GE Data Sheet KHHD015A0F HammerheadTM Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 12A/15A Output RoHS Compliant Applications Wireless Networks Hybrid power architectures Optical and Access Network Equipment Enterprise Networks including Power over Ethernet (PoE) Industrial markets Options Negative Remote On/Off logic (preferred) Surface Mount/Tape and Reel (-SR Suffix) Auto-restart Over current/Over voltage protections (preferred) Shorter through hole pin trim Features Compliant to RoHS II EU "Directive 2011/65/EU (-Z versions) Compliant to REACH Directive (EC) No 1907/2006 Ultra-wide Input Voltage Range, 18Vdc to 75Vdc No minimum load High efficiency - 90.5% at full load (VIN=48Vdc) 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) Surface mount (SMT) or Through hole (TH) Reflow process compliant, both SMT and TH versions Positive Remote On/Off logic Output overcurrent/voltage protection (hiccup) Over-temperature protection Output Voltage adjust: 80% to 110% of Vo,nom Wide operating temperature range (-40C to 85C) UL*Recognized to UL60950-1, CAN/CSA C22.2 No.60950-1, and EN60950-1(VDE 0805-1) Licensed CE mark meets 2006/95/EC directive Meets the voltage and current requirements for ETSI 300132-2 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 The KHHD015A0F series power modules are isolated DOSA compliant 1/16th brick dc-dc converters that operate over an ultrawide input voltage range of 18 Vdc -75Vdc and provide a single precisely regulated output voltage at 3.3Vdc. The output is fully isolated from the input, allowing versatile polarity configurations and grounding connections. The modules exhibit high efficiency of 90.5% 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 (c)2012 General Electric Company. All rights reserved. Page 1 GE Data Sheet KHHD015A0F HammerheadTM Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 12A/15A 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 All VIN -0.3 80 Vdc All VIN, trans -0.3 100 Vdc All TA -40 85 C Storage Temperature All Tstg -55 Altitude* All I/O Isolation Voltage (100% factory Hi-Pot tested) All Input Voltage (Continuous) Transient (100ms) Operating Ambient Temperature Unit (see Thermal Considerations section) 125 C 4000 m 2250 Vdc * For higher altitude applications, contact your GE Sales Representative for alternative conditions of use. Electrical Specifications Unless otherwise indicated, specifications apply at VIN = 48Vdc, resistive load, and TA = 25C conditions. Parameter Device Symbol Min Typ Max Unit All VIN 18 24/48 75 Vdc All IIN,No load 40 50 mA All IIN,stand-by 6 8 mA Maximum Input Current (VIN=18Vdc, IO= IO,MAX) All IIN, MAX 2.65 Adc Inrush Transient All I2t 0.05 A2s Input Reflected Ripple Current, peak-to-peak (5Hz to 20MHz, 12H source impedance; VIN=0V to 75Vdc, IO= IOmax ; see Test configuration section) All 30 mAp-p Input Ripple Rejection (120Hz) All 60 dB Operating Input Voltage Input No Load Current (VIN = 48Vdc IO = 0A, module enabled) Input Stand-by Current (VIN = 24 to 48Vdc, module disabled) 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 (c)2012 General Electric Company. All rights reserved. Page 2 GE Data Sheet KHHD015A0F HammerheadTM Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 12A/15A Output Electrical Specifications (continued) Unless otherwise indicated, specifications apply at VIN = 48Vdc, resistive load, and TA = 25C conditions. Parameter Output Voltage Set-point (VIN=24 to 48Vdc, IO=IO, max,) Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life) Adjustment Range Selected by external resistor Remote Sense Range Output Regulation Line (VIN=VIN, min to VIN, max) Load (IO=IO, min to IO, max) Temperature (Tref=TA, min to TA, max) Output Ripple and Noise on nominal output Measured with 10uF Tantalum||1uF ceramic (VIN=24 to 48Vdc, IO=80%IO, max) RMS (5Hz to 20MHz bandwidth) Peak-to-Peak (5Hz to 20MHz bandwidth) External Capacitance (see Note 1 in Feature Specifications) Output Current (VIN =36V to 75V) Device Symbol Min Typ Max Unit All VO, set 3.25 3.30 3.35 Vdc All VO -3.0 +3.0 % VO, set All VO, adj -20 +10 % VO, set +10 % VO, set All All All