270VDC Input, 500 Watt, Military DC to DC Converter

This custom 270V dc to dc converter was designed for an overseas military contractor requiring mil-spec compliance. The converter needed to provide 500 watts of 28Vdc and would be used to power electronic controls for a rotary type aircraft. One critical design requirement was the limited space allocated to the converter. The maximum outline limits were 1.5” x 2.0” x 6.0”. Additionally, this 270 Volt dc-dc converter would have to meet an operating temperature range of -40° to 85°C. 

To meet this project requirements, the design would require a custom chassis and unique PCB layout to achieve the specific electrical performance requirements and mechanical constraints. The agreed to design would incorporate the EMI filter stage, the surge protection components and the high efficiency, dc to dc, converter section on a discrete PCB to fit into the chassis. This design would meet MIL-STD-461F, MIL-STD-704 and MIL-STD-1275.