Data Sheet August 20, 2010 ESTW015A0F Series (Eighth-Brick) DC-DC Converter Power Modules 36–75Vdc Input; 3.3Vdc Output; 15A Output Current STINGRAY™ SERIES Features Compliant to RoHS EU Directive 2002/95/EC (-Z versions) Compliant to ROHS EU Directive 2002/95/EC with lead solder exemption (non-Z versions) Delivers up to 15A Output current High efficiency 91% at full load (Vin=48Vdc) Full load at TA=85 C for airflow of 1 m/s(200 LFM) or greater o Industry standard, DOSA compliant footprint 57.9mm x 22.8mm x 8.5mm (2.28 in x 0.9 in x 0.335 in) Wide input voltage range: 36-75 Vdc Applications Tightly regulated output Distributed power architectures Constant switching frequency Wireless networks Positive remote On/Off logic Access and optical network Equipment Input under voltage protection Enterprise Networks including Power over Ethernet (PoE) Output overcurrent and overvoltage protection Over-temperature protection Remote sense Output Voltage adjust: 80% to 110% of Vo,nom Wide operating temperature range (-40°C to 85°C) UL*Recognized to UL60950-1, CAN/CSA C22.2 ‡ No.60950-1, and EN60950-1(VDE 0805-1) Licensed RoHS Compliant Latest generation IC’s (DSP, FPGA, ASIC) and Microprocessor powered applications Options † Negative Remote On/Off logic (-1 option, preferred/standard) Surface Mount version (-S option) CE mark meets 2006/95/EC directive Auto-restart (-4 option, preferred/standard) Trimmed leads (-6 or -8 options) Meets the voltage and current requirements for ETSI 300-132-2 and complies with and licensed for Basic insulation rating per EN60950-1 2250 Vdc Isolation tested in compliance with IEEE ¤ 802.3 PoE standards ISO 9001 and ISO 14001 certified manufacturing facilities § ** Description The Lineage Power® Stingray™ Series, ESTW015A0F, Eighth-brick power modules are cost optimized isolated dc-dc converters that can deliver up to 15A of output current and provide a precisely regulated output voltage over a wide range of input voltages (Vin = 36 -75Vdc). The module achieves full load efficiency of 91% at 3.3Vdc output voltage. The open frame modules construction, available in both surface-mount and through-hole packaging, enable designers to develop cost- and space-efficient solutions. Standard features include remote On/Off, remote sense, output voltage adjustment, overvoltage, overcurrent and overtemperature protection. * UL is a registered trademark of Underwriters Laboratories, Inc. † CSA is a registered trademark of Canadian Standards Association. VDE is a trademark of Verband Deutscher Elektrotechniker e.V. § This product is intended for integration into end-user equipment . All of the required procedures of end-use equipment should be followed. ¤ IEEE and 802 are registered trademarks of the Institute of Electrical and Electronics Engineers, Incorporated. ** ISO is a registered trademark of the International Organization of Standards ‡ Document No: DS09-004 ver.1.01 PDF name: ESTW015A0F.pdf Data Sheet August 20, 2010 ESTW015A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 15A Output Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings can cause permanent damage to the device. These are absolute stress ratings only, functional operation of the device is not implied at these or any other conditions in excess of those given in the operations sections of the data sheet. Exposure to absolute maximum ratings for extended periods can adversely affect the device reliability. Parameter Device Symbol Min Max Unit Input Voltage Continuous All VIN -0.3 80 Vdc Transient, operational (≤100 ms) All VIN,trans -0.3 100 Vdc All TA -40 85 °C Storage Temperature All Tstg -55 125 °C I/O Isolation voltage (100% factory Hi-Pot tested) All 2250 Vdc Operating Ambient Temperature (see Thermal Considerations section) Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Parameter Operating Input Voltage Maximum Input Current (VIN= VIN, min to VIN, max, IO=IO, max) Input No Load Current (VIN = VIN, nom, IO = 0, module enabled) Input Stand-by Current Device Symbol Min Typ Max Unit All VIN 36 48 75 Vdc All IIN,max 2.0 Adc All IIN,No load 30 IIN,stand-by 6 All (VIN = VIN, nom, module disabled) I2t mA 8 mA 1 A2s Inrush Transient