Executive Summary

In modern high voltage power supply design, engineers are often forced to choose between "performance compromise" and "design complexity". From the perspective of DfR (Design for Reliability) and DfM (Design for Manufacturability), HVCA (Dean Technology)'s traditional product line has gradually reached its physical performance ceiling.

HVC (High Voltage Components) has launched the HVD series through material and packaging optimization. Single-unit voltage extends to 600kV, reverse recovery time is pushed toward 35ns, and IP67-grade epoxy packaging is available—supporting a drop-in upgrade path where PCB layout changes are often unnecessary.

1. Pain Point Reconstruction: HVCA Traditional Technology Route's "Design Debt"

In communication with many senior power supply engineers, we found that HVCA products often force the design side to carry heavy "technical debt":

A. Topology Complexity from Voltage Ceiling

HVCA's standard product catalog typically stops at 60kV. When designing 150kV or 300kV X-Ray generators, engineers are forced to adopt multi-stage series stacking solutions.

• Design Hazard: Series structures must introduce high-precision voltage balancing resistors and compensation capacitors, which not only increases BOM costs but also introduces additional parasitic parameters.
• Failure Model: According to reliability physics models, the MTBF (Mean Time Between Failures) of series links decreases exponentially as the number of nodes increases. A single diode breakdown often leads to cascading failure of the entire rectifier bridge.

B. Frequency Limitations Lock Down Power Density

Modern resonant converters (such as LLC, LCC) pursue higher switching frequencies to reduce magnetic component volume. However, HVCA's standard rectifiers typically have Trr at 100-150ns, even degrading to 200ns at high temperatures.

• Thermal Runaway Risk: In high-frequency (>50kHz) hard-switching topologies, slow reverse recovery generates massive reverse recovery losses (Prr), causing junction temperature to rapidly climb to the Tjmax limit.

C. Environmental Vulnerability

Many older HVCA models (such as partial HVBF series) still retain non-sealed or simple potting structures, heavily relying on external insulating oil or SF6 gas protection. This increases system maintenance difficulty and environmental compliance costs.

2. Parametric Superiority: HVC's Engineering Value

The HVC HVD series is not a simple "domestic replacement", but a "parametric reconstruction" based on third-generation high-voltage rectification technology.

Key Parameter	HVCA Specification Baseline	HVC HVD Performance Boundary	Design Dividend
Voltage Range (VR)	15kV - 60kV	1kV - 600kV	Eliminate series stacking: Single unit direct voltage bearing, BOM reduced by 60%, system MTBF increased 2.5x.
Reverse Recovery (Trr)	100ns - 150ns	20ns - 100ns	Support high-frequency: Adapted for 50kHz+ resonant switching, switching loss (Prr) reduced by 35%, magnetic core volume reduced by 40%.
Surge Capability (IFSM)	10A (typical)	20A - 800A	Enhanced robustness: Easily meets IEC 61000-4-5 standard, external TVS protection tubes can be removed in most scenarios.
Leakage Current (IR)	μA level	nA level	Reduced thermal accumulation: Heat generated by leakage current at ultra-high voltage is halved, effectively preventing thermal runaway.
Packaging Rating	Standard / Oil-immersion required	IP67 epoxy vacuum potting	Maintenance-free design: Supports air-insulated or solid-insulated applications, eliminating oil leakage risk.

3. Hardcore Practice: Full-Scenario 1:1 Seamless Replacement Matrix

To ensure design engineers can switch with "zero risk", HVC has compiled a replacement list covering three major scenarios: medical imaging, high-frequency power supplies, and precision instruments based on HVCA physical measurements.

Scenario A: Ultra-High Voltage Medical Imaging and Non-Destructive Testing (X-Ray / CT / NDT)

For HVCA's HVBF series (long-form board-level rectifiers), HVC's HVD-2CLG series achieves dual excellence in dimensions and performance. Particularly for 600kV extreme high-voltage applications, HVC is one of the few manufacturers globally with single-unit mass production capability.