All 0.05 0.05 0.2 0.2 1.0 % VO, set % VO, set % VO, set 25 75 5000 mVrms mVpk-pk F All CO, max 0 All Io 0 15.0 Adc All Io 0 12.0 Adc (VIN =36V to 75V) All IO, lim 16.5 21 Adc (VIN =18V to 36V) All IO, lim 13.2 16.5 Adc Output Short-Circuit Current (VO 250 mV) All IO, s/c 2.5 Arms Efficiency (VIN=24Vdc, IO=IO, max) All 87.5 88.5 % Efficiency (VIN=48Vdc, IO=IO, max) All 89.5 90.5 % All fsw 450 kHz Peak Deviation All Vpk 3.0 % VO, set Settling Time (Vo<10% peak deviation) All ts 400 s Unit (VIN =18V to 36V) All Output Current Limit Inception (Hiccup Mode) Switching Frequency (Fixed) VIN=24 to 48Vdc, IO= IO, max Dynamic Load Response (Io/t=0.1A/s) Load Change from Io= 50% to 75% or 25% to 50% of Io,max: Isolation Specifications Parameter Symbol Min Typ Max Isolation Capacitance Ciso 1000 pF Isolation Resistance Riso 10 M I/O Isolation Voltage All 2250 Vdc April 1, 2013 (c)2012 General Electric Company. All rights reserved. Page 3 GE Data Sheet KHHD015A0F HammerheadTM Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 12A/15A Output General Specifications Parameter Min Calculated Reliability based upon Telcordia SR-332 Issue 2: Method I Case 3 (IO=80%IO, max, TA=40C, airflow = 200 lfm, 90% confidence) Typ Max Unit FIT 274.7 109/Hours MTBF 3,640,826 Hours Weight 13 (0.46) g (oz.) Feature Specifications Unless otherwise indicated, specifications apply at VIN = 48Vdc, resistive load, and TA = 25C 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 (Von/off = -0.7Vdc) All Ion/off 0.15 mA Logic Low - On/Off Voltage All Von/off -0.7 0.8 Vdc Logic High Voltage (Ion/off = 0Adc) All Von/off 2.4 7 Vdc Logic High maximum allowable leakage current All Ion/off 25 A 35 50 ms 24 50 ms 30 50 ms 3 % VO, set Vdc Turn-On Delay and Rise Times (IO=80% of IO, max) Case 1: Input power is applied for at least 1second, and then the On/Off input is set from OFF to ON (Tdelay = on/off pin transition until VO = 10% of VO, set) All Case 2: On/Off input is set to Module ON, and then input power is applied (Tdelay = VIN reaches VIN, min until VO = 10% of VO,set) All Output voltage Rise time (time for Vo to rise from 10% of Vo,set to 90% of Vo, set) All Tdelay Case1 Tdelay Case2 Trise Output Voltage Overshoot (IO=80% of IO, max, VIN= 24 to 48Vdc) Output Overvoltage Protection All VO, limit 4.0 5.5 Input Undervoltage Lockout Turn-on Threshold All Vuv/on 17 18 Vdc Turn-off Threshold All Vuv/off 14 15 Vdc Hysterisis All Vhyst 2.0 Vdc Note: 1.The module requires a minimum of 470 F external output capacitor to avoid exceeding the OVP maximum limits during startup into open loop fault conditions. April 1, 2013 (c)2012 General Electric Company. All rights reserved. Page 4 GE G Data Sh heet KHHD01 K 15A0F Ha ammerheadTM Se eries; DC C-DC Con nverter Power P Mo odules 18-75Vdc 1 In nput; 3.3Vd dc, 12A/15A A Output Characteris C stic Curvess EFFICIENCY, (%) INPUT CURRENT, IIN (A) The T following figures provide typical characteristics for the e KHHD015A0FF (3.3V, 12A/15A) at 25oC. The e figures are id dentical for either e positive o or negative rem mote On/Off log gic. OUTPU UT CURRENT, IO (A A) Figure e 2. Converterr Input Currentt versus Input Voltage. OUTPUT VOLTAGE VO (V) (50mV/div) OUTPUT CURRENT OUTPUT VOLTAGE Io(A) (2A/div) VO (V) (100mV/div) Figure 1. Convverter Efficien ncy versus Outtput Current. INPUT VOLLTAGE, VIN (V) TIME, t (1s/div) TIME, t (5 500s/div) Figure e 4. Transient Response to 0.1A/S 0 Dynam mic Load Chang ge from 50% to o 75% to 50% % of full load, Vin=48V. V INPUT VOLTAGE VIN (V) (20V/div) On/Off VOLTAGE VOn/Off V) (2V/div) OUTPUT VOLTAGE VO (V) (1V/div) OUTPUT VOLTAGE VO ( (V) (1V/div) Figure 3. Typiical output ripple and noise (Io = Io,max). TIM ME, t (20ms/div) Figure 5.Typiccal Start-up Ussing Remote On/Off, O negativve logic version shown (VIN = 24V 2 or 48V, Io = Io,max). April A 1, 2013 TIME, t (2 20ms/div) Figure e 6. Typical Sta art-up Using In nput Voltage (VIN = 48V, Io = Io,max). (c)2 2012 General Ele ectric Company. A All rights reserve ed. Page 5 GE Data Sheet KHHD015A0F HammerheadTM Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 12A/15A Output Test Configurations Design Considerations CURRENT PROBE TO OSCILLOSCOPE 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 7, a 33F electrolytic capacitor (ESR<0.7 at 100kHz), mounted close to the power module helps ensure the stability of the unit. Consult the factory for further application guidelines. LTEST Vin+ BATTERY 12H CS 220F Input Source Impedance 33F E.S.R.