GE Industrial Solutions JRCW450R User Manual

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Data Sheet

JRCW450R Orca* Series; DC-DC Converter Power Modules

36–75 Vdc Input; 32Vdc Output; 450W Output

RoHS Compliant

Applications

 RF Power Amplifier  Wireless Networks  Switching Networks

Options

 Output OCP/OVP auto restart  Shorter pins  Unthreaded heatsink holes  Tunable Loop for transient response optimization

Features

 Compliant to RoHS II EU Directive 2011/65/EC (-Z versions)  Compliant to REACH Directive (EC) No 1907/2006

 High power density: 166 W/in  Very high efficiency: >94% Typ at Full Load  Industry standard half-brick pin-out  Low output ripple and noise  Industry standard, DOSA compliant half-brick footprint

57.7mm x 60.7mm x 12.7mm (2.27” x 2.39” x 0.5”)

 Remote Sense  2:1 input voltage range  Single tightly regulated output  Constant switching frequency  Constant Current Overcurrent limit  Latch after short circuit fault shutdown  Over temperature protection auto restart  Output voltage adjustment trim, 16.0V  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

 ISO

9001 and ISO 14001 certified manufacturing facilities

 Compliant to IPC-9592A, Category 2, Class II

to 35.2Vdc

‡

0805-1 (EN60950-1, 2nd Ed.) Licensed

Description

The JRCW450R Orca series of dc-dc converters are a new generation of isolated, very high efficiency DC/DC power modules providing up to 450W output power in an industry standard, DOSA compliant half-brick size footprint, which makes it an ideal choice for high voltage and high power applications. Threaded-through holes are provided to allow easy mounting or addition of a heatsink for high-temperature applications. The output is fully isolated from the input, allowing versatile polarity configurations and grounding connections. This module contains an optional new feature, the Tunable Loop, that allows the user to optimize the dynamic response of the converter to match the load with reduced amount of output capacitance, leading to savings on cost and PWB area.

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.

** ISO is a registered trademark of the International Organization of Standards

Data Sheet

JRCW450R Orca Series; DC-DC Converter Power

Modules

36–75 Vdc Input; 32.0Vdc Output; 450W 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 Ta

Operating Case Temperature (See Thermal Considerations section, Figure 17)

Storage Temperature All T

I/O Isolation Voltage: Input to Case, Input to Output All

Output to Case All

All Tc -40 100 °C

IN,trans

stg

   

-0.3 80 Vdc

-0.3 100 Vdc

-40 85 °C

-55 125 °C

1500 Vdc

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 V

Maximum Input Current

(VIN=36V to 75V, IO=I

Inrush Transient All I2t 2 A2s

Input Reflected Ripple Current, peak-to-peak (5Hz to 20MHz, 12H source impedance; V see Figure 7)

Input Ripple Rejection (120Hz) All 50 dB

when using trim-up feature)

IN MIN

) All I

O, max

=0V to 75V, IO= I

Omax

;

All V

All 20 mA

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 25 A 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.

36 48 75 Vdc

IN,max

14.0 Adc

p-p

Data Sheet

JRCW450R Orca Series; DC-DC Converter Power

Modules

36–75 Vdc Input; 32.0Vdc Output; 450W Output

Electrical Specifications (continued)

Parameter Device Symbol Min Typ Max Unit

Output Voltage Set-point (V

IN=VIN,nom

, IO=I

O, max

, Tc =25°C)

All V

O, set

Output Voltage Set-Point Total Tolerance (Over all operating input voltage, resistive load, and temperature

All V

conditions until end of life) Output Regulation

Line (VIN=V Load (IO=I

IN, min

O, min

to V

) All

IN, max

to I

) All

O, max

Temperature (Tc = -40ºC to +100ºC) All

Output Ripple and Noise on nominal output

(VIN=V

IN, nom

and IO=I

O, min

to I

)

O, max

RMS (5Hz to 20MHz bandwidth) All

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

All,

except -T

-T C

All I

O,max

O, lim

O, sc

All  94.0 94.4

External Capacitance (ESR

Without the Tunable Loop (ESR With the Tunable Loop (ESR > 50 m)

> TBD m)

MAX

= 80m)

-T C

Output Power (Vo=32V to 35.2V) All P

Output Current All I Output Current Limit Inception (Constant current until Vo<V

trimMIN

duration <4s) Output Short Circuit Current (VO 0.25Vdc)

Hiccup mode 5 A

Efficiency V

IN=VIN, nom

, Tc=25°C IO=I

O, max , VO

= V

O,set

Switching Frequency f

Dynamic Load Response

(Io/t=1A/10s; Vin=Vin,nom; Tc=25°C; Tested with a 470 F

aluminum and a 10 µF ceramic capacitor across the load.)

