Bel Power Solutions
152 North 3rd Street, Suite 805
San Jose, CA 95112 USA
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Bel Power Solutions offers a complete range of input filters to help
control EMI in board-level DC-DC converter applications. The
table below lists combinations of input filters and DC-DC
converters that have test data available. These test results are
presented only to provide general guidelines, as EMI issues
vary considerably based on many variables specific to each
application.
Due to the large number of possible permutations of DC-DC
converters and input filters, not all combinations have been tested.
Therefore, please refer to the data presented for each filter to
select filters that may work in combinations not specified below.
DC-DC CONVERTER SERIES
FILTER SERIES
PAGE
FES
FC
13
HBD
FC
13
HES
FC
13
IAD
FC
13
IAS
FC
13
IES
FC
13
LES
FC
13
OET
FC
13
Q24
F
2, 7
Q48
F
2, 7
QBS
FC
13
QD48
F
2, 7
QES
FC
13
QL48
F
2, 7
QM48
F
7
QME48
F
7
SQ24
F
2, 7
SQ48
F
2, 7
SQE48
F
2, 7
SQM48
F
2, 7
SQT48
F
7
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RoHS lead free solder and lead solder exempted
products are available
Maximum current 4 A with no derating
Maximum operating input voltage 80 V
100 V 100 mS transient withstand capability
Differential LC-filter stage
Surface mounted design
Small footprint – only 0.75 sq. inch
Low profile: 0.267 inch [6.7 mm] maximum
Low weight: 0.13 oz [3.66 g]
Operation over -40° C to 85 ° C ambient temperature
range
No airflow required up to 85 °C
Enables DC-DC converter compliance with
EN55022 and FCC Class B requirements
conducted emissions
Approved to the latest revision of safety standards:
UL/CSA60950-1 and EN/IEC60950-1
The F4804A Input Filter minimizes the conducted and
radiated emissions generated by switch mode DC-DC
converters, and allows board designs utilizing DC-DC
converters to meet stringent FCC and EN55022 Class
B conducted emissions requirements.
Unlike most available off-the-shelf filter modules, the
F4804A, in addition to common mode noise
reduction components, is provisioned with a differential
LC-filter stage, which virtually guarantees compliance
with conducted noise standards across the frequency
range from 150 kHz to 30 MHz, including fundamental
switching frequency and its harmonics. Test results
show headroom of 15-20 dB for conducted noise
quasi-peak levels, in relation to Class B requirements.
F4804A filter is designed specifically for distributed
power solutions in conjunction with DC-DC converters.
Low profile and small size (only 0.75 sq. in.) in a
surface mount package helps the designer save
system board real estate, and simplifies the layout.
Differential and Common Mode filtering for DC-DC
converters:
o Telecommunications
o Data communications
o Distributed Power Solutions
A single filter can be used with multiple converters, and
is capable of providing up to 4 A to the converter input
bus at 85 °C. When used as specified within this data
sheet, these filters do not require airflow and/or derating
at high temperatures.
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Conditions: TA = 25 ºC, No Airflow, Vin = 48 VDC, unless otherwise specified.
PARAMETER
NOTES
MIN
TYP
MAX
UNITS
Absolute Maximum Ratings
Input Voltage
Continuous
0
100
VDC
Operating Ambient Temperature
-40
85
°C
Storage Temperature
-55
125
°C
Electrical Characteristics
Operating Input Voltage Range
0
48
80
VDC
Maximum Operating Current
85 °C ambient, no airflow
4
ADC
DC Resistance (total for two legs)
0.07
Ω
Filter differential inductance
5
µH
Filter common mode inductance
For frequencies below 10 MHz
60
µH
Differential mode Attenuation at 400 kHz1
35
dB
Differential mode attenuation at 30 MHz1
56
dB
Common mode Attenuation at 400 kHz2
50
dB
Common mode Attenuation at 30 MHz2
60
dB
Efficiency at Maximum Load
Vin = 48V @ 4 A
99.2
99.4
%
The F4804A filter contains input and output capacitors, plus differential and common mode inductors. The separate
differential inductor, L2, allows a differential attenuation of 55 dB, a value substantially higher in comparison with other
available off-the-shelf filters (typically 25-30 dB).
Absolute maximum voltage and maximum operating voltage in Electrical Specifications Table are for the filter itself; check
maximum rating for corresponding DC-DC converters. Filter will not be damaged by reversed input voltage, or by applying
voltage to the output pins.
Figure1 - Schematic Diagram
1
50 Ω source and 50 Ω load impedance. See Figure 2 for differential mode attenuation in 50 kHz-100 MHz frequency range.
