GE Data Sheet ERCW003A6R Power Modules; DC-DC Converters 36 - 75Vdc Input; 28Vdc Output; 3.6Adc Output ORCA SERIESTM Features RoHS Compliant Applications * RF Power Amplifier * Wireless Networks * Switching Networks Options Output OCP/OVP auto restart Shorter pins Unthreaded heatsink holes * Compliant to RoHS EU Directive 2002/95/EC (-Z versions) * Compliant to ROHS EU Directive 2002/95/EC with lead solder exemption (non-Z versions) * High power density: 139W/ in3 * Very high efficiency: 93.4% Typ at Full Load (48Vin, 28Vout/3.6A) * Industry standard 1/8 brick pin-out * Low output ripple and noise * Supports repetitive loads (AC+DC) up to 2 kHz * * Industry standard, DOSA compliant 1/8 brick footprint 58.4mm x 23.0mm x 8.8mm (2.3" x 0.9" x 0.35") Remote Sense * 2:1 input voltage range * Single tightly regulated output * Constant switching frequency * Output overcurrent and overvoltage protection * Over temperature protection auto restart * Output voltage adjustment trim, 15.0Vdc to 35.2Vdc * Wide operating case temperature range (-40C to 100C) * CE mark meets 2006/95/EC directives * ANSI/UL* 60950-1, 2nd Ed. Recognized, CSA C22.2 No. 60950-1-07 Certified, and VDE 0805-1 (EN60950-1, 2nd Ed.) Licensed * ISO** 9001 and ISO 14001 certified manufacturing facilities * Compliant to IPC-9592A, Category 2, Class II Description The ERCW003A6R ORCATM series of dc-dc converters are a new generation of isolated, very high efficiency DC/DC power modules providing up to up to 3.6Adc output current at a nominal output voltage of 28Vdc in an industry standard, DOSA compliant 1/8 brick size footprint, which makes it an ideal choice for high voltage and high power applications. The ERCW003A6R modules have typical efficiency of 93% at full-load and nominal output voltage of 28V. The maximum output ripple of the module is 20mVrms, which helps to reduce external filtering capacitors and system cost. Threaded-through holes are provided to allow easy mounting or addition of a heat sink for high-temperature applications. The output is fully isolated from the input, allowing versatile polarity configurations and grounding connections. June 22, 2016 (c)2012 General Electric Company. All rights reserved. Page 1 GE Data Sheet ERCW003A6R Power Modules; DC-DC Converters 36 - 75 Vdc Input; 28Vdc Output; 3.6Adc Output Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings will cause permanent damage to the device. These are absolute stress ratings only, functional operation of the device is not desired at these or any other conditions in excess of those given in the operations sections of the technical requirements. Exposure to absolute maximum ratings for extended periods can adversely affect the device reliability. Parameter Device Symbol Min Max Unit Continuous All VIN -0.3 80 Vdc Input Voltage Transient, operational ( 9 ms) All VIN,trans -0.3 100 Vdc Operating Ambient Temperature All Ta -40 85 C Operating Case Temperature (See Thermal Considerations section, Figure 17) All Tc -40 100 C Storage Temperature All Tstg -55 125 C I/O Isolation Voltage: Input to Case, Input to Output All 2250 Vdc All 500 Vdc Output to Case Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Parameter Operating Input Voltage (see Figure 12 for VIN MIN when using trim-up feature) Device Symbol Min Typ Max Unit All VIN 36 48 75 Vdc All IIN,max 3.5 Adc All I2t 2 A2s 35 mAp-p Maximum Input Current (VIN=36V to 75V, IO=IO, max) Inrush Transient Input Reflected Ripple Current, peak-to-peak (5Hz to 20MHz, 12H source impedance; VIN=0V to 75V, IO= IOmax ; see Figure 12) Input No Load Current Vin = 48V, (Io = 0, module enabled) Input Stand-by Current (Vin = 48V, module disabled) Input Ripple Rejection (120Hz) All All 70 All All mAdc 10 50 mAdc 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 being an integrated part of complex power architecture. To preserve maximum flexibility, internal fusing is not included. Always use an input line fuse, to achieve maximum safety and system protection. The