DC/DC converters for demanding applications, ranging from industrial, railway systems, and satellites to communications and information technology equipment (ITE), are required to meet stringent requirements. They call for enhanced performance and high reliability, including operating in extreme conditions, while often requiring compact designs.
Over the past year, DC/DC converter manufacturers have focused on providing higher efficiency, offering greater flexibility with more options, saving board space with smaller packages, and delivering more cost-effective solutions. These devices are available in a variety of form factors, including brick types, DIPs, and modules.
Here’s a sampling of DC/DC converters introduced over the past year that deliver improvements in performance and packaging while providing the right-sized features for the application.
Meeting demanding requirements
Many of the latest families of DC/DC converters are designed to operate in demanding and harsh environments, including industrial, railway, ITE, and communications. They also often need to fit into tight spaces.
XP Power recently developed a family of DC/DC converters for space-constrained applications in demanding environments such as industrial, ITE, and communications systems. The BCT40T series of 40-W DC/DC converters offer high power density in a 1 × 1-inch (25.4 × 25.4-mm) package.
The BCT40T series features high efficiency, up to 89% depending on the model, and remote on/off functionality to enable energy savings and safe shutdowns. The series offers a wide 4:1 input voltage range, enabling operation across multiple input voltages. Models are available with nominal 24-VDC inputs (ranging from 9.0 V to 36.0 VDC) and 48-VDC inputs (ranging from 18.0 V to 75.0 VDC).
The devices operate over a wide operating temperature range of −40°C to 105°C and a broader full-load operating temperature range than many alternatives, XP Power said.
The BCT40T offers single regulated outputs ranging from 3.3 V to 24 VDC, as well as dual regulated outputs at ±12 VDC and ±15 VDC. The single-output models offer the flexibility of ±10% output voltage adjustment via an external trim resistor, enabling specific voltage requirements.
Targeting applications such as test and measurement, robotics, process control, analytical instruments, and communications equipment, these DC/DC converters feature an ultra-compact metal package that saves printed-circuit-board (PCB) area and allows more room for customer application circuitry, according to XP Power. In addition, these devices are smaller than many 40-W alternatives, which typically come in larger, 2 × 1-inch (50.8 × 24.4-mm) packages, reducing required board space by 50%.
The series meets worldwide safety approvals, including IEC/UL/EN62368-1 standards, as well as applicable CE and UKCA directives. It also complies with EN55032 Class A/B for conducted and radiated emissions and EN61000-4-x for immunity. The BCT40T series is available now.
Murata Manufacturing launched a high-performance, 1-W DC/DC converter with reinforced isolation and ultra-low capacitance, targeting communications and analog front-end measurement circuits.
The NXJ1T series addresses the need for robust isolation, delivering high electrical isolation, noise immunity, and thermal reliability for industrial, energy, and medical applications with 4.2-kVDC isolation (Hi Pot Test) and compliance with UL62368 safety standards.
The NXJ1T series, housed in a compact, 10.55 × 13.70 × 4.04-mm footprint, is designed for safety and durability in demanding environments. It features an unregulated, 1-W 5-V input to 5-V/200-mA output design, which is suited for embedded systems.
Each device delivers reinforced insulation to 200 Vrms and basic insulation to 250 Vrms. This adds a layer of protection in high-voltage environments. The undervoltage lockout (UVLO) functionality enhances operational stability, which prevents erratic behavior under fluctuating power conditions, Murata said.
These devices can also be used in medical equipment, where low leakage current is critical for patient-connected applications. They feature ultra-low isolation capacitance, which helps minimize unwanted leakage, supporting compliance with stringent safety standards such as IEC 60601-1 when used within a certified system, the company said.
The DC/DC converters also leverage proprietary molding technology, providing high ingress protection against dust and particulates in harsh industrial environments and extreme temperatures. The device has successfully undergone 1,000 temperature cycles between −40°C and 125°C, demonstrating its ability to withstand the highest levels of thermal stress, Murata said.
