GE Data Sheet ESTW004A2C Stingray* Series DC-DC Converter Power Modules 36-75Vdc Input; 15.0Vdc/4.2Adc Output RoHS Compliant Applications Features Compliant to RoHS EU Directive 2011/65/EU (-Z versions) Compliant to REACH Directive (EC) No 1907/2006 Industry standard, DOSA compliant footprint 57.9mm x 22.8mm x 7.6mm (2.28 in x 0.9 in x 0.30 in) Low profile height and reduced component skyline Wide input voltage range: 36-75 Vdc Tightly regulated output Remote sense Output Voltage adjust: 80% to 110% of Vo,nom Constant switching frequency Positive remote On/Off logic Input under/over voltage protection Output overcurrent and overvoltage protection Over-temperature protection No reverse current during output shutdown Wireless Networks Access and Optical Network Equipment Wide operating temperature range (-40C to 85C) Industrial Equipment Suitable for cold wall cooling using suitable Gap Pad applied directly to top side of module UL# 60950-1 2nd Ed. Recognized, CSA C22.2 No. 60950-107 Certified, and VDE (EN60950-1 2nd Ed.) Licensed CE mark meets 2006/95/EC directive Options 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 Negative Remote On/Off logic (preferred) Over current/Over voltage protections (Auto-restart) (preferred) Heat plate version (-H) Surface Mount version (-S) Description The ESTW004A2C Series, eighth-brick, low-height power modules are isolated dc-dc converters that provide a single, precisely regulated output voltage over a wide input voltage range of 36-75Vdc. The ESTW004A2C provides 15Vdc nominal output voltage rated for 4.2Adc output current. The module incorporates Lineage Power's vast heritage for reliability and quality, while also using the latest in technology, and component and process standardization to achieve highly competitive cost. The open frame module construction, available in both surface-mount and through-hole packaging, enable designers to develop cost and space efficient solutions. The module achieves typical full load efficiency greater than 90% at VIN=48Vdc. Standard features include remote On/Off, remote sense, output voltage adjustment, overvoltage, overcurrent and overtemperature protection. An optional heat plate allows for external standard, eighth-brick heat sink attachment to achieve higher output current in high temperature applications. * Trademark of General Electric Company # 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 March 8, 2016 (c)2016 General Electric Company. All rights reserved. Page 1 GE Data Sheet ESTW004A2C Stingray Series DC-DC Converter Power Modules 36-75Vdc Input; 15.0Vdc/4.2Adc 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 Unit Input Voltage Continuous All VIN -0.3 80 Vdc Transient, operational (100 ms) All VIN,trans -0.3 100 Vdc All TA -40 85 C Storage Temperature All Tstg -55 125 C I/O Isolation voltage (100% factory Hi-Pot tested) All 2250 Vdc Operating Ambient Temperature (see Thermal Considerations section) Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Parameter Operating Input Voltage Maximum Input Current (VIN= VIN, min to VIN, max, IO=IO, max) Input No Load Current (VIN = 48V, IO = 0, module enabled) Input Stand-by Current Device Symbol Min Typ Max Unit All VIN 36 48 75 Vdc All IIN,max 2.0 Adc All IIN,No load 90 IIN,stand-by 5 All (VIN = 48V, module disabled) I2t mA 8 mA 0.5 A2s Inrush Transient All Input Reflected Ripple Current, peak-to-peak (5Hz to 20MHz, 1H source impedance; VIN, min to VIN, max, IO= IOmax ; See Test configuration section) All 30 mAp-p Input Ripple Rejection (120Hz) All 50 dB 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 fast-acting fuse with a maximum rating of 10 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. March 8, 2016 (c)2016 General Electric Company. All rights reserved. Page 2 GE Data Sheet ESTW004A2C Stingray Series DC-DC Converter Power Modules 36-75Vdc Input; 15.0Vdc/4.2Adc Output