GE Industrial Solutions KW010-015-020-025 User Manual

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Page 1

Data Sheet October 7, 2013

KW010/015/020/025 (Sixteenth-Brick) Power Modules:

36 –75Vdc Input; 1.2Vdc to 5.0Vdc Output;10A to 25A Output Current

Features

 Compliant to RoHS EU Directive 2002/95/EC (-Z

versions)

 Compliant to RoHS EU Directive 2002/95/EC with

lead solder exemption (non-Z versions)

 Delivers up to 25A output current

5V(10A), 3.3V(15A), 2.5V(20A), 1.8V-1.2V(25A)

 High efficiency – 91% at 3.3V full load  Small size and low profile:

33.0 mm x 22.9 mm x 8.5 mm (1.30 in x 0.9 in x 0.335 in)

 Industry standard DOSA footprint  -20% to +10% output voltage adjustment trim  Remote On/Off  Remote Sense  No reverse current during output shutdown  Over temperature protection (latching)  Output overcurrent/overvoltage protection

(latching)

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

 Meets the voltage isolation requirements for

ETSI 300-132-2 and complies with and is licensed for Basic Insulation rating per EN60950-1

 UL* 60950-1Recognized, CSA† C22.2 No.

60950-1-03 Certified, and VDE‡ 0805 (IEC60950 3rd Edition) Licensed

 CE mark meets 2006/95/EC directive§

 ISO** 9001 and ISO 14001 certified manufacturing

facilities

Applications

 Distributed power architectures  Wireless networks  Access and optical network Equipment  Enterprise Networks  Latest generation IC’s (DSP, FPGA, ASIC) and

Microprocessor powered applications

Options

 Negative Remote On/Off logic  Surface Mount (Tape and Reel, -SR Suffix)

 Over current/Over temperature/Over voltage

protections (auto-restart)

 Shorter lead trim

Description

The KW (Sixteenth-brick) series power modules are isolated dc-dc converters that operate over a wide input voltage range of 36 to 75Vdc and provide a single precisely regulated output. The output is fully isolated from the input, allowing versatile polarity configurations and grounding connections. The modules exhibit high efficiency, typical efficiency of 91% for 3.3V/15A. These open frame modules are available either in surface-mount (-SR) or in through-hole (TH) form.

RoHS Compliant

Representative Photo, actual product may vary.

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

†

CSA is a registered trademark of Canadian Standards Association.

‡

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

§ This product is intended for integration into end-use equipment. All of the required procedures of end-use equipment should be followed ** ISO is a registered trademark of the International Organization of Standards

Document No: DS04-045 ver. 1.09

PDF name: kw010-015-020-025_ds.pdf

Page 2

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

Parameter

Device

Symbol

Min

Max

Unit

Input Voltage

Continuous

All

-0.3

Vdc

Transient (100 ms)

All

IN,trans

-0.3

100

Vdc

Operating Ambient Temperature

All

TA -40

°C

(see Thermal Considerations section)

Storage Temperature

All

stg

-55

125

°C

I/O Isolation voltage (100% Factory Hi-Pot tested)

All



1500

Vdc

Parameter

Device

Symbol

Min

Typ

Max

Unit

Operating Input Voltage

All

VIN

Vdc

Maximum Input Current

All

IN,max

1.7

2.0

Adc

(VIN= V

IN, min

to V

IN, max

, IO=I

O, max

)

Input No Load Current

All

IN,No load

55 mA

(VIN = V

IN, nom

, IO = 0, module enabled)

Input Stand-by Current

All

IN,stand-by

5 7

(VIN = V

IN, nom

, module disabled)

Inrush Transient

All

I2t

0.1

A2s

Input Reflected Ripple Current, peak-to-peak

(5Hz to 20MHz, 1μH source impedance; V

IN, min

IN, max, IO

= I

Omax

; See Test configuration section)

All

p-p

Input Ripple Rejection (120Hz)

All

100

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.

