Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current RoHS Compliant Features  Compliant to RoHS EU Directive 2011/65/EU (Z versions)  Compliant to RoHS EU Directive 2011/65/EU under exemption 7b (Lead solder exemption). Exemption 7b will expire after June 1, 2016 at which time this produc twill no longer be RoHS compliant (non-Z versions)  Delivers up to 25A output current 5V(10A), 3.3V(15A), 2.5V(20A), 1.8V-1.2V(25A) Representative Photo, actual product may vary.  High efficiency – 91% at 3.3V full load  Small size and low profile: Applications 33.0 mm x 22.9 mm x 8.5 mm  Distributed power architectures (1.30 in x 0.9 in x 0.335 in)  Wireless networks  Industry standard DOSA footprint  Access and optical network Equipment  -20% to +10% output voltage adjustment trim  Enterprise Networks  Remote On/Off  Latest generation IC’s (DSP, FPGA, ASIC) and  Remote Sense Microprocessor powered applications  No reverse current during output shutdown  Over temperature protection (latching) Options  Output overcurrent/overvoltage protection (latching)  Negative Remote On/Off logic  Wide operating temperature range (-40°C to 85°C)  Surface Mount (Tape and Reel, -SR Suffix)  Meets the voltage isolation requirements for  Over current/Over temperature/Over voltage ETSI 300-132-2 and complies with and is licensed for protections (auto-restart) Basic Insulation rating per EN60950-1  Shorter lead trim †  UL* 60950-1Recognized, CSA C22.2 No. 60950-1-03 ‡ rd Certified, and VDE 0805 (IEC60950 3 Edition) Licensed §  CE mark meets 2006/95/EC directive  ISO** 9001 and ISO 14001 certified manufacturing facilities 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. * 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 October 5, 2015 ©2012 General Electric Company. All rights reserved. Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings can cause permanent damage to the device. These are absolute stress ratings only, functional operation of the device is not implied at these or any other conditions in excess of those given in the operations sections of the data sheet. Exposure to absolute maximum ratings for extended periods can adversely affect the device reliability. Parameter Device Symbol Min Max Unit Input Voltage Continuous All V -0.3 80 Vdc IN Transient (100 ms) All V -0.3 100 Vdc IN,trans Operating Ambient Temperature All TA -40 85 °C (see Thermal Considerations section) Storage Temperature All Tstg -55 125 °C   I/O Isolation voltage (100% Factory Hi-Pot tested) All 1500 Vdc Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Parameter Device Symbol Min Typ Max Unit Operating Input Voltage All VIN 36 48 75 Vdc Maximum Input Current All IIN,max 1.7 2.0 Adc (VIN= VIN, min to VIN, max, IO=IO, max) Input No Load Current All I 55 mA IN,No load (VIN = VIN, nom, IO = 0, module enabled) Input Stand-by Current All I 5 7 mA IN,stand-by (VIN = VIN, nom, module disabled) 2 2 Inrush Transient All It 0.1 A s Input Reflected Ripple Current, peak-to-peak (5Hz to 20MHz, 1μH source impedance; V to V All 30 mA IN, min IN, p-p I = I ; See Test configuration section) max, O Omax Input Ripple Rejection (120Hz) All 50 60 100 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 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. October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 2 Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Electrical Specifications (continued) Parameter Device Symbol Min Typ Max Unit Output Voltage Set-point A VO, set 4.93 5.0 5.08 Vdc (V =V , I =I , T=25°C) F V 3.25 3.3 3.35 V IN IN, min O O, max A O, set dc G V 2.46 2.5 2.54 V O, set dc Y VO, set 1.77 1.8 1.83 Vdc M VO, set 1.48 1.5 1.53 Vdc P VO, set 1.18 1.2 1.22 Vdc Output Voltage All V -3.0 +3.0 % V O O, set (Over all operating input voltage, resistive load, and temperature conditions until end of life) Adjustment Range All VO,adj -20.0 +10.0 % VO, set Selected by an external resistor Output Regulation Line (VIN=VIN, min to VIN, max) A, F, G   0.1 % VO, set Y, M, P 2 mV Load (I =I to I) A, F, G 0.1 % V O O, min O, max   O, set Y, M, P 2 mV Temperature (Tref=TA, min to TA, max) All   1.0 % VO, set Output Ripple and Noise on nominal output (VIN=VIN, nom ,IO= IO, max , TA=TA, min to TA, max) RMS (5Hz to 20MHz bandwidth)  25  mVrms A, F, G, Y Peak-to-Peak (5Hz to 20MHz bandwidth) 75 mV   pk-pk RMS (5Hz to 20MHz bandwidth)  33  mVrms M, P Peak-to-Peak (5Hz to 20MHz bandwidth)  100  mV pk-pk External Capacitance All C 0 10,000 μF