2
50 Ω source and 50 Ω load impedance; external common-mode capacitors 0.47 µ F (from IN+ and IN- to the common chassis). See Figure 3 and
Figure 4 for attenuation in 50 kHz-100 MHz frequency range.
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Differential attenuation plot in the frequency range of 50 kHz-100 MHz is shown in Figure 2, and can be seen to be flat
(around 55-60 dB) from 0.5 MHz to 50 MHz.
Figure 2 - Differential mode attenuation, 0.05-100 MHz. Source
and load resistances
are 50 Ω. Vertical scale: 20 dB/div, with
zero level marked by arrow. No load @ 25 ºC
Figure 3 and Figure 4 show Common mode attenuation with 50 Ω source and load. The attenuation depends on the value
of external Y-capacitors, connected between input pins and frame or a reference ground.
Figure 3 - Common Mode attenuation, 0.05-100 MHz. Source and
Figure 4 - Common Mode attenuation, 0.05-100 MHz. Source and
load resistances are 50 Ω. Two 0.1µ F Y-caps to common
line. load resistances are 50 Ω. Two 0.47 µ F Y-caps to common
line.
Vertical scale: 20 dB/div, with zero dB level marked by
arrow. Vertical scale: 20 dB/div, with zero dB level marked by
arrow.
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Because of low series internal DC resistance, the F4804A filter generally does not require airflow and/or derating to ambient
temperatures up to 85 ˚C, if placed and interconnected as described below.
Good thermal design includes the appropriate placement of the filter on the system board as to maximize heat exchange
through the power pins. For high temperature operation in low airflow environments, use of 1-2 oz copper for the external
connection pads and provision for some extra copper at all four I/O pins is encouraged. Good thermal connection to the
power planes is important.
To check filter thermal characteristic in an actual system environment, attach a thermocouple to the top of each inductor.
The maximum temperature at these test points should not exceed 120 ˚C.
A typical application schematic is shown in Figure 5. The filter can be used to Bel Power Solutions or more converters.
For applications requiring filter current greater than 4 A divide the converters into smaller groups and use multiple filters or
use a F4810 or F2410 filter which is capable of providing up to 10 A. Do not connect filters in parallel.
Figure 5 - F4804A - Typical Application
For additional information regarding layout and EMC, refer to the Layout Considerations and EMI Considerations
Application notes.
The following bulleted items are considerations regarding the external components for the typical application shown in
Figure 5.
Input electrolytic capacitor C1. We recommend 1-2 µ F/W for 48 V applications. This capacitor is needed to ensure
stability of converters in presence of their negative input impedance characteristic. Note that electrolytic capacitors at -
40 º C have 3-5 times less capacitance than at room temperature, and therefore it is good practice to check the power
system at worst case conditions from this point of view, i.e. lowest ambient temperature, minimum input voltage, and
maximum load. If electrolytic capacitors are restricted for use in the system, please contact the factory.
Input capacitors C2, C3 are optional; they decrease input ripple current and improve EMI. One or two of the following
ceramic chip capacitors per converter are recommended:
–TDK C4532X7R2A105, 1.0 µ F, 100 V
Common-mode capacitor (Y-cap) values and their EMI attenuation effects depend on system grounding and layout.
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If connection of capacitors between input and output is prohibited because of system restrictions, connect Y-
capacitors only from each input pin to system ground (CY1 and CY2 on Figure 5). The value of these capacitors in this
case is “the bigger the better” (preferably 0.1µF or larger). Voltage rating of Y-capacitors depends on the system
isolation and safety requirements.
Output capacitors C8, C9 are optional to reduce output ripple. Addition of one-two 47µ F ceramic capacitors, for
example, for low voltage applications 3.3 V and below, significantly decreases output ripple from 25-40 mV peak-to-
peak to 5-10 mV. Recommended capacitor for these low voltage applications is C3225X5R0J476 from TDK.
F4804A filter should be protected with a 5 Amps fuse (R451005 from Littelfuse). Smaller value fuses can be used as
required for protection to a lower power limit.
All dimensions are in inches [mm]
Connector Material: Copper
Connector Finish: Gold over Nickel
Converter Weight: 0.13 oz [3.66 g]
Recommended Surface-Mount Pads:
Min. 0.080” x 0.112” [2.03 x 2.84]
Max. 0.092” x 0.124” [2.34 x 3.15]
PRODUCT SERIES
INPUT VOLTAGE
RATED LOAD CURRENT
TAPE AND REEL
ENVIRONMENTAL
F
48
04A
-
R
G
Filter Module
≤ 80 V
4 A
No letter Bulk
R Tape and Reel
G RoHS compliant
for all six
substances
The example above describes P/N F4804A-R: 0-80 V input, 4 A @ 80 V output, tape and reel, and
Eutectic Tin/Lead solder.
Please consult factory for the complete list of available options and G option RoHS.
PAD/PIN CONNECTIONS
PAD/PIN #
FUNCTION
+IN
Vin (+)
-IN
Vin (-)
-OUT
Vout (-)
+OUT
Vout (+)
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RoHS lead free solder and lead solder exempted
products are available
Maximum current 10 A with no derating
Maximum operating input voltage 80 V (45 V for
F2410 version)
100 V/50 V 100 mS transient withstand capability
Differential LC-filter stage
Surface mounted design
Small footprint – less than 1 sq. inch
Low profile: 0.378 inch [9.6 mm] maximum
Low weight: 0.34 oz [9.5 g]
Operation over -40 °C to 85 ° C ambient
temperature range
No airflow required up to 85 °C
Enables DC-DC converter compliance with
EN55022 and FCC Class B requirements
conducted emissions
Approved to the latest revision of safety standards:
UL/CSA60950-1 and EN/IEC60950-1
The F4810 and F2410 Input Filters minimize the conducted
and radiated emissions generated by switch mode DC-DC
converters, and allow board designs utilizing DC-DC
converters to meet stringent FCC and EN55022 Class B
conducted emissions requirements.
Unlike most available off-the-shelf filter modules, the
F4810 and F2410, in addition to common mode noise
reduction components, are provisioned with a differential
LC-filter stage, which virtually guarantees compliance with
conducted noise standards across the frequency range
from 150 kHz to 30 MHz, including fundamental switching
frequency and its harmonics. Test results show headroom of
15-20 dB for conducted noise quasi-peak levels, in relation
to Class B requirements.
F4810/F2410 filters are designed specifically for distributed
power solutions in conjunction with dc-dc converters. Low
profile and small size (less than 1 sq. in.) in a surface mount
package helps the designer save system board real estate,
and simplifies the layout.
Differential and Common Mode filtering for DC-DC
converters with 48 V and 24 V input:
o Telecommunications
o Data communications
o Distributed Power Solutions
A single filter can be used with multiple converters, and is
capable of providing up to 10 A to the converter input bus
at 85° C. When used as specified within this data sheet,
these filters do not require airflow and/or derating at high
temperatures.
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Conditions: TA = 25 º C, No Airflow, Vin = 48 VDC, unless otherwise specified.
PARAMETER
NOTES
MIN
TYP
MAX
UNITS
Absolute Maximum Ratings
Input Voltage (F4810)
Continuous
0
100
VDC
(F2410)
Continuous
0
50
VDC
Operating Ambient Temperature
-40
85
°C
Storage Temperature
-55
125
°C
Electrical Characteristics
Operating Input Voltage Range (F4810)
0
48
80
VDC
(F2410)
0
24
45
VDC
Maximum Operating Current
85 °C ambient, no airflow
10
ADC
DC Resistance (total for two legs)
0.016
Ω
Filter differential inductance
4.5
H
Filter common mode inductance
For frequencies below 10 MHz
6.5
H
Differential mode Attenuation at 400 kHz3
F4810
57
dB
F2410
63
dB
Differential mode attenuation at 30 MHz1
F4810
56
dB
F2410
57
dB
Common mode Attenuation at 400 kHz4
F4810, F2410
24
dB
Common mode Attenuation at 30 MHz2
F4810, F2410
50
dB
Efficiency at Maximum Load
Vin = 48 V @ 10 A
99.6
99.7
%
The F4810 and F2410 filters contain input and output capacitors, plus differential and common mode inductors. Shown in
Figure 1, the schematic diagrams of both filters are similar, the only difference are changes in C1, C2 capacitor values. The
separate differential inductor, L2, allows a 50 Ω differential attenuation of 60 dB across the stated frequency range, a value
substantially higher in comparison with other available off-the-shelf filters (typically 25-30 dB).
The F4810 can be used in 24 V or 48 V systems without any limitations; however, in 24 V systems the F2410 differential
attenuation is better. At low frequencies around 100-200 kHz the difference is 20 dB, but at high frequencies the plots are
close to identical.
Absolute maximum voltage and maximum operating voltage in Electrical Specifications Table are for the filter itself; check
maximum rating for corresponding DC-DC converters. The filter will not be damaged by reversed input voltage, or by
applying voltage to the output pins.
Figure 1 - Schematic diagram for F4810, F2410. The Capacitor values shown are for F4810; for F2410 C1=10
μ
F; C2=13
μ
F
.
3
50 Ω source and 50 Ω load impedance. See Figure 2 and 3 for differential mode attenuation in the 20 kHz-100 MHz frequency range.
4
50 Ω source and 50 Ω load impedance; external common-mode capacitors 0.1 µF (from IN+ and IN- to the common chassis). See
Figure 4 for
attenuation in the 20 kHz-100 MHz frequency range.
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Figure 2 - F4810 - Differential mode attenuation, 0.2-100 MHz.
Source and load resistances
are 50 Ω. Vertical scale: 10 dB/div, with zero level marked by arrow. No load, 25 ºC
Differential attenuation plots for the F4810 and F2410 filters in the extended frequency range of 20 kHz-100 MHz are shown
in Figure 2 and Figure 3, respectively, and can be seen to be flat (around 55-60 dB) from 0.35 MHz to 40 MHz.
Figure 4 shows Common mode attenuation with 50 Ω
source and load. The attenuation is the same for both filters, and
depends on the value of external Y-capacitors, connected between input pins and frame or a reference ground.
Figure 3 - F2410 - Differential mode attenuation, 0.2-100 MHz.
Source and load resistance
50 Ω. Vertical scale: 10 dB/div,
with zero level marked by arrow. No load, 25 ºC.
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Figure 4 - F4810/F2410 - Common Mode attenuation, 0.2-100
MHz. Source and load resistances are 50 Ω.
Two 0.1 uF Y-
caps to common line. Vertical scale: 10 dB/div, with zero dB
level marked by arrow.
Because of low series internal DC resistance, the F4810/F2410 filters generally do not require airflow and/or derating to
ambient temperatures up to 85 ˚C, if placed and interconnected as described below.
Good thermal design is consistent with appropriate placement to gain additional heat exchange through the I/O pins to the
system board. For high temperature operation in low airflow environments, use of 1-2 oz copper for the external connection
pads and provision for some extra copper at all four I/O pins is encouraged. Thermal derating data shown were taken on
special thermal board with each input and output pin connected to 0.5 sq. in pad of 2 oz copper.
To check filter thermal characteristic in an actual system environment, attach a thermocouple to the top of differential
inductor, L2; it is the INDUCTOR closest to OUT+ pin.
The maximum temperature at this test point should not exceed 120 ˚C, and a minimum of 5-10 ˚C headroom is suggested
for better reliability.
A typical application schematic is shown in Figure 5. Either filter can be used to Bel Power Solutions or more converters.
Maximum filter output current should be limited 10 A - or less - depending upon system thermal environment.
The required filter current drawn by the converter loads, IREQ’d(Filter), will be the sum of the loads of all connected
converters:
IREQ’d(filter) = Σ[Pi,OUT/(VIN, min * ηi, min)] [A]
where:
IREQ’d(filter)
maximum required filter current
Pi,OUT(converter)
converter output power, i=1, 2…
= Vi,OUT(converter) * Ii,OUT(converter)
VIN, min
converter input voltage
ηi, min
converter minimum efficiency, i=1, 2,…
For applications requiring a filter current greater than 10 A, divide the converters into smaller groups and use multiple filters.
Do not connect filters in parallel.
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Figure 5 - F4810 – Typical Application
For additional information regarding layout and EMC, refer to the Layout Considerations and EMI Considerations
Application notes.
The following bulleted items are considerations regarding the external components for the typical application shown in
Figure 5.
Input electrolytic capacitor C1. We recommend 1-2 µ F/W for 48 V applications, and 2-4 µ F/W for 24 V applications.
This capacitor is needed to ensure stability of converters in presence of their negative input impedance characteristic.
Note that electrolytic capacitors at –40 º C have 3-5 times less capacitance than at room temperature, and therefore it
is good practice to check the power system at worst case conditions from this point of view, i.e. lowest ambient
temperature, minimum input voltage, and maximum load. If electrolytic capacitors are restricted for use in the system,
please contact the factory.
Input capacitors C2, C3 are optional; they decrease input ripple current and improve EMI. One or two of the following
ceramic chip capacitors, as required, per converter are recommended:
– TDK C4532X7R2A105, 1.0 µ F, 100 V – for 48 V applications
– TDK C4532X7R1H475, 4.7 µ F, 50 V – for 24 V applications
Common-mode capacitor (Y-cap) values and their EMI attenuation effects depend on system grounding and layout
(they are not shown on Figure 5). In EMI testing with the filter, ceramic capacitors between input and output of the
converter (C4 – C7) were very helpful. Typical values for the capacitor between Vin- and Vout- are 3,300 pF – 5,100
pF, and for the capacitor between Vin+ and Vout+, 0 to 3,300 pF.
