Drawing on Vicor’s 30 years of experience supporting thousands of defense system designs, this webinar explains how to overcome the multitude of challenges faced by power system designers. Viewers will learn how to meet demanding requirements for electrical performance, harsh environmental conditions, small size and light weight while ensuring high reliability.

1. 1
Meeting DC-DC Power System Requirements
in Defense Applications
Presented by: Vamshi Domudala
System Applications Engineer at Vicor

2. 2
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

3. 3
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

4. 4
› 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

5. 5
EMC Standards Requirement Applicability

6. 6
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

7. 7
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

8. 8
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)

9. 9
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

10. 10
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

11. 11
Vicor Power Components
MIL-COTS Input Filter
DC-DC Converter
Transient
Protection
Circuit
DC Power
Supply
+
–
EMI Filter
DCM in a VIA Package

12. 12
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

13. 13
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

14. 14
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

15. 15
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 W
Up 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)

16. 16
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

17. 17
› 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
Advantages
ChiP Package
VIA Package

18. 18
What Standards are Met with
LV and HV MIL-COTS Filter + DCM in a VIA Package?
Specifications
HV MFM +
M-Grade DCM VIA
HV MFM +
T-Grade DCM VIA
LV MFM +
M-Grade DCM VIA
LV MFM +
T-Grade DCM VIA
Conducted Emissions
per 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 YES
MIL-STD-704A
Over Voltage
MIL-STD-704A
Over Voltage
MIL-STD-1275D/E YES NO
Operating Temperature
(-55ºC to 125ºC)
YES NO YES NO

19. 19
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
LOADCout
Cin
+
-
DCM™ in a VIA Package
EMI
Receiver
20dB
Attenuator
CE102 Test Setup
EMI
Receiver
Current
Probe
CE101 Test Setup
50Ω Termination

20. 20
Test Results: CE101
Figure: CE101 EMI scans for HVMFM + 300 Vin to 28 Vout DC system
Positive Lead
0% Load
Negative Lead
0% Load

21. 21
Test Results: CE101
Positive Lead
100% Load
Negative Lead
100% Load
Figure: CE101 EMI scans for HVMFM + 300 Vin to 28 Vout DC system

22. 22
Test Results: CE102
Figure: CE102 EMI scans for HVMFM + 300 Vin to 28 Vout DC system
Positive Lead
0% Load
Negative Lead
0% Load

23. 23
Test Results: CE102
Positive Lead
100% Load
Negative Lead
100% Load
Figure: CE102 EMI scans for HVMFM + 300 Vin to 28 Vout DC system

24. 24
Transient Immunity of 28Vin DC system
Figure: Transient Immunity for LVMFM + 28 Vin to 12 Vout
DC system, 100 Volts > 50 msec, -55ºC input transient
Figure: Transient Immunity for LVMFM + 28 Vin to 12 Vout
DC system, 60 Volts, 350 msec, -55ºC input transient

25. 25
Typical Application
MIL-COTS Filter + DCM VIA with Pulsed Loads
HV MFM
Pulsed
Load
COUT
CIN
DCM™ in a VIA Package
+IN
-IN
+OUT
-OUT
EMI GND
+IN
-IN
+OUT
-OUT
DC
Power
Supply
Pulse Load Characteristics
Time
Power Output Voltage
Load Current
Average Power

26. 26
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

27. 27
Vicor Online Tools
http://www.vicorpower.com/powerbench

28. 28
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

29. 29
Thank You

30. 30
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