Military COTS AC Line Filter

MACF-U-230-ET
Technical
Specification
Military COTS AC Line Filter
85 to 264Vrms 5Arms 500W @ 115Vrms 180mΩ @ 100ºC
Input
Output 1kW @ 230Vrms
Max Series
Voltage
Current
Resistance
Output Power
F ull P ower O peration : -55ºC
to
>55dB @ 250kHz
Differential-mode Attenuation
(external capacitance
required)
+100ºC
MCOTS series of EMI AC Line Filters brings SynQor’s
field proven technology and manufacturing expertise to
the industrial power applications marketplace. SynQor’s
innovative packaging approach ensures survivability
in the most hostile environments. Compatible with
the industry standard format, these filters have high
differential-mode and common-mode attenuation
and low series resistance. They follow conservative
component derating guidelines and they are designed
and manufactured to the highest standards.
-M er
ET-N
-230- Line Filt 5-800 Hz
U
F
s4
AC
MAC
TS
5Arm
MCO 264Vrms
85 to
MACF-U-230-ET-N-M Module
Operational Features
Mechanical Features
• -55°C to +100°C Operation
• 5Arms output current
• Very low series resistance
• Standard Size: .99" x 2.39" x 0.50" (25.04 x 60.60 x 12.70mm)
• Total weight: TBD
• Flanged baseplate version available
• High Differential & Common-mode Attenuation
• All capacitors are safety-rated X7R multi-layer ceramic
• Meets common EMC standards in properly designed system
with SynQor's MPFC module and MCOTS 270 converters
• 45 - 800 Hz input frequency
In-Line Manufacturing Process
• AS9100 and ISO 9001:2008 certified facility
• Full component traceability
Contents
Compliance Features
MACF Series filters (with MPFC & MCOTS converters)
are designed to meet:
• MIL-STD-461 for EMC
• MIL-STD-1399
• MIL-STD-704
Product # MACF-U-230-ET
Phone 1-888-567-9596
Page No.
Technical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Operations and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standards & Qualification Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encased Mechanical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flanged Mechanical Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordering Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Doc.# 005-0006778 Rev. 1
09/02/2015
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Page 1
MACF-U-230-ET
Technical
Specification
Technical Diagrams
Fundamental Circuit Diagram
AC POWER INPUT
AC POWER OUTPUT
PFC L1
L1
PFC L2
L2
GND
Typical Connection Diagram
Need short connection to ground plane
AC L1
Fuse 1
MOV 1
115 Vac, 60 Hz
C5
9.4n
PFC L1
L1
C6
9.4n
L1
C1
168n
MACF-U-230-ET
C3
9.4n
+
C2
168n
L2
AC L2
TVS 1
MCOTS PFC
Module
L2/N
PFC L2/N
GND
+Vout
C Hold-up
-Vout
C4
9.4n
Need short connection to ground plane
MOV 1: 300VAC, 60J; (EPCOS S10K300E2)
TVS 1: 400V, 3J; (Two VISHAY 1.5KE200CA devices connected in series)
C Hold-up: 450V, 390μF; (United Chemi-Con ELXS451VSN391MR50S)
Fuse 1: 250VAC, 6.3A; (Littelfuse 021606.3MXEP)
C1, C2: Three 56nF in parallel; (Murata GA355XR7GB563KW06L)
C3, C4, C5, C6: Two 4.7nF in parallel; (Murata GA355DR7GF472KW01L)
Product # MACF-U-230-ET
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-0006778 Rev. 1
09/02/2015
Page 2
MACF-U-230-ET
Technical
Specification
MACF-U-230-ET Electrical Characteristics
Vin <= 264Vrms, Iout <= 5Arms unless otherwise specified
Parameter
Min.
Typ.
Max.
