eMobility
High-voltage DC/DC converters for electric vehicles
Efficiently converts power
A DC/DC converter changes
the higher voltage of the battery
to lower voltage to power
infotainment and safety systems.
Eaton has vast expertise and a
strong legacy of building highly
reliable DC/DC converters and
can design custom solutions
while leveraging standard
production processes.
Supported xEV applications:
• Light vehicle / passenger cars
• Medium-duty bus and truck
• Heavy-duty bus and truck
• Quiet / clean output power – enables Why Eaton?
powering of sensitive load including radios and
controllers • Recognized as a global leader in power conversion
• Custom design – tailored configurations • Deep expertise in industrial power electronics
leveraging common designs • Transferable future technology from
• Proven design – 50+ years of DC converter Electrical Sector
expertise, including 5+ years of BEV production
• Vehicle expertise
• Compact, light-weight design
• Greater system flexibility – accepts wide input
voltage range and multiple output voltages
DC/DC converter
DC/DC converter key features
Wide range input
225 – 450 V

Compact design

94% efficiency

Output voltages
of 12, 24 V IP67 and IP6K9K sealed
Custom aluminum enclosures

DC/DC 3 kW
DC/DC 3 kW Mains Standards Insulation
Input voltage: 225 V to 450 VDC The device is compliant with the Functional safety:
standards:
Output voltage: 14 V The DC DC converter is developed in
ISO 6469-3 accordance with ISO26262 ASIL B
Output power: 3000 W
Directive UNECE 10-5 Dielectric:
Efficiency: ≥92%
Directive UNECE 100-2 HV Input / (LV output + CAN +
Purpose Chassis Ground): 2500VAC or 3535VDC
LV 123
3 kW DC/DC Unit On Board Converter Insulation:
• LV 124
able to deliver 14 VDC or 28V output. HV Input / (LV output + CAN +
• Input is supplied by HV battery voltage Environment Ground Chassis): 100 MΩ/500 VDC
• Mechanically integrated in standard Operating Temperature: -40°C to +60°C LV output + CAN / Ground Chassis:
aluminum housing including a liquid Storage Temperature: -40°C to +70°C 100 MΩ/100VDC
cooled system.
IP classification: IP6K9K
Weight: 5.3 kg
Product Safety: ASIL B

2 EATON DC/DC converters for electric vehicles www.eaton.com

DC/DC converter drawing

EATON DC/DC converters for electric vehicles www.eaton.com 3

DC/DC converter specifications
Parameter Min. Typ. Max. Unit Notes & Conditions
Input Characteristics
Operating input voltage range 225 [232-443] 455 Vdc
UVP switch off <225 232 >239 Vdc
OVP switch off >430 443 <455 Vdc
Input reverse polarity protection Yes By poka yoke on connector
5 s Active discharge HV < 60V
Active & passive discharge
120 s Passive discharge HV < 60V
Inrush current limitation No No inrush current limitation on hv bus
Output Characteristics
Operating voltage 6 14 16 Vdc Current limited above 14V (power limitation to 3.1kW)
Nominal output voltage 12 14 16 Vdc At ambient temperature +25°C and +65°C Liquid cooling temperature
Nominal power 3.1 kW At ambient temperature +25°C and +65°C liquid cooling temperature
Max operating current 211 222 233 A Up to 14V output voltage
Short circuit current protection Yes
Adjustment of output voltage CAN 12 V to 16 V
Adjustment output current CAN
Output current protection No LV battery fuse on vehicle side is needed
Reverse polarity Yes On LV battery connection through reverse polarity parallel diode
Overvoltage protection (SW1) >16.6 Vdc Switch off the converter, detection within 1s (software protection - response time
reduces at higher voltages) restarts if voltage drops below 15 V
Start-up time 1.2 s This time is the time necessary to the product to deliver the full functionality
Other Characteristics
Efficiency 92 92.7 ≥94 % At 345 Vdc, +25°C ambient temperature and +40°C liquid cooled
Over temperature (base plate) 90 °C Switch off and re-start automatically
Crash signal Active discharge activated by crash signal received on can bus
CAN communication CAN 2.0B, speed 500kbits/s Diagnostic according UDS and J1939
Insulation Characteristics
Insulation voltage (dielectric strength) 2500 Vac HV input / (LV output + can + ground)
Reliability Characteristics
Calculated MTBF (UTEC 80810) 200 103 Hrs 12h/day, 260d/y ambient components +65°C and +45°C liquid
cooled temperature
Cooling Characteristics
Coolant flow rate 7 7 10 l.min-1
Coolant continuous pressure 2.5 bars
Coolant peak pressure 3 bars

Learn more at Eaton.com/eMobility

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