Circuit Protection Device
At Captor Corporation, our strong background in building electronic assemblies for aerospace applications prompted one of our clients to approach us for a replacement circuit protection device. What they had in their possession was an incomplete build package, so they leveraged our engineering expertise to fill in the blanks.
Designed to convert 115 VAC, 3-phase, 400 Hz input to 270 VDC, 6.5 A output, this device incorporated custom internal wire harnesses, AC power line filter, DC power lines, and lightning protection. It featured military grade input and output terminations and was constructed to withstand operating temperatures in the -55°C to +105°C range. Our sourcing engineer was responsible for finding replacement parts for obsolete components, and we manufactured some of the components in-house after procuring a suitable substitution for some obsolete materials.
Built according to IPC-A-610 Class 3 workmanship standards for high-reliability and mission critical applications, this device featured overall dimensions of 12.00″ in length x 8.00″ in width x 5.00″ in height and weighted approximately 7 lbs. We constructed the chassis from dip brazed aluminum to produce leak-tight and EMI shielded joints then applied an aerospace grade coating to provide a tough, resilient finish resistant to chemicals, solvents, and abrasion.
This device required extensive electrical and environmental testing. Various MIL-STD-202 test methods validated criteria such as dielectric withstand voltage (DWV), insulation resistance, capacitance, insertion loss, and point-to-point DCR. Environmental testing determined the effect of vibration, thermal shock, thermal cycling, humidity, and altitude.
Feedback from the client was outstanding. They confirmed that it functioned perfectly as a direct replacement, even with the material substitution. We supplied them with a complete new build package to simplify future sourcing.
If you would like more information about this project or our ability to engineer, build, and assemble custom circuit protection devices, contact us today.
Circuit Protection Capabilities
This product is a built to a customer print for an Air Force Application. It features 115 VAC to 270 VDC Rectifier, Internal Wire Harnesses, AC Power Line filter, DC power lines, and provides lightning protection.
Operating Voltages and Currents
115 VAC, 3 phase, 400 Hz, 4 amps
270 VDC, 6.5 amps
Electrical Testing Performed
DWV: MIL-STD-202, Method 301
Insulation Resistance: MIL-STD-202, Method 302, Test Condition A
Capacitance: MIL-STD-202, Method 305
Burn-In at rated voltages and currents
Insertion Loss: MIL-STD-220
Point to Point DCR measurements
Environmental Testing Performed
Vibration: MIL-STD-202, Method 204, Test Condition D
Thermal Shock/Cycling: MIL-STD-202 Method 107, Test Condition A
Humidity: MIL-STD-810 Method 507
Altitude: MIL-STD-202, Method 105, Perform DWV and IR
Overall Part Dimensions
12.00 x 8.00 x 5.00 inches
Operating Temperature Range
-55° to +105°C
Non-Operating Temperature Range
-55° to +125°C
Dip Brazed Aluminum
Painted in accordance with MIL-PRF-85285
Angle Bracket Feet
Industry for use
Air Force, Aerospace
AS9100 quality system, ANSI/IPC-A-610 Class 3 workmanship, IPC/WHMA-A-620