99 military emi/rfi filters mil-prf-28861 qpl list all are class b available in gold and tin/tin-lead plated finish (except /12) mil-prf-28861/01 style -001 thru -006, -009 thru -016 -019 thru -026, -031 thru -036 mil-prf-28861/04 style -001 thru -036 (all) mil-prf-28861/05 style -001 thru -024 (all) mil-prf-28861/12 style -001 thru -036 (all) mil-prf-15733 qpl list mil-prf-15733/23 style -0001 thru -0006, -0013 thru -0018 -0025 thru -0030, -0037 thru -0042 -0049 thru -0054 mil-prf-15733/24 style -0005 thru -0008 mil-prf-15733/26 style -0001 thru -0007, -0009 thru -0011 -0013 thru -0019, -0021 thru -0023 mil-prf-15733/34 style -0015 -0019 -0026 mil-prf-15733/38 style -0002 -0004 thru -0006 -0008 mil-prf-15733/49 style -0003, -0004, -0006, -0007 high-rel emi filters noise is the enemy of good engineering design. properly installed emi filters suppress such electromagnetic interfer- ence on power and signal lines, while allowing desired sig- nals to pass. for critical emi filter applications, high reliability is of the utmost importance. high reliability applications have diverse requirements, rang- ing from a need for a long operating life in medical or military systems to avoiding the prohibitive cost of replacing a faulty component in a satellite, undersea cable, or other inaccessi- ble system. high-rel filters satisfy application-critical require- ments in many environments: ? space/satellite systems ? radar systems ? military aircraft ? electro optical systems ? guidance systems ? electronic countermeasures ? command, control & ? electronic warfare communications (c 3 ) ? pacemakers ? missile systems ? medication monitors ? weapon systems high-rel standards reliability must be designed into an emi filter. every step in its manufacture from material selection through testing and characterization must be considered. to assure confor- mance to clearly define product and performance parameters, specifications have evolved for electrical performance, mechanical configurations, test methods, screening and qualification procedures. avx filters delivers high quality emi filters which meet appli- cable portions of these high-reliability standards: ? mil-f-15733 ? mil-f-28861 ? mil-i-45208a ? mil-std-202 ? mil-std-220 ? mil-q-9858 ? nasa nhb 5300 ? mil-std-790 ? mil-prf-123 ? iso 9000 ? mil-std-1547 ? eia-rs-469 avx filters at the leading edge avx filters corporation continues to provide innovative solu- tions to the high performance needs of its customers. it has pioneered many breakthroughs which have advanced the state-of-the-art in this demanding discipline, including: ? the first to qualify to the new high-reliability filter spec, mil-f-28861. ? facility qualified to mil-std-790 during first round of audits for filter manufacturers. ? the first solder-in filter line to offer 400c installation tem- perature. ? the first filter line designed to meet the new mil-spec requirements for hear rise/reactive current in 125 vac and 230 vac 400 hz applications. ? the first to offer a filter line of hermetically sealed bolt style filters. ? the first manufacturer of medical implantable filters. military series dscc dwg.# dscc capacitance specification # description range 84083 hermetic emi filter jd series 84084 hermetic emi filter jd series 84080 solder-in emi filter ws series 84081 solder-in emi filter xs series 84082 solder-in emi filter ys series 88010 solder-in emi filter zs series 86131 bolt emi filter sa series 88051 bolt emi filter sa series 55562 smt transient suppressor transguards
100 military emi/rfi filters custom and semi-custom in addition to standard catalog and qpl emi filters, avx filters produces two classes of these special products: semi-custom and custom. semi-custom involves variations in electrical parameters, testing, and limited mechanical changes from standard product designs. delivery is slightly longer and price is slightly higher than standard products. custom products require longer lead time for design and manufacturing, but give designers freedom to specify non- standard mechanical and electrical filter designs. avx filters dedicates a unique internal part number to every semi-custom and custom component. this insures contin- ued configuration control for each part, allows future changes to be easily implemented, and provides assurance that the design always matches the customer requirements. engineer to engineer our application engineering staff will assist in defining your filter requirements, while recommending advantages, reliabil- ity, quality assurance levels, and filter performance at the lowest practical cost. they will help in filter selection and specification, including meeting desc requirements. scd models are available to assist you in the design process. a custom filter part number will be assigned exclusively to your scd. to obtain prompt professional assistance, call (818) 767-6770. quality assurance quality assurance is built into every stage of manufacturing and testing. avx filters controls the entire process, from the capacitors dielectric formulation