MCD10059 Rev. 1.1, 21-Jan-10 Page 1 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
Introduction
Power-One 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
Tested with
Filter Model
Numbers
Filter
Series
Page
FES FC100V20A FC 14
HBD FC100V5A FC 14
HES FC100V5A FC 14
IAD FC100V5A FC 14
IAS FC100V5A FC 14
IES FC100V5A FC 14
LES FC100V5A FC 14
OET FC100V5A FC 14
Q24 F4804A, F2410,
F4810
F 2, 8
Q48 F4804A, F4810 F 2, 8
QBS FC100V5A FC 14
QD48 F4804A, F4810 F 2, 8
QES FC100V5A FC 14
QL48 F4804A, F4810 F 2, 8
QM48 F4810 F 8
QME48 F4810 F 8
SQ24 F4804A, F2410,
F4810
F 2, 8
SQ48 F4804A, F4810 F 2, 8
SQE48 F4804A, F4810 F 2, 8
SQM48 F4804A, F4810 F 2, 8
SQT48 F4810 F 8
Detailed Table of Contents
F4804A, 0-80V, 4 Amps, SMT Mount ...................2
Features...............................................................2
Description...........................................................2
Electrical Specifications.......................................3
Physical Information ............................................7
Filter Part Numbering Ordering Information ........7
F2410 & F4810, 0-45V/0-80V, 10 Amps,
SMT Mount .............................................................8
Features...............................................................8
Description...........................................................8
Electrical Specifications.......................................9
Thermal Considerations ....................................11
Physical Information ..........................................13
Filter Part Numbering Ordering Information ......13
FC Series, 0-100V, 5/10/20 Amps, TH Mount ....14
Model Selection.....................................................15
FC Model Numbering Convention.........................15
Design Considerations ..........................................16
DC Current Ratings ...........................................17
Safety Considerations ...........................................17
Isolation .............................................................17
Fusing ................................................................17
Case Grounding ................................................17
Input Shutdown Pin ...............................................17
Reflected Input Current .........................................18
FC100V5A Module Details....................................18
FC100V10A Module Details..................................21
FC100V20A Module Details..................................24
EMI Measurement Methodology ...........................24
Printed Circuit Board Design.................................29
Manufacturing Issues ............................................29
Processing of Completed Power Modules ........29
Notes on Processing of Completed Power
Modules .............................................................29
Mechanical Drawings ............................................30
FC Filters Ordering Information.............................31
F4804, Not for New Designs...............................32
Features.............................................................32
Description.........................................................32
Electrical Specifications.....................................33
Physical Information ..........................................41
Filter Part Numbering Ordering Information ......41
MCD10059 Rev. 1.1, 21-Jan-10 Page 2 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
F4804A, 0-80V, 4 Amps, SMT Mount
F4804A Applications
Differential and Common Mode filtering for dc-dc
converters:
Telecommunications
Data communications
Distributed Power Solutions
Features
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. in.
Low profile: 0.267” [6.78 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
UL60950 recognition in U.S. & Canada, and
DEMKO certification per IEC/EN60950
Description
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. Filter F4804A is a fully compatible replacement for F4804, with improved
electrical and thermal characteristics.
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.
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.
.
MCD10059 Rev. 1.1, 21-Jan-10 Page 3 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
F4804A, 0-80V, 4 Amps, SMT Mount
Electrical Specifications
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
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 %
Additional Notes:
1. 50 source and 50 load impedance. See Fig 2 for differential mode attenuation in 50 kHz-100 MHz frequency range.
2. 50 source and 50 load impedance; external common-mode capacitors 0.47 µF (from IN+ and IN- to the common chassis).
See Fig. 3 and Fig. 4 for attenuation in 50 kHz-100 MHz frequency range.
MCD10059 Rev. 1.1, 21-Jan-10 Page 4 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
F4804A, 0-80V, 4 Amps, SMT Mount
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.
Vout+
L1-2
C2
1 F
L2
4.7 H
C1
2 F
C3
2 F
Vin-
Vin+
L1-1
2 x 30 H
Vout-
Fig. 1: Schematic diagram.
Differential attenuation plot in the frequency range of
50 kHz-100 MHz is shown in Fig. 2, and can be seen
to be flat (around 55-60 dB) from 0.5 MHz to
50 MHz.
Fig. 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.
Fig. 3 and Fig. 4 show Common mode attenuation with
50 source and load. The attenuation depends on the
value of external Y-capacitors, connected between input
pins and frame or a reference ground.
Fig. 3: Common Mode attenuation, 0.05-100 MHz. Source and
load resistances are 50 Ω. Two 0.1 µF Y-caps to common
line. Vertical scale: 20 dB/div, with zero dB level marked by
arrow.
