Data Sheet GE ESTW004A2C Stingray* Series DC-DC Converter Power Modules 36–75V Input; 15.0V /4.2A Output dc dc dc 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 V dc  Tightly regulated output  Remote sense  Output Voltage adjust: 80% to 110% of V o,nom  Constant switching frequency RoHS Compliant  Positive remote On/Off logic  Input under/over voltage protection  Output overcurrent and overvoltage protection Applications  Over-temperature protection  Wireless Networks  No reverse current during output shutdown  Access and Optical Network Equipment  Wide operating temperature range (-40°C to 85°C)  Suitable for cold wall cooling using suitable Gap Pad  Industrial Equipment applied directly to top side of module #  UL 60950-1 2nd Ed. Recognized, CSA† C22.2 No. 60950-1- 07 Certified, and VDE‡ (EN60950-1 2nd Ed.) Licensed §  CE mark meets 2006/95/EC directive Options  Meets the voltage and current requirements for ETSI 300- 132-2 and complies with and licensed for Basic insulation  Negative Remote On/Off logic (preferred) rating per EN60950-1  Over current/Over voltage protections (Auto-restart) ¤  2250 Vdc Isolation tested in compliance with IEEE 802.3 (preferred) PoE standards **  Heat plate version (-H)  ISO 9001 and ISO 14001 certified manufacturing facilities  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 36-75V . The ESTW004A2C provides 15V nominal dc dc output voltage rated for 4.2A output current. The module incorporates Lineage Power’s vast heritage for reliability and dc 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 ©2016 General Electric Company. All rights reserved. Page 1 Data Sheet GE ESTW004A2C Stingray Series DC-DC Converter Power Modules 36–75V Input; 15.0V /4.2A Output dc dc dc 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 Operating Ambient Temperature All T -40 85 °C A (see Thermal Considerations section) Storage Temperature All T -55 125 °C stg I/O Isolation voltage (100% factory Hi-Pot tested) All   2250 Vdc Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Parameter Device Symbol Min Typ Max Unit Operating Input Voltage All VIN 36 48 75 Vdc Maximum Input Current All I 2.0 A IN,max dc (VIN= VIN, min to VIN, max, IO=IO, max) Input No Load Current All I 90 mA IN,No load (VIN = 48V, IO = 0, module enabled) Input Stand-by Current All IIN,stand-by 5 8 mA (VIN = 48V, module disabled) 2 2 Inrush Transient All It 0.5 A s Input Reflected Ripple Current, peak-to-peak (5Hz to 20MHz, 1μH source impedance; V to V I = All 30 mA IN, min IN, max, O p-p I ; See Test configuration section) Omax 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 ©2016 General Electric Company. All rights reserved. Page 2 Data Sheet GE ESTW004A2C Stingray Series DC-DC Converter Power Modules 36–75V Input; 15.0V /4.2A Output dc dc dc Electrical Specifications (continued) Parameter Device Symbol Min Typ Max Unit Nominal Output Voltage Set-point VIN= 48V IO=IO, max, TA=25°C) All VO, set 14.7 15.0 15.3 Vdc Output Voltage All V 14.55 15.45 V (Over all operating input voltage, resistive load, and O  dc temperature conditions until end of life) Output Regulation Line (VIN=VIN, min to VIN, max) All   ±0.2 % VO, set Load (I =I to I ) All ±0.2 % V O O, min O, max   O, set Temperature (Tref=TA, min to TA, max) All   % VO, set ±1.0 Output Ripple and Noise (VIN=48V, IO= IO, max, TA=25°C, see Figure 7.) RMS (5Hz to 20MHz bandwidth) All 35 60 mV  rms Peak-to-Peak (5Hz to 20MHz bandwidth) All  100 180 mVpk-pk External Capacitance All CO, max 0  2,000 μF Output Current All I 0 4.2 A O  dc Output Power (I ≤ I) All P 0 63 W O O, max O  Output Current Limit Inception (Hiccup Mode ) IO, lim Adc All 4.6 5.2 6.0 (VO= 90% of VO, set) Output Short-Circuit Current All IO, s/c 5 Arms (V≤250mV) ( Hiccup Mode ) O Efficiency V =48V, T =25°C, I =2.1A, V = 15V All η 88.0 % IN A O O V =48V, T =25°C, I =4.2A, V = 15V All η 90.0 % IN A O O