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About On Systems.
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On Systems are leading designers and
manufacturers of COTS power supplies and
complete power conversion equipment for
harsh military environments including Land,
Sea and Air applications.
Focussed entirely on power
conversion, our highly experienced
team can work with you to ensure
that your power conversion
requirement is delivered on time
and on budget, by utilising a
combination of standard COTS
modules and semi custom design
capabilities.
Our
comprehensive
range of standard, high
quality AC-DC and DCDC converters, ranging
from PCB mounted units
of a few watts to large
system units of several
kW, significantly shorten
the development time,
ensuring that the most
cost effective, reliable,
low risk, compliant power
converters are selected
from the outset of a
program.
On Systems Military Power Reliable Power. Reliable Source.
Fully compliant product
Our thorough knowledge of the harsh environments required for Military
COTS power supplies drives our development teams to deliver standard
products that meet the rigours of:
DEF-STAN 61-5 Issue 6, DO-160,
MIL-STD 1275 and MIL-STD 704
surges and transients that protect
your equipment from electrical
damage.
Standard EMC filters and modules
ensure compliance to DEF-STD
59-411 Land Class A, MIL-STD
461 and TEMPEST, our team
can work with you to select the
optimum filter using our in house
pre-compliance EMC test facility.
DEF-STAN 0035, DO 160
and MIL-STD 810 Harsh
environmental
specifications
are met with standard product
and are supported for use in
your product with our detailed
application notes.
SURGES AND TRANSIENTS
EMC AND IMMUNITY
ENVIRONMENTAL
DEF-STAN 61-5 Issue 6
MIL-STD 1275
MIL-STD 704
DEF-STAN 59-411 Land Class A
MIL-STD 461
TEMPEST
DEF-STD 0035
MIL-STD 810
Our in house development team
uses a comprehensive range
of software products to model
your requirement. This up front
design capability ensures that
the optimum design is chosen
very early on in a program to
significantly reduce the design
effort of using standard modules
or providing a complete power
convertor product.
All of our standard Military COTS
products are available as 3D solid
models to reduce your design in
effort backed by industry leading
technical support.
Semi-custom design capability
Although many applications can
be satisfied using our range of
standard building block modules,
increasingly scarce in house
resource can be freed up by
outsourcing the entire power
supply system.
We offer a highly controlled,
project managed design resource
that can work with you from initial
design concept to final delivery of
a fully compliant power supply or
power system. All of our semicustom designs follow our strict
QMS procedures and are supplied
with thorough Design Verification
Testing (DVT) and type test.
Gated design process
Initial
Concept
Specification
& Proposal
Product
Design &
3D Models
DVT &
Prototype
Product
Approval
Released to
Production
High quality products
Designed and manufactured in the UK to our strict Quality Management
processes of BS EN 9100, ISO14001, IPC-A-610 and J-STD-001 our military
COTS power supplies offer a fully traceable bill of materials with high levels
of workmanship ensuring long service life.
On Systems Military Power Reliable Power. Reliable Source.
Comprehensive design capabilities
and engineering expertise
On Systems Military Power Reliable Power. Reliable Source.
Thorough in house
test capability
Design with
confidence
All of our units are subjected to
thorough testing using our in
house test capabilities providing
full parametric operational test
results. This thorough testing
virtually
eliminates
infant
mortality whilst still maintaining
a cost effective product is
repeatedly delivered.
All of our Military COTS power
supplies are free from ITAR
restrictions and can therefore be
used with confidence in any UK
military program without the
fear of any future restriction of
supply.
Urgent Operational
Requirement (UOR)
support
Our UK based design team can
react quickly to support your
UOR requirements by offering a
fast track, immediate response to
your power supply needs. Fast
delivery of standard or modified
stock products, matched by
a dynamic procurement and
supply chain management team
dramatically shortens design-in
and production supply times.
Leading edge R&D and business focus
We consistently invest in R&D to ensure that we provide industry leading
products that offer high efficiency, high power density off the shelf products
that maintain our ethos of COTS power supplies.
Working closely with customers, suppliers and industry champions we
continuously improve the key attributes required to grow our portfolio
of products and our business with strategically important customers and
contracts in the military market.
There are two commonly used specifications in the military market; UK MOD DEF-STANs and USA MIL-STDs.
This guide serves to demonstrate some of the key factors that need to be considered when choosing
a power supply for electronic equipment.
Surges and Transients
Most military vehicles are 24V DC systems, commonly referred to as 28V systems. Connected electrical equipment has to meet MIL-STD-1275
and DEF-STAN 61-5 part 6, Avionic equipment has to meet MIL-STD-704.
