` FEATURES High efficiency: 93% @12V/10A Size: 58.4mm x 22.8mm x 9.5mm (2.30”x0.90”x0.37”) w/o heat-spreader 58.4mm x 22.8mm x 12.7mm (2.30”x0.90”x0.5”) with heat-spreader Industry standard pin out Fixed frequency operation Input UVLO, Output OTP, OCP, OVP Monotonic startup into normal and Pre-biased loads 2250V Isolation and basic insulation No minimum load required SMD and through-hole versions No negative current during power or enable on/off ISO 9001, TL 9000, ISO 14001, QS 9000, OHSAS 18001 certified manufacturing facility UL/cUL 60950 (US & Canada) recognized, and TUV (EN60950) certified Delphi Series E48SH, 120W Eighth Brick Family DC/DC Power Modules: 48V in, 12V/10A out The Delphi Series E48SH Eighth 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 either a through-hole or surface-mounted package and provides up to 120 watts of power or 50A of output current (1.2V and below) in an industry standard footprint and pinout. The E48SH converter operates from an input voltage of 36V to 75V and is available in output voltages from 1.0V to 15V. Efficiency is 93% for the 12V output 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 models are fully protected from abnormal input/output voltage, current, and temperature conditions. The Delphi Series converters meet all safety requirements with basic insulation. DATASHEET DS_E48SH12010_10212014 CE mark meets 73/23/EEC and 93/68/EEC directive OPTIONS Positive On/Off logic Short pin lengths available External Synchronization Output OVP latch mode Through hole pins with Heat spreader APPLICATIONS Telecom/DataCom Wireless Networks Optical Network Equipment Server and Data Storage Industrial/Test Equipment TECHNICAL SPECIFICATIONS (TA=25°C, airflow rate=300 LFM, Vin=48Vdc, nominal Vout unless otherwise noted.) PARAMETER NOTES and CONDITIONS E48SH12010 (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 2 Inrush Current(I t) 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 Voltage Remote Sense Range Output Over-Voltage Protection GENERAL SPECIFICATIONS MTBF Weight Weight Over-Temperature Shutdown Over-Temperature Shutdown ( Without heat spreader) (With heat spreader) Max. Units 80 100 85 125 2250 Vdc Vdc °C °C Vdc 75 Vdc 35 33 3 3.9 90 10 1 Vdc Vdc Vdc A mA mA 2 As mA dB 12.00 12.12 Vdc ±10 ±10 ±50 ±20 ±20 12.24 mV mV mV V 40 10 80 20 10 140 mV mV A % 110 110 100 200 200 mV mV us 15 20 25 30 5000 ms ms µF 100ms -40 -55 36 33 31 1 34 32 2 100% Load, 36Vin 3 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 115°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 20 60 11.88 11.76 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 Full load; no overshoot of Vout at startup 92 92 93 93 % % 2250 10 Vdc MΩ pF 225 kHz 1.2 50 V V 1.2 50 1 50 V V mA uA -20 10 % 13.8 10 16.2 % V 1500 185 Von/off at Ion/off=1.0mA Von/off at Ion/off=0.0 µA Von/off at Ion/off=1.0mA Von/off at Ion/off=0.0 µA Ion/off at Von/off=0.0V Logic High, Von/off=15V Pout ≦ max rated power, trim up curve refer to figure4 Pout ≦ max rated power, refer to figure4 Over full temp range; % of nominal Vout 200 3 3 Io=80% of Io, max; 300LFM @25C Without heat spreader With heat spreader Refer to Figure 22 for Hot spot 1 location (48Vin,80% Io, 200LFM,Airflow from Vin- to Vin+) Refer to Figure 24 for Hot spot 2 location (48Vin,80% Io, 200LFM,Airflow from Vin- to Vin+) Over-Temperature Shutdown ( NTC resistor ) Note: Please attach thermocouple on NTC resistor to test OTP function, the hot spots’ temperature is just for reference. DS_E48SH12010_10212014 Typ. 2.2 25 36.6 M hours grams grams 130 °C 118 °C 125 °C 2 ELECTRICAL CHARACTERISTICS CURVES Figure 1: Efficiency vs. load current for minimum, nominal, and Figure 2: Power dissipation vs. load current for minimum, nominal, and maximum input voltage at 25°C. trim up ratio (%) maximum input voltage at 25°C 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 25C 36 36.5 37 37.5 38 38.5 55C 39 39.5 40 Input voltage (V) Figure 3: Typical full load input characteristics at room temperature Figure 4: trim up curve at full load, 200LFM, 25°C and 200LFM, 55°C DS_E48SH12010_10212014 3 ELECTRICAL CHARACTERISTICS CURVES For Negative Remote On/Off Logic 0 0 0 0 Figure 5: Turn-on transient at zero load current (5 ms/div). Vin=48V.Top Trace: Vout, 10V/div; Bottom Trace: ON/OFF input, 5V/div Figure 6: Turn-on transient at full rated load current (constant current load) (5 ms/div). Vin=48V.Top Trace: Vout, 10V/div; Bottom Trace: ON/OFF input, 5V/div For Input Voltage Start up 0 0 0 0 Figure 7: Turn-on transient at zero load current (5 ms/div). Vin=48V.Top Trace: Vout, 10V/div, Bottom Trace: input voltage, 50V/div DS_E48SH12010_10212014 Figure 8: Turn-on transient at full rated load current (constant current load) (5 ms/div). Vin=48V.Top Trace: Vout, 10V/div; Bottom Trace: input voltage, 50V/div 4 ELECTRICAL CHARACTERISTICS CURVES Figure 9: 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. Trace: Vout (50mV/div, 100us/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: 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. Trace: Vout (50mV/div, 100us/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 11: 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 12: Input Terminal Ripple Current, ic, at full rated output current and nominal input voltage with 12µH source impedance and 33µF electrolytic capacitor (500 mA/div, 2us/div). DS_E48SH12010_10212014 5 ELECTRICAL CHARACTERISTICS CURVES Copper Strip Vo(+) 10u 1u SCOPE RESISTIVE LOAD Vo(-) Figure 13: Input reflected ripple current, is, through a 12µH source inductor at nominal input voltage and rated load current (20 mA/div, 2us/div). Figure 14: Output voltage noise and ripple measurement test setup Figure 15: Output voltage ripple at nominal input voltage and rated load current (Io=10A)(20 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. Figure 16: Output voltage vs. load current showing typical current limit curves and converter shutdown points. DS_E48SH12010_10212014 6 DESIGN CONSIDERATIONS Safety 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. 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 E48SH12010XXXX to meet class B in CISSPR 22. Schematic and Components List Cx1: 100V/2.2uF * 2 MLCC, Cx=4.7uF MLCC Cx2: 100V/2.2uF MLCC+ 100V/100uF Al cap Cy: 3000V/3.9nF *2 MLCC, Cy1=Cy2=4.7nF MLCC L1=0.08mH, L2= 0.85mH 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. L1 leakage=0.5uH, L2 leakage=4uH Test Result: Vin=48V, Io=8A, SDC ADP Team 25.Sep 06 15:48 Att 10 dB dBµV 80 RBW 9 kHz MT 100 ms PREAMP OFF 1 MHz Marker 1 [T2 ] 47.42 dBµV 29.980000000 MHz 10 MHz Delta 2 [T2 ] 0.00 dB UNCAL 0.000000000 Hz 70 SGL 55022QP 2 AV 60 CLRWR TDF 55022AV 50 1 2 Soldering and Cleaning Considerations 40 30 20 10 0 150 kHz Date: 25.SEP.2006 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 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. 30 MHz 15:48:32 DS_E48SH12010_10212014 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 Vi(+) Vo(+) Over-Current Protection Sense(+) The E48SH modules include an internal output over-current protection circuit, which will endure current limiting for an unlimited duration during output overload. When the output current exceeds the OCP set point, the current limit function will work by initially reduce duty cycle of the module, the unit will go out of regulation but remains in safe operating area before the output drops below 50%. When output drops below 50%, the modules will automatically shut down and enter hiccup mode. During hiccup, 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 module will shut down and restart after 200mS. latch off mode is optional. Under latch off mode the over-voltage latch is reset by either cycling the input power or by toggling the on/off signal for one second. ON/OFF Sense(-) Vi(-) Figure 17: 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). Vi(+) Over-Temperature Protection 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_E48SH12010_10212014 Vo(+) Sense(+) 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 try to restart after shutdown. If the over-temperature condition still exists during restart, the module will shut down again. This restart trial will continue until the temperature is within specification. Vo(-) Sense(-) Vi(-) Contact Resistance Vo(-) Contact and Distribution Losses Figure 18: Effective circuit configuration for remote sense operation 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 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 does not exceed the maximum rated power. 8 FEATURES DESCRIPTIONS (CON.) Output Voltage Adjustment (TRIM) 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 SENSE(+) or SENSE(-). The TRIM pin should be left open if this feature is not used. Figure 20: Circuit configuration for trim-up (increase output voltage) Figure 19: Circuit configuration for trim-down (decrease output voltage) If the external resistor is connected between the TRIM and SENSE (+) the output voltage set point increases (Fig. 20). The external resistor value required to obtain a percentage output voltage change △% is defined as: Rtrim up If the external resistor is connected between the TRIM and SENSE (-) pins, the output voltage set point decreases (Fig.19). The external resistor value required to obtain a percentage of output voltage change △% is defined as: Rtrim down 511 10.2K Ex. When Trim-down -10%(12V×0.9=10.8V) Rtrim down 511 10.2 40.9K 10 5.11 Vo (100 ) 511 10.22K 1.225 Ex. When Trim-up +10%(12V×1.1=13.2V) Rtrim up 5.1112 (100 10) 511 10.22 489.3K 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. DS_E48SH12010_10212014 9 THERMAL CONSIDERATIONS THERMAL CURVES (WITHOUT HEAT SPREADER) 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 185mmX185mm,70μm (2Oz),6 layers 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 22: Hot spot 1's temperature measured point. ＊The allowed maximum hot spot temperature is defined at 123℃ E48SH12010(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Transverse Orientation) Output Current(A) 11 10 9 Natural Convection 8 100LFM 7 200LFM 6 300LFM 5 400LFM 4 500LFM 3 PWB FANCING PWB 2 MODULE 1 0 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature (℃) Figure 23: Output current vs. ambient temperature and air velocity @Vin=48V (Transverse Orientation, airflow from Vin- to Vin+, without heat spreader) 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 21: 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_E48SH12010_10212014 10 THERMAL CURVES (WITH HEAT SPREADER) Figure 24: Hot spot 2's temperature measured point. ＊The allowed maximum hot spot temperature is defined at 106℃ Output Current(A) 11 E48SH12010(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Transverse Orientation,With Heatspreader) 10 Natural Convection 9 8 100LFM 7 200LFM 6 300LFM 5 400LFM 4 500LFM 3 600LFM 2 1 0 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature (℃) Figure 25: Output current vs. ambient temperature and air velocity @Vin=48V (Transverse Orientation, airflow from Vin- to Vin+, with heat spreader) DS_E48SH12010_10212014 11 PICK AND PLACE LOCATION(SMD) RECOMMENDED PAD LAYOUT (SMD) SURFACE-MOUNT TAPE & REEL DS_E48SH12010_10212014 12 LEADED (Sn/Pb) PROCESS RECOMMEND TEMP. PROFILE(SMD) Note: The temperature refers to the pin of E48SH, measured on the pin +Vout joint. LEAD FREE (SAC) PROCESS RECOMMEND TEMP. PROFILE(SMD) 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 E48SH, measured on the pin +Vout joint. DS_E48SH12010_10212014 13 MECHANICAL DRAWING (WITHOUT HEATSPREADER) 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 Notes: All pins are copper alloy with matte tin plated over Nickel under-plating. DS_E48SH12010_10212014 14 MECHANICAL DRAWING (WITH HEATSPREADER) * 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. Notes: All pins are copper alloy with matte tin plated over Nickel under-plating. DS_E48SH12010_10212014 15 RECOMMENDED PAD LAYOUT (THROUGH-HOLE MODULE) DS_E48SH12010_10212014 16 PART NUMBERING SYSTEM E 48 S H 120 10 N R Type of Product Input Voltage Number of Outputs Product Series Output Voltage Output Current ON/OFF Logic Pin Length/Type E- Eighth Brick 48-36V~75V S- Single H-50A series 120 - 12V 10 -10A N- Negative P- Positive R- 0.170” N- 0.145” K- 0.110” M- SMD F A Option Code F- RoHS 6/6 A- Standard Functions (Lead Free) H - With heatspreader MODEL LIST MODEL NAME INPUT OUTPUT EFF @ 100% LOAD E48SH12010NRFA 36V~75V 3.9A 12V 10A 93% E48SH12010NKFA 36V~75V 3.9A 12V 10A 93% 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: Telephone: +31-20-655-0967 Fax: +31-20-655-0999 Email: [email protected] Asia & the rest of world: Telephone: +886 3 4526107 x 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_E48SH12010_10212014 17