If connection of capacitors between input and output is prohibited because of system restrictions, connect Y-
capacitors only from each input pin to system ground. The value of these capacitors in this case is “the bigger the
better” (preferably 0.1µF or larger). Voltage rating of Y-capacitors depends on the system isolation and safety
requirements.
Output capacitors C8, C9 are optional to reduce output ripple. Addition of one-two 47µ F ceramic capacitors, for
example, for low voltage applications 3.3 V and below, significantly decreases output ripple from 25-40 mV peak-to-
peak to 5-10 mV. Recommended capacitor for these low voltage applications is C3225X5R0J476 from TDK.
UL testing was performed with a 12 Amps fuse (R451012 from Littelfuse). Fuses larger than 12 Amps should not be
used. Smaller value fuses can be used as required for protection to a lower power limit.
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All dimensions are in inches [mm]
Connector Material: Copper
Connector Finish: Gold over Nickel
Converter Weight: 0.34 oz [9.5 g]
Recommended Surface-Mount Pads: Min. 0.080” x 0.112”
[2.03 x 2.84]
PRODUCT SERIES
INPUT VOLTAGE
RATED LOAD CURRENT
TAPE AND REEL
ENVIRONMENTAL
F
24
10
-
R
G
Filter Module
48: 80 V
24: 45 V
10 A
No letter Bulk
R Tape and Reel
G RoHS compliant for all six
substances
The example above describes P/N F2410-R: 0-45 V input, 10 A output current, tape and reel, and
Eutectic Tin/Lead solder.
Please consult factory for the complete list of available options and G option RoHS.
PAD/PIN CONNECTIONS
PAD/PIN #
FUNCTION
+IN
Vin (+)
-IN
Vin (-)
-OUT
Vout (-)
+OUT
Vout (+)
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Meets Class B conducted limits
Optimized for Bel Power Solutions' high
density, board- mounted products
PCB mountable
Common mode and differential mode filtering
Industry-standard pinout
-40 ºC to 80 º C case operation
>30 dB insertion loss at 500 kHz
100 VDC operation
1500 V isolation
Approved to the latest revision of safety
standards: UL/CSA60950-1 and
EN/IEC60950-1
The FC series EMI filters are accessories to the Bel Power
Solutions line of DC-DC power converters. They are
intended to be used in series with the inputs to the
converters, between the source and the converter (with its
necessary external input capacitor). A
properly-sized filter
can serve for multiple converters.
There are three sizes of FC filters, differentiated by their DC
current ratings. They are all rated for up to 100 VDC
continuous,
and for 1500 VDC test voltage from input (or
output) to ground. The three DC current ratings are 5.0A,
10A, and 20A
through current.
Each filter provides both normal mode and common mode
attenuation in normal application.
Viewing this Document:
The figures and graphs in this section may be difficult to read with normal resolution
video displays. For improved legibility, print this section.
Notes:
MTBF predictions may vary slightly from model to model.
Specifications typically at 25 º C, normal line, and
full load, unless otherwise
stated.
Soldering conditions: I/O pins, 260 ºC, 10 seconds; fully compatible with
commercial wave-soldering equipment.
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There are presently three models in the FC Series, all rated for zero to up to 100 VDC input voltage. They differ by current
capability. In general, the higher current filters offer higher attenuation than the lower current models.
Table 1 - FC Filter Series Models
MODEL
OPERATING CURRENT
Amps
INSERTION LOSS5
DIFFERENTIAL MODE
(dB)
INSERTION LOSS 1
COMMON MODE
(dB)
TYPICAL RESISTANCE6
(MOHMS)
FC100V5A-G
5
28
30
27
FC100V10A-G
10
31
28
17
FC100V20A-G
20
26
32
6.6
Custom models with alternate input voltages, or input current range, or different physical constructions are available.
Consult the Bel Power Solutions factory.
Switching Power Converter modules, because they are essentially constant efficiency over the input voltage range, must be
connected to a low AC impedance source of DC voltage.
A constant efficiency power module exhibits an input voltage versus current characteristic which electrically resembles a
negative resistor in the normal operating range of the module. Constant efficiency means that if the output power is held
constant, the input power will remain constant across the operating input voltage range. If the source voltage rises, the
current drawn from the source will fall, to maintain a constant product of voltage and current, hence, constant input power.