<0.1 @ 20C 100kHz Vin- NOTE: Measure input reflected ripple current with a simulated source inductance (LTEST) of 12H. Capacitor CS offsets possible battery impedance. Measure current as shown above. Figure 7. Input Reflected Ripple Current Test Setup. CO PPER STRIP V O (+) RESISTIVE LO AD 1uF . 10uF SC OPE V O (- ) G RO UND PLANE 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 8. Output Ripple and Noise Test Setup. Rdistribution Rcontact Rcontact Vin+ Vout+ RLOAD VO VIN Rdistribution Rcontact Rcontact Vin- Rdistribution Rdistribution Vout- 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 9. Output Voltage and Efficiency Test Setup. VO. IO Efficiency = VIN. IIN x 100 % 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 (IEC60950, 3rd Edition). 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. 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 6A fast acting fuse in the ungrounded lead. April 1, 2013 (c)2012 General Electric Company. All rights reserved. Page 6 GE Data Sheet KHHD015A0F HammerheadTM Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 12A/15A Output Feature Description Input Undervoltage Lockout Remote On/Off 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. 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. Once operating, the module will continue to operate until the input voltage is taken below the undervoltage turn-off threshold, VUV/OFF. Over Voltage Protection Vin+ Vout+ TRIM The output overvoltage protection shall consist of circuitry that independently monitors the output voltage, and shuts the module down if the output voltage exceeds specified limits. 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. Vout- Output Voltage Programming Ion/off ON/OFF Von/off Vin- Figure 10. Circuit configuration for using 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. Logic low is 0V Von/off 0.8V. The maximum Ion/off during a logic low is 0.15mA, the switch should be maintain a logic low level whilst sinking this current. During a logic high, the typical Von/off generated by the module is 4.0V, and the maximum allowable leakage current at Von/off = 4.0V is 25A. 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(-). Overcurrent Protection Trimming allows the user to increase or decrease the output voltage set point of the module. This is accomplished by connecting an external resistor between the TRIM pin and either the Vout+ pin or the Vout- pin. Trim Down - Decrease Output Voltage By connecting an external resistor (Radj-down) between the TRIM pin and VO(-) or SENSE(-) pin (see figure 11), the output voltage set point decreases. The following equation determines the external resistor value to obtain an output voltage change from Vo,set to the desired Vo,desired: 511 R adj down 10 . 22 k % V o , set V o , desired Where % V o , set 100 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 autorestart 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 equipped with a thermal shutdown circuit. The unit will shut down if the thermal reference point Tref (Figure 16), exceeds 135oC (typical), but the thermal shutdown is not intended as a guarantee that the unit will survive temperatures beyond its rating. The module will automatically restart upon cool-down to a safe temperature. April 1, 2013 Figure 11. Circuit Configuration to Decrease Output Voltage. Trim Up - Increase Output Voltage By connecting an external resistor (Radj-up) between the TRIM pin and VO(+) or SENSE(+) pin (see figure 12), the output voltage set point increases. The following equation determines the external resistor value to obtain an output voltage change from Vo,set to the desired Vo,desired: (c)2012 General Electric Company. All rights reserved. Page 7 GE G Data She eet KHHD01 K 15A0F