Data Sheet
August 30, 2011
ESTW004A2C Series (Eighth-Brick) DC-DC Converter Power Modul es
36–75Vdc Input; 15.0Vdc/4.2Adc Output
*
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
Document No: DS11-015 ver. 1.0
PDF name: ESTW004A2C.pd
f
Stingray Series™
Features
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)
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: 90% to 110% of V
o,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
Wide operating temperature range (-40°C to 85°C)
Suitable for cold wall cooling using suitable Gap
Pad applied directly to top side of module
UL*Recognized to UL60950-1, CAN/CSA
†
C22.2
No.60950-1, and EN60950-1(
VDE
‡
0805-1)
Licensed
CE mark meets 2006/95/EC directive
§
Meets the voltage and current requirements for
ETSI 300-132-2 and complies with and licensed for
Basic insulation rating per EN60950-1
2250 V
dc
Isolation tested in compliance with IEEE
802.3
¤
PoE standards
ISO
**
9001 and ISO 14001 certified manufacturing
facilities
Applications
Wireless Networks
Access and Optical Network Equipment
Industrial Equipment
Options
Negative Remote On/Off logic (preferred)
Over current/Over temperature/Over voltage
protections (Auto-restart) (preferred)
Heat plate version (-H)
Surface Mount version (-S)
Description
The ESTW004A2C [Stingray™] 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
dc
. The ESTW004A2C
provides 15V
dc
nominal output voltage rated for 4.2A
dc
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 V
IN
=48V
dc
. 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.
RoHS Compliant
Data Sheet
August 30, 2011
ESTW004A2C Series DC-DC Converter Power Modules
36–75Vdc Input; 15.0Vdc/4.2Adc Output
LINEAGE POWER 2
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 TA -40 85 °C
(see Thermal Considerations section)
Storage Temperature All Tstg -55 125 °C
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 IIN,max 2.0 Adc
(VIN= VIN, min to VIN, max, IO=IO, max)
Input No Load Current All IIN,No load 90 mA
(VIN = 48V, IO = 0, module enabled)
Input Stand-by Current All IIN,stand-by 5 8 mA
(VIN = 48V, module disabled)
Inrush Transient All I2t 0.5 A2s
Input Reflected Ripple Current, peak-to-peak
(5Hz to 20MHz, 1μH 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.
Data Sheet
August 30, 2011
ESTW004A2C Series DC-DC Converter Power Modules
36–75Vdc Input; 15.0Vdc/4.2Adc Output
LINEAGE POWER 3
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 VO 14.55 15.45 Vdc
(Over all operating input voltage, resistive load, and
temperature conditions until end of life)
Output Regulation
Line (VIN=VIN, min to VIN, max) All
±0.2 % VO, set
Load (IO=IO
,
min to IO
,
max) All ±0.2 % VO
,
set
Temperature (Tref=TA, min to TA, max) All
±1.0 % VO, set
Output Ripple and Noise
(VIN=48V, IO= IO, max, T
A
=25°C, see Figure 7.)
RMS (5Hz to 20MHz bandwidth) All 35 60 mVrms
Peak-to-Peak (5Hz to 20MHz bandwidth) All 100 180 mVpk-pk
External Capacitance All CO, max 0 2,000 μF
Output Current All IO 0 4.2 Adc
Output Power (IO ≤ IO, max) All PO 0 63 W
Output Current Limit Inception (Hiccup Mode ) All IO, lim 4.6 5.2 6.0 Adc
(VO= 90% of VO, set)
Output Short-Circuit Current All IO, s/c 5 Arms
(VO≤250mV) ( Hiccup Mode )
Efficiency
VIN=48V, TA=25°C, IO=2.1A, VO = 15V All η 88.0 %
VIN=48V, TA=25°C, IO=4.2A, VO= 15V All η 90.0 %
Switching Frequency All fsw 280 kHz
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 Vpk 3 % VO, 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
Calculated Reliability based upon Telcordia SR-332
Issue 2: Method I Case 3 (IO=80%IO, max, TA=40°C,
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.)