This characteristic is that of a negative resistor. When a negative resistance is fed from a positive source impedance which
has a greater magnitude than that of the negative resistance, either the system crashes or it becomes unstable. A good
general rule is that the magnitude of the source impedance must be lower than the magnitude of the input impedance of
the module, at all frequencies up to the switching frequency of the module. (The classic reference is Middlebrook and Cuk,
“Input Filter Considerations in Design and Application of Switching Regulators,” Advances in Switched-Mode Power
Conversion, pp 91-107, TeslaCo, 1981.) This rule is especially important, and harder to follow, with higher power modules
because the magnitude of the negative input impedance is lower.
The normal solution is to place a low impedance capacitor directly across the input terminals of the module. 100 to 220 µ F
is usually recommended for output power levels up to 300 Watts. This capacitor insures that the magnitude of the source
impedance is lower than that of the module input impedance. Note: this assumes that the DC source resistance is
5
Typical loss at 500 kHz (50 Ohms)
6
Resistance per leg
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sufficiently low; nothing can correct this problem. Too high a DC source resistance means that the necessary energy
required by the input of the module is not available, and this system will not work.
Use of the capacitor complicates the system design. There must be some consideration of the surge current required to
charge the capacitor when power is first applied. A surge limiting mechanism may be required. The capacitor may form a
resonant circuit with the inductance of an EMI filter. If this happens, the resonance will require damping. The capacitor must
be rated to handle all of the reflected ripple current of the module. Adding damping in the form of a resistor in series with
the capacitor may reduce the ripple current in the capacitor. A small value, high ripple current capacitor may then be
required in parallel with the damped electrolytic in order to meet the EMI requirements. The system designer must evaluate
all of these requirements and make the correct choices for the application.
Figure 1 - Application of Input Filters
FC filters are rated for 5.0, 10.0, and 20.0 amperes DC at up to +60 °C. Ambient temperature with 400 LFM of forced air
across the module surface, or with the case temperature otherwise held to a maximum of +100 ° C. With no forced air and
no additional cooling, the same modules are rated for 3.5, 6.5, and 13 amperes maximum.
The FC Series EMI filters have 1500 Volt DC isolation from input or output to ground, but no isolation from input to output.
The output voltage is the input voltage.
These filters have no external fuse. An external fuse must always be employed. In general, a 250 volt rated fuse must be
used to meet international safety requirements. The fuse value should be selected to be greater than the maximum input
current of the filter, which occurs at the minimum input voltage of the modules being powered through the filter. Both input
traces and the chassis ground trace (if used) must be capable of conducting a current of 1.5 times the value of the fuse
without opening. If one of the input lines is connected to chassis ground, then the fuse must be in the other input line.
The FC Series filters have a non-metallic case. It cannot be grounded. Each filter has a ground pin which must be
connected, with as low an impedance as possible, to chassis ground in order for the filter to function properly.
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Many DC-DC converter modules have an input “shutdown”, or “control” or “ON/OFF” pin. In most cases, the reference or
return for this pin is the negative input pin of the module. When using such a system with an EMI filter module, the
shutdown return must be made directly to the pin of the module, which is the output of the filter, and not at the input of the
filter. This requires either an optical coupler or a relay, or other fully isolated device to control the module. There must not
be any path for DC current to bypass the module, or its filtering characteristics will be severely compromised.
In order to operate without the internal common mode inductors magnetically saturating, the positive leg and negative leg
currents in the filter must exactly equal. Even a small imbalance, as small as 10 ma, can create saturation of the inductors.
When this happens, they no longer function as filter elements.
Figure 2 - Use of the Shutdown Pin with Input Filters
The input reflected current can be reduced with the EMI filters. The amount of the reduction is determined by the quality of
the capacitor across the input of the module. In most cases, this reduction will not be great at the switching frequency of
the converter.
Figure 3 - Filter Block Schematic
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Table 2 - FC100V5A Specifications
FC100V5A Electrical Specifications EMI Filter
PARAMETER
MIN
TYP
MAX
UNITS
CONDITIONS
NOTES
Input
Input Voltage Range
0
48
100
V
All specifications typical at
+25º C, nominal line, and full
load unless otherwise noted.
Specifications subject to
change without notice.
Maximum average current
5
A
Ta = 60° C 400 lfm air
3.5
A
Ta = 60° C natural convection
Frequency
0
60
Hz
Typical Characteristics
Resistance per leg
27
mΩ
Common-mode insertion loss
30
dB
At 500 kHz, 50 Ohm circuit
Differential-mode insertion loss
28
dB
At 500 kHz, 50 Ohm circuit
Isolation voltage;
Allows power module to meet
FCC CISPR and EN55022
Class B conducted limits.
1500
VDC
MTBF
Mhr
Consult Factory
(Bellcore TR-NWT-000332)
Environmental
Case Operating Temperature
-40
+100
°C
Storage Temperature Range
-40
+100
°C
Operating & Storage Humidity
95
%
Non-Condensing
Temperature Coefficient
0.03
%/° C
Vibration
5
G
Three orthogonal axes; 5 minute
test on each; 10 to 55 Hz
Physical
Case Dimensions
1.00 L
1.0 W
0.40 H
in
Figure 4 - Differential Mode Attenuation Plot
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BCD.00344_AB
Figure 5 - Common Mode Attenuation Plot
Figure 6 - Output Impedance Plot
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BCD.00344_AB
Figure 7 - Filter Block Schematic
Table 3 - FC100V10A Specifications
FC100V10A Electrical Specifications EMI Filter
PARAMETER
MIN
TYP
MAX
UNITS
CONDITIONS
NOTES
Input
Input Voltage Range
0
48
100
V
All specifications typical at
+25º C, nominal line, and
full load unless otherwise
noted. Specifications
subject to change without
notice.
Maximum average current
10
A
Ta = 60°C 400 lfm air
6.5
A
Ta = 60°C natural convection
Frequency
0
60
Hz
Typical Characteristics
Resistance per leg
17
mΩ
Common-mode insertion loss
28
dB
At 500 kHz, 50 Ohm circuit
Differential-mode insertion loss
31
dB
At 500 kHz, 50 Ohm circuit
Isolation voltage;
Allows power module to meet
FCC CISPR and EN55022
Class B conducted limits.
1500
VDC
MTBF
Mhr
Consult Factory
(Bellcore TR-NWT-000332)
Environmental
Case Operating Temperature
-40
+60
°C
Storage Temperature Range
-40
+125
°C
Operating & Storage Humidity
95
%
Non-Condensing
Temperature Coefficient
0.03
%/° C
Vibration
5
G
Three orthogonal axes; 5 minute
test on each; 10 to 55 Hz
Physical
Case Dimensions
2.00 L
1.0 W
0.44 H
in
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BCD.00344_AB
Figure 8 - Differential Mode Attenuation Plot
Figure 9 - Common Mode Attenuation Plot
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BCD.00344_AB
Figure 10 - Output Impedance Plot
Figure 11 - Filter Block Schematic
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BCD.00344_AB
Table 4 - FC100V20A Specifications
FC100V20A Electrical Specifications EMI Filter
PARAMETER
MIN
TYP
MAX
UNITS
CONDITIONS
NOTES
Input
Input Voltage Range
0
48
100
V
All specifications typical at
+25º C, nominal line, and full
load unless otherwise noted.
Specifications subject to
change without notice.
Maximum average current
20
A
Ta = 60 °C 400 lfm air
13
A
Ta = 60 °C natural convection
Frequency
0
60
Hz
Typical Characteristics
Resistance per leg
6.6
mΩ
Common-mode insertion loss
32
dB
At 500 kHz, 50 Ohm circuit
Differential-mode insertion loss
26
dB
At 500 kHz, 50 Ohm circuit
Isolation voltage;
Allows power module to meet
FCC CISPR and EN55022
Class B conducted limits.
1500
VDC
MTBF
Mhr
Consult Factory
(Bellcore TR-NWT-000332)
Environmental
Case Operating Temperature
-40
+100
°C
Storage Temperature Range
-40
+100
°C
Operating & Storage Humidity
95
%
Non-Condensing
Temperature Coefficient
0.03
%/° C
Vibration
5
G
Three orthogonal axes; 5 minute
test on each; 10 to 55 Hz
Physical
Case Dimensions
2.05 L
1.65 W
0.46 H
in
Figure 12 - Differential Mode Attenuation Plot
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BCD.00344_AB
Figure 13 - Common Mode Attenuation Plot
Figure 14 - Output Impedance Plot
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There are two methods of measurement for input conducted EMI: voltage measurements and current measurements. The
voltage data presented uses a 50S LISN (Line Impedance Stabilization Network) and measures the input voltage spectrum
from each input line of the converter to ground, using FCC and CISPR measurement techniques. The current data uses a
10 microfarad capacitor from each input line to ground, and measures the current in both lines simultaneously using the
measurement technique defined in section 3.4.5, part B3 of the Bellcore document GR-1089-CORE. In each case, there
was no external input filter. There was only an appropriate value capacitor across the input lines. The case of the unit under
test
was grounded to the reference ground plane, as was the output common of the unit. All spectra presented were taken
with production grade modules, operating from 48 VDC at the full-rated output load current.
