Liquid-cooled 4kW DC-DC converter launched

Early hybrid cars first started using DC-DC converters to take power from the traction battery pack and convert run 12-volt components such as lights, infotainment and control electronics while the internal combustion engine is off, while also keeping the 12-volt battery charged, in some cases when the vehicle is parked and not in use.

Now DC-DC converters are a crucial component in hybrid and electric vehicles and Bel Power Solutions has launched a liquid-cooled 4kW DC-DC converter.

It is compatible with 240-450V DC traction batteries and produces an adjustable DC voltage ranging from 10-15V, with claimed efficiency of up to 95 per cent.

The converter’s robust design is IP67 and IP6k9k rated, making it suitable for passenger and off-highway vehicles, underground mining equipment, and marine applications.

Bel Power says the liquid cooling system ensures optimal performance even in extreme conditions, operating with coolant temperatures ranging from -40°C to +65°C and even up to +85°C with limited power output.

Measuring 356 x 284mm, including connectors that offer full galvanic isolation between input and output, the converter dissipates heat generated during operation using a 50:50 mixture of water and propylene or ethylene glycol as coolant, with a coolant flow rate of 10-20 litres per minute at a maximum pressure of 2 bar.

“Our new converter’s advanced design, high reliability, and flexibility are ideal for demanding industries,” said Bel Power Solutions eMobility, product and business development director Frank Vondenhoff.

A comprehensive set of safety features, including input reverse polarity protection, over-temperature protection, and output over-voltage, over-current, and reverse-polarity protection, ensure the stability and safety of the 12V system.

The converter also has a CAN bus interface for output trimming and offers additional features such as Unified Diagnostic Services (UDS), CAN FD, and cyber-security options, complying with e-Mark certification and ECE regulations for automotive components.

“We’re helping meet the evolving needs of manufacturers and operators while maintaining strict regulatory compliance,” said Vondenhoff.