GE Industrial Solutions ESTW025A0F User Manual

Data Sheet

October 11, 2011

ESTW025A0F Series (Eighth-Brick) DC-DC Converter Power Modules

36–75Vdc Input; 3.3Vdc Output; 25A Output Current

STINGRAY™ SERIES

RoHS Compliant

Applications

 Distributed power architectures

 Wireless networks

 Access and optical network Equipment

 Enterprise Networks including Power over Ethernet

(PoE)

 Latest generation IC’s (DSP, FPGA, ASIC) and

Microprocessor powered applications

Options

 Negative Remote On/Off logic (-1 option,

preferred/standard)

 Surface Mount version (-S option)

 Auto-restart (-4 option, preferred/standard)

 Trimmed leads (-6 or -8 options)

Features

 Wide input voltage range: 36-75 Vdc

 Delivers up to 25A Output current

 Monotonic startup into prebiased load

 Output Voltage adjust: 80% to 110% of V

o,nom

 Remote sense

 Constant switching frequency

 Positive remote On/Off logic

 Input under voltage protection

 Output overcurrent and overvoltage protection

 Over-temperature protection

 Industry standard, DOSA compliant footprint

57.9mm x 22.8mm x 8.5mm

(2.28 in x 0.9 in x 0.335 in)

 Low profile height and reduced component skyline

 Suitable for cold wall cooling using suitable Gap

Pad applied directly to top side of module

 High efficiency 92% at full load (Vin=48V

)

 No thermal derating up to 68°C, 1.0m/s (200 LFM)

 Wide operating temperature range (-40°C to 85°C)

 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)

 UL* 60950-1, 2

Ed. Recognized, CSA

60950-1-07 Certified, and VDE

‡

†

C22.2 No.

(EN60950-1, 2nd

Ed.) 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

802.3

 ISO

Isolation tested in compliance with IEEE

PoE standards

9001 and ISO 14001 certified manufacturing

facilities

Description

The ESTW025A0F series, Eighth-brick power modules are isolated dc-dc converters that can deliver up to 25A of output current and provide a precisely regulated output voltage over a wide range of input voltages (Vin = 36 -75V module achieves typical full load efficiency of 92% at 3.3V

output voltage. The open frame modules construction, available

in both surface-mount and through-hole packaging, enable designers to develop cost- and space-efficient solutions.

UL is a registered trademark of Underwriters Laboratories, Inc.

†

CSA is a registered trademark of Canadian Standards Associ ation.

‡

VDE is a trademark of Verband Deutscher Elektrotechniker e.V.

This product is intended for integration into end-user equipm ent . All of the required procedures of end-use e quipment should be followed. ¤ IEEE and 802 are registered trademarks of the Institute of Electrical and Electronics Engineers, Incorporated. ** ISO is a re

istered trademark of the International Organization of Standards

). The

Document No: DS09-013 ver.1.01

PDF name: ESTW025A0F.pd

Data Sheet October 11, 2011

ESTW025A0F Series Eighth-Brick Power Modules

36–75Vdc Input; 3.3Vdc Output; 25A Output

Absolute Maximum Ratings

Stresses in excess of the absolute maximum ratings can cause permanent damage to the device. These are absolute stress ratings only, functional operation of the device is not implied at these or any other conditions in excess of those given in the operations sections of the data sheet. Exposure to absolute maximum ratings for extended periods can adversely affect the device reliability.

Parameter Device Symbol Min Max Unit

Input Voltage

Continuous All V

Transient, operational (≤100 ms) All V

Operating Ambient Temperature All T

Maximum Base-plate Operating Temperature -18H, H T

IN,trans

-0.3 80 Vdc

-0.3 100 Vdc

-40 85 °C

-40 110 °C

(see Thermal Considerations section)

Storage Temperature All T

I/O Isolation voltage (100% factory Hi-Pot tested) All

stg

 

-55 125 °C

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

(VIN= V

IN, min

to V

IN, max

, IO=I

Input No Load Current

(VIN = V

, IO = 0, module enabled)

IN, nom

Input Stand-by Current

(VIN = V

, module disabled)

IN, nom

O, max

)

All I

IN,max

IN,No load

IN,stand-by

Inrush Transient All I2t 1 A2s

2.7 Adc

50 mA

6 8 mA

Input Reflected Ripple Current, peak-to-peak (5Hz to 20MHz, 1μH source impedance; V IO= I

; See Test configuration section)

Omax

IN, min

to V

IN, max,

All 30 mA

p-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 5 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.

