V48SC05020 100W DC/DC Power Modules FEATURES High efficiency : 91.0% @ 5V/20A Size: Without heat spreader: 33.0mm*22.8mm*9.5mm(1.30”*0.90”*0.37’’) With heat spreader: 33.0mm*22.8mm*12.7mm(1.30’’*0.90’’*0.50’’) Standard footprint Industry standard pin out Fixed frequency operation Input UVLO Hiccup output over current protection (OCP) Hiccup output over voltage protection (OVP) Auto recovery OTP Monotonic startup into normal and pre-biased loads 1500V isolation and basic insulation No minimum load required ISO 9001, TL 9000, ISO 14001, QS9000, OHSAS18001 certified manufacturing facility UL/cUL 60950-1 (US & Canada) recognized Delphi Series V48SC, Sixteenth Brick Family DC/DC Power Modules: 36~75V in, 5V/20A out, 100W OPTIONS Positive or negative ON/OFF logic The Delphi Module V48SC05020, sixteenth brick, 36~75V Heat spreader or open frame input, single output, isolated DC/DC converter is the latest SMD or through-hole pin offering from a world leader in power system and technology and manufacturing ― Delta Electronics, Inc. This product provides up to 100 watts of power in an industry standard footprint and pin out. With creative design technology and optimization of component placement, these converters possess outstanding electrical and thermal performances, as well as extremely high reliability under highly stressful operating conditions. The V48SC05020 offers more than 91.0% high efficiency at 20A load. DS_V48SC05020_06262013 APPLICATIONS Telecom / Datacom Wireless Networks Optical Network Equipment Server and Data Storage Industrial / Testing Equipment E-mail: [email protected] http://www.deltaww.com/dcdc P1 TECHNICAL SPECIFICATIONS PARAMETER NOTES and CONDITIONS V48SC05020 Min. ABSOLUTE MAXIMUM RATINGS Input Voltage Continuous Transient 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 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 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 36 100ms -40 -55 Units 75 100 85 125 1500 Vdc Vdc °C °C Vdc 48 75 Vdc 32.0 30.0 34.0 32.0 2 36.0 34.0 Vdc Vdc Vdc A mA mA A2s mA dB Full Load, 36Vin Vin=48V, Io=0A Vin=48V, Io=0A 50 10 3.4 P-P thru 12µH inductor, 5Hz to 20MHz 120 Hz 20 -50 1 Vin=48V, Io=0, Tc=25°C Vin=48V, Io=Io min to Io max Vin=36V to 75V, Io=Io min Vin=48V, Tc= min to max case temperatrue 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 4.925 5.0 5.075 Vdc ±10 ±10 5.15 mV mV mV Vdc 20 30 mV mV A A ±33 4.85 80 30 0 22 48V, 10µF Tan & 1µF Ceramic load cap, 0.1A/µs 50% Io.max to 75% 75% Io.max to 50% 100 100 300 mV mV µs 30 30 ms ms µF 0 5000 Vin=48V Vin=48V 91.0 91.5 % % 1500 Vdc MΩ pF 510 kHz 0 3.5 0.8 10 -20 10 10 150 V V mA uA % % % 10 1000 420 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=10V % of nominal Vout Refer to Figure 18 for Hot spot 1 location (48Vin,80% Io, 200LFM,Airflow from Vo+ to Vin+) Refer to Figure 20 for Hot spot 2 location Over-Temperature Shutdown (With heat spreader) (48Vin,80% Io, 200LFM,Airflow from Vo+ 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. ( Without heat spreader) 465 115 Weight(without heat spreader) Weight(with heat spreader) Over-Temperature Shutdown Max. 36 Io=80% of Io max; Tc=25°C;Airflow=300LFM， Issue 3 MTBF Typ. 10.53 M hours 18.0 28.0 Grams Grams 135 °C 118 °C 125 °C TA=25°C, Natural convection, Vin=48Vdc, nominal Vout unless otherwise noted; DS_V48SC05020_06262013 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, and 75V input voltage at 25°C. Figure 3: Full load input characteristics at room temperature. DS_V48SC05020_06262013 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). Top Trace: Vout; 2V/div; Bottom Trace: ON/OFF input: 5V/div. Figure 5: Turn-on transient at full load current (10 ms/div). 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_V48SC05020_06262013 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%-50% of full load; di/dt = 0.1A/µs). Load cap: 10µF, tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout; 100mV/div; Bottom Trace: output current: 5A/div, Time: 100us/div Figure 9: Output voltage response to step-change in load current (50%-75%-50% of full load; di/dt = 2.5A/µs). Load cap: 10µF, tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout; 500mV/div; Bottom Trace: output current: 5A/div, Time: 100us/div 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 (250 mA/div，2us/div). DS_V48SC05020_06262013 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 (10 mA/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 (20 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_V48SC05020_06262013 E-mail: [email protected] http://www.deltaww.com/dcdc P6 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 100μF electrolytic capacitor (ESR < 0.7 Ω at 100 kHz) mounted close to the input of the module to improve the stability. Test Result: At T = +25C , Vin = 48 V and full load Green line is quasi peak mode; Blue line is average mode. 