The series also uses Murata’s proprietary block-coil transformer technology, providing high isolation and low leakage current, and facilitates lower switching frequencies (500 kHz to 2 MHz) and higher efficiencies of approximately 80%.
The result is exceptional common-mode transient immunity and significantly lower isolation capacitance, according to Murata, making it suited for high-performance power isolation in electrically noisy environments.
Recom GmbH developed a 20-W DC/DC converter in a compact, 1.6 × 1 × 0.4-inch (40.6 × 25.4 × 10.2 mm) package, calling it a new level of high efficiency in DC/DC performance. The RPA20-FR series, targeting rail applications, delivers 20 W over its full 36-VDC to 160-VDC input range (200-VDC peak for 1 second) from −40°C to 70°C and 105°C with derating.
The series offers fully regulated, low-noise, and protected single outputs (5 V, 5.1 V, 12 V, 15 V, and 24 VDC), trimmable by +20%/−10% minimum, with ±5-V, ±12-V and ±15-VDC options available. The devices feature remote on/off control with positive or negative logic, UVLO is included, and no minimum load is required.
The parts are designed specifically for rolling stock applications with nominal input voltages of 48 V, 72 V, or 110 VDC. They are EN 45545-2– and EN 50155–compliant and meet UL/IEC/EN 62368-1 for audio/video and IT applications. Full 3-kVAC/1-minute reinforced isolation is provided, and the parts comply with EMC “Class A” levels as well as rail EMC standard EN 50121-3-2. A separate protection module, RSP150-168, is available to protect against surges according to RIA12 and NF F01-51 standards.
The RPA20-FR series meets environmental standards required for rail applications, particularly EN 45545-2 for fire protection, EN 60068-2-1 for dry and damp heat, and EN 61373 for shock and vibration. Mean time between failure is rated over 1.5 Mhrs at 25°C according to MIL-HDBK-217F GB.
Cincon Electronics Co. Ltd. recently launched the EC3AW8 and EC4AW8 series, delivering 3 W and 6 W of regulated power, respectively, tailored for demanding industrial environments. Applications include instruments, industrial automation and control systems, telecom and data communication equipment, test and measurement, IPC and embedded systems, and IT systems.
The EC3AW8 and EC4AW8 DC/DC converters feature an ultra-wide 8:1 input voltage range. They are available with single-output voltages of 3.3, 5, 12, or 15 VDC and dual outputs of ±5, ±12, or ±15 VDC, and they offer an optional positive remote on/off control for ease of system integration.
With an ultra-wide input range from 9 to 75 VDC, the EC3AW8 and EC4AW8 series are suited for industrial and IT power systems such as 12 V, 24 V, and 48 V. They deliver high efficiency up to 87% and ensure reliable performance under harsh conditions. The operating temperature range is −40°C to 105°C (with de-rating), and the maximum case temperature is 115°C.
Other features include very low no-load input current (7 mA max. for 3 W; 8 mA max. for 6 W), reducing power consumption in standby mode, and a range of protection including input UVLO, output overvoltage protection, overcurrent protection, and continuous short-circuit protection.
These converters also meet key safety and electromagnetic-interference (EMI) standards, including EN 55032 Class A without an external filter, simplifying design and integration for space-constrained applications, Cincon said.
They are also compliant with MIL-STD-810F for shock and vibration and support operating altitudes up to 5,000 meters. They meet IEC/UL/EN 62368-1 safety standards and provide 3,000-VDC input-to-output isolation.
These DC/DC converters are housed in a standard industrial DIP-24 package measuring 1.25 × 0.8 × 0.4 inches (31.8 × 20.3 × 10.2 mm).
Space and satellites
Micross Components Inc. recently introduced a series of Class H+-screened DC/DC converters for harsh space-based applications. The AFLS28XX Series of DC/DC converters delivers a radiation-tolerant power conversion solution for low-Earth-orbit (LEO) satellite constellations, new space missions, launch vehicles, and other space-based systems.