Fig. 4: Common Mode attenuation, 0.05-100 MHz. Source and
load resistances are 50 Ω. Two 0.47 µF Y-caps to common
line. Vertical scale: 20 dB/div, with zero dB level marked by
arrow.
MCD10059 Rev. 1.1, 21-Jan-10 Page 5 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
F4804A, 0-80V, 4 Amps, SMT Mount
Thermal Considerations
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 Fig. 5.
The filter can be used to power one 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.
Rload1
F4804A
Input Filter
Vin (+)
Vin (-)
ON/OFF
Vout (+)
Vout (-)
TRIM
SENSE (+)
SENSE (-)
(Top View)
Converter
DC-DC
(Top View)
C8
C2
C4
Vin-
Vin+
F1
5 A
CY2
CY1
+
C1
C5
Rload2
Vin (+)
Vin (-)
ON/OFF
Vout (+)
Vout (-)
TRIM
SENSE (+)
SENSE (-)
(Top View)
Converter
DC-DC
C9
C3
C6
C7
Fig. 5: F4804A - Typical application
MCD10059 Rev. 1.1, 21-Jan-10 Page 6 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
F4804A, 0-80V, 4 Amps, SMT Mount
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 Fig. 5.
Input electrolytic capacitor C1. We recommend
1-2 µF/W for 48V applications. This capacitor is
needed to ensure stability of converters in
presence of their negative input impedance
characteristic. Note that electrolytic capacitors at
-40 ºC 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 µF, 100 V
Common-mode capacitor (Y-cap) values and
their EMI attenuation effects depend on system
grounding and layout.
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
Fig. 5). The value of these capacitors in this case
is “the bigger the better” (preferably 0.1 µF 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 47 µF 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.
MCD10059 Rev. 1.1, 21-Jan-10 Page 7 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
F4804A, 0-80V, 4 Amps, SMT Mount
Physical Information
TOP VIEW
-IN
SIDE VIEW
+IN
-OUT
+OUT
Filter Part Numbering Ordering Information
Product
Series
Input
Voltage
Rated Load
Current Tape and Reel Environmental
F 48 04A - R
Filter Module
80 V
4 A
No letter Bulk
R Tape and Reel
No suffix character
RoHS lead-solder
exemption
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.
Pad/Pin Connections
Pad/Pin # Function
+IN Vin (+)
-IN Vin (-)
-OUT Vout (-)
+OUT Vout (+)
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]]
MCD10059 Rev. 1.1, 21-Jan-10 Page 8 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
F2410 & F4810, 0-45V/0-80V, 10 Amps, SMT Mount
F4810 (on left) and F2410 Input Filters
F2410 & F4810 Applications
Differential and Common Mode filtering for DC-DC
converters with 48 V and 24 V input:
Telecommunications
Data communications
Distributed Power Solutions
Features
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)
100V/50V 100 ms transient withstand capability
Differential LC-filter stage
Surface mounted design
Small footprint – less than 1 sq. in.
Low profile: 0.378” [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
Safety approved to UL/CSA60950-1, EN60950-1,
and IEC60950-1
Description
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.
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.
MCD10059 Rev. 1.1, 21-Jan-10 Page 9 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
F2410 & F4810, 0-45V/0-80V, 10 Amps, SMT Mount
Electrical Specifications
Conditions: TA = 25 ºC, 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
Filter differential inductance 4.5 H
Filter common mode inductance For frequencies below 10 MHz 6.5 H
Differential mode Attenuation at 400 kHz1 F4810 57 dB
F2410 63 dB
Differential mode attenuation at 30 MHz1 F4810 56 dB
F2410 57 dB
Common mode Attenuation at 400 kHz2 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 %
Additional Notes:
1. 50 source and 50 load impedance. See Fig 2 and 3 for differential mode attenuation in the 20 kHz-100 MHz frequency range.
2. 50 source and 50 load impedance; external common-mode capacitors 0.1 µF (from IN+ and IN- to the common chassis). See
Fig. 4 for attenuation in the 20 kHz-100 MHz frequency range.
MCD10059 Rev. 1.1, 21-Jan-10 Page 10 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
F2410 & F4810, 0-45V/0-80V, 10 Amps, SMT Mount
The F4810 and F2410 filters contain input and output
capacitors, plus differential and common mode
inductors. Shown in Fig. 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 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
20dB, 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.
C2
L1-1 VOUT+
VOUT-
L1-2
L2
C1
4.2 H
VIN-
VIN+
R1
49.9
4 F3 F
Fig. 1: Schematic diagram for F4810, F2410. The Capacitor
values shown are for F4810; for F2410 C1=10 μF; C2=13 μF.
Fig. 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.
Fig. 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.
Differential attenuation plots for the F4810 and
F2410 filters in the extended frequency range of
20 kHz-100 MHz are shown in Fig. 2 and Fig. 3,
respectively, and can be seen to be flat (around
55-60 dB) from 0.35 MHz to 40 MHz.
