E48SP05040 200W DC/DC Power Modules FEATURES Delphi Series E48SP050, Eighth Brick Family DC/DC Power Modules: 36~75V in, 5.0V/40A out, 200W The Delphi Series E48SP050, Eighth Brick, 36V~75Vin input, High efficiency: 94% @ 5V/40A Size: 58.4x22.8x11.0mm (2.30”x0.90”x0.43”) w/o heat-spreader 58.4x22.8x12.7mm (2.30”x0.90”x0.50”) with heat-spreader Industry standard footprint and pinout Fixed frequency operation Input UVLO OTP and output OVP Output OCP hiccup mode Output voltage trim down : -20% Output voltage trim up: +10% Monotonic startup into normal and pre-biased loads 1500V 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 OPTIONS Negative or Positive remote On/Off Open frame/Heat spreader 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 provides up to 200 watts of power or 40A of output current. 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 APPLICATIONS Optical Transport Data Networking Communications Servers 5V/40A module is greater than 94%. DS_E48SP05040_01132014 E-mail: [email protected] http://www.deltaww.com/dcdc P1 TECHNICAL SPECIFICATIONS (TA=25°C, airflow rate=100 LFM, Vin=48Vdc, nominal Vout unless otherwise noted.) PARAMETER NOTES and CONDITIONS E48SP05040 (Standard) Min. ABSOLUTE MAXIMUM RATINGS Input Voltage Continuous Transient (100ms) Operating Ambient 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 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(hiccup mode) 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 Output Capacitance (note1) EFFICIENCY 100% Load 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 Voltage Remote Sense Range Output Over-Voltage Protection GENERAL SPECIFICATIONS MTBF Weight Weight Typ. 0 100ms -40 -55 Max. Units 80 100 85 125 1500 Vdc Vdc Vdc °C °C Vdc 36 48 75 Vdc 32.0 30.0 1 34.0 32.0 2 36.0 34.0 3 6.5 Vdc Vdc Vdc A mA mA A2s mA dB Full Load, 36Vin Vin=48V, Io=0A Vin=48V, Io=0A 85 9 P-P thru 12µH inductor, 5Hz to 20MHz 120 Hz 20 50 1 Vin=48V, Io=Io.max, Tc=25°C Io=Io, min to Io, max Vin=36V to 75V Tc=-40°C to 85°C Over sample load, line and temperature 5Hz to 20MHz bandwidth Vin=48V, Full Load, 1µF ceramic, 10µF tantalum Vin=48V, Full Load, 1µF ceramic, 10µF tantalum Vin=36V to75V Output Voltage 10% Low 4.925 5.0 4.85 5.075 Vdc ±10 ±10 ±50 5.15 mV mV mV V 40 56 mV mV A A 120 30 0 44 48Vin, 10µF Tan & 1µF Ceramic load cap, 0.1A/µs 75% Io.max to 50% Io.max 50% Io.max to 75% Io.max 150 150 200 mV mV µs 40 40 mS mS µF Full load; 5% overshoot of Vout at startup 10000 Vin=36V Vin=48V Vin=48V 94 94 94 % % % 1500 1100 Vdc MΩ pF 300 KHz 10 Von/off Von/off Von/off Von/off Ion/off at Von/off=0.0V Logic High, Von/off=5V Pout ≦ max rated power,Io ≦ Io.max Pout ≦ max rated power,Io ≦ Io.max % of nominal Vout Io=80% of Io, max; Ta=25°C, airflow rate=300LFM Without heat spreader With heat spreader Refer to Figure 18 for Hot spot 1 location Over-Temperature Shutdown ( Without heat spreader) (48Vin,80% Io, 200LFM,Airflow from Vin- to Vin+) Refer to Figure 20 for Hot spot 2 location Over-Temperature Shutdown (With heat spreader) (48Vin,80% Io, 200LFM,Airflow from Vin- to Vin+) Over-Temperature Shutdown ( NTC resistor ) Refer to Figure 18 for NTC resistor location Note: Please attach thermocouple on NTC resistor to test OTP function, the hot spots’ temperature is just for reference. 3.0 0.8 5 V V 3.0 0.8 5 V V mA 10 10 140 % % % -20 115 6.62 29.8 38.2 Mhours hours grams grams 132 °C 120 °C 125 °C Note1: For applications with higher output capacitive load, please contact Delta. DS_E48SP05040_01142014 E-mail: [email protected] http://www.deltaww.com/dcdc P2 ELECTRICAL CHARACTERISTICS CURVES Figure 1: Efficiency vs. load current for 36V, 48V, and 75V input voltage at 25°C. Figure 2: Power dissipation vs. load current for 36V, 48V, 75V, and 75V input voltage at 25°C. Figure 3: Full load input characteristics at room temperature. DS_E48SP05040_01142014 E-mail: [email protected] http://www.deltaww.com/dcdc P3 ELECTRICAL CHARACTERISTICS CURVES For Negative Remote On/Off Logic Figure 4: Turn-on transient at zero load current (10ms/div). Vin=48V. Top Trace: Vout; 2V/div; Bottom Trace: ON/OFF input: 5V/div. Figure 5: Turn-on transient at full load current (10ms/div). Vin=48V. Top Trace: Vout: 2V/div; Bottom Trace: ON/OFF input: 5V/div. For Input Voltage Start up Figure 6: Turn-on transient at zero load current (10 ms/div). Top Trace: Vout; 2V/div; Bottom Trace: input voltage: 30V/div DS_E48SP05040_01142014 Figure 7: Turn-on transient at full load current (10 ms/div). Top Trace: Vout; 2V/div; Bottom Trace: input voltage:30V/div. E-mail: [email protected] http://www.deltaww.com/dcdc P4 ELECTRICAL CHARACTERISTICS CURVES Figure 8: Output voltage response to step-change in load current (50%-75% of Io, max; di/dt = 0.1A/µs; Vin=48V). Load cap: 10µF tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (0.1V/div, 200us/div), Bottom Trace: Iout (20A/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 (75%-50% of Io, max; di/dt = 0.1A/µs; Vin=48V). Load cap: 10µF tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (0.1V/div, 200us/div), Bottom Trace: Iout (20A/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 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 max output current and nominal input voltage with 12µH source impedance and 33µF electrolytic capacitor (500 mA/div，2us/div). DS_E48SP05040_01142014 E-mail: [email protected] http://www.deltaww.com/dcdc P5 ELECTRICAL CHARACTERISTICS CURVES Figure 12: Input reflected ripple current, is, through a 12µH source inductor at nominal input voltage and max load current (25mA/div，2us/div). Figure 13: Output voltage noise and ripple measurement test setup. Figure 14: Output voltage ripple at nominal input voltage and max load current (30 mV/div, 2us/div) Load capacitance: 1µF ceramic capacitor and 10µF tantalum capacitor. Bandwidth: 20 MHz. Figure 15: Output voltage vs. load current showing typical current limit curves and converter shutdown points. DS_E48SP05040_01142014 E-mail: [email protected] http://www.deltaww.com/dcdc P6 Safety Considerations DESIGN 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., UL60950-1, CSA C22.2 NO. 60950-1 2nd and IEC 60950-1 2nd : 2005 and EN 60950-1 2nd: 2006+A11+A1: 2010, if the system in which the power module is to be used must meet safety agency requirements. 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 100μF electrolytic capacitor (ESR < 0.7 Ω at 100 kHz) mounted close to the input of the module to improve the stability. 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. 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 E48SP05040 to meet class B in CISSPR 22. 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: Schematic and Components List Vin(+) + CX1 L1 CX2 L2 CY2 - CX3 Cin E48SP05040 Vin(-) 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. 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. Vo(+) CY1 Vin Load Vo(-) Cin is 100uF low ESR Aluminum cap: CX1,CX2 are 2*2.2uF ceramic cap: CX3 are 2.2uF ceramic cap: CY1,CY2 are 3.3nF ceramic cap: L1,L2 are common-mode inductor, L1=L2=0.63mH. 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. Test Result:Vin=48V,Io=40A. The power module has extra-low voltage (ELV) outputs when all inputs are ELV. dBμV 80.0 Limits 55022MQP 55022MAV 70.0 60.0 50.0 40.0 Transducer 8130 Traces PK+ AV 30.0 20.0 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 20A 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 10.0 0.0 150 kHz 1 MHz DS_E48SP05040_01142014 10 MHz 30 MHz 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 E-mail: [email protected] http://www.deltaww.com/dcdc P7 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. Vi(+) Vo(+) Sense(+) ON/OFF trim Rload Sense(-) Vi(-) Vo(-) FEATURES DESCRIPTIONS Over-Current Protection Figure 16: Remote on/off implementation 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 shut down (hiccup mode). The modules 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. 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 protection circuit will constrain the max duty cycle to limit the output voltage, if the output voltage continuously increases the modules will shut down, and then restart after a hiccup-time (hiccup mode). 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.The module will restart after the temperature is within specification. Output Voltage Adjustment (TRIM) To increase or decrease the output voltage set point, connect an external resistor between the TRIM pin and the SENSE(+) or SENSE(-). The TRIM pin should be left open if this feature is not used. For trim down, the external resistor value required to obtain a percentage of output voltage change △% is defined as: 511 Rtrim down 10.22 K Ex. When Trim-down -20% (5.0V×0.8=4.0V) 511 Rtrim down 10.22 K 15.33K 20 For trim up, the external resistor value required to obtain a percentage output voltage change △% is defined as: Rtrim up Ex. When Trim-up +10% (5.0V×1.1=5.5V) Rtrim up 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. DS_E48SP05040_01142014 5.11Vo (100 ) 511 10.22K 1.225 5.11 5.0 (100 10) 511 10.22 168K 1.225 10 10 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. E-mail: [email protected] http://www.deltaww.com/dcdc P8 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 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’’). PWB FANCING PWB MODULE 50.8(2.00") AIR VELOCITY AND AMBIENT TEMPERATURE SURED BELOW THE MODULE AIR FLOW Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches) Figure 17: Wind tunnel test setup 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. DS_E48SP05040_01142014 E-mail: [email protected] http://www.deltaww.com/dcdc P9 THERMAL CURVES THERMAL CURVES (WITHOUT HEAT SPREADER) (WITH HEAT SPREADER) HOT SPOT 1 HOT SPOT 2 AIRFLOW NTC RESISTOR AIRFLOW Figure 18: * Hot spot 1& NTC resistor temperature measured points. The allowed maximum hot spot temperature is defined at 116℃. E48SP05040(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Transverse Orientation) Output Current (A) Figure 20: * Hot spot 2 temperature measured point. The allowed maximum hot spot temperature is defined at 110℃. E48SP05040(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Transverse Orientation,With Heat Spreader) Output Current (A) 40 40 Natural Convection 35 35 Natural Convection 30 100LFM 30 200LFM 25 100LFM 25 300LFM 200LFM 20 20 300LFM 400LFM 15 400LFM 15 500LFM 10 500LFM 10 600LFM 5 600LFM 5 0 25 0 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature (℃) Figure 19: Output current vs. ambient temperature and air velocity @Vin=48V(Transverse Orientation, airflow from Vin- to Vin+,without heat spreader) DS_E48SP05040_01142014 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, airflow from Vin- to Vin+,with heat spreader) E-mail: [email protected] http://www.deltaww.com/dcdc P10 PICK AND PLACE LOCATION RECOMMENDED PAD LAYOUT (SMD) TAPE & REEL PACKAGE FOR SURFACE MOUNT MODELS DS_E48SP05040_01142014 E-mail: [email protected] http://www.deltaww.com/dcdc P11 LEADED (Sn/Pb) PROCESS RECOMMEND TEMP. PROFILE(for SMD models) Note: The temperature refers to the pin of E48SP05040, measured on the +Vout pin joint. LEAD FREE (SAC) PROCESS RECOMMEND TEMP. PROFILE(for SMD models) Temp. Peak Temp. 240 ~ 245 ℃ 217℃ Ramp down max. 4℃/sec. 200℃ Preheat time 100~140 sec. 150℃ Time Limited 90 sec. above 217℃ Ramp up max. 3℃/sec. 25℃ Time Note: The temperature refers to the pin of E48SP05040, measured on the +Vout pin joint. DS_E48SP05040_01142014 E-mail: [email protected] http://www.deltaww.com/dcdc P12 MECHANICAL DRAWING (WITH HEAT SPREADER) For modules with through-hole pins and the optional heatspreader, they are intended for wave soldering assembly onto system boards; please do not subject such modules through reflow temperature profile. DS_E48SP05040_01142014 E-mail: [email protected] http://www.deltaww.com/dcdc P13 MECHANICAL DRAWING (WITHOUT HEAT SPREADER) Surface-mount module Pin No. 1 2 3 4 5 6 7 8 Name +Vin ON/OFF -Vin -Vout -SENSE TRIM +SENSE +Vout 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 Pin Specification: Pins 1-3,5-7 Pins 4 & 8 1.00mm (0.040”) diameter 2. 1.50mm (0.059”) diameter Note: All pins are copper alloy with matte Tin(Pb free) plated over Nickel under plating. DS_E48SP05040_01142014 E-mail: [email protected] http://www.deltaww.com/dcdc P14 RECOMMENDED PAD LAYOUT (THROUGH-HOLE MODULE) DS_E48SP05040_01142014 E-mail: [email protected] http://www.deltaww.com/dcdc P15 PART NUMBERING SYSTEM E 48 Form Input Factor Voltage E - 1/8 Brick S Number of Product Outputs S– 4836V~75V P Single Series P- 050 40 N R Output Output ON/OFF Pin Voltage Current Logic Length 050- Series 5.0V 4040A N– Negative Number F A Option Code K – 0.110’’ F - RoHS 6/6 N - 0.145” (Lead Free) R - 0.170” M - SMD pin A – Standard Function H– With Heatspreader Space - RoHS5/6 MODEL LIST MODEL NAME E48SP05040NRFA INPUT 36V~75V OUTPUT 6.5A 5.0V EFF @ 100% LOAD 40A 94.0% @ 48Vin Default remote on/off logic is negative and pin length is 0.170” For different remote on/off logic and pin length, please refer to part numbering system above or contact your local sales office. For modules with through-hole pins and the optional heatspreader, they are intended for wave soldering assembly onto system boards; please do not subject such modules through reflow temperature profile. 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: Phone: +31-20-655-0967 Fax: +31-20-655-0999 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 DS_E48SP05040_01142014 E-mail: [email protected] http://www.deltaww.com/dcdc P16