TYPE KAH (No. P-KAH-E003) Type KAH micro fuse is designed for circuit protection against excessive current in portable electronic equipment, electronic circuit around battery, etc. because the demand for high capacity batteries is increasing. Further miniaturization and low profile with extended rated range can be used for wider application. Also, the ecology design of Type KAH is friendly to environment due to complete lead free. FEATURES 1. 5-face terminals structure ensure superior performance of shear strength (10 N for 5-face terminals, 5 N for conventional type). 2. With new development of micro fuse using our original production method, Type KAH, size 1005 can ensure same fusing characteristics of size 1608 of our Type KAB. 3. Complete lead-free Type KAH is designed to eco-friendly. 4. UL file number E170721. (UL248-1 & 14) 5. Surface temperature rise is 75C or less when applying rated current. This offers less influence on the peripheral units. 6. 1005 is the Ultra-small size. (1.0 x 0.5 x 0.35 mm) 7. Suitable for automatic mounting 8. Precise dimensions allows high-density mounting and symmetrical construction of terminals provide "Self-Alignment". 9. Resistance to soldering heat : Reflow or flow soldering 10 seconds at 260C 10. High accuracy carrier tape by using pressed pocket paper ensures excellent mounting. RATING Item Category Temperature Range Rated Current Rated Voltage Voltage Drop Insulation Resistance Fusing Characteristics Ratings - 40~+125C 0.2-0.25-0.315-0.4-0.5-0.63-0.8-1.0-1.25-1.6-2.0-2.5A 24 VDC Refer to CATALOG NUMBERS AND RATING 1000 M or more Fusing within 1 minute if the current is 200% of rated current. Breaking voltage : 24 V Breaking current : 50 A Clearing Characteristics ORDERING INFORMATION KAH Type KAH Code 2402 RV 24V 2402 Code 201 251 321 401 501 631 102 Rated current 0.2 A 0.25 A 0.315 A 0.4 A 0.5 A 0.63 A Code 801 102 132 162 202 252 NA Rated current 0.8 A 1.0 A 1.25 A 1.6 A 2.0 A 2.5 A CATALOG NUMBERS AND RATING Case size Code NA Packaging type 180 Reel Code 07 Case size 1.0x0.5 January, 2013 Internal resistance m (Typical) KAH 2402 20107 1.0 x 0.5 0.2 1148 KAH 2402 25107 1.0 x 0.5 0.25 797 KAH 2402 32107 1.0 x 0.5 0.315 548 KAH 2402 40107 1.0 x 0.5 0.4 372 KAH 2402 50107 1.0 x 0.5 0.5 261 KAH 2402 63107 1.0 x 0.5 0.63 181 KAH 2402 80107 1.0 x 0.5 0.8 125 KAH 2402 10207 1.0 x 0.5 1.0 90 KAH 2402 13207 1.0 x 0.5 1.25 65 KAH 2402 16207 1.0 x 0.5 1.6 46 KAH 2402 20207 1.0 x 0.5 2.0 35 KAH 2402 25207 1.0 x 0.5 2.5 27 For the taping type, the packaging code "NA" will be entered in Catalog numbers are approved by UL and cUL. (File No. E170721) Catalog number 07 Rated current A 1 Voltage drop mV (Max.) 350 300 260 225 195 170 150 135 120 110 110 110 Rated voltage VDC Breaking current A 24 50 DIMENSIONS Main bodyAlumina ceramic TerminalTin plating (mm) Case size Case code L W T max P 1005 07 1.000.05 0.500.05 0.35 0.200.10 MARKING Code Rated current Code Rated current P 0.20 A V Q 0.25 A R 0.315 S T U 0.80 A 1 1.00 A A W 1.25 A 0.40 A X 1.60 A 0.50 A 2 2.00 A 0.63 A Y 2.50 A CONSTRUCTION Name Body Protective coating Fuse element Terminal Mate Protective coating Silicone resin Fuse element Copper alloy Body Alumina ceramic Terminal Tin painting RECOMMENDED PAD DIMENSIONS (mm) Size b a C a 0.4 b 0.5 c 0.6 STANDARD TEST BOARD 100 mm 33 mm 5 mm Glass epoxy on one side Board thickness1.6 mm Copper layer35mm 0.6 mm 2 1005 PERFORMANCE No. 1 2 Item Temperature rise Current-carrying capacity Performance Temperature rise shall not exceed 75. Apply rated current. Test method Shall not open within 1 hour. Apply rated current. Arc shall not be continued. Marking shall be legible. Voltage drop is below the value specified in CATALOG NUMBERS AND RATING. Breaking voltage24 V Breaking current50 A 3 Clearing characteristics 4 Voltage drop 5 Fusing characteristics Fusing within 1 min. 6 Insulation resistance 1000 M or more 7 Electrode strength (Bending) No mechanical damage. Resistance change after the test shall be within 20%. 8 Shear test No mechanical damage. Resistance change after the test shall be within 20%. 9 Substrate bending test No mechanical damage. Resistance change after the test shall be within 20%. 10 Solderability (Solder Wetting time) Solder Wetting time : within 3sec. 11 Solderability (new uniform coating of solder) The dipped surface of the terminals shall be covered more than 95% with new solder. 12 Resistance to soldering heat Marking shall be legible. No mechanical damage. Resistance change after the test shall be within 20%. 13 Solvent resistance 14 Ultrasonic Cleaning 15 Vibration No mechanical damage. Resistance change after the test shall be within 20%. 16 Shock No mechanical damage. Resistance change after the test shall be within 20%. 17 Thermal shock No mechanical damage. Resistance change after the test shall be within 20%. 18 Atomizing salt water No mechanical damage. Resistance change after the test shall be within 20%. 19 Moisture resistance No mechanical damage. Resistance change after the test shall be within 20%. 20 Load life No mechanical damage. Resistance change after the test shall be within 20%. 21 Stability No mechanical damage. Resistance change after the test shall be within 20%. 22 Accelerated damp heat steady state No mechanical damage. Resistance change after the test shall be within 20%. Marking shall be legible. No mechanical damage. Resistance change after the test shall be within 20%. Marking shall be legible. No mechanical damage. Resistance change after the test shall be within 20%. 3 Apply rated current. Apply 200% of rated current. (Ambient temperature10-30C Insulation resistance between terminals and case (alumina ceramic) Board supporting width90 mm Bending speedApprox. 0.5 mm/sec. Duration30 sec. Bending3 mm Applied force10 N (1.02 kgf) Duration10 sec. ToolR0.5 Direction of the pressside face Supporting dimension0.5 mm Applied force5 N (0.51 kgf) ToolR0.5 Direction of the pressthickness direction of product. Solder : Sn-3Ag-0.5Cu Temperature : 245 3C meniscograph method Solder : JISZ3282 H60A, H60S, H63A Temperature : 230 2C meniscograph method Solder : Sn-3Ag-0.5Cu Temperature : 245 3C Dipping : 3 sec. Solder : JISZ3282 H60A, H60S, H63A Temperature : 230 2C Dipping : 3 sec. Dipping (1 cycle) Preconditioning100 to 150C, 60 sec. Temperature265 3C /6-7 sec. Reflow soldering (2 cycles) Preconditioning1-2 min, 180C or less Peak250 5C, 5 sec. Holding230-250C, 30-40 sec. Coolingmore than 2 min. Manual soldering Temperature350 10C Duration3-4 sec. Measure after 1 hour left under room temp. and humidity. Dipping rinse SolventIsopropyl alcohol Duration90 sec. 2 Ultrasonic : 20mW/cm 28kHz SolventIsopropyl alcohol Duration60 sec. Frequency range10-55-10 Hz/min Vibration amplitude1.5 mm Duration2 hours in each of XYZ directions (total6 hours) 2 Peak value490 m/s (50 G) Duration11 m sec. 6 aspects 3 times (total18 times) -55 3C : 30 min. Room temperature2-3 min or less 125 2C 30 min Room temperature2-3 min or less Repeat above step for 10 cycles. Temperature : 35 2C Concentration (weight ratio) : 5 1% Duration : 24 hours Temperature85 3C Humidity85 5% RH Duration1000 hours Temperature85 2C Applied currentRated current 70% Duration1000 hours Temperature125 2C Duration1000 hours Temperature85 3C Humidity85 5% RH Applied current : Rated current 70% Duration1000 hours I2T - T CHARACTERISTICS 0.20A 0.25A 0.315A 0.40A 0.50A 0.63A 0.80A 1.00A 1.25A 1.60A 2.00A 2.50A FUSING CHARACTERISTICS 100 2.50A 2.00A 1.60A 1.25A 1.00A 0.80A 0.63A 0.50A 0.40A 0.315A 0.25A 0.20A 1000 100 2 Joule integral (A s) 10 Fusing time (sec) 1 0.1 10 1 0.1 0.01 0.01 0.001 0.001 0.0001 0.0001 0.1 1 10 100 0.00001 0.0001 0.001 0.01 Applied current (A) 1 10 100 Fusing time (sec) DISTRIBUTION OF FUSING CHARACTERISTICS KAH 2402 102NA07 DISTRIBUTION OF FUSING TIME KAH 2402 102NA07 1000 Fusing time (sec) 1 100 10 Fusing time (sec) 0.1 0.1 0.01 200% of rated current is 0.001 400% of rated current is 1 0.0001 0 0.1 20 40 60 Number of pcs 0.01 0.001 0.0001 0.1 1 10 100 Applied current (A) 4 80 100 DETERMINATION OF RATED VALUE AND SELECTION OF MICRO FUSE(TYPE KAH,SIZE 1005) Determine the rated value of the micro fuse, and select the correct micro fuse for your circuit. If you select the correct micro fuse, safety of your circuit can be ensured. How to determine the rated value of the micro fuse is described below : Flow for fuse selection 1. Measurement of circuit values using actual device Measure the circuit values, such as operating current of the circuit. 2. Calculation from operating current From the obtained operating current and the category temperature, calculate the minimum rated value to determine the applicable fuse. 3. Calculation from overload current From the obtained overload current, calculate the maximum rated value to determine the applicable fuse. 4. Calculation from inrush current From the inrush current, calculate the minimum rated value to determine the applicable fuse. 5. Final determination of rated value From the calculation results of steps 2 through 4, determine the rated value. 6. Operation check using actual device After selecting the rating, confirm if the device works properly under the pre-determined conditions. Fuse selection 1.Measurement of circuit values using actual device Before determining the rated value of the fuse, preliminarily measure the following using the actual device. 1-1 Operating current Using an oscilloscope or equivalents, measure the operating current of the circuit. 1-2 Overload current Using an oscilloscope or equivalents, measure the overload current that needs to break the circuit. 1-3 Inrush current Using an oscilloscope or equivalents, measure the inrush current of the circuit at power-on or power-off. In addition, determine the number of inrush current applied. 1-4 Category temperature Measure the ambient temperature of the fuse circuit. EXAMPLE TO SELECT RATINGS OF TYPE KAH <Fuse selection> Effective operating current : 1.2 A 6.0 Effective overload current : 6.0 A Inrush current waveform : Fig. A (Pulse width : 1 ms, Wave height : 6.0 A) Numbers to withstand inrush current : 100,000 times 1ms Category temperature : 85C Fig. A : Inrush current waveform 2. Calculation from operating current 2-1 Measurement of operating current Using an oscilloscope or equivalents, measure operating current (effective current) of the actual circuit. Example : Effective operating current = 1.2 A 2-2 Derating Temperature derating factor Fig.B 1.4 Rated derating factor Rated derating factor = 0.75 Use Formula 1 to calculate the rated current of the fuse to be used for the circuit. Rated current of fuse Operating current ( ) ... Formula 1 Example : Category temperature = 85C, Operating current = 1.2 A Derating factor (%) Using Fig. B, find the temperature derating factor correspond to the temperature. 1.2 1.0 0.8 0.6 0.4 0.2 0.0 Temperature derating factor = 0.90 (Refer to Fig. B.) -50 Rated derating factor = 0.75 -25 0 25 50 75 100 Temperature ( ) Calculation using Formula 1 : Rated current 1.2 (0.90 0.75) = 1.78 A The above calculation result shows that the fuse with rated current of 1.78 A or more should be selected for this circuit. Type KAH, with rated current of 2.0 A or more can be selected. 5 125 3. Calculation from overload current 3-1 Measurement of overload current Using an oscilloscope or equivalents, measure the overload current that needs to break the circuit. Example : Effective overload current = 6.0 A 3-2 Calculation from overload current Determine the rated current so that the overload current can be 2 times larger than the rated current. Use Formula 2 to calculate the rated current of the fuse. Rated current of fuse Overload current 2.0 ... Formula 2 Example : Overload current = 6.0 A Use Formula 2 to calculate the rated current. Rated current 6.02.0 = 3.0 A The above calculation result shows that the fuse with rated current of 3.0 A or less should be selected for this circuit. Type KAH, with rated current of 2.5 A or less can be selected. 4. Calculation from inrush current 4-1 Measurement of inrush current waveform Using an oscilloscope or equivalent, measure the waveform of the inrush current of the actual circuit. 6A 4-2 Creation of approximate waveform Generally, the waveform of inrush current is complicated. For this reason, 1ms create the approximate waveform of inrush current as shown on Fig. C to simplify calculation. Fig. C : Inrush current waveform Red line : Actual measurement waveform Black line : Approximate waveform 4-3 Calculation of I2t of inrush current Calculate I2t (Joule integral) of the approximate waveform. The formula for this calculation depends on the approximate waveform. Refer to Table A. Example : Pulse applied = 1 ms, Peak value = 6.0 A, Approximate waveform = Triangular wave Since the approximate waveform is a triangular wave, use the following formula for calculation I t of rush current = 13 Im2 t ... Formula 3 2 (Im : Peak value, t : Pulse applying time) Use Formula 3 to calculate the I2t of the rush current : I t = 13 6 6 0.001 = 0.012 (A s) 2 2 JOULE-INTERGRAL VALUES FOR EACH WAVEFORM Table A Name Waveform Sine wave (1 cycle ) Im 0 Sine wave (half cycle) 1 2 t Im 0 Triangular wave Rectangular wave t Im 0 2 Name 1 I m2 t 2 Trapezoidal wave 1 I m2 t 2 Various wave 1 t Im 0 I t Various wave 2 1 I m2 t 3 Charge/ discharge waveform I m2 t t 2 I t0 tdt 2 6 2 Im 0 t1 t2 t3 I 0 0 t1 t2 3 I1 t3 I m i (t) = I m e 1 2 1 2 I 1 t1+{I1I2+ (I1-I2) } 3 1 32 (t2-t1)+ I 2 (t3-t2) 3 -t/ 0.368 I m 0 1 I m2 t1 + I m2 (t2-t1) + 3 1 I m2 (t3-t2) 3 I 1I 2 t + 1 (I1-I2) 2 t I1 2 t I2 * Following formula is generally used for calculation of I t as i(t) equal to current. 2 I t Waveform -t 1 I m2 2 4-4 Search of load ratio Set up the number of cycles to withstand. (generally PULSE RESISTANCE CHARACTERISTICS 100,000 times) Fig. D Obtain the load ratio from Pulse resistance characteristics. (Fig. D) Example : 100,000 times is required against inrush current applied. 1000000 Determine the load ratio using Fig. D. Numbers of pulse resistance (cycle) If the rated current is 0.2 to 2.0 A : 30% or less If the rated current is 2.5 A : 26% or less 100000 10000 1000 0.2A to 2.0 A 2.5A 100 10 0 10 20 30 40 50 60 70 80 90 100 Load ratio (%) 4-5 Calculation from Joule integral and load ratio 2 Use Formula 4 to calculate the standard I t for the fuse to be JOULE INTEGRAL VS. FUSING TIME used. Fig. E Standard I t of fuse > (I t of inrush current load ratio) .......... 2 2 ..........Formula 4 2 2 Example : I t of pulse = 0.012 A s, 2.50A 2.00A 1.60A 1.25A 1.00A 0.80A 0.63A 0.50A 0.40A 0.315A 0.25A 0.20A 1000 Pulse applied = 1 ms, Required load ratio = 30% (at 0.2 to 2.0 A Fuse) or 26% (at 2.5 A Fuse) : Example of 2.0 A Fuse : Use Formula 4 to calculate the 100 2 standard I t of fuse. 2 2 Standard I t of fuse > 0.012/0.3 = 0.04 (A s) 2 10 2 Joule integral (A2s) The standard I t of the fuse should be 0.04 (A s) or more. Since the rush pulse applied is 1 ms, obtain the intersection 2 of 1 ms (horizontal axis) and 0.04 A s (vertical axis) from Fig. E (refer to the arrow shown on Fig. E). Select a fuse whose curve is above the intersection. Type KAH, with rated current of 2.0 A or more should be selected. 1 0.1 0.01 5. Final determination of rated value 0.001 Determine the rated current of the micro fuse. The rated current should meet all the above calculation results. 0.0001 Example : Rated current of 2.0 A and 2.5 A meet the all requirements. 0.00001 0.0001 0.001 6. Operation check using actual device After selecting the rating, confirm if the device works properly 0.01 0.1 1 Fusing time (s) under the pre-determined conditions. 7 10 100 Application Notes for Micro Fuse 1. Circuit Design Micro Fuse should be designated only after confirming operating conditions and Micro Fuse performance characteristics. When determining the rated current, be sure to observe the following items : (1) Micro Fuse should always be operated below the rated current (the value considered in the temperature derating rate) and voltage specifications. According to item 2,2-2 in page 5. (2) Micro Fuse should always be operated below the rated voltage. (3) Micro Fuse should be selected with correct rated value to be fused at overload current. (4) When Micro Fuse are used in inrush current applications, please confirm sufficiently inrush resistance of Micro Fuse. (5) Please do not apply the current exceeding the breaking current to Micro Fuse. (6) Use Micro Fuse under the condition of category temperature. (7) Micro Fuse should not be used in the primary power source. (2) Protective eyeglasses should always be worn when performing fusing tests. However, there is a fear that Micro Fuse will explode during test. During fusing tests, please cover particles not to fly outward from the board or testing fixture. Caution is necessary during usage at all times. 6. Environmental Conditions Micro Fuse should be selected by determining the operating conditions that will occur after final assembly, or estimating potential abnormalities through cycle testing. (1) Micro Fuse should not be operated in acid or alkali corrosive atmosphere. (2) Micro Fuse should not be vibrated, shocked, or pressed excessively. (3) Micro Fuse should not be operated in a flammable or explosive atmosphere. (4) Please do not use Micro fuse in the environment where dew condensation occurs. In case Micro fuse has to be used under the dew condensation condition, please apply moisture-proof coating over Micro fuse. Covering Micro fuse with moisture-proof coating may affect electrical characteristics, please evaluate the effects sufficiently before use. 2. Assembly and Mounting 7. Emergency During the entire assembly process, observe Micro Fuse body temperature and the heating time specified in the performance table. In addition, observe the following items : (1) Mounting and adjusting with soldering irons are not recommended since temperature and time control is difficult. In case of emergency for using soldering irons, be sure to observe the conditions specified in the performance table. (2) Micro Fuse body should not contact a soldering iron directly. (3) Once Micro Fuse mounted on the board, they should never be remounted on boards or substrates. (4) During mounting, be careful not to apply any excessive mechanical stresses to the Micro Fuse. In case of fire, smoking, or offensive odor during operation, please cut off the power in the circuit or pull the plug out. 8. Storage (1) Micro Fuse should be stored at room temperature (-10C ~ +40C) without direct sunlight or corrosive atmosphere such as H2S(hydrogen sulfide) or SO2(sulfur dioxide). Direct sunlight may cause decolorization and deformation of the exterior and taping. Also, solderability will be remarkably lower in high humidity. (2) If the products are stored for an extended period of time, please contact Matsuo Sales Department for recommendation. The longer storage term causes packages and tapings to worsen. If the products will be stored for longer term, please contact us for advice. (3) The products in taping, package, or box should not be given any kind of physical pressure. Deformation of taping or package may affect automatic mounting. 3. Solvents For cleaning of Micro Fuse, immersion in isopropyl alcohol for 90 seconds (at 20 ~ 30C liquid temp.) will not be damaged. If organic solvents (Pine AlphaTM, Techno CareTM, Clean ThroughTM, etc.) will be applied to the Micro Fuse, be sure to preliminarily check that the solvent will not damage Micro Fuse. 9. Disposal 4. Ultrasonic Cleaning When Micro Fuse are disposed of as waste or "scrap", they should be treated as "industrial waste". Micro Fuse contain various kinds of metals and resins. Ultrasonic cleaning is not recommended for Micro Fuse. This may cause damage to Micro Fuse such as broken terminals which results in electrical characteristics effects, etc. depending on the conditions. If Ultrasonic cleaning process must be used, please evaluate the effects sufficiently before use. 10. Samples Micro Fuse received as samples should not be used in any products or devices in the market. Samples are provided for a particular purpose such as configuration, confirmation of electrical characteristics, etc. 5. Caution During Usage (1) Micro Fuse with electricity should never be touched. Micro Fuse with electricity may cause burning due to Micro Fuse high temperature. Also, in case of touching Micro Fuse without electricity, please check the safety temperature of Micro Fuse. R MATSUO M A T S U O E L E C T R IC C O . , L T D . Please feel free to ask our sales department for more information on Micro Fuse. Overseas Sales Dep 5-3, 3-Chome, Sennari-cho, Toyonaka-shi, Osaka 561-8558, Japan Tel : 06-6332-0883 Fax : 06-6332-0920 Head Office 5-3, 3-Chome, Sennari-cho, Toyonaka-shi, Osaka 561-8558, Japan Tel : 06-6332-0871 Fax : 06-6331-1386 URL http://www.ncc-matsuo.co.jp/ The specifications on this catalog are subject to change without prior notice. Please inquire of our Sales Department to confirm the specifications prior to use. 8