The AFLS series of 28-V, 120-W DC/DC converters builds on the AFL series, with updated technology and design enhancements. These converters meet MIL-PRF-38534 Class H screening requirements and include additional tests such as PIND and radiography to support reliability in LEO and new space environments. The AFLS series offers radiation specifications of 50-krad (Si) TID and 60-MeV·cm2/mg SEE.
These devices are tailored for space missions requiring radiation tolerance at a lower cost than traditional space-grade-qualified power supplies, Micross said.
The hermetically packaged DC/DC converters are available in single- and dual-output voltage configurations ranging from 5 V to 28 V. They feature proprietary magnetic pulse feedback for optimized dynamic line and load regulation and parallel operation for outputs above 120 W, with synchronization capability to a system clock in the 525-kHz range.
Other features include internal current sharing for balanced load distribution and high power density with no de-rating across the full operating temperature range. In addition, they meet reduced size, weight, and power (SWaP) requirements by eliminating shielding requirements and delivering lower power consumption.
These parts are currently under test, and engineering samples are available within four to six weeks ARO.
Also targeting space applications is a series of off-the-shelf, 15-W DC/DC converters from Microchip Technology Inc. This space-grade, non-hybrid DC/DC isolated power converter with a companion EMI filter operates from a 28-V satellite bus in harsh environments.
The SA15-28 radiation-hardened DC/DC power converter with a companion SF100-28 EMI filter are designed to meet MIL-STD-461 specifications. The SA15-28 and SF100-28 are fully compatible with Microchip’s existing SA50 series of power converters and SF200 filter.
The SA15-28 operates across a wide temperature range from −55°C to 125°C and offers radiation tolerance up to 100 krad TID. It is available with 5-V triple outputs that can be used with point-of-load converters and low-dropout linear regulators to power FPGAs and microprocessors. The output voltage combinations can be customized.
The SA15-28 weighs 60 grams and is approximately 1.68 in.3 to meet SWaP requirements. Microchip provides comprehensive analysis and test reports including worst-case analysis, electrical stress analysis, and reliability analysis. The SA15-28 DC/DC power converter and SF100-28 external EMI filter are now available.
Brick converters
Advanced Energy Industries Inc. recently added two quarter-brick modules to its ultra-efficient, non-isolated bus converter family for 48-V power conversion. These DC/DC converters target advanced information and communication technology equipment including AI servers, compute and networking, and industrial applications such as robotics and test and measurement.
The Advanced Energy Artesyn NDQ1300 1,300-W and NDQ1600 1,600-W quarter-brick modules operate with peak efficiencies up to 98%, making them suited for high-performance applications. Each of the modules can convert a 48-V input into a fully regulated, 12-V output for non-isolated, low-voltage, high-current power stages as well as PCIE slots and memory devices.
The NDQ devices feature a flat efficiency curve that ensures that the modules deliver optimized power conversion across a wide load range. They also feature an integrated PMBus interface to support flexible digital control and monitoring as well as current-share and remote-sensing options to enable the connection of multiple power supplies in parallel, supporting higher load current or redundancy.
The NDQ modules use an advanced baseplate for better thermal management and heat-sink integration. They also benefit from an inherently safe, transformer-based topology that is resilient to transient loads and makes designing applications for inrush current control on startup easier, the company said.
Another new converter in a brick format is Bel Fuse’s compact, 100-W DC/DC converter for rugged applications such as industrial automation, railway systems, telecom infrastructure, and electric vehicles/e-mobility. The PRA100 Series is housed in a standard 1/8th brick format, addressing the increased need for higher power density. The devices provide enhanced thermal performance, wide input flexibility, and an environmentally robust design.