Load Change from Io= 50% to 75% of Io,max:

Settling Time (Vo<10% peak deviation)

Peak Deviation

All

Load Change from Io= 25% to 50% of Io,max:

Note: use a minimum 2 x 220uF output capacitor. Recommended capacitor is Nichicon CD series, 220uF/35V. If the ambient temperature is less

than -20

C, use more than 3 of recommended minimum capacitors.

External capacitors may require using the new Tunable Loop feature to ensure that the module is stable as well as getting the best transient

response. See the Tunable Loop section for details.

Settling Time (Vo<10% peak deviation)

Peak Deviation

31.5 32 32.5 V

31.0

  

 



0.1 0.2 %V

0.25 0.5 %V

45 55 mV

80 200 mV

440 6500 F

440 470 F 440 10,000 F

 

0 14.0 Adc

16.0



60 Apk



175

 

1.5

33.0 V

o,set

rms

pk-pk

450 W

20.0 Adc

rms

kHz

O, set



 

Isolation Specifications

Parameter Symbol Min Typ Max Unit

Isolation Capacitance C

Isolation Resistance R

iso



 

M

)

Data Sheet

JRCW450R Orca Series; DC-DC Converter Power

Modules

36–75 Vdc Input; 32.0Vdc Output; 450W Output

General Specifications

Parameter Device Symbol Min Typ Max Unit

Calculated Reliability based upon Telcordia SR-332 Issue 3:

I Case 3 (I

Method confidence

=80%I

, TA=40°C, airflow = 200 lfm, 90%

O, max

All

Weight All

FIT 214.5 10

MTBF 4,661,316 Hours



76.4



2.69 oz.

/Hours

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

Turn-On Delay and Rise Times (Vin=V

Case 1: T

with Remote On/Off set to ON,

Case 2: T Remote On/Off from Off to On with V one second.

Output Voltage Overshoot (IO=80% of I

Output Voltage Adjustment (See Feature Descriptions):

Output Voltage Remote-sense Range (onl Output Voltage Set-point Adjustment Range (trim)

Output Overvoltage Protection

Over Temperature Protection All T (See Feature Descriptions, Figure 17) Input Under Voltage Lockout V

Input Over voltage Lockout V

IN, min

to V

; open collector or equivalent,

IN, max

terminal)

IN-

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

, IO=I

in,nom

delay

, 25C)

O, max

= Time until VO = 10% of V

from application of Vin

O,set

from application of

O,set

already applied for at least

All T

All,

= time for VO to rise from 10% to 90% of V

rise

O,set

except -T

All with -T

, TA=25°C)

O, max

for No Trim or Trim down application )

All V

Turn-on Threshold All Turn-off Threshold All

Hysteresis All

Turn-on Threshold All Turn-off Threshold All

Hysteresis All

on/off

delay

rise



 

5 V

 



120

110

1.0 mA

1.2 Vdc

50 A



3 % V

sense

16.0 --- 35.2 Vdc

trim

O, limit

ref

IN, UVLO

IN, OVLO

37 

35 36 Vdc

31 32 Vdc

3 Vdc

 81 83

--- 3 --- Vdc



110

79.5 81 V

2 %V

40 Vdc



o,nom

°C

Vdc

O, set

/Off VOLTAGE OUTPUT

VOLTAGE

INPUT VOLTAGE OUTPUT VOLTAGE

Data Sheet

JRCW450R Orca Series; DC-DC Converter Power

Modules

36–75 Vdc Input; 32.0Vdc Output; 450W Output

Characteristic Curves

The following figures provide typical characteristics for the JRCW450R (32V, 14A) at 25ºC. The figures are identical for either positive or negative Remote On/Off logic.

(V) (10V/div)

EFFICIENCY (%)

(V) (5V/div) V

OUTPUT CURRENT, Io (A) TIME, t (40ms/div)

Figure 1. Converter Efficiency versus Output Current.

ON/OFF

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

= 440µF.

o,ext

(V) (100mV/div)

OUTPUT VOLTAGE

TIME, t (1s/div)

Figure 2. Typical Output Ripple and Noise at Room

= I

; C

Temperature and 48Vin; I

(V) (500mV/div)

(A) (5A/div) V

OUTPUT CURRENT OUTPUT VOLTAGE

o,max

TIME, t (1ms/div)

= 440µF.

o,ext

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, C

= 440µF.

o,ext

(V) (10V/div)

(V) (20V/div) V

Figure 5. Typical Start-Up V

OUTPUT CURRENT OUTPUT VOLTAGE

step; C

(V) (500mV/div)

(A) (5A/div) V

= 470µF.

o,ext

TIME, t (40ms/div)

from VIN, on/off enabled prior to

TIME, t (1ms/div)

Figure 6. Dynamic Load Change Transient Response from 50 % to 75% to 50% of Full Load at Room Temperature and 48 Vin; 0.1A/uS, C

= 440µF.

o,ext

Data Sheet

JRCW450R Orca Series; DC-DC Converter Power

36–75 Vdc Input; 32.0Vdc Output; 450W 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 470F Low ESR aluminum capacitor, C ensure the stability of the unit. Consult the factory for further application guidelines.

, mounted close to the power module helps

Output Capacitance

The JRCW450R power module requires a minimum output capacitance of 440µF Low ESR aluminum capacitor, C 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 2

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

(+) and VO(+) are grounded simultaneously.

Modules

Ed., and VDE0805-1 EN60950-1, 2nd Ed.

out

Data Sheet

JRCW450R Orca Series; DC-DC Converter Power

36–75 Vdc Input; 32.0Vdc Output; 450W 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 25 A fast-acting or time-delay fuse in the ungrounded input connection.

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.

To turn the power module on and off, the user must supply a switch (open collector or equivalent) to control the voltage

) between the ON/OFF terminal and the VIN(-) terminal

on/off

(see Figure 10). Logic low is 0V  V

during a logic low is 1mA, the switch should be maintain

on/off

a logic low level whilst sinking this current. During a logic high, the typical maximum V

the module is 5V, and the maximum allowable leakage current at V

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 V

= 5V is 50A.

on/off

 1.2V. The maximum

on/off

generated by

on/off

(-).

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 V to low to support V circuit load condition exists, the module will shutdown immediately.

A latching shutdown option is standard. Following shutdown, the module will remain off until the module is reset by either cycling the input power or by toggling the on/off pin for one second. An auto-restart option (4) is also available in a case where an auto recovery is required. If overcurrent greater than 19A 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.

Modules

. If the load resistance is

trimMIN

in an overcurrent condition or a short

trimMIN

Data Sheet

JRCW450R Orca Series; DC-DC Converter Power

36–75 Vdc Input; 32.0Vdc Output; 450W Output

Feature Description (continued)

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.:

(+)–Vo(-)] – [SENSE(+) – SENSE(-)]  2% of V

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 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.

(+) and SENSE(-) to Vo(-) at the module.

o,nom

Vout (V)

35 40 45 50 55 60 65 70 75

Figure 12. Output Voltage Trim Limits vs. Input Voltage.

Trim Down – Decrease Output Voltage

With an external resistor (R SENSE(-) pins, the output voltage set point (V (see Figure 13). The following equation determines the required external-resistor value to obtain a percentage output voltage change of %.

For output voltages:

Without –T Option



downadj 2

 kR

 

Where,



= Desired output voltage set point (V).

desired

Modules

O,nom

100













desirednomo





nomo

Upper Trim Limit

Lower Trim Limit

Vin (V)

) between the TRIM and

adj_down

= 32V

With –T Option



 kR downadj 11

 

100%

) decreases

o,adj

1000









 

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.

