(R) VERSA-PAC(R) Inductors and Transformers (Surface Mount) Description * Six winding, surface mount devices that offer more than 500 usable inductor or transformer configurations * High power density and low profile * Low radiated noise and tightly coupled windings * Power range from 1 Watt - 70 Watts * Frequency range to over 1MHz * 500 VAC Isolation Applications * Inductors: buck, boost, coupled, choke, filter, resonant, noise filtering, differential, forward, common mode * Transformers: flyback, feed forward, push-pull, multiple output, inverter, step-up, step-down, gate drive, base drive, wide band, pulse, control, impedance, isolation, bridging, ringer, converter, auto Environmental Data * Storage temperature range: -55C to 125C * Operating ambient temperature range: -40C to +85C (range is application specific). The internal "hot spot" temperature defines the maximum allowable currents, which are limited to 130C, including ambient * Infrared reflow temperature: +240C for 30 seconds maximum Part (1) Number VPH1-1400(10) VP1-1400(10) VPH1-0190 VP1-0190 VPH1-0102 VP1-0102 VPH1-0076 VP1-0076 VPH1-0059 VP1-0059 VPH2-1600(10) VP2-1600(10) VPH2-0216 VP2-0216 VPH2-0116 VP2-0116 VPH2-0083 VP2-0083 VPH2-0066 VP2-0066 VPH3-0780(10) VP3-0780(10) VPH3-0138 VP3-0138 VPH3-0084 VP3-0084 VPH3-0055 VP3-0055 VPH3-0047 VP3-0047 L(BASE) H (NOM)(2) 201.6 +/-30% 89.6 +/-30% 27.4 +/-20% 12.2 +/-20% 14.7 +/-20% 6.5 +/-20% 10.9 +/-20% 4.9 +/-20% 8.5 +/-20% 3.8 +/-20% 160 +/-30% 78.4 +/-30% 21.6 +/-20% 10.6 +/-20% 11.6 +/-20% 5.7 +/-20% 8.3 +/-20% 4.1 +/-20% 6.6 +/-20% 3.2 +/-20% 132 +/-30% 63.2 +/-30% 23.3 +/-20% 11.2 +/-20% 14.2 +/-20% 6.8 +/-20% 9.3 +/-20% 4.5 +/-20% 7.94 +/-20% 3.8 +/-20% ISAT(BASE) Amps (TYP)(3)(4) 0.04 0.06 0.29 0.43 0.53 0.80 0.72 1.06 0.92 1.37 0.07 0.10 0.53 0.76 0.99 1.41 1.39 1.95 1.74 2.50 0.07 0.10 0.41 0.59 0.67 0.97 1.02 1.46 1.19 1.73 IRMS(BASE) Amps (TYP)(3)(5) 0.55 0.85 0.55 0.85 0.55 0.85 0.55 0.85 0.55 0.85 0.95 1.26 0.95 1.26 0.95 1.26 0.95 1.26 0.95 1.26 0.97 1.47 0.97 1.47 0.97 1.47 0.97 1.47 0.97 1.47 Packaging * Supplied in tape and reel packaging, 600 (VP01), 300 (VP02), and 200 (VP03) per reel * Supplied in bulk packaging (VP04 and VP05) * VP04 & VP05 tape and reel packaging available. Please contact factory for details. R(BASE) Ohms (MAX)(6) 0.344 0.145 0.344 0.145 0.344 0.145 0.344 0.145 0.344 0.145 0.159 0.090 0.159 0.090 0.159 0.090 0.159 0.090 0.159 0.090 0.14 0.061 0.14 0.061 0.14 0.061 0.14 0.061 0.14 0.061 Volt-SEC(BASE) EPEAK(BASE) Vs J (MAX)(7) (TYP)(8) 32.9 0.11 21.8 0.11 32.9 0.77 21.8 0.77 32.9 1.45 21.8 1.45 32.9 1.92 21.8 1.92 32.9 2.48 21.8 2.48 48.3 0.29 33.7 0.29 48.3 2.11 33.7 2.11 48.3 3.94 33.7 3.94 48.3 5.47 33.7 5.47 48.3 7.01 33.7 7.01 39.8 0.24 27.7 0.24 39.8 1.36 27.7 1.36 39.8 2.23 27.7 2.23 39.8 3.38 27.7 3.38 39.8 4.00 27.7 4.00 Leakage Inductance (BASE) H (TYP) 0.212 0.096 0.212 0.096 0.212 0.096 0.212 0.096 0.212 0.096 0.165 0.083 0.165 0.083 0.165 0.083 0.165 0.083 0.165 0.083 0.125 0.058 0.125 0.058 0.125 0.058 0.125 0.058 0.125 0.058 Thermal Resistance C/Watt (TYP)(9) 60.7 60.7 60.7 60.7 60.7 60.7 60.7 60.7 60.7 60.7 44.0 44.0 44.0 44.0 44.0 44.0 44.0 44.0 44.0 44.0 43.4 43.4 43.4 43.4 43.4 43.4 43.4 43.4 43.4 43.4 (R) VERSA-PAC(R) Inductors and Transformers (Surface