O, max  Rated Output Current A I 0 10 A O, Rated  dc F I 0 15 A O, Rated  dc G IO, Rated 0  20 Adc Y I 0 25 A O, Rated  dc M I 0  25 A O, Rated dc P IO, Rated 0  25 Adc Output Current Limit Inception (Hiccup Mode ) I All O, lim 106 120 146 %I O, Rated (VO= 90% of VO, set) Output Short-Circuit Current All IO, s/c  3  Arms (VO≤250mV) ( Hiccup Mode ) October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 3 Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Electrical Specifications (continued) Parameter Device Symbol Min Typ Max Unit Efficiency A η 92.0 % VIN= VIN, nom, TA=25°C F η 91.0 % I =I V = V G η 89.0 % O O, max , O O,set Y η 87.0 % M η 85.0 % P η 84.0 % Switching Frequency All f 190 200 235 kHz sw Dynamic Load Response (dIo/dt=0.1A/s; VIN = VIN, nom; TA=25°C) Load Change from Io= 50% to 75% or 25% to 50% of Io,max; Peak Deviation All Vpk  2  % VO, set Settling Time (Vo<10% peak deviation) All ts  200  s (dIo/dt=1A/s; VIN = VIN, nom; TA=25°C) Load Change from Io= 50% to 75% or 25% to 50% of Io,max; Peak Deviation All Vpk  5  % VO, set Settling Time (Vo<10% peak deviation) All ts  200  s Isolation Specifications Parameter Device Symbol Min Typ Max Unit Isolation Capacitance All C 1000 pF iso   Isolation Resistance All R 10 MΩ iso   I/O Isolation Voltage All All   1500 Vdc General Specifications Parameter Device Min Typ Max Unit Calculated Reliability Based upon Telcordia SR-332 Issue 2: MTBF F 2,864,101 Hours Method I, Case 3, (IO=80%IO, max, TA=40°C, Airflow = 200 lfm), 9 FIT F 349 10 /Hours 90% confidence Powered Random Vibration (V =V , I =I , T =25°C, 0 to 5000Hz, IN IN, min O O, max A All 90 Minutes 10Grms) Weight All  11.3 (0.4)  g (oz.) October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 4 Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature 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 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 All Ion/off   1.0 mA Logic Low - On/Off Voltage All V -0.7 1.2 V on/off  Logic High Voltage – (Typ = Open Collector) All V  5 V on/off Logic High maximum allowable leakage current All Ion/off   10 μA Turn-On Delay and Rise Times o (I =I V =V T = 25 C) O O, max , IN IN, nom, A All Tdelay — 15 20 msec Case 1: On/Off input is set to Logic Low (Module ON) and then input power is applied (delay from instant at which V = V until Vo=10% of Vo,set) IN IN, min All Tdelay — 4 10 msec Case 2: Input power is applied for at least 1 second and then the On/Off input is set from OFF to ON (Tdelay = from instant at which V =V until V = 10% of V ). IN IN, min O O, set All Trise — 8 12 msec Output voltage Rise time (time for Vo to rise from 10% of Vo,set to 90% of Vo, set) All Trise — 8 12 msec Output voltage Rise time (time for Vo to rise from 10% of Vo,set to 90% of Vo, set with max ext capacitance) 3 Output voltage overshoot – Startup — % V O, set o I = I ; V =V to V , T = 25 C O O, max IN IN, min IN, max A Remote Sense Range A, F, G +10 % V O, set Y, M, P 0.25 V dc Output Overvoltage Protection A VO, limit 6.1  7.0 Vdc F VO, limit 4.0  4.6 Vdc G V 3.1 3.7 V O, limit  dc Y VO, limit 2.3  3.2 Vdc M VO, limit 2.3  3.2 Vdc P V 2.0 2.8 V O, limit  dc Input Undervoltage Lockout Turn-on Threshold All V 35 36 V uv/on  dc Turn-off Threshold All V 32 33 V uv/off  dc Hysterisis All Vhyst 1   Vdc October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 5 Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Characteristic Curves o The following figures provide typical characteristics for the KW010A0A (5V, 10A) at 25 C. The figures are identical for either positive or negative remote On/Off logic. 12 95 Vin =36V 2.0 m/s (400 lfm) 90 10 85 Vin =48V 8 NC 80 0.5 m/s Vin =75V (100 lfm) 6 75 1.0 m/s (200 lfm) 70 4 02 46 8 10 20 30 40 50 60 70 80 90 O OUTPUT CURRENT, IO (A) AMBIENT TEMPERATURE, TA C Figure 1. Converter Efficiency versus Output Current. Figure 4. Derating Output Current versus Local Ambient Temperature and Airflow. TIME, t (5ms/div) TIME, t (1s/div) Figure 2. Typical output ripple and noise (VIN = VIN,NOM, Io = Figure 5. Typical Start-up Using Remote On/Off, Io,max). negative logic version shown (VIN = VIN,NOM, Io = Io,max). TIME, t (5ms/div) TIME, t (100 s /div) Figure 3. Transient Response to Dynamic Load Change Figure 6. Typical Start-up Using Input Voltage (VIN = from 75% to 50% to 75% of full load. VIN,NOM, Io = Io,max). October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 6 OUTPUT CURRENT, OUTPUT VOLTAGE OUTPUT VOLTAGE Io (A) (5A/div) V (V) (20mV/div) EFFICIENCY,  (%) O V (V) (20mV/div) O OUTPUT VOLTAGE On/Off VOLTAGE OUTPUT VOLTAGE INPUT VOLTAGE OUTPUT CURRENT, Io (A) VO (V) (2V/div) VOn/off (V) (2V/div) VO (V) (2V/div) VIN (V) (2V/div) Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Characteristic Curves o The following figures provide typical characteristics for the KW015A0F (3.3V, 15A) at 25 C. The figures are identical for either positive or negative remote On/Off logic. 