Ha ammerheadTM Se eries; DC C-DC Con nverter Power P Mo odules 18-75Vdc 1 In nput; 3.3Vd dc, 12A/15A A Output Feature F De escriptions (continued) Radj up The ermal Conssiderationss 5 .11 Vo , set (100 %) 511 10 .22 k % 1 .225 % V Vo , set % o , desired Where W V o , set The power p moduless operate in a variety v of therm mal envirronments; how wever, sufficientt cooling shoulld be provided to he elp ensure relia able operation. Conssiderations include ambient temperature, airflow, module powe er dissipation, and a the need for f increased re eliability. A reduction in the operating temperature of the m module will resullt in an increase in reliability. 100 Figure F 12. Circu uit Configurattion to Increasse Output Volta age. The thermal t data presented p here is based on ph hysical meassurements taken in a wind tu unnel, using automated therm mo-couple insttrumentation to o monitor key component c temp peratures: FETss, diodes, contrrol ICs, magnettic cores, ceramic capacitorss, opto-isolatorrs, and module pwb cond ductors, while controlling c the ambient airflow w rate and temp perature. For a given airflow and a ambient te emperature, th he module output pow wer is increased d, until one (or more) of the ponents reaches its maximum m derated ope erating comp temp perature, as de efined in IPC-95 592A. This proccedure is then repea ated for a diffe erent airflow orr ambient temp perature until a family of module ou utput derating curves is obta ained. The T combinatio on of the outpu ut voltage adjusstment and the e output o voltage initial tolerancce must not excceed the allowa able trim range of 80 0% to 110% off the nominal output o voltage as measured m betw ween the Vout+ + and Vout- pin ns. The T KHHD015A A0F power mod dules have a fixxed current-lim mit set point. p Thereforre, as the outpu ut voltage is ad djusted down, the t available a outpu ut power is redu uced. Pre-bias P Vin U Under Voltag ge Test The T module sha all recover from m UVLO [Unde er Voltage Lockk Out] without w protecttive shutdown from OCP or OVP or hard fa ailure, when w subjecte ed to Vin Und der Voltage transients t with h the fo ollowing conditions: Vin(V) Tdip (ms) 48 5 48 5 48 10 48 10 48 5 48 5 48 10 48 10 60 5 60 5 60 10 60 10 60 5 60 5 60 10 60 10 Vin Tfall = 10us 5V April A 1, 2013 Co (uF) 0 2200 0 2200 0 2200 0 2200 0 2200 0 2200 0 2200 0 2200 Load (A) 0 0 0 0 15 15 15 15 0 0 0 0 15 15 15 15 Figurre 13. Thermal Test Setup . Heatt Transfer via a Convection n Incre eased airflow over o the module enhances the e heat transferr via convection. Derating figures showing s the m maximum outpu ut ent that can be e delivered by each e module versus local curre ambient temperatu ure (TA) for natu ural convection n and up to 3m/ss (600 ft./min) are a shown in th he respective Characteristics C Curves section. A No ote "Thermal Ch haracterization n Pleasse refer to the Application Proce ess For Open-FFrame Board-M Mounted Power Modules" for a detailed discussion n of thermal asp pects including g maximum devicce temperature es. Tdip Trise = 5us (c) (c)2012 General Electric Companyy. All rights reservved. Pagee 8 GE G Data Sh heet KHHD01 K 15A0F Ha ammerheadTM Se eries; DC C-DC Con nverter Power P Mo odules 18-75Vdc 1 In nput; 3.3Vd dc, 12A/15A A Output OUTPUT CURRENT, IO (A) ( ) Thermal T Co onsideratio ons (continued) es: C1 and C4 are low impedance SMT cera amics. Note Ci C1, C4 C2, C3 GRM32D DR73A153KW0 01L, 15nF, 1000 0V (*2) RDHX33 33K302HKT, 33nF, 3000V (Holystone) 202S48W W334KT, 33nF,, 2000V (Johan nson) Figurre 17. Suggestted Configurattion for EN550 022 Class B. C5, C6 OUTPUT CURRENT, IO (A) ( ) LO OCAL AMBIENTT TEMPERATURE, TA (C) Figure F 14. Outp put Current De erating for the e Open Frame KHHD015A0F K in the Transverse Orientatio on; Airflow Direction D from Vin(+) to Vin(--); Vin = 24V. See Figu ure 7 2.2uF, 10 00V, 1210 1210Y1K K50103KXTDW WV, 10nF, 1500V V (*2) RDHX22 23K302HKT, 22nF, 3000V (Holystone) LO OCAL AMBIENTT TEMPERATURE, TA (C) Figure F 15. Outp put Current De erating for the e Open Frame KHHD015A0F K in the Transverse Orientatio on; Airflow Direction D