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ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
The ULE Series "Eighth-Brick" DC/DC Converters are high-current isolated power converters designed for use in high-density system boards.
Typical unit
FEATURES
RoHS compliant New 1/8-brick package, 1/4-brick pinout in through-hole or SMT version 0.89 x 2.22 x 0.36 in. (22.6 x 56.4 x 9.1mm) Output current: 1.25-30 Amps Output voltages: 1.2V to 48V Input voltage: 12V, 24V and 48V nominal Interleaved, synchronous-rectifier topology delivers: * Outstanding efficiency (to 94%) * Low noise * Stable no-load operation * No output reverse conduction Excellent thermal performance On/off control, trim and sense pins Fully isolated (2250Vdc BASIC) Fully I/O protected; Thermal shutdown Designed to meet UL/IEC/EN 60950-1 and CAN/CSA C22.2 No.60950-1 Lead-free construction/attach
PRODUCT OVERVIEW
Measuring just 0.89 x 2.22 x 0.36 inches (22.6 x 56.4 x 9.1mm), these open-frame, low-profile E-bricks fit the industry-standard quarter-brick footprint. Now you can "cut-and-paste" the layout from your last Q-brick design to save time and save 44% board space (1.86 square inches versus 3.3) in the process. From a 9-18V, 18-36V or 36-75V input, ULEs deliver 1.2 to 48 Volt outputs with current up to 30 Amps. They employ an interleaved, synchronous-rectifier topology that exploits 100% of their duty cycle. They simultaneously achieve high efficiency, low noise, tight line/load regulation, and quick step response. An open-frame design, high efficiency, low-onresistance FETs, and planar magnetics embedded in heavy-copper pc boards all contribute to impressive thermal derating. The ULEs feature set includes high isolation (2250Vdc, 48V models), input pi filters, input undervoltage shutdown, output overvoltage protection, current limiting, short-circuit protection, and thermal shutdown. The standard footprint carries VOUT trim, on/off control, and sense pins (sense pins are not available on 12V or higher models). All ULE E-Bricks are designed to meet the BASICinsulation requirements of UL/EN/IEC60950-1, and all "D48" models (36-75V input ranges) carry the CE mark. Safety certifications, EMC compliance testing and qualification testing are available.
NOTE: See pages 19 and 20 for simplified block diagrams.
For full details go to www.murata-ps.com/rohs
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MDC_ULE Series.C11 Page 1 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
PERFORMANCE SPECIFICATIONS AND ORDERING GUIDE Output VOUT (V)
1.2 1.5 1.5 1.8 1.8 2.5 2.5 3.3 3.3 3.3 5 5 5 12 12 24 48
Input Regulation (Max.)
Line 0.15% 0.15% 0.25% 0.25% 0.05% 0.05% 0.05% 0.05% 0.1% 0.05% 0.1% 0.1% 0.05% 0.05% 0.3% 0.175% Load 0.15% 0.15% 0.25% 0.25% 0.05% 0.1% 0.05% 0.05% 0.25% 0.05% 0.25% 0.25% 0.075% 0.075% 0.875% 3.2%
Efficiency
Model Family ULE-1.2/30-D48N-C ULE-1.5/20-D24P-C ULE-1.5/20-D48N-C ULE-1.8/20-D24P-C ULE-1.8/20-D48N-C ULE-2.5/20-D24P-C ULE-2.5/20-D48N-C ULE-3.3/20-D12P-C ULE-3.3/20-D24P-C ULE-3.3/20-D48N-C ULE-5/10-D12P-C ULE-5/12-D24P-C ULE-5/12-D48N-C ULE-12/4.2-D24P-C ULE-12/4.2-D48N-C ULE-24/3-D48N-C ULE-48/1.25-D48N-C
IOUT (A)
30 20 20 20 20 20 20 20 20 20 10 12 12 4.2 4.2 3 1.25
Power (W)
36 30 30 36 36 50 50 66 66 66 50 60 60 50.4 50.4 72 60
R/N (mVp-p)
Typ. 25 25 40 40 30 50 60 50 50 60 50 50 50 50 400 640 Max. 60 60 80 80 50 75 100 80 100 125 100 100 150 150 700 750
VIN Nom. Range (V) (V)
24 48 24 48 24 48 12 24 48 12 24 48 24 48 48 48 18-36 36-75 18-36 36-75 18-36 36-75 9-18 18-36 36-75 9-18 19-36 36-75 18-36 36-75 36-75 36-75
IIN no load (mA)
40 40 40 40 95 55 100 60 60 160 160 90 55 55 45 75
IIN full load (A)
1.42 0.74 1.74 0.87 2.35 1.17 6.15 3.09 1.54 4.63 2.78 1.38 2.31 1.14 1.63 1.35
Min. 86.0% 84.0% 84.5% 84.5% 87.0% 88.0% 88.9% 88.0% 87.0% 87.0% 88.0% 88.5% 89.5% 91.0% 90.8% 91.0%
Typ. 88.0% 84.5% 86.0% 86.5% 88.5% 89.0% 89.4% 89.0% 89.0% 90.0% 90.0% 90.5% 91.0% 92.0% 92.0% 92.5%
Package (Case, Pinout)
C56, C52, P32 C56, C52, P32 C56, C52, P32 C56, C52, P32 C56, C52, P32 C56, C52, P32 C56, C52, P32 C56, C52, P32 C56, C52, P32 C56, C52, P32 C56, C52, P32 C56, C52, P32 C56, C52, P32 C56, C52, P32 C56, C52, P32 C56, C52, P32 C56, P32
Please contact Murata Power Solutions for further information.
Please refer to the full model number structure for additional ordering part numbers and options. Preliminary specifications - please contact MPS for availability. All specifications are at nominal line voltage and full load, +25C unless otherwise noted. See detailed specifications.
If VIN = 19-20V, IOUT = 8A Max. Min. load = 10%. If VIN = 9-10V, IOUT = 18A Max.
PART NUMBER STRUCTURE
U LE - 1.2 / 30 - D48 N M Lx - C
Output Configuration: U = Unipolar/Single RoHS-6 hazardous substance compliant
Pin Length Option (Through-hole packages only) Eighth-Brick Package Nominal Output Voltage Surface Mount Package Maximum Rated Output Current in Amps Input Voltage Range: D12 = 12V nominal D24 = 24V nominal D48 = 48V nominal
20
Blank = standard length 0.180 inches (4.6mm) L1 Pin length 0.1100.010 inches (2.790.25mm)* L2 Pin length 0.1450.010 inches (3.680.25mm)* *Minimum order quantity required.
Note:
Some model number combinations may not be available. Contact Murata Power Solutions for further information.
Remote On/Off Control Polarity: P = Positive polarity (standard for D12 and D24 models, optional special order for D48 models) N = Negative polarity (standard for D48 models, optional special order for D12 and D24 models)
See notes on page 5.
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MDC_ULE Series.C11 Page 2 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
INPUT CHARACTERISTICS
Load Current Remote On/Off Control Under Reflected InterStart-up Voltage (back) Full Inrush nal Reverse Positive Negative threshold Shut- Ripple Load Transient Output Low Standby Input Polarity CurLogic Logic Min. down Current Condi- Conditions Short No Load Line Mode Filter Protec- rent "P" model "N" model (V) (V) (mA) tions (A2sec) Circuit (mA) (A) (mA) Type tion (mA) suffix suffix 34.0 17.0 34.0 17.0 33.0 17.0 33.0 8.5 17.0 34.5 8.5 19.0 34.5 17.0 35.0 35.0 35.0 33.0 16.0 33.0 16.0 31.0 16.0 32.0 15-45, See model Ordering 16.0 dependent Guide 33.5 8.0 17.5 33.5 16.0 34.0 33.0 33.5 8.0 1.20 1.96 0.98 2.33 1.16 3.23 1.55 40-250 40-160 7.42 1-8 model model model 4.10 depen- dependependent dent 2.05 dent 6.14 3.30 1.82 3.04 1.51 2.17 1.46 150 6-90 150 6-90 See Notes OFF=Ground pin OFF=open or 6-90, model to +0.8V max. +3.5V to dependent 1.0 ON=open or +13.5V max. 3.5V to +13.5V ON=Ground pin max. to +0.8V max. 6-90, model dependent Start-up Time VIN to VOUT Remote On/Off regulated to VOUT regu(Max.) lated (Max.) mSec mSec
Model Family ULE-1.2/30-D48 ULE-1.5/20-D24 ULE-1.5/20-D48 ULE-1.8/20-D24 ULE-1.8/20-D48 ULE-2.5/20-D24 ULE-2.5/20-D48 ULE-3.3/20-D12 ULE-3.3/20-D24 ULE-3.3/20-D48 ULE-5/10-D12 ULE-5/12-D24 ULE-5/12-D48 ULE-12/4.2-D24 ULE-12/4.2-D48 ULE-24/3-D48 ULE-48/1.25-D48
0.5-1
L-C
OUTPUT CHARACTERISTICS
Capacitive Loading Max. VOUT Accuracy Low ESR <0.02 Max. resistive load VOUT 50% Load (F) (V) % of VNOM 1.2 1.5 1.5 1.8 1.8 2.5 2.5 1 to 2 of VNOM, 3.3 model 3.3 dependent 3.3 5 5 5 12 12 24 48 2000 680 470 300 mA No Minimum none 10% none 10,000 -20 to +10% 0.02% of of VNOM, model VOUT range/C dependent No Minimum Load18 See Ordering Guide +10% Current Limit Inception 98% of VOUT after warmup (A) 34 24 24 24 25 24 24 24 24 26 13 15 16 6 6.25 4.25 2.5
Model Family ULE-1.2/30-D48 ULE-1.5/20-D24 ULE-1.5/20-D48 ULE-1.8/20-D24 ULE-1.8/20-D48 ULE-2.5/20-D24 ULE-2.5/20-D48 ULE-3.3/20-D12 ULE-3.3/20-D24 ULE-3.3/20-D48 ULE-5/10-D12 ULE-5/12-D24 ULE-5/12-D48 ULE-12/4.2-D24 ULE-12/4.2-D48 ULE-24/3-D48 ULE-48/1.25-D48
Adjustment Range
Temperature Coefficient
Minimum Loading
Ripple/Noise Remote Sense (20 MHz Line/Load Compensation bandwidth) Regulation
Efficiency
See notes on page 5.
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MDC_ULE Series.C11 Page 3 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
ISOLATION CHARACTERISTICS DYNAMIC CHARACTERISTICS
Model Family ULE-1.2/30-D48 ULE-1.5/20-D24 ULE-1.5/20-D48 ULE-1.8/20-D24 ULE-1.8/20-D48 ULE-2.5/20-D24 ULE-2.5/20-D48 ULE-3.3/20-D12 ULE-3.3/20-D24 ULE-3.3/20-D48 ULE-5/10-D12 ULE-5/12-D24 ULE-5/12-D48 ULE-12/4.2-D24 ULE-12/4.2-D48 ULE-24/3-D48 ULE-48/1.25-D48
Input to Output Min. (V)
Isolation Resistance (M)
Isolation Capacitance Isolation (pF) Safety Rating
Model Family ULE-1.2/30-D48 ULE-1.5/20-D24 ULE-1.5/20-D48 ULE-1.8/20-D24 ULE-1.8/20-D48
Dynamic Load Response (50-75-50% load step) 100Sec to 1% of final value 100Sec to 1.5% of final value 100Sec to 1.5% of final value 100Sec to 1.5% of final value 100Sec to 1.5% of final value 150Sec to 1% of final value 80Sec to 1.5% of final value 150Sec to 1.25% of final value 150Sec to 1.5% of final value 150Sec to 1% of final value 75Sec to 2% of final value 75Sec to 2% of final value 100Sec to 1% of final value 150Sec to 1.25% of final value 150Sec to 1.25% of final value 200Sec to 2% of final value 200Sec to 1% of final value
Switching Frequency KHz 26015 28015 28015 34015 34015 38515 38545 31015 38515 36515 32515 45015 45015 40015 38015 24030 25015
1750
ULE-2.5/20-D24 ULE-2.5/20-D48
20002250 min., model dependent
ULE-3.3/20-D12 100 Basic Insulation ULE-3.3/20-D24 ULE-3.3/20-D48 470 ULE-5/10-D12 ULE-5/12-D24 ULE-5/12-D48 1750 2000 1500 ULE-12/4.2-D24 ULE-12/4.2-D48 ULE-24/3-D48 ULE-48/1.25-D48
MISCELLANEOUS CHARACTERISTICS
Operating Temperature Range Calculated MTBF See derating curves Operating PCB Storage Temperature Temperature (no derating) Range Thermal Protection/ Shutdown Short Circuit Current 3A 3A 3A 3A 3A 3A 3A -40 to +105C -55 to +125C +105 to +125C, model dependent 300mA 3A 3A 5A 5A 2A 3A 3A 0.65A 500mA Overvoltage Protection12 via magnetic Short Circuit feedback Protection Short Circuit (V) Method Duration16 2.0 2.3 2.0 2.3 2.3 3.5 3.0 3.96 3.96 3.96 6.0 6.0 6.4 15.0 14.0 28.0 55.0 Current limiting, hiccup autorestart. Remove overload for recovery Continuous, output shorted to ground. No damage. To +85C/85% noncondensing
Model Family ULE-1.2/30-D48 ULE-1.5/20-D24 ULE-1.5/20-D48 ULE-1.8/20-D24 ULE-1.8/20-D48 ULE-2.5/20-D24 ULE-2.5/20-D48 ULE-3.3/20-D12 ULE-3.3/20-D24 ULE-3.3/20-D48 ULE-5/10-D12 ULE-5/12-D24 ULE-5/12-D48 ULE-12/4.2-D24 ULE-12/4.2-D48 ULE-24/3-D48* ULE-48/1.25-D48
Relative Humidity
TBC
-40 to +85C with derating
*No derating is required up to 85C. See notes on page 5.
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MDC_ULE Series.C11 Page 4 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
PERFORMANCE SPECIFICATION NOTES
1. All models are tested and specified with external 1||10 F ceramic/tantalum output capacitors and a 22 F external input capacitor. All capacitors are low ESR types. These capacitors are necessary to accommodate our test equipment and may not be required to achieve specified performance in your applications. All models are stable and regulate within spec under no-load conditions. General conditions for Specifications are +25 deg.C, VIN=nominal, VOUT=nominal, full load. Adequate airflow must be supplied for extended testing under power. 2. Input Ripple Current is tested and specified over a 5 Hz to 20 MHz bandwidth. Input filtering is CIN=33 F tantalum, CBUS=220 F electrolytic, LBUS=12 H. 3. Note that Maximum Power Derating curves indicate an average current at nominal input voltage. At higher temperatures and/or lower airflow, the DC/DC converter will tolerate brief full current outputs if the total RMS current over time does not exceed the Derating curve. All Derating curves are presented at sea level altitude. Be aware of reduced power dissipation with increasing density altitude. 4. Mean Time Before Failure is calculated using the Telcordia (Belcore) SR-332 Method 1, Case 3, ground fixed conditions, Tpcboard=+25C, full output load, natural air convection. 5. The On/Off Control is normally controlled by a switch. But it may also be driven with external logic or by applying appropriate external voltages which are referenced to Input Common. The On/Off Control Input should use either an open collector or open drain transistor. 6. Short circuit shutdown begins when the output voltage degrades approximately 2% from the selected setting. 7. The outputs are not intended to sink appreciable reverse current.. 8. Output noise may be further reduced by adding an external filter. See I/O Filtering and Noise Reduction. 9. All models are fully operational and meet published specifications, including "cold start" at -40C. 10. Regulation specifications describe the deviation as the line input voltage or output load current is varied from a nominal midpoint value to either extreme. 11. Alternate pin length and/or other output voltages are available under special quantity order. 12. Electronic overvoltage shutdown is not included on 48V input models to comply with certain telecom reliability requirements. These requirements attempt continued operation despite input overvoltage. The converter is rated only to the maximum input voltage. 13. Do not exceed maximum power specifications when adjusting the output trim. 14. At zero output current, the output may contain low frequency components which exceed the ripple specification. The output may be operated indefinitely with no load. 15. If reverse polarity is accidentally applied to the input, a body diode will become forward biased and will conduct considerable current. To ensure reverse input protection with full output load, always connect an external input fuse in series with the +VIN input. Use approximately twice the full input current rating with nominal input voltage. 16. Output current limit is non-latching. When the overcurrent fault is removed, the converter will immediately recover. 17. The Sense inputs are not included on 12V, 24V & 48V input models. 18. ULE-12/4.2-D24 minimum load is 0.42 Amps (10%) for rated specifications. 19. ULE-5/12-D24 IOUT=8A max. if VIN=19-20V. 20. ULE-12/4.2-D48 has no surface mount option. 21. Full load conditions, see ordering guide.
PHYSICAL CHARACTERISTICS AND SAFETY
Outline dimensions Pin material Pin diameter Pin finish Weight Electromagnetic interference (conducted and radiated) (external filter required) Safety See mechanical specs (below) Copper alloy 0.04/0.062" (1.016/1.524mm) Nickel underplate with gold overplate 1 ounce (28 grams) Designed to meet FCC part 15, class B, EN55022 Designed to meet UL/cUL 60950-1, CSA-C22.2 No. 60950-1, IEC/EN 60950-1
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MDC_ULE Series.C11 Page 5 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
MECHANICAL SPECIFICATIONS Through-hole Pin Changes for 2008 In 2008, for through-hole models only, MPS will gradually phase over to a different extruded 0.040" (1.02 mm) diameter pin design and elimination of the spacer standoffs on most models. This will have no effect on installation, interchangeability, electrical or mechanical specifications. Any machined 0.062" (1.57 mm) diameter pin will transition to a straight wire 0.062" pin. The new 0.040" pins will insert properly to existing host PC boards and include an integral pin shoulder to form the mounting plane (Figure 1). There is no model number change, only a slightly changed appearance. Use the drawings and table below to identify the new pin design. Older drawings are retained in this data sheet for archival reference. And, surface mount ULEs are not affected. All new production models are RoHS-6 compliant and always use the -C model number suffix. Older non-RoHS models are also being changed over to the new extruded pins; however non-RoHS models are not listed in this table.
0.040 (1.02) dia. pin Pin shoulder, 0.072 0.002 dia. (1.83 0.05) ULE Converter Seating plane
Extruded 0.040-inch Pin Configurations RoHS Models (-C) ULE-1.2/30-D48 ULE-1.5/20-D24P ULE-1.5/20-D48 ULE-1.8/20-D24 ULE-1.8/20-D48 ULE-2.5/20-D24 ULE-2.5/20-D48 ULE-3.3/20-D12 ULE-3.3/20-D24 ULE-3.3/20-D48N ULE-3.3/20-D48P ULE-5/10-D12 ULE-5/12-D24 ULE-5/12-D48 ULE-12/4.2-D24 ULE-12/4.2-D48 ULE-24/3-D48N ULE-48/1.25-D48 0.040" Pin depth* 0.25 (6.4) 0.25 (6.4) 0.25 (6.4) 0.25 (6.4) 0.25 (6.4) 0.19 (4.8) 0.19 (4.8) 0.19 (4.8) 0.25 (6.4) 0.25 (6.4) 0.19 (4.8) 0.19 (4.8) 0.19 (4.8) 0.25 (6.4) 0.25 (6.4) 0.25 (6.4) 0.25 (6.4) 0.25 (6.4)
Keep-out area Pin depth, see table
Dimensions are in inches (mm)
User's host PC Board
Drawing not to scale
*The "0.040-inch pin depth" is the distance between the mounting plane of the ULE converter (at the pin shoulder) and the inserted tip of the pin. Therefore it is the length of pin which the host receiving PC board must accept. The ULE mounting plane interfaces to the top mounting surface (seating plane) of the user's PC board. The ULE mounting plane is established either by an integral pin shoulder (new) or a plastic standoff (older) but not both. Users should avoid placing components immediately below the converter. **Dimensions in inches (mm)
Figure 1. Extruded 0.040-inch Pin
The "integral" pin shoulder is formed as part of the extruded pin fabrication and replaces the plastic standoff spacer. The shoulder diameter is 0.072 +/-0.002" and forms the mounting plane of the converter. The user should provide sufficient clearance for a 0.040" pin hole but well below the 0.072" shoulder diameter. This mounting plane avoids mechanical stress placed on the converter components. Do not place the components below the converter. PIN STRUCTURE DIMENSIONS (NO LONGER USED)
ULE-12/4.2-D48 ULE-5/12-D48 (machined pins only) Printed Circuit Board O 0.06 0.002 (1.6 0.05)
The pin finish for all models remains as gold plate over nickel underplate. The pin material is a copper alloy. The pin finish is suitable for both leaded and lead-free solders.
0.26 0.02 (6.6 0.5)
O 0.08 0.002 (2.1 0.05) 0.19 0.005 (4.8 0.1)
O 0.04 0.001 (1 0.03) Standard Pins (6)
Dimensions are in inches (mm)
O 0.06 0.001 (1.5 0.03) VOUT Pins (2)
Drawing not to scale
This is an older pin design. This drawing is retained for archival purposes only. Please refer to the Pin Change discussion.
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MDC_ULE Series.C11 Page 6 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
MECHANICAL SPECIFICATIONS (continued)
ULE Mechanical Dimensions
Input/Output Connections
Model Family ULE-1.2/30-D48 ULE-1.5/20-D24 ULE-1.5/20-D24M ULE-1.5/20-D48 ULE-1.5/20-D48M ULE-1.8/20-D24 ULE-1.8/20-D24M ULE-1.8/20-D48 ULE-1.8/20-D48M ULE-2.5/20-D24, -D48 ULE-2.5/20-D24M ULE-3.3/20-D12, -D48 ULE-3.3/20-D12M ULE-3.3/20-D24
Height (Max.)* 0.365 (9.27) 0.404 (10.26) 0.404 (10.26) 0.381 (9.68) 0.404 (10.26) 0.404 (10.26) 0.404 (10.26) 0.381 (9.68) 0.404 (10.26) 0.409 (10.39) 0.404 (10.26) 0.409 (10.39) 0.404 (10.26) 0.381 (9.68)
Model Family ULE-3.3/20-D24M ULE-3.3/20-D48M ULE-5/10-D12 ULE-5/10-D12M ULE-5/12-D24 ULE-5/12-D24M ULE-5/12-D48 ULE-5/12-D48M ULE-12/4.2-D24, -D48 ULE-12/4.2-D24M ULE-24/3-D48 ULE-48/1.25-D48 ULE-48/1.25-D48M ULE-68/1.5-D48
Height (Max.)* 0.404 (10.26) 0.404 (10.26) 0.405 (10.29) 0.400 (10.16) 0.405 (10.29) 0.400 (10.16) 0.377 (9.58) 0.400 (10.16) 0.377 (9.58) 0.400 (10.16) 0.425 (10.8) 0.448 (11.38) 0.446 (11.33) 0.377 (9.58)
Pin 1 2 3 4 5 6 7 8
Function P32 -Input On/Off Control* +Input -Output -Sense** Output Trim +Sense** +Output
* The Remote On/Off can be provided with either positive (P suffix) or negative (N suffix) polarity. ** 12V or greater models do not include sense inputs.
*Dimensions are in inches (mm). Please refer to pg. 2 for complete model numbers.
Case C56 Through-Hole Package
See table 2.30 (58.4) A See table
Case C52 Surface-Mount Package
2.30 (58.4)
0.210 0.015 (5.3 0.4)
PINS 1-3, 5-7: 0.040 0.001 (1.016 0.025) PINS 4, 8: 0.062 0.001 (1.575 0.025) (for nylon spacer models) 2.00 (50.80)
0.025 (0.6) (Nylon Spacers)
COPPER SMT LEADS COPLANAR TO 0.004
A B A
0.125 TYP. (3.2)
A
4 5 0.90 (22.9) 6 7 8 0.600 (15.2) 4 EQ. SP. @ 0.150 (3.8)
Third Angle Projection
B
B
1 1 0.600 (15.2) 4 5 2 6 7 3 8 0.300 (7.6) 0.600 (15.2) 4 EQ. SP. @ 0.150 (3.8) 0.110 TYP. (2.8) 0.90 (22.9) 3 BOTTOM VIEW 0.600 (15.2)
2
BOTTOM VIEW 0.300 (7.6)
Please refer to the Pin Change discussion on page 6.
Dimensions are in inches (mm shown for ref. only).
Tolerances (unless otherwise specified): .XX 0.02 (0.5) .XXX 0.010 (0.25) Angles 2 Components are shown for reference only.
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MDC_ULE Series.C11 Page 7 of 23
A
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
Absolute Maximum Ratings
Input Voltage: Continuous: 12 Volt input models 24 Volt input models 48 Volt input models Transient (100 mSec. Max.) 12 Volt input models 24 Volt input models 48 Volt input models On/Off Control (pin 2) Input Reverse Polarity Protection Output Overvoltage Protection Output Current * Storage Temperature Lead Temperature
18 Volts 36 Volts 75 Volts 25 Volts 50 Volts 100 Volts See specifications 5 Amps, 10 sec. max. Magnetic feedback. See note (7). Current-limited. Devices can with stand sustained short circuit without damage. -55 to +125C. Refer to solder profile.
Start-Up Time The VIN to VOUT Start-Up Time is the interval of time between the point at which the ramping input voltage crosses the Start-Up Threshold and the fully loaded output voltage enters and remains within its specified accuracy band. Actual measured times will vary with input source impedance, external input/output capacitance, and load. The ULE Series implements a soft start circuit that limits the duty cycle of its PWM controller at power up, thereby limiting the input inrush current. The On/Off Control to VOUT start-up time assumes the converter has its nominal input voltage applied but is turned off via the On/Off Control pin. The specification defines the interval between the point at which the converter is turned on and the fully loaded output voltage enters and remains within its specified accuracy band. Similar to the VIN to VOUT start-up, the On/Off Control to VOUT start-up time is also governed by the internal soft start circuitry and external load capacitance. The difference in start up time from VIN to VOUT and from On/Off Control to VOUT is therefore insignificant. Input Source Impedance ULE converters must be driven from a low ac-impedance input source. The DC/DC's performance and stability can be compromised by the use of highly inductive source impedances. The input circuit shown in Figure 2 is a practical solution that can be used to minimize the effects of inductance in the input traces. For optimum performance, components should be mounted close to the DC/DC converter. If the application has a high source impedance, low VIN models can benefit of increased external input capacitance. I/O Filtering, Input Ripple Current, and Output Noise All models in the ULE 24-60 Watt DC/DC Converters are tested/specified for input reflected ripple current and output noise using the specified external input/ output components/circuits and layout as shown in the following two figures. External input capacitors (CIN in Figure 2) serve primarily as energy-storage elements, minimizing line voltage variations caused by transient IR drops in conductors from backplane to the DC/DC. Input caps should be selected for bulk capacitance (at appropriate frequencies), low ESR, and high rms-ripple-current ratings. The switching nature of DC/DC converters requires that dc voltage sources have low ac impedance as highly inductive source impedance can affect system stability. In Figure 2, CBUS and LBUS simulate a typical dc voltage bus. Your specific system configuration may necessitate additional considerations.
TO OSCILLOSCOPE LBUS CBUS
-
These are stress ratings. Exposure of devices to greater than any of these conditions may adversely affect long-term reliability. Proper operation under conditions other than those listed in the Performance/Functional Specifications Table is not implied. * The outputs are not intended to sink appreciable current.
TECHNICAL NOTES
Input Fusing Certain applications and/or safety agencies may require the installation of fuses at the inputs of power conversion components. Fuses should also be used if the possibility of sustained, non-current-limited, input-voltage polarity reversals exist. For MPS ULE 24-60 Watt DC/DC Converters, you should use slow-blow type fuses, installed in the ungrounded input supply line, with values no greater than the following. Model 12 Volt Input 24 Volt input 48 Volt Input Fuse Values 10 Amps 5 Amps 4 Amps
All relevant national and international safety standards and regulations must be observed by the installer. For system safety agency approvals, the converters must be installed in compliance with the requirements of the end-use safety standard, e.g., IEC/EN/UL60950-1. Input Undervoltage Shutdown and Start-Up Threshold Under normal start-up conditions, devices will not begin to regulate until the ramping-up input voltage exceeds the Start-Up Threshold Voltage. Once operating, devices will not turn off until the input voltage drops below the Undervoltage Shutdown limit. Subsequent re-start will not occur until the input is brought back up to the Start-Up Threshold. This built in hysteresis prevents any unstable on/off situations from occurring at a single input voltage.
CURRENT PROBE
+INPUT
+
VIN
CIN
-INPUT CIN = 33F, ESR < 700m @ 100kHz CBUS = 220F, ESR < 100m @ 100kHz LBUS = 12H Figure 2. Measuring Input Ripple Current
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MDC_ULE Series.C11 Page 8 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
In critical applications, output ripple/noise (also referred to as periodic and random deviations or PARD) may be reduced below specified limits using filtering techniques, the simplest of which is the installation of additional external output capacitors. These output caps function as true filter elements and should be selected for bulk capacitance, low ESR and appropriate frequency response. All external capacitors should have appropriate voltage ratings and be located as close to the converter as possible. Temperature variations for all relevant parameters should also be taken carefully into consideration. The most effective combination of external I/O capacitors will be a function of line voltage and source impedance, as well as particular load and layout conditions. In Figure 3, the two copper strips simulate real-world pcb impedances between the power supply and its load. In order to minimize measurement errors, scope measurements should be made using BNC connectors, or the probe ground should be less than 1/2 inch and soldered directly to the fixture. rise above the designed operating temperature, a precision temperature sensor will power down the unit. When the internal temperature decreases below the threshold of the temperature sensor, the unit will self start. See Performance/ Functional Specifications. Output Overvoltage Protection ULE output voltages are monitored for an overvoltage condition via magnetic feedback. The signal is coupled to the primary side and if the output voltage rises to a level which could be damaging to the load, the sensing circuitry will power down the PWM controller causing the output voltages to decrease. Following a time-out period the PWM will restart, causing the output voltages to ramp to their appropriate values. If the fault condition persists, and the output voltages again climb to excessive levels, the overvoltage circuitry will initiate another shutdown cycle. This on/off cycling is referred to as "hiccup" mode. Contact MPS for an optional output overvoltage monitor circuit using a comparator which is optically coupled to the primary side thus allowing tighter and more precise control. Current Limiting As soon as the output current increases to 10% to 50% above its rated value, the DC/DC converter will go into a current-limiting mode. In this condition, the output voltage will decrease proportionately with increases in output current, thereby maintaining somewhat constant power dissipation. This is commonly referred to as power limiting. Current limit inception is defined as the point at which the full-power output voltage falls below the specified tolerance. See Performance/Functional Specifications. If the load current, being drawn from the converter, is significant enough, the unit will go into a short circuit condition as specified under "Performance." Short Circuit Condition When a converter is in current-limit mode, the output voltage will drop as the output current demand increases. If the output voltage drops too low, the magnetically coupled voltage used to develop primary side voltages will also drop, thereby shutting down the PWM controller. Following a time-out period, the PWM will restart causing the output voltages to begin ramping to their appropriate values. If the short-circuit condition persists, another shutdown cycle will be initiated. This on/off cycling is referred to as "hiccup" mode. The hiccup cycling reduces the average output current, thereby preventing internal temperatures from rising to excessive levels. The ULE is capable of enduring an indefinite short circuit output condition. Features and Options On/Off Control The input-side, remote On/Off Control function can be ordered to operate with either polarity: Standard models are equipped with Positive-polarity ("P" part-number suffix) and these devices are enabled when the On/Off Control is left open or is pulled high, as per Figure 4. Positive-polarity devices are disabled when the On/Off Control is pulled low.
+SENSE +OUTPUT
COPPER STRIP
C1
C2
SCOPE
RLOAD
-OUTPUT -SENSE COPPER STRIP
C1 = 0.47F CERAMIC C2 = NA LOAD 2-3 INCHES (51-76mm) FROM MODULE
Figure 3. Measuring Output Ripple/Noise (PARD)
Floating Outputs Since these are isolated DC/DC converters, their outputs are "floating" with respect to their input. Designers will normally use the -Output (pin 4) as the ground/return of the load circuit. You can, however, use the +Output (pin 8) as ground/return to effectively reverse the output polarity. Minimum Output Loading Requirements ULE converters employ a synchronous-rectifier design topology and all models regulate within spec and are stable under no-load to full load conditions. Operation under no-load conditions however might slightly increase the output ripple and noise. Thermal Shutdown These ULE converters are equipped with thermal-shutdown circuitry. If environmental conditions cause the internal temperature of the DC/DC converter to
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MDC_ULE Series.C11 Page 9 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
+ Vcc ON/OFF CONTROL CONTROL
ON/OFF CONTROL +SENSE 20k 5-20 TURNS -INPUT +OUTPUT
TRIM
LOAD
-SENSE
-INPUT
+INPUT
-OUTPUT
Figure 4. Driving the Positive Polarity On/Off Control Pin
Figure 6. Trim Connections Using A Trimpot
Optional Negative-polarity devices ("N" suffix) are off when the On/Off Control is open (or pulled high), and on when the On/Off Control is pulled low with respect to -VIN as shown in Figure 5.
-INPUT
+OUTPUT
+SENSE ON/OFF CONTROL
TRIM R1 -SENSE
LOAD
+INPUT
-OUTPUT
Figure 7. Trim Connections To Increase Output Voltages Using a Fixed Resistor
Figure 5. Driving the Negative Polarity On/Off Control Pin
-INPUT
+OUTPUT
Dynamic control of the remote on/off function is facilitated with a mechanical relay or an open-collector/open-drain drive circuit (optically isolated if appropriate). The drive circuit should be able to sink appropriate current (see Performance Specs) when activated and withstand appropriate voltage when deactivated. Applying an external voltage to the On/Off Control when no input power is applied to the converter can cause permanent damage to the converter. Trimming Output Voltage ULE converters have a trim capability that allows users to adjust the output voltages -15% to +10% of VOUT. Adjustments to the output voltages can be accomplished via a trim pot (Figure 6) or a single fixed resistor as shown in Figures 7 and 8. A single fixed resistor can increase or decrease the output voltage depending on its connection. The resistor should be located close to the converter and have a TCR less than 100ppm/C to minimize sensitivity to changes in temperature. If the trim function is not used, leave the trim pin floating.
+SENSE ON/OFF CONTROL
TRIM R2 -SENSE
LOAD
+INPUT
-OUTPUT
Figure 8. Trim Connections To Decrease Output Voltages
A single resistor connected from the Trim to the +Output, or +Sense where applicable, will increase the output voltage in this configuration. A resistor connected from the Trim to the -Output, or -Sense where applicable, will decrease the output voltage in this configuration. Trim adjustments greater than the specified 5% can have an adverse affect on the converter's performance and are not recommended. Excessive voltage differences between VOUT and Sense, in conjunction with trim adjustment of the output voltage, can cause the overvoltage protection circuitry to activate (see Performance Specifications for overvoltage limits). Power derating is based on maximum output current and voltage at the converter's output pins. Use of trim and sense functions can cause output voltages to increase, thereby increasing output power beyond the converter's specified rating or cause output voltages to climb into the output overvoltage region. Therefore: (VOUT at pins) x (IOUT) <= rated output power
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MDC_ULE Series.C11 Page 10 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
Trim Equations
Trim Up 3.3 Volt Output
RT UP (k) = 13.3(VO - 1.226) VO - 3.3 -10.2 RTDOWN (k) = 16.31 3.3 - VO -10.2
Trim Down
Remote Sense Note: The Sense and VOUT lines are internally connected through low value resistors. Nevertheless, if the sense function is not used for remote regulation the user should connect the +Sense to +VOUT and -Sense to -VOUT at the DC/DC converter pins. ULE series converters have a sense feature to provide point of use regulation, thereby overcoming moderate IR drops in pcb conductors or cabling. The remote sense lines carry very little current and therefore require minimal cross-sectional-area conductors. The sense lines are used by the feedback control-loop to regulate the output. As such, they are not low impedance points and must be treated with care in layouts and cabling. Sense lines on a pcb should be run adjacent to dc signals, preferably ground. In cables and discrete wiring applications, twisted pair or other techniques should be implemented. ULE series converters will compensate for drops between the output voltage at the DC/DC and the sense voltage at the DC/DC provided that: [VOUT(+) -VOUT(-)] -[Sense(+) -Sense (-)] 5% VOUT Output overvoltage protection is monitored at the output voltage pin, not the Sense pin. Therefore, excessive voltage differences between VOUT and Sense in conjunction with trim adjustment of the output voltage can cause the overvoltage protection circuitry to activate (see Performance Specifications for overvoltage limits). Power derating is based on maximum output current and voltage at the converter's output pins. Use of trim and sense functions can cause output voltages to increase thereby increasing output power beyond the ULE's specified rating or cause output voltages to climb into the output overvoltage region. Also, the use of Trim Up and Sense combined may not exceed +10% of VOUT. Therefore, the designer must ensure: (VOUT at pins) x (IOUT) rated output power
Contact and PCB resistance losses due to IR drops -INPUT +OUTPUT IOUT
5 Volt Output
RT UP (k) = 20.4(VO - 1.226) VO - 5 -10.2 RTDOWN (k) = 25.01 5 - VO -10.2
12 Volt Output
RT UP (k) = 49.6(VO - 1.226) VO - 12 -10.2 RTDOWN (k) = 60.45 12 - VO -10.2
24 Volt Output
RT UP (k) = 101(VO - 1.226) VO - 24 -10.2 RTDOWN (k) = 124.2 24 - VO -10.2
Note: Resistor values are in k. Adjustment accuracy is subject to resistor tolerances and factory-adjusted output accuracy. VO = desired output voltage. Soldering Guidelines
Murata Power Solutions recommends the specifications below when installing these converters. These specifications vary depending on the solder type. Exceeding these specifications may cause damage to the product. Be cautious when there is high atmospheric humidity. We strongly recommend a mild pre-bake (100 C. for 30 minutes). Your production environment may differ therefore please thoroughly review these guidelines with your process engineers.
Reflow Solder Operations for surface-mount products (SMT)
For Sn/Ag/Cu based solders: Preheat Temperature Time over Liquidus Maximum Peak Temperature Cooling Rate For Sn/Pb based solders: Preheat Temperature Time over Liquidus Maximum Peak Temperature Cooling Rate Less than 1 C. per second 60 to 75 seconds 235 C. Less than 3 C. per second
+INPUT -OUTPUT
Less than 1 C. per second 45 to 75 seconds 260 C. Less than 3 C. per second
ON/OFF CONTROL
+SENSE Sense Current TRIM Sense Return -SENSE IOUT Return LOAD
Contact and PCB resistance losses due to IR drops
Figure 9. Remote Sense Circuit Configuration
Wave Solder Operations for through-hole mounted products (THMT)
For Sn/Ag/Cu based solders: Maximum Preheat Temperature Maximum Pot Temperature Maximum Solder Dwell Time For Sn/Pb based solders: Maximum Preheat Temperature Maximum Pot Temperature Maximum Solder Dwell Time 105 C. 250 C. 6 seconds 115 C. 270 C. 7 seconds
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MDC_ULE Series.C11 Page 11 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
Typical Performance Curves
ULE-1.5/20-D48N Efficiency vs. Line Voltage and Load Current @ +25C 90 88 86 84 Efficiency (%) 82 80 78 Output Current (Amps) 15 20 25 ULE-1.5/20-D48 Maximum Current Temperature Derating (VIN = 48V, air flow direction is transverse)
100 lfm 200 lfm 300 lfm
10
VIN = 36V VIN = 48V
400 lfm
76 74 72 70 2 4 6 8 10 12 14 16 18 20 Load Current (Amps)
VIN = 75V
5
0 -40
0
25
30
35
40
45
50
55
60
65
70
75
80
85
Ambient Temperature (C)
ULE-2.5/20-D24N Efficiency vs. Line Voltage and Load Current @ +25C 92 90 19.5 88 86 Efficiency (%) 84 19 Output Current (Amps) 18.5 18 17.5 17 16.5 2 4 6 8 10 12 14 16 18 20 20
ULE-2.5/20-D24N Maximum Current Temperature Derating VIN = 24V, transverse air flow at sea level
VIN = 19V
82
Natural convection 100 lfm 200 lfm 300 lfm 400 lfm
VIN = 24V
80
VIN = 36V
78 76 74 Load Current (Amps)
20
25
30
35
40
45
50
55
60
65
70
75
80
85
Ambient Temperature (C)
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MDC_ULE Series.C11 Page 12 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
Typical Performance Curves
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MDC_ULE Series.C11 Page 13 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
Typical Performance Curves
ULE-5/10-D12 Efficiency vs. Line Voltage and Load Current @ +25C 94 92 90 88 Efficiency (%) 86
VIN = 9V
84
VIN = 12V
82
VIN = 18V
80 78 1.2
2.4
3.6
4.8
6
7.2
8.4
9.6
10.8
12
Load Current (Amps)
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MDC_ULE Series.C11 Page 14 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
Typical Performance Curves
ULE-5/12-D48 Maximum Current Temperature Derating (VIN = 48V, air flow direction from input to output) 12.5 12 11.5 Output Current (Amps) 11 10.5 10 9.5 9
100 lfm
200 lfm
300 lfm
8.5 8 -40
0
30
35
40
45
50
55
60
65
70
75
80
85
90
Ambient Temperature ( C)
ULE-12/4.2-D24 Efficiency Vs. Line Voltage and Load Current @25C 94 92 90 Output Current (Amps) 88 Efficiency (%) 86 84 82 80 78 76 0.20 4.2 4.1 4.0 3.9 3.8 3.7 3.6 3.5 3.4 3.3 3.2 0.60 1.00 1.40 1.80 2.20 2.60 3.00 3.40 3.80 4.20
ULE-12/4.2-D24N Maximum Current Temperature Derating (VIN=24V, transverse airflow at sea level)
VIN = 18V VIN = 24V VIN = 26V
Natural convection 100 lfm 200 lfm 300 lfm 400 lfm
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
Load Current (Amps)
Ambient Temperature (C)
ULE-12/4.2-D48N Maximum Current Temperature Derating (VIN=48V, transverse airflow at sea level) 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 Ambient Temperature (C)
Output Current (Amps)
Natural convection 100 lfm 200 lfm 300 lfm 400 lfm
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MDC_ULE Series.C11 Page 15 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
Typical Performance Curves
ULE-24/3-D48 Efficiency vs. Line Voltage and Load Current @ +25C 93
92 ULE-48/1.5-D48 Efficiency vs. Line Voltage and Load Current @ +25C
92 91
Efficiency (%)
90 88 86 84 82 80 78 76 74 VIN = 36V VIN = 48V VIN = 60V VIN = 75V
90 Efficiency (%) 89 88 87 86 85 VIN = 36V VIN = 48V VIN = 60V VIN = 75V
72
84 0.3 0.65 1 1.3 1.65 2 2.3 2.65 3 Load Current (Amps)
70 0.10
0.22
0.33
0.45
0.56
0.68
0.79
0.91
1.02
1.14
1.25
Load Current (Amps)
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MDC_ULE Series.C11 Page 16 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
Typical Performance Curves
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MDC_ULE Series.C11 Page 17 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
Typical Performance Curves
ULE-24/3-D48 Power Dissipation vs. Load Current @ +25C
6.5 6 5.5 5
Power Dissipation (Watts)
4.5 4 3.5 3 2.5 2 1.5 1 0.3 0.65
VIN = 75V VIN = 60V VIN = 48V VIN = 36V
1
1.3
1.65
2
2.3
2.65
3
Load Current (Amps)
ULE-48/1.5-D48 Power Dissipation vs. Load Current @ +25C
7
6
Power Dissipation (Watts)
5
VIN = 75V VIN = 60V VIN = 48V VIN = 36V
4
3
2
1 0.1 0.2 0.3 0.4 0.6 0.7 0.8 0.9 1.0 1.1 1.3
Load Current (Amps)
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MDC_ULE Series.C11 Page 18 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
ULE Block Diagrams The ULE series consist of a number of unique high performance designs sharing similar mechanical outlines and pinouts. The internal architecture uses several different topologies including push-pull, flyback and others. The block diagrams below are typical examples and are not intended to be exact representations. Please be aware that MPS may change these designs as needed.
ULE-3.3/20-D48N
+SENSE +VIN GATE DRIVE FEEDBACK -VIN -VOUT -SENSE +VOUT
PWM CONTROLLER
ON/OFF CONTROL
UV, OV AND OVER-TEMPERATURE COMPARATORS
OPTO ISOLATION
REFERENCE & ERROR AMP
TRIM
Typical topology is shown.
ULE-12/4.2-D48N
+VIN -VIN +VOUT -VOUT FEEDBACK
ON/OFF CONTROL
PWM CONTROLLER REFERENCE & ERROR AMP
UV, OV AND OVER-TEMPERATURE COMPARATORS
Typical topology is shown.
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MDC_ULE Series.C11 Page 19 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
Simplified Block Diagrams (continued)
ULE-24/2-D48N
+VIN -VIN ON/OFF CONTROL FEEDBACK +VOUT
PWM CONTROLLER -VOUT UV, OV AND OVER-TEMPERATURE COMPARATORS OPTO ISOLATION REFERENCE & ERROR AMP
TRIM
Typical topology is shown.
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MDC_ULE Series.C11 Page 20 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
Surface-Mount Package ("M" suffix) MPS's ULE series SMT DC/DC converters are the only higher-power DC/DCs that can be automatically "pick-and-placed" using standard vacuum-pickup equipment and subsequently reflowed using high-temperature, lead-free solder. Virtually all SMT DC/DCs today are unprotected "open-frame" devices assembled by their vendors with high-temperature solder (usually Sn96.5/Ag3.5 with a melting point +221C) so that you may attach them to your board using low-temperature solder (usually Sn63/Pb37 with a melting point of +183C). Conceptually straightforward, this "stepped" solder approach has its limitations . . . and is clearly out of step with an industry trending toward the broad use of lead-free solders. Users need to experiment and develop reflow profiles that ensure the components on their DC/DC never exceed 215-216C. If those components get too hot, "double-reflow" could compromise the reliability of their solder joints. Virtually all these devices demand you "cool down" the Sn63 profile you are likely using today. MPS is not exempted from the Laws of Physics. And we do not have magic solders no one else has. We do have a simple and practical, straightforward approach that works. We assemble our SMT DC/DCs on a thermally-stable plastic lead-frame (nylon 46, UL94V-0 flammability rated) using a high temperature lead-free solder. The lead-frame ensures coplanarity (to within 0.004 in.) of the unit's tin-plated (150 microinches) copper leads and also supports a removable heat shield. The disposable heat shield, with a cutaway exposing the package leads, provides thermal insulation to internal components during reflow and doubles as the vacuum pick-up location. The insulation properties of the heat shield are so effective that temperature differentials as high as 50C develop inside-to-outside the shield. Oven temperature profiles with peaks of 250-260C and dwell times exceeding 2 minutes above 221C are easily achieved. MPS's new-generation SMT units are shipped in stackable, JEDEC-style plastic trays (Figure 13). Automated Assembly Production Notes MPS's new high-efficiency DC/DC converters are designed for modern surfacemount technology (SMT) automated assembly using screened solder paste, "pick and place" component positioning and forced hot air reflow oven soldering. If you are new to SMT techniques and have a volume application, these features save time, cost and improve manufacturing efficiency. MPS's DC/DC assembly operations themselves make extensive use of such techniques. Even if you have previous SMT experience, you should read the sections below on solder reflow profiles and heat shields. This information is not intended to replace the documentation for your SMT system. We assume that you are already experienced with all the components of your SMT system. This section will discuss several SMT issues, including: I/O Mechanical Configuration Part Handling and Supply Printed Circuit Board (pcb) Mounting Soldering using Reflow Technology Temperature Profiling Heat Shields and Removal Solder Balls ULE converters are thoroughly inspected according to military standard J-STD-001B for the presence of solder balls. The specification allows small solder balls as long as they are rigidly attached and do not compromise the spacing and clearance requirements needed to maintain electrical isolation.
Figure 10. ULE SMT DC/DC with Disposable Heat Shield
Mechanical Configuration of Input/Output Connections These new converters are supplied either using traditional through-hole pins or SMT leads. (Note that some models are offered only with lead mounting). The pin options insert into plated-through holes in the host pcb. Be aware that some heat dissipation is carried off by either the pins or leads. The Derating Curves assume that some additional pad area is available on your host pcb to absorb the heat. The lead option uses either short tabs in "gullwing" style or standoff leads under the converter. The gullwing leads typically are copper alloy with 150 microinches of tin plating. Solder paste (typically 0.008" to 0.009" thick) is applied to the host pcb using a solder mask pressure screening technique and the board is heated and cooled long enough for the solder to reflow and adhere to both the host pads and the converter's mounting leads. After such mounting, the entire mechanical mounting load is carried by the solder. Obviously the converters must be accurately positioned all during the solder reflow period. Where solder surface tension is sufficient to force tiny components into position, these larger converters may not move and must be accurately positioned by your SMT system. Part Handling and Supply SMT eighth- and quarter-brick DC/DC converters (plus installed heat shields if used) are supplied in JEDEC-standard 5.35" by 12.4" waffle trays which are compatible with the feeders on industry-standard pick-and-place machines. Since the converters are larger and heavier than many other components, make sure your system can reliably remove the units from their trays, move them to the host pcb and accurately position them. The plastic heat shield (Figure 10) doubles as a vacuum pickup area.
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MDC_ULE Series.C11 Page 21 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
250
200 Degrees Celsius
150
Heat Shield Test Board Air Under Shield
Orientation: When loaded into JEDEC trays, the converters are oriented in the same direction. See the diagram below. For the ULE series, a notch is placed on the top of the case (on the removal tabs) to indicate the pin 1 position. You should visually inspect the tray to be sure of this orientation. Most pick-and-place automatic assembly systems use a camera which must be trained to recognize the orientation of the converter before it is assembled onto the host PC board. This "training" locates and identifies prominent, dimensionally stable landmarks such as the board corners or fiducial marks.
100
50
Z1 Z2 Z3 Z4 Z5 Z6 Z7
100
200
300
Seconds
400
500
600
Figure 11. Recommended Solder Profile (When the Heat-shield temperature exceeds +250C, the air within is 50C cooler)
Post Reflow Procedures After successful solder reflow, be sure to completely clean and dry your assembled boards using a recommended wash solution and dryer. Failure to remove all flux may cause long term deterioration of on-board conductors and components. And, traces of contaminants which are not removed may reduce isolation voltages or risk a safety hazard. Be aware that low remaining concentrations of flux or other assembly compounds can be very difficult to detect by eye. Pick and Place pcb Mounting The main issues here are pad area, orientation, positioning accuracy, vacuum pickup and coplanarity. MPS recommends that pcb pads to interface with the DC/DC converter should be sized as shown in the diagram below. The pads footprint accommodates the positioning accuracy of your SMT equipment and manufactured tolerances of the DC/DC mounting leads.
On the bottom of the converter, the ULE series include optical fiducial marks viewable by your SMT imaging system. Observing from the bottom, your SMT imaging camera should find these marks to identify the converter and verify pin 1. On most pick-and-place systems, during head transit, the imaging system will automatically fine tune the end mounting position of the converter using image comparisons from these fiducials or other reference marks you have chosen. The fiducial marks are placed fairly close together because many imaging systems have a one inch or less observing area since most SMT parts are considerably smaller than these converters. You may prefer to train your imaging system to use a corner of the converter or an I/O lead. The fiducial marks will remain identical within any date code lot of converters. In the remote possibility that the fiducials may have changed position with a PC board revision, you should not mix different date lots on any one production assembly session. In addition, to avoid non-recognition or misplacement of the converter, retrain your imaging system at the beginning of each series of assembly sessions. There may be tiny variations in the absolute position from unit to unit. If you use a camera above the pcb after placement on the solder paste, do not rely on the inkjet marking on the heat shield to verify proper orientation. Use the pin 1 notch instead. Coplanarity: MPS manufactures these converters with very flat mounting leads (see coplanarity specs) however your host pcb must also be flat for a successful mounting. Be aware of possible warping of the pcb under heat gradients and/or humidity conditions. The solder paste will tolerate a small amount of mismatch and will tend to "wet" the entire pad area by capillary action if the temperatures are correct. Vacuum Pickup: Select the vacuum collet on your SMT placement system for the weight and size of the DC/DC converter. Note that units with heatsinks are slightly heavier. Tests at MPS have shown that excellent acceleration and transit head speed are available for these converters if the collet size is proper and the vacuum is sufficient. When positioning the vacuum collet, use the geometric center of the heat shield as the pickup area since the center of gravity is very close. Soldering Reflow technology works well for small parts. However, larger components such as these DC/DC's with higher thermal mass may require additional reflow time (but not enough to disturb smaller parts also being reflowed concurrently with the DC/DC). When this is combined with higher temperature lead-free solders (or solders with reduced heavy metals), there is increased risk of reheating components inside the DC/DC enough so that they either change positions (and possibly stop functioning) or the components are damaged by the heat.
SMT UNIT
SMT LEAD
0.020 (0.51) PCB Copper Pad 2.340 (59.44) 1.975 (50.17) 0.183 (4.65)
0.300 TYP. (7.62)
0.150 TYP. (3.81)
0.020 REF. (0.51)
0.130 TYP. (3.30) DIMENSIONS ARE IN INCHES (MM)
Figure 12. Recommended SMT Mounting Pad Dimensions
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Technical enquiries email: sales@murata-ps.com, tel: +1 508 339 3000
MDC_ULE Series.C11 Page 22 of 23
ULE Series
Isolated, High Density, Eighth-Brick 1.25-30 Amp, DC/DC Converters
For these reasons, MPS developed disposable heat shields using high temperature plastic. The DC/DC is installed and reflowed with the shield in place. After successful reflow and cooling, and before washing, the heat shield should be removed. Temperature Profiling We wish to ramp the temperature up and down to successfully reflow the solder without heat damage. Each reflow oven, humidity conditions, solder paste type, oven feed rate, and the number of heat zones all require a different profile. Therefore you may have to experiment. Since these converters are constructed using high temperature solders, there will be no heat problems on your host pcb using traditional solder with 63% lead and 37% tin with a melting point of +183C. Device lead temperature must remain below 230C for less than 75 seconds, assuming that the heat shield is in place. MPS uses a 216C melt lead-free tin/silver/copper alloy to assemble these converters. There are several lead-free solders suitable for your host pcb depending on your SMT system and whatever local certification and environmental regulations you must observe. Contact MPS if you need specific advice. Heat Shield Careful thermocouple testing has shown that the interior of the DC/DC under the heat shield is tens of degrees cooler than the outside ambient temperature for typical reflow profiles. This protects internal components and limits the amount of reflow where it is not desired. The heat shield also includes marking for product identification and a date/lot code. On ULE models, the heat shield is attached to the converter using molded plastic pins on the heat shield interior which insert into recessed dimples in the pinframe. An extra molded pin on the heat shield at the pin 1 location (and corresponding notch on the pcb) can only be installed one way properly on the pinframe. If the shield accidentally comes loose, it may be reinstalled by aligning the pins and dimples. To remove the shield from the converter, after successful mounting and cooling, squeeze the heat shield ears inward toward the converter body and pull the shield upwards. Discard or recycle the shield. If you are using a flux wash cycle, remove the heat shield before washing to avoid coming loose inside the washer.
1.032 (26.21) 12.40 (314.96) 2.875 (73.03) 5.35 (135.89) 1.50 (38.1) 1.50 (38.1)
PIN 1 DIMPLE
2.875 (73.03)
2.875 (73.03)
DIMENSIONS ARE IN INCHES (MM)
Figure 13. Shipping Tray
USA: Canada: UK: France: Germany: Japan: China: Singapore:
Mansfield (MA), Tel: (508) 339-3000, email: sales@murata-ps.com Toronto, Tel: (866) 740-1232, email: toronto@murata-ps.com Milton Keynes, Tel: +44 (0)1908 615232, email: mk@murata-ps.com Montigny Le Bretonneux, Tel: +33 (0)1 34 60 01 01, email: france@murata-ps.com Munchen, Tel: +49 (0)89-544334-0, email: munich@murata-ps.com Tokyo, Tel: 3-3779-1031, email: sales_tokyo@murata-ps.com Osaka, Tel: 6-6354-2025, email: sales_osaka@murata-ps.com Shanghai, Tel: +86 215 027 3678, email: shanghai@murata-ps.com Guangzhou, Tel: +86 208 221 8066, email: guangzhou@murata-ps.com Parkway Centre, Tel: +65 6348 9096, email: singapore@murata-ps.com
Technical enquiries email: sales@murata-ps.com, tel: +1 508 339 3000
Murata Power Solutions, Inc. 11 Cabot Boulevard, Mansfield, MA 02048-1151 U.S.A. Tel: (508) 339-3000 (800) 233-2765 Fax: (508) 339-6356
www.murata-ps.com email: sales@murata-ps.com ISO 9001 and 14001 REGISTERED
02/05/09
Murata Power Solutions, Inc. makes no representation that the use of its products in the circuits described herein, or the use of other technical information contained herein, will not infringe upon existing or future patent rights. The descriptions contained herein do not imply the granting of licenses to make, use, or sell equipment constructed in accordance therewith. Specifications are subject to change without notice. (c) 2008 Murata Power Solutions, Inc.
www.murata-ps.com
MDC_ULE Series.C11 Page 23 of 23

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