Fig. 4 shows Common mode attenuation with 50
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.
Fig. 4: F4810/F2410 - Common Mode attenuation, 0.2-100
MHz. Source and load resistances are 50 Ω. Two 0.1uF Y-
caps to common line. Vertical scale: 10 dB/div, with zero dB
level marked by arrow.
MCD10059 Rev. 1.1, 21-Jan-10 Page 11 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
F2410 & F4810, 0-45V/0-80V, 10 Amps, SMT Mount
Thermal Considerations
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 Fig. 5.
Either filter can be used to power one 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.
Fig. 5: F4810 – Typical application
C6
C3
C7
Rload2
Vin (+)
Vin (-)
ON/OFF
Vout (+)
Vout (-)
TRIM
SENSE (+)
SENSE (-)
(Top View)
Converter
QmaXTM Series
C9
C1
F4810
V
IN -
V
IN +
+48V
-48V
+Vout
-Vout
P3
P4
P1
P2
+
F1
12A
C2
C5
Rload1
Vin (+)
Vin (-)
ON/OFF
Vout (+)
Vout (-)
TRIM
SENSE (+)
SENSE (-)
(Top View)
Converter
QmaXTM Series
C8
C4
(Top View)
Input Filter
For further information
regarding connection of CM
capacitors and other
pertinent layout and EMC
information, please refer to
the Layout Considerations
and EMI Considerations
Application notes.
DC-DC
Converter
(Top View)
DC-DC
Converter
(Top View)
MCD10059 Rev. 1.1, 21-Jan-10 Page 12 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
F2410 & F4810, 0-45V/0-80V, 10 Amps, SMT Mount
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 Fig. 5.
Input electrolytic capacitor C1. We recommend
1-2 µF/W for 48 V applications, and 2-4 µF/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 ºC 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 µF, 100V - for
48 V applications
– TDK C4532X7R1H475, 4.7 µF, 50V - 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 Fig.
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 0.1 µF 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 47 µF 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.
MCD10059 Rev. 1.1, 21-Jan-10 Page 13 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
F2410 & F4810, 0-45V/0-80V, 10 Amps, SMT Mount
Physical Information
TOP VIEW
-IN
SIDE VIEW
+IN
-OUT
+OUT
Filter Part Numbering Ordering Information
Product
Series
Input
Voltage
Rated Load
Current Connector Finish Tape and Reel Environmental
F 24 10 - S R
Filter Module
48: 80 V
24: 45 V
10 A
No letter Gold Plated
S Tin/Lead Plated 2
No letter Bulk
R Tape and
Reel
No suffix character RoHS
lead-solder exemption
G RoHS compliant
for all six substances
The example above describes P/N F2410-SR: 0-45 V input, 10 A output current, Tin/Lead plated connector, tape and reel, and
Eutectic Tin/Lead solder. Please consult factory for the complete list of available options.
1 The solder exemption refers to all the restricted materials except lead in solder.
2 Not available with “G” Environmental Option.
3 Not available with “S” Connector Finish.
Pad/Pin Connections
Pad/Pin # Function
+IN Vin (+)
-IN Vin (-)
-OUT Vout (-)
+OUT Vout (+)
All dimensions are in inches [mm]
Connector Material: Copper
Connector Finish: Gold over Nickel
Optional: Tin/Lead 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
]
MCD10059 Rev. 1.1, 21-Jan-10 Page 14 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
FC Series, 0-100V, 5/10/20 Amps, TH Mount
Features
RoHS lead free solder and lead solder exempted
products are available
Meets Class B conducted limits
Optimized for Power-One's high density, board-
mounted products
PCB mountable
Common mode and differential mode filtering
Industry-standard pinout
-40 ºC to 80 ºC case operation
>30 dB insertion loss at 500 kHz
100 VDC operation
1500 V isolation
FC Series Description
The FC series EMI filters are accessories to the Power-One 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 5.0 A, 10 A, and 20 A
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 ºC, normal line, and full load, unless otherwise
stated.
Soldering conditions: I/O pins, 260 ºC, 10 seconds; fully compatible with
commercial wave-soldering equipment.
MCD10059 Rev. 1.1, 21-Jan-10 Page 15 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
FC Series, 0-100V, 5/10/20 Amps, TH Mount
Model Selection
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
Loss 1
Differential
Mode
(dB)
Insertion
Loss 1
Common
Mode
(dB
Typical
Resistance 2
(mOhms)
FC100V5A 5 28 30 27
FC100V10A 10 31 28 17
FC100V20A 20 26 32 6.6
1 Typical loss at 500 kHz (50 Ohms)
2 Resistance per leg
FC Model Numbering Convention
FC - 100 V - Y A
Series - Input Voltage - Iin
(Max.) (Max.)
