HVI 5K-3U7

600Vdc Input Industrial DC-DC Converter

This rugged, industrial quality, high input voltage DC-DC power converter uses field proven technology to generate the required output power. The design is based on topology with a track record in numerous applications. The unit is built with two FID2000 and four KHI 1200 internal modules. A built-in redundancy diode allows for parallel connection of a number of 5kW  converter units to create a 10kW, 15kW, or higher DC-power solution, or N+1 redundancy. The output separation diode also makes the units suitable for battery charging applications.

The DC-DC converter accepts 600Vdc input, with a wide input range of 400V to 800Vdc. Output options include 24V, 48V, 110Vdc, 125Vdc or custom. Output regulation is ±1% combined across all input line and load conditions, including output separation diode. Efficiency is a minimum of 85% at full load depending on input/output configuration required.

The converters are equipped with heavy filtering on the input and output for low noise. The input meets EN 55032 Class A with wide margins (Class B as an option). This ensures that the units can be used in EMI sensitive environments without additional filtering. The converters comply with the requirements of EN/IEC 61010-1 and related standards.

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 4300Vdc input to output.

The units are equipped with reverse polarity protection, inrush current limiting, output current limiting, short-circuit protection and self-resetting thermal shut-down in the case of insufficient airflow.

High quality built-in fans provide sufficient airflow for operation within a 0°C to 50°C temperature range without de-rating. The fans draw air into the unit, and exhaust at the terminal side of the unit. All heat generating components are installed on aluminum heatsink blocks which are thermally connected to the base plate. This also ensures exceptional mechanical ruggedness. Conformal coating provides protection against humidity and airborne contaminants.

The HVI 5K-3U7 unit is enclosed in a 3U 7 132 x 432 x 407 mm (5.2″ x 17″ x 16″) chassis-mount package. A 19” rack-mounted version also available

The HVI 5K-3U7 heavy-duty, high input voltage DC-DC converters are typically employed in power utility, industrial control, automotive, marine and telecommunications environments.


  • Control Input
  • Alarm Outputs
  • Other input voltage range on request
  • Other output voltage range on request
  • Heavy ruggedizing


Output Voltage24V, 48V, 110V or 125dc
Other outputs on request
Output is floating; either
terminal can be grounded
CoolingForced air by high quality built-in
fans and conduction to customer
heat sink or chassis.
Fans draw air into the unit.
Output Separation DiodeInstalled internallyEnvironmental ProtectionBasic ruggedizing
Conformal coating
Heavy ruggedizing available as an
Line/Load Regulation±1% combined from zero load to
full load including output
separation diode
Shock/VibrationIEC 61373 Cat 1 A&B
Dynamic ResponseMax 5% voltage deviation for 10%
to 50% load step, with better than
1msec recovery time
Humidity5 – 95% non-condensing
Output Ripple/NoiseBetter than 0.2% Vrms or
1% Vpp of the output voltage
(20MHz BW)
MTBF85,000 hours @45ºC
(fans excluded)
Demonstrated MTBF is
significantly higher.
Output Overload ProtectionRectangular current limiting with
short-circuit protection (no hiccup)
Thermal shutdown in case of
insufficient airflow (self-reseting)
IndicatorsGreen OUTPUT ON LED on each
internal module visible through
the rear perforation
Output Overvoltage ProtectionSecond regulator loop, completely
stable and independent of main
regulator loop
Control InputNone on standard version
Available as option
StandardsDesigned to meet EN 60950-1
and related standards
Alarm OutputsNone
Available as option
EMIEN55032 Class A with marginsWeight14 kg, 31 lb
Switching Frequency55kHz ±3kHzConnectionsInput: Terminal block HV assembly
Output: Threaded studs, M6
RoHS ComplianceCompliantWarrantyTwo years subject to application
within good engineering practice
Contamination related failures and
shipping costs excluded