26KW DC/DC Converter | 1500V Input, 58V Output – HLF26K-D60-1500 Levane Power
HLF26K-D60-1500
26kW Lightweight High-Voltage DC/DC Converter for Tethered Drones
Overview
HLF26K-D60-1500 is a high‑power, lightweight DC/DC converter purpose‑built for tethered drone and unmanned aerial vehicle (UAV) power delivery systems. Delivering a continuous 26 kW from a high‑voltage 1500 VDC input to a factory‑configured 58.5 VDC output (compatible with 48V and 60V drone payload systems) at >97% peak efficiency, it serves as the high‑density power conversion core for long‑endurance tethered drone operations. Engineered with liquid‑cooled thermal management, ruggedised construction, and a parallel‑ready architecture, this converter delivers the power density, reliability, and simplicity required for mission‑critical, 24/7 UAV operations.
Key Features
| Feature | Description |
|---|---|
| 26 kW High Power Density | Delivers sustained full‑load output in a compact 400×300×200 mm form factor, minimising onboard and ground‑station weight. |
| Ultra‑High Voltage Input (1500 VDC) | Directly interfaces with 1500 VDC battery racks, photovoltaic strings, or high‑voltage DC microgrids, enabling long‑distance tether cable transmission with reduced I²R losses. |
| Factory‑Configured 58.5 VDC Output | Fixed 58.5 VDC output (48V, 52V, or 60V variants available upon request) – no digital configuration required. |
| Advanced Analogue & Hardware Protection | DSP‑based adaptive control with comprehensive hardware protection suite including UVP, OVP, OCP, SCP, OTP, reverse polarity, and input surge protection. |
| Forced Liquid Cooling (Mandatory) | Integrated cold plate with high‑capacity thermal management ensures reliable 26 kW operation under continuous heavy loads. |
| Redundancy‑Ready Parallel Architecture | Master‑less active current sharing supports up to 10 units in parallel (imbalance ≤±5%), enabling N+1 or scalable power zones for multi‑drone charging stations. |
Applications in Tethered Drone Operations
| Use Case | Description |
|---|---|
| Long‑Endurance Surveillance Drones | Provides continuous, reliable power for ISR (Intelligence, Surveillance, Reconnaissance) drones requiring 24/7 uptime. |
| Emergency Response & Disaster Relief | Enables rapid deployment of tethered communication relays and high‑altitude observation platforms. |
| Industrial Inspection | Powers drones for infrastructure inspection (power lines, pipelines, telecommunications towers). |
| Military & Defence | Supports unmanned ground support equipment and fixed‑site UAV charging systems. |
| Broadcast & Event Coverage | Delivers clean, stable power for broadcast drones operating in low‑temperature or high‑wind environments. |
| Scientific Research | Provides continuous power for atmospheric, environmental, and agricultural drone‑borne sensor platforms. |
Technical Specifications
| Parameter | Specification |
|---|---|
| Model | HLF26K-D60-1500 |
| Input Voltage Range | 1200 – 1500 VDC |
| Output Voltage | 58.5 VDC (48V / 52V / 60V variants available) |
| Output Power | 26 kW continuous |
| Output Current (nominal) | ~444 A @ 58.5 VDC |
| Peak Efficiency | > 97% @ 50–100% load; > 96.5% @ full load |
| Thermal Dissipation | ~0.9 kW @ full load (coolant inlet ≤45°C, flow ≥6 L/min) |
| Standby Power Consumption | < 15 W (idle mode) |
| Communication & Control | None – pure analogue / hardware‑controlled converter; no digital communication interface |
| Protections | Under‑voltage (UVP), over‑voltage (OVP), over‑current (OCP), short‑circuit (SCP), over‑temperature (OTP), reverse polarity, input surge |
| Fault Diagnostics | Hardware fault indication via dedicated fault output pin (open‑collector) |