[Core Benchmark Data]
(Data sourced from HVC laboratory measurements and HVCA Datasheet)

HVCA Part Number	Specs (VR/IO/Trr)	HVC 1:1 Replacement	Engineer's Upgrade Points
HVBF600	600kV/ 1050mA / 100ns	HVD-2CLG600KV/1050mA	Ultimate withstand voltage: Single unit 600kV, lower temperature rise at 1050mA full load.
HVBF200	200kV / 385mA / 100ns	HVD-2CLG200KV/385mA	Thermal management optimization: Large chip technology, surge capability increased 20%.
HVBFP150	150kV / 286mA / 100ns	HVD-2CLG150KV/290mA	Redundant design: Rated current increased to 290mA, improved overload safety margin.
HVBFN100	100kV / 242mA / 100ns	HVD-2CLG100KV/245mA	Pin-to-Pin: Completely consistent mounting hole positions and terminal definitions.

Scenario B: High-Frequency Switching Power Supplies and Inverters (SMPS / Inverters)

In high-frequency applications above 20kHz, HVCA's HVFE (Fast Recovery) series is often criticized by engineers for heating issues. HVC's HVD-SL series is specifically designed to solve this pain point, providing 35ns ultra-fast recovery characteristics.

[Core Benchmark Data]

HVCA Part Number	Specs (VR/IO/Trr)	HVC 1:1 Replacement	Engineer's Upgrade Points
HVFE5000	5kV / 600mA / 35ns	HVD-SL6150T	High-frequency tool: Measured Trr stable at 35ns, significantly reducing MOSFET turn-on losses.
HVFE2500	2.5kV / 600mA / 35ns	HVD-SL34G	Low-temperature operation: Junction temperature 15°C lower than original under same conditions, extending system life.
HVF2500	2.5kV / 500mA / 150ns	HVD-SL32G	Cost optimization: High cost-performance solution for auxiliary power supplies insensitive to speed.

Scenario C: General High Voltage Rectification (General Purpose)

For the most commonly used HV series, HVC provides standardized axial lead products, with all series passing AEC-Q101 standard reliability verification.

[Core Benchmark Data]

HVCA Part Number	Specs (VR/IO)	HVC 1:1 Replacement	Engineer's Upgrade Points
HV5000	5kV / 600mA	HVD-2CL5KV/600mA	Stock support: Available inventory, solving R&D sample waiting pain points.
HV20000	20kV / 600mA	HVD-2CL20KV/600mA	Insulation upgrade: Enhanced epoxy encapsulation, eliminating creepage and flashover.

Appendix: Complete Model Cross-Reference Table

A. High Voltage X-Ray Board-Level Rectifiers (HVCA)

HVCA Part Number	Reverse Voltage (kV)	Avg Current (mA)	Recovery Time (ns)	HVC Replacement
HVBF200	200	660	100	HVD-2CLG200KV/660mA
HVBF250	250	660	100	HVD-2CLG250KV/660mA
HVBF300	300	660	100	HVD-2CLG300KV/660mA
HVBF350	350	780	100	HVD-2CLG350KV/780mA
HVBF450	450	780	100	HVD-2CLG450KV/780mA
HVBF600	600	1050	100	HVD-2CLG600KV/1050mA
HVBFN100	100	242	100	HVD-2CLG100KV/245mA
HVBFN150	150	286	100	HVD-2CLG150KV/290mA
HVBFN200	200	385	100	HVD-2CLG200KV/385mA
HVBFP100	100	242	100	HVD-2CLG100KV/245mA
HVBFP150	150	286	100	HVD-2CLG150KV/290mA
HVBFP200	200	385	100	HVD-2CLG200KV/385mA
HVB200	200	300	–	HVD-2CL200KV/300mA
HVB250	250	360	–	HVD-2CL250KV/360mA
HVB300	300	360	–	HVD-2CL300KV/360mA
HVB350	350	390	–	HVD-2CL350KV/390mA
HVB450	450	480	–	HVD-2CL450KV/480mA
HVBN75	75	110	–	HVD-2CL75KV/110mA
HVBN100	100	132	–	HVD-2CL100KV/135mA
HVBN125	125	143	–	HVD-2CL125KV/145mA
HVBN150	150	176	–	HVD-2CL150KV/180mA
HVBP75	75	110	–	HVD-2CL75KV/110mA
HVBP100	100	132	–	HVD-2CL100KV/135mA
HVBP125	125	143	–	HVD-2CL125KV/145mA
HVBP150	150	176	–	HVD-2CL150KV/180mA
HVBD75	75	110	–	HVD-2CL75KV/110mA
HVBD100	100	132	–	HVD-2CL100KV/135mA
HVBD125	125	143	–	HVD-2CL125KV/145mA
HVBD150	150	176	–	HVD-2CL150KV/180mA
HVMBF225	225	506	100	HVD-2CLG225KV/510mA
HVMBF325	325	598	100	HVD-2CLG325KV/600mA
HVMBR450	450	805	100	HVD-2CLG450KV/810mA
HVMB175	175	230	–	HVD-2CL175KV/230mA
HVMB225	225	276	–	HVD-2CL225KV/280mA
HVMB275	275	299	–	HVD-2CL275KV/300mA
HVMB325	325	368	–	HVD-2CL325KV/370mA
HVSBF100	100	308	100	HVD-2CLG100KV/310mA
HVSBF150	150	364	100	HVD-2CLG150KV/365mA
HVSBF200	200	364	100	HVD-2CLG200KV/365mA
HVSB100	100	140	–	HVD-2CL100KV/140mA
HVSB150	150	182	–	HVD-2CL150KV/185mA
HVSB200	200	224	–	HVD-2CL200KV/225mA
XRBF100	100	352	100	HVD-2CLG100KV/355mA
XRBF125	125	352	100	HVD-2CLG125KV/355mA
XRBF150	150	416	100	HVD-2CLG150KV/420mA
XRBF175	175	416	100	HVD-2CLG175KV/420mA
XRBF200	200	416	100	HVD-2CLG200KV/420mA
XRBF250	250	560	100	HVD-2CLG250KV/560mA
XRB100	100	160	–	HVD-2CL100KV/160mA
XRB125	125	192	–	HVD-2CL125KV/195mA
XRB150	150	208	–	HVD-2CL150KV/210mA
XRB175	175	256	–	HVD-2CL175KV/260mA
XRB200	200	256	–	HVD-2CL200KV/260mA
XRLBF100	100	374	100	HVD-2CLG100KV/375mA
XRLBF125	125	374	100	HVD-2CLG125KV/375mA
XRLBF150	150	442	100	HVD-2CLG150KV/445mA
XRLBF175	175	442	100	HVD-2CLG175KV/445mA
XRLBF200	200	442	100	HVD-2CLG200KV/445mA
XRLBF250	250	595	100	HVD-2CLG250KV/595mA
XRLB100	100	170	–	HVD-2CL100KV/170mA
XRLB125	125	204	–	HVD-2CL125KV/205mA
XRLB150	150	221	–	HVD-2CL150KV/225mA
XRLB175	175	221	–	HVD-2CL175KV/225mA
XRLB200	200	272	–	HVD-2CL200KV/275mA

