FEATURES High efficiency: 93.1% @ 3.3V/40A Size: 58.4x22.8x10.9mm (2.30”x0.90”x0.43”) Industry standard footprint and pin out Fixed frequency operation SMD and through-hole versions Input UVLO OTP and output OCP, OVP Output voltage trim: -20%, +10% Monotonic startup into normal and pre-biased loads 2250V isolation and basic insulation No minimum load required No negative current during power or enable on/off ISO 9001, TL 9000, ISO 14001, QS 9000, OHSAS18001 certified manufacturing facility UL/cUL 60950-1 (US & Canada) Recognized Delphi Series E48SP3R340, 1/8th Brick 132W DC/DC Power Modules: 48V in, 3.3V, 40A out th The Delphi Series E48SP3R340, 1/8 Brick, 48V input, single output, isolated DC/DC converter, is the latest offering from a world leader in power systems technology and manufacturing ― Delta Electronics, Inc. This product family provides up to 132 watts of power or 40A of output current (3.3V and below) in an industry th standard 1/8 brick form factor (2.30” x 0.90”). The 3.3V output offers one of the highest output currents available and provides up to 93.1% efficiency at full load. 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. All modules are protected from abnormal input/output voltage, current, and temperature conditions. DATASHEET DS_E48SP3R340_06052012 OPTIONS SMD pins Short pin lengths available Positive remote On/Off With heat spreader APPLICATIONS Optical Transport Data Networking Communications Servers TECHNICAL SPECIFICATIONS (TA=25°C, airflow rate=300 LFM, Vin=48Vdc, nominal Vout unless otherwise noted.) PARAMETER NOTES and CONDITIONS E48SP3R340 (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) Start up Current Input Terminal Ripple Current 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 Over Current Protection 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) ON/OFF Current (for both remote on/off logic) Leakage Current (for both remote on/off logic) Output Voltage Trim Range Output Voltage Remote Sense Range Output Over-Voltage Protection GENERAL SPECIFICATIONS MTBF Weight Over-Temperature Shutdown DS_E48SP3R340_06052012 100ms Refer to figure 20 for measuring point Typ. Max. Units 80 100 117 125 2250 Vdc Vdc °C °C Vdc 75 Vdc 34 32 2 3.9 80 8 35.5 33.5 2.5 4.5 120 12 1 Vdc Vdc Vdc A mA mA A2s 4.5 0.15 20 45 6.75 0.25 30 A A mA dB 3.3 3.35 Vdc ±5 ±5 ±33 ±10 ±10 3.4 mV mV mV V 80 30 120 45 40 150 mV mV A % 50 50 100 100 100 200 mV mV us 28 28 40 40 ms ms 10000 µF -40 -55 36 32.5 30.5 1.5 100% Load, 36Vin With 100uF external input capacitor Peak, Vin=36V, 100% Load, With 10000uF Co RMS, Vin=48V, With 100uF input cap. 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 to125°C Over sample load, line and temperature 5Hz to 20MHz bandwidth Full Load, 1µF ceramic, 10µF tantalum Full Load, 1µF ceramic, 10µF tantalum Output Voltage 10% Low 3.25 3.2 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 Cap ESR>=15mohm; Full load; 5% overshoot of Vout at startup; 0 Vin=48V Vin=48V 92% 91.5% 93.1% 92.5% % % 2250 1500 Vdc MΩ pF 250 kHz 10 Von/off Von/off Von/off Von/off Ion/off at Von/off=0.0V Ion/off at Von/off=2V Logic High, Von/off=15V Pout ≦ max rated power Pout ≦ max rated power Over full temp range; % of nominal Vout Io=75% of Io, max; Ta=25°C, airflow rate=400FLM Open frame Refer to figure 20 for measuring point -0.7 2 0.8 15 V V -0.7 2 0.8 15 0.3 130 V V mA uA uA % % % 4.79 28 125 M hours grams °C 10 50 10 10 -20 2 ELECTRICAL CHARACTERISTICS CURVES 14 96.0 94.0 12 92.0 10 88.0 Loss (W) Efficiency (%) 90.0 86.0 8 6 84.0 4 82.0 80.0 2 78.0 0 8 76.0 8 16 24 32 40 16 24 32 40 Output Current (A) Output Current (A) 36Vin 48Vin 36Vin 75Vin Figure 1: Efficiency vs. load current for minimum, nominal, and maximum input voltage at 25°C 48Vin 75Vin Figure 2: Power dissipation vs. load current for minimum, nominal, and maximum input voltage at 25°C. 5 INPUT CURRENT(A) 4 3 2 1 0 30 35 40 45 50 55 60 65 70 75 INPUT VOLTAGE(V) Figure 3: Typical full load input characteristics at room temperature DS_E48SP3R340_06052012 3 ELECTRICAL CHARACTERISTICS CURVES For Negative Remote On/Off Start up Figure 4: Turn-on transient at full rated load current (10 ms/div). Vin=48V. Top Trace: Vout, 1.0V/div; Bottom Trace: ON/OFF input, 5V/div Figure 5: Turn-on transient at zero load current (10 ms/div). Vin=48V. Top Trace: Vout: 1.0V/div, Bottom Trace: ON/OFF input, 5V/div For Input Voltage Start up Figure 6: Turn-on transient at full rated load current (10 ms/div). Vin=48V. Top Trace: Vout, 1.0V/div; Bottom Trace: Vin , 30V/div 0 Figure 7: Turn-on transient at zero load current (10 ms/div). Vin=48V. Top Trace: Vout, 1.0V/div; Bottom Trace: Vin, 30V/div 0 0 0 Figure 8: Output voltage response to step-change in load current (75%-50%-75% of Io, max; di/dt = 0.1A/µs). Load cap: 10µF tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (100mV/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 DS_E48SP3R340_06052012 Figure 9: Output voltage response to step-change in load current (75%-50%-75% of Io, max; di/dt = 1.0A/µs). Load cap: 10µF tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (100mV/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 4 ELECTRICAL CHARACTERISTICS CURVES is ic Vin+ + + 0 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 above Figure 11: Input Terminal Ripple Current, ic, at full rated output current and nominal input voltage with 12µH source impedance and 100µF electrolytic capacitor (100 mA/div, 2us/div) Copper Strip Vo(+) 0 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 measurement test setup noise and ripple 0 Figure 14: Output voltage ripple at nominal input voltage and rated load current (Io=40A)(100 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. DS_E48SP3R340_06052012 5 Safety Considerations 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 33 to 100 µF electrolytic capacitor (ESR < 0.7 Ω at 100 kHz) 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. Below is the reference design for an input filter tested with E48SP3R3XXXX to meet class B in CISSPR 22. Schematic and Components List Vi n(+) Vo( +) CY1 Vin CX L1 - Cin DCDC Module CY2 V in(-) Vo (-) CY Cin is 100uF*2 low ESR Aluminum cap; CX is 2.2uF ceramic cap; CY1 are 10nF ceramic caps; CY2 are 10nF ceramic caps; CY is 1nF ceramic cap; L1 is common-mode inductor, L1=0.88mH; Test Result LOA D 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 Fast-acting fuse with 30A 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 48V Vin, Full load, Yellow line is quasi peak mode; Blue line is average mode. DS_E48SP3R340_06052012 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. 6 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 hiccup mode or latch mode, which is optional. 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. Vi(+) For hiccup mode, the module will try to restart after shutdown. If the over current condition still exists, the module will shut down again. This restart trial will continue until the over-current condition is corrected. Sense(+) ON/OFF Sense(-) 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-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. For hiccup mode, the module will try to restart after shutdown. If the over voltage condition still exists, the module will shut down again. This restart trial will continue until the over-voltage 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. Vo(+) Vi(-) Vo(-) Figure 15: Remote on/off implementation Remote Sense Remote sense compensates for voltage drops on the output by sensing the actual output voltage at the point of load. The voltage between the remote sense pins and the output terminals must not exceed the output voltage sense range given here: [Vo(+) – Vo(–)] – [SENSE(+) – SENSE(–)] ≤ 10% × Vout This limit includes any increase in voltage due to remote sense compensation and output voltage set point adjustment (trim). 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 in auto-restart mode or latch mode, which is optional. Vi(+) Vo(+) Sense(+) Sense(-) For auto-restart mode, the module will monitor the module temperature after shutdown. Once the temperature is dropped and within the specification, the module will be auto-restart. 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. Contact Resistance Vi(-) Vo(-) Contact and Distribution Losses Figure 16: Effective circuit configuration for remote sense operation Remote On/Off If the remote sense feature is not used to regulate the output at the point of load, please connect SENSE(+) to Vo(+) and SENSE(–) to Vo(–) at the module. 