Data Sheet October 11, 2011 ESTW025A0F Series (Eighth-Brick) DC-DC Converter Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A Output Current STINGRAY™ SERIES RoHS Compliant Features Wide input voltage range: 36-75 Vdc Delivers up to 25A Output current Monotonic startup into prebiased load Output Voltage adjust: 80% to 110% of Vo,nom Remote sense Constant switching frequency Positive remote On/Off logic Input under voltage protection Output overcurrent and overvoltage protection Over-temperature protection Industry standard, DOSA compliant footprint 57.9mm x 22.8mm x 8.5mm (2.28 in x 0.9 in x 0.335 in) Low profile height and reduced component skyline Applications Distributed power architectures Wireless networks Access and optical network Equipment Enterprise Networks including Power over Ethernet (PoE) Latest generation IC’s (DSP, FPGA, ASIC) and Microprocessor powered applications Options Suitable for cold wall cooling using suitable Gap Pad applied directly to top side of module High efficiency 92% at full load (Vin=48Vdc) No thermal derating up to 68°C, 1.0m/s (200 LFM) Wide operating temperature range (-40°C to 85°C) 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) UL* 60950-1, 2nd Ed. Recognized, CSA† C22.2 No. 60950-1-07 Certified, and VDE‡ (EN60950-1, 2nd Ed.) Licensed Negative Remote On/Off logic (-1 option, preferred/standard) Surface Mount version (-S option) Auto-restart (-4 option, preferred/standard) CE mark meets 2006/95/EC directive 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 ESTW025A0F series, Eighth-brick power modules are isolated dc-dc converters that can deliver up to 25A of output current and provide a precisely regulated output voltage over a wide range of input voltages (Vin = 36 -75Vdc). The module achieves typical full load efficiency of 92% 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. * 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: DS09-013 ver.1.01 PDF name: ESTW025A0F.pdf Data Sheet October 11, 2011 ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A 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 Continuous All VIN -0.3 80 Vdc Transient, operational (≤100 ms) All VIN,trans -0.3 100 Vdc All TA -40 85 °C -18H, H TC -40 110 °C Storage Temperature All Tstg -55 125 °C I/O Isolation voltage (100% factory Hi-Pot tested) All 2250 Vdc Input Voltage Operating Ambient Temperature Maximum Base-plate Operating Temperature (see Thermal Considerations section) Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Parameter Device Symbol Min Typ Max Unit All VIN 36 48 75 Vdc All IIN,max 2.7 Adc All IIN,No load 50 All IIN,stand-by 6 Inrush Transient All It 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 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 (VIN = VIN, nom, module disabled) 2 mA 8 mA 1 As 2 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 fast-acting 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 October 11, 2011 ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A Output Electrical Specifications (continued) Parameter Device Symbol Min Typ Max Unit All VO, set 3.250 3.300 3.350 Vdc All VO 3.200 3.400 Vdc All All All ±0.2 ±0.1 10 % VO, set mV % VO, set All 8 20 mVrms All 40 75 mVpk-pk 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 (Co=1uF,ceramic+10uF,tantalum, VIN=VIN, nom ,IO= IO, max , TA=TA, min to TA, max) RMS (5Hz to 20MHz bandwidth) Peak-to-Peak (5Hz to 20MHz bandwidth) External Capacitance 1 Output Current Output Current Limit Inception (Hiccup Mode ) (VO= 90% of VO, set) Output Short-Circuit Current (VO≤250mV) ( Hiccup Mode) All CO, max 0 20,000 μF All Io 0 25.0 Adc All IO, lim 26.3 29 32.5 Adc All IO, s/c All All η η 1.6 Arms 91.0 91.0 92.0 92.0 % % 85.5 87.0 % 355 kHz Efficiency VIN= VIN, nom, TA=25°C, IO=IO, max , VO= VO,set VIN= VIN, nom, TA=25°C, IO=10A , VO= VO,set VIN= VIN, nom, TA=25°C, IO=5A , VO= VO,set All η All fsw (Co=1uF,ceramic+220uF,tantalum, dIo/dt=0.1A/s; VIN = 48V; TA=25°C) Load