All Input Reflected Ripple Current, peak-to-peak (5Hz to 20MHz, 1μH source impedance; VIN, min to VIN, max, IO= IOmax ; See Test configuration section) All 30 mAp-p Input Ripple Rejection (120Hz) All 50 dB CAUTION: This power module is not internally fused. An input line fuse must always be used. This power module can be used in a wide variety of applications, ranging from simple standalone operation to an integrated part of sophisticated power architectures. To preserve maximum flexibility, internal fusing is not included, however, to achieve maximum safety and system protection, always use an input line fuse. The safety agencies require a time-delay fuse with a maximum rating of 5 A (see Safety Considerations section). Based on the information provided in this data sheet on inrush energy and maximum dc input current, the same type of fuse with a lower rating can be used. Refer to the fuse manufacturer’s data sheet for further information. LINEAGE POWER 2 Data Sheet August 20, 2010 ESTW015A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 15A Output Electrical Specifications (continued) Parameter Device Symbol Min Typ Max Unit All VO, set 3.25 3.3 3.35 Vdc All VO 3.2 3.4 Vdc ±0.2 ±0.1 10 % VO, set mV % VO, set Nominal Output Voltage Set-point VIN=VIN, nom, IO=IO, max, TA=25°C) Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life) Output Regulation Line (VIN=VIN, min to VIN, max) Load (IO=IO, min to IO, max) Temperature (Tref=TA, min to TA, max) Output Ripple and Noise on nominal output (VIN=VIN, nom ,IO= IO, max , TA=TA, min to TA, max) RMS (5Hz to 20MHz bandwidth) Peak-to-Peak (5Hz to 20MHz bandwidth) All All All All 8 20 mVrms All 40 75 mVpk-pk External Capacitance All CO, max 0 5,000 μF Output Current Output Current Limit Inception (Hiccup Mode ) (VO= 90% of VO, set) Output Short-Circuit Current (VO≤250mV) ( Hiccup Mode) Efficiency All Io 0 15.0 Adc All IO, lim 19 Adc All IO, s/c 60 2.5 Apk AAVG VIN= VIN, nom, TA=25°C, IO=IO, max , VO= VO,set All η 90.0 91.0 % VIN= VIN, nom, TA=25°C, IO=10A , VO= VO,set All η 90.0 91.0 % VIN= VIN, nom, TA=25°C, IO=4A , VO= VO,set All η 85.5 87.0 % All fsw 355 kHz All Vpk 210 mV All ts 200 µs Device Symbol Min Typ Max Unit Isolation Capacitance All Ciso 1000 pF Isolation Resistance All Riso 10 MΩ I/O Isolation Voltage (100% factory Hi-pot tested) All All 2250 Vdc Device Symbol Min Typ Max Switching Frequency Dynamic Load Response (dIo/dt=0.1A/µs; VIN = VIN, nom; TA=25°C) Load Change from Io= 50% to 75% or 25% to 50% of Io,max Peak Deviation Settling Time (Vo<10% peak deviation) Isolation Specifications Parameter General Specifications Parameter Unit 9 Calculated Reliability based upon Telcordia SR-332 Issue 2: Method I Case 3 (IO=80%IO, max, TA=40°C, airflow = 200 lfm, 90% confidence) All FIT 212.2 10 /Hours All MTBF 4,713,305 Hours Weight All LINEAGE POWER 15.2 (0.6) g (oz.) 3 Data Sheet August 20, 2010 ESTW015A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 15A Output Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions for additional information. Parameter Device Symbol Min Typ Max Unit Remote On/Off Signal Interface (VIN=VIN, min to VIN, max ; open collector or equivalent, Signal referenced to VIN- terminal) Negative Logic: device code suffix “1” Logic Low = module On, Logic High = module Off Positive Logic: No device code suffix required Logic Low = module Off, Logic High = module On Logic Low - Remote On/Off Current (Von/off = -0.7 Vdc) All Ion/off 0.15 mA Logic Low - On/Off Voltage All Von/off -0.7 0.6 Vdc Logic High Voltage (Ion/off = 0Adc) All Von/off 2.4 6.7 Vdc Logic High maximum leakage current All Ion/off 25 μA Case 1: Input power is applied for >1 second and then the On/Off input is set to ON (Tdelay = time from instant On/Off signal is ON until VO = 10% of VO, set) All Tdelay ― 12 ― msec Case 2: On/Off input is set to Logic Low (Module ON) and then input power is applied (Tdelay = time at which VIN = VIN, min until Vo=10% of VO,set) All Tdelay ― 20 ― msec Output voltage Rise time (time for Vo to rise from 10% of Vo,set to 90% of Vo, set) All Trise ― 4 ― msec ― 5 % VO, set Turn-On Delay1 and Rise Times (IO=IO, max , VIN=VIN, nom, TA = 