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MIL-COTS Power Solutions
XP Power offers a wide range of MIL-COTS AC/DC and DC/DC products that enable a designer to easily meet key industry standards such as
MIL-STD461E/F, 1275A-D,704A-F & 810F, DEF STAN 59-41 & 61-5 and DO160
All products are commercial off the shelf (COTS) items and available from stock or on short leadtimes.
Click here to view our MIL COTS DC/DC Selector Guide .
Click here for the latest Defense and Avionics brochure.
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| COTS Product Overview |
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MTC: DC-DC Converter |
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5-35 Watts max |
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10-50 VDC input voltage |
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-55 ºC to +100 ºC operating range |
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High power density |
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Rugged construction |
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MTF: Active EMI Filter & Surge Suppression |
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50 Watts |
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10-50 VDC input voltage |
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-55 ºC to +105 ºC operating range |
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MIL-STD 1275A-D, 704A-F & DEF STAN 61-5 |
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EMI to MIL-STD 461E & DEF STAN 59-41 |
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MCM60: Rugged AC-DC Power Supply |
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60 Watts |
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Compact size - high power density |
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Rugged construction |
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Wide operating temperature |
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EMI to MIL-STD 461E |
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CCM250: AC-DC Power Supply |
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250 Watts |
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Very high efficiency up to 95% |
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Class B conducted & radiated emissions |
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80-275 VAC operation |
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300 Watt peak for 500 ms |
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MCC: Configurable DC-DC Converter |
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400-600 Watts |
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28 V MIL-STD 1275A-D input |
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-40 ºC to +90 ºC operating range |
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1-4 factory configurable outputs |
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EMI to MIL-STD 461E |
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DSF: Active EMI Filter & Surge Suppression |
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100-500 Watts |
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Up to 28 A Output Current |
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Active Surge Protection |
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MIL-STD 461E, 1275A-D, 810F & DEF STAN 59-41 |
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Reverse Voltage Protection |
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MQP: DC-DC Converter |
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120 Watts |
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9.5-40 VDC input |
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Isolated & regulated outputs |
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Continuous short circuit protection |
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Five-sided metal case |
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BCC; AC-DC Power Supply |
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200-400 Watts |
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Baseplate-cooled |
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Wide operating temperature range |
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Parallel operation |
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Active PFC |
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CI, I, IT, IV & SS: DC-AC Inverter |
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200 VA to 12 kVA |
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Single output DC-AC inverter |
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DC inputs 10-400 V |
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Sinusoidal output 12-480 V |
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Static switches |
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Military Power Supplies |
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| COTS: A definition, advantages and disadvantages |
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Commercial off-the-shelf (COTS) is a term for components which are manufactured commercially, readily available, and are non-development items. This term is most often used in military systems. COTS systems are in contrast to systems that are produced entirely and uniquely for the specific application and therefore offer potentially large cost and time savings.
Most COTS items are not produced for the defense market. This means they either need to be modified or the user must accept some level of commercial or technical risk such as obsolescence, process changes, environmental, electrical performance or EMI issues when designing them into a system. Also, due to the relatively small volumes used in the defense industry, compared with industrial, consumer or telecoms markets, companies are finding it increasingly difficult to obtain the level of technical support they demand for high reliability programs.
XP Power provides COTS products designed specifically for the defense and avionics market. Our systems and people are geared to support these markets.
XP Power also has a wide range of standard power products sold to medical, industrial and telecoms customers many of these products can be used or adapted for defense and avionic applications.
Considerations in deploying COTS components in high reliability application
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Reliability |
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Long service life |
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Input voltage |
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Electromagnetic compatibility |
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Environmental factors |
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Stringent space and weight requirements |
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Industry knowledge and support available from manufacturer |
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| DO160 Aircraft Power |
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XP Power can provide solutions compliant to DO160 environmental and EMI
requirements for use in civil avionics and inflight entertainment (IFE)
systems. We have developed a range of solutions that enable us to create a
solution for typical DO160 power supply requirements.
Typical DO160 PSU requirements
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DO160 standard |
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115 VAC (100-134 VAC steady state) |
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400 Hz and 800 Hz "wild frequency" |
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Total harmonic distortion limits |
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Input voltage surges and spikes |
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Emissions and susceptibility to DO160 |
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Power interruptions typically up to 200 mS |
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Cooling via natural convection or conduction |
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Extended operating temperatures (-55 ºC to 70 ºC) |
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MTC & MTF Series |
The MTC and MTF Series has been specifically developed for 28 VDC input defense and avionic systems – enabling a COTS modular power system to be built using the minimum of external components and design time.
