GE Datasheet EHHD024A0A HAMMERHEAD* Series; DC-DC Converter Power Modules 18-75Vdc Input; 5Vdc, 24A, 120W Output Features RoHS Compliant Applications Compliant to RoHS II EU "Directive 2011/65/EU (-Z versions) Compliant to REACH Directive (EC) No 1907/2006 Flat and high efficiency curve Industry standard, DOSA compliant footprint 58.4mm x 22.8mm x 8.9mm (2.30 in x 0.9 in x 0.35 in) Ultra wide input voltage range: 18-75 Vdc Tightly regulated output Remote sense Output Voltage adjust: 90% to 110% of VO,nom Constant switching frequency Positive remote On/Off logic Output overcurrent and overvoltage protection Overtemperature protection Distributed Power Architectures Wide operating temperature range (-40C to 85C) Wireless Networks Enterprise Networks including Power over Ethernet (PoE) Suitable for cold wall cooling using suitable Gap Pad applied directly to top side of module Industrial Equipment ANSI/UL#60950-1-2011 and CAN/CSA C22.2 No. 60950-107, Second Edition + A1:2011 (MOD), dated March 19, 2011; and DIN EN 60950-1 (VDE 0805 Teil 1):2011-01; EN 609501:2006 + A11:2009 + A1:2010, DIN EN 60950-1/A12 (VDE 0805-1/A12):2011-08; EN 60950-1/A12:2011-02, IEC 609501(ed.2);am1:2009 CE mark meets 2006/95/EC directive Meets the voltage and current requirements for ETSI 300132-2 and complies with and licensed for Basic insulation rating per EN60950-1 2250 Vdc Isolation tested in compliance with IEEE 802.3 PoE standards Options Negative Remote On/Off logic (preferred) Over current/Over temperature/Over voltage protections (Auto-restart) (preferred) 1/8th Brick Heat plate for 1/8th heatsinks 1/4th Brick heat plate with unthreaded inserts Surface Mount version (-S) ISO**9001 and ISO 14001 certified manufacturing facilities Description The EHHD024A0A [HAMMERHEAD*] Series, eighth-brick, low-height power modules are isolated dc-dc converters which provide a single, precisely regulated output voltage over an ultra-wide input voltage range of 18-75Vdc. The EHHD024A0A provides 5Vdc nominal output voltage rated for 24Adc output current. The module incorporates GE's vast heritage for reliability and quality, while also using the latest in technology, and component and process standardization to achieve highly competitive cost. The open frame module construction, available in both surface-mount and through-hole packaging, enable designers to develop cost and space efficient solutions. The module achieves typical full load efficiency greater than 91% at VIN=24Vdc and VIN=48Vdc. Standard features include remote On/Off, remote sense, output voltage adjustment, overvoltage, overcurrent and overtemperature protection. An optional heat plate allows for external standard, eighth-brick or quarter-brickheat sink attachment to achieve higher output current in high temperature applications. * Trademark of General Electric Corporation. # UL is a registered trademark of Underwriters Laboratories, Inc. CSA is a registered trademark of Canadian Standards Association. VDE is a trademark of Verband Deutscher Elektrotechniker e.V. This product is intended for integration into end-user equipment . All of the required procedures of end-use equipment should be followed. IEEE and 802 are registered trademarks of the Institute of Electrical and Electronics Engineers, Incorporated. ** ISO is a registered trademark of the International Organization of Standards March 13, 2014 (c)2014 General Electric Corporation. All rights reserved. Page 1 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W 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 All VIN -0.3 80 Vdc Input Voltage Continuous Transient, operational (100 ms) Operating Ambient Temperature Maximum Heat Plate Operating Temperature All VIN,trans -0.3 100 Vdc All TA -40 85 C -18H, H TC -40 105 C All Tstg -55 125 C (see Thermal Considerations section) Storage Temperature Altitude* All * For higher altitude applications, contact your GE Sales Representative for alternative conditions of use. I/O Isolation voltage (100% factory Hi-Pot tested) All 4000 m 2250 Vdc Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Parameter Operating Input Voltage Maximum Input Current (VIN= VIN, min to VIN, max, VO= VO, set, IO=IO, max) Device Symbol Min Typ Max Unit All VIN 18 24/48 75 Vdc All IIN 7.3 7.8 Adc All IIN,No load 120 80 IIN,stand-by 5 Input No Load Current VIN = 24Vdc, (IO = 0, module enabled) VIN = 48V, (IO = 0, module enabled) Input Stand-by Current All (VIN = 24 to 48V, module disabled) I2t mA 11 mA 0.5 A2s Inrush Transient All Input Reflected Ripple Current, peak-to-peak (5Hz to 20MHz, 12H source impedance; VIN, min to VIN, max, IO= IOmax ; See Test configuration section) All 30 mAp-p Input Ripple Rejection (120Hz) All 60 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 15 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. March 13, 2014 (c)2014 General Electric Corporation. All rights reserved. Page 2 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W Output Electrical Specifications (continued) Unless otherwise indicated, specifications apply at VIN = 48Vdc, resistive load, and TA = 25C conditions. Parameter Nominal Output Voltage Set-point VIN= 24V to 48V IO=IO, max, TA=25C) Output Voltage (Over all operating input voltage, resistive load, and temperature conditions until end of life) Adjustment Range (*Vin > 20V) Selected by external resistor Output Regulation Line (VIN=VIN, min to VIN, max) Load (IO=IO, min to IO, max) Temperature (Tref=TA, min to TA, max) Output Ripple and Noise on nominal output Measured with 10uF Tantalum||1uF ceramic (VIN=24 to 48, IO=80% IO, max , TA=25) RMS (5Hz to 20MHz bandwidth) Peak-to-Peak (5Hz to 20MHz bandwidth) Device Symbol Min Typ Max Unit All VO, set 4.93 5 5.07 Vdc All VO -3.0 +3.0 % VO, set All VO, adj -10 +10* % VO, set 0.2 0.2 1.5 % VO, set % VO, set % VO, set All All All All 30 mVrms All 100 mVpk-pk External Capacitance All CO, max 0 Output Current All IO 0 5 IO, lim 26.5 All IO, s/c VIN=24V, TA=25C, IO=24A, VO = 5V All VIN=48V, TA=25C, IO=24A, VO = 5V All Output Current Limit Inception (Hiccup Mode ) (VO= 90% of VO, set) Output Short-Circuit Current (VO250mV) ( Hiccup Mode ) Efficiency Switching Frequency 10,000 F 24 Adc 29 Adc 1.2 Arms 92 % 91.5 % All fsw 280 kHz All Vpk 3 % VO, set All ts 800 s Unit Dynamic Load Response (dIo/dt=0.1A/s; VIN = 24V or 48V; TA=25C; CO>100F) Load Change from Io= 50% to 75% or 25% to 50% of Io,max Peak Deviation Settling Time (Vo<10% peak deviation) Isolation Specifications Parameter Device Symbol Min Typ Max Isolation Capacitance All Ciso 1000 pF Isolation Resistance All Riso 10 M I/O Isolation Voltage (100% factory Hi-pot tested) All All 2250 Vdc Device Symbol Min Typ Max General Specifications Parameter Calculated Reliability based upon Telcordia SR-332 Issue 2: Method I Case 3 (IO=80%IO, max, TA=40C, airflow = 200 lfm, 90% confidence) Unit All FIT 112.7 109/Hour s All MTBF 8,869,389 Hours Weight (Open Frame) All 23(0.8) g (oz.) Weight (with Heatplate) All 37(1.3) g (oz.) March 13, 2014 (c)2014 General Electric Corporation. All rights reserved. Page 3 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W 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 0.15 mA 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 Logic Low - On/Off Voltage All Von/off -0.7 0.6 Vdc Logic High Voltage - (Typ = Open Collector) All Von/off 2.5 5 6.7 Vdc Logic High maximum allowable leakage current All Ion/off 20 A All Tdelay -- 35 -- msec Case 2: On/Off input is set to Logic Low (Module ON) and then input power is applied (Tdelay from instant at which VIN = VIN, min until Vo=10% of VO,set) All Tdelay -- 35 - msec Output voltage Rise time (time for Vo to rise from 10% of Vo,set to 90% of Vo, set) All Trise -- 20 Turn-On Delay and Rise Times (IO=IO, max , VIN=VIN, nom, TA = 25oC) Case 1: Input power is applied for at least 1 second, and then the On/Off input is set from OFF to ON (Tdelay = on/off pin transition until VO = 10% of VO, set) Output voltage overshoot - Startup All IO= IO, max; VIN=VIN, min to VIN, max, TA = 25 oC Remote Sense Range All VSENSE Output Overvoltage Protection1 All VO, limit 5.9 msec -- 3 % VO, set 10 % VO, set 7.0 Vdc Overtemperature Protection - Hiccup Auto Restart Input Undervoltage Lockout Tref 135 O C Tref 120 O C VUVLO Turn-on Threshold 17.5 Vdc Turn-off Threshold 15 15.5 Vdc Hysteresis 1 2 Vdc Turn-on Threshold 76 79 Turn-off Threshold 81 Hysteresis 1 2 Input Overvoltage Lockout 1 Open frame Heat Plate All All VOVLO Vdc Vdc Vdc - Module complies with 7Vmax with Trim Pin short to Sense+, with and without external cap. For Open Loop condition max OVP was 7.3V with min. 220F external cap March 13, 2014 (c)2014 General Electric Corporation. All rights reserved. Page 4 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W Output Characteristic Curves The following figures provide typical characteristics for the EHHD024A0A (5V, 24A) at 25 OC. The figures are identical for either positive or negative remote On/Off logic. 95 OUTPUT VOLTAGE VO (V) (200mV/div) Vin=18V 85 Vin=48V Vin=36V Vin=24V Vin=75V 80 75 70 0 4 8 12 16 20 24 OUTPUT CURRENT Io(A) (5A/div) EFFICIENCY, (%) 90 OUTPUT CURRENT, IO (A) TIME, t (200s/div) Figure 1. Converter Efficiency versus Output Current. Figure 4. Transient Response to 0.1A/S Dynamic Load Change from 50% to 75% to 50% of full load, Vin=48V. 48Vin 75Vin OUTPUT VOLTAGE VO (V) (2V/div) OUTPUT VOLTAGE VO (V) (50mV/div) 24Vin On/Off VOLTAGE VOn/Off (V) (5V/div) 18Vin TIME, t (10ms/div) TIME, t (2s/div) Figure 5. Typical Start-up Using Remote On/Off, negative logic version shown (VIN = 48V, Io = Io,max). OUTPUT CURRENT Io(A) (5A/div) OUTPUT VOLTAGE VO (V) (2V/div) OUTPUT VOLTAGE VO (V) (200mV/div) INPUT VOLTAGE VIN (V) (20V/div) Figure 2. Typical output ripple and noise (Io = Io,max). TIME, t (200s/div) TIME, t (10ms/div) Figure 3. Transient Response to 0.1A/S Dynamic Load Change from 50% to 75% to 50% of full load, Vin=24V March 13, 2014 Figure 6. Typical Start-up Using Input Voltage (VIN = 48V, Io = Io,max). (c)2014 General Electric Corporation. All rights reserved. Page 5 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W Output Test Configurations Design Considerations Input Filtering CURRENT PROBE TO OSCILLOSCOPE LTES T Vin+ BATTERY 12H 33-100F CS 220F E.S.R.<0.1 @ 20C 100kHz Safety Considerations Vin- NOTE: Measure input reflected ripple current with a simulated source inductance (LTEST) of 12H. Capacitor C S offsets possible battery impedance. Measure current as shown above. Figure 7. Input Reflected Ripple Current Test Setup. COPPER STR IP V O (+) RESISTIVE LOAD SCOPE V O (- ) 1uF 10uF GROUND PLANE NOTE: All voltage measurements to be taken at the module terminals, as shown above. If sockets are used then Kelvin connections are required at the module terminals to avoid measurement errors due to socket contact resistance. Figure 8. Output Ripple and Noise Test Setup. Rdistribution Rcontact Rcontact Vin+ Rdistribution RLOAD VO Rcontact Rcontact Vin- Rdistribution Vout+ VIN Rdistribution Vout- NOTE: All voltage measurements to be taken at the module terminals, as shown above. If sockets are used then Kelvin connections are required at the module terminals to avoid measurement errors due to socket contact resistance. Figure 9. Output Voltage and Efficiency Test Setup. VO. IO Efficiency = VIN. IIN x 100 % 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 100F 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. 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 VDE08051(IEC60950-1). If the input source is non-SELV (ELV or a hazardous voltage greater than 60 Vdc and less than or equal to 75Vdc), for the module's output to be considered as meeting the requirements for safety extra-low voltage (SELV), all of the following must be true: The input source is to be provided with reinforced insulation from any other hazardous voltages, including the ac mains. One VIN pin and one VOUT pin are to be grounded, or both the input and output pins are to be kept floating. The input pins of the module are not operator accessible. Another SELV reliability test is conducted on the whole system (combination of supply source and subject module), as required by the safety agencies, to verify that under a single fault, hazardous voltages do not appear at the module's output. Note: Do not ground either of the input pins of the module without grounding one of the output pins. This may allow a non-SELV voltage to appear between the output pins and ground. The power module has extra-low voltage (ELV) outputs when all inputs are ELV. All flammable materials used in the manufacturing of these modules are rated 94V-0, or tested to the UL60950 A.2 for reduced thickness. For input voltages exceeding -60 Vdc but less than or equal to -75 Vdc, these converters have been evaluated to the applicable requirements of BASIC INSULATION between secondary DC MAINS DISTRIBUTION input (classified as TNV-2 in Europe) and unearthed SELV outputs. The input to these units is to be provided with a maximum 15 A fast-acting fuse in the ungrounded lead. March 13, 2014 (c)2014 General Electric Corporation. All rights reserved. Page 6 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W Output 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. Vin+ The amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. When using remote sense and trim, the output voltage of the module can be increased, which at the same output current would increase the power output of the module. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power (Maximum rated power = Vo,set x Io,max). Vout+ SENSE(+) SENSE(-) Ion/off ON/OFF TRIM SUPPLY II VI(+) VO(+) VI(-) VO(-) CONTACT RESISTANCE Von/off Vout- Vin- Figure 10. Remote On/Off Implementation. To turn the power module on and off, the user must supply a switch (open collector or equivalent) to control the voltage (Von/off) between the ON/OFF terminal and the VIN(-) terminal (see Figure 10). Logic low is 0V Von/off 0.6V. The maximum Ion/off during a logic low is 0.15mA; the switch should 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 1A. If not using the remote on/off feature: For positive logic, leave the ON/OFF pin open. For negative logic, short the ON/OFF pin to VIN(-). Remote Sense Remote sense minimizes the effects of distribution losses by regulating the voltage at the remote-sense connections (See Figure 11). The voltage between the remote-sense pins and the output terminals must not exceed the output voltage sense range given in the Feature Specifications table: [VO(+) - VO(-)] - [SENSE(+) - SENSE(-)] 0.5 V Although the output voltage can be increased by both the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim. IO LOAD CONTACT AND DISTRIBUTION LOSSE Figure 11. Circuit Configuration for remote sense . Input Undervoltage Lockout At input voltages below the input undervoltage lockout limit, the module operation is disabled. The module will only begin to operate once the input voltage is raised above the undervoltage lockout turn-on threshold, VUV/ON. Once operating, the module will continue to operate until the input voltage is taken below the undervoltage turn-off threshold, VUV/OFF. Overtemperature Protection To provide protection under certain fault conditions, the unit is equipped with a thermal shutdown circuit. The unit will shutdown if the thermal reference point, Tref, exceeds 120 and 124 OC (Figure 13, typical) or 105 OC (Figure 14, typical), but the thermal shutdown is not intended as a guarantee that the unit will survive temperatures beyond its rating. The module will automatically restart upon cool-down to a safe temperature. Output Overvoltage Protection The output over voltage protection scheme of the modules has an independent over voltage loop to prevent single point of failure. This protection feature latches in the event of over voltage across the output. Cycling the on/off pin or input voltage resets the latching protection feature. If the auto-restart option (4) is ordered, the module will automatically restart upon an internally programmed time elapsing. Overcurrent Protection To provide protection in a fault (output overload) condition, the unit is equipped with internal current-limiting circuitry and can endure current limiting continuously. At the point of current-limit inception, the unit enters hiccup mode. If the unit is not configured with auto-restart, then it will latch off following the over current condition. The module can be restarted by cycling the dc input power for at least one second or by toggling the remote on/off signal for at least one second. March 13, 2014 (c)2014 General Electric Corporation. All rights reserved. Page 7 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W Output Feature Descriptions (continued) If the unit is configured with the auto-restart option (4), it will remain in the hiccup mode as long as the overcurrent condition exists; it operates normally, once the output current is brought back into its specified range. The average output current during hiccup is 10% IO, max. Output Voltage Programming Trimming allows the output voltage set point to be increased or decreased from the default value; this is accomplished by connecting an external resistor between the TRIM pin and either the VO(+) pin or the VO(-) pin. VIN(+) VO(+) Rtrim-up ON/OFF LOAD VOTRIM Rtrim-down VIN(-) VO(-) Figure 12. Circuit Configuration to Trim Output Voltage. Connecting an external resistor (Rtrim-down) between the TRIM pin and the VO(-) (or Sense(-)) pin decreases the output voltage set point. To maintain set point accuracy, the trim resistor tolerance should be 1.0%. The following equation determines the required external resistor value to obtain a percentage output voltage change of % 511 Rtrim - down = - 10 .22 % Where % = 5 . 0V - V desired x 100 5 . 0V For example, to trim-down the output voltage of the module by 6% to 4.7V, Rtrim-down is calculated as follows: % = 6 511 Rtrim - down = - 10 .22 6 R trim - down = 74 .9 Connecting an external resistor (Rtrim-up) between the TRIM pin and the VO(+) (or Sense (+)) pin increases the output voltage set point. The following equation determines the required external resistor value to obtain a percentage output voltage change of %: For example, to trim-up the output voltage of the module by 4% to 5.2V, Rtrim-up is calculated is as follows: % = 4 5 .11 x 5 .0 x (100 + 4 ) 511 R trim - up = - - 10 .22 1 .225 x 4 4 Rtrim-up = 404.3 The voltage between the VO(+) and VO(-) terminals must not exceed the minimum output overvoltage protection value shown in the Feature Specifications table. This limit includes any increase in voltage due to remote-sense compensation and output voltage set-point adjustment trim. Although the output voltage can be increased by both the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim. The amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. When using remote sense and trim, the output voltage of the module can be increased, which at the same output current would increase the power output of the module. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power (Maximum rated power = VO,set x IO,max). Thermal Considerations The power modules operate in a variety of thermal environments; however, sufficient cooling should be provided to help ensure reliable operation. Considerations include ambient temperature, airflow, module power dissipation, and the need for increased reliability. A reduction in the operating temperature of the module will result in an increase in reliability. The thermal data presented here is based on physical measurements taken in a wind tunnel, 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. 5.11 x 5.0 x (100 + %) 511 Rtrim -up = - - 10 .22 1.225 x % % Where % = V desired - 5 . 0 x 100 5 .0 March 13, 2014 (c)2014 General Electric Corporation. All rights reserved. Page 8 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W Output Thermal Considerations (continued) each module versus local ambient temperature (TA) for natural convection and up to 3m/s (600 ft./min) forced airflow are shown in Figures 15 - 21. Please refer to the Application Note "Thermal Characterization Process For Open-Frame Board-Mounted Power Modules" for a detailed discussion of thermal aspects including maximum device temperatures. OUTPUT CURRENT, IO (A) 24 20 NC 16 100LFM (0.5m/s) 200LFM (1.0m/s) 12 400LFM (2.0m/s) 8 600LFM (3.0m/s) 4 0 The thermal reference points, Tref1, & Tref2, used in the specifications for open frame modules are shown in Figure 13. For reliable operation these temperatures should not exceed 120 OC and 124 OC 25 35 45 55 65 75 85 AMBIENT TEMEPERATURE, T ( C) Figure 15. Output Current Derating for the Open Frame Module; Airflow in the Transverse Direction from Vout(-) to Vout(+); VIN =48V, VO=5V. A o Tref2 Tref 1 AIRFLOW Figure 13. Tref Temperature Measurement Locations for Open Frame Module. The thermal reference point, Tref, used in the specifications for modules with heatplate is shown in Figure 14. For reliable operation this temperature should not exceed 98 OC. OUTPUT CURRENT, IO (A) 24 20 NC 16 100LFM (0.5m/s) 12 200LFM (1.0m/s) 400LFM (2.0m/s) 8 4 0 25 35 45 55 65 75 85 AMBIENT TEMEPERATURE, TA (oC) Figure 16. Output Current Derating for the Module with Heatplate; Airflow in the Transverse Direction from Vout(-) to Vout(+);VIN =48V, VO=5V. Figure 14. Tref Temperature Measurement Location for Module with Heat plate. Heat Transfer via Convection Increased airflow over the module enhances the heat transfer via convection. Derating curves showing the maximum output current that can be delivered by March 13, 2014 (c)2014 General Electric Corporation. All rights reserved. Page 9 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W Output Thermal Considerations (continued) OUTPUT CURRENT, IO (A) 24 OUTPUT CURRENT, IO (A) 24 20 NC 16 100LFM (0.5m/s) 12 200LFM (1.0m/s) 8 400LFM (2.0m/s) NC 16 100LFM (0.5m/s) 12 200LFM (1.0m/s) 400LFM (2.0m/s) 8 4 0 4 25 35 45 55 65 75 85 AMBIENT TEMEPERATURE, TA (oC) 0 25 35 45 55 65 75 85 AMBIENT TEMEPERATURE, TA (oC) Figure 17. Output Current Derating for the Module with -18H Heatplate; Airflow in the Transverse Direction from Vout(-) to Vout(+);VIN =48V, VO=5V 24 OUTPUT CURRENT, IO (A) 20 NC 100LFM (0.5m/s) 12 400LFM (2.0m/s) 200LFM (1.0m/s) Heat Transfer via Conduction The module can also be used in a sealed environment with cooling via conduction from the module's top surface through a gap pad material to a cold wall, as shown in Figure 22. This capability is achieved by insuring the top side component skyline profile achieves no more than 1mm height difference between the tallest and the shortest power train part that benefits from contact with the gap pad material. The output current derating versus cold wall temperature, when using a gap pad such as Bergquist GP2500S20, is shown in Figure 21. 20 16 Figure 20. Output Current Derating for the Module with -18 Heatplate; Airflow in the Transverse Direction from Vout(-) to Vout(+);VIN =24V, VO=5V. 8 4 0 25 35 45 55 65 75 85 AMBIENT TEMEPERATURE, TA (oC) Figure 18. Output Current Derating for the Open Frame Module; Airflow in the Transverse Direction from Vout(-) to Vout(+); VIN =24V, VO=5V. Figure 21. Cold Wall Mounting 24 20 NC 16 OUTPUT CURRENT, IO (A) OUTPUT CURRENT, IO (A) 24 100LFM (0.5m/s) 12 200LFM (1.0m/s) 400LFM (2.0m/s) 8 4 0 25 35 45 55 65 75 16 12 8 4 85 AMBIENT TEMEPERATURE, TA (oC) Figure 19. Output Current Derating for the Module with Heatplate; Airflow in the Transverse Direction from Vout(-) to Vout(+);VIN =24V, VO=5V. March 13, 2014 20 0 20 30 40 50 60 70 80 90 COLDPLATE TEMEPERATURE, TC (oC) Figure 22. Derated Output Current versus Cold Wall Temperature with local ambient temperature around module at 85C; VIN =24V or 48V. (c)2014 General Electric Corporation. All rights reserved. Page 10 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W Output Through-Hole Soldering Information Lead-Free Soldering The EHHD024A0A xx RoHS-compliant through-hole products use SAC (Sn/Ag/Cu) Pb-free solder and RoHScompliant components. They are designed to be processed through single or dual wave soldering machines. The pins have a RoHS-compliant finish that is compatible with both Pb and Pb-free wave soldering processes. A maximum preheat rate of 3C/s is suggested. The wave preheat process should be such that the temperature of the power module board is kept below 210C. For Pb solder, the recommended pot temperature is 260C, while the Pb-free solder pot is 270C max. Paste-in-Hole Soldering The EHHD024A0A xx module is compatible with reflow paste-in-hole soldering processes shown in Figures 24-26. Since the EHHD024A0A xxZ module is not packaged per JSTD-033 Rev.A, the module must be baked prior to the paste-in-hole reflow process. EHHD024A0A xx-HZ modules are not compatible with paste-in-hole reflow soldering. Please contact your GE Sales Representative for further information. Surface Mount Information Nozzle Recommendations The module weight has been kept to a minimum by using open frame construction. Even so, these modules have a relatively large mass when compared to conventional SMT components. Variables such as nozzle size, tip style, vacuum pressure and placement speed should be considered to optimize this process. The minimum recommended nozzle diameter for reliable operation is 6mm. The maximum nozzle outer diameter, which will safely fit within the allowable component spacing, is 9 mm. Oblong or oval nozzles up to 11 x 9 mm may also be used within the space available. Tin Lead Soldering MSL Rating The EHHD024A0A -SZ module has a MSL rating of 2a. Storage and Handling The recommended storage environment and handling procedures for moisture-sensitive surface mount packages is detailed in J-STD-033 Rev. A (Handling, Packing, Shipping and Use of Moisture/Reflow Sensitive Surface Mount Devices). Moisture barrier bags (MBB) with desiccant are provided for the EHHD024A0Axx-SZ modules. These sealed packages should not be broken until time of use. Once the original package is broken, the floor life of the product at conditions of 30C and 60% relative humidity varies according to the MSL rating (see J-STD-033A). The shelf life for dry packed SMT packages is a minimum of 12 months from the bag seal date, when stored at the following conditions: < 40 C, < 90% relative humidity. Pick and Place The EHHD024A0A modules use an open frame construction and are designed for a fully automated assembly process. The modules are fitted with a label designed to provide a large surface area for pick and place operations. The label meets all the requirements for surface mount processing, as well as safety standards, and is able to withstand reflow temperatures of up to 300oC. The label also carries product information such as product code, serial number and the location of manufacture. March 13, 2014 Figure 23. Pick and Place Location. The EHHD024A0A power modules are lead free modules and can be soldered either in a lead-free solder process or in a conventional Tin/Lead (Sn/Pb) process. It is recommended that the customer review data sheets in order to customize the solder reflow profile for each application board assembly. The following instructions must be observed when soldering these units. Failure to observe these instructions may result in the failure of or cause damage to the modules, and can adversely affect long-term reliability. In a conventional Tin/Lead (Sn/Pb) solder process peak reflow temperatures are limited to less than 235oC. Typically, the eutectic solder melts at 183oC, wets the land, and subsequently wicks the device connection. Sufficient time must be allowed to fuse the plating on the connection to ensure a reliablesolder joint. There are several types of SMT reflow technologies currently used in the industry. These surface mount power modules can be reliably soldered using natural forced convection, IR (radiant infrared), or a combination of convection/IR. For reliable soldering the solder reflow profile should be established by accurately measuring the modules CP connector temperatures. Lead Free Soldering The -Z version of the EHHD024A0A modules are lead-free (Pb-free) and RoHS compliant and are both forward and backward compatible in a Pb-free and a SnPb soldering process. Failure to observe the instructions below may result in the failure of or cause damage to the modules and can adversely affect long-term reliability. (c)2014 General Electric Corporation. All rights reserved. Page 11 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W Output provides a recommended forced-air-convection reflow profile based on the volume and thickness of the package (table 4-2). The suggested Pb-free solder paste is Sn/Ag/Cu (SAC). The recommended linear reflow profile using Sn/Ag/Cu solder is shown in Figure 26. 300 P eak Temp 235oC REFLOW TEMP (C) 250 Co o ling zo ne 1-4oCs -1 Heat zo ne max 4oCs -1 200 150 300 So ak zo ne 30-240s 100 Per J-STD-020 Rev. D Tlim above 205oC Peak Temp 260C 250 Reflow Temp (C) P reheat zo ne max 4oCs -1 50 200 * Min. Time Above 235C 15 Seconds 150 0 REFLOW TIME (S) Figure 24. Reflow Profile for Tin/Lead (Sn/Pb) process. Heating Zone 1C/Second Cooling Zone *Time Above 217C 60 Seconds 100 50 240 0 Reflow Time (Seconds) MAX TEMP SOLDER (C) 235 225 Figure 26. Recommended linear reflow profile using Sn/Ag/Cu solder. 220 Post Solder Cleaning and Drying Considerations 230 215 210 205 200 0 10 20 30 40 50 60 Figure 25. Time Limit Curve Above 205oC for Tin/Lead (Sn/Pb) process Pb-free Reflow Profile 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 (AN04-001). Power Systems will comply with J-STD-015 Rev. D (Moisture/Reflow Sensitivity Classification for Nonhermetic Solid State Surface Mount Devices) for both Pb-free solder profiles and MSL classification procedures. This standard March 13, 2014 (c)2014 General Electric Corporation. All rights reserved. Page 12 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W Output EMC Considerations The circuit and plots in Figure 27 shows a suggested configuration to meet the conducted emission limits of EN55022 Class B. FLT012A0 EHHD024 FILTER Figure 27. EMC Considerations For further information on designing for EMC compliance, please refer to the FLT012A0 data sheet (DS05-028). VIN = 48V, Io = Io,max, L Line March 13, 2014 VIN = 48V, Io = Io,max, N Line (c)2014 General Electric Corporation. All rights reserved. Page 13 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W 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 side label includes GE name, product designation and date code. Top View Side View *For optional pin lengths, see Table 2, Device Coding Scheme and Options Bottom View* VO- VI- SENSEON/OFF TRIM SENSE+ VI+ March 13, 2014 VO+ (c)2014 General Electric Corporation. All rights reserved. Page 14 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W Output Mechanical Outline for Surface Mount Module (-S Option) Dimensions are in millimeters and [inches]. Tolerances: x.x mm 0.5 mm [x.xx in. 0.02 in.] (Unless otherwise indicated) x.xx mm 0.25 mm [x.xxx in 0.010 in.] * Top side label includes GE name, product designation and date code. Top View Side View Bottom View* VI- VOSENSE- ON/OFF TRIM SENSE+ VI+ March 13, 2014 (c)2014 General Electric Corporation. All rights reserved. VO+ Page 15 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W Output Mechanical Outline for Through-Hole Module with Heat Plate (-H Option) Dimensions are in millimeters and [inches]. Tolerances: x.x mm 0.5 mm [x.xx in. 0.02 in.] (Unless otherwise indicated) x.xx mm 0.25 mm [x.xxx in 0.010 in.] Top View Side View *For optional pin lengths, see Table 2, Device Coding Scheme and Options Bottom View* VO- VI- SENSEON/OFF TRIM SENSE+ VI+ VO+ *Bottom side label includes product designation and date code. **Side View **Side label contains product designation and date code. March 13, 2014 (c)2014 General Electric Corporation. All rights reserved. Page 16 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W Output Mechanical Outline for Through-Hole Module with 1/4 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.] Top View Side View *For optional pin lengths, see Table 2, Device Coding Scheme and Options Bottom View* VO- VI- SENSEON/OFF TRIM SENSE+ VI+ VO+ **Side View **Side label contains product designation and date code. March 13, 2014 (c)2014 General Electric Corporation. All rights reserved. Page 17 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W Output Recommended Pad Layout Dimensions are in millimeters and [inches]. Tolerances: x.x mm 0.5 mm [x.xx in. 0.02 in.] (Unless otherwise indicated) x.xx mm 0.25 mm [x.xxx in 0.010 in.] 58.4[2.30] 47.2[1.86] 39.0[1.54] 26.1[1.03] 17.9[.70] 5.4[.22] 1 Pin 1 2 3 4 5 6 7 8 2 22.8 [.90] Function Vi(+) ON/OFF Vi(-) Vo(-) SENSE(-) TRIM SENSE(+) Vo(+) KEEP OUT AREAS 7 6 5 11.7 [.46] 3 7.62 [.300] 8 4 3.8[.15] 3.8 [.15] 3.81 [.150] 50.80[2.000] SMT Recommended Pad Layout (Component Side View) 58.4[2.30] 47.2[1.86] 39.0[1.54] Pin Function 1 Vi(+) 2 ON/OFF 3 Vi(-) 4 Vo(-) 5 SENSE(-) 6 TRIM 7 SENSE(+) 8 Vo(+) NOTES: FOR 0.030" X 0.025" RECTANGULAR PIN, USE 0.050" PLATED THROUGH HOLE DIAMETER FOR 0.62 DIA" PIN, USE 0.076" PLATED THROUGH HOLE DIAMETER 26.1[1.03] 17.9[.70] 5.4[.22] KEEP OUT AREAS 1 22.8 [.90] 2 6 4 3.8[.15] 3.8 [.15] 7 5 11.7 [.46] 7.62 [.300] 8 50.80[2.000] 3.81 [.150] TH Recommended Pad Layout (Component Side View) March 13, 2014 (c)2014 General Electric Corporation. All rights reserved. Page 18 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W Output Packaging Details The surface mount versions of the EHHD024A0A (suffix -S) are supplied as standard in the plastic trays shown in Figure 30. Each tray contains a total of 12 power modules. The trays are self-stacking and each shipping box for the EHHD024A0A (suffix -S) surface mount module will contain 4 full trays plus one empty hold down tray giving a total number of 48 power modules. Tray Specification Material Max surface resistivity Color Capacity Min order quantity Antistatic coated PVC 1012/sq Clear 12 power modules 48 pcs (1 box of 4 full trays + 1 empty top tray) Figure 28. Surface Mount Packaging Tray March 13, 2014 (c)2014 General Electric Corporation. All rights reserved. Page 19 GE Datasheet EHHD024A0A Series: DC-DC Converter Power Module 18 to 75Vdc Input; 5Vdc, 24A, 120W Output Ordering Information Please contact your GE Sales Representative for pricing, availability and optional features. Table 1. Device Codes Output Output Product Codes Input Voltage On/Off Logic Voltage Current EHHD024A0A 41Z 24/48V (18-75Vdc) 5V 24A Negative EHHD024A0A 41-HZ 24/48V (18-75Vdc) 5V 24A Negative EHHD024A0A 41-18HZ 24/48V (18-75Vdc) 5V 24A Negative EHHD024A0A 41-SZ 24/48V (18-75Vdc) 5V 24A Negative Connector Type Through hole Through hole Through hole Surface mount Comcodes 150029828 150029827 150029830 150029829 Ratings Table 2. Device Coding Scheme and Options Characteristic Form Factor Family Designator Input Voltage Output Current Output Voltage Pin Length Action following Protective Shutdown Options On/Off Logic Customer Specific Mechanical Features RoHS Character and Position E HH D 024A0 A Definition E = 1 /8th Brick HH = H ammerheadTM Series D = UltraWide Range, 18V-75V 024A0 = 024.0 Amps Maximum Output Current A=5V Nominal Omit = Default Pin Length shown in Mechanical Outline Figures 6 = Pin Length: 3.68 mm 0.25mm , (0.145 in. 0.010 in.) 8 = Pin Length: 2.79 mm 0.25mm , (0.110 in. 0.010 in.) 6 8 4 = Auto-restart following shutdown (Overcurrent/Overvoltage) Must be ordered 4 Omit = Positive Logic 1 = Negative Logic 1 XY XY = Customer Specific Modified Code, Omit for Standard Code Omit = Standard open Frame Module H = 1/8th Brick size heat plate, for use with heat sinks (not available H with -S option) 18H 18H = 1/4th Brick size heat plate with unthreaded inserts for use in coldwall applications (not available with -S option) S S = Surface Mount connections Omit = RoHS 5/6, Lead Based Solder Used Z Z = RoHS 6/6 Compliant, Lead free Contact Us 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.gecriticalpower.com March 13, 2014 (c)2014 General Electric Corporation. All rights reserved. Version 1.3 Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: GE (General Electric): EHHD024A0A41-HZ EHHD024A0A41-SZ EHHD024A0A41-18HZ