MIL-STD-461 EMI INPUT FILTER FGDS-20A-50V : up to 20A CURRENT Hi-Rel Hi-Rel Grade Grade 20A EMI Filter Module 9 to 50 VDC Input Range MIL-STD-461D/E/F & DO-160C/D/E/F/G Compliant * To comply with MIL-STD-461D/E/F power leads : * CE 102 : Emission requirement over 10 KHz to 10MHz * CS 101 : Susceptibility requirement over 30Hz to 150KHz * CS 114 : Susceptibility requirement over 10KHz to 400MHz * CS 115 : Susceptibility requirement for spikes * To comply with DO-160C/D/E/F/G power lines : 1-General * Conducted emission requirement over 15 KHz to 152MHz * Conducted susceptibility requirement over 10Hz to 400MHz * Temperature range : * operating temperature : -40C/+105C case * storage temperature : -55C/+125C * RoHS process The GAIA Converter filter module FGDS-20A-50V provides a state-of-the-art product to fulfill Electromagnetic Interferences (EMI) requirements for Aerospace and Defence applications. The FGDS-20A-50V is a very compact and low loss solution for applications requiring up to 20A input current. The FGDS-20A-50V complies with major standards including : * the US MIL-STD-461 rev D, E and rev F * the international DO-160 rev C, D, E, F & rev G In particular, the filter module is compliant with the following requirements of MIL-STD-461D/E and DO-160-C/D/E standards : * MIL-STD-461D/E/F 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 * CS116, damped sinusoidal transient * DO-160-C/D/E/F/G requirements : * Conducted Emission (CE) * Section 21 power lines, emission over 15KHz to 152MHz, 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 * MIL-STD-1275B with 100V/50ms The FGDS-20A-50V is suitable for all GAIA Converter DC/DC converters and DC architecture * from 50W up to 300W output power * up to 20A output current * up to 50V permanent input voltage. 2-Product Selection FGDS-20A-50V/ option Options : /T : option for -55C start up operating temperature /S : option for screening and serialization REDEFINING THE SOURCE OF POWER (c) Gaia Converter FC05-050.07/13 Revision D For locations, phone, fax, E-Mail see back cover 6 EMI Filter FGDS-20A-50V Hi-Rel Grade 3- Electrical Specifications Data are valid at +25C, unless otherwise specified. FGDS-20A-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 Maximum A 20 Maximum W 300 Parameter Input Output Permanent output current Permanent output power Full temperature range up to 100C case Ui min. to max. Full temperature range up to 100C case Ui min. to max. Power dissipation Current 20A @ 25C Current 20A @ 85C Maximum Maximum W W 2 2,6 Thermal resistance Case to ambient in free air cooling Nominal C/W 15 Case to any pin Gnd pin to any other pin Minimum Minimum VDC VDC 500 500 @40C @85C @40C @85C Hours Hours Hours Hours 27 000 000 7 000 000 13 000 000 3 500 000 General Electrical strengh test voltage Reliability data MTBF according MIL-HDBK-217F Conditions Gf Conditions AIC 6 EMI compliance Conducted emission Power leads Power lines Power lines MIL-STD-461D/E/F DO-160C cat B & AZ DO-160D/E/F/G cat B & LMH CE102 Section 21 Section 21 See section 6 See section 6 See section 6 Conducted susceptibility 50 Ohm impedance 10A 10KHz to 400MHz MIL-STD-461D/E/F MIL-STD-461D/E/F DO-160C/D/E/F/G CS115 CS116 Section 20 Compliant Compliant Compliant (c) Gaia Converter FC05-050.07/13 Revision D 2 For locations, phone, fax, E-Mail see back cover EMI Filter FGDS-20A-50V Hi-Rel Grade 4- EMI Filter Electrical Schematics The GAIA Converter FGDS-20A-50V is suitable for all GAIA Converter DC/DC converters and combinations : * from 50W up to 300W total output power and up to 20A output 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 Modules The GAIA Converter FGDS-20A-50V can be used directly in front of any DC/DC converter and combination of DC/DC converters from 50W up to 300W power and up to 20A input current. In order to exceed the EMI requirements of MIL-STD-461D/E/F or DO-160C/D/E/F/G it is recommended to use 2x FGDS-20A-50V in series as shown in the following figure. Configuration with one FGDS-10A-50V in certain case can be implemented : please consult factory. For better EMI performance and stability purpose GAIA Converter recommends to use a R*C* cell (see section 4) together with common mode noise capacitance (10nF typical) connected to the converters as it is detailed in individual DC/DC converter datasheet. Cc Cc BP Vo VI Vin Vo VI EMI input filter EMI input filter FGDS-20A-50V FGDS-20A-50V GI GI Vo R* MGDM-series Go C* Gin Go Gnd Go BP Gnd Cc Cc BP: Base Plate 4-2 EMI Filter Electrical Schematics in a Complete Front-end Architecture The GAIA Converter FGDS-20A-50V can be used in a complete architecture combining transient protection module LGDS series and combination of DC/DC converters. In order to exceed the EMI requirements of MIL-STD-461D/E/F or DO-160C/D/E/F/G it is recommended to use 2x FGDS-20A-50V directly in series up front as shown in the following figure. Configuration with one FGDS-20A-50V in certain case can be implemented : please consult factory. For better EMI performance and stability purpose GAIA Converter recommends to use a R*C* cell (see section 4-3) (together with individual DC/DC decoupling capacitors as detailed in individual DC/DC converter datasheet). This schematics is designed to propose a solution to achieve : * EMI filtering compliant with conducted emission VI +Vo * transient protection 6 MGDM-series Vi Vo Vi Vo EMI input filter FGDS-20A-50V EMI input filter FGDS-20A-50V Gi Gi R* 1 2 3 Gnd Go Gnd Go VI +Vo Vo 7 Vi 8 9 LGDS-300 220F/50V C* Go GI 5 MGDM-series GI Go VI +Vo Gi MGDM-series GI (c) Gaia Converter FC05-050.07/13 Revision D Go 3 For locations, phone, fax, E-Mail see back cover EMI Filter FGDS-20A-50V Hi-Rel Grade 4- EMI Filter Electrical Schematics (continued) 4-3 R*C* Network Discussion The RC damping network is used for stability purposes in negative input impedance systems such as DC/DC converters. DC/DC converters are negative input impedance systems whereas, filters are composed of passive elements and display 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 x Vin2 Zin = ____ Pin = _________ Po where : Vin is the converter input voltage, Pin is the converter input power, Po is the converter output power 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 quality factor 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 RC network has to be adjusted to dampen sufficiently the filter's resonance and make its output impedance lower than the converter's input impedance. The value of the RC network 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-461 or DO-160 ... ) this because measurements method (LISN) differs from one standard to another affecting the C value. 6 In most applications a low ESR aluminium electrolytic capacitor can be used for damping the network and it's internal ESR value will be enough to dampen the input voltage without adding external resistor. The table hereafter summarizes the recommended capacitor value at 100% output load for various power according to DO160 and to MIL-STD-461 standards. The capacitor value can be linearly reduced depending on output power; for example, it can divided by 2 at 50 % load... Total Power 75W 100W 150W 200W 300W Capacitor Value for MIL-STD-461 standards 330 F 470 F 470 F 680 F 1 000 F Capacitor Value for DO-160 standards 100 F 100 F 220 F 220 F 330 F (c) Gaia Converter FC05-050.07/13 Revision D 4 For locations, phone, fax, E-Mail see back cover EMI Filter FGDS-20A-50V Hi-Rel Grade 5- MIL-STD-461D/E/F Conducted Emission Tests Set-Up 5-1 MIL-STD-461D/E/F Measurement Method The conducted noise emission measurement method is described in the MIL-STD-461D/E/F 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 dBV +28V out +28V in LISN To 50 ohms input receiver DUT To 50 ohms termination LISN Return in Return out 2m 6 (c) Gaia Converter FC05-050.07/13 Revision D 5 For locations, phone, fax, E-Mail see back cover EMI Filter FGDS-20A-50V Hi-Rel Grade 6- MIL-STD-461E Conducted Emission Level Results MIL-STD-461E : MGDS-75-H-J with FGDS-20A-50V MIL-STD-461E : MGDS-100-M-26 with FGDS-20A-50V MIL-STD-461E : MGDS-150-H-J with FGDS-20A-50V MIL-STD-461E : 2 x MGDS-75-H-J with FGDS-20A-50V 6 (c) Gaia Converter FC05-050.07/13 Revision D 6 For locations, phone, fax, E-Mail see back cover EMI Filter FGDS-20A-50V Hi-Rel Grade 6- D0-160C Conducted Emission Level Results DO-160C : MGDS-75-H-J with FGDS-20A-50V DO-160C : MGDS-75-O-C with FGDS-20A-50V DO-160C : MGDS-100-M-26 with FGDS-20A-50V DO-160C : MGDS-150-H-J with FGDS-20A-50V 6 (c) Gaia Converter FC05-050.07/13 Revision D 7 For locations, phone, fax, E-Mail see back cover EMI Filter FGDS-20A-50V Hi-Rel Grade 6- D0-160E Conducted Emission Level Results DO-160E : MGDS-75-H-J with FGDS-20A-50V DO-160E : MGDS-75-O-C with FGDS-20A-50V DO-160E : MGDS-100-M-26 with FGDS-20A-50V DO-160E : MGDS-150-H-J with FGDS-20A-50V 6 (c) Gaia Converter FC05-050.07/13 Revision D 8 For locations, phone, fax, E-Mail see back cover EMI Filter FGDS-20A-50V Hi-Rel Grade 6- D0-160G Conducted Emission Level Results DO-160G : MGDS-75-H-F with FGDS-20A-50V DO-160G : MGDS-75-O-J with FGDS-20A-50V DO-160G : MGDS-150-H-C with FGDS-20A-50V DO-160G : MGDS-150-H-J with FGDS-20A-50V 6 (c) Gaia Converter FC05-050.07/13 Revision D 9 For locations, phone, fax, E-Mail see back cover EMI Filter FGDS-20A-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 @ 105C case, unit operating @ 125C ambient, unit not operating MIL-STD-202G Method 108A Altitude Altitude level C Duration Climb up Stabilization Status of unit 40.000 ft@-55C 30 min. 1 000 ft/min to 70 000 ft@-55C, 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 % 31C to 41C unit not operating MIL-STD-810E Method 507.3 Humidity steady Damp heat Temperature Duration Status of unit 93 % relative humidity 40C 56 days unit not operating MIL-STD-202G Method 103B Salt atmosphere Temperature Concentration NaCl Duration Status of unit 35C 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 -40C / +85C 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 -55C / +105C 10 sec. 20 min. unit not operating MIL-STD-202G Method 107G 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 2 000 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 2 000 bumps in each axis 40 g 6 ms unit not operating MIL-STD-810D Method 516.3 Climatic Qualifications Life at high temperature Mechanical Qualifications (c) Gaia Converter FC05-050.07/13 Revision D 6 10 For locations, phone, fax, E-Mail see back cover EMI Filter FGDS-20A-50V Hi-Rel Grade 8- Dimensions Dimension are given in mm (inches). Tolerance : +/- 0,2 mm (+/- 0.01 ") unless otherwise indicated. Weight : 35 grams (1.22 Ozs) max. Pin dimensions : Pins 5, 6 : O 0,73 mm (0.029'') Pins 1, 2, 3, 4 : O 1,29 mm (0.051'') 9- Materials Case : Metallic case black anodized coating. Pins : Plated with pure matte tin over nickel underplate. 10- Product Marking Upper face : Company logo, location of manufacturing. Side face : Module reference, option, date code : year and week of manufacturing. 6 11- Connections 6 Pin Single 1 + Input (Vi) 2 - Input (Gi) 4 1 3 - Output (Go) 3 2 4 + Output (Vo) 5 Ground (Gnd) 6 Ground (Gnd) 5 Bottom view (c) Gaia Converter FC05-050.07/13 Revision D 11 For locations, phone, fax, E-Mail see back cover International Headquarters Marketing and Sales department GAIA 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 GAIA 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 FC05-50.07/13 Revision D. Graphisme : Philippe Clicq For more detailed specifications and applications information, contact :