B. High Voltage Rectifier Modules - Axial Lead Series 1

HVCA Part Number	Reverse Voltage (kV)	Avg Current (mA)	Recovery Time (ns)	HVC Replacement
HV5000	5	600	–	HVD-2CL5KV/600mA
HV7500	7.5	600	–	HVD-2CL7.5KV/600mA
HV10000	10	600	–	HVD-2CL10KV/600mA
HV15000	15	600	–	HVD-2CL15KV/600mA
HV20000	20	600	–	HVD-2CL20KV/600mA
HV25000	25	600	–	HVD-2CL25KV/600mA
HV30000	30	600	–	HVD-2CL30KV/600mA
HVF2500	2.5	500	150	HVD-SL32G
HVF5000	5	500	150	HVD-SL6150T
HVF7500	7.5	500	150	HVD-CL08-08
HVF10000	10	500	150	HVD-CL08-10
HVF12500	12.5	500	150	HVD-SLG4009
HVF15000	15	500	150	HVD-CL05-15S
HVF20000	20	500	150	HVD-CL08-20
HVFE2500	2.5	600	35	HVD-SL34G
HVFE5000	5	600	35	HVD-SL6150T
HVFES2500	2.5	1300	35	HVD-SL34G
HVFES5000	5	1300	35	HVD-SL6150T
HVFS2500	2.5	750	250	HVD-2CLG2.5KV/750mA
HVFS5000	5	750	250	HVD-2CLG5KV/750mA
HVFS7500	7.5	750	250	HVD-2CLG7.5KV/750mA
HVFS10000	10	750	250	HVD-2CLG10KV/750mA
HVFS12500	12.5	750	250	HVD-2CLG12.5KV/750mA
HVFS15000	15	750	250	HVD-2CLG15KV/750mA
HVFS20000	20	750	250	HVD-2CLG20KV/750mA
HVFS25000	25	750	250	HVD-2CLG25KV/750mA
HVFS30000	30	750	250	HVD-2CLG30KV/750mA
HVS2500	2.5	1100	–	HVD-2CL2.5KV/1100mA
HVS5000	5	1100	–	HVD-2CL5KV/1100mA
HVS7500	7.5	1100	–	HVD-2CL7.5KV/1100mA
HVS10000	10	1100	–	HVD-2CL10KV/1100mA
HVS12500	12.5	1100	–	HVD-2CL12.5KV/1100mA
HVS15000	15	1100	–	HVD-2CL15KV/1100mA
HVS20000	20	1100	–	HVD-2CL20KV/1100mA
HVS25000	25	1100	–	HVD-2CL25KV/1100mA
HVS30000	30	1100	–	HVD-2CL30KV/1100mA
HVUF2500	2.5	500	75	HVD-SL32G
HVUF5000	5	500	75	HVD-SL6150T
HVUF7500	7.5	500	75	HVD-CL08-08
HVUF10000	10	500	75	HVD-CL08-10
HVUF12500	12.5	500	75	HVD-SLG4009
HVUF15000	15	500	75	HVD-CL05-15S
HVUF20000	20	500	75	HVD-CL08-20
HVUF25000	25	500	75	HVD-2CLG25KV/500mA
HVUSF2500	2.5	500	35	HVD-SL34G
HVUSF5000	5	500	35	HVD-SL6150T
HVUSF10000	10	500	35	HVD-CL08-10
HVUSF12500	12.5	500	35	HVD-SLG4009
HVUSF15000	15	500	35	HVD-CL05-15S
HVUSF20000	20	500	35	HVD-CL03-18C
HVUSF7500	75	500	35	HVD-2CLG75KV/500mA
HVUSFS2000	2.5	1250	40	HVD-SL34G
HVUSFS5000	5	1250	40	HVD-SL6150T
HVUSFS7500	7.5	1250	40	HVD-2CLG7.5KV/1.5A
HVUSFS10000	10	1250	40	HVD-2CLG10KV/1.5A
HVUSFS12500	12.5	1000	40	HVD-2CLG12KV/1A
HVUSFS15000	15	1000	40	HVD-2CLG15KV/1A
HVUSFS20000	20	1000	40	HVD-2CLG20KV/1A