The figures below show the surges and transients associated with MIL-STD-1275.
Mil 1275 –D surges and Transients for Normal Mode and Generator Mode
Envelope of Surges in Normal Operating Mode for 28 VDC Systems
Envelope of Spikes in Normal Operating Mode for 28 VDC Systems
45
300
40V, 50mS
250V, 70µs
40
250
32V, 500mS
35
200
40V, 1mS
32V
30V
30
150
25
25V
20
50
15
23V, 600mS
18V, 500mS
10
25V TO 30V
0
-50
5
0
STEADY STATE VOLTAGE
100
23V
18V
VOLTS
VOLTS
STEADY STATE VOLTAGE LIMITS
-100
0
100
200
300
400
500
600
700
800
900
-150
1000
-40V, 1mS
-200
RECOVERY TIME (mS)
-250
-250V, 70µs
-300
0
100
200
300
400
500
600
700
800
900
1000
RECOVERY TIME (mS)
Envelope of Surges in Generator-only Mode for 28 VDC Systems
Envelope of Spikes in Generator-only Mode for 28 VDC Systems
110
300
100V, 50mS
250V, 70µs
100
250
90
200
80
150
100V, 1mS
STEADY STATE VOLTAGE
100
40V, 500mS
60
50
VOLTS
VOLTS
70
50
40
-50
40V
33V
30
-100
STEADY STATE VOLTAGE LIMITS
23V
20
23V TO 33V
0
16V
-150
15V
10
-200
15V, 500mS
0
0
100
200
300
400
16V, 600mS
500
600
700
-100V, 1mS
800
900
1000
-250
-250V, 70µs
-300
RECOVERY TIME (mS)
0
100
200
300
400
500
600
700
800
RECOVERY TIME (mS)
DEF-STAN 61-5 part 6 issue 6
This standard covers both 12V and 24V vehicle systems. It differentiates between the voltages seen in the vehicle original fit equipment,
(Platform) and those seen by any externally connected equipment (Terminal).
On Systems power supplies are designed to meet the harsher Platform equipment levels as standard.
NOMINAL 12V
NOMINAL 24V
TERMINAL
EQUIPMENT
PLATFORM
EQUIPMENT
TERMINAL
EQUIPMENT
PLATFORM
EQUIPMENT
LOWER VOLTAGE
9V
9V
18V
18V
UPPER VOLTAGE
16V
19V
32V
38V
PLATFORM AND TERMINAL EQUIPMENT OPERATING VOLTAGES
900
1000
On Systems Military Power Reliable Power. Reliable Source.
Useful Reference Guide to Military Specifications
The figures below show the harsher surges and long transients for terminal equipment in 12V and 24V vehicles.
DETA03.A – 12V LIMITS
DETA03.A – 24V LIMITS
25
50
20V, 0.05s
40V, 0.05s
20
40
15V, 1.0s
PEAK VOLTAGE (VOLTS)
16V, 0.1s
PEAK VOLTAGE (VOLTS)
On Systems Military Power Reliable Power. Reliable Source.
Surges
15
STEADY STATE >1s
11.5V, 0.5s
10
12.5V, 1.0s
5
0
30V, 1.0s
32V, 0.1s
30
STEADY STATE >1s
25V, 0.5s
20
25V, 1.0s
10
0.001
0.01
1.0
0.1
∞
0
0.001
0.01
∞
1.0
0.1
RECOVERY TIME (SECONDS)
RECOVERY TIME (SECONDS)
Short Transients
V
t2
t3
Vs
0
VA
t1
NEGATIVE PULSE TRANSIENTS
These transients simulate the spike present from relay switch arcing and other electro mechanical switch bounce. The unit must withstand
both positive and negative short transients, positive transients are identical in shape to those shown above.
SYSTEM VOLTAGE
12V
24V
Pulse amplitude
-150V
-200V
Positive pulse
100V
200V
Durations:
t1 = 100μS
t2=10mS
t3=90mS
Impedance = 50Ω
Load Dump
A very harsh surge is the load dump. This is present in vehicle systems that have a loose battery connection.