through final filter test. this results in absolute traceability by lot number to a specific dielectric batch, as well as the subsequent materials, equip- ment and employees involved in the tightly-controlled manu- facturing and testing process. in addition, critical processes are monitored using sqc, spc techniques. high-reliability filter design guide to produce a high-rel filter, the manufacturing processes, the procedures, and the materials used must be kept under tight control. by monitoring and tagging these on a lot and order basis, any product failures or performance abnormali- ties can be traced. at avx filters, such information is kept on file for later traceability and analysis. baseline C a baseline is a system of documentation that is used to guarantee manufacturing consistency, control change, and establish reporting structure. it sets up the mechanisms to define manufacturing, materials and compo- nents selection and qualification, as well as inspections and tests. it can also define mechanisms for direct comparisons to test the difference between lots and orders. an example of a baseline is the mil-prf-28861 baseline that is defined for the space level components. with this baseline in place, all the mechanisms are defined to support class s filter production and quality assurance. avx filters is qualified as a class s facility. changes to the baseline are monitored and approved by desc, nasa and aerospace corporation. custom baselines can also be developed to fulfill specific customer requirements. mil-std-790 C this standard sets up a full reliability assur- ance program plan with full traceability to raw materials, manufacturing processes, assembly, and tests. at avx filters there is full traceability down to the raw materials such as plating elements, base metals, ceramic materials, and inks, in accordance with mil-std-790. other programs in this standard include failure analysis, documentation control and operator training requirements. mil-prf-28861 relies on this standard to define the reliability assurance program for the class s filters. qpl C emi filters which fully meet mil standards are placed on a qualified products list (qpl) by a specifying agency such as desc. the mil-qualified filters can then be ordered directly by qpl part number. this is indicated by the mil-prf-28861 and mil-prf-15733 qpl sections of the catalog. reliability quality assurance a key factor in insuring quality components, and high relia- bility performance, is the implementation of appropriate tests and inspections during the manufacturing process. there are a number of defined standards that specify the design parameters, tests and test setups, materials used, and the quality assurance provisions required. vendor parts that are qualified to the standards are put on qpl lists for that standard. design and component engineers can order these standard qpl filters with their attendant specifications. other parame- ters can be added to meet specific needs or define a full quality assurance program. mil-prf-15733 C this is an older standard developed for specifying emi/rfi filters. it defines specific electrical and mechanical requirements, as well as stress tests and inspections. mil-prf-15733 does not require full 100% testing of each component, but relies upon sample testing for each lot. it also defines quality assurance inspections, and specifies a quality assurance reporting mechanism with yearly reports required on overall quality assurance performance. it makes use of standards such as mil-std-202 to define test methods. mil-prf-28861 C this is a modern standard, defining stringent classes of quality. the higher level. class s, is for critical space type applications where failure may have cata- strophic results. detailed group a screening and group b environmental and qualification tests are fully described.
101 mil-prf-28861 is approved for use by all departments and agencies of the department of defense. like the earlier 15733, it defines filters for emi applications. however, it goes into detailed requirements for a number of attributes such as baseline control, capacitor dielectrics, filter inductors, case and lead finishes, potting/impregnants, x-ray, dpa, slam and soldering methods. quality conformance inspection (qci), or group a testing, is performed on 100% of the filters for each production lot with limits on the number of failures allowed. for class s filters, baseline documentation is required to track the major process steps and inspection points in manufacturing and quality assurance. this baseline also locks in the design through configuration control. changes to the product design, or the process steps for defined areas, can only be done with formal government approval. class s devices are qualified on a lot-by-lot basis, with group a and b screening and testing documented on each manufacturing lot. all avx filters internal design standards reflect these three standards of performance and reliability. for detailed informa- tion on these standards, see filter design