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 V48SC05020 to meet class A in CISSPR 22. Schematic and Components List EMI test positive line C1= 3.3uF/100 V C2= 47uF/100 V C3= 47uF/100 V C4=C5=1nF/250Volt T1=1mH, common choke, type P53910(Pulse) EMI test negative line 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., UL60950-1, 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. DS_V48SC05020_06262013 E-mail: [email protected] http://www.deltaww.com/dcdc P7 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. 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 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 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. 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 shut down, and will try to restart after shutdown(hiccup mode). 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. 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. Figure 16: Remote on/off implementation DS_V48SC05020_06262013 E-mail: [email protected] http://www.deltaww.com/dcdc P8 Output Voltage Adjustment (TRIM) THERMAL CONSIDERATIONS 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. 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. 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 Hence, the choice of equipment to characterize the thermal performance of the power module is a wind tunnel. Thermal Testing Setup 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 5.11Vo (100 ) 511 10.22K 1.225 Ex. When Trim-up +10% (5.0V×1.1=5.5V) Rtrim up 5.11 5.0 (100 10) 511 10.22 168.1K 1.225 10 10 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 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. AIR VELOCITY AND AMBIENT TEMPERATURE SURED BELOW THE MODULE Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power. 50.8(2.00") 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. 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_V48SC05020_06262013 E-mail: [email protected] http://www.deltaww.com/dcdc P9 THERMAL CURVES THERMAL CURVES (WITHOUT HEAT SPREADER) (WITH HEAT SPREADER) HOT SPOT1 HOT SPOT2 AIRFLOW AIRFLOW NTC RESISTOR Figure 18: * Hot spot 1& NTC resistor temperature measured points, the allowed maximum hot spot 1 temperature is defined at 122℃ Figure 20: * Hot spot 2 temperature measured point,the allowed maximum hot spot 2 temperature is defined at 111℃ V48SC05020(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Either Orientation) V48SC05020(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Either Orientation,With Heatspreader) Output Current (A) 20 Output Current (A ) 600LFM Natural Convection Natural Convection 16 20 16 100LFM 100LFM 200LFM 12 12 200LFM 300LFM 300LFM 8 400LFM 8 400LFM 500LFM 4 4 600LFM 500LFM 0 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(Either Orientation, without heat spreader) DS_V48SC05020_06262013 25 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(Either Orientation, with heat spreader) E-mail: [email protected] http://www.deltaww.com/dcdc P10 PICK AND PLACE LOCATION RECOMMENDED PAD LAYOUT (SMD) SURFACE-MOUNT TAPE & REEL DS_V48SC05020_06262013 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 V48SC, measured on the pin +Vout joint. LEAD FREE (SAC) PROCESS RECOMMEND TEMP. PROFILE(for SMD models) 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 V48SC, measured on the pin +Vout joint. DS_V48SC05020_06262013 E-mail: [email protected] http://www.deltaww.com/dcdc P12 MECHANICAL DRAWING 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. Through-hole module with heat spreader DS_V48SC05020_06262013 E-mail: [email protected] http://www.deltaww.com/dcdc P13 Surface-mount module Through-hole module without heat spreader Through hole Pin Specification: Pins 1-3,5-7 Pins 4 &8 1.00mm (0.040”) diameter 2.1.50mm (0.059”) diameter All pins are copper alloy with matte Tin(Pb free) plating over Nickel under plating DS_V48SC05020_06262013 E-mail: [email protected] http://www.deltaww.com/dcdc P14 PART NUMBERING SYSTEM V 48 S C 050 20 N N Form Input Number of Product Output Output ON/OFF Pin Factor Voltage Outputs Series Voltage Current Logic Length S – Single C- Series 050- 5.0V 20- 20A N –Negative V- 48- Sixteenth 36V~75V Number Brick F A Option Code K – 0.110’’ F - RoHS 6/6 A – Standard Function N - 0.145” (Lead Free) H– With Heatspreader R - 0.170” Space - RoHS5/6 M - SMD pin MODEL LIST MODEL NAME V48SC05020NNFA INPUT 36V~75V OUTPUT 3.4A 5.0V EFF @ 100% LOAD 20A 91.0% 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_V48SC05020_06262013 E-mail: [email protected] http://www.deltaww.com/dcdc P15