Data Sheet GE KSTW004A2B Barracuda™ Series; DC-DC Converter Power Modules 36-75Vdc Input; 12Vdc, 4.2A, 50W Output Features RoHS Compliant  Compliant to RoHS II EU “Directive 2011/65/EU (-Z versions)  Compliant to REACH Directive (EC) No 1907/2006  Compliant to IPC-9592A (September2008), Category 2, Class II  Ultra-wide Input Voltage Range, 36Vdc to 75Vdc  No minimum load  High efficiency – 90% at full load (V =48V ) IN dc  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) 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 V o,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 IEC  Negative Remote On/Off logic (preferred) 60950-1:2005 (2nd edition) + A1:2009 and EN 60950-1:2006  Surface Mount/Tape and Reel (-SR Suffix) +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  Meets the voltage and current requirements for ETSI 300-132-  Shorter through hole pin trim 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 KSTW004A2B series power modules are isolated DOSA compliant 1/16 brick dc-dc converters that operate over an ultra- wide input voltage range of 36 V -75V and provide a single precisely regulated output voltage at 12V . The output is fully dc dc dc 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. April 1, 2013 ©2012 General Electric Company. All rights reserved. Page 1 Data Sheet GE KSTW004A2B Barracuda™ Series; DC-DC Converter Power Modules 36-75Vdc Input; 12Vdc, 4.2A, 50W 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 I/O Isolation Voltage (100% factory Hi-Pot tested) All 2250 Vdc   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 36 48 75 Vdc Input No Load Current All IIN,No load 40 50 mA (I = 0A, module enabled) O Input Stand-by Current All I 8 mA IN,stand-by (V = 48V , module disabled) IN dc Maximum Input Current (VIN=36Vdc, IO= IO,MAX) All IIN, MAX 1.6 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 6A (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. April 1, 2013 ©2012 General Electric Company. All rights reserved. Page 2 Data Sheet GE KSTW004A2B Barracuda™ Series; DC-DC Converter Power Modules 36-75Vdc Input; 12Vdc, 4.2A, 50W 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 11.82 12.00 12.36 V O, set dc (VIN=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 =48V , I =80%I) IN dc O O, max RMS (5Hz to 20MHz bandwidth)   40 mVrms All Peak-to-Peak (5Hz to 20MHz bandwidth)   150 mVpk-pk External Capacitance (see Note 1 in Feature Specifications) All CO, max 0  2200 μF Output Current All Io 0  4.2 Adc Output Current Limit Inception (Hiccup Mode) All IO, lim 4.6  5.9 Adc Output Short-Circuit Current (VO ≤ 250 mV) All IO, s/c  2.5  Arms Efficiency (V =48V , I =I) All η 89.0 90.0 % IN dc O O, max  Switching Frequency (Fixed) All f 350 kHz sw   VIN=48Vdc, IO= IO, max Dynamic Load Response (Io/t=0.1A/s, V =48Vdc) IN Load Change from Io= 50% to 75% or 25% to 50% of I: o,max Peak Deviation All V  3.0  % V pk O, set Settling Time (Vo<10% peak deviation) All t 400 s   s 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 General Specifications Parameter Min Typ Max Unit 9 FIT 261.1 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 3,829,239 Hours Weight  13 (0.46)  g (oz.) April 1, 2013 ©2012 General Electric Company. All rights reserved. Page 3 Data Sheet GE KSTW004A2B Barracuda™ Series; DC-DC Converter Power Modules 36-75Vdc Input; 12Vdc, 4.2A, 50W Output Feature Specifications Unless otherwise indicated, specifications apply at V = 48V , resistive load, and T = 25°C conditions. See Feature Descriptions for IN dc A additional information. Parameter Device Symbol Min Typ Max Unit Remote On/Off Signal Interface (V =V to V ; open collector or equivalent, IN IN, min IN, max Signal referenced to VIN- terminal) Negative Logic: device code suffix “1” Logic Low = module On, Logic High = module Off Positive Logic: No device code suffix required Logic Low = module Off, Logic High = module On Logic Low - Remote On/Off Current (Von/off = -0.7Vdc) All Ion/off   0.15 mA Logic Low - On/Off Voltage All V -0.7 0.8 V on/off  dc Logic High Voltage (Ion/off = 0Adc) All Von/off 2.4  TBD Vdc Logic High maximum allowable leakage current All Ion/off   25 μA Turn-On Delay and Rise Times (I =80% of I) O O, max Case 1: Input power is applied for at least 1second, and then the Tdelay On/Off input is set from OFF to ON (T = on/off pin transition until All 30 50 ms delay  Case1 V = 10% of V ) O O, set Case 2: On/Off input is set to Module ON, and then input power is Tdelay applied All 20 50 ms  Case2 (Tdelay = VIN reaches VIN, min until VO = 10% of VO,set) Output voltage Rise time (time for V to rise from 10% o All Trise  5 10 ms of V to 90% of V ) o,set o, set Output Voltage Overshoot 3 % V O, set (IO=80% of IO, max, VIN= 48Vdc) 1 Output Overvoltage Protection All VO, limit 14.0  17.0 Vdc Input Undervoltage Lockout Turn-on Threshold All Vuv/on  34 36 Vdc Turn-off Threshold All Vuv/off 30 32  Vdc Hysterisis All V 2.0 V hyst   dc 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. April 1, 2013 ©2012 General Electric Company. All rights reserved. Page 4 Data She eet G GE K KSTW004A2B Ba arracuda a™ Series s; DC-DC C Conver rter Powe er Modules 3 36-75Vdc In nput; 12.0V Vdc, 4.2A, 5 50W Outpu ut C Characteris stic Curves s o T The following figures provide typical characteristics for the e KSTW004A2B B (12.0V, 4.2A) a at 25 C. The fig gures are ident tical for either p positive or nega ative remote O On/Off logic. OUTP PUT CURRENT, IO (A) INPUT VO OLTAGE, VIN (V) Figure 1. Conv verter Efficien ncy versus Out tput Current. Figur re 2. Converte er Input Curren nt versus Input Voltage. TIME, t (200µs/div) T TIME, t (2s/div) Figure 3. Typi ical output ripple and noise (Io = Io,max). Figur re 4. Transient t Response to 0.1A/µS Dynamic Load Chan nge from 50% to 75% to 50% % of full load, V Vin=48V, CO>100μF TIME, t (10ms/div) TIME, t (10ms/div) Figure 5.Typic cal Start-up Us sing Remote O On/Off, negativ ve Figur re 6. Typical St tart-up Using Input Voltage e (VIN = 48V, Io = = logic version shown (V = 4 48V, Io = I ). Io,max) ). IN o,max A April 1, 2013 ©2 2012 General Ele ectric Company. A All rights reserve ed. Page 5 5 On/Of On/Off f VOL VOLT TA AG GE E OUT OUTP PUT UT V VO OLTAGE LTAGE EFFICIENCY,  (%) OUTPUT VOLTAGE V (V) (2V/div) V (V) (5V/div) On/Off O VO (V) (100mV/div) OUTPUT CURRENT OUTPUT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE Io(A) (1A/div) V (V) (200mV/div) INPUT CURRENT, I (A) O IN V V (V) ( (V) (2 20 0V V/di /div v)) V V (V (V) ( ) (5 5V/di V/div v ) ) IN IN O O Data Sheet GE KSTW004A2B Barracuda™ Series; DC-DC Converter Power Modules 36-75Vdc Input; 12.0Vdc, 4.2A, 50W 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<0.7 at 100kHz), mounted close to the power module E.S.R.<0.1 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 the ac mains. Kelvin connections are required at the module terminals 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 O IN 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 terminals, as shown above. If sockets are used then The power module has extra-low voltage (ELV) outputs when all 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 VO. IO secondary DC MAINS DISTRIBUTION input (classified as TNV-2 Efficiency  = x 100 % V . I in Europe) and unearthed SELV outputs. IN IN The input to these units is to be provided with a maximum 6A fast acting fuse in the ungrounded lead. April 1, 2013 ©2012 General Electric Company. All rights reserved. Page 6 BATTERY Data Sheet GE KSTW004A2B Barracuda™ Series; DC-DC Converter Power Modules 36-75Vdc Input; 12.0Vdc, 4.2A, 50W 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 Von/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 (V ) between the ON/OFF terminal and the V (-) terminal. on/off IN Trim Down – Decrease Output Voltage Logic low is 0V ≤ V ≤ 0.8V. The maximum I during a on/off on/off 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 Von/off generated by the module determines the external resistor value to obtain an output is 4.0V, and the maximum allowable leakage current at Von/off = voltage change from V to the desired V : o,set o,desired 4.0V is 25μA.  511  R   10.22 k If not using the remote on/off feature: adjdown   %   For positive logic, leave the ON/OFF pin open.   V V o ,set o ,desired For negative logic, short the ON/OFF pin to VIN(-).   % 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 Vo,set to the desired Vo,desired: April 1, 2013 ©2012 General Electric Company. All rights reserved. Page 7 Data She eet G GE K KSTW004A2B Ba arracuda a™ Series s; DC-DC C Conver rter Powe er Modules 3 36-75Vdc In nput; 12.0V Vdc, 4.2A, 5 50W Outpu ut F Feature De escriptions (continued) The ermal Cons siderations s The p power modules s operate in a v variety of therm mal 5.11V  (100%)  511  envir ronments; how wever, sufficient t cooling shoulld be provided o,set R R    10.22 k adjup   to he elp ensure relia able operation. 1.225% %   Cons siderations include ambient temperature, airflow, module   V V o ,desired o,set   % 100 W Where powe er dissipation, a and the need f for increased re eliability. A   V o,set   reduction in the operating temperature of the m module will resullt in an increase in reliability. The t thermal data p presented here is based on ph hysical meas surements taken in a wind tu unnel, using automated therm mo-couple inst trumentation to o monitor key c component temp peratures: FETs s, diodes, contr rol ICs, magnet tic cores, ceramic capacitors s, opto-isolator rs, and module pwb cond ductors, while c controlling the ambient airflow w rate and temp perature. For a given airflow a and ambient te emperature, th he module output pow wer is increased d, until one (or more) of the comp ponents reaches its maximum m derated ope erating temp perature, as de efined in IPC-95 592A. This proc cedure is then repea ated for a diffe erent airflow or r ambient temp perature until a a family of module ou utput derating curves is obta ained. F Figure 12. Circu uit Configurat tion to Increas se Output Volta age. T The combinatio on of the outpu ut voltage adjus stment and the e o output voltage initial toleranc ce must not exc ceed the allowa able trim range of 80 0% to 110% of f the nominal o output voltage as m measured betw ween the Vout+ + and Vout- pin ns. T The KSTW004A2B power mod dules have a fix xed current-lim mit set p point. Therefor re, as the outpu ut voltage is ad djusted down, t the a available outpu ut power is redu uced. P Pre-bias Vin U Under Voltag ge Test T The module sha all recover from m UVLO [Unde er Voltage Lock k Out] w without protect tive shutdown from OCP or OVP or hard fa ailure, w when subjecte ed to Vin Und der Voltage t transients with h the fo ollowing conditions: Vin(V) Tdip (ms) Co (uF) Load (A) 48 5 0 0 48 5 2200 0 48 10 0 0 Figur re 13. Thermal Test Setup. 48 10 2200 0 Heat t Transfer via a Convection n 48 5 0 4.2 48 5 2200 4.2 Incre eased airflow o over the module enhances the e heat transfer r 48 10 0 4.2 via convection. Derating figures s showing the m maximum outpu ut 48 10 2200 4.2 curre ent that can be e delivered by e each module versus local 60 5 0 0 ambient temperatu ure (T ) for natu ural convection n and up to A 60 5 2200 0 3m/s s (600 ft./min) a are shown in th he respective C Characteristics 60 10 0 0 Curves section. 60 10 2200 0 Pleas se refer to the A Application No ote “Thermal Ch haracterization n 60 5 0 4.2 Proce ess For Open-F Frame Board-M Mounted Power Modules” for a 60 5 2200 4.2 detailed discussion n of thermal asp pects including g maximum 60 10 0 4.2 devic ce temperature es. 60 10 2200 4.2 Vin Tdip Tfall = 10us Trise = 5us 5V A April 1, 2013 © ©2012 General Electric Company y. All rights reserv ved. Page e 8 Data She eet G GE K KSTW004A2B Ba arracuda a™ Series s; DC-DC C Conver rter Powe er Modules 3 36-75Vdc In nput; 12.0V Vdc, 4.2A, 5 50W Outpu ut LO OCAL AMBIENT T TEMPERATURE, TA (C) F Figure 14. Outp put Current De erating for the e Open Frame Figur re 17. KSTW00 04A2B Vin+ Lin ne EMC signatu ure using K KSTW004A2B in the Transverse Orientatio on; Airflow abov ve filter, Vin=4 48V, Blue=PK, R Red=Avg. D Direction from Vin(-) to Vin(+ +); Vin = 48V. For further informa ation on design ning for EMC co ompliance, T The thermal ref ference point, T Tref, used in the specifications is pleas se refer to the FLTR100V10 data sheet (FDS01-043EPS). s shown in Figure e 16. For reliab ble operation th his temperatur re o s should not exce eed 119 C. Lay yout Consid derations The K KSTW004A2B p power module series are low profile in order to be e used in fine pitch system ca ard architecture es. As such, comp ponent clearan nce between th he bottom of th he power module and the mo ounting board is limited. Avoid placing copp per areas on the outer layer d directly underneath the powe er module. Also avoid d placing via interconnects un nderneath the powe er module. For a additional layou ut guide-lines, refer to the FLT TR100V10 data a shee et. The K KSTW004A2B f family of power modules is av vailable for F Figure 15. T T Temperature M Measurement t Location. ref eithe er Through-Hole (TH) or Surfac ce Mount (SMT T) soldering. Thro ough-Hole S Soldering In nformation E EMC Requir rements F Figure 16 show ws a maximum filter configura ation to meet th he The R RoHS-complian nt (Z codes) thr rough-hole pro oducts use the c conducted emis ssion limits of E EN55022 Class s B. SAC ((Sn/Ag/Cu) Pb- -free solder and d RoHS-compliiant comp ponents. They y are designed to be processe ed through N Notes: C1 and C4 are low impedance SMT c ceramics. single or dual wave e soldering machines. The pin ns have an RoHS S-compliant fin nish that is com mpatible with b both Pb and Pb- free w wave soldering g processes. A maximum preheat rate of 3C/s s is suggested.. The wave pre eheat process s should be such h that the temperatu ure of the powe er module boar rd is kept below w 210C. For Pb solde er, the recomm mended pot tem mperature is 260C, while the Pb b-free solder po ot is 270C max. Not all RoHS S- comp pliant through- -hole products s can be proces ssed with paste e- throu ugh-hole Pb or r Pb-free reflow w process. If ad dditional information is need ded, please con nsult with your GE repre esentative for m more details. Ci See Figure 7 C1, C4 2.2uF, 100V, 1210 1210 0Y1K50103KXT TDWV, 10nF, 15 500V (*2) C2, C3 RDH HX223K302HKT T, 22nF, 3kv RDH HX333K302HKT T, 33nF, 3000V (Holystone) C5, C6 202S S48W334KT, 33 3nF, 2000V (Johanson) F Figure 16. Sugg gested Configu uration for EN55022 Class B B. A April 1, 2013 ©2 2012 General Ele ectric Company. A All rights reserve ed. Page 9 9 OUTPUT CURRENT, IO () (A) Data Sheet GE KSTW004A2B Barracuda™ Series; DC-DC Converter Power Modules 36-75Vdc Input; 12.0Vdc, 4.2A, 50W Output There are several types of SMT reflow technologies currently Surface Mount Information used in the industry. These surface mount power modules Pick and Place can be reliably soldered using natural forced convection, IR (radiant infrared), or a combination of convection/IR. The The KSTW-SR series of DC-to-DC power converters use an recommended linear reflow profile using Sn/Pb solder is open-frame construction and are designed for surface mount shown in Figure 19 and 20. For reliable soldering the solder assembly within a fully automated manufacturing process. reflow profile should be established by accurately measuring the module’s pin connector temperatures. The KSTW-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 zone o -1 max 4 Cs 0 REFLOW TIME (S) Note: All dimensions in mm [in]. Figure 19. Recommended Reflow Profile for Sn/Pb solder. Figure 18. Pick and Place Location. 240 235 Z Plane Height 230 The ‘Z’ plane height of the pick and place location is 7.50mm 225 nominal with an RSS tolerance of +/-0.25 mm. 220 215 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 when compared with conventional SMT components. 0 10 203040 50 60 Variables such as nozzle size, tip style, vacuum pressure and TIME LIMIT (S) placement speed should be considered to optimize this o process. Figure 20. Time Limit, T , Curve Above 205 C Reflow . lim 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 KSTW004A2B 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 Oblong or oval nozzles up to 11 x 6 mm may also be used below may result in the failure of or cause damage to the within the space available. modules and can adversely affect long-term reliability. For further information please contact your local GE Technical Pb-free Reflow Profile Sales Representative. Power Systems will comply with J-STD-020 Rev. C Reflow Soldering Information (Moisture/Reflow Sensitivity Classification for Nonhermetic Solid State Surface Mount Devices) These power modules are large mass, low thermal resistance devices and typically heat up slower than other for both Pb-free solder profiles and MSL classification SMT components. It is recommended that the customer procedures. This standard provides a recommended forced- review data sheets in order to customize the solder reflow air-convection reflow profile based on the volume and profile for each application board assembly. thickness of the package (table 4-2). The suggested Pb-free solder paste is Sn/Ag/Cu (SAC). The recommended linear reflow The following instructions must be observed when SMT profile using Sn/Ag/Cu solder is shown in Figure 21. 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. April 1, 2013 ©2012 General Electric Company. All rights reserved. Page 10 MAX TEMP SOLDER (C) REFLOW TEMP (C) Data Sheet GE KSTW004A2B Barracuda™ Series; DC-DC Converter Power Modules 36-75Vdc Input; 12.0Vdc, 4.2A, 50W Output Surface Mount Information (continued) 300 Per J-STD-020 Rev. C 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 21. Recommended linear reflow profile using Sn/Ag/Cu solder. MSL Rating The KSTW004A2B 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). April 1, 2013 ©2012 General Electric Company. All rights reserved. Page 11 Reflow Temp (°C) Data She eet G GE K KSTW004A2B Ba arracuda a™ Series s; DC-DC C Conver rter Powe er Modules 3 36-75Vdc In nput; 12.0V Vdc, 4.2A, 5 50W Outpu ut M Mechanical Outline fo or KSTW004A2B Surfa ace-Mount t Module D Dimensions are e in millimeters s and [inches]. T Tolerances: x.x mm  0.5 mm [x.xx in.  0.02 in.] (Unless oth herwise indicat ted) x.xx mm  0.25 mm m [x.xxx in  0.0 010 in.] Top View Side View Bottom View PIN FUNCTIO ON 1 VIN(+) 2 On/Off f 3 VIN(-) 4 Vo(-) 5 Sense(- -) 6 Trim 7 Sense(+ +) 8 Vo(+) A April 1, 2013 © ©2012 General Electric Company y. All rights reserv ved. Page 1 12 Data Sheet GE KSTW004A2B Barracuda™ Series; DC-DC Converter Power Modules 36-75Vdc Input; 12.0Vdc, 4.2A, 50W Output Mechanical Outline for KSTW004A2B 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(+) April 1, 2013 ©2012 General Electric Company. All rights reserved. Page 13 Data She eet G GE K KSTW004A2B Ba arracuda a™ Series s; DC-DC C Conver rter Powe er Modules 3 36-75Vdc In nput; 12.0V Vdc, 4.2A, 5 50W Outpu ut R Recommen nded Pad La ayout for S Surface Mo ount and Th hrough Hol le Module D Dimensions are e in millimeters s and [inches]. T Tolerances: x.x mm  0.5 mm [x.xx in.  0.02 in.] (Unless oth herwise indicat ted) x.xx mm  0.25 mm m [x.xxx in  0.0 010 in.] Surface Mount Pad Layout Throu ugh-Hole Pad Layout F For .025 x .030 0 rectangular p pin, use a .050 0 diameter pla ated through h hole For .062 diameter pin, u use a .076 diam meter plated through hole. A April 1, 2013 © ©2012 General Electric Company y. All rights reserv ved. Page 1 14 Data Sheet GE KSTW004A2B Barracuda™ Series; DC-DC Converter Power Modules 36-75Vdc Input; 12.0Vdc, 4.2A, 50W Output Packaging Details The KSTW004A2B 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 KSTW004A2B - 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 /PET resistivity Color Clear Capacity 25power modules 75pcs (1 box of 3 full Min order trays + 1 empty top quantity tray) April 1, 2013 ©2012 General Electric Company. All rights reserved. Page 15 Data Sheet GE KSTW004A2B Barracuda™ Series; DC-DC Converter Power Modules 36-75Vdc Input; 12.0Vdc, 4.2A, 50W Output Ordering Information Please contact your GE Sales Representative for pricing, availability and optional features. Table 1. Device Codes Output Output Remote On/Off Connector Product codes Input Voltage Comcodes Current Voltage Logic Type KSTW004A2B41Z 48V (36-75Vdc) 4.2A 12.0V Negative Through hole 150030462 KSTW004A2B41-SRZ 48V (36-75Vdc) 4.2A 12.0V Negative Surface mount 150030461 Table 2. Device Options 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.ge.com/powerelectronics April 1, 2013 ©2012 General Electric Company. All rights reserved. Version 1.01