GE Data Sheet EHHD006A0B Hammerhead* Series; DC-DC Converter Power Modules 18-75Vdc Input; 12Vdc, 6.0A, 72W Output Features Compliant to RoHS Directive 2011/65/EU and amended Directive (EU) 2015/863 (-Z versions) Compliant to REACH Directive (EC) No 1907/2006 Flat and high-efficiency curve Industry standard, DOSA compliant footprint 57.9mm x 22.8mm x 7.6mm (2.28 in x 0.9 in x 0.30 in) Low-profile height and reduced component skyline Ultra-wide input voltage range: 18-75 Vdc Tightly regulated output Remote sense Output voltage adjust: 90% to 110% of VO,nom Applications Constant switching frequency Distributed Power Architectures Positive remote On/Off logic Wireless Networks Input under/overvoltage protection Access and Optical Network Equipment Output overcurrent and overvoltage protection Overtemperature protection Industrial Equipment No reverse current during output shutdown Wide operating temperature range (-40C to 85C) Suitable for cold wall cooling using suitable Gap Pad applied directly to top side of module ANSI/UL# 62368-1 and CAN/CSA C22.2 No. 62368-1 Recognized, DIN VDE 0868-1/A11:2017 (EN62368-1:2014/A11:2017) 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 ISO**9001 and ISO 14001 certified manufacturing facilities RoHS Compliant Options Negative Remote On/Off logic (preferred) Overcurrent/Overtemperature/Overvoltage protections (Auto-restart) (preferred) Heat plate version (-H) Description The EHHD006A0B Series, eighth-brick, low-height power modules are isolated DC-DC converters that provide a single, precisely regulated output voltage over an ultra-wide input voltage range of 18-75Vdc. The EHHD006A0B provides 12Vdc nominal output voltage rated for 6Adc 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 through-hole packaging, enables designers to develop cost and space efficient solutions. The module achieves typical full load efficiency greater than 92% at VIN=24Vdc and greater than 90% at 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 heat sink attachment to achieve higher output current in high temperature applications. * 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. 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 September 3, 2020 (c)2012 General Electric Company. All rights reserved. Page 1 Data Sheet GE EHHD006A0B Hammerhead Series; DC-DC Converter Power Modules 18-75Vdc Input; 12Vdc, 6.0A, 72W 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 Continuous All VIN -0.3 80 Vdc Transient, operational (100 ms) All VIN,trans -0.3 100 Vdc All TA -40 85 C Storage Temperature All Tstg -55 125 C Altitude All I/O Isolation Voltage (100% factory Hi-Pot tested) All Input Voltage Operating Ambient Temperature (see Thermal Considerations section) 4000 m 2250 Vdc * For higher altitude applications, contact your GE Sales Representative for alternative conditions of use. 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) Input No Load Current (VIN = 48V, IO = 0, module enabled) Input Stand-by Current Device Symbol Min Typ Max Unit All VIN 18 24/48 75 Vdc All IIN 4.4 5.0 Adc All IIN,No load 80 IIN,stand-by 5 All (VIN = 48V, module disabled) I2t mA 8 mA 0.5 A2s Inrush Transient All Input Reflected Ripple Current, peak-to-peak (5Hz to 20MHz, 1H source impedance; VIN, min to VIN, max, IO= IOmax ; See test configuration section) All 30 mAp-p Input Ripple Rejection (120Hz) All 50 dB CAUTION: This power module is not internally fused. An input line fuse must always be used. This power module can be used in a wide variety of applications, ranging from simple standalone operation to an integrated part of sophisticated power architectures. To preserve maximum flexibility, internal fusing is not included; however, to achieve maximum safety and system protection, always use an input line fuse. The safety agencies require a fast-acting fuse with a maximum rating of 10 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. September 3, 2020 (c)2012 General Electric Company. All rights reserved. Page 2 Data Sheet GE EHHD006A0B Hammerhead Series; DC-DC Converter Power Modules 18-75Vdc Input; 12Vdc, 6.0A, 72W Output Electrical Specifications (continued) Parameter Nominal Output Voltage Set-point VIN= 24V to 48V IO=IO, max, TA=25C) Output Voltage (Overall operating input voltage, resistive load, and temperature conditions until end of life) 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 (VIN=VIN, min to VIN, max, IO= IO, max , TA=TA, min to TA, max) RMS (5Hz to 20MHz bandwidth) Peak-to-Peak (5Hz to 20MHz bandwidth) Device Symbol Min Typ Max Unit All VO, set 11.80 12.00 12.24 Vdc All VO 11.64 12.36 Vdc All All All 0.2 0.2 1.0 % VO, set % VO, set % VO, set All 25 50 mVrms All 75 200 mVpk-pk 2,000 F 6 Adc 9.0 Adc External Capacitance All CO, max 0 Output Current All IO 0 All IO, lim 6.6 All IO, s/c 5 Arms VIN=24V, TA=25C, IO=3A, VO = 12V All 90.0 % VIN=24V, TA=25C, IO=6A, VO = 12V All 92.5 % VIN=48V, TA=25C, IO=3A, VO = 12V All 90.0 % VIN=48V, TA=25C, IO=6A, VO = 12V All 90.5 % All fsw 280 kHz All Vpk 3 % VO, set All ts 200 s Device Symbol Min Typ Max Unit Isolation Capacitance All Ciso 1000 pF Isolation Resistance All Riso 100 M I/O Isolation Voltage (100% factory Hi-pot tested) All All 2250 Vdc Device Symbol Min Typ Max Calculated Reliability based upon Telcordia SR-332 Issue 3: Method I Case 3 (IO=80%IO, max, TA=40C, airflow = 200 lfm, 90% confidence) All FIT 169.9 All MTBF 5,887,341 Hours Weight (Open Frame) All 19 (0.7) g (oz.) Weight (with Heat Plate) All 30 (1.1) g (oz.) Output Current Limit Inception (Hiccup Mode ) (VO= 90% of VO, set) Output Short-Circuit Current (VO250mV) ( Hiccup Mode ) Efficiency Switching Frequency 7.8 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 General Specifications Parameter September 3, 2020 (c)2012 General Electric Company. All rights reserved. Unit 109/Hours Page 3 Data Sheet GE EHHD006A0B Hammerhead Series; DC-DC Converter Power Modules 18-75Vdc Input; 12Vdc, 6.0A, 72W Output Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load and temperature conditions. See Feature Descriptions for additional information. Parameter Device Symbol Min Typ Max Unit Remote On/Off Signal Interface (VIN=VIN, min to VIN, max ; open collector or equivalent, Signal referenced to VIN- terminal) Negative Logic: device code suffix "1" Logic Low = module On, Logic High = module Off Positive Logic: No device code suffix required Logic Low = module Off, Logic High = module On Logic Low - Remote On/Off Current All Ion/off 0.15 mA Logic Low - On/Off Voltage All Von/off -0.7 0.6 Vdc Logic High Voltage - (Typ = Open Collector) All Von/off 2.5 20 Vdc Logic High maximum allowable leakage current All Ion/off 25 A Case 1: Input power is applied for at least 1 second then the On/Off input is set from OFF to ON (Tdelay = On/Off pin transition until VO = 10% of VO, set) All Tdelay 12 msec Case 2: On/Off input is set to Logic Low (Module ON) then input power is applied (Tdelay = VIN reaches VIN, min until Vo=10% of VO,set) All Tdelay 25 35 msec Output voltage Rise time (time for Vo to rise from 10% of Vo,set to 90% of Vo, set) All Trise 15 25 msec 3 % VO, set 10 % VO, set 110 % VO, set 16.5 Vdc Turn-On Delay and Rise Times (IO=IO, max , VIN=VIN, nom, TA = 25oC) Output Voltage Overshoot - Startup IO= IO, max; VIN=VIN, min to VIN, max, TA = 25 oC All Remote Sense Range All Output Voltage Adjustment Range All Output Overvoltage Protection All VSENSE 90 VO, limit 13.8 Overtemperature Protection - Hiccup Auto Restart Heat Plate Input Undervoltage Lockout Open frame Heat Plate All Tref 135 O Tref 120 OC C VUVLO Turn-on Threshold 17 18 Vdc Turn-off Threshold 14 15.5 16 Vdc Hysteresis 1 2.0 Turn-on Threshold 76 77 Vdc Turn-off Threshold 79 81 Vdc Hysteresis 1 2 Vdc Input Overvoltage Lockout September 3, 2020 All Vdc VOVLO (c)2012 General Electric Company. All rights reserved. Page 4 Data Sheet GE EHHD006A0B Hammerhead Series; DC-DC Converter Power Modules 18-75Vdc Input; 12Vdc, 6.0A, 72W Output Characteristic Curves EFFICIENCY, (%) OUTPUT VOLTAGE OUTPUT CURRENT VO (V) (200mV/div) Io(A) (1A/div) The following figures provide typical characteristics for the EHHD006A0B (12.0V, 6A) at 25oC. The figures are identical for either positive or negative remote On/Off logic. OUTPUT CURRENT, IO (A) Figure 4. Transient Response to 0.1A/S Dynamic Load Change from 50% to 75% to 50% of full load, Vin=48V, CO>100F. OUTPUT VOLTAGE VO (V) (5V/div) OUTPUT VOLTAGE VO (V) (100mV/div) On/Off VOLTAGE VOn/Off (V) (5V/div) Figure 1. Converter Efficiency versus Output Current. TIME, t (200s/div) TIME, t (10ms/div) TIME, t (2s/div) Figure 5. Typical Start-up Using Remote On/Off, negative logic version shown (VIN = 24V or 48V, Io = Io,max). OUTPUT VOLTAGE VO (V) (200mV/div) OUTPUT VOLTAGE VO (V) (5V/div) OUTPUT CURRENT Io(A) (1A/div) INPUT VOLTAGE VIN (V) (20V/div) Figure 2. Typical output ripple and noise (Io = Io,max). TIME, t (200s/div) Figure 3. Transient Response to 0.1A/S Dynamic Load Change from 50% to 75% to 50% of full load, Vin=24V, CO>100F. September 3, 2020 TIME, t (10ms/div) Figure 6. Typical Start-up Using Input Voltage (VIN = 24V, Io = Io,max). (c)2012 General Electric Company. All rights reserved. Page 5 Data Sheet GE EHHD006A0B Hammerhead Series; DC-DC Converter Power Modules 18-75Vdc Input; 12Vdc, 6.0A, 72W Output Test Configurations Design Considerations Input Filtering CURRENT PROBE TO OSCILLOSCOPE LTEST Vin+ BATTERY 12H 33-100F CS 220F E.S.R.<0.1 @ 20C 100kHz Vin- Safety Considerations NOTE: Measure input reflected ripple current with a simulated source inductance (LTEST) of 12H. Capacitor CS offsets possible battery impedance. Measure current as shown above. Figure 7. Input Reflected Ripple Current Test Setup. COPPER STRIP VO (+) RESISTIVE LOAD SCOPE V O (- ) 1uF 10uF 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. Rcontact Vin+ Rdistribution Rdistribution RLOAD VO Rcontact Rcontact Vin- 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 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) or ES1, all of the following must be true: Figure 8. Output Ripple and Noise Test Setup. Rcontact For safety agency approval the power module must be installed in compliance with the spacing and separation requirements of the end-use safety agency standards, i.e., UL ANSI/UL* 62368-1 and CAN/CSA+ C22.2 No. 62368-1 Recognized, DIN VDE 0868-1/A11:2017 (EN623681:2014/A11:2017) GROUND PLANE Rdistribution 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 33-100F electrolytic capacitor (ESR<0.7 at 100kHz), mounting close to the power module helps ensure the stability of the unit. Consult the factory for further application guidelines. x 100 % 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 (SELV) or ES1 outputs when all inputs are SELV or ES1 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 10 A fast-acting fuse in the ungrounded lead. September 3, 2020 (c)2012 General Electric Company. All rights reserved. Page 6 Data Sheet GE EHHD006A0B Hammerhead Series; DC-DC Converter Power Modules 18-75Vdc Input; 12Vdc, 6.0A, 72W 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 VI(+) VO(+) VI(-) VO(-) II 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 -0.7V Von/off 0.6V. The maximum Ion/off during a logic low is 0.15mA and the switch should maintain a logic low level while sinking this current. During a logic high, the typical maximum Von/off generated by the module is 5.6V and the maximum allowable leakage current at Von/off = 5.6V is 25A. 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 LOSSES 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 135OC (Figure 13, typical) or 120OC (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 overvoltage protection scheme of the modules has an independent overvoltage loop to prevent single point of failure. This protection feature latches in the event of overvoltage across the output. Cycling the On/Off pin or input voltage resets the latching protection feature. If the autorestart 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, it will latch off following the overcurrent 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. September 3, 2020 (c)2012 General Electric Company. All rights reserved. Page 7 Data Sheet GE EHHD006A0B Hammerhead Series; DC-DC Converter Power Modules 18-75Vdc Input; 12Vdc, 6.0A, 72W Output 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. Once the output current is brought back into its specified range, the unit will operate normally. 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 % = 12.0V - Vdesired 100 12.0V For example, to trim-down the output voltage of the module by 6% to 11.28V, Rtrim-down is calculated as follows: % = 6 511 Rtrim-down = - 10.22 6 Rtrim-down = 74.9 5.11 12.0 (100 + 4) 511 Rtrim-up = - - 10.22 1.225 4 4 Rtrim-up = 1.16 M 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. 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 %: 5.11 12.0 (100 + %) 511 Rtrim-up = - - 10.22 1.225 % % Where - 12 .0 V % = d esired 100 12 .0 For example, to trim-up the output voltage of the module by 4% to 12.48V, Rtrim-up is calculated is as follows: % = 4 September 3, 2020 (c)2012 General Electric Company. All rights reserved. Page 8 Data Sheet GE EHHD006A0B Hammerhead Series; DC-DC Converter Power Modules 18-75Vdc Input; 12Vdc, 6.0A, 72W Output OUTPUT CURRENT, IO (A) Thermal Considerations (continued) AMBIENT TEMEPERATURE, TA (oC) The thermal reference points, Tref, used in the specifications for open frame modules is shown in Figure 13. For reliable operation, these temperatures should not exceed 125oC. OUTPUT CURRENT, IO (A) Figure 15. Output Current Derating for the Open Frame Module; Airflow in the Transverse Direction from Vout(-) to Vout(+); VIN =48. AIRFLOW AMBIENT TEMEPERATURE, TA (oC) Figure 16. Output Current Derating for the Module with Heat plate; Airflow in the Transverse Direction from Vout(-) to Vout(+);VIN =48V. The thermal reference point, Tref, used in the specifications for modules with a heat plate is shown in Figure 14. For reliable operation, this temperature should not exceed 115 OC. AIRFLOW OUTPUT CURRENT, IO (A) Figure 13. Tref Temperature Measurement Locations for Open Frame Module. AMBIENT TEMEPERATURE, TA (oC) Figure 14. Tref Temperature Measurement Location for Module with Heat plate. Figure 17. Output Current Derating for the Open Frame Module; Airflow in the Transverse Direction from Vout(-) to Vout(+); VIN =24V. 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 each module versus local ambient temperature (TA) for natural convection and up to 2m/s (400 ft./min) forced airflow are shown in Figures 15 - 18. September 3, 2020 (c)2012 General Electric Company. All rights reserved. Page 9 Data Sheet GE EHHD006A0B Hammerhead Series; DC-DC Converter Power Modules 18-75Vdc Input; 12Vdc, 6.0A, 72W Output Thermal Considerations (continued) Through-Hole Soldering Information OUTPUT CURRENT, IO (A) Lead-Free Soldering AMBIENT TEMEPERATURE, TA (oC) Figure 18. Output Current Derating for the Module with Heat plate; Airflow in the Transverse Direction from Vout(-) to Vout(+);VIN =24V. 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. The EHHD006A0Bxx RoHS-compliant through-hole products use 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 Pbfree 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 EHHD006A0Bxx module is compatible with reflow pastein-hole soldering processes shown in Figures 23-25. Since the EHHD006A0BxxZ module is not packaged per J-STD-033 Rev.A, the module must be baked prior to the paste-in-hole reflow process. EHHD006A0Bxx-HZ modules are not compatible with paste-in-hole reflow soldering. Please contact your ABB Sales Representative for further information. Pick and Place 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 19. 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 20. Figure 19. Cold Wall Mounting The EHHD006A0 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. Figure 21. Pick and Place Location. OUTPUT CURRENT, IO (A) 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. COLDPLATE TEMEPERATURE, TC (oC) Figure 20. Derated Output Current versus Cold Wall Temperature with Local Ambient Temperature Around Module at 85C; VIN =24V or 48V. September 3, 2020 Oblong or oval nozzles up to 11 x 9 mm may also be used within the space available. (c)2012 General Electric Company. All rights reserved. Page 10 Data Sheet GE EHHD006A0B Hammerhead Series; DC-DC Converter Power Modules 18-75Vdc Input; 12Vdc, 6.0A, 72W Output The EHHD006A0B 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 235C. Typically, the eutectic solder melts at 183C, wets the land, and subsequently wicks the device connection. Sufficient time must be allowed to fuse the plating on the connection to ensure a reliable solder joint. There are several types of reflow technologies currently used in the industry. These 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 connector temperatures. Lead Free Soldering Figure 23. Time Limit Curve Above 205oC for Tin/Lead (Sn/Pb) process Pb-free Reflow Profile Power systems will comply with J-STD-015 Rev. C (Moisture/Reflow Sensitivity Classification for Nonhermetic Solid State Surface Mount Devices) for both Pb-free solder profiles and MSL classification procedures. This standard 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 24. 300 Per J-STD-020 Rev. C Peak Temp 260C 250 REFLOW TEMP ( C) Reflow Temp (C) The -Z version of the EHHD006A0B modules are lead-free (Pbfree) 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. MAX TEMP SOLDER ( C) Tin Lead Soldering 200 * Min. Time Above 235C 15 Seconds 150 Heating Zone 1C/Second Cooling Zone *Time Above 217C 60 Seconds 100 50 0 Reflow Time (Seconds) Figure 24. Recommended linear reflow profile using Sn/Ag/Cu solder. Post Solder Cleaning and Drying Considerations REFLOW TIME (S) Figure 22. Reflow Profile for Tin/Lead (Sn/Pb) process. September 3, 2020 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). (c)2012 General Electric Company. All rights reserved. Page 11 Data Sheet GE EHHD006A0B Hammerhead Series; DC-DC Converter Power Modules 18-75Vdc Input; 12Vdc, 6.0A, 72W Output EMC Considerations The circuit and plots in Figure 24 shows a suggested configuration to meet the conducted emission limits of EN55022 Class B. Figure 25. EMC Considerations For further information on designing for EMC compliance, please refer to the FLT007A0 data sheet (DS05-028). VIN = 48V, Io = Io,max, L Line September 3, 2020 VIN = 48V, Io = Io,max, N Line (c)2012 General Electric Company. All rights reserved. Page 12 Data Sheet GE EHHD006A0B Hammerhead Series; DC-DC Converter Power Modules 18-75Vdc Input; 12Vdc, 6.0A, 72W 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. September 3, 2020 (c)2012 General Electric Company. All rights reserved. Page 13 Data Sheet GE EHHD006A0B Hammerhead Series; DC-DC Converter Power Modules 18-75Vdc Input; 12Vdc, 6.0A, 72W 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.] September 3, 2020 (c)2012 General Electric Company. All rights reserved. Page 14 Data Sheet GE EHHD006A0B Hammerhead Series; DC-DC Converter Power Modules 18-75Vdc Input; 12Vdc, 6.0A, 72W 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.] Pin 1 2 3 4 5 6 7 8 NOTES: Function Vi(+) ON/OFF Vi(-) Vo(-) SENSE(-) TRIM SENSE(+) Vo(+) FOR 0.030" X 0.025" RECTANGULAR PIN, USE 0.050" PLATED THROUGHHOLE DIAMETER FOR 0.62 DIA" PIN, USE 0.076" PLATED THROUGHHOLE DIAMETER TH Recommended Pad Layout (Component Side View) September 3, 2020 (c)2012 General Electric Company. All rights reserved. Page 15 Data Sheet GE EHHD006A0B Hammerhead Series; DC-DC Converter Power Modules 18-75Vdc Input; 12Vdc, 6.0A, 72W Output Ordering Information Please contact your GE Sales Representative for pricing, availability and optional features. Table 1. Device Codes Output Output On/Off Logic Voltage Current 12.0V 6A Negative Connector Type Through-hole Product Codes Input Voltage Comcodes EHHD006A0B41Z 24/48V (18-75Vdc) EHHD006A0B641Z 24/48V (18-75Vdc) 12.0V 6A Negative Through-hole 150024112 EHHD006A0B41-HZ 24/48V (18-75Vdc) 12.0V 6A Negative Through-hole CC109167755 EHHD006A0B641-HZ 24/48V (18-75Vdc) 12.0V 6A Negative Through-hole 150024113 EHHD006A0B841-HZ 24/48V (18-75Vdc) 12.0V 6A Negative Through-hole CC109171443 CC109159364 Table 2. Device Coding Scheme and Options Contact Us For more information, call us at USA/Canada: +1 877 546 3243, or +1 972 244 9288 Asia-Pacific: +86-21-53899666 Europe, Middle-East and Africa: +49.89.878067-280 Go.ABB/Industrial GE Critical Power reserves the right to make changes to the product(s) or information contained herein without notice, and no liability is assumed as a result of their use or application. No rights under any patent accompany the sale of any such product(s) or information. September 3, 2020 (c)2016 General Electric Company. All rights reserved. Version 2.5