Delta E48SH2R535PRFA Delphi series e48sh, 120w eighth brick family dc/dc power modules: 48v in, 2.5v/35a out Datasheet

FEATURES

High efficiency: 89.5% @2.5V/35A

Size:
58.4mm x 22.8mm x9.5mm
(2.30”x0.90”x0.37”)

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

No negative current during power or enable
on/off

ISO 9001, TL 9000, ISO 14001, QS 9000,
OHSAS 18001 certified manufacturing
facility

UL/cUL 60950-1 (US & Canada)
Recognized, and TUV (EN60950-1)
Certified

CE mark meets 73/23/EEC and 93/68/EEC
directives
Delphi Series E48SH, 120W Eighth Brick Family
DC/DC Power Modules: 48V in, 2.5V/35A 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 89.5% for 2.5V output at 35A 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_E48SH2R535_11012013
OPTIONS

Positive On/Off logic

Short pin lengths available

External Synchronization

Output OVP latch mode

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
E48SH2R535 (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
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
Over-Temperature Shutdown
100ms
Refer to Figure 21 for measuring point
Typ.
-40
-55
36
33
31
1
34
32
2
100% Load, 36Vin
Max.
Units
75
100
128
125
2250
Vdc
Vdc
°C
°C
Vdc
75
Vdc
35
33
3
3.4
Vdc
Vdc
Vdc
A
mA
mA
2
As
mA
dB
50
4
1
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
50
2.475
2.5
2.525
Vdc
±3
±3
±15
±10
±10
2.538
mV
mV
mV
V
60
20
35
135
mV
mV
A
%
2.463
30
10
0
105
48V, 10µF Tan & 1µF Ceramic load cap, 0.1A/µs
50% Io.max to 75% Io.max
75% Io.max to 50% Io.max
60
60
100
mV
mV
us
15
15
ms
ms
µF
Full load; no overshoot of Vout at startup
10000
89.5
91
%
%
2250
10
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
Across Pins 9 & 5, Pout ≦ max rated power
Pout ≦ max rated power
Over full temp range; % of nominal Vout
Io=80% of Io, max; 300LFM @25℃
Refer to Figure 21 for measuring point
1500
Vdc
MΩ
pF
250
kHz
3
3
-20
120
3.4
25
135
1.2
50
V
V
1.2
50
1
50
10
10
140
V
V
mA
uA
%
%
%
M hours
grams
°C
E48SH2R535_11012013
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.
E48SH2R535_11012013
3
ELECTRICAL CHARACTERISTICS CURVES
For Negative Remote On/Off Logic
0
0
0
0
Figure 4: Turn-on transient at zero load current (2 ms/div).
Vin=48V.Top Trace: Vout, 1V/div; Bottom Trace: ON/OFF input,
5V/div.
Figure 5: Turn-on transient at full rated load current (constant
current load) (2 ms/div). Vin=48V.Top Trace: Vout, 1V/div;
Bottom Trace: ON/OFF input, 5V/div.
For Input Voltage Start up
0
0
0
0
Figure 6: Turn-on transient at zero load current (2 ms/div).
Vin=48V.Top Trace: Vout, 1V/div, Bottom Trace: input voltage,
50V/div.
Figure 7: Turn-on transient at full rated load current (constant
current load) (2 ms/div). Vin=48V.Top Trace: Vout, 1V/div;
Bottom Trace: input voltage, 50V/div.
E48SH2R535_11012013
4
ELECTRICAL CHARACTERISTICS CURVES
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. Trace: Vout
(20mV/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..
0
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. Trace: Vout
(20mV/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..
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 above.
Figure 11: Input Terminal Ripple Current, ic, at full rated output
current and nominal input voltage with 12µH source impedance
and 33µF electrolytic capacitor (200 mA/div, 2us/div).
E48SH2R535_11012013
5
ELECTRICAL CHARACTERISTICS CURVES
Copper
Strip
Vo(+)
10u
0
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.
0
Figure 14: Output voltage ripple at nominal input voltage and
rated load current (Io=35A)(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 15: Output voltage vs. load current showing typical
current limit curves and converter shutdown points.
E48SH2R535_11012013
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.
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 base plate 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 10A 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.
E48SH2R535_11012013
7
FEATURES DESCRIPTIONS
Vi(+)
Over-Current Protection
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, in
option code A, 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. In option code B (available for
1.2V, 1.8V, and 2.5V), when the output current exceeds
the OCP set point, the modules will immediately 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.
Vo(+)
Sense(+)
ON/OFF
Sense(-)
Vi(-)
Vo(-)
Figure 16: 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(+)
Vo(+)
Sense(+)
Over-Temperature Protection
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.
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(-)
Contact
Resistance
Vo(-)
Contact and Distribution
Losses
Figure 17: 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.
E48SH2R535_11012013
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.
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
1.225

