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)
Military Series DSCC DWG.#
DSCC
Specification #
84083
84084
84080
84081
84082
88010
86131
88051
55562
Description
Hermetic EMI Filter
Hermetic EMI Filter
Solder-in EMI Filter
Solder-in EMI Filter
Solder-in EMI Filter
Solder-in EMI Filter
Bolt EMI Filter
Bolt EMI Filter
SMT Transient Suppressor
Capacitance
Range
JD Series
JD Series
WS Series
XS Series
YS Series
ZS Series
SA Series
SA Series
TransGuards
MIL-PRF-15733 QPL LIST
MIL-PRF-15733/23
Style
-0001 thru -0006, -0013 thru
-0025 thru -0030, -0037 thru
-0049 thru -0054
MIL-PRF-15733/24
Style
-0005 thru -0008
MIL-PRF-15733/26
Style
-0001 thru -0007, -0009 thru
-0013 thru -0019, -0021 thru
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
-0018
-0042
-0011
-0023
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
3
• Pacemakers
Communications (C )
• Missile Systems
• Medication Monitors
• Weapon Systems
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 400°C 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.
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,
99
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.
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 –
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 –
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.
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.
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
– 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
– 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.
QUALITY ASSURANCE
Quality assurance is built into every stage of manufacturing
and testing. AVX Filters controls the entire process, from the
capacitor’s 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 –
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.
100
Military EMI/RFI Filters
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 –
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 –
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.
101
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.
S-CLASS, B-CLASS TESTING
Test
Thermal Shock
Burn-in
MIL-STD-202
(method)
107, cond. A
108
Description
S-class: 5 cycles from -55°C to +125°C. Through hole mounting required.
B-class: as above except mounting not required.
S-class: 168 hours minimum at 2.0X rated voltage, 125°C 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.
S-class, B-class: 2.5X rated DC voltage for 5 seconds minimum,
1 minute maximum, 50 mA charging current.
S-class: test at 100 VDC or rated, V, whichever is less. Pass/fail limits are
lot also based upon 125°C readings from first 50 pieces.
B-class: same as above, except omit pass/fail as per 50 piece calculation.
S-class, B-class: test at 1000 ± 100 Hz, 0.1 to 1.2 VRMS.
S-class, B-class: per MIL-STD-220 at load, no-load as specified.
S-class, B-class: test is optional if DC Voltage Drop Test performed.
S-class, B-class: M28861 para 4.6.6.1 (AC rated), para 4.6.6.2 (DC rated)
S-class, B-class: 2 views required with 10X examination of images.
S-class: condition C
B-class: condition A or D
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.
S-class, B-class: 5 samples.
Dielectric
Withstanding Voltage
Insulation
Resistance
Capacitance and
Dissipation Factor
Insertion Loss
DC Resistance
Voltage Drop
Radiographic Inspection
Seal Test
Visual and Mechanical
301
302, cond. A
305
—
303
—
209
112
—
Solderability
208
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.
ANALYSIS MIL-PRF-15733 vs. MIL-PRF-28861
MIL-PRF-15733
Characteristics
Case
Capacitor (Discoidal)
• Dielectrics
•K
• VTL
• Cap Range
MIL-PRF-28861
Filter/Design/
Construction
Standard
Standard
X7R, Z5U
2200-10K
N/A
Max Cap/Case Size
Testing
MIL-STD-105,
1.0% AQL
None
Filter/Design/Construction
Class B
Class S
Standard
Standard
Special Design
Special Design
BR
BX
2K max
2K max
+15%, -40%
+15%, -25% (when design permits)
Limited Cap/Case Size
Limited Cap/Case Size &
Conversion Design
MIL-PRF-123 Req’ts Conversion Design
Testing
100% Test
100% Test
Thermal Shock, Burn-in*,
IR & DWV–2% each test Cap,
Volt. Drop, Insertion
Loss -3% max combined
Total 10% max
MIL-STD-202 Method 209
MIL-STD-202 Method 209
Condition “A” Gross Leak
Condition “A” Gross Leak
Condition “C” Fine Leak
PDA 10% max
PDA 10% max
160 Hrs. @ 2 x rated voltage – 168 Hrs. (250 Hrs. max) @ 2 x rated voltage
Resistor protected
– Fuse protected
*PDA .2% max last 50 hrs.
