MIL-STD-461 EMI INPUT FILTER FGDS-2A-50V up to 2A CURRENT Hi-Rel Hi-Rel Grade Grade 2A EMI Filter Module 9 to 50 VDC Input Range MIL-STD-461C/D/E Compliant • To comply with MIL-STD-461D/E power leads : • CE 102 : Emission requirement over 10KHz to 10MHz • CS 101 : Susceptibility requirement over 30Hz to 150KHz • CS 114 : Susceptibility requirement over 10KHz to 400MHz • CS 115 : Susceptibility requirement for spikes 1-General • To comply with MIL-STD-461C power leads : • CE 03 : Emission requirement over 15KHz to 50MHz • CS 01 : Susceptibility requirement over 30Hz to 50KHz • CS 02 : Susceptibility requirement over 15KHz to 400MHz • CS 06 : Susceptibility requirement for spikes • To comply with DO-160C/D/E power lines : • Conducted emission requirement over 15KHz to 30MHz • Conducted susceptibility requirement over 10KHz to 400MHz • Susceptibility requirement for induced transients • Temperature range : • operating temperature : -40°C/+105°C case • storage temperature : -55°C/+125°C The GAIA Converter filter module FGDS-2A-50V provides a state-of-the-art product to fulfill Electromagnetic Interferences (EMI) requirements for Aerospace/Defence applications. The FGDS-2A-50V complies with major standards including : • the US MIL-STD-461 rev C, rev D and rev E • the international DO-160 rev C, rev D and rev E In particular, the filter module is compliant with the following requirements of MIL-STD-461C/D/E standards : • MIL-STD-461C Part 2. & 3. requirements : • Conducted Emission (CE) • CE03, power leads, emission over 15KHz to 50MHz, narrowband, Class A1 • CE03, power leads, emission over 15KHz, broadband, Class A1 curve# 1&2 • Conducted Susceptibility (CS) • CS01, power leads, frequency over 30Hz to 50KHz, class A1, consult factory for criteria • CS02, power leads, frequency 15KHz to 400MHz, class A1 • CS06, power leads, spike #1 • MIL-STD-461D/E Part 2. & 3. requirements : • Conducted Emission (CE) • CE102, power leads, emission over 10KHz to 10MHz, basic curve • Conducted Susceptibility (CS) • CS101, power leads, frequency 30Hz to 150KHz, curve #1 • CS114, bulk cable injection, frequency 10KHz to 400MHz, • CS115, spikes, bulk cable injection, calibrated spike • DO-160-C/D/E requirements : • Conducted Emission (CE) • Section 21 power lines, emission over 15KHz to 30MHz, category B, AZ & LMH • Conducted Susceptibility (CS) • Section 20 power lines, frequency 10KHz to 400MHz In addition, this filter withstands in a transparent state without dammage the transient and spike requirements of : • MIL-STD-704A with 80V/100ms & 600V/10µs • MIL-STD-1275B with 100V/50ms & 250V/70µs The FGDS-2A-50V is suitable for all GAIA Converter DC/DC converters and architecture • from 4W up to 50W power • up to 2A input current • up to 50V permanent input voltage. 2-Product Selection FGDS-2A-50V (/T) and/or (/S) (/T) : option for -55°C start up operating temperature. (/S) : option for screening and serialization REDEFINING THE SOURCE OF POWER © Gaia Converter FC05-050.03/08 Revision B For locations, phone, fax, E-Mail see back cover 6 EMI Filter FGDS-2A-50V Hi-Rel Grade 3- Electrical Specifications Data are valid at +25°C, unless otherwise specified. FGDS-2A-50V Conditions Limit or typical Units Nominal input voltage Full temperature range Nominal VDC 28 Permanent input voltage range (Ui) Full temperature range Min. - Max. VDC 9 - 50 Transient input voltage Full load Maximum Maximum VDC/ms VDC/ms 80/100 100/50 Output power Full temperature range Ui min. to max. Maximum W 50 Permanent output current Full temperature range Ui min. to max. Min. - Max. A 0-2 Power dissipation Maximum output current Maximum W 1 DC resistance Maximum output current Min. - Max. mOhm Case to any pin Gnd pin to any other pin Minimum Minimum VDC VDC 500 500 @40°C @85°C @40°C @85°C Hours Hours Hours Hours 23 000 000 6 000 000 12 300 000 3 300 000 Conducted emission Power leads Power leads Power lines Power lines MIL-STD-461C MIL-STD-461D/E DO-160C catA, B & Z DO-160D/E cat B & LMH CE03 CE102 Section 21 Section 21 Spikes & surges withstands 50 Ohm impedance 0.1 Ohm impedance 50 Ohm impedance 15 mJ energy content 50 Ohm impedance MIL-STD-461C MIL-STD-461C MIL-STD-461D/E MIL-STD-1275B DO-160C/D/E DEF STANAG CS06 : 600V/10µs CS06 : 200V/150ns CS115 Level 250V/70µs Section 22 : 600V/10µs Parameter Input Output 120 - 140 General Electrical strengh test voltage Reliability data MTBF according MIL-HDBK-217F Conditions Gf Conditions AIC 6 EMI compliance © Gaia Converter FC05-050.03/08 Revision B See section 6 See section 6 / / Compliant Compliant Compliant Compliant Compliant Compliant 2 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade EMI Filter FGDS-2A-50V 4- EMI Filter Electrical Schematics The GAIA Converter FGDS-2A-50V is suitable for all GAIA Converter DC/DC converters and combinations : • from 4W up to 50W total input power and up to 2A input current • up to 50V permanent input voltage and up to 100V transient input voltage during 50ms 4-1 EMI Filter Electrical Schematics in Front of MGDM-04/10/18/20/26 & CGDM Series The GAIA Converter FGDS-2A-50V can be used directly in front of any DC/DC converter and combinations using of MGDM-04, MGDM-10, MGDM-18, MGDM-20, MGDM-26 and CGDM series. For better EMI performance and stability purpose, GAIA Converter recommends to use a RC cell (see section 4-4) together with a common mode noise capacitance Cc (10nF typical) connected between Gin and Gout pins of each DC/DC converter. Vo VI R* EMI input filter MGDM-series FGDS-2A-50V GI Vo VI C* Go GI Go Gnd Cc 4-2 EMI Filter Electrical Schematics in front of MGDM-25, MGDM-35 Series The GAIA Converter FGDS-2A-50V can be used by adding an LC cell in front of any DC/DC converter and combinations of MGDM-25, MGDM-35 series. For better EMI performance and stability purpose, GAIA Converter recommends to use a RC cell (see section 4-4) and a LC cell (L=4.7µH, C=4.7µF) together with a common mode noise capacitance Cc (10nF typical) connected between Gin and Gout pins of each DC/DC converter. LC cell Vo VI R* EMI input filter MGDM-series FGDS-2A-50V GI Vo VI C* Go GI Go 6 Gnd Cc 4-3 EMI Filter Electrical Schematics in Front of Pre-regulator PGDS Series : The GAIA Converter FGDS-2A-50V can be used directly in front of pre-regulators PGDS series with any DC/DC converter and combinations of MGDM-04, MGDM-10, MGDM-18, MGDM-20, MGDM-26 and CGDM series. For better EMI performance and stability purposes, GAIA Converter recommends to use a RC cell (see section 4-4) together with a common mode noise capacitance Cc (10nF typical) connected between Gin and Gout pins of each converter. Vimes Vo VI EMI input filter R* FGDS-2A-50V C* GI Go Gnd Vo VI PGDS50 GI Vo VI MGDM-series Go GI Go On/off Cc © Gaia Converter FC05-050.03/08 Revision B 3 For locations, phone, fax, E-Mail see back cover EMI Filter FGDS-2A-50V Hi-Rel Grade 4- EMI Filter Electrical Schematics (continued) 4-4 R*C* Network Discussion The RC damping network is a network used for stability purposes in negative input impedance systems such as DC/DC converters. R and C is a network whose function is to lower the filter’s output impedance. The value of the capacitor C strongly depends on the application’s conditions (input voltage range and total power drawn from the source) as well as the standards that the equipment has to meet MIL-STD-461C, or D/E, ... this because measurements method (LISN) differs from one standard to another affecting the C value. DC/DC converters are negative input impedance systems whereas a filter composed of passive elements displays a positive output impedance to the converter. To ensure the stability of the whole system “LISN + input Filter + DC/DC converters”, the filter output impedance must be kept below the converter’s input impedance, which is given by the following formula : Vin2 Zin = ____ Pin Vin2 x h = _________ Po where : Vin is the converter input voltage, Pin is the converter input power, Po is the converter output power h is the efficiency of the converter. As it can be seen from the preceding equation, the worst case for system’s stability is at Vinmin, so this is the condition which should be considered for the filter design. As the filter is made of low ESR inductors and ceramic capacitors, it has an important Q which causes a sharp increase of the filter’s output impedance at the resonant frequency and leads to a violation of the stability criteria, causing the system to break into oscillations. Consequently, the values of C and R have to be adjusted to dampen sufficiently the filter’s resonance and make its output impedance lower than the converter’s input impedance (a 10dB margin between both values is recommended). The following formula can be used to determine the capacitor value : ( LLISN + 4 .10-6 ) x Po x k C > _________________________________ 6 Vin2 x (R + RL) Where : LLISN is the LISN inductor value Po is the filter output power R is the capacitor esr (equivalent serial resistor) of C RLis the input bus equivalent resistor. It is the sum of the line + LISN network + input connector resistors k is the stability margin factor. This factor is given by the following formula : Stability margin (dB) = 20 log (k) Vin is the converter input voltage © Gaia Converter FC05-050.03/08 Revision B 4 For locations, phone, fax, E-Mail see back cover EMI Filter FGDS-2A-50V Hi-Rel Grade 5- MIL-STD-461C/D/E Conducted Emission Tests Set-Up 5-1 MIL-STD-461C Measurement Method The conducted noise emission measurement method of MIL-STD-461C is described in MILSTD-462C standard. The «DUT» (Device Under Test) is powered thru a 1 meter lengh parallel wire. One end is terminated with the DUT and the other end is terminated with 10µF capacitors to the ground plane. The measurements are made with a current probe, the unit of measurement being dBµA. To 50 ohms input +28V out +28V in Current probe 10µF DUT 10µF Return in Return out 1m 5-2 MIL-STD-461D/E Measurement Method The conducted noise emission measurement method is described in the MIL-STD-461D/E standards. The «DUT» (Device Under Test) is powered thru a 2 meters length parallel wire. One end is terminated with the DUT and the other end is terminated with LISN networks. The measurements are made with a measurement receiver, the unit being dBµV 6 +28V out +28V in LISN To 50 ohms input receiver DUT To 50 ohms termination LISN Return in Return out 2m © Gaia Converter FC05-050.03/08 Revision B 5 For locations, phone, fax, E-Mail see back cover EMI Filter FGDS-2A-50V Hi-Rel Grade 6- MIL-STD-461C & MIL-STD-461E Conducted Emission Level Results MIL-STD-461C : MGDS-O4-H-C with FGDS-2A-50V MIL-STD-461E : MGDS-O4-H-C with FGDS-2A-50V MIL-STD-461C : MGDS-10-J-C with FGDS-2A-50V MIL-STD-461E : MGDS-10-J-C with FGDS-2A-50V 6 