GE Data Sheet
October 5, 2015 ©2012 General Electric Company. All rights reserved.
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
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)
High efficiency – 91% at 3.3V full load
Small size and low profile:
33.0 mm x 22.9 mm x 8.5 mm
(1.30 in x 0.9 in x 0.335 in)
Industry standard DOSA footprint
-20% to +10% output voltage adjustment trim
Remote On/Off
Remote Sense
No reverse current during output shutdown
Over temperature protection (latching)
Output overcurrent/overvoltage protection (latching)
Wide operating temperature range (-40°C to 85°C)
Meets the voltage isolation requirements for
ETSI 300-132-2 and complies with and is licensed for
Basic Insulation rating per EN60950-1
UL* 60950-1Recognized, CSA† C22.2 No. 60950-1-03
Certified, and VDE‡ 0805 (IEC60950 3rd Edition)
Licensed
CE mark meets 2006/95/EC directive§
ISO** 9001 and ISO 14001 certified manufacturing
facilities
Applications
Distributed power architectures
Wireless networks
Access and optical network Equipment
Enterprise Networks
Latest generation IC’s (DSP, FPGA, ASIC) and
Microprocessor powered applications
Options
Negative Remote On/Off logic
Surface Mount (Tape and Reel, -SR Suffix)
Over current/Over temperature/Over voltage
protections (auto-restart)
Shorter lead trim
Description
The KW (Sixteenth-brick) series power modules are isolated dc-dc converters that operate over a wide input voltage range
of 36 to 75Vdc and provide a single precisely regulated output. The output is fully isolated from the input, allowing
versatile polarity configurations and grounding connections. The modules exhibit high efficiency, typical efficiency of 91%
for 3.3V/15A. These open frame modules are available either in surface-mount (-SR) or in through-hole (TH) form.
* 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
RoHS Compliant
Representative Photo, actual product may vary.
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 2
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 (100 ms) All VIN,trans -0.3 100 Vdc
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 IIN,No load 55 mA
(VIN = VIN, nom, IO = 0, module enabled)
Input Stand-by Current All IIN,stand-by 5 7 mA
(VIN = VIN, nom, module disabled)
Inrush Transient All I2t 0.1 A2s
Input Reflected Ripple Current, peak-to-peak
(5Hz to 20MHz, 1μH source impedance; VIN, min to VIN,
max, IO= IOmax ; See Test configuration section)
All 30 mAp-p
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.
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 3
Electrical Specifications (continued)
Parameter Device Symbol Min Typ Max Unit
Output Voltage Set-point A VO, set 4.93 5.0 5.08 Vdc
(VIN=VIN, min, IO=IO, max, TA=25°C) F VO, set 3.25 3.3 3.35 Vdc
G VO, set 2.46 2.5 2.54 Vdc
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 VO -3.0 +3.0 % VO, 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 (IO=IO, min to IO, max) A, F, G
0.1 % VO, 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) A, F, G, Y 25 mVrms
Peak-to-Peak (5Hz to 20MHz bandwidth) 75 mVpk-pk
RMS (5Hz to 20MHz bandwidth) M, P
33 mVrms
Peak-to-Peak (5Hz to 20MHz bandwidth) 100 mVpk-pk
External Capacitance All CO, max 0 10,000 μF
Rated Output Current A IO, Rated 0 10 Adc
F IO, Rated 0 15 Adc
G IO, Rated 0 20 Adc
Y IO, Rated 0 25 Adc
M IO, Rated 0 25 Adc
P IO, Rated 0 25 Adc
Output Current Limit Inception (Hiccup Mode ) All IO, lim 106 120 146 %IO, Rated
(VO= 90% of VO, set)
Output Short-Circuit Current All IO, s/c 3 Arms
(VO≤250mV) ( Hiccup Mode )
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 4
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 %
IO=IO, max , VO= VO,set G η 89.0 %
Y η 87.0 %
M η 85.0 %
P η 84.0 %
Switching Frequency All fsw 190 200 235 kHz
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 Ciso 1000 pF
Isolation Resistance All Riso 10 MΩ
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:
Method I, Case 3, (IO=80%IO, max, TA=40°C, Airflow = 200 lfm),
90% confidence
MTBF F 2,864,101 Hours
FIT F 349 109/Hours
Powered Random Vibration (VIN=VIN, min, IO=IO, max, TA=25°C, 0 to 5000Hz,
10Grms) All 90 Minutes
Weight All
11.3 (0.4) g (oz.)