Change from Io= 50% to 75% or 25% to 50% of Io,max Peak Deviation All Vpk 127 mV Settling Time (Vo<10% peak deviation) All ts 200 s Unit Switching Frequency Dynamic Load Response 1. See Note 2 under Feature Specifications. Isolation Specifications Parameter Device Symbol Min Typ Max Isolation Capacitance All Ciso 1000 pF Isolation Resistance All Riso 30 MΩ I/O Isolation Voltage (100% factory Hi-pot tested) All All 2250 Vdc Device Symbol Typ Max All FIT 229.4 10 /Hours All MTBF 4,359,904 Hours General Specifications Parameter 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) Min Unit 9 Weight (Open Frame) All 22 (0.78) g(oz) Weight (with Heatplate) All 35 (1.23) g(oz) LINEAGE POWER 3 Data Sheet October 11, 2011 ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A 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 All Ion/off 0.15 mA Logic Low - On/Off Voltage All Von/off -0.7 0.6 Vdc Logic High Voltage – (Typ = Open Collector) All Von/off 2.4 15.0 Vdc Logic High maximum allowable 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 10 % VO, set 1 Turn-On Delay and Rise Times o (IO=IO, max , VIN=VIN, nom, TA = 25 C) Output voltage overshoot – Startup All o IO= IO, max; VIN=VIN, min to VIN, max, TA = 25 C Prebias Output Load Performance: Output Start up characteristic All Back Bias current drawn from output (Module Enabled) All Remote Sense Range All Output Voltage Adjustment Range Monotonic mAdc -15 VSENSE -20 +10 % VO, set All VO, limit 3.9 5.1 Vdc Overtemperature Protection – Hiccup Auto Restart All Tref 125 Input Undervoltage Lockout All VUVLO Turn-on Threshold 34.0 35.5 Vdc Turn-off Threshold 30.5 32.0 Vdc Hysteresis 1.0 2.0 Vdc Output Overvoltage Protection (CO=470μF) 1. 2. All 2 O C The module has an adaptable extended Turn-On Delay interval, Tdelay, of 25mS. The extended Tdelay will occur when the module restarts following the rapid cycling of Vin from normal levels to less than the Input Undervoltage Lockout (which causes module shutdown), and then back to normal. The module requires a minimum of 470 μF external output capacitor to prevent shutdown during full load to no load transients and to avoid exceeding the OVP maximum limits during startup into open loop fault conditions. LINEAGE POWER 4 Data Sheet October 11, 2011 ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A Output Characteristic Curves o Figure 3. Transient Response to 0.1A/µS Dynamic Load Change from 25% to 50% to 25% of full load. LINEAGE POWER On/Off VOLTAGE OUTPUT VOLTAGE TIME, t (200µs/div) VO (V) (200mV/div) TIME, t (10ms/div) OUTPUT VOLTAGE Vo (V) (1V/div) VIN (V) (20V/div Figure 5. Typical Start-up Using Remote On/Off, negative logic version shown (VIN = VIN,NOM, Io = Io,max). INPUT VOLTAGE OUTPUT VOLTAGE VO (V) (20mV/div) 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). Io(A) (5A/div) OUTPUT CURRENT OUTPUT VOLTAGE Figure 4. Transient Response to 0.1A/µS Dynamic Load Change from 50% to 75% to 50% of full load. Figure 1. Converter Efficiency versus Output Current. TIME, t (2s/div) TIME, t (200µs/div) VO (V) (1V/div) OUTPUT CURRENT, IO (A) VOn/off (V) (5V/div) EFFICIENCY, (%) The following figures provide typical characteristics for the ESTW025A0F (3.3V, 25A) at 25 C. The figures are identical for either positive or negative remote On/Off logic. TIME, t (5ms/div) Figure 6. Typical Start-up Using Input Voltage (VIN = VIN,NOM, Io = Io,max). 5 Data Sheet October 11, 2011 ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A Output Test Configurations Design Considerations Input Filtering CURRENT PROBE TO OSCILLOSCOPE LTEST Vin+ BATTERY 12μH CS 220μF 100μF E.S.R.