150037559 - ABB - Datasheet.Directory

Data Sheet

ERCW003A6R Power Modules; DC-DC Converters

36 – 75Vdc Input; 28Vdc Output; 3.6Adc Output

ORCA 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)

• 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 (-40°C to

100°C)

• 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

Applications

• RF Power Amplifier

• Wireless Networks

• Switching Networks

Options

 Output OCP/OVP auto restart

 Shorter pins

 Unthreaded heatsink holes

Description

The

ERCW003A6R ORCA™ 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.

RoHS Compliant

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

Input Voltage

Continuous All VIN -0.3 80 Vdc

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

Output to Case All   500 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

(see Figure 12 for VIN MIN when using trim-up feature)

All VIN 36 48 75 Vdc

Maximum Input Current

(VIN=36V to 75V, IO=IO, max) All IIN,max 3.5 Adc

Inrush Transient All I2t 2 A2s

Input Reflected Ripple Current, peak-to-peak

(5Hz to 20MHz, 12μH source impedance; VIN=0V to 75V, IO= IOmax ;

see Figure 12)

All 35 mAp-p

Input No Load Current

Vin = 48V, (Io = 0, module enabled)

All 70 mAdc

Input Stand-by Current

(Vin = 48V, module disabled)

All 10 mAdc

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 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.

Data Sheet

ERCW003A6R Power Modules; DC-DC Converters

36 – 75 Vdc Input; 28Vdc Output; 3.6Adc Output

Electrical Specifications (continued)

Parameter

Device

Symbol

Min

Typ

Max

Unit

Output Voltage Set-point

(VIN=VIN,nom, IO=IO, max, Tc =25°C)

All

VO, set 27.5 28 28.5 Vdc

Output Voltage Set-Point Total Tolerance

(Over all operating input voltage, resistive load, and temperature

conditions until end of life)

All VO 27.0  29.0 Vdc

Output Regulation

Line (VIN=VIN, min to VIN, max) All 

0.1 0.2 %Vo,set

Load (I

O, min

to I

O, max

)

All



0.1

0.2

o,set

Temperature (Tc = -40ºC to +100ºC) All  0.4 0.75 %Vo,set

Output Ripple and Noise on nominal output

(VIN=VIN, nom and IO=IO, min to IO, max)

RMS (5Hz to 20MHz bandwidth) All  10 20 mVrms

Peak-to-Peak (5Hz to 20MHz bandwidth) All  30 60 mVpk-pk

External Capacitance ( 2.5mΩ< ESR < 80mΩ)1

CO,

220



1500

μF

Output Power (Vo=28V to 35.2V) All PO,max   100 W

Output Current All Io 0 3.6 Adc

Output Current Limit Inception (Constant current until V

trimMIN,

duration <4s)

All IO, lim 4.0   Adc

Output Short Circuit Current (VO≤ 0.25Vdc) All IO, sc 30 Arms

Efficiency

IN, nom

, T

=25°C I

O, max ,

= V

O,set

All η  93.4  %

Switching Frequency fsw  280  kHz

Dynamic Load Response

(∆Io/∆t=1A/10µs; VIN=VIN,nom; Tc=25°C;

Tested with a 220μF aluminum and a 10 µF ceramic capacitor

across the load.)

Load Change from I

= 25%-50%-25% of I

O,max

Peak Deviation

Settling Time (VO<10% peak deviation)

All Vpk



1.5



%VO, set

Load Change from IO= 50%-75%-50% of IO,max:

Peak Deviation

Settling Time (VO<10% peak deviation)

All Vpk



1.5



%VO, set

(∆Io/∆t=10%IO,max /10µs; VIN=VIN,nom; Tc=25°C; Tested with a 470μF

aluminum and a 10 µF ceramic capacitor across the load, see

Figure 16.

Load Change from IO= 0%-120% of IO,max:

Peak Deviation

Settling Time (VO<10% peak deviation)

All Vpk



1.5



%VO, set

Load Change from Io= 120% to 50% of Io,max:

Peak Deviation

Settling Time (Vo<10% peak deviation)

All Vpk



1.5



%VO, set

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.

