Data Sheet GE KHHD010A0F Hammerhead™ Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 10A Output Features  Compliant to RoHS II EU “Directive 2011/65/EU (-Z versions)  Compliant to REACH Directive (EC) No 1907/2006  Ultra-wide Input Voltage Range, 18V to 75V dc dc  No minimum load  High efficiency – 90%(Typ) at full load (VIN=48Vdc)  Constant switching frequency  Low output ripple and noise  Small Size and low profile, follows DOSA standard 1/16th footprint RoHS Compliant 33.0 mm x 22.9 mm x 9.3 mm (1.30 in x 0.9 in x 0.37 in) Applications • Surface mount (SMT) or Through hole (TH)  Wireless Networks  Reflow process compliant, both SMT and TH versions  Hybrid power architectures  Positive Remote On/Off logic  Optical and Access Network Equipment  Output overcurrent/voltage protection (hiccup)  Enterprise Networks including Power over Ethernet (PoE)  Over-temperature protection  Industrial markets  Output Voltage adjust: 80% to 110% of Vo,nom  Wide operating temperature range (-40°C to 85°C) Options  ANSI/ UL* 60950-1-2011 Recognized, CAN/CSA† C22.2 No.60950-1-07, Second Edition + A1:2011 (MOD) Certified  Negative Remote On/Off logic (preferred) IEC 60950-1:2005 (2nd edition) + A1:2009 and EN 60950-  Surface Mount/Tape and Reel (-SR Suffix) 1:2006 +A11:2009 +A1:2010 +A12:2011, and VDE‡0805 (EN60950-1 3rd edition) Licensed  Auto-restart Over current/Over voltage protections § (preferred)  CE mark meets 2006/95/EC directive  Shorter through hole pin trim  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 Description th The KHHD010A0F series power modules are isolated DOSA compliant 1/16 brick dc-dc converters that operate over an ultra- wide input voltage range of 18 Vdc -75Vdc and provide a single precisely regulated output voltage at 3.3Vdc. 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. September 26, 2013 ©2013 General Electric Corporation. All rights reserved. Page 1 Data Sheet GE KHHD010A0F Hammerhead™ Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 10A 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 VIN -0.3 80 Vdc Transient (100ms) All VIN, trans -0.3 100 Vdc Operating Ambient Temperature All TA -40 85 °C (see Thermal Considerations section) Storage Temperature All T -55 125 °C stg Altitude* All 4000 m I/O Isolation Voltage (100% factory Hi-Pot tested) All ⎯ ⎯ 2250 Vdc * For higher altitude applications, contact your GE Sales Representative for alternative conditions of use. Electrical Specifications Unless otherwise indicated, specifications apply at V = 48V , resistive load, and T = 25°C conditions. IN dc A Parameter Device Symbol Min Typ Max Unit Operating Input Voltage All VIN 18 24/48 75 Vdc Input No Load Current All IIN,No load 40 50 mA (VIN = 48Vdc IO = 0A, module enabled) Input Stand-by Current All I 6 8 mA IN,stand-by (V = 24 to 48V , module disabled) IN dc Maximum Input Current (VIN=18Vdc, IO= IO,MAX) All IIN, MAX 2.65 Adc 2 2 Inrush Transient All It 0.05 A s Input Reflected Ripple Current, peak-to-peak (5Hz to 20MHz, 12μH source impedance; VIN=0V to 75Vdc, IO= IOmax ; All 30 mAp-p see Test configuration section) Input Ripple Rejection (120Hz) All 60 dB 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. September 26, 2013 ©2013 General Electric Corporation. All rights reserved. Page 2 Data Sheet GE KHHD010A0F Hammerhead™ Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 10A Output Electrical Specifications (continued) Unless otherwise indicated, specifications apply at V = 48Vdc, resistive load, and T = 25°C conditions. IN A Parameter Device Symbol Min Typ Max Unit Output Voltage Set-point All V 3.25 3.30 3.35 V O, set dc (VIN=24 to 48Vdc, IO=IO, max,) Output Voltage All V -3.0 ⎯ +3.0 % V (Over all operating input voltage, resistive load, and temperature O O, set conditions until end of life) Adjustment Range All V -20 +10 % V O, adj O, set Selected by external resistor All Remote Sense Range +10 % VO, set Output Regulation Line (V =V to V) All ⎯ 0.05 0.2 % V IN IN, min IN, max O, set Load (IO=IO, min to IO, max) All ⎯ 0.05 0.2 % VO, set Temperature (Tref=TA, min to TA, max) All ⎯ ⎯ 1.0 % VO, set Output Ripple and Noise on nominal output Measured with 10uF Tantalum||1uF ceramic (V =24 to 48V , I =80%I) IN dc O O, max RMS (5Hz to 20MHz bandwidth) ⎯ ⎯ 35 mVrms All Peak-to-Peak (5Hz to 20MHz bandwidth) ⎯ ⎯ 100 mVpk-pk External Capacitance (see Note 1 in Feature Specifications) All CO, max 0 ⎯ 5000 μF Output Current (VIN =36V to 75V) All Io 0 ⎯ 10 Adc (VIN =18V to 36V) All Io 0 ⎯ 10 Adc Output Current Limit Inception (Hiccup Mode) (VIN =36V to 75V) All IO, lim 11 ⎯ 14 Adc (VIN =18V to 36V) All IO, lim 11 ⎯ 14 Adc Output Short-Circuit Current (VO ≤ 250 mV) All IO, s/c ⎯ 2.5 ⎯ Arms Efficiency (VIN=24Vdc, IO=IO, max) All η 89 ⎯ % Efficiency (VIN=48Vdc, IO=IO, max) All η 90 ⎯ % Switching Frequency (Fixed) All f 350 kHz sw ⎯ ⎯ VIN=24 to 48Vdc, IO= IO, max Dynamic Load Response (ΔIo/Δt=0.1A/μs) Load Change from Io= 50% to 75% or 25% to 50% of Io,max: Peak Deviation All V 3.0 % V pk ⎯ ⎯ O, set Settling Time (Vo<10% peak deviation) All t 400 s ⎯ ⎯ μs Isolation Specifications Parameter Symbol Min Typ Max Unit Isolation Capacitance Ciso ⎯ 1000 ⎯ pF Isolation Resistance Riso 10 ⎯ ⎯ MΩ I/O Isolation Voltage All 2250 Vdc ⎯ ⎯ September 26, 2013 ©2013 General Electric Corporation. All rights reserved. Page 3 Data Sheet GE KHHD010A0F Hammerhead™ Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 10A Output General Specifications Parameter Min Typ Max Unit 9 FIT >270 10 /Hours Calculated Reliability based upon Telcordia SR-332 Issue 2: Method I Case 3 (I =80%I , T =40°C, airflow = 200 lfm, 90% confidence) O O, max A MTBF >3,600,000 Hours Weight 13 (0.46) g (oz.) ⎯ ⎯ 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=VIN, min to VIN, max ; open collector or equivalent, Signal referenced to Vterminal) IN- 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 = -0.7V) All I 0.15 mA on/off dc on/off ⎯ ⎯ Logic Low - On/Off Voltage All Von/off -0.7 ⎯ 0.8 Vdc Logic High Voltage (I = 0A) All V 2.4 ⎯ 7 V on/off dc on/off dc Logic High maximum allowable leakage current All I 25 μA on/off ⎯ ⎯ Turn-On Delay and Rise Times (IO=80% of IO, max) Case 1: Input power is applied for at least 1second, and then the T delay On/Off input is set from OFF to ON (Tdelay = on/off pin transition until All ⎯ 35 50 ms Case1 VO = 10% of VO, set) Case 2: On/Off input is set to Module ON, and then input power is T delay applied All ⎯ 24 50 ms Case2 (Tdelay = VIN reaches VIN, min until VO = 10% of VO,set) Output voltage Rise time (time for Vo to rise from 10% All T ⎯ 30 50 ms rise of Vo,set to 90% of Vo, set) Output Voltage Overshoot 3 % VO, set (I =80% of I , V = 24 to 48V) O O, max IN dc Output Overvoltage Protection All V 4.0 5.5 V O, limit ⎯ dc Input Undervoltage Lockout Turn-on Threshold All V ⎯ 17 18 V uv/on dc Turn-off Threshold All V 14 15 V uv/off ⎯ dc Hysterisis All Vhyst ⎯ 2.0 ⎯ Vdc Note: 1.The module requires a minimum of 470 μF external output capacitor to avoid exceeding the OVP maximum limits during startup into open loop fault conditions. September 26, 2013 ©2013 General Electric Corporation. All rights reserved. Page 4 Data Sheet GE KHHD010A0F Hammerhead™ Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 10A Output Characteristic Curves o The following figures provide typical characteristics for the KHHD010A0F (3.3V, 10A) at 25 C. The figures are identical for either positive or negative remote On/Off logic. OUTPUT CURRENT, IO (A) INPUT VOLTAGE, VIN (V) Figure 1. Converter Efficiency versus Output Current. Figure 2. Converter Input Current versus Input Voltage. 75Vin 48Vin 24Vin 18Vin TIME, t (2μs/div) TIME, t (500μs/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. TIME, t (10ms/div) TIME, t (10ms/div) Figure 5.Typical Start-up Using Remote On/Off, negative Figure 6. Typical Start-up Using Input Voltage (VIN = 48V, Io = logic version shown (V = 24V or 48V, Io = I ). Io,max). IN o,max September 26, 2013 ©2013 General Electric Corporation. All rights reserved. Page 5 On/Off VOLTAGE OUTPUT VOLTAGE OUTPUT VOLTAGE EFFICIENCY, η (%) VOn/Off V) (2V/div) VO ( (V) (1V/div) VO (V) (50mV/div) OUTPUT CURRENT OUTPUT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE Io(A) (5A/div) VO (V) (100mV/div) INPUT CURRENT, IIN (A) VIN (V) (20V/div) VO (V) (1V/div) Data Sheet GE KHHD010A0F Hammerhead™ Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 10A Output Test Configurations Design Considerations CURRENT PROBE TO OSCILLOSCOPE Input Source Impedance L TEST The power module should be connected to a low Vin+ ac-impedance source. Highly inductive source impedance can 12μH affect the stability of the power module. For the test configuration in Figure 7, a 33μF electrolytic capacitor C 220μF S 33μF (ESR<0.7Ω at 100kHz), mounted close to the power module E.S.R.<0.1Ω helps ensure the stability of the unit. Consult the factory for @ 20°C 100kHz further application guidelines. Vin- Safety Considerations NOTE: Measure input reflected ripple current with a simulated source inductance (L ) of 12μH. Capacitor C offsets TEST S possible battery impedance. Measure current as shown For safety-agency approval of the system in which the power above. module is used, the power module must be installed in compliance with the spacing and separation requirements of Figure 7. Input Reflected Ripple Current Test Setup. the end-use safety agency standard, i.e., UL 60950-1-3, CSA COPPER STRIP rd C22.2 No. 60950-00, and VDE 0805 (IEC60950, 3 Edition). V (+) RES IST IVE O If the input source is non-SELV (ELV or a hazardous voltage LO AD greater than 60 Vdc and less than or equal to 75Vdc), for the 1uF . 10uF SC O PE module’s output to be considered as meeting the requirements V (– ) O for safety extra-low voltage (SELV), all of the following must be true: GROUND PLANE  The input source is to be provided with reinforced NOTE: All voltage measurements to be taken at the module insulation from any other hazardous voltages, including terminals, as shown above. If sockets are used then Kelvin connections are required at the module terminals the ac mains. to avoid measurement errors due to socket contact resistance.  One VIN pin and one VOUT pin are to be grounded, or both Figure 8. Output Ripple and Noise Test Setup. the input and output pins are to be kept floating.  The input pins of the module are not operator accessible. Rdistribution Rcontact Rcontact Rdistribution  Another SELV reliability test is conducted on the whole Vin+ Vout+ 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 R LOAD V V IN O the module’s output. Note: Do not ground either of the input pins of the module R R R R distribution contact contact distribution without grounding one of the output pins. This may Vin- Vout- allow a non-SELV voltage to appear between the output pins and ground. NOTE: All voltage measurements to be taken at the module The power module has extra-low voltage (ELV) outputs when all terminals, as shown above. If sockets are used then Kelvin connections are required at the module terminals inputs are ELV. to avoid measurement errors due to socket contact resistance. For input voltages exceeding –60 Vdc but less than or equal to –75 Vdc, these converters have been evaluated to the Figure 9. Output Voltage and Efficiency Test Setup. applicable requirements of BASIC INSULATION between V . I O O secondary DC MAINS DISTRIBUTION input (classified as TNV-2 Efficiency η = x 100 % in Europe) and unearthed SELV outputs. VIN. IIN The input to these units is to be provided with a maximum 6A fast acting fuse in the ungrounded lead. September 26, 2013 ©2013 General Electric Corporation. All rights reserved. Page 6 BATTERY Data Sheet GE KHHD010A0F Hammerhead™ Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 10A Output Input Undervoltage Lockout Feature Description At input voltages below the input undervoltage lockout limit, Remote On/Off the module operation is disabled. The module will only begin to Two remote on/off options are available. Positive logic turns operate once the input voltage is raised above the the module on during a logic high voltage on the on/off pin, undervoltage lockout turn-on threshold, VUV/ON. and off during a logic low. Negative logic remote on/off, device Once operating, the module will continue to operate until the code suffix “1”, turns the module off during a logic high and on input voltage is taken below the undervoltage turn-off during a logic low. threshold, VUV/OFF. Over Voltage Protection Vin+ Vout+ The output overvoltage protection shall consist of circuitry that independently monitors the output voltage, and shuts the I module down if the output voltage exceeds specified limits. on/off ON/OFF This protection feature latches in the event of over voltage TRIM across the output. Cycling the on/off pin or input voltage resets the latching protection feature. If the auto-restart option (4) is V on/off ordered, the module will automatically restart upon an internally programmed time elapsing. Vout- Vin- Output Voltage Programming Trimming allows the user to increase or decrease the output Figure 10. Circuit configuration for using Remote On/Off voltage set point of the module. This is accomplished by Implementation. connecting an external resistor between the TRIM pin and either the Vout+ pin or the Vout- pin. To turn the power module on and off, the user must supply a switch (open collector or equivalent) to control the voltage (Von/off) between the ON/OFF terminal and the VIN(-) terminal. Trim Down – Decrease Output Voltage Logic low is 0V ≤ Von/off ≤ 0.8V. The maximum Ion/off during a By connecting an external resistor (Radj-down) between the logic low is 0.15mA, the switch should be maintain a logic low TRIM pin and V (-) or SENSE(-) pin (see figure 11), the output O level whilst sinking this current. voltage set point decreases. The following equation During a logic high, the typical V generated by the module on/off determines the external resistor value to obtain an output is 4.0V, and the maximum allowable leakage current at V = on/off voltage change from V to the desired V : o,set o,desired 4.0V is 25μA. 511   R = − 10 .22 kΩ If not using the remote on/off feature: adj −down   Δ %   For positive logic, leave the ON/OFF pin open. V −V  o ,set o ,desired For negative logic, short the ON/OFF pin to V (-). IN   Δ% = × 100 Where   V o ,set   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 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. Overtemperature Protection To provide protection under certain fault conditions, the unit is Figure 11. Circuit Configuration to Decrease Output Voltage. equipped with a thermal shutdown circuit. The unit will shut Trim Up – Increase Output Voltage down if the thermal reference point Tref (Figure 16), exceeds o By connecting an external resistor (Radj-up) between the TRIM 135 C (typical), but the thermal shutdown is not intended as a pin and VO(+) or SENSE(+) pin (see figure 12), the output voltage guarantee that the unit will survive temperatures beyond its set point increases. The following equation determines the rating. The module will automatically restart upon cool-down external resistor value to obtain an output voltage change to a safe temperature. from V to the desired V : o,set o,desired September 26, 2013 ©2013 General Electric Corporation. All rights reserved. Page 7 Data Sheet GE KHHD010A0F Hammerhead™ Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 10A Output Feature Descriptions (continued) Thermal Considerations The power modules operate in a variety of thermal 5.11×V × (100 + Δ%)  511  o,set environments; however, sufficient cooling should be provided R = − − 10.22 kΩ adj −up   to help ensure reliable operation. 1.225 × Δ% Δ%   Considerations include ambient temperature, airflow, module   V −V o ,desired o ,set   Δ% = ×100 Where power dissipation, and the need for increased reliability. A   V o ,set   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 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 KHHD010A0F power modules have a fixed current-limit set point. Therefore, as the output voltage is adjusted down, the available output power is reduced. 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 Figure 13. Thermal Test Setup . 48 10 2200 0 Heat Transfer via Convection 48 5 0 15 48 5 2200 15 Increased airflow over the module enhances the heat transfer 48 10 0 15 via convection. Derating figures showing the maximum output 48 10 2200 15 current that can be delivered by each module versus local 60 5 0 0 ambient temperature (TA) for natural convection and up to 60 5 2200 0 3m/s (600 ft./min) are shown in the respective Characteristics 60 10 0 0 Curves section. 60 10 2200 0 Please refer to the Application Note “Thermal Characterization 60 5 0 15 Process For Open-Frame Board-Mounted Power Modules” for a 60 5 2200 15 detailed discussion of thermal aspects including maximum 60 10 0 15 device temperatures. 60 10 2200 15 Vin Tdip Tfall = 10us Trise = 5us 5V September 26, 2013 ©2013 General Electric Corporation. All rights reserved. Page 8 Data Sheet GE KHHD010A0F Hammerhead™ Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 10A Output Notes: C1 and C4 are low impedance SMT ceramics. Thermal Considerations (continued) Ci See Figure 7 C1, C4 2.2uF, 100V, 1210 1210Y1K50103KXTDWV, 10nF, 1500V (*2) C2, C3 RDHX223K302HKT, 22nF, 3000V (Holystone) LOCAL AMBIENT TEMPERATURE, T (°C) A GRM32DR73A153KW01L, 15nF, 1000V (*2) Figure 14. Output Current Derating for the Open Frame C5, C6 RDHX333K302HKT, 33nF, 3000V (Holystone) KHHD010A0F in the Transverse Orientation; Airflow 202S48W334KT, 33nF, 2000V (Johanson) Direction from Vin(+) to Vin(-); Vin = 24V. Figure 17. Suggested Configuration for EN55022 Class B. Figure 18. EMC signature using above filter, KHHD010A0F. LOCAL AMBIENT TEMPERATURE, TA (°C) Figure 15. Output Current Derating for the Open Frame For further information on designing for EMC compliance, KHHD010A0F in the Transverse Orientation; Airflow please refer to the FLTR100V10 data sheet (FDS01-043EPS). Direction from Vin(+) to Vin(-); Vin = 48V. The thermal reference point, Tref, used in the specifications is Layout Considerations shown in Figure 16. For reliable operation this temperature o The KHHD010A0F power module series are low profile in order should not exceed 135 C. 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 KHHD010A0F family of power modules is available for either Through-Hole (TH) or Surface Mount (SMT) soldering. Through-Hole Soldering Information Figure 16. T Temperature Measurement Location. ref The RoHS-compliant (Z codes) through-hole products use the SAC (Sn/Ag/Cu) Pb-free solder and RoHS-compliant EMC Requirements components. They are designed to be processed through Figure 17 shows a maximum filter configuration to meet the single or dual wave soldering machines. The pins have an conducted emission limits of EN55022 Class B. September 26, 2013 ©2013 General Electric Corporation. All rights reserved. Page 9 OUTPUT CURRENT, IO (A) OUTPUT CURRENT, IO (A) Data Sheet GE KHHD010A0F Hammerhead™ Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 10A Output Reflow Soldering Information Layout Considerations (continued) RoHS-compliant finish that is compatible with both Pb and Pb- These power modules are large mass, low thermal free wave soldering processes. A maximum preheat rate of resistance devices and typically heat up slower than other 3°C/s is suggested. The wave preheat process should be such SMT components. It is recommended that the customer that the temperature of the power module board is kept below review data sheets in order to customize the solder reflow 210°C. For Pb solder, the recommended pot temperature is profile for each application board assembly. 260°C, while the Pb-free solder pot is 270°C max. Not all RoHS- The following instructions must be observed when SMT compliant through-hole products can be processed with paste- soldering these units. Failure to observe these instructions through-hole Pb or Pb-free reflow process. If additional may result in the failure of or cause damage to the modules, information is needed, please consult with your GE and can adversely affect long-term reliability. representative for more details. There are several types of SMT reflow technologies currently Surface Mount Information used in the industry. These surface mount power modules can be reliably soldered using natural forced convection, IR Pick and Place (radiant infrared), or a combination of convection/IR. The recommended linear reflow profile using Sn/Pb solder is The KHHD-SR series of DC-to-DC power converters use an shown in Figure 20 and 21. For reliable soldering the solder open-frame construction and are designed for surface mount reflow profile should be established by accurately measuring assembly within a fully automated manufacturing process. the module’s pin connector temperatures. The KHHD-SR series modules are designed to use the main magnetic component surface to allow for pick and place. 300 o Peak Temp 235 C 250 Cooling zo ne Heat zo ne 200 o -1 o -1 1-4 Cs max 4 Cs 150 So ak zone 10 0 T above 30-240s lim o 205 C 50 Preheat zo ne o -1 max 4 Cs 0 REFLOW TIME (S) Figure 20. Recommended Reflow Profile for Sn/Pb solder. Note: All dimensions in mm [in]. 240 Figure 19. Pick and Place Location. 235 230 Z Plane Height 225 The ‘Z’ plane height of the pick and place location is 7.50mm 220 nominal with an RSS tolerance of +/-0.25 mm. 215 Nozzle Recommendations 210 The module weight has been kept to a minimum by using open 205 frame construction. Even so, they have a relatively large mass 200 0 10 203040 50 60 when compared with conventional SMT components. Variables such as nozzle size, tip style, vacuum pressure and TIME LIMIT (S) placement speed should be considered to optimize this o Figure 21. Time Limit, T , Curve Above 205 C Reflow. lim process. Lead Free Soldering The minimum recommended nozzle diameter for reliable operation is 5mm. The maximum nozzle outer diameter, which The –Z version SMT modules of the KHHD010A0F series are will safely fit within the allowable component spacing, is lead-free (Pb-free) and RoHS compliant and are compatible in a 6.5mm. Pb-free soldering process. Failure to observe the instructions below may result in the failure of or cause damage to the Oblong or oval nozzles up to 11 x 6 mm may also be used modules and can adversely affect long-term reliability. within the space available. For further information please contact your local GE Technical Sales Representative. September 26, 2013 ©2013 General Electric Corporation. All rights reserved. Page 10 MAX TEMP SOLDER (°C) REFLOW TEMP (°C) Data Sheet GE KHHD010A0F Hammerhead™ Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 10A 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 Per J-STD-020 Rev. D Peak Temp 260°C 250 Cooling 200 Zone * Min. Time Above 235°C 15 Seconds 150 Heating Zone *Time Above 217°C 1°C/Second 60 Seconds 100 50 0 Reflow Time (Seconds) Figure 22. Recommended linear reflow profile using Sn/Ag/Cu solder. MSL Rating The KHHD010A0F 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). September 26, 2013 ©2013 General Electric Corporation. All rights reserved. Page 11 Reflow Temp (°C) Data Sheet GE KHHD010A0F Hammerhead™ Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 10A Output Mechanical Outline for KHHD010A0F Surface-Mount Module Dimensions are in millimeters and [inches]. Tolerances: x.x mm ± 0.5 mm [x.xx in. ± 0.02 in.] (Unless otherwise indicated) x.xx mm ± 0.25 mm [x.xxx in ± 0.010 in.] Top View Side View Bottom View PIN FUNCTION 1 VIN(+) 2 On/Off 3 VIN(-) 4 Vo(-) 5 Sense(-) 6 Trim 7 Sense(+) 8 Vo(+) September 26, 2013 ©2013 General Electric Corporation. All rights reserved. Page 12 Data Sheet GE KHHD010A0F Hammerhead™ Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 10A Output Mechanical Outline for KHHD010A0F 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.] 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(+) September 26, 2013 ©2013 General Electric Corporation. All rights reserved. Page 13 Data Sheet GE KHHD010A0F Hammerhead™ Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 10A Output 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.] 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. September 26, 2013 ©2013 General Electric Corporation. All rights reserved. Page 14 Data Sheet GE KHHD010A0F Hammerhead™ Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 10A Output Packaging Details The KHHD010A0F 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 KHHD010A0F - 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 ± 0.5 mm (unless otherwise indicated) x.xx mm ± 0.25 mm Material PET (1mm) Max surface 9 11 10 -10 Ω/PET resistivity Color Clear Capacity 25power modules 75pcs (1 box of 3 full Min order trays + 1 empty top quantity tray) September 26, 2013 ©2013 General Electric Corporation. All rights reserved. Page 15 Data Sheet GE KHHD010A0F Hammerhead™ Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 10A Output Ordering Information Please contact your GE Sales Representative for pricing, availability and optional features. Table 1. Device Codes Output Remote On/Off Connector Product codes Input Voltage Output Current Comcodes Voltage Logic Type 150030199 KHHD010A0F41Z 24V/48V (18-75Vdc) 10 3.3V Negative Through hole 150030198 KHHD010A0F41-SRZ 24V/48V (18-75Vdc) 10 3.3V Negative Surface mount Table 2. Device Options Character and Position Characteristic Definition Form Factor K K = 1 /16th Brick Family Designator HH = ammer ead™ Series HH H h Input Voltage D D = UltraWide Range, 18V-75V Output Current 010A0 010A0 = 010.0 Amps Maximum Output Current Output Voltage F F=3.3V Nominal Omit = Default Pin Length shown in Mechanical Outline Figures Pin Length 6 6 = Pin Length: 3.68 mm ± 0.25mm , (0.145 in. ± 0.010 in.) 8 = Pin Length: 2.79 mm ± 0.25mm , (0.110 in. ± 0.010 in.) 8 Action following 4 = Auto-restart following shutdown (Overcurrent/Overvoltage) 4 Protective Shutdown Must be ordered Omit = Positive Logic On/Off Logic 1 = Negative Logic 1 Customer Specific XY = Customer Specific Modified Code, Omit for Standard Code XY Omit = Standard open Frame Module Mechanical Features SR = Surface Mount connections: = Tape & Reel Packaging S R Omit = RoHS 5/6, Lead Based Solder Used RoHS Z = RoHS 6/6 Compliant, Lead free Z 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 1.1 Options Ratings