Mount) Part (1) Number VPH4-0860(10) VP4-0860(10) VPH4-0140 VP4-0140 VPH4-0075 VP4-0075 VPH4-0060 VP4-0060 VPH4-0047 VP4-0047 VPH5-1200(10) VP5-1200(10) VPH5-0155 VP5-0155 VPH5-0083 VP5-0083 VPH5-0067 VP5-0067 VPH5-0053 VP5-0053 L(BASE) H (NOM)(2) 159.65 +/-30% 87.0 +/-30% 23.7 +/-20% 11.3 +/-20% 12.7 +/-20% 6.1 +/-20% 10.1 +/-20% 4.9 +/-20% 7.94 +/-20% 3.8 +/-20% 173 +/-30% 76.8 +/-30% 22.3 +/-20% 9.9 +/-20% 12 +/-20% 5.3 +/-20% 9.65 +/-20% 4.3 +/-20% 7.63 +/-20% 3.4 +/-20% ISAT(BASE) Amps (TYP)(3)(4) 0.11 0.15 0.65 0.95 1.21 1.75 1.52 2.18 1.94 2.81 0.14 0.20 1.05 1.60 1.96 2.95 2.43 3.63 3.07 4.59 IRMS(BASE) Amps (TYP)(3)(5) 1.41 1.70 1.41 1.70 1.41 1.70 1.41 1.70 1.41 1.70 1.70 2.08 1.70 2.08 1.70 2.08 1.70 2.08 1.70 2.08 R(BASE) Ohms (MAX)(6) 0.0828 0.057 0.0828 0.057 0.0828 0.057 0.0828 0.057 0.0828 0.057 0.0711 0.047 0.0711 0.047 0.0711 0.047 0.0711 0.047 0.0711 0.047 (1) The first three digits in the part number signify the size of the package. The next four digits specify the AL, or nanoHenries per turn squared. (2) L = Nominal Inductance of a single winding. (3) I is the lessor of I ( ) and I ( ). (4) Peak current that will result in 30% saturation of the core. This current value assumes that equal current flows in all six windings. For applications in which all windings are not simultaneously driven (i.e. flyback, SEPIC, Cuk, etc.), the saturation current per winding may be calculated as follows: SAT BASE ISAT 2 EnergySERIES = S x 2 RMS BASE = 6 x ISAT(BASE) Number of Windings Driven (5) RMS Current that results in a surface temperature of approximately 40C above ambient. The 40C rise occurs when the specified current flows through each of the six windings. (6) Maximum DC Resistance of each winding. (7) For multiple windings in series, the volt-second (Vs) capability varies as the number of windings in series (S): TOTAL EnergyPARALLEL = P x 1 2 x 2 1 2 0.7LBASE x I SAT(BASE) 2 x 0.7LBASE x I SAT(BASE) For multiple windings, the energy capability varies as the square of the number of windings. For example, six windings (either parallel or series) can store 36 times more energy than one winding. (9) Thermal Resistance is the approximate surface temperature rise per Watt of heat loss under still-air conditions. Heat loss is a combination of core loss and wire loss. The number assumes the underlying PCB copper area equals 150% of the component area. (10) These devices are designed for feed-forward applications, where load current dominates magnitizing current. Volt-secTOTAL = S x Volt-sec(BASE) For multiple windings in parallel, the volt-second is as shown in the table above. TOTAL Thermal Resistance C/Watt (TYP)(9) 39.4 39.4 39.4 39.4 39.4 39.4 39.4 39.4 39.4 39.4 30.3 30.3 30.3 30.3 30.3 30.3 30.3 30.3 30.3 30.3 (8) Maximum Energy capability of each winding. This is based on 30% saturation of the core: BASE BASE Leakage Inductance (BASE) H (TYP) 0.156 0.075 0.156 0.075 0.156 0.075 0.156 0.075 0.156 0.075 0.235 0.105 0.235 0.105 0.235 0.105 0.235 0.105 0.235 0.105 Volt-SEC(BASE) EPEAK(BASE) Vs J (MAX)(7) (TYP)(8) 64.6 0.57 44.7 0.57 64.6 3.54 44.7 3.54 64.6 6.55 44.7 6.55 64.6 8.16 44.7 8.16 64.6 10.52 44.7 10.52 98.4 1.11 65.6 1.11 98.4 8.83 65.6 8.83 98.4 16.07 65.6 16.07 98.4 19.83 65.6 19.83 98.4 25.10 65.6 25.10 (Vs) capability VERSA-PAC temperature rise depends on total power losses and size. Any other PCM configurations other than those suggested could run hotter than acceptable. Certain topologies or applications must be analyzed for needed requirements and matched with the best VERSA-PAC size and configuration. Proper consideration must be used with all parameters, especially those associated with current rating, energy storage, or maximum volt-seconds. VERSA-PAC should not be used in off-line or safety related applications. The breakdown voltage from one winding to any other winding is 500 VAC maximum. PCM (R) VERSA-PAC(R) Inductors and Transformers (Surface Mount) Mechanical Diagrams VP1 and VPH1 RECOMMENDED PCB LAYOUT TOP VIEW WHITE DOT PIN #1 1 M 12 1 VPH_-_ _ _ _ D (12 PLCS) N LOGO (OPTIONAL) A J 6 K (12PLCS) P (10PLCS) 12 NOTES COMPONENT SIDE 0 (10PLCS) 7 6 B C L (12PLCS) 1) Tolerances A - I are 0.25 mm unless specified otherwise. 2) Tolerances J - P are +/- 0.1 mm unless specified otherwise. 3) Marking as shown a) Dot for pin #1 identification b) On top of unit: -- VPHx-xxx (product code, size, 4 digit part number per family table.) c) On top of unit: Versa Pac Logo (optional) d) On bottom of unit: wwllyy = (date code) R = (revision level) 4) All soldering surfaces must be coplanar within 0.102 mm. 7 4 10 1 5 7 11 2 6 8 12 FRONT VIEW E F I (12 PLCS) G (2 PLCS) H 3 WWLLYY R VP1 and VPH1 A mm max 12.9 B mm ref 9.2 C mm max 13.0 D mm ref 0.7 E mm ref 5.9 F mm max 6.2 G mm ref 1.5 H mm ref 0.1 9 1:1:1:1:1:1 I mm ref 0.25 J mm ref 11.5 K mm L mm 1.5 2.25 M mm ref 9.7 N mm max 14.2 O mm P mm 2.0 0.5 VP2 and VPH2 RECOMMENDED PCB LAYOUT TOP VIEW WHITE DOT PIN #1 1 M 12 1 VPH_-_ _ _ _ D (12 PLCS) N LOGO (OPTIONAL) A J 6 K (12PLCS) P (10PLCS) 12 NOTES COMPONENT SIDE 0 (10PLCS) 7 6 B C L (12PLCS) 1) Tolerances A - I are 0.25 mm unless specified otherwise. 2) Tolerances J - P are +/- 0.1 mm unless specified otherwise. 3) Marking as shown a) Dot for pin #1 identification b) On top of unit: -- VPHx-xxx (product code, size, 4 digit part number per family table.) c) On top of unit: Versa Pac Logo (optional) d) On bottom of unit: wwllyy = (date code) R = (revision level) 4) All soldering surfaces must be coplanar within 0.102 mm. 7 4 10 1 5 7 11 2 6 8 12 FRONT VIEW E F I (12 PLCS) G (2 PLCS) H 3 WWLLYY R VP2 and VPH2 A mm max 16.3 B mm ref 12.0 C mm max 16.8 D mm ref 0.7 E mm ref 6.7 F mm max 7.8 G mm ref 2.0 H mm ref 0.1 9 1:1:1:1:1:1 I mm ref 0.30 J mm ref 14.25 K mm L mm 1.75 2.5 M mm ref 13.0 N mm max 18.0 O mm P mm 2.5 0.75 (R) VERSA-PAC(R) Inductors and Transformers (Surface Mount) Mechanical Diagrams VP3 and VPH3 TOP VIEW WHITE DOT PIN #1 D (12 PLCS) M L 1 12 1 I VPH_-_ _ _ _ 12 COMPONENT SIDE A LOGO (OPTIONAL) 6 J (12PLCS) O (10PLCS) N (10PLCS) 6 7 NOTES K (12PLCS) 1) Tolerances A - I are 0.25 mm unless specified otherwise. 2) Tolerances J - P are +/- 0.1 mm unless specified otherwise. 