FEATURES High Efficiency: 96.8% @9.6V/50A Standard footprint: 58.4 x 36.8 x12.3mm (2.30”x1.45”x0.48’’) Industry standard pinout Input OVP, UVLO; output OCP and OTP 1500V isolation Basic insulation Monotonic startup into normal load and pre-bias loads No minimum load required Constant 500W output power Parallelable for higher power output ISO 9001, TL 9000, ISO 14001, QS9000, OHSAS18001 certified manufacturing facility UL/cUL 60950 (US & Canada), and TUV (EN60950) pending CE mark Pending Delphi Series Q48SB, 500W Bus Converter DC/DC Power Modules: 48V in, 9.6V/55A out The Delphi Series Q48SB, 48V input, single output, quarter brick, 500W bus converter is the latest offering from a world leader in power systems technology and manufacturing -- Delta Electronics, Inc. This product family supports intermediate bus architectures and powers multiple downstream non-isolated point-of-load (POL) converters. The Q48SB9R6 (5:1) operates from a nominal 48V input and provides up to 500W of power or up to 63A (@ 38Vin) of output current in an industry standard quarter brick footprint. The Q48SB 5:1 bus converter operates with 500W constant output power, hence when input voltage drops, the output current will increase accordingly. Typical efficiency for the 9.6V/50A output is 96.8%. With optimized component placement, creative design topology, and numerous patented technologies, the Q48SB bus converter delivers outstanding electrical and thermal performance. An optional heatsink is available for harsh thermal requirements. OPTIONS Positive On/Off logic Heatspreader available for extended operation Latch mode output OCP and OTP APPLICATIONS Datacom / Networking Wireless Networks Optical Network Equipment Server and Data Storage Industrial/Testing Equipment DATASHEET DS_Q48SB9R650_07102006 TECHNICAL SPECIFICATIONS (TA=25°C, airflow rate=300 LFM, Vin=48Vdc, nominal Vout unless otherwise noted.) PARAMETER NOTES and CONDITIONS Q48SB9R650NRFA Min. ABSOLUTE MAXIMUM RATINGS Input Voltage Continuous Operating Temperature Storage Temperature Input/Output Isolation Voltage INPUT CHARACTERISTICS Operating Input Voltage Input Under-Voltage Lockout Turn-On Voltage Threshold Turn-Off Voltage Threshold Lockout Hysteresis Voltage Input Over-Voltage Lockout Turn-Off Voltage Threshold Turn-On Voltage Threshold Lockout Hysteresis Voltage Maximum Input Current No-Load Input Current Off Converter Input Current Inrush Current(I2t) Input Reflected-Ripple Current Internal input filter component value Recommend external input capacitor for system stability Capacitance ESR OUTPUT CHARACTERISTICS Output Voltage Set Point Output Voltage Regulation Over Load Over Line Over Temperature Total Output Voltage Range Output Voltage Ripple and Noise Peak-to-Peak RMS Operating Output Power Range 38V<Vin≤42V 42V<Vin≤55V Output DC Powert-Limit Inception 38V≤Vin≤55V Current share accuracy (2 units in parallel) DYNAMIC CHARACTERISTICS Output Voltage Current Transient Positive Step Change in Output Current Negative Step Change in Output Current Settling Time (within 1% Vout nominal) Turn-On Transient Start-Up Time, From On/Off Control Start-Up Time, From Input Maximum Output Capacitance Single module operation Single module operation 2 pcs Parallel module operation 2 pcs Parallel module operation EFFICIENCY 55A 50A 33A ISOLATION CHARACTERISTICS Input to Output Isolation Resistance Isolation Capacitance FEATURE CHARACTERISTICS Switching Frequency ON/OFF Control for single module operation Negative Remote On/Off logic Logic Low (Module On) Logic High (Module Off) Positive Remote On/Off logic Logic Low (Module Off) Logic High (Module On) ON/OFF Current (for both remote on/off logic) Leakage Current (for both remote on/off logic) GENERAL SPECIFICATIONS MTBF Weight (open frame) Over-Temperature Shutdown Refer to Fig.17 for the measuring point 100% Load, 38V Vin Typ. -40 -55 Max. Units 57 124 125 1500 Vdc °C °C Vdc 36 48 57 Vdc 32.5 30.5 34 32 2 35.5 33.5 Vdc Vdc Vdc 59 57 60.5 58.5 2 62 60 Vdc Vdc Vdc A mA mA A2s mA uH/uF 80 With 100uF external input capacitor P-P thru 12µH inductor, 5Hz to 20MHz L/C 12 20 0.47/4.4 100 0.2 uF ohm Vin=48V, Io=no load, Ta=25°C 9.6 Vdc Io=Io,min to Io,max Vin=38V to 55V Tc=-40°C to 100°C over sample load, line and temperature 5Hz to 20MHz bandwidth Full Load, 1µF ceramic, 10µF tantalum Full Load, 1µF ceramic, 10µF tantalum 400 600 3.8 400 11.5 mV V mV V 80 25 120 50 mV mV 480 500 W W 130% 10 W % 300 300 200 mV mV us 35 35 ms ms 10000 5000 10000 8000 µF µF µF µF 100KHz -40oC to 100oC 47 0.1 13.5 200 15 1 40 6.8 0 0 output voltage 10% lower 120% % of rated output current 48V, 10µF Tan & 1µF Ceramic load cap, 1A/µs 50% Io.max to 75% Io.max 75% Io.max to 50% Io.max Start up with 20A Load Start up with 55A Load Start up with 20A Load Start up with 110A Load 95.4 95.8 95.8 10 Ion/off at Von/off=0.0V Logic High, Von/off=15V Io=80% of Io, max; Ta=25°C; 300LFM airflow Refer to Fig.17 for the measuring point 96.4 96.8 96.8 % % % 1500 1000 Vdc MΩ pF 130 kHz -0.7 2 0.8 18 V V -0.7 2 0.8 18 0.3 50 V V mA uA 0.25 TBD 54 129 M hours grams °C DS_Q48SB9R650_07102006 2 ELECTRICAL CHARACTERISTICS CURVES 25.00 98.00 48V 94.00 Loss(W) Efficiency(%) 38V 20.00 96.00 48V 38V 55V 92.00 90.00 55V 15.00 10.00 5.00 88.00 0.00 86.00 0 10 20 30 40 50 60 0 70 Output Current(A) 10 20 30 40 50 60 70 Output Current(A) Figure 1: Efficiency vs. load current for minimum, nominal, and maximum input voltage at 25°C Figure 2: Power loss vs. load current for minimum, nominal, and maximum input voltage at 25°C. 12.00 Output Voltage(V) 10.00 8.00 6.00 48V 4.00 38V 2.00 55V 0.00 0 20 40 60 80 Output Current(A) Figure 3: Output voltage regulation vs load current showing typical current limit curves and converter shutdown points for minimum, nominal, and maximum input voltage at room temperature. DS_Q48SB9R650_07102006 3 ELECTRICAL CHARACTERISTICS CURVES For Negative Remote On/Off Logic Figure 4: Turn-on transient at full rated load current (5 ms/div). Top Trace: Vout; 5V/div; Bottom Trace: ON/OFF input: 2V/div Figure 5: Turn-on transient at zero load current (5 ms/div). Top Trace: Vout: 5V/div; Bottom Trace: ON/OFF input: 2V/div For Positive Remote On/Off Logic Figure 6: Turn-on transient at full rated load current (5 ms/div). Top Trace: Vout; 5V/div; Bottom Trace: ON/OFF input: 2V/div Figure 7: Turn-on transient at zero load current (5 ms/div). Top Trace: Vout: 5V/div; Bottom Trace: ON/OFF input: 2V/div DS_Q48SB9R650_07102006 4 ELECTRICAL CHARACTERISTICS CURVES Figure 8: Output voltage response to step-change in load current (50%-75%-50% of Io, max; di/dt = 0.1A/µs). Load cap: 10µF, tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (200mV/div, 200us/div), Bottom Trace: Iout (10A/div). Scope measurement should be made using a BNC cable (length shorter than 20 inches). Position the load between 51 mm to 76 mm (2 inches to 3 inches) from the module. is Figure 9: Output voltage response to step-change in load current (50%-75%-50% of Io,max; di/dt=1A/µs). Load cap: 10uF, tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (200mV/div, 200us/div), Bottom Trace: Iout (10A/div). Scope measurement should be made using a BNC cable (length shorter than 20 inches). Position the load between 51 mm to 76 mm (2 inches to 3 inches) from the module. ic Vin+ + + Vin- Cs: 220uF 100uF, ESR=0.2 ohm @ 25oC 100KHz Figure 10: Test set-up diagram showing measurement points for Input Terminal Ripple Current and Input Reflected Ripple Current. Note: Measured input reflected-ripple current with a simulated source Inductance (LTEST) of 12 µH. Capacitor Cs offset possible battery impedance. Measure current as shown below Figure 11: Input Terminal Ripple Current, ic, at full rated output current and nominal input voltage with 12µH source impedance and 47µF electrolytic capacitor (1A/div, 2us/div). DS_Q48SB9R650_07102006 5 ELECTRICAL CHARACTERISTICS CURVES Copper Strip Vo(+) 10u 1u SCOPE RESISTIVE LOAD Vo(-) Figure 12: Input reflected ripple current, is, through a 12µH source inductor at nominal input voltage and rated load current (20 mA/div, 2us/div). Figure 13: Output voltage noise and ripple measurement test setup. Figure 14: Output voltage ripple at nominal input voltage and rated load current (50 mV/div, 2us/div). Load capacitance: 1µF ceramic capacitor and 10µF tantalum capacitor. Bandwidth: 20 MHz. Scope measurements should be made using a BNC cable (length shorter than 20 inches). Position the load between 51 mm to 76 mm (2 inches to 3 inches) from the module. DS_Q48SB9R650_07102006 6 DESIGN CONSIDERATIONS Input Source Impedance The impedance of the input source connecting to the DC/DC power modules will interact with the modules and affect the stability. A low ac-impedance input source is recommended. If the source inductance is more than a few μH, we advise adding a typical 100uF electrolytic capacitor (ESR > 0.1 Ω at 100 kHz, -40oC to 100oC.) mounted close to the input of the module to improve the stability. Layout and EMC Considerations Delta’s DC/DC power modules are designed to operate in a wide variety of systems and applications. For design assistance with EMC compliance and related PWB layout issues, please contact Delta’s technical support team. An external input filter module is available for easier EMC compliance design. Application notes to assist designers in addressing these issues are pending release. Safety Considerations The power module must be installed in compliance with the spacing and separation requirements of the end-user’s safety agency standard, i.e., UL60950, CAN/CSA-C22.2 No. 60950-00 and EN60950: 2000 and IEC60950-1999, if the system in which the power module is to be used must meet safety agency requirements. Basic insulation based on 75 Vdc input is provided between the input and output of the module for the purpose of applying insulation requirements when the input to this DC-to-DC converter is identified as TNV-2 or SELV. An additional evaluation is needed if the source is other than TNV-2 or SELV. When the input source is SELV circuit, the power module meets SELV (safety extra-low voltage) requirements. If the input source is a hazardous voltage which is greater than 60 Vdc and less than or equal to 75 Vdc for the module’s output to meet SELV requirements, all of the following must be met: The input source must be insulated from the ac mains by reinforced or double insulation. The input terminals of the module are not operator accessible. If the metal baseplate is grounded, one Vi pin and one Vo pin shall also be grounded. A SELV reliability test is conducted on the system where the module is used, in combination with the module, to ensure that under a single fault, hazardous voltage does not appear at the module’s output. When installed into a Class II equipment (without grounding), spacing consideration should be given to the end-use installation, as the spacing between the module and mounting surface have not been evaluated. The power module has extra-low voltage (ELV) outputs when all inputs are ELV. This power module is not internally fused. To achieve optimum safety and system protection, an input line fuse is highly recommended. The safety agencies require a normal-blow fuse with 50A maximum rating to be installed in the ungrounded lead. A lower rated fuse can be used based on the maximum inrush transient energy and maximum input current. Soldering and Cleaning Considerations Post solder cleaning is usually the final board assembly process before the board or system undergoes electrical testing. Inadequate cleaning and/or drying may lower the reliability of a power module and severely affect the finished circuit board assembly test. Adequate cleaning and/or drying is especially important for un-encapsulated and/or open frame type power modules. For assistance on appropriate soldering and cleaning procedures, please contact Delta’s technical support team. DS_Q48SB9R650_07102006 7 FEATURES DESCRIPTIONS Over-Current Protection The modules include an internal output over-current protection circuit, which will endure current limiting for an unlimited duration during output overload. If the output current exceeds the OCP set point, the modules will automatically shut down, and enter latch mode or hiccup mode, which is optional. For hiccup mode, the module will try to restart after shutdown. If the overload condition still exists, the module will shut down again. This restart trial will continue until the overload condition is corrected. For latch mode, the module will latch off once it shutdown. The latch is reset by either cycling the input power or by toggling the on/off signal for one second. Over-Temperature Protection The over-temperature protection consists of circuitry that provides protection from thermal damage. If the temperature exceeds the over-temperature threshold the module will shut down, and enter latch mode or auto-restart mode, which is optional. Remote On/Off The remote on/off feature on the module can be either negative or positive logic. Negative logic turns the module on during a logic low and off during a logic high. Positive logic turns the modules on during a logic high and off during a logic low. Remote on/off can be controlled by an external switch between the on/off terminal and the Vi(-) terminal. The switch can be an open collector or open drain. For negative logic if the remote on/off feature is not used, please short the on/off pin to Vi(-). For positive logic if the remote on/off feature is not used, please leave the on/off pin to floating. Vi(+) Vo(+) R ON/OFF Vi(-) Load Vo(-) Figure 15: Remote on/off implementation For auto-restart mode, the module will monitor the module temperature after shutdown. Once the temperature is within the specification, the module will be auto-restart, For latch mode, the module will latch off once it shutdown. Either cycling the input power or toggling the on/off signal for one second can reset the latch. DS_Q48SB9R650_07102006 8 THERMAL CONSIDERATIONS THERMAL CURVES Thermal management is an important part of the system design. To ensure proper, reliable operation, sufficient cooling of the power module is needed over the entire temperature range of the module. Convection cooling is usually the dominant mode of heat transfer. Hence, the choice of equipment to characterize the thermal performance of the power module is a wind tunnel. Thermal Testing Setup Delta’s DC/DC power modules are characterized in heated vertical wind tunnels that simulate the thermal environments encountered in most electronics equipment. This type of equipment commonly uses vertically mounted circuit cards in cabinet racks in which the power modules are mounted. Figure 17: Hot spot temperature measured point *The allowed maximum hot spot temperature is defined at 124℃ Output Current(A) The following figure shows the wind tunnel characterization setup. The power module is mounted on a test PWB and is vertically positioned within the wind tunnel. The space between the neighboring PWB and the top of the power module is constantly kept at 6.35mm (0.25’’). Q48SB9R650(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Transverse Orientation, From Pin 4 to Pin 7, Preliminary Derating Curve) 50 400LFM 45 40 35 Natural Convection 30 100LFM 200LFM 25 PWB FACING PWB 20 300LFM 15 MODULE 10 5 0 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature (℃) Figure 18: Output current vs. ambient temperature and air velocity@ Vin=48V(Transverse orientation, from pin 4 to pin 7, preliminary derating curve, without heatspreader) AIR VELOCITY AND AMBIENT TEMPERATURE MEASURED BELOW THE MODULE 50.8 (2.0”) AIR FLOW 12.7 (0.5”) Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches) TBD Figure 16: Wind tunnel test setup Thermal Derating Heat can be removed by increasing airflow over the module. The module’s maximum hot spot temperature is 124℃. To enhance system reliability, the power module should always be operated below the maximum operating temperature. If the temperature exceeds the maximum module temperature, reliability of the unit may be affected. Figure 19: Output current vs. ambient temperature and air velocity@ Vin=48V(Transverse Orientation, with heat spreader) DS_Q48SB9R650_07102006 9 MECHANICAL DRAWING (WITHOUT HEATSPREADER) Pin No. Name Function 1 2 3 4 5 6 7 -Vin ON/OFF +Vin -Vout +Vout -Vout +Vout Negative input voltage Remote ON/OFF Positive input voltage Negative output voltage (optional) Positive output voltage Negative output voltage Positive output voltage (optional) Pin Specification: Pins 1-3 1.0mm (0.040”) diameter Pins 4-7 1.5mm (0.060”) diameter All pins are copper with Tin plating DS_Q48SB9R650_07102006 10 MECHANICAL DRAWING (WITH HEAT SPREADER) DS_Q48SB9R650_07102006 11 PART NUMBERING SYSTEM Q 48 S Type of Product Input Number of Voltage Outputs Q- Quarter 48- 48V S- Single Brick B 9R6 50 N R Product Series Output Voltage Output Current ON/OFF Logic Pin Length B- Bus 9R6 - 9.6V Converter 50 - 55A @ N- Negative 48Vin P- Positive F Option Code R- 0.170” F- RoHS 6/6 N- 0.145” (Lead Free) K- 0.110” A A- 4 output pin, no heat spreader C- 2 output pin, no heat spreader H- 4 output pin, with heat spreader MODEL LIST MODEL NAME INPUT OUTPUT Eff. @ 48Vin, 480W Po Q48SB9R650NRFA 36V~57V 14A 9.6V 55A 96.8% Q48SB12040NRFA 36V~57V 14A 12V 40A 96.8% Default remote on/off logic is negative and pin length is 0.170” Hiccup output OCP and auto-restart OTP are default; For different remote on/off logic, pin length and output OCP and OTP mode, please refer to part numbering system above or contact your local sales CONTACT: www.delta.com.tw/dcdc USA: Telephone: East Coast: (888) 335 8201 West Coast: (888) 335 8208 Fax: (978) 656 3964 Email: [email protected] Europe: Telephone: +41 31 998 53 11 Fax: +41 31 998 53 53 Email: [email protected] Asia & the rest of world: Telephone: +886 3 4526107 x6220 Fax: +886 3 4513485 Email: [email protected] WARRANTY Delta offers a two (2) year limited warranty. Complete warranty information is listed on our web site or is available upon request from Delta. Information furnished by Delta is believed to be accurate and reliable. However, no responsibility is assumed by Delta for its use, nor for any infringements of patents or other rights of third parties, which may result from its use. No license is granted by implication or otherwise under any patent or patent rights of Delta. Delta reserves the right to revise these specifications at any time, without notice. DS_Q48SB9R650_07102006 12