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 5
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 Von/off -0.7 1.2 V
Logic High Voltage – (Typ = Open Collector) All Von/off 5 V
Logic High maximum allowable leakage current All Ion/off 10 μA
Turn-On Delay and Rise Times
(IO=IO, max , VIN=VIN, nom, TA = 25 oC)
Case 1: On/Off input is set to Logic Low (Module
ON) and then input power is applied (delay from
instant at which VIN = VIN, min until Vo=10% of Vo,set)
All Tdelay — 15 20 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 VIN=VIN, min until VO = 10% of VO, set).
All Tdelay — 4 10 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)
All Trise — 8 12 msec
Output voltage overshoot – Startup — 3
% VO, set
IO= IO, max; VIN=VIN, min to VIN, max, TA = 25 oC
Remote Sense Range A, F, G +10 % VO, set
Y, M, P 0.25 Vdc
Output Overvoltage Protection A VO, limit 6.1 7.0 Vdc
F VO, limit 4.0 4.6 Vdc
G VO, limit 3.1 3.7 Vdc
Y VO, limit 2.3 3.2 Vdc
M VO, limit 2.3 3.2 Vdc
P VO, limit 2.0 2.8 Vdc
Input Undervoltage Lockout
Turn-on Threshold All Vuv/on 35 36 Vdc
Turn-off Threshold All Vuv/off 32 33 Vdc
Hysterisis All Vhyst 1 Vdc
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 6
Characteristic Curves
The following figures provide typical characteristics for the KW010A0A (5V, 10A) at 25oC. The figures are identical for either
positive or negative remote On/Off logic.
EFFICIENCY, (%)
OUTPUT CURRENT, Io (A)
4
6
8
10
12
20 30 40 50 60 70 80 90
2.0 m/s
(400 lfm)
1.0 m/s
(200 lfm)
0.5 m/s
(100 lfm)
NC
OUTPUT CURRENT, IO (A) AMBIENT TEMPERATURE, TA OC
Figure 1. Converter Efficiency versus Output Current. Figure 4. Derating Output Current versus Local Ambient
Temperature and Airflow.
OUTPUT VOLTAGE
VO (V) (20mV/div)
OUTPUT VOLTAGE On/Off VOLTAGE
VO (V) (2V/div) VOn/off (V) (2V/div)
TIME, t (1s/div) TIME, t (5ms/div)
Figure 2. Typical output ripple and noise (VIN
= VIN,NOM, Io
=
Io,max).
Figure 5. Typical Start-up Using Remote On/Off,
negative logic version shown (VIN = VIN,NOM, Io = Io,max).
OUTPUT CURRENT, OUTPUT VOLTAGE
Io (A) (5A/div) VO (V) (20mV/div)
OUTPUT VOLTAGE INPUT VOLTAGE
VO (V) (2V/div) VIN (V) (2V/div)
TIME, t (100 s /div) TIME, t (5ms/div)
Figure 3. Transient Response to Dynamic Load Change
from 75% to 50% to 75% of full load.
Figure 6. Typical Start-up Using Input Voltage (VIN
=
VIN,NOM, Io = Io,max).
70
75
80
85
90
95
0246810
Vin =48V
Vin =75V
Vin =36V
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 7
Characteristic Curves
The following figures provide typical characteristics for the KW015A0F (3.3V, 15A) at 25oC. The figures are identical for
either positive or negative remote On/Off logic.
EFFICIENCY, (%)
72
75
78
81
84
87
90
93
03 691215
VIN = 75V
VIN = 48V
VIN = 36V
OUTPUT CURRENT, Io (A)
3
6
9
12
15
18
20 30 40 50 60 70 80 90
1.0 m/s
(200 lfm)
0.5 m/s
(100 lfm)
NC
2.0 m/s
(400 lfm)
OUTPUT CURRENT, IO (A) AMBIENT TEMPERATURE, TA OC
Figure 7. Converter Efficiency versus Output Current. Figure 10. Derating Output Current versus Local Ambient
Temperature and Airflow.
OUTPUT VOLTAGE
VO (V) (10mV/div)
OUTPUT VOLTAGE On/Off VOLTAGE
VO (V) (1V/div) VOn/off (V) (5V/div)
TIME, t (1s/div) TIME, t (5ms/div)
Figure 8. Typical output ripple and noise (VIN
= VIN,NOM, Io
=
Io,max).
Figure 11. Typical Start-up Using Remote On/Off, negative
logic version shown (VIN = VIN,NOM, Io = Io,max).
OUTPUT CURRENT, OUTPUT VOLTAGE
Io(A) (5A/div) VO (V) (50mV/div)
OUTPUT VOLTAGE INPUT VOLTAGE
VO (V) (1V/div) VIN (V) (50V/div)
TIME, t (1ms/div) TIME, t (5ms/div)
Figure 9. Transient Response to Dynamic Load Change
from 50% to 75% to 50% of full load.