| Parallel Operation | Active current sharing with ±5% imbalance (master‑less architecture), supports up to 10 units in parallel |
| Cooling System | Forced liquid cooling (mandatory); cold plate integrated; recommended coolant: water‑glycol mixture (30%–50% glycol) |
| Coolant Flow Rate | ≥ 6 L/min (recommended); 4 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) | 260 × 200 × 200 mm |
| Weight | ≤ 8 kg |
| Operating Temperature | -40°C to +50°C (ambient, with derating above 55°C) |
| Storage Temperature | -40°C to +85°C |
| Relative Humidity | 5% – 95% (non‑condensing) |
| Altitude | ≤ 5000 m (derating above 3000 m) |
| MTBF | > 500,000 hours (Telcordia SR‑332, ground fixed, 40°C) |
| MTTR | < 30 minutes (field‑replaceable modules) |
Protection & Safety Features
| Protection Type | Trigger Threshold | Action / Response | Recovery Mechanism |
|---|---|---|---|
| Input Under‑Voltage Lockout (UVLO) | < 1150 VDC (typ) | Prevents startup; stops output if running | Auto‑restart when input > 1200 VDC |
| Input Over‑Voltage Protection (OVP) | > 1550 VDC (typ) | Shutdown (latch‑off) | Manual reset / power‑cycle |
| Output Over‑Voltage Protection | Clamp at 65 VDC; latch‑off if exceeded | Output clamped; latch‑off | Manual reset / power‑cycle |
| Output Over‑Current Protection | Limits current at 488 A (110% of nominal) | Constant‑current limit → Foldback after 10s | Auto‑restart when load reduced |
| Short‑Circuit Protection | Output < 0.3 Ω | Hiccup mode (1Hz retry) | Auto‑recovery when short removed |
| Over‑Temperature Protection | Shuts down at 90°C (coolant outlet) | Immediate shutdown | Auto‑restart when temp < 75°C |
| Reverse Polarity Protection | ≤ -1500 VDC (1 min withstand) | Series MOSFET disconnects input | Auto‑recovery upon correct polarity |
| Input Surge Protection | Withstands 1500 VDC surges for 100 ms | Input clamped | Internal auto‑recovery |
Why Choose the HLF26K-D60-1500?
✅ Proven Efficiency for Extended Operations
Delivers > 97% peak efficiency, minimising energy losses in tether cables and reducing cooling requirements for both ground and airborne systems.
✅ Simple, Reliable Analogue Control
No digital communication interface means simplified integration, reduced vulnerability to software faults, and deterministic fault response – ideal for critical drone applications.
✅ True Redundancy with Active Current Sharing
Parallel up to 10 units with < 5% current imbalance, enabling N+1, 2N, or distributed redundancy architectures without external controllers.
✅ Lightweight, High‑Power Density
At just 8 kg, the HLF26K‑D60‑1500 offers an exceptional power‑to‑weight ratio, making it ideal for portable ground stations and vehicle‑mounted platforms.
✅ Thermally Optimised for Continuous Heavy Loads
Liquid‑cooled cold plate with optimized thermal resistance ensures stable operation under 26 kW continuous load, even in elevated ambient temperatures.
✅ Scalable Building Block for Drone Fleets
Modular design allows scaling from 26 kW to several MW for multi‑drone charging depots and high‑power tethered drone arrays.
Ordering & Support
The HLF26K-D60-1500 is engineered for the most demanding drone power challenges.
Custom output voltage configurations (e.g., 48V, 52V, 60V) and extended temperature range options are available upon request.
For detailed technical specifications, thermal integration guidelines, parallel configuration support, or to discuss your specific application requirements, please contact our UAV Power Systems Engineering Team.
Document Revision History
| Revision | Date | Description |
|---|---|---|
| 1.0 | 2026‑09‑07 | Initial release – drone‑specific version, no CAN interface. Dimensions (260×200×200 mm) and weight (8 kg) as per customer specification. |
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.
