GE Industrial Solutions JRW450U User Manual

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JRW450U Orca* Series; DC-DC Converter Power Modules

36–75 Vdc Input; 48Vdc Output; 450W Output

Data Sheet

RoHS Compliant

Applications

 RF Power Amplifier  Wireless Networks  Switching Networks

Options

 Output OCP/OVP auto restart  Shorter pins  Unthreaded heat sink holes

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 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, 28.8V  Wide operating case temperature range (-40°C to 100°C)  CE mark meets 2006/95/EC directives

 ANSI/UL

60950-1-07 Certified, and VDE Licensed

 ISO

60950-1, 2nd Ed. Recognized, CSA† C22.2 No.

9001 and ISO 14001 certified manufacturing facilities

to 57.6Vdc

‡

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

Description

The JRCW450U 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 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 heat sink for high-temperature applications. The output is fully isolated from the input, allowing versatile polarity configurations and grounding connections.

* Trademark of the 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

JRCW450U Orca Series; DC-DC Converter Power

Modules

36–75 Vdc Input; 48.0Vdc 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 Case Temperature (See Thermal Considerations section, Figure 19)

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

-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 40 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

JRCW450U Orca Series; DC-DC Converter Power

Modules

36–75 Vdc Input; 48.0Vdc Output; 450W Output

Electrical Specifications (continued)

Parameter Device Symbol Min Typ Max Unit

Output Voltage Set-point

, IO=I

IN=VIN,nom

O, max

, Tc =25°C)

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

External Capacitance (ESR > 10 m)1 All C

Output Power (Vo=48V to 57.6V) 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) All I

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:

Peak Deviation

Settling Time (Vo<10% peak deviation)

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

Peak Deviation

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. When starting into maximum external capacitor, do not simultaneously apply

a Constant Current electronic load set to greater than 0.5 x I

Settling Time (Vo<10% peak deviation)

or delay application of full CC load until Vo >1.0V.

oMAX;

All

All V

O, set

47.0 48 49.0 V

47.0

  

 

440 6500 F

 

0 9.4 Adc

11.0

15 A

All I

O,max

O, lim

O, sc

All  93.5 94.0



 

All



49.0 V

0.1 0.2 %V

0.25 0.5 %V

100 125 mV 300 400 mV

450 W



12.2 Adc



180

1.5



 

rms

kHz

o,set

rms

pk-pk

O, set

Isolation Specifications

Parameter Symbol Min Typ Max Unit

Isolation Capacitance C

Isolation Resistance R

iso



 

M

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 136.3 10

MTBF 7,338,052 Hours



76.4



2.69 oz.

/Hours

Data Sheet

JRCW450U Orca Series; DC-DC Converter Power

Modules

36–75 Vdc Input; 48.0Vdc Output; 450W 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”

IN, min

to V

; open collector or equivalent,

IN, max

terminal)

IN-

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

on/off



   

5 V

1.0 mA

0.8 Vdc

50 A 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

, 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

All T

120 ms

delay



20 ms

least one second.

= time for VO to rise from 10% of V

rise

to 90% of V

O,set

. All T

O,set

rise



Synchronous Rectifier Activation Level and Delay* Minimum I

Minimum time to activate synch rectifier mode (I

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) All V

Output Overvoltage Protection (TA=25C)

Over Temperature Protection All T

(See Feature Descriptions, Figure 19)

Input Under Voltage Lockout V

Input Over voltage Lockout V

* Note: Module has internal circuit that inhibits output synchronous rectifier mode, during module startup, until I time> T

to activate synch rectifier mode I

OUT

> I

OUT

, TA=25°C)

O, max

) T

OUT,SYNC

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

. Once output synchronous mode is activated, module remains in synchronous rectifier mode, even if load is reduced to

SYNC

OUT,SYNC

SYNC

sense

28.8 --- 57.6 Vdc

trim

O, limit

ref

IN, UVLO

IN, OVLO

2.4 A

1 ms

3 % V

60 



115

2 %V

65 Vdc



35 36 Vdc

31 32 Vdc

2.5 3 Vdc

 80 83

79.5 81 V



2.5 3 --- Vdc

> I

OUT

OUT,SYNC

°C

Vdc

for

0A, until module output is turned off using on/off pin or loss of input voltage.