Switching Frequency All f 280 kHz sw Dynamic Load Response (dIo/dt=0.1A/s; VIN = 48V; TA=25°C) Load Change from Io= 50% to 75% or 25% to 50% of Io,max Peak Deviation All V 3 % V pk   O, set Settling Time (Vo<10% peak deviation) All ts  200  s Isolation Specifications Parameter Device Symbol Min Typ Max Unit Isolation Capacitance All Ciso  1000  pF Isolation Resistance All Riso 100   MΩ I/O Isolation Voltage (100% factory Hi-pot tested) All All   2250 Vdc General Specifications Parameter Device Symbol Typ Unit 9 Calculated Reliability based upon Telcordia SR-332 Issue 2: All FIT 321.5 10 /Hours Method I Case 3 (IO=80%IO, max, TA=40°C, airflow = 200 lfm, All MTBF 3,110,164 Hours 90% confidence) Weight (Open Frame) All 19 (0.7) g (oz.) Weight (with Heatplate) All 30 (1.1) g (oz.) March 8, 2016 ©2016 General Electric Company. All rights reserved. Page 3 Data Sheet GE ESTW004A2C Stingray Series DC-DC Converter Power Modules 36–75V Input; 15.0V /4.2A Output dc dc dc 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 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 (V = -0.7V) All I 0.15 mA on/off dc on/off   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 μA Turn-On Delay and Rise Times o (IO=IO, max , VIN=VIN, nom, TA = 25C) Case 1: Input power is applied for at least 1second, and then the On/Off input is set from OFF to ON All Tdelay — 12 — msec (Tdelay = on/off pin transition until VO = 10% of VO, set) Case 2: On/Off input is set to Module ON, and then input power is applied All T — 25 35 msec delay (Tdelay = VIN reaches VIN, min until VO = 10% of VO,set) Output voltage Rise time (time for V to rise from 10% o All T — 15 25 msec rise of Vo,set to 90% of Vo, set) Output voltage overshoot – Startup All — 3 % VO, set o IO= IO, max; VIN=VIN, min to VIN, max, TA = 25 C Remote Sense Range All VSENSE 10 % VO, set Output Voltage Adjustment Range All 80 110 % V O, set Output Overvoltage Protection All VO, limit 17.0  20.0 Vdc Open O Overtemperature Protection – Hiccup Auto Restart Tref1  135  C Frame Heat O T  120  C ref2 Plate Input Undervoltage Lockout All V UVLO Turn-on Threshold  34 36 V dc Turn-off Threshold 30 32 34 V dc Hysteresis 1 2 V dc Input Overvoltage Lockout All VOVLO Turn-on Threshold 76 77  Vdc Turn-off Threshold 77 79 81 Vdc Hysteresis 1 2 Vdc March 8, 2016 ©2016 General Electric Company. All rights reserved. Page 4 Data Sheet GE ESTW004A2C Stingray Series DC-DC Converter Power Modules 36–75V Input; 15.0V /4.2A Output dc dc dc Characteristic Curves o The following figures provide typical characteristics for the ESTW004A2C (15.0V, 4.2A) at 25 C. The figures are identical for either positive or negative remote On/Off logic. OUTPUT CURRENT, I (A) TIME, t (10ms/div) O Figure 1. Converter Efficiency versus Output Current. Figure 4. Typical Start-up Using Remote On/Off, negative logic version shown (VIN = 48V, Io = Io,max). TIME, t (2s/div) TIME, t (10ms/div) Figure 2. Typical output ripple and noise ( Io = Io,max). Figure 5. Typical Start-up Using Input Voltage (VIN = 48V, Io = Io,max). TIME, t (200µs/div) Figure 3. Transient Response to 0.1A/µS Dynamic Load Change from 50% to 75% to 50% of full load, V =48V. IN March 8, 2016 ©2016 General Electric Company. All rights reserved. Page 5 OUTPUT VOLTAGE OUTPUT CURRENT OUTPUT VOLTAGE V (V) (200mV/div) I (A) (1A/div) EFFICIENCY,  (%) O O V (V) (100mV/div) O OUTPUT VOLTAGE INPUT VOLTAGE OUTPUT VOLTAGE On/Off VOLTAGE VO (V) (5V/div) VIN (V) (10V/div) VO (V) (5V/div) VOn/Off (V) (5V/div) Data Sheet GE ESTW004A2C Stingray Series DC-DC Converter Power Modules 36–75V Input; 15.0V /4.2A Output dc dc dc Test Configurations Design Considerations Input Filtering CURRENT PROBE TO OSCILLOSCOPE The power module should be connected to a low ac-impedance source. Highly inductive source L TEST Vin+ impedance can affect the stability of the power module. 12μH For the test configuration in Figure 6 a 33-100μF electrolytic capacitor (ESR<0.7 at 100kHz), mounted 33-100μF CS 220μF close to the power module helps ensure the stability of E.S.R.<0.1 the unit. Consult the factory for further application @ 20°C 100kHz guidelines. Vin- Safety Considerations For safety-agency approval of the system in which the NOTE: Measure input reflected ripple current with a simulated source inductance (L ) of 12μH. Capacitor C offsets TEST S power module is used, the power module must be possible battery impedance. Measure current as shown above. installed in compliance with the spacing and separation requirements of the end-use safety agency standard, i.e. Figure 6. Input Reflected Ripple Current Test Setup. UL60950-1, CSA C22.2 No.60950-1, and VDE0805- COPPER STRIP 1(IEC60950-1). If the input source is non-SELV (ELV or a hazardous V O (+) RESISTIVE LOAD voltage greater than 60 V and less than or equal to dc + SCOPE 75V ), for the module’s output to be considered as dc meeting the requirements for safety extra-low voltage V (– ) O 1uF 10uF (SELV), all of the following must be true:  The input source is to be provided with reinforced GROUND PLANE insulation from any other hazardous voltages, NOTE: All voltage measurements to be taken at the module terminals, as shown above. If sockets are used then including the ac mains. Kelvin connections are required at the module terminals  One V pin and one V pin are to be grounded, or IN OUT to avoid measurement errors due to socket contact resistance. both the input and output pins are to be kept Figure 7. Output Ripple and Noise Test Setup. 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 R R R R distribution contact contact distribution subject module), as required by the safety agencies, Vin+ Vout+ to verify that under a single fault, hazardous voltages do not appear at the module’s output. R LOAD V V IN O Note: Do not ground either of the input pins of the module without grounding one of the output R R R R pins. This may allow a non-SELV voltage to distribution contact contact distribution Vin- Vout- appear between the output pins and ground. The power module has extra-low voltage (ELV) outputs NOTE: All voltage measurements to be taken at the module when all inputs are ELV. terminals, as shown above. If sockets are used then Kelvin connections are required at the module terminals All flammable materials used in the manufacturing of to avoid measurement errors due to socket contact resistance. these modules are rated 94V-0, or tested to the UL60950 A.2 for reduced thickness. Figure 8. Output Voltage and Efficiency Test Setup. For input voltages exceeding –60 V but less than or dc V . I O O equal to –75 V , these converters have been evaluated dc Efficiency = x 100 %  to the applicable requirements of BASIC INSULATION V . I IN IN 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 ©2016 General Electric Company. All rights reserved. Page 6 BATTERY Data Sheet GE ESTW004A2C Stingray Series DC-DC Converter Power Modules 36–75V Input; 15.0V /4.2A Output dc dc dc output of the module. Care should be taken to ensure Feature Description that the maximum output power of the module remains Remote On/Off at or below the maximum rated power (Maximum rated power = Vo,set x Io,max). 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 SENSE(+) remote On/Off, device code suffix “1”, turns the module SENSE(–) off during a logic high and on during a logic low. Negative logic is the preferred option. VI(+) VO(+) IO SUPPL Y LOAD II VI(-) VO(–) CONTACT CONT ACT AND Vin+ Vout+ RESIST ANCE DISTRIBUTION LOSSE I Figure 10. Circuit Configuration for remote sense . on/off ON/OFF TRIM Input Undervoltage Lockout Von/off At input voltages below the input undervoltage lockout limit, the module operation is disabled. The module will only begin to operate once the input voltage is raised Vout- Vin- above the