from Vin(+) to Vin(--); Vin = 48V. The T thermal refference point, Tref, used in the specifications is shown s in Figure e 16. For reliab ble operation th his temperaturre should s not exce eed 117oC. Figurre 18. EMC signature using above a filter, KHHD015A0. ation on design ning for EMC co ompliance, For further informa pleasse refer to the FLTR100V10 data sheet (FDS01-043EPS). Layyout Consid derations The KHHD015A0F K 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 directly d underneath the powe er module. Also avoid d placing via interconnects un nderneath the powe er module. For additional a layou ut guide-lines, refer to the FLTTR100V10 data a shee et. Figure F 16. Tref Temperature T M Measurement t Location. EMC E Requirrements Figure F 17 show ws a maximum filter configura ation to meet th he conducted c emisssion limits of EN55022 E Classs B. April A 1, 2013 The KHHD015A0F K f family of power modules is avvailable for eithe er Through-Hole (TH) or Surfacce Mount (SMTT) soldering. Thro ough-Hole Soldering S In nformation The RoHS-complian R nt (Z codes) thrrough-hole pro oducts use the SAC ((Sn/Ag/Cu) Pb--free solder and d RoHS-compliiant comp ponents. Theyy are designed to be processe ed through single or dual wave e soldering machines. The pin ns have an (c)2 2012 General Ele ectric Company. A All rights reserve ed. Page 9 GE Data Sheet KHHD015A0F HammerheadTM Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 12A/15A Output Layout Considerations (continued) Reflow Soldering Information RoHS-compliant finish that is compatible with both Pb and Pbfree 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 RoHScompliant through-hole products can be processed with pastethrough-hole Pb or Pb-free reflow process. If additional information is needed, please consult with your GE representative for more details. These power modules are large mass, low thermal resistance devices and typically heat up slower than other SMT components. It is recommended that the customer review data sheets in order to customize the solder reflow profile for each application board assembly. Surface Mount Information Pick and Place The KHHD-SR series of DC-to-DC power converters use an open-frame construction and are designed for surface mount assembly within a fully automated manufacturing process. The KHHD-SR series modules are designed to use the main magnetic component surface to allow for pick and place. The following instructions must be observed when SMT 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. 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. The recommended linear reflow profile using Sn/Pb solder is shown in Figure 20 and 21. For reliable soldering the solder reflow profile should be established by accurately measuring the module's pin connector temperatures. 300 P eak Temp 235oC REFLOW TEMP (C) 250 Co o ling zo ne 1-4oCs -1 Heat zo ne max 4oCs -1 200 150 So ak zo ne 30-240s 100 50 Tlim above 205oC P reheat zo ne max 4oCs -1 0 REFLOW TIME (S) Figure 20. Recommended Reflow Profile for Sn/Pb solder. Note: All dimensions in mm [in]. Figure 19. Pick and Place Location. 240 Z Plane Height The `Z' plane height of the pick and place location is 7.50mm nominal with an RSS tolerance of +/-0.25 mm. Nozzle Recommendations The module weight has been kept to a minimum by using open frame construction. Even so, they have a relatively large mass when compared with conventional SMT components. Variables such as nozzle size, tip style, vacuum pressure and placement speed should be considered to optimize this process. The minimum recommended nozzle diameter for reliable operation is 5mm. The maximum nozzle outer diameter, which will safely fit within the allowable component spacing, is 6.5mm. Oblong or oval nozzles up to 11 x 6 mm may also be used within the space available. For further information please contact your local GE Technical Sales Representative. April 1, 2013 MAX TEMP SOLDER (C) 235 230 225 220 215 210 205 200 0 10 20 30 40 50 60 TIME LIMIT (S) Figure 21. Time Limit, Tlim, Curve Above 205oC Reflow. Lead Free Soldering The -Z version SMT modules of the