New Industry Products

Ruggedized 3kW Bi-Directional DC-DC Converter for 48V/12V Battery Systems

April 17, 2020 by Paul Shepard

Calex Manufacturing Company Inc. announced the launch of the BCA (48S12.3K0BCA), a 3kW bi-directional non-isolated dc-dc converter. The BCA is compact and light-weight, weighing only 2.86 pounds, and features a low-profile design with dimensions measuring 8.67 x 6.14 x 1.01".  The ruggedized design boasts an efficiency of 97%, one of the highest power densities in the industry. The packaging and thermal design makes the converter suited for harsh shock and vibration requirements, as well as easy integration with a battery pack.

Standard hybrid electric vehicle architecture typically requires the use of two independent batteries at different voltages, and Calex created the 3kW bi-directional dc-dc converter in response to these requirements. The BCA charges a low side (12V) battery during normal operation (buck mode) and charges or assists the high voltage (48V) battery in emergency situations (boost mode). In the event that the 48V battery requires charging while in the boost mode, the unit enters into pre-charge mode.

The BCA's features include a disconnect switch based on a back to-back MOSFET configuration for the low side (12V battery), reverse voltage protection, short circuit protection, as well as low standby current for the low side. The baseplate of the enclosure allows for ease of mounting to a chill plate or chassis. The operational baseplate temperature range of the BCA is -40˚C to 100˚C.

The BCA uses a Controller Area Network (CAN) 2.0B interface for complete control of the converter, as well as monitoring the LS current and the internal temperature. Additionally, the BCA uses a high-speed CAN-Transceiver for communication with the microcontroller.

"The BCA provides a complete solution for in-vehicle power distribution in 48V/12V battery configurations, making this an outstanding choice for OEM vehicle electrical systems," says Michael McNally, director of product marketing at Calex Manufacturing.