Figure 12. Typical Start-up Using Input Voltage (VIN
=
VIN,NOM, Io = Io,max).
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 8
Characteristic Curves (continued)
The following figures provide typical characteristics for the KW020A0G (2.5V, 20A) at 25oC. The figures are identical for
either positive or negative remote On/Off logic.
EFFICIENCY, (%)
72
75
78
81
84
87
90
93
048121620
Vin = 36V
Vin = 48V
Vin = 75V
OUTPUT CURRENT, Io (A)
0.0
5.0
10.0
15.0
20.0
25.0
20 30 40 50 60 70 80 90
2.0 m/s
(400 lfm)
1.0 m/s
(200 lfm)
0.5 m/s
(100 lfm)
NC
OUTPUT CURRENT, IO (A) AMBIENT TEMPERATURE, TA OC
Figure 13. Converter Efficiency versus Output Current. Figure 16. Derating Output Current versus Local Ambient
Temperature and Airflow.
OUTPUT VOLTAGE
VO (V) (20mV/div)
OUTPUT VOLTAGE On/Off VOLTAGE
VO (V) (1V/div) VOn/off (V) (2V/div)
TIME, t (1s/div) TIME, t (5ms/div)
Figure 14. Typical output ripple and noise (VIN
= VIN,NOM, Io
=
Io,max).
Figure 17. Typical Start-up Using Remote On/Off, negative
logic version shown (VIN = VIN,NOM, Io = Io,max).
OUTPUT CURRENT OUTPUT VOLTAGE
Io(A) (5A/div) VO (V) (50mV/div)
OUTPUT VOLTAGE INPUT VOLTAGE
VO (V) (1V/div) VIN (V) (20V/div)
TIME, t (1ms/div) TIME, t (5ms/div)
Figure 15. Transient Response to Dynamic Load Change
from 50% to 75% to 50% of full load.
Figure 18. Typical Start-up Using Input Voltage (VIN
=
VIN,NOM, Io = Io,max).
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 9
Characteristic Curves (continued)
The following figures provide typical characteristics for the KW025A0Y (1.8V, 25A) at 25oC. The figures are identical for
either positive or negative remote On/Off logic.
EFFICIENCY, (%)
72
75
78
81
84
87
90
93
0510152025
VIN = 75V
VIN = 48V
VIN = 36V
OUTPUT CURRENT, Io (A)
10
15
20
25
30
20 30 40 50 60 70 80 90
2.0 m/s
(400 lfm)
1.0 m/s
(200 lfm)
0.5 m/s
(100 lfm)
NC
OUTPUT CURRENT, IO (A) AMBIENT TEMPERATURE, TA OC
Figure 19. Converter Efficiency versus Output Current. Figure 22. Derating Output Current versus Local
Ambient Temperature and Airflow.
OUTPUT VOLTAGE
VO (V) (100mV/div)
OUTPUT VOLTAGE On/Off VOLTAGE
VO (V) (0.5V/div) VOn/off (V) (5V/div)
TIME, t (1s/div) TIME, t (5ms/div)
Figure 20. Typical output ripple and noise (VIN
= VIN,NOM, Io
=
Io,max).
Figure 23. Typical Start-up Using Remote On/Off,
negative logic version shown (VIN = VIN,NOM, Io = Io,max).
OUTPUT CURRENT, OUTPUT VOLTAGE
Io (A) (10A/div) VO (V) (20mV/div)
OUTPUT VOLTAGE INPUT VOLTAGE
VO (V) (0.5V/div) VIN (V) (50V/div)
TIME, t (1ms/div) TIME, t (5ms/div)
Figure 21. Transient Response to Dynamic Load Change
from 50% to 75% to 50% of full load.
Figure 24. Typical Start-up Using Input Voltage (VIN
=
VIN,NOM, Io = Io,max).
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 10
Characteristic Curves (continued)
The following figures provide typical characteristics for the KW025A0M (1.5V, 25A) at 25oC. The figures are identical for
either positive or negative remote On/Off logic.
EFFICIENCY, (%)
74
76
78
80
82
84
86
88
90
0 5 10 15 20 25
Vin = 75V
Vin = 36V
Vin = 48V
OUTPUT CURRENT, Io (A)
10
15
20
25
30
20 30 40 50 60 70 80 90
2.0 m/s
(400 lfm)
1.0 m/s
(200 lfm)
0.5 m/s
(100 lfm)
NC
OUTPUT CURRENT, IO (A) AMBIENT TEMPERATURE, TA OC
Figure 25. Converter Efficiency versus Output Current. Figure 28. Derating Output Current versus Local Ambient
Temperature and Airflow.
