Data Sheet September 9, 2008 KW006-010 Series (Sixteenth-Brick) DC-DC Converter Power Modules: 36–75Vdc Input; 3.3Vdc to 5.0Vdc Output; 6A to 10A Output Current RoHS Compliant Features Applications Distributed power architectures Wireless networks Access and optical network Equipment Enterprise Networks Latest generation IC’s (DSP, FPGA, ASIC) and Microprocessor powered applications 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 33W output power: 3.3V(10A), 5.0V(6A) Small size and low profile: 33.0 mm x 22.9 mm x 8.75 mm (1.30 in x 0.9 in x 0.344 in) Industry standard DOSA footprint Output voltage adjustment trim (-20%, +10%) Remote On/Off, Positive logic Remote Sense Over-temperature protection (non-latching) Output over-current protection (non-latching) Output over-voltage protection (latching) Wide operating temperature range (-40°C to 85°C) Meets the voltage isolation requirements for ETSI 300-132-2 and complies with and is licensed for Basic Insulation rating per EN60950-1 CE mark meets the 2006/95/EC directive§ UL* 60950-1Recognized, CSA† C22.2 No. 60950-1-03 Certified, and VDE‡ 0805 (EN60950 3rd Edition) Licensed ISO** 9001 and ISO 14001 certified manufacturing facilities Surface Mount (Tape and Reel, -SR Suffix) Options Negative Remote On/Off logic Description The KW (Sixteenth-brick) series power modules are isolated dc-dc converters that operate over a wide input voltage range of 36 to 75Vdc and provide a single precisely regulated output. The output is fully isolated from the input, allowing versatile polarity configurations and grounding connections. The modules exhibit high efficiency, typical efficiency of 87% for 3.3V/10A. These open frame modules are available in surface-mount (-SR) form. * 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-user equipment should be followed. ** ISO is a registered trademark of the International Organization of Standards Document No: DS06-114 ver.1.31 PDF name: kw006-010.ds.pdf Data Sheet September 9, 2008 KW0006-010 Series Power Modules: 36 – 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current 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 (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 tested) All ⎯ ⎯ 1500 Vdc Input Voltage 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 Device Symbol Min Typ Max Unit Operating Input Voltage All VIN 36 48 75 Vdc Maximum Input Current All IIN,max 1.5 Adc All IIN,No load 40 75 mA All IIN,stand-by 3 5 mA Inrush Transient All It 0.1 As 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 Input Ripple Rejection (120Hz) All (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) EMC, EN55022 2 30 50 2 mAp-p dB See EMC Considerations section 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 September 9, 2008 KW0006-010 Series Power Modules: 36 – 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current Electrical Specifications (continued) Parameter Output Voltage Set-point Device Symbol Min Typ Max Unit All VO, set -1.5 ⎯ +1.5 % VO, set All VO -3.0 ⎯ +3.0 % VO, set All VO,adj -20.0 +10.0 Vdc (VIN=VIN, min, IO=IO, max, TA=25°C) Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life) Adjustment Range Selected by an external resistor Output Regulation Line (VIN=VIN, min to VIN, max) All ⎯ ⎯ 0.1 % VO, set Load (IO=IO, min to IO, max) All ⎯ ⎯ 5 mV Temperature (Tref=TA, min to TA, max) All ⎯ ⎯ ±1.0 % VO, set F ⎯ ⎯ 20 mVrms Peak-to-Peak (5Hz to 20MHz bandwidth) F ⎯ ⎯ 60 mVpk-pk RMS (5Hz to 20MHz bandwidth) A ⎯ ⎯ 25 mVrms Peak-to-Peak (5Hz to 20MHz bandwidth) A Output Ripple and Noise on nominal output (VIN=VIN, nom ,IO= IO, max , TA=TA, min to TA, max) (see Figure 14 for test conditions) RMS (5Hz to 20MHz bandwidth) External Capacitance Output Current Output Current Limit Inception (Hiccup Mode ) (VO= 90% of VO, set) Output Short-Circuit Current (VO≤250mV) ( Hiccup Mode ) Efficiency ⎯ ⎯ 75 mVpk-pk F CO, max 0* ⎯ 5,000 μF A CO, max 0* ⎯ 2,000 μF A Io 0 ⎯ 6 Adc F Io 0 ⎯ 10 Adc All IO, lim 101 130 % Io All IO, s/c ⎯ ⎯ Arms All η 87.0 % All fsw 300 kHz All Vpk 1 VIN= VIN, nom, TA=25°C IO=IO, max , VO= VO,set Switching Frequency Dynamic Load Response (dIo/dt=1.0A/μs; VIN = VIN, nom; TA=25°C) Load Change from Io= 50% to 75% or 25% to 50% of Io,max; 470µF external capacitance (ESRmax< 20 mΩ) Peak Deviation ⎯ 3 ⎯ % VO, set Settling Time (Vo<10% peak deviation) 200 All ts μs ⎯ ⎯ (* See Output Overvoltage Protection Information in the Feature Specifications and Feature Descriptions for advise on minimum output capacitance) LINEAGE POWER 3 Data Sheet September 9, 2008 KW0006-010 Series Power Modules: 36 – 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current Isolation Specifications Parameter Device Symbol Min Typ Max Isolation Capacitance All Isolation Resistance All I/O Isolation Voltage All Unit Ciso ⎯ 120 ⎯ pF Riso 10 ⎯ ⎯ MΩ All ⎯ ⎯ 1500 Vdc Min Typ Max Unit General Specifications Parameter Calculated MTBF Based upon Telcordia SR-332 Issue 2: Method 1 Case 3, 90% confidence (IO=80%IO, max, TA=40°C, Airflow = 200 lfm) Powered Random Vibration (VIN=VIN, min, IO=IO, max, TA=25°C, 0 to 5000Hz, 10Grms) Weight Device F 3,765,608 All Hours 90 ⎯ All Minutes 10 (0.35) ⎯ g (oz.) 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 ⎯ 0.37 1.0 mA Logic Low - On/Off Voltage All Von/off -0.7 ⎯ 1.2 V Logic Threshold – change of state All Von/off All Von/off 3 3.4 5 V All Ion/off ⎯ ⎯ 10 μA 15 V Logic High Voltage – (Typ = Open Collector) Logic High maximum allowable leakage current (current flow sourced from the unit) External voltage allowed on on/off pin 2.4 V Turn-On Delay and Rise Times o (IO=IO, max , VIN=VIN, nom, TA = 25 C) Case 1: On/Off input is set to Logic Low (Module ON) and then input power is applied (delay from instant at which VIN = VIN, min until Vo=10% of Vo,set) All Tdelay ― 2 5 msec Case 2: Input power is applied for at least 1 second and then the On/Off input is set from OFF to ON (Tdelay = from instant at which VIN=VIN, min until VO = 10% of VO, set). All Tdelay ― 2 5 msec Output voltage Rise time (time for Vo to rise from 10% of Vo,set to 90% of Vo, set, with 0 to max ext capacitance) All Trise ― 8 12 msec Output voltage overshoot – Startup All o IO= IO, max; VIN=VIN, min to VIN, max, TA = 25 C ― 3 % VO, set Remote Sense Range All All 10 % VO, set Output Overvoltage Protection (requires 660 µF output A VO, limit 5.75 ⎯ 7 Vdc capacitance to meet limits, when Output Overvoltage is caused by internal module failure; see Feature Descriptions for further detail) F VO, limit 3.8 ⎯ 4.6 Vdc Turn-on Threshold All Vuv/on ⎯ 34 36 Vdc Turn-off Threshold All Vuv/off 24 27 ⎯ Vdc Hysterisis All Vhyst ⎯ 6 ⎯ Vdc Input Undervoltage Lockout LINEAGE POWER 4 Data Sheet September 9, 2008 KW0006-010 Series Power Modules: 36 – 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current Characteristic Curves The following figures provide typical characteristics for the KW010A0F (3.3V, 10A) at 25oC. The figures are identical for either positive or negative remote On/Off logic. 