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   MΩ

General Specifications

Parameter Device Symbol Min Typ Max 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 101.6 109/Hours

MTBF 9,842,207 Hours

Weight (open frame)

All

 22.8  g

0.81 oz.

Weight (heat plate) 29.8 g

1.05 oz.

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

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

All

Ion/off



1.0

Logic Low - On/Off Voltage

All

Von/off



1.2

Vdc

Logic High Voltage – (Typ = Open Collector)

All

Von/off

2.5

Vdc

Logic High maximum allowable leakage current

All

on/off



μA

Turn-On Delay and Rise Times

(Vin=Vin,nom, IO=IO, max, 25C)

Case 1: T

delay

= Time until V

= 10% of V

O,set

from application of

Vin with Remote On/Off set to ON,

All Tdelay 30 ms

Case 2: T

delay

= Time until V

= 10% of V

O,set

from application of

Remote On/Off from Off to On with Vin already applied for at

least one second.

All Tdelay  30 ms

rise

= time for V

to rise from 10% of V

O,set

to 90% of V

O,set

All

rise



Output Voltage Overshoot

3 % VO, set

(IO=80% of IO, max, TA=25°C)

Output Voltage Adjustment

(See Feature Descriptions):

Output Voltage Remote-sense Range All Vsense

2 %Vo,nom

Output Voltage Set-point Adjustment Range (trim)

Note: see Figure 12

All Vtrim 15.0 --- 35.2 Vdc

Output Overvoltage Protection

All

VO, limit



Vdc

Over Temperature Protection

All

Tref

(See Feature Descriptions, Figure 17, open frame version)



135



°C

(See Feature Descriptions, Figure 18, base plate version)



120



°C

Input Under Voltage Lockout

VIN, UVLO

Turn-on Threshold

All

Vdc

Turn-off Threshold

All

Vdc

Hysteresis

All

Vdc

Input Over voltage Lockout

IN, OVLO

Turn-on Threshold

All



79.5

Turn-off Threshold

All



Hysteresis

All

---

Vdc

Data Sheet

ERCW003A6R Power Modules; DC-DC Converters

36 – 75 Vdc Input; 28Vdc Output; 3.6Adc Output

Characteristic Curves

The following figures provide typical characteristics for the ERCW003A6A0R (28V, 3.6A) at 25ºC. The figures are identical for either

positive or negative Remote On/Off logic.

EFFICIENCY (%)

On/Off VOLTAGE OUTPUTVOLTAGE

VON/OFF(V) (2V/div) VO (V) (10V/div)

OUTPUT CURRENT, I

(A)

TIME, t (20ms/div)

Figure 1. Converter Efficiency versus Output Current.

Figure 4. Typical Start-Up Using negative Remote On/Off; C

o,ext

220µF.

OUTPUT VOLTAGE

VO (V) (20mV/div)

INPUT VOLTAGE OUTPUT VOLTAGE

Vin (V) (20V/div) VO(V) (10V/div)

TIME, t (2µs/div)

TIME, t (20ms/div)

Figure 2. Typical Output Ripple and Noise at Room

Temperature and 48Vin; Io = Io,max; Co,ext = 220µF.

Figure 5. Typical Start-Up from V

, on/off enabled prior to V

step; Co,ext = 220µF.

OUTPUT CURRENT OUTPUT VOLTAGE

IO (A) (1A/div) VO(V) (100mV/div)

OUTPUT CURRENT OUTPUT VOLTAGE

(A) (1A/div) V

(V) (100mV/div)

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 = 220µF.

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 = 220µF.

Data Sheet

ERCW003A6R Power Modules; DC-DC Converters

36 – 75 Vdc Input; 28Vdc Output; 3.6Adc Output

Test Configurations

Note: Measure the input reflected-ripple current with a simulated

source inductance (LTEST) of 12 µH. Capacitor CS offsets possible

battery impedance. Measure the current, as shown above.

Figure 7. Input Reflected Ripple Current Test Setup.

Note: Use a Cout (470 µF Low ESR aluminum or tantalum capacitor

typical), a 0.1 µF ceramic capacitor and a 10 µF 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.

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.

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 150μF 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.

Output Capacitance

The ERCW003A6R power module requires a minimum

output capacitance of 220µF 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

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 internally-

generated 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.

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 50μA.

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(-).

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 over-

voltage 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 milli-

seconds, 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.

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.:

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 Single-

Module 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.

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 ∆%.

_ =󰇣

% 10.22󰇤

Where % = ,,

, ×100

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 betw een

the SENSE(+) and TRIM pins, the output voltage set

point (Vo,adj) increases (see Figure 14).

The following equation determines the required external-

resistor value to obtain a percentage output voltage change

of ∆%.

Data Sheet

ERCW003A6R Power Modules; DC-DC Converters

36 – 75 Vdc Input; 28Vdc Output; 3.6Adc Output

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.

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

%40100

28 8.1628

%=×

−

=∆

Ω=











−= kR

downadj

56.222.10

511

To trim up the output of a nominal 28V module to 32.0V

%3.14100

28 280.32

%=×

−

=∆

Ω











−−

××

=KR

upadj

.10

3.14 )511(

3.14

225.1 )3.14

100(2811.5

Radj_up = 887kΩ

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

Δ%. 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

SENSE(-)

Vo(–)

DAC R

LOAD

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.

Figure 16. AC-DC Load Profile

The output voltage peak deviation shall not exceed the peak

values listed in the Electrical Specifications Table.

Over Temperature Protection

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 ºC (typical)

for open frame version, and 120 ºC for base plate version.

the converter will shut down and disable the output. When

the base plate temperature has decreased by

approximately 20 ºC the converter will automatically restart.

Thermal Considerations

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

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.

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 ºC.

Figure 17. Case (TREF ) Temperature Measurement

Location (top view).

The thermal reference points, Tref, used in the

specifications for base plate module is shown in Figure

18. For reliable oper at ion, the temperature should not

exceed 113 ºC.

Figure 18. Case (TREF ) Temperature Measurement

Location (top view).

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 ºC. For application 2, the module is cooled by heat

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 19. Cold Wall Mounting

Output Current, IO (A)

Ambient Temperature, T

(oC)

Figure 20. Derating Output Current vs. Cold Wall

Temperature with local ambient temperature around

module at 85C; Vin =48V

Output Current, I

(A)

Ambient Temperature, T

(oC)

Figure 21. Derating Output Current vs. local Ambient

temperature and Airflow, open frame or No baseplate,

Vin=48V, airflow from Vi(-) to Vi(+).

Tref1

Data Sheet

ERCW003A6R Power Modules; DC-DC Converters

36 – 75 Vdc Input; 28Vdc Output; 3.6Adc Output

Output Current, I

(A)

Ambient Temperature, T

(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 3°C/s is

suggested. The wave preheat process should be such that

the temperature of the power module board is kept below

210°C. For Pb solder, the recommended pot temperature is

260°C, while the Pb-free solder pot is 270°C 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.

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

PET (1mm)

Max surface

resistivity

-10

Ω/PET

Color

Clear

Capacity

18 power modules

Min order quantity

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

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

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.]

Data Sheet

ERCW003A6R Power Modules; DC-DC Converters

36 – 75 Vdc Input; 28Vdc Output; 3.6Adc Output

Mechanical Outline for Through-Hole Module with ¼ 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.]

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

Hole Dia mm [in]

Pad Dia mm [in]

1, 2, 3, 5, 6, 7

1.6 [.063]

2.1 [.083]

4, 8

2.2 [.087]

3.2 [.126]

Preliminary Data Sheet

ERCW003A6R Power Modules; DC-DC Converters

36 – 75 Vdc Input; 28Vdc Output; 3.6Adc Output

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.

Ordering Information

Input Voltage

Output

Voltage

Output

Current

Efficiency

Connector

Type

MSL

Rating

Product codes Comcodes

48V (36-75Vdc) 28V 3.6A 93% Through hole 2a ERCW003A6R41Z 150037559

48V (36-75Vdc) 28V 3.6A 93% Through hole 2a ERCW003A6R41-HZ 150037560