CBAM™ EFIL-28
1
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
6/4/09 ECO # 121116-1
Features
Meets the requirements of MIL-STD-461E, CE101
and CE102
Designed for systems with 28VDC nominal input
voltage
1/2 brick package (2.28” x 2.40” x 0.50”)
Rated up to 200 Watts
Aluminum substrate technology
All ceramic solution
Common mode and differential mode ltering
All applicable materials used are a minimum of
UL94V-0 rated. Designed to meet UL60950.
Excellent MTBF
Five year warranty
Available with RoHS compliant construction, simply
add “(RoHS)” after the part number i.e. EFIL-28
(RoHS)
Optional Case- Add “-T” to the end of the part
number to order the El-28 with a 0.55” tall case.
i.e EFIL-28-T or EFIL-28-T (RoHS).
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Description
The EFIL-28 Module is an EMI Filter designed for use with
Calex DC/DC Converters. Built in a 1/2 brick package
for systems with 24VDC and 28VDC nominal input, the
EFIL-28 module can provide ltering for up to two Calex
DC/DC Converters.
Figure 1. EFIL-28 Connection Diagram
CBAM™ EFIL-28
2
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
6/4/09 ECO # 121116-1
Input Parameters
Model EFIL-28 Units
Input Voltage Range MIN
TYP
MAX
9.5
28
36
VDC
Input Overvoltage 100ms MAX 50 VDC
Reverse Polarity Protection None (1)
Input Current MAX 20 A
Efciency TYP 99 %
Recommended Input Fuse (2)
Output Parameters
Output Voltage Vout = Vin - (lin x Rdc) VDC
DC Resistance (Rdc) TYP 5 mOhm
Output Power (4) (5) MAX 200 W
External Output Capacitance Required (5) (6) See Table 1
Electromagnetic Compliance (7)
Standard Test
Conducted Emissions MIL-STD-461E CE101, CE102
All parameters measured TA=25ºC, and 200W of output power unless otherwise noted.
Notes:
(1) Reverse Polarity Protection: Reverse polarity will NOT damage
the module. However, precautions must be taken to ensure
downstream circuitry is protected. Calex HEW series DC/DC
converters implement reverse polarity protection.
(2) Refer to the CALEX Application Notes for information on fusing.
(3) Thermal impedance is tested with the module mounted vertically
and facing another printed circuit board 1/2 inch away.
(4) Contact the factory for higher output power capabilities.
(5) Due to the negative input resistance characteristics of DC/DC
converters, the addition of an input lter may cause instability. To
ensure a stable system, the output impedance of the lter must
be smaller in magnitude than the converter input impedance.
This can be ensured with the addition of an external capacitor
connected to the input of the converter. Under normal operating
conditions, specied as 28VDC input at 200 Watts, the EFIL-28
does not require any external capacitance.
(6) Due to the added inductance (50 µH) of the Line Impedance
Stabilization Network (LISN) used in MIL-STD-461E testing,
capacitor C1 is required to maintain converter stability. See
Figures 2 and 3.
(7) Measurements comply with the requirements set forth in MIL-
STD-461E, CE101 and CE102.
(8) The case thermal impedance is dened as the case temperature
rise over ambient per package watt dissipated.
(9) Isolation is measured by applying a DC voltage between pins and
baseplate.
(10) Calex CBAM™ modules are designed to withstand most
solder/wash processes. Careful attention should be used
when assessing the applicability in your specic manufacturing
process. The CBAM™ modules are not hermetically sealed.
(11) Torque fasteners into threaded mounting inserts at 12 in.oz. or
less. Greater torque may result in damage to the unit and void
the warranty.
(12) MTBF is calculated based on MIL-HDBK-217F under the following
conditions:
Reliability prediction method = Part Stress Analysis
Baseplate temperature = 40ºC
Environment = Ground, Benign
(13) Available with RoHS and Non-RoHS construction, contact factory
for details.
(14) RoHS Compliance:
See Calex Website www.calex.com/RoHS.html for the complete
RoHS Compliance statement.
The RoHS marking is as follows.
CBAM™ EFIL-28
3
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
6/4/09 ECO # 121116-1
General Specications
Model EFIL-28 Units
Isolation
Baseplate to Pins (9) MIN 700 VDC
Environmental
Baseplate Operating Temp Range MIN
MAX
-40
100
ºC
Storage Temperature Range MIN
MAX
-40
120
ºC
Case Thermal Impedance (3), (8) TYP 7 ºC/Watt
MTBF MIL-STD-217F (12) 710,705 h
General
Unit Weight TYP 95 g
Case Dimension
Optional Case “-T” models
2.28” x 2.40” x 0.50”
2.28” x 2.40” x 0.55”
Torque on Mounting Inserts (11) MAX 12 in. oz.
