GE Industrial Solutions KHHD006A0A User Manual

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Data Sheet

KHHD006A0A Hammerhead™ Series; DC-DC Converter Power Modules

18-75Vdc Input; 5.0Vdc, 6A Output

Features

 Compliant to RoHS II EU “Directive 2011/65/EU

 Compliant to REACH Directive (EC) No 1907/2006

RoHS Complian

Applications

 Wireless Networks

 Hybrid power architectures

 Optical and Access Network Equipment

 Enterprise Networks including Power over Ethernet (PoE)

 Industrial markets

Options

 Negative Remote On/Off logic (preferred)

 Surface Mount/Tape and Reel (-SR Suffix)

 Auto-restart Over current/Over voltage protections

(preferred)

 Shorter through hole pin trim

 Ultra-wide Input Voltage Range, 18V

 No minimum load

 High efficiency – 90% at full load (V

 Constant switching frequency

 Low output ripple and noise

 Small Size and low profile, follows DOSA standard 1/16th

footprint

33.0 mm x 22.9 mm x 9.3 mm (1.30 in x 0.9 in x 0.37 in)

• Surface mount (SMT) or Through hole (TH)

 Reflow process compliant, both SMT and TH versions

 Positive Remote On/Off logic

 Output overcurrent/voltage protection (hiccup)

 Over-temperature protection

 Output Voltage adjust: 80% to 110% of V

 Wide operating temperature range (-40°C to 85°C)

 ANSI/ UL* 60950-1-2011 Recognized, CAN/CSA† C22.2

No.60950-1-07, Second Edition + A1:2011 (MOD) Certified IEC 60950-1:2005 (2nd edition) + A1:2009 and EN 609501:2006 +A11:2009 +A1:2010 +A12:2011, and VDE‡0805 (EN60950-1 3rd edition) Licensed

 CE mark meets 2006/95/EC directive

 Meets the voltage and current requirements for ETSI 300-

132-2 and complies with and licensed for Basic insulation rating per EN60950-1

 2250 Vdc Isolation tested in compliance with IEEE 802.3

PoE standards

 ISO** 9001 and ISO 14001 certified manufacturing facilities

to 75Vdc

=48Vdc)

o,nom

Description

The KHHD006A0A series power modules are isolated DOSA compliant 1/16th brick dc-dc converters that operate over an ultrawide input voltage range of 18 V

-75Vdc and provide a single precisely regulated output voltage at 5.0Vdc. The output is fully

isolated from the input, allowing versatile polarity configurations and grounding connections. The modules exhibit high efficiency of 90% typical at full load. Built-in filtering for both input and output minimizes the need for external filtering. The module is fully self-protected with output over-current and over-voltage, over-temperature and input under voltage shutdown control. Optional features include negative or positive on/off logic and SMT connections.

* UL is a registered trademark of Underwriters Laboratories, Inc.

†

CSA is a registered trademark of Canadian Standards Association.

‡

VDE is a trademark of Verband Deutscher Elektrotechniker e.V.

§ This product is intended for integration into end-user equipment. All of the required procedures of end-use equipment should be followed. ¤ IEEE and 802 are registered trademarks of the Institute of Electrical and Electronics Engineers, Incorporated. ** ISO is a registered trademark of the International Organization of Standards.

Data Sheet

KHHD006A0A Hammerhead™ Series; DC-DC Converter Power Modules

18-75Vdc Input; 5.0Vdc, 6A Output

Absolute Maximum Ratings

Stresses in excess of the absolute maximum ratings can cause permanent damage to the device. These are absolute stress ratings only, functional operation of the device is not implied at these or any other conditions in excess of those given in the operations sections of the data sheet. Exposure to absolute maximum ratings for extended periods can adversely affect the device reliability.

Parameter Device Symbol Min Max Unit

Input Voltage (Continuous) All V

Transient (100ms) All V

Operating Ambient Temperature All T

(see Thermal Considerations section)

Storage Temperature All T

Altitude* All

I/O Isolation Voltage (100% factory Hi-Pot tested) All

IN, trans

stg

⎯ ⎯

* For higher altitude applications, contact your GE Sales Representative for alternative conditions of use.

Electrical Specifications

Unless otherwise indicated, specifications apply at VIN = 48Vdc, resistive load, and TA = 25°C conditions.