undervoltage lockout turn-on threshold, VUV/ON. Figure 9. Remote On/Off Implementation. Once operating, the module will continue to operate until To turn the power module on and off, the user must the input voltage is taken below the undervoltage turn- supply a switch (open collector or equivalent) to control off threshold, VUV/OFF. the voltage (Von/off) between the ON/OFF terminal and the Overtemperature Protection VIN(-) terminal (see Figure 9). Logic low is - To provide protection under certain fault conditions, the 0.7Vdc ≤ Von/off ≤ 0.6Vdc. The maximum Ion/off during a logic low is 0.15mA; the switch should maintain a logic low unit is equipped with a thermal shutdown circuit. The level while sinking this current. unit will shutdown if the thermal reference point, T ref1 o o exceeds 135 C (Figure 12, typical), or Tref2 exceeds 120 C During a logic high, the typical maximum Von/off (Figure 13, typical), but the thermal shutdown is not generated by the module is 6.7Vdc, and the maximum intended as a guarantee that the unit will survive allowable leakage current is 25μA. temperatures beyond its rating. The module will If not using the remote on/off feature: automatically restart upon cool-down to a safe For positive logic, leave the ON/OFF pin open. temperature. For negative logic, short the ON/OFF pin to V (-). IN Output Overvoltage Protection Remote Sense The output over voltage protection scheme of the Remote sense minimizes the effects of distribution losses modules has an independent over voltage loop to by regulating the voltage at the remote-sense prevent single point of failure. This protection feature connections (See Figure 11). The voltage between the latches in the event of over voltage across the output. remote-sense pins and the output terminals must not Cycling the on/off pin or input voltage resets the latching exceed the output voltage sense range given in the protection feature. If the auto-restart option (4) is Feature Specifications table: ordered, the module will automatically restart upon an internally programmed time elapsing. [V (+) – V (–)] – [SENSE(+) – SENSE(–)]  0.5 V O O Overcurrent Protection Although the output voltage can be increased by both the remote sense and by the trim, the maximum To provide protection in a fault (output overload) increase for the output voltage is not the sum of both. condition, the unit is equipped with internal The maximum increase is the larger of either the remote current-limiting circuitry and can endure current sense or the trim. limiting continuously. At the point of current-limit inception, the unit enters hiccup mode. If the unit is The amount of power delivered by the module is defined not configured with auto–restart, then it will latch off as the voltage at the output terminals multiplied by the following the over current condition. The module can be output current. When using remote sense and trim, the restarted by cycling the dc input power for at least one output voltage of the module can be increased, which at second or by toggling the remote on/off signal for at the same output current would increase the power least one second. March 8, 2016 ©2016 General Electric Company. All rights reserved. Page 7 Data Sheet GE ESTW004A2C Stingray Series DC-DC Converter Power Modules 36–75V Input; 15.0V /4.2A Output dc dc dc Feature Descriptions (continued) 5.11V  (100%)  511  o,set R   10.22 trimup   If the unit is configured with the auto-restart option (4), it 1.225% %   will remain in the hiccup mode as long as the overcurrent condition exists; it operates normally, once   V V Where desired o,set   %  100 the output current is brought back into its specified   V o,set   range. The average output current during hiccup is 10% For example, to trim-up the output voltage of the module IO, max. by 5% to 15.75V, R is calculated is as follows: trim-up Output Voltage