safety agencies require a time-delay or fast-acting fuse with a maximum rating of 10A in the ungrounded input connection (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. June 22, 2016 (c)2012 General Electric Company. All rights reserved. Page 2 GE Data Sheet ERCW003A6R Power Modules; DC-DC Converters 36 - 75 Vdc Input; 28Vdc Output; 3.6Adc Output Electrical Specifications (continued) Parameter Device Output Voltage Set-point (VIN=VIN,nom, IO=IO, max, Tc =25C) Output Voltage Set-Point Total Tolerance (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 (Tc = -40C to +100C) Output Ripple and Noise on nominal output (VIN=VIN, nom and IO=IO, min to IO, max) RMS (5Hz to 20MHz bandwidth) Symbol Min Typ Max Unit VO, set 27.5 28 28.5 Vdc VO 27.0 29.0 Vdc All All All 0.1 0.1 0.4 0.2 0.2 0.75 %Vo,set %Vo,set %Vo,set All 10 20 mVrms 30 60 1500 100 mVpk-pk F W 3.6 Adc Adc 30 Arms All All Peak-to-Peak (5Hz to 20MHz bandwidth) External Capacitance ( 2.5m< ESR < 80m)1 Output Power (Vo=28V to 35.2V) All All PO,max 220 Output Current Output Current Limit Inception (Constant current until Vo<VtrimMIN, duration <4s) Output Short Circuit Current (VO 0.25Vdc) Efficiency VIN=VIN, nom, Tc=25C IO=IO, max , VO= VO,set Switching Frequency All Io 0 All IO, lim 4.0 All IO, sc All 93.4 % fsw 280 kHz All Vpk ts 2 1.5 %VO, set ms All Vpk ts 2 1.5 %VO, set ms Load Change from IO= 0%-120% of IO,max: Peak Deviation Settling Time (VO<10% peak deviation) All Vpk ts 2 1.5 %VO, set ms Load Change from Io= 120% to 50% of Io,max: Peak Deviation Settling Time (Vo<10% peak deviation) All Vpk ts 2 1.5 %VO, set ms CO, Dynamic Load Response (Io/t=1A/10s; VIN=VIN,nom; Tc=25C; Tested with a 220F aluminum and a 10 F ceramic capacitor across the load.) Load Change from IO= 25%-50%-25% of IO,max: Peak Deviation Settling Time (VO<10% peak deviation) Load Change from IO= 50%-75%-50% of IO,max: Peak Deviation Settling Time (VO<10% peak deviation) (Io/t=10%IO,max /10s; VIN=VIN,nom; Tc=25C; Tested with a 470F aluminum and a 10 F ceramic capacitor across the load, see Figure 16. 1 Note: use a minimum 220uF output capacitor. Recommended capacitor is Nichicon CD series, 220uF/35V. If the ambient temperature is less than -20OC, use more than 3 of recommended minimum capacitors. June 22, 2016 (c)2012 General Electric Company. All rights reserved. Page 3 GE Data Sheet ERCW003A6R Power Modules; DC-DC Converters 36 - 75 Vdc Input; 28Vdc Output; 3.6Adc Output Isolation Specifications Parameter Symbol Min Typ Max Unit Isolation Capacitance Ciso 15 nF Isolation Resistance Riso 10 M Min Typ Max General Specifications Parameter Device 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 Symbol FIT 101.6 MTBF 9,842,207 Hours Weight (open frame) All Weight (heat plate) June 22, 2016 Unit 109/Hours (c)2012 General Electric Company. All rights reserved. 22.8 0.81 g oz. 29.8 g 1.05 oz. Page 4 GE Data Sheet ERCW003A6R Power Modules; DC-DC Converters 36 - 75 Vdc Input; 28Vdc Output; 3.6Adc 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 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 Logic Low - On/Off Voltage Logic High Voltage - (Typ = Open Collector) Logic High maximum allowable leakage current Turn-On Delay and Rise Times (Vin=Vin,nom, IO=IO, max, 25C) Case 1: Tdelay = Time until VO = 10% of VO,set from application of Vin with Remote On/Off set to ON, Case 2: Tdelay = Time until VO = 10% of VO,set from application of Remote On/Off from Off to On with Vin already applied for at least one second. Trise = time for VO to rise from 10% of VO,set to 90% of VO,set. Output Voltage Overshoot (IO=80% of IO, max, TA=25C) Output Voltage Adjustment (See Feature Descriptions): Output Voltage Remote-sense Range Output Voltage Set-point Adjustment Range (trim) Note: see Figure 12 Output Overvoltage Protection Over Temperature Protection (See Feature Descriptions, Figure 17, open frame version) (See Feature Descriptions, Figure 18, base plate version) Input Under Voltage Lockout Turn-on Threshold Turn-off Threshold Hysteresis Input Over voltage Lockout Turn-on Threshold Turn-off Threshold Hysteresis June 22, 2016 Device Symbol Min Typ Max Unit All All All All Ion/off Von/off Von/off Ion/off 0 2.5 1.0 1.2 10 50 mA Vdc Vdc A All Tdelay All Tdelay All Trise ms 30 ms 50 ms 3 % VO, set 2 %Vo,nom __ Vtrim 15.0 --- 35.2 Vdc VO, limit 37 42 Vdc Tref 135 120 C C 31 35 32 3 36 Vdc Vdc Vdc 81 --- 79.5 83 3 81 --- Vdc Vdc Vdc Vsense All All All All All All 30 __ All All All All VIN, UVLO VIN, OVLO (c)2012 General Electric Company. All rights reserved. Page 5 GE Data Sheet ERCW003A6R Power Modules; DC-DC Converters 36 - 75 Vdc Input; 28Vdc Output; 3.6Adc Output Characteristic Curves OUTPUT CURRENT, Io (A) INPUT VOLTAGE Vin (V) (20V/div) OUTPUT VOLTAGE VO (V) (20mV/div) TIME, t (2s/div) TIME, t (20ms/div) OUTPUT VOLTAGE VO(V) (100mV/div) Figure 5. Typical Start-Up from VIN, on/off enabled prior to VIN step; Co,ext = 220F. OUTPUT CURRENT IO (A) (1A/div) OUTPUT CURRENT IO (A) (1A/div) OUTPUT VOLTAGE VO(V) (100mV/div) Figure 2. Typical Output Ripple and Noise at Room Temperature and 48Vin; Io = Io,max; Co,ext = 220F. TIME, t (1ms/div) Figure 3. Dynamic Load Change Transient Response from 25% to 50% to 25% of Full Load at Room Temperature and 48 Vin; 0.1A/uS, Co,ext = 220F. June 22, 2016 TIME, t (20ms/div) Figure 4. Typical Start-Up Using negative Remote On/Off; Co,ext = 220F. OUTPUT VOLTAGE VO(V) (10V/div) Figure 1. Converter Efficiency versus Output Current. On/Off VOLTAGE VON/OFF(V) (2V/div) EFFICIENCY (%) OUTPUTVOLTAGE VO (V) (10V/div) The following figures provide typical characteristics for the ERCW003A6A0R (28V, 3.6A) at 25C. The figures are identical for either positive or negative Remote On/Off logic. TIME, t (1ms/div) Figure 6. Dynamic Load Change Transient Response from 50 % to 75% to 50% of Full Load at Room Temperature and 48 Vin; 0.1A/uS, Co,ext = 220F. (c)2012 General Electric Company. All rights reserved. Page 6 GE Data Sheet ERCW003A6R Power Modules; DC-DC Converters 36 - 75 Vdc Input; 28Vdc Output; 3.6Adc Output Test Configurations Design Considerations Input Source Impedance The power module should be connected to a low ac-impedance source. A highly inductive source impedance can affect the stability of the power module. For the test configuration in Figure 7, a 150F Low ESR aluminum capacitor, CIN , mounted close to the power module helps ensure the stability of the unit. Consult the factory for further application guidelines. Note: Measure the input reflected-ripple current with a simulated source inductance (LTEST) of 12 H. Capacitor CS offsets possible battery impedance. Measure the current, as shown above. Figure 7. Input Reflected Ripple Current Test Setup. Output Capacitance The ERCW003A6R power module requires a minimum output capacitance of 220F Low ESR aluminum capacitor, Cout to ensure stable operation over the full range of load and line conditions, see Figure 8. If the ambient temperature is under -20C, it is required to use at least 3 pcs of minimum capacitors in parallel. In general, the process of determining the acceptable values of output capacitance and ESR is complex and is load-dependent. Safety Considerations Note: Use a Cout (470 F Low ESR aluminum or tantalum capacitor typical), a 0.1 F ceramic capacitor and a 10 F ceramic capacitor, and Scope measurement should be made using a BNC socket. Position the load between 51 mm and 76 mm (2 in. and 3 in.) from the module. Figure 8. Output Ripple and Noise Test Setup. 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, 2nd Ed., CSA No. 60950-1 2nd Ed., and VDE0805-1 EN60950-1, 2nd Ed. For end products connected to -48V dc, or -60Vdc nominal DC MAINS (i.e. central office dc battery plant), no further fault testing is required. *Note: -60V dc nominal battery plants are not available in the U.S. or Canada. For all input voltages, other than DC MAINS, where the input voltage is less than 60V dc, if the input meets all of the requirements for SELV, then: The output may be considered SELV. Output voltages will remain within SELV limits even with internallygenerated non-SELV voltages. Single component failure and fault tests were performed in the power converters. One pole of the input and one pole of the output are to be grounded, or both circuits are to be kept floating, to maintain the output voltage to ground voltage within ELV or SELV limits. However, SELV will not be maintained if VI(+) and VO(+) are grounded simultaneously. Note: All measurements are taken at the module terminals. When socketing, place Kelvin connections at module terminals to avoid measurement errors due to socket contact resistance. Figure 9. Output Voltage and Efficiency Test Setup. June 22, 2016 (c)2012 General Electric Company. All rights reserved. Page 7 GE Data Sheet ERCW003A6R Power Modules; DC-DC Converters 36 - 75 Vdc Input; 28Vdc Output; 3.6Adc Output Safety Considerations (continued) For all input sources, other than DC MAINS, where the input voltage is between 60 and 75V dc (Classified as TNV-2 in Europe), the following must be meet, if the converter's output is to be evaluated for SELV: The input source is to be provided with reinforced insulation from any hazardous voltage, including the ac mains. One Vi pin and one Vo pin are to be reliably earthed, or both the input and output pins are to be kept floating. Another SELV reliability test is conducted on the whole system, as required by the safety agencies, on the combination of supply source and the subject module to verify that under a single fault, hazardous voltages do not appear at the module's output. All flammable materials used in the manufacturing of these modules are rated 94V-0, or tested to the UL60950 A.2 for reduced thickness. The input to these units is to be provided with a maximum 10A fast-acting or time-delay fuse in the ungrounded input connection. Feature Descriptions 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. 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 10). Logic low is 0V Von/off 1.2V. The maximum Ion/off during a logic low is 1mA, the switch should be maintain a logic low level whilst sinking this current. During a logic high, the typical maximum Von/off generated by the module is 5V, and the maximum allowable leakage current at Von/off = 5V is 50A. If not using the remote on/off feature: For positive logic, leave the ON/OFF pin open. Figure 10. Circuit configuration for using Remote On/Off Implementation. Overcurrent Protection To provide protection in a fault output overload condition, the module is equipped with internal current limiting protection circuitry, and can endure continuous overcurrent by providing constant current output, for up to 4 seconds, as long as the output voltage is greater than VtrimMIN. If the load resistance is too low to support VtrimMIN in an overcurrent condition or a short circuit load condition exists, the module will shut down immediately. A auto-restart option is standard. Following shutdown, the module will restart after a period of 3 seconds if the shutdown happens due to over-current protection being triggered or the module will restart after a period of 2.5 seconds when the shutdown happens due to output overvoltage protection getting enabled. An latching shutdown option (4) is also available in a case where an auto recovery is required. If overcurrent greater than 4A persists for few milliseconds, the module will shut down and auto restart until the fault condition is corrected. If the output overload condition still exists when the module restarts, it will shut down again. This operation will continue indefinitely, until the overcurrent condition is corrected. Over Voltage Protection The output overvoltage protection consists of circuitry that monitors the voltage on the output terminals. If the voltage on the output terminals exceeds the over voltage protection threshold, then the module will shutdown and latch off. The overvoltage latch is reset by either cycling the input power for one second or by toggling the on/off signal for one second. The protection mechanism is such that the unit can continue in this condition until the fault is cleared. An auto-restart option (4) is also available in a case where an auto recovery is required. 