FEATURES High efficiency: 90% @ 3.3V/10A Industry standard 1x2 pinout Size: 33.0 x 24.4 x 8.55mm (1.30”x0.96”x0.34”) SMD and Through-hole versions Fixed frequency operation Input UVLO, OVP OTP and output OCP, OVP (default is auto-restart) Monotonic startup into normal and pre-biased loads 2250V isolation and basic insulation No minimum load required ISO 9001, TL 9000, ISO 14001, QS9000, OHSAS18001 certified manufacturing facility Delphi Series S48SP, 35W 1x1 Brick DC/DC Power Modules: 48V in, 3.3V/10A out The Delphi Series S48SP, 1x1 Brick, 48V input, single output, isolated DC/DC converters are the latest offering from a world leader in power systems technology and manufacturing ― Delta Electronics, Inc. This product family is available in a surface mount or through-hole package and provides up to 35 watts of power or 10A of output current (3.3V and below) in a new 1x1 form factor (1.30”x0.96”x0.33”). The UL/cUL 60950 (US & Canada) recognized OPTIONS SMD module available Remote On/Off OTP and Output OVP, OCP mode, Auto-restart (default) or latch-up Short pin lengths Encapsulated case optional pinout is compatible with the industry standard 1x2 products. With creative design technology and optimization of component placement, these converters possess outstanding electrical and thermal performance, as well as extremely high reliability under highly stressful operating conditions. Typical efficiency of the 3.3V/10A module is better than 90%. All modules are fully protected from abnormal input/output voltage, current, and temperature conditions. APPLICATIONS Optical Transport Data Networking Communications, including Wireless and traditional Telecom DATASHEET DS_S48SP3R310_10252013 Servers TECHNICAL SPECIFICATIONS (TA=25°C, airflow rate=300 LFM, Vin=48Vdc, nominal Vout unless otherwise noted.) PARAMETER NOTES and CONDITIONS S48SP3R310 (Standard) Min. ABSOLUTE MAXIMUM RATINGS Input Voltage Continuous Transient (100ms) 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 Maximum Input Current No-Load Input Current Off Converter Input Current Inrush Current (I2t) Input Reflected-Ripple Current Input Voltage Ripple Rejection 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 Current Range Output DC Current-Limit Inception 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 EFFICIENCY 100% Load 60% Load ISOLATION CHARACTERISTICS Input to Output Isolation Resistance Isolation Capacitance FEATURE CHARACTERISTICS Switching Frequency ON/OFF Control, Negative Remote On/Off logic Logic Low (Module On) Logic High (Module Off) ON/OFF Control, 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) Output Voltage Trim Range Output Over-Voltage Protection GENERAL SPECIFICATIONS MTBF Weight Over-Temperature Shutdown DS_S48SP3R310_10252013 100ms Refer to Figure 20 for the measuring point Typ. -40 -55 36 32.5 30.5 1.0 34 32 2 100% Load, 36Vin Max. Units 80 100 110 125 2250 Vdc Vdc °C °C Vdc 75 Vdc 35.5 33.5 3.0 1.10 Vdc Vdc Vdc A mA mA A2s mA dB 40 10 0.01 P-P thru 12µH inductor, 5Hz to 20MHz 120 Hz Vin=48V, Io=Io.max, Tc=25°C Io=Io, min to Io, max Vin=36V to 75V Tc=-40°C to 100°C Over load, line and temperature 5Hz to 20MHz bandwidth Full Load, 1µF ceramic, 10µF tantalum Full Load, 1µF ceramic, 10µF tantalum Output Voltage 10% Low 10 60 3.25 3.3 3.35 Vdc ±3 ±3 ±33 ±10 ±10 3.4 mV mV mV V 60 20 10 140 mV mV A % 3.2 30 10 0 110 48V, 10µF Tan & 1µF Ceramic load cap, 0.1A/µs 50% Io.max to 75% Io.max 75% Io.max to 50% Io.max 100 100 50 mV mV us 15 15 ms ms µF Full load; 5% overshoot of Vout at startup 5000 90.0 89.0 % % 2250 1000 Vdc MΩ pF 400 kHz 10 Von/off Von/off Von/off Von/off Ion/off at Von/off=0.0V Logic High, Von/off=15V Across Trim Pin & +Vo or -Vo, Pout≦max rated Over full temp range; % of nominal Vout Io=80% of Io, max; Ta=25°C; air flow 300LFM Refer to Figure 20 for the measuring point -0.7 2 0.8 18 V V -0.7 2 0.8 18 V V mA uA % V 0.25 30 10% 4.62 -10% 3.8 1.98 10.5 117 M hours grams °C 2 ELECTRICAL CHARACTERISTICS CURVES Figure 1: Efficiency vs. load current for minimum, nominal, and maximum input voltage at 25°C Figure 2: Power dissipation vs. load current for minimum, nominal, and maximum input voltage at 25°C. Figure 3: Typical full load input characteristics at room temperature DS_S48SP3R310_10252013 3 ELECTRICAL CHARACTERISTICS CURVES For Negative Remote On/Off Logic 0 0 0 0 Figure 4: Turn-on transient at full rated load current (5 ms/div). Vin=48V. Top Trace: Vout, 1.0V/div; Bottom Trace: ON/OFF input, 2V/div Figure 5: Turn-on transient at zero load current (5 ms/div). Vin=48V. Top Trace: Vout, 1.0V/div, Bottom Trace: ON/OFF input, 2V/div For Positive Remote On/Off Logic 0 0 0 0 Figure 6: Turn-on transient at full rated load current (5 ms/div). Vin=48V. Top Trace: Vout, 1.0V/div; Bottom Trace: ON/OFF input, 2V/div Figure 7: Turn-on transient at zero load current (5 ms/div). Vin=48V. Top Trace: Vout, 1.0V/div; Bottom Trace: ON/OFF input, 2V/div DS_S48SP3R310_10252013 4 ELECTRICAL CHARACTERISTICS CURVES 0 0 0 0 Figure 8: Output voltage response to step-change in load current (75%-50% of Io, max; di/dt = 0.1A/µs). Load cap: 10µF tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (100mV/div, 50us/div), Bottom Trace: Iout (2A/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 Figure 9: Output voltage response to step-change in load current (50%-75% of Io, max; di/dt = 0.1A/µs). Load cap: 10µF tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (100mV/div, 50us/div), Bottom Trace: Iout (2A/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 0 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 DS_S48SP3R310_10252013 Figure 11: Input Terminal Ripple Current, ic, at full rated output current and nominal input voltage with 12µH source impedance and 33µF electrolytic capacitor (50 mA/div, 1us/div) 5 ELECTRICAL CHARACTERISTICS CURVES Copper Strip Vo(+) 0 10u 1u SCOPE RESISTIV 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, 1us/div) Figure 13: Output voltage noise and ripple measurement test setup Figure 14: Output voltage ripple at nominal input voltage and rated load current (Io=10A)(20 mV/div, 1us/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 Figure 15: Output voltage vs. load current showing typical current limit curves and converter shutdown points 0 DS_S48SP3R310_10252013 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 10 to 100 µF electrolytic capacitor (ESR < 0.7 Ω at 100 kHz) mounted close to the input of the module to improve the stability. 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. 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: DS_S48SP3R310_10252013 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 fuse with 3A 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. 7 FEATURES DESCRIPTIONS Over-Current Protection Remote On/Off 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 hiccup mode or latch mode, which is optional. 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. 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. 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 floating. Over-Voltage Protection The modules include an internal output over-voltage protection circuit, which monitors the voltage on the output terminals. If this voltage exceeds the over-voltage set point, the module will shut down, and enter in hiccup mode or latch mode, which is optional. ON/OFF Vo(-) Vi(-) Trim R Load Vi(+) 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. Vo(+) Figure 16: Remote on/off implementation 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 hiccup mode or latch 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. DS_S48SP3R310_10252013 8 FEATURES DESCRIPTIONS (CON.) Output Voltage Adjustment To increase or decrease the output voltage set point, the modules may be connected with an external resistor between the TRIM pin and either the Vo(+) or Vo(-). The TRIM pin should be left open if this feature is not used. ON/OFF Vo (-) R trim-up Vi (-) Trim R Load Vi (+) Vo (+) ON/OFF Vo (-) Vi (-) Trim Figure 18: Circuit configuration for trim-up (increase output voltage) R Load R trim-down Vi (+) Vo (+) Figure 17: Circuit configuration for trim-down (decrease output voltage) If the external resistor is connected between the TRIM and Vo(+) pins, the output voltage set point decreases (Fig. 17). The external resistor value required to obtain an output voltage