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Meeting DC-DC Power System Requirements in Defense Applications

Presented by: Vamshi Domudala

System Applications Engineer at Vicor

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Agenda

1. Requirements in Defense Applications

2. Filtering Requirement to Meet Military Standard Emission Specifications

3. MIL-COTS Filter in Detail

4. About Vicor DCM™ Isolated, Regulated DC-DC Converters

5. Typical Emission Test Results

6. Typical Application

7. General Layout Guidelines for Effective Noise Reduction

8. Vicor Online Tools

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Requirements in Defense Applications

› SWaP-C Requirements (Size, Weight and Power - Cost)

– Reduced size, weight & cost

– Increased power

› EMC Performance Requirements

– Conducted emissions and susceptibility

– Radiated emissions and susceptibility

› Electrical Power Characteristics

› Environmental Qualification Requirements

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› EMC Performance Requirements

– Conducted emissions and susceptibility; MIL-STD-461E/F (CE101, CE102, CS101, CS114, CS115, CS116)

› Electrical Power Characteristics– Transient Immunity; MIL-STD-704F (MIL-HDBK-704); MIL-STD-1275D/E

› Environmental Qualification Requirements

– Salt fog, fungus, mechanical shock, vibration, temperature cycling & altitude; MIL-STD-810G

– Resistance to solvents; MIL-STD-202G

› Both standalone DC-DC converters and overall system should meet MIL-STD

MIL-STD Requirements for DC-DC Converters

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EMC Standards Requirement Applicability

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Figure: CE101-4. CE101 limit for Navy ASW aircraft and Army aircraft (including flight line) applications

Figure: CE102-1. CE102 limit (EUT power leads, AC and DC) for all applications

CE101 CE102

› Input power leads, current through power leads

› Input power leads, voltage across 50Ω terminations of LISN

Conducted Emissions: MIL-STD-461E/F

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Conducted Susceptibility: MIL-STD-461E/F

CS101

Figure: CS101-1. CS101 voltage limit for all applications

› Positive input power lead only

› Defined noise signal is injected into the EUT through positive lead

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Figure: Envelope of normal voltage transient for 270 volts DC system

Normal Transients Abnormal Transients (per Table HDC105-III, HDC302-III)

› Overvoltage from 280 VDC to 350 VDC

› Undervoltage from 280 VDC to 180 VDC

High Voltage Transient Immunity: MIL-STD-704F (MIL-HDBK-704)

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Figure: Envelope of surges for 28 volts DC system

Low Voltage Transient Immunity: MIL-STD-1275A/B/D/E

Figure: Envelope of spikes in normal operating mode for 28 volts DC systems

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Filtering Requirement to Meet Military Standard Emission Specifications

Usually requires several discrete components Differential-Mode Elements

Common-Mode Elements

Transient Protection Circuitry

DC-DC Converter

Transient Protection

Circuit

DC Power Supply

+

–

EMI Filter

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Vicor Power Components

MIL-COTS Input Filter

DC-DC Converter

Transient Protection

Circuit

DC Power Supply

+

–

EMI Filter

DCM in a VIA Package

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Vicor Integrated Filter Solution

Input filter specifically designed to meet specific military standard requirements when used with the DCM™ in a VIA package

› Low Voltage MIL-COTS Input Filter Module (16 – 50 VDC)

› High Voltage MIL-COTS Input Filter Module (160 – 420 VDC)

1.76 x 1.40 x 0.36 in.

44.6 x 35.5 x 9.2 mm

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MIL-COTS Filters in Detail

Electrical Specifications High Voltage (HV) MFM Low Voltage (LV) MFM

Input Voltage Range 160 – 420 VDC 16 – 50 VDC

Maximum Output Power 640 W 350 W

Maximum Output Current 4 A 22 A

Efficiency 99.4% 99.6%

Internal Operating Temperature -55°C to 125°C

Dielectric Withstand (IN/OUT to EMI GND/Case)

2,121 VDC 1,500 VDC

Mounting Options PCB Mount, Chassis Mount

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About Vicor DCM™ Isolated Regulated DC-DC Converters

Product Features

› Wide input voltage range, multiple output voltages

› Efficiency Up to 93%

› High Power Density

› C, T, M-Grade Options

› Different Packages

› 3623 & 4623 DCM in a ChiP Package

› 3414 & 3714 DCM in a VIA Package

› VIA Mounting Styles

› PCB Mount & Chassis Mount

3623: 38.72 x 22.8 x 7.26 mm

4623: 47.91 x 22.8 x 7.26 mm

ChiP Package

3414: 3.38 x 1.40 x 0.37 in

3714: 3.75 x 1.40 x 0.37 in

VIA Package

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About Vicor DCM™ Isolated Regulated DC-DC Converters

Electrical Characteristics

Up to 160 W

Up to 320 W

Up to 320 W

Up to 320 WUp to 375 W

Up to 500 W

Up to 400 W

Up to 600 W

9 16 18 36 50 75 120 160 180 200 420

3623 ChiP & 3414 VIA

3 – 52.8 VOUT (V)

4623 ChiP & 3714 VIA

3 – 52.8 VOUT (V)

VIN (V)

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Industrial/Telecom

› Battery Charging

› Data Centers

Defense Applications

› Ground Based Vehicular Systems

› Targeting Systems

› Flat Panel Displays

› RF Jamming

› GPS Mobile Tracking

Airborne

› Legacy Airborne System

› Tethered Drones

About Vicor DCM™ Isolated Regulated DC-DC Converters

Typical Applications

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› High Power Density

› Cost Effective Solutions

› Easy to Design a Power System Solution

› Fast Design Time

› Low Design Risk

About Vicor DCM™ Isolated Regulated DC-DC Converters

AdvantagesChiP Package

VIA Package

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What Standards are Met with LV and HV MIL-COTS Filter + DCM in a VIA Package?

SpecificationsHV MFM +

M-Grade DCM VIAHV MFM +

T-Grade DCM VIALV MFM +

M-Grade DCM VIALV MFM +

T-Grade DCM VIA

Conducted Emissionsper MIL-STD-461E/F

YES YES YES YES

Conducted Susceptibility per MIL-STD-461E/F

YES YES YES YES

Transient Immunity per MIL-STD-704F

YES YESMIL-STD-704AOver Voltage

MIL-STD-704A Over Voltage

MIL-STD-1275D/E YES NO

Operating Temperature (-55ºC to 125ºC)

YES NO YES NO

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Test Setup for Conducted Emissions

50Ω Termination

DC Power Supply

Screen Room/ Filters

LISN

LISN

HV MFM

+IN

-IN

+OUT

-OUT

EMI GND

+IN

-IN

+OUT

-OUT

LOADCoutCin

+

-

DCM™ in a VIA Package

EMI Receiver

20dB

Attenuator

CE102 Test Setup

EMI Receiver

Current

Probe

CE101 Test Setup

50Ω Termination

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Test Results: CE101

Figure: CE101 EMI scans for HVMFM + 300 Vin to 28 Vout DC system

Positive Lead0% Load

Negative Lead0% Load

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Test Results: CE101Positive Lead100% Load

Negative Lead100% Load

Figure: CE101 EMI scans for HVMFM + 300 Vin to 28 Vout DC system

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Test Results: CE102

Figure: CE102 EMI scans for HVMFM + 300 Vin to 28 Vout DC system

Positive Lead0% Load

Negative Lead0% Load

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Test Results: CE102Positive Lead100% Load

Negative Lead100% Load

Figure: CE102 EMI scans for HVMFM + 300 Vin to 28 Vout DC system

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Transient Immunity of 28Vin DC system

Figure: Transient Immunity for LVMFM + 28 Vin to 12 VoutDC system, 100 Volts > 50 msec, -55ºC input transient

Figure: Transient Immunity for LVMFM + 28 Vin to 12 VoutDC system, 60 Volts, 350 msec, -55ºC input transient

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Typical Application MIL-COTS Filter + DCM VIA with Pulsed Loads

HV MFMPulsed Load

COUTCIN

DCM™ in a VIA Package

+IN

-IN

+OUT

-OUT

EMI GND

+IN

-IN

+OUT

-OUT

DC Power Supply

Pulse Load Characteristics

Time

Power Output VoltageLoad Current

Average Power

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General Layout Guidelines for Effective Noise Reduction

› Add ground planes and ground fill

› Eliminate return path discontinuities

› PCB layer Stackup

Components

Ground Plane

Power Plane

Signal Traces

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Vicor Online Tools

http://www.vicorpower.com/powerbench

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Useful Vicor Website Links

DCM™ DC-DC Converter Module Product Family

http://www.vicorpower.com/dc-dc/isolated-regulated/dcm

MIL-COTS Filter Module

http://www.vicorpower.com/mil-cots-dc-dc/MFM%20Filter%20Module

MIL EMI and Transient Solutions Application Note

http://www.vicorpower.com/documents/application_notes/vichip_appnote22.pdf

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Thank You

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IEEE PDH Information

› Webinar title:

Meeting DC-DC Power System Requirements in Defense Applications

› Code: 2017IEEE04S2

› Link to form: https://fs25.formsite.com/ieeevcep/form112/index.html