O, set

o,nom

Data Sheet

JRCW450U Orca Series; DC-DC Converter Power

Modules

36–75 Vdc Input; 48.0Vdc Output; 450W Output

Characteristic Curves

The following figures provide typical characteristics for the JRCW450U (48V, 9.4A) at 25ºC. The figures are identical for either positive or negative Remote On/Off logic.

(V) (20V/div)

EFFICIENCY (%)

(V) (5V/div) V

OUTPUT CURRENT, Io (A) TIME, t (50ms/div)

Figure 1. Converter Efficiency versus Output Current.

ON/OFF

On/Off VOLTAGE OUTPUTVOLTAGE

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) (20V/div)

(V) (20V/div) V

INPUT VOLTAGE OUTPUT VOLTAGE

Figure 5. Typical Start-Up

step; C

(V) (500mV/div)

(A) (5A/div) V

OUTPUT CURRENT OUTPUT VOLTAGE

= 470µF.

o,ext

TIME, t (50ms/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

JRCW450U Orca Series; DC-DC Converter Power

36–75 Vdc Input; 48.0Vdc 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 C 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.

(470 µF Low ESR aluminum or tantalum capacitor

out

Design Considerations

Input Source Impedance

The power module should be connected to a low ac-impedance source. A highly inductive source can affect the stability of the power module. For the test

impedance

configuration in Figure 7, a 470F 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 JRCW450U 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 V grounded simultaneously.

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.

Modules

Low ESR aluminum

out

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

(+) and VO(+) are

Data Sheet

JRCW450U Orca Series; DC-DC Converter Power

36–75 Vdc Input; 48.0Vdc Output; 450W Output

Safety Considerations (continued)

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.

To insure safety compliance, the temperature at T

(Figure

ref

16) at full load should not exceed the listed temperature when operating at the indicated input voltage.

input 36Vdc input

75V

Test

Condition

ref1

ref2

ref3

ref1

ref2

ref3

No heat sink 83.4°C 130°C 89.6°C 130°C

1 in. heat sink 73.8°C 130°C 90.2°C 130°C

Cold wall 75.5°C 130°C 95.0°C 130°C

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

= 5V is 50A.

on/off

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

Figure 10. Circuit configuration for using Remote On/Off Implementation.

 0.8V. The maximum

on/off

generated by

on/off

(-).

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 too low to support V short circuit load condition exists, the module will shut down 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 12A 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 shut down 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.:

(+)–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

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

Modules

. If the load resistance is

trimMIN

in an overcurrent condition or a

trimMIN

o,nom

Data Sheet

JRCW450U Orca Series; DC-DC Converter Power

36–75 Vdc Input; 48.0Vdc Output; 450W Output

Feature Description (continued)

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.

For output voltages:

100



downadj 2

 kR







Where,



= Desired output voltage set point (V).

desired

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 %.

For output voltages: V



upadj

 k

Where,

desired

 





= Desired output voltage set point (V).

Modules

O,nom







 

desirednomo



nomO

nomo



nomo

, the output voltage set point (V

O,nom

%225.1



nomodesired

100%



= 48V

100%

= 48V

%)100(



)

o,adj



%))2(100(









 

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 %.

) between the TRIM and

adj_down

) decreases

o,adj

Figure 14. Circuit Configuration to Increase Output Voltage.

Data Sheet

JRCW450U Orca Series; DC-DC Converter Power

36–75 Vdc Input; 48.0Vdc Output; 450W Output

Feature Description (continued)

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 48V module, without –T option, to 40V

4048



% 



% = 16.7%

100

 



= 3.99

adj _ down

To trim up the output of a nominal 48V module, without –T option, to 52.8V

% 



% = 10





_ upadj

 

= 429.8k

adj _ up

100



 KR downadj 2



7.16



488.52



100



)10100(48





10225.1

Active Voltage Programming

For the JRCW450Ux 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 will be dependent on the voltage step and range of the DAC and the desired values for trim-up and trim-down contact your GE technical representative to obtain more details on the selection for this resistor.



