GE
Data Sheet
September 26, 2013
©2013 General Electric Corporation. All rights reserved.
Page 1
Features
Compliant to REACH Directive (EC) No 1907/2006
Compliant to RoHS II EU “Directive 2011/65/EU”
Ultra-wide Input Voltage Range, 36V
dc
to 75Vdc
No minimum load
High efficiency – 90% at full load (V
IN
=48Vdc)
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
o,nom
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 60950-
1:2006 +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
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
Description
The KSTW002A5B series power modules are isolated DOSA compliant 1/16th brick dc-dc converters that operate over a wide
input voltage range of 36 Vdc -75Vdc and provide a single precisely regulated output voltage at 12Vdc. 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 selfprotected 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
*Trademark of General Electric Corporation
#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.
RoHS Compliant
KSTW002A5B Barracuda* Series; DC-DC Converter Power Modules
36-75Vdc Input; 12Vdc, 2.5A Output
GE
Data Sheet
KSTW002A5B Barracuda* Series; DC-DC Converter Power Modules
36-75Vdc Input; 12Vdc, 2.5A Output
September 26, 2013
©2013 General Electric Corporation. All rights reserved.
Page 2
Parameter
Device
Symbol
Min
Max
Unit
Input Voltage (Continuous)
All
V
IN
-0.3
80
Vdc
Transient (100ms)
All
V
IN, trans
-0.3
100
Vdc
Operating Ambient Temperature
All
TA -40
85
°C
(see Thermal Considerations section)
Storage Temperature
All
T
stg
-55
125
°C
Altitude*
All
4000
m
I/O Isolation Voltage (100% factory Hi-Pot tested)
All
2250
Vdc
Parameter
Device
Symbol
Min
Typ
Max
Unit
Operating Input Voltage
All
VIN
36
48
75
Vdc
Input No Load Current
All
I
IN,No load
45 mA
(VIN = 48Vdc IO = 0A, module enabled)
Input Stand-by Current
All
I
IN,stand-by
8 mA
(VIN = 36 to 48Vdc, module disabled)
Maximum Input Current (VIN=36Vdc, IO= I
O,MAX
)
All
I
IN, MAX
1.2
Adc
Inrush Transient
All
I2t
0.05
A2s
Input Reflected Ripple Current, peak-to-peak
(5Hz to 20MHz, 12μH source impedance; VIN=36V to 75Vdc, IO= I
Omax
;
see Test configuration section)
All
25 mA
p-p
Input Ripple Rejection (120Hz)
All
60 dB
EMC, EN55022 See EMC Considerations section
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.
* 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.
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 3A
(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.
GE
Data Sheet
KSTW002A5B Barracuda ™ Series; DC-DC Converter Power Modules
36-75Vdc Input; 12Vdc, 2.5A Output
September 26, 2013
©2013 General Electric Corporation. All rights reserved.
Page 3
Parameter
Device
Symbol
Min
Typ
Max
Unit
Output Voltage Set-point
(VIN= 48Vdc, IO=I
O, max
,)
All
V
O, set
11.82
12.00
12.18
Vdc
Output Voltage
All
VO -3.0 +3.0
% V
O, set
(Over all operating input voltage, resistive load, and temperature
conditions until end of life)
Adjustment Range
All
V
O, adj
-20 +10
% V
O, set
Selected by external resistor
Remote Sense Range
All
+10
% V
O, set
Output Regulation
Line (VIN=V
IN, min
to V
IN, max
)
All
0.05
0.2
% V
O, set
Load (IO=I
O, min
to I
O, max
)
All
0.05
0.2
% V
O, set
Temperature (T
ref=TA, min
to T
A, max
)
All
1.0
% V
O, set
Output Ripple and Noise on nominal output
Measured with 10uF Tantalum||1uF ceramic
(VIN= 48Vdc, IO=80%I
O, max
)
RMS (5Hz to 20MHz bandwidth)
All
30 mV
rms
Peak-to-Peak (5Hz to 20MHz bandwidth)
100
mV
pk-pk
External Capacitance (see Note 1 in Feature Specifications)
All
C
O, max
0 2200
μF
Output Current
(VIN =36V to 75V)
All
Io 0 2.5
Adc
Output Current Limit Inception (Hiccup Mode)
(VIN =36V to 75V)
All
I
O, lim
2.7 3.8
Adc
Output Short-Circuit Current (VO ≤ 250 mV)
All
I
O, s/c
2.7 A
rms
Efficiency (VIN=48Vdc, IO=I
O, max
)
All η
90 %
Switching Frequency (Fixed)
All
f
sw
350 kHz
VIN=36 to 48Vdc, IO= I
O, max
Dynamic Load Response
(Io/t=0.1A/s)
Load Change from Io= 50% to 75% or 25% to 50% of I
o,max
:
Peak Deviation
All
Vpk 2 % V
O, set
Settling Time (Vo<10% peak deviation)
All
ts 200
s
Parameter
Symbol
Min
Typ
Max
Unit
Isolation Capacitance
C
iso
1000 pF
Isolation Resistance
R
iso
10
MΩ
I/O Isolation Voltage
All
2250
Vdc
Parameter
Min
Typ
Max
Unit
Calculated Reliability based upon Telcordia SR-332 Issue 2: Method I Case 3
(IO=80%I
O, max
, TA=40°C, airflow = 200 lfm, 90% confidence)
FIT
>270
109/Hours
MTBF
>3,600,000
Hours
Weight
13 (0.46)
g (oz.)
Electrical Specifications (continued)
Unless otherwise indicated, specifications apply at VIN = 48Vdc, resistive load, and TA = 25°C conditions.
Isolation Specifications
General Specifications
GE
Data Sheet
KSTW002A5B Barracuda* Series; DC-DC Converter Power Modules
36-75Vdc Input; 12Vdc, 2.5A Output
September 26, 2013
©2013 General Electric Corporation. All rights reserved.
Page 4
Parameter
Device
Symbol
Min
Typ
Max
Unit
Remote On/Off Signal Interface
(VIN=V
IN, min
to V
IN, max
; open collector or equivalent,
Signal referenced to V
IN-
terminal)
Negative Logic: device code suffix “1”
Logic Low = module On, Logic High = module Off
Positive Logic: No device code suffix required
Logic Low = module Off, Logic High = module On
Logic Low - Remote On/Off Current (V
on/off
= -0.7Vdc)
All
I
on/off
0.15
mA
Logic Low - On/Off Voltage
All
V
on/off
-0.7 0.8
Vdc
Logic High Voltage (I
on/off
= 0Adc)
All
V
on/off
2.4 7
Vdc
Logic High maximum allowable leakage current
All
I
on/off
25
μA
Turn-On Delay and Rise Times
(IO=80% of I
O, max
)
Case 1: Input power is applied for at least 1second, and then the
On/Off input is set from OFF to ON (T
delay
= on/off pin transition until
VO = 10% of V
O, set
)
All
T
delay
Case1
30
50
ms
Case 2: On/Off input is set to Module ON, and then input power is
applied
(T
delay
= VIN reaches V
IN, min
until VO = 10% of V
O,set
)
All
T
delay
Case2
20
50
ms
Output voltage Rise time (time for Vo to rise from 10%
of V
o,set
to 90% of V
o, set
)
All
T
rise
5
10
ms
Output Voltage Overshoot
3
% V
O, set
(IO=80% of I
O, max
, VIN= 48Vdc)
Output Overvoltage Protection (see Note1 below)
All
V
O, limit
14 17
Vdc
Input Undervoltage Lockout
Turn-on Threshold
All
V
uv/on
34
36
Vdc
Turn-off Threshold
All
V
uv/off
30
32 Vdc
Hysteresis
All
V
hyst
2.0 Vdc
Feature Specifications
Unless otherwise indicated, specifications apply at VIN = 48Vdc, resistive load, and TA = 25°C conditions. See Feature Descriptions for
additional information.
Note: 1.The module requires a minimum of 220 μF external output capacitor to avoid exceeding the OVP maximum limits during startup into open
loop fault conditions.
GE
Data Sheet
KSTW002A5B Barracuda* Series; DC-DC Converter Power Modules
36-75Vdc Input; 12Vdc, 2.5A Output
September 26, 2013
©2013 General Electric Corporation. All rights reserved.
Page 5
EFFICIENCY, (%)
INPUT CURRENT, I
IN
(A)
OUTPUT CURRENT, IO (A)
INPUT VOLTAGE, VIN (V)
Figure 1. Converter Efficiency versus Output Current.
Figure 2. Converter Input Current versus Input Voltage.
OUTPUT VOLTAGE
V
O
(V) (100mV/div)
OUTPUT CURRENT OUTPUT VOLTAGE
Io(A) (1A/div) V
O
(V) (200mV/div)
TIME, t (2s/div)
TIME, t (200µs/div)
Figure 3. Typical output ripple and noise (Io = Io,max).
Figure 4. Transient Response to 0.1A/µS Dynamic Load
Change from 50% to 75% to 50% of full load, Vin=48V,
CO>100μF
On/Off VOLTAGE OUTPUT VOLTAGE
V
On/Off
(V) (2V/div) V
O
(V) (5V/div)
INPUT VOLTAGE OUTPUT VOLTAGE
V
IN
(V) (20V/div) V
O
(V) (5V/div )
TIME, t (10ms/div)
TIME, t (10ms/div)
Figure 5.Typical Start-up Using Remote On/Off, negative
logic version shown (VIN = 48V, Io = I
o,max
).
Figure 6. Typical Start-up Using Input Voltage (VIN = 48V, Io =
Io,max).
Characteristic Curves
The following figures provide typical characteristics for the KSTW002A5B (12.0V, 2.5A) at 25oC. The figures are identical for either
positive or negative remote On/Off logic.
GE
Data Sheet
KSTW002A5B Barracuda* Series; DC-DC Converter Power Modules
36-75Vdc Input; 12Vdc, 2.5A Output
September 26, 2013
©2013 General Electric Corporation. All rights reserved.
Page 6
TO OSCILLOSCOPE
CURRENT PROBE
L
TEST
12μH
BATTERY
CS 220μF
E.S.R.<0.1
@ 20°C 100kHz
33μF
Vin+
Vin-
NOTE: Measure input reflected ripple current with a simulated
source inductance (L
TEST
) of 12μH. Capacitor CS offsets
possible battery impedance. Measure current as shown
above.
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.
V
O
(+)
V
O
( – )
1uF .
RESISTIVE
LOAD
SCOPE
COPPER STRIP
GROUND PLANE
10uF
Vout+
Vout-
Vin+
Vin-
R
LOAD Rcontact Rdistribution
R
contact Rdistribution Rcontact
R
contact Rdistribution
R
distribution
V
IN VO
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.
=
VO.
I
O
VIN.
I
IN
x 100 % Efficiency
Test Configurations
Figure 7. Input Reflected Ripple Current Test Setup.
Figure 8. Output Ripple and Noise Test Setup.
Figure 9. Output Voltage and Efficiency Test Setup.
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<0.7 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, 3rd Edition).
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
IN
pin are to be grounded, or both
OUT
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 3A
fast acting fuse in the ungrounded lead.
GE
Data Sheet
KSTW002A5B Barracuda* Series; DC-DC Converter Power Modules
36-75Vdc Input; 12Vdc, 2.5A Output
September 26, 2013
©2013 General Electric Corporation. All rights reserved.
Page 7
ON/OFF
Vin+
Vin-
I
on/off
V
on/off
Vout+
TRIM
Vout-
kRdownadj
22.10
%
511
Where
100%
,
,,
seto
desiredoseto
V
VV
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.
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
(V
) between the ON/OFF terminal and the VIN(-) terminal.
on/off
Logic low is 0V ≤ V
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 VIN(-).
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 15), exceeds
135oC (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.
≤ 0.8V. The maximum I
on/off
on/off
during a
on/off
generated by the module
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 between the TRIM pin and
and Vo(-) 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
to the desired V
o,set
o,desired
:
Figure 11. Circuit Configuration to Decrease Output Voltage.
Trim Up – Increase Output Voltage
By connecting an external resistor between the TRIM pin and
VO(+) 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
:
GE
Data Sheet
KSTW002A5B Barracuda* Series; DC-DC Converter Power Modules
36-75Vdc Input; 12Vdc, 2.5A Output
September 26, 2013
©2013 General Electric Corporation. All rights reserved.
Page 8
k
V
R
seto
upadj
22.10
%
511
%225.1
%)100(11.5
,
Where
100%
,
,,
seto
setodesiredo
V
VV
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
2.5
48 5 2200
2.5
48
10 0 2.5
48
10
2200
2.5
60 5 0 0 60 5 2200
0
60
10 0 0
60
10
2200
0
60 5 0
2.5
60 5 2200
2.5
60
10 0 2.5
60
10
2200
2.5
Vin
5V
Tdip
Tfall = 10us
Trise = 5us
Feature Descriptions (continued)
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 KSTW002A5B power modules have a fixed current-limit set
point. Therefore, as the output voltage is adjusted down, the
available output power shall be reduced.
Pre-bias Vin Under Voltage Test
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.
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:
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 (TA) for natural convection and up to
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.
GE
Data Sheet
KSTW002A5B Barracuda* Series; DC-DC Converter Power Modules
36-75Vdc Input; 12Vdc, 2.5A Output
September 26, 2013
©2013 General Electric Corporation. All rights reserved.
Page 9
OUTPUT CURRENT, I
O
(A)
LOCAL AMBIENT TEMPERATURE, TA (C)
Figure 14. Output Current Derating for the Open Frame
KSTW002A5B in the Transverse Orientation; Airflow
Direction from Vin(-) to Vin(+); Vin = 48V.
Ci
See Figure 7
C1, C4
2.2uF, 100V, 1210
C2, C3
1210Y1K50103KXTDWV, 10nF, 1500V (*2)
RDHX223K302HKT, 22nF, 3kv
C5, C6
RDHX333K302HKT, 33nF, 3000V (Holystone)
202S48W334KT, 33nF, 2000V (Johanson)
The thermal reference point, T
shown in Figure 15. For reliable operation this temperature
should not exceed 119oC.
used in the specifications is
ref,
Figure 17. EMC signature using above filter, KSTW002A5B,
Vin=48V, Blue=PK, Red=Avg.
For further information on designing for EMC compliance,
please refer to the FLTR100V10 data sheet (FDS01-043EPS).
Layout Considerations
The KSTW002A5B power modules 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 KSTW002A5B power modules are available for either
Through-Hole (TH) or Surface Mount (SMT) soldering.
Figure 15. T
EMC Requirements
Figure 16 shows a maximum filter configuration to meet the
conducted emission limits of EN55022 Class B.
Notes: C1 and C4 are low impedance SMT ceramics.
Temperature Measurement Location.
ref
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
RoHS-compliant finish that is compatible with both Pb and Pbfree wave soldering processes. A maximum preheat rate of
3C/s is suggested. The wave preheat process should be such
that the temperature of the power module board is kept below
210C. For Pb solder, the recommended pot temperature is
260C, while the Pb-free solder pot is 270C max. Not all RoHS-
compliant through-hole products can be processed with pastethrough-hole Pb or Pb-free reflow process. If additional
information is needed, please consult with your GE
representative for more details.
Figure 16. Suggested Configuration for EN55022 Class B
GE
Data Sheet
KSTW002A5B Barracuda* Series; DC-DC Converter Power Modules
36-75Vdc Input; 12Vdc, 2.5A Output
September 26, 2013
©2013 General Electric Corporation. All rights reserved.
Page 10
REFLOW TEMP (C)
REFLOW TIME (S)
MAX TEMP SOLDER (C)
TIME LIMIT (S)
Surface Mount Information
Pick and Place
The KSTW-SR series of DC-to-DC power modules use an openframe construction and are designed for surface mount
assembly within a fully automated manufacturing process.
The KSTW-SR series of DC-to-DC power modules use an openframe construction and are designed for surface mount are
designed to use the main magnetic component surface to
allow for pick and place.
Note: All dimensions in mm [in].
Figure 18. 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.
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 19 and 20. For reliable soldering the solder
reflow profile should be established by accurately measuring
the module’s pin connector temperatures.
Figure 19. Recommended Reflow Profile for Sn/Pb solder.
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.
Figure 20. Time Limit, T
, Curve Above 205oC Reflow .
lim
Lead Free Soldering
The –Z version SMT modules of the KSTW002A5B 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.
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 forcedair-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 21.
GE
Data Sheet
KSTW002A5B Barracuda* Series; DC-DC Converter Power Modules
36-75Vdc Input; 12Vdc, 2.5A Output
September 26, 2013
©2013 General Electric Corporation. All rights reserved.
Page 11
Per J-STD-020 Rev. D
0
50
100
150
200
250
300
Reflow Time (Seconds)
Heating Zone
1°C/Second
Peak Temp 260°C
* Min. Time Above 235°C
15 Seconds
*Time Above 217°C
60 Seconds
Cooling
Zone
Surface Mount Information (continued)
Figure 21. Recommended linear reflow profile using
Sn/Ag/Cu solder.
MSL Rating
The KHHD002A5B 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 GE Board Mounted
Power Modules: Soldering and Cleaning Application Note
(AP01-056EPS).
GE
Data Sheet
KSTW002A5B Barracuda* Series; DC-DC Converter Power Modules
36-75Vdc Input; 12Vdc, 2.5A Output
September 26, 2013
©2013 General Electric Corporation. All rights reserved.
Page 12
Top
View
Side
View
Bottom
View
PIN
FUNCTION
1
VIN(+)
2
On/Off
3
VIN(-) 4 Vo(-)
5
Sense(-)
6
Trim
7
Sense(+)
8
Vo(+)
Mechanical Outline for KSTW002A5B 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.]
GE
Data Sheet
KSTW002A5B Barracuda* Series; DC-DC Converter Power Modules
36-75Vdc Input; 12Vdc, 2.5A Output
September 26, 2013
©2013 General Electric Corporation. All rights reserved.
Page 13
Top
View
Side
View
* 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(+)
Mechanical Outline for KHHD002A5B Through Hole Module
Dimensions are in millimeters and [inches].
Tolerances: x.x mm 0.5 mm [x.xx in. 0.02 in.] (Unless otherwise indicated)
x.xx mm 0.25 mm [x.xxx in 0.010 in.]
GE
Data Sheet
KSTW002A5B Barracuda* Series; DC-DC Converter Power Modules
36-75Vdc Input; 12Vdc, 2.5A Output
September 26, 2013
©2013 General Electric Corporation. All rights reserved.
Page 14
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.
Recommended Pad Layout for Surface Mount and Through Hole Module
Dimensions are in millimeters and [inches].
Tolerances: x.x mm 0.5 mm [x.xx in. 0.02 in.] (Unless otherwise indicated)
x.xx mm 0.25 mm [x.xxx in 0.010 in.]
GE
Data Sheet
KSTW002A5B Barracuda* Series; DC-DC Converter Power Modules
36-75Vdc Input; 12Vdc, 2.5A Output
September 26, 2013
©2013 General Electric Corporation. All rights reserved.
Page 15
Tape Dimensions
Dimensions are in millimeters
.
Reel Dimensions
Outside Diameter: 330mm
Inside Diameter: 178mm
Tape Width: 56mm
Material
PET (1mm)
Max surface
resistivity
109 -1011/PET
Color
Clear
Capacity
25power modules
Min order
quantity
75pcs (1 box of 3 full
trays + 1 empty top
tray)
Packaging Details
The KSTW002A5B series SMT version of the modules are supplied in tape & reel as standard. Details of tape dimensions are shown
below. Modules are shipped in quantities of 140 modules per reel.
Tray Dimensions
The KSTW002A5B - series Through Hole (TH) 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 0.5 mm (unless otherwise indicated)
x.xx mm 0.25 mm
GE
Data Sheet
KSTW002A5B Barracuda* Series; DC-DC Converter Power Modules
36-75Vdc Input; 12Vdc, 2.5A Output
Contact Us
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
September 26, 2013
©2013 General Electric Corporation. All rights reserved.
Version 1.0
Product codes
Input Voltage
Output Current
Output
Voltage
Remote On/Off
Logic
Connector
Type
Comcodes
KSTW002A5B41Z
48V (36-75Vdc)
2.5
12V
Negative
Through hole
150031223
KSTW002A5B41-SRZ
48V (36-75Vdc)
2.5
12V
Negative
Surface mount
150031222
Characteristic
Definition
Form Factor K K = 1 /16th Brick
Family Designator ST ST = Low Power Barracuda* Series
Input Voltage
W
W = Wide Range, 36V-75V
Output Current
002A5 002A5 = 002.5 Amps Maximum Output Current
Output Voltage B B=12V Nominal
Omit = Default Pin Length shown in Mechanical Outline Figures
6
6 = Pin Length: 3.68 mm ± 0.25mm , (0.145 in. ± 0.010 in.)
8
8 = Pin Length: 2.79 mm ± 0.25mm , (0.110 in. ± 0.010 in.)
Omit = Positive Logic
1
1 = Negative Logic
Customer Specific XY
XY = Customer Specific Modified Code, Omit for Standard Code
Omit = Standard open Frame Module
SR
S = Surface Mount connections: R = Tape & Reel Packaging
Omit = RoHS 5/6, Lead Based Solder Used
Z
Z = RoHS 6/6 Compliant, Lead free
Ratings
Options
Pin Length
Action following
Protective Shutdown
4
4 = Auto-restart following shutdown (Overcurrent/Overvoltage)
Must be ordered
On/Off Logic
Mechanical Features
RoHS
Character and Position
Ordering Information
Please contact your GE Sales Representative for pricing, availability and optional features.
Table 1. Device Codes
Table 2. Device Options
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