500 W Railway DC/DC Converter with 3:1 Input Range

The CLS-500 is a 500 W railway DC/DC converter engineered for rolling stock applications requiring high reliability, wide input voltage tolerance, and stable auxiliary power under harsh operating conditions.

 

Wide input range for railway battery systems

The CLS-500 operates over a 50.4 to 137.5 Vdc input range (3:1), allowing a single converter to support both 72 V and 110 V nominal railway battery profiles. This wide input capability simplifies system design and logistics by reducing the need for multiple converter variants across different train platforms, while maintaining compliance with EN 50155 requirements for onboard electronics.

 

Regulated isolated output and efficiency

The converter delivers an isolated and regulated 24 Vdc output suitable for auxiliary loads such as control electronics, communication systems, and sensors. It supports a 10% peak power margin to accommodate dynamic load conditions commonly found in railway applications.

 

With a typical efficiency of 95%, the CLS-500 minimizes conversion losses, reducing thermal stress and improving overall energy efficiency in onboard power architectures.

 

Electrical safety and insulation

To ensure safe operation under demanding electrical conditions, the CLS-500 incorporates reinforced insulation rated up to 5 kVdc. This insulation level supports reliable isolation between input and output circuits, contributing to system safety and compliance with railway electrical protection requirements.

 

Thermal performance and environmental robustness

The converter is designed with a baseplate cooling concept and a robust thermal architecture that enables derating-free operation up to +70 °C. It can also withstand temperatures of up to +85 °C for periods of up to 15 minutes, meeting OT4 and ST1/ST2 classifications.

 

This thermal resilience ensures stable performance during high ambient temperatures, transient thermal events, and installation in confined or poorly ventilated enclosures typical of rolling stock environments.

 

Protection and system integration features

The CLS-500 integrates multiple protection and control features to support secure and flexible system integration:

These features enable the converter to be used in both standalone and redundant power architectures, supporting high availability requirements in safety-critical train systems.

 

Standards compliance and railway suitability

The CLS-500 complies with key railway standards, including EN 50155 for electronic equipment on rolling stock, EN 45545-2 for fire protection, and EN 50121-3-2 for electromagnetic compatibility. Compliance with these standards confirms suitability for environments characterized by vibration, humidity, temperature extremes, and electrical disturbances.

 

Application context

By combining a wide input range, high efficiency, reinforced insulation, and robust thermal design, the CLS-500 addresses common challenges in onboard power conversion. Its ability to cover multiple battery voltages with a single unit makes it particularly relevant for modern railway platforms seeking to simplify design, improve reliability, and meet stringent regulatory requirements.

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