Programming  %  5 Trimming allows the output voltage set point to be 5.1115.0 (100 5) 511   increased or decreased, this is accomplished by R    10.22  trimup   1.225 5 5 connecting an external resistor between the TRIM pin   and either the VO(+) pin or the VO(-) pin. R  1.20M trimup The voltage between the V (+) and V (–) terminals must O O V (+) V (+) IN O not exceed the minimum output overvoltage protection value shown in the Feature Specifications table. This limit R trim-up includes any increase in voltage due to remote-sense ON/OFF compensation and output voltage set-point adjustment LOAD V TRIM O trim. Although the output voltage can be increased by both R trim-down the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. V (-) V (-) IN O 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 Figure 11. Circuit Configuration to Trim Output multiplied by the output current. When using remote Voltage. sense and trim, the output voltage of the module can be increased, which at the same output current would Connecting an external resistor (Rtrim-down) between the increase the power output of the module. Care should be TRIM pin and the V (-) (or Sense(-)) pin decreases the O taken to ensure that the maximum output power of the output voltage set point. To maintain set point accuracy, module remains at or below the maximum rated power the trim resistor tolerance should be ±1.0%. I should O, max (Maximum rated power = V x I ). not be exceeded even trimming to a lower output O,set O,max voltage. Output Current Limit Inception is independent of Thermal Considerations trimmed Vout. The power modules operate in a variety of thermal The following equation determines the required external environments; however, sufficient cooling should be resistor value to obtain a percentage output voltage provided to help ensure reliable operation. change of ∆% 511   Considerations include ambient temperature, airflow, R   10 .22  trimdown    % module power dissipation, and the need for increased   reliability. A reduction in the operating temperature of   V V Where o,set desired the module will result in an increase in reliability. The   %  100   V thermal data presented here is based on physical o,set   measurements taken in a wind tunnel. The thermal For example, to trim-down the output voltage of the reference point, Tref1, used in the specifications for open module by 8% to 13.8V, Rtrim-down is calculated as frame modules is shown in Figure 12. For reliable follows: o operation this temperature should not exceed 130 C. % 8 511  AIRFLOW R  10.22 trimdown   8   R  53 .655 trim down 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 Figure 12. Tref Temperature Measurement Location determines the required external resistor value to obtain for Open Frame Module. a percentage output voltage change of ∆%: March 8, 2016 ©2016 General Electric Company. All rights reserved. Page 8 Data Sheet GE ESTW004A2C Stingray Series DC-DC Converter Power Modules 36–75V Input; 15.0V /4.2A Output dc dc dc Thermal Considerations (continued) The thermal reference point, T , used in the ref2 specifications for modules with heatplate is shown in Figure 13. For reliable operation this temperature should o not exceed 104 C. AIRFLOW o AMBIENT TEMEPERATURE, T ( C) A Figure 13. T Temperature Measurement Location Figure 15. Output Current Derating for the Module ref for Module with Heatplate. with Heatplate; Airflow in the Transverse Direction from V (+) to V (-); V =48V. OUT OUT IN Heat Transfer via Convection Increased airflow over the module enhances the heat Heat Transfer via Conduction transfer via convection. Derating curves showing the The module can also be used in a sealed environment maximum output current that can be delivered by with cooling via conduction from the each module versus local ambient temperature (TA) module’s top surface through a gap pad material to a for natural convection and up to 2m/s (400 ft./min) cold wall, as shown in Figure 16. This capability is forced airflow are shown in Figure 14. achieved by insuring the top side component skyline profile achieves no more than 1mm height difference Please refer to the Application Note “Thermal between the tallest and the shortest power train part Characterization Process For Open-Frame Board- that benefits from contact with the gap pad material. Mounted Power Modules” for a detailed discussion of The output current derating versus cold wall thermal aspects including maximum device temperature, when using a gap pad such as Bergquist temperatures. GP2500S20, is shown in Figure 17. Figure 16. Cold Wall Mounting o AMBIENT TEMEPERATURE, TA ( C) Figure 14. Output Current Derating for the Open Frame Module; Airflow in the Transverse Direction from V (+) to V (-); V =48V. OUT OUT IN o COLDPLATE TEMEPERATURE, T ( C) C Figure 17. Derated Output Current versus Cold Wall Temperature with local ambient temperature around module at 85C; V =48V. IN March 8, 2016 ©2016 General Electric Company. All rights reserved. Page 9 OUTPUT CURRENT, I (A) O OUTPUT CURRENT, I (A) OUTPUT CURRENT, I (A) O O Data Sheet GE ESTW004A2C Stingray Series DC-DC Converter Power Modules 36–75V Input; 15.0V /4.2A Output dc dc dc The CP connector design is able to compensate for large Surface Mount Information amounts of co-planarity and still ensure a reliable SMT Pick and Place o solder joint. Typically, the eutectic solder melts at 183 C o (Sn/Pb solder) or 217-218 C (SAC solder), wets the land, The ESTW004A2C modules use an open frame and subsequently wicks the device connection. Sufficient construction and are designed for a fully automated time must be allowed to fuse the plating on the assembly process. The modules are fitted with a label connection to ensure a reliable designed to provide a large surface area for pick and place operations. The label meets all the requirements Tin Lead Soldering for surface mount processing, as well as safety standards, and is able to withstand reflow temperatures The ESTW004A2C power modules are lead free modules o of up to 300 C. The label also carries product and can be soldered either in a lead-free solder process or in a conventional Tin/Lead (Sn/Pb) process. It is information such as product code, serial number and the recommended that the customer review data sheets in location of manufacture. 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 o reflow temperatures are limited to less than 235 C. o Typically, the eutectic solder melts at 183 C, wets the land, and subsequently wicks the device connection. Figure 18. Pick and Place Location. Sufficient time must be allowed to fuse the plating on the Nozzle Recommendations connection to ensure a reliable solder joint. There are The module weight has been kept to a minimum by several types of SMT reflow technologies currently used using open frame construction. Even so, these modules in the industry. These surface mount power modules have a relatively large mass when compared to can be reliably soldered using natural forced convection, IR (radiant infrared), or a combination of convection/IR. conventional SMT components. Variables such as nozzle For reliable soldering the solder reflow profile should be size, tip style, vacuum pressure and placement speed established by accurately measuring the modules CP should be considered to optimize this process. The connector temperatures. minimum recommended nozzle diameter for reliable operation is 6mm. The maximum nozzle outer diameter, Lead Free Soldering which will safely fit within the allowable component spacing, is 9 mm. The –Z version of the ESTW004A2C modules are lead- free (Pb-free) and RoHS compliant and are both forward Oblong or oval nozzles up to 11 x 9 mm may also be and backward compatible in a Pb-free and a SnPb used within the space available. soldering process. Failure to observe the instructions The surface mountable modules in the ESTW family use below may result in the failure of or cause damage to our newest SMT technology called “Column Pin” (CP) the modules and can adversely affect long-term connectors. Figure 19 shows the new CP connector reliability. 