KHHD015A0F series are lead-free (Pb-free) and RoHS compliant and are compatible in a Pb-free soldering 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. (c)2012 General Electric Company. All rights reserved. Page 10 GE Data Sheet KHHD015A0F HammerheadTM Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 12A/15A Output Surface Mount Information (continued) Pb-free Reflow Profile Power Systems will comply with J-STD-020 Rev. C (Moisture/Reflow Sensitivity Classification for Nonhermetic Solid State Surface Mount Devices) for both Pb-free solder profiles and MSL classification procedures. This standard provides a recommended forced-air-convection reflow profile based on the volume and thickness of the package (table 4-2). The suggested Pb-free solder paste is Sn/Ag/Cu (SAC). The recommended linear reflow profile using Sn/Ag/Cu solder is shown in Figure 22. 300 Per J-STD-020 Rev. C Peak Temp 260C Reflow Temp (C) 250 200 * Min. Time Above 235C 15 Seconds 150 Heating Zone 1C/Second Cooling Zone *Time Above 217C 60 Seconds 100 50 0 Reflow Time (Seconds) Figure 22. Recommended linear reflow profile using Sn/Ag/Cu solder. MSL Rating The KHHD015A0F 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 30C 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 (c)2012 General Electric Company. All rights reserved. Page 11 GE G Data She eet KHHD01 K 15A0F Ha ammerheadTM Se eries; DC C-DC Con nverter Power P Mo odules 18-75Vdc 1 In nput; 3.3Vd dc, 12A/15A A Output Mechanica M l Outline fo or KHHD01 15A0F Surfa ace-Mountt Module Dimensions D are e in millimeterss and [inches]. Tolerances: T x.x mm 0.5 mm [x.xx in. 0.02 in.] (Unless oth herwise indicatted) x.xx mm 0.25 mm m [x.xxx in 0.0 010 in.] Top View Side View Bottom View PIN 1 2 3 4 5 6 7 8 FUNCTIO ON VIN(+) On/Offf VIN(-) Vo(-) Sense(--) Trim Sense(++) Vo(+) April A 1, 2013 (c) (c)2012 General Electric Companyy. All rights reservved. Page 1 12 GE Data Sheet KHHD015A0F HammerheadTM Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 12A/15A Output Mechanical Outline for KHHD015A0F 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 1 2 3 4 5 6 7 8 FUNCTION VIN(+) On/Off VIN(-) Vo(-) Sense(-) Trim Sense(+) Vo(+) April 1, 2013 (c)2012 General Electric Company. All rights reserved. Page 13 GE G Data She eet KHHD01 K 15A0F Ha ammerheadTM Se eries; DC C-DC Con nverter Power P Mo odules 18-75Vdc 1 In nput; 3.3Vd dc, 12A/15A A Output Recommen R nded Pad La ayout for Surface S Mo ount and Th hrough Holle Module Dimensions D are e in millimeterss and [inches]. Tolerances: T x.x mm 0.5 mm [x.xx in. 0.02 in.] (Unless oth herwise indicatted) x.xx mm 0.25 mm m [x.xxx in 0.0 010 in.] Surface Mount Pad Layout Throu ugh-Hole Pad Layout For F .025 x .030 0 rectangular pin, p use a .050 0 diameter pla ated through hole h For .062 diameter pin, use u a .076 diam meter plated through hole. April A 1, 2013 (c) (c)2012 General Electric Companyy. All rights reservved. Page 1 14 GE Data Sheet KHHD015A0F HammerheadTM Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 12A/15A Output Packaging Details The KHHD015A0F 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 KHHD015A0F - 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 April 1, 2013 (c)2012 General Electric Company. All rights reserved. Material PET (1mm) Max surface resistivity 109 -1011/PET Color Clear Capacity 25power modules Min order quantity 75pcs (1 box of 3 full trays + 1 empty top tray) Page 15 GE Data Sheet KHHD015A0F HammerheadTM Series; DC-DC Converter Power Modules 18-75Vdc Input; 3.3Vdc, 12A/15A Output Ordering Information Please contact your GE Sales Representative for pricing, availability and optional features. Table 1. Device Codes Product codes Input Voltage KHHD015A0F41Z 24V/48V (18-75Vdc) KHHD015A0F41-SRZ 24V/48V (18-75Vdc) Output Current 12A (18-36VIN) 15A (36-75VIN) 12A (18-36VIN) 15A (36-75VIN) Output Voltage Remote On/Off Logic Connector Type 3.3V Negative Through hole CC109172994 3.3V Negative Surface mount CC109173002 Comcodes 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 (c)2012 General Electric Company. All rights reserved. Version 1.01