Units Notes & Conditions
ABSOLUTE MAXIMUM RATINGS
Input Voltage (Continuous)
264
Isolation Voltage
2150
Vdc
5
Arms
Output Current (Continuous)
Output Current (Surge)
Vrms
150
A2 S
Operating Case Temperature
-55
100
°C
Storage Case Temperature
-65
135
°C
300
°C
Lead Temperature (20 s)
Input/output to gnd pin & baseplate
Baseplate temperature
RECOMMENDED OPERATING CONDITIONS
Input Voltage (Continuous)
250
Vrms
5
Arms
Output Current (Continuous)
ELECTRICAL CHARACTERISTICS
Output Voltage (Continuous)
Vout = Vin - (Iin x Rs)
V
120
mΩ
Series Resistance Rs
Total
Tcase = 25ºC
Tcase = 100ºC
180
mΩ
Power Dissipation
5Arms output current
Tcase = 25ºC
3.0
Tcase = 100ºC
W
4.5
Total Differential-Mode Capacitance
Total Common-Mode Capacitance
W
0.5
µF
Measured across input or output pins
2x5
nF
Measured between gnd pin and any other pin
Leakage current in PE GND Pin
0.5
mArms 250Vac L-N 50Hz with no external Y cap, see Note 1
Noise Attenuation
See Fig 1
Isolation Resistance
100
MΩ
Any pin to gnd pins
RELIABILITY CHARACTERISTICS
Calculated MTBF (MIL-217) MIL-HDBK-217F
TBD
106 Hrs. Ground Benign, Tb = 70 °C
Calculated MTBF (MIL-217) MIL-HDBK-217F
TBD
106 Hrs. Ground Mobile, Tb = 70 °C
Field Demonstrated MTBF
106 Hrs. See our website for details
Note 1: If the neutral line is interrupted, leakage current may reach twice this level.
Product # MACF-U-230-ET
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-0006778 Rev. 1
09/02/2015
Page 3
MACF-U-230-ET
Technical
Specification
BASIC OPERATION AND FEATURES
A typical application would place the MCOTS AC line filter close to the AC
input power entry point. The AC Line Filter GND pin would be connected to
the chassis ground that is common with AC input power protective earth
(PE GND) or other earthed point used for EMI measurement. There are no
connections to the metal baseplate, which may also be connected to the
chassis ground if desired.
Do not connect the outputs of multiple MCOTS AC line filters in parallel.
Connecting filters in this manner may result in slightly unequal currents to
flow in the positive and return paths of each filter. These unequal currents
will cause the internal common-mode chokes to saturate and thus cause
degraded common-mode rejection performance.
External common-mode and differential-mode capacitance is required to
work with SynQor eighth brick AC line filter. Refer to "Typical Connection
Diagram" for suggested parts and connection.
LISN
Source
50 Ω
Imeas
Vin(+)
20
0
-20
Attenuation (dB)
This module is a multi-stage differential-mode and common-mode passive
EMI filter designed to interface an AC power source with a SynQor MCOTS
PFC module and one or more SynQor converters (or other loads that create
EMI). Each stage of this filter is well damped to avoid resonances and
oscillations, and only X7R multi-layer ceramic safety rated capacitors are
used.
-40
-60
-80
-100
-120
Common-mode Attenuation
-160
1.00E+03
1.00E+04
Source
50 Ω
Imeas
Vin(+)
LISN
LISN
Vout(-)
Figure 2: Typical Common Mode and Differential Mode Attenuation provied by
the filter as a function of frequency. Source and load resistance are 50Ω.
Product # MACF-U-230-ET
Phone 1-888-567-9596
Inoise
Com In
Com Out
50 Ω
Com Out
Vin(-)
1.00E+07
Vout(+)
EMI Filter
Com In
50 Ω
1.00E+06
Figure 1: Typical Common Mode and Differential Mode Attenuation provied by
the filter as a function of frequency when using parts suggested in the "Typical
Connection Diagram". Source and load resistance are 50Ω.
LISN
Inoise
1.00E+05
Frequency (Hz)
Vout(+)
EMI Filter
Differential-mode Attenuation
-140
Vin(-)
Vout(-)
Figure 3: Typical Common Mode and Differential Mode Attenuation provied by
the filter as a function of frequency. Source and load resistance are 50Ω.
www.synqor.com
Doc.# 005-0006778 Rev. 1
09/02/2015
Page 4
MACF-U-230-ET
Technical
Specification
Standards & Qualification Testing
MIL-STD-810G Test
Fungus
Method
508.6
Mil-COTS MIL-STD-810G Qualification Testing
Description
Table 508.6-I
500.5 - Procedure I
Storage: 70,000ft. / 2 Hr. duration
500.5 - Procedure II
Operating; 70,000ft. / 2 Hr. duration; Ambient Temperature
Rapid Decompression
500.5 - Procedure III
Storage: 8,000ft. to 40,000ft.