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. Figure 19. Column Pin Connector Before and After Reflow Soldering . March 8, 2016 ©2016 General Electric Company. All rights reserved. Page 10 Data Sheet GE ESTW004A2C Stingray Series DC-DC Converter Power Modules 36–75V Input; 15.0V /4.2A Output dc dc dc Sn/Ag/Cu solder is shown in Figure 22. Surface Mount Information (continued) 300 Per J-STD-020 Rev. C 300 Peak Temp 260°C o 250 Peak Temp 235 C 250 Cooling Cooling 200 Zone zone Heat zone * Min. Time Above 235°C 200 o -1 15 Seconds o -1 1-4 Cs Cs max 4 150 Heating Zone *Time Above 217°C 1°C/Second 60 Seconds 150 100 Soak zo ne 10 0 T above 50 30-240s lim o 205 C 0 50 Preheat zone Reflow Time (Seconds) o -1 max 4 Cs Figure 22. Recommended linear reflow profile using 0 Sn/Ag/Cu solder. REFLOW TIME (S) Figure 20. Reflow Profile for Tin/Lead (Sn/Pb) process ratings of 2 or greater. These sealed packages should 240 not be broken until time of use. Once the original 235 package is broken, the floor life of the product at conditions of  30°C and 60% relative humidity varies 230 according to the MSL rating (see J-STD-033A). The shelf 225 life for dry packed SMT packages will be a minimum of 12 months from the bag seal date, when stored at the 220 following conditions: < 40° C, < 90% relative humidity. 215 Post Solder Cleaning and Drying Considerations 210 Post solder cleaning is usually the final circuit-board 205 assembly process prior to electrical board testing. The 200 result of inadequate cleaning and drying can affect both 0 10 203040 5060 the reliability of a power module and the testability of o Figure 21. Time Limit Curve Above 205 C for Tin/Lead the finished circuit-board assembly. For guidance on (Sn/Pb) process appropriate soldering, cleaning and drying procedures, refer to Lineage Power Board Pb-free Reflow Profile Mounted Power Modules: Soldering and Cleaning Application Note (AN04-001). Power Systems will comply with J-STD-020 Rev. C (Moisture/Reflow Sensitivity Classification for Nonhermetic Solid State Surface Mount Devices) for both Through-Hole Lead-Free Soldering Pb-free solder profiles and MSL classification procedures. Information This standard provides a recommended forced-air- convection reflow profile based on the volume and The RoHS-compliant through-hole products use the SAC thickness of the package (table 4-2). The suggested Pb- (Sn/Ag/Cu) Pb-free solder and RoHS-compliant free solder paste is Sn/Ag/Cu (SAC). The recommended components. They are designed to be processed linear reflow profile using 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 MSL Rating maximum preheat rate of 3C/s is suggested. The wave The ESTW004A2C modules have a MSL rating as stated preheat process should be such that the temperature of in the Device Code table, last page of this document. the power module board is kept below 210C. For Pb Storage and Handling solder, the recommended pot temperature is 260C, while the Pb-free solder pot is 270C max. Not all RoHS- The recommended storage environment and handling compliant through-hole products can be processed with procedures for moisture-sensitive surface mount paste-through-hole Pb or Pb-free reflow process. If packages is detailed in J-STD-033 Rev. A (Handling, additional information is needed, please consult with Packing, Shipping and Use of Moisture/Reflow Sensitive your Lineage Power representative for more details. Surface Mount Devices). Moisture barrier bags (MBB) with desiccant are required for MSL March 8, 2016 ©2016 General Electric Company. All rights reserved. Page 11 MAX TEMP SOLDER (C) REFLOW TEMP (C) Reflow Temp (°C) Data Sheet GE ESTW004A2C Stingray Series DC-DC Converter Power Modules 36–75V Input; 15.0V /4.2A Output dc dc dc 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 VIN = 48V, Io = Io,max, N Line March 8, 2016 ©2016 General Electric Company. All rights reserved. Page 12 Data Sheet GE ESTW004A2C Stingray Series DC-DC Converter Power Modules 36–75V Input; 15.0V /4.2A Output dc dc dc 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 Function 1 Vi(+) 2 ON/OFF 3 Vi(-) 4 Vo(-) 5 SENSE(-) 6 TRIM 7 SENSE(+) 8 Vo(+) March 8, 2016 ©2016 General Electric Company. All rights reserved. Page 13 Data Sheet GE ESTW004A2C Stingray Series DC-DC Converter Power Modules 36–75V Input; 15.0V /4.2A Output dc dc dc 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 Function 1 Vi(+) 2 ON/OFF 3 Vi(-) 4 Vo(-) 5 SENSE(-) 6 TRIM 7 SENSE(+) 8 Vo(+) March 8, 2016 ©2016 General Electric Company. All rights reserved. Page 14 Data Shee et GE ESTW W004A2C C Stingra ay Series s DC-DC Convert ter Powe er Modules 36–75 5V Input; 15.0V /4.2A Outpu ut dc dc dc Mechanical Out tline for Through-Hole e Module w with Heat P Plate (-H Op ption) Dimens sions 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.xxx x in  0.010 in.] ] Top View Side View *F For optional pin n lengths, see T Table 2, Device e Coding Schem me and Options s Bottom m View* * * Bottom side label inclu udes Lineage P Power name, pr roduct designa ation and date code. * Side label contains pro oduct designat tion and date c code. Pin Funct tion 1 Vi(+) 2 ON/O OFF 3 Vi(-) 4 Vo(-) 5 SENSE(-) 6 TRIM 7 SENSE(+) 8 Vo(+) March 8, 2016 ©2016 G General Electric C Company. All righ hts reserved. Page 15 Data Sheet GE ESTW004A2C Stingray Series DC-DC Converter Power Modules 36–75V Input; 15.0V /4.2A Output dc dc dc 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 Function 1 Vi(+) 2 ON/OFF 3 Vi(-) 4 Vo(-) 5 SENSE(-) 6 TRIM 7 SENSE(+) 8 Vo(+) SMT Recommended Pad Layout (Component Side View) Pin Function 1 Vi(+) 2 ON/OFF 3 Vi(-) 4 Vo(-) 5 SENSE(-) 6 TRIM 7 SENSE(+) 8 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 ©2016 General Electric Company. All rights reserved. Page 16 Data Sheet GE ESTW004A2C Stingray Series DC-DC Converter Power Modules 36–75V Input; 15.0V /4.2A Output dc dc dc Each tray contains a total of 12 power modules. The trays Packaging Details are self-stacking and each shipping box for the The surface mount versions of the ESTW004A2C (suffix –S) ESTW004A2C (suffix –S) surface mount module will contain are supplied as standard in the plastic trays shown in 4 full trays plus one empty hold down tray giving a total Figure 24. number of 48 power modules. Tray Specification Material Antistatic coated PVC 12 Max surface resistivity 10 /sq Color Clear Capacity 12 power modules Min order quantity 48 pcs (1 box of 4 full trays + 1 empty top tray) Figure 24. Surface Mount Packaging Tray March 8, 2016 ©2016 General Electric Company. All rights reserved. Page 17 Data Sheet GE ESTW004A2C Stingray Series DC-DC Converter Power Modules 36–75V Input; 15.0V /4.2A Output dc dc dc Ordering Information Please contact your Lineage Power Sales Representative for pricing, availability and optional features. Table 1. Device Codes Output Output On/Off Connector MSL Product Codes Input Voltage Comcodes Voltage Current Logic Type Rating ESTW004A2C41Z 48V (36-75Vdc) 15.0V 4.2A Negative Through hole n/a CC109170461 ESTW004A2C841Z 48V (36-75V) 15.0V 4.2A Negative Through hole n/a CC109170494 dc ESTW004A2C41-HZ 48V (36-75V) 15.0V 4.2A Negative Through hole n/a CC109170486 dc ESTW004A2C41-SZ 48V (36-75V) 15.0V 4.2A Negative Surface mount 2a CC109170478 dc 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 ©2016 General Electric Company. All International rights reserved. Version 1.12