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Data Sheet

October 11, 2011

ESTW025A0F Series Eighth-Brick Power Modules

36–75Vdc Input; 3.3Vdc Output; 25A Output

Electrical Specifications (continued)

Parameter Device Symbol Min Typ Max Unit

Nominal Output Voltage Set-point

VIN=V

IN, nom

, IO=I

, TA=25°C) All V

O, max

O, set

Output Voltage

(Over all operating input voltage, resistive load, and

All V

temperature conditions until end of life)

Output Regulation

Line (VIN=V Load (IO=I

Temperature (T

IN, min

O, min

to V

to I

O, max

ref=TA, min

) All

IN, max

)

to T

) All  ±0.2

A, max

All

  10 mV

Output Ripple and Noise on nominal output

(Co=1uF,ceramic+10uF,tantalum, VIN=V

max

, TA=T

min

to T

max

)

IN, nom

,IO= I

RMS (5Hz to 20MHz bandwidth) All

Peak-to-Peak (5Hz to 20MHz bandwidth) All

External Capacitance 1 All C

Output Current All I

Output Current Limit Inception (Hiccup Mode ) (VO= 90% of V

O, set

)

Output Short-Circuit Current (VO≤250mV)

( Hiccup Mode)

All

All I

O, max

O, lim

O, s/c

Efficiency

VIN= V

Switching Frequency All f

, TA=25°C, IO=I

IN, nom

, TA=25°C, IO=10A

IN, nom

, TA=25°C, IO=5A

IN, nom

O, max , VO

, VO

= V

, VO

= V

All η 91.0 92.0 %

O,set

= V

All η 91.0 92.0 %

O,set

All η 85.5 87.0 %

O,set

Dynamic Load Response

(Co=1uF,ceramic+220uF,tantalum, dIo/dt=0.1A/s; V

= 48V; TA=25°C)

Load Change from Io= 50% to 75% or 25% to 50% of I

o,max

Peak Deviation All V

Settling Time (Vo<10% peak deviation)

1. See Note 2 under Feature Specifications.

All t

3.250 3.300 3.350 V

3.200

 



3.400 V

±0.1 % V

 

8 20 mV

40 75 mV

 

20,000 μF

25.0 Adc

% V

O, set

rms

pk-pk

26.3 29 32.5 Adc

1.6 A

rms

355 kHz



127

200



 s

Isolation Specifications

Parameter Device Symbol Min Typ Max Unit

Isolation Capacitance All C

Isolation Resistance All R

I/O Isolation Voltage (100% factory Hi-pot tested) All All

iso

 

1000

 

2250 Vdc

MΩ

General Specifications

Parameter Device Symbol Min Typ Max Unit

Calculated Reliability based upon Telcordia SR-332 Issue 2: Method

I Case 3 (I

=80%I

O, max

, TA=40°C,

airflow = 200 lfm, 90% confidence)

All FIT 229.4 10

All MTBF 4,359,904 Hours

Weight (Open Frame) All 22 (0.78)

Weight (with Heatplate) All 35 (1.23)

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/Hours

g(oz)

Data Sheet October 11, 2011

ESTW025A0F Series Eighth-Brick Power Modules

36–75Vdc Input; 3.3Vdc Output; 25A 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=V Signal referenced to V 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 I

Logic Low - On/Off Voltage All V

Logic High Voltage – (Typ = Open Collector) All V

Logic High maximum allowable leakage current All I

Turn-On Delay1 and Rise Times

(IO=I

Case 1: Input power is applied for >1 second and then

the On/Off input is set to ON (T On/Off signal is ON until V

Case 2: On/Off input is set to Logic Low (Module ON) and then input power is applied (T at which V

Output voltage Rise time (time for Vo to rise from 10% of V

Output voltage overshoot – Startup

IO= I

Prebias Output Load Performance:

Output Start up characteristic All Monotonic

Back Bias current drawn from output (Module Enabled) All

Remote Sense Range All V

Output Voltage Adjustment Range All -20 +10 % V

Output Overvoltage Protection (CO=470μF)2 All V

Overtemperature Protection – Hiccup Auto Restart All T

Input Undervoltage Lockout All V

Turn-on Threshold

Turn-off Threshold

Hysteresis 1.0 2.0

1. The module has an adaptable extended Turn-On Delay interval, T

2. The module requires a minimum of 470

to V

IN, min

O, max , VIN=VIN, nom, TA

= V

to 90% of V

o,set

; VIN=V

O, max

; open collector or equivalent,

IN, max

terminal)