Figure 15 - Input Conducted EMI Voltage Test Circuit
Figure 16 - Input Conducted EMI Current Test Circuit
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An EMCO model 94430-1 current probe was used in this test circuit. The probe has a transfer impedance which is not
constant with frequency. The transfer impedance, expressed in dBS, must be subtracted from the reading as measured on
the spectrum analyzer in dBµ V, in order to obtain the true current, measured in dBµ A. Note that this is a common-mode
current measurement, where both input lines to the unit under test are measured simultaneously.
Figure 17 - EMCO Model 94430-1 EMI Current Probe Transfer Impedance Curve
For optimum filtering, all shunt capacitors which are used in either the input or output circuits must be wired with "Four-
Terminal" techniques. Traces enter the node of the capacitor on one side of its pad (surface mount or discrete) and depart
from the other side. Capacitors are never "Tee'd" from other traces. The traces feeding the capacitors should be close
together and parallel. Never leave large loops in input (or output) and return traces in the printed circuit board designs for
power converters. Large loops form large antennas; large antennas create the most radiated EMI.
It is recommended that one layer of the board which carries the filter and converter(s) be dedicated as a ground plane.
Preferably, this is the layer directly under the modules. It should extend out beyond the edges of the modules. The ground
plane should be connected to earth ground, or to +Vin.
The incorporation of completed power modules into assemblies, or installation into mother boards, can be handled by the
conventional industry methods. The stanchions which are fabricated of PPS plastic, along with all the other component
parts used, will withstand normal preheat temperatures associated with standard soldering operations. The most common
method for mass soldering of the power supply to a mother board is “wave soldering” and should be profiled approximately
as follows:
1.
The solder pot should be set at 500 °F and the conveyor should have a speed preset to insure that each section of the
bottom side of the assembly dwells in the molten solder wave for 3 to 4 seconds. It is imperative that a correct
temperature profile be used, not only to reduce solder defects but to eliminate any chance of thermal shock on the
components.
2.
The motherboard should attain a top side preheat temperature of 220° to 240° F before it enters the solder wave. The
temperature change between the preheat and the soldering zones should be minimized.
The cooling rate after the solder wave should be similar in drop in temperature to the preheat rise.
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Bel Power Solutions through-hole pins are tin/lead plated and are easily soldered if all process parameters are met.
However, in fluxing, the flux density, the activity and the ratio of flux foam to wave height must be closely monitored
and controlled to
maintain minimum solder defects.
In controlling the solder profile, preheating of the assembly in two or three stages minimizes the thermal shock
damage and increases the end life of the unit.
If the power converters are to be hand soldered into the motherboard, a temperature controlled iron of 700° F (MAX)
is recommended.
While Bel Power Solutions power converters generally spend about 3 seconds in the wave, they are designed to
withstand soldering temperatures of 500 ° F for up to 10 seconds.
If non-conventional methods are to be used to solder Bel Power Solutions power supplies to the motherboard,
contact Bel Power Solutions Technical Support before proceeding.
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BCD.00344_AB
Tolerances
Inches: (Millimeters)
XX ± 0.020 X ± 0.5
XXX ± 0.010 XX ± 0.25
Pin: ± 0.002 ± 0.05
(Dimensions as listed unless otherwise specified.)
DESCRIPTION
SUFFIX TO ADD TO PART NUMBER
RoHS compliant for all six substances
Add a hyphen and then the letter "G" as the last character of the part number
Sample order code: FC100V5A-G represents an FC filter which has a 100 VDC input voltage rating, an operating current of
5 Amps, and is
fully RoHS compliant for all six substances.
NUCLEAR AND MEDICAL APPLICATIONS - Products are not designed or intended for use as critical components in life support systems, equipment used in
hazardous environments, or nuclear control systems.
TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on the date
manufactured. Specifications are subject to change without notice.
PIN
FUNCTION
5 A Module
1
+Vin
2
Ground
3
-Vin
4
+Vout
5
-Vout
PIN
FUNCTION
10 A Module
1
+Vin
2
-Vin
3
Ground
4
+Vout
5
-Vout
PIN
FUNCTION
20 A Module
1
-Vin
2
-Vin
3
+Vin
4
+Vin
5
Ground
6
-Vout
7
-Vout
8
+Vout
9
+Vout