MIL-STD-461C : 3 x MGDS-10-J-C with FGDS-2A-50V © Gaia Converter FC05-050.03/08 Revision B MIL-STD-461E : 3 x MGDS-10-J-C with FGDS-2A-50V 6 For locations, phone, fax, E-Mail see back cover EMI Filter FGDS-2A-50V Hi-Rel Grade 6- MIL-STD-461C & MIL-STD-461E Conducted Emission Level Results MIL-STD-461C : MGDS-26-H-C with FGDS-2A-50V MIL-STD-461E : MGDS-26-H-C with FGDS-2A-50V MIL-STD-461C : MGDS-35-H-C with FGDS-2A-50V MIL-STD-461E : MGDS-35-H-C with FGDS-2A-50V 6 © Gaia Converter FC05-050.03/08 Revision B 7 For locations, phone, fax, E-Mail see back cover EMI Filter FGDS-2A-50V Hi-Rel Grade 7- Environmental Qualifications The modules have been subjected to the following environmental qualifications. Characteristics Conditions Severity Test procedure Duration Temperature / status of unit Test D : 1.000 Hrs @ 105°C case, unit operating @ 125°C ambient, unit not operating MIL-STD-202G Method 108A Altitude Altitude level C Duration Climb up Stabilization Status of unit 40.000 ft@-55°C 30 min. 1.000 ft/min to 70.000 f@-55°C, 30 min. unit operating MIL-STD-810E Method 500.3 Humidity cyclic Number of cycle Cycle duration Relative humidity variation Temperature variation Status of unit 10 Cycle I : 24 Hrs 60 % to 88 % 31°C to 41°C unit not operating MIL-STD-810E Method 507.3 Humidity steady Damp heat Temperature Duration Status of unit 93 % relative humidity 40°C 56 days unit not operating MIL-STD-202G Method 103B Salt atmosphere Temperature Concentration NaCl Duration Status of unit 35°C 5% 48 Hrs unit not operating MIL-STD-810E Method 509.3 Temperature cycling Number of cycles Temperature change Transfert time Steady state time Status of unit 200 -40°C / +85°C 40 min. 20 min. unit operating MIL-STD-202A Method 102A Temperature shock Number of shocks Temperature change Transfert time Steady state time Status of unit 100 -55°C / +105°C 10 sec. 20 min. unit not operating MIL-STD-202G Method 107G Climatic Qualifications Life at high temperature Mechanical Qualifications Vibration (Sinusoidal) Number of cycles Frequency / amplitude Frequency / acceleration Duration Status of unit 10 cycles in each axis 10 to 60 Hz / 0.7 mm 60 to 2000 Hz / 10 g 2h 30 min. per axis unit not operating MIL-STD-810D Method 514.3 Shock (Half sinus) Number of shocks Peak acceleration Duration Shock form Status of unit 3 shocks in each axis 100 g 6 ms 1/2 sinusoidal unit not operating MIL-STD-810D Method 516.3 Bump (Half sinus) Number of bumps Peak acceleration Duration Status of unit 2000 bumps in each axis 40 g 6 ms unit not operating MIL-STD-810D Method 516.3 © Gaia Converter FC05-050.03/08 Revision B 6 8 For locations, phone, fax, E-Mail see back cover EMI Filter FGDS-2A-50V Hi-Rel Grade 8- Dimensions Dimension are given in mm (inches). Tolerance : +/- 0,2 mm (+/- 0.01 “) unless otherwise indicated. Weight : 10 grams (0.3 Ozs) max. 35,50 20,50 (1.4") (0.80") 10,20 10,70 (0.4") (0.42") 5 min (0,20") 7,62 (0.30") 15,24 27,94 (0.60") (1.10") Pin dimensions : O 0,73 mm (0.029 ”) plastic case black solder plated pin 9- Product Marking Upper face : Company logo, location of manufacturing. Side face : Module reference, option, date code : year and week of manufacturing. 10- Connections 6 Pin 2 4 3 1 Single 1 + Input (Vi) 2 + Output (Vo) 3 Ground (Gnd) 4 - Output (Go) 5 - Input (Gi) 5 Bottom view © Gaia Converter FC05-050.03/08 Revision B 9 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. 6 Printed in France by GAIA Converter Gaia Converter FC05-050.03/08 Revision B. Graphisme : Philippe Clicq For more detailed specifications and applications information, contact :