250
200
150
100
50
0
0
50
100
150
200
250
300
350
Parameter
12V 61-5 System
24V 61-5 System
24V 1275 System
Vpk
111V
202V
100V
Rise time
10ms
10mS
0mS
Period
0mS
0mS
50mS
Decay time
400ms
350mS
10mS
Energy
4j/Amp
30J/Amp
3J/Amp
Source impedance
0.5 Ohms
1 Ohm
0.5 Ohms
400
TIME (ms)
This is classed as an extreme condition and equipment is allowed to turn off during the surge. On Systems have products that can operate
through this surge without turning off. This is particularly useful in systems that have a long re-boot time.
Envelope of Normal AC Voltage Transients
Envelope of Normal Voltage Transients for 28 Volts DC Systems
60
200
180V, 0.010s
50V, 0.0125s
50
160
40
VOLTS, DC
180
VOLTS, DC
140
29V, 0.0825s
30
118V, 0.0875s
120
20
118V
113V
22V, 0.1000s
18V, 0.0150s
108V
10
100
108V, 0.080s
0.000
0.025
0.050
0.075
0.100
0.025
0.125
0.150
TIME FROM ONSET OF TRANSIENT (SECONDS)
80
80V, 0.010s
60
40
0.000
0.025
0.050
0.075
0.100
0.025
0.125
0.150
0.175
TIME FROM ONSET OF TRANSIENT (SECONDS)
Envelope of Normal AC Voltage Transients for 270 Volts DC Systems
340
320
330V, 0.020s
300
280V, 0.040s
280V
VOLTS, DC
280
260
250V
240
250V, 0.040s
220
200V, 0.010s
200
180
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.1
TIME FROM ONSET OF TRANSIENT (SECONDS)
MIL-STD-704, 28V DC equipment which is required to operate in emergency conditions, must do so with an extended DC steady state range
between 16 and 29 volts. This does not apply to 270V DC equipment.
DO 160 classifies equipment into four categories, A B Z and D, the result is a more complex document that cannot be captured in this
reference guide. The electrical specification is similar to MIL-STD-704, and common requirements include 50mS holdup for category B
equipment and 200mS for category Z. This large holdup time can challenge the design of the power supply, On Systems have products
that conform to both requirements in a compact footprint.
0.175
On Systems Military Power Reliable Power. Reliable Source.
MIL STD 704F & DO 160F – Avionic systems
The USA standard MIL-STD-461 and UK standard DEF-STAN-59-411 (replaced DEF-STAN-59-41) are used to limit the amount of electrical
noise introduced onto the electrical system, and ensure that electrically coupled noise on the system doesn’t affect the equipment.
EMC emissions are the most difficult to achieve compliance to and the levels are shown in the figures below.
110
100
LIMIT LEVEL (dBµV)
90
NOMINAL EUT SOURCE
VOLTAGE (AC & DC)
LIMIT RELAXATION
28V
BASIC CURVE
115V
6dB
220V
9dB
270V
10dB
=/> 440V
12dB
80
70
BASIC CURVE
60
50
40
10k
100k
1M
10M
100M
FREQUENCY (Hz)
MIL-STD-461F – Limits for all systems including the relaxation levels for different input voltages.
140
500Hz, 130dB
4kHz, 130dB
120
CONDUCTED EMISSION CURRENT dBµA
On Systems Military Power Reliable Power. Reliable Source.
EMC and Susceptibility
100
80
60
300kHz, 40dB
40
600kHz,25dB
150MHz, 40dB
Class D
150MHz,25dB
Class C
20
1.2MHz, 10dB
0
10Hz
2MHz, 0dB
100Hz
1kHz
10kHz
100kHz
1MHz
150MHz, 10dB
Class B
150MHz, 0dB
Class A
10MHz
100MHz
1GHz
FREQUENCY
DEF-STAN-59-411 – Limits for Land Service Use for different classes of equipment.
Environmental Specifications
USA Specification MIL-STD-810 land air and sea and UK Specification DEF-STAN-0035, define the limits and severity levels that the equipment
will be subjected to. The levels of shock, vibration, temperature, water ingress, atmospheric pollution and humidity vary considerably
depending on where the equipment is installed.
It is vital that these environmental requirements are considered when designing in a power supply to ensure a long equipment lifetime.
Thermal management along with mechanical integration have the largest impact on reliability, On Systems engineers have considerable
knowledge of selecting and designing in a power supply to ensure that you use a reliable, cost effective product in your equipment.
This useful reference guide is intended to demonstrate the requirements of Military power supplies, it is not intended for use as a design document and On Systems recommends that
original copies of the specifications must be used for equipment design. On Systems cannot accept responsibility if this document is used outside it’s intended purpose.
{
On Systems Limited
Telephone 0844 809 4608
[email protected]
www.on-systems.co.uk