Ex. When Trim-up +10%(2.5V×1.1=2.75V)
Rtrim  up 
5.11 2.5  (100  10 ) 511

 10.2  53.41  K  
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.
Figure 18: 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:
Rtrim  down 
511
 10.2K 

Ex. When Trim-down -10%(2.5V×0.9=2.25V)
Rtrim  down 
511
 10.2  40.9K 
10
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.
Frequency Synchronization
This product family can be synchronized with external clock
signal to the TRIM pin. This reduces system noise and
interference in multiple converter systems.
Figure 19: Circuit configuration for trim-up (increase output
voltage)
E48SH2R535_11012013
9
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.
Hence, the choice of equipment to characterize the
thermal performance of the power module is a wind
tunnel.
Heat can be removed by increasing airflow over the module.
The hottest point temperature of the module is 128℃. 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 21: Case temperature measurement location.
Pin locations are for reference only.
The allowed maximum hot spot temperature is defined at 128℃
*
E48SH2R535(Standard) Output Current vs. Ambient Temperature and Air Velocity
@Vin = 48V (Transverse Orientation)
Output Current(A)
35
PWB
FACING PWB
Natural
Convection
30
MODULE
100LFM
25
200LFM
300LFM
20
400LFM
500LFM
15
AIR VELOCITY
AND AMBIENT
TEMPERATURE
MEASURED BELOW
THE MODULE
10
50.8 (2.0”)
5
AIR FLOW
0
40
12.7 (0.5”)
45
50
55
60
65
70
75
80
85
Ambient Temperature (℃)
Figure 22: Output current vs. ambient temperature and air velocity
@Vin= 48V (Transverse Orientation)
Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches)
Figure 20: Wind tunnel test setup
E48SH2R535_11012013
10
PICK AND PLACE LOCATION
SURFACE-MOUNT TAPE & REEL
RECOMMENDED PAD LAYOUT (SMD)
E48SH2R535_11012013
11
LEADED (Sn/Pb) PROCESS RECOMMEND TEMP. PROFILE
Note: The temperature refers to the pin of E48SH, 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℃
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 E48SH, measured on the pin +Vout joint.
E48SH2R535_11012013
12
MECHANICAL DRAWING (WIHTOUT 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
E48SH2R535_11012013
13
MECHANICAL DRAWING (WITH HEATSPREADER)
THROUGH-HOLE MODULE
E48SH2R535_11012013
14
PART NUMBERING SYSTEM
E
48
S
H
2R5
35
N
R
Type of
Product
Input
Voltage
Number of
Outputs
Product
Series
Output
Voltage
Output
Current
ON/OFF
Logic
Pin
Length
E- Eighth
Brick
48-36V~75V
S- Single
H-50A series
2R5 – 2.5V
35 -35A
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,
with output OCL
(Lead Free)
B- Standard Functions,
with output OCP
(Available for 1.2V,
1.8V and 2.5V)
H- With heat spreader
MODEL LIST
MODEL NAME
INPUT
OUTPUT
EFF @ 100% LOAD
E48SH1R250NRFA
36V~75V
2.3A
1.2V
50A
86.5%
E48SH1R540NRFA
36V~75V
2.2A
1.5V
40A
89%
E48SH1R840NRFA
36V~75V
2.7A
1.8V
40A
90%
E48SH2R535NRFA
36V~75V
3.4A
2.5V
35A
89.5%
E48SH3R330NRFA
36V~75V
3.6A
3.3V
30A
92%
E48SH05020NRFA
36V~75V
3.7A
5.0V
20A
90%
E48SH12010NRFA
36V~75V
4.3A
12V
10A
93.5%
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.
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.
E48SH2R535_11012013
15
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