The isolated MTC DC-DC converter uses a forward converter topology switching at 450 kHz, and utilizes synchronous rectification for lower output voltages to boost efficiency. The units are packaged in miniature aluminium heatsink cases, with a cooling plate that enables operation over extreme ambient temperatures. The MTC has mounting holes that can be used to
mechanically secure the unit, improving thermal conductivity as well as shock and vibration performance.
The MTC has an extensive signal and control set including: inhibit, voltage trim, thermal warning signal (MTC30 unit), remote sense and ability to synchronize switching frequency to an external source.
The MTF Filter module is available to condition the input to meet a wide range of military EMI and immunity specifications. This product contains an active surge and spike protection circuit as well as a passive EMI filter.
Both MTC and MTF have been extensively qualified for the key environmental parameters associated with high reliability applications such as shock, vibration, bump, humidity, salt-fog and altitude.
MTC Design System
The MTF is designed as a system input module for the MTC Series. Its high performance surge protection ensures that the MTC is protected from the surges, spikes and ripples commonly seen in defense and avionic applications. The system requires very few external components to meet stringent military requirements and is supported by applications notes and XP’s engineering team.
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| Key features of the MTC Series |
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15-40 VDC steady state input |
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10-50 VDC transient input meets MIL-STD 704 B-F |
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Meets MIL-STD 704A with MTF50 or DSF filter |
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5-35 Watts output power |
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Standard outputs: 3.3, 5, 12, 15 and 28 VDC |
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-55 to 100 ºC operating range |
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Defense EMI, immunity and environmental performance |
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High power density |
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Inhibit |
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Frequency synchronization |
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Voltage trim |
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Thermal warning (Battle Mode) |
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Remote sense |
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Removable OVP and OTP |
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MCC Series |
Configurable and Flexible Power Solutions
The MCC Series is a 28 VDC input power system developed from proven technology for defense applications. The MCC provides a standard power supply platform that is configurable at time of order. This type of power solution has been available from XP Power for its industrial customers for many years.
The MCC Series has a high performance filter qualified to meet MIL-STD 1275A/B/C and MIL-STD 704A-F. It has been qualified to the CE and CS requirements of MIL-STD 461E. Extensive environmental qualification provides a proven product which is sufficiently robust for applications such as tracked and wheeled vehicles, military communications, naval systems and aerospace.
The MCC was developed in the XP Engineering Services group using its extensive experience of military power supply design. This means, unlike other DC-DC converters, the MCC platform is easily customizable for relatively low NRE and production volumes. This modification could be as simple as providing a non-standard output voltage, increasing a power limit, adding a parallel connection or making mechanical changes.
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| Key features of the MCC Series |
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28 VDC input (18–36 VDC continuous) |
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16 VDC input available as an option |
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400 Watts regulated output power with 1 – 4 outputs |
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Output Voltages 1.8 to 48 VDC |
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Operating temperature: -40 to 90 ºC baseplate |
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Military EMI, immunity and environmental performance |
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Global inhibit |
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Inhibit |
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Factory trimmable outputs |
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Remote sense |
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OVP and overload protection
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Flexible High Reliability Solutions |
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XP Power is a market-leading designer and manufacturer of switch mode power conversion products. Our customers are typically OEMs in industries as diverse as medical, industrial, communications and defense. Here we highlight a selection of products that were developed for our whole customer base that are of interest to defense customers.
These products are used in many high reliability applications such as VME/cPCI systems, navy sonar, battery charging systems, vetronics and secure communications systems.
Due to XP’s in-depth understanding of the issues surrounding high reliability power system design, our engineers can advise on the integration of these products with particular emphasis on key issues such as:
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Low temperature operation |
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Ruggedization |
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EMI control to military EMI specifications |
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Immunity to military electrical specifications |
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Electrical modification |
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Design control |
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Long term availability |
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Engineering Services - Design Philosophy |
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Our philosophy is to design non-standard power solutions from our comprehensive range of commercial off-the-shelf (COTS) power supplies, many of which were developed specifically as building blocks for use in military applications. These power supplies and modules are manufactured in volume for numerous customers, allowing us to pass on the advantage of economies of scale and proven manufacturing.
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Low Development Costs |
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We use standard or modified standard products as building blocks, to lower costs |
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Low Risk |
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Proven technology with known performance and space envelope |
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Short Development Times |
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We will often have an existing design that can be adapted to meet a new requirement |
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Low Unit Cost |
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Take advantage of the economies of scale generated by thousands of customers worldwide |
XP Power Engineering Services Group in North America are fully compliant with International Arms Regulation (ITAR) and US department of state regulations for the design and manufacture of non-standard power supplies.
For more details about our custom power solutions - click here
A range of technical articles are also available here
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