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). For No Trim or Trim down application, 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 i.e.: June 22, 2016 (c)2012 General Electric Company. All rights reserved. Page 8 GE Data Sheet ERCW003A6R Power Modules; DC-DC Converters 36 - 75 Vdc Input; 28Vdc Output; 3.6Adc Output [VO(+)-VO(-)] - [SENSE(+) - SENSE(-)] 2% of Vo,nom The voltage between the Vo(+) and Vo(-) terminals must not exceed the minimum output overvoltage shut-down value indicated in the Feature Specifications table. This limit includes any increase in voltage due to remote-sense compensation and output voltage set-point adjustment (trim). See Figure 11. If not using the remote-sense feature to regulate the output at the point of load, then connect SENSE(+) to Vo(+) and SENSE(-) to Vo(-) at the module. 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. Figure 11. Effective Circuit Configuration for SingleModule Remote-Sense Operation Output Voltage. Output Voltage Programming Trimming allows the user to increase or decrease the output voltage set point of a module. Trimming down is accomplished by connecting an external resistor between the TRIM pin and the SENSE(-) pin. Trimming up is accomplished by connecting external resistor between the SENSE(+) pin and TRIM pin. The trim resistor should be positioned close to the module. Certain restrictions apply to the input voltage lower limit when trimming the output voltage to the maximum. See Figure 12 for the allowed input to output range when using trim. If not using the trim down feature, leave the TRIM pin open. Figure12. Output Voltage Trim Limits vs. Input Voltage. Figure 13. Circuit Configuration to Decrease Output Voltage. Trim Up - Increase Output Voltage With an external resistor (Radj_up) connected between the SENSE(+) and TRIM pins, the output voltage set point (Vo,adj) increases (see Figure 14). The following equation determines the required externalresistor value to obtain a percentage output voltage change of %. Trim Down - Decrease Output Voltage With an external resistor (Radj_down) between the TRIM and SENSE (-) pins, the output voltage set point (Vo,adj) decreases (see Figure 13). The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. 511 _ = % - 10.22 Where % = June 22, 2016 , -, , x 100 (c)2012 General Electric Company. All rights reserved. Page 9 GE Data Sheet ERCW003A6R Power Modules; DC-DC Converters 36 - 75 Vdc Input; 28Vdc Output; 3.6Adc Output %. Please contact your GE Power technical representative to obtain more details on the selection for this resistor. Vi(+) ON/OFF CASE Vi(-) Vo(+) SENSE(+) TRIM DAC RG RLOAD SENSE(-) Vo(-) Figure 14. Circuit Configuration to Increase Output Voltage. The voltage between the Vo(+) and Vo(-) terminals must not exceed the minimum output overvoltage shut-down value indicated in the Feature Specifications table. This limit includes any increase in voltage due to remote- sense compensation and output voltage set-point adjustment (trim). See Figure 11. Figure 15. Circuit Configuration to Actively Adjust the Output Voltage. AC+DC Load Capability The ERCW003A6Rx is compatible with load profiles as shown in Figure 16. 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 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. Examples: To trim down the output of a nominal 28V module to 16.8V % = 28 - 16.8 x 100 = 40% 28 Figure 16. AC-DC Load Profile The output voltage peak deviation shall not exceed the peak values listed in the Electrical Specifications Table. 511 Radj _ down = - 10.22 = 2.56k 40 To trim up the output of a nominal 28V module to 32.0V 32.0 - 28 x 100 = 14.3% 28 5.11 x 28 x (100 + 14.3) (511) - - 10.22 K Radj _ up = 14.3 1.225 x 14.3 % = Radj_up = 887k The ERCW003A6R module provides a non-latching over temperature protection. A temperature sensor monitors the operating temperature of the converter. If the reference temperature, TREF 1, exceeds a threshold of 135 C (typical) for open frame version, and 120 C for base plate version. the converter will shut down and disable the output. When the base plate temperature has decreased by approximately 20 C the converter will automatically restart. Thermal Considerations Active Voltage Programming For ERCW003A6Rx , a Digital-Analog converter (DAC), capable of both sourcing and sinking current, can be used to actively set the output voltage, as shown in Figure 15. The value of RG will be dependent on the voltage step and range of the DAC and the desired values for trim-up and trim-down June 22, 2016 Over Temperature Protection The power modules operate in a variety of thermal environments; however, sufficient cooling should be provided to help ensure reliable operation of the unit. Heat-dissipating components inside the unit are thermally coupled to the case. Heat is removed by conduction, convection, and radiation to the surrounding environment. Proper cooling can be verified (c)2012 General Electric Company. All rights reserved. Page 10 GE Data Sheet ERCW003A6R Power Modules; DC-DC Converters 36 - 75 Vdc Input; 28Vdc Output; 3.6Adc Output by measuring the case temperature. Peak temperature (TREF) occurs at the position indicated in Figure 17 and 18. 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. Figure 19. Cold Wall Mounting Output Current, IO (A) The output power of the module should not exceed the rated power for the module as listed in the ordering Information table. Although the maximum TREF temperature of the power modules is discussed above, you can limit this temperature to a lower value for extremely high reliability. The thermal reference points, Tref, used in the specifications for open frame module is shown in Figure 17. For reliable operation, the temperatures should not exceed 122 C. removal into a forced airflow that passes through the interior of the module and over the top base plate and/or attached heatsink. Figure 22 shows thermal derating curves for ERCW003A6R module with baseplate attached. Figure 17. Case (TREF ) Temperature Measurement Location (top view). Figure 20. Derating Output Current vs. Cold Wall Temperature with local ambient temperature around module at 85C; Vin =48V Output Current, IO (A) The thermal reference points, Tref, used in the specifications for base plate module is shown in Figure 18. For reliable operation, the temperature should not exceed 113 C. Ambient Temperature, TA (oC) Tref1 Figure 18. Case (TREF ) Temperature Measurement Location (top view). Ambient Temperature, TA (oC) Thermal Derating Thermal derating is presented for two different applications: 1) Figure 19 and 20, the ERCW003A6R module is thermally coupled to a cold plate inside a sealed clamshell chassis, without any internal air circulation; and 2) Figure 21, the ERCW003A6R module is mounted in a traditional open chassis or cards with forced air flow. In application 1, the module is cooled entirely by conduction of heat from the module primarily through the top surface to a cold plate, with some conduction through the module's pins to the power layers in the system board and can deliver full load upto 100 C. For application 2, the module is cooled by heat June 22, 2016 Figure 21. Derating Output Current vs. local Ambient temperature and Airflow, open frame or No baseplate, Vin=48V, airflow from Vi(-) to Vi(+). (c)2012 General Electric Company. All rights reserved. Page 11 GE Data Sheet ERCW003A6R Power Modules; DC-DC Converters Output Current, IO (A) 36 - 75 Vdc Input; 28Vdc Output; 3.6Adc Output Ambient Temperature, TA (oC) Figure 22. Derating Output Current vs. local Ambient temperature and Airflow, with Baseplate, Vin=48V, airflow from Vi(-) to Vi(+). Layout Considerations The ERCW003A6R power module series are constructed using a single PWB with integral base plate; as such, component clearance between the bottom of the power module and the mounting (Host) board is limited. Avoid placing copper areas on the outer layer directly underneath the power module. 