DC-DC converters for 800V EVs with 48V zones

Vicor has released three automotive-grade power modules for 48V electric vehicles: a bidirectional 2.5kW 800V to-from 48V converter, a 2kW 48V to 12V regulator and a 2.5kW 48V to 48V regulator.

Vicor 800V 48V EV dcdcs

The unregulated fixed-ratio 2.5kW isolated bi-directional 800V to-from 48V dc-dc converter is a member of the BCM6135 family, with a power density of 158kW/litre according to the company.

“The bidirectional rapid current transient response rate of 8MA/s allows the BCM6135 to replace a 25lb 48V battery, serving as a virtual 48V battery,” said Vicor.


Pre-charging high-voltage inverters from a low-voltage battery is another potential application.


DCM3735 is the 2kW 48V (35 to 58V) input non-isolated converter that produces a regulated 12V output, trimmable across 8 to 16V, measuring 36.6 x 35.4 x 7.4mm.

Claimed power density is 300kW/litre, and the company said: “DCM3735 can be mounted remotely to create a local 12V supply in a vehicle zone, for example on the right-hand side.

PRM3735 is a non-isolated 2.5kW dc-dc that converts an input between 31 and 58V to a nominally 48V regulated output, adjustable between 36 and 54V.

It measures 36.6 x 35.4 x 7.4mm.

Automotive grade?

“The modules cannot be classified into any of the AEC categories so we cannot qualify the final part – BCM6135 for example – to an AEC level,” the company told Electronics weekly. “However, the parts are tested to numerous automotive ISO and SAE standards as part of the PPAP process.”

Steve Bush

Steve Bush is the long-standing technology editor for Electronics Weekly, covering electronics developments for more than 25 years. He has a particular interest in the Power and Embedded areas of the industry. He also writes for the Engineer In Wonderland blog, covering 3D printing, CNC machines and miscellaneous other engineering matters.

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