100%
100%
MIL-STD-202 Method 208
MIL-STD-202 Method 208
5 Samples
5 Samples
10%
Group A
• Test
• PDA
(parts defective
allowed)
X-Ray
Leak Test
Burn-In
Insertion Loss
Solderability
None
Condition “A” Gross Leak
None generally. A few slash
sheets require 1.4 x rated voltage
1.0% AQL
None
102
Military EMI/RFI Filters
MIL-PRF-28861/01, /04, /05, /12
HOW TO ORDER
MIL-PRF-28861
/02
- 001
G
B
Mil-Spec Number
Slash Sheet
Dash Number
Finish*
G = Gold
T = Tin/Tin Lead
Class
MIL-PRF-28861/01
B
.200
±.010
A
.140
MIN
.410
MAX
.120
MIN
Dash
number
Cir-
cuit
Rated
voltage
DC
AC 1/
volts volts
50
50
70
70
100
100
200
---
---
---
---
---
---
125
Min.
capaci-
tance
(µF)
1.2
1.2
0.7
0.7
0.45
0.45
0.15
Dash
number
Cir-
cuit
Rated
voltage
DC
AC 1/
volts volts
200
200
200
200
200
200
200
125
125
125
125
125
125
125
Min.
capaci-
tance
(µF)
0.15
0.01
0.01
0.0027
0.0027
0.001
0.001
001, 011
002, 012
003, 013
+.010
.115
-.015
L2
C
L2
C
L2
C
L2
010, 020
021, 031
022, 032
023, 033
024, 034
025, 035
026, 036
C
L2
C
L2
C
L2
C
004, 014
005, 015
006, 016
009, 019
2 PLACES
.410
DIA. MAX
.070±.010 DIA.
2 PLACES
.250-2B UNF-2A
MIL-PRF-28861/04
L
.200
±.010
.145
±.045
+.010
A
.145
±.045
Dash Cir- Max.
Min.
Max. Max.
number cuit current capaci- voltage DC
(amps) tance
drop resist-
(µF) (volts) ance
(ohms)
001, 019
002, 020
003, 021
004, 022
005, 023
006, 024
007, 025
008, 026
009, 027
L1
L2
π
L1
L2
π
L1
L2
π
0.10
0.10
0.10
0.30
0.30
0.30
0.50
0.50
0.50
0.70
0.70
1.4
0.70
0.70
1.4
0.70
0.70
1.4
0.17
0.17
0.17
0.23
0.23
0.23
0.18
0.18
0.18
1.7
1.7
1.7
0.77
0.77
0.77
0.36
0.36
0.36
Dash Cir- Max.
Min.
Max. Max.
number cuit current capaci- voltage DC
(amps) tance
drop resist-
(µF) (volts) ance
(ohms)
010, 028
011, 029
012, 030
013, 031
014, 032
015, 033
016, 034
017, 035
018, 036
L1
L2
π
L1
L2
π
L1
L2
π
1.0
1.0
1.0
3.0
3.0
3.0
5.0
5.0
5.0
0.70
0.70
1.4
0.70
0.70
1.4
0.70
0.70
1.4
0.14
0.14
0.14
0.15
0.15
0.15
0.075
0.075
0.075
0.14
0.14
0.14
0.05
0.05
0.05
0.015
0.015
0.015
.115
-.015
2 PLACES
.410
DIA. MAX
.250-2B UNF-2A
.070±.010 DIA.
2 PLACES
103
Analog electronics
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