The PRA100 operates across a 9-VDC to 74-VDC input range and delivers up to 54-V output with 3,000-VDC isolation. The operating temperature is −40°C to 105°C. All models are fully compliant with EN 62368-1 and carry CE, UKCA, and UL/cUL certifications. It is also compliant with EN 50155, making it well-suited for railway applications. The series offers optional baseplate cooling and negative logic features to extend its versatility in harsh conditions and EV platforms, Bel Fuse said.
DC/DC converter modules
TDK Corp. developed a series of its microPOL (μPOL) power modules with full telemetry (voltage, current, and temperature). The FS160* series μPOL DC/DC converters deliver high power density in the smallest package sizes.
All FS160* μPOL modules measure 3.3 × 3.3 × 1.35 mm, making it easier to place them near complex ICs such as ASICs, FPGAs, and SoCs. Full telemetry is accessible via an I2C interface. The modules operate across a broad junction temperature range from −40°C to 125°C.
There are several versions of each of the 3-A parts (the FS1603 series), 4-A parts (the FS1604 series), and 6-A parts (the FS1606 series). The FS line also includes models at 12 A (the FS1412) and 25 A (the FS1525). The selection of DC/DC converter modules that range from 3 A to 200 A (if eight FS1525’s are connected in parallel) covers a wide range of applications, including big data, machine learning, AI, 5G cells, IoT, and enterprise computing.
TDK calls the module family’s configuration innovative, integrating a high-performance controller, drivers, MOSFETs, and logic core, using a semiconductor embedded in substrate. This packaging eliminates wire bonds and enhances thermal performance. Also integrated are the modules’ inductor and passives into a chip-embedded package to minimize parasitic inductance, which improves the module’s efficiency. Boot and Vcc capacitors are also incorporated into the module.
The FS160* series DC/DC converters deliver 1-W/mm3 in modules that are roughly half the size of other products in the same class, according to the company. In addition, TDK said the modules are so effective that they require no airflow for up to 15 W to 30 W in up to 100°C ambient temperature.
TDK has created multiple design tools, including tools specific to FPGAs from each of the major FPGA suppliers. Additional design tools for the FS160* series include SPICE simulator designs on QSPICE.
Evaluation boards are available, one each for modules at 3 A, 4 A, and 6 A. Fast starter designs for schematic and PCB layout are available at Ultra Librarian.
Aimed at the industry’s shift to high-performance, 48-V systems, Vicor Corp. launched its 48-V to 12-V DCM DC/DC converter modules last year. The DCM3717 and DCM3735 DC/DC power modules, offering up to 2 kW of output power, support the shift to 48-V power delivery networks (PDNs) that provide greater power system efficiency, power density, and lower weight than 12-V-based PDNs in a variety of applications, including communications, computing, automotive, and industrial.
The DCM products are non-isolated, regulated DC/DC converters, operating from a 40-V to 60-V input to generate a regulated output adjustable from 10 V to 12.5 V. The DCM3717 family is available in two power ranges, 750 W and 1 kW, and the DCM3735 is a 2-kW device. These DCM products can be paralleled with up to four modules to scale system power levels.
Claiming industry-leading power density at 5 kW/in.3, these high-density power modules enable power system designers to deploy 48-V PDNs for legacy 12-V loads, delivering size, weight, and efficiency benefits. These devices deliver high efficiency at 96% in a low-height, surface-mount converter housed in package, delivering a 6× reduction in size.
The smaller module is the DCM3717, with a wide input range of 40–60 V (48-V nominal) and an output of 10–12.5 V (12-V nominal). It comes with two power options, 750 W and 1 kW, and 96.5% efficiency. The module is housed in a compact, 36.7 × 17.3 × 5.2-mm footprint.
In a side-by-side comparison with a top competing product, the DCM3717 is less than half the size, with 20% higher output power and 7× higher power density, according to the company.
The larger device, the DCM3735, offers the same wide input range of 40–60 V (48 V nominal) and output of 10–12.5 V (12 V nominal). The power option is 2 kW with 96.4% efficiency. The module is housed in a compact, 36.7 × 35.4 × 5.2-mm footprint.
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