Figure 13. Circuit Configuration to Decrease Output Voltage.

Trim Up – Increase Output Voltage

With an external resistor (Radj_up) connected between the SENSE(+) and TRIM pins increases (see Figure 14).

The following equation determines the required externalresistor value to obtain a percentage output voltage change of %.

, the output voltage set point (V

o,adj

)

Data Sheet

JRCW450R Orca Series; DC-DC Converter Power

36–75 Vdc Input; 32.0Vdc Output; 450W Output

Feature Description (continued)

For output voltages: V

Without –T Option



nomO

upadj

With –T Option

Where,



desired

 k

 

27122



 kR upadj 12.15

= Desired output voltage set point (V).









nomodesired



nomo

O,nom

100%





 



= 32V

%)100(



%225.1









%)2(100(





 

_ KR downadj

To trim up the output of a nominal 32V module, without –T option, to 35.2V

% 



adj _ up





_ upadj

 

= 275.3k

Active Voltage Programming

For both the JRCW450Rx and JRCW450Rx-T, 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 R step and range of the DAC and the desired values for trim-up and trim-down representative to obtain more details on the selection for this resistor.

Modules

100

 





%. Please contact your GE technical



 1052



5.47



322.35



)10100(32





10225.1

will be dependent on the voltage

%10100





)102(100(





 

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 32V module, without –T option, to 16.8V

8.1632



% 



%5.47100

Figure 15. Circuit Configuration to Actively Adjust the Output Voltage.

Tunable Loop

The JRCW450Rx-T modules have a new feature that optimizes transient response of the module called Tunable Loop.

External capacitors are usually added to the output of the module for two reasons: to reduce output ripple and noise and to reduce output voltage deviations from the steadystate value in the presence of dynamic load current changes. Adding external capacitance however affects the voltage control loop of the module, typically causing the loop to slow down with sluggish response. Larger values of external capacitance could also cause the module to become unstable.

The Tunable Loop voltage control loop to match the filter network connected to the output of the module. The Tunable Loop by connecting a series R-C between the SENSE(+) and TRIM pins of the module, as shown in Fig. 16. This R-C allows the

allows the user to externally adjust the

is implemented

JRCW450R Orca Series; DC-DC Converter Power Modules

36–75 Vdc Input; 32.0Vdc Output; 450W Output

user to externally adjust the voltage loop feedback compensation of the module.

Figure 16. Circuit diagram showing connection of R

to tune the control loop of the module.

TUNE

and

Table 1 shows the recommended values of R

TUNE

and C

TUNE

for different values of electrolytic output capacitors up to 8800uF that might be needed for an application to meet output ripple and noise requirements.

Table 1. General recommended values of R

TUNE

and C

TUNE

for various external electrolytic capacitor values.

(µF) 1100 2200 4400 6600 8800

out

ESR (mΩ) 60 30 15 10 7.5

TUNE

12k 4.7k 1.8k 820 390

220nF 220nF 220nF 220nF 220nF

Please contact your GE technical representative to obtain more details of this feature as well as for guidelines on how to select the right value of external R-C to tune the module for best transient performance and stable operation for other output capacitance values.

Over Temperature Protection

The JRCW450R module provides a non-latching over temperature protection. A temperature sensor monitors the operating temperature of the converter. If the reference temperature, T ºC (typical), 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. 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.

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 by measuring the case temperature. Peak temperature (T occurs at the position indicated in Figure 17.

, (see Figure 17) exceeds a threshold of 115

REF 1

REF

)

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, using automated thermo-couple instrumentation to monitor key component temperatures: FETs, diodes, control ICs, magnetic cores, ceramic capacitors, opto-isolators, and module pwb conductors, while controlling the ambient airflow rate and temperature. For a given airflow and ambient temperature, the module output power is increased, until one (or more) of the components reaches its maximum derated operating temperature, as defined in IPC-9592. This procedure is then repeated for a different airflow or ambient temperature until a family of module output derating curves is obtained.

Heat-dissipating components inside the unit are thermally coupled to the case. Heat is removed by conduction, convection, and radiation to the surrounding environment.