Electrical Specifications

Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature 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 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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Page 3

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

Parameter

Device

Symbol

Min

Typ

Max

Unit

Output Voltage Set-point

O, set

4.93

5.0

5.08

(VIN=V

IN, min

, IO=I

O, max

, TA=25°C)

O, set

3.25

3.3

3.35

G V

O, set

2.46

2.5

2.54

Y V

O, set

1.77

1.8

1.83

M V

O, set

1.48

1.5

1.53

P V

O, set

1.18

1.2

1.22

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

O,adj

-20.0 +10.0

% V

O, set

Selected by an external resistor

Output Regulation

Line (VIN=V

IN, min

to V

IN, max

)

A, F, G



0.1

% V

O, set

Y, M, P

2 mV

Load (IO=I

O, min

to I

O, max

)

A, F, G



0.1

% V

O, set

Y, M, P

2 mV

Temperature (T

ref=TA, min

to T

A, max

)

All



1.0

% V

O, set

Output Ripple and Noise on nominal output

(VIN=V

IN, nom

,IO= I

O, max

, TA=T

A, min

to T

A, max

)

RMS (5Hz to 20MHz bandwidth)

A, F, G, Y

 25  mV

rms

Peak-to-Peak (5Hz to 20MHz bandwidth)

 75  mV

pk-pk

RMS (5Hz to 20MHz bandwidth)

M, P

 33  mV

rms

Peak-to-Peak (5Hz to 20MHz bandwidth)

 100  mV

pk-pk

External Capacitance

All

O, max

0  10,000

μF

Rated Output Current

O, Rated

0  10

Adc F

O, Rated

0  15

Adc G

O, Rated

0  20

Adc

Y I

O, Rated

0  25

Adc M

O, Rated

0  25

Adc P

O, Rated

0  25

Adc

Output Current Limit Inception (Hiccup Mode )

All

O, lim

106

120

146

O, Rated

(VO= 90% of V

O, set

)

Output Short-Circuit Current

All

O, s/c

 3 

rms

(VO≤250mV) ( Hiccup Mode )

Electrical Specifications (continued)

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Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

Parameter

Device

Symbol

Min

Typ

Max

Unit

Efficiency

A η

92.0 %

VIN= V

IN, nom

, TA=25°C

F η

91.0 %

IO=I

O, max , VO

= V

O,set

G η

89.0 %

Y η 87.0 %

M η 85.0 % P η

84.0 %

Switching Frequency

All

190

200

235

kHz

Dynamic Load Response

(dIo/dt=0.1A/s; VIN = V

IN, nom

; TA=25°C)

Load Change from Io= 50% to 75% or 25% to 50% of Io,max;

Peak Deviation

All

 2 

% V

O, set

Settling Time (Vo<10% peak deviation)

All



200



s

(dIo/dt=1A/s; VIN = V

IN, nom

; TA=25°C)

Load Change from Io= 50% to 75% or 25% to 50% of Io,max;

Peak Deviation

All

 5 

% V

O, set

Settling Time (Vo<10% peak deviation)

All



200



s

Parameter

Device

Symbol

Min

Typ

Max

Unit

Isolation Capacitance

All

iso



1000  pF

Isolation Resistance

All

iso



MΩ

I/O Isolation Voltage

All



1500

Vdc

Parameter

Device

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

MTBF F 2,864,101

Hours

FIT

349

109/Hours

Powered Random Vibration (VIN=V

IN, min

, IO=I

O, max

, TA=25°C, 0 to

5000Hz, 10Grms)

All 90

Minutes

Weight

All



11.3 (0.4)



g (oz.)

Electrical Specifications (continued)

Isolation Specifications

General Specifications

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Page 5

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

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

All

on/off



1.0

Logic Low - On/Off Voltage

All

on/off

-0.7  1.2

Logic High Voltage – (Typ = Open Collector)

All

on/off



5 V

Logic High maximum allowable leakage current

All

on/off



μA

Turn-On Delay and Rise Times

(IO=I

O, max , VIN=VIN, nom, TA

= 25 oC)

Case 1: On/Off input is set to Logic Low (Module ON) and then input power is applied (delay from instant at which VIN = V

IN, min

until Vo=10% of Vo,set)

All

Tdelay ― 15

msec

Case 2: Input power is applied for at least 1 second and then the On/Off input is set from OFF to ON (T

delay

from instant at which VIN=V

IN, min

until VO = 10% of V

O, set

All

Tdelay ― 4

msec

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

o,set

to 90% of V

o, set

)

All

Trise ― 8 12

msec

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

o,set

to 90% of V

o, set

with max ext capacitance)

All

Trise ― 8 12

msec

Output voltage overshoot – Startup

―

% V

O, set

IO= I

O, max

; VIN=V

IN, min

to V

IN, max

, TA = 25 oC

Remote Sense Range

A, F, G +10

% V

O, set

Y, M, P 0.25

Vdc

Output Overvoltage Protection

O, limit

6.1  7.0

Vdc

F V

O, limit

4.0  4.6

Vdc

G V

O, limit

3.1  3.7

Vdc Y

O, limit

2.3  3.2

Vdc M

O, limit

2.3  3.2

Vdc P

O, limit

2.0  2.8

Vdc

Input Undervoltage Lockout

Turn-on Threshold

All

uv/on



Vdc

Turn-off Threshold

All

uv/off

33  Vdc

Hysterisis

All

hyst



Vdc

Feature Specifications

Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions for additional information.