Acceleration
513.6 - Procedure II
Operating - 15g’s
Salt Fog
509.5
Storage
501.5 - Procedure I
Storage: 135°C / 3 hrs
501.5 - Procedure II
Operating: 100°C / 3 hrs
502.5 - Procedure I
Storage: -65C / 4 hrs
502.5 - Procedure II
Operating: -55C / 3 hrs
Temperature Shock
503.5 - Procedure I - C
Storage: -65C to 135C; 12 cycles
Rain
506.5 - Procedure I
Wind Blown Rain
Immersion
512.5 - Procedure I
Non-Operating
Humidity
507.5 - Procedure II
Aggravated cycle @ 95% RH (Figure 507.5-7 aggravated temp - humidity cycle, 15 cycles)
Random Vibration
514.6 - Procedure I
10-2000 Hz, PSD level of 1.5 g2/Hz(54.6grms), duration = 1 hr/axis
516.6 - Procedure I
20g’s peak, 11ms, Functional Shock (Operating no load) (saw tooth)
516.6 - Procedure VI
514.6 - Category 14
510.5 - Procedure I
Bench Handling Shock
Rotary wing aircraft - helicopter, 4hrs/axis, 20g’s (sine sweep from 10 - 500HZ)
Blowing Dust
510.5 - Procedure II
Blowing Sand
Altitude
High Temperature
Low Temperature
Shock
Sinusoidal vibration
Sand and Dust
Mil-COTS DC-DC Converter and Filter Screening
Screening
Process Description
S-Grade
M-Grade
-55˚C to +100˚C
-55˚C to +100˚C
-65˚C to +135˚C
-65˚C to +135˚C
●
●
100˚C Baseplate
12 Hours
96 Hours
100%
25˚C
-55˚C, +25˚C, +100˚C
MIL-STD-2008
●
●
Baseplate Operating Temperature
Storage Temperature
Pre-Cap Inspection
Temperature Cycling
IPC-610, Class III
Method 1010, Condition B, 10 Cycles
Burn-In
Final Electrical Test
Final Visual Inspection
Product # MACF-U-230-ET
Phone 1-888-567-9596
www.synqor.com
●
Doc.# 005-0006778 Rev. 1
09/02/2015
Page 5
MACF-U-230-ET
Technical
Specification
Parameter
Notes & Conditions
STANDARDS COMPLIANCE
UL 60950-1/R2011-12
Basic Insulation
CAN/CSA-C22.2 No. 60950-1/A1:2011
EN60950-1/A12:2011
Certified by TUV
All Filter versions meet EN60950-1 leakage current requirements with a 250Vrms L-N 50/60Hz input.
The 400Hz filter version also meets EN60950-1 leakage current requirements with a 115 Vrms L-N 400Hz input but not with a 250Vrms L-N 400Hz input.
Note: An external input fuse must always be used to meet these safety requirements, see the Typical Connection Diagram.
Contact SynQor for official safety certificates on new releases or download from the SynQor website.
Parameter
QUALIFICATION TESTING
Life Test
Vibration
Mechanical Shock
Temperature Cycling
Power/Thermal Cycling
Design Marginality
Humidity
Solderability
Altitude
# Units
32
5
5
10
5
5
5
15 pins
2
Test Conditions
95% rated Vin and load, units at derating point, 1000 hours
10-55 Hz sweep, 0.060" total excursion, 1 min./sweep, 120 sweeps for 3 axis
100g minimum, 2 drops in x, y, and z axis
-55 °C to 100 °C, unit temp. ramp 15 °C/min., 500 cycles
Toperating = min to max, Vin = min to max, full load, 100 cycles
Tmin-10 °C to Tmax+10 °C, 5 °C steps, Vin = min to max, 0-105% load
85 °C, 95% RH, 1000 hours, continuous Vin applied except 5 min/day
MIL-STD-883, method 2003
70,000 feet (21 km), see Note
Note: A conductive cooling design is generally needed for high altitude applications because of naturally poor convective cooling at rare atmospheres.
Product # MACF-U-230-ET
Phone 1-888-567-9596
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Doc.# 005-0006778 Rev. 1
09/02/2015
Page 6
MACF-U-230-ET
Technical
Specification
Encased Mechanical Diagram
SEATING PLANE HEIGHT
0.500 0.025
[12,70 0,63]
1.000 [25,40]
PIN EXTENSION
0.180 [4,57]
SEE NOTE 4
4
5
0.004 [0,10]
1.650
[41,91]
1.84
[46,6]
2.386
[60,60]
2.000 [50,80]
3
1
2
THREADED INSERT
SEE NOTE 1
(2 PLACES)
0.30 [7,6]
1
0.300 [7,62]
0.600 [15,24]
0.318 [8,08]
NOTES
1)
PIN DESIGNATIONS
2)
3)
Applied torque per screw should not exceed 6in-lb. (0.7 Nm).
Baseplate flatness tolerance is 0.004" (.10 mm) TIR for surface.
Pins are 0.040” (1.02mm) diameter, with 0.080”
(2.03mm) diameter standoff shoulders.
4)
All Pins: Material - Copper Alloy
5)
6)
7)
8)
9)
Finish: Matte Tin over Nickel plate
Undimensioned components only for visual reference.
Total weight: TBD
Threaded and Non-Threaded options available
All dimensions in inches (mm)
Tolerances: x.xx +/-0.02 in. (x.x +/-0.5mm)
x.xxx +/-0.010 in. (x.xx +/-0.25mm)
Pin
Name
1
2
3
4
5
L1
L2/N
PE GND
PFC L2/N
PFC L1
Function
AC Line 1
AC Line 2 / Neutral
Protective Earth
PFC Input Line 2 / Neutral
PFC Input Line 1
- unless otherwise noted.
Workmanship: Meets or exceeds current IPC-A-610 Class II
Product # MACF-U-230-ET
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-0006778 Rev. 1
09/02/2015
Page 7
MACF-U-230-ET
Technical
Specification
Flanged Mechanical Diagram
1.450 [36,83]
1.270 [32,26]
0.986 [25,04]
SEATING PLANE HEIGHT
0.500 0.025
[12,70 0,63]
PIN EXTENSION
0.180 [4,57]
SEE NOTE 4
4
5
0.010 [0,25]
1.300 2.066
[33,02] [52,48]
0.36 [9,1]
2.386
[60,60]
2.000
[50,80]
3
1
2
1
0.300 [7,62]
FLANGE THICKNESS
0.125 [3,18]
0.600 [15,24]
0.94 [23,8]
NOTES
1)
2)
3)
4)
5)
6)
7)
8)
PIN DESIGNATIONS
Applied torque per screw should not exceed 6in-lb. (0.7 Nm).
Baseplate flatness tolerance is 0.004" (.10 mm) TIR for surface.
Pins are 0.040” (1.02mm) diameter, with 0.080”
(2.03mm) diameter standoff shoulders.
All Pins: Material - Copper Alloy
Finish: Matte Tin over Nickel plate
Undimensioned components only for visual reference.
Pin
Name
1
2
3
4
5
L1
L2/N
PE GND
PFC L2/N
PFC L1
Function
AC Line 1
AC Line 2 / Neutral
Protective Earth
PFC Input Line 2 / Neutral
PFC Input Line 1
Weight: TBD
All dimensions in inches (mm)
Tolerances: x.xx +/-0.02 in. (x.x +/-0.5mm)
x.xxx +/-0.010 in. (x.xx +/-0.25mm)
- unless otherwise noted.
Workmanship: Meets or exceeds current IPC-A-610 Class II
Product # MACF-U-230-ET
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-0006778 Rev. 1
09/02/2015
Page 8
MACF-U-230-ET
Technical
Specification
Ordering Specifications
Family
Input Frequency
Input Voltage
Package
MACF
U
230
E
MACF: AC Line Filter
U:
45 - 800 Hz
230: 85 to 264Vrms
ET: Eighth-Brick Tera
Thermal Design
N:
F:
N
Encased Threaded
Flanged
Screening Level
S:
M:
S
Standard
Military
Part Number Example: MACF-U-230-ET-N-M
APPLICATION NOTES
ORDERING INFORMATION
A variety of application notes and technical white papers can be
downloaded in pdf format from our website.
Not all combinations make valid part numbers, please contact
SynQor for availability. See the Product Summary web page for
more options.
Contact SynQor for further information and to order:
PATENTS
Phone:
Toll Free:
Fax:
E-mail:
Web:
Address:
Product # MACF-U-230-ET
978-849-0600
888-567-9596
978-849-0602
[email protected]
www.synqor.com
155 Swanson Road
Boxborough, MA 01719
USA
Phone 1-888-567-9596
SynQor holds numerous U.S. patents, one or more of which apply to most of its power converter
products. Any that apply to the product(s) listed in this document are identified by markings on
the product(s) or on internal components of the product(s) in accordance with U.S. patent laws.
SynQor’s patents include the following:
5,999,417
6,222,742
6,545,890
6,594,159
6,731,520
6,894,468
6,896,526
6,927,987
7,050,309
7,072,190
7,085,146
7,119,524
7,269,034
7,272,021
7,272,023
7,558,083
7,564,702
7,765,687
7,787,261
8,023,290
8,149,597
8,493,751
8,644,027
Warranty
SynQor offers a two (2) year limited warranty. Complete warranty
information is listed on our website or is available upon request from
SynQor.
www.synqor.com
Doc.# 005-0006778 Rev. 1
09/02/2015
Page 9