25oC) Output voltage overshoot – Startup IO= IO, max; VIN=VIN, min to VIN, max, TA = 25 oC All Remote Sense Range All Output Voltage Adjustment Range All Output Overvoltage Protection (CO=220μF) All VO, limit 3.9 Overtemperature Protection – Hiccup Auto Restart All Tref Input Undervoltage Lockout All VUVLO VSENSE -20 10 % VO, set +10 % VO, set 5.0 Vdc 138 O C Turn-on Threshold 32 34.5 Vdc Turn-off Threshold 27.5 30 Vdc 1 2 Vdc Hysteresis 1. The module has an adaptable extended Turn-On Delay interval, Tdelay, of 25mS. The extended Tdelay will occur when the module restarts following either: 1) the rapid cycling of Vin from normal levels to less than the Input Undervoltage Lockout (which causes module shutdown), and then back to normal; or 2) toggling the on/off signal from on to off and back to on without removing the input voltage. The normal Turn-On Delay interval, Tdelay, will occur whenever a module restarts with input voltage removed from the module for the preceding 1 second. LINEAGE POWER 4 Data Sheet August 20, 2010 ESTW015A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 15A Output Characteristic Curves o VO (V) (200mV/div) Io(A) (5A/div) EFFICIENCY, η (%) OUTPUT CURRENT OUTPUT VOLTAGE The following figures provide typical characteristics for the ESTW015A0F (3.3V, 15A) at 25 C. The figures are identical for either positive or negative remote On/Off logic. OUTPUT CURRENT, IO (A) OUTPUT VOLTAGE VOn/Off (V) (1V/div) VO (V) (2V/div) Figure 4. Transient Response to 0.1A/µS Dynamic Load Change from 50% to 75% to 50% of full load. On/Off VOLTAGE VO (V) (20mV/div) OUTPUT VOLTAGE Figure 1. Converter Efficiency versus Output Current. TIME, t (200µs/div) TIME, t (10ms/div) TIME, t (2µs/div) TIME, t (200µs/div) Figure 3. Transient Response to 0.1A/µS Dynamic Load Change from 25% to 50% to 25% of full load. LINEAGE POWER OUTPUT VOLTAGE VIN (V) (1V/div) VO (V) (20V/div Figure 5. Typical Start-up Using Remote On/Off, negative logic version shown (VIN = VIN,NOM, Io = Io,max). INPUT VOLTAGE VO (V) (200mV/div) Io(A) (5A/div) OUTPUT CURRENT OUTPUT VOLTAGE Figure 2. Typical output ripple and noise (VIN = VIN,NOM, Io = Io,max). TIME, t (5ms/div) Figure 6. Typical Start-up Using Input Voltage (VIN = VIN,NOM, Io = Io,max). 5 Data Sheet August 20, 2010 ESTW015A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 15A Output Test Configurations Design Considerations Input Filtering CURRENT PROBE TO OSCILLOSCOPE LTEST Vin+ BATTERY 12μH CS 220μF 33μF E.S.R.<0.1Ω @ 20°C 100kHz Safety Considerations Vin- NOTE: Measure input reflected ripple current with a simulated source inductance (LTEST) of 12μH. Capacitor CS offsets possible battery impedance. Measure current as shown above. Figure 7. Input Reflected Ripple Current Test Setup. COPPER STRIP VO (+) RESISTIVE LOAD SCOPE V O (–) 0.01uF 0.1uF 10uF GROUND PLANE NOTE: All voltage measurements to be taken at the module terminals, as shown above. If sockets are used then Kelvin connections are required at the module terminals to avoid measurement errors due to socket contact resistance. Figure 8. Output Ripple and Noise Test Setup. Rdistribution Rcontact Rcontact Vin+ Rdistribution RLOAD VO Rcontact Rcontact Vin- Rdistribution Vout+ VIN Rdistribution Vout- NOTE: All voltage measurements to be taken at the module terminals, as shown above. If sockets are used then Kelvin connections are required at the module terminals to avoid measurement errors due to socket contact resistance. Figure 9. Output Voltage and Efficiency Test Setup. VO. IO Efficiency η = LINEAGE POWER VIN. IIN x 100 % The power module should be connected to a low ac-impedance source. Highly inductive source impedance can affect the stability of the power module. For the test configuration in Figure 7 a 33μF electrolytic capacitor (ESR<0.7Ω at 100kHz), mounted close to the power module helps ensure the stability of the unit. Consult the factory for further application guidelines. For safety-agency approval of the system in which the power module is used, the power module must be installed in compliance with the spacing and separation requirements of the end-use safety agency standard, i.e. UL60950-1, CSA C22.2 No.60950-1, and