KG9501 - GAIA Converter - Datasheet.Live

MIL-STD-461-C INPUT EMI FILTER

for 4W up to 50W DC/DC Converters

KG 9501

• 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

Gaia Converter FC97-003.04/05 Revision H

REDEFINING THE SOURCE OF POWER

1-Subject

Accessories

For locations, phone, fax, E-Mail see back cover

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)

For locations, phone, fax, E-Mail see back cover

Accessories

KG9501 Series

Gaia Converter FC97-003.04/05 Revision H

Pre-regulator

PGDS-50-M-K

+ Input

- Input

D1 L1 L2 L3

C2 R2

C1 R1

C4 R4

C3 R3

*Chassis ground

MGDM-Series

Common mode noise capacitance C = 10nF

(See note below) c

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.

* 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- 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

3-2 Connection to GAIA Converter Pre-regulator PGDS-50 & DC/DC Converters

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.

Common mode noise capacitance C = 10nF

(See note below) c

MGDM-Series

+ Input

- Input

D1 L1 L2 L3

C2 R2

C1 R1

C4 R4

C3 R3

*Chassis ground

For locations, phone, fax, E-Mail see back cover

Accessories

KG9501 Series

Gaia Converter FC97-003.04/05 Revision H

4- Component Dimensions

4-2 Ferrite Bead Implementation & Dimensions (L2)

4-3 Common Mode Choke Implementation & Dimensions (L1)

4-1 Differential Mode Inductance Implementation & Dimensions (L3)

Conductor in Figure herabove is 1.27 mm (.050) wide x 0.2 mm (.008) thick flat TCW

Impedance (ΩΩ

ΩΩ

Ω)

@10 MHz

48 min

Impedance (ΩΩ

ΩΩ

Ω)

@25 MHz

45 min

Impedance (ΩΩ

ΩΩ

Ω )

@100MHz

95±20%

Rdc

(mΩΩ

ΩΩ

Ω)

0.9 max

(g)

.30

(mm/in)

2.85±0.2

.112

(mm/in)

3.05±0.1

.120

(mm/in)

9.6-0.95

.359

(mm/in)

1.5±0.5

.059

(mm/in)

4.5

.177

(mm/in)

7.5

.295

(mm/in)

1.8

.071

(mm/in)

3.0

.118

Parts per Reel

2800

TapeWidth

.629

Impedance (ý)

@25 MHz

16min

Impedance (ý)

@100 MHz

33±20%

Rdc

(mý)

0.8 max

(g)

.30

(mm/in)

2.85±0.2

.112

Bold numbers are in mm, light numbers are in inch

(mm/in)

5.6±0.2

.220

(mm/in)

5.0-0.6

.185

(mm/in)

1.35±0.25

.053

(mm/in)

1.0

.O40

(mm/in)

4.0

.157

(mm/in)

1.8

.071

(mm/in)

3.0

.118

Parts per Reel

2400

TapeWidth

.472

(mm/in)

2.54±0.1

0.1

(mm/in)

2.54

.100

Bold numbers are in mm, light numbers are in inch

4Internal Pattern 1

For locations, phone, fax, E-Mail see back cover

Accessories

KG9501 Series

Gaia Converter FC97-003.04/05 Revision H

5-1 Grounding Design

GAIA Converter recommend to use four layer boards. The

two outer layers will be used for power and ground pla-

nes, 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.

5-2 Component and Trace Routing Design

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.

Vin

Gin

Vout

Gout

Input

Bus

Primary Ground Plane

Secondary Ground Plane

Common

mode noise

capacitance

Primary Ground Plane

Ground

28V

Ground

Plated

hole

KG9501 PGDS-50

Vin Vout

Gin Gout

5- Lay-out Recommendation

L2 L3

D1 Vin

Gin

Vout

Gout

Input

Bus

Primary Ground Plane

Secondary Ground Plane

Common

mode noise

capacitance

Primary Ground Plane

Ground

28V

Ground

Plated

hole

For locations, phone, fax, E-Mail see back cover

Accessories

KG9501 Series

Gaia Converter FC97-003.04/05 Revision H

6- Emission Level CE03 Results

Single module without filter

(MGDS-04-J-C module)

Single module with front filter KG9501

(MGDS-04-J-C module)

Single module without filter

(MGDS-10-J-C module)

Single module with front filter KG9501

(MGDS-10-J-C module)

Module architecture stand alone Module architecture with front filter KG9501

6-2 Emission Level with Multiple Module Architecture Filtered by KG9501

6-1 Emission Level CE03 Results with Single Module

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

Represented by :

For more detailed specifications and applications information, contact :

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