C. High Voltage Rectifier Modules - Axial Lead Series 2

HVCA Part Number	Reverse Voltage (kV)	Avg Current (mA)	Recovery Time (ns)	HVC Replacement
G20PE	20	15	100	HVD-SL20G15
G25PE	25	15	100	HVD-SL25G15
G30PE	30	15	100	HVD-SL30G15
RHV15	15	25	100	HVD-SL15G25
RHV20	20	25	100	HVD-SL20G25
RHV25	25	25	100	HVD-SL25G25
RHV30	30	25	100	HVD-SL30G25
RHV40	40	25	100	HVD-SL40G25
RHV50	50	25	100	HVD-SL50G25
RHV60	60	25	100	HVD-SL60G25
RHV90	90	25	100	HVD-SL90G25
RHV120	120	25	100	HVD-SL120G25
RHV150	150	25	100	HVD-SL150G25
BCHV08	8	100	–	HVD-CL01-08
BCHV10	10	100	–	HVD-CL01-10
BCHV12	12	100	–	HVD-CL01-12
BCHV15	15	100	–	HVD-CL01-15
BCHV20	20	100	–	HVD-2CL20KV/100mA
BCHV25	25	100	–	HVD-2CL25KV/100mA
BCHV30	30	100	–	HVD-2CL30KV/100mA
BCHV35	35	100	–	HVD-2CL35KV/100mA
BCHV40	40	100	–	HVD-2CL40KV/100mA
BCHV50	50	100	–	HVD-2CL50KV/100mA
BCHV60	60	100	–	HVD-2CL60KV/100mA
RTHV08	8	100	100	HVD-CL08-08
RTHV10	10	100	100	HVD-CL08-10
RTHV15	15	100	100	HVD-CL05-15S
RTHV20	20	100	100	HVD-2CL2FM
RTHV25	25	100	100	HVD-2CLG25KV/100mA
RTHV30	30	100	100	HVD-2CL2FP
RTHV40	40	100	100	HVD-2CLG40KV/100mA
RTHV45	45	100	100	HVD-2CLG45KV/100mA
RTHV50	50	100	100	HVD-2CLG50KV/100mA
RTHV60	60	100	100	HVD-2CLG60KV/100mA
RTHV80	80	100	100	HVD-2CLG80KV/100mA
RSUF2	2	650	35	HVD-SL32G
RSUF3	3	650	35	HVD-SL34G
RSUF5	5	550	35	HVD-SL6150T
RSUF7	7	500	35	HVD-SL37G
RSUFH12	1.2	1500	35	HVD-SL31G
RSUFH18	1.8	1500	35	HVD-SL32G
RSUFH24	2.4	1250	35	HVD-SL34G
RSUFH36	3.6	1250	35	HVD-SL34G
RSUFH42	4.2	1250	35	HVD-SL6150T

D. Full-Wave Bridge Rectifiers (HVCA)

HVCA Part Number	Reverse Voltage (kV)	Avg Current (mA)	Recovery Time (ns)	HVC Replacement
HV400F2	2	7	300	HVD-2CL69
HV400F4	4	10	300	HVD-2CL69
HV400F6	6	16	300	HVD-2CL70
HV400F8	8	16	300	HVD-2CL71
HV400F10	10	20	300	HVD-2CL72

4. Technical Deep Dive: Why HVC Can Surpass the Original

Many engineers ask: "With the same specifications, why can HVC achieve better performance?" The answer lies in the underlying "Three Major Process Innovations":

1. Large Die Technology

HVC has increased the effective chip area by 30% at significant cost. According to J = I/A (current density formula), larger area directly reduces current density, thereby decreasing forward voltage drop (VF) and heat generation.

2. Nano-Passivation Process

Using unique glass passivation (GPP) or polyimide passivation processes, leakage current (IR) at high temperatures is locked at the microamp level, completely cutting off the "leakage-heat-leakage increase" thermal runaway positive feedback loop.

3. Vacuum Epoxy Potting

All products undergo epoxy resin encapsulation in a vacuum environment, completely eliminating internal micro-bubbles (the breeding ground for Partial Discharge), enabling stable long-term operation at 120% rated voltage.

5. Engineer's Action Guide: How to Validate HVC Performance?

We don't want you to replace blindly, but rather recommend verifying HVC's advantages through rigorous data. The recommended DVT (Design Verification Test) process is as follows:

1. Thermal Imaging Comparison: Under full load conditions, use an infrared thermal imager to compare the case temperature of HVCA and HVC equivalent models. You will see HVC averages 10-20°C lower.
2. Double Pulse Test: In high-frequency applications, observe the reverse recovery current (Irr) tail through double pulse testing. HVC's waveform will be "sharper" with less ringing.
3. High Temperature Reverse Bias (HTRB): Apply 80% rated reverse voltage at 125°C for 168 hours, monitoring leakage current drift.

Conclusion

The HVC HVD series is not just a replacement for HVCA, but an evolution of power system performance. It frees engineers from tedious series voltage balancing design and complex thermal calculations, allowing focus on system architecture innovation.

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