VDE0805-1(IEC60950-1). If the input source is non-SELV (ELV or a hazardous voltage greater than 60 Vdc and less than or equal to 75Vdc), for the module’s output to be considered as meeting the requirements for safety extra-low voltage (SELV), all of the following must be true: The input source is to be provided with reinforced insulation from any other hazardous voltages, including the ac mains. One VIN pin and one VOUT pin are to be grounded, or both the input and output pins are to be kept floating. The input pins of the module are not operator accessible. Another SELV reliability test is conducted on the whole system (combination of supply source and subject module), as required by the safety agencies, to verify that under a single fault, hazardous voltages do not appear at the module’s output. Note: Do not ground either of the input pins of the module without grounding one of the output pins. This may allow a non-SELV voltage to appear between the output pins and ground. The power module has extra-low voltage (ELV) outputs when all inputs are ELV. All flammable materials used in the manufacturing of these modules are rated 94V-0, or tested to the UL60950 A.2 for reduced thickness. For input voltages exceeding –60 Vdc but less than or equal to –75 Vdc, these converters have been evaluated to the applicable requirements of BASIC INSULATION between secondary DC MAINS DISTRIBUTION input (classified as TNV-2 in Europe) and unearthed SELV outputs. The input to these units is to be provided with a maximum 5 A time-delay fuse in the ungrounded lead. 6 Data Sheet August 20, 2010 ESTW015A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 15A Output Feature Description Remote On/Off Two remote on/off options are available. Positive logic turns the module on during a logic high voltage on the ON/OFF pin, and off during a logic low. Negative logic remote On/Off, device code suffix “1”, turns the module off during a logic high and on during a logic low. be increased, which at the same output current would increase the power output of the module. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power (Maximum rated power = Vo,set x Io,max). SENSE(+) SENSE(–) SUPPLY Vin+ Vout+ VI(+) VO(+) VI(-) VO(–) II CONTACT RESISTANCE IO LOAD CONTACT AND DISTRIBUTION LOSSES Ion/off ON/OFF TRIM Von/off Input Undervoltage Lockout Vin- Vout- Figure 10. Remote On/Off Implementation. To turn the power module on and off, the user must supply a switch (open collector or equivalent) to control the voltage (Von/off) between the ON/OFF terminal and the VIN(-) terminal (see Figure 10). Logic low is -0.7V ≤ Von/off ≤ 0.6V. The maximum Ion/off during a logic low is 0.15mA, the switch should maintain a logic low level while sinking this current. During a logic high, the typical maximum Von/off generated by the module is 6.7V, and the maximum allowable leakage current at Von/off = 2.4V is 25μA. If not using the remote on/off feature: For positive logic, leave the ON/OFF pin open. For negative logic, short the ON/OFF pin to VIN(-). Remote Sense Remote sense minimizes the effects of distribution losses by regulating the voltage at the remote-sense connections (See Figure 11). The voltage between the remote-sense pins and the output terminals must not exceed the output voltage sense range given in the Feature Specifications table: [VO(+) – VO(–)] – [SENSE(+) – SENSE(–)] ≤ 0.5 V Although the output voltage can be increased by both the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim. The amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. When using remote sense and trim, the output voltage of the module can LINEAGE POWER Figure 11. Circuit Configuration for remote sense . At input voltages below the input undervoltage lockout limit, the module operation is disabled. The module will only begin to operate once the input voltage is raised above the undervoltage lockout turn-on threshold, VUV/ON. Once operating, the module will continue to operate until the input voltage is taken below the undervoltage turn-off threshold, VUV/OFF. Overtemperature Protection To provide protection under overtemperature fault conditions, the unit is equipped with a thermal shutdown circuit. The unit will shutdown if the thermal o reference points Trefx (Figure 13), exceed 138 C (typical). However, the thermal shutdown is not intended as a guarantee that the unit will survive temperatures beyond its rating. The module restarts automatically after the unit cools down below the overtemperature protection thresholds. Output Overvoltage Protection The output over voltage protection scheme of the modules has an independent over voltage loop to prevent single point of failure. This protection feature latches in the event of over voltage across the output. Cycling the on/off pin or input voltage resets the latching protection feature. If the auto-restart option (4) is ordered, the module will automatically restart upon an internally programmed time elapsing. Overcurrent Protection To provide protection in a fault (output overload) condition, the unit is equipped with internal current limiting circuitry and can endure current limiting continuously. At the point of current limit inception, the unit enters hiccup mode. If the unit is not configured with auto–restart, then it will latch off following the over current condition. The module can be restarted by cycling the dc input power for at least one second or by toggling the remote on/off signal for at least one second. If the unit is configured with the 7 Data Sheet August 20, 2010 ESTW015A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 15A Output Feature Descriptions (continued) auto-restart option (4), it will remain in the hiccup mode as long as the overcurrent condition exists; it operates normally, once the output current is brought back into its specified range. The average output current during hiccup is 10% IO, max. Output Voltage Programming Trimming allows the output voltage set point to be increased or decreased, this is accomplished by connecting an external resistor between the TRIM pin and either the VO(+) pin or the VO(-) pin (Figure 12). 5.11 × Vo, set × (100 + ∆%) 511 Rtrim − up = − − 10.22 ΚΩ 1 . 225 % % × ∆ ∆ Where V − Vo , set ∆ % = desired V o , set × 100 For example, to trim-up the output voltage of the module by 5% to 3.465V, Rtrim-up is calculated is as follows: ∆% = 5 5.11 × 3.3 × (100 + 5) 511 Rtrim −up = − − 10.22 ΚΩ 1.225 × 5 5 Rtrim −up = 176.7ΚΩ VIN(+) VO(+) Rtrim-up ON/OFF LOAD VOTRIM Rtrim-down VO(-) VIN(-) Figure 12. Circuit Configuration to Trim Output Voltage. Connecting an external resistor (Rtrim-down) between the TRIM pin and the VO(-) (or Sense(-)) pin decreases the output voltage set point. To maintain set point accuracy, the trim resistor tolerance should be ±1.0%. The following equation determines the required external resistor value to obtain a percentage output voltage change of Δ% The voltage between the VO(+) and VO(–) terminals must not exceed the minimum output overvoltage protection value shown in the Feature Specifications table. This limit includes any increase in voltage due to remote-sense compensation and output voltage set-point adjustment trim. Although the output voltage can be increased by both the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim. The amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. When using remote sense and trim, the output voltage of the module can be increased. Therefore, for the same output current, this would increase the output power of the module. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power (Maximum rated power = VO,set x IO,max). 511 − 10.22 ΚΩ Rtrim − down = ∆% Where ∆ % = Vo, set − Vdesired Vo, set × 100 For example, to trim-down the output voltage of the module by 8% to 3.036V, Rtrim-down is calculated as follows: ∆% = 8 511 − 10.22 ΚΩ Rtrim − down = 8 Rtrim − down = 53.655ΚΩ Connecting an external resistor (Rtrim-up) between the TRIM pin and the VO(+) (or Sense (+)) pin increases the output voltage set point. The following equation determines the required external resistor value to obtain a percentage output voltage change of Δ%: LINEAGE POWER 8 Data Sheet August 20, 2010 ESTW015A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 15A Output Thermal Considerations Please refer to the Application Note “Thermal Characterization Process For Open-Frame BoardMounted Power Modules” for a detailed discussion of the thermal aspects including maximum device temperatures. The power modules operate in a variety of thermal environments; however, sufficient cooling should be provided to help ensure reliable operation. Considerations include ambient temperature, airflow, module power dissipation, and the need for increased reliability. A reduction in the operating temperature of the module will result in an increase in reliability. The thermal data presented here is based on physical measurements taken in a wind tunnel. The thermal reference points, Trefx used in the specifications for open frame modules are shown in Figure 13. For reliable operation Tref1 and Tref2 o temperatures should not exceed 125 C and Tref3 o temperature should not exceed 110 C. Figure 13. Tref Temperature Measurement Location for Open Frame Module. Heat Transfer via Convection Increased airflow over the module enhances the heat transfer via convection. Derating curves, showing the maximum output current that can be delivered by the module versus local ambient temperature (TA) for natural convection and up to 1m/s (200 ft./min) forced airflow, are shown in Figure 14. Full power up o to TA=85 C, is achieved for airflow of 1 m/s(200 LFM) or greater. OUTPUT CURRENT, IO (A) 16 15 NC 14 0.5m/s (100LFM) 13 1.0m/s (200LFM) 12 11 10 20 30 40 50 60 70 80 90 o AMBIENT TEMEPERATURE, TA ( C) Figure 14. Output Current Derating for the Open Frame Module; Airflow in the Transverse Direction from Vout(+) to Vout(-); Vin =48V. LINEAGE POWER 9 Data Sheet August 20, 2010 ESTW015A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 15A Output Surface Mount Information The ESTW015A0F modules use an open frame construction and are designed for a fully automated assembly process. The modules are fitted with a label designed to provide a large surface area for pick and place operations. The label meets all the requirements for surface mount processing, as well as safety standards, and is able to withstand reflow o temperatures of up to 300 C. The label also carries product information such as product code, serial number and the location of manufacture. technologies currently used in the industry. These surface mount power modules can be reliably soldered using natural forced convection, IR (radiant infrared), or a combination of convection/IR. For reliable soldering the solder reflow profile should be established by accurately measuring the modules CP connector temperatures. REFLOW TEMP (°C) Pick and Place Figure 15. Pick and Place Location. The module weight has been kept to a minimum by using open frame construction. Even so, these modules have a relatively large mass when compared to conventional SMT components. Variables such as nozzle size, tip style, vacuum pressure and placement speed should be considered to optimize this process. The minimum recommended nozzle diameter for reliable operation is 6mm. The maximum nozzle outer diameter, which will safely fit within the allowable component spacing, is 9 mm. Oblong or oval nozzles up to 11 x 9 mm may also be used within the space available. Figure 16. Reflow Profile for Tin/Lead (Sn/Pb) process. MAX TEMP SOLDER (°C) Nozzle Recommendations REFLOW TIME (S) Tin Lead Soldering o The ESTW015A0F power modules are lead free modules and can be soldered either in a lead-free solder process or in a conventional Tin/Lead (Sn/Pb) process. It is recommended that the customer review data sheets in order to customize the solder reflow profile for each application board assembly. The following instructions must be observed when soldering these units. Failure to observe these instructions may result in the failure of or cause damage to the modules, and can adversely affect long-term reliability. In a conventional Tin/Lead (Sn/Pb) solder process peak reflow temperatures are limited to less than o o 235 C. Typically, the eutectic solder melts at 183 C, wets the land, and subsequently wicks the device connection. Sufficient time must be allowed to fuse the plating on the connection to ensure a reliable solder joint. There are several types of SMT reflow LINEAGE POWER Figure 17. Time Limit Curve Above 205 C for Tin/Lead (Sn/Pb) process Lead Free Soldering The –Z version of the ESTW015A0F modules are lead-free (Pb-free) and RoHS compliant and are both forward and backward compatible in a Pb-free and a SnPb soldering process. Failure to observe the instructions below may result in the failure of or cause damage to the modules and can adversely affect long-term reliability. Reflow Soldering Information The surface mountable modules in the ESTW015A0F-S family use our newest SMT technology called “Column Pin” (CP) connectors. 10 Data Sheet August 20, 2010 ESTW015A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 15A Output Surface Mount Information (continued) Figure 18 shows the new CP connector before and after reflow soldering onto the end-board assembly. at conditions of ≤ 30°C and 60% relative humidity varies according to the MSL rating (see J-STD-033A). The shelf life for dry packed SMT packages will be a minimum of 12 months from the bag seal date, when stored at the following conditions: < 40° C, < 90% relative humidity. Post Solder Cleaning and Drying Considerations The CP is constructed from a solid copper pin with an integral solder ball attached, which is composed of tin/lead (Sn63/Pb37) solder for non-Z codes, or Sn/Ag3.8/Cu0.7 (SAC) solder for –Z codes. The CP connector design is able to compensate for large amounts of co-planarity and still ensure a reliable SMT solder joint. Typically, the eutectic solder melts o o at 183 C (Sn/Pb solder) or 217-218 C (SAC solder), wets the land, and subsequently wicks the device connection. Sufficient time must be allowed to fuse the plating on the connection to ensure a reliable solder joint. There are several types of SMT reflow technologies currently used in the industry. These surface mount power modules can be reliably soldered using natural forced convection, IR (radiant infrared), or a combination of convection/IR. Pb-free Reflow Profile Power Systems will comply with J-STD-020 Rev. C (Moisture/Reflow Sensitivity Classification for Nonhermetic Solid State Surface Mount Devices) for both Pb-free solder profiles and MSL classification procedures. This standard provides a recommended forced-air-convection reflow profile based on the volume and thickness of the package (table 4-2). The suggested Pb-free solder paste is Sn/Ag/Cu (SAC). The recommended linear reflow profile using Sn/Ag/Cu solder is shown in Figure 19. MSL Rating The ESTW015A0F modules have a MSL rating of 1. Storage and Handling The recommended storage environment and handling procedures for moisture-sensitive surface mount packages is detailed in J-STD-033 Rev. A (Handling, Packing, Shipping and Use of Moisture/Reflow Sensitive Surface Mount Devices). Moisture barrier bags (MBB) with desiccant are required for MSL ratings of 2 or greater. These sealed packages should not be broken until time of use. Once the original package is broken, the floor life of the product LINEAGE POWER 300 Per J-STD-020 Rev. C Peak Temp 260°C 250 Reflow Temp (°C) Figure 18. Column Pin Connector Before and After Reflow Soldering . Post solder cleaning is usually the final circuit board assembly process prior to electrical board testing. The result of inadequate cleaning and drying can affect both the reliability of a power module and the testability of the finished circuit board assembly. For guidance on appropriate soldering, cleaning and drying procedures, refer to Lineage Power Board Mounted Power Modules: Soldering and Cleaning Application Note (AN04-001). 200 * Min. Time Above 235°C 15 Seconds 150 Heating Zone 1°C/Second Cooling Zone *Time Above 217°C 60 Seconds 100 50 0 Reflow Time (Seconds) Figure 19. Recommended linear reflow profile using Sn/Ag/Cu solder. Through-Hole Lead-Free Soldering Information The RoHS-compliant through-hole products use the SAC (Sn/Ag/Cu) Pb-free solder and RoHS-compliant components. They are designed to be processed through single or dual wave soldering machines. The pins have a RoHS-compliant finish that is compatible with both Pb and Pb-free wave soldering processes. A maximum preheat rate of 3°C/s is suggested. The wave preheat process should be such that the temperature of the power module board is kept below 210°C. For Pb solder, the recommended pot temperature is 260°C, while the Pb-free solder pot is 270°C max. Not all RoHS-compliant through-hole products can be processed with paste-through-hole Pb or Pb-free reflow process. If additional information is needed, please consult with your Lineage Power representative for more details. 11 Data Sheet August 20, 2010 ESTW015A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 15A Output EMC Considerations The filter circuit schematic and plots in Figure 20 shows a suggested configuration as tested to meet the conducted emission limits of EN55022 Class A. Note: Customer is ultimately responsible for the proper selection, component rating and verification of the suggested parts based on the end application. VCC RTN L1 C1 + C2 C3 -48V + DC/DC C6 LOAD GND C4 C5 GND LISN connected to L Line LISN connected to N Line Figure 20. EMC Considerations For further information on designing for EMC compliance, please refer to the FLT007A0 data sheet (DS05-028). LINEAGE POWER 12 Data Sheet August 20, 2010 ESTW015A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 15A Output Mechanical Outline for Through-Hole Module Dimensions are in millimeters and [inches]. Tolerances: x.x mm ± 0.5 mm [x.xx in. ± 0.02 in.] (Unless otherwise indicated) x.xx mm ± 0.25 mm [x.xxx in ± 0.010 in.] Top side label includes Lineage Power name, product designation and date code. Top View* Side View *For optional pin lengths, see Table 2, Device Options Bottom View Pin 1 2 3 4 5 6 7 8 LINEAGE POWER Function Vi(+) ON/OFF Vi(-) Vo(-) SENSE(-) TRIM SENSE(+) Vo(+) 13 Data Sheet August 20, 2010 ESTW015A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 15A Output Mechanical Outline for Surface Mount Module Dimensions are in millimeters and [inches]. Tolerances: x.x mm ± 0.5 mm [x.xx in. ± 0.02 in.] (Unless otherwise indicated) x.xx mm ± 0.25 mm [x.xxx in ± 0.010 in.] * Top side label includes Lineage Power name, product designation and date code. Top View* Side View Bottom View Pin 1 2 3 4 5 6 7 8 LINEAGE POWER Function Vi(+) ON/OFF Vi(-) Vo(-) SENSE(-) TRIM SENSE(+) Vo(+) 14 Data Sheet August 20, 2010 ESTW015A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 15A Output Recommended Pad Layout Dimensions are in millimeters and [inches]. Tolerances: x.x mm ± 0.5 mm [x.xx in. ± 0.02 in.] (Unless otherwise indicated) x.xx mm ± 0.25 mm [x.xxx in ± 0.010 in.] SMT Recommended Pad Layout (Component Side View) TH Recommended Pad Layout (Component Side View) LINEAGE POWER 15 Data Sheet August 20, 2010 ESTW015A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 15A Output Packaging Details The surface mount versions of the ESTW015A0F modules (suffix –S) are supplied as standard in the plastic tray shown in Figure 21. The tray has external dimensions of 135.1mm(W) x 321.8mm(L) x 12.42mm(H) or 5.319in(W) x 12.669in(L) x 0.489in(H). Tray Specification Material Antistatic coated PVC Max surface resistivity Color Capacity Min order quantity 10 Ω/sq Clear 12 power modules 48 pcs (1 box of 4 full trays) 12 Each tray contains a total of 12 power modules. The trays are self-stacking and each shipping box will contain 4 full trays plus one empty hold down tray giving a total number of 48 power modules. Figure 21. Surface Mount Packaging Tray. LINEAGE POWER 16 Data Sheet August 20, 2010 ESTW015A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 15A Output Ordering Information Please contact your Lineage Power Sales Representative for pricing, availability and optional features. Table 1. Device Codes Product Codes Input Voltage Output Voltage Output Current On/Off Logic Connector Type ESTW015A0F61 48V (36-75Vdc) 3.3V 15A Negative Through hole CC109158093 ESTW015A0F641 48V (36-75Vdc) 3.3V 15A Negative Through hole CC109158102 ESTW015A0F41Z 48V (36-75Vdc) 3.3V 15A Negative Through hole CC109158085 ESTW015A0F641-Z 48V (36-75Vdc) 3.3V 15A Negative Through hole CC109159942 ESTW015A0F41-SZ 48V (36-75Vdc) 3.3V 15A Negative Surface Mount CC109159422 Comcodes Table 2. Device Options Document No: DS09-004 ver.1.01 PDF name: ESTW015A0F.pdf