IN-

on/off

 

-0.7

2.4

 

0.15 mA

0.6 Vdc

15.0 Vdc

25 μA

= 25oC)

until Vo=10% of V

IN, min

)

o, set

to V

IN, min

IN, max

= time from instant

delay

= 10% of V

O, set

delay

O,set

)

= time

)

All T

, TA = 25 oC

All

― 12 ― msec

delay

― 20 ― msec

delay

rise

SENSE

O, limit

ref

UVLO

― 4 ― msec

― 5 % V

-15

10 % V

3.9 5.1 Vdc



125



30.5 32.0

34.0 35.5 V

 

, of 25mS. The extended T following the rapid cycling of Vin from normal levels to less than the Input Undervoltage Lockout (which causes module shutdown), and then back to normal.

exceeding the OVP maximum limits during startup into open loop fault conditions.

μF external output capacitor to prevent shutdown during full load to no load transients and to avoid

delay

will occur when the module restarts

delay

Vdc

O, set

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Data Sheet October 11, 2011

ESTW025A0F Series Eighth-Brick Power Modules

36–75Vdc Input; 3.3Vdc Output; 25A Output

Characteristic Curves

The following figures provide typical characteristics for the ESTW025A0F (3.3V, 25A) at 25oC. The figures are identical for either positive or negative remote On/Off logic.

(V) (200mV/div)

EFFICIENCY,  (%)

Io(A) (5A/div) V

OUTPUT CURRENT, IO (A) TIME, t (200µs/div)

Figure 1. Converter Efficiency versus Output Current.

OUTPUT CURRENT OUTPUT VOLTAGE

Figure 4. Transient Response to 0.1A/µS Dynamic Load Change from 50% to 75% to 50% of full load.

(V) (20mV/div)

OUTPUT VOLTAGE

TIME, t (2s/div)

Figure 2. Typical output ripple and noise (V

o = Io,max).

(V) (200mV/div)

Io(A) (5A/div) V

OUTPUT CURRENT OUTPUT VOLTAGE

TIME, t (200µs/div) TIME, t (5ms/div)

IN = VIN,NOM,

Figure 3. Transient Response to 0.1A/µS Dynamic

Load Change from 25% to 50% to 25% of full load.

(V) (1V/div)

(V) (5V/div) V

On/off

On/Off VOLTAGE OUTPUT VOLTAGE

TIME, t (10ms/div)

Figure 5. Typical Start-up Using Remote On/Off,

negative logic version shown (VIN = VIN,NOM, Io = Io,max).

(V) (1V/div)

(V) (20V/div V

INPUT VOLTAGE OUTPUT VOLTAGE

Figure 6. Typical Start-up Using Input Voltage (VIN =

IN,NOM, Io = Io,max).

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Data Sheet

October 11, 2011

Test Configurations

SCOPE

Vout+

Vout-

CURRENT PROBE

100μF

RESISTIVE LOAD

x 100 %

Vin+

Vin-

contactRdistribution

LOAD

TO OSCILLOSCOPE

TEST

12μH

CS 220μF

BATTERY

NOTE: Measure in put reflected ri pple current wit h a simula ted

E.S.R.<0.1

@ 20°C 100k H

sourc e induct ance (L possibl e battery imped ance. Measure cu rrent as shown above.

) of 12 μH. Capa citor CS offsets

TEST

Figure 7. Input Reflected Ripple Curren t Te st Setup.

COPPER STRIP

(+)

( – )

0.01uF

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.

0.1uF

GROUND PLANE

10uF

Figure 8. Output Ripple and Noise Test Setup.

contact

distribution

contact

distribution

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 term inals to avoid measurement errors due to socket cont act resistance.

Vin+

Vin-

Figure 9. Output Voltage and Efficiency Tes t Setup.

. I

Efficiency



VIN. I

ESTW025A0F Series Eighth-Brick Power Modules

36–75Vdc Input; 3.3Vdc Output; 25A Output

Design Considerations

Input Filtering

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 7 a 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 V

pin and one V

pin are to be grounded,

OUT

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 5 A fast-acting fuse in the ungrounded lead.

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