Custom models with alternate input voltages, or input current range, or different physical constructions are available. Consult
the Power-One factory.
MCD10059 Rev. 1.1, 21-Jan-10 Page 16 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
FC Series, 0-100V, 5/10/20 Amps, TH Mount
Design Considerations
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 µF 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 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
MCD10059 Rev. 1.1, 21-Jan-10 Page 17 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
FC Series, 0-100V, 5/10/20 Amps, TH Mount
DC CURRENT RATINGS:
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.
Safety Considerations
ISOLATION:
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.
FUSING:
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.
CASE GROUNDING:
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.
Input Shutdown Pin
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.
MCD10059 Rev. 1.1, 21-Jan-10 Page 18 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
FC Series, 0-100V, 5/10/20 Amps, TH Mount
Figure 2. Use of the Shutdown Pin With Input Filters
Reflected Input Current
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.
FC100V5A Module Details
Figure 3. Filter Block Schematic
MCD10059 Rev. 1.1, 21-Jan-10 Page 19 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
FC Series, 0-100V, 5/10/20 Amps, TH Mount
Table 2. FC100V5A Specifications
FC100V5A
Electrical Specifications
EMI Filter
PARAMETER MIN TYP MAX UNITS CONDITIONS NOTES
INPUT
Input Voltage Range 0 48 100 V
Maximum average current 5 A Ta = 60° C 400 lfm air
3.5 A Ta = 60° C natural convection
All specifications typical at
+25º C, nominal line, and full
load unless otherwise noted.
Specifications subject to
change without notice.
Frequency 0 60 Hz
Typical Characteristics
Resistance per leg 27 m
Common-mode insertion loss 30 dB At 500 kHz, 50 Ohm circuit
Differential-mode insertion loss 28 dB At 500 kHz, 50 Ohm circuit
1500 VDC
Isolation voltage;
Allows power module to meet
FCC CISPR and EN55022
Class B conducted limits.
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
MCD10059 Rev. 1.1, 21-Jan-10 Page 20 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
FC Series, 0-100V, 5/10/20 Amps, TH Mount
Figure 4. Differential Mode Attenuation Plot
Figure 5. Common Mode Attenuation Plot
Module: FC100V5A, five ampere EMI filter.
Instrument: Hewlett-Packard model 4194A
Start Freq: 1.0 kHz.
Stop Frequency: 100 MHz.
Scale: 10 dB per division.
System: 50 in and 50 out.
Module: FC100V5A, five ampere EMI filter.
Instrument: Hewlett-Packard model 4194A
Start Freq: 1.0 kHz.
Stop Frequency: 100 MHz.
Scale: 10 dB per division.
S
y
stem: 50 in and 50 out.
MCD10059 Rev. 1.1, 21-Jan-10 Page 21 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
FC Series, 0-100V, 5/10/20 Amps, TH Mount
Figure 6. Output Impedance Plot
FC100V10A Module Details
Figure 7. Filter Block Schematic
Module: FC100V5A, five ampere EMI filter.
Plot: Impedance of the module, looking into
the output pins with the input pins short
circuited.
Instrument: Hewlett-Packard model 4194A
Start Freq: 100 Hz.
Stop Frequency: 100 kHz.
Scale: Log: 1.0 m to 100
Note: The dc resistance baseline is higher
than actual because of fixture limitations.
The DC resistance of the module is 56 m.
MCD10059 Rev. 1.1, 21-Jan-10 Page 22 of 41 www.power-one.com
F & FC Series DC-DC Converter Input Filters
FC Series, 0-100V, 5/10/20 Amps, TH Mount
Table 3. FC100V10A Specifications
FC100V10A
Electrical Specifications
EMI Filter
PARAMETER MIN TYP MAX UNITS CONDITIONS NOTES
INPUT
Input Voltage Range 0 48 100 V
Maximum average current 10 A Ta = 60° C 400 lfm air
6.5 A Ta = 60° C natural convection
All specifications typical at
+25º C, nominal line, and full
load unless otherwise noted.
Specifications subject to
change without notice.
Frequency 0 60 Hz
Typical Characteristics
Resistance per leg 17 m
Common-mode insertion loss 28 dB At 500 kHz, 50 Ohm circuit
Differential-mode insertion loss 31 dB At 500 kHz, 50 Ohm circuit
1500 VDC
Isolation voltage;
Allows power module to meet
FCC CISPR and EN55022
Class B conducted limits.
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
Figure 8. Differential Mode Attenuation Plot
Module: FC100V10A, ten ampere EMI filter.
Instrument: Hewlett-Packard model 4194A
Start Freq: 100 kHz.
Stop Frequency: 30 MHz.
Scale: 12 dB per division.
S
y
stem: 50 in and 50 out.