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. The output voltage can be increased by both the remote sense and the trim; however, the maximum increase is the larger of either the remote sense or the trim, not the sum of both. DS_E48SP3R340_06052012 7 FEATURES DESCRIPTIONS (CON.) When using remote sense and trim, 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 does not exceed the maximum rated power. Output Voltage Adjustment (TRIM) To increase or decrease the output voltage set point, connect an external resistor between the TRIM pin and either the SENSE(+) or SENSE(-). The TRIM pin should be left open if this feature is not used. Figure 18: Circuit configuration for trim-up (increase output voltage) If the external resistor is connected between the TRIM and SENSE (+) the output voltage set point increases (Fig. 19). The external resistor value required to obtain a percentage output voltage change △% is defined as: Rtrim − up = 5 .11Vo (100 + ∆ ) 511 − − 10 .2 (K Ω ) 1.225 ∆ ∆ Ex. When Trim-up +10% (3.3V×1.1=3.63V) Figure 17: Circuit configuration for trim-down (decrease output voltage) If the external resistor is connected between the TRIM and SENSE (-) pins, the output voltage set point decreases (Fig. 18). The external resistor value required to obtain a percentage of output voltage change △% is defined as: 511 Rtrim − down = − 10 .2 (K Ω ) ∆ Ex. When Trim-down -10% (3.3V×0.9=2.97V) 511 Rtrim − down = − 10 . 2 (K Ω ) = 40 . 9 (K Ω ) 10 Rtrim − up = 5.11 × 3.3 × (100 + 10) 511 − − 10.2 = 90.1(KΩ ) 1.225 × 10 10 Trim resistor can also be connected to Vo+ or Vo- but it would introduce a small error voltage than the desired value. The output voltage can be increased by both the remote sense and the trim, however the maximum increase is the larger of either the remote sense or the trim, not the sum of both. When using remote sense and trim, 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_E48SP3R340_06052012 8 THERMAL CONSIDERATIONS Thermal Derating 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. 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. Hence, the choice of equipment to characterize the thermal performance of the power module is a wind tunnel. 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: Temperature measurement location The allowed maximum hot spot temperature is defined at 117℃. Output Current (A) E48SP3R340(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Transverse Orientation) 40 Natural Convection 35 100LFM 30 200LFM 25 PWB FACING PWB 300LFM 20 MODULE 400LFM 15 500LFM 10 600LFM 5 AIR VELOCITY AND AMBIENT TEMPERATURE MEASURED BELOW THE MODULE 0 25 50.8 (2.0”) 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature (℃) Figure 21: Output Current vs. Ambient Temperature and Air Velocity @ Vin=48V (Transverse Orientation) AIR FLOW 12.7 (0.5”) Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches) Figure 19: Wind tunnel test setup DS_E48SP3R340_06052012 9 PICK AND PLACE LOCATION RECOMMENDED PAD LAYOUT (SMD) SURFACE-MOUNT TAPE & REEL DS_E48SP3R340_06052012 10 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 E48SP, 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 E48SP, measured on the pin +Vout joint. DS_E48SP3R340_06052012 11 MECHANICAL DRAWING Surface-mount module Pin No. 1 2 3 4 5 6 7 8 Name +Vin ON/OFF -Vin -Vout -SENSE TRIM +SENSE +Vout DS_E48SP3R340_06052012 Through-hole module Function Positive input voltage Remote ON/OFF Negative input voltage Negative output voltage Negative remote sense Output voltage trim Positive remote sense Positive output voltage 12 PART NUMBERING SYSTEM E 48 Type of Product E - 1/8 Brick S Input Number of Voltage Outputs 4836V~75V S - Single P 3R3 40 N R Product Series Output Voltage Output Current ON/OFF Logic Pin Length/Type P - High Power 3R3 - 3.3V 40 - 40A N- Negative P- Positive R - 0.170” N - 0.145” M - SMD F A Option Code F- RoHS 6/6 A - Standard Functions (Lead Free) H - with Heat spreader MODEL LIST MODEL NAME INPUT OUTPUT EFF @ 100% LOAD E48SP3R340NRFA 36V~75V 5.0A 3.3V 40A 93.1% E48SP3R340NMFA 36V~75V 5.0A 3.3V 40A 93.1% Default remote on/off logic is negative and pin length is 0.170’’. CONTACT: www.delta.com.tw/dcdc USA: Telephone: East Coast: 978-656-3993 West Coast: 510-668-5100 Fax: (978) 656 3964 Email: [email protected] Europe: Phone: +41 31 998 53 11 Fax: +41 31 998 53 53 Email: [email protected] Asia & the rest of world: Telephone: +886 3 4526107 Ext 6220~6224 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_E48SP3R340_06052012 13