Electrical Specifications (continued) Parameter Device Symbol Min Typ Max Unit All VO, set 14.7 15.0 15.3 Vdc All VO 14.55 15.45 Vdc All All All 0.2 0.2 1.0 % VO, set % VO, set % VO, set All 35 60 mVrms All 100 180 mVpk-pk Nominal Output Voltage Set-point VIN= 48V IO=IO, max, TA=25C) Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life) 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 (VIN=48V, IO= IO, max, TA=25C, see Figure 7.) RMS (5Hz to 20MHz bandwidth) Peak-to-Peak (5Hz to 20MHz bandwidth) External Capacitance All CO, max 0 2,000 F Output Current All IO 0 4.2 Adc Output Power (IO IO, max) Output Current Limit Inception (Hiccup Mode ) (VO= 90% of VO, set) Output Short-Circuit Current (VO250mV) ( Hiccup Mode ) Efficiency All PO 0 63 W All IO, lim 4.6 5.2 6.0 Adc All IO, s/c 5 Arms VIN=48V, TA=25C, IO=2.1A, VO = 15V All 88.0 % VIN=48V, TA=25C, IO=4.2A, VO= 15V All 90.0 % All fsw 280 kHz All Vpk 3 % VO, set All ts 200 s Device Symbol Min Typ Max Unit Isolation Capacitance All Ciso 1000 pF Isolation Resistance All Riso 100 M I/O Isolation Voltage (100% factory Hi-pot tested) All All 2250 Vdc Switching Frequency Dynamic Load Response (dIo/dt=0.1A/s; VIN = 48V; TA=25C) Load Change from Io= 50% to 75% or 25% to 50% of Io,max Peak Deviation Settling Time (Vo<10% peak deviation) Isolation Specifications Parameter General Specifications Parameter Device Symbol Typ Unit Calculated Reliability based upon Telcordia SR-332 Issue 2: Method I Case 3 (IO=80%IO, max, TA=40C, airflow = 200 lfm, 90% confidence) All FIT 321.5 109/Hours All MTBF 3,110,164 Hours Weight (Open Frame) All 19 (0.7) g (oz.) Weight (with Heatplate) All 30 (1.1) g (oz.) March 8, 2016 (c)2016 General Electric Company. All rights reserved. Page 3 GE Data Sheet ESTW004A2C Stingray Series DC-DC Converter Power Modules 36-75Vdc Input; 15.0Vdc/4.2Adc Output 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 All Ion/off 0.15 mA 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) Logic Low - On/Off Voltage All Von/off -0.7 0.6 Vdc Logic High Voltage (Ion/off = 0Adc) All Von/off 2.5 6.7 Vdc Logic High maximum allowable leakage current All Ion/off 25 A 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 Tdelay -- 12 -- msec 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 Tdelay -- 25 35 msec Output voltage Rise time (time for Vo to rise from 10% of Vo,set to 90% of Vo, set) All Trise -- 15 25 msec -- 3 % VO, set Turn-On Delay and Rise Times (IO=IO, max , VIN=VIN, nom, TA = 25oC) Output voltage overshoot - Startup All IO= IO, max; VIN=VIN, min to VIN, max, TA = 25 oC Remote Sense Range All Output Voltage Adjustment Range All Output Overvoltage Protection All VSENSE 80 10 % VO, set 110 % VO, set Vdc VO, limit 17.0 20.0 Tref1 135 O C Tref2 120 O C Turn-on Threshold 34 36 Vdc Turn-off Threshold 30 32 34 Vdc Hysteresis 1 2 Turn-on Threshold 76 77 Vdc Turn-off Threshold 77 79 81 Vdc Hysteresis 1 2 Overtemperature Protection - Hiccup Auto Restart Input Undervoltage Lockout Input Overvoltage Lockout March 8, 2016 Open Frame Heat Plate All All VUVLO Vdc VOVLO (c)2016 General Electric Company. All rights reserved. Vdc Page 4 GE Data Sheet ESTW004A2C Stingray Series DC-DC Converter Power Modules 36-75Vdc Input; 15.0Vdc/4.2Adc Output Characteristic Curves OUTPUT VOLTAGE VO (V) (5V/div) EFFICIENCY, (%) On/Off VOLTAGE VOn/Off (V) (5V/div) The following figures provide typical characteristics for the ESTW004A2C (15.0V, 4.2A) at 25oC. The figures are identical for either positive or negative remote On/Off logic. OUTPUT CURRENT, IO (A) TIME, t (10ms/div) Figure 4. Typical Start-up Using Remote On/Off, negative logic version shown (VIN = 48V, Io = Io,max). OUTPUT VOLTAGE VO (V) (100mV/div) OUTPUT VOLTAGE INPUT VOLTAGE VO (V) (5V/div) VIN (V) (10V/div) Figure 1. Converter Efficiency versus Output Current. TIME, t (10ms/div) TIME, t (2s/div) Figure 5. Typical Start-up Using Input Voltage (VIN = 48V, Io = Io,max). OUTPUT VOLTAGE OUTPUT CURRENT VO (V) (200mV/div) IO(A) (1A/div) Figure 2. Typical output ripple and noise ( Io = Io,max). TIME, t (200s/div) Figure 3. Transient Response to 0.1A/S Dynamic Load Change from 50% to 75% to 50% of full load, VIN=48V. March 8, 2016 (c)2016 General Electric Company. All rights reserved. Page 5 GE Data Sheet ESTW004A2C Stingray Series DC-DC Converter Power Modules 36-75Vdc Input; 15.0Vdc/4.2Adc Output Test Configurations Design Considerations Input Filtering CURRENT PROBE TO OSCILLOSCOPE LTES T Vin+ BATTERY 12H 33-100F CS 220F E.S.R.<0.1 @ 20C 100kHz Safety Considerations Vin- NOTE: Measure input reflected ripple current with a simulated source inductance (LTEST) of 12H. Capacitor C S offsets possible battery impedance. Measure current as shown above. Figure 6. Input Reflected Ripple Current Test Setup. COPPER STRIP V O (+) RESISTIVE LOAD + V O (- ) 1uF SCOPE 10uF GROUND 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 7. Output Ripple and Noise Test Setup. Rdistribution Rcontact Rcontact Vin+ Rdistribution RLOAD VO Rcontact Rcontact Vin- Rdistribution Vout+ VIN 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 8. Output Voltage and Efficiency Test Setup. VO. IO Efficiency = VIN. IIN x 100 % 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 6 a 33-100F 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. 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. UL60950-1, CSA C22.2 No.60950-1, and VDE08051(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 10 A fast-acting fuse in the ungrounded lead. March 8, 2016 (c)2016 General Electric Company. All rights reserved. Page 6 GE Data Sheet ESTW004A2C Stingray Series DC-DC Converter Power Modules 36-75Vdc Input; 15.0Vdc/4.2Adc Output 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. Negative logic is the preferred option. 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). SENSE(+) SENSE(-) SUPPLY Vin+ Vout+ II VI(+) VO(+) VI(-) VO(-) CONTACT RESISTANCE IO LOAD CONTACT AND DISTRIBUTION LOSSE Figure 10. Circuit Configuration for remote sense . Ion/off ON/OFF TRIM Von/off Vin- Vout- Figure 9. 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 9). Logic low is 0.7Vdc Von/off 0.6Vdc. The maximum Ion/off during a logic low is 0.15mA; the switch should maintain a logic low level while sinking this current. During a logic high, the typical maximum Von/off generated by the module is 6.7Vdc, and the maximum allowable leakage current 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(-). Remote Sense Remote sense minimizes the effects of distribution losses by regulating the voltage at the remote-sense connections (See Figure 11). 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 March 8, 2016 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 turnoff 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, Tref1 exceeds 135oC (Figure 12, typical), or Tref2 exceeds 120oC (Figure 13, 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. 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 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. (c)2016 General Electric Company. All rights reserved. Page 7 GE Data Sheet ESTW004A2C Stingray Series DC-DC Converter Power Modules 36-75Vdc Input; 15.0Vdc/4.2Adc Output Feature Descriptions (continued) 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. VIN(+) VO(+) Rtrim-up ON/OFF LOAD VOTRIM Rtrim-down VIN(-) VO(-) Figure 11. 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%. IO, max should not be exceeded even trimming to a lower output voltage. Output Current Limit Inception is independent of trimmed Vout. The following equation determines the required external resistor value to obtain a percentage output voltage change of % 511 10 . 22 R trim down % Where % Vo , set V desired Vo , set 100 For example, to trim-down the output voltage of the module by 8% to 13.8V, Rtrim-down is calculated as follows: % 8 511 Rtrim down 10.22 8 R trim down Where % V desired Vo , set Vo , set 100 For example, to trim-up the output voltage of the module by 5% to 15.75V, Rtrim-up is calculated is as follows: % 5 Rtrim up 5 .11 15 . 0 (100 5 ) 511 10 .22 1 . 225 5 5 Rtrim up 1 .20 M 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. 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, Tref1, used in the specifications for open frame modules is shown in Figure 12. For reliable operation this temperature should not exceed 130oC. AIRFLOW 53 . 655 Connecting an external resistor (Rtrim-up) between the TRIM pin and the VO(+) (or Sense (+)) pin increases the output voltage set point. The following equation determines the required external resistor value to obtain a percentage output voltage change of %: March 8, 2016 5.11 Vo, set (100 %) 511 10.22 Rtrim up 1 . 225 % % Figure 12. Tref Temperature Measurement Location for Open Frame Module. (c)2016 General Electric Company. All rights reserved. Page 8 GE Data Sheet ESTW004A2C Stingray Series DC-DC Converter Power Modules 36-75Vdc Input; 15.0Vdc/4.2Adc Output The thermal reference point, Tref2, used in the specifications for modules with heatplate is shown in Figure 13. For reliable operation this temperature should not exceed 104oC. AIRFLOW OUTPUT CURRENT, IO (A) Thermal Considerations (continued) AMBIENT TEMEPERATURE, TA (oC) Figure 13. Tref Temperature Measurement Location for Module with Heatplate. Figure 15. Output Current Derating for the Module with Heatplate; Airflow in the Transverse Direction from VOUT(+) to VOUT(-); VIN =48V. Heat Transfer via Convection Increased airflow over the module enhances the heat transfer via convection. Derating curves showing the maximum output current that can be delivered by each module versus local ambient temperature (TA) for natural convection and up to 2m/s (400 ft./min) forced airflow are shown in Figure 14. OUTPUT CURRENT, IO (A) Please refer to the Application Note "Thermal Characterization Process For Open-Frame BoardMounted Power Modules" for a detailed discussion of thermal aspects including maximum device temperatures. Heat Transfer via Conduction The module can also be used in a sealed environment with cooling via conduction from the module's top surface through a gap pad material to a cold wall, as shown in Figure 16. This capability is achieved by insuring the top side component skyline profile achieves no more than 1mm height difference between the tallest and the shortest power train part that benefits from contact with the gap pad material. The output current derating versus cold wall temperature, when using a gap pad such as Bergquist GP2500S20, is shown in Figure 17. AMBIENT TEMEPERATURE, TA (oC) Figure 14. Output Current Derating for the Open Frame Module; Airflow in the Transverse Direction from VOUT(+) to VOUT(-); VIN =48V. OUTPUT CURRENT, IO (A) Figure 16. Cold Wall Mounting COLDPLATE TEMEPERATURE, TC (oC) Figure 17. Derated Output Current versus Cold Wall Temperature with local ambient temperature around module at 85C; VIN=48V. March 8, 2016 (c)2016 General Electric Company. All rights reserved. Page 9 GE Data Sheet ESTW004A2C Stingray Series DC-DC Converter Power Modules 36-75Vdc Input; 15.0Vdc/4.2Adc Output Surface Mount Information Pick and Place The ESTW004A2C modules use an open frame construction and are designed for a fully automated assembly process. The modules are fitted with a label designed to provide a large surface area for pick and place operations. The label 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 18. 