For reliable operation this temperature should not exceed 100ºC at either T

REF 1

or T

REF 2

forced convection airflow or cold plate applications. 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 T

REF

modules is discussed above, you can limit this temperature to a lower value for extremely high reliability.

Data Sheet

for applications using

temperature of the power

Output Current, IO

(A)

Output Current, IO

(A)

Data Sheet

JRCW450R Orca Series; DC-DC Converter Power

36–75 Vdc Input; 32.0Vdc Output; 450W Output

(A)

Output Current, I

Figure 17. (top view).

Thermal Derating

Thermal derating is presented for two different applications:

1) Figure 18, the JRCW450R module is thermally coupled to a cold plate inside a sealed clamshell chassis, without any internal air circulation; and 2) Figure 19, 20 and 21, the JRCW450R 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. 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.

Case (T

) Temperature Measurement Location

REF

Figure 19. Derating Output Current vs. local Ambient temperature and Airflow, No Heatsink, Vin=48V, airflow from Vi(-) to Vi(+).

Figure 20. Derating Output Current vs. local Ambient temperature and Airflow, 0.5” Heatsink, Vin=48V, airflow from Vi(-) to Vi(+).

Modules

Ambient Temperature, TA (oC)

Ambient Temperature, T

(oC)

Output Power (W)

Cold plate (inside surface) temperature

Figure 18. Output Power Derating for JRCW450R in Conduction cooling (cold plate) applications; T adjacent to module; V

= V

IN,NOM

(ºC)

<70ºC

Ambient Temperature, T

Figure 21. Derating Output Current vs. local Ambient temperature and Airflow, 1.0” Heatsink, Vin=48V, airflow from Vi(-) to Vi(+).

(oC)

Data Sheet

JRCW450R Orca Series; DC-DC Converter Power

36–75 Vdc Input; 32.0Vdc Output; 450W Output

Layout Considerations

The JRCW450R 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 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 JRCW450R can not be processed with paste-through-hole Pb or Pb-free reflow process. If additional information is needed, please consult with your GE representative for more details.

Modules

Data Sheet

JRCW450R Orca Series; DC-DC Converter Power

36–75 Vdc Input; 32.0Vdc Output; 450W 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*

SIDE VIEW**

BOTTOM VIEW

Pin Description

1 Vin (+) 2 On/Off 3 Baseplate 4 Vin (–) 5 Vout (–) 6 Sense (-) 7 Trim 8 Sense (+) 9 Vout (+)

*Top side label includes GE name, product designation, and data code.

Modules

Data Sheet

JRCW450R Orca Series; DC-DC Converter Power

36–75 Vdc Input; 32.0Vdc Output; 450W Output

Recommended Pad Layout 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. ]

Modules

Data Sheet

JRCW450R Orca Series; DC-DC Converter Power

Modules

36–75 Vdc Input; 32.0Vdc Output; 450W Output

Ordering Information

Please contact your GE Sales Representative for pricing, availability and optional features.

Table 2. Device Code

Input Voltage

48V (36-75Vdc) 32V 14A 94% Through hole JRCW450R4Z CC109162054 48V (36-75Vdc) 32V 14A 94% Through hole JRCW450R41Z CC109153706 48V (36-75Vdc) 32V 14A 94% Through hole JRCW450R541Z CC109168761 48V (36-75Vdc) 32V 14A 94% Through hole JRCW450R41-TZ CC109164315 48V (36-75Vdc) 32V 14A 94% Through hole JRCW450R641-TZ CC109164397 48V (36-75Vdc) 32V 14A 94% Through hole JRCW450R841-TZ CC109166773 48V (36-75Vdc) 32V 14A 94% Through hole JRCW450R41-18Z 150027329 48V (36-75Vdc) 32V 14A 94% Through hole JRCW450R641-18Z CC109164777

Table 3. Device Options

Output

Voltage

Output

Current

Efficiency

Connector

Type

Product codes Comcodes

For more information, call us at

USA/Canada:

+1 888 546 3243, or +1 972 244 9288

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+86.021.54279977*808

Europe, Middle-East and Africa:

+49.89.878067-280

India: +91.80.28411633

www.ge.com/powerelectronics

GE Industrial Solutions JRCW450R User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual