GE Industrial Solutions ESTW004A2C Series - Manual (Page 6)

Data Sheet
August 30, 2011
ESTW004A2C Series DC-DC Converter Power Modules
36–75V
dc
Input; 15.0V
dc
/4.2A
dc
Output
LINEAGE POWER 6
Test Configurations
TO OSCILLOSCOPE CURRENT PROBE
L
TES T
12μH
BA
T
T
ER
Y
C S 220μF
E.S.R.<0.1 
@ 20°C 100kHz
33-100μF
Vin+
Vin-
NOTE: Measure input reflected ripple current with a simulated
source inductance (L
TEST
) of 12μH. Capacitor C
S
offsets
possible battery impedance. Measure current as shown
above.
Figure 6. Input Reflected Ripple Current Test
Setup.
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.
V O (+)
V O ( – )
RESISTIVE
LOAD
SCOPE
COPPER STRIP
GROUND PLANE
10uF 1uF
+
Figure 7. Output Ripple and Noise Test Setup.
Vout+
Vout-
Vin+
Vin-
R
LOAD
R contact R distribution
R contact R distribution R contact
R contact R distribution
R distribution
V
IN
V O
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 Voltage and Efficiency Test
Setup.
 =
V
O
. I
O
V
IN
. I
IN
x 100 % Efficiency
Design Considerations
Input Filtering
The power module should be connected to a low
ac-impedance source. Highly inductive source
impedance can affect the stability of the power
module. For the test configuration in Figure 6 a 33-
100μF electrolytic capacitor (ESR<0.7
 at 100kHz),
mounted close to the power module helps ensure the
stability of the unit. Consult the factory for further
application guidelines.
Safety Considerations
For safety-agency approval of the system in which the
power module is used, the power module must be
installed in compliance with the spacing and
separation requirements of the end-use safety agency
standard, i.e. UL60950-1, CSA C22.2 No.60950-1,
and VDE0805-1(IEC60950-1).
If the input source is non-SELV (ELV or a hazardous
voltage greater than 60 V
dc
and less than or equal to
75V
dc
), for the module’s output to be considered as
meeting the requirements for safety extra-low voltage
(SELV), all of the following must be true:
 The input source is to be provided with reinforced
insulation from any other hazardous voltages,
including the ac mains.
 One V
IN
pin and one V
OUT
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 V
dc
but less than or
equal to –75 V
dc
, 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.