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Data Sheet September 9, 2008
KW006-010 Series (Sixteenth-Brick) DC-DC Converter Power Modules:
36-75Vdc Input; 3.3Vdc to 5.0Vdc Output; 6A to 10A Output Current
RoHS Compliant
Features
Compliant to RoHS EU Directive 2002/95/EC (-Z versions) Compliant to RoHS EU Directive 2002/95/EC with lead solder exemption (non-Z versions) Delivers up to 33W output power: 3.3V(10A), 5.0V(6A) Small size and low profile: 33.0 mm x 22.9 mm x 8.75 mm (1.30 in x 0.9 in x 0.344 in) Industry standard DOSA footprint Output voltage adjustment trim (-20%, +10%) Remote On/Off, Positive logic Remote Sense Over-temperature protection (non-latching) Output over-current protection (non-latching) Output over-voltage protection (latching) Wide operating temperature range (-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 CE mark meets the 2006/95/EC directive UL* 60950-1Recognized, CSA C22.2 No. 60950-1-03 Certified, and VDE 0805 (EN60950 3rd Edition) Licensed ISO** 9001 and ISO 14001 certified manufacturing facilities Surface Mount (Tape and Reel, -SR Suffix)
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
Description
The KW (Sixteenth-brick) series power modules are isolated dc-dc converters that operate over a wide input voltage range of 36 to 75Vdc and provide a single precisely regulated output. The output is fully isolated from the input, allowing versatile polarity configurations and grounding connections. The modules exhibit high efficiency, typical efficiency of 87% for 3.3V/10A. These open frame modules are available in surface-mount (-SR) form.
* UL is a registered trademark of Underwriters Laboratories, Inc. CSA is a registered trademark of Canadian Standards Association. VDE is a trademark of Verband Deutscher Elektrotechniker e.V.
This product is intended for integration into end-user equipment. All of the required procedures of end-user equipment should be followed. ** ISO is a registered trademark of the International Organization of Standards
Document No: DS06-114 ver.1.31 PDF name: kw006-010.ds.pdf
Data Sheet September 9, 2008
KW0006-010 Series Power Modules: 36 - 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current
Absolute Maximum Ratings
Stresses in excess of the absolute maximum ratings can cause permanent damage to the device. These are absolute stress ratings only, functional operation of the device is not implied at these or any other conditions in excess of those given in the operations sections of the data sheet. Exposure to absolute maximum ratings for extended periods can adversely affect the device reliability.
Parameter Input Voltage Continuous Transient (100 ms) Operating Ambient Temperature (see Thermal Considerations section) Storage Temperature I/O Isolation voltage (100% Factory 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
Max 75 1.5
Unit Vdc Adc mA
40
75
All
IIN,stand-by
3
5
mA
0.1
As
2
All
30
mAp-p
All
50 See EMC Considerations section
dB
CAUTION: This power module is not internally fused. An input line fuse must always be used.
This power module can be used in a wide variety of applications, ranging from simple standalone operation to an integrated part of sophisticated power architectures. To preserve maximum flexibility, internal fusing is not included, however, to achieve maximum safety and system protection, always use an input line fuse. The safety agencies require a time-delay fuse with a maximum rating of 5 A (see Safety Considerations section). Based on the information provided in this data sheet on inrush energy and maximum dc input current, the same type of fuse with a lower rating can be used. Refer to the fuse manufacturer's data sheet for further information.
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Data Sheet September 9, 2008
KW0006-010 Series Power Modules: 36 - 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current
Electrical Specifications (continued)
Parameter Output Voltage Set-point (VIN=VIN, min, IO=IO, max, TA=25C) 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) (see Figure 14 for test conditions) 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 Output Current Output Current Limit Inception (Hiccup Mode ) (VO= 90% of VO, set) Output Short-Circuit Current (VO250mV) ( Hiccup Mode ) Efficiency VIN= VIN, nom, TA=25C IO=IO, max , VO= VO,set Switching Frequency Dynamic Load Response (dIo/dt=1.0A/s; VIN = VIN, nom; TA=25C) Load Change from Io= 50% to 75% or 25% to 50% of Io,max; 470F external capacitance (ESRmax< 20 m) Peak Deviation All Vpk 3 % VO, set Settling Time (Vo<10% peak deviation) 200 All ts s (* See Output Overvoltage Protection Information in the Feature Specifications and Feature Descriptions for advise on minimum output capacitance) All fsw 300 kHz All All All 0.1 5 1.0 % VO, set mV % VO, set All VO,adj -20.0 +10.0 Vdc All VO -3.0 +3.0 % VO, set Device All Symbol VO, set Min -1.5 Typ Max +1.5 Unit % VO, set
F F A A F A A F All All All CO, max CO, max Io Io
0* 0* 0 0 101

20 60 25 75 5,000 2,000 6 10 130
mVrms mVpk-pk mVrms mVpk-pk F F Adc Adc % Io
IO, lim
IO, s/c
1 87.0
Arms %
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Data Sheet September 9, 2008
KW0006-010 Series Power Modules: 36 - 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current
Isolation Specifications
Parameter Isolation Capacitance Isolation Resistance I/O Isolation Voltage Device All All All Symbol Ciso Riso All Min 10 Typ 120 Max 1500 Unit pF M Vdc
General Specifications
Parameter Calculated MTBF Based upon Telcordia SR-332 Issue 2: Method 1 Case 3, 90% confidence (IO=80%IO, max, TA=40C, Airflow = 200 lfm) Powered Random Vibration (VIN=VIN, min, IO=IO, max, TA=25C, 0 to 5000Hz, 10Grms) Weight Device F All All Min Typ 3,765,608 90 10 (0.35) Max Unit Hours Minutes g (oz.)
Feature Specifications
Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions for additional information.
Parameter 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
Device
Symbol
Min
Typ
Max
Unit
Logic Low - Remote On/Off Current Logic Low - On/Off Voltage Logic Threshold - change of state Logic High Voltage - (Typ = Open Collector) Logic High maximum allowable leakage current (current flow sourced from the unit) External voltage allowed on on/off pin 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, with 0 to 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 (requires 660 F output
capacitance to meet limits, when Output Overvoltage is caused by internal module failure; see Feature Descriptions for further detail)
o o
All All All All All
Ion/off Von/off Von/off Von/off Ion/off
-0.7 3
0.37 2.4 3.4
1.0 1.2 5 10 15
mA V V V A V
All
Tdelay
2
5
msec
All All
Tdelay Trise All

2 8
5 12 3 10
msec msec % VO, set % VO, set Vdc Vdc Vdc Vdc Vdc
All A F All All All
All VO, limit VO, limit Vuv/on Vuv/off Vhyst 5.75 3.8 24 34 27 6
7 4.6 36
Input Undervoltage Lockout Turn-on Threshold Turn-off Threshold Hysterisis
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Data Sheet September 9, 2008
KW0006-010 Series Power Modules: 36 - 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current
Characteristic Curves
The following figures provide typical characteristics for the KW010A0F (3.3V, 10A) at 25oC. The figures are identical for either positive or negative remote On/Off logic.
90
12.0
OUTPUT CURRENT, Io (A)
10.0 8.0 6.0 4.0 2.0 0.0 20 30 40 50 60 70
O
85
EFFICIENCY, (%)
80
Vin = 75V Vin = 48V Vin = 36V
NC
75
1.0 m/s (200 lfm) 2.0 m/s (400 lfm) 3.0 m/s (600 lfm)
70 0 2 4 6 8 10
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.
OUTPUT VOLTAGE On/Off VOLTAGE VO (V) (1V/div) Von/off (V) (5V/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 INPUT VOLTAGE
OUTPUT VOLTAGE
VO (V) (100mV/div)
OUTPUT CURRENT,
TIME, t (400 s /div)
VIN (V) (50V/div)
Io (A) (5A/div)
VO (V) (1V/div)
TIME, t (5ms/div)
Figure 3. Transient Response to Dynamic Load Change from 75% to 50% to 75% of full load with an external 470uF tantalum capacitor (dI/dt =1.0A/s).
Figure 6. Typical Start-up Using Input Voltage (VIN = VIN,NOM, Io = Io,max).
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Data Sheet September 9, 2008
KW0006-010 Series Power Modules: 36 - 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current
Characteristic Curves (continued)
The following figures provide typical characteristics for the KW006A0A (5.0V, 6A) at 25oC. The figures are identical for either positive or negative remote On/Off logic.
90 Vin = 36V 85
7.0
OUTPUT CURRENT, Io (A)
6.0 5.0 4.0 3.0 2.0 1.0 0.0 20 30 40 50 60 70
O
EFFICIENCY, (%)
Vin = 48V 80 Vin = 75V 75
NC 0.5 m/s (100 lfm) 1.0 m/s (200 lfm) 2.0 m/s (400 lfm)
3.0 m/s (600 lfm) 90
70 0 1 2 3 4 5 6
80
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 Vo (V) (2V/div) VON/OFF (V) (5V/div)
OUTPUT VOLTAGE
VO (V) (20mV/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
VO (V) (50mV/div)
INPUT VOLTAGE OUTPUT VOLTAGE
Io(A) (2A/div)
TIME, t (1ms/div)
VIN (V) (50V/div)
Vo (V) (2V/div)
TIME, t (5ms/div)
Figure 9. Transient Response to Dynamic Load Change from 50% to 75% to 50% of full load with an external 470uF tantalum capacitor (dI/dt =1.0A/s).
Figure 12. Typical Start-up Using Input Voltage (VIN = VIN,NOM, Io = Io,max).
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Data Sheet September 9, 2008
KW0006-010 Series Power Modules: 36 - 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current
Test Configurations
TO OSCILLOSCOPE LTEST 12H VIN(+) 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 13, 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
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 13. 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 14. Output Ripple and Noise Test Setup.
Rdistribution
Rcontact VIN(+) VOUT(+)
Rcontact
Rdistribution
VIN
VO
RLOAD
For safety-agency approval of the system in which the power module is used, the power module must be installed in compliance with the spacing and separation requirements of the end-use safety agency standard, i.e., UL 60950-1-3, CSA C22.2 No. 60950-00, and VDE 0805:2001-12 (IEC60950-1). If the input source is non-SELV (ELV or a hazardous voltage greater than 60 Vdc and less than or equal to 75Vdc), for the module's output to be considered as meeting the requirements for safety extra-low voltage (SELV), all of the following must be true: The input source is to be provided with reinforced insulation from any other hazardous voltages, including the ac mains. One VIN pin and one VOUT pin are to be grounded, or both the input and output pins are to be kept floating. The input pins of the module are not operator accessible. Another SELV reliability test is conducted on the whole system (combination of supply source and subject module), as required by the safety agencies, to verify that under a single fault, hazardous voltages do not appear at the module's output. Note: Do not ground either of the input pins of the module without grounding one of the output pins. This may allow a non-SELV voltage to appear between the output pins and ground. The power module has extra-low voltage (ELV) outputs when all inputs are ELV. All flammable materials used in the manufacturing of these modules are rated 94V-0, or tested to the UL60950 A.2 for reduced thickness. For input voltages exceeding -60 Vdc but less than or equal to -75 Vdc, these converters have been evaluated to the applicable requirements of BASIC INSULATION between secondary DC MAINS DISTRIBUTION input (classified as TNV-2 in Europe) and unearthed SELV outputs (-B option only). The input to these units is to be provided with a maximum 5 A time-delay fuse in the ungrounded lead.
Rdistribution
Rcontact VIN(-) VOUT(-)
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 15. Output Voltage and Efficiency Test Setup.
VO. IO Efficiency = VIN. IIN x 100 %
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Data Sheet September 9, 2008
KW0006-010 Series Power Modules: 36 - 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current
Feature Description
Remote On/Off
Two remote on/off options are available. Positive logic turns the module on during a logic high voltage on the ON/OFF pin, and off during a logic low. Negative logic remote On/Off, device code suffix "1", turns the module off during a logic high and on during a logic low.
VIN(+)
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
CONT ACT RESIST ANCE
CONT ACT AND DISTRIBUTION LOSSE
TRIM
Von/off
Figure 17. Circuit Configuration for remote sense .
Input Under-Voltage Lockout
VIN(-)
VOUT(-)
Figure 16. Remote On/Off Implementation. To turn the power module on and off, the user must supply a switch (open collector or equivalent) to control the voltage (Von/off) between the ON/OFF terminal and the VIN(-) terminal (see Figure 16). Logic low is 0V Von/off 1.2V. The maximum Ion/off during a logic low is 1mA, the switch should be maintain a logic low level whilst sinking this current. The typical open circuit Von/off generated by the module is 3.4V. The ION/OFF leakage current, through the switch, is required to be less than 10uA otherwise the unit will reach the threshold at which it switches. If not using the remote on/off feature: For positive logic, leave the ON/OFF pin open. For negative logic, short the ON/OFF pin to VIN(-).
At input voltages below the input under-voltage lockout limit, the module operation is disabled. The module will only begin to operate once the input voltage is raised above the undervoltage lockout turn-on threshold, Vuv/on. Once operating, the module will continue to operate until the input voltage is taken below the undervoltage turn-off threshold, Vuv/off.
Over-Temperature Protection
To provide protection under certain fault conditions, the unit is equipped with a thermal shutdown circuit. The unit will shutdown if the thermal reference test point RT1 (Figure 19), exceeds 110oC (typical), but the thermal shutdown is not intended as a guarantee that the unit will survive temperatures beyond its rating. The module will automatically restart upon cool-down to a safe temperature.
Output Over-Voltage Protection
The output over-voltage protection scheme of the modules has an independent over-voltage loop to prevent single point of failure. This protection feature latches-off the module in the event of over-voltage across the output. Recycling the input voltage or momentarily switching-off the module via the remote on/off pin resets the latch. The independent over-voltage loop has a relatively slow response time. There are no precautions necessary to meet the output over-voltage protection limits for externally caused over-voltage conditions, such as excessive remote sense or output trim adjustments. However, special precautions are necessary to insure the over-voltage limits are met when the over-voltage is caused by internal module control loop failure. Either a minimum of 660 F external output capacitance is required, or an external
Remote Sense
Remote sense minimizes the effects of distribution losses by regulating the voltage at the remote-sense connections (See Figure 17). The voltage between the remote-sense pins and the output terminals must not exceed the output voltage sense range given in the Feature Specifications table: [VO(+) - VO(-)] - [SENSE(+) - SENSE(-)] 10% VO,Set Although the output voltage can be increased by both the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim. The amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. When using remote sense and
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Data Sheet September 9, 2008
KW0006-010 Series Power Modules: 36 - 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current
Feature Descriptions (continued)
OVP pull-down circuit is required. The OVP pull-down circuit will also provide significantly lower peak output over-voltages for applications that are particularly sensitive to over-voltage stress. Please contact your local Lineage Power sales representative for further information on the external OVP pull-down circuit.
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 trimming the output voltage higher:
Over-Current Protection
To provide protection in a fault (output overload) condition, the unit is equipped with internal current-limiting circuitry and can endure current limiting continuously. At the point of current-limit inception, the unit enters hiccup mode. The unit will remain in the hiccup mode as long as the overcurrent condition exists; it operates normally, once the output current is brought back into its specified range. The average output current during hiccup is < 1A.
5.11 x Vo , set x (100 + %) 511 - - 10 .22 Rtrim - up = % 1.225 x %
Where % = Vo , set - V desired Vo , set x 100
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
For example, to trim-up the output voltage of 3.3V module (KW010A0F/F1) by 6% to 3.498V, Rtrim-up is calculated is as follows:
% = 6
5 .11 x 3 .3 x (100 + 6 ) 511 R trim - up = - - 10 . 22 1 . 225 x 6 6
Rtrim -up = 147 .8
The voltage between the VO(+) and VO(-) terminals must not exceed the minimum output overvoltage protection value shown in the Feature Specifications table. This limit includes any increase in voltage due to remote-sense compensation and output voltage setpoint adjustment trim. Although the output voltage can be increased by both the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim. The amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. When using remote sense and trim, the output voltage of the module can be increased, which at the same output current would increase the power output of the module. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power (Maximum rated power = Vo,set x Io,max).
Figure 18. Circuit Configuration to Trim Output Voltage. Connecting an external resistor (Rtrim-down) between the TRIM pin and the VO(-) (or Sense(-)) pin decreases the output voltage set point. To maintain set point accuracy, the trim resistor tolerance should be 1.0%. The following equation determines the required external resistor value to obtain a percentage output voltage change of % For trimming the output voltage lower:
511 R trim - down = - 10 . 22 %
Where % = V o , set - V desired V o , set
x 100
For example, to trim-down the output voltage of 3.3V module (KW010A0F/F1) by 8% to 3.036V, Rtrim-down is calculated as follows:
% = 8
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Data Sheet September 9, 2008
KW0006-010 Series Power Modules: 36 - 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current
EMC Considerations
The KW006/010 power module is designed to meet EN55022 Class B Conducted emissions with a simple filter, as shown in Figure 19. Test results are shown in Figure 20. Further improvement to the emissions at the fundamental can be achieved by increasing the value of C3 and C4. Please contact your Lineage Power sales representative, if you need further information.
C3
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 in this data sheet is based on physical measurements taken in a wind tunnel. The test set-up is shown in Figure 21. Please refer to the Application Note "Thermal Characterization Process For Open-Frame Board-Mounted Power Modules" for a detailed discussion of thermal aspects including maximum device temperatures. The thermal reference point, Tref , used in the specifications, is shown in Figure 22. For reliable operation this temperature should not exceed 125oC.
VIN +
L1 Vin + C1 C2 KW006A0A4 Vout +
VIN Vin Vout -
C1 = 4.7uF Ceramic C2 = 33uF Electrolytic C3 = 1nF Ceramic C4 = 1nF Ceramic L1 = P0354 (1.17mH, 1.2A rated) Figure 19. EMC Filter.
90 80 70 60 EN 55022 Class B Conducted AV (Mains Ports) 50 40 30 20 EN 55022 Class B Conducted AV (Mains Port)
C4
EN 55022 Class A Conducted AV (Mains Ports)
Lev el (dB uV )
10 150k Frequency (Hz)
1M
10M
30M
Figure 21. Tref Temperature Measurement Locations.
90 80 70
EN 55022 Class B Conducted AV (Mains Port)
EN 55022 Class A Conducted AV (Mains Ports) 60 50 40 30 20 EN 55022 Class B Conducted AV (Mains Ports)
AIRFLOW
Lev el (dB uV )
10 150k Frequency (Hz)
1M
10M
30M
Figure 20. EMC Results (top VIN+, bottom VIN-)
Figure 22. Tref Temperature Measurement Locations.
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Data Sheet September 9, 2008
KW0006-010 Series Power Modules: 36 - 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current
Surface Mount Information
Pick and Place
The KW006/010 modules use an open frame construction and are designed for a fully automated assembly process. The pick and place location on the module is the larger magnetic core as shown in Figure 23. The modules are fitted with a label which meets all the requirements for surface mount processing, as well as safety standards, and is able to withstand reflow o temperatures of up to 300 C. The label also carries product information such as product code, serial number and the location of manufacture.
must be observed when soldering these units. Failure to observe these instructions may result in the failure of or cause damage to the modules, and can adversely affect long-term reliability. In a conventional Tin/Lead (Sn/Pb) solder process peak o reflow temperatures are limited to less than 235 C. o Typically, the eutectic solder melts at 183 C, wets the land, and subsequently wicks the device connection. Sufficient time must be allowed to fuse the plating on the connection to ensure a reliable solder joint. There are several types of SMT reflow technologies currently used in the industry. These surface mount power modules can be reliably soldered using natural forced convection, IR (radiant infrared), or a combination of convection/IR. For reliable soldering the solder reflow profile should be established by accurately measuring the modules CP connector temperatures.
300
P eak Temp 235oC
250
REFLOW TEMP (C)
200
Heat zo ne max 4oCs -1
Co o ling zo ne 1 oCs -1 -4
1 50
1 00
So ak zo ne 30-240s P reheat zo ne max 4oCs -1
Tlim above 205oC
50
0
REFLOW TIME (S)
Figure 24. Reflow Profile for Tin/Lead (Sn/Pb) process Figure 23. Pick and Place Location.
240 235
MAX TEMP SOLDER (C)
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.
230 225 220 215 210 205 200 0 10 20 30 40 50 60
Tin Lead Soldering
The KW006/010 power modules (both non-Z and -Z codes) can be soldered either in a conventional Tin/Lead (Sn/Pb) process. The non-Z version of the KW006/010 modules are RoHS compliant with the lead exception. Lead based solder paste is used in the soldering process during the manufacturing of these modules. These modules can only be soldered in conventional Tin/lead (Sn/Pb) process. It is recommended that the customer review data sheets in order to customize the solder reflow profile for each application board assembly. The following instructions
Figure 25. Time Limit Curve Above 205 C for Tin/Lead (Sn/Pb) process
o
Lead Free Soldering
The -Z version of the KW006/010 modules are leadfree (Pb-free) and RoHS compliant and are both forward and backward compatible in a Pb-free and a SnPb soldering process. The non-Z version of the KW006/010 modules are RoHS compliant with the lead exception. Lead based solder paste is used in the soldering process during the manufacturing of these modules. These modules can only be soldered in 11
LINEAGE POWER
Data Sheet September 9, 2008
KW0006-010 Series Power Modules: 36 - 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current
Surface Mount Information (continued)
Reflow Temp (C)
300 Per J-STD-020 Rev. C Peak Temp 260C 250 Cooling Zone
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.
200 * Min. Time Above 235C 15 Seconds 150 Heating Zone 1C/Second 100 *Time Above 217C 60 Seconds
Pb-free Reflow Profile
Power Systems will comply with J-STD-020 Rev. C (Moisture/Reflow Sensitivity Classification for Nonhermetic Solid State Surface Mount Devices) for both Pb-free solder profiles and MSL classification procedures. This standard provides a recommended forced-air-convection reflow profile based on the volume and thickness of the package (table 4-2). The suggested Pb-free solder paste is Sn/Ag/Cu (SAC). The recommended linear reflow profile using Sn/Ag/Cu solder is shown in Figure 26.
50
0
Reflow Time (Seconds)
Figure 26. Recommended linear reflow profile using Sn/Ag/Cu solder.
MSL Rating
The KW006/010 modules have a MSL rating of 2.
Storage and Handling
The recommended storage environment and handling procedures for moisture-sensitive surface mount packages is detailed in J-STD-033 Rev. A (Handling, Packing, Shipping and Use of Moisture/Reflow Sensitive Surface Mount Devices). Moisture barrier bags (MBB) with desiccant are required for MSL ratings of 2 or greater. These sealed packages should not be broken until time of use. Once the original package is broken, the floor life of the product at conditions of 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 guidance on appropriate soldering, cleaning and drying procedures, refer to Lineage Power Board Mounted Power Modules: Soldering and Cleaning Application Note (AN04-001).
LINEAGE POWER
12
Data Sheet September 9, 2008
KW0006-010 Series Power Modules: 36 - 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current
Mechanical Outline for Surface Mount Module
Dimensions are in millimeters and [inches]. Tolerances: x.x mm 0.5 mm [x.xx in. 0.02 in.] (unless otherwise indicated) x.xx mm 0.25 mm [x.xxx in 0.010 in].
Top View
Side View
Bottom View
PIN 1 2 3 4 5 6 7 8 FUNCTION VIN(+) On/Off VIN(-) Vo(-) Sense(-) Trim Sense(+) Vo(+)
LINEAGE POWER
13
Data Sheet September 9, 2008
KW0006-010 Series Power Modules: 36 - 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current
Recommended Pad Layout
Dimensions are in millimeters and [inches]. Tolerances: x.x mm 0.5 mm [x.xx in. 0.02 in.] (unless otherwise indicated) x.xx mm 0.25 mm [x.xxx in 0.010 in.]
SMT Recommended Pad Layout (Component Side View)
LINEAGE POWER
14
Data Sheet September 9, 2008
KW0006-010 Series Power Modules: 36 - 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current
Packaging Details
The Sixteenth-brick SMT versions are supplied in tape & reel as standard. Details of tape dimensions are shown below. Modules are shipped in quantities of 140 modules per reel. Tape Dimensions Dimensions are in millimeters.
LINEAGE POWER
15
Data Sheet September 9, 2008
KW0006-010 Series Power Modules: 36 - 75Vdc Input; 3.3 to 5.0Vdc Output; 6 to 10A Output Current
Ordering Information
Please contact your Lineage Power Sales Representative for pricing, availability and optional features. Table 1. Device Code
Product Codes KW010A0F41-SR KW010A0F41-SRZ KW006A0A41-SR KW006A0A41-SRZ Input Voltage 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) Output Voltage 3.3V 3.3V 5V 5V Output Current 10A 10A 6A 6A On/Off Logic Negative Negative Negative Negative Connector Type Surface mount Surface mount Surface mount Surface mount Comcode 108996360 CC109114113 108996385 CC109128798
-Z Indicated RoHS Compliant Modules Table 2. Device Options Option*
Negative remote on/off logic Over-Current (auto-restart)/ Over-Temp Protection(auto-restart) /Over-Voltage (latching) Surface mount connections (Tape & Reel)
Suffix**
1 4 (must be ordered) -SR (must be ordered)
Asia-Pacific Headquarters Tel: +65 6416 4283 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: DS06-114 ver.1.31 PDF name: kw006-010.ds.pdf

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