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

Over Temperature Protection

The JRCW450U 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 1-2 ºC the converter will automatically restart.

Thermal Considerations



))102(100(





 

%. Please

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 16.

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.

Modules

, (see Figure 16) exceeds a threshold of 115

REF 1

REF

)

JRCW450U Orca Series; DC-DC Converter Power Modules

36–75 Vdc Input; 48.0Vdc Output; 450W Output

Thermal Considerations (continued)

(A)

Output Current, I

Ambient Temperature, TA (oC)

Figure 17. Derating Output Current vs. local Ambient temperature and Airflow, No Heat sink, Vin=48V, airflow from Vi(-) to Vi(+).

Data Sheet

For reliable operation with Vin=48V this temperature should no texceed 100ºC at either T

REF 1

or T

REF 2

, or 130 ºC at T

REF3

for applications using forced convection airflow without heat sink, or in cold plate applications. The temperatures at either T

or T

REF 1

should not exceed 90ºC, when using a 1in. heat

REF 2

sink in forced convection airflow. 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

temperature of the power modules is

REF

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

Figure 16.

Case (T

) Temperature Measurement Location

REF

(top view).

Thermal Derating

Thermal derating is presented for different applications in Figure 17, 18 and 19. The JRCW450U module is mounted in a traditional open chassis or cards with forced air flow. 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 heat sink. Conduction cooled thermal derating is presented in Figure 20.

(A)

Output Current, I

Ambient Temperature, T

Figure 18. Derating Output Current vs. local Ambient temperature and Airflow, 0.5” Heat sink, Vin=48V, airflow from Vi(-) to Vi(+).

(A)

Output Current, I

Ambient Temperature, T

Figure 19. Derating Output Current vs. local Ambient temperature and Airflow, 1.0” Heat sink, Vin=48V, airflow from Vi(-) to Vi(+).

(oC)

Data Sheet

JRCW450U Orca Series; DC-DC Converter Power

36–75 Vdc Input; 48.0Vdc Output; 450W Output

Thermal Considerations (continued)

(W)

Output Power, P

Cold Plate (inside surface) Temperature, T Figure 20. Derating Output Power in conduction cooling

(cold plate) applications, Vin=48V.

(oC)

Layout Considerations

The JRCW450U 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 a 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 JRCW450U cannot 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

JRCW450U Orca Series; DC-DC Converter Power

Modules

36–75 Vdc Input; 48.0Vdc 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.]

Pin Description

TOP VIEW*

SIDE VIEW**

BOTTOM VIEW

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.

Data Sheet

JRCW450U Orca Series; DC-DC Converter Power

36–75 Vdc Input; 48.0Vdc 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

JRCW450U Orca Series; DC-DC Converter Power

Modules

36–75 Vdc Input; 48.0Vdc Output; 450W Output

Ordering Information

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

Table 1. Device Code

Input Voltage

48V (36-75Vdc) 48V 9.4A 94% Through hole JRCW450U641Z CC109168992 48V (36-75Vdc) 48V 9.4A 94% Through hole JRCW450U64-18Z 150022105 48V (36-75Vdc) 48V 9.4A 94% Through hole JRCW450U641-18Z 150021936 48V (36-75Vdc) 48V 9.4A 94% Through hole JRCW450U641-TZ CC109168984 48V (36-75Vdc) 48V 9.4A 94% Through hole JRCW450U64-18TZ CC109172838

Table 2. 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

Asia-Pacific:

+86.021.54279977*808

Europe, Middle-East and Africa:

+49.89.878067-280

India: +91.80.28411633

www.ge.com/powerelectronics

GE Industrial Solutions JRW450U User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual