MIL-STD-461-C INPUT EMI FILTER for 4W up to 50W DC/DC Converters KG 9501 Accessories • To comply with MIL-STD-461-C power leads : • CE 03 : Emission requirement over 15 kHz • CS 01 : Susceptibility requirement over 30Hz to 50KHz • CS 02 : Susceptibility requirement over 50KHz to 400MHz • CS 06 : Susceptibility • Current range up to 2A • Reverse polarity protection • SMD Components • Small surface : 20 mm x 25 mm (0.8” x 1”) • Temperature range : -55°C/+105°C 1-Subject The EMI front filter kit KG9501 enables Gaia Converter DC/DC modules or preregulators front-end modules below 50W power to be fully compliant with the MIL-STD-461-C Part 2 & 3 standard as follow : • CE03, class A1, narrowband • CE03, class A1, broadband, curve# 1 & 2 • CS01, class A1, consult factory for criteria • CS02, class A1 • CS06, class A1, spike # 2 This EMI front filter kit is compatible with all GAIA Converter DC/DC modules with J family of input range (16-40 Vdc) or H family of input range (9-36 Vdc), with all pre-regulator PGDS-50 series and can drive up to 2A input current. This EMI front filter KG9501 is a kit of 15 components as follow. 2- Components D1 ............... : Diode TO-220 format, BYW29-200 SGS-Thomson or Philips L1 ............... : Common mode choke Fair-rite type 2744041447 or equivalent Ferroxcube CMS2-5.6/3/4.8-4S2 (replacement of obsolete Philips type 12NC433003036881) L2 ............... : Ferrite bead Fair-rite type 2743021447 or equivalent Ferroxcube type BDS 3/3/8.9-3S1 (replacement of obsolete Philips type 12NC43300303645) L3 ............... : Ferrite bead Fair-rite type 2743021447 or for better performances differential mode inductance Coilcraft type DO3316P-472 (both components are provided in the GAIA Converter kit.) C1, C2, C3 & C4*: SMD 10µF tantalum capacitor, 7343D 10µF 20% 293D serial D package CTC3 type C5 & C6 ........ : SMD 1206 ceramic capacitor, 100nF/50 V 20% X7R type Vishay reference VJ1206Y104MXAT or TDK reference C3216x7R1H104KT R1, R2, R3 & R4 : SMD 0805 resistor, 1M 5% 200 PPM 150V 0.125W * Note : The choice of capacitor rating values depends on level of transients required (i.e 60V, 80V or 100V) REDEFINING THE SOURCE OF POWER © Gaia Converter FC97-003.04/05 Revision H For locations, phone, fax, E-Mail see back cover 4 Accessories KG9501 Series 3- Schematic The EMI front filter kit KG9501 can be used either : • directly in front of any GAIA Converter DC/DC modules or assembly of DC/DC modules up to 50W power • in front of GAIA Converter pre-regulator PGDS-50 series. Both schematics are resumed hereafter. 3-1 Connection to GAIA Converter DC/DC Converter D1 L1 L2 + Input C5 L3 Vo Vi C1 R1 C3 R3 C2 R2 C4 R4 - Input MGDM-Series Go Gi C6 Common mode noise capacitance Cc = 10nF (See note below) *Chassis ground Notes : it is suggested to use a common mode capacitor Cc (10 nF/1.500V) to increase EMI performance. This capacitor should be layed-out as close as possible from the DC/DC converter. 4 * For connection to chassis ground, if a higher isolation is required, it is suggested to use 10nF with voltage rating compliant with application requirements as capacitors C5 and C6. 3-2 Connection to GAIA Converter Pre-regulator PGDS-50 & DC/DC Converters Vi Vo MGDM-Series D1 + Input L1 L2 L3 C5 1 C1 R1 C3 R3 C2 R2 C4 R4 - Input 4 Vi Vo Pre-regulator PGDS-50-M-K Gi Go 6 Gi Go Vi Vo MGDM-Series 5 Gi Go Vi Vo C6 *Chassis ground MGDM-Series Gi Go Common mode noise capacitance Cc = 10nF (See note below) Notes : it is suggested to use a common mode capacitor Cc (10 nF/1.500V) for each DC/DC converter to increase EMI performance. This capacitor should be layed-out as close as possible from the DC/DC converter. * For connection to chassis ground, if a higher isolation is required, it is suggested to use 10nF with voltage rating compliant with application requirements as capacitors C5 and C6. © Gaia Converter FC97-003.04/05 Revision H 2 For locations, phone, fax, E-Mail see back cover KG9501 Series Accessories 4- Component Dimensions 4-1 Differential Mode Inductance Implementation & Dimensions (L3) 4-2 Ferrite Bead Implementation & Dimensions (L2) 4 Conductor in Figure herabove is 1.27 mm (.050) wide x 0.2 mm (.008) thick flat TCW Ω) Impedance (Ω Ω) Impedance (Ω Ω) Impedance (Ω @10 MHz @25 MHz @100MHz 48 min 45 min 95±20% Rdc (mΩ Ω) Wt (g) A (mm/in) 0.9 max .30 2.85±0.2 .112 B (mm/in) C (mm/in) 3.05±0.1 9.6-0.95 .120 .359 D V W (mm/in) (mm/in) (mm/in) 1.5±0.5 .059 4.5 .177 7.5 .295 X (mm/in) 1.8 .071 TapeWidth Parts per Reel Y (mm/in) 3.0 .118 16 .629 2800 Bold numbers are in mm, light numbers are in inch 4-3 Common Mode Choke Implementation & Dimensions (L1) 1 3 2 Impedance (ý) @25 MHz 16min Impedance (ý) Rdc @100 MHz (mý) 33±20% 0.8 max Internal Pattern 4 Wt (g) A (mm/in) B (mm/in) C (mm/in) D (mm/in) E (mm/in) .30 2.85±0.2 .112 5.6±0.2 .220 5.0-0.6 .185 1.35±0.25 .053 2.54±0.1 0.1 1 4 2 3 V W (mm/in) (mm/in) 1.0 .O40 4.0 .157 X (mm/in) 1.8 .071 TapeWidth Parts per Reel Y Z (mm/in) (mm/in) 3.0 .118 2.54 .100 12 .472 2400 Bold numbers are in mm, light numbers are in inch © Gaia Converter FC97-003.04/05 Revision H 3 For locations, phone, fax, E-Mail see back cover Accessories KG9501 Series 5- Lay-out Recommendation 5-1 Grounding Design 5-2 Component and Trace Routing Design GAIA Converter recommend to use four layer boards. The two outer layers will be used for power and ground planes, and the two inner layers for low levels signals. Where necessary, extra planes to beef-up high current paths can be added on the inner layers. We recommend that the top layer, located closest to the modules, be used for the ground planes and divided into two parts as follow : - primary ground part, divided into two sub-parts (see KG9501 datasheet for further information) - secondary ground parts, Both parts must be as large as possible and spread out over the entire surface of the board; a grid could be used to avoid a complete copper surface. GAIA Converter recommend the use of a decoupling common mode noise capacitance (10nF) between primary and secondary ground planes. If more than one module is used, additionnal common mode noise capacitance are recommended. The «case» pin of the modules (if available) can be connected either to primary or secondary ground plane and a 6 sides shielding can be achieved with the PCB ground plane. The component placement is also a key factor between a good result and a nightmare. The first step in placing the component is to determine the power flow through the board. The most popular flow structure is from one side of the board to the other and avoiding cross-overs. If more than one DC/DC modules is used it is recommended to place the modules side-by-side so that the power signals can be easily routed avoiding croos-overs. It is also recommended to leave 1/2 inch between each module to avoid that radiation from power stage of one module can affect the control stage of the adjacent module and cause cross-talk. The second step is to place the EMI filter (KG9501 or other) next and as close as possible to the modules minimizing trace lenghts to avoid «antenna» phenomenum and minimize loop areas and straight inductances that can limit the effectiveness of the filter. When placing theses components make sure to leave enough room for power carrying traces to run through. Please consult also KG9501 datasheet for additionnal routing information. Secondary Ground Plane Ground 4 Vin Vout 28V KG9501 Input Bus Gin Gout PGDS-50 Vin Vout Gin Gout 0V Primary Ground Plane Primary Ground Plane Common mode noise capacitance Ground Ground L2 28V Secondary Ground Plane C5 L3 Vin Vout D1 Input Bus Plated hole C1 R1 C3 R3 C2 R2 C4 R4 L1 0V Gin Gout Primary Ground Plane Primary Ground Plane C6 Ground © Gaia Converter FC97-003.04/05 Revision H Plated hole Common mode noise capacitance 4 For locations, phone, fax, E-Mail see back cover KG9501 Series Accessories 6- Emission Level CE03 Results 6-1 Emission Level CE03 Results with Single Module Single module without filter Single module with front filter KG9501 (MGDS-04-J-C module) (MGDS-04-J-C module) Single module without filter Single module with front filter KG9501 4 (MGDS-10-J-C module) (MGDS-10-J-C module) 6-2 Emission Level with Multiple Module Architecture Filtered by KG9501 Module architecture stand alone © Gaia Converter FC97-003.04/05 Revision H Module architecture with front filter KG9501 5 For locations, phone, fax, E-Mail see back cover International Headquarters Marketing and Sales department GAÏA Converter - France Address : B.P. 26 - 33186 LE HAILLAN - FRANCE Tel. : + (33)-5-57-92-12-80 Fax : + (33)-5-57-92-12-89 North American Headquarters GAÏA Converter Canada, Inc Address : 6611 Thimens ST-LAURENT, QUEBEC - CANADA H4S 1W2 Tel. : (514)-333-3169 Fax : (514)-333-4519 Represented by : Information given in this datasheet is believed to be accurate and reliable. However, no responsibility is assumed for the consequence of its use nor for any infringement of patents or other rights of third parties which may result from its use. These products are sold only according to GAIA Converter general conditions of sale, unless otherwise confirmed by writing. Specifications subject to change without notice. Printed in France by GAIA Converter Gaia Converter FC97-003.04/05 Revision H. Graphisme : Philippe Clicq For more detailed specifications and applications information, contact :