<0.1 @ 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 = 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 100μF electrolytic capacitor (ESR<0.7 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 fast-acting fuse in the ungrounded lead. 6 Data Sheet October 11, 2011 ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A 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+ II VI(+) VO(+) VI(-) VO(–) CONTACT RESISTANCE IO LOAD CONTACT AND DISTRIBUTION LOSSE 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 0V ≤ Von/off ≤ 1.2V. The maximum Ion/off during a logic low is 1mA, 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 15V, and the maximum allowable leakage current at Von/off = 5V is 1μA. 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 certain fault conditions, the unit is equipped with a thermal shutdown circuit. The unit will shutdown if the thermal reference point o Tref (Figure 13), exceeds 125 C (typical), but the thermal shutdown is not intended as a guarantee that the unit will survive temperatures beyond its rating. 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 auto-restart option (4) is ordered, the module will automatically restart upon cool-down to a safe temperature. 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 7 Data Sheet October 11, 2011 ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A Output Feature Descriptions (continued) 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 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. VIN(+) VO(+) Rtrim-up ON/OFF LOAD VOTRIM Rtrim-down VIN(-) VO(-) 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 output voltage set point. The following equation determines the required external resistor value to obtain a percentage output voltage change of Δ%: 5.11 Vo , set (100 %) 511 Rtrim up 10.22 1 . 225 % % Where V V o , 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 10 . 22 R trim up 1 . 225 5 5 Rtrim up 176 .7 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, 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). 511 R trim down 10 . 22 % Where V V desired % o , set V o , 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 Rtrim down 10 .22 8 Rtrim down 53 .655 Connecting an external resistor (Rtrim-up) between the TRIM pin and the VO(+) (or Sense (+)) pin increases LINEAGE POWER 8 Thermal Considerations 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, Tref1,Tref2 and Tref3 used in the specifications for open frame modules are shown in Figures 13a and 13b. For reliable operation o o these temperatures should not exceed 125 C, 110 C and 105oC respectively. ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A Output for natural convection and up to 2.0 m/s (400 ft./min) forced airflow, are shown in Figure 15. OUTPUT CURRENT, IO (A) Data Sheet October 11, 2011 o AMBIENT TEMEPERATURE, TA ( C) Figure 15. Output Current Derating for the Open Frame Module; Airflow in the Transverse Direction from Vout(+) to Vout(-); Vin =48V. Heat Transfer via Conduction Figure 13b. Tref 2 and Tref 3 Temperature Measurement Locations for Open Frame Module. The thermal reference point, Tref, used in the specifications for modules with heatplate is shown in Figure 14. For reliable operation this temperature should not exceed 110oC. Figure 16. Cold Wall Mounting OUTPUT CURRENT, IO (A) Figure 13a. Tref 1 Temperature Measurement Location for Open Frame Module. The module can also be used in a sealed environment with cooling via conduction from the module’s top surface through a gap pad material to a cold wall, as shown in Figure 16. The output current derating versus cold wall temperature, when using a gap pad such as Bergquist GP2500S20, is shown in Figure 17. o COLDPLATE TEMEPERATURE, TC ( C) Figure 14. Tref Temperature Measurement Location for Module with Heatplate. 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 each module versus local ambient temperature (TA) LINEAGE POWER Figure 17. Derated Output Current versus Cold Wall Temperature with local ambient temperature around module at 85C; Vin=48V. Please refer to the Application Note “Thermal Characterization Process For Open-Frame BoardMounted Power Modules” for a detailed discussion of thermal aspects including maximum device temperatures. 9 Data Sheet October 11, 2011 ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A Output Surface Mount Information Pick and Place The ESTW025A0F 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. 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. For reliable soldering the solder reflow profile should be established by accurately measuring the modules CP connector temperatures. 300 P eak Temp 235oC REFLOW TEMP (C) 250 200 150 So ak zo ne 30-240s 100 50 Tin Lead Soldering The ESTW025A0F 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 235oC. Typically, the eutectic solder melts at 183oC, wets the land, and subsequently wicks the device connection. Sufficient time must be allowed to fuse LINEAGE POWER P reheat zo ne max 4oCs -1 REFLOW TIME (S) Figure 19. Reflow Profile for Tin/Lead (Sn/Pb) process. 240 235 MAX TEMP SOLDER (C) 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. Tlim above 205oC 0 Figure 18. Pick and Place Location. Nozzle Recommendations Co o ling zo ne 1-4oCs -1 Heat zo ne max 4oCs -1 230 225 220 215 210 205 200 0 10 20 30 40 50 60 o Figure 20. Time Limit Curve Above 205 C for Tin/Lead (Sn/Pb) process Lead Free Soldering The –Z version of the ESTW025A0F 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 ESTW025A0F-S family use our newest SMT 10 Data Sheet October 11, 2011 ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A Output Surface Mount Information (continued) technology called “Column Pin” (CP) connectors. Figure 19 shows the new CP connector before and after reflow soldering onto the end-board assembly. ESTW Board should not be broken until time of use. Once the original package is broken, the floor life of the product 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 Solder Ball End assembly PCB Figure 21. Column Pin Connector Before and After Reflow Soldering . 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. 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). 300 Per J-STD-020 Rev. C Peak Temp 260°C 250 Reflow Temp (°C) Insulator 200 * Min. Time Above 235°C 15 Seconds Cooling Zone 150 Heating Zone 1°C/Second *Time Above 217°C 60 Seconds 100 50 0 Reflow Time (Seconds) 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 22. MSL Rating The ESTW025A0F modules have a MSL rating of 2a. 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 LINEAGE POWER Figure 22. 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 3C/s is suggested. The wave preheat process should be such that the temperature of the power module board is kept below 210C. For Pb solder, the recommended pot temperature is 260C, while the Pb-free solder pot is 270C 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 October 11, 2011 ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A Output EMC Considerations The filter circuit schematic and plots in Figure 23 shows a suggested configuration as tested to meet the conducted emission limits of EN55022 Class B. Note: Customer is ultimately responsible for the proper selection, component rating and verification of the suggested parts based on the end application. Figure 23. EMC Considerations For further information on designing for EMC compliance, please refer to the FLT007A0 data sheet (DS05-028). LINEAGE POWER 12 Data Sheet October 11, 2011 ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A 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 October 11, 2011 ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A 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 October 11, 2011 ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A Output Mechanical Outline for Through-Hole Module with 1/8th Heat Plate (-H Option) 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 View Side View *For optional pin lengths, see Table 2, Device Coding Scheme and Options Bottom View* Pin 1 2 3 4 5 6 7 8 LINEAGE POWER Function Vi(+) ON/OFF Vi(-) Vo(-) SENSE(-) TRIM SENSE(+) Vo(+) 15 Data Sheet October 11, 2011 ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A Output Mechanical Outline for Through-Hole Module with 1/4th Heat Plate (-18H Option) 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.] Pin 1 2 3 4 5 6 7 8 Function Vi(+) ON/OFF Vi(-) Vo(-) SENSE(-) TRIM SENSE(+) Vo(+) LINEAGE POWER 16 Data Sheet October 11, 2011 ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A 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) LINEAGE POWER 17 Data Sheet October 11, 2011 ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A Output TH Recommended Pad Layout (Component Side View) LINEAGE POWER 18 Data Sheet October 11, 2011 ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A Output Packaging Details The surface mount versions of the ESTW025A0F modules (suffix –S) are supplied as standard in the plastic tray shown in Figure 24. 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 1012/sq Clear 12 power modules 48 pcs (1 box of 4 full trays) 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 24. Surface Mount Packaging Tray. LINEAGE POWER 19 Data Sheet October 11, 2011 ESTW025A0F Series Eighth-Brick Power Modules 36–75Vdc Input; 3.3Vdc Output; 25A Output Ordering Information Please contact your Lineage Power Sales Representative for pricing, availability and optional features. Table 1. Device Codes ESTW025A0F41Z 48V (36-75Vdc) Output Voltage 3.3V ESTW025A0F41-HZ 48V (36-75Vdc) 3.3V 25A Negative Through hole ESTW025A0F41-SZ 48V (36-75Vdc) 3.3V 25A Negative Surface Mount CC109159505 CC109159496 ESTW025A0F641 48V (36-75Vdc) 3.3V 25A Negative Through hole CC109159125 ESTW025A0F4Z 48V (36-75Vdc) 3.3V 25A Positive Through hole ESTW025A0F641Z 48V (36-75Vdc) 3.3V 25A Negative Through hole CC109168118 CC109169363 ESTW025A0F841Z 48V (36-75Vdc) 3.3V 25A Negative Through hole CC109167367 ESTW025A0F64-18HZ 48V (36-75Vdc) 3.3V 25A Positive Through hole CC109172846 Product Codes Input Voltage Output Current 25A On/Off Logic Negative Connector Type Through hole Comcodes CC109158498 Table 2. Device Options Character and Position Ratings Characteristic Form Factor Family Designator Input Voltage Output Current Output Voltage E ST W 025A0 F Pin Length Action following Protective Options On/Off Logic Customer Specific 6 8 4 1 XY H Mechanical Features 18H RoHS Definition E = Eighth Brick ST = Stingray Series W = Wide Range, 36V-75V 025A0 = 025.0 Amps Maximum Output Current F = 3.3V nominal Omit = Default Pin Length shown in Mechanical Outline Figures 6 = Pin Length: 3.68 mm ± 0.25mm , (0.145 in. ± 0.010 in.) 8 = Pin Length: 2.79 mm ± 0.25mm , (0.110 in. ± 0.010 in.) Omit = Latching Mode 4 = Auto-restart following shutdown (Overcurrent/Overvoltage) Omit = Positive Logic 1 = Negative Logic XY = Customer Specific Modified Code, Omit for Standard Code Omit = Standard open Frame Module H = 1/8th Brick size heat plate, for use with heat sinks (not available with –S option) 18H = 1/4th Brick size heat plate with unthreaded inserts for use in coldwall applications (not available with –S option) S = Surface mount connections Omit = RoHS 5/6, Lead Based Solder Used Z Z = RoHS 6/6 Compliant, Lead free Asia-Pacific Headquarters Tel: +65 6593 7211 World Wide Headquarters Lineage Power Corporation 601 Shiloh Road, Plano, TX 75074, USA +1-800-526-7819 (Outside U.S.A.: +1-972-244-9428) www.lineagepower.com e-m ail: [email protected] Europe, Middle-East and Africa Headquarters Tel: +49 89 878067-280 India Headquarters Tel: +91 80 28411633 Lineage Power reser ves the right to make c hanges to the product(s) or inf ormation contained herei n without notice. N o liability is ass umed as a res ult of their use or application. No rights under any patent accompany the sale of any suc h produc t(s) or infor mati on. Lineage Power DC-DC products are protected under various patents. Information on these patents is availabl e at www.lineagepower.c om/patents. © 2011 Lineage Power Corporation, (Plano, Texas) All Int ernational Rights Reser ved. Document No: DS09-013 ver.1.01 PDF name: ESTW025A0F.pdf