Data Sheet
August 30, 2011
ESTW004A2C Series DC-DC Converter Power Modules
36–75Vdc Input; 15.0Vdc/4.2Adc Output
LINEAGE POWER 4
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 (Von/off = -0.7Vdc) All Ion/off 0.15 mA
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
(IO=IO, max , VIN=VIN, nom, TA = 25oC)
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
Output voltage overshoot – Startup All
― 3 % VO, set
IO= IO, max; VIN=VIN, min to VIN, max, TA = 25 oC
Remote Sense Range All VSENSE 10 % VO, set
Output Voltage Adjustment Range All 90 110 % VO, set
Output Overvoltage Protection All VO, limit 17.0 20.0 Vdc
Overtemperature Protection – Hiccup Auto Restart Open
Frame Tref1 135 OC
Heat
Plate Tref2 120 OC
Input Undervoltage Lockout All VUVLO
Turn-on Threshold 34 36 Vdc
Turn-off Threshold 30 32 34 Vdc
Hysteresis 1 2 Vdc
Input Overvoltage Lockout All VOVLO
Turn-on Threshold 76 77 Vdc
Turn-off Threshold 77 79 81 Vdc
Hysteresis 1 2 Vdc
Data Sheet
August 30, 2011
ESTW004A2C Series DC-DC Converter Power Modules
36–75Vdc Input; 15.0Vdc/4.2Adc Output
LINEAGE POWER 5
Characteristic Curves
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.
EFFICIENCY, (%)
OUTPUT VOLTAGE On/Off VOLTAGE
VO (V) (5V/div) VOn/Off (V) (5V/div)
OUTPUT CURRENT, IO (A) TIME, t (10ms/div)
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).
OUTPUT VOLTAGE
VO (V) (100mV/div)
OUTPUT VOLTAGE INPUT VOLTAGE
VO (V) (5V/div) VIN (V) (10V/div)
TIME, t (2s/div) TIME, t (10ms/div)
Figur e 2. Ty pic al ou tp ut ripp le an d noi s e ( Io= Io,max). 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)
TIME, t (200µs/div)
Figure 3. Tr ans ie n t Resp onse to 0.1A
/
µS Dynamic
Load Change from 50% to 75% to 50% of full load,
V
IN
=48
V
.
Data Sheet
August 30, 2011
ESTW004A2C Series DC-DC Converter Power Modules
36–75Vdc Input; 15.0Vdc/4.2Adc Output
LINEAGE POWER 6
Test Configurations
TO OSCILLOSCOPE CURRENT PROBE
LTEST
12μH
BATTER Y
CS 220μF
E. S.R .< 0 .1
@ 20 °C 100kHz
33-100μF
Vi n+
Vin-
NOTE: Measure input reflected ripple current with a simulated
source indu ctance (LTE S T) of 12μH. Capacitor CS offsets
possible battery impedance. Mea sure current as show n
above.
Figure 6. Input Reflected Ripple Current Test
Setup.
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.
V
O
(+)
V
O
(
–
)
RESISTIVE
LOAD
SCOPE
COPPER STRIP
GROUND PLANE
10uF
1uF
+
Figure 7. Output Ripple and Noise Test Setup.
Vout+
Vout-
Vin+
Vin-
RLOAD
Rcontact Rdistribution
Rcontact Rdistribution
Rcontact
Rcontact
Rdistribution
Rdistribution
VIN VO
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 Effici ency Te s t
Setup.
=
VO. IO
VIN. IIN
x 100 %
Efficiency
Design Considerations
Input Filte ring
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-
100μF 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.
Safety Considerations
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 VDE0805-1(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.
Data Sheet
August 30, 2011
ESTW004A2C Series DC-DC Converter Power Modules
36–75Vdc Input; 15.0Vdc/4.2Adc Output
LINEAGE POWER 7
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.
ON/OFF
Vin+
Vin-
Ion/off
Von/off
Vout+
TRIM
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 25μA.
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 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).
Figure 10. Circuit Configuration for remote
sense .
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
turn-off 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.
VO(+)
SENSE(+)
SENSE(–)
VO(–)
VI(+)
VI(-)
IOLOAD
CONTACT AND
DISTRIBUTION LOSS
E
SUPPLY II
CONTACT
RESISTANCE
Data Sheet
August 30, 2011
ESTW004A2C Series DC-DC Converter Power Modules
36–75Vdc Input; 15.0Vdc/4.2Adc Output
LINEAGE POWER 8
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.
VO(+)
VOTRIM
VO(-)
Rtrim-down
LOAD
VIN(+)
ON/OFF
VIN(-)
Rtrim-up
Figur e 11. Circ uit Configuration to Tr im Ou tpu t
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%.
The following equation determines the required
external resistor value to obtain a percentage output
voltage change of Δ%
22.10
%
511
downtrim
R
Where 100% ,
,
seto
desiredseto V
VV
For example, to trim-down the output voltage of the
module by 8% to 13.8V, Rtrim-down is calculated as
follows:
8%
22.10
8
511
downtrim
R
655.53
downtrim
R
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 Δ%:
22.10
%
511
%225.1
%)100(11.5 ,seto
uptrim V
R
Where 100% ,
,
seto
setodesired
V
VV
For example, to trim-up the output voltage of the
module by 5% to 15.75V, Rtrim-up is calculated is as
follows:
5%
22.10
5
511
5225.1 )5100(0.1511.5
uptrim
R
MR uptrim 20.1
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.
Figure 12. Tref Temperature Measurement
Location for Open Frame Module.
AIRFLOW
Data Sh ee t
August 30, 2011
ESTW004A2C Series DC-DC Converter Power Modules
36–75Vdc Input; 15.0Vdc/4.2Adc Output
LINEAGE POWER 9
Thermal Considerations
(continued)
The thermal reference point, T
ref2
,
used in the
specifications for modules with heatplate is shown in
Figure 13. For reliable operation this temperature
should not exceed 104
o
C.
Figure 13. T
ref
Temperature Measureme nt
Location for Module with Heatplate.
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 (T
A
)
for natural convection and up to 2m/s (400 ft./min)
forced airflow are shown in Figure 14.
Please refer to the Application Note “Thermal
Characterization Process For Open-Frame Board-
Mounted Power Modules” for a detailed discussion of
thermal aspects including maximum device
temperatures.
OUTPUT CURRENT, I
O
(A)
AMBIENT TEMEPERATURE, T
A
(
o
C)
Figure 14. Output Current Derating for the Open
Frame Module; Airflow in the Transverse Direction
from V
OUT
(+) to V
OUT
(-); V
IN
=48V.
OUTPUT CURRENT, I
O
(A)
AMBIENT TEMEPERATURE, T
A
(
o
C)
Figure 15. Ou tpu t Current Derating for the Module
with Heatplate; Airflow in the Transverse Direction
from V
OUT
(+) to V
OUT
(-); V
IN
=48V.
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.
Figure 16. Cold Wall Mounting
OUTPUT CURRENT, I
O
(A)
COLDPLATE TEMEPERATURE, T
C
(
o
C)
Figure 17. Derated Output Current versus Cold
Wall Temperature with local ambient temperature
around module at 85C; V
IN
=48V.
AIRFLOW
Data Sheet
August 30, 2011
ESTW004A2C Series DC-DC Converter Power Modules
36–75Vdc Input; 15.0Vdc/4.2Adc Output
LINEAGE POWER 10
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.
Figure 19. Column Pin Connector Before and After
Reflow Soldering .
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 F r ee S o ldering
The –Z version of the ESTW004A2C modules are
lead-free (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.
Data Sheet
August 30, 2011
ESTW004A2C Series DC-DC Converter Power Modules
36–75Vdc Input; 15.0Vdc/4.2Adc Output
LINEAGE POWER 11
Surface Mount Information (continued)
REFLOW TEMP (C)
REFLOW TIME (S)
Figure 20. Reflo w Profile for Tin/Le ad (Sn/ Pb)
process
MAX TEMP SOLDER (C)
Figure 21. Time Limit Curve Above 20 5oC 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-air-convection reflow profile based on the
volume and thickness of the package (table 4-2). The
suggested Pb-free solder paste is Sn/Ag/Cu (SAC).
The recommended linear reflow profile using
MSL Rating
The ESTW004A2C modules have a MSL rating of 2a.
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
Sn/Ag/Cu solder is shown in Figure 23.
Figure 22. Recommended linear reflow profile
using Sn/Ag/Cu solder .
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 30°C 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.
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 Lineage Power Board
Mounted Pow er Module s : Sold ering a nd Clean in g
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 RoHS-compliant 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.
0
50
10 0
15 0
200
250
300
Preheat zone
max 4
o
Cs
-1
Soak zone
30-240s
Heat zone
max 4
o
Cs
-1
Peak Temp 235
o
C
Cooling
zo ne
1- 4
o
Cs
-1
T
lim
above
205
o
C
200
205
210
215
220
225
230
235
240
0 10 203040 5060
Pe r J-STD-020 Rev. C
0
50
100
150
200
250
300
Re flo w Time (Se c ond s)
Reflow Temp (°C )
He ating Zone
1°C/Seco nd
Peak Temp 260°C
* Min. Time Above 235°C
15 Se co nds
*Time Above 217°C
60 Sec onds
Cooling
Zone
Data Sheet
August 30, 2011
ESTW004A2C Series DC-DC Converter Power Modules
36–75Vdc Input; 15.0Vdc/4.2Adc Output
LINEAGE POWER 12
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).
V
IN = 48
V
, Io = Io,max, L Line
V
IN = 48
V
, Io = Io,max, N Line
Data Sheet
August 30, 2011
ESTW004A2C Series DC-DC Converter Power Modules
36–75Vdc Input; 15.0Vdc/4.2Adc Output
LINEAGE POWER 13
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 Lineage Power name, product designation and date code.
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(+)
Data Sheet
August 30, 2011
ESTW004A2C Series DC-DC Converter Power Modules
36–75Vdc Input; 15.0Vdc/4.2Adc Output
LINEAGE POWER 14
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
View*
* Top side label includes Lineage Power name, product designation and date code.
Side
View
Botto
m View
Pin Function
1 Vi(+)
2 ON/OFF
3 Vi(-)
4 Vo(-)
5 SENSE(-)
6 TRIM
7 SENSE(+)
8 Vo(+)
Data Sh ee t
August 30, 2011
ESTW004A2C Series DC-DC Converter Power Modules
36–75Vdc Input; 15.0Vdc/4.2Adc 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.]
Top
View
Side
View
*For optional pin lengths, see Table 2, Device Coding Scheme and Options
Bottom
View*
* Bottom side label includes Lineage Power name, product designation and date code.
* Side label contains product designation and date code.
Pin Function
1 Vi(+)
2 ON/OFF
3 Vi(-)
4 Vo(-)
5 SENSE(-)
6 TRIM
7 SENSE(+)
8 Vo(+)
Data Sheet
August 30, 2011
ESTW004A2C Series DC-DC Converter Power Modules
36–75Vdc Input; 15.0Vdc/4.2Adc Output
LINEAGE POWER 16
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)
Data Sheet
August 30, 2011
ESTW004A2C Series DC-DC Converter Power Modules
36–75Vdc Input; 15.0Vdc/4.2Adc Output
LINEAGE POWER 17
Packaging Details
The surface mount versions of the ESTW004A2C
(suffix –S) are supplied as standard in the plastic trays
shown in Figure 24.
Tray Specification
Material Antistatic coated PVC
Max surface resistivity 1012/sq
Color Clear
Capacity 12 power modules
Min order quantity 48 pcs (1 box of 4 full trays
+ 1 empty top tray)
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.
Figure 24. Surface Mount Packaging Tray
Data Sheet
August 30, 2011
ESTW004A2C Series DC-DC Converter Power Modules
36–75Vdc Input; 15.0Vdc/4.2Adc Output
Document No: DS11-015 ver. 1.0
Ordering Information
Please contact your Lineage Power Sales Representative for pricing, availability and optional features.
Table 1. Device Codes
Product Codes Input Voltage Output
Voltage Output
Current On/Off
Logic Connector
Type Comcodes
ESTW004A2C41Z 48V (36-75V
dc
) 15.0V 4.2A Negative Through hole CC109170461
ESTW004A2C841Z 48V (36-75V
dc
) 15.0V 4.2A Negative Through hole CC109170494
ESTW004A2C41-HZ 48V (36-75V
dc
) 15.0V 4.2A Negative Through hole CC109170486
ESTW004A2C41-SZ 48V (36-75V
dc
) 15.0V 4.2A Negative Surface mount CC109170478
Table 2. Device Coding Scheme and Options
World Wide Headquarter s
Lineage Power Corporatio n
601 Shiloh Road, Plano, TX 75074, USA
+1-888-LINEAGE(546-3243)
(Outside U.S.A.: +1-972-244-WATT(9288))
www.lineagepower.com
e-mail: techsupport1@lineagepower.com
Asia-Pacific H ead quarters
Tel: +86.021.54279977*808
Europe, Mi ddle-East and Africa He adquarters
Tel: +49.89.878067-280
India Headquarters
Tel: +91.80.28411633
Lineage Power reserves the right to make changes to the product(s) or information contained herein without notice. No liability is assumed as a result of their use or
a
pplication. No rights under any patent accompany the sale of any such product(s) or information.
Lineage Power DC-DC products are protected under various patents. Information on these patents is available at www.lineagepower.com/patents.
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2010 Lineage Power Corporation, (Plano, Texas) All International Rights Reserved.