change from 3.3V to the desired Vo_adj is defined as: Rtrim_down ( Vo_adj − 2.5 ) ⋅ 5110 3.3 − Vo_adj − 2050 3.3 − 2.97 3 Rtrim_down = 5.228 × 10 ohm 2.5 ⋅ 5110 Vo_adj − 3.3 − 2050 Ex. When Trim-up +10% Vo_adj=3.3V×(1+10%)=3.63V 2.5 ⋅ 5110 3.63 − 3.3 − 2050 4 Rtrim_up = 3.666 × 10 ohm Vo_adj=3.3V×(1-10%)=2.97V ( 2.97 − 2.5 ) ⋅ 5110 Rtrim_up Rtrim_up Ex. When Trim-down -10% Rtrim_down If the external resistor is connected between the TRIM and Vo(-) the output voltage set point increases (Fig. 18). The external resistor value required to obtain an output voltage change from 3.3V to the desired Vo_adj is defined as: − 2050 When using trim function, the output voltage of the module is usually increased, which increases the power output of the module with the same output current. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power. DS_S48SP3R310_10252013 9 THERMAL CONSIDERATIONS 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 Derating Heat can be removed by increasing airflow over the module. 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. THERMAL CURVES 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. 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’’). Figure 20: Hot spot temperature measured point ＊The allowed maximum hot spot temperature is defined at 110℃ PWB FACING PWB MODULE S48SP3R310(Standard) Output Load vs. Ambient Temperature and Air Velocity @Vin=48V (Either Orientation) Output Current(A) 11 10 Natural Convection 9 8 AIR VELOCITY AND AMBIENT TEMPERATURE MEASURED BELOW THE MODULE 100LFM 7 6 200LFM 300LFM 5 50.8 (2.0”) AIR FLOW 400LFM 500LFM 4 600LFM 3 2 1 12.7 (0.5”) 0 60 65 70 75 80 85 Ambient Temperature (℃) Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches) Figure 19: Wind tunnel test setup DS_S48SP3R310_10252013 Figure 21: Output load vs. ambient temperature and air velocity@Vin=48V (Either Orientation) 10 PICK AND PLACE LOCATION SURFACE-MOUNT TAPE & REEL RECOMMENDED PAD LAYOUT (SMD) DS_S48SP3R310_10252013 11 LEADED (Sn/Pb) PROCESS RECOMMEND TEMP. PROFILE Temperature (°C ) 250 200 150 Ramp-up temp. 0.5~3.0°C /sec. 2nd Ramp-up temp. Peak temp. 1.0~3.0°C /sec. 210~230°C 5sec. Pre-heat temp. 140~180°C 60~120 sec. Cooling down rate <3°C /sec. 100 Over 200°C 40~50sec. 50 0 60 120 Time ( sec. ) 180 240 300 Note: The temperature refers to the pin of S48SP, measured on the pin +Vout joint. LEAD FREE (SAC) PROCESS RECOMMEND TEMP. PROFILE Temp. Peak Temp. 240 ~ 245 ℃ 217℃ Ramp down max. 4℃/sec. 200℃ 150℃ Preheat time 100~140 sec. Time Limited 90 sec. above 217℃ Ramp up max. 3℃/sec. 25℃ Time Note: The temperature refers to the pin of S48SP, measured on the pin +Vout joint. DS_S48SP3R310_10252013 12 MECHANICAL DRAWING Surface-mount module Pin No. 1 2 3 4 5 6 Name +Vin -Vin ON/OFF (Optional) -Vout TRIM (Optional) +Vout DS_S48SP3R310_10252013 Through-Hole module Function Positive input voltage Negative input voltage Remote ON/OFF (Optional) Negative output voltage Output voltage trim (Optional) Positive output voltage 13 PART NUMBERING SYSTEM S 48 S P Product Type Input Number of Product Voltage Outputs Series S - Small Power 4836V~75V S - Single 3R3 10 N R Output Voltage Output Current ON/OFF Logic Pin Length/Type 1x1, 10A 3R3 - 3.3V 10 – 10A N - Negative (Default) P - Positive R - 0.170” (Default) N - 0.145” E- No remote on/off control function K - 0.110” M - SMD F B Option Code F- RoHS 6/6 (Lead Free) A - No trim pin B - With trim pin (Default) MODEL LIST MODEL NAME S48SP3R310NRFB S48SP05007NRFB S48SP12003NRFB S48SP15002NRFB INPUT 36V~75V 36V~75V 36V~75V 36V~75V OUTPUT 1.1A 1.2A 1.2A 1.0A 3.3V 5.0V 12.0V 15.0V EFF @ 100% LOAD 10.0A 7.0A 3.0A 2.0A 90.0% 90.0% 90.0% 90.0% Note: 1. 2. Default OTP and output OVP, OCP mode is auto-restart; For different option, please refer to part numbering system above or contact Delta local sales. CONTACT: www.deltaww.com/dcdc USA: Telephone: East Coast: 978-656-3993 West Coast: 510-668-5100 Fax: (978) 656 3964 Email: [email protected] Europe: Telephone: +31-20-655-0967 Fax: +31-20-655-0999 Email: [email protected] Asia & the rest of world: Telephone: +886 3 4526107 x6220~6224 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_S48SP3R310_10252013 14