guide, m28861 screening and r-level screening sections of catalog. group a, b tests C these tests or inspections are typically defined by mil-prf-15733. the group a screening test sequence will include thermal shock, voltage conditioning, and the measurement of basic electrical parameters for the filter. it also defines visual and radiographic inspections. all filters in a lot are 100% tested, when group a per mil- prf-28861 is performed. sample inspection of a filter lot is performed when group a per mil-prf-15733 is specified. group a per mil-prf-28861 stipulates that up to 10% of tested class b filters can be defective, and are simply removed from the lot. failure rates in excess of 10% will cause the entire lot to be rejected. class s filters are only allowed pda rates ranging from 2 to 3% on individual tests. if the combined total failures exceed 10%, then the lot must be scrapped. group b screening defines environmental tests on samples from the production lots. some of these tests are destruc- tive, including destructive physical analysis (dpa). these tests permit a percentage of failure for each sampling of class b filters. no failures are permitted for class s filters. dpa C destructive physical analysis to rs-469 is a quality assurance technique that involves taking lot samples and cross-sectioning them for internal inspection. a filter is sectioned and then polished for microscopic examination. this is used to detect specific filter defects, such as flawed interconnects, capacitor voids, improper margins, dielectric separation (delamination), and improper dielectric grain growth. for detailed information see dpa criteria section. military emi/rfi filters
102 military emi/rfi filters filter design guide high reliability/military qualified products mil-prf-28861 screening class s, class b the group a sequence as outlined in mil-prf-28861 is performed on a 100% basis whenever reliability codes for class s or class b are specified by the customer. differences between class s and class b screening are shown in the descriptions. mil-std-202 test (method) description thermal shock 107, cond. a s-class: 5 cycles from -55c to +125c. through hole mounting required. b-class: as above except mounting not required. burn-in 108 s-class: 168 hours minimum at 2.0x rated voltage, 125c polarity reversal for the first 24-72 hours; fused b/i circuit for each filter. b-class 164 4 hours at 2.0x rated voltage. dielectric 301 s-class, b-class: 2.5x rated dc voltage for 5 seconds minimum, withstanding voltage 1 minute maximum, 50 ma charging current. insulation 302, cond. a s-class: test at 100 vdc or rated, v, whichever is less. pass/fail limits are resistance lot also based upon 125c readings from first 50 pieces. capacitance and 305 b-class: same as above, except omit pass/fail as per 50 piece calculation. dissipation factor s-class, b-class: test at 1000 100 hz, 0.1 to 1.2 vrms. insertion loss s-class, b-class: per mil-std-220 at load, no-load as specified. dc resistance 303 s-class, b-class: test is optional if dc voltage drop test performed. voltage drop s-class, b-class: m28861 para 4.6.6.1 (ac rated), para 4.6.6.2 (dc rated) radiographic inspection 209 s-class, b-class: 2 views required with 10x examination of images. seal test 112 s-class: condition c b-class: condition a or d visual and mechanical s-class: m28861 para. 4.6.1.2 which includes element, subassembly, and pre-cap inspections. b-class: m28861 para. 4.6.1.1 for external visual only. solderability 208 s-class, b-class: 5 samples. s-class, b-class testing analysis mil-prf-15733 vs. mil-prf-28861 mil-prf-15733 mil-prf-28861 characteristics filter/design/ filter/design/construction construction class b class s case standard standard standard capacitor (discoidal) standard special design special design ? dielectrics x7r, z5u br bx ? k 2200-10k 2k max 2k max ? vtl n/a +15%, -40% +15%, -25% (when design permits) ? cap range max cap/case size limited cap/case size limited cap/case size & conversion design mil-prf-123 reqts conversion design testing testing group a mil-std-105, 100% test 100% test ? test 1.0% aql ? pda none 10% thermal shock, burn-in*, (parts defective ir & dwvC2% each test cap, allowed) volt. drop, insertion loss -3% max combined total 10% max x-ray none mil-std-202 method 209 mil-std-202 method 209 leak test condition a gross leak condition a gross leak condition a gross leak condition c fine leak pda 10% max pda 10% max burn-in none generally. a few slash 160 hrs. @ 2 x rated voltage C 168 hrs. (250 hrs. max) @ 2 x rated voltage sheets require 1.4 x rated voltage resistor protected C fuse protected *pda .2% max last 50 hrs. insertion loss 1.0% aql 100% 100% solderability none mil-std-202 method 208 mil-std-202 method 208 5 samples 5 samples military qualified products there have been many questions raised regarding the differ- ences between mil-prf-15733 and mil-prf-28861. to clarify these differences we have incorporated the following analysis chart which compares the differences between these two military specifications.
103 mil-prf-28861 mil-spec number /02 slash sheet - 001 dash number g finish* g = gold t = tin/tin lead b class military emi/rfi filters mil-prf-28861/01, /04, /05, /12 .200 .010 .410 max .120 min .140 min .410 dia. max b a .115 2 places .070 .010 dia. 2 places .250-2b unf-2a +.010 -.015 .200 .010 l .145 .045 .145 .045 .410 dia. max a .070 .010 dia. 2 places .250-2b unf-2a .115 2 places +.010 -.015 dash cir- rated min. number cuit voltage capaci- dc ac 1/ tance volts volts (f) 010, 020 c 200 125 0.15 021, 031 l2 200 125 0.01 022, 032 c 200 125 0.01 023, 033 l2 200 125 0.0027 024, 034 c 200 125 0.0027 025, 035 l2 200 125 0.001 026, 036 c 200 125 0.001 mil-prf-28861/01 how to order dash cir- max. min. max. max. number cuit current capaci- voltage dc (amps) tance drop resist- (f) (volts) ance (ohms) 010, 028 l1 1.0 0.70 0.14 0.14 011, 029 l2 1.0 0.70 0.14 0.14 012, 030 1.0 1.4 0.14 0.14 013, 031 l1 3.0 0.70 0.15 0.05 014, 032 l2 3.0 0.70 0.15 0.05 015, 033 3.0 1.4 0.15 0.05 016, 034 l1 5.0 0.70 0.075 0.015 017, 035 l2 5.0 0.70 0.075 0.015 018, 036 5.0 1.4 0.075 0.015 mil-prf-28861/04 dash cir- rated min. number cuit voltage capaci- dc ac 1/ tance volts volts (f) 001, 011 l2 50 - - - 1.2 002, 012 c 50 - - - 1.2 003, 013 l2 70 - - - 0.7 004, 014 c 70 - - - 0.7 005, 015 l2 100 - - - 0.45 006, 016 c 100 - - - 0.45 009, 019 l2 200 125 0.15 dash cir- max. min. max. max. number cuit current capaci- voltage dc (amps) tance drop resist- (f) (volts) ance (ohms) 001, 019 l1 0.10 0.70 0.17 1.7 002, 020 l2 0.10 0.70 0.17 1.7 003, 021 0.10 1.4 0.17 1.7 004, 022 l1 0.30 0.70 0.23 0.77 005, 023 l2 0.30 0.70 0.23 0.77 006, 024 0.30 1.4 0.23 0.77 007, 025 l1 0.50 0.70 0.18 0.36 008, 026 l2 0.50 0.70 0.18 0.36 009, 027 0.50 1.4 0.18 0.36
104 military emi/rfi filters mil-prf-28861/01, /04, /05, /12 .200 .010 .793 max .145 .045 .145 .045 .410 dia. max a .070 .010 dia. 2 places .250-2b unf-2a .115 2 places +.010 -.015 (see mil-prf-22861 for insertion loss and other specification details.) mil-prf-28861/05 dash cir- max. capaci- max. max. number cuit current tance voltage dc (amps) (f) drop resist- +100% (volts) ance -0% (ohms) 001, 013 l1 0.25 0.15 0.375 1.5 002, 014 l2 0.25 0.15 0.375 1.5 003, 015 0.25 0.30 0.375 1.5 004, 016 l1 1.0 0.15 0.250 0.25 005, 017 l2 1.0 0.15 0.250 0.25 006, 018 1.0 0.30 0.250 0.25 dash cir- max. capaci- max. max. number cuit current tance voltage dc (amps) (f) drop resist- +100% (volts) ance -0% (ohms) 007, 019 l1 3.0 0.15 0.150 0.05 008, 020 l2 3.0 0.15 0.150 0.05 009, 021 3.0 0.30 0.150 0.05 010, 022 l1 5.0 0.15 0.075 0.015 011, 023 l2 5.0 0.15 0.075 0.015 012, 024 5.0 0.30 0.075 0.015 .020 glass seal .128 .156 .25 .03 2 pls .030 .002 a b ref c onf i gu ra t i on a .020 glass seal .128 .156 .25 .03 2 pls .030 .002 a b ref c onf i gu ra t i on b mil-prf-28861/12 dash circuit rated minimum number voltage capacitance dc (pf) 001, 017 l 50 15000 003, 019 l 100 2700 005, 021 l 100 5000 007, 023 l 200 10 009, 025 l 200 25 011, 027 l 200 100 013, 029 l 200 500 015, 031 l 200 1000 033, 035 l 50 10000 dash circuit rated minimum number voltage capacitance dc (pf) 002, 018 c 50 15000 004, 020 c 100 2700 006, 022 c 100 5000 008, 024 c 200 10 010, 026 c 200 25 012, 028 c 200 100 014, 030 c 200 500 016, 032 c 200 1000 034, 036 c 50 10000 * only available in gold finish
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