HLF8K-D60-H1000 8KW Ultra-High Voltage Light weight Airborne Power Supply | 800-1000V to 58.5V
HLF8K-D60-H1000 8KW Ultra-High Voltage Airborne DC/DC Power Converter
Overview
HLF8K-D60-H1000 is an 8 kW light weight onboard DC/DC power converter for heavy-duty UAVs and tethered aerial platforms. It converts an 800–1000 VDC input (optimal operating voltage 950 VDC) into a regulated 58.5 VDC output, designed to match 14S Li-ion/Li-Po battery systems (4.24 V/cell).
Ultra-high-voltage DC transmission significantly reduces power losses over long cable runs and lowers tether weight. The 58.5 V output aligns with the charge/discharge requirements of 14S battery packs and can directly power high-demand avionics and payloads, eliminating the need for an additional conversion stage.
The converter is a single, fully integrated board requiring no external controller, peripheral modules, or additional configuration for operation. It employs a 97% efficient topology in a compact, ruggedized construction, with integrated input reverse-polarity, overvoltage, overcurrent, short-circuit, and overtemperature protection, plus soft-start. Designed for severe vibration and wide-temperature operation, it delivers stable, uninterrupted power under high thermal and mechanical stress for high-load, long-endurance missions.
Key Features
800–1000 VDC Ultra-High-Voltage Input
800–1000 VDC input range (optimal operating voltage 950 VDC) supports high-voltage tether transmission, reducing cable I²R losses and tether weight, and is compatible with next-generation high-voltage UAV battery packs.
8 kW Continuous Output with ≥97% Efficiency
Delivers 8 kW continuous output at ≥97% conversion efficiency, reducing thermal load and supporting longer runtime, higher payload capability, and lower thermal-management overhead.
Regulated 58.5 VDC / 136 A Output
Provides a regulated 58.5 VDC output at 136 A, matching 14S Li-ion/Li-Po battery systems and directly powering high-demand avionics, sensors, actuators, and communication payloads without an additional conversion stage.
Integrated Protection Suite
Input reverse-polarity protection, input UV/OV protection, output UV/OV/OCP, short-circuit protection, overtemperature protection with intelligent power derating, and soft-start.
CAN Communication
CAN interface supports real-time system monitoring, diagnostics, parameter configuration, and integration into vehicle control and health-management networks.
Rugged, Compact Board-Level Construction
Compact, ruggedized single-board construction with shock-absorbing mounts and an optimized thermal path; engineered for severe vibration and wide-temperature operation in heavy-duty flight environments.
Applications
Next-Generation Heavy-Duty and Tethered UAVs
Designed for long-endurance surveillance, heavy-payload inspection, and long-range communication relay. The 800–1000 VDC input reduces tether cable I²R losses and conductor weight, while the regulated 58.5 VDC / 136 A output powers avionics, sensors, actuators, and payloads directly—without an additional conversion stage.
High-Altitude Long-Endurance (HALE) Platforms
Provides regulated 8 kW conversion from high-voltage DC buses, reducing transmission losses and thermal load in weight- and efficiency-sensitive HALE architectures.
Advanced Robotic and Unmanned Systems
Suitable for high-power unmanned vehicles requiring 800–1000 VDC input compatibility and a regulated 58.5 VDC output, including platforms based on 14S Li-ion/Li-Po battery packs.
Technical Specifications
| Parameter | Specification |
|---|---|
| Model | HLF8K-D60-H1000 |
| Input Voltage | 800–1000 VDC |
| Output Voltage | 58.5 VDC (adjustable 56–61 VDC) |
| Output Current | 136 A |
| Output Power | 8 kW (8000 W) |
| Efficiency | ≥97% |
| Communication | CAN 2.0B |
| Protections | Input UVP/OVP; output UVP/OVP/OCP; short-circuit protection; over temperature protection; fuse |
| Cooling Method | Heat sink with forced air cooling (required for full 8 kW continuous operation) |
| Vibration Resistance | Rubber damping pads; MIL-STD-810G compliant design |
| Dimensions (L × W × H) | 187 × 185 × 70 mm |
| Weight | 2.2 kg |
| Operating Temperature | −40 °C to +65 °C |
Why Choose the HLF8K-D60-H1000
800–1000 VDC Input for High-Voltage Architectures
Supports 800–1000 VDC input (optimal 950 VDC), reducing tether cable I²R losses and weight while matching next-generation high-voltage UAV battery packs.
8 kW in a light weight 2.2 kg Board
Delivers 8 kW continuous output from a 2.2 kg, 187 × 185 × 70 mm single-board converter, preserving payload and space in weight/volume-sensitive aerial platforms.
≥97% Efficiency, Lower Thermal Load
Regulated 58.5 VDC / 136 A Output
Provides a regulated 58.5 VDC output at 136 A, matching 14S Li-ion/Li-Po battery systems and directly powering avionics, sensors, actuators, and payloads without an additional conversion stage.
Single-Board Integration with CAN 2.0B
A fully integrated single board requires no external controller, peripheral modules, or additional configuration. CAN 2.0B supports real-time monitoring, diagnostics, parameter configuration, and vehicle health management.
Protection and Ruggedization for Flight Environments
Integrated input UVP/OVP, output UVP/OVP/OCP, short-circuit, overtemperature, and fuse protection; MIL-STD-810G compliant design with rubber damping pads for severe vibration and −40 °C to +65 °C operation.
Ordering & Support
For technical datasheets, application engineering support, or commercial inquiries, please contact our sales team and reference model:
HLF8K-D60-H1000.
Vicor vs. Levanepower: 8kW PowerSupply Comparison
This document compares the Vicor and LevanePower power supply solutions in terms of cost, weight, heatsink, input/output voltage, and external circuit design.
1. Single Module Comparison
Parameter | Vicor BCM4414xH0E5035yzz | LevanePower HLF8K-D60-H1000 |
Module Type | Fixed-ratio Bus Converter (BCM®) – 1:16 ratio | Non-isolated Regulated DC-DC Converter |
Input Voltage | 500 – 800 VDC | 800 – 1000 VDC |
Output Voltage | 31.3 – 50.0 VDC (follows input) | 58.5V VDC (fixed) |
Output Current | 35 A | 160 A |
Max Output Power | 1.6 kW | 8 kW |
Peak Efficiency | Up to 97.7% | ≥ 97% |
Dimensions (L x W x H) | 111 × 35.5 × 9.4 mm | 197 × 186 × 68 mm |
Weight | ~150 g (estimated) ,Need to configure peripheral circuits | 2.2 kg, No need for peripheral circuits, can be used directly |
Control Interface | PMBus™ | CAN bus |
Cooling | Conduction / baseplate | Forced air / conduction |
2. System-Level Comparison at EquivalentPower (8 kW)
To achieve 8kW output power, 5 Vicor modules (5 × 1.6 kW) arerequired in parallel, compared to 1LevanePower module.
Parameter | 5× Vicor BCM4414 (8 kW System) | 1× LevanePower HLF8K-D60-H1000 (8 kW System) |
Number of Modules | 5 | 1 |
Total Output Power | 8 kW | 8 kW |
Total Volume (approx.) | 111 × 177.5 × 9.4 mm (~185 cm³), (without extend circuits) | 197 × 186 × 68 mm (~2,490 cm³) |
Volume Ratio | Larger overall and weighter when including heatsink and external circuitry | ~13.5× larger |
Total Weight (approx.) | ~2 kg | 2.2 kg |
System Complexity | High (parallel design, current sharing, PCB layout, heatsink) | Low (single module, used directly (no external components)) |
Output Regulation | Unregulated (depends on input) | Fully regulated 58.5 VDC(fixed) |
3. Price Comparison (Estimated – ForReference Only)
Note: Actual pricing depends on volume, distributor, andnegotiation. The following estimates are based on typical market ranges forindustrial quantities.
Configuration | Estimated Sample Price per Module | Total Cost for 8 kW System |
Vicor BCM4414 (1.6 kW) | $1074 | $5370 (5 modules) ,Significantly higher when including required PCB, enclosure, circuitry, and heatsink |
LevanePower HLF8K (8 kW) | $3000 | $3000 (1 module) , Included in module cost |
Conclusion on Cost:
At the 8 kW systemlevel, both solutions are cost-competitive, with the Lefeiersolution offering simplerintegration and regulated output at a similar orslightly lower total cost.
4. Volume Comparison at Equivalent Power (8kW)
Metric | 5× Vicor BCM4414 | 1× LevanePower HLF8K |
Total Volume | ~1850 cm³(Include extend circuitry) | ~2,421 cm³ |
Power Density | ~4.32 kW/L | ~3.2 kW/L |
Footprint Advantage | ✅ High – ideal for space-constrained systems | ✅ High – ideal for space-constrained systems |
Note: When scaled to 8kW, the Lefeier Energy 8kWsolution and the Vicor solution offer almost identical power density.Therefore, the LevanePower solution is also well suited for applications withstrict limitations on PCB area and height (e.g., embedded systems, aerospace).
Additionally,the LevanePower solution provides fully regulated output, simplerthermal management, and lower design complexity.
5. Summary & Recommendation
Consideration | Vicor BCM4414 (5-module array) | LevanePower HLF8K-D60-H1000 |
Input Range | 500 – 800 VDC | 800 – 1000 VDC(950V optimal) |
Output | Unregulated (1:16 ratio) | Fixed 58.5VDC |
Power Density | Very high | Very high |
Design Effort | High (parallel, current sharing, layout) | Low (single module) |
Best For | Space-critical, distributed power architectures | Simple 58.5VDC power in one block |
Choose LevanePower HLF8K-D60-H1000 if:
· Your input voltage is stable at ≥ 900 VDC
· You need a simple,single-module 8 kW solution
· Regulated 58.5VDC output isrequired
· System volume is notthe absolute priority
Choose Vicor BCM4414 array if:
· Input voltage is 500–800VDC
· Extreme power density (smallfootprint) is critical
· You are building a distributedpower architecture with multiple downstream loads
· Your team has experience with high-density power module design
If you can share your exact input voltage range, cooling method,and physical spaceconstraints, Our teams can help narrow down the recommendationfurther.