90 OUTPUT CURRENT, Io (A) 12.0 EFFICIENCY, η (%) 85 Vin = 75V 80 Vin = 48V Vin = 36V 75 70 0 2 4 6 8 Figure 3. Transient Response to Dynamic Load Change from 75% to 50% to 75% of full load with an external 470uF tantalum capacitor (dI/dt =1.0A/μs). LINEAGE POWER (600 lfm) 2.0 0.0 30 40 50 60 70 80 90 AMBIENT TEMPERATURE, TA C OUTPUT VOLTAGE VO (V) (1V/div) On/Off VOLTAGE Von/off (V) (5V/div) TIME, t (5ms/div) OUTPUT VOLTAGE VO (V) (1V/div) Figure 5. Typical Start-up Using Remote On/Off, negative logic version shown (VIN = VIN,NOM, Io = Io,max). VIN (V) (50V/div) TIME, t (400 μs /div) 4.0 1.0 m/s (200 lfm) 2.0 m/s (400 lfm) 3.0 m/s Figure 4. Derating Output Current versus Local Ambient Temperature and Airflow. INPUT VOLTAGE OUTPUT VOLTAGE VO (V) (20mV/div) VO (V) (100mV/div) Io (A) (5A/div) OUTPUT CURRENT, OUTPUT VOLTAGE Figure 2. Typical output ripple and noise (VIN = VIN,NOM, Io = Io,max). NC 6.0 O OUTPUT CURRENT, IO (A) TIME, t (1μs/div) 8.0 20 10 Figure 1. Converter Efficiency versus Output Current. 10.0 TIME, t (5ms/div) Figure 6. Typical Start-up Using Input Voltage (VIN = VIN,NOM, Io = Io,max). 5 Data Sheet September 9, 2008 KW0006-010 Series Power Modules: 36 – 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current Characteristic Curves (continued) The following figures provide typical characteristics for the KW006A0A (5.0V, 6A) at 25oC. The figures are identical for either positive or negative remote On/Off logic. 90 7.0 OUTPUT CURRENT, Io (A) Vin = 36V EFFICIENCY, η (%) 85 Vin = 48V 80 Vin = 75V 75 70 0 1 2 3 4 5 LINEAGE POWER 2.0 1.0 0.0 30 40 50 60 70 3.0 m/s (600 lfm) 80 90 Vo (V) (2V/div) VON/OFF (V) (5V/div) OUTPUT VOLTAGE On/Off VOLTAGE Figure 9. Transient Response to Dynamic Load Change from 50% to 75% to 50% of full load with an external 470uF tantalum capacitor (dI/dt =1.0A/μs). 3.0 Figure 10. Derating Output Current versus Local Ambient Temperature and Airflow. TIME, t (5ms/div) INPUT VOLTAGE Vo (V) (2V/div) Figure 11. Typical Start-up Using Remote On/Off, negative logic version shown (VIN = VIN,NOM, Io = Io,max). VIN (V) (50V/div) VO (V) (50mV/div) Io(A) (2A/div) OUTPUT CURRENT, OUTPUT VOLTAGE TIME, t (1ms/div) 4.0 AMBIENT TEMPERATURE, TA C OUTPUT VOLTAGE VO (V) (20mV/div) OUTPUT VOLTAGE TIME, t (1μs/div) NC 0.5 m/s (100 lfm) 1.0 m/s (200 lfm) 2.0 m/s (400 lfm) O OUTPUT CURRENT, IO (A) Figure 8. Typical output ripple and noise (VIN = VIN,NOM, Io = Io,max). 5.0 20 6 Figure 7. Converter Efficiency versus Output Current. 6.0 TIME, t (5ms/div) Figure 12. Typical Start-up Using Input Voltage (VIN = VIN,NOM, Io = Io,max). 6 Data Sheet September 9, 2008 KW0006-010 Series Power Modules: 36 – 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current 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 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 13, a 33μF electrolytic capacitor (ESR<0.1Ω at 100kHz), mounted close to the power module helps ensure the stability of the unit. Consult the factory for further application guidelines. VIN(-) Safety Considerations 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 13. Input Reflected Ripple Current Test Setup. COPPER STRIP VO (+) RESISTIVE LOAD SCOPE V O (–) 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 14. Output Ripple and Noise Test Setup. Rdistribution Rcontact Rcontact VIN(+) RLOAD VO VIN Rdistribution Rcontact Rcontact VIN(-) Rdistribution VOUT(+) 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 15. Output Voltage and Efficiency Test Setup. VO. IO Efficiency η = LINEAGE POWER VIN. IIN x 100 % 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., UL 60950-1-3, CSA C22.2 No. 60950-00, and VDE 0805:2001-12 (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 (-B option only). The input to these units is to be provided with a maximum 5 A time-delay fuse in the ungrounded lead. 7 Data Sheet September 9, 2008 KW0006-010 Series Power Modules: 36 – 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current 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. 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). SENSE(+) SENSE(–) VIN(+) VOUT(+) SUPPLY II VI(+) VO(+) VI(-) VO(–) CONTACT RESISTANCE Ion/off IO LOAD CONTACT AND DISTRIBUTION LOSSE ON/OFF TRIM Von/off Figure 17. Circuit Configuration for remote sense . Input Under-Voltage Lockout VIN(-) VOUT(-) Figure 16. 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 16). Logic low is 0V ≤ Von/off ≤ 1.2V. The maximum Ion/off during a logic low is 1mA, the switch should be maintain a logic low level whilst sinking this current. The typical open circuit Von/off generated by the module is 3.4V. The ION/OFF leakage current, through the switch, is required to be less than 10uA otherwise the unit will reach the threshold at which it switches. 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 17). 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(–)] ≤ 10% VO,Set 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 LINEAGE POWER At input voltages below the input under-voltage 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. Over-Temperature 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 test point RT1 (Figure 19), exceeds 110oC (typical), but the thermal shutdown is not intended as a guarantee that the unit will survive temperatures beyond its rating. The module will automatically restart upon cool-down to a safe temperature. Output Over-Voltage 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-off the module in the event of over-voltage across the output. Recycling the input voltage or momentarily switching-off the module via the remote on/off pin resets the latch. The independent over-voltage loop has a relatively slow response time. There are no precautions necessary to meet the output over-voltage protection limits for externally caused over-voltage conditions, such as excessive remote sense or output trim adjustments. However, special precautions are necessary to insure the over-voltage limits are met when the over-voltage is caused by internal module control loop failure. Either a minimum of 660 µF external output capacitance is required, or an external 8 Data Sheet September 9, 2008 KW0006-010 Series Power Modules: 36 – 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current Feature Descriptions (continued) OVP pull-down circuit is required. The OVP pull-down circuit will also provide significantly lower peak output over-voltages for applications that are particularly sensitive to over-voltage stress. Please contact your local Lineage Power sales representative for further information on the external OVP pull-down circuit. Over-Current 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. The unit 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 < 1A. 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(+) ⎡ 511 ⎤ Rtrim − down = ⎢ − 10 .22 ⎥ ΚΩ 8 ⎣ ⎦ R trim − down = 53 . 655 ΚΩ Connecting an external resistor (Rtrim-up) between the TRIM pin and the VO(+) (or Sense (+)) pin increases the output voltage set point. The following equations determine the required external resistor value to obtain a percentage output voltage change of Δ%: For trimming the output voltage higher: ⎡ 5.11 × Vo , set × (100 + Δ %) 511 ⎤ − − 10 .22 ⎥ ΚΩ Rtrim − up = ⎢ Δ% 1.225 × Δ % ⎣ ⎦ Where Δ % = ⎛⎜ Vo , set − V desired ⎜ Vo , set ⎝ ⎞ ⎟ × 100 ⎟ ⎠ For example, to trim-up the output voltage of 3.3V module (KW010A0F/F1) by 6% to 3.498V, Rtrim-up is calculated is as follows: Δ% = 6 ⎡ 5 .11 × 3 .3 × (100 + 6 ) 511 ⎤ R trim − up = ⎢ − − 10 . 22 ⎥ ΚΩ 1 . 225 × 6 6 ⎣ ⎦ Rtrim −up = 147 .8ΚΩ VO(+) Rtrim-up ON/OFF LOAD VOTRIM Rtrim-down VIN(-) VO(-) Figure 18. 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% For trimming the output voltage lower: 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 setpoint 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 ⎥ ΚΩ ⎣ Δ% ⎦ Where Δ % = ⎛⎜ V o , set − V desired ⎜ V o , set ⎝ ⎞ ⎟ × 100 ⎟ ⎠ For example, to trim-down the output voltage of 3.3V module (KW010A0F/F1) by 8% to 3.036V, Rtrim-down is calculated as follows: Δ% = 8 LINEAGE POWER 9 Data Sheet September 9, 2008 KW0006-010 Series Power Modules: 36 – 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current EMC Considerations Thermal Considerations The KW006/010 power module is designed to meet EN55022 Class B Conducted emissions with a simple filter, as shown in Figure 19. Test results are shown in Figure 20. Further improvement to the emissions at the fundamental can be achieved by increasing the value of C3 and C4. Please contact your Lineage Power sales representative, if you need further information. The power modules operate in a variety of thermal environments; however, sufficient cooling should be provided to help ensure reliable operation. C3 L1 VIN + Vin + C1 Vout + C2 KW006A0A4 VIN Vin - C1 = 4.7uF Ceramic C2 = 33uF Electrolytic C3 = 1nF Ceramic C4 = 1nF Ceramic L1 = P0354 (1.17mH, 1.2A rated) 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 in this data sheet is based on physical measurements taken in a wind tunnel. The test set-up is shown in Figure 21. Please refer to the Application Note “Thermal Characterization Process For Open-Frame Board-Mounted Power Modules” for a detailed discussion of thermal aspects including maximum device temperatures. The thermal reference point, Tref , used in the specifications, is shown in Figure 22. For reliable operation this temperature should not exceed 125oC. Vout - C4 Figure 19. EMC Filter. 90 EN 55022 Class B Conducted AV (Mains Port) 80 70 EN 55022 Class A Conducted AV (Mains Ports) 60 EN 55022 Class B Conducted AV (Mains Ports) 50 Lev el (dB uV ) 40 30 20 10 150k Frequency (Hz) 90 1M 10M 30M Figure 21. Tref Temperature Measurement Locations. EN 55022 Class B Conducted AV (Mains Port) 80 70 EN 55022 Class A Conducted AV (Mains Ports) 60 AIRFLOW EN 55022 Class B Conducted AV (Mains Ports) 50 Lev el (dB uV ) 40 30 20 10 150k Frequency (Hz) 1M 10M 30M Figure 20. EMC Results (top VIN+, bottom VIN-) Figure 22. Tref Temperature Measurement Locations. LINEAGE POWER 10 Data Sheet September 9, 2008 KW0006-010 Series Power Modules: 36 – 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current Surface Mount Information Pick and Place The KW006/010 modules use an open frame construction and are designed for a fully automated assembly process. The pick and place location on the module is the larger magnetic core as shown in Figure 23. The modules are fitted with a label which 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. 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 o reflow temperatures are limited to less than 235 C. o 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 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 Co o ling zo ne 1-4oCs -1 Heat zo ne max 4oCs -1 200 150 So ak zo ne 30-240s 100 50 Tlim above 205oC P reheat zo ne max 4oCs -1 0 REFLOW TIME (S) Figure 24. Reflow Profile for Tin/Lead (Sn/Pb) process Figure 23. Pick and Place Location. 240 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 recommended nozzle diameter for reliable operation is 6mm. Oblong or oval nozzles up to 11 x 6 mm may also be used within the space available. MAX TEMP SOLDER (°C) 235 Nozzle Recommendations 230 225 220 215 210 205 200 0 Tin Lead Soldering The KW006/010 power modules (both non-Z and –Z codes) can be soldered either in a conventional Tin/Lead (Sn/Pb) process. The non-Z version of the KW006/010 modules are RoHS compliant with the lead exception. Lead based solder paste is used in the soldering process during the manufacturing of these modules. These modules can only be soldered in 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 LINEAGE POWER 10 20 30 40 50 60 o Figure 25. Time Limit Curve Above 205 C for Tin/Lead (Sn/Pb) process Lead Free Soldering The –Z version of the KW006/010 modules are leadfree (Pb-free) and RoHS compliant and are both forward and backward compatible in a Pb-free and a SnPb soldering process. The non-Z version of the KW006/010 modules are RoHS compliant with the lead exception. Lead based solder paste is used in the soldering process during the manufacturing of these modules. These modules can only be soldered in 11 Data Sheet September 9, 2008 KW0006-010 Series Power Modules: 36 – 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current Surface Mount Information (continued) 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 26. Per J-STD-020 Rev. C Peak Temp 260°C 250 Reflow Temp (°C) conventional Tin/lead (Sn/Pb) 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. 300 200 * 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) Figure 26. Recommended linear reflow profile using Sn/Ag/Cu solder. MSL Rating The KW006/010 modules have a MSL rating of 2. 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 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 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). LINEAGE POWER 12 Data Sheet September 9, 2008 KW0006-010 Series Power Modules: 36 – 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current 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 View Side View Bottom View PIN 1 2 3 4 5 6 7 8 FUNCTION VIN(+) On/Off VIN(-) Vo(-) Sense(-) Trim Sense(+) Vo(+) LINEAGE POWER 13 Data Sheet September 9, 2008 KW0006-010 Series Power Modules: 36 – 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current 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 14 Data Sheet September 9, 2008 KW0006-010 Series Power Modules: 36 – 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current Packaging Details The Sixteenth-brick SMT versions are supplied in tape & reel as standard. Details of tape dimensions are shown below. Modules are shipped in quantities of 140 modules per reel. Tape Dimensions Dimensions are in millimeters. LINEAGE POWER 15 Data Sheet September 9, 2008 KW0006-010 Series Power Modules: 36 – 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current Ordering Information Please contact your Lineage Power Sales Representative for pricing, availability and optional features. Table 1. Device Code Product Codes Input Voltage KW010A0F41-SR KW010A0F41-SRZ KW006A0A41-SR KW006A0A41-SRZ 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) Output Voltage 3.3V 3.3V 5V 5V Output Current 10A 10A 6A 6A On/Off Logic Negative Negative Negative Negative Connector Type Surface mount Surface mount Surface mount Surface mount Comcode 108996360 CC109114113 108996385 CC109128798 -Z Indicated RoHS Compliant Modules Table 2. Device Options Option* Negative remote on/off logic Over-Current (auto-restart)/ Over-Temp Protection(auto-restart) /Over-Voltage (latching) Surface mount connections (Tape & Reel) Suffix** 1 4 (must be ordered) -SR (must be ordered) Asia-Pacific Headquarters Tel: +65 6416 4283 World Wide Headquarters Lineage Power Corporation 3000 Skyline Drive, Mesquite, TX 75149, USA +1-800-526-7819 (Outside U.S.A.: +1-972-284-2626) www.lineagepower.com e-mail: [email protected] Europe, Middle-East and Africa Headquarters Tel: +49 89 6089 286 India Headquarters Tel: +91 80 28411633 Lineage Power reserves the right to make changes to the product(s) or information contained herein without notice. No liability is assumed as a result of their use or application. No rights under any patent accompany the sale of any such product(s) or information. © 2008 Lineage Power Corporation, (Mesquite, Texas) All International Rights Reserved. Document No: DS06-114 ver.1.31 PDF name: kw006-010.ds.pdf