OUTPUT VOLTAGE
VO (V) (50mV/div)
OUTPUT VOLTAGE On/Off VOLTAGE
VO (V) (500mV/div) VOn/off (V) (2.5V/div)
TIME, t (1s/div) TIME, t (4ms/div)
Figure 26. Typical output ripple and noise (VIN
= VIN,NOM, Io
=
Io,max).
Figure 29. Typical Start-up Using Remote On/Off, negative
logic version shown (VIN = VIN,NOM, Io = Io,max).
OUTPUT CURRENT OUTPUT VOLTAGE
Io(A) (10A/div) VO (V) (50mV/div)
OUTPUT VOLTAGE INPUT VOLTAGE
VO (V) (500mV/div) VIN (V) (20V/div)
TIME, t (500us/div) TIME, t (5ms/div)
Figure 27. Transient Response to Dynamic Load Change
from 50% to 75% to 50% of full load.
Figure 30. Typical Start-up Using Input Voltage (VIN
=
VIN,NOM, Io = Io,max).
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 11
Characteristic Curves (continued)
The following figures provide typical characteristics for the KW025A0P (1.2V, 25A) at 25oC. The figures are identical for
either positive or negative remote On/Off logic.
EFFICIENCY, (%)
74
76
78
80
82
84
86
88
90
0 5 10 15 20 25
Vin = 75V
Vin = 36V
Vin = 48V
OUTPUT CURRENT, Io (A)
10
15
20
25
30
20 30 40 50 60 70 80 90
2.0 m/s
(400 lfm)
1.0 m/s
(200 lfm)
0.5 m/s
(100 lfm)
NC
OUTPUT CURRENT, IO (A) AMBIENT TEMPERATURE, TA OC
Figure 31. Converter Efficiency versus Output Current. Figure 34. Derating Output Current versus Local
Ambient Temperature and Airflow.
OUTPUT VOLTAGE
VO (V) (50mV/div)
OUTPUT VOLTAGE On/Off VOLTAGE
VO (V) (0.25V/div) VOn/off (V) (5V/div)
TIME, t (1s/div) TIME, t (5ms/div)
Figure 32. Typical output ripple and noise (VIN
= VIN,NOM, Io
=
Io,max).
Figure 35. Typical Start-up Using Remote On/Off,
negative logic version shown (VIN = VIN,NOM, Io = Io,max).
OUTPUT CURRENT OUTPUT VOLTAGE
Io (A) (10A/div) VO (V) (50mV/div)
OUTPUT VOLTAGE INPUT VOLTAGE
VO (V) (0.5V/div) VIN (V) (20V/div)
TIME, t (1ms/div) TIME, t (5ms/div)
Figure 33. Transient Response to Dynamic Load Change
from 75% to 50% to 75% of full load.
Figure 36. Typical Start-up Using Input Voltage (VIN
=
VIN,NOM, Io = Io,max).
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 12
Test Configurations
TO OSCILLOSCOPE CURRENT PROBE
LTEST
12μH
BATTERY
CS 220μF
E.S.R.<0.1
@ 20°C 100kHz
33μF
Vin+
Vin-
NOTE: Measure input reflected ripple current with a simulated
source inductance (LTEST) of 12μH. Capacitor CS offsets
possible battery impedance. Measure current as shown
above.
Figure 37. Input Reflected Ripple Current Test Setup.
NOTE: All voltage measurements to be taken at the module
terminals, as shown above. If sockets are used then
Kelvin connections are required at the module terminals
to avoid measurement errors due to socket contact
resistance.
V
O (+)
V O ( – )
RESISTIVE
LOAD
SCOPE
COPPER STRIP
GROUND PLANE
10uF
0.1uF
Figure 38. Output Ripple and Noise Test Setup.
Vout+
Vout-
Vin+
Vin-
RLOAD
Rcontact Rdistribution
Rcontact Rdistribution
Rcontact
Rcontact
Rdistribution
Rdistribution
VIN VO
NOTE: All voltage measurements to be taken at the module
terminals, as shown above. If sockets are used then
Kelvin connections are required at the module terminals
to avoid measurement errors due to socket contact
resistance.
Figure 39. Output Voltage and Efficiency Test Setup.
=
VO. IO
VIN. IIN
x 100 %
Efficiency
Design Considerations
Input Filtering
The power module should be connected to a low
ac-impedance source. Highly inductive source
impedance can affect the stability of the power module.
For the test configuration in Figure 37, a 33μF electrolytic
capacitor (ESR<0.1 at 100kHz), mounted close to the
power module helps ensure the stability of the unit.
Consult the factory for further application guidelines.
Safety Considerations
For safety-agency approval of the system in which the
power module is used, the power module must be
installed in compliance with the spacing and separation
requirements of the end-use safety agency standard, i.e.,
UL 60950-1-3, CSA C22.2 No. 60950-00, and VDE
0805:2001-12 (IEC60950-1).
If the input source is non-SELV (ELV or a hazardous
voltage greater than 60 Vdc and less than or equal to
75Vdc), for the module’s output to be considered as
meeting the requirements for safety extra-low voltage
(SELV), all of the following must be true:
The input source is to be provided with reinforced
insulation from any other hazardous voltages,
including the ac mains.
One VIN pin and one VOUT pin are to be grounded, or
both the input and output pins are to be kept
floating.
The input pins of the module are not operator
accessible.
Another SELV reliability test is conducted on the
whole system (combination of supply source and
subject module), as required by the safety agencies,
to verify that under a single fault, hazardous
voltages do not appear at the module’s output.
Note: Do not ground either of the input pins of the
module without grounding one of the output
pins. This may allow a non-SELV voltage to
appear between the output pins and ground.
The power module has extra-low voltage (ELV) outputs
when all inputs are ELV.
All flammable materials used in the manufacturing of
these modules are rated 94V-0, or tested to the UL60950
A.2 for reduced thickness.
For input voltages exceeding –60 Vdc but less than or
equal to –75 Vdc, these converters have been evaluated
to the applicable requirements of BASIC INSULATION
between secondary DC MAINS DISTRIBUTION input
(classified as TNV-2 in Europe) and unearthed SELV
outputs.
The input to these units is to be provided with a
maximum 5 A time-delay fuse in the ungrounded lead.
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 13
Feature Description
Remote On/Off
Two remote on/off options are available. Positive logic
turns the module on during a logic high voltage on the
ON/OFF pin, and off during a logic low. Negative logic
remote On/Off, device code suffix “1”, turns the module
off during a logic high and on during a logic low.
ON/OFF
Vin+
Vin-
Ion/off
Von/off
Vout+
TRIM
Vout-
Figure 40. Remote On/Off Implementation.
To turn the power module on and off, the user must
supply a switch (open collector or equivalent) to control
the voltage (Von/off) between the ON/OFF terminal and the
VIN(-) terminal (see Figure 40). Logic low is
0V ≤ Von/off ≤ 1.2V. The maximum Ion/off during a logic low
is 1mA, the switch should be maintain a logic low level
whilst sinking this current.
During a logic high, the typical maximum Von/off
generated by the module is 15V, and the maximum
allowable leakage current at Von/off = 5V is 1μA.
If not using the remote on/off feature:
For positive logic, leave the ON/OFF pin open.
For negative logic, short the ON/OFF pin to VIN(-).
Remote Sense
Remote sense minimizes the effects of distribution losses
by regulating the voltage at the remote-sense
connections (See Figure 41). The voltage between the
remote-sense pins and the output terminals must not
exceed the output voltage sense range given in the
Feature Specifications table:
[VO(+) – VO(–)] – [SENSE(+) – SENSE(–)] 0.5 V
Although the output voltage can be increased by both
the remote sense and by the trim, the maximum
increase for the output voltage is not the sum of both.
The maximum increase is the larger of either the remote
sense or the trim.
The amount of power delivered by the module is defined
as the voltage at the output terminals multiplied by the
output current. When using remote sense and trim, the
output voltage of the module can be increased, which at
the same output current would increase the power
output of the module. Care should be taken to ensure
that the maximum output power of the module remains
at or below the maximum rated power (Maximum rated
power = Vo,set x Io,max).
VO(+)
SENSE(+)
SENSE(–)
VO(–)
VI(+)
VI(-)
IOLOAD
CONTACT AND
DISTRIBUTION LOSS
E
SUPPLY II
CONTACT
RESISTANCE
Figure 41. Circuit Configuration for remote sense .
Input Undervoltage Lockout
At input voltages below the input undervoltage lockout
limit, the module operation is disabled. The module will
only begin to operate once the input voltage is raised
above the undervoltage lockout turn-on threshold,
VUV/ON.
Once operating, the module will continue to operate until
the input voltage is taken below the undervoltage turn-
off threshold, VUV/OFF.
Overtemperature Protection
To provide protection under certain fault conditions, the
unit is equipped with a thermal shutdown circuit. The
unit will shutdown if the thermal reference point Tref
(Figure 43), exceeds 125oC (typical), but the thermal
shutdown is not intended as a guarantee that the unit
will survive temperatures beyond its rating. The module
can be restarted by cycling the dc input power for at
least one second or by toggling the remote on/off signal
for at least one second. If the auto-restart option (4) is
ordered, the module will automatically restart upon cool-
down to a safe temperature.
Output Overvoltage Protection
The output over voltage protection scheme of the
modules has an independent over voltage loop to
prevent single point of failure. This protection feature
latches in the event of over voltage across the output.
Cycling the on/off pin or input voltage resets the latching
protection feature. If the auto-restart option (4) is
ordered, the module will automatically restart upon an
internally programmed time elapsing.
Overcurrent Protection
To provide protection in a fault (output overload)
condition, the unit is equipped with internal
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 14
Feature Descriptions (continued)
current-limiting circuitry and can endure current limiting
continuously. At the point of current-limit inception, the
unit enters hiccup mode. If the unit is not configured with
auto–restart, then it will latch off following the over
current condition. The module can be restarted by
cycling the dc input power for at least one second or by
toggling the remote on/off signal for at least one second.
If the unit is configured with the auto-restart option (4), it
will remain in the hiccup mode as long as the
overcurrent condition exists; it operates normally, once
the output current is brought back into its specified
range. The average output current during hiccup is 10%
IO, max.
Output Voltage Programming
Trimming allows the output voltage set point to be
increased or decreased, this is accomplished by
connecting an external resistor between the TRIM pin
and either the VO(+) pin or the VO(-) pin.
VO(+)
VOTRIM
VO(-)
Rtrim-down
LOAD
VIN(+)
ON/OFF
VIN(-)
Rtrim-up
Figure 42. Circuit Configuration to Trim Output
Voltage.
Connecting an external resistor (Rtrim-down) between the
TRIM pin and the Vo(-) (or Sense(-)) pin decreases the
output voltage set point. To maintain set point accuracy,
the trim resistor tolerance should be ±1.0%.
The following equation determines the required external
resistor value to obtain a percentage output voltage
change of ∆%.
For output voltage: 1.2V (SMT versions only):
kR downtrim 65.7
%5.255
Where 100
2.1
2.1
%
V
VV desired
For output voltage: 1.2V (Through-Hole versions only)
and all 1.5V to 12V:
kR downtrim 22.10
%
511
Where 100% ,
,
seto
desiredseto V
VV
For example, to trim-down the output voltage of 2.5V
module (KW020A0G/G1) by 8% to 2.3V, Rtrim-down is
calculated as follows:
8%
kR downtrim 22.10
8
511
kR downtrim 655.53
Connecting an external resistor (Rtrim-up) between the
TRIM pin and the VO(+) (or Sense (+)) pin increases the
output voltage set point. The following equations
determine the required external resistor value to obtain
a percentage output voltage change of ∆%:
For output voltage: all 1.5V to 12V:
k
V
Rseto
uptrim 22.10
%
511
%225.1
%)100(11.5 ,
Where 100%
,
,
seto
setodesired
V
VV
For output voltage: 1.2V (SMT versions only):
k
V
Ruptrim 665.7
%5.255
%225.1 %)100(2.111.5
Where 100
2.1 2.1
%
VVVdesired
For output voltage: 1.2V (Through-Hole versions only):
k
V
Ruptrim 22.10
%
511
%6.0 %)100(2.111.5
Where 100
2.1 2.1
%
VVVdesired
For example, to trim-up the output voltage of 1.2V
through hole module (KW025A0P/P1) by 5% to 1.26V,
Rtrim-up is calculated is as follows:
5%
kR uptrim 22.10
5
511
56.0 )5100(2.111.5
kR uptrim 2.102
The voltage between the Vo(+) and Vo(–) terminals must
not exceed the minimum output overvoltage protection
value shown in the Feature Specifications table. This limit
includes any increase in voltage due to remote-sense
compensation and output voltage set-point adjustment
trim.
Although the output voltage can be increased by both
the remote sense and by the trim, the maximum
increase for the output voltage is not the sum of both.
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 15
Feature Descriptions (continued)
The maximum increase is the larger of either the remote
sense or the trim. The amount of power delivered by the
module is defined as the voltage at the output terminals
multiplied by the output current.
When using remote sense and trim, the output voltage
of the module can be increased, which at the same
output current would increase the power output of the
module. Care should be taken to ensure that the
maximum output power of the module remains at or
below the maximum rated power (Maximum rated
power = Vo,set x Io,max).
Thermal Considerations
The power modules operate in a variety of thermal
environments; however, sufficient cooling should be
provided to help ensure reliable operation.
Considerations include ambient temperature, airflow,
module power dissipation, and the need for increased
reliability. A reduction in the operating temperature of
the module will result in an increase in reliability. The
thermal data presented here is based on physical
measurements taken in a wind tunnel.
The thermal reference point, Tref used in the
specifications is shown in Figure 43. For reliable
operation this temperature should not exceed 120oC.
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.
0
10
20
30
40
50
60
70
80
Level [dBµV]
150k 300k 500k 1M 2M 3M 5M 7M 10M 30M
Frequency [Hz]
MES CE0921041009_pre PK
LIM EN 55022A V QP Voltage QP Limit
Figure 44. KW015A0F Quasi Peak Conducted Emissions
with EN 55022 Class A limits, no external filter (VIN =
VIN,NOM, Io = 0.85 Io,max).
0
10
20
30
40
50
60
70
80
Level [dBµV]
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 (VIN =
VIN,NOM, Io = 0.85 Io,max).
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 16
Surface Mount Information
Pick and Place
The KW010-025 modules use an open frame
construction and are designed for a fully automated
assembly process. The pick and place location on the
module is the larger magnetic core as shown in Figure
46. The modules are fitted with a label which meets all
the requirements for surface mount processing, as well
as safety standards, and is able to withstand reflow
temperatures of up to 300oC. The label also carries
product information such as product code, serial
number and the location of manufacture.
Figure 46. Pick and Place Location.
Nozzle Recommendations
The module weight has been kept to a minimum by
using open frame construction. Even so, these modules
have a relatively large mass when compared to
conventional SMT components. Variables such as nozzle
size, tip style, vacuum pressure and placement speed
should be considered to optimize this process. The
recommended nozzle diameter for reliable operation is
6mm. Oblong or oval nozzles up to 11 x 6 mm may also
be used within the space available.
Tin Lead Soldering
The KW010-025 power modules (both non-Z and –Z
codes) can be soldered either in a conventional Tin/Lead
(Sn/Pb) process. The non-Z version of the KW010-025
modules are RoHS compliant with the lead exception.
Lead based solder paste is used in the soldering process
during the manufacturing of these modules. These
modules can only be soldered in conventional Tin/lead
(Sn/Pb) process. It is recommended that the customer
review data sheets in order to customize the solder
reflow profile for each application board assembly. The
following instructions must be observed when soldering
these units. Failure to observe these instructions may
result in the failure of or cause damage to the modules,
and can adversely affect long-term reliability.
In a conventional Tin/Lead (Sn/Pb) solder process peak
reflow temperatures are limited to less than 235oC.
Typically, the eutectic solder melts at 183oC, wets the
land, and subsequently wicks the device connection.
Sufficient time must be allowed to fuse the plating on the
connection to ensure a reliable solder joint. There are
several types of SMT reflow technologies currently used
in the industry. These surface mount power modules
can be reliably soldered using natural forced convection,
IR (radiant infrared), or a combination of convection/IR.
For reliable soldering the solder reflow profile should be
established by accurately measuring the modules CP
connector temperatures.
REFLOW TEMP (C)
0
50
10 0
15 0
200
250
300
Preheat zo ne
max 4oCs-1
So ak zone
30-240s
Heat zone
max 4oCs-1
Peak Temp 235oC
Cooling
zo ne
1- 4 oCs-1
T
lim
above
205
o
C
REFLOW TIME (S)
Figure 47. Reflow Profile for Tin/Lead (Sn/Pb) process
MAX TEMP SOLDER (C)
200
205
210
215
220
225
230
235
240
0 102030405060
Figure 48. Time Limit Curve Above 205oC for Tin/Lead
(Sn/Pb) process
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 17
Surface Mount Information (continued)
Lead Free Soldering
The –Z version of the KW010-025 modules are lead-free
(Pb-free) and RoHS compliant, and are both forward and
backward compatible in a Pb-free and a SnPb soldering
process. The non-Z version of the KW006/010 modules
are RoHS compliant with the lead exception. Lead based
solder paste is used in the soldering process during the
manufacturing of these modules. These modules can
only be soldered in conventional Tin/lead (Sn/Pb)
process. Failure to observe the instructions below may
result in the failure of or cause damage to the modules
and can adversely affect long-term reliability.
Pb-free Reflow Profile
Power Systems will comply with J-STD-020 Rev. D
(Moisture/Reflow Sensitivity Classification for
Nonhermetic Solid State Surface Mount Devices) for both
Pb-free solder profiles and MSL classification procedures.
This standard provides a recommended forced-air-
convection reflow profile based on the volume and
thickness of the package (table 4-2). The suggested Pb-
free solder paste is Sn/Ag/Cu (SAC). The recommended
linear reflow profile using Sn/Ag/Cu solder is shown in
Fig. 49.
MSL Rating
The KW010-025 modules have a MSL rating of 2A.
Storage and Handling
The recommended storage environment and handling
procedures for moisture-sensitive surface mount
packages is detailed in J-STD-033 Rev. A (Handling,
Packing, Shipping and Use of Moisture/Reflow Sensitive
Surface Mount Devices). Moisture barrier bags (MBB)
with desiccant are required for MSL ratings of 2 or
greater. These sealed packages should not be broken
until time of use. Once the original package is broken,
the floor life of the product at conditions of 30°C and
60% relative humidity varies according to the MSL rating
(see J-STD-033A). The shelf life for dry packed SMT
packages will be a minimum of 12 months from the bag
seal date, when stored at the following conditions: < 40°
C, < 90% relative humidity.
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 (AN04-001).
Figure 49. Recommended linear reflow profile using
Sn/Ag/Cu solder.
Through-Hole Lead-Free Soldering
Information
The RoHS-compliant through-hole products use the SAC
(Sn/Ag/Cu) Pb-free solder and RoHS-compliant
components. They are designed to be processed
through single or dual wave soldering machines. The
pins have an RoHS-compliant finish that is compatible
with both Pb and Pb-free wave soldering processes. A
maximum preheat rate of 3C/s is suggested. The wave
preheat process should be such that the temperature of
the power module board is kept below 210C. For Pb
solder, the recommended pot temperature is 260C,
while the Pb-free solder pot is 270C max. Not all RoHS-
compliant through-hole products can be processed with
paste-through-hole Pb or Pb-free reflow process. If
additional information is needed, please consult with
your GE representative for more details.
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 18
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(+)
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 19
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(+)
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 20
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)
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
October 5, 2015 ©2012 General Electric Company. All rights reserved. Page 21
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.
GE Data Sheet
KW010/015/020/025 Series Power Modules
36 – 75Vdc Input; 1.2 to 5.0Vdc Output; 10 to 25A Output current
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
Ordering Information
Please contact your GE Sales Representative for pricing, availability and optional features.
Table 1. Device Code
Product Codes Input Voltage Output
Voltage
Output
Current On/Off Logic Connector
Type Comcode
KW010A0A41-SR 48V (36-75Vdc) 5.0V 10A Negative Surface mount 108992434
KW015A0F41-SR 48V (36-75Vdc) 3.3V 15A Negative Surface mount 108989934
KW015A0F41 48V (36-75Vdc) 3.3V 15A Negative Through hole 108992590
KW025A0Y41 48V (36-75Vdc) 1.8V 25A Negative Through hole 108989942
KW010A0A41-SRZ 48V (36-75Vdc) 5.0V 10A Negative Surface mount CC109112042
KW010A0A41Z 48V (36-75Vdc) 5.0V 10A Negative Through hole CC109112050
KW015A0F41-SRZ 48V (36-75Vdc) 3.3V 15A Negative Surface mount CC109105888
KW015A0F41Z 48V (36-75Vdc) 3.3V 15A Negative Through hole CC109112067
KW015A0F841Z 48V (36-75Vdc) 3.3V 15A Negative Through hole CC109144696
KW020A0G4-SRZ 48V (36-75Vdc) 2.5V 20A Positive Surface mount CC109112653
KW020A0G41-SRZ 48V (36-75Vdc) 2.5V 20A Negative Surface mount CC109128212
KW020A0G41Z 48V (36-75Vdc) 2.5V 20A Negative Through hole CC109141710
KW020A0G41-BZ 48V (36-75Vdc) 2.5V 20A Negative Through hole CC109108395
KW025A0Y41-SRZ 48V (36-75Vdc) 1.8V 25A Negative Surface mount CC109112091
KW025A0Y41Z 48V (36-75Vdc) 1.8V 25A Negative Through hole CC109112100
KW025A0Y641Z 48V (36-75Vdc) 1.8V 25A Negative Through hole CC109127445
KW025A0M41Z 48V (36-75Vdc) 1.5V 25A Negative Through hole CC109128492
KW025A0P41-SRZ 48V (36-75Vdc) 1.2V 25A Negative Surface mount CC109123964
KW025A0P41Z 48V (36-75Vdc) 1.2V 25A Negative Through hole CC109128385
-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.