Pin Pin Dia. Function
1 0.080” - INPUT
2 0.040” BASEPLATE
4 0.080” + INPUT
5 0.080” - OUTPUT
9 0.080” + OUTPUT
Mechanical tolerances unless otherwise noted:
X.XX dimensions: ±0.020 inches
X.XXX dimensions: ±0.005 inches
CBAM™ EFIL-28
4
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
6/4/09 ECO # 121116-1
Component Rating / Type Drawing Notes
C1
No Capacitor Required Figure 1. For Vin ≥ 18 VDC
220 µF, 100 VDC,
Electrolytic
Figure 2 and 3 For 9.5 ≤ Vin <18 VDC and with EMI
Test Setup. See Notes (5) (6)
C3, C4 0.01 µF, 1000 VDC,
Ceramic
Figure 1, 2 and 3 Converter Common mode capacitors
Table 1. External Components
Figure 2. EFIL-28 with Calex HEW Series DC/DC Converter
CBAM™ EFIL-28
5
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
6/4/09 ECO # 121116-1
EFIL-28 with 24S3.30HEW, Full Load
EFIL-28 with 24S5.30HEW, Full Load
Figure 3. MIL-STD-461E CE102 Test Conguration
MIL-STD-461E Conducted Emissions Results CE102, 28VDC Input
CBAM™ EFIL-28
6
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
6/4/09 ECO # 121116-1
EFIL-28 with 24S12.12HEW, Full Load
EFIL-28 with 24S15.10HEW, Full Load
EFIL-28 with 24S24.6HEW, Full Load
CBAM™ EFIL-28
7
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
6/4/09 ECO # 121116-1
EFIL-28 with 24S3.30HEW, Full Load
EFIL-28 with 24S5.30HEW, Full Load
MIL-STD-461E Conducted Emissions Results CE101, 28VDC Input
EFIL-28 with 24S12.12HEW, Full Load
CBAM™ EFIL-28
8
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
6/4/09 ECO # 121116-1
EFIL-28 with 24S15.10HEW, Full Load
EFIL-28 with 24S24.6HEW, Full Load
CBAM™ EFIL-28
9
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
6/4/09 ECO # 121116-1
Care must be taken when using an input lter in front
of any DC/DC converter. The negative input resistance
characteristic of the converter can cause instability if the
output impedance of the lter is larger (in magnitude) than
the input resistance of the converter. To make certain this
does not occur, a properly sized, low ESR electrolytic
capacitor is connected to the input of the converter. This
effectively drops the impedance the converter “sees”
looking out of its input pins. This behavior will be at
its worst at low line voltage conditions, a result of the
constant power characteristic of the DC/DC converter.
The lower input voltage leads to a larger input current,
thus decreasing the input impedance of the converter. As
a result, a larger value capacitor is required across the
input. Table 1 on page 4 shows the capacitance required
for proper operation. This assumes that the DC source
providing the power has sufciently low impedance. Most
adequately sized power supplies or batteries should not
have a problem with this matter.
Inductance of the input line may also contribute to
instability. In the case of MIL-STD-461E, a LISN with
50µH of inductance is required for testing. To compensate
for the inductance, a low ESR electrolytic capacitor
was connected between the lter and converter; (see
Table 1 and Figure 3). In addition, consider temperature
range requirements. Electrolytic capacitors decrease
in capacitance as temperature decreases, therefore a
larger value may be necessary to account for worst-case
conditions. The EFIL-28 is designed to meet MIL-STD-
461E CE101 and CE102 requirements at 25ºC.
EFIL-28 Application Section
Filter Operation Using Remote ON/OFF
Some Calex Converters use a remote ON/OFF function
for conserving battery power or limiting inrush current
when the converter is used in pulsed applications. The
reference for this pin is the -Input of the converter. When
implementing the Remote ON/OFF with the EFIL-28
module connected, an isolated relay or optocoupler is
necessary. This is due to the use of a common mode
inductor in the EFIL-28. Any DC current bypassed from
the lter may cause saturation of this inductor and will
severely degrade the ltering performance.
See Figure 4 and 5 for recommended circuits.
Figure 4.
Isolated ON/OFF driver using an optocoupler
Figure 5.
Low power relay which also offers isolation
For best EMI performance, it is recommended to mount
both the EFIL-28 and the Calex Converter directly to
chassis ground. This results in a low impedance path
from the internal EMI ground to chassis ground. If
this is not possible, connect to chassis ground via the
“Baseplate” pin on the EFIL-28 and the “Case” pin on the
Calex Converter. The use of heavy gauge wire and the
shortest possible path will minimize the impedance and
improve performance.
Baseplate Connection
CBAM™ EFIL-28
10
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
6/4/09 ECO # 121116-1
It is possible to effectively lter up to two (2) Calex DC/
DC converters using one (1) EFIL-28 module. However,
the EFIL-28 maximum power rating of 200W must not be
exceeded. This results in operating 2 converters at less
than their maximum power output. With 28VDC input,
this means approximately 7.2 amperes through the
EFIL-28. Another precaution that must be taken is the
addition of external capacitance between the lter and
converters. Figure 6 shows the connection diagram with
the required external capacitors. For operation below
28VDC input, these capacitors will need to increase
to 470µF each. Note the external Y-capacitors at each
converter output and at the input of the second converter.
Contact the factory for lters with increased output power
capabilities.
Using Two Calex Converters
Figure 6. Connection diagram for 2 Calex DC/DC Converters
CBAM™ EFIL-28
11
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
6/4/09 ECO # 121116-1
Additional Data:
MIL-STD-461E Conducted Emissions Results CE102, 24VDC Input
EFIL-28 with 24S3.30HEW, 24VDC Input, Full Load
EFIL-28 with 24S5.30HEW, 24VDC Input, Full Load
CBAM™ EFIL-28
12
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
6/4/09 ECO # 121116-1
EFIL-28 with 24S12.12HEW, 24VDC Input, Full Load
EFIL-28 with 24S15.10HEW, 24VDC Input, Full Load
EFIL-28 with 24S24.6HEW, 24VDC Input, Full Load
CBAM™ EFIL-28
13
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
6/4/09 ECO # 121116-1
MIL-STD-461E Conducted Emissions Results CE101, 24VDC Input
EFIL-28 with 24S3.30HEW, 24VDC Input, Full Load
EFIL-28 with 24S5.30HEW, 24VDC Input, Full Load
CBAM™ EFIL-28
14
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
6/4/09 ECO # 121116-1
EFIL-28 with 24S12.12HEW, 24VDC Input, Full Load
EFIL-28 with 24S15.10HEW, 24VDC Input, Full Load
EFIL-28 with 24S24.6HEW, 24VDC Input, Full Load