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 minimum recommended nozzle diameter for reliable operation is 6mm. The maximum nozzle outer diameter, which will safely fit within the allowable component spacing, is 9 mm. Oblong or oval nozzles up to 11 x 9 mm may also be used within the space available. The surface mountable modules in the ESTW family use our newest SMT technology called "Column Pin" (CP) connectors. Figure 19 shows the new CP connector before and after reflow soldering onto the end-board assembly. The CP is constructed from a solid copper pin with an integral solder ball attached, which is composed of tin/lead (Sn/Pb) solder for non-Z codes, or Sn/Ag3/Cu (SAC) solder for -Z codes. The CP connector design is able to compensate for large amounts of co-planarity and still ensure a reliable SMT solder joint. Typically, the eutectic solder melts at 183oC (Sn/Pb solder) or 217-218 oC (SAC solder), 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 Tin Lead Soldering The ESTW004A2C power modules are lead free modules and can be soldered either in a lead-free solder process or in a 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. Lead Free Soldering The -Z version of the ESTW004A2C modules are leadfree (Pb-free) and RoHS compliant and are both forward and backward compatible in a Pb-free and a SnPb 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. Figure 19. Column Pin Connector Before and After Reflow Soldering . March 8, 2016 (c)2016 General Electric Company. All rights reserved. Page 10 GE Data Sheet ESTW004A2C Stingray Series DC-DC Converter Power Modules 36-75Vdc Input; 15.0Vdc/4.2Adc Output Surface Mount Information (continued) Sn/Ag/Cu solder is shown in Figure 22. 300 300 Per J-STD-020 Rev. C Peak Temp 260C P eak Temp 235oC 250 Co o ling zo ne 1-4oCs -1 Heat zo ne max 4oCs -1 200 Reflow Temp (C) REFLOW TEMP (C) 250 150 So ak zo ne 30-240s 100 Tlim above 205oC * Min. Time Above 235C 15 Seconds 150 Heating Zone 1C/Second *Time Above 217C 60 Seconds 100 50 0 P reheat zo ne max 4oCs -1 50 Cooling Zone 200 Reflow Time (Seconds) Figure 22. Recommended linear reflow profile using Sn/Ag/Cu solder. 0 REFLOW TIME (S) Figure 20. Reflow Profile for Tin/Lead (Sn/Pb) process 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. 240 MAX TEMP SOLDER (C) 235 230 225 220 215 Post Solder Cleaning and Drying Considerations 210 205 200 0 10 20 30 40 50 60 Figure 21. Time Limit Curve Above 205oC for Tin/Lead (Sn/Pb) process 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-airconvection reflow profile based on the volume and thickness of the package (table 4-2). The suggested Pbfree solder paste is Sn/Ag/Cu (SAC). The recommended linear reflow profile using MSL Rating The ESTW004A2C modules have a MSL rating as stated in the Device Code table, last page of this document. 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 March 8, 2016 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 Lineage Power Board Mounted Power Modules: Soldering and Cleaning Application Note (AN04-001). 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 a 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 RoHScompliant 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 Lineage Power representative for more details. (c)2016 General Electric Company. All rights reserved. Page 11 GE Data Sheet ESTW004A2C Stingray Series DC-DC Converter Power Modules 36-75Vdc Input; 15.0Vdc/4.2Adc Output EMC Considerations The circuit and plots in Figure 23 shows a suggested configuration to meet the conducted emission limits of EN55022 Class B. Figure 23. EMC Considerations For further information on designing for EMC compliance, please refer to the FLT007A0 data sheet (DS05-028). VIN = 48V, Io = Io,max, L Line March 8, 2016 VIN = 48V, Io = Io,max, N Line (c)2016 General Electric Company. All rights reserved. Page 12 GE Data Sheet ESTW004A2C Stingray Series DC-DC Converter Power Modules 36-75Vdc Input; 15.0Vdc/4.2Adc Output 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 side label includes Lineage Power name, product designation and date code. Top View* Side View *For