3) Marking as shown a) Dot for pin #1 identification b) On top of unit: -- VPHx-xxx (product code, size, 4 digit part number per family table.) c) On top of unit: Versa Pac Logo (optional) d) On bottom of unit: wwllyy = (date code) R = (revision level) 4) All soldering surfaces must be coplanar within 0.102 mm. 7 1 4 12 2 9 5 11 3 8 6 B C FRONT VIEW E H (12 PLCS) G (12 PLCS) F (2 PLCS) 7 10 1:1:1:1:1:1 A mm max VP3 and VPH3 17.1 B mm ref 16.0 C mm max 22.3 D mm ref 0.7 E mm max 8.4 F mm ref 3.0 G mm ref 0.1 H mm ref 0.4 I J mm mm ref 14.49 1.79 K mm L M mm mm ref max 3.43 16.88 23.74 N mm O mm 2.54 0.75 VP4 and VPH4 WHITE DOT PIN #1 D (12 PLCS) M L TOP VIEW 1 12 1 I VPH_-_ _ _ _ COMPONENT SIDE A LOGO (OPTIONAL) 6 J (12PLCS) O (10PLCS) 12 6 N (10PLCS) 7 NOTES K (12PLCS) 1) Tolerances A - I are 0.25 mm unless specified otherwise. 2) Tolerances J - P are +/- 0.1 mm unless specified otherwise. 3) Marking as shown a) Dot for pin #1 identification b) On top of unit: -- VPHx-xxx (product code, size, 4 digit part number per family table.) c) On top of unit: Versa Pac Logo (optional) d) On bottom of unit: wwllyy = (date code) R = (revision level) 4) All soldering surfaces must be coplanar within 0.102 mm. 7 1 4 12 2 9 5 11 3 8 6 B C FRONT VIEW E H (12 PLCS) G (12 PLCS) F (2 PLCS) 7 10 1:1:1:1:1:1 A mm max VP4 and VPH4 18.0 B mm ref 18.0 C mm max 24.6 D mm ref 0.7 E mm max 10.0 F mm ref 3.3 G mm ref 0.1 H mm ref 0.4 I J mm mm ref 14.25 1.75 K mm L M mm mm ref max 3.43 19.14 26.0 N mm O mm 2.5 0.75 (R) VERSA-PAC(R) Inductors and Transformers (Surface Mount) Mechanical Diagrams VP5 and VPH5 TOP VIEW WHITE DOT PIN #1 D (12 PLCS) M L 1 12 1 J (12PLCS) I VPH_-_ _ _ _ COMPONENT SIDE A LOGO (OPTIONAL) O (10PLCS) 12 6 N (10PLCS) 7 K (12PLCS) 6 NOTES 7 1 4 12 2 9 5 11 3 8 6 1) Tolerances A - I are 0.25 mm unless specified otherwise. 2) Tolerances J - P are +/- 0.1 mm unless specified otherwise. 3) Marking as shown a) Dot for pin #1 identification b) On top of unit: -- VPHx-xxx (product code, size, 4 digit part number per family table.) c) On top of unit: Versa Pac Logo (optional) d) On bottom of unit: wwllyy = (date code) R = (revision level) 4) All soldering surfaces must be coplanar within 0.102 mm. B C FRONT VIEW E H (12 PLCS) G (12 PLCS) F (2 PLCS) 7 10 1:1:1:1:1:1 A mm max VP5 and VPH5 21.0 B mm ref 21.0 C mm max 28.5 D mm ref 0.7 E mm max 10.8 F mm ref 2.95 G mm ref 0.1 H mm ref 0.4 I J mm mm ref 17.25 2.25 Normalized Roll-Off Curve of High Inductance VERSA-PAC K mm 3.15 L mm ref 22.7 M mm max 29.0 N mm O mm 3.0 0.75 (R) 100.0% 90.0% 80.0% % of OCL 70.0% 60.0% 50.0% 40.0% 30.0% 20.0% 10.0% 0.0% 0.0% 20.0% 40.0% 60.0% 80.0% 100.0% 120.0% % of Isat 140.0% 160.0% 180.0% 200.0% (R) VERSA-PAC(R) Inductors and Transformers (Surface Mount) HOW TO USE MULTIPLE WINDINGS Discrete inductors combine like resistors, when connected in series or parallel. For example, inductors in series add and inductors in parallel reduce in a way similar to Ohm's Law. LSeries = L1 + L2 + L3...Ln LParallel = 1/ [1/L1 + 1/ L2 + 1/ L3....1/Ln] Windings on the same magnetic core behave differently. Two windings in series result in four times the inductance of a single winding. This is because the inductance varies proportionately to the square of the turns. Paralleled VERSA-PAC windings result in no change to the net inductance because the total number of turns remains unchanged; only the effective wire size becomes larger. Two parallel windings result in approximately twice the current carrying capability of a single winding. The net inductance of a given PCM configuration is based on the number of windings in series squared multiplied by the inductance of a single winding (L ). The current rating of a PCM configuration is derived by multiplying the maximum current rating of one winding (I ) by the number of windings in parallel. Examples of simple two-winding devices are shown below: BASE BASE Series Connected (2 Windings) Parallel Connected (2 Windings) 10H 1 Amp 10H 1 Amp 10H 1 Amp 10H 1 Amp 2 LTOTAL = LBASE x S IMAX = IBASE x P = 1 Amp x 1 = 10 H x 2 = 1 Amp = 40 H L 2 2 TOTAL = LBASE x S IMAX = IBASE x P = 10 H x 1 = 1 Amp x 2 = 10 H = 2 Amps 2 Where: LBASE = Inductance of a single winding P = Number of windings in parallel (use 1 with all windings in series) S = Number of windings in series IBASE = Maximum current rating of one winding (R) VERSA-PAC(R) Inductors and Transformers (Surface Mount) HOW TO PIN-CONFIGURE VERSA-PAC (R) Each VERSA-PAC can be configured in a variety of ways by simply connecting pins together on the Printed Circuit Board (PCB). As shown below, the connections on the PCB are equal to the pin configuration statement shown at the bottom of the schematic symbol. Connecting a number of windings in parallel will increase the current carrying capability, while connecting in series will multiply the inductance. Each VERSA-PAC part can be configured in at least 6 combinations for inductor use or configured in at least 15 turns ratios for transformer applications. Given 25 VERSA-PAC part numbers, this allows for at least 500 magnetic configurations. The PCM configurations can either be created by the designer or simply chosen from the existing PCM diagrams. The following inductor example shows 6 windings in series, which result in an inductance of 36 times the base inductance and 1 times the base current. INDUCTOR EXAMPLE FOR SIZES VP3, VP4 AND VP5 LTOTAL = 36 x LBASE 1 4 12 9 2 11 5 8 3 6 10 7 Component View = 36 times the base Inductance from Data Table. 1 12 6 7 1 7 PIN CONFIGURATIONS (2,12)(3,11)(4,10)(5,9)(6,8) Each VERSA-PAC may be used in at least 15 transformer applications. More than 375 transformer combinations may be achieved using the available 25 VERSA-PAC parts. TRANSFORMER EXAMPLE FOR SIZES VP3, VP4 AND VP5 1:5 1 4 12 9 2 11 5 8 3 6 10 7 1 12 6 7 LPRIMARY = 1 x LBASE 1 2 IPRI = 1 x IBASE ISEC = 1 x IBASE 12 7 PIN CONFIGURATIONS (3,11)(4,10)(5,9)(6,8) The PCM configurations may be selected from the examples on the following pages or created by the designer. Six PCM inductor and fifteen PCM transformer configurations and equivalent circuit schematics are shown. The printed circuit board layout in each example illustrates the connections to obtain the desired inductance or turns ratio. The examples may be used by the PCB designer to configure VERSA-PAC as desired. To assist the designer, VERSA-PAC phasing, coupling and thermal issues have been considered in each of the PCM configurations illustrated. Additionally, the inductance and current ratings, as a function of the respective base values from the following Data Tables, are shown in each PCM example. Turns ratios are also given for each PCM Transformer shown. It is important to carefully select the proper VERSA-PAC part in order to minimize the component size without exceeding the RMS current capability or saturating the core. The Data Tables indicate maximum ratings. (R) VERSA-PAC(R) Inductors and Transformers (Surface Mount) VERSA-PAC (R) Performance Characteristics Bipolar (Push-Pull) Power vs Frequency Unipolar (Flyback) Power vs Frequency 40.0 70.0 35.0 60.0 30.0 VP 5 25.0 VP 5 40.0 Watts Watts 50.0 30.0 20.0 VP 4 15.0 VP 4 20.0 VP 3 10.0 VP 3 VP 2 10.0 5.0 VP 2 VP 1 0.0 100 200 300 400 VP 1 0.0 100 500 200 300 400 500 Frequency, kHz Frequency, kHz These curves represent typical power handling capability. Indicated power levels may not be achievable with all configurations. 3.3V Buck Converter 5V to 3.3V Buck Converter With 5V Output This circuit utilizes the gap of the VP5-0083 to handle the 12.5 Amp output current without saturating. In each of the five VERSAPAC sizes, the gap is varied to achieve a selection of specific inductance and current values (see VERSA-PAC Data Table). This circuit minimizes both board space and cost by eliminating a second regulator. VERSA-PAC's gap serves to prevent core saturation during the switch on-time and also stores energy for the +5V load which is delivered during the flyback interval. The +3.3V buck winding is configured by placing two windings in series while the +5V is generated by an additional flyback winding stacked on the 3.3V output. Extra windings are paralleled with primary windings to handle more current. The turns ratio of 2:1 adds 1.67V to the +3.3V during the flyback interval to achieve +5V. All six windings are connected in parallel to minimize AC/DC copper losses and to maximize heat dissipation. With VERSAPAC, this circuit works well at or above 300 KHz. Also, the closed flux-path EFD geometry enables much lower radiation characteristics than open-path bobbin core style components. +V VERSA-PAC VP5-0083 +V Synchronous Controller IC 1 2 3 4 5 6 12 11 10 9 8 7 RTN 1,2 Synchronous Controller IC VERSA-PAC VP5-0083 +5V@ 1A 7 6 +3.3V@ 12.5A 12,11 3,4,5 + + LEVEL SHIFT 10,9,8 RTN +3.3V@ 4.2A + LITHIUM-ION BATTERY TO 3.3V SEPIC CONVERTER The voltage of a Lithium-Ion Battery varies above and below +3.3V depending on the degree of charge. The SEPIC configuration takes advantage of VERSA-PAC's multiple tightly coupled windings. This results in lower ripple current which lowers noise and core losses substantially. The circuit does not require a snubber to control the voltage "spike" associated with switch turnoff, and is quite efficient due to lower RMS current in the windings. PM-4301 1/04 (c) Cooper Electronic Technologies 2004 VERSA-PAC VP5-0083 12 11 10 4 5 6 + + Controller IC W/Integral Switch 1 2 3 +3.3V@ 6A 9 8 7 + Visit us on the Web at www.cooperET.com 3601 Quantum Boulevard Boynton Beach, Florida 33426-8638 Tel: +1-561-752-5000 Toll Free: +1-888-414-2645 Fax: +1-561-742-1178 This bulletin is intended to present product design solutions and technical information that will help the end user with design applications. Cooper Electronic Technologies reserves the right, without notice, to change design or construction of any products and to discontinue or limit distribution of any products. Cooper Electronic Technologies also reserves the right to change or update, without notice, any technical information contained in this bulletin. Once a product has been selected, it should be tested by the user in all possible applications.