HLF60K-D120-H1500 – 60 kW Lightweight DC/DC Converter | 1500 V Input, 120 V Output
HLF60K-D120-H1500
60 kW Ultra-High Voltage Lightweight DC/DC Converter for Tethered Drones & Underwater Robots
Overview
The HLF60K-D120-H1500 is a high-power, ultra-high-voltage DC/DC converter purpose-built for tethered drone power stations and underwater robot power systems. Delivering a continuous 60 kW from a 1200–1500 VDC input to a software-configurable 120 VDC output at >97% peak efficiency, it serves as the high-density power conversion core for high-voltage tether cables, battery racks, and next-generation unmanned platform power delivery. Engineered with liquid-cooled thermal management, dual isolated CAN FD control, and a parallel-ready architecture, this converter delivers the scalability, redundancy, and digital intelligence required for continuous, high-availability drone and underwater operations.
Applications
Tethered Drone Power Stations – Converts 1200–1500 VDC from ground power units or battery banks to 120 VDC for onboard drone power distribution, enabling persistent flight and high-power payloads.
Underwater Robot Power Supplies – Provides stable 120 VDC from high-voltage tether cables for ROVs, AUVs, and subsea equipment, ensuring reliable power in deep-water operations.
High-Voltage Tether Systems – Directly interfaces with long tether cables, reducing transmission losses and copper weight for extended mission endurance.
Mobile Ground Power Units – Compact, rugged design supports rapid deployment in field operations, disaster relief, and remote inspection.
Battery-Powered Unmanned Platforms – Provides a stable DC bus for lithium-ion battery systems, ensuring seamless transition to stored energy during peak loads.
High-Availability Power for Critical Missions – Ideal for ISR, heavy-lift logistics, underwater inspection, and subsea intervention where failure is not an option.
Technical Specifications
| Parameter | Specification |
|---|---|
| Model | HLF60K-D120-H1500 |
| Input Voltage Range | 1200 – 1500 VDC |
| Output Voltage | 120 VDC (factory-default; field-programmable via CAN) |
| Output Power | 60 kW continuous |
| Output Current (nominal) | ~500 A @ 120 VDC |
| Peak Efficiency | >97% @ 50–100% load; >96.5% @ full load |
| Thermal Dissipation | ~2.1 kW @ full load (coolant inlet ≤45°C, flow ≥8 L/min) |
| Standby Power Consumption | <15 W (idle mode) |
| Communication & Control | Dual isolated CAN FD 2.0 (CAN-open support), full digital monitoring, data logging, FOTA |
| Protections | UVP, OVP, OCP, SCP, OTP, reverse polarity, input surge |
| Fault Diagnostics | Real-time fault logging with time-stamped event history; AI-ready telemetry |
| Parallel Operation | Active current sharing with ±5% imbalance (master-less), up to 10 units |
| Cooling System | Forced liquid cooling (mandatory); cold plate integrated; water-glycol 30%–50% |
| Coolant Flow Rate | ≥8 L/min (recommended); 6 L/min (minimum for derated operation) |
| Coolant Inlet Temperature | -20°C to +55°C (full power up to 45°C; derating above 45°C) |
| Dimensions (L×W×H) | 400 × 300 × 200 mm |
| Weight | ≤25 kg |
| Operating Temperature | -40°C to +55°C (ambient, derating above 55°C) |
| Storage Temperature | -40°C to +85°C |
| Relative Humidity | 5% – 95% (non-condensing) |
| Altitude | ≤3000 m (derating above 2000 m) |
| MTBF | >500,000 hours (Telcordia SR-332, ground fixed, 40°C) |
| MTTR | <30 minutes (field-replaceable modules) |
Protection & Safety Features
| Protection Type | Description |
|---|---|
| Input Under-Voltage Lockout (UVLO) | Shuts down when input drops below 1000 VDC; auto-restart upon recovery |
| Input Over-Voltage Protection (OVP) | Shuts down when input exceeds 1600 VDC; auto-restart upon recovery |
| Output Over-Voltage Protection | Clamps output at 140 VDC; latches off, requires reset |
| Output Over-Current Protection | Limits current at 550 A (110% of nominal); constant current with foldback after 10 s |
| Short-Circuit Protection | Hiccup mode with auto-recovery |
| Over-Temperature Protection | Shuts down at 90°C (coolant outlet); auto-restart at 75°C |
| Reverse Polarity Protection | Input protected against reverse connection (≤ -100 VDC for 1 minute) |
| Input Surge Protection | Withstands 1000 VDC surges for 100 ms per IEC 61000-4-5 |
Why Choose the HLF60K-D120-H1500?
✅ Proven Efficiency for Demanding Missions
97% peak efficiency improves system endurance and reduces thermal load.
✅ True Redundancy with Active Current Sharing
Parallel up to 10 units with <5% imbalance, enabling N+1, 2N, or distributed redundancy without external controllers.
✅ Certified for Mission-Critical Uptime
Compliant with IEC 61800-5-1; hardware designed to support ISO 26262 ASIL-D, ensuring 99.999% availability.
✅ Intelligent, Software-Defined Power Core
Remote configuration, firmware updates, predictive maintenance, and energy optimization via CAN FD.
✅ Thermally Optimized for Continuous Heavy Loads
Liquid-cooled cold plate ensures stable 60 kW continuous operation.
✅ Built for Extreme Conditions
Rugged industrial design from -40°C to +85°C, with comprehensive surge and transient protection.
✅ Scalable Building Block for Megawatt Systems
Modular design scales from 60 kW to 6 MW+ by paralleling multiple units.
FAQ
What is the HLF60K-D120-H1500?
A 60 kW ultra-high-voltage DC/DC converter with 1200–1500 VDC input and 120 VDC output, designed for tethered drones and underwater robots.
What is the input voltage range?
1200–1500 VDC.
What is the output voltage?
120 VDC, factory-default, field-programmable via CAN FD.
What is the efficiency?
97% peak, >96.5% at full load.
Does it support parallel operation?
Yes, up to 10 units with active current sharing (±5% imbalance).
What cooling is required?
Forced liquid cooling (mandatory).
What protections are included?
UVP, OVP, OCP, SCP, OTP, reverse polarity, and input surge protection.
Ordering & Support
HLF60K-D120-H1500
For detailed technical specifications, thermal integration guidelines, parallel configuration support, or to discuss your specific application requirements, please contact our Unmanned Systems Power Solutions Engineering Team.
This document is for informational purposes and may be updated without notice. All specifications are subject to change. For the latest version, please contact the manufacturer.
