High-Performance Industrial DC to DC Power Conversion
Engineered to deliver clean, stabilized DC output voltages across demanding environments. Our isolated and non-isolated DC to DC converters support step-up, step-down, and 1:1 voltage matching for mission-critical infrastructure, railway, defence, power utilities, telecommunications, and heavy industrial applications.
Whether you require standard PCB mount converters, DIN rail industrial units, EN50155 railway certified supplies, or custom 19-inch rackmount power distribution chassis, Helios Power Solutions delivers backed by ISO 9001:2015 quality management and 100% factory burn-in testing.
Browse DC to DC Converter Architectures
Select from core form factors optimized for electrical isolation, environmental ruggedness, and mechanical mounting requirements.
Industrial DC/DC Converters
Rugged, heavy-duty industrial converters engineered for harsh ambient conditions, wide input windows, and high surge immunity.
- Power range: 100W – 30,000W
- Input options: 12V, 24V, 48V, 110V, 220VDC
- Features: Convection or forced cooling, N+1 parallel operation
PCB Mount DC/DC Converters
Compact SIP, DIP, and brick form factors providing high power density, precise output regulation, and high galvanic isolation for embedded systems.
- Power range: 0.5W – 700W
- Formats: SIP, DIP, 1/16th to Full Brick
- Isolation: Up to 5,000VAC medical/industrial isolation
DIN Rail Mount DC/DC Converters
Easy-to-install TS-35 DIN-rail converters with wide input ranges, pluggable terminal blocks, and encapsulated ruggedized enclosures.
- Power range: 15W – 480W
- Features: Adjustable output, DC-OK dry contacts
- Protection: Overvoltage, short circuit, reverse polarity
Railway DC/DC Converters
Fully compliant with EN50155, EN45545-2 fire safety, and RIA12 surge requirements for rolling stock and trackside signaling infrastructure.
- Nominal inputs: 24V, 36V, 48V, 72V, 96V, 110VDC
- Environmental: Shock & vibration tested to EN61373
- Design: Conformal coated PCBs, extended temperature (-40°C to +85°C)
High Input Voltage Industrial Converters
Designed for power utilities, solar arrays, and high-voltage DC bus systems requiring reliable step-down to standard control voltages.
- Input range: 300VDC – 1000VDC
- Outputs: 12V, 24V, 48VDC regulated
- Efficiency: Up to 93% conversion efficiency
Mil-Spec Isolated DC/DC Converters
Hardened COTS and custom military-grade converters qualified to MIL-STD-810G, MIL-STD-461 EMC, and MIL-STD-1275 vehicle power standards.
- Platforms: Tactical land vehicles, naval vessels, avionics
- Enclosures: Sealed IP65/IP67 chassis, conduction cooled
- Reliability: Full component traceability and environmental screening
Featured In-Stock DC to DC Converter Modules
Pre-tested, field-proven 120W isolated converters available for immediate allocation under the Helios Priority Programme.
APK120-4812 (48V to 12V DC)
120W convection-cooled isolated converter. 48VDC nominal input (36-72V continuous), 12VDC output @ 10A (+/- 7% adjustable). Field-proven MTBF > 260,000 hours.
- Mounting: DIN Rail & Panel Mount
- Cooling: Natural Convection
- Isolation: Fully Galvanic Isolated I/O
APK120-4824 (48V to 24V DC)
120W ruggedized isolated converter. 48VDC input, 24VDC output @ 5A (+/- 7% adjustable). Fully encapsulated and EMC hardened for dirty electrical environments.
- Mounting: DIN Rail & Panel Mount
- Protections: Overcurrent, Overvoltage, Short Circuit
- Burn-In: 100% Factory Burn-In Tested
APK120-2412 (24V to 12V DC)
120W industrial grade converter. 24VDC input (18-36V continuous), 12VDC output @ 10A. Designed for industrial control systems and land mobile radio installations.
- Mounting: DIN Rail & Panel Mount
- Terminations: Pluggable screw terminals
- Hardening: Conformal coated for humidity protection
DC to DC Converter Selection Matrix
Use this technical matrix to evaluate conversion topologies based on key electrical and mechanical parameters.
| Product Series | Input Range (VDC) | Output Range (VDC) | Power Rating | Galvanic Isolation | Primary Standards & Certifications |
|---|---|---|---|---|---|
| PCB Brick Modules | 9 – 154 VDC (4:1 / 8:1) | 3.3, 5, 12, 15, 24, 48 VDC | 0.5W – 700W | 1500VDC – 3000VAC | IEC/EN 62368-1, CE, UL Recognized |
| DIN Rail Industrial | 18 – 75 VDC / 90 – 350 VDC | 12, 24, 48 VDC (Adj.) | 15W – 480W | 2000VDC – 3000VDC | EN 61000-6-2, EN 61000-6-4 industrial EMC |
| Railway EN50155 | 14.4 – 154 VDC continuous | 5, 12, 24, 48, 110 VDC | 50W – 1000W | 3000VAC reinforced | EN 50155, EN 45545-2, EN 61373 Shock/Vib |
| High Input Voltage (HVI) | 200 – 1200 VDC | 12, 24, 48, 110 VDC | 100W – 5kW | 4000VAC primary-to-secondary | Substation / Utility Standards, IEC 61850 compliance |
| 19-Inch Custom Rackmount | 24, 48, 110, 220 VDC | Custom Single / Multi-Output | 500W – 30kW | Fully Isolated Channels | ISO 9001:2015 Engineered, FAT Documentation |
Over 50% of shipped systems are customized to client engineering specifications Need a Custom Rackmount, N+1 Redundant, or Multi-Output DC-DC System?
Standard datasheets do not always meet complex site conditions. Helios Power Solutions specializes in value-added engineering, transforming standard DC-DC modules into fully integrated turnkey systems tailored to your technical requirements.
- 19-Inch Rack Assembly: 1U to 6U custom rackmount integration with input/output circuit breakers and busbars.
- Redundancy & Current Sharing: N+1 or N+2 hot-swappable configurations with internal OR-ing diodes and active load sharing.
- Monitoring & Control: Remote telemetry integration supporting DNP3, Modbus RTU/TCP, SNMP traps, and dry alarm contacts.
- Environmental Protection: Tropicalization via conformal coating, shock/vibration ruggedization, and IP54/IP65 outer enclosures.
Frequently Asked Questions by Technical Buyers
Isolated DC to DC converters utilize an internal transformer to physically and electrically separate the input circuit from the output circuit (galvanic isolation). This eliminates ground loops, insulates delicate electronic control equipment from high-voltage input surges, and permits negative or floating ground configurations. Non-isolated converters share a continuous ground line between input and output; they offer smaller physical dimensions and slightly higher conversion efficiency at lower cost, making them ideal when isolation is provided elsewhere in the circuit.
Yes. Over half of our delivered solutions involve custom engineering. We build complete 1U–6U 19-inch rackmount assemblies incorporating multiple DC-DC converter channels, input/output distribution circuit breakers, status LEDs, alarm relays, voltmeters, and communication interfaces tailored to utility SCADA or telecom management systems.
Our product portfolio covers compliance with major global industrial and military standards. These include EN 50155 and EN 45545-2 for railway rolling stock, MIL-STD-810G, MIL-STD-461, and MIL-STD-1275 for defence applications, IEC/EN 62368-1 for IT and industrial safety, and IEC 61000-6-2/4 for heavy industrial electromagnetic compatibility.
Our application engineers perform thorough thermal modeling based on your installation ambient (e.g., +50°C to +70°C enclosed cabinets). We specify high-efficiency modules, heavy aluminum heatsinking, conduction cooling baseplates, or controlled forced-air ventilation to ensure continuous full-load operation without unexpected thermal shutdown.
Require Technical Advice or a Custom Quotation?
Contact our senior power application engineers to review your input/output voltage, power rating, and enclosure specification.