temperature range that spans from -25°C to 85°C.

With a compact form factor measuring just 238x145x30.85mm, this open construction unit can be cold wall mounted—allowing the baseplate temperature to be kept at 100°C or below without the need for complex, expensive thermal management. An array of protection mechanisms are incorporated into the module to ensure functional longevity. These include an I2C temperature sensor to prevent overheating and an automatic reverse polarity to safeguard against mixing up of power connections. In addition to specification in automotive designs, these DC-DC converter products are also highly suited to implementation in remote battery; generator or fuel cell powered sites (such as mobile infrastructure and industrial monitoring stations), back-up power systems, as well as various up-mast applications. They are fully compliant with the EN60950-1 safety standard.

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