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| Data Sheet March 26, 2008 KW010/015/020/025 (Sixteenth-Brick) Power Modules: 36 -75Vdc Input; 1.2Vdc to 5.0Vdc Output;10A to 25A Output Current RoHS Compliant 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 25A output current 5V(10A), 3.3V(15A), 2.5V(20A), 1.8V-1.2V(25A) High efficiency - 91% at 3.3V full load Small size and low profile: 33.0 mm x 22.9 mm x 8.5 mm (1.30 in x 0.9 in x 0.335 in) Industry standard DOSA footprint -20% to +10% output voltage adjustment trim Remote On/Off Remote Sense No reverse current during output shutdown Over temperature protection (latching) Output overcurrent/overvoltage protection (latching) Wide operating temperature range (-40C to 85C) Meets the voltage isolation requirements for ETSI 300-132-2 and complies with and is licensed for Basic Insulation rating per EN60950-1 UL* 60950-1Recognized, CSA C22.2 No. 60950-1-03 Certified, and VDE 0805 (IEC60950 rd 3 Edition) Licensed CE mark meets 2006/95/EC directive ISO** 9001 and ISO 14001 certified manufacturing facilities Applications Distributed power architectures Wireless networks Access and optical network Equipment Enterprise Networks Latest generation IC's (DSP, FPGA, ASIC) and Microprocessor powered applications Options Negative Remote On/Off logic Surface Mount (Tape and Reel, -SR Suffix) Over current/Over temperature/Over voltage protections (auto-restart) Shorter lead trim 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 91% for 3.3V/15A. These open frame modules are available either in surface-mount (-SR) or in through-hole (TH) 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-use equipment. All of the required procedures of end-use equipment should be followed ** ISO is a registered trademark of the International Organization of Standards Document No: DS04-045 ver. 1.05 PDF name: kw010-015-020-025_ds.pdf Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A 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 Input Voltage Continuous Transient (100 ms) Operating Ambient Temperature (see Thermal Considerations section) Storage Temperature I/O Isolation voltage (100% Factory Hi-Pot tested) All All Tstg -55 125 1500 C Vdc All All All VIN VIN,trans TA -0.3 -0.3 -40 80 100 85 Vdc Vdc C Device Symbol Min Max Unit 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 (VIN = VIN, nom, module disabled) Inrush Transient Input Reflected Ripple Current, peak-to-peak (5Hz to 20MHz, 1H source impedance; VIN, min to VIN, max, IO= IOmax ; See Test configuration section) Input Ripple Rejection (120Hz) EMC, EN55022 All It 2 Device All All All Symbol VIN IIN,max IIN,No load Min 36 Typ 48 1.7 55 Max 75 2.0 Unit Vdc Adc mA All IIN,stand-by 5 7 mA 0.1 As 2 All 30 mAp-p All 50 60 100 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 March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Electrical Specifications (continued) Parameter Output Voltage Set-point (VIN=VIN, min, IO=IO, max, TA=25C) Device A F G Y M P 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) 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) RMS (5Hz to 20MHz bandwidth) Peak-to-Peak (5Hz to 20MHz bandwidth) External Capacitance Rated Output Current A, F, G, Y M, P All A F G Y M P Output Current Limit Inception (Hiccup Mode ) (VO= 90% of VO, set) Output Short-Circuit Current (VO250mV) ( Hiccup Mode ) All All CO, max IO, Rated IO, Rated IO, Rated IO, Rated IO, Rated IO, Rated IO, lim IO, s/c 0 0 0 0 0 0 0 115 25 75 33 100 120 3 10,000 10 15 20 25 25 25 125 mVrms mVpk-pk mVrms mVpk-pk F Adc Adc Adc Adc Adc Adc %IO, Rated Arms A, F, G Y, M, P A, F, G Y, M, P All 0.1 2 0.1 2 1.0 % VO, set mV % VO, set mV % VO, set All VO,adj -20.0 +10.0 % VO, set All Symbol VO, set VO, set VO, set VO, set VO, set VO, set VO Min 4.93 3.25 2.46 1.77 1.48 1.18 -3.0 Typ 5.0 3.3 2.5 1.8 1.5 1.2 Max 5.08 3.35 2.54 1.83 1.53 1.22 +3.0 Unit Vdc Vdc Vdc Vdc Vdc Vdc % VO, set LINEAGE POWER 3 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Electrical Specifications (continued) Parameter Efficiency VIN= VIN, nom, TA=25C IO=IO, max , VO= VO,set Device A F G Y M P Switching Frequency Dynamic Load Response (dIo/dt=0.1A/s; VIN = VIN, nom; TA=25C) Load Change from Io= 50% to 75% or 25% to 50% of Io,max; Peak Deviation Settling Time (Vo<10% peak deviation) (dIo/dt=1A/s; VIN = VIN, nom; TA=25C) Load Change from Io= 50% to 75% or 25% to 50% of Io,max; Peak Deviation Settling Time (Vo<10% peak deviation) All All Vpk ts 2 200 % VO, set s All Symbol fsw 190 Min Typ 92.0 91.0 89.0 87.0 85.0 84.0 200 235 Max Unit % % % % % % kHz All All Vpk ts 5 200 % VO, set s Isolation Specifications Parameter Isolation Capacitance Isolation Resistance I/O Isolation Voltage Device All All All Symbol Ciso Riso All Min 10 Typ 1000 Max 1500 Unit pF M Vdc General Specifications Parameter Calculated Reliability Based upon Telcordia SR-332 Issue 2: Method I, Case 3, (IO=80%IO, max, TA=40C, Airflow = 200 lfm), 90% confidence MTBF FIT Device F F All All Min Typ 2,864,101 349 90 11.3 (0.4) Max Unit Hours 10 /Hours Minutes g (oz.) 9 Powered Random Vibration (VIN=VIN, min, IO=IO, max, TA=25C, 0 to 5000Hz, 10Grms) Weight LINEAGE POWER 4 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions for additional information. Parameter 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 Logic Low - On/Off Voltage Logic High Voltage - (Typ = Open Collector) Logic High maximum allowable leakage current Turn-On Delay and Rise Times (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) 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). Output voltage Rise time (time for Vo to rise from 10% of Vo,set to 90% of Vo, set) Output voltage Rise time (time for Vo to rise from 10% of Vo,set to 90% of Vo, set with max ext capacitance) Output voltage overshoot - Startup IO= IO, max; VIN=VIN, min to VIN, max, TA = 25 C Remote Sense Range Output Overvoltage Protection A, F, G Y, M, P A F G Y M P Input Undervoltage Lockout Turn-on Threshold Turn-off Threshold Hysterisis All All All Vuv/on Vuv/off Vhyst 32 2 35 33 36 Vdc Vdc Vdc VO, limit VO, limit VO, limit VO, limit VO, limit VO, limit 6.1 4.0 3.1 2.3 2.3 2.0 +10 0.25 7.0 4.6 3.7 3.2 3.2 2.8 % VO, set Vdc Vdc Vdc Vdc Vdc Vdc Vdc o o Device Symbol Min Typ Max Unit All All All All Ion/off Von/off Von/off Ion/off -0.7 1.0 1.2 5 mA V V A 10 All Tdelay 15 20 msec All Tdelay 4 10 msec All All Trise Trise 8 8 12 12 3 msec msec % VO, set LINEAGE POWER 5 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Characteristic Curves The following figures provide typical characteristics for the KW010A0A (5V, 10A) at 25oC. The figures are identical for either positive or negative remote On/Off logic. 95 Vin =36V 12 2.0 m/s (400 lfm) 10 85 Vin =48V 80 Vin =75V OUTPUT CURRENT, Io (A) 90 EFFICIENCY, (%) 8 NC 0.5 m/s (100 lfm) 1.0 m/s (200 lfm) 75 6 70 0 2 4 6 8 10 4 20 30 40 50 60 70 O 80 90 OUTPUT CURRENT, IO (A) AMBIENT TEMPERATURE, TA C Figure 1. Converter Efficiency versus Output Current. Figure 4. Derating Output Current versus Local Ambient Temperature and Airflow. On/Off VOLTAGE OUTPUT VOLTAGE VOn/off (V) (2V/div) VO (V) (2V/div) OUTPUT VOLTAGE VO (V) (20mV/div) TIME, t (1s/div) TIME, t (5ms/div) Figure 2. Typical output ripple and noise (VIN = VIN,NOM, Io = Io,max). Figure 5. Typical Start-up Using Remote On/Off, negative logic version shown (VIN = VIN,NOM, Io = Io,max). OUTPUT VOLTAGE VO (V) (20mV/div) INPUT VOLTAGE OUTPUT VOLTAGE OUTPUT CURRENT, Io (A) (5A/div) TIME, t (100 s /div) VO (V) (2V/div) VIN (V) (2V/div) TIME, t (5ms/div) Figure 3. Transient Response to Dynamic Load Change from 75% to 50% to 75% of full load. Figure 6. Typical Start-up Using Input Voltage (VIN = VIN,NOM, Io = Io,max). LINEAGE POWER 6 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Characteristic Curves The following figures provide typical characteristics for the KW015A0F (3.3V, 15A) at 25oC. The figures are identical for either positive or negative remote On/Off logic. 93 90 18 EFFICIENCY, (%) 87 84 81 78 75 72 0 3 6 9 12 15 OUTPUT CURRENT, Io (A) 15 2.0 m/s (400 lfm) 12 NC 0.5 m/s (100 lfm) 1.0 m/s (200 lfm) 9 VIN = 36V VIN = 48V VIN = 75V 6 3 20 30 40 50 60 70 O 80 90 OUTPUT CURRENT, IO (A) AMBIENT TEMPERATURE, TA C Figure 7. Converter Efficiency versus Output Current. Figure 10. Derating Output Current versus Local Ambient Temperature and Airflow. On/Off VOLTAGE OUTPUT VOLTAGE VOn/off (V) (5V/div) VO (V) (1V/div) OUTPUT VOLTAGE VO (V) (10mV/div) TIME, t (1s/div) TIME, t (5ms/div) Figure 8. Typical output ripple and noise (VIN = VIN,NOM, Io = Io,max). Figure 11. Typical Start-up Using Remote On/Off, negative logic version shown (VIN = VIN,NOM, Io = Io,max). OUTPUT CURRENT, OUTPUT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE VO (V) (50mV/div) Io(A) (5A/div) TIME, t (1ms/div) VO (V) (1V/div) VIN (V) (50V/div) TIME, t (5ms/div) Figure 9. Transient Response to Dynamic Load Change from 50% to 75% to 50% of full load. Figure 12. Typical Start-up Using Input Voltage (VIN = VIN,NOM, Io = Io,max). LINEAGE POWER 7 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Characteristic Curves (continued) The following figures provide typical characteristics for the KW020A0G (2.5V, 20A) at 25oC. The figures are identical for either positive or negative remote On/Off logic. 93 Vin = 36V 90 25.0 OUTPUT CURRENT, Io (A) EFFICIENCY, (%) 87 84 81 78 75 72 0 4 8 12 16 20 Vin = 48V Vin = 75V 20.0 2.0 m/s (400 lfm) 15.0 NC 10.0 0.5 m/s (100 lfm) 1.0 m/s (200 lfm) 5.0 0.0 20 30 40 50 60 70 OUTPUT CURRENT, IO (A) AMBIENT TEMPERATURE, TA C O 80 90 Figure 13. Converter Efficiency versus Output Current. Figure 16. Derating Output Current versus Local Ambient Temperature and Airflow. On/Off VOLTAGE OUTPUT VOLTAGE VOn/off (V) (2V/div) VO (V) (1V/div) OUTPUT VOLTAGE VO (V) (20mV/div) TIME, t (1s/div) TIME, t (5ms/div) Figure 14. Typical output ripple and noise (VIN = VIN,NOM, Io = Io,max). OUTPUT VOLTAGE Figure 17. Typical Start-up Using Remote On/Off, negative logic version shown (VIN = VIN,NOM, Io = Io,max). OUTPUT CURRENT TIME, t (1ms/div) OUTPUT VOLTAGE VO (V) (1V/div) Io(A) (5A/div) INPUT VOLTAGE VIN (V) (20V/div) VO (V) (50mV/div) TIME, t (5ms/div) Figure 15. Transient Response to Dynamic Load Change from 50% to 75% to 50% of full load. Figure 18. Typical Start-up Using Input Voltage (VIN = VIN,NOM, Io = Io,max). LINEAGE POWER 8 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Characteristic Curves (continued) The following figures provide typical characteristics for the KW025A0Y (1.8V, 25A) at 25oC. The figures are identical for either positive or negative remote On/Off logic. 93 90 30 2.0 m/s (400 lfm) 25 EFFICIENCY, (%) 87 84 81 OUTPUT CURRENT, Io (A) 20 VIN = 36V 78 75 72 0 5 10 15 20 25 NC 0.5 m/s (100 lfm) VIN = 48V VIN = 75V 15 1.0 m/s (200 lfm) 10 20 30 40 50 60 70 O 80 90 OUTPUT CURRENT, IO (A) AMBIENT TEMPERATURE, TA C Figure 19. Converter Efficiency versus Output Current. Figure 22. Derating Output Current versus Local Ambient Temperature and Airflow. On/Off VOLTAGE OUTPUT VOLTAGE VOn/off (V) (5V/div) VO (V) (0.5V/div) OUTPUT VOLTAGE VO (V) (100mV/div) TIME, t (1s/div) TIME, t (5ms/div) Figure 20. Typical output ripple and noise (VIN = VIN,NOM, Io = Io,max). Figure 23. Typical Start-up Using Remote On/Off, negative logic version shown (VIN = VIN,NOM, Io = Io,max). OUTPUT CURRENT, OUTPUT VOLTAGE VO (V) (20mV/div) INPUT VOLTAGE OUTPUT VOLTAGE TIME, t (1ms/div) VO (V) (0.5V/div) Io (A) (10A/div) VIN (V) (50V/div) TIME, t (5ms/div) Figure 21. Transient Response to Dynamic Load Change from 50% to 75% to 50% of full load. Figure 24. Typical Start-up Using Input Voltage (VIN = VIN,NOM, Io = Io,max). LINEAGE POWER 9 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Characteristic Curves (continued) The following figures provide typical characteristics for the KW025A0M (1.5V, 25A) at 25oC. The figures are identical for either positive or negative remote On/Off logic. 90 88 86 84 82 80 78 76 74 0 5 10 15 20 25 Vin = 48V Vin = 75V 30 Vin = 36V OUTPUT CURRENT, Io (A) 2.0 m/s (400 lfm) 25 NC 20 0.5 m/s (100 lfm) 1.0 m/s (200 lfm) EFFICIENCY, (%) 15 10 20 30 40 50 60 70 O 80 90 OUTPUT CURRENT, IO (A) AMBIENT TEMPERATURE, TA C Figure 25. Converter Efficiency versus Output Current. Figure 28. Derating Output Current versus Local Ambient Temperature and Airflow. VOn/off (V) (2.5V/div) VO (V) (500mV/div) On/Off VOLTAGE OUTPUT VOLTAGE OUTPUT VOLTAGE VO (V) (50mV/div) TIME, t (1s/div) TIME, t (4ms/div) Figure 26. Typical output ripple and noise (VIN = VIN,NOM, Io = Io,max). OUTPUT VOLTAGE Figure 29. Typical Start-up Using Remote On/Off, negative logic version shown (VIN = VIN,NOM, Io = Io,max). INPUT VOLTAGE VIN (V) (20V/div) OUTPUT CURRENT VO (V) (50mV/div) TIME, t (500us/div) OUTPUT VOLTAGE VO (V) (500mV/div) Io(A) (10A/div) TIME, t (5ms/div) Figure 27. Transient Response to Dynamic Load Change from 50% to 75% to 50% of full load. Figure 30. Typical Start-up Using Input Voltage (VIN = VIN,NOM, Io = Io,max). LINEAGE POWER 10 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Characteristic Curves (continued) The following figures provide typical characteristics for the KW025A0P (1.2V, 25A) at 25oC. The figures are identical for either positive or negative remote On/Off logic. 90 88 30 Vin = 36V EFFICIENCY, (%) 86 84 82 80 78 76 74 0 5 10 15 20 25 Vin = 75V Vin = 48V OUTPUT CURRENT, Io (A) 2.0 m/s (400 lfm) 25 20 NC 0.5 m/s (100 lfm) 15 1.0 m/s (200 lfm) 10 20 30 40 50 60 70 O 80 90 OUTPUT CURRENT, IO (A) AMBIENT TEMPERATURE, TA C Figure 31. Converter Efficiency versus Output Current. Figure 34. Derating Output Current versus Local Ambient Temperature and Airflow. On/Off VOLTAGE OUTPUT VOLTAGE VOn/off (V) (5V/div) VO (V) (0.25V/div) OUTPUT VOLTAGE VO (V) (50mV/div) TIME, t (1s/div) TIME, t (5ms/div) Figure 32. Typical output ripple and noise (VIN = VIN,NOM, Io = Io,max). Figure 35. Typical Start-up Using Remote On/Off, negative logic version shown (VIN = VIN,NOM, Io = Io,max). VO (V) (50mV/div) INPUT VOLTAGE OUTPUT VOLTAGE OUTPUT CURRENT VOLTAGE TIME, t (1ms/div) VO (V) (0.5V/div) Io (A) (10A/div) VIN (V) (20V/div) OUTPUT TIME, t (5ms/div) Figure 33. Transient Response to Dynamic Load Change from 75% to 50% to 75% of full load. Figure 36. Typical Start-up Using Input Voltage (VIN = VIN,NOM, Io = Io,max). LINEAGE POWER 11 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Test Configurations TO OSCILLOSCOPE LTEST Vin+ 12H CURRENT PROBE Design Considerations Input Filtering 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 37, a 33F electrolytic capacitor (ESR<0.1 at 100kHz), mounted close to the power module helps ensure the stability of the unit. Consult the factory for further application guidelines. BATTERY CS 220F 33F E.S.R.<0.1 @ 20C 100kHz Vin- Safety Considerations 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. 6095000, 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. The input to these units is to be provided with a maximum 5 A time-delay fuse in the ungrounded lead. NOTE: Measure input reflected ripple current with a simulated source inductance (LTEST) of 12H. Capacitor CS offsets possible battery impedance. Measure current as shown above. Figure 37. Input Reflected Ripple Current Test Setup. COPPER STRIP VO (+) SCOPE V O (-) 0.1uF RESISTIVE LOAD 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 38. Output Ripple and Noise Test Setup. Rdistribution Rcontact Vin+ Vout+ Rcontact Rdistribution VIN VO RLOAD Rdistribution Rcontact VinVout- Rcontact Rdistribution 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 39. Output Voltage and Efficiency Test Setup. VO. IO Efficiency = VIN. IIN x 100 % LINEAGE POWER 12 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A 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. Vin+ 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). SENSE(+) SENSE(-) Vout+ VI(+) SUPPL Y II VI(-) VO(+) VO(-) IO LOAD Ion/off ON/OFF CONTACT RESISTANCE CONTACT AND DISTRIBUTION LOSSES TRIM Von/off Figure 41. Circuit Configuration for remote sense . Input Undervoltage Lockout Vin- Vout- Figure 40. 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 40). 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. 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 1A. 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(-). 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 43), 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. Remote Sense Remote sense minimizes the effects of distribution losses by regulating the voltage at the remote-sense connections (See Figure 41). 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 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 LINEAGE POWER 13 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current 511 Rtrim - down = - 10.22 8 R trim - down = 53 . 655 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 %: For output voltage: 1.5V to 12V Feature Descriptions (continued) 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 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. 5.11 x Vo , set x (100 + %) 511 Rtrim - up = - - 10 .22 1.225 x % % For output voltage: 1.2V 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 VOTRIM Rtrim-down VIN(-) VO(-) LOAD 5.11 x Vo, set x (100 + %) 511 - - 10.22 Rtrim - up = 0. 6 x % % Where V - V o , set % = desired V o , set x 100 For example, to trim-up the output voltage of 1.2V module (KW025A0P/P1) by 5% to 1.26V, Rtrim-up is calculated is as follows: % = 5 R trim - up 5 .11 x 1 . 2 x (100 + 5 ) 511 = - - 10 .22 0 .6 x 5 5 Rtrim - up = 102 .2 Alternative voltage programming for output voltage: 1.2V (-V Option) An alternative set of trimming equations is available as an option for 1.2V output modules, by ordering the -V option. These equations will reduce the resistance of the external programming resistor, making the impedance into the module trim pin lower for applications in high electrical noise applications. R trim - down Figure 42. 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 % For output voltage: 1.2V to 12V 511 R trim - down = - 10 . 22 % 100 = - 2 % 100 = % R trim - up Where V - V o , set % = desired V o , set x 100 Where % = V o , set - V desired V o , set x 100 For example, to trim-up the output voltage of 1.2V module (KW025A0P/P1-V) by 5% to 1.26V, Rtrim-up is calculated is as follows: % = 5 R trim - up For example, to trim-down the output voltage of 2.5V module (KW020A0G/G1) by 8% to 2.3V, Rtrim-down is calculated as follows: 100 = 5 Rtrim - up = 20 .0 % = 8 The value of the external trim resistor for the optional -V 1.2V module is only 20% of the value required with the standard trim equations. LINEAGE POWER 14 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Feature Descriptions (continued) 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). EMC Considerations The KW series modules are designed to meet the conducted emission limits of EN55022 class A with no filter at the input of the module. The module shall also meet limits of EN55022 Class B with a recommended single stage filter. Please contact your Lineage Power Sales Representitive for further information. Level [dBV] 80 70 60 50 40 30 20 10 0 150k 300k 500k 1M 2M Frequency [Hz] 3M 5M 7M 10M 30M MES CE0921041009_pre PK LIM EN 55022A V QP Voltage QP Limit 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 point, Tref used in the specifications is shown in Figure 43. For reliable operation this temperature should not exceed 120oC. Figure 44. KW015A0F Quasi Peak Conducted Emissions with EN 55022 Class A limits, no external filter (VIN = VIN,NOM, Io = 0.85 Io,max). Level [dBV] 80 70 60 50 40 30 20 10 0 + 150k 300k 500k 1M 2M Frequency [Hz] 3M 5M 7M 10M 30M + MES CE0921041009_fin AV MES CE0921041009_pre AV LIM EN 55022A V AV Voltage AV Limit Figure 45. KW015A0F Average Conducted Emissions with EN 55022 Class A limits, no external filter (VIN = VIN,NOM, Io = 0.85 Io,max). Figure 43. Tref Temperature Measurement Locations. 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. LINEAGE POWER 15 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current 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 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. Surface Mount Information Pick and Place The KW010-025 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 46. 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 o withstand reflow temperatures of up to 300 C. The label also carries product information such as product code, serial number and the location of manufacture. 300 P eak Temp 235oC 250 REFLOW TEMP (C) 200 Heat zo ne max 4oCs -1 Co o ling zo ne 1 oCs -1 -4 150 100 So ak zo ne 30-240s P reheat zo ne max 4oCs -1 Tlim above 205oC 50 Figure 46. Pick and Place Location. 0 Nozzle Recommendations 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. REFLOW TIME (S) Figure 47. Reflow Profile for Tin/Lead (Sn/Pb) process 240 235 MAX TEMP SOLDER (C) 230 225 220 215 210 205 200 0 10 20 30 40 50 60 Tin Lead Soldering The KW010-025 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 KW010-025 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 Figure 48. Time Limit Curve Above 205oC for Tin/Lead (Sn/Pb) process LINEAGE POWER 16 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Surface Mount Information (continued) Lead Free Soldering The -Z version of the KW010-025 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 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. 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 260C 250 Cooling Zone Reflow Temp (C) 200 * Min. Time Above 235C 15 Seconds Heating Zone 1C/Second *Time Above 217C 60 Seconds 150 100 50 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 Fig. 49. 0 Reflow Time (Seconds) Figure 49. 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 an 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. MSL Rating The KW010-025 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 at conditions of 30C 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 LINEAGE POWER 17 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A 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 18 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current 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 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 19 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Recommended Pad Layout Dimensions are in and millimeters [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 20 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A 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 21 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Ordering Information Please contact your Lineage Power Sales Representative for pricing, availability and optional features. Table 1. Device Code Product Codes KW010A0A41-SR KW010A0A41 KW015A0F41-SR KW015A0F41 KW025A0Y1-SR KW025A0Y41 KW025A0M41-SR KW010A0A41-SRZ KW010A0A41Z KW010A0A841Z KW015A0F41-SRZ KW015A0F41Z KW015A0F641Z KW020A0G1-SRZ KW020A0G4-SRZ KW020A0G41-SRZ KW020A0G41Z KW020A0G641Z KW025A0Y41-SRZ KW025A0Y41Z KW025A0Y641Z KW025A0M41Z KW025A0P41-SRZ KW025A0P41Z Input Voltage 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) Output Voltage 5.0V 5.0V 3.3V 3.3V 1.8V 1.8V 1.5V 5.0V 5.0V 5.0V 3.3V 3.3V 3.3V 2.5V 2.5V 2.5V 2.5V 2.5V 1.8V 1.8V 1.8V 1.5V 1.2V 1.2V Output Current 10A 10A 15A 15A 25A 25A 25A 10A 10A 10A 15A 15A 15A 20A 20A 20A 20A 20A 25A 25A 25A 25A 25A 25A On/Off Logic Negative Negative Negative Negative Negative Negative Negative Negative Negative Negative Negative Negative Negative Negative Positive Negative Negative Negative Negative Negative Negative Negative Negative Negative Connector Type Surface mount Through hole Surface mount Through hole Surface mount Through hole Surface mount Surface mount Through hole Through hole Surface mount Through hole Through hole Surface mount Surface mount Surface mount Through hole Through hole Surface mount Through hole Through hole Through hole Surface mount Through hole Comcode 108992434 108992582 108989934 108992590 108990578 108989942 108994736 CC109112042 CC109112050 CC109133146 CC109105888 CC109112067 CC109132172 CC109112075 CC109112653 CC109128212 CC109141710 CC109132164 CC109112091 CC109112100 CC109127445 CC109128492 CC109123964 CC109128385 -Z Indicated RoHS Compliant Modules LINEAGE POWER 22 Data Sheet March 26, 2008 KW010/015/020/025 Series Power Modules: 36 - 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Table 2. Device Options Option* Negative remote on/off logic Auto Re-start (for Over Current / Over voltage Protections) Pin Length: 3.68 mm 0.25 mm, (0.145 in. 0.010 in.) Pin Length: 2.79 mm 0.25 mm, (0.110 in. 0.010 in.) Surface mount connections (Tape & Reel) Alternative Voltage Programming equations (1.2V modules only) Suffix** 1 4 6 8 -SR -V * Legacy device codes may contain a -B option suffix to indicate 100% factory Hi-Pot tested to the isolation voltage specified in the Absolute Maximum Ratings table. The 100% Hi-Pot test is now applied to all device codes, with or without the -B option suffix. Existing comcodes for devices with the -B suffix are still valid; however, no new comcodes for devices containing the -B suffix will be created. Asia-Pacific Headquarters Tel: +65 6416 4283 Europe, Middle-East and Africa Headquarters Tel: +49 89 6089 286 India Headquarters Tel: +91 80 28411633 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: techsupport1@lineagepower.com 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. (c) 2008 Lineage Power Corporation, (Mesquite, Texas) All International Rights Reserved. Document No: DS04-045 ver. 1.05 PDF name: kw010-015-020-025_ds.pdf |
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