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Page 6

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

EFFICIENCY,  (%)

OUTPUT CURRENT, Io (A)

20 30 40 50 60 70 80 90

2.0 m/s

(400 lfm)

1.0 m/s

(200 lfm)

0.5 m/s

(100 lfm)

OUTPUT CURRENT, IO (A)

AMBIENT TEMPERATURE, TA OC

Figure 1. Converter Efficiency versus Output Current.

Figure 4. Derating Output Current versus Local Ambient Temperature and Airflow.

OUTPUT VOLTAGE

(V) (20mV/div)

OUTPUT VOLTAGE On/Off VOLTAGE

(V) (2V/div) V

On/off

(V) (2V/div)

TIME, t (1s/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 CURRENT, OUTPUT VOLTAGE

Io (A) (5A/div) V

(V) (20mV/div)

OUTPUT VOLTAGE INPUT VOLTAGE

(V) (2V/div) V

(V) (2V/div)

TIME, t (100 s /div)

TIME, t (5ms/div)

Figure 3. Transient Response to Dynamic Load Change from 75% to 50% to 75% of full load.

Figure 6. Typical Start-up Using Input Voltage (VIN = VIN,NOM, Io = Io,max).

0 2 4 6 8

Vin =48V

Vin =75V

Vin =36V

Characteristic Curves

The following figures provide typical characteristics for the KW010A0A (5V, 10A) at 25oC. The figures are identical for either positive or negative remote On/Off logic.

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Page 7

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

EFFICIENCY,  (%)

0 3 6 9 12 15

VIN = 75V

VIN = 48V

VIN = 36V

OUTPUT CURRENT, Io (A)

20 30 40 50 60 70 80 90

1.0 m/s

(200 lfm)

0.5 m/s

(100 lfm)

2.0 m/s

(400 lfm)

OUTPUT CURRENT, IO (A)

AMBIENT TEMPERATURE, TA OC

Figure 7. Converter Efficiency versus Output Current.

Figure 10. Derating Output Current versus Local Ambient Temperature and Airflow.

OUTPUT VOLTAGE

(V) (10mV/div)

OUTPUT VOLTAGE On/Off VOLTAGE

(V) (1V/div) V

On/off

(V) (5V/div)

TIME, t (1s/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

Io(A) (5A/div) V

(V) (50mV/div)

OUTPUT VOLTAGE INPUT VOLTAGE

(V) (1V/div) V

(V) (50V/div)

TIME, t (1ms/div)

TIME, t (5ms/div)

Figure 9. Transient Response to Dynamic Load Change from 50% to 75% to 50% of full load.

Figure 12. Typical Start-up Using Input Voltage (VIN = VIN,NOM, Io = Io,max).

Characteristic Curves

The following figures provide typical characteristics for the KW015A0F (3.3V, 15A) at 25oC. The figures are identical for either positive or negative remote On/Off logic.

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Page 8

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

EFFICIENCY,  (%)

0 4 8 12 16 20

Vin = 36V

Vin = 48V

Vin = 75V

OUTPUT CURRENT, Io (A)

0.0

5.0

10.0

15.0

20.0

25.0

20 30 40 50 60 70 80 90

2.0 m/s

(400 lfm)

1.0 m/s

(200 lfm)

0.5 m/s

(100 lfm)

OUTPUT CURRENT, IO (A)

AMBIENT TEMPERATURE, TA OC

Figure 13. Converter Efficiency versus Output Current.

Figure 16. Derating Output Current versus Local Ambient Temperature and Airflow.

OUTPUT VOLTAGE

(V) (20mV/div)

OUTPUT VOLTAGE On/Off VOLTAGE

(V) (1V/div) V

On/off

(V) (2V/div)

TIME, t (1s/div)

TIME, t (5ms/div)

Figure 14. Typical output ripple and noise (VIN = VIN,NOM, Io = Io,max).

Figure 17. Typical Start-up Using Remote On/Off, negative logic version shown (VIN = VIN,NOM, Io = Io,max).

OUTPUT CURRENT OUTPUT VOLTAGE

Io(A) (5A/div) V

(V) (50mV/div)

OUTPUT VOLTAGE INPUT VOLTAGE

(V) (1V/div) V

(V) (20V/div)

TIME, t (1ms/div)

TIME, t (5ms/div)

Figure 15. Transient Response to Dynamic Load Change from 50% to 75% to 50% of full load.

Figure 18. Typical Start-up Using Input Voltage (VIN = VIN,NOM, Io = Io,max).

Characteristic Curves (continued)

The following figures provide typical characteristics for the KW020A0G (2.5V, 20A) at 25oC. The figures are identical for either positive or negative remote On/Off logic.

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Page 9

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

EFFICIENCY,  (%)

0 5 10 15 20 25

VIN = 75V

VIN = 48V

VIN = 36V

OUTPUT CURRENT, Io (A)

20 30 40 50 60 70 80 90

2.0 m/s

(400 lfm)

1.0 m/s

(200 lfm)

0.5 m/s

(100 lfm)

OUTPUT CURRENT, IO (A)

AMBIENT TEMPERATURE, TA OC

Figure 19. Converter Efficiency versus Output Current.

Figure 22. Derating Output Current versus Local Ambient Temperature and Airflow.

OUTPUT VOLTAGE

(V) (100mV/div)

OUTPUT VOLTAGE On/Off VOLTAGE

(V) (0.5V/div) V

On/off

(V) (5V/div)

TIME, t (1s/div)

TIME, t (5ms/div)

Figure 20. Typical output ripple and noise (VIN = VIN,NOM, Io = Io,max).

Figure 23. Typical Start-up Using Remote On/Off, negative logic version shown (VIN = VIN,NOM, Io = Io,max).

OUTPUT CURRENT, OUTPUT VOLTAGE

Io (A) (10A/div) V

(V) (20mV/div)

OUTPUT VOLTAGE INPUT VOLTAGE

(V) (0.5V/div) V

(V) (50V/div)

TIME, t (1ms/div)

TIME, t (5ms/div)

Figure 21. Transient Response to Dynamic Load Change from 50% to 75% to 50% of full load.

Figure 24. Typical Start-up Using Input Voltage (VIN = VIN,NOM, Io = Io,max).

Characteristic Curves (continued)

The following figures provide typical characteristics for the KW025A0Y (1.8V, 25A) at 25oC. The figures are identical for either positive or negative remote On/Off logic.

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Page 10

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

EFFICIENCY,  (%)

0 5 10 15 20 25

Vin = 75V

Vin = 36V

Vin = 48V

OUTPUT CURRENT, Io (A)

20 30 40 50 60 70 80 90

2.0 m/s

(400 lfm)

1.0 m/s

(200 lfm)

0.5 m/s

(100 lfm)

OUTPUT CURRENT, IO (A)

AMBIENT TEMPERATURE, TA OC

Figure 25. Converter Efficiency versus Output Current.

Figure 28. Derating Output Current versus Local Ambient Temperature and Airflow.

OUTPUT VOLTAGE

(V) (50mV/div)

OUTPUT VOLTAGE On/Off VOLTAGE

(V) (500mV/div) V

On/off

(V) (2.5V/div)

TIME, t (1s/div)

TIME, t (4ms/div)

Figure 26. Typical output ripple and noise (VIN = VIN,NOM, Io = Io,max).

Figure 29. Typical Start-up Using Remote On/Off, negative logic version shown (VIN = VIN,NOM, Io = Io,max).

OUTPUT CURRENT OUTPUT VOLTAGE

Io(A) (10A/div) V

(V) (50mV/div)

OUTPUT VOLTAGE INPUT VOLTAGE

(V) (500mV/div) V

(V) (20V/div)

TIME, t (500us/div)

TIME, t (5ms/div)

Figure 27. Transient Response to Dynamic Load Change from 50% to 75% to 50% of full load.

Figure 30. Typical Start-up Using Input Voltage (VIN = VIN,NOM, Io = Io,max).

Characteristic Curves (continued)

The following figures provide typical characteristics for the KW025A0M (1.5V, 25A) at 25oC. The figures are identical for either positive or negative remote On/Off logic.

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Page 11

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

EFFICIENCY,  (%)

0 5 10 15 20 25

Vin = 75V

Vin = 36V

Vin = 48V

OUTPUT CURRENT, Io (A)

20 30 40 50 60 70 80 90

2.0 m/s

(400 lfm)

1.0 m/s

(200 lfm)

0.5 m/s

(100 lfm)

OUTPUT CURRENT, IO (A)

AMBIENT TEMPERATURE, TA OC

Figure 31. Converter Efficiency versus Output Current.

Figure 34. Derating Output Current versus Local Ambient Temperature and Airflow.

OUTPUT VOLTAGE

(V) (50mV/div)

OUTPUT VOLTAGE On/Off VOLTAGE

(V) (0.25V/div) V

On/off

(V) (5V/div)

TIME, t (1s/div)

TIME, t (5ms/div)

Figure 32. Typical output ripple and noise (VIN = VIN,NOM, Io = Io,max).

Figure 35. Typical Start-up Using Remote On/Off, negative logic version shown (VIN = VIN,NOM, Io = Io,max).

VOLTAGE

Io (A) (10A/div) V

(V) (50mV/div)

OUTPUT VOLTAGE INPUT VOLTAGE

(V) (0.5V/div) V

(V) (20V/div)

TIME, t (1ms/div)

TIME, t (5ms/div)

Figure 33. Transient Response to Dynamic Load Change from 75% to 50% to 75% of full load.

Figure 36. Typical Start-up Using Input Voltage (VIN = VIN,NOM, Io = Io,max).

Characteristic Curves (continued)

The following figures provide typical characteristics for the KW025A0P (1.2V, 25A) at 25oC. The figures are identical for either positive or negative remote On/Off logic.

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Page 12

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

TO OSCILLOSCOPE

CURRENT PROBE

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 ( – )

RESISTIVE

LOAD

SCOPE

COPPER STRIP

GROUND PLANE

10uF

0.1uF

Vout+

Vout-

Vin+

Vin-

LOAD Rcontact Rdistribution

contact Rdistribution Rcontact

contact Rdistribution

distribution

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.

VIN.

x 100 % Efficiency

Test Configurations

Design Considerations

Input Filtering

The power module should be connected to a low ac-impedance source. Highly inductive source impedance can affect the stability of the power module. For the test configuration in Figure 37, a 33μF 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.

Safety Considerations

For safety-agency approval of the system in which the power module is used, the power module must be

Figure 37. Input Reflected Ripple Current Test Setup.

Figure 38. Output Ripple and Noise Test Setup.

Figure 39. Output Voltage and Efficiency Test Setup.

installed in compliance with the spacing and separation requirements of the end-use safety agency standard, i.e., UL 60950-1-3, CSA C22.2 No. 6095000, and VDE 0805:2001-12 (IEC60950-1).

If the input source is non-SELV (ELV or a hazardous voltage greater than 60 Vdc and less than or equal to

75Vdc), for the module’s output to be considered as

meeting the requirements for safety extra-low voltage (SELV), all of the following must be true:

 The input source is to be provided with reinforced

insulation from any other hazardous voltages, including the ac mains.

 One VIN pin and one V

pin are to be

OUT

grounded, or both the input and output pins are to be kept floating.

 The input pins of the module are not operator

accessible.

 Another SELV reliability test is conducted on the

whole system (combination of supply source and subject module), as required by the safety agencies, to verify that under a single fault, hazardous voltages do not appear at the module’s output.

Note: Do not ground either of the input pins of the

module without grounding one of the output pins. This may allow a non-SELV voltage to appear between the output pins and ground.

The power module has extra-low voltage (ELV) outputs when all inputs are ELV.

All flammable materials used in the manufacturing of these modules are rated 94V-0, or tested to the UL60950 A.2 for reduced thickness.

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

The input to these units is to be provided with a maximum 5 A time-delay fuse in the ungrounded lead.

LINEAGE POWER 12

Page 13

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

ON/OFF

Vin+

Vin-

on/off

Vout+

TRIM

Vout-

VO(+)

SENSE(+)

SENSE(–)

VO(–)

VI(+)

VI(-)

LOAD

CONTACT AND

DISTRIBUTION LOSSES

SUPPLY

CONTACT

RESISTANCE

Figure 41. Circuit Configuration for remote sense .

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 40. Remote On/Off Implementation.

To turn the power module on and off, the user must supply a switch (open collector or equivalent) to control the voltage (V terminal and the VIN(-) terminal (see Figure 40). Logic low is 0V ≤ V

≤ 1.2V. The maximum I

on/off

logic low is 1mA, the switch should be maintain a logic low level whilst sinking this current.

During a logic high, the typical maximum V generated by the module is 15V, and the maximum allowable leakage current at V

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(-).

Remote Sense

Remote sense minimizes the effects of distribution losses by regulating the voltage at the remote-sense connections (See Figure 41). The voltage between the remote-sense pins and the output terminals must not exceed the output voltage sense range given in the Feature Specifications table:

[VO(+) – VO(–)] – [SENSE(+) – SENSE(–)]  0.5 V Although the output voltage can be increased by both

the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim.

The amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. When using remote

) between the ON/OFF

on/off

= 5V is 1μA.

on/off

during a

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).

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

Overtemperature Protection

To provide protection under certain fault conditions, the unit is equipped with a thermal shutdown circuit. The unit will shutdown if the thermal reference point Tref (Figure 43), exceeds 125oC (typical), but the thermal shutdown is not intended as a guarantee that the unit will survive temperatures beyond its rating. The module can be restarted by cycling the dc input power for at least one second or by toggling the remote on/off signal for at least one second. If the auto-restart option (4) is ordered, the module will automatically restart upon cool-down to a safe temperature.

Output Overvoltage Protection

The output over voltage protection scheme of the modules has an independent over voltage loop to prevent single point of failure. This protection feature latches in the event of over voltage across the output. Cycling the on/off pin or input voltage resets the latching protection feature. If the auto-restart option (4) is ordered, the module will automatically restart upon an internally programmed time elapsing.

Overcurrent Protection

To provide protection in a fault (output overload) condition, the unit is equipped with internal

LINEAGE POWER 13

Page 14

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

VO(+)

VOTRIM

VO(-)

trim-down

LOAD

VIN(+)

ON/OFF

VIN(-)

trim-up

  



 









kRdowntrim

65.7

5.255

Where

100

2.1

% 

 



 







desired

  



 









kRdowntrim

22.10

511

Where

100%





 





 







seto

desiredseto

8% 



 



 





kRdowntrim

22.10

511



kRdowntrim

655.53



 



 

















seto

uptrim

22.10

511

%225.1

%)100(11.5

Where

100%





 





 







seto

setodesired



 



 

















uptrim

665.7

5.255

%225.1

%)100(2.111.5

Where

100

2.1

% 

 



 







desired



 



 





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









uptrim

22.10

511

%6.0

%)100(2.111.5

Where

100

2.1

% 

 



 







desired

5% 



 



 











kRuptrim

22.10

511

56.0

)5100(2.111.5



kRuptrim

2.102

Feature Descriptions (continued)

current-limiting circuitry and can endure current limiting continuously. At the point of current-limit inception, the unit enters hiccup mode. If the unit is not configured with auto–restart, then it will latch off following the over current condition. The module can be restarted by cycling the dc input power for at least one second or by toggling the remote on/off signal for at least one second. If the unit is configured with the auto-restart option (4), it will remain in the hiccup mode as long as the overcurrent condition exists; it operates normally, once the output current is brought back into its specified range. The average output current during hiccup is 10% I

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.

O, max

For example, to trim-down the output voltage of 2.5V module (KW020A0G/G1) by 8% to 2.3V, Rtrim-down is calculated as follows:

Connecting an external resistor (R

) between the

trim-up

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 Δ%:

For output voltage: all 1.5V to 12V:

For output voltage: 1.2V (SMT versions only):

For output voltage: 1.2V (Through-Hole versions

Figure 42. Circuit Configuration to Trim Output

only):

Voltage.

Connecting an external resistor (R

trim-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 Δ%. For output voltage: 1.2V (SMT versions only):

For example, to trim-up the output voltage of 1.2V through hole module (KW025A0P/P1) by 5% to

1.26V, R

is calculated is as follows:

trim-up

For output voltage: 1.2V (Through-Hole versions only) and all 1.5V to 12V:

The voltage between the Vo(+) and Vo(–) terminals must not exceed the minimum output overvoltage protection value shown in the Feature Specifications table. This limit includes any increase in voltage due to remote-sense compensation and output voltage set-point adjustment trim.

Although the output voltage can be increased by both the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both.

LINEAGE POWER 14

Page 15

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

Le v e l [ dBµ V]

150k 300k 500k 1M 2M 3M 5M 7M 10M 30M

Fr eq u e n c y [ Hz ]

M ES CE0 9 210 4 1 0 0 9 _ p r e PK LI M E N 5 50 22 A V Q P Vo lt a g e Q P L im it

Le v e l [ d Bµ V ]

150k 300k 500k 1M 2M 3M 5M 7M 10M 30M

Fr e qu e nc y [ Hz ]

+ M ES CE0 9 2 1 04 10 09 _f in A V

M ES CE0 9 2 1 04 10 09 _p r e AV LI M EN 55 0 22 A V A V V o lt ag e AV Lim it

Feature Descriptions (continued)

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).

Thermal Considerations

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

Considerations include ambient temperature, airflow, module power dissipation, and the need for increased reliability. A reduction in the operating temperature of the module will result in an increase in reliability. The thermal data presented here is based on physical measurements taken in a wind tunnel.

The thermal reference point, T

used in the

ref

specifications is shown in Figure 43. For reliable operation this temperature should not exceed 120oC.

Figure 43. T

Temperature Measurement

ref

Locations.

Please refer to the Application Note “Thermal Characterization Process For Open-Frame BoardMounted Power Modules” for a detailed discussion of thermal aspects including maximum device temperatures.

EMC Considerations

The KW series modules are designed to meet the conducted emission limits of EN55022 class A with no filter at the input of the module. The module shall also meet limits of EN55022 Class B with a recommended single stage filter. Please contact your Lineage Power Sales Representitive for further information.

LINEAGE POWER 15

Figure 44. KW015A0F Quasi Peak Conducted Emissions with EN 55022 Class A limits, no external filter (VIN = V

IN,NOM

, Io = 0.85 I

o,max

Figure 45. KW015A0F Average Conducted Emissions with EN 55022 Class A limits, no external filter (VIN = V

IN,NOM

, Io = 0.85 I

o,max

Page 16

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

REFLOW TEMP (C)

REFLOW TIME (S)

MAX TEMP SOLDER (C)

Surface Mount Information

Pick and Place

The KW010-025 modules use an open frame construction and are designed for a fully automated assembly process. The pick and place location on the module is the larger magnetic core as shown in Figure 46. The modules are fitted with a label which meets all the requirements for surface mount processing, as well as safety standards, and is able to withstand reflow temperatures of up to 300oC. The label also carries product information such as product code, serial number and the location of manufacture.

in the failure of or cause damage to the modules, and can adversely affect long-term reliability.

In a conventional Tin/Lead (Sn/Pb) solder process peak reflow temperatures are limited to less than 235oC. Typically, the eutectic solder melts at 183oC, wets the land, and subsequently wicks the device connection. Sufficient time must be allowed to fuse the plating on the connection to ensure a reliable solder joint. There are several types of SMT reflow technologies currently used in the industry. These surface mount power modules can be reliably soldered using natural forced convection, IR (radiant infrared), or a combination of convection/IR. For reliable soldering the solder reflow profile should be established by accurately measuring the modules CP connector temperatures.

Figure 46. Pick and Place Location.

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.

Tin Lead Soldering

The KW010-025 power modules (both non-Z and –Z codes) can be soldered either in a conventional Tin/Lead (Sn/Pb) process. The non-Z version of the KW010-025 modules are RoHS compliant with the lead exception. Lead based solder paste is used in the soldering process during the manufacturing of these modules. These modules can only be soldered in conventional Tin/lead (Sn/Pb) process. It is recommended that the customer review data sheets in order to customize the solder reflow profile for each application board assembly. The following instructions must be observed when soldering these units. Failure to observe these instructions may result

Figure 47. Reflow Profile for Tin/Lead (Sn/Pb) process

Figure 48. Time Limit Curve Above 205oC for Tin/Lead (Sn/Pb) process

LINEAGE POWER 16

Page 17

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

Surface Mount Information (continued)

Lead Free Soldering

The –Z version of the KW010-025 modules are leadfree (Pb-free) and RoHS compliant, and are both forward and backward compatible in a Pb-free and a SnPb soldering process. The non-Z version of the KW006/010 modules are RoHS compliant with the lead exception. Lead based solder paste is used in the soldering process during the manufacturing of these modules. These modules can only be soldered in conventional Tin/lead (Sn/Pb) process. Failure to observe the instructions below may result in the failure of or cause damage to the modules and can adversely affect long-term reliability.

Pb-free Reflow Profile

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).

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 Fig. 49.

MSL Rating

The KW010-025 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.

Figure 49. Recommended linear reflow profile using Sn/Ag/Cu solder.

Through-Hole Lead-Free Soldering Information

The RoHS-compliant through-hole products use the SAC (Sn/Ag/Cu) Pb-free solder and RoHS-compliant components. They are designed to be processed through single or dual wave soldering machines. The pins have an RoHS-compliant finish that is compatible with both Pb and Pb-free wave soldering processes. A maximum preheat rate of 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 paste-through-hole Pb or Pb-free reflow process. If additional information is needed, please consult with your Lineage Power representative for more details.

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

LINEAGE POWER 17

Page 18

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

Top View

Side View

Bottom View

FUNCTION

VIN(+)

On/Off

VIN(-) 4 Vo(-)

Sense(-)

Trim

Sense(+)

Vo(+)

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.]

LINEAGE POWER 18

Page 19

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

Top View

Side View

Bottom View

FUNCTION

VIN(+)

On/Off

VIN(-)

Vo(-)

Sense(-)

Trim

Sense(+)

Vo(+)

Mechanical Outline for Through-Hole Module

Dimensions are in millimeters and [inches]. Tolerances: x.x mm  0.5 mm [x.xx in.  0.02 in.] (unless otherwise indicated) x.xx mm  0.25 mm [x.xxx in  0.010 in.]

LINEAGE POWER 19

Page 20

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

SMT Recommended Pad Layout (Component Side View)

TH Recommended Pad Layout (Component Side View)

Recommended Pad Layout

Dimensions are in and millimeters [inches]. Tolerances: x.x mm  0.5 mm [x.xx in.  0.02 in.] (unless otherwise indicated) x.xx mm  0.25 mm [x.xxx in  0.010 in.]

LINEAGE POWER 20

Page 21

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

Tape Dimensions

Dimensions are in millimeters.

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.

LINEAGE POWER 21

Page 22

Data Sheet October 7, 2013

KW010/015/020/025 Series Power Modules:

36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current

Product Codes

Input Voltage

Output

Voltage

Output

Current

On/Off Logic

Connector

Type

Comcode

KW010A0A41-SR

48V (36-75Vdc)

5.0V

10A

Negative

Surface mount

108992434

KW015A0F41-SR

48V (36-75Vdc)

3.3V

15A

Negative

Surface mount

108989934

KW015A0F41

48V (36-75Vdc)

3.3V

15A

Negative

Through hole

108992590

KW025A0Y41

48V (36-75Vdc)

1.8V

25A

Negative

Through hole

108989942

KW010A0A41-SRZ

48V (36-75Vdc)

5.0V

10A

Negative

Surface mount

CC109112042

KW010A0A41Z

48V (36-75Vdc)

5.0V

10A

Negative

Through hole

CC109112050

KW015A0F41-SRZ

48V (36-75Vdc)

3.3V

15A

Negative

Surface mount

CC109105888

KW015A0F41Z

48V (36-75Vdc)

3.3V

15A

Negative

Through hole

CC109112067

KW015A0F841Z

48V (36-75Vdc)

3.3V

15A

Negative

Through hole

CC109144696

KW020A0G4-SRZ

48V (36-75Vdc)

2.5V

20A

Positive

Surface mount

CC109112653

KW020A0G41-SRZ

48V (36-75Vdc)

2.5V

20A

Negative

Surface mount

CC109128212

KW020A0G41Z

48V (36-75Vdc)

2.5V

20A

Negative

Through hole

CC109141710

KW020A0G41-BZ

48V (36-75Vdc)

2.5V

20A

Negative

Through hole

CC109108395

KW025A0Y41-SRZ

48V (36-75Vdc)

1.8V

25A

Negative

Surface mount

CC109112091

KW025A0Y41Z

48V (36-75Vdc)

1.8V

25A

Negative

Through hole

CC109112100

KW025A0Y641Z

48V (36-75Vdc)

1.8V

25A

Negative

Through hole

CC109127445

KW025A0M41Z

48V (36-75Vdc)

1.5V

25A

Negative

Through hole

CC109128492

KW025A0P41-SRZ

48V (36-75Vdc)

1.2V

25A

Negative

Surface mount

CC109123964

KW025A0P41Z

48V (36-75Vdc)

1.2V

25A

Negative

Through hole

CC109128385

Option*

Suffix**

Negative remote on/off logic

Auto Re-start (for Over Current / Over voltage Protections)

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

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

Surface mount connections (Tape & Reel)

-SR

World Wide Headquarters Lineage Power Corporation

601 Shiloh Road, Plano, TX 75074, USA +1-888-LINEAGE(546-3243) (Outside U.S.A.: +1-972-244-WATT(9288))

www.lineagepower.com e-mail: techsupport1@lineagepower.com

Asia-Pacific Headquarters

Tel: +86.021.54279977*808

Europe, Middle-East and Africa Headquarters

Tel: +49.89.878067-280

India Headquarters Tel: +91.80.28411633

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.

Lineage Power DC-DC products are protected under various patents. Information on these patents is available at www.lineagepower.com/patents. © 2010 Lineage Power Corporation, (Plano, Texas) All International Rights Reserved.

Ordering Information

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

Table 1. Device Code

-Z Indicated RoHS Compliant Modules

Table 2. Device Options

* Legacy device codes may contain a –B option suffix to indicate 100% factory Hi-Pot tested to the isolation voltage specified in the Absolute Maximum Ratings table. The 100% Hi-Pot test is now applied to all device codes, with or without the –B option suffix. Existing comcodes for devices with the –B suffix are still valid; however, no new comcodes for devices containing the –B suffix will be created.

Document No: DS04-045 ver. 1.09

PDF name: kw010-015-020-025_ds.pdf