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 Power Board Mounted Power Modules: Soldering and Cleaning Application Note. Through-Hole Lead-Free Soldering Information The RoHS-compliant through-hole products use the SAC (Sn/Ag/Cu) Pb-free solder and RoHS-compliant components. They are designed to be processed through single or dual wave soldering machines. The pins have an RoHS-compliant finish that is compatible with both Pb and Pb-free wave soldering processes. A maximum preheat rate of 3C/s is suggested. The wave preheat process should be such that the temperature of the power module board is kept below 210C. For Pb solder, the recommended pot temperature is 260C, while the Pb-free solder pot is 270C max. The ERCW003A6R can be processed with paste-through-hole Pb or Pb-free reflow process. If additional information is needed, please consult with your GE Power representative for more details. June 22, 2016 (c)2012 General Electric Company. All rights reserved. Page 12 GE Data Sheet ERCW003A6R Power Modules; DC-DC Converters 36 - 75 Vdc Input; 28Vdc Output; 3.6Adc Output Packaging details All versions of the ERCW003A6R are supplied as standard in the plastic trays shown in Figure 23. Each tray contains a total of 18 power modules. The trays are self-stacking and each shipping box for the ERCW003A6R module contains 2 full trays plus one empty hold-down tray giving a total number of 36 power modules. Tray Specification Material Max surface resistivity Color Capacity Min order quantity PET (1mm) 109 -1011/PET Clear 18 power modules 36 pcs (1 box of 2 full trays + 1 empty top tray) Open Frame Module Tray Base Plate Module Tray Figure 23. ERCW003A6R Packaging Tray June 22, 2016 (c)2012 General Electric Company. All rights reserved. Page 13 GE Data Sheet ERCW003A6R Power Modules; DC-DC Converters 36 - 75 Vdc Input; 28Vdc Output; 3.6Adc 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* VIEW *Top side label includes GE name, product designation and date code. SIDE VIEW **For optional pin lengths, see Table 2, Device Coding Scheme and Options BOTTOM VIEW June 22, 2016 (c)2012 General Electric Company. All rights reserved. Page 14 GE Data Sheet ERCW003A6R Power Modules; DC-DC Converters 36 - 75 Vdc Input; 28Vdc Output; 3.6Adc Output Mechanical Outline for Through-Hole Module with Heat Plate (-H 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.] June 22, 2016 (c)2012 General Electric Company. All rights reserved. Page 15 GE Data Sheet ERCW003A6R Power Modules; DC-DC Converters 36 - 75 Vdc Input; 28Vdc Output; 3.6Adc Output Mechanical Outline for Through-Hole Module with 1/4 Brick Heat Plate (-18H 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.] June 22, 2016 (c)2012 General Electric Company. All rights reserved. Page 16 GE Data Sheet ERCW003A6R Power Modules; DC-DC Converters 36 - 75 Vdc Input; 28Vdc Output; 3.6Adc Output Recommended 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.] Hole and Pad diameter recommendations: Pin Number 1, 2, 3, 5, 6, 7 4, 8 June 22, 2016 Hole Dia mm [in] 1.6 [.063] 2.2 [.087] Pad Dia mm [in] 2.1 [.083] 3.2 [.126] (c)2012 General Electric Company. All rights reserved. Page 17 GE Preliminary Data Sheet ERCW003A6R Power Modules; DC-DC Converters 36 - 75 Vdc Input; 28Vdc Output; 3.6Adc Output Ordering Information 48V (36-75Vdc) Output Voltage 28V Output Current 3.6A 48V (36-75Vdc) 28V 3.6A Input Voltage 93% Connector Type Through hole MSL Rating 2a 93% Through hole 2a Efficiency Product codes Comcodes ERCW003A6R41Z 150037559 ERCW003A6R41-HZ 150037560 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 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. June 22, 2016 (c)2016 General Electric Company. All International rights reserved. Version 1.04