optional pin lengths, see Table 2, Device Coding Scheme and Options Bottom View Pin 1 2 3 4 5 6 7 8 March 8, 2016 Function Vi(+) ON/OFF Vi(-) Vo(-) SENSE(-) TRIM SENSE(+) Vo(+) (c)2016 General Electric Company. All rights reserved. Page 13 GE Data Sheet ESTW004A2C Stingray Series DC-DC Converter Power Modules 36-75Vdc Input; 15.0Vdc/4.2Adc Output Mechanical Outline for Surface Mount Module (-S Option) 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 side label includes Lineage Power name, product designation and date code. Top View* Side View Botto m View Pin 1 2 3 4 5 6 7 8 March 8, 2016 Function Vi(+) ON/OFF Vi(-) Vo(-) SENSE(-) TRIM SENSE(+) Vo(+) (c)2016 General Electric Company. All rights reserved. Page 14 GE Data Shee et ESTW W004A2C C Stingra ay Seriess DC-DC Convertter Powe er Modules 36-75 5Vdc Input; 15.0Vdc/4.2Adc Outpu ut Mechanical Outtline for Through-Hole e Module with w Heat Plate P (-H Op ption) Dimenssions are in milllimeters and [in nches]. Tolerances: x.x mm 0.5 mm [x.xx in n. 0.02 in.] (Un nless otherwise e indicated) x.xx mm 0.25 mm [x.xxxx in 0.010 in.]] Top View Side View *FFor optional pin n lengths, see Table T 2, Device e Coding Schem me and Optionss Bottom m View** * Bottom side label inclu udes Lineage Power P name, prroduct designa ation and date code. * Side label contains pro oduct designattion and date code. c Pin 1 2 3 4 5 6 7 8 March 8, 2016 Functtion Vi(+) ON/O OFF Vi(-) Vo(-) SENSE(-) TRIM SENSE(+) Vo(+) (c)2016 General G Electric Company. C All righ hts reserved. Page 15 GE Data Sheet ESTW004A2C Stingray Series DC-DC Converter Power Modules 36-75Vdc Input; 15.0Vdc/4.2Adc Output Recommended Pad Layout 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.] Pin 1 2 3 4 5 6 7 8 Function Vi(+) ON/OFF Vi(-) Vo(-) SENSE(-) TRIM SENSE(+) Vo(+) SMT Recommended Pad Layout (Component Side View) Pin 1 2 3 4 5 6 7 8 Function Vi(+) ON/OFF Vi(-) Vo(-) SENSE(-) TRIM SENSE(+) Vo(+) NOTES: FOR 0.030" X 0.025" RECTANGULAR PIN, USE 0.050" PLATED THROUGH HOLE DIAMETER FOR 0.62 DIA" PIN, USE 0.076" PLATED THROUGH HOLE DIAMETER TH Recommended Pad Layout (Component Side View) March 8, 2016 (c)2016 General Electric Company. All rights reserved. Page 16 GE Data Sheet ESTW004A2C Stingray Series DC-DC Converter Power Modules 36-75Vdc Input; 15.0Vdc/4.2Adc Output Packaging Details The surface mount versions of the ESTW004A2C (suffix -S) are supplied as standard in the plastic trays shown in Figure 24. Each tray contains a total of 12 power modules. The trays are self-stacking and each shipping box for the ESTW004A2C (suffix -S) surface mount module will contain 4 full trays plus one empty hold down tray giving a total number of 48 power modules. Tray Specification Material Max surface resistivity Color Capacity Min order quantity Antistatic coated PVC 1012/sq Clear 12 power modules 48 pcs (1 box of 4 full trays + 1 empty top tray) Figure 24. Surface Mount Packaging Tray March 8, 2016 (c)2016 General Electric Company. All rights reserved. Page 17 GE Data Sheet ESTW004A2C Stingray Series DC-DC Converter Power Modules 36-75Vdc Input; 15.0Vdc/4.2Adc Output Ordering Information Please contact your Lineage Power Sales Representative for pricing, availability and optional features. Table 1. Device Codes Product Codes ESTW004A2C41Z ESTW004A2C841Z ESTW004A2C41-HZ ESTW004A2C41-SZ Input Voltage 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) 48V (36-75Vdc) Output Voltage 15.0V 15.0V 15.0V 15.0V Output Current 4.2A 4.2A 4.2A 4.2A On/Off Logic Negative Negative Negative Negative Connector Type Through hole Through hole Through hole Surface mount MSL Rating n/a n/a n/a 2a Comcodes CC109170461 CC109170494 CC109170486 CC109170478 Table 2. Device Coding Scheme and Options 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. March 8, 2016 (c)2016 General Electric Company. All International rights reserved. Version 1.12