18 93 2.0 m/s (400 lfm) 90 15 87 NC 12 84 0.5 m/s (100 lfm) 81 9 1.0 m/s VIN = 36V 78 (200 lfm) 6 VIN = 48V 75 VIN = 75V 3 72 20 30 40 50 60 70 80 90 03 69 12 15 O OUTPUT CURRENT, IO (A) AMBIENT TEMPERATURE, TA C Figure 7. Converter Efficiency versus Output Current. Figure 10. Derating Output Current versus Local Ambient Temperature and Airflow. TIME, t (1s/div) TIME, t (5ms/div) Figure 8. Typical output ripple and noise (VIN = VIN,NOM, Io = Figure 11. Typical Start-up Using Remote On/Off, negative Io,max). logic version shown (VIN = VIN,NOM, Io = Io,max). TIME, t (1ms/div) TIME, t (5ms/div) Figure 9. Transient Response to Dynamic Load Change Figure 12. Typical Start-up Using Input Voltage (VIN = from 50% to 75% to 50% of full load. VIN,NOM, Io = Io,max). October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 7 OUTPUT CURRENT, OUTPUT VOLTAGE OUTPUT VOLTAGE Io(A) (5A/div) V (V) (50mV/div) EFFICIENCY,  (%) O V (V) (10mV/div) O OUTPUT VOLTAGE On/Off VOLTAGE OUTPUT VOLTAGE INPUT VOLTAGE OUTPUT CURRENT, Io (A) VO (V) (1V/div) VOn/off (V) (5V/div) VO (V) (1V/div) VIN (V) (50V/div) Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Characteristic Curves (continued) o The following figures provide typical characteristics for the KW020A0G (2.5V, 20A) at 25 C. The figures are identical for either positive or negative remote On/Off logic. 93 25.0 Vin = 36V 2.0 m/s 90 (400 lfm) 20.0 87 84 15.0 Vin = 75V NC 81 0.5 m/s 10.0 (100 lfm) 78 Vin = 48V 1.0 m/s (200 lfm) 75 5.0 72 04 8 12 16 20 0.0 20 30 40 50 60 70 80 90 O OUTPUT CURRENT, IO (A) AMBIENT TEMPERATURE, TA C Figure 13. Converter Efficiency versus Output Current. Figure 16. Derating Output Current versus Local Ambient Temperature and Airflow. TIME, t (5ms/div) TIME, t (1s/div) Figure 14. Typical output ripple and noise (VIN = VIN,NOM, Io = Figure 17. Typical Start-up Using Remote On/Off, negative Io,max). logic version shown (VIN = VIN,NOM, Io = Io,max). TIME, t (1ms/div) TIME, t (5ms/div) Figure 15. Transient Response to Dynamic Load Change Figure 18. Typical Start-up Using Input Voltage (VIN = from 50% to 75% to 50% of full load. VIN,NOM, Io = Io,max). October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 8 OUTPUT CURRENT OUTPUT VOLTAGE OUTPUT VOLTAGE Io(A) (5A/div) V (V) (50mV/div) EFFICIENCY,  (%) O V (V) (20mV/div) O OUTPUT VOLTAGE On/Off VOLTAGE OUTPUT VOLTAGE INPUT VOLTAGE OUTPUT CURRENT, Io (A) VO (V) (1V/div) VOn/off (V) (2V/div) VO (V) (1V/div) VIN (V) (20V/div) Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Characteristic Curves (continued) o The following figures provide typical characteristics for the KW025A0Y (1.8V, 25A) at 25 C. The figures are identical for either positive or negative remote On/Off logic. 30 93 2.0 m/s 90 (400 lfm) 25 87 84 20 81 NC VIN = 36V 0.5 m/s 78 (100 lfm) VIN = 48V 15 75 1.0 m/s VIN = 75V (200 lfm) 72 05 10 15 20 25 10 20 30 40 50 60 70 80 90 O OUTPUT CURRENT, IO (A) AMBIENT TEMPERATURE, TA C Figure 19. Converter Efficiency versus Output Current. Figure 22. Derating Output Current versus Local Ambient Temperature and Airflow. TIME, t (5ms/div) TIME, t (1s/div) Figure 20. Typical output ripple and noise (VIN = VIN,NOM, Io = Figure 23. Typical Start-up Using Remote On/Off, Io,max). negative logic version shown (VIN = VIN,NOM, Io = Io,max). TIME, t (1ms/div) TIME, t (5ms/div) Figure 21. Transient Response to Dynamic Load Change Figure 24. Typical Start-up Using Input Voltage (VIN = from 50% to 75% to 50% of full load. VIN,NOM, Io = Io,max). October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 9 OUTPUT CURRENT, OUTPUT VOLTAGE OUTPUT VOLTAGE Io (A) (10A/div) V (V) (20mV/div) EFFICIENCY,  (%) O V (V) (100mV/div) O OUTPUT VOLTAGE On/Off VOLTAGE OUTPUT VOLTAGE INPUT VOLTAGE OUTPUT CURRENT, Io (A) VO (V) (0.5V/div) VOn/off (V) (5V/div) VO (V) (0.5V/div) VIN (V) (50V/div) Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Characteristic Curves (continued) o The following figures provide typical characteristics for the KW025A0M (1.5V, 25A) at 25 C. The figures are identical for either positive or negative remote On/Off logic. 30 90 2.0 m/s Vin = 36V 88 (400 lfm) 25 86 84 NC Vin = 48V 0.5 m/s 20 82 Vin = 75V (100 lfm) 1.0 m/s 80 (200 lfm) 78 15 76 74 10 0 5 10 15 20 25 20 30 40 50 60 70 80 90 O OUTPUT CURRENT, I (A) AMBIENT TEMPERATURE, T C O A Figure 25. Converter Efficiency versus Output Current. Figure 28. Derating Output Current versus Local Ambient Temperature and Airflow. TIME, t (4ms/div) TIME, t (1s/div) Figure 26. Typical output ripple and noise (VIN = VIN,NOM, Io = Figure 29. Typical Start-up Using Remote On/Off, negative Io,max). logic version shown (VIN = VIN,NOM, Io = Io,max). TIME, t (500us/div) TIME, t (5ms/div) Figure 27. Transient Response to Dynamic Load Change Figure 30. Typical Start-up Using Input Voltage (VIN = from 50% to 75% to 50% of full load. VIN,NOM, Io = Io,max). October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 10 OUTPUT CURRENT OUTPUT VOLTAGE OUTPUT VOLTAGE Io(A) (10A/div) V (V) (50mV/div) EFFICIENCY,  (%) O V (V) (50mV/div) O OUTPUT VOLTAGE On/Off VOLTAGE OUTPUT VOLTAGE INPUT VOLTAGE OUTPUT CURRENT, Io (A) VO (V) (500mV/div) VOn/off (V) (2.5V/div) VO (V) (500mV/div) VIN (V) (20V/div) Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Characteristic Curves (continued) o The following figures provide typical characteristics for the KW025A0P (1.2V, 25A) at 25 C. The figures are identical for either positive or negative remote On/Off logic. 30 90 Vin = 36V 2.0 m/s 88 (400 lfm) 25 86 84 NC 82 20 0.5 m/s Vin = 75V 80 (100 lfm) 1.0 m/s Vin = 48V (200 lfm) 78 15 76 74 10 0 5 10 15 20 25 20 30 40 50 60 70 80 90 O OUTPUT CURRENT, I (A) AMBIENT TEMPERATURE, T C O A Figure 31. Converter Efficiency versus Output Current. Figure 34. Derating Output Current versus Local Ambient Temperature and Airflow. TIME, t (5ms/div) TIME, t (1s/div) Figure 32. Typical output ripple and noise (VIN = VIN,NOM, Io = Figure 35. Typical Start-up Using Remote On/Off, Io,max). negative logic version shown (VIN = VIN,NOM, Io = Io,max). TIME, t (1ms/div) TIME, t (5ms/div) Figure 33. Transient Response to Dynamic Load Change Figure 36. Typical Start-up Using Input Voltage (VIN = from 75% to 50% to 75% of full load. VIN,NOM, Io = Io,max). October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 11 OUTPUT CURRENT OUTPUT VOLTAGE OUTPUT VOLTAGE Io (A) (10A/div) V (V) (50mV/div) EFFICIENCY,  (%) O V (V) (50mV/div) O OUTPUT VOLTAGE On/Off VOLTAGE OUTPUT VOLTAGE INPUT VOLTAGE OUTPUT CURRENT, Io (A) VO (V) (0.25V/div) VOn/off (V) (5V/div) VO (V) (0.5V/div) VIN (V) (20V/div) Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Test Configurations Design Considerations Input Filtering CURRENT PROBE TO OSCILLOSCOPE The power module should be connected to a low ac-impedance source. Highly inductive source L TEST Vin+ impedance can affect the stability of the power module. 12μH For the test configuration in Figure 37, a 33μF electrolytic capacitor (ESR<0.1 at 100kHz), mounted close to the C 220μF S 33μF power module helps ensure the stability of the unit. E.S.R.<0.1 Consult the factory for further application guidelines. @ 20°C 100kHz Vin- Safety Considerations For safety-agency approval of the system in which the NOTE: Measure input reflected ripple current with a simulated power module is used, the power module must be source inductance (L ) of 12μH. Capacitor C offsets TEST S possible battery impedance. Measure current as shown installed in compliance with the spacing and separation above. requirements of the end-use safety agency standard, i.e., UL 60950-1-3, CSA C22.2 No. 60950-00, and VDE Figure 37. Input Reflected Ripple Current Test Setup. 0805:2001-12 (IEC60950-1). COPPER STRIP If the input source is non-SELV (ELV or a hazardous V O (+) RESISTIVE voltage greater than 60 Vdc and less than or equal to LOAD 75Vdc), for the module’s output to be considered as SCOPE meeting the requirements for safety extra-low voltage V O (– ) (SELV), all of the following must be true: 10uF 0.1uF  The input source is to be provided with reinforced GROUND PLANE insulation from any other hazardous voltages, NOTE: All voltage measurements to be taken at the module including the ac mains. terminals, as shown above. If sockets are used then  One V pin and one V pin are to be grounded, or Kelvin connections are required at the module terminals IN OUT to avoid measurement errors due to socket contact both the input and output pins are to be kept resistance. floating. Figure 38. Output Ripple and Noise Test Setup.  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 R R R R distribution contact contact distribution subject module), as required by the safety agencies, Vin+ Vout+ to verify that under a single fault, hazardous voltages do not appear at the module’s output. R LOAD Note: Do not ground either of the input pins of the V VIN O module without grounding one of the output pins. This may allow a non-SELV voltage to R R R R distribution contact contact distribution appear between the output pins and ground. Vin- Vout- The power module has extra-low voltage (ELV) outputs when all inputs are ELV. NOTE: All voltage measurements to be taken at the module terminals, as shown above. If sockets are used then All flammable materials used in the manufacturing of Kelvin connections are required at the module terminals to avoid measurement errors due to socket contact these modules are rated 94V-0, or tested to the UL60950 resistance. A.2 for reduced thickness. Figure 39. Output Voltage and Efficiency Test Setup. For input voltages exceeding –60 Vdc but less than or equal to –75 Vdc, these converters have been evaluated VO. IO to the applicable requirements of BASIC INSULATION Efficiency  = x 100 % V . I IN IN 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. October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 12 BATTERY Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current the same output current would increase the power Feature Description output of the module. Care should be taken to ensure that the maximum output power of the module remains Remote On/Off at or below the maximum rated power (Maximum rated Two remote on/off options are available. Positive logic power = Vo,set x Io,max). turns the module on during a logic high voltage on the ON/OFF pin, and off during a logic low. Negative logic SENSE(+) remote On/Off, device code suffix “1”, turns the module off during a logic high and on during a logic low. SENSE(–) VI(+) VO(+) IO SUPPL Y LOAD II Vin+ Vout+ VI(-) VO(–) CONTACT CONT ACT AND RESIST ANCE DISTRIBUTION LOSSE I on/off ON/OFF Figure 41. Circuit Configuration for remote sense . TRIM V on/off Input Undervoltage Lockout At input voltages below the input undervoltage lockout Vout- limit, the module operation is disabled. The module will Vin- only begin to operate once the input voltage is raised above the undervoltage lockout turn-on threshold, VUV/ON. Figure 40. Remote On/Off Implementation. Once operating, the module will continue to operate until the input voltage is taken below the undervoltage turn- off threshold, V . To turn the power module on and off, the user must UV/OFF supply a switch (open collector or equivalent) to control Overtemperature Protection the voltage (Von/off) between the ON/OFF terminal and the V (-) terminal (see Figure 40). Logic low is To provide protection under certain fault conditions, the IN 0V ≤ V ≤ 1.2V. The maximum I during a logic low unit is equipped with a thermal shutdown circuit. The on/off on/off unit will shutdown if the thermal reference point Tref is 1mA, the switch should be maintain a logic low level o (Figure 43), exceeds 125 C (typical), but the thermal whilst sinking this current. shutdown is not intended as a guarantee that the unit During a logic high, the typical maximum Von/off will survive temperatures beyond its rating. The module generated by the module is 15V, and the maximum can be restarted by cycling the dc input power for at allowable leakage current at Von/off = 5V is 1μA. least one second or by toggling the remote on/off signal If not using the remote on/off feature: for at least one second. If the auto-restart option (4) is For positive logic, leave the ON/OFF pin open. ordered, the module will automatically restart upon cool- For negative logic, short the ON/OFF pin to VIN(-). down to a safe temperature. Remote Sense Output Overvoltage Protection Remote sense minimizes the effects of distribution losses The output over voltage protection scheme of the by regulating the voltage at the remote-sense modules has an independent over voltage loop to connections (See Figure 41). The voltage between the prevent single point of failure. This protection feature remote-sense pins and the output terminals must not latches in the event of over voltage across the output. exceed the output voltage sense range given in the Cycling the on/off pin or input voltage resets the latching Feature Specifications table: protection feature. If the auto-restart option (4) is [VO(+) – VO(–)] – [SENSE(+) – SENSE(–)]  0.5 V ordered, the module will automatically restart upon an internally programmed time elapsing. Although the output voltage can be increased by both the remote sense and by the trim, the maximum Overcurrent Protection increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote To provide protection in a fault (output overload) sense or the trim. condition, the unit is equipped with internal 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 October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 13 Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Feature Descriptions (continued) For example, to trim-down the output voltage of 2.5V current-limiting circuitry and can endure current limiting module (KW020A0G/G1) by 8% to 2.3V, Rtrim-down is continuously. At the point of current-limit inception, the calculated as follows: unit enters hiccup mode. If the unit is not configured with % 8 auto–restart, then it will latch off following the over current condition. The module can be restarted by 511   cycling the dc input power for at least one second or by R  10.22 k trimdown   8   toggling the remote on/off signal for at least one second. If the unit is configured with the auto-restart option (4), it R  53 .655 k trimdown will remain in the hiccup mode as long as the overcurrent condition exists; it operates normally, once Connecting an external resistor (R ) between the trim-up the output current is brought back into its specified TRIM pin and the V (+) (or Sense (+)) pin increases the O range. The average output current during hiccup is 10% output voltage set point. The following equations I . O, max determine the required external resistor value to obtain a percentage output voltage change of ∆%: Output Voltage Programming For output voltage: all 1.5V to 12V: Trimming allows the output voltage set point to be 5.11V  (100%)  511  increased or decreased, this is accomplished by o,set R   10.22 k trimup   connecting an external resistor between the TRIM pin 1.225% %   and either the VO(+) pin or the VO(-) pin. V V  desired o,set   % 100 Where   V V (+) V (+) IN O o,set   R trim-up For output voltage: 1.2V (SMT versions only): ON/OFF LOAD 5.111.2V(100%) 255.5  V TRIM O R    7.665 k trimup   1.225% %   R trim-down V  1.2V desired  %  100 Where   1.2V   V (-) V (-) IN O For output voltage: 1.2V (Through-Hole versions only): Figure 42. Circuit Configuration to Trim Output 5.111.2V(100%) 511   Voltage. R   10.22 k trimup   0.6% %   Connecting an external resistor (Rtrim-down) between the V  1.2V TRIM pin and the Vo(-) (or Sense(-)) pin decreases the desired  %  100 Where output voltage set point. To maintain set point accuracy, 1.2V   the trim resistor tolerance should be ±1.0%. The following equation determines the required external For example, to trim-up the output voltage of 1.2V resistor value to obtain a percentage output voltage through hole module (KW025A0P/P1) by 5% to 1.26V, change of ∆%. Rtrim-up is calculated is as follows: For output voltage: 1.2V (SMT versions only):  %  5  5.11 1.2 (100 5) 511   255 .5  R    10 .22 k trimup R   7.65 k   trimdown   0.6 5 5    %   R  102.2k trimup  1.2VV  desired %  100 Where   1.2V   The voltage between the Vo(+) and Vo(–) terminals must not exceed the minimum output overvoltage protection For output voltage: 1.2V (Through-Hole versions only) value shown in the Feature Specifications table. This limit and all 1.5V to 12V: includes any increase in voltage due to remote-sense compensation and output voltage set-point adjustment  511  R   10 .22 k trimdown   trim. %   Although the output voltage can be increased by both V V  o,set desired   the remote sense and by the trim, the maximum %  100 Where   V o,set increase for the output voltage is not the sum of both.   October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 14 Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Feature Descriptions (continued) Level [dBµV] The maximum increase is the larger of either the remote 80 sense or the trim. The amount of power delivered by the 70 module is defined as the voltage at the output terminals 60 multiplied by the output current. 50 When using remote sense and trim, the output voltage 40 of the module can be increased, which at the same 30 output current would increase the power output of the 20 module. Care should be taken to ensure that the 10 maximum output power of the module remains at or 0 150k 300k 500k 1M 2M 3M 5M 7M 10M 30M below the maximum rated power (Maximum rated Frequency [Hz] power = Vo,set x Io,max). MES CE0921041009_pre PK LIM EN 55022A V QP Voltage QP Limit Thermal Considerations Figure 44. KW015A0F Quasi Peak Conducted Emissions with EN 55022 Class A limits, no external filter (V = IN The power modules operate in a variety of thermal V , I = 0.85 I ). IN,NOM o o,max environments; however, sufficient cooling should be provided to help ensure reliable operation. Level [dBµV] Considerations include ambient temperature, airflow, 80 module power dissipation, and the need for increased 70 + reliability. A reduction in the operating temperature of 60 the module will result in an increase in reliability. The 50 thermal data presented here is based on physical 40 measurements taken in a wind tunnel. 30 The thermal reference point, Tref used in the 20 specifications is shown in Figure 43. For reliable 10 o operation this temperature should not exceed 120 C. 0 150k 300k 500k 1M 2M 3M 5M 7M 10M 30M Frequency [Hz] + MES CE0921041009_fin AV MES CE0921041009_pre AV LIM EN 55022A V AV Voltage AV Limit Figure 45. KW015A0F Average Conducted Emissions with EN 55022 Class A limits, no external filter (V = IN V , I = 0.85 I ). IN,NOM o o,max Figure 43. Tref Temperature Measurement Locations. Please refer to the Application Note “Thermal Characterization Process For Open-Frame Board- Mounted Power Modules” for a detailed discussion of thermal aspects including maximum device temperatures. 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 GE Sales Representitive for further information. October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 15 Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current result in the failure of or cause damage to the modules, Surface Mount Information and can adversely affect long-term reliability. Pick and Place In a conventional Tin/Lead (Sn/Pb) solder process peak o reflow temperatures are limited to less than 235 C. The KW010-025 modules use an open frame o Typically, the eutectic solder melts at 183 C, wets the construction and are designed for a fully automated land, and subsequently wicks the device connection. assembly process. The pick and place location on the Sufficient time must be allowed to fuse the plating on the module is the larger magnetic core as shown in Figure connection to ensure a reliable solder joint. There are 46. The modules are fitted with a label which meets all several types of SMT reflow technologies currently used the requirements for surface mount processing, as well in the industry. These surface mount power modules as safety standards, and is able to withstand reflow can be reliably soldered using natural forced convection, o temperatures of up to 300 C. The label also carries IR (radiant infrared), or a combination of convection/IR. product information such as product code, serial For reliable soldering the solder reflow profile should be number and the location of manufacture. established by accurately measuring the modules CP connector temperatures. 300 o Peak Temp 235 C 250 Cooling zone Heat zo ne 200 o -1 o -1 1-4 Cs max 4 Cs 150 So ak zo ne 10 0 T above 30-240s lim o 205 C 50 Preheat zo ne o -1 max 4 Cs 0 Figure 46. Pick and Place Location. REFLOW TIME (S) Figure 47. Reflow Profile for Tin/Lead (Sn/Pb) process Nozzle Recommendations 240 The module weight has been kept to a minimum by using open frame construction. Even so, these modules 235 have a relatively large mass when compared to 230 conventional SMT components. Variables such as nozzle size, tip style, vacuum pressure and placement speed 225 should be considered to optimize this process. The 220 recommended nozzle diameter for reliable operation is 6mm. Oblong or oval nozzles up to 11 x 6 mm may also 215 be used within the space available. 210 205 Tin Lead Soldering 200 The KW010-025 power modules (both non-Z and –Z 0 1020 30 4050 60 codes) can be soldered either in a conventional Tin/Lead o Figure 48. Time Limit Curve Above 205 C for Tin/Lead (Sn/Pb) process. The non-Z version of the KW010-025 (Sn/Pb) process 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 October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 16 MAX TEMP SOLDER (C) REFLOW TEMP (C) Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current result of inadequate cleaning and drying can affect both Surface Mount Information (continued) the reliability of a power module and the testability of Lead Free Soldering the finished circuit-board assembly. For guidance on appropriate soldering, cleaning and drying procedures, The –Z version of the KW010-025 modules are lead-free refer to GE Board (Pb-free) and RoHS compliant, and are both forward and Mounted Power Modules: Soldering and Cleaning backward compatible in a Pb-free and a SnPb soldering Application Note (AN04-001). 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 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. Figure 49. Recommended linear reflow profile using This standard provides a recommended forced-air- Sn/Ag/Cu solder. 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 Through-Hole Lead-Free Soldering Fig. 49. Information The RoHS-compliant through-hole products use the SAC MSL Rating (Sn/Ag/Cu) Pb-free solder and RoHS-compliant The KW010-025 modules have a MSL rating of 2A. components. They are designed to be processed through single or dual wave soldering machines. The pins have an RoHS-compliant finish that is compatible Storage and Handling with both Pb and Pb-free wave soldering processes. A The recommended storage environment and handling maximum preheat rate of 3C/s is suggested. The wave procedures for moisture-sensitive surface mount preheat process should be such that the temperature of packages is detailed in J-STD-033 Rev. A (Handling, the power module board is kept below 210C. For Pb Packing, Shipping and Use of Moisture/Reflow Sensitive solder, the recommended pot temperature is 260C, Surface Mount Devices). Moisture barrier bags (MBB) while the Pb-free solder pot is 270C max. Not all RoHS- with desiccant are required for MSL ratings of 2 or compliant through-hole products can be processed with greater. These sealed packages should not be broken paste-through-hole Pb or Pb-free reflow process. If until time of use. Once the original package is broken, additional information is needed, please consult with the floor life of the product at conditions of  30°C and your GE representative for more details. 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 October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 17 Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current 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.] 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(+) October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 18 Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current 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.] 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(+) October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 19 Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current 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.] SMT Recommended Pad Layout (Component Side View) TH Recommended Pad Layout (Component Side View) October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 20 Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current 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. Tape Dimensions Dimensions are in millimeters. October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 21 Data Sheet GE KW010/015/020/025 Series Power Modules 36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current Ordering Information Please contact your GE Sales Representative for pricing, availability and optional features. Table 1. Device Code Output Output Connector Product Codes Input Voltage On/Off Logic Comcode Voltage Current Type 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 -Z Indicated RoHS Compliant Modules Table 2. Device Options Option* Suffix** Negative remote on/off logic 1 Auto Re-start (for Over Current / Over voltage Protections) 4 Pin Length: 3.68 mm ± 0.25 mm, (0.145 in. ± 0.010 in.) 6 Pin Length: 2.79 mm ± 0.25 mm, (0.110 in. ± 0.010 in.) 8 Surface mount connections (Tape & Reel) -SR * 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. Contact Us For more information, call us at USA/Canada: +1 877 546 3243, or +1 972 244 9288 Asia-Pacific: +86.021.54279977*808 Europe, Middle-East and Africa: +49.89.878067-280 www.gecriticalpower.com GE Critical Power reserves the right to make changes to the product(s) or information contained herein without notice, and 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. October 5, 2015 ©2012 General Electric Company. All International rights reserved. Version 1.11