Parameter Device Symbol Min Typ Max Unit

Operating Input Voltage All VIN 18 24/48 75 Vdc

Input No Load Current

(VIN = 48Vdc IO = 0A, module enabled)

Input Stand-by Current

(VIN = 24 to 48Vdc, module disabled)

Maximum Input Current (VIN=18Vdc, IO= I

Inrush Transient All I2t 0.05 A2s

Input Reflected Ripple Current, peak-to-peak (5Hz to 20MHz, 12μH source impedance; V see Test configuration section)

Input Ripple Rejection (120Hz) All 60 dB

) All I

O,MAX

=0V to 75Vdc, IO= I

Omax

;

All I

All 30 mA

IN,No load

6 8 mA

IN,stand-by

IN, MAX

-0.3 80 Vdc

-0.3 100 Vdc

-40 85 °C

-55 125 °C

4000 m

2250 Vdc

40 50 mA

2.5 Adc

p-p

EMC, EN55022 See EMC Considerations section

CAUTION: This power module is not internally fused. An input line fuse must always be used.

This power module can be used in a wide variety of applications, ranging from simple standalone operation to being part of complex power architecture. To preserve maximum flexibility, internal fusing is not included; however, to achieve maximum safety and system protection, always use an input line fuse. The safety agencies require a fast-acting fuse with a maximum rating of 5A. (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.

Data Sheet

KHHD006A0A Hammerhead™ Series; DC-DC Converter Power Modules

18-75Vdc Input; 5.0Vdc, 6A Output

Electrical Specifications (continued)

Unless otherwise indicated, specifications apply at VIN = 48Vdc, resistive load, and TA = 25°C conditions.

Parameter Device Symbol Min Typ Max Unit

Output Voltage Set-point

=24 to 48Vdc, IO=I

O, max

All V

O, set

Output Voltage

(Over all operating input voltage, resistive load, and temperature

All V

conditions until end of life) Adjustment Range Selected by external resistor Remote Sense Range Output Regulation

Line (VIN=V

Load (IO=I

Temperature (T

IN, min

O, min

to V

) All

IN, max

to I

) All

O, max

to T

ref=TA, min

) All

A, max

Output Ripple and Noise on nominal output

All V

All

O, adj

+10 % V

Measured with 10uF Tantalum||1uF ceramic

(VIN=24 to 48Vdc, IO=80%I

RMS (5Hz to 20MHz bandwidth)

Peak-to-Peak (5Hz to 20MHz bandwidth) External Capacitance (see Note 1 in Feature Specifications) All C Output Current (VIN =36V to 75V) All I

(VIN =18V to 36V) All I

Output Current Limit Inception (Hiccup Mode) (VIN =36V to 75V) All I

(VIN =18V to 36V) All I

Output Short-Circuit Current (VO ≤ 250 mV) All I

Efficiency (VIN=24Vdc, IO=I

Efficiency (VIN=48Vdc, IO=I

Switching Frequency (Fixed) VIN=24 to 48Vdc, IO= I

O, max

)

O, max

All

) All η 89.0 90.0

O, max

) All η 90.0 91.0

O, max

All f

O, max

O, lim

O, s/c

Dynamic Load Response

(ΔIo/Δt=0.1A/μs)

Load Change from Io= 50% to 75% or 25% to 50% of I

o,max

Peak Deviation All Vpk

Settling Time (Vo<10% peak deviation) All ts

4.95 5.00 5.05 Vdc

-3.0

-20

⎯ ⎯ ⎯ ⎯

⎯ ⎯

⎯

0.05 0.2 % V

10 25 mV 60 100 mV ⎯

+3.0 % V

+10 % V

1.0 % V

5000 μF

O, set

rms

pk-pk

0 0

⎯ ⎯

6 Adc 6 Adc

⎯

2.5

350

3.0

400

8.5 Adc

⎯

kHz

% V

μs

rms

O, set

Isolation Specifications

Parameter Symbol Min Typ Max Unit

Isolation Capacitance C

Isolation Resistance R

I/O Isolation Voltage All

iso

⎯

⎯ ⎯

1000

⎯ ⎯

⎯

2250 Vdc

MΩ

Data Sheet

KHHD006A0A Hammerhead™ Series; DC-DC Converter Power Modules

18-75Vdc Input; 5.0Vdc, 6A Output

General Specifications

Parameter Min Typ Max Unit

Calculated Reliability based upon Telcordia SR-332 Issue 2: Method I Case 3 (I

=80%I

, TA=40°C, airflow = 200 lfm, 90% confidence)

O, max

Weight

FIT >270 10

MTBF >3,600,000 Hours

⎯

13 (0.46)

⎯

Feature Specifications

Unless otherwise indicated, specifications apply at VIN = 48Vdc, resistive load, and TA = 25°C conditions. See Feature Descriptions for additional information.

Parameter Device Symbol Min Typ Max Unit

Remote On/Off Signal Interface

(VIN=V

Signal referenced to V

Negative Logic: device code suffix “1”

Logic Low = module On, Logic High = module Off

Positive Logic: No device code suffix required

IN, min

to V

; open collector or equivalent,

IN, max

terminal)

IN-

/Hours

g (oz.)

Logic Low = module Off, Logic High = module On

Logic Low - Remote On/Off Current (V

= -0.7Vdc) All I

on/off

Logic Low - On/Off Voltage All V

Logic High Voltage (I

= 0Adc) All V

on/off

Logic High maximum allowable leakage current All I

on/off

⎯ ⎯

-0.7

2.4

⎯ ⎯

⎯

0.15 mA

0.8 Vdc

7 Vdc

25 μA

Turn-On Delay and Rise Times

(IO=80% of I

Case 1: Input power is applied for at least 1second, and then the On/Off input is set from OFF to ON (T

= 10% of V

Case 2: On/Off input is set to Module ON, and then input power is

applied

= VIN reaches V

delay

Output voltage Rise time (time for Vo to rise from 10% of V

o,set

Output Voltage Overshoot

(IO=80% of I

Output Overvoltage Protection

Input Undervoltage Lockout

Turn-on Threshold All V

Turn-off Threshold All V

Hysterisis All V

)

O, max

O, set

= on/off pin transition until

delay

)

All

until VO = 10% of V

IN, min

to 90% of V

O, max

)

o, set

, VIN= 24 to 48Vdc)

O,set

)

All T

All V

delay

Case1

delay

Case2

O, limit

uv/on

uv/off

rise

hyst

⎯

6.0

⎯

14 15

⎯

25 50 ms

35 50 ms

5 10 ms

3 % V

⎯

17 18 V

2.0

7.0 Vdc

⎯

Vdc

O, set

Note: 1.The module requires a minimum of 680 μF external output capacitor to avoid exceeding the OVP maximum limits during startup into open loop fault conditions.

On/Off

VOLTAGE

OUTPUT

VOLTAGE

Data Sheet

KHHD006A0A Hammerhead™ Series; DC-DC Converter Power Modules

18-75Vdc Input; 5.0Vdc, 6A Output

Characteristic Curves

The following figures provide typical characteristics for the KHHD006A0A (5.0V, 6A) at 25oC. The figures are identical for either positive or negative remote On/Off logic.

(A)

EFFICIENCY, η (%)

OUTPUT CURRENT, IO (A) INPUT VOLTAGE, VIN (V)

Figure 1. Converter Efficiency versus Output Current.

75Vin

48Vin

24Vin

(V) (50mV/div)

OUTPUT VOLTAGE

18Vin

TIME, t (2μs/div) TIME, t (500μs/div)

= I

Figure 3. Typical output ripple and noise (I

( (V) (2V/div)

o,max

INPUT CURRENT, I

Figure 2. Converter Input Current versus Input Voltage.

(V) (200mV/div)

OUTPUT CURRENT OUTPUT VOLTAGE

Io(A) (2A/div) V

). Figure 4. Transient Response to 0.1A/µS Dynamic Load

Change from 50% to 75% to 50% of full load, Vin=48V.

(V) (2V/div)

V) (2V/div) V

On/Off

TIME, t (10ms/div) TIME, t (10ms/div)

Figure 5.Typical Start-up Using Remote On/Off, negative logic version shown (V

= 24V or 48V, Io = I

o,max

(V) (20V/div) V

INPUT VOLTAGE OUTPUT VOLTAGE

Figure 6. Typical Start-up Using Input Voltage (V I

o,max

= 48V, Io=

Data Sheet

KHHD006A0A Hammerhead™ Series; DC-DC Converter Power Modules

18-75Vdc Input; 5.0Vdc, 6A Output

Test Configurations

Vout+

Vout-

x 100 %

CURRENT PROBE

33μF

SC O PE

Vin+

Vin-

RESISTI V E

LO A D

contact Rdistribution

TO OSCILLOSCOPE

TEST

12μH

CS 220μF

BATTERY

NOTE: Measure input reflected ripple current with a simulated

E.S.R.<0.1Ω

@ 20°C 100kHz

source inductance (L possible battery impedance. Measure current as shown above.

) of 12μH. Capacitor CS offsets

TEST

Figure 7. Input Reflected Ripple Current Test Setup.

C OP PER STRIP

(+)

1uF .

( – )

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.

10uF

GROUND PLANE

Figure 8. Output Ripple and Noise Test Setup.

contact

distribution

contact

distribution

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 c ontact resistance.

Vin+

Vin-

Figure 9. Output Voltage and Efficiency Test Setup.

. I

Efficiency

VIN. I

LOAD

Design Considerations

Input Source Impedance

The power module should be connected to a low ac-impedance source. Highly inductive source impedance can affect the stability of the power module. For the test configuration in Figure 7, a 33μF electrolytic capacitor (ESR<0.7Ω at 100kHz), mounted close to the power module helps ensure the stability of the unit. Consult the factory for further application guidelines.

Safety Considerations

For safety-agency approval of the system in which the power module is used, the power module must be installed in compliance with the spacing and separation requirements of the end-use safety agency standard, i.e., UL 60950-1-3, CSA C22.2 No. 60950-00, and VDE 0805 (IEC60950, 3

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 V

pin and one V

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.

For input voltages exceeding –60 Vdc but less than or equal to –75 Vdc, these converters have been evaluated to the applicable requirements of BASIC INSULATION between secondary DC MAINS DISTRIBUTION input (classified as TNV-2 in Europe) and unearthed SELV outputs.

The input to these units is to be provided with a maximum 6A fast acting fuse in the ungrounded lead.

pin are to be grounded, or both

OUT

Edition).

Data Sheet

KHHD006A0A Hammerhead™ Series; DC-DC Converter Power Modules

18-75Vdc Input; 5.0Vdc, 6A Output

Feature Description

Remote On/Off

Two remote on/off options are available. Positive logic turns the module on during a logic high voltage on the on/off pin, and off during a logic low. Negative logic remote on/off, device code suffix “1”, turns the module off during a logic high and on during a logic low.

Vin+

on/off

ON/OFF

Vin-

Figure 10. Circuit configuration for using 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

) between the ON/OFF terminal and the VIN(-) terminal.

on/off

Logic low is 0V ≤ V

≤ 0.8V. The maximum I

on/off

logic low is 0.15mA, the switch should be maintain a logic low level whilst sinking this current.

During a logic high, the typical V is 4.0V, and the maximum allowable leakage current at V

4.0V is 25μA. 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 V

Overcurrent Protection

To provide protection in a fault (output overload) condition, the unit is equipped with internal current-limiting circuitry and can endure current limiting continuously. At the point of current-limit inception, the unit enters hiccup mode. If the unit is not configured with auto–restart, then it will latch off following the over current condition. The module can be restarted by cycling the dc input power or by toggling the remote on/off signal. If the unit is configured with the autorestart option (4), it will remain in the hiccup mode as long as the overcurrent condition exists; it operates normally, once the output current is brought back into its specified range.

Overtemperature Protection

To provide protection under certain fault conditions, the unit is equipped with a thermal shutdown circuit. The unit will shut down if the thermal reference point Tref (Figure 16), exceeds

C (typical), but the thermal shutdown is not intended as a

135 guarantee that the unit will survive temperatures beyond its rating. The module will automatically restart upon cool-down to a safe temperature.

Vout+

TRIM

Vout-

during a

on/off

generated by the module

on/off

(-).

on/off

Input Undervoltage Lockout

At input voltages below the input undervoltage lockout limit, the module operation is disabled. The module will only begin to operate once the input voltage is raised above the undervoltage lockout turn-on threshold, V

UV/ON

Once operating, the module will continue to operate until the input voltage is taken below the undervoltage turn-off threshold, V

UV/OFF

Over Voltage Protection

The output overvoltage protection shall consist of circuitry that independently monitors the output voltage, and shuts the module down if the output voltage exceeds specified limits. This protection feature latches in the event of over voltage across the output. Cycling the on/off pin or input voltage resets the latching protection feature. If the auto-restart option (4) is ordered, the module will automatically restart upon an internally programmed time elapsing.

Output Voltage Programming

Trimming allows the user to increase or decrease the output voltage set point of the module. This is accomplished by connecting an external resistor between the TRIM pin and either the Vout+ pin or the Vout- pin.

Trim Down – Decrease Output Voltage

By connecting an external resistor (R pin and V

(-) or SENSE(-) pin (see figure 11), the output voltage

set point decreases. The following equation determines the external resistor value to obtain an output voltage change

from V

Where

to the desired V

o,set



−kRdownadj

 

511

=Δ

o,desired



−

   

22.10

 

−



desiredoseto



seto



Figure 11. Circuit Configuration to Decrease Output Voltage.

) between the TRIM

adj-down

100%

Trim Up – Increase Output Voltage

By connecting an external resistor (R pin and V

(+) or SENSE(+) pin (see figure 12), the output voltage

set point increases. The following equation determines the external resistor value to obtain an output voltage change from V

to the desired V

o,set

o,desired

) between the TRIM

adj-up

Data Sheet

KHHD006A0A Hammerhead™ Series; DC-DC Converter Power Modules

18-75Vdc Input; 5.0Vdc, 6A Output

Feature Descriptions



−

upadj

 

Where

Figure 12. Circuit Configuration to Increase Output Voltage.

The combination of the output voltage adjustment and the output voltage initial tolerance must not exceed the allowable trim range of 80% to 110% of the nominal output voltage as measured between the Vout+ and Vout- pins.

The KHHD006A0A power modules have a fixed current-limit set point. Therefore, as the output voltage is adjusted down, the available output power is reduced.

seto

 

=Δ

 

Δ×

seto

(continued)

Δ+××

%225.1

−

setodesiredo

%)100(11.5

511

− Δ

 

100%

 



−

22.10

 

Pre-bias Vin Under Voltage Test

The module shall recover from UVLO [Under Voltage Lock Out] without protective shutdown from OCP or OVP or hard failure, when subjected to Vin Under Voltage transients with the following conditions:

Vin(V) Tdip (ms) Co (uF) Load (A)

48 5 0 0 48 5 2200 0 48 10 0 0 48 10 2200 0 48 5 0 10 48 5 2200 10 48 10 0 10 48 10 2200 10 60 5 0 0 60 5 2200 0 60 10 0 0 60 10 2200 0 60 5 0 10 60 5 2200 10 60 10 0 10 60 10 2200 10

Vin

Tfall = 10us

Tdip

Trise = 5us

Thermal Considerations

The power modules operate in a variety of thermal environments; however, sufficient cooling should be provided to help ensure reliable operation.

Considerations include ambient temperature, airflow, module power dissipation, and the need for increased reliability. A reduction in the operating temperature of the module will result in an increase in reliability.

The thermal data presented here is based on physical measurements taken in a wind tunnel, using automated thermo-couple instrumentation to monitor key component temperatures: FETs, diodes, control ICs, magnetic cores, ceramic capacitors, opto-isolators, and module pwb conductors, while controlling the ambient airflow rate and temperature. For a given airflow and ambient temperature, the module output power is increased, until one (or more) of the components reaches its maximum derated operating temperature, as defined in IPC-9592A. This procedure is then repeated for a different airflow or ambient temperature until a family of module output derating curves is obtained.

Figure 13. Thermal Test Setup .

Heat Transfer via Convection

Increased airflow over the module enhances the heat transfer via convection. Derating figures showing the maximum output current that can be delivered by each module versus local ambient temperature (T 3m/s (600 ft./min) are shown in the respective Characteristics Curves section.

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.

) for natural convection and up to

Data Sheet

KHHD006A0A Hammerhead™ Series; DC-DC Converter Power Modules

18-75Vdc Input; 5.0Vdc, 6A Output

Thermal Considerations (continued)

(A)

Ci See Figure 7 C1, C4 2.2uF, 100V, 1210

1210Y1K50103KXTDWV, 10nF, 1500V (*2) RDHX223K302HKT, 22nF, 3000V (Holystone)

GRM32DR73A153KW01L, 15nF, 1000V (*2) RDHX333K302HKT, 33nF, 3000V (Holystone) 202S48W334KT, 33nF, 2000V (Johanson)

OUTPUT CURRENT, I

LOCAL AMBIENT TEMPERATURE, TA (°C)

Figure 14. Output Current Derating for the Open Frame KHHD006A0A in the Transverse Orientation; Airflow Direction from Vin(+) to Vin(-); Vin = 24V.

C2, C3

C5, C6

Figure 17. Suggested Configuration for EN55022 Class B.

(A)

OUTPUT CURRENT, I

LOCAL AMBIENT TEMPERATURE, TA (°C)

Figure 15. Output Current Derating for the Open Frame KHHD006A0A in the Transverse Orientation; Airflow Direction from Vin(+) to Vin(-); Vin = 48V.

The thermal reference point, T shown in Figure 16. For reliable operation this temperature should not exceed 135

Figure 16. T

ref

Temperature Measurement Location.

used in the specifications is

ref,

EMC Requirements

Figure 17 shows a maximum filter configuration to meet the conducted emission limits of EN55022 Class B.

Notes: C1 and C4 are low impedance SMT ceramics.

Figure 18. EMC signature using above filter, KHHD006A0A.

For further information on designing for EMC compliance, please refer to the FLTR100V10 data sheet (FDS01-043EPS).

Layout Considerations

The KHHD006A0A power module series are low profile in order to be used in fine pitch system card architectures. As such, component clearance between the bottom of the power module and the mounting board is limited. Avoid placing copper areas on the outer layer directly underneath the power module. Also avoid placing via interconnects underneath the power module.

For additional layout guide-lines, refer to the FLTR100V10 data sheet.

The KHHD006A0A family of power modules is available for either Through-Hole (TH) or Surface Mount (SMT) soldering.

Through-Hole Soldering Information

The RoHS-compliant (Z codes) through-hole products use the SAC (Sn/Ag/Cu) Pb-free solder and RoHS-compliant components. They are designed to be processed through single or dual wave soldering machines. The pins have an

Data Sheet

KHHD006A0A Hammerhead™ Series; DC-DC Converter Power Modules

18-75Vdc Input; 5.0Vdc, 6A Output

Layout Considerations (continued)

RoHS-compliant finish that is compatible with both Pb and Pbfree wave soldering processes. A maximum preheat rate of 3

°C/s is suggested. The wave preheat process should be such

that the temperature of the power module board is kept below 210

°C. For Pb solder, the recommended pot temperature is

260

°C, while the Pb-free solder pot is 270°C max. Not all RoHS-

compliant through-hole products can be processed with pastethrough-hole Pb or Pb-free reflow process. If additional information is needed, please consult with your GE representative for more details.

Surface Mount Information

Pick and Place

The KHHD-SR series of DC-to-DC power converters use an open-frame construction and are designed for surface mount assembly within a fully automated manufacturing process.

The KHHD-SR series modules are designed to use the main magnetic component surface to allow for pick and place.

Note: All dimensions in mm [in].

Figure 19. Pick and Place Location.

Z Plane Height

The ‘Z’ plane height of the pick and place location is 7.50mm nominal with an RSS tolerance of +/-0.25 mm.

Nozzle Recommendations

The module weight has been kept to a minimum by using open frame construction. Even so, they have a relatively large mass when compared with conventional SMT components. Variables such as nozzle size, tip style, vacuum pressure and placement speed should be considered to optimize this process.

The minimum recommended nozzle diameter for reliable operation is 5mm. The maximum nozzle outer diameter, which will safely fit within the allowable component spacing, is

6.5mm. Oblong or oval nozzles up to 11 x 6 mm may also be used

within the space available. For further information please contact your local GE Technical

Sales Representative.

Reflow Soldering Information

These power modules are large mass, low thermal resistance devices and typically heat up slower than other SMT components. It is recommended that the customer review data sheets in order to customize the solder reflow profile for each application board assembly.

The following instructions must be observed when SMT 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.

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. The recommended linear reflow profile using Sn/Pb solder is shown in Figure 20 and 21. For reliable soldering the solder reflow profile should be established by accurately measuring the module’s pin connector temperatures.

300

250

200

150

10 0

REFLOW TEMP (°C)

Pe ak Temp 235oC

Heat zo ne

oCs-1

max 4

Soak zone 30-240s

Pr eheat zone

oCs-1

max 4

REFLOW TIME (S)

T 205

lim

Co oling zo ne 1- 4

above

oCs-1

Figure 20. Recommended Reflow Profile for Sn/Pb solder.

240

235

230

225

220

215

210

MAX TEMP SOLDER (°C)

205

200

0 10 203040 5060

TIME LIMIT (S)

Figure 21. Time Limit, T

, Curve Above 205oC Reflow .

lim

Lead Free Soldering

The –Z version SMT modules of the KHHD006A0A series are lead-free (Pb-free) and RoHS compliant and are compatible in a Pb-free soldering process. Failure to observe the instructions below may result in the failure of or cause damage to the modules and can adversely affect long-term reliability.

Data Sheet

KHHD006A0A Hammerhead™ Series; DC-DC Converter Power Modules

18-75Vdc Input; 5.0Vdc, 6A Output

Surface Mount Information (continued)

Pb-free Reflow Profile

Power Systems will comply with J-STD-020 Rev. D (Moisture/Reflow Sensitivity Classification for Nonhermetic Solid State Surface Mount Devices) for both Pb-free solder profiles and MSL classification procedures. This standard provides a recommended forced-air-convection reflow profile based on the volume and thickness of the package (table 4-2). The suggested Pb-free solder paste is Sn/Ag/Cu (SAC). The recommended linear reflow profile using Sn/Ag/Cu solder is shown in Figure 22.

300

250

200

150

Reflow Temp (°C)

100

Per J-STD-020 Rev. D

Heating Zone

1°C/Second

Peak Temp 260°C

* Min. Time Above 235°C

15 Seconds

*Time Above 217°C

60 Seconds

Cooling

Zone

Reflow Time (Seconds)

Figure 22. Recommended linear reflow profile using Sn/Ag/Cu solder.

MSL Rating

The KHHD006A0A series SMT modules have a MSL rating of 2a.

Storage and Handling

The recommended storage environment and handling procedures for moisture-sensitive surface mount packages is detailed in J-STD-033 Rev. A (Handling, Packing, Shipping and Use of Moisture/Reflow Sensitive Surface Mount Devices). Moisture barrier bags (MBB) with desiccant are required for MSL ratings of 2 or greater. These sealed packages should not be broken until time of use. Once the original package is broken, the floor life of the product at conditions of

≤ 30°C and

60% relative humidity varies according to the MSL rating (see J-STD-033A). The shelf life for dry packed SMT packages will be a minimum of 12 months from the bag seal date, when stored at the following conditions: < 40° C, < 90% relative humidity.

Post Solder Cleaning and Drying Considerations

Post solder cleaning is usually the final circuit board assembly process prior to electrical board testing. The result of inadequate cleaning and drying can affect both the reliability of a power module and the testability of the finished circuit board assembly. For guidance on appropriate soldering, cleaning and drying procedures, refer to Lineage Power Board Mounted Power Modules: Soldering and Cleaning Application Note (AN04-001).

Data Sheet

KHHD006A0A Hammerhead™ Series; DC-DC Converter Power Modules

18-75Vdc Input; 5.0Vdc, 6A Output

Mechanical Outline for KHHD006A0A Surface-Mount Module

Dimensions are in millimeters and [inches].

Tolerances: x.x mm x.xx mm

Top

View

Side

View

0.5 mm [x.xx in. ± 0.02 in.] (Unless otherwise indicated)

0.25 mm [x.xxx in ± 0.010 in.]

Bottom

View

PIN FUNCTION

1 V 2 On/Off 3 V 4 V 5 Sense 6 Trim 7 Sense 8 Vo

IN(+)

IN(-)

o(-)

(-)

(+)

Data Sheet

KHHD006A0A Hammerhead™ Series; DC-DC Converter Power Modules

18-75Vdc Input; 5.0Vdc, 6A Output

Mechanical Outline for KHHD006A0A Through Hole Module

Dimensions are in millimeters and [inches]. Tolerances: x.x mm x.xx mm

Top

View

Side

View

± 0.5 mm [x.xx in. ± 0.02 in.] (Unless otherwise indicated)

± 0.25 mm [x.xxx in ± 0.010 in.]

* Optional PIN Lengths shown In Device Option Table

Bottom View

PIN FUNCTION

1 VIN(+) 2 On/Off 3 VIN(-) 4 Vo(-) 5 Sense(-) 6 Trim 7 Sense(+) 8 Vo(+)

Data Sheet

KHHD006A0A Hammerhead™ Series; DC-DC Converter Power Modules

18-75Vdc Input; 5.0Vdc, 6A Output

Recommended Pad Layout for Surface Mount and Through Hole Module

Dimensions are in millimeters and [inches].

Tolerances: x.x mm x.xx mm

0.5 mm [x.xx in. ± 0.02 in.] (Unless otherwise indicated)

0.25 mm [x.xxx in ± 0.010 in.]

Surface Mount Pad Layout

Through-Hole Pad Layout

For .025 x .030 rectangular pin, use a .050 diameter plated through hole

For .062 diameter pin, use a .076 diameter plated through hole.

Data Sheet

KHHD006A0A Hammerhead™ Series; DC-DC Converter Power Modules

18-75Vdc Input; 5.0Vdc, 6A Output

Packaging Details

The KHHD006A0A series 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

Reel Dimensions

Outside Diameter: 330mm Inside Diameter: 178mm Tape Width: 56mm

Tray Dimensions

The KHHD006A0A - series Through Hole versions are supplied in trays as standard. Details of tray dimensions are shown below. Modules are shipped in quantities of 75 modules per box. Dimensions are in millimeters. Tolerances: x.x mm x.xx mm

± 0.5 mm (unless otherwise indicated)

± 0.25 mm

Material PET (1mm)

Max surface

resistivity

Color Clear

Capacity 25power modules

Min order

quantity

-1011Ω/PET

75pcs (1 box of 3 full

trays + 1 empty top

tray)

Data Sheet

KHHD006A0A Hammerhead™ Series; DC-DC Converter Power Modules

18-75Vdc Input; 5.0Vdc, 6A Output

Ordering Information

Please contact your GE Sales Representative for pricing, availability and optional features.

Table 1. Device Codes

Product codes Input Voltage Output Current

KHHD006A0A41Z 24V/48V (18-75Vdc) 6 5V Negative Through hole

KHHD006A0A41-SRZ 24V/48V (18-75Vdc) 6 5V Negative Surface mount

Table 2. Device Options

Characteristic Definition

Form Factor K K = 1 /16th Brick Family Designator HH Input Voltage D D = UltraWide Range, 18V-75V

RatingsOptions

Output Current 006A0 006A0 = 006.0 Amps Maximum Output Current Output Voltage A A=5V Nominal

Pin Length

Action following Protective Shutdown

On/Off Logic

Customer Specific XY

Mechanical Features

RoHS

Character and Position

6 8

Output

Voltage

= Hammerhead™ Series

Omit = Default Pin Length shown in Mechanical Outline Figures

= Pin Length: 3.68 mm ± 0.25mm , (0.145 in. ± 0.010 in.)

= Pin Length: 2.79 mm ± 0.25mm , (0.110 in. ± 0.010 in.)

= Auto-restart follow ing shutdown (Overcurrent/Overvoltage)

Must be ordered Omit = Positive Logic

= Negative Logic

= Customer Specific Modified Code, Omit for Standard Code

Omit = Standard open Frame Module

SRS = Surface Mount connections: R = Tape & Reel Packaging

Omit = RoHS 5/6, Lead Based Solder Used

ZZ = RoHS 6/6 Compliant, Lead free

Remote On/Off

Logic

Connector

Type

Comcodes

150030197

150030196

For more information, call us at

USA/Canada:

+1 888 546 3243, or +1 972 244 9288

Asia-Pacific:

+86.021.54279977*808

Europe, Middle-East and Africa:

+49.89